Pwd Specifications for Building Works 2014 (All Chapters i.e. 1 to 25)

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Akhilesh Gupta
Executive Engineer
PWD SPECIFICATIONS
FOR
BUILDING WORKS
2014
GOVERNMENT OF RAJASTHAN
PUBLIC WORKS DEPARTMENT
FOREWORD
The specifications for Building works are the basic component of the projects on
buildings infrastructure. The process of updating the specifications is continuous to
match the requirement of new technologies and materials. BIS specifications are also
revised periodically through amendments. These specifications not only set the
standards for building designs but also serve as guide lines for execution/ acceptance
of works, measurements and rates. Many new items and construction technologies,
which are used in various PWD works have also to be incorporated. Revision of
Rajasthan PWD specifications for buildings was imperative. Specifications are useful
in execution of works and are used as a guide by a number of Engineering departments,
public sector undertakings,Architects and Builders. PWD specifications have been
accordingly modified / revised to incorporate the above.
The initiative taken by the PWD for such revision is quite commendable and I
congratulate officials of the department for their efforts.
I am sure that these specifications shall be useful to all in the building infrastructure
sector in order to improve the quality and technology of construction.
J.C. Mohanty, i.a.s

Principal Secretary, PWD
Govt. of Rajasthan.
Jaipur. Dated : 03.06.2014

PREFACE
The PWD Specifications for building works was first issued in 1968 and their revision
/ updating was overdue to adopt SI units, include new materials, innovative
technologies and revisions/amendments to BIS codes, constructional procedures/
techniques and innovative architectural designs of buildings. Specifications are
useful in execution of works and are used as a guide by a number of Engineering
Departments, Public Sector Undertakings, Architects and Builders. These
specifications not only give the standards for building materials but also serve as
guidelines for execution /acceptance of works, measurements and rates. Many new
items and construction technologies, which are used in various PWD works and
projects have been incorporated in Basic Schedule of Rates of various circles in
PWD. Some items have become obsolete over a period of time and are not in use.
Further, there were no specifications for pile work, Aluminium work, water proofing,
& Horticulture and Landscape. PWD Specifications have been accordingly modified/
revised and updated to incorporate the above changes.
The revised/updated specifications are being published in twenty five Chapters

covering three volumes.
I wish to place on record the appreciation for initiative taken by Shri ChiranjiLal
former Secretary PWD, efficient coordination and Value additions by Shri Rajmal
Jaln ACE PWD Zone I, Jaipur, Mrs.Anju Sharma, SE PWD, Shri N.K.Sethi, SE City
Circle, Jaipur, proactive contribution of the Executive Engineers Sarva Shri Anil
Pareek, ArvindK.Jaln, Sunil Gupta, Nagesh Sharma, Anil Vijayvargiya, Suml Jalsingh
and Dinesh Agarwal and Shri Amit Garg and their colleague AEs who assisted them
on the task. Thanks to M/s. Sharikon Consultants, Jaipur for the technical inputs and
due efforts in finalizing these specifications.
The revised Specifications shall be useful to all concerned in the building industry in
general including other departments and corporations in the State and PWD in
particular.
Er. R.P. Khandelwal

Secretary, PWD
Rajasthan, Jaipur.
ACKNOWLEDGEMET
1.0 Rajasthan PWD Specifications for Building works, 2014 are the revised edition of
existing PWD Specifications. These are published in 3 volumes as under:
Volume 1 Chapter No. Description

1. Earth Work
2. Building Materials
3. Carriage of Materials
4. Mortars
5. Plain Cement Concrete .
6. Reinforced Cement Concrete .
7. Brick work
8. Stone work
9. Plastering & pointing work
Volume 2. 10. Wood work
11. Steel work
12. Flooring & marble work
13. Roofing work
14. White and Colour washing.
15. Aluminium, PVC & Glass work
16. Repairs & Maintenance of Buildings
17. Dismantling & Demolishing work
Volume 3. 18. Miscellaneous Building works
19. Sanitary Installation
20. Horticulture & Landscaping work
21. Water Supply work
22. Drainage work
23. Tube wells & Water harvesting work
24. NBC guide lines on planning & designing
of buildings
25. Fire Protection works
2.0 These PWD Specifications, 2014 will replace existing PWD Specifications, 1968
along with correction slips issued if any.
3.0 Details of new construction technology/ mechanization have been introduced for
execution of different works by using various electrical and mechanical equipments
i.e. excavators, tower cranes, mobile cranes, mechanical platforms,
Batch Mix plant, transit mixers and pumps, piling rigs, pneumatic cutters, chisels,
chippers, hammers etc.
4.0 Specifications of pile work, aluminum work, water proofing and horticulture and
landscape are incorporated for the first time.
5.0 Salient up-dations in different Chapters are as follows:
5.1 Earth Work: Specifications for Earth work by mechanical means, i.e excavators and
transporting equipment are introduced. Specifications for earth work for major works,
import of earth and earth levelling works have been incorporated. Use of Aldrin is
deleted and Lindane is introduced as anti-termite chemical. Further, constructional
measures have been provided instead of pre-construction anti-termite treatment.
5.2 Building Materials: Specifications of basic building material has been taken in this
chapter. Specific materials have been placed in respective chapters
5.3 Carriage of Materials: Provision of routes other than shortest route in case of
unavoidable circumstances is introduced. Standards of stacking and storage of various
construction materials incorporated.
5.4 Mortars: Specifications of lime mortar which although not in much use now has been
retained as Rajasthan is rich in lime stone and cost of cement may force reversion
to lime mortars /concrete. Standards of fly-ash have been up-dated.
5.5 Plain Cement Concrete : Specifications of Cement Concrete with Brick aggregate,
Light weight aggregate, chemical Admixtures, Construction joints, Concreting under
special conditions, its testing, durability and Ready mix concrete incorporated.
5.6 Plain / Reinforced Cement Concrete: Specifications of fly ash admixed cement
concrete (FACC) and fly ash blended cements (PPCC), HSD bars of grade Fe 415D,
Fe 415 S,Fe 500D and Fe 550D, Fe 500 S, Fe 550, Fe 550 D, &Fe 600, physical
properties and chemical composition of TMT bars, stripping time of formwork for
RCC work using OPC 43 grade cement and PPC, surface treatment of shuttering by
polymer based water soluble compounds, gas pressure welding and RMC
incorporated.
5.7 Brick Work: Specifications of mechanized autoclave fly ash lime bricks, sewer
bricks, acid resistant bricks, burnt clay perforated building bricks and gypsum
partition panels incorporated.
5.8 Stone Work: Specifications of gang saw cut stone, providing and fixing stone
cladding and structural steel frame work for stone cladding have been added.
5.9 Plastering and Pointing Work: Specifications of Lime Plaster of different thickness,
Lime punning, Lime Sandia, Cement Plaster of different thickness, floating coat of
neat cement, Rough cast plaster, Pebble Dash finish, Sand face plaster, Stone grit
fmish, cement Lime plaster, Lime Surkhi plaster, Araish Plaster, Cement water
proofing compound, Mud plaster, Gypsum plaster and pointing on Brick work, Tile
work, Stone work incorporated.
5.10 Wood Work: Wood work in doors & windows for frames / shutters in deodar wood
deleted as deodar wood is not easily available. Specifications of other species of
wood,available in market and factory made shutters have been incorporated.
5.11 Steel Work: Steel glazed doors & windows fixed, side hung, top hung, centre hung,
composite units including mullion bar and steel beadings are clubbed together and
to be paid in kg in one item instead of earlier being measured in sqm. Profiles of
pressed steel door & window frames revised. Specifications for factory made
windows and doors, ERW tubular pipes for handrails etc. incorporated.
5.12 Flooring: Specifications pertaining to obsolete items deleted. Specifications for
laying tiles in flooring and dado with polymer based adhesives included.
5.13 Roofing: Non-asbestos cement sheet provided in place of asbestos cement sheet
roofing.Items of corrugated G.S. sheet roofing 1.60 mm thick & 1.25 mm thick
deleted as these are not readily available. 20 mm thick wooden planks ceiling, 18
mm insulating board, 18 mm flame retardant board on roofs deleted as boards of
these thicknesses are not readily available. Lime concrete terracing has been retained
as one of the useful items for terracing in the temperate climate of Rajasthan.
5.14 White Washing, Colour Washing, Painting and other Finishes: Specifications of
white washing, colour washing, Distempring, Painting, Varnishing, french
polishing, cement Paint and wax polishing incorporated.
5.15 Aluminium PVC&Glass work; Items in current use have been included.
5.16 Repairs to Buildings: Items pertaining to repairs in various sub-heads are shifted to
this head.Specifications are up-dated.
5.17 Dismantling and Demolishing: Specifications of dismantling and demolishing of
different elements of structures and appropriate safety measures included.
5.18 Miscellaneous Building Works: Items of works in use have been included.
5.19 Sanitary Installations: Items of long pan W.C., C.P. brass trap & union, G.I. chain
with G.I.pull are not in use now a days and hence deleted. Specifications of PVC
cisterns and stainless steel kitchen sink have been added.
5.20 Horticulture &Landscaping work: Items as required are included.
5.21 Water Supply: Specifications of PE-AL-PE pipes, PP-R pipes and CPVC pipes
included. Items not in use have been deleted.
5.22 Drainage: Specifications of Stone ware pipes, RCC pipes etc updated and items not
in use deleted.
5.23 Tube wells & Water Harvesting work.
5.24 Guide lines on planning & designing of buildings.
5.25 Fire Protection works.
6.0 I wish to place on record the appreciation for initiative taken, efficient coordination
and Value additions by Mrs. Anju Sharma, SE PWD, N.K. Sethi SE PWD City Circle
Jaipur, Shri Nagesh Sharma SE, proactive contribution of the Executive Engineers
Sarva Shri Anil Pareek, Arvind. K. Jain, Suml Gupta, Anil Vijayvargiya, Sunil
Jaisingh, Dinesh Agarwal and AE Shri Amit Garg and his colleagues who assisted
the EEs on the task.
7.0 Such specifications are regularly updated by BIS and other stake holders and as and
when any amendments that comes to the knowledge of users, may be brought to the
notice of the SE PWD city circle,Jalpur for necessary updating the specifications.
8.0 The specifications have a list of the relevant BIS codes with each chapter. For further
details, these may be referred to. EE's are advised to procure these codes from the
Bureau of Indian Standards for their divisional library.
9.0 Each chapter has a sheet for recording amendments (likely to be issued by the BIS
and other bodies) and PWD officers, along with the officer ordering them with
referenced order and date. Such amendments could be pasted on the blank pages at
the beginning of each chapter.
10.0 PWD and other building engineers are exhorted to adhere to these specifications in
the best interest of quality and durability of works.
11.0 The use of SI units mandates that all units are written in lower case letters and
singular represents plurals and no plurals are required.
12.0 Suggestions for further value additions shall be thankfully acknowledged.
M.L. Meena
Chief Engineer (S&S) Public
Works Department Rajasthan,
Jaipur.
Jaipur. Dated : 03.06.14

COMMITTEES FOR DRAFTING OF RAJASTHAN PWD
SPECIFICATIONS - 2014
PWD specifications are very comprehensive and contain not only standards for the
construction materials but also guidelines for execution of works, testing for quality
assurance and mode of measurements for billing. These Specifications are integral part of
contract documents also and also take cognizance of field conditions. It was, therefore, felt
necessary to take inputs from many field officers and in corporate their suggestions.
Accordingly, the following committees were constituted by the Chief Engineer cum
Additional Secretary PWD, Jaipur to draft the specifications:
1 Drafting Committee
Chairman
(i) Er. R.P. Khandelwal (then ACE zone I, Jaipur),
Member
(ii) Er. Sunil Gupta Executive Engineer,
Member
(iii) Er. Anil Vijayvargiya Executive Engineer,
Member
(v) Er. Dinesh Agrawal Executive Engineer,
Member
(v) Er. Nagesh Chandra Sharma, Executive Engineer
2. Committee for revision of Chapters of PWD Specifications.
Er. Sunil Gupta EE, assisted by Er. Pawan Kulshreshta AE, Er. Ravi
Gupta AE,
Er. Anil Vijayvargiya EE, Assisted by Er. Anil Sharma AE, Er. Vishnu
Vijayvargiya AE,
Er. Dinesh Agarwal EE, Assisted by Er. P.P. Singh AE, Er. Nikhil Gupta
AE.
Er. Nagesh C. Sharma EE, Assisted by Er.Ashish Gupta AE, Er. B.S.
Sharma AE.
I convey my gratitude /sincere thanks to above members of committees for preparation
of this document. I also thank other officers/ assistants and officials, who may not be
formally members of any committee, but have widely contributed to the finalisation of
these specifications. I am sure that Rajasthan PWD Specifications, 2014 will be use ful
to all concerned.
Due care has been taken to edit Rajasthan PWD Specifications, 2014. Error or omission
if any, may be brought to the notice of the Superintending Engineer City Circle, Nirman
Bhawan, Jacob Road, Jaipur for editing.
These specifications are dedicated to all the Engineers in the building construction sector
in the State.
N.K. Sethi
SE PWD, City Circle Jaipur
RAJASTHAN P.W.D. BUILDING SPECIFICATIONS 2014
CHAPTER No. 1
EARTH WORK
CHAPTER No.1 : EARTH WORK
CONTENTS
Clause No Brief Description Page No.
Record of Amendments. 2
1.1 Scope. 3
1.2 Definitions. 3
1.3 Preliminary Works. 3
1.4 Identification of Soils. 4
1.5 Antiquities, Archaeological finds. 5
1.6 Protections 5
1.7 Site clearance 5
1.8 Setting out works, bench marks, marking profile. 6
1.9 Earth work by Mechanical means 13
1.10 Earth work in filling 14
1.11 Blasting 20
1.12 Excavation in all kinds of soils. 21
1.13 Excavation in ordinary/hard rock. 22
1.14 General recommendations for Safety considerations in excavation. 22
1.15 Shoring and Timbering. 23
1.16 Excavation in or under water, mud or foul position, 25
1.17 Earth work for Major works. 26
1.18 Lift in Excavation and Earth work 27
1.19 Earth work for filling in trenches, plinth, under floor etc.. 28
1.20 Sand filling in plinth. 28
1.21 Surface dressing. 29
1.22 Jungle clearance. 29
1.23 Felling of trees. 29
1.24 Antitermite Treatment 30
Figures 35
Appendix À': Classification & Identification of Soils. 42
Appendix `B': Mechanical Equipment for Earth Work 48
Appendix `C': Blasting operations, materials and methodology. 54
Appendix `D': Trenchless Excavation for sewerage and water supply etc.. 57
List of Relevant BIS Codes. 61
Rajasthan PWD Building Specifications 2014 Chapter 1 : Earth Work Page 1 of 62

RECORD OF AMENDMENTS

CHAPTER No. 1
EARTH WORK
1.1 Scope:
The scope of earth work is defined for excavation of foundation in all kind of strata as per foundation
layout plan by adopting suitable method with all kind of safety of persons, works involved in
excavation of work and adjacent structures, towers, service lines, facilities etc.
1.2 Definitions:
Engineer-in-Charge, Contractor, Site, Store, and Department as defined in the works contract.
i) Deadmen or Tell Tales: Modules of earth left undisturbed ( for measurements) in pits dug
out for borrowing earth.
ii) Burjis or Reference pillars: Short pillars of bricks / stone having top surface finished with
cement plaster for marking of levels and centre lines etc.
iii) Formation or Profile: Final shape of the ground after excavation or filling up.
iv) Foul Position: Filthy and unhygienic conditions where physical movements are hampered
such as soil mixed with sewage or night soil.
v) Lead: It is the removal of materials from one location to another by any means. Also see
clause 1.8.18
vi) Ground level: The average ground level at a building project site in plane or rolling terrain.
On hills, it may vary for different parts of the same building project and shall be decided by the
Engineer-in-Charge and indicated so on the drawings.
vii) Lift : The vertical distance for removal with reference to the ground level. Also see clause
1.8.18
1.3 Preliminary Works:
The following preliminary works will have to be executed along with the actual work of setting out
to be taken-up. No separate payment is admissible for these preliminary works or setting out and the
expenditure on these shall be treated as included in the rates quoted for the individual items.
a) Demarcation of Land as per approved plan drawings.
b) The site should be cleared of all grass, bushes, trees (with due permission from the statutory
authority), organic soil etc.
c) Spot levels of ground should be recorded after removal of loose organic soil.
d) A temporary bench mark (like the plinth of a permanent building in the vicinity) is to be
established at the project site. This will serve to establish the Plinth and other levels of the
project buildings.
e) Construction of masonry reference pillars of a suitable height in sufficient numbers ( one for
each junction of the land plan) but not less than 4 nos. for visual assessment of land boundaries.

f) Setting out the buildings as per approved drawings and establishing reference pillars at the
centre line /junctions of all walls and pillars.
g) Establishing the local flood level and the highest water table at the project site.
h) Confirming the subsoil strata up to 1.5 m below the proposed founding level of the project
buildings.
i) Study the Environmental Impact and its mitigation at the site, as required as per statutory
provisions. Any foul smell from any direction and its mitigation.
J) Study the social Impact and its mitigation at the site, as per the Govt.'s, Resettlement and
Rehabilitation policy.
k) In case of any unsuitable ground conditions, marshes/water logging, water course, flood
proneness, depressions or made up ground is encountered, the contractor shall immediately
bring it to the notice of the Engineer-in Charge in writing
1.4 Identification of Soil from point of view of ease to excavate and measurement:
The earth work shall be classified under the following categories and measured separately for
each category (also see cl: 1.8.5 and Appendix A) :
1.4.1 a) All Kind of Soils/ ordinary soil :- Generally any strata / material, which for excavation,
yields to application of spades, picks, shovel jumper, scarifiers, ripper and other manual digging
equipment. Soils such as turf, sand, , moist clay or soft shale, mud (Mixture of soil and water
in weak solid state), mixture of sand and clay, shingle, river or water course bed soil mixed
with cobbles boulders, berms/siding of roads, path , etc.
b) Hard/Dense Soil -Generally any soil which requires the close application of picks, or
jumpers or scarifiers to loosen; such as stiff clay, loam murrum, gravel, cobblestone, hard core
macadam surface of any description , water bound macadam, Phyllite, Tarmac, lime concrete,
mud concrete and their mixtures / combinations etc., and soling of roads/ dry stone kharanj a etc.
.
NOTE - Cobblestone is the rock fragment usually rounded or semi-rounded having maximum
diameter in any one direction between 80 mm and 300 mm.
1.4.2 Soft/Disintegrated /Ordinary Rock:- Generally any rock which can be excavated by splitting
with crow bars or picks and does not require blasting, wedging or similar means for excavation
such as lime stone, sand stone, hard laterite, hard conglomerate and un-reinforced cement
concrete below ground level.
If required, light controlled blasting may be resorted to, for loosening the materials but this will
not in any way entitle the material to be classified as `Hard Rock'.
1.4.3 Hard Rock:- Generally any rock or boulder for the excavation of which controlled blasting is
required such as quartzite, granite, gneiss, trap, basalt, reinforced cement concrete
(reinforcement to be cut through but not separated from concrete) below ground level and the
like.
1.4.4 Hard Rock (Blasting Prohibited) :- Hard rock requiring blasting as described under 1.4.3 but
where blasting is prohibited for any reason and excavation has to be carried out by chiselling,
wedging or with any other mechanical excavator as approved by the Engineer-in-charge.

1.5 Antiquities and other Useful, Archaeological Materials
1.5.1 Anything of archaeological interest/value, found during excavation, such as relics of antiquity,
idols, coins, fossils or other articles of value, shall be delivered in safe/sound condition to the
Engineer-in-charge and shall be the property of the Government.
1.5.2 Any reusable material obtained from the excavation which in the opinion of the Engineer-in-
charge, is useful for construction , shall be stacked separately in regular stacks at site as directed
by the Engineer-in-charge and shall be the property of Government.
1.6 Protections: Excavations, where directed by the Engineer-in-charge shall be securely fenced
/barricaded and provided with proper caution signs, conspicuously displayed during the day
and properly illuminated with red light during the night to avoid accidents.
1.6.1 The contractor shall take adequate protective measures to see that the excavation operations do
not damage the adjoining structures or dislocate the services. Water supply pipes, Sluice valves
chambers, sewerage pipes, manholes, drainage pipes and chambers, communication cables,
power supply cables etc. met within course of excavation , shall be properly supported and
adequately protected so that these services remain functional, till alternate arrangement are
made. However, if any service is damaged during excavation, it shall be restored in reasonable
time by the contractor at his cost.
1.6.2 For excavations of basements, adequate precautions against the protection to cut slopes
(planking), safety of labour ( helmets, ropes, belt, chain, first aid etc.) , and preventing accidents,
as per an approved safety plan duly supervised by a safety Engineer and as directed by the
Engineer-in-Charge shall be taken . Excavation shall not be carried out below the foundation
level of the adjacent buildings until underpinning, shoring etc. is proposed to be done as per
directions of Engineer-in-charge for which payment shall be made separately.
1.6.3 Any damages done by the contractor to any existing work / services (owned by Govt. or
private) shall be made good by him at his own cost. Existing drain pipes, culverts, overhead
wires, water supply lines and similar services encountered during the course of execution shall
be protected against damage by the contractor/ or his men. The contractor shall not store material
or otherwise occupy any part of the site in a manner likely to hinder the operations of such
services.
1.6.4 All necessary precautions for construction safety shall be taken as per construction safety plan
prepared as per IS: SP 70, National Building Code ( latest revision) , PWD guide lines or guide
lines issued by the Engineer-in-Charge and complied with under the professional supervision
of a trained and dedicated `Safety Engineer' .
1.7 Site Clearance:
1.7.1 Before the earth work in excavation is started, the area coming under cutting and filling, EW
operations shall be cleared of all shrubs, rank vegetation, grass, brushwood, trees and saplings
of girth up to 30cm measured at a height of one metre above ground level and rubbish etc.,
removed up to a distance of 50 metre outside the periphery of the area under clearance. The
roots of trees and saplings shall be removed to a depth of 60cm below ground level or 30cm
below formation level or 15cm below subgrade level, whichever is lower, and the holes or
hollows filled up with the earth, rammed and levelled. The wood and other products shall be the
property of the Govt., and shall be stacked/delivered as directed by the Engineer-in-Charge.
1.7.2 The trees of girth above 30cm measured at a height of one meter above ground shall be cut

only after permission of the Engineer-in-charge is obtained in writing. The root of trees shall
also be removed to its full extent. Left overs of roots if any, shall be coated with bitumen to
prevent regrowth. The wood and other products shall be the property of the Govt., and shall be
stacked /delivered as directed by the Engineer-in-Charge. Payments for cutting such trees and
removing the roots shall be made separately.
1.7.3 Existing structures such as old buildings, culverts, fencing, and services like water supply pipe
lines, sewers, power cables, communication cables, drainage pipes etc., within or adjacent to the
area if required to be diverted, relocated/ removed, shall be diverted, relocated / dismantled
as per directions of the Engineer-in-charge and payment for such diversion/ relocation,
dismantling work shall be made separately. All reusable materials shall be treated as Govt.
property and properly stacked at site. Pipes, cables and other materials shall be duly measured
and handed over to the service provider agencies against a receipt , as directed by the Engineer-
in-Charge
1.7.4 In case of Archaeological monuments within or adjacent to the area, the contractor shall be
responsible to protect these as per directions of the Engineer-in-Charge and provide necessary
fencing around such monuments as per the directions of the Engineer-in-charge and protect the
same properly during execution of works. Payment for providing fencing / protecting shall
be made separately.
1.8 Setting Out works, Bench Mark , Marking Profile and reference pillars ( Ref: IS 11134-
1984).
1.8.1 The contractor shall set out the buildings, providing all labour and materials, tools and tackle
required to set out the works as per detailed foundation drawings, with reference to the
existing buildings and roads etc. For all depths and heights, the proposed plinth level shall be
treated as +/(-) 0.00. On sloping ground, different buildings may have different plinth levels
to economise the cost of foundations. The setting out shall be thoroughly checked by the
Engineer-in Charge or his authorised representative.
1.8.2 All distance measurements shall be taken by a tape conforming to IS: 1269-1964. A tension
device shall be used with the tape. The values measured shall be corrected for temperature, sag,
slope and tension. All angular measurements shall be done with a theodolite with accuracy of 20
seconds for primary and 1 minute for secondary system.
1.8.3 The setting out shall first be marked on the traverse survey of the site, duly identifying the
Primary, secondary, position points, the grid, primary / secondary bench mark, position level,
check measurements etc. The set out at the ground is then done and checked with respect to this
plan and the discrepancies rectified through adjustments. The final set out shall be duly
approved by the Engineer-in-charge.
1.8.4 Setting out a Building
1.8.4.1 To take up the work of setting out, most important factor is to establish a base line. This
should be done as per the site plan requirements and offsets may be taken from the existing
road or existing building and after marking the base line, the marking out of centrelines as
per foundation/ layout plan of building.
1.8.4.2 Setting out of structure shall be carried out in a systematic manner. Thereafter the centreline
peg with the nail on top is encased in bricks in cement mortar 1:6 . The top of brick pillar is
neatly plastered to the level with cement sand mortar 1:4 and finished with a floating

coat of neat cement. The contractor is supposed to build and maintain the brick pillars and
the markings till these are not required further by the Engineer-in-Charge.
1.8.4.3 The position of centre lines of walls, columns are marked on the top plastered surface of the
pillars which will be very useful during construction of the foundation and starting of
superstructure work.
1.8.4.4 A masonry pillar to serve as a bench mark will be erected at a suitable point in the area,
which is visible from anywhere in the largest area. This bench mark shall be constructed as
per drawing and connected with the GTS or other standard bench mark as approved by the
Engineer-in-charge. Necessary profiles with the strings stretched on pegs, bamboos or Burjis
shall be made to indicate the correct plinth/formation level before work is started. Erection
and maintenance of Bench Mark and Burjis, setting out and marking profiles etc. shall be
done by contractor at his own cost.
1.8.4.5 Wherever directed by the Engineer-in-Charge, the ground levels shall be recorded at 5 to
15 m interval in uniformly sloping ground and at a closer interval where local mounds, pits
or undulations are met with. The ground levels shall be recorded in field level books and
plotted on plans. The plan shall be plotted on a scale of 1: 500 or any other suitable scale
decided by the Engineer-in-charge. North direction line and position of temporary bench
mark shall invariably be shown on the plans. These plans shall be signed by the contractor
and the Engineer-in-charge or their authorized representatives before the earth work is
started. The surveyors and survey equipment, required for taking / recording levels shall be
supplied by the contractor at his own cost.
1.8.4.6 Finishing the excavation for buildings and structures:
Foundation trenches shall be accurately excavated to the dimensions shown on the drawings,
sides shall be left plumb where the soil permits, but the sides must be sloped back or shored
up carefully wherever soil appears likely to cave in. The bottom of the trenches shall be
watered , rammed and got examined before placing concrete and duly approved by the
Engineer-in-Charge and the patches of soft / loose ground if found or any extra depth
erroneously excavated shall be filled with foundation concrete as directed by the Engineer-
in-Charge. Concrete for loose ground shall be payable but the concrete for extra depth of
cutting / excavation erroneously done shall be at the contractor's cost.
1.8.4.7 Antitermite treatment as provided for, shall be done before concreting.
1.8.5 General Rules: (Refer IS:1200-P-1, 1992)
1.8.5.1 Clubbing of Items: Items may be clubbed together provided that the break-up of the clubbed
items is agreed to be on the basis of the detailed description of the items stated in this
standard.
1.8.5.2 Booking of Dimensions: In booking dimensions. the order shall be consistent and generally
in the sequence of length, breadth or width and height or depth or thickness.
1.8.5.3 Measurements: Unless otherwise stated hereinafter all work shall be measured net in
decimal system, as fixed in position as given below:
a) Each dimension shall be measured' to the nearest 0.01 m;
b) Areas shall be worked out to the nearest 0.01 m2, and
c) Cubical contents shall be worked out to the nearest 0.01 m3.

1.8.5.4 Work to be Measured Separately: Work executed in the following conditions shall be
measured separately:
a) Work in or under water,
b) Work in or under foul situations,
c) Work under tidal conditions, and
d) Work in snow.
1.8.5.4.1 The levels of high and low water tides where occurring, shall be stated.
1.8.5.5 Bills of Quantities: The bills of quantities shall fully describe the materials and
workmanship, and accurately represent the work to be executed.
1.8.5.6 The following works shall not be measured separately and allowance for the. same, shall be
deemed to have been made in the description of main item:
a) Setting out works, profiles, etc.
b) Site clearance, such as cleaning grass and vegetation;
c) Unauthorized battering or benching or excavation;
d) Forming (or leaving) `dead men' and `tell tales' in borrow pits and their removal after
measurements;
e) Forming (or leaving) steps in sides of deep excavation and their removal after
measurements;
f) Excavation for insertion of planking and strutting;
g) Unless otherwise specified, removing slips or falls in excavations; and
h) Bailing out or pumping of water in excavation from rains.
1.8.5.7 Special pumping other than what is required for conditions given in 1.8.5.4 (a) and included in
1.8.5.6 (h) and tube well/well point dewatering where resorted to, shall each be measured
separately for all stages of pumping, including intermediate stages unless otherwise stated, in
KW. Hrs. or HP Hrs. against separate specific provision(s) made for the purpose.
1.8.6 Classification: The materials to be excavated shall be classified as follows unless otherwise
specified.
a) Soft and Loose Soil - Generally any soil which yields to the ordinary application of
pick and shovel, or to spade, rake or other ordinary digging implement; such as
vegetable or organic soil, turf, gravel, sand, silt, loam, clay peat, etc.
b) Hard/Dense Soil -Generally any soil which requires the close application of picks,
or jumpers or scarifiers to loosen; such as stiff clay, gravel, cobblestone, water bound
macadam and soling of roads.
NOTE - Cobblestone is the rock fragment usually rounded or semi-rounded having
maximum diameter in any one direction between 80 mm and 300 mm.
c) Mud: - A mixture of soil and water in fluid or weak solid state.
d) Foul Condition: Means a mixture of soil and sewerage or night soil.
e) Soft/Disintegrated Rock (Not Requiring Blasting) -Rock or boulders which may
be quarried or split with crowbars. This will also include laterite and hard

conglomerate.
f) Hard Rock ( Requiring Blasting ) - Any rock or boulder for the excavation of which
blasting is required. Hard rock can be excavated by machines and requires blasting,
chiselling in edging or in another method can be considered as ordinary rock.
NOTE:-Boulder is a rock fragment usually rounded by weathering disintegration and
exfoliation or abrasion by water or ice, having maximum diameter in any direction of
more than 300 mm round lying loose on the surface or embedded in river bed. soil,
talus, slope wash and terrace material of dissimilar origin.
g) Hard Rock ( Blasting Prohibited) - Hard rock requiring blasting as described under
(e) but where blasting is prohibited for any reason and excavation has to be carried
out by chiseling, wedging or any other agreed method.
NOTE - A broad classification of soil and rock for earthwork suitable for conditions
generally occurring in practice has been provided where necessary., further sub-
classification may be done to suit Individual cases depending on the properties of the
substrate.
1.8.7 Method of Measurement or various types of Excavation:
1.8.7.1 The measurement of earthwork shall be done in cubic metre, unless otherwise mentioned. The
measurements to be taken shall be those of the authorized dimensions from which soil has
been taken out and shall be measured without allowance for increase in bulk.
1.8.7.2 Excavation in Earthwork Including Rock Cutting: The measurement of excavation in
earthwork including rock cutting shall be made as follows:
a) Where the excavation is in trenches or from borrow pits in fairly uniform ground, the
measurements of cutting trenches or borrow pits shall be made. `Dead men' or `tell-
tales' may be left at suitable intervals to determine the average depth of excavation.
b) Where the ground is not uniform, levels shall be taken before the start, after site
clearance and after the completion of the work and the quantity of excavation in
cutting computed from these levels.
c) Where soft/disintegrated rock and hard rock are mixed the measurement for the total
quantity shall be made by method (a) and/or (b) given above. The hard rock excavated
shall be stacked and measured in stack. The quantity of the hard rock excavated shall
be arrived at by applying pre-accepted deductions ( stated as a percentage) for voids.
From the total quantity of the mixture the quantity of hard rock excavated thus arrived
at shall be deducted to work out the quantity of the soft/ disintegrated rock excavated.
Where hard/dense soil, soft/disintegrated rock excavated.
d) Where hard/dense soil, soft/disintegrated rock and hard rock are mixed, the measure-
ment for the total quantity shall be made by methods (a) and/or (b) given above. If
possible after the removal of the hard/ dense soil the levels of the exposed rocks
surface should be taken and the quantity of the hard/dense soil removed, worked out
from the difference between the original levels and new levels. If this is not possible

the excavation should be completed leaving[,tell-tales and from the cross-section of
these tell-tales, the area of the hard/dense soil excavated should be worked out and
then the volume of the hard/dense soil excavated arrived at. Quantity of hard dense soil
should then be deducted from the total quantity of hard rock and soft/disintegrated rock.
The quantities of hard rock and soft' disintegrated rock should then be separated as in (
c) above by stacking the hard rock separately.
e) Where soft/loose soil, hard/dense soil, soft/ disintegrated rock and hard rock are mixed,
the measurements of the entire quantity shall be made by methods ( a ) and/ or ( b) given
above. The separate quantities of soft/loose soil and hard/dense soil shall be worked
out from the cross-section based on dead men or tell-tales as mentioned in (d ). in case
of hard/dense soil. The total quantity of soft/loose and hard/dense soil shall then be
deducted from the total excavation to arrive at the total quantity of rock excavated. The
quantities of sof /disintegrated rock and hard rock excavated & worked out separately
as in case of ( c) above.
1.8.7.2.1 Wherever, it is not possible or convenient to take measurements from borrow pits or
cutting, excavation shall be worked out from `filling' ( see 1.8.8 ).
1.8.7.2.2 Dressing or trimming sides of excavations and levelling or grading and ramming of bottoms
shall be described with the item of excavation except in the case of rough excavation ( see
1.8.10).
1.8.7.2.3 All excavation shall be measured in successive stages of 1.5 m stating the commencing
level. This shall not apply to cases where no lift is involved as in hillside cutting.
1.8.7.2.4 All excavation shall generally be described as èxcavate and get out'. Getting out shall
include throwing the excavated earth at least one metre or U3 depth ( see Note) of excavation
whichever is more clear of edge of the excavation. The subsequent disposal of surplus
excavated material shall either be stated as a separate item or included with the item of
excavation stating the lead.
NOTE -In special cases where disposal area is limited or where application of this
requirement is impracticable, the person in-charge may adopt a berm of reduced width in any
case not less than 600 mm provided the material being excavated is sufficiently stable and
shoring is designed to carry the additional loads.
1.8.7.2.5 In case of the following works, quantities (calculated on the basis of working space) or
those actually whichever, are less, shall be measured:
a) In work which requires formwork;
b) In work which will be covered externally with a damp proof covering;
c) In work which will be covered externally with protective masonry work of brick,
stone, precast concrete, etc.
d) Trenches which are to receive post tensioned concrete ground beams;
e) Special works like guniting, etc. and
f) In work which requires workmen to operate from outside.
1.8.7.2.5.1 Authorised working space shall be specified in each case. Where authorised working
space is not so specified the following shall apply:
a) 600 mm measured from the face of substructure (including protective measures, if

any) at lowest level, where extra working space is required. In addition, for item (d)
given in 1.8.7.2.5 (d) the extra length at each end shall be I.5 m.
1.8.7.2.6-Battering and benching shall be specified and measured along with main item of
excavation.
1.8.8-Filling:
1.8.8.1-Actual measurement of fill shall be calculated by taking levels of the original ground before
start of the work after site clearance and after compaction of the fill at suitable intervals and the
quantity of fill computed from these levels.
1.8.8.2-Deductions shall be made from actual measurements in all cases of fills except for floors as in
1.8.17 to arrive at net measurement of filling based on pre-accepted or specified deduction ( stated
as percentage ) for voids.
1.8.8.3-If the filling is obtained from the borrow pits it shall be measured from the. borrow pits as
èxcavation' ( see 1.8.7.2 ).
1.8.9-Surface Dressing: Trimming of natural ground, excavated surface and filled up area to remove
vegetation and/or small inequalities not exceeding I50 mm deep shall be described as surface dressing
and measured in square metre.
1.8.10-Rough Excavation: Excavation not requiring dressing of sides and bottom and reduction to
exact levels, such as winning earth from borrow pits, hillside cutting, etc. shall be described as rough
excavation and measured in cubic metre.
1.8.11- Surface Excavation: Excavation exceeding 1.5 m in width as well as 10 m2 on plan but not
exceeding 300 mm in depth shall be described as `surface excavation' and measured in square metre.
1.8.12-Excavation Over area: Excavation exceeding 1.5 m in width as well as 10 m2 on plan, and 300
mm in depth shall be described as excavation over areas and measured in cubic metre.
1.8.13-Excavation in Trenches for Foundations and for Pipes, Cables, etc.: Excavation in trenches
for foundations and for pipes, cables, etc., not exceeding 1.5 m in width and for shafts, wells, cesspits
and the like not exceeding 10 m2 on plan shall be so described and measured in cubic metre.
1.8.13.1-The authorized quantities ( calculated on the basis of authorized width) or those excavated
whichever are less shall be measured in case of excavation for pipes, cables, etc. For the purpose of
calculating the contents, cross-sections shall be taken at suitable intervals. The authorised width shall
be specified in each case.
1.8.13.2-Excavation Trenches , for Foundations : For depth exceeding 1 m, an allowance of 50
mm/m depth for each side of trench shall be added to the specified width.
1.8.14-Post Holes : Independent post holes (or similar holes ), each not exceeding 0.5 m in length,
width and depth , shall be enumerated and the description shall include return, fill and ram and
removal of surplus spoil.
1.8.15-Return, Fill and Ram: Returning, filling and ramming of excavated earth where not described
with the item of excavation shall be measured in cubic metre and shall include spreading in layers not
exceeding 200 mm in depth, watering, well ramming and levelling.
1.8.16-Embankments Forming embankments and filling to make up levels shall be measured in
cubic metre and shall include the formation of slopes. If the material is to be deposited in layers,

this shall be described stating the thickness of such layers. The method of consolidation shall be
described. The measurement shall be taken in successive stages of 1.5 m stating commencing level. In
case of special soils like marine clay, the allowance for change in the original levels due to load of an
embankment shall be specified.
1.8.17-Filling under floors shall be measured in cubic metre and shall include spreading in layers
not exceeding 200 mm in depth watering, well ramming and levelling.
1.8.18- Lead and Lift:
1.8.18.1 Lead :The distance for removal shall be measured over the shortest practicable route and not
necessarily the route actually taken. Distances not exceeding 250 m shall be measured in units of 50
m. Distance exceeding 250 m and not exceeding 500 m shall be measured as a separate item. Leads
beyond 500 m shall be measured in units of 500 m, that is, there will be one item for lead exceeding
500 m and not exceeding 1 000 m, another item for lead exceeding 1 000 m and not exceeding 1500
m and so on up to 5 km. Where the lead exceeds 5 km, it will be measured in units of 1 km, half km
and above that be reckoned as one km and less than half kilometre shall be ignored.
1.8.18.1.1 The description of items shall include loading and unloading.
1.8.18.1.2- If spoil heaps requiring re-handling have become consolidated due to passage of time or
any other reason, it shall be so stated and such heaps shall be measured separately.
1.8.18.1.3- For the purpose of measurements of lead, the area excavated shall be divided into suitable
blocks and for each block the distance from the centre of the block to centre of placed earth pertaining
to this block shall be taken as lead.
1.8.18.2- Lift :Lift shall be measured from ground level. Excavation up to 1.5 m depth below ground
level and depositing excavated material on the ground shall be included in the item of earthwork for
various kinds of soil. Extra lift shall be measured in unit of 1.5 m or part thereof. Obvious lifts shall
only be measured; that is lifts inherent in the lead due to ground slope shall not be measured ( except
for lead up to 250 m ). When earth has to be carried over a bank / obstruction and dumped beyond it,
the lift shall be the difference in level between the centre of gravity of the excavated earth and the
top of bank/construction.
1.8.19- Planking and Strutting: The planking and strutting required to uphold the face of excavated
earth, etc. shall be measured in square metre of face supported, and grouped; separately in stages of
1.5 m.
1.8.19.1-The description shall include use and waste of all necessary timber work, including wales,
struts and open or close poling boards, their fixing and subsequent removal.
1.8.19.2-Planking and strutting to the following shall be measured separately:
a) Trenches;
b) Areas (the description shall include use and waste of raking shores); and
c) Shafts, wells, cesspits, manholes and the like.
1.8.19.3-Where tightly driven close butt jointed sheeting is necessary as in the case of running sand,
the item shall be measured separately and the packing of cavities behind sheeting with suitable
material shall be included in description of the item.
1.8.19.4 Planking and strutting required to be left permanently in position shall be measured
separately.

1.8.20- Removing Trees and Hedges:
1.8.20.1-Clearing of shrubs, brushwood, small trees not exceeding 300 mm girth shall be
measured in square metre, and shall deem to include removal and disposal. The girth shall be
measured at 1 m above ground level.
1.8.20.2-Cutting down hedges and removal of fences shall be fully described and measured in
running metre and shall deem to include removal and disposal.
1.8.20.3-Cutting down trees of 300 mm girth and over up to 1 000 mm girth shall be enumerated as
one item. The cutting down of trees exceeding 1000 mm in girth shall be enumerated stating the
girth. The girth shall be measured at one metre above ground level. The item shall include lopping
of branches and removal and disposal.
1.8.20.4-Digging out of roots including stacking shall be measured separately and enumerated. 1.9.
Earth Work by Mechanical Means:
Earth work by mechanical means involves careful planning keeping in view site conditions i.e. type of
soil, nature of excavation, distances through which excavated soil is to be transported and working
space available for deploying these machines. The earth moving equipment should be accordingly
selected. The earth moving equipment consists of excavating and transporting equipment. Excavating
equipment may be further classified as excavators and tractor based equipment. For details, see
Appendix 'B'.
The measurement ( as per IS:1200-part 27, 1992) of earthwork shall be done in cubic meters
unless otherwise mentioned.
The measurement to be taken with staff and level. The level shall be recorded to correct to 5
mm and depth of cuttings and heights of levels calculated correct to 5 mm. Cubical contents
shall be done to the nearest place of decimals in cubic metre. Where ordinary rock and soil is
mixed, the measurement of the excavation shall be recorded for the entire excavation.
Excavated material of ordinary rock shall be stacked, separately measured and reduced by 50
percent to allow for voids to arrive at quantity payable under ordinary rock. The difference
between the entire excavation and dome of the quantity payable under ordinary rock shall be
payable as excavation in ordinary soil.
1.9.1.2 Where it is not possible or convenient to take measures from borrow pits or cuttings
volume of work done shall be worked out from filling. The actual measurement of the fill
shall be calculated after taking the levels of the original grounds before start of the work after
site clearance and after compaction of fill at the desired density which should be specified
in advance.
1.9.1.3 All works shall be measured net in decimal system as fixed in position as given below:
a) Each dimensions shall be measured to the nearest 0.01 m where any dimension is
more than 25 m it shall be measured nearest to 0.1 m,
b) Areas shall be worked out to the nearest 0.01 m2 and
c) Cubical contents shall be worked out to the nearest 0.01 m3. 1.9.1.4
Work executed in the following conditions shall be measured separately:
a) work in or under water,
b) Work in or under foul position,

c) Work under tides, and
d) work under snow.
1.9.1.5 The bill of quantities shall fully describe the material, workmanship and accurately represent
the work to the executed.
1.9.1..6 The description of items shall include loading and unloading.
1.9.1.7 The following work shall not be measured separately and allowance for the same shall be
deemed to have been made in the description of item:
a) Setting out of work, profiles etc.,
b) Site clearance, such as, cleaning grass and vegetation,
c) Unauthorized battering or benching of excavation,
d) Excavation for insertion of planting or strutting,
e) Unless otherwise specified removing slips or falls in excavation,
f) Bailing out or pumping out of water in excavation from rains,
g) Bailing out or pumping out of water when measured underground, and
h) Slinging pipes electric cables, etc., met during excavation.
1.9.2 Backfilling done by mechanical means should be calculated by deducting the volume of
structure below the underground from the original measured volume of excavation done.
1.9.3 Lead :The lead for filling and removal shall be measured over the specified route or over the
shortest practicable route to be traversed by machinery. The leads exceeding 500 m should
be measured in units of 500 m. Where the lead exceeds 5 km it shall be measured in units of
1 km. Half km and above should be reckoned as one and less than half km ignored.
1.9.3.1 Travelling distance by reasonable path from centre of gravity of the excavated pond to
centre of gravity of the dumping ground be taken as lead.
1.9.3.2 Spoil heap when it has become consolidated due to passage of time or otherwise shall be so
stated and measured separately.
1.9.4 Lifts : In earth work done by mechanical means, lift shall not be measured separately.
1.9.5 The planking and strutting required to uphold the face of excavated earth shall be measured in
square metre of face supported. The description shall include use and wastage of all works
including waste struts boards inclusive of fixing and removal. Planking and strutting required
to be left permanently in position shall be measured separately.
1.10 : Earth work in Filling:
a) The earth used for filling shall be free from all roots, grass, shrubs, rank vegetation,
brushwood, tress, sapling and rubbish.
b) Filling with excavated earth shall be done in regular horizontal layers each not exceeding 20
cm in thickness. All lumps and clods exceeding 8 cm in any direction shall be broken. Each
layer shall be watered and consolidated with steel rammer or 0.5 tonne roller. Where specified,
every third and top most layer shall also be consolidated with power roller of minimum 8
tonnes. Wherever depth of filling exceeds 1.5 metre, vibratory power roller shall be used to
consolidate the filling unless otherwise directed by Engineer-in-charge. The top and sides

of filling shall be neatly dressed. The contractor shall make good all subsidence and shrinkage
in earth fillings, embankments, traverses etc. during execution and till the completion of work
unless otherwise specified.
1.10.1 Measurements :
a) The length and breadth of excavation shall be measured with a calibrated steel tape correct
to the nearest cm. The depth of cutting or height of filling shall be measured, correct to 5
mm, by recording levels before the start of the work and after the completion of the work. The
cubical contents shall be worked out to the nearest two places of decimal in cubic metre.
b) In case of open footings up to the depth of 1.5 metre, an excavation of 30 cm in width beyond
the outer dimension of footing shall be measured all around for payment to make allowances
for centring and shuttering. Any additional excavation beyond this limit shall be at the risk and
cost of the contractor and shall not be measured for payment.
c) In case of open footings/Rafts at a depth of more than 1.5 metre, all around excavation of 75
cm wide shall be measured for payment to make allowance for centring and shuttering.
Additional excavation beyond this limit shall be at the risk and cost of the contractor and
shall not be measured for payment.
d) In case the ground is fairly uniform and where the site is not required to be levelled, the
Engineer-in-Charge may permit the measurements of depth of cutting or height of filling
with a calibrated steel tape, correct to the nearest cm. In case of borrow pits, diagonal ridges,
cross ridges or dead-men, the position of which shall be fixed by the Engineer-in-Charge,
shall be left by the contractor to permit accurate measurements being taken with steel tape on
the completion of the work Deduction of such ridges and dead men shall be made from the
measurements unless the same are required to be removed later on and the earth so removed
is utilized in the work. In the latter case nothing extra will be paid for their removal as
subsequent operation.
e) Where ordinary rock and hard rock is mixed. The measurement of the excavation for each
such layer shall be made with level instruments) levels at a pre-determined grid before and after
excavation) as directed by the Engineer-in-Charge. The two kinds of rock shall be stacked separately
and measured in stacks. The net quantity of the two kinds of rocks shall be arrived at by applying
deduction of 50% to allow for voids in stacks. If the sum of net quantity of two kinds of rocks exceeds
the total quantity of the excavated material, then the quantity for each type of rock shall be worked out
from the total quantity in the ratio of net quantities in stack measurements of the two types of rocks. If
in the opinion of the Engineerin-charge stacking is not feasible, the quantity of ordinary and hard rock
shall be worked out by means of cross-sectional measurements.
Where soil, ordinary rock and hard rock are mixed, the measurements for the entire excavation shall be
made as specified in (e )above. Excavated materials comprising soil, hard rock and ordinary rock shall
be stacked separately, measured, and each reduced by 50% to allow for voids to arrive at the net
quantity.
Recording Measurements for Earth Levelling Work:
Level Books: In case of levelling operations and earthwork, measurements are required to be
recorded in level books in addition to Measurement Books. The Level Books should be

numbered, accounted for and handled like Measurement Books. The level measurements shall
be taken before and after the work at a grid of l x 1 m to 10x 10 m depending upon the
terrain/site conditions. The grid shall be specified by the Engineer-in Charge.
Preparatory Works: Before starting the earth work, following steps should be taken:
Original ground levels should be recorded in the Level Book in the presence of the contractor or
his authorized representative, and should be signed by him and the Department Officer who
records the levels. All the local mounds and depressions should be indicated clearly in the
drawing and the field Level Book and should be checked by the Assistant Engineer/ Engineer-
in-Charge before the levelling work is started.
(b) A suitable baseline should be fixed with permanent masonry pillars at distances not
exceeding
150 metre to provide a permanent reference line for facilitating check work. The base line
(s) should be entered in the Level Book with co-ordinates. These baselines should be
maintained till the final payment for the work has been made.
(c) While recording the levels, it should be ensured that the circuit is closed by taking final levels
of the starting point or any other point, the R.L. of which was previously determined.
(d) Plans showing initial levels, location of bench marks and reduced levels, should be prepared
and signed by both the parties ( Engineer-inCharge and the Contractor) and attached to the
agreement before commencement of the work.
1.10.4 Test Check of the Levels :
(a) The Junior Engineer shall cross check all levels, the Assistant Engineer should exercise test
check at least to the extent of 50%, and the Executive Engineer at least to the extent of 10%
wherever the value of this item of work exceeds 10% of the Contract value .
(b) The test check of the levels should be carried out independently by each officer, and the
readings should be recorded in the prescribed Level Book in red ink against the old levels
which should be neatly scored out wherever necessary. If the test check carried out reveals
serious mistakes in the original levels, these should be taken or re-taken and re-checked.
(c) The test check carried out by an officer should be as representative/ well spread as possible
for the entire work done, ensuring connect measurement & payment.
(d) On completion of work, the levels should again be recorded in the Level Book and the
contractor's signatures obtained. These levels should also be test checked by the Junior
Engineer /Assistant Engineer / Executive Engineer to the same extent as indicated in (a)
within one month of the date of completion of the earth work, and according to the procedure as
laid down in the case of initial levels as indicated above.
(e) The formation levels as per final execution of the work should be compared with the
designed / proposed formation levels and the work got rectified within permissible
tolerance.
1.10.5 Payment of Levelling Work:
(a) Every running bill and the final bill should be paid on the basis of levels.
1.10.6 Large Scale Levelling Work:
(a) In case of large scale levelling work involving both cutting and filling, an accurate site plan
should be prepared before the work is commenced. The portions requiring cutting and filling
shall then be divided into squares and corresponding squares into filling, which are
complementary to the squares in cutting given the same number.
(b) A table may be written upon the plan showing leads involved between the various
complementary squares. This would form a lead chart for the work to be done.
(c) Before the work of levelling is commenced, the lead chart shall be checked by the Assistant
Engineer in the presence of the contractor or his authorized representative, and his signatures
shall be obtained on the same. This should form an integral part of the contract and should be
duly signed by both the parties ( Engineer-in-Charge and the contractor) before
commencement of the work.
(d) The quantity payable for earthwork shall be lower of the quantity derived from cutting or
filling. The payment for lead shall be based on lead chart prepared in the aforesaid manner.
1.10.7 Import of Earth:
In case of earth is to be imported, the area (and the quality of soil be approved) from where the earth
is to be imported, should be pre-determined wherever possible before the start of the work, and
wherever feasible, the average lead should be worked out and stipulated in the tender. After this is
determined, initial levels of the area to be filled should be recorded. The levels should be properly
checked during the progress of work and on completion.
1.10.8 Rates : As quoted/specified for Earthwork, shall include the following:
(a) Excavation and depositing / disposal of excavated material as specified.
(b) Handling of antiquities and useful material as specified.
(c) Safety and Protection as specified.
(d) Site clearance as specified.
(e) Setting out and making profiles as specified.
(f) Forming (or leaving) dead - men or `Tell Tales' in borrow pits and their removal after
measurements.
(g) Bailing out or pumping of rain water from excavations.
(h) Initial lead of 50 m and lift of 1.5 m.
(i) Blasting operations for hard rock as specified.
1.10.8.1 No deduction shall be made from the rate if in the opinion of the Engineer- in-charge,
operations specified in 1.10.8 (b) to (h) are not required to be carried out on any account
whatsoever.
1.10.9 Surface Excavation : Excavations exceeding 1.5 m in width and 10 sqm on plan but not
exceeding 30 cm in depth in all types of soils and rocks shall be described as surface excavation and
shall be done as specified in 1.4.1 and 1.4.2-1.4.4. It shall be measured and paid in square metre.
1.10.9.1 Measurements : The length and breadth shall be measured with a calibrated steel tape
correct to the nearest cm and the area / volumes worked out to the nearest two places of decimal in
square metre/ cubic metre as specified in IS 1200 (P-I)-1992.
1.10.9.2 Rate shall be as specified inl.10.8.
1.10.10. Rough Excavation and Filling:
a) Excavation for earth from borrow pits, cutting hill side slopes etc. shall be described as
rough excavation and shall be done as specified in respective clauses 1.4.1-1.4.4 above.
b) Wherever filling is to be done, suitable earth from excavation shall be directly used for
Filling
and no payment for double handling of earth shall be admissible. Filling of excavated earth
shall be done as specified in 1.10. In case of hill side cutting, where the excavated materials is
thrown down the hill slopes, payment for filling excavated earth shall not be admissible.
1.10.11 Measurements shall be in cum as specified in 1. 10.9.1.
1.10.12 Rates shall be as specified in 1.10.8.
1.10.13 Excavation Over Area (all kinds of soil): This shall comprise:
(a) Excavation exceeding 1.5 m in width and 10 sqm on plan and exceeding 30 cm in depth.
(b) Excavation for basements, water tanks etc.
(c) Excavation in trenches exceeding 1.5 m in width and 10 sqm on plan.
1.10.13.1 Excavation shall be done as specified in 1.4.1.
1.10.13.2 Measurements shall be as specified in 1.10.9.1/ IS : 1200 (P-I) -1992.
1.10.13.3 Rates shall be as specified in 1.10.8.
1.10.14 Excavation Over Area (Ordinary/ Hard Rock):This shall comprise:
1.10.14.1 Excavation shall be done as specified in 1.4.2 and 1.4.4.
1.10.14.2 Measurements shall be done as specified in 1.10.9.1 / IS: 1200 (P-I)-1992.
1.10.15 Excavation in Trenches for Foundations and Drains (all kinds of soil): This shall
comprise excavation not exceeding 1.5 m in width or 10 sqm on plan and to any depth in
trenches (excluding trenches for pipes, cables, conduits etc.).
1.10.15.1- Excavation shall be done as specified in 1.4.1.
1.10.15.2- Measurements shall be as specified in 1.10.9.1.
1.10.15.3- Rates shall be as specified in 1.10.8.
1.10.16 Excavation over area (all kinds of soil):
1.10.16.1 This shall comprise:
1.10.16..2 Excavation shall be done as specified in 1.4.1
1.10.16.3 Measurements shall be as specified in 1.10.
1.10.16..4 Rates shall be as specified in 1.10.8.
1.10.17 Excavation in Trenches for Foundation and Drains (ordinary/ hard rock):This shall
comprise excavation not exceeding 1.5m in width or 10 sqm. On plan and to any depth in
trenches (excluding trenches for pipes, cables, conduits etc.)

1.10.17.1 Excavation shall be done as specified in 1.4.2, 1.4.3 and 1.4.4.
1.10.17.2 Measurements shall be as specified in 1.10.11.
1.10.18 Excavation over areas in trenches for foundations and drains (ordinary/hard rock): for
excavations exceeding 1.5 m in width and 10 sqm on plan, shall be excavated as per 1.4.2-1.4.4, shall
be measured as per 1.10 and the rates applicable shall be as per 1.10.8
1.10.19 Excavation in Trenches for Pipes, Cables etc. and Refilling : This shall comprise
excavation not exceeding 1.5 m in width or 10 sqm in plan and to any depth for trenches for pipes,
cables etc. and returning the excavated material to refill the trenches after pipes, cables etc. are laid
and their joints tested and passed and disposal of surplus excavated material up to 50 m lead.
1.10.19.1 Width of Trench :
(a) Up to one metre depth, the authorized width of trench for excavation shall be arrived at by
adding 25 cm to the external diameter of pipe (not socket/ collar) cable, conduit etc. Where a pipe
is laid on concrete bed/ cushioning layer, the authorised width shall be the external diameter of pipe
(not socket/ collar) plus 25 cm or the width of concrete bed/ cushioning layer whichever is more.
(b) For depths exceeding one metre, an allowance of 5 cm per metre of depth for each side of the
trench shall be added to the authorized width (that is external diameter of pipe plus 25 cm) for
excavation. This allowance shall apply to the entire depth of the trench. In firm soils the sides of
the trenches shall be kept vertical up to depth of 2 metre from the bottom. For depths greater
than 2 m, the excavation profiles shall be widened by allowing steps of 50 cm on either side
after every two metre from bottom.
(c) Where more than one pipe, cable, conduit etc., are laid, the diameter shall be reckoned as the
horizontal distance from outside to outside of the outermost pipes, cable, conduit etc.
(d) Where the soil is soft, loose or slushy, width of trench shall be suitably increased or side sloped
or the soil shored up as directed by the Engineer-in-Charge. It shall be the responsibility of the
contractor to take complete instructions in writing from the Engineer-in-Charge regarding increase
in the width of trench. Sloping or shoring to be done for excavation in soft, loose or slushy soils.
1.10.19.2 Excavation: Shall be done as specified inl.4.1, 1.4.2, 1.4.3 and 1.4.4.
1.10.19.3 Refilling : Filling in trenches shall be commenced soon after the joints of pipes, cables,
conduits etc. have been tested and passed. The space all around the pipes, cables conduits
etc. shall be cleared of all debris, brick bats etc. Where the trenches are excavated in hard/ soft
soil, the filling shall be done with earth on the side and top of pipes in layers not exceeding
20 cm in depth. Each layer shall be watered, rammed and consolidated. All clods and lumps
of earth exceeding 8 cm in any direction shall be broken or removed before the excavated earth
is used for filling. In case of excavation trenches in ordinary/ hard rock, the filling up to a depth
of 30cm above the crown of pipe, cable, conduits etc. shall be done with fine material like earth,
moorum or pulverized/ decomposed rock according to the availability at site. The remaining
filling shall be done with boulders of size not exceeding 15cm mixed with fine material like
decomposed rock, moorum or earth as available to fill up the voids, watered, rammed and
consolidated in layers not exceeding 30cm. Excavated material

containing deleterious material, salt peter earth etc. shall not be used for filling. Ramming
shall be done with iron rammers where feasible and with blunt ends of crow bars where
rammers cannot be used. Special care shall be taken to ensure that no damage is caused to the
pipes, Cables, Conduits etc. laid in the trenches. The as laid details (invert leveUdepth, location
on plan etc.) , shall be recorded and plotted on the as built drawings.
1.10.19.4 Measurements: Trenches for pipes, cables, conduits etc. shall be measured in running
metre correct to the nearest cm in stages of 1.5 m depth and described separately as under:
(a) Pipes, cables, conduits, etc. not exceeding 80 mm dia.
(b) Pipes, cables, conduits etc. exceeding 80 mm dia. but not exceeding 300mm dia.
(c) Pipes, cables, conduits etc. exceeding 300 mm dia.
1.10.19.5 Where two or more categories of each work are involved due to different classification of
soil within the same stage of trench depth or where the soil is soft loose or slushy requiring
increase in the width of trench or sloping sides or shoring, trenches for pipes, cables, conduits,
etc. shall be measured in cubic metre as specified in 1.10. Extra excavation, if any, on account
of collar/ socket of pipes shall neither be measured nor paid for separately.
1.10.19.6 Rates : The rate shall be as specified in 1.10.8 and shall also include the cost of refilling and
all other operations described above.
1.10.20 Excavation in Trenches for Pipes, Cables etc. and Refilling : For widths exceeding 1.5 m
and exceeding 10 sqm on plan shall be excavated as per 1.4.1, 1.4.2-1.4.4, measured as per
1.10.1 and rates applicable shall be as per 1.10.8
1.11 Blasting:
1.11.1 Where hard rock is met with and blasting operations are considered necessary, the contractor
shall obtain the approval of the Engineer-in-charge in writing and/or from the competent body
as per the law ( Indian Explosives Act) for blasting operations before resorting to blasting
operations. The methodology and equipment for controlled blasting shall be got approved by
the Engineer-in-Charge. The blasting shall be done with all due precautions / warnings as
required under the Explosives Act. Approval by the Engineer-in Charge shall not relieve the
contractor of his overall responsibility for damages to public & others properties, men or
animal, equipment etc. on account of improper blasting.
1.11.2 In ordinary rock, blasting operations shall not be generally adopted. However, the contractor
may resort to blasting with the permission as above, but nothing extra shall be paid for such
blasting operations.
1.11.3 or to blasting operations contractor shall obtain license from the competent authority for
undertaking blasting operations as well as for procuring and storing explosives as per
Explosive Act, 1884 as amended up to date and the Explosive Rules - 1983. The Contractor
shall purchase the explosive fuses, detonators etc. only from a licensed dealer. The contractor
shall be responsible for the safe custody and proper accounting of the explosive materials.
Fuses and detonators shall be stored separately and away from the explosives. The Engineerin-
charge or his authorized representative shall have the right to check the contractor's store and
account of explosives. The Contractor shall provide necessary facilities for this. The
contractor shall be responsible for any damage arising out of accident to workmen, public or
property due to storage, transportation and use of explosive during blasting operation.

1.11.4 See Appendix 'C' for blasting materials and methodology.
1.12 Excavation operations in all Kinds of Soils :
a) All excavation operations manually or by mechanical means shall include excavation and
`getting out' the excavated materials. In case of excavation for trenches, basements, water tanks
etc. `getting out' shall include throwing the excavated materials at a distance of at least one metre
or half the depth of excavation, whichever is more, clear off the edge of excavation. In all other
cases `getting out' shall include depositing the excavated materials as specified. The subsequent
disposal of the excavated material shall be either stated as a separate item or included with the
items of excavation stating lead.
b) During the excavation, the natural drainage of the area shall be maintained. Excavation shall
be done from top to bottom. Undermining or undercutting shall not be done.
c) In firm soils, the sides of the trenches shall be kept vertical up to a depth of 2 metre from the
bottom. For greater depths, the excavation profiles shall be widened by allowing steps of 50 cm
on either side after every 2 metre from the bottom. Alternatively, the excavation can be done
so as to give slope of 1:4 (1 horizontal: 4 vertical). Where the soil is soft, loose or slushy, the
width of steps shall be suitably increased or sides sloped or the soil shored up as directed by the
Engineer-in-
Charge. It shall be the responsibility of the contractor to take complete instructions in writing
from the Engineer-in-Charge regarding the stepping, sloping or shoring to be done for
excavation deeper than 2 metre.
d) The excavation shall be done true to levels, slope, shape, drawings, and pattern indicated by
the Engineer-in-Charge. Only the excavation shown on the drawings with additional allowances
for centring and shuttering or as required by the Engineer-in-Charge shall be measured and
recorded for payment.
e) In case of excavation for foundation in trenches or over areas, the bed of excavation shall be
dressed to the correct level or slope and consolidated by watering and ramming. If the excavation
for foundation is done to depth greater than that shown in the drawings or as required by the
Engineer-in-Charge, the excess depth , erroneously dug , shall be made good by the contractor at
his own cost with concrete of the mix used for levelling / bed concrete for foundations.
Soft/defective spots at the bed of the foundations shall be dug out and filled with bed concrete
(to be paid separately) as directed by the Engineer-in-Charge.
f) While carrying out the excavation for drain work, care shall be taken to cut the side and bottom
to the required shape, slope and gradient. The surface shall then be properly dressed. If the
excavation is done to a depth greater than that shown on the drawing or as required by the
Engineer-in-Charge, the excess depth shall be made good by the contractor at his own cost with
stiff clay puddle at places where the drains are required to be pitched and with ordinary earth,
properly watered and rammed, where the drains are not required to be pitched. In case the drain
is required is to be pitched, the back filling with clay puddle, if required, shall be done
simultaneously as the pitching work proceeds. The brick pitched storm water drains should be
avoided as far as possible in filled-up areas and loose soils.
g) In all other cases of drains , where the excavation is taken deeper by the contractor, it shall be
brought to the required level by the contractor at his own cost by filling in with earth duly
watered, consolidated and rammed.

In case the excavation is done wider than that shown on the drawings or as required by the
Engineer-in-Charge, additional filling wherever required on this account shall be done by the
contractor at his own cost.
The excavation shall be done manually or by mechanical means as directed by Engineer-in-
charge considering feasibility, urgency of work, availability of labour /mechanical equipment and
other factors involved. Contractor shall ensure all safety measures for the workers. Neither any
deduction will be made nor any extra payment will be made on this account.
j) Excavation in wet soil: When the excavation is below subsoil water level, it is classified as wet
excavation. The contractor shall clarify from the Engineer-in-Charge about the level from which
wet excavation commences before excavating in wet soil. The mode of bailing out and disposal
of water shall be got approved from the Engineer-in-Charge before taking up such work.
1.13 Excavation operations in Ordinary/Hard Rock.:
1.13.1 Chiselling and wedging: When rock requiring blasting is to be taken out close to another
building or when blasting is prohibited by the Engineer, the excavation shall be carried out by
chiselling, wedging or any other method approved by the Engineer-in-Charge.
1.13.2 Stacking of useful materials: All the useful materials obtained from rock excavation shall be
stacked at site by the contractor at his own expense as directed by the Engineer-in-Charge. No
extra payment shall be made for this and this shall be a part of the item of excavation.
1.13.3 The Contractor shall be responsible for any damage arising out of accident to work men,
public or property due to storage, transportation and use of explosives during blasting
operations. He shall procure wholesome insurance covers for any occurrence at his cost in the
joint name of the Engineer-in-charge and himself.
1.14 General recommendation for Safety considerations (IS 3764-1996) in Excavation work:
a) Responsibilities of Foremen and Supervisors
In all works, an experienced and competent foreman or supervisor shall be placed in charge of
the work whose authority and responsibilities have been made clear to him and his subordinates.
The foreman or supervisor shall be made responsible for the strict observance, of the safety
rules. He shall have full authority to enforce the rules, guard against the use of defective safety
appliances, rigging, tools and materials, to see that no man is permitted to do work for which he
is not qualified, and to brief all workmen on the plan of work before work is started with special
emphasis on all potential hazards and on the ways to eliminate or guard against them.
b) Sides of excavation shall be inspected by foreman or supervisor during the course of
excavation from time to time and after every rain, storm or other hazard-increasing occurrence
and protection against slides and caving shall be increased, if necessary.
c) Complete information on the underground structures (such as water pipelines, sewers, gas
mains, electrical conduit system and other civic facilities) is essentially to be provided by the
Engineer-in-Charge, before doing the excavation work. Proper precautions shall be taken to
prevent accident to such services, the workmen engaged in excavation work and accidental
calamities for the general public.
d) No excavation or earthwork below the level of any foundation of building or structure shall be
commenced or continued unless adequate steps are taken to prevent damage/danger to the

structure, persons employed or general public, from collapse of the structure or fall of any part
thereof. Such eventualities shall be adequately covered with an insurance cover procured by the
contractor in the joint name of the Engineer-in-charge and himself. The Engineer-in-Charge
shall depute his Assistant Engineer/Junior Engineer exclusively to supervise such excavations
and issue detailed `do's and don'ts to the contractor for such excavations.
e) Where medical facilities are not available nearby, first aid facilities like a first-aid kit and a
trained paramedic shall be maintained at the site of work. This shall be kept at a conspicuous
place in the charge of trained person(s). The kit shall be recouped periodically.
f) Workers :Workers shall be instructed to use safety devices and appliances provided to them
whenever it is necessary to do so.
g) Workers who are not aware of the hazards peculiar to the work shall not be permitted to proceed
with the work without being properly instructed. They should preferably be under the close watch
of a properly qualified and authorized person whose instructions shall be obeyed by these
workers.
h) In case any worker feels that he cannot perform a work safely, he shall immediately inform
the foreman or supervisor of his inability to carry on with the work.
i) Safety helmets and chains /belt shall be worn by all persons entering trench where hazards
from falling stones, timber or other materials exist.
j) Appropriate safety footwear (rubber boots, protective gloves, etc.) shall be worn by workers/
employees who are engaged in work requiring such protection.
1.15 Shoring and Timbering : General
a) All trenches in soil more than 1.5 m deep shall be securely shored and timbered.
b) All trenches in friable or unstable rock exceeding 2 m in depth shall be securely shored and
timbered.
Notes:
1. The above requirements do not apply in cases where the sides of the trenches are sloped
to within 1.5 m of the bottom. The slope that is provided for such purposes shall be
inspected and certified as stable by the Engineer-in-charge /persons in charge of work in
all cases.
2. Notwithstanding anything said above, it shall be understood that the need for shoring is
a matter which shall receive careful and frequent consideration even in trenches less than
1.5 m or 2 m in depth (as the case may be) and where there is any doubt as to the safety
of the work without shoring, no further excavation or other work shall be continued until
adequate shoring is provided.
c) Where the sides of trenches are sloped as specified but not to within 1.5 m of the bottom, the
vertical sides shall be shored and the shoring shall extend at least 30 cm above the vertical sides.
When open spaced sheathing is used, a toe board shall be provided to prevent material rolling
down the slope and falling into the part of the trench with vertical walls.
d) Shoring and timbering shall be carried along with the opening of a trench but when conditions
permit, protection work, such as sheet piling may be done before the excavation commences.

e) When the depth of excavation in loose/soft soil exceed 1.5 m. stepping, sloping and and/or
planking and strutting of sides shall be done. In case of loose and slushy soils, the depths at
which these precautions are to be taken, shall be determined by the Engineer-in-charge
according to the nature of soil.
f) Planking and strutting shall be `Close' or Òpen' depending on the nature of soil and the depth
of trench. The type of planking and strutting shall be sufficient to resist the soil pressure and shall
be determined by the Engineer-in-charge. It shall be responsibility of the contractor to take all
necessary steps to prevent the sides of trenches from collapse.
1.15.1 Planking and Strutting:
i) When the depth of trench in soft/loose soil exceeds 2 metre, stepping, sloping and/or planking
and strutting of sides shall be done. In case of loose and slushy soils, the depths at which these
precautions are to be taken , shall be determined by the Engineer-in-Charge according to the
nature of soil.
ii) Planking and strutting shall be `close' or òpen' depending on the nature of soil and the depth
of trench. The type of planking and strutting shall be determined by the Engineer-in-Charge. It
shall be the responsibility of the contractor to take all necessary steps to prevent the sides of
trenches from collapse.
iii) Engineer-in-Charge should take guidance from IS: 3764 for designing the shoring and
strutting arrangements and specifying the profile of excavation.
1.15.2 Close Planking and Strutting :
i) Close planking and strutting shall be done by completely covering the sides of the trench
generally with short upright, members called `poling boards'. These shall be 250x38 mm in
section or as directed by the Engineer-in-Charge. The boards shall generally be placed in
position vertically in pairs. One board on either side of cutting.
ii) These shall be kept apart by horizontal wailing's of strong wood at a maximum spacing of 1.2
metre cross strutted with ballies, or as directed by Engineer-in-Charge. The length and diameter
of the ballies strut shall depend upon the width of the trench. Typical sketch of close timbering
is given in Fig. 2.(page 34).
iii) Where the soil is very soft and loose, the boards shall be placed horizontally against the sides
of the excavation and supported by vertical `wailing's' which shall be strutted to similar timber
pieces on the opposite face of the trench. The lowest boards supporting the sides shall be taken
in the ground for a minimum depth of 75 mm. No portion of the vertical side of the trench shall
remain exposed.
iv) The withdrawal of the timber members shall be done very carefully to prevent collapse of the
trench. It shall be started at one end and proceeded systematically to the other end. Concrete or
masonry shall not be damaged while removing the planks. No claim shall be entertained for
any timber which cannot be withdrawn and is lost or buried, unless required by the Engineerin-
Charge to be left permanently in position.
1.15.3 Open Planking and Strutting:
i) In case of open planking and strutting, the entire surface of the side of the trench is not required
to be covered. The vertical boards 250 mm wide & 38 mm thick , shall be spaced sufficiency

apart to leave unsupported strips of 50 cm average width. The detailed arrangement, sizes of the
timber and the distance apart shall be subject to the approval of the Engineer-in-Charge. In all
other respect, specifications for close planking and strutting shall apply to open planking and
strutting. Typical sketch of open planking and strutting is given in fig. 2.
1.15.4 Measurements:
i) The dimensions shall be measured correct to the nearest cm and the area of the face supported
shall be worked out in square metre correct to two places of decimal. Works shall be grouped
according to the following:
(a) Depth not exceeding 1.5 m.
(b) Depth exceeding 1.5m in stages of 1.5 m.
Planking and strutting to the following shall be measured separately:
(a) Trenches.
(b) Areas- The description shall include use and waste of raking shores.
(c) Shafts, walls, cesspits, manholes and the like
(d) Where tightly driven close but jointed sheeting is necessary as in case of running sheeting
is necessary as in case of running sand the item shall be measured separately and packing
of cavities behind sheeting with suitable materials included with the item.
(e) Planking and strutting required to be left permanently in position shall be measured
separately.
1.15.5 Rates:
Rates shall include all operations, use and waste of all necessary timber work as mentioned above
including fixing and subsequent removal.
1.16 Excavation in or under Water, Mud or Foul position:
1.16.1 All water that may accumulate in excavation during the progress of the work from springs, tidal
or river seepage, broken water mains or drains (not due to negligence of the contractor) and seepage
from sub soil aquifer shall be bailed, pumped out or otherwise removed with well point or other
suitable equipment. The contractor shall take adequate measures for bailing and/or pumping out water
from excavation and construct diversion channels, bunds, sumps, coffer dams etc. as may be required.
Pumping shall be done directly from the foundation trenches or sump outside the excavation in such
a manner as to preclude the possibility of movement of water through any fresh concrete or masonry
and washing away parts of concrete or motor. During laying of concrete or masonry and for a period
of at least 24 hrs. thereafter, pumping shall be done from a suitable sump separated from concrete or
masonry by effective means. Steady water level in the trial pits before the commencement of bailing
or pumping operations shall be the sub-soil water level in that area. To prevent slipping of sides,
planking and strutting may also be done with the approval of the Engineer-in-charge.
1.16.2 Unless stated otherwise, the work of dewatering shall be extra and paid over and above the
rate of excavation, but no payment shall be made for bailing out of rainfall water.
1.16.3 Capacity and number of pumps, location at which the pumps are to be installed, pumping
hours etc. shall be decided from time to time in consultation with the Engineer-in-Charge.
1.16.4 Pumping shall be done in such a way as not to cause damage to the work or adjoining

property by subsidence etc. Disposal of water shall not cause inconvenience or nuisance in the area
or cause damage to any public or private property and structure nearby.
1.16.5 To prevent slipping of sides, planking and strutting may also be done with the approval of the
Engineer-in-Charge. It shall be payable extra.
a) The unit, namely, metre depth shall be the depth measured from the level of foul position/
subsoil water level and up to the centre of gravity of the cross sectional area of excavation
actually done in the conditions classified in 1.18.6, metre depth shall be reckoned correct to 0.1
m, 0.05 m or more shall be taken as 0.1 m and less than 0.05 m ignored.
b) The extra payment ( as percentage of the base rate or otherwise) is applicable in respect of each
item but the measurements shall be limited only to the quantities of earth work actually executed
in the conditions classified in1.18.6.
1.16.7 In case earth work in or under foul position is also in or under water and/or Liquid mud, extra
payment shall be admissible only for the earth work actually Executed in or under foul position.
1.16.8 Pumping or bailing out water met within excavations from the sources Specified in 1.18. lwhere
envisaged and specifically ordered in writing by the Engineer-in-Charge shall be measured separately
and paid. in KW. Hrs. or HP Hrs. against separate specific provision(s) made for the purpose. This
payment shall be in Addition to the payment under respective items of earthwork and shall be
admissible Only when pumping or bailing out water has been specifically ordered by the Engineerin-
Charge in writing.
1.16.9 Planking and strutting or any other protection work done with the approval of the Engineerin-
Charge to keep the trenches dry and/or to save the foundations against damage by corrosion of rise in
water levels shall be measured and paid for separately.
1.16.10 Bailing or pumping out rain water, accumulated in excavation, is included under respective
items of earthwork and is not to be paid separately.
1.16.11 Rates:
The rates for respective items described above shall include cost of all the operations as may be
applicable.
1.17 Earth Work for Major Works:
1.17.1 Excavation shall be undertaken to the width of the Basement/Retaining wall footing including
necessary margins for construction operation as per drawing or as directed otherwise. Where the
nature of soil or the depth of the trench and season of the year, do not permit vertical sides, the
contractor at his own expense shall put up the necessary shoring, strutting and planking or cut slopes
with or without steps, to a safer/stable angle or both with due regard to the safety of personnel and
works and to the satisfaction of the Engineer-in-Charge. Measurement of plan area ( as per approved
drawings) of excavation for payment shall be permitted only.
1.17.2 All the major excavation shall be carried out by mechanical excavator. No extra payment
shall be made for that.
a) The contractor shall make at his own cost all necessary arrangements for maintaining water level,
in the area where works are under execution low enough so as not to cause any harm to the work.
It shall be considered as inclusive of pumping out or bailing out water, if required, for which no
extra payment shall be made. This will include water coming from any source,

such as rains, accumulated rain water, floods, leakages from sewer and water mains , subsoil
water table being high or due to any other cause whatsoever. The contractor shall make
necessary provision of pumping, dredging, bailing out water coming from all above sources
and excavation and other works shall be kept free of water by providing suitable arrangements
b) In case the Sub-soil water table at work site is reported to be below the general ground level as
observed in the month of April and the water level is likely to rise up to 1 to 2 m. during rainy
season. The contractor, in order to avoid possibility of basement floor of main building being
getting uplifted/damaged due to water pressure, shall lower the ground water table below the
proposed foundation level by boring tube wells all around the proposed building using well
point sinking method or any suitable method as approved by Engineer-in-charge. Sub soil water
table shall be maintained at least 50 cm. below the P.C.C. bottom level during laying of PCC ,
water proofing treatment, laying of basement raft and beams including filling of earth/ sand under
the basement floor.
c) The water table shall not be allowed to rise above base of raft level until completion of outer
retaining walls including water proofing of vertical surface of walls and back filling along the
walls up to ground level and until the structure attains such height to counter balance the uplift
pressure. However, the contractor should inspect the site and make his own assessment about
sub-soil water level likely to be encountered at the time of execution and quote his rates
accordingly. Rate of all items are inclusive of pumping out or bailing out water, if required.
Nothing extra on this account whatsoever shall be paid to him. The sequence of construction shall
be got approved by the Engineer-in-charge.
1.17.3 The contractor shall take all necessary measures for the safety of traffic during construction and
provide, erect and maintain such barricades including signs, markings, flags, lights and flagman, as
necessary at either end of the excavation/embankment and at such intermediate points as directed by
the Engineer-in-charge for the proper identification of construction area. He shall be responsible for
all damages and accidents caused due to negligence on his part.
1.17.4 The contractor shall provide suitable barricading with suitably painted single row of G.I.
Sheets about 3'- 0" wide (90 cm.) nailed or bolted with wooden poles spaced 2 to 3 metre apart and
each pole 1.6 m to 2 m long, 8 cm. to 10 cm. dia. The poles will be embedded in mobile ( wheel
mounted) iron pedestal rings suitably framed for giving stable support as per direction of the Engineerin-
charge. All management (including watch and ward) of barricades shall be the full responsibility of
the contractor. The barricades shall be removed only after completion of the work or part of the work.
The contractor's rate shall include all above items of work and nothing extra shall be paid to the
contractor over and above his quoted rates.
1.18 Lift in Excavation / Earth Work : It is the vertical distance for removal against gravity with
reference to the ground level. The excavation up to 1.5 meter depth below the ground level and
depositing the excavated materials up to 1.5m meter above the ground level are included in the rate
of earth work. Lift inherent in the lead due to ground slope shall not be paid for.
1.18.1 Extra Width and Depth of Earth Work Excavation:
1.18.2 In all cases where the excavation is taken deeper by the contractor it shall be brought to the
required level by the contractor at his own cost by additional quantity of foundation concrete at his

cost. The extra depth also shall not be paid.
1.18.3 In case the excavation is done wider than that shown on the drawing or as required by the
Engineer-in-charge, the contractor shall provide side shuttering to the foundation concrete at his
cost. The extra width shall not be paid.
1.18.4 Measurements : The length and breadth of excavation of filling shall be measured with a
steel tape correct to the nearest cm. The depth of cutting or height of filling shall be measured correct
to 5mm by recording levels before the start of the work and after the completion of the work. The
cubical contents shall be worked out to nearest two places of decimal in cubic meter.
1.19 Earth work for Filling in Trenches plinth, under Floor etc.:
1.19.1 The Earth used for filling shall be free from all roots, shrubs, rank vegetation, brushwood,
organic soiUmatter , trees, sapling and rubbish.
1.19.2 Filling of excavated earth shall be done in regular horizontal layers each layer not exceeding
20cm in depth. All lumps and clods exceeding 8 cm in any direction shall be broken. Each layer
shall be watered to OMC and consolidated to MDD with steel rammer or 1/2 tonne roller. Where
specified, every third and top most layer shall also be consolidated with power roller of minimum 8
tonnes. The top and side of the filling shall be neatly dressed. The contractor shall make good all
subsidence and shrinkage in earth fillings embankments, traverses etc. during excavation and till the
completion of work unless otherwise specified.
1.19.3 Use of excavated Earth:
Normally excavated earth from same area shall be used for filling. Earth used for filling shall be free
from shrubs, rank vegetation, grass, brushwood, stone shingle and boulders (larger than 75 mm in any
direction), organic or any other foreign matter. Earth containing deleterious materials, salt peter earth
etc. shall not be used for filling. All clods and lumps of earth exceeding 8 cm in any direction shall
be broken or removed before the earth is used for filling.
1.19.4 Filling:
The space around the foundations, and drains in trenches shall be cleared of all debris, brick bats etc.
The filling shall be done in layers not exceeding 20 cm in depth. Each layer shall be watered, rammed
and consolidated as specified. Ramming shall be done with iron rammers where possible and with
blunt end of crow bars where rammers cannot be used. Special care shall be taken to ensure that no
damage is caused to the pipes, drains, masonry or concrete in the trenches. In case of filling under
floor, the finished level of filling shall be kept to the slope intended to be given to the floor.
1.20 Sand Filling in Plinth:
1.20.1 Sand:
Sand shall be clean and free from dust organic and foreign matter and its grading shall be within the
limits of grading zone IV specified in Chapter 4 'Mortars'.
1.20.2 Filling :
Sand filling shall be done in a manner similar to earth filling in plinth specified in 1.21.2 except that
consolidation shall be done by flooding with water. The surface of the consolidated sand filling shall
be dressed to the required level or slope and shall not be covered till the Engineer-in-Charge has
inspected and approved of the sand filling.

The length, breadth and depth of consolidated sand layer shall be measured with steel tape correct to
the nearest cm and cubical contents worked out in cubic metre correct to two places of decimal.
1.21 Surface Dressing:
1.21.1 Surface dressing shall include cutting and filling up to a depth of 15 cm and clearing of shrubs,
rank vegetation, grass, brushwood, trees and saplings of girth up to 30 cm measured at a height of
one metre above the ground level and removal of rubbish and other excavated material up to a distance
of 50 metre outside the periphery of the area under surface dressing. High portions of the ground shall
be cut down and hollow depressions filled up / compacted to the required level with the excavated
earth so as to give an even, neat and tidy look.
1.22 Jungle Clearance:
1.22.1 Jungle clearance shall comprise uprooting of rank vegetation, grass, brushwood, shrubs,
stumps, trees and saplings of girth up to 30 cm measured at a height of one metre above the ground
level. Where only clearance of grass is involved it shall be measured and paid for separately.
1.22.2 Uprooting of vegetation:
The roots of trees and saplings shall be removed to a depth of 60 cm below ground level or 30 cm
below formation level or 15 cm below subgrade level, whichever is lower. The stumps/ roots shall be
coated with Bitumen to prevent regrowth. All holes or hollows formed due to removal of roots shall
be filled up with earth rammed and levelled. Trees, shrubs, poles, fences, signs, monuments, pipe lines,
cable, etc. within or adjacent to the area which are not required to be disturbed during uprooting
shall be properly protected by the contractor at his own cost and nothing extra shall be payable.
1.22.3 Stacking and disposal:
All useful materials obtained from clearing and grubbing operation shall be stacked in the manner as
directed by the Engineer-in-Charge. Trunks and branches of trees shall be cleared of limbs and tops
and stacked neatly at places indicated by the Engineer-in-Charge. The materials shall be the property
of the Government. All unserviceable materials which in the opinion of the Engineer-in-Charge
cannot be used or auctioned shall be removed up to a distance of 50 m outside the periphery of the
area under clearance. It shall be ensured by the contractor that unserviceable materials are disposed
off in such a manner that there is no likelihood of getting mixed up with the materials meant for
construction.
1.22.4 Clearance of grass :
Clearing and grubbing operations involving only the clearance of grass shall be measured and paid for
separately and shall include removal of rubbish up to a distance of 50 m outside the periphery of the
area under clearance.
1.23 Felling of Trees :
1.23.1 Felling:
While clearing jungle, grown trees above 30 cm girth (measured at a height of one metre above
ground level) to be cut, shall be approved by the Engineer-in-Charge and then marked at site. Felling
trees shall include taking out roots up to 60 m below ground level or 30 cm below formation level or15
cm below sub-grade level, whichever is lower and treating the root stumps with bitumen

All excavations below general ground level arising out of the removal of trees, stumps. etc. shall be
conform to the surrounding area. The trunks and branches of trees shall be cleared of limbs and tops
and cut into suitable pieces as directed by the Engineer-in-Charge.
1.23.2 Stacking and Disposal :
Wood, branches, twigs of trees and other useful material shall be the property of the Government. The
serviceable materials shall be stacked in the manner as directed by the Engineer-in-Charge up to lead
of 50 m. All unserviceable material, which in the opinion of Engineer-in-Charge cannot be used or
auctioned shall be removed from the area and disposed off as per the directions of the Engineer-in-
Charge. Care shall be taken to see that unsuitable waste materials are disposed off in such a manner
that there is no likelihood of these getting mixed up with the materials meant for construction.
1.24 Anti-Termite Treatment ( Ref: IS 6313 P I-III):
1.24.1 General:
a) Sub-terranean termites are responsible for most of the termite damage in buildings. Typically,
they form nests or colonies underground, in the soil near ground level in a stump or other
suitable piece of timber in a conical or dome shaped mound. The termites find access to the
super-structure of the building either through the timber buried in the ground or by means of mud
shelter tubes constructed over unprotected foundations.
b) Termite control in existing as well as new building structures is very important, as the damage
likely to be caused by the termites to wooden members of building and other household article
like furniture, clothing, stationary etc. is considerable. Anti-termite treatment can be either
during the time of construction, i.e., pre-constructional chemical treatment or after the building
has been constructed, i.e. post construction treatment for existing buildings.
c) Prevention of the termite from reaching the super-structure of the building and its contents can
be achieved by creating a chemical barrier-between the ground, from where the termites come
and other contents of the building which may form food for the termites. This is achieved by
treating the soil beneath the building and around the foundation with a suitable insecticide.
1.24.2 Materials:
1.24.2.1 Chemicals:
a) Any chemical as per IS : 8944 in water emulsion to achieve the percentage concentration
specified against each chemical shall be used for anti-termite treatment.
b) Chemicals are available in concentrated form in the market and concentration is indicated on
the sealed containers. To achieve the specified percentage of concentration, chemical should be
diluted with water in required quantity before it is used. Graduated containers shall be used for
dilution of chemicals with water in the required proportion to achieve the desired percentage of
concentration.
c) Engineer-in-Charge shall procure the chemical of required concentration in sealed original
containers directly from the reputed and authorised dealers. The chemical shall be kept in the
custody of the Engineer-in-Charge or his authorised representatives and issued for use to meet
the day's requirements. Empty containers after washing and concentrated chemical left unused at
the end of the day's work shall be returned to the Engineer-in-Charge or his authorised
representative.

1.24.2.2 Measurement: Concentrated chemical in sealed containers shall be measured in litre.
Chemicals of different types and concentration shall be measured separately.
1.24.2.3 Rate: The rate for the concentrated chemical shall include the cost of material, containers
and all the operations involved in transportation and delivery at the place specified.
1.24.2.4 Safety Precautions:
a) All chemical used for anti-termite treatment are Poisons. These chemicals can have an adverse
effect upon health when absorbed through the skin, inhaled as vapours or spray mists or
swallowed. The containers having emulsifiable concentrates shall be clearly labelled and kept
securely closed in stores so that children or pet cannot get at them. Storage and mixing of
concentrates shall not be done near any fire source or flame. Persons using these chemical shall
be warned that absorption through skin is the most likely source of accidental poisoning.
Particular care shall be taken to prevent skin contact with concentrates and prolonged exposure
to dilute emulsion shall also be avoided. After handling the concentrates or dilute emulsion,
workers shall wash themselves with soap and water and wear clean clothing, especially before
eating and smoking. In the event of severe contamination, clothing shall be removed at once and
the skin washed with soap and water. If chemical has splashed into the eyes, they shall be flushed
with plenty of soap and water and immediate medical attention shall be sought.
b) Care should be taken in the application of chemicals to see that they are not allowed to
contaminate wells or springs which serve as source of drinking water.
1.24.3 Pre-construction Anti-termite Chemical Treatments:
1.24.3.1 Chemical treatment of soils for the protection of buildings from attack of subterranean
termites shall be done as per IS: 6313 (Part II). Treatment shall be got done only from the approved
specialised agencies using the chemical procured directly by the Engineer-in-Charge from reputed and
authorised dealers. Graduated containers shall be used for dilution and spraying of the chemical shall
be done using hand operated pressure pumps. Proper check should be kept to ensure that the specified
quantity of chemical is used for the required area during the operation.
1.24.3.2 Time of application: Soil treatment should start when foundation trenches and pits are
ready to take bed concrete/levelling course in foundations. Laying of bed concrete/levelling course
should start when the chemical emulsion has been absorbed by the soil and the surface is quite dry.
Treatment should not be carried out when it is raining or soil is wet with rain or sub-soil water.
Treatment to the surface of earth filling within the plinth shall also be done in the same manner
before laying the sub-grade / earth filling for flooring.
1.24.3.3 Disturbance: The treated soil barrier shall not be disturbed. If for some reasons the treated
soil barriers are disturbed, immediate steps shall be taken to restore the continuity and completeness
of the barrier system.
1.24.3.4 Treatment for Masonry Foundations & Basements:
(a) The bottom surface and the sides (up to a height of 300 mm) of the excavations made for
masonry foundations and basements shall be treated with the chemical at the rate of 5 litres
per square metre surface area.
(b) After the masonry foundations and the retaining wall of the basements come up, the backfill in
the immediate contact with the foundation structure shall be treated at the rate of 7.5 litre per sqm
of the vertical surface of the sub-structure for each side. If water is used for ramming the earth
fill, the chemical treatment shall be carried out after the ramming operation is done by
rodding ( with 12 mm dia mild steel rods) the earth at 150 mm centers close to the wall surface
and spraying the chemical with the above dosage. The earth is usually returned in layers and the
treatment shall be carried out in similar stages. The chemical emulsion shall be directed towards
the concrete or masonry surfaces of the columns and walls so that the earth in contact with these
surfaces is well treated with the chemical.
1.24.3.5 Treatment for RCC Foundation and Basements: In the case of RCC foundations, the
concrete mix is dense (being 1:2:4 or richer). It is, therefore, unnecessary to start the treatment from
the bottom of excavations. The treatment shall start at the depth of 500 mm below ground level
except when such ground level is raised or lowered by filling or cutting after the foundations have been
cast. In such cases, the depth of 500 mm shall be determined from the new soil level resulting from the
filling or cutting mentioned above, and soil in immediate contact with the vertical surfaces of RCC
foundations shall be treated at the rate of 7.5 litre per square metre. The other details of treatment
shall be as laid down in IS 6313-1981.
1.24.3.6 Treatment of Top Surface of Plinth Filling: The top surface of the filled earth within the
plinth walls shall be treated with chemical emulsion at the rate of 5 litre per sqm of the surface before
the sandy sub-grade is laid. Holes up to 50 to 75 mm deep at 150 mm centre both ways shall be made
with crow bars (12 mm dia) on the surface to facilitate saturation of the soil with chemical emulsion.
1.24.3.7 Treatment at Junction of the Walls and the Floor: To achieve continuity of the vertical
chemical barrier on inner wall surfaces from the ground level, a small channel 30x 30 mm shall be
made at all the junctions of walls and columns with the floor (before lying the sub-grade) and rod holes
made the channel up to ground level 150 mm apart and the chemical emulsion poured along the channel
@ 7.5 litre per sqm of the vertical wall or column surface so as to soak the soil right to bottom. The
soil shall be tamped back into place after this operation.
1.24.3.8 Treatment of Soil along External Perimeter of Building: After the building is complete,
300 mm deep holes shall be sunk in the soil with iron rods (12 mm dia) along the external perimeter
of the building at intervals of about 150 mm and these holes shall be filled with chemical emulsion at
the rate of 7.5 litre per sqm vertical surfaces of the external walls. If the depth of filling is more than
300 mm, the external perimeter treatment shall extend to the full depth of filling up to the ground
level so as to ensure continuity of the chemical barrier. In case the earth outside the building is graded
on completion of building, this treatment shall be carried out on completion of such grading.
1.24.3.9 Treatment of Soil under Apron (Plinth Protection) along External Perimeter of
Building : Top surface of the consolidated earth over which the apron is to be laid shall be treated-
with chemical emulsion at the rate of 5litre per square metre of the surface before the apron is laid. If
consolidated earth does not allow emulsion to seep through, holes up to 50 to 75 mm deep at 150 mm
c/c may be made with 12 mm diameter mild steel rod on the surface to facilitate saturation of the soil
with the chemical emulsion.
1.24.3.10 Treatment for expansion joints: Anti-termite treatment shall be supplemented by treating
with chemical emulsion through the expansion joint after the sub-grade has been laid @ 2 litre per
linear metre of expansion joint.
1.24.3.11 Treatment of Walls Retaining Soil above Floor Level: Retaining walls like the basement
walls or outer walls above the floor level retaining soil need to be protected by providing chemical
barrier by treatment of retained soil in the immediate vicinity of the walls, so as to prevent entry of

termites through the voids in masonry, cracks and crevices, etc. above the floor level. The soil
retained by the walls shall be treated at the rate of 7.51itres per square metre of the vertical surface so
as to effect a continuous outer chemical barrier, in continuation of the one formed under 1.24.3.4.
1.24.3.12 Treatment of Soil Surrounding Pipes, Wastes and Conduits: When pipes, wastes and
conduits enter the soil inside the area of the foundations, the soil surrounding the points of entry
shall be loosened around each such pipe water or conduit for a distance of 150 mm and to a depth of
75 min before treatment is commenced. When they enter the soil external to the foundations, they shall
be Similarly treated for a distance of over 300 mm unless they stand clear of the walls of the buildings
by about 75 mm.
1.24.3.13 Measurements: All dimensions shall be measured correct to a cm. The measurements for
all the operations described above shall be the plinth area of the building in square-metre at floor 1
level (Ground floor). Nothing extra shall be measured for payment.
1.24.3.14 Rate: The rate for the anti-termite treatment shall include the cost of labour and all other
inputs (except concentrated chemical) involved in all the operations described above.
1.24.4 Treatment for Existing Building:
1.24.4.1 Once the termites have an ingress into the building, they keep on multiplying and destroy the
wooden and cellulosic materials, and as such it becomes essential to take measures for protection against
termites. Anti-termite measures described below are necessary for the eradication and control of
termites in existing buildings. To facilitate proper penetrations of chemical into the surface to be
treated, hand operated pressure pump shall be used. To have proper check for uniform penetration of
chemical, graduated containers shall be used. Proper check should be kept so that the specified quantity
of chemical is used for the required area during the operation. Chemical treatment for the eradication
and control of sub-terranean termites in existing buildings shall be done as per IS: 6313 (Part III)-
2001 Treatment shall be got done only from the approved specialised agencies using the chemical
procured directly by the Engineer-in-Charge from reputed and authorised dealers.
1.24.4.2 Treatment Along Outside of Foundations :
a) The soil in contact with the external wall of the building shall be treated with chemical emulsion
at the rate of 7.5 liter per square metre of the vertical surface of the sub-structure to a depth of
300 mm. To facilitate this treatment a shallow, channel shall be excavated along and close to the
wall face. The chemical emulsion shall be directed towards the wall at 1.75 liter per running
metre of the channel. Rodding with 12 mm diameter mild steel rods at 150mm apart shall be
done in the channel, if necessary, for uniform dispersal of the chemical to 300 mm depth from
the ground level. The balance chemical of 0.5 liter per running metre shall then be used to treat
the backfill earth as it is returned to the channel directing the spray towards the wall surface.
b) If there is a concrete or masonry apron around the building, approximately 12 mm diameter
holes shall be drilled as close as possible to the plinth wall about 300 mm apart, deep enough to
reach the, soil below and the chemical emulsion pumped into these holes to soak the soil below
at the rate of 2.25 l i f t per linear metre.
c) In case of RCC framed structures, the soil (backfill) in contact with the column sides and plinth
beam along the external perimeter of the building shall be treated with chemical emulsion at the
rate of 7. litre/sqm of the vertical surface of the structure. To facilitate this treatment,

trenches shall be excavate, equal to the width of the shovel exposing the sides of the column and
plinth beams up to a depth of 300 mm or up to the bottom of the plinth beam, if this level is less
than 300mm. The chemical emulsion shall be sprayed on the backfill earth as it is returned into
the trench directing the spray against the concerned surface of the beam or column as the case
may be.
1.24.4.3 Treatment of Soil Under Floors: Chemical treatment shall be done by drilling 12 mm
holes at the junction of floor and walls along the cracks on the floor and along the construction joints
at the interval of 300 mm to reach the soil below. Chemical emulsion shall be squirted into these
holes using a hand operated pressure pump to soak the soil below until refusal or up to a maximum
of one litre per hole. The holes shall then be sealed properly with cement mortar 1:2 (1 cement: 2
coarse sand) finished to mater the existing floors. The cement mortar applied shall be cured for at
least 10 days as per instructions of Engineer-in-Charge.
1.24.4.4 Treatment of Voids in Masonry: The movement of termites through the masonry wall
may be arrested by drilling holes in masonry wall at plinth level and squirting chemical emulsions into
the holes to soak the masonry. The holes shall be drilled at an angle of 45° from both sides of the plinth
wall at 300 mm intervals and emulsion squirted through these holes to soak the masonry using a hand
operated pump. This treatment shall also be extended to internal Walls having foundations in the
soil. Holes shall also be drilled at wall corners and where door and window frames are embedded in
the masonry or floor at ground. Emulsion shall be squirted through the holes till saturation or to a
maximum of one litre per hole. Care shall be taken to seal the holes after the treatment.
1.24.4.5 Treatment at Points of Contact of Wood Work: All existing wood work in the building
which is in contact with the floor or walls and which is infested by termites, shall be treated by
spraying at the points of contacts with the adjoining masonry with the chemical emulsion by drilling 6
mm holes at a downward angle of about 45° at the junction of wood work and masonry and squirting
chemical emulsion into these holes till refusal or to a maximum of half a litre per hole. The treated
holes shall then be sealed.
1.24.4.6 Measurements: All dimensions shall be measured correct to a cm. The measurements shall
be made of the surface actually provided with anti-termite treatment. Measurements shall be done
separately for treatment of foundations, soils under floors, voids in masonry and wood work as detailed
below:
(a) Treatment along outside of foundations: The measurements shall be made in running metre
taking lengths along the plinth of the building.
(b) Treatment of soil under floors: The measurements shall be made in square metre. Inside clear
dimensions of rooms, verandah, etc. shall be taken.
(c) Treatment of voids in masonry: The measurements shall be made in running metre along the
plinth of the building.
(d) Treatment to wood work: The measurements shall be made in running metre for chowkhats,
joists, purlins, beams, etc.
1.24.4.7 Rates: The rates shall include the cost of labour and all other inputs (except concentrated
chemical) involved in all the operations described above including drilling, refilling and making
good the holes.

Appendix -'A'
CLASSIFICATION AND IDENTIFICATION OF SOILS
1.0 Soils : classification of soils are given below (As per provisions of IS : 1498- 1997(reaffirmed):-
1.01. Terminology :For the purpose of this standard, the definitions given in IS : 2809-1972 and the
following shall apply.
a) CIay - An aggregate of microscopic and sub-microscopic particles derived from the chemical
decomposition and disintegration of rock constituents. It is plastic within a moderate to wide
range of water content.
b) Silt-A fine-grained soil with little or no plasticity. If shaken in the palm of the hand, a part of
saturated inorganic silt expels enough `water to make its surface appear glossy. If the pat is
pressed or squeezed between the fingers, its surface again becomes dull.
c) Sand and Gravel - Cohesion less aggregates of angular, sub-angular, sub-rounded, rounded,
flaky or flat fragments of more or less unaltered rocks or minerals.
According to this system, gravel is a fraction of the soil material between 80 mm and the 4.75-
mm IS Sieve size and sand is the material between the 4.75-mm IS Sieve size and the 75-
micron IS Sieve size.
1.02 Soil : Classification and Identification:
Division - Soils shall be broadly divided into three divisions as under:
1.02.01 Coarse-Grained Soils - In these soils, more than half the total material by weight is larger
than 7Smicron IS Sieve size. These are further subdivided in to following:
a) Gravels - In these soils, more than half the coarse fraction ( +75 micron) is larger than 4.75-
mm IS Sieve size. This subdivision includes gravels and gravelly soils.
b) Sands- In these soils, more than half the coarse fraction (+75 micron) is smaller than 4.75-mm
IS Sieve size. This subdivision includes sands and sandy soils.
1.02.02 Fine-Grained Soils - In these soils, more than half of the material by weight is smaller than
75-micron IS Sieve size. The fine-grained soils shall be further divided in to three subdivisions on the
basis of the following arbitrarily selected values of liquid limit.
a) Silts and clays of low compressibility - having a liquid limit less than 35 (represented by
symbol L),
b) Silts and clays of medium compressibility - having a liquid limit greater than 35 and less
than 50 (represented by symbol I), and
c) Silts and clays of high compressibility - having a liquid limit greater than 50 ( represented
by symbol H).
NOTE - In this system the fine-grained soils are not divided according to particle size but according
to plasticity and compressibility. The term `compressibility' here shall imply volume change,
shrinkage during dry periods and swelling during wet periods, as well as. consolidation under load.
Soil particles finer than 2-micron may , however, be designated as clay-size particles and the particles
between 75micron and 2-micron as silt size particles.
1.02.03 Highly Organic Soils and Other Miscellaneous Soil Materials - These soils contain large
percentages of fibrous organic matter, such as peat, and particles of decomposed vegetation. In
addition, certain soils containing shells, concretions, cinders, and other non-soil materials in
sufficient quantities are also grouped in this division.
Table 1: Basic Soil Components : (Clause 3.3.2 of IS 1498)
S.No Soil Soil Symbol Particle size -Range and description
component
i) Coarse - Boulder none Rounded to angular, bulky, hard, rock particle;
grained average diameter > 300 mm.
components Cobble None Rounded to angular, bulky, hard, rock particle;
average diameter < 300 mm
But retained on 80 mm IS Sieve.
Gravel G Rounded to angular, bulky, hard, rock particle;
passing 80 mm IS Sieve
But retained on 4.75 mm IS Sieve.
Coarse : 80-mm to 20- mm IS Sieve,
Fine: 20-mm to 4.75 mm IS Sieve.
Sand S Rounded to angular, bulky, hard, rock particle;

passing 4.75 mm IS Sieve
But retained on 75 micron IS Sieve.
Coarse: 4.75 -mm to 2.0 mm IS Sieve,
Medium: 2.0- mm to 425 micron IS Sieve,
Fine : 425 -micron to 75 micron IS Sieve

ii) Fine grained Silt M Particles smaller than 75 -micron IS Sieve;
components identified by behaviour, that is , it can be made
to exhibit plastic or non-plastic regardless of
moisture and exhibits little or no strength when
air dried.
Clay C
Particles smaller than 75 -micron IS Sieve;
identified by behaviour, that is , it can be made
to exhibit plastic properties within a certain
range of moisture and exhibits considerable
strength when air dried.
Organic 0 Organic matter in various sizes and stages of
matter decomposition.

For field identification, take a representative sample in the palm of your hand, remove all particles >80
mm . If > 50% (by weight) of the particles can be seen by the unaided eye ,it is coarse grained or else
it is fine grained.
i) If the soil is coarse grained, estimate and record the % of (a) gravel sized particles ranging from 80
mm -4.75 mm, (b) sand size particles ranging from 4.75 mm to 75 micron and (c) fines: silt /clay
particles < 75 micron sieve.
ii) Gravelly soils: If the percentage of gravel is > the that of the sand , the soil is a gravel and can be
classified either as clean gravel containing <5% fines (passing 0.075 mm sieve) or dirty gravels
containing >12% fines, depending upon the percentage of particles not visible to the unaided eye.
Gravels containing 5-12% fines are given boundary classification.
Clean gravels and clean sands are either well graded (W) or poorly graded (P). The four clean
gravels and sands are:
a) Clean well graded Gravel (GW),
b) Clean poorly graded Gravel (GP),
c) Clean well graded Sand (SW),
d) Clean poorly graded Sand (SP),
ii) To identify a clean, coarse grained soil, spread the soil thin on a flat surface , carefully observe all
particles carefully feel the smallest particles,
iii) try the dust formation test:
iv) { take a large handful of completely dry , coarse grained soil (gravel removed) to a height of
about 450 mm and drop it onto a hard surface. If little or no dust flies , the material is clean - less
than 5% fines. If a small dust cloud forms , the material is dirty}, try the ;
v) Hand stain test: Squeeze in hand a handful of moist coarse grained soil (gravel removed) , if
the hand is not discoloured or stained it is clean otherwise dirty.
vi) Final gradation and classification should be decided by sieving.
vii) Dirty Gravels and Dirty Sands :
viii) (fines >12%, dust test showing dust, hand stain test confirming stain ): There are 4 types,
a) Silty Gravel (GM)
b) Clayey Gravel (GC)
c) Silty Sand (SM)
d) Clayey Sand (SC).
The actual % of fines in the sample should be determined through "sedimentation test" based on
the fact that particles settle in water at a rate proportional to their size.

CLASSIFICATION OF SOILS AS PER IS SYSTEM
Soil Group Description Symbol Unit Dry Weight, gm/ CBR % at Light
cucm (IS :2720, P-7-1980) Compaction
- Light compaction Density
1. Well graded gravel and gravel GW 2.00-2.24 60-90
sand mixture ( fines < 5%)
2. Poorly graded gravel and gravel GP 1.76-2.24 25-60
sand mixture ( fines < 5%)
3. Silty gravel and gravel sand GM 2.08-2.22 20-80
mixtures ( fines > 12%)
4. Clayey gravels and gravel sand GC 1.92-2.24 20-80
silt mixtures ( fines > 12%)
5. Well graded sand and gravely SW 1.76-2.08 20-60
sand ( fines < 5%)
6. Poorly graded sands and
gravely sand ( fines < 5%) SP 1.59-1.92 10-30
7. Silty sand and sand-silt SM 1.92-2.16 10-40
mixtures (fines > 12%)
8. Clayey sands and sand-clay SC 1.68-2.08 15-50
mixtures ( fines > 12%)
9. Inorganic silt, very fine rock ML 1.60-2.00 5-20
flour.
10. Clayey Silt or fine, inorganic CL 1.60-2.00 5-15
clay, gravelly, sandy or silty
11. Organic silt and silty clays OL 1.44-1.60 3-8
12. Inorganic silt, elastic and MH 1.28-1.60 3-8
micaceous silts
13. Inorganic fat clays CH 1.44-1.76 3-5
14. Organic silt and clays OH 1.28-1.68 2-4

Appendix ‘B’
MECHANICAL EQUIPMENT FOT EARTH WORK.
A: (i) Dipper-shovel : It is used for excavating against a face or bank consisting of open-top bucket
or dipper with a bottom opening door, fixed to an arm or dipper stick which slides and pivots on
the jib of the crane. It is suitable for excavating all clay chalk and friable materials and for
handling rock and stone. However, it is not suitable for surface excavation for which a skimmer
is used.
(ii) Backhoe: It is similar to face shovel except that the dipper stick pivots on the end of the jib
and the dipper or bucket works towards the chassis and normally has no bottom door but is
emptied by swinging away from the chassis to invert the bucket. It may be designed to carry both
a front -mounted bucket loading mechanism and a rear mounted backhoe. It is mainly used to
excavate trenches and occasionally used for the excavation of open areas such as small
basements. In the backhoe mode the bucket lifts, swings and discharges materials while the
undercarriage is stationary. When used in the `loader' mode, the machine loads or excavated
through forward motion of the machine, and lifts, transports and discharges materials.
(iii) Skimmer : This arrangement is similar to the face shovel except that in this case the bucket
slides on rollers directly along the jib and thus has a more restricted movement. It is used for
surface excavation and levelling in conjunction with transport to haul away the excavated
material.
(iv) Dragline : It is usually fitted with a long slender boom or jib and the bucket, which in operation
faces towards the machine and has no door, is supported by cable only as on a crane. It works
from the side of the excavation at normal ground level and is used for excavating large open
excavations such as basements when the depth is beyond the limit of the boom of a backhoe. It
is commonly used for open cast mining operations.
(v) Clamshell : It consists of two hinged half-buckets or jaws pivoted to a frame which is
suspended by cable from a long jib of an excavation. The grab is used for deep excavations of
limited area on all types of soil except rock. Crane and Grab is a variant of this type of
equipment.
B: Tractor-based Equipment
It is a self-propelled crawler or wheeled machine used to exert a push or pull force through mounted
equipment. It is designed either as attachments to normal tracked or wheeled tractors or as machines
in which the earth moving attachments and the tractor are designed as a single integrated unit. A
tractor, which is hydraulically operated, can be rigged as :
(i) Loaders: It is used for loading, light dozing, scraping and grabbing operations, lifting and
transporting the materials (loose earth, rubble, sand, gravel aggregate etc.) at various sites
through forward motion of the machine.
(ii) Tractor Shovel : This consists of a tipping bucket at the front attached by strong pivoted arms
or booms to the frame of the machine. It is used for stripping top soil, excavating against a face,
bulldozing and for loading spoil or loose materials. It is similar to crawler dipper-shovel.
(iii) Trench Digger: It operates on the same principle as a backhoe excavator except that the
bucket is controlled by hydraulic rams instead of cables and pulleys.

(iv) Scraper: Scrapers provide unique capability to excavate, load, haul and dump materials.
Scrapers are available in various capacities by a number of manufacturers with options such as
self - loading with elevators, twin engines or push-pull capability. They are cost effective where
the haul distance is too long for bulldozers, yet too short for trucks. This distance typically
ranges from 120 m to 1200 m; however, the economics should be evaluated for each project.
Scraper has an open bowl with a cutting edge positioned between the axles, which cuts, loads,
transports, discharges and spreads through forward motion of the machine. Loading through
forward motion of the machine can be assisted by a powered mechanism (elevator) fixed to the
scraper bowl.
(v) Bulldozer and Angle-dozer: The most common equipment used for clearing and levelling
activities is a bulldozer. The terms bulldozer is used to define a tractor mounted with a dozing
blade.
The bulldozer consists of a rectangular steel blade with renewable cutting edge set at right
angles (capable of only tilting but not angling) to the direction of travel and attached by steel
arms to the side frames of a crawler tractor. It may be used for excavating natural soil or for
moving loose soil or debris, which is pushed forward as the tractor forces it ahead.
(vi) Angle dozer is capable of both tilting and angling.
More details of mechanical equipment are as under:
Bacl;hoe Loader: A backhoe loader, also called a loader backhoe or tractor backhoe, is a heavy
equipment vehicle that consists of a tractor fitted with a bucket on the front and a small backhoe on
the back. Due to its relatively small size and versatility, backhoe loaders are very common in urban
construction projects. These machines travel on rubber tires, and can actually travel at speeds of
approx. 25 mph/40 kmh. This makes these machines very popular where travel between worksites or
excavations is required often. These machines can dig small excavations, dig trenches, and using the
loader attachment on the front of the machine can move material such as sand or gravel and can be
used to can load trucks.

Excavator
Tracked: Excavators, also known as a track hoe, are heavy equipment consisting of a boom, dipper
stick, bucket and cab on a rotating platform. The cab sits atop an undercarriage with tracks or wheels.
All movement and functions of the excavator are accomplished through the use of hydraulic fluid. The
tracked excavator is very versatile in the mining, forestry, construction and pipeline industries.

Wheeled Excavator: Wheeled excavators offer mobility to travel up to 23 mph (37km/h) and can
move quickly from job to job minimizing the need for additional transportation. They are ideally

suited for a number of applications, like ditch cleaning or road maintenance that require travel
while using a work tool.
Trencher: A trencher is a piece of construction equipment used to dig trenches, typically for laying
pipes or cables, or for drainage. Trenchers range in size from walk-behind models to heavy tracked
heavy equipment. Trenchers come in two designs, chain trencher or wheel trencher.
Chain: A chain trencher cuts with a digging chain that is driven around a rounded metal frame, or
boom. It resembles a giant chainsaw. This type of trencher can cut ground that is too hard to cut with

a bucket-type excavator. This type of trencher can cut narrow and deep trenches. The angle of the
boom can be adjusted to control the depth of the cut. To cut a trench, the boom is held at a fixed
angle while the machine creeps slowly.
Wheel: A wheel trencher or rock wheel is composed of a toothed metal wheel. It is cheaper to
operate and maintain and can cut harder ground than chain-type trenchers. Thanks to the wheel it is
possible to work in hard or soft soils. This is due to the fact that a cutting wheel works by clearing the
soil like a bucket-wheel does. They are also used to cut pavement for road maintenance and to gain
access to utilities under roads.

Appendix 'C'
Blasting operations materials, and methodology
1.0 Operations:
i) Blasting operations shall be carried out under the supervision of a responsible authorized agent of
the contractor (referred subsequently as agent only), during specified hours as approved in writing
by the Engineer-in-Charge. The agent shall be conversant with the rules of blasting. In case of
blasting with dynamite or any other high explosive, the position of all the bore holes to be drilled
shall be marked in circles with white paint. These shall be inspected by the contractor's agent.
Bore holes shall be of a size that the cartridge can easily pass down. After the drilling operation,
the agent shall inspect the holes to ensure that drilling has been done only at the marked
locations and no extra hole has been drilled. The agent shall then prepare the necessary charge
separately for each bore hole. The bore holes shall be thoroughly cleaned before a cartridge is
inserted. Only cylindrical wooden tamping rods shall be used for tamping. Metal rods or rods
having pointed ends shall never be used for tamping. One cartridge shall be placed in the bore
hole and gently pressed but not rammed down. Other cartridges shall then be added as may be
required to make up the necessary charge for the bore hole. The top most cartridge shall be
connected to the detonator which shall in turn be connected to the safety fuses of required
length. All fuses shall be cut to the length required before being inserted into

the holes. Joints in fuses shall be avoided. Where joints are unavoidable a semi-circular notch
shall be cut in one piece of fuse about 2 cm deep from the end and the end of other piece inserted
into the notch. The two pieces shall then be wrapped together with string. All joints exposed to
dampness shall be wrapped with rubber tape.
ii) The maximum of eight bore holes shall be loaded and fired at one occasion. The charges shall
be fired successively and not simultaneously. Immediately before firing, warning shall be given
and the agent shall see that all persons have retired to a place of safety. The safety fuses of the
charged holes shall be ignited in the presence of the agent, who shall see that all the fuses are
properly ignited.
iii) Careful count shall be kept by the agent and others of each blast as it explodes. In case all the
charged bore holes have exploded, the agent shall inspect the site soon after the blast but in
case of misfire the agent shall inspect the site after half an hour and mark red crosses (X) over
the holes which have not exploded. During this interval of half an hour, nobody shall approach
the misfired holes. No driller shall work new such bore until either of the following operations
have been done by the agent for the misfired boreholes.
(a) The contractor's agent shall very carefully (when the tamping is of damp clay) extract the
tamping with a wooden scraper and withdraw the fuse, primer and detonator. After this a
fresh detonator, primer and fuse shall be placed in the misfired holes and fired, or
(b) The holes shall be cleaned for 30 cm of tamping and its direction ascertained by placing
a stick in the hole. Another hole shall then be drilled 15 cm away and parallel to it. This
hole shall be charged and fired. The misfired holes shall also explode along with the new
one.
Before leaving the site of work, the agent of one shift shall inform the another agent
relieving him for the next shift, of any case of misfire and each such location shall be
jointly inspected and the action to be taken in the matter shall be explained to the relieving
agent. The Engineer-in-Charge shall also be informed by the agent of all cases of misfires,
their causes and steps taken in that connection.
1.01 General Precautions
i) For the safety of persons red flags shall be prominently displayed around the area where blasting
operations are to be carried out. All the workers at site, except those who actually ignite the
fuse, shall withdraw to a safe distance of at least 200 metre from the blasting site. Audio
warning by blowing whistle shall be given before igniting the fuse.
Blasting work shall be done under careful supervision and trained personnel shall be employed.
Blasting shall not be done with in 200 metre of an existing structure, unless specifically
permitted by the Engineer-in-Charge in writing.
All procedures and safety precautions for the use of explosives drilling and loading of explosives
drilling and loading of explosives before and after shot firing and disposal of explosives shall be
taken by the contractor as detailed in IS 4081, safety code for blasting and related drilling
operation.
1.02 Precautions against Misfire
i) The safety fuse shall be cut in an oblique direction with a knife. All saw dust shall be cleared
from inside of the detonator. This can be done by blowing down the detonator and tapping the

open end. No tools shall be inserted into the detonator for this purpose.
ii) If there is water present or if the bore hole is damp, the junction of the fuse and detonator
shall be made water tight by means of tough grease or any other suitable material.
iii) The detonator shall be inserted into the cartridge so that about one third of the copper tube is
left exposed outside the explosive. The safety fuse just above the detonator shall be securely tied
in position in the cartridge. Water proof fuse only shall be used in the damp bore hole or when
water is present in the bore hole.
iv) If a misfire has been found to be due to defective fuse, detonator or dynamite, the entire
consignment from which the fuse detonator or dynamite was taken shall be got inspected by the
Engineer-in-Charge or his authorized representative before resuming the blasting or returning
the consignment.
2.0 Commercial Explosives: These are of 4 types.
a) Dynamite: It is a Nitro-glycerine-based product. It is most sensitive of all the generic classes
of explosives. It is available in many grades and sizes (1" to 8" in dia. and 8" to 24 " long) to meet
the requirements of the particular job. The approximate strength of a dynamite is specified as a
percentage (weight of nitro-glycerine) to the total weight of a cartridge.
b) Slurries: Slurry is a generic term used for both water gels and emulsion. They are water-resistant
explosive mixtures of Ammonium Nitrate and a fuel sensitizer. The primary sensitising methods
are :
i) Introduction of air throughout the mixture,
ii) The addition of Aluminium particles,
iii) The addition of Nitrocellulose.
In comparison to different explosives (such as ANFO) , slurries have a higher cost per kg
and have less energy. They are not water sensitive. An advantage of slurries over
dynamite is that the separate ingredients can be hauled to the project site in bulk and
mixed immediately before loading the blast holes.
c) ANFO : ANFO is a blasting agent that is produced by mixing prilled Ammonium Nitrate and
fuel oil (3.5 quarts or 1136 ml fuel oil to 100 lb. or 43.4 kg of Ammonium nitrate as the
optimum ratio and the detonation efficiency is controlled by this ratio). It is a free flowing
mixture. This is used most on construction projects as it is the cheapest and safest among others.
The first three are the principal explosives used for bore hole charges.
d) Two-component Explosives: Are similar to ANFO, but the components maybe different. Two
component explosives are not classified as an explosive until mixed.
3.0 Methodology: There are three parts to a controlled blasting.
a) Initiating and delay devices: Firing several holes or rows of holes at one time. Fragmentation,
backbreaker, vibration, and violence of a blast are all controlled by the firing sequence of the
individual blast holes. The order and timing of the detonation of the individual holes is regulated
by the initiation system. Electrical and Non- Electrical systems are available. When selecting the
proper system, one should consider both blast design and safety.
b) Electric blasting caps: With an electric cap an explosion is caused by passing an electric
current through a wire bridge, similar to an electric light bulb filament. A current of app. 1.5

amp heats the bridge to ignite a heat-sensitive flash compound. The ignition sets of a primer
which in turn fires a base charge in the cap.
c) Delay blasting systems: These are caps used to obtain a specified firing sequence. These caps
are available for delay intervals varying from a small fraction of a second to about 7 seconds.
When explosives charges in two or more rows of holes parallel to the face are fired in one shot,
it is desirable to fire the charges in the holes nearest the face a short time ahead of those in the
second row
This procedure will reduce the burden in the second row , and hence will permit the explosives
in the second row to break more effectively. In the case of more than two rows of explosives, the
same delayed firing sequence will be followed for each successive row.
d) Detonating cord: It is a non-electric initiation system consisting of a flexible cord having a
centre core of high explosive. It is used to detonate dynamite and other cap -sensitive explosives.
e) Blasting shall invariably be carried out by a qualified, experienced and authorised personnel
strictly in accordance with the explosives Act.
Appendix-___
Trenchless excavation for sewerage and water supply etc.
1.0 Trenchless technology: is a type of subsurface construction work that requires few trenches or no
continuous trenches. It is a rapidly growing sector of the construction and civil engineering industry.
It can be defined as "a family of methods, materials, and equipment capable of being used for the
installation of new or replacement or rehabilitation of existing underground infrastructure with
minimal disruption to surface traffic, business, and other activities."u
Contents
 1 Trenchless construction
 2 Trenchless rehabilitation
2.0 Trenchless construction :Trenchless construction includes such construction methods as
tunneling, microtunneling (MTM), horizontal directional drilling (HDD) also known as directional
boring, pipe ramming (PR), pipe jacking (PJ), moling, horizontal auger boring (HAB) and other
methods for the installation of pipelines and cables below the ground with minimal excavation. Large
diameter tunnels such as those constructed by a tunnel boring machine (TBM), and drilling and
blasting techniques are larger versions of subsurface construction. The difference between trenchless
and other subsurface construction techniques depends upon the size of the passage under
construction.
3.0 The method requires considering soil characteristics and the loads applied to the surface. In cases
where the soil is sandy, the water table is at shallow depth, or heavy loads like that of urban traffic are
expected, the depth of excavation has to be such that the pressure of the load on the surface does not
affect the bore, otherwise there is danger of surface caving in.

Pipe replacement by pipe bursting
4.0 Trenchless rehabilitation includes such construction methods as sliplining, thermoformed pipe,
pipe bursting, shotcrete, gunite, cured-in-place pipe (CIPP), grout-in-place pipe, mechanical spot
repair, and other methods for the repair, rehabilitation, or replacement of existing buried pipes and
structures without excavation, or at least with minimal excavation. Mechanical spot repair is applied
where damaged pipelines require the re-instatement of structural integrity. Sliplining, CIPP, and
thermoformed pipe lining involve pulling or inverting a new liner into an existing pipe, then applying
heat and/or pressure to force the liner to expand to fill the pipe. CIPP technologies combine a carrier
(felt or Fibre glass) impregnated with heat, ultraviolet light, or ambient curable resin to form a "pipe
within a pipe". Pipe bursting fractures a pipe from the inside and forces the fragments outwards
while a new pipe is drawn in to replace the old. The other methods are primarily for fixing spot leaks.
Trenchless rehabilitation methods are generally more cost-effective than traditional exhume (dig) and
replace methods.
5. SCOPE OF WORKS:
The Scope of works generally envisaged under Trenchless tender include but not limited to the
following:
 Interpretation and verification of all data in respect of hydrological and geotechnical surveys,
furnished by the owner. Carrying out all additional surveys required for connecting data related to
design and construction of the crossings.
 Design and Engineering of crossing to meet the technical parameters of the Crossing and
specifications.
 Performing all engineering and design calculations to verify suitability of pipe thickness
proposed for installation in accordance with requirements of application codes/ standard for
owner's review and approval.
 Preparation of all detailed construction/Installation drawing and methodology for trenchless

and look up for owner's approval.

 Submission of QA/QC Procedure for owner's approval.
 Procurement and inspection of all materials and consumables required for or in connection
with execution of the crossing other than those specially undertaken to be supplied by the
owner.
 Mobilizing equipment, manpower and other resources etc., site preparation including
arranging of additional land required for pipeline/fabrication, stringing, placement of
equipment and preparation of pipeline connecting area and access to work site.
 Setting out works including establishing the location of extremity points (i.e. entry and exit
locations of drilled portion of the pipeline to be laid by trenchless techniques, etc.) on ground
including carrying out of pre construction survey and collection of all necessary data.
 Preparation of pipe string, installation of the carrier pipe string below the river/water course
bed or at the designated crossing location prepared by single trenchless operation to the correct
profile as per the drawing approved by the owner.
 Disposal of drilling fluid returns and cutting produced from drilling operation from worksite
including arranging disposal site at contractors cost and initiative.
 Submission of daily log activities with all relevant details connected with trenchless
operations for installing pipeline as required by Engineer in Charge.
 Final clean up & restoration of ROW including de-mobilization
 Submission of as built drawings, reconciling the owner issue material and returning the
balance items to the owner's stores.
 All other works, which are not specifically indicated above, but required for successful
completion of the trenchless work, associated mainline work and allied works as per the tender
documents, drawings, construction methodology & details engineering calculation etc.
6.0. Specifications (to be incorporated in Contracts/ Work Orders)
 The contractor shall familiarize himself with the site conditions and technical requirement. CPM
chart of the entire Trenchless work shall be prepared in sufficient details and shall be got
approved from GE before start of Work. Permission shall be obtained by GE from authorities
holding right of way like local civil municipal corporation, GAIL, Oil companies, Water/
sewage/ electric supply utilities.
 The contractor shall work out following design requirements before start of Trenchless
work:-
o Equipment Requirement
o Consumables including handling and operational details.
o Project layouts including sizes, location and depth of entry and exit pits
o Crossing length and depth requirements including bending radius of product pipe line if
required as per project requirements.
o Horizontal and Vertical Clearance
The contractor shall carry out Trenchless work ensuring public safety, protecting existing
underground utilities and structures on ground at site.
 The entire Trenchless equipment shall be operated by contractor strictly as per manufacturer's
operation manual and a copy of same shall be provided to Engineer-in-Charge by contractor. All
underground utilities shall be indentified and mapped and shall be submitted before start of work.
The mapping shall include both horizontal as well as vertical position of underground utility and
structures/ obstructions.
7. Necessary permissions from all concerned authorities shall be obtained by Engineer-in-

Charge before starting Trenchless work.
 The Trenchless Contractor shall mark the entry and exit locations and proposed alignment at
10 metre interval and shall got it approved from Engineer-in-Charge before start of work.
 Necessary Traffic control plan shall be made by Engineer-in-Charge and necessary approval
of Urban Authorities, Traffic police as applicable shall be taken and contractor shall be directed to
deploy necessary manpower for traffic control as required by competent authorities.
 The contractor shall handle and dispose of all construction waste as per directions of Engineer-
in-Charge and it will be ensured that drilling fluid / excavated solids do not enter roadways,
drains and sewer lines. Drilling fluid shall be disposed of in environmentally safe manner as per
govt. regulations.
 Back filling operations shall not begin until written unless the entire work has been inspected
and passed by Engineer-in-Charge..
 The contractor shall submit the As-Built drawings supported by tracking data and record
drawings in duplicate hard copy as well as soft copy ( giving horizontal and vertical alignment
and details of existing utility locations) of Trenchless installations within 30 days of completion
of Trenchless work.
 The Trenchless contractor shall clean the site on completion of Trenchless work and shall
ensure that no heaving or humping of ground has occurred.
 Defect rectification period of Trenchless installation shall be two years from the date of
completion issued by GE shall be liable for rectification of all defects notified to him during the
intervening period.
 Specification of tenchless techniques shall be as per the Codes of Practice suiting Indian
Conditions published by the Indian Society for Trenchless

LIST OF BUREAU OF INDIAN STANDARD CODES
S. No. I.S. No. Subject
1. 1200 (Pt 1)-1992 Method of measurement of earth work
2. 1200 (Pt-27)-1992 Method of measurement of earth work (by Mechanical
Appliances).
3. 1498-1997 Classification and Identification of Soils for general Engineering
purposes.
4. 2314-1986 Steel sheet piling section
5. 3696-1991 Scaffolds and ladders ( P-MI)
6. 3764-1996, SP 70 Excavation work-Code of safety
7. 4081-1986 Safety code for Blasting and related drilling operation.
8. 4988 (Part IV)-1968 Excavators
9. 6313 (pt-II)-1981 Anti-Termite measures in buildings (pre -constructional).
10. 6313(pt.-III)-2001 Anti-Termite Measures in Buildings for existing buildings
11. 12138-1993 Earth moving Equipment.
12. 11134-1984 Setting out of Buildings
13. SP 70-2001 Hand Book on construction safety practices.
14. SP 62 (S&T)-1997 Hand Book on Building Construction Practices (Excluding
Electrical work).
Further Reading and References. (IndSTT: Indian Society for Trenchless Technology).
Technical Proceedings of Seminar on Trenchless Technology organized by HQ CE Delhi Zone

Delhi Cantt -10 on 22-23 Dec 09
Md. STT Publication - Basics of Trenchless Technology.
Md. STT Publication - HDD Good Practices Guidelines
Md. STT Publication - Microtunneling & Pipe Jacking Good Practices Guidelines
Md. STT Publication - Rehabilitation Methods
Md. STT Publication - Replacement Methods
Md. STT Publication - Trenchless Technology & Subsurface Construction (SSTT)
Md. STT Publication - Subsurface Asset Development Guidelines (SSAD)
Md. STT Publication - Subsurface Asset Administration (SSAA)
Ind. STT Publication - Subsurface Asset Termination (SSAT)
Md. STT Publication - Safety Issues in Subsurface Networks Development & Management
Ind. STT Publication - Waste Management & Trenchless Technology
Md. STT Publication - Pipeline Condition Assessment
Ind. STT Publication - Training Manual for HDD Operation
Md. STT Publication - Training Manual for Microtunneling Operation.

Md. STT Publication - Training Manual for Moling Operation.
Ind. STT Publication - Training Manual for Pipe Bursting Operation.
Ind. STT Publication - Training Manual for Pipe Ramming Operation.
Ind. STT Publication - Standard General Conditions for Construction Contracts Employing
Trenchless Technology
Ind. STT Publication - Guidelines for Application for Conditions in Construction Contracts
Employing Trenchless Technology
Ind. STT Publication - Schedule of Rates for Construction Contracts Employing Trenchless
Technology (Third Edition)
Ind. STT Publication - Model Consultancy Contract for HDD Crossing (MCC-HDD)
Ind. STT Publication - General Conditions of Contract Document for Horizontal Directional
Drilling (GCC-HDD)
Ind. STT Publication - Introduction to Pipeline Rehabilitation
Practical Guideline for the Application of Microtunnelling Methods for the ecological, cost-
minimised installation of than and sewers
Trenchless Technology for Installation of Cables and Pipelines
Handbook of Pipe Bursting Practice
Ind. STT: 101-2009-Code of Practice for Horizontal Direction Drilling.
Ind. STT: 102-2009-Code of Practice for Microtunneling & Pipe Jacking.
Ind. STT: 201-2009-Technique Suiting Indian Conditions Code of Practice for Cured in Place
Pipe
Technique Suiting Indian Conditions.
Ind. STT: 202-2009:Code of Practice for Glass Reinforced Pipe (GRP) Technique Suiting Indian
Conditions.
Ind. STT: 301-2009:Code of Practice for Pipe Bursting.
CHAPTER No. 2
CARRIAGE AND STACKING
OF MATERIALS
CHAPTER No. : 2
CARRIAGE AND STACKING OF MATERIALS
CONTENTS
Clause No. Particulars Page No.
Record of Amendments 2
2.1 Scope 3
2.2 Carriage of Material 3
2.3 Lead 3
2.4 Stacking of Materials 3
2.5 Size of Stacks 9
2.6 Protection against Atmospheric Agencies 9
2.7 Protection against Fire and Other Hazards 9
2.8 Units for Measurements 10
2.9 Measurements of Stacks 10
2.10 Rate 11
List of Relevant IS Codes 11
Rajasthan PWD Building Specifications 2014 Chapter 2 : Carriage and Stacking of Materials Page 1 of 11
C H A P T E R No. 2
CARRIAGE AN D STACKING OF MATERIALS
2.1 Scope:
2.1.1 The specification lays down requirements regarding loading, transportation, unloading and
stacking of various building materials and their Mode of Measurement.
2.2 Carriage of Materials:
2.2.1 Carriage of materials shall include loading, transportation and unloading of materials. Materials
shall be carried either by a animal /man driven carts or by auto vans, mechanical transport such as
trucks/tractor/trailers etc. to the site of works, store, or any other specified place provided for the
reception of the materials.
2.2.2 Materials shall be loaded, carried down and unloaded in such a way as not to cause any sort of
damage to materials. In case of damage, the damaged material shall either be rejected or the cost of
damaged material and hire charges shall be recovered and no carriage for such materials shall be
paid. In case of loss/ damage, recovery of cost shall be affected at twice the prevailing market rates as
determined by the Engineer-in-charge.
2.2.3 The carriage of materials includes loading within a lead of 50 metre, unloading and stacking
within a lead of 50 metre.
2.3 Lead:
2.3.1 All distances shall be measured over the shortest practical route and not necessarily the route
actually taken.
2.3.2 Carriage by manual labour shall be reckoned in units of 50 metre.
2.3.3 Carriage by animal/man and mechanical transport shall be reckoned in one km unit. Distances
of 0.5 km. or more shall be taken as 1 km. and distance of less than 0.5 km shall be ignored. However
when the total lead is less than 0.5 km., it will not be ignored but paid for separately in successive
stages of 50 metre subject to the condition that the rate worked on this basis does not exceed the rate
for initial lead of 1 km by mechanical/animal/manual transport.
2.4. Stacking of Materials:
2.4.1 Materials shall be stacked on site or in a store (As per IS : 4082-1996) in regular stacks of
specified size gives in Table-1 on a prepared ground uniformly levelled or on a platform provided for
the purpose. Different type of materials shall be stacked separately and in such a way that counting
and measurement can be done without disturbing the stacks. Stacking shall be carried out as per
instructions of the Engineer in charge.
2.4.2 Earth, dismantled materials, rubbish and other similar materials shall be stacked as directed
by Engineer-in-Charge.
2.4.3 Pipes of RCC, SW, GI, Cl etc. shall be stacked in rows.
2.4.4 Lime, Stone metal (Coarse aggregate), Sand and such similar materials shall be stacked in
standard stacks or as directed by the Engineer-in-charge.
2.4.5 Timber:
a) Timber should not be stacked directly on the ground. The ground, where stack is to be
constructed, is cleared and is levelled for good drainage. The same should be stacked over even
surfaced beams, Sleepers , or Brick or Concrete or Creosoted wood or Wood coated with Coal
tar , on pillars of the same level to maintain minimum 300 mm clearance from ground. The
different types of members should be stored separately, in different lengths.
b) While arranging a stack, longer pieces should be placed at bottom layers and the shorter pieces
should be placed in top layers. A gap of minimum 25mm (air space) is to be provided/ maintained
between adjacent members. The two layers are separated by wooden battens or say crossers. In
case no separate crossers are available, smaller sections of available timber may be provided
as crossers or spacers.
The length of stack depends on length of timber pieces, its height and width usually limited to
1500 mm and 2000 mm respectively.
The minimum distance between adjacent stacks should be 300 to 600 mm.
The stacks should be protected from fast blowing wind, rain and extreme heat of sun.
2.4.6 Roofing Sheets:
Roofing Sheets especially AC sheets should be stacked & handled very carefully. AC sheets (plain or
corrugated) shall be stacked horizontally up to a height of not more than 1.00 m on a firm & level
ground. The sheets should not be stacked directly on the ground but on timber or any other packing
pieces/ material. If the sheets are stored in open space they should be covered preferably by water
proofing sheets, Plastic sheets or Glass Reinforced Plastic sheets (GRP) and shall not be stacked in
open and to a height of the stack should not be more than 5OOmm.
2.4.7 Gypsum Boards, Plywood Fibre Board, Particle Board, Block Boards etc.:
The boards of different sizes and types shall be stacked separately.
To stack the boards a wooden frame of almost the size of the board with timber of size 50 mm x
25mm battens has to be made. The frame is placed on a neat and levelled platform. The sheets are so
arranged over the frame that all corners & sides rest on the frame. In the centre portion of the frame
timber pieces are provided also, so that support is available in the centre portion of the board as well.
The board shall be placed strictly in vertical alignment. The top sheet of each stack should be weighed
down to avoid any warpage. In case of decorative boards where the surface may get damaged due to
dragging of one sheet over the other, the sheets should be lifted in pairs facing each other.
2.4.8 Glass Sheets: The most important factor in storage of glass sheets is that the same should be
stored in a covered shed and should always be kept dry, even if they are packed in wooden crates. The
glass sheets shall be stored on their long edges against vertical walls or any other support in such a
manner that provide proper inclination to the first sheet so that subsequent sheets rest on it without
falling.
Not more than 25 panes shall be stacked in one stack.
2.4.9 Cast Iron, Galvanized Iron and Asbestos Cement Pipes and Fittings: The stacking shall
be done in horizontal layers on firm/level ground. The pipes shall be stacked by taking care that the
height of the stack does not exceed 1.50 m and wedges should be provided at the bottom layer to
keep the stacks stable.
The stacks should be arranged as per class and size of pipe, and as far as possible marked with
consignment number and particulars of suppliers.
All deliveries of pipes and pipe fittings shall be accompanied by a safety rules sheet given in IS
11769(Part I) : 1987 (Reaffirmed 2006).
2.4.10 Oil Paints:
A separate room with good ventilation, free from direct rays of sun, excessive heat, sparks of flame,
is the main requirement for storage of all containers of paints, thinners and allied materials. The
above containers shall be stored on floor with Sand cushion. The containers shall be opened only while
using and should be fitted with lid immediately and shall not be kept open. The date of manufacture
marked on the container should be highlighted and efforts should be made to use all the paint before
it is likely to be spoiled.
2.4.11 Cement:
a) Cement on site should be stored in a shed (covered from all sides) or godown or containers
which should be moisture proof and heat proof as far as possible. Thus, it should be dry in all
seasons. The shed where cement is to be stored should have minimum number of windows and
doors which should be closely fitted and should be kept closed as far as possible.
b) Cement bags should not be stacked directly on the ground or floor, but about 150 mm to 200
mm above the floor, on wooden planks so that the bags will not come into the direct contact with
any dampness or moisture. The cement bags should be stacked in piles. The height of stack
shall not be more than 10 bags to avoid the possibility of lumping under pressure. In stacks
more than 8 bags high, the cement bags shall be arranged alternately length-wise and cross-wise
so as to tie the stacks together and minimize the danger of topping over. The width of the stack
shall be not more than four bags length or 3 metre. A distance of about 300 mm should be kept
between the piles of cement .Passages of width about 900 mm should be kept between the piles.
A space of 600 mm minimum shall be left all-round between the exterior walls and the stacks.
c) Cement bags shall be stacked in a manner to facilitate their removal and use in the order in
which they are received, a table showing date of receipt of cement shall be put on each stack to
know the age of cement.
d) In the stacks the Cement bags shall be kept close together to reduce circulation of air as much
as possible. Owing to pressure on the bottom layer of bags sometimes `warehouse pack' is
developed in these bags. This can be removed easily by rolling the bags when the cement is taken
out for use. Lumped bags, if any should be removed and disposed off.
e) For extra safety during the monsoon, or when it is expected to store for an unusually long
period, the stack shall be completely enclosed by a water proofing membrane such as
polyethylene, which shall close on the top of the stack. Care shall be taken to see that the
waterproofing membrane is not damaged any time during use.
f) Cement in gunny bags, paper bags and Polyethylene bags shall be stored separately.
g) In case cement is received in drums:
These shall be stored on plane level ground, as far as possible near the concrete mixing place.
After taking out the required quantity of cement, the lid of the drum shall be securely tied to
prevent ingress of moisture.
h) In case cement is received in silos:
The silos shall be placed near the concrete batching plant. Proper access shall be provided for the
replacement of silos.
i) Different types of Cements shall be stacked and stored separately.
2.4.12 Quick Lime before Slacking: If quick lime is subject to exposure it takes moisture and
carbon dioxide from atmosphere and deteriorates rapidly, hence it should be slaked as soon as
possible. If immediate slaking is not possible the same can be stacked in compact heaps having
minimum exposed area.
2.4.13 Hydrated Lime: To prevent deterioration due to dampness etc. the hydrated lime should be
stored in a building with a concrete floor and having least ventilation to eliminate air draughts
through the walls and roof. The Godown suitable for cement storage is also suitable for storage of
hydrated lime. The hydrated lime can be stored up to three months if the air movement is practically
reduced to minimum.
2.4.14 Bricks:
a) The bricks should be stacked as near as possible to the site of work, on a firm & levelled ground.
A recommended size of stack shall not be more than 50 bricks in length, not more than 4 bricks
in width and 10 bricks in height. Clear distance between adjacent stacks shall not be less than
0.8 m. However, each truck load shall be put in a separate stack. Stacks should be so arranged
that the inspection, sampling and counting the bricks and removal for use should be easy. The
bricks under no circumstances shall be dumped at site, when unloaded. They must be stacked in
regular tiers.
b) Bricks of different types, such as clay bricks, clay fly ash bricks, fly ash lime bricks, sand lime
(calcium silicate) bricks, auto-clave bricks etc. shall be stacked separately. Bricks of different
classification and size consideration (such as, conventional and modular) shall be stacked
separately. Also bricks of different types, such as, solid, hollow and perforated shall be stacked
separately.
2.4.15 Blocks:
i) Blocks are available as hollow and solid concrete blocks, hollow and solid light weight
concrete blocks, autoclaved aerated concrete blocks, concrete stone masonry blocks and soil
based blocks.
ii) Blocks shall be unloaded one at a time and stacked in regular tiers to minimize breakage and
defacement. These shall not be dumped at site. The height of the stack shall not be more than 1.2
m. The length of the stack shall not be more than 3.0 m, as far as possible and the width shall
be of two or three blocks.
iii) Normally blocks cured for 28 days only should be received at site. In case blocks cured for less
than 28 days are received, these shall be stacked separately. All blocks should be water cured
for 10 to 14 days and air cured for another 15 days; thus no blocks with less than 28 days curing
shall be used in building construction.
iv) Blocks shall be placed close to the site of work so that least effort is required for their
transportation.
v) Blocks manufactured at site shall be stacked at least for required minimum curing period as
specified.
vi) The date of manufacture of the blocks shall be suitably marked on the stacks of blocks
manufactured at factory or site.
2.4.16 Floor, Wall and Roof Tiles: The tiles shall be stacked on a good platform, possibly under a
covered shed. They shall not be dumped in a heap but stacked neatly in tiers and layers. The height of
stacks should not exceed 1.00 m
Care should be taken while stacking tiles that the mould surface of one tile faces the mould surface of
other tile. The unloading should be done very carefully to avoid breakages.
2.4.17 Steel:
Steel reinforcement shall be stored with precaution to avoid deterioration and corrosion. To prevent
steel from corrosion and deterioration, at the time of stacking before that steel is stacked it should be
coated with cement wash to prevent corrosion. Also to identify the different type of reinforcement the
ends of bars should be painted in different colours.
The bars of different size and length should be stored separately so as to facilitate the movement as per
requirement of material, If steel is to be stored for longer period the same shall be stacked at least
150 mm above levelled ground.
2.4.18 Aluminium Section:
The Aluminium sections should be stored under cover. The different classification /sections of sizes
and lengths shall be stored separately. The Aluminium sections shall not be pulled or pushed or made
to slide on each other while removing from stack, this will damage the anodizing layer. Paper /
Polythene sheet wrapped around Aluminium Section should not be removed while stacking /
transportation or during handling.
2.4.19 Doors, Windows and Ventilators:

During unloading, handling, shifting and stacking timber or other lignocellulosic material, metal and
plastic door and window frames and shutters, one should be careful to prevent the surfaces of the
material from scratches and damages, during the transportation or shifting the material , should not
drag one over the other, to avoid damage to the surface of the material especially the
veneered/decorative shutters. The material should be lifted and carried flat without damaging the
sides and corners.
Doors, windows and ventilators made of metal or plastic shall be stacked vertically up right (on their
sills) on levelled ground preferably on battens. Proper care should be taken to see that the materials
do not come in contact with moisture, dirt and ashes.
The frames of doors, windows and ventilators made of metal or plastic should be stored upside down
with kick plates at top. However these shall not be stacked for a long period as the door frames may
go out of shape and the hinges will get strained.
2.4.20 Coarse Aggregates (Stone Aggregate or Stone Metal) IS: 383-1970 ( Reaffirmed 2002)
Aggregate should be chemically inert, strong, hard, durable, of limited porosity, free from adherent
coatings, clay lumps, coal, and coal residues and should contain no organic or other admixture that
may cause corrosion of reinforcement or impair the strength or durability of the structure.
The contamination of stone aggregates, with clay, dust, vegetable and other foreign matter must be
prevented & for this the stone aggregates should be stored on a hard, dry & level ground. If suitable
ground as required is not available, a platform with lean concrete or old iron sheets, or floor of dry
brick should be provided.
2.4.21 Fine Aggregates (Sand/ crusher sand and other similar materials) IS: 383-1970
(reaffirmation 2002).
The material smaller than 4.75 mm size is called fine aggregate. Natural sands are generally used as
fine aggregate. It should be washed to free it from clay and silt.
The fine aggregates should also be stored on a platform as explained for coarse aggregate but
sufficient gap should be maintained to separate coarse & fine aggregates to avoid intermixing with
each other. At site of major works it is advisable to construct a dividing wall between the two to
store different types of aggregates. However, care should be taken to stack fine aggregates in a place
where the loss due to rain and wind effect is minimum.
2.4.22 Polyethylene Pipes:
i) Natural polyethylene pipe should be stored under cover and protected from direct sunlight.
However, black polyethylene pipes may be stored either under cover or in the open.
ii) Coils may be stored either on edges or stacked flat one on top of the other, but in either case
they should not be allowed to come into contact with hot water or steam pipes and should be
kept away from hot surface.
iii) Straight lengths should be stored on horizontal racks giving continuous support to prevent
the pipe taking on a permanent set.
iv) Storage of pipes in heated areas exceeding 27° C should be avoided.
2.4.23 Unplasticized PVC Pipes:
i) The pipe should be given adequate support at all times. Pipes should be stored on a reasonably
flat surface free from stones and sharp projections so that the pipe is supported throughout its
length. In storage, pipe racks should be avoided. Pipe should not be stacked in large piles,
especially under warm temperature conditions as the bottom pipes may distort, thus giving rise
to difficulty in jointing. Socket and spigot pipes should be stacked in layers with sockets placed
at alternate ends of the stacks to avoid lopsided stacks.
ii) It is recommended not to store pipe inside another pipe.
iii) On no account should pipes be stored in a stressed or bent condition or near the sources of
heat.
iv) Pipes should not be stacked more than 1.5 m high. Pipes of different sizes and classes should
be stacked separately.
v) The ends of pipe should be protected from abrasion particularly those specially prepared for
jointing either spigot or socket solvent welded joints or soldered for use with couplings.
vi) In tropical conditions, pipes should be stored in shade. In very cold weather, the impact
strength
of PVC is reduced making it brittle and more care in handling shall be exercised in wintry
condition.
vii) If due to unsatisfactory storage of handling a pipe becomes kinked, the damaged portion
should be cut out completely. Kinking is likely to occur only on very thin walled pipes.
2.4.24 Bitumen, Road Tar, Asphalt, Etc. : All types of bitumen, road tar, asphalt, etc, in drums or
containers shall be stacked vertically on their bottoms up to 3 tiers. Leaky drums shall be segregated.
Empty drums shall be stored in pyramidal stacks neatly in rows.
2.4.25 Water: Wherever water is to be stored for construction purposes this shall be done in proper
storage tanks to prevent any organic impurities getting mixed up with it.
2.4.26 Sanitary Appliances:
All sanitary appliances shall be carefully stored under cover to prevent damage. When accepting and
storing appliances, advance planning shall be made regarding the sequence of removal from the store
to the assembly positions. Supporting brackets shall be so stored as to be readily accessible for use
with the appliances.
2.4.27 Other Materials: Small articles like nails, screws, nuts and bolts, door and window fittings,
polishing stones, protective clothing, spare parts of machinery, linings, packing, water supply and
sanitary fittings, electrical fittings, insulation board, etc., shall be kept in suitable and properly
protected store rooms. Valuable small material such as, copper pipes and fittings shall be kept under
lock and key.
2.5. Size of Stacks :
2.5.1 Unless otherwise specified stacking of the following materials shall be carried out in regular
stacks of the sizes given below.
Table-1
S. Size of Stack Effective
No. Material Capacity
Length Breadth Height height of
in cum.
in m. in m. in m. stack in m.
1 Building stone 5.00 2.00 0.60 0.50 5.00
2 Coarse Aggregate 2.00 2.00 0.55 0.50 2.00
3 Kankar for soling 5.00 2.00 0.60 0.50 5.00
4 Kankar as coarse aggregate 2.00 2.00 0.55 0.50 2.00
5 Fine aggregate e.g. sand, 2.00 2.00 0.60 0.50 2.00
surkhi and cinder
2.5.2 All other building materials shall be stacked in a manner as specified in their respective
specifications. Building materials for which method of stacking is not specified, should be stacked as
per instruction of the Engineer-in-charge.
2.5.3 For aggregates and other similar materials, the contractor shall provide suitable bottom less
boxes conforming to specified sizes for stacking purposes.
2.6 Protection Against Atmospheric Agencies: Materials stored at site, depending upon the
individual characteristics, shall be protected from atmospheric actions, such as rain, sun, winds and
moisture to avoid deterioration.
2.7 Protection Against Fire and other Hazards: Materials like timber, coal, paints, etc. shall be
stored in such a way that there may not be any possibility of fire hazards. Inflammable materials like
kerosene and petrol , shall be stored in accordance with the relevant rules and regulations so as to
ensure the desired safety during storage. Stacks shall not be piled so high as to make them unstable
under fire fighting conditions and in general they shall not be more than 4.5 m in height. The provisions
given in IS 13416 (Part 5) -1994 ( Reaffirmed 2002) shall be followed.
2.8 Units for Measurement:
i) The measurement should be done by weight or by volume or by numbers for different materials.
Specified deduction from the stack measurements shall be effected to arrive at the net payable
quantities. No reduction shall be made in respect of articles or materials for which mode of
payment is by length or weight or number.
ii) Table 2 (given below) specifies the units of measurement, for some of the commonly used
building materials,:-
Table-2
Materials Unit
Building stone ton
Building stone tonne or cum Per
Building Bricks thousand No.
Coarse aggregate cum or tonne
Stone for soling Purpose tonne or cum
Coarse aggregate, Fine aggregate e.g. cum or tonne
cum or tonne
Sand cinders, surkhi, Lime
Steel quintal or kg or tonne
Cement tonne or by Number of Bags
Timber Scantlings cum
Stone slab for roofing and lintels cum/sqm
sqm
Flag stone for flooring and sun shade purpose
Galvanised iron sheets and corrugated A.C. quintal or sqm. quintal
Sheets/Aluminium sheet Cast iron and steel or kg or tonne quintal
or kg or tonne
2.9 Measurements of Stacks: Length, breadth and height of stacks shall be measured correct to a cm.
The quantity shall be worked out in cubic metre correct to two place of decimal. The volume of stacks
shall be reduced by percentages as shown against each for looseness in stacking to arrive at the net
quantity for payment. No reduction shall be made in respect of articles or materials for which mode
of payment is by length or weight or number.
2.9.1 Earth:
2.9.1.1 In loose stacks such as cart loads, lorry loads, etc. - 20%
2.9.1.2 In fills consolidated by light mechanical machinery - 10%
2.9.1.3 In fills consolidated by heavy mechanical machinery
but not under OMC (Optimum Moisture Content) - 5%
2.9.1.4 In fills consolidated by heavy mechanical machinery at OMC - Nil
2.9.1.5 Consolidated fills in confined situation such as under floors. etc. - Nil
2.9.2 Other Materials:
2.9.2.1 Manure or sludge 8%
2.9.2.2 Moorum, building rubbish Lime and sand Nil
2.9.2.3 Stone metal, 40 mm nominal size and above 7.5%
2.9.2.4 Coarse aggregate/ stone metal below 40 mm nominal size Nil
2.9.2.5 Soling stone/ Boulder 100 mm and above 15%
2.9.2.6 Excavated rocks 50%
2.10 Rate: The rate for carriage of materials is inclusive of all the operations described
above. LIST OF RELAVENT BUREAU OF INDIAN STANDARD
CODES
S. No. I.S. Code No. Subject
1. IS: 383-1970 ( Reaffirmed 2002) Coarse Aggregate & Fine Aggregate
2. IS: 1141-1993 ( Reaffirmed 2004) Seasoning of Timber - Code of Practice
3. IS: 4082-1996 Stacking & storage of construction materials and
components at site - Recommendations.
4. IS: 11769 (P-I)-1987 Safe use of Products containing Asbestos.
(Reaffirmed 2006)
5. IS 13416 ( P-5)-1994 Preventive Measures against Hazards at work
(Reaffirmed 2002) place. Protection against Fire & Other Hazards
CHAPTER No. 3
BUILDING MATERIALS
CHAPTER No. : 3
BUILDING MATERIALS
CONTENTS
3.1 Stone 3
3.2 Brick 6
3.3 Steel 10
3.4 Timber 15
3.5 Lime 37
3.6 Cement 44
3.7 Fine aggregate 53
3.8 Coarse Aggregate 57
3.9 Kankar 62
3.10 Builders Hardware 63
3.11 Paints 65
3.12 Other and Manufactured materials 70
List of Relevant IS Code for Building Materials 70
Rajasthan PWD Building Specifications 2014 Chapter 3 : Building Materials Page 1 of 72


CHAPTER No. 3
BUILDING MATERIALS
3.1 Stone:
3.1.1 Scope:
This specification lays down requirement regarding shape size, texture and colour etc. of a building
stone as used in all types of masonry work, cut stonework and roofing. It also specifies the mode of
measurement. This specification does not cover the stones used for flooring, lintel, shelves, and
various other works.
3.1.2 Requirements of good Structural Stone:
3.1.2.1 The structural stones shall primarily be (a) Strong against crushing (b) Durable (resistant to
moisture and weathering) (c) Good in appearance (colour) (d) Susceptible of being quarried in large
sizes.
3.1.2.2 A fresh fracture of good stone suitable for structural work shall be bright clean and sharp,
free from loose grains and shall not have an earthy smell. The stone shall be hard durable, free from
cleavage and other defects, which would adversely affect their strength and appearance.
3.1.2.3 For dressing, stones may be comparatively soft, yet durable, compact grained and
homogeneous in texture, rather than crystalline and free from veins and planes of cleavage; the
specific gravity should not be less than 2.65 and the water absorption after immersion in water for 24
hours, not more than 2%.
3.1.3 Stone Used in Building Construction:
The principal stones used in building construction shall be Granite, Gneiss, Trap or Basalt, Quartzite,
Laterite, Lime stone, Sand stone, and Slate. Representative samples of the stone proposed to be used
shall be got approved first by Engineer-in-Charge. Subsequently, all supplies shall be as per the
original sample (which would remain in the custody of the Engineer), failing which the Engineer shall
reject the lot and the Contractor shall at his own expense remove these stones from the site of work
within 7 days.
3.1.4 Stone for Ashlar and Cut Stone Work: Shape and size: The stone shall be rectangular in
shape for Ashlar work. Length shall be greater than twice the height and breadth shall not be less
than the height but in any case not less than 30 cm unless otherwise specified by the Engineer-
incharge. For cut stone work, the shape and size shall be such that the finished thickness after dressing
is as stated in the schedule of quantities, or as shown in drawings.
3.1.4.1 The minimum height of the `Fine Tooled' dressed stone, according to specifications, shall be
30 cm. In case of rough tooled and `pitched face' dressed stone the height shall be 20 cm, minus the
joint thickness, unless specified otherwise, by the Engineer-in-Charge.
3.1.4.2 Texture and Colour: The stones shall be of uniform colour and texture and as far as possible
shall be obtained from one quarry only.

3.1.5 Stone for Coursed Masonry : Shape and size : The length and breadth shall not be less
than the height.
3.1.5.1 The minimum height of the dressed stone shall not be less than 15 cm minus the joint
thickness.
3.1.5.2 Texture and Colour: The texture and colour of stones for Course Rubble facing masonry
of first sort shall be uniform.
3.1.6 Stone for Rubble Masonry:
This shall be as obtained from the quarry, but the dimensions should be such that it shall not pass
through a circular ring of 15 cm dia. The thickness of the stone in any directions (except for the
spalls) shall not be less than 15 cm. As per IS: 1127-1970 (Reaffirmed 1998) dimension of natural
building stone is as shown in Table No.1
Table - 1 : Dimensions of Natural Building Stones
S. No. Type of Masonry Length Breadth Height
(mm) (mm) (mm)
(1) (2) (3) (4) (5)
i) Stone for Ashlar 597 297 297
697 347 347
797 397 397
ii) Stones for block in course 394 194 194
494 244 244
iii) Stones for Square Rubble 90 90 90
140 90, 140 90, 140
190 90, 140, 190 90, 140,190
240 90, 140, 190 90, 140, 200
290 90, 140, 190, 240 90, 140, 190, 240,
290
390 90, 140, 190, 240, 90, 140, 190, 240,
290 290
440 90, 140, 190, 240, 90, 140, 190, 240,
290 290
490 90, 140, 190, 240, 90, 140, 190, 240,
290 290
590 90, 140, 190, 240, 90, 140, 190, 240,
290 290
iv) Stones for Random May be of any size and shape but not less than 150 mm
Rubble in any direction
v) Stones for sills and lintels a) 890, 990, 90, 190, 290, 390, 90, 140, 190
1000, 1190, 490
1290

---------- do ---------- do
b) 1390,
----------- -----------
1490, 1590,
1690, 1790,
vi) Stones for Arches, Domes The dimensions depend on the particulars of the curve.
and circular moulded work.
vii) Coping stones 190, 290, 200, 300, 400, 500, 100, 150, 200
390, 490, 600
590, 690,
790
viii) Kerb stones 390, 490, 100, 200, 300 300, 400, 500
590, 690,
790
Note Tolerance: For Ashlar: ± 5mm in length and breadth and ± 3mm in height. For other
type of masonry +5, - 1 0 = in length and breadth respectively and ± 5mm in height.
3.1.7 Stone Slab for Roofing:

3.1.7.1 The stone shall be Bhankari, Jodhpur, Modak, Mandal, Bijoliya/ Dabi, Budhpura, or of any
other place as specified in the schedule of quantities or as approved by the Engineer-in -Charge. In
case of Jodhpur stone slabs only `Chhittar' stone slabs (also known as Soorsagar slabs) shall be used.
The stone slab shall be free from any cracks or fine joints (veins) loose materials or laminate or any
other defects.
3.1.7.2 Shape and Size: The slab shall be rectangular in shape with a permissible deviation from
the right angle that shall not exceed 150 mm. The thickness of the slab shall be as specified below:
Table - 2 : Thickness of slabs in cm
Source Clear spans
Less than 2 m. 2 m. and 2.5 m and 3 m & below
below 2.5 m. below 3 m. 3.3 m
1 2 3 4 5
1. Jodhpur, 7 to 8 cm 8 to 9 cm 9 to 10 cm Not less than 10 cm.
Bhankri,
Mandal,
Bijoliya/Dabi,
Budhpura.
2. Modak Not less than 6 to 7 cm. 7 to 8 cm. Not less than 8 cm.
6 cm. Not less than 7 cm. at
any point.
Note: For Stone slab from sources other than mentioned above, the thickness shall be as given in
schedule of quantities or as specified by the Engineer-in-charge. Stone slabs for roofing may be used
only with specific permission from the Engineer-in-charge.

3.1.8 Mode of Measurement:
3.1.8.1 The building stone for masonry and cut stone work shall be measured either in quintals or in
cubic metre.
3.1.8.2 Stone slabs for roofing purposes shall be measured in square metre, thickness of the slab
being specified.
3.2 Brick:
3.2.1 Common Burnt Clay Bricks:
3.2.1.1 Scope: This specification lays down the requirements for dimensions, quality and strength of
Common burnt clay bricks and their mode of measurement.
3.2.1.2. General:
Bricks shall be made from carefully selected good soil (loam), free from Gravel, Coarse sand,
Kankar, Sulphate or other harmful salts and shall either be hand or machine moulded, allowance
being provided for shrinkage in drying and burning. Sample bricks, shall be got made from the soil,
proposed to be used for brick making and burnt at an existing Kiln to check for shrinkage for
moulding properties. These shall be free from nodules of free lime, visible cracks, flaws warpage, and
organic matter, Frog of 1 to 2 cm deep shall be provided for 9 or 7 cm high bricks. No frog is required
for 4 or 3 cm high bricks and extruded bricks. Shape and size of the frog shall conform to IS: 1077-
1992 (Reaffirmed 1997). The brick shall have smooth rectangular faces with sharp corners and shall
be of uniform red colour.
The approved sample of bricks shall conform to and shall remain in the custody of the Engineer-in-
Charge and all subsequent supply shall conform to these samples.
3.2.1.3 Classification:
The common burnt clay bricks shall be classified on the basis of average compressive strength as
shown below in the Table 3 below:
Table-3
Class Designation Average Compressive Strength, Not Less
than, kg /cm2 N/sqmm
35 350 35
30 300 30
25 250 25
20 200 20
17.5 175 17.5
15 150 15
12.5 125 12.5
10.0 100 10
7.5 75 7.5
5.0 50 5.0
3.5 35 3.5

Note : For Burnt Clay Bricks having compressive strength ( clause No 3.2.2) more than 400 kg /
cm2, Ref: IS:2180- 1988 ( Reaffirmed 1997)
3.2.1.4: Dimensions: - The standard modular size of common building bricks 190x90x90 mm and
190x90x40 mm, and for Non Modular bricks the size shall be 230x110x70 mm , and 230x110x30 mm.
3.2.1.5 Tolerances: - Dimensions of bricks shall be within the following limits per 20 bricks
Modular Bricks Non-modular Bricks
a) Length-mm 380±8 460±8
b) Width-mm 180±4 220±4
c) Height-mm
(For 90-mm high bricks) 180±4 140±4 ( for 70 mm high bricks)
(For 40-mm high bricks) 80±4 60±4 ( for 30 mm high bricks)
Note : For measurement of tolerance of burnt clay building bricks, refer to 3.2.1.2 and Fig.2 of
IS:1077-1992( Reaffirmed 1997).
3.2.1.5.1-Sampling and Criterion for Conformity: The sampling and criterion for conformity shall
be in accordance with the procedure laid down in IS: 5454: 1978. Twenty (or more according to the
size of stack) whole bricks shall be selected at random from the sample selected. All blisters, loose
particles of clay and small projections shall be removed. They shall then be arranged upon a level
surface successively (as indicated in Fig. 2A, 2B and 2C of IS: 1077-1992) in contact with each other
and in a straight line. The overall length of the assembled bricks shall be measured with a steel tape or
other suitable inextensible measure sufficiently long to measure the whole row at one stretch.
Measurement by repeated application of short rule or measure shall not be permitted. If, for any reason
it is found impracticable to measure bricks in one row, the sample may be divided into rows of 10
bricks each which shall be measured separately to the nearest millimeter. All these dimensions shall
be added together.
Table 3a : Scale of Sampling and Permissible Number of Defectives For Visual and
Dimensional Characteristics.
No. of Bricks For Characteristics Specified For For dimensional
in the Lot Individual Brick characteristics specified
No. of Bricks to be Permissible No. of for group of 20 bricks-
selected defectives in the sample. No . of bricks to be
selected..
(1) (2) (3) (4)
2001-10,000 20 1 40
10,001-35,000 32 2 60
35,001-50,000 50 3 80
NOTE - In case the lot contains 2000 or less bricks, the sampling shall be subject to agreement
between the purchaser and the supplier.

Table 3b. - Scale of Sampling for Physical Characteristics.
No. of Bricks Sample Size For Permissible No.
Compressive Warpage
in the Lot of Defectives Sample size Permissible
Strength, Breaking Load, for
Transverse Strength, Bulk Efflorescence . of
Density, Water Absorption No.
And Effloresce defectives.
1 2 3 4 5
2001-10,000 5 0 10 0
10,001-35,000 10 0 20 1
35,001-50,000 15 1 30 2
Physical Requirements:
3.2.1.6.1 Compressive Strength: The bricks when tested in accordance with IS: 3495 (P-I) 1992 ,shall
have a minimum average compressive strength for various classes as gives in table-3. Compressive
strength of any individual brick shall not fall below the minimum compressive strength specified for
the corresponding class of brick. The lot shall then be checked for the next lower class of bricks.
3.2.1.6.2 Water Absorption: The bricks when tested in accordance with IS: 3495 (P-I) 1992, the
water absorption shall be not more than 20 percent by weight up to class 12.5 and not more than 15
percent by weight for higher classes.
3.2.1.6.3 Efflorescence: The bricks when tested in accordance with IS: 3495 (P-I) 1992, the rating of
efflorescence shall be not more than `moderate' up to class 12.5 and not more than `slight' for higher
classes.
3.2.1.7 Rejected Bricks: Bricks rejected by the Engineer-in-Charge shall be removed from the site
of work by the contractor within 7 days at his own cost and labour. In case the contractor fails to do
so, these shall be removed by the department and expenses charged to the contractor thereof.
3.2.1.8 Mode of Measurement:
The bricks shall be measured in number, after these are properly stacked in regular stacks.
3.2.2 Heavy-Duty Burnt Clay Bricks:
3.2.2.1 Scope - Requirements regarding dimensions, general quality and physical properties of
heavy-duty burnt clay building bricks (as per IS: 2180 - 1988, Reaffirmed 1997).
3.2.2.2 Classification: The heavy duty bricks shall be classified on the basis of average compressive
strength as under:
Class designation Average Compressive strength.

Not less than N/mm2 less than N/mm2
(kgf/cm2approximate) (kgf/cm2 approximate)
40 40/400 45/0
45 45/450 -/-
3.2.2.3 General Quality: These Bricks shall be made either by pressing or by extrusion process

and shall be free from cracks and other flaws and Lime nodules. Bricks shall have smooth rectangular
faces with sharp corners and two bricks when struck together shall emit a clear metallic ring, and be
uniform in colour.
3.2.2.4 Dimensions: The standard size of heavy duty building bricks shall be 190x90x90 mm and
190x90x40 mm.
3.2.2.5 Tolerances: The maximum permissible tolerances in individual bricks, on the dimensions
shall be as under:
Mm Dimensions () Tolerances mm
190 ±4
90 ±2
40 ±2
3.2.2.6 Physical Requirements:

3.2.2.6.1 Compressive Strength: The bricks when tested in accordance with the procedure laid
down in IS: 3495 (Part 1) - 1976 shall have a minimum average compressive strength for various
classes as given in 3.2.2.2, and shall not fall below the minimum required compressive strength by
more than 20% .
Note: In case any of the test results for compressive strength exceed the upper limit of the class, the
same shall be limited to the upper limit of the class for the purpose of averaging
3.2.2.6.2 Water Absorption: The bricks when tested in accordance with the procedure laid down in
IS: 3495 (Part 2)- 1976 after immersion in water for 24 hours, the average water absorption by mass
shall not be more than 10 percent.
3.2.2.6.2.1 If specified by the purchaser, 5 hours boiling test according to the procedure laid down in
IS: 3495 (Part 2)- 1976 may also be done. In that case the average water absorption by mass shall not
be more than 15 percent.
3.2.2.6.3 Efflorescence: The bricks when tested in accordance with the procedure laid down in IS:
3495 (Part 3)- 1976, the rating of efflorescence shall be nil.
3.2.2.6.4-Bulk Density: The density of bricks shall not be less than 2.5g/cm3. For obtaining the bulk
density, the brick shall be dried in a ventilated oven at a temperature of 105 to 115°C till it attains
substantially constant mass. The brick shall be cooled to room temperature and its mass shall be
obtained. Thereafter, the dimensions of the brick shall be measured accurately and the overall
volume computed. The bulk density shall then be calculated as mass per unit volume.
3.2.2.6.5-Sampling and Criterion for Conformity: Refer clause 3.2.1.5.1 above.
3.2.3 Sun Dried Bricks:
3.2.3.1 Scope: This specification lays down the requirements for dimensions, quality and strength of
Sun dried bricks, and their mode of measurement.
3.2.3.2 General:
These shall be manufactured from good brick earth and shall be free from cracks, flaws, stones or
lumps of any kind. They shall have defined edges and their size shall be as for burnt clay, unless
otherwise specified. These shall be measured as per mode of measurement for common burnt clay
bricks.
3.2.4 Sand Lime Bricks (IS 4139-1976) : Bricks shall be sound, compact and uniform in shape and
free from visible cracks, warpage and organic matter.
3.2.4.1: Dimensions: shall be 190x90x90 mm and 190x90x40 mm. Tolerance of length ± 3 mm
and of breadth and height ±2 mm.
3.2.4.2: Classes: shall be of the following four classes depending on average compressive strength.
Class Average Compressive strength kg/cm2 (N/mm2)

Not less than Less than
kg/cm2 N/mm2 kg/cm2 N/mm
2
75 75 7.5 100 10
100 100 10 150 15
150 150 15 200 20
200 200 20
Note: For methods of test, refer to Appendix À' of IS 3495 (Pt.-I)-1992
3.3-Steel:
3.3.1 Structural Steel :
Scope- General requirements relating a supply of structural steel shall conform to IS 8910.
Requirements for mild steel (standard quality) plate, sections bars, etc. designated as E250 (Fe 410-
W) for use in structural work. (as per IS:2062-2006, superseding IS 1977, 8500). Also refer Chapter
11 on Steel work .
3.3.1.1 Chemical Composition:
Grade Quality Ladle Analysis Percent Maximum Carbon Method of
Designation Equivalentl Deoxidation
C Mn S P Si
1 2 3 4 5 6 7 8 9
E 165 (Fe. 290) - 0.25 1..25 .045 0.045 - - Semi killed or
Killed/
E 250 (Fe 410W) A 0.23 1.50 .045 .045 0.40 0.42 -do-
E 250( Fe 410W) B 0.22 1.50 0.045 0.045 0.40 0.41 Killed
E 250 ( Fe 410W) C 0.20 1.50 0.040 0.040 0.40 0.39 Killed
E 300 (Fe 440) - 0.20 1.30 .045 .045 0.45 0.40 Semi killed or
Killed/
E 350 ( Fe 490) - 0.20 1.50 0.045 0.045 0.45 0.42 Semi killed or
Killed/
Killed/
E 450( Fe. 570) D 0.22 1.60 0.045 0.45 0.45 0.46 Semi killed or
Killed/
E 450 (Fe 990) E 0.22 1.80 0.045 0.045 0.45 0.48 Semi killed or
Killed/
1
"To be supplied subject to the agreement between the purchaser and the manufacturer".

Notes-I:
1. Carbon equivalent (CE) based on ladle analysis =C+ Mn/6 +(Cr+Mo+ V)/5+ (Ni Cu)/15
2. When the steel is killed by aluminium alone, the total aluminium content shall not be less than
0.02 per cent. When the steel is killed by silicon alone, the silicon content shall not be less than
0.10 per cent. When the steel is silicon-aluminium killed, the silicon content shall not be less
than 0.30 per cent and total aluminium content shall not be less than 0.01 per cent.
3. Micro alloying element like Nb, V, Ti and B shall be added singly or in combination. Total
micro alloying element shall not be more than 0.25.
4. New grades designation system based on yield stress has been adopted, simultaneously old
designations have also been given in parentheses.
5. Steel of qualities A, B and C are generally suitable for welding processes. The Weldability
increases from quality A to C.
6. Copper may be present between 0.20 to 0.35 per cent as mutually agreed to between the
purchaser and the manufacturer. The copper bearing quality shall be designated with a suffix Cu,
for example, E 250 Cu. In case of product analysis the copper content shall be between 0.17
and 0.38 per cent.
7. Nitrogen content of steel shall not exceed 0.012 per cent which shall be ensured by the
manufacturer by occasional check analysis. For micro alloyed steel this is to be reduced to
0.009 per cent.
8. The steel, if required may be treated with rare earth element for better formability.
9. Lower limits for carbon equivalent and closer limits for other elements may be mutually
agreed to between the purchaser and the manufacturer.
10. Incidental element-Elements not quoted in Table 1 shall not be intentionally added to steel
without the agreement of the purchaser, other than for the purpose of finishing the heat. All
reasonable precautions shall be taken to prevent the addition from scrap or other materials used
in manufacture of such elements which affect the hardenability, mechanical properties and
applicability.
Note-II : When steel is required in copper-bearing quality, the copper content shall be between 0.20
to 0.35 percent.
3.3.1.2 Freedom from defects:- Finished material shall be free from cracks, surface flaws,
laminations, rough, jagged and imperfect edges, etc. Monitored surface defects may be removed by
grinding provided the thickness is not reduced locally by more than 4 percent (with a maximum of
3mm).
3.3.1.3 Mechanical Properties:
3.3.1.3.1 Tensile Test: Tensile strength, yield strength and percentage elongation when determined in
accordance with IS 1608 shall be be as given in Table 4.

Table - 4 : Mechanical Properties
Grade Quality Tensile Yield stress Min. Percentage Internal Charpy 'V'
Designation strength MPa Elongation, Bend notch
Min. MPa À'at gaugae Diameter. impact energy.
length Lo : Minl. `J'
5 .65 'ISO
<20 20- >40 <25 >25 Room -20°C

40 Temprature
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
E 165(Fe 290) - 290 165 23 2t - - -
E 250 (Fe 410W) A 410 250 240 230 23 3t 2t - -
E 250 ( Fe 410W) B 410 250 240 230 23 2t 3t 272 (see Note 3)

E 250 (Fe 410W) C 410 250 240 230 23 2t 3t 272 (see Note 3)
E 300 ( Fe 440) - 440 300 290 280 22 2t 3t 50 30
E 350 W 9 0 ) - 490 350 330 320 22 2t 3t 50 25
E 410 ( Fe 540) - 540 410 390 380 20 2t 3t 50 25
E 450( Fe 570) D 570 450 430 420 20 2t 3t 45 20
E 450 ( Fe 590) E$ 590 450 430 420 20 2t 3t 45 20
Notes: 1. : 1 MPa=1N/sgmm = 1 MN/sqm=0.102 kgf/mm2 =144.4 psi

2. : Temperature of Charily Impact value will be subject to mutual agreement.
3. : The more stringent requirements than those given above, may be as agreed to between
the purchaser and manufacturer,
is the thickness of the test piece.
'Room temperature = 25 ± 2° C for impact test.
3.3.1.3.2 Bend Test: Shall withstand without cracking the prescribed test when doubled over until
internal diameter is not greater than 3 times the thickness of test piece (2 times diameter in case of bars
up to 2 5 = diameter).
3.3.1.4 Dimensions and Tolerances: Dimensions of rolled steel products shall conform to the
relevant Indian Standards as listed in section 4 of the IS: 1852-1985 (Reaffirmed 1998). Rolling and
cutting tolerances shall also conform to IS:1852-1985.
3.3.1.5 Weight: shall be calculated on the basis that steel weights 7.85 g/cm3.
3.3.2 Galvanised Steel Sheets (Plain And Corrugated): IS: 277-1992 (Reaffirmed 1997)
3.3.2.1 Classification: Classification of Galvanised plain coils and sheets, as well as corrugated
sheets are classified as per Table-5, which also shows other grade of raw material which is required
for the manufacture.

Table -5
Type Designation Grade Reference of Raw material.
IS-107911S 513
1 2 3
Ordinary GP Grade `0'
Ordinary hard GPH Grade `0'
Lock forming GPL Grade `D'
Deep Drawing GPD Grade `DD'
Extra Deep drawing GPED Grade ÈDD'
Corrugated Ordinary GC Grade `0'
Corrugated Ordinary Hard GCH Grade `0' Hard
This standard also covers the requirements for galvanized steel sheets in coil form as per IS:277:1992
(Reaffirmed 1997).
3.3.2.2 Freedom From Defects: Galvanized plain sheets, corrugated plain sheets and coils , shall be
reasonably flat and free from twist, buckle, bare spots, holes, tears and other harmful defects.
Corrugated sheets shall have uniform corrugations, true in depth and pitch and parallel to the sides of
the sheet.
3.3.2.3 Dimensions:
Length 1.8, 2.2, 2.5, 2.8, 3 and 3.05 m.
Width 0.75, 0.90, 1.0, 1.2 m.
Thickness 1.60, 1.25, 1.00, 0.80,0.63, 0.55, 0.50, 0.45, 0.40, 0.32, 0.28, 0.25,
0.22, 0.18 mm.
Corrugation, depth 17.5mm (nominal); Pitch 75 mm (nominal).
Grade À' 17.5 mm, (nominal) , -do-
Grade `B' 12.5 mm ( nominal), -do-
Overall width and Number of corrugations Per sheet:
Number of Grade Overall width of sheet
corrugations Before After
corrugation-mm corrugation -mm
1 2 3 4
8 A 750 660
10 A 900 810
11 A 1000 910
13 A 1200 1110
8 B 750 680
10 B 900 830
11 B 1000 930
13 B 1200 1130

Note : For details regarding dimensions and weights Refer IS:277-1992 (Reaffirmed 1997).
3.3.2.4 Tolerance:
3.3.2.4.1-On plain sheets/coils :
(a) Length: No sheet shall be smaller in length than that specified. Tolerances on length on plus
side shall be 15 mm or 0.5 percent of length, whichever is greater.
(b) The diagonal distance between opposite corners of any sheet shall not differ by more than 20
mm.
(c) Width: No plain sheet shall be smaller in width than that specified. The positive tolerances
on width shall be 10 mm.
(d) Thickness : The tolerance on thickness of sheet and coil shall be according to IS 1079: 1988
or IS 513: 1986 as applicable.
(e) Tolerance on Mass : The tolerance on mass of individual sheets calculated in accordance with
shall be within ±10 percent and tolerance on mass of each bundle of sheet shall be ±15 percent.
3.3.2.4.2: On Corrugated sheets:
(a) Width: Overall width after corrugation- ±25mm
(b) Depth of corrugation - ± 2.5mm.
(c) Pitch of corrugation - ± 5.0 mm.
3.3.2.5 Bend Test : Test piece shall withstand bending through 180° round a mandrel of specified
diameter as per Table 3 of IS: 277-1992, without peeling or flaking of zinc coating, crack or fracture
of base metal developing at the edge of the specimen or coarse grain developing at the line of the
bend shall be disregarded.
3.3.2.6 Zinc Coating:
(a) The zinc coating shall conform to the requirement of any one of the grades prescribed in Table
8. The mass of coating referred to in this standard shall represent the total mass of zinc, both
sides inclusive.
(b) Any other mass of coating, than those specified in Table 6, may be supplied, if agreed to
between the purchaser and the manufacturer.
(c) The following are recommended grades of zinc coating for the various thickness of sheets:
Thickness Grade of Zinc Coating
0-18 to 0-28 ( both inclusive ) 200
0-30 to 0-55 (both inclusive ) 220
0.63 to I.0 ( both inclusive ) 275
above 1.00 mm 350
NOTES
1. The recommended thickness for roofing application is 0.63 mm and corresponding
recommended grade of coating shall be minimum 275
2. of: agreed to between the manufacturer and Purchaser, for thickness 0.18 mm to 0.28 mm
(both inclusive), other coating grades 180 and 120 may be used.

Table 6 : Mass of Coating ( Total Both Sides )
Grade of Coating Minimum Average Coating Triple Minimum Average
Coating Triple Spot Test- g/m2 Single Spot Test1- g/m2
(1) (2) (3)
600 600 510
450 450 380
350 350 300
275 275 235
220 220 190
200 200 170
180 180 155
120 120 100
1) Minimum individual value obtained in triple spot test.
3.3.2.6.1 : Test Procedure: Refer clause 9 of IS: 277-1992 and as per method given in IS:6745-
1972 & shall conform to both the values specified in Table above.
3.4. Timber: 3.4.1 Scope:
This specification lays down requirements for grading of out size timber. It covers timber as used for
structural and non-structural purposes in buildings and also include timber required for joinery.
3.4.2 Terminology:
3.4.2.1 Baulk: A piece of sawn timber whose cross sectional dimensions exceed 5 cm in one direction
and 20 cm. in other direction.
3.4.2.2 Boxed Heart: A piece of timber so sawn or shown that the pitch or the centre heart falls
entirely within the four surfaces throughout its length.
3.4.2.3 Check: A Fine Crack.
3.4.2.4 Compression Wood: Abnormal wood which is formed on the lower sides of branches and
inclined stems of coniferous trees.
3.4.2.5 Heart Wood : The inner portions of wood in a tree or a log which is usually of a darker
colour.
3.4.2.6 Knot : Base of a branch or limb embedded in the tree which becomes visible when it is cut.
3.4.2.7 Pitch Pocket : Accumulation of resin between growth rings of coniferous wood as seen on
the cross section.
3.4.2.8 Pith : The soft tissues found near about the centre of the log.
3.4.2.9 Sap Wood : The outer layers of the log, which in the growing tree contain living cells. The
sap is usually lighter in colour.
3.4.2.10 Shake : A partial or complete separation between adjoining layers of tissues.
3.4.2.11 Split : A crack extending from one face to another face.

3.4.2.12 Warp : A deviation in sawn timber from a true plane surface.
3.4.2.13 Wane : The original rounded surface of a tree remaining on a piece of converted timber.
3.4.2.14 Slope of Grain : The tangential slope of grain to be measured on tangential side as a
deviation of fibres and the radial slope of grain on a radial side as a deviation of annular rings from
corner of a piece.
3.4.2.15 Worm Holes : Holes caused by worms (kinds of invertebrate limbless creeping animals, or
internal parasite).
3.4.2.16 Loose Grains : The timber shall be called loose grained if the number of rings are more
than 6 rings per 25 mm.
3.4.3. Structural Timber:
Timber used or intended for use in Building where strength is the primary consideration is called
Structural Timber. Sample of Timber having a weight less than 75% of the average weight of that
species of Timber shall not be used for structural work.
3.4.3.1.Grading :Structural Timber, shall be graded into three grades viz. Special grade, Grade 1, and
Grade 2, depending on the prohibited and permissible defects in cut size of Timber (IS: 190-1991,
Reaffirmed 2005).
(a) Special Grade :- Timber of this grade shall not contain defects, the estimated effect of
which tends to reduce the basic strength of Timber by more than 12.5%.
(b) Grade 1 :- Timber of this grade shall not contain defects, the estimated effect of which tends
to reduce the basic strength of timber by more than 25%.
(c) Grade 2 :- Timber of this grade shall not contain defects, the estimated effect of which tends
to reduce the basic strength of timber by more than 37.5%.
3.4.3.2 Defects :
(a) Prohibited : Sawn timber of all three grades shall be free from spiral or twisted grain, warp, any
kind of decay or live insect attack. Special Grade sawn timber shall be free from centre h e , wane,
cup shakes, borer holes (dead infestation) or sap stain (blue stain) also. Grade 1 shall be free from cup
shakes also (see Table 7).
(b) Permissible : Wanes are permitted provided they are not combined with knots and the reduction
in strength on account of the wanes is not more than the reduction caused by maximum allowable
knots. Wanes may also be permitted provided there is no objection to its use as bearing area, nailing
edge and general appearance. Worm holes other than those due to powder post beetles located and
grouped to reduce the strength of timber shall be evaluated in the same may as knots. All other
defects which do not affect any of the mechanical properties of timber shall be permitted. Defects to
the extent permissible in all the three grades are shown in Table 7.

Table -7 : Permissible Defects For Different Grades of Coniferous Sawn Timbers
Si. Defect Special Grade Grade 1 Grade 2

No.
i) Cross grain Max. deviation of 1 in Max. deviation of 1 in 10 Max. deviation of 1 in 8
16
ii) End splits Total length of all Total length of all Total length of all
longest end splits at longest end splits at each longest end splits at
each end shall not end shall not exceed 8cm each end shall not
exceed 6 cm per metre per metre run of piece, exceed 10cm. per metre
run of piece. run of piece.
iii) Knots. a) Live Knots Nil a) Live knots up to a) Live knots up to
25mm in dia. and live 35mm in dia. and live
knots from 25 to 35mm knots from 35 to 50 mm
in dia. to the extent of 3 in dia. to the extent of 3
knots per metre length of knots per metre length
piece shall be of piece shall be
permissible provided permissible provided
these are not grouped or these are not grouped or
located in such a manner located in such a
as to affect unduly the manner as to effect
yield and strength of unduly the yield and
converted timber. Live strength of converted
knots from 35 to 50 mm timber. Live knots from
in dia. to the extent of 50 to 75 mm in dia. to
one knot per metre the extent of one knot
length of piece. per metre length of
piece
b) Dead knots up to b) Dead knots up to b) Dead knots, even
15mm dia. to the extent 15mm in dia. to the more than two, up to 15
of one knot per metre extent of not more than mm in dia. provided
length of piece. two knots per metre they are not numerous
length of piece and dead and not grouped or
knots from 15 to 25mm located in such a
in dia. to the extent of manner as to affect
one knot per metre unduly the yield on
length of piece. Knots conversion and
more than 25 mm dia. usefulness of the timber.
not permitted. Dead knots from 15 to
25 mm in dia. to the
extent of three knots per
metre of length of piece.
More than 25 and up to
35mm. two knots per
metre length. Knots
more than 35mm in dia.
not permitted.
Si.
Defect Special Grade Grade 1 Grade 2
No.
iv) Sap wood Permissible Permissible Permissible
v) Surface Not exceeding 7.5 mm Not exceeding 15 mm in Not exceeding 25 mm in
cracks in depth on any face. In depth on any face. In depth on any face. In
case one of faces is case one of faces is case one of faces is
entirely free from entirely free from cracks, entirely free from
cracks the opposite the opposite face may cracks, the opposite face
face may have a few have a few individual may have a few
individual cracks up to cracks up to 25 mm in individual cracks up to
10 mm in depth. depth. 40 mm in depth.
vi) Sap stain Not permissible Permissible Permissible
vii) Wane Not permissible Up to one-fifth of width Up to one-fourth of
on a broad face subject width on a broad face
to a max. of 70 mm. and subject to a max. of
up to one-third of width 8 0 . and up to one-
on narrow face subject to third of width on narrow
a max of 50 mm. face subject to a max. of
provided that one broad 60 mm. provided that
face is completely free one broad face is
from defect. Wane shall completely free from
be measured at the this defect. Wane shall
deepest part. be measured at its
deepest part.
viii) Borer holes Not permissible Permissible on one face Permissible on two
(dead only provided such holes faces only provided
infestation) are not deeper than such holes are not
10mm and are well deeper than 10 mm and
scattered. are scattered, on a single
face only provided they
are not deeper than 20
mm and are well
scattered.
ix) Centre heart Not permissible Permissible when it is Permissible when it is
not farther than 35 mm not farther than 50 mm
from the nearest edge. from the nearest edge.
x) Cup shake Not permissible Not permissible Permissible to a total
length (Max.) of 150
mm. When measured
along and are up to a
max. depth of 150 mm.
provided they appear
only on one end.

3.4.4. Timber for Non-Structural Purpose:
3.4.4.1 Grading: Timber for non-structural purpose i.e. for such purposes where strength is not the
primary consideration, e.g. furniture and other such uses shall be of two grades viz. Grade 1 and
Grade 2 depending on permissible defects.
Grade-1 Timber of this grade shall not contain defects which will unduly weaken and effect the
timber when used for permanent constructions exposed.
Grade-2 Timber of this grade may contain defects which when plugged in, permit their use in
temporary constructions not exposed to weather.
3.4.4.2. Defects:
(a) Defects Prohibited:- Timber for non-structural use shall be free from heart wood rot, sap
rot, brashness, shakes, insect attack shall not be permitted.
(b) Defects Permissible:-Defects to the extent specified in Table 8 shall be measured as given
in IS:3364-1965.
(c) No knot shall be permissible if it is within 1% times the smallest thickness of the members in
the joint Knots shall not be grouped as to affect unduly the usefulness of the member.
(d) In Grade 2 defective knots, such as decayed knots, dead Knots, Knot holes etc. may be
permitted provided they shall not unduly weaken the member. These knots shall be completely
bored or cut out and tightly plugged with a cross grained seasoned plug of the same species of
Timber and properly
(e) The grain of plug shall run in the direction of the grain of the piece. Boxed heart shall be
permitted. Pith pocket shall be permitted except on the exposed edges, provided they are clean
and filled up with putty or filler. Where pith pockets are located on exposed edges of the core
they shall be cut out and fitted and glued in with a plug of wood or similar species of timber,
with grains running in the same direction as that of the piece.
Some of the permissible defects for Grade 1 and Grade 2 are given in Table-8 (For complete
information refer IS: 1331-1971, Reaffirmed 2002, Superseeding IS:1629-1960).
Table 8: Defects Permissible in Cut Size Timber for Non-Structural use.
S. Defect Grade 1 Grade 2
No.
1 Slope of grain maximum 1 in 15 1 in 12
2 Live Knots
(i) Size Maximum. 13 mm. 25 mm.
(ii) Number per metre length, Maximum 1 2
(iii) Decayed Knots, dead knots and knot holes _ Permitted provided these
shall be completely bored
or cut out and tightly
plugged with a cross
grained seasoned timber
being of the same species
of timber and glued, so that
its grain run in the direction
of main piece.

No.
3 Checks, depth Maximum 3 mm. One fourth of the total
thickness of piece or 6 mm.
whichever is less.
4 End split (largest at end and added together) 3 percent 5 percent of length
of length
5 Pitch pockets _ Permitted except on the
exposed edges, provided
they are clear and filled up
with the putty or filler.
When these are located on
the exposed edges of the
core, they shall be cut out
and fitted and glue in with
plug of similar species of
timber with grains running
in the same direction as
6 Bow 2mmper 4mmper300
that of the pieces.
300
7 Warp Deviation Deviation of 2 percent
of
1 percent
8 Spring 1 mm per 2 mm per 2 m
3m
9 Cracks 1 mm up 2 mm up to 5 cm thickness
to 5cm
thickness
2 mm for 3mm for 5-10 cm thickness
5-10cm
thickness
6 mm for more than 10 cm
4mm for
thickness
more than
10cm
thickness
10 Twist 4 mm per 6 mm per 3 m of length
3 m of
length
11 Centre Heart Permitted Permitted
in pieces
over 250
sq cm of
cross
section
provided it
is sound
and well
boxed
No.
12 Cup 4 mm per 8 mm per
3 m of
length
3 m of
length
13 Wane Not more Not more than 8 percent on
than the surface on which it
4 percent appears
on the
surface on
which it
appears
Note: For methods of measurement of defects in timber, refer to IS : 3364 (Part II-1976) Methods of
measurement and evaluation of defects in timber: Part II Converted timber (first revision).
3.4.5 Timber for Joinery:
3.4.5.1 Defects:
(a) Defects Prohibited: - Timber as used for joinery work shall be free from decay, fungal
growth, boxed h e , pitch pockets or streaks on the exposed edges, borer, holes, splits and
cracks.
(b) Defects Permissible: - Knots shall be grouped as not to affect unduly the usefulness of the
member. No knot shall be permissible if it is over or touching a place of jointing. Defective
knots such as Decayed knots, Knot holes, etc. may be permitted only in grade 2 Timber (as
given under Table 9), provided they shall not unduly weaken the member any further, that they
shall be plugged, if they appear on the exposed edges.
Table -9 Defects Permissible in Timber for Joinery Work.
S. No. Defect Grade 1 Grade 2
1. Cross Grain Not steeper than 1 in 15. Not steeper than 1 in 12.
2. Live knots and Sound
knots
a) On rails Max. 12.5 mm. and not Max. 25 mm. and not more 2 Knots
more than one knot per per metre length.
metre length.
b) On panels Max. 20 mm. and not more Max. 40 mm. and not more than
than one knot per panel. one Knot per 0.2 sqm. of panel.
3. Pitch pockets or None Permissible except on the exposed edges,
Streaks provided that they are clean and filled up
with suitable putty or filler. Where pith
pockets or the streaks are located on the
exposed edges of the core. They shall be
cut and fitted with pieces of wood of
similar grains running in the same
direction. The pieces shall be well
glued.
3.4.6 Classification By Sizes:
3.4.6.1. Batten (Fillet):- A piece of sawn timber whose cross sectional dimensions do not exceed 5
cm. either in breadth or in thickness.
3.4.6.2 Scantlings :- A piece of sawn timber, whose cross sectional dimensions exceed 5 cm. but do
not exceed 20 cm. in both the directions.
3.4.6.3 Baulk:-A piece of sawn timber whose cross sectional dimensions exceeds 5 cm. in one
direction and 20 cm. in the other dimensions.
3.4.6.4 Plank :- A piece of sawn timber with thickness not exceeding 5 cm. and the width exceeding
5 cm.
3.4.7. Seasoning and Preservation of Timbers:
3.4.7.1. Seasoning and preservation of timber shall be done in accordance to the methods prescribed
under Explanatory Notes for timber.
3.4.7.2. The Max. permissible moisture content before use of timber to which it should be seasoned,
depends on the service requirement of the finished article and climatic conditions of the locality.
This shall be as per Table No.10 below for some of the common uses of timber.
Table - 10
S. Use Moisture Moisture
No. Content Content %
% Zone I Zone II.
1. and 12 14
Beams Rafter
2. Doors and Windows 10 12
3. Flooring strips for general purposes 8 10
4. Furniture and Cabinet making 10 12
5. Handles 12 12
6. Pattern Making 8 10
Zones :- The country has been b broadly divided into four zones, viz. - Zone I, II, III & IV based on
climatic consideration. Western part of Rajasthan comes under Zone I and rest of it under Zone II.
3.4.8. Mode of Measurement of Timber: Timber shall be measured in cubic metre, type and grade
of timber being specified. Different species of timber shall be stored and measured separately.
Wrought timber (i.e. Planed timber) shall be measured in cubic metre separately.
3.4.9. Mode of Measurement of Defects:
3.4.9.1. Checks, Splits and Shakes :- Shakes are measured by their extensions on one end in
centimetre or in parts of that side of the piece on which their projections are greater. n e t appearance
on the other end is not taken into account. Exterior shakes, Checks and Splits are measured on the
sides of the piece by their depth in centimetre or in parts of the length of the piece. End zones Shakes,
Checks and Splits are measured by their depth in millimetre from the end.
Note :-The size of maximum chord is taken as the extension of the Ring Shake.
3.4.9.2. Compression Wood :- Compression wood is measured as percentage of the face area.

3.4.9.3 Heart wood :- Heart wood rot is measured as percentage of the sectional area.
3.4.9.4. Knots :- The diameter of a knot is the maximum distance between two points for these
apart on the periphery of a round knot on the face of which it becomes possible.
3.4.9.5. Sap rot :- Sap rot measured lengthwise in centimetres or as percentage of the sectional
area.
3.4.9.6. Slope of grain :- The tangential slope of grain is measured on tangential side as a deviation
of fibres and the radial slope of grain on a radial side as a deviation of annular rings from corners of a
piece in cm per one linear metre.
3.4.9.7. Loose grain :- Loose grains shall be measured in terms of number of rings per 25 mm and
grain shall be considered loose if the number of rings are more than 6 in number per 25 mm.
3.4.9.8. Wane :- The maximum width of wane is visible on the face.
3.4.9.9. Worm holes :- The number of worm holes is counted according to their variety per one
metre of length of timber or is taken in relation to the full length of a piece.
3.4.9.10. Boxed Heart :- Boxed heart is measured as percentage of the area of the face on which it
becomes visible.
3.4.10. Plywood:
3.4.10.1. Definition : A board formed of three or more layers of Veneer (a thin sheet of wood of
uniform thickness obtained by slicing rotary cutting or sawing) Cemented or glued together, usually
with the grain of adjacent Veneers running at right angles to each other.
3.4.10.2. General : Plywood used in the building construction has been divided into two categories.
(a) Plywood for general purposes conforming to IS: 303-1989(Reaffirmed 2003).
(b) Decorative plywood conforming to IS:1328- 1982.
3.4.10.3. Grades : Plywood for general purposes shall be of two grades depending upon the bond
strength developed by the adhesive used for bonding the veneers, namely :
i) Boiling water resistant or BWR grade,
ii) Moisture Resistant or MR grade.
3.4.10.4. Types : Plywood for general purposes shall be classified in to three types namely AA, AB,
BB, based on the quality of two surfaces namely À' and `B' in terms of general permissible defects.
The type of plywood shall, therefore, be designated by the kind of surfaces of the panels. The better
quality surface shall be called `face', and
the opposite side shall be called `back'. If the face and the back are of the same quality, they are not
distinguished. The type of plywood shall denote first the quality of face followed by the quality of
back. For example, Type AA shall have both surfaces of quality A, Type AB shall have face of
quality A and the back of quality B
and Type BB shall have both the surfaces of quality B. The quality requirements for each kind of
face shall conform to the requirements specified in Table 11 (As per IS:303-1989 Reaffirmed 2003).

Table 11: Quality Requirement of Plywood for General Purposes
S. Defect Types of Surfaces
No.
A B
(1) (2) (3) (4)
i) Blister Nil Nil
ii) Checks Individual check not more than Individual check not more than
50 mm in length, and the total 100 mm in length, and the total
300mm/m2 1000 mm/m2
iii) Discolouration Nil 5 percent
iv) Dote 5 cm/sqm 15 cm/m2
v) Insect hole Scattered up to 12 holes/m2 Scattered up to 24 holes/m2
vi) Joints None in 250 mm wide face and No restrictions.
in wider faces, one joint for
every multiple of 200 mm in
width provided no individual
piece is less than100 mm in
width.
vii) Knots (dead) 2 up to 1 2 = dia./m2 4 up to 20 mm dia./m2
viii) Pin knots (dead; 2 /m2 6 /m2
ix) Pin Knots (live) No restriction No restriction
x) Knots (tight) 6 up to 2 5 = dia./m2 No restriction
xi) Patches 4 patches / m2 they are all tight Any number, provided they are
patches and do not mar the all tight patches and are matched
appearance for colour.
xii) Splits Two splits, each not more than 3 splits, each not more than 4 mm
1.0 mm wide and not longer wide and total length not more than
than 1 0 0 = provided it is filled 150 mm provided they are filled
with a suitable filler. with suitable veneer inserts. Splits up
to 25 mm long and 0.8 mm wide may
be ignored provided they are suitably
filled with a filler.
xiii) Swirl Unlimited, provided they do not No restriction.
mar the appearance
xiv) Minimum 3 5
number of
Categories of
Permissible
Defects per
sq metre

3.4.10.5. Material : Timber: Any species of timber can be used for plywood manufacture. For a
list of species refer Annex B of IS 303-1989
3.4.10.6. Adhesives The adhesives used for bonding the Veneers in different grades of plywood
shall be the corresponding type of adhesives conforming to IS:848-2006.
3.4.10.7 Assembly: Thickness: The thickness of ail veneers shall be uniform within a tolerance of ±
5 percent. Corresponding veneers on either side of the central ply and those of face and back veneers
shall be of species having similar physical and mechanical properties, such as, density, modulus of
electricity, shrinkage, etc. to ensure balanced construction.
3.4.10.8 Joints in Veneers : Veneers that require to be joined to form a ply shall be spliced ( edge
jointed) before assembly. All joints shall be cut square. They may be taped on the Face of the outer
veneers in which case the tape shall be removed at a later stage, and metal clips or staples, if used, shall
be removed. Perforated tapes may be used on the glue side of the veneers. In assembly, joints in veneers
running in the same direction shall be staggered. End joints and butt joints shall not be permitted for
any of the surfaces.
3.4.10.9 Grain Direction: Unless otherwise specified by the purchaser and except in boards
comprising an even number of plies, the direction of grain of the veneer in adjacent plies shall be at
right angles to each other, and that of the outer plies shall run parallel to the longer side of the board.
In boards comprising even number of plies, the grain of the centre pair shall follow the same direction.
In adjacent plies, the grain should be at right angles to each other. However, a deviation not exceeding
100 may be permitted. In all cases, the grain on both faces of the assembly boards shall run in the same
direction.
3.4.10.10 Scarf Joints: When sizes larger than the available press sizes are required, scarf joints
through the thickness of the board are permitted. All scarf joints shall be bonded with the same or a
better .adhesive than the one used for the manufacture of plywood, and shall be made with an
inclination not greater than 1 in 12.
3.4.10.11 Permissible Defects: Gaps in cores and cross-bands may be permitted except for 3 ply
plywood provided the width of the gap does not exceed 1 mm in case of and 2 mm in case of plywood
of more than 5 ply and provided such gaps, if more than one, shall be spaced not less than 80 mm away
from each other and are staggered not less than 50 mm away as between ply, the next ply having the
same grain direction. Splits in cores and cross-bands may be permitted to an extent of 2 per core or
cross band. Overlap shall not be permitted.
3.4.10.12 Dimensions and Tolerances : The dimensions of plywood boards shall be as given in IS
12049: 1987.
NOTE- Any other dimension as agreed to between the manufacturer and the purchaser may be used.
3.4.10.13 Thickness : Unless otherwise specified, thickness of plywood boards shall be as specified
in Table 14. The thickness shall be measured up to one place of decimal.
3.4.10.14 Tolerances :The following tolerances on the nominal sizes of finished boards shall be
permissible:
Dimension
a) Length +6mm , -0mm

b) Width +3mm,-0mm

c) Thickness
1) less than 6mm ±10%
2) 6 mm and above ±5%
d) Squareness 0.2%
e) Edge straightness 0.2%
Table 12 - Thickness of Plywood Boards
Board Thickness-mm Board Thickness -mm
1 2 3 4
3 ply 3,4,5,6 9 ply 12,15,16,19
5 ply 5,6,8,9 11 ply 19,22,25
7 ply 9,12,15,16 Above 11 ply As ordered
3.4.10.15 Workmanship and Finish : The plywood boards shall be of uniform thickness within
the tolerance limits specified under 3.4.10.14
3.4.10.16 The faces of plywood boards shall be reasonably smooth and face veneers shall be of
reasonably uniform thickness. Slight sanding may be given to rough boards in order to make them
reasonably smooth. The squareness and edge straightness of the board when measured according to
the procedure given in Annex C (of IS 303-1989) shall be as given in 3.4.10.14.
3.4.10.17 Sampling : The method of drawing representative samples and the criteria for conformity
shall be as prescribed in IS 7638: 1975.
3.4.10.18 Tests : Six test pieces, cut from each of the boards selected under 3.4.10.17 shall be
subjected to the tests specified in IS code.
3.4.10.19 Glue Adhesion : Glue adhesion shall be deemed satisfactory if the plywood complies
with the requirements specified in 3.4.10.20 to 3.4.10.22.
3.4.10.20 Glue Shear Strength in Dry State : The plywood when tested in accordance with IS
1734 ( Part 4) : 1983 shall have an average and a minimum individual shear strength not less than the
values specified in Table 13 against each grade.
3.4.10.21 Mycological Test :The plywood when tested in accordance with IS 1734 ( Part 7) : 1983
shall have an average and a minimum individual shear strength, not less than the values shown in
Table 13 against each grade.
3.4.10.22 Water Resistance Test :The plywood when tested in accordance with IS 1734 ( Part 6) :
1983 shall have an average and a minimum individual shear strength, not less than the values shown
in Table 13 against each grade.
3.4.10.23 Moisture Content : The plywood when tested in accordance with IS 1734 ( Part 1 ) :
1983 shall have a moisture content not less than 5 percent and not more than 15 percent.
3.4.10.24 For the purpose of tests specified above , the mean of all the observations and the minimum
individual value of the observations shall be reported in the form given in Annex. D (IS 303-1989).

Table -13 : Average and Minimum Individual Shear Strength for Plywood
S. No. Grade Dry State Mycological Resistance to
Moisture
i) BWR Minimum Average 1350 1000 1000
Individual 1100 800 800
ii) MR Minimum Average 1000 800 800
Individual 800 650 650
3.4.10.25 Marking :. Each plywood board shall be legibly and indelibly marked or stamped with the
following:
a) Indication of the source of manufacturer.
b) Year of manufacture.
c) Batch No.
d) The grade and type as follows
BWR/AA, BWR/AB, BWR/BB, MR/AA,MR/AB„ MR/BB .
All markings shall be done on the face of the board near one corner.
3.4.11 Veneered Decorative Plywood:
3.4.11.1 Requirements:- Requirements of types of plywood with ornamental veneers on one or both
faces used for decorative purposes such as furniture making, panelling of all kinds, including panelling
for railway coaches, buses and ships as per IS:1328:1982. Decorative veneers shall be rotary cut or
sliced and shall be not more than 1.0 mm in thickness. The veneers shall be spliced or taped at the
edges. The veneers may have end grain joints in cases of special matching like centre-matching, V-
matching, etc. Veneers forming any one ply and the corresponding ply on the opposite side of the
central plane of plywood shall be of the same species of timber and of the same nominal thickness,
except in case of faces where they shall be of such thickness and strength as to balance each other.
3.4.11.2 Types -Shall be of two types, namely. Type 1 and Type 2.
Type 1- Veneered decorative plywood shall comply with the requirements specified as under:
(a) Open splits, checks or open joints not more than 150 mm in length and 0.5 mm in width shall
be permissible, provided the same are rectified with a veneer insert bonded with synthetic resin
adhesive as the case may be, and further provided that the insert matches with the surrounding
veneer in colour as well as in figure.
(b) The decorative veneered surfaces shall be free from torn grain, dead knots, dote, discoloration
and sapwood.
(c) The decorative veneered surface shall be selected for figure, texture, colour and grain
characteristics. It-shall be free from all manufacturing and wood defects except to the extent
permitted under (a). All veneers shall be matched or mismatched to achieve a decorative effect
in colour, figure and grain.
(d) If the purchaser requires boards with the decorative veneers matched to a particular design, for
example, quartered, centred, diamond or V-matched or where it is required that there

should be complete absence of pin knots, it shall be so specified. If certain number of decorative
matched plywood panels are required to form a group to give an overall general effect it shall be
so specified by the purchaser giving the number of panels in each such group.
Type 2: Veneered decorative plywood shall comply with the requirements specified in (a) to (c)
below.
(a) Open splits, checks, or open joints not more than 200 mm in length and 1 mm in width shall be
permissible, provided these are rectified in the manner specified under (a) in Type 1. Tight knots
and patches not more than 25 mm in diameter, and pin knots not more than 4 mm in diameter,
shall be permissible.
(b) The decorative veneer shall be free from the torn grain, dead knots, dote and discolouration.
Sapwood, if it does not affect the appearance, shall be permissible.
(c) The decorative veneered surface shall be selected for figure, texture, colour and grain
characteristics. It shall be free from all manufacturing and wood defects, except to the extent
permitted in (a) and (b). All veneers shall be matched or mismatched to achieve a decorative
effect in colour, figure and grain.
3.4.11.3 Designation of Dimensions and Tolerances:
(a) The dimensions and tolerances (including on thickness) of plywood shall be as given in IS
12049: 1987.
(b) Thickness Unless otherwise specified, thickness of the plywood boards shall be 3 mm, 4
mm, 6mm,9mm, 12 mm, 19 mm or 25 mm.
3.4.11.4 Finish:
(a) The decorative plywood shall be uniform in thickness within the tolerance limits specified in
3.4.11.3 (a) .
(b) The edges of the decorative plywood shall be trimmed square within 3 mm and sanded to a
smooth finish.
3.4.11.5 Sampling and Criteria for Conformity:
The method of drawing representative samples and criteria for conformity shall be as per IS 7638 :
1986.
3.4.11.6 Tests: Test boards selected as described in 3.4.11.5 shall be subjected to test specified for
moisture content and water resistance test as under:
(a) Moisture Content : Decorative veneered plywood of either type when tested in accordance
with IS 1734 (Part 1) : 1983sha11 have a moisture content of not less than 5 percent and not
more than 15 percent.
(b) Water Resistance Test : Decorative veneered plywood of either type, when tested in the
manner specified in (c ) below, shall not show delamination or blister formation.
(c) Three test specimens of size 250 mm x 100 mm shall be prepared from each of the boards
selected and submerged in water at 60± 2°C for a period of 3 hours and dried for 8 hours at a
temperature of 65 ±2°C and then followed by two more cycles of soaking and drying under the
same conditions described above.

3.4.11.7 Inspection and Delivery : Inspection:
All boards shall be visually inspected to ensure that the decorative veneered sides conform to the
requirements specified in 3.4.12.1 . They shall also be inspected for delamination, blisters or surface
defects.
3.4.11.8 Material:
(a) Species of timber for decorative face veneer in decorative plywood shall be specified by the
purchaser. The species of Timber commonly used are as per Annex. `B' of IS: 1328-1982.
(b) Any species of timber may be used for cores and backs of decorative veneered plywood.
However, a list of species, given in Annex B of IS 303: 1989 may be used for guidance. Non-
durable timbers and sapwood of all other timbers shall be given a preservative treatment. The
preservative used shall be such as not to impart any colour or lasting smell, oiliness or stain to
the plywood and shall not adversely affect the glueing of the veneer and the waxing and
polishing of the surface.
(c) Adhesive : The adhesive for bonding of veneers shall be MR type synthetic resin adhesive,
conforming to IS: 848-1974.
(d) Plywood : plywood , when used in the manufacture of veneered decorative plywood shall be
of MR Type conforming to IS 303-1989.
3.4.11.9 Marking :. Each plywood board shall be legibly and indelibly marked or stamped with the
following:
a) Indication of the source of manufacturer.
b) Year of manufacture.
c) Batch No., and
d) The type.
3.4.12 Block Boards :
3.4.12.1.Scope-Requirements of commercial and decorative blockboards meant for interior and
exterior uses. As per 1S:1659:1979. Block board is a board having a core made up of strips of wood,
not exceeding 30 mm in width, which may or may not be glued together and the core is glued to two or
more veneers, on either side with grain direct ion of core and veneers running at right angles to one
another.
3.4.12.2. Grades and Types: Grades : these shall be of two following grades.
a) BWP grade: Such block board may be used for bus bodies, railway coaches, prefabricated
houses, etc., where it is likely to be exposed to high humidity and for external use.
b) MR Grade: Such block board may be used for interior use such as furniture, partition,
panelling, ceiling, etc.
3.4.12.3 Each of the grades specified above shall be of the following two types:
a) Decorative Type - These are block boards with decorative face veneers on one or both sides
for use in high class furniture, panelling, interior decoration, partitions, etc.
b) Commercial Type - These are block boards with veneers of commercial timber on both sides
and are used for ordinary furniture, table tops, partitions and panelling to be painted

over flooring and seats of bus bodies, railway carriages, etc.
3.4.12.4 The grades and types of block boards shall be represented by the symbols given below:
Grade and Type Symbol
BWP-DEC
BWP Grade, Decorative type BWP-COM
BWP Grade, Commercial type MR-DEC
MR Grade, Decorative type MR-COM
MR Grade, Commercial type
3.4.12.5 Materials:
a) Timber : (i) Any suitable species of timber may be used for block board manufacture. A list of
species for manufacture of block board is (given in Annex. B of IS: 1659-2004) for guidance only.
For ECO-Mark only species of wood from sources other than natural forests such as wood from
rubber, cashew industrial and social forestry plantations, etc., and shade trees from tea and coffee
estates, shall be used for the manufacture of block board.
Face Veneers for Decorative Type of Block Boards : The species of timber for the decorative
face veneer in decorative type of block board shall be specified by the purchaser while placing the
order. The species of timber commonly used for face veneers of decorative type of block boards
is (given in Annex. C of IS: 1652-2004) for guidance only. For ECO-Mark only species of wood
from sources other than natural forests such as wood from rubber, cashew industrial and social
forestry plantations, etc., and shade trees from tea and coffee estates shall be used.
(b) Adhesives : The adhesives used for bonding purposes shall be the BWP type conforming to
IS 848 for BWP Grade block boards. For MR Grade block boards, the adhesives shall be MR
type conforming to IS 848.
3.4.12.6 -Manufacture : Preservative Treatment :
i) Species of timber marked with (*) in Annex B and Annex. C of IS: 1659-2004 and sapwood
of all species, and all non-durable species shall be treated as mentioned in 1S 401. Trimmed and
cut ends of a finished block board may be given a protective treatment.
v) Core : The wooden strips for core shall be cut from timber seasoned to a moisture content not
exceeding 12 percent according to IS 1141. The width of each strip of wood shall not exceed 30
mm and such strip shall be placed edge to edge without significant gaps. These strips may be of
small lengths placed end to end where the end joints shall be staggered. However, for the edge strip
along the length, the width of strip may be up to 45 mm.
Cross Bands and Faces : Veneers used for cross bands and faces shall be either rotary cut or
sliced and shall be smooth. The moisture content in the veneers shall be between 8 and 12 percent.
Cross band shall be not less than 1.0 mm but not more than 3.0 mm in thickness. Face veneers shall
be between 0.5 to 1.5 mm in thickness for commercial type of block boards and 0.5 to 1.2 mm
in thickness for decorative type of block boards.
The construction shall be well balanced around the central line.
Permissible defects and tolerances on thickness shall conform to IS 303 and IS 1328 for
v) commercial and decorative veneers respectively.
vi)

3.4.12.7 Dimensions and Tolerances :
a) Thickness: The Thickness of block boards shall be -12,15, 19, 25, 30, 35, 40, 45 and 50
mm.
b) Sizes:
Length - mm Width-mm
2440 1220
2140 1220
2140 920
1830 1220
1830 920
Any other dimension (length, breadth and thickness) as agreed to between the manufacturer
and the purchaser may also be used.
c) Tolerances : Tolerances on nominal size of finished boards shall be as given below.
a) Length : +6mm , -0mm

b) Width +3mm,-0mm
c) Thickness ±5%
variation in thickness not more than 0.5 mm
on a board.
d) Squareness 0.2% or 2 mm per 1000 mm
e) Edge straightness 0.2% , or 2 mm per 1000 mm
3.4.12.8-Sampling and Inspection :
(a) Lot : In any consignment, all block boards of the same grade, type and thickness and
manufactured under similar conditions shall be grouped together to constitute a lot.
(b) The conformity of a lot to the requirements of this standard shall be ascertained on the basis
of tests on block boards selected from it.
(c ) The method of drawing representative samples and the criteria for conformity shall be as
prescribed in 1S 7638.
3.4.12.9-Defects : All block boards selected as in (c) shall be inspected visually for surface defects
[see 3.4.13.6 (vi)] and if one or more block boards are found unsatisfactory, the lot shall be declared
as unacceptable.
3.4.12.10-Length and Width : All block boards selected as in (c) shall have length and width
within the tolerances specified under 3.4.12.7 (c).
3.4.12.11-Thickness : All block boards selected as in 3.4.12.8 (c) shall have its mean thickness and
variation in thickness between any two points on a block board as specified under 3.4.12.7 (c) when
tested by the method.
3.4.12.12-Test Specimens and Number of Tests:
(a) The selected block boards as in 3.4.12.8 (c) shall be taken up for cutting of test specimens
for further testing.
(b) From each of the block boards selected, following test specimens shall be cut from the
portion 150 mm away from the edges:
i) Six test specimens of size 200 mm X 12 mm for the test mentioned in 3.4.12.14 (c) ;
ii) Three test specimens of size 200 mm x 100 mm for the test mentioned in 3.4.12.14 (d);
iii) Three test specimens of size 200 mm x 100 mm for the test mentioned in 3.4.12.14 (g);
iv) Three test specimens of size 150 mm x 100 mm for the test mentioned in 3.4.12.14 (h);
v) Three test specimens of size (50 mm + 20 d) length and 75 mm width in full thickness of
board for the test mentioned in 3.4.12.14 ( i ) , where d is the nominal thickness in mm.
Greater dimensions shall be in the direction along the face grain; and
vi) One test specimen of entire cross-sectional area across its full width for the test
mentioned in 3.4.12.14(j).
(c) The test specimens so obtained shall be conditioned in accordance with 3.4.12.14 (a) and the
thickness of each test specimen shall be measured by the method and the mean of all such
measurements calculated. The test specimens shall then be tested for the corresponding tests.
3.4.12.13-Criteria for Conformity: A lot shall be considered as conforming to the requirements of
this standard, if the requirements mentioned in 3.4.12.14 (c) to (j ) are all satisfied.
3.4.12.14- Tests:
(a) Preparation and Conditioning of Test Pieces : The required test specimens shall be cut to
the specified size as given in 3.4.12.12 (b). Each test specimen shall be rectangular with all
edges cut square to the surface. Before any tests are made, the prepared test pieces shall be
suitably conditioned.
Note: Exposure for 24 h to the air of a well-ventilated room will often suffice but when a greater
degree of accuracy is required, the test piece shall be exposed to an atmosphere maintained at
a temperature of 27± 2°C and at a relative humidity of 65± 5 percent until they are substantially
constant in mass.
(b) The block boards shall be subjected to the following tests and shall satisfy the requirements
specified under each test.
(c) Dimensional Changes Caused by Humidity: When tested according to Annex E, the
dimensions shall not change by more than +1 mm at relative humidities of 90 percent and 40
percent compared to the dimensions of the specimens conditioned at 65 percent relative
humidity. There shall be no delamination at the extreme ranges of humidity and the changes in
local planeness measured as d/L shall be as follows:
d/L < 1/150
where
d = vertical gap between any two points, and L = horizontal distance between these points.
(d) Resistance to Water : When tested according to the methods specified in (e) and (f) below,
the block boards shall satisfy the requirements given therein.
(e) Test specimens from BWP Grade block boards, after soaking in boiling water for 72 h and
tested as in Annex. F shall comply with the requirements of (g) below.
(f) Test specimens from MR Grade block boards: after soaking of test pieces for 3 h in water
at a temperature of 60 ± 2°C and shall comply with the requirements of (g) below.

(g) Adhesion of Plies : The adhesion of plies shall be tested and the fractured surface of the
specimen shall show adherent fibres of a `pass standard'.
(h) Mycological Test : MR Grade block board specimens, when tested shall show no visible
signs of separation at the edges.
(i) Modulus of Rupture and Modulus of Elasticity: The modulus of rupture and modulus of
elasticity when tested according to the method given, BWP Grade and MR Grade boards shall
have average and minimum individual values as given below:
BWP Grade MR
Grade
Modulus of rupture, N/mm2:
Average 50 40
Minimum, individual 42 34
Modulus of elasticity, N/mm2:

Average 5000 4000
Minimum individual 4200 3400
(j) Spot Test : The preservative treatment when tested according to the method, at any given place
after cutting across entire cross-sectional area for the width of block board shall show through and
through penetration of preservative chemical.
3.4.12.15- Additional Requirements for Eco-Mark:
(a) General Requirements:
(i) The block board shall conform to the requirements of quality and performance as specified
in this standard.
(ii) The manufacturers shall produce to BIS environmental consent clearance from the concerned
State Pollution Control Board as per the provisions of the Water (Prevention and Control of
Pollution) Act, 1974 and Air (Prevention and Control of Pollution) Act, 1981 and Water
(Prevention and Control of Pollution) Act, 1977 along with the authorization, if required under
the Environment (Protection) Act, 1986 while applying for ECO-Mark, appropriate with
enforced rules and regulations of Forest Department.
(iii) Specific Requirements : The block board shall conform to the specific requirements given
for ECO-Mark under relevant clause of the standard.
NOTE- The manufacturers shall provide documentary evidence by way of certificate or
declaration to Bureau of Indian Standards while applying for ECO-Mark.
3.4.12.16- Marking:
Each block board shall be legibly and indelibly marked on any of its face with the following
a) Indication of the source of manufacture;
b) Grade and type of block board;
c) Size (length, width and thickness);
d) Batch number and year of manufacture; and
e) The criteria for which the block boards have been labelled as ECO-Mark.

Note - For test procedures see Appendices C to H of the standard.
IS:1734 (Part I)-1972 Part I Determination of density and moisture content (first revision).
IS:1734 (Part IV)-1972 Part IV Determination of glue shear strength (first revision).
IS:1734 (Part V)-1972 Part V Test for adhesion of plies (first revision).
IS:1734 (Part VII)-1972 Part VII Mycological test (first revision).
IS:1734 (Part IX)-1972 Part IX Determination of tensile strength (first revision).
3.4.13 Decorative Plywood Using Plurality Of Veneers For Decorative Faces:
3.4.13.1Scope: - Covers decorative plywood with ornamental faces produced by use of plurality of
veneers meant for decorative use, such as interior panelling of buildings, buses, ships, etc., and for
decorative furniture of all types as per IS : 7316:1974(Reaffirmed 2003).
3.4.13.2 Grades: Decorative plywood from plurality of veneers shall be only of one grade conforming to
the requirements given in this standard. The pattern of the decorative face shall be as agreed to between
the purchaser and the manufacturer.
3.4.13.3-Materials: (a) Timber - Timber for cores, backs and face veneers of decorative plywood
shall be either Class I, II or Ill timbers specified in IS:303-1975. Non-durable timbers and sapwood
of all other timbers shall be given a preservative treatment. The preservative used shall be such as not
to impart any colour or lasting smell, oiliness or stain to the plywood and shall not adversely affect
the gluing of the veneer and the waxing and polishing of the surface. For the faces generally it is a
plurality of veneers of different species or, if of the same species of different colours, either natural
colours or artificially coloured.
(b) Adhesive -The adhesive for bonding of veneers shall be synthetic resin adhesive BWR or
WWR conforming to IS : 848-1974 as may be specified by the purchaser.
(c) Plywood, when used in the manufacture of veneered decorative plywood shall be of BWR or W
WR synthetic resin bonded type conforming to IS : 303-1960: as may be specified by the purchaser.
3.4.13.4 Manufacture:
(a) Decorative Face Veneers - Decorative face veneers shall be rotary cut or sliced from a wooden
flitch made by laminations of veneers of different colours in pre-determined pattern and either
rectangular or in a pre-determined moulded shape. These veneers shall not be more than 1 mm
in thickness and shall be suitably matched and spliced.
(b) Decorative plywood shall be manufactured either by bonding the various layers of veneers in
one operation or by bonding decorative veneers on to BWR or WWR synthetic resin bonded
plywood of suitable thickness.
(c) Where decorative veneer is used on one side of the plywood only, a suitable back of required
thickness balancing the strength of the decorative face veneer shall be provided.
(d) Veneers forming any one ply and the corresponding ply on the opposite side of the central plane
of plywood shall be of the same species of timber and of the same nominal thickness, except in
case of faces where they shall be of such thickness and strength as to balance each other.
(e) If the purchaser requires boards with the decorative veneers matched to a particular design, for
example, quartered, centred, serial, diamond or V-matched, it shall be so specified. If certain
number of decorative matched plywood panels are required to form a group to give an

overall general effect, it shall be so specified by the purchaser giving the number of panels in
each such group.
3.4.13.5- Permissible Defects:
(a) Open splits, checks or open joints not more than 150 mm in length and 0.5 mm in width shall
be permissible provided the same are rectified with a veneer insert bonded with BWR or WWR
adhesive, as the case may be, and further provided that the insert matches with the surrounding
veneer in colour and in figure.
(b) Decorative veneered surface shall be free from torn, grain, dote, worm hole, discolouration or
other visual defects.
(c) Decorative veneer surface shall be selected for figure, texture, colour and grain characteristics.
It shall be free from all manufacturing and wood defects except to the extent permitted under (a).
All veneers shall be matched or mismatched to achieve a decorative effect in colour, figure and
grain.
3.4.13.6- Dimensions and Tolerances:
(a) The dimensions of plywood boards shall be quoted in the following order, the first
dimension shall represent the length, the second the width and the third the thickness.
(b) Standard Dimensions:
Length 240, 210, 180, 150, 120, and 90cm
Width 120 and 90cm
Thickness 3. 4, 6, 9, 12, 19 and 25mm
(c) Tolerances :
Length up to 120 cm +3 mm
-0 mm
Length above 120 cm +6 mm
-0 mm
Width up to 90 cm +3 mm
-0 mm
Width up to 90 cm +6 mm
-0 mm
Thickness: The following tolerances shall be permitted on thickness.
Positive: +0.2 mm +5 percent of nominal thickness
Negative -0.1 mm + 2.5 percent of nominal thickness
Rectangular panels shall have their diagonal lengths not varying beyond 9 mm.
3.4.13.7. Finish:- Decorative plywood shall be uniform in thickness within the tolerance limits
specified under 3.4.13.6 (c). Decorative plywood shall be trimmed square and sanded to a smooth
finish. Decorative surface shall be smooth and of the desired decorative pattern and have good
pleasing locks, texture and feel.

3.4.13.8-Sampling:
(a) Lot -All plywood boards/sheets of the same type, grade, size and manufactured in the same
batch of production shall constitute a lot.
(b) Samples shall be selected and tested separately from each lot for determining its conformity
or otherwise to the requirements of the specification.
(c) Scale of Sampling and Method of Selection -The number of boards/sheets to be selected
from a lot shall depend upon the size of the lot and shall be in accordance with Table 14.
(d) Boards/sheets to be selected from the lot shall be chosen by the method of simple random
sampling following the procedure given in IS : 4905-1968t. As an alternative the method of
systematic sampling explained in (e) below may be followed.
(e) Starting from any board in a lot, the boards shall be counted as 1, 2 .......... r and so on in one
order. Every rth board thus counted shall be withdrawn to constitute the sample, where r is the
integral part of N/n (N and n being the lot size and the corresponding sample size respectively.
This procedure shall be stopped as soon as the required number of boards is obtained.
(f) For example, if a total sample of 32 boards is to be selected from a lot of 1330 boards, then
the value of r is obtained as the integral part of 1330/32 ( = 41.6), which is 41. Starting from any
board, the boards shall be counted in one order and every 41st board shall be withdrawn.
Table 14- Scale of Sampling and Permissible Number of Defectives
No. of Boards/Sheets Sample Size Acceptance Number

in the Lot
(N) (n) (a)
up to 300 5 0
301 to 500 8 0
501 to 1000 13 0
1001 and above 20 1
3.4.13.9- Testing of Samples and Criteria for Conformity - All boards/ sheets in the sample shall
be inspected for the dimensional requirements and tested for moisture content and water resistance
test. A board shall be considered as defective if it fails to satisfy the requirements of any one or more
of the characteristics. The lot shall be declared as conforming to the requirements of the specification if
the number of defective boards/ sheets in the sample is less than or equal to the corresponding
acceptance number given in col 3 of Table 16. Boards selected as described under 3.4.13.8 shall be
subjected to the following tests.
(i) Moisture content: Decorative veneered plywood conforming to the standard when tested in
accordance with IS : 1734 ( Part I)-1972 shall have a moisture content of not less than 5 percent
and not more than 15 percent.
(ii) Water Resistance Test - Decorative veneered plywood conforming to the grade specified in
this standard shall not show delamination or blister formation, when tested in the manner
specified under (c) below.
(iii) Three test specimens of size 15 x 15 cm shall be prepared from each of the boards selected
and submerged in water at room temperature for a period of 48 hours and dried for 8 hours at a
temperature of 65±2°C and then followed by two cycles of soaking each for 16 hours and

drying for 8 hours under conditions described above.
3.4.13.10-Marking : Decorative veneered plywood shall be clearly marked in a suitable position
with the following information.
a) Manufacturer's name or trademark,
b) Approved pattern mark,
c) BWR or R.
3.4.13 .11 Other Miscellaneous Products: The following products , if used , shall confirm to the
codes indicated against them.
S.No. Product Relevant BIS code
1. Ply wood for Concrete Shuttering Work. 4990-2011
2. Fire Retardant Plywood. 5509-2000
3. Preservative Treated Ply wood. 5539-1969
4. Fibre Hard Board 1658-2006
5. Wood Particle Boards ( Medium Density) 3087-2005
6. Veneered Particle Board. 3097-2006
7. Low density Particle Board. 3129-1985
8. Wood Wool Building Slabs. 3308-1981
9. Fibre Insulation Board. 3348-1965
10. High Density Wood Particle Boards. 3478-1966
3.5 Lime : Ref. IS: 712-1984 ( Reaffirmed 2009)

3.5.1. Scope:
3.5.1.1. This specification lays down requirements for building Limes used for Construction purposes.
3.5.2. Terminology: (Ref. IS: 6508-1972)
3.5.3. Classification: Building limes shall be classified as follows:
Class A - Eminently hydraulic lime used for structural purposes.
Class B - Semi-hydraulic lime used for masonry mortars, lime concrete and plaster
undercoat.
Class C - Fat lime used for finishing coat in plastering, whitewashing, composite mortars,
etc., and with addition of pozzolanic materials for masonry mortar.
Class D - Magnesium/dolomitic lime used for finishing coat in plastering, white washing,
etc.
Class E - K u lime used for masonry mortars.
Class F - Siliceous dolomitic lime used for undercoat and finishing coat of plaster.
NOTE I - Lime shall be available either in hydrated or quick form, except that of Classes A
and E which shall be supplied in hydrated form.

3.5.3.1 Forms in which lime is available:
a) Quicklime :- A Calcined material, the major part of which is calcium oxide in natural
association with a relatively smaller amount of magnesium oxide, capable of slaking with
water.
b) Fat Lime :- The lime which has high calcium oxide content and is dependant for setting and
hardening solely on the absorption of carbon dioxide from the atmosphere.
c) Hydraulic lime :- Lime containing small quantities of silica and alumina and or iron oxide
which are in chemical combination with some of the calcium oxide content, giving a putty or
mortar which has the property of setting and hardening under water.
d) Hydrated Lime :- A dry powder resulting from treatment of quicklime with water enough to
satisfy its chemical affinity for water under the condition of its hydration.
e) Lump Lime :- Quicklime as it comes from kilns.
3.5.4. Physical and Chemical Requirements:
3.5.4.1. Physical requirements :- The physical requirements of building lime is as given in Table-
15.
3.5.4.2. Chemical requirements :- The chemical requirements of building lime shall be as given in
Table 16.
3.5.5. Supply and Storage:
3.5.5.1. Class A lime shall be supplied as hydrated lime only.
3.5.5.2. Class B and Class C lime shall be supplied both as quick lime and hydrated lime.
3.5.5.3. Hydrated lime shall be in the form of a fine dry powder produced by treating quick lime in
any suitable form with sufficient water so as to produce a "dry" sound product.
3.5.5.4. The material shall be supplied at the site and stacked as given below in a store or any other
place to be dry and under corner well protected from rain.
3.5.5.5. Quick lime deteriorates quickly as it attracts moisture and carbon dioxide from atmosphere
as such should be run to putty as quickly as possible. For storing it should be piled up and covered
with a blanket of lime dust to exclude moist air.
3.5.5.6. When hydrated lime is to be stored for a long time it should be filled in bags and kept in a
dry place.
3.5.6. Rejected Lime:Lime which has been rejected by the Engineer shall be removed from the site
of work by the contractor at his own expenses within 3 days.
3.5.7. Mode of Measurement : Quick and hydrated limes shall be measured separately, in quintals.
The class of lime being specified.
3.5.8: Surkhi: This specification lays down requirements regarding fineness and strength of Surkhi
as used in mortars . Surkhi is powdered burnt bricks fully burnt or slightly under burnt but not over
burnt) , brick bats or burnt loam ( should not contain any unburnt soil) and is used as an admixture to
lime, cement or both for making structural mortar.

3.5.8.1: General properties:
a) Surkhi shall be perfectly clean, free from admixture or any foreign matter and shall
confirm to IS 1344-1981 ( for testing refer IS 1727-1967).
b) Surkhi shall not contain any soluble sulphate more than 0.5% for exposed work and work in
damp situations, and not more than 1% when used for works for dry and internal situations.
Surkhi shall not be used in situations where there is much salt in the soil.
c) On sieving through IS sieve No 9, the residue left on the sieve shall not be more than 10%
by weight of the sample.
d) Designation: Calcined clay pozzolana shall be supplied in the following grades,
corresponding to the properties specified in (e) below.
Grade Designation General use

Grade I For incorporation in unblended cement mortar and concrete and in lime-pozzolana
mixture, and for manufacture of Portland Pozzolana
cement.
Grade II For incorporation in Unblended cement mortar and concrete and in lime Pozzolana
mixture. Also for manufacture of Portland Pozzolana
cement by inter grinding method subject to requirements of
IS 1489-1976.

e) Raw materials; Clay for manufacture of Pozzolana shall confirm generally to the following
chemical requirements on an oven dry basis (at 105°C).
Constituents Contents
Silica + alumina + iron oxide Not less than 70 percent
(SiO2+A12O3+Fe2O3)
Silica (SiO2) Not less than 40 percent
Calcium Oxide (Ca 0) Not less than 10 percent
Magnesium oxide (Mg 0) Not more than 3 percent
Sulphuric anhydride (SO3) - do-
Soda and Potash (Na2O+K2O) - do-
Water-soluble alkali Not more than 0.1 percent
Water soluble material Not more than 1 percent
Loss on ignition Not more than 10 percent
NOTE- For chemical analysis of clays, reference shall be made to IS : 1727-1967.
f) Physical Requirement:
S. Requirement
No. Characteristic
Grade I Grade II
1 2 3 4
i) Fineness-Specific Surface in sq m/kg by Blaine's 320 250
permeability method. Min.
ii) Lime reactivity-Average compressive strength in 4.0 3.0
N/sq mm. Min.
iii) Compressive strength* at 28 days .Min. Not less than 80 percent of the
strength of corresponding
plain cement mortar cubes.
iv) Drying shrinkage. Max. 0.15 0.10
Not with standing the strength requirements as above, mixes in which Calcined clay is incorporated
shall show a progressive strength in increase.
*Applicable in case of Pozzolana to be used for manufacture of Portland-Pozzolana cement only.
3.5.8.2 Preparation of Raw material and calcination: Surkhi /Calcined clay pozzolana shall be
obtained by Calcining processed clay at suitable temperature and grinding the resulting product to
required fineness. The clay may be prepared with suitable additions of water in to a plastic mass,
weeding out gritty material, pebbles and sticks etc., to form the clay in to bricks, tiles or balls for
calcination.
3.5.8.3-Calcination: The clay prepared as above shall be Calcined at a temperature suitable to the type
of clay used in the manufacture. The exact degree of calcination for each clay shall be determined After
making necessary experiments with samples prepared at different temperatures and ground to
specified fineness and testing for strength and other properties with lime and cement.
NOTE- The optimum temperature of burning is presumed to be that at which the crystal structure of

the clay mineral just collapses and the oxides of silicon, aluminium and iron are in fine active form.
Generally. the optimum temperatures of burning of different clays at which maximum reactivity is
produced have been found to be the following:
For montmorillonite type of clay 600 to 800°C
For kaolinite type of clay 700 to 80°C
For illite type of clay 900 to 1000°C
3.5.83: Procedure for Sampling - Each sample for testing shall consist of a mixture of approximately
equal portions selected from at least 12 different positions in the heap, when the Calcined clay
pozzolana is loose, or from not less than 12 different bags or other packages, when the Calcined clay
pozzolana is not loose: or where there is a lesser number than 12 different bags or other packages, then
from each bag or package. Every care shall be taken in the selection to obtain a fair average sample.
The final sample shall weigh at least 5 kg for every 100 tonne of material. The sample, thus collected,
shall be stored in a suitable container for being forwarded to an approved testing laboratory. It shall be
tested as per IS :1727-1967.
3.5.8.4: General properties:
a) Surkhi shall be perfectly clean, free from admixture or any foreign matter and shall confirm
to IS 1344-1981 ( for testing refer IS 1727-1967).
b) Surkhi shall not contain any soluble sulphate more than 0.5% for exposed work and work in
damp situations, and not more than 1% when used for works for dry and internal situations.
Surkhi shall not be used in situations where there is much salt in the soil.
c) On sieving through IS sieve No 9, the residue left on the sieve shall not be more than 10% by
weight of the sample.
3.5.8.5 Lime reactivity: When tested in accordance with IS 1344-1981, the lime reactivity of Surkhi
shall be such that the average compressive strength of test cubes (of side 70.6 mm) on seven days of
curing shall not be less than 40 kg/sqcm. Cubes shall be prepared from one part of Lime -Surkhi mortar
(1:2) mixed with three parts of standard sand.
3.5.8.6 Stacking: Surkhi shall be stacked on masonry or wooden platform in regular stacks in regular
stacks as per specification at places as directed by the Engineer and shall be protected from dust,
rains, and dampness and shall be kept under adequate coverings provided by the contractor.
3.5.8.7 Measurement: Surkhi shall be measured in cum in standard stacks as specified. Allowance
for looseness of stacks shall be made by measuring 600 mm high stacks as 500 mm high.
3.5.8.8 Compressive Strength: Standard test cubes 70.6 mm, size prepared from 1:3 mix , one part
of mixture ( comprising of 4 part Surkhi and one part cement) and 3 parts standard sand when tested
for compressive strength test in accordance to IS 1344-1981 and compared with cement mortar (1:3)
mix under similar condition, and shall give following results:
a) At the age of 28 days- 80% of the strength of the corresponding
cement mortar cube.
3.6. Cement: 3.6.1. Scope :
3.6.1.1. This specification covers various types of cements, their supply, storage and mode of
measurement.

3.6.2. General :
3.6.2.1. Unless otherwise specified cement shall conform to following Indian Standard Specifications.
(i.) 33 Grade ordinary and low heat Portland cement conforming to IS 269-2013 (IIIrd. Rev.)
Table 17- Physical Requirements for Ordinary Portland Cement, 33 Grade
S. No.
Characteristic Requirement Method of Test
1 2 3 4
i) Fineness m2/kg. Min 225 IS : 4031 ( P-II)
ii) Soundness
a) By Le Chatelier method, mm, Max 10 IS 4031 (Part 3)
b) By autoclave test method, percent, Max 0.8
(see Note 1)
iii) Setting time: IS 4031 (Part 5)
a) Initial,
b) Final, min, Max 30 Min.
600 Min.
(See Note 2)
iv) Compressive strength, MPa (see Note 4) IS 4031 (Part 6)
a) 72 ± 1 h,
b) 168±2h, Min 16
c) 672±4h, Min22
Min33
Max 48
v) Transverse strength (optional) See Notes 3 and 4 IS 4031 (Part 8)
NOTES
1. In the event of cements failing to comply with any one or both the requirements of soundness
specified in this table, further tests in respect of each failure shall be made as described in IS 4031
(Part 3), from another portion of the same sample after aeration. The aeration shall be done by
spreading out the sample to a depth of 75 mm at a relative humidity of 50 to 80 percent for a
total period of 7 days. The expansion of cements so aerated shall be not more than 5 mm and
0.6 percent when tested by Le Chatelier method and autoclave test respectively.
2. If cement exhibits false set, the ratio of final penetration measured after 5 min of completion
of mixing period to the initial penetration measured exactly after 20 s of completion of mixing
period, expressed as percent, shall be not less than 50. In the event of cement exhibiting false set,
the initial and final setting time of cement when tested by the method described in IS 4031 (Part
5) after breaking the false set, shall conform to the value given in this table.
3. By agreement between the purchaser and the manufacturer, transverse strength test of plastic
mortar in accordance with the method described in IS 4031 (Part 8) may be specified. The
permissible values of the transverse strength shall be mutually agreed to between the purchaser
and the supplier at the time of placing the order.
4. Notwithstanding the compressive and transverse strength requirements specified as per this
table, the cement shall show a progressive increase in strength from the strength at 72 h.

3.6.2.2 Manufacturer's Certificate:
a) The manufacturer shall satisfy himself that the cement conforms to the requirements of this
standard and, if requested, shall furnish a test certificate to this effect to the purchaser or his
representative, within ten days of testing of the cement (except for 28 days compressive strength
test results, which shall be furnished after completion of the test). The type and percentage
addition of performance improver(s) shall also be indicated in the certificate.
b) The manufacturer shall furnish a certificate indicating the alkali content, if requested.
c) The net quantity of cement per bag shall be 50 kg subject to provisions and tolerance given in
Annex B of IS 269-2013.
d) The net quantity of cement per bag may also be 25 kg, 10 kg, 5 kg, 2 kg or 1 kg subject to
tolerances as given in (e) below and packed in suitable bags as agreed to between the purchaser
and the manufacturer.
e) The number of bags in a sample taken for weighment showing a minus error greater than 2
percent of the specified net quantity shall be not more than 5 percent of the bags in the sample.
Also the minus error in none of such bags in the sample shall exceed 4 percent of the specified
net quantity of cement in the bag. However, the average of net quantity of cement in a sample
shall be equal to or more than 25 kg, 10 kg, 5 kg, 2 kg or 1 kg, as the case may be.
3.6.2.3 Marking:
10.1 Each bag of cement shall be legibly and indelibly marked with the following:
a) Manufacturer's name and his registered trademark;
b) The words Òrdinary Portland Cement, 33 Grade';
c) Net quantity, in kg;
d) The words Ùse no hooks' ;
e) Batch/Control unit number in terms of week, month and year of packing;
f) Address of the manufacturer; and
g) Type and percentage of performance improver(s) added, in case of addition of performance
improvers.
3.6.2.4 High Strength (43 Grade) ordinary Portland cement conforming to IS 8112-2013.
S. No.
1 2 3 4
2
i) Fineness m /kg. Min 225 IS : 4031 ( P-II)
370 for 43-S grade
ii) Soundness
c) By Le Chatelier method, mm, Max 10 IS 4031 (Part 3)
d) By autoclave test method, percent, Max 0.8
(see Note 1)
b) Initial, min, 30 Min., 60 for 43
S-grade

S. No.
1 2 3 4
b) Final, Nn, Max 600 Min.
(See Note 2)
iv) Compressive strength, MPa (see Note 4) IS 4031 (Part 6)
d) 72 ± 1 h,
e) 168±2h,
Min 23
Min33,
1) 672±4h, 37.5 for 43 S-grade
Min43
Max 58
NOTES
1. In the event of cements failing to comply with any one or both the requirements of soundness
0.6 percent when tested by Le Chatelier method and autoclave test respectively. For 43-S grade
cement, the requirement of soundness of unaerated cement shall be maximum expansion of 5
mm when tested by the Le Chatelier method.
table, the cement shall show a progressive increase in strength from the strength at 72 h.Others
as for 33 Grade cement.

3.6.2.5 : 53 Grade ordinary Portland cement conforming to IS 12269-2013
S. No.
1 2 3 4
i) Fineness m2/kg. Min 225 IS : 4031 ( P-II)
370 for 53-S grade
ii) Soundness IS 4031 (Part 3)
e) By Le Chatelier method, mm, Max 10
1) By autoclave test method, percent, Max 0.8
(see Note 1)
c) tial, min,
Ini 30 Min., 60 for 53
S-grade
b) Final, Nn, Max 600 Min.
(See Note 2)
iv) IS 4031 (Part 6)
Compressive strength, MPa (see Note 4)
g) 72 ± 1 h, Min 27
h) 168 ± 2 h, Min 37, 37.5 for
53 S-grade
i) 672±4h,
Min53
NOTES 1. In the event of cements failing to comply with any one or both the requirements of soundness
0.6 percent when tested by Le Chatelier method and autoclave test respectively. For 53-S grade
cement, the requirement of soundness of unaerated cement shall be maximum expansion of 5
mm when tested by the Le-Chatelier method.

table, the cement shall show a progressive increase in strength from the strength at 72 h.Others
as for 33 Grade cement.
3.6.2.6 : Rapid hardening Portland cement conforming to IS 8041-1990 ( Reaffirmed 2005) a)
Physical Requirements:
i) Fineness : When tested for fineness in -terms of specific surface by Blaine's air permeability
method as described in IS 4031( Part 2) : 1988, the specific surface of rapid hardening Portland
cement shall be not less than 325 m2/kg.
ii) Soundness : When tested by `Le-Chatelier' method and autoclave test described in IS 4031
(Part 3) : 1988, unaerated cement shall not have an expansion of more than 10 mm and 0.8
percent respectively.
 In the event of cements failing to comply with any one or both the requirements specified
in 6.2.1, further tests in respect of each failure shall be made as described in IS 4031 (
Part 3) : 1988 from another portion of the same sample after aeration. The aeration shall be
done by spreading out the sample to a depth of 75 mm at relative humidity-of 50 to 80
percent for a total period of 7 days. The expansion of cements so aerated shall be not more
than 5 mm and 0.6 percent when tested by `Le-Chatelier' method and autoclave test
respectively.
iii) Setting Time : The setting time of the when tested by the Vicat apparatus method described in IS
4031 (Part 5) : 1988 shall conform to the following requirements:
a) Initial setting time in minutes not less than 30, and
b) Final setting time in minutes, not more than 600.
 If cement exhibits false set, the ratio of final penetration measured after 5 min of
completion of mixing period to the initial penetration measured exactly after 20 s of
completion of mixing period, expressed as percent, shall be not less than 50 when tested by
the method described in IS 4031 (Part 14) : 1989. In the event of cement exhibiting Use
set, the initial and final setting time of cement when tested by the method described in IS
4031 (Part 5) :1988 after breaking the false set, shall conform to (iii) above.
iv) Compressive Strength: The average compressive strength of at least three mortar cubes (area
of face 50 cm2) composed of one part of cement and three parts of standard sand (conforming
to IS 650: 1966 ) by mass and P/4 + 3.0 percent ( of combined mass of cement and sand) water,
and prepared, stored and tested in the manner described in IS 4031( Part 6): 1988, shall be as
follows:
a) 24 hours ± 30 min-Not less than 16 MPa
b) 72 ± 1 hours Not less than 27 MPa
NOTE-P is the percentage of water required to produce a paste of standard consistency
 Notwithstanding the strength requirements specified in (iii) above, the cement shall show
a progressive increase in strength from the strength at 24 hours. Others as per 33 Grade
Cement.
3.6.2.7: White Portland Cement conforming to IS 8042-1989 ( Reaffirmed 2009).
a) Physical Requirements : Physical requirements of white Portland cement shall be as laid down
in IS 269: 1989 except that compressive strength of mortar prepared from white Portland

cement shall not be less than 90 percent of those specified for 33 grade ordinary Portland
cement.
NOTE - Those Industries which require fineness of white Portland cement In terms of residue
by dry sieving, tested by the method described In IS4031( Part 1): 1988, may specify the same
additionally while placing order to a manufacturer by mutual agreement.
b) Notwithstanding the strength requirements specified above, the cement shall show a
progressive increase in strength from the strength at 72 hours.
c) Degree of Whiteness: The reflectance of neat cement ring, prepared and tested In accordance
With Annex B (IS 8042) Shall not be less than 70 percent,
3.6.2.7.1- Test for Degree of Whiteness of White Portland Cement
i) Preparation of Sample:
ii) Heap some quantity of dry neat cement into a mould of the shape of a ring of 30 mm diameter
and 3 mm height ( or any other mould or the mould supplied with the reflectivity measuring
equipment) placed on a clean glass plate and gently press it down with another clean glass plate
so that the density of the cement compact is close to that of the standard magnesium oxide
blocks mentioned under (iii). Lift the ring gently with the compacted cement inside and prepare
two such specimens for measuring the degree of whiteness.
iii) Testing: Compare the reflectivity of the compact cement surface with standard magnesium
Oxide blocks of certified reflectivity on absolute scale with the help of a suitable apparatus, for
example, a reflectometer or reflectance spectrophotometer
iv) Reporting of Results:
Average reflectance of two specimens shall be reported, the two values should not differ by
more than two units,
For details on other cements as below refer the relevant BIS codes
3.6.2.8 Hydrophobic cement conforming to IS 8043-1978 (First Rev.)
3.6.2.9 Portland slag cement conforming to IS 455-1976 (IIIrd. Rev)
3.6.2.10 Portland pozzolana cement (fly ash based) conforming to IS 1489 (Part 1)-1991 (
Reaffirmed 2005).
(a) Physical Requirements:
i) Fineness : when tested by the air permeability period described in IS 4031 ( part 2) 1988, the
specific surface of Portland-Pozzolana cement shall be not less than 300sgm/kg.
ii) Soundness: when tested by `Le-Chatelier' method and autoclave test respectively as described
in IS 4031( Part 3) : 1988, unareated Portland -Pozzolana Cement shall not have an expansion
of more than 10 mm and 0.8 percent respectively.
iii) In the event of cement falling to comply with any or both the requirements specified in (ii)
further tests in respect of each failure shall be made as described in IS 4031 ( Part 3 ): 1988
from another portion of the same sample after aeration. The aeration shall be done by spreading
out the sample to a depth of 75 mm at a relative humidity of 50 to 80 percent for a total period of
7 days. The expansion of cement so aerated shall be not more than 5 mm and 0.6 percent when
tested by 'Le-Chatelier" method and autoclave test respectively as described in IS 4031
(P art 3): 1988.
iv) Setting Time: The setting time of Portland-pozzolana cement, when tested by the Vicat
apparatus method described in IS 4031 ( Part 5) : 1988, shall be as follows:
a) Initial setting time: 30 min, Min.
b) Final setting time: 600 min, Max.
v) If cement exhibits false set, the ratio of final penetration measured after 5 min of completion
period, expressed as percent, shall be not less than 50 when tested by the method described in IS
4031 ( Part 14) : 1989. In the event of cement exhibiting false set, the initial and final setting
time of cement when tested by the method described in IS 4031 ( Part 5 ): 1988, after breaking
the false set, shall conform to (iv) .
vi) Compressing Strength: The average compressive strength of not less than three mortar cubes
( area of face 50 cm2) composed of one part of cement, three parts of standard sand ( see Note 2)
by mass, and P/4 + 3.0 percent (of combined mass of cement and sand) water, and prepared,
stored and tested in the manner described in IS 4031 ( Part 6) : 1988 shall be as follows:
a) At 72 ± 1 h = I6 MPa, Min
b) At 168 ± 2 h = 22 MPa, Min
c) At 672 ± 4 h = 33 MPa, Min
NOTES:
1. P is the percentage of water required to produce a paste of standard consistency (
Quantity of water as per IS 4031-P4-1988 ).
2. Standard sand shall conform to IS 650: 1966.
vii) Notwithstanding the cubes satisfying the strength requirements specified in (vi) , they shall
also show a progressive increase in strength .
3.6.2.11 Portland pozzolana cement (Calcined clay based) conforming to IS 1489
(Part-2)-1991( reaffirmed 2009).
a) Physical Requirements
i) Fineness : When tested by the air permeability method described in IS 4031 ( Part 2) :
1988, the specific surface of Portland-pozzolana cement shall not be less than 300 sqm/ kg.
ii) Soundness : When tested by -Le Chatelier' method and autoclave test described in IS
4031 (Part 3) : 1988. Un-aerated Portland-pozzolana cement shall not have an expansion
of more than 10 mm and 0.8 percent respectively.
iii) In the event of cement falling to comply with any or both the requirements specified in
(ii) further tests in respect of each failure shall be made as described in IS 4031( Part 3):
1988 from another portion of the same sample after aeration. The aeration shall be done
by spreading out the sample to a depth of 75 mm at a relative humidity of 50 to 80 percent
for a total period of 7 days. The expansion of cement so aerated shall be not more than 5
mm and 0.6 percent when tested by `Le-Chatelier' method and autoclave test respectively
as described in IS 4031 ( Part 3) : 1988.
iv) Setting Time : The setting time of Portland-pozzolana cement when tested by the Vicat
apparatus method described in IS 4031 ( Part 5) : 1988 shall be as follows:

a) Initial setting time 30 min, Min
b) Final setting time 600 min, Max
If cement exhibits false set, the ratio of final penetration measured after 5 min of completion of
mixing period to the initial penetration measured exactly after 20 s of completion of mixing
period, expressed as percent, shall be not less than 50 when tested by the method described in IS
4031 ( Part 14) : 1989• In the event of cement exhibiting Use set. the initial and final setting
time of cement, when tested by the method described in IS 4031 (Part 5) : 1988 after breaking
the false set, shall conform to (iv) .
vi) Compressing Strength: The average compressive strength of not less than three mortar cubes (
area of face 50 cm2) composed of one part of cement, three parts of standard sand ( see Note 2)
by mass, and P/4 + 3.0 percent (of combined mass of cement and sand) water, and prepared,
stored and tested in the manner described in IS 4031 ( Part 6) : 1988 shall be as follows:
a) At 72 ± 1 h = I6 MPa, Min
b) At 1 6 8 ± 2 h = 2 2 MPa, Min
c) At 672 ± 4 h = 33 MPa, Min
NOTES:
1. P is the percentage of water required to produce a paste of standard consistency (
Quantity of water as per IS 4031-P4-1988 ).
2. Standard sand shall conform to IS 650: 1966.
Notwithstanding the cubes satisfying the strength requirements specified in (vi) , they shall
also show a progressive increase in strength .
In the event of cement falling to comply with any or both the requirements specified in (ii)
further tests in respect of each failure shall be made as described in IS 4031 ( Part 3 ): 1988
from another portion of the same sample after aeration. The aeration shall be done by spreading
out the sample to a depth of 75 mm at a relative humidity of 50 to 80 percent for a total period
of 7 days. The expansion of cement so aerated shall be not more than 5 mm and 0.6 percent when
tested by 'Le-Chatelier" method and autoclave test respectively as described in IS 4031
(P art 3): 1988.
3.6.2.12 Low heat Portland cement conforming to IS 12600-1989 ( reaffirmed 2009) Sulphate
3.6.2.13 resisting Portland cement conforming to IS 12330-1988 ( reaffirmed 2009) Masonry
3.6.2.14 Cement conforming to IS 3466-1988 ( reaffirmed 2008) .
3.6.2.15 High Alumina Cement for Structural use conforming to IS 6452-1989 ( reaffirmed 2009).
3.6.2.16 Super Sulphated Cement conforming to IS 6909-1990 ( Reaffirmed 2010) .
3.6.2.17 Different types of cement shall not be used, mixed together at a time, in case more than one
type of cement is used in work, a record shall be kept showing the location and type of cement used.
3.6.2.18 Pozzolana: i) Calcined Clay Pozzolana conforming to IS 1344-1981 ( Second Rev.) .
ii) Fly Ash for use as Pozzolana and admixture, conforming to IS 3812-1981 (also see para 3.7.8).
3.6.2.19 Supply : Cement shall be delivered at the site of work in batches to commensurate with

the progress of the work. It may either be supplied from the departmental store or may be supplied by
the contractor. In later case the contractor shall produce a test certificate about the quality of the cement
delivered, failing which the Engineer shall get it tested at his end, the cost of all such testing shall be
borne by the contractor.
3.6.2.20 Storage : Cement shall be stored in damp proof and draught free sheds on a raised floor to
prevent deterioration and shall be used in the order in which it is received. The store shall be large
enough to hold sufficient cement to ensure the continuity of the work and each consignment shall be
stacked separately therein to permit easy access for inspection. The cement bags should be stored
clear of walls. Bags shall not be stacked more than 2 metre high to avoid "Warehousing Set" which
resulting from cement becoming compacted and damage occurring to cement .The damage to cement
due to faulty storage in contractor's sheds shall be his liability. The cement shall be used as far as
possible in the order in which it has been stored. if for any reason the stored cement shows signs of
deterioration or contamination it shall be got tested before use, to ascertain its strength, setting time
etc.
3.6.2.21 Mode of Measurement : Cement shall be measured in Tonne or by number of bags received.
3.7 Fine Aggregate:
3.7.1 Aggregate most of which passes through 4.75 mm IS Sieve is known as fine aggregate. Fine
aggregates shall consist of natural sand, crushed stone dust or crushed gravel sand stone dust or
marble dust, fly ash and Surkhi (crushed brick and cinder) conforming to IS:2686: It shall be hard,
durable, chemically inert, clear and free from adherent coatings, organic matter etc. and shall not
contain any appreciable amount of clay balls pellets and harmful impurities e.g. iron pyrites, alkalis,
salts, coal, mica, shale or similar laminated materials in such form or in such quantities as to cause
corrosion of metal or affect adversely the hardening, the strength, the durability or the appearance of
mortar, plaster or concrete., the sum of the percentages of all deleterious materials shall not exceed
5%.Fine aggregate must be checked for organic impurities such as decayed vegetation humps, coal
dust etc.
3.7.2 Silt Content: The maximum quality of silt in sand shall not exceed 5%. Fine aggregate
containing more than allowable percentage of silt shall be washed so as to bring the silt content
within allowable limits for which nothing extra shall be paid.
3.7.3 Grading: On the basis of particle size, fine aggregate is graded into four zones. The grading
when determined in accordance with the prescribed procedure shall be within the limits given in
Table 22 below. Where the grading falls outside the limits of any particular grading zone of sieves,
other than 600 micron IS sieve, by a total amount not exceeding 5 %, it shall be regraded as falling in
that grading zone.

Table 20 - Grading of Fine Aggregate
Percentage passing for.
I.S. Sieve.
Designation. Grading Zone I. Grading Zone II. Grading Zone III. Grading Zone IV
10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600--Micron 15-34 35-59 60-79 80-100
300--Micron 5-20 8-30 12-40 15-50
150--Micron 0-10 0-10 0-10 0-15
Note 1 :- For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 % .
This does not affect the 5% allowance permitted in applying to other sieves.
Note 2 :- Allowances of 5% permitted in all, it can split up, for example it could be 1% on each of
three sieves and 2% on another or 4% on one sieve and 1 % on another.
Note 3 :- Fine aggregate conforming to Grading Zone IV shall not be used in reinforced cement
concrete unless test have been made to ascertain the suitability of proposed mix proportions.
Note 4 :- Sand used in mortar for plaster work shall conform to IS: 1542 and for masonry work
shall conform to IS:2116.
3.7.4 Type and grading of fine aggregate to be used shall be specified. It shall be coarse sand, fine
sand, stone dust or marble dust, fly ash and surkhi. Use of sea sand shall not be allowed, unless
otherwise specified.
(a) Coarse sand shall be either river sand or pit sand or combination of the two. It shall be clear,
sharp angular, gritty to touch and composed of hard siliceous material. Its grading shall fall
within the limits or grading Zone I, II, III of Table 20.
(b) Fine sand shall be either river sand or pit sand or combination of the two, its grading shall fall
within the limits of Grading Zone IV of Table 20. As a guideline, fine sand conforming to
grading Zone IV can be generally obtained.
(c) Stone dust shall be obtained by crushing hard stones or gravel. Its grading shall fall within
the limits of grading Zone I, II or III of Table 20.
(d) Marble dust shall be obtained by crushing marble Its grading shall fall within the limits of
Grading zone IV of Table 20.
(e) Sand for Masonry and for Plaster.
Sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of
any of these. Sand shall be hard, durable, clean a free from adherent coatings and organic matter
and shall net contain the amount to clay, silt and fine dust more than specified as under.
(0 Standard Sand for testing of Cement:
i) Sand Shall be of quartz, light grey or whitish variety. It shall be free from silt. Sand

grains shall be angular, the shape of grains approximating to spherical form, and elongated
and flattened grains being present only in negligible quantities. It shall be free from
organic impurities. Loss of weight on extraction with hot hydrochloric acid ( specific
gravity 1.16) shall not exceed 0.25 percent.
ii) Grading:
Passing through 2-mm IS Sieve 100 percent.
Retained on 90 micron IS Sieve 100 percent
Particle size greater than 1 mm 33.33 percent
Particle size smaller than 1 mm
but greater than 500 micron. 33.33 percent
Particle size below 500 micron 33.33 percent.
3.7.4.1-Deleterious Material: Sand shall not contain any harmful impurities such as iron, pyrites,
alkalis, salts, coal or other organic impurities, mica, shale or similar laminated materials, soft
fragments, sea shade in such form or in such quantities as to affect adversely the hardening strength or
durability of the mortar.
The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand shall not
exceed the following limits.
1) Clay, fine salt and fine dust when determined in accordance with IS:2386 (Part II) In
natural sand or crushed gravel and crushed and stone sand Not more than 5% by mass.
2) Organic impurities when determined in accordance with IS:2386 (Part II)
Colour of the liquid shall be lighter than that indicated by the standard specified in IS:2386
(Part II)
Grading of sand for use in masonry mortar shall be conforming to IS:2116 (Table 21).
Grading of sand of use in plaster shall be conforming to IS: 1542 (Table 21).
Table -21 Grading of sand for use in masonry mortar
I.S. Sieve. Percentage passing Ref. of method of test.

Designation. by mass
4.75 mm 100
2.36 mm 90-100
1.18 mm 70-100
600--Micron 40-100 IS 2386 (Part I)
300--Micron 5-70
150--Micron 0-15

Table- 22 Grading of sand for use in Plaster
I.S. Sieve. Percentage passing Ref. of method of test.
Designation.
.
mm
4.75 mm 95-100 IS 1542
2.36 mm 95-100
1.18 mm 90-100
600--Micron 80-100
300--Micron 20-65
150--Micron 0-50
For crushed stone stands, the permissible limit on 150 micron IS sieve is increased to 2 %.
this does not affect the 5% allowance IS-2386 (Part-I).
3.7.5 Bullring: Fine aggregate, when dry or saturated, has almost the same volume but dampness
causes increase in volume. In case fine aggregate is damp at the time of proportioning the ingredients
for mortar or concrete, its quantity shall be increased suitable to allow for bulk age. Table 23 gives the
relation between moisture content and percentage of bulk for guidance only.
Table - 23 Bulking of sand
Moisture content % age Bulking %age (by volume)
2 15
3 20
4 25
5 30
3.7.6 Stacking: Fine aggregate shall be so stacked as to prevent due and foreign matter getting mixed
up with it as far practically possible.
3.7.7 Measurement: As the fine aggregate bulks to a substantial extent when partially wet,
measurement shall be taken if stacks are dry or appropriate allowance made for bulking in special case,
weight can be also measured.
3.7.8 Fly Ash:
(a) Scope: Fly Ash is a by-product of Thermal Power plants. It is very useful for CC as pozzolanic
material for part replacement of cement (fly ash with loss on ignition up to 12% may be used) in CC
mixes. Extraction ( from flue gases of ground or pulverised coal, or lignite fired boilers by any suitable
process, such as cyclone separation or electrostatic precipitation) physical and chemical requirement
of fly ash for use as a Pozzolana in C.C. mixes or with lime , for use as an admixture and for
manufacture of Portland -Pozzolana cement conforming to IS 1489-1976.

3.7.9: Designation: Fly ash shall be supplied in the following grades:
Grade Designation General use
Grade I For incorporation in Cement mortar and concrete and in lime Pozzolana mixture, and
for manufacture of Portland Pozzolana cement
Grade II For incorporation in cement mortar and concrete and in
lime Pozzolana mixture.
Also for manufacture of Portland -Pozzolana cement subject to
requirement of IS 1489-1976
3.7.10: Physical Requirements: See table below.
S.No. Characteristics Requirement

Grade I Grade II
1 2 3 4
i) Fineness-Specific surface in m2/kg by 320 250
Blaine's permeability method. Min.
ii). Lime reactivity-Average compressive 40 3.0
strength in N/mm2 Min.
iii) Compressive strength at 28 days. Min. Not less than 80 percent of the strength
of corresponding plain cement mortar cubes.
iv) Drying shrinkage, percent Max. 0.15 0.10
v) Soundness by autoclave test, expansion 0.8 0.8
of specimen, percent. Max.
For methods of test -refer IS 1727-1967
3.8 Coarse Aggregate:
3.8.1 General: Aggregate most of which is retained on 4.75 mm sieve and contains fractions only as
permitted in 1S: 383 for various sizes and grading is known as coarse aggregate. Coarse aggregate shall
be specified as stone aggregate, gravel or brick aggregate and it shall be obtained from approved
authorized sources.
(a) Stone Aggregate : It shall consist of naturally occurring (=crashed, crushed or broken) stones.
It shall be hard, strong, dense, durable and clean. It shall be free from veins adherent coatings,
injurious amounts of disintegrated pieces, alkali, vegetable matter and other deleterious
substances. It is to be roughly cubical in snaps. Flaky and elongated pieces shall be avoided. It
shall conform to relevant IS code unless otherwise specified.
(b) Gravel : It shall consist of naturally occurring (=crashed, crushed or broken) river bed. Shingle,
pit gravel. It shall be, sound, laired and clean It shall be free from flat perfidies or shale or
similar laminate of real, powdered clay, silt, loam, adhere coatings alkali, vegetable, matter and
other deleterious substances, gravel shall be washed and it did not contains materials adhering to
it. These conform to 1S:383-1978 unless otherwise specified
(c) Brick Aggregates: Brick aggregate shall be obtained by breaking well burnt or over burnt
dense brick bats. They shall be homogeneous in texture roughly cubical in shape and clean.

They shall free form unburnt clay particles, soluble salt ,adherent coating of soil, vegetable
matter and deleterious substances. Such aggregate should not contain more than one percent of
sulphates and should not absorb more than 10% of their own mass of water, when used in cement
concrete and 20% when used in lime concrete. It shall confirm to IS:3068-1986 unless otherwise
specified.
(d) Light weight aggregates such as fly ash aggregate may also be used provided the Engineer-In-
charge is satisfied with the data on the proportion of concrete made with them.
3.8.2 Deleterious Material: Aggregate shall not contain in excess of the limits given in Table 24 any
harmful material, such as pyrites, coal, lignite, mica. shale or similar laminated material, alkali,
seashells and organic impurities and those which may attack the reinforcement. Aggregates shall not
be chemically reactive with alkalis of cement. Maximums quantity of deleterious material shall not be
more than five percent of the weight of coarse aggregate when determined in accordance with IS:2386
Part II.
Table - 24: Limits of Deleterious Materials

S. Deleterious Method Fine Aggregate Coarse Aggregate
No. Substance of Test as Percentage by Weight Percentage by Weight
per IS I Max. Max.
Part
Uncrushed Crushed Uncrushed Crushed
1 2 3 4 5 6 7
i) Coal and Lignite 2386-P-II 1.0 1.0 1.0 1.0
ii) Clay lumps -do- 1.0 1.0 1.0 1.0
iii) Materials finer than 75 2386-P-I 3.0 15.0 3.0 3.0
micron sieve.
iv) Soft Fragments 2386-P-II - - 3.0 -
v) Shale -do- 1.0 - - -
Total percentage of all 5.0 2.0 5.0 5.0
deleterious material
including S. No (i) to
(v), for column 4, 6, &
7 and S. No (i) and (ii)
for Col. 5 only
Note : 1. The presence of mica in the fine aggregate has been found to reduce considerably the
durability and compressive strength of concrete and further investigations are underway
to determine the extent of the deleterious effect of mica. It is advisable, therefore, to
investigate the mica content of fine aggregate and make suitable allowances for the
possible reduction in the strength of concrete or mortar.
2. The aggregate shall not contain harmful organic impurities [tested in accordance with [IS
: 2386 (Part II)- I963] in sufficient quantities to affect adversely the strength or durability
of concrete. A fine aggregate which fails in the test of organic impurities may be used,
provided that, when tested for the effect of organic impurities on the strength of

mortar, the relative strength at 7 and 28 days, reported in accordance with IS : 2386 (Part
VI )-1963 is not less than 95 percent.
3.8.2.1 Limits of deleterious Material: The maximum quantity of deleterious materials shall not
exceed the limits specified in Table 26 when tested in accordance with IS : 2386-1963. However, the
Engineer-in-charge at his discretion, may relax some of the limits as a result of-some further tests
and evidence of satisfactory performance of the aggregates.
3.8.2.2 Aggregate Crushing Value: The aggregate crushing value, when determined in accordance
with IS: 2386 (Par! IV)-1963 shall not exceed 45 percent for aggregate used for concrete other than
for wearing surfaces, and 30 percent for concrete for wearing surfaces, such as runways, roads and
pavements.
3.8.2.3 Aggregates Impact Value: As an alternative to 3.8.2.2, the aggregate impact value may be
determined in accordance with the method specified in IS : 2386 (Part IV )-1963. The aggregate
impact value shall not exceed 45 percent by weight for aggregates used for concrete other than for
wearing surfaces and 30 percent by weight for concrete for wearing surfaces, such as runways, roads
and pavements.
3.8.2.4 Aggregate Abrasion Value: Unless otherwise agreed to between the purchaser and the
supplier, the abrasion value of aggregates, when tested in accordance with the method specified in
IS:2386 (Part IV)-1963 using Los Angeles machine, shall not exceed the following values:
a) For aggregates to be used in concrete for wearing surfaces : 30 percent
b) For aggregates to be used in other concrete : 50 percent
3.8.2.5 Soundness of Aggregate: For concrete liable to be exposed the action of frost, coarse and fine
aggregates shall pass a sodium or magnesium Sulphate accelerated soundness test specified in IS: 2386
(Part V)-1963, the limits being set by agreement between the purchaser and the supplier, except that
aggregates failing in the accelerated soundness test may be used if they pass a specified freezing and
thawing test satisfactory to the user.
Note- As a general guide, it may be taken that the average loss of weight after 5 cycles shall not
exceed the following:
a) For fine aggregate 10 percent when tested with Sodium Sulphate (Na2SO4 )2 and 15
percent when tested with Magnesium Sulphate ( Mg504).
b) For coarse aggregate 12 percent when tested with Sodium Sulphate (Na2 S04 )2 and 18
percent when tested with Magnesium Sulphate (MgS04)
3.8.3. Size and Grading:
(i) Stone aggregate and gravel: It shall be either graded or single sized as specified. Nominal size
and grading shall be as under ;-
(a) Nominal size of graded stone aggregates or gravel shall be 40, 20, 16 or 12.5mm as specified. For
any one of the nominal sizes the proportion of other sizes specified is as under: (Table 25)

Table- 25 Percentage Passing for Single sized Aggregate of Nominal Size
Percenta (by weight) size of
I.S. Sieve. ge for nominal
Designation 63 mm p 40
a s smm
ing 20 mm 16 mm 12.5 mm 10 mm
80 mm 100 - - - - -
63 mm 85-100 100 - - - -
40 mm 0-30 85-100 100 - - -
20 mm 0-5 0-20 85-100 100 - -
16 mm - - - 85-100 100 -
11.2 mm - - - - 85-100 100
10 mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75 mm - - 0-5 0-5 0-10 0-20
2.36 mm - - - - - 0-5
(b) Nominal sizes of single sized stone aggregate or gravel shall be 63, 40, 20,10, 12.5 or 10 nun
as specified. For anyone of the nominal size the proportion of other size shall be in accordance
with Table 26.
Table -26 Percentage Passing for Graded Aggregate of Nominal Size
I.S. Sieve. Percentage passing (by weight) for nominal size of

Designation 40 mm 20 mm 16 mm 12.5 mm
80 mm 100 - - -
63mm - - - -
40 mm 95-100 100 - -
20 mm 30-70 95-100 100 100
16 mm - - 90-100 -
12.5 mm - - - 90-100
10 mm 10-35 25-55 30-70 40-85
4.75 mm 0-5 0-10 0-10 0-10
2.36mm - - - -
(c) When stone aggregate or gravel brought to site is single sized (ungraded), It shall be mixed
with single sized aggregate of different size in the proportion to be determined by field tests to
obtain graded aggregate of nominal size, the proportion of another size in mixed with aggregate
as determined by the method prescribed in IS: 2386 Part-8 1963. Recommended proportions by
volume for mixing of different sizes of single size (ungraded) aggregate to obtain the required
nominal size of graded aggregate are given in Table 27.

Table -27, Single Sized (Ungraded) Stone Aggregate or gravel
Cement Parts size of size
Nominal size of of aggregat
Concrete
graded aggregate single
50 mm 40 mm 20 mme s 12.5 mm 10 mm
required
1:5:10 63 - 7.5 - 2.5 -
1:5:10 40 - 7.5 2.5 - -
1:4:8 63 - - 2 - -
1:4:8 40 6 6 2 - -
1:3:6 63 - - 1.5 - -
1:3:6 40 4.5 4.5 1.5 - -
1:3:6 20 - - 4.5 - 1.5
1:2:4 40 - 2.5 1 - 1.5
1:2:4 20 - - 3 - 1
1:2:4 12.5 - - - 3 1
1:1.5:3 20 - - 2 - 1
1:1.5:3 12.5 - - - 3 1
3.8.3.1: Coarse Aggregate for mass Concrete: Shall be sizes specified in the following table.
Class and Size IS Sieve Designation Percentage Passing
Vary large, 160-80 mm 160 mm 90-100
80 mm 0-10
Large, 80-40 mm 80 mm 90-100
40 mm 0-10
Medium, 40-20 mm 40 mm 90-100
20 mm 0-10
Small, 20-4.75 mm 20 mm 90-100
4.75 mm 0-10
2.36 mm 0-2
3.8.3.2 All in Aggregate: When available, the grading shall be according to the following table.
IS Sieve Designation Percentage Passing for All-in-Aggregate of Nominal size.
40 mm 20 mm
80 mm 100 -
40 mm 90-100 100
20 mm 45-75 95-100
4.75 mm 25-45 30-50
600 micron 8-30 10-35
150 micron 0-6 0-6

3.8.4 Stacking:- Aggregate shall be stacked on a hard, dry and level patch of ground. When stack
piling, the aggregate shall not form pyramids resulting in segregation of different sized materials, it
shall be stacked separately according to nominal size of coarse aggregate. Stacking shall be done in
regular stacks of height not exceeding 100cm.
3.8.5 Testing: Coarse aggregate shall be tested for the following (as per IS:2386, part 3- 1963).
1. Determination of Particle size and shape
2. Determination of organic impurities
3. Test for surface
4. Determination of 10% fine value
3.8.6 Measurements: The aggregates shall be measured in stacks and paid for after making a
deduction of 7.5% of the gross measurements of stacks in respect of aggregates of nominal size 40
mm and above. No deduction from the gross measurements of the stacks is to be made in respect of
aggregates of nominal size below 40 mm.
3.8.7 Admixtures: When required admixtures of approved quality shall be mixed with concrete as
specified. The admixtures shall confirm to IS:9103-1999 (reaffirmed 2004).
3.9 Kankar: 3.9.1 Scope:
3.9.1.1 This specification lays down requirement for shape, size etc. and mode of measurement of
Kankar.
3.9.2 General Requirements:
3.9.2.1 Kankar used for ballast or for manufacturing lime shall be hard, clean and shall show a bluish
surface on fracture. The quarry from which the kankar is obtained shall be subject to the approval of
the Engineer-in-charge.
3.9.2.2 Kankar shall be angular in shape and sizes as given below :-
(i) For Kankar Lime 25 to 75 mm size.
(ii) As ballast for concrete 12 to 50 mm size.
(iii) For soling 75 to 150 mm size.
3.9.3 Material Supply :
3.9.3.1 The kankar shall be cleaned of earth and other deleterious materials and sorted to required
size at the quarries before being brought to the site of work.
3.9.3.2 Sample of kankar shall be approved by the Engineer in Charge and kept in his custody. Each
lot shall conform to the approved sample, failing which the lot shall be rejected and removed from the
site of work within 7 days of rejection at the cost of the contractor.
3.9.4 Stacking: Kankar shall be stacked as per Specification No. 2.1 of Chapter 2.
3.9.5 Mode of Measurement :
3.9.5.1 Kankar shall be measured in cubic metres, Allowance for looseness of stacks shall be made
in accordance to Specification No. 2.1 of Chapter 2.

3.10 Builders Hardware:
3.10.1 Scope:
3.10.1.1 The specification covers the following articles of Builders Hardware and lays down the
different types, corresponding sizes and method of measurement of sizes.
3.10.1.2 For detail specification the respective Indian Standards mentioned below with the name of
articles under clause 3.10.2. be referred.
3.10.1.3 The various article covered are as follows :-
Door bolts for use with pad locks.
Tower Bolts.
Hinges
Butt
Parliament.
Tee and Strap.
Double acting spring hinges.
Door spring Rat tail type.
Door stoppers. Door
Handles. Hasps and
staples.
Fan light pivots.
Fan light catch.
3.10.2 General :
3.10.2.1 All articles except item No. (h) & (i) are manufactured both from brass and steel.
3.10.3 Type and Sizes :
3.10.3.1 Door Bolts for use with pad locks :- (As per I.S. 281-1991, Reaffirmed 1996)
(a) Mild Steel Type sliding bolts (Size 250 and 300 mm. )
(b) Brass sliding Bolts -do-
3.10.3.2 Tower Bolts : (As per I.S. 204(P-I/II) -1991/1992, Reaffirmed 2007)
Unless otherwise only approved Barrel Tower Bolts and Skeleton Tower Bolts shall be used of the
types given below :-
(a) Barrel Tower Bolts :
Type Name Size
(i) Mild steel barrel tower bolts with mild steel Barrel and mild 150-300 mm.
steel bolt.
(ii) Brass Barrel Tower Bolts with Brass sheet Barrel and rolled or 150-300 mm.
drawn brass bolts.

(b) Skeleton Tower Bolts:
Type Name Size
(i) Mild steel skeleton tower bolts with steel sheet pressed plate 375-900 mm.
and staples and rolled steel bolts.
(ii) Brass skeleton Tower Bolts with cast brass plates and staples -do-
and rolled or drawn Bolts.
3.10.3.3 Hinges:
Steel Butt Hinges :-(As per I.S. 1341-1992, Reaffirmed 2007))
Non -Ferrous Metal Butt hinges :- (As per I.S. 205-1992, Reaffirmed 2001)
Tee and Strap hinges. (as per I.S. 206-1981)
Mild steel double acting spring hinges. (As per I.S. 453-1973)
3.10.3.4 Door Spring Rat Rail Type:.
Type Name Size
(i) Mild Steel door springs Rat tail type. 300 & 375 mm.
(ii) Brass Door Spring Rat tail type. -do-
3.10.3.5 Floor Door Stoppers :- (As per IS: 1823-1980)
3.10.3.6 Door Handles :- (As per IS: 208-1979) 3.10.3.7
Fanlight pivots :- (As per IS: 1837-1966) 3.10.3.8
Fanlight Catch :- (As per IS:.364-1970)
Type Name Size
(i) Cast Brass fanlight catch. 50=
3.10.4 Measurement of Articles :

S. No. Name of Articles. How Measured
1. Door Bolts for use with Padlocks.
(a) Mild Steel sliding Bolts.
(b) Brass sliding Bolts. The length of the sliding bolts.
2. Tower Bolts.
(a) Barrel Tower Bolts.
(b) Skeleton Tower Bolt.
The length of the barrel (excluding
the socket.)
3.
Hinges.
(a) Butt.
(b) Tee and strap Hinges. The length of joint.
(c) Double acting spring hinges. The length of the leaf.
The length of the flap.
4. Door spring Rat tail type. The distance from the centre of the spindle
to the centre of Roller.

5. Floor Door Stoppers. The distance between the rubber piece
and the part which would be pressed
while closing shutter 5 mm.
6. Door Handles.
(a) Cast type. Grip length.
(b) Pressed oval type. Overall length.
7. Fan light Pivot. Not designated by size but by (Nos.)
should be compared with dimensions
in detailed specification.
8. Fan light Catches. The flat overall length in elevation of
the plate with spring catch excluding
the striking plate.
3.11. Paints: 3.11.1

Definition :
3.11.1.1 Paints are liquid compositions of pigments and Binders which when applied to the surface in
thin coats dry to form a solid film to impart the surface a decorative finish apart from giving
protection to the base material from weathering corrosion and other chemical and Biological attacks.
3.11.2 Constituents : Any kind of paint essentially consists of :-
Pigment for colour opacity, Protection, Insulation.

Binder, Vehicle or medium -for film forming materials.
Solvent or thinner-to adjust flow.
Additive to modify the properties much as drying, stability flow etc.
3.11.3 Classification :
3.11.3.1 Standardising the classification of Paints is difficult in view of the large number of variation
in each of the constituents, but a simple classification based on the media or binder and on the basis
of its ultimate use and performance is suggested as under :--
(a) Classification based on Binders :-
(i) Oil Paints.
(ii) Paints based on non-oil Resins.
(iii) Cellulose Paints.
(iv) Water Base Paints.
(v) Misc. paints.
(b) Classification based on ultimate use:-
(i) General purpose - Paint including, Primers under coat paint and finishing coat paints.
(ii) Acid and Alkali Resistant Paints..
(iii) Fire Resistant paints.
(iv) Fungicidal Paints.
(v) Misc. Paints- including Fire resistant paints Anti condensation paint etc.

3.11.4 Ready Mixed Paints Vs. In Situ Mixed Paints :
3.11.4.1 Until recently, it was the normal practice for most of the Paints to be mixed at site by the
decorator, but the recent scientific research and development of alternate materials have led to the bulk
use of Ready mixed Paints. The main advantage of this is that a number of materials which be blended
together, under the controlled factory conditions, and which are therefore unsuitable for site mixing,
can be utilized, and advantage taken of their properties.
3.11.4.2 Ready mixed paints are manufactured in both brushing and spraying consistencies, for the
specific purpose for which the paint may be needed but the supplies should be obtained from a
manufacturer of repute. The paint should conform to the relevant I.S: 158-1981 ( reaffirmed 2011) and
while using it the manufacturer's instructions should be strictly followed.
3.11.5 Oil Paints:
3.11.5.1 The binder of an oil paint is essentially a drying oil or drying oil modified complex dissolved in
a volatile solvent. The drying process commences with the evaporation of solvents and is completed by a
chemical reaction of the vehicle with oxygen absorbed from the atmosphere. and a hard film remains
adhered to the surface.
3.11.5.2 The oil paints may be the traditional straight oil type such as using Linseed oil, Tung oil, Soya
oil etc. or it may be oleo resinous type containing modified binder in which the ingredients of oil like
fatty acids may be present but have no free glycerine of the oil group. These paints which are also called
Alkyd type are based on Synthetic alkyd resin Vehicles.
3.11.5.3 The straight run oil paints tend to show brush marks and are slow in drying whereas the
Alkyd base paints dry quicker and are good for brushing high gloss hard flexible film.
3.11.5.4 Suitable treatment of the drying oil produce paints which have high degree gloss and
excellent properties but these have slow hardening properties and are difficult to apply. many primers,
and under coats, however, contain a proportion of treated drying oil which serves as elastic binder and
toughens the vehicle, many I.S. Specifications for ready mixed paints are based on this group. For
details refer IS: 133-2004 ( Reaffirmation 2009 for Enamel, interior decorative paints, IS: 341-1973 (
Reaffirmed 2012) for Black Japan À', `B' and `C' paints.
3.11.6 Paints based on Non-oil Binder Resins :

3.11.6.1 In These paints, film forming materials or binder for pigment particles are some synthetic
resin varnishes or non-oil binders (instead of straight or modified oil as in oil paints) such as epoxy.
chlorinated rubber, Urea formaldehyde etc. These paints, Show some of the properties of chemical
resistance.
3.11.7 Cellulose Derivatives:
3.11.7.1 These materials made from nitrocellulose, plasticizers, resins etc. dry entirely by evaporation of
the volatile solvent. The main difference of paints based on these derivatives from oil paints is that
the paint dries entirely by the evaporation of the volatile solvent. These paints are more suitable for
application with spray than the brush and employed widely in industrial finishes.
3.11.7.2 These paints dry very quickly and tend to develop extremely hard film which is very resistant
to abrasion and normal wear and tear. These paints should be applied to rigid surfaces and not to soft
wood etc. as the hard film gives cracking and flaking troubles.

3.11.8 Water Base Paints :
3.11.8.1 In these paints the binder, which may be dissolved in water or which may be similar to that in
some oil paint, is made miscible with water by an emulsification technique and the drying is brought
about by evaporation of water, acting as a thinner, and may not be followed by an oxidizing reaction
depending upon the nature of the binder, Dry distempers, Oil bound water paint or oil emulsion
distemper can be included in this classification.
(a) Distempers :- This may be washable or non-washable type. In washable distempers the vehicle
is water, in presence of glue or other stabilizers. The water after application evaporates and the
film produced is more or less insoluble in water and hence the paint can be washed up with
mild soap solution to get clear appearance. The pigment used are varied according to the job
needed. These are also called oil Bound Distempers.
The non-washable or soft distempers consist of whiting bound with glue size, tinted with dry
strainers and thinned to working consistency with water. It dries by evaporation of water but on
washing with water, the water will remove the paint and the same would be washed off
completely. For details refer IS 427-2005 (Reaffirmed 2011) for Dry distemper, IS: 428-2000 (
reaffirmation 2012) for washable distempers.
(b) Emulsion Paints :- The principal film forming constituent of this paint is emulsified in water so
that, it may be thinned with water instead of solvent. The film former is usually based on a
polymer such as styrene, alkyd resin or polyvinyl acetate and the degree of finish of these paints
may vary from matt to full gloss. The characteristic features of emulsion paints are:-
(i) Ease and speed of application.
(ii) Rapid drying.
(iii) Rapid attainment of maximum hardness.
(iv) Lack of odour.
(v) Tolerance to damp and immunity to alkali attack materials and are of great value in
treatment of new plaster, Cement, Concrete etc. these are however not suitable for use on
metals as these promote corrosion. These are not as strong in adhesion to a surface as that
possessed by oil paint or oil bound water paints.
3.11.9 Miscellaneous Paints:
3.11.9.1 Bituminous Paints : These consist of materials made from pitch, asphalt or resin in
combination with heat treated oils and suitable solvents. Its properties include good tenacity, resistance to
moisture a high degree of resistance to chemical and atmospheric conditions and flexibility. After
application, it tends to remain soft and plastic but its colour range is however somewhat limited.
Typical uses include the treatment of bridges, cranes, steel and chemical works installations etc.
3.11.9.2 Cement Paints:-
(a) These are white or coloured cement with the addition of accelerators and water proofing agent,
and are supplied in powder form and prepared for use by mixing with water, these provide hard
durable matt surface and are resistant to chemical attack. Oil paints are liable to be attacked by
cement paint and as such not applied on such surfaces.
(b) Cement paints are suitable for use on exterior and interior surfaces of Concrete, Cement
rendering or Asbestos cement sheets but these should not be used on damp materials containing
excess sulphates.

3.11.9.3 Metallic Paints:-
(a) Aluminium or Bronze paints are usually made by adding Aluminium metal powder or Copper
bronze to a cellulose lacquer or oil varnish. Metallic powder and medium are generally supplied
separately in dual containers and are mixed immediately prior to application. These paints have
great covering capacity and give an opaque and shining surface.
(b) Aluminium paints are used as primers and sealers on external wood surfaces, finishing paints
for storage tanks to prevent losses through evaporation.
3.11.10 Constituents of oil Paints :
3.11.10.1 In addition to the bulk use of ready mixed paints, a considerable part of the work is being
carried out by mixing different ingredients at site of work.
3.11.10.2 Brief descriptions of some of the essential ingredient for oil paint is given below:-
(a) Base Pigment :-- Following materials are generally used :-
(i) White lead: (Lead carbonate 2PbCO3 conforming I.S. 342-1973). It turns yellow after
some use and therefore used only for under coats.
(ii) Red Lead :-- Lead oxide Pb3O4 . It protects iron from rusting and therefore best
suitable on Ferrous surfaces.
(iii) Zinc white: Zinc oxide Z2O. In this the white colour is not effected by weathering.
(iv) Lithopone, this is very opaque pure white pigment and used for under coatings and
flat finishes.
(v) Titanium dioxide :(IS: 411-1991, Reaffirmed 2009), a white pigment of pure white
colour possessing great opacity.
(b) Vehicle :-- Some of the Vehicles for oil Paints are as under :-
(i) Linseed oil Raw conforming to I.S:75-1973, Reaffirmed 2010 ( superseding IS: 76 and
78) gives transparent film.
(ii) Tung oil used for superior paints.
(c) Drier :-
(i) Litharge (PbO), Red Lead (Pb3 04), sulphates of Zinc and Manganese are used as driers.
Litharge is most common in use but in general Lead drier should not be used with Zinc
paints.
(ii) Drier in finishing coat causes flaking and not recommended.
(d) Pigments for Paints (IS: 44-1991, Reaffirmed 2012, superseding IS: 45 and 49) :-- A variety
of pigments are available such as carbon black , Lamp black. , Vegetable black , Ultramarine
Blue , Prussian Blue , Yellow Ochre , Natural Umber , Green Oxide of Chromium , etc.
(e) Solvent :- Turpentine (I.S.533-2007, superseding IS: 83) is the most commonly used
solvent. Other solvent in use is white spirit.
3.11.11 Preparation of Paint in Situ :
3.11.11.1 The base pigment is thoroughly ground in oil and thinning agent is mixed to get the
required workability. Colouring pigment and drier are ground separately and mixed with thinning
agent to the required consistency. Drier should be used only if quick drying of the oil is required but it
shall not be used for paints used as finishing coats. The two parts as prepared shall be thoroughly

mixed and the whole mass strained through muslin cloth. Paints using driers shall be consumed
within about 18 hours.
3.11.12 Proportion of Ingredients for Common purpose Paints:
3.11.12.1 Red lead paint :- This paint is used for protection of heavy structural steel and similar
purposes.
Red Lead 77 to 82%
Linseed Oil 18 to 13%
Turpentine (Solvent) including drier 5%
3.11.12.2 White lead Paint for General Purpose :-

White Lead 64 to 72%
Linseed Oil 31 to 23%
Turpentine 5%
For Priming purpose above paint be thinned by adding one Litre of Linseed oil and half Lite of
turpentine to 8 litre of above paint.
3.11.12.3 Paint for under coating on exterior surface :-
White Lead 50%

Extenders and Colouring Pigments 15%
Turpentine or other solvent Not more than 10%
Linseed Oil Remainder
3.11.12.4 White paint for finishing coat on exterior surface:-
White Lead 50%
Zinc Oxide 16%
Turpentine or other spirits 5%
Linseed Oil 29%
3.11.12.5 Colouring Paints for Finishing coat :-

White Lead 20%
Zinc Oxide 20%
Extender (Argillaceous matter) 6%
Whiting 6%
Colouring pigments 8%
Linseed Oil 35%
3.11.12.6 White Paints for Highway signs :-
Titanium Dioxide (I.S. 411-1991, Reaffirmed 2009)
Zinc Oxide 19%
Extender 6%

Linseed Oil 32%
The above paint is for finishing coat. For under coat the proportion of solvent may be increased to 12
% and that of Linseed oil decreased to 26 %.
3.11.12.7-Sampling and Testing of Paints:
i) IS: 82-1073 (Reaffirmed 2012): Method of sampling and testing for Thinners and
solvents for paints.
ii) IS: 101( Part 1 to 9) -1986 to 1993: Methods of sampling and testing for Paints,
varnishes and related products.
3.11.12.8- Measurements: Work of Painting , Primers and Putty's are measured in sqm to the nearest
0.01 m of the finished work. Refer IS: 1200 ( Part 13)-1994 ( reaffirmed 1997). Paints and other
materials are procured in litre, kg.
3.12: Other and Manufactured Materials: Many manufactured products, although not primary
building materials like aggregate or sand, are integral to the construction of Buildings. These may be
referred from the manufacturer's specifications.
LIST OF RELEVANT IS CODES FOR BUILDING MATERIALS.
S. BIS code for
No. Materials
Specifications Sampling/Testing:IS
:IS
CEMENT AND CONCRETE
1. Ordinary and Low Heat Portland Cement 269-1976 4031 & 4032-1968
2. Coarse and Fine Aggregates from natural 383-1970 2386 (Part 1-8) 1963
sources for concrete
3. Portland Slag Cement 455-1976 4031& 4032-1968
4. Standard sand for testing of cement 650-1966 650-1966
5. Portland -Pozzolana Cement. 1489-1976 (I),
8112/12269 4031 & 4032-1968
6. Sand for Plaster 1542-1992
7. Sand for Masonry mortars. 2116-1980
8. Cinder as Fine Aggregate for lime Concrete. 2686-1977
9. Broken Brick Aggregate for Lime Concrete. 3068-1986
10. Masonry Cement 3466-1967 4031-1968
11. Chemical Analysis of Hydraulic Cement 4032-1968
12. High Alumina Cement for Structural use 6452-1972 4031 & 4032-1968
13. Supersulphated Cement 6909-1973 -do-
14. Rapid Hardening Portland Cement 8041-1978 -do-
15. White Portland Cement 8042-1978 -do-

S. BIS code for
No. Materials
:IS
16. Hydrophobic Portland Cement 8043-1978 -do-
17. High Strength Ordinary Portland Cement 8112-1976 -do-
18. Admixtures for Concrete 9103-1999 -do-
19. 53 Grade Ordinary Portland Cement 12269-2013 -do-
20. Sulphate Resisting Portland Cement 12330-1988 -do-
21. Low heat Portland Cement 12600-1989 -do-
POZZOLANAS
1. Calcined Clay Pozzolana ( Surkhi) 1344-1981 1727-1967
(Reaffirmed 2004)
2. Fly Ash for use as Pozzolana and Admixture. 3812-1981 1727-1967
(Reaffirmed 2004)
BUILDING LIMES
1. Building Limes 712-2001 6932 ( PI-X)-1973
BUILDERS HARDWARE
1. Tower Bolts (Ferrous and Non-Ferrous 204(P-I/II)-
metals) 1991/1992
2. Non Ferrous Metal Butt Hinges 205-1992
3. Tee and Strap Hinges 206-1981
4. Door Handles 208-1979
5. Door bolts for use with Padlocks 281-1991
6. Fan Light Catch 364-1970
7. Mild steel double acting steel hinges. 453-1973
8. Steel butt Hinges 1341-1992
9. Floor door stoppers 1823-1980
10. Fan Light Pivots. 1837-1966
STONES
1. Recommendations for Dimensions and 1127-1970 1127-1974
workmanship of Natural Building stones for
Masonry work.
CLAY PRODUCTS FOR BUILDINGS
2. Common Burnt Clay Building Bricks. 1077-1976 3495-1992 (P-I/II/III/IV)
3. Heavy Duty Burnt Clay Building Bricks. 2180-1970 --do--
4. Sand Lime bricks. 4139-1976
5. Sampling of Bricks for testing. 5454-1978

S. BIS code for
No. Materials
:IS
TIMBER
1. Coniferous Sawn Timber (Baulks and 190-1991 3364-1976
Scantling)
2. Cut sizes of Timber ( Superseding IS 1629-1960) 1331-1971. -do-
3. Methods of measurements and evaluation 3364-1976
of defects in Timber ( Logs).
Wood Products-Plywood etc.
1. Ply wood for General Purposes. 303-1989 1734( P-lto 20) -1983
Synthetic Resins Adhesive for Plywood 848-2006
2. Veneered Decorative Ply Wood. 1328-1982 -do-
3. Block Boards. 1659-1979 1659-1979
7. Decorative Ply Wood using Plurality of 7316-1974 9316-1974
Veneers for Decorative Faces.
Steel
1. Structural Steel (Standard Quality). IS: 226-1975 1608-1972, 1599-1974,
2. Specification for galvanized steel sheets IS: 277-1977 IS: 6745-1972
(Plain and corrugated
3. Specifications for Cold Rolled low carbon IS 513-1986
steel sheets and strips.
4. Standard specifications for welding of IS 823-1964
Mild steel.
5. Structural Steel (High Tensile). IS: 961-1975 -do-
6. Hot Rolled Carbon Steel Sheet and Strip. IS:1079-1973 IS: 1663-1972,
1608-1972, 1692-1974
7. Bend Test for Metallic Materials. 1599-2012 Superseding IS 1692,
3260, and 4598
8. Mechanical Testing of structural steel. 1608-2005
9. Rolling and cutting Tolerance of Rolled 1852-1985
Steel Products.
10. Structural steel (ordinary quality) IS: 1977-1975 -do-
ll. Hot Rolled low, medium and high tensile IS: 2062-1980 -do-
structural steel
12. Weld able Structural steel (Medium and IS: 8500-1977 -do-, 1757-1974
high strength Qualities
CHAPTER No. 4
MORTARS
CHAPTER No. 4 : MORTARS
CONTENTS
4.1 Scope 3
4.2 Terminology 3
4.3 Necessary Information 4
4.4 Materials 4
4.5 Cement 5
4.6 Fine Aggregate 7
4.7 Broken Brick (Burnt Clay) Fine Aggregate 10
4.8 Fly Ash 11
4.9 Lime 11
4.10 Design Considerations 11
4.11 Criterion For Selection of Masonry Mortar 13
4.12 Mud Mortar 17
4.13 Cement Fly Ash Sand Mortar 17
4.14 Lime Mortar 18
4.15 Composite Mortar 21
Appendix 'A': Determination of compressive strength of masonry mortar. 23
Appendix 'B': Determination of consistency of masonry mortars. 28
Appendix' C': Determination of water retentivity of masonry mortars. 29
Appendix' D': Test for organic Impurities. 32
Appendix 'E': Test for particle size ( sieve analysis). 33
Appendix 'F' : Test for silt content. 34
Appendix 'G': Bulking of fine aggregates/sand ( field methods) 34
Appendix 'H' : Physical requirements of Flyash. 35
List of Relevant IS Codes 35
Rajasthan PWD Building Specifications 2014 Chapter 4 : Mortars Page 1 of 36


CHAPTER No. 4
MORTARS
4.1. Scope:
This standard covers the preparation of masonry mortars and their use in masonry works.
NOTE-Use of gypsum mortars and bituminous mortars is not covered in this standard.
4.2. Terminology:
For the purpose of this standard, the following definitions in addition to those given in IS : 6508-
1972(Glossary of terms relating to building lime) and IS : 4305-1967 (Glossary of terms relating to
Pozzolana) shall apply.
i) Mortar - Mortar is a homogeneous mixture, produced by intimately mixing cementious
materials, water and inert materials, such as sand, to the required consistency for use in building
together with masonry units.
ii) Lime Mortar: - A mortar containing lime and sand.
iii) Composite Mortar:-A mortar containing cement and lime in addition to other ingredients.
iv) Grade of Masonry Mortar:-The `grade' of a masonry mortar will be defined by its
compressive strength in N/mm2 at the age of 28 days, as determined by the standard procedure
detailed in AppendixÀ'.
 Consistency: -The working consistency of a mortar or plastering mix as judged by the worker
from its behaviour during application. Its assessment includes characteristics, such as initial
fluidity, water retentivity, etc.
 Hardening: -The physio-chemical changes observed in a mortar due to the effect of one or
more of the following phenomena:
a) Absorption of carbon dioxide,
b) Recrystallization, and
c) Chemical reaction.
 Setting: - The physical and chemical changes observed in a mortar mainly due to the hydration
of hydraulic constituents of the mortar or due to the interaction of some of the constituents or a
combination of both the types of reactions.
 Water Retentivity: - The ability of mortars to retain water against suction and evaporation in
general. It is indirectly a measure of the workability of mortars. It is measured by the flow of
mortar when tested on a standard flow table before and after application of a specified suction (
see Appendix C ).
ix) Workability:-That property of freshly mixed mortar which determines the ease and
homogeneity with which it can be mixed, placed,compacted and finished. It is the amount of
energy to overcome friction and cause full consolidation.

4.3. Necessary Information:
4.3.1 Proper selection of mortars for various uses depends upon the following factors :
a) Type of masonry, namely brick work, stone work, concrete block work, etc., and strength of
individual masonry unit,
b) Situation of use of the masonry, namely, whether in foundation,superstructure, etc.
Conditions of surrounding soil in the case of foundation work,
c) Load which the masonry will have to bear,
d) Conditions of exposure to weather or soil conditions in the case of masonry buried below
ground level,
e) Type and grading of fine aggregates to be used in the mortar, namely, whether sand, burnt-
clay aggregate or cinder aggregate,
f) In the case of hydraulic structures weathering conditions under water contact and under
water head action; and
g) In case of use in storage of acidic or alkaline substances like fertilizers.
4.3.2 Desirable properties of mortars for use in masonry are:
(a) Workability
(b) Water retentivity
(c) Rate of stiffing
(d) Strength
(e) Resistance to rain penetration
(f) Durability
4.4Materials:
4.4.1 Water: Water used for mixing and curing shall be clean and free from injurious quantities of
alkalis,acids, oils, salts, sugar, organic materials, vegetable growth or other substance that may be
deleterious to bricks, stone, concrete or steel. Potable water is generally considered satisfactory for
mixing. The pH value of water shall be not less than 6. The following concentrations represent the
maximum permissible values (of deleterious materials in water).
(a) Limits of Acidity:To neutralize 100m1 sample of water, using phenolphthalein as an
indicator, it should not require more than 5m1 of 0.02 normal NaOH. The details of test shall be
as given in IS: 3025 (part 22)-1986.
(b) Limits of Alkalinity:To neutralise 100m1 sample of water, using mixed indicator, it should
not require more than 25m1 of 0.02 normal H2SO4. The details of tests shall be as given in IS:
3025 (part 23)-1986.
(c) Percentage of Solids: Maximum permissible limits of solids when tested in accordance with
IS: 3025 shall be as under:
Organic 200mg/ litre
Inorganic 3000mg/ litre
Sulphates 400 mg/ litre

Chlorides 2000 mg/ litre for concrete not containing embedded steel and 500
mg./litre for reinforced concrete work.
Suspended matter 2000 mg/ litre
The physical and chemical properties of ground water shall be tested along with soil investigation and
if the water is not found conforming to the requirements of IS 456-2000; the tender documents shall
clearly specify that the contractor has to arrange good quality water for construction indicating the
source.
4.4.2 Water found satisfactory for mixing is also suitable for curing. However, water used for curing
shall not produce any objectionable stain or unsightly deposit on the surface.
4.4.3 Sea water shall not be used for mixing or curing.
4.4.4 Water from each source shall be tested before the commencement of the work and there after
once in every three months till the completion of the work. In case of ground water, testing shall also
be done for different points of drawdown. Water from each source shall be got tested during the dry
season before monsoon and again after monsoon.
4.5 Cement:
4.5.1 The cement used shall be any of the following grades and the type selected should be appropriate
for the intended use.
33 grade ordinary Portland cement conforming to IS: 269-1976.
Rapid hardening Portland cement conforming to IS: 8041-1978.
Portland slag cement conforming to IS: 455-1976.
Portland Pozzolana cement (flyash based) conforming to IS 1489: (Part 1)-1976.
Portland Pozzolana cement (Calcined clay based) conforming to IS: 1489 (part 2)-1976.
Hydrophobic cement conforming to IS 8043-1978 Low heat Portland cement
conforming to IS 12600-1989. Sulphate resisting Portland cement conforming to IS:
12330-1988
White cement conforming to IS: 8042-1978
For details on various type of cement, refer Chapter 3, Building materials. Different types
of cement shall not be mixed together. In case more than one type of cement is used in any work, a
record shall be kept showing the location and the types of cement used.
4.5.2 Caution in Use of Cement Grade 53 in Construction:
a) Because of the faster hydration process,the concrete releases heat of hydration at a much faster
rate initially and release of heat is higher incase of Grade. 53. The heat of hydration being
higher, the chances of micro-cracking of concrete ismuch greater. Thus, during initial setting
period of concrete, the higher heat of hydration can lead to damaging micro-cracking within the
concrete which may not be visible at surface. This cracking is different from shrinkage cracks which
occur due to faster drying of concrete in windy conditions.The situation can be worse when we
tend to increase the quantity of the cement in the concrete with a belief that such increases are
better for both strength and durability of concrete. Thus, it is very essential

to be fore- warned that higher grade cement specially grade 53 should be used only where
suchuse is warranted for making higher strength concrete and also where good Quality
Assurance measuresare in place, by which proper precaution are taken to relieve the higher
heat of hydration through chilling of aggregates or by proper curing of concrete. There are
instances where higher grade cement is being used even for low strength concrete, as, mortar or
even for plastering. This can lead to unnecessary cracking of concrete/ surfaces.
b) Another issue to be cautioned against is the tendency of the manufacturers to project Grade 53
cement as stronger cement, where as Grade 33 or 43 are enough to produce the concrete of
desired characteristic strength. The scenario of method of production of cement by various
manufacturers should also be kept in mind while ordering various grades of cement. The ability
to produce cements of particular fineness gets fixed by the machinery installed by the
manufacturers, and thus the ability to produce other various grades of cement by a particular
manufacturer also gets limited. Where as tendency today is to supply the consumer what he
orders for by the manufacturers by simply stamping such grades on the bags. Thus, it is often
observed that cement bags marked as grade 33 or 43 may really be containing cements of much
higher grade.
4.5.3 Compressive Strength:
Compressive strength requirement of each type of cement for various grades when tested in
accordance with IS 4031 (part 6) shall be as under:
Table -1
Sample Strength in N/mm2 not less than for
Age at testing Gr. 33 Gr.43 Gr. 53
72 + 1 hour 16 23 27
168 + 2 hour 22 33 37
672 + 4 hour 33 43 53
4.5.4 Setting Time: Setting time of cement of any type of any grade when tested by Vicat's
apparatusmethod described in IS 4031 shall conform to the following requirement:
(a) Initial setting time : Not less than 30 minutes
(b) Final setting time : Not more than 600 minutes
4.5.5 Supply:
The cement shall be packed in jute sacking bags conforming to IS 2580, double Hessian bituminized
(CM type) or woven HDPE conforming to IS: 11652-. Woven polypropylene conforming to IS:
11653, jute synthetic union conforming to IS: 12174, or any other approved composite bag, bearing
the manufacturer's name or his registered trade mark, if any, with grade, batch no. and type of cement,
with date of manufacturing of batch of cement.Every delivery of cement shall be accompanied by a
producer's certificate conforming that the supplied cement conforms to relevant specifications. These
certificates shall be endorsed to the Engineer-in-Charge for his record. Every consignment of cement
must have identification marks on packages indicating date of manufacturing grade and type of
cement batch no. etc. Cement brought to works shall not be more than 6 weeks old from the date of
manufacture.Effective precautionary measures shall be taken to eliminate dust-nuisance during
loading or transferring cement.

4.5.6Stacking and Storage:
i) Cement in bags shall be stored and stacked in a shed which is dry, leak proof and as moisture-
proof as possible. Flooring of the shed shall consist of the two layers of drybricks laid on well
consolidated earth to avoid contact of cement bags with the floor. Stacking shall be done about
150 to 200 mm clear above the floor using wooden planks. Cement bags shall be stacked atleast
450 mm clear off the walls and in rows of two bags leaving in a space of atleast 600 mm
betweentwo consecutive rows. In each row the cement bags shall be kept close together so as to
reduce aircirculation. Stacking shall not be more than 10 bags high to avoid lumping under
pressure. In stacksmore than 8 bags high, the cement bags shall be arranged in header and
stretcher fashion i.e.alternately lengthwise and crosswise so as to tie the stacks together and
minimise the danger of toppling over.
ii) Different types of cement shall be stacked and stored separately.
iii) Cement bags shall be stacked in a manner to facilitate their removal and use in the order in
which they are received.
iv) For extra safety during monsoon, or when cement is expected to be stored for an unusually long
period, each stack shall be completely enclosed by a water proofing membrane, such as
polyethylene,which shall cover the top of the stack. Care shall be taken to see that the water
proofing membrane isnot damaged at any time during use.
v) Storage of cement at the work site shall be at the contractor's expense and risk. Any damage
occurring to cement due to faulty storage in contractor's shed or on account of negligence on his
partshall be the liability of the contractor.
4.6 Fine Aggregate:
4.6.1 Aggregate most of which passes through 4.75 mm IS sieve is known as fine aggregate. Fine
aggregate shall consist of natural sand, crushed stone sand, crushed gravel sand stone dust or marble
dust, fly ash and broken brick (Burnt clay). It shall be hard, durable, chemically inert, clean and free
from adherent coatings, organic matter etc. and shall not contain any appreciable amount of clay
balls orpellets and harmful impurities e.g. iron pyrites, alkalis, salts, coal, mica, shale or similar
laminated materials in such form or in such quantities as to cause corrosion of metal or affect
adversely the hardening, the strength, the durability or the appearance of mortar, plaster or concrete.
The sum of the percentages of all deleterious material shall not exceed 5%. Fine aggregate must be
checked for organic impurities such as decayed vegetation humps, coal dust etc. in accordance with
the procedure prescribed in Appendix `D'.
4.6.2Silt Content:
The maximum quantity of silt in sand as determined by the method prescribed in Appendix `F' shall
not exceed 8%.Fine aggregate containing more than allowable percentage of silt shall be washed as
many times as directed by Engineer-in-charge so as to bring the silt content within allowable limits for
which nothing extra shall be paid.
4.6.3 Grading:
On the basis of particle size, fine aggregate is graded in to four zones. The gradingwhen determined
in accordance with the procedure prescribed in Appendix È' shall be within the limits given in Table
2 below. Where the grading falls outside the limits of any particular grading zone of sieves, other than
600 micron IS sieve, by a total amount not exceeding 5 per cent, it shall be regarded as

falling within that grading zone.
Table-2 :Fine Aggregates (Sand conforming to IS 2116-1980)
IS Sieve Percentage passing for
Grading Zone I Grading Zone II Grading Zone III Grading Zone IV

10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
150 microns 0-10 0-10 0-10 0-15
Note 1: For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 percent.
This does not affect the 5 per cent allowance permitted in other clauses applying to other
sieves.
Note 2: Allowance of 5% permitted in other clauses can be split up, for example it could be 1% on
each of three sieves and 2% on another or 4% on one sieve and 1% on another.
Note 3: Fine aggregate conforming to Grading Zone IV shall not be used in reinforced cement
concrete unless tests have been made to ascertain the suitability of proposed mix
proportions.
Note 4: Sand requiring use for mortar for plaster work shall conform to IS 1542-1992 and for
masonry work shall conform to IS 2116-1980.
4.6.4 Type and grading of fine aggregate to be used shall be specified. It shall be coarse Sand, fine
Sand, Stone dust or Marble dust, Fly ash and Surkhi. Use of sea sand shall not be allowed, unless
(a) Coarse sand shall be either river sand or pit sand or a combination of the two. It shall be clean,
sharp, angular and gritty totouch and composed of hard siliceous material. Its grading shall fall
within the limits of gradingzone I, II, III of Table 2. Grading of sand shall conform to IS: 2116-
1980 for use in Masonry work.
(b) Fine sand shall be either river sand or pit sand or a combination of the two. Its grading shall
fall within the limits of Grading zone IV of Table 2. Grading of sand shall conform to IS:
1542-1992 for use in plaster work.
(c) Stone dust shall be obtained by crushing hard stones or gravel. Its grading shall fall within the
limits of grading Zone, I, II, or III of Table 2.
(d) Marble dust shall be obtained by crushing marble. Its grading shall fall within the limits of
Grading Zone IV of Table 2. Grading of Marble dust for use in Mortar shall be as per following
Table 3.

Table -3 Grading of Marble Dust
IS Sieve Percentage Passing
10 mm 100
4.75 mm 95-100
2.36 mm 95-100
1.18 mm 90-100
600 micron 80-100
300 micron 15-50
150 micron 0-15
(e) Sand for Masonry Mortar and for Plaster:-Sand shall consist of natural sand, crushed stone
sand or crushed gravel sand or a combination of any of these. Sand shall be hard durable, clean
and free from adherent coating and organic matter and shall not contain the amount of clay, silt
and fine dust more than specified as under.
4.6.4.1 Deleterious Material: Sand shall not contain any harmful impurities such as Iron, Pyrites,
Alkalis, Salts, Coal or other organic impurities, Mica, Shale or similar laminated materials, soft
fragments, sea shale in such form or in such quantities as to affect adversely the hardening, strength or
durability of the mortar.The maximum quantities of clay, fine silt, fine dust and organic impurities in
the Sand / Marble dust shall not exceed the following limits:
(1) Clay, fine silt and fine dust when determined in accordance within IS:2386(Part II-1963). In
natural sand or crushed gravel sand & crushed stone sand not more than 5% by mass.
(2) Organic impurities, when determined in accordance with IS:2386 (Part II)-1963, Colour of the
liquid shall be lighter than that indicated by the standard specified in IS 2386 (Part II)-1963.
Grading of sand for use in masonry mortar shall be conforming to IS: 2116-1980 (Table4 below).
Grading of sand for use in plaster shall be conforming to IS: 1542-1992 (Table4 below):
Table-4: Grading of Sand for use in Masonry Mortar and Plaster
Grading of sand for use in masonry mortar Grading of sand for use in plaster
IS Sieve Percentage passing IS Sieve Percentage passing
Designation bymass Designation by Mass.
10mm 100 10mm 100
4.75 mm 100 4.75 mm 95 to 100
2.36 mm 90 to 100 2.36 mm 95 to 100
1.18 mm 70 to 100 1.18 mm 90 to 100
600 micron 40 to 100 600 micron 80 to 100
Note: For crushed stone sands, the permissible limit on 150 micron IS Sieve is increased to 20%,
this does not affect the 5% allowance as per IS 2386 (Part 1)-1963.

4.6.4.2 Bulking:
Fine aggregate, when dry or saturated, has almost the same Volume but dampness causes increase in
volume. In case fine aggregate is damp at the time of proportioning the ingredients for mortar or
concrete, its quantity shall be increased suitably to allow for Bulking , which shall be determined by
the method prescribed in Appendix `G'.Table 5 gives the relation between moisture content and
percentage of bulking for guidance only.
Table-5
Moisture content % age Bulking % age (by volume)
2 15
3 20
4 25
5 30
4.6.4.3 Stacking:
Fine aggregate shall be so stacked as to prevent dust and foreign matter getting mixed up with it as far
as practically possible. Marble dust in dry condition shall be collected in bags and properly staked
so as not to form lumps, suitable arrangements shall be made to protect it from moisture similar to
those adopted for stacking of cement bags.
4.6.4.4 Measurements:
As the fine aggregate bulks to a substantial extent when partially wet,measurements shall be taken
when the stacks are dry or appropriate allowance made for bulking.
4.7 Broken Brick (Burnt Clay) Fine Aggregate: Broken Brick (Burnt Clay) Fine Aggregate, also
known as Surkhi, shall be made by grinding well burnt (but not under or over burnt) broken bricks as
specified in IS: 3068-1986. It shall not contain any harmful impurities, such as iron pyrites, salts, coal,
mica, shale or similar laminated or other materials insuch form of quantity as to adversely affect
hardening, strength, durability or appearance of the mortar.The maximum quantities of clay, fine silt,
fine dust and organic impurities in Surkhi (all taken together)shall not exceed five per cent by weight.
The particle size grading of Surkhi for use in lime mortars shall be within the limits specified in
Table 6.
Table-6
IS Sieve Designation Percentage passing (by
4.75 mm 100 weight)
2.36mm 90-100
1.18 mm 70-100
600 microns 40-100
300 microns 5-70
150 microns 0-15
4.7.2 Stacking:
Surkhi shall be stacked on a hard surface or platform so as to prevent the admixture of clay, dust,
vegetation and other foreign matter. It shall be also protected from rain and dampness and kept

under adequate coverings.
4.7.3 Measurements: Surkhi shall be measured in regular stacks in cubic metre. Alternatively it
may be measured by weight when supplied in bags.
4.8 Fly Ash:
4.8.1 Fly ash is finely divided residue resulting from the combustion of pulverized coal in boilers. Fly
ash is the pulverized fuel ash extracted from the flue gases by any suitable process such as cyclone
separation or electrostatic precipitation. The ash collected from the bottom of boilers is termed as
bottom ash. Flyash is finer than bottom ash. Siliceous fly ash (ASTM Class F) containing calcium
oxide less than 10%by mass is normally produced from burning anthracite or bituminous coal and
possesses pozzolanic properties. Calcareous fly ash (ASTM Class C) is produced by burning lignite or
sub-bituminous coal and contains calcium oxide more than 10% by mass, the content could be as
high as 25%. This fly ash has both hydraulic and pozzolanic properties. It shall be clean and free from
any contamination of bottom ash, grit or small pieces of pebbles. It is obligatory on the part of supplier/
manufacturer that the fly ash conforms to the requirements if mutually agreed upon & shall furnish a
certificate to this effect to the purchaser or his representative.
4.8.2 Characteristics: The physical requirements of fly-ash shall be as specified in Annexure `H' of
Chapter 4. The chemical properties of fly ash shall be as per IS 3812 (part 1 & 2) depending on the
usage.
4.8.3 Stacking: Fly ash shall be protected from dirt collecting on it.
4.8.4 Measurements: Fly ash shall be measured in regular stacks in cubic metre. Alternatively it
may be measured by weight when supplied in bags.
4.8.5 Burnt-clay, Fly ash and Cinder aggregate: shall conform to IS: 3182-1975, IS : 3812 ( Part
III)-1966 and IS : 2686-1977.
4.9 Lime: (shall conform to IS : 712-1973).
4.9.1 Hydraulic and semihydraulic limes corresponding to class A and Bof IS : 712-1973 are
eminently suitable for use in masonry mortars, whereas fat limes corresponding to class C will
require mixing of burnt clay Pozzolana or other pozzolanic materials. ClassC and D limes may also be
used with addition of cement and pozzolanic materials.
4.9.2 Class À' lime of IS : 712-1973:: shall be supplied as hydrated lime alone. Class B, C, D and E
lime as specified in IS : 712-1973, shall be supplied both as quick lime and hydrated lime. Quick lime
shall never be used for structural purpose. It must be slacked first. Slaking at site of work shall be done
in accordance with IS : 1635-1975.
NOTE - The quality and characteristics of lime are considerably influenced by the method of slaking
in addition to the chemical composition. Also, inadequately slaked particles of lime will continue to
hydrate after the lime is used in the mortar and consequently lead to defects, such as popping,
blowing, crack development, etc.
4.9.3 Lime Pozzolana Mixture: It shall conform to IS: 4098-1967.
4.9.4 Storage of materials: Storage of materials shall be in accordance with IS 4082-1977.
4.10. Design Considerations:
4.10.1 Durability: The durability of masonry mortars depends upon the following factors:

a) Volumetric changes during the process of setting, hardening, and later due to temperature
variations or due to moisture movements in the surroundings, and the extent to which the
mortarwill internally accommodate the stresses induced by these volumetric changes before
yielding;
b) The nature and distribution of the resulting cracks, whether as fine cracks well-distributed
throughout or large localized cracks;
c) The extent to which the bond between the mortar and the masonry units is ruptured by
volumetric changes and structural movements resulting not only in reduction in strength of
masonry but also in provision of channels of seepage for water and other solution into the
masonry which would further the process of deterioration; and
d) Resistance to chemical attack in aggressive environment.
4.10.1 All mortars are likely to deteriorate to a greater or lesser extent under prolonged exposure to the
environment. The rate of deterioration depends not only upon the composition of the mortar, but also
upon thorough, uniform and intimate mixing and the workmanship in laying the masonry.
4.10.2 Effect of Volume Change:
4.10.3 In the early stages, when mortar is green, temperature fluctuations and variations in moisture
content cause volume changes that are detrimental to a masonry mortar in course of time.
Generally,the effect of temperature fluctuations is negligible compared to that of moisture variation.
If there is excessive volume change due to alternate wetting and drying, the bond between the mortar
and the masonry is liable to be destroyed, causing cracks to appear in the hard set mortar.
4.10.4 Since lime mortars undergo only negligible volume change after setting and initial shrinkage
and the hardening of the mortar is also a slow process, the mortar is able to retain its bond with the
masonry unit and be free from cracks.
4.10.5 Lime mortars are also able to take normal movements in masonry mortar caused by volume
changes by virtue of internal accommodation, in this process it will undergo elastic or creep
deformations and may recover fully or partly. The extensibility of masonry mortar, which indicates
its capacity for internal accommodation, ranges from 2to 3 x 10-4. This is generally larger than the
volume change (maximum shrinkage) that normally occurs in lime mortars on hardening. Because of
the accommodation of the mortar, the stresses that develop due to various deformations, such as
expansion, contraction and deflection, will get distributed in the mortar and their intensities will be
low.
4.10.6 Resistance to Sulphate Attack: The sources of sulphate giving rise to this trouble will be:
a) In exceptional circumstances, sulphate derived from the brick constituting the masonry unit;
b) Sulphate contained in the sand or fine aggregate use in the mortar where sulphate content in
these has to be allowed high from economic consideration; and
c) Sulphate from soil in the case of masonry in contact with soil.
4.10.6.1 The cement in the mortar will undergo expansive reactionin the presence of sulphate, which
will lead to cracks in the mortar.Where serious sulphate attack is expected, Portland slag cement, or
Portland pozzolana cement may preferably be used instead of ordinaryPortland cement. Other general
precautions to be taken against sulphate attack in masonry design as well as workmanship are
covered in IS: 2212-1962.

4.10.6.2 Hardening of Mortar: A masonry mortar should harden at such a rate that it causes no
delay in the progress of work, but at the same time it is able to retain its plastic properties for a
sufficient interval till the initial shrinkage of the mortar is complete. This will minimize the danger of
cracks and opening of joints in masonry. The rate of hardening of lime mortars is slower than that of
cement mortars, but is satisfactory for most of the normal building works, except where high strength
is required.
4.10.63 Strength Development: Strength development is an, important requirement before masonry is
loaded to the full extent, and the rate of construction should synchronize with the development of the
strength on masonry, particularly in the case of masonry with weak mortars, Extra time shall be
allowed for hardening of mortar when the atmospheric temperature during construction is very low
(minimum 5% in 24 h). The period will have to be increased by 100 percent for the time during
which the temperature remains below 5°C and by 50 percent for the time when temperature is
between 5 and 10°C.
4.10.6.4 The strength of lime mortars is dependent on the class of lime(see IS: 712-1973) and other
constituents used in the mortar(see Table 1 ). Incorporation of cement and/or pozzolana in lime
mortar mixes made with Class `B' and Class È' lime will increase the strength and rate of hardening
of the mortars without appreciably reducing workability.
4.10.6.5 Quantity of Water: The quantity of water to be added to the mortar shall be such that the
working consistency (see 2.1) is obtained.Excess water shall be avoided.
4.11 Criteria for selection of Masonry Mortar:
a) The selection of masonry mortars from durability consideration will have to cover both the
loading and exposure conditions of the masonry. The masonry mortar shall generally be as
specified in (b) to (g).
b) In case of masonry exposed frequently to rain and where there is further protection by way of
plastering or rendering or other finishes, the grade of mortar shall not be less than MM 0.7 but
shall preferably be of grade MM2, Where no protection is provided, the grade of mortar for
external walls shall not be less than MM2.
c) In case of load bearing internal walls, the grade of mortar shall preferably be MM 0.7 or
more for high durability but in no case less than MM 0.5.
d) In the case of masonry work in foundations laid below damp proof course, the grade of
mortar for use in masonry shall be as specified below:
i) Where soil has little moisture, masonry mortar of grade not less than MM 0.7 shall be
used.
ii) Where soil is very damp, masonry mortar of grade preferably MM 2 or more shall be
used. But in no case shall the grade of mortar be less than MM2.
(iii) Where the soil is saturated with water. Masonry mortar of grade MM 3 shall be used but in
no case shall the grade of mortar be less than MM 2.
For masonry in building subject to vibration of machinery, the grade of mortar shall not be
less than MM3.
For parapets, where the height is greater than thrice the thickness, the grade of masonry mortar
shall not be less than MM3. In case of low parapets the grade of mortar shall be the same as

used in the wall masonry.
g) The grade of mortar for bedding joints in masonry with large concrete blocks shall not be
less than MM3.
h) The compressive strength shall be determined in accordance with the procedure given in IS
2250-1981.
(i) While mixing the pozzolanic material like fly ash in mortars Ordinary Portland cement
only shall be used.
4.11.lGrade of Masonry Mortar :
The grade of a masonry mortar will be defined by its compressive strength in N/mm2 at the age of 28
days as determined by the standard procedure, detailed as per Table-7.
Table -7: Grade of Masonry Mortars
S1. Grade Mortar Mix (By Loose Volume) Compressive
No. Strength At
Cement Lime Pozzolana Lime Sand 28 days
Pozzolana
Mixture
1 2 3 4 5 6 7 8
1. MM 0-5 0 1B or E 0 0 3 0.5 to 0.7
2 0 0 0 1 (LP-7) 1.25
3 0 1 C or D 1 0 2
4 MM 0-7 0 0 0 1 (LP-20) 1.5
5 0 0 0 1 (LP-40) 2.25
6. 1 3CorD 0 0 12 0.7to1.5
7. 1 0 0 0 8
8. 1 0 0.4* 0 10
9. MM 1-5 0 0 0 1 (LP-20) 1.25
10. 0 0 0 1 (LP-40) 2
11. 1 0 0 0 7 1.5to2
12. 1 0 0.4* 0 8.75
13. 0 1A 0 0 3
14. MM 2 0 1A 0 0 2
15. 0 1CorD 3* 0 0
16. 1 2CorD 0 0 9
17. 0 0 0 1 (LP-20) 1 2 to 3
18. 0 0 0 1 (LP-40) 1.75
19. MM 3 0 1 C or D 2* 0 0
20. 1 1 C or D 0 0 0
21. 1 0 0 0 6

S1. Grade Mortar Mix (By Loose Volume) Compressive
No. Strength At
Cement Lime Pozzolana Lime Sand 28 days
Pozzolana
Mixture
1 2 3 4 5 6 7 8
22. 0 1A 0 0 1
23. It 0 0.21* 0 4.2 3to5
24. 0 0 0 1 (LP-40) 1.5
25. 1 0 0.4* 0 7.5
26. MM 3 1 0 0 2 (LP-20) 12
27. MM 5 1 0 t o B , C, D or E 0 0 4
28. 1 0 0 0 5 5 to 7.5
29. 0 0 0 0 (LP-40) 1
30. 1 0 0.4 0 6.25
31. 1 0 0.4 0 5
32. MM 7.5 1 ¼CorD 0 0 3
33. 1 ' C or D 0 0 4.5
34. 1 0 0 0 4
35. It 0 0.2* 0 2.1
36. 1 0 0 0 3 7.5 and Above
37. 1 0 0.4 0 3.75
38. MM 7.5 1 0 0 1 (LP-20) 8
Note I : A,B.C,D and E denote the classes of limes to be used (See IS:712-2001 specification for
building limes).
Note II : The strength values of lime mortar given in the table are after wet grinding of the mortar
ingredients.
Note III : The compressive strength shall be determined in accordance with the procedure given in
IS : 2250 -1981.
* Pozzolana of minimum lime reactivity of 4 N/mm2 •
This ratio by volume corresponds approximately to cement Pozzolana ratio of 0:8.02 by weight. In
this case, only ordinary Portland cement is to be used.
4.11.2 For proportioning the ingredients by volume, the conversion of weight into volume shall be
made on the following basis:
Unit Weight of Materials in Loosely Placed Condition
(a) Burnt Clay Pozzolana 860 kg/cum (775-945)
(b) Coarse Sand (dry) 1280 kg/cum (variable)
(c) Fine sand (dry) 1600 kg/ cum (-do-)

(d) Fly Ash 590 kg/ cum (570-600)
( e) Dry hydrated lime. 700 kg/cum (630-770)
Note 1 : Loosely placed condition is achieved by pouring or filling the material in the container
loosely, that is without giving any jerk to the container.
Note 2 : The unit weight of dry and loose sand shall be found by actual field measurements. Note
3 : For details of grades and criteria for selection of Masonry mortars see Appendix À'. 4.11.3
Cement Mortar :
4.11.3.1 Scope: This specification covers materials, proportions, preparation, curing and mode of
measurement of cement mortar.
4.11.3.2 Materials:
(a) Cement: Unless otherwise specified, Cement shall be the ordinary Portland cement
conforming to IS - 269.
(b) Sand: Sand shall conform to grading as per Table 4.
(c) Water: Same as that for lime mortar.
This shall be prepared by mixing cement and sand with or without the addition of Pozzolana
inspecified proportions as per Appendix 'H'.
4.11.3.3Proportionmg: Proportioning on weight basis shall be preferred taking into account specific
gravity of sand and moisture content. Boxes of suitable size shall be prepared to facilitate
proportioning on weight basis. Cement bag weighting 50 kg shall be taken as 0.035 cubic metre.
Other ingredients in specified proportion shall be measured using boxes of size 40 x 35 x 25 cm.
Sand shall be measured on the basis of its dry volume in the case of volumetric proportioning.
4.11.3.4Mixing of Mortar:The mixing of mortar shall be done in mechanical mixers operated
manually or by power as decided by Engineer-in-Charge. The Engineer-in-Charge may, however,
permit hand mixing at hisdiscretion taking into account the nature, magnitude and location of the
work and practicability of the use of mechanical mixers or where item involving small quantities are
to be done or if in his opinion the use of mechanical mixer is not feasible in cases, where mechanical
mixers are not to be used. The contractor shall take permission of the Engineer-in-Charge in writing
before the commencement of thework.
(a) Mechanical Mixing:Cement and sand in the specified proportions shall be mixed dry
thoroughly in a mixer. Water shall then be added gradually and wet mixing continued for at
least three minutes. Only the required quantity of water shall be added which will produce
mortar of workable consistency but not stiff paste. Only the quantity of mortar, which can be used
within 30 minutes of its mixing, shall be prepared at a time. Mixer shall be cleaned with water
each time before suspending the work.
(b) Hand Mixing: The measured quantity of sand shall be levelled on a clean masonry platform
and cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by being
turned over and over, backwards and forwards, several times till the mixture is of a uniform
colour. The quantity of dry mix which can be used within 30 minutes shall then be mixed in a
masonry trough with just sufficient quantity of water to bring the mortar to a stiff paste of
necessary working / uniform consistency and colour.

4.11.3.5Precautions: Mortar shall be used as soon as possible after mixing and before it begins to
set, and in any case within half hour, after the water is added to the dry mixture.
4.11.3.6 Curing: Work in which Cement mortar shall be used, shall be kept shaded and cured with
water at least for seven days. Mortars using PPC shall be cured for a minimum of 15 days.
4.11.3.7 Measurement: Cement/ lime / composite mortar of stiff consistency shall be measured in
cubic meters. 60 cm high stacks being measured as 50 cm to allow for looseness in stacking.
4.12 Mud Mortar:
4.12.1Scope: This specification covers materials, preparation and mode of measurements of mud
mortar for setting stones or Bricks in structures.
4.12.2 Clay: Good clay soil, having a minimum sand content, in such a quantity that a dried lump of
the mixture shall not show signs of cracking, and duly approved by the Engineer, shall be used. The
P.I. Value shall be between 5 and 7. This shall be broken up to fine powder form, and shall be free
from stone, roots and other foreign matter. Clay, obtained from localities having salts and, or infected
by white ants shall not be used.
4.12.3Preparation of Mortar:
a) The mud shall be well trodden with men's feet and spades and worked into a thick paste by
adding water. It shall be left for a week allowing water to stand on the top in a shallow pool. The
mud mortar thus made shall be well tamped with water by treading before being used, care
being taken to remove all clods and stones if any.
b) All excavations made for and during preparation of mortar (e.g. for getting clay), dug within
100 metre of the site shall be filled in and dressed properly, on the completion of work.
4.12.3.1 Measurement: Mortar of stiff consistency shall be measured in cubic meters. 60 cm high
stacks being measured as 50 cm to allow for looseness in stacking.
4.13. Cement Fly-Ash Sand Mortar:
This shall be prepared by mixing cement, flyash and sand in specified proportions as perAppendix `H' .
Mixing shall be done in a mechanical mixer (operated manually or by power) unless otherwise
permitted by the Engineer-in-Charge in writing. The Engineer-in-Charge may, however, permit hand
mixing at his discretion in exceptional circumstances , taking into account the nature, magnitude and
location of the work and practicability of the use of mechanical mixer or where items involving small
quantities are to be done or ifin his opinion the use of mechanical mixer is not feasible. In case,
where mechanical mixer is not to be used, the contractor shall take permission of the Engineerin-
Charge in writing before the commencement of the work.
4.13.1 Proportioning: Proportioning on weight basis shall be preferred taking into account specific
gravity of Fly Ash, sand and moisture content. Boxes of suitable size shall be prepared to facilitate
proportioning on weight basis. Cement bag weighing 50 kg shall be taken as 0.035 cubic metre.
Otheringredients in the specified proportions shall be measured using boxes of suitable sizes. Sand and
flyash shall be measured on the basis of their dry volume in the case of volumetric proportioning.
4.13.2Mixing:
(a) Mechanical Mixing: Sand and flyash in the specified proportions shall be mixed dry in a
mixer and then the specified quantity of cement shall be added and mixed dry thoroughly.

Water shall then be added gradually and wet mixing continued for atleast one minute. Water shall
be just sufficient to bring the mortar to the consistency of a workable paste. Only the quantity
of mortar which can be used within 30 minutes of its mixing shall be prepared at a time.
(b) Hand Mixing:The measured quantity of sand and flyash shall be mixed dry on a clean masonry
platform before adding specified quantity of cement to it. The resulting mixture of cement,
sandand flyash shall then be mixed thoroughly being turned over and over, backward several
times till the mixture is of a uniform colour. The quantity of dry mix which can be used within
30 minutes shall then be mixed in a clean water tight masonry trough with just sufficient
quantity of water, to bring the mortar to a stiff paste of necessary working consistency.
4.13.3 Precautions: Shall be same as specified in IS 2250-1981
4.14 Lime Mortar:
4.14.0 Scope: This specification covers materials, proportions, preparation, storage, rejection and
mode of measurement of Lime mortars.
4.14.1 Materials:
4.14.1.1 Water:
a) Water used for mixing and curing shall be clean and free from injurious quantities of alkalis,
acids, oils, salts, sugar, organic materials, vegetable growth or other substances that may be
deleterious to bricks, stone, concrete or steel. Potable water is generally considered satisfactory
for mixing. The pH value of water shall generally be not less than 6.
b) Water found satisfactory for mixing is also suitable for curing. However, water used for curing
shall not produce any objectionable stain or unsightly deposit on the surface. The presence of
tannic acid or iron compounds in the water meant for curing is objectionable. .
c) Sea water shall not be used for mixing or curing.
d) Water from each source shall be tested before the commencement of the work and thereafter
once in every three months till the completion of the work. In case of ground water, testing
shall also be done for different points of drawdown. Water from each source shall be got tested
during the dry season before monsoon and again after monsoon.
4.14.1.2 Lime: Lime used shall conform to IS: 712-2001. Building limes are classified as follows:
Class A: Eminently hydraulic Lime used for structural purposes.
Class B: Semi hydraulic Lime used for masonry mortars.
Class C: Fat Lime used for finishing coat in plastering,White washing etc. and addition of
Pozzolanic material for Masonry Mortar.
Class D: Magnesium Lime used for finishing coat in plastering, White washing etc.
Class E: Kankar Lime used for masonry mortars.
4.14.1.3 Aggregates: Any of the following or their mixture in the given proportion shall be used.
(i) Fine Aggregate: Sand for plaster work shall conform to IS: 1542-1977 and for masonry work
shall conform to IS: 2116-1980.
Surkbi: Broken Brick (Burnt Clay) Fine aggregate, known as Surkhi, shall be made by grinding
well burnt (but not under or over burnt) broken bricks as specified in IS: 3068-1986. It shall

not contain any harmful impurities, such as Iron pyrites, Salts, Coal, Mica, Shale or similar
laminated or other materials in such form of quantity as to adversely affect hardening, strength,
durability or appearance of the mortar. The maximum quantities of clay, fine silt, fine dust and
organic impurities in Surkhi (all taken together) shall not exceed five percent by weight. The
particle size grading of Surkhi for use in lime mortars shall be within the limits specified in
Table 8.
Table-8
IS Sieve Designation Percentage passing (by wt)
4.75mm 100
2.36mm 90 -100
1.18mm 70 -100
600 microns 40-100
300 microns 5-70
150 microns 0-15
(iii) Cinder: Cinder shall be used in the mortars on a written permission of the Engineer in charge
which shall be given only when other types of aggregates are not available or when specified in
the schedule of quantities. Cinder mortars shall not be used for plaster or any other exposed
work.
4.14.1.4 Proportions:
4.14.1.4 The Proportion of mix for mortar shall depend upon the percentage purity of lime with
regard to its CaO content. In case the CaO content of lime is lower, the proportion of lime shall be
suitably increased to compensate, for the lower CaO content of the lime used.
4.14.1.5 The volume of lime for purpose of this table shall be on dry hydrated lime basis. Where
Quick lime is used the ratio shall be worked out accordingly, so as to provide the necessary quantity
of dry hydrated lime.
4.14.1.6 Preparation of Mortar:
a) Quick Lime: Quick Lime shall be supplied in the form of lumps and not in powder. Soon after
delivery, lump lime shall be separated from powder and all under burnt/ over burnt lumps and
the powder removed. Quick lime shall not be used directly in the work and shall invariably be
slaked and converted to lime putty before use. Slaking shall be carried as per IS 712-2001
b) Hydrated Lime: Hydrated lime shall be in the form of a fine dry powder. It shall be supplied
in suitable containers such as jute bags lined with water proofing membrane. The bags shall
bear marking indicating the class of lime, net weight, date of manufacture and the brand name.
It shall be used within 4 months of its date of manufacture. The hydrated lime can be used as
such for making mortar or may be run into putty and then used for making mortar (In contrast to
Quick lime.).
4.14.1.7. Slaking of lime:
Tank Slaking:
(a) Two or preferably three tanks lined with stone or brick large enough to permit, stirring and

hoeing shall be prepared (generally tanks suitable for 5 quintals or 10 quintals of quick lime
are used in practice).
(b) One of these shall be at the higher level and about 0.5 m deep and the remaining about 0.7 to
0.8 m. deep at lower level such that the contents of higher tank shall flow into the lower tanks
by gravity.
(c) The upper tank shall be filled to half its depth with water. Quick lime shall be gradually added
till it fills the entire bottom to about half the depth of water. (Never add water to lime). While
quick lime is being added it shall be constantly stirred and hoed so as to break up the lumps. No
part of the lime shall be allowed to expose above water level. As the lime slakes with evolution
of heat temperature begins to rise and more lime or water may be added till the required
temperature is reached and that temperature should be maintained by the addition of more lime
or water till all the lime apparently has slaked, the stirring and hoeing shall be continued during
the above process and for some period even after the slaking is apparently over.
4.14.1.8 Maturing: After the lime has cooled down, it shall be transferred to the lower tank allowing
it to flow through I.S. sieve No.1.18mm. more water shall be added if required and it shall be left
undisturbed as under:
Class A Lime for not more than 2 days;
Class B Lime for not less than 3 days for mortar used for finishing coat of plaster;
Class C Lime "not less than two days" for mortar used for other purposes. The putty shall be used
allowed to mature but not allowed to dry out till it is used.
4.14.1.9 Making Putty from Hydrated Lime: The putty shall be obtained by adding hydrated lime
to water in a tank and stirring to the Consistency of cream and allowing to stand as under:
Class A Lime = Not more than 12 hours
Class B Lime = Not more than 2 days
Class C Lime = Not less than 2 days for mortar used for finishing coat of plaster. Class
C Lime = Not less than 16 hours for mortar used for other purpose. 4.14.1.10 Making of
coarse stuff:
(a) Manual Mixing: After the lime has matured as specified above more water shall be added and
the putty stirred, till milk of lime is obtained. The fine aggregate shall be added with a whirling
motion of hand so that the aggregate falls evenly in the tank. The milk of lime shall be stirred
and hoed continuously till the required quantity of fine aggregate is added.
(b) Mortar mill (Gharat) Mixing: Quick lime shall not be used directly for making mortar. Putty
or dry hydrated lime and fine aggregates in required proportions shall be put along with water in
the Gharat Spreading uniformly all along its circumference and ground till a mortar of uniform
colour and desired consistency is obtained. As grinding is done the mixture shall be continuously
raked and turned over and over specially from corners and sides. Mortar shall be ground not less
180 revolutions or for 3 hours minimum.
(c) Mortar for final coat of plaster: It shall be ground for a second time after an interval of 2
days for class C limes. For class B and Class A limes care shall be taken that the mortar is
reground immediately. In case the time of first grinding and in case of class B limes either

immediately or after a suitable interval provided that the mortar should be used within 2 days
from the preparation of putty or making of mortar as the case may be.
4.14.1.11 Storage of Lime mortar:
4.14.1.11 Lime mortars prepared from class A and class B limes shall be used up as soon as possible
after mixing but not later than 12 hours from the time of making putty or first grinding as the case may
be. Mortars from Class C limes can be used for periods longer than 3 days after the making of mortar
provided they are protected from drying out. After the close of each day's work, mixing through pans
shall be thoroughly washed and cleaned. Lime mortar shall be kept damp with wet sack or by any
other suitable means and shall on no account be allowed to dry.
Note: Addition of Surkhi or other Pozzolana in making of mortars gives the properties of
hydraulic mortars and should be treated like class A and class B lime mortars, depending upon
hydraulicity.
4.14.1.12 Rejection of Mortar:
Mortar not found in accordance with the Specifications above and unsuitable according to field and
laboratory tests of lime mortar shall be rejected. Rejected mortar shall be removed from the site of
work within 3 days by the contractor at his own cost.
4.14.1.13 Measurement :Stone lime mortar of stiff consistency shall be measured in cubic meters.
60 cm high stacks being measured as 50 cm to allow for looseness in stacking.
4.15 Composite Mortars:
4.15.0 Scope: This specification covers materials, proportions, preparations, storage and mode of
measurement of composite mortars.
4.15.1 Materials:
(a) Cement: Cement shall be Ordinary Portland Cement conforming to IS -269-1976 for 33
grade, IS -8112-1976 for 43 grade, IS - 12269-1987 for 53 grade & IS - 1489-1976 for PPC.
(b) Lime: Lime shall conform to IS - 712-2001.
(c) Sand: Sand shall conform to IS-1542-1992 for plaster work & IS-2116 -1980for Masonry
work.
(d) Surkhi : Surkhi shall conform to IS-3068-1986
4.15.2 Proportions: Cement, lime putty/dry hydrated lime and sand shall be taken in specified
proportions. Cement bag weighing 50 kg shall be taken as 0.035 cubic metre. Other ingredients in
specified proportion shall be measured using boxes of size 40 x35 x25 cm. Sand shall be measured on
the basis of its dry volume.
4.15.3 Preparation of Mortar: 4.15.3.1 Mixing and Grinding:

(a) Mechanical Mixing: Lime putty and Sand shall be mixed and ground in the manner described
earlier before mixing the same with cement. In case where factory made dry hydrated lime
powder is used, prior grinding of lime and sand is not necessary. In that case mixing may be done
in one operation in mechanical mixer. Only the quantity of this mixture which could be used
within two hours of its mixing with cement, shall be taken out and mixed thoroughly

with specified quantity of cement in mechanical mixer.
(b) Hand Mixing: Cement and sand shall be mixed dry thoroughly on clean and water tight masonry
platforms or in troughs. Lime putty shall be mixed with water to make milk of lime, which shall
be added to the mixture of cement and sand. The mixture shall be kneaded back and forth for
about 10 minutes with addition of milk of lime to obtain mortar of workable consistency.
4.15.4 Storage: Composite mortar shall be mixed only in such quantity, which can be used within 25
minutes from the moment cements is mixed wet. No mortar, which has begun to set, shall be used
and shall be removed from the site of work at contractors risk and cost.
4.15.5 Curing :
4.15.5 Work done with composite mortar shall be kept well wetted at least for first four days and
cured as for lime mortars for the remaining period.
4.15.6 Measurement: Composite mortar of stiff consistency shall be measured in cubic meters. 60
cm high stacks being measured as 50 cm to allow for looseness in stacking.

APPENDIX À'
DETERMINATION OF COMPRESSIVE STRENGTH OF MASONRY MORTAR
(IS 2250-1981)
A-l. Object:
A-1.1 To determine the compressive strength of the masonry mortars at 28 days..
A-2. Apparatus:
A-2.1 Scales: The scales used in weighing materials for mortar mixes shall conform to the following
requirements. On scales in use, the permissible variation at a load of 2000g shall be (+/-) 2.0g. The
permissible variation on new scales shall be one-half of this value. The sensibility reciprocal shall be
not greater than twice the permissible variation.
A-2.2 Specimen and Moulds: The test specimens shall be cubes ofsize 50 mm and shall conform to
the requirements given in A-2.2.1.
A-2.2.1 Cube Moulds: The moulds for the 50 mm cube specimen shall be metal not attacked by
cement, cement-pozzolana mixture or lime pozzolana mixture and there shall be sufficient strength
and stiffness to prevent spreading and warping. The moulds shall be rigidly constructed in such a
manner as to facilitate the removal of the moulded specimen without damage. The moulds shall be
machined so that when assembled ready for use, the dimensions and internal faces shall be accurate to
the following limits:
The height of the mould and the distance between the opposite faces shall be 50 mm. The angle
between adjacent interior faces and between interior faces and top and bottom planes of the mould
shall be 90 ± 0.5 degrees. The interior faces of the moulds shall be plane surfaces with a permissible
variation of 0.03 mm.Each mould shall be provided with a base plate having a plane surface machined
to a tolerance 0-10 mm and made of non-absorbent,non-corrodible and non-reactive material. The base
plate shall be of such dimensions as to support the mould during the filling without leakage.
The parts of the mould when assembled shall be positively held together, and suitable methods of
ensuring this, both during the filling and on subsequent removal of the filled mould, shall be provided in
order to prevent the moulded specimen from damage.
A-2.3 Mixing Apparatus: The mixing apparatus shall conform to the requirements specified in A-
2.3.1 and A-2.3.2.
A-2.3.1, Mixer - The mixer shall be an electrically driven mechanical mixer which shall consist
essentially of the following:
a) A stainless steel mixing bowl with a nominal capacity of 5 litreof the shape and dimensions as
shown in Fig. 1 and provided with means by which it can be securely fixed to the mixing frame
during mixing, and
b) A mixer blade of the form and dimensions shown in Fig. 2revolving about its is as it is
driven in a planetary movement around the bowl by an electric motor.
A-2.3.1.1 The two directions of rotation shall be opposite. The speed of rotation during mixing
shall be as follows:
a) Blade revolving about its own is 140 (+/-) 5 rev/min
b) Planetary movement 62 (+/-). 5 rev/min
NOTE - The above bowl and blade shall be used when the mass of the solid material including
putty is between 3 and 4.5 kg.

A-2.3.2 A plastic scraper.
A-2.4 Tamping Rod: A metal bar 25 mm square and 200 mm long.
A-2.5 Trowel : This shall have a steel blade 100 to 150 mm in length with straight edges. A-
2.6 Flow Table: The flow table shall be as given in IS : 5512-1969
A-3. Preparation of Moulds:
A-3.1 The interior faces of the specimen moulds shall be thinly covered with mineral oil or light cup
grease. After the moulds are assembled,excessive oil or grease shall be removed from the interior
faces and thetop and bottom surfaces of each mould. Moulds shall then be set onplane, non-absorbent
non-corrodible and non-reactive base plates that have been thinly coated with mineral oil,
petrolatum, or light cup grease.
A-4. Preparation of Mortar:
A-4.1 The mortar shall be of the materials and proportions intended fo ruse in the construction mixed
to give a flow of 110 to 115. The mixing procedure for sample made in the laboratory shall be as given
in A-4.2.1.
A-4.1.1 Trial Mixing - Trial mortars shall be made with specified proportion of dry ingredients and
adding different percentages of water will the specified flow is obtained. Each trial shall be made with
fresh mortars, The mixing shall be done mechanically as described in A-4.1.1.1 to A-4.1.1.5.
A-4.1.1.1 The mixing of the ingredients shall be carried out at a temperature of 27 ± 2°C and all
ingredients before mixing shall bebrought to the same temperature.
A-4.1.1.2 The dry ingredients shall then be placed in the mixing bowl and mixed for 30 seconds.
Over the next 30 seconds, while mixing,water shall be poured at a uniform rate into the bowl and
the mixing shall be continued for 60 seconds.
A-4.1.1.3 The mixer shall then be stopped and the paddle and sides of the bowl shall be cleaned
down in about 15 seconds with the plastic scraper. The bowl shall be covered with a damp cloth and
the mortar be allowed to stand for a period of 10 minutes.
*Specification for flow table for use in tests of hydraulic cements and pozzolanic materials. A-
4.1.1.4 The mortar shall then be remixed for 60 seconds.
A-4.1.1.5 When using lime putty, the procedure shall be as described above, except that the sand
and lime putty shall be premixed by hand or in the mixer until the lime appears to be uniformly
distributed.
A-4.2 Remixing of Mortars in the Laboratory - Samples of mortar received in the laboratory for
testing shall be examined for any leakage or evaporation and segregation or bleeding of the liquid. The
whole of the sample, with any liquid which has separated or has condensed inside the container, shall
be transferred as completely as possible to an impermeable working surface and remixed, using a
trowel, until it appears homogeneous.
A-4.2.1 The top of the flow table shall be carefully wiped clean,dried and the flow mould shall be
placed at the centre. A layer of mortar about 25 mm in thickness and mixed in accordance with A-
4.1.1shall be placed in the mould and tamped 20 times with the tamping rod.The tamping pressure
shall be just sufficient to ensure uniform filling of the mould. The mould shall then be filled to
overflow with mortar and tamped, as specified for the first layer. The mortar shall be cut off plane and
level with the top of the mould by drawing the straight edge of a trowel ( held perpendicular to

the mould) with a sawing motion across the top of the mould. The top of the table shall be wiped
cleanand dried, taking care to remove any water from around the edge of the flow mould. The mould
shall then be lifted away from the mortar and the flow table shall be immediately dropped through a
height of 12.5 mm, 25 times in 15 seconds. The flow is the resulting increase in average base diameter
of the mortar mass, measured on at least four diameters at approximately equispaced intervals
expressed as a percentage of the original base diameter.
A-5. Test Specimens:
A-5.1 Cubes- The mould as prepared under A-3.1 shall be filled with the mortar to about half height
and the layer compacted by tamping it with the tamping rod ( see A-2.4) in a uniform manner over
the mortar surface in such a way as to produce full compaction of the mortar with neither segregation
nor excessive laitance. The mould shall then be completely filled and the upper layer of the mortar
compacted in asimilar manner, after which the surface of the mortar shall be struck off plane and
level with the top of the mould, using a trowel (see A-2.5).
A-5.2 Curing and Storage of Test Specimens: The specimens shall be stored at a place free from
vibration, either in moist air at a temperature of 27 ± 2°C and relative humidity of not less than 90
percent or under damp sacks, matting or other suitable damp material covered completely with
polyethylene or other similar impervious sheeting, at a temperature of 27 +/- 2°C for 1 to 3 days,
depending on the early strength of the mortar, from the time of adding the water to the other
ingredients. The specimen shall then be marked for later identifications, removed from the moulds and
stored in clean water until the time of test.The temperature of the storage water shall be 27 +/-2°C.
NOTE - Lime mortar cubes may, however, be stored in the laboratory air at at emperature of 27 +/-
2°C for the entire curing period.
A-5.2.1 When cubes are made at site, records of the maximum and minimum air and water storage
temperature shall be kept during the period, using maximum and minimum thermometers or
continuous recording instruments. The cubes shall be sent to the testing laboratory when they are
not less than 3 days nor more than 7 days old, well packed in damp sand or in wet sacks, and when
necessary enclosed in polyethylene bag or sealed container, So that they arrive at the laboratory in a
damp condition not less than 24 h before the time of test. On arrival at the testing laboratory, the cubes
shall be stored in clean water maintained at a temperature of 27 +/- 2°C until the time of test.
A-5.3 Number of Specimens: Three or more specimens shall be made for each period of test
specified.
A-6. Procedure:
A-6.1 The specimen shall be tested immediately on removal from the curing water in which it has been
stored and while it is still in a wet condition. Any loose material shall be removed from the sides of
the specimen. The dimensions of the specimen shall be noted before testing.The bearing surfaces of
the testing machine shall be wiped clean and the specimen shall be placed in the machine in such a
manner that the load shall be applied to opposite sides of the cube as cast, that is, not to the top and
bottom.
A-6.2 The is of the cube shall be carefully aligned with the centre of thrust of steel plates bearing
the testing machine. No packing other than auxiliary steel plates shall be used between the faces of the
specimen and steel plates of the testing machine.

A-6.3 The load on the specimen shall be applied without shock and at a uniform rate of 2N/mm2 to
6N/mm2 per minute until failure occurs.A-6.4 The maximum load at failure shall be noted.
A-7. Calculation:
A-7.1 The compressive strength shall be calculated as follows:
Compressive strength (N/mm2) =Maximum load at failure (N)/Cross-sectional area (mm2 )
A-7.1.1 The individual results shall be calculated to the nearest 0.05 N/mm2.
A-8. Report:
A-8.1 The average of all the determinations shall be reported.
APPENDIX `B'
DETERMINATION OF CONSISTENCY OF MASONRY MORTAR
B-1. Object:
B-1.1 To determine the consistency of masonry mortar.
B-2. Apparatus:
B-2.1 This shall consist of a standard cone weighing 300 ± 2 g, 150 mm in height, and a diameter at a
base of 75 mm. The cone is mounted ona vertical shaft fastened to an adjustable holder. The holder
has a mechanism which releases the shaft. The apparatus has also an instrument dial which records the
depth of penetration of the cone into the mortar mix kept in a conical container below.
B-2.1.1 The conical container for mortar shall be 180 mm deep with a diameter at top of 1 5 0 . B-
2.2 Flow Table - This shall be as given in IS : 5512-1969*.
*Specification for flow table for use in tests of hydraulic cements and pozzolanic materials.
B-3. Procedure:
B-3.1 The conical container shall be filled with mortar mix -to a level that is 1 cm below its rim.
Mortar mix shall be placed in a conical mould in one continuous operation and shall be compacted by
tamping rod as given in A-2.4. The mould filled with mortar mix is bumped 5or 6 times over a flow
table so as to level the surface of the mortar. The container shall be placed over the base below the
penetration cone of the apparatus, as shown in Fig. 3. The apex of the penetrating cone shall be brought
first in contact with the surface of the mortar and the cone clamped in position. The instrument dial is set
to be in contact with acone at this position. The cone is then released and allowed to sink into the mortar
mix. After the cone has stopped penetrating into the mortar,the dial is once more set to record the
position of the cone and the difference between dial readings before and after penetration gives the depth
of penetration of the cone into the mortar.
B-3.1.1 The test shall be repeated on another sample of the mortar.
B-4. Report:
B-4.1 The average of the two determinations shall be reported as the consistency of the mortar.

B-5. Field Test:
B-5.1 For quick field determination, the procedure may be further simplified. The shaft of the cone
shall be held by hand in a perpendicular position so as to be in contact with the surface of the
mortarand gently released to sink into the mortar taking care that the shaft remains vertical during
penetration. The depth of penetration may be computed from the measurement of the wetted depth
along the surface of the cone.
APPENDIX `C'
DETERMINATION OF WATER RETENTIVITY OF MASONRY MORTAR
C-1. Object:
C-1.1 To determine the water retentivity characteristics of masonry mortar.
C-2. Apparatus:
C-2.1 Apparatus Assembly for theWater Retention Test - For the retention test, an apparatus
essentially the same as that shown in Fig. 4 shall be used. This apparatus consists of a water aspirator
or other source of vacuum controlled by a mercury column relief and connected by way of a three-
way stopcock to a funnel upon which rests a perforated dish. The perforated dish shall be made of
metal not attacked bymasonry mortars. The metal in the base of the dish shall have a thickness of 1.7
to 1.9 mm and shall conform to the outline shown Fig. 4. The bore of the stopcock shall have 4 mm
diameter, and the connecting glass tubing shall have a minimum inside diameter of 4 mm.A mercury
manometer, connected as shown in Fig. 4, indicates the vacuum. A synthetic rubber gasket shall be
permanently sealed to the top of the funnel and shall be lightly coated with petrolatum or light
cupgrease during the test to ensure a seal between the funnel and the dish.Care shall be taken to ensure
that none of the holes in the perforated dish is clogged from the grease used on the rubber gasket.
Hardened filter paper of a grade equivalent to Carl Schleicher & Schuell filter paperNo. 576 or to
Whatman No. 50 filter paper shall be used. It shall be ofsuch diameter that is will lie flat and
completely cover the bottom of the dish.
C-2.2 Straight Edge:- Steel straight edge should be not less than200 mm long, and not less than
1.5 mm nor more than 3 mm in thickness.
C-2.3 Other Apparatus:- Other apparatus required for the water retention test shall conform to the
requirements specified in Appendix D.
C-3. Procedure:
C-3.1 Adjust the mercury relief column so as to maintain a vacuum of 5 cm as measured on the
manometer. Seat the perforated dish on the greased gasket of the funnel. Place a wetted filter paper in
the bottom of the dish. Turn the stopcock to apply the vacuum to the funnel and check the apparatus
for leaks and to determine that the required suction is obtained. Then turn the stopcock to shut off the
vacuum from the funnel.
C-3.2 Mix the mortar to a consistency to give a flow of 110 to 115 (see 3.1). Immediately after
making, the flow test return the mortar on the flow table to the mixing bowl and remix the entire
batch for 15seconds at medium speed. Immediately after remixing of the mortar, fill the perforated
dish with the mortar to slightly above the rim. Tamp the mortar 15 times with the tamper. Ten of the

temping strokes shadl be applied at approximately uniform spacing adjacent to the rim of the dish and
with the long is of the tamping face held at right angles to the radius of the dish. The remaining five
tamping strokes shall be applied at random points distributed over the central area of the dish.The
tamping pressure shall be just sufficient to ensure filling of the dish. On completion of tamping, the top
of the mortar should extend slightly above the rim of the dish. Smooth off the mortar by drawing the flat
side of the straight edge (with the leading edge slightly raised) across the top of the dish.
INSTRUMENT DIAL
ADJUSTABLE HOLDER
PENETRATING
CONE
-CONICAL
CONTAINER
- PLATFORM

Then cut off the mortar to a plane surface flush with the rim of the dish by drawing the straight edge
with a sawing motion across the top of the dish in two cutting strokes, starting each cut from near the
centre of the dish. If the mortar is pulled away from the side of thedish during the process of drawing
the straight edge across the dish, gently press the mortar back into contact with the side of the dish
using the tamper.
C-3.3 Turn the stopcock to apply the vacuum to the funnel. The time elapsed from the start of mixing
the cement and water to the time of applying the vacuum shall not exceed 8 minutes. After suction for
60 seconds quickly turn the stopcock to expose the funnel to atmospheric pressure. Immediately slide
the perforated dish off from the funnel, touch it momentarily on a damp cloth to
remove droplets of water andset the dish on the table. Then, using the bowl scraper, flow and mix the
mortar in the dish for 15 seconds. Upon completion of mixing, place the mortar in the flow mould
and determine the flow. The entire operation shall be carried out without interruption and as quickly
as possible, and shall be completed within an elapsed time of 11 minutes after the start of mixing the
cement and water for the first flow determination.
C-4. Calculation:
C-4.1 Calculate the water retention value for the mortar as follows:
Water retention value=(A/B) X 100
where
A = flow after suction, and
B = flow immediately after mixing.
APPENDIX `D'
TEST FOR ORGANIC IMPURITIES
D-1: The aggregate must also be checked for organic impurities such as decayed vegetation humus,
coaldust etc.What is called the colour test is reliable indicator of the presence of harmful organic
matter in aggregate, except in the area where there are deposits of lignite.
D-2: Fill a 350 ml clear glass medicine bottle up to 70 ml mark with a 3% solution of caustic soda
or Sodium hydroxide. The sand is next added gradually until the volume measured by the sandy
layer is 125 ml. The volume is then made upto 200 ml by addition of more of solution. The bottle is
then Stoppard and shaken vigorously and allowed to stand for 24 hours. At the end of this period, the
colour of the liquid will indicate whether the sand contains a dangerous amount of matter. A
colourless liquid indicates a clean sand free from organic matter. A straw coloured solution indicates
some organic matter but not enough to be seriously objectionable. Darker colour means that the sand
contains injurious amounts and should not be used unless it is washed, and a retest shows that it is
satisfactory.
D-3: Add 2.5 ml of two per cent solution of tannic acid in 10 per cent alcohol, to 97.5 ml of three
per cent Sodium hydroxide solution. Place in a 350 ml bottle, fix the stopper, shake vigorously and
allow to stand for 24 hours before comparison with the solution above the sand.
Note: A three percent solution of caustic soda is made by dissolving 3 g of sodium hydroxide in 100
ml of water, preferably distilled. The solution should be kept in a glass of bottle tightly closed with a
rubber stopper. Handling Sodium hydroxide with moist hands may result in serious burns. Care should
be taken not to spill the solution for it is highly injurious to clothing, leather, and other materials.

APPENDIX È'
TEST FOR PARTICLE SIZE (SIEVE ANALYSIS)
E-1:Apparatus: Perforated plate sieves of designation 10 mm, 4.75 mm and fine mesh sieve of
designation2.36 mm,1.18 mm, 600 micron, 300 micron and 150 micron should be used.The balance
or scale shall be such that it is readable and accurate to 0.1 per cent of the weight of the test sample.
E-2: Sample: The weight of sample available shall not be less than the weight given in the table
below. Thesample of sieving shall be prepared from the larger sample either by quartering or by
means of a sample divider.
Table- Showing Minimum Weights for Sampling
Maximum size present in substantial Minimum weight of sample
proportions (mm) for sieving (Kg)
10 0.5
4.75 0.2
2.36 0.1
E-3: Test Procedure: The sample shall be brought to an air-dry condition before weighing and
sieving. This may be achieved either by drying at room temperature or by heating at a temperature of
100 degree to 110 degree centigrade. The air dry sample shall be weighed and sieved successively on
the appropriate sieves starting with the largest. Care shall be taken to ensure that the sieves are clean
before use.
E-4: Each sieve shall be shaken separately over a clean tray until not more than a trace passes, but
in any case for a period of not less than two minutes. The shaking shall be done with a varied
motion,backwards and forwards, left to right, circular clockwise and anti-clockwise, and with frequent
jarring, so that the material is kept moving over the sieve surface in frequently changing directions.
Materials shall not be forced through the sieve by hand pressure, but on sieves coarser than 20 mm,
placing of particles over the sieve apertures is permitted.
E-5: Lumps of fine material, if present may be broken by gentle pressure with fingers against the
side of the sieve. Light brushing of underside of the sieve with a soft brush may be used to clear the
sieve openings. Light brushing with a fine camel hair brush may be used on the 150 micron IS sieve
to prevent segregation of powder and blinding of apertures. Stiff or worn out brushes shall not be
used for this purpose and pressure shall not be applied to the surface of the sieve to force particles
through the mesh. On completion of sieving the material retained on each sieve, together with any
material cleaned from the mesh, shall be weighed.
Reporting of Results: The results shall be calculated and reported as:
(a) The cumulative percentage by weight of the total sample passing each of the sieves, to the
nearest whole number:or
(b) The percentage by weight of the total sample passing one sieve and retained on the next
smaller sieve, to the nearest 0.1 percent.

APPENDIX `F'
TEST FOR SILT CONTENT
F-1: The sand shall not contain more than 8% of silt as determined by field test with measuring
cylinder. The method of determining silt contents by field test is given below:
A sample of sand to be tested shall be placed without drying in a 200 ml measuring cylinder. The
volume of the sample shall be such that it fills the cylinder upto 100 ml mark. Clean water shall
be added upto 150 ml mark. Dissolve a little salt in the water in the proportion one tea spoon
to half a litre. The mixture shall be shaken vigorously, the last few shakes being sidewise direction
to level off the sand and the contents allowed to settle for three hours. The height of the silt visible
as settled layer above the sand shall be expressed as a percentage of the height of sand below.
The sand containing more than the above allowable percentage of silt, shall be washed so as to
bring the silt contents within allowable limits.
APPENDIX `G'
BULKING OF FINE AGGREGATES/SAND (FIELD METHODS)
G-1: Two methods are suggested for determining the bulking of sand/fine aggregate. The procedure
may be suitably varied, if necessary. Both depend on the fact that the volume of inundated sand/fine
aggregate is the same if the sand/fine aggregate were dry.
G-2: Method -1: Put sufficient quantity of sand loosely into a container until it is about two-third
full. Level off the top of the sand and push a steel rule vertically down through the sand at the middle
to bottom,measure the height. Suppose this is `X' cm.
G-3: Empty the sand out of the container into another container where none of it is lost. Half fill the
first container with water. Put back about half the sand and rod it with a steel rod, about 6 mm in
diameter, so that its volume is reduced to a minimum. Then add the remainder and level the top
surface of the inundated sand. Measure its depth at the middle with the steel rule. Suppose this is `Y'
cm.
The percentage of bulking of the sand due to moisture shall be calculated from the formula:
Percentage bulking = (X/Y -1) X 100.
G-4: Method-2: In a 250 ml measuring cylinder, pour the damp sand, consolidate it by staking until
it reached the 200 ml mark. Then fill the cylinder with the water and stir the sand well (the water
shall be sufficient to submerge the sand completely). It will be seen that the sand surface is now
below its original level. Suppose the surface is at the mark of Yml, the percentage of bulking of sand
due to moisture shall be calculated from the formula.
Percentage bulking = (200/Y - 1) x 100

APPENDIX `H'
PHYSICAL REQUIREMENTS OF FLY ASH
Requirement of Fly Ash
S. Characteristics For use as
No. For use as admixture
Pozzolana in Cement Mortar
and concrete
1. 2. 3. 4.
(i) Fineness- Specific surface in m2/kgby 320 200
Blaine'spermeability method, min
(ii) Lime reactivity - average compressive 4.5 -
strength i / = 2 Min
(iii) Compressive strength at 28 days in Not less than 80 -
NI mm2 per cent of the
strength of
corresponding to
mortar cubes.
(iv) Soundness of autoclave test expansion 0.8 0.8
of specimens, per cent, max
(v) Particles retained on 45 micron IS 35 40
sieve (wetsieving) in percent maximum

S.No. IS Code No. Subject
1. 269-1989 Specification for 33 grade Ordinary Portland cement.
2. 383-1997 Specification for coarse and fine aggregate from natural source
for concrete.
3. 455-1989 Specification for Portland slag cement.
4. 456-2000 Plain and Reinforced Concrete.
5. 460 (Part I) Specification for test sieves: wire cloth test sieves.
6. 650-1991 Specification for standard sand for testing of cement.
7. 12269-1987 Specification for 53 grade Ordinary Portland cement.
8. 1344-1981 Specification for Calcined clay Pozzolana.
9. 1489 (P-1, II)- Specification for Portland Pozzolana Cement (fly ash based
1976/1991 and Calcined clay based).
10. 1542-1992 Specification for sand for plaster.
11. 1727-1967 Methods of Test for Pozzolanic materials.
12. 2116-1980 Specification for sand for masonry mortar.
13. 2250-1981 Code of practice for preparation and use of Masonry Mortar.

S.No. IS Code No. Subject
14. 2386 (Pt-I)1963 Method of test for aggregate for concrete (Particle size and shape).
15. 2386 (Pt-II)-1963 -Do- Estimation of deleterious materials and organic impurities.
16. 2386 (Pt-III)-1963 -Do- Specific gravity, density, voids, absorption and bulking.
17. 3025(P-22, 23)-1986 Method of sampling and test for water
18. 3466-1967 Specification for masonry cement.
19. 3812 (P I)-1981 Specification for fly ash for use as pozzolana in cement mortar
and concrete
20. 3812 (P II)-1981 Specification for fly ash for use as admixture in cement mortar/
concrete.
21. 4031 (Part I) to Method of Physical test for hydraulic cement
(Part XIII)-1996
22. 4032-1968 Method of chemical analysis of Hydraulic cement.
23. 4305-1967 Glossary of terms relating to pozzolana.
24. 6508-1988 Glossary of terms relating to building limes.
25. 8041-1978 Rapid hardening Portland cement.
26. 8042-1978 Specification for white cement.
27. 8043-1978 Hydrophobic Portland Cement
28. 8112-1976 Specification for 43 grade Ordinary Portland Cement
29. 12269-1987 Specifications for 53 grade cement
30. 12330-1988 Sulphate resisting Portland cement .
31. 12600-1989 Low heat Portland cement.
CHAPTER No. 5
PLAIN CEMENT CONCRETE

CHAPTER No-5 : PLAIN CEMENT CONCRETE
CONTENTS
Clause No. Brief Description Page No.
5.0 Scope 3
5.1 Materials. 3
5.2 Chemical Admixtures. 10
5.3 Cement Concrete. 11
5.4 Construction Joints 26
5.5 Concreting under Special Conditions. 27
5.6 Curing 27
5.7 Raising masonry over Concrete. 28
5.8 Testing of Concrete. 28
5.9 Formwork. 28
5.10 Finishes 28
5.11 Durability of Concrete. 28
5.12 Ready Mixed Concrete 33
5.13 Measurement 53
5.14 Rate. 55
5.15 Damp Proof Course. 55
5.16 Cement Fly Ash Concrete 56
Appendix 'A': List of Mandatory Tests. 58
Appendix Cube test for compressive strength of concrete. 59
Appendix `C': Concrete mix information 61
to be supplied by the purchaser.
Appendix `D' : Determination of particle size. 62
Appendix È' :Test for surface moisture. 63
Appendix F : Determination of Ten percent Fines value 63
Appendix `G' : Nominal Mix Concrete 65
Appendix `H' :Workability of Concrete. 68
Appendix Ì' : Immersion Vibrators. 73
Appendix : Illustrative example on concrete mix proportioning.. 74
Appendix `K' Guide lines for Self compacting concrete. 78
List of relevant BIS codes 78
Rajasthan PWD Building Specifications 2014 Chapter 5 : Plain Cement Concrete Page 1 of 80
CHAPTER No. 5
PLAIN CEMENT CONCRETE
5.0 Scope:
This specification cover the proportioning, mixing, placing and other requirement of Plain Cement
Concrete in building construction.
5.1 Materials:
a) Aggregate (coarse and fine sand, crusher dust), Water, cement, surkhi and fly ash are the main
constituents of plain concrete, these should conform to the specifications as detailed in Chapter
3- Building Materials. Concrete should conform to IS: 456-2000 and the admixtures should
conform to IS::9103-1959 (Reaffirmed 1999).
b) Other types of aggregates such as slag and crushed overbumt brick or tile, which may be found
suitable with regard to strength, durability of concrete and freedom from harmful effects may be
used for plain concrete members. but such aggregates should not contain more than 0.5 percent
of sulphates as SO3 and should not absorb more than 10 percent of their own mass of water.
c) Heavy weight aggregates or light weight aggregates such as bloated clay aggregates and
sintered fly ash aggregates may also be used provided the Engineer-in-charge is satisfied with
the data on the properties of concrete made with them.
5.1.1 Coarse Aggregate:
(i) General: Aggregate, most of which is retained on 4.75 mm IS Sieve and contains only as much
fine material as is permitted in IS: 383-1970 ( Reaffirmed 2002) for various sizes and grading
is known as coarse aggregate. Coarse aggregate shall be specified as stone aggregate, gravel or
brick aggregate and it shall be obtained from approved/ authorized sources.
(ii) The nominal maximum size of coarse aggregate should be as large as possible within the limits
specified but in no case greater than one-fourth of the minimum thickness of the member, provided
that the concrete can be placed without difficulty so as to surround all reinforcement thoroughly
and fill the corners of the form. For most work, 20 mm aggregate is suitable. Where there is no
restriction to the flow of concrete into sections, 40 mm or larger size may be permitted. In
concrete elements with thin sections, closely spaced reinforcement or small cover,
consideration should be given to the use of 10 mm nominal maximum size. Plums above 160
mm and up to any reasonable size may be used in plain concrete work up to a maximum limit
of 20 percent by volume of concrete when specifically permitted by the Engineer-in-charge.
The plums shall be distributed evenly and shall be not closer than 150 mm from the surface.
(iii) Coarse and fine aggregate shall be batched separately. All in aggregate may be used only
where specifically permitted by the Engineer-in-charge.
(iv) Stone Aggregate: It shall consist of naturally occurring (uncrushed, crushed or broken) stones.
It shall be hard, strong, dense, durable and clean. It shall be free from veins, adherent coating,
injurious amounts of disintegrated pieces, alkali, vegetable matter and other deleterious
substances. It shall be roughly cubical in shape. Flaky and elongated pieces shall be avoided. It
shall conform to IS: 383-1970 unless otherwise specified.
(v) Gravel: It shall consist of naturally occurring (uncrushed, crushed or broken) river bed shingle
or pit gravel. It shall be sound, hard and clean. It shall be free from flat particles of shale or
similar laminated material, powdered clay, silt, loam, adherent coatings, alkali, vegetable
matter and other deleterious substances. Pit gravel shall be washed, if it contains soil materials
adhering to it. These shall conform to IS: 383-1970 unless otherwise specified.
Brick Aggregate: Brick aggregate shall be obtained by breaking well burnt or over burnt dense
brick/ brick bats. They shall be homogeneous in texture, roughly cubical in shape and clean. They
shall be free from unburnt clay particles. Soluble salt, silt, adherent coating of soil, vegetable
matter and other deleterious substances. Such aggregate should not contain more than one
percent of sulphates and should not absorb more than 10% of their own mass of water, when
used in cement concrete. It shall conform to IS: 3068-1986 ( reaffirmed 2000) unless otherwise
specified.
(vii) Light weight aggregate : Such as sintered fly ash aggregate may also be used provided the
Engineer-in-Charge is satisfied with the data on the proportion of concrete made with them.
5.1.1.1 Deleterious Material: Coarse aggregate shall not contain any deleterious material, such as
Pyrites, Coal, Lignite, Mica, Shale or similar laminated material, Clay, Alkali, soft fragments, sea shells
and organic impurities in such quantity as to adversely affect the strength or durability of the
concrete. Coarse aggregate to be used for reinforced Cement concrete shall not contain any material
likely to attack the steel reinforcement. Aggregates which are chemically reactive with alkalis of
cement shall not be used. The maximum quantity of deleterious material shall not be more than five
percent of the weight of coarse aggregate when determined in accordance with IS: 2386 (P-III)-
1963.
5.1.1.2 Size and Grading:
(a) Stone aggregate and Gravel: It shall be either graded or single sized as specified. Nominal size
and grading shall be as under:-
(i) Nominal sizes of graded stone aggregate or gravel shall be 40, 20, 16, or 12.5 mm as
specified. For any one of the nominal sizes, the proportion of other sizes as determined by
the method prescribed in Appendix `D' shall be in accordance with Table 1.
Table -1: Graded Stone Aggregate or Gravel
Percentage passing (by weight) for nominal size of
IS Sieve
80 mm 100 - - -
63mm - - - -
40 mm 95 to 100 100 - -
20 mm 30 to 70 95 to 100 100 100
Percentage passing (by weight) for nominal size of
IS Sieve
16 mm - - 90 to 100 -
12.5 mm - - - 90 to 100
10 mm 10 to 35 25to 55 30 to 70 40 to 85
4.75mm Oto5 Oto10 Oto10 Oto10
(ii) N o n e sizes of single sized stone aggregate or gravel shall be 63, 40, 20, 16, 12.5 or
10 mm as specified. For any one of the nominal size, the proportion of other sizes as
determined by the method prescribed in Appendix `D' shall be in accordance with Table
2.
Table -2 : Single Sized (Ungraded) Stone Aggregate or Gravel

Percenta (by weight) for
IS Sieve ge nom
Designation 63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
passing inal
80 mm 100 - - - -size of -
63 mm 85-100 100 - - - -
40 mm 0-30 85-100 100 - - -
20 mm 0- 5 0-20 85-100 100 - -
16 mm - - - 85-100 100 -
12.5 mm - - - - 85-100 100
10 mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75 mm - - 0-5 0-5 0-10 0-20
2.36 mm - - - - - 0-5
(iii) When stone aggregate or gravel brought to site is single sized (ungraded), it shall be
mixed with single sized aggregate of different sizes in the proportion to be determined by
field tests to obtain graded aggregate of specified nominal size. For the required
nominal size, the proportion of other sizes in mixed aggregate as determined by method
prescribed in Appendix `D' shall be in accordance with Table 1. Recommended
proportions by volume for mixing of different sizes of single size (ungraded) aggregate
to obtain the required nominal size of graded aggregate are given in Table 3.
Table -3 : Single Sized (Ungraded) Stone Aggregate Or Gravel
Cement Parts size of size
Nominal size of of aggregat
concrete graded aggregate 50 mm 40 mm 20 mm 12.5 mm 10 mm
single e
required
1 2 3 4 5 6 7
1:6:12 63 9 - 3 - -
1:6:12 40 - 9 3 - -
1:5:10 63 7.5 - 2.5 - -
1:5:10 40 - 7.5 2.5 - -
1:4:8 63 6 - 2 - -
1:4:8 40 - 6 2 - -
1:3:6 63 4.5 - 1.5 - -
1:3:6 40 - 4.5 1.5 - -
1:3:6 20 - - 4.5 - 1.5
1:2:4 40 - 2.5 1 - 1.5
1:2:4 20 - - 3 - 1
1:2:4 12.5 - - - 3 1
1:11/2:3 20 0 0 2 - 1
Note: The proportions indicated in Table 3 above are by volume , when considered necessary, these
proportions may be varied marginally by Engineer-in-Charge after making sieve analysis of aggregate
brought to site for obtaining required graded aggregate. No adjustments in rate shall be made for any
variation in the proportions so ordered by the Engineer-in-Charge. If single size coarse aggregate
are not premixed at site to obtain the graded coarse aggregate required for the mix, the volume of
single size aggregates required for the mix shall be suitably increased to account for reduction in
total volume at the site of mixing.
5.1.1.3 Brick Aggregate: Nominal size of brick aggregate shall be 40 mm and its grading shall be as
specified in Table 4 when tested for sieve analysis for the method prescribed in Appendix `D'.
Table -4 : Brick Aggregate
IS Sieve Designation Percentage passing (by weight)
75 mm 100
37.5 mm 95-100
20.0 mm 45-100
4.75 mm 0.50
5.1.1.4 Testing: Coarse aggregate shall be tested for the following (as per IS 2386-1963, Parts 1-7).
Test procedures as per Appendix `D' to `F'.
(a) Determination of particle size and shape (Appendix `D') : Part 1
(b) Estimation of organic impurities (Part 2)
Estimation of Specific Gravity, Density, Voids, Absorption, and Bulking (Part 3)
Estimation of Mechanical Properties ( Part 4)
Estimation of Soundness ( Part 5)
Estimation of Mortar making properties of Fine aggregate. ( part 6)
Estimation of Alkali Aggregate Reactivity (P-7)
5.1.1.5 Coarse and fine aggregate shall be batched separately. All-in-aggregate may be used only
where specifically permitted by the Engineer-in-charge.
5.1.2 Water :
Water used for mixing and curing shall be clean and free from injurious amounts of oils, Acids,
Alkalis, Salts, Sugar, organic materials or other substances that may be deleterious to concrete or
steel. Potable water is generally considered satisfactory for mixing and curing of concrete. As a
guide the following concentrations represent the maximum permissible values:
a) To neutralize 100 ml sample of water, using phenolphthalein as an indicator, it should not
require more than 5 ml of 0.02 normal NaOH. The details of test are given in IS: 3025 (Part 22)-
1986.
b) To neutralize 100 ml sample of water, using mixed indicator, it should not require more than
25 ml of 0.02 normal H2SO4. The details of test shall be as given in IS: 3025 (Part 23) - 1986.
Permissible limits for solids shall be as given in Table 5. In case of doubt regarding development
of strength, the suitability of water for making concrete shall be ascertained by the compressive
strength and initial setting time tests specified in IS: 516-1959 (1999), and IS 4031 (Part 5)-
1996, respectively.
Table 5: Permissible limits for solids in water.

S. No. Tested as per Permissible Limits-Max.
i) Organic IS 3025-(P 18) - 1984 200 mg/1
ii) Inorganic IS 3025-(P-18) - 1984 3000 mg/1
iii) Sulphates as SO, IS 3025-(P-24) - 1986 400 mg/1
iv) Chlorides as Cl IS 3025-(P-32) - 1988 2000 mg/1, for plain CC,
500 mg/1 for CC, Containing
steel reinforcement.
v) Suspended matter IS 3025-(Part-17) - 1984 2000 mg/1
The sample of water taken for testing shall represent the water proposed to be used for
concreting, due account being paid to seasonal variation. The sample shall not receive any
treatment before testing other than that envisaged in the regular supply of water proposed for use
in concrete. The sample shall be stored in a clean container previously rinsed out with similar
water.
d) Average 28 days compressive strength of at least three 150 mm concrete cubes prepared with
water proposed to be used shall not be less than 90 percent of the average of strength of three
similar concrete cubes prepared with distilled water. The cubes shall be prepared, cured and
tested in accordance with the requirements of IS: 516-1959 (1999).
e) The initial setting time of test block made with the appropriate cement and the water proposed to
be used shall not be less than 30 min and shall not differ by ± 30 minute from the initial setting
time of control test block prepared with the same cement and distilled water. The test blocks shall
be prepared and tested in accordance with the requirements of IS 4031 (Part 5)-1988.
The pH value of water shall generally be not less than 6.
Water found satisfactory for mixing is also suitable for curing Concrete. However, it should
not contain Tanic acid or Iron compounds and should not produce any objectionable stain or
unsightly deposit on the Concrete surface.
5.1.3 Fine Aggregate:
a) Aggregate most of which passes through 4.75 mm IS Sieve is known as fine aggregate. Fine
aggregates shall consist of natural sand, crushed stone dust or crushed gravel, sand stone dust or
marble dust, fly ash and Surkhi (crushed brick and cinder) conforming to IS:2686-1977
(Reaffirmed 2009). It shall be hard, durable, chemically inert, clear and free from adherent
coatings, organic matter etc. and shall not contain any appreciable amount of clay balls, pellets
and harmful impurities e.g. Iron pyrites, Alkali, Coal, Salts, Mica, Shale or similar laminated
materials in such form or in such quantities as to cause corrosion of metal or affect adversely the
hardening, the strength, the durability or the appearance of mortar, plaster or concrete, the sum
of the percentages of all deleterious materials shall not exceed 5%. Fine aggregate must be
checked for organic impurities such as decayed vegetation humps, coal dust etc.
b) Silt Content: The maximum quality of silt in sand shall not exceed 5%. Fine aggregate
containing more than allowable percentage of silt shall be washed so as to bring the silt content
within allowable limits for which nothing extra shall be paid.
c) Grading: On the basis of particle size, fine aggregate is graded into four zones. The grading
when determined in accordance with the prescribed procedure shall be within the limits given in
Table 6 below. Where the grading falls outside the limits of any particular grading zone of sieves,
other than 600 micron IS sieve, by a total amount not exceeding 5 %, it shall be regarded as
falling in that grading zone.
Table 6 -Grading of Fine Aggregate
Percentage passing for.
IS Sieve
Designation Grading I. Grading II. Grading III. Grading IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600--Micron 15-34 35-59 60-79 80-100
300--Micron 5-20 8-30 12-40 15-50
150--Micron 0-10 0-10 0-10 0-15
Note 1 :- For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 %.
This does not affect the 5% allowance permitted in applying to other sieves.
Note 2 :- Allowances of 5% permitted, can split up, for example it could be 1% on each of
three sieves and 2% on another or 4% on one sieve and 1% on another.
Note 3 :- Fine aggregate conforming to Grading Zone IV shall not be used in reinforced cement
concrete unless test have been made to ascertain the suitability of proposed mix
proportions.
(d) Type and grading of fine aggregate to be used shall be specified. It shall be coarse sand, fine
sand, stone dust or marble dust, fly ash and surkhi. Use of sea sand shall not be allowed, unless
(i) Coarse sand shall be either river sand or pit sand or combination of the two. It shall be
clear, sharp angular, gritty to touch and composed of hard siliceous material. Its grading
shall fall within the limits of grading Zone I, II, III of Table 6.
(ii) Fine sand shall be either river sand or pit sand or combination of the two, its grading shall
fall within the limits of Grading Zone IV of Table 6. As a guideline, fine sand conforming
to grading Zone IV can be generally obtained
(iii) Stone dust shall be obtained by crushing hard stones or gravel. Its grading shall fall
within the limits of grading Zone I, II or III of Table 6.
(iv) Marble dust shall be obtained by crushing marble. Its grading shall fall within the limits
of Grading zone IV of Table 6.
(v) Sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a
combination of any of these. Sand shall be hard, durable, clean and free from adherent
coatings and organic matter and shall not contain the amount of clay, silt and fine dust
more than specified as under.
5.1.3.1 Deleterious Material: Sand shall not contain any harmful impurities such as Iron, Pyrites,
Alkalis, Salts, Coal or other organic impurities, Mica, Shale or similar laminated materials, soft
fragments, sea shale in such form or in such quantities as to affect adversely the hardening strength or
durability of the Concrete.
i) The maximum quantities of Clay, Fine silt, Fine dust and organic impurities in the Sand shall
not exceed the following limits. Clay, Fine silt and Fine dust shall be determined in accordance
with 1S:2386 (Part II) -1963 ( Reaffirmed 2002)
ii) In natural Sand or crushed Gravel and crushed stone sand, not more than 5% by mass.
iii) Organic impurities when determined in accordance with 1S:2386 (Part II) -1963, Colour of
the liquid shall be lighter than that indicated by the standard specified in IS: 2386 (Part II)-
1963
5.1.4 Cement :
5.1.4.1 Scope : This specification covers use of various types of Cement for Concrete,
5.1.4.2. Unless otherwise specified Cement shall conform to following Indian Standard
Specifications.
(i) 33 Grade ordinary Portland Cement conforming to IS: 269-1989-1976. Refer clause 3.6.2.1
of Chapter 3, "Building materials".
(ii) 43 Grade ordinary Portland Cement conforming to IS: 8112-1989. -do- clause 3.6.2.4
(iii) 53 Grade ordinary Portland Cement conforming to IS: 12269-2013. -do- clause 3.6.2.5
(iii.) Rapid hardening Portland Cement conforming to IS: 8041-1990. -do- clause 3.6.2.6
(iv.) Portland slag Cement conforming to IS: 455-1989
(v.) Portland Pozzolana Cement (fly ash based) conforming to IS: 1489 (Part 1)-1991.Refer
Clause 3.6.2.10 of Chapter 3 "Building Materials".
(vi.) Portland Pozzolana Cement (Calcined clay based) conforming to IS: 1489 (Part-2)-1991-do-
3.6.2.11
(vii.) Hydrophobic Cement conforming to IS: 8043-1978
(viii) Low heat Portland Cement conforming to IS: 12600-1989 (Reaffirmed2009)
(ix.) Sulphate resisting Portland Cement conforming to IS: 12330-1988 (Reaffirmed2009)
5.1.4.3. Different types of Cement shall not be used in the same work or mixed together at a time, in
case more than one type of cement is used in a work, a record shall be kept showing the location and
type of cement used.
5.2 Chemical Admixtures:
i) When required, admixtures of approved quality shall be mixed with concrete with the approval
of the Engineer-in-Charge (to accelerate or to retard the setting time), as specified. The
admixtures shall conform to IS: 9103-1959 (Reaffirmation 1999).
ii) Admixture. if used shall comply with IS 9103. Previous experience with and data such
materials should be considered in relation to the likely standards of supervision and workmanship
to the work being specified.
iii) Admixtures should not impair durability. (If concrete nor combine with the constituent to
form harmful compounds nor increase the risk of corrosion of reinforcement.
iv) The workability, compressive strength and the slump loss of concrete with and without the
use of admixtures shall be established during the trial mixes before use of admixtures.
v) The relative density of liquid admixtures shall he checked for each drum containing
admixtures and compared with the specified value before acceptance.
vi) The chloride content of admixtures shall be independently tested for each batch before
acceptance.
5.2.1 Type of admixtures: Admixtures maybe any one of the following classes for use in concrete:-
Water Reducing Admixtures
Retarding Admixtures
Accelerating Admixtures.
Water Reducing and Retarding Admixtures.
Water Reducing and Accelerating Admixtures.
Permeability Reducing (water proofing) Admixtures.
5.2.2 Liquid admixtures: Admixtures introduced into the concrete as liquids generally fall into the
following categories.
(a) Air Entraining.
(b) Water Reducing.
Water Reducing Retarders.
Retarders.
Water Reducing Accelerators.
Accelerators.
5.2.3 Recommendation for dosage:
(a) Dosage of these admixtures may vary according to manufacturer's specification.
(b) Two or more admixtures may not be compatible in the same solution. It is therefore mandatory
that when two admixtures manufactured by the same manufacturer are being used
simultaneously, the manufacturer shall certify their compatibility. In case the two or more
admixtures are produced by different manufacturers, then, before their use in concrete, test
shall be performed by the manufacturer to establish their compatibility, all such test reports
shall be furnished to the Engineer-in-Charge for his approval before their use in concrete.
(c) Some admixtures may be in the form of powder, particle or high concentration liquids which
may require mixing with water prior to dosing. Under these conditions water (suitable for
concrete) in solution shall be considered as part of total water content in the batch in order to
maintain the water-cement ratio.
(d) For mixing of Admixture, manufacturer's recommendation shall be carefully followed so as to
ensure complete solubility of the product or to prepare a standard solution of uniform strength
for easier use.
(e) Certain admixtures may contain significant amounts of finely divided insoluble materials or
active ingredients which may or may not be readily soluble. It is essential for such admixtures
that precautions be taken to ensure that these constituents be kept in a state of uniform
suspension before actual batching. When relatively small amounts of powdered admixtures are
to be used directly, these shall be pre-blended with Cement.
(f) Admixtures are sold under various trade names and may be in the form of liquids or powders.
The proprietary name and the net quantity of content shall be clearly indicated in each package
or container of admixtures. The mixing of admixtures shall be uniform within each batch and
uniform between all batches.
(g) No admixtures shall be accepted for use in concrete unless these are tested in accordance with
IS: 9103-1959 (reaffirmed 1999) and the test results are approved by the Engineer-in-Charge.
5.3 Cement Concrete:
5.3.1 Grades of Cement Concrete : The Cement Concrete shall be in grades designated as per
Table 7.
a) The characteristic compressive strength is defined as the strength of material below which
not more than 5 percent of the test results are expected to fall.
b) The minimum grade of Concrete for plain and reinforced Concrete shall be as per Table 8.
c) Concrete of grades lower than those given in Table-8 may be used for lean Concrete ,
foundations for masonry walls and temporary reinforced Concrete construction.
d) Properties of Concrete- Increase of Strength with Age : There is normally a gain of strength
beyond 28 days. The quantum of increase depends upon the grade and type of Cement, curing
and environmental conditions, etc. The design should be based on 28 days characteristic strength
of Concrete unless there is an evidence to justify a higher strength for a particular structure
due to age.
e) For Concrete of grade M 30 and above, the rate of increase of compressive strength with age
shall be based on actual investigations.
f) Where members are subjected to lower direct load during construction, they should be
checked for stresses resulting from combination of direct load and bending during
construction.
Table-7 : Grades of Concrete
Group Grade
Specified characteristic compressive strength of
Designation
150 mm size cube at 28 Days in
N/mm2
1 2 3
Ordinary M10 10
Concrete M15 15
M20 20
Standard M25 25
Concrete M30 30
M35 35
M40 40
M45 45
M50 50
M55 55
High Strength M60 60
Concrete M65 65
M70 70
M75 75
M80 80
Notes : 1. In the designation of concrete mix M refers to the mix and the number to the specified
compressive strength of 150 mm size cube at 28 days, expressed in N/mm2.
2. For concrete of compressive strength greater than M55, design parameters given in the
standard may not be applicable and the values may be obtained from specialized literatures
and experimental results.
3. Concrete of grades lower than those given in Table 7 ( such as M 5 and M 7.5) maybe used
for lean concrete, in foundation for masonry walls or temporary reinforced cement concrete
construction with due approval of the Engineer-in-Charge.
5.3.1.1 Characteristic Strength: The characteristic strength of concrete is defined as the strength
below which not more than 5 percent of the test results are expected to fall.
Table 8 : Minimum Cement Content, Maximum Water-Cement Ratio and Minimum
Grade of Concrete for Different Exposures with Normal Weight Aggregates
of 20 mm Nominal/ Maximum Size.
S1. Exposure
Plain Concrete Reinforced Concrete
No.
Mnimum Maximum Minimum Mimmum Maximum Mimmum
Cement Free Water Grade of Cement Free Water Grade of
Content Cement Concrete Content Cement Concrete
kg/m 3 Ratio kg/m3 Ratio
1 2 3 4 5 6 7 8
(i) Mild 220 0.60 - 300 0.55 M20
(ii) Moderate 240 0.60 M15 300 0.50 M25
(iii) Severe 250 0.50 M20 320 0.45 M30
(iv) Very Severe 260 0.45 M20 340 0.45 M35
(v) Extreme 280 0.40 M25 360 0.40 M40
Notes: 1. Cement content prescribed in this Table is irrespective of the grades of cement. The additions
such as fly or ground granulated blast furnace slag may be taken into account in the concrete
composition with respect to the cement content and water-cement ratio, if the suitability is
established and as long as the maximum amounts taken into account do not exceed the limit of
Pozzolana and Slag specified in IS: 1489 (Part 1) -1991 and IS: 455-1989 respectively.
2. Minimum grade for plain concrete under mild exposure condition is not specified.
3. The above minimum cement content and maximum water cement ratio apply only to 20 mm
nominal / maximum size aggregate. For other sizes of aggregate, these should be changed as per
Table 9.
Table -9 : Adjustments to Minimum Cement Contents for Aggregates
other than 20 mm Nominal Minimum Size
S. No.
Nominal Maximum Aggregate Size, Adjustments to Minimum Cement
mm Contents in Table- 8 (kg/cum)
(i) 10 +40
(ii) 20 0
(iii) 40 -30
The minimum grade of concrete for plain and reinforced concrete shall be as per Table 8 above.
5.3.1.2 Workability of concrete: Refer Appendix `H'
53.1.3 Concrete mix proportioning : The mix proportions shall be selected to ensure the workability
of the fresh concrete and when concrete is hardened, it shall have the required strength, durability and
surface finish. The determination of the proportion of Cement, Aggregate and Water to attain the
required strength shall be made as follows:
(a) By designing the concrete mix: Such concrete shall be called `Design mix concrete', for
details reference may be made to Appendix-J ( Illustrative Example).
(b) By adopting nominal concrete mix: Such concrete shall be called `Nominal mix concrete'.
Design mix concrete is preferred to nominal mix. If design mix concrete cannot be used for any
reason on the work for grades of M20 or lower, nominal mixes may be used with the permission
of Engineer-in-Charge, which however, is likely to involve a higher cement content.
5.3.1.4 Nominal Mix Concrete:
Nominal Mix Concrete may be used for concrete of M20 or lower. The proportions of materials for
nominal mix concrete shall be in accordance with Table 10. The cement content of the mix specified in
Table 10 for any nominal mix shall be proportionately increased if the quantity of water in the mix
has to be increased to overcome the difficulty or placement and compaction, so that the water cement
ratio as specified is not exceeded.
Table -10: Proportions For Nominal Mix Concrete
S. Grade of Total Quantity of Dry Proportion of Fine uantity of Water

No. Concrete Aggregate to Coarse Quantity
(in lt.) per 50 kg of
Aggregates by Mass per
50 kg of Cement, to be taken Aggregate (by Mass) Cement, (max.)
as the sum of the Individual
Masses of Fine and Coarse
Aggregates, kg, (max)
1 2 3 4 5
1 M5 800 Generally 1:2 but 60
2 M 7.5 625 subject to an upper 45
3 M 10 480 limit of 1:1.5 and a 34
4 M 15 330 Limit lower of 1:2.5 32
5 M 20 250 30
Note: 1. The proportionof fine to to coarse se aggregate should be adjusted from upper limit
progressively as the grading of fine aggregate becomes finer and the maximum size of coarse
aggregate becomes larger. Graded coarse aggregate shall be used.
Note: 2 Quantity of water required from durability point of view may be less than the value given
above.
Note: 3. Grade of mix M5 and M7.5 as mentioned above is only a lean concrete mix used for
preparation of base for designed concrete.
Example: For an average grading of fine aggregate (that is, Zone II of Table 4 of IS:383-1997), the
proportions shall be 1:1.5, 1:2 and 1:2.5 for maximum size of aggregates 10 mm, 20 mm and 40 mm
respectively.
5.3.1.5 -Design Mix Concrete:
a) As the guarantor of quality of concrete used in the construction, the constructor shall carry out
the mix design and the mix so designed (not the method of design) shall be approved by the
employer within the limitations of parameters and other stipulations laid down by this standard.
b) The mix shall be designed to produce the grade of concrete having the required workability
and a characteristic strength not less than appropriate values given in Table 7. The target mean
strength of concrete mix should be equal to the characteristic strength plus 1.65 times the
standard deviation.
c) Mix design done earlier not prior to one year may be considered adequate for later work
provided there is. no change in source and the quality of the materials,
5.3.1.6 -Standard Deviation: The standard deviation for each grade of concrete shall be calculated,
separately.
i) Standard deviation based on test strength of sample
a) Number of test results of samples-The total number of test strength of samples required
to constitute an acceptable record far calculation of standard deviation shall be not less than
30. Attempts should be made to obtain the 30, samples, as early as possible, when mix is
used for the first time.
b) In case of significant changes in concrete- When significant changes are made in the
production of concrete batches (for example changes in the materials used, mix design,
equipment or technical control). the standard deviation value shall be separately calculated
for such batches of concrete.
c) Standard deviation to be brought up to date -The calculation of the standard
deviation shall be brought up to date after every change of mix design.
ii) Assumed standard deviation ; Where sufficient test results for a particular grade of concrete
are not available. the value of standard deviation given in Table 12A maybe assumed for design
of mix in the first instance. As soon as the results of samples are available, actual calculated
standard deviation shall be used and the mix designed properly. However, when adequate past
records for a similar grade exist and justify to the designer a value of standard deviation different
from that shown in Table 11, it shall be permissible to use that value.
Table 11 : Assumed Standard deviation

Grade of concrete Assumed standard deviation-N/mm2
M 10 3.5
M 15 3.5
M 20 4.0
M 25 4.0
M 30 5.0
M 35 5.0
M 40 5.0
M 45 5.0
M 50 5.0
Note: The above values correspond to the site control having proper storage of cement, weigh
batching of all materials, controlled addition of water, regular checking of all materials,
aggregate
grading and moisture content, and periodical checking of workability and strength. Where,
there is deviation from the above, the values given in the above table shall be increased by 1N/
mm2
5.3.1.7-Quality Assurance of Concrete:
a) Quality Assurance Measures : In order that the properties of the completed structure be
consistent with the requirements and the assumptions made during the planning and the design,
adequate quality assurance measures shall be taken. The construction should result in
satisfactory strength, serviceability and long term durability so as to lower the overall life-cycle
cost. Quality assurance in construction activity relates to proper design, use of adequate materials
and components to execution of works by the contractor and ultimately proper care during the
use of structure including timely maintenance and repair by the owner.
b) Quality assurance measures are both technical and organizational. Some common cases should
be specified in a general Quality Assurance Plan which shall identify the key elements necessary
to provide fitness of the structure and the means by which they are to be provided and measured
with the overall purpose to provide confidence that the realized project will work satisfactorily
in service fulfilling intended needs. The job of quality control and quality assurance would
involve quality audit of both the inputs as well as the outputs. Inputs are in the form of materials
for concrete workmanship in all stages of batching. mixing, transportation, placing, compaction
and curing: and the related plant, machinery and Equipment resulting in the output in the form
of concrete in place. To ensure proper performance, it is necessary that each step in concreting
which will be covered by the next step is inspected as the work proceeds.
c) Each party involved in the realization of a project should establish and implement a Quality
Assurance Plan. for its participation in the project. Supplier's and subcontractor's activities shall
be covered in the plan. The individual Quality Assurance Plans shall into the general Quality
Assurance Plan. A Quality Assurance Plan shall define the tasks and responsibilities of all
persons involved. Adequate control and checking procedures, and the organization and
maintaining adequate documentation of the building process and its results. Such documentation
should generally include:
Table 12: Quality Assurance Plan
S. Particulars Contractor JE/AE EE SE

No.
1. Test reports on raw materials To provide To check-100% To check-10% To review
and manufacturer's certificate
for materials
2. Concrete mix design details; To submit To check-100% Testing 10% -do-
cubes
3. Pour cards for site organization To submit To ensure Review -do-
and clearance for concrete compliance compliance
placement
4. Ensuring quality, workmanship, To ensure and Ensure quality Ensure quality Conduct
all field tests conduct all and witness/ and witness/ 5% tests,
tests as confirm all tests confirm 10% Certify
specified tests. quality
5. Non-conformance reports (NCR). To comply To issue NCR To issue To review
change orders; change orders
and satisfaction
of NCR
S. Particulars Contractor JE/AE EE SE
No.
6. Quality control documentation; To provide To check To review. -do-
adequacy and
completeness
7. Statistical analysis To carry out To analysis and Review and -do-
and submit confirm Suggest
compliance improvements
5.3.1.8 Batching:
To avoid confusion and error in batching, consideration should be given to using the smallest practical
number of different concrete mixes on any site or in any one plant. In batching concrete, the quantity of
both cement and aggregate shall be determined by mass, admixture, if solid, by mass, liquid
admixture may however be measured in volume or mass. Water shall be weighed or measured by
volume in a calibrated tank (see also IS: 4925-1968).
Ready-mixed concrete supplied by ready-mixed concrete plant shall be preferred. For large and
medium project sites the concrete shall be sourced from ready-mixed concrete plants or from on site
or off site batching and mixing plants (see IS: 4926-2003).
5.3.1.9 Except where it can be shown to the satisfaction of the Engineer-in-Charge that supply of
properly graded aggregate of uniform quality can be maintained over a period of work, the grading
aggregate should be controlled by obtaining the coarse aggregate in different sizes and blending them
in the right proportions when required, the different sizes being stocked in separate stock-piles. The
material should be stock-piled for several hours preferably a day before use. The grading of coarse and
fine aggregate should be checked as frequently as possible, the frequency for a given job being
determined by the Engineer-in-Charge to ensure that the specified grading is maintained. The grading
can also be achieved at site as illustrated in Appendix `D'.
5.3.1.10- The accuracy of the measuring equipment shall be within ± 2 percent of the quantity of
cement being measured and within ± 3 percent of the quantity of aggregate, admixtures and water
being measured.
5.3.1.11-Proportion/type and grading of aggregates shall be made by trial in such a way so as to
obtain densest possible concrete. All ingredients of the concrete should be used by mass only.
5.3.1.12- Volume batching may be allowed only where weigh-batching is not practicable and provided
accurate proportions to be used in concrete have earlier been established. Allowance for bulking
shall be made in accordance with IS: 2386 (Part 3)-1963. The mass volume relationship should be
checked as frequently as necessary, the frequency for the given job being determined by Engineerin-
Charge to ensure that the specified grading is maintained.
5.3.1.13- It is important to maintain the water cement ratio constant at its correct value. To this end,
determination of moisture contents in both fine and coarse aggregates shall be made as frequently as
possible, the frequency for a given job being determined by the Engineer-in-Charge according to
weather conditions. The amount of the added water shall be adjusted to compensate for any observed
variations in the moisture contents. For the determination of moisture content in the aggregates, IS:
2386 (Part 3)-1963 may be referred to. To allow for the variation in mass for aggregate due to
variations in their moisture content, suitable adjustments in the masses of aggregates shall be made.
In the absence of exact data, only in the case of nominal mixes, the amount of surface water may be
estimated from the values given in Table 13.
Table -13: Surface Water Carried By Aggregate.
S. Aggregate Approximate Quantity Surface Water
No. of Per cent by Mass litre/m3
(1) (2) (3) (4)
(i) Very wet sand 7.5 120
(ii) Moderately wet sand 5.0 80
(iii) Moist sand 2.5 40
(iv) Moist gravel or crushed rock 1.25-2.5 20-40
NOTE(1) Coarser the aggregate, less the water it will carry.
5.3.1.14 No substitution in materials used on the work or alteration in the established proportions,
except as permitted in 5.3.1.3 and 5.3.1.4 shall be made without additional tests to show that the
quality and strength of concrete are satisfactory.
5.3.1.15- Mixing:
a) Concrete shall be mixed in mechanical batch type concrete mixers conforming to IS 1791-1985
having two blades and fitted with power loader (lifting hopper type). Half bag mixers and
mixers without lifting hoppers shall not be used for mixing concrete. Before mixing, the brick
aggregate shall be well soaked with water for a minimum period of two hours and stone aggregate
or gravel shall be washed with water to remove, dirt, dust and other foreign materials. For
guidance, the mixing time may be 1.5 to 2 minutes, for hydrophobic cement it may be taken as
2.5 to 3 minutes.
b) For guidance, the mixing time shall be at least 2 minutes. For other types of more efficient
mixers, manufacturers recommendations shall be followed, for hydrophobic cement it may be
decided by the Engineer-in-charge.
c) Workability should be checked at frequent intervals (Ref. IS 1199-1959, Reaffirmed 1999).
d) Dosages of retarders, plasticisers and superplasticisers shall be restricted to 0.5, 1.0 and2.0
percent respectively by weight of cementitious materials unless a higher value is agreed upon
between the manufacturer and the constructor based on performance test.
5.3.1.16-Power Loader :-
i) Mixer will be fitted with a power loader complying with the following requirements.
a) The hopper shall be of adequate capacity to receive and discharge the maximum nominal
batch of unmixed material without spillage under normal operating conditions on a level
site.
Note:- In such a case the volume of the maximum nominal batch of mixed material is 50%
greater than the nominal mixed batch capacity.
b) The minimum inside width of the feeding edge of the hopper shall be as specified
below in Table 14.
Table -14
Nominal size of mixer (T,NT or R) Minimum inside width of hopper
litre feeding edge (m)
140 1.0
200 1.1
280 1.2
375 1.4
500 1.5
1000 2.0
T= Tilting NT= Non tilting R= Reverse
c) The design of the loader shall be such that it allows the loading hopper to be elevated to
such a height that the centre line of the chute plate of the hopper when in discharge
position is at an angle of not less than 50° to the horizontal. A mechanical device to aid
discharge of the contents as quickly as possible from the hopper to the drum may also be
provided. Even when a mechanical device is provided, it is recommended that the angle of
centre line of the chute plate of the hopper when in discharge position, should be as large
as practicable preferably not less than 40° to horizontal.
d) When the means used for raising and lowering the loading hopper includes flexible wire
ropes winding on to a drum or drums, the method of fastening the wire to rope and drums
shall be such as to avoid, as far as possible any tendency to cut the strands of the ropes and
the fastening should preferably be positioned clear of the barrel of the drum, for example
outside the drums flange. When the loading hopper is lowered to its normal loading
position, there should be at least one and half drums of rope on the drum.
e) Clutch brake and hydraulic control lever shall be designed so as to prevent displacement
by vibration or by accidental contact with any person
f) The clutch and brake control arrangements shall also be so designed that the operator
can control the falling speed of the loader.
g) Safety device shall be provided to secure the hopper in raised position when not in use.
ii) Mixing Efficiency :- The mixer shall be tested under normal working conditions in accordance
with the method specified in IS: 4634-1991 with a view to check its ability to mix ingredients
properly to obtain concrete mix having uniformity within the prescribed limits. The uniformity
of mixed concrete shall be evaluated by finding the percentage variation in quantity (mass in
water) of cement, fine aggregate and coarse aggregate in freshly mixed batch of concrete. The
percentage variation between the quantities of cement, fine aggregate and coarse aggregate (as
found by weighing in water) in the two halves of a batch and average of the two halves of the
batch shall not be more than the following limits.
Cement = 8%
Fine Aggregate = 6%
Coarse Aggregate = 5%
5.3.1.17 Machine Mixing :- The mixer drum shall be flushed clean with water. Measured quantity of
coarse aggregate shall be placed first in the hopper. This shall be followed with measured quantity of
fine aggregate and then cement. In case fine aggregate is damp, half the required quantity of coarse
aggregate shall be placed in the hopper, followed by fine aggregates and cement. Finally the balance
quantity of coarse aggregate shall be fed in the hopper & then the dry materials are slipped into the
drum by raising the hopper. The dry material shall be mixed for at least four turns of the drum. While
the drum is rotating, water shall be added gradually to achieve the water cement ratio as specified or as
required by the Engineer in charge. After adding water, the mixing shall be continued until concrete of
uniform colour, uniformly distributed material and consistency is obtained. Mixing shall be done for
at least two minutes after adding water. If there is segregation after unloading from the mixer, the
concrete should be remixed.
The drum shall be emptied before recharging, when the mixer is closed down for the day or at any
time exceeding 20 minutes the drum shall be flushed cleaned with water.
5.3.1.18 Hand Mixing:- When hand mixing has been specifically permitted in exceptional
circumstances by the Engineer in charge in writing, subject to adding 10% extra cement, it
shall be carried out on a smooth clean and water tight platform of suitable size. Measured
quantity of sand shall be spread evenly on the platform and the cement shall be dumped on the sand
and distributed evenly. Sand and cement shall be mixed intimately with spade until mixture is of
even colour throughout. Measured quantity of coarse aggregate shall be spread on top of cement
sand mixture and mixing done by shovelling and turning till the coarse aggregate gets evenly
distributed in the cement sand mixture. Three quarters of the total quantity of water required shall be
added in a hollow made in the middle of mixture pile and the material is turned towards the middle
of pile with spade. The whole mixture is turned slowly again and again & the remaining quantity of
water is added gradually, the mixing shall be continued until concrete of uniform colour and
consistency is obtained. The mixing platform shall be washed and cleaned at the end of the day.
5.3.1.19 (a) Transporting, and Placing of concrete: Concrete shall be transported from the mixture
to the place of laying as rapidly as possible by methods which will prevent the segregation or loss of
any of the ingredients and maintaining the required workability . During hot or cold weather,
concrete shall be transported in deep containers. Other suitable methods to reduce the loss of water by
evaporation in hot weather and heat loss in cold weather may also be adopted.
i) After proper mixing, the Concrete should be transported to the form work as rapidly as possible
without segregation or loss of any ingredients or ingress of any foreign matter or water and
maintaining the required workability. During hot or cold weather, Concrete should be
transported in deep containers. It should reach the form and be placed and compacted before the
initial set begins. Transit mixtures are best for such transportation.
ii) Concrete shall be compacted and fully worked around the reinforcement, around embedded
fixtures and in to corners of the formwork. Vibrators complying with IS : 2505, 2506,2514, and
4656. Over vibration and under vibration of Concrete are harm full and should be avoided. Where
vibration has to be applied externally, the design of formwork and the disposition of vibrators
should be such as to avoid surface blemishes.
iii) Curing is the process of preventing the loss of moisture from the Concrete whilst maintaining
a satisfactory temperature regime. It is more important if the water Cement ratio is low, if the
Cement has a high rate of strength development, and if the Concrete contains granulated blast
furnace Slag or pulverized fuel ash. Super sulphated Cement Concrete is seriously affected by
inadequate curing.
iv) Exposed surfaces of Concrete shall be kept continuously wet at least for 7 days (for OPC), by
ponding, or by covering with a layer of sacking, canvas, Hessian or other similar material. The
period should be 10 days for where mineral admixtures or blended Cements are used, and also
for Concrete in dry and hot weather conditions. It is better to keep the period of curing as a
minimum of 14 days.
v) Approved curing compounds may be used, in lieu of moist curing, by applying them to all
exposed surfaces of the Concrete immediately after setting. Impermeable membranes such as
polyethylene sheeting covering closely the Concrete surface may also be used to prevent
evaporation.
(b) Placing :- Concrete should be placed gently to preclude segregation, avoiding displacement of
reinforcement, or movement of formwork. The maximum free fall of Concrete may be 1.5 m.
The concrete shall be deposited as nearly as practicable in its final position to avoid rehandling. It shall
be thoroughly vibrated and compacted before setting commences and should not be subsequently
disturbed. Method of placing shall be such as to preclude segregation. Care shall be taken to avoid
displacement of reinforcement or movement of form work and damage due to rains. As a general
guidance, the maximum free fall of concrete may be taken as 1.5 metre.
5.3.1.20 Compaction : -
a) Concrete shall be thoroughly compacted and fully worked around embedded fixtures and into
corners of the form work. Compaction shall be done by mechanical vibrator of appropriate type
till a dense concrete is obtained. The mechanical vibrators shall conform to IS: 2505-1992, IS:
2506-1985, IS: 2514-1965 and IS: 4656-1968. To prevent segregation, over vibration shall be
avoided.
b) Compaction shall be completed before the initial setting starts. For the items where mechanical
vibrators are not to be used, the contractor shall take permission of the Engineer-in-Charge in
writing before the start of the work. After compaction the top surface shall be finished even
and smooth with wooden trowel before the concrete begins to set. Also refer Appendix Ì' on
vibrators.
c) Surface vibrators should be essentially used on slabs / PCC and horizontal members of the
structure.
d) Over and under vibration are harmful and should be avoided. Vibration of wet mixes should
also be avoided. Whenever vibration has to be applied externally, the design of form work and
the disposition of vibrators should receive special consideration to ensure efficient compaction
and to avoid surface blemishes.
5.3.1.21-Alkali Aggregate Reaction: -Some aggregates containing particular varieties of silica may
be susceptible to attack by alkalis (Na2O and K2O) present in Cement or other sources, producing
expansive reaction causing cracking and disruption of Concrete. It will happen only when the
following are present together: -
(a) A high moisture level with in the Concrete.
(b) Cement with high alkali content, or another source of alkali.
(c) Aggregate containing an alkali reactive constituent.
Where the service record of particular cement/aggregate combination are well established, and
do not included any instances of cracking due to alkali aggregate reaction, no further
precautions should be necessary. When the materials are unfamiliar, precautions should take one
or more of the following forms.
(a) Use of non-reactive aggregates from alternate sources.
(b) Use of low alkali (<0.6% as Na2O equivalent) OPC. Replacement of Cement (min.20%)
by Fly ash (grade I) conforming to IS : 3812-1981 or granulated blast furnace Slag (min.
50%) conforming to IS : 12089-1987 ( reaffirmed 2004) .
(c) Use of impermeable membrane to reduce degree of saturation of Concrete during service.
(d) Limiting Cement content in the Concrete mix and there by limiting total alkali content
in the concrete mix.
(e) Refer specialist literature for more guidance.
5.3.1.22-Concrete in Aggressive soils and water: - The destructive action of aggressive waters on
Concrete is progressive. It increases with porous Concrete and salt content of water and decreases with
stronger and dense Concrete. Where structures are only partially immersed or are in Contact with
aggressive soils or waters on one side only, evaporation may cause serious concentrations of salts with
subsequent deterioration, even where the original .salt content of the soil or water is not high. The
solution lies in placing a properly designed and produced dense Concrete, preventing flooding of
water and removal of aggressive soils from around the structure if possible and using impermeable
membranes etc. Proper drainage of such sites, protection to Concrete with chemically resistant stone
(Mandana) or POP covered with jute impregnated with bituminous material can be helpful.
NOTE - Guidance regarding requirements for concrete exposed to Sulphate attack is given in 5.11.1.5.
At sites where alkali concentrations are high or may become very high, .the ground water should be
lowered by drainage so that it will not come into direct contact with the concrete. Additional protection
may be obtained by the use of chemically resistant stone facing or a layer of plaster of Paris covered
with suitable fabric, such as jute thoroughly impregnated with bituminous material.
5.3.1.23-Concrete Mix Proportioning:
a) Mix Proportion: The mix proportions shall be selected to ensure the Workability of the fresh
concrete and when concrete is hardened, it shall have the required strength, durability and
surface finish.
b) The determination of the proportions of cement, aggregates and water to attain the required
strengths shall he made as follows:
i) By designing the concrete mix; such concrete shall be called 'Design mix concrete', or
ii) By adopting nominal concrete mix: such concrete shall be called 'Nominal mix concrete'.
Design mix concrete is preferred to nominal mix. If design mix concrete cannot be used
for any reason on the work for grades of M 20 or lower) nominal mixes may be used with
the permission of Engineer-in-charge. which, however. is likely to involve a higher cement
content.
c) Information Required: In specifying a particular grade of concrete, the following information
shall be included:
Type of mix, that is, design mix concrete or nominal mix concrete:
Grade designation;
Type of cement;
Maximum nominal size of aggregate;
Minimum cement content (for design mix concrete);
Maximum water-cement ratio;
Workability;
Mix proportion (for nominal mix concrete);
Exposure conditions as per Table 16;
Maximum temperature of concrete at the time of placing;
Method of placing; and
Degree of supervision.
d) In appropriate circumstances. the following additional information may be specified:
i) Type of aggregate,
ii) Maximum cement content. and
iii) Whether an admixture shall or shall not be used and the type of admixture and the
condition of use.
5.3.1.24-Production of Concrete: - It
will involve the following steps:-
(a) Selection of a trial grade of Concrete with respect to Environment, Durability and workability.
Decide the characteristic compressive strength and the standard deviation etc. If a nominal
mix is to be used, pick up proportions from the table in Appendix `G'.
(b) Selection of materials and know their properties from the data available, and decide on their
suitability.
(c) Study the environment and conditions (salt in soil, pounding of water) at the point of
placement.
(d) Design the mix; study the travel of the mix before placement and the need for transit mixers
etc. Concrete should be mixed in an ordinary mixer (IS : 1791-1985,12119-1987, Reaffirmation
2004) weigh batcher and best in a batch mix plant (IS : 4926-2003). All these equipment should
have arrangements to measure the quantity to be mixed.
(e) Decide on admixtures required.
(f) Prepare a quality assurance plan and follow it.
(g) Ready the field lab and the testing equipment. Such a plan should target at: - (i) Proper
design, for the mix, structure including construction joints, design life etc.
ii) Use of adequate materials and components. All materials to be measured by mass except
liquid admixtures, which may be measured by volume. The accuracy of the measuring
equipment shall be within +/- 2% of the quantity of Cement being measured and with +/-
3% of the quantity of aggregate, admixtures and water being measured.
iii) Proper workmanship in the execution of works.
iv) Proper care during the use of structure including timely maintenance and repair.
v) The construction should result in satisfactory strength, serviceability, long term
Durability so as to lower the overall life cycle cost.
vi) Quality audit of inputs as Well as out puts.
5.3.1.25-Sampling and Strength of Designed Concrete Mix : General : Samples from fresh
concrete shall be taken as per IS 1199 and cubes shall be made, cured and tested at 28 days in
accordance with acceptance criteria as at 5.3.1.26.
a) In order to get a relatively quicker idea of the quality of concrete, optional tests on beams for
Modulus of rupture at 72 ± 2 h or at 7 days, or compressive strength tests at 7 days may be
carried out in addition to 28 days compressive strength test. For this purpose the values should
be arrived at based on actual testing. In all cases, the 28 days compressive strength specified in
Table 2 shall one be the criterion for acceptance or rejection of the concrete.
b) Frequency of Sampling -Sampling Procedure : A random sampling procedure shall be
adopted to Ensure that each concrete batch shall have a reasonable chance of being tested that is,
the sampling should be spread over the entire period of concreting and cover all mixing units.
c) Frequency : The minimum frequency of sampling of concrete of each grade shall be in
accordance with the following:
Quantity of Concrete in the Number of Samples
Work, m3
1-5 1
6-15 2
16-30 3
3 1 - 50 4
51 and above 4 Plus One additional sample for each
additional 50 m3 or part thereof.
Note-At least one sample shall be taken from each shift. Where concrete is produced at continuous
production unit, such as ready-mixed concrete plant, frequency of sampling may be agreed upon
mutually by suppliers and purchasers.
d) Test Specimen: Three test specimens shall be made for each sample for testing at 28 days.
Additional specimen may be required for various purposes such as to determine the strength of
concrete at 7 days or at the time of striking the formwork, or to determine the duration of curing,
or to check the testing error. Additional samples may also be required for testing specimen
cured by accelerated methods as described in IS:9013. The specimen shall be tested as described
in IS:516.
e) Test Results of Sample: The test results of the sample shall be the average of the strength of
three specimens. The individual variation should not be more than ±15 percent of the average.
If more, the test result of the sample are invalid.
5.3.1.26-Acceptance Criteria : a) Compressive Strength : The concrete shall be deemed to comply
with the strength requirements when both the following conditions are met:
i) The mean strength determined from any group of four non overlapping consecutive test results
compiles with the appropriate limits in col 2 of Table15.
ii) Any individual test result complies with the appropriate limits in col 3 of Tablel5.
Table-15: Characteristics Compressive Strength Compliance Requirement
Specified Grade Mean of the Group of 4 Non- Individual Test Results in N/mm3
Overlapping Consecutive Test
Results in N/mm2
(1) (2) (3)
M15 = fck + 0.825 x established
standard deviation (rounded off to
nearest 0.5
N/mm2)
or
fck+3N/mm2
Whichever is greater
=fck-3N/mm2
M20 or above = fck + 0.825 x established =fck-3N/mm2
standard deviation (rounded off to
nearest 0.5 N/mm2)
or
fck+3N/mm2,Whichever is greater
Note:In the absenceof established blished value of standard deviation, the values givenin Table may be
assumed, and attempt should be made to obtain results of 30 samples as early as possible to establish
the value of standard deviation.
b) Flexural Strength: When both the following conditions are met the concrete complies with
the specified flexural strength.
i) The mean strength determined from any group of four consecutive test results exceeds
the specified characteristic strength by at least 0.3 N/mm2.
ii) The strength determined from any test result is not less than the specified characteristic
strength less 0.3 N/mm2
c) Quantity of Concrete Represented by Strength Teat Results: The quantity of concrete
represented by a group of four consecutive test results shall include the batches from which the
first and last samples were taken together with all intervening batches. For the individual test
result requirements given in col 2 of Table 15 or in item (b) above, only the particular batch
from which the sample was taken shall be at risk. Where the mean rate of sampling is not
specified the maximum quantity of concrete that four consecutive test results represent shall be
limited to 60 m3.
d) If the concrete is deemed not to comply persuant to 5.3.1.26 (a) or (b) as the case may be the
structural adequacy of the parts affected shall be investigated and any consequential action as
needed shall be taken.
e) Concrete of each grade shall be assessed separately.
f) Concrete is liable to be rejected if it is porous or honey-combed. its placing has been interrupted
without providing a proper construction joint. The reinforcement has been displaced beyond the
tolerances specified. or construction tolerances have not been met. However. the hardened concrete
may be accepted after carrying out suitable remedial measures to the satisfaction of the Engineer-
in-Charge.
53.1.27- Inspection and testing of Structures : Inspection: To ensure that the construction complies
with the design an inspection procedure should be set up covering materials, records, workmanship and
construction.
a) Tests should be made on reinforcement and the constituent materials of concrete in accordance with
the relevant standards. Where applicable, use should be made of suitable quality assurance
schemes.
b) Care should be taken to see that:
(i) design and detail are capable of being executed to a suitable standard, with due allowance
for dimensional tolerances;
(ii) there are clear instructions on inspection standards;
(iii) there are clear instructions on permissible deviations;
(iv) elements critical to workmanship, structural performance. durability and appearance are
identified; and
(v) there is a system to verify that the quality is satisfactory in individual parts of the
structure, especially the critical ones.
c) Immediately after stripping the form work, all Concrete shall be carefully inspected and any
defective work or small defects either removed or made good before concrete has thoroughly
hardened.
d) Testing : In case of doubt regarding the grade of concrete used, either due to poor workmanship or
based on results of cube strength tests, compressive strength tests of Concrete on the basis of (e)
and/or load test may be carried out.
e) Core Test : The points from which cores are to be taken and the number of cores required shall be
at the discretion of the engineer-in-charge and shall be representative of the whole of concrete
concerned. In no case. however. shall fewer than three cores be tested.
Cores shall be prepared and Tested as described in IS 516-1959 ( Reaffirmed 1999) .
Concrete in the member represented by a core test shall be considered acceptable if the average
equivalent cube strength of the cores is equal to at least 85 percent of the cube strength of the
grade of concrete specified for the corresponding age and no individual core has a strength less
than 75 percent.
h) In case the core test results do not satisfy the requirements of (g) or where such tests have not been
done, load test may be resorted to.
5.4 Construction Joints:
Concreting shall be carried out continuously up to construction joints. The position and arrangements
of construction joints shall be as shown in the structural drawings or as directed by the Engineer in
Charge. Number of such joint shall be kept minimum. Joints shall be kept as straight as possible.
Construction joints should comply with IS:11817-1986.
(a) Action before concrete placement- When the work has to be resumed on a surface which has
hardened, such surface shall be roughened. It shall then be swept clean and thoroughly wetted.
For vertical joints, neat cement slurry, of workable consistency by using 2 kg of cement per
sqm shall be applied on the surface before it is dry. For horizontal joints, the surface shall be
covered with a layer of mortar about 10-15 mm thick composed of cement and sand in the same
ratio as the cement and sand in concrete mix. This layer of cement slurry of mortar shall be
freshly mixed and applied immediately before placing of the concrete.
(b) Action after concrete placement- Where the concrete has not fully hardened, all laitance shall
be removed by scrubbing the wet surface with wire or bristle brushes, care being taken to avoid
dislodgement of particles of coarse aggregate. The surface shall be toughly wetted and all free
water removed. The surface shall then be coated with neat cement slurry @ 2 kg of cement /sqm.
On this surface a layer of concrete not exceeding 150 mm in thickness shall first be placed and
shall be well rammed against old work particular attention being paid to corners and close spots
of work, thereafter, shall proceed the normal way.
5.5 Concreting Under Special Condition :
5.5.1 Work in Extreme Weather Conditions: During hot and cold weather, the concreting shall be
done as per the procedure set out in IS:7861(Part I)-1975 and IS:7861(Part II)-1981 respectively.
Concreting shall not be done when the temperature falls below 4.5° C. In cold weather, the concrete
placed shall be protected against frost. During hot weather, it shall be ensured that the temperature of
wet concrete does not exceed 38° C.
5.5.2 Under Water Concreting :- Concrete shall not be deposited under water if it is practicable to
de-water the area and place concrete in the regular manner. When it is necessary to deposit concrete
under water, the methods, equipment, materials and proportions of the mix to be used shall be
approved by the Engineer-in-Charge before the work is started.
Under-water concrete should have a slump recommended in 5.3.1.2. The water-cement ratio shall not
exceed 0.6 and may need to be smaller, depending on the grade of concrete or the type of chemical
attack.
5.6 Curing: Curing is the process of preventing loss of moisture from the concrete. The following
methods shall be employed for effective curing.
5.6.1 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 7 days from the 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 the case
of concrete where mineral admixtures or blended cements are used, it is recommended that above
minimum periods may be extended to 14 days.
5.6.2 Membrane Curing : In such curing , the moisture in the concrete is prevented from loss due to
evaporation. It is by covering the concrete with a preventive film or sealing the exposed surface with
chemical to minimise evaporation loss.
a) Plastic Sheet : Impermeable membrane such as Polythene sheet covering the concrete surface
may be used to provide effective barrier against the evaporation. The sheets should be in
close contact with concrete surface. Wind should not be allowed to blow between the concrete
surface and the sheets, causing rapid drying of the moisture in the top surface of concrete. The
Polyethylene film should be of at least 0.10 mm thick and preferably be transparent or white
opaque in colour when used in warm weather. Black sheets can be used during cool weather.
b) Curing Compounds : Approved curing compounds may be used in lieu of moist curing with
the permission of the Engineer-in-Charge. Curing compounds generally consist of waxes,
resins, chlorinate rubber and solvents of high volatility and form a thin liquid membrane on the
concrete surfaces and result in preventing evaporation loss up to a certain extent. Such
compound shall be applied to all exposed surfaces of the concrete as soon as possible after the
concrete has set. Curing compound should be sprayed uniformly in the two layers. The second
layer must be sprayed at the right angle to the first layer.
c) Freshly laid concrete shall be protected from rain by suitable covering.
5.7 Raising of Masonry Over Concrete: Over the foundation concrete, the masonry work may be
started after 48 hours of its compaction but the curing of exposed surfaces of cement concrete shall be
continued along with the masonry work for at least 7 days and where cement concrete is used as base
concrete for flooring, the flooring may be commenced before the curing period of base concrete is over
but the curing of base concrete shall be continued along with top layer of flooring for a minimum
period of 7 days
5.8 Testing of Concrete: Testing of concrete will be done as described in Appendix `B'.
5.8.1 Regular testing (in the laboratory and in the field) on the concrete shall be carried out to
determine the strength achieved. Testing procedure shall be as per IS: 516-1959.
5.8.2 Samples of fresh concrete being laid shall be drawn as per IS: 1199-1959 and tested for 28
days compressive strength as per IS: 516-1959. Acceptance shall be subject to standard deviation
determined and approved by the Engineer-in-Charge.
5.8.3 Frequency of sampling:
5.8.3.1 Sampling: It shall be well spread over the duration of concreting and shall be drawn from all
mixing units.
5.8.3.2 The tested strength of the cubes shall be average of the 3 cubes of the same sample but it
shall not be less than the characteristic compressive strength of the Concrete.
5.9 Form Work: Form work shall be as specified in RCC chapter no. 6 and shall be paid for
separately unless otherwise specified.
5.10 Finishes: Plastering and special finishes other than those, obtained through form work shall be
specified and paid for separately unless otherwise specified.
5.11 Durability of Concrete:
a) A durable concrete is one that performs satisfactorily in the working environment during its
anticipated exposure conditions during service. The materials and mix proportions shall be
such as to maintain its integrity and, if applicable, to protect reinforcement from corrosion.
b) One of the main characteristics influencing the durability of concrete is its permeability to the
ingress of Water, Oxygen, Carbon-dioxide, Chloride, Sulphates and other potentially deleterious
substances.
c) Impermeability is governed by the constituents and workmanship used in making the concrete. With
normal weight aggregates, a suitable low permeability is achieved by having an adequate cement
content. Sufficiently low free water-cement ratio, by ensuring complete compaction of the
concrete, and by adequate curing.
The factors influencing durability include:
(a) The environment;
The cover to embedded steel;
(b)
The type and quality of constituent materials;
(c)
The cement content and water/ cement ratio of the concrete;
(d)
(e) Workmanship, to obtain full compaction and efficient curing; and
(f) The shape and size of the member.

5.11.1 Requirements for Durability:
(a) General Environment: The shape or design details of exposed structures should be such as to
promote good drainage of water and to avoid standing pools and rundown of water. Care should
also be taken to minimise any cracks that may collect or transmit water
b) Adequate curing is essential to avoid the harmful effects of early loss of moisture (specially
for concretes with low WC ratio/ super sulphated cement).
c) Member profiles and their intersection with other members shall be designed in a way to
ensure easy flow of concrete and proper compaction during concreting.
d) Thin sections, sections under hydrostatic pressure from one side only, in partially immersed
sections and at corners and edges of elements are more vulnerable. This can be saved with extra
cover, chamfering the corners, or by using circular sections, or by coatings which prevent or
reduce the ingress of water.
5.11.1.1- Maximum Cement content: Cement content including fly ash / granulated blast furnace
slag in excess of 450 kg/cum should not be used unless special conditions have been given in the
design to the increased risk of cracking due to drying shrinkage in thin sections, or to early thermal
cracking and to the increased risk of damage due to alkali silica reactions.
5.11.1.2- Free water cement ratio: It is an important factor in governing the durability of concrete
and the maximum free water cement ratios ( for 20 mm aggregate) as given in Table 8 above.
5.11.1.3- Compaction, Finishing and Curing:
a) Adequate compaction without segregation should be ensured by providing suitable workability
and by employing appropriate placing and compacting equipment and procedures. Full
compaction is particularly important in the vicinity of construction and movement joints and of
embedded water bars and reinforcement.
b) Good finishing practices are essential for durable concrete.
c) Overworking the surface and addition of water / cement to aid in finishing should be avoided;
the resulting laitance will have impaired strength and durability and will be particularly
vulnerable to freezing and thawing under wet conditions. It is essential to use proper and
adequate curing techniques to reduce the permeability of the concrete and enhance its durability
by extending the hydration of the cement, particularly in its surface zone,
d) Over vibration and under vibration of concrete is harmful, vibration of very wet mixes
should be avoided.
e) Wherever, external vibration is deployed, the design of form work and disposition of vibrators
shall receive special consideration to ensure efficient compaction and to avoid surface
blemishes.
f) Since properly graded aggregate cannot be ensured, the grading should be controlled by
obtaining the coarse aggregate in different sizes and blending them in the right proportion
when required. The material should be stock piled sufficiently in advance.
g) The grading of coarse and fine aggregate should be checked as frequently as possible to ensure
that the specified grading is maintained. An example for grading is placed in Appendix `G'.
h) The general environment to which the concrete will be exposed during its working life is
classified into five levels of severity, that is, mild, moderate, severe, very severe and extreme as
described in Table -16
Table -16: Environmental Exposure Conditions
S. Environment Exposure Conditions Nominal cover to meet

No. durability requirements
(1) (2) (3) (4)
(i) Mild Concrete surface protected 20 mm.
against weather or aggressive
conditions, except those situated
in coastal area.
(ii) Moderate Concrete surfaces sheltered from 30 mm.
severe rain or freezing whilst wet
Concrete exposed to
condensation and rain. Concrete
continuously underwater.
Concrete in contact or buried
under non-aggressive soil/ground
water. Concrete surfaces
sheltered from saturated salt air
in coastal area.
(iii) Severe Concrete surfaces exposed to 45 mm.
severe rain, alternate wetting and
drying or occasional freezing
whilst wet or severe
condensation. Concrete exposed
to coastal environment.
(iv) Very Severe Concrete surfaces exposed to 50 mm.
sea water spray, corrosive fumes
or severe freezing conditions
whilst wet. Concrete in contact
with or buried under aggressive
sub-soil/ground water.
(1) (2) (3) (4)
(v) Extreme Surface of members in tidal 75mm.
zone. Members in direct contact
with liquid/solid aggressive
chemicals.
Note: For the purpose of determining exposure conditions, all places within a distance of 10 km of
Coastal line, Sea front would be treated as coastal area.
5.11.1.4- Freezing and Thawing : Where freezing and thawing actions under wet conditions exist,
enhanced durability can be obtained by the use of suitable air entraining admixtures. When concrete
lower than grade M50 is used under these conditions, the mean total air content by volume of the
fresh concrete at the time of delivery into the construction should be:
Table - 17
S. Nominal Maximum Size of Aggregate Entrained Air Percentage
No. (mm)
1. 20 5±1
2. 40 4±1
5.11.1.5-Exposure to Sulphate Attack:

a) Table 18 gives recommendations for the type of cement, maximum free water/cement ratio
and minimum cement content, which are required at different sulphate concentrations in near-
neutral ground water having pH of 6 to 9.
b) For the very high sulphate concentration in Class 5 conditions given in Table-18, some form
of lining such as polyethylene or Polychloroprene sheet or surface coating based on asphalt,
chlorinated rubber, epoxy or polyurethane materials should also be used to prevent access by the
sulphate solution.
5.11.1.6- Sulphates in Concrete : Sulphates are present in most cements and in some aggregates,
excessive amounts of water-soluble Sulphate from these or other mix constituents can cause
Expansion and disruption of concrete. The total water-soluble sulphate content of the concrete mix,
expressed as SO3 should not exceed 4 per cent by mass of the cement in the mix. The sulphate
content should be calculated as the total from the various constituents of the mix. The 4.0 percent limit
does not apply to concrete made with super sulphate cement complying with IS: 6909-1990.
TABLE-18: Requirements for Concrete Exposed to Sulphate Attack.
S. Class Concentration of sulphates, Type of F
No. Expressed as SO3 Concentrate Cement Dense,
made ully
with 20 mm
compacted
nominal size
In soil In ground
Aggregates
Total SO3 S03 in 2:1 water (0) Minimum Maximum
complying with IS 383
(%) (water: soil Cement free Water
extract) Content kg/ Cement
(g/1) cum Ratio
(1) (2) (3) (4) (5) (6) (7) (8)
(i) 1 Traces Less than Less than Ordinary Portland 280 0.55
(<0.2) 1.0 0.3 Cement or Portland
slag cement or Portland
Pozzolana cement
(ii) 2 0.2 to 0.5 1.0 to 1.9 0.3 to 1.2 -do- 330 0.50
Super sulphated cement 310 0.5
or Sulphate Resistant
Portland cement.
(iii) 3 0.5 to 1.0 1.9 to 3.1 1.2 to 2.5 -do- 330 0.5
Portland Pozzolana 350 0.45
cement or Portland
slag cement
(iv) 4 1.0 to 2.0 3.1 to 5.0 2.5 to 5.0 Super sulphated 370 0.45
cement or Sulphate
Resistant Portland
cement.
(v) 5 More than More than More than Sulphate Resisting 400 0.40
2.0 5.0 5.0 Portland cement. Or
Super sulphated cement
with protective coatings.
Notes 1. Cement content given in this Table is irrespective of grades of cement.

2. Use of super sulphated cement is generally restricted where the prevailing temperature is
above 40°C.
3. Super sulphated cement gives an acceptable life provided that the concrete is dense and
prepared with a water-cement ratio of 0.4 or less, in mineral acids, down to pH 3.5.
4. The cement contents given in col. 7 of this Table are the minimum recommended. For S03
contents near the upper limit of any class, cement contents above these minimum are advised.
5. For severe conditions, such as thin sections under hydrostatic pressure on one side only and
sections partly immersed, considerations should be given to a further reduction of water-cement
ratio.
6. Portland Slag Cement conforming to IS 455-1989 with slag content more than 50 per cent
exhibits better sulphate resisting properties.
7. Where chloride is encountered along with sulphates in soil or ground water, ordinary Portland
cement with C3A content from 5 to 8 per cent shall be desirable to be used in concrete,
instead of sulphate resisting cement. Alternatively, Portland slag cement conforming to IS 455-
1989 having more than 50 per cent slag or a blend of ordinary Portland cement and slag may be
used provided sufficient information is available on performance of such blended cements in
these conditions.
5.11.1.7-Chlorides in Concrete :
a) Whenever there is chloride in concrete there is an increased risk of corrosion of embedded
metal. The higher the chloride content, or if subsequently exposed to warm moist conditions. the
greater the risk of corrosion. All constituents may contain chlorides and . concrete may be
contaminated by chlorides from the external environment. To minimize the chances of
deterioration of concrete from harmful chemical salts, the levels of such harmful salts in
concrete coming from concrete materials, that is, cement, aggregates water and admixtures.as
well as by diffusion from the environment should be limited. The total amount of chloride
content (as Cl) in the concrete at the time of placing shall be as given in Table 19.
b) The total acid soluble chloride content should be calculated from the mix proportions and the
measured Chloride contents of each of the constituents. Wherever possible, the total chloride
content of the concrete should be determined. The total amount of chlorides content (as Cl) in
the concrete at the time of placing shall be as under :
Table -19
S. Type of Use of Concrete Maximum Total Acid
No.
Soluble-Chloride Content
Expressed as kg/m3 of
concrete.
1 2 3
(i) Concrete containing metal and steam cured at elevated 0.4
temperature and pre-stressed concrete
(ii) Reinforced concrete or plain concrete containing 0.6
embedded meW.
(iii) Concrete not containing embedded metal or any material 3.0
required protection from chloride.
5.12- Ready Mixed Concrete (as per IS : 4926-2003): 5.12.1- Materials:
5.12.1.1- Selection and Approval of Materials : Materials used should satisfy the requirements for
the safety, structural performance durability and appearance of the finished structure, taking full
account of the environment to which it will be subjected. The selection and use of materials shall be
in accordance with IS : 456-2000. Materials used shall conform to the relevant Indian Standards as
applicable. Where materials are used which are not covered by the provisions of the relevant Indian
Standard, there should be satisfactory data on their suitability and assurance of quality control.
Records and details of performance of such materials should be maintained. Account should be taken
of possible interactions and compatibility between IS : 4926-2003 and materials used. Also, prior
permission of the purchaser shall be obtained before use of such materials.
5.12.1.2-Cement : Cement used for Concrete shall be in accordance with the requirements of IS :
456:2000.
5.12.1.3 Mineral Admixtures : Use of mineral admixtures shall be permitted in accordance with the
provisions of IS : 456:2000.
5.12.1.4 Aggregates : Aggregates used for Concrete shall be in accordance with the requirement of
IS : 456-2000. Unless otherwise agreed testing frequencies for aggregates in plant shall be as given IS
: 4926-2003.
5.12.1.5 Chemical Admixtures
(i) Use of chemical admixtures shall be permitted in accordance, with the provisions of IS: 456
-23000 and IS: 9103-1999.
(ii) It shall be the responsibility of the producer to establish compatibility and suitability of any
admixture with the other ingredients of the mix and to determine the dosage required to give the
desired effect.
(iii) Admixtures should be stored in a manner that prevents degradation of the product and
consumed within the time period indicated by the admixture supplier. Any vessel containing an
admixture in the plant or taken to site by the producer shall be clearly marked as to its content.
(iv) When offering or delivering a mix to a purchaser it should be indicated if such a mix contains
an admixture or combination of admixtures or not. The admixtures may be identified generically
and should be declared on the delivery ticket.
(v) The amount of admixture added to mix shall be recorded in the production record. In special
circumstances, if necessary, additional dose of admixture may be added at project site to regain
the workability of Concrete with the mutual agreement between the producer and the purchaser.
5.12.1.6 Water : Water used shall be in accordance with the requirement of IS : 456-2000. The use
of re-cycled water is encouraged as long as Concrete of satisfactory performance can be produced and
steps are taken to monitor the build-up of Chlorides in any re circulated water and that any
subsequent adjustments to the mix design are made to ensure that any overall limit on Chloride
contents is satisfied. The addition of any recycled water shall be monitored and controlled to meet
these requirements.
The total amount of water added to the mix shall be recorded in the production record. The water
content of Concrete shall be regulated by controlling its workability or by measuring and adjusting the
moisture contents of its constituent materials. The producer's production staff and truck-mixer, drivers
shall be made aware of the appropriate responses to variations in Concrete consistency of a particular
mix caused by normal variations in aggregate moisture content or grading.
5.12.2-General Requirements:
5.12.2.1- Basis of Supply: Ready-mixed Concrete shall be supplied having the quality and the
quantity in accordance with the requirement agreed with the purchaser or his agent. Not withstanding
this the Concrete supplied shall generally comply with requirements of IS : 456-2000.
All Concrete will be supplied and invoiced in terms of cubic metres (full or part) of compacted
Concrete. All proportioning is to be carried out by mass except water and admixture, which may be
measured by volume.
5.12.2.2 Transport of Concrete : Ready-mixed Concrete shall be transported from the mixer to the
point of placing as rapidly as practicable by methods that will maintain the required workability and
will prevent segregation, loss of any constituents or ingress of foreign matter or water. The Concrete
shall be placed as soon as possible after delivery, as close as is practicable to its final position to
avoid re-handling or moving the Concrete horizontally by vibration. If required by the purchaser the
producer can utilize admixtures to slow down the rate of workability loss, however this does not
remove the need for the purchaser to place the Concrete as rapidly as possible. The purchaser should
plan his arrangements so as to enable a full load of Concrete to be discharged within 30 minutes of
arrival on site.
Concrete shall be transported in a truck-mixer unless the purchaser agrees to the use of non-agitating
vehicles. When non-agitating vehicles are used, the mixed Concrete shall be protected from gain or
loss of water.
5.12.2.3 Time in Transport : The general requirement is that Concrete shall be discharged from the
truck-mixer within 2 hours of the time of loading. However, a longer period may be permitted if
retarding admixtures are used or in cool humid weather or when chilled Concrete is produced. The
time of loading shall start from adding the mixing water to the dry mix of Cement and Aggregate or
of adding the Cement to the wet aggregate whichever is applicable. Ready-mixed Concrete plant
shall have test facilities at its premises to carry out routine tests as per the requirement of the
standard.
5.12.3- Sampling and Testing of Ready-Mixed Concrete:
5.12.3.1 Point and Time of Sampling:
i) For the assessment of compliance of ready-mixed Concrete, the point and time of sampling
shall be at discharge from the producer's delivery vehicle or from the mixer to the site or when
delivered into the purchaser's vehicle. It is critical that the sampling procedure and equipment
used enables as representative a sample as possible to be taken of the quantity of Concrete
delivered.
ii) After the truck mixer has re-mixed its delivery on site, allow at least the first one-third of
Concrete to be discharged prior to taking any samples. Take at least 4 incremental samples
from the remainder of the load avoiding sampling the last cubic metre of Concrete. Thoroughly
re-mix this composite sample either on a mixing tray or in the sampling bucket and proceed
with the required testing.
iii) The sampling may be carried out jointly by the purchaser and the supplier with its frequency
mutually agreed upon. However, it will not absolve the supplier of his responsibility from
supplying Concrete as per the requirement given in this standard or otherwise agreed to where so
permitted in the standard.
5.12.3.2 Workability:
The test for acceptance is to be performed upon the producer's delivery vehicle discharge on site or
upon discharge into the purchaser's vehicle. If discharge from the producer's vehicle is delayed on site
due to lack of preparedness on behalf of the purchaser then the responsibility passes to the purchaser
after a delay of more than 30 min. The workability shall be within the following limits on the specified
value as appropriate:
Slump: ± 25 mm or ± 1/3 of the specified value, whichever is less.
Compacting factor : ± 0.03, where the specified value is 0.90 or greater,
± 0.04, where the specified value is less than 0.90 but more than 0.80, ±
0.05, where the specified value is 0.80 or less.
Flow table test may be specified for Concrete, for very high workability (see IS: 9103-1999)
Acceptance criteria for spread (flow) are to be established between the supplier and the purchaser.
5.12.3.3 Specified Strength:
(i) Compliance shall be assessed against the requirements of IS: 456-2000 or other agreed Indian
Standard. The purchaser may perform his sampling and testing or may enter into an arrangement
with the producer to provide his testing requirements.
(ii) Unless otherwise agreed between the parties involved, the minimum testing frequency to be
applied by the producer in the absence of a recognized ready- mixed Concrete industry method
of production control should be one sample for every 50 m3 of production or every 50 batches,
whichever is the greater frequency. Three test specimens shall be made up for each sample for
testing at 28 days (see also IS : 456-2000).
In order to get a relatively quicker idea of the quality of Concrete, optional test on beams for
modulus of rupture at 72 ± 2 h or at 7 days or compressive strength test at 7 days may be carried
out in addition to 28 days compressive strength test. For this purpose the value should be arrived
at based on actual testing. In all cases 28 days compressive strength shall alone be the criteria for
acceptance or rejection of the Concrete.
(iii) The purchaser shall inform the producer if his requirements for sampling and testing are
higher than one sample every 50 m3 or 50 batches, whichever is the greater frequency.
5.12.3.4 Additional Compliance Criteria: Any additional compliance criteria shall be declared to the
producer by the purchaser prior to supply and shall be mutually agreed upon in terms of defuution,
tolerance frequency of assessment, method of test and significance result.
5.12.3.5 Non-Compliance : The action to be taken in case of non-compliance shall be declared and
mutually agreed upon.
5.12.4 Information to be supplied by the purchaser:
5.12.4.1 The purchaser shall provide to the producer the details of the Concrete mix or mixes
required by him and all pertinent information on the use of the Concrete and the specified
requirements. or to supply taking place, it is recommended that a meeting is held between the
purchaser and the producer. Its objective is to clarify operational matters such as notice to be given
prior to delivery, delivery rate, the name of the purchasers authorized representative who will
coordinate deliveries, any requirements for additional services such as pumping, on site testing or
training, etc.
5.12.4.2 Designed Mixes : Where the purchaser specifies a designed mix to be supplied, it is
essential that all relevant information is conveyed to the producer.
5.12.4.3 Prescribed Mixes: The Concrete mix shall be specified by its constituent materials and the
properties or quantities of those constituents to produce a Concrete with the required performance. The
assessment of the mix proportions shall form an essential part of the compliance requirements. The
purchaser shall provide the producer with all pertinent information on the use of the Concrete and the
specified requirements. In order to assist in this, the format given in Appendix `C' may be
followed with suitable modifications as applicable to prescribed mixes.
5.12.5 Information to be supplied by the producer :
The purchaser shall provide to the producer the details of the Concrete mix or mixes required by him
and all pertinent information on the use of the Concrete and the specified requirements. or to supply
taking place, it is recommended that a meeting is held between the purchaser and the producer. Its
objective is to clarify operational matters such as notice to be given prior to delivery, delivery rate, the
name of the purchasers authorized representative who will coordinate deliveries, any requirements for
additional services such as pumping, on site testing or training ,etc. When requested, the producer
shall provide the purchaser with the following information also before any Concrete is supplied:
(a) Nature and source of each constituent material,
(b) Source of supply of Cement,
(c) Proposed proportions or quantity of each constituent/ m3 of fresh Concrete.
(d) Generic types of the main active constituents in the admixture;
(e) Whether or not the admixture contains Chlorides and if so, the Chloride content of the
admixture expressed as a percentage of Chloride ion by mass of admixture;
(f) Where more than one admixture is used, confirmation of their compatibility and
(g) Initial and final setting time of Concrete when admixture is used at adopted dosage (tested as
per IS : 8142-1976, Reaffirmed 2002).
5.12.6 Production and Delivery:
5.12.6.1 Materials Storage and Handling:
(i) Cement: Separate storage for Different types and grades of Cement shall be provided. Containers
may be used to store Cement of different types provided these are emptied before loading new Cement.
Bins or silos shall be weatherproof and permit free flow and efficient discharge of the Cement.
Each silo or compartment of a silo shall be completely separate and fitted with a filter or
alternative method of dust control. Each filter or dust control system shall be of sufficient size
to allow delivery of Cement to be maintained at a specified pressure, and shall be properly
maintained and prevent undue emission of Cement dust and prevent interference with weighing
accuracy by build-up of pressure. Cement shall be stored and stacked in bags and shall be kept
free from the possibility of any dampness or moisture coming in contact with them and where
Cement can be stored and retrieved without undue damage to the bags. The bags are to be
protected from becoming damp either from the ground or the weather. The Cement is to be used
in the order it is delivered (see also IS : 4082-1996, Reaffirmed 2003). In case, the Cement
remains in storage for more than 3 months, the Cement shall be retested before use and shall be
rejected, if it fails to conform to any of the requirements given in the relevant Indian Standard.
Dry Pulverized Fuel Ash and Other Mineral Admixtures : Suitable separate arrangement for
storage of pulverized Fuel ash, Silica fume, Metakeolin, Rice husk ash, ground granulated Blast
furnace Slag such as for Cement, shall be provided, in the plants utilizing these materials.
Aggregates (Coarse and Fine): Stockpiles shall be free draining and arranged to avoid
contamination and to prevent intermingling with adjustment material. Handling procedures
for loading and unloading aggregates shall be such as to reduce segregation to a minimum.
Provision shall be made for separate storage for each nominal size and type of aggregate and the
method of loading of storage bins shall be such as to prevent intermingling of different sizes
and types. Fine aggregates shall be stacked in a place where loss due to the effect of wind is
minimum (see also IS : 4082-1996, Reaffirmed 2003) and IS : 456-2000).
(iv) Water : An adequate supply shall be provided and when stored on the plant such storage
facilities shall be designed to minimize the risk of contamination.
(v) Chemical Admixtures : Tanks or drums containing liquid admixtures shall be clearly labelled
for identification purposes and stored in such a way to avoid damage, contamination or the
effects of prolonged exposure to sunlight (if applicable). Agitation shall be provided for liquid
admixture, which are not stable solutions.
5.12.6.2 Batching Plants and Batching Equipment :
i) Hoppers for weighing Cement, mineral admixtures, aggregates and water and chemical
admixture (if measured by mass) shall consist of suitable container freely suspended from a
scale or other suitable load-measuring device and equipped with a suitable discharging
mechanism. The method of control of the loading mechanism shall be such that, as the quantity
required in the weighing hopper is approached the material may be added at controllable rate and
shut off precisely within the weighing tolerances specified. The weighing hoppers for Cement,
mineral admixtures aggregate shall be capable of receiving their rated load, without the weighed
material coming into contact with the loading mechanism. Where the rated capacity of a batching
plant mixing cycle is less than 2.0 m3, additional precautions shall be taken to ensure that the
correct number of batches are loaded into the truck mixer. The weighing hoppers shall be
constructed so as to discharge efficiently and prevent the build-up of materials. A tare adjustment,
up to 10 percent of the nominal capacity of the weigh scale, shall be provided on the weighing
mechanism so that the scale can be adjusted to zero at least once each day. Dust seals shall be
provided on Cement hoppers between the loading mechanism and the weigh hopper, and shall
be fitted so as to prevent the emission of Cement dust and not affect weighing accuracy. The
hopper shall be vented to permit escape of air without emission of Cement dust.
ii) Vibrator or other attachment, where fitted, shall not affect the accuracy of weighing. There
shall be sufficient protection to Cement and Aggregate weigh hoppers and weighing mechanism to
prevent interference with weighing accuracy by weather conditions or external build-up of
materials.
Where chemical admixture dispensers are used, they shall be capable of measurement within the
specified tolerance, and calibrated container or weigh scales shall be provided to check the
accuracy of measurement at least once a month.
Where a continuous mixer with ribbon loading is used the batching procedure specified by the
manufacture of the plant shall be followed.
Each control on the batching console and weigh-dial or display shall be clearly labelled with its
function and where concerned with the batching of materials, the materials type.
When more than one type or grade of Cement is being used, the weighing device and discharge
screw or other parts of the transfer system shall be empty before changing from one type of
Cement to another.
vii) When more than one type or grade of Cement is being used, the weighing device and discharge
screw or other parts of the transfer system shall be empty before changing from one type of
Cement to another.
When pulverized fuel ash and other mineral admixtures are batched through the Cement weigh
system, the weighing device and discharge screw or other parts of the transfer system shall be
empty when the weighing system has returned to zero reading or completed the batch.
Where a back weigh system is utilized to weigh materials a system shall be in place so as to
prevent materials being loaded during the process of weighing.
5.12.6.3 Measurement of Materials:
Cement and mineral admixture materials shall be measured by mass in a hopper or compartment
separate from those used for other materials and on a scale of appropriate sensitivity, measurement
being taken from a zero reading. Aggregates shall be measured by mass, allowance being made for the
free moisture content of the aggregates. The added water shall be measured by volume or by mass.
Any liquid chemical admixture (or paste) shall be measured by volume or by mass and any solid
admixture by mass. When weighing materials any build up in the hopper during the day must be tared
out or allowed for in the batch weights. After measurement all materials shall be discharged into the
mixer without loss.
The accuracy of the measuring equipment shall be within ± 2 percent of the quantity of Cement and
mineral admixtures being measured and within ± 3 percent of the quantity of aggregate, chemical
admixture and water being measured. The plant operator shall be provided with a clear display of the
quantities of materials to be batched for each mix and batch size with information identifying the
display to be selected for each designed and prescribed mix to be produced. Analogue scale displays
for the weighing of Cement, mineral admixtures, aggregates and water shall be readily discernible
from the operating position. For digital readouts the numerals shall be readily discernible from the
operating position.
Fully automatic production systems shall be fitted with control equipment to allow the correct
operation of the plant to be monitored during weighing and batching. Automatic control systems on
batching plants shall not commence batching until all hoppers have been emptied and /or tared and the
scales zeroed unless such systems are designed to take account of build-up in their programming.
5.12.6.4 Mixing:
(i) Washing Out Water: Before loading Concrete materials or mixed Concrete into either a
stationary mixer or truck mixer any water retained in the mixing drum for washing out purposes
shall be completely discharged.
(ii) Stationary or Central Mixers: Stationary mixers shall not be loaded in excess of the
manufacturer's rated capacity. The mixing time shall be measured from the time all the materials
required for the batch, including water, are in the drum of the mixer. The mixing time shall not
be less than that recommended by the manufacturer. Where a continuous mixing plant is used,
the complete mixing time shall be sufficient to ensure that the Concrete is of the required
uniformity.
(iii) Truck Mixers : When a truck mixer is used for the partial or complete mixing of Concrete,
mixing shall be considered to commence from the moment when all the materials required for
the batch, including water, are in the rotating drum of the mixer.
Truck or agitators shall not be loaded in excess of the manufacturer's rated capacity. In order
to produce a satisfactory mix, and where there is no data available to establish different period
and speed of revolutions, mixing shall continue for not less than 60 revolutions of the truck mixer
drum at a rate of not less than 7 revolutions/min. All completely truck mixed Concrete shall be
visually inspected for uniformity prior to leaving the plant.
When a truck mixer or agitator is used for transporting Concrete which has been mixed before
leaving the plant, the Concrete shall be agitated during transit and remixed at the site for at
least 2 min. so that the Concrete is of the required uniformity.
Where water is added to the Concrete in the truck mixer through the truck mixer water meter and
when such water is being accounted for in the total water within the mix, it shall be ensured
that the truck mixer water meter is in operational condition and properly calibrated. Where a
water meter is not available, water must be measured in a suitable container before being added
to the truck mixer.
(iv) Condition of Mixers : Stationary and truck mixers shall be maintained in an efficient and clean
condition with no appreciable build-up of hardened Concrete or Cement in the mixing drum, on
the mixing blades, or on the loading hopper or discharge chutes.
5.12.6.5 Delivery Ticket : Immediately before discharging the Concrete at the point of delivery, the
producer or his representative shall provide the purchaser with a pre-printed delivery ticket for each
delivery of Concrete on which is printed, stamped.
5.12.7 Quality Control : Quality control of ready-mixed Concrete may be divided into three
components, forward control, immediate control and retrospective control.
5.12.7.1 Forward control : Forward control and consequent corrective action are essential aspects of
quality control. Forward control includes the following.
(i) Control of purchased material Quality.
(ii) Control of Materials storage.
(iii) Mix design and mix design modification.
(iv) Transfer and Weighing Equipment : The producer shall be able to demonstrate that a
documented calibration procedure is in place. The use of electro-mechanical weighing and
metering systems, that is, load cells, flow meters, mega meters, etc., is preferable over purely
mechanical system, that is knife edge and lever systems.
(v) Plant mixers where present and truck mixers used shall be in an operational condition.
5.12.7.2 Immediate Control : Immediate control is concerned with instant action to control the
quality of the Concrete being produced or that of deliveries closely following. It includes the
production control and product control.
(a) Production Control :
i) The production of Concrete at each plant shall be systematically controlled. This is to
ensure that all the Concrete supplied shall be in accordance with these requirements and
with the specifications that has formed the basis of the agreement between the producer
and purchaser.
ii) Each load of mixed Concrete shall be inspected before dispatch and prior to discharge.
The workability of the Concrete shall be controlled on a continuous basis during
production and any necessary corrective action taken.
iii) For each load, written, printed or graphical records shall be made of the mass of the
materials batched, the estimated slump, the total amount of water added to the load, the
delivery ticket number for that load, and the time the Concrete was loaded into the truck.
iv) Regular routine inspections shall be carried out on the condition of plant and equipment
including delivery vehicles.
(b) Product Control :
i) Concrete mixes shall be randomly sampled and tested for workability and where
appropriate, plastic density, temperature and air content. Where significant variations
from target values are detected, corrective action shall be taken.
ii) It is important to maintain the water Cement ratio constant at its correct value. The
amount of added water shall be adjusted to compensate for any observed variations in
the moisture contents in the aggregates. Suitable adjustments should also be made in
masses of the aggregates due to this variation (see IS : 456-2000). Any change in water
content due to change in aggregate grading shall be taken care of by forward control by
suitable modifications to mix design.
5.12.7.3- Retrospective Control : Retrospective control is concerned with those factors that influence
the control of production. Retrospective control may cover any property of materials or Concrete, such
as aggregate grading, slump, or air content, but is particularly associated with 28 day cube strength,
because by its very nature it is not a property which can be measured ahead of, or at the time of its
manufacture.
5.12.7.4 - Mix Performance : The producer shall be responsible for ensuring that suitable control
procedures are in place ensure the following.
i) Design Mixes : A quality control system shall be operated to control the strength of design mixes
to the levels required as per IS : 456-2000 and shall be based on random tests of mixes which
form the major proportion of production. The system shall include continuous analysis of results
from cube tests to compare actual with target values together with procedures for modifying
mix proportions to correct for observed differences. Compressive strength testing shall be carried
out using a machine that meets the requirements of IS :14858-2000 ( Reaffirmed 2005)
(ii) Prescribed Mixes : Periodic and systematic checks shall be made to ensure that the Cementious
material contents of prescribed mixes comply with their mix descriptions.
5.12.7.5 Stock Control of Materials : The producer shall operate a materials stock control procedure to
enable verification of total quantities used and to confirm that only approved materials have been
received.
5.12.7.6 Complaints : The producer shall have a procedure in place to enable the diagnosis and
correction of faults identified from complaints.
5.12.8 Order Processing: A competent person to interpret the specified requirements and relate
these to mix design criteria shall systematically review specification and orders supplied by the
purchaser. These shall be formally recorded together with any modification to the specification
resulting from subsequent agreed documentation to ensure that the plant operator is given the correct
instructions for batching and mixing. When mixes or materials are offered as alternatives to requested
mixes or where there is no specification supplied by the purchaser, orders whether received verbally
or in writing, shall be agreed with the purchaser and the fact recorded. Alternatives to the mix
description or compliance requirements in the purchaser's specification shall be clearly identified in
the quotation.
5.12.9 Records: Records shall be maintained by the producer to provide confirmation of the quality
and quantity of Concrete produced. The records shall be retained for the purposes of these
requirements for a period of at least one year. They shall cover the following aspect:
(a) Production and delivery:
(i) Batching instruction
(ii) Batching Records,
(iii) Delivery tickets, and
(iv) Equipment calibration and plant maintenance.
(b) Materials and production control:
(i) Concrete production and materials purchase, usage and stocks, and
(ii) Certificates or test results for materials.
I Production quality control: Control test results.
5.12.10 Placing Concrete by pumping:
5.12.10.1 General : Concrete conveyed by pressure through either rigid pipes or flexible hoses and
discharged directly into the desired area is termed as pumped Concrete. Method of applying pressure
to Concrete is by pumps. Pumps to be used shall be either of the two types as mentioned below:-
(a) Piston type pumps
(b) Squeeze pressure type pumps.
Compressed air pressure pumps shall not be used in the works.
5.12.10.2 Pumping Equipment :
a) Piston Pumps: Piston pump to be used in the works shall consist of a receiving hopper for mixed
Concrete, an inlet valve, an outlet valve, and the pump shall be a twin-piston pump. The two
pistons shall be so arranged that one piston retracts when the other is moving forward and pushing
Concrete into the pipe line to maintain a reasonably steady flow of Concrete. Single piston
pumps shall not be acceptable.
Inlet and outlet valve shall be any one of the following types:-
 Rotating plug type
 Sliding plate type
 Guided plunger type
 Swing type
 Flapper type
 Or any combination of the above.
The pistons shall be mechanically driven using a crank or chain or hydraulically driven using
oil or water.
The receiving hopper shall have a minimum capacity of 1.0 cum and the hopper shall be fitted with
remixing rotating blades capable of maintaining consistency and uniformity of Concrete.
The primary power for pumps may be supplied by gasoline, diesel, or electric motors. The
primary power unit and the pump unit may be truck, trailer or skid mounted.
b) Squeeze Pressure Pumps : Squeeze pressure pumps shall consist of a receiving hopper fitted
with re-mixing blades. Re-mixing blades shall be such that these can push the Concrete into the
flexible hose connected at the bottom of the hopper.
The flexible hose shall pass through a metal drum around the inside periphery of the drum and
come out through the top part of the drum.
The drum shall be maintained under a very high degree of a vacuum during operation. The
drum shall be so fitted with hydraulically operation metal rollers., which when rotating, create a
squeeze pressure on the flexible hose carrying Concrete and forces the Concrete out into the pipe
line.
c) Effective Range and Discharge of Pumps : Effective range of pumps to be used in the work
shall be decided after studying the site conditions. However, the minimum horizontal range shall
not be less than 150 metres and minimum vertical range shall not be less than 50 metres.
Selection of pumps bases on discharge capacity shall be decided after studying the requirements
for the project. Discharge capacity shall be worked out by the contractors and approval obtained
from the Engineer-in-Charge. As a guide line figure the contractor may assume a discharge
capacity of 15 cubic metre/hour/pump.
d) Pipe Lines : All Concrete carrying pipe lines shall generally be rigid pipe lines. Flexible pipe
lines may only be used at bend curves in lines or at discharge ends if required. Placements of
flexible units shall be done judiciously and connected to the pipe lines only when it meets the
approval of the Engineer-in-Charge.
i) Rigid Line/ Hard Line/ Slick line : Such lines shall be made either of Steel or plastic.
Aluminium alloy pipes shall not be used. Minimum pipeline diameter shall be 100
millimetre and shall have normal maximum length of 3 metre in each section connected
through couplers.
(ii) Flexible Pipe Line: Flexible lines shall be made out of rubber or spiral wound flexible
metal or plastic. The pipe shall again be such that they are in sections of 3 metre length
each and connected through couplers. These pipes shall be such that they are
interchangeable with rigid lines. While installing flexible units, care shall be taken that
there are no links in the pipeline, which is a normal tendency with these pipes having
diameter 100 mm and above.
e) Couplers : Couplers to be used for connecting pipe line sections (either hard or flexible) shall
have adequate strength to withstand stresses due to handling, misalignments, poor support to
pipe lines etc.
For horizontal runs of pipes and for vertical run up to 30 metre height the couplers shall be
rated for a minimum pressure of 35 kg/ cm2. Couplers used for rising runs between 30 metre and
50 metre heights shall have a minimum pressure rating of 50 kg/cm2 . Couplers shall be
designed to allow for replacement of any pipe section without displacing other sections. These
shall provide for the full internal cross section. These shall provide for the full internal cross
section with no constructions or service. Which may disrupt the smooth flow of Concrete. For
pipelines of size 150mm and above, double togged type coupler with a thick rubber gasket and
secondary wedge-take-up is recommended. Types of couplers that may be used shall be any of
the following:-
 Grooved end coupler
 One piece extended lever swing type couplers
 And full flow oil line type couplers.
f) Other Accessories : Other accessories which shall be catered for, are as under:-
(i) Back up pump of rigid and flexible pipes of varying lengths of similar rating/
specifications.
(ii) Curved sections of rigid pipes.
(iii) Swivel joints and rotary distributors.
(iv) Pin and gate valves to prevent back flow in pipe lines.
(v) Switch valves to direct the flow into another pipe line
(vi) Connection devices to fill forms from the bottom up
(vii) Splints, rollers, and other devices for protection of conduit over rock Concrete
Reinforcing Steel and form and to provide lifting and lashing points in the pipe line.
(viii) Transitions for connecting different sizes of pipe sections
(ix) Air vents for downward pumping.
(x) Clean out equipment.
For concreting of columns, walls and scattered small placement, recommendation is made for
special cranes or power controlled booms carrying pipe lines with a pendant type Concrete
delivery hose.
g) Lubricating of Pipe Line: Before pumping Concrete into the pipeline, the line shall be lubricated
with a properly designed mortar/grout lubricant. This shall be ensured by starting the pumping
operation with a properly designed mortar or with a batch of regular Concrete with the Coarse
aggregate omitted. The quantity of mortar required as lubricant is dependent on the smoothness
and cleanliness of the pipelines. As a guide line, for a 100 mm diameter pipe line of 100 metre
length, 0.08 cum to 0.10 cum of mortar should normally be adequate, but this shall not be taken
as specified, and the contractor shall establish his requirements.
The quantity of mortar that comes out of the delivery end of the pipeline shall not be used in
place of the Concrete work. However, with the approval of Engineer-in-Charge, this mortar
may be used as bedding mortar against construction joints. The rest of the mortar shall be
wasted.
Lubrication shall be maintained as long as the pumping of Concrete continues.
5.12.10.3-Guidelines for field practice:
5.12.10.3.1 General Precautions:
(a) Proper planning of Concrete supply, pump locations, line layout, placing sequence and the
entire pumping operation will result in savings of time and expense.
(b) The pump shall be placed as near the placement area as practicable. The surrounding area of
the pump shall be free of obstructions to allow for movement of Concrete delivery trucks. The
surface must be strong enough to withstand the loaded trucks operating on it. If the surface is a
suspended slab, the truck route shall be adequately supported in consultation with the Engineer in-
Charge.
(c) Pipe lines from the pump to the placing area shall be laid with minimum number of bend. For
large placement areas, alternate lines shall be installed for rapid connection when required. A
flexible pipe at the discharge end will permit placing over a large area directly without re-
handling of pipelines. The pipeline shall be firmly supported.
If more than one size of pipe must be used, the smaller diameter pipe shall be placed at the
pump end and the larger diameter at the discharge end.
When pumping downwards, an air release valve shall be provided at the middle of the top bend
to prevent vacuum or air build-up. Similarly, while pumping upwards, a no-return valve shall be
provided near the pump to prevent the reverse flow of Concrete.
It is essential that direct radio/telecommunication be maintained between the pump operator and
the Concrete placing crew. Good communication between the pump operator and the bathing
plant is also essential. The placing rate shall be estimated by the pump operator so that Concrete
can be ordered at an appropriate delivery rate.
The pump shall be started for a check run and operated without Concrete to ensure that all
moving parts are in operation properly. Before placing Concrete, the pump shall be run with
some grout/mortar for lubricating the line.
When Concrete is received in the hopper, the pump shall be run slowly until the lines are
completely full and the Concrete is steadily moving. A continuous pumping must be ensured,
because, if the pump is stopped, Concrete in the line may be difficult to move again.
When a delay occurs because of Concrete delivery or some form repair works or for any other
reason, the pump shall be slowed down to maintain some movement of Concrete in the pipe line.
For longer delays, Concrete in the receiving hopper shall be made to last as long as possible by
moving the Concrete in the lines occasionally with intermittent strokes of the pump. It is
sometimes essential to run a return line back to the pump so that Concrete can be re-circulated
during long delays.
a) If after a long delay, Concrete cannot be moved in the line, it maybe necessary to clean out the
entire line. However, quite often only a small section of pipe line may be plugged and requires
cleaning. The pump operator who know such details as the length of line, age of Concrete in the
line etc., should be depended upon to aid in deciding the appropriate section to be cleaned.
(k) When the form is nearly full, and there is enough Concrete in the line to complete the placement,
the pump shall be stopped and a "go devil" inserted at the appropriate time so that Concrete
ahead of the go-devil shall be forced completion of the work. The go-devil shall be forced
through the pipeline to clean it out. Use of water pressure is a safer method. The go-devil shall
be stopped at the discharge end to ensure that water does not spill on the placement area, if air
pressure is used, extreme care shall be taken and the pressure must be carefully regulated. A trap
shall be installed at the end of the line to prevent the go-devil being ejected as a dangerous
projectile. An air release valve shall also be installed in the line to prevent air pressure build up.
(1) It is essential to clean the line after Concrete placing operation is complete. Cleaning shall be
done in the reverse direction from the form work end to the pump-end where the Concrete in
the line can be dumped in bucket. After removal of all Concrete, all pipe lines and other
equipment shall be cleaned thoroughly and made ready for the next use.
5.12.11- Submittals: Along with their bid the contractors shall be required to submit the following
information regarding the equipment proposed to be used by them:-
(i) Type, number, capacity, range, mounting, nature of primary power used and the operating
weight of pump and mounting.
Manufacturer's specifications for pipelines giving pressure ratings, sizes and material for
straight and curved sections.
(iii) Manufacturer's certificates.
5.12.12 Sampling and Testing (Materials):
a) Aggregates:
(i) Supplier of aggregates shall furnish the following information before the material is
delivered to site:-
 Precise location of source from where the material is to be supplied.
 Trade group of principal rock type as per Table 20 shown below:
 Presence of reactive minerals.
Table-20
Trade group name of : Granite, Gabbros,
Aggregates to be used for Concrete : Dolerite, Rhyolite, Basalt, Quartzite, Gneiss.
(ii) The supplier shall also furnish reports on test results giving the following information for
approval to Engineer-in-Charge before delivery of material at site:-
Specific gravity
Bulk density
Moisture content Absorption Value
Aggregate crushing strength
Aggregate impact value
Abrasion value
Flakiness index
Elongation index
Limits of deleterious substances in the aggregate
Soundness of aggregate
Potential reactivity of aggregates.
All tests shall be conducted in accordance with IS :2386 (Part-I to VIII)-1963 ( Reaffirmed
2002).
(iii) Change in quality of aggregate as per trade group name shall not be acceptable in the work.
Change in source of aggregates shall also not be acceptable under normal circumstances, even
if the aggregate belong to the same trade group. Engineer-in-Charge may with his discretion
allow a change in the source. But, in that case, all test mentioned in para 5.12.12 (a) above shall
have to be repeated for the aggregates form the changed source and the test results submitted
to Engineer-in-Charge for his approval before the delivery of material at site.
(iv) In addition to above, the following tests have to be performed on representative samples from
every lot of aggregate after delivery at site. These test results are to be submitted to the
Engineer-in-Charge for his approval. Acceptance criteria for aggregates shall be based on the
results of this set of tests only. If in the opinion of the Engineer-in-Charge, the test results are not
with in permissible limits, the lot of aggregates from which the samples have been obtained for
testing shall stand rejected and the material shall be removed from the site. Mandatory tests on
Aggregates at site
Tests Nos. of test on each 50 cum of
Material or part thereof
1. Specific gravity 3
2. Bulk density 3
3. Aggregate crushing strength 3
4. Limits of deleterious substances 3
5. Aggregate impact value 3
Mean value of the results from above test shall be taken as there presentative value and the
acceptance criteria shall be based on these. All test procedures and computations for test results
shall be as per IS: 2386-1963.
(v) All other tests in Para (iv) being incompliance with requirements set in specifications, if only
the limits of deleterious substances do not meet the requirements, and attempt may be made to
wash the aggregate to bring the limits within permissible values. Under such circumstances,
moisture content check shall be made and allowance made before batching.
(vi) Apart from mandatory tests specified above, the Engineer-in-Charge may in this discretion,
call for any additional tests that he may consider necessary. Sampling, procedure and
computations for such test shall be done in accordance with IS :2430- 1986 ( Reaffirmed 2005)
and IS :2386-1963 as applicable.
b) Cement: Supplier of Cement shall furnish the following documents before the Cement is
delivered to site:-
(i) Certificate confirming that chemical composition and physical characteristics are within
the stipulated values for types of Cement supplied as per relevant codes.
(ii) Certificate confi«~ung that the Chloride content in the Cement is not in excess of 0.05
percent of mass of Cement.
(iii) If during subsequent testing of Cement supplied in lots any of the properties are found
to be outside the acceptable limits, the lot of Cement shall be rejected.
(iv) Each 1000 bags or part there of the Cement or each wagon load of Cement shall constitute
one lot of Cement for the purpose of conducting test sat site before Cement is accepted.
(vi) Samples for testing at site shall be taken at random from 2% of the total quantity supplied
in one lot. For Cement supplied in bags, samples shall be drawn from minimum of 5 bags
and the 2% value shall be rounded off to the next higher integer.
For bulk Cement, sampling shall be done with the help of slotted sampler to be as per IS:
3535-1986 ( reaffirmed 2004).
(vi) Results of test conducted on samples drawn shall be submitted to the Engineer-in-Charge for
his approval. If in the opinion of the Engineer-in-Charge, the test results are not within
permissible limits, the lot of Cement from which samples have been obtained from testing shall
stand rejected and the material shall be removed from site.
(vii) Following tests shall be conducted at site on each lot of Cement delivered:-
1. Consistency of standard cement

paste
Mandatory Mean values of tests the results from the
2.
5 Initial above results shall Number all of be taken test per as
lot the Ref. to IS representative 4031 -1988
3.
partCompressive
4 strength
test
10
part 7
 Certificate confirming the exact dosage of admixture of a particular brand. Certificate
stating the specific purpose for which the admixture is to be used.
 Special precautionary measures to be taken in the manufacturer of Concrete when using
the particular brand of admixture.
 Certificate confirming that the admixture conforms to specifications of IS :9103-1959
(Reaffirmed 1999)
(ii) Engineer-in-Charge at his discretion may require tests to be performed to reconfirm the
characteristic properties of any admixture. All such tests shall be done in accordance with IS
:9103-1959.
(iii) All tests described in Appendix À' shall be done at the site laboratory or at a laboratory to
be identified by the Engineer-in-Charge depending on the test to be conducted.
(iv) All test shall be done in the presence of a representative nominated by the Engineer-in-Charge
and a representative of the Concrete Manufacturer/ Contractor, when tests are performed at the
site laboratory. All observation and reports of test shall be jointly signed by the two
representatives before the test results are submitted to the Engineer-in-Charge.
(v) Expenses for all materials used for testing, sampling procedures and testing including
preparing reports shall be borne by the Concrete Manufacturer/Contractor.
(vi) Rate of Concrete is inclusive of cost of admixtures. The contractor shall not be paid anything
extra for admixtures required for achieving direct workability without any change in specified
water Cement ratio for RCC/CC work.
5.12.13 -Sampling and Testing for Quality Control of Fresh Concrete: Fresh Concrete shall be
tested for
(a) Slump
(b) Compacting Factor/ Workability
(c) Consistency
(d) Weight per cubic metre, Cement factor and air content.
5.12.13.1-Slump:
(i) For Concrete totally mixed in a central plant, slump shall be checked at:-
(a) Immediately during loading of trucks
(b) Point of discharge from the delivery truck
(c) Final placement location
(d) (i) At placement location the slump measured shall conform to the design slump.
Manufacturer of Concrete shall adjust for loss of slump in transit and establish the
requirements of design mix. All slump measurements shall be done within a period of 20
minutes from the time Cement is added to the mixer. Placement contractor shall transport
Concrete from truck discharge point to actual placement location within10 minutes of
delivery, before the final slump reading is taken at placement location.
(ii) For Concrete entirely mixed in transit or for shrink mix Concrete, slump reading shall be
taken at:- (a) Point of discharge from delivery trucks (b) Final placement location
In this case also, the slump measured at the final placement location shall conform to the design
slump. The placement contractor shall be responsible for transporting Concrete from delivery
truck discharge point to final placement location within 10 minutes. However, in this case, the
truck shall discharge the Concrete within lhour and 30 minutes from the time Cement is added
in the mixer and slump measured at point of discharge immediately on delivery. Manufacturer
of Concrete shall ensure that the final slump measurement corresponds to the ordered slump.
(iii) For measuring Concrete slump at point of discharge from delivery trucks, samples shall be
taken from Concrete omitting the first and the lastl5% of the load. For Concrete delivery of
which is placed by pumping, sampling shall be similar to those specified for delivery trucks.
(iv) Slump measurements of ready mix Concrete transported by buckets shall be at locations
specified in Para 5.12.3.2 with same limits on time. Sampling from buckets shall be such that
the buckets containing discharge from mixer for the last 15% are omitted.
(v) At placement locations, samples for checking slump shall be collected from every20cumof
Concrete or part thereof placed at location for each type to Concrete.
(vi) For all slump checks in the field at least two recordings shall be made and the average value
taken as the recorded slump.
(vii) Slump checks for Concrete in the laboratory shall be carried out as and when required by the
manufacturer of Concrete during the mix design stage and during the progress of work for
control on field results.
(viii) Slump readings shall only be a guideline for Concrete consistency and shall not be taken as
the acceptability criteria for Concrete placed at location. All slump test shall be carried out in
accordance with IS :1199-1959 ( Reaffirmed 1999).
5.12.13.2 Compacting Factor:
(i) For Concrete whose ordered slump is 50 mm or less, compacting factor test shall be conducted at
both field and central batch plant in addition to slump tests mentioned above.
Compacting factor check shall be done in field only at placement location, and shall also be
conducted at central batch plant if Concrete is totally mixed in plant.
For this test, sampling shall be done as for slump measurements in field and within the same
frame as for slump test.
Only one compaction factor test shall be conducted for every 20 cum of Concrete or part thereof
placed at location for each type of Concrete. Since the test is sensitive, every care shall be taken
to conduct this test totally in compliance with procedure mentioned in IS :1199-1959 (reaffirmed
1999).
(v) Laboratory tests for determining compacting factor of Concrete shall be done as per
manufacturer's requirements for establishing and controlling the design mix of Concrete.
(vi) Compacting factor test shall not be taken as an acceptance criteria and shall be treated only
as a guideline to workability of Concrete.
5.12.13.3-Consistency of Concrete:
This test shall be performed only at the batching plant laboratory using a Vee-Bee Consistency
meter, for determining and predicting the slump of Concrete. Number and frequency of these tests
shall be based on requirements of the manufacturer of Concrete. Care shall be taken in producing mix
design of required characteristic strengths of Concrete within limits of Vee-Bee- Degrees between
1.6 and 4.5 for Concrete transported and placed by normal method and between 0.8 and 3.5 for
Concrete transported and placed by pumping methods.
5.12.13.4-Weight,Cement Factor and Air contents Test: Freshly mixed Concrete for every type
shall be tested in the batch plant laboratory for each batch of Concrete produced to determine weight
per cubic metre of freshly mixed Concrete, Cement factor in Concrete and the air content of the
Concrete. Frequency and number of test shall be finalized by the manufacturer of Concrete in
consultation with the Engineer-in-Charge for his requirement of the mode of measurement of Concrete
produced.
The Engineer-in-Charge may at his discretion require further tests over and above those specified to
be conducted on fresh Concrete. The manufacturer and the placement contractor shall have to comply
with all such requirements.
5.12.13.5 Sampling and Testing for Quality Control of Hardened Concrete:
(i) Test on cube crushing strength of Concrete in accordance and compliance with IS :456-2000 and
IS :516 -1959 ( Reaffirmed 1999) shall done as under:-
(a) Sample of fresh Concrete shall be taken from Concrete at central batch plant mixer while
loading delivery trucks or other transport and also from Concrete transported to
placement location.
(b) Test on specimens made from samples collected at placement location shall be
considered as field test specimens and results there from shall be the criterion of Concrete
strength. Test in specimens made from samples at the batch plant shall only be taken as
guidelines test. Only in the case of doubtful result, the Engineer-in-Charge may refer to such
guideline results for deciding on the quality of Concrete.
(c) For truck mix Concrete and shrink mix Concrete guideline test specimens shall be made
from samples collected at discharge location from mixing trucks. For this purpose first and
lastly% of the load shall be omitted while collecting samples.
(d) Frequency of sampling shall be as per 5.3.1.10 (c) given below in for each grade of
Concrete of different workability's and for each type of specimens (field test specimens
and guideline test specimens) for conducting 28 days crushing strength tests.
Each sample shall be of adequate quantity so that a minimum of 3specimen cubes can be made
test of the sample in accordance with IS :516-1959 ( reaffirmed 1999).
(e) All test specimens shall be made compacted cured and tested in compliance with IS
:516-1959 ( Reaffirmed 1999) and test result interpreted in accordance with IS:456-2000 for
acceptance of Concrete strength, field specimens test results shall not be less than values given
in Table 7.
(f) In addition to 28 day crushing strength test on specimens made at frequencies specified
in para (d) above, early strength tests at 7 days shall also be conducted on field specimens as
well as guideline test specimens. Frequency of sampling for this set of test shall also be same as
those specified in para 5.3.1.25(c) above. 7 day strength shall conform to values given earlier.
But these test results even if conforming to specified values shall only be taken a guideline
values for projecting Concrete strength and shall not be construed as conforming to
specifications.
(g) For each grade of Concrete and for all workability conditions with different water-Cement
ratios and compositions of admixtures, preliminary test shall be conducted for crushing strength
on finalization to design mix for each type of Concrete. Such test shall be conducted both at 7
days and 28 days under laboratory conditions. Six test specimens shall be made for 7 days test
and six test specimens shall be made for 28 days test. Average of the six test results of different
periods shall not be less than those specified in Table 7.
(h) Crushing strengths on cubes shall also be conducted during the process of finalization of
Concrete design mix. Frequency and number of such tests shall be as per Mix of requirements
of Concrete manufacturer.
(i) All test specimens for conducting crushing strength shall be properly labelled for
identification indicating:-
(i) Date of making specimen
(ii) Grade of Concrete
(iii) Placement location exact
(iv) Purchasers order number
a) In addition to crushing strength test on Concrete, the Engineer-in-Charge may call for other tests
on hardened Concrete. The placement contractor and the manufacturer of Concrete shall comply
with all such instructions.
(ii) Non- destructive Tests
(a) When the 28 days crushing values on field specimens and/or specimens made for guideline test
fall short of specified values, or in case of doubtful placement of Concrete, the Engineerin-Charge
shall call for non-destruction tests on the structure. Such tests may be anyone or a combination
of the following:-
 Rebound hammer test
 Windsor Penetration Probe test
 Pulse velocity(sonic or Ultrasonic)test
 Core test
 Load test
(b) Interpretation of rebound hammer, Winds or Probe and Pulse velocity test results shall rest
with the Engineer-in-Charge.
(c) Core test, if ordered by the Engineer-in-Charge, shall be done in accordance with IS: 516-1959
( reaffirmed 1999) . Samples for such test shall be taken from locations to be identified by the
Engineer-in-Charge and such samples shall be collected in compliance with IS: 1199-1959 (
Reaffirmed 1999) .
(d) If felt necessary, the Engineer-in-Charge may instruct load testing for any part of the structure
based on doubtful Concrete strengths. Such test shall be carried out as per details to be provided
by the Engineer-in-Charge in consultation with the structural consultants.
(e) The Concrete manufacturer/ Concrete placement contractor shall arrange for all test to be
conducted in accordance with these specifications, including all necessary tools, plants,
equipment and material, and shall be responsible for conducting all test at his cost.
(f) All test conducted at the field laboratory shall be carried out by qualified technicians employed
by the Concrete manufacturer/Concrete placement contractor, in presence of authorized
representative of the Engineer-in-Charge. All test reports and observation reports shall be
jointly signed by the Engineer-in-Charge, authorized representative of the contractor and the
technician conducting such test.
(g) Engineer-in-Charge shall one decide where such tests are to be conducted. He may instruct
tests to be conducted at laboratories other than the field laboratory and such instructions shall
be followed without claiming extra charges on this account.
(h) The Concrete Manufacturer/ Placement contractor shall set up a laboratory at his own expense
which shall have facilities, for conducting all necessary field test on materials and field and
laboratory test on Concrete. The laboratory shall be staffed by the Concrete Manufacturer/
Placement Contractor with qualified and experienced scientists and technicians.
5.13 Measurement: Dimensions of length, breadth and thickness shall be measured correct to
nearest cm. except for the thickness of slab and partition which shall be measured to nearest 5 mm.
Areas shall be worked out to nearest 0.01 sqm and the cubic contents of consolidated concrete shall
be worked out to nearest 0.01 cum. Any work done in excess over the specified dimension or sections
shown in the drawing shall be ignored for measurement.
5.13.1 Cast-in-situ and precast concrete work shall be measured separately
5.13.2 Concrete work expected in the following conditions shall be measured separately:
a) Work in or under water,
b) Work in liquid mud,
c) Work in or under foul positions,
5.13.3 Cast-in-situ concrete or precast concrete work shall be measured in stages described in the
item of work, such as:
At or near the ground level
a) Up to specified floor level
b) Between two specified floor levels
c) Up to specified height above or depth below plinth level/defined datum level
d)
e) Between two specified heights or depths with reference to plinth level/defined datum level.
5.13.4 Cast-in-situ concrete shall be classified and measured as follows:
Foundation, footings, bases for columns
a) Walls (any thickness) including attached pilasters, buttresses, plinth and string courses, fillets
b) etc.
Shelves
c) Slabs
d) Chhajjas including portions bearing on the wall
e)
Lintels, Beams,
F)
Columns, Piers Abutments, Pillars, Post and Struts
g) Stair case including stringer beams but excluding landings.
h)
i) Balustrades newels and railing.
j) Spiral staircase (including landings)
k) Arches.
1) Domes, vaults.
m) Shell roof, arch ribs and folded plates.
n) Chimneys and shaft.
o) Breast walls, retaining, walls, return walls.
p) Concrete filling to precast components.
q) Kerb, steps and the like.
r) String or lacing courses, parapets, copings, bed block, anchor blocks, plain window sills and
the like.
s) Cornices and moulded window Sills Sunshade etc.
t) Louvers, fins, facia.
5.13.5 Precast cement concrete solid articles shall be measured separately and shall include use of
moulds, finishing the top surfaces even and smooth with wooden trowel before setting in position in
cement mortar 1:2 (1 cement :2 coarse sand). Plain and moulded work shall be measured separately and
the work shall be classified and measured as under:
Table -21
S. Na Classifications Method of measurement
1 Wall panels In square meter stating the thickness.
2 String or lacing courses, copings, bed plates, In cubic meter.
plain window sills, shelves, louver, steps etc.
3 Kerb, edgings etc. In cubic meter.
4 Solid block work In square meter stating the thickness
or in cubic meter.
5 Hollow block work. In square meter stating the thickness
or in cubic meter.
6 Light weight Partitions In square meter stating the partition's
thickness.
5.13.6 Dimensions of length, breadth and thickness shall be measured correct to nearest cm. except for
the thickness of slab and partition which shall be measured to nearest 5 mm. Areas shall be worked
out to nearest 0.01 square meter and the cubic contents of consolidated concrete shall be worked out
to nearest 0.001 cubic meter. Any work done in excess over the specified dimension or sections shown
in the drawing and over to directions of Engineer-in-charge be ignored.
5.13.7 No deduction shall be made for the following:
a) Ends of dissimilar materials for example beams, posts, girders, rafters, Purlins trusses corbels
and steps up to 500 sq cm in cross sections.
b) Opening up to 0.1 sq. m. (1000 sq.cm.)
c) Volume occupied by pipes, conduits, sheathing etc. not exceeding 100 sq.cm. each in cross
sectional areas.
d) Small voids those do not exceed 40 sq.cm. each in cross section.
Note: In calculating area of opening, the thickness of any separate lintel or sill shall be included in
the height. Nothing extra shall be payable for forming such openings or voids.
Area of Fig. A to G shall be = L x B
Area of Fig. H & J shall be = L x {Average of B and B' }
5.14: Rate: The rate is inclusive of the cost of labour and materials involved in all the operations
described above.
5.15 Damp Proof Course: 5.15.1
Cement Concrete layer:
This shall consist of cement concrete of specified proportions and thickness. The surface of brick or
stone masonry work shall be levelled and prepared before laying the cement concrete. Edge of damp
proof course shall be straight, even and vertical. Side shuttering shall consist of steel forms and shall
be strong and properly fixed so that it does not get disturbed during compaction and the mortar does
not leak through. The concrete mix shall be of workable consistency and shall be tamped thoroughly
to make a dense mass. When the sides are removed, the surface should come out smooth without
honey-combing. Continuity shall be maintained while laying the cement concrete layer and laying
shall be terminated only at the predetermined location where damp proof course is to be discontinued.
There shall be no construction joint in the Damp Proof Course.
5.15.2 Curing: Damp proof course shall be cured for at least seven days, after which it shall be
allowed to dry.
5.15.3 Application of Hot Bitumen : Where so directed, hot bitumen in specified quantity shall be
applied over the dried up surface of cement concrete, properly cleaned with brushes and finally with
a piece of cloth soaked in kerosene oil, bitumen of penetration A 90 or equivalent where used shall be
heated to a temperature of 160° + 5°C. The hot bitumen shall be applied uniformly all over, so that no
blank spaces are left anywhere. It will be paid for separately.
5.15.4 Water proofing Materials: Where so specified, water proofing materials of approved quality
shall be added to the concrete mixture in accordance with the manufacture's specifications stating the
quantity of water proofing material in litre or kg per 50 kg of cement and will be paid for separately.
5.15.5 Measurements: The length and breadth shall be measured correct to nearest cm and its area
shall be calculated in square meters correct to two places of decimal. The depth shall not be less than
the specified thickness at any section.
5.15.6 Rate: The rate is inclusive of the cost of materials and labour involved in all the operations
described above except for the application of a coat of hot bitumen and addition of water proofing
materials which shall be paid for separately, unless otherwise specified.
5.16 Cement- Fly Ash Concrete:
5.16.1 Fly ash concrete shall be prepared by mixing graded coarse aggregate of nominal size as
specified with fine aggregate, ordinary Portland cement and fly ash in specified proportions with
required quantity of water. The recommended composition of cement fly ash concrete are as under:
Table -22: Fly Ash Concrete Mixes
Composition (Dry Volume) Proportion (Dry Compressive Strength at seven
Volume) days in kg/sqcm
Lean Concrete (1:5:10)
Cement (Ordinary Portland) 1.0
Fly ash 2.5
Sand 4.0
Stone aggregate 11.0
Lean Concrete (1:4:8)
Cement (Ordinary Portland) 1.0 37 kg/cm2
Fly ash 2.0
Sand 3.5
Stone aggregate 9.0
Note: No fly ash is tobe added to Portland Pozzol a cement in any case which itself c o n t n s fly
itself contains fly ash.
5.16.2 Proportioning:
Proportioning shall be done by volume. Boxes of suitable size shall be used for measuring fly ash,
sand and aggregate. The internal dimensions of the boxes shall be generally 35x25x40 cm.
deep or as otherwise approved by the Engineer-in-charge. The unit of measurement of cement shall
be a bag of 50 kg. and this shall be taken as 0.035 cum. While measuring the aggregate, shaking,
ramming or heaping shall not be done. The proportioning of sand shall be on the basis of its dry volume
and in case of damp sand, allowances for Bulkage shall be made as given in the chapter 4 for mortar.
5.16.3 Mixing shall be as specified in 5.3.1.15 to 5.3.1.18 except that the fly ash shall be placed in the
hopper before cement in case of machine mixing.
5.16.4 Placing and compaction shall be as specified in 5.3.1.19 (b) and 5.3.1.20.
5.16.5 Curing shall be as specified in 5.6.
5.16.6 Form work shall be as specified in 5.9.
5.16.7 Measurements shall be as specified in 5.13.
5.16.8 Water Proofing Materials:
Where so specified, water proofing material of approved quality shall be added to the concrete
mixture in accordance with the manufacturer's specification stating the quantity of water proofing
material in litres or kg per 50 kg of cement and will be paid for separately.
The length and breadth shall be measured correct to a cm and its area shall be calculated in square
metres correct to two places of decimal. The depth shall not be less than the specified thickness at any
section.
5.16.10 Rate:
The rate is inclusive of the cost of materials and labour involved in all the operations described above
except for the applications of a coat of hot bitumen and addition of water proofing materials which
shall be paid for separately, unless otherwise specified.
APPENDIX À'
LIST OF MANDATORY TESTS
Material Clause Test Field! Test Min. Frequency of
Laboratory procedure quantity of Testing
Material for
Carrying out
test
1 2 3 4 5 6 7
Stone 5.1.1 (a) Percentage of Field or IS 2386- As required For all quantities
aggregate soft or deleterious Laboratory Part II by Engineer-
material Test as in-charge
required
5.1.3 Particle size Field! Lab Appendix 45 cum For every 45 cum
(a) À' or part thereof for
RCC Work only.
For rest of items
as decided by
Engineer-in-charge
5.1.4 Estimation of Field! Lab IS :2386- 10 cum For every 40 cum
(b) organic impurities Part II or part thereof
(d) Surface moisture Field/ Lab IS 2386 10 cum -do-
(d) Determination of Field/ Lab IS 2386 10 cum -do-
10% fine value
(c) Specific gravity Field/ Lab IS 2386 10 cum -do-
(c) Bulk density Field/ Lab IS 2386 10 cum -do-
(d) Aggregate Field/ Lab IS 2386 10 cum -do-
crushing strength
(d) Aggregate impact Field/ Lab IS 2386 10 cum -do-
value
Concrete 5.3.1.2 Slump test Field/Lab Appendix 10 cum 15 cum or part
'H' thereof
5.3.1 Determination of Field/Lab Appendix 1 cum 1-5 cum: 1(3 cubes)
compressive 'B' 6-15 cum:2
strength. 16-30 cum:3
31-50 cum :4
51 and above:
4+1 additional
sample for each 50
cum or part thereof.
APPENDIX `B'
CUBE TEST FOR COMPRESSIVE STRENGTH OF CONCRETE-

MANDATORY LAB TEST. IS: 516-1959 (Reaffirmed 1999)
B-0 One sample (consisting of six cubes 15x15x15 cm shall be taken for every 20 cum or part thereof
Concrete work ignoring any part less than Scum or as often as considered necessary by the Engineer
in- Charge. The test of Concrete cubes shall be carried out in accordance with the procedure as described
below. A register of cubes shall be maintained at the site of work. The casting of cubes, Concrete used
for cubes and all other incidental charge, such are curing, carriage to the testing laboratory shall be
borne by the contractors. The testing fee for the cubes, if any, shall be borne by the department.
B-1 Test Procedure:
B-1.1 Mould:
The mould shall be of size 15 cm x15 cm x15 cm for the maximum nominal size of aggregate not
exceeding 40 mm. For Concrete with aggregate size more than 40 mm size of mould shall be
specified by the Engineer-in-charge, keeping in view the fact that the length of size of mould should
be about four times the size of aggregate.
The moulds for test specimens shall be made of non-absorbent material and shall be substantially
strong enough to hold their form during the moulding of test specimens. They shall not vary from the
standard dimensions by more than one percent. The moulds shall be so constructed that there is no
leakage of water from the test specimen during moulding. All the cube moulds for particular site
should, prior to use, be checked for accuracy in dimensions and geometric form and such test should
at least be made once a year.
Each mould shall be provided with a base plate having a plane surface and made of non-absorbent
material. This plate shall be large enough in diameter to support the moulds properly without leakage.
Glass plates not less than 6.5mm thick or plain metal not less than 12mm thick shall be used for this
purpose. A similar plate shall be provided for covering the top surface of the test specimen when
moulded.
Note: Satisfactory moulds can be made from machine or Steel castings, rolled metal plates or
galvanized.
B-1.2 Sample of Concrete
Sample of Concrete for test specimen shall be taken at the mixer or in the case of ready mixed
Concrete from the transportation vehicle discharge or as directed by Engineer-in-Charge. Such
samples shall be obtained by repeatedly passing a scoop or pail through the discharge stream of
Concrete. The sampling operation should be spread over evenly to the entire discharging operation.
The samples thus obtained shall be transported to the place of moulding of the specimen to counteract
segregation. The Concrete shall be mixed with a shovel until it is uniform in appearance. The location
in the work of the batch of Concrete this sample shall be noted for further reference. In case of paving
Concrete, samples shall be taken from the batch immediately after deposition of the sub grade. At least
five samples shall be taken from different portion of the pile and these samples shall be thoroughly
mixed before being used to form the test specimen. The sampling shall be
spread as evenly as possible throughout the day. When wide changes occur during concreting,
additional sample shall be taken if so desired by the Engineer-in-Charge.
B-1.3 Preparation of Test Specimens: The interior surfaces of the mould and base plate shall be
lightly oiled before the Concrete is placed in the mould.
i) When the job Concrete is compacted by manual methods, the test specimen shall be moulded
by placing the fresh Concrete in the mould in three layers, each approximately one third of the
volume of the mould. In placing each scoopful of Concrete the scoop shall be moved around the
top edge do the mould as the Concrete there sided from it, in order to ensure a uniform
distribution of Concrete within the mould. Each layer shall be rodded 35 times with 16 mm rod,
60 cm in length, bullet pointed at the lower end. The strokes shall be distributed in uniform
manner over the cross section of the mould and shall penetrate into underlying layer. The bottom
layer shall be rodded through its depth. After the top layer has been rodded, the surface of the
Concrete shall be struck off with a trowel and covered with a glass plate at least 6.5 mm thick or
a machined plate. The whole process of moulding shall be carried out in such a manner as to
preclude the change of the water Cement ratio of the Concrete, by loss of water either by leakage
from the bottom or over flow from the top of the mould.
ii) When the job Concrete is placed by vibration and the consistency of the Concrete is such that
the test specimens cannot be properly moulded by hand rodding as described above, the
specimens shall be vibrated to give a compaction corresponding to that of the job Concrete. The
fresh Concrete shall be placed in mould in two layers, each approximately half the volume of the
mould. In placing each scoopful of Concrete the scoop shall be moved around the top edge of
the mould as the Concrete there slides from it, in order to ensure a symmetrical distribution of
Concrete within the mould. Either internal or external vibrators may be used. The vibration of
each layer shall not be continued longer than is necessary to secure the required density. Internal
vibrators shall only be used when the Concrete is required to be compacted in layers. In
compacting the first layer, the vibrators shall not be allowed to rest on the bottom of the mould.
In placing the Concrete for top extent that there will be no mortar loss during vibrations. After
vibrating the second layer enough Concrete shall be added to bring level above the top of the
mould. The surface of the Concrete shall then the struck off with a trowel and covered with a
glass or Steel plate as specified above. The whole process of moulding shall be carried out in
such a manner as to preclude the alteration of water-Cement ratio of the Concrete by loss of water,
either by leakage for the bottom or over flow from the top of the mould.
B-1.4 Curing and Storage of Test Specimen:

In order to ensure reasonably uniform temperature and moisture conditions during the first 24 hours
for curing the specimen and to protect them from damage, moulds shall be covered with wet straw or
gunny sacking and placed a storage box so constructed and kept on the work site that its air
temperature when containing Concrete specimens shall remain 22°C to 33°C. Other suitable means
which provide such a temperature and moisture conditions may be used.
Note:- It is suggested that the storage box be made of 25 mm dressed tongued and grooved timber,
Well braced with battens to avoid warping. The box should be Well painted inside and outside and
should be provided with a hinged cover and padlock.
The test specimen shall be removed from the moulds at the end of 24 hours and stored in a moist
condition at a temperature within 24°C to 30°C until the time of test. If storage in water is desired, a
saturated lime solution shall be used.
B-1.5 Testing
The specimens shall be tested in accordance with procedure as described below:
(a) The tests shall be made at an age of Concrete corresponding to that for which the strengths
are specified.
(b) Compression tests shall be made immediately upon removal of the Concrete test specimen
from the curing room i.e. the test specimen shall be loaded in damp condition. The dimensions
of the test specimens shall be measured in mm accurate to 0.5 mm.
(c) The metal bearing plates of the testing machine shall be placed in contact with the ends of the
test specimens. Cushioning materials shall not be used. In the case of cubes, the test specimen
shall be placed in the machine in such a manner that the load is applied to sides of the specimens
as cast. An adjustable bearing block shall be used to transmit the load to the test specimen. The
size of the bearing block shall be the same or slightly larger than that of test specimen. The
upper or lower section of the bearing block shall be kept in motion as the head of the testing
machine is brought to a bearing on the test specimen.
(d) The load shall be applied axially without shock at the rate of approximately 140 kg. per sq.cm.
per minute. The total load indicated by the testing machine at failure of test specimen shall be
recorded and the unit compressive strength is calculated in kg per sq. cm. using the area
computed from the measured dimension of the test specimen. The type of failure and
appearance of the Concrete shall be noted.
APPENDIX-`C'
CONCRETE MIX INFORMATION TO BE SUPPLIED BY THE PURCHASER
RMC: (Grade) ........................................................... Contractor : ...................................................
AE/EE .............................. Name of work/Location ........................................................................
MIXCODE
Grade(N/mm2) (Characteristic Strength)
Minimum Cement Content (kg./m3)/
Maximum Pozzolanic material %
Mineral Additives (Pulverized fuel
ash/Slag/Others) (kg/m3)
Maximum Free water Cement Ratio
Nominal Maximum Aggregate size
Cement Type and Grade (if preferred)
Target workability ( S l u m p ) ( )
Target workability at site
Maximum Temperature of Concrete at the
time of placing
Class of sulphate Resistance (if applicable)
Exposure condition (if applicable)
Class of finish (if applicable)
Mix Application
Method of Placing
Any other requirements (early strength
workability retention, permeability testing,
Chloride content restriction, maximum
Cement content, etc.)
Concrete Testing (Frequency)
Material's Testing (any non-routine
requirements)
Alternatives to be offered: Yes/No
Method of Curing to be used by
contractor
Quantiry(m3)
Note: Additional Proforma for further information may be used, such as for specific test to be
achieved for Concrete or raw materials ,exact method statements of the contractors proposed site
practice.
APPENDIX `D'
DETERMINATION OF PARTICLE SIZE
The apparatus, sample size and test procedure shall be same as specified in Chapter 4- `MORTARS'.
In order that the sieves shall not be overloaded, care must be taken to ensure that the maximum sieve
loads shown in Table-1 (below) are not exceeded at the completion of sieving.
Table -1
I.S. Sieve Size Maximum weight for
Designation 45 cm dia. sieve kg 30 cm dia. sieve kg
45 mm 10 4.5
40mm 8 3.5
31.5mmor22.1mm 6 2.5
20mm 4 2.0
16mmor12.5mm 3 1.5
10 mm 2 1.0
5.6mm 1.5 0.75
4.75 mm 1.0 0.50
3.35 mm - 0.30
The sample weight taken will thus normally require several operations on each sieve. Each sieve
should be taken separately over a clean tray or receiver until not more than a trace passes, but in any
case for not less than two minutes. Materials should not be forced through the apertures but hand
placing is permitted. A light brush should be used with fine sieves. The cumulative weight passing
each sieve should be calculated as percentage of the total sample weight to the nearest whole number.
APPENDIX È'
TEST FOR SURFACE MOISTURE
Take a sample of wet aggregate and weigh it (A). Then place it in a flying pan and gently apply heat,
meanwhile stirring with a glass rod until the surface moisture disappears. This is apparent when the
aggregate looses its shining, wet appearance and becomes dull, or when it just attains a free funning
condition. The saturated surface dry material is then weighed (B). Continue the heating thereafter
until the moisture is evaporated and weigh the dry sample (C). The surface moisture is then
calculated as follows:
Surface moisture = 100 x _ CB
It is expressed as a percentage of dry aggregate.
APPENDIX `F'
DETERMINATION OF TEN PER CENT FINES VALUE.

(Refer IS 2386 part IV-1963)
Apparatus: The apparatus for the standard test shall consist of the following:
(a) A 15 cm diameter open-ended steel cylinder, with plunger and base-plate: The surfaces in
contact with the aggregate shall be machined and case hardened or otherwise treated so as to
have a diamond (VH) pyramid hardness number of not less than 650 VH.
(b) A straight metal tamping rod of circular cross-section 16 mm in diameter and 45 to 60 cm
long, rounded at one end.
(c) A balance of capacity 3 kg, readable and accurate to one gram.
(d) I.S. Sieve of sizes 12.5, 10 and 2.36 mm.
(e) A compression testing machine capable of applying a load of 50 tonnes and which can be
operated to give a uniform rate of loading so that the maximum load in any test is reached in 10
minutes. This load may vary from 0.5 to 50 tonnes.
(f) For measuring the sample, a cylindrical metal measure of sufficient rigidity to retain its form
under rough usage and of the following internal dimensions:
Diameter 11.5 cm
Height 18.0 cm
(g) Means of measuring the reduction in the distance between the plates of the testing machine
to the nearest one millimetre during the test (for example, dial gauge).
Test Sample: Material for the test shall consist of aggregate passing a 12.5 mm I.S. Sieve and
retained on a 10 mm I.S. Sieve. The aggregate shall be tested in a surface dry condition. If dries by
heating the period of drying shall not exceed four hours, the temperature shall be 100°C to 110°C and
the aggregate shall be cooled to room temperature before testing.
The quantity of aggregate shall be such that the depth of material in the cylinder, after tamping as
described below, shall be 10 cm. The weight of material comprising the test sample shall be
determined (weight A) and the same weight of sample shall be taken for the repeat test.
Note: About 6.5 kg of natural aggregate is required to provide the two test samples. Less of light
weight aggregate is required.
The measuring cylinder is filled in three layers of approximately equal depth with aggregate passing a
12.5 mm I.S. Sieve and retained on 10 mm I.S. Sieve. Each layer is subjected to 25 strokes from the
tamping rod (16 mm dia. and 45 to 60 cm long) rounded to one end, care being taken in case of weak
materials not to break the particles. The surface of the aggregate shall be are fully levelled and the
plunger inserted so that it rests horizontally on this surface.
Test Procedure: The apparatus, with the test sample and plunger in position, shall then be placed in
the compression testing machine. The load shall be applied at a uniform rate so as to cause a total
penetration of a plunger in 10 minutes of about 15.0 mm for rounded or partially rounded aggregates
(for example uncrushed gravel) 20 mm for nominal crushed aggregate & 24 mm for honey combed
aggregate (for example expanded shale and slag). These figures may be varied according to the
extent of the rounding or honey combing.
After reaching the required maximum penetration, the load shall be released and the whole of the
material removed from the cylinder and sieved on a 2.36 mm I.S. Sieve. The fines passing the sieve
shall be weighed, and this weight expressed as a percentage of the weight of the test sample. Normally,
this percentage will fall within the range 7.5 to 12.5, but if it does not, a further test shall be made at
a load adjusted appropriately, to bring the percentage fines within the range of 7.5 to 12.5.
A repeat test shall be made at the load that gives as percentage fines within the range 7.5 to 12.5.
Calculations: The mean percentage fines from the two tests at this load shall be used in the following
formula to calculate the load required to give 10 percentage fines.
Load required for 10 percent fines = (14xX)/ (Y+4)
Where X = Load in tonnes and
Y = mean percentage Fines
from 2 tests at X
tonnes load.
Reporting of Results: The load required to produce 10 percent fines shall be reported to the nearest
whole number for loads of 10 tonnes or more, the nearest 0.5 tonne for loads of less than 10 tonnes.
The value expressed to the nearest 0.5 tonne should be as follows:
(a) For normal concrete, not less than 5 tonnes.
(b) For wearing surfaces, not less than 10 tonnes.
(c) For granolithic concrete, not less than 15 tonnes.
APPENDIX `G'
NOIMINAL MIX CONCERTE:
For works involving minor quantities of Cement Concrete, in remote areas, IS 456-2000 has
laid down the essentials of Nominal Mix Concrete in place of design Mixes as under:
1. Production of concrete: All RCC and PCC have to be weighed and batch mixed. IS 456-2000
does not recognize volume batched nominal mixes. For small quantities of P.C.C, volume
batching, if necessary, should be done in a hopper type drum mixer and the input materials
measured with measurement boxes. Mixes using at least one cement bag should be mixed in one
mass. Water should also be measured by 1 and 5 litre cans. Nominal mix Concrete may be used
for Concrete of M 20 or lower. The proportion of materials for nominal mix shall be in
accordance with Table-below:
Proportions for Nominal Mix Concrete

Grade of Total quantity of dry aggregate by Proportions of Quantity of water
Concrete mass per 50 kg of Cement, to be Fine Aggregate to per 50 kg of
taken Coarse Aggregate Cement .Max.
as the sum of the individual masses (by mass)
M5 of
800 Generally 1:2 but 60
fine and Coarse Aggregate: kg subject to an upper limit
M 7.5 625 45
of 1:1.5 and lower limit
M-10 480 of 1:2.5 34
M-15 330 32
M-20 250 30
Note: The proportion of the fine to Coarse aggregate should be adjusted from the upper limit to the
lower
limit progressively as the grading of the fine aggregate becomes finer and the maximum size of Coarse
aggregate becomes larger. Graded Coarse aggregate shall be used.
Example: For an average grading of fine aggregate (that IS : , zone II of Table 4 of IS : 383-
1970), the proportion shall be 1:1.5, 1:2, 1:2.5 for maximum size of aggregates 10 mm, 20 mm
and 40 mm respectively.
Notes: (a) Since properly graded aggregate cannot be ensured, the grading should be controlled by
obtaining the Coarse aggregate in different sizes and blending them in the right proportion
when required. The material should be stock piled sufficiently in advance.
(b) The grading of Coarse and fine aggregate should be checked as frequently as possible to ensure
that the specified grading is maintained. An example in grading is placed below:
2. Method for proportioning two materials to obtain a mix of specified gradation
a. Column 3,4 and 5 of table below, show the details of specification limits for a particular
gradation.
b. Column 2 and 6 in the table give the particular size distribution of materials À' and `B'
which do not satisfy the gradation requirement of the specification.
c. The inverse ratio of the totals in column 1 and 7 gives the proportion of materials to be
mixed to obtain the desired mix = A:B = 45:139 (1:3)
(d) Mixing 25% of material A and 75% of material B would give the desired gradation as shown in
the table
Numerical Material A Sieve size Limits per Average Material B Numerical
difference percent cent passing percent percent difference
between passing passing passing between
material A material B
and average and average
percent percent
passing passing
1 2 3 4 5 6 7
- 100 40 mm 100 100 100 -
8 98 20 mm 80-100 90 73 17
26 94 10 mm 55-80 68 55 13
33 83 4.75 mm 40-60 50 42 8
32 72 2.36 mm 30-50 40 35 5
33 55 600 micron 15-30 22 21 1
7 17 75 micron 5-15 10 9 1
Total=139 Total= 45
(e) The accuracy of measuring equipment shall be within +/(-) 2% for of the quantity of Cement
being measured and within +/(-) 3% of the quantity of aggregates, admixtures and water being
measured. This is possible only through measuring boxes. For loading these materials in the
mixer, a hopper fitted mixer is the best option. IS: 1791-1985 (reaffirmed 2005) for mixers
includes only hopper type mixers.
(f) Proportion / type and grading of aggregates shall be made by trial in such a way so as to
obtain densest possible Concrete. All ingredients of the Concrete should be used by mass
only.
g) Volume batching may be allowed only where weigh batching is not practical and provided
accurate bulk densities of the materials to be actually used in Concrete have earlier been
established. Allowance for bulking shall be made in accordance with IS: 2386 (Part 3)-1963
(reaffirmed 2002). The mass volume relationship should be checked as frequently as necessary,
the frequency for the given job being determined by the Engineer-in-charge to ensure that
specified grading is malntalned.
h) It is important to maintain the water Cement ratio constant at its correct value. To this end,
determination of moisture contents in both fine and Coarse aggregates shall be made as
frequently as possible (IS: 2386-part 3-1963, reaffirmed 2002), the frequency for a given job
being determined by the Engineer-in-charge according to weather conditions, the amount of
added water shall be adjusted to compensate for any observed variations in the moisture
contents. To allow for variations in the mass of aggregates due to variation in their moisture
content, suitable adjustments in the masses of the aggregates shall also be made. In the absence of
exact data, only in the case of nominal mixes, the amount of surface water may be estimated from
the values given in table 13 of this chapter.
i) On works only designed and weigh batched mixes can produce Concrete of reliable quality.
Volume batched mixes prepared and used are contrary to the codal provisions and should be
prohibited. However, the field engineers/contractor essentially require a strong written directive
to be issued by Engineer-in-charge in this respect, directing that volume batched CC, if allowed
be produced as an exception for minor works, should be prepared in accordance with the above
procedure only to be acceptable.
j) On works only designed and weigh batched mixes can produce Concrete of reliable quality.
Volume batched mixes prepared and used are contrary to the codal provisions and should be
prohibited. However, the field engineers/contractor essentially require a strong written directive
to be issued by Engineer-in-charge in this respect, directing that volume batched CC, if allowed
be produced as an exception for minor works, should be prepared in accordance with the above
procedure only to be acceptable.
k) Volume batching of Concrete may be allowed only where weigh batching is not practical and
provided accurate bulk densities of material to be actually used in Concrete have earlier been
established. Allowance for bulking shall be made as per IS : 2386. (Part 3). The bulking will be
about 15% for 2% moisture by weight, 25% for 3%, 25% for 4% and 30% for 5%. The mass
volume relationship should be checked as frequently as necessary.
1) In the nominal mix, if water has to be increased to overcome difficulties of placement and
compaction, the Cement content of the mix should also be increased proportionately to maintain
the water Cement ratio. If nominal Concrete mix made in accordance with the proportions given
for a particular grade does not yield the specified strength, it shall be classified as belonging to
the appropriate lower grade, but if such a Concrete gives a higher strength, it will not be placed
in the higher grade.
APPENDIX-`H'
TESTING WORKABILITY OF CONCRETE:
1.01- Workability of concrete The workability of Concrete is its ability to flow to the placing
positions and its ability to be compacted with the means available. Suggested workability's are
as under ( ref: IS : 456-2000, IS : 1199):
1.02- The concrete mix proportions shall be such that the concrete is of adequate workability for the
placing conditions of the concrete and can be properly compacted with the means available.
Suggested ranges of workability measured in accordance with IS 1199 as under:
Table : 1
S. Placing conditions Degree of Slump (mm)
No workability
1. Blinding concrete; shallow sections; Very low Strict control
Pavements using pavers; necessary:
Compacting factor 0.75
2. low to 0.80
25-75 mm
Mass concrete; Lightly reinforced
sections in slabs; hems; walls;
columns; Floors; Hand placed
pavements; canal linings; strip
footings.
3. Heavily reinforced sections in slabs; Medium 50-100
beams; columns;
4. Slip form work; Pumped concrete 75-100
5. Trench fill, High 100-150
6. Tremie concrete. Very high Determination of flow
(IS 9103)
Vibration:
1. The diameter of the needle shall be determined based on the density and spacing of
reinforcement bars and thickness of sections. For Tremie concrete, vibrators are not required to
be used.
2. For different vibrators, refer IS 2505, IS 2506, IS 2514 and IS 4656, and Clause 5.3.1.20 of
this chapter.
3. Over vibration and under vibration of concrete are harmful and should be avoided. Vibration
of very wet mixes should also be avoided.
4. Whenever vibration has to be applied externally ( form vibrators) , the design of form work
and the disposition of vibrators should receive special consideration to ensure efficient
compaction and to avoid surface blemishes.
5. For most of the placing conditions, internal vibrators (needle vibrators) are suitable. The
diameter of the needle shall be determined based on the density and spacing of reinforcement
bars and thickness of sections. For Tremie concrete, vibrators are not required to be used (see
also 5.3.1.20)
Notes on slump :-
(1) In the `very low' category of workability where strict control is necessary, for example, pavement
quality concrete, measurement of workability be determination of compacting factor will be more
appropriate than slump (see IS: 1199-1959, Reaffirmation 1999) and a value of compacting
factor of 0.75 to 0.80 is suggested.
(2) In the `very high' category of workability, measurement of workability by determination of
flow will be appropriate (see IS: 9103-1999).
(3) In normal works, measurement of slump (for aggregate size < 38 mm) with a slump cone is
done. This is a frustum of a cone 200 mm as the bottom dia., 100 mm as the top dia. and a
height of 300 mm. There is a 16 mm dia. tamping rod, 600 mm long, rounded at the end.
Apparatus: Mould shall consist of a metal frustum of cone having the following internal dimensions:
Bottom diameter .....................................................................................20 cm
Top diameter ...........................................................................................10 cm
Height .....................................................................................................30 cm
The mould shall be of a metal other than brass and aluminium of at least 1.6 mm (or 16 BG)
thickness. The top and bottom shall be open and at right angles to the axis of the cone. The mould shall
have a smooth internal surface. It shall be provided with suitable foot pieces and handles to facilitate
lifting it from the moulded concrete test specimen in a vertical direction as required by the test. A
mould provided with a suitable guide attachment may be used.
Tamping rod shall be of steel or other suitable material 16 mm in diameter 60 mm long and rounded
at one end.
1.03- Procedure-The samples of Concrete obtained as described under the test specimen shall be
immediately moulded by one of the following methods as indicated below:-
i) The internal surface of the mould shall be thoroughly cleaned and freed from superfluous
moisture and any set Concrete before commencing the test. The mould shall be placed on a
smooth, horizontal, rigid and non-absorbent surface, such as a carefully levelled metal plate, the
mould being firmly held in place while it is being filled.
ii) The mould shall be filled in four layers, each approximately one-quarter (75 mm) of the height
of the mould. Each layer shall be tampered with twenty-five strokes of the rounded end of the
tamping rod. The strokes shall be distributed in a uniform manner over the cross-section of the
mould and for the second and subsequent layers shall penetrate in the underlying layer. The
bottom layer shall be tamped throughout its depth.
iii) After the top layer has been rodded, the Concrete shall be struck off level with a trowel or the
tamping rod, so that the mould is exactly filled.
iv) Any mortar which may have leaked out between the mould and the base plate shall be
cleaned away.
v) The mould shall be removed from the Concrete immediately by raising it slowly and carefully
in a vertical direction. This allows the Concrete to subside and the slump shall be measured
immediately by determining the difference between the height of the mould and that of the
highest point of the specimen being tested.
vi) The above operations shall be carried out at a place free from vibration or shock, and within
a period of two minutes after sampling.
vii) The slump test shall not be used for very dry mixes as the results obtained are not accurate.
1.04-Result The slump measured shall be recorded in terms of millimetre of subsidence of the
specimen during the test. Any slump specimen which collapses or shears off laterally gives incorrect
result and if this occurs the test shall be repeated with another sample. If, in the repeat test also, the
specimen should shear, the slump shall be measured and the fact that the specimen sheared, shall be
recorded.
Procedure-
a) A slump test as described earlier shall be performed in the sheet metal cylindrical pot of the
Consistometer. The glass disc attached to the swivel arm shall be moved and placed just on the
top of the slump cone in the pot and before the cone is lifted up, the position of the Concrete
cone shall be noted by adjusting the glass disc attached to the swivel arm.
b) The cone shall then be lifted up and the slump noted on the graduated rod by lowering the glass
disc on top of the Concrete cone. The electrical vibrator shall then be switched on and the
Concrete shall be allowed to spread out in the pot.
c) The vibration shall then be continued until the whole Concrete surface uniformly adheres to
the glass disc , and the time taken for this to be attained shall be rioted with a stop watch. The
time is recorded in seconds.
Result -The consistency of the Concrete shall be expressed in VB-degrees which is equal to the time
in seconds recorded in the above procedure.
NOTE-Some indication of the cohesiveness and workability of the mix can be obtained, if after the
slump measurement has been completed, the side of the Concrete is tapped gently with the tamping
rod, a Well-proportioned Concrete which has an appreciable slump will gradually slump further, but
if the mix has been badly proportioned, it is likely to fall apart.
1.05-Compacting Factor Test :
i) This clause specifies a procedure for determining the workability of Concrete, where the
nominal maximum size of the aggregate does not exceed 38 mm. The test is designed primarily
for use in the laboratory, but if circumstances permit, it may also be used if the field. It is more
precise and sensitive than the slump test and is particularly useful for Concrete mixes of very low
workability as are normally used when Concrete is to be compacted by vibration, such Concrete
may Consistently fail to slump.
ii) The apparatus shall consist of the two conical hoppers (A and B ) mounted above a cylindrical
mould. The hopper and cylinder shall be of rigid construction, true to shape and smooth inside.
The lower ends of the hoppers shall be closed with tightly fitting hinged trap-doors having
quick release catches. The apparatus shall also include two ordinary brick layer's trowels, one
hand scoop about 15.2 cm long, a rod of Steel or other suitable material of 1.6 cm diameter, 61
cm long rounded at one end, and scales (or a balance) to weigh up to 30 kg, to the nearest 10 g.
iii) Procedure: a) A sample of Concrete to be tested shall be placed gently in the upper hopper,
using the hand
scoop. The hopper shall be filled level with its brim and the trap-door shall be opened so that the
Concrete falls into the lower hopper.. Certain mixes have a tendency to stick in one or both of the
hoppers. If this occurs, the Concrete may be helped through by pushing the rod gently into the
Concrete from the top. During this process, the cylinder shall be covered by the trowels.
b) Immediately after the Concrete has come to rest, the cylinder shall be uncovered, the trap-door
of the lower hopper opened, and the Concrete allowed to fall into the cylinder. The excess of
Concrete remaining above the level of the top of the cylinder shall then be cut off by holding a
trowel in each hand, with the plane of the blades horizontal, and moving them simultaneously
one from each side across the top of the cylinder, at the same time keeping them pressed on the
top edge of the cylinder. The outside of the cylinder shall then be wiped clean.
c) The above operation shall be carried out at a place free from vibration or shock. The `weight of
the Concrete in the cylinder shall then be determined to the nearest 10 g. This weight shall be
known as C the weight of partially compacted Concrete .
d) The cylinder shall be refilled with Concrete .from the same sample in layers approximately 5
cm deep, the layers being heavily rammed or preferably vibrated so as to obtain full
compaction. The top surface of the fully compacted Concrete shall be carefully struck off level
with the top of the cylinder. The outside of the cylinder shall then be wiped clean.
Note - The test is sufficiently sensitive to enable differences in workability arising from the initial
processes in the hydration of the Cement to be measured. Each test, therefore, should be carried out
at a constant time interval after the mixing is completed if strictly comparable results are to be,
obtained. A convenient time for releasing the Concrete from the upper hopper has been found to be 2
minutes after the completion of mixing.
1.06- Calculation-The compacting factor is defined as the ratio of the weight of partially compacted
Concrete to the weight of fully compacted Concrete. It shall normally be stated to the nearest second
decimal place.
1.07- Flow of Cement Concrete by the Use of the Flow Table:
This method of test specifies the procedure for the use of the flow table to determine the fluidity of
Concrete, where the nominal size of the aggregate does not exceed 38 mm.
1.07.1- Apparatus :
a) Mould -The mould shall be made of a smooth metal casting, in the form of the frustum of a
cone with the following internal dimensions. A base 25 cm in diameter, upper surface 17 cm in
diameter, and height 12 cm; the base and the top shall be open and at right angles to the axis of
the cone. The mould shall be provided with handles.
b) Procedure -
i) Immediately preceding the test, the table top, and inside of the mould shall be wetted and cleaned
of all gritty material and the excess water removed with a rubber squeezer. The mould, centred
on the table, shall be firmly held in place and filled in two layers, each approximately one-half
the volume of the mould. Each layer shall be rodded with 25 strokes of a straight round metal
rod 1.6 cm in diameter and 61 cm long, rounded at the lower tamping end. The strokes shall be
distributed in a uniform manner over, the cross-section of the mould and shall
penetrate into the underlying layer. The bottom layer shall be rodded throughout its depth.
ii) After the top layer has been rodded, the surface of the Concrete shall be struck off with a
trowel so that the mould is exactly filled. The excess Concrete which has overflowed the mould
shall be removed and the area of the table outside the mould again cleaned.
iii) The mould shall be immediately removed from the Concrete by a steady upward pull. The table
shall then be raised and dropped 12.5 mm, 15 times in about 15 seconds. The diameter of the
spread Concrete shall be the average of six symmetrically distributed calliper measurements
read to the nearest 5 mm.
1.07.2- Recording: The flow of the Concrete shall be recorded as the percentage increase in diameter
of the spread Concrete over the base diameter of the moulded Concrete.
1.08- Determination of Consistency of Concrete by Vee-Bee Consistometer Method:
This clause deals with the determination of consistency of Concrete using a Vee-Bee Consistometer,
which determines the time required for transforming, by vibration, a Concrete specimen in the shape
of a conical frustum into a cylinder.
1.08.1 -Apparatus: The Vee-Bee Consistometer consists of:
a) A vibrator table resting upon elastic supports, A

b) metal pot,
c) A sheet metal cone, open at both ends, and
d) A standard iron rod.
i) The vibrator table is 380 mm long and 260 mm wide and is supported on rubber shock
absorbers at a height of about 305 mm above floor level. The table is mounted on a base
which rests on three rubber feet and is equipped with an electrically operated vibrometer
mounted under it, operating on either 65 or 220 volts three phase, 50 cycles alternating
current.
ii) A sheet metal cone open at both ends is placed in the metal pot and the metal pot is fixed
on to the vibrator table by means of two wing-nuts . The sheet metal cone is 30 cm high and
its bottom diameter is 20 cm and top diameter 10 cm. A swivel arm holder is fixed to the
base and, into this is telescoped another swivel arm with funnel and guide-sleeve. The
swivel arm can be readily detached from the vibrator table.
The graduated rod is fixed on to the swivel arm and at the end of the graduated arm. A Glass
disc is screwed. The division of the scale on the rod records the slump of Concrete cone in
centimetre and the volume of Concrete after vibration of the cone in the pot.
The standard iron rod is 20 mm in diameter and 500 mm in length. The electrical rod is 20
mm in diameter and 500 mm in length. The electrical equipment mounted on the base of
the Consistometer consists of a fixed plug and connector for the electric supply cable, plug
and socket contacts for the detachable cable connected to the vibrometer and a control
switch.
APPENDIX Ì'
IMMERSION VIBRATORS
1. SIZES
1.1 The size of the vibrator shall be denoted by the nominal outside diameter of the vibrating
needle expressed in mm.
1.1.1 The actual outside diameter of the needle measure anywhere in its length excluding the
bottom cap shall not differ from the nominal diameter by more than +/(-) 2 mm.
1.1.2 The standard nominal outside diameter in mm and mass in kg of- the vibrating needle shall
be as given below:
S.No Diameter (mm) mass in
kg
i) 25, 1
ii) 35, 2
iii) 40, 2
iv) 50, 3
v) 60, 4
vi) 75, 5
vii) 90 6
The selection of vibrator, will depend on the section of RCC member, size of aggregate and the
minimum space between reinforcement steel as detailed in the chapter on RCC.
NOTE- The mass of the vibrating needle excludes the chuck of the flexible shaft guard ring.
1.1.3 Length of the Vibrating Needle; The length of the vibrating needle shall be measured from the
outer end of the bottom cap to the joint between needle casing and upper eccentric housing.
Tolerance on the length shall be ±5 mm. The length of the flexible shaft shall be 4 or 6 m.
NOTE- The following standard lengths in mm are recommended for selection of suitable length,
depending upon the nature of the job required. These sizes have been recommended arbitrarily,
purely with a view to aiding rationalized production by limiting the number of sizes:
300, 325. 350, 375, 400, 425, 475, 500, 525, 550, 575, 600, 625, and, 650.
1.1.4 Operation:
The vibrator shall be operated continuously for 20 hours with not more than 2 stoppages of 15
minutes required for change of prime mover in a barrel of crushed stone aggregate, sand and water
simulating a concrete mix. The minimum size of the barrel shall be such that the cross-sectional area
is at least equal to the range of action, the depth being at least twice the length. The vibrator shall be
able to complete this test without any break down. It shall be a type test.
APPENDIX-`J'
ILLUSTRATIVE EXAMPLE ON CONCRETE MIX PROPORTIONING
J-0 An example illustrating the mix proportioning for a concrete of M40 grade is given in J. l to J-
11.
J-1: Stipulations For Proportioning:
a) Grade designation. M40
b) Type of cement. OPC 43 grade conforming to IS:8112
c) Maximum nominal size of aggregate. 20mm
d) Minimum cement content. 320 kg/m3
e) Maximum water-cement ratio. 0.45
f) Workability. 100 mm (slump)
g) Exposure condition. Severe (for reinforced concrete)
h) Method of concrete placing. Pumping
j) Degree of supervision. Good
k) Type of aggregate. Crushed angular aggregate
m) Maximum cement content. 450 kg/m3
n) Chemical admixture type. Superplasticizer
J-2 : Test Data For Materials:
a) Cement used. OPC 43 grade conforming to IS 8112
b) Specific gravity of cement. 3.15
c) Chemical admixture. Superplasticizer conforming to IS 9103
d) Specific gravity of:
i) Coarse aggregate 2.74
ii) Fine aggregate. 2.74
e) Water absorption:
i) Coarse aggregate. 0.5 percent
ii) Fine aggregate. 1.0 percent
f) Free (surface) moisture:
i) Coarse aggregate. Nil (absorbed moisture also nil)
ii) Fine aggregate. Nil
g) Sieve analysis:
n Coarse aggregate.
Table : J-1
IS Sieve Analysis of Coarse Percentage of Different Remarks
Sizes-mm Aggregate Fraction Fractions
I II I-60% II-40% Combined-
100%
20 100 100 60 40 100 Conforming to
Table 2 of IS
383
10 0 71.2 0 28.5 28.5
4.75 - 9.40 - 3.7 3.7
2.36 - 0 - - -
2. Fine aggregate : Conforming to grading Zone I of Table 4 of IS 383 J-
3 Target Strength For Mix Proportioning : f a = f k + 1.65 s where
Lk = target average compressive strength at 28 days,
Lk= characteristic compressive strength at 28 days, and s
= standard deviation.
From Table I (of IS 456: 2000), standard deviation,
s =5 N/mm2
Therefore, target strength = 40 + 1.65 x 5 = 48.25 N/mm2
J•4 Selection of Water-Cement Ratio
From Table 5 of IS 456, maximum water-cement ratio = 0.45.
Based on experience, adopt water-cement ratio as = 0.40.
0.40 < 0.45, hence O.K.
J-5 : Selection of Water Content :
Table J-2 Maximum Water Content per Cubic Metre of Concrete for Nominal Maximum Size of
Aggregate.
Table : J-2
S.No. Nominal Maximum size of Maximum water content' -kg
Aggregate -mm
(1) (2) (3)
i) 10 208
ii) 20 186
iii) 40 165
Note: These quantities of Mixing water are for use in computing cementitious materials contents
for trial batches
' Water content corresponding to saturated surface Aggregate.
From Table 2, maximum water content = 186litre (for 25 to 50 mm slump range) for
20 mm aggregate
Estimated water content for 100 mm slump = 186+(6/100)x186
= 197 litre
As superplasticizer is used, the water content can be reduced up 20 percent and above.
Based on trials with superplasticizer water content reduction of 29 percent has been achieved.
Hence, the arrived water content: = 197 x 0.71 = 140 litre
J-6 Calculation of Cement Content
Water-cement ratio = 0.40
Cement content = 140/0.40
= 350 kg/m3
From Table 8 of this chapter, minimum cement content for 'severe' exposure condition = 320
kg/m3
350 kg/m3 > 320 kg/m3, hence, O.K.
J•7 : Proportion of Volume of Coarse Aggregate and Fine Aggregate Content.
Table J-3 Volume of Coarse Aggregate per Unit Volume of Total Aggregate for Different Zones of
Fine Aggregate
Table : J-3
S. Nominal Maximum Volume of coarse aggregate' per unit volume of
No. size of Total Aggregate for different zones of
aggregate-mm
Fine Aggregate.
Zone I Zone II Zone III Zone IV
(1) (2) (3) (4) (5) (6)
i) 10 0.50 0.48 0.46 0.44
ii) 20 0.66 0.64 0.62 0.60
iii) 40 0.73 0.73 0.71 0.69
VolumesarebasedonAggregatesegatesinsaturatedsurfacedrycondition.FromTableJ-3,volumeofcoarseaggregatecocorrespondingto20mm aggregate egate and fine

aggregate (Zone I) for water-cement ratio of 0.50 = 0.60.
In the present case water-cement ratio is 0.40. Therefore. volume of coarse aggregate is required to be
increased to decrease the fine aggregate content. As the water-cement ratio is lower by 0.10. the
proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05
change in water-cement ratio).
Therefore. corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.40 =
0.62.
NOTE- In case the coarse aggregate is not angular one. then also volume of coarse aggregate may be
required to be increased suitably, based on experience.
For pumpable concrete these values should be reduced by 10 percent.
Therefore, volume of coarse aggregate = 0.62 x 0.9 = 0.56.
Volume of fine aggregate content = I - 0.56 = 0.44.
J-8 Mix Calculations:
The mix calculations per unit volume of concrete shall be as follows:
a) Volume of concrete = 1 m3
b) Volume of cement = (Mass of cement/ Specific gravity of cement)xl/1000 _
(350/3.15) x (1/1000)
= 0.111 m3
c) Volume of water. _ (Mass of water/ Specific gravity of cement)x1/1000 _
(140/1) x (1/1000)
= 0.140 m3
d) Volume of chemical admixture (superplasticizer) (@ 2.0 percent by mass of cementitious
material)
= (mass of chemical admixture/specific gravity of admixture)xl/1000
= (7/1.145)x(1/1000) =
0.006 m3
e) Volume of all in aggregate. = [a-(b+c+d)]
= 1-(0.111+0.140+0.006) =
= 0.743 m3
f) Mass of coarse aggregate. = e x Volume of coarse aggregate x Specific gravity of
coarse aggregate x I 000
= 0.743 x 0.56 x 2.74 x 1 000
= 1140 kg
g) Mass of fine aggregate. = e x volume of fine aggregate x Specific gravity of
fine aggregate x 1000
= 0.743 x 0.44 x 2.74 x I 000
= 896kg
J-9 MIX PROPORTIONS FOR TRIAL NUMBER 1:
Cement = 350 kg/m3
Water = 140 kg/m3
Fine aggregate = 896 kg/m3
Coarse aggregate = I 140 kg/m3
Chemical admixture = 7 kg/m3
Water-cement ratio = 0.4
NOTE- Aggregates should be used in saturated surface dry condition. If otherwise, when computing
the requirement of mixing water, allowance shall be made for the free (surface) moisture contributed
by the fine and coarse aggregates. On the other hand. if the aggregates are dry, the amount of mixing
water should be increased by an amount equal to the moisture likely to be absorbed by the aggregates.
Necessary adjustments are also required to be made in mass of aggregates. The surface water and
percent water absorption of aggregates shall be determined according to IS 2386.
J-IO The slump shall be measured and the water content and dosage of admixture shall be adjusted for
achieving the required slump based on trial, if required. The mix proportions shall be reworked for the
actual water content and checked for durability requirements.
J-11 Two more trials having variation of ±10 percent of water-cement ratio in J-I0 shall be carried out
and a graph between three water-cement ratios and their corresponding strengths shall be plotted to
work out the mix proportions for the given target strength for field trials. However, durability
requirement shall be met.
APPENDIX-`K'
GUIDE LINES FOR SELF COMPACTING CONCRETE
K-1: General:
Self compacting concrete is a concrete that fills uniformly and completely every corner of formwork
by its own weight without application of any vibration, without segregation, whilst maintaining
homogeneity.
K-2: Application Area:
Self compacting concrete may be used in precast concrete applications or for concrete placed on site.
It may be manufactured in a site batching plant or in a ready mixed concrete plant and delivered to site
by truck mixer. It may then be placed either by pumping or pouring into horizontal or vertical forms.
K-3: Features of Fresh Self Compacting Concrete:
The following are some of the features of self compacting concrete:
a) Slump flow: 600 mm Min.
b) Sufficient amount of fines (<125 mm) preferably in the range of 400 kg/m3 to 600 kg/m3. This
can be achieved by having sand content more than 38% and using mineral admixtures to the
order of 25% to 50% by mass of cementitious materials.
c) Use of high range water reducing (HRWR) admixture and viscosity modifying agent (VMA)
in appropriate dosages.
LIST OF RELEVANT B I S CODES
S.No. IS. No. Subject
1. IS:269-1989, Specifications for 33 Grade Ordinary Portland Cement.
Reaffirmed 1998
2. IS: 383-1997 Specification for coarse and fine aggregate from Natural Source
for Concrete. (Reaffirmed 2002).
3. IS: 455-1989 Portland Slag Cement. ( Reaffirmed 1995).
4. IS: 456-2000 Code of practice for Plain and Reinforced Cement Concrete.
5. IS:516-1959, Method of test for strength of concrete. Reaffirmed 2004
6. IS:1199-1959 Method of sampling and analysis of concrete. Reaffirmed 1999
7. IS:1200 (Part II)- Method of measurement of building and civil engineering
1974 work (concrete work)
8a. IS:1322-1993 Specification for bitumen felt for water proofing and damp
proofing. Reaffirmed 2003
8b. IS: 1343-1980 Code of practice for Prestressed concrete.
9. IS:1489-(P-1)-1976 Portland Pozzolana Cement ( Fly ash based).
10a. IS: 1489-(P-2)-1991. Portland Pozzolana Cement ( Calcined Clay based).
1Ob. IS: 1566-1982 Specification for hard drawn steel wire fabric for concrete
reinforcement.
11. IS:1791-1985 Specification for batch type concrete mixers. Reaffirmed 1995.
12. IS:2386-1963 Method of test for aggregate for concrete work.
(a)-1963- Part I Particle size and shape. Reaffirmed 2002
(b) 1963- Part II Estimation of deleterious materials and organic impurities.
Reaffirmed 2011
(c)-1963, Part III Specific gravity, density, voids absorption and bulking.
Reaffirmed 2002
(d)1963,- Part IV Mechanical properties. Reaffirmed 2002
IS; 2386-1963 Part -5, Soundness of Aggregate. (Reaffirmed 2002
IS; 2386 -1963 Part-6, Measuring Mortar making property of Fine Aggregate.
Reaffirmed 2011
IS; 2386 -1963 Part -7, Alkali Aggregate Reactivity. Reaffirmed 2002
13. IS:2505-1992 General requirement for concrete vibrators immersion type.
Reaffirmed 1999
14. IS:2506-1985 General requirement for concrete screed board concrete vibrators.
Reaffirmed 1996
15a. IS:2645-2003 Specification for integral cement , concrete water proofing
compounds. Reaffirmed 2005.
15b. IS: 2514-1963 Specifications for Concrete Vibrating Table.
16. IS:2686-1977 Specification for cinder as fme aggregate for use in lime concrete.
Reaffirmed 2009.
17. IS 3025-(P-17) 1986, Sampling and Testing of water -Suspended matter, Non filterable
residue. (Reaffirmed 1996)
18. IS 3025-(P-18) 1984, Sampling and Testing of water -Volatile and fixed residue.
Reaffirmed 2002
19. IS 3025-(P-22) 1986, Sampling and Testing of water -Acidity. Reaffirmed 2003
20. IS 3025-(P-23) 1986, Sampling and Testing of water -Alkalinity. Reaffirmed 2003
21. IS 3025-(P-24) 1986, Sampling and Testing of water -Sulphates. Reaffirmed 2009
22. IS 3025-(P-32) 1988, Sampling and Testing of water -Chlorides. Reaffirmed 2007
23. IS:3068-1986 Specification for broken burnt (clay) coarse aggregate for use in
(Reaffirmed 2000) lime concrete.
24. IS:3812(P-1)-1981 Specification for Pulverised Fuel ash for use as pozzolana in
Cement .
25. IS: 4031(P-5)-1996, Method of Test for Initial and Final setting time for Hydraulic
Cements Edition 2003.
26. IS: 4634-1991 Methods of testing of batch type mixers for Cement Concrete.
(Reaffirmed 2005)
27a. IS:4656-1968 Specification for form vibrators for concrete. Reaffirmed 1996
27b. IS:4845-1968 Definitions and Terminology for Hydraulic cements.
28. IS:4925-1968 Concrete batching and Mixing Plants.
29a. IS:4926-2003 Code of Practice for Ready Mix Concrete.
29b. IS: 6452-1989 Specifications for High Alumina cement for structural use.
30. IS:6909-1990 Specifications for super sulphated Cement. Reaffirmed 2010
31. IS:7861(PartI)-1975 Code of practice for extreme Hot weather concreting
(reaffirmed 2011) recommended practice for hot weather concreting.
32. IS:7861 (Part II)- Code of Practice for Cold weather concreting.
1981
33. IS:8041-1990 Rapid Hardening Portland Cement.
34. IS: 8043-1991 Hydrophobic Cement
35. IS: 8112-1989 Specifications for 43 Grade Ordinary Portland Cement.
35b. IS:9013-1999 Method of making, curing and determining compressive strength
of accelerated cured concrete test specimen.
36. IS:9103-1959 Chemical admixtures for concrete.
37. IS:11817-1986 Classification of Joints in Buildings. Reaffirmed 2002.
38. IS 12269-1987, Specifications for 53 Grade Ordinary Portland Cement.
Reaffirmed 1999
39. IS: 12330-1988 Sulphate Resisting Portland Cement. Reaffirmed 1995
40. IS: 12600-1989 Low heat Portland Cement. Reaffirmed 1995.
41. IS: 13311-1992 Methods of Non-destructive testing of concrete. (part I/II)
42. IS: 15388-2003 Specifications for Silica fumes.
CHAPTER No. 6
REINFORCED CEMENT CONCRETE

CHAPTER No. 6 : REINFORCED CEMENTCONCRETE WORKS
CONTENTS
6.0 Scope 3
6.1 Materials 3
6.2 Formwork 12
6.3 Reinforcement 18
6.4 Cement Concrete 28
6.5 Encasing Rolled Steel sections in Cement Concrete 46
6.6 Precast Reinforced Concrete 48
6.7 Precast Cement Concrete Jali. 49
6.8 Cement Concrete Design Mix. 49
6.9 Pile foundations 52
Appendix : A : (Additional Tests for Concrete: 67
Rebound Hammer test, Cutting cores, Ultrasonic test,
Load test on individual precast units, Non-destructive tests,
Destructive tests, special tests, Load test on structures or
part of structures)
Appendix : B : General Guide lines for provision of movement 69
joints in buildings.
Appendix : C : Admixtures for Cement Concrete. 75
List of Relevant BIS Codes 77
Rajasthan PWD Building Specifications 2014 Chapter 6 : R.C.C. Works Page 1 of 79


C H A P T E R No. 6
REINFORCED CEMENT CONCRETE W O R K
6.0 Scope:
The specification covers the providing and laying of Reinforced Cement Concrete work, which may
be cast-in-situ or Precast as may be directed by Engineer-in-charge according to the nature of work.
Reinforced Cement Concrete work shall comprise of the following which may be paid separately or
collectively as per the description of the item of work.
(a) Form work (Centring and Shuttering)
(b) Reinforcement
(c) Concreting
• Cast-in-situ Concrete
• Precast Concrete
6.1 Materials:
6.1.1 Water, Cement, Fine and Coarse aggregate shall satisfy the requirements already specified in
respective clauses of Chapter-3of Building Materials as applicable. Fly ash blended Cements and
reinforcement shall be specified in this chapter.
6.1.2 Fly ash Blended Cements conforming to IS : 1489 (Part I)-1976:
Fly ash admixed Concrete (FACC) and Fly ash Blended Cements in Cement Concrete (PPCC)
conforming to IS : 1489 (Part I) -1976 may be used in RCC structures as per guidelines given below
:
(i) IS : 456- 2000 Code of Practice for Plain and Reinforced Concrete (as amended up to date)
shall be followed in regard to Concrete Mix Proportion and its production as under :
 The Concrete mix design shall be done as per "Design Mix Concrete" as prescribed in
clause-9 of IS : 456 -2000.
 Concrete shall be manufactured in accordance with clause 10 of IS : 456 -2000 covering
quality assurance measures both technical and organizational, which shall also necessarily
require a qualified Concrete Technologist to be available during manufacture of Concrete
for certification of quality of Concrete.
(ii) Minimum M-25(as per IS : 456) grade of Concrete shall be used in all structural elements
made with RCC both in load bearing and framed structure.
(iii) The mechanical properties such as modulus of elasticity, tensile strength, creep and shrinkage
of Fly ash mixed Concrete or Concrete using Fly ash blended Cements (PPC) are not likely to
be significantly different and their values are to be taken same as those used for Concrete made
with OPC.
(iv) To control higher rate of carbonation in early ages of Concrete both in Fly ash admixed as
Well as PPC based Concrete, water/binder ratio shall be kept as low as possible, which shall

be closely monitored during Concrete manufacture.If necessitated due to low water/binder
ratio, required workability shall be achieved by the use of Chloride free chemical admixtures
conforming to IS : 9103-1999 (reaffirmed 2004). The compatibility of chemical admixtures
and super plasticizers with each set OPC, Fly ash and /or PPC received from different sources
shall be ensured by trials.
(v) In environment subjected to aggressive Chloride or Sulphate, use of Fly ash as admixture or
PPC based Concreteis recommended. In cases, where structural Concreteis exposed to excessive
Magnesium sulphate, Flyash substitution/content shall be limited to 18% by weight. Special type
of Cement with low C3A content may also be alternatively used. Durability criteria like
minimum binder content and maximum water /binder ratio also need to be given due
consideration in such environment.
(vi) Wet curing period shall be enhanced to a minimum of 10 days or its equivalent. In hot &arid
regions, the minimum curing period shall be 14 days or its equivalent.
(vii) Subject to General Guidelines detailed out in 6.1.2, PPC manufactured conforming to IS: 1489-
1976 (Part-I) shall be treated at par with OPC for manufacture of Design Mix Concrete for
structural use in RCC.
(viii) Till the time, BIS makes it mandatory to print the percentage of Fly ash on each bag of Cement,
the certificate from the PPC manufacture indicating the same shall be insisted upon before
allowing use of such Cements in works.
(ix) While using PPC for structural Concrete work, no further admixing of Fly ash shall be
permitted. 6.1.2.1-Use of Fly ash Admixed Cement Concrete (FACC) in RCC structures:
There shall be no baron use of FACC in RCC structures subject to following additional conditions.
(i) Fly ash shall have its chemical characteristics and physical requirements etc. conforming to
IS :3812 (part I&II) -1981 and shall be duly certified.
(ii) To ensure uniform blending of Flyash with Cement in conformity with IS : 456-2000, a
specificfacility needs to be created at site with complete computerized automated process
control to achieve design quality or with similar facility from Ready Mix Concrete (RMC)
plants.
(iii) As per IS :1489 (Part-I) -1976 maximum 35% of OPC by mass is permitted to be substituted
with Fly ash conforming to IS : 3812 (Part-I)-1981 and same is reiterated.
(iv) Separate storage for dry Flyash shall be provided. Storage bins or silos shall be weather proof
and permit a free flow and efficient discharge of Fly ash. The filter or dust control system
provided in the bins or silos shall be of sufficient size to allow delivery of Flyash maintained at
specified pressure to prevent undue emission of Flyash dust, which may interfere weighing
accuracy.
6.1.2.2 Use of Fly Ash Blended Cementsin Cement Concrete (PPCC) in RCC Structures:
(i) Subject to General Guidelines detailed out as above, PPC manufactured conforming to IS :
1489 (Part-I 1976) shall be treated at par with OPC for manufacture of Design Mix Concrete for
structural use in RCC.
(ii) Till the time, BIS makes it mandatory to print the % age of Flyash on each bag of Cement, the
certificate from the PPC manufacture indicating the same shall be insisted up on before allowing
use of such Cements in works.

(iii) While using PPC for structural Concrete work, no further admixing of Flyash shall be permitted.
6.1.2.3 : Water for mixing and curing: Refer clause 5.1.5 in the Chapter on concrete.
6.1.3: Steel for reinforcement: For the purpose of this standard, the following definitions shall
apply.
i) Batch - Any quantity of bars, wires of same size and grade whether in coils or bundles
presented for examination and test at one time.
ii) Bundle-Two or more coils or a number of lengths properly bound together.
Elongation - T h e increase inlengthofa tensiletest piece under stress. The elongation at fracture
is conventionally expressed as a percentage of the original gauge length of a standard test piece.
iv) Longitudinal Rib :A uniform continuous protrusion, parallel to the axis of the bar/wire
(before cold-working, if any).
v) Nominal Diameter or Size - The diameter of a plain round bar/wire having the same mass
per metre length as the deformed bar/wire.
vi) Nominal Mass - The mass of the bar/wire of nominal diameter and of density 0.00785 kg/
mm3 per meter.
vii) Nominal Perimeter of a Deformed Bar/Wire: 3.14 times the nominal diameter.
viii) 0.2Percent Proof Stress - The stress at which a non-proportional elongation equal to 0.2
percent of the original gauge length takes place.
ix) Percentage Total Elongation at Maximum Force: The elongation corresponding to the
maximum load reached in a tensile test (also termed as uniform elongation).
x) Tensile Strength - The maximum load reached in a tensile test divided by the effective cross-
sectional area of the gauge length portion of the test piece (also termed as ultimate tensile
stress).
xi) Transverse Rib - Any rib on the surface of a bar/wire other than a longitudinal rib.
xii) Yield Stress: Stress (that is, load per unit cross sectional area) at which elongation first occurs
in the test piece without increasing the load during the tensile test. In the case of steels with no
such definite yield point, proof stress shall be applicable.
6.1.3.1: General requirements:
i) All reinforcement shall be free from loose mill scales, loose rust and coats of paints, oil, mud
or anyother substances which may destroy or reduce bond .Sand blasting or other treatment is
recommended to clean reinforcement.
ii) Special precautions like coating of reinforcement may be required for reinforced concrete
elements in exceptional cases and for rehabilitation of structures.Specialist literature may be
referred to in such cases. Reduction in design bond strength of coated bars shall be looked in to.
iii) The modulus of elasticity of steel shall be taken as 200 kN/mm2. The characteristic yield
strength of different steel shall be assumed as the minimum yield stress/0.2 percent proof stress
specified in the relevant Indian Standard.
6.1.3.2: The Steel used for reinforcement shall be any of the following types:
a) Mild Steel and medium tensile bars conforming to IS:432 (Part I)-1982 ( Reaffirmed 1995)

b) High strength deformed Steel bars conforming to IS : : 1786-1985 (superseding IS 1139-
1966) reaffirmed 1990)
c) Hard drawn Steel wire fabric conforming to IS :: 1566-1982 (Reaffirmed 1995)
d) Structural Steel conforming to Grade A of IS : : 2062-1999
e) Thermo-mechanically treated (TMT) Bars
6.1.3.3 Elongation Percent on gauge length 5.65 VA , where 'A' is the cross sectional areas of the
test piece.
6.1.3.4 Mild Steel bars are not recommended for the use in structures located in earthquake zone
subjected to severe damage and for structures subjected to dynamic loading (other than wind loading)
such as railway and highway bridges.
6.1.33 Welding of reinforcement bars covered in this specification shall be done in accordance
with the requirements of IS : 2751-1979 (Reaffirmed 1998).
6.1.3.6 Nominal Size, Cross Sectional Area and Mass :
The values for the nominal size, cross sectional area and mass of individual bars/wires shall be given
in Table 1, subjected to the tolerance on nominal mass given in Table 2. The mass/ weight calculated
on the basis that the masses of the bar/wire of nominal diameter and of density 0.785 kg/ cm3 or .00785
kg/mm3.
Table : 1
Nominal Size, Cross Sectional Area, Weight and Perimeter of Steel Bars.
S. No. Nominal (dia.) Cross Sectional weight per metre Perimeter-cm
Size (mm) Area (mm2) (kg)
1 5 19.6 0.154 1.6
2 6 28.3 0.222 1.9
3 8 50.3 0.395 2.5
4 10 78.6 0.617 3.1
5 12 113.1 0.888 3.8
6 16 201.2 1.58 5.0
7 20 314.3 2.47 6.3
8 25 491.1 3.85 7.8
9 28 616.0 4.83 8.8
10 32 804.6 6.31 10.1
11 36 1018.3 7.99 11.3
12 40 1257.2 9.85 12.6
13 45 1591.1 12.50 14.1
14 50 1964.31 15.42 15.7
Note : These are as per clause 6.2 of IS : 1786--1985

Table : 2
Tolerance on Nominal Mass
S. Nominal size in mm Tolerance on the Nominal mass (Percent)
No.
Batch Individual Individual Sample
Sample (+) for coil (x)
(a) Upto and including 10 mm +7 (-) 8 +8
(b) Over 10, upto and including 16 mm +5 (-) 6 +6
(c ) Over 16 mm +3 (-) 4 +4
+ for individual sample plus tolerance is not specified . A single sample taken from a batch (bars
and wires of the same size and grades presented for examination or test at one time) shall not be
considered as individual sample .( Amendment No. 1, Feb. 1993)
(x) for coil batch tolerance is not applicable
Tolerance shall be determined in accordance with method given in IS :1786-2008.
6.1.3.7: High strength deformed Steel bars conforming to IS : 1786-2008: It
shall besupplied in the following grades:
a) Fe 415, Fe 415 D, Fe 415 S
b) Fe 500, Fe 500 D, Fe 500 S
c) Fe 550, Fe 550 D, &
d) Fe 600
Note :
1. The figures following the symbol Fe indicate the specified minimum 0.2 % proof stress or
yield stress in N/mm2.
2. The letter D & S following the strength grade indicate the category with same specified
minimum 0.2 % proof stress or yield stress in N/mm2 but enhanced specified minimum
percentage elongation.
i) Highstrengthdeformedbars&wiresshallconformtoIS :1786-2008. The mechanical
properties for all sizes of Steel bars are mentioned below inTable 3.
Table : 3
Mechanical Properties of HYSD Bars
S1. Property Fe 415 Fe 415D Fe 415 S Fe 500 Fe 500D Fe 500 S Fe 550 Fe 550D Fe 600
No.
1. 0.2% proof 415/- 415/- 415/540 500/- 500/- 500/625 550/- 550/- 600/-
Stress/yield
stress,Min./
Max-N/mm2
2. TS/YS ratio', =1.10, =1.12,but 1.25, =1.08, =1.10,Bu 1.25 =1.06, =1.08, =1.06,
N/mm2 But TS TS not But TS TS tnot But TS But TS But TS
not less less than not less less than not less not less not less
than 485.0 500.00 than 565.0 than than than
N/mm2 N/mm2 545.0 2 N/mm2
N/mm 585.0 2 N/mm
N/mm 600.0 2 660.0
N/mm2

Si. Property Fe 415 Fe 415D Fe 415 S Fe 500 Fe 500D Fe 500 S Fe 550 Fe 550D Fe 600
No.
3. Elongation, 14.5 18.0 20.0 12.0 16.0 18.0 10.0 14.5 10.0
percent Min.
on gauge
5.65vA,
where A is
the X-
Sectional
Area of the
test piece
4. Total - 5 10 - 5 8 - 5 -
Elongation
at maximum
force Mn.
on gauge
5.65vA,
where A IS :
the X-
Sectional
Area of the
test piece'
ITS/YS ratio refers to ratio of tensile strength to the 0.2 percent proof stress or yield stress of the test piece
'Test, wherever specified by the purchaser.
6.1.3.8:Tests:
i) Selection and preparation of Test sample. All the tests pieces shall be selected by the Engineer-
in-Charge or his authorized representative, in the presence and with consent of the contractor/
or his authorised representative. The sample shall be collected either-
(a) From cutting of bars, or
(b) If he so desires, from any bar after it has been cut to the required or specified size and
the test piece taken from and any part of it.
ii) The test pieces obtained in accordance with as above shall be full sections of the bars as rolled
and subsequently cold worked and shall be subjected to physical tests without any further
modifications. No deduction in size by machining or otherwise shall be permissible. No test
piece shall be enacted or otherwise subject to heat treatment. Any straightening which a test piece
may require shall be done cold.
a) TensileTest: 0.2 % proof stress and percentage elongation- This shall be done as per IS:
1608-2005, read in conjunction with IS : 2062-2006.
i) The tensile strength, percentage elongation, percentage total elongation at
maximum force and 0.2 percent proofstress of bars/wires shall be determined in
accordance with requirements of IS 1608 read in conjunction with IS 2062,
ii) Alternatively and by agreement between the purchaser and the supplier, for routine
testing, the proof stress may be determined in conjunction with the tensilestrength test
and may be taken as the stress measuredon the specimen whilst under load
corresponding to an increase measured by an extensometer of 0.4 percentfor Fe 415,
Fe 415 S and Fe 4 15D bars/wires, 0.45 percent for grade Fe 500, Fe 500 S

and Fe 500D bars/wires and 0.47 percentfor grade Fe 550, Fe 550D and Fe 600
bars/wires the total strain on any convenient gauge length. When this alternative is
availed, the total strain shall be measured only by extensometer and not by any other
means. In case of dispute the proof stress determined in accordance with IS 1608 shall
be the deciding criteria.
iii) The stresses shall be calculated using the effective cross-sectional area of the bar/
wire.
b) Bend Test: The bend test shall be performed in accordance with the requirements of IS
1599 and the maximum mandrel diameter for different grades shall be as specified in
Table 4 of IS: 1786-2008. The test piece, when cold, shall be doubled over the mandrel by
continuous pressure until the sides are parallel. The specimen shall be considered to have
passed the test if there is no rupture or cracks visible to a person of normal or corrected
vision on the bent portion.
c) Rebend Test( IS: 1786-2008): The test piece shall be bent to an included angle of 135°
causing a mandrel of appropriate diameter (see IS:1786-2008). The bent piece shall be aged
by keeping in boiling water (100°C) for 30 tin and then allowed to cool. The piece shall
then be bent back to have an included angle of 157.5°. The specimen shall beconsidered
to have passed the test if there is no rupture or cracks visible to a person of normal or
corrected vision on the rebent portion.
d) Retest: This shall be done as per IS : 1786-2008.
e) Pull out test: This shall be conducted in accordance with IS:2770(Pt.-I)-1967 Bonded
length of the bar embedded in the concrete shall be 5 times the dia. of the bar, the rest of
the embedded length shall be made an bonded by providing plastic sleeve for that portion.
6.1.3.9- Selection of Test Specimens: For checking nominal mass, tensile strength, bend test and
rebend test, test specimen of sufficient length shall be cut from each size of the finished bar/wire at
random at a frequency not less than that specified in the table below.
Frequency For Nominal Mass, Tensile, Bend and Rebend Tests
Nominal size Quantity
For Casts/Heats For Casts/Heats of
below 100 tonnes 100 tonnes or more
(1) (2) (3)
For all sizes 2 per cast 3 per cast
Requirements forBond: a) High strength deformed bars/wires shall satisfy the requirements given in either (b) or (d) for
routine testing. Pull-out test in accordance with shall be done in addition to (b) for approval of
new or amended geometry for first time.
b) Deformations and Surface Characteristics: For high strength deformed bars/wires, the mean area
of ribs (in = 2 ) per unit length (in mm) above the core of the bar/wire, projected on a plane
normal to the axis of the bar/wire calculated in accordance with IS: 1786-2008 (clause 5.4) shall
not be less than the following values:
i) 0.12 b for < 10 mm dia

ii) 0.15for10mm<<16mm,and
iii) 0.17 c for I > 16 mm.

where is the nominal diameter of bar /wire, in mm. The mean projected area of transverse ribs
one shall be not less than one-third of the values given above.
c) The ribs contributing the projected area considered in 5.2 shall consist of i) Two longitudinal
ribs in the form of continuous helix in case of twisted bars/wires, and optional longitudinal ribs
in case of untwisted bars/wires which may be continuous or discontinuous, and ii) Transverse
ribs which after hot-rolling or cold workingare uniform in size and shape in each row along the
length of the bar/wire, and arespaced along the bar/wire at substantially uniform distance,
except in the area of marking.
d) When subjected to pull-out testing in accordance with IS 2770 (Part 1), the bond strength
calculated from the load at a measured slip of 0.025 mm and 0.25 mm for deformed bars/ wires
shall exceed that of a plain round bar of the same nominal size by 40 percent and 80 percent
respectively.
6.1.3.10 Chemical Composition:
The chemical analysis of Steel for various grades, when made as per relevant parts of IS : 228 shall
have maximum permissible percentages of constituents are mentioned below in Table 4 and the
permissible variation from the limits specified shall be as below Table 4
Table 4 : Chemical Composition of HYSD Bars
S1. Constituents Percentage,
No. Fe 415 Fe 415
Maximum
Fe 415 Fe 500 Fe 500 Fe 500 Fe 550 Fe 550 Fe 600
D S D S D
1. Carbon 0.30 0.25 0.25 0.30 0.25 0.25 0.30 0.25 0.30
2. Sulphur 0.060 0.045 0.045 0.055 0.040 0.040 0.055 0.040 0.040
3. Phosphorus 0.060 0.045 0.045 0.055 0.040 0.040 0.050 0.040 0.040
4. Sulphur & 0.110 0.085 0.085 0.105 0.075 0.075 0.100 0.075 0.075
Phosphorus 0.085
Table 5 : Permisible Variation in Composition of HYSD Bars

S1. Constituents Variation, Over specified Maximum Limit, %, Max
No.
1. Carbon 0.02
2. Sulphur 0.005
3. Phosphorus 0.005
4. Sulphur & Phosphorus 0.010
If any one test piece from the selected pieces of sample fails in any one test specified above.Then the
remaining two pieces of sample should pass all the tests, otherwise the material represented by the
sample may be considered as not having compiled with standards.

6.1.3.11 Thermo Mechanically Treated Reinforcement bars:
(a) There is no BIS code for TMT bars. The available code IS: 1786-1985 pertains to HYSD
Bars. Therefore there should be no stipulation that TMT bars should conform to relevant.
(b) The TMT bars are being produced under valid license from either of the firms namely Temp
core, Thermax, Evcon Turbo & Turbo Quench. These firms have acquired patents and are
giving licenses to various producers to produce TMT Bars.
(c) The TMT bars shall conform to IS:1786-1985 pertaining to Fe 415 D or Fe 500 D or Fe
grade of Steel as specified.
(d) In design and construction of reinforced Concrete building in seismic zone III and above, Steel
reinforcement of Grade Fe 415 D shall be used. However, high strength deformed Steel bars,
produced by thermo mechanical treatment process of grade Fe 415, Fe 500 and Fe 550 having
elongation more than 14.5. % and conform to other requirements of Fe 415 D, Fe 500
D and Fe 550 D respectively of IS : 1786-1985 may also be used for reinforcement. In future,
latest provision of IS: 456-2000 and IS : 13920-1993 or any other relevant code as modified from
time to time shall be applicable.
6.13.12 Stacking and Storage:
Steel for reinforcement shall be stored in such a way as to prevent distorting and corrosion. Care
shall be taken to protect the reinforcement from exposure to saline atmosphere during storage,
fabrication and use. It may be achieved by treating the surface of reinforcement with Cement wash or
by suitable methods. Bars of different classifications, sizes and lengths shall be stored separately to
facilitate issue in such sizes and lengths to cause minimum wastage in cutting from standard length.
6.1.3.12 Identification:
Care shall also be taken to properly identify these bars at site. The staff shall be specially trained for
looking for identification marks on these bars given by the manufacturers which are generally given
colour code. It will be advisable to see that only one type/grade of bars are brought to site and used in
the project after conducting tests for each lot.
6.1.3.13 Manufacturer's Certificate: In the case of bars/ wires which have not been inspected at the
manufacturer's works, the manufacturer or supplier, as the case maybe, shall supply the purchaser or
his authorized representative with the certificate stating the process of manufacture and also the test
sheet signed by the manufacturer giving the result of each mechanical test applicable to the material
purchased,and the chemical composition, if required. Each test certificate shall indicate the number
of the cast to which it applies, corresponding to the number or identification mark to be found on the
material. The test certificate shall contain the following information:
a) Place of manufacture of the reinforcing steel,
b) Nominal diameter of the steel,
c) Grade of the steel,
d) Rolled-in marking on the steel,
e) Cast/heat number,
0 Date of testing,
g) Mass of the tested lot, and

h) Individual test results for all the properties,
6.13.14-Identification and Marking:
a) The manufacturer or supplier shall have ingots,billets and bars or bundles of bars/wires marked
in such a way that all finished bars/wires can be traced to the cast from which they were made.
Every facility shall be given to the purchaser or his authorized representativefor tracing the
bars/wires to the cast from which they were made.
b) For each bundle/coil of bars/wires a tag shall be attached indicating cast/lot number, grade
and size.
c) All bars/wires should be identifiable by marks/brands introduced during rolling which
indicate thename of the manufacturer or their brand name.
d) Identification marks like brand name, trade-mark,etc, that are introduced during rolling shall
be designed and located in such a manner that the performance in use of the bar is not affected.
6.1.3.15-BIS Certification Marking:

Each bundle containing the bars/wires may also be suitably marked with the Standard Mark in
which case the concerned test certificate shall also bear the standard mark.
6.2 Form work (Centring & Shuttering): General :The formwork shall be designed and constructed
so as to remain sufficiently rigid during placing and compaction of concrete, and shall be such as to
prevent loss of slurry from the concrete. For further details regarding design, detailing, etc., reference
may be made to IS 14687.The tolerances on the shapes, lines and dimensions shown in the drawing
shall be within the specified tolerances (6.2.2)
Form work shall include all temporary or permanent forms or moulds required for forming
the Concrete which is cast-in-situ, together with all temporary construction required for
their support.
It shall be strong enough to withstand the dead and live loads and forces caused by
ramming and vibrations of Concrete and other incidental loads, imposed upon it during and
after casting of Concrete. It shall be made sufficiently rigid by using adequate number of
ties and braces, Screw jacks or hard board wedges where required shall be provided to make
up any settlement in the form work either before or during the placing of Concrete.
c) Forms shall be so constructed as to be removable in sections in the desired sequence,

without damaging the surface of Concrete or disturbing other sections. Care shall be
taken to see that no piece is keyed into the Concrete.
6.2.2 Design & Tolerance in Construction

Form work shall be designed and constructed to the shapes, lines and dimensions shown on the
drawings with the tolerance given in Table 6.

Table 6: Tolerance in Formwork
S1. Particular Tolerance
No.
1. Deviation from specified dimension of cross --6=
and +12 mm
2. section
Deviation from of columns of
dimensions beams
footings
i. Dimension in Plan -12 mm
+50 mm
ii. Eccentricity in plan 0.02 times the width of the footings
in the direction of deviation but not
more than 50 mm.
iii. Thickness ± 0.05 times the specified thickness
(Note- Tolerance apply toConcrete di dimensions only, an not to positioning of vertical Steel or
dowels.)
6.2.3 General Requirement:
6.2.3.1 Material for Form Work:
(a) Propping and Centring: All propping and centring should be either of Steel tubes with
extension pieces or built up sections of rolled Steel.
6.2.3.2:(a) Centring/Staging: Staging should be as designed with required extension pieces as
approved by Engineer-in-Charge to ensure proper slopes, as per design for slabs/beams
etc. and as per levels as shown in drawings. All the staging to be either of Tubular Steel
structure with adequate bracings as approved or made of built up structural sections
made from rolled structural Steel sections.
(b) In case of structures with two or more floors, the weight of Concrete, centring and
Shuttering of any upper floor being cast shall be suitably supported on one floor below
the top most floor already cast.
(c) Form work and concreting of upper floor shall not be done until Concrete of lower
floor has set atleast for 14 days.
6.2.3.3 Shuttering:
Shuttering used shall be of sufficient stiffness to avoid excessive deflection and joints shall be tightly
butted to avoid leakage of slurry. If required, rubberised lining of material as approved by the
Engineer-in-Charge shall be provided in the joints. Steel Shuttering (Steel plates with interlocking Steel
props) used for concreting should be sufficiently stiffened. The Steel Shuttering should also be
properly repaired before use and properly cleaned to avoid stains, honey combing, seepage of slurry
through joints etc.
(a) Runner Joists: RSJ, MS Channel or any other suitable section of the required size shall be
used as runners.
(b) Assembly of beam head over props. Beam head is an adopter that fits snugly on the head
plates of props to provide wider support under beam bottoms.
c) Only Steel Shuttering shall be used, except for unavoidable portions and very small works for
which 12 mm thick water proof ply of approved quality may be used. Wooden ballies shall not
be used to support the ply.

6.2.3.4 Form work shall be properly designed for self-weight, weight of reinforcement, weight of fresh
Concrete, and in addition, the various live loads likely to be imposed during the construction process
(such as workmen, materials and equipment). In case the height of centring exceeds 3.50 metres, the
prop may be provided in multi-stages. A typical detail of multistage Shutteringis given in Fig. 9 A and
9B.
6.23.5 Camber :
Suitable camber shall be provided in horizontal members of structure, especially in cantilever spans to
counteract the effect of deflection. The form work shall be so assembled as to provide for camber. The
camber for beams and slabs shall be 4 mm per metre (1 to 250) or as directed by the Engineerin-
Charge, so as to offset the subsequent deflection. For cantilevers the camber at free end shall be 1/50th
of the projected length or as directed by the Engineer-in-Charge.
6.2.3.5.1 Typical arrangement of form work for `Beams, columns and walls' are shown in Figure 1 to
8 and form secured by wall ties is shown in Fig. 3A and 3B.
6.2.3.6 -Walls:
The form faces have to be kept at fixed distance apart and an arrangement of wall ties with spacer
tubes or bolts is considered best. A typical wall form with the components identified is given in Fig
1A and 1 B , 2 & 3 A and B. The two shutters of the wall are to be kept in place by appropriate ties,
braces and studs. Some of the accessories used for wall forms are shown in Fig. 3A and 3 B.
6.2.3.7 -Removal of Form work(Stripping time) :
In normal circumstances and where ordinary Portland Cement is used, forms may generally be
removed after the expiry of the following periods shown in Table 7.
Table 7 : Stripping Time of Formwork
S. No. Type of Formwork Minimum Period Minimum Period Minimum
Before Striking Before Striking Period Before
Formwork for Formwork for Striking
OPC 33 grade OPC 43 grade Formwork for
PPC
1. Vertical formwork to columns, 16 - 24 h 16 - 24 h 24- 36 h
walls, beams.
2. Soffit formwork to slabs 3 days 3 days 4 days
(Props to be refixed
immediately after removal of
formwork)
3. Soffit formwork to beams 7 days 7 days 10 days
(Props to be refixed
immediately after removal of
formwork)
4. Props to slabs:
i.) Spanning upto 4.5m 7 days 7 days 10 days
ii.) Spanning over 4.5m 14 days 14 days 20 days

S. No. Type of Formwork Minimum Period Minimum Period Minimum
Before Striking Before Striking Period Before
Formwork for Formwork for Striking
OPC 33 grade OPC 43 grade Formwork for
PPC
5.
Props to beams and Arches:
i.) Spanning upto 6m 14 days 14 days 20 days
ii.) Spanning over 6m 21 days 21 days 30 days
Note 1: For other types of Cement, the stripping time recommended for ordinary Portland Cement
may be suitably modified. Generally, if Portland Pozzolana or low heat Cement or OPC with direct
addition of Fly ash has been used for Concrete, the stripping time will be 10/7 of the period stated for
OPC with 43 grade Cement above.
Note 2: The number of props left under, their sizes and disposition shall be such as to be able to
safely carry the full dead load of the slabs, beam or Arch as the case may be together with any live
load likely to occur during curing or further construction.
Note 3: For rapid hardening Cement, 3/7 of above periods for OPC 33 grade will be sufficient in all
cases except for vertical side of slabs, beams and columns which should be retained for at least 24
hours.
Note 4: In case of cantilever slabs and beams, the centring shall remain till structures for counter
acting or bearing down have been erected and have attained sufficient strength.
Note 5: Proper precautions should be taken to allow for the decrease in the rate of hardening that
occurs with all types of Cement in cold weather and accordingly stripping time shall be increased.
Note 6: Work damaged through premature or careless removal of forms shall be reconstructed
within 24 hours.
6.2.4 - Surface Treatment of form work :
6.2.4.1 - Oiling the Surface:
i) Shuttering gives such longer service life if the surfaces are coated with suitable mould oil
which acts both as a parting agent and also gives surface protections.
ii) A typical mould oil is heavy mineral oil or purified cylinder oil containing not less than 5%
Pentachlorophenol well mixed to a viscosity of 70-80 centipoise.
iii) After 3-4 uses and also in cases when Shuttering has been stored for a long time. It should be
recoated with mould oil before the next use.
iv) The second categories of Shuttering oils/ leavening agents are Polymer based water soluble
compounds. They are available as concentrates and are diluted with water in the ratio of 1:20 or
as per manufacturer specifications for use. The diluted solution is applied by brush applications
on the Shuttering both of Steel as Well as plywood. The solution is applied after every use.
6.2.4.2 The design of form work shall conform to sound Engineering practices and relevant IS
codes. Design of form work shall be got approved by the Engineer-in-Charge.

6.2.5 -Inspection of Form Work:
i) The completed form work shall be inspected and approved by the Engineer-in-charge before
the reinforcement bars are placed in position.
ii) Proper form work should be adopted for concreting so as to avoid honey combing, blow holes
grout loss, stains or discoloration of Concrete etc. Proper and accurate alignment and profile of
finished Concrete surface will be ensured by proper designing and erection of form work which
will be approved by Engineer-in-Charge.
iii) Shuttering surface before concreting should be free from any defect/deposits and fully cleaned
so as to give perfectly straight smooth Concrete surface. Shuttering surface should be therefore
checked for any damage to its surface and excessive roughness before use.
6.2.5.1-Erection of Form Work (Centring and Shuttering): Following points shall be borne in
mind while checking during erection.
(a) Any member which is to remain in position after the general dismantling is done, should be
clearly marked.
(b) Material used should be checked to ensure that, wrong items/rejects are not used.
(c) If there are any excavations nearby which may influence the safety of form works, corrective
and strengthening action must be taken.
(d) (i) The bearing soil must be sound and Well prepared and the sole plates shall bear Well on
the ground.
(ii) Sole plates shall be properly seated on their bearing pads or sleepers.
(iii) The bearing plates of Steel props shall not be distorted.
(iv) TheSteel parts on the bearing members shall have adequate bearing areas.
Safety measures to prevent impact of traffic, scour due to water etc., should be taken. Adequate
precautionary measures shall be taken to prevent accidental impacts etc.
(f) Bracing, struts and ties shall be Installed along with the progress of form work to ensure strength
and stability of form work at intermediate stage. Steel sections (especially deep section) shall be
adequately restrained against tilting, overturning and form work should be restrained against
horizontal loads. All the securing devices and bracing shall be tightened.
(g). The stacked materials shall be placed as catered for, in the design.
(h) When adjustable Steel props are used, they should:
be restrained be undamaged and not visibly bent.

have the Steel pins provided by the manufacturers for use,
laterally near each end.
have means for centralising beams placed in the fork heads.
Screw adjustment of adjustable props shall not be over extended.
Double wedges shall be provided for adjustment of the form to the required position wherever
any settlement/elastic shortening of props occurs. Wedges should be used only at the bottom end
of single prop. Wedges should not be too steep and one of the pair should be tightened/ clamped
down after adjustment to prevent their shifting.
(k) No member shall be eccentric upon vertical member.

(1) The number of nuts and bolts shall be adequate.
(m) All provisions of the design and/or drawings shall be complied with.
(n) Cantilever supports shall be adequate.
(0) Props shall be directly under one another in multistage constructions as far as possible.
(p) Guy ropes or stays shall be tensioned properly.
(q) There shall be adequate provision for the movement and operation of vibrators and other
construction plant and equipment.
(r) Required camber shall be provided over long spans.
(s) Supports shall be adequate, and in plumb within the specified tolerances.
6.2.6 -Measurements:
6.2.6.1 -General : The form work shall include the following:
(a) Splayed edges, notching, allowance for overlaps and passing at angles, sheathing battens,
strutting, bolting, nailing, wedging, easing, striking and removal.
(b) All supports, struts, braces, wedges as Well as mud sills, piles or other suitable arrangements
to support the form work.
(c) Bolts, wire ties, clamps, spreaders, nails or any other items to hold the sheathing together.
(d) Working scaffolds. Ladders, gangways, and similar items.
(e) Filleting to form stop chamfered edges of splayed external angles not exceeding 20 mm wide
to beams, columns and the like.
(f) Where required, the temporary openings provided in the forms for pouring Concrete, inserting
vibrators, and cleaning holes for removing rubbish from the interior of the sheathing before
pouring Concrete.
(g) Dressing with oil to prevent adhesion and
(h) Raking or circular cutting
6.2.6.2 Classification of Measurements: Where it is stipulated that the form work shall be paid for
separately, measurements shall be taken of the area of Shuttering in contact with the Concrete
surface. Dimensions of the form work shall be measured correct to a cm. The measurements shall be
taken separately for the following:
Foundations, footings, bases of columns etc. and for mass Concrete and precast shelves,
Walls (any thickness) including attached pilasters, buttresses, plinth and string courses etc.
Suspended floors, roofs, landings, shelves and their supports and balconies. lintels beams,
girders, and cantilevers. Columns, pillars, posts and struts.
Stairs (excluding landings) except Spiral Staircase.
Spiral staircases (including landings).
Arches.
Domes, Vaults, Shell roofs, Arch ribs and folded plates.
Chimneys and shafts.
Well steining.

Vertical and horizontal fins individually or forming box, louvers and bands.
W e or ribbed slabs.
Edges of slabs and breaks in floors and walls (to be measured in running metres where below
200 mm in width or thickness).
(0)
Cornices and mouldings.
(p) Small surfaces, such as cantilevers ends, brackets and ends of steps, caps and boxes to pilasters
and columns and the like.
(q) Chullah hoods, weather shades, chhajjas, corbels etc. including edges and. Elevated water
reservoirs.
6.2.6.3 Centring, and Shuttering where exceeding 3.5 metre height in one floor shall be measured
and paid for separately.
6.2.6.4 Where it is not specifically stated in the description of the item that form work shall be paid for
separately, the rate of the RCC item shall be deemed to include the cost of form work.
6.2.6.5 No deductions from the Shuttering due to the openings/obstructions shall be made if the area
of such openings/obstructions does not exceed 0.4 square metre. Nothing extra shall be paid for
forming such openings.
6.2.6.6 Form work of elements measured under categories of Arches, Arch ribs, Domes, Spiral
staircases, Well steining, Shell roofs, curvilinear folded plates & curvilinear eaves board, circular
shafts & chimneys shall not qualify for extra rate for circular work.
6.2.6.7 Extra for circular work shall be admissible for surfaces circular or curvilinear in plan or in
elevation beyond the straight edge of supporting beam in respective mode of measurement. However,
there may be many different types of such structures. In such cases, extra payment shall be made
judiciously after deducting areas where Shuttering for circular form work is not involved.
6.2.7 Rate: The rate of the form work includes the cost of labour and materials required for all the
operations described above.
6.3 Reinforcement:General Requirements: Steel Conforming to para 6.1.3 for reinforcement shall
be clear and free from loose mill scales, dust, loose rust, coats of paints, oil or other coatings which
may destroy or reduce bond. It shall be stored in such a way as to avoid distortion and to prevent
deterioration and corrosion. or to assembly of reinforcement on no account any oily substance shall
be used for removing the rust.
6.3.1. Anchoring Bars in Tension: Deformed bars may be used without end anchorages provided,
development length requirement is satisfied. Hooks should normally be provided for plain bars in
tension. Development length of bars will be determined as per IS : 456 - 2000.
6.3.1.1 Anchoring Bars in Compression: The anchorage length of straight bar in compression shall
be equal to the `Development length' of bars in compression as specified in IS : 456-2000. The
projected length of hooks, bends and straight lengths beyond bend, if provided for a bar in
compression, shall be considered for development length.
6.3.1.2 Binders, stirrups, links etc.: In case of binders, stirrups, links etc. the straight portion
beyond the curve at the end shall be not less than eight times and nominal size of bar.
6.3.1.3 Welding of Bars : Wherever facility for electric arc welding is available, welding of bars
shall be done in lieu of overlap. The location and type of welding shall be got approved by the

Engineer-in-Charge. Welding shall be as per IS : 2751-1979 (Reaffirmed 1988) and IS : 9417-1989
(Reaffirmed 1994).
6.3.2 A ssembly of reinforcement:
a) Reinforcement shall be bent and fixed in accordance with procedure specified in IS 2502. The
high strength deformed steel bars should not be rebent or straightened without the approval of
the Engineer-in-charge. Bar bending schedules should be prepared for all reinforcement work.
b) All reinforcement shall be placed and maintained in position as shown in the drawings by
providing proper cover blocks, spacers, supporting bars etc. The bars crossing one another shall
be tied together at every intersection with two strands of annealed Steel wire 0.9 to 1.6 mm
thickness twisted tight to make the skeleton of the Steel work rigid so that the reinforcement does
not get displaced during deposition of Concrete. Crossing bars should not be tack welded for
assembly of reinforcement unless permitted by Engineer-in-Charge.
c) Preferably bars of full length shall be used. Necessary cutting and straightening is also included.
Over lapping of bars, where necessary shall be done as directed by the Engineer-in-Charge.
The overlapping bars shall not touch each other and these shall be kept apart with Concrete
between them by 25 mm or 1.25 times the maximum size of the Coarse aggregate whichever is
greater. But where this is not possible, the overlapping bars shall be bound together at intervals
not exceeding twice the dia. of such bars with two strands annealed Steel wire of 0.90 mm to
1.6 mm twisted tight. The overlaps/splices shall be staggered as per directions of the Engineer-
in-Charge. But in no case the over lapping shall be provided in more than 50% of cross sectional
area at one section.
6.3.2.1- Placing of Reinforcement: Rough handling, shock loading (prior to embedment) and the
dropping of reinforcement from a height should be avoided. Reinforcement should be secured
against displacement outside the specified limits.
6.3.2.2- Tolerances on Placing of Reinforcement : Unless otherwise specified by the Engineer-in-
Charge, reinforcement shall be placed within the tolerances given in Table 8.
Table 8 : Tolerance on Placing of Reinforcement
S. No. PARTICULAR TOLERANCE IN SPACING
1. mm +1- 10 mm
2. For
For effective depth, more thanor200
effective depth, 200 less.mm. +/- 15 mm
- Tolerance for Cover : Unless specified otherwise, actual concrete cover
 should not deviate from the required nominal cover by +10/0 mm,
 Nominal cover as given in 6.3.2.8 should be specified to all steel reinforcement including links.
Spacers between the links (or the bars where no links exist)and the formwork should be of the
same nominal size as the nominal cover.
 Spacers, chairs and other supports detailed on drawings, together with such other supports as
may be necessary, should be used to maintain the specified nominal cover to the steel
reinforcement.
 Spacers or chairs should be placed at a maximum spacing of 1m and closer spacing may
sometimes be necessary.
 Spacers,cover blocks should be of concrete of same strength or PVC.

6.3.2.4-Spacing of Reinforcement : For the purpose of this clause the diameter of around bar shall
be its nominal diameter and in the case of bars which are not round or in the case of deformed bars or
crimped bars, the diameter shall be taken as the diameter of a circle giving an equivalent effective
area. Where spacing limitations and minimum concrete cover are based on bar diameter, a group of
bars bundled in contact shall be treated as a single bar of diameter derived from the total equivalent
area.
6.3.2.5- Minimum Distance between Individual Bars : The following shall apply for spacing of bars:
a) The horizontal distance between two parallel main reinforcing bars shall usually be not less
than the greatest of the following:
i) The diameter of the bar if the diameter are equal.
ii) The diameter of the larger bar if the diameters are unequal. and
iii) 5 mm more than the nominal maximum size of coarse aggregate.
Note- This does not preclude the use of larger size of aggregates beyond the congested reinforcement
in the same member, the size of aggregates may be reduced around congested reinforcement
to comply with this provision.
b) greater horizontal distance than the minimum specified in(a) should be provided wherever
possible. However when needle vibrators are used the horizontal distance between bars of a group
may be reduced to two-thirds the nominal maximum size of the coarse aggregate, provided that
sufficient space is left betweengroups of bars to enable the vibrator to be immersed.
c) Where there are two or more rows of bars, the bars shall he vertically in line and the minimum
vertical distance between the bars shall be 15 mm, two-thirds the nominal maximum size of
aggregate or the maximum size of bars,whichever is greater.
6.3.2.6- Maximum Distance Between Bars in Tension: Unless the calculation of crack widths
shows that a greater spacing is acceptable, the following rules shall he applied to flexural members in
normal internal or external conditions of exposure.
a) Beams- The horizontal distance between parallel reinforcement bars, or groups, near the
tension
face of a beam shall not be greater than the values given below depending on the amount of
redistribution carried out in analysis and the characteristic strength of the reinforcement.
b) Slabs :
i) The horizontal distance between parallel main reinforcement bars shall not be more
than three times the effective depth of solid slab or 300 mm whichever is smaller.
ii) The horizontal distance between parallel reinforcement bars provided against shrinkage
and temperature shall not be more than five times the effective depth of a solid slab or 300
mm which-ever is smaller.
f Percent to or from section
30 age
-15 0 considered
+15 +30
redistr
i b u Clear
t i o n distance between bars
2
N/mm mm mm mm mm mm
250 215 260 300 300 300
415 125 155 180 210 235
500 105 130 150 175 195

Note: the spacing's given in the table are not applicable to members subjected to particularly
aggressive environments unless in the calculation of the moment of resistance fyhas been limited to
300 N/mm2 in limit state design and 6X limited to 165 N/mm2 in working stress design.

6.3.2.7 Bending at Construction Joints:
Where reinforcement bars are bent aside at construction joints and afterwards bent back into their
original position care should be taken to ensure that at no time the radius of the bend is less than 4
bar diameters for plain mild Steel or 6 bar diameters for deformed bars. Care shall also be taken when
bending back bars to ensure that the Concrete around the bar is not damaged.
6.3.2.8 Cover :
(i) Requirement of Concrete cover :- The protection of the Steel in Concrete against corrosion
depends upon an adequate thickness (cover) of good quality Concrete. The nominal cover to meet
Durability requirements shall be provided as under (clause 26.4 of IS : 456-2000).
(a) Nominal coveris the design depth of Concrete cover to all Steel reinforcements, including
links. It shall be not less than the diameter of the bar.
(b) Minimum Cover :- For the longitudinal reinforcing bar in a column, nominal cover shall be
not less than 40 mm, or less than the diameter of such bar. In case of columns of minimum
dimension of 200 mm or under, whose reinforcing bars do not exceed 12 mm, a nominal cover
of 25 mm may be used.
(c) For footings the minimum cover shall be 50 mm. Nominal Cover to Meet
Specified Period of Fire Resistance
Fire NOMINAL COVER
Resistance
Beams Slabs Ribs Columns
Simply Continuous Simply Continuous Simply Continuous
supported supported supported
Hours mm mm mm mm mm mm mm
0.5 20 20 20 20 20 20 40
1 20 20 20 20 20 20 40
1.5 20 20 25 20 35 20 40
2 40 30 35 25 45 35 40
3 60 40 45 35 55 45 40
4 70 50 55 45 65 55 40
Notes :- 1. The no=n covers given relate specifically ly to the minimum member dimension given
in fig. lof IS 456-2000 21.4 page 34..
2. Cases that lie below the bold line require attention to the additional measures necessary
to reduce the risks of spalling. To prevent this additional measures such as application
of fire resistance finishes, fire resistant false ceilings and sacrificial steel in tensile zone
should be adopted . In case the nominal covers required exceeds 40 mm for beams and
35 mm for slabs.
The minimum nominal cover to meet durability requirements shall be as Table 9

Table 9 :
Minimum Nominal Cover
S. No. Exposure Nominal Concrete Cover
in mm not Less than
1 Mild 20
2 Moderate 30
3 Severe 45
4 Very Severe 50
5 Extreme 75
Notes:
1. For main reinforcement upto 1 2 = diameter bar for mild exposure the nominal cover may
be reduced by 5 = .
2. Unless specified otherwise, actual Concrete cover should not deviate from the required
nominal cover by +10 mm
3. For exposure condition `severe' and `very severe', reduction of 5 mm may be made, where
Concrete grade IS : M35 and above.
4. Nominal cover to meet specified period of fire resistance shall not be less than as given in
Table 9.
6.33 Measurement
Reinforcement including authorised spacer bars and laps shall be measured in length of different
diameter, as actually (not more than as specified in the drawings) used in the work nearest to a
centimetre and their weight calculated on the basis of standard weight given in Table 2. In case actual
unit weight of the bars is less than standard unit weight, but within variation, in such cases weight
of reinforcement shall be calculated on the basis of actual unit weight. Wastage and unauthorized
overlaps shall not be paid for. Annealed Steel wire required for binding or tack welding shall not be
measured, its cost being included in the rate of reinforcement.
Wherever tack welding is used in lieu of binding, such welds shall not be measured. Chairs separators
etc. shall be provided as directed by the Engineer-in-Charge and measured separately and paid for.
6.3.4 Rate
The rate for reinforcement shall include the cost of labour and materials required for all operations
described above such as cleaning of reinforcement bars, straightening, cutting, hooking, bending,
binding, placing in position etc. as required or directed including tack welding on crossing of bars in
lieu of binding with wires.
6.4 Cement Concrete:

6.4.1 The Concrete shall be as specified under Chapter 5 of Concrete work. The proportion by
volume or by the weight of ingredients shall be as specified. All structural Concrete shall be as per
approved design mix (by weight, through batch mix plants). Nominal mixes shall be used as an
exception with the written permission of the Engineer-in-Charge.
Guidelines for use of Fly ash Blended Cements in Cement Concrete (PPCC) and Fly Ash admixed
Cement Concrete (FACC) in RCC structures shall also be specified in this chapter.

6.4.1.2 Use of Fly Ash Blended Cements in Cement Concrete (PPCC) in RCC Structures
6.4.1.3 Use of Fly ash Admixed Cement Concrete (FACC) in RCC structures. For both,
Refer clause 6.1.2 above.
6.4.2 Consistency:The Concrete which will flow sluggishly into the forms and around the
reinforcement without any segregation of Coarse aggregate from the mortar, shall be used. The
consistency shall depend on whether the Concreteis vibrated on or hand tamped. It shall be determined
by slump test as prescribed in chapter 5 Plain Cement Concrete, under work ability requirement.
6.4.2.1 Workability and Durability of Concrete: Refer appendix `H' of Chapter 5 : Concrete.
6.4.3 Placing of Concrete:
6.4.3.1 Concreting shall be commenced only after Engineer-in-charge has inspected the Centring,
Shuttering and reinforcement as placed and passed the same. Shuttering shall be clean and free from
all shavings, saw dust, pieces of wood, or other foreign material and surfaces shall be treated as
prescribed in 6.2.4.
6.4.3.2 In case of concreting of slabs and. Beams, wooden plank or cat walks of chequered MS plates
or bamboo chalies or any other suitable material supported directly on the centring by means of
wooden blocks or lugs shall be provided to convey the Concrete to the place of deposition without
disturbing the reinforcement in any way. Labour shall not be allowed to walk over the reinforcement.
6.4.3.3 In case of columns and walls, it is desirable to place Concrete without construction joints. The
progress of concreting in the vertical direction shall be restricted to one metre per hour.
6.4.3.4 The Concrete shall be deposited in its final position in a manner to preclude segregation of
ingredients. In deep trenches and footings Concrete shall be placed through chutes or as directed by
the Engineer-in-Charge. In case of columns and walls, the Shuttering shall be so adjusted that the
vertical drop of Concrete is not more than 1.5 metre at a time.
6.4.3.5 During cold weather, concreting shall not be done when the temperature falls below 4.5°C.
The Concrete placed shall be protected against frost by suitable covering. Concrete damaged by frost
shall be removed and work redone.
6.4.3.6 During hot weather precaution shall be taken to see that the temperature of wet Concrete
does not exceed 38°C. No Concrete shall be laid within half an hour of the closing time of the day,
unless permitted by the Engineer-in-Charge.
6.4.3.7 It is necessary that the time between mixing and placing of Concrete shall not exceed 30
minutes so that the initial setting process is not interfered with.
6.4.4 Compaction: It shall be as specified in respective para of Chapter 5 on Concrete of this
Specification.
6.4.4.lConcrete shall be compacted into dense mass immediately after placing by means of
mechanical vibrators designed for continuous operations. The Engineer-in-Charge may however
relax this conditions at his discretion for certain items, depending on the thickness of the members and
feasibility of vibrating the same and permit hand compaction instead. Hand compaction shall be done
with the help of tamping rods so that Concrete is thoroughly compacted and completely worked
around the reinforcement, embedded fixtures, and into corners of the form. The layers of Concrete
shall be so placed that the bottom layer does not finally set before the top layer is placed. The vibrators
shall maintain the whole of Concrete under treatment in an adequate state of agitation,

such that deaeration and effective compaction is attained at a rate commensurate with the supply of
Concrete from the mixers. The vibration shall continue during the whole period occupied by placing
of Concrete, the vibrators being adjusted so that the centre of vibrations approximates to the centre of
the mass being compacted at the time of placing.
6.4.4.2 Concrete shall be judged to be properly compacted, when the mortar fills the spaces between
the Coarse aggregate and begins to cream up to form an even surface. When this condition has been
attained, the vibrator shall be stopped in case of vibrating tables and external vibrators. Needle
vibrators shall be withdrawn slowly so as to prevent formation of loose pockets in case of internal
vibrators. In case both internal and external vibrators are being used, the internal vibrator shall be first
withdrawn slowly after which the external vibrators shall be stopped so that no loose pocket is left in
the body of the Concrete. The specific instructions of the makers of the particular type of vibrator
used shall be strictly complied with. Shaking of reinforcement for the purpose of compaction should be
avoided. Compaction shall be completed before the initial setting starts, i.e. within 30 minutes of
addition of water to the dry mixture.
6.4.5 Expansion Joints:

Expansion joints shall be provided as shown in the structural drawings or as indicated in Fig 10 to 25
or as directed by Engineer-in-charge, for the purpose of general guidance. However it is
recommended that structures exceeding 45 m in length shall be divided by one or more expansion
joints. The filling of these joints with bitumen filler, bitumen felt or any such material and provision
of copper plate, etc. shall be paid for separately in running metre, The measurement shall be taken upto
two places of decimal stating the depth and width of joint.
6.4.6 Construction Joints:

6.4.6.1 Concreting shall be carried out continuously upto the construction joints, the position and
details of which shall be as shown in structural drawing or as indicated in Fig. or as directed by
Engineer-incharge. Number of such joints shall be kept to minimum. The joints shall be kept at
places where the shear force is the minimum. These shall be straight and shall be at right angles to the
direction of main reinforcement. Construction joints should comply with IS:11817-1986
(Reaffirmed 2002).
6.4.6.2 In case of columns the joints shall be horizontal and 10 to 15 cm below the bottom of the
beam running into the column head. The portion of the column between the stepping off level and the
top of the slab shall be concreted with the beam.
6.4.6.3 When stopping the Concrete on a vertical plane in slabs and beams, and approved stop-board
(see Fig. 26 C) shall be placed with necessary slots for reinforcement bars or any other obstruction to
pass the bars freely without bending. The construction joints shall be keyed by providing a triangular or
trapezoidal fillet nailed on the stop-board. Inclined or feather joints shall not be permitted. Any
concreteflowing through the joints of stop-board shall be removed soon after the initial set. When
Concrete is stopped on a horizontal plane, the surface shall be roughened and cleaned after the initial
set.
6.4.6.4 When the work has to be resumed, the joint shall be thoroughly cleaned with wire brush and
loose particles removed. A coat of neat Cement slurry at the rate of 2.75 kg of Cement per square
meter shall then be applied on the roughened surface before fresh Concrete is laid.

6.4.7 Curing:
After the Concrete has begun to harden i.e. about 1 to 2 hours after it laying, it shall be protected
from quick drying by covering with moist Gunny bags, Sand, Canvass, Hessian or any other material
approved by the Engineer-in-charge. After 24 hours of laying of Concrete, the surface shall be cured
by ponding. With water for a minimum period of 7 days from the date of placing of Concrete in case of
OPC 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 condition.
6.4.8 Finishing :
6.4.8.1 In case of roof slabs the top surface shall be finished even and smooth with wooden trowel,
before the Concrete begins to set. Sprinkling of dry Cement while finishing shall not be resorted to.
6.4.8.2 Immediately on removal of forms, the R.C.C. work shall be examined by the Engineer in-
Charge, before any defects are made good.
a) The work that has sagged or contains honey combing to an extent detrimental to structural
safety or Architectural concept shall be rejected as given in para 6.4.10.4. for visual inspection
test.
b) Surface defects of a minor nature may be accepted. On acceptance of such a work by the
Engineer-in-Charge, the same shall be rectified as follows:
The work that has sagged or contains honey combing to an extent detrimental to structural
safety or Architectural concept shall be rejected as given in para 6.4.10.4. for visual
inspection test.
Surface defects which require repair when forms are removed, usually consist of bulges
due to movement of forms, ridges at form joints, honey-combed areas, damage resulting
from the stripping of forms and bolt holes, bulges and ridges are removed by careful
chipping or tooling and the surface is then rubbed with a grinding stone. Honey-combed
and other defective areas must be chipped out, the edges being cut as straight as possible
and perpendicularly to the surface, or preferably slightly undercut to provide a key at the
edge of the patch.
iii) Shallow patches are first treated with a coat of thin grout composed of one part of Cement
and one part of fine Sand and then filled with mortar similar to that used in the Concrete.
The mortar is placed in layers not more than 10 mm thick and each layer is given a scratch
finish to secure bond with the succeeding layer. The last layer is finished to match the
surrounding Concrete by floating, rubbing or tooling on formed surfaces by pressing the
form material against the patch while the mortar is still plastic.
Large and deep patches require filling up with Concrete held in place by forms. Such
patches are reinforced and carefully dowelled to the hardened Concrete.
Holes left by bolts are filled with mortar carefully packed into places in small amounts. The
mortar is mixed as dry as possible, with just enough water so that it will be tightly
compacted when forced into place.
Tiered holes extending right through the Concrete may be filled with mortar with a
pressure gun similar to the gun used for greasing motor cars.
Normally, patches appear darker than the surrounding Concrete, possibly owing to the
presence on their surface of less Cement laitance. Where uniform surface colour is

important, this defect shall be remedied by adding 10 to 20 percent of white Portland
Cement to the patching mortar, the exact quantity being determined by trial.
(viii) The same amount of care to cure the material in the patches should be taken as with the
whole structure. Curing must be started as soon as possible, after the patch is finished to
prevent early drying. Damp hessian may be used but in some locations it may be difficult
to hold it in place. A membrane curing compound in these cases will be most convenient.
(c) The exposed surface of R.C.C. work shall be plastered with Cement mortar 1:3 (1 Cement :3
fine Sand) of thickness not exceeding 6 mm to give smooth and even surface true to line and
form. Any RCC surface which remains permanently exposed to view in the completed structure,
shall be considered exposed surface for the purpose of this specification.
Where such exposed surface exceeding 0.5 sqm in each location is not plastered with Cement
mortar 1:3 (1 Cement :3 fine Sand) 6 mm thick, necessary deduction shall be made for plastering
not done.
(d) The surface which is to receive plaster or where it is to be joined with brick masonry wall, shall
be properly roughened immediately after the Shutteringis removed, taking care to remove the
laitance completely without disturbing the Concrete. The roughening shall be done by hacking.
Before the surface is plastered, it shall be cleaned and wetted so as to give bond between
Concrete and plaster. RCC work shall be done carefully so that the thickness of plaster required
for finishing the surface is not more than 6 mm.
(e) The surface of RCC slab on which the Cement Concrete or mosaic floor is to be laid shall be
roughened with brushes while the Concrete is green. This shall be done without disturbing the
Concrete.
6.4.9 Strength of Concrete : The compressive strength on work tests for different mixes shall be as
given in Table 10 below :-
Table 10 :
S. No. Concrete Mix Compressive Strength in
(Nominal Mix on Volume (k N/cm2)
basis)
7 days 28 days
1. 1:1:2 21.0 31.5
1. 1 :1.5:3 17.5 26.5
2. 1:2:4 14.0 21.0
6.4.10 Testing of Concrete :
6.4.10.1 Regular mandatory tests on the workability of the fresh Concrete shall be done to achieve the
specified compressive strength of Concrete. These will be of two types
(a) Mandatory Lab Test
(b) Mandatory Field Test
Results of Mandatory Field Test will prevail over mandatory Lab Test.

6.4.10.2-Cube Test for Compressive Strength of Concrete : Mandatory Lab Test
Mandatory Lab test and shall be carried out as prescribed in Appendix A of this Chapter.
6.4.10.3-Additional Test:
Additional test, if required, shall be carried out as prescribed in Appendix B of this Chapter.
6.4.10.3-Slump Test: This test shall be carried out as prescribed in IS:1199 : 1959 (Reaffirmed
1999).
6.4.10.4-Visual Inspection Test : The Concrete will be inspected after removal of the form work as
described in para 6.4.8.2. The question of carrying out mandatory test or other tests will arise only
after satisfactory report of visual inspection.
The Concreteis liable to be rejected if :
i) It is porous or honeycombed as per para 6.4.8.2 (a).
(ii) Its placing has been interrupted without providing a proper construction joint.
(iii) The reinforcement has been displaced beyond tolerance specified or construction tolerances
have not been met.
However, the hardened Concrete may be accepted after carrying out suitable remedial measures to
the satisfaction of the Engineer-in-charge at the risk and cost of the contractor.
6.4.11-Standard of Acceptance for Nominal Mix:
6.4.11.1-Mandatory Lab Test: For Concrete sampled and tested as prescribed in Appendix D of
this chapter, the following requirement shall apply.
6.4.11.2 Out of six sample cubes, three cubes shall be tested at 7 days and remaining three cubes at
28 days.
6.4.11.3:- 7 Day's tests:
Sampling: The average of the strength of three specimens shall be accepted as the compressive
strength of the Concrete provided the variation in strength of individual specimen is not more than ±
15% of the average. Difference between the maximum and minimum strength should not exceed 30%
of average strength of three specimens. If the difference between maximum and minimum strength
exceeds 30% of the average strength, then 28 days' test shall have to be carried out.
Strength: If the actual average strength of sample accepted in para `sampling' above is equal to or
higher than specified strength upto 15%, then strength of the Concrete shall be considered in order.
In case the actual average strength of sample accepted in the above para is lower than the specified or
higher by more than 15% then 28 days' test shall have to be carried out to determine the compressive
strength of Concrete cubes.
6.4.11.4 : 28 Day's test:
(a) The average of the strength of three specimen be accepted as the compressive strength of the
Concrete provided the strength of any individual cube shall neither be less than 70% nor higher
than 130% of the specified strength.
(b) If the actual average strength of accepted sample exceeds specified strength by more than 30%,
the Engineer-in-charge, if he so desires, may further-investigate the matter. However, if the
strength of any individual cube exceeds more than 30% of specified strength, it will be
restricted to 130% only for computation of strength.

(c) If the actual average strength of accepted sample is equal to or higher than specified strength
upto 30% then strength of the Concrete shall be considered in order and the Concrete shall be
accepted at full rates.
(d) If the actual average strength of accepted sample is less than specified strength but not less than
70% of the specified strength, the Concrete may be accepted at reduced rate at the discretion of
Engineer-in-Charge (See para 6.4.14.2).
(d) If the actual average strength of accepted sample is less than 70% of specified strength, the
Engineer-in-charge shall reject the defective portion of work represented by sample and nothing
shall be paid for the rejected work. Remedial measures necessary to retain the structure shall be
taken at the risk and cost of contractor. If, however, the Engineer-in-Charge so desires, he may
order additional tests (See Appendix B of this chapter) to be carried out to ascertain if the
structure can be retained. All the charges in connection with these additional tests shall be
borne by the contractor.
6.4.11.5 Acceptance Criteria of Field Test (Additional Test - Not Mandatory):
(A) Preparation of Standard Test Cubes for calibration of Rebound Hammer at site:
(i) In the beginning the standard test cubes of the specified mix shall be prepared by field units
before undertaking any Concrete work in each project.
(ii) At least 18 standard cubes necessary for formation of one specimen of specified mix, shall be
cast by site staff well in advance. From these 18 cubes any 3 cubes may be selected at random
to be tested for crushing strength of 7 days. The crushing strength obtained should satisfy the
specified strength for the mix as per specification or agreement. If the strength is satisfactory
then the remaining cube will form the standard samples for calibration of rebound hammer. In
case of failure, the site staff should totally reject the samples and remove them also and then
make another set of samples by fresh mixing or alternatively, out of the remaining 15 cubes, 3
cubes will be tested on 28 days. If the 28 days' tests are found satisfactory then remaining 12
cubes will form the standard sample for calibration at 28 days' strength otherwise all samples
shall be rejected and whole procedure repeated to form a fresh specimen. All the results shall
be recorded in a register.
(iii) No concreting will be allowed unless the standard specimen cubes are obtained. The criteria
for acceptance and calibration of hammer will be 28 days' strength. The 7 days strength is only
to facilitate the work to start.
(iv) No work (for the Concrete cast between 8th and 28th day) shall be allowed to be paid unless
28 days' cube strength is obtained. For the Concrete cast between 8th and 28th day, the decision
to make the payment may be taken by the Engineer-in-charge on the basis of existing criteria.
Concrete work will be rejected if 28 days' strength falls short as per acceptance criteria. No
further work will be allowed till the acceptable standard cubes are obtained.
(e) Frequency: It will be once in each quarter or as per the direction and discretion of Engineerin-
Charge. When ever the acceptance criteria is changed or Concrete mix or type of Cement is
changed or Engineer-in-Charge feels it necessary for recorded reasons with the approval of the
authority according to technical sanction, fresh specimen shall be prepared.
(B) Calibration of Hammer:

(i) Simultaneously, same three cubes to be tested on 28 days as referred in para A(ii),
above shall be used to correlate the compressive strength of their Concrete with
rebound number as per procedure described in para 5.2 of the IS :13311 (Part 2) -1992
(reaffirmed 1999) "Indian standard for non-destructive testing of Concrete. Method of
test by rebound hammer which is given below in para B (b). The average of values of
there bound number (minimum readings) obtained in respect of same three cubes
passing on 28 days' work test shall form the datum reference for remaining cubes for the
strength of cubes.
(ii) The Concrete cubes specimens are held in a compression testing machine under a
fixedload, measurements of rebound hammer taken and then compressive strength
determined as per IS:516-1959 (Reaffirmed 1999) The fixed load required of the order
of 7N/mm 2 when the impact energy of the hammer is about 2.2 Nm.
If the specimen are wet cured, they should bere moved from wet storage & kept in the
laboratory atmosphere for about 24 hours be fore testing.
Only the vertical faces of the cubes as cast should be tested for rebound number.
Atleast nine readings should be taken on each of the three vertical faces accessible in
the compression testing machine when using rebound hamm ers. The points of impact
in the specimen must not be nearer than 20 mm from the edge & should not be less
than 20 mm from each other. The same points must not be impacted more than once.
(iii) The rebound number of hammer will be determined on each of the remai ning (18-3-
3=12) cubes. When ever the rebound number of hammer of any individual cube varies
by more than + 25% form the datum readings referred to in para B (a) above, that cube
will be excluded and will not be considered for standard specimen cubes for
calibration. It must be ensured that at least 8 cubes out of 12 that IS : 66.67 % are
within the permissible range of variation of rebound number i.e. +25% or otherwise
whole procedure shall have to be repeated and fresh specimen prepared.
These 8 cubes will form one standard sample in the beginning before commencement
of work and shall be kept carefully for the visiting officers who will calibrate their
hammers on these cubes.
(iv) This calibration will be done by field staff with their hammer and then chart of
calibration giving the details of the average readings, date & month of casting, mix of
the Concrete etc. shall be prepared and signed by Engineer-in-Charge and will be duly
preserved for future reference as and when required.
(C) Preservation of Cubes at site: Standard sample cubes cast shall be carefully
preserved at site under the safe custody of AE or his representative for making them
available together with the charts, to the officers of QCTA/CTE or any other senior
departmental officer, during their inspection of the work. They will calibrate their
hammer on these cubes if required.
(D) Testing at Site:
(i) Testing Equipment.
(ii) Testing will be done generally by non-destructive methods like rebound hammers etc.
Each field Division/Sub Division/Unit will purchase rebound hammers and keep them
in

working order at work site. The testing will be done only by hammers which are duly calibrated.
(iii) The relative strength of actual field work will be tested with reference to strength of these
standard cubes and calibration charts of a hammer for determining the rebound number on the
field work. The hammer will be used as per manufacturer's guidelines at various locations
chosen at random. The number of location/reading on each wall, beam or column etc. Shall not
be less than 12. All the readings should be within the +25% range of values prescribed in
calibration chart normally. However, reading indicating good strength will be when it is at par
with calibrated value or between 100% & 125% and verygood if more than 125% any value
between 100% & 75% of calibrated value shall be considered satisfactory. Values from 75%
to 50% shall be considered for payment at rates reduced on prorate basis. The Concrete
indicating rebound number less than 50% of calibrated value shall be rejected and not paid for.
(E) Acceptance of Field Tests and Strength:
If the relative strength of actual field work is found satisfactory considering the calibration
charts with reference to the standard cube test kept at site, the representative work will be
considered satisfactory. If the work is considered be low satisfactory, the same will be dealt as
stated in Para D-(iii) above.
(F) 7 day's Strength in Rare Case sonly:
Normally cube crushing strength on 28 day's test shall form the basis of acceptance. How ever
in rare cases of time bound projects/ urgent repairs 7day's cube test strength criteria may be
adopted on similar lines using 7 days' standard test cubes and calibration graphs/curves/ charts
for 7day's in lieu of 28 days' and testing work done at 7 day's.
(G) Non-destructive Testing: i) Non-destructive tests are used to obtain estimation of the
properties of concrete in the structure. The methods adopted include ultrasonic pulse velocity (IS
13311, Part I) and rebound hammer [IS 13311 (Part-II) probe penetration, pull outand maturity.
Non-destructive tests provide alternatives to core tests for estimating the strength of concrete in
a structure, or can supplement the data obtained from a limited number of cores. These methods
are based onmeasuring a concrete properly that bears some relationship to strength. The
accuracy of these methods, in part, is determined by the degree of correlation between strength
and the physical quality measured by the non-destructive test. Any of the methods can be
adopted in which case the acceptance criteria shall be agreed upon prior to testing.
(ii) The rebound hammers are influenced by number off actor like type of Cement, aggregate,
surfacec on ditions, moisture content, age of Concrete & extent of calibration of Concreteetc,
hence care shall be taken to compare the Cement, aggregate etc, and tested under the similar
surface conditions having more or less same moisture content and age. However effect of age
can be ignored for Concrete between 3 days & 3 months old.
6.4.12 Measurement :
6.4.12.1 Dimensions shall be measured nearest to a cm except for the thickness of slab which shall be
measured correct to 0.5 cm. The areas shall be worked out nearest to 0.01 sqm. The cubical contents
shall be worked out to nearest 0.01 cubic metre.
6.4.12.2 Reinforced Cement Concrete whether cast-in-situ or precast shall be classified and measured
separately as follows:
(a) Raft, footing, bases of columns etc. and mass Concrete.

(b) Walls (any thickness) including attached pilasters, buttresses, plinth and string course, fillets
etc.
(c) Suspended floors, roofs, landings and balconies.
(d) Shelves
(e) Chhajjas
(f) Lintel, beams and bresummers.
(g) Columns, pillars, piers, abutments, posts and struts.
(h) Stair-cases including waist or waist less slab but excluding landing except in (i) below.
(i) Spiral stair-case (including landing)..
G) Arches, Arch ribs, Domes and vaults. (k)
Chimneys and shafts.
(1) Well steining.
(m) Vertical and horizontal fins individually or forming box, louvers and facia.
(n) Kerbs, steps and the like.
(o) String courses, bands, coping, bed plates, anchor blocks, plain window sills and the like.
(p) Mouldings as in cornices window sills etc.
(q) Shell, dome and folded plates.
(r) Extra for Shuttering in circular work in plan.
6.4.12.3 Work under the following categories shall be measured separately.
(a) Rafts, footings, basis of columns etc. and mass Concrete.
(b) All other items upto floor two level. I From floor two level to floor three level and so on.
(d) R.C.C. above roof level shall be measured along with R.C.C. work in floor just below.
6.4.12.4 No deduction shall be made for the following:
(a) Ends of dissimilar materials (e.g. Joists, beams, post girders, rafters, purlins trusses, corbels
steps etc.), upto 500 sqcm in, cross-section.
(b) Opening upto 0.1 sqm.
Note: In calculating area of openings upto 0.1 sqm the size of opening shall include the
thickness of any separate Lintels or sills. No extra labour for forming such openings or voids
shall be paid for.
(c ) The volume occupied by reinforcement.
(d) The volume occupied by water pipes, conduits etc. not exceeding 25 sqcm each in cross
sectional area. Nothing extra shall be paid for leaving and finishing such cavities and holes.
6.4.12.5 Measurement shall be taken before any rendering is done in Concrete members.
Measurement will not include rendering. The measurement of R.C.C. work between various units shall
be regulated as below:
(a) Slabs shall be taken as running continuously through except when slab is monolithic with the
beam. In that case it will be from the face to face of the beam:

(b) Beams shall be measured from face to face of columns and shall include haunches, if any,
between columns and beam. The depth of the beam shall be from the bottom of slab to the
bottom of beam if beam and slab are not monolithic. In case of monolithic construction where
slabs are integrally connected with beam, the depth of beam shall be from the top of the slab to
the bottom of beam.
(c) The columns measurement shall be taken through.
(d) Chhajjas alongwith its bearing on wall shall be measured in cubic metre nearest to two places
of decimal. When chhajjas is combined with lintel, slab or beam, the projecting portion shall be
measured as chhajjas, built in bearing shall be measured as per item of lintel, slab or beam in
which chhajja bears.
(e) Where the band and lintels are of the same height and the band serves as lintel, the portion of
the band to be measured as lintel shall be for clear length of opening plus twice the overall
depth of band.
6.4.13 Tolerances:
Subject to the condition that structural safety is not impaired and Architectural concept does not
hamper, the tolerances in dimensions of R.C.C. members shall be as specified in the drawings by
the designer. Whenever these are not specified, the permissible tolerance shall be decided by the
Engineer in-Charge after consultations with the Designer, if necessary.
When tolerances in dimensions are permitted, following procedure for measurements shall apply.
(a) If the actual dimensions of R.C.C. members do not exceed or decrease the design dimensions
of the members plus or minus tolerance limit specified above, the design dimensions shall be
taken for the purpose of measurements.
(b) If the actual dimensions exceed the design dimensions by more than the tolerance limit, the
design dimensions only shall be measured for the purpose of payment.
IIf the actual dimensions decrease more than the tolerance limit specified, the actual dimensions
of the RCC members shall be taken for the purpose of measurement and payment.
(d) For acceptance of RCC members whose dimensions are not exactly as per design dimensions, the
decision of Engineer-in-Charge shall be final. For the purpose of payment, however, the
clarification as given in para a, b & c above shall apply.
6.4.14 Rate :
6.4.14.1 The rate includes the cost of materials and labour involved in all the operations described
above except for the cost of centring and Shuttering.
6.4.14.2 On the basis of mandatory lab tests, in case of actual average compressive strength
being less than specified strength but upto 70% of specified strength, the rate payable shall be
in the same proportion as actual average compressive strength bears to the specified
compressive strength.
Example:
1. Average compressive strength is 80% of specified strength. Rate payable shall be 80% of
agreement rate.
2. In case average compressive strength is less than 70%of the specified strength, the work
represented by the sample shall be rejected.

3. However, on the basis of mandatory field tests, where they prevail, the rates of the work
represented by samples showing actual compressive strength less than specified strength shall be
worked out by Rebound Hammer test at site. In addition, Engineer-in-charge may order for
additional tests to be carried out at the cost of contractor to ascertain if the portion of structure
where in Concrete represented by the samples has been used, can be retained on the basis of these
tests. Engineer-in-Charge may take further remedial measures as necessary to retain the structure
at the risk and cost of the contractor.
6.4.14.3 Where throating or plaster drip or moulding is not required to be provided in RCC chhajjas,
deduction for not providing throating or plaster drip or moulding shall be made from the item of
R.C.C. in chhajjas. The measurement for deduction item shall be made in running metres correct to a
cm of the edge of chhajja.
6.4.14.4 No extra payment for richer mix which projects into any member from another member
during concreting of junctions of beams and columns etc. will be made except to the extent structurally
considered necessary and when so indicated in the structural drawings. The payments for work done
under items of different mixes shall be limited strictly to what is indicated in the structural drawings.
6.5.Encasing Rolled Steel sections in Cement Concrete:
6.5.1 GeneralRequirements: Before Concrete works started, the Engineer-in-Charge 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/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.
6.5.2 Wrapping:
6.5.2.1 In case of columns, the wrapping shall be arranged as illustrated in Fig. 27 to pass through the
centre of the Concrete covering. The wrapping of the entire length of the columns be carried out in
stages and no stage shall cover more than 1.5 metre of height of columns. Successive wrappings shall
be carried out only after the immediate adjacent wrapping has been encased in Concrete. The surface
and edges of the flanges of the Steel columns shall have a Concrete cover of not less than 50 mm. The
wrappings of successive stages shall be tied together.
6.5.2.2 In the case of beams and grillages, the wire mesh or expanded metal shall be wrapped round
the lower flange of the beam as illustrated in Fig. 28 and the wrapping shall be suspended by wire
hangers 5 mm diameter placed at about 1.2 metres centres. The surfaces and edges of the Steel
sections shall have a Concrete cover of not less than 50mm. The wrapping shall pass through the
centre of the Concrete covering at the edges and soffits of the flanges.

6.5.3 Form Work shall be as specified in 6.2
6.5.4 Concreting:
Concrete shall consist of a mix of 1:2:4 (1 Cement: 2 Coarse and: 4 graded stone aggregate of 12.5
mm . nominal size) unless a richer mix IS : specified. The mix shall be poured solidly around the
Steel sections and around the wrapping by vibrating the Concrete into position. Consistency of

Concrete, placing of Concrete and its compaction, curing, finishing and strength of Concrete shall be
as described in 6.4.
6.5.5 Measurements:
The length shall be measured correct to one cm and other dimensions correct to 0.5 cm. The
CementConcrete shall be measured as per gross dimensions of the encasing exclusive of the thickness
of plaster. No deduction shall be made for the volume of Steel sections, expanded metal, mesh or
any other reinforcement used therein. However, in case of boxed stanchions or girders, the boxed
portion only shall be deducted.
Fabric reinforcement such as expanded metal shall be measured separately in square metres stating the
mesh and size of strands.
The description shall include the bending of the fabric as necessary, Raking or circular cutting and
waste shall be included in the description.
6.5.6 Rate:
The rate shall include the cost of materials and labour required for all the operations described above
except the cost of fabric reinforcement. The cost of providing and erecting Steel section and wire
hangers shall be paid for separately.
6.6 Precast Reinforced Concrete:
6.6.1 General requirements:
Precast reinforced Concrete units such as columns, fencing posts, door and window frames, lintels,
chhajjas, 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 fibreglass 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 a Cement or
Steel platform which shall be adequately oiled provided the surface finish is of the same standard as
obtained in the forms. Each unit shall be cast in one operation.
6.6.2 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
honeycombing.
6.6.3 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
wouldinterfere with the proper placing of the units. All angles of the precast units with the exception
of the angles resulting from the splayed or chamfered faces shall be true right angles. 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 of the units should present a clean homogeneous
appearance.
6.6.4 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.
6.6.5 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.
6.6.6 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.
6.6.7 Marking:
Precast units shall be clearly marked to indicate the top of member and its location and orientation in
the structure.
6.6.8 Precast units shall be stored, transported and placed in position in such a manner that they will
not be overstressed or damaged.
6.7 Precast Cement Concrete Jali: The Jali shall be of Cement Concrete M 20 grade (1:1.5:3) (1
Cement :1.5Coarse Sand: 3 stone aggregate 6 mm nominal size) reinforced with 1:6 mm thick mild
Steel wire, unless otherwise specified.
6.7.1 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 jali
uniformly on all sides.
The Jali shall be measured for its gross superficial area. The length and breadth shall be measured
correct to a cm. The thickness shall not be less than that specified.
6.7.3 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.
6.8. CementConcreteDesign Mix: Definition :
Design mix Concreteis that Concrete in which the design of mix i.e. the determination of proportions
of Cement, aggregate & water is arrived as to have target mean strength for specified grade of
Concrete. The minimum mix of M20 shall be used in all structural elements in both load bearing &
RCC framed construction.
6.8.1 Mix design and proportioning:
6.8.1.1 Mix proportions shall be designed to ensure that the workability of fresh Concrete is suitable
for conditions of handling and placing, so that after compaction it surrounds all reinforcements and
completely fills the formwork. When Concrete is hardened, it shall have the stipulated strength,
durability and in permeability.
6.8.1.2 Determination of the proportions by weight of Cement, aggregates and water shall be based
on design of the mix.
6.8.1.3 As a trial the manufacturer of Concrete may prepare a preliminary mix according to provisions
of SP: 23-1982 & IS : 456 : 2000.
6.8.1.4 Mix design shall be tried and the mix proportions checked on the basis of tests conducted at
a recognized laboratory approved by the Engineer-in-Charge.
6.8.1.5 All Concrete proportions for various grades of Concrete shall be designed separately and the
mix proportions established keeping in view the workability for various structural elements, methods

of placing and compacting.
6.8.1.6 Before using an admixture in Concrete, its performance shall be evaluated by comparing the
properties of Concrete with the admixture and Concrete without any admixture. Chloride content of
admixture should be declared by the manufacturer of admixture and shall be within limits stipulated by
IS ::9103-1999.
6.8.2 Standard Deviation
6.8.2.1 Standard deviation calculations of test results based on tests conducted on the same mix
design for a particular grade designation shall be done in accordance with IS : 456-2000.
6.8.3 Acceptance Criteria:
6.8.3.1 Compressive Strength: The Concrete shall be deemed to comply with the strength
requirements when both the following conditions are met :
(a) The mean strength determined from any group of four consecutive test results complies with
the appropriate limits in col. 2 of Table 11.
(b) Any individual test result complies with the appropriate limits in col 3 of Table 11
6.8.3.2 Flexural Strength: When both the following conditions are met, the Concrete complies
with the. Specified flexural strength.
(a) The mean strength determined from any group of four consecutive test results exceeds the
specified characteristic strength by at least 0.3 N/mm2.
(b) The strength determined from any test result is not less than the specified characteristic
strength / 0.3 N/mm2.
6.8.3.3 Quantity of Concrete Represented by Strength Test Results:
The quantity of Concrete represented by a group of four consecutive test results shall include the
batches from which the first and last samples were taken together with all intervening batches.
For the individual test result requirements given in col. 3 of Table 19 or in item (b) of 6.8.3.2, only
the particular batch from which the sample was taken shall be at risk.
Where the mean rate of sampling is not specified the maximum quantity of Concrete that four
consecutive test results represent shall be limited to 60 m3.
6.8.3.4 If the Concreteis deemed not to comply pursuant to 6.8.3.3, the structural adequacy of the
parts affected shall be investigated and any consequential action as needed shall be taken.
6.8.3.5 Concrete of each grade shall be assessed separately.
6.8.3.6 Concreteis liable to be rejected if it is porous or honey-combed, its placing has been interrupted
without providing a proper construction joint, the reinforcement has been displaced beyond-the
tolerances specified, or construction tolerances have not been met. However, the hardened Concrete
may be accepted after carrying out suitable remedial measures to the satisfaction of the Engineerin-
Charge.
6.8.4 Cement Content of Concrete:

6.8.4.1 For all grades of Concrete manufactured/produced, minimum Cement content in the Concrete
shall be 310 kg per cubic metre of Concrete. Also, irrespective of the grade of Concrete, the maximum
Cement content shall not be more than 500 kg per cubic metre of Concrete. These limitations shall
apply for all types of Cements of all strengths.

6.8.4.2 Actual Cement content in each grade of Concrete for various conditions of variables shall
be established by design mixes within the limits specified in Para 6.8.4.1 above.
6.8.5 Water Cement ratio and Slump:
6.8.5.1 In proportioning a particular mix, the manufacturer/producer/contractor shall give due
consideration to the moisture content in the aggregates, and the mix shall be so designed as to restrict
the maximum free water Cement ratio to less than 0.5.
6.8.5.2 Due consideration shall be given to the workability of the Concrete thus produced. Slump shall
be controlled on the basis of placement in different situations. For normal methods of placing
Concrete, maximum slump shall be restricted to 100 mm when measured in accordance with IS:
1199-1959 (Reaffirmed 1999) .
Table-11 :
Characteristic Compressive Strength Compliance Requirement
Specified Mean of the of 4 Non- Individual Test
Grade Overlapping Consecutive Test Results Results in N/mm3
in N/mm2
1 2 3
M15 > fck + 0.825 x established standard > ffck-3N/=2
deviation (rounded off to nearest 0.5
N / = 2)
or
fck+3N/mm2
Whichever is greater
M20 or > fck+ 0.825 x established standard > fck-3N/=2
above deviation (rounded off to nearest 0.5
N / = 2)
or
fck+3N/mm2, Whichever is greater
Note:In theabsence of established value of standard deviation, the valuesgiven i Table may be
assumed, and attempt should be made to obtain results of 30 samples as early as possible to establish
the value of standard deviation.
6.8.6 Approval of Design Mix:
6.8.6.1 The producer/manufacturer/contractor of Concrete shall submit details of each trial mix of each
grade of Concrete designed for various workability conditions to the Engineer-in-Charge for his
comments and approval. Concrete of any particular design mix and grade shall be produced/
manufactured for works only on obtaining written approval of the Engineer-in-Charge.
6.8.6.2 For any change in quality/quantity in the ingredients of a particular Concrete, for which mix
has been designed earlier and approved by the Engineer-in-Charge, the mix has to be redesigned and
approval obtained again.

6.9- Pile foundations: Refer IS: 2911-( Part I, II etc.) -2010 :
6.9.1 Definition:
This work shall consist of construction of all types of piles for structures in accordance with the
details shown on the drawings and conforming to the requirements of these specifications.
6.9.2- Terminology :
For the purpose of this standard, the followingdefinitions shall apply.
Allowable Load- The load which maybe applied to a pile after taking into account its ultimate
load capacity, group effect, the allowable settlement, negative skin friction and other relevant
loading conditions.
Anchor Pile-An anchor pile means a pile meant for resisting pull or uplift forces.
Batter Pile (Raker Pile) - The pile which is installed at an angle to the vertical using temporary
casing or permanent liner.
Bored Cast In-situ Pile -A pile formed by boring a hole in the ground by percussive or rotary
method with the use of temporary/permanent casing or drilling mud and subsequently filling the
hole with reinforced concrete.
 Cut-off Level - It is the level where a pile is cut-off to support the pile caps or beams or
any other structural components at that level.
 Diameter of Piles - Piles of 600 mm or less in diameter are commonly known as small
diameter piles while piles greater than 600 m diameter are called large diameter piles. Minimum pile
diameter shall be 450 mm.
 Elastic Displacement - This is the magnitude of displacement of the pile head during
rebound on removal of a given test load. This comprises two components:
a) Elastic displacement of the soil participating in the load transfer, and
b) Elastic displacement of the pile shaft.
 Factor of Safety - It is the ratio of the ultimate load capacity of a pile to the safe load on
the pile.
 Gross Displacement - The total movement of the pile top under a given load.
 Initial Load Test - A test pile is tested to determine the load-carrying capacity of the pile
by loading either to its ultimate load or to twice the estimated safe load.
 Initial Test Pile - One or more piles, which are not working piles, may be installed if required
to assess the load-carrying capacity of a pile. These piles are tested either to their ultimate load
capacity or to twice the estimated safe load.
 Load Bearing Pile - A pile formed in the ground for transmitting the load of a structure to
the soil by the resistance developed at its tip and/or along its surface. It may be formed either
vertically or at an inclination (batter pile) and may be requiredto resist uplift forces.If the pile
supports the load primarily by resistance developed at the pile tip or base it is called Ènd
bearing pile' and, if primarily by friction along its surface, then `Friction pile'.
 Net Displacement - The net vertical movement of the pile top after the pile has been
subjected to a test load and subsequently released.
 Pile Spacing - The spacing of the piles means the center-to-center distance between adjacent
piles.

xv) Routine Test Pile - A pile which is selected for load testing may form a working pile itself,
if subjected to routine load test up to one and 1.5 times the safe load.
xvi) Safe Load - It is the load derived by applying a factor of safety on the ultimate load capacity
of the pile or as determined from load test.
xvii) Ultimate Load Capacity - The maximum load which a pile can carry before failure, that is,
when the founding strata fails by shear as evidenced from the load settlement curve or the pile
fails as a structural member.
xviii) Working Load - The load assigned to a pile as per design.
xix) Working Pile - A pile forming part of the foundation system of a given structure.
6.93. Planning:
The construction of pile foundations requires a careful choice of the piling system depending upon
sub-soil conditions and loading characteristics and type of structure. The permissible limits of total
and differential settlements, unsupported length of pile under scour, impact/entanglement of floating
bodies and any other special requirements of project are also equally important criteria for selection of
the piling system. The method of installing the piles, including details of the equipment shall be
submitted by the Contractor and got approved from the Engineer.
6.9.4- Necessary Information: For the satisfactory design and construction of bored cast in-situ
piles the following information would be necessary:
a) Site investigation data as laid down under IS 1892-1979 (Reaffirmed 2002). Sections of trial
boring, supplemented, wherever appropriate, by penetration tests, should incorporate data/
information down to depth sufficiently below the anticipated level of founding of piles but this
should generally be not less than 10 m beyond the pile founding level. Adequacy of the bearing
strata should be ensured by supplementary tests, if required.
b) The nature of the soil both around and beneath the proposed pile should be indicated on the
basis of appropriate tests of strength, compressibility, etc. Ground waterlevel and artesian
conditions, if any, should also be recorded. Results of chemical tests to ascertain the Sulphate,
chloride and any other deleterious chemical content of soil and water should be indicated.
c) For piling work in water, as in the case of bridge foundation, data on high flood levels,water
level during the working season,maximum depth of scour, etc., and in the case of marine
construction, data on high and lowtide level, corrosive action of chemicals present and data
regarding flow of water should be provided.
d) The general layout of the structure showing estimated loads and moments at the top of pile caps
but excluding the weight of the piles and caps should be provided. The top levels of finished
pile caps shall also be indicated.
e) All transient loads due to seismic, wind,water current, etc., are to be indicated separately.
f) In soils susceptible to liquefaction during earthquake, appropriate analysis may be done to
determine the depth of liquefactionand consider the pile depth accordingly.
As far as possible all informations given in above shall be made available to the agency
responsible for the design and/or construction of piles and/or foundation work.The design
details of pile foundation shall give the information necessary for setting out and layout of
piles, cut-off levels, finished cap level, layout and orientation of pile cap in the foundation plan
and the safe capacity of each type of pile, etc.

6.9.5 Equipment's and Accessories:
i) The equipment's and accessories would depend upon the type of bored cast in-situ piles chosen
for ajob after giving due considerations to the subsoil strata, ground water condition, types of
founding material and the required penetration therein.
ii) Among the commonly used plants, tools and accessories, there exists a large variety,
suitability of which depends on the subsoil condition andmanner of operation, etc.
Boring operations are generally done by percussion type rigs or rotary rigs using direct mud
circulation or reverse mud circulation methods to bring the cuttings out. In soft layers and loose
sands, bailers and chisel method should be used with caution to avoid the effect of suction.
iv) For percussion boring using bailer chisel and for rotary rigs, stabilization of bore holes may
be done either by circulation or suspended mud.
v) Kent ledge: Dead weight used for applying a test load on a pile.
6.9.6. Sub-Surface Investigation (IS:1892-1979,Reaffirmed 2002):
6.9.6.1 A complete sub-surface investigation of strata in which pile foundations are proposed shall be
carried out in advance and by in-situ pile tests. For details of geotechnical sub-surface explorations
reference may be made to Sub soil test reports. At least one bore-hole for every building block shall
be executed. Borings should be carried upto sufficient depths so as to ascertain the nature of strata
around the pile shaft and below the pile tip. However, depth of boring shall not be less than:
a) TYPE OF FOUNDATION DEPTH OF EXPLORATION(D)
i) Isolated spread footing or raft One and a half time the width (B).
ii) Adjacent footings with clear spacing. One and half times the length of the footing (L)
less than twice the width
iii) Adjacent rows of footings As per 1892-1979 ( Reaffirmed 2002)
Pile and well foundations To a depth of 1.5 times the width of
the structure From the bearing level
(toe of pile) or bottom of the well.
1. Road cuts Equal to the bottom width of the cut.
2. Fill Two metre below ground level or equal to
the height of the fill whichever is greater.
b) The sub-surface investigation shall define adequately stratification of sub-strata including the
nature and type of strata, its variation and extent and specific properties of the same. The investigation
shall be adequate for the purpose of selection of appropriate piling system and for estimating design
capacities for different diameters and length of piles.
Pressure meter tests may be used in the case of rock, gravel or soil for direct evaluation of strength
and compressibility characteristics. Though these tests are of specialised nature they are most
appropriate for difficult/uncertain sub-strata especially for important projects.
For piles socketed into rocks, it is necessary to determine the uniaxial compressive strength of the
rock and its quality.
The investigation shall also include location of ground water table and other parameters including
results of chemical tests showing sulphate and Chloride content and any other deleterious
chemical content in soil and/or ground water, likely to affect durability.

6.9.7 Type of piles:
The piles may be of Reinforced Concrete, Prestressed Concrete, Steel or Timber. The piles may be of
solid or hollow sections or Steel cased piles filled with Concrete. Concrete piles may be driven cast-
in-situ or precast or bored cast-in-situ or precast piles driven into performed bores. The shape of piles
may be circular, square, hexagonal, octagonal, "H" or "I" Section.
6.9.8 Materials:
Materials of piles shall conform to the appropriate specifications given on approved design and
drawings.
6.9.9-Recording of Data:
i) A competent inspector shall be maintained at site to record necessary information during
installation of piles and the data to be recorded shall essentially contain the following:
a) Sequence of installation of piles in a group,
b) Type and size of driving hammer and its stroke,
c) Dimensions of the pile including the reinforcement details and mark of the pile,
d) Cut-off level and working level,
e) Depth driven,
f) Time taken for driving and for concreting recorded separately, and
g) Any other important observations, during driving, concreting and after withdrawal of
casing tube.
6.9.10. Concrete in Piles (Ref. MOSRT & H specifications Fifth Rev. 2013) - section 1100
i) Grade of Concrete to be used in cast-in-situ piles shall not be less than M 35 and the Cement
content shall not be less than 400 kg per cubic meter of Concrete. Grades of Concrete for precast
reinforced and prestressed Concrete piles shall not be less than M 35. Minimum water Cement
ratio for cast in situ and precast piles shall be 0.4.
ii) The minimum slump of Concrete for driven cast-in-situ piles shall be 150 mm to 200 mm and
that of bored cast-in-situ piles 150 mm to 200 mm. For precast piles, the slump shall be 50 to 75
mm.
iii) The Concrete mix should have homogeneous mixture with required workability for the system
of piling adopted. Suitable and approved admixtures may be used in Concrete mix where
necessary.
iv) Where piles are exposed to action of harmful chemicals or severe conditions of exposure higher
grades of Concrete, lower w/c ratio, special type of Cement or additives shall be used as directed
by the Engineer-in-Charge.
6.9.11 Test piles:
6.9.11.1. Test piles which are shown on the drawings or specified in the contract or installed by the
Contractor on his own to determine the lengths of piles to be furnished shall conform to the
requirements for piling as indicated in these specifications, if they are to be incorporated in the
completed structure.
ii) Test piles that are to become a part of the completed structure shall be installed with the same
type of equipment that is proposed to be used for piling in the actual structure.

iii) Test piles which are not to be incorporated in the completed structure shall be removed to at
least 600 mm below the proposed soffit level of pile cap and the remaining hole shall be
backfilled with earth or other suitable material.
iv) The piles shall be load tested in accordance with provisions laid down in IS 2911 ( Part 4 ) -
1985.
6.9.12. Precast Concrete piles:
6.9.12.1 General:
Precast Concrete piles shall be of the size and shape as shown in the approved drawings. If a square
section is employed, the corners shall be chamfered at least 25 mm unless otherwise specified on the
drawings. The length of pile shall not normally exceed 25 metre. However, where special equipment
for handling and installation are available to the satisfaction of the Engineer-in-charge, longer length
could be permitted. Piles shall be cast with a driving point and for hard driving, shall be shoed with a
metal shoe approved by the Engineer-in-charge.
6.9.12.2 Stacking, Storing and Handling: Care shall be taken that all stages of transporting, lifting
and handling, piles are not damaged or cracked. During transport and stacking of piles, they shall be
supported at the same points as those provided for lifting purposes. If the piles are put down
temporarily during handling, they shall be placed on trestles or blocks located at the same points.
ii) Piles shall be stored at least 300 mm above firm level ground which is not liable to unequal
subsidence or settlement under the weight of the stack of piles. They shall be placed on timber
supports which are level and spaced so as to avoid bending. The supports shall be vertically
one above the other. Spaces shall be left around the piles to enable them to be lifted without
difficulty. The order of stacking shall be such that the older piles can be withdrawn without
disturbing newer piles. Separate stacks shall be provided for different lengths of piles. Where
piles are stacked in layers, the number of layers shall not exceed three. Whenever curing is
needed during storage, arrangements shall be made to enable the piles to be watered. For
detailed precautions with regard to curing operations specifications for structural Concrete shall
be followed as directed by Engineer-in-charge.
iii) Before the operation of handling and driving the piles, the minimum periods counted from the
time of casting shall be allowed for as indicated in Table 12. Prestressed piles shall not be
lifted or handled until fully stressed.
Table 12 - Time for Curing Precast Piles
(Ref. MOSRT&H specifications Fifth Rev. 2013) - section 1100
Ty pe of Cement used in Minimum periods from time of casting
casting the pile Strike side- End of wet Lift from Drive (days)
shutters curing (days) casting bed
(hours) (days)
Ordinary Portland 24 7 10 28
Rapid hardening Portland 12 7 7 10
Note: For cold weather er periods when am temperatures peratures are less than an 10°C during the day.
These periods may be doubled. For weather conditions the periods will be specified by the Engineerin-
Charge

6.9.12.3 Lengthening of Piles:
Where a pile is to have another length cast on it during driving, the longitudinal reinforcement shall
preferably be joined by full penetration butt welding. The Concrete at the top of the original pile
shall be cut down to expose not less than 200 mm of the bars to avoid spalling of the Concrete by heat
of welding . The added bars have to be held accurately and rigidly in position during welding. Where
facilities on site are insufficient to make proper butt welding practicable, the joint may be made by
lapping. The reinforcement at the head of pile will need to be exposed for full anchorage length or 600
mm whichever is greater and the new bars over-lapped for this distance. Unless otherwise specified,
the extension of the pile shall be formed to the same cross-sectional profile and with Concrete of at
least the same strength as that specified for the original pile. The stirrup spacing shall in no case be
greater than 150 mm. Not more than one extension shall be permitted. In case more than one extension
is permitted by the Engineer-in-charge, only approved mechanical coupler shall be used.
Driving shall not be resumed until:
(i) The strength of the Concrete in the extension is at least equal to the specified characteristic
strength of Concrete in pile, and
(ii) The approval of the Engineer-in-charge has been obtained.
6.9.12.4 Removal of Surplus Length:
Any length of pile surplus to that required for incorporation in the structure shall be cut off neatly and
removed. During the process of cutting off, it shall be ensured that projecting reinforcement to be
anchored into the pile cap and the prestressing strands/wires are not damaged. When stripping
prestressed Concrete piles, shock release of tendons shall be avoided. Reference may also be made to
IS: 2911(Part I Section 3)-1979 in this connection.
6.9.12.5 Risen Piles:

Level reading should be taken on each pile after driving and again after all the piles are driven. Piles
which are found to have risen due to ground heave or as a result of driving adjacent piles shall be re-
driven to the original depth or resistance unless re-driving tests on adjacent piles have shown this to
be unnecessary.
6.9.12.6-Manufacture:
i) The pile should be cast in one continuous operation from end to end of each pile. Manufacture
of precast Concrete piles shall conform to the guidelines contained IS : 2911 (Part I, Section 3)-
1979.
ii) Pile shall be provided with suitable shoe for protecting the point of the pile during driving in
hard ground. Piles shall not be moved from casting bed until the Concrete has hardened
sufficiently.
iii) Piles shall not be driven in less than 28 days after casting or unless their strength at the time
of driving is at least that specified for 28 days.
6.9.13 Precast Prestressed Concrete Piles:
Additional specifications for precast prestressed Concrete piles shall conform to those contained in
IS : 2911 (Part I Section 3)-1979.

6.9.14-Cast-in-situ Concrete piles:
i) Cast-in-situ Concrete piles may be either installed by drilling a bore into the ground by removal
of material or by driving a metal casing with a shoe at the tip and displacing the material
laterally. The two types of piles are termed as "bored piles" and "driven piles" respectively.
Cast-in-situ Concrete piles may be cast in metal Shells which may remain permanently in place.
However, other types of cast-in-situ Concrete piles, plain or reinforced, cased or uncased, may be
used, if in the opinion of the Engineer-in-charge the soil conditions permit their use and if their
design and the methods of placing are satisfactory.
ii) The metal casing shall be of sufficient thickness and strength to hold its original form and show
no harmful distortion after it and adjacent casings have been driven and the driving core, if
any, has been withdrawn.
iii) Cast-in-situ Concrete driven piles shall be installed using a properly designed detachable shoe
at the bottom of the casing.
iv) Any liner or bore-hole which is improperly located or shows partial collapse that would affect
the load carrying capacity of the pile, shall be rejected or repaired as directed by the Engineerin-
charge at the cost of the Contractor.
v) Boring shall be carried out using rotary equipment. Percussion type of equipment shall be
used only if approved by the Engineer-in-charge.
vi) or to the lowering of the reinforcement cage into the pile shaft, the shaft shall be cleaned of
all loose materials. Cover to reinforcing Steel shall be maintained by suitable spacers.
vii) The diameter of the finished pile shall not be less than that specified and a continuous record
shall be kept by the Engineer-in-charge as to the volume of Concrete placed in relation to the
length of the pile that is cast .
viii) Defective piles shall be removed or left in place as judged convenient without affecting the
performance of adjacent piles or pile cap. Additional piles shall be provided to replace the
defective piles.
6.9.15 Steel Piles: Steel piles shall be "H" or "I" sections
i) Steel piles shall be protected by suitable anti-corrosive painting as specified on the drawing.
Piles shall be stored above the ground using protective packing to minimise damage to surface
coating. Each pile shall be supplied preferably in one piece without splices.
ii) Steel piling consisting of structural Steel plates welded together may be substituted for the
rolled sections specified, provided that the depth, width and average thicknesses are at least
equal to those of the rolled sections, the Steel plates conform to specification given in IS: 1730-
1989 (Reaffirmed 2004, Superseding IS:1731.), the flanges are welded to the web with
continuous fillet welds on either side of the web, and the welding conforms to the specifications
IS: 9595-1996.
iii) The length of the Steel pile may be built up in sections either before or during driving operations.
The sections shall be of identical cross-section. Pile splices shall be made with full penetration
but welds over the whole cross-section carried out as per approved drawings and specifications.
Pile splices shall develop at least the yield strength of pile.
iv) The connection shall be made by butt welding, the entire cross section in accordance with the
provisions of IS: 9595-1996 ( Reaffirmed 2003) Care shall be taken to properly align the

sections connected so that the is of the pile will be straight. The number of welded connections
in the length of pile shall be as few as possible.
6.9.16 Timber Piles : (i) Each pile on the butt with a stamp which shall make an impression that is
readily legible. Treated timber piles will be inspected by the Engineer-in-charge after treatment.
ii) Treated timber piles shall be driven within 6 months after treatment.
iii) Tips of timber piles shall be furnished with tip protection and protected by the use of Steel
straps. Tip protection shall be suitable for use on Timber piling of the size to be driven. Details
of tip protection shall be furnished to the Engineer-in-charge for review and approval before
driving piles. Not less than 2 separate Steel straps shall be placed within 600 mm of the butt of
each pile after the pile is square cut. Not less than 2 separate Steel straps shall be placed within
300 mm of the tip of each pile. Additional intermediate Steel straps shall be placed at intervals
of not more than 3 metre measured along the length of the pile.
iv) Timber piles which are to be capped shall be separately cut off so that true bearing is obtained
on every pile. Piles inaccurately cut off shall be replaced. Splicing of timber piles shall not be
permitted except by written permission of the Engineer-in-charge.
6.9.17-Pile Driving Equipment:
i) Piles or their casings may be driven with any type of drop hammer, diesel hammer or single-
acting steam or compressed air hammer, provided they penetrate to the prescribed depth or
attain the designed resistance without being damaged. The weight or power of the hammer
should be sufficient to ensure a penetration of at least 5 mm per blow, unless rock has been
reached. It is always preferable to employ the heaviest hammer practicable and to limit the
stroke, so as not to damage the pile. The minimum weight of the hammer shall be 2.5t. In the
case of precast Concrete piles the mass of the hammer shall be not less than 30 times the mass of
300 mm length of pile.
ii) Steam or air hammers shall be furnished along with boiler or air compressor of capacity at least
equal to that specified by the manufacturer of the hammers. The boiler or air compressor shall be
equipped with an accurate pressure gauge at all times. The valve mechanism and other parts of
steam, air or diesel hammers shall be maintained in first class condition so that the length of
stroke and number of blows per minute, for which the hammer is designed, will be obtained.
Inefficient steam, air or diesel hammers shall not be used on the work.
6.9.18-Driving:
6.9.18.1 General Procedure:
i) Details of the equipment and the method proposed for driving the piles shall be submitted with
the tender for scrutiny and approval of the Engineer-in-charge. Piles shall be installed from
firm ground or from temporary supports or from fixed platform. The arrangement shall provide
sufficient rigidity to ensure accuracy of pile driving under all conditions of tide, stream flow or
hammer drop.
ii) During driving the top of pile shall be protected by a suitable helmet of substantial Steel
construction. The helmet shall provide uniform bearing across the top of the pile and shall hold
the pile centrally under the hammer. No pile shall be driven unless inspected and approved by the
Engineer-in-charge.

iii) Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of driving within
specified tolerances. The force of the hammer shall be directed centrally and axially during
driving.Forces producing undue bending or torsional stresses in piles shall not be applied
during driving.
The stroke of a single acting or drop hammer shall be limited to 1.2 m unless otherwise permitted
by the Engineer-in-charge. A shorter stroke may be necessary when there is a danger of damaging
the pile.
 Piles shall not be bent or sprung into position but shall be effectively guided and held on-line
during the initial stages of driving. Attempts to correct any tendency for the pile to run off-line by
the application of significant horizontal restraint will not be permitted. Shortly after the
commencement of driving and at regular intervals throughout the driving operation, checks shall
be made to ensure that the pile frame does not exert any undue lateral force on the pile due to
restraint within the helmet.
 If the indications are that a pile will finish outside the specified tolerances, driving operations
on that pile will cease. The pile shall be withdrawn, the hole filled and the pile re-driven at the cost
of the contractor.
 To avoid the possibility of premature "set-up" pile driving shall be continuous in the later
stages, without any deliberate stops. (Delays of an hour or less may lead to significant "set-up"
in piles i.e. resistance to further driving increases after driving is stopped).
 If any pile is damaged in any way during driving, it shall be repaired or replaced as directed by
the Engineer-in-charge, at the cost of the contractor. If during driving, the head of a pile is
damaged to the extent that further driving is not possible, the head shall be cut off and driving
continued. The cost of cutting off shall be borne by the Contractor and where, as a result of such
cutting off the head, the pile is too short, the Contractor, shall, at his own cost, supply and splice
on sufficient length of pile to restore the pile to its correct length.
Piles should be driven to the minimum acceptable penetration shown on the drawings. This may
require preboring and/or jetting as indicated in the specifications with the approval of the
Engineer-in-charge.
Piles shall be driven to nominal refusal or the required ultimate dynamic capacity mentioned on
the drawings or until the top of the pile is at the level required and specified on the drawing
whichever gives the lowest toe elevation. The Engineer-in-charge's decision in these matters shall
be final. Nominal refusal shall be taken as equivalent to 25 mm total penetration for the final 20
blows using a hammer of driving energy as specified and shall be used as the criterion for
acceptance for piles founded on rock. Severe driving which results in an average set per blow
less than 0.5 mm will not be permitted.
xi)Where hard drilling is encountered because of dense strata or obstructions located above the
predetermined pile tip level, nominal refusal shall not be considered to have been achieved
unless the Engineer-in-charge is satisfied that the total number of blows, as the average driving
resistance specified for nominal refusal, indicates that further driving will not advance the pile
through dense strata or obstructions.
xii) The pile shall be driven as accurately as possible to the vertical or to specified batter. Straining
the pile into position can damage it and the driving equipment should be adjusted as much as
possible to follow the position of the pile. Any deviation from the proper alignment shall be

noted and promptly reported to the Engineer-in-charge. If the deviation is to such an extent that
the resulting eccentricity cannot be taken care of by strengthening the pile cap or pile tips, such
a pile shall, at the discretion of the Engineer-in-charge, be replaced or supplemented by an
additional pile. Unless otherwise specified, the permissible positional deviation for piles shall
be limited to those indicated in Clause 6.9.11.
xiii) Care shall be taken not to damage the pile by over driving. Any sudden change in the rate of
penetration which cannot be ascribed in the nature of the ground be recorded and its cause
ascertained if possible before driving is continued further.
xiv) No plie shall be bored or driven within 3 m of a freshly cast pile, until at least 24 hours after
completion of its installation.
xv) Driving piles in loose sand tends to compact the sand which in turn increases the skin friction.
Therefore, driving a number of friction piles in a group shall proceed outward from the centre as,
otherwise, it may be difficult to drive the inner piles to the same depth as the others. In the case
of stiff clay also, the driving for a group of piles shall proceed outward from the centre.
xvi) However, in very soft soil, the driving may proceed from outside to inside so that the soil is
restrained from flowing out during driving operations. If there is a major variation in the depths
at which adjacent foundation piles in a group meet refusal, a boring shall be made nearby to
ascertain the cause of this difference. If the boring shows that the soil contains pockets of highly
compressive material underneath the shorter piles, it will be necessary to enforce the
penetration of all the piles to a level below the bottom of the zone which shows such pockets.
6.9.18.2 Preboring and Jetting:
i) Driving of the piles shall be assisted by preboring holes or by the use of jets or both subject to
the approval of the Engineer-in-charge. These may be used essentially to achieve the minimum
penetration shown on the drawings where such penetration is not achieved by normal conditions
of driving indicated in the clause 6.9.11.1.
ii) The diameter of the hole shall not be greater than the diagonal dimension of the pile less 100
mm.
iii) The maximum depth of the preboring shall be such that the specified set (or less) is obtained
when the toe of the pile is at founding level. Preboring shall be as approved by the Engineerin-
charge and shall not be carried out up to a level of one metre above the founding level. The pile
shall be driven to at least one metre below the prebored hole. To ensure that the pile is properly
supported laterally in the hole, any space remaining around the pile at the ground level after
driving is finished shall be backfilled with approved granular material.
iv) When water jetting is used, at least two jets shall be attached to the pile symmetrically when
this type of technique is used. The volume and pressure of water at the outlet nozzles shall be
sufficient to freely erode material adjacent to the toe of the pile. The maximum depth of jetting
shall be such that the specified set (or less) is obtained when the toe of the pile is at founding
level. Jetting shall cease as directed by the Engineer-in-charge and shall proceed only up to one
metre above the founding level. The pile shall be driven at least one metre below the pre-bored
hole.
v) To avoid very hard driving and vibration in materials such as Sand, jetting of piles by means
of water may be carried out only by express permission of the Engineer-in-charge and in such

a manner as not to impair the bearing capacity of the piles already in place, the stability of the
soil or the safety of any adjoining buildings. Details of the arrangement for jetting shall be got
approved from the Engineer-in-charge in advance.
vi) If, for jetting, large quantities of water are used, provision shall be made for collecting and
draining of water when it comes to the surface of the ground, so that the stability of the piling
plant is not endangered by the softening of the ground.
vii) Jetting shall be stopped before completing the driving which shall always be finished by
ordinary methods. Jetting shall be stopped if there is any tendency for the pile tips to be drawn
towards the pile already driven owing to the disturbance to the ground.
6.9.19 Raker (inclined) piles: The maximum rake to be permitted in piles shall not exceed the
following:
i) 1 in 6 for all bored piles.
ii) 1 in 6 for cast-in-situ piles
iii) 1 in 4 for precast driven piles
6.9.20-Pile tests: The required tests on pile work shall be carried out as per IS: 2911-Part 4-
1985
6.9.21-Pile cap:
i) Casting of Pile cap should be at a level higher than low water level unless functionally required
to be below low water level. In such cases dewatering shall be resorted to allow concreting in dry
conditions. Pile Caps shall be of reinforced Concrete. A minimum offset of 150 mm shall be
provided beyond the outer faces of the outer most piles in the group. If the pile cap is in contact
with earth at the bottom, a levelling course of minimum 80 mm thickness of M 15 nominal mix
Concrete shall be provided. In marine conditions or areas exposed to the action of harmful
chemicals, the pile cap shall be protected with a coating such as Bituminous based coal tar epoxy
or epoxy based coating or with suitable anticorrosive paint. Concrete with high Alumina Cement
shall not be used in marine environment,
ii) The attachment of the pile head to the cap shall be adequate for the transmission of loads and
forces. A portion of pile top may be stripped of Concrete and the reinforcement anchored into
the cap. Manual chipping may be permitted after three days after casting of pile, while
pneumatic tools for chipping shall not be used before seven days after pile casting. The top of
pile after stripping shall project at least 50 mm into the pile cap.
iii) The top of Concrete in a pile shall be brought above cut-off level to permit removal of all
laitance and weak Concrete before pile cap is laid. This will ensure good Concrete at the cut-off
level.
6.9.22. Important considerations, inspection / precautions for different types of piles
6.9.22.1 Driven Cast-in-Situ Piles : Specialist literature and the guidelines from the pile construction
industry shall be consulted regarding the method of installation, equipment and accessories for pile
driving and recording of data.
6.9.22.2 Final set: Driving, installation of piles, the final `set' penetration of pile per blow of hammer
shall be checked taking an average penetration of the last 10 blows.
6.9.22.3 Pile shoe: The Pile shoes which may be of either cast iron conical type or mild Steel flat

type shall have double reams for proper seating of the removable casing tube inside the space
between the reams.
6.9.22.4 Casing: Before commencement of pouring of concrete, it shall be ensured that there is no
ingress of water in the casing tube from bottom.Further adequate control during the process of
withdrawal of the casing it is essential so as to maintain sufficient head of Concrete inside the casing
tube at all stages of withdrawal.
6.9.22.5 Casting height: Concrete in piles shall be cast upto a minimum height of 600 mm above the
designed top level of pile, which shall be stripped off at the time of construction of pile cap.
6.9.22.6 Bored Cast-in-Situ Piles :Prevention of inflow : While concreting, sufficient head of
Concrete shall be maintained to prevent inflow of soil or water into the Concrete. Precaution shall also
be taken during concreting to minimise the softening of the soil by excess water.
6.9.22.7. Drilling mud level: The Drilling mud such as bentonite suspension shall be maintained at a
level sufficiently above the surrounding ground water level throughout the boring process, to ensure
the stability of the strata which is being penetrated until the pile has been Concreted.
6.9.22.8-Properties of suspension: Where bentonite suspension is used to maintain the stability of
the bore-hole, it is essential that the properties of the material be carefully controlled at all stages of
mixing, supply to the bore-hole and immediately before Concrete is placed. It is to usual limit:
i) The density of bentonite suspension to 1.05 g/cc
ii) The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 per cent
v) The liquid limit of bentonite not less than 400%
These aspects shall act as controlling factors for preventing contamination of bentonite slurry for
clay and silt.
6.9.22.9-Bentomte flushing:
The bores shall be washed by bentonite flushing to ensure clean bottom in two stages viz. one after
completion of boring and the prior to concreting but after placement of reinforcement cage. Flushing of
bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and
out-flowing slurry is similar.
6.9.22.10-Tremie precautions:
The concrete should invariably be poured through a Tremie with a funnel, so that the concrete can be
properly deposited in the hole without segregation. For concreting done by Tremie , the following
requirements which are particularly applicable shall be ensured.
a) The hopper and Tremie should be a leak proof system.
b) Diameter of Tremie shall be not less than 200 mm for use with 20 mm diameter down
aggregate.
c) The first charge of concrete should be placed with sliding plug pushed down the tube ahead of
it or with a steel plate with adequate charge to prevent mixing of concrete and water. However,
the plug should not be left in the concrete as a lump.
d) The Tremie pipe should always penetrate well in to the concrete with adequate margin of

safety against accidental withdrawal of the pipe. The Tremie should be always full of concrete.
e) The pile should be concreted wholly by Tremie and the method of deposition should not be
changed part way up the pile, to prevent laitance from being entrapped within the pile.
f) All Tremie tubes shall be thoroughly cleaned after use.
g) For concrete placed through Tremie, there is no need to add 10% extra cement.
h) Concreting of piles shall be carried out continuously. In exceptional cases of interruption of
concreting, the Tremie shall not be taken out of the concrete under any circumstances. The
Tremie pipe shall be raised and lowered slowly from the time to time to prevent it from getting
struck in the concrete, while ensuring its lower end does not come out of concrete. The concreting
shall be resumed before final setting time of concrete, which shall be established before the
start of piling operation. For achieving longer setting time of the concrete, super plasticisers
having retarding properties / retarders can be used. If any of these requirements are not met,
the pile shall be rejected.
6.9.22.11. Use of admixture: For very long or large diameter piles, use of retarding plasticiser in
Concrete may be specified.
6.9.22.12. Pile integrity test : For large diameter piles, it may be essential to conduct non-destructive
pile integrity tests to evaluate integrity of the pile.
6.9.22.13-Base grouting of piles : Where possible, it may be desirable to grout the base of pile with
Cement slurry under suitable pressure after the Concrete in the pile attains the desired strength. For
this purpose, conduit pipes with easily removable plugs at the bottom end should be placed in the bore
along with reinforcement cage before concreting.
6.9.23. Tolerances:
6.9.23.1. Permissible Tolerances for Pile:
(i) Precast Concrete Piles:
(a) Variation in cross-sectional dimensions ±5 mm

(b) Variation in length ±25 mm
(c) Surface irregularities measured with 5mm
3 m straight edge
(d) Bow for length in mm
1 mm/m length of Pile
limited to 20 mm.
(ii) Driven Piles
(a) Variation in cross-sectional dimensions: +50 mm, -10 mm
(b) Variation from vertical for vertical piles: 1 in 50
(c) For vertical piles, deviation at piling platform level 75mm
(d) Variation of level of top of piles ±25 mm
(iii) Bored Piles
(a) Variation in cross-sectional dimensions +50mm,-lOmm
(b) Variation from vertical for vertical piles 1in150
(c) For vertical piles, deviation at piling platform level 75 mm

(d) Variation of level of top of piles ±25 mm
(iv) For Raker Piles from specified rake 1 in 25.
(v) Permissible Tolerances for Pile Caps:
(a) Variation in dimensions . +50 mm, -10 mm
(b) MIS :placement from specified position in plan 15mm
(c) Surface irregularities measured with
3 m straight edge . 5mm
(d) Variation of level of top of piles . ± 25 mm
6.9.24 Tests and standards of acceptance
6.9.24.1 Standards : The materials shall be tested in accordance with these specifications and shall
meet the prescribed criteria and requirements.
The work shall conform to these specifications and shall meet the prescribed standards of acceptance.
6.9.25: Measurement for payment:
i) For supply of precast concrete, timber or steel piles of specified cross-section, the measurement
shall be in metre of length of piles ordered in writing by the Engineer-in-charge measured from
the head to the butt of the shoe or the tapered point. Reinforcement in precast concrete piles
shall not be measured for payment.
ii) For cast in-situ driven and bored concrete piles of specified cross-section, the measurement
shall be the length in metre of the accepted pile that remains in the finished structure complete in
place. Reinforcement in cast in-situ driven and bored concrete piles shall be measured for
payment as per IS: 1200.Routine and Initial Pile Load Tests shall not be measured for payment.
iii) For installation of the pile, i.e. by drilling in the case of precast concrete, timber, steel and cast
in-situ driven piles, and by boring in the case of cast in-situ bored pile the measurement shall be
the length in metres that remains in the finished structure complete in place, limited to that shown
on drawings or ordered by the Engineer-in-charge. No distinction shall be made for penetration
through hard strata or rock and socketing into rock.
iv) For steel liners/ casing shown on the drawings too be permanently left in place, the
measurement shall be by weight in tonnes that remains in the finished structure complete in
place limited to that shown on drawings or ordered by the Engineer.
v) For the pile cap, the quantity of concrete shall be measured in cubic metres as per Section 1700
of MOSRT&H Specifications and reinforcement in pile cap shall be measured in tonnes as per
Section 1600 of MOSRT&H Specifications.
6.9.26 Rate:
i) The contract unit rate for supplying precast concrete, timber or steel piles shall include cost of all
labour, materials, tools and equipment, and other work involved in making or fabricating the pile
complete as shown on the drawing, and where required its loading, transport, delivery to site,
unloading and stacking at the place indicated by the Engineer-in-charge. The Cost of
reinforcement including treatment as per Section 1600 of MOSRT&H specifications in precast
concrete shall be deemed to be included in the quoted rate for supply of piles. The Contract
Unit rate shall also include cost of all labour, materials, equipment's and all other incidentals
involved in conducting routine and initial pile load tests, including installation of piles for initial
load tests.

ii) The Contract Unit rate for cast in-situ driven and bored piles shall include the cost of concrete
and all other items as per Section 1700 of MOSRT&H specifications. The Contract Unit Rate
shall also include costs of all labour, materials, equipment's and all other incidentals involved in
conducting routine and initial pile load tests, including installation of piles for initial load
tests.The Contract Unit Rate for reinforcement in cast-situ driven and bored piles shall be as per
IS: 1200
iii) The Contract Unit Rate for installation of piles shall include full compensation for furnishing
all labour, materials, tools and equipment, and incidentals for doing all the works involved in
driving timber, precast concrete and steel piles, driving or making bores for cast in-situ driven
and bored concrete piles, cutting of pile heads, all complete in place to the specified penetration
of piles. Providing Temporary liner/casing and its withdrawal and placing reinforcement in
position shall also be deemed to be included in the rate of installation of piles and no additional
payment shall be made for the same.
The Contract Unit rate for permanent steel liners shall include cost of all labour, fabrication,
treatment to the liner and placing the steel liner to the required depth as shown on the drawings
and as ordered by the Engineer in charge.
iv) The Contract Unit rate for concrete in pile cap shall cover all costs of labour, materials, tools,
plant and equipment, formwork and staging including placing in position, sampling and testing
and all as per Section 1700 of MOSRT&H specifications. Unit rate quoted shall also include the
treatment to be given to the surfaces of the pile cap. Reinforcement in the pile cap shall be paid
for separately as per Section 1800 of MOSRT&H specifications.
6.9.27 Trained Personnel:
The qualifications and training skills undergone by the skilled personnel, such as supervisors,
operators and mechanics, who are proposed to be employed in the work, shall be submitted for the
approval of the engineer since conformance to standards and attainments of quality and Quality
Assurance depend upon such personnel.
The work shall not commence till approval of the engineer is taken. If any of these personnel leaves
the work, due to any reason, during the progress of work, the engineer in charge shall be informed as
well as action proposed to be taken for substituting such a trained operative is furnished for
engineer's approval. Engineer's directions in this regard shall be adhered to.

APPENDIX À'
ADDITIONAL TESTS FOR CONCRETE
A-0 In case the Concrete falls when tested as per the method prescribed in Appendix A, one or more
of the following check tests may be carried out at the discretion of Engineer-in-Charge to satisfy the
strength of the Concrete laid. All testing expenditure shall be borne by the contractor, the number of
additional tests to be carried out shall be determined by the Engineer-in-Charge. He shall be the final
authority for interpreting the results of additional test and shall decide upon the acceptance or otherwise.
His decision in this regard shall be final and binding. For the purpose of payment, the Hammering test
results only shall be the criteria. Some of the tests are outlined below:-
A-1 Rebound hammer test:

If a rebound hammer is regularly used by trained personnel in accordance with procedure described in
IS : 13311 (part II) and a continuously malntalned individual charts are kept showing a large number
of reading and the relation between the reading and strength of Concrete cubes made from the same
batch of Concrete, such charts may be used in conjunction with hammer readings to obtain an
approximate indication of the strength of Concrete in a structure for element. If calibration charts are
available from manufactures, it can be used. When making rebound hammer test each result should
be the average of at least 12 readings. Reading should not be taken within 20mm of the edge of
Concrete members and it may be necessary to distinguish between readings taken on a trawled face
and those on a moulded face. When making the tests on a precast unit, special care should be taken
to bed them firmly against the impact of the hammer.
A-2 Cutting cores :

This method involves drilling and testing cores from the Concrete for determination of compressive
strength. In suitable circumstances, the compressive strength of the Concrete in the structure may be
assessed by drilling cores from the Concrete and testing. The procedure used shall comply with the
requirements of IS : 1199 and IS : 516.
The points from which cores shall be taken shall be representative of the whole Concrete and at least
three cores shall be obtained and tested. If the average of the strength of all cores cut from the structure
is less than the specified strength, the Concrete represented by the cores shall be liable to rejection and
shall be rejected if a static load test (B-5) either cannot be carried out or is not permitted by the
Engineer-in-Charge.
A-3 Ultrasonic test :

If an ultrasonic apparatus is regularly used by trained personnel in accordance with IS : 13311 (part
I) and continuously malntalned individual charts are kept showing a large number of readings & the
relation between the reading and strength of cubes made from the same batch of Concrete, such
charts may be used to obtain approximate indications of the strength of Concrete in the structures. In
cases of suspected lack of compaction or low cube strength the results obtained from the ultrasonic test
results on adjacent acceptable section of the structures may be used for the purpose of assessing the
strength of Concrete in the suspected portion.
A-4 Load tests on individual precast units:
The load tests described in this clause are intended as check on the quality of the units and should not
be used as substitute for normal design procedure. Where members require special testing. Such

special testing procedures shall be in a accordance with the specification. Test loads shall be applied
and removed incrementally.
A-4.1 Non Destructive Tests:
The unit shall be supported at its designed point of support and loaded for five minutes with a load
equal to the sum of the characteristic dead load plus one and a quarter time the characteristic imposed
load. The deflection is then recorded. The maximum deflection after application of the load shall be in
accordance with the requirements defined by the Engineer-in-Charge. The recovery is measured five
minutes after the removal of the load and the load then re -imposed. The percentage recovery after the
second loading shall be not less than that after the first loading nor less than 90% of the deflection
recorded during the second loading. At no time during the tests, shall the unit show any sign of
weakness or faulty construction as defined by the Engineer-in-Charge in the light of reasonable
interpretation of relevant data.
A-4.2 Destructive Tests:

The unit is loaded while supported at its design point of support and must not fail at its design load for
collapse, within 15 minutes of time when the test load becomes operative. A deflection exceeding 1/40
of the test span is regarded as failure of the unit.
A-4.3 Special Tests:
For very large units or units not readily amenable to the above test e.g. columns, the precast parts of
composite beams and members designed for continuity or fixity, the testing arrangements shall be
agreed upon before such units are cast.
A-5 Load Test of Structures or Parts of Structures:
The test described in this clause are intended as a check where there is a doubt regarding structural
strength. Test loads are to be applied and removed incrementally.
A-5.1 Age at Tests: The test is to be carried as soon as possible after the expiry of 28 days from the
time of placing of the Concrete. When the test is for a reason other than the quality of Concrete in the
structure being in doubt, the test may be carried out earlier, provided that the Concrete has already
reached its specified characteristic strength.
A-5.2 Test Load: The test loads to be applied for the limit state of deflection and local damage are the
appropriate design loads i.e., the characteristic dead and superimposed loads. When the limit state
of collapse is being considered the test load shall be equal to the sum of characteristic dead load plus
one and a quarter times the characteristic imposed load and shall be maintained or a period of 24
hours. In any of the test temporary supports of sufficient strength to take the whole load shall be placed
in position underneath but not in contact with the members being tested. Sufficient precautions must
be taken to safeguard persons in the vicinity of the structure.
A-5.3 Measurement During Tests: Measurements of deflection and crack width shall be taken
immediately after applications of the load and, in the case of 24 hour sustained load test, at the end of
24 hour loaded period, after removal of the load and after 24 hour recovery period. Sufficient
measurements shall be taken to enable side effect to be taken in account. Temperature and weather
conditions shall be recorded during the tests.
A-5.4 Assessment of Results : In assessing the strength of a structure or a part of the structure
following a loading test, the possible effects of variation in temperature and humidity during the

period of the test shall be considered.
The following requirements shall be met:
(a) The maximum width of any crack measured immediately on application of the test load for
local damage, is to be not more than 2 / r of the value of the appropriate limit state requirement.
(b) For members spanning between two supports the deflection measured immediately on
application of the test load for deflection is to be not more than 1/500 of the effective span
limits shall be agreed upon before testing cantilevered portions of structure.
c) If maximum deflection in mm shown during 24 hour under load is less than 40L2/D where L is
effective span in mm and D is overall depth of construction in mm, it is not necessary for the
recovery to be measured and the requirement (D) does not apply, and
(d) If within 24 hours of the removal of test load for collapse as calculated in clause (a) a reinforced
Concrete structure does not show a recovery of at least 75 per cent of the maximum deflection
shown during the 24 hour under load, the loading should be repeated. The structure should be
considered to have failed to pass the test if the recovery after second loading is not at least 75 per
cent of the maximum deflection shown during the second loading.
A-6 Determination of water soluble and acid soluble Chlorides in Concrete shall be done as per
method of test given in IS : 14959 (Part 1, Part 2)-2001 which covers volumetric method of test.
APPENDIX `B'
General Guidelines for Provision of
Movement Joints in Buildings
S.No. Particulars Movement Joint and Other Measures
1. i) Load Bearing Structures:- Provide vertical expansion joints 20 to 40 mm wide, 25
a) Buildings with flat roof to 40 m apart. For this purpose, introduce twins walls or
having cross walls at a wall and start from DPC Level and should be through
intervals as in residences, walls
as Well as floors, roof and parapet. In RCC roof
hostels, hospitals, office slab, provide additional expansion joints such that length
buildings, business of a slab does not exceed 15 to 20 m. It is necessary to
premises, schools etc. locate some expansion joints at change of direction and
at sections of substantial change in height of a building,
concealing the joints in recess, where feasible. When
blocks of buildings, such as residential flats are built in
continuous rows, expansion joints should be provided at
junctions of blocks.
b) Buildings of warehouse Provide vertical expansion joints 20 to 40 mm wide at
type of factory buildings 20 to 30m intervals with twin hems at the joints. In case
with flat roof having no or pillars or columns are provided in the building to support
very few cross walls. the hems, it will be necessary to provide twin pillars/
columns at the joints. If walls are panel walls between
columns which support roof beams, vertical expansion
joints should be provided 25 to 40 m apart, as in (i) (a)
above.

c) Buildings of warehouse For expansion of walls in the longitudinal direction,
type or factory buildings expansion joints should be provided as in (i) (b), with
having sloping roof with either twin trusses at the joints or single truss on one
sheet or tiles on trusses. side of the joint and slotted holes in purlins resting over
the truss, to allow for movement in the longitudinal
direction . No joints are required in roofing sheets and
other purlins since slight play in bolt-holes is enough to
take care of thermal movements in these items. For Steel
trusses with riveted joints, no provision for movement
of trusses in the transverse direction for spans up to 15
m is necessary as slight play in riveted joints allows for
necessary movements. For spans between 15 and 25m
in case of welded trusses, one end of the truss should be
fixed and the other end should have slotted holes with a
slip joint at the support to allow for transverse movement.
Trusses exceeding 25 m in length should have roller and
rocker bearing arrangement.
d) RCC roof slab having In hot and dry regions like North India, where variations
adequate thermal insulation in temperature are more than 15° C, provide expansion
on top. joints in slabs 20 to 25 mm wide and 15 to 20 m apart.
Where variations in temperature are less than 15° C,
additional joints apart from those of (i) (a) are not needed.
e) RCC roof slab having no or Provide expansion joints in slab 10 to 15 m apart.
very little thermal insulation
or protective cover on top.
1) Supports for RCC slabs Provide slip joint between the slab and the bearing wall,
exceeding 4 to 6 m length keeping a gap of about 12 mm width between slab and
brick cover.
ii) RCC framed structures:- Provide vertical expansion joints 25 to 40 mm wide, at
a) RCC framed structure 30 to 45 m interval. Joints should be provided by
introducing twin columns having combined footing. It
IS : necessary to locate some expansion joints at change
of direction and at sections of substantial change in height
of a building concealing the joins in recess, where
feasible . Roof slab should have adequate thermal
insulation on top.
b) Panel walls for cladding Provide a horizontal expansion joint about 10 mm in
width between the top of panel and soffit of hem. This
gap may be filled up with mastic compound fmished with
some sealant or filled with weak mortar up to a depth of
3 cm on the external face and left open on the internal
face. If structurally necessary lateral restraint to the panel
at the top should be provided by using telescopic
anchorages.

In case of panels longer than 5 to 8 m, either provide a
groove in the plaster at the junction of RCC column and
brick panel, or fix a 10 cm wide strip of metal mesh or
lathing over the junction before plastering. The reinforced
strip of plaster can accommodate differential movement
without cracking, to some extent.
c) Masonry Partitions Provide horizontal expansion joints as in (ii) (b)
iii) Junction between old and Provide vertical slip joints or expansion joints, depending
new structures upon the length of the old/ new portions; make suitable
arrangement for preventing seepage of rain water into
the joint from top and sides.
iv) Long compound walls of Provide vertical expansion joints 5 to 8 mm wide at 5 to
Masonry 8 m interval from grade level upwards; also provide
expansion joints at changes of direction, provide
additional control joints in coping stones mid-way.
v) Concrete Pavements
Provide expansion joints 20 to 25 mm wide at4 to 5 m
interval together with control joints at 8 to 10 m interval
depending on thickness of pavement, extent of
temperature variation anticipated and local conditions.
Thinner the pavement , closer the spacing of control and
expansion joints. Joints are needed both in longitudinal
and transverse direction. In the transverse direction, a
spacing of 4 to 5 m for control joints is generally adopted
depending upon the size of construction equipment
available; control joints normally function as construction
joints as Well. As far as possible, panels should be square
in shape-length to breadth ratio should not exceed 1.5
m. Incidence of Shrinkage cracking in panels which are
rectangular in shape is comparatively more than that of
square panels.
vi) a) RCC sun-shades Provide expansion joints 5 to 8 mm wide and 4 to 6 m
apart, joints should be only in the exposed portion, that
is, projected portion, some joints should invariably be
located at a change of direction,reinforcement should not
be continued through the joint. It is not necessary to fill
the joint with any jointing material.
b) RCC facia Provide expansion joints as in (vi) (a).
c) RCC balcony Provide vertical expansion joints 8 to 12 mm wide and
6 to 9 m apart, with water bar, filled with mastic
compound.
d) RCC railing Provide expansion joint 5 to 8 mm wide, 6 to 9 m apart.

e) Open veranda with RCC Provide vertical expansion joints in slabs (parallel) to
slab floors/ roof. the span) 10 to 15 mm wide and 6 to 9 m apart, joints
should be located at the centre of supporting pillars, joints
may be filled with mastic compound and V-grooved at
the bottom and suitable arrangement made at the top to
prevent leakage of water through the joint.
1) Brick tiling over mud Brick tiles should be laid with joints 8 to 10 mm wide,
phuska for roof terracing grouted with mortar, 1 Cement: 1 lime: 6 Sand; no
expansion joints are required.
g) Lime Concrete terrace over Provide 10 to 15 mm wide dummy joints , 4 to 6 m apart;
roof slab fill the joints with some mastic compound.
h) Pre-cast Concrete slabs over Size of slabs should be 0.6 to 0.75 m square and theses
lime Concrete terracing. should be laid in lime mortar with 10 mm wide expansion
joints, 4 to 6 m apart in both directions, joints should be
filled with some mastic compound.
j) Concrete/ terrazzo flooring Provide control joints 1 to 2 m apart alternatively provide
strip of Glass, Aluminium or some plastic material at
0.75 to 1.20 m interval in both the directions; joints or
strips are required mainly to prevent shrinkage cracks.
When laying floor over an RCC structural slabs, ensure
good bond with RCC slab by thorough cleaning of slab
surface (roughening it by hacking if necessary) and
priming with Cement slurry. Alternatively, provide a
lime
Concrete base course 5 to 7.5 cm thick over structural
k) Plaster work slab. • Joints in brick masonry should be raked to 10 mm
depth while mortar is green. Plastering should be done
after masonry has been cured and dried.
• At the junction of wall and ceiling provide a groove
in plaster about 10 mm in width as shown in Fig.13.
When plastering over long masonry walls, abutting
RCC columns, either give a vertical groove in the
plaster at the junction or embed in the plaster over
the junction, a 10 mm wide strip of metal mesh or
lathing as in item (ii) (b).
• Sometimes longitudinal cracks occur in the plaster
along conduits/ pipes embedded in chases in masonry.
To avoid these cracks, conduits/ pipes should be placed
at least 15 mm wide below the wall surface and
embedded up to wall surface in Concrete 1:2:3
Cement : Sand : Coarse aggregate, using Well graded
course Sand and 6 mm and downgradedCoarse
aggregate. Concrete surface should be finished rough
and plastered over after 7 days or more at the time of
general plastering of the wall.

NOTE:-For seismic Zones III, IV and V, expansion joints have to be much wider for which IS :
4326-1993 (Reaffirmed 2003) Code of practice for earthquake resistant design and construction of
buildings (first revision) should be referred.
PROVISION OF MOVEMENT JOINTS IN STRUCTURES :-
Joints in construction are introduced to prevent setting up of unduly high stresses, causing unsightly
cracks. These are of three kinds :-
EXPANSION JOINTS :-
a) These are pre-planned gaps (6mm to 40 mm ,more in jobs executed in winter than in summers)
in construction that will permit expansion as Well as contraction. The size of gap is more in
seismic zones III, IV and V.
b) In load bearing structures, with a combination of long and cross walls, the provision of
expansion joint could be farther, but in structures like factory sheds the exp. Joints are to be
located at closer intervals.
c) In framed structures ( capable of bearing stresses due to thermal movements) ,the joints could
be farther, while for slender members like the parapets and sunshades , these have to be closer.
CONTROL JOINTS :- Joints that allow only contraction.A control joint is a straight butt joint,
without any bond at the interface. A dummy joint is also a control joint, provided at a reduced section
(2/3rd. of the thickness of a member). The resulting grooves are filled with a mastic to conceal the
crack and prevent water getting in to the joint.
SLIP JOINTS :- Joints that allow sliding of one component over another.These are joints that permit
easy slipping of one component over the other to prevent appearance of cracks etc. Joints of RCC slabs
resting on walls in buildings or the RCC slabs resting on abutments of C.D. works are slip joints.
These are provided with the help of Bitumen impregnated paper inserted between to two components.
The top surface of the wall etc. is rendered smooth before placing the Bitumen paper. A groove should
generally be provided at such locations and the joint sealed for ingress of moisture.
Expansion of a structure causes compression and contraction causes tension. Basic materials like
CC and Masonry are always strong in compression but weak in tension. Cracking mainly occurs due
to contraction or shrinkage. Control joints are provided to control/ manage this contraction or
shrinkage. The control joints in a CC pavements are spaced closer than the expansion joints for this
purpose.In case of masonry walls with PCC blocks or Sand lime bricks,control joints are sometimes
provided by first constructing a mortar free joint, to filled later with lean mortar, after shrinkage.
PROVISION OF CONSTRUCTION JOINTS AND COLD JOINTS:

a) They are a common source of weakness and should be avoided. They should be provided if
required, with respect to IS : 11817 -1986 ( Reaffirmed 2002) and clearly indicated on the plans
by the designer. Construction joints shall be placed at accessible locations to permit cleaning
out of laitance, Cement slurry and unsound Concrete, in order to create rough / uneven surface.
It is recommended to cleanout laitance and Cement slurry using wire brush on the surface of
joint immediately after initial setting of Concrete .The prepared surface should be in a clean
surface dry condition when fresh Concrete is placed against it. If the joint is at a location where
the previous pour has been cast against the Shuttering, the aggregate at

the exposed edge should blasted with a high pressure jet or any other appropriate means.
b) Fresh Concrete should be thoroughly vibrated near construction joints so that the mortar from the
new Concrete flows between the large aggregates and develop proper bond with the old
Concrete.
(c) Where high shear resistance is required at the construction joints, shear keys may be provided.
Sprayed curing membranes and release agents should be thoroughly removed from the joint
surfaces.
General Position of Construction Joints: The horizontal joints should be arranged with levels to
blend with the general Architectural appearance.
(i) The vertical joints should be situated at positions where the length of the joint is shortest or
where a symmetrical pattern can be arranged. In columns, beams, slabs and walls the following
general rules should be observed in positioning construction joints.
(ii) Columns should be filled to a level, preferably a few cm below the junction of a beam or
alternatively to the bottom of any Haunching.
(iii) Joints in beams and slabs should be formed at the points of minimum shear. Thus for beams,
the joint should at the centre of span or within the middle third Slabs spanning in one direction
and of short span should have the joints at middle span if they are at right angles to the direction
of spanning. Joints in the direction in which the slabs are designed to span should be with in the
middle third. Joints in slabs spanning in two directions should be with in the middle third of
either span.
(iv) If for any reason a joint has to be made between the slab and the beam, it is then necessary to
provide some form of key and to add shear reinforcement to meet any weakness at the joint.
(v) Horizontal joints in walls are usually made at such positions as the top of a plinth or the top or
bottom of a window opening.
Forming Construction Joint:-
a) All vertical joints should be formed against a stop board as raking joints often results in
honeycombing. All horizontal joints should be level. Battens may be nailed to form work to
ensure a horizontal line and if desired may be used to form a grooved joint. If the thickness of
Concrete permits, it IS : desirable to provide a key of the tongue and groove type at all
construction joints. The width of the groove should be about one third the thickness of the
Concrete.
b) For tank walls or similar work it IS : preferable to form all joints with a strip of sheet metal
about 15 cm wide inserted half way in to the Concrete at the top of the lift to form a continuous
water barrier.
c) When resuming work at construction joints on a Concrete surface which has hardened, such
surface should be roughened. It should then be swept clean, thoroughly wetted and covered
with a 15 mm layer of mortar composed of Cement and Sand in the same ratio as the Cement and
Sand in the Concrete mix. This layer should be freshly mixed and placed immediately before
placing the fresh Concrete.
d) Where the work has to be resumed on a Concrete surface which has not fully hardened, all
laitance should be removed by scrubbing. The surface should then be coated with neat Cement
grout. The first layer of Concrete to be placed against this surface should not exceed 15 cm in
thickness and should be Well rammed against the old work.

APPENDIX`C'
1. Admixtures:-In Concrete, admixturesare used for a specific purpose. Admixtures to CC when
intended should conform to the IS : 9103-1959 (reaffirmed 1999). Also refer clause 5.2 of
Chapter 5. Their classification, purpose and chemical constituents are:-
S.No. Type of Material Desired Effect
Admixture
1. Air Entrained - Salts of wood resins, Increase durability, if
- Some synthetic detergents, the water Cement ratio
- Salts of sulphonatedlignin, is reduced
- Salts of petroleum acids.
- Salts of proteineous materials.
- Fatty and resinous acids and their
Salts.
- Organic Salts of sulphonatedhydro-
carbons.
2. Shrinkage Calcium sulphate plus Cause expansion of setting
Compensator calciumsulphoaluminates'
Finely divided Iron plus oxidizing agent.
3. Gas former Aluminium Powder. --Do--
4. Water reducer Lignosulphonates and their derivatives. Increase strength and
Saltsofhydroxylated carboxylic acids Workability.
and their derivatives.
5. Superplasticisers Sulphonated melamine formaldehyde --Do--
(Workability condensate.
Agents) Naphthalenesulphonated formaldehyde
condensate.
Modified lignosulphonate.
6. Accelerator Calcium Chloride, other soluble Increase early strength
Chlorides, carbonates, silicates. and supersulphate.
Alkali Hydroxides, Triethanolamine
7. Retarder Lignin, Borax Sugars, Tartaric acid, Retardation of set.
and Salts.
8. Air detainer Tributyl Phosphate To dissipate excess air
other than gas
9. Flocculating Synthetic polyelectrolytes To reduce flow of pastes
agent and mortars and to increase
cohesion of mortar.
10. Pumping Aids Polyethylene oxide, Cellulose Improve the handling of
derivatives, Alginates. Concrete.
11. Pozzolana Flyash,Volcanic glass, Diatomite, Some To reduce the heat of
clays and shale. hydration, for effecting
economy.

S.No. Type of Material Desired Effect
Admixture
12. Foaming Sodium Sulphates, Alkyl For making light weight
Agents arylsulphonates Concrete.
13. Water proofing Some soaps, Butyl stearate, some To prevent passage of
Agents petroleum products. water through Concrete.
14. Bonding Agents Organic Polymer emulsions To increase bond strength
between old and new
Concrete.
15. Corrosion Sodium benzoates, Calcium Corrosion protection of
Inhibitors lignosulphonate, Sodium nitrate reinforcement Steel
16. Fungicides and Copper compounds, Dieldrin emulsion, To impart fungicidal
germicides Poly halogenated phenols. germicidal or insecticidal
properties to CC.
17. Pigments Colour Pigments To impart colour to CC
Admixtures if used should comply to IS : 9103. Previous experience with and data on such
materials should be considered in relation to the likely standards of supervision and
workmanship to the work being specified.
They should not impair durability of Concrete nor combine with constituents to form
harm full compounds nor increase the risk of corrosion of reinforcement.
The workability, compressive strength and the slump loss of Concrete, with and without
the use of admixtures shall be established during the trial mixes before the use of
admixtures.
The relative density of liquid admixtures shall be checked for each drum containing
admixtures and compared with the specified value before acceptance.
The Chloride content of admixtures shall be independently tested for each batch before
acceptance.
If two or more admixtures are used simultaneously in the same Concrete mix, data
should be obtained to assess their interaction and to ensure their compatibility.
2. Sulphates in Concrete: -Refer page 29 of Chapter 5 : Concrete.
3. Alkali Aggregate reaction: Refer page 20 of Chapter 5 : Concrete.
4. Concrete in Aggressive soils and water: - Refer page 21 of Chapter 5 : Concrete.
5.
Production of Concrete: - Refer page 22 of Chapter 5 : Concrete.
6.
Transporting, Placing, and Compaction :Refer page 19 of Chapter 5 : Concrete.
7.
8. Curing: Refer page 26 of Chapter 5 : Concrete.
Testing Workability of Concrete:Refer appendix `H' of Chapter 5

LIST OF RELEVANT BUREAU OF INDIAN STANDARDS CODES
S.No. I.S. No. Subject
1. IS :226-1975 StructuralSteel ( standard Quality)
2. IS : 228-1987 Chemical Analysis of Steel
3. IS: 269 : 1989 Ordinary Portland cement, 33 grade - Specification (fourth
revision)
4. IS: 280-1978 Mild Steel wire for General Engineering Purposes.
5. IS :432(PI)-1982 Specificationfor mildSteelandmediumtensileSteelbars.
6. IS :432(Partf)-1982 Specification for mild Steel and medium tensile Steel bars and
hard drawn Steel wire for Concrete rein forcement.
7. IS: 455-1989 Portland slag cement Specification (fourth revision)
8. IS :456-2000 CodeofPracticesforplainandReinforcedConcrete.
9. IS :516-1959 MethodoftestforstrengthofConcrete.
10. IS : 1070-1992 Reagents for chemical Grade water. Specifications
11. IS: 1139-1966 Hot Rolled Mild Steel, Medium Tensile Steel, and high Yield
strength Steel Deformed bars for ConcreteReinforcement.
12. IS :1199-1959 MethodofsamplingandanalysisofConcrete.
13. IS :1343-1980 CodeofPracticeforPrestressedConcrete
14. IS :1200(PII)-1974 Methodofmeasurementof buildingandcivilengineeringwork-
Concrete work
15. IS :1200(PartV)-1982 Methodofmeasurementof buildingandcivilengineeringwork-
Concretework (Part 5-Formwork)
16. IS : 1489(P-I/II)1976/ Portland-pozzolana cement Specification:, (Part 1) : 1991 Fly
1991 ash based (third revision), (Part 2) : 1991 Calcined clay based
(third revision)
17. IS :1566-1992 Specification for hard drawn Steel wire fabric for Concrete
requirement.
IS: 1642-1989 Code of practice for Fire safety of buildings (General -details
of construction
18. IS 1785(P- I)-1966 Plain Hard-drawn ( Cold Drawn Stress Relieved Wire) For Pre-
stressed Concrete.
19. IS 1785(P- II)-1966 Plain Hard-drawn ( As- Drawn Wire) For Pre-stressed Concrete.
20. IS :1786-2008 Specification for high strength deformed Steel and wires for
Concretereinforcement.
21. IS :1791-1985 SpecificationforbatchtypeConcretemixes
22. IS: 1892-1979 Code of practice for sub-surface investigations for foundations
(first revision)
23. IS: 1893 (P-1)-1984 Criteria for earthquake resistant design of structures : Part 1
General provision and buildings (fifth revision)

24. IS : 2062-2006 Hot rolled low, medium and high tensile structural steel (sixth
revision)
25. IS: 2090-1962 High Tensile Steel bars used in Pre-stressed Concrete.
26. IS: 2131 : 1981 Method for standard penetration test for soils (first revision)
27. IS : 2386-1963 Methods of test for Aggregates.
28. IS : 2430-1986 Methods for sampling for aggregates.
29a. IS :2502-1963 Code of practice for bending and fixing of bars for Concrete
reinforcement.
29b. IS: 2505-1980 Concrete Vibrators-Immersion type., General requirements.
29c. IS: 2506-1985 General requirements for screed board concrete vibrators.
29d. IS:2514-1963 Specifications for concrete vibrating table.
30. IS :2751-1979 Recommended practice for welding of mild Steel plain and
deformed bars for reinforced Concrete construction.
31. IS : 2911-2010 Code of practice for design and construction of pile foundations:
(Part 3) : 1980 Under-reamed piles (first revision), (Part 4) :
1984 Load test on piles.
32a. IS : 3025-1964 Method of sampling and tests for water.
32b. IS: 3414-1968 Code of practice for Design and installation of joints in
33. IS : 3535-1986 Buildings.
Methods of sampling Hydraulic Cement.
34. IS : 3812 (I,II)-1981 Pulverised Fly Ash for use as Pozzolana in Cement, Cement
Mortar and Concrete
35. IS : 4031-1996 Physical tests for Hydraulic Cement.
36a. IS:4326-1993 Code for EQ resistant design and construction of buildings.
36b. IS: 4656-1968 Specification for Form vibrators for concrete.
37. IS :4925-1968 Specification for Concrete batching and mixing plant
38. IS :4926-2003 Ready-Mixed Concrete
39. IS: 4968-( P-1,2,3) Method for sub-surface sounding for soils:(Part 1-3) : 1976
40. IS: 6003-1970 Indented wire for Pre-stressed Concrete.
41. IS: 6006-1970 Uncoated Stress Relieved Strand for Pre-stressed Concrete.
42. IS :6523-1983 Specification for precast reinforced Concrete door, window
frames
43. IS:6909-1990 Specifications for super sulphated cement.
44. IS 7887-1975 Mild Steel wire Rod for General Engineering Purposes.
45. IS: 8041 : 1990 Rapid hardening Portland cement Specification (second
revision).
46. IS: 8043 : 1991 Hydrophobic Portland cement Specification (second revision)
47. IS: 8112 : 1989 43 grade ordinary Portland cement Specification (first revision)

48. IS : 9103-1959 Admixtures for Concrete-specifications.
49. IS : 9417-1989 Welding of Reinforcement bars.
50. IS:9595-1996 Metal Arc welding of carbon and carbon manganese steels.
51. IS :10262-1982 Recommended guidelines for Concrete mix design
51. IS : 11817-1986 Classification of joints in Buildings.
52. IS 12089-1987 Specifications for Granulated slag.
53. IS:12119-1987 General Requirement for Pan mixers for Concrete.
54. IS:12269 : 1987 Specification for 53 grade ordinary Portland cement
55. IS: 12330 : 1988 Specification for Sulphate resisting Portland cement
56. IS: 12600 : 1989 Portland cement, low heat Specification
57. IS :13311 (P I)-1992 Indian standard for non-destructive testing of Concrete. Method
of test for ultrasonic pulse velocity
58a. IS :13311 (P II)-1992 Indian standard for non-destructive testing of Concrete. Method
of testing by rebound hammer.
58b. IS: 14687-1999 Guide lines for false work for concrete structures.
59. IS : 14858-2000 Compressive strength testing for Concrete and Mortars.
60. IS : 14959 (P-I) Determination of water soluble and acid soluble Chlorides in
fresh mortar and concrete..
61. IS : SP 23-1982 Hand book of Concrete Mix Design.
62. IS: 14687-1999 Guide lines on False work for Concrete Structures.
63. IS: 14959(P-2)-2001 Determination of water soluble and acid soluble chlorides in
hardened Mortar and Concrete.
CHAPTER No. 7
BRICK WORK
CHAPTER No. 7 : BRICK WORK
CONTENTS
7.1 Scope 3
7.2 Terminology. 3
7.3 Materials. 4
7.4 Joints. 14
7.5 Scaffolding. 14
7.6 Honeycomb Brick work. 15
7.7 Mode of measurement. 15
7.8 Rate. 17
7.9 Protections, washing and mortar. 17
7.10 Jointing old Brick work with new brick work. 18
7.11 Moulding and Cornices. 18
7.12 Brick work under water and foul conditions. 19
7.13 Exposed Brick work. 19
7.14 Brick Arches. 20
7.15 Cavity walls. 22
7.16 Reinforced Brick work. 24
7.17 Brick Edging . 25
Appendix A: Sampling and Testing of common Burnt Clay Bricks. 25
Appendix B: Tests for Dimensional Tolerance 27
Appendix C:Tests for compressive strength. 28
Appendix D: Tests for water Absorption. 29
Appendix E: Tests for Efflorescence 30
Figures 31-37
List of Mandatory Tests 38
List of relevant IS codes 38
Rajasthan PWD Building Specifications 2014 Chapter 7 : Brick Work Page 1 of 38


CHAPTER No. 7
BRICK WORK
7.1 Scope:
This specification lays down requirement of materials, bond, joints, laying, curing and mode of
measurement of brick work.
7.2 Terminology:
i) Bed Joint-Horizontal joint in brick work or masonry.
ii) Bond - The arrangement of the bricks in successive courses to tie the brick work together both
longitudinally and transversely. The arrangement is usually designed to ensure that no vertical
joint of one course is exactly over the one in the next course above or below it, and there is
greatest possible amount of lap.
iii) Closer- Any portion of a brick used in constructing a wall, to close up the bond next to the
end brick of a course.
iv) Coping or Weathering- The cover applied over or the geometrical form given to a part of
structure to enable it to shed rain water.
v) Corbel-A cantilever projecting from the face of a wall to form a bearing (see Fig.1D).
vi) Cornice-Horizontal or ornamental feature projecting from the face of a wall (see Fig.1D).
vii) Course - A layer of bricks including bed mortar.
viii) Cross joint -A joint other than a bed Joint normal to the wall face.
ix) Efflorescence- A powdery incrustment of salts left by evaporation. This may be visible on
the surface or may be below surface. In the latter case, this is termed as crypto Efflorescence.
x) Frog - The depression made in the large side bricks in order to form a key for the mortar at
joints.
xi) Jamb - The part of the wall at the side of an opening.
xii) Joint-A junction of bricks in brick masonry.
xiii) Jointing-The operation of finishing joints as the masonry work proceeds.
xiv) Header-A brick laid with its length across the wall.
xv) Indenting-Leaving recesses into which future work can be bonded.
xvi) Pier-A thickened section forming integral part of the wall placed at intervals along the wall
primarily to increase the stiffness of the wall or to carry a vertical concentrated load. The
thickness of a pier is the over all thickness including the thickness of the wall or when bonded
into one leaf of a cavity wall the thickness obtained by treating this leaf as an independent wall.
xvii) Pillar- Pillar means a detached masonry support. This can be rectangular, circular, elliptical
etc. In case of rectangular pillar, the breadth shall not exceed three times the thickness and
thickness itself shall not exceed more than thrice the length of brick.

xviii)Reveals- The portion of the jamb exposed beyond the frames is known as reveal.
xix) Scaffolding-A temporary erection of timber or steel work used in the construction, alteration,
demolition or repairs of a building to support or to attend the hoisting or lowering of workmen,
their tools and materials. Scaffoldings are of two types, namely single and double scaffoldings.
Single scaffolding consists of a row of verticals connected to wall by horizontal supported on and
tied to the structure. Double scaffolding consists of two rows of verticals secured or leashed
together with horizontal and diagonal bracings forming essentially a structure independent of
the building. It may also connect to the structure at convenient points for the sake of better
stability.
xx) Sill- A brick work forming the lower boundary of door or window opening.
xxi) Stretcher- A brick laid with its length in the direction of the wall.
xxii) String Course- A horizontal course projecting from a wall, usually introduced at every floor
level or windows or below parapet for imparting architectural appearance to the structure and
also keeping off the rain water.
xxiii) Spandrel-The space between the haunches and the road decking of an arch.
xxiv) Toothing- Bricks left projecting in alternate courses to bond with future work.
xxv) Template-A pattern of sheet metal used as a guide for setting out specific section and shape.
xxvi) Quoin-An external corner in brick work, the term may also denote the brick used to form the
quoin.
xxvii) Wall joint-A joint parallel to the wall face.
73 Materials:
73.1 Bricks/Brick Tiles/Brick Bats/Mechanized Autoclave Fly Ash Lime Brick: Bricks used in
the masonry may be of the following type.
(a) Common Burnt Clay Bricks: Common Burnt Clay Bricks shall conform to IS:1077-1976 and
shall be hand moulded or machine moulded. They shall be free from nodules of free lime, visible
cracks, flaws warpage and organic matter, have a frog 100 mm in length 40 mm in width and
10 mm to 20 mm deep on one of its flat sides. Bricks made by extrusion process and brick tiles
may not be provided with frogs. Each brick shall be marked (in the frog where provided) with
the manufacturer's identification mark or initials.
(b) Fly Ash Lime Bricks (FALG Bricks): The Pulverised Fly Ash Lime Bricks (FALG Bricks)
shall conform to IS 12894-2002. Visually the bricks shall be sound, compact and uniform in
shape free from visible cracks, warpage, flaws and organic matter. The bricks shall be solid
and with or without frog on one of its flat side. Bricks made by extrusion process and brick
tiles may not be provided with frogs. Each brick shall be marked (in the frog where provided)
with the manufacturer's identification mark or initials. The materials involved in these bricks are:
(i) Fly Ash: Fly ash shall conform to IS 3812-1981.
Note: This item will be operated only for load bearing structure upto 2 storeys and for non-
load bearing walls 230 mm thick for multi-storeyed buildings. Bottom ash used as
replacement of sand shall not have more than 12% loss on ignition when tested.
(ii) Sand : Deleterious materials, such as clay and silt in the sand shall preferably be less
than 5%.

(iii) Lime:Lime shall conform to class `C' hydrated lime of IS :712-2001.
(iv) Additives: Any suitable additive considered not detrimental to the durability of bricks
may be used.
(c) Clay Fly Ash Bricks: The clay fly ash bricks shall conform to IS: 13757-1999. The bricks shall
besound, compact and uniform in shape and colour. Bricks shall have smooth rectangular faces
with sharp and square corners. The bricks shall be free from visible cracks, flaws, warpage, nodules
of free lime and organic matter, the bricks shall be hand or machine moulded. The bricks shall
have frog of 100 mm in length 40 mm width and 10 to 20 mm deep on one of its flat sides. If
made by extrusion process may not be provided with frogs. Fly Ash shall conform to grade I or
grade II of IS 3812-1981.
(h) Calcium Silicate Bricks: The bricks shall conform to IS: 4139-1976. The Calcium silicate
bricks shallbe sound, compact and uniform in shape. Bricks shall be free from visible cracks,
warpage,organic matter, large pebbles and nodules of free lime. Bricks shall be solid and with
or without frog. The bricks shall be made of finely grounded sand siliceous rock and lime. In
addition limited quantity of fly ash conforming to IS 3812-1981 may be used in the mix. These
bricks are also known as Fly Ash Sand Lime bricks in the construction industry.
(i) Tile Brick: The bricks of 40mm height shall be moulded without frogs. Where modular tiles
are not freely available in the market, the tile bricks of F.P.S. thickness 44 mm (1-3/4") shall be
used unless otherwise specified.
(l) Brick Bats:Brick bats shall be obtained from well burnt bricks.
(k) Mechanized Autoclave Fly Ash Lime Brick: These bricks shall be machine moulded and
prepared in plant by appropriate proportion of fly ash and lime. The autoclave fly ash bricks shall
conform to IS: 12894-2002. Visually, the bricks shall be sound, compact and uniform shape,
free from visible cracks, warpage and organic matters. The brick shall be solid with or without
frog, and of 100/80 mm in length, 40 mm width and 10 to 20 mm deep one of its flat side as per
IS: 12894-2002. The brick shall have smooth rectangular faces with sharp corners and shall be
uniform in shape and colour. Fly ash shall conform to IS 3812-1981 and lime shall conform to
class `C' hydrated lime of IS 712-2001.
7.3.1.1 Dimensions: The brick may be modular or non-modular. Sizes for both types of bricks/tiles
shall be as per Table 1. While use of modular bricks/tiles is recommended, non-modular (FPS)
bricks/tiles can also be used where so specified. Non-modular bricks/tiles of sizes other than the
sizes mentioned in Table 1 may also be used where specified.
Table 1 :
Type of Bricks Nominal Size -mm Actual Size-mm
Modular Bricks 200 x 100 x 100 mm 190 x 90 x 90 mm
Modular tile bricks 200 x 100 x 40 mm 190 x 90 x 40 mm
Non-modular bricks 229 x 114 x 70 mm 225 x 111 x 70 mm
Non-modular tile bricks 229 x 114 x 44 mm 225 x 111 x 44 mm
7.3.1.2 Classification : Bricks/Brick tiles shall be classified on the basis of their minimum
compressive strength as given below in Table 2:

Table 2 :
Average compressive strength
C1ass Designation
Not less than N/mm2 Not less than (kgf/cm2)
35 35 350
30 30 300
25 25 250
20 20 200
17.5 17.5 175
15 (150) 15.0 150
12.5 (125) 12.5 125
10 (100) 10.0 100
7.5 (75) 7.5 75
5 (50) 5.0 50
3.5 (35) 3.5 35
The bricks shall have smooth rectangular faces with sharp corner and shall be uniform in colour and
emit clear ringing sound when struck.
(Note: Upper limits specified in Table 2 are for calculating the average compressive strength in
accordance with Appendix C.
7.3.1.3 Sampling and Tests: Samples of bricks shall be subjected to the following tests:
(a) Dimensional tolerance. (Refer Appendix 'B')
(b) Water absorption. (Refer Appendix `D')
(c) Efflorescence. (Refer Appendix È')
(d) Compressive strength. (Refer Appendix `C')
7.3.1.4 Sampling: For carrying out compressive strength, water absorption, efflorescence and
dimensional tests, the samples of bricks shall be taken at random according to the size of lot as given
in Table 3 below. The sample thus taken shall be stored in a dry place until tests are made. For the
purpose of sampling, the following definition shall apply.
(a) Lot : A collection of bricks of same class and size, manufactured under relatively similar
conditions of production. For the purpose of sampling a lot shall contain a maximum, of 50,000
bricks.In case a consignment has bricks more than 50,000 of the same classification and size
and manufactured under relatively similar conditions of production, it shall be divided into lots
of 50,000 bricks or part thereof.
(b) Sample : A collection of bricks selected for inspection and/or testing from a lot to reach the
decision regarding the acceptance or rejection of the lot.
(c) Defective : A brick failing to meet one or more of the specified requirements.
7.3.1.4 The samples shall be taken as below:
(i) Sampling from a Stack: When it is necessary to take a sample from a stack, the stack shall be
divided into a number of real or imaginary sections and the required number of bricks drawn

from each section. For this purpose bricks in the upper layers of the stack shall be removed to
enable units to be sampled from places within the stack.
Note: For other methods of sampling i.e. sampling in motion and sampling from lorries or
trucks,IS :5454-1978 may be referred.
7.3.1.5 Scale of sampling and criteria for conformity for visual and dimensional characteristics:
(i) Visual characteristics: The bricks shall be selected and inspected for ascertaining their
conformity to the requirements of the relevant specification.The number of bricks to be selected
from a lot shall depend on the size of lot and shall be in accordance of Col. 1 and 2 of Table 3 for
visual characteristics in all cases and dimensional characteristics if specified for individual
bricks.All the bricks selected above in accordance with Col. 1 and 2 of Table 3 shall be
examined for visual characteristics. If the number of defective bricks found in the sample is
less than or equal to the corresponding number as specified in Col. 3 of Table 3 the lot shall be
considered as satisfying the requirements of visual characteristics, otherwise the lot shall be
deemed as not having met the visual requirements.
(ii) Dimensional Characteristics: The number of bricks to be selected for inspecting the
dimensions and tolerance shall be in accordance with Col. 1 and 4 of Table 3. These bricks will
be divided into groups of 20 bricks at random and each of the group of 20 bricks thus formed
will be tested for all the dimensions and tolerances. A lot shall be considered having found
meeting the requirements of dimensions and tolerance if none of the groups of bricks inspected
fails to meet the specified requirements.
Table 3 :
Scale of Sampling and Permissible Number of Defectives for Visual and
Dimensional Characteristics
For characteristics specified for For dimensional
No. of bricks in the Lot individual bricks characteristics for
group of 20 bricks
No. of bricks to Permissible No. of No. of bricks to be
be selected. defective in the to beselected
sample.
(1) (2) (3) (4)
2001-10000 20 1 40
10001-35000 32 2 60
35001-50000 50 3 80
Note: In case the lot contains 2000 or less bricks the sampling shall be as per decision of the
Engineer-in-Charge.
(iii) Scale of Sampling and Criteria for Physical Characteristics: The lot which has been found
satisfactory in respect of visual and dimensional requirements shall be next tested for physical
characteristics like compressive strength, water absorption, efflorescence (refer Appendix - D)
as specified in relevant material specification. The bricks for this purpose shall be taken at
random from those already selected above. The number of bricks to be selected for each of
these characteristics shall be in accordance with relevant columns of Table 4.

Table 4 :
Scale of Sampling for Physical Characteristics
Lot size Sample size for Permissible No of Sample size for Permissible no.
compressive defectives for warpage of defectives
strength, water efflorescence
absorption and
efflorescence
(1) (2) (3) (4) (5)
2001-10000 5 0 10 0
10001-35000 10 0 20 1
35001-50000 15 1 30 2
Note: i) In case the lot contains 2000 or less bricks, the sampling shall be as per decision of
Engineer-in-Charge.
ii) The efflorescence when tested as per IS 5454-1978, should be moderate up to class
12.5 and slight for higher classes.
(iv) A lot shall be considered having satisfied the requirements of physical characteristics if the
condition stipulated here in are all satisfied.
(a) From the test results for compressive strength, the average shall be calculated and
shall satisfy the requirements specified in relevant material specification.
Note: In case any of the test results for compressive strength exceeds the upper limit for
the class of bricks, the same shall be limited to the upper limit of the class for the purpose
of averaging.
(b) Wherever specified in the material specification, the compressive strength of any
individual bricks tested in the sample shall not fall below the minimum average
compressive strength specified for the corresponding class of brick by more than 20
percent.
(c) From the test results for water absorption, the average for the bricks in the sample shall
be calculated and shall satisfy the relevant requirements specification in material
specification.
(d) The number of bricks failing to satisfy the requirements of the efflorescence specified
in the relevant specification should not be more than the permissible no. of defectives
given in Col. 3 of Table 4.
7.3.1.6 Dimensional Tolerances: The dimensions of modular bricks when tested as described above
as per procedure described in Appendix `B' shall be within the following limits per 20 bricks or
locally available size as approved by Engineer-in-charge.
(a) For modular size:
Length-3720 to 3880 mm (3800 ± 80 mm)
Width-1760 to 1840 mm (1800 ± 40 mm)
Height-1760 to 1840 mm (1800 ± 40 mm) for 90 mm high bricks
760 to 840 mm (800 ± 40 mm) for 40 mm high bricks

(b) For non-modular bricks:
Length 4680 to 4520 mm (4600 ± 80 mm)
Width 2240 to 2160 mm (2200 ± 40 cm)
Height 1440 to 1360 mm (1400 ± 40 mm) for 70 mm high bricks
640 to 560 mm (600 ± 40 mm) for 30 mm high bricks
(c) For Brick Tiles:
840 to 760 mm (800 ± 40 mm) for 40 mm high brick tiles
In case of non-modular bricks, % age tolerance will be ± 2% for group of 20 numbers of class
10 bricks, and ± 4% for other class of bricks.
7.3.1.7 Compressive Strength: The bricks, when tested in accordance with the procedure laid down
in Appendix `C' shall have a minimum average compressive strength for various classes as given in
Table 2. The compressive strength of any individual brick tested shall not fall below the min. average
compressive strength specified for the corresponding class of brick by more than 20%. In case
compressive strength of any individual brick tested exceeds the upper limit specified in Table 2 for
the corresponding class of bricks, the same shall be limited to upper limit of the class as specified in
Table 2 for the purpose of calculating the average compressive strength.
7.3.1.8 Water Absorption: The average water absorption of bricks when tested in accordance with
the procedure laid down in Appendix `D' shall be not more than 20% by weight for bricks up to class
12.50 and 15% for higher classes.
7.3.1.9 Efflorescence: The rating of efflorescence of bricks when tested in accordance with the
procedure laid down in Appendix È' shall be moderate up to class 12.5 and slight for higher classes.
73.2 Sewer Bricks:
7.3.2.1 Sewer bricks are intended for the lining of walls, roofs and floors of sewers used for ordinary
sanitary (domestic) sewage. The general practice in the country is also to utilize common building
bricks in the construction of sewers which is not satisfactory. However, these sewer bricks may not
be suitable for sewers dealing with industrial effluent (sewage) for which the use of acid resistant
bricks in accordance with IS 4860-1968 may be considered. Sewer bricks shall conform to IS 4885-
1988.
7.3.2.2 Dimensions and Tolerances:

Dimensions: The standard sizes of the sewer bricks shall be as follows:
Length (mm) mm
Width(mm)
Height ()
190 90 90
190 90 40
For sewers of special shapes, such as the oval sewers, the bricks may have to be suitably tapered to
conform to the radii of curvature of the arches and barrels and sides of sewers.

Tolerance: The permissible tolerance on the dimensions specified in 7.3.2.2 shall be as follows:
Dimensions Total tolerance for 20 bricks

mm mm
190 ±80
90 ±40
40 ±40
7.3.2.3 Compressive Strength: The average compressive strength obtained on a sample of sewer
bricks when tested in accordance with the procedure laid down in IS3495 (Part I) -1992 shall be not
less than 17.5 N/mm2 (175 kg f/cm2 approximately) and the individual strength of any brick shall be
not less than 16 N/mm2 (160 kg f/cm2 approximately).
7.3.2.4 Water Absorption: The average value of water absorption for five bricks after 24 hour cold
water immersion test when tested in accordance with IS 3495 (Part 2) -1992 shall not exceed 10 percent
of the average dry weight of the brick and the absorption for any individual brick shall not exceed 12
percent.
7.3.2.5 Efflorescence: When the bricks are tested in accordance with the method laid down in IS
3495 (Part 3), the rating of efflorescence shall not be more than `slight'.
73.3 Burnt Clay Perforated Building Bricks:
7.3.3.1 General quality: The bricks shall be made of suitable clay and shall be thoroughly burnt at
the maturing temperature of clay. They shall be free from cracks, flaws and nodules of free lime.
They shall have rectangular face with sharp straight edge at right angle. They shall be of uniform
colour and texture. These bricks generally should conform to IS 2222-1991.
7.3.3.2 Dimensions and Tolerances: The standard size of burnt clay perforated bricks shall be as
follows:
Type Length (mm) Width (mm) Height (mm)
Modular 190 90 90
Non-modular 230 110 70
The permissible tolerances on the dimensions shall be as follows:
Dimension Tolerance
(mm) (mm)
70, 90 ±4
110, 190 ±7
230 ±10
Note: The tolerances specified above shall apply to measurements on individual bricks.
7.3.3.3 Perforations: The area of perforation shall be between 30% and 45% of the total area of the
corresponding face of the bricks. The perforation shall be uniformly distributed over the surface. In
the case of rectangular perforations, the larger dimension shall be parallel to the longer side of the
brick. The shorter side of the perforation shall be less than 20 mm. incase of rectangular perforations
and less than 25 mm diameter in case of circular perforations. The area of each perforation shall not

exceed 500 mm 2 . The thickness of any shell shall not be less then 15 mm and that of any web not
less than 10 mm.
7.3.3.4 Compressive Strength : The bricks when tested in accordance with the procedure laid
down in IS 3495 (Parts 1 to 4)-1992 shall have a minimum average compressive strength of 7 N/
sgmm on net area.The compressive strength of any individual brick tested shall not fall below the
minimum compressive strength specified for the corresponding class of bricks. If it falls below it,
the lot shall then be checked for next lower class of brick.
7.3.3.5 Water Absorption: The bricks when tested in accordance with the procedure laid own in
IS: 3495 (Parts 1 to 4)-1992: after immersion in cold water for 24 hours water absorption shall not
be more than20 percent by weight.
7.3.3.6 Efflorescence: The bricks when tested in accordance with the procedure laid down in IS
3495-1992 (Parts 1 to 4) shall have a rating of efflorescence not more than `slight'.
73.3.7 Warpage: The bricks when tested in accordance with the procedure laid down in IS: 3495-
1992 (Parts 1 to 4) the average warpage shall not exceed 3%.
7.3.4 Mortar: Mortar shall be as specified and confirm to accepted standards, lime mortar shall not
be used where steel reinforcement is provided in brick work. Strength of mortar should match with
the strength of brick work required.
73.5 Preparatory work: Soaking of Bricks:
Bricks shall be soaked in water before use for a period for the water to just penetrate the whole
depth of the bricks. Alternatively bricks may be adequately soaked in stacks by profusely spraying
with clean water at regular intervals for a period not less than six hours. The bricks required for
masonry work using mud mortar shall not be soaked. When the bricks are soaked they shall be
removed from the tank sufficiently early so that at the time of laying they are skin-dry. Such soaked
bricks shall be stacked on a clean place where they are not again spoiled by dirt earth.
Note I: The period of soaking may be easily found at site by a field test in which the bricks are
soaked in water for different periods and then broken to find the extent of water penetration.
The least period that corresponds to complete soaking will be the one to be allowed for in
construction work.
Note II: If the bricks are soaked for the required time in water that is frequently changed the
soluble salt in the bricks will be leached out, and subsequently efflorescence will be reduced.
7.3.6 Laying:
7.3.6.1 Bricks shall be laid in English Bond (see Drgs. attached) unless otherwise specified. For
brick work in half brick wall, bricks shall be laid in stretcher bond. Half or cut bricks shall not
be used except as closer where necessary to complete the bond. Closers in such cases, shall be
cut to the required size and used near the ends of the wall. Header bond shall be used preferably
in all courses in curved plan for ensuring better alignment.
Note: Header bond shall also be used in foundation footing sunless thickness of walls (width
of footing) makes the use of headers impracticable. Where thickness of footing is uniform for
a number of courses, the top course of footing shall be headers.
7.3.6.2 All loose materials, dirt and set lumps of mortar which may be lying over the surface
on which brick work is to be freshly started, shall be removed with a wire brush

and surface wetted. Bricks shall be laid on a full bed of mortar, when laying, each brick
shall, be properly bedded and set in position by gently pressing with the handle of a trowel.
Its inside face shall be buttered with mortar be fore the next brick is laid and pressed
against it. Joints shall be fully filled and packed with mortar such that no hollow space are
left inside the joints.
7.3.6.3 The walls shall be taken up truly in plumb or true to the required batter where
specified. All courses shall be laid truly horizontal and all vertical joints shall be truly
vertical. Vertical joints in the alternate cou rse shall come directly one over the other.
Quoin, Jamb sand other angles shall be properly plumbed as the work proceeds. Care shall
be taken to keep the perpends properly aligned within following maximum permissible
tolerances:
(a) Deviation from vertical with in a storey shall not exceed 6 mm per 3 m height.
(b) Deviation in verticality in total height of any wall of building more than one storey
in height shall not exceed 12.5 mm.
(c) Deviation from position show non plan of any brick work shall not exceed 12.5
mm.
(d) Relative displacement between load bearing wall in adjacent storeys intended to be
vertical alignments shall not exceed 6 mm.
(e) A set of tools comprising of wooden straight edge, masonic spirit levels, square, 1
metre rule line and plumb shall be kept on the site of work for every 3 masons for
proper check during the progress of work.
7.3.6.4 All quoins shall be accurately constructed and the height of brick courses shall be
kept uniform. This will be checked using graduated wooden straight edge or storey rod
indicating height of each course including thickness of joints. The position of damp proof
course, window sills, bottom of lintels, top of the wall etc. along the height of the wall
shall be marked on the graduated straight edge or storey rod. Acute and o btuse quoins
shall be bonded, where practicable in the same way as square quoins. Obtuse quoins shall
be formed with squint showing three quarters brick on one face and quarter brick on the
other.
7.3.6.5 The brick work shall be built in uniform layers. No part of the wall during its
construction shall rise more than one metre above the general construction level. Parts of
wall left at different levels shall be raked back at an angle of 45 degrees or less with the
horizontal. Toothing shall not be permitted as an alternative to raking back. For half brick
partition to be keyed in to main walls, indents shall be left in the main walls.
7.3.6.6 All pipe fittings and specials, spouts, hold fasts and other fixtures which are
required to be built into the walls shall be embedded, as specified, in their correct position
as the work proceeds unless otherwise directed by the Engineer -in-Charge.
7.3.6.7 Top courses of all plinths, parapets, steps and top of walls below floor and roof
slabs shall be laid with brick on edge, unless specified otherwise. Brick on edge laid in the
top courses at corner of walls shall be properly radiated and keyed into position to form
cut (maru) corners as shown in Fig. attached. Where bricks can not be cut to the required
shape to form cut (maru) corners, cement concrete 1:2:4 (1 cement : 2 coarses and : 4 graded
stone aggregate 20 mm nominal size) equal to thickness of course shall be provided in lieu
of cut bricks.
7.3.6.8 Bricks shall be laid with frog (where provided) up. However, when top course is
exposed, bricks shall be laid with frog down. For the bricks to be laid with frog down, the frog
shall be filled with mortar before placing the brick in position.
7.3.6.9 In case of walls one brick thick and under, one face shall be kept even and in proper
plane, while the other face may be slightly rough. In case of walls more than one brick thick,
both the faces shall be kept even and in proper plane.
7.3.6.10 To facilitate taking service lines later without excessive cutting of completed work,
sleeves (to be paid separately) shall be provided, where specified, while raising the brick
work. Such sleeves in external walls shall be sloped down outward so as to avoid passage of
water inside.
7.3.6.11 Top of the brick work in coping and sills in external walls shall be slightly tilted.
Where brick coping and sills are projecting beyond the face of the wall, drip course/ throating
(to be paid separately) shall be provided where indicated.
7.3.6.12 Care shall be taken during construction that edges of jambs, sills and projections
are not damage dincase of rain. New built work shall be covered with gunny bags or tar
paulin so as top revent them or tar from being washed away. Damage, if any, shall be made
good to the satisfaction of the Engineer-in-Charge.
7.3.6.13 Vertical reinforcement in the form of bars (MS orhigh strength deformed bars or
thermo-mechanically treated bars as per direction of Engineer-in-Charge), considered
necessary at the corners and junction of walls and jamb opening doors, windows etc. shall
be encased with cement mortar not leaner than 1:4 (1 cement: 4 coarse sand), or cement
concrete mix as specified. The reinforcement shall be suitably tied, properly embedded in the
foundation and at roof level. The dia. of bars shall not be less than 8 mm and concrete grade
shall be minimum 1:3:6 (1 cement: 3 coarses and : 6 graded stone aggregate 20 mm nominal
size).
7.3.6.14 In retaining walls and the like, where water is likely to accumulate, weep holes, 100
mm square/ round shall be provided at 1.5 m vertically and horizontally, duly staggered in
courses, unless other wise specified. The lowest weep hole shall be at about 30 cm above the
ground level. All weep holes shall be surrounded by a specified inverted filter and shall have
sufficient fall (1:100) to drain out (to the outer side of the retaining wall) the water quickly.
Note: Work of providing inverted filter (finer to larger aggregate towards the inner end of the pipe/
square) will be payable extra.
7.3.6.15 Work of cutting chases, wherever required to be made in the walls for housing G.I. pipe, CI
pipe or any other fixtures shall be carried out in various locations as per guidelines given below:
(a) Cutting of chases in one brick thick and above load bearing walls :
(i) As far as possible services should be planned with the help of vertical chases.
Horizontal chases should be avoided.
(ii) The depths of vertical chases and horizontal chases shall not exceed one- third and one-
sixth of the thickness of the masonry respectively.
(iii) When narrow stretches of masonry (or short length of walls) such as between doors and
windows, can not be avoided they should not be pierced with openings for soil pipes or waste

pipes or timber joints, etc. Where there is a possibility of load concentration such narrow lengths
of walls shall be checked for stresses and high strength bricks in mortar or concrete walls
provided, if required.
(iv) Horizontal chases when unavoidable should be located in the upper or lower one-third of height
of storey and not more than three chases should be permitted in any stretch of a wall. No
continuous horizontal chase shall exceed one metre in length. Where unavoidable, stresses in the
affected area should be checked and kept within the permissible limits.
(v) Vertical chases should not be closer than 2 m in any stretch of a wall. These shall be kept away
from bearings of beams and lintels. If unavoidable, stresses in the affected area should be
checked and kept within permissible limits.
(vi) Masonry directly above a recess, if wider than 30 cm horizontal dimension) should be supported
on lintel. Holes in masonry may be provided up to 30 cm width and 30 cm height without any
lintel. In the case of circular holes in the masonry, no lintel need be provided for holes up to 40
cm in diameter.
(b) Cutting of chases in half brick load bearing walls.
No chase shall be permitted in half brick load bearing walls and as such no recessed conduits and
concealed pipes shall be provided with half brick thick load bearing walls.
(c) Cutting of chases in half brick non-load bearing wall:
Services should be planned with the help of vertical chases. Horizontal chase should be provided
only when unavoidable.
7.4 Joints :
7.4.1 Thickness of Joints: The thickness of all types of joints including brick wall joints and cross
joints shall be such that four course and three joints taken consecutively shall measure as follow:
In case of modular bricks conforming to IS 1077-1976 specification for common burnt clay buildings
bricks, equal to 39 cm.
a) In case of non-modular bricks, it shall be equal to 31 cm.
Note: Specified thickness of joints shall be of 1cm. Deviation from the specified thickness of all
joints shall not exceed one-fifth of specified thickness.
7.4.2 Finishing of Joints: The face of brick work may be finished flush or by pointing. In flush
finishing either the face joints of the mortar shall be worked out while still green to give a finished
surface flush with the face of the brick work or the joints shall be squarely raked out to a depth of 1 cm
while the mortar is still green for subsequent plastering. 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. In
pointing, the joints shall be squarely raked out to a depth of 1 cm while the mortar is still green and
raked joints shall be brushed to remove dust and loose particles and well wetted and shall be later
refilled with mortar to give ruled finish. Some such finishes are flush, weathered, ruled, etc.
7.4.3 Curing : The brick work shall be constantly kept moiston all faces for a minimum period of
seven days. Brick work done during the day shall be suitably marked indicating the date on which the
work is done so as to keep a watch on the curing period.
7.5 Scaffolding: Single scaffolding shall not be used on important works, since subsequent filling up
of the putlog holes and rendering of their surface would give an unsightly appearance. Another
disadvantage with single scaffolding is that the workmen opt to support them on window and similar
openings, thereby spoiling frames and shutters.

7.5.1 Where single scaffolding is adopted, the placing of the poles, which are to rest on the brick
work under construction, shall be so adjusted to affect only one of the headers at the point of support
at various courses.
7.5.2 Scaffolding shall be designed and should conform to IS : 3696-1987. Scaffolding shall be
strong to withstand all dead, live and impact loads which are likely to come on them. Scaffolding
shall be provided to allow easy approach to every part of the work.
7.5.3 Scaffolding for exposed bricks work or tile work shall be double scaffolding, having two sets
of vertical supports. For all other brick works in buildings, single scaffolding may be permitted. For
such scaffolding, holes for scaffolding shall not be allowed in pillars/columns less than 1 m width,
holes also shall not be permitted immediately near skew backs of arches. The holes left in the masonry
works shall be filled and made good before plastering.
7.5.4 Where the brick work or tile work is to be exposed and not to be finished with plastering etc.
double scaffolding having two in dependent supports, clear of the work, shall be provided.
7.6 Honey Comb Brick Work:
When brick work in honey comb is specified it shall be of specified class of brick and mortar,
thickness and design. All joints and edges shall be struck flush to give an even surface. The bearing
shall not be less than 4 cm in any case. The mortar in the joint shall be struck flush as the work
proceeds. The thickness of the brick honey comb work shall be half-brick only, unless otherwise
specified. Openings shall be equal and alternate with half brick laid with a bearing of 2 cm on either
side.
7.6.1 Half Brick Work:
Brick work in half brick walls shall be done in the same manner as described above except that the
bricks shall be laid in stretcher bond. When the half brick work is to be reinforced, 2 Nos. M.S. bars
of 6 mm dia. shall be embedded in every third course or as given in the item (the dia. of bars shall not
exceed 8 mm). These shall be securely anchored at their end where the partitions end. The free ends
of the reinforcement shall be keyed into the mortar of the main brick work to which the half brick
work is joined. The mortar used for reinforced brick work shall be rich dense cement mortar of mix
1:4. Lime mortar shall not be used. Overlaps in reinforcement, if any, shall not be less than 30 cm.
The mortar interposed between the reinforcement bars and the brick shall not be less than 5 mm. The
mortar covering in the direction of joints shall not be less than 15 mm.
7.6.2 Brick Tile Work: The work shall be done in the same manner as described in 7.3.6 except that
brick tile shall be used instead of bricks. The measurement and rate shall be same as specified under
7.7 and 7.8 respectively.
7.7 Mode of Measurement:
7.7.1 Brick work shall be measured in cubic metre unless otherwise specified. Any extra work over
the specified dimensions shall be ignored. Dimensions shall be measured correct to the nearest 0.01
m i.e. 1 cm. Areas shall be calculated to the nearest 0.01 sq m and the cubic contents shall be worked
out to the nearest 0.01 cum.
7.7.2 Brick work shall be measured separately in the following stages:
(a) From foundation to floor one level (Plinth level)
(b) Plinth (floor one) level to floor two level

(c) Between two specified floor levels above floor two level
Note: (i) Brick work in parapet walls, mumty, lift machine room and water tanks constructed on the
roof up to 1.2 m height above roof shall be measured together with the corresponding work of the floor
next below.
a) Brick work of one brick thickness or more, generally shall be measured in cubic metre.
b) Walls of half brick thickness and less shall be measured in square metre stating the thickness.The
length and height of the wall shall be measured correct to a cm. The area shall be calculated in
sqm. Where half brick wall is joined to the main walls of one brick or greater thickness and
measurements for half brick wall shall be taken for its clear length from the face of the thicker
wall.
c) Bricks walls beyond half brick thickness ,upto and including three bricks in thickness shall be
measured in multiples of half brick thickness which shall be deemed to be inclusive of the
mortar joints. Where fraction of half brick occurs due to architectural or other reasons the
measurements shall be taken as follows.
i) up to 1/4' Brick- actual measurement, and
ii) exceeding 1/4th. Brick-full half brick (10 cm).
d) For walling which is more than three brick in thickness the actual thickness of wall shall be
measured to the nearest one cm.
e) Brick work circular in plan to a mean radius not exceeding 6 m shall be measured separately and
shall include all cutting and waste. Brick work curved on plan to a mean radius exceeding 6 m
shall be included with the general brick work and measured net.
O Honey comb brick work walling shall be measured is square metre stating the thickness of wall
and pattern of honey combing. The honey comb openings shall not be deducted.
g) Square or rectangular pillars shall be measured separately in cubic metre in multiple of half
brick.
h) Circular pillars shall be measured separately in cubic metre as per actual dimensions.
i) String courses, projecting pilasters, aprons, sills and other projections shall be fully described
and measured separately in running metre stating dimensions of each projection.
j) Pillars other than rectangular and square shall be measured separately and grouped as follows.
Polygonal and circular pillars, to be measured net only and shall be inclusive of cutting and
wastage.
k) Fire places, chimneys etc.: Brick work in chimney breasts, chimney stacks, smoke or air flues
not exceeding 0.25 sqm in sectional area shall be measured as solid and no extra measurement
shall be made for pargetting and coring such flues. Where flues exceed 0.25 sqm.in sectional area
deduction shall be made for the same and pargetting and coring flues given in square metre.
Apertures for fire places shall not be deducted and extra labour shall not be measured for splaying
of jambs and throating.
1) Brick work in independent chimney shafts: Brick work in independent chimney shafts (as for large
steam boilers) shall be measured net and kept separate under two categories.
Square or rectangular on plan, and Curved on plan to any radius the height of the chimney
from the ground level shall be stated.

m) Brick work curved onplan shall be measured like the brick work in straight walls and shall
include all cutting and wastage of bricks, tapered vertical joints and use of extra mortar, if any.
Brick work curved on plan to a mean radius not exceeding six metre shall be measured
separately and extra shall be payable over the rates for brick work in straight walls. Nothing
extra shall be payable if the mean radius of the brick work curved in plan exceeds six metre.
n) Tapered walls shall be measured net as walls and extra payment shall be allowed for making
tapered surface for brick work in walls.
o) Tile brick work shall be measured separately and the rules for measuring ordinary bricks shall
be followed.
p) No deductions or additions shall be done and no extra payment made for the following:
i) Ends of dissimilar materials (i.e. joists, beams, posts, girders, rafters, purlins, trusses
upto 0.1 sqm in section.
ii) Opening upto 0.1 sqm. in section (see note).
iii) Wall plates, bed plates, and bearing of slabs, chajjas and the like, where thickness does
not exceed 10cm and bearing does not extend over the full thickness of wall;
iv) Cement concrete blocks as for hold fast sand holding down bolts;
v) Iron fixtures, such as wall ties, pipes upto 300 mm diameter and hold fasts for doors and
windows; and
vi) Chases of section not exceeding 50 cm in girth.
vii) Bearing portion of drip course, bearing of moulding and cornice, chajjas, sills, shelves
and the like but the bearing shall not be measured in the respective items. Note: (i)
Brick work in parapet walls, mumty, lift machine room and water tanks constructed on
the roof up to 1.2 m height above roof shall be measured together with the
corresponding work of the floor next below.
(ii) In calculating area of an opening, any separate lintel or sills shall be included with
the size of the opening but end portions of lintel shall be excluded. Extra width of rebated
reveals, if any, shall also be excluded.
7.8 Rate : The rate shall include the cost of materials and labour required for Al the operations
described above except the vertical reinforcement and its encasement in cement mortar or cement
concrete the rate shall also include the following:
a) Raking out joints or finishing joints flush as the work proceeds;
b) Preparing tops of existing walls for raising further new brick work.
c) Rough cutting and waste for forming gables, splay at eaves and the like.
d) Leaving holes for pipes upto 150 mm dia. and encasing hold fasts etc.
e) Rough cutting and waste for brick work curved in plan and for backing to stone or other
types of facing.
I) Embedding in ends of beams, joists, slabs, lintels, sills, trusses etc.
g) Bedding wall plates, lintels, sills, roof tiles, corrugated sheets, etc. in or on walls if not
covered in respective items and
h) Leaving chases of section not exceeding 50 cm in girth or 350 sqcm in cross-section.
i) Brick on edge courses, cut brick corners splays reveals, cavity walls, brick works curved
on plan to a mean radius exceeding six metres.
7.9 Protection, Washing, Mortar etc.:
The protection and washing of brick and brick work not to be plastered and mortar work etc. done in
facing type brick, shall be as per requirements laid down for stone masonry under general
specifications for the same.

7.10 Jointing Old Brick Work With New Brick Work :
7.10.1 In case the height of the bricks of old as well as new work is same, the old work shall be
toothed to the full width of the new wall and to the depth of a quarter of brick in alternate courses. In
case the height of the bricks is unequal, then the height of each course of new work shall be made
equal to the height of the old work by adjusting thickness of horizontal mortar joints in the new wall.
Where necessary, adjustment shall be made equal to thickness of old wall by adjusting the thickness
of vertical joints.
7.10.2 For joining new cross wall to old mainwalls, a number of rectangular recesses of width equal
to the thickness of cross wall, three courses in height and half a brick in depth shall be cut in the
main walls. A space of the three courses shall be left between two consecutive recesses. The new
cross wall shall be bonded in to the recesses to avoid any settlement.
7103 Joining of old brick work with the new brick work shall be done in such a way that there shall
not be any hump or projection at the joint.
7.10.4 Measurement : The height and thickness of vertical face in contact with new work shall be
measured to the nearest 0.01 mand the area shall be calculated to the nearest 0.01 sqm.
7.10.5 Rate : The rate includes the cost of labour and material involved in all the operations described
above.
7.11 Moulding and Cornices :
7.11.1 The specifications described under 7.3 shall apply in so far these are applicable. Mouldings and
cornices shall be made with bricks as specified for brick work. The bricks shall be cut and dressed
to the required shape as shown in the architectural drawings.
7.11.2 Cornices shall not ordinarily project by more than 15 cm to 20 cm and this projection shall be
obtained by projecting each brick course by more than one fourth of the length. For cornices
projecting more than 20 cm and requiring more than quarter bricks projection, metal cramps shall be
used and paid for separately.
7.11.3 Corbelling shall be brought roughly to shape by plastering with the specified mortar. When the
mortar is still green, the mouldings shall be finished straight and true
with the help of metal templates.
7.11.4 Curing and Protection:
The mouldings and cornices shall be cured for atleast seven days. These
shall be protected from the effects of sun and rain by suitable covering
and also from damage during the execution of the work.
For the purpose of measurements, the sectional periphery of mouldings
and cornices (excluding the portion in contact with wall) shall be
measured in centimetre and length in metre (fig.) The girth and length
shall be measured correct to a cm. No deduction shall be made from the
masonry of wall for the bearing of the moulding and cornices.
Note: 1. The sectional periphery curve A B C D E F. 2. Length FA
shall not be measured.
7.11.6 Rate : The rate includes the cost of materials and labour
involved in all the operations described above.

7.12 Brick Work Under Water and Foul Conditions:
Brick Work under following conditions :
(i) Work in or under water / or liquid mud;
(ii) Work in or under foul positions
Shall be measured separately for payment of extra rate over and above the quantity measured and
paid under para 7.7.
7.13 Exposed Brick Work:
7.13.1 Facing Bricks:
The facing bricks made from suitable soils shall be free from cracks, flaws, nodules of freelime
warpage and organic matter. These shall be thoroughly burnt and shall have plane rectangular faces
with parallel sides and sharp straight right angled edges. Facing bricks shall have uniform colour
and even texture. Unless otherwise specified, facing bricks shall be machine moulded only. As far as
possible, total requirement of facing bricks for a work shall be arranged from the same kiln. Bricks
with chipped edges and broken corners shall not be used.
7.13.2 Dimensions and Tolerances
The standard sizes of machine moulded facing bricks shall be as specified in 7.3
7.13.2.1 The permissible tolerances shall be as under :
Dimension Tolerance (For Machine moulded bricks)
nun nun
Length 190 or 225 ±3
Width 90 or 111 + 1.5
Thickness 40 or 44 + 1.5
Note: Tolerance and Dimensions for selected hand moulded bricks ± 4 mm in length and ±3 mm in
width and thickness).
7.13.2.2 Sampling : As per Para 7.3.
7.13.2.3 Physical Requirements :
Facing bricks shall be of class designation 75 unless otherwise specified. Average compressive
strength shall not be less than 7.5 N/= 2, water absorption shall not exceed 20 per cent by weight and
efflorescence rating shall be Al when tested in accordance with the procedure laid down and
tolerance in dimensions shall be checked as per the procedure laid down in Appendix B. Mortar,
Soaking of Bricks and laying shall be as specified in Para 7.3.
7.13.3.3 Joints in the exposed brick work shall be truly horizontal and vertical and kept uniform
with the help of wooden or steels trips. The thickness of joints shall be as per 7.3.
7.13.3.4 Curing and scaf folding shall be as specified in clauses above..
7.13.3.5 Measurements :
Exposed brick work in face using machine moulded bricks and selected hand moulded bricks shall
be measured separately and the measurement shall be as specified in 7.7.
7.13.3.6 Rate:
The rates shall be as specified in 7.8 and shall also include the following:

(a) Labour for selecting bricks and wastage of bricks where use of selected hand moulded brick
is specified.
(b) Leaving uniform horizontal and vertical grooves of specified depth and providing joints of
required thickness using wooden or steel strips as the work proceeds.
7.14 Brick Arches:
7.14.1 Scope:
This specification lays down requirements for materials, joints, rings, bond, cantering, laying and
removal of cantering and mode of measurement of brick arches.The detailed specifications for brick
work mentioned in 7.3 shall apply, in so far as these are applicable. Arch work shall include masonry
for both gauged as well as plain arches. In gauged arches, cut or moulded bricks shall be used. In plain
arches, uncut bricks shall be used. Brick forming skew-backs shall be dressed or cut so as to give
proper radial bearing to the end voussoirs. Defects in dressing of bricks shall not be covered by extra
vagant use of mortar, nor shall the use of chips or bats etc. be permitted. The bricks of the spandrel
wall at their junctions with the extrudes of the arch shall be cut to fit the curvature of the arch.
7.14.2 Terminology:
7.14.2.1 Rough Plain Arch:- The arch made with the ordinary rectangular bricks without cutting them
to be wedge shape is known as rough or Plain Arch.
7.14.2.2 Gauged Arch:- The Arch made with the specially moulded or the ordinary bricks cut and
rubbed true to the wedge shape is known as gauged Arch.
7.14.2.3 Thickness of Joints: The thickness of joints, for rough arches shall not be more than 10
mm towards the intrados end and not more than 20 mm at the extrados end of the joint in any ring.The
thickness of the joints shall be uniform and defects in dressing up bricks shall not be covered by
extra use of mortar, nor use of chips be permitted.
7.14.3 Circular Arch:
i) These shall be either (a) plain arches, and shall be built in half brick concentric rings with break
joints, or (b) gauged arches built with bricks cut or moulded to proper shape. The arch work shall
be carried up from both ends simultaneously and keyed in the centre. The bricks shall be flush
with mortar and well pressed into their positions so as to squeeze out a part of their mortar and
leave the joints thin and compact. All joints shall be full of mortar and thickness of joints shall not
be less than 5 mm nor more than 15 mm.
ii) After the arch is completed, the haunches shall be loaded by filling up the spandrels upto the
crown level of the arch. Care shall be taken to load the haunches on two sides of the spandrels.
iii) When the arch face is to be pointed (and not plastered), the face bricks shall be cut to proper
shape or moulded, so as to have the joints not more than 5 mm thick. These shall be laid with
radial joints to the full depth of the arch. The voussoirs shall break joints to the full depth of the
arch.
7.14.4 Flat Arches:
These shall be gauged arches of brick cut or moulded to proper shape. The extrados shall be kept
horizontal and the intrados shall be given slight camber of 1 in 100 of the span. The centre of the
arch from which joints shall radiate, shall be determined by the point of the inter-section of the two

lines drawn from the ends of the arch at the springing level and at 60° to horizontal.
In flat arches, bricks shall be laid with radial joints to the full depth of arch and voussoirs braking joints
with each other. The arch work shall be carried up from both ends simultaneously and keyed in the
centre. The thickness of the joints shall not exceed 5 mm. Flat arches may be used for the sake of
appearance but for purpose of carrying loads of the wall above, these shall be used in conjunction with
relieving arches, lintels placed below.
7.14.5 Keys:
All arches of 2 m span and above shall be provided with keys. For spans 2 m and upto 4 m there shall
be one key at the crown and for spans exceeding 4 m additional keys shall be proved so that the distance
between the keys is not more than 2 m along the intrados. The keys may be of stone, concrete or brick
work in cement.
7.14.6 Centring and Shuttering:
7.14.6.1 The centring and shuttering shall be of wrought wood and made on pillars built up from the
ground or on any other structure to be approved by the Engineer-in-charge before the arch work is
started.It shall be strong enough to bear the load of the masonry and workman, without undergoing any
appreciable deflection. The top surface of the centring shall be smooth and to the correct curvature and
shall be covered with close boarding or any other material to prevent the mortar running through the
joints. The shuttering shall be tightened with hard wood wedges & sand boxes, so that the same could
be eased without jerks being transmitted to the arch. The sequence of easing the shuttering shall be got
approved from the Engineer-in-Charge. The shuttering shall be struck within 48 hours of the
completion of the arch but not before 24 hours. This shall be done after the spandrel has been filled in
and the arch loaded.
7.14.6.2 Templates shall be provided by the contractor at his own expense for checking the curvature.
The courses of brick work shall be marked out on the surface of centering. It should be checked up
before erection of centering that all the piers and abutments are at the same level and their axes and
parallel, also the vertical line passing through the centre of the span passes through the middle of the
key brick or crown.
7.14.7 Laying:
(i) The skew-backs shall be formed of bricks correctly cut to radiate truly from the centre of
curvature and shall not be packed with mortar or chips to affect this.
(ii)All arches shall be built up evenly from abutments and or piers or columns. In all cases whether in
gauged arches or rough arches care must be taken that the centre line of the brick face is radially placed.
The arch rings shall in all cases be bonded together by special keys which may be of stone, concrete or
brick work in cement. All the arch rings shall be true to the curvature and no damaged or broken brick
shall be used in any part of the work.
7.14.8 Easing and Removal of Centring:
(i) The centering shall be eased the days after the arch masonry has been completed unless otherwise
ordered by the Engineer-in-charge. This shall be done after the spandrel has been filled in and the
arches loaded.The design of centring must permit such easing being effected. The centring should not
be removed less than one week after the completion of the arch and then too with the permission of the
Engineer-in-charge.

(i) Brick work in arches shall be measured net in cubic metres the length being measured on the
centre line of the total arch ring or the mean of the extrados and intrados of the arch, correct to 1 cm.
The bread thin the direction of the thickness of wall shall be measured as specified. The thickness of
the arch shall be measured in multiples of the half brick.
(ii) All work upto 6 m spans shall include centring and for spans exceeding 6 m centering shall be
measured separately (span refer to clear span).
(iii)Rough arches and gauged arches shall be measured separately the type and class of brick and
type of mortar specified.
7.15 Cavity Walls:
It is a wall comprising of two leaves, each leaf being built of masonry units and separated by a cavity
so as to provide an air space within the wall and tied together with metal ties or bonding units to ensure
that two leaves act as one structural unit. The width of the cavity shall not be less than 50 mm and not
more than 115 mm. Each leaf of the cavity wall shall not be less than 75 mm. The space between the
leaves being either left as cavity or filled with non-load bearing insulating and water proofing
materials.
7.15.1.1 Scope:
This specification covers materials, construction and mode of measurement of cavity walls.
7.15.2 Materials:
7.15.2.1 Bricks: The bricks shall confirm to the specification under Building material (Chapter-3)
7.15.2.2 Mortars:- The mortars shall be as specified in the schedule of quantities and conform to
the specifications in Building material (Chapter-3).
7.15.2.3 Metal Wall ties:- The wall ties shall be made of galvanized iron, wrought iron, gun metal,
brass, copper, stainless steel, or any such corrosion resistant metal, made of flats 20x5 mm cranked or
twisted at their midpoint with ends split and fish tailed. The ties shall be built in to horizontal bed joints
during erection, placed sloping towards the exterior side top revent water from flowing along it from
outer to inner leaf side (For details refer Fig. 7).
a) The M.S. flat 20 x 5 mm shall be made from structural steel of corrosion resistant quality,
wrought iron, gun metal, brass or stainless steel etc.
b) The G.I. wire shall conform to I.S. 280. M.S. flat for ties shall be 20 x 2 x 0.3cm. cut and bent
to shape. The G.I. wire tie shall be of No. 9 wire and of the size and shape of precast R.C.C.
units.
7.15.2.4 Bonding Units: These shall be preferably precast R.C.C. units.
Length of the bonding units will be sum of thickness of both leaves plus width of cavity if the leaves
are 75 mm or 115 mm thick. If the leaves are more than 115 mm thick, then the length of a unit will
be 2 x 115 + width of cavity. Precast R.C.C. units shall be provided with 2 No., 6 mm mild steel
reinforcement bars tied with 2 No. 3 mm dia. (M.S. wire of hard drawn wire) cross bars placed in
the centre of units.
Cement concrete used in the bonding units shall not be leaner than 1:3:6 (1 cement: 3 coarse sand: 6
graded stone aggregate 20 mm nominal size).

7.15.2.5 Spacing:- Metal ties/bonding units shall be spaced not more than 90 cm apart horizontally
and 45 cm vertically and staggered in each course. Additional ties shall be used near openings. A
minimum of 5 ties per sqm.of surface area of the wall shall be provided. See figure in drawings.
7.15.2.6 Section of Cavity Wall :
7.15.2.7 Cavity shall not be less than 5 cm and not more than 7.5 cm.
7.15.2.8 Thickness of leaves: The thickness of leaves (outer and inner) shall be as specified but not
less than 75 mm (normally 10 cm). The thicker leaf shall be arranged on the inside.
7.15.2.9 Construction :Unless otherwise specified the inner & outer leaf walls shall be brought up in
brick of class designation 100 as per specification for brick work under chapter 3 (Building Material).
7.15.2.10 In case the leaves are constructed in any other form of masonry, the same shall be as per
specification under chapter of masonry the two separate walls shall either be constructed right from
the top of the base concrete or from 20 to 30 cm. below the level of D.P.C. In the first case the gap
shall be filled with C.C. 1:3:6 and top sloped towards outer walls. In the second case, in base of the
cavity a triangular fillet in cement mortar 1:4 of size 2 cm thick and equal to the width of cavity shall
be provided.
7.15.2.11 Weep holes shall be provided to drain off any water collected inside the cavity. These holes
shall be in the vertical joints and spaced at 3 to 5 bricks or 60 to 100 cm apart.
7.15.2.12 The wall ties as specified in the schedule of quantities shall be embedded with a slight fall
towards the external leaf and spaced as described above.
7.15.2.12 At all changes and else-where wherever, convenient, bricks shall be left out at the base of
the cavity and the dropped mortar removed at the end of each day's work.
7.15.2.13 When work has risen above the level of 1St row of wall ties, battens shall be placed across the
ties for collecting mortar droppings, the batons being raised as soon as the level of next row of ties is
reached. The batten shall be 25 mm thick and of a width 12 mm less than the thickness of cavity.
Any mortar which may unavoidably fall on the wall ties shall also be removed dally and temporary
openings shall be provided to permit the dally removal of mortar droppings from the bottom of the
cavity.
7.15.2.14 Fair bricks shall be provided above the ground floor level and below the eaves level of the
roof to the extent of 50 sqcm areas of bricks to every 20 square metre area of the wall spaced
approximately at 1 metre apart.
7.15.2.15 Restrictions :- Cavity walls shall not normally be built more than 7.5 metre in height and 9
metre in length. Where large lengths and heights are desired, the wall shall be divided into panels with
strengthening measures such as pillars etc. Cavity shall be covered at the top with at least two courses
of masonry unit and/or a coping over it.
Adoption of cavity walls is not recommended when heavy concentrated load from beam etc. are to be
supported by walls.
7.15.2.16 Treatment where the two leaves come into contact:
The two leaves come in contact:
a) At door, window or any other such openings. They shall be separated by a damp -proof course as
specified in the schedule or quantities and shall be done according to the specification for damp
proof courses.

b) At the head of the cavity D.P.C. shall be provided as per specifications.
7.15.2.17 - Mode of Measurement and Rate:
a) Cavity walls shall be measured net in cubic metres excluding the volume occupied by the
cavity and bricks similarly as for stone masonry or brick work.
b) The forming of cavity shall be given in square metres stating the width of cavity and shall
include wall ties the material of ties being stated.
c) The measurements for cavity shall be taken along the plane at the centre of the cavity,
deduction being made for all openings and solid portions of wall.
d) Extra labour & wastage of material for closing of cavities at jambs, shall be measured
separately in running metres.
e) The item includes use of course for keeping the cavity clear and forming the requisite weep
and vent holes.
0 Damp proof course shall be measured and paid for separately.
7.16 Reinforced Brick Work:
7.16.1 Scope:
This specification lays down requirements for materials, laying and mode of measurement of
reinforced brick work.
7.16.2 Materials:
7.16.2.1 Bricks: Bricks shall be class designation 100 bricks having compressive strength not less
than 140 kg/sq. cm and shall conform to specification under chapter 3 (Building Material).
7.16.2.2 Mortar: Cement mortar of proportion 1:4 or as specified in schedule of quantities shall be
used. Only that much quantity of water shall be mixed in the mortar which is required to give the
necessary workability in joints. In no case lime mortar shall be used.
7.16.3 Reinforcement: The reinforcement shall be of steel bars conforming to I.S. 432-1982. The steel
shall be of tested quality and obtained from an approved manufacturer. If the Engineer-incharge so
desires a test certificate for each batch of steel, should be obtained from manufactures. For RB work
in walling mild steel flats or hoop iron, expanded mesh, mild steel bars or fabric, not exceeding 8 mm.
thickness or diameter shall be used as shown in the drawings.
7.16.3.1 Fabrication of Reinforcement:
The steel bars shall be cut to the required sizes and bent cold as per bar bending schedule. Bars,
which have been bent wrongly, shall not be straightened and used without the permission of the
Engineer-in-charge, and heat shall not be used for bending any reinforcement.
7.16.4 Form Work : Same as specified under chapter of RCC work.
7.16.5 Laying :
Bricks shall be laid as shown on detailed drawings. The side joints shall not be less than 3.0 cm thick
and the bed joints not less than 5 cm. If two or more layers are laid, the vertical lines shall break
joints as far as possible. Bricks should be so arranged that there is no joint vertically above the edge
of supporting wall and parallel to it. The bricks near the edges should be half on the wall and half
projecting out. Mild steel bars shall be placed centrally in the joints as per drawing. The terracing
over RB roofing shall not be commenced before fortnight of removal of forms. In case of

RB walling the reinforcement shall be securely anchored at their ends into which the partitions
bond. The thickness of RB walling shall not be less than 10 cm.
7.16.6 Removal of Form Work:
Form work shall be removed in accordance to the specification laid for R.C.C.
7.16.7 Curing : Curing shall be done for at least seven days as per specifications on R.C.C.
a) R.B. work shall be measured separately from general brick work and shall be measured in
cubic metre. No deduction shall be allowed for the joints or reinforcement.
b) Unless otherwise specified steel shall be measured separately as specified under R.C.C.
Unless otherwise specified centring shall be measured separately.
7.17 Brick Edging : The edging shall be of bricks of class specified in the item. The specifications of
bricks shall be as described in 7.3. Trenches of required depth and width shall first be made along the
edge of the plinth protection to receive the bricks for edging. The bed of trenches shall be compacted
to a firm and even surface. The brick shall be laid true to line in cement mortar 1 : 4 (1 cement : 4
fine sand) with length parallel and butting the plinth protection. The top face of the brick edging
shall be in one level to conform to the finished level of the plinth protection adjacent to the edging.
After the concreting is done, no portion ofthe brick edging shall project above the adjacent concrete
surface. Cement mortar shall conform to the specification described in chapter 3.
7.17.1 Measurements : The brick edging shall be measured in running metre correct a cm. 7.17.2
Rate : Rate shall include the cost of materials and labour involved in all operations.
Appendix À'
SAMPLING AND TESTING OF COMMON BURNT CLAY BRICKS A-
1 Checking of Tolerances:
A-1.1 Twenty whole bricks shall be selected randomly. All the blisters, loose particles of clay and
small projections shall be removed. These shall then be arranged upon a level surface in contact
with each other and in a straight line.
The total length of the assembled bricks shall be measured with a steel tape or other suitable
inextensible measuring device sufficiently long to measure the whole row at one stretch. If for any
reason it is impracticable to measure the bricks in one row of 20 bricks, it may be divided into two
rows of 10 bricks each and shall be measured separately to the nearest millimetre. Both dimensions
shall be added.
Dimension (cm) Tolerance (for machine moulded bricks)(m)

Length 372 to 388 cm 380 ± 8 cm
Width 176 to 184 cm 180 ± 4 cm
Thickness 176 to 184 cm 180 ± 4 cm
(for 9 cm thick bricks)
76to84cm 80±4cm
(for 4 cm thick bricks)

A-2 Sampling and Criteria for Conformity:
A-2.1 The sample size for all the tests prescribed shall be as follows:
Brick Lot Size Sample
Class 100 For every 50,000 or P t h e r e of 20 Bricks
Class 75,50,35 For every 1 Lac or part there of 20 Bricks
A-2.2 The sampling shall be at and the samples shall be stored in a dry place until the tests
are done.
A-3 Tests
A-3.1 Compressive Strength :
Five bricks shall be tested. The average compressive strength shall be as per class designation. The
compressive strength of individual brick shall not less than 20 percent of the specified value.
A-3.1.1 The bricks shall be immersed in water for 24 h at 27°C ± 2°C. The surplus water shall be
allowed to drain. The frog of the bricks should be filled with 1:3 cement mortar, flush to the surface
and shall be cured under the jute bags for 24 h, the bricks shall then be immersed in water for 72 h.
The bricks after removal shall be wiped clean.
A-3.1.2 The brick shall be placed with flat faces horizontal with the frog with mortar upside. Loads
shall be applied at a uniform rate of 140 kgf/cm2 per minute, after placing a plywood sheet or similar
uniform surface on the upper side.
A-3.1.3 Average of five results of compressive strength shall be reported. The compressive strength
is load at failure of brick divided by surface area of brick expressed as kgf/cm2.
If any value exceeds the specified value, this may be taken into account in reporting the results.
A-4 Water Absorption:
A-4.1 Water absorption by brick shall not exceed 20 percent by weight.
A-4.2 Five bricks shall be tested for water absorption. The bricks shall be dried in an oven at 110°C
to 150°C till they attain constant weight. Then they shall be allowed to cool at room temperature. Oven
drying may take 48 h and cooling another 4 h on an average.
The cooled bricks shall be weighed, W1.
Then they shall be immersed in water at 27 ± 2°C for 24 h. After removal they shall be wiped clean
and shall be weighed again, W2.
A-4.3 The difference between the two weights as a percentage of the weight W1 shall be recorded
and the average of five bricks shall be reported as the moisture absorption.
A-5 Efflorescence:
A-5.1 Five bricks shall be tested for efflorescence. A shallow dish with distilled water may be
arranged. The bricks on end are immersed in the water in the dish to a height of 2.5 cm. The brick
should be allowed to absorb the whole water. Again pour some water and allow it to evaporate as
before. The brick shall be examined after the second evaporation.
A-5.2 Check for efflorescence, the efflorescence shall be `nil' to 'moderate'. For `nil' there is no
perceptible deposit of efflorescence. For `slight' there is no more than 10 percent of area of the brick
covered with a thin deposit of salts. For `moderate' a heavy deposit covering up to 50 percent of the
area of the brick surface but not accompanied by flaking.

APPENDIX `B'
TEST FOR DIMENSIONAL TOLERANCE
B-1.-Sampling: As per para 7.3.1.3 and 7.3.1.4.

B-2. Procedure- All the blisters, loose particles of clay and small projections shall be removed from
the surface of bricks. Each specimen of 20 bricks shall then be arranged upon a level surface
successively in contact with each other and in straight line. The over all length of the assembled
bricks (20 Nos) shall be measured with a steel tape sufficiently long to measure the whole row at
one stretch.
B-3. Tolerance- The actual dimensions of bricks when tested as described in-2 shall be with in the
following limits per 20 bricks.
Modular Bricks
Length 3720 to 3880 mm (3800 ± 80 mm)
Width 1760 to 1840 mm (1800 ± 40 mm)
Height 1760 to 1840 mm (1800 ± 40 mm) for 90 mm high brick
760 to 840 mm (800 ± 40 mm) for 40 mm high brick

Non-Modular Bricks
For class 10
Length (4520 to 4680) mm (4600 ± 80 mm)
Width (2240 to 2160) mm (2200 ± 40mm)
Height (1440 to 1360) mm (1400 ± 40mm) for 70 mm high bricks
(640 to 560) mm (600 ± 40 mm) for 30 mm high bricks
For other classes

Length (4320 to 4680) mm
Width (2130 to 2310) mm
Height (1340 to 1460) mm for 70 mm high bricks
(840 to 920) mm for 44 mm high bricks
B-4. Criteria for Conformity:
A lot shall be considered conforming to the requirements of dimensions and tolerances if all the
groups of bricks are tested to meet the specified requirements.

APPENDIX `C'
TEST FOR COMPRESSIVE STRENGTH
C-1. Specimen:
Five whole bricks shall be taken from the samples as specimens for this test. Length and width of
each specimen shall be measured correct to 1 mm.
C-2. Apparatus:
The apparatus consists of compression testing machine, the compression plate of which shall have a
ball seating in the form of portion of a sphere the centre of which shall coincide with the centre of the
plate.
C-3. Procedure:
(a) Pre-conditioning: The specimen shall be immersed in the water for 24 hour sat 250 to 290 C.
Any surplus moisture shall be allowed to drainatroomtemperature.Thefrogofthebricksshouldbe
filled flush with mortar 1:3 (1 cement : 3 clean coarses and of grade 3 mm and down) and shall
be kept under damp jute bags for 24 hours, after that these shall be immersed in clean water for
three days.
After removal from water, the bricks shall be wiped out of any traces of moisture.
(b) Actual Testing: Specimen shall be placed with flat faces horizontal and mortar filled face up
ward between three 3 ply plywood sheets each of thickness 3 mm and carefully centred between
plates of the testing machine. Plaster of Paris canal so be used in place of plywood sheets to
ensure a uniform surface.
Load shall be applied carefully axially at uniform rate of 14 N/mm2 per minute till the failure of
the specimen occurs.
C-4. Reporting the Test Results: The compressive strength of each specimen shall
be calculate din N/mm2 as under:
Maximum load at failure (in N) Area of Specimen (in sq mm)

Compressive Strength =
In case the compressive strength of any individual brick tested exceeds
the upper limit of the average compressive strength specified for the
corresponding class of brick, the same shall be limited to the upper limit of the class specified in
7.3.1.2 for the purpose of calculating the average compressive strength. Compressive strength of all
the individual bricks comprising the sample shall be averaged and reported.
C-5. Criteriafor Conformity
A lot shall be considered having satisfied the requirements of average compressive strength if the
average compressive strength specified in 7.3.1.2 for the corresponding class of brick tested is not
below the minimum average compressive strength specified for the corresponding class of bricks by
more than 20 percent.

APPENDIX `D'
TEST FOR WATER ABSORPTION
D-1. No. of Specimen:

Five whole bricks shall be taken from samples as specimen forth is test.
D-2. Apparatus:
A balance required for this test shall be sensitive to weigh 0.1 percent of the weight of the specimen.
D-3. Procedure:
(a) Pre-conditioning: The specimen shall be allowed to dry in a ventilated oven at a 110°C to 115°
C till it attains a substantially constant weight. If the specimen is known to be relatively dry, this
would be a ccomplished in 48 hours, if the specimen is wet, several additional hours may be required
to attain a constant weight. It shall be allowed to cool at room temperature. In a ventilated room,
properly separated bricks will require four hours for cooling, unless electric fan passes air over them
continuously in which case two hours may suffice.
The cooled specimen shall be weigh (W1) a warm specimen shall not be used for this purpose.
(b) Actual Testing: Specimen shall be completely dried before immersion in the water. It shall be
kept in clean water at a temperature of 27° C ± 2° C for 24 hours. Specimen shall be wiped out of the
traces of water with a damp cloth after removing from the water and then shall be weighed within
three minutes after removing from water (W2).
D-4. Reporting the Test Results:
The water absorption of each specimen shall be calculated as follows and the average of five tests
shall be reported.
Water Absorption = W2 -WI X 100
D-5. Criteria for Conformity:

A lot shall be considered having satisfied the requirements of water absorption if the average water
absorption is not more than 20% by weight.

APPENDIX È'
TEST FOR EFFLORESCENCE
E-1. No. of Specimen:
Five whole bricks shall be taken as specimen for this test.
E-2. Apparatus:
Apparatus required for this test shall be a shallow flat bottom dish containing distilled water.
E-3. Procedure (actual testing):
The brick shall be placed vertically in the dish with 2.5 cm immersed in the water. The room shall be
warm (18°C to 30°C) and well ventilated. The bricks should not be removed until it absorbs whole
water. When the whole water is absorbed and the brick appears to be dry, place a similar quantity of
water in that dish and allow it to evaporate as before. The brick shall be examined after the second
evaporation.
E-4. Reporting the Test Results:
The rating to efflorescence in ascending order shall be reported as `NIL', `SLIGHT', `MODERATE',
`HEAVY' or `SERIOUS' in accordance with the following:
(a) NIL: When there is no perceptible deposit of efflorescence.
(b) SLIGHT: When not more than 10 percent of the area of the brick is covered with a thin
deposit of salts.
(c) MODERATE: When there is heavier deposit and covering up to 50% of the area of the brick
surface but unaccompanied by powdering or flaking of the surface.
(d) HEAVY: When there is a heavy deposit of salts covering 50% or more of the brick surface
but unaccompanied by powdering or flaking of the surface.
(e) SERIOUS: When there is heavy deposit of salts, accompanied powdering and/or flaking of
the surface and tending to increase in the repeated wetting of the specimen.
E-5. Criteria for Conformity:
A lot be considered having satisfied the requirements of efflorescence if for 4 out of the specimen of
5 bricks, the rating of efflorescence is not beyond "Moderate".

CHAPTER No. 8
STONE WORK
CHAPTER No. 8 : STONE WORK
CONTENTS
8.1 Stone Masonry 3
8.2 Precast Concrete Stone Block Masonry 17
8.3 Hollow and Solid Concrete Block Masonry 22
8.4 Stone Sun Shed (Chhajja) 30
8.5 Shelves, Coping, Plain, Cornices, String Courses etc. 31
8.6 Stone Jali 31
8.7 Dry Stone Cladding 31
8.8 Structural Steel Frame Work for Dry Stone Cladding 32
8.9 Adjustable Stainless Steel Cramps 33
Appendix À' Measurement of Dimensions of Concrete Masonry Blocks 34
Appendix `B' Method for Determination of Block Density of 34
Concrete Masonry Blocks
Appendix `C' Method for Determination of Compressive Strength of 35
Appendix `D' Method for Determination of Absorption of 37
Appendix È' Method for Determination of Drying Shrinkage of 37
Appendix `F' Method for Determination of Moisture Movement 39
Illustrations on Stone Work 40
List of Bureau of Indian Standard Codes 52
Rajasthan PWD Building Specifications 2014 Chapter 8 : Stone Work Page 1 of 52


CHAPTER No. 8
STONE WORK
8.1 Stone Masonry:
8.1.1 Terminology For Stone Masonry:
a) Ashlar: Stone masonry using dressed square stone block of given dimensions have faces
perpendicular to each other and laid in courses.
b) Bed Joint : The joint where one stone presses on another, for example, a horizontal joint in a
wall or radiating joint between the voussoirs or arch. (see fig.l and 13)
c) Block :
(i) Hollow (Open and Closed Cavity) Block: A concrete masonry unit with any one of the
external dimension greater than the corresponding dimension of a brick and having one or
more large holes or cavities which either pass through the block (open cavity) or do
effectively pass through the block (closed cavity) and having the solid material between
50% and 75% of the total volume of the block calculated from the overall dimensions.
(ii)Solid Block: A concrete masonry unit with external dimensions greater than
corresponding dimension of a brick and having solid material not less than 75% of the
total volume of the block calculated from over all dimension.
d) Bond : An interlocking arrangement of structural unit in a wall to ensure stability.
e) Bond Stone (Through Stone) :Selected long stone used to hold a wall together transversely.
(see fig. 8).
t~ Corbel: Stone bonded well into the wall with part of it projecting out of the face of wall to form
a bearing surfaces.
g) Cornice : A horizontal moulded projection which crowns or finishes either a wall, any
horizontal division of wall, or any architectural feature.(see fig. 1C )
h) Cramp: A small piece of metal or the hardest or toughest stone procurable, sunk in mortises
and fixed across joints as additional ties. The ends of metal cramps are bent at right angles and
stone cramps are dovetailed. (see fig. 1 B)
i) Course : A layer of stones in wall including the bed mortar.
j) Dowels: Dowels are small sections of metal, stone or pebbles bedded with mortar in
corresponding mortise in bed or side joint or adjacent stones. (see fig. IA).
k) Jamb : The part of the wall at the side of an opening.
1) Joggle: A key between the stone by providing a groove in one stone to take a corresponding
concealed projection in the edges on the other stone. (see fig. 1 B)
m) Natural Bed: The planes of stratification that occurs in sedimentary rocks.
n) Parapet :A solid or pierced guard wall for flat stone terrace or balcony (or a bridge) or a
curb

wall at the lower part of a pitched roof which is exposed to atmosphere on face back and top.
(see fig. 1C)
o) Quoin: A quoin is the external angle of wall or building. The term is also applied to stone
specially selected and neatly dressed for forming such angle.
p) Random: Random or irregular size and shapes.
q) Reveal: The part of the jamb between the frame and the arris.
r) Rubble Masonry : Masonry built of stones either irregular in shapes as quarried or squared
and only hammer dressed and having comparatively thick joints. As far as possible, stones for
rubble masonry shall be angular.
s) Skewback: Sloping surface against which the springing of an arch rests.
t) Spandrel :Space between the haunches below the decking level.
u) String Course: A horizontal band, plain or moulded, usually projecting slightly from the
face of wall. (see fig. 1C)
v) Surfacing or Dressings of Stones: The stones are dressed to have different surfaces as
indicated below:
Template or Bed Block: A block of stone or concrete bedded on a wall to distribute the
pressure from a concentrated load.
Self Faced Surfaces :Surfaces of stone slabs used for roofing, flooring, lintels etc. as
obtained from quarry.
Squared Back Surface: Means the surface shall be dressed back at right angles to the
face of the stone.
Chisel Drafted Margin: The dressing done with a drafting chisel in narrow strips of
width generally 2 to 5 cm. Chisel drafted margin shall be punch dressed.
Hammer Dressed Surface : A hammer dressed stone shall have no sharp and irregular
corners and shall have a comparatively even surface so as to fit well in masonry. Hammer
dressed stone is also known as hammer faced, quarry faced and rustic faced. The bushing
from the general wall face shall not be more than 40 mm. on exposed face and 10 mm. on
faces to the plastered. (fig. 2)
Rock Faced Surface : A rock faced stone shall have a minimum of 25 mm. wide chisel
drafted margin at the four edges, all the edges being in the same plane. (fig. 3)
Rough Tooled Surface : A rough tooled surface shall have a series of bands, made by
means of a plane chisel 4 to 5 cm. wide, more or less parallel to tool marks all over the
surface. These marks may be either horizontal, vertical or at an angle of 45° as directed.
The edges and corners shall be square and true. The depth or gap between the surface and
straight edge, held against the surface shall not be more than 3 mm. (rough tooled stones
are used where fairly regular plane faces are required for masonry work).
viii) Punched Dressed Surface : A rough surface is further dressed by means of
punch chisel to show series of parallel ridges. The depth of gap between the surface and
a straight edge held against the surface shall not exceed 3 mm. Punched dressed stones
are used where even surfaces are required. (see fig.5)
ix) Close Picked Surface : A punched stone is further dressed by means of point chisel so

as to obtain a finer surface, ridges or chisel marks left over being very tiny. The depth of
gap between the surface and a straight edge kept over the surface shall not exceed 1.5
mm. (see fig. 6)
x) Fine Tooled Surface : Close picked surface is further dressed so that all the projections
are removed and fairly smooth surface is obtained. The surfaces shall have 3 to 4 lines per
cm. width depending on the degree of hardness of stone and degree of fineness required.
This type of dressing is commonly adopted for Ashlar work. (see fig. 7)
xi) Polished Surface : Surfaces having a higher gloss finish. Polishing of stones shall be
done by rubbing them with suitable abrasive, wetting the surface where necessary with
water. Alternatively polishing of stones shall be done by holding them firmly on the top
of revolving table to which some abrasive material like sand or carborundum is fed. The
final polishing shall be performed by rubber or felt, using oxide of lime (called by trade
name as putty powder) as a polishing medium.
xii) Moulded: Cut to profile of a moulding with punched dressed surfaces, unless otherwise
specified.
8.1.2 Random Rubble Masonry:
8.1.2.1 Stone:
a) The stone shall be of the type specified such as Granite, Trap, Limestone, Sand stone, Quartzite,
and Shale etc. be obtained from the quarries, approved by the Engineer-in-charge. Stone shall be
hard, sound, durable and free from weathering decay and defects like cavities, cracks, flaws,
sand holes, injurious veins, patches of loose or soft materials and other similar defects that may
adversely affect its strength and appearance. As far as possible stones shall be of uniform
colour, quality or texture. Generally stone shall not contain Crypts crystalline Silica or Chart,
Mica and other deleterious materials like Iron-oxide organic impurities etc.
b) Stones with round surface shall not be used.
c) The compressive strength of common types of stones shall be as per Table 1 and the percentage
of water absorption shall generally not exceed 5% for stones other than specified in Table 1. For
Laterite this percentage is 12%.
Table -1
Type of Stone Maximum water absorption Minimum compressive
percentage by weight strength kg/sq cm.
Granite 0.5 1000
Basalt 0.5 400
Lime stone (slab & tiles) 0.15 200
Sand stone (slab & tiles) 2.5 300
Marble 0.40 500
Quartzite 0.40 800
Laterite (block) 12 35
Note 1:- Test for compressive strength shall be carried out as laid down in IS1121 (Part-I):1974
(Reaffirmed 2008), Edition 2.1, 2008-09

Note 2:- Test for water absorption shall be carried out as laid down in IS 1124.: 1974 (Reaffirmed
2003)
8.1.2.2. Size of stones:
Normally stones used should be small enough to be lifted and placed by hand. Unless otherwise
indicated the length of stones for stone masonry shall not exceed three times the height and the
breadth or base shall not be greater than three-fourth the thickness of wall, or no less than 15 cm.
The height of stone may be up to 30 cm.
8.1.2.3 Shape:
i) Random rubble masonry shall be un coursed or brought to courses as specified (Fig.8 and 9).
Un course random rubble masonry shall be constructed with stones of sizes as referred to in
para 8.1.2.2.and shapes picked up random from the stones brought from the approved quarry.
Stones having sharp corners or rough surface shall, however, not be used.
ii) Random rubble masonry brought to the course is similar to un coursed random rubble masonry
except that the courses are roughly levelled at intervals varying from 30 cm. to 90 cm. in height
according to the size of stones used.
8.1.2.4. Dressing:
Each stone shall be hammer dressed on the face, the sides and the bed. Hammer dressing shall enable
the stones to be laid close to neighbouring stones such that the bushing in the face shall not project
more than 40 mm. on the exposed face and 10 mm. on the face to be plastered.
(i) Face stone: At least 25% stones shall be headers tailing into the work at least 2/3rd the
thickness of wall in super structure masonry. Such stones shall not be less than 200 sq. Cm. in
cross sections.
(ii) Hearting Stones: The hearting or interior filling of a wall face shall consist of rubble stones
not less than 150 mm. in any direction, carefully laid, hammered down with a wooden mallet into
position and solidly bedded in mortar. The hearting should be laid nearly level with facing and
backing.
(iii) Quoin Stone: Quoin stone shall be less than 0.03 cum. in volume.
(iv) Jamb stones: The jambs shall not be made with stones specified for quoins except that the
stones which were required to be provided at 1 metre centre to centre on both the exposed faces
shall here be provided only on the jamb and the length shall be equal to the thickness of the wall
for wall up to 60 cm. and a line of headers shall be provided for walls thicker than 60 cm as
specified for bond.
8.1.2.5 (a) Courses: The masonry shall be carried out in regular courses of height not exceeding 50
cm and masonry on any day will not be raised more than 60 cm. in height when using mortars having
compressive strength less than 20 kg./sq cm. at 28 days and 100 cm. when using mortars exceeding
this strength.
8.1.2.5 (b) Thickness of Joints :The joint thickness shall not exceed 30 mm. at any point on the
face. Chips of the stone and spalls shall be wedged into seating bed of face stones to avoid excessive
bed thickness. No pinning shall be allowed to avoid excessive joint thickness.
8.1.2.6. Mortar: The mortar used for joining shall be as specified.

8.1.2.7. Laying:
i) All stones shall be wetted before use. Each stone shall be placed close to the stones already laid
so that the thickness of the mortar joints at the face is not more than 20 mm. Face stones shall be
arranged suitably to stagger the vertical joints and long vertical joints shall be avoided. Stones
for hearting or interior filling shall be hammered down with wooden mallet into the position
firmly bedded in mortar. Masonry shall be built with breaking joints in all the three directions.
Bond stone and headers shall be properly laid into the work and shall be marked by the contractor
with white lead paint. The bond stones shall be provided as specified in para 8.1.2.9.
Chips or sprawls of stones may be used/wedged in to the work wherever necessary for filing of
interstices between the adjacent stones in heartening and these shall not exceed 20% of the
quantity of stone masonry. No dry work or hollow spaces shall be allowed and every stone
whether large or small shall be carefully selected to fit snugly the interstices between the large
stones.
To form a bond between successive courses plum stones projecting vertically by about 15 to 20
cm. shall be firmly embedded in the heartening at the interval of about one metre in every course.
No hollow space shall be left anywhere in the masonry.
ii) The masonry work in wall shall be carried up true to plumb or to specified batter.
iii) Random rubble masonry shall be brought to the level courses at plinth, window sills, lintel and
roof levels. Levelling shall be done with concrete comprising of one part of the mortar as used
for masonry and two pats of graded stone aggregate of 20 mm. nominal size.
iv) The masonry in structure shall be carried uniformly. Where the masonry of one part is to be
delayed, the work shall be raked back at an angle not steeper than 45°.
8.1.2.8 Raking out joints: All the joints on the faces to be pointed or plastered shall be raked out
with raking tool to a depth of 20mm while the mortar is still green.
8.1.2.9. Bond Stones:
i) Bond or through stones running right through the thickness of walls, shall be provided in walls
up to 60 cm. thick and in case of walls above 60 cm. thickness, a set of two or more bond stones
overlapping each other by at least 15 cm. shall be provided in a line from face of the wall to the
back.
ii) In case of highly absorbent types of stones (porous lime stone and sand stone etc.) single piece
bond stones may give rise to dampness for all thicknesses of such walls, a set of two or more
bond stones overlapping each other by at least 15 cm. shall be provided. Length of each such
bond stone shall not be less than two-third of the thickness of the wall.
iii) Where bond stones of suitable length are not available precast cement concrete block of 1:3:6
mix (1 cement : 3 coarse sand :6 graded stone aggregate 20 mm. nominal size) of cross section
not less than 225 sq cm. and length equal to the thickness of wall shall be used in lieu of bond
stones. (This shall be applicable only in masonry below ground level and where masonry above
ground level is finally required to be plastered).
iv) At least one bond stone or a set of bond stones shall be provided for every 0.5 sq m. of the
area of wall surface and shall be provided at 1.5 m. to 1.8 m. apart clear in every course.
v) All bond stones shall be marked suitably with paint as directed by the Engineer-in-charge.

8.1.2.10. Quoin and Jamb Stones : The quoin and jamb stones shall be of selected stones neatly
dressed with hammer or chisel to form the required angle. Quoin stones shall not be less than 0.01
cum. in volume. Heights of quoins and jamb stones shall not be less than 15 cm. Quoins shall be laid
header and stretcher alternatively.
8.1.2.11 Joints: Stones shall be so laid that all joints are fully packed with mortar and chips. Face joints
shall not be more than 20 mm. thick. The joints shall be struck flush and finished at the time of laying
when plastering or pointing is not to be done. For the surfaces to be plastered or pointed, the joints
shall be raked to a minimum depth of 20 mm. when the mortar is still green.
8.1.2.12. Scaffolding: Single scaffolding having one set of vertical support shall be allowed. The
supports shall be sound and strong tied together by horizontal pieces, over which the scaffolding
planks shall be fixed. The inner end of the horizontal scaffolding member may rest in a hole provided
in the masonry. Such holes, however, shall not be allowed in pillars under one metre in width or near
the skew back of arches. The holes left in masonry work for supporting scaffolding shall be filled
and made good with cement concrete 1:3:6 (1 cement : 3 coarse sand :6 stone aggregate 20 mm.
nominal size).
8.1.2.13. Curing: Masonry work in cement or composite mortar shall be kept constantly moist on all
faces for a minimum period of seven days. In case of masonry with fat lime mortar curing shall
commence two days after laying of masonry & shall continue for at least seven days thereafter.
8.1.2.14 Protection: Green work shall be protected from rain by suitable covering. The work shall
also be suitably protected from damage, mortar dropping and rain during construction.
8.1.2.15. Measurements:
(A) The length, height and thickness shall be measured correct to a cm. The thickness of wall shall
be measured at joints excluding the bushing. Only specified dimensions shall be allowed.
Anything extra shall be ignored. The quantity shall be calculated in cubic metre nearest to two
places of decimal.
(B) The work under the following categories shall be measured separately.
i) From foundation to plinth level (level one):
a. Work in or under water and or liquid mud.
b. Work in or under foul positions.
ii) From plinth level (level one) to floor two level.
iii) From floor two level to floor three level and so on.
iv) Stone masonry in parapet shall be measured together with the corresponding item in the
wall of the storey next below.
(C) No deduction shall be made nor extra payment made for the following:
i) Ends of dissimilar materials (that is joists, beams, lintels, posts, girders, rafters
purlins, trusses, corbels, steps etc.) up to 0.1 sq m. in section.
ii) Openings each up to 0.1 sq m. in area. In calculating the area of openings, any separate
lintels or sills shall be included along with the size of opening but the end portions of
the lintels shall be excluded and the extra width of rebated reveals, if any, shall also be
excluded.
iii) Wall plates and bed plates, and bearing of chajja and the like, where the thickness does

not exceed 10 cm and the bearing does not extend over the full thickness of the wall
iv) Drain holes and recesses for cement concrete block to embed hold fasts for doors,
windows etc.
Note: The bearing of floor and roof shall be deducted from wall masonry.
v) Building in masonry, iron fixture, pipes up to 300 mm. Dia. holdfasts of doors and
windows etc.
vi) Forming chases in masonry each up to section of 350 sq cm.
Masonry (excluding fixing brick work) in chimney breasts with smoke of air flues not
exceeding 20 sq. Dm. (0.20 sq m.) in sectional area shall be measured as solid and not extra
payment shall be made for pargetting and coring such flues. Where flues exceed 20 sq.dm.
(0.20 sq m.) sectional area, deduction shall be made for the same and pargetting and coring
flues shall be measured in running metre stating size of flues and paid for separately.
(D) Apertures:
Apertures for fire places shall not be deducted and extra labour shall not be measured for
splaying of jambs, throating and making arch to support the opening.
(E) Square or Rectangular Pillars:
These shall be measured as walls, but extra payment shall be allowed for stone work in square or
rectangular pillars over the rate for stone work in walls. Rectangular pillar shall mean a
detached masonry support rectangular in section, such that its breadth does not exceed two and
a half times the thickness.
(F) Circular Pillars (Columns) :
These shall be measured as per actual dimensions, but extra payment shall be allowed for stone
work in circular pillars over the rate for stone work in walls. The diameter as well as length
shall be measured correct to a cm.
(G) Tapered w a s :
Tapered walls shall be measured net, as per actual dimensions and paid for as other walls.
(H) Curved Masonry :
Stone masonry curved on plan to a mean radius exceeding 6 metres shall be measured and
included with general stone work. Stone work circular on plan to a mean radius not exceeding
6 metres shall be measured separately and shall include all cuttings and waste and templates. It
shall be measured as the mean length of the wall
8.1.2.16 Rate : The rate shall include the cost of materials and labour required for all the operations
described above and shall include the following:
i) Raking out joints for plastering or pointing done as a separate item, or finishing flush as the
work proceeds.
ii) Preparing tops and sides of existing walls for raising and extending.
iii) Rough cutting and waste for forming gables cores, skew backs or spandrels of arches, splays
at eaves and all rough cutting in the body of walling unless otherwise specified.
iv) Bond stones or cement concrete bond blocks.

v) Leading and making holes for pipes etc.
vi) Bedding and pointing wall plates, lintels, sills etc. in or on walls, bedding roof tiles and
corrugated sheets in or on walls.
vii) Building in ends of joists, beams, lintels etc. 8.1.3
Coursed Rubble Masonry - First Sort. (Fig. 9) 8.1.3.1
Stone: Shall be as specified in 8.1.2.1. 8.1.3.2. Size of
stone: Shall be as specified in 8.1.2.2.
8.1.3.3. Dressing: Face stones shall be hammer dressed on all beds, and joints so as to give them
approximately rectangular block shape. These shall be squared on all joints and beds. The bed joint
shall be rough chisel dressed for at least 8 cm. back from the face, and side joints for at least 4 cm.
such that no portion of the dressed surface is more than 6 mm. from a straight edge placed on it. The
bushing on the face shall not project more than 4 cm. as an exposed face and one cm on a face to be
plastered. The hammer dressed stone shall also have a rough tooling for minimum width of 2.5 cm.
along the four edges of the face of the stone, when stone work is exposed.
8.1.3.4. Mortar: The mortar for jointing shall be as specified.
8.1.3.5. Laying:
i) All stones shall be wetted before use. The walls shall be carried up truly plumb or to specified
batter. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical.
The height of each course shall not be less than 15 cm. nor more than 30 cm.
ii) Face stones shall be laid alternate headers and stretchers. No pinning shall be allowed on the
face. No face stone shall be less in breadth than its height and at least one third of the stones
shall tail into the work for length not less than twice their height.
iii) The hearting or the interior filling of the wall shall consist of stones carefully laid on their
proper beds in mortar; chips and spalls of stone being used where necessary to avoid thick
bends of joints of mortar and at the same time ensuring that no hollow spaces are left anywhere in
the masonry. The chips shall not be used below the hearting stone to bring these up to the level
of face stones. The use of chips shall be restricted to the filling of interstices between the adjacent
stones in hearting and these shall not exceed 10% of the quantity of stone masonry.
iv) The masonry in a structure shall be carried up uniformly but where breaks are unavoidable
the joints shall be raked back at angle not steeper than 45°. Toothing shall not be allowed.
8.1.3.6 Bond Stones : Shall be as specified in 8.1.2.10 except that a bond stone or a set of bond
stones shall be inserted 1.5 to 1.8 metre apart, in every course.
8.1.3.7 Quoins: The quoins shall be of the same height as the course in which these occur. These
shall be at least 45 cm long and shall be laid stretchers and headers alternatively. These shall be laid
square on the beds, which shall be rough-chisel dressed to a depth of at least 10 cm. In case of
exposed work, these stones shall have a minimum of 2.5 cm. wide chisel drafts at four edges, all the
edges being in the same plane.
8.1.3.8 Joints : All bed joints shall be horizontal and all side joints vertical. All joints shall be fully
packed with mortar, face joints shall not be more than 10 mm thick.
When plastering or pointing is not required to be done, the joints shall be struck flush and finished at
the time of laying. Otherwise, joints shall be raked to a minimum depth of 20 mm. by raking tool

during the progress of work, when the mortar is still green.
8.1.3.9. Curing, Scaffolding, Measurements and Rates: Shall be as specified under 8.1.2 and
dressing of stones for coursed rubble facing shall be measured sqm. and paid separately.
8.1.4 Coursed Rubble Masonry - Second Sort (Fig. 9):
8.1.4.1 Stone : Shall be as specified in 8.1.2.1.
8.1.4.2 Size of Stone: Shall be as specified in 8.1.2.2.
8.1.4.3 Dressing: Shall be as specified in 8.1.3.3 except that no portion of dressed surface shall
exceed 10 mm from a straight edge placed on it.
8.1.4.4 Mortar: The mortar for jointing shall be as specified
8.1.4.5 Laying: Shall be as specified in 8.1.3.5 except that the use of chips shall not exceed 15% of
the quantity of stone masonry and stone, in each course need not be of the same height but not more
than two stones shall be used in the height of a course.
8.1.4.6 Bond Stone, Quoins: Shall be as specified in 8.1.3.6 and 8.1.3.7 respectively.
8.1.4.7 Joints: All bed joints shall be horizontal and all side vertical. All joints shall be fully packed
with mortar, face joints shall not be more than 20mm thick.
When plastering or pointing is not required to be done, the joints shall be struck flush and finished at
the time of laying . Otherwise, the joints shall be raked to a minimum depth of 20 mm. by raking tool
during progress of work, where the mortar is still green
8.1.4.8 Curing, Scaffolding, Measurement and Rates: Curing, scaffolding, measurement and rate,
Shall be as specified under 8.1.2 and dressing of stones for coursed rubble facing shall be measured
in sqm. and paid separately.
8.1.5. Plain Ashlar Masonry (Fig. 10):
8.1.5.1 Stone: Stone shall be of the type specified. It shall be hard, sound, durable and tough, free from
cracks, decay and weathering and defects like cavities, cracks, flaws, sand holes, veins, patches of soft
or loose materials etc.
Before starting the work, the contractor shall get the stones approved by Engineer-in-charge.
8.1.5.2 Size of Stone: Normally stones used should be small enough to be lifted and placed by hand.
The length of the stone shall not exceed three times the height and the breadth or base shall not be
greater than three fourth of the thickness of wall nor less than 15 cm. The height of stone may be up to
30 cm.
8.1.5.3 Dressing:
a) Every stone shall be cut to the required size and shape, so as to be free from waviness and to give
truly vertical and horizontal joints. In exposed masonry, the faces that are to remain exposed in
the final position and the adjoining faces to a depth of 6 mm shall be the fine chisel dressed so
that when checked with 60 cm straight edge, no point varies from it by more than 1 mm. The top
and bottom faces that are to form the bed joints shall be chisel dressed so that variation from 60
cm. straight edge at no point exceeds 3 mm. Faces which are to form the vertical joints should
be chisel dressed so that variation at any point with 60 cm. straight edge does not exceed 6 mm.
Any vertical face that is to come against backing of masonry shall be dressed such that variation
from straight edge does not exceed 10 mm. All angles and edges that are to remain exposed in
the final position shall be true, square and free from chippings.

b) A sample of dressed stone shall be prepared for approval of Engineer-in-charge. It shall be kept
at the worksite as a sample after being approved.
8.1.5.4 Mortar : The mortar for jointing shall be as specified.
8.1.5.5 Laying:
a) All stones shall be wetted before placing in position. These shall be floated on mortar and
bedded properly in position with wooden mallets without the use of chips or under pinning of
any sort.
b) The walls and pillars shall be carried up truly plumb or battered as shown in drawings. All
courses shall be laid truly horizontal and all vertical joints shall be truly vertical.
c) In case of Ashlar work without backing of Brick work or Coursed rubble masonry, face stone
shall be laid headers and stretchers alternately unless otherwise directed. The headers shall be
arranged to come as near as possible in the middle of stretchers above and below. Stone shall be
laid in regular courses of not less than 15 cm in height and all the courses shall be of same height,
d) For Ashlar facing with backing of brick work or coursed rubble masonry face stone shall be
laid in alternate courses of heads and stretchers unless otherwise directed. Face stone and bond
stone course shall be maintained throughout. All connected masonry in a structure shall be carried
up nearly at one uniform level throughout, but where breaks are avoidable, the joint shall be
made in good long steps so as to prevent cracks developing between new and old work. Bond
stone provided in the masonry shall be payable in the item of Ashlar masonry. Neither any
deduction will be made from the brick masonry for embedding the bond stone in the backing nor
any extra payment shall be made for any extra labour involved in making holes in brick masonry
backing.
e) When necessary, jib crane or other mechanical appliances shall be used to hoist the heavy pieces
of stones and place these into correct positions, care being taken that the corners of the stone are
not damaged. Stone shall be covered with gunny bags, before tying chain or rope is passed over
it, and it shall be handled carefully. No piece which has been damaged shall be used in work.
8.1.5.6 Bond Stones: Shall be as specified in 8.1.2.8
8.1.5.7 Joints: All joints shall be fu11 of mortar. These shall be not more than 6 mm. thick. Face
joints shall be uniform throughout and a uniform recess of 20 mm. depth from face shall be left with
the help of steel plate during the progress of work.
8.1.5.8 Pointing: All exposed joints shall be pointed with mortar as specified. The pointing when
finished shall be sunk from stone face by 5 mm or as specified. The depth of mortar in pointing work
shall not be less than 15 mm.
8.1.5.9 Curing: Masonry work in cement or composite mortar shall be kept constantly moist on all
faces for a minimum period of seven days. In case of masonry with fat lime mortar, curing shall
commence two days after laying on masonry and shall continue for, at least seven days thereafter.
8.1.5.10 Protections: Green work shall be protected from rain by suitable covering. The work shall
also be suitably protected from damage, mortar dropping and rain during construction.
8.1.5.11 Scaffolding: Double scaffolding having two sets of vertical supports shall be provided.
The supports shall be sound and strong, tied together with horizontal pieces over which scaffolding

planks shall be fixed.
8.1.5.12 Measurements: The finished work shall be measured correct to a cm. in respect of length,
breadth and height. The cubical contents shall be calculated in cubic metre nearest to two places of
decimal.
a) General: Neither deduction, nor any extra payment shall be made for the following:-
i) Ends of dissimilar materials (that is joists, beams, lintels, posts, girders, rafters, purlins,
trusses, corbels, steps etc.) up to 0.1 sq m. in section.
ii) Openings up to 0.1 sq m. in area. In calculating the area of opening, any separate lintels
or sills shall be included along with the size of the opening but the end portion of the
lintels shall be excluded and extra width of rebated reveals, if any shall also be excluded.
iii) Wall plates and bed plates and bearing of chajja and the like, where the thickness does
not exceed 10 cm. and the bearing does not extend over the full thickness of the wall.
iv) Drainage holes and recesses left for cement concrete blocks to embed hold-fasts for doors
and windows, building in the masonry iron fixture and pipes up to 300 mm. diameter.
v) Stone walling in chimney breasts, chimney stacks, smoke or air flues not exceeding
0.20 sq m. in sectional area shall be measured as solid and no extra measurement shall
be made for pargetting and coring such flues. Where flues exceed 0.20 sq m. in
sectional area, deduction shall be made for the same and pargetting and coring flues
paid for separately.
b) Square, Rectangular or Circular Pillars: Square, rectangular or circular pillars Shall be
measured and paid for as walls, but extra payment shall be allowed for such pillars and columns
over the rate for stone work in walls.
c) Curved Stone Work: Stone work curved on a plan to mean radius exceeding six metre shall
be measured net and included with general stone work. Stone work circular on a plan to a mean
radius not exceeding six metre shall be measured separately and extra cutting and waste and
templates. It shall be measured as the mean length of wall.
8.1.5.13 Rate: The rate shall include the cost of materials and labour required for all the operations
described above. Stone facing or wall lining up to and not exceeding 8 cm. thickness shall be paid for
under "stone work for wall lining etc. (Veneer work)". The stone work of thickness exceeding 8 cm
shall be paid under relevant items of work.
8.1.6 Punched Ashlar (Ordinary) Masonry (Fig. 10):
8.1.6.1 Stone: Shall be as specified in 8.1.5.1
8.1.6.2 Size of Stone : Shall be as specified in 8.1.5.2
8.1.6.3 Dressing: Shall be as specified in 8.1.5.3. except that the faces exposed in view shall have a
fine dressed chisel draft 2.5 cm. wide all round the edges and shall be rough tooled between the drafts,
such that the dressed surface shall not be more than 3 mm. from a straight edge placed over it.
8.1.6.4 Other Details: The specifications for mortars, laying and fixing, bond stone, joints, pointing,
curing, protections, scaffolding, measurements and rates shall be same as specified in 8.1.5.

8.1.7 Moulded, Sunk, Carved Ashlar Masonry (Fig. 12):
8.1.7.1 Stone: Stone shall be as specified in 8.1.5.1 8.1.7.2
Dressing:
a) Every stone shall be cut to the required size and shape and chisel dressed on all beds and joints
so as to be free from any waviness and the give perfectly vertical, horizontal, radial or circular
joints with adjoining stones as the case may be. The dressed surface shall not be more than 3
mm. from a straight edge placed on it. The face shall be gauged, cut, chamfered, grooved, and
rebated sunk or plain moulded and fine tooled as shown in the working drawings. The joints 6
mm from the face shall also be fine tooled so that straight edge laid along it is in contact with
every point. It shall be finest surface which can be given to a stone with the chisel and without
rubbing.
b) In case of sunk or moulded masonry, the corner stone shall be dressed at true right angles or
true to the shape as specified. The corners being straight and vertical.
c) For arch (see fig.13) dome or circular work (see fig.12) the stone shall be dressed to required
wedge shape so that joints shall be truly radial.
d) Sample
i) The full size layout of the moulding etc. shall be prepared on platform from which sheet
templates shall be cut and stone dressed to templates to a uniform and fine finish. All
visible angles and edge shall be true square and free from chippings. A sample of dressed
stone shall be prepared for approval and it shall be kept as sample after being approved by
Engineer-in-charge.
ii) In case of ashlar moulded and carved columns a full size model of the required moulding,
carving etc. shall be prepared in plaster of Paris and kept at site of work as sample work
after being approved by the Engineer-in-charge. The stones shall be moulded and carved
in accordance with the approved model to a uniform and fine finish.
8.1.7.3 Other Details:
Shall be as specified in 8.1.5.4, 8.1.5.5 and 8.1.5.8 to 8.1.5.11
8.1.7.4 Centring and Shuttering: Centring and shuttering required for arch dome or circular moulded
work shall be constructed as directed by the Engineer-in-charge.
i) The dimensions of the circumscribing rectangles of the dressed stone used in the work shall
be measured correct to a cm and cubical contents shall be calculated in cubic metres, nearest to
two places of decimal.
ii) In case of sunk of moulded work the measurements for the work shall be taken, course by
course. The plain stone used in conjunction with sunk or moulded stone shall be measured and
paid for under the relevant item of stone work.
iii) Sunk or moulded work in rectangular, square and circular pillars, moulded cornices and string
course shall be measured under stone work sunk or moulded but extra payment shall be allowed
over the general work in each case. No such extra payment shall be allowed for moulded string
and plinth courses.
iv) In case of arch dome or circular moulded work for arches exceeding six metres in clear span

extra payment for additional cost of centring shall be made on the actual area of soffit including
strutting, bolting, wedging, easing, striping and removal.
8.1.7.6 Rate: The rate includes the cost of all materials and labour involved in all the operations
described above, including centring and shuttering for arch, dome or circular moulded work.
8.1.8 Stone Veneering Work:
Stone lining up to 8 cm. shall be treated as veneering work and lining of greater thickness as plain
Ashlar masonry.
8.1.8.1 Stone: Shall be as specified in 8.1.5.1. The stone shall be cut into slabs of required thickness
along the planes parallel to the natural bed of stone.
8.1.8.2 Dressing: Shall be as specified in 8.1.5.3 except that dressing at the back shall not be done, so
as to ensure better grip with the hearting or backing. The dressed slabs shall be of the thickness as
specified, with permissible tolerance of +/- 2 mm.
8.1.8.3 Mortar: Mortar for fixing shall be as specified.
8.1.8.4 Laying:
i) The stone shall be wetted before laying. It shall then be fixed with mortar in position without
the use of chips or underpinning of any sort.
ii) Where so desired, the adjoining stones shall be secured to each other by means of copper
pins 75 mm long and 6 mm. diameter or as specified.
iii) Further the stones shall be secured to the backing by means of cramps. The material for cramps
shall have high resistance to corrosion under conditions of dampness and against the chemical
action of mortar or concrete in which cramps are usually embedded.
iv) Cramps shall be of 25 mm. x 6 mm. and 30 cm. long in case of backing of stone masonry walls
and brick masonry walls thicker than of 230 mm. In case of backing with brick masonry walls
230 mm. or less thick or RCC members, cramps shall be of 25 mm. x 6 mm. and length as per
requirement made out of gun metal or any other metal specified in para 8.1.8.4.6. Generally the
outer length of cramp in half brick work backing shall be 115 mm. and in one brick work
backing, shall be 150 mm. Cramps shall be spaced not more than 60 cm. apart horizontally.
v) Alternatively the stone may be secured to the backing, the means of stone dowels 10 x 5 x 2.5
cm. (as per shape indicated in fig. 14) and the adjoining stone secured to each other by means of
gun metal cramps or copper pins of the specified size. Minimum one cramp per stone dowel
shall be used to secure one slab to the backing.
vi) Cramps may be attached to its sides (see Fig. 16A, 16B) or top and bottom (see Fig. 8.16C to
F) or sides, top and bottom (see Fig. 16G & H). The minimum number of cramps required for
fixing facing unit to the wall are illustrated in Fig. 16. The actual number of cramps and their
sections , shall be as per requirements of design to carry the loads.
vii) Where cramps are used to hold the unit in position only, the facings shall be provided with a
continuous support on which the stones rest at the ground level and other storey level, the
support being in the form of projection from or recess into the concrete floor slab, or a beam
between the columns or a metal angle attached to the floor slab or beams. These supports shall
preferably be at vertical intervals not more than 3.5 m. apart and also over the heads of all
openings. Such supports shall also be provided where there is transition from thin facings

below to thick facings above.
viii) Alternatively cramps may be used to hold the units in position and in addition to support the
units thus transferring the weight of the units to the backing. Such cramp should be properly
designed as per IS 4101 (Part-1):1967(Reaffirmed1995).
ix) The cramps may be of gun metal or copper alloyed with zinc, tin, nickel, lead and/or
stainless steel.
x) The pins, cramps and dowels shall be laid in cement mortar 1: 2 (1 cement : 2 fine sand) and
their samples got approved by the Engineer-in-charge and kept at site.
xi) The walls shall be carried up truly plumb. All courses shall be laid truly horizontal and all
vertical joints truly vertical. The stone shall break joints on the face for at least half the height of
the course, unless otherwise shown in the drawings. The stone shall be laid in regular courses
not less than 20 cm. height and all the stones shall be of the same height unless otherwise
specified. No stone shall be less in length than one & half times its height unless otherwise
specified.
xii) As far as possible the backing shall be carried up simultaneously with the face work. In case
of reinforced cement concrete backing, the lining shall be secured to the backing after it has set
and got cured. The cramps shall be fixed in concrete at the required positions, while laying.
8.1.8.5 Joints:
i) The joints shall be done with composite cement lime mortar 1:1:6 (1 cement: 1 lime putty : 6
fine sand). All joints shall be full of mortar. Special care shall be taken to see that the groundings
for veneer work are full of mortar. If any hollow grounding are detected by taping the face
stones, these shall be taken out and relaid. The thickness of joints shall be as small as possible,
not exceeding 5 mm. For a close butt jointed facing the thickness shall not exceed 1.5 mm. The
face joints shall be uniform throughout.
ii) Where joint filler or compound is to be used, the joints shall be raked out to a depth of at least
25 nun. after the mortar in the joints has set sufficiently and the filler or compound applied.
The joints may be subsequently finished with a mortar suited to the appearance of the work. It
is preferable to use joint sealing compounds where the facings are exposed to heavy rainfall
and winds and their selections would depend upon local experience and availability of joint
sealing compounds. In their absence only masonry mortars 1:1:6 (1 cement:1lime putty: 6 sand)
which are proved to be successful from local exposure conditions shall be used.
8.1.8.6 Other Details: Specifications for pointing, curing, protections and scaffolding shall be
specified under 8.1.5.
The length and breadth of the finished work shall be measured in m. correct to cm. The area should
be calculated in sq. metre correct to two places of decimal.
The veneering work curved on plan shall be measured as plain work, but extra payment shall be
allowed for radii not exceeding six metres on external face. For radii beyond six metres the work
shall be measured as plain work only, even the face may have to dressed to curve.
8.1.8.8 Rate : The rate includes the cost of materials and labour involved in all the operations
described above, except for the cost of providing and fixing for pins, dowels and metal cramps and
ledges and supports which shall be paid separately for unless otherwise stipulated in the item of
work.

8.1.9 Laterite Stone Masonry:
8.1.9.1 Stone : Stones shall be obtained from the approved quarry, as indicated, and shall not be less
than 5 cm thick. Stones shall be carefully hammered down into place with wooden mallet and firmly
bedded with mortar. Chips and spalls shall be wedged in to avoid thick bed joints of the mortar.
Spalls and pinning's may show on face. Thickness of mortar in beds and joints shall not exceed 25
mm.
8.1.9.2 Dressing : Laterite stones shall be hammer dressed into rectangular blocks so that all faces are
free from waviness and unevenness, and the edges are true and square. The least thickness/ breadth
shall be not less than height. The length shall generally be equal to twice the breadth, unless otherwise
specified.
8.1.9.3 Laying : The dressed stones shall be laid in regular courses of not less than 15 cm. height. All
courses in the masonry shall be of the same height unless otherwise directed. The stones shall be laid
in alternate header stretcher fashion, alternative courses of header and stretchers or in any other
suitable fashion as directed. The vertical joints shall break by at least 65 mm. No specific corner
stones are necessary. Quoin may be provided, where so indicated.
8.1.9.4 Joints : All bed joints shall be truly horizontal/vertical, the thickness of joints shall not
exceed 15 mm. Each stone shall be carefully laid in place with joint completely filled with mortar. On
faces, where neither plastering nor pointing is required to be done the joints shall be struck flush as the
work proceeds. In other cases, joints shall be raked square to a minimum depth of 15 mm. by a raking
tool during the progress of work while the mortar is still green.
8.1.9.5 Scaffolding, Curing & Protection: Scaffolding, Curing & Protection same as in para 8.1.5
shall apply.
8.1.9.6 Measurement and Rates: Measurement and Rates same as in para 8.1.5 shall apply.
8.1.10 Slate Stone Masonry:
8.1.10.1 Stone :
a) Slate stones shall be obtained from the approved quarry, as indicated, and shall not be less than
5 cm thick. Slate stones shall be carefully hammered down into place with wooden mallet and
firmly bedded with mortar. Chips and spalls shall be wedged into avoid thick bed joints of the
mortar. Spalls and pinning's may show on face. Thickness of mortar in beds and joints shall not
exceed 25 mm. No face work shall be provided.
b) Slate stone masonry shall be built un coursed. Walls shall be levelled up at the top of plinth,
sill and lintel level of openings and at top with minimum amount of chips and spalls. For walls
up to 45 cm thick, 25% of face area shall be of bond stones. For walls over 45 cm thick, 10% of
face area shall be of bond stones. Quoin and jambs stones shall be laid headers and stretchers
alternatively.
8.1.10.3 Scaffolding Curing & Protection.: These shall be as specified in 8.1.5.
8.1.10.4 Measurement and Rate. : These shall be as specified in 8.1.5
8.2. Pre Cast Concrete Stone Block Masonry:
a) Terminology : For the purpose of this standard, the following definitions shall apply :
i) Block Density- The density calculated by dividing the mass of a block by the overall
volume including holes or cavities.

ii) Stone Spalls: Broken Stone pieces of varying sizes obtained by breaking the natural
river boulders or quarry stones.
iii) Concrete Stone Masonry Block- A precast cement concrete solid block having stone
spalls in it (25-30 per cent of block volume) and cement concrete with dense stone
aggregate and sand. It should be 100% solid.
iv) Stone Face Exposed Block- A concrete stone masonry block where the stone spalls are
exposed at one of its face. The face, when forms the exposed wall face, the wall gets the
texture of stone surface exposed.
8.2.1. Dimensions & Tolerances:
i) Concrete stone masonry block is a solid block and shall be referred to by its nominal dimensions.
The term `nominal' means that the dimension includes the thickness of the mortar joint. Actual
dimensions shall be 10 mm. short of the nominal dimensions.
ii) The nominal dimensions of concrete stone masonry block shall be as follows:
Length 300 mm.
Height 150 mm. and
Width 100, 150 and 200 mm.
iii) In addition, block shall be manufactured in one-third, half, two-thirds and three quarters of
its full length.
iv) The nominal dimensions of the units are so designed that taking account of the thickness of
mortar joints, they will produce wall lengths and heights which will conform to the principles of
modular coordination.
v) Blocks of other nominal dimensions may also be made if so directed by the Engineer-in-
charge.
vi) The maximum variation in the length of the units shall not be more than ± 5 mm. and
maximum variation in height and width of units more than ± 3 mm.
vii) Subject to the tolerances specified in 8.2.3, the faces of blocks shall be flat and rectangular,
opposite faces shall be parallel, and all arises shall be square. The bedding surfaces shall be at
right angles to the faces of the blocks.
8.2.2. Earthquake Resistant Block: For accommodating vertical reinforcement, required in
earthquake resistant construction, special block of half width and with semi-circular recess in it shall
be used. These dimensions are suitable for 200 mm. thick wall. Similar blocks shall be made for walls
of thickness greater than 200 mm.
8.2.3. Block with Special Faces: Blocks with special faces shall be manufactured and supplied as
specified in the item agreement.
8.2.4. Classification: Concrete stone masonry blocks shall be classified according to their average
compressive strength.
8.2.5. Materials:
8.2.5.1 Cement:- Cement complying with any of the following Indian Standards may be used at the
discretion of the Engineer-in-charge.
IS 1489 (Part-I):1991. Portland Pozzolana Cement.

IS 269:1976 Specification for Ordinary and Low heat Cement. IS
8043:1978 Specification for Hydrophobic Portland Cement. IS
8042:1978 Specification for White Portland Cement.
IS 8041:1978 Specification for Rapid hardening Portland Cement.
IS 455: 1976 Specification for Portland Slag Cement IS 6909:1973
Specification for Super Sulphate Cement.
8.2.5.2 Stone Spalls:- The stone spalls shall be of size ranging from 50 to 250 mm in dimension.
The stone spalls shall be hard, sound, round in shape, durable, free from decay and weathering. These
shall not be flaky. The spalls shall have rough surface for better bond with cement concrete. Good
quality stones, such as granite, sand stone and basalt shall be used. State shale or any other soft and
flaky stone shall not be used. The spalls shall be obtained from approved quarry or by breaking river
boulder. Large size shall be broken into the required sizes and shall be stacked into two categories.
a. 100 mm and above, and
b. Below 100 mm
8.2.5.3 Aggregates:- The aggregates used in the manufacture of block shall be clean and free from all
deleterious matter, and shall conform to the requirements of IS 383:1970 (Reaffirmed 1997).
Maximum size of the coarse aggregate shall be 10 mm. Sand used in the manufacture of blocks shall
be well graded. Clean and free from deleterious matter, and shall conform to the requirements of IS
383:1970 (Reaffirmed1997). Besides it shall have fine particles 15 to 20% passing 300 micron I.S.
Sieve and 5 to 15% passing 150 micron I.S. Sieve.
It is recommended that the fineness modules of the combined aggregate shall be between 3.6 and 4.
8.2.5.4 Fly ash: Fly ash conforming to IS 3812 (Part I) : 2003 maybe used for part replacement of fine
aggregate up to a limit of 20%.
8.2.6. Manufacture: Blocks may be manufactured either at construction site or in factory on a
central casting platform using steel moulds with or without surface vibration for compaction of
cement concrete.
8.2.6.1 Mould: Moulds shall be fabricated using mild steel plates and mild steel angles for stiffening
the plates.
The mould shall be either fixed type (box with four side walls fixed at corners, and top and bottom
open) or split type.
Split type may be either individual or gang mould. Where the compaction of the concrete is done
manually, the mould may be either fixed type or split type. When the compaction of the blocks is
done with surface vibrator, the mould shall be only split type (individual or gang mould).
8.2.7. Mix:
i) The cement concrete mix for concrete stone masonry blocks shall not be richer than one part
by volume of cement to 9 parts by volume of combined fine and coarse aggregates, and shall not
be leaner than one part by volume of cement to 13 parts by volume of combined fine and coarse
aggregates.
ii) In case of block where compaction is done manually, concrete mix of medium consistency

(10-12 mm slump) shall be used in order to enable proper compaction and demoulding. The
consistency of the mix should be such that it may cohere when compressed in the hand without
free water being visible.
iii) In case of blocks where compaction is done by external vibrator, concrete mix of very low
consistency (zero slump) shall be used in order to vibrate and compact the concrete under
pressure.
iv) Mixing: Concrete shall normally be mixed in a mechanical mixer unless otherwise permitted
by Engineer-in-charge. In case of hand mixing 10% extra cement shall be used without any
extra payment.
Mixing shall be continued until there is a uniform distribution of the materials, and the mass is
uniform in colour and consistency.
8.2.8. Placing and Compaction:
i) Depending upon the size of the stone spalls, these shall be used either in one layer or in two
layers. When used in two layers, a large size spalls of 100 mm. and above shall be placed in the
bottom and concrete poured all around and at top, and shall be tamped manually. Second layer
of stone spalls of size 50 mm. and above shall be placed over the first layer, and again concrete
is poured all around and up to 20 to 30 mm. above the top level of mould.
ii) Blocks may be compacted manually as well as mechanically. In case of manual compaction,
the concrete laid after the first layer of stone spalls shall be tamped with mason's tool and again
it shall be tamped with suitable tampers and compacted from top and finally struck off level with
trowel.
In case of mechanical compaction, the mould shall be filled up to overflow, vibrated and
mechanically tamped using external vibrator and struck off level.
iii) Demoulding shall be done 5 to 10 minutes after compaction. In case of fixed type mould it shall
be pulled up with side handles while pressing down the block with the plate at top with thumb.
In case of split type mould, the sides shall be removed first and the partition plates (gang mould
shall be pulled up subsequently).
iv) After demoulding, the blocks shall be protected until they are sufficiently hardened to permit
handling without damage.
8.2.9. Curing :
The blocks hardened shall then be cured in a curing water tank or in a curing yard and shall be kept
continuously moist for at least 14 days.
8.2.10. Drying:
After curing, the blocks shall be dried for a period of two to four weeks depending upon weather
before being used on the work. the blocks shall be allowed to complete their initial shrinkage before
they are laid in a wall.
8.2.11. Physical Requirements:
8.2.11.1 General: All blocks shall be sound and free from cracks or other defects which may interfere
with the proper placing of the unit or impair the strength or performance of the construction.
Where blocks are to be used in exposed wall construction, the face or faces that are to be exposed

shall be free from chips, cracks or other imperfections, except that not more than 5% of a consignment
contains slight cracks or small chipping.
8.2.11.2. Dimensions: The overall dimensions of the blocks when measured as given in Appendix-A
of IS 12440:1988 shall be in accordance with 8.2.1 subject to the tolerance mentioned therein.
8.2.11.3 Compressive Strength: The minimum compressive strength at 28 days, being the average
of eight blocks, and the minimum compressive strength at 28 days of individual blocks, when tested
in the manner described in Appendix B of IS 12440:1988, shall be as prescribed as under:
Table -2 :Compressive Strength of Concrete Stone Masonry Blocks
Class Designation Minimum average compressive Minimum strength of
strength on blocks N/mm2 individual blocks N/mm2
5 5.0 3.5
6 6.0 4.2
8 8.0 5.0
9 9.0 6.3
10 10.0 8.5
8.2.11.4 Water Absorption:- The water absorption being the average of three blocks, when
determined in the manner prescribed in Appendix `C' of IS 12440:1988 shall be not more than 6% by
mass.
8.2.12. Tests:
i) Tests as described in Appendix A of IS 12440:1988 shall be conducted on samples of blocks
selected according to the sampling procedure given in 8.2.13.2 to ensure conformity the physical
requirements laid down in 8.13.12.
ii) A sample of 15 blocks shall be taken from a lot of 5000 or part there of manufactured under
similar conditions, of the same size and batch.
8.2.13. Criteria for Conformity:
i) The lot shall be considered as conforming to the requirements of the specification if the
conditions mentioned in 8.2.13.(ii), 8.2.13.(iii) are satisfied.
ii) The number of blocks with dimensions outside the tolerance limit and/or with visual defects,
among those inspected shall be not more than two.
iii) For compressive strength, the mean value determined shall be greater than equal to the
minimum limit specified in 8.2.11.4.
iv) For water absorption the mean value determined shall be equal to or less than maximum
limit specified in 8.2.11.5.
8.2.14. Laying: The laying of precast concrete stone blocks masonry shall be as per para 8.3.17.
8.3. Hollow and Solid Concrete Block Masonry:
(A) Block :
a. Hollow (open and closed cavity) block: A concrete masonry unit with any one of the external
dimension greater than the corresponding dimension of a brick and having one of more large

holes or more large holes or cavities which either pass through the block (open cavity) or do
effectively pass through the block (closed cavity) and having the solid material between 50% and
75% of the total volume of the block calculated from the overall dimensions.
b. Solid Block : A concrete masonry unit with external dimensions greater than corresponding
dimension of a brick and having solid material not less than 75% of the total volume of the
block calculated from the overall dimensions.
8.3.1. Hollow and solid concrete blocks-shall conform the requirements of IS 2185: (Part-I)-1979
(Reaffirmed 2003) Edition 3.1(1984 -05). 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 or impair the strength or performance of construction.
8.3.2. Dimensions and Tolerances:

i) 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, butt, and partition
block and concrete floor units.
ii) 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 100, 150, 200, 250 or 300 mm.
In addition, block shall be manufactured in half length as 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 ± 3mm.
8.3.3. Classification:
8.3.3.1 Hollow (open and closed cavity) Concrete Blocks: The hollow (open and closed cavity)
concrete blocks shall conform to the following three grades:
a. Grade À'- These are used as load bearing units and shall have a minimum block density of
1500 kgm3. These shall be manufactured for minimum average compressive strengths of 3.5,
4.5, 5.5 and 7.0 N/mm2 respectively at 28 days (As per Table 3).
b. Grade `B'- These are also used as load bearing units and shall have a block density less than
1500 kgm3 but not less than 1000 kgm3. These shall be manufactured for minimum average
compressive strengths of 2.0, 3.0 and 5.0 N/mm2 respectively at 28 days (As per Table 3).
c. Grade `C'- These are used as non-load bearing units and shall have a block density less than
1500 kgm3, but not less than 1000 kgm3. These shall be manufactured for minimum average
compressive strengths of 1.5 N/mm2 at 28 days (As per Table 3)
8.3.3.2 Solid Concrete Blocks: Grade `D'- The solid concrete blocks are used as load bearing units
and shall have a block density not less than 1800 kgm3. These shall be manufactured for minimum
average compressive strengths of 4.0 and 5.0 N/mm2 respectively at 28 days (As per

Table 3).
8.3.4. Materials:
8.3.4. 1. Cement : Cement complying with any of the following Indian Standards may be used at the
discretion of the manufacturer:
IS : 269-1976 Specification for ordinary and low heat Portland cement ( third revision) IS
: 455-1976 Specification for Portland slag cement (third revision)
IS : 1489-1976 Specification for Portland pozzolana cement (second revision) IS
: 6909-1973 Specification for super sulphated cement
IS : 8041-1978 Specification for rapid hardening Portland cement
IS : 8042-1978 Specification for white Portland cement
IS : 8043-1978 Specification for hydrophobic Portland cement
(i) When cement conforming to IS : 269-1976 is used, replacement of cement by fly ash conforming
to IS : 3812 (Part I)-1966 may be permitted up to a limit of 20 percent. However, it shall be
ensured that blending of fly ash with cement is as intimate as possible, to achieve maximum
uniformity.
8.3.4.2. Aggregates : The aggregates used in the manufacture of blocks at the mixer or the mixing
platform shall be clean and free from deleterious matter and shall conform to the requirements of IS
: 383-1970.
8.3.4.2.1 The grading of the combined aggregates shall conform as near as possible to the requirements
indicated in IS: 383-1970. It is recommended that the fineness modulus of the combined aggregates
shall be between 3.6 and 4.
8.3.4.2.2 Fly ash conforming to IS: 3812 (Part III)-1966 may be used for part replacement of fine
aggregate up to a limit of 20 percent.
8.3.4.3. Water: The water used in the manufacture of concrete masonry units shall be free from
matter harmful to concrete or reinforcement, or matter likely to cause efflorescence in the units and
shall conform to the requirements of IS : 456-2000.
8.3.4.4. Additives or Admixtures: Additives or admixtures may be added either as additives to the
cement during manufacture, or as admixtures to the concrete mix. Additives or admixtures used in the
manufacture of concrete masonry units may be:
a) Accelerating, water-reducing and air-entraining admixtures conforming to IS: 9103-1979,
b) Fly ash conforming to IS: 3812 (Part II)-1966,
c) Waterproofing agents conforming to IS: 2645-1975,
d) Colouring pigments.
Where no Indian Standards apply, the additives or admixtures shall be shown by test or experience,
to be not detrimental to the durability of the concrete.
8.3.5. Manufacture:
8.3.5.1. Mix:
8.3.5.1.1 The concrete mix used for blocks shall not be richer than one part by volume of cement to 6
parts by volume of combined aggregates before mixing.

8.3.5.1.2 In case of hand-moulded block where compaction is done manually, concrete mix should be
sufficiently consistent to enable demoulding immediately after casting. The consistency of the mix
should be such that it may cohere when compressed in the hand without free water being visible.
Too little water causes the mix to be friable, while too much water causes difficulty in the immediate
withdrawal of the mould.
8.3.5.1.3 In case of machine-moulded blocks, the web markings on the units as they come from the
machine give a good indication as to whether the proper consistency of concrete has been used. In
addition to the grading of the aggregate and the quantity of cement, the amount of water required for
mix will depend to an extent on the type of machine on which blocks are produced. It is possible to
judge the proper consistency by squeezing a handful of concrete mixture. When traces of moisture show
on the outside of the squeezed mass it is usually considered to be suitable.
8.3.5.2 Mixing
8.3.5.2.1 Concrete shall normally be mixed in a mechanical mixer.
8.3.5.2.1.1 Mixing shall be continued until there is a uniform distribution of the materials, and the
mass is uniform in colour and consistency.
8.3.5.2.1.2 When hand mixing is permitted by the engineer-in-charge, it shall be carried out on a
water-tight platform and care shall be taken to ensure that mixing is continued until the mass is
uniform in colour and consistency. Ten percent extra cement may be added when hand-mixing is
resorted to.
8.3.5.3 Placing and Compaction:
8.3.5.3.1 In the case of manual compaction, the mixture shall be placed into the mould in layers of
about 50 to 75 mm and each layer thoroughly tamped with suitable tampers until the whole mould is
filled up and struck off level with a trowel.
8.3.5.3.2 In the case of mechanical compaction, the mould shall be filled up to overflow, vibrated or
mechanically tamped and struck off level.
8.3.5.3.3 After demoulding the blocks shall be protected until they are sufficiently hardened to
permit handling without damage.
8.3.5.4 Curing:
8.3.5.4.1 The blocks hardened in accordance with 8.3.5.3.3 shall then be cured in a curing water tank
or in a curing yard (see Note), and shall be kept continuously moist for at least 14 days. When the
blocks are cured in an immersion tank, the water of the tank shall be changed at least every 4 days.
Note: The curing yard is a paved yard subdivided by shallow drains in 4 to 5 m square platforms
which are provided with water fountains in the centre. The blocks are stacked on the platforms
around the fountains, which work continuously. The fountains are connected to an elevated water
storage tank.
8.3.5.4.2 Steam curing of blocks hardened in accordance with 8.3.5.3.3 may be adopted instead of
methods specified in 8.3.5.4.1, provided the requirements of pressure or non-pressure steam curing are
fulfilled.
8.3.5.5 Drying: After curing the blocks shall be dried for a period of 4 weeks 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 a wall.
8.3.6. Surface Texture and Finish:
8.3.6.1 Concrete masonry units can be given a variety of surface textures ranging from a very fine
close texture to a coarse open texture by the proper selection, grading, and proportioning of aggregates
at the time of manufacture. Textures may also be developed by treating the face of the units while still
green by wire brushing or combing, by slightly eroding the surface by playing a fine spray of water
upon it, and by splitting (split block). Colour may be introduced by incorporating non-fading mineral
pigments in the facing concrete, or by applying a coloured cement grout or paint to the face of the units
soon after they are removed from the moulds. Selected coloured aggregates may also be used in the
facing and exposed by washing with water or dilute hydrochloric acid.
8.3.6.2 Well made concrete masonry may not require plaster in case of unimportant buildings in low
rainfall areas; two or three coats of a cement paint being sufficient to render it resistant to rain water.
If however, it is intended to plaster concrete masonry, the block shall have a sufficiently rough surface
to afford a good key to the plaster. Water proofing admixtures may be used for preparing the plaster.
8.3.7. Physical Requirements:
8.3.7.1. General: All units shall be sound and free of cracks or other defects which interfere with the
proper placing of the unit or impair the strength or performance of the construction. Minor chipping
resulting from the customary methods of handling during delivery, shall not be deemed grounds for
rejection.
8.3.7.1.1 Where units are to be used in exposed wall construction, the face or faces that are to be
exposed shall be free of chips, cracks, or other imperfections, except that if not more than 5 percent
of a consignment contains slight cracks or small chippings not larger than 25 mm, this shall not be
deemed grounds for rejection.
8.3.7.2. Block Density: The block density, when determined as in Appendix B, shall conform to the
requirements given in 8.3.3.
8.3.7.3 Compressive Strength: The average compressive strength of eight blocks, when determined
in accordance with IS 2185: (Part I) 1979 (Reaffirmed 2003) shall be not less than as specified in
table given below :-
Table -3:
Physical Requirements
Type Grade Density of block Minimum average Minimum strength
Kg/m3 compressive of individual units
strength of units N/mm2
N/mm2
Hollow (open & A(3.5) Not less than 1500 3.5 2.8
closed cavity) non A(4.5) 4.5 3.6
load bearing unit A(5.5) 5.5 4.4
A(7.0) 7.0 5.6
B(2.0) Less than 1500 2.0 1.6
B(3.0) but not less than 3.0 2.4
B(5.0) 1000 5.0 4.0

Type Grade Density of block Minimum average Minimum strength
Kg/m3 compressive of individual units
strength of units N/mm2
N/mm2
Hollow (open & C(1.5) Less than 1500 1.5 1.2
closed cavity load but not less
bearing unit than 100
Solid load bearing D(5.0) Not less than 5.0 4.0
units D(4.0) 1800 4.0 3.2
Note:- The density of Block is specified for the guidance of Manufactures while ordering the blocks,
purchaser shall specify the grade only.
8.3.7.4. Drying Shrinkage: The drying shrinkage of the blocks (average of three blocks), when
unrestrained, shall be determined in accordance with IS 2185: (Part I) 1979 (Reaffirmed 2003) and
shall not be exceed 0.1 per cent.
8.3.7.5. Moisture Movement: The moisture movement of the dried Blocks an immersion in water for
24 hours (average of three blocks), when determined in the manner described in IS: 2185 (Part I): 1979
(Reaffirmed 2003) shall not be exceed 0.09 per cent.
8.3.7.6. Water Absorption: The water absorption (average of three blocks), when determined in the
manner described in IS: 2185 (Part I): 1979 (Reaffirmed 2003) shall be not more than 10 per cent
by mass.
8.3.8 Tests:
8.3.8.1 Tests as described in Appendices A to F shall be conducted on samples of units selected
according to the sampling procedure given in 8.3.9 to ensure conformity with the physical
requirements laid down in 8.3.7.
8.3.9. Sampling:
8.3.9.1 The blocks required for carrying out the tests laid down in this standard shall be taken by one
of the methods given in 8.3.9.2 and 8.3.9.3. In either case, a sample of 20 blocks shall be taken from
every consignment of 5 000 blocks or part thereof of the same size and same batch of manufacture.
From these samples, the blocks shall be taken at random for conducting the tests.
8.3.9.2 The required number of blocks shall be taken at regular intervals during the loading of the
vehicle or the unloading of the vehicle depending on whether sample is to be taken before delivery or
after delivery. When this is not practicable, the sample shall be taken from the stack in which case
the required number of blocks shall be taken at random from across the top of the stacks, the sides
accessible and from the interior of the stacks by opening trenches from the top.
8.3.9.3 The sample of blocks shall be marked for future identification of the consignment it represents.
The blocks shall be kept under cover and protected from extreme conditions of temperature, relative
humidity and wind until they are required for test. The tests shall be undertaken as soon as practicable
after the sample has been taken.
8.3.9.4 Number of Tests:
8.3.9.4.1 All the 20 blocks shall be checked for dimensions and inspected for visual defects. (see
8.3.2 ).

8.3.9.4.2 Out of the 20 blocks, 3 blocks shall be subjected to the test for block density (see 8.3.7.2),
8 blocks to the test for compressive strength (see 8.3.7.3), 3 blocks to the test for water absorption (see
8.3.7.6), 3 blocks to the test for Drying Shrinkage (see 8.3.7.4) and later to the test for Moisture
Movement (see 8.3.7.5).
The remaining 3 blocks shall be reserved for retest for Drying Shrinkage and Moisture Movement, if
a need arises.
8.3.10. Criteria for Conformity:
8.3.10.1 The lot shall be considered as conforming to the requirements of the specification if the
conditions mentioned in 8.3.10.2 to 8.3.10.5 are satisfied.
8.3.10.2 The number of blocks with dimensions outside the tolerance limit and/or with visual defects,
among those inspected shall be not more than two.
8.3.10.3 For block density ( see Note in Table 8.3) and compressive strength, the mean value
determined shall be greater than or equal to the minimum limit specified in 8.3.7.2 and 8.3.7.3
respectively.
8.3.10.4 For drying shrinkage and moisture movement, all the test specimens shall satisfy the
requirements of the test. If one or more specimens fail to satisfy the requirements, the remaining 3
blocks shall be subjected to these tests. All these blocks shall satisfy the requirements.
8.3.10.5 For water absorption, the mean value determined shall be equal or less than maximum
limit specified in 8.3.7.6.
8.3.11. Manufacturer's Certificate:
8.3.11.1 The manufacturer shall satisfy himself that the masonry units conform to the requirements of
this specification and, if requested, shall supply a certificate to this effect to the purchaser or his
representative.
8.3.12. Independent Tests:
8.3.12.1 If the purchaser or his representative requires independent tests, the samples shall be taken
before or immediately after delivery, at the option of the purchaser or his representative and the tests
shall be carried out in accordance with this specification.
8.3.12.2 The manufacturers shall supply free of charge the units required for testing.
8.3.12.3 Cost of Testing: Unless otherwise specified in the enquiry or order, the cost of the tests
shall be borne as follows:
a) By the manufacturer in the event of the results showing that the blocks do not conform to
this specification, or
b) By the purchaser in the event of the results showing that the blocks conform to this
specification. 8.3.13. Marking:
8.3.13.1 Concrete masonry units manufactured in accordance with this specification shall be marked
permanently with the following information:
a) The identification of the manufacturer
b) The grade of the unit and
c) The year of manufacture, if required by the purchaser.

8.3.14 Face shells: 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 4).
Table -4:
Minimum face shell and Web Thickness
Nominal Block Face shell thickness Thickness of web Total web thickness per
width (mm). min. (mm) min. (mm) mm
course in any(mm)
of walling 200
100 or less 25 25 25 leng
th
over 100 to 150 25 25 30
over 150 to 200 30 25 30
over 200 35 30 38
8.3.14.1. Tolerances: Subject to the tolerances specified in 8.3.2 and the provisions of 8.3.14.2. The
face of masonry units shall be flat and rectangular, opposite face shall be parallel, and all arises shall
be square. The bedding surfaces shall be at right angles to the faces of the blocks.
83.14.2 Blocks With Special Faces: Shall be manufactured and supplied as directed by the Engineerin-
charge.
8.3.15. Construction of Masonry:
For single storied buildings, the hollows of blocks in foundation and basement masonry shall be
filled up with sand and only the top foundation course shall be of solid blocks. But for two or more
storied buildings, solid concrete blocks shall be used in foundation courses, plinth, and basement
walls, unless otherwise indicated. If hollow blocks are used, their hollows shall be filled up with
cement concrete 1:3:6 using 12.5 mm. nominal size aggregate.
8.3.16. 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.
8.3.17 Laying:
All courses shall be laid true horizontal and all vertical joints made truly vertically. Blocks shall
break joint with those above and below for not less 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.
8.3.18. Provisions 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 at least 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.

8.3.19. 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.
8.3.20 Intersecting Walls:
When two walls meet or intersect and the courses 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.
8.3.21. Piers:
The top course of block in the pier shall be built in solid blocks. Hollow concrete block shall not be
used for isolated piers, unless their hollows are specified to be filled with cement concrete 1:3:6with
12.5 mm. aggregate .
8.3.22. Fixtures, Fittings:
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. 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.
8.3.23. 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.
Joints on internal faces, unless otherwise indicated, shall be raked for plastering. If the internal faces
of masonry are not to be plastered the joints shall be finished flush as the work proceeds or pointed
flush where so indicated.
8.4 Stone Sun Shed (Chhajja) (Fig.13):
8.4.1 Stone Slabs :
i) Stone slabs shall be hard, sound and durable. These shall be chisel dressed on all faces which
are exposed to view and rough dressed at other surface. Angles shall be true and edge lines
straight. The finished thickness shall be as stipulated with permissible tolerance of ± 2 mm.
The length of stone slabs in sun shed (chhajja) shall not be less than 60 cm unless otherwise
specified.
ii) In case of sloping Sun shed (chhajja) the stone shall be sloped as specified. It shall have
minimum bearing of 20 cm. measured horizontally on the wall and the bearing shall also be
similarly sloped. Each slab shall have a hole in the centre of the bearing area through which the
anchoring M.S. holding down bolt shall pass. The holding down bolts shall be 12 mm. dia. and
shall be bent at right angles at its lowest end and buried horizontally for at least 7 cm. in a joint
30 cm. below the bearing surface. Each holding down bolt shall be secured at

top by suitable washer and nut.
iii) The Sun shed (chhajja) shall be provided with cove supports, where cove is in brick
masonry, it shall project out from the wall as under.
45 cm. wide Sun shed (chhajja), cove projection 15 cm, depth of cove 3 courses. 60
cm. wide Sun shed (chhajja), cove projection 20 cm, depth of cove 4 courses. 75 cm.
wide Sun shed (chhajja), cove projection 25 cm, depth of cove 5 courses. 90 cm.
wide Sun shed (chhajja), cove projection 30 cm, depth of cove 6 courses.
iv) In case of horizontal Sun shed (chhajja), the stone shall be fixed horizontally with a slight
outer slope of about 1 cm. It shall have minimum bearing of 15 cm. on the wall. Holding down
bolts shall be provided, only where so specified.
8.4.2 Pointing: The joints shall be pointed with 1:2 cement mortar (1 cement: 2 stone dust) with an
admixture of pigment to match the stone shade, and properly cured.
8.4.3 Other Details: Specifications for curing, protections and scaffolding shall be as specified
under 8.1.2 or 8.1.5
8.4.4 Measurements: The length and breadth of the finished work shall be measured correct to a
cm. The area of Sun shed (chhajja) projecting beyond the wall shall be calculated in sq m correct to
In case of sloping Sun shed (chhajja), the sloping breadth shall be measured correct to a cm. and the
area of Sun shed (chhajja) projecting beyond the wall shall be calculated in sqm. correct to two places
of decimal.
8.4.5 Rate: The rate shall include the cost of all materials and labour involved in all the operations
described above. Anchoring the coves shall be deemed to be included in the rate, only when it is so
stipulated in the description of the item.
8.5 Shelves, Coping, Plain, Cornices, String Courses etc.:
8.5.1 Stone: Stone shall be of uniform colour and texture and of the kind as stipulated.
8.5.2 Dressing: The exposed faces and sides of shelves shall be chisel dressed such that the dressed
surface shall not be more than 3 mm. from a straight edge placed on it. All visible angles and edges
shall be free from chippings. The surfaces to be buried in the masonry shall be rough dressed.
8.5.3 Laying: These shall be laid in mortar of specified mix and fixed as shown in drawing or as
directed by the Engineer-in-Charge.
8.5.4 Other Details: Specifications for Pointing, Curing, Protections and Scaffolding shall be as
specified under 8.1.2.
8.5.5 Measurements:
8.5.5.1 Shelves: The length and breadth shall be measured inclusive of bearings correct to a cm. The
thickness shall be as specified with permissible tolerance of ± 2 mm. The area shall be calculated in
sq m. correct to two places of decimal.
8.5.5.2Copings: The dimensions of the circumscribing rectangles of the dressed stones as used in
work shall be measured correct to a cm. The cubical contents shall be calculated correct to two places
of decimal in cum.
8.5.5.3 Plain Cornices, String Courses and Plinth Courses: The length, breadth and depth of

the stone including bearing shall be measured correct to a cm. The cubical contents shall be
calculated correct to two places of decimal in cum.
8.5.5.4No deduction shall be made from the masonry of wall for the bearing of stone shelves,
cornices, string courses.
8.5.6 Rate: The rate shall include the cost of all materials and labour required in all the operations
described above.
8.6 Stone Jali:
8.6.1 Stone: Stone shall be as specified in 8.1.5.1.
8.6.2 Dressing and Fixing: The stone shall be cut into slabs of required thickness so as to make jali
of the specified thickness. The jali shall be cut as per pattern shown on the drawings. All exposed
faces shall be fine tooled to a uniform and smooth finish. Fixing shall be done with the adjoining
work in grooves, rebates etc., as shown in the drawing or as directed by the Engineer-in-Charge. A
tolerance of ± 2 mm. shall be allowed in the specified thickness of the jali.
8.6.3 Stone Jali shall be fixed in grooves/rebates etc. to adjoining Stone work/Brick work/RCC as
shown in the drawing or as directed by Engineer-in-Charge. Necessary sample for the same shall be
got approved from the Engineer-in-charge before execution. The breakage of stone jail during fixing
shall be the responsibilities of the contractor and replacement shall be provided at his risk and cost.
8.6.4 Measurements: The length and breadth of the stone forming the jali including its borders shall
be measured correct to a cm and the area shall be calculated in square metres nearest to two places
of decimal.
8.6.5 Rate: It includes the cost of labour and materials required for all the operations described
above. It also includes the cost of making grooves or rebates in the adjoining work for fixing jail
8.7 Dry Stone Cladding:
8.7.1 Material:
(i) Stone shall be of the type as specified in the item. It shall be hard, sound durable and tough
free from cracks, decay and weathering and defects like cavities cracks, flaws, holes, veins,
patches of soft or loose materials etc. Thickness of stone shall be as specified.
(ii) Stone shall be cut with the gang saw to the required size and shape on all beds and joints so as
to free from any waviness and to give truly vertical horizontal surface as required. The exposed
face and sides of stones forming joints shall be such that the straight edge laid along the face of
the stone is in contact with every point on it. All the visible angle and edges shall be square and
free from chipping. The dressed stone shall be of the thickness specified with permissible
tolerance of ± 2 mm.
(iii) Before starting the work, the contractor shall get the samples of stone approved by Engineer-
In- charge. Approved sample shall be kept in custody of Engineer-in-Charge and stones
supplied and used on the work shall conform to sample with regard to soundness, colour,
veining and general texture. The stone shall be cut by gang saw into slabs of required thickness
along the places parallel to the natural bed. When necessary double scaffolding for fixing the
stone at greater heights, jib crane or other mechanical appliances shall be used to hoist the heavy
pieces of stone and placed them into correct positions. Care shall have to be taken that corners
of the stone are not damaged. Stone shall be covered with gunny bags

before tying chain or rope is passed over and it shall be handled carefully. No pieces which has
been damaged shall be used that work.
8.7.2 Stacking and Storing: Stone slabs are thin and brittle and should never be stacked flat across
timber supports. They should therefore, be stacked on edge on timber or like runners. Packing
pieces inserted between the slabs may be rope or timber. Slabs shall be well covered with plastic
sheeting to protect them from any possible staining.
8.7.3 Scaffolding: As specified in 8.1.5.11.
8.7.4 Fixing:
(i) The size & shape of the cramps shall be as per drawing and as per directions of Engineer-
incharge. The samples of steel cramps should be approved in advance before starting the stone
cladding work. The cramp shall be attached to top and bottom of the stone. The cramps shall have
inbuilt adjustment for vertical and horizontal alignment. The cramps used to hold support and
transfer the load of stone unit to the supporting structured steel shall be designed by the
manufacturer and approval of the same shall be obtained from the Engineer-in-Charge.
(ii) The minimum number of clamps required shall be as per requirement of design to carry the
load of individual stone slabs. The cramps shall be spaced not more than 60 cm horizontally
and vertically along the stone side for insertion of pins / bolt attached with the steel cramps.
Adequate cutting in stone shall be made with precision instrument to hold the cramps pins at the
joints.
(iii) Stone shall be secured with clamps with high quality workmanship. The walls shall be carried
up truly plumb. All the courses shall be laid truly horizontal and all the vertical joints truly
vertical. The sequence of execution for cladding work shall be approved by the Engineer-in-
Charge.
8.7.5 Jointing: Joints horizontal and vertical shall be filled with weather sealant of make as approved
by Engineer-in-charge with the help of pouring gun for filling the sealant. Before filling the joint with
sealant, masking tape are required to be fixed on stones surface on both edges of joints of the stones,
so that sealant may not spoil the surface of the stone. When all the joints are filled and sealant has
dried, the masking tape may be removed.
8.7.6 Protection: Work shall be protected from rain by suitable covering. The work shall also be
suitably protected from damage and rain during construction.
8.7.7 Measurement : The length and breadth shall be measured correct to a cm. The area shall be
calculated in square metre correct to two places of decimal. Any opening of area 0.01 sq m. or less
shall not be deducted.
8.7.8 Rate : The rate includes the cost of materials and labour involved in all operations described
above including cost of support scaffolding staging, sealant, pouring guns but excluding the cost of
steel cramps drilling holes / making recesses in stones which shall be paid for separately.
8.8 Structural Steel Frame Work for Dry Stone Cladding:
8.8.1 Specification: Specification for structural frame work for dry stone cladding are same
specifications as for steel work in built up sections (welded or bolted).
8.8.2 Fixing of Frame:
a) The properly designed structural frame for withstanding the weight of stone slab are fixed/

supported on wall surface with the help of M.S. brackets/lugs of angle iron/flat etc. which is
welded at each junctions of member of frame and also embedded in cement concrete block
1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm. nominal size) of size 300 x 230
x 300 mm. The concrete block can be made by cutting the hole of size as mentioned in brick wall
and filling the hole with cement concrete including provision of necessary centring/shuttering
for holding of concrete. The frame can also be supported on RCC surface with the help of
approved expansion hold fastener by drilling the holes in RCC surface.
b) Steel cramps are either welded or bolted to the frame (by making necessary holes in frame
work) for holding of stone.
8.8.3 Measurement: The mode of measurement shall be the same, as specified for steel work in
built up section except that the weight of welding material shall not be added in weight of members
for payment and nothing extra shall be paid for making holes for temporary fastening of members
during erection before welding, which also includes cost of cement concrete block, centring and
shuttering and making holes in walls, but excluding the cost of expansion fastener, steel clamps
which shall be paid for separately.
8.8.4 Rate: The rate shall include the cost of all labour and material involved in all the operation
described above.
8.9 Adjustable Stainless Steel Cramps:
i) The cramps shall be of stainless steel of make approved by the Engineer-in-charge.
ii) The weight of the stainless steel clamp (including weight of nut and washer) shall not be less
than260 gm.
Necessary holes at suitable locations are to be done on steel frame work for dry stone cladding
to be fixed.
iv) Necessary recessed are required to be done in stone slab which is required to be supported by
clamps.
v) The one end of steel clamp is fixed on frame with nut and bolt and other end is inserted into
recesses/hole for fixing the dry cladding stone on frame.
vi) The rate includes cost of materials and other operations mentioned as above.

APPENDIX- À'
MEASUREMENT OF DIMENSIONS OF CONCRETE MASONRY BLOCKS
1. Apparatus
1.1 Overall dimensions shall be measured with a steel scale graduated in 1 mm. divisions. Face shell
and web thickness shall be measured with a caliper rule graduated in 0.5 mm. divisions and having
parallel jaws not less than 15 mm. nor more than 25 mm. in length.
2. Specimens
2.1 Twenty full size units shall be measured for length, width and height. Cored units shall also be
measured for minimum thickness of face shells and webs.
Note : These specimens shall be used for other tests also.
3. Measurements and Report
3.1 Individual measurements of the dimensions of each unit shall be read to the nearest division of
the scale or caliper and the average recorded.
3.2 Length shall be measured on the longitudinal centre line of each face, width across the top and
bottom bearing surfaces at mid length, and height on both faces at mid length. Face-shell thickness
and web thickness shall be measured at the thinnest point of each such element 15 mm above the
mortar-bed plane. Where opposite face shells differ in thickness by less than 3 mm, their
measurements shall be averaged. Sash grooves, dummy joints, and similar details shall be disregarded
in the measurements.
3.3 The report shall show the average length, width, and height of each specimen, and the minimum
face-shell and web thickness and total web thickness in 200 mm length of walling per course as an
average for the 20 specimens.
APPENDIX- `B'
METHOD FOR THE DETERMINATION OF BLOCK DENSITY OF CONCRETE
MASONRY BLOCKS
1. PROCEDURE
1.1 Three blocks taken at random from the samples selected in accordance with 8.3.9, shall be dried
to constant mass in a suitable oven heated to approximately 100°C. After cooling the blocks to room
temperature, the dimensions of each block shall be measured in cm. (to the nearest mm.) and the
overall volume computed in cubic cm.. The blocks shall then be weighed in kilograms (to the nearest
10 g) and the density of each block calculated as follows:
Density = (Mass of block in kg / Volume of specimen in cm3) x 106 kg/m3

1.2 The average for the three blocks shall be taken as the average density.

APPENDIX- `C'
METHOD FOR THE DETERMINATION OF COMPRESSIVE STRENGTH

OF CONCRETE MASONRY BLOCKS
1. Apparatus:
1.1 Testing Machine: The testing machine shall be equipped with two steel bearing blocks (See
Note) one of which is a spherically seated block that will transmit load to the upper surface of the
masonry specimen, and the other a plane rigid block on which the specimen will rest.
When the bearing area of the steel blocks is not sufficient to cover the bearing area of the masonry
specimen, steel bearing plates meeting the requirements of 1.2 shall be placed between the bearing
blocks and the capped specimen after the centroid of the masonry bearing surface has been aligned
with the centre of thrust of the bearing blocks (see 4.1).
Note: It is desirable that the bearing faces of blocks and plates used for compression testing of
concrete masonry have a hardness of not less than 60 (HRC).
C-1.2 Steel Bearing Blocks and Plates: The surfaces of the steel bearing blocks and plates shall
not depart from a plane by more than 0.025 mm in any 15 mm dimension. The centre of the sphere of
the spherically seated upper bearing block shall coincide with the centre of its bearing face. If a bearing
plate is used, the centre of the sphere of the spherically seated bearing block shall lie on a line passing
vertically through the centroid of the specimen bearing face. The spherically seated block shall be
held closely in its seat, but shall be free to turn in any direction. The diameter of the face of the bearing
blocks shall be at least 15 cm. When steel plates are employed between the steel bearing blocks and
the masonry specimen (see 4.1) the plates shall have a thickness equal to at least one-third of the
distance from the edge of the bearing block to the most distant corner of the specimen. In no case shall
the plate thickness be less than 12 mm.
2. Test Specimens:
2.1 Eight full-size units shall be tested within 72 hours after delivery to the laboratory, during which
time they shall be stored continuously in normal room air.
2.2 Units of unusual size, shape, or strength may be sawed into segments, some or all of which shall
be tested individually in the same manner as prescribed for full-size units. The strength of the full-size
units shall be considered as that which is calculated from the average measured strength of the
segments.
2.3 For the purpose of acceptance, age of testing the specimens shall be 28 days. The age shall be
reckoned from the time of the addition of water to the dry ingredients.
Capping Test Specimen:
3.0 Bearing surfaces of units shall be capped by one of the methods described in 3.1 and 3.2.
3.1 Sulphur and Granular Materials: Proprietary or laboratory prepared mixtures of 40 to 60
percent Sulphur (by mass), the remainder being ground fire clay or other suitable inert material
passing 150-micron IS sieve with or without a plasticizer, shall be spread evenly on a non-absorbent
surface that has been lightly coated with oil (see Note). The Sulphur mixture shall be heated in a
thermostatically controlled heating pot to a temperature sufficient to maintain fluidity for a reasonable
period of time after contact with the capping surface. Care shall be exercised to prevent overheating,

and the liquid shall be stirred in the pot just before use. The capping surface shall be plane within 0.075
mm. in 40 cm. and shall be sufficiently rigid and so supported as not to be measurably deflected
during the capping operation. Four 25 mm. square steel bars shall be placed on the surface plate to
form a rectangular mould approximately 12 mm. greater in either inside dimension than the masonry
unit. The mould shall be filled to a depth of 6 mm with molten Sulphur material. The surface of the
unit to be capped shall quickly be brought into contact with the liquid, and the specimen, held so that
its is is at right angles to the surface of the capping liquid, shall be inserted. The unit shall be allowed
to remain undisturbed until solidification is complete. The caps shall be allowed to cool for a minimum
of 2 hours before the specimens are tested. Patching of caps shall not be permitted. Imperfect caps
shall be removed and replaced with new ones.
NOTE: The use of oil on capping plates may be omitted if it is found that plate and unit can be
separated without damaging the cap.
3.2 Gypsum Plaster Capping: A neat paste of special high-strength plaster (see Note under 4.1)
and water shall be spread evenly on a non-absorbent surface that has been lightly coated with oil.
Such gypsum plaster, when gauged with water at the capping consistency, shall have a compressive
strength at a 2-hour age of not less than 25 N/mm2 when tested as 50 mm cubes. The casting surface
plate shall conform to the requirements described in 3.1. The surface of the unit to be capped shall be
brought into contact with the capping paste; the specimen which is held with its is at right angles to
the capping surface, shall be firmly pressed down with a single motion. The average thickness of the
cap shall be not more than 3 mm.
Patching of caps shall not be permitted. Imperfect caps shall be removed and replaced with new
ones. The caps shall be aged for at least 2 hours before the specimens are tested.
4. Procedure:
4.1 Position of Specimens : Specimens shall be tested with the centroid of their bearing surfaces
aligned vertically with the centre of thrust of the spherically seated steel bearing block of the testing
machine (see Note). Except for special units intended for use with their cores in a horizontal direction,
all hollow concrete masonry units shall be tested with their cores in a vertical direction. Masonry
units that are 100 percent solid and special hollow units intended for use with their hollow cores in a
horizontal direction may be tested in the same direction as in service.
NOTE: For homogeneous materials, the centroid of the bearing surface shall be considered to be
vertically above the centre of gravity of the masonry unit.
4.2 Speed of Testing : The load up to one-half of the expected maximum load may be applied at
any convenient rate, after which the control of the machine shall be adjusted as required to give a
uniform rate of travel of the moving head such that the remaining load is applied in not less than one
nor more than two minutes.
5. Calculation And Report:
5.1 The compressive strength of a concrete masonry unit shall be taken as the maximum load in
Newton's divided by the gross cross-sectional area of the unit in square mm. The gross area of a unit
is the total area of a section perpendicular to the direction of the load, including areas within cells
and within re-entrant spaces unless these spaces are to be occupied in the masonry by portions of
adjacent masonry.
C- 5.2 Report the results to the nearest 0.1 N/mm2 separately for each unit and as the average for the
8 units.

APPENDIX- `D'
METHOD FOR THE DETERMINATION OF ABSORPTION
1. Apparatus:
1.1 The balance used shall be sensitive to within 0.5 percent of the mass of the smallest specimen
tested.
1.2 Three full-size units shall be used.
2. Procedure:
2.1 Saturation: The test specimens shall be completely immersed in water at room temperature for
24 hours. The specimens shall then be weighed, while suspended by a metal wire and completely
submerged in water. They shall be removed from the water and allowed to drain for one minute by
placing them on a 10 mm or coarser wire mesh, visible surface water being removed with a damp
cloth, and immediately weighed.
2.2 Drying : Subsequent to saturation, all specimens shall be dried in a ventilated oven at 100 to
115°C for not less than 24 hours and until two successive weighing's at intervals of 2 hours show an
increment of loss not greater than 0.2 percent of the last previously determined mass of the specimen.
3. Calculation and Report: 3.1 Absorption - Calculate
the absorption as follows:
Absorption, kg/m3 = (A-B/A-C)xl000
Absorption, percent = (A-B/ B) x 100
where
A = wet mass of unit in kg,
B = dry mass of unit in kg, and
C = suspended immersed mass of unit in kg.
3.2 Report - Report all results separately for each unit and as the average for the three units.
APPENDIX- È'
METHOD FOR THE DETERMINATION OF DRYING SHRINKAGE

E-1. Number of Tests:
E-1.1 Of the samples selected in accordance with 10, three shall be tested for drying shrinkage. Three
more blocks shall be set aside and stored in air-tight containers at normal room temperature so as to
be available for duplicate tests if they are required at a later stage. (see Note).
NOTE- In order to facilitate storage, instead of blocks, sections cut from these additional blocks
may be stored until necessary in separate air-tight containers at normal room temperature.
E-2 Apparatus:
E-2.1 Measuring Apparatus: A measuring apparatus shall be used which incorporates a

micrometer gauge or a suitable dial gauge reading accurately to 0.002 5 mm. This gauge shall be
rigidly mounted in a measuring frame and have a recessed end which may be located upon a 5-mm
diameter ball or other reference point cemented on the specimen. The other end of the frame shall have
a similar recessed seating which may be located upon the other ball or reference point in the specimen.
An Invar steel rod of suitable length with 5-mm. diameter hemispherical ends or with 5-mm diameter
steel balls mounted on the ends, shall be used as a standard of length against which readings of the
gauge may be checked, thus enabling corrections to be made for any change in the dimensions of the
apparatus between successive measurements of a test specimen. The apparatus shall preferably be
adjusted for specimens of different lengths and Invar steel rod of lengths near to those of the
specimens to be tested shall be available.
E-2.2 Drying Oven: The drying oven shall comply with the following requirements:
a) It shall have an internal volume equivalent to not less than 8 litres per specimen, with a
minimum total volume of 50 litres.
b) It shall be reasonably air-tight and shall be provided with a fan to keep the air circulating
effectively during the drying of the specimen.
c) It shall be capable of maintaining a constant temperature of 50 ± 1°C.
d) The relative humidity of the air in the oven shall be controlled at approximately 17 percent by
means of saturated calcium chloride solution. Suitable dishes or trays containing this solution
shall be provided to give an exposed area of solution not less than 10 cm for each liter of volume
of the oven. The dishes or trays shall contain sufficient solid calcium chloride to show above the
surface of the solution throughout the test.
E-3. Preparation Of Specimens:
E-3.1 One sample shall be cut from each of the blocks such that the length of each specimen is not less
than 15 cm and the cross section is as near to 7.5 x 7.5 cm as practicable in the case of solid blocks
and 7.5 cm x thickness of the wall in the case of other blocks. Two reference points consisting of 5 mm
diameter steel balls or other suitable reference points providing a hemispherical bearing shall be
cemented with neat rapid-hardening Portland cement or other suitable cementing material at the centre
of each end of each specimen after drilling or cutting a shallow depression. After fixing, the surface
of the steel balls shall be wiped clean of cement, and dried and coated with lubricating grease to
prevent corrosion. The specimens shall then be completely immersed in water for 4 days, the
temperature being maintained at 27 ± 2°C at least for the last 4 hours.
E-4. Procedure For Testing:

E-4.1 Immediately after removal of the specimens from the water, the grease shall be wiped from the
steel balls and the length of each specimen measured to an accuracy of 0.002 5 mm by the apparatus
described in E-2.1. This shall be taken as the original wet measurement.
NOTE - The instrument reading required is not the absolute length of the specimen but the difference
in length between the specimens and an Invar rod of approximately the same length.
E-4.2 The specimens shall then be dried for at least 44 hours in an oven of the type described in E-
2.2, at the specified temperature and humidity. The specimens shall then be removed from the oven
and cooled for at least 4 hours in a desiccators containing solid calcium chloride or a saturated solution
of calcium chloride. Each specimen shall then be measured as described in E-4.1, at a temperature
of 27 ± 2°C.

E-4.3 The cycle of drying, cooling and measuring shall be repeated until constant length is attained,
that is when the difference between consecutive readings separated by a period of drying of at least 44
hours followed by cooling for at least 4 hours, is less than 0.005 mm for a 15 cm specimen and pro
rata for a larger specimen. The final reading shall be taken as the dry measurement.
E-4.4 During the above drying process further wet specimen shall not be placed in the same oven
and there shall be free access of air to all surfaces of the specimen.
E-4.5 After the dry measurement has been taken, the length of the specimen shall be measured,
adjacent to the steel balls, to the nearest mm. and this shall be taken as the `dry length'.
E-5. Calculation of Results:
E-5.1 The `drying shrinkage' shall be calculated for each specimen as the difference between the
òriginal wet measurement' and the `dry measurement' expressed as a percentage of the `dry length' .
E-5.2 Report all results separately for each unit.
APPENDIX- `F'
METHOD FOR THE DETERMINATION OF MOISTURE MOVEMENT

F-1. Procedure:
F-1.1 The specimens which have previously been used for the drying shrinkage test (see Appendix E)
shall after the completion of that test, be immersed in water for 4 days, the temperature being
maintained at 27 ± 2°C for at least 4 hours prior to the removal of the specimens and the wet length
measured. The moisture movement shall be determined as the difference between the dry and wet
lengths and expressed as a percentage of the dry length for each specimen.
F-1.2 Should the value obtained with any one of the three specimens tested be greater than the limit
specified in 8.7, the test shall be repeated on the further three blocks which were set aside. In
repeating the moisture movement test, the drying shrinkage test shall be repeated if the previous
specimens have failed on that test also, otherwise, the drying shrinkage test may be omitted. The
three new specimens, in that event, shall be dried to constant length at 50 ± 1°C measured after
cooling and the moisture movement test carried out as described in F-1.1.

Material Test Requirement Field! Test Minimum Frequency of
laboratory Procedure Qty. of Testing
Test material for
carrying out
test
Stone (i) Water Not more than Laboratory IS 1124 50 sqm. 100 sqm/20
absorption 2.5% by mass for for slabs and cum. or part
sand stone and as 10 cum in thereof or
specified in stone change of
IS 1123 for other masonry source as per
Stones. direction of
Engineer- in-
Charge
(ii) Transverse Not less than Laboratory IS 1121 -do- -do-
strength 7 N/mm2 (70 Part II
Kg f/cm2) for sand
stone and as
specified in IS 1123
for other Stones.
(iii) Resistance Not greater than Laboratory IS 1706 -do- -do-
to wear 2 mm on the
average and 2.5 mm
for any individual
specimen for sand
stone and as
specified in
IS 1123 for
other Stones.
(iv)Durability Shall not develop Laboratory IS 1126 -do- -do-
signs of spalling,
disintegration or
cracks for sand
stone and as
specified in
IS 1123 for
other Stones.
LIST OF RELEVANT BUREAU OF INDIAN STANDARD CODES

S. No. IS Code No. Subject
1. IS 383-1970 Coarse Aggregate & Fine Aggregate for Concrete
2. IS 737 Specifications for Wrought Aluminium and Aluminium Alloy,
Steel and Strip for General Engineering Purpose.
3. IS 1121 - (Pt. I) Methods of Determination of Properties and Strengths of
Natural Building Stones (Part-I Compressive Strength).
4. IS 1122 Methods for Determination of Specific Gravity of Natural
Building Stone
5. IS 1123 Methods of Identification of Natural Building Stones.
6. IS 1124 Methods of Test of Determination of Water Absorption,
Apparent, Specific Gravity and Porosity of Natural Building
Stones.
7. IS 1125 Methods of Test of Determination of Weathering of Natural
Building Stone
8. IS 1126 Methods of test for determination of durability of natural
building stone
9. IS 1128 Specification for Lime Stone (Slab & Tiles).
10. IS 1129 Recommendations for Dressing of Natural Building Stones.
11. IS 1200 (Pt. IV) Methods of Measurements of Building and Civil
Engineering Works - Stone Masonry.
12. IS 1197 (Pt. I) Code of practice for Construction of Rubble Stone Masonry
13. IS 1597 (Pt. II) Code of practice for Construction of Ashlar Stone Masonry
14. IS 1805 Glossary of Terms Relating to Stones, Quarrying and Dressing
15. IS 3620 Specification for Laterite Stone Block for Masonry
16. IS 3622 Sand Stone (Slab & Tiles)
17. IS 4104 (Pt. I) Code of practice for External Facings and Veneers (Part I-
Stone Facing).
18. IS 4101 (Part II) Code of practice for External Facing and Veneers: (Part II-
Cement Concrete Facing).
19. IS 1489(P-1):1991. Specification for Portland Pozzolana Cement.
20. IS 269:1976 Specification for Ordinary and Low heat Cement.
21. IS 8043:1978 Specification for Hydrophobic Portland Cement.
22. IS 8042:1978 Specification for White Portland Cement.
23. IS 8041:1978 Specification for Rapid hardening Portland Cement.
24. IS 455: 1976 Specification for Portland Slag Cement
25. IS 6909:1973 Specification for Super Sulphate Cement.
26. IS 3812(Part I) Specification for Pulverized Fuel Ash (For use as Pozzolana
in Cement, Cement Mortar & Concrete).
CHAPTER No. 9
PLASTERING AND POINTING

CHAPTER No. 9 : PLASTERING AND POINTING
CONTENTS
9.1 General Specifications & Terminology 3
9.2 12 mm Thick Lime Plaster 30
9.3 15mm Thick Lime Plaster 31
9.4 18mm Thick Lime Plaster ( two coat work) 31
9.5 Lime Punning 32
9.6 25 mm Thick Lime Plaster(Three coat Work) 33
9.7 Lime Sandia Finish & Neeru Finish 34
9.8 Plastering with Gypsum 34
9.9 Cement Plaster 37
9.10 Cement Plaster with a Floating Coat of Neat Cement(Punning) 38
9.11 12 mm thick Cement Plaster 39
9.12 20 mm thick Cement Plaster ( Two coat work) 39
9.13 25 mm thick Cement Plaster ( Three coat work) 39
9.14 6 mm thick Cement Plaster on Cement Concrete and
Reinforced Cement Concrete Work 40
9.15 6 mm thick Cement Plaster for Slab Bearing 41
9.16 Rough Cast Plaster 42
9.17 Pebble Dash Finish (In Situ Work) 42
9.18 Providing and Applying 19 mm thick Sand Face Plaster 43
9.19 Washed Stone Grit Finish (Two coat work) 43
9.20 18 mm thick Plaster with Terrazo Finish 44
9.21 18 mm thick Artificial Red Stone Plaster 46
9.22 Plain Bands of Cement Mortar 46
9.23 Moulded Bands of Cement Mortar (Single Coat Work) 47
9.24 Moulded Bands of Cement Mortar (Two Coat Work) 48
9.25 Cement Lime Plaster (Single coat work) 48
9.26 Cement Lime Plaster (Two coat work) 48
9.27 Lime Plaster of Marble Shade 49
9.28 Lime Surkhi Plaster 49
9.29 18 mm thick Lime Surkhi Plaster 50
9.30 Araish Plaster 50
9.31 Cement Water Proofing Compound 51
9.32 18 mm Thick Mud Plaster 52
9.33 Pointing on Brick Work, Tile Work and Stone Work 53
Appendix 'A': Mortars 56
Appendix 'B': Cement Plaster-Defects, causes and remedies 58
Appendix `C': Determination of Soluble Sodium and Magnesium Salts. 63
Appendix `D': Determination of Loss on Ignition. 63
Appendix È': Determination of Free Lime. 63
List of Bureau of Indian Standards Codes 64
Rajasthan PWD Building Specifications 2014 Chapter 9 : Plastering and Pointing Page 1 of 64
CHAPTER No. 9
PLASTERING & POINTING WORK
9.1 General Specification and Terminology:

9.1.1 Scope : The general specifications for plastering covers its purpose, types and mixes of mortars,
terminology, plaster coats, and their thickness, preparation of various backgrounds, different types of
finishes scaffolding, curing, protection, defect, remedies, mode of measurement and rates.
9.1.2 Purpose of Plastering: The plastering over surfaces is done to serve either or both of the
following purposes.
(a) Protection from atmospheric agents such as rain, acidic fumes etc. and damp from subsoil
by interposing a thin layer of suitable materials between atmospheric agents , subsoil
dampness etc., and the structural walling , column etc.
(b) To provide even surfaces for desired finish for appearance.
9.1.2.1 External Plaster : The primary function of external plaster is to provide
 Good aesthetics to the building
 Protection and durability to the building from atmospheric agents and weathering
effects.
 Strong Mechanical and Chemical bond to structural substrate.
9.1.2.2 Internal Plaster: Internal plaster is important in creating a clean/smooth and healthy indoor
environment. The purpose of internal plaster in a building is to provide :-
 Aesthetics
 Even and smooth surface
 Durability and flexibility to withstand thermal and moisture movement in walls /
surfaces.
 Easy maintenance and cleaning of surface
 Safety to Substrate from direct moisture contact.
9.1.3 Terminology (IS 10403-1983, Reaffirmed 1998) :
For the purpose of this specification, following definition shall apply :
A
1. Acoustic Plaster : - A plaster designed to provide a surface having improved sound audibility
properties.
2. Additives -Chemicals or other materials added to the mortar of normal plaster to obtain special
effects such as waterproofing, aeration, etc.
3. Applications-The separate operations are carried out over the whole area to be plastered, which
together constitute a coat. A finishing coat, for instance, may be applied in three separate operations,
often referred to as trowel, float and finishing trowel coat respectively, from the particular objective/
tool used in each case.
4 Ashlar Marking - The marking of a rendering to stimulate a wall constructed of masonry blocks.
B
1. Background : a) The surface to be plastered is called background. The material or combination
of materials to which the first coat of plaster or rendering is applied.
2. Backing Coat - A coat of plaster other than the finished coat.
3. Bay - The area plastered, rendered, or screeded in one operation.
4. Bell coat: The shaping of the lower edge of an external rendering to shed rain.
5. Bleeding - The separation of water from an unhardened mix.
6. Blistering : -The development of one or more local swellings on the finished plaster surface.
7. Butter Coat -The soft final coat to which the aggregate is applied in pebble, spar or shingle
dashing.
C
1. Coarse Stuff - A wet mixture of lime and sand for use in under coats, it may also contain hair.
2. Close in (Tighten in) -The operation of consolidating the surface of a final coat with a finishing
trowel.
3. Combing --Operation of giving parallel wavy scratch marks on the surface after partial setting of
the intermediate coat to provide proper grip of the finishing coat.
4. Cracking - The development of one or more fissures not assignable to structural cause.
NOTE - Cracks in plaster in the vicinity of a structural crack are not assignable to structural failure
unless they are in conformity with the structural crack.
5. Crazing -The development of a series of hair cracks on the `finished plaster surface, known as
`map crazing', when it forms an haphazard pattern over the wall surface affected.
D
1. Dashed Finish -A rough textured finish ( usually external rendering) of dry or wet dash.
i) Dry Dash: - A finish in which suitably sized aggregate of natural or manufactured materials is
thrown on to a freshly applied final coat of mortar and left exposed.
ii)Wet Dash - A finish produced when the final coat, containing a proportion of fairly coarse aggregate,
is thrown on as a wet mix and is left in the `rough ' condition. The texture desired is regulated by the
size of the coarse aggregate.
2. Drip - Providing of shaped grooves in the plastered surfaces on the underside of projection near
the edges.
3. Dot : - A small patch of plaster, fixed at intervals on a background, plumbed or levelled, and used
in fixing screeds. Or a short piece of wood lath bedded in plaster.
4. Dry Lining - The technique of surfacing walls with plaster board instead of wet plastering.
5. Dubbing Out - The operation of attaching pieces of Slate, Tile, etc. to a wall with plaster, and
then likewise covering them in order to fill out hollows or to form projections.
E
1. Efflorescence- A deposit of soluble salts on the surface (white spots) of the plaster or on the
back ground.
F
1. Final Coat - The final continuous coat of rendering material. In dry finishes, it is the coat on to
which the dash is thrown while the coat is still soft. In rough cast or machine-applied finishes it is the
last coat thrown on to complete the finish.
2. Final Set - The condition at which the plasticity of a mix permits little or no movement under the
trowel. Trowelling after the final set has the effect either of polishing or in other cases of weakening
or disrupting the surface.
3. Fineness Modulus- A numeral indicating the fineness of an aggregate, as determined by
ascertaining the percentage residue, by weight or volume, remaining on each of a series of fine sieves
with apertures ranging from 40 mm to 150 micron, summing, and dividing by 100.
4. Finishing -The smooth final coat to an external / internal rendering.
5. Finishing Coat - The final coat in two or three coat plaster work. This is also referred to as the
final coat, setting coat, face coat or skimming coat (the term `skimming coat' is also applied to single-
coat work).
6. Finishing Treatment - The final treatment provided to the final coat of plaster (see also
Dashed finish).
7. Flaking -The scaling away of patches of plaster surface due to lack or loss of adhesion with the
earlier coat.
8. Floating Coat -The undercoat immediately preceding the final coat.
9. Framing : Light wood or metal battens fixed to solid backgrounds for subsequent attachment of
expanded metal or sheet materials.
G
1. Gauging - The mixing of various constituents of a plaster. This term is also used for denoting the
addition of cement to a lime-sand mix or of lime to a cement-sand mix. À gauging' is the term given
to an individual plaster work.
2. Green Suction-The early suction of a cement-based backing which develops during setting.
3. Grinning-The appearance on the surface of the plaster of the pattern of joints or similar breaks in
the continuity of the surface characteristics of the background.
4. Gypsum Plaster- Plaster based on calcium sulphate.
a) Anhydrous Gypsum Plaster - Plaster consisting essentially of calcium sulphate,
CaSO4, in anhydrous form which has been produced by the dehydration of gypsum by
heat and whose set has been suitably accelerated.
b) Semi-hydrate Gypsum Plaster -Plaster consisting essentially of material from which
only part of the water has been removed during the Calcining of gypsum.
c) Pre-mixed Light mass Gypsum Plaster - A plaster in which a light-mass aggregate
has been pre-mixed dry with a gypsum plaster to give a low density plaster mix.
H
1. Hacking -The roughing of solid backgrounds, by hand or mechanical methods, to provide a
suitable key.
K
1. Killing -Destroying the set of a plaster by continued mixing, with some anhydrous gypsum
plasters.
2. Key: Indentations, openings, grooves or other irregularities on the surface of the background or
undercoat into or through which the rendering material can be pressed in such a way that it will bond
to the surface.
M
1. Machine Applied Finish -A final rendering coat applied by means of hand or power-operated
machines which spatter or throw the material on to the wall. The roughness of the finished surface
varies with the material used and the type of machine.
2. Mechanical Application- The application of plaster by machine usually by pumping and
spraying. P
1. Pattern Staining - Surface staining which sometimes occurs when the two sides of a composite
structure are consistently exposed to different temperatures. The cause of such staining is the
differential deposition of atmospheric dust on those portions of the structure which are cooler, as a
result of higher thermal conductivity.
2. Peeling-The dislodgement of substantial areas of plaster work from the background.
3. Plaster - The general term for a material used to cover specified surfaces, which is applied
while plastic and which hardens after application ( also known as Rendering ).
4. Plastering - The range of operations involved in the application of plaster to internal /external
surfaces.
5. Plasticizer - An additive to improve the plasticity of mix, usually by entraining air.
6. Popping or blowing - The appearance on the surface of the plaster or rendering of conical
hollows (pops or blows). They are due to the presence of particles of reactive material which expand,
after the plaster has set, with sufficient force to push out the plaster in front of the particle.
7. Pricing up Coat - The first coat on metal framing.
8. Pugging - Coarse stuff or other suitable material used above ceilings, between joists, to assist in
sound proofing.
9. Punning - Fine finishing of plastered surfaces with addition of thin layer of binding material.
R
1. Raking: - Removing mortar from masonry joints to provide suitable key for the plastering and
pointing.
2. Retempering - The re-mixing of a plastering or rendering mix which has begun to stiffen.
3. Rendering - A mix which is applied while plastic to building surfaces and which hardens after
application ( see plaster ).
S
1. Scraped Finish - A finish in which the final rendering coat, after being levelled and allowed to
stiffen for a few hours, is scrapped with a suitable tool to remove the surface skin.
2. Screed -Narrow strips or bands of plaster laid on walls or ceilings to serve as guide for bringing
the whole work to a true or even surface, the screeds being incorporated in the final undercoats.
3. Screeding - The range of operation involved in laying a screed to receive a proper finish.
4. Separating Layer - A layer of material between the screed and the next coat to prevent adhesion.
5. Snap Set -The very rapid hardening of some semi-hydrate Gypsum plasters following a normal
initial set.
6. Spatter dash - A mix of cement and fairly coarse sand, prepared as a thick slurry. It is thrown on
as initial coating to provide a key on dense backgrounds having poor suction, or to reduce or even-out
suction of other types of background.
7. Sponge Plaster Finish- A textured finish produced by dabbing with a sponge.
8. Stipple Finish -A textured finish produced by dabbing with a brush or sponge.
9. Stucco - A form of rough cast plastering.
10. Suction - That property of a background which determines its rate of absorption of water.
T
1. Textured Finish -A finish having an ornamental patterned or textured surface produced by
treatment of the freshly applied final coat with various tools.
2. Thin-Wall Plaster- Ready-mixed plaster normally supplied as a paste for application generally
by spraying as a thin coat and hardening by drying.
U
1. Undercoats- Plaster coats (often referred to as backing coats) the main function of which is to
provide surfaces suitable for the application of succeeding coats. There are two types of undercoats.
a) Rendering Coat:-The coat which is applied directly to the building surfaces to be plastered (also
referred to as the `first coat').
b) Floating coat-The coat used in three-coat work to bring the first coat to a true and even surface
before the finishing coat is applied (also referred to as the `second coat').
W
1. Water Proofing Plaster - Applying mortars with special additives to surface for making the same
dense and resistant to percolation of water.
9.1.3.1 Thickness of a Coat : The average thickness of a particular coat excluding the thickness of
material required for filling and levelling up the background or for filling the raked joints. For
measurements, the minimum specified thickness of the plastering shall be as found on the most
outstanding bushing on masonry stone or brick etc.
9.1.3.2 Suction : The property of background which determines its rate of absorption of water.
9.1.3.3 Workability : That property of freshly mixed mortar which determines the ease and
homogeneity with which it can be mixed, placed ,compacted and finished. It is the amount of energy
to overcome friction and cause full consolidation. .It is the quality of mix and its properties, affecting
its behaviour during application. The operative's opinion of workability is influenced by the flow
properties, the cohesiveness of the mix and its retentivity of moisture against the suction of the
background.
9.1.3.4 Site operations:
9.1.3.4.1 Dubbing Out : Dubbing may be necessary where the background is very uneven and that
unevenness cannot be made up in regular course of plastering. The process of dubbing consists in
filling the holes and depressions with mortar of the same mix as for the first coat. The patches of
plaster thus done are left rough so that the subsequent coat of plaster would stick to it.
9.1.3.4.2 Back Rendering: The coat of rendering material applied on the inner face of the lathing.
9.1.3.4.3 Finishing Coat : The final coat in two or three coat plaster work. This is also referred to as
the final coat, setting coat, face coat or skimming coat (the term 'skimming coat' is also applied to
single-coat work).
9.1.3.4.4 Gauging : The mixing of various constituents of a plaster. This term is also used for
denoting the addition of cement to a lime-sand mix or of lime to a cement sand mix. 'A gauging' is the
term given to an individual plaster work.
9.1.3.4.5 Screeds : Narrow strips or bands of plaster laid on walls or ceiling to serve as guides for
bringing the whole work to a true or even surface, the screeds being incorporated in the final
undercoats.
9.1.3.5 Finishing Treatment :
9.1.3.5.1 Machine Applied Finishes : A variety of finishes of which the final coat is applied by
means of hand or power-operated machines which spatter or throw the material on to the wall. The
roughness of the finished surface varies with the material used and the type of machine.
9.1.3.5.2 Rough cast : A finish in which the final coat containing a proportion of fairly coarse
aggregate is thrown on as a wet mix and is left in the rough condition. The texture desired is regulated
by the size of the coarse aggregate which is generally of size between 6 to 12 mm.
9.1.3.5.3 Scraped Finish : A finish in which the final coat, after being levelled and allowed to stiffen
for a few hours, is scraped with a steel straight edge, old saw blade or other tools to remove the surface
skin.
9.1.3.5.4 Textured Finishes : Finishes having ornamental, patterned or textured surfaces produced by
treatment of the freshly applied final coat with various tools. The horizontal or vertical ribbed
texture, the fan texture, torn texture and the English cottage texture are some of the variations
attained by such treatment.
9.1.3.5.5 Flaking : The scaling away of patches of plaster surface due to lack or loss of adhesion
with the previous coat.
9.1.3.5.6 Grinning : The appearance on the surface of the plaster of the pattern of joints or similar
breaks in the continuity of the surface characteristics of the background.
9.1.3.5.7 Peeling : The dislodgement of substantial areas of plaster work from the background.
9.1.3.5.8 Popping or Blowing : The appearance on the surface of the plaster of conical hollows
(pops or blows) in the backing and/or finishing coats.
9.1.4 Necessary Information (IS 1661-1972, Reaffirmed 1996):
9.1.4.1 In the selection of materials for plasters and in their mixing and application, information is
necessary on the following points' and detailed consideration shall be given to them before starting
plaster work:
a) Types of surface over which it is proposed to apply plaster, so that constructional details may be
suitably adopted to them and the amount of subsequent preparation necessary before plastering
may be minimized.
Note-This is of particular importance in the case of concrete soffits, and the construction details
shall include the necessary provisions for adequate mechanical key left permanently embedded in
or adhering.to the concrete.
b) Area, types of finish and thicknesses required, together with sufficient details of the nature of
the surface to be plastered.
c) Details of finish at junctions with doors, windows, and other openings, with ceilings, linings,
etc., and at all corners.
d) Types of cornice, arris and return treatments desired, and of dado treatments where required.
e) Details of scaffolding (staging) for access to work in the correct sequence, together with
provision for adequate protection of adjacent surfaces during plastering operations, particularly in
ceiling work.
f) Details of fixing accessories, templates, etc., to be embedded in the plaster.
g) Types of surface or decorative finish to be applied over the plaster and detailed information on
the compatibility of the plaster with the proposed decorative finish.
9.1.4.2 All information required as above shall be made available to those who are responsible for the
plastering work. Necessary drawings and instructions for preparatory work shall also be given.
9.1.4.3 Arrangements shall be made for the proper exchange of information between those engaged in
plastering and all others whose work will affect or will be affected.
9.1.4.4 Materials, Tools and Accessories:
The following materials, conforming to relevant Indian Standard specifications, shown against them,
shall be used:
a) Cement conforming to IS : 269-1989( Reaffirmed 1998) or IS : 455-I989 ( Reaffirmed 1995),
b) Sand conforming to IS : 1542-1992 ( Reaffirmed 2003)
c) Lime Class B and C conforming to IS : 712-1984 (Edition 4.1-1989-01, Reaffirmed 2000), I,e
i) Fat Lime : The lime which has high calcium oxide content and is dependent for setting
and hardening solely on the absorption of carbon dioxide from the atmosphere.
ii) Hydrated Lime :A dry powder obtained by treating quicklime with water enough to satisfy
its chemical affinity for water under the conditions of its hydration. It consists essentially
of Calcium hydroxide and Magnesium hydroxide.
iii) Hydraulic Lime:Lime containing small quantities of Silica and Alumina and/or Iron oxide
which are in chemical combination with some of the Calcium oxide content, giving a putty
or mortar which has the property of setting and hardening under water.
iv) Quick Lime : A calcined material, the major part of which Calcium oxide in natural
association with a relatively small amount Magnesium oxide, capable of slaking in water.
Lumplime is quicklime it comes from the kilns.
9.1.4.5 The following requirements shall also be complied with where applicable:
a) Lime Putty ( or Neeru ): This shall be obtained by slaking lime with fresh water, and sifting it.
The slaking shall be done in accordance with IS: 1635-1992 ( Reaffirmed 1999) . Putty shall be
kept moist until used, and the quantity prepared at a time shall be not more than what may be
consumed in 7 days.
b) Water:The water used for mixing shall be clean, free from deleterious matter and also from
unusual proportions of dissolved salts. Sea water or tidal astuary or brackish water shall not be
used. Water fit for drinking is normally suitable, in case of doubt, the quality of water should
be analysed to ascertain conformity with clause 5.4 of IS: 456-2000.
c) Wood Lath : The pieces of wood used for wood lath shall be free from all decay and insect
attack. Both hard woods and soft woods may be used according to availability. Laths shall be
free from knots or knot holes that are greater than one half the width of the lath. The timber
shall be partially seasoned; and the moisture content shall not be greater than 20 percent.
d) Metal Lathing :Metal lathing used as background for plastering should weigh not less than
1.6 kg/m3.
e) Galvanized Wire Netting: Where required to provide a mechanical key, galvanized wire
netting of mesh not greater than 50 mm shall be used.
9.1.4.6 Tools and Accessories: used in plaster work may advantageously be in conformity with IS :
1630-1960 ( Reaffirmed 1984) .
9.1.4.7 Storage of Materials:
a) Cement: Cement shall be stored off the ground, under cover and away from damp surfaces so
as to prevent deterioration either by moisture or by intrusion of foreign matter. If these
precautions are neglected cement will be rendered less effective or useless ( see IS : 4082-1967,
Reaffirmed 1998 ).
b) Lime: Lime shall also be stored off the ground, under cover and away from damp surfaces.
Quicklime may progressively deteriorate with keeping through absorption of atmospheric
moisture and carbon dioxide. For this reason, it shall be kept in a dry place and be protected
from direct contact with water, fumes from boilers or similar contamination. Hydrated lime
will not develop any serious deterioration for a period of six months provided it is left
undisturbed in the bag and kept in a cool dry place free from draughts, fumes from boilers or
similar contamination ( see IS : 4082-1967, Reaffirmed 1998) .
c) Sand: Sand for plaster shall be stored under clean conditions to prevent contamination by soil
or other deleterious substances.
9.1.4.8 Care of Tools and Accessories:
a) Tools:Al1 tools shall be cleaned by scraping and washing at the end of each day's work, or
after use with different materials. Metal tools shall be cleaned and greased after each operation.
The tools shall be examined and thoroughly cleaned before plastering is begun. Cleanliness is
particularly important with cement plasters, where contamination with set material may
seriously affect the performance as well as reduce the effective life of the tools.
b) Scaffolding ( Staging) : A temporary framework of bamboo, wood or steel to provide a
platform from which the mason does the plastering work. Wooden ballies, bamboos, planks,
trestles and other scaffolding materials shall be sound and in accordance with local building
regulations. These shall be properly examined before erection and use.
9.1.4.9 Design Considerations :
9.4.1.9.1 Suitability of Cement Lime Mixes :
a) Plastering mixes containing Lime putty, Dry Hydrated Lime, Cement and Sand are characterised by
high workability and marked ease of application. Such properties become less pronounced as the
proportion of cement increases.
b) Cement-lime mixes have a reasonably longer working time (max. 2 hours ), a fairly slow rate
of strength development increasing with the amount of cement added and adequate early
strength to withstand modern building conditions. They need moisture to complete the setting
process and, therefore, rapid drying in the early stages should be avoided.
c) The weaker mixes of cement lime plaster containing smaller proportions of cement, shall not
be used in conjunction with a strong finishing coat. Weaker mixes offer certain advantages
over the stronger (richer) mixes when applied to non-rigid backgrounds, such as lathing.
d) For trowel finishes ( very smooth surfaces ), mixes of lime and cement shall not, in general, be
used for finishing coats, as their shrinkage on drying creates a tendency for surface crazing.
9.1.4.10 Number of Plaster Coats :
The ideal number of coats, where practicable, is two, namely, the undercoat followed by a finishing
coat. It is recognised, however, much successful work has been carried out in the past with plaster
finishing coats with a single coat on reasonably plane backgrounds of brick, concrete and similar
materials. However, for very rough surfaces, such as rough stone masonry, three coat plastering may
be necessary. Metal lathing normally requires a three coat plaster finish for successful results.
Renovation work on wood laths should also be carried out in three coats.
9.1.4.11 Different types of background and number of plaster coats:
Thickness of Plaster will depend upon the type of wall masonry such as RR masonry, Brick masonry,
Cement block work etc. RR masonry more undulations as compared to brick work or block masonry
construction. As such different thicknesses of plasters will be required for different back grounds. If
possible, Cement plastering in thicknesses more than 25 mm should not be carried out in a single
coat as it would cause heavy shrinkage and consequent cracking. Lime plasters shall preferably be
done in 3 coats.
Types of mortar, consumption of material and thickness of lime plaster is given in Appendix "A".
The range of coats normally employed for different back grounds is as follows :-
Back ground No. of coats
Brick work or Hollow clay tiles 2 or 1 2 or
Concrete cast in situ 1
Building Blocks 2 or 1
Wood or metal lath 3 or 2 2
Fibre building Board (Insulating Board) or 1 2
Wood Wool slabs or 1
Cork Slabs 2 or 1
Uneven and rough stone masonry 3 or 2
9.1.4.12 A summary of background data for internal plastering is given below:
Table : 1- Data for Internal Plaster
S. Class Type Drying Characteristics Preparation of Remark
No Shrinkage Surface
Movement
(1) (2) (3) (4) (5) (6) (7)
i) Solid a) Dense clay Negligible Low Suction and May require more See Note
bricks and blocks poor key agents, raking of joints for 1
spatter-dash or bonding
wire-mesh or
special plasters
b) Normal Clay Negligible Moderate to high Rake joints unless See Note
brick and blocks suction and key provided 2
reasonable key
c) Dense concrete Low to high Suction generally Unless keyed, use See Note
either precast or differential low but varies spatter-dash 3
cast in-situ thermal move- according to bonding treatment
ment varies with aggregate and or special plasters
aggregate poor water cement
key ratio
d) No fines Varies from low to Low suction and None -
concrete moderate varies good key
with aggregate
e) Open textured Moderate to high Low suction and None See Note
concrete with good key 4
light weight
aggregate
f) Close textured Moderate to high Variable suction May need treat- See Note
concrete blocks ment with bonding 5
agent to provide
key
g) Aerated Moderate to high Moderate to high May be necessary See Note
concrete suction reaso- to reduce suction 6
nable key unless special
plasters are used.
ii) Slab a) Wood-Wool High but Low suction and None other than See Note
generally fixed good key joint scrimming 7
and may also
be restrained
b) Strawboard - No key Key can be -
provided by use of
bonding treatment
or wire netting or
metal lathing.
Joints should be
scrimmed
S. Class Type Drying Characteristics Preparation of Remark
No Shrinkage Surface
Movement
(1) (2) (3) (4) (5) (6) (7)
c) Cork - Low suction key If the surface -
variable provides insuffi-
cient mechanical
key a 1:1 cement
fine sand slurry
should be brushed
on and wire mesh
fixed.
iii) Boards a) Plaster board Negligible Low suction Joints to be -
adequate key with scrimmed unless
suitable plasters. gypsum lath is
used.
b) Insulating fibre High, but fixed Low suction Joints to be See Note 8
board dry and easily adequate key with scrimmed
suitable plasters
c) Expanded - Low suction None, other than See Note 9
plastics adequate key with joint scimming
suitable plasters when recommen-
ded by manufa-
cturer.
iv) Metal Metal and clay - Good key None -
lathing
Note :-
1. Spatter-dash coat, 1:2 or 3 cement : coarse sand should be allowed to harden before applying
under coat. Wire mesh should be fixed at least 6 mm clear distance from surface.
2. Should be dry to minimize efflorescence.
3. Use bonding treatment or special plasters according to manufacturers recommendations.
4. Should be dry to minimize shrinkage movement.
5. Differential thermal movement may be high with some aggregates.
6. Should be dry to minimize shrinkage movement.
7. Scrimming is cleaning and preparing / filling the joints. When used as permanent shuttering,
special precautions are necessary.
8. Boards must be conditioned at site.
9. Consideration should be given to the strength of the board and the possibility of impact
damage. 9.1.4.13 Backgrounds for Renderings is given in the table below:
Table : 2
S. Backing Strength Porosity and Mechanical Key Resistance to
No Materials Suction and Adhesion Penetration, Protection
Required
i) Poured Strong Low Roughening, mois - Suffi resistance; no
cement tening and further treatment apart
concrete sometimes trea- from rendering
ii) Cement ting the surface
concrete with cement sand
blocks grout (1:1) is
iii) Bricks necessary
(very dense
type), stones
iv) Bricks, Moderately High Satisfactory, if Sufficient resistance, no
ordinary Strong suction is irregular further treatment apart
porous type use cement and from rendering
sand mix 1:1 over
the surface
v) No-fines Sometimes Large voids, a very -
concrete weak few small pores, satisfactory
capillarity ab-
sent, suction low
vi) Lathing Shall be - Purpose is to

Two coats of rendering
strength- provide key
are necessary. First coat
ended
shall be of relatively
impervious mix
9.1.5: Thickness of Plaster :
a) Finishing coats(and single-coat work, whereemployed)sh shallbe ofsuchminimum thickness as
just to provide a sufficient body of material to harden satisfactorily under the site conditions
in any particular case.
b) The total thickness of two-coat work exclusive of keys or dubbing- out shall be generally
about, but shall not normally exceed 20 mm and it shall not exceed 15 mm in the case of in situ
concrete soffits. The thickness of three-coat work shall be about, but shall not normally exceed
25 mm.
c) The thickness of an individual coat shall generally be as recommended in the Table below.
d) Recommended Mix Proportions (IS 1661-1972, Reaffirmed 1992).
Suitable Mix proportions for cement plaster, Lime plaster and external rendering are given in the
Tables below:
Table : 3
Recommended proportions & thickness for various coats of Cement Lime Plasters.
S. No. of Coat of Plaster Situation Mix* Thickness
No (Proportion by
Volume)
(1) (2) (3) (4) (5)
i) Single coat plaster Both internal and 1:0:3 10 to 15 mm
external 1:0:4
1:0:6
1:1:6
1:2:9
ii) Two coat plaster: - do - 1:0:3 10 to 12 mm
a) Backing coat 1:0:4
1:0:6
1:1:6
b) Finishing Coat 1:0:3 to 6 3 to 8 mm
1:1:6
1:2:9
iii) Three coat plaster Very rough surface;
both internal and
external
a)Basecoat 1:0:3 10to15mm
1:0:4
1:0:6
1:1:6
b) Second coat 1:0:3 to 6 3 to 8 mm
1:1:6
1:2:9
c) Finishing coat Fat lime and fine 3 to 5 mm
sand or marble dust
in equal proportions
Note 1 - Wh ere two or three coat plaster is adopted, as far as possiblethe mix for the under coats
should contain coarse sand conforming to grading zone II of IS: 383 - 1970, Reaffirmed 1997#) and
having fineness modulus not less than 2.0.
Note 2 -For single coat plaster, fineness modulus of sand should be as far as possible 1.5 and
conforming to grading zone IV of IS: 383 - 1970, Reaffirmed 1997#. Where only fine sand is
available the fineness modulus of sand may be improved by mixing the required percentage of coarse
sand. The strength of plaster mix gets reduced with the reduction in the fineness modulus of sand.
Note 3 - Other mixes of cement/lime and sand may also be adopted depending on the quality of sand
available and local conditions provided the strength conforms to any of the above mixes given in
Table.
*Cement : Lime : Sand
# Specification for coarse and fine aggregates from natural sources for concrete ( Second revision).
9.1.5.1 The mix for the finishing coat shall depend on the texture and colour of the surface desired.
If the surface is to have a lime-putty finish, then it is advisable to have rich mix of 1 part of cement, 1
part of lime and 3 parts of sand. For any rough finish a mix of 1 part of cement to 3 to 4 parts of sand
is recommended.
9.1.5.2 Surface Finish:
Internal plasters are usually finished to a smooth surface. If textured finishes are required, special
techniques may have to be employed and the success of the treatment is largely dependent on good
craftsmanship.
Table 4: Recommended Mix Proportions for Lime Plaster.
S. Type of Coat Mix Proportion Class of lime
No by volume conforming to
appendix in IS :
712-1984,
( Reaffirmed 2000)
(1) (2) (3) (4)
i) Dubbing and first coat A and B
1 lime : 2 to 3 sand
(both for external and
or
internal surfaces) C
1 lime : 1 pozzolana : 1 to 2 sand
or
1 lime : 2 to3 pozzolana (for first coat C
in the case of two coat work)
ii) Second Coat 1 lime : 1 pozzolana : 2 to 3 sand C
iii) Neeru finishing coat Lime and fine sand ground in equal C
proportions
Table-5
Recommended Mixes for External Rendering.
Background Type of Finish Type of Mix Recommended for given
Material exposure Conditions
First and Subsequent Final Coat
Undercoat
Severe Moderate Light Severe Moderate Light
(1) (2) (3) (4) (5) (6) (7) (8)
Dense and Wood float 1 2 2 or 3 1 2 2,3 or 4
strong Scraped or
Textured 2 3 2 or 3 2 3 2 or 3
Moderately Rough cast 5 5 5 6 6 6
strong and
porous Dry-dash 5 5 5 - - -
(1) (2) (3) (4) (5) (6) (7) (8)
Moderately Wood float
weak and Scraped or 2 3 4 Same as for under coats
porous textured
No-fines Wood float 1 2 2 or 3 1 2 3 or 4
concrete scraped or textured
Rough cast 5 5 5 6 6 6
Dry dash 5 5 5 - - -
Metal lathing Wood float scraped 1 1 1 2 2 2
or expanded or textured
metal Rough cast 5 5 5 6 6 6
Dry dash 5 5 5 - - -
Note : Mix type 1 - 1:0:4, Type 2-1:0:5 to 6, Type 3-1:1:6 to 7 , Type 4-1:2:9 to 10, Type 5-1:0:3,
Type 6-1:3. Type 1 to 5 shall consist of Cement: Lime :Sand by volume; Type 6 shall consist of
Cement, Coarse Aggregate of size 6 to 12mm by volume.
9.1.5.3 Corrosive Effect on Metals : In normal circumstances, matured plaster work maybe regarded
as dry and therefore non-corrosive. Such dangers of corrosion likely to arise, may occur during the
initial drying period and subsequently during periods of heavy condensation. Plaster containing un-
carbonated lime ( for example, lime and cement mixes ) have a protective effect on Iron and Steel,
but are likely when persistently damp to corrode lead and aluminum unless protected by a suitable
paint.
9.1.5.4 Plastering mixes in which sand or water contaminated with sea-salts have been used are
likely to be continually damp, due to the deliquescent or moisture-attracting nature of the salts, and
may corrode metals in contact with them. Frost proofing additives containing soluble chlorides, for
example, calcium chloride, are likely to have similar effects.
9.1.5.5 Protection may be given to Steel and Aluminum when necessary by means of suitable metallic or
paint coatings. Sleeves of material, resistant to any corrosive effects, may sometimes provide a
convenient means of avoiding contact of metal pipes or conduits with plasters which accelerate
corrosion, or the metal may be embedded in a plastering mix of a more suitable composition. Under
persistently wet conditions, no form of plastering can be relied on to protect metals from corrosion.
Other additional protective coatings may be specified by the Engineer.
9.1.5.6 With cold water service pipes, the provision of an insulating sleeve serves also to avoid
condensation of moisture in the plaster in their immediate vicinity during the subsequent life of the
building.
9.1.5.7 Effect of Atmospheric Conditions : The prevailing weather at the time of plastering or
during the setting, drying and hardening period may affect the finished work as follows:
a) Frost: The destructive effect of frost on plaster work is substantial. Unless special precautions
are adopted, plastering work shall be suspended entirely during frosty weather.
Recommendations have been made from time to time in countries which experience long
continued periods of frosty weather and they should serve as a guide to good practice in this
country.
b) Cold: The setting and hardening times of all plasters are appreciably lengthened by a reduction
in the atmospheric temperature. Where plastering has got to be carried out in cold weather, the
time intervals shall be lengthened to allow for this, and the work programmed or re-programmed
accordingly.
c) Condensation: In certain localities condensation resulting from cold wintry conditions may be
so excessive as to impair the finished plaster work. It may also retard or prevent the drying out
of wet building operations for periods of week, or even months, thus presenting conditions
unsuitable for plastering.
d) Extreme dry Conditions: Under hot/ dry conditions ( April to June) , the applied plaster may
become dry before the setting process is sufficiently advanced. The partially set weak material
often has a powdery surface which will not provide a satisfactory base for the subsequent coat
or for decoration. Plasters containing Cement are particularly sensitive in this respect. In such
contingencies the surface should be continuously kept wet during the curing period.
9.1.5.8 General Precautions in Plastering:
a) Cleanliness and Protection of Existing Work : Cleanliness is essential in carrying out plaster
work. Adequate protection shall be given to all existing work and fittings which are liable to be
damaged, not only in the area of plastering operations, but also in the approaches thereto by
covering up with boards, dust sheets, etc., as necessary.
b) Cleaning off on Completion -On completion, all work affected by plastering operations shall
be left clean. Special care is necessary when removing set plaster from glass to avoid damaging
its surface.
c) Suction Adjustment : The careful adjustment of suction is very necessary for good plastering
and may be done either by wetting the backing suitably, if it is dry, or by sprinkling with a
cement mix as in the case of a concrete surface with low suction. Without the aid of suction,
plaster would creep and slide down due to its own weight. On the other hand, high rate of
suction withdraws all moisture from the plaster and makes it weak, porous and friable. Too
much water makes it impossible to keep the mortar in position till it sets. A failure in bond due
to excessive water leads to further failures as the pocket formed may hold water and break up the
plaster when the water freezes, or if the water is salt-laden, the same results will be produced on
evaporation by crystal formation.
d) The wall shall not be soaked but only damped evenly before applying the plaster. If the surface
becomes dry in spots, such areas shall be moistened again to restore uniform suction. A fog-
spray is recommended for this work.
9.1.5.9 Adjustment of Working to the Setting properties of Plaster :
a) Cement plasters and cement-lime plasters contain materials which set when brought into
contact with water, and the full use of their strength producing properties is not made unless the
mix is applied before the setting process has started. If retempering of such mixes is carried out
after the set has commenced, an inevitable loss in strength and efficiency will result.
b) In the case of cement plasters, the commencement of the set is accompanied by a noticeable
stiffening of the mix. In the case of cement plaster heavily gauged with lime, it is not always
obvious to the operator as to when the set has started and it is with this type of mix that the
retention of the full measure of strength afforded by the cementitious material is particularly
important. Such plasters may be overworked both before and after application with resultant
impairment of the set of the gauging plaster. This not only reduces the strength of the material,
but also gives it the shrinkage characteristics of a pure-lime plaster with its liable
accompaniment of the surface crazing. It is essential, therefore, that mixes shall be used as soon
as possible after water has been added and that working periods recommended in the code shall
not be exceeded.
9.1.5.10 Control of Cracking: This is normally a structural problem, but the plaster will be able to
reduce the effects of structural cracking by making a trowel cut between adjacent surfaces.
9.1.5.11 Maintenance of proper time intervals: Shrinkage, partly irreversible, occurs on drying,
causing stresses to be set up both in the applied coat and in the undercoat or background, and in
order to avoid break-down of adhesion between successive coats, it is very important that the drying
shrinkage of the first coat should be materially complete before a subsequent coat is applied. The
rate of drying will vary widely with conditions of temperature, humidity and ventilation. Proper time
interval serves to diminish the possibility of efflorescent salts finding their way to the final plaster
surface, and also of the drying and naturing shrinkage ( map crazing) of the undercoat reaching the
finished plaster face over a period of time. The surface, then , shall be allowed to set for at least a day
or two depending upon the weather ( one day in summer and two days in winter). During this period
the surface of this coat shall be kept damp and shall not be allowed to dry.
9.1.5.12 Preliminary Programming of Work :
a) All materials necessary for plastering shall be kept readily available at the site. In cases where
lime putty is to be used, it shall be run sufficiently in advance so as to mature before use. An
adequate supply of water suitable for mixing the plaster and for curing purposes shall be
available.
b) In building operations, such as construction of brick and block walls, the encasement of steel
columns and beams with concrete etc., requiring plastering shall be so programmed that they are
sufficiently matured to receive the plaster without subsequent damage to plaster or decoration.
Careful programming and avoidance of last minute alterations in the design or in the sequence
of work can avoid serious damage to the plaster finish. Where such alterations are unavoidable
the permanent decoration shall be postponed.
c) Plastering operations shall not be started until all necessary fixing, such as door and window
frames, mantel pieces are completed and all pipes and conduits to be embedded in the wall or
plaster are installed.
d) A preliminary inspection shall be made to ensure that the surfaces are in a suitable condition
for plastering, particularly as regards their planeness and dryness. If dubbing out is necessary, it
should be done in advance, so that an adequate time interval may be permitted before the
application of the first undercoat. Plastering operations shall be so scheduled as to allow
sufficient interval between undercoats and finishing coats.
9.1.5.13 Sequence of Operations:
a) For external plaster, the plastering operations may be started from the top floor and carried
downwards. For internal plaster, the plastering operations may be started wherever the building
frame and cladding work are ready and the temporary supports of the ceiling resting on the wall
or the floor have been removed.
b) The surfaces to be plastered shall first be prepared as described in 9.1.5.14
c) When the preparation has been done, arrangements may be made for a constant supply of
plastering material prepared as described in 9.1.5.15.
d) The first undercoat is then applied to ceilings and walls. It is an advantage to plaster the ceilings
first to permit removal of scaffolding before plastering the wall. In the case of high rooms, the
same scaffolding may be needed for plastering the top portions of the walls.
e) After a suitable time interval (preferably not more than 5 days) the second coat may be applied.
Surface of the first undercoat shall be adjusted and screeds laid to serve as guides in bringing the
work to an even surface. After a further suitable time interval, the finishing coat may be applied
first to the ceilings and then to the walls.
f) Plastering of cornices, decorative features, etc., shall normally be completed before the
finishing coat is applied.
g) Sometimes, ends of scaffolding ballies have to be housed in the wall which is being treated
with plaster. In such cases after the ballies are taken out, the hole or holes left in the wall shall
be filled up with brick and mortar, and the patch plastered up true, even and smooth in
conformity with the rest of the wall, so that no sign of any patch work shows out;
h) Where corners and edges have to be rounded off, it shall be completed along with the
finishing coat to save marks showing out later.
9.1.5.14 Preparation of Background for Application of Plaster.
a) The joints shall be raked out properly. Dust and loose mortar from the walls / surface shall be
brushed out. Efflorescence if any shall be removed by brushing and scrapping. The surface
shall then be thoroughly washed with water, cleaned and kept wet before plastering is
commenced. In case of concrete surface, if a chemical retarder has been applied to the form
work, such surface shall be roughened by wire brushing and all the resulting dust and loose
particles cleaned off and care shall be taken that none of the retarders is left on the surface.
b) For the durability of the plaster or rendering it is vital to obtain a satisfactory bond between the
background and the first plaster coat and also to ensure that the bond is maintained
subsequently. Necessary preparation of the background shall be done to fulfil these
requirements. The requirements of good background in this respect are explained in (c) to (j) as
under. The preparation for different types of backgrounds is individually dealt with in para `k' to
`r' below.
c) Cleanliness- The loose layer of dust on masonry shall be removed either by watering or by
brushing as required. A freshly cast concrete surface is often covered by laitance and this shall
be removed. A concrete surface may also often be contaminated by the soap which is formed
with calcium hydroxide and the oils in the moulds. The contaminated layer shall be removed by
brush. Special care shall be taken in repairing for rendering an old plaster coat. Old layers of the
plaster coat shall be completely removed and made good. Crumbled and frost-damaged parts
shall be cut out and patched. Any trace of algae or moss formation shall be removed. If the
background contains soluble salts, particularly sulphates , the application of the plaster shall be
done only after the efflorescence of the salts is complete, and the efflorescence is thoroughly
removed from the surface.
d) Roughness-The roughness of the background may generally improve the bond of the plaster.
A smooth surface may be roughened by wire brushing, if it is not hard, or by hacking or bush-
hammering, if it is hard. Alternatively, to obtain a rough surface, a mortar 1 cement : 1.5 to 3
coarse sand by volume prepared to a wet consistency may be forcibly dashed or to the surface
(Spatterdash treatment) by suitable means on to a hard surface like concrete. After roughening
the surface, care shall be taken to moisten the surface sufficiently before plastering, as otherwise
the surface may tend to absorb considerable amount of water from the plaster. In addition to
general roughness in the masonry, the joints shall also be raked to a depth of about one
centimeter for providing key to the plaster. On a soft smooth surface after hacking a thin coat of
cement slurry (1:1 : : cement : fine sand) may be applied. In special cases, wire netting, etc.,
may be fixed to improve further the key to the plaster.
e) Suitable Suction -The adjustment of suction of the background during the application of plaster
is already dealt with in 9.1.5.8 (c) . The amount of water introduced in the background during its
construction has an important bearing and adequate drying intervals shall be allowed between
erection and plastering to bring! the surface suitable for suction adjustment.
f) Evenness- The background shall be even in order to avoid variations in the thickness of the
plaster. Any unevenness must be levelled before the plaster is applied. Local projections in
brickwork are serious from the point of view of plastering. For three-coat plaster work, the local
projection shall not exceed 1.2 cm proud of the general surface as determined by the periphery
of the surface concerned and local depression shall not exceed 2.0 cm. For two-coat plaster, a
local projection shall not exceed 0.6 cm and local depression 1.2 cm.
g) Strength and Elasticity - The strength and elasticity of the plaster shall be compatible with
that of the background. The recommendations given in this standard already cover this aspect.
h) Immobility- The background must be immobile at the time of application of the plaster or
subsequently the movements of the background shall be in step with and in the same direction
as those of the plaster. Differential movements between the background and the plaster due to
moisture change, temperature change, structural settlement, deflection etc., will cause cracking
of the plaster. The major part of such movements shall be allowed to set in before the plaster is
applied, as for example, by giving in the case of moisture movement sufficient drying interval
to the background.
i) Precaution Against Discontinuity in Backgrounds - Cracking of walls or of plaster is often
caused by discontinuity, for instance changing from concrete to brickwork, from clay brickwork
to lightweight concrete block work or even changing from one type of brick to another.
Differential drying shrinkage is probably the main cause but difference in thermal movements
may also contribute. Reinforcement of the plaster by metal lathing or scrim over the junction is
not always successful. The best treatment may be to separate the two portions by a neat cut
through the plaster at the junction. The junction may be masked, if so desired, by fixing a cover
strip to one side.
j) A change from wall to ceiling can be regarded as a discontinuity. To provide for the crack, a
cornice that would allow slight movement without cracking or a straight cut through the plaster
at the junction may be provided.
k) When plaster is applied to provide an unbroken surface over a board or slab background, the
plaster coat bridging the joints is subject to higher stresses and any movement in the background
will show at once by cracks along the joints. To avoid this, the plaster is reinforced at the
joints by fixing jute scrim (namely`scrinuning'), or a suitable wire netting gauge. This treatment
may still be ineffective if large changes in humidity take place and if thin board backgrounds
with high moisture movement are used.
1) Surface Preparation for Brickwork or Hollow Block Masonry: The masonry shall be allowed
to dry out for sufficient period so that initial drying shrinkage is fairly complete, and suction
adjustment is possible during plastering .
m) Joints of new brickwork or block masonry, if particularly the bricks or blocks are smooth, shall
be raked out as the work proceeds . Projecting bricks shall be trimmed off where necessary.
n) Old brickwork shall be considered on its merits with the object of securing adequate key. The
surface shall be thoroughly brushed down to remove dust and loose particles or efflorescence
where it has occurred. Low spots may, where necessary, be dubbed out at this stage by means of
a mix similar to that intended for the first coat of plaster but stronger ( richer) and coarser.
o) Surface Preparation for in situ Concrete : The surface shall be cleaned and roughened as
in (b) and (c) above.
p) Concrete surfaces shall have sufficient roughness to provide proper adhesion ( see `c') above.
The surface shall be evenly wetted ( not saturated) to provide correct suction ( see `d' ).
q) If a chemical retarder has been applied to the formwork, a roughened surface may be formed
by wire-brushing and all the resulting dust and loose particles cleaned off, and care shall be
taken that none of the retarders is left on the concrete or on other surfaces, as it may interfere
with the set of the plaster or with other building operations.
r) Where mechanical key-forming devices have been used in the concrete, these shall be
stripped off if still adhering and the resulting surface cleaned down.
9.1.5.15 Preparation of Plaster:
a) Proportioning : The material used in the preparation of plastering mixes may be measured
by volume using gauge boxes.
b) Cement shall be measured by weight. For the purpose of proportioning one cubic metre of
cement shall be taken to weight 1440 kg approximately.
c) Proportioning of lime may be done by measurement of volume as lime putty or dry hydrated
lime before the preparation of putty. The mix proportion of lime, unless otherwise stated,
generally refers to the volume of putty.
NOTE 1 - Lime putty weighs about 1280 kg/m3.
NOTE 2- One m3of dry hydrated lime normally gives about 0.8 to 0.9 m3 of lime putty.
d) Quantity of Water: For general cement-plaster work with 1 : 3 proportion, the quantity of
water required is about 70 percent by weight of cement. This may, however, vary depending on
the following factors, and adjustment shall be done as explained in IS : 2250-1981 (Reaffirmed
2000).
a) The nature and condition of the fine aggregate;
b) The temperature and humidity at the time of working;
c) Richness of the mix, namely, whether rich or leaner than 1: 3;
d) The varying quantities of lime in composite mortars; and
e) The use of admixtures added for improving the workability. e)
Mixing:
i) Cement-Lime Plaster: The cement-lime plaster shall be prepared by mixing dry in the
required proportions cement and sand. Lime putty mixed with water shall then be added to
the mix and the contents mixed for some time until a satisfactory mortar is obtained.
ii) Cement Plaster-Cement and sand shall be mixed dry in the required proportions to obtain
a uniform colour. Water shall then be added to get the required consistency for the plaster.
Cement-Lime plaster shall be used within two hours after the addition of water to Cement
provided it is kept agitated or turned over at intervals of at least 20 minutes. Cement
plasters shall be used within half an hour after the addition of water. Any mortar or plaster
which is partially set shall be rejected and removed forthwith from the site.
iii) Mixing may be done either manually or mechanically. ` Hand mixing ' shall be carried
out on a clean, water-tight platform. During mixing, the mortar shall be mixed back and
forth for 10 to 15 minutes after the water is added. In ` Machine Mixing ' the mixer shall
run at least 5 minutes after placing all the ingredients in the drum.
iv) Machine mixing is preferable to hand mixing for all mortars.
9.1.6 Application of undercoats: The Rendering or First Coat:
9.1.6.1 The rendering coat shall be 10 to 15 mm thick and carried to the full length of the wall or to
natural breaking points like doors or windows. Before the rendering coat hardens, it shall be roughened
to provide mechanical key for the second coat.
9.1.6.2 Masonry walls: On which plaster is to be applied directly, shall be properly set and cured with
the joints raked to a depth of at least 10 mm. Before applying the rendering coat, the surface shall be
cleaned and damped evenly to control suction, an essential treatment for securing first class work. The
rendering coat shall be trowelled hard and tight, forcing it into surface depressions to obtain a
permanent bond.
9.1.6.3 On smooth concrete walls: The surface shall be roughened according to 9.1.5. 15 (c ) and the
rendering coat shall be dashed on to ensure adequate bond. The dashing of the rendering coat shall
be done using a strong whipping motion at right angles to the face of the wall, or it may be applied
with a plaster-machine or Cement-gun. In either case, the plaster shall be projected on to the surface
with considerable force.
9.1.6.4 The Floating or Second Coat : Before starting to apply the second coat, the surface of the
rendering coat shall be damped evenly as described earlier. The second coat shall be approximately
3 to 8 mm thick. It shall be brought to a true, even surface and then roughened to provide bond for the
finishing coat. Each under coat shall be damp-cured for at least two days.
9.1.6.5 Application of Finishing Coat: Before starting to apply the finishing coat, the second coat
shall be damped evenly as described earlier. Whenever possible, textures shall be applied from top to
bottom in one operation to eliminate joining marks.
9.1.6.6 Coloured Cement Work : This work may be classified under two categories as follows:
a) In which the coloured cement used in the work, is made by intimately grinding mineral
pigments with the cement clinker, and
b) Where mineral pigments are added to white or ordinary (grey) cement to get the required
shade.
The former method has the advantage that the work can be carried out in the absence of skilled
workmen. The mineral pigment added shall not in any way interfere with the physical and
chemical properties of cement.
c) In the case of coloured cement plastering: It is necessary to add an integral water proofer in
the undercoats to minimize the risk of efflorescence. Where a coloured cement plastering is to
be done on an already existing mortar base, it is recommended to apply a surface water proofer
on the base and also mix an integral water-proofer with the coloured cement plaster for the
finishing coat.
9.1.6.7 Special Finishing Textures: Various types of special textures for rendered surfaces may be
obtained by using special tools for the application of the final coat. The special finishes shall be
applied in accordance with the details given in IS : 2402-1963*.
( *Code of practice for external rendered finishes.)
9.1.6.8 Trueness of Plastering System : The finished plaster surface shall not show any deviation
more than 4 mm when checked with a straight edge of 2 m length placed against the surface.
9.1.6.9 Curing : To develop maximum strength and. density in the plaster, it is necessary to cure
cement and cement-lime plasters properly. Each coat shall be kept damp continuously till the next coat
is applied or for a maximum period of 7 days. Moistening shall commence as soon as the plaster has
hardened sufficiently and is not susceptible to injury. The water shall be applied by using a fine fog-
spray. Soaking of wall shall be avoided and only as much water as can be readily absorbed shall be
used. Excessive evaporation on the sunny or windward sides of buildings in hot dry weather may be
prevented by hanging mattings or gunny bags on the outside of the plaster and keeping them wet.
9.1.6.10. : After the completion of the finishing coat, the plaster shall be kept wet for at least seven
days, and shall be protected during that period from extremes of temperature and weather.
9.1.6.11 Inspection and Diagnosis: Interrelation of Various Factors : It is essential to determine
the cause of any defects of plaster work before any attempt is made to remedy or repair them and
unless the cause is properly dealt with, the majority of defects will continue to recur after repair.
The interpretation of defects of plaster work and the determination of their causes can only be done
by approaching the subject in a systematic and logical manner.
9.1.6.12 :Since, it is the final plaster finish which claims the attention of the casual observer, it is a
common error to blame only the plastering materials or workmanship for all defects. Actually, these,
although perhaps the most important, are not the only factors that may influence the final result.
9.1.6.13 :Every defect in plastering is more or less connected with the whole history and treatment of
the background. Consideration shall be given not only to the plastering material used and to the quality
of workmanship, but also the climatic conditions prior to, or during and after the plastering process,
and to the correct choice of the plastering system.
9.1.6.14 :Detailed consideration has already been made in 9.1.4.9 and 9.1.5.8 or several factors in this
connection such as:
a) the possible causes for lack of bond between successive coats of plaster and between the first
undercoat and the background concerned,
b) the possible effect of inadequate time intervals in promoting severe efflorescence or `map
crazing' on the finished surface, and
c) the effect of climatic conditions in causing or aggravating the above as well as other
troubles.
9.1.6.15: Besides, the active influences of the various atmospheric conditions, the effect of the
physical properties of the building surface prior to plastering shall also receive due consideration.
9.1.6.16: Plastering defects and their remedies :
General - It is not possible to give simple rules for the correction of all plastering defects or failures.
Many serious defects may be shown to have causes outside the materials or techniques used in the
plastering operations and it is often useless to repair or even replace the plaster without first having
discovered and corrected the primary fault.
9.1.6.17 (a) Thus, penetration of moisture through an external wall may cause blistering,
efflorescence, flaking or complete disintegration of the plaster. To patch or to replaster such a wall
without first taking steps to prevent further damp penetration would be useless.
 Again, plastered ceilings may develop cracks because the ceiling construction permits
excessive deflection, and no plaster repair could be expected to be effective in preventing it.
 Recurrent surface dampness may be associated with the presence of deliquescent salts in the
plasterwork, but it would not necessarily be effective to renew the plaster. The salts may also be
in the background and would probably migrate into the new plaster and bring about a renewal
of the trouble. This type of defect usually traced to the use of an unwashed estuarine or sea sand,
is best corrected by battening out and erecting a new plaster base out of capillary contact with
the affected area.
9.1.6.18: Defects caused by the use of unsuitable plastering materials or by faulty technique may be
corrected by means of an appropriate repair as advised by the Engineer.
9.1.6.19: Typical Plastering Defects:
a) Blistering: -This is due to intense local relative movement of the final coat, where the
component of the splitting force at right angles to the plaster surface exceeds the bond strength
at the inter-face, which is aggravated by the absence of an adequate key between the final coat
and undercoat. The most common cause is local exposure to radiant heat.
b) Bond Failure or Loss of Adhesion: This, according to its severity, results in ` hollow ' patches,
flaking of top coats, or peeling off of substantial areas. It is essential to prevent moisture
penetration from the outside, as otherwise peeling off will eventually occur.
c) Cracking: This is usually caused by movement in the background or the surrounding structure.
Shrinkage movement in undercoats based on cement or lime or the use of unsuitable grades of
sand may cause cracking of the final coat.
d) Crazing: -The effect of this may, however, be reduced to tolerable or even to negligible
proportions by attention to the points enumerated in è' below and 9.1.6.19.
e) Cement plaster or Cement-Lime plaster: attempts to shrink on hardening but is restrained
by bond with the background which, either has already undergone most of the shrinkage if of
concrete, or is practically immune from movement, if of brick or stone. This restraint to
shrinkage causes tensile stress in the plaster which is maximum at the skin. If the shrinkage is
great, these failures develop in to cracks which exist through the whole depth of the plaster. In
order to prevent this formation, it is necessary to limit the differences in shrinkage and thereby
reduce the tensile stress to within safe limits.
9.1.6.20 : Attention to the following points will reduce the tendency to surface crazing to a minimum:
a) Use of well-graded sand and the most suitable proportions of cement and sand as
recommended in this code;
b) Avoidance of overworking of cement finishing so that excess cement may not be drawn to
the surface to cause shrinkage at the top layer;
c) Observance of adequate time intervals between undercoats and subsequent finishing coat, so
that each successive coat undergoes a portion of its shrinkage before the next is applied and thus,
reduces the skin tension in the preceding coat; and
d) Suitable control over variations in moisture-content and temperature subsequent to plastering.
9.1.6.21 Efflorescence: This is caused by the presence of soluble salts, such as sulphates of Sodium,
Calcium and Magnesium normally in the background, and sufficient water to carry these to the
surface as the structure dries.
9.1.6.22 Remedy: Sealing coats may not effectively hold back strong efflorescence. Dry brushing of
the growth as it appears is the only remedy. Efflorescent salts shall not be removed by washing with
water as it may carry some of the salts back into the pores. On redrying, efflorescence may be even
worse than before if the salts were still present in the structure. Efflorescence will continue as long as
there is sufficient water in the structure or plaster backings to carry the soluble salts forward and it is
useless to attempt to seal the moisture by the paint film on the surface. The treatment of an old wall
with Silicone solution will frequently stop the efflorescence as the liquid blocks the passage for
movement of moisture. In the case of efflorescence due to the rising of salt solutions through
capillary action from sub-soil the only remedy is to provide bitumen or metallic seals in the walls
above the ground level so that an effective barrier to the capillary action is created.
9.1.6.23 Grinning : Grinning is generally caused by marked differences in suction of the background
which are not masked by the procedure of adjusting the suction, and which are manifested as areas of
varying texture on the plaster surface. Such differences are often caused by the use of a mortar having
suction characteristics markedly different from those of the bricks or blocks with which it is used.
Grinning is more usually associated with single coat work ( two coat work is normally provided on most
solid backgrounds and with this thickness of plasterwork grinning is rare).
9.1.6.24: Irregularity of Surface Texture: This may be caused by faulty workmanship, but even a
skilled craftsman may be unable to prevent it on backgrounds exhibiting varying suction
characteristics unless three coat plastering is employed.
9.1.6.25 Popping or Blowing: These occasionally occur in plaster mixes which contain particles of
materials which may keep on expanding even after the plaster coat has set. The expansive force is
sufficiently great to push out the plaster in front of the particles, leaving a conical hole known as a `
Pop or Blow' . Insufficiently slaked and unmatured lime is frequently the source of unsound particles
causing popping or blowing. Popping may also be caused by the presence of particles of coal or other
oxidizable material contained in the sand used for the plaster mix.
9.1.6.26 Recurrent Surface Dampness: The presence of deliquescent salts as occur in sea-water will
bring about recurrent dampness in plaster finishes when the atmospheric humidity is high. It may
also be caused by condensation of moisture in chimney flues with a permeable lining, for example,
where slow combustion stoves are employed.
9.1.6.27 Softness or Chalkiness: This may result from excessive suction of the background, undue
thinness of the finishing coat, working past the setting point, or subsequent exposure of the finishing
coat to excessive heat or draught during setting.
9.1.6.28 Maintenance : Plastering work shall be protected at all stages of its life from persistent
attack by water or moisture either through the undercoats or through the outer surface. The matter is
particularly important during the interval between plastering and decorating. Subsequent decoration
on the whole surface may be vitiated by a persistent stream of water down on particular part due to
flooding of upper floors under construction, delay in provision of gutters, etc. This would be
particularly serious if conditions are favourable to formation of efflorescence. In extreme cases, the
plaster surface may be softened or badly channeled, necessitating local repair.
9.1.6.29 Precaution against Discontinuity in Backgrounds :
a) Cracking of walls or plaster is often caused by discontinuity, for instance changing from
concrete to brickwork, from clay brickwork to lightweight concrete block-work or even
changing from one type of brick to another. Differential drying shrinkage is probably the main
cause but difference in thermal movements may also contribute. Reinforcement of the plaster by
metal lathing or scrim over the junction is not always successful. The best treatment may be to
separate the two portions by a neat cut through the plaster at the junction. The junction may be
masked, if so desired, by fixing a cover strip to one side.
b) A change from wall to ceiling can be regarded as a discontinuity. To prevent the cracks, a
cornice that would allow slight movement without cracking or a straight cut through the plaster
at the junction may be provided.
9.1.7 Scaffolding:
a) For all exposed brick, stone, tile work, double scaffolding independent of the work having two
sets of vertical supports shall be provided. The supports shall be sound and strong, tied together
with horizontal pieces over which scaffolding planks shall be fixed.
b) For all other brick work in buildings, single scaffolding shall be permitted. In such cases the,
inner end of the horizontal scaffolding pole shall rest in a hole provided only in the header
course for the purpose. Only one header for each pole shall be left out. Such holes for scaffolding
shall, however, not be allowed in pillars/columns less than one metre in width or immediately
near the skew backs of arches. The holes left in masonry works for scaffolding purposes shall be
filled and made good before plastering.
Note : In case of special type of brick, stone work, scaffolding shall be got approved from
Engineer-in charge in advance.
9.1.8 Precaution and Protection:
a) Any cracks which appear in the surface and all portions which sound hollow when tapped, or are
found to be soft or otherwise defective, shall be cut out in rectangular shape and redone as
(i) When ceiling plaster is done, it shall be finished to chamfered edge at an angle at its junction
with a suitable tool when plaster is being done. Similarly when the wall plaster is being
done, it shall be kept separate from the ceiling plaster by a thin straight groove not deeper
than 6 mm drawn with any suitable method with the wall while the plaster is green.
To prevent surface cracks appearing between junctions of column/beam and walls, 150
mm wide chicken wire mesh should be fixed with U nails 150 mm, centre to centre before
plastering the junction. The plastering of walls and beam/column in one vertical plane
should be carried out in one go. For providing and fixing chicken wire mesh with U nails
payment shall be made separately.
b) Sufficient number of plasterers shall be employed to complete the wall /ceiling work in one
day otherwise it will be patchy.
c) Cleaning: Remove temporary protection and enclosure of other work. Promptly remove plaster
from doorframes, windows, and other surfaces these are not to be plastered. Repair floors,
walls, and other surfaces stained, marred, or otherwise damaged from plastering work. When
plastering work is complete, remove unused materials, containers, and equipment, clean floors
of plaster debris.
d) Protection : The Contractor shall make all arrangements for the protection of plaster from
deterioration and damage during the remainder of the construction period as per the direction of
Engineer in Charge.
9.1.9 Defects:
The contractor shall remove the defects in the plaster. If the plaster perishes or defects are not
removed, the work shall be removed and redone at the contractor's expense. Contractor shall Cut,
patch, point-up and repair plaster as necessary to accommodate other work and to restore cracks,
dents, and imperfections. Repair or replace plaster to eliminate blisters, buckles, excessive crazing and
check cracking, dry-outs, efflorescence, sweat-outs, and similar defects, including areas of the work
which do not comply with specified tolerances and where bond to the substrate has failed. Sand
smooth-trowel finishes lightly to remove trowel marks and arrises. The table given in Appendix `B'
Lists the unwanted conditions (defects), possible causes and preventions or possible remedies. These
conditions include soft plaster, shrinkage cracks, structural cracking, plaster deterioration, crazing,
efflorescence, discolouration, lack of bond, lap marks and leaks.
Measures to prevent defects in plaster are given in Appendix 'B'.
9.1.10 Mode of Measurements ( Ref. IS 1200):
i) Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metre correct to two places of decimal.
ii) Thickness of the plaster shall be excluding of the thickness of the key i.e. grooves, or open
joints in brick and stone work.
The measurements of wall plaster shall be taken between the walls or partitions (the dimensions
before the plastering shall be taken) for the length and from the top of the floor or skirting to the
ceiling for the height. Depth of coves (concave moulding between the wall and ceiling) or
cornices if any shall be deducted.
iv) The following shall be measured separately from wall plaster.
(a) Plaster bands 30 cm wide and under
(b) Cornice beadings and architraves or architraves moulded wholly in plaster.
(c) Circular work not exceeding 6 m in radius.
v) Plaster over masonry pilasters will be measured and paid for as plaster only.
A coefficient of 1.63 shall be adopted for the measurement of one side plastering on honey
comb work having 6 x 10 cm opening.
Moulded cornices and coves.
(a) Length shall be measured at the centre of the girth.
(b) Moulded cornices and coves shall be given in square metres, the area being arrived at by
multiplying length by the girth.
(c) Flat or weathered top to cornices when exceeding 15 cm in width shall not be included in
the girth but measured with the general plaster work.
(d) Cornices which are curved in their length shall be measured separately.
viii) Exterior plastering at a height greater than 10 m from average ground level shall be
measured separately in each storey height. Patch plastering (in repairs) shall be measured as
plastering new work, where the patch exceed 2.5 sqm, extra payment being made for preparing
old wall, such as dismantling old plaster, raking out the joints and cleaning the surface. Where
the patch does not exceed 2.5 sqm in area it shall be measured under the appropriate item under
sub head 'Repairs to Buildings'.
ix) Deductions in measurements, for opening etc. will be regulated as follows:
(a) No deduction will be made for opening or ends of joists, beams, posts, girders, steps etc.
up to 0.5 sqm in area and no additions shall be made either, for the jambs, soffits and sills
of such openings. The above procedure will apply to both faces of wall.
(b) Deduction for opening exceeding 0.5 sqm but not exceeding 3 sqm each shall be made
for reveals, jambs, soffits sills, etc. of these openings.
(i) When both faces of walls are plastered with same plaster, deductions shall be made
for one face only.
When two faces of walls are plastered with different types of plaster or if one face is
plastered and other is pointed or one face is plastered and other is un plastered,
deduction shall be made from the plaster or pointing on the side of the frame for the
doors, windows etc. on which width of reveals is less than that on the other side
but no deduction shall be made on the other side. Where width of reveals on both
faces of wall is equal, deduction of 50% of area of opening on each face shall be
made from area of plaster and/or pointing as the case may be.
(iii) For opening having door frame equal to or projecting beyond thickness of wall, full
deduction for opening shall be made from each plastered face of wall.
Note: Different qualities of plastering referred in this para shall not include 18 mm
plastering with terrazzo finish as given in para 9.20 as the method of measurement in the
case of the later is different. In such cases where the plaster on the other face consists of a
plaster with terrazzo finish method of addition and deductions for the ordinary plaster
face shall be regulated as if that face alone is plastered and the other is given an entirely
different type of non-comparable treatment
(c) For opening exceeding 3 sqm in area, deduction will be-made in the measurements for
the full opening of the wall treatment on both faces, while at the same time, jambs, sills
and soffits will be measured for payment.
In measuring jambs, sills and soffits deduction shall not be made for the area in contact with the
frame of doors, windows etc.
Note : In calculating areas of opening, the extra width of rebated reveals, if any shall be excluded.
9.1.11 Curing: To develop maximum strength and density in the plaster, it is necessary to cure lime,
cement and cement-lime plasters properly. Each coat shall be kept damp continuously till the next coat
is applied for a maximum period of 7 days. All plaster work (except mud plaster) shall be kept damp
continuously for a period of 7 days after application of final coat. Moistening shall commence as
soon as the plaster has hardened sufficiently and is not susceptible to injury. The water shall be
applied by using a fine fog-spray. Soaking of wall shall be provided and only as much water as can be
readily absorbed shall be used. Excessive evaporation on the sunny or windward sides of buildings
in hot dry weather may be prevented by hanging mattings or gunny bags on the outside of the plaster
and keeping them wet.
9.2 12 mm Thick Lime Plaster:

9.2.1 Scaffolding shall be as specified in 9.1.7.
9.2.2 Preparation of Surface shall be as specified in 9.1.5.14
9.2.3 Mortar: The mortar of specified mix shall be used. Lime mortars shall be as specified in
Chapter 4. Lime mortar shall be kept damp & shall never be allowed to go dry. If the mortar has
become hardened or set before being used, it shall be rejected and removed from site.
9.2.4 Application of Plaster: Ceiling plaster should be taken up first & then plaster to the walls
starting from the top and working down wards. Plaster patch of 150 mm x 150 mm shall first be
applied to ensure even thickness and a true surface.
i) Ceiling plaster shall be completed before commencement of wall plaster.
ii) Plastering shall be started from the top and worked down, towards the floor. All put-log holes
shall be properly filled in advance of the plastering as the scaffolding is being taken down. To
ensure, even thickness and a true surface, plaster about 15 x 15 cm shall be first applied,
horizontally and vertically, at not more than 2 metre intervals over the entire surface to serve as
gauges. The surfaces of these gauged areas shall be truly in the plane of the finished plaster
surface. The mortar shall then be laid on the wall between the gauges with trowel. The mortar
shall be applied in a uniform surface-slightly more than the specified thickness. This shall be
beaten with thin strips of bamboo about one metre long to ensure thorough filling of the joints,
and then brought to a true surface, by working a wooden/Aluminium straight edge reaching
across the gauges with small upward and sideways movements at a time. Finally the surface shall
be finished off true with trowel or wooden float accordingly a smooth or a-sandy granular
texture is required. Excessive troweling or over working the float shall be avoided. During this
process, a solution of lime putty shall be applied on the surface to make the latter workable.
iii) All corners, arrises, angles and junctions shall be truly vertical or horizontal as the case may be
and shall be carefully finished. Rounding or chamfering corners, arrises ( sharp corners) ,
provision of grooves at junctions etc. wherever required shall be done without any extra
payment. Such rounding, chamfering or grooving shall be carried out with proper templates of
battens to the sizes required.
iv) When suspending work at the end of the day, the plaster shall be left, cut clean to line both
horizontally and vertically. When recommencing the plastering the edge of the old work shall be
scrapped cleaned and wetted with lime putty before plaster is applied to the adjacent areas, to
enable them to joined together properly. Plastering work shall be closed at the end of the day
on the body of wall and not nearer than 15 cm to any corners or arrises. It shall not be closed
on the body of the features such as plasters, bands and cornices, nor at the corners or arrises.
Horizontal joints in plaster work shall not also occur on parapet tops and couplings as these
invariably lead to leakages.
No portion of the surface shall be left out initially to be patched up later on.
9.2.5 Finish: The plaster shall be finished to a true line and plumb surface and to the proper degree of
smoothness as required. The work shall be tested frequently as the work proceeds with a true straight
edge not less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested
with a level and all jambs and corners with a plumb bob as the work proceeds.
9.2.6 Thickness: The thickness of the plaster specified shall be measured excluding of the thickness
of key i.e. grooves or open joints in brick, stone work. The average thickness of plaster shall not be
less than the specified thickness here i.e. 12 mm. The minimum thickness over any portion of the
surface shall not be less than specified thickness by more than 3 mm. The average thickness should
be regulated at the time of plastering by keeping suitable thickness of the gauges. Extra thickness
required in dubbing behind rounding or corners at junctions of wall or in plastering of masonry
cornices etc. will be ignored.
9.2.7 Curing: shall be as specified in. 9.1.11. 9.2.8
Precaution: shall be as specified in 9.1.8. 9.2.9
Measurements: shall be as specified in 9.1.10.
9.2.10 Rate: The rate shall include the cost of all labour and materials involved in all the operations
described above.
9.3-15 mm Thick Lime Plaster: 15 mm thick lime plaster shall be done on rough side of single or
half brick work. The average thickness of plaster shall not be less than 15 mm and the minimum
thickness of the plaster at any place shall not be less than 10 mm. All other details shall be as
specified in 9.2.
9.4- 18 mm Thick Lime Plaster Two Coats Work:
9.4.1 Scaffolding , Preparation of Surface and Mortar: The details of scaffolding and preparation
of surface and mortar shall be as specified under 9.2.
9.4.2. Application of Plaster:
9.4.2.1 The plaster shall be applied in two coats, i.e. 12 mm under coat and then 6 mm finishing coat
and shall have an average final thickness of not less than 18 mm.
9.4.2.2 12 mm thick undercoat: This shall be applied in the same manner as specified under 12 mm
lime plaster except that (a) the finishing after the mortar has been brought to a level with the wooden
straight edge shall be done with wooden float only and (b) during the process lime putty solution
shall not be applied.
The surface shall be further roughened by furrowing about 2 mm deep with a scratching tool
diagonally both ways to form a key for the finishing coat. The scratched lines shall be at not more than
15 cm apart. The surface shall be kept wet till the finishing coat is applied. Before the first coat hardens
its surface shall be beaten up by edges of wooden tapers to consolidate/ compress the mortar (cracks
are closed).
9.4.2.3 6 mm Finishing Coat: The finishing coat shall be applied in a day or two after the under
coat has set. The later shall not be allowed to dry out, before the finishing coat is laid on. The
finishing coat shall be applied in -a uniform thickness of slightly more than 6 mm. The method of
application shall be described in 9.2 except that the surface shall not be beaten with bamboo strips.
The final thickness of the top coat shall be 6 mm.
9.4.3 Thickness:
i) The thickness of the under coat of plaster specified shall be excluding the thickness of key. The
average thickness of the under coat shall not be less than 12 mm whether the wall treated is of
brick or stone. In case of brickwork the minimum thickness over any portion of the surface
shall not be less than 10 mm while in the case of stonework, the minimum thickness over the
bushing shall not be less than 6 mm.
ii) 6 mm finishing coat shall be uniformly 6 mm thick over the under coat in the case of both
brick and stone masonry.
9.4.4 Finish, Curing, Precautions, Measurements, Rate:
Specifications for other details such as Finish, Curing, Precautions, Measurements, Rate etc. shall be
as described under 9.2.
9.5 Lime Punning:
9.5.1 Scaffolding: Scaffolding shall be as specified in 9.1.7.
9.5.2 Mortar: The mortar for punning shall consist of 1 lime putty and 1 fine sand unless otherwise
described in the item. It shall be prepared as specified in the chapter on mortars.
9.5.3 Application: The surface of the under coat on which the punning is to be done shall be left
rough. The punning shall be applied when the under coat is still green. The mortar for punning shall
be applied in uniform layer slightly more than 3 mm thick between gauged pads with which to ensure
an even and uniformly thick surface by frequent checking with a wooden straight edge. It shall be
finished to an even and smooth surface with trowels.
All corners, arrises, angles and junctions shall be truly vertical and horizontal as the case may be and
shall be carefully and neatly finished. Rounding or chamfering corners, arrises, junctions etc. wherever
required shall be punned without any extra payment. Such rounding, chamfering or grooving shall be
carried out with proper templates or battens to the sizes required.
No portion of the surface shall be left out initially to be patched up later on.
9.5.4 Thickness: The thickness of the finished punning shall not be less than 3 mm thick.
9.5.5 Curing: Curing shall be started as soon as the punning has sufficiently hardened not to be
damaged when watered, and in any case not earlier than 24 hours after the punning has been
completed. The punning shall be kept wet for a period of at least 7 days. During this period, it shall be
suitably protected from all damages at the contractor's expense by such means as the Engineerin-
charge may approve. The dates on which the plastering is done shall be legibly marked on the various
sections plastered so that curing for the specified period thereafter can be watched.
9.5.6 Finishing, Precautions: Specifications for finishing, precautions, etc. shall be as specified
under 9.2.
9.5.7 Measurements:
i) The measurements for lime punning shall be taken over the finished work. The length and
breadth shall be measured correct to a cm. The area shall be calculated in sqm correct to two
places of decimal.
ii) Punning over Plaster on bands, skirting, coping, cornices, drip courses, string courses etc. shall
not be measured separately but only as wall surfaces. In these cases the measurements shall be
taken girthed over the above features.
iii) Punning over plaster on circular work also, of any radius shall be measured only as wall
surfaces, and not separately.
iv) Lime punning in patch repairs irrespective of the size of the patch shall be measured as new
work, and in this case the rate shall include for cutting the patch to rectangular shape before lime
punning.
v) Deductions in measurements for openings shall be regulated generally as described in 9.1.10.
described above.
9.6 - 25 mm thick Lime Plaster (Three Coat Work):
9.6.1 Scaffolding & Preparation of Surface and Mortar : The details of scaffolding & preparation
of surface and mortar shall be as specified under 9.2.
9.6.2 Application of Plaster:
i) The plaster shall be applied in 3 coats i.e. 15 mm under coat, 8 mm floating coat & 2 mm
finishing coat.
ii) 15 mm first or under coat. This shall be applied in the same manner as specified in 9.4.2.2.
except the thickness being 15 mm.
iii) 8 mm second or floating coat shall be applied in the same manner is specified under 9.4.2.3
except the thickness being 8 mm. The surface shall be brought true and even surface and then
roughened to provide bond for the finishing coat. The coat shall be damp-cured till the fmishing
coat is applied.
iv) Third or finishing coat : Immediately after the completion of second coat another coat of pure
lime plaster shall be applied. The mortar for final coat shall consist of pure lime ground to fine
paste and reduced to consistency of cream by addition of water. This shall be applied with
brush to a thickness of 2 mm and gently rubbed till it hardens. It shall then be rubbed with a
stone until a very fine polish is produced. The quality of plaster depends mainly on ensuring that
the mortar for the last coat is absolutely free from grit and is being constantly rubbed till it is
quite dry. This process must be continued till the appearance of moisture ceases.
9.6.3 Thickness:
i) The thickness of the under coat of plaster specified shall be excluding of the thickness of
key. The average thickness of the undercoat shall not be less than 15 mm.
ii) The average thickness of the floating coat shall not be less than 8 mm.
iii) The finishing coat shall be uniformly 2 mm thick over the floating coat.
9.6.4 Finish, Curing, Precautions, Measurements, Rate: Specification for other details such as
finish, curing, precautions, measurements, rate etc. shall be as described under 9.2.
9.7. Lime Sandia Finish & Neeru Finish :
a)Lime Sandia Finish:
9.7.1 Preparation of Sandia : Well burnt "kankar" nodules shall be picked up and slaked well into a
thin cream in a pit. The slaked lime shall be then run through a sieve of 16 meshes to 92.5 cm into
another pit and left open for at least 24 hours. The excess water will either evaporate or soak in
ground leaving liquid sandla in the pit. This should be again left into the pit for another 3 days till it
turns it into a stiff paste. The sandla should be pure white and free from dust, dirt, earth or sand. Any
sandla which is not so or is blackish or is not stiff shall be rejected. Sandla must under no
circumstances be made by liquifying slaked lime which has been kept for some time. The sand to be
used with this sandla should be very fine and screened through a screen of 32 meshes to 2.5 cm.
9.7.1.1 Sandia Finish : Equal parts of Sandia and fine sand shall be ground together to fine paste and
applied to the top coat of plaster which has not been allowed to dry and shall be rubbed smooth and
polished in one day. Sufficient labour shall be employed to complete a wall in a day as otherwise the
wall will be patchy.
b) Neeru Finish:
9.7.2 Preparation : Fat lime of best quality shall be slaked and mixed with sufficient water to form
a thick paste, it shall be passed through a fine sieve of 3mm mesh, to remove all un slaked particles
and foreign matter and allowed to mellow under water for at least 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 with sand and jute. The proportion of sand shall be 1 cum of fine washed sand passed
through I.S. Sieve No.60 to 4 cum of lime putty. The jute shall be finely chopped and shall be used
in the proportion of 4 kg of jute per cum of mortar. 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 not more
than that can be consumed in 15 days shall be prepared at a time.
9.7.2.1 Neeru Finish : 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 a perfectly smooth and
even finish working from top to bottom. While troweling is going on, soap stone powder contained in
thin muslin bags shall be dusted over the surface and worked in.
9.8 Plastering with Gypsum :
9.8.1 Scope: This specification lays down requirements regarding preparation of surfaces, application
and finishing of gypsum plaster.
9.8.2 Materials:
9.8.2.1 Gypsum plaster : The Gypsum plaster shall confirm to I.S. No. 2547( part I & II) -1976.
Unless otherwise specified semi-hydrate of Gypsum shall be used. Gypsum plaster shall be classified
as follows:
a) Plaster of paris,
b) Retarded hemihydrate gypsum plaster:
Type I - Under coat:
a) Browning plaster,
b) Metal lathing plaster,
Type II-Final coat plaster:
a) Finish plaster,
b) Board finish plaster,
c) Anhydrous gypsum plasters are for finishing only, and
d) Keene's plaster is for finishing only.
NOTE - Keene's plaster is of the anhydrous type. It is characterized by being more easily brought to a
smooth and clean finish associated with gradual set. In this standard Keene's plaster is differentiated from
a anhydrous gypsum plaster by a higher standard of purity (CaSO4 not less than 80 percent) and
hardness. The special qualities traditionally associated with this type of plaster cannot be dealt with at
present by any convenient direct test.
9.8.2.2 Chemical requirements : The chemical composition of the plasters shall be given below.
Table 6.
S. Particulars Requirement Method of

No Plaster of Paris Anhydrous Keene's Test
Retarded
(b-hemihydrate) Hemihydrate Gypsum Plaster Plaster
Gypsum Plaster.
i) S03, min. 35 35 40 47 See IS 1288-

percent by mass 1982*
(reaffirmed
1999)
ii) CaO 2/3 of SO3 2/3 of SO3 2/3 of SO3 2/3 of SO3 -do-
content content content content
iii) Soluble 0.3 0.3 0.3 0.3 See Appendix
magnesium salts 'D'
expressed as
percentage of
MgO. Max.
iv) Soluble Sodium 0.3 0.3 0.3 0.3 -do-
salts, expressed
as percentage
of Na,O3, Max.
v) Loss on ignition, Not greater than Not greater than 3.00 Max. 2.00 Max. See Appendix
percent by mass 9 and not less 9 and not less 'E'
than 4 than 4
vi) Free Lime, - 3# - - See Appendix
Min. percent `F'
* Method of test for Mineral Gypsum and gypsum products.
# Applicable to metal Lathing plaster.
9.8.2.3 Physical requirements :
a) Purity-No material shall be added to gypsum plasters except those which are necessary to control
the setting, such as sodium citrate, break-down products of Keratin, Potassium Sulphate, Alum and
Zinc Sulphate, or working characteristics, or to impart anti-corrosion or fungicidal
properties. Not withstanding the requirements specified in 9.8.2.1, additives for the purpose
of colouring may be added to Keene's plaster.
b) Gypsum plaster shall also satisfy the requirements given in Table 7 (below), when tested
according to the procedures given in IS : 2542 (Part I)-1981(Reaffirmed2002)*.
Table 7: Physical Requirements
S. Particulars Requirements
No Plaster of Paris Retarded Anhydrous Keene's
Hemihydrate Gypsum Plaster Plaster
Gypsum Plaster
i) Setting Time, - - - -
Minutes
a) Plaster sand 45-120 120-900 - -
mixture
b) Neat Plaster 20-40 60-180 20-360 20-360
ii) Transverse 5 4* - -
strength, kg/cm2,
Min.
iii) Soundness Set Plaster Pats Set Plaster Pats Set Plaster Pats Set Plaster Pats
shall not show shall not show shall not show shall not show
any sign of any sign of any sign of any sign of
disintegration, disintegration, disintegration, disintegration,
popping or popping or popping or popping or
pitting. pitting. pitting. pitting.
iv) Mechanical - # Diameter of Diameter of the Diameter of the
resistance of set the indentation indentation shall indentation shall
neat plaster. shall not be less not be more not be more
than 3 mm and than 4.0 mm than 3.5 mm
not more than
4.5 mm
v) Residue on 90 5.0 5.0 2.0 2.0
micron IS Sieve
Percentage, Max.
vi) Expansion on - 0.24 at 24 h$ - 0.5 at 96 h
setting, Percentage
Max.
* Applicable to undercoat plasters only.
# Applicable to final coat plasters.
$ Applicable to board finish plasters only.
9.8.3 Suitability :The Gypsum plastering is suitable for internal plaster only.
9.8.4 Plaster coats and Thickness: The plastering shall be done in two coats, thickness of the
finishing coat shall be about 8 mm. Rest of the thickness shall be of under coat. The total thickness
shall be 15, 20 or 25 mm depending upon the condition of surface.
9.8.5 Preparation of Surfaces:
9.8.5.1 General : The wall or ceiling to be plastered shall be perfectly dry.
9.8.5.2 The raking of joints, cleaning the surface etc. shall be done in accordance with the relevant
clauses under "Specification for Lime Plaster" taking special care as provided under clause 9.1.5.15
above.
9.8.6 Application:
9.8.6.1 Application of undercoat :- The Gypsum plaster shall be mixed with such quantity of water
so as to give a plastic and easily workable mortar. Before applying the under coat, square patches of
about 10 cm. wide both horizontally and vertically (at suitable spacing or vertical strips about 10 cm.
wide), shall be applied to such thickness that the surface of all the patches or strips are in the same
horizontal or vertical plane and the average thickness of the under coat will be obtained. After having
applied these reference pats or strips, the mortar shall be applied over the whole surface pressed well
into all the joints and shall be rendered with a straight edge so as to give a dead but slightly rough
surface.
9.8.6.2 Application of Finishing Coat :- The day after the application of the under coat the finishing
coat shall be applied to a thickness of 8 mm. The finishing coat shall be of consistency of a thick
cream. This shall be spread over the whole surface evenly and shall be rubbed smooth, polished and
completed in one operation.
Note : No curing is required for the plastering work with Gypsum plaster, rather it is detrimental.
9.8.7 Finish: The resulting surface shall be perfectly smooth and plumb. For applying paint, distemper
etc. the wall shall require sand papering.
9.8.8 Protection and Mode of Measurement: Protection and mode of measurement shall be as
specified in Clause 9.1.8 and 9.1.10 respectively.
9.9 Cement Plaster: The cement plaster shall be 12 mm,15 mm, 20 mm or 25 mm thick as specified
in the item.
9.9.1 Scaffolding and Preparation of Surface : Scaffolding and preparation of surface shall be as
specified under 9.1.7 and 9.1.5.15
9.9.2 Mortar : The mortar of the specified mix using the type of sand described in the item, shall be
used. It shall be as specified in Chapter 4. For external work and undercoat work, the fine aggregate
shall conform to grading W. For finishing coat work the fine aggregate conforming to grading zone V
shall be used.
9.9.3 Application: : The specifications as in 9.2.4 shall apply except in the following respects :
(a) Beating with thin bamboo strips shall not be done on the cement plaster, and
(b) No lime putty solution shall be applied on the face when finishing. Further the plastering and
finishing shall be completed within half an hour of adding water to the dry mortar.
9.9.4 Thickness: Where the thickness required as per description of the item is 20 mm-the average
thickness of the plaster shall not be less than 20 mm whether the wall treated is of brick or stone. In
the case of brick work, the minimum thickness over any portion of the surface shall be not less than
15 mm while in case of stone work the minimum thickness over the bushings shall be not less than
12mm.
The finished plaster surface shall not show any deviation more than 3 mm when checked with a
straight edge of 2m length placed against the surface.
9.9.5 Curing: Curing shall be started as soon as the plaster has hardened sufficiently not to be
damaged when watered. The water shall be applied by using a fine fog spray.
The plaster shall be kept wet for a period of at least 7 days. During this period, it shall be suitably
protected from all damages at the contractor's expense by such means as the Engineer-in-Charge
may approve. The dates on which the plastering is done shall legibly be marked on the various
sections plastered so that curing for the specified period thereafter can be watched. The rest of the
specifications as described in 9.1.11 shall apply.
9.9.6 Finish, Precautions, Measurements and Rate: Specifications for Finish, Precautions,
Measurements and Rate shall be as described under 9.1
9.10- Cement Plaster with a floating coat of neat cement (Punning): The cement plaster shall be
6, 12, 20 or 25 mm thick, finished with a floating coat of neat cement, as described in the item.
9.10.1 Specifications: Specifications for this item of work shall be same as described in 9.9 except
for the additional floating coat which shall be carried out as below:
When the plaster has been brought to a true surface with the wooden straight edge (Clause 9.9.3) it
shall be uniformly treated over its entire area with a paste of neat cement and rubbed smooth, so that
the whole surface is covered with neat cement coating. The quantity of cement applied for floating
coat shall be 1 kg per sqm. Smooth finishing shall be completed with trowel immediately and in no
case later than half an hour of adding water to the plaster mix. The rest of the specifications described in
9.9 shall apply.
9.10.2 Neat Cement Punning:
i) The specifications given for floating coat described earlier shall apply.
ii) Specification for scaffolding and curing shall be as described earlier. Specifications for
Finish and Precautions shall be as described earlier.
iii) Measurements:
a) The measurements for cement punning shall be taken over the finished work. The length
and breadth shall be measured correct to a cm. The area shall be calculated in sqm correct
to two places of decimal.
b) Punning over Plaster on bands, skirting, coping, cornices, drip courses, string courses etc.
shall not be measured separately but only as wall surfaces. In these cases the
measurements shall be taken girthed over the above features.
c) Punning over plaster on circular work also, of any radius shall be measured only as wall
surfaces, and not separately.
d) Cement punning in patch repairs irrespective of the size of the patch shall be measured
as new work, and in this case the rate shall include for cutting the patch to rectangular
shape before lime punning.
e) Deductions in measurements for openings shall be regulated generally as described
earlier.
v) Rate: The rate shall include the cost of all labour and materials involved in all the
9.11- 12 mm thick Cement Plaster:
9.11.1 The Specification for scaffolding and preparation-of surface shall be as described in 9.9.
9.11.2 Mortar: The mortar shall be as specified in chapter 4 for mortars. It must be firstly mixed for
immediate use and in such quantities as to permit the whole batch being used in the work before the
mortar has commenced to set. Water proofing compound is to be mixed should be as per
manufacturers specification or as per direction of Engineer in-charge. Cement Mortar for internal
finishing, if ordered, can be gauged with 10% lime.
The plaster material should be mechanically mixed. It should not be hand mixed except where
small amounts are needed usually less than one bag of plaster material.
9.11.3 Application: The plaster shall be laid with more than the required thickness and levelled with
wooden rule. The finished thickness shall be sufficient to cover by 10 mm the surface of wall in brick
masonry and by 6 mm all the projections in the case of random rubble masonry.
The plaster shall be well pressed into the joints and the surface rubbed smooth with a floating coat of
about 3 mm of pure cement. The coat must be applied while the base coat is still fresh.
9.11.4 Curing, Finishing, Precautions, Measurements and Rate: Specification for curing,
finishing, precautions, measurements and rate shall be as described under 9.9.
9.12 20 mm thick Cement Plaster (Two Coat Work):
9.12.1 Scaffolding and Preparation of Surface: The specification for scaffolding and preparation
of surface shall be as described in 9.9.
9.12.2 Mortar : The mix and type of the fine aggregate specified in the description of the item shall
be used for the respective coats. It shall be as specified in Chapter 4. Generally the mix of the finishing
coat shall not be richer than the under coat unless otherwise described in item.
Generally coarse sand shall be used for the under coat and fine sand for the finishing coat, unless
otherwise specified for external work and undercoat work, the fine aggregate shall conform to
grading zone IV for finishing coat work the fine aggregate conforming to grading zone V shall be
used.
9.12.3 Application:
9.12.3.1 The plaster shall be applied in two coats i.e. 12 mm undercoat and then 8 mm finishing
coat and shall have an average total thickness of not less than 20 mm.
9.12.3.2 12 mm thick Under Coat: This shall be applied as specified in 9.9.3 except that when the
plaster has been brought to a true surface a wooden straight edge and the surface shall be left rough
and furrowed 2 mm deep with a scratching tool diagonally both ways, to form key for the finishing
coat. The surface shall be kept wet till the finishing coat is applied.
9.12.3.3- 8 mm thick Finishing Coat: The finishing. coat shall be applied after the undercoat has
sufficiently set but not dried and in any case within 48 hours and finished in the manner specified in
9.9.3.
9.12.4 Curing, Finishing; Precautions, Measurements and Rate: Specifications of Curing,
finishing, Precautions, Measurements and Rate shall be as described under 9.9.
9.13 25 mm thick Cement Plaster (Three Coat Work):
9.13.1 Scaffolding and Preparation of Surface: The specification for scaffolding and preparation
9.13.2 Mortar: The mortar shall be as specified in 9.9.
9.13.3 Application:
9.13.3.1 First Coat : The under coat shall be 12 mm thick and carried to the full length of the wall or
to natural breaking points like doors or windows. Before the coat hardened, it shall be roughened to
provide mechanical key for the second coat.
9.13.3.2 Floating or Second Coat : Before starting to apply the second coat, the surface of the under
coat shall be suction adjusted. The second coat shall be approximately 8 mm thick. It shall be brought
to a true, even surface and then roughened with a wooden float to provide bond for the finishing coat.
The second coat shall be damp cured for atleast two days and then allowed to become
9.13.3.3 Third & Finishing Coat : Before starting to apply finishing coat, the second coat shall be
damped evenly. Whenever possible, the textures should be applied from top to bottom in one operation
to eliminate joining marks. If the finishing coat is factory made material the manufacturers direction
for application should be followed closely. The finishing coat shall generally consist of one part
cement mixed with two parts of sand and shall be about 6 mm thick.
9.13.4 Curing, Finishing, Precautions, Measurements And Rate : Specifications for curing,
finishing, precautions, measurements and rate shall be as described under 9.11.
9.14 6 mm thick Cement Plaster on Cement Concrete and Reinforced Cement Concrete :
9.14.1 Scaffolding: Stage scaffolding-shall be provided for the work. This shall be independent of the
walls.
9.14.2 Preparation of Surface: Projecting burrs of mortar formed due to the gaps at joints in
shuttering shall be removed. The surface shall be scrubbed clean with wire brushes. In addition
concrete surfaces to be plastered shall be pock marked with a pointed tool, at spacing's of not more
than 5 cm centres, the pock being made not less than 3 mm deep. This is to ensure a proper key for the
plaster. The mortar shall be washed off and surface cleaned of all oil, grease etc. and well wetted before
the plaster is applied.
9.14.3 Mortars: Mortar of the specified mix using the types of sand described in the item shall be
used. It shall be as specified in Chapter 4.
9.14.4 Application: To ensure even thickness and a true surface, gauges of plaster 15 x 15 cm shall
be first applied at not more than 1.5 m intervals in both directions to serve as guides for the plastering.
Surface of these gauged areas shall be truly in the plane of the finished-plaster surface. The plaster
shall be then applied in a uniform surface to a thickness slightly more than the specified thickness and
shall then be brought to true and even surface by working a wooden straight edge reaching across
the gauges. Finally the surface shall be finished true with a trowel or with wooden float to give a
smooth or sandy granular texture as required. Excess troweling or over working of the floats shall be
avoided. The plastering and finishing shall be completed within half an hour of adding water to the
dry mortar.
Plastering of ceiling shall not be commenced until the slab above has been finished and centring has
been removed. In the case of ceiling of roof slabs, plaster shall not be commenced until the terrace
work has been completed. These precautions are necessary in order that the ceiling plaster is not
disturbed by the vibrations set up in the above operations.
9.14.5 Finish: The plaster shall be finished to a true and plumb surface and to the proper degree of
edge not less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested
with a level and all jambs and corners with a plumb bob as the work proceeds.
9.14.6 Thickness: The average thickness of plaster shall not be less than 6 mm. The minimum
thickness over any portion of the surface shall not be less than 5 mm.
9.14.7 Curing: The specifications shall be as detailed in 9.9. 9.14.8
Precaution's: These shall.be as described in 9.1.5.8 & 9.1.8 9.14.9
Measurements:
i) Length and breadth shall be measured correct to a cm and its areas shall be calculated in sqm
correct to two places of decimal. Dimensions before plastering shall be taken.
ii) Thickness of plaster shall be excluding of the thickness of the key i.e. depth or rock marks
and hacking.
iii) Plastering on ceiling at height greater than 5 m above the corresponding floor level shall be so
described and shall be measured separately stating the height in stages of 1 m or part thereof.
iv) Plastering on the sides and soffits of the projected beams of ceiling at a height greater than 5
m above the corresponding floor level shall be measured and added to the quantity measured
under above.
v) Plastering on spherical and groined ceiling and circular work not exceeding 6m in radius,
shall be measured and paid for separately.
vi) Flowing soffits (viz. portion under spiral stair case etc.) shall be measured and paid for
separately.
Ribs and mouldings on ceiling shall be measured as for cornices, deductions being made from
the plastering on ceiling in case the width of the moulding exceed 15 cm.
viii) The mode of measurement of exterior plaster and patch repair of plaster shall be as laid
down in 9.1.10
ix) Deductions shall not be made for openings or for ends of columns, or columns caps of 0.5 sqm
each in area and under. No additions will be made either for the plastering of the sides of such
openings. For openings etc. of areas exceeding 0.5 sqm deduction will be made for the full
opening but the sides of such openings shall be measured for payment.
described above.
9.15. - 6 mm thick Cement Plaster for slab bearing: Cement plaster shall be 6 mm thick finished
with a floating coat of neat cement and thick coat of lime wash on top of walls for bearing of slabs.
9.15.1 Application: The plaster shall be applied over the cleaned and wetted surface of the wall
when the plaster has been brought to a true surface with the wooden straight edge (Clause 9.9.3) it
shall be uniformly treated over its entire area with a paste of neat cement and rubbed smooth, so that
the whole surface is covered with neat cement coating. The quantity of cement applied for floating
coat shall be 1 kg per sqm. Smooth finishing shall be completed with trowel immediately and in no
case later than half an hour of adding water to the plaster mix. The rest of the specifications as
described in 9.9.3 shall apply.
9.15.2 Lime Wash: This shall be applied in a thick coat after curing the plaster for three days.
9.15.3 Measurements :Length and breadth shall be measured correct to a cm and area worked out in
sqm correct to two places of decimal.
described above.
9.16- Rough cast plaster : Rough cast finish comprises of a mixture of sand and gravel in specified
proportions dashed over a freshly plastered surface and is left in rough condition. The texture desired is
regulated by the size of sand / gravel / crushed aggregate.
9.16.1 Scaffolding : Scaffolding shall be done as specified in 9.1.7.
9.16.2 Preparation of surface : The joints shall be raked out, dust and loose mortar, shall be brushed
out. The surface shall be thoroughly washed with water, cleaned and kept evenly wet before
plastering is commenced.
9.16.3 Mortar: Mortar of specified mix-using the type of sand described in the item shall be used,
where coarse sand is to be used, the fineness modulus of the sand shall not be less than 2.5 mm.
9.16.4 Application:
9.16.4.1 Plaster base : The plaster base over which rough cast finish is to be applied shall consist of
two coats, under layer 12 mm thick and top layer 10 mm.
9.16.4.2- 12 mm thick under layer: This shall be applied in the same manner as specified in pars
9.4.2 under 18 mm Lime plaster except that the surface shall be beaten with bamboo strips.
9.16.4.3- Top layer: The top layer shall be applied a day or two after the under layer has taken initial
set. The later shall not be allowed to dry out, before the top layer is laid on. The mortar used for
applying top layer shall be sufficiently plastic and of rich mix 1 : 3 (1 cement : 3 fine sand) or as
otherwise specified so that the mix of sand and gravel gets well pitched with the plaster surface. In
order to make the base plastic, about 10% of finely grouted hydrated lime by volume of cement,
shall be added when preparing mortar for the top layer.
9.16.5 Finish: It shall be ensured that the base surface which is to receive rough cast mixture is in
plastic state. The rough cast mixture shall consist of sand or gravel or crushed stone of uniform
colour from 2.36 mm to 12.55 mm or as specified and in the proportions as specified accurately to the
effect required. The mixture shall be wetted and shall be dashed on the plaster base in plastic state
by hand scoop so that the mix get well pitched into the plaster base. The mix shall again be dashed
over the vacant spaces, if any, so that the surface represents a homogeneous surface of sand mixed
with gravel. A sample of rough cast plaster shall be got approved by the Engineer-in-Charge.
9.16.6 Precautions, Measurement and Rate: Specification for other details like precautions,
measurement and rate shall be as described under 9.1.
9.17 Pebble dash finish (In situ work):
9.17.1 Specification : The specification shall be the same as for rough cast plaster, except that the
washed pebble or crushed stone graded from 12.5 mm to 6.3 mm or as specified shall be dashed over
the plaster base and the vacant spaces if any shall be filled in by pressing pebbles or crushed stone as
specified by hand, so that the finished surface represents a homogeneous surface. The pebble used
for dashing shall be well washed & drained and thrown wet onto this coat while it is still plastic.
9.17.2 Scaffolding, Preparation of Surface, mortar, measurements and rate :Specification for
Scaffolding, Preparation of surface, Mortar, Measurements and Rate shall be as described under
9.16.
9.18 Providing and applying 19 mm thick Sand face plaster:
(a) This shall be applied in 2 coats. The first coat or the base coat should be approximately 12 mm
and shall be continuously carried out without break to the full length of wall or natural breaking
points such as doors, windows etc. The base coat shall be splashed on to the prepared surface
with heavy pressure, brought to true and even surface and then lightly roughened by cross
scratch lines, to provide bond for the finishing coat. The mortar proportion for this base coat shall
be as specified in the respective item of work. The base coat shall be cured for at least seven
days.
(b) The second coat shall be 6 mm thick. Before application of the second coat, the base coat shall
be evenly damped. This coat shall be applied from top to bottom in one operation and without
joints, finish shall be straight, true and even. The mortar proportion of this coat shall be as
specified under the respective item of work. Sand to be used for finishing work shall be as
specified in the item description. The second coat shall be finished with sponge. Grooves shall
be made as per the drawings.
It shall be same as per clause 9.1.10
9.19 Washed Stone Grit Finish (two coat work): It
is recommended for exterior finish.
9.19.1 Scaffolding: It shall be as specified in 9.1.7.
9.19.2 Preparation of surface : It shall be as specified in 9.1.5.15.
9.19.3 Materials:
9.19.3.1 Stone Chippings : Stone chippings size 10 mm (passing 100% through 12.5 mm sieve and
fully retained on 6.3mm sieve), obtained by crushing hard stone shall be free from dust and deleterious
material. Stone chippings shall be thoroughly washed with water and sieved before use.
9.19.3.2 Mortar: Cement mortar for under coat and cement mortar to be mixed with stone chippings
for top coat shall be as specified.
9.19.4 Application of Plaster:
9.19.4.1 12 mm under coat :- Under coat of cement mortar 1:4 (1 cement : 4 coarse sand) shall be
applied as specified except that the finishing -after the mortar has been brought to level with the
wooden straight edge, shall be done with wooden float only. The surface shall be further roughened
by furrowing with a scratching tool. Furrowing shall be done diagonally both ways and shall be
about 2 mm deep to provide a key for the top coat. The scratched lines shall not be more than 10 cm
apart. The surface shall be kept wet till top coat is applied.
9.19.4.2 15 mm top coat :- Top coat comprising cement Mortar and stone chippings shall have an
overall proportion of 1:0.5:2 (1 cement : 0.5 coarse sand : 2 stone chippings 10 mm nominal size) or
as specified. The top coat shall be applied a day or two after the under coat has taken the initial set.
The surface of the under coat shall be cleaned and a coat of cement slurry at 2 kg of cement per sqm.
shall be applied before the application of coat. The top coat shall be applied in uniform thickness
on the under coat after the application of slurry and sufficiently pressed with wooden float for proper
bonding with the under coat. Vacant space if may shall be filled with the specified mix.
9.19.5 Finish : The top coat of plaster shall be finished to a true and plumb surface. The surface
shall be tested frequently as the work proceeds with a true straight edge not less than 2.5 m long and
with plumb bobs. All horizontal lines and surfaces shall be tested with a level and all jambs and
corners with a plumb bob as the work proceeds. All the corners, angles and junctions shall be truly
vertical or horizontal as the case may be. Rounding or chamfering of corners junctions etc. where
required shall be true to template.
Finished surface of the top coat after the mix has taken the initial set, shall be scrubbed and washed
with suitable brushes and plain water. Scrubbing and washing shall continue till the stone chippings
are sufficiently exposed. Stone chippings which may come out while scrubbing shall be replaced
using the specified mortar mix. A sample of the washed stone grit plaster shall be got approved from
the Engineer-in-Charge.
9.19.6 Grooves:- Grooves of size 15 mm x 15 mm or as specified shall be provided as shown on the
drawing or as required by the Engineer-in-charge. Tapered wooden battens to match the size and shape
of the grooves shall be fixed on the under coat with nails before the application of the top coat and
these shall be removed carefully so that the edges of the panels of top coat are not damaged. Damage,
if any, shall be made good by the contractor.
9.19.7 Curing : Curing shall be done as specified 9.1.11 except that the dates are not be marked.
i) Length and breadth shall be measured correct to the nearest cm and the area shall be
calculated in sqm. correct to two places of decimal.
ii) Measurements shall be taken for the work actually done with deductions for all openings and
addition for all jambs soffits and sills. However, no deduction is to be made for the grooves
provided as specified in 9.1.10
iii) Washed stone grit plaster on circular surfaces not exceeding 6 m in radius and on external
surfaces at a height greater than 10 m shall be measured separately.
9.20- 18 mm thick Plastering with Terrazzo finish:
9.20.1 Scaffolding: Double scaffolding shall invariably be adopted.
9.20.2 Preparation of surface: The joints shall be raked out properly. Dust and loose mortar shall be
brushed out. Efflorescence, if any, shall be removed by brushing and hacking and scraping. The
surface shall then be thoroughly washed with water, cleaned and kept wet before plastering is
commenced.
In case of concrete surface if a chemical retarder has been applied to the form work, the surface shall
be roughened by wire brushing and all the resulting dust and loose particles cleaned off and care
shall be taken that none of the retarders is left on the surface.
9.20.3 Mortar:
i) The mortar shall be prepared as specified in chapter 4.
ii) 12 mm undercoat: This shall generally consist of cement mortar 1 : 3 (1 cement: 3 coarse
sand) unless otherwise specified in the item.
iii) 6 mm top Coat: The specifications described in chapter 12 (marble chips flooring) shall hold
good as far as applicable.
9.20.4 Application of plaster:
9.20.4.1-12 mm undercoat: This shall be applied in the manner specified in 9.9.3 except that when
the plaster has been brought to a true surface with a wooden straight edge, the surface shall be left
rough and furrowed 2 mm deep with a scratching tool diagonally both ways to form key for the top
coat. The scratched lines shall be not more than 15 cm apart. The surface shall be kept wet till the
finishing coat is applied.
9.20.4.2- 6 mm top coat: The top coat shall be applied after the under coat has sufficiently set but not
dried, and in any case within 48 hours and finished in the same manner as specified under "40 mm
Marble chips flooring" as far as applicable.
9.20.4.3 All corners, arrisers, angles and junction's shall be truly vertical or horizontal as the case may
be, arrisers shall be carefully and neatly finished and rubbed smooth. Rounding or chamfering corners,
arrisers, junctions etc. where required shall be true to template and shall be carried out without any
extra payment.
9.20.5 Finish: The finished surface shall be smooth, highly polished and absolutely even so that
when light from side ways is reflected on it, it does not show any kind of waviness.
9.20.6 Thickness:
i) The thickness of the under coat of plaster specified shall be excluding the thickness of key. The
average thickness of the under coat shall not be less than 12 mm whether the wall treated is of
brick or stone. In the case of brick work the minimum thickness over any portion of the surface
shall be less than 10 mm while in the case of stone work, the minimum thickness over the
bushing shall not be less than 6 mm.
ii) 6 mm finishing coat shall be uniformly 6 mm thick over the under coat in the case of both
brick and stone masonry.
9.20.7 Curing: Curing shall be started as soon as the plaster has hardened sufficiently not to be
damaged when watered.
The plaster shall be kept wet for a period of at least 7 days. During this period, it shall be suitably
protected from all damages at the contractor's expense by such means as the Engineer-in-charge may
approve. The date on which the plastering is done shall be legibly marked on the various sections
plastered so that curing for the specified period thereafter can be watched.
9.20.8 Precautions: Any cracks which appear on the surface and all portions, which sound hollow
when tapped, or are found to be soft or otherwise defective, shall be cut out in rectangular shape and
redone as directed by the Engineer- in-charge. In addition care shall be taken that the finish of the
rectified work is indistinguishable from the rest of the portions and does not show as a patch.
i) Measurements of length and breadth shall be correct to a cm and its area shall be calculated
correct to two places of decimal. The measurement of plaster shall be taken between the wall or
partition (being the dimension before plastering).
ii) Measurement of the work as actually done with all deductions of opening etc., addition of
jambs, sills and soffits shall be taken. However, openings less than 0.5 sqm in area will be
ignored.
iii) Skirting not exceeding 30 cm in height shall be measured in sqm separately, stating the
number of coats, thickness of each coat and whether plain, chamfered or beaded on top.
iv) Circular work not exceeding 6 m in radius shall also be separately measured.
v) Moulded cornices and coves shall be measured as follows :
(a) Length shall be measured at the centre of the girth.
(b) Moulded cornices and coves shall be given in sqm the area being arrived at by
multiplying length by the girth.
(c) Flat or weathered top to cornices when exceeding 15 cm in width shall not be included
in the girth but measured with the general plaster work.
(d) Cornices which are curved in their length shall be measured separately.
9.20.10 Rate: The rate shall include the cost of all labour and materials involved in the operations
described above.
9.21 18 mm thick Artificial red stone plaster:
9.21.1 Scaffolding and preparation of surface : The specification for scaffolding and preparation
9.21.2 Mortar:
9.21.2.1-12 mm thick under coat: Mortar of the mix and type of sand specified in the description of
the item shall be used. This shall be generally 1 :4 (1 cement : 4 coarse sand) mortar, unless described
otherwise.
9.21.2.2- 6 mm thick finishing coat: This shall consist of cement, marble dust and stone dust in the
ratio of 1:1:3 mixed with red oxide at the rate of 15.4 kg per quintal of cement or as determined at site
to obtain a shade matching red sand stone. The red oxide used should be of approved make. The colour
shall be mixed thoroughly with dry cement, then the mortar shall be mixed in the same manner as
ordinary cement mortar, using the pigmented cement and stone dust and marble dust mixture.
9.21.3 Application, thickness, curing, finishing, precaution and rate: Application, thickness,
curing, finishing, precaution and rate shall be as specified under 9.12 except that the surface finish
shall be neither too rough nor too smooth but should resemble red stone work in texture.
9.21.4 Measurements: These shall be as specified in 9.20.9.
Lining out plaster in imitation of stone or concrete block walling shall be given in sqm as extra over
general plaster work.
9.22 Plain bands of cement mortar: "Plain band' is a plaster strip of uniform width not exceeding 30
cm and of uniform thickness, provided for decorative or other purpose flush with, sunk below or
projecting beyond the wall plaster. A flush band is one where due to the difference in mix or shade of
the mortar, the band is executed as a separate and distinct operation from the wall plaster.
9.22.1 Thickness: The thickness of a raised band is the thickness of the projection beyond the plane
of the wall plaster. In the case of a flush or a sunk band, the thickness will be the thickness of the
plaster measured from the untreated wall surface.
9.22.2 Preparation of surface and application:
i) In case of flush or sunk bands the joints shall be raked out properly. Dust and loose mortar shall
be brushed out. Efflorescence if any shall be removed by brushing the scraping. The surface
shall then be thoroughly washed with water, cleaned and kept wet before plastering is
commenced.
ii) In case of concrete surface if a chemical retarder has been applied to the form work, the surface
shall be roughened by wire brushing and hacking and all the resulting dust and loose particles
cleaned off and care shall be taken that none of the retarders is left on the surface.
iii) In case of raised band the surface shall be prepared as specified in 9.2 & 9.1.6 , except in
following respects (a) beating with thin bamboo strips shall not be done and (b) the lime putty
solution shall be applied on the surface when finishing is completed . The surface of the wall
plaster behind the band shall be left rough and furrowed 2 mm deep with a scratching tool,
diagonally both ways to form key for the band. No reduction in the rate for the above backing
wall plaster shall, however, be made for not finishing the same smooth.
9.22.3 Mortar: Mortar of the mix and type of sand specified in the description of the item shall be used.
9.22.4 Finish: The bands shall be finished exactly to the size as shown in the drawings. The
horizontal or vertical lines of bands shall be truly parallel and straight and the surfaces shall be
finished truly plane and smooth. The lines and surface shall be checked with fine threads for
straightness, level and accuracy.
9.22.5 Scaffolding, Curing and Precaution : Scaffolding, Curing and Precaution shall be as
described Under 9.1.
9.22.6 Measurements: Length will be measured in running metre correct to a cm. The length shall be
taken along the finished face. The width shall not be measured by girth. For width of band 30 cm or
below, the width shall be measured in cm correct to 5 mm. The quantity shall be calculated in
metre/cm units.
described above. Nothing extra shall be paid for mitres, stops nor for bands on curved surface of
whatever radius, they may be. The rate is also inclusive of all rounding or chamfering at corners,
arrisers, providing grooves at junctions etc.
9.23 Moulded bands of cement mortar (single coat work): Moulded band is a plaster strip of
uniform width but with varying thickness across its section formed over wall plaster for decorative
purposes. The sectional periphery of the band is formed by a combination of straight lines or curves
or straight lines and curves.
9.23.1 Thickness: The higher thickness stipulated in the description of the item shall refer to the
upper limiting thickness of the moulding at its most projected portion, measured from the wall
plaster.
9.23.2 Preparation of surface, mortar, scaffolding, curing and precautions :Preparation of
Surface, Mortar, Scaffolding, Curing and Precautions shall.be as specified under 9.22.
9.23.3 Application and Finish: Proper templates conforming accurately to the sectional periphery of
the moulded band shall be got approved, before use. The finished band shall be true to the template
at all sections. The line of the band shall be truly parallel and straight with surfaces smoothly finished.
9.23.4 Measurements: The width of the band 30 cm or below shall be measured in cm correct to 5
mm and shall be measured along the sectional periphery of the moulded band, from wall plaster face
to wall plaster face. The length shall be measured, in running metres correct to a cm. It shall be taken
along the finished face of the band at the centre of its girth. The quantity should be calculated in
metre/cm units.
described above. Nothing extra shall be paid for mitres, stops nor for bands on curved surfaces of
whatever radius, may be. The rate is also inclusive of all rounding or chamfering at corners, arrisers
etc.
9.24 Moulded bands of cement mortar (Two Coat Work): Moulded band is a plaster strip of
uniform width but with varying thickness across its section formed over wall plaster for decorative
purposes. The sectional periphery of the band is formed by a combination of straight lines or of
curves or of straight lines and curves.
9.24.1 Thickness: The higher thickness stipulated for the undercoat in the description of the item shall
refer to the upper limiting thickness of the under coat of the moulding at its most projected portion
from the wall plaster. The thickness stipulated for the finishing coat is the uniform thickness of the
finished peripheral surface of the moulded band from the under coat.
9.24.2 Mortar: The under coat shall consist of cement mortar 1 : 5 (1 cement : 5 coarse sand) and the
top coat shall be of cement mortar 1 : 4 (1 cement : 4 fine sand) unless otherwise specified in the
description of item.
9.24.3 Application and Finish: Proper templates conforming to the sectional periphery of the
moulded band as at the stages of the under coat and the finished final coat shall be made and got
approved and used at the proper stages in executing the bands to true and accurate profile. The lines
of the bands as finally completed shall be truly parallel and straight with the surfaces smoothly
finished.
9.24.4 Measurement, Rate : All other details shall be as specified under 9.23.
9.25 Cement Lime plaster (single coat work):
9.25.1 The cement lime plaster shall be 12 mm or 15 mm as specified in the item.
9.25.2 Mortar: The mortar of the mix and types of sand specified in the description of the item shall
be used. The cement lime mortar shall be as specified in Chapter 4.
9.25.3 Application: It shall be as specified under 9.9.3, except that the plastering and finishing shall
be completed within half an hour of adding slurry of Lime putty to the dry Cement Sand mixture or
mixing cement to ground lime mortar.
9.25.4 Scaffolding, preparation of surface, finish, thickness, curing, precautions,
measurements and rate :Specifications for scaffolding, Preparation of surface, Finish, Thickness,
Curing, Precautions, Measurements and Rate shall be as described under 9.9.
9.26 Cement Lime plaster (two coat work):
9.26.1 Specifications: It shall be 18 mm thick unless otherwise specified.
9.26.2 Mortar : Mortar of the mix and type of sand specified in the description of item shall be used.
The under coat may be of either Cement mortar or Cement Lime mortar as specified.
Generally the mix of under coat shall not be weaker than the finishing coat unless otherwise specified.
Generally coarse sand shall be used for the under coat and fine sand for the finishing coat unless
9.26.3 Application of mortar : The application shall be as specified in 9.12.3.
9.26.4 Curing: Curing shall be started as soon as the plaster has hardened and not to be damaged
when watered.
The plaster shall be kept wet for a period of at least 7 days. During this period it shall be suitably
protected from all damages at the contractor's expense by such means as the Engineer-in Charge
may approve. The dates on which the plastering is done shall be legibly marked on the various
sections plastered so that curing for the specified period thereafter can be watched.
9.26.5 Scaffolding, preparation of surface, finish, precautions, measurements and rate:
Specifications for Scaffolding, Preparation of surface, Finish, Precautions, Measurements and Rate
shall be as specified under 9.2.
9.27 Lime Plaster of Marble shade:
9.27.1 Scaffolding and preparation of surface :Scaffolding and preparation of surface shall be as
specified under 9.12.1
9.27.2 Mortar and Application: The work shall consist of three coats. First 12 mm under coat, then
6 mm middle coat and finally a brushed and polishing finishing coat.
i) 12 mm under coat : Mortar of the mix and type of sand specified in the description of the item
shall be used. This shall be generally 1:4 cement mortar using coarse sand, unless otherwise
described in the item. The application shall be as described in 9.12.3.2.
ii) 6 mm middle coat : This shall consist of Makrana Lime Paste, Fine marble chips and marble
dust mixed in the ratio 2:1:2 (2 Makrana Lime paste : 1 fine marble chips : 2 marble dust). The
lime paste shall be prepared by mixing lime in water and allowing the same to settle over night.
The water is decanted off next morning, and fresh water is added to lime and then stirred. This
process is repeated for a week and the lime paste is obtained. The middle coat of the above
specified mix shall be applied in 6 mm thick layer and finished smooth. The surface shall be
wetted for 7 days and then allowed to dry for about one month if it is in summer and two months
if in winter.
iii) Finishing coat : Makrana lime paste shall be prepared as detailed in the preceding para. It shall
be mixed with curd in the proportion of 1 cum of paste: 16 kg of curd. This shall be screened
through a fine muslin cloth and powdered mishri (crystallised sugar) dissolved with it at the rate
of 16 kg per cum of paste. The mixture so prepared shall have the consistency of cream. It shall
be applied with a brush on the rendered surface. The finishing coat is kept wet for four days and
allowed to dry to seven days. The surface shall then be rubbed with round glass or mohur stone
till it gets highly polished. Finally the surface is rubbed with a fine muslin cloth and selkhari
(soap stone) powder using coconut water. This shall be continued till a finally glazed surface
is obtained.
9.27.3 Thickness, curing, finish, precaution and rate: Thickness, Curing, Finish, Precaution and
Rate shall be as specified under 9.12.
9.27.4 Measurements and rate: These shall be as specified in 9.20.9 and 9.20.10.
9.28. Lime Surkhi plaster:
9.28.1 12 mm thick Lime Surkhi plaster:
9.28.1.1-Mortar : Mortar of the mix and type of sand specified in the description of item shall be
used. The Lime surkhi mortar shall be as specified in Chapter 4.
9.28.1.2 Scaffolding, preparation of surface, application, thickness, curing, finish, precautions,
measurements and rate : Specifications for scaffolding, Preparation of surface, Application,
Thickness, Curing, Finish, Precautions, Measurements and Rate shall be as specified under 9.2.
9.29- 18 mm thick Lime Surkhi plaster (two coat work):
9.29.1 Mortar : Mortar of the mix and type of sand as specified in the description of the item shall be
used. The same mortar will be used for both under coat and finishing coat. The lime surkhi mortar
shall be as specified under Chapter 4.
9.29.2 Scaffolding, preparation of surface, application, thickness, curing, finishing, precautions,
measurements and rate : Specifications for Scaffolding, Preparation of surface, Application,
Thickness, Curing, Finishing, Precautions, Measurements and Rate shall be as specified under 9.4.
9.30 Araish plaster:
9.30.1 Araish plaster : This specification covers materials, preparation of Jhinkra, application of
Kara and Araish.
9.30.2 Terminology : For the purposes of this specification the following definition shall apply :-
9.30.2.1 Jhinki :- The aggregate obtained by crushing marble stone or chips, is known as Jhinki.
9.30.2.2 Jhinkra :- The plastic mortar of a thin consistency obtained by mixing Jhinki with slaked
lime, slaked as given below is known as Jhinkra (contrast with Kara clause 9.30.2.3)
9.30.2.3 Kara :- The mortar obtained by mixing Jhinki with slaked lime slaked as specified is
known as Kara.
9.30.2.4 Jhanwa :- A local stone piece used for rubbing down the Kara background and Jhinkra
coat is known as Jhanwa. In Jaipur area stone from ' Kota' is used for this purpose.
9.30.2.5 Naliyas :- Small sized polished iron trowels are known as Naliyas.
9.30.2.6 Ghonty :- A very hard stone piece used for rubbing the final coat to give it a glossy surface
is known as Ghonty.
9.30.3 Materials : Lime -Lime shall be class `C' (Fat) Lime conforming to specifications and shall
be of pure white colour. Jhinki -shall conform to specifications in all respects except the size which
shall be such that all of it pass through 600 micron I.S. sieve and retained on 150 micron I.S. sieve.
9.30.4 Proportions of Kara and Jhinkra : The proportion for Kara and Jhinkra shall be one part
putty of standard consistency as per I.S. 712-1984, prepared as per specifications and as per given
under clause No. 9.30.5 below respectively and two parts of Jhinki by volume.
9.30.5 Preparation of Jhinkra : Lime shall be slaked (Tank slaking) as specified under `mortars' for
mortar to a consistency thicker than white wash and matured for at least 60 days. The water added
to putty during maturing should be changed twice a week and replaced with fresh water. The matured
putty shall be passed through coarse cloth (equivalent I.S. sieve No. 600 micron).
Jhinki shall be stacked (in the required quantity) in the form of a cone, putty shall be added and
mixed thoroughly by adding required quantity of water to putty.
9.30.6 Preparation of back ground:
9.30.6.1 General :- Araish including Kara is applied in very thin coats totalling to only 5 mm
thickness. As such the back ground must be in one plane and rough in the texture.
9.30.6.2 Brick masonry and Stone masonry excluding Ashlar masonry:- The surface shall be
lime plastered according to clause 9.2, except that no finishing coat will be applied.
9.30.6.3 R.C.C.: Steel centring / shuttering should not be used for the faces to which Araish will be
applied. The work shall be allowed to dry out completely at least for 20 days after curing is completed.
The surface shall be hacked if found necessary to provide more mechanical key.
9.30.6.4 Ashlar :- Ashlar columns, sills etc. should be only rough tooled dressed.
9.30.6.5 Kara Plaster : The surface shall be cleaned off dust, dirt, oil and point marks if any as
specified in clause 9.1 and thoroughly wetted, then Kara plaster shall be applied as given under
clause No. 9.30.7 below.
9.30.7 Application of Kara Plaster : The Kara shall be applied to prepared back grounds in a
uniform thickness of 5 mm. and rubbed with wooden floats. The rubbed surface shall be in one plane
and perfect plumb. It shall be cured for at least 10 days and allowed to dry out completely and left for
at least six months or more as to allow it to undergo the effects of at least one monsoon before the
application of Jhinkra.
9.30.8 Application of Araish :
9.30.8.1 Application of Jhinkra: - After the application of Kara as given above it shall be rubbed
with Thanwa and a thin layer of mortar ' Jhinkra' shall be applied and rubbed with Jhanwa water
being sprinkled before rubbing. The application of Jhinkra, sprinkling of water, and rubbing shall be
repeated three times when a fairly smooth surface shall be obtained.
9.30.8.2 Application of putty :- After the application of Jhinkra, a uniform coat of pure putty (See
clause 9.8.6.2 or 9.5.3) shall be applied and rubbed with Thanwa. Water shall be sprinkled and above
process repeated twice.
9.30.8.3 Application of colour :- The colour shall be applied if so specified in the schedule of
quantities. The colour as desired by the Engineer-in-charge and prepared as per specifications for
colour washing shall be applied immediately after the application of putty in three coats, sprinkled
with water and rubbed with Thanwa, after the application of each coat.
9.30.8.4 Colour designs for decoration :- Any colour design etc. can be put upon while the surface
is semi-glossed. The surface shall be kept moistened during the preparation of design and until
finally beaten with Naliyas and rubbed with Ghonties.
9.30.8.5 Polishing :-
(a) A coat of the mixture of khopra (kernel of coconut) rubbed on stone sill, and Lime water shall
be applied the surface rubbed with clean muslin cloth and left over for two or three days for
drying.
(b) After the surface has dried a thin coat consisting of a mixture of equal parts of putty and Ghee
shall be applied and surface wiped off clean immediately and finally rubbed with muslin cloth.
9.30.9 Protection and mode of measurement :
9.30.9.1 Protection and mode of measurement shall be as specified in clause 9.1.
9.31 Cement Water proofing compound: It shall be used for cement mortar for plastering on
concrete work.
9.31.1 Water proofing compound ( providing and mixing to Cement): Integral cement water
proofing compound conforming to IS : 2645-1975 and of approved brand and manufacture, enlisted
by the Engineer-in-charge from time to time shall be used.
9.31.2 Material : The contractor shall bring the materials to the site in their original packing. The
containers will be opened and the material mixed with dry cement in the proportion by weight,
recommended by the manufacturers or as specifically described in the description of the item. Care
shall be taken in mixing to see that the water proofing material gets well and integrally mixed with the
cement and does not run out separately when water is added.
9.31.3 Measurement : It shall be measured by weight.
described above.
9.32 18 mm thick Mud plaster (two coats):
9.32.1 Scaffolding : Single Scaffolding shall be done as specified under 9.2.
9.32.2 Preparation of surface: The joints shall be raked out and surface washed of all dust and
allowed to dry before plaster is applied.
9.32.3 Mortar:
i) Mud mortar shall be prepared from good brick earth. This shall be free from grass roots, gravel
kankar etc. The earth shall contain no efflorescent salts nor shall it be collected from a locality
where there are white ants. The earth shall be reduced to fine powdered state and mixed with
plenty of water in a pit, adding chopped straw at about 33 kg per cum of earth.
ii) The mixture of earth, straw and water shall be allowed to mature for not less than 4 days. During
this period it shall be worked up at intervals with foot and/or spades so that it is plugged into
a homogeneous mixture.
iii) The mortar when ready shall be of such consistency that it will readily slide off the face of
trowel but shall not be so wet that the mortar parts into large drops while falling.
9.32.4 Application: Plastering shall be started from the top and worked towards the grounds.
i) The plaster shall be applied in two coats of 12 mm and 6 mm thickness. The prepared mixture
shall be applied to the surface in a uniform coat of average thickness of 12 mm and then
smoothened and made even with a straight edge and with floats. This shall be allowed to set but
not become dry before the second coat is applied. The latter shall be 6 mm thick uniform
throughout. It shall be finally polished with a trowel after it has been smoothened with wooden
floats.
ii) All corners, arrises, angles and junctions shall be truly vertical or horizontal as the case may be
and shall be carefully and neatly finished. Rounding and chamfering corners, arises, grooves at
junctions etc. where required, shall be done without any extra payments. Such rounding,
chamfering and grooving shall be carried out with proper templates or battens to the sizes as
required.
9.32.5 Finish: The plaster shall be finished to a true and plumb surface and to the proper degree of
edge not less than 2.5 m long and with plumb bobs. All horizontal lines surfaces shall be tested with a
level and all jambs and corners with a plumb bob as the work proceeds.
9.32.6 Precautions: No curing shall be done. The surface shall be protected from damage till it dries
out. Any cracks that open out during drying shall be opened out and thoroughly repaired with a mixture
of clay and cow dung. Any portions which sound hollow when tapped shall also be redone after
cutting out the hollow portions.
9.32.7 Thickness: The average thickness of the finished plaster excluding the key of the joints
shall not be less than 18 mm. The minimum thickness of the plaster over any portion of the wall of
brick work shall not be less than 15 mm at any point while in the case of stone walls, this shall not
be less than 12 mm over the bushings.
9.32.8 Measurements: The specifications for measurement shall be described in 9.2.9 except for
the following.
All bands and skirting irrespective of width, moulded beadings, architrave and archivolt bands and
circular work of any radius shall be measured and paid for under plastering areas only and not
separately.
9.32.9 Rate : The rate shall include the cost of all labour and materials involved in all the operations
described above.
9.33 Pointing on Brick work, The work and Stone work: Pointing shall be of the type shown in
figure below :
9.33.1 Scaffolding:
i) For all exposed brick work or tile work, independent double scaffolding having two sets of
vertical supports shall be provided. The supports shall be sound and strong tied together with
horizontal pieces over which scaffolding planks shall be fixed.
ii) All other brick works in building, single scaffolding shall be permitted. In such cases, the inner
end of the horizontal scaffolding pole shall rest in a hole provided only in the header course for
the purpose. Only one header for each pole shall be left out. Such holes for scaffolding shall,
however, not be allowed in pillars/columns less than one metre in width, or immediately near the
skew backs of arches. The holes left in masonry works for scaffolding purposes shall be filled
and made good before plastering.
Note : In case of special type of brick work, scaffolding shall be got approved from Engineer-in-
Charge in advance.
9.33.2 Preparation of surface:
i) The joints shall be raked out properly. Dust and loose mortar shall be brushed out.
Efflorescence if any shall be removed by brushing and scraping. The surface shall then be
thoroughly washed with water, cleaned and kept wet before pointing is commenced.
ii) In case of concrete surface, if a chemical retarder has been applied to the form work, the
surface shall be roughened by wire brushing and all the resulting dust and loose particles
cleaned off and care shall be taken that none of the retarders is left on the surface.
iii) The joints shall be raked to such a depth that the minimum depth of the new mortar measured
from either the sunk surface of the finished pointing or from the edge of the brick shall not be
less than 12 mm.
9.33.3 Mortar: Mortar of specified mix shall be used. It shall be as specified under Chapter 4.
9.33.4 Application and Finishing:
9.33.4.1 The mortar shall pressed into the raked out joints, with a pointing trowel, either flush sunk or
raised, according to the type of pointing required. The mortar shall not spread over the corner, edges
or surface of the masonry. The pointing shall then be finished with the proper tool, in the manner
described below.
9.33.4.2 Flush pointing : The mortar shall be pressed into the joint and shall be finished off flush and
level with the edges of the bricks, tiles or stones so as to give a smooth appearance. The edges shall
be neatly trimmed with a trowel and straight edge.
9.33.4.3 Ruled Pointing : The joint shall be initially formed as for flush pointing and then while the
mortar is still green, a groove of shape and size as shown in drawings or as instructed, shall be formed
by running a forming tool, straight along the line of the joints. This operation shall be continued till
a smooth and hard surface is obtained. The vertical joints shall also be finished in a similar way. The
vertical lines shall make true right angles at their junctions with the horizontal lines and shall not
project beyond the same.
9.33.4.4 Cut or weather struck Pointing : The mortar shall first be pressed into the joint. The top of
the horizontal joints shall then be neatly pressed back about 3 mm or as directed, with the pointing tool
so that the joints are sloping from top to bottom.
The vertical joints shall be ruled pointed. The junctions of vertical joints with the horizontal joints shall
be at true right angles.
9.33.4.5 Raised and cut Pointing :
i) Raised and cut pointing shall project from the wall facing with its edges cut parallel so as to
have a uniformly raised band about 6 mm and width 10 mm or more as directed.
ii) The superfluous mortar shall be cut off from the edges of the lines and the surface of the
masonry shall also be cleaned off all mortar. The finish shall be such that the pointing is to the
exact size and shape required and the edges are straight, neat and clean.
9.33.5 Curing: The pointing shall be kept wet for seven days. During this period it shall be suitably
protected from all damages.
The pointing lines shall be truly horizontal and vertical except where the joints are slanting as in
random rubble masonry. Line of joints from different directions should meet neatly at the junctions
instead of crossing beyond.
i) Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metres upto two places of decimal.
ii) The various types of pointing for example struck, keyed, flush, tuck, etc. shall each be
measured separately.
Pointing on different types of walls, floors, roofs etc. shall each be measured separately. The
type and material of the surface to be pointed shall be described.
Pointing in a single detached joint as for flashing shall be given in running metres.
For jambs, soffits, sills etc. for opening not exceeding 0.5 sqm each in area, ends of joints,
beams, posts girders, steps, etc. not exceeding 0.5 sqm each in area and opening not exceeding 3
sqm each deductions and additions shall be made in the following way, in case of pointing on
external face only.
(a) No deduction shall be made for ends of joists, beams, posts etc. and openings not
exceeding 0.5 sqm each, and no addition shall be made for reveals, jambs, soffits, sills etc.
of these openings.
(b) Deductions for openings exceeding 0.5 sqm but not exceeding 3 sqm each shall be made
as follows and no additions shall be made for reveals, jambs, soffits, sills, etc. for these
openings.
(c) When both the faces of the wall are pointed with the same pointing, deduction shall be
made for one face only.
(d) When two faces of wall are pointed with different kinds of pointing or if one face is
plastered and other is pointed or plastered, deduction shall be made from the plaster or
pointing on the side of frames for doors, windows, etc. on which the width of the reveal is
less than that on the other side, but no deduction shall be made from the other side.
(e) Where width of reveals on both faces of wall are equal, deduction of 50% of area of
opening on each face shall be made from area of pointing or plaster as the case may be.
(f) For opening having door frame equal to or projecting beyond thickness of wall, fu11
deduction for opening shall be made from each pointed face of wall.
vi) In case of opening of area above 3 sqm each, deduction shall be made for the openings, but
jambs, soffits and sills shall be measured.
) The following shall be measured separately:
(a) Raking out joints for old work only shall be measured and given in square metres.
(b) Raking out joints of old work built in Mud mortar, Lime mortar and Cement mortar
shall each be measured separately.
(c) Raking out joints of different types of old walls, floors etc. shall each be measured
separately.
(d) Raking single detached joints as for flashing old work shall be given in running metres.
described above.
Appendix - À'
MORTARS
There are various types of mortars for plaster suitable to different atmospheric conditions and type of
structures i.e. permanent or temporary.
a) Lime sand or Lime Surkhi
b) Cement sand mortar
c) Composite mortar
d) Mud mortar
For Rajasthan, Lime mortar plaster may be suitable for all general purposes. Cement Sand and Cement
Lime plasters are now in general use where water tight surfaces are required. Mud mortar plaster can
be used for temporary structures in the arid regions of Rajasthan.
Table Al : Materials required for 100 sqm for various Cement Sand plaster
S. Mix Materials Thickness in nun
No Propo- Required 3 6 10 12.5 20 25 30 40
rtion
1. 1:1 Cement (q) 3.17 6.32 10.55 13.18 21.11 26.36 31.66 42.21
Sand
(cum) 0.22 0.439 0.732 0.992 1.464 1.831 2.196 2.927
2. 1:1½ Cement (q) 2.55 5.10 8.50 10.60 17.01 21.21 25.52 34.02
Sand
(cum) 0.266 0.533 0.886 1.108 1.772 2.216 2.659 3.545
3. 1:2 Cement (q) 2.14 4.28 7.14 8.93 14.28 17.85 21.42 28.56
Sand
(cum) 0.297 0.596 0.991 1.239 1.982 2.478 2.974 3.965
4. 1:2½ Cement (q) 1.83 3.65 6.09 7.61 12.18 15.23 18.27 24.36
Sand
(cum) 0.317 0.634 1.058 1.32 2.115 2.64 3.172 4.229
5. 1:3 Cement (q) 1.59 3.17 5.30 6.64 10.61 13.27 15.91 21.21
Sand
(cum) 0.332 0.664 1.105 1.339 2.21 2.772 3.314 4.418
6. 1:4 Cement (q) 1.25 2.50 4.15 5.20 8.30 10.40 12.44 16.59
Sand (cum) 0.346 0.69 1.152 1.439 2.301 2.877 3.456 4.601
7. 1:6 Cement (q) 0.88 1.76 2.94 3.68 5.88 7.35 8.82 11.76
Sand
(cum) 0.368 0.735 1.226 1.533 2.451 3.066 3.676 4.9
8. 1:8 Cement (q) 0.70 1.39 2.31 2.89 4.62 5.78 6.93 9.24
Sand
(cum) 0.386 0.772 1.283 1.607 2.566 3.113 3.849 5.132
5% extra has been considered for wastage both in Cement and Sand.
Table A2 : Recommended Thickness for Lime Plaster Work
mmmmmm
S. Type of Workork First Coat Third Coat
No Second Coat ()
() ()
(1) (2) (3) (4) (5)
i) Brick masonry:
a) Single coat Work 15 - -
b) Double coat work 10 10 -
ii) Stone masonry 15 10 -
iii) Stone masonry (very rough surface) 15 10 10
Table : Recommended Mixes for external Renderings
Type of Mix Recommended for given exposure

Conditions
Background Type of
Material Finish First and Subsequent Final Coat
Undercoat
Severe Moderate Light Severe Moderate Light
(1) (2) (3) (4) (5) (6) (7) (8)
Dense and Wood float 1 2 2 or 3 1 2 2,3 or 4
strong Scraped or
Textured 2 3 2 or 3 2 3 2 or 3
Moderately Roughcast 5 5 5 6 6 6
strong
and porous Dry-dash 5 5 5 - - -
Moderately Wood float
weak and Scraped or 2 3 4 Same as for undercoats
porous textured
No-fines Wood float 1 2 2 or 3 1 2 3 or 4
concrete scraped or 1 2 2 or 3 1 2 3 or 4
textured
Roughcast 5 5 5 6 6 6
Dry dash 5 5 5 - - -
Metal lathing Wood float 1 1 1 2 2 2
or scraped or
expanded textured 5 5 5 6 6 6
metal Roughcast/ 5 5 5 - - -
Dry dash
: Mix type 1 - 1:0:4. Type 2-1:0:5 to 6, Type 3-1:1:6 to 7, Type 4-1:2:9 to 10, Type 5-1:0:3, Type 6-1:3 Type 1 to 5 shall
Note
consist of cement lime sand by volume; Type 6 shall consist of cement, coarse aggregate of size 6 to 1 2 m m by volume.
APPENDIX- `B'
CEMENT PLASTER
Defects - Causes and Remedies.
Cement and Cement-Lime plaster, soft plaster
Defect Possible Cause Possible Remedy or Future Preventive
measures
(a) Soft Plaster 1. Excessive water in mortar. 1. Measure water. Control slump
2. Excessive aggregate. 2. Measure aggregate as per IS specification

3. Inadequate curing. 3. At least 48 hours damp curing. Unset
plaster may be redeemed by continuous
wetting until proper set and hardness are
obtained.
4. Inadequate mixing. 4. At least 5 minutes after all materials are
in the mixer.
5. Impurities (occasionally in 5. Test water and aggregate (colour) in bottle
water or aggregate). method.
6. Freezing temperatures. 6. Plaster may harden upon resumption of
damp curing above 2 deg. Celsius ; if
plaster does not harden, remove and re-
plaster.
7. Low temperatures 7. Damp cure above 2 deg. Celsius. until
(retarding hydration plaster hardens.
8. Improper use of admixtures 8. Prohibit addition of unspecified
(gypsum plaster, detergents, admixtures.
soaps, etc.)
9. Poor quality or improperly 9. Specify standard gradation.
graded aggregate.
Shrinkage Cracks:
(b) Shrinkage 1. Excessive water in mortar. 1. Keep slump as low as possible.
cracks
2. Inadequate curing. 2. Enforce moist curing to avoid too rapid
evaporation.
3. Insufficient control joints. 3. Place vertical joints maximum 10" apart
and horizontal joints 15" apart. If the
project permits, place them closer.
4. Too much suction. 4. Control suction by wetting ahead of plaster.
5. Over-restraint. 5. Whenever possible use unrestrained
method.
Defect Possible Cause Possible Remedy or Future Preventive
measures
6. Improperly graded 6. Specify particle sizes and distribution of
aggregate. aggregate.
7. Improper mix. 7. Specify approved mixes.

8. Hot, dry or windy weather. 8. Shield fresh plaster, fog spray
continuously to moist cure or temporarily
stop work.
9. Finish coat denser or harder 9. Provide uniform density of each coat.
than basecoat.
10. Deviation in plaster 10. Plaster should have uniform thickness.
thickness.
Structural Cracking-Deterioration:
(c) Structural 1. Transfer of structural 1. Separate plaster diaphragm from
cracking stresses. (Thermal, wind structural members wherever possible to
load, seismic, dimensional inhibit transfer of stresses greater than
change, creep, plastic flow, plaster can absorb.
deflection, wood shrink and
warping, impact or
vibration etc)
2. Foundation settlement. 2. Provide adequate foundation (dimension,
reinforcing, pad, etc.)
3. Expanding soil (such as 3. Provide adequate foundation (dimension,
adobe). reinforcing, pad, etc.)
4. Insufficient plaster thickness. 4. Specify thickness of each coat.
5. Reinforcement not properly 5. Provide for proper furring of
embedded in plaster reinforcement.
membrane.
Deterioration:
(d) Plaster 1. Alkalinity (sulphates). 1. Stop plaster above finish grade or control
deterioration. moisture in adjacent soil.
2. Freeze, thaw deterioration. 2. Seal cracks and joints.
3. Reactive aggregate. 3. Use low alkali cement and prohibit use
of reactive aggregate.
4. Paint with oil paint or non- 4. Prohibit non-breathing coating.
breathing coatings
Defects Possible Cause Possible Remedy or Future Preventive
Condition
Cement and Cement-Lime Plaster Craze Cracking-Efflorescence
(e) Crazing 1. Improper and inadequate 1. Do not permit too rapid evaporation.
(alligator or curing.
hair-cracking).
2. Too rich mixes. 2. Do not use too rich mixes. Use well
graded sand and suitable proportions of
cement.
3. Overworking surface 3. Avoid over working of cement finishes
so that excess cement may not be drawn
to the surface. Use sand-float finish.
4. Too great suction. 4. Control suction.
(f) Efflorescence 1. Water-borne contaminants. 1. Check water for salts.
(discolouration
2. Check aggregates for impurities.
or bloom created 2.Aggregate-borne
by salts traveling contaminants.
in solution). 3. Base-borne contaminants. 3. Check surface to be plastered; Alkali salts
may be present in material to which
plaster is applied and may be brought out
in solution with the water in plaster.
4. Cement. 4. Conforming to specifications; also check
for manufacturing defect.
5. Moving moisture brings salts 5. Stop plaster above soil line to prevent
into plaster membrane. movement of alkali solution into plaster
by contacting soil.
Discolouration:
(g) Discolou- 1. Colour pigment unevenly 1. Discourage job-mixed colour pigments;
ration -uneven mixed. use proprietary pre-mixed colour coats
colour whenever possible.
2. Trowel burning or dry 2. Do not over-trowel or float without water
floating. in one area.
3. Control of water. 3. Water content must be uniform in colour
coat mortar; and basecoat surface must be
uniformly moistened to control suction.
4. Glazing or uneven texture of 4. Basecoat surface must be uniformly
base-coat; uneven suction. prepared and cured to control suction.
5. Curing (ordinarily colour 5. If extreme wind or heat dictate colour coat
coat does not have to be has to be cured, it should be done with a
cured). fine fog spray. Do not allow water to run
down the wall face.
Condition
6. Dirty tools or floating 6. Keep tools and working water clean.
water.
7.Jointing's 7. Each scaffold platform at level of a wall
panel is to be applied simultaneously if
possible; otherwise each platform level is
to be followed down without delay to a
break in the panel. Use adequate clean
water when floating, jointing's.
8.Rain on fresh colour coat. 8. Do not plaster either immediately before
or after rain.
9. Stains from flashings, 9. Protect from staining from drip and run-
rusted screeds, roofs and off from adjacent materials. Provide non-
untreated wood, etc. corrosive flashing.
10.Dark colours, pigment 10.Avoid dark, heavily pigmented colours in
separation. hand applications.
Lack of Bond:
(h) Lack of Bond. 1. Surface to be plastered too 1. Specify proper scoring or floating to
(Bond Failure) smooth. create proper mechanical key. Sand blast,
chip, and apply cement dash bond coat or
bonding agent. If over concrete, be sure
forms are rough and that concrete is not
too high slump and is not over-worked,
bringing laitance to the surface,
developing a shell with no suction.
2. Form coating. 2. Use the proper type of form oil.
3. Insufficient suction. 3. See point 1 above. Be sure that surface is
not too thirsty, pulling from plaster the
water needed for its hydration.
4. Insufficient thickness of 4. Cut back scratch at grounds to allow full
coat because of build-up of thickness of coat.
scratch coat at jambs or
grounds.
measures.
Cement and Cement-Lime Plaster: Lap Marks, Leaks.
(i) Lap marks. 1. Not working proper area. 1. Plaster should be applied in as large area
as possible from top to bottom and side
to side in panels.
2. Cold joints. 2. A cold joint in the under coat must not be
at same level as cold joint in scratch.
(j) Leaks 1. Hydrostatic pressure from 1. Drain ground in contact with structure,
wet ground or capillary provide adequate waterproof membrane.
action.
2. Deficiencies of adjacent 2. Eliminate possibility of water penetation

work. at junctures.
3. Roof flow of water 3. Provide proper disposition of water and
cascading over plastered drips.
wall.
4. Absence of building paper 4. Provide proper weather protection.
or felt.
5. Porosity of Plaster. 5. Compact under coat, use proper mix.
6. Cracks. 6. See (b) and (c) above.
7. Cold joints. 7. This is a source of leaks, particularly in
structures with slab floors, use perforated
foundation screed.
General Comments:
(k) Adequate flashing with corrosion-resistant metal is of the utmost importance to prevent water
penetration
of the wall at vulnerable points such as at openings, at tops and sides of trim, under copings and sills, at
intersections of walls
(1) Materials used and roof,
for plaster under
must be ofbuilt-in gutters,The
good quality. andmixture
at any places
must bewhere watertomight
designed gain
provide entrance.
a workable,
cohesive mixture of low water-cement ratio.
(m) Curing deserves special attention. It is essential that cement plaster retain enough moisture for hydration
until setting and hardening has taken place. Moist curing helps develop maximum strength, density and
impermeability, reduces shrinkage and offsets crazing and cracking.
(n) Plaster must be applied so as to obtain full bond between successive coats to concrete or masonry.
(o) When reinforcement is applied to structure, it supports plaster in place and restrains initial shrinkage,
relief joints must be installed and spaced to control cracking.
(p) The under coat must be compacted. It should not be floated, however, while too wet. (This could
glaze
the coatnot
(q) Do bybring
drawing fines tocoat
the scratch the surface and so may destroy
out to approximately bond ofofthe
full thickness finish coat.)
grounds. (This leaves too thin an
undercoat at frames or other build-in grounds, and at surface applied grounds or screeds.
(r) Decorative finish plaster may be obtained with various textures by adding pigments to the mixture, or
embedment of coloured aggregates.
APPEN
DIX-
`C'
Determination of Soluble Sodium and Magnesium Salts :
(IS : 2547 ( Part I) - 1976, Reaffirmed 2002)
C-1.1 Weigh 1 g of the plaster, ground to pass a 212-micron IS Sieve complying with the
requirements of IS:460( P-I) -1985(Reaffirmed 1998) into a polyethylene bottle, add 100
ml of water to room temperature and 1 g of salt free gypsum. Shake the bottle occasionally
during the next hour to prevent caking and then allow it to stand until a clear supernatant
liquid is obtained.
C-1.2 Determine the contents of soluble sodium salts and magnesium salts in portions of
the clear supernatant liquid. Express the results as Na20 and MgO.
APPEN
DIX- `D' Determination of Loss on Ignition
D-1.1 Weigh 2 g of the plaster into a squat weighing bottle, previously weighed complete
with cover. Distribute the plaster evenly over the bottle to constant mass at a temperature
between 280°C and 300°C. Cover the weighing bottle and reweigh immediately it is cool.
APPEN
DIX- È' Determination of Free Lime
E-1. PROCEDURE
E-1.1 Suspend 5 g of the sample in approximately 100 ml of water. Add several drops of
phenolphthalein indicator solution ( 0.5 percent in 50 percent aqueous ethanol) and titrate
with 0.5 N hydrochloric acid until the pink colour of the indicator just disappears.
Continue the titration until the pink colour does not return after standing for 2 to 3 minutes.
With 5 g sample, 1 ml 0.5 N hydrochloric acid = 0.37 percent Ca(OH).
LIST OF BUREAU OF INDIAN STANDARD CODES.
S. No. BIS Code STANDARD TITLE
1. IS: 269-1984 Ordinary Portland Cement 33 Grade.
2. IS:348-1968 French Polish.
3. IS: 383-1997 Specifications for Coarse and Fine Aggregates for Concrete.
4. IS: 427-2005 Dry Distemper/colour.
5. IS: 428-2000 Distemper Oil bound/emulsion, colour.
6. IS: 455-1967 Portland Slag Cement
7. IS: 456-2000 Plain and R.C. Concrete.
8. IS: 460(P-I) -1985 Test Sieves, wire cloth. (Reaffirmed 2002)
9. IS: 460(P-II) -1985 Test Sieves, Perforated Metal Plate. (Reaffirmed 2004).
10. IS: 712-1984 Specifications for Building Limes.
11. IS 1200 : Part 12 : Method of measurement of Building and Civil Engineering
1976 Works - Part XII : Plastering and Pointing.
12. IS: 1200 ( part 13)- Methods of Measurements of Building and Civil Engineering
1976 works, white washing, colour washing, Distempering and Painting)
13. IS: 1200 ( part 15)- Methods of Measurements of Building and Civil Engineering
1976 works, painting, polishing, varnishing).
14. IS: 1288-1982 Methods of Test for Mineral Gypsum.
15. IS 1542 : 1992 Specification for sand for plaster
16. IS 1630 : 1984 Specification for mason's tools for plaster work and pointing work
17. IS 1661 : 1972 Code of practice for application of cement and cement-lime
plaster finishes.
18. IS: 2250-1981 Code of Practice for Preparation of Mortars.
19. IS 2394 : 1984 Code of practice for application of lime plaster finish
20. IS 2402 : 1963 Code of practice for External Rendered Finishes.
(reaffirmed 2001)
21. IS: 2542 Methods of Test for Gypsum Plaster.
(Part1to8)1981
22. IS :2547 Specification for Gypsum Building Plaster. Part-I Excluding
(Part I)- 1976 Premixed Lightweight Plasters
23. IS:2547(Part II)- Specification for Gypsum Building Plaster. Part-II
1976 Premixed Lightweight Plasters.
24. IS: 2645-1975 Integral Cement Water Proofing Compounds.
25. IS: 5410-1992 Specifications for Cement Paint
26. IS: 15489-2004 Paint Plastic Emulsion Interior Use (superseding IS 5411-P MI)
CHAPTER No. 10
WOOD WORK
CHAPTER No.10 : WOOD WORK
CONTENTS
10.0 Scope 3
10.1 Terminology 3
10.2 Timber 5
10.3 Panelling Material 9
10.4 Door, Window and Ventilator Frames Ceiling & Partition Frames
False Ceiling and Partition Frames 24
10.5 Trusses 25
10.6 Panelled Glazed or Panelled and Glazed Shutters 26
10.7 Flush Door Shutters 31
10.8 Battened and Framed Door and Window Shutter 35
10.9 Ledged & Battened or Ledged Braced and Battened Doors and
Window Shutters 35
10.10 Ledged Braced and Battened Garage Doors Shutters 36
10.11 Louvered Shutters 36
10.12 Louvers Fixed to Frames 37
10.13 Wire Gauze Fly Proof Shutters 37
10.14 Wall Lining 37
10.15 Shelves 38
10.16 Trellis (Jaffri) Work 39
10.17 Pelmets 39
10.18 Hold Fasts 40
10.19 Expanded Metal, Hard Drawn Steel Wire Fabric and
Wire Gauze in Wooden Frames 40
10.20 Sal Balli Work 41
10.21 Fittings 41
10.22 Wooden Stair Case 51
10.23 Laminated Veneer Lumber (LVL) 52
Appendix A Permissible Defects for Various Grade of Timbers 56
Appendix B Moisture Content of Timber 57
Appendix C Physical and Mechanical Properties of Plywood 58
Appendix D Physical and Mechanical Properties of FPT or Graded Particle Board. 59
Appendix E Test for Flush Door Shutters 60
Appendix F Schedule of Fitting for Doors and Windows 70
Appendix G Method of Test for Edge Straightness and Squareness of Plywood 72
Appendix H Method of Test for Edge Straightness and Squareness of
Coir Veneer Board 72
Appendix I Method for Test of Coir Veneer Board for Determination of
Glue Shear Strength 73
Fig l - 6 75 to 80
List of Bureau of Indian Standard Codes 81
Rajasthan PWD Building Specifications 2014 Chapter 10 : Wood Work Page 1 of 83

CHAPTER No. 10
WOOD WORK
10.0 Scope :These specifications laid down requirements for materials and covers construction,
fixing, finish and mode of measurement of wood work, for doors, windows, ventilators etc.
10.1 Terminology:
a) Baffles : M n round poles usually without bark.
b) Beam : A structural timber generally long in proportion to its width and thickness and used
for supporting load primarily by its internal resistance to bending.
c) Block Board : A Board having a core made up of strips of wood, each not exceeding 25mm
in width laid separately or glued or otherwise joined to form a slab which is glued between two
or more outer veneers with the direction of the grain of the core blocks running at right angles
to that of the adjacent outer veneers.
d) Core : The inner layers of a composite wood product :
e) Cross Band : A general term indicating a transverse layer of veneer and veneers in
composite wood products.
f7 Decorative Veneers : Veneers having attractive appearance due to figure, colour, grain, lustre
etc.
g) Hard Wood : A conventional term used to denote the wood obtained from broad leaved trees.
It has no relationship to the physical properties of hardness or strength. On account of the
confusion this word might cause, its use is discouraged.
h) Freeze Rai1: Horizontal member, mortised or otherwise secured to the stiles of a door,
provided just below the freeze panel usually provided for decorative purpose in the uppermost
portion of the door.
i) Joint : A prepared connection for joining adjacent pieces of wood, veneer etc.
j) Dovetail Joint : A joint at the corner of two pieces in such a way that the notches made in one
are fitted exactly into projections of corresponding size and shape made in the other. There are
various kinds of dovetail joints for instance, lapped dovetail joint. Wedge shaped dovetail joint,
etc. joints in a way which will resist withdrawal except in the direction in which it was assembled.
(Fig. 1 C)
k) Mitred Joint : A joint, between two members at an angle which bisects the joining angle
usually the joining faces are cut at 45° to from a right angle. (Fig. 1 B)
1) Mortise and Tenon Joint : A joint in which the reduced end (Tenon) of one member fits into
the corresponding slot (mortise) in another members. (Fig. 1 D)
m) Tongue and Groove Joint: A joint in which a tongue is provided on edge of one member to
fit into a corresponding groove on the other. . (Fig. 1 A)
n) Knot: Base of a branch or limb embedded in the tree which becomes visible when it is cut.

o) Diameter of a Knot: The maximum distance between two points farthest apart on the
periphery of a round knot, on the face where it becomes visible. In the case of a spike or splay
knot, the maximum width of the knot visible on the face on which it appears shall be taken as
its diameter.
p) Muntin: Small horizontal or vertical dividing bars within basic frame work of a window, or
door sub-dividing and supporting the glass panes or panels of doors.
q) Particle Board : A board manufactured from particles of wood or other lingo- cellulose
material, for example flakes, granules, shavings, slivers, splinter agglomerated, formed and
pressed together by use of an organic binder together with one or more of the agents, such as
heat, pressure, moisture and a catalyst.
r) Particle : Distinct particle or fraction of wood or other lingo- cellulose material produced
mechanically for use as the aggregate for making a particle board. This may be in the form of
flake, granule, shaving, splinter and sliver.
s) Plywood : A board formed of three or more layers of veneers cemented or glued together,
usually with the grain of adjacent veneers running at right angles to each other.
t) Rebate : A recess along the edge of a piece of timber to receive another piece or a door, sash
or frame
u) Sapwood : The outer layers of the log, which in the growing tree contain living cells and feed
material. The sapwood is usually lighter in colour, and is readily attacked insects and fungi.
v) Seasoning : A process involving the reduction of moisture content in timber under more or less
controlled conditions towards or to an amount suitable for the purpose for which it is to be used.
w) Seasoned Timber : Timber whose moisture content has been reduced to the specified
minimum, under more or less controlled process of drying.
x) Structural Timber : Timber used in framing and load bearing structure or timbers used or
intended for use in buildings where strength is the primary consideration
y) Flake : Specially made thin particle, with the grain of the wood essentially parallel to the
surface of the flake, prepared with the cutting action of the knife in a plane parallel to the grain
but at an angle to the is of the fibre.
z) Granule : Particle in which the length, width and thickness are approximately equal, such as
particle of saw dust.
aa) Shaving : M n slice or strip of wood pared off with a knife, planer or other cutting instrument, the
knife action being approximately along the is of the fibre, such as the shavings produced in
planning the surface of wood.
ab) Splinter and Sliver : Particle of nearly square or rectangular cross section with a length parallel
to the grain of at least four times the thickness.
ac) Cement Bonded Particle Board: Particle board made from a mixture of wood particles and
Portland cement.
ad) First Class Wood: Individual hard and sound knots shall not be more than 25 mm in diameter
and the aggregate area of all the knots shall not exceed one per cent of the area of the piece.
ae) Second Class Wood: Individual hard and sound knot shall not be more than 40 mm in

diameter and aggregate of all the knots shall not exceed one and half per cent of the area of the
piece. Wood shall be generally free from sapwood, but traces of sapwood may be allowed.
10.2 Timber : Timbers classified as under:
(i) Teak wood
(ii) Deodar wood
(iii) Non-coniferous timber other than teak.
(iv) Coniferous timber other than deodar.
The timber shall be free from decay, fungal growth, boxed h e , pitch pockets or streaks on the
exposed edges, splits and cracks. The timber shall be graded as first grade and second grade on the
basis of the permissible defects in the timber (as given in Appendix À'). For both the grade, knots
should be avoided over a specified limit.
10.2.1 Teak Wood (Tectona Grandis): It is of outstanding merit in retention of shape and durability.
The heart wood is one of the most naturally durable woods of the world. It usually remains immune to
white ant attack and insect attack for very long period. It is, however, not always immune from fungus
attack (rot). Taken as a whole, good quality teak wood is very durable and is used for making furniture
and all important timber construction.
10.2.1.1. Superior Class Teak Wood such as Balarsha, Malabar and Dandeli: Individual hard and
sound knot shall not be more than 12 mm in diameter and the aggregate area of all the knots shall
not exceed one half per cent of the area of the piece. It shall be close grained.
10.2.1.2. First Class Teak Wood: Individual hard and sound knot shall not be more than 25mm in
diameter and the aggregate area of all the knots shall not exceed one per cent of the area of the piece.
10.2.1.3 Second Class Teak Wood: Individual hard and sound knot shall not be more than 40mm in
diameter and the aggregate of all the knots shall not exceed one and half per cent of the area of the
piece. Wood shall be generally free from sapwood, but traces of sapwood may be allowed.
10.2.2. Deodar Wood (Cedrus Deodars):It is the strongest of the India conifers. Its weight and
strength is 20 per cent less than teak. It is easy to saw and works to a smooth finish. It is not, however,
a suitable wood for polish or paint work as the oil in the wood and especially near knots, always, seeps
through such finishes and discolours them. It is used for house building, furniture and other
construction work. It is also suitable for beams, floors, boards, posts, window frames and light
furniture etc.
10.2.2.1 First Class Deodar Wood: No individual hard and sound knot shall be more than 25mm in
diameter and the aggregate area of all the live knots shall not exceed 1% of the area of the piece.
10.2.2.2 Second class Deodar Wood: No individual hard and sound knot shall be more than 40mm in
diameter, and the aggregate area of all the knots shall not exceed 1.5% of the piece. Wood shall be
generally free from sapwood, but traces of sapwood may be allowed.
10.2.3 Sal Wood (Shoera Robusta): Sal is about 30 per cent heavier than teak, 50 per cent harder,
and about 20 to 30 percent stronger. In shock resistance it is about 45 per cent above teak. Its heart
wood is a naturally durable wood, and usually remains immune to attack by white ants and fungi for a
long period, while its sapwood is very perishable and should not be used. Well dried Sal is not a really
easy wood to saw and work. It is a rough constructional wood than a carpentry timber. No individual
hard and sound knot shall exceed 25 mm in diameter and the aggregate area of all the
knots shall not exceed 1% of the area of the piece. It can be used for a variety of purposes, such as for
beams, rafters, flooring, piles, bridging, tool handles arms and tent pegs, etc.
10.2.4 Kai1 Wood (Pinus Roxburghie ):Kail Wood is not a very durable wood. But it is easy to
saw and work and is usually very popular in workshops. It can be brought to a fine smooth surface,
but is more suitable for paint and enamel finishes than for polish work. It is useful for Joinery works.
Constructional work, light furniture and house fitments.
10.2.4.1 First Class Kail Wood: No individual hard and sound knot shall exceed 25mm in diameter
and the aggregate area of all the knots shall not exceed 1% of the area of the piece. Wood shall be
generally free from sapwood, but traces of sapwood shall be allowed.
10.2.4.2 Second Class Kail Wood: No individual hard and sound knot shall exceed 40mm in
diameter and the aggregate area of all the knots shall not exceed 1.5% of the area of the piece. Wood
shall be generally free from sapwood, but traces of sapwood shall be allowed.
10.2.5. Other Species: Some other species of timber can also be used for various activities of
building construction. The chief characteristics of the species are given below:
10.2.5.1 Khair (Acacia Catechu Wild):The heart wood is very durable and is seldom attacked by
while ants and fungi. It is an extremely strong and very hard and rough timber. A some what difficult
timber to saw and machine, especially if the wood is old and dry. stiff tools should be used in
machining and turning. It finishes and polishes extremely well. It is used for posts in house
construction. Tool handles, tool bodies.
10.2.5.2 Babul (Acacia Nilotica SSP Indicia):Its functions and uses are similar to those described in
10.2.5.1.
10.2.5.3 Haldu (Andina Cordifolia): Haldu is a fairly hard and strong wood. It is about 10 per cent
harder than teak but slightly weaker in transverse strain, elasticity and compression. It is very easy
wood to saw and machine. It also finishes very easily and takes strain and polish remarkably well. It
cannot be dovetailed because it breaks away. It is commonly used for door and window frames, floor
boards, turning carving, furniture, panelling and house hold fitments.
10.2.5.4 Mango (Mangifera Indica): It is a very study wood when seasoned and it is as good as
teak in this respect but is not a very durable wood in exposed positions and is not immune to white ant
attack. It received preservative treatment well. It can be easily finished to smooth surface. Its chief
uses are for cheap furniture, planking, floor and ceiling boards.
10.2.5.5 Chir (Pinus Rexburghi): Chir is not a very durable wood unless treated with a preservative. It
is easy to saw and is usually popular in workshops. It can be brought to a fine smooth surface, but are
more suitable for paint and enamel finishes than for polish work. It is used for constructional work
and house fitments.
10.2.5.6 Hollock (Terminalia Myriocarpa): Hollock is not a durable wood unless properly treated .
It can be readily treated with wood preservatives. It can be finished to fairly good surface, but needs
careful filling before it is polished. It is used for house building in the form of scantlings, beams,
rafters and planking. It also makes up into excellent furniture.
10.2.5.7 Benteak (Largerstroemia Lanceoleta): Benteak is very close to teak in strength. It is
suitable for all constructional purpose and is not prone to fungus attack. It is finished to a fine smooth
surface and takes a good polish .It is used for house building, furniture, carriage building and general
carpentry.
10.2.5.8 Gamari (Gmelina Arborea): Gamari is lighter and not so strong as teak. It is a durable
wood, but not immune to white ants attack for a very long period if placed in the ground. It is used for
making furniture, panelling and other general utility and domestic purposes. It is a good wood for
patterns.
10.2.5.9 Bahera : Seasoned wood is considerably immune to attack of fungus and insect. It can be
treated fairly readily with wood preservatives. It is an easy wood to saw but difficult to bring to a
smooth surface. It is used for rafters and boards. It is mainly used for plywood work.
10.2.5.10 Bijasal (Ptrocarpus Marsupium): It is a timber of natural durability above the average. It
can be brought to a good finish and with ample filling, takes a good polish. Its chief use is for building
purposes. It is also used for furniture.
Table-1 : Species of Timber
SI. Botanical Name Trade Availa
Average bility
No. Name Unit wt North East Central West South
Kg/m 3 Zone Zone Zone Zone Zone
1. Tectone grandis linnf Teak 640 - Y X X X
2. Acacia Catechiu Willd Khair 1010 X X X Y Y
3. Acacia Arabica Willd Babul 785 X X X Y Z
4. Adina Cordifolia Roxb HK.f Haldu 675 X - - - X
5. Cedrus Deodara D Don Deodar 545 X - - - -
6. Magnifera Indica Linn Mango 690 X X Y Y X
7. Pinus Wallichiana A.B. Jucks Chir 575 X - - - -
8. Pinus Excelsa Wall Kali 515 X - - - -
9. Shorea Robusta Gaertn. Sal (U.P.) 881 X X X - -
10. Terminalia Myrioecarpa
Heurcket Muell Arg. Hollock 610 - X - - -
11. Lagerstroemia Lanceolata Benteak 675 - - - Y X
Wall
12. Gamelinc Arborea Linn Gamari 515 Y Y Y Z Y
13. Terminalia Bellirica Roxb. Bahora 801 X X X Y X
14. Pterocarpus Marsupium Roxb Bijasal 800 - X X Y Y
Note : The average unitwt. is at 12 per cent moisture content.
Availability : The territories comprising India, Sikkim and Bhutan have been divided into five Zones,
which cover roughly the following areas :
North Zone : Jammu and Kashmir, Punjab, Himachal Pradesh, Delhi, Uttar Pradesh and Rajasthan
East Zone : Assam, Manipur, Tripura, West Bengal, Bihar, Orissa, S m , Bhutan, Andaman's,
North East Frontier Agency and Nagaland.
Central Zone : Madhya Pradesh, Vidharbha areas of Maharashtra State and the North East Part of
Andhra Pradesh (Godavari delta area).
West Zone : Maharashtra State (Except Vidharbha areas), Gujarat and North West Part of Karnataka.
South Zone : Tamil Nadu, Andhra Pradesh (Except the Godavari delta area), Kerala and Karnataka
(except North West Part)
The availability of timbers is categorised under three classes as indicated below :
X - Most common, 1415 m3 (1000 tonnes) and more per year.
Y - Common, 355 m3 (250 tonnes) to 1415 m3 (1000 tonnes) per year and
Z - Less common, below 355 m3 (250 tonnes) per year.
10.2.6 Moisture Content: Control on moisture content of timber is necessary to ensure its proper
utility in various climatic conditions. For specifying the permissible limit of moisture content in the
timber the country has been divided into four climatic Zones as per IS:287-1993. These Zones are
zonel, zone II, zone III and zone IV. In each of the zones, maximum permissible limit of moisture
content of timber for different uses shall be as per Table 2. & can be determined as per IS: 287-1993.
10.2.6.1 Tolerance on Moisture Content: Average Moisture content of all the samples from a lot
shall be within + 3 per cent and moisture content of individual samples within + 5 per cent of
maximum permissible moisture content specified in Table 2. These tolerance are the absolute values
over the percentage moisture content S .No. 1 & 2 of Table 2. No tolerance on moisture content is
permitted for S .No. 3 & 4 of Table 2.
Table -2: Maximum Permissible Moisture Content of Timber

S. No. Use Max. Moisture Content Percentage
Zone I Zone II Zone III Zone IV
1. Beams, Rafters & Posts 12 14 17 20
2. Doors and windows
(a)- 50 mm and above thickness 10 12 14 16
(b)-Thinner than 50 mm 8 10 12 14
3. Flooring Strips 8 10 10 12
4. Furniture & Cabinet making 10 12 14 15
10.2.7. Seasoning of Timber: The process of drying timber under controlled conditions is called
seasoning of timber. Timber shall be either air seasoned or kiln-seasoned and in both cases moisture
content of the seasoned timber shall be as specified in Table 2. Unless otherwise specified, air
seasoned timber shall be used. Kiln seasoning of timber, where specified, shall be done as per IS:
1141-1993 in a plant approved by Engineer-in-charge.
10.2.8. Preservation of Timber: Preservative treatment does not improve basic properties of timber
but gives varying degree of protection against deterioration due to attacks by fungi, termites, borers
and marine organisms. Preservative treatments, where specified shall be done using Oil type, Organic
solvent type or Water soluble type preservative. Oil Type preservatives shall be used if the timber is
not required to be polished or painted. Before preservative treatment, the timber shall be sawn and
seasoned. All surfaces exposed after treatment, except due to planning, shall be thoroughly brushed
with the preservation before jointing. Preservative treatment of timber shall be done as per IS:401-
2001in a plant approved by the Engineer-in-Charge.
10.3. Panelling Material:
10.3.1.Timber: Timber panels shall be preferably made of timber of larger width. The minimum
width and thickness of a panel shall be 150 mm and 15mm respectively. When made from more than
one piece, the pieces shall be joined with a continuous tongue and groove joint, glued together and
reinforced with metal dowels. The grains of timber panels shall run along the longer dimensions of the
panels. The panels shall be designed such that no single panel exceeds 0.5 square meter in area.
10.3.2. Plywood/ Plywood Boards:
10.3.2.1. Plywood boards are formed by gluing and pressing three or more layers of veneers with the
grains of adjacent veneers running at right angles to each other. The veneers shall be either rotary
cut or sliced and shall be sufficiently smooth to permit an even spread of glue. Face veneers may be
either commercial or decorative on both sides or one side commercial and the other decorative. Plywood
shall be BWP grade or BWR grade as per IS:303-1989.
10.3.2.2. Adhesive: Adhesive used for bonding BWP grade of plywood boards shall be BWP type
synthetic resins conforming to IS:848-2006 respectively.
10.3.2.3. Thickness: The thickness of all veneers shall be uniform, within a tolerance of ± 5 percent.
Corresponding veneers on either side of the centre one shall be of the same thickness and species. The
requirement of thickness and core veneers shall be as follows:
(a) In 3 ply boards up to 5mm thick. The combined thickness of the face veneers shall not
exceed twice the thickness of centre ply.
(b) In a multiply boards, the thickness of any veneer shall not be more than thrice the thickness
of any other veneer.
(c) The sum of the thickness of the veneers in one direction shall approximate to the sum of the
thickness of the veneers at right angle to them and shall not be greater than 1.5 times this sum
except for 3 ply as specified in (a).
10.3.2.4. Tolerance
Plywood boards are available in thickness ranging from 3 to 25mm. Tolerance in thickness shall be +
10% for boards up to and including 5mm; ± 7% for boards from 6 to 9mm and ± 5% for boards above
9 mm thickness. The boards shall be of uniform thickness and the surfaces of the boards shall be sanded
to a smooth finish. Number of ply in plywood boards shall be as per Table 3.
Table -3 : Numbers of Ply in Plywood Boards
Thickness in mm No. of Ply Thickness in mm No. of Ply
3,4,5,6 3 12,15,16,19 9
5,6,8,9 5 19,22,25 11
9,12,15,16 7 (Above 11 Ply as ordered)
Note: Plywood of 9 mm thick ck of 5 or 7 ply may be used generally.
10.3.2.5. Moisture content of the plywood boards shall not be less than 5 per cent and not more than
15 percent in accordance with IS:1734 (Part 1)-1983.
10.3.2.6. Testing: One sample for every 100 sqm or part thereof shall be taken and testing done as
per IS 303-1989. However, testing may not be done if the total requirement of plywood boards is
less than 30 sqm. All the samples tested shall meet the requirements of physical and mechanical
properties of plywood boards as specified in Appendix C.
10.3.2.7 Grade: Type of face veneer and grade of plywood boards shall be as specified. Unless
otherwise stated, only BWP grade plywood boards shall be used.
10.3.3. Particle Boards:
10.3.3.1.Specifications: Particle boards shall be of medium density and manufactured from particles
of agro waste, wood or lignocelluloses i.e., material blended with adhesive and formed into solid
panels under the influence of heat, moisture, pressure etc. The particle boards shall be flat pressed with
single, three or multi layers and graded and of Type-1 as per Table-1 of IS:3087-2005. Both surfaces
of the boards shall be sanded to obtain a smooth finish.
10.3.3.2 Adhesives: Adhesives used for bonding shall be BWP type synthetic resin conforming to
IS:848-2006.
10.3.3.3. Thickness and Tolerance: Particle boards are available in thickness ranging from 6 mm to
40 mm. Tolerance in thickness shall be ± 5% for boards up to and including 25mm thick and ± 2.5
per cent for boards above 25mm thickness. Each boards shall be of uniform thickness.
10.3.3.4. Testing:
One sample for every 100 sqm. or part thereof shall be taken and testing done as per IS:3087-2005.
However, testing may not be done if the total requirement of particle boards in a work is less than 30
sqm. All the samples tested shall meet the requirement of physical and mechanical properties of
particle boards specified in Appendix D.
10.3.4. Veneered Particle Boards:
10.3.4.1. Veneered Particle Boards have a solid core of medium density Type I particle boards (which
is covered with commercial or decorative veneers on one face and commercial veneers on the other).
Face veneers are bonded using adhesives under the influence of heat and pressure. Veneered particle
boards shall be of exterior grade (grade I) as per IS:3097-2006. Both surfaces of the boards shall be
sanded to a smooth finish.
10.3.4.2. Adhesives: The adhesives used for bonding shall be BWP synthetic resin conforming to
IS:848-2006.
10.3.4.3 Thickness and Tolerance: Veneered particle boards are available in thickness ranging from
6 to 50mm.
Tolerance in thickness shall be ± 5% for boards up to and including 25mm thick and ± 2.5% for
boards above 25 mm thickness. Each boards shall be of uniform thickness.
10.3.4.4 Testing: One sample for every 100 sq m. or part thereof shall be taken and testing done as per
IS:3097-2006. However, testing may not be done if the total requirement of veneered particle boards
in a work is less than 30 sqm. All the samples tested shall meet the requirements of physical and
mechanical properties of veneered particle boards specified as under..
1. Moisture Content 5-15%
2. Water Absorption
(a) 2 hrs. soaking Not more than 25%
(b) 24 hrs. soaking Not more than 50%
3. Water Resistance No sign of disintegration or
delaminating after 3 hrs. boiling in
water.
4. Swelling in Water
(a) General absorption for 2 hrs. immersion Not more than 7%
(b) Surface absorption for 2 hrs. Not more than 5%
5. Adhesion of plies Knife test
10.3.4.5 Grade & Type : Type of face veneers, thickness of veneered particle boards and adhesive used
for bonding shall be as specified. Unless otherwise stated, exterior grade veneered particle boards
with BWP Type. Synthetic resin adhesive shall be used.
10.3.5 Hard Board:
10.3.5.1 Hard boards are generally classified into the following three types according to their method
of manufacture, density and other related mechanical and physical properties.
a) Medium hard board . A homogenous fibre building board having a density exceeding 480
kg/ cum but not exceeding 800 kg/Cum.
b) Normal hard board: A homogenous fibre building board having a density exceeding 800 kg/
cum but not exceeding 1200 kg/cum.
c) Tempered hard board: Hard board which has been further treated in the course of
manufacture to increase its density, strength and water resistance.
10.3.5.2 The hard board used for panelling of door shutters, shall be of tempered quality. The
thickness of hard board panelling used shall not be less than 12mm in case of single panels shutter and
10 mm in case of two or more panels shutter. The hard board shall be regular and, unless otherwise
specified shall have square edges. The lengths of the two diagonals of the boards shall not differ by
more than ± 3 mm per meter length of the diagonal. The tolerance on length and width shall be ± 3
mm and on thickness ± 0.3 mm.
10.3.5.3 Workability: The hard boards shall not crack, split or chip when drilled, sawed or nailed
perpendicular to the surface.
10.3.5.4 Finish: The boards shall be the uniform thickness subject to tolerance stated above. They
shall be free from warp. The surfaces shall be flat, free from cracks and lumps and of natural colour.
At least one face shall be smooth.
10.3.6. Block Board: Block Boards have a solid core made up of uniform strip of wood each not
exceeding 25mm in width, laid separately, or spot glued, or otherwise jointed to form a slab which is
glued between two or more outer veneers, with the direction of the grain of the core block running at
right angles to that of adjacent veneers. In any one block board, the core strips shall be of one species
of timber only. Face veneers may be decorative or commercial on both faces or decorative on one face
and commercial on the other. Block boards shall be Grade I (Exterior Grade) as per
IS:1659-2004. Both surfaces of the boards shall be sanded to a smooth finish.
10.3.6.2. Adhesives: The adhesives used for bonding shall be BWP type synthetic resin conforming
to IS:848-2006 for Grade I block boards.
10.3.6.3. Thickness and Tolerance: Block boards are available in thickness ranging from 12 to 50
mm. Tolerance in thickness shall be ± 5% for boards up to and including 25mm thick and ± 2.5% for
boards above 25mm thickness. Each boards shall be of uniform thickness.
10.3.6.4. Testing: One sample for every 100sgm. or part thereof shall be taken and testing done as per
IS:1659. However, testing may not be done if the total requirement of block boards in a work is less
than 30 sqm. All the samples tested shall meet the requirement of physical and mechanical properties
of block boards specified in the relevant B.I.S Code.
10.3.6.5. Type of face veneers, thickness and grade of block boards shall be as specified. Unless
otherwise stated, grade I (exterior grade) block boards bonded with BWP Type synthetic resin shall
be used.
10.3.7. Asbestos Cement Board: This should conform to IS:2096-1992. The material used in the
manufacture of asbestos cement building boards shall be composed of an inert aggregate consoling of
clean asbestos fibre cemented together by ordinary Portland cement, rapid hardening and low heat
Portland cement or blast furnace slag cement. No organic or inorganic materials shall be added to the
composition. Pigments which are embodied in the asbestos cement for colouring purpose shall be
permanent colours and shall conform to the requirements. The thickness of the asbestos cement board
used for panelling shall not generally be less than 6.5 mm. in case of single panels shutters and 5mm
in case of two or more panel shutter. Asbestos cement building boards shall be of two classes, namely
class 'A' and class `B'. The thickness of class A shall be 6.5mm and for class `B' 5mm. The tolerance
on thickness shall be ± 0.5mm.
10.3.8. Fibre Boards:

10.3.8.1. Fibre board shall be of medium density and manufactured from wood fibre, produced by
fiberizing steamed wood under pressure, blended with adhesive and wax and formed into solid panels
under controlled conditions of heat and pressure. Fibre board flat pressed single layer and shall be
Exterior Grade as per IS:12406-2003. Both surfaces of the boards shall be sanded to a smooth finish.
10.3.8.2. Adhesives: The adhesives used for bonding shall be BWP type synthetic resin conforming
to IS:848-2006.
10.3.8.3. Thickness: Fibre boards are available in thickness ranging from 6 to 40mm. the tolerance in
thickness shall be ± 0.3mm up to and including 9mm thickness and ± 0.6mm for thickness above
9mm. Thickness of fibre boards and adhesive used for bonding shall be as specified. Unless otherwise
stated, exterior grade fibre board bonded with BWP type synthetic resin adhesive shall be used.
.10.3.8.4. Testing: One sample for every 100 sqm. or part thereof shall be taken and testing done as
per IS:12406-2003. However, testing may not be done if the total requirement of fibre board in a
work is less than 30 sqm. All the samples tested shall meet the requirements of physical and
mechanical properties of fibre board specified in the relevant BIS Codes.
10.3.9. Sheet Glass, Frosted Sheet Glass:
10.3.9.1. Sheet Glass shall be flat, transparent and clear as judged by the unaided eye. It may,
however, possess a slight tint when viewed edgewise. Sheet glass shall be of selected quality (SQ)
or Ordinary Quality (OQ) as per IS:2835-1987. Glass shall be free from cracks. Unless otherwise
specified ordinary quality sheet glass shall be used.
10.3.9.2. Dimensions: Normal thickness and range of thickness of sheet glass shall be as per Table
4. Tolerance on cut sizes (length and width) shall be ± 2.0mm.
Table 4: Thickness and Weight of Sheet Glass
Nominal Thickness mm Range of Thickness mm Weight (kg/sqm)
3.0 2.8 to 3.2 7.5
4.0 3.8 to 4.2 10.0
4.8 4.6 to 5.1 11.9
5.5 5.2 to 5.8 13.5
6.3 6.0 to 6.6 15.5

10.3.9.3. Sheet Glass of 4 = nominal thickness, weighing not less than 10 kg/sqm shall be used for
glass panel of area up to 0.5 sqm. For panel exceeding 0.5 sqm. in area, the nominal thickness of the
glass to be used shall be as specified.
10.3.10. Wire Cloth (Wire Gauge):
10.3.10.1.Specifications: Wire Cloth which shall generally conform to IS:1568-1970 shall be
regularly woven with equally spaced galvanized mild steel wires in both wrap and weft directions. The
wire cloth shall be properly salvaged by one or more wires in each edge.
10.3.10.2. Mesh: -Average width of aperture and the nominal diameter of the wire shall be as
under:
Average width of Aperture mm Nominal dia. of wire mm
1.40 0.63
1.18 0.556
1.00 0.50
10.3.10.3. Width of aperture: Width of aperture and dia. of wire of wire cloth shall be as specified.
Unless otherwise stated, wire cloth of 1.40 mm average aperture width woven with 0.63 mm nominal
dia. galvanized mild sheet wire shall be used.
10.3.10.4. Fly- proof wire cloth: Fly- proof wire cloth (aperture 1.40 mm) is generally provided in
Kitchen and dining areas while wire cloth of smaller aperture is used in mosquito proof shutters.
10.3.11.Gypsum Board: Gypsum Board is formed by enclosing and bonding together a core gypsum
plaster (a calcium sulphate mineral) with or without fibre between two sheets of highly durable paper.
The gypsum board shall be non-resonant, dimensionally stable and possesses flame retardant qualities.
The boards shall conform to IS:2095-2011 and gypsum plaster shall conform to IS:2547. The surfaces
of the boards shall be true and free from imperfection that would render the board unfit for use with
or without decoration.
10.3.11.1. Types: Gypsum plaster boards are classified according to their use.
10.3.11.2.Gypsum Wall Board with Reduced Water Absorption Rate: These boards have additives
in the core and /or the paper liners to reduce the water absorption rate. They may be suitable for
special application in buildings where reduced absorption properties are required to improve the
performance of the board. Unless stated otherwise, decoration may be applied to the face.
10.3.11.3.Gypsum Wall Board with Improved Core Cohesion at High Temperatures: These
boards have mineral fibres and /or other additives in the gypsum core to improve core cohesion at
high temperatures. They have a face suitable for direct decoration.
10.3.11.4 Gypsum Plaster Base Board: These boards have a face suitable to receive gypsum
plaster and may be perforated during primary manufacture.
10.3.11.5. Gypsum Plaster Base Board with Improved Core Cohesion at High Temperatures:
These boards have mineral fibres and/or other additives in the gypsum core to improve core cohesion at
high temperatures. They have a face suitable to receive gypsum plaster and may be perforated during
primary manufacture.
10.3.11.6. Dimensions: The width, length and thickness of the boards shall be as given in Table 6.
The lengths of the two longitudinal of the boards shall not differ more than ± 3 mm per meter length of
the diagonal.
10.3.11.7. Tolerance: The tolerance on dimension shall be as given below:
Typ e nun
Tolerance in
Width Length Thickness
GypsumWallBoards 0to5 0 t o 6 on ±0.6
Gypsum Base Board
(a) Non-perforated 0 to 8 0 to 6 ± 0.6
(b) Perforated 0 to 8 0 to 10 ± 0.6
10.3.11.8. Transverse Strength: Breaking load for gypsum plaster boards shall be in accordance
with Table 5 given below:
Table -5: Breaking Load of Gypsum Plaster Boards
Type of Board Thickness Breaking Load, Minimum
Transverse Longitudinal
Direction N Direction N
Plaster Board 9.5 140 360
12.5 180 500
15.0 220 650
Base Board 9.5 123 180
12.5 165 235
Table -6. Dimensions of Gypsum Plaster Boards

Type of Board Width in mm Length in mm Thickness in mm
Wall Board 600,900 and 1800 to 3600 in step of 9.5, 12.5 and 15
1200 100 mm
Base Board 400 and 900 1200, 1500 and 1800 9.5 and 12.5
10.3.12.Cement Bonded Particle Boards:
10.3.12.1. Species of wood which do not hinder the process of setting of cement shall be used.
Suitable additives such as sodium silicate conforming to IS 381 and aluminium sulphate conforming to
IS: 260 shall be used to prevent inhibitive effect of setting of cement when other species are used.
10.3.12.2. Cement conforming to IS: 8112-1989 shall be used.
10.3.12.3. Manufacture: Wood particles for the manufacture of particle boards bonded with cement
shall be produced by cutting wood into shavings, flakes, splinters or slivers of sizes up to 15mm in
length. 3 mm in width and 0.3 mm in thickness on a suitable chipping machine. Particles up to 30 per
cent by dry weight shall be blended with requisite quantity of cement, other chemical additives and
water. The mixture shall then be formed into a board. Boards thus formed shall be stacked in the
stacking device and then compressed and clamped in a hydraulic press. Boards after compression shall
be allowed to set in a curing chamber in the clamped condition. Cured boards shall be allowed to
mature for a period of 12 days and then dried in a drying chamber. Subsequently boards shall be
trimmed to required size.
10.3.12.4. Finish: The particle boards shall be uniform thickness and density throughout the length
and width of the boards. All particle boards shall be flat and smooth.
10.3.12.5. Dimensions and Tolerances: The sizes of cement bonded particle boards shall be as
follows:
Length 3050 mm and 2440 mm
Width 1220mm
10.3.12.6. Thickness: The thickness of cement bonded particle boards shall be as given below: 6,
8,10, 12, 16, 20, 25, 30 and 40 mm

10.3.12.7. Tolerances: The following tolerances for the dimensions shall be permitted.
Length ± 5mm
Width ± 5mm
Thickness Tolerance
(i) Un sanded boards
6mm to 12mm ± 1mm
12mm to 12mm ±1.5 mm
20 mm and more ± 2mm
(ii) Sanded boards (for all thickness) ±0.3mm
Edge straightness ± 2mm per 1000 mm
Squareness ± 2mm per 1000 mm
10.3.12.8. Density: The average density of the board when tested in accordance with IS:14276-
1995 shall not be less than 1250 kg/cum.
10.3.12.9. Moisture Content: The average moisture content of the boards when determined in
accordance with IS:14276-1995 shall not exceed the prescribed limits given in Table 7. The moisture
content of individual test specimen shall not vary from the mean percentage by more than ± 3
percent.
10.3.12.10. Water Absorption: The water absorption of the boards when determined in accordance
with IS:14276-1995 shall not exceed the prescribed limits given in Table 7 for 2h and 24h soaking.
10.3.12.11. Swelling in Water: The swelling in thickness, length and width when determined in
accordance with IS:14276-1995 shall not exceed the limits given in Table 6.
10.3.12.12. Workability: The boards shall not crack or split when drilled shaved or nailed
perpendicular to surface.
Table -7: Requirements of Physical and Mechanical Properties
for Cement Bonded Particle Boards.
S. No. Properly Requirement
i Density (min) Kg/m 3 1250
ii Moisture content, percent 6 to 12
iii Water absorption (max), percent
2h soaking 13
24h s o n g 25
iv Swelling in water (max), percent (After 2h soaking) 2.0
(a) Thickness 0.5
(b) Length 0.5
(c) Width 0.5
v Modulus of rupture (min), N/mm z
Dry condition 9
Wet Condition 5.5
vi Modulus of elasticity (min) N/mm z 3,000
vii Tensile strength perpendicular to surface (min), N
(a) DRY 0.4
(b) +Accelerated ageing 0.25
viii Screw withdrawal strength (min) N
Face 1250
Edge 850
ix +pH 11 to 13
*MOR in wet condition- Specimens are soaked in water at 27±2°c for period of 24h. Modulus of
rapture shall be determined in wet state.
+ Accelerated ageing- Specimens are boiled in water for a period of 2h, After wards they are dried at
27± 2°C to a moisture content around 12 percent and then tensile strength perpendicular to surface shall
be determined.
+pH- Specimens are immersed in water at 24± 2°C for a period of 72h. After removing the specimens
pH value of the water shall be determined using a pH meter.
10.3.13 Veneered Decorative Plywood: Decorative plywood shall be of two grades namely BWR
and MR Decorative Plywood shall be of two types. Type 1 and type 2 and shall conform to IS: 1328-
1996.
10.3.13.1 Requirement of Type-I Veneered decorative plywood shall be as under:
(a) Open slits checks or open joints not more than 150 mm in length and 0.5 mm in width shall
be permissible provided the same are rectified with a veneer insert bounded with synthetic resin
adhesive, as the case may be and further provided that the insert matches with the surrounding
veneer in colour as well as figure.
(b) The decorative veneered surface shall be free from torn grain, dead knots decolourisation
and sapwood.
(c) The decorative veneered surface shall be selected for figure, texture, colour and grain etc. It
shall be free from all manufacturing and wood defects except to the Engineer-in-charge
permitted under para 10.2.8.1(a). All veneers shall be matched or mismatched to achieve a
decorative effect in colour figure and grain.
10.3.13.2 Adhesive : The adhesive for bonding veneers shall be MR and BWR type synthetic resin
adhesive conforming to IS: 848-2006 for MR and BWR grade veneered decorative plywood
respectively.
10.3.13.3 Dimensions and Tolerances:
10.3.13.3.1 The dimensions of plywood boards shall be as follows:
2400 mm x 1200 mm 2100mmx900mm
2100 mm x 1200 mm 1800mmx900mm
1800 mm x 1200 mm
10.3.13.3.2 Thickness: The thickness of plywood board shall be 3 mm, 4 mm, 6 mm, 9 mm, 12
mm, 19 mm and 25 mm.
Note: Any other dimensions (length, width and thickness) as agreed to between the manufacturer
and the purchaser may also be used.
10.3.13.3.3 Tolerances: Tolerances on the nominal sizes of finished boards shall be as follows:
Dimension Tolerance
Length +6 mm
0
Width +3 mm
 0mm
Thickness:
(i) Less than 6 mm ± 10 per cent
(ii) 6 mm and above ± 5 per cent
Edge straightness 2 mm per 1000 mm
or 0.2 per cent
Squareness 2 mm per 1000 mm
or 0.2 per cent
Note : Edge straightness and squareness shall be tested as per Appendix H.
10.3.13.4 Finish : The decorative plywood shall be uniform in thickness within the tolerances limits
specified. The ends shall be trimmed straight and square edge straightness and squareness when tested
as per Appendix `H' shall be within the tolerance specified in 10.3.13.3.3.
10.3.13.5 Sampling and Criteria for Conformity : The method for drawing representative samples
and criteria for conformity shall be as per IS 7638-1999
10.3.13.6 Tests : Boards shall be subjected to following tests :
(i) Moisture content: Decorative veneered plywood of either type when tested in accordance with
IS 1734 (Pt. I)-1983 shall have a moisture content not less than 5 per cent and not more than 15
per cent.
(ii) Water Resistance Test : Three test specimen of size 250 mm x 100 mm shall be prepared for
each of the boards selected and submerged in water at 62 ±2° C for a period of 3 hours and
dried for 8 hours at a temperature of 65 ± 2°C and then followed by two more cycles of soaking
and drying under same conditions described above. Decorative Veneered plywood of either
type shall not show delaminating or blister formation.
10.3.13.7 Marking : Each plywood bound shall be legibly and indelibly marked or stamped with
the following on the face of board near one corner.
Indication of the source of manufacture
Year of manufacture
Batch no.
Type of plywood
Criteria for which the plywood has been labelled as ECO mark
The decorative veneered plywood may also be marked with standard BIS certification
Mark. 10.3.14 Prelaminated Particle Boards:
10.3.14.1 Prelaminated particle boards are available in two grades namely Grade I and II as per IS:
12823. Each grade is further classified in four types, namely Type-I, II, III, W.
10.3.14.2 Material:
10.3.14.2.1 Particle Board Prelaminated particle board Grade-1 (FPT-I or graded wood particle
board FPT-I) bonded with BWP type synthetic resin and prelaminated conforming to IS: 12823
Grade-I, type II or I shall be used.
10.3.14.2.2 Impregnated Base Paper: Printed or plain coloured absorbent base paper having a weight
of 60-140 g/m2 impregnated in a suitable synthetic resin and dried to a volatile content of 4-8 per
cent shall be used for prelamination on both surfaces of particle board.
10.3.14.2.3 Impregnant Overlay: An absorbent tissue paper having a weight of 18-40 g/m2
impregnated in a suitable synthetic resin and dried to volatile content of 4-8 per cent.
10.3.14.3 Dimension and Tolerances:
10.3.14.3.1 Dimensions of prelaminated particle boards shall be as follows:
Length :
The length of prelaminated particle boards shall be 4.8, 3.6, 3.0, 2.7, 2.4, 2.1,
1.8, 1.5, 1.2, 1.0 and 0.9 metres.
Width
The width of prelaminated particle boards shall 1.8, 1.5, 1.2, 1.0, 0.9, 0.6 and
0.45 metres.
The thickness of prelaminated particle boards shall be 6, 9, 12, 15, 20, 25, 30,
Thickness 35, 40 and 45 mm.
10.3.14.3.2 Tolerances : Tolerances on the nominal sizes of finished boards shall be as given
below :
Dimension Tolerance
Length +6mm
0
Width +3mm
0
5 per cent
Thickness
Edge straightness 2 mm per 1000 mm or 0.2 per cent
Squareness 2 mm per 1000 mm or 0.2 per cent
Note : Edge straightness and squareness shall be tested as per IS: 12823-1990.
10.3.14.4 Sampling and Inspection : The number of prelaminated particle board to be selected
from a lot shall be in accordance with the Table 8 given below:
Table- 8
Lot Size Number of prelaminated
boards to be selected
Upto 50 2
51 to 100 3
101 to 200 4
201 to 300 5
301 to 500 7
501 and above 10
10.3.14.4.1 The pre laminated particle boards shall be selected at random (ref. IS 4903). In order to
ensure randomness of selection, all the pre laminated particle boards in the lot may be arranged in a
serial order and every rth pre laminated particle board may be selected till the required number is
obtained, `r' being the integral part of N/n, where N is the lot size and n is the sample size.
10.3.14.4.2 All board selected as given in para 10.2.9.4.1 shall be tested as specified in IS: 2380 (P-
t-21-1977), P-22, 23-1981, for length, width, thickness, edge straightness and squareness shall comply
with the requirements specified under para 10.2.9.3.2.
10.3.14.5 Testing and Number of Tests : For each of particle board selected as per para 10.2.9.4 Test
specimens shall be cut out from portion 150 mm away from the edges for tests and tests shall be carried
out as per IS 12823-1990.
10.3.14.6 Criteria for Conformity: A lot shall be considered as in conformity to the requirements of
the specification if no group of specimens for any of the characteristics falls to meet the conditions
as prescribed in para 10.2.9.3 & 10.2.9.5 of this specification.
In case of a failure, double sample shall be taken from the lot for testing. The lot shall be considered
as passed, if all these samples conform to the specified requirement.
10.3.14.7 Marking : Each prelaminated particle board shall be legibly and indelibly marked on
any of its edges with following :
(a) Indication of source of manufacturer
(b) Grade and type of pre laminated particle board
(c) Thickness
(d) Batch number and year of manufacture 10.3.15
Coir Veneer Board for General Purposes:
10.3.15.1 Coir veneer board is manufactured with a combination of coconut fibre needled felt, veneer
and jute fibres with craft paper coconut fibre. Needled felt can be used as core cross bands or as outer
skin formed with jute fibres and craft paper. However, the composite ply should be a balanced
construction on either side of central ply. The blended mass of glued fibres is laid to form a mat which
is pre needled.
10.3.15.2 Coir veneer board generally shall conform to IS 14842-2000.
Grades : Coir veneer board for general purposes shall be of two grades:
(a) Boiling water resistant (BWR) grade
(b) Moisture resistant (MR) grade
10.3.15.3 Material:
(a) Coconut Fibre : Coconut fibre layer used in the manufacture of coir veneer board shall be
uniform with minimum of 600 g/m2.
(b) Jute : Jute fibre layer used in the manufacture of coir veneer board shall be uniform with
minimum of 60 g/m2.
(c) Adhesive : Adhesive for manufacture of coir veneer board shall be conform to BWR/MR of
IS 848 for BWR/MR grade boards respectively.
(d) Veneer : Any species of timber may be used for the manufacture of veneers.
(e) Kraft Paper : Kraft paper used in manufacture of coir veneer board shall be uniform with
minimum of 4 0 g/m2 .
10.3.15.4 Permissible Defects : Gap in cores and cross band shall not be permitted. Splits in cores and
cross bands may be permitted to an extent of 2 per core or cross band and overlap shall be permitted
in core/cross bands only.
10.3.15.5 The Dimensions and Tolerances: The dimensions and tolerances of coir veneer board
shall be quoted in following order. The first dimension shall represent the length, the second
dimension the width and the third dimension the thickness. The dimensions and tolerances shall be
as per IS: 12049-1987.
Thickness of coir veneer board shall be 3 mm, 4 mm, 5 mm, 6 mm, 9 mm, 12 mm, 16 mm, 18
mm, 2 0 mm and 2 5 mm.
The following tolerance on nominal thickness shall be permissible
(a) Less than 6 mm ± 10%
(b) 6 mm and above +5%
10.3.15.6 Workmanship and Finish : Coir veneer board shall be of uniform thickness and
density throughout the length and width of board. The squareness and edge straightness of the
board shall be as per para 9 of IS 12842-1989 and Appendix I.
10.3.15.7 Sampling : The method of drawing representative samples and criteria for conformity
shall be as prescribed in IS 7638-1999.
10.3.15.8 Tests: The tests shall be carried out as specified in IS 14842-2000 , Appendix J.
10.3.15.9 Moisture Content: Coir veneer board when tested in accordance with IS 3734 (Part I)
shall have a moisture content not less than 5 percent and not more than 15 percent.
10.3.15.10 Marking: Each coir veneer board shall be legibly and indelibly marked or stamped
with the following near one corner.
(a) Identification of source
(b) Year of manufacturing
(c) Batch no.
(d) The grade and type as follows.
(i) Boiling water resistant (BWR) and
(ii) Moisture resistant (MR)
10.3.15.11 BIS Certification Marking : Coir veneer board may also be marked with the standard
mark governed by the BIS Act, 1986.
10.3.16 Marine Plywood:
10.3.16.1 Marine plywood shall be generally conforming to IS 710-2010. Selection of timber species
for manufacture of plywood shall be as prescribed in IS 710 and as far as possible a single species
of timber shall be used.
10.3.16.2 Adhesive :The adhesive used for bonding the veneer shall be of the hot press synthetic
resin, phenol formaldehyde type (BWP) and shall conform to IS 848-2006. Extender shall not be
added to the adhesive by the plywood manufactures. Fillers, if used, shall not exceed 10 percent by
mass of solid content of the glue.
10.3.16.3 Dimensions:
10.3.16.3.1 The dimensions of plywood boards shall be as stated in para 10.3.15.5.
10.3.16.3.2 The
thickness of any board shall not exceed the number of pieces multiplied by 2.5
mm. The two face veneers in finished board shall be of the same nominal thickness.
10.3.16.4 Tolerances : The following tolerances in the nominal size of finished boards shall be
permitted.
Table - 9
Dimension Nominal Size Tolerance
Length Upto 120 cm. + 3 mm
Above 120 cm. + 6 mm
Width Upto 90 cm. + 3 mm
Above 90 cm + 6 mm
Thickness Upto 4 mm ± 10 per cent
Above 4 mm ± 5 per cent
10.3.16.5 Sampling : The method of drawing representative samples and criteria for conformity
shall be as prescribed in IS :7638-1999.
10.3.16.6 Tests: Test pieces cut from each of board as specified at para 10.3.16.5 shall be subjected
to following tests.
(a) Moisture content
(b) Glue adhesive in dry state
(c) Water resistance test.
(d) Tensile strength
(e) Mycological test Retention
(f) of preservative.
These tests shall be carried out as specified in IS:710-2010.
10.3.16.7 Marking : Each plywood board shall be legibly and indelibly marked or stamped with
following particulars along with such other marks as the purchaser may stipulate at the time of
placing order.
(a) Manufacturer's name, initials or recognized trade mark, if any.
(b) Year of manufacturing.
(c) Abbreviation indicating the species of timber used in each ply as indicated in col. 3 of Table -
land 2 of IS 710-2010.
(d) Batch number
10.3.16.8 BIS Certification Marling : The plywood board may also be marked with the standard
mark, governed by the BIS Act,1986.
10.3.16.9 Tender Sample, Inspection and Acceptance: Where samples are required to be tendered,
three samples each not less than 90 x 60 mm in size shall be submitted by the supplier, and these
samples, if the tender is accepted shall constitute the standard as regards the type of timber, quality
and finish.
10.3.17 Fire Retardant Plywood:
10.3.17.1 Fire retardant plywood shall generally conform to IS 5509-2000. The plywood to be given
fire retardant treatment shall conform to BWR grade of IS 303-1989 to be able to stand pressure
impregnation. Plywood for treatment shall be clean, free from oil or dirt patches on the surface and
at a moisture content not exceeding 15 percent. In case of veneered decorative plywood care shall
be taken that colour of the solution does not spoil to decorative surface.
For Eco-mark the plywood shall conform to the requirements of Eco-mark specified in IS 303-
1989.
10.3.17.2 Fire Retardant Treatment: This shall be either pressure impregnation or soaking
treatment as per IS 5509-2000.
10.3.17.3 Choice of Treatment: The choice of treatment may be left to the manufacturer of plywood
as per fire resistant requirements prescribed in IS:5509-2000. The purchaser should however, specify
whether plywood is to be treated with fire retardants only or with fire retardants and preservatives.
The recommended retention of fire retardant chemicals for different hazards like interior or exterior
use not subject to leaching by rain and water is of the order of 50 kg/m3.
10.3.17.4 Conditioning after Treatment: The plywood after treatment shall be conditioned to
suitable equilibrium moisture content of not more than 20 per cent.
10.3.17.5 Dimension and Tolerances shall conform to IS:12049-1987. The tolerance of thickness
shall conform to IS:303-1989.
10.3.17.6 Sampling : The method of drawing representative sample and the criteria of conformity
shall be as prescribed in IS:7638-1999.
10.3.17.7 Test Specimen and Number of Tests: From each of fire retardant plywood selected as
above para 10.2.12.6, following test specimens shall be cut from portions 150 mm away from the
edges for tests specified as under:
(a) For Flammability : Six test specimens 125 mm x 125 mm in full thickness of material from
each sample.
(b) For Flame Penetration : Three test specimens 125 mm x 125 mm in full thickness of material
from each sample.
(c) For Rate of Burning : Three test specimen 100 mm x 12.5 mm in full thickness of material
from each sample.
10.3.17.8 Test Requirements and Other Tests
(i) Moisture Content : Shall not exceed 20%.
(ii) Flammability : When tested as per IS:1734-1983, time taken for second ignition shall not be
less than 30 minutes.
(iii) Flame Penetration: When tested as per IS:1734-1983, time taken for flame penetration shall
not be less than 15 minutes for every 6 mm thickness.
(iv) Rate of Burning : When tested as per IS 1734-1983, the time taken to loose weight from 30
per cent to 70 per cent shall not be less than 20 minutes.
10.3.17.9 Marking : Each board shall be legibly and indelibly marked near the edge with the
following:
(a) Manufacturer's name, his initials or his recognized trade mark, if any.
(b) Year of manufacture
(c) Type of treatment
(d) Criteria for which the plywood has been labelled as ECO mark.
10.3.17.10BIS Marking : Each board may also be marked with standard mark governed by the
BIS Act,1986.
10.3.18 Decorative Thermosetting Synthetic Resin Bonded Laminated sheets:
10.3.18.1 Scope : Decorative thermosetting synthetic resin bonded laminated sheets shall generally
conform to IS 2046-1995. This material is intended for interior use and is not intended for load
bearing applications.
10.3.18.2 Terminology: For the purpose of this standard, the definition given under para 2 of IS
1998 shall apply.
10.3.18.3 Types : The material shall be of two types namely:-
(a) Type 1- Having only one side bearing decorative surface the other side being roughened or
given an appropriate treatment to promote adhesion to the base. This type shall generally be
used, unless specified otherwise.
(b) Type 2- Having both sides bearing the decorative surface, the two sides may be different in
colour or pattern or both.
10.3.18.4 Requirements:
(i) Appearance : The types of surface finish of decorative and reverse side, edge finish, colour and
pattern shall be as agreed to between the purchaser and the supplier. The sheets shall be
reasonably free from local deformation.
Note : Since sheets may vary slightly in colour and appearance, it is recommended that sheets
for any one scheme may be matched.
Flatness : For nominal thickness 1.5 mm - when a sheet is tested for flatness in accordance with
the method given in IS 2046-1995, the height above the flat surface at the edge of full
manufactured and trimmed width shall nowhere exceed 150 mm.
Tolerance to nominal thickness : The departure from nominal thickness of sheet at any point,
shall not exceed the value given below:
Nominal Thickness Tolerance
Up to 1.5 mm ± 0.25 mm
(iv) Straightness of edges of rectangular finished panels, resistance to dry heat, resistance to
boiling water, resistance to staining, gross breaking strength, packing and marking, sampling and
criteria for conformity etc. shall be as per IS: 2046-1995.
10.4. Door, Window, Ventilator, False ceiling & Partition Frames:
10.4.1. Timber : Timber for door, window and ventilators frames shall be as specified. Timber shall
be sawn in the direction of the grains. All members of a frame shall be of the same species of timber
and shall be straight without any warp or bow. Frames shall have smooth, well planed (wrought)
surfaces except the surfaces touching the walls, lintels , sill etc., which may be left clean sawn.
Rebates, rounding or moulding shall be done before the members are jointed into Frames. The depth
of the rebate for housing the shutters shall be 15mm, and the width of the rebates shall be equal to the
thickness of the shutters. A tolerance of ± 3mm and 2mm shall be permitted in the specified finished
dimensions of timber sections in frames.
10.4.2. Joints: The frames shall have dovetail joints. The jamb posts shall be through tennoned in to
the mortise of the transoms to the full thickness of the transoms and the thickness of the Tenon shall
be not less than 2.5 cm. The Tenon's shall closely fit into the mortise without any wedging or filling.
The contact surface of tenon and mortise before putting together shall be glued with polyvinyl acetate
dispersion based adhesive conforming to IS:4835 or Adhesive conforming the WBP or MR Grade of
IS:851 and pinned with 10 mm dia., hard wood dowels or bamboo pins or star shaped metal pins.
The joints shall be at right angles when checked from the inside surfaces of the respective members.
The joints shall be pressed in position. Each assembled door frame shall be fitted with a temporary
stretcher and temporary diagonal brace on the rebated faces.
10.4.3. Fixing or Frames: The frames shall be got inspected and approved by the Engineer-in -
Charge before being painted, oiled or otherwise treated and before fixing in position. The surface of
the frames abutting masonry or concrete and the portions of the frames embedded in floors shall be
given a coating of coal tar. Frames shall be fixed to the abutting masonry or concrete with holdfasts
or metallic fasteners as specified. After fixing , the jamb post of the frames shall be plugged suitably
and finished neat. Vertical members of the door frames shall be embedded in the floor for the full
thickness of the floor finish and shall be suitably strutted and wedged in order to prevent warping
during construction. A minimum of three hold fasts shall be fixed on each side of door and window
frames one at centre point and other two at 30 cm from the top and bottom of the frames. In case of
window and ventilator frames of less than lm in height two hold fasts shall be fixed on each side at
quarter point of the frames. Hold fasts and metallic fasteners shall be measured and paid for separately.
10.4.4. Measurements: Wood work wrought, framed and fixed shall be measured for finished
dimension without any allowance for the wastage or for dimensions beyond specified dimensions.
However, in case of members having mouldings, rounding or rebates and members of circular or
varying sections, finished dimensions shall be taken as the sides of the smallest square or rectangle
from which such a section can be cut. Length of each member shall be measured over all to the
nearest cm so as to include projection for Tenon's. Width and thickness shall be measured to the
nearest mm and the quantity shall be worked out in unit of 10 cubic decimeter in whole numbers.
10.4.5. Rate : The rate shall include the costs of material and labour involved in all the operations
described above except the hold fasts or metallic fasteners which will be paid for separately.
10.4.6. False Ceiling and Partition Frames: This work shall done as specified in 10.4.1 to 10.4.5
except that the scantlings need not be planed unless otherwise specified.
10.5. Trusses: The work shall be carried out as per detailed drawings and as directed by Engineerin-
Charge. Specified timber shall be used. Sawing shall be truly straight and square, and the direction of
the grains. The scantlings shall be accurately planned smooth to the full dimensions and rebate
rounding and mouldings shown in the drawings, before the same are framed. Patching or plugging of
any kind shall not be permitted. A tolerance of -2/+3 mm shall be allowed in the finished cross sectional
dimension.
10.5.1 Joints: Joints shall be simple, neat and strong. All mortise and tenon joints, mitred joints,
scarf etc. shall fit in fully and accurately without wedging or fillings. The joints shall be as per
detailed drawings. Holes of correct sizes shall be drilled before inserting screws/ bolts. Holes of bolts
shall be of uniform diameter. The screws, bolts and nails shall be dipped in oil before using. The heads
of nails and screws shall be sunk and puttied or dealt with as instructed by Engineer-in-Charge. The
gauge and Length of nails, screws and bolts shall be approved by the Engineer-in-Charge before
using on works.
10.5.2 Shaping form and cutting: The wood sections, as specified or required, shall be straightened,
cut square and to correct lengths. A fine accuracy shall be ensured in the fabrication of various
member so that these can be assembled without being unduly packed, strained or forced into position
and when build up, shall be true to shape and free from twist, kinks, buckles or open joints.
10.5.3. Fabrication: As per drawing, a full size truss diagram shall first be drawn on a levelled
platform. From this full size diagram, templates of all joints as for Tenon's, mortises, scarves etc.
shall be made for use in the fabrication. The template shall be made 10 correspond to each member
and plate holes for screws and bolts shall be marked accurately on them and drilled. The templates
shall be laid on wooden members and the holes for screwing and bolting marked on them . The ends
of the wooden members shall also be marked for cutting. The base of columns and the position of
anchor bolts shall be carefully set out. Before fabrication of the truss individual members shall be
assembled together to ensure close abutting or lapping of the surfaces of the different members and
fitted close together as per drawing.
10.5.4. Hoisting and Placing in Position: The trusses shall be hoisted and placed in position
carefully, without any damage to itself and other building work and injury to workman. The trusses
shall be secured to walls by means of holding down bolts or as directed by the Engineer-in-Charge.
The necessary mechanical appliances such as lifting tackle, winch etc. for hoisting the truss shall be
used. The trusses shall be stayed temporarily till they are permanently secured in position and
connected with each other by means of purlins. Holding down bolts cleats used for purlins and
bottom plates used for tie and rafter member shall be paid for separately.
10.5.5. Surface Treatment: Wood work shall not be painted, oiled or otherwise treated before it has
been approved by the Engineer-in- Charge. All portions of timber built into or against or close to
masonry or concrete of buried in ground shall be given two coats of boiling coal tar. All junctions of
rafters, purlins, beams and wall plates shall be painted with approved wood primer.
10.5.6. Measurements: Wood work shall be measured for finished dimensions. No allowance shall
be made for dimensions supplied beyond those specified. Length of each piece shall be measured
over all nearest to a cm. so as to include projections for tenons, scarves or miters. Width and thickness
shall be measured to the nearest mm. cubical contents can be worked out in units of 10 cubic
decimeter in whole number.
10.5.7. Rate: The rate includes the cost of materials and labour involved in all the operations
described above. Unless otherwise specified, iron fixtures such as bolts and nuts, MS Steel plates,
holding down bolts and staining. Priming painting or polishing of the work shall be paid for separately.
10.6. Panelled Glazed or Panelled & Glazed shutters (Fig. 2): Panelled or glazed shutters for
doors, windows, ventilator's and cupboards shall be constructed in the form of timber frame work of
stiles and rails with panel inserts of timber, plywood, block board, veneered particle board, fibre board
wire gauze or sheet glass. The shutters, may be single or multi-panelled, as shown in the drawings
or as directed by Engineer-in-Charge. Timber for frame work, material for panel inserts and thickness
of shutters shall be as specified. All members of the shutters shall be straight without any warp or bow
and shall have smooth well planed face at right angles to each other.
Any warp or bow shall not exceed 1.5 mm. The right angle for the shutter shall be checked by measuring
the diagonals and the difference between the two diagonals should not be more than ± 3mm.
10.6.1 Frame Work:
10.6.1.1 Timber: Timber for stiles and rails shall be of the same species and shall be sawn in the
directions of grains. Sawing shall be truly straight and square. The timber shall be planed smooth
and accurate to the required dimensions. The stiles and rails shall be joined to each other by plain or
launched mortise and tenon joints and the rails shall be inserted 2 5 = short of the width of the stiles.
The bottom rails shall have double tenon joints and for other rails single tenon joints shall be provided.
The lock rails of door shutter shall have its / line at a height of 800 mm from the bottom of the shutters
unless otherwise specified. The thickness of each tenon shall be approximately one third the finished
thickness of the members and the width of each tenon shall not exceed three times its thickness.
10.6.1.2 Gluing of Joints: The contact surfaces of tenon and mortise shall be treated, before putting
together, with bulk type synthetic resin adhesive conforming to IS:851-1978 suitable for construction
in wood or synthetic resin adhesive (Phenolic and amino-plastic) conforming to IS:848-2006 or
polyvinyl acetate dispersion based adhesive conforming to IS:4835-1979 and pinned with 10 mm
dia. hardwood dowels or bamboo pins or star shaped metal pins, after the frames are put together
and pressed in position by means of press.
10.6.1.3 Stiles and bottom rail shall be made out of one piece of timber only. Intermediate rail
exceeding 200 mm in width may be out of one or more pieces of timber. The width of each piece
shall be not less than 75mm. where more than one piece of timber is used for rails, they shall be
joined with a continuous tongued and grooved joint glued together and reinforced with metal dowels at
regular intervals not exceeding 200 mm.
(A) Door Shutters: Finished dimensions and tolerances of components of door shutters has
been given in Table 10 below.
Table 10: Dimensions and Tolerances of Components of Door Shutters
S1. No. Description nun Thickness mm
Width () A DOOR SHUTTERS
(a) Vertical Stile, top and freeze rail 100 ± 3 35 ± 1 or 40 ± 1
(b) Lock rail 50 ± 3 35 ± 1 or 40 ± 1
(c) Bottom rail 200 ± 3 35 ± 1 or 40 ± 1
(d) Muntin 100 ± 3 35 +1 or 40 ± 1
(e) Glazing bar 40 ± 3 35 ± 1 or 40 ± 1
i) Size and Types : Size and types of the timber panels and glazed shutters shall generally conform
to modular sizes specified in Table 11 below.
Table 11: Dimension of Door Shutters
Si. No. Designation of Doors Width (mm) Height (nun)
(1) (2) (3) (4)
(i) 8DS 20 700 1905 (1945 )
(ii) 8DS 21 700 2005 (2045)
(iii) 9DS 20 800 1905 (1945)
(iv) 9DS 21 800 2005 (2045)
(v) 10 DS 20 900 1905 (1945)
(vi) 10 DS 21 900 2005 (2045)
(vii) 12 DT 20 11001) 1905 (1945)
(viii) 12 DT 21 11001) 2005 (2045)
Notes :
(1) The designation refers to modular sizes of door openings. First number stands for width and the
last for height in modules (M = 100 mm). Alphabet D refers to doors, `S' to single and `T' to
double leaf shutter.
(2) Standard sizes of door frames are covered in IS: 4021-1976 and IS: 4351-1976.
(3) The standard widths and heights for panel doors are arrived at as shown IS 1003 (Pt. 1)-2003.
Part II-1994.In case the modular height is taken from the finished floor level, the height of the
door shall be the one given in bracket. In the case of double leave shutters, the rebate in the
shutter shall be as given in 6.15 of IS 1003 (Pt. 1)-2003.
(B) Window and Ventilator Shutters : Window and ventilator shutters shall conform to IS: 1003
(Part 2)-1994.
i) Dimensional Sizes and Tolerances : The finished dimensions and tolerances of different
component shall be as given in Table 12.
Table :12-Dimensions and Tolerances of Components of Window and Ventilator Shutters
Description of Window Shutters Ventilator Shutters
components Width mm Thickness mm Width mm Thickness mm
Stiles and rails 80± 3 25± 1 80± 3 20 ± 1
30 ± 1 22.5 ± 1
25 ± 1
27.5 ± 1
30 ± 1
Mounting 60 ± 3 25 ± 1 60 ± 3 -do-
30 ± 1
Glazing bars 40 ± 1 25 ± 1 40 ± 1 -do-
30 ± 1
ii) Designation : Window and ventilator shutters shall be designated by symbols denoting the
width, type and height of window and ventilators in following manner.
(a) Width : It shall be indicated by the number of modules in the width of opening
(b) It shall be indicated by the following letters of alphabet:
W-window, V- Ventilator, S-Single shutter, T-Double shutter
(c) Height : It shall be indicated by the number of modules in the height of opening.
Example : 10 WT 12 would mean a window shutter suitable for a double shutter window of
10 modules width and 12 modules height.
12 V 6 would mean ventilator shutter suitable for a ventilator of 12 modules width and 6
modules height.
iii) Sizes : Sizes of window and ventilator shutters shall generally conform to the modular sizes
specified in Tables 13 and 14 respectively. These sizes are derived after allowing the thickness
of the frame and a margin of 5 mm all round based on 100 mm module.
iv) Tolerances on the overall dimensions of window and ventilator shutter shall be ± 3 mm.
Table -13: Dimensions of Timber Window Shutters
Designation Width mm Height mm
(1) (2) (3)
6 WS 12 500 1100
10WT 12 460 1100
WT 560 1100
12 12
6 WS 13 500 1200
10 WT 13 460 1200
12 WT 13 560 1200
Table -14 : Dimensions of Timber Ventilator Shutters

Designation Width mm Height mm
(1) (2) (3)
6V6 500 500
10 V 6 900 500
12 V 6 1100 500
10.6.2 Mounting :Mounting and glazing bars where required shall be sub tennoned to the maximum
depth which the size of the member would permit or to a depth of 25 mm whichever is less. Unless
otherwise specified the finished dimensions of the components of frame work of shutters shall be as
given in Table 12. Tolerance on width of stiles and rails shall be ± 3 = . The thickness of all
components of frame work shall be the same as the thickness of the shutter. Tolerance on over all
dimensions of the shutter shall be ± 3 = .
10.6.3. Rebating: The shutters shall be single-leaf or double leaved as shown in the drawings or as
directed by the Engineer-in-Charge . In case of double leaved shutters, the meeting of the stiles shall
be rebated by one third the thickness of the shutter. The rebating shall be either splayed or square
type as shown in Fig 2.
10.6.4. Panelling: The panel inserts shall be either framed into the grooves or housed in the rebate of
stiles and rails. Timber, plywood, hard board and particle board panels shall be fixed only with grooves.
The depth of the groove shall be 1 2 = and its width shall accommodate the panel inserts such that
the faces are closely fitted to the sides of the groove. Panel inserts shall be framed into the grooves of
stiles and rails to the full depth of the groove leaving on space of 1 . 5 = Width and depth of the
rebate shall be equal to half the thickness of stiles and rails. Glass panels, asbestos panels wire gauze
panels and panel inserts of cupboard shutters shall be housed in the rebates of stiles and rails.
10.6.4.1 Timber panels: Timber panels shall be preferably made of timber of large width, the
minimum width and thickness of the panel shall be 1 5 0 = , and 1 5 = respectively. When made
from more than one piece, the piece shall be jointed with a continuous tongued and grooved joint
glued together and reinforced with headless nails at regular intervals not exceeding 1 0 0 = . Depth and
thickness of such joint shall be equal to one third of thickness of panel. The panels shall be designed
such that no single panel exceeds 0.5 square metre in area. The grains of timber panels shall run
along the longer dimensions of the panels. All panels shall be of the same species of timber unless
10.6.4.2 Plywood Panels: Plywood boards used for panelling of shutters shall be BWP type or grade
as specified in 10.3.2. Each panels shall be single piece of thickness, 9mm for two or more panel
construction and 12mm for single panel construction unless otherwise specified.
10.6.4.3 Block Board Panels: Block board used for panelling shutters shall be Grade I (Exterior
Grade ) bonded with BWP Type Synthetic resin adhesives as specified in 10.3.6. Each panel shall be
a single place of thickness 12mm unless otherwise specified.
10.6.4.4.1 Veneered Particle Board Panels: Veneered Particle board used for panelling of shutters
shall be Exterior Grade bonded with BWP Type synthetic resin adhesive as specified in 10.3.4. Each
panel shall be a single piece of thickness 12mm unless otherwise specified.
10.6.4.5 Fibre Board Panels: Fibre board used for panelling of shutters shall be Exterior Grade
bonded with BWP type synthetic resin adhesive as specified in 10.3.8. Each fibre board panel shall be
a single piece of thickness 10 mm unless otherwise specified.
10.6.4.6. Wire Gauge Panels: Wire Gauze used for panelling of shutters shall be woven with 0.63
mm dia galvanized mild steel wire to form average aperture size of 1.40mm as specified in 10.3.10 .
Wire gauze shall be securely housed into the rebates of stiles and rails by giving right angle bend turned
back and fixed by means of suitable staples at intervals of 75mm and over this wooden beading shall
be fixed. The space between the rebate and the beading shall be fixed with putty to give a neat finish.
Each wire gauze panel shall be as single piece, and the panels shall be so designed that no single panels
exceeds 0.5 sqm in area. However, care shall be taken to prevent sagging of wire gauge, of panel by
providing and fixing 20x20 mm square or equivalent beading on the external face in the required
patterns as decided by the Engineer-in-Charge.
10.6.4.7. Glass Panels: Glass panelling (Glazing) shall be done with sheet glass of ordinary quality
as specified in 10.3.9 Glazing in the shutters of door, window and ventilator of bath, WC and
Lavatories shall be provided with frosted glass the weight of which shall be not less than 10 Kg/
sqm. Frosted glass panels shall be fixed with frosted face on the inside. Glass panels shall be fixed by
providing a thin layer of putty conforming to IS:419-1967 applied between glass pane and all along
the length of the rebate and also between glass panes and wooden beading.
i) Putty can be prepared by mixing one part of white lead with three parts of finely powdered chalk
and then adding boiled linseed oil to the mixtures to form a stiff paste and adding varnish to the
paste at the rate of 1 litre of varnish to 18 kg. of paste. Fixing of glass panes without beading
shall not be permitted. Glazing shall be done after the shutters have been primed and prepared
for painting, so that wood may not draw oil out of putty.
10.6.4.8. Finish: Panels of shutters shall be flat and well sanded to a smooth and level surface.
10.6.5. Beading: Beading in panelled shutter shall be provided where specified in architectural
drawing or directed by the Engineer-in-Charge. Each length of beading shall be single piece. Joints at
the corners shall be mitred and exposed edges shall be rounded. Beading shall be fixed with headless
nails at 75mm intervals. For external shutters, the beading shall be fixed on the outside face.
10.6.6. Machine/Factory made shutters: Machine made shutters, where specified, shall be procured
from an approved factory. For machine made. Shutters, operations like sawing, planning, making
tongue and tenons, cutting grooves, mortises and rebates, drilling holes and pressing of joints shall be
done by suitable machines. Machines made shutters shall be brought to the site fully assembled but
without any priming coat. Panel inserts of sheet glass and wire gauge may, however, be fixed at site.
10.6.7. Fixing of Shutters: For side hung shutters of height up to 1.2m, each leaf shall be hung on two
hinge at quarter points and for shutter of height more than 1.2m, each leaf shall be hung on three
hinges one at the centre and the other two at 200 mm from the top and bottom of the shutters. Top hung
and bottom hung shutters shall be hung on two hinges fixed at quarter points of top rail or bottom rail.
Centre hung shutter shall be suspended on a suitable pivot in the centre of the frame. Size and type
of hinges and pivots be as specified. Flap of hinges, shall be neatly counter sunk into the recesses cut
to the exact dimensions of flap. Screws for fixing the hinges shall be screwed in with screw driver
and not hammered in. unless otherwise specified, shutters of height more than 1.2mm shall be hung
on butt hinges of size 100 mm and for all other shutters of lesser height butt hinges of size 75mm
shall be used. For shutter of more than 40mm thickness butt hinges of size 125x90x4 mm shall be
used. Continuous (piano) hinges shall be used for fixing cup-board shutters where specified.
10.6.8. Fittings: Fittings shall be provided as per schedule of fittings decided by Engineer-in-Charge.
Cost of providing and fixing shutter shall include cost of hinges and necessary screws for fixing the
same. All other fittings shall be paid for separately. The fittings shall conform to specifications laid
down in 10.21. Where the fittings are stipulated to be supplied by the department free of cost, screws
for fixing these fittings shall be provided by contractor and nothing extra shall be paid for the same.
10.6.9. Wooden Cleats and Blocks: Wooden cleats and blocks shall be fixed to doors and windows
as directed by Engineer-in-charge, as per size and shape approved by him. These are included in the
cost of providing and fixing the shutters.
10.6.10. Measurements: Framework and panelling shall be measured separately.
i) Framework :The overall length and width of the framework of the shutters shall be measured
nearest to a cm in fixed position (overlaps not to be measured in case of double leaved shutters)
and the area calculated in square metres correct to two places of decimeter. No deduction shall
be made to form panel openings or louvers. No extra payments shall be made for shape, joints
and labour involved in all operations described above.
ii) Panelling :For panelling of each type or for glazed panel length and width of opening for panels
inserts or glazed panels shall be measured correct to a cm before fixing the beading and the
area shall be calculated to the nearest 0.01 sqm. The portions of the panel inserts or glazed panel
inside the grooves or rebates shall not be measured for payment.
10.6.11 Rate: Rate includes the cost of materials and labour involved in all the operations described
above. The frame work and panelling of each type or glazed panels shall be paid separately. The rate
for frame work includes the cost of butt hinges and necessary screws as specified in 10.6.7. However,
extra shall be paid for providing moulded beading where specified. Nothing extra shall be paid for
plain beading as stated in 10.6.5 when specified in drawing.
10.7. Flush Door Shutters (Fig. 3): Flush door shutters shall have a solid core and may be of the
decorative or non-decorative (Paintable type as per IS:2202 (Part-I)-1999. Nominal thickness of
shutters may be 25, 30 or 35mm. Thickness and type of shutters shall be as specified.
Type and Construction: Solid core flush door shutter maybe of the decorative type or non-decorative
(paintable) type. The nature of construction of these shutters shall, therefore, be specified based both
on the type and different constructions of the core as given in Table below.
Table-15 : Nature of Construction of Wooden Flush Door Shutters (Solid Core Type)
S.No. Core Type Abbreviation
(1) (2) (3) (4)
i) Block board Decorative BD
Non Decorative BN
ii) Particle board with Decorative PD
or without block board Non-Decorative PN
iii) Decorative MD
Non Decorative MN
10.7.1 Size/Shape : Width th and height of the shutters shall be as shown in the drawings or as
indicated by the Engineer-in-Charge. All four edges of the shutters shall be square. The shutter shall
be free from twist or warp in its plane. The moisture content in timbers used in the manufacture of
flush door shutters shall be not more than 12 per cent when tested according to IS:1708-1986.
Sizes of the door shutters shall generally conform to the Modular sizes specified in Table 16 (see
Fig. 3). Sizes other than modular sizes, as agreed to between the manufacturer and the purchaser,
may also be permitted; provided, the thickness of shutters in such cases shall be equal to that
specified against the nearest higher modular size. The nominal thickness of the shutters shall be 25
mm, 30 mm and 35 mm corresponding to each of the sizes as indicated in Table 16. However for sizes
greater than 12DT21, the thickness of such shutters shall be greater than 35 mm and shall be as agreed
to between the manufacturer and the purchaser.
Table-16: Designation and Dimensions of Flush Door Shutters
S.No Designation of Doors Width-mm Height-mm Thickness-mm
i) 8 DS 20 700 1905 (1945) 25
ii) 8 DS 21 700 2005 (2045) 25
iii) 9 DS 20 800 1905 (1945) 30
iv) 9 DS 21 800 2005 (2045) 30
v) 10 DS 20 900 1905 (1945) 35
vi) 10 DS 21 900 2005 (2045) 35
vii) 12 DT 20 1100" 1905 (1945) 35
viii) 12 DT 21 1100" 2005 (2045) 35
Notes: 1: D-Door, S =Single shutter, and T= Double leaf shutter.

2: The designation indicates the size of door opening, the first number referring to width in
modules of 100 mm and the last number the height in modules of 100 mm.
3 : Standard sizes of door frames are covered in IS 4021.
4: In arriving at the standard widths and height. for flush door shutters an allowance of 60 mm has
been made for door frames, 40 mm for floor finish and 5 mm for clearance all round (see also
Fig. 3) between the door opening and door frame and 15 mm for rebate all round for the
shutter into the frame. Further, a gap of 5 mm has been provided between the bottom of the
shutter and the finished floor level. In case, the modular height of door opening is taken from the
finished floor level, the height of the flush door shall be the one given in the bracket. In the case
of double shutters, the rebate shall be as given in 10.7.5
"Combined width of two shutters in closed position".
10.7.2. Core: The core of the flush door shutters shall be a block board having wooden strips held in a
frame constructed of stiles and rails. Each stile and rail shall be a single piece without any joint. The
width of the stiles and rails shall not be less than 75mm and not more than 100mm. the width of each
wooden strip shall not exceed 30mm. Stiles, rails and wooden strips forming the core of a shutter shall
be equal and uniform thickness. Wooden strips shall be parallel to the stiles.
End joints of the pieces of wooden strips of small Lengths shall be staggered. In a shutter, stiles and
rail shall be of one species of timber. Wooden strips shall also be one species only but it may or may
not be the same species as that of the stiles and rails.
10.7.3 Face Panel: The face panel shall be formed by gluing, by the hot press process on both faces
of the core, either plywood or cross bands and face veneers. The thickness of the cross bands as such
or in the plywood shall be between 1.0mm and 3.0 mm. The thickness of the face veneers as such in
the plywood shall be between 0.5mm and 1.5 mm for commercial veneers and between 0.4 mm and
1.0mm for decorative veneers. The direction of the veneers adjacent to the core shall be at right angles
to the direction of the wooden strips. Finished faces shall be sanded to smooth even texture.
10.7.4 Lipping: Lipping shall be provided, if so desired by the purchaser. Lipping, where provided,
May be internal or external as specified by the purchaser. Joints shall not be permitted in the lipping.
Lipping, where specified, shall be provided internally on all edges of the shutters. Lipping shall be
done with battens of first class hardwood or as specified of depth not less than 25mm. For double
leaved shutters, depth of the lipping at meeting of stiles shall be not less than 35mm. Joints shall not
be permitted in the lipping. External lipping, where provided, shall be solid and shall measure at
least 6 mm on the face of the door.
10.7.5 Rebating: In the case of double leaves shutters the meeting of stiles shall be rebated by 8 mm
to 10 mm. The rebating shall be either splayed or square type as shown in drawing where lipping is
provided. The depth of lipping at the meeting of stiles shall not be less than 30 mm.
10.7.6. Opening for Glazing: Where specified the opening for glazing shall be 25 cm in height and
15 cm .or 20 cm in width unless directed otherwise. The bottom of the opening shall be at height of
1.40 m from the bottom of the shutter. Opening for glazing shall be lipped internally with wooden
batten of width not less than 25mm. Opening for glazing shall be provided where specified or shown
in the drawing.
10.7.7. Venetian Opening: Where specified the height of the Venetian opening shall be 35 cm from
the top of the bottom rail unless directed otherwise. The width of the opening shall be as directed but
shall provide for a clear space of 75mm between the edge of the door and Venetian opening but in no
case the opening shall extend beyond the stiles of the shutter. The top edge of the opening shall be
lipped internally with wooden battens of width not less than 25mm. Venetian opening shall be
provided where specified or shown in the drawing.
10.7.8.Fittings: Shutters shall be shop-prepared for taking mortice locks or latches as may be agreed
to. Shop-preparing the door with mortised holes for lock fixing shall be done only when desired,
suitable blocks of wood may be provided for fixing the hardware, in the absence of specific
requirements, the sizes of blocks shall preferably correspond to the maximum size of lock covered in
IS 2209.
10.7.9.Workmanship and Finish: All the four edges of the door shutter shall be square. Both faces
of the door shutter shall be sanded to a smooth even texture. If required by the purchaser, all the
surfaces of shutters which are required to be painted ultimately shall be covered evenly by brush
painting with suitable priming coat as may be ordered by the purchaser (see also IS 2338 -Part 1).
However, only unpainted doors shall be subjected to the tests mentioned under Appendix E.
Workmanship and the finish of the face panels shall be in conformity with those specified in IS: 303
for non-decorative type and IS 1328 for decorative type.
10.7.10. Tolerance: Tolerance on width and height shall be ± 3 mm and tolerance on nominal
thickness shall be ± 1.2mm. The thickness of the door shutter shall be uniform throughout with a
permissible variation of not more than 0.8mm when measured at any two points.
10.7.11. Adhesive: Adhesive used for bonding various components of flush door shutters namely,
core, core frame, lapping cross bands, face veneers, plywood etc. and for bonding plywood shall
conform to BWP type, phenol formaldehyde synthetic resin adhesive conforming to IS:848-2006.
10.7.12. Testing: Flush door shutters shall tested as laid down in Appendix E.
10.7.13. Sample Size: Shutters of decorative and non-decorative type from each manufacturer,
irrespective of their thickness, shall be grouped separately and each group shall constitute a lot. The
number of shutters (sample size) to be selected at random from each lot for testing shall be as
specified in Table 17. If the total number of shutters of each type in a work (and not the lot) is less than
twenty five, testing may be done at the discretion of the Engineer-in-Charge and in such cases extra
payment shall be made for the sample shutter provided the sample does not fail in any of the test
specified in 10.7.12.
Table -17 : Sample Size and Criteria for Conformity
Lot Size Sample Size Permissible no. Sub. Sample size
of defective
(1) (2) (3) (4)
Up to 26 to 50 8 0 1
51 - 100 13 1 2
101 - 150 20 1 2
151 - 300 32 1 3
301 - 500 50 2 4
501 and above 80 2 5
10.7. 14. Criteria for Conformity: All the samples shutters when tested shall satisfy the requirements
of the tests laid down in specifications. If the number of sample shutters found unsatisfactory for a test
is one, twice the number of samples initially tested shall be selected and tested for the test. All sample
shutters so tested shall satisfy the requirement of the test. If the number of samples found
unsatisfactory for a test is two or more, the entire lot shall be considered unsatisfactory.
10.7.15. Fixing: This shall be as specified in 10.6.7.
10.7.16. Measurements: Length and width of the shutters shall be measured to the nearest cm in
closed position covering the rebates of the frames but excluding the gap between the shutter and the
frame. Overlap of two shutters shall not be measured.
All work shall be measured net as fixed and area calculated in square metres to nearest two places of
decimal. No deduction shall be made for providing Venetian opening and opening for glazing
10.7.17. Rate: The rate includes the cost of material and labour involved in all the operation described
above. Extra rate shall be payable for providing rebates in double leaved shutters.
10.8 Battened and Framed Door and Window Shutters:
Specified timber shall be used, and it shall be sawn in the direction of the grains. Sawing shall be
truly straight and square. The timber shall be planed smooth and accurate to the full dimensions,
rebates, rounding and mouldings as shown in the drawing made before assembly. Patching or plugging of
any kind shall not be permitted except as provided.
10.8.1 Planks: Planks for battens shall be 20mm thick unless otherwise specified and of the uniform
width of 75 to 100mm. These shall be planed and made smooth and provided with minimum 12mm
rebated joints. The finished work with a tolerance of ±1mm in thickness and ±3/2 mm in width of
battens etc. shall be accepted. The ends of battens shall be feather tongued into stiles and rails, which
shall be provided with 12mm groove to fit in the batten. The specification for fixing, wooden cleats
and blocks, fittings and measurements shall be as described under 10.6.
10.8.3. Rate: It includes the cost of material and labour involved in all the operations described
above.
10.9 Ledged and Battened, or Ledged Braced and Battened Door & Window Shutter:
rebates, rounding and mouldings as shown in the drawings made before assembly. Patching or
plugging of any kind shall not be permitted except as provided. Thickness of the doors shall be the
thickness of the battens only and not the combined thickness of battens and braces.
10.9.1 Planks: Planks for battens shall be 20mm thick unless otherwise specified and of the uniform
width of 75 to 100mm. These shall be planed and made smooth and provided with minimum 12mm
rebated joints. The finished work with a tolerance of ±1mm in thickness and ±3/2 mm in width of
battens, ledges etc. shall be accepted. The end of battens shall be provided with 12mm grooved fit in
the batten.
10.9.2. Ledges and Braces : The battens shall be fixed together by 25mm thick ledges and braces
fixed to the inside face of door shutters with screws. The ledge shall be 175mm wide and brace
125mm wide unless otherwise specified. The braces shall incline downwards towards the side on
which the door is hung. Edges and ends of ledges and braces shall be chamfered. Tee hinges shall be
provided in ledges only. The finished work with a tolerance of ±1mm in thickness and ±3/2mm in
width of battens, ledges etc. shall be accepted.
10.9.3. Specifications: The specifications for fixing wooden cleats, blocks, fittings and measurements
shall be as described under 10.6.
10.9.4. Rate: It includes the cost of materials and labour involved in all the operations described
above.
10.10. Ledged Braced and Battened Garage Door Shutters:
rebates, rounding and mouldings and shown in the drawings made, before assembly. Patching or
plugging of any kind shall not be permitted except as provided. The thickness of the doors shall be the
thickness the batten only and not the combined thickness of battens and braces.
10.10.1 Battens: Planks for battens shall be 20mm thick unless otherwise specified and of uniform
width of 125 and 175 mm. These shall be planed and made smooth, and provided with minimum
12mm rebated joints. The joint lines shall be chamfered. The finished work with a tolerance of ±1 mm
in thickness and ±3/2 mm in width of battens etc. shall be accepted.
10.10.2. Ledges and Braces: The battens shall be fixed together by 30mm thick (unless otherwise
specified), ledges and braces on the inside face of door shutter with minimum two numbers of 50mm
long wood screws per batten. The ledges shall be 225mm wide and braces 175mm wide, unless
otherwise specified . The braces shall incline downwards towards the side on which the door is hung.
Edges and ends of ledges and braces shall be chamfered.
10.10.3. Fittings and Fixing: Garage door shutter shall be fixed to the wall masonry with six pintle
sets. Each set shall consists of a pin clamp of 50x6 mm flat iron 45cm long, bent and forked at one end
and provided with 20mm dia. M.S. pin on the other end and 50x6mm double strap 60cm long. The pin
shall be firmly riveted or welded to the pin clamp, the other end of which shall be embedded in masonry
by means of cement concrete block 40x20x20cm mix 1:3:6 mix (1 cement : 3 coarse sand: 6 graded
stone aggregate 20 mm nominal size.). These shall be so placed that the bottom pin shall face upwards
and the top in downwards, in order that the gate may not be removed by lifting over pins. The fixing
shall be so done that the door shutter can open on the outside by 180°.
The double strap shall fit in the pin side and shall be fixed to the shutter at ledges on the other side with
4 bolts and nuts of 12mm diameter. One hook and eye 450 mm size of mild steel shall be provided
for each shutter to keep it fixed in open position. A cement concrete block 15x10x20 cm in 1:2:4 (1
cement :2 coarse sand:4 graded stone aggregate 20mm nominal size) mix shall be embedded in the
floor at junction of two shutters so that the door shutters open only on the outside and not on the inside.
An iron sliding bolt (Aldrop) 450x 16mm in diameter shall be provided and fixed. Tolerance of ±0.5
mm in diameter may be allowed.
10.10.4 Measurements: The overall length and width of the shutter shall be measured nearest to a
cm in fixed position (overlaps not to be measured in case of double leaved shutters) and area
calculated in square metres correct to two places of decimal.
10.10.5. Rate: It includes the cost of materials and labour required for all operations described above.
Nothing extra shall be paid for cement concrete blocks, nor anything deducted from the measurement
of masonry of wall on account of cement concrete blocks etc.
10.11 Louvered Shutters:
rebates, rounding and mouldings as shown in the drawings made, before assembly. Patching or
plugging of any kind shall not be permitted except as provided.
10.11.1. Frames; Where the shutters have to be provided in the same frames as for the ordinary
door or window, the thickness of the frame shall be increased by the specified thickness of the
shutters, which shall be paid for separately under the relevant items of work.
10.11.2 Stiles and Rails: It shall be as specified in 10.6.
10.11.3 Venetians: The panel space shall be fitted with Venetians which shall be 12mm thick, unless
otherwise specified. The Venetian blades shall slope down towards the outside at angle as shown in
the drawings and shall be fixed in stiles. These shall overlap each other by about half of their widths.
The Venetians, may be fixed or movable as specified. The fuushed work with a tolerance of ±1mm in
thickness and ±3/2 in width of battens etc. shall be accepted.
10.11.4. Specification: The specification for fittings, wooden cleats and blocks and measurements
shall be as specified under 10.6.
10.11.5. Rate: It includes the cost of materials and labour involved in all the operations described
above. The rate for frame work includes the cost of butt hinges and necessary screws as specified in
10.6.7. The rate for Venetian / louvers shall include the cost of beading if specified.
10.12. Louvers Fixed to Frames:
The louvers shall be of wood, glass, AC sheet or any other material as specified.
10.12.1. Fixing: These shall be fixed in grooves of minimum 1.25 mm depth, made in the frame.
The Venetian blades shall slope down towards the outside at an angle of 45° or as shown in the
drawings. these shall overlap each other by about half of their widths.
10.12.2. Measurements: The width and height of the clear opening shall be measured to the nearest
cm and area calculated in square metre correct to two places of decimal for the purpose of payment.
10.12.3. Rate: The rate is inclusive of the cost of materials and labour required for all the operations
described above.
10.13 Wire Gauge Fly Proof Shutters:
rebates, rounding and mouldings as shown in the drawing made, before assembly. Patching or
plugging of any kind shall not be permitted except as provided.
10.13.1. Stiles and Rails: The specifications shall be as described under 10.6. The stiles and rails shall
be given a rebate to receive the wire gauge which shall form the panels.
10.13.2. Wire Gauge: This shall be unless specified otherwise conform to Para 10.3.10 and 10.6.4.6.
The wire gauge shall be bent at right angles in the rebates of stiles and rails, turned back and fixed light
with blue tacks at about 75mm centre, fixed alternately in the two faces of the rebates. Over this,
wooden beading shall be fixed with brads or small screws at about 75mm centre. The space between
the beading and rebates, where the wire gauge is bent shall be neatly finished with putty, so that the
end of the wire gauge may not be visible.
10.13.3 Fixing : Fixing, Fittings Wooden cleats, blocks and Measurement shall be as specified under
10.6.
10.13.4. Rate: This includes the cost of materials and labour involved in all the operations described
above, and as specified under 10.6.
10.14 Wall Lining: Specified timber shall be used and it shall be sawn in the direction of the grains.
Sawing shall be truly straight and square. The timber shall be planed smooth and accurate to the full
dimensions, rebates, rounding and mouldings as shown in the drawings made before assembly.
Patching or plugging of any kind shall not be permitted except as provided.
10.14.1 Grounds: Grounds shall be provided where so specified. These shall consists of first class
hard wood plugs or the class of wood used for fabricating the frames, of trapezoidal shape having base
of 50x50 mm and top 35x35mm with depth of 5.0cm and embedded in the wall with cement mortar
1:3 (1 cement:3 fine sand) and batten of first class hard wood or as specified of size 50x25 mm or as
specified, fixed over the plugs with 50mm long wood screws. The plugs shall be spaced at 45 to 60mm
centre, depending upon the nature of work. The battens shall be painted with priming coat, of approved
wood primer before fixing.
10.14.2 Panelling:
10.14.2.1. Teak Wood Panelling: The thickness of panel shall be 16mm up to a width 40cm and
19mm for a greater width. Solid wood panels shall be made out of one or more pieces of timber of not
less than 12.5 cm in width. In order to avoid warping, splitting and cracking, normally pieces not
exceeding 20cm in width should be used. When made from more than one piece, the pieces shall be
joined with a continuous tongued and grooved joint glued together and reinforced with metal dowels.
The grains of the solid panel shall run along the longer dimensions of the panel. The finished work
with a tolerance of ±1mm in thickness may be accepted.
10.14.2.2. Block Board Panelling: This panelling shall be decorative or non-decorative (Paintable)
type as per design and thickness specified by the Engineer-in-Charge. These shall be specified in
details of the type and construction of core. The specifications in general shall conform to IS:2202
(Part-I)-1999 and IS : 2202 (Part-II)1999.
10.14.2.3 Ornamental Work: The Ornamental wood work shall be painted on the back with priming
coat of approved wood primer before fixing the same to the grounds with screws, which shall be
sunk into the wood work and their tops covered with putty. The ornamental work shall be made true
and accurate to the dimensions shown in the working drawings. The fixing shall be done true to lines
and levels. The planks for wall lining shall be tongued and grooved, unless otherwise specified.
10.14.2.4. Measurements: Length and breadth shall be measured correct to a cm. Wall panelling such
as teakwood panelling and block panelling., plain lining, and plain skirting each shall be measured
separately in square metre nearest to two places of decimal. The moulded work shall be measured in
cm running metre i.e., in running metres stating the girth in cm. The sectional periphery (girth) of
moulding excluding the portion in contact with wall shall be measured in cm correct to 5 mm and
length in metre correct to a cm. The measurement for ground shall be taken on the basis of cubical
content of battens and paid for separately, unless otherwise specified. Where only plugs are required
to be fixed for the ornamental work, the costs for the same shall be deemed to be included in the rate
of ornamental work and no separate payment shall be made for plugs.
10.14.2.5. Rate: The rate includes the cost of materials and labour required for all the operations
described above.
10.15. Shelves:
Shelves and vertical partitions of cupboards shall be of timber planks fibre board, particle board,
block board or veneered particle board specified. Thickness and type of planks or boards shall be as
specified. Each shelf shall be a single piece and vertical partitions between two consecutive shelves
shall be without any joint. Exposed edges of boards having particle board core shall be sealed with
3mm thick single piece teak wood strips of width equal to the thickness of board with headless pins.
The arrangement of shelves and vertical partitions shall be as per drawings or as directed by the
Engineer-in-Charge.
10.15.1. Fixing: Planks for shelves shall be planed on all faces and edges. In case of boards they
shall be sawn to the required size truly straight and square. Timber battens 25x40mm unless otherwise
specified shall be planed smooth and fixed inside the cupboard with wooden plugs and screws.
Shelves shall be fixed to the battens and vertical portions shall be held in positions by fixing them to
the battens and shelves using screws. Teakwood strips for edge sealing of the boards shall be planed
smooth and fixed with headless nails. Tolerance in width shall be ±1.5mm and in thickness ±1mm.
10.15.2. Measurements: Length and width of shelves and vertical partitions shall be measured
correct to a cm. separately for each type of board stating its thickness. Area shall be calculated correct
to 0.01 sqm.
10.15.3 Rate: It includes the cost of materials and labour required for all the operations described
above.
10.16. Treffis (Jaffri) work:
Specified timber shall be sawn in the direction of the grains. Sawing shall be truly straight and square.
The timber shall be planed smooth and accurate to the full dimensions, rebates, rounding, and
mouldings as shown in the drawings made, before assembly. Patching or plugging of any kind shall
not be permitted except as provided.
10.16.1. Plain Treffis (Jafri): This shall consist of wooden strips or laths 35x10 mm sections unless
otherwise specified planed and nailed together at every alternate crossing. The strips shall cross each
other at right angle and shall be spaced 35mm apart, so as to form 35x35mm square opening or as
shown in the drawing. These shall be fixed with nails to the frame. To cover the ends of strips,
50xl2mm beading shall be fixed to the frame with screws. The finished work with a tolerance of
±1mm may be accepted.
10.16.2. Trellis (Jafri) Doors and Windows Shutters: Shutters frame of specified timber shall
consist of two stiles and top, lock and bottom rails, each of section 75x35mm unless otherwise
specified. The stiles and rails shall be properly mortised and tennoned. The tenon shall pass through
the stiles for at least 3/4' of the width of the stile. Shutter frame shall be assembled and passed by the
Engineer-in-Charge before jointing. The joint shall be pressed and secured by bamboo pins of about
6mm diameter. To this frame, plain trellis (Jafri) work as described in 10.16.1 shall be fixed as shown
in the drawings or as directed by the Engineer-in-Charge. Fixing, fittings, wooden cleats and blocks
shall be provided as specified under 10.6.
10.16.3. Measurements: Width and height of plain trellis work and trellis shutters shall be measured
overall correct to a cm. The area shall be calculated in square metres nearest to two places of decimal.
In case of shutters, the measurement shall be as specified in 10.6.
10.16.4. Rate: It includes the cost of materials and labour required for all the operations described
above.
10.17. Pelmets:
Planks and curtain rods of specified timber shall be used, and it shall be sawn in the direction of the
grain. Sawing shall be truly straight and square. The timber shall be planed smooth and accurate to the
full dimensions, rebates, rounding's, and mouldings as shown in the drawings made before assembly.
Patching or plugging of any kind shall not be permitted.
10.17.1. Sides: Sides, front and top of the pelmets shall be of 12mm planks or boards of specified
quality and width unless otherwise stated. These shall project from the wall face by 15mm or as
specified , and shall be securely fixed to walls with wood screws by means of wooden plugs and
10cm long 25x3mm M.S. flat bent in the form of angle or by any other device approved by the
Engineer-in-Charge. The pelmets shall be provided with curtain rods and brackets or curtain rails with
rollers, stop ends and brackets wooden, brass or chromium plated brass as specified. Intermediate
wooden brackets shall be provided, if the front length of pelmet exceeds 1.5 metres.
10.17.2 Measurements: The pelmets box shall be measured along the sides and front planking
correct to a centimetre.
10.17.3. Rate: The rate includes the cost of sides, front and top planking curtain rods with brackets or
curtain rails with rollers labour and materials required for all the operations described above.
10.18. Hold fasts : These shall be made from mild steels flat 40x5mm size conforming to IS:7196-
1974 without any bums or dents 5cm length of M.S. flat at one end shall be bent at right angle and one
hole 11mm dia. shall be made in it for fixing to wooden frame with 10mm dia. nut bolt. The bolt
head shall be sunk into the wooden frame, 10mm deep and plugged with wooden plug. At the other
end 10cm length of the hold fast flat shall be forked and bent at right angle in opposite direction and
embedded in cement concrete block of size 30x 10x 15cm of mix 1:3:6 (1 cement:3 coarse sand:6
graded stone aggregate, 20mm nominal size) or as specified (See Fig 4)
10.18.1 Measurements: Measurements for the hold fasts shall be in number if not included in basic
item.
10.18.2. Rate: It includes the cost of labour and material involve in all the operations described
above including fixing bolt and cement concrete blocks.
10.19. Expanded Metal, Hard Drawn Steel Wire Fabric and Wire Gauge in Wooden Frames:
10.19.1. Metal : Expanded metal hard drawn steel wire fabric or wire gauge or weld mesh as
described in the item of work shall be fixed to the window frames on the outside or inside as per
detailed drawings or as directed by the Engineer-in-Charge. These shall be free from rust and other
defects.
10.19.2. Expanded Metal: This shall be in the form of rhombus with its opening diagonals 20x6Omm
and stands 3.25mm wide and 1.6mm thick weighing 3.633kg/sqm. unless otherwise specified.
10.19.3. Welded Steel Drawn Wire Fabric: This shall conform to IS:4948-1974 and shall have
rectangular mesh of 75x25 mm size with wires of diameter not less than 5 mm longitudinally and
3.15mm transversely. Its weight shall be not less than 7.75 kg/sqm. unless otherwise specified.
10.19.4 Wire Gauge: This shall confirm to clause 10.3.10.
10.19.5. Fixing: Expanded metal, hard drawn steel wire fabric and wire gauge shall cut in one piece to
the size of the frame (out of out). Expanded metal and hard drawn steel wire fabric shall be fixed on
to the frame with staples, over which wooden beading 60x20 mm shall be fixed with wood screws.
10.19.6. Measurements: The length and breadth shall be measured correct to a cm, the area from
outside to outside of beading shall be calculated in square metre nearest to two places of decimal.
10.19.7 Rate: It includes the cost of labour and materials required for all the operations described
above.
10.20 Sal Ball work:
10.20.1 Ballies :Ballies shall be free from large and dead knots, cracks and wooden borer infection.
The Sal ballies shall be of the variety popularity known as gola in Northern India. These shall be as
far as possible straight and of uniform section. The diameter specified shall be the mean diameter. This
mean diameter shall be the average of two diameters at ends. The tolerance shall be permitted as per
Table 18.
Table -18:Tolerance for Sal Ballies

Length Mean Diameter or Tolerance in Diameter at the
Diameter at the centre Thinner end
Ballies not exceeding Not less than the specified The diameter at the thinner end shall
3 metre length diameter not be less than specified by more
than 10mm
Ballies exceeding Not less than the specified The diameter at the thinner end shall
3 metre length diameter not be less than specified by more
than 20 mm
10.20.2. Surface Treatment: It shall be as specified in 10.5.5.
10.20.3. Fixing: The fixing of the ballies for posts, purlins and rafters shall be done by clamps, bolts
and nuts and spikes (country nails) as specified or as directed by the Engineer-in-charge. In case of
the last alternative the large nail with a cap shall be driven through about 40mm beyond the ballies to
be fixed together and the end of the nail turned back so as to ensure proper fastening. Where so
require, holes of slightly smaller size may be drilled before hammering in spike.
10.20.4. Trusses: The ballies in truss work shall be as far as possible of full lengths. Where making
up is considered necessary it may be done by half lap joints secured together with 50x6mm M.S.
clamps of suitable length and shape fixed with bolts and nuts.
10.20.5.Measurements: The Sal Ballies shall be measured in running metre correct to a cm. Each
piece shall be measured overall so as to include half lap joints etc.
10.20.6.Rate: The rate includes the cost of materials and labour required for all the operations
described above. The cost of bolts, nuts, flat iron clamps and other iron work except nails and spikes
shall be paid for separately under relevant item of steel work.
10.21. Fittings: Fitting shall be of mild steel brass, Aluminium or as specified. Some mild steel may
have components of cast iron. These shall be well made, reasonably smooth, and free from sharp
edges and corners, flaws and other defects. Screw holes shall be counter sunk to suit the head of
specified wood screws. These shall be of the following types according to the material used.
(a) Mild Steel Fittings: These shall be bright satin finish black stone enamelled or copper
oxidized (black finish), nickel chromium plated or as specified.
(b) Brass Fittings: These shall be finished bright satin finish or nickel chromium plated or
copper oxidized or as specified.
(c) Aluminium Fittings: These shall be anodized to natural matt finish or dyed anodic coating
not less than grade AC 10 of IS: 1868-1996.
The fitting to be actually provided in a particular work shall be as per IS 1868-1996 or as directed by
Screws used for fittings shall be of the same metal, and finish as the fittings. However, chromium
plated brass screws or stainless steel shall be used for fixing aluminium fittings. These shall be of the
size as directed by the Engineer-in-charge.
Fittings shall be fixed in proper position as directed by the Engineer-in-charge. These shall be truly
vertical or horizontal as the case may be. Screws shall be driven home with screw driver and not
hammered in. Recesses shall be cut to the exact size and depth for the counter sunk the hinges.
10.21.1. Butt Hinges: These shall be of the following types according to the material used.
(a) Mild steel butt hinges (Medium)
(b) Cast brass butt hinges light/ordinary or heavy.
(c) Extruded aluminium alloy butt hinges.
10.21.1.1 Mild Steel (Medium): These shall be medium type manufactured from M.S. Sheet. These
shall be well made and shall be free from flaws and defects of all kinds. All Hinges shall be cut clean
and square and all sharp edges and corners shall be removed. These shall conform to IS: 1341-1992.
a) Hinge Pin: Hinge pin shall be made of mild steel wire. It shall fit inside the knuckles firmly
and riveted head shall be well formed so as not to allow any play or shake, and shall allow
easy movement of the hinge but shall not cause looseness.
b) Knuckle: The number of knuckles in the hinges of different size shall be as per IS : 1341-
1992. The size of knuckles shall be straight and right angle to the flap. The movement of the
hinges shall be free and easy and working shall not have any play or shake.
c) Screw Holes: The screw holes shall be clean and counter sunk. These shall be suitable for
counter sunk head wood screws and of the specified size for different types, and sizes of hinges.
The size of the holes shall be such that when it is counter sunk it shall be able to accommodate
the full depth of counter sunk head of the wood screws.
10.21.1.1.1 Sampling and Criteria for Conformity: Shall be done in accordance with IS:1341-
1992.
10.21.1.2. Cast Brass: These shall be light/ordinary or heavy as specified. These shall be well made
and shall be free from flaws and defects of all kinds. These shall be finished bright or chromium plated
or oxidized or as specified. These shall confirm to IS: 205-1978.
a) Hinge Mn : Hinge Pin shall be made of brass or of phosphor bronze. The hinge pins shall be
firmly riveted and shall be properly finished. The movement of the hinge pin shall be free,
easy and square and shall not have any play or shake.
b) Knuckle: The number of knuckles in each hinge shall not be less than five. The number of
knuckles in case of sizes less than 40mm shall be three. The sides of the knuckles shall be
straight and at right angle to the flap. The movement of the hinge pin shall be free and easy and
working shall not have any play or shake.
c) Screw Holes: The screws holes shall be suitable for counter sunk head wood screws, and of
the specified sizes for different types of hinges. The size of the holes shall be such that when it is
counter sunk it shall be able to accommodate the full depth of counter sunk head of wood screw
specified.
10.21.1.3 Extruded Aluminium Alloy: These shall be manufactured from extruded sections. These
shall be well made and free from flaws and defects of all kinds. These shall confirm to IS: 205-1978.
a) Hinge Pin: Hinge pin shall be made of mild steel (galvanized) or aluminium alloy. The
aluminium alloy hinge pin shall be anodized. The hinge pin shall be finally riveted and shall be
properly finished. The movement of hinges shall be free, easy and square and shall not have
any play or shake.
b) Knuckles: Number of knuckles in each hinge pin shall be three. The sides of the knuckles shall
not less than 50mm. The number of knuckles in case of sizes less than 40mm shall be three.
The sides of the knuckles shall be straight and at right angle to the flap. The movement of the
hinge pin shall be free and easy working and shall not have any play or shake.
c) Screw Holes: The screw holes shall be suitable for counter sunk head wood screws and
specified sizes for different type of hinges. The size of the holes shall be such that when it is
counter sunk it shall be able to accommodate the full depth of counter sunk head of wood screw
specified.
10.21.1.4 Sampling and Criteria for Conformity: It shall be done in accordance with IS:205-
1978.
10.21.2 Parliament Hinges: These shall be of mild steel cast brass or as specified and shall generally
conform to IS : 362-1982. The size of Parliament hinges shall be taken as the width between open
flanges. Mild steel parliamentary hinges shall be copper oxidized (thick finish) or as specified. The
brass parliament hinges shall be finished bright, chromium plated or oxidized or as specified.
10.21.3 Spring Hinges : (Single or double acting): These shall be single acting when the shutter is
to open on one side only or double acting when the shutter opens on both sides. These shall be made
of M.S. or brass as specified and shall generally conform to IS : 453-1973. Hinges shall work smoothly
and shall hold the door shutter truly vertical in closed position.
10.21.4 Rising Hinges: These shall be made of brass, finished bright or chromium plated or oxidized
or as specified. Its shape and pattern shall be approved by the Engineer-in-charge. The size of the
rising hinge shall be taken as the length of its plate.
10.21.5 Continuous Piano Hinges:
10.21.5.1 General : These shall be made from mild steel or aluminium alloy sheet and generally
conform to IS : 3818. All screw holes shall be clean and counter sunk. Piano hinges shall be fixed in
the entire length of the cupboard shutters. Its size will be the width of the two flaps when open.
10.21.5.2 M.S. Piano Hinges: These shall be made from 1mm or 0.80mm thick M.S. Sheets and
shall be protected with anti-corrosive treatment, such as bright polished, chromium plated or oxidized
finish. Hinge pin shall be of galvanized mild steel. It shall fit in the knuckle firmly so as not to allow
any play or s h e and shall allow easy movement of hinge, but shall not cause looseness.
The sides of the knuckles shall be straight and at right angles to the flap. The movement of the hinge
shall be free and easy and working shall not have any play and shake.
10.21.5.3 Aluminium Piano Hinges: These shall be made of aluminium alloy sheet and shall be
anodized. The anodic coating shall not be less than the grade AC 15 of IS : 1868-1996.
Hinge pin shall be made of aluminium alloy with anodic coating not less than the grade AC-15 of IS
: 1868-1996. The hinge pin shall fit in the knuckle firmly so as not to allow any play or shake and
shall allow easy movement of hinge but shall not cause looseness.
The sides of the knuckles shall be straight and at right angle to the flap. The movement of the hinge
shall be free and easy and working shall not have any play and shake.
10.21.6 Tee Hinges:
These shall be made from M.S. Sheet and shall be either bright finished or stove enamelled black or
as specified. These shall generally conform to IS : 206-1981. Tee hinges shall be well made, free
from burrs, flaws and defects of any kind. The movement shall be square and the working shall be free
and easy without any play or shake. The hole for the hinge shall be central to the bore and shall be
square. The hinge pin shall be firm and riveted over, so that the heads are well formed. All screw hole
shall be clear and counter sunk and shall be suitable for the counter sunk head of wood screws.
10.21.7 Sliding Door Bolts (Aldrops) : These shall be of mild steel cast brass aluminium or as
specified and shall be capable of smooth sliding action.
10.21.7.2 M.S. Sliding Door Bolts: These shall be made of M.S. sheets and M.S. rods and shall
generally conform to IS : 281-1973. M.S. sliding door bolts shall be copper oxidized (black finish) or
as specified.
10.21.7.3 Cast Brass sliding door bolts: These shall be made from rolled brass and shall generally
conform to IS: 2681-1993. The hasp shall be of cast brass and secured to the bolt properly.
Alternatively, the hasp and the bolt may be cast in one piece. The fixing and staple bolts shall be
cast with 6mm studs. Bolts shall be finished to shape (and have threaded ends and provided with
round washers and nuts of square or hexagon type) and shall be finished smooth and polished before
assembly. Cast brass sliding bolts shall be finished bright or chromium plated or oxidized or as
specified.
10.21.7.4 Aluminium sliding door bolts: These shall be made of aluminium alloy and shall generally
conform to IS : 2681-1993. Aluminium sliding door bolts shall be anodized. All screw holes shall be
counter sunk to suit the counter sunk head of screws of specified sizes. All edges and corners shall
be finished smooth. In case of single leaf door, when iron socket plate or a brass or aluminium fixing
bolts (or sliding door bolt) cannot be fixed, hole of suitable size shall be drilled in the door frame
and an iron or brass plate cut to shape shall be fixed at the face of the hole. The leading dimensions
of the sliding door bolts are illustrated.
10.21.8 Tower Bolts:

10.21.8.1 These shall generally conform to IS : 204 (Part-I)-1978& IS : 204 (Part-II)-1978. Tower
bolts shall be well made and shall be free from defects. The bolts shall be finished to the correct
shape and size shall have a smooth action. All tower bolts made with sheet of 1.2mm thickness and
above shall have counter sunk screw holes to suit counter sunk head of wood screws. All sharp edges
and corner shall be removed and finished smooth. The height of knob of tower bolt when the door,
window etc. is in closed position from the floor level shall be not more than 1.9 metre.
10.21.8.2 Tower bolts shall be of the following types. :
(a) Aluminium barrel tower bolts with barrel and bolt of extruded sections of aluminium alloy.
The knob shall be properly screwed to the bolt and riveted at the back.
(b) Brass tower bolts with cast brass barrel and rolled or cast brass bolt.
or
Brass tower bolts with barrel of extruded sections of brass and rolled or drawn brass bolt.
The knobs of brass tower bolts shall be cast and the bolt fixed with knob, steel spring and ball
shall be provided between the bolt and the barrel.
(c) Mild steel barrel tower bolts with mild steel barrel or mild steel bolt. or
Mild steel tower bolts with mild steel barrel and cast iron bolts.
The plates and straps after assembly shall be firmly riveted or spot welded. The rivet head shall be
properly formed and the rivet back shall be flush with the plate.
These shall be made in one piece.
10.21.8.3 Unless otherwise specified bolt shall have finish as given below:
(a) Mild steel tower bolts (Types 1 and 2) bolts bright finished or plated as specified and barrel
and socket stove enamelled black.
(b) Brass tower bolts (type 3 to 5) bolt and barrel polished or plated as specified.
(c) Aluminium alloy tower bolts (type 6) bolt and barrel anodized.
The anodic film may be either transparent or dyed as specified. The quality of anodized finish shall
not be less than grade AC-10 of IS : 1868-1996.
10.21.8.4 Sampling and Criteria for Conformity : It shall be same as specified in 10.21.1.4.
10.21.9 Flush Bolts:
10.21.9.1 These should generally conform to IS : 5187-1972. These shall be of cast brass, cast
aluminium alloy or extruded aluminium alloy as specified. Only one material shall be used in the
manufacture of all the components of flush bolts except spring which shall be phosphor bronze or steel
strip. When the rod is completely in its maximum bolting position it shall be retained in that position
by the spring. The length of the bolt shall be such that, when the bolt is pulled down, the top of the
bolt shall be flush with the top of the lip face. The top of the bolt given a taper of 45° to enable easy
pull or push.
10.21.9.2 Brass flush bolt shall be satin or bright polished. Alternatively they may be nickel or
chromium plated as specified in IS : 4827 or copper oxidized in accordance with IS : 1378-1987.
Aluminium flush bolts shall be anodized and the quality of the anodized finish shall not be less than
grade AC-15 of IS : 1868-1996.
Note :- The working of flush bolts is found satisfactory only in case of shutters made of high quality
timber like teakwood properly seasoned and when there is no warping due to changes in weather. Brass
flush bolts which give a more satisfactory performance are costly and uses scarce materials. Hence
use of flush bolts is to be discouraged.
10.21.10 M.S. Locking Bolt with holes for pad locks:
10.21.10.1 This shall conform to IS : 7534-1985.
10.21.10.2 This shall be of mild steel polished bright or copper oxidized batch electro-galvanized or
stove enamelled. In case of stone enamelled looking bolts, the bolt may be finished bright.
10.21.11 Pull Bolt Locks:
10.21.11.1 These shall be of M.S. cast brass or aluminium as specified. M.S. pull bolt locks shall be
copper oxidized (black finish) or as specified.
10.21.11.2 Brass pull locks shall be finished bright, chromium plated or oxidized as specified.
Aluminium pull bolt locks shall be anodized and the anodic coating shall not be less than grade A.C.
10 of IS : 1868-1996. The bolt shall be 10 mm in diameter and the fixing plate 3 mm thick. The stop
block shall be screwed to the fixing plate by a small ball and spring over which the bolt shall slide.
10.21.11.3 The fixing plate shall have four holes for fixing it to the door leaf, two of which shall be
square to receive 6 mm dia. bolts with round heads the remaining two shall receive machine screwed
with lock nuts. The receiving plate shall be of the same width and thickness as the fixing plate and
shall have 3 counter sunk holes. Where the bolt slides into wooden members like the chowkhat which
have a rebate the receiving plate shall also be correspondingly shaped so as to fit into the rebate. The
screws and bolts shall have the same finish as the main bolt. The leading dimensions of pull bolt locks
are given in the drawing. The denominating size of the pull bolt locks shall be length of the fixing
plate between guides plus the thickness of the guides.
10.21.12 Door Latch:

10.21.12.1 This shall be of mild steel, cast brass or as specified and shall be capable of smooth sliding
action. In case of mild steel latch, it shall be copper oxidized (black finish) or as specified and in
case of brass, it shall be finished bright, chromium plated or oxidized or as specified. The size of
door latch shall be taken as the length of the latch.
10.21.13 Indicating Bolt (Vacant / Engaged): These shall be of cast brass finished bright chromium
plated or oxidized or as specified. The shape and pattern shall be approved by the Engineer-incharge.
10.21.14 Mortise Lock and Latch :
10.21.14.1 This should generally confirm to IS : 2209-1976.
10.21.14.2 The size of the mortise lock shall be denoted by the length of the body towards the face and
it shall be 65mm, 75mm and 100mm as specified. The measured length shall be not vary more than 3
mm from the length specified. Handles shall confirm to IS : 4992-1975.
10.21.15. Mortise latch (with locking bolt)
10.21.15.1 These are generally used in doors of bath rooms, WC's and private rooms.
10.21.15.2 Mortise latch shall in respect of shape, design and mechanism of the latch and its
components parts generally confirm to IS : 5930. The material used for the different component parts
of the latch shall comply with tables 1 & 2 of IS : 5930, unless otherwise specified.
10.21.15.3 The size of the latch shall be denoted by the length of the body towards the face and shall
be 65mm, 75mm or 100mm as specified. The depth of the body shall not be more than 15mm .
10.21.15.4 The latch shall be of size 10x18 mm of shape as shown in fig 1 of IS : 5930. The locking
bolt shall be of section not less than 8x25 mm for all size of locks. The mechanism of the latch bolt,
its spring, striking plate etc. shall be as described in tables 182 of IS : 5930.
10.21.15.5. The handles provided shall confirm to IS : 4992-1976.
10.21.16 Mortise Lock and Latch (Rebated):
10.21.16.1 These are slightly different from mortise lock described in 10.21.14 and are designed for
use in double leaved doors. These should generally confirm to I.S.: 6607-1972 (Reaffirmed 2006).
10.21.17 Mortise Night Latch:
10.21.17.1 This is mortise lock having a single spring bolt withdrawn from the outside by using the
key and from inside by turning the knob and with and arrangement whereby the lock can be prevented
from being opened by its key from outside while the night latch is used from inside the room. This
should generally confirm to IS : 3847-1992.
10.21.17.2 It shall be cast or sheet brass, cast or sheet aluminium alloy or mild steel as specified and of
best quality of approved make. These shall be bright finished or copper oxidized (black) finish as
specified. Nominal size of the latch shall be denoted by the length of the face over the body in
millimetre. These shall have not less than two levers. False (Dummy) levers shall not be allowed.
10.21.18 Cupboard or Wardrobe Lock: This should generally confirm to IS : 729-1979. The size of
the cupboard lock shall be 40, 50, 65 & 75 mm. This shall be made of cast brass and shall be of the
best make of approved quality. These shall be finished bright or chromium plated or oxidized or as
specified. The size of the lock shall be denoted by the length of the face across the body in mm.
These locks shall be fitted with four, five or six levers as specified. False (dummy) lever shall not be
used.
10.21.19 Ball Catchers For Wooden Almirahs:
10.21.19.1 This should generally confirm to IS : 8756-1978. These may be brass sheets or cast brass with
steel balls of sizes 6,7.5,9.5 or 12mm dia. as specified. The size shall be denoted by the external diameter
of the cylinder holding the steel ball with spring. When the almirah is in the closed position it shall be
retained in that position by the spring section of the ball catch and shall be so in continuous usage. The
door shall open only when it is pulled open.
10.21.20 Finger Plate:
10.21.20.1 This shall be finished bright chromium plated, oxidized of brass or anodized aluminium or
transparent plastic or as specified. This shall be made from brass or aluminium plate of 1.6mm
thickness with bevelled or square edge as specified. This size of the plate shall be 300x65mm unless
otherwise specified. The shape and pattern shall be approved by Engineer-in-charge.
10.21.21 Kicking Plates:
10.21.21.1 This shall be of brass (finished bright or chromium plated or oxidized) bronze, stainless
steel, aluminium or as specified. Aluminium kicking plates shall be anodized and the anodic coating shall
not be less than grade AC-10 of IS : 1868-1996. It shall be made from a plate of minimum thickness
3.0mm & 1 . 5 = in case of stainless steel. Shape of the plate shall be as specified. This shall have
bevelled or straight edges and shall be fixed by means of counter sunk or rounded screws of the same
material and finished as that of the plate. The shape and pattern shall be according to the drawings and
as approved by the Engineer-in-charge.
10.21.22 Handles (Doors and Windows):

10.21.22.1 These should generally confirm to IS : 208-1979. The door handles shall be well made and
free from defects. These shall be finished correct to shape and dimensions. All edges and corners shall
be removed and finished smooth so as to facilitate easy handling. Cast handle shall be free from casting
defects. Where the grip portion of the handles is joined with the piece by mechanical means, the
arrangement shall be such that the assembled handle shall have adequate strength comparable to that
of integrally cast type handles.
10.21.22.2 Door handles shall be of the following types according to the material used:
(a) Cast or Sheet Aluminium Alloy Handles: These shall be of aluminium of specified size, and
of shape and pattern as approved by the Engineer-in-change. The size of the handle shall be
determined by the inside grip of the handle. Door handles shall be of 100mm size and window
handles of 75mm size depending upon thickness door shutters unless, otherwise specified.
These shall be fixed with 25mm long wood screws of designation No. 6. Aluminium handles
shall be anodized and the anodic coating shall not be less than grade AC-15-IS : 1868-1996 as
specified. The finish can be bright natural, matt or satin or dyed as specific.
(b) Cast Brass Handles : These shall be of cast brass of specified size and of the shape and pattern
as approved by the Engineer-in-charge. The size of the handle shall be determined by the inside
grip of the handle. Door handles shall be of 100mm to 150mm size and window handles of
75mm to 100mm depending upon thickness door shutters unless otherwise specified. These shall
be fixed with 25mm long wood screws of designation No. 6. Brass handles shall be finished
bright satin or nickel chromium plated or copper oxidized or as specified.
(c) Mild Steel Handles : These shall be of mild steel sheet, pressed into oval section. The size of
the handles will be determined by the inside grip of the handle. Door handles shall be of 100mm
to 150mm size and window handles of 75mm to 100mm size depending upon thickness door
shutters unless otherwise specified. These shall be fixed with 25mm long wood screws of
designation No. 6. Iron handle shall be copper oxidized (black finish) or stove enamelled black
or as specified.
10.21.22.3 Sampling and Criteria for conformity : The number of handles to be selected from a lot
shall depend on the size of lot. Handles for testing shall be selected at random for at least 10 percent
of packages. Subject to a minimum 3, equal number of door handles being selected from each such
package. All door handles shall be checked for dimensional requirement and finish. Any door handle
which fails to satisfy the requirement of dimensions or finish or both shall be considered as defective.
10.21.23 Floor Door Stopper:
10.21.23.1 General: The floor door stopper shall conform to IS : 1823-1980. This shall be made of
cast brass of overall size as specified and shall have rubber cushion. The shape and pattern of stopper
shall be approved by the Engineer-in-charge. It shall be of brass finished bright, chromium plated or
oxidized or as specified. The size of floor stopper shall be determined by the length of its plate. It shall
be well made and shall have four counter sunk holes for fixing the door stoppers to the floor by means
of wood screws. The body or housing of the door stopper shall be cast in one piece and it shall be fixed
to the cover plate by means of brass or mild steel screws and cover plate shall be of casting or of sheet
metal. The spring shall be fixed firmly to the pin. Tongue which would be pressed while closing or
opening of the door shall be connected to the lower part by means of copper pin. On the extreme end
a rubber piece shall be attached to absorb shock. All parts of the door stopper shall be of good
workmanship and finish, burrs and sharp edges removed. It shall be free from surface and casting
defects. Aluminium stopper shall be anodized and anodic film shall not be less than grade AC-10 of
IS : 1868-1996. The rubber for the floor stopper shall meet the requirements as per Table 19.
Table 19 : Requirements for Rubber for Use in Floor Door Stopper
Particulars Requirements Testing Procedure
Relative density Max. 1.3 IS 3400 (Part IX)
Hardness 60 ± 5 IS 3400 (Part 2)
Ageing for 24 hours at (a) Change in initial hardness -do-
100° ±1°C (b) Shall not develop brittleness
+5, - 0
10.21.24 Hanging Rubber Door Stopper:
10.21.24.1 These shall be of cast brass, finished bright, chromium plated or as specified. Aluminium
stopper shall be anodized and the anodic coating shall not be less than grade AC-10 of IS : 1868-1996.
The size and pattern of the door stopper shall be approved by the Engineer-in-charge. The size shall
be determined by its length.
10.21.25 Universal Hydraulic Door Closer (Exposed Type):
10.21.25.1 These shall be made of cast iron/aluminium alloy/zinc alloy and of shape and pattern as
10.21.25.2 These shall generally conform to specifications for door closers (Hydraulically regulated)
IS: 3564-1995.
10.21.25.3 The door closer may be polished or painted and finished with lacquer to desired colour.
Aluminium alloy door closer shall be anodized and the anodic coating shall not be less than grade AC-
15 of IS:1868. All dents, burrs and sharp edges shall be removed from various components and they
shall be pickled, scrubbed and rinsed to remove grease, rust, scale or any other foreign elements. After
pickling, all the M.S. parts shall be given phosphate treatment in accordance with IS : 3618-1966.
10.21.25.4 The nominal size of door closers in relation to the weight and width of the door size to
which it is intended to be fitted shall be as given in Table 25.
Table - 20 Type and Designation of Door Closers
Designation Weight of the Size of the Remarks
of Closers Door (Kg.) Door
1. Up to 35 Up(mm)
to 700 For light doors such as double leaved and toilet
doors.
2. 36 to 60 701 to 850 Interior doors, such as of bed rooms, kitchen
and store.
3. 61 to 80 851 to Main doors in a building such as entrance
1000 doors.
10.21.25.5. Sampling and Criteria for Conformity: It shall be carried out in accordance of IS:1868
10.21.25.6 Endurance Test- Two door closer in case of lot size 280 or less and five door closers in
case of lot size more than 280 shall be selected from those already found satisfactory. These door
closers shall be tested for the endurance test. If all the door closers tested for endurance test satisfy the
requirement of this standard, the lot shall be deemed as having satisfied the requirements of endurance
test, otherwise not.
10.21.25.7. Performance Requirements: After being fitted in its position when the door is opened
through 90°, the same should swing back to angle of 20°± 5° with nominal speed but thereafter, the
speed should get automatically related and in case of doors with latches, it should be so regulated that
in its final position the door smoothly negotiates with the latch.
10.21.26. Hooks and Eyes : These shall be mild steel or hard drawn brass or as specified. Mild
steel hooks and eyes shall be copper oxidized (black finish) or as specified. Cast brass hooks, eyes
shall be finished bright or chromium plated. These shall be well made and free from defects. They
shall be finished to the correct shape and dimensions so as to function properly when they are in use.
Cast hooks eyes and plates shall be free from casting and other defects. All these shall generally confirm
to IS : 207. All size of hooks and eyes shall be determined by the length of the hooks measured out
to out. Unless otherwise specified the articles shall be finished bright.
10.21.27. Casement Window Fasteners: These shall be made of cast brass, finished bright,
chromium plated or oxidized or of nylon or as specified. Casement fasteners for single leaf window
shutter shall be left or right handled as specified. These shall not weight less than 0.20 kg. per
fastener. Nylon window fasteners shall conform to IS : 6318-1971.
10.21.28. Casement Brass Stays (Straight peg type) :
10.21.28.1. Material : These shall be made of mild steel, cast brass, aluminium (extruded section) or
plastic (Polypropylene) as specified. Mild steel casement stays shall be copper oxidized (blank finish)
or as specified. Cast brass stays shall be finished bright or chromium plated or as specified. Aluminium
stays shall be anodized and the anodic coating shall not be less than grade AC-10 of IS : 1868-1996.
Aluminium and M.S. stays shall be made from channel section. The stays shall not weight less than
that indicated below :
200 mm 0.24 Kg. each
10.21.28.2.Shape : The shape and pattern of the stays shall be approved by the Engineer-in-charge.
The size of stays shall be determined by its length as shown in the plate. The plastic (Polypropylene)
stays shall confirm to IS : 6318-1971.
10.21.29. Fan Light Pivots:
10.21.29.1. Specification: These shall generally confirm to IS : 1837-1966. These shall be of mild
steel or cast brass or Aluminium or as specified. The brass, fan light pivots shall be finished bright,
chromium plated or as specified, M.S. fan light pivot shall be copper oxidized (black finish) or as
specified. The base and socket plate of M.S. fan light pivots shall be made from minimum 3.0 mm
M.S. sheet and the pivot shall be of round M.S. bar of minimum 10mm diameter projecting out by
minimum 12mm length and firmly riveted to the base plate.
10.21.29.2. The base and socket plate of cast brass fan light pivots shall be made from minimum
3.0mm thick brass plate and the projected pivot shall not be less than 12mm diameter and 12mm
length, cast in single piece with the base plate.
10.21.30. Fan Light Catch: This shall confirm to IS:364-1970. This shall be made of mild steel or
cast brass or Aluminium or as specified. M.S. fan light shall be copper oxidized (black finish) or as
specified. Brass catch shall be finished bright, chromium plated or oxidized or as specified.
10.21.31. Chain with Hook for Ventilator:
10.21.31.1 This shall generally confirm to IS : 3828-1966. This shall be made of mild steel, hard
drawn brass of cast brass welded or twisted or as specified. The brass chain shall be finished bright,
chromium plated or oxidized or as specified M.S. chain shall be copper oxidized (black finish) or as
specified. One end of the chain shall be provided with an eye and the other end with a staple. The
minimum thickness of plates shall be 3mm. The chain shall be 300 mm long made from minimum
4mm hard drawn wire with properly jointed or twisted ends.
10.21.32. Quadrant Stays 3 0 0 : These shall be made of cast brass and finished bright or
chromium plated or as specified. The shape and pattern shall be approved by the Engineer-incharge.
It shall not weight less than 0.20 kg each.
10.21.33. Hasp and Staple Safety Type :
10.21.33.1 Specification : This shall be made of mild steel, cast brass or aluminium as specified.
This shall generally confirm o IS : 363-1976. M.S. Hasp and staples shall be finished black enamelled,
or copper oxidised (black finish) or as specified. Brass hasp and staples shall be finished bright
chromium plated or oxidized or as specified. Aluminium hasp and staples shall be anodized and the
anodic coating shall not be less than grade AC-15 of IS : 1868-1996.
10.21.33.2 Hasp : M.S. hasp and staples shall be manufactured from M.S. sheet and brass hasp and
staples by casting and Aluminium hasp and stales shall be made from dye section. The hinge pin
which in all cases shall be of mild steel, shall be firm and its riveted heads well formed. The
movement of hasp shall be free, easy and square and shall not have any play or shake. The hasp shall
fit, in the staple correctly. The size shall be determined by the length of the bigger of the hasp.
10.21.33.3 Staple :The staple except in the case of cast one, shall be riveted properly to its plate.
The ends of the hinge pin for the safety type hasp shall be riveted and properly finished. All screw
holes be clean and counter sunk to suit counter sunk wood screw. All edges and corners shall be
rounded.
10.22 Wooden Stair Cases:
10.22.1 Scope: This clause covers, the types of staircases materials, general dimensions, construction,
and mode of measurement of wooden staircases.
10.22.2. Types of Stair Cases: These can be `Doglegged, open well or open newel type, or
geometrical.
10.22.3. Materials:
10.22.3.1 Timber :- The species of timber shall be of class I confirming to IS : 399-1963. This shall
be treated in accordance with the relevant provisions of IS : 883-1994.
10.22.3.2 Wood Screws :- Shall confirm to IS : 451-1999.
10.22.3.3 Nails :- Shall confirm to I.S. 723-1972. 10.22.4
General Dimensions:
10.22.4.1 Head room : Minimum of 2.1 metres as measured vertically from the ceiling, Soffit etc.
to the pitch line and also minimum clearance of 1.5 metres being left as measured at right angles to
pitch line.
10.22.4.2 Pitch : - The pitch shall not be more than 45° and not less than 25°.
10.22.4.3 Going and Rise : Going and rise in any one flight shall remain same for all steps. The
going shall not be less than 20 cm.
Going and rise shall follow the following empirical rules :
(a) The value "2xRise + Going" shall be between 55 cm. to 60 cm. and
(b) The value "Rise x Going" shall be between 400 to 430 cm2.
10.22.4.4 Tread : Treads shall not be less than 22 cm in width. Their nosing shall project beyond the
face of risers by not less than 15mm and not more than the thickness of tread and the profile of the
nosing shall be rounded from the top surface.
10.22.4.5 Width of Stairs :- The clear width of stairs as measured from inside of end strings shall
not be less than 0.75 metres.
10.22.4.6 Width of Landing :- The width of landing shall not be less than the width of stairs.
10.22.4.7 Length of flights :- The length of flights shall be such that there are not more than 15
risers.
10.22.4.8 Winders :- Wherever provided these shall be arranged such that three winders are required
to occupy quarter space and six winders to occupy half space.
10.22.4.9 Height of Hand Rail :- The vertical height from the pitch line to the of any sloping hand
rail shall not be less than 0.75 metres and not more than 0.85 metres. The vertical height from the floor
surface to the top of any horizontal hand rail shall not be less than 0.9 metres.
10.23 Laminated Veneer Lumber (LVL):
10.23.1 Laminated Veneer Lumber door frames and shutters shall conform to IS 14616-1999.
10.23.2 Material:
10.23.2.1Laminated Veneer Lumber (LVL):
(a) Laminated Veneer Lumber is made of rubber wood silver oak, Eucalyptus, Poplars, Acacias
etc. veneers glued together having grains of all the veneers in one direction under high
temperature and pressure to develop high Modulus of Rupture & Modulus of elasticity. Veneers
for LVL shall be of thickness between 1.5 to 2.5 mm.
(b) Veneers shall be free from knot holes, decayed knots except pin knots, unfilled splits wider
than 3 mm, concentrated borer holes, shakes, objectionable decay or termite attack, except that
for the face veneers none of these defects nor cross grain exceeding 1 in 10 shall be permitted.
The nominal thickness of all the veneers used shall be identical and uniform within a tolerance
of ± 5 percent.
(c) Adhesives : Only BWP grade adhesive conforming to IS 848-2006 shall be used for making
LVL.
(d) Preservatives : Veneers used for LVL shall be given suitable preservative treatment before
lamination, with a preservative that is compatible with the adhesive to be used. Only fixed type
of water soluble preservatives, CCA or CCB, or non-leachable, solvent soluble preservatives as
per IS 401 shall be used for treating the veneers. Retentions of preservatives shall be as per IS
401 depending upon the proposed end use.
10.23.3 Moisture Content: The average moisture content of three test specimens, when determined
in accordance with IS 1734 (Part 1)-1983 shall be between 5 to 15%.
10.23.4 Tests: The tests as per Table-1 of IS 14616-1999 shall be carried out by the manufacturer on
the LVL (Laminated Veneer Lumber) sections on each batch.
10.23.5 Laminated Veneer Lumber (LVL) Door Shutters:
10.23.5.1 This specification lays down requirements regarding types, sizes, material, construction,
workmanship and finish, performance evaluation, sampling, measurements, rates and testing of
Laminated Veneer Lumber (LVL) door shutter for use in domestic buildings, offices, schools,
hospitals etc. This specification does not cover large size door shutters for industrial and special
buildings such as workshops, garages, go downs etc.
10.23.5.2 The material of each lot shall be supported by a certificate to that effect:
Each lot of LVL materials shall be accompanied by the test reports. Fabricator shall take up
manufacturing of shutters only if provisions of clause 10.23.4 are fulfilled; failing which, shutters so
manufactured are liable for rejection.
10.23.5.3 Panelling Materials:
10.23.5.3.1 Plain Particle Board: Plain particle boards used for panels shall be FPT-1 conforming
to IS 3087:2005 and shall have been bonded with BWP type of synthetic resin adhesive as per IS 848-
2006. (Ref. para 10.3.3)
10.23.5.3.2 Pre-laminated Particle Board: Pre-laminated particle boards used for panels shall
conform to IS 12823-1990:. The plain particle boards used in pre-laminated particle boards shall be
as per para 10.3.14 above.
10.23.5.3.3 Medium Density Fibre Board: Medium density fibre board used for panels shall
conform to exterior grade as per IS 12406-2003 made from agro-forest products or agricultural
wastes or natural fibres.
10.23.5.3.4 Pre-laminated Medium Density Fibre Board: Pre-lamination in pre-laminated
medium density fibre board shall conform to the requirements such as Abrasion Resistance,
Resistance to Steam, Crack Resistance, Resistance to Cigarette Burn and Resistance to Stain as
specified in IS 12823-1990. The medium density fibre board used in pre-laminated medium density
fibre board shall be as per para 10.3.8 above.
10.23.5.3.5 Glass: Glass for glazing shall conform to IS 2835-1987 or IS 2553 (P-1) 1990, P-2, 1992,
The use of other types of glass, such as frosted glass, wired glass and coloured glass may also be
specified by the Engineer-in- Charge. (Ref. para 10.6).
10.23.5.3.6 Wire Gauze: Wire gauze shall generally conform to IS 1568-1970 and shall be regularly
woven with equally spaced galvanized mild steel wires of 0.63 mm nominal diameter in both warp
and weft directions to form aperture of average width 1.40 mm. (Ref para 10.3.10).
10.23.6 Construction and Workmanship:
10.23.6.1 Laminated Veneer Lumber (LVL) panelled, glazed and panelled and glazed shutter shall
be constructed in the form of LVL framework of stiles and rails with panel inserts conforming to para
10.23.5 above of plain or per laminated particle board, plain or pre laminated medium density fibre
board, wire gauze or glass. The panels shall be fixed by either providing grooves in stiles and rails
and beading as specified. The stiles, top rails, lock rails and bottom rails shall be jointed to each other
by Mortice and tenon joints [See Fig. 5(A)]. Rails having width of 150 mm or more shall have plain
double tenon joints as shown in Fig. 5(B). Other rails shall have single tenon joints. The bottom lock
and top rails shall be inserted 25+3 mm short of the width of stiles
to form a stub Mortice & tenon joint. After assembling shutter complete with panels, Bamboo pins of
6 mm dia. shall be fitted on each tenon & Mortice joint by drilling suitable size of holes (2 pins per
joint for rail width up to 150 mm and 3 pins for rails of greater width). All the four edges of shutter
shall be beaded with 12 mm thick rubber wood /plantation wood lipping (See Fig.5). Lipping shall be
seasoned and chemically treated as per clause 10.23.4. Lipping on top and bottom rails shall be of
one piece and lipping on stiles may be in two pieces. All lipping shall be glued to shutter with water
resisting glue (Synthetic rubber passed adhesive) at the rate of 0.15 kg/m2.
10.23.6.2 All members of the shutters shall be straight, smooth and with well planed faces at right
angles to each other. Any warp or bow shall not exceed 1.5 mm. The right angle for the shutters shall
be checked by measuring the two diagonals from one extreme corner to the opposite one and the
difference between the two diagonals shall not be more than 3 mm.
10.23.6.3 Beading: All the panels except glass and wire gauze shall be fixed with grooves [see Fig.
5(C)] but additional beading may be provided either on one side or on both the sides, if so specified.
In so far as glass and wire gauze panels are concerned, beading shall be provided without grooves.
In such a case where beading is provided without the grooves, the beading shall be only on one side,
the other side being supported by rebate from stiles. The beading shall have a size not less than 15 mm
x 10 mm. It can be fixed by suitable headless nailing or screwing. The beading shall be of plantation
timber section, preservative chemically treated of fixed type as per IS 401-1982.
10.23.6.4 Stiles, top rails, bottom rails and lock rails of shutters shall each be made in one piece of
LVL, only. Mullions and glazing bars shall be stub tennoned to the maximum depth which the size of
the member would permit or to a depth of 25 mm, whichever is less.
Two common methods for jointing of panels with stiles/rails are shown in Fig. 5C. The minimum
depth of grooves of stiles and rails shall be 12 mm for all types of panelling. The panels shall be
framed into grooves to the full depth of groove leaving an air space of 1.5 mm and the faces shall be
closely fitted to the sides of the groove.
LVL Shutters shall be manufactured in factories under controlled conditions.
10.23.7 Panelling:
10.23.7.1 Plain and Pre-laminated Particle Board Panelling: The panels shall be made of one
piece of plain or pre-laminated particle board of thickness 12 mm or more.
10.23.7.2 Wire Gauze Panelling : Wire gauze panel shall be so designed that no single panel shall
exceed 0.5 sqm. in area.
10.23.8 Rebating: In case of double leaved shutters, the meeting of the stiles shall be rebated either
splayed or square type as shown in Fig. as per clause 6.12 of IS 1003 (part-1).
10.23.9 Gluing of Joints: The contact surfaces of tenon and Mortice shall be treated before putting
together as per clause 6.13 of IS 1003 (Part-I). All the tenon and Mortice joints should be glued
together and pinned to full thickness of the door with Bamboo pins.
10.23.10 Dimensions, Sizes and Tolerances:
10.23.10.1 Dimensions of Components and Tolerances: The finished dimensions and tolerances of
the different components of door shutter shall be as per para 10.6.1.4.1.
Tolerances: Tolerance on the size of door shutter shall be + 3 mm and in thickness + 1.2 mm.
10.23.11 Locations of Fittings and Accessories:
10.23.11.1 Each door shutter shall be fixed to the frame with four hinges, unless otherwise specified
by the Engineer-in-Charge, of the type specified.
The lock rail of door shutters, where provided, shall be so placed that its centre line is at a height
850+5 mm from the bottom of the shutter. Hinges and other fixtures shall be fixed to shutter with full
threaded steel screws after coating the screws with adhesive such as fevicol etc. For fixing of hinges,
holes of 3.5 mm diameter and 52 mm length shall be bored and No. 10 full threaded parallel shank
steel screws, 50 mm long, coated with adhesive shall be used. In no circumstances screws shall be
hammered into board.
10.23.11.2 Cleats and blocks made of LVL wood shall be fixed to door shutter, if required, by the user
as per size and shape approved. Pull bolt or sliding door bolt etc. shall be provided in the door shutter
at a height of 850 mm from bottom of shutter. These shall be fixed to shutter as per method of fixing
described in 10.23.11.
For re screwing, a plastic sleeve of appropriate diameter shall be inserted into the hole and then
fixing with full threaded screws shall be done. Fittings other than hinges shall be provided as per
schedule of fittings decided by the user. The fittings shall conform to specifications as described in
clause 10.21.
Panelled shutter may be provided with louvers of vision panels as specified. Where such a provision
is made, the position, sizes and shape of louver or vision panel opening shall be as specified.
10.23.12 Finish: All the four edges of the shutter shall be square. The shutter shall be free from twist
or warp in its plane. Panels of the door shutters shall be flat and well sanded to a smooth and level
surface. All the surfaces shall be delivered without protective coat of wood primer polish or varnish.
10.23.13 Glazing:
10.23.13.1 Glazing in the shutters of door and window shall be as per specified sizes of the openings
or panels of glass, the first dimension shall be width. The glass shall be embedded in putty and
secured to the rebate by the wooden beading of suitable size and shape.
10.23.13.2 Measurement: Length and width of the shutter shall be measured to the nearest
centimetre in closed position covering the rebates of the frames but excluding the gap between the
shutter and the frame. Overlap of the two shutters shall not be measured. All work shall be measured
net as fixed and area calculated in square metres to nearest two places of decimal. No deduction shall
be made to form panel opening, louver Venetian opening and opening for glazing. No extra payment
shall be made for shape, joints and labour involved in operations described above.
10.23.13.3 Rates: The rate includes the cost of material and labour involved in all the operations
described above. Extra rate shall be payable for providing rebates in double leaf shutters. Fittings
described in 10.23.11.2 shall be payable extra. Nothing extra shall be payable for complying with the
provisions described. Cost of tests as described shall be borne by Department. If test reports are
found satisfactory. Rate shall include cost of material and labour involved in providing plain beading.
Extra shall be paid for providing moulded/plain beading on panels where specified.
APPENDIX À'
TABLE FOR PERMISSIBLE DEFECTS FOR VARIOUS GRADES OF TIMBERS
S1. No. Defects First Grade Second Grade
(1) (2) (3) (4)
(i) Cross-grain Not steeper than 1 in 15 Not steeper than 1 in 10
(ii) Sound (i) Stiles and Rails (i) Stiles and rails
knots and live (a) Short Exposed Face: Not more (a) Short exposed Face - Not
knots than 15 mm size and not more more than 15 mm size and not
than 1 knot/metre more than 3 knots per stile and
1 knot per rail
(b) Long Exposed Face- Not
(b) Long Exposed Face- Not more
more than 20 mm size and not
than 15 mm size and not more
more than 3 knots per stile and 1
than 1 knot/m. No knot shall
knot per rail
occur within 20 mm of the edges
(ii) Panels - Not more than 20 mm
(ii) Panels - Not more than 20 mm
size and not more the 4 knot/m2.
size and not more than
No knots shall occur on edge of
2 knots/m2. No knot shall
any component of a panel.
occur on edge of any
component of a panel.
(iii) Dead and (i) Stiles and Rails - Not more than (i) Stiles and Rails - Not more than
loose knots 10 mm size - centrally located 10 mm size, centrally located
(plugged) and not more than 1 knot / m and not more than 3 knots per
(ii) Panels - Not more than 15 mm stile and 1 knot per rail.
size and not more than (ii) Panels - Not more than 15 mm
2 knots/m2. No knot shall occur size and not more than 4 knots/m2.
on edges of any component of a No knot shall occur on edge of
panel. any component of a panel.
(iv) Pitch pockets None Permissible except on exposed
or streaks edges provided that they are clean
and filled up with suitable putty or
filler when pitch pockets or streaks
are located on the exposed edges of
the core, they shall be cut out and
filled with piece of wood of
similar species with grain running in
the same direction. The piece shall
be well glued.
(v) Sapwood Total not exceeding 5 mm wide and Total not exceeding 10 mm wide
150 mm long per metre. and 300 mm long per metre.
(This restriction applies only to super (This restriction applies only to
group species). super group species).
(vi) Pin holes Permitted provided they are not Permitted.
in cluster
Si. No. Defects First Grade Second Grade
(1) (2) (3) (4)
(vii) Worm holes None Permitted provided they are not
more than 10 mm in diameter and
not more than one per metre
and provided such worm holes
are plugged with similar timber in
such a manner that the plugging
merges with the surrounding area
both as to colour and grain.
Note :(i) Dead and loose knots are permitted only if they are suitably plugged. (ii) Knot shall not occur
where hinges or locks are to be fixed.
APPENDIX `B'
MOISTURE CONTENT OF TIMBER

B-1 Moisture content of timber shall be checked for every 1 cum or part thereof by electrical
moisture meters as per IS 287-1993.
B-2 Electrical moisture meters are of resistance type and shall be used when the moisture content is
within a range of 8 to 25 per cent. When checking moisture content with electrical moisture
meter, it shall be ensured that :
(a) Timber is not hot or surface wet and the moisture gradient is not large due to wet cores.
(b) Electrode probes are of adequate depth (not less than one-fifth the thickness of the
timber).
B-3 Sufficient number of reading at different positions are taken on each piece of timber to eliminate
localised variations in surface moisture and species corrections are applied for the make of
electrical resistance type moisture meter.
B-4 If for any reason, whatsoever, the result of electrical moisture are not to be relied upon the
moisture content shall be checked by the oven drying method.
B-5 For checking moisture content by oven drying method, a complete test cross section, 12 to 19
mm long in the direction of timber grain, free from all defects shall be cut from each piece of
timber selected for test as follows :
(a) If weighing can be done immediately, the test section shall be cut from a point at least
45 cm from one end of the piece or from its centre.
(b) In case cutting of test section from the piece is not permissible the moisture content in
the whole section can also be determined by collecting a boring to a depth of half of the
thickness of the piece by means of an auger, in a pre weighed weighing bottle which
should then be sealed properly.
B-6 The test sections obtained above shall be weighed, immediately after cutting, on a balance the
sensitivity of which is not less than 10 mg. They shall be dried in a ventilated, and preferably
thermostatically controlled, oven at a temperature of 100°C to 105°C until the weight is
constant. The weight of the test section shall be deemed to have become constant if successive
weighing at intervals of 2 to 5 hours do not differ from one another by more than 50 mg. The test
weight shall be taken to be the oven dry weight of the test section.
B-7 The percentage moisture content in the test section shall be calculated as follows :
W1 - Wo
Moisture content (Per cent) = x 100
Wo
Where :
W 1 = initial weight of test section and Wo =
oven dry weight of test section
B-8 When moisture content of timber is checked by oven drying method, results of electrical
moisture meter shall be ignored.
APPENDIX `C'
PHYSICAL AND MECHANICAL PROPERTIES OF PLYWOOD
C-1 Moisture content: 5 to 15 per cent.

C-2 Shear strength:
Dry State Resistance to Moisture
Average 135 100
Individual 110 80
PHYSICAL AND MECHANICAL PROPERTIES OF
FPT OR GRADED PARTICLE BOARD
Si. No. Properties Flat pressed Three layer multilayer and graded
Grade- I Grade-II
(i) Density variation, percent ± 10 ± 10
(ii) Water absorption, percent
(a) 2 h soaking 10 20
(b) 24 h soaking 40 80
(iii) Linear expansion (swelling in water).
2 h soaking-percent
(a) Length 0.5 0.5
(b) Width 0.5 0.5
(iv) Thickness, swelling, percent 2 h soaking 8 12
(v) Swelling in thickness due to surface
absorption, percent 6 9
(vi) 2
Modulus of rupture, N/mm
(a) Average 15 13
(b) Minimum 11 10
(vii) Modulus of elasticity, N/mm2
(a) Average 2500 2250
(b) Minimum 2000 1800
(viii) Tensile strength perpendicular to
surface, N/mm2
(a) Upto 20 mm thickness 0.45 0.40
(b) Above 20 mm thickness 0.3 0.3
(ix) Tensile strength perpendicular to
surface, N/mmz
(a) After cyclic test 0.2 0.15
(b) Accelerated water resistance test2) - -
(x) Screw withdrawal strength, N
(a) Face 1250 850
(b) Edge (for thickness >12mm) 1250 700
1) Cyclic T e s t - Specimen are immersed in water at 27 ± 2°C for a period of 72 h, followed by

drying in air at 27 ± 2°C for 24 H and then heating in dry air at 70°C for 72 h. Three such
cycles are to be followed and then the specimens are tested for tensile strength perpendicular to
surface.
2) Accelerated Water Resistance T e s t - Specimen are immersed in water at 27 ± 2°C and water
is brought to boiling and kept at boiling temperature for 2 h. Specimen are then cooled in water
to 27 ± 2°C and then tested for tensile strength perpendicular to surface.
TESTS FOR FLUSH DOOR SHUTTERS
FLUSH DOOR SHUTTERS - METHODS OF TESTS :IS 4020 (PART 2).

1. TESTS.
1.1 The door shutters shall be subjected to the following tests, in the order detailed below:
It may be noted that while all tests on all types of doors may not be necessary, only the required
tests on different doors may be performed for performance evaluation, which are given in the
individual specification on door shutters. The door shutters for the tests shall not be painted/
varnished.
1.1.1 General Precautions: The test specimens shall not have been exposed to a temperature below
4°C for 24 hours immediately preceding the test and shall be free from all visible moisture.
The specimen shall be inspected and any specimen with visible flaws shall be discarded.
1.1.2 If any test specimen falls because of mechanical reason, such as failure of testing equipment or
improper specimen preparation, it shall be discarded and another specimen taken.
` N O T E - In the case of a door shutter with rebated edges, the dimension of height or width should
be measured to the inner edges of the rebate.'
a) Dimensions and Squareness test : al)
Procedure:
a2) Measurement of Height: Measure the height along the lines A-A and B-B (see fig. a-1), each
of which is parallel to and 20 mm or less from a longitudinal ( height) edge. The height shall be
measured with an accuracy of 1 mm.
a3) Measurement of Width: Measure the width along the lines C-C and D-D ( see fig. a-1) each
of which is parallel to and 20 mm or less from a transverse ( width) edge. The width shall be
measured with an accuracy of 1 mm.
a4) Measurement of Thickness: Measure the thickness at six points which are located
approximately 20 mm from the edges, at the middle of the width of the door shutter and at each
one-third of the height ( see fig. a-1). The thickness shall be measured with an accuracy of 0.1
mm.
a5) Measurement Squareness: Determine the deviation from squareness of adjacent edges of the
door shutter at all the four corners of the door leaf with a square (gunia) with arms 500 mm long
(see fig. a-2). The deviation from squareness shall be measured to an accuracy of 0.1 mm.
b) General flatness test :
bi) Procedure:
b2) Measurement of Twist :The door shutter is held freely in a vertical plane or mounted vertically
so that there is no external restraint. Any three comers of this face determine a plane of reference.
The deviation of the fourth corner is measured with respect to this plane with a plumb bob or any
other suitable device (see Fig. b-1). The measuring points shall not be more than 20 mm from
the edges. It shall be measured to an accuracy of 1 mm.
b3) Measurement of Warping and Cupping
The door shutter is held as given in 1.1. Measurements) of warping and cupping on one of the
faces of the door shutters is measured with respect to straight lines parallel to each edge and
located 20 mm or less from the edge. The distance of the face from these straight lines is
measured ( see fig. b-2) . The deviation shall be measured to an accuracy of 1 mm.
c) Local planeness test : This test (IS :4020-Part 4) specifies method of test to ascertain the
general smoothness of the surface of the door shutters.
cl) Procedure: The door shutter shall be position or held freely in placed in a horizontal and
convenient position. Squares of 200 mm x 200 mm shall be drawn, spread over the entire area
of the shutter for measurement purposes. A suitable measuring device suitably fixed at the
centre of a straight edge of 150 mm length shall be placed on ten different squares on the face of
the door shutter. The depth at each point shall be measured to an accuracy of 0.1 mm.
c.2) Criteria of Acceptability: The ratio of the depth by length shall be ordinarily less than 1/100'
and is considered as most acceptable if it is less than 1/150.
d) Impact indentation test : This test (IS: 4020-Part 5) specifies two tests to determine the
impact indentation on door shutters.
di) Steel Ball Impact Test:
d2) Procedure: The door shutter shall be placed horizontally resting on a suitable frame equally on
all the four edges. A steel ball of about 50 mm diameter and weighing 500 ± 10 g, shall be allowed
to fall freely from a height of 750 ± 5 mm at any randomly selected 10 different points on both
the surfaces of the door shutter leaving distance of 75 mm from the edges. The depth of
indentation shall be measured to an accuracy of 0.1 mm.
d3) Criteria of Acceptability: On dropping the steel ball at any point there should be no abnormal
defects, such as cracking, tearing, or delamination's and no indentation more than 0.2 mm.
e) Flexure test: This test (IS: 4020-Part 6) specifies method of test for flexure resistance of
door shutters.
el) Procedure: The door shutter shall be held firmly along one long edge and the adjacent short
edge and it shall be ensured that the three fixed corners are in one horizontal plane.
Loading shall be done on the top corner of the door shutter 50 mm from the free edge, resulting
deformation in the vertical plane of the door shutter. The loading shall be done in steps of 100
N (10 kg 0 up to a maximum of 500 N (50 kg f) and unloaded after 15 minutes in the same steps.
The deflection shall be measured initially and after 15 minutes with the load and finally after 3
minutes of the removal of the load. All deflections of the free corner shall be measured to an
accuracy of 0.1 mm with reference to the diagonally opposite fixed corner.
e.2) Criteria of Acceptability: The following deflections of the free corner shall be obtained in
the order mentioned:
R1= Immediately after the door is placed and allowed to hold under its own weight by; R2=24
hours after the door is placed and allowed to hold under its own weight `this is recorded;
R3= After measuring R2 and immediately after placing a 50 kg weight on the free corner by
means of suitable hangers;
R4= 24 hours later. With load this is recorded;
R5= After measuring R4 and immediately after removal of the load; and
R6= 24 hours after removal of the load this is recorded.
The difference of deflection as indicated below shall not exceed the limits prescribed :
a) R2 - R1 shall not exceed 1/10'h of the deflection R2.
b) R4- R3 „ 1/15' „ R4.
c) R5 - R6 „ „ „ 1/10' „ „ „ R5.
d) Difference between R1 and R6 shall not be more than 0.1 cm.
If any of the values calculated in (a), (b), (c), or (d), exceeds the limits the test shall be repeated on the
opposite corner in the same direction by fixing the other two edges suitably , and the same
observations as above shall be made. The criteria at (a), (b), (c), or (d),above shall be satisfied , and
the permissible deflection for bending for 50 kg weight after 24 hours of loading (that is R4) shall be
not more than 1/40'h of the length and 1/20' of the width of the door.
f) Edge loading test:

f.l) Procedure: The door shutter shall be hung vertically, bearing or with 12 mm dia. Pivot supported at
the top and bottom or hinged on one longitudinal edge. The test set up shall be sufficiently rigid to
withstand the test load without deflecting to an extent likely to impair jointing or to impose bending
stresses on the test specimen. If installation conditions are known, the specimen shall wherever
practical, be installed to simulate these. The door shall be opened at an angle of 45° or 90° and
measurements taken at the lower corner of the door shutter, to the nearest 0.1 mm. The load shall be
applied on the top of the other longitudinal edge parallel to the plane of the door shutter at a distance
of 50 mm from the edge. The loading shall be done in steps of not more than 200 N.
f.2) Criteria of Acceptability: There shall be no visible damage in any part of the door after the
first fifteen blows on each end.
g) Shock resistance test : This test (IS: 4020-Part 8) specifies two tests for determining the resistance
of door shutters to shock. Both the tests as specified in g.l and g.3 are to be carried out.
g.l) Soft and Light Body Impact Test:
g.2) Procedure: The door shutter shall be hinged in a vertical plane flush with a fixed frame on
which door of various sizes can be mounted in a manner similar to their installation in practice. The
frame shall be sufficiently rigid so that any deformation that occurs in the frame during testing will
have negligible effect on the test results. The rope with a leather ball of approximately 200 mm in
dia. And containing 50 N (5 kg f) of sand hung vertically by a rope required for giving the shock. The
rope with the leather ball shall be tied on the central vertical line just above the door. The length of the
rope shall be such that the ball may strike the door at a point 200 ±10 mm above the bottom end on
the vertical central line of the door (see Fig. g-1). The ball shall be pulled away from the door to a
height of 1.25 m from the plane of striking place and shall be allowed to strike the door for twenty
five times at the rate of 4 to 5 shocks/minute.
g.3) Soft and Heavy Body Impact Test
: g4) Procedure :
An arrangement for mounting the door shutter as specified in g.l shall be made. A spherical leather
sail cloth bag of approximately 350 mm in diameter is filled with sand of apparent density
approx.1500 kg/m3 (sand which passes through a sieve of aperture size 2 mm) until it reaches a
mass of 300 N (30 kg O. The bag shall be hung as a pendulum arrangement to strike the door shutter
at the level of the handle in the position shown, and hung in such a way that when at rest the bag just
touches the shutter (see Fig. g-2). The normally hung shutter (with hangings, fixings and fastenings),
is given five impacts, of spherical leather bag at the handle level on both sides of the shutter.
g.5) Criteria of Acceptability: There shall be no visible damage in any part of the door after the
first fifteen blows on each end.
h) Buckling resistance test: This test (IS:4020 -Part 9) specifies method of test to determine the
resistance of door shutters to buckling.
h.1) Procedure : The door shutter shall be placed in a rigid rig and fixed in a way similar to actual
installation. The door shutter shall be opened to an angle of 90 ± 5° and secured at its top free corner
to prevent any lateral movement. A typical method of attachment of the load and its location is
shown in Fig. h-1 for guidance. A load of 400 N (40 kg f) is applied at 1000 ±5 mm from the bottom
of the door at right angles to the plane of the door shutter and in the direction of opening, in increments
of 100 N each. Incremental load is applied only after stabilization of the deformation created by the
previous loading. The deformation at the lower free corner is measured to an accuracy of 1 mm 5
minutes after the application of the load and 15 minutes after unloading.
i) Test Omitted
j) Slamming test: This test (IS: 4020-Part 10) specifies two tests to determine the effect on door
shutters due to slamming actions. Any one of the following tests shall be followed.
j.l) TEST- I:
j.2) Procedure: Suitable fixture shall be made to hold the door shutter horizontally flat and hinged
on one long edge and resting freely on a wooden rail 50 mm from the other long edge. The door
shutter shall be placed in a horizontal position suitably hinged at three equidistant
places or at the discretion of the manufacturer on one of the long edges. The other edge is lifted up so
as to form an angle of not less than 30° at the hinged edge and allowed to drop under its own weight,
50 times on the rail at the rate of 4-5 drops per minute.
j.3) TEST- II:
j.4) Procedure: Door shutter shall be hung with three hinges vertically on one long edge or as per
manufacturer's instructions in a suitable frame. Suitable arrangement to apply a force of 150 N (15 kg
0 to the shutter at not more than 150 mm from the locking edge of the shutter shall be made. The force
shall act perpendicularly to the plane of the frame throughout the closing movement (see Fig. j-1).The
door shutter shall be opened at an angle of 60 ± 5° and shall be made to close for hundred times by the
continuous application of a force of 150 N which ceases to act at the moment of impact.
j.5) Criteria of Acceptability: There shall be no visible damage caused in any part of the door by
the first fifty drops.
k) Misuse test: This test (IS: 4020-Part 11) specifies method of test to determine the resistance of
door shutters to misuse.
k.l) Procedure: Suitable frame to hold the door shutter vertically in a manner similar to its
installation in practice shall be made. The door shutter shall be hinged on one long edge to the frame.
A hard wood slip such as Laurel, Sal, Bijasal of 50 mm x 50 mm and of thickness,
adequate to match the thickness of the door shutter shall be placed vertically at the bottom of the
hinged stile of the frame in such a way as to keep the door open at 70 ± 5°. The force is applied
progressively to the handle or equivalent position and at right angles to the plane of the frame in the
direction of closing until it reaches 200 N (20 kg t) (see Fig. k-1).
1) Varying humidity test : This test(IS:4020-Part 12) specifies method which is to be used to test
the behaviour, under humidity variations, of door shutters placed in successive
uniform climates.
1.1) Procedure :The door shutter shall be placed in a conditioning chamber at a temperature 27°C ±
2°C, and humidity maintained at 30 ± 5 percent for one week. The height, width, thickness as per Part
2 of this standard, general flatness as per Part 3 of this standard, local planeness as per Part 4 of this
standard and diagonal of the door shutter shall be measured. Then the humidity shall be raised to 85 ±
5 percent and the door shutter shall remain there again for one week. Again, the length, breadth,
thickness and diagonal of the door shutter shall be measured. The changes in the above dimensions
shall be noted. After this, the door shutter shall be kept inside the chamber for one week at a humidity
level of 30 ± 5 percent.
The test may be stopped before the end of the period specified, if two successive measurements
of general flatness taken at 2 day interval, do not differ by more than 1 percent.
1.2) Criteria of Acceptability: There shall not be any visible warping, twisting or delamination and
where precision is required the maximum departure from the general planeness shall not be more
than 1.0 mm. The maximum increase of the size at the high humidity (RH=80 percent)shall not be
more than 0.5 percent and the recovery to the original size of the door again at the lower humidity
(RH=40 percent) shall be at least 90 percent.
m) END IMMERSION TEST Door shutters shall be tested for resistance of their base to
immersion in water as follows :
The door shutter shall be immersed vertically to a height of 30 cm in water at room temperature
for 24 hours and then allowed to dry for 24 hours at 27 ± 2°C and relative humidity of 65 ± 5
per cent. The cycle shall be repeated eight times. There shall be no delamination at the end of the
test.
n) KNIFE TEST
(i) Apparatus : The type of knife required to be used in the test is given in Fig. below. It may
be made from a 250 x 25 mm file. The cutting edge should be kept chisel sharp. The test
shall be carried out on a stout table to which a wooden batten is screwed against which
the edge of test piece is placed.
(ii) Procedure : The knife is inserted with its cutting edge parallel to the grain of the outer
veneer and worked into, or if possible along a glue line and the veneer is prised upwards. A
hard and dense specie of plywood requires considerable force to effect entry and to prise
and veneer. In a soft timber the knife tends to follow an easy course through the wood
and in this case it is essential that the knife be firmly guided along the glue line.
The bond should just pass the requirement, it is judged by the relative amount of wood
fibre left on the core veneer, and the area prised off. The grading is assessed chiefly on the
appearance of the break. The force needed to effect separation is also an accompanying
requirement.
The bond is èxcellent', when it is difficult to find the glue line and impossible to keep the
tool within it for more than 6 mm without cutting adjacent wood. On prising upwards, the
veneer usually breaks off over a width slightly greater than that of the tool.
The bond is `poor' when knife meets little opposition in the glue line and the prise results
in the easy removal of almost all the veneers from one side of the test piece. The separated
veneers are usually almost free from adherent fibre.
(iii) Reporting of test results : The results shall be reported as `pass standard' èxcellent' or
'poor'.
o) GLUE ADHESION TEST
Four square sections, 150 x 150 mm shall be cut from the corners of the door. These four corner
sections as cut from the door shall be immersed in boiling water for 4 hours, then dried at 27 ± 2°C
and relative humidity of 65 ± 5 per cent for 24 hours. At the end of the drying period, the samples shall
be examined for delamination. In the case of the glue lines in the plywood, all the four exposed edges
of the plywood on both faces of a specimen shall be examined for delamination.
A specimen shall be considered to have passed the test if no delamination has occurred in the glue lines
in the plywood and if no single delamination more than 50 mm in length and more than 3 mm in
depth has occurred in the assembly glue lines between the plywood faces and the stile and rail.
Delamination at the corner shall be measured continuously around the corner. Delamination at a knot,
knot hole, a pitch pocket and worm hole or other permissible wood defects shall not be considered
in assessing the sample. A door shall be deemed to have passed this test if three of the four specimens
tested pass the test.
p) Screw withdrawal resistance test: This test (IS:4020-Part 16) specifies method of test to
determine the screw withdrawal resistance of door shutters.
p.1) Procedure : This test shall be carried out on three test specimens of size 150 mm x 75 mm cut
along the longitudinal edge of upper/lower half portion of the door shutter, using a suitable test
equipment having an arrangement to pull the screws fixed on the specimen so as to measure the
maximum load required for complete withdrawal. Prior to testing, the test specimen shall be
conditioned at 27 ± 2°C and at relative humidity of 65 ± 5 percent for one week. Two pre bores of 3
mm diameter shall be made along the stile at an interval of 50 mm on the face and along the edges of
the specimen. Screws of size No. 8 and 50 mm length (see IS : 6760) shall be fixed at these points
to a depth of 25 mm. The specimen shall then be placed on the test equipment and load applied at the
specified rate of 2 mm per minute for withdrawal of one screw at a time. The maximum load required
for complete withdrawal shall be noted in each case.
APPENDIX - `F'
SCHEDULE OF FITTING FOR DOORS AND WINDOWS
Si. Name of Fittings Double Single Single Single Single Single Fan Desi- Length Rema-
No leaf leaf leaf leaf leaf leaf light/ gna- in mm rks
doors door door wire war- window clear tion no. of
shutters shutters shutters guaze drobe/ shutters storey of wood
panelled external inter door cup- panelled window wood screws
or panelled commu- shutters board or shutters screw IS
glazed or nicating shutters glazed 6760
glazed panelled
or
glazed
1 2 3 4 5 6 7 8 9 10 11 12
1. Butt Hinges 100 mm 3 3 3 - - - 9 40 6
2 Butt Hinges 75 mm - - - - - 2 2 8 20
3 Butt Hinges 50 mm - - - - 1 1 - 6 20 For
fixing
wooden
cleat
4 Piano Hinges - - - - - - - 6 20
5 Tower Bolt 250 mm 3 2 3 2 - 1 - 10 30
6 Tower Bolt 150 mm - - - - - 1 - 8 30
7 Tower Bolt 100 mm - - - - - - - 6 30
8 Sliding door Bolt 1 - - - - - - 9 35
300 mm
9 Sliding door Bolt - 1 - - - - - 9 35
250 mm
10 Floor door stopper 2 1 1 - 1 - - 9 30
11 Door handle with 2 2 2 1 - - - 6 25
plate 100 mm
12 Window handle - - - - - 1 - 6 20
with plate 75 mm
13 Casement stay - - - - - 1 - 6 30
300 mm
14 Helical door spring - - - 1 - - - 6 30
(Superior quality)
15 Cupboard - - - 1 1 - - 6 20
/Wardrobe Lock
16 Fanlight Catch - - - - - - 1 8 30
Notes
A : Door Shutters
1. Door of room adjoining the verandah, corridor, lobby or hall, shall be considered as external
door.
2. Where the height of the door leaf exceeds 2.15 metres above the floor level, one extra binge
shall be provided for every additional height of 0.50 metre, or part thereof and the length of top
bolts shall be increased by the height of the leaf above 2.15 metres from floor level.
3. Single leaf door shutters of more than 0.80 m in width shall be provided with one extra hinge.
4. Fan light shutters of more than 0.80 metre width shall be provided with one extra hinge and
extra quadrant stay.
5. In double leaf shutters of doors, two door bolts shall be fixed to the first shutter and one to
the closing shutter at the top.
6. In case of single leaf inter communicating, panelled, glazed or panelled door shutter for bath
and w.c. one tower bolts will be replaced by a bathroom latch.
7. For shutter exceeding 40 mm thickness, heavy type M.S. butt hinges of 125 x 90 x 4 mm
shall be used.
8. In case of external door shutters, instead of sliding door ball mortice lock can be provided
where specified.
9. Cupboard and wardrobe shutters will have ball catches where specified.
10. Finger plates shall be provided in case of bath and we shutters in office buildings.
B : Window Shutters
11. In case of windows with double shutters, two tower bolts shall be fixed to the closing
shutters and one tower bolt to the first shutter at the top.
12. In case of window shutters, hooks and eyes may be provided in lieu of casement stays where
specified.
13. Where the height of window shutter exceeds 1.20 metres one extra hinge shall be provided
and length of top bolts shall be increased by height of the leaf above 2.15 metres from the floor
level.
14. Window shutter with steel frames shall be provided with six hinges in case of double leaf
shutters and three hinges in case of single leaf shutters, irrespective of height and width of
shutters.
C : Fanlight and Clerestory Window or Ventilator
15. Centrally hung and bottom hung CS windows and fan lights, will be provided with chain and
hook bamboo pole with hook for opening ventilators shall be provided for each residence or for
set of 4 rooms in case of office building.
16. Centrally hung clerestory windows or fan lights will have fan light pivots in lieu of hinges.
APPENDIX -'G'
METHOD OF TEST FOR EDGE STRAIGHTNESS

AND SQUARENESS OF PLY WOOD
G-1PROCEDURE FOR EDGE STRAIGHTNESS
G-1.1 The straightness of the edge and ends of plywood shall be verified against a straight edge not
less than the full length of the plywood. If the edge on the end of the plywood is convex, it shall be
held against the straight edge in such a way as to give approximately equal gap at each end. The
largest gap between the straight edge and the edge shall be measured to the nearest millimetre and
recorded.
G.I.2 PROCEDURE FOR SQUARENESS

G.I.2.1 The squareness of plywood shall be checked with a 1200 mm x 1200 mm square by
applying one arm of the square to the plywood. The maximum width of the gap shall be recorded.
APPENDIX -'H'
METHOD FOR TEST FOR EDGE STRAIGHTNESS AND

SQUARENESS OF COIR VENEER BOARD
H-1 PROCEDURE FOR EDGE STRAIGHTNESS
H-1.1 The straightness of the edges and ends of coir veneer board shall be verified against a
straightedge not less than the full length of the coir veneer board. If the edge on the end of coir
veneer board is convex, it shall be held against the straight edge in such a way as to give
approximately equal gap at each end. The largest gap between the straightness and the edge shall be
measured to the nearest millimetre and recorded.
H-2 PROCEDURE FOR SQUARENESS
H-2.1 The squareness of coir veneer board shall be checked with a 1200 mm x 1200 mm square, by
applying one arm of the square to the coir veneer board. The maximum width of the gap shall be
recorded.
APPENDIX Ì'
METHOD OF TEST FOR COIR VENEER BOARD FOR
DETERMINATION OF GLUE SHEAR STRENGTH
I-1 OBJECT
I-1.1 This test is intended to estimate the tenacity with which the bonding material holds the coir
veneer board together.
I-2 TEST SPECIMEN
I-2.1 Six test specimens shall be cut from the coir veneer board from three locations separated by
the greatest possible distance from each other.
I-2.2 The test specimens shall be prepared as shown in Fig. 1 below.
I-2.3 The test pieces for 3 ply coir veneer board shall be prepared by gluing an additional 3 ply coir
veneer board as shown in Fig. 1A below. The test pieces for 5 ply shall be prepared as shown in Fig.
1B below. The test pieces for 7 ply coir veneer board shall be prepared as shown in Fig. 1C below.
The specimen is glued with room temperature setting epoxy resin and clamped/tied overnight.
Note - This method of preparation of specimen will avoid the failure on notches.
I-2.4 Before test, the specimen shall be conditioned to constant mass at relative humidity of 65 ± 5
per cent and at a temperature of 270° C ± 20°C.
I-3 PROCEDURE
I-3.1 Each test specimen shall be gripped symmetrically at two ends in the jaws of a suitable
testing machine, and shall be pulled apart. The distance between the notches on the test specimen and
the ends of the gripping jaws of the testing, machine shall be between 10 mm and 20 mm. The pull
should be, as far as possible, in the centre line of the central veneer. The grain of the centre ply shall
be perpendicular to the direction of application of load. The width of each specimen and distance
between the notches shall be measured to nearest 0.025 cm. to determine the shear area.
I-3.2 During the test, the load shall be applied to the test specimens as uniformly as possible, and
so adjusted as to have the traverse of the movable head of 1 mm/min.
I-3.3 The maximum load at the time of complete failure of each specimen shall be recorded.
Record shall be made regarding the type of failure whether in ply or in glue by visual examination of
the area under shear. In case of ply failure, the percentage ply failure shall also be recorded.
I-4 REPORT
I-4.1 Shear strength of the specimens determined in accordance with K-3 shall be straight averaged.
I-4.2 All details shall be recorded under the following sub-heads.

(a) Name of the manufacturer/source from whom the coir veneer board is procured
(b) Type and grade of coir veneer board
(c) Adhesive used
(d) End use of coir veneer board
(e) Specimen No. /Ref.
(f) Area of cross-section of bonding surface under shear
(g) Maximum load and
(h) Percentage failure of glue/ply
Material Test Field! Test Quantity Frequency of
Laboratory Procedure of Material for Testing
Test car rying out the
test
1 2 3 4 5 6
Timber Moisture Field Appendix 'C' 1 cum Every one cum
content (by moisture or part thereof.
meter)
laboratory
test as required
by Engineer-in-
Charge
Flush door End Laboratory IS 2202 26 shutters As per
immersion Test Appendix 'F' sampling
knife test and testing
Adhesion Test specified in
clause 10.7.13
Mortice Testing of Laboratory IS 2209- 50 Nos 100 or part
Locks spring Appendix 'G' thereof.
LIST OF RE LAVENT BU REAU OF INDIAN IAN STANDARD CODES

S. IS No. Subject
No.
1. 204 (Part I)-1978 Specification for tower bolts (ferrous bolt)
2. 204 (Part 11)-1978 Specification for tower bolts (non ferrous metals)
3. 205-1978 Specification for non ferrous metal butt hinges
4. 206-1981 Specification for Tee and strap hinges
5. 207-1964 Specification for Gate and shutter hook and eye
6. 208-1979 Specification for door handles
7. 281-1973 Specification for mild steel door bolts for use with pad locks
8. 287-1993 Recommendations for maximum permissible moisture contents of timber
used for different purpose
9. 303-1989 Specification for plywood for general purposes
10. 362-1982 Specification for parliament hinges
11. 363-1976 Specification for hasps and stapple
12. 364-1970 Specification for fan light catch
13. 401-2001 Code of practice for preservation of timber
14. 419-1967 Putty for use on window frames
15. 451-1999 Technical supply condition for wood screws
16. 452-1973 Specification for door spring rat tail type
17. 453-1973 Specification for double acting spring hinge
18. 707-1976 Glossary of terms applicable to timber technology and utilization
19. 710-2010 Specifications for Marine Plywood
20. 723-1972 Specification for steel counter sunk head wire nails.
21. 729-1979 Specification for drawer lock, cup board lock and box locks
22. 848-2006 Specification for synthetic resin adhesive for plywood (phenoic and amino
plastic)
23. 851-1978 Specification for synthetic resin adhesive for const. work (non structural in
wood)
24. 852-1994 Specification for animal glue for general wood work purpose
25. 1003 (Part I)-2003 Specification for timber panelled and glazed shutter Part I (door shutters)
26. 1003 (Part II)-1994 Specification for timber panelled and glazed shutter Part II (window and
ventilator shutter)
27. 1141-1993 Specification for code of practice for seasoning of timber
28. 1200 Part XIV-1984 Method of measurement of building and civil engineering work glazing.
29. 1200 Part XII-1976 Wood work and joinery
30. 1328-1982 Specification for veneered decorative plywood
31. 1341-1992 Specification for steel butt hinges
32. 1378-1987 Specification for oxidized copper finishes
33. 1566-1982- Specification for hard drawn steel wire fabric
34. 1568-1970 Specification for wire cloth for general purpose
35. 1658 Specification for hard drawn steel wire fabric
36. 1659-1979 Specification for block boards
37. 1708 (Part 1 to 18)- Testing of sma l clear specimen for timber
1986
38. 1734-1983 Determination of density and moisture content.
39. 1823-1980 Specification for floor door stopper
40. 1868-1996 Specification for anodic coating on aluminium and its alloy
41. 2046-1995 -do- Decorative thermosetting synthetic resin bonded laminated sheet
42. 2095 (P-1) -2011 Specification for gypsum plaster board.
43. 2096-1992 Specification for asbestos cement flat sheet.
44. 2202 (Pt I)-1999 Specification for wooden flush door shutter, solid core type (plywood face
panels )
45. 2202 (Part II )-1983 -do- (Particle boards and hard board face panels)
46. 2209-1976 Specification for mortice lock (Vertical Type )
47. 2380-1977 (p-1-21) Method of test for wood particle board and board for lignocelluloses
material
48. 2547-1976 Specification for gypsum plaster
49. 2753(p-1)-1991 Method for estimation of preservatives in treated timber and in treating
solutions.
50. 2681-1993 Specification for non-ferrous metal sliding door bolts use with pad locks
51. 3087-2005 Specification for wood particle boards (Medium density) for general
purpose.
52. 3097-2006 Specification for veneered particle board
53 3828-1966 Specification for ventilator chain
54 3400 (Part II)-2012 Method of test for Vulcanized rubber (hardness)
55. 3400 (Part IV)-2012 Accelerated aging of vulcanised rubber.
56. 3400 (Part IX)-2012 Density of vulcanised rubber
57. 3564-1995 Specification for door closer (hydraulically regulated)
58. 3618-1966 Phosphate treatment of iron and steel for protection against corrosion
59. 3813-1967 "C" hooks for use with swivels
60 3818-1992 Specification for continuous (Piano) hinges
61. 3847-1992 Specification for Mortice night latch
62. 4835-1979 Specification for polyvinyl acetate dispersion based adhesive for wood
63. 4948-2002 Specification for welded steel wire fabric for general use
64. 4992-1975 Specification for door handles for Mortice lock
65. 5187-1972 Specification for flush bolts
66 5509-2000 Specification for The Retardant Plywood
67. 5930-1970 Specification for Mortice latch
68. 6318-1971 Specification for plastic wire window fastners
69. IS 6607-1972 Specification for rebated Mortice lock (Vertical type)
70. 6760-1972 Specification for slotted counter sunk head wood screws.
71. 7196-1974 Specification for hold fast
72. 7534-1985 Specification for sliding locking bolts for use with pad lock
73. 7638-1999 Wood/lignocellulosic based panel products - Method for sampling
74. 8756-1978 Specification for Mortice ball catch for use in wooden almirah
75. 9308 (Part II)-1987 Specification for mechanically extracted coir fibres. (Mattress coir fibres)
76. 9308 (Part III)-1987 -do- Decorated coir fibre
77. 11215-1991 Moisture content of timber and timber products method of determination
78. 12049-1987 Dimensions and tolerance relating to wood based panel materials
79. 12406-2003 Specification for medium density fibre board
80. 12817-1997 Specification for stainless steel Butt Hinges
81. 12823-1990 Specification for wood products -Prelaminated particle Boards
82. 14616-1999 Specifications for laminated veneer lumber
83. 14842-2000 Specification for coir veneer board for general purposes
84. 14856-2000 Specification for glass fibre reinforced plastic (FRP) panel type door
85. 14900-2000 Specifications for transparent float glass
CHAPTER No. 11
STEEL WORK
CHAPTER No.11 : STEEL WORK
CONTENTS
Records of Amendments 2
11.0 Scope 3
11.1 Definitions/Terminology 3
11.2 Materials 3
11.3 Steel work in single sections fixed independently with 10
connecting plate
11.4 Steel Work in Built up Section (Riveted and Bolted) 11
11.5 Steel Work in Built up Section (Welded) 21
11.6 Collapsible Steel Gates 22
11.7 M.S. Sheet Sliding Shutter 23
11.8 M.S. Sheet Shutters 23
11.9 Rolling Shutters 25
11.10 Rolling Grills -Shutters 27
11.11 Steel Doors, Windows, Ventilators & Composite Units 27
11.12 T-fron Doors, Windows & Ventilators Frames 33
11.13 Pressed Steel Door Frames 34
11.14 Fabrication and Connection For Tubular Structure 36
11.15 Fan Clamps 39
11.16 Mild Steel Clamps and Rings For Chicks 39
11.17 Mild Steel Bars & M.S. Grills in Wooden or Steel Frames 40
11.18 M.S. Hollow Rectangular Door Frames (L-Type Section) 41
11.19 Factory Made Glazed Steel Doors, Windows and Ventilators 42
11.20 Steel Work Welded in Built Up Section for Hand Rail using
M.S. Tubular/ERW Tubular Pipes and G.I. Pipes. 42
11.21 Introduction to Pre Fabricated Steel Buildings 43
11.22 Design of Pre Engineered/Pre Fabricated Steel Buildings 44
Appendix A Mechanical Properties and Chemical Composition of Steel 49
Appendix B Welding Process 52
Appendix C Steel Tubes for Structural Purposes 53
Appendix D Shapes, Weights and Designation of M S Rolled Steel Section 55
Fig. 1 to 9 Welds and Rivets, Collapsible Steel Gate, Typical M.S. Sheet 58
Shutters, Doors, Windows and Ventilators, Fixing Butt Hinges to
T-fron Frame with M.S. Flat Welded to Frame, Pressed
Steel Door & Window Frames, Fan Clamps
List of Relevant Bureau of Indian Standards Codes 68
CHAPTER No. 11
STEEL WORK
11.0 Scope:
i) This chapter covers use of hot rolled steel section including tubes in general building
construction, in particular fabrication practices and connections. This is with the design codes,
one for general building construction and others for individual structures depending on loads,
service conditions, etc.
ii) There are three basic methods of connecting steel members through rivets, bolts and welding.
Thus, the grip bolts are being used in construction which reduces noise during fabrication on
site, and is based on the principle of friction through grip.
11.1 Definitions/ Terminology:
a) Bead: A single run of weld metal deposited on surface.
b) Butt Weld: A weld in which the weld metal lies substantially within the extension of the planes
arc the surfaces on the parts joined.
c) Crater: A depression left in weld metal where the arc was broken or the flame was removed.
d) End Crater: A crater at the end of a weld or at the end of a joint.
e) Fillet Weld: A weld of approximately triangular cross-section joining two surfaces approximately
at the right angles to each other in a lap joint, tee joint or corner joint. It is of two types:
(1) Continuous
(2) Intermittent.
f) Fusion Welding: Any welding process in which the weld is made between metals in a state of
fusion without hammering or pressure.
g) Non- fusion Welding: A term applied to the deposition, by the Oxy-Acetylene process of filler
metal on parent metal without fusion of the latter.
h) Oxy-Acetylene Pressure Welding: Pressure welding in which any Oxy-Acetylene flame is
used to make the surface to be united plastic. No filler metal is used.
i) Run: The metal deposited during one passage of the electrode or blow pipe in the making of a
joint.
j) Throat thickness: See Fig.l.
k) Weld: A union between two pieces of metal at faces rendered plastic or liquid by heat or
pressure, or both, Filler metal may be used to effect the union.
11.2. Materials:
11.2.1. Structural Steel: Structural steel shall conform to IS 8910-2010, IS 2062 -2006
(superseding IS 1977, IS 8500) and any other structural steel as specified with minimum guaranteed
yield point. The following definitions in addition to those given in the relevant parts of IS 1956 (p 1
to 5) -2003 shall apply.
a) Micro-Alloying Elements: Elements such as niobium, boron, vanadium and titanium added
singly or in combination to obtain higher strength to weight ratio and better toughness,
formability and weld ability as compared to unalloyed steel of similar strength level.
b) Weldability: A metallic substance is considered to be weld able by a given process and for the
given purpose, when metallic continuity to a stated degree can be obtained by welding using a
suitable procedure, so that the joints comply with the requirements specified in regard to both
their local properties and their influence on the construction of which they form a part.
c) Controlled Rolling: A hot rolling process in which the temperature of the steel and its
reduction ratio are controlled, particularly during the final rolling passes, in order to achieve
fine grain micro structure and optimum mechanical properties.
d) Normalizing Rolling: A hot rolling process in which the final rolling passes are carried out at
a suitable higher temperature, followed by cooling in natural air to a temperature below the
transformation temperature, in order to produce a structure, analogous to that obtained by a
separate normalizing treatment of hot rolled product.
e) Grades : There shall be nine grades of steel as given in Appendix À' (Tables 1 and 2).
While placing the order the steel should be designated by `Grade Designation'
f) Manufacture : The processes used in the steel making and further hot rolling into steel plates,
strips, sections, flats, bars, etc., are left to the discretion of the manufacturer/ supplier. If
required, secondary refining may follow steel making, as also normalizing rolling/ controlled
rolling during manufacturing of sections or as per the agreement between the purchaser and the
manufacturer/ supplier.
g) Freedom from Defects:
i) All finished materials shall be well and cleanly rolled to the dimensions, sections and
masses specified. The finished material shall be reasonably free from surface flaws;
laminations; rough/ jagged and imperfect edges and all other harmful defects.
ii) Minor surface defects may be removed by the manufacturer/supplier by grinding provided
the thickness is not reduced locally by more than 4 percent below the minimum specified
thickness. Reduction in thickness by grinding greater than 4 percent but not exceeding 7
percent may be made subject to mutual agreement between the purchaser and
manufacturer/supplier.
iii) Subject to agreement with the purchaser, surface defects which cannot be dealt with as
in clause g(ii) may be repaired by chipping or grinding followed by welding and
inspection by a mutually agreed procedure such that :
(a) After complete removal of the defects and before welding, the thickness of the item is
not to be reduced by more than 20 percent at any place.
(b) Welding is carried out by procedure approved by competent authority with approved
electrodes and the welding is ground smooth to the correct nominal thickness; and
(c) Subsequent to the finish grinding, the item may be required to be normalized or otherwise
heat- treated at the purchaser's discretion.
iv) Welding as mentioned in clause g(iii) is not permissible for grade designation E 250
material.
h) Chemical Composition: Ladle Analysis of the steel, when carried out by the method specified
in the relevant part of IS:228-1987(2002) or any other established instrumental /chemical
method, shall be as given in Table 1 ( Appendix-À') . In case of dispute, the procedure given
in IS:228-1987 and its relevant parts shall be the referee method and where test methods are
not specified shall be as agreed to between the purchaser and the manufacturer/supplier.
11.2.2. Rivets : Rivets shall conform to IS :1929 -1982 and IS:2155-1982 as appropriate. High tensile
steel rivet bars shall conform to IS:1149 - 1982. Hot rolled mild steel rivet bars shall conform to IS:
1148-1982.
11.2.3. Bolts:
a) These are of two types namely turned and fitted bolts and black bolts. Turned & fitted bolts are
turned to exact diameter in automatic lathe. For these bolts, whether reamed or drilled bolts,
the same unit stresses are allowed as for rivets. In case of black bolts which are not finished to
exact sizes, a lower working stress other than for turned bolts is adopted. They shall conform
to IS:1367-2002 Technical supply conditions for threaded steel fasteners.
b) Friction Grip Bolts:-High tensile friction grip nuts shall conform to IS 6623:1985 and high
tensile friction grip washers shall conform to IS 6649 :1985.
11.2.4. Welding Consumables (Electrodes): Covered electrodes shall conform to IS 814: 1991, or
IS 1278 : 1972. Electrodes for submerged arc welding shall conform to IS 7280 : 1974. Combination
of wire and flux shall satisfy IS 3613: 197 . Filler rods and bare electrodes for gas shielded metal arc
welding shall conform to IS 6419: 1974 and to IS 6560: 1972 as appropriate.
11.2.5. Steel Castings: Steel castings shall conform to grade 23-45 of IS 1030 : 1989.
11.2.6. Bolts and Nuts: Bolts and nuts shall conform to IS 1363 (Parts 1, 2, 3) : 1992. IS 1364
(Part 1, 2 , 3) : 1992, IS 1367 ( Part 3) : 1991, and IS 3640 : 1982 as appropriate.
11.2.7. Washers : Washers shall conform to IS 5369: 1975, IS 5370: 1969, IS 5374: 1975 and IS
6610 : 1972, as appropriate.
11.2.8. Cement Concrete: Cement concrete used in association with structural steel shall conform to
IS 456 : 2000.
11.2.9. Hot Rolled: Hot rolled sections shall conform to Indian Standards. It also lists other
relevant Indian Standards and Handbooks prepared so far in relation to steel construction.
11.2.10-Selection and Preparation of Test Samples:
11.2.10.1- The position from which test samples are taken samples which may be required shall be
so located in the product as to yield the clearest possible information regarding properties in the
cross-sectional and longitudinal planes . The recommended locations for taking test samples for
plates, sections and bars are indicated in Fig. 1. Alternatively, in case of sections, the samples may
be taken from the web.
11.2.10.2 Wherever practicable, the rolled surface of the steel shall be retained on the two opposite
sides of the test samples.
11.2.10.3 In case of flat test samples for tensile test, both surfaces are normally to be left on the test
samples for strips and plates up to 32 mm thick. At least one rolled surface shall be left on
rectangular test samples taken from plates exceeding 32 mm in thickness. Round test samples are
permitted, but should only be adopted for thickness exceeding 28 mm.
11.2.10.4 In case of flats up to 16 mm thick, the test sample shall undergo, if possible, no machining
whatever prior to use as a test piece. If this is not possible, the test sample shall undergo the
minimum amount of machining.
11.2.10.5 Bars below 28 mm shall be tested without the machining. In case of bars having diameters
thickness between 28 mm and 71 mm, the bars may be symmetrically reduced by machining. For
bars having diameters or thicknesses exceeding 71 mm, the test sample may be taken from the
position shown in Fig. as under.
11.2.10.6 In case of plates, strips, sections and flats, bend tests shall be carried out on rectangular
test samples which, as far as possible, should be of the full thickness of the product. In case of
plates, sections and flats exceeding 28 mm in thickness, it is permissible to. remove metal from one
side of the test sample before' using it as a test piece. The rolled surface of the test piece shall be on
the outer side of the bend during the test.
11.2.10.7 Before test samples are detached, full particulars regarding cast number, size and mass of
plates, strips, sections, flats and bars in each cast shall be furnished by the manufacturer to the
purchaser. In case of plates, the number of plates in each cast shall also be given.
11.2.10.8 Test samples shall be cut in such a manner that the deformation is avoided as far as
possible. If shearing or flame-cutting is employed, an adequate allowance shall be left for removal by
machining.
11.2.10.9 Test samples shall not be subjected to heat treatment unless the material from which they
are cut is similarly treated, in which case the test samples shall be similarly and simultaneously treated
with the material before testing. Any slight straightening of test samples which may be required shall
be done cold.
11.2.10.10-Tensile Test:
a) Number of Tensile Tests
b) Plates, Strips, Sections (Angles, Tees, Beams, Channels, etc.) and Fiats : One tensile test shall
be made from finished steel for every 50 tonne or part thereof rolled continuously from each
cast, a separate test being made for each class of steel product (namely, plates, strips, sections
and flats) rolled from a cast.
i) Where plates, strips, sections or flats of more than one thickness are rolled from the same
cast, one additional tensile test shall be made from the material in each class of product
for each variations in thickness of 6 mm.
ii) Bars (Round, Square and Hexagonal) : One tensile test shall be made from finished
product for each 50 tonne or part thereof. If more than one diameter or thickness of the
bar is processed, one additional tensile test shall be made for each variation of 3 mm
above or below the diameter or thickness of the bar ordered.
11.2.10.11 Tensile Test Pieces : The tensile strength, yield strength and percentage elongation of steel
shall be determined from standard test pieces cut crosswise from plates and strips and lengthwise
from sections, flats and bars. The test shall be carried out on the standard test pieces prepared in
accordance with IS 1608
a) As a rule, test pieces with a proportional gauge length complying with the requirements Lo=
5.65 Sa should be used for the tensile test, where Lo is the gauge length and So is the cross
sectional area of the test piece.
b) Test pieces with a non-proportional gauge lengths, other than 5.65 Sa , may also be used
in which case the elongation values shall be converted to 5.65 So in accordance with IS 3803
(Part I).
11.2.10.12 Tensile Test :
Tensile strength, yield strength and percentage elongation when determined in accordance with IS
1608 shall be as given in Table 2 (Appendix 'A').
a) In case of sections the thickness of which is not uniform throughout the profile, the limits of
sizes given in Table 3 shall be applied according to the actual maximum thickness of the piece
adopted for testing.
b) Should a tensile test piece break outside the middle half of the gauge length (see IS 1608) and
the percentage elongation obtained is less than that specified, the test may be discarded at the
manufacturer's option and another test made from the sample plate, strip, section, flat or bar.
11.2.11- BEND TEST
11.2.11.1- Number of Bend Tests
Bend test shall be made from finished steel from each cast. The number of tests for every 50 tonne
of material or part thereof, rolled continuously, shall be as given below. One additional test shall be
made for each class of product and for each variation of thickness.
Class of Steel Product Number of Bend Tests
Plates, strips One crosswise
Sections One lengthwise for each type
Flats and bars (round, hexagonal, etc.) One lengthwise
11.2.11.2- Bend Test Piece : The test pieces shall be cut crosswise from plates and strips and
lengthwise from sections, flats and bars. When section permits, these shall be not less than 40 mm
wide. If the manufacturer so desires, round, square, hexagonal and flat bars and structural sections
shall be bent in the full section as rolled.
a) In all bend test pieces, the rough edge or arris resulting from shearing may be removed by
filing or grinding or machining but the test pieces shall receive no other preparation.
b) Bend Test : Bend test shall be conducted in accordance with IS: 1599-2012
c) For bend test, the test piece at room temperature shall withstand bending through 180° to an
internal diameter not greater than that given in Table 2 without cracking.
11.2.12- Impact Test:
11.2.12.1 Impact test shall normally be carried out on products having thickness/diameter greater
than or equal to 12 mm. The test specimen shall be so machined that the is of the test specimen is
parallel to the direction of rolling and the base closer to the rolled surface is more than 1 mm from
it. The notch a s shall be perpendicular to the rolled surface.
a) If stated in the order, impact tests may be carried out on products having a thickness less than 12
mm; the dimensions of the test pieces shall be in conformity with IS 1757 (see also Note of
Table 2).
11.2.12.2- This test is carried out using a V-notch test piece (see IS 1757) the value for consideration
being the arithmetic mean of the results obtained on three test pieces taken-side by side from the
same product (see Table 2 of IS 1757).
11.2.12.3 -The test sample shall be taken from the thickest product. If the test sample taken from the
thickest product rolled from a cast meets the requirements, the whole cast shall be deemed to meet
the requirements of the test. If not, the test shall be performed on a section of next lower thickness
rolled from the same cast and if it meets the requirements specified, this particular thickness as also
other sections of lower thickness shall be deemed to satisfy the specification. If this thickness also
does not meet the requirements, the test shall be carried out on the next lower thickness and so on,
because the toughness of the product will be dependent on the rolling direction as well as on the
section size.
a) A test sample shall be taken from each 50 tonne or part thereof from the same cast.
11.2.12.4 -The material represented shall be deemed to comply with the standard, if the average
value of 3 test specimens, meets the requirements given in Table 2 (page 50) provided no individual
value shall be less than 70 percent of the specified value. If the average value of the three charpy
impact tests fails to comply by an amount not exceeding 15 percent of the specified minimum
average value, three additional test pieces from the same sample shall be tested and the results added
to those previously obtained and a new average calculated. Provided this new average complies with
the specified requirement, the material represented shall be deemed to comply with this standard.
11.2.13- Y Groove Crackability Test: Y groove crackability tests may be carried out in accordance
with IS 10842-2006 for products of only Grade C material having thickness above 12 mm, if
specifically agreed to between the manufacturer and the purchaser.
NOTE- The Y groove crackability test will not be applicable for rounds and it is mainly for plates and
sections.
11.2.14 -Dimensions: Unless otherwise agreed to between the purchaser and the manufacturer, the
nominal dimensions of rolled products conforming to this standard shall be in accordance with the
relevant Indian Standard. Currently available Indian Standards are listed in Table as under.
11.2.15- Tolerances: The rolling and cutting tolerances for steel products conforming to this
standard shall be those specified in IS 1852. Stricter tolerances may be followed if agreed to between
the purchaser and the manufacturer.
11.2.16- Retest: Should any one of test pieces first selected fail to pass any of the tests specified in
this standard, two further samples shall be selected for testing in respect of each failure. Should the test
pieces from both these additional samples pass, the material represented by the test samples shall be
deemed to comply with the requirements of that particular test. Should the test pieces from either of
these additional samples fail, the material represented by the test samples shall be considered as not
having complied with this standard.
Table : Indian Standards Which Give Nominal Dimensions of Rolled Steel Products
Product Relevant Indian Standard
(1) (2)
Beam, column, channel IS 808 : 2004 Dimensions for hot rolled
and angle sections steel beam, column, channel and angle
sections (third revision)
Tee bars IS 1173 : 1978 Hot rolled slit steel tee bars
(second revision)
Bulb angles IS 1252 : 1991 Hot rolled steel bulb
angles-Dimensions (first revision)
Plates, strips and flats IS 1730 : 1989 Steel plates sheet&, strips
and flats for structural and general engineering
purposes (second revision)
Round and square bars IS 1732 : 1989 Dimensions for round and
Square steel bars for structural and
general engineering purposes (first revision)
Bulb flats IS 1863 : 1979 Hot rolled steel bulb flats
(first revision)
Sheet piling sections IS 2314 : 1986 Steel sheet piling sections
(first revision)
Channel sections IS 3954 : 1991 Hot rolled steel channel
sections for general engineering purposes
(first revision).
Track shoe sections IS 10182 (Part I) : 1982 Dimensions and
tolerances for hot rolled track shoe sections
: Part I Section TS-LI
IS 10182 (Part 2) : 1985 Dimensions and
tolerances for hot rolled track shoe sections :
Part 2 Section TS-HI
11.3. Steel Work in Single Section, Fixed Independently with Connecting Plate: The steel work
in single sections of R.S. joists, flats, tees, angles fixed independently with or without connecting
plate, is described in these clauses.
11.3.1. Fabrication:
i) The steel sections as specified shall be straightened and cut square to correct lengths and
measured with a steel tape. The cut ends exposed to view shall be finished smooth. No two
pieces shall be welded or otherwise jointed to make up the required length of a member.
ii) All straightening and shaping to form, shall be done by pressure. Bending or cutting shall be
carried out in such a manner as not to impair the strength of the metal.
11.3.2. Painting: All surfaces which are to be painted, oiled or otherwise treated shall be dry and
thoroughly cleaned to remove all loose scale and loose rust. Surfaces not in contact but inaccessible
after shop assembly, shall receive the full specified protective treatment before assembly. This does
not apply to the interior of sealed hollow sections. Part to be encased in concrete shall not be painted
or oiled. A priming coat of approved steel primer i.e. Red Oxide Zinc chrome primer conforming to
IS : 2074-1992 shall be applied before any member of steel structure are placed in position or taken
out of workshop.
11.3.3. Erection: Steel work shall be hoisted and erected in position carefully without any damage to
itself and other building work and injury to workmen. Where necessary mechanical appliances such
as lifting tackle, winch etc. shall be used. The suitability and capacity of all plant and equipment
used for erection shall be to the satisfaction of the Engineer-in-Charge.
11.3.4. Measurements:
i) The work as fixed in place shall be measured in running metres correct to a millimetre and
weights calculated on the basis of standard tables correct to the nearest kilogram .The standard
weight of steel sections shall conform to IS 808 with tolerance in sizes as per IS 1852. Tolerance
in weight is given in Table 3 ( Appendix À'). Steel sections shall be acceptable within tolerance
limits. Payment for steel sections shall be made as per actual weight within tolerances. Sections
having weight on higher side than permissible tolerance, may be acceptable but payment shall
be made on the basis of standard weight only. Steel sections having weight variations lower side
than permissible variation shall not be acceptable.
ii) Unless otherwise specified, weight of cleats, brackets, packing pieces, bolts, nuts, washers,
distance pieces, separators, diaphragm gussets ( taking overall square dimensions) fish plates,
etc. shall be added to the weight of respective items. In riveted work, allowance is to be made
for weight of rivet heads. Unless otherwise specified an addition of 2.5 % of the weight of
structure shall be made for shop and site rivet heads in riveted steel structures.
iii) No deduction shall be made for rivet! or bolt holes (excluding holes for anchor or holding
down bolts).
iv) Deduction in case of rivet or bolt hole shall however be made if its area exceeds 0.02 sqm.
v) The weight of steel sheets, plates and strips shall be taken from relevant Indian Standards
based on 7.85 kg/ m2 for every millimetre sheet thickness, For rolled sections, steel rods and
steel strips, weight given in relevant Indian Standards shall be used.
11.3.5. Rate : Rate includes the cost of labour and materials required for all the operations described
above.
11.4. Steel Work in Built up Sections (Riveted & Bolted):
The steel work in built up sections (Riveted and bolted ) such as in trusses, framed work etc. is
specified in this clause.
11.4.1 Laying Out: A figure of the steel structure to be fabricated shall be drawn on a level platform
to full scale. This may be done in full or in parts, as shown on drawings or as directed by the
Engineer-in-Charge. Steel tape shall be used for measurements
11.4.2 Fabrication and Erection:
i) Fabrication shall generally be done as specified in IS : 800 - 1984. In major works or where so
specified, shop drawings giving complete information for the fabrication of the component
parts of the structure including the location, type, size, length and details or rivets, bolts or
welds, shall be prepared in advance of the actual fabrication and approved by the Engineer-in-
charge. The drawings shall indicate the shop and field rivets, bolts and welds. The steel
members shall be distinctly marked or stencilled with paint with the identification marks as
given in the shop drawings.
ii) Great accuracy shall be observed in the fabrication of various members, so that these can be
assembled without being unduly packed, strained or forced into position and when built up,
shall be true and free from twist, kinks, buckles or open joints.
iii) Wooden or metal sheet templates shall be made to correspond to each member, and position of
rivet holes shall be marked accurately on them and holes drilled. The templates shall then be
laid on the steel members, and holes for riveting and bolting marked on them. The ends of the
steel members shall also be marked for cutting as per required dimensions. The base of steel
columns and the positions of anchor bolts shall be carefully set out at the required location.
11.4.2.1 General: As much fabrication work as is reasonably practicable shall be completed in the
shops where steel work is fabricated. Tolerances for fabrication of steel structures shall conform to IS
7215: 1974. Tolerances for erection of steel structures shall conform to IS 12843 : 1989. For general
guidance on fabrication by welding reference may be made to IS 9595 : 1980.
11.4.2.2. Minimum Thickness of Metal - Corrosion Protection:
(a) Steel work exposed to weather: - Where steel work is directly exposed to weather and is fully
accessible for cleaning and repainting, the thickness shall be not less than 6 mm; and where
steel is exposed to the weather and is not accessible for cleaning and painting, the
thickness shall not be less than 8 mm. This shall not apply to hot rolled sections covered by
Indian Standards.
(b) Steel work not Directly exposed to the weather:- The thickness of steel work not directly
exposed to the weather shall be not less than 6 mm. The thickness of steel in secondary
members shall be not less than 4.5 mm. For hot rolled sections, the mean thickness of flange
be considered and not the web thickness.
These requirement of (a) and (b) do not apply to light structural work or to sealed box section or to
steel work in which special provision against corrosion has been made, also in case of steelwork
exposed to highly corrosive industrial fumes or vapour or saline atmosphere, the minimum thickness
shall be as agreed to between the customer and designer.
11.4.2.3. Fabrication Procedures:
(a) Straightening - All material shall be straight and, if necessary, before being worked shall be
straightened and / or flattened by pressure, unless required to be curve linear and shall be free
from twists. These shall be cut square either by shearing or sawing to correct length and
measured by steel tape. No two pieces shall be welded or joined to make up for the required
length of member.
(b) Clearances - The erection clearance of cleated end of members connecting steel to steel should
preferably be not greater than end of beams without web cleats should be not more than 3 mm
at each end, but where, for practical purposes, greater clearance is necessary, suitably designed
seating's should be provided. Where black bolts are used, the diameter of holes shall be
generally 1.5 mm more than the diameter of permanent bolts and 3 mm more than diameter of
erection bolts.
(c) Cutting:
(i) Cutting may be effected by shearing, cropping or sawing. Gas cutting by mechanically
controlled torch may be permitted for mild steel only . Gas cutting of high tensile steel may
also be permitted provided special care is taken to leave sufficient metal to be removed by
machining so that all metal that has been hardened by flame is removed. Hand flame cutting may
be permitted subject to approval by the authority.
(ii) Except where material is to be subsequently joined by welding, no loads shall be transmitted
in to metal through a gas cut surface.
(iii) Shearing, cropping and gas cutting shall be clean, reasonably square, and free from any
distortions and should the Authority find it necessary, the edges shall be ground after wards.
(d) Making Holes:
(i) Holes through more than one thickness of material for members, such as, compound
stanchion and girder flanges shall, where possible, be drilled after the members are
assembled and tightly clamped or bolted together. Punching may be permitted before
assembly, provided the holes are punched 3 mm less in diameter than the required size
and reamed after assembly to the full diameter. The thickness of material punched shall
not be greater than 16 mm. For dynamically loaded structures, punching shall be avoided.
(ii) When holes are drilled in one operation through two or more separable parts, these
parts, when so specified, shall be separated after drilling and the burrs removed.
(iii) Holes in connecting angles and plates other than splices, also in roof members and light
framing, may be punched full size through material not over 12 mm thick, except when
required for close tolerance bolts or barred bolts.
(iv) Matching holes for rivets and black bolts gauge of 1.5 mm or 2.00 mm (as the case may
be depending on the diameter of rivet or bolt is less than or more than 25 mm) less in
diameter than the diameter of the holes will pass freely through the assembled members
in the direction at right angle to such members. Finished holes shall be not more than 1.5
mm or 2.0 mm (as the case may be) in diameter larger than the diameter of the rivet or
black bolt passing through them, unless otherwise specified.
(v) Holes for turned and fitted bolts shall be drilled to a diameter equal to the nominal
diameters of the shank or barrel subject to tolerance specified in IS: 919 ( Part 1): 1993.
Part to be connected with close tolerance or barrel bolts shall preferably be tightly held
together through all the thickness at one operation and subsequently reamed to size. All
holes not drilled through all the thickness in one operation shall be drilled to a smaller
size and reamed out after assembly. Where this is not practicable, the parts shall be drilled
and reamed separately through hard bushed steel jigs. Holes for turned and fitted bolts
shall be drilled or reamed large by 0.2 to 8 mm depending upon the dia. of bolts.
(vi) Holes for rivets or bolts shall not be formed by gas cutting process.
(vii) Holes shall have their axis perpendicular to the surface bored through. The drilling or
reaming shall be free from burrs, and the holes shall be clean and accurate.
(viii) Holes for counter sunk bolts shall be made in such a manner that their heads sit flush
with the surface after fixing.
e) Assembly:
i) Before making holes in individual members, for fabrication and steel work intended to
be welded or bolted together shall be assembled and clamped properly and tightly so as
to ensure close abutting, or lapping of the surfaces of the different members. All stiffeners
shall bear tightly both at top and bottom without being drawn or caulked. The abutting
joints shall be cut or dressed true and straight, and fitted close together.
ii) Web plates of girders, which have no cover plates, shall have their ends flush with the
tops of angles unless otherwise required. The web plates when spliced, shall have
clearance of not more than 5 mm. The erection clearance for cleated ends of members
connecting steel to steel shall preferably be not greater than 1.5 mm. The erection
clearance at the ends of beams without web cleats shall not be more than 3mm at each
end but where for practical reasons, greater clearance is necessary suitably designed seating
shall be provided.
iii) Column splices and butt joints of struts and compression members depending on contact
for stress transmission shall be accurately, machined and close butted over the whole
section. In column caps and bases, the ends of shafts together with the attached gussets,
angles, channels etc. after riveting together shall be accurately machined so that the parts
connected, butt against each other over the entire surfaces of contact. Connecting angles
or channels shall be fabricated and placed in position with great accuracy so that they are
not unduly reduced in thickness by machining.
iv) The ends of all bearing stiffeners shall be machined or grounded to fit tightly both at top
and bottom.
f7 Riveting: Rivets shall be used, where the connection is such that slip under load has to be
avoided.
(i) Rivets shall be heated red hot uniformly throughout their length without burning or
excessive scaling and shall be of sufficient length to provide a head of standard
dimensions. They shall when driven, completely fill the holes, and if countersunk, the
countersunk shall be fully filled by the rivet; any protrusion of the countersunk head
being dressed off flush, if required.
(ii) Preliminaries before Riveting: Riveted members shall have all parts firmly drawn and
held together before and during riveting, and special care shall be taken in this respect for
all single riveted connection. For multiple riveted connections, a service bolt shall be
provided in every third of fourth hole.
(iii) Wherever practicable, machine riveting shall be carried out by using machines of the
steady pressure type. However, where such facilities are not available, hand riveting may
be permitted by the Engineer-in-charge.
(iv) All loose, burned or otherwise defective rivets shall be cut out and replaced before the
structure is loaded, and special care shall be taken to inspect all single riveted
connections.
(v) Special care shall be taken in heating and driving long rivets.
For testing rivets, a hammer weighing 0.25 kg shall be used and both heads of the rivet
(specially the machine head) shall be tapped. When so tested, the rivets shall not give a
hollow sound and ajar. Where so specified other tests shall be carried out to ensure the
soundness of rivets. All rivets heads shall be painted with approved steel primer paint
within a week of their fixing.
g) Bolting:
i) The nominal length of the bolt shall be the distance from the underside of the head to the
further end of the shank. The nominal diameter of the bolt shall be the diameter at the
shank above the screwed threads. Bolts, nuts and washers shall be thoroughly cleaned
and dipped in double boiled linseed oil, before use. All bolts heads and nuts shall be
hexagonal unless specified otherwise. The screwed threads shall conform to IS 1363(P-
1)-2002 and the threaded surface shall not be tapered. The bolts shall be of such length
as to project at least two clear threads beyond the nuts when fixed in position, and these
shall fit in the holes without any shake. The nuts shall fit in the threaded ends of bolts
properly.
ii) Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads
and nuts of bolts a satisfactory bearing. The threaded portion of each bolt shall project
through the nut at least two thread. In all cases where the full bearing area of the bolt is
to be developed, the bolt shall be provided with a washer of sufficient thickness under
the nuts to avoid any threaded portion of the bolt being within the thickness of the parts
bolted together.
iii) Where there is a risk of the nuts being removed or becoming loose due to vibrations or
reversal of stresses, these shall be secured from slackening by the use of lock nut, spring
washers as directed by the Engineer-in-charge.
h) Welding :
(i) Welding shall be in accordance with IS 816 : 1969, IS 819 : 1957, IS 1024: 1979, IS
1261 : 1959, IS 1323 : 1982 and IS 9595 : 1980 as appropriate.
(ii) For welding any particular type of joint. Welders shall give evidence acceptable to the
Authority of having satisfactorily completed appropriate test as described in any of the
Indian Standards, namely, IS 817 (Part I ) : 1992, IS 1393 : 1961, IS 7307 (Part I) : 1974,
IS 7310 (Part I) : 1974 and IS 7318 ( Part 1) : 1974 as appropriate.
i) Erection:
i) Steel members shall be hoisted and erected in position carefully, without any damage to
itself, other structures and equipment and injury to workmen. The method of hoisting and
erection proposed to be adopted by the contractor shall be got approved from the
Engineer-in-charge in advance. The contractor however shall be fully responsible for the
work being carried out in a safe and proper manner without unduly stressing the various
members and proper equipment such as derricks, lifting tackles, winches, ropes etc. shall
be used.
ii) The work of erection may be done in suitable units as may be directed by the Engineer-
in- charge. Fabricated members shall be lifted at such points so as to avoid deformation
or excessive stress in members. The structure or part of it placed in position shall be
secured against over-turning or collapse by suitable means.
iii) During execution, the steel members shall be securely bolted or otherwise fastened when
necessary temporarily braced to provide for all loads including those due to erection
equipments and its operation to be carried safely by structure during erection. The steel
members shall be placed in proper position as per approved drawing, final riveting or
permanent bolting shall be done only after proper alignment has been checked and
confirmed.
iv) Trusses shall be lifted only at nodes. The trusses above 10 m in span shall not be lifted
by slinging at two mid points of rafters, which shall be temporary braced by a wooden
member of a suitable section. After the trusses are placed in position, purlins and wind
bracings shall be fixed as soon as possible.
v) The end of the truss which faces the prevailing winds shall be fixed with holding down
bolts, and the other end kept free to move. In case of trusses of spans up to 10m the free
end of the truss shall be laid on lead sheet or steel plate as per design, and the holes for
holding down bolts shall be made in the form of oblong slots so as to permit the free
movements of the truss end. For larger spans the truss shall be provided with proper bearing
as per design.
Columns and stanchions shall be erected truly vertical with the necessary cross bracing etc.
and the base shall be properly fixed with the foundation concrete by means of anchor bolts
etc. as per drawing.
Anchor bolts to be placed in the concrete foundation should be held in position with a
wooden template. At the time of concreting anchor bolt locations shall be provided
with suitable timber mould or pipe sleeve to allow for adjustment which shall be removed
after initial setting of concrete. The spaces left around anchor bolts shall be linked to a
stopping channel in the concrete leading to the side of the pedestal and on the underside
of the base plate to allow the spaces being grouted up after the base plate is fixed in the
position along with the column footing. Grouting shall be of cement mortar 1:3 (1 cement:
3 coarse sand) or as specified.
j) Bedding of Column, Stanchions etc.:-
i) Bedding shall not be carried out until the steel work has been finally levelled, plumbed
and connected together. The stanchion shall be supported on steel wedges and adjusted to
make the column plumb. For multi storied buildings, the bedding shall not be done until
sufficient number of bottom lengths of stanchions have been properly lined, levelled and
plumbed and sufficient floor beams are fixed in position. The base plates shall be wedged
clear of the bases by M.S. wedges and adjusted where necessary to plumb the columns.
The gaps under the base plate may be made up to 25 mm which shall be pressure grouted
with cement grouts.
ii) With small columns, if permitted by the Engineer-in-charge, the column base shall be
floated on a thick cement grout on the concrete pedestal. The anchor bolt holes in the
base plate may be made about 10 to 15 mm larger than the bolts. In such cases suitable
washers shall be provided.
k) Machining of Butts, Caps and Bases:
(i) Column splices and butt joints of struts and compression members depending on contact
for stress transmission shall be accurately machined and closed butted over the whole
section with a clearance not exceeding 0.2 mm locally at any place. In column caps and
bases, the ends, of shafts together with attached gussets, angles, channels, etc, after
riveting together should be accurately machined so that parts connected butt over entire
surfaces of contact. Care should be taken that these gussets, connecting angles or
channels, are fixed with such accuracy that they are not reduced in thickness by
machining more than 2.0 mm.
(ii) Where sufficient gussets and rivets or welds are provided to transmit the entire loading,
the column ends need not be machined, the design of column members should cover this.
(iii) Ends of all bearing stiffness shall be machined or ground to fit tightly both at top and
bottom.
(iv) Slab bases and caps, except when cut from material with true surfaces, shall be accurately
machined over the bearing surfaces and shall be in effective contact with the end of the
stanchion. A bearing surface which is to be grouted direct to a foundation need not be
machined if such face is true and parallel to the upper face.
(v) To facilitate grouting, holes shall be provided where necessary in stanchion bases for
the escape of air.
L) Solid Round Steel Columns:
(i) Solid round steel columns with shouldered ends shall be provided with slab caps and shall
be tightly shrunk or welded in position.
(ii) The tolerance between the reduced end of the shaft and the hole in case of slabs welded
in position, shall not exceed 0.25 mm.
(iii) Where slabs are welded in position, the reduced end of the shaft shall be kept just
sufficiently short to accommodate a fillet weld around the hole without weld metal being
proud of the slab. Alternatively, the caps and bases may be directly welded to the column
without bearing or shouldering. All bearing surfaces of slabs intended for metal to metal
contact shall be machined perpendicular to the shaft.
11.4.3 Painting: Painting shall be done as prescribed in IS 1477 (Parts 1 and 2) : 1971.
(i) All surfaces to be painted, oiled or otherwise treated shall be dry and thoroughly cleaned to
remove all loose scale and loose rust.
Shop contact surfaces need not be painted unless specified. If so specified, they shall be brought
together while the paint is still wet.
Surfaces not in contact, but inaccessible after shop assembly shall receive the full specified
protective treatment before assembly. This does not apply to the interior of hollow sections (see
IS 3202: 1981).
(iv) Chequered plates (see IS 3502: 1981) shall be painted but the details of painting shall be
specified by the Authority.
(v) In case the surfaces are to be welded, the steel shall not be painted or metal coated within a
suitable distance of any edges to be welded, if the paint specified or metal coating would be
harmful to the welders or impair the quality of welds.
(vi) Welds and adjacent parent metal shall not be painted prior to de - slugging, inspection and
approval.
(vii) Parts to be encased in concrete shall not be painted or oiled.
11.4.4 Marking: Each piece of steel work shall be distinctly marked before delivery, and bear
such other marks as in accordance with a marking diagram as well to facilitate erection.
11.4.5 Shop Assembly:
(i) The steel work shall temporarily shop assembled complete or as arranged with the Authority
so that accuracy of fit may be checked before dispatch. The parts shall be shop assembled with
sufficient numbers of parallel drifts to bring and keep the parts in place.
(ii) In case of parts drilled or punched, through steel jigs with bushes resulting in all similar parts
being interchangeable the steel work may be shop erected in such position as arranged with the
authority.
11.4.6 Packing: All projecting plates or bars and all ends of members at joints shall be stiffened, all
straight bars and plates shall be bundled, all screwed ends and machined surfaces shall be suitably
packed, and all rivets, bolts, nuts, washers and small loose parts shall be packed separately in cases so
as to prevent damage or distortion during transit.
11.4.7 Inspection and Testing:
(i) The Authority shall have free access at all reasonable times to these parts of the manufactures'
work which are concerned with the fabrication of steel work and shall be afforded all reasonable
facilities to satisfy that the fabrication is being undertaken in accordance with the
specifications.
(ii) Unless specified otherwise, inspection prior to despatch shall not interfere with the operation of
the work.
11.4.8 Field Connections: All field assembly by bolts, rivets and welding shall be executed in
accordance with the requirements for shop fabrication excepting such as manifestly apply to shop
conditions only. Where the steel has been delivered painted, the paint shall be removed before field
welding, for a distance of 50 mm at least on either side of the joint.
11.4.9 Painting after Erection:
(i) Before painting of such steel which is delivered unpainted is commenced, all surfaces to be
painted shall be dry and thoroughly cleaned from all loose scale and rust.
(ii) The specified protective treatment shall be completed after erection. All rivet and bolt heads
and site welds after de-slugging shall be cleaned. Damaged or deteriorated paint surfaces shall
be first made good with the same type of paint as the shop coat. Where specified, surfaces which
will be in contact after site assembly shall receive a coat of paint (in addition to any shop priming)
and shall be brought together while paint is still wet.
(iii) Where the steel has received a metal coating in the shop, this coating shall be completed on site
so as to be continuous over any welds and site rivets and bolts ; but subject to the approval of
Authority, protection may be completed by painting on site. Bolts which have been galvanized
or similarly treated are exempted from this requirement.
(iv) Surfaces which will be inaccessible after site assembly shall receive the full specified
treatment before assembly.
(v) Site painting should not be done in frosty or foggy weather, or when humidity is such as to
cause condensation on the surfaces to be painted.
11.4.10 Bedding: Bedding of Stanchion Bases and Bearings of Beams and Girders on Stone, Brick
or Concrete (Plain or Reinforced)
(i) Bedding shall be carried out with cement grout or mortar or with cement concrete as in IS
456: 2000.
(ii) For multi-storeyed buildings, this operation shall not be carried out until a sufficient number
of bottom lengths of stanchions have been properly lined, levelled and plumbed and sufficient
floor beams are in position.
(iii) Whatever method is employed, the operation shall not be carried out, until the steelwork has
been finally levelled and plumbed, the stanchion bases being supported mean while by steel
wedges; and immediately before grouting, the space under the steel shall be thoroughly cleaned.
(iv) Bedding of structure shall be carried out with grout or mortar which shall be of adequate
consistency and shall either be placed under pressure or by ramming against fixed supports.
11.4.11-Connections: As much of the work of fabrication as is reasonably practicable shall be
completed in the shops, where the steel work is fabricated.
11.4.12 Rivets, Close Tolerance Bolts, High Strength Friction Grip Fastener, Black Bolts and
Welding: Where a connection is subject to impact or vibration or to reversal of stress (unless such
reversal is solely due to wind) or where for some special reason, such as continuity in rigid framing
or precision in alignment of machinery, rivets or close tolerance bolts, high strength friction grip
fasteners or welding shall be used. In all other cases bolts in clearance holes may
be used provided that due allowance is made for any slippage.
11.4.13-Composite Connections: In any connection which takes a force directly transferred to it
and which made with more than one type of fastening, only rivets and turned and fitted bolts may be
considered as acting together to share the load. In all other connections sufficient number of one type
of fastening shall be provided to transfer the entire load for which the connection is designed.
11.4.14 Members Meeting at a Joint: For triangulated frames designed on the assumption of pin
jointed connections, members meeting at a joint, shall, where practicable, have their centroidal axes
meeting at a point and wherever practicable the centre of resistance of a connection shall be on the
line of action of the load so as to avoid eccentricity moment on the connections.
(i) However, where eccentricity of members or if connection is present, the members and the
connections shall provide adequate resistance to the induced bending moments.
(ii) Where the design is based on non-intersecting members at a joint all stresses arising from
eccentricity shall be calculated and this stress within limits specified.
11.4.15 Bearing Brackets: Wherever applicable, connections of beams to columns shall include a
bottom bracket and top cleat, where web cleats are not provided, the bottom bracket shall be capable
of carrying the whole of the load.
11.4.16 -Gussets: Gusset plates shall be designed to resist the shear, direct and flexural stress
acting on the weakest or critical section. Re-entrant cut shall be avoided as far as practicable.
11.4.17-Lug Angles: Lug angles connecting a channel shaped member, shall as far as possible, be
disposed symmetrically with respect to the section of the member.
(i) In case of angle members, the lug angles and their connection to gusset or other supporting
member shall be capable of developing a strength not less than 20 percent in excess of the force
in the outstanding leg of the angle and number shall be capable of developing 40 percent in
excess of that force.
(ii) In the case of channel members, the lug angles and their connections to the gusset or other
supporting member shall be capable of developing a strength of not less than 10 percent in
excess of the force not accounted for by direct connection of the member, and the attachment
of the lug angles to the member shall be capable of developing 20 percent in excess of that
force.
(iii) In no case shall fewer than two bolts or rivets be used for attaching the lug angle to the gusset
or other supporting member.
(iv) The effective connection of the lug angle shall, as far as possible terminate at the end of the
member connected, and the fastening of the lug angle to the member shall preferably start in
advance of the direct connection of the member to the gusset or other supporting member.
11.4.18 Pitch of Rivets-i) Minimum Pitch:- The distance between centre of rivets shall not be less
than 2.5 times the nominal diameter of the rivet.
(ii) Maximum Pitch:-
a) The maximum pitch for any two adjacent rivets shall not exceed 32t where t is the
thickness of the thinner outside plate or 300 mm.
b) In tension members the distance between any two adjacent rivets. In a line lying in the
direction of stress, shall not exceed 16t or 200 mm. and 12t or 200 mm for compression
members. In case of butting compression members, the distance shall not exceed 4.5
times the diameter of the rivets for a distance from the abutting faces equal to 1.5 times
the width of the member.
c) The distance between centres of any two consecutive rivets in a line adjacent and parallel
to an edge of an outside plate shall not exceed (100 mm + 4t) or 200 mm whichever is
less in compression or tension members.
d) When rivets are staggered at equal intervals and the gauge does not exceed 75 mm, the
distances specified herein between centres of rivets, may be increased by 50 percent.
(iii) Edge Distances: - The minimum edge distance from the centre of any hole to the edge of the
plate shall not be less than as given below :
Table-1
Dia. of Hole Distance to Sheared or Hand Distance to Rolled, Machine
(mm) mm Flame Cut, or Planed
Flame Cut Edge Sawn(
Edge (mm)
13.5 and below 19 ) 17
15.5 25 22
17.5 29 25
19.5 32 29
21.5 32 29
23.5 38 32
25.5 44 38
29.0 51 44
32.0 57 51
35.0 57 51
When two or more parts are connected together, a line of rivets or bolts shall be provided at a distance
of not more than (34 mm + 4 t) the nearest edge. In case of work not exposed to weather, this may be
increased to 12 t.
(iv) Tacking Rivets:
a) Tacking rivets not subject to calculated stress shall be used, in case the maximum distances
specified is exceeded. The pitch of tacking rivets in line shall not exceed 33 t or 300 mm
whichever is less. When the plates are exposed to weather, the pitch in line shall not exceed 6
t or 200 mm, whichever is less. In both cases, the lines of tacking rivets shall not be a part at a
distance greater than the pitches.
b) In tension members composed of two angles, flats, channels or tees in contact back-to-back by
a distance not more than the aggregate thickness of the connected part, tacking rivets shall be
at a pitch not exceeding 1000 mm. For compression members as above, the pitch shall not
exceed 600 mm.
11.4.19 Pitch of Bolts: They shall be as for rivets including edge distances and tacking bolts.
11.4.20 Measurements: The mode of measurements shall be same as specified in 11.3.4, except the
weight of welding material shall not added in the weight of members for the payment and nothing
extra shall be paid for making and filling holes for temporary fastening of members during erection
before welding.
11.4.21 Rate: Rate should be inclusive of labour, material, for all the operations described above.
11.5 Steel Work in Built Up Section (Welded): The steel work in built up sections (welded) such
as in trusses, form work etc. is specified in this clause.
11.5.1 Laying out: It shall be for fabrication as specified in 11.3.1. 11.5.2
Fabrication:
11.5.2.1 Straightening, shaping: Straightening, shaping to form, cutting and assembling, shall be
as per 11.3.2 as far as applicable, except that the words "riveted or bolted" shall be read as "welded"
and holes shall only be used for the bolts used for temporary fastening as shown in drawings.
11.5.2.2 Welding:
i) Welding shall generally be done by electric arc process as per IS:816-1969 and IS:823. The
electric arc method is usually adopted and is economical. Where electricity for public is not
available generators shall be arranged by the contractor at his own cost unless otherwise
specified. Gas welding shall only by resorted to using oxyacetylene flame with specific
approval of the Engineer-in-charge. Gas welding shall not be permitted for structural steel work
Gas welding required heating of the members to be welded along with the welding rod and is
likely to create temperature stresses in the welded members. Precautions shall therefore be
taken to avoid distortion of the members due to these temperature stresses.
ii) The work shall be done as shown in the shop drawings which should clearly indicate various
details of the joint to be welded, type of welds, shop and site welds as well as the types of
electrodes to be used. Symbol for welding on plans and shops drawings shall be according to
IS 813-1986.
iii) As far as possible every efforts shall be made to limit the welding that must be done after the
structure is erected so as to avoid the improper welding that is likely to be done due to heights
and difficult positions on scaffolding etc. apart from the aspect of economy. The maximum dia.
of electrodes for welding work shall be as per IS:814. Joint surfaces which are to be welded
together shall be free from loose mill scale, rust, paint, grease or other foreign matter, which
adversely affect the quality of weld and workmanship.
11.5.23 Precautions: All operation connected with welding and cutting equipment shall conform to
the safety requirements given in IS 818 for safety requirements and Health provision in Electric and
gas welding and cutting operations.
11.5.2.4 Operation, Workmanship and process of Welding: Operation, Workmanship and
process of Welding is described in Appendix `B',
11.5.2.5 Inspection and testing: Inspection and testing of welds shall be as per IS:822-1970.
11.5.2.6 Assembly: Before welding is commenced, the members to be welded shall first be brought
together and firmly clamped or tack welded to be held in position. This temporary connection has to
be strong enough to hold the parts accurately in place without any disturbance.
Tack welds located in places where final welds will be made later shall conform to the final weld in
quality and shall be cleaned off slag before final weld is made.
11.5.2.7 Erection: The specification shall be as described in 11.3.3 except that while erecting a
welded structure adequate means shall be employed for temporary fastening the members together
and bracing the frame work until the joints are welded. Such means shall consists of applying of
erection bolts, tack welding or other positive devices imparting sufficient strength and stiffness to
resist all temporary loads and lateral forces including wind. Owing to the small number of bolts
ordinarily employed for joints which are to be welded, the temporary support of heavy girders
carrying columns shall be specially attended. Different members which shall be fillet welded, shall
be brought into as close contact as possible. The gap due to faulty workmanship or incorrect fit if
any shall not exceed. 1.5 mm if gap exceeds 1.5 mm or more occurs locally the size of fillet weld
shall be increased at such position by an amount equal to the width of the gap.
11.5.2.8 Painting : Before the member of the steel structures are placed in position or taken out of
the workshop these shall be painted as specified in para 11.2.2.
11.5.3 Measurements: The mode of measurements shall be the same as specified in 11.2.4 except
that weight of welding material shall not be added in the weight of members for payment and nothing
extra shall be paid for making and filling holes for temporary fastening of members during erection
before welding.
described above.
11.6. Collapsible Steel Gates: These shall be of approved manufacture and shall be fabricated from
the mild steel sections.
11.6.1. Steel Sections :
i) The gates shall consist of double or single collapsible gates depending on the size of the
opening. These shall consists of vertical double channels each 20 x 10 x 2 mm. at 10 cm centre
to centre braced with flat iron diagonals 20 x 5 mm and top and bottom rails of T-iron 40 x 40
x 6 mm @ 3.5 kg/m with 40 mm dia. ball bearings in every fourth double channel, unless
otherwise specified. Wherever collapsible gate is not provided within the opening and fixed
along the outer surface, T-iron at the top may be replaced by flat iron 40 x 10 mm.
ii) The collapsible gate shall be provided with necessary bolts and nuts, locking arrangement,
stoppers and handles. Any special fittings like spring, catches and locks, shall be so specified in
the description of item where so required. The gate shall open and close smoothly and easily.
11.6.2. Fixing: T-iron rails shall be fixed to the floor and to the lintel at top by means of anchor bolts
embedded in cement concrete of floor and lintel. The anchor bolts shall be placed approximately at
45 cm centre's alternatively in the two flags of the T-iron. The bottom runner (T-iron) shall embedded
in floor and proper grooved shall be formed along the runner for the purpose. The collapsible shutter
shall be fixed at sides by fixing the end double channels with T-iron rails and also by hold-fasts
bolted to the end double channel and fixed in masonry of the side walls on the other side. In case the
collapsible shutter is not required to reach the lintel, beam or slab level, a Tee-section suitably
designed may be fixed at the top, embedded in masonry
and provided with necessary clamps and roller arrangement at the top. All the adjoining work
damaged in fixing of gate shall be made good to match the existing work, without any extra cost.
11.6.3. Painting: All the members of the collapsible gate including T-iron shall be thoroughly
cleaned off rust, scales, dust etc. and given a priming coat of approved steel primer i.e. red oxide
zinc chrome primer conforming to IS: 2074-1992 before fixing them in position.
11.6.4. Measurements : The height and breadth shall be measured correct to a cm. The height of
the gate shall be measured as the length of the double channels and breadth from outside to outside
of the end fixed double channels in open position, of the gate. The area shall be calculated in square
metres, correct to two places of decimal.
11.6.5. Rate: The rate shall include the cost of materials and labour involved in all the operations
described above.
11.7. M.S. Sheet Sliding Shutter: These shall be manufactured as per drawings and specifications.
These shall be fabricated from mild steel sheets.
11.7.1 Steel Sections:
i) The shutters shall be double or single leaf shutter as specified. The shutters shall be fabricated
of specified size of M.S. angle iron frame diagonally braced with the same size of M.S. angle
riveted/ welded together with 3mm gusset plate at junction to form a rigid frame. M.S. sheet of
1 mm thickness or as specified shall be fixed to the frame with rivets/welds, as approved by the
Engineer-in-Charge. These shall also be provided with top and 1 bottom guide rails of specified
size angles or T-irons and 25 mm diameter bottom and guide block with steel pulleys at the
top. The shutters shall also be provided with locking arrangement, handles, stoppers, holdfasts,
and other fittings as specified in the description of the item.
ii) The guide rails shall be sufficiently long and continued along the wall on both ends so that
the sliding shutters can rest against the walls, giving full opening when so required.
11.7.2. Fixing: The guide rails shall be fixed to the floor by means of anchor bolts embedded in the
cement concrete floor. The steel section at the top shall be suitably supported from the walls. Two
channel sections shall be suitably fixed vertically below the extreme clamps in the wall and floor to
avoid the shutter from going out of the supports at top and bottom. A suitable clamping arrangement
will be provided at either end of the opening to avoid the shutters from rolling back in to the opening.
All the adjoining work damaged in fixing shall be made good to match the existing work.
11.7.3. Painting: All members of the sliding shutters including fittings shall be thoroughly cleaned of
rust, scales, dust etc. and given a priming coat of approved steel primer i.e. Red oxide zinc chrome
primer confirming to IS : 2074-1992 before fixing them in position.
11.7.4. Measurements: The height and width shall be measured correct to a cm and its area for
payment shall be calculated in square metres correct to two places of decimal. The height of the
shutter shall be measured from outside to outside of the guide rail and width outside to outside of
the shutter including the vertical position channels in sides, when closed.
11.7.5. Rate: The rate shall include the cost of materials and labour involved in all the operation
described above. It also includes the cost of the full length of guide rails.
11.8. M.S. Sheet Shutters: These shall be manufactured as per drawing and specifications. These
shall be fabricated from mild steel sheets and angle iron.
11.8.1. Steel Sections:
i) The doors shall be provided as double leaf shutters unless otherwise specified. The shutters
shall be fabricated with frame of M.S. angle 40 x 40 x 6 mm @ 3.5 kg/ metre and two diagonal
braces of the same section as shown in fig.3 unless otherwise specified. The frame shall be
riveted and / or welded at the junctions. Wherever riveting shall be done 3.15 mm thick gusset
plate shall be provided at the junctions, M.S. sheet of 1 mm thickness or as specified, shall be
fixed to the frame with rivets or welds as approved by the Engineer-incharge.
ii) Alternatively the diagonal bracing may be replaced by one horizontal and two cross flats 30 x
6 mm as shown in Fig. 3 unless otherwise specified.
iii) The outer frame shall be provided with cleats made of section 40 x 10 mm and bent in the shape
of angle cleats with one arm 150 mm long and the other arm 50 mm long and fixed to the angle
Iron frame of the door with two 12 mm dia. Bolts and nuts. For doors up to 2.40 m height, two
angles cleats per door shall be provided.
iv) The cleat shall have a vertical leg of 150 mm which shall be fixed with frame and horizontal
leg of about 50 mm which shall be provided with a hole of 24 mm dia. And fixed in the
projected pin of the pin clamp.
11.8.2. Fittings and Fixtures:
i) The shutter shall be fixed to the wall masonry with four pin clamps (pintles) where the height of
the shutter is up to 2.4 m. Each pin clamp shall consist of 50 x 6 mm flat iron 45 cm long bend
and forked at one end and provided with 20 mm diameter M.S. pin on the other. The pin shall
be firmly riveted or welded to the pin clamp, the other end of which shall be embedded in
masonry by means of cement concrete block 40 x 23 x 20 cm of 1:3:6 mix (1 cement : 3 coarse
sand : 6 graded stone aggregate 20 mm nominal size). It shall be so placed that bottom pin shall
face upwards and (top pin downwards) in order that the gate may not be removed be lifting
over pins.
iii) One hook with eye 45 cm long of 10 mm diameter shall be provided for each shutter to keep it
fixed in open position. The hook shall be fixed in wall masonry with wooden block and the eye
shall be fixed on 6 mm thick M.S. palate as staple and fixed in the shutter frame with rivet or
weld.
iv) A cement concrete block 15 x 10 x 20 cm in 1:2:4 (1 cement: 2 coarse sand : 4 grades stone
aggregate of 20 mm nominal size) mix shall be embedded in the floor or at junction of two
shutters so that door shutter open only on the outside and not on the inside.
v) The shutters shall also be provided with locking arrangement and two handles of the shape
and pattern as approved by the Engineer-in-Charge.
11.8.3. Painting: All the members of the door including angle iron shall be thoroughly cleaned off
rust, scales, dust etc. and given a priming coat of approved steel primer i.e. Red oxide Zinc chrome
primer confirming to IS: 2074-1992 before fixing them in position.
11.8.4. Measurements: The width and height of shutters shall be measured to the nearest cm. The
area shall be calculated in square metre correct to two places of decimal.
11.8.5. Rate :The rate shall include the cost of materials and labour involved in all the operations
described above. Nothing extra shall be paid for cement concrete blocks or wooden blocks nor
anything deducted for these from the measurement of the masonry wall.
11.9. Rolling Shutters :
11.9.1. Specifications: Rolling shutters shall conform to IS : 6248-1979. These shall include
necessary locking arrangement and handles etc. These shall be suitable for fixing in the position as
specified i.e. outside or inside on or below lintel or between jambs of the opening. The door shall be
either push and pull type or operated with mechanical device supplied by the firm. Shutters up to 10
sq metre shall be of push and pull type and shutters with an area of over 10 sq. metre shall generally
be provided with reduction gear operated by mechanical device with chain or handle, if bearings are
specified for each of operation, these shall be paid for separately.
11.9.2 Shutter: The shutter shall be built up of interlocking lath section formed from cold rolled
steel strips. The thickness of the sheets from which the lath sections have been rolled shall be not
less than 0.90 mm for the shutters up to 3.5 m width and not less than 1.20 mm for shutters above
3.5 m width. Shutters above 9 meters in width should be divided in 2 parts with provision of one
middle fixed or movable guide channel or supported from the back side to resist wind pressure. The
lath section shall be rolled so as to have interlocking curls at both edges and a deep corrugation at
the centre with a bridge depth of not less than 12 mm to provide sufficient curtain of stiffness for
resisting manual pressures and normal wind pressure. Each lath section shall be continuous single
piece without any welded joint. When interlocked, the lath sections shall have a distance of 75 mm
rolling centres. Each alternate lath section shall be fitted with malleable cast iron or mild steel clips
securely riveted at either ends, thus locking the lath sections at both ends and preventing lateral
movement of the individual lath sections. The clips shall be so designed as to fit the contour of the
lath sections.
11.9.3. Spring: The spring shall be of coiled type. The spring shall be manufactured from high tensile
spring steel wire or strips of adequate strength conforming to IS : 4454-Part I-2001
11.9.4. Roller and Brackets:
i) The suspension shaft of the roller shall be made of steel pipe conforming to heavy duty as per
IS : 1161-1998. For shutter up to 6 metre width and height not exceeding 5 metre, steel pipes
of 50 mm nominal bore shall be used. The shaft shall be supported on mild steel brackets of
size 375 x 375 x 3.15 mm for shutters up to a clear height of 3.5 metre. The size of mild steel
brackets shall be 500 x 500 x 10 mm for shutters of clear height above 3.5 m and up to 6.5 m.
The suspension shaft clamped to the brackets shall be fitted with rotatable cast iron pulleys to
which the shutter is attached. The pulleys and pipe shaft shall be connected by means of pre-
tensioned helical springs to counter balance the weight of the shutter and to keep the shutter in
equilibrium in any partly open position.
ii) When the width of the opening is greater than 3.5 m. the cast iron pulleys shall be
interconnected with a cage formed out of mild steel flats of at least 32 x 6 mm and mild steel
dummy rings made of similar flats to distribute the torque uniformly. Self aligning two row ball
bearing with special cast iron casings shall be provided at the extreme pulley and caging rings
shall have a minimum spacing of 15 mm and at least 4 number flats running throughout length
of roller shall be provided.
iii) In case of shutters of large opening with mechanical device for opening the shutter the roller
shall be fitted with a purion wheel at one end which in contact with a worm fitted to the bracket
plate, caging and pulley with two ball bearing shall be provided.
11.9.5. Guide Channel:
i) The width of guide channel shall be 25 mm the minimum depth of guide channels shall be as
below:
Clear width of shutters Depth of guide channel

Up to 3.5 m 65 mm
3.5mupto8m 75mm
8 m and above 100 mm
ii) The gap between the two legs of the guide channels shall be sufficient to allow the free
movement of the shutter and at the same time close enough to prevent rattling of the shutter due
to wind.
iii) Each guide channel shall be provided with a minimum of three fixing cleats or supports for
attachment to the walls or column by means of bolts or screws. The spacing of cleats shall not
exceed 0.75 m. Alternatively, the guide channels may also be provided with suitable dowels,
hooks or pins for embedding in the walls.
iv) The guide channels shall be attached to the jambs, plumb and true either in the overlapping
fashion or embedded in grooves, depending on the method of fixing.
11.9.6. Cover: Top cover shall be of mild steel sheets not less than 0.90 mm thick and stiffened
with angle or flat stiffeners at top and bottom edges to retain shape.
Lock plates with sliding bolts, handles and anchoring rods shall be as per IS : 6248-1979.
11.9.7 Fixing:
i) The arrangement for fixing in different situations in the opening shall be as per IS : 6248-
1979.
ii) Brackets shall be fixed on the lintel or under the lintel as specified with rawl, plugs, and
screws, bolts etc. The shaft along with the spring shall then be fixed on the brackets.
iii) The lath portion (shutter) shall be laid on ground and the side guide channels shall be bound
with ropes etc. The shutter shall than be placed in position and top fixed with pipe shaft with
bolts and nuts. The side guide channels and cover frames shall then be fixed to the walls through
the plate welded to the guides. These plates and bracket shall be fixed by means of steel screws
bolts, and rawl plugs concealed in plaster to make their location invisible. Fixing shall be done
accurately in a workmen like manner that the operation of the shutter is easy and smooth.
11.9.8 Measurements: Clear width and clear height of the opening for rolling shutter shall be
measured correct to a mm. The clear distance between the two jambs of the opening shall be clear
width and the clear distance between the sill and the soffit (bottom of lintel) of the opening shall be
the clear height.
11.9.9 Rate: The rate shall include the cost of materials and labour involved in all the operations
described above including cost of top cover and spring except ball bearing and mechanical device of
chain and crank operation, which shall be paid for separately.
11.10. Rolling Grills Shutters:
11.10.1 Scope:
i) Rolling grill is meant to provide visibility or ventilation or both, the degree of protection and
safety is less as compared to a rolling shutter. The situations where a certain amount of
ventilation combined with safety is required rolling shutter-cum-grill may be provided in which
the rolling shutter may have a rolling grill portion either at the top or at the bottom or at both
places. In addition, the rolling grill portion may also be provided in the middle of the shutter.
The total height of the grill portion in all the segments of rolling shuttercum-grill shall not
exceed 1.0 m and the height of the grill portion in any individual segment shall not be more than
0.5 m.
ii) Rolling grills are similar in design, construction and operation to rolling shutters and all the
provisions of para 11.9 shall be applicable to rolling grills except in respect of the shutter
portion, and shall conform to IS : 6248-1979.
11.10.2. Shutters: Rolling grill shutter and the rolling grill portion of the rolling shutter-cumgrill
shall be fabricated with 8 mm diameter mild steel round bars. Straight bars and bars bent to the
required profile are placed alternatively and held in position with 20 mm wide and 5 mm thick mild
steel flat links. Straight bars shall be spaced not exceeding 150 mm centre to centre and the bars bent
to required profile shall be straight bars. Unless otherwise specified or directed by the Engineer-in-
charge, bars placed alternatively with straight bars shall be bent to form a corrugated profile such
that the pitch of the corrugation is 100 to 120 mm and the depth of corrugation is 80 to 100 mm. All
the bent bars shall have uniform profile. Straight bar along with the adjoining bent bars on it both
sides shall be held in position by passing the bars through holes in the links. Each link shall have
three holes and the length of the links shall be such that the distance from the centre of the hole the
nearest edge of the flat is not less than the diameter of the hole. The corner of the links shall be
rounded. All links shall be of uniform size and shape. The spacing of the links measured along the
straight bar shall be of uniform size and shape. The spacing of the links measured along the straight
bar shall be the same as centre to centre distance between two consecutive crests/ troughs of the bars
bent to the required profile. Each bar and link shall be a continuous single piece without any joint.
11.10.3. Measurements and Rate: The measurements and rate shall be as specified in 11.9.8 and
11.9.9 respectively. In case of Rolling shutter-cum-Grill where the area of the grill portion is half or
less than half the area of opening, it shall be measured and paid as rolling shutter and where the area
of grill portion is more than half the area of opening, it shall be measured and paid as rolling grill.
11.11. Steel Door, Windows, Ventilators & Composite Units: (Fig. 4)
11.11.1 Specifications :
i) Hot rolled steel sections for fabrication of steel doors, windows, ventilators and fixed lights shall
conform to IS : 7452-1990. Shapes weights and designations of hot rolled sections shall be as
per IS 7452-1990. Appendix `D' of chapter 11 indicates the purpose or the situation where the
sections are normally used. Tolerance in thickness of the sections shall be + 0.2 mm. The steel
doors, windows, ventilators and composite units shall confirm to IS 1038-1983 with up-to-date
amendments and shall be IS marked (IS 1038). Be got fabricated in workshop approved by the
Engineer in Charge.
ii) The steel doors and windows shall be according to the specified sizes and design. The size of
doors and windows shall be calculated, so as to allow 1.25 cm clearance on all the four sides
of opening to allow for easy fitting of doors windows and ventilators in to opening. The actual
sizes of doors, windows and ventilators shall not vary by more than + 1.5 mm from those given
in the drawing.
11.11.2.1. Frames: Both the fixed and opening frames shall be made of sections which have been
cut to length and mitred. The corner of fixed and opening frames shall be welded to form a solid
flush welded joint conforming to the requirements given below. All frames shall be square and flat .
The process of welding adopted shall be flash butt welding. The section for glazing shall be tennoned
and riveted into the frames and where they intersect the vertical tie shall be broached and horizontal
tee threads through it, and the intersection closed by hydraulic pressure.
11.11.2.2. Requirements of welded joints:
(i) Visual Inspection Test: When two opposite corners of the frame are cut, paint removed and
inspected, the joint shall conform to the following :
(a) Welds should have been made all along the place of meeting the members and tack
welding shall not be permitted.
(b) Welds should have been properly grounded and Complete cross section of the corner
shall be checked up to see that the joint is completely solid and there are no cavities
visible.
(ii) Micro and Macro Examinations: From the two opposite corners obtained for visual test, the
flanges of the sections shall be cut with the help of a saw. The cut surface of the remaining
portions shall be polished, etched and examined. The polished and etched faces of the weld and
the base metal shall be free from cracks and reasonably free from under cutting, overlaps, gross
porosity and entrapped slag.
(iii) Fillet Weld Test: The fillet weld in the remaining portion of the joint shall be fractured by
hammering. The fractured surfaces shall be free from slag inclusion porosity, crack penetration
defects and fusion defects.
11.11.2.3. Door:
i) The hinges shall be of 50 mm projecting type, Non projecting type Hinges may also be used if
approved by the Engineer-in-Charge. The hinge pin shall be of electro-galvanized steel or
aluminium alloy of suitable thickness and size. Door handles shall be approved by the
Engineer-in-Charge. A suitable latch lock for door openable both from inside and outside shall
be provided.
ii) In the case of double doors, the first closing leaf shall be the left hand leaf locking at the door
from the push side. The first closing shutter shall have a concealed steel bolt at top and bottom.
The bolts shall be so constructed as not to work loose or drop by its own weight.
iii) Single and double shutter (door may be) provided with a three way bolting device. Where the
device is provided in the case of double shutters, concealed brass or steel bolts shall not be
provided.
11.11.2.4. Windows:
(a) Fixed windows: For fixed windows, the frames shall be fabricated as per 11.11.2.1.
(b) Side hung windows:
i) For fixing steel hinges, slots shall be cut in the fixed frame and hinges inserted inside and
welded to the frame at the back. The hinges shall be of projecting type with thickness not
less than 3.15 mm and length not less than 65 mm and width not more than 25 mm . Non-
projecting type hinges may also be allowed if approved by the Engineer-in-charge. The
diameter of hinges pins shall not be less than 6 mm. The hinge pin and washer shall be of
galvanised steel or aluminium alloy of suitable thickness.
ii) For fixing hinges to inside frame, the method described above may be adopted but the
weld shall be cleaned, or the holes made in the inside frame and hinge riveted.
iii) The handle of side hung shutters shall be pressed brass, cast brass, aluminium or steel
protected against rusting and shall be mounted on a steel plate. Thickness of handle shall
not be less than 3 mm in case of steel or brass and 3.mm in case of aluminium. The handle
plate shall be welded, screwed and/ or riveted to the opening frame in such a manner that
it should be fixed before the shutter is glazed and should not be easily removable after
glazing.
iv) The handle shall have a two point nose which shall engage with a brass or aluminium
alloy striking plate on the fixed frame in a slightly opened position as well as closed
position. The back of handle shall incorporate a friction device to prevent the handle from
dropping under its own weight and the assembly shall be so designed that the rotation of
the handle may not cause it to unscrew from the pin.
v) The height of the handle plate in each type of standard windows will be as specified.
Otherwise it shall be at a height of 3/8 of the height of shutter, from its bottom. The strike
plate shall be so designed and fixed in such a position in relation to the handle that with
the later bearing against its stop, There shall be adequately tight fit between the casement
and outer frames.
vi) In case where no friction type hinges are provided, the windows shall be fitted with peg
stays which shall be either of black oxidized steel, pressed or cast brass or as specified,
300 mm long with steel peg and locking brackets. The pegs stay shall have three holes to
open the side hung casement in three different angles. The peg stay shall be of minimum
thickness 2 mm in case of brass or aluminium and 1.25 mm in case of steel. Where
specified friction hinges shall be provided. Side hung shutters fitted with friction hinges
shall not be provided with a peg. Stay.
vii) If specified, side hung shutters may be fitted with an internal removable fly proof screen
in a 1.25 mm thick sheet steel frame to the another frame of the shutter by brass turn
buckles at the jambs, and brass studs at the sill to allow the screen being readily removed.
The windows with removable fly proof screen shall be fitted with a through-the-screen
level operator at the sill level to permit the operation of the shutter through an angle of 90°
with out having to remove the fly proof screen. The lever shall permit keeping the shutter
open in minimum three different positions.
11.11.2.5. Ventilators:
(a) Top Hung Ventilators: The steel butt hinges for top hung ventilators shall be riveted to the fixed
frame or welded to it at the back after cutting a slot in it. Hinges to the opening frame shall be riveted
or welded. Top hung ventilators shall be provided with a peg stay with three holes which when closed
shall be held tightly by the locking bracket. The locking bracket shall either be fitted to the fixed
frames or to the window.
(b) Centre Hung Ventilators:
i) Central hung ventilators shall be hung on two pairs of brass or aluminium cup pivots as
specified, riveted to the inner and outer frames of ventilators to permit the ventilator shutter
to swing to angle of 85°. The opening portion of the ventilators shall be so balanced that
it remains open at any desired angle under normal weather conditions.
ii) A black oxidized steel spring catch approved by the Engineer-in-charge shall be fitted in
the centre of the top of the centre hung ventilator for the operation of ventilators. The
spring catch shall be secured to the frame with M.S. screws and shall close into a mild
steel or malleable iron catch plate riveted, screwed or welded to the outside of the outer
window frame bar.
iii) A black oxidized cord pulley wheel in galvanized mild steel brackets shall be fitted at sill
of the centre hung window with mild steel screws or alternatively welded together with a
mild steel or malleable iron cord-eye riveted or welded to the bottom inner frame bar of
the window in a position corresponding for that of pulley.
iv) Removable fly-proof screen may be provided as specified in 11.11.2.4 (b). This shall be
fitted with a through-the screen operator to enable operating and keeping the shutter open
in minimum three different positions.
11.11.2.6 Composite Units: Composite Units consist of a combination of two or more units of doors,
windows and ventilators etc. as the case may be. The different units shall be coupled by using
coupling sections. K-11 B (Ref. Appendix D) as the case may be.
Wherever the ventilators, windows and doors shall be coupled with a coupling sections, mastic
cement shall be applied between the junction to make the joint water tight.
11.11.3. Glazing:
i) Specifications: Glazing shall be done as specified. The glass panes shall have square corners
and straight edges. The glass panes shall be so cut that it fits slightly loose in the frames. In
doors, windows and clerestory windows of bath, WC and lavatories, frosted glass panes shall
be used which shall weigh not less than 10.00 kg/m2.
ii) Glass panes: Glazing shall be provided on the outside of the frame unless otherwise specified.
Putty of approved make conforming to IS: 419-1967 shall be used for fixing glass panes. Putty
shall be applied between glass panes and glazing bars. Putty shall then be applied over the glass
pane, which shall stop 2 to 3 mm from the sight line of the back rebate to enable the painting
to be done up to the sight line to seal the edge of the putty to the glass. The oozed out putty
shall be cleaned and from putty cut to straight line. Quantity of putty shall not be less than 185
gm/metre of glass. Putty shall be painted within 2 to 3 weeks, after glazing is fixed to avoid its
cracking.
Note : Putty may be prepared by mixing one part of white lead with three parts of finely
powdered chalk and then adding boiled linseed oil to the mixture to form a stiff paste and
adding varnish to the paste at the rate of 1 litre of varnish to 18 kg. of paste.
iii) Glazing Pins / clips: Four glazing clips may be provided per glass pane for a size larger than
30 cm x 60 cm for all types, where the glass panes size exceed 80 cm x 200 cm, 6 glazing clips
shall be used. In case of doors, windows and ventilators without horizontal glazing bars, the
glazing clips may be spaced according to the slots, in the vertical members provided the spacing
does not exceed 30 cm otherwise the spacing shall be 30 cm.
Note : Where large size glass panes are required to be used or where the door or window is
located in heavily exposed situation, holes for glazing clips have to be drilled prior to
fabrication and cannot be done at any later stages. Use of glazing clips, shall be specified while
placing the order.
iv) Where specially stipulated, fixing of glass panes may be done with metal or wooden beading
instead of mere putty. Where beading are proposed to be used, the manufactures shall be
intimated in advance to drill holes for hard screws. Usually beads shall be fixed with screws
spaced not more than 10 cm from each corner and the intermediate not more than 20 cm apart.
When glass panes are fixed with wooden or metal beading having mitred joints, a thin layer of
putty shall be applied between glass panes and sash bars and also between glass panes and the
beading. Where metal beading is specified extra payment shall be made on this account.
11.11.4. Finishing:
i) All steel surfaces shall be thoroughly cleaned of rust, scale and dirt. Where so specified, the
steel surfaces shall be treated for rust proofing by the hot dip, zinc spray or electro galvanizing
process. A priming coat of approved steel primer i.e. red oxide zinc chrome primer conforming
to IS: 2074-1992 shall be given. The fabricated steel door, windows, ventilators and composite
units shall be inspected in the factory and approved by the Engineerin-charge before priming
coat is applied.
ii) Final finishing coat shall be given to the doors, windows and ventilators after they are erected
and fixed in final position. The rate shall be exclusive of final finishing coats but shall include
the priming coat.
11.11.5. Fixing:
(a) Steel, doors and windows shall be so stacked as to keep them in true shape without damage.
Doors, windows and ventilators shall be fixed as described below :
(b) Opening may be flush or rebated as shown in the drawings. Those opening may have rendered
finish or a "fair faced" finish (i.e. without rendering as in case of marble or stone facing). Where
openings are flush and with a rendered fmish a clearance of 1.25 cm shall be provided between
the steel frame and opening (see Fig. 6). In case of external masonry finish " fair faced" and
with rebated jambs, a minimum 1.25 cm clearance between frame and opening shall be
provided (See Fig.6) opening in steel work shall be so designed that the outer flange of the
door, windows, or ventilator frame section overlaps the steel surface by 10 mm (See Fig. 6).
NOTE: The sizes of Indian Standard doors, windows and ventilators, are designed for modular
opening 1.25 cm larger all round than the doors, windows etc. This gap of 1.25
cm is for the purpose of fixing of doors, windows etc. In masonry openings, the gap is filled up
with mastic cement and plaster after the door of windows is fixed in position. In the case of steel
or timber modular openings, extra steel or timber fillets will be necessary to cover this gap of
1.25 cm.
(c) Fixing in Masonry Openings:
(i) Fixing with Lugs: Doors, windows and ventilators unit, shall not be " built in " as the
work proceeds but opening shall be left out and frames fitted afterwards so that the
minimum specified clearance between opening and unit frame is left all-round. The size
of the opening shall first be checked and cleared of obstruction, if any. The position of
the unit and fixing holes shall be marked on the jamb. Necessary holes shall be made in
the masonry and lugs not less than 10cm long 15 x 3 mm size fixed in cement concrete
blocks 15 x 10 x 10 cm size of 1 : 3 : 6 mix (1 cement : 3 coarse sand : 6 graded stone
aggregate 20 mm nominal size). The frames of units shall be set in the opening by using
wooden wedges at the jamb, head and sill, (wedges shall preferably be placed near the
points where a glazing bar meets the frames and be plumbed in position).
(ii) After it, the frame shall be fixed with the lugs with 20 mm long and 6.3 mm dia. G.I.
counter sunk machine screws and nuts. In case of flush opening which are rendered
smooth, wedges shall be removed and gap between unit and the jambs shall be filled with
cement mortar (Fig. 5).
(iii) In case of flush jamb with external " fair faced" finish the gap between the opening and
frame shall be filled with mastic from inside till it oozes out on external face. The oozing
mastic shall be cleaned and flush pointed. The internal gap shall be filled with mastic to
about 1/3rd depth and the rest with cement mortar ( Fig. 5).
(iv) In case of rebated jambs and jambs finished "fair faced" externally, the mastic shall be
freely applied to the inside channel of frame, jamb and sill, so as to ensure a watertight
joint. After the unit is firmly fixed in position surplus mastic shall be cleaned and pointed,
as shown in (Fig. 5).
(v) Fixing with screws and plugs: In R.C.C. work where lugs cannot be embedded due to
reinforcement bars etc. rawl plugs or other approved metallic fasteners may be fixed in
proper position and frame fixed to them with 60 mm galvanised wood screws of
designation 10.
(d) Fixing in Wood Work Opening: Opening in wood work are normally rebated and approved
mastic or rubber linings shall be applied to jambs, sill and channel before fixing in position. The
frame shall be set in opening using wooden wedges as specified in 11.10.5.3. and fixed to the
opening with 60 mm galvanised wood screw of designation 10. Extra timber fillets of hard
wood to match the adjoining work shall also be provided around the frame to close the extra
gap between opening and frame (Fig. 5).
(e) Fixing in Steel Work Opening: Before placing the unit frame in position approved mastic
shall be applied as specified in 11.10.5.3. (a, iv) and a mild steel or hard wood fillet shall be
provided around the frame to close the extra gap between opening and frame. The unit shall
then be fixed to the opening with fixing clips or with nuts and bolts as shown in the drawings
or as directed by the Engineer-in-charge (Fig. 5).
(f) Fixing of Composite Units: The fixing procedure for composite units shall generally be as
described under 11.10.5.1. to 11.10.5.5. except that :
Where large units shall be formed by coupling individual units together (with coupling
sections), the mullions and transom shall be bedded in mastic to ensure water tightness. Mastic
shall be applied liberally to the channels of the outside frame sections before assembly and after
coupling. All oozing out mastic shall be cut out neatly.
11.11.6 Precautions: Care shall be taken that steel doors and windows etc. are not deformed/
damaged during subsequent constructions. Particular care shall be taken that scaffolding do not rest
on the steel door window frames or glazing bars. All fittings and hinges (projecting hinges) shall be
protected, preferably with alkathene sheets so that these may not be damaged during execution of
work.
11.11.7 Measurement: The height and width shall be measured correct to 1 mm. The area shall be
calculated in square metre correct to two places of decimal. The fixed side hung and top hung,
categories shall be measured separately.
All composite units shall first be measured as fixed extra shall then be added for side hung, top hung
and centre hung portions. The measurements for extra for side hung, centre hung and top hung
windows shall be measured from outside to outside of the casement frames.
11.11.8. Rate: Rate shall include the cost of materials and labour involved in all the operations
described above excluding two coats of painting but including cost of glazing and priming including
the cost of projecting hinges in case of side hung doors/ windows, plain hinges in case of top/bottom
hung windows/ventilators and pivots for centre hung windows/ ventilators. Metal beading and other
fittings such as peg stays and casement window fasteners etc. shall be enumerated and paid for
separately.
11.12. T-Iron Doors, Windows and Ventilators Frames:
i) General: T-iron doors, windows and ventilators frames shall be manufactured from uniform mild
steel Tee section. The steel shall be of the grade as provided in 11.2.1. The frames shall be got
fabricated as per IS 1083-1978 in Workshop approved by Engineer in Charge.
11.12.1. Specifications :
i) The sizes of doors, windows and ventilator frames shall be as per drawing or as decided by the
Engineer in charge MS tie bar of 10 mm dia shall welded at bottom of the frame. The size of
doors windows and ventilators shall be calculated so as to allow 12.5 mm clearance on all sides
to allow an easy fittings in opening. The actual size of doors, windows and ventilators shall not
vary by more than ± 2 mm than those shown in the drawings.
ii) The size of T Section used for manufacture of doors, windows and ventilators shall not be less
than those specified in IS : 1038 (See Fig. 5). Unless otherwise directed by the Engineer in-
Charge.
i) The frame shall be constructed in section which has been cut to length and meted. The corners
of the frames shall be butt welded to form a true and right angle. All frames shall be square
and flat meeting the requirements stated under para 11.11.2.1.
ii) The T Section shall be mitre joined and continuously butt welded all along. The requirement
of welded joints shall be as specified under para 11.11.2.2.
11.12.3. Fittings: Requisite number of holes shall be made in the frame for fixing of fitting. Detailed
arrangements of fixing fittings shall be as shown in (Fig. 6). All fitting shall be fillet welded to T
iron frame all along the periphery of contact. But hinges shall be fixed to the frame as below:
MS flat of size 100 mm x 25 mm x 6 mm will be welded with fillet weld all along the periphery of
contact on the rear side of the web of T- iron to receive the hinges. Requisite number of holes shall
be made in T iron frame and MS flat for fixing of hinges with counter sunk steel screws as shown in
Fig. 6.
(ii) An alternate method of fixing butt hinges can be adopted by fillet welding the hinge to the T-iron
frame on three sides. No welding shall be done along the hinge pin to allow free movement of butt
hinges as shown in Fig. 7.
11.12.4. Fixing Procedure: Fixing procedure for T iron doors, windows and ventilator frames in
masonry opening shall be as described in 11.11.5. Fixing arrangements of shutters to such frames is
shown in Fig. 6.
11.12.5. Measurements: T iron door, windows and ventilator frames shall be measured in running
metre, along the centre line of the frame correct to a 1 mm and weight calculated on the basis of
standard tables. No deduction or extra payment shall be made for making holes and making
arrangements for fixing fittings including packing wherever necessary. No deduction will be made for
not providing tie bars in case of windows and ventilators.
11.12.6. Rate: The rate includes cost of materials and labour involved in all the operations described
above. It shall include the necessary butt hinges and screws for fixing the same with frame or as
specified. But it does not include the cost of other door, window and ventilator fittings.
11.13. Pressed Steel Door Frames:
11.13.1. Material: Steel door frames shall be manufactured from commercial mild steel sheet of 1.25
mm / specified thickness, conforming to IS : 4351-2003 and IS:2062-1999.
Steel door frames with or without fan light shall be made in the profiles indicated in Fig.8 which may
be manufactured to suit doors of either type opening inwards or outwards as directed by the Engineer-
in-Charge.
11.13.2. Construction: Each door frame shall consist of hinge jamb, lock jamb, head and if required
angle threshold (See Fig. 8). These shall be welded or rigidly fixed together by mechanical means.
Where no angle threshold is required, temporary base tie shall be screwed to the feet of frames in
order to form a rigid unit. Where so specified base ties shall be of pressed mild steel 1.25 mm thick
adjustable to suit floor thickness of 35 or 40 mm and removable, or alternatively, threshold of mild
steel angle of section 50 x 25 mm, minimum shall be provided for external doors frames.
11.13.3. Fabrication: The pressed steel door frames shall be got fabricated in an approved workshop
as approved by Engineer in Charge.
11.13.3.1 Fixing lugs (Fig. 8): There shall be three adjustable lugs with split end tail to each jamb
without fan light, and four for jamb with fan light.
The head of the fixing lug shall be of one of the following lengths:
(a) 98 mm long for use with profile A
(b) 120 mm long for use with profile B
(c) 160 mm log for use with profile C
The head shall be made from flat steel strip 25 mm wide and not less than 1.60 mm thick.
The tail of the lugs shall be 200 mm long and shall be made of steel strip not less than 40 mm wide
and not less than 1 mm thick.
11.13.3.2. Hinges (Fig. 8):
i) 100 mm mild steel butt hinges shall be used. For door frames 80 cm wide and under, three
hinges shall be rigidly fixed to one jamb and for frames and for door above 89.0 cm wide, four
hinges shall be rigidly fixed to one jamb, if it is single shutter. Where the height of door shutter
exceeds 2.15 metres, one additional hinge shall be provided for every 0.5 m or part there of the
additional height.
ii) In all cases the hinges shall be so fixed that the distance from the inside of the head to rebate to
the top of the upper hinge is 20 cm and distance from top of upper range to the lower range is
about 175 cm. members at their junctions with other members in continuous frame. Such
stiffeners shall be placed in pairs on opposite sides of the web of the member which extends
continuously through the joint.
11.133.3 Mortar Guards : Mortar guards of thickness of main frame sheet shall be provided in
accordance to provisions of IS 4351-2003 and as instructed by Engineer-in-charge shall be provided.
These shall be welded to the frame at the head of the frame for double shutter doors to make provision
for bolts. These shall also be provided to the frame behind the hinges, mortice locks and latches,
slots, aldrop and sliding /tower bolts.
11.13.3.4 Lock - Strike Plate: There shall be an adjustable lock- strike plate of steel complete with
mortar guard to make provision for locks or latches complying with the relevant Indian Standards.
(IS 4351-2003) Lock-strike plates shall be of galvanized mild steel and fixed at 95 cm from the head
of the frame.
11.13.3.5 Shock Absorbers: For side hung door there shall not be less than three buffers or rubber
or other suitable material inserted in holes in the rebate. One shall be located at the centre of the lock
jamb and the other two shall be at 30 cm. from top and bottom of the frame. For double leaf shutter
door, two buffers shall be provided
11.13.4 Finishing: The surface of door frame shall be thoroughly cleaned, free of rust, mi11-scale dirt
oil etc. either by mechanical means, for example sand or shot blasting or by chemical means such as
picking. After pre treatment of the surface one coat of approved primer i.e. red oxide zinc chrome
primer conforming to IS 2074-1992. Two coats of paints as directed by the Engineer-in-charge shall
be applied to the exposed surface.
11.13.5 Fixing:
i) Frames shall be fixed up right in plumb and plane. To avoid sag or bow in width during fixing
or during construction phase, temporary struts across the width preventing sides bulging
inwards may be provided. Wall shall be built solid on each side and grouted at each course to
ensure solid contact with frame leaving no voids behind the frame.
ii) Three lugs shall be provided on each jamb with spacing not more than 75 cm. The temporary
struts should not be removed till the masonry behind the frame is set. In case screwed base tie
is provided, this should be left in position till the flooring is laid when it can be removed.
iii) After pre treatment of the surface, one coat of steel primer and two coats, of paint, as directed
by Engineer-in-charge shall be applied to the exposed surface.
11.13.6 Measurements: The length shall be measured in running metre correct to a cm along the
centre line of the frames.
11.13.7 Rate: The rate shall include the cost of labour and material involved in all the operation
described above including one coat of approved steel primer but excluding two coats of paint.
11.14. Fabrication and Connection for Tubular Structures:
11.14.1. General: The use of tubular steel in structural work would result in considerable savings,
particularly in case of roof trusses, latticed girders and compression members in general. This clause
on fabrication and connections for tubular structures is complimentary to the provisions of 1 to 5.
Requirements which are of special application to construction using steel tubes are included here.
11.14.2. Materials:
11.14.2.1Structural Steel Tube: These shall be of:
1. Hot finished welded (HFW) type, or
2. Hot finished seamless (HFS) type, or
3. Electric resistance or induction butt welded (ERW), having carbon content less than 0.03
percent, yield stress of 21.5 kg/mm2 (YST 210) type.
(a) Steel tubes shall be hot rolled finished tubes conforming to IS 1161: 1998. The steel tubes when
analysed in accordance with the method specified in IS 228-1987 shall show not more than
0.06 percent sulphur, and not more than 0.06 per cent phosphorous. Tubes made by other than
hot finishing processes or which have been subjected to cold working, shall be regarded as hot
finished, if they have subsequently been heat-treated and are supplied in normalized conditions.
Tubes shall be designated by their nominal bore. These shall be light, medium or heavy as
specified depending upon the wall thickness. The standard size and weights of tubes are listed
in Appendix C. Hollow sections shall be as per IS 4923-1997. Tubes shall be clean finished
and reasonably free from scale. They shall be free from cracks, surface flaws, laminations and
other defects. The ends shall be cut clean and square with axis of tube, unless otherwise
specified
Note : Grade ERWY St 22 tubes specified in IS 1161 : 1998 with a carbon content less than
0.03 percent, may be considered as hot finished for this purpose.
(b) Electrodes used for welding of steel tubes shall conform to IS 814 : 1991.
(c) Minimum Thickness:
(i) For tubular steel work painted with one priming coat of red oxide and zinc chromate paint after
fabrication and periodically repainted and maintained regularly, the wall thickness of tubes used
for construction exposed to weather shall be not less than 4 mm for construction not exposed
to weather, it shall be not less than 3.2 mm and where structures are not readily accessible for
maintenance, the minimum thickness shall be 5 mm.
(ii) Steel tubes used for construction exposed to weather shall be not less than 3.2 mm thick and
for construction not exposed to weather shall be not less than 2.6 mm thick provided that in
each case the tube is applied with :
One coat of zinc primer conforming to IS 104: 1979, followed by a coat of paint conforming to
IS 2074: 1992; or
Two coats of paint conforming to IS 123 : 1962.
This painting schedule should be reviewed after every two years in the case of tubes exposed to
weather. In case some other metallic corrosion protecting material is used, such as aluminium
painting, the renewal of coating may be done after longer intervals.
(a) As mentioned, provisions of 11.1 to 11.5 shall apply to construction using tubes also. Where
welding is adopted provisions of IS 816 : 1969 shall apply, as appropriate.
(b) The component parts of the structure shall be assembled in such a manner that they are neither
twisted nor otherwise damaged and be so prepared that the specified cambers, if any, are
maintained. The tubular steel work shall be painted with one coat of approved steel primer after
fabrication. All fabrication and welding is to be done in an approved workshop. The joint details
shall be generally as per S.P-38 of B.I.S publication.
(c) Straightening - All material before assembly shall be straightened, if necessary, unless
otherwise required to be a curvilinear form and shall be free from twist.
(d) Bolting:
(i) Washers shall be specially shaped where necessary, or other means used, to give the
nuts and the heads of bolts a satisfactory bearing.
(ii) In all cases where the full bearing area of the bolt is to be developed, the threaded portion
of the bolt shall not be within the thickness of the parts bolted together, and washers of
appropriate thickness shall be provided to allow the nut to be completely tightened.
(e) Cut Edges: Edges should be dressed to a neat and workman like finish and free from
distortion where parts are to be in contact metal-to-metal.
(f) Caps and Bases for Columns: The ends of all tubes for columns, transmitting loads through
the ends, shall be true and square to the is of the tube and should be provided with a cap of base
accurately fitted to the end of the tube and screwed, welded or shrunk on. The cap or base plate
should be true and square to the is of the columns.
(g) Sealing of Tubes: When the end of a tube is not automatically sealed by virtue of its
connection by welding to another member, the end shall be properly and completely sealed.
Before sealing, the inside of the tube should be dry and free from loose scale.
(h) Flattened Ends: In tubular construction, the ends of tubes may be flattened or otherwise
formed to provide for welded, riveted or bolted connections, provided that the methods
adopted for such flattening do not injure the material. The change of section shall be gradual.
(j) Oiling and Painting: If not galvanized, all tubes shall, unless otherwise specified, be painted or
oiled of otherwise protectively coated before exposure to the weather. If they are to be painted
with any special requirements, this has to be arranged.
11.14.4. Connections:
(a) General- Connections in structures using steel tubes shall be provided by welding, riveting or
bolting. Wherever possible, connections between tubes shall be made directly tube to
tube without gusset plates and other attachments. Each tube may be flattened as specified in
11.13.3 (h) or otherwise formed to provide for welded, riveted or bolted connections. When
loads are required to be carried from one tube to another or are required to be distributed
between tubes, diaphragms which may be tubular, designed with sufficient stiffness to distribute
the load between tubes, shall be used.
(b) Eccentricity of Members- Tubes meeting at a point shall wherever practicable, have their
gravity axes meeting at a point so as to avoid eccentricity. Where ever practicable, the centre
of resistance of the connection shall lie on the line of action of the load so as to avoid
eccentricity of the connections.
(c) Welded Connections : Welding shall be as per IS 816:1969.
(i) A weld connecting two tubes end-to-end shall be full penetration butt weld. The effective
throat thickness of the weld shall be taken as thickness of the thinner part joined.
(ii) A weld connecting the end of one tube (branch tube) to the surface of another tube (main
tube) with their axes at an angle of not less than 30° shall be of the following type:
 Butt weld throughout.
 Fillet weld throughout, and
 Fillet-butt weld, the weld being a fillet weld in one part and a but weld in another
with a continuous change from one form to another form in the intervening portions.
A butt weld throughout may be used whatever the ratio of the diameters of the tubes
joined, provided complete penetration is secured either by the use of backing material, or
by depositing a sealing run of metal on the back of the joint, or by some special method
of welding. When butt weld running throughout is not employed, a fillet running
throughout should be used where the diameter of the of the branch tube is less than one-
third of the diameter of the main tube. The combined fillet-butt weld should be used when
the diameter of the branch tube is equal to or greater than one-third of the diameter of the
main tube.
(iii) A weld connecting the end of one tube to the surface of another, with axes of tubes
intersecting at an angle less than 30°, shall be permitted only if adequate efficiency of
the junctions has been demonstrated.
(iv) Connections where the axes of the two tubes do not intersect- A weld connecting the end
of one tube to the surface of another, where the axes of the tubes do not intersect, shall
be subject to the provision of 11.14.4 CO) and (ii) provided that no part of the curve of
intersection of the eccentric curve of intersection of the corresponding largest permissible
eccentric tube with the main tube.
11.14.5 Hoisting and Erection: Tubular trusses shall be hoisted and erected in position carefully,
without damage to themselves, other structure, equipment and injury to workman. The method of
hoisting and erection proposed to be adopted shall be got approved from the Engineer-incharge. The
contractor shall however be fully responsible, for the work being carried out in a safe and proper
manner without unduly stressing the various members. Proper equipment such as derricks, lifting
tackles, winches, ropes etc. shall be used.
11.14.6. Measurements: The work as fixed in place shall be measured in running metres correct to
a cm. and their weights calculated on the basis of standard tables correct to the nearest kilogram unless
Weight of cleats, brackets, packing pieces bolts, nut, washers distance pieces separators diaphragm
gussets (taking overall square dimensions) fish plates, etc. shall be added to the weight of respective
items unless otherwise specified. No deduction shall be made for stew cuts.
11.14.7. Rates: The rate shall include the cost of labour and materials involved in all the operations
described above including application of one coat of approved steel primer, i.e. red oxide zinc
chrome primer conforming to IS : 2074-1992.
11.15 Fan Clamps:
11.15.1. Types: The fan clamp shall be of the following types :
(a) Fan clamp to be fixed during the laying of R.C.C. slab, shall be of type (A), as shown in (Fig.
9) This shall be made of 16 mm M.S. bar bent to shape with its ends hooked. The overall height
of the clamps shall be made to suit the depth of the slab.
(b) Fan clamp for beams shall be of type (B) as shown (Fig. 9). It shall be similar to fan clamp,
type (A), except that its height shall be greater depending on the depth of the beam rib.
(c) In case low ceiling heights, circular cast iron box for ceiling fan clamp shall be fixed during the
laying of R.C.C. slab and shall be as shown in (Fig.9). The size of cast iron box shall be 140
mm internal dia. With 73 mm height, the thickness of cast iron rim shall be 4.5 mm bottom and
top lid shall be of 1.5 mm thick M.S. sheet, with its top surface hacked so as to ensure proper
bonding with the concrete. The lids shall be screwed into the cast iron box by means of 3.3 mm
dia. Round head screws one each at the corners. The box can be of M.S. sheet, the thickness of
side walls can be reduced to 3 mm without effecting inner dia. of the box. The fan clamp shall
be made of 12 mm dia M.S. bar bent to shape with it stands bent as per drawing.
11.15.2. Fixing: Holes for inserting the fan clamps in the positions shown in the drawing or as
instructed by the Engineer-in-Charge shall be made in the shuttering after the later has been fixed in
position. After steel reinforcement is tied, fan clamps shall be fixed with their loops truly vertical
and at the correct depth from the underside of the slab or beam. The hooked arms and the loop shall
be tied to the reinforcement, either directly or through cut pieces of M.S. bars with annealed steel
wire 1.6 mm or 1.00 mm thick. The clamp shall neither be disturbed out of position during concreting
nor shall they be bent out of shape when shuttering of slabs or beams is removed.
The exposed portion of loops of the clamp shall be given two or more coats of paint, including
priming coat, of approved steel primer as ordered by the Engineer-in-Charge.
11.15.3. Measurements: Clamps of type (A) and (C) shall be counted in numbers. Fan clamps type
II, shall be counted and paid for under fan clamps type I, but they shall in addition be paid for their
extra height as determined by the depth of the beam.
11.15.4. Rate: The rate per fan clamp shall include the cost of labour and materials involved in all
the operations described above. In the case of type (A) and (C) clamps, the rate shall apply
irrespective of the thickness of the slabs.
11.16. Mild Steel Clamps and Rings for Chicks:
11.16.1. M.S. Clamps: These shall be fabricated from M.S. flat iron 20 mm x 6 mm. One end
shall be bent at right angles for 25 cm length and other end shall be tapered to a point. Total length
of clamp shall not be less than 15 cm.
These shall be built into the wall masonry, while the work is in progress, so as to project 2.5 cm
from the finished surface. These shall be fixed in cement mortar. All clamps shall be fixed in straight
horizontal line as shown in drawings or as specified by the Engineer-in-Charge.
11.16.2. M.S. Rings:
These shall be made of 6 mm dia. Bars with 40 mm internal diameter. Their joint shall be well
formed or welded together. These shall be provided with a 50 mm forked clamp of 10 x 3 mm M.S.
flat iron. It shall be wide at the fork end and pointed on the other end.
These shall be fixed in the masonry as specified in 11.15.1
11.163. Measurements: The M.S. clamps and rings shall be counted in numbers.
11.16.4. Rate: The rate shall include the cost of materials and labour involved in all the operations
described above.
11.17 M.S. Bars and M.S. Grills in Wooden or Steel Frames:
M.S. round or square bars, with or without M.S. flats M.S. grills of different pattern with flats with
M.S. or without M.S. bars, round or square, fixed in wooden or steel windows or clearstory windows
etc. are described in this clause.
i) When M.S. bars round or square are to be fixed in wooden or steel frame these are cut in the
required length to form the required pattern. Then fixed as per drawing. In the case of wooden
frames the length will be for fixing in the hole 5 cm deep in one frame and right through and
flush with outer side of the frame.
ii) When M.S. round or square bars are to be fixed to steel frames or in combination with M.S.
flats these are to be cut to proper size, welded to steel frames or MS flats to form the required
pattern. In case of M.S. flats, they should have counter sunk holes to facilitate fixing them to
wooden frames with wood screws. Welding to be done in an approved workshop and not at
site.
iii) When the gri11 is to be fabricated mainly with M.S. flats with or without M.S. round or square
bars, the flats of required size are cut and bent to form the required pattern and design as per
drawing or as directed by the Engineer-in-charge. The cut and bent flat and bars are then welded
by fillet welding all around the width of the flats or circumference of bars which are joined,
forming at right angle corners of flat proper mitred joint angle shall be provided with welding
for full width. Welding to be done in approved workshop and not at site.
11.17.2. Fixing :
i) When MS round or square bars are to be fixed to wooden frames the bars shall be passed in to
the wooden frame, from the end having a through hole and fixed flush with that end while at
the other end it will be 5 cm deep in the hole drilled in the frame. In case of steel frames, the
bars will be welded to the steel frame by fillet weld all along the circumference of the bars in
an approved workshop and not at site.
ii) In case of grill of bars welded to M.S. Flat forming the required pattern, the outer frame
of M.S. flats shall be fixed to the wooden frame with wood screws in the counter sunk holes
drilled in M.S. flats ensuring that screws are driven with some screw driver (not hammered) till
the screws are embedded fully inside flush with the M.S. flats.
In case of fixing to steel frames, M.S. flats of required pattern with or without M.S. round or
square bars, the method of fixing will be similar to what is described above.
iii) Any kind of welding at site shall be permitted only under written order of the Engineerin-
Charge.
11.17.4. Measurements: he different types of M.S. grills as described in 11.17.1. will be measured
separately and paid for. The length of bars and flats used in grills will be measured correct to a cm
and then weights calculated in kg by using standard tables.
11.17.5. Rate: The rate shall include the cost of materials and labour required for all the operations
described above. Grill of different types mentioned in 11.17 shall be paid for separately.
11.18 M.S. Hollow Rectangular Door Frames (L -Type Section):
11.18.1 Materials: Steel door frames shall be manufactured from commercial mild steel sheet of 1.60
mm thickness, conforming to IS:2062-1999 and IS:4351-2003. Steel door frames shall be made in
the profiles as per drawings and/or as directed by the Engineer- in-charge.
11.18.2 Construction: Each door frame shall consist of hinge jamb, lock jamb, head and if required
angle threshold. These shall be welded or rigidly fixed together by mechanical means. Where no
angle threshold is required, temporary base tie shall be screwed to the feet of frames in order to form
a rigid unit. Where so specified base ties shall be pressed mild steel 1.60 mm thick adjustable to suit
floor thickness of 35 or 40 mm and removable, or alternatively, threshold of mild steel angle of
section 50 x 25 mm, minimum shall be provided for external doors frames.
11.18.3 Fabrication: The M.S hollow rectangular steel door frames shall be got fabricated in an
approved workshop as approved by the Engineer-in Charge.
11.18.3.1 Fixing Lugs : There shall be three adjustable lugs with split end tail to each jamb. The
head of the fixing lug shall be 120 mm long and made up flat steel strip 25 mm wide andl.60 mm
thick.
11.18.3.2 Hinges :
i) 100 mm mild steel butt hinges shall be used. Floor door frames 80 cm wide and under, three
hinges shall be rigidly fixed to one jamb and for frames of door above 80 cm wide, four hinges
shall be rigidly fixed to one jamb, if it is single shutter. Where the height of door shutter exceeds
2.15 metres, one additional hinge shall be provided for every 0.5 m or part thereof of the
additional height.
ii) In all cases the hinges shall be so fixed that the distance from the inside of the head rebate to
the top of the upper hinge is 20 cm and the distance from the bottom of the door frame to the
bottom of the bottom hinge is also kept about 200 mm. The middle hinges shall be at equal
distance from lower and upper hinges or as agreed to between the purchaser and the supplier.
Hinges shall be made of steel 2.5 mm thick with zinc coated removable pin of 6 mm diameter.
The space between the two leaves of the hinge when closed shall be 3 mm and the leaf that is
not welded to the frame shall have four counter sunk holes to take Number-10 cross recessed
head wood screws.
11.18.3.3 Aldrop, Sliding Bolts and Tower Bolts : Provisions shall be made for aldrop, sliding
bolts and tower bolts in the frames as per the positions given by the purchaser. Necessary mortar
guards/metallic or nylon bushes shall be provided inside the frames for aldrop, sliding bolts and
tower bolts.
11.18.3.4 Lock Strike Plate: Provision shall be made to fix lock strike plates of mortise locks or
latches, complying with the relevant Indian Standards. A slot suitable for lock strike plate shall be
pierced into the rebate of the frame and necessary fixing arrangement and mortar guard from the
inside of the frame shall be provided.
11.18.3.5 Shock Absorbers: For side-hung door there shall be not less than three buffers of rubber
or other suitable material inserted in holes in the rebate and one shall be located at the centre of the
lock jamb of frame and other two shall be 300 mm from top and bottom of the frame. For double
leaf doors two buffers shall be provided.
11.18.4 Finishing: The surface of door frame shall be thoroughly cleaned, free of rust, mill - scale
dirt, oil etc. either by mechanical means, for example sand or shot blasting or by chemical means
such as picking. After pre treatment of the surface one coat of approved primer i.e. red oxide zinc
chrome primer conforming to IS 2074. Two coats of paints as directed by the Engineer-in-Charge
shall be applied to the exposed surface.
11.18.5 Fixing:
i) Frames shall be fixed up right in plumb and plane. To avoid sag or bow in width during fixing
or during construction phase, temporary struts across the width preventing sides bulging
inwards may be provided. Wall shall be built solid on each side and grouted at each course to
ensure solid contact with frame leaving no voids behind the frame.
ii) Three lugs shall be provided on each jamb with spacing not more than 75 cm the temporary
struts should not be removed till the masonry behind the frame is set. In case screwed base tie
is provided, this should be left in position till the flooring is laid when it can be removed.
iii) After pre treatment of the surface one coat of steel primer and two coats, of paint, as directed
by Engineer-in-charge shall be applied to the exposed surface.
11.18.6 Measurements: The length shall be measured in running metre correct to a cm. along the
centre line of the frames.
11.18.7 Rate: The rate shall include the cost of labour and material involved in all the operation
described above including one coat of approved steel primer but excluding two coats of paint.
11.19 Factory made Glazed Steel Doors, Windows and Ventilators:
11.19.1. Specifications for this item to be same as for standard steel glazed doors, windows and
ventilators as mentioned in para 11.10, except that Doors, windows and ventilators to be
manufactured in a workshop, approved by the Chief engineer. Also owner of the workshop shall
have a valid ISI license for manufacture of doors, windows and ventilators.
11.20. Steel Work Welded in Built-Up Sections for Hand Rail using M.S.Tubular/ ERW
Tubular Pipes and G.I. Pipes:
11.20.1 Specification: General specifications to be same as for steel work welded in built-up
section as mentioned in para 11.5.
11.20.2 Materials:
11.20.2.1 Steel tube: Hot finished welded (HFW) Hot finished seamless (HFS) and electric
resistance welded tube shall conform to IS 1161-1998.
11.20.2.2 G.I. Pipe : G.I. pipes used for Hand rail to be conforming to IS 1239-Part I-1990 for
medium grade. GI pipes to be screwed and socketed type and of required nominal bore.
11.20.2.3 Galvanising: Galvanising of GI pipes shall conform to IS 4736-1986.
11.20.2.4 All screwed tubes and socket of GI pipes shall have pipe threads conforming to the
requirements of IS 554-1999.
11.20.2.5 Fittings: The fittings for GI pipes to be conforming to IS 1239 (Part-II)-1992.
11.203 Measurement of Hand Rail of M.S. Tubular/E.R.W Tubular Pipes: The work as fixed in
place shall be measured in running metres correct to a centimetre and their weights calculated on the
basis of standard tables correct to the nearest kilogram or actual weight whichever is less unless
11.21 Introduction to Pre-Fabricated (Pre-Engineered) Steel Buildings: These are predesigned
and prefabricated steel structures supplied and executed on a turnkey basis including sheeting,
rainwater disposal, wind ties, side sheeting / panelling etc. These are used on Toll plazas, escalators,
industrial buildings and bridges.
11.21.1 Scope of Supply: The standard building scope of supply shall include the structural framing,
metal roofing & siding, bracing, doors, windows, insulation, hardware, fasteners, sealants and any
other component parts for the metal building as specified or shown on the drawings.
11.21.2 Type of Pre - Fabricated Steel Buildings:
11.21.2.1 Clear span, Rigid Frame Buildings : "RF2" (Rigid Frame). The building shall be a
single gable, Clear span, Tapered column, Pin base, by frame girts, 1:10 roof slope, rigid frame type.
1121.2.2 Clear span space saver buildings: "SV" (Space saver). The building shall be a single
gable, clear span, straight column, pin base, flush framed girts 0.5:10 roof slope, rigid frame type.
11.21.2.3 Beam and Column buildings: "BC" (Beam & Column). The building shall be a single
gable, tapered column, pin base, by frame girts, 1:10 roof slope, rigid frame type, supported type
intermediate columns as shown on drawings.
11.21.2.4 Clear span, Single Slope Buildings: "SS" (Single Slope). The building shall have a single
slope roof with tapered columns pinned at base and straight rafters. The roof slope shall be 0.5:10
and sidewalls sheeted with by framed girts.
11.21.2.5 T-Canopy buildings: "T-CAN" (T-Canopy). The building shall consist of single straight
columns fixed at base at each frame with a double cantilever roof sloping towards the centre columns.
The roof slope shall be 1:10 and the wall shall be fully open.
11.21.2.6 L-Canopy Buildings:"L-CAN" (L-CANOPY). The building shall consist of single
straight columns fixed base at each frame with a single cantilever roof sloping towards the column.
The roof slope shall be 1:10 and wall sheeted with by framed girts.
11.21.2.7 Lean to Buildings: "LT" (LEAN-TO). The building shall have a single slope roof and
connected on the high side to the main building on which it depends for partial support. The roof
slope shall be either 1:10 or 0.5:10 matching with the main building roof slope and wall sheeted with
flush girts.
11.21.3 Components of Pre Fabricated Steel Buildings: A typical Pre Fabricated Steel Building
consists of the following components:
11.21.3.1 Primary:
(a). Transverse R.F. (Rigid Frame), (b). L-To Rafters & Columns, (c). Canopy Rafters, (d). Interior
Columns (Beam & Column Frame), (e). Bearing Frame Rafters and Corner Columns, (f) End wall
Wind Columns.
11.213.2 Secondary:
(a). Purlins, (b). Girts, (c). Eave Struts, (d). Wind bracing, (e ). Flange Brace, (f). Base Plates and
(g). Clips and other miscellaneous structural parts.
11.21.3.3 Sheeting:
(a). Roof Sheeting, (b). Wall Sheeting, (c). Liner Panels, (d). Decking Panels, I. Miscellaneous
Accessories like Fasteners/Sealers/Flashing/Trim & Closures.
11.21.3.4. Special Options: a). Mezzanine, (b). Crane Structure, (c). Fascia, (d). Canopy, (e).
Partitions, (f). Sandwich Panels
11.21.3.5 Accessories ® a). Doors (Personal Walk Door, Sliding Doors & Roll up Doors),
(b). Windows, (c). Roof Curb & Roof jack, (d). Louvers, (e). Ridge Ventilators, (f). Gutter &
Down Spout and (g). Insulation
11.22 Design of Pre-engineered/Pre-Fabricated Steel Buildings:
11.22.1 General:
i) All Structural steel sections and welded plate members shall be designed in accordance with
the applicable sections, relating to design requirements and allowable stresses, of the latest
edition of the American Institute of Steel Construction "Specification for the Design,
Fabrication and Erection of the Structural Steel for Buildings".
ii) All light gauge, cold formed, structural members and covering shall be designed in accordance
with the applicable sections, relating to design requirements and allowable stresses, of the latest
edition of the American Iron & Steel Institute "Specification for the Design of Cold Formed
Steel Structural Members.
iii) Analysis and design computer softwares like `STADD' could be used.
11.22.2 Design Criteria:
11.22.2.1. Design Method : Design be done as per BIS Specifications (IS: 800-2007).
11.22.2.2 Deflections : Unless otherwise specified (the deflections will be based on MBMA and
AISC Criteria)
11.22.2.3 Primary Frames : Moment Resisting Plane Frames with printed or fixed bases.
11.22.2.4 Secondary : Cold-Formed Z-sections for purlins and girts designed as continuous beams
spanning over rafters and columns with laps.
11.22.2.5 Longitudinal stability : Wind Load on building end walls is transferred through roof
purlins to braced bays and carried to foundations through diagonal bracing.
11.22.3 Design Loads:
11.22.3.1. The design loads shall depend upon location and requirement of the building and shall
be based on IS/MBMA standards.
11.22.3.2 Loads are applied as follows:
a). Live Load and Dead Load- applied to entire horizontal projection of the roof.
b). Wind load- the wind load shall be applied in accordance with the Metal Building Manufacturers
Association "Recommended Design Practices Manual". (Metal Building Manufacturers
Association recommendations are based on the U.S. Department of the Navy publication.
"NAVFAC DM-2 Design Manual"). Wind is applied to the primary members as either pressure
of suction on the walls, and uplift of pressure on the roof. (Magnitude and direction is
determined using factors based on shape coefficients times the basic wind pressure). The full
specified wind pressure is applied to the secondary members as uplift on the roof, either
pressure or suction on the walls; as well as on the wind bracing members.
11.22.3.3 Design load combinations:
a). Dead Load + Live Load
b). Dead Load + Wind Load
11.22.4 Design Process:
i) The frame data is assembled based on the number of frame members, number of joints, number
of degrees of freedom, the conditions of restraint and the elastic properties of the members.
Based on this, the data is stored and the member section properties are computed. The overall
joint stiffness matrix is generated based on the above frame data by summation of the individual
stiffness matrices considering all possible displacements. The load vector is then generated
based on the loading data and the unknown displacements are obtained by inverting the overall
joint stiffness matrix and multiplying with the load vector. Knowing the free joint displacements,
the member end actions are obtained by back substitution. The axial, shear and bending forces
are then transformed to the section neutral axis and the additional moment created by the
eccentricity of the thrust is added to the moment value. These values are generated for different
load combinations and the final design checks are performed.
ii) The allowable stress values are computed as per the RISC specification with due consideration
for the web depth/thickness ratios and the flange width/thickness ratios with the appropriate
correction factors as per RISC. For computation of the allowable bending stress, the effective
unbraced lengths for each segment are used based on the brace point location defined by the
user. The effective length factor K is used for calculating the slenderness ratios in order to
compute the allowable axial stresses. The coefficients for bending are calculated based on the
end conditions for each member and the corresponding end moment values. The stress ratios
are then computed as actual/allowable stresses and are then combined to check that total
aggregate value is under unity.
iii) The joint displacements and supports reaction are reported for various load cases and
combinations along with the clear heights at haunch and peak to check for clearances.
iv) A detailed connections report is generated based on the forces acting at all the splice joints and
designed as per the specification of AISC. The connections used in the super structure for all
the main frame splices conform to the specification of ASTM A 325 for High strength friction
grip bolts.
11.22.5. Materials Specifications:
11.22.5.1 Primary Members:
a) Members fabricated from plate or bar stock shall have flanges and webs joined on one side of the
web by a continuous welding process. This plate or bar stock shall have a minimum yield
strength of 345 MN/m2(50,000 psi) and will conform to the physical specification of ASTM A-
570 (Grade 50) or equivalent.
b). Members fabricated by cold forming process shall have a minimum yield strength of 345
MN/m2 (50,000 psi) and will conform to the physical specifications of ASTM A-570 (Grade
50) or equivalent.
c). Members fabricated from hot rolled structural shapes shall have a minimum yield strength of
250 MN/m2 (36,000 psi) and will conform to the physical specification ASTM A-36 or
equivalent.
d). Beam and Column interior columns will be fabricated from square tube column sections
conforming to ASTM A-500 (Grade C) or equivalent with a minimum yield strength of 345
MN/m2 (50,000 psi).
11.22.5.2 Secondary Members:
(a) Purlins, girts and eave struts shall be cold formed from steel, which has a minimum yield strength
of 345 MN/m2 (50,000 psi) and will conform to the physical specifications of ASTM A-607
(Grade 50) or equivalent.
(i) Purlins and girts shall be roll formed Z sections, 200 mm deep with 63 mm flanges.
Each flanges shall have a 17 mm stiffening lip formed at 45° to the flange.
(ii) Eave struts are 200 mm deep with a 105 mm wide top flange, a 117.5 mm wide bottom
flange, both are formed parallel to the roof slope. Each flange has a 22.5 mm stiffener.
b). Rod bracing shall have a minimum yield strength of 250 MN/m2 (36,000 psi) and will
conform to the physical specifications of ASTM A-36 or equivalent.
c). All other miscellaneous secondary members shall have a minimum yield strength of 250
MN/m2 (36,000 psi)
11.22.5.3 Sheeting: General: Typical roof, wall and liners panels shall be colour coated, 24 or 26
gauge, galvanized steel, ribbed panels.
1.22.5.4 Panel Material:
a). Base material for colour coated galvanized or galvalume substrate steel panels shall have a
minimum yield strength of 345 Mpa (50,000 psi) and will conform to the physical
specifications of ASTM A-446 or A 792 or equivalent.
b). The Zinc coating is a hot dip galvanization process conforming to ASTM Specification A-525
with a coating class of G-90 (0.90 oz/ff2 or 275 g/m2) or with galvalume coating to ASTM A-
792 - AZ 150 (150 g/m2) or equivalent.
c). The painting shall be baked enamel polyester (white) or silicon polyester (colour-blue or gold)
with a film thickness of 1.0 mil. The reverse side shall be white with 0.5 mil film thickness.
11.22.5.5 Panel Configuration:
a). Roof panel shall have 32 mm deep major ribs which taper in width from 25 mm to 79 mm,
and are spaced 333 mm on centre. Between major ribs are additional minor stiffening ribs
spaced at 111 mm on centre. Each panel shall provide one meter coverage.
b). Wall panel shall have 26.4 mm deep major ribs which taper in width form 29 mm to 59 mm
and are spaces 333 mm on centre. Between the ribs the panel shall be formed into a sculptured
"Valley" shape. Each panel shall provide one meter coverage.
c). Deck panel shall have 41 mm deep major ribs which taper width form 12 mm to 42 mm, and
are spaced 164 mm on centre. Additional minor stiffening ribs are located between major ribs,
at 82 mm on centre. Each panel shall provide 820 mm coverage.
11.22.5.6 Fasteners: Standard fasteners shall be No. 14, Type A, self tapping sheet metal screws
with metal and neoprene washers, which conform to American Standards Association
Specifications. All screws shall have hex heads, be colour coated to match roof or wall panel and
shall be zinc plated steel.
11.22.5.7 Sealer : Sealer for side laps, end laps and self-flashing windows shall be 6 mm wide x 5mm
thick, asbestos fibre filled, pressure sensitive butyl tape. The sealer shall be non-asphaltic, non-
shrinking, non-dying and non-toxic and shall have superior adhesion to metals, plastic and painted
surfaces and temperatures from-50° C to + 104° C.
11.22.5.8 Flashing, Trim & Closers :
a). Flashing and / or trim shall be furnished at the rake, corners eaves framed openings, and
wherever necessary to provide weather tightness and finished appearance.
b). Colour coated, galvanized steel for flashing, metal closure, trim and other miscellaneous uses
shall be 26 gauge of the same specification as the roof and wall covering material.
c). A formed peak panel matching the slope and profile of adjoining panels shall be provided
along the building ridge.
d). Solid or closed cell, performed, E.T.P. (Ethylene Polypropylene Terpolymer) closures
matching the profile of the panel shall be installed along the eave, rake and other locations.
11.22.6 Special Options:
11.22.6.1 Mezzanine: It is an intermediate floor consisting of Beams/ Columns/Joists, Deck and
Edge angles to receive reinforced concrete used for flooring. The material specifications conforming to
Primary, Secondary & Sheeting panel specifications.
11.22.6.2 Crane Structure: It consists of runway beam & brackets, which confirm to material
specifications for primary members.
11.22.6.3 Multi Storied Buildings: Material specification is a combination of Primary, Secondary &
other number based on custom design.
11.22.6.4 Fascia: It is a structural framing member projecting / flushed on the wall surface for
decoration purpose, material specification conforming to that of secondary members and sheeting
panels.
11.22.6.5 Canopy: It is a cantilever conforming to same material specification as of Primary,
Secondary, & sheeting panels.
11.22.6.6 Partitions: Material specifications conforming to secondary members & sheeting panels.
11.22.6.7 Sandwich panels : These are double sheeted panels with Polyurethane foam core in
various sizes, thickness and BTU values conforming to DIN-4102, non-inflammable & self
extinguishing. The skin of the sandwich panel conforming to ASTM A 792 grade 345B AZ 150 or
ASTM A446 (Grade D) or D/A-653 (Grade 50) with galvanising to ASTM A 525 G-90.
11.22.6.8 Accessories: All accessories conform to various ASTM standards & yield strength as per
customized requirement.
11.22.6.9 Anchor Bolts : The Anchor Bolts shall be conforming to ASTM A 307 material (Grade 36).
11.22.7 -Fabrication:
i) All shop connections should be welded using either submerged or shielded arc process, and
welding shall be in accordance with the applicable sections, relating to design requirements and
allowable stress of the latest editions of the American Welding Society "Structural Welding
Code".
ii) The manufacture of the building should be done in accordance with relevant American Codes.
Welding is performed by pre-qualified welders using approved welding processes as per
structural welding code AWS D1.1 published by American Welding Society. The built up
sections are welded in an automatic Conrac beam welding line using submerged arc welding
process. The splice plates and other attachments are welded by the inner shield or C02 welding
process. All butt welds are full penetration welds. Stage inspections shall be carried out at
various stages in the manufacturing process and results documented. The welds should be
subjected to NDT tests including Dye Penetrate Inspection (DPI), Magnetic Particle Inspection
(MPI), Ultrasonic Testing (UT) or Radiography as required. A 100% visual and dimensional
check is performed on all members. Manufacturing tolerances are in accordance with MBMA
and AWS specifications.
iii) The standard surface treatment for fabricated steel is mechanical wire brushing to SSPC ST3
and application of one coat of red oxide primer to a nominal dry film thickness of 25 microns.
11.22.8 Site Assembly & Erection:
i) The most important part of erection in a Pre Fabricated Building is to execute the work of
assembly of various components (Primary, Secondary, Sheeting etc.) in a most systematic way
by adopting all precautionary and safety measures required, in order to avoid any damage to Pre-
Fabricated structures. Thus it is suggested that the erection work shall only be executed by
certified builders of the Pre-fabricated buildings.
ii) The erection team should follow erection drawings and erection procedures manual which
includes all the information required for the site assembly of the building. The erector must use
the proper tools and equipment and sequence of erection as specified in the manual. The high
strength bolts at the primary connections are pre-tightened to the specified tension or torques
shown in the erection drawings. The method of tightening may be either using a calibrated
tension or torque wrench or turn of the nut method as specified in AISC manual. Erection should
always start with a braced bay and the red steel must be fully plumbed before starting cladding
erection. Erection tolerances are as set forth in RISC Code of Practice except individual members
are considered plumb and aligned if the deviation does not exceed 1:300 as per MBMA
specifications.
Equivalent IS Codes for ASTM Codes Used for Pre Fabricated Steel Buildings
American Standards of Specification Indian Codes of Specifications
For Nuts & Bolts:
1. ASTM A-325 (Zinc Plated with bronze indite films)
2. ASTM A-307 (Zinc Plated) IS 1363 - 1992
For Panels :
1. ASTM A-446 (345 Mpa - 50,000 psi)
2. ASTM A-792 (345 Mpa - 50,000 psi)
3. ASTM 525
4. ASTM A-792 - AZ 150 (150 g/m2) IS 811 - 1987
APPENDIX À'
MECHANICAL PROPERTIES AND CHEMICAL COMPOSITION OF STEEL Table 1 :
Chemical Composition
Grade Quality Ladle Analysis Percent Maximum Carbon Method of
Designation Equivalent' Deoxidation
C Mn S P Si
1 2 3 4 5 6 7 8 9
E 165 ( Fe. 290) - 0.25 1..25 .045 0.045 - - Semi killed or
Killed/
E 250 ( F e 410W) A 0.23 1.50 .045 .045 0.40 0.42 -do-
E 250( Fe 410W) B 0.22 1.50 0.045 0.045 0.40 0.41 Killed
E 250 ( Fe 410W) C 0.20 1.50 0.040 0.040 0.40 0.39 Killed
E 300 (Fe 440) - 0.20 1.30 .045 .045 0.45 0.40 Semi killed or
Killed/
Killed/
Killed/
E 450 ( Fe. 570) D 0.22 1.60 0.045 0.45 0.45 0.46 Semi killed or
Killed/
E 450 (Fe 990) E 0.22 1.80 0.045 0.045 0.45 0.48 Semi killed or
Killed/
Notes:
(Cr+Mo+V) (Ni+Cu)
1. Carbon equivalent (CE) based on ladle analysis = + +
C6 5 15
2. When the steel is killed by aluminium alone, the total aluminium content shall not be less than
0.02 per cent. When the steel is killed by silicon alone, the silicon content shall not be less than
0.10 per cent. When the steel is silicon-aluminium killed, the silicon content shall not be less than
0.30 per cent and total aluminium content shall not be less than 0.01 per cent.
3. Micro alloying element like Nb, V, Ti and B shall be added singly or in combination. Total
micro alloying element shall not be more than 0.25.
4. New grades designation system based on yield stress has been adopted, simultaneously old
designations have also been given in parentheses.
5. Steel of qualities A, B and C are generally suitable for welding processes. The eldability
increases from quality A to C.
6. Copper may be present between 0.20 to 0.35 per cent as mutually agreed to between the
purchaser and the manufacturer. The copper bearing quality shall be designated with a suffix
Cu, for example, E 250 Cu. In case of product analysis the copper content shall be between
0.17 and 0.38 per cent.
7. Nitrogen content of steel shall not exceed 0.012 per cent which shall be ensured by the
manufacturer by occasional check analysis. For micro alloyed steel this is to be reduced to
0.009 per cent.
8. The steel, if required may be treated with rare earth element for better formability.
9. Lower limits for carbon equivalent and closer limits for other elements may be mutually
agreed to between the purchaser and the manufacturer.
10. Incidental element-Elements not quoted in Table 1 shall not be intentionally added to steel
without the agreement of the purchaser, other than for the purpose of finishing the heat. All
reasonable precautions shall be taken to prevent the addition from scrap or other materials used
in manufacture of such elements which affect the hardenability, mechanical properties and
applicability.
' T o be supplied subject to the agreement between the purchaser and the manufacturer".
Table 2 : Mechanical Properties

Grade Quality Tensile Yield stress Percentage Internal Charpy 'V'
Designation strength Min. MPa Elongation, Bend notch Impact
Min. 'A'at gauge Diameter. energy.
MPa length Lo :
5.65 $° Min.
<20 20-40 >40 <25 >25 Room -20°C
Temp-
rature
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
E 165( Fe 290) - 290 165 23 2t - - -
E 250 (Fe 410W) A 410 250 240 230 23 3t 2t - -
E 250 ( Fe 410W) B 410 250 240 230 23 2t 3t 272 (see Note 3)
E 250 (Fe 410W) C 410 250 240 230 23 2t 3t 272 (see Note 3)
E 300 ( Fe 440) - 440 300 290 280 22 2t 3t 50 30
E 350 (Fe490) - 490 350 330 320 22 2t 3t 50 25
E 410 ( Fe 540) - 540 410 390 380 20 2t 3t 50 25
E 450( Fe 570) D 570 450 430 420 20 2t 3t 45 20
E 450 ( Fe 590) E$ 590 450 430 420 20 2t 3t 45 20
Notes: 1. 1 MPa=1N/sgmm = 1 MN /sqm=0.102 kgf/mm2 =144.4 psi
2. Temperature of Charpy Impact value will be subject to mutual agreement.
3. The more stringent requirements than those given above , may be as agreed to between the purchaser
and manufacturer,
`t' is the thickness of the test piece.
2 Room temperature=25±2° C for impact test.
Table - 3 : Tolerances
Si. Steel Section Tolerance in weight per meter Standard
No. percentage weight as per
IS
Plus Side Minus Side
(i) Beams and columns (RS joists) (8910) Beams (-) 1 IS 808
< 200 mm
(+) 4
(b) > 200 mm
2.5 2.5
(ii) Channels 2.5 2.5 IS 808
(iii) Equal and unequal leg Angles
(a) up to 3 mm thickness 5 5 IS 808
(b) Over 3 mm thickness 5 3
(iv) Tee bars
(a) Web thickness up to 3 mm 5 5 IS 1173
(b) Web thickness above 3 mm 2.5 2.5
(v) Bulb angles 2.5 2.5 IS 1252
(vi) Bars in straight length
Up to and including 10 mm 7 7 IS 1732
Over 10 mm and up to and including 5 5
16mm
Over 16 mm 3 3
(vii) Bars in coils Weight tolerance is not applicable
(viii) Flats
Up to 3 mm thickness 5 5
Over 3 mm thickness 5 3
(ix) Plates 5 2.5 IS 1730
(x) Strips 10 10 IS 1730
Consignment in straight length
(i) up to 5 tons 7 7 IS 1730
(ii) Above 5 tons 5 5
(xi) Sheets
Thickness
Over in mm Up to and Tolerance on IS 1730
including in mm calculated
weight
(Percent)
- 1.25 mm +9
1.25 mm 1.60 ±8
1.6 4.00 ±7
APPENDIX `B'
WELDING PROCESS
(a) The work shall be positioned for downward welding wherever possible.
(b) Arc length voltage and amperage shall be suited to the thickness of material, type of groove
and other circumstances of the work. The welding current and electrode sizes for different
types of joints shall be as per IS 9595-1996.
(c) The sequence of welding shall be such as will avoid undue distortion and minimized residual
shrinkage stresses. Recommendation of IS 9595-1996 shall be followed.
Process of Welding:
(1) The electrode manipulation during welding shall be such as to ensure that The parent metal is
in a fused stage when the filler metal makes contact with it.
The weld metal does not overflow upon any un fused parent metal forming overlapping. The
(2)
(3) parent metal is not under-cut along the weld toes.
(4) The flowing metal floats, the slag, the oxides, and the gas bubbles to the surface behind the
advancing pool. In case any of these requirements is unattainable by manipulation, the current
shall be adjusted or the electrode size changed.
Each time the arc is started the electrode shall be moved in such a way that the fusion of base
metal at the starting point is assured. At the completion of a run the movement of electrode
shall be slowed down to fill the arc crater.
After every interruption of the arc except at completion of a run, the arc shall be restarted ahead
of the previous deposit and then move back to fill the crater or such alternative technique shall
be used as will ensure complete filling of the crater, or complete fusion between the new and
old deposit and the base metal at the point of junction, and result in continuity of weld, Before
welding operation is completed, all traces of slag shall be removed from the deposit, by
chipping if necessary, and the deposit and the adjoining base metal shall be wire brushed and
cleaned at all points. The requirements shall apply not only to successive layers, but also to
successive beads, and to the over lapping area wherever a junction is made on starting a new
electrode.
The welds shall be free from cracks, discontinuity in welding and other defects such as (i)
under-size (ii) over-size, (iii) under-cutting and (iv) over-cutting in the case of fillet welds and
defects (ii), (iii) & (iv) in the case of butt welds.
All defective welds which shall be considered harmful to the structural strength shall be cut
out and re- welded.
In case of welded butt joints in steel of thickness up to 50mm the weld joint shall be subjected to
radiographic examination as described in IS 1182-2000.
All welds shall be cleaned of slag and other deposits after completion. Till the work is inspected and
approved painting shall not be done. The surface to be painted shall be cleaned of spatter, rust, loose
scale, oil and dirt.
APPENDIX `C'
STEEL TUBES FOR STRUCTURAL PURPOSES
Nominal Bore Outside Diameter Class Wall Thickness Weight
(mm) (mm) (mm) (kg/m)
15 21.3 H 3.2 1.44
20 26.9 H 3.2 1.87
25 33.7 M 3.2 2.41
H 4.0 2.93
32 42.4 L 2.60 2.54
M 3.2 3.10
H 4.00 3.79
40 48.3 L 2.90 3.23
M 3.2 3.56
H 4.0 4.37
50 60.3 L 2.9 4.08
M 3.6 5.03
H 4.5 6.19
65 76.1 L 3.2 5.71
M 3.6 6.42
H 4.50 7.93
80 88.9 L 3.2 6.72
M 4.00 8.36
H 4.8 9.9
90 101.6 L 3.6 8.7
M 4.0 9.63
H 4.8 11.50
100 114.3 L 3.6 9.75
M 4.5 12.2
H 5.4 14.5
110 127.0 L 4.5 13.6
M 4.8 14.50
H 5.4 16.2
125 139.7 L 4.50 15.00
M 4.8 15.90
H 5.4 17.90
135 152.4 L 4.50 16.40
M 4.8 17.50
H 5.40 19.60
150 165.1 L 4.50 17.80
M 4.8 18.90
H 5.40 21.30
150 168.3 L 4.50 18.20
M 4.8 19.40
H-1 5.40 21.70
H-2 6.3 25.20
175 193.7 L 4.8 22.40
M 5.40 25.10
H 5.9 27.30
200 219.1 L 4.8 25.40
M 5.60 29.50
H 5.90 31.00
225 244.5 H 5.90 34.70
250 273 H 5.90 38.90
300 323.90 H 6.30 49.30
350 355.60 H 8.00 68.60
L means Light M means Medium H means Heavy
APPENDIX `D'
SHAPES, WEIGHTS AND DESIGNATION OF MS ROLLED STEEL SECTION
Designation Wt kg/m Situation of Use of Section
T2 1.036 Vertical and horizontal glazing bars for doors and shushes :
windows, ventilators glazing bars for door side lights sub
dividing bars for fixed length, sash bars for doors, windows
and ventilators wheel steel aluminium or wooden beading is
used for fixing glasses.
T3 1.14 Vertical glazing bar for FZ 7 frame
T6 0.839 Vertical and horizontal glazing bar for standard windows and
ventilators.
F2 1.46 Inner frames for open-in windows.
F3 2.28 Outer frames for open-in windows.
F5 1.55 (a) Inner and middle frames in centre-hung ventilators
(b) F5 is some times used as inner frames for open-out
windows. Also used as inner frame for bottom hung
ventilators
(c) F8 is also used as outer frame for bottom hung
ventilators.
F4B 2.28 Central mullion (meeting bar for shutters) for windows and
ventilators using F7D as inner frames, outer frames for open-
in windows in rainy areas, subdividing bars for openable
windows and top-hung ventilators.
F7D 1.419 Inner and outer frames for windows and top hung ventilators,
for inner frames for centre-hung ventilators and outer frames
for door sidelights.
FX6 2.52 Inner frame for doors
FZ7 1.90 Used as outer frame for industrial shashes. Also used for
outer frame for wooden doors
FX8 2.31 Outer frames for doors
FZ5 2.52 Inner frames for doors
K11B 1.80 (a) Vertical coupling mullion for standard windows
(b) Can be used as horizontal coupling bar when openable
windows are to be coupled above fixed ones or between
two fixed windows.
(c) Can also be used as horizontal coupling mullion where
windows are not exposed to weather.
PWD
Rajasthan Building Specifications 2014 Chapter 11 : Steel Work Page 55 of 69
LIST OF MANDATORY TESTS:
Material Test Test ti ty Frequency of
Laboratory Procedure of Material for Testing
Test carrying out the
test
1 2 3 4 5 6
Steel if (a) Tensile Laboratory IS 1599 20 tonne Every 20
arranged strength tonne or part
by the (b) Bend test thereof.
contractor
Steel (8910) Tensile Laboratory IS 1608 Every 8 tonne Every 8 tonne
tubular pipes Test IS 2329 or part or part
(b) Bend Test IS 2328 thereof Thereof
I Flattening
Test
LIST OF RE LAVENT BUREAU OF INDIAN IAN STANDARDS CODES

S. IS Code No. Subject
No.
1. 123-1962 coats of Paint on steel
2. 228-1987 Structural steel (Standard quality)
3. 419-1999 Putty for Glass panes
4. 554-1999 Thread fastners-Screw, socket etc.
5. IS 800-2007 Code of practice for use of structural steel in general in steel con-
struction
6. IS 806-1991 Code of practice for use of steel Tubes in general building construc-
tion
7. IS 808-2004 Dimensions for Hot rolled steel beams, columns, channel and
angle sections
8. IS 812-2008 Glossary of terms relating to welding and cutting metals
9. IS 813-1986 Scheme of symbols for welding
10. IS 814-2004 Covered electrodes for manual metal arc welding of carbon and
carbon manganese steel
11. IS 816-1969 Code of practice for use of metal arc welding for general construc-
tion in mild steel
12. IS 818-2003 Code of practice for safety and healthy requirements in electric
and gas welding and cutting operations
13. IS 822-1970 Code of procedure for inspection of welds
14. IS 823- Manual for metal arc welding in mild steel
15. IS 1038-1983 Steel doors, windows and ventilators
16. IS 1081-2006 Code of practice for fixing and glazing of metal (Steel and
aluminium) doors, windows and ventilators
17. 1083-1978 T iron for door window frames.
18. 1161-1998 Steel tubes for structural purposes
19. 1182-2000 Recommended practice for radiographic examination of fusion
welded butt joints in steel plates
20. 1200- (Pt. VIII) Method of measurements of steel work and iron works
21. 1239(P-1/II)- GI pipes
1990/ 1992
22. 1363 Part I-2002 Hexagon head bolts, screws, and nuts of product grade C (Hexagon
Head bolt)
23. 1367-2002 Technical supply conditions for threaded steel fasteners
24. 1599-2012 Method for bend test
25. 1608-2006 Metallic materials - Tensile Testing at Ambient Temperature.
26. 1894-1972 Method for tensile testing of steel tubes
27. 1977-1975 Structural steel (ordinary quality)
28. 2062-1999 Hot Rolled low, medium and high tensile structural steel
29. 2074-1992 Ready mixed paint, air drying redoxide zinc chrome priming
30. 4351-2003 Specification for Pressed steel door frames
31. 4454 (Part I)-2001 Steel wires for mechanical springs. Cold drawn unalloyed steel wire.
32. 4711-2008 Methods for sampling of steel pipes, tube and fittings.
33. 4736-1986 Hot - dip zinc coating on mild steel tubes
34. 4923-1997 Hollow Steel Sections for Structural Use - Specification
35. 6248-1979 Metal rolling shutters and rolling grills
36. 7452-1990 Specification for hot rolled steel sections for doors,
windows and ventilators.
37. 8910-2010 Specifications for structural steel.
38. 9595-1996 Metal Arc welding for Structural steel
40. 10842-2006 Y-Groove crackability test for structural steel.
CHAPTER No. 12
FLOORING WORK
CHAPTER No.12 : FLOORING WORK
CONTENTS
Clause No. Brief Description Page
No.
12.1 Scope 3
12.2 Brick on Edge Flooring 3
12.3 Cement Concrete Flooring 4
12.4 Cement Concrete Flooring with Topping of Red Oxide 7
12.5 Cement Concrete Flooring with Metallic Hardener Topping 8
12.6 Cement Plaster in Risers of Steps, Skirting & Dado 9
12.7 Cement Plaster Skirting Finished With Red Oxide 10
12.8 Cement Concrete Pavement in Courtyard and Terrace, etc. 10
12.9 Terrazzo (Marble Chips) Flooring laid in situ 13
12.10 Cement Mortar Skirting in Situ 15
12.11 Wax Polishing 16
12.12 Crazy Marble Flooring 16
12.13 Terrazzo Tile Flooring 17
12.14 Terrazzo Tiles in Risers of Steps, Skirting & Dado 20
12.15 Chequered Tile Flooring 21
12.16 Chequered Tiles in Stairs Treads 22
12.17 Marble Stone Flooring 23
12.18 Marble Stone in Risers of Steps and Skirting 26
12.19 Kota Stone Flooring 26
12.20 Kota Stone in Risers of Steps, Skirting & Dado 27
12.21 Rough Dressed Sand Stone Flooring 28
12.22 Fine Dressed Sand Stone Flooring 29
12.23 Fine Dressed and Rubbed Sand Stone Flooring 29
12.24 P. V. C. sheet/Tiles Flooring 30
12.25 P.V.C. Asbestos Floor Tiles 33
12.26 Linoleum Flooring 34
12.27 Rubber Flooring 35
12.28 Wooden Flooring 37
12.29 Wood Block Flooring 38
12.30 Granolithic Floor Finish 39
12.31 Pressed Ceramic /Glazed Tile Flooring 42
12.32 Pressed Ceramic Tile Flooring (Vitrified Tile Flooring) 44
12.33 Fixing of Tile Flooring with Cement based High Polymer
Modified Quick Set Adhesive (Water Based) 44
12.34 Pressed Ceramic Tiles in Skirting & Dado. 45
12.35 Acid or Alkali Resistant Tiles 46
12.36 Marble Work 47
Appendix A Abrasion Test for Concrete Hardening Compounds 53
Appendix B Test Requirements and Procedure for Testing Pre-Cast Cement
Concrete/Terrazzo Tiles 53
Appendix C Linoleum sheets 54
Appendix D Determination Of Sub-Floor Dryness 55
List of Bureau of than Standards Codes 57
CHAPTER No. 12
FLOORING WORK
12.1 Scope:
The specification lays down requirements for materials, preparation of sub-grade, thickness,
proportion, mixing, laying and mode of measurement of different type of floors.
12.2 Brick on Edge Flooring :
12.2.1 Bricks :Bricks of Specified dimensions and designations shall be used. These shall confirm to
the specifications. Broken bricks shall not be used in flooring except for closing the line. The bricks
shall be laid on edge.
12.2.2. Mortar: The Mortar used shall be as specified, (in case of dry bricks flooring fine sand shall
be filled in the joints).
12.2.3. Base Concrete :
12.2.3.1 Flooring shall be laid on base concrete. The base concrete shall be provided with the slope
required for the flooring. Floors in veranda , courtyard, kitchens, baths shall have slope ranging from
1:36 to 1:48 depending upon locations as decided by the Engineer-in-Charge. Floors in water closet
portion shall have slope of 1:30 or as decided by the Engineer-in-Charge to drain off washing water.
Plinth masonry off-set shall be depressed so as to allow the base concrete to rest on it.
12.2.3.2 If the base is of lean cement concrete, the flooring shall commence within 48 hours of the
laying of base, failing which, the surface of base shall be roughened with steel wire brushes without
disturbing the concrete.
Before laying the flooring the base shall be wetted and smeared with a coat of cement slurry at 2 kg
of cement spread over an area of one sqm so as to get a good bond between sub-grade and flooring.
12.2.3.3 Where base concrete is not provided, the earth below flooring shall be properly levelled,
sloped, watered, rammed and consolidated. Before laying the flooring, it shall be moistened.
12.2.4. Soaking of Bricks : Bricks required for flooring shall be adequately soaked in stacks before
use, by profusely spraying with clean water at regular intervals for a period of not less than six hours
so as to keep them wet to the satisfaction of the Engineer-in-Charge. (In case the joints are to be
filled with sand, the bricks need not be soaked).
12.2.5. Laying:
12.2.5.1.The bricks shall be laid on the edge in plain, diagonal herring bone bond, or other pattern as
specified or directed by the Engineer-in-Charge.
12.2.5.2. Bricks shall be laid on edge on 20 mm thick mortar bed and each brick shall be properly
bedded and set home by gentle topping with trowel handle or wooden mallet. Its inside face shall be
buttered with mortar, before the next brick is laid and pressed against it.
12.2.5.3. On completion of a portion of flooring, the vertical joints shall be fully filled from the top
with mortar. The surface of the flooring during laying, shall be frequently checked with a straight
edge at least 2 m long, so as to obtain a true plain surface with the required slope.
12.2.6. Joints: Bricks shall be so laid that all joints are full of mortar. The thickness of joints shall
not exceed 1.0 cm for brick work, with bricks of any class designation. All face joints shall be raked
to a minimum depth of 15 mm by raking tool during the progress of work when the mortar is still
green so as to provide proper key for the plaster or pointing to be done. Where plastering or pointing
is not required to be done, the joints shall be struck flush and finished at the time of laying. The face
of brick work shall be cleaned on the same day on which brick work is laid and all mortar droppings
removed promptly.
12.2.7. Curing: Brick work shall be protected from rain by suitable covering when the mortar is
green. Work shall be kept constantly moist on all faces for a minimum period of seven days. Brick
work carried out during the day shall be suitably marked indicating the date on which the work is
done so as to keep a watch on the curing period.
i) Length and breadth shall be measured correct to a cm and area as laid shall be calculated in
square metre correct to two places of decimal. Length and breadth shall be measured before
laying skirting, dado or wall plaster.
ii) No deduction shall be made nor extra paid for voids not exceeding 0.20 sqm. Deduction for
ends of dissimilar materials or other articles embedded shall not be made for areas not
exceeding 0.10 sqm.
iii) Brick flooring when laid in diagonal herring bone bond or other pattern as specified or
directed by the Engineer-in-Charge shall be measured separately.
12.2.9. Rate : The rate shall include the cost of all materials and labour involved in all the operations
described above, including application of cement slurry on base concrete or RCC slab and cleaning
of base. Base concrete shall be paid for separately.
12.2.10. Dry Brick Flooring : All provisions in 12.2.1 to 12.2.8 will be applicable subject to
following modifications. Bricks need not be soaked. Bricks will be laid on a bed of 12mm thick mud
mortar laid to required slope. The joints shall be as fine as possible and should not exceed 5mm,
which will be filled with fine sand. No curing is to be done.
12.2.10.1 Rate: The rate shall include the cost of all materials and labour involved in all the
12.3. Cement Concrete Flooring:
12.3.1. Cement Concrete: Cement concrete of specified mix shall be used. It shall conform the
requirements/ specifications as specified in chapter 5 of cement concrete .
12.3.2. Base Concrete :
12.3.2.1 Flooring shall be laid on base concrete where so provided. The base concrete shall be
provided with the slopes required for the flooring. Flooring in veranda, Courtyard, kitchens & baths
shall have slope ranging from 1:48 to 1:60 depending upon location and as decided by the Engineer-
in-Charge. Floors in water closet portion shall have slope of 1:30 or as decided by the Engineer-in-
Charge to drain off washing water. Plinth masonry off set shall be depressed so as to allow the base
concrete to rest on it.
12.3.2.2 If the base is of lean cement concrete, the flooring shall be commenced preferably within 48
hours of the laying of base concrete. The surface of the base shall be roughened with steel wire
brushes without disturbing the concrete. Immediately before laying the flooring, the base shall be
wetted and a coat of cement slurry at 2 kg of cement spread over an area of one sqm. so as to get a
good bond between the base and concrete floor.
12.3.2.3 If the cement concrete flooring is to be laid directly on the RCC slab the top surface of RCC
slab shall be cleaned and the laitance shall be removed and a coat of cement slurry at 2 kg of cement
spread over an area of one sqm so as to get a good bond between the base and concrete floor.
12.3.3. Thickness: The thickness of floor shall be as specified in the description of the item.
123.4 Laying:
12.3.4.1 Panels: Flooring of specified thickness shall be laid in the pattern including the border/ or
as given in the drawings or as directed by the Engineer-in-Charge. The border panels shall not exceed
450mm in width and the joints in the border in line with panel joints. The panels shall be of uniform
size and no dimension of a panel shall exceed 2 m and the area of a panel shall not be more than 2
sqm. The joints of borders at corners shall be mitred for provision of strips.
12.3.4.2. Laying of flooring with strips:
i) Normally cement concrete flooring shall be laid in one operation using glass/plain asbestos/
aluminium /PVC/brass strips or any other strips as required as per drawing or instructions of
the Engineer-in-Charge, at the junction of two panels.
ii) This method ensures uniformity in colour of all the panels and straightness at the junction of
the panels. 4 mm thick glass strips or 5mm thick plain asbestos sheet, 2mm PVC strips or 2mm
aluminium or brass strips shall be fixed with their tops at proper level, giving required slopes.
Cost of providing and fixing strips shall be paid for separately.
iii) Concreting : Cement concrete shall be placed in the panels and be levelled with the help of
straight edge and trowel. The blows shall be fairly heavy in the beginning but as consolidation
takes place, light rapid strokes shall be given. Beating shall cease as soon as the surface is found
covered with a thin layer of cream of mortar. The evenness of the surface shall be tested with
straight edge and made true to required slopes. While laying concrete, care shall be taken to see
that the strips are not damaged/disturbed by the labourers. The tops of strips shall be visible
clearly after finishing with cement slurry.
12.3.4.3. Laying of flooring without Strips :
i) Laying of cement concrete flooring in alternate panels may be allowed by the Engineer-in-
Charge in case strips are not to be provided.
ii) Shuttering : The panels shall be bounded by angle iron or flats. The angle iron/flat shall have
the same depth as the concrete flooring. These shall be fixed in position, with their top at proper
level giving required slopes. The surface of the angle iron or flats, to come in contact with
concrete shall be smeared with soap solution or non-sticking oil (Form oil or raw linseed oil)
before concreting. The flooring shall butt against the =plastered masonry wall.
iii) Concreting : The concreting shall be done in the manner described under 12.3.4.2. The angle
iron/flats used for shuttering, shall be removed on the next day of the laying of cement
concrete. The ends thus exposed shall be repaired, if damaged with cement mortar 1:2 (1
cement : 2 coarse sand) and allowed to set for minimum period of 24 hours. The alternate panels
shall then be cleaned of dust, mortar, droppings etc. and concrete laid. While laying concrete,
care shall be taken to see that the edges of the previously laid panels are not damaged and fresh
mortar is not splashed over them. The joints between the panels should come out as fine straight
lines.
123.5. Finishing :
12.3.5.1 The finishing of the surface shall follow immediately after the cessation of beating. The
surface shall be left for some time, till moisture disappears from it or surplus water can be mopped
up. Use of dry cement or cement and sand mixture sprinkled on the surface to stiffen the concrete or
absorb excessive moisture shall not be permitted. Excessive trowelling shall be avoided.
12.3.5.2 Fresh cement shall be mixed with water to form a thick slurry and spread at the rate of 2 kg
of cement over an area of one sqm. of flooring while the flooring concrete is still green. The cement
slurry shall then be properly processed and finished smooth.
123.5.3 The edges of sunk floors shall be finished and rounded with cement mortar 1:2 (1 cement : 2
coarse sand) and finished with a floating coat of neat cement.
12.3.5.4 The junctions of floor with wall plaster, dado or skirting shall be rounded off where so
specified.
12.3.5.5 The men engaged on finishing operations shall be provided with raised wooden platform to
sit on so as to prevent damage to new work.
123.6 Curing : The curing shall be done for a minimum period of ten days. Curing shall not be
commenced until the top layer has hardened. Covering with empty gunnies bag shall be avoided as the
colour of the flooring is likely to be bleached due to the remnants of cement dust from the bags.
12.3.7 Precautions: Flooring in lavatories / water closet and bath room shall be laid only after fixing
of water closet and squatting pans and floor traps. Traps shall be plugged while laying the floors and
opened after the floors are cured and cleaned. Any damage done to W.C.'s, squatting pans and floor
traps during the execution of work shall be made good.
During cold weather, concreting shall not be done when the temperature falls below 4°C. The
concrete placed shall be protected against frost by suitable covering. Concrete damaged by frost
shall be removed and work redone. During hot weather, precautions shall be taken to see that the
temperature of wet concrete does not exceed 38°C. No concreting shall be laid within half an hour
of the closing time of the day, unless permitted by the Engineer-in-Charge. To facilitate rounding of
junction of skirting, dado and floor, the skirting/dado shall be laid along with the border or adjacent
panels of floor.
12.3.8 Measurement: Length and breadth shall be measured before laying skirting dado or wall
plaster. No deduction shall be made nor extra paid for voids not exceeding 0.20 sqm. Deduction for
ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10
sqm.
The flooring done either with strips (in one operation) or without strips (in alternate panels) shall
be treated as same and measured together.
12.3.9 Rate : The rate shall include the cost of all materials and labour involved in all the operations
described above including application of cement slurry on RCC slab or on base concrete including
roughening and cleaning the surface but excluding the cost of strips which shall be paid separately
under relevant item. Nosing of steps where provided shall be paid for separately in running metre.
Nothing extra shall be paid for laying the floor at different levels in the same room or courtyard and
rounding off edges of sunk floors. In case the flooring is laid in alternate panels, nothing extra shall
be paid towards the cost of shuttering used for this purpose.
12.4. Cement Concrete Flooring With Topping of Red Oxide :
12.4.1 Cement Concrete: Cement concrete of specified mix shall be used.
12.4.2 Base Concrete: It shall be as specified in 12.3.2.
12.4.3. Under Layer: The under layer of flooring shall be of cement concrete of specified thickness.
The mix shall be 1:2:4 (1 cement :2 coarse sand :4 graded stone aggregate 12.5 mm nominal size)
by volume. As regards laying, the work shall be carried out in the manner specified in 12.3.4 except
that :
a) Angle or flat iron used for shuttering shall be to the height of both the under and top layers
of the floor.
b) The under layer shall not be left smooth but roughened with 2 mm deep diagonal lines at 7.5
cm centres both ways with a scratching tool to form a key for the finishing coat of red oxide
of iron. No cement slurry be added to the concrete surface
c) The angle or flat shall be removed only 24 hours after the top layer has been laid. The
surface of under layer shall be left even and true to slope.
12.4.4. Top Layer: This shall consist of uniform and smooth layer of plaster of 10 mm minimum
thickness unless otherwise specified and of mix 1:3 (1 cement :3 coarse sand) unless otherwise
specified, finished with a floating coat of neat cement. In both plaster and floating coat the ratio of
cement to red oxide of iron specified in the description of item shall be adopted. Normally 3.5 kg.
of red oxide of approved quality to 50 kg of cement shall be mixed. This ratio may, however, be
adjusted to the tinge ordered by the Engineer-in-Charge. The red oxide shall be dry mixed thoroughly
with the cement and then sand added and mixed. The full quantity of dry mortar required for a room
shall be prepared in one lot in order to ensure uniform colour. Wet mortar shall be prepared in the
usual manner as and when required.
a) Laying :
i) The top layer shall be laid, the following day after the under layer has been laid. The plaster
shall be done to a uniform thickness of 10 mm and finished smooth with cement slurry (2.0 kg
of cement, red oxide mix per square metre of flooring mixed in the ratio used for the plaster.
The surface shall then be brought to a fine polish by use of polishing stones.
ii) The angle or flats used for shuttering of panels shall be removed the next day, after the laying
of the top layer and broken edges repaired with the same coloured mortar as in plaster.
iii) The under layers of the alternate panels and the coloured plaster on top shall then be laid as
described above. In laying such alternate panels care shall be taken that concrete and coloured
mortar droppings do not disfigure the coloured topping previously finished.
iv) The junction of floor with wall plaster, dado or skirting shall be rounded off neatly where
so required, up to 25mm radius. Men engaged on the finishing operations shall be provided
with raised wooden platforms to sit on, so as to prevent damage to new work.
12.4.5 Thickness: The thickness of the under layer panels shall be as specified in the description of
the item and shall be measured correct to 1 cm. The thickness of the top layer shall not be less than
that specified.
12.4.6 Curing: The curing shall be done for a minimum period of ten days. Curing shall not be
commenced until the top layer has hardened. Covering with empty cement gunnies shall be avoided
as the colour is likely to be bleached with the remains of cement from the bags.
12.4.7 Precautions : These shall be as specified in para 12.3.7. 12.4.8
Measurements: These shall be as specified in para 12.3.8. 12.4.9
Rate:
i) The rate shall include the cost of all materials and labour involved in all the operations described
above including application of cement slurry on base concrete including roughening and cleaning
the surface of base concrete. The base concrete shall be paid for separately. Strips and nosing
of steps where provided shall be paid for separately in running metre. Nothing extra shall be
paid for laying the floor at different levels in the same room or courtyard and rounding off
edges of sunk floors. In case the flooring is laid in alternate panels, nothing extra shall be paid
towards the cost of shuttering used for this purpose.
ii) Where the quantity of red oxide used is different from what is described in the item to get the
tinge required by the Engineer-in-Charge, the difference in quantity shall be subject to
corresponding adjustment in the rate for the item.
12.5. Cement Concrete Flooring with Metallic Hardener Topping :
Wherever floors are required to withstand heavy wear and tear, use of floor hardener shall be avoided
as far as possible by using richer mixes of concrete, unless the use of a metallic hardener is justified
on the basis of cost. Where metallic hardener topping is used, it shall be 12mm thick.
12.5.1 Metallic Hardening Compound : The compound shall be of approved quality consisting of
uniformly graded iron particles, free from nonferrous metal particles, oil, grease, sand, soluble
alkaline compounds.
12.5.2 Base Concrete: It shall be as specified in 12.3.2.
12.5.3 Under Layer: Cement concrete flooring of specified thickness and mix shall be laid as under
layer. (12.4.1 and 12.4.3) The top surface shall be roughened with brushes while the concrete is still
green and the forms shall be kept projecting up 12mm over the concrete surface, to receive the metallic
hardening compound topping.
12.5.4. Topping:
i) This shall consist of 12mm thick layer of mix 1:2 (1 cement: 2 stone aggregate 6 mm nominal size)
by volume or as otherwise specified with which metallic hardening compound is mixed in the
ratio of 1:4 (1 metallic concrete hardener : 4 cement) by weight. Metallic hardener shall be dry
mixed thoroughly with cement on a clean dry pucca platform. This dry mixture shall be mixed
with stone aggregate 6 mm nominal size or as otherwise specified in the ratio of 1:2 (1 cement :
2 stone aggregate) by volume, and well turned over. Just enough water shall then be added to
this dry mix as required for floor concrete.
ii) The mixture so obtained shall be laid in 12mm thickness, on cement concrete floor within 2 to
4 hours of its laying. The topping shall be laid true to provide a uniform and even surface. It
shall be firmly pressed into the bottom concrete so as to have good bond with it. After the initial
set has started, the surface shall be finished smooth and true to slope with steel floats.
iii) The junction of floor with wall plaster, dado or skirting and finishing operations shall be dealt
with as described in 12.3.5.
iv) The men engaged on finishing operations shall be provided with raised wooden platform to
sit on, so as to prevent damage to new work.
12.5.5 Curing, Measurements and Rates :The specifications for curing, precautions to be taken,
`Measurements' and `Rates' shall be as specified in 12.3.
12.6 Cement Plaster in Risers of Steps, Skirting, Dado:
A band of plaster at the bottom of wall not exceeding 30 cm in height above the floor shall be
classified as skirting. It shall be flush with wall plaster or projecting out uniformly by 6 mm from the
wall plaster, as specified. The work shall be preferably carried out simultaneously with the laying of
floor. It's corners and junctions with floor shall be finished neatly as specified.
12.6.1 Thickness: The thickness of the plaster specified shall be measured exclusive of the thickness
of key i.e. grooves or open joints in brick work. The average thickness shall not be less than the
specified thickness. The average thickness should be regulated at the time of plastering by keeping
suitable thickness of the gauges. Extra thickness required in rounding of the corners at junctions of
wall shall be ignored.
12.6.2 Preparation of Wall Surface: The joints shall be raked out to a depth of at least 15mm in
masonry walls. In case of concrete walls, the surfaces shall be roughened by hacking. The surface
shall be cleaned thoroughly, washed with water and kept wet before skirting is commenced.
12.6.3 Application: Skirting with specified mortar and to specified thickness shall be laid
immediately after the surface is prepared. It shall be laid along with the border or adjacent panels of
floor. The joints in skirting shall be kept true and straight in continuation of the line of joints in
borders or adjacent panels. The skirting shall be finished smooth and true, with top truly horizontal
and joints truly vertical except where otherwise indicated.
12.6.4. Finishing: The finishing of the surface shall be done simultaneously with the borders of the
adjacent panels of floor. The cement to be applied in the form of slurry for smooth finishing shall be
at the rate of 2 kg of cement per litre of water applied over an area of 1 sqm. Where skirting is flush
with plaster, a groove 10 mm wide and up to 5 mm deep shall be provided in plaster at the junction
of skirting with plaster.
12.6.5. Curing: Curing shall be commenced on the next day of plastering when the plaster has
hardened sufficiently and shall be continued for a minimum period of 7 days.
12.6.6 Measurement: Length and height shall be measured correct to a cm and its area shall be
calculated in sqm correct to two places of decimals stating the thickness. Length shall be measured as
the finished length of skirting. Height shall be measured from the finished level of floor correct to 5
mm.
12.6.7 Rate: Rate shall include the cost of all materials and labour involved in all the operations
described above.
12.7 Cement Plaster Skirting Finished with Red Oxide:
12.7.1 Under Coat: The under coat of skirting shall be of cement plaster of the thickness and mix
described in the item. Specifications given under 12.6, 12.6.1 and 12.6.2 shall apply. As regards
application, the work shall be carried out in the manner described in para 12.6.3 except that the under
coat shall be finished rough with a scratching tool to form a key for the top coat.
12.7.2 Top Coat: 12.7.2.1 Mortar:
i) This shall consist of uniform and smooth layer of plaster of specified thickness and of mix 1:3
(1 cement : 3 coarse sand) unless otherwise specified, finished with a floating coat of neat
cement. In both plaster and floating coat the ratio specified in the description of item shall be
adopted. Normally 3.5 kg of red oxide of approved quality to 50 kg of cement shall be mixed.
This ratio may, however, be adjusted to the tinge ordered by the Engineer-in-Charge.
ii) The red oxide shall be mixed with the cement and then sand added and mixed. The full quantity
of dry mortar required for a room shall be prepared in one lot in order to ensure uniform colour.
Wet mortar shall be prepared in the usual manner as and when required.
12.7.2.2. Application: The top coat shall be done the next day after the under coat has been applied.
The plaster shall be done with the thickness specified and finished smooth, by application of cement-
red oxide mix, at the rate of 1.0 kg. per square metre of surface. The ratio adopted for the mix being
the same as that of the plaster. When the surface has hardened sufficiently it shall be brought to a
fine polish by use of polishing stones.
12.7.3. Thickness: The thickness of the bottom and top coats shall be as specified. The total
thickness of skirting specified is of total thickness of plaster as measured from the un-plastered face
of the masonry. Average thickness of the under coat shall not be less than 6 mm and minimum
thickness over any portion of the surface shall not be less than 4 mm. The thickness of top coat shall
not be less than the thickness specified.
12.7.4 Curing: Curing shall be commenced on the next day of plastering when the plaster has
hardened sufficiently and shall be continued for a minimum period of 7 days.
12.7.5 Measurements: Length and height shall be measured correct to a cm and its area shall be
calculated in sqm correct to two places of decimals stating the thickness. Length shall be measured
as the finished length of skirting. Height shall be measured from the finished level of floor correct
to 5 mm.
12.7.6. Rate: The rate shall include the cost of all materials and labour involved in all the operations
described above. Where the quantity of red oxide used is different from what is described in the item
to get the tinge required by the Engineer-in-Charge, the difference in quantity used will be subject
to corresponding adjustment in the rate for the item.
12.8. Cement Concrete Pavement in Courtyard and Terrace etc.:
12.8.1 Conventional Method:
12.8.1.1 Specifications described in 12.3 shall hold good as far as applicable except that :
i) The panels shall be of uniform size and no dimension of a panel shall exceed 1.25 m and the area
of panel should not exceed 1.25 sqm for the thickness of panels up to 50 mm.
ii) Concreting shall be done in alternate panels only and no glass/asbestos strips shall be provided.
12.8.1.2 Finishing: The finishing of the surface shall follow immediately after the cessation of
beating. The surface shall be left for some time, till moisture disappears from it or surplus water can
be mopped up.
Use of dry cement or cement and sand mix sprinkled on the surface to stiffen the concrete or to
absorb excessive moisture shall not be permitted. Excessive trowelling shall be avoided. When the
surface becomes fairly stiff, it shall be finished rough with wooden floats or where so specified
Chequered uniformly by pressing a piece of expanded metal of approved size.
12.8.1.3 Measurements: Same as 12.3.8 except that the volume will be calculated in cum nearest to
two decimal places.
12.8.1.4 Rate : The rate shall include the cost of all materials and labour involved in all the
operations described above except the base concrete below flooring which shall be paid for
separately. Chequering to pattern shall be paid for separately unless otherwise specified.
12.8.2 Vacuum Dewatering Process:
12.8.2.1 Suitability: This method is suitable to achieve a high quality concrete floor or pavement
which requires not only to be levelled but also to have high wear resistance, high compressive
strength, reduced shrinkage, minimum water permeability and minimum dusting. For such
requirement, this method is a system for laying high quality concrete floors with superior cost-
effectiveness.
a) The key to the use of this method is the dewatering of concrete by vacuum process. Surplus
water from the concrete is removed, reducing the water cement ratio to optimum level,
immediately after placing. Therefore, adoption of this method, facilitates use of concrete with
better workability than what is normally possible.
b) In order to obtain a high quality concrete floor using this method, it is essential to follow the
various operations, in the correct sequence.
c) Initially, poker vibration is a must, especially at the panel edges. This results in proper
compaction of wet concrete and hence elimination of voids and entrapped air.
d) Poker vibration never really gives a levelled surface. It is therefore essential to combine this
vibration with surface vibration in order to obtain a flat, level and vibrated concrete surface.
The surface vibrator should normally be run twice over the wet concrete. The machine can be
easily pulled by two men, standing on either side of the panel.
e) Surface vibration should always start as soon as there is enough concrete in front of the surface
vibrator .Two passes with the surface vibrator are required. During first pass, concrete must be
distributed evenly in front of the surface vibrator. There should always be a roll of concrete of
about 10-20 mm in front of the leading beam along the entire length of the vibrator .When the
concrete has been placed and vibrated to a length of about 5 meter, the second pass is carried
out. The machine should be pulled at a speed of maximum 1 metre/ minute and without
interruption to avoid linings on the surface. Keep the surface of channels (on which the surface
vibrator is supported), clean from concrete.
f) Vacuum dewatering process removes the surplus water always present in the concrete. This is
done using the vacuum equipment comprising of suction mat Top Cover, Filter Pads and
Vacuum Pump. The process starts immediately after surface vibration is over. Vacuum
dewatering process must start within 30 minutes from the time of starting concrete
pouring. Filter pads are placed on the fresh concrete leaving about 100 mm of fresh concrete
exposed on all sides. Filter pads should be overlapped with each other by at least 250 mm. The
recesses or other obstacles within the area to be vacuum processed must be covered and sealed
using polythene sheets before the filter pads are placed. If the obstacles are flush with the
surface level or above, filter pads must be folded. The Top Cover is then placed centrally on
the filter pads and rolled out till it covers the strips of exposed concrete on all sides. The mat is
then connected to the vacuum pump and the pump is started.
g) Vacuum is immediately created between the filter pads and the top cover. Atmospheric
pressure compresses the concrete and the surplus water is squeezed out of the concrete. This
process lowers the water content in the concrete by 15%-25%.
h) The dewatering operation takes approx.1- 1.5 minutes per centimetre of thickness of the floor.
The dewatered concrete is tightly compacted and dried to such an extent that a man can walk
on it, without leaving any foot prints. This is the proper indication of concrete being ready for
finishing. Guidelines for selecting dewatering time at normal condition are shown in the table
1.
i) The finishing operations - Floating and Trowelling- take place right after the dewatering.
Table 1:
Thickness Dewatering Time (min.)
mm. inch
50 2 7
100 4 15
125 5 20
150 6 25
200 8 30
250 10 40
300 12 45
a) Floating with a disc-The first finishing operation is carried out with floating disc. All four
sides of the dewatered panel must be floated first and the remaining central area is to be floated
later. Any corrections, if required, are to be made at this stage with the concrete collected at the
time of raking only. Never use any cement paste, mixture of cement and sand or fresh concrete
for patch work. Normally two passes with the disc with skim floater operating at higher speed
are sufficient for skid free surface.
b) Trowelling with blades - It is carried out with the same machine, two passes of trowelling
blades are required for smooth surface finish. The first trowelling operation can start after about
30 minutes after the final floating operation and surface is sufficiently dry. This can be start
with low speed and minimum blade angle and with lower speed near channels, form edges,
obstacles etc. Blade angle and speed can be increased to achieve smoother finish.
c) Repeated passes with disc and blades, improve the wear resistance substantially.
d) Curing can be done by ponding, covering with plastic sheets or gunny bags. In any case the
surface should be kept wet with water , at least for 7 days. Curing can also be done with curing
compound.
e) Size of panel : The floor area divided such that the size of panel not exceeding 3 sqm. in area,
so as to reduce the risk of cracking of the surface and longer dimension of any panel not
exceeding more than 2 m.
f) Specifications described in 12.8.1 shall hold good as far as applicable except the above. 12.9.
Terrazzo (Marble Chips) Flooring Laid in Situ:
12.9.1 Under Layer: Cement concrete of specified mix shall be used. The panels shall be of uniform
size, not exceeding 2 sqm in area or 2 m in length for inside situations. In exposed situations, the
length of any side of the panel shall not be more than 1.25 metre. Cement slurry @ 2.00 kg per sqm
shall be applied before laying of under layer over the cement concrete/RCC base.
12.9.2. Fixing of Strips: 4mm thick glass strips or 5 mm thick plain asbestos sheet or 2mm thick PVC
strips/aluminium strips/brass strips unless otherwise specified shall be fixed with their top at proper
level to required slope. Strips of stone or marble or of any other material of specified thickness can
also be used if specifically required. The fixing and laying shall be as specified in para 12.3.4.2.
12.9.3. Top Layer:
12.9.3.1 Mortar:
i) The mix for terrazzo topping shall consist of cement with or without pigment, marble powder,
marble aggregate (marble chips) and water. The cement and marble powder shall be mixed in
the proportion of three parts of cement to one part marble powder by weight.
ii) For every part of cement marble powder mix, the proportion of aggregate by volume shall be
as shown in Table 2.
iii) The marble chips shall be white or pink Makrana black Bhainslana, Chittor black, Jaisalmer
Yellow, Baroda green, Dehradun white, Chittor pink, yellow Patam Cherala (Madras), Grey
Gadu (Surat), Chittor green and yellow and Alwar black or as specified. It shall be hard, sound,
dense and homogenous in texture with crystalline and coarse grains. It shall be uniform in colour
and free from stains, cracks, decay and weathering. The minimum thickness of the top layer
for various sizes of marble aggregates (marble chips) shall be as shown in Table 2.
Table 2 : Proportion & Thickness of Top Layer
Grade No. Size of aggregates Proportion of Minimum thickness of
in (mm) aggregates to top layer (mm)
binder mix
0 1-2 1.75 : 1 6
0 2-4 1.75 : 1 6
1 4-7 1.75 : 1 9
2 7-10 1.5 : 1 12
iv) Where aggregate of size larger than 10 mm are used, the minimum thickness of topping shall
not be less than 1-1/2 times the maximum size of the chips. Where large size chips such as
20mm or 25 mm are used, they shall be used only with a flat shape and bedded on the flat face
so as to keep the minimum thickness of wearing layer.
v) Before starting the work, the contractor shall get the sample of marble chips approved by the
Engineer-in-charge. The cement to be used shall be ordinary grey cement, white cement, coloured
cement with admixture of colouring matter of approved quality in the ratio specified in the
description of the item to get the required shade as ordered by the Engineer-in-Charge. Colouring
materials where specified shall be mixed dry thoroughly with the cement and marble powder
and then marble chips added and mixed as specified above. The full quantity of dry mixture of
mortar required for a room shall be prepared in a lot in order to ensure a uniform colour. This
mixture shall be stored in a dry place and well covered and protected from moisture. The dry
mortar shall be mixed with water in the usual way as and when required. The mixed mortar
shall be homogenous and stiff and to contain just sufficient water to make it workable.
vi) The terrazzo topping shall be laid while the under layer is still plastic, but has hardened
sufficiently to prevent cement from rising to the surface. This is normally achieved between 18
to 24 hours after the under layer has been laid. A cement slurry preferably of the same colour
as the topping shall be brushed on the surface immediately before laying is commenced. It shall
be laid to a uniform thickness slightly more than that specified in order to get the specified
finished thickness after rubbing. The surface of the top layer shall be trowelled over, pressed
and brought true to required level by a straight edge and steel floats in such a manner that the
maximum amount of marble chips come up and are spread uniformly over the surface.
12.9.3.2 Polishing, Curing and Finishing :
i) Polishing shall be done by machine. About 36 hours after laying the top layer, the surface shall
be watered and ground evenly with machine fitted with special rapid cutting grit blocks
(carborundum stone) of coarse grade (No.60) till the marble chips are eventually exposed and
the floor is smooth. After the first grinding, the surface shall be thoroughly washed to remove
all grinding mud and covered with a grout of cement and colouring matter in same mix and
proportion as the topping in order to fill any pin holes that appear. The surface shall be allowed
to cure for 5 to 7 days and then rubbed with machine fitted with fine grit blocks (No.120). The
surface is cleaned and repaired as before and allowed to cure again for 3 to 5 days. Finally the
third grinding shall be done with machine fitted with fine grade grit blocks (No.320) to get
even and smooth surface without pin holes. The finished surface should show the marble chips
evenly exposed.
ii) Where use of machine for polishing is not feasible or possible, rubbing and polishing shall be
done by hand, in the same manner as specified for machine polishing except that carborundum
stone of coarse grade (No.60) shall be used for the Ist rubbing, stone of medium grade (No.80)
for second rubbing and stone of fine grade (No.120) for final rubbing and polishing.
iii) After the final polish either by machine or by hand, oxalic acid shall be dusted over the surface
@ 33 gm per square metre sprinkled with water and rubbed hard with a Nemdah block (Pad
of Woollen rags). The following day, the floor shall be wiped with a moist rag
and dried with a soft cloth and finished clean.
iv) Curing shall be done by suitable means such as laying moist sawdust or ponding water. 12.9.4
Precautions:
i) Flooring in lavatories and bathrooms shall be laid after fixing of water closet and squatting
pans and floor traps. Traps shall be plugged, while laying the floors and opened after the floors
are cured and cleaned. Any damage done to WC's squatting pans and floor traps during the
execution of work shall be made good.
ii) During cold weather, concreting shall not be done when the temperature falls below 4°C. The
concrete placed shall be protected against frost by suitable coverings. Concrete damaged by frost
shall be removed and work redone. During hot weather, precautions shall be taken to see that
the temperature of wet concrete does not exceed 38°C. No concreting shall be laid within half
an hour of the closing time of the day, unless permitted by the Engineerin-Charge.
i) Length and breadth shall be measured correct to a cm before laying skirting, dado or wall
plaster. The area as laid shall be calculated in sqm. correct to two decimal places.
ii) The thickness of the under layer shall be measured correct to a cm. The thickness of top
layer shall not be less than that specified.
iii) No deduction shall be made, nor extra paid for voids not exceeding 0.20 square metre.
Deduction for ends of dissimilar materials or other articles embedded shall not be made for
areas not exceeding 0.10 square metre. Nothing extra shall be paid for laying the floor at
different levels in the same room or courtyard..
iv) Terrazzo (Marble Chips) flooring laid as floor borders, margins and similar bands up to 30 cm
width and on staircase treads shall be measured under the item of terrazzo flooring but extra
shall be paid for such work.
v) This extra in the case of staircase treads shall include the cost of forming the nosing also.
However, moulded nosing shall be paid extra in running metres except where otherwise stated,
returned moulded ends and angles to mouldings shall be included in the description. Extra shall
also be paid for laying flooring in narrow bands not exceeding 7.5 cm in width and such bands
shall be measured in running metres for this purpose.
vi) Dividing strips inserted in terrazzo to form bays, patterns shall be described stating the
materials, its width and thickness and measured in running metres.
vii) Special surface finishes to treads, risers and the ends of concrete steps and the like shall be
measured separately and given in square metres and shall include form work, if required.
described above including cleaning of surface of RCC slab or base concrete and application of
cement slurry but shall not include the cost of base concrete and cost of providing and fixing strips
of glass or aluminium or of any other material used for making panels, which shall be paid for
separately.
12.10 Cement Mortar Skirting in Situ:
12.10.1 Under Layer: The under coat of skirting shall be of cement plaster of the thickness and
mix described in the item. Specifications given under 12.6, 12.6.1 and 12.6.2 shall apply. As regards
application, the work shall be carried out in the manner described in para 12.6.3 except that the under
coat shall be finished rough with a scratching tool to form a key for the top coat.
12.10.2. Top Layer: The specification as in para 12.9.3 shall hold good as far as applicable and shall
include cutting to line and fair finish to top edges of terrazzo and polishing.
12.10.3 Thickness: The thickness of the bottom and top coats shall be as specified. The total
thickness of skirting specified is of total thickness of plaster including top coat as measured from the
un-plastered face of the masonry. Average thickness of the under coat shall not be less than 6 mm
and minimum thickness over any portion of the surface shall not be less than 4 mm. The thickness
of top coat shall not be less than the thickness specified.
12.10.4 Measurements: Length and height shall be measured correct to a cm and its area shall be
calculated in sqm correct to two places of decimals. Length shall be measured from the finished level
of floor correct to 5mm where the height of skirting does not exceed 30 cm and when the height
exceeds 30 cm it shall be measured correct to a cm.
12.10.5 Rates: The rate shall include the cost of all materials and labour involved in all the operations
described above.
12.11: Wax Polishing:
12.11.1 Application, Polishing and Precautions:
Wax polish shall be of approved brand and manufacture and in sealed containers. It shall be applied
in uniform layer to the dry surface of the floor/skirting.
When the layer of the wax is stiffened and surface of floor is saturated with the polish, polishing
shall be resorted with machine fitted with bobs (pad of rags) and shall be done until shades of all
chips have appeared and glossy surface is obtained.
The fresh polished floor surface shall be spread with dry saw dust to a thickness of about 12 mm
uniformly. After the surplus wax has been soaked from the floor surface the saw dust shall be
removed.
12.11.2 : Measurement: Length and breadth shall be measured correct to a cm and its area shall be
calculated in sqm correct to two places of decimal.
12.11.3:Rate : The rate shall include the cost of all materials and labour involved in all the operations
described above.
12.12. Crazy Marble Flooring:
12.12.1 Base Concrete:
Crazy marble stone flooring shall be laid on cement or lime concrete base. The base concrete shall
be provided with slope required for the flooring in veranda and courtyards to drain off washing and
rain water. The surface of base shall be roughened with steel wire brushes, without disturbing the
concrete, wetted and smeared with a floating coat of cement slurry at 2 kg of cement spread over an
area of one sqm. so as to get a good bond between base and flooring.
Before laying the flooring on RCC slabs, the laitance shall be removed, the surface of slab hacked and
a coat of cement slurry at 2 kg of cement spread over an area of one sqm. shall be applied so as to
get a good bond between RCC slab and floor.
12.12.2 Under Layer: The under layer of crazy marble flooring shall be of cement concrete of
thickness 25 mm or as specified. The mix shall normally be 1:2:4 (1 cement :2 coarse sand : 4 graded
stone aggregate 12.5 mm nominal size) by volume unless otherwise specified. It shall conform to
the specifications given under para 5.2 of chapter `Cement Concrete'.
12.12.3. Top Layer:
i) The mix of crazy marble stone flooring shall consist of white cement with or without pigment,
marble powder, marble chips of 00 Nos. and marble stone pieces and water. The marble stone
pieces shall be hard, sound, dense and homogenous in texture with crystalline and coarse grains.
It shall be uniform in colour and free from stains, cracks, decay and weathering. Before starting
the work the contractor shall get the sample of marble stone approved by the Engineer-in-
Charge. The marble stone pieces shall be of sizes as approved by the Engineer-in-Charge but
the thickness shall be according to the overall thickness specified which could be achieved
when laid over the under layer as specified. Thus for 50 mm thick floor, the thickness of marble
pieces will be 25mm while for 40 mm thick floor, the thickness will be 15 mm.
ii) The white cement and marble powder shall be mixed in proportion of three parts of cement and
one part of marble powder by weight, and the proportion of marble chips to binder mix by
volume shall be 7 parts of marble chips to 4 parts of binder mix. The marble chips shall be as
specified. It shall be hard, sound, dense and homogenous in texture. It shall be uniform in colour
and free from stains, cracks decay and weathering.
12.12.4 Laying: A coat of cement slurry at the rate of 2 kg of cement per sqm. of area shall be spread
and then the marble stone pieces shall be set by hand in such a manner that the top surface of all the
set marble stones shall be true to the required level and slopes. After fixing the stones, the cement
marble chips mixture shall be filled in between the gaps of laid marble stone pieces. The filled
surface then shall be trowelled over, pressed and brought to the level of the laid marble stone pieces.
12.12.5 Polishing , Curing and Finishing: These shall be as described in 12.9.3.2.
12.12.6. Precautions: Flooring in lavatories and bathrooms shall be laid after fixing of water closet
and squatting pans and floor traps. Traps shall be plugged, while laying the floors and opened after
the floors are cured and cleaned.
12.12.7 Measurements: Length and breadth shall be measured correct to a cm before skirting, dado
or wall plaster and it shall be calculated in sqm correct to two decimal places. No deduction shall be
made nor extra paid for voids not exceeding 0.20 square metre. Deductions for ends of dissimilar
materials or other articles embedded shall not be made for areas not exceeding 0.10 square metre.
Nothing extra shall be paid for laying floor at different levels in the same room or courtyards.
described above including the cost of cleaning of RCC slab surface and applying the cement slurry,
but it shall not include the cost of base concrete.
12.13. Terrazzo Tile Flooring:
12.13.1 Terrazzo Tiles
12.13.1.1Terrazo tiles shall generally confirm to IS : 1237-1980. Unless otherwise specified, the
tiles shall be supplied with initial grinding and grouting of wearing layer.
The size of tiles shall be as given in Table 3 or as shown in the drawings or as required by the
Engineer-in-Charge. Half tiles for use with the full tiles shall be such as to make two half tiles when
joined together, match with the dimensions of one full tile. The normal sizes are i) 200x200x20 mm,
ii) 250x250x22 mm, and iii) 300x300x25 mm.
12.13.1.2. Tolerance:
i) Tolerance on length and breadth shall be plus or minus one millimetre, and tolerance on
thickness shall be plus 5 mm. The range of dimensions in any one delivery of tiles shall not
exceed 1 mm on length and breadth and 3 mm on thickness.
ii) The tiles shall be manufactured in a factory under pressure process subjected to hydraulic
pressure of not less than 140 kg per square centimetre and shall be given the initial grinding
with machine and grouting of the wearing layer before delivery to site. The wearing layer shall
be free from projections, depressions, cracks, holes and cavities. The edges of wearing layer
may be rounded
iii) The proportion of cement to aggregate in the backing of tiles shall be not leaner than 1:3 by
weight. Where colouring material is used in the wearing layer, it shall not exceed 10 per cent by
weight of cement used in the mix.
iv) The finished thickness of the upper layer shall not be less than 5 mm for size of marble chips
from the smallest up to 6 mm and also, not less than 5 mm for size of marble chips ranging
from the smallest up to 12 mm, and not less than 6 mm for size of marble chips varying from
the smallest up to 20 mm.
12.13.2. Laying:
12.13.2.1.Base:
i) Base concrete or RCC slab on which the tiles are to be laid shall be cleaned, wetted and
mopped. The bedding for the tiles shall be with cement mortar as specified, prepared in
conformity with provisions in relevant para of Chapter 4 on `Mortar'.
ii) The ingredients shall be thoroughly mixed by volume in dry form. Care shall be taken to ensure
that there are no hard lumps present. Water shall then be added and the ingredients thoroughly
mixed.
iii) Cement mortar 1:4 (1 cement : 4 coarse sand) bedding be used and the average thickness of
the bedding mortar shall be 20 mm and the thickness at any place shall not be less than 10 mm.
iv) Over the cement mortar bedding neat grey cement slurry of honey like consistency shall be
spread at the rate of 4.4 kg of cement per square metre over such an area as would accommodate
about twenty tiles. Tiles shall be washed clean and shall be fixed in this grout one after another,
each tile being gently The ingredients shall be thoroughly mixed by volume in dry form. Care
shall be taken to ensure that there are no hard lumps present. Water shall then be added and the
ingredients thoroughly mixed.
v) Cement mortar 1:4 (1 cement : 4 coarse sand) bedding be used and the average thickness of the
bedding mortar shall be 20 mm and the thickness at any place shall not be less than 10 mm.
12.13.2.2. Fixing:
i) Over the cement mortar bedding neat grey cement slurry of honey like consistency shall be
spread at the rate of 4.4 kg of cement per square metre over such an area as would accommodate
about twenty tiles. Tiles shall be washed clean and shall be fixed in this grout one after another,
each tile being gently tapped with a wooden mallet till it is properly bedded, and in level with
the adjoining tiles. The joints shall be kept as thin as possible not exceeding 1.5 mm and in
straight lines or to suit the required pattern.
ii) The surface of the flooring during laying shall be frequently checked with a straight edge at
least 2 metre long, so as to obtain a true surface with the required slope.
iii) Where full tiles or half tiles cannot be fixed, tiles shall be cut (sawn) from full tiles to the
required size and their edges rubbed smooth to ensure a straight and true joint.
iv) Tiles which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the
plaster, skirting or dado. The junction between wall plaster and tile work shall be finished neatly
and without waviness.
v) After the tiles have been laid, surplus cement grout that may have come out of the joints shall
be cleared off.
12.13.3. Curing, Polishing and Finishing:
i) The day after the tiles are laid all joints shall be cleaned of the grey cement grout with a wire
brush or trowel to a depth of 5 mm and all dust and loose mortar removed and cleaned. Joints
shall than 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. The same cement slurry shall be applied
to the entire surface of the tiles in a thin coat with a view to protect the surface from abrasive
damage and fill the pin holes that may exist on the surface.
ii) The floor shall then be kept wet for a minimum period of 7 days. The surface shall thereafter
be grounded evenly with machine fitted with coarse grade grit block (No.60). Water shall be
used profusely during grinding. After grinding the surface shall be thoroughly washed to
remove all grinding mud, cleaned and mopped. It shall then be covered with a thin coat of grey
or white cement, mixed with or without pigment to match the colour of the topping of the
wearing surface in order to fill any pin hole that appear. The surface shall be again cured. The
second grinding shall then be carried out with machine fitted with fine grade grit block
(No.120).
iii) The final grinding with machine fitted with the finest grade grit blocks (No.320) shall be carried
out the day after the second grinding described in the preceding para or before handing over
the floor, as ordered by the Engineer-in-Charge.
iv) For small areas or where circumstances so require, hand polishing may be permitted in lieu of
machine polishing after laying. For hand polishing the following carborundum stones, shall be
used :
Ist grinding - coarse grade stone (No.24-60)
Second grinding- medium grade (No.120-150)
Final grinding - fine grade (No.220-350)
In all other respects, the process shall be similar as for machine polishing.
v) After the final polish, oxalic acid shall be dusted over the surface at the rate of 33 gm per square
metre sprinkled with water and rubbed hard with a `Namdah' block (pad of woollen rags). The
following day the floor shall be wiped with a moist rag described in the preceding para or before
handing over the floor, as ordered by the Engineer-in-Charge.
vi) For small areas or where circumstances so require, hand polishing may be permitted in lieu of
machine polishing after laying with the exclusive permission of the Engineer-in-Charge. For
hand polishing the following carborundum stones, shall be used :
Ist grinding - coarse grade stone (No.24-60)
Second grinding- medium grade (No.120-150)
Final grinding - fine grade (No.220-350)
In all other respects, the process shall be similar as for machine polishing.
vii) After the final polish, oxalic acid shall be dusted over the surface at the rate of 33 gm per square
metre sprinkled with water and rubbed hard with a `Namdah' block (pad of woollen rags). The
following day the floor shall be wiped with a moist rag and dried with a soft cloth and finished
clean.
viii) If any tile is disturbed or damaged, it shall be refitted or replaced, properly jointed and
polished.
The finished floor shall not sound hollow when tapped with a wooden mallet.
i) Terrazzo tiles flooring with tiles manufactured from ordinary grey cement without pigment and
coloured terrazzo tile flooring shall be measured separately and classified as in para 12.9.5.
Terrazzo tile flooring shall be measured as laid in square metre correct to two places of decimal.
For length and breadth dimensions correct to a cm before laying skirting, dado or wall plaster
shall be taken. No deduction shall be made nor extra paid for voids not exceeding 0.20 sqm.
Deductions for ends of dissimilar materials or other articles embedded shall not be made for
areas not exceeding 0.10 square metre. Nothing extra shall be paid for use of cut tiles nor for
laying the floor at different levels in the same room or courtyard.
ii) Terrazzo tile flooring laid in floor borders and similar band shall be measured under the item
of terrazzo tile flooring. Nothing extra shall be paid in respect of these and similar bands
formed of half size of multiplies of half size standard tiles or other uncut tiles.
iii) Treads of stairs and steps paved with tiles without nosing, shall also be measured under
flooring. Moulded nosing shall be paid in running metre except where otherwise stated,
returned moulded ends and angles to mouldings shall be included in the description. Extra shall,
however, be paid for such areas where the width of treads does not exceed 30 cm.
described above. Where cement mortar bedding is used in place of lime mortar the rate will be
adjusted accordingly.
12.14. Terrazzo Tiles in Risers of Steps, Skirting and Dodo:
12.14.1. Specifications: The terrazzo tiles shall be as specified in 12.13.1, as far as applicable. The
minimum finished thickness of tiles shall, however, be 12 mm. The finished thickness of the upper
layer shall be not less than 5 mm for size of marble chips from the smallest up to 12 mm
and not less than 6 mm for size of chips varying from the smallest up to 20 mm. Where the bigger
sized chips are used the tiles shall be not less than 20 mm thick.
12.14.2. Preparation of Surface: The specification for this shall be same as specified in 12.6.2.
12.14.3. Laying: 12mm thick plaster of cement mortar 1:3 (1 cement:3 coarse sand) or mix as
specified, shall then be applied and allowed to harden. The plaster shall than be roughened with wire
brushes or by scratching diagonal lines 2 mm deep at approximately 7.5 cm centres both ways. The
back of tiles shall be buttered with a coat of grey cement slurry and edges with grey or white cement
slurry with or without pigments to match the shade of tiles, and set in the bedding mortar. These
shall be tamped and corrected to proper planes and lines. The tiles shall be set in the required pattern
and but jointed. The joints shall be as fine as possible. Top of skirting or dado shall be truly horizontal
and joints truly vertical except where otherwise indicated.
The risers of steps, skirting or dado shall rest on the top of the tread or flooring. Where full size tiles
cannot be fixed, the tiles shall be cut (sawn) to the required size and their edges rubbed smooth.
12.14.4. Curing, Polishing and Finishing: The specifications as in 12.13.3 shall hold good as far
as applicable. Polishing shall be done only with hand.
12.14.5. Measurements: The thickness of the skirting shall be as stated. Length shall be measured
along the finished face of riser, skirting or dado correct to a cm. Height shall be measured from the
finished level of tread or floor to the top (the underside of tread in the case of steps). This shall be
measured correct to 5 mm in case of risers and skirting not exceeding 30 cm in height. In case of
heights more than 30 cm, as in the case of dado and on walls, the height shall be measured correct
to a cm and such work shall be paid for separately. The area shall be calculated in square metre,
correct to two places of decimal.
Where the height of risers, skirting or dado does not a t of full size or other finished size tiles and
the tiles are to be cut (sawn), nothing extra shall be paid for the same.
described above. Nothing extra shall be payable for use of cut (sawn) tiles to suit the size of risers,
skirting, portions of dado etc.
12.15. Chequered Tile Flooring :
12.15.1 Chequered Tiles: The tiles shall be of nominal sizes such as 20x20 cm 25x25 cm and 30x30
cm or of standard sizes with equal sides. The size of tiles to be used shall be as shown in drawings
or as required by the Engineer-in-Charge. The centre to centre distance of chequers shall not be less
than 2.5 cm and not more than 5 cm.
The overall thickness of the tiles shall not be less than 22 mm. The grooves in the chequers shall be
uniform and straight. The depth of the grooves shall not be less than 3 mm. The chequered tiles shall
be cement tiles, or terrazzo tiles as specified in the description of the item. The thickness of the upper
layer, measured from the top of the chequers shall not be less than 6 mm.
The tiles shall conform to the specifications for plain cement concrete or terrazzo tiles in respect of
method of manufacture and the mix of the backing and wearing layers.
12.15.2. Laying, Curing, Polishing and Finishing shall be as specified in 12.13.2 and 12.13.3 except
that the polishing of the tiles and the chequers grooves, after laying, may be done by hand. Special
care shall be taken to polish the grooves in such a manner as to get a uniform section
and that their finish shall match with the finish of flat portion of the tiles. Cement concrete tiles
normally do not require polishing but where polishing is required the same shall be done as described
above.
12.15.3. Measurement and Rate: Shall be as specified in 12.13.4 and 12.13.5.
12.16. Chequered Tiles in Stairs & Treads:
12.16.1 Chequered Tiles: The specifications for tiles shall be as specified in 12.15.1 except in the
following respects:-
1) The length of the tiles including nosing shall be as specified.
2) The nosing edge of the tile shall be rounded.
3) The minimum thickness of the tile shall be 30 mm.
4) The front portion of the tile for a minimum length of 75 mm from and including the nosing
shall have grooves running parallel to the nosing and at centres not exceeding 25 mm. Beyond
that the tiles shall have the normal chequers pattern.
5) The nosing shall also have the same wearing layer as the top.
12.16.2 Preparation of Surface and Laying:
i) RCC or brick work in treads on which the tiles are to be laid shall be cleaned wetted and
mopped. The bedding for tiles shall be with lime mortar of either 1:1:1 (1 lime putty : 1 surkhi
: 1 coarse sand) or 1:4 (1 cement : 4 coarse sand) or of specified mix. The minimum thickness
of bedding mortar at any place shall be 10 mm. Bedding mortar shall be spread, tamped and
corrected to proper levels. After laying bedding mortar, neat grey cement slurry of honey like
consistency shall be spread over the mortar at the rate of 4.4 kg of cement per square metre
over each tread. Tiles shall be washed cleaned and shall be fixed in this grout one after another.
Each tile being gently tapped with a wooden mallet till it is properly bedded, and is in level and
line
ii) The joints shall be kept as thin as possible and in straight lines. The surface shall be checked
with a straight edge during laying to obtain a true surface.
iii) The square end of the tile shall, as far as possible butt against the riser face of the concrete or
brick tread and in any case shall be embedded under the side wall plaster, skirting or dado and
under the riser tile or other finish to a depth of not less than 10 mm.
vi) Where full size tiles cannot be fixed, these shall be cut (sawn) to the required size (along the
groove of the chequers where the cut edge is exposed) and used. The cut in the case of
embedded edges will be neat and true while the cut in the case of exposed edges shall in addition
be rubbed smooth to ensure a straight and true joints.
v) After the tiles have been laid surplus cement grout shall be cleaned off.
12.16.3. Curing, Polishing and Finishing: The specifications shall be as described in 12.13.3
except that polishing of the treads nosing and chequered grooves, after laying, may be done by hand
in the same manner as specified under terrazzo tile flooring. Special care shall be taken to polish the
nosing and the grooves in such a manner as to get a uniform, section for the grooves and the nosing
and their finish shall match with the finish of the flat portion of the tiles.
12.16.4. Measurements: Chequered tiles on stair & treads shall be measured in square metre
correct to two places of decimal. Length shall be measured correct to a cm before laying skirting,
dado or wall plaster. Width shall be measured correct to a cm from the outer edge of the nosing, as
laid, before providing the riser. In the case of the edge tiles of the landing and wide steps, width shall
be measured up to the near edge of the chequered stair tread tiles. Deductions for ends of dissimilar
materials or other articles embedded shall not be made for areas not exceeding 0.10 square metre.
described above. Nothing extra shall be payable for cutting the tiles to suit the size of treads and also
for nosing.
12.17 Marble Stone Flooring:
12.17.1 Marble:
12.17.1.1 Specifications:
i) Marble shall be hard, sound, dense and homogenous in texture with crystalline texture as far
as possible. It shall generally be uniform in colour and free from stains, cracks, decay and
weathering.
ii) Marbles are metamorphic rocks capable of taking polish, formed from the re-crystallization of
lime stones or dolomitic lime stones and are distinguished from lime stone by even visibly
crystalline nature and non-flaggy stratification.
Note : Marble is a product of nature hence it is difficult to guarantee uniformity of colour, veining or
other characteristics that may be represented in any sample submitted. A sample will indicate only
an average of colour, veining and other general texture and specified finish.
12.17.1.2 Classification: The marble blocks, slabs and tiles shall be classified broadly in the
following two categories :
(i) White Marble
(ii) Coloured Marble such as black, green, pink, brown, grey marble etc.
12.17.1.2.1 White Marble:
(A) Plain White Marble :-
(a) Makrana first quality White Marble : Plain white marble without streaks
(b) Makrana second quality White Marble : White marble having lighter shades or spots.
(c) Abu White Marble : White Marble with Blue and grey shades available at Ambaji.
(d) Raj Nagar Marble : It shall be plain white marble with coarse grains predominantly showing
mica particles giving reflection in bright light.
(B) Abu Panther Marbles : White marble with irregular blue black spots available in
Ambaji,White Veined Marbles:
(a) Makrana Doongri Adanga Marble : Light greyish white marble having grey and brown
veins.
(b) Makrana Chak Doongri Marble : White marble having black streaks.
(c) Abu White Veined Marble.
(d) White marble with grey or black veins available at Ambaji.
12.17.1.2.2 Coloured Marble:
(A) Black Marble:
(a) Plain or Bhainslana Black Marble .Black marble sawn along veins available at Bhainslana.
(B) Black Zebra Marble :
(a) Bhainslana Black Zebra Marble : Black marble having grey or white veins available at
Bhainslana.
(b) Kishangarh Black Zebra Marble: Black marble with grey and/or white veins available at
Kishangarh.
(c) Abu Black Zebra Marble : Black marble having white patches and streaks available at Abu.
(d) Narnaul Black Zebra Marbles : Black marble with thin white veins available at Narnaul.
(C) Green Marble :
(a) Baroda Green Marble : Dark green marble with flowery pattern available at Baroda.
(b) Abu Green Marble : Light green marble with green and/or brown streaks on white ground
available at Ambaji.
(c) Falna Green Marble.: Green marble with prominent yellowish pattern available at Falna.
(d) Bundi Green Marble : Green marble with pinkish shades available at Umar. (Bundi).
(D) Pink Marble:
(a) Plain Pink Marble : Pink Marble with light or dark shades available at Makrana and Bar.
(b) Pink Adanga Marble
(i) Makrana Pink Adanga Marble : Pink marble with brown or greenish and white streaks
available at Makrana. It has both light and dark shades of pink.
(ii) Bar Pink Adanga Marble : Pink marble with green veins available at Bar.
(iii) Bundi Pink Adanga Marble : Pink marble with grey streaks available at Umar (Bundi).
(E) Grey Marble :
(a) Kumari Grey Marble : Grey marble having light blue shades available at Makrana.
(b) Bundi Grey Marble : Grey Marble with pink or green or black streaks available at Umar
(Bundi).
(F) Brown Marble:
(a) Bar Brown Marble/Brown Marble with light and dark brown shades available at Bar.
(b) Narnaul Brown Marble Brown marble having teak wood shades available at Narnaul.
12.17.2 Dressing of Slabs: Every stone shall be cut to the required size and shape, fine chisel dressed
on all sides to the full depth so that a straight edge laid along the side of the stone shall be fully in
contact with it. The top surface shall also be fine chisel dressed to remove all waviness. In case
machine cut slab are used, fine chisel dressing of machine cut surface need not be done provided a
straight edge laid anywhere along the machine cut surfaces is in contact with every point on it. The
sides and top surface of slabs shall be machine rubbed or table rubbed with coarse sand before
paving. All angles and edges of the marble slabs shall be true, square and free from chippings and
the surface shall be true and plane.
The thickness of the slabs shall be 18 to 20 mm as specified in the description of the item.
Tolerance of + 3% shall be allowed for the thickness. In respect of length and breadth of slabs a
tolerance of +/-2% shall be allowed.
12.17.3 Laying :
i) Base concrete or the RCC slab on which the slabs are to be laid shall be cleaned, wetted and
mopped the bedding for the slabs shall be with cement mortar 1:4(1 cement : 4 coarse sand)
or as given in the description of the item.
ii) The average thickness of the bedding mortar under the slab shall be 20 mm and the thickness
at any place under the slab shall be not less than 12 mm.
iii) The slabs shall be laid in the following manner:
a) Mortar of the specified mix shall be spread under the area of each slab, roughly to the
average thickness specified in the item. The slab shall be washed clean before laying. It
shall be laid on top, pressed, tapped with wooden mallet and brought to level with the
adjoining slabs. It shall be lifted and laid aside. The top surface of the mortar shall then
be corrected by adding fresh mortar at hollows. The mortar is allowed to harden a bit and
cement slurry of honey like consistency shall be spread over the same at the rate of 4.4
kg of cement per sqm. The edges of the slab already paved shall be buttered with grey or
white cement with or without admixture of pigment to match the shade of the marble
slabs as given in the description of the item.
b) The slab to be paved shall then be lowered gently back in position and tapped with
wooden mallet till it is properly bedded in level with and close to the adjoining slabs with
as fine a joint as possible. Subsequent slabs shall be laid in the same manner. After each
slab has been laid, surplus cement on the surface of the slabs shall be cleaned off. The
flooring shall be cured for a minimum period of seven days. The surface of the flooring
as laid shall be true to levels, and, slopes as instructed by the Engineer-in-Charge.
c) Due care shall be taken to match the grains of slabs which shall be selected judiciously
having uniform pattern of veins/streaks or as directed by the Engineer-in-Charge.
vi) The slabs shall be matched as shown in drawings or as instructed by the Engineer-in-Charge.
vii) Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the
plaster skirting or dado. The junction between wall plaster and floor shall be finished neatly
viii) Marble slabs flooring shall also be laid in combination with other stones and/or in simple
regular pattern/design as described in item of work and/or drawing.
12.17.4 Polishing and Finishing : Slight unevenness at the meeting edges of slabs shall then be
removed by fine chiselling and finished in the same manner as specified in 12.12.3 except that cement
slurry with or without pigments shall not be applied on the surface before each polishing.
12.17.5 Measurements: Marble stone flooring with different kind of marble shall be measured
separately and in square metre correct to two places of decimal. Length and breadth shall be
measured correct to a cm before laying skirting, dado or wall plaster. No deduction shall be made nor
extra paid for voids not exceeding 0.20 square metre. Deductions for ends of dissimilar materials or
other articles embedded shall not be made for areas not exceeding 0.10 square metre. Nothing extra
shall be paid for laying the floor at different levels in the same room. Steps and
treads of stairs paved with marble stone slabs shall also be measured under the item of Marble Stone
flooring. Extra shall, however, be paid for such areas where the width of treads does not exceed 30
cm. Nosing for treads shall be measured in running metre and paid for extra. The width of treads
shall be measured from the outer edge of the nosing, as laid, before providing the riser.
described above.
12.18. Marble Stone in Risers of Steps and Skirting:
12.18.1: Specifications: Marble Stone Slabs and Dressing of Slabs shall be as specified in 12.17.1 and
12.17.2. A tolerance of ± 3% mm shall be allowed, unless otherwise specified in the description of the
item.
12.18.2. Preparation of Surface: Where necessary, the wall surface shall be cut uniformly to the
requisite depth so that the skirting face shall have the projection from the finished face of wall as
shown in drawings or as required by the Engineer-in-Charge.
12.18.3. Laying:
i) The risers of steps and skirting shall be in grey or white cement admixed with or without
pigment to match the shade of the stone, as specified in the description of the item, with the
line of the slab at such a distance from the wall that the average width of the gap shall be 12
mm and at no place the width shall be less than 10 mm, if necessary, the slabs shall be held in
position by temporary M.S. hooks fixed into the wall at suitable intervals. The skirting or riser
face shall be checked for plane and plumb and corrected. The joints shall thus be left to harden
then the rear of the skirting or riser slab shall be packed with cement mortar 1:3 (1 cement : 3
coarse sand) or other mix as specified in the description of the item. The fixing hooks shall be
removed after the mortar filling the gap has acquired sufficient strength.
ii) The joints shall be as fine as possible. The top line of skirting and risers shall be truly
horizontal and joints truly vertical, except where otherwise indicated.
iii) The risers and skirting slab shall be matched as shown in drawings or as instructed by the
Engineer-in-Charge.
12.18.4. Curing, Polishing and Finishing: It shall be as specified in 12.13.3 as far as applicable,
except that cement slurry with or without pigment shall not be applied on the surface and polishing
shall be done only with hand. The face and top of skirting shall be polished.
12.18.5 Measurements: Length shall be measured along with the finished face of riser or skirting,
correct to a cm. Height shall be measured from the finished level of tread or floor, to the top (the
underside of tread, in the case of steps) correct to 1 mm. The areas shall be calculated in square metre
correct to two places of decimal. Dado and lining of pillars etc. shall be measured as `Marble work'
in wall lining. If the thickness is up to 25 mm or as `Marble Work' in Jambs, walls, columns and
other plain work if the thickness is more.
described above.
12.19 Kota Stone Flooring :
12.19.1 Kota Stone Slabs: The slabs shall be of selected quality, hard, sound, dense and
homogeneous in texture free from cracks, decay, weathering and flaws. They shall be hand or
machine cut to the requisite thickness. They shall be of the colour indicated in the drawings or as
instructed by the Engineer-in-Charge.
The slabs shall have the top (exposed) face polished before being brought to site, unless otherwise
specified. The slabs shall conform to the size required. Before starting the work the contractor shall
get the samples of slabs approved by the Engineer-in-Charge.
12.19.2. Dressing: Every slab shall be cut to the required size and shape and fine chisel dressed on
the sides to the full depth so that a straight edge laid along the side of the stone shall be in full contact
with it. The sides (edges) shall be table rubbed with coarse sand or machine rubbed before paving.
All angles and edges of the slabs shall be true, square and free from chippings and the surface shall
be true and plane.
The thickness of the slab after it is dressed shall be 20,25,30 or 40 mm as specified in the description
of the item. Tolerance of ±2 mm shall be allowed for the thickness. In respect of length and breadth
of slabs tolerance of ±5 mm for hand cut slabs and ±2 mm for machine cut slabs shall be allowed.
12.19.3. Preparation of Surface and Laying: The specification shall be as described in12.17.2, &
12.17.3 except that the edges of the slabs to be jointed shall be buttered with grey cement, with
admixture of pigment to match the shade of the slab. The thickness of the joints should be minimum
as possible (hair joint).
12.19.4. Curing, Polishing and Finishing : The specifications shall be as described in 12.13.3
except that
(a) first polishing with coarse grade carborundum stone shall not be done,
(b) cement slurry with or without pigment shall not be applied on the surface before polishing.
12.19.5. Measurements and Rates: These shall be as described in para 12.17.5 and 12.17.6.
12.20. Kota Stone in Risers of Steps, Skirting and Dado:
12.20.1. Specifications : Kota Stone Slabs and Dressing shall be as specified in 12.19.1 and 12.19.2
except that the thickness of the slabs shall be 25 mm or as specified in the description of the item.
The slabs may be of uniform size if required.
12.20.2. Preparation of surface: Preparation of surface shall be as specified in 12.18.2.
12.20.3. Laying: Laying shall be as specified in 12.18.3 except that the joints of the slabs shall be
set in grey cement mixed with pigment to match the shade of the slabs.
12.20.4. Curing, Polishing and Finishing: Curing, Polishing and Finishing shall be as specified in
12.18.4 except that first polishing with coarse grade carborundum stone shall not be done.
12.20.5. Measurements: Length shall be measured along with the finished face of riser or skirting,
correct to a cm. Height shall be measured from the finished level of tread or floor, to the top (the
underside of tread, in case of steps) correct to 1 mm. The areas shall be calculated in square metre
correct to two places of decimal. Lining of pillars etc. shall also be measured under this item.
12.20.6. Rate: The rate shall include the cost of all materials and labour involved in all the
12.21. Rough Dressed Sand Stone Flooring:
12.21.1. Stone Slabs:
i) The slabs shall be red or white as specified in the description of the item. The stone slabs shall
be hard, sound, durable and tough, free from cracks, decay and weathering. In case of red sand
stone, white patches or streaks shall not be allowed. However, scattered spots up to 10 mm
diameter will be permitted. Before starting the work the contractor shall get samples of slabs
approved by the Engineer-in-Charge.
ii) The slabs shall be hand or machine cut to the requisite thickness along planes parallel to the
natural bed of stone and should be of uniform size if required.
12.21.2. Dressing of Slabs :
i) Every slab shall be cut to the required size and shape, and rough chisel dressed on the top, so
that the dressed surface shall not be more than 6 mm from a straight edge when placed on it.
The edge of depressions or projections shall be chisel dressed in a slant so that the surface does
not have sharp unevenness. The sides shall also be chisel dressed to a minimum depth of 20 mm
so that the dressed edge shall at no place be more than 30 mm from a straight edge butted
against it. Beyond this depth the sides may be dressed slightly splayed so as to form inverted
`V' shaped joint with adjoining slabs. All angles and edges of the slabs shall be true, square and
free from chippings and the surface reasonably true and plane.
ii) Where slabs are used for treads without nosing, the exposed edges shall be rough chisel
dressed to full depth and cut to uniform thickness.
iii) The thickness of the slabs after it is dressed shall be 40 mm or as specified in the description
of the item with a permissible tolerance of ± 2mm.
12.21.3. Laying:
i) Base concrete on which the slabs are to be laid shall be cleaned, wetted and mopped. The
bedding for the slabs shall be with cement mortar 1:5 (1 cement : 5 coarse sand) or as given in
the description of the item.
ii) The average thickness of the bedding mortar under the slabs shall be 20 mm and the
thickness at any place under the slabs shall not be less than 12 mm.
iii) The slab shall be laid in the following manner : Mortar of specified mix shall be spread under
each slab. The slab shall be washed clean before laying. It shall then be laid on top, pressed
and carried, so that all hollows underneath get filled and surplus mortar works up through the
joints. The top shall be tapped with a wooden mallet and brought to level and close to the
adjoining slabs, with thickness of joint not exceeding 5 mm. Subsequent slabs shall be laid in
the same manner. After laying each slab surplus mortar on the surface of slabs shall be cleaned
off and joints finished flush.
iv) In case pointing with other mortar mix is specified, the joint shall be left raked out uniformly
and to a depth of not less than 12 mm when the mortar is still green. The pointing shall be cured
for a minimum period of 7 days. The surface of the flooring as laid shall be true to levels and
slopes as instructed by the Engineer-in-Charge.
v) Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the
plaster, skirting or dado. The junction between wall plaster skirting and floor shall be
finished neatly and without waviness.
vi) The finished floor shall not sound hollow when tapped with wooden mallet.
12.21.4. Finishing : Any unevenness exists between the edges of slabs at joints shall be removed by
chiselling in a slant.
12.21.5. Measurements: These shall be as specified in para 12.17.5.
described above. Where pointing is to be done, this will be paid extra unless specifically included in
the description of the item.
12.22. Fine Dressed Sand Stone Flooring :
12.22.1 Stone Slab: Stone Slab shall be as specified in 12.21.1.
12.22.2. Dressing: Every slab shall be cut to the required size and shape and chisel dressed on all
sides to a minimum depth of 20 mm. The top and the joints shall be fine tooled so that straight edge
laid along the face is fully in contact with it. In case machine cut stones are used, chisel dressing and
fine tooling of machine cut surface need not be done provided a straight edge laid anywhere along
the machine cut surface is in contact with every point on it. The thickness of the slabs after dressing
shall be 40 mm or as specified in the description of item with a permissible tolerance of ±2 mm.
12.22.3. Laying: Laying Shall be as specified in 12.21.3.
12.22.4. Finishing : In case of chisel dressed stone flooring slight unevenness, if any existing
between the edges of slabs at joints shall then be removed by chiselling in a slant.
12.22.5. Measurement and Rate: Measurement and Rate shall be as specified in 12.21.5 and
12.21.6.
12.23. Fine Dressed and Rubbed Sand Stone Flooring:
12.23.1 Stone Slabs: Stone Slabs shall be as specified in 12.21.1.
12.23.2. Dressing: The specifications for dressing the top surface and the sides shall be as described
in 12.21.2. In addition the dressed top and sides shall be table rubbed with coarse grade carborundum
stone before paving, to obtain a perfectly true and smooth surface free from chisel marks. The
thickness of the slabs after dressing shall be as specified with a permissible tolerance of ±2 mm.
12.23.3. Laying :
i) The slabs shall be laid with 3 mm thick or 5 mm thick joints as specified in the description of
the item.
ii) Where the joints are to be limited to 3 mm thickness, the slabs shall be laid as specified in
12.16.3 except that the bedding mortar shall be as specified in 12.20.3 and sides of the slabs to
be jointed shall be buttered with cement mortar 1:2 (1 cement : 2 stone dust) admixed with
pigment to match the shade of the slab.
iii) Where the slabs are to be laid with 5 mm thick joints the specifications for laying shall be as
described in 12.21.3.
12.23.4. Finishing: Finishing shall be as specified in 12.21.4 except that chisel marks and
unevenness shall be removed by rubbing with coarse grade carborundum stone.
12.23.5. Measurement and Rate: Measurement and Rate shall be as specified in 12.21.5 and
12.21.6.
12.24. PVC Sheet / Tiles Flooring :
i) P.V.C. Flooring material is normally used for covering floor from decorative point of view in
residential and non-residential buildings. This material gives a resilient and non-porous surface
which can be easily cleaned with a wet cloth as dust and grime do not penetrate the surface.
Since a burning cigarette will damage the neat surface of the P.V.C. sheet, special care should
be taken to prevent burning cigarette stumps to come in contact with the P.V.C. flooring
materials.
ii) It shall be laid on a base that is finished even and smooth such as concrete, metal or timber
boarding. Unevenness or undulations in the base will show badly on the surface and are liable
to damage the P.V.C. sheet/tiles.
12.24.1 Materials:
i) The PVC flooring material shall conform to IS:3462-1986. It may be in the form of tiles, sheets or
rolls as specified. It shall consist a thoroughly blended composition of thermoplastic binder, filler
and pigments. The thermoplastic binder shall consist substantially of one or both of the
following :
a) Vinyl Chloride polymer
b) Vinyl Chloride copolymer
The polymeric material shall be compounded with suitable plasticizers and stabilizers.
12.24.1.2 Thickness :
i) The preferred thickness of PVC tiles for normal floor covering shall be 1.5, 2.0, 2.5, 3.0 or 4.0
mm. Thickness of P.V.C. sheets shall be measured with micrometre of Ratchet type or a dial
gauge graduated to 0.02 mm. The micrometre shall have flat bearing surfaces of at least 6.5
mm diameter at both contact points.
ii) For sheets and rolls the thickness of the specimen shall be measured at twenty scattered
points.
iii) For polystyrene wall tiles, the cavity depth of the test specimen shall be measured at five
points taken at random on the rear surface of each tile with a suitable depth gauge.
12.24.1.3. Width and Measurement:
i) The width of flooring sheets and rolling in continuous length shall be 1000,1500 and 2000
mm. When supplied in rolls the length of the rolls shall not be less than 10 metre.
ii) The measurement shall be carried out with a microscope or suitable scale graduated to 0.02
mm. Each tile shall be measured for length and width at the three quarter point in each
direction.
12.24.1.4. Tolerance:
Thickness ± 0.15 mm
a)
b) Width
i) 300 mm square tiles ±0.2 mm
ii) 600 mm square tiles ±0.4 mm
iii) 900 mm square tiles ±0.6 mm
iv) Sheets and rolls ± 0.1 per cent
12.24.1.5. Adhesive: Rubber based adhesives are suitable for fixing PVC flooring over concrete
wooden and metal sub-floors. PVC based adhesives shall be used for concrete and wooden subfloors.
PVA based adhesives are not suitable for metallic surfaces and also for locations where there is
constant spillage of water.
12.24.2 Preparation of Sub Floors :
i) Before laying PVC Sheets/tiles, it is essential to ensure that the base is thoroughly dry and
damp proof as evaporation of moisture cannot take place once the PVC flooring is laid.
Moisture slowly damages the adhesive resulting in PVC sheet/tiles being separated from the
base and curled up. In case of new work a period of 4 to 8 weeks shall be allowed for drying
the subfloor under normal conditions.
ii) Concrete subfloors on the ground floor shall be laid in two layers. The top of the lower layer
of concrete shall be painted with two coats of A-90 grade (conforming to IS:1580-1991) applied
at the rate of 1.5kg/sgm. The top surface of the lower layer shall be finished smooth while laying
the concrete so that the bitumen can be applied uniformly. The bitumen shall be applied after the
concrete has set and is sufficiently hard. Bitumen felt conforming to IS:1322-1993 shall be
sand-witched in the sub-floor laid in two layers.
iii) In new concrete floor, the smooth finish required shall be produced by using cement slurry
spread on fresh concrete floor and finished smooth. If the concrete floor is old and surface not
even, the surface should be made smooth by first cleaning it free of all foreign material and
then a layer of cement mortar 1:2 (1 cement : 2 coarse sand) of average thickness of 6 mm shall
be applied on the surface finishing the surface smooth. The finished surface shall be cured for
7 days and then allowed to dry thoroughly.
iv) Where it is expected that the dampness may find its way from the surrounding walls, the same
shall also be effectively damp-proofed up to at least 150 mm above the level of the sub-floor
and the damp-proof treatment below the floor shall be extended over the walls.
12.24.3. Laying and Fixing:
i) or to laying, the flooring tiles/rolls/sheets shall be brought to the temperature of the area in
which it is to be laid by stacking in a suitable manner within or near the laying area for a period
of about 24 hours.
ii) Where air-conditioning is installed, the flooring shall not be laid on the subfloor until the
conditioning units have been in operation for at least seven days. During this period the
temperature shall neither fall below 20°C nor exceed 30°C. These conditions shall be
maintained during laying and for 48 hours, thereafter.
iii) Before commencing the laying operations, the sub-floor shall be examined for evenness and
dryness. The sub-floor shall then be cleaned with a dry cloth. The PVC flooring shall not be
laid on a sub-floor unless the sub-floor is perfectly dry.
iv) The layout of the PVC flooring on the sub-floor to be covered should be marked with
guidelines. The PVC flooring shall be first laid for trial, without using the adhesive, according
to the required layout.
v) The adhesive shall be applied by using a notched trowel (See Fig. ) to the sub-floor and
to the back side of the PVC sheet or tile flooring. When set sufficiently for laying, the adhesive
will be sticky to touch, but will not mark the fingers. In general, the adhesive will require about
half an hour for setting. It should not be left after setting for too long a period as the adhesive
properties will be lost owing to dust films and other causes.
Drawing not to scale.

Fig : Details of a typical notched trowel.
vi) Care should be taken while laying the flooring under high humidity conditions so that
condensation does not take place of the adhesive. It is preferable to avoid laying under high
humidity conditions.
vii) The area of adhesive to be spread at one time on the sub-floor depends entirely upon local
circumstances. In case of a small room, adhesive may be spread over the entire area but
relatively small areas of tiles/sheets flooring should be treated in a larger room.
viii) When the adhesive is just tack free, the PVC flooring sheet shall be carefully taken and placed
in position from one end onwards slowly so that the air will be completely squeezed out
between the sheet and the background surface. After laying the sheet in position, it shall be
pressed with suitable roller weighing about 5 kg to develop proper contact with the sub-floor.
The next sheet with its back side applied with the adhesive shall be laid to edge with the sheet
already laid and fixed in exactly the same manner as the first sheet was fixed. The sheets shall
be laid edge to edge so that there is minimum gap between joints.
ix) The alignment should be checked after laying of each row of sheet is completed. If the
alignment is not perfect, the sheets may be trimmed by using a straight edge.
x) The tiles shall be fixed in exactly the same manner as for the sheets. It is preferable to start
laying of the tiles from the centre of the area. Care should be taken that the tiles are laid close
to each other with minimum gap between joints. The tiles should always be lowered in position
and pressed firmly on to the adhesive. Care should be taken not to slide them as this may result
in adhesive being squeezed up between the joints. PVC tiles after laying shall be rolled with a
light wooden roller weighing about 5 kg to ensure full contact with a under layer. Any
undulations noticed on the PVC surface shall be rectified by removing and relaying the tiles
after thorough cleaning of the underside of the affected tiles. The adhesives applied earlier in
such places shall be thoroughly removed by using proper solvents and the surface shall be
cleaned to remove the traces of solvents used. Work should be constantly checked against
guidelines in order to ensure that all the four edges of adjacent tiles meet accurately.
xi) Any adhesive which may squeeze up between sheets or tiles should be wiped off immediately
with a wet cloth before the adhesive hardens. If, by chance, adhesive dries up and hardens on
the surface of the sheet or tile, it should be removed with a suitable solvent. A solution of one
part of commercial acetate and three parts of turpentine oil is a suitable solvent for the purpose.
xii) A minimum period of 24 hours shall be given after laying the flooring for developing proper
bond of the adhesive. During this period, the flooring shall not be put to service. It is preferable
to lay the PVC flooring after completion of plastering, painting and other decorative finish works
so as to avoid any accidental damage to the flooring.
xiii) When the flooring has been securely fixed, it shall be cleaned with a wet cloth soaked in
warm soap solution (two spoons of soap in 5 litres of warm water).
xiv) Where the edges of the PVC sheets or tiles are exposed, as for example, in doorways and on
stair treads, it is important to provide protection against damage of flooring materials. Metallic
edge strips may be used and should be securely fastened to the sub-floor to protect edges of the
flooring.
12.24.4. Precaution for Maintenance:
i) PVC Flooring subject to normal usage may be kept clean by mopping with soap solution using
a clean damp cloth. Water shall not be poured on the PVC flooring for cleaning purpose as the
water may tend to seep through the joints and cause the adhesive to fail. To maintain a good
wearing surface and a good appearance, the flooring may be periodically polished. When polish
is applied frequently, a thick layer builds up which collects dirt and dust and is tacky to walk
on.
ii) If the traffic is light, the floor shall be given frequent brushing, regular polishing by an
application of new polish every 4 to 6 weeks. Under moderate traffic conditions the floor shall
be given an occasional wash with a wet mop but no detergents shall be used so that the polish
is not removed.
iii) Application of polish may be done every one to three weeks. P.V.C. flooring should not be
over-waxed. When this condition develops, the coatings should be cleared off with white spirit
or paraffin and a light even coat of polish applied. When the P.V.C. flooring has been polished,
it will remain bright for a considerable period if dry mop is applied each day. It is this daily
`dry polish' that maintains the glossy surface. After exceptionally heavy traffic, PVC flooring
should be swept with a hair groom, rubbed with a mop or cloth frequently rinsed in clean water
and finally rubbed dry.
12.24.5. Measurements: Length and breadth shall be measured correct to a cm and its area shall be
calculated in sqm correct to two places of decimal. No deduction shall be made nor extra paid for
voids not exceeding 0.20 square metre. Deductions for ends of dissimilar materials or other articles
embedded shall not be made for areas not exceeding 0.10 square metre. Nothing extra shall be paid
for providing PVC flooring in borders and margins, irrespective of their width.
described above, except those described in 12.24.4. The rate does not include the cost of sub-floor
or damp proof treatment if any. It also does not include the cost of metallic edge strip to protect edge
of flooring, wherever provided, it shall be paid separately.
12.25 : PVC-Asbestos Floor Tiles : Material, Dimensions and Tolerances, colour and finish,
physical requirements and test shall be as per IS:3461-1980 and the rest shall be as per 12.24.
These shall be used with the approval of the Engineer-in-charge.
12.26. Linoleum Flooring:
i) Linoleum may be laid on any base that is finished even and smooth, such as concrete, timber
boarding or mastic asphalt. Unevenness or undulations in the base will show badly on the
surface even and are liable to damage the linoleum. Linoleum flooring is suitable only for
locations wholly inside the building. Linoleum is not resistant to indentations from heels or
static load. heavy objects left in one position may leave indentations. As linoleum flooring can
become dangerously slippery when highly polished or wet, care should be taken to use polish
with reduced tendency to slipperiness. If full damp proofing of the base surface cannot be
ensured, the linoleum should not be used for floor covering. Linoleum is a combustible material
and should not be used where an incombustible flooring is required. Linoleum flooring is a
specialised work which shall be carried out through specialist firms.
12.26.1 Materials:
i) Linoleum: Linoleum shall confirm in all respects to IS:653-1992. Linoleum shall be of thickness
specified in the description of the item. Linoleum shall be of either plain, smooth or marble
type or a combination of the above types as shown in drawings or as directed by the Engineer-
in-Charge. Linoleum shall be stored in a clean, dry and well ventilated place without exposure
to direct sunlight. Before starting the work the contractor shall get the samples of Linoleum
ii) Recommended thickness : Linoleum used shall be of a thickness adequate for the conditions of
surface and situation. The following thickness shall generally be used :
Situation Thickness
(a) For public buildings, cinemas, - 6 to 6.7 mm
restaurants, ships and the like
(b) For offices, shops and the like, - 3.2 to 4.5 mm
depending upon the intensity of traffic
(c) For residential house - 3.2 mm
iii) Adhesive: The adhesive used for laying the linoleum shall be those recommended by
manufactures of the floor covering and shall confirm to specifications laid down for adhesive in
IS:1198-1982. It shall be of heavy consistency and of reasonably short drying time.
12.26.2. Laying:
i) It shall confirm to IS:1198-1982.
ii) Before laying linoleum it is essential to ensure that the base is thoroughly dry and damp proof
as moisture slowly rots the base and damage the adhesive resulting in the linoleum being
separated from the base and curled up. Damp proofing where required may be either with an
impervious membrane incorporated in the thickness of the base or with a layer of mastic asphalt
of 12.5 mm minimum thickness spread and finished even and smooth on the concrete or other
base.
iii) Linoleum shall be kept at a temperature of not less than 20°C for at least 48 hours before it is
unrolled.
iv) Linoleum shall be unrolled and loose laid out flat for 2 to 3 days before it is cut to size, as it
shrinks in length and expands in width after rolling. Till the expansion of spread of roll stops,
the two widths of linoleum should be overlap and after the expansion stops it should be cut to
fit the size. Laying should be taken up only after the sheets are finally cut to size after expansion
has stopped. Linoleum pieces shall be cut to the required size and shapes with a sharp straight
edge and gauge as explained below and laid dry to the margin and pattern as shown in the
drawings or as directed by the Engineer-in-Charge.
v) The length for borders shall be first cut and adjusted. The Linoleum shall then be adjusted in
the central portion with their edges overlapping the adjacent pieces by about 12 mm. The edges
shall then be cut with the help of a special instrument called the `Gauge' which enables the
marking of the edge of the top pieces exactly over the edge of the adjacent piece, so that when
the overlapping is cut along the line, the edges of adjacent sheets butt against each other without
any gap, what so ever.
vi) Adhesive shall then be brushed over the base which shall have been thoroughly cleaned in
advance, and shall be allowed to become tacky. The sheets shall then be firmly pressed down
and rolled with a light cast iron 70 kg roller, to ensure that they stick evenly to the base and no
air pockets are left under them. If any air pockets are left the sheets shall be removed and re-
laid after brushing more adhesive on the base and roll. The sheets shall be laid with butt joints
throughout and the joints shall be very fine. Sand bags shall be placed over the edges and joints
to keep the sheets pressed down and prevent curling. Linoleum shall not be used for coves,
skirting and dados.
vii) Coves of wood or metal may be formed to cover or mask the joints between the linoleum
flooring and the wall facing where so required, but this shall be paid for separately.
12.26.3. Finishing: After laying, any adhesive contaminating the face of the sheets shall be removed
immediately with kerosene oil or spirit. The flooring shall be cleaned with soap and wet cloth and
then wiped dry. It shall then be wax polished to give a smooth shining surface, taking care to ensure
that the flooring does not slippery due to excessive polish.
12.26.4. Precautions: Linoleum shall not be creased, as it will crack. Excess water, which is liable
to creep into the joints and strongly alkaline soaps shall not be used for cleaning. Mild bar soap may
be used. Linoleum shall be handled carefully with its exposed face protected from damage by sharp
points.
12.26.5. Measurements: Lengths and breadths of superficial area of the finished work shall be
measured correct to a cm. The area shall be calculated in square metre correct to two places of
decimal. No deduction shall be made nor extra paid for voids not exceeding 0.20 square metre.
Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas
not exceeding 0.10 square metre.
described above but will not include the cost of base or damp proof treatment mentioned in 12.24 and
12.24.2.
12.27. Rubber Flooring (IS: 809-1992) :
a) Rubber flooring and skirting may be laid with rubber sheets, or rubber tiles.
b) Rubber sheets or tiles may be (i) Plain or Marbled, (ii) Ribbed or fluted, (iii) With fabric
backing or fabric insert, (iv) With sponge rubber backing or (v) with plain rubber backing, as
specified.
c) Rubber flooring shall not be used in situations exposed to direct sunlight or rain as the
flooring is likely to deteriorate quickly.
d) In maintaining rubber flooring, lavish use of water, scrubbing with strongly alkaline soaps
and cleaning with rough brushes should be avoided.
e) Rubber flooring made from natural rubber shall not be used in situations where it is likely to
come in contact with fats, grease, oil or petrol. To meet such conditions rubber flooring made
from certain synthetic rubber will have to be used.
12.27.1 Materials
a) Rubber Tiles
i) Rubber tiles shall confirm in all respect to IS:809-1992. These shall be of standard sizes, such
as 200x200 mm, 300x300 mm or 500x 500mm as shown in the drawings or as directed by the
Engineer-in-Charge. Where the room length and width are not exact multiples of the size of the
tiles, the end rows shall be cut sizes of tiles. The thickness of the tiles shall be 3.2. mm, 4.8 mm
or 6.4 mm as specified in the description of the item, with permissible tolerance of plus 0.8 mm
and minus 0.2 mm.
ii) The tiles shall be `plain' or `Marbled', unless otherwise specifically described in the item. The
colour of the tiles shall be as shown in the drawings or as directed by the Engineerin-Charge.
iii) Before starting the work, the contractor shall get the samples of rubber tiles approved by the
Engineer-in-Charge.
b) Adhesive: The adhesive shall be a rubber adhesive of approved quality of the type and make
recommended by the manufacturers of rubber tiles. It shall be got approved by the Engineer-
in-Charge. It shall be a rubber solvent preparation with a reasonably short drying time and shall
give a tough adhesive film. The surplus adhesive should not be allowed to remain longer than
24 hours.
12.27.2 Laying:
i) Laying Shall generally confirm to IS : 1197-1970.
ii) Rubber tiles shall be laid to margins and pattern as shown in the drawings or as directed by
iii) Rubber flooring may be laid on any base that is finished even and smooth, such as concrete,
timber boarding or mastic asphalt. A rough surface makes for poor adhesion of the rubber and
its consequent separation from the base in due course.
iv) It is important that the base is thoroughly dry and damp proof as dampness causes failure of
the adhesive, leading to the curling of tiles. Nothing extra shall be paid for the rubber used in
sealing the edges at the entrance.
v) The base shall be smooth, thoroughly clean and dry. Adhesive shall be applied to the
base, and to the back and edges of the tiles and allowed to become surface dry. The tiles
shall then be firmly pressed and smoothened down with a suitable tool. Weights shall be
used to keep the tiles flat if any tendency to curl is noticed. Care shall be taken to ensure
that no air pockets are left under the tiles. If any air pocket is left, the tiles shall be
removed and relaid after applying more adhesive on the base and back of tiles and pressed
in position. The tiles shall be laid with butt joints throughout and the joints shall be very
fine.
vi) Coves of wood or metal may be formed to cover or mask the joints between the rubber flooring
and the wall facing where so required, but these shall be paid for separately.
12.27.3 Finishing: After laying , any adhesive sticking on the face of the tiles shall be removed
immediately, since if allowed to harden a solvent may be required to remove it and this will harm the
rubber. The surface shall be cleaned with a mild soap and wet cloth after a week of its laying. After
drying, the surface shall be polished with an approved emulsion type polish to give a smooth shining
surface.
decimal. No deduction shall be made nor extra paid for any opening in the floor up to 0.20 sq m. in
area. Deduction for ends of dissimilar materials or other articles embedded shall not be made for
areas not exceeding 0.10 square metre. Nothing extra shall be paid for borders and margin,
irrespective of their width. Nothing extra shall be paid for the use of cut tiles in the work.
described above but shall not include the cost of the base or damp proof treatment (12.26.2.ii) or the
cost of coves (See 12.26.2.vii).
12.28 Wooden Flooring :
12.28.1. Seasoning & Preservation: All timber used for timber floors shall be thoroughly seasoned
in accordance with IS: 1141-1993. After seasoning the timber shall be treated with preservative in
accordance with IS: 401-1982. Seasoning and preservative treatment shall be paid for separately unless
otherwise specifically included in the description of the item of flooring.
12.28.2. Supporting Joists: Main beams and joists of the class of wood sections specified in the
description of the item for beams and joists, or as instructed by the Engineer-in-Charge shall be fixed
in position to dead levels. The width of the joints shall not be less than 50 mm. The arrangement and
spacing of beams joists etc. shall be as per design furnished.
12.28.3 Boards:
i) It shall be of the class of timber and thickness specified in the description of the item. Only
selected boards of uniform width shall be used. Unless otherwise specified or shown in the
drawings, the width of boards selected shall not be less than 100 mm nor more than 150 mm.
The same width of boards shall be maintained throughout except where the width of the room
is not an exact multiple of the boards. In the latter case, the difference shall be equally adjusted
between the two end boards (adjacent to walls). The length of the boards shall not exceed 3
metre anywhere. Ordinarily, the minimum length of boards shall be such that the boards shall
rest at least on three supports, except where otherwise required by the pattern specified in the
drawings or as directed by the Engineer-in-Charge.
ii) The boards shall be planed true on the top face only unless otherwise specified in the
description of the item. Where the bottom face is exposed and it is also required to be planed,
then such planning shall be paid for extra.
iii) Unless otherwise described in the item, the longitudinal joints of planks shall be tongued and
grooved to a minimum depth of 12 mm while the heading joints shall be of the square butt type
and shall occur over the centre line of the supporting joists. Heading joists in adjacent boards
shall be placed over the same joists.
12.28.4. Iron Screws: Iron screws shall be of the slotted counter sunk head type, of length not less
than the thickness of planks plus 25 mm, subject to a minimum of 40 mm, and of designation No.9
conforming to IS:451-1972.
12.28.5 Fixing:
i) The joists on which the planks shall be fixed shall be checked and corrected to levels. The end
boards shall be accurately fixed with the sides parallel and close to the walls. Each adjoining
board shall be carefully jointed and shall be tightened in position and screwed. For fixing the
boards to the joists, two screws shall be used at each end of the boards and one screw at each
of the intermediate joists in a zig-zag manner. The screws shall be countersunk and screw holes
filled with approved stopping.
ii) The junction between timber flooring and adjacent flooring shall be formed by inserting a metal
strip (brass or aluminium) at the junction. The metal strip shall be fixed to the end of the planks
by screws. The strips shall be paid for extra.
iii) The flooring shall be truly level and plane. The joints shall be truly parallel and perpendicular
to the walls, unless otherwise specified.
iv) The floor shall be planed in both directions and made perfectly even, true and smooth.
Note : No wood of any kind shall be placed within 60 cm of any fire place or flue. Provision shall
be made for ventilation of the space below the floor in case of ground floor and between floor and
top of ceiling in the case of upper floor. Such arrangements shall be paid for separately.
12.28.6. Finishing: The surface of the floor shall be bees waxed or finished otherwise as directed by
the Engineer-in-Charge. The lower face shall be painted or treated with wood preservative as
directed. The finishing shall be paid for separately unless specifically included in description of the
flooring item.
12.28.8. Rate: The rate shall include the cost of the labour and materials involved in all the
operations described above, with the exceptions noted in the relevant sub-para.
12.29. Wood Block Flooring :
12.29.1 Wood Blocks: The wood blocks shall be of the class of timber specified in the description of
the item and shall be in accordance with the general specifications for `Wood Work'. The size of
blocks shall be as shown in the drawings. The longitudinal edges of the blocks shall be truly
rectangular in shape with clean sharp edges and true faces. The top and sides shall be planed true. The
thickness of the blocks shall be 38 mm unless otherwise specified. The timber used for making the
blocks shall be thoroughly seasoned in accordance with IS:1141-1993. After seasoning, the timber
shall be treated with preservatives in accordance with IS:401-1982.
12.29.2. Base Concrete : The specifications shall be same as in 12.3.2.
12.29.3. Levelling Concrete: The levelling layer of concrete shall be of cement concrete 1:2:4 (1
cement : 2 coarse sand : 4 stone aggregate 10 mm nominal size) by volume unless otherwise
described in the item. Its thickness shall be 25 mm. Cement concrete shall be placed in position
and levelled up with the help of a straight edge and trowel. It shall then be beaten with wooden
'nappy' or a mason's trowel till the cream comes up. The surface shall be finished with a wooden
float to give a sand paper finish, plane and true to level. The finished level of the concrete shall be
lower than the proposed finished level of the flooring by the specified thickness of the wooden blocks
plus a minimum of 1.5 mm. The levelling layer shall be cured for a week and then allowed to dry
thoroughly, before paving with wood blocks.
12.29.4. Laying:
i) The wood blocks shall be first laid `dry' to the margin and pattern shown in the drawings or as
directed by the Engineer-in-Charge. The blocks shall fit closely and sides and end shall be
corrected by further planing if necessary to get closed and even joints. After the blocks have
been fitted and matched they shall be removed and stacked in such a way as to facilitate their
repaving in the same order.
ii) The surface of the levelling course shall be thoroughly cleaned and a small area of the surface
shall be coated with a thin layer of a hot bitumen such as blown type petroleum bitumen grade
85/25 of IS: 702-1988 or other equivalents, applied at a temperature of not less than 180°C and
at the rate of 2.45 kg per square metre. The wood blocks shall then be taken in turn serially and
be dipped in the same hot bitumen for about half their depth so as to coat thoroughly the bottom
and part of the sides and quickly set and pressed into place to required patterns, on the
previously coated concrete surface so that the dovetailed grooves at the edges of the blocks get
filled up with bitumen. The joints of the work shall be very thin and fine.
iii) When all the blocks shall have been set in position, the surface shall be cleaned of any
bitumen droppings and planed machined level and smooth.
iv) The floor shall then be given a final smooth finish by rubbing down with sand paper. Note
: No wood of any kind shall be placed within 60 cm of any fire place or flue.
12.29.5. Finishing: The floor shall be Bees waxed or polished with readymade wax polish or given
any other finish as required.
12.29.6. Measurements: Length and breadth of superficial areas of the finished work shall be
12.29.7. Rate: The rate shall include the cost of all labour and materials involved in all the operations
described above but shall not include the cost of the base concrete, bees waxing or other finishing
referred to in para 12.29.2., 12.29.5 and 12.28.8 unless otherwise specifically described in the item.
1230. Granolithic Floor-Finish:
12.30.1. Specifications: The specification covers the mode of laying and finishing of Granolithic
floors both of Integral and bonded type.
12.30.2. General :
i) Flooring, if laid on ground, shall consist of :-(a)
Base :- Laid over compacted subgrade.
(b) Granolithic-Finish :-
ii) If laid on upper floors no base shall be required.
12.30.3. Materials for Granolithic Finish:
i) Cement : Ordinary grey Portland Cement conforming to IS.269-1989.
ii) Water : Water used shall be clean and free from oil, acid, alkali or soluble salts etc.
iii) Coarse Sand or Fine Aggregates : Fine aggregate shall consist of clean, hard, durable
particles and shall be free from all impurities. Aggregates shall be of Grading Zone I or
Grading Zone II, conforming to specifications. Great care should be taken on the
selection of aggregates as the behaviour of the floor shall be dependent on the quality of
aggregates.
iv) Coarse Aggregates : The coarse aggregates shall consists of graded broken granite or
equally hard stone and should be hard, durable, clean and free from any deleterious
matter.
12.30.4. Preparation of Sub-Grade : Same as for Lime concrete base for floors.
12.30.5. Base: Same as for cement concrete flooring.
12.30.6. Protection Against Dampness : If the Engineer-in-charge so desires or it be specified in
the contract that the floor is to be safeguarded against any damps shall be covered with an effective
water proofing film to protect the floor against any dampness.
12.30.7. Granolithic Finish :
i) Classification of finish: The finish shall be any one of the following types.
a) Integral finish : Finish laid, while concrete base or structural slab is still in plastic
stage.
b) Bonded finish : Granolithic finish is bonded to the hardened surface of the concrete base
or structural slab.
ii) Thickness: Thickness of Granolithic finish Unless others specified the following thickness
shall be adopted :
(a) Integral finish : For integral finish the thickness adopted shall be 25 mm.
(b) Bonded finish : Thickness adopted shall be 40 mm.
iii) Mix: The mix ratio used shall be as stated in the Schedule of Rates, the usual ratios used
being as under :-
(a) One part of Portland Cement to two parts of fine aggregate such as very coarse sand.
(b) One part of Portland Cement, one part of fine aggregate such as coarse sand and one
part of still coarser aggregate consisting of clean, hard, crushed, rock like granite.
(c) For harder surfaces, where floor is subject to considerable wear such as trucking, mixture
composed of one part of cement, half part of coarse sand, and one and a half parts of
coarser aggregates may be used.
(d)
For special duty floors abrasive grit may be sprinkled over the surface during floating
operations at the rate of 1.5 kg. to 2 kg./m2.
iv) Preparation of Base:
a) Integral finish: For integral finish the granolithic mix must be placed within 11 hours of
laying the base concrete or Structural Slab, which at the time of placing of
Grano-finish shall be still plastic. If there is any excess of water or laitance on the surface,
the same must be removed before laying the Grano-finish.
b) Bonded-finish: The surface shall be cleaned of all dirt, laltance, oil etc. and then soaked
with water. The free water from the base being removed, a coat of a mixture of cement
and water of the consistency of thick cream shall be brushed on to the surface just prior
to placing the topping.
v) Mixing:
a) Thorough mixing of the materials shall be carried out so that all the aggregate particles
get coated with mortar (or cement in case of mortar mix) and the whole mass gives a
uniform appearance.
b) Mixing and transportation shall confirm to specifications laid down, for plain cement
concrete.
vi) Size of Panel: When the granolithic topping is over a hardened base it shall be laid in alternate
sections not exceeding 2 m2. in area, each side not exceeding 1.5 m. the intermediate sections
being laid two days after-wards. The forms shall be such that these do not get displaced during
the placing of concrete or mortar.
vii) Laying: The mix shall be laid immediately after the mixing is over, on the freshly grouted base
in case of bonded finish and on the green base in case of integral finish. It shall be spread evenly
and straight edged carefully, any low place being filled, humps removed and the whole surface
again straight edged.
viii) Compaction: As soon as the layer is even, the surface shall be rapidly compacted by
ramming or beating and screeded to a uniform line, levelled and floated. .
ix) Floating : In case it is desired the surface shall be made non skid by dusting carborundum
powder on the top before trowelling with steel floats at the rate of 1.5. kg. to 2 kg./sqm.
x) Trowelling : Trowelling with steel float shall be commenced only after the surface has
hardened sufficiently, as to guard the aggregate particles from being dislodged. The operation
shall be performed with heavy pressure so as to produce a dense, smooth water tight surface free
from blemishes.
xi) Finishing: On no account shall neat cement or dry cement and sand mixture be sprinkled over
the surface with the object of absorbing moisture for hastening the time of trowelling or for
obtaining a smooth surface.
xii) Curing : Immediately after fmal trowelling, the surface shall be protected from rapid drying.
As soon as it has hardened sufficiently, it shall be covered with clean sand in a layer of 20 mm
thickness and kept flooded with water for at least 14 days. It is most important for the rich mix
used in Grano-finish that adequate curing is carried out otherwise it may result in shrinkage
cracks.
xiii) Grinding : After 7 days of laying the finish, the surface shall be ground by surface grinding
machines.
12.30.8. Surface Dressing : After the floor has dried, the surface shall be given three coats of
sodium silicate each after the previous has dried and scrubbed with water.
1230.9. Measurements :
i) The Grano-finish shall be measured net, the area being given in sq. metres specifying the
mix and thickness of the finish.
ii) Abrasive grit, or Carborundum powder if sprinkled shall be measured separately. 12.31
Pressed Ceramic / Glazed Tile Flooring:
12.31.1 Scope:
i) This specification applicable only to pressed ceramic glazed / unglazed tiles of first quality for
use as floors and wall coverings. The tiles should have of approved make and shall confirm to
IS : 15622-2006. The tiles shall be tested as per IS:13630-2006. They shall be flat, and true to
shape and free from blisters crazing, chips, welts, crawling or other imperfections detracting
from their appearance.
ii) Classification and Characteristics of pressed ceramic tiles shall be as per IS:13712-2006.
iii) The surface of tiles and components belonging to this group can be smooth, profiled, wavy,
decorated or finished in some other way. It can be unglazed (UGL ), glossy, matt or semi-matt
( GL ). The underside of the tiles shall not have glaze on more than 5% of the area in order that
the We may adhere properly to the base. The edges of the tiles shall be preferably free from
glaze. However, any glaze if unavoidable, shall be permissible on only up to 50 per cent of the
surface area of the edges.
12.31.2 Shape and Sizes:
i) The tiles shall be square or rectangular in shape. Table 1,3,5, and 7 of IS:15622-2006 give the
modular preferred sizes and table 2,4,6 and 8 give the most common non modular sizes. Non-
modular sizes of tiles ranging between 10 cm x 10 cm to 90 cm x 120 cm. The manufacturer
shall choose the work size in such a way that difference between the work size and the nominal
size is not more than ± 2 5 and 5 mm.
ii) Modular preferred sizes for tiles are 10 cm x 10 cm, 15 cm x 15 cm, 20 cm x 10 cm, 20 cm x
15 cm, 20 cm x 20 cm, 30 cm x 30 cm, 40 cm x 40 cm & 45 cm x 45 cm. The manufacturer
shall choose the work size in order to allow a nominal joint width between 2 m m a n d 5 m m .
iii) The thickness shall be specified by the manufacturer. It includes the profile on the visible face
and on the rear side. Manufacturer/supplier and party shall choose the work size of tiles in order
to allow a nominal joint width up to 2mm for un rectified floor tiles and up to 1mm for rectified
floor tiles. The joint in case of spacer lug tile shall be as per spacer. The tiles shall conform to
IS : 15622-2006 with water absorption 3 to 6% (Group B II).
iv) Spacer lug tiles : The tiles may have spacer lugs. Spacer lugs are projections, usually 0.6 mm
that are located along certain edges of tiles so that when two tiles are placed together in line,
the lugs on adjacent edges separate the tiles by a distance not less than the specified width of
joints. Lugs are positioned so that the joint between the tiles may be filled with grout without
the lugs remaining exposed.
v) Pressed tiles may be made with other spacer lug system and in such cases the manufacturer's
work size shall apply.
12.31.3 Coloured Tiles: Only the glaze shall be coloured as specified. The sizes and specifications
shall be the same as for the white glazed tiles.
12.31.4 Decorative Tiles: The type and size of the decorative tiles shall be as follows :
(i) Decorated white back ground tiles: The size of these tiles shall be as per IS:15622-2006.
(ii) Decorated and having coloured back-ground: The sizes of the tiles shall be as per IS:
15622-2006.
1231.4 Dimensional and Surface Quality, Physical and Chemical Requirements:
a) The tiles shall be flat and true to shape and free from blisters crazing, chips, welts, crawling or
other imperfections detracting from their appearance. Pressed ceramic tiles divided into
following four groups :
Group B I a :-Tiles with water absorption, E = 0.08 % Group
B I b :-Tiles with water absorption, 0.08 < E = 3 % Group B II
:-Tiles with water absorption, 3 < E = 6 % Group B III :-Tiles
with water absorption, E > 6 %
The sampling and testing requirements for tiles shall be as per IS: 13630-2006 :
12.31.5 Preparation of Surface and Laying:
i) Base concrete or RCC slab on which the tiles are to be laid shall be cleaned, wetted and mopped.
The bedding for the tile shall be with cement mortar 1:4 (1 cement : 4 coarse sand) or as
specified. The average thickness of the bedding shall be 20 mm while the thickness under any
portion of the tiles shall not be less than 10 mm.
ii) 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 to enable the mason to place wooden
plank across and squat on it.
iii) Over this mortar bedding neat grey cement slurry of honey like consistency shall be spread @
3.30 kg of cement per square metre. Tiles shall be soaked in water, washed clean and shall be
fixed in this grout one after another. Each tile gently being tapped with a wooden mallet till it
is properly bedded and in level with the adjoining tiles. The joints shall be kept as thin as
possible and in straight lines or to suit the required pattern.
iv) The surface of the flooring during laying shall be frequently checked with a straight edge
about 2 meter long, so as to obtain a true surface with the required slope.
v) Where full size tiles cannot be fixed, these shall be cut (sawn) to the required size, and their
edge rubbed smooth to ensure straight and true joints. Tiles which are fixed in the floor
adjoining the wall shall enter not less than 10 mm under the plaster, skirting or dado.
vi) After tiles have been laid, surplus cement slurry shall be cleaned off.
12. 31.6 Pointing And Finishing: The joints shall be cleaned off the grey cement slurry with
wire/coir brush or trowel to a depth of 2 mm to 3 mm and all dust and loose mortar removed. Joints
shall then be flush pointed with white cement added with pigment if required to match the colour of
tiles. The floor shall than be kept wet for 7 days. After curing, the surface shall be washed and
finished clean. The finished floor shall not sound hollow when tapped with a wooden mallet.
12. 31.7 Measurements:
i) The length and breadth shall be measured correct to one cm before laying skirting, dado or wall
plaster and the area calculated in square metre correct to two places of decimal. Where coves
are used at the junctions, the length and breadth shall be measured between the lower edges of
the coves.
ii) No deduction shall be made nor extra paid for voids not exceeding 0.20 square metre. Deductions
for ends of dissimilar materials or other articles embedded shall not be made for areas not
exceeding 0.10 square metre. Areas, where glazed tiles or different types of decorative tiles are
used will be measured separately.
12. 31.8 Rates:
i) The rate for flooring shall include the cost of all materials and labour involved in all the
operations described above. Nothing extra shall be paid for the use of cut (sawn) tiles in the
work.
ii) Extra over and above the normal rate for tiles shall be paid where dark shade coloured tiles
(like burgundy, bottle green, black etc.) or any other type of decorative tiles have been used.
12.32 : Pressed Ceramic Tile Flooring (Vitrified Tile Flooring):
12.32.1 Specifications: Operations as described inl2.30.1 to 12.30.7 shall be followed except the
tiles shall conform to IS 15622 (Tiles with water absorption E = 0.08 per cent Group B I a) and the
joint thickness in flooring shall not be more than 1 .
12.32.2 Rates: The rate for flooring shall include the cost of all materials and labour involved in all
the operations described above. Nothing extra shall be paid for the use of cut (sawn) tiles in the
work.
12.33: Fixing of Tile Flooring With Cement Based High Polymer Modified Quick Set Adhesive
(Water Based):
12.33.1 Scope: When tile flooring is to be laid over the existing flooring without dismantling old
flooring it can be laid with adhesive. The old flooring shall be thoroughly cleaned and checked for
undulations, if any shall be rectified with cement mortar 1:3 (1 cement: 3 coarse sand). Old cement
concrete surface shall be hacked and cleaned off to have proper bond with the old surface.
12. 33.2: Laying:
i) High polymer modified quick set tile adhesive (conforming to IS 15477-2004) shall be
thoroughly mixed with water and a paste of zero slump shall be prepared so that it can be used
with in 1.5 to 2 hours. It shall be spread over an area not more than one sqm at one time.
Average thickness of adhesive shall be 3 mm The adhesive so spread shall be combed using
suitable trowel. Tiles shall be pressed firmly in to the position with slight twisting action
checking it simultaneously to ensure good contact gently being tapped with wooden mallet till
it is properly backed with adjoining tiles. The tiles shall be fixed within 20 minutes of
application of adhesive. The surplus adhesive from the joints, surface of the tiles shall be
immediately cleaned.
ii) The surface of the flooring shall be frequently checked during laying with straight edge of
above 2m long so as to attain a true surface with required slope.
iii) Where spacer lugs tiles are provided these shall be filled with grout with lugs remaining
exposed.
iv) Where full size tile cannot be fixed these shall be cut (sawn) to the required size and edges
rubbed smooth to ensure straight and true joints. Tiles which are fixed in floor adjoining to
wall shall enter not less than 10 mm under plaster, skirting or dado.
12. 33.3: Finishing: Para 12.29.5 shall apply.
12. 33.4: Measurements : Para 12.29.6 shall apply. 12.
33.5: Rate: Provisions of para 12.29.7 shall apply.
12.34:Pressed Ceramic Tiles in Skirting and Dado:
12.34.1 : Specifications :
i) The tiles shall be of approved make and shall generally conform to IS: 15622-2006. The tiles
shall be pressed ceramic covered by a glaze thoroughly matured and fitted to the body. The
tiles shall be sound, true to shape, flat and free from flaws and other manufacturing defects
affecting their utility.
ii) The top surface of the tiles shall be glazed. The underside of the tiles shall not have glaze on
more than 5% of the area in order that the tile may adhere properly to the base. The edges of
the tiles shall be free from glaze, however, any glaze if unavoidable shall be permissible on
only up to 50 per cent of the surface area of edges.
iii) The glaze shall be free from welts, chips, craze, specks, crawling or other imperfections
detracting from the appearance when viewed from a distance of one metre. The glaze shall be
either glossy or matt as specified. The glaze shall be white in colour except in the case of
coloured tiles when colours shall be specified by the Engineer-in-Charge. There may be more
than one colour on a tile.
1234.2. Dimensions And Tolerances:
i) Glazed pressed ceramic tiles shall be made square or rectangular in sizes Table 1,3,5, & 7 of IS
:15622-2006 give the modular sizes and table 2,4,6,& 8 of IS 15622-2006 gives the sizes of
non-modular tiles. The tiles shall conform to IS 15622-2006 for dimensional tolerance, physical
and chemical properties.
ii) Half tiles for use as full tiles shall have dimensions which shall be such as to make the half tiles
when jointed together (with 1 mm joint) match with dimensions of full tiles. Tiles may be
manufactured in sizes other than those specified. above.
iii) The thickness of the tiles shall be 5 mm or 6 mm or as specified.
iv) The dimensions of fittings associated with the glazed tiles namely cover base, round edge tile,
angles corner cups, ridge and legs, cornices and capping beads shall be of the shape and
dimensions as required and the thickness of fittings shall be the same as the thickness of tiles
given above.
12.34.3 Preparation of Surfaces:
i) The joints shall be raked out to a depth of at least 15 mm in masonry walls.
ii) In case of concrete walls, the surface shall be hacked and roughened with wire brushes. The
surface shall be cleaned thoroughly, washed with water and kept wet before skirting is
commenced.
12.34.4 Laying:
i) 12 mm thick plaster of cement mortar 1:3 (1 cement: 3 coarse sand) mix of as specified shall
be applied and allowed to harden. The plaster shall be roughened with wire brushes or by
scratching diagonal at closed intervals.
ii) The tiles should be soaked in water, washed clean, and a coat of cement slurry applied liberally
at the back of tiles and set in the bedding mortar. The tiles shall be tamped and
corrected to proper plane and lines. The tiles shall be set in the required pattern and jointed.
The joints shall be as fine as possible. Top of skirting or dado shall be truly horizontal and
joints truly vertical except where otherwise indicated. Odd size/cut size of file shall be adjusted
at bottom to take care of slope of the flooring. Skirting and dado shall rest on the top of the
flooring. Where full size files cannot be fixed these shall be cut (sawn) to the required size and
their edges rubbed smooth. Skirting /dado shall not project from the finished "surface of wall"
by more than the tile thickness, undulations if any shall be adjusted in wall.
12.34.5 Curing and Finishing:
i) The joints shall be cleaned off the grey cement grout with wire/coir brush or trowel to a depth
of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush pointed with
white cement added with pigments if required to match the colour of tiles. The work shall then
be kept wet for 7 days.
ii) After curing, the surface shall be washed and finished clean. The finished work shall not
sound hollow when tapped with a wooden mallet.
12.34.6: Measurements:
i) Length shall be measured correct to a cm. Height shall be measured correct to a cm in the case
of dado and 5 mm in the case of riser and skirting. The area shall be calculated in square metre,
correct to two places of decimal. Length and height shall be measured along the finished face
of the skirting or dado including curves where specials such as coves, internal and external
angles and beads are used. Where cornices are used the area of dado shall be measured
excluding the cornices. Nothing extra will be paid for cutting (sawn) the tiles to sizes.
ii) Areas where coloured files or different types of decorative files are used will be measured
separately to be paid extra over and above the normal rate for white files.
12.34.7: Rates: The rate shall include the cost of all material and labour involved in all the operations
described above, for tiles of sizes up to 0.14 sqm. unless otherwise specified in the description of
the item. The specials such as coves, internal and external angles and beading shall be measured and
paid for separately. The rate shall not include cost of cornices which shall be measured and paid for
in running meters separately.
12.35 : Acid or Alkali Resistant Tiles:
1235.1 Manufacture and Finish:
i) The tiles shall be of vitreous ware and free from deleterious substances. The iron oxide content
allowable in the raw material shall not exceed two percent. The tiles shall be vitrified at the
temperature of 1100°C and above and shall be kept unglazed. The finished, file, when fractured
shall appear fine grained in texture, dense and homogenous. The files shall be sound, true to
shop, flat and free from flows and manufacturing defects affecting their utility.
ii) The files shall be conforming to IS : 4457-2007. The files to be tested for water absorption,
compressive strength, acid resistance as per IS : 4457-2007. Sampling procedure for acceptance
tests and criteria for conformity to be as per IS : 4457-2007. The tiles shall be of required
colour.
12.35.2 Dimensions and Tolerances: Ceramic unglazed vitreous acid-resistant tiles shall be made
in three sizes namely 98.5 X98.5 mm,148.5 X 148.5 mm and 198.5 X 198.5 mm. They shall be
available in the following thickness: 35, 30, 25,20 and 15 mm. The depth of the grooves on the
underside of the tile shall not exceed 3 mm. Tolerance on length, breadth and thickness of tiles shall
be ± 2 percent.
12. 35.3 Shape: The tiles shall be square shaped. Half tiles rectangular in shape shall also be
available. Half tiles for use with full tiles shall have dimensions which shall be such as to make two
half tiles, when joined together, match with the dimension of full tile. The shape of tiles other than
square shall be as agreed to between the purchaser and the manufacturer. Tiles shall be checked for
squareness and warp as per IS : 4457-2007.
12. 35.4 Performance Requirements: The tiles when tested in accordance with method given in IS
4457-2007, shall conform to be requirement specified in the code (IS : 4457-2007).
12.35.5 Loss in Abrasion: The maximum percentage of loss in abrasion of the ceramic unglazed
vitreous acid resistant tiles determined in accordance with the procedure laid down in IS:1237-1980,
shall be as mentioned in IS:4457-2007.
12.35.6 Marking: Tiles shall be legibly marked on the back with the name of the manufacturer or
his trade mark. Manufacturer's batch number and year of manufacture.
Each tile may also be marked with the ISI certification mark.
12.35.7 Preparation of Surface and Laying: Preparation of surface and laying to be according to
para 12.30.4, except the cement used to be acid and or alkali resistant cement and cement mortar to
be used to be acid and or Alkali resistant mortar. Thickness of bedding of mortar for flooring to be
10 mm or specified on the item and for dado/skirting to be 12 mm or specified on item.
12. 35.7 Pointing and Finishing: As per para 12.31.6, except that cement used for pointing to be
acid and or alkali resistant cement.
12. 35.8 Measurements: As per para 12.31.7.
12. 35.9 Rate: The rate for flooring shall include the cost of all materials and labour involved in all
the operations described above. For tiles of sizes up to 0.16 Sqm unless otherwise specified in the
description of the item. Nothing extra shall be paid for the use of cost (Sawn) tiles in the work.
1236: Marble Work:

i) Marble shall be hard, sound, dense and homogenous in texture with crystalline texture as far
as possible. It shall generally be uniform in colour and free from stains, cracks, decay and
weathering.
ii) Marbles are metamorphic rocks capable of taking polish, formed from the re-crystallization of
lime stones or dolomitic lime stones and are distinguished from lime stone by even visibly
crystalline nature and non-flaggy stratification.
Note : Marble is a product of nature hence it is difficult to guarantee uniformity of colour,
veining or other characteristics that may be represented in any sample submitted. A sample will
indicate only an average of colour, veining and other general texture and specified finish.
12. 36.1 Classification: As per item no. 12.17.1.2.
12. 36.2 Sizes and Tolerances:
a) The size of marble blocks, slabs and tiles shall be as mentioned in Table-3.
Table - 3 : Sizes of Marble Blocks, Slabs and Tiles
Length-cm Width-cm Thickness-cm
1. Blocks 30 to 250 30 to 100 30 to 90
2. Slabs 70 to 250 30 to 100 1.5 to 2.5
3. Tiles 10 to 60 10 to 60 0.8 to 2.0
Notes :
1. All dimensions are in centimetre
2. The length and width, of the blocks shall be in multiple of 30 cm.
3. Length and width of slab shall be in multiple of 10 cm. and thickness in multiple of 1 cm.
4. Tiles shall be square cut and linear dimensions in multiple of 10 cm.
5. Only slabs and tiles shall be machine cut and factory made.
6. For 8 mm thick tiles, special precautions will be required for fixing them like using special
adhesive as per manufacturer's specifications. Such tiles are not suitable for outside veneering
work exposed to rains/sun if used in large areas in continuous stretches. For tiles of thickness
20mm and above cramps may be provided if approved by Engineer-in-Charge.
b) Tolerance: The following tolerances shall be allowed in the dimension of blocks, slabs and
tiles:
(a) Blocks : (i) Length =+ 2 per cent, (b) Width =+ 2 per cent, (c) Thickness= + 2 per cent
(b) Slabs : (i) Length = + 2 per cent, (ii) Width= + 2 per cent, (iii) Thickness =+ 3 per cent
(c) Tiles : (i) Linear dimension =+ 3 per cent, (ii) Thickness = + 1 per cent
The sizes other than those mentioned above may be provided as directed by the Engineer-in-
Charge and nothing extra shall be payable on this account.
12.36.3 Physical Properties:
i) The physical properties of marble for blocks, slabs and tiles and method of tests are mentioned
in Table 4.
Table 4 : Physical Properties of Marble & Granite
Characteristic Requirements Method of Test
1. Moisture absorption after 24 hr Max 0.4% by weight IS : 1224*
immersion in cold water
2. Hardness Min. 3 Mhos Scale
3. Specific Gravity Min. 2.5 IS : 1122#
* Method of test for water absorption of natural building stone.
# Method of determination of specific gravity and porosity of natural building stone.
ii) Approval of Sample: Before starting the work, the contractor shall get samples of marble
approved by the Engineer-in-Charge. Approved samples shall be kept in the custody of the
Engineer-in-Charge and the marble supplied and used on the work shall conform to samples with
regard to soundness, colour, veining and general texture.
12. 36.4 Sampling: In any consignment all the blocks/slabs/tiles of the same group, size and finish
shall be grouped together to constitute a lot. Sample shall be selected and tested separately for each
lot for determining its conformity or otherwise to the requirements of the specification. The number
of blocks/slabs/tiles to be selected for the samples shall depend upon the size of the lot and shall be
in accordance with the Table 5.
Table 5 : Sample Size and Criteria for Conformity
Number of block/ Number of blocks/slabs/ Permissible number of Sub sample size in
Slabs/ Tiles in the lot tiles to be selected in defectives no.
sample
(1) (2) (3) (4)
Up to 25 3 0 2
26 to 100 5 0 2
101 to 200 8 0 3
201 to 500 13 0 4
501 to 1000 20 1 5
The blocks/slabs/tiles in th the sample shall be taken at random an and inorderto ensure to
randomness of selection, random tables may be used.
Explanation 1 : All the blocks/slabs/tiles, selected in the sample, shall be examined for dimensions
workmanship and general requirements. Any block/slab/tile failing in any one or more of the above
requirements shall be considered as defective. A lot shall be considered as conforming to these
requirements if the number of defectives obtained is not more than permissible no. of defectives
given in Col. 3 of Table 5.
Explanation 2 : The lot having been found satisfactory with respect to dimensions, workmanship and
general requirement shall be tested for physical properties of the marble. For this purpose a sub
sample of the size given in Col. 4 of Table 5 shall be selected at random. These blocks/ slabs/tiles in
the sub sample shall be tested for moisture absorption, hardness and specified gravity. The lot shall be
considered having satisfied the requirements of the physical properties if none of the
blocks/slabs/tiles tested for the requirements fails in any of these tests.
12. 36.5 Marble Work - Table Rubbed and Polished (Plain Work): Marble work in steps, jambs,
columns and other plain work shall be as specified below:
i) Joints in staircase treads, kitchen platforms shall be permitted only at curvature or when
width/length is more than 0.6/2 m. respectively. Number of joints in each direction shall
not be more than one number for every 2 m. length beyond the initial 2.00 m length.
Additional joints due to curvature or for providing fixture shall be provide judiciously.
12. 36.5.1 Dressing, Cutting and Rubbing:
Every marble stone shall be gang saw/machine cut to the required size and shape, chisel dressed
machine finished on all beds and joints, so as to be free from any waviness and to give truly vertical,
horizontal, radial or circular joints as required. The exposed faces and sides of stones forming joints
up to 6mm. from the face shall be fine tooled machine cut such that a straight edge laid along the face
of the stone is in contact with every point on it. All window sills, tread of steps, counters vanities
moulding edges etc. shall be machine cut & polished to give high gloss mirror finish as per direction
of Engineer-in-Charge. These surfaces shall then be rubbed smooth. All visible angles and edges shall
be true, square and free from chipping. Beyond the depth of 6 mm from face, the joints shall be
dressed with a slight splay so that the thickness of joint increases, in an inverted V shape. The
surfaces of the stones coming in contact with backing need not be chisel dressed.
'A sample of dressed and rubbed stone shall be prepared for approval and it shall be kept on worksite
after being approved by the Engineer-in Charge.
12. 36.5.2 Mortar: The mortar used for jointing shall be as specified. 12.
36.5.3 Laying:
i) Base concrete or the RCC slab on which the slabs are to be laid shall be cleaned, wetted and
mopped. The bedding for the slabs shall be with cement mortar 1:4 (1 cement : 4 coarse sand)
or as given in the description of the item.
ii) The average thickness of the bedding mortar under the slab shall be 20 mm and the thickness
at any place under the slab shall be not less than 12 mm.
iii) The slabs shall be laid in the following manner:
a) Mortar of the specified mix shall be spread under the area of each slab, roughly to the
average thickness specified in the item. The slab shall be washed clean before laying. It
shall be laid on top, pressed, tapped with wooden mallet and brought to level with the
adjoining slabs. It shall be lifted and laid aside. The top surface of the mortar shall then
be corrected by adding fresh mortar at hollows. The mortar is allowed to harden a bit and
cement slurry of honey like consistency shall be spread over the same at the rate of 4.4
kg of cement per sqm. The edges of the slab already paved shall be buttered with grey or
white cement with or without admixture of pigment to match the shade of the marble
slabs as given in the description of the item.
b) The slab to be paved shall then be lowered gently back in position and tapped with
wooden mallet till it is properly bedded in level with and close to the adjoining slabs with
as fine a joint as possible. Subsequent slabs shall be laid in the same manner. After each
slab has been laid, surplus cement on the surface of the slabs shall be cleaned off. The
flooring shall be cured for a minimum period of seven days.
The surface of the flooring as laid shall be true to levels, and, slopes as instructed by the Engineer-
in-Charge. Joint thickness shall not be more than 1 mm.
c) Due care shall be taken to match the grains of slabs which shall be selected judiciously
having uniform pattern of Veins/streaks or as directed by the Engineerin-Charge.
iv) The slabs shall be matched as shown in drawings or as instructed by the Engineer-in-Charge.
v) Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the
plaster skirting or dado. The junction between wall plaster and floor shall be finished neatly
vi) Marble slabs flooring shall also be laid in combination with other stones and/or in simple
regular pattern/design as described in item of work and/or drawing.
12.36.5.4 Joints: The depth of joints 6 mm from the face shall be uniform and as fine as possible
but shall be not more than 1.5 mm thick on the exposed face. Beyond the depth of 6 mm from face,
the thickness of joints shall increase in an inverted V shape so as to give good mortar bond between
two stones. The inverted portion of the joints shall be filled with bedding mortar and the face 6 mm
portion with pointing mortar.
12.36.5.5 Curing: The work shall be kept constantly moist on all faces for a period of at least seven
days.
12.36.5.6 Polishing and Finishing:
i) After the marble work is cured, it shall be rubbed with carborundum stone of different grades
no. 60, 120 and 320 in succession or with electrical rubbing machines rubbed with
carborundum items 0 to 6 nos.in succession, so as to give a plane true and highly smooth
surface. It shall then be cleaned & polished with a solution of oxalic acid, washed and finished
clean.
ii) Slight unevenness at the meeting edges of slabs shall then be removed by fine chiselling and
finished in the same manner as specified in 12.12.3 except that cement slurry with or without
pigments shall not be applied on the surface before each polishing.
12.36.5.7 Protection: Green work shall be protected from rain by suitable coverings. The work shall
also be suitably protected from damage during construction.
12.36.5.8 Tolerances : As per para 12.17.2
12.36.5.9 Measurements : Marble stone flooring with different kind of marble shall be measured
separately and in square metre correct to two places of decimal. Length and breadth shall be
measured correct to a cm before laying skirting, dado or wall plaster. No deduction shall be made
nor extra paid for voids not exceeding 0.20 square metre. Deductions for ends of dissimilar materials
or other articles embedded shall not be made for areas not exceeding 0.10 square metre. Nothing
extra shall be paid for laying the floor at different levels in the same room. Steps and treads of stairs
paved with marble stone slabs shall also be measured under the item of Marble Stone flooring. Extra
shall, however, be paid for such areas where the width of treads does not exceed 30 cm. Nosing for
treads shall be measured in running metre and paid for extra. The width of treads shall be measured
from the outer edge of the nosing, as laid, before providing the riser.
For plain work: Measurements shall be taken correct to a cm in length and breadth and correct to 0.5
cm in thickness.
i) In the case of radially dressed or circular stone used in the work, the dimensions of the
circumscribing rectangle of the dressed stone, shall be measured correct to a centimetre and
thickness, correct to 0.5 cm. The cubical contents shall be calculated in cubic decimetre nearest
to two places of decimal.
ii) The marble work in arches and domes shall be measured as for plain work, but extra shall be
allowed for such work over the rate for plain work.
iii) Sunk or moulded work in marble shall be measured by volume as per plain marble work or
work in arches or domes as the case may be on the basis of circumscribed rectangular block of
the finished work but extra shall be paid for such work over the rate for plain work for work in
arches and domes. For the purpose of extra payment, volume of every stone sunk or moulded
shall be considered.
12.36.5.10 Rate: The rate includes the cost of materials and labour required for all the operations
including cutting of recesses in wall cutting moulding corners edge rounding finishing & polishing as
specified.
12.36.5.11 Use of Finished Marble Slabs and Tiles: In case such finished tiles are used, these shall
be measured and paid for separately.
12.36.6 Marble Jali : Specifications described under 12.17.1 and 12.17.2 shall apply, as approved by
12.36.6.1 Thickness: The thickness & pattern of jail shall be as specified . All exposed faces shall
be fine tooled to a uniform and smooth finish. Fixing shall be done with adjoining work in grooves,
rebates etc. as shown in the drawings or as specified by the Engineer-in- charge. Tolerance of +2
mm shall be allowed in the specified thickness.
12.36.6.2 Measurements: The length and breadth forming the jail including its border, shall be
measured correct to a cm. The area shall be calculated in square metre nearest to two places of
decimal.
12.36.6.3 Rate: It includes the cost of labour and materials involved in all the operations described
above. It also includes the cost of making grooves or rebates in the adjoining work for fixing jali.
APPENDIX - À'
ABRASION TEST FOR CONCRETE HARDENING COMPOUND
A-1 Preparation of Sample:
25 mm cylinder shall be prepared in ratio 1: 2 (1 cement: 2 graded stone aggregate 6 mm nominal size
by weight) one each with and without the admixture of concrete hardening compound. The concrete
hardening compound shall be used in the proportion by weight of cement as recommended by the
firm. The cylinder shall be placed inside a damp box for 24 hours and then cured in water for 27
days. After that, they shall be subject to abrasion test on Dory Type Avery Abrasion Testing Machine,
using Emery Powder No. 80 as the abrasing medium under the condition given in para A2 below:
A-2 Conditions of Test:
(a) Area of rubbing surface shall be same in both the cylinders
(b) Age of cylinder 28 days
(c) Duration of Test 60 minutes
(d) Total distance traversed during rubbing About 2.4 km
(e) Pressure on rubbing surface 0.04 kg/cm2
A-3 Results of Tests:
The following observations shall be made in both the cases :
(a) Composition of the Test specimen
(b) Mean thickness rubbed away
(c) Percentage loss in weight
A-4 Remarks:
Percentage loss in weight in the case of cylinders with concrete hardening compound; should not be
more than 40 per cent of the percentage loss in the case of cylinder without concrete hardening
compound.
APPENDIX - `B'
TEST REQUIREMENTS AND PROCEDURE FOR TESTING "PRECAST
CEMENT CONCRETE / TERRAZZO TILES"
B-1 Sampling: The tiles required for carrying out test described below shall be taken by 'random
sampling'. Each tile sample shall be marked to identify the consignment from which it was selected.
Minimum quantity of tiles for carrying out the test and frequency of test shall be as specified in the
list of Mandatory Test. The number of tiles selected for each mandatory test shall be as follows:
(a) For conformity to requirements on shape and-dimensions,
wearing layer, and general quality - 12 tiles
(b) For wet transverse strength test - 6 tiles
(c) For resistance to wear test - 6 tiles
(d) For water absorption test - 6 tiles
NOTE :
(1) The tests on the tiles shall not be carried out earlier than 28 days from-the date of
manufacture.
(2) The tiles selected for (a) may as well after verification of requirements be used for (b).
B-2 Flatness of the Tiles Surface: The tiles when tested according to procedure laid down in
IS:1237-1996 edition 2.3, the amount of concavity and convexity shall not exceed 1 mm.
B-3 Perpendicularity: When tested in accordance with the procedure laid down in IS:1237-1996
edition 2.3, the longest gap between the arm of the square and edge of the tile shall not exceed
2 per cent of the length of edge.
B-4 Straightness: When tested as per IS:1237-1996 edition 2.3, the gap between the thread and
the plane of tile shall not exceed 1 percent of the length of edge.
B-5 Water Absorption: When tested the average water absorption shall not exceed 10 per cent.
B-6 Wet Transverse Strength Test: Six full size tiles shall be tested for the determination of wet
transverse strength. When tested according to the procedure laid down in Appendix 'E' of IS:
1237-1996, the average wet transverse strength shall not be less than 3 N/mm2 (30 kgf/ cm2).
B-7 Resistance to Wear Test :When tested according to IS 1237 -1996, average wear shall not
exceed 3.5 mm and the wear on any individual specimen shall not exceed 4 mm, for general
purpose tiles. And 2 mm and 2.5 mm of average wear on any individual specimen, respectively
for heavy duty floor tiles.
APPENDIX - `C'
LINOLEUM SHEETS
C-1 Materials
C- 1.1 Linoleum shall consist of a composition pressed on hessian backing. There shall be adequate
adhesion between the composition and the hessian backing. The composition shall contain oxidized
or polymerized, linseed oil conforming to IS specification for linseed oil or other suitable drying-oil
or oils with necessary driers, fossil or other tensions and/or resins intimately mixed with ground cork
or wood flour or both and pigments.
C-1.2 The hessian used for the backing shall have not less than 43 ends and 33 shots per decimetre.
A piece 90 x 100 cm shall weigh not less than 200 gram. .
C-1.3 Unless specified otherwise, the paint when used for painting the hessian backing shall
conform to IS: 640.
C-2 Dimensions : C-2.1 Thickness:

The linoleum shall be manufactured to the following thickness
Thickness Type
6.7 All
6.0 Plain and Marble
4.5 All
3.2 All
2.0 All
1.6 Moire and Jaspe
C-2.2 Measurement of Thickness: The thickness of linoleum shall be measured with a micrometre
gauge or a dial micrometre gauge having a flat foot and capable of reading up to 0.01 mm. The foot
of the micrometre gauge shall exert a pressure of 1.5 kg/cm2 on the linoleum surface. The
measurement shall be made at least at 16 points and the mean value shall not vary by more than 0.1
mm from the specified thickness.
C-2.3 Width: Unless specified otherwise the width of the linoleum shall be 2m with a tolerance of
±1.5 mm.
C-2.4 Length: Unless specified otherwise, all types of linoleum of all thicknesses other than 6.0 and
6.7 mm thickness shall be supplied in rolls of length of not less than 5.5 m. In case of 6.0 and 6.7
mm thicknesses linoleum, the length shall be not less than 3 m. The length shall be measured to the
nearest centimetre.
C-3 Colour :The composition of plain linoleum shall be of uniform colour extending evenly
throughout the thickness from the surface to the hessian backing to form a sheet of approved colour.
In marble sheet linoleum portion of the mix shall be of different colours and shall be compressed
into a single sheet. The several colours shall extend from the surface to the base in random relation
to form a variegated surface showing an approved pattern.
C-4 Finish : The surface of the linoleum shall be smooth, uniform and free from indentations and
protrusions.
APPENDIX - `D'
DETERMINATION OF SUB-FLOOR DRYNESS
D-1 General:
D-1.1 These tests for determining concrete sub-floor dryness are given in this appendix. It is intended
that the first test should be carried out as a preliminary test as it is an approximate method only, and
adequate to separate very wet slabs from those which are dry or nearly dry, but will not discriminate
satisfactorily between the later two conditions. Should this preliminary test indicate that the floor is
'dry' confirmatory test should be made by one of the other two procedures given in D-3 and D-4.
D-2 Preliminary Test : D-2.1 Materials: The following
materials are required:
(a) A sheet of glass about 30 x 30 cm. or rubber mat or a sheet of polyethylene (not less than 0.1
mm thick) or the PVC flooring material of about 60 x 60 cm. and
(b) Putty adhesive or other suitable mastic for scaling the edges of the sheet material. D-
2.2 Procedure:
i) A sheet of glass, rubber or plastic materials shall be placed on the concrete floor slab to 'be
tested, and sealed thoroughly around the edges, using the mastic material.
ii) After a period of not less than 24 hours time covered portion of the concrete slab should
be inspected for signs of dampness. If this area is even slightly darker in colour than the remainder
of the slab, the floor shall be considered too wet. A careful inspection is required, as in conditions
of 'good ventilation, the difference in colour may rapidly disappear after the sheet has been lifted.
iii) The test shall be made in several places on the slab, and repeated at regular intervals until no sign of
dampness appears. The floor should then be tested at several points by either surface hygrometer
method or the electrical resistance method until satisfactory results of floor dryness are obtained
before the floor should be considered sufficiently dry.
D-3 Hygrometer Test :
D-3.1 Apparatus: A hygrometer is so constructed that when sealed to the floor with mastic or by other
suitable means, the relative humidity of a small quantity of air confined between the slab and the case of
the instrument is measured.
D-3.2 Procedure : The case of the hygrometer shall be carefully sealed to the slab and left for a period
not less than 16 hours. The relative humidity reading shall then be taken.
D-3.3 Results : The dryness of the concrete slab shall be considered satisfactory for conditions of
laying the PVC flooring, if the relative humidity reading does not exceed 70 per cent.
Note : The instrument shall be so placed that sunlight does not fall on it, as this may produce a false
low reading.
D-4 Electrical Resistance Test :
D-4.1 Apparatus : The apparatus shall comprise the following: (a)
Resistance Meter :
One, of suitable range to be calibrated in terms of the moisture content of the slab in the range of 4 to 8
per cent and having sufficient sensitivity to clearly distinguish Changes of 0.5 percent

Material Test Field! Test quantity Frequency of testing
Laboratory Procedure of material for
Test carrying out
the test
1 2 3 4 5 6
Terrazzo 1. Transverse Laboratory IS: 1237 5000 Nos.
-1980 (no testing One test for every 10,000
Tiles strength
need be done Nos. or part thereof for
2. Water
if total each type and size from a
absorption
number of single manufacturer. (One
3. Abrasion
tiles of all test to be done even if the
test
types of all number of terrazzo tiles of
sizes from all any type and size from a
manufacturers single manufacturers is
used in a work less than 5000 Nos.
is less provided the total
than 5000 Nos.) number of terrazo tiles
of all types and sizes
from all manufac-
turers used in a work
exceed 5000 Nos.
1 2 3 4 5 6
Pressed 1. Dimensions Laboratory I S:13630 3000 Nos. 3000 Nos. or part
ceramic tiles and surface -2006 thereof
(for floor quality IS:777
& wall) 2. Physical -1988
properties
3. Chemical
properties
Marble (a) Moisture Laboratory IS : 1124 50 Sqm. 50 Sqm. or Part
absorption -1974 thereof
(b) Mhos Scale
hardness Test

S. No IS NO. Subject
1 210-1993 Grey iron Castings (4th Revision)
3 401-1982 Code of practice for preservation of timber (3rd Revision) (Amendments
2) (Reaffirmed 1990)
4 451-1972 Technical supply conditions for wood screws (2nd Revision)
(Amendment 1) (Reaffirmed 1991)
6 653-1992 Specification for linoleum sheets and tiles (3rd Revision)
7 661-1974 Code of practice for thermal insulation of cold storages (2nd Revision)
(Amendments 2)
8 702-1988 Specification for industrial bitumen (2nd Revision) (Amendment 1)
9 777-1988 Specification for glazed earthenware wall tiles (2nd Revision)
(Superseded by IS : 13753, 13754, 13755,13756)
10 809-1992 Specification for rubber flooring materials for general purposes (2nd
Revision)
13 1130-1969 Specification for marble (blocks, slabs and tiles) (Reaffirmed 1993)
14 1141-1993 Code of practice for Seasoning of timber (2nd Revision)
15 1197-1970 Code of practice for laying rubber floors (1st Revision) (Reaffrmed 1990)
16 1198-1982 Code of practice for laying, fixing and maintenance of linoleum floor
(1st Revision) (Reaffirmed 1990)
17 1200-1977 Method of measurement of Building and Civil Engineering work (Part
XI) paving, floor finishes, dado and skirting) (3rd Revision) (Amendment
18 1237-1980 Specification on cement concrete flooring tiles (1st Revision) (Reaffirmed
1990)
19 1322-1993 Specification for bitumen felts for water proofing and damp-proofing
(4th Revision)
20 1443-1970 Code or practice for laying and finishing of cement concrete flooring
tiles (1st Revision) (Reaffirmed 1991)
23 1580-1991 Specification for bituminous compounds for water proofing and caulking
purpose (2nd Revision)
24 2078-1979 Method of tensile testing of grey cast iron (1st Revision) (Reaffirmed
1991)
25 2114-1984 Code of practice for laying in-situ terrazzo floor finish (Pt Revision)
26 2571-1970 Code of practice for laying in-situ cement concrete flooring (1~t Revision)
(Reaffirmed 1991)
27 3400 (Pt.1 to 22) Method of tests for vulcanized rubber
2003
28 3400-1980 Methods of test for vulcanized rubbers (Part II) - Hardness (1st Revision)
(Reaffirmed 1991)
29 3400-1977 Method of test for vulcanized rubbers (Part X) - Compression set at
constant strain (1st Revision) (Reaffirmed 1990)
30 3461-1980 Specification for PVC-asbestos floor tiles (1st Revision) (Amendments
31 3462-1986 Specification for un backed flexible PVC flooring (2nd Revision)
32 3622-1977 Specification for sand stone (Slab & Tiles) (1st Revision) (Reaffirmed
1993)
33 3670-1989 Code of practice for construction of timber floors (1 st Revision)
34 4101(part-l)-1967 Code of Practice for external facing and veneers : part 1 stone facing.
Reaffirmed 1990.
35 4457-2007 Ceramic tiles-Acid Alkali Resistant .
36 5318-1969 Code of practice for laying of flexible PVC sheet and tile flooring
(Reaffrrmed 1990)
37 5766-1970 Code of practice for laying of burnt clay brick flooring (Reaffrrmed
1991)
43 13712-2006 Definitions, classification of Ceramic tiles.
44 13630-2006 Testing of Pressed Ceramic Tiles
45 15477-2004 Quick set Tiles Adhesive
43 15622-2006 Specification for Glazed Tiles
CHAPTER No. 13
ROOFING WORK
CHAPTER No.13 : ROOFING
CONTENTS
13.0 Terminology 3
13.1 Stone Slab Roofing. 3
13.2 Galvanized Corrugated Steel Sheet Roofing 21
13.3 Ridges and Hips of Plain Galvanized Steel Sheets. 25
13.4 Valley and Flashing of Plain Galvanized Steel Sheets. 25
13.5 Gutters Made of Plain Galvanised Steel Sheets 26
13.6 Asbestos Cement Sheet Roofing 27
13.7 Poly Propylene Reinforced Cement Corrugated Sheet Roofing 43
13.8 High Impact Poly Propylene Reinforced
Cement Semi-Corrugated Sheet Roofing 49
13.9 Ridge sand Hips of Non-Asbestos High Impact Poly
Propylene Reinforced Cement 50
13.10 Other Roofing Accessories of Non-Asbestos High Impact
Poly Propylene Reinforced Cement 51
13.11 Eaves and Valley Gutters of Non-Asbestos High Impact Poly-Propylene
Reinforced Cement Propylene Reinforced Cement 52
13.12 Jack Arch Roofing 54
13.13 Mangalore Tile Roofing 58
13.14 Miscellaneous Items 61
13.15 Lime Concrete Terracing with Brick Aggregate 61
13.16 Cement Concrete Gola 63
13.17 Shell Roof (Curved Roof) 64
13.18 Suspended ceilings (False ceiling.) 72
13.19 Wooden Ceiling 86
13.20 Rain Water Spouts. 87
13.21 Cast Iron Rain Water Pipes 88
13.22 Cast lion Accessories for Rain Water Pipes 90
13.23 Thermal Insulation for Roofing 91
13.24 Unplasticised Polyvinyl Chloride Pipes and Fittings 97
Figures 99-105
List of Bureau of Indian Standards Codes 106
CHAPTER No. 13
ROOFING
13.0 Terminology :
i) Accessories:
Purpose made fittings, such as apron flashing pieces, barge boards, bottom glazing flashing,
corner piece (corner flashing), eaves filler pieces, expansion joints, hip capping, hip tile or cap,
ridge capping, ridge finials, roof lights, ventilators, with which the roof is furnished.
ii) Eaves: The lower edge of the inclined roof.
iii) Finial: A decorative fitting used at the Junction of ridges and hips to form a water proof
covering and at the top of conical, pyramidal, or dome roofs.
iv) Flashing : As trip of impervious material, usually metal used to exclude water from the
junction between a roof covering and an other part of the structure.
v) Gable : Part of wall above the general eaves level at tie end of ridged or partially hipped
roof.
vi) Gutter : Any form of roof water channel to dispose off rain water.
vii) Hip : The outer angle (more than 180 degree) formed by the inclined ridge between two
intersecting roof slopes.
viii) Pitch : The angle of inclination with the horizontal of the rafters or substructure surface on
which the roof coverings are laid.
a) In patent glazing, the angle at which the plane of a stretch of glazing is inclined to the
horizontal.
ix) Pitched Roof : A roof the pitch of which is greater than 10 degree to the horizontal.
x) Ridge: The horizontal inter-section at the apex of the two rising roof surfaces inclined in
opposite directions.
xi) Valley :The re-entrant angle formed by the inter-section of two inclined roof surfaces.
xii) Verge : Free edge of a roof surface ending at a gable.
13.1. Stone Slab Roofing: Scope : This specification lays down requirement regarding materials,
laying, protection, plastering and pointing and mode of measurement of stone slab roofing.
13.1.1.Materials: Stone Slabs:
13.1.2 General : The stone slabs shall be hard, even, sound and durable and shall conform to
standards as detailed in chapter of stone work. Slabs shall have been sawn orchiselled in a plane
parallel to the natural bed of the stone. These weigh about 2700 kg/cum. The thickness of the slab
shall be uniform and as specified in the item with a permissible tolerance of 2mm. The slabs shall be
uniform in length, the length being 5 to 8 mm less than the centre to centre spacing of the supporting
wooden Joists (Karries) or RCC battens/ supporting walls. Unless the design requires
some other shape the slabs shall be rectangular. The width of the slabs may vary unless otherwise
stipulated. It shall not be less than 40 cm. These shall rest on 12 mm thick ( min) 1:4 cement plaster
on walls.
The mineral composition and permissible stress in stone slabs is as under :
Mineral Permissible stress -kg/cm2
a) Granite 15
b) Sand stone including quartzite 8
c) Lime stone. 8
d) Slate
The stone slabs shall be Bhankri Jodhpur, Modak, Mandal, Bijoliya or of any other place as specified
in the schedule of quantities or as approved by the Executive Engineer. In case of Jodhpur stone slabs
only 'Chittor' stone slabs also known as 'Soor Sagar' slabs shall be used.Source /thickness and laying
of stone slabs for roofing shall be specifically permitted by the Engineerin-charge.
13.1.2.1 Quality:-
a) The stone slabs shall be free from any cracks or fine joints (veins) loose materials or
laminations of any other defects.Stone slabs as obtained from the quarry shall. be hard,
durableand tough. They shall be free from decay, sand holes, flaws, cracks andother defects.
They shall be quarried in such a way as to be suitable forthe roof slabs.
b) The thickness of a slab at every point shall not be less than what is specified for use in
accordance with structural calculations, subject to a minimum of 3 cm. The tolerance on stone
dimensions shall be the sameas given in IS: 1127-1957.
c) The slabs may be flat chisel dressed to a smooth or rough surface according to the requirements
of finishes at top and bottom of the floor. The slabs shall not absorb more than 5 percent of
water. The toughness and durability of a newly quarried stone may be improved by seasoning
and dressing. When tested for transverse strength in accordance with the procedure laid down
in IS: 1121-1957, the stone shall have strength of not less than 55 kg/cm2.
13.1.2.2. Dressing:-
i) The slabs shall be rough chisel dressed on the top so that the dressed surface shall not be more
than 6 mm from a straight edge placed on it. The edges of the depressions or projections shall
be chisel dressed in a slant, so that surface does not have sharp unevenness. The sides shall also
be chisel dressed to aminimum depth of 20 mm so that the dressed edges shall at no place be
more than 3 mm from as traight edge butted against it.
ii) At least one surface of the slab shall be even, such that the depth of the gap between the surface
and a straight edge held against the surface in any direction shall not be more than 10 mm.
When such a surfaces not obtained in natural slabs and the ceiling is not to be plastered, the
uneven projections shall be removed by chisel dressing to the requirement given above. When
the ceiling is to be finished with plaster, the under surface shall be left as such, provided that
no point should have bushings more than 1 cm.The two long edges shall be dressed true and
square so as to make them straight with a permissible depression of 10 mm. when a straight
edge is held over the surface.
13.1.2.3. Size & Shape :- The slab shall be square with a permissible deviation from the right
angle not exceeding 1 in 150. The thickness of the slab for varying spans shall be as specified
belowin Table 1:-
Table 1 : Thickness of slabs in cm
S. Source Clear Span.
No. Less Than 2m. 2m. and below 2.5 m. and 3 m. and below
2.5 m. below 3m. 3.5 m.
1. Jodhpur Bhankri 7 to 8 cm 8 to 9 cm 9 to 10 cm 10 to 11cm
2. Modak >6cm. 6to7cm 7to8cm 8to9cm
* Stone slab roofing above 3 m. span should only be allowed by the Engineer-in-charge only in
exceptional cases.
Note:-
(a) For patty slab from sources other than mentioned above, the thickness of slab shall be as
specified by the Engineer-in-charge.
(b) The thicknesses specified above are the least thickness at any section at the slab.
13.1.2.4.Rafter Spacing: The maximum spacing of rafters (karries-wooden beams) or RCC battens
supporting the slabs shall not exceed figures given in Table-2
Table-2
Thickness of Slab Maximum Spacing of Rafters
40 mm 525 mm.
45 mm 600 mm.
50 mm 680 mm.
The bearing of slabs over the supporting rafts karries shall not be less than 30 mm. Where a
rafter/karry supports a slab from one side only, the bearing of such slab shall be for full width of
the rafts. For bearing over the wall, the stone slabs shall be bedded over a layer of cement mortar
1:4 (1 cement : 4 fines and) of thickness not less than 12 mm.
13.1.2.5. Laying: The slabs shall be washed clean and wetted before being laid. The stone slabs
shall be jointed in cement mortar 1:4 (1 cement : 4 coarse sand). The width of joints shall not be
more than 8 mm not less than 5 mm. The top joints shall be finished flush and ceiling joints pointed
with the cement mortar 1:3 (1 cement : 3 fines and).
13.1.2.6. Finish : The finished surface shall be truly leveled or slopped as shown in the plan or as
directed by the Engineer-in-Charge. It shall be cleaned off all mortar droppings and cement
markings both on top and on the under side.
13.1.2.7. Curing: The slabs and their joints shall be kept wet during progress of work and for 7
days after completion.
13.1.2.8. Measurements: Length and width of finished stones lab work including bearing shall be
measured correct to a cm. The area shall be calculated in sqm correct up to two places of decimal.
No deduction in area shall be made for openings in roof slab for chimney, stacks, roof lights etc. of
area up to 0.40 sqm nor any extra shall be paid for extra labour, materials etc.
involved in cutting and wastage, informing such openings. For openings exceeding 0.40 sqm in area,
deduction shall be made in measurements for the full opening but extra shall be paid for extra labour,
material etc. required informing such openings.
13.1.2.9. Rate: The rate shall include the cost of all materials and labour involved in all the
13.1.2.10. Mortars:
(a) Cement sand mortar for joining :- The cement sand mortar shall be of 1:3 mix and shall
conform to specification for cement mortar.
(b) Lime mortar for Ralthal & Kharanja :- The lime mortar shall be 1:3 (1 lime : 3 Surkhi or
sand) or as specified in the schedule of quantities & shall conform to specifications for lime mortar.
13.1.2.11. Stone chips for Kharanja :-Quality :- The quality of stone for chips shall conform to
specification No.3.2. on "Building stone". The stone chips shall be wedge like pieces, their thickness
shall not be more than 2.5 cm. length between 5 to 7 cm and the depth varying from 6 to 10 cm
depending upon the thickness of Kharanja.
13.1.2.12. Stone aggregate for dhar of Jodhpur practice: Quality :- The quality of stone
aggregate shall conform to specification of building material on aggregates. The aggregate size for
the lower layer shall be 25 to 40 mm. and for the upper layer aggregate size shall be 6 mm to 13 mm.
13.1.2.13. Materials for Dhar :-
a) Lime :- Lime shall be fat lime and shall conform to specification laid down in Chapter of
building material.
b) Surkhi :- Surkhi shall conform to specification laid down in Chapter of building material.
c) Sand :- Sand shall conform to specification laid down in Chapter of building material.
d) Old lime mortar :- The old lime mortar shall be powdered such that all will pass through
I.S. sieve 4.75 mm.
e) Stone grit :- The grit shall conform to specification laid down in Chapter of building
material.
f) Hemp :- Hemp shall be new and of good quality This serves as a binding and reinforcing in-
gradient. Half of it will be chopped to 2 to 3 cm. pieces and remaining half used as long strands.
g) DanaMethi :- The Dana Methi flour shall be powdered just like barley flour (not fine like
wheat flour).
h) Gur or Molasses :- A solution of Gur shall be prepared by adding sufficient quantity of
water and stirring well so as not to leave any solid pieces.
13.1.3. Preparation of Mortar for Lime Dhar:
13.1.3.1. Proportions :- The proportion of Dhar Mortar shall be one part freshly slaked lime with two
parts Surkhi or sand and two parts old lime mortar powder and two part of stone grit by volumes.
The following shall be required for each cubic metre of freshly slaked lime:-
1. Hemp. 7 kg.
2. Dana Methi 7 kg.
3. Gur or molasses 7 kg.
Half of the hemp shall be added while preparing dhar and half while lying on the roof above the
Kharanja.The slaked lime is added in a small tank called 'Houdie' and the requisite quantities of
Dana Methi flour and Gur solution added to the lime in tank. All these are mixed well to give a
uniform mixture. The required quantities of all, lime mortar powder, Surkhi, grit and chopped hemp
(½ of the total required quantity) shall be added to lime solution. These ingredients shall be turned
over and over with spades till a mortar form consistency is obtained.The moisture is allowed to
mature for a period of about 12 hours, and mortar shall be used within 24 hours.
13.1.4. Bearing of Slabs and Length:
13.1.4.1. End and side bearings :- The minimum bearing should be 15 cm. (nominal 6") at any
point and so the length of patties should be a minimum of 30 cm. more, than the clear span.
Intermediate walls and beams etc. over which the roof is continuous and no expansion joint is
constructed; the bearing shall be half the width of wall or beam. The side shall not be less than 10
cm.
13.1.5. Slope of Terrace: The slope of the terrace shall be such as to drain of promptly all rain water
falling on the roof.The slope shall not be less than 1 in 50 and as per approved drawing. The slope
shall generally be given in 'Ralthal' 'Kharanja' and 'Dhar'
13.1.6. Laying of Stone Slab Roofing:
13.1.6.1. Laying of slabs :- The slabs shall be laid in the manner indicated in the detailed drawings
or as directed by Engineer-in-charge. The even surface being kept downwards and the laying shall
start from the end walls. In any span the first and last slab shall overlap on the non-bearing walls
atleast 10 cm. The other slabs shall laid abutting each other closely. The gap between the slabs shall
not be more than 2.5 cm. at any point. After the slabs have been laid in position on wall or on srivan
( stone slab laid along the length of the supporting joist) with lime mortar 1:3, they shall be supported
properly by cross beams and ballies to avoid breakages and subsequent accidents.
13.1.6.2. Jointing slabs with stone chips and cement mortar: Wooden strips about 5 cm. wide
shall be suspended below the joints of slabs touching their underside. The joints shall be filled with
cement sand mortar 1 : 4 packed with stone chips of wedge shape, and top finished round with
cement sand mortar 1:4 so as to project little above the slabs.The joints shall be cured for a minimum
of 7 days or until the Ralthal is started whichever is earlier.The space left over the walls between the
slabs where the roof is continuous shall be filled with cement concrete of grade M.15.
13.1.6.3. Laying Ralthal :- The top surface of slab which may be uneven due to the unequal
thicknesses of slabs or uneven surface or both should be levelled by stone chips laid flat in lime
mortar 1:3 and cured for a minimum of 7 days or until the Kharanja work is started which shall not
be done earlier than two days after the laying of Ralthal.The surface should be checked for evenness
by a straight edge.
13.1.6.4. Laying Kharanja :- 'Kharanja' shall then be laid over the Ralthal in an average thickness of
10 cm. A layer of lime mortar 1 : 3 shall be laid of approximate 3 cm. thickness. The stone chips on
edges shall be laid close to each other to make square panels of size not more than 60 cm sides. The
square panels shall then be packed with stone chips laid as above in the form of circular or spiral
rings and the central stone chips wedged.It should be ensured while laying stone chips that the mortar
rises vertically in the joints upto a height about 1 cm. below the surface
of Kharanj a.
The completed surface should be checked up for slope and evenness with a straight edge and sprit
level. The finished surface shall slope evenly from all sides towards rain water spouts. It shall be
cured for a minimum period of 10 days. and then allowed to dry.
13.1.6.5. Laying Roof Finish :- The roof finish shall be any of the following or as specified in the
schedule of quantities.
a) Dhar (Jaipur Practice) :- The average thickness of 'Dhar" shall be 8 cm (consolidated thickness).
i) The prepared 'Dhar Mortar' shall be laid over the 'Kharanja' to half the required thickness
and hemp laid in mesh form. Another layer of mortar shall then be laid to make up the
remaining thickness and slope and beaten with bamboo battens (splits) for eight to ten
hours or until the surface is covered with cream of lime and becomes sufficiently hard such
that the bamboo splits do not make deep impressions over it.
ii) The surface should be checked from time to time for evenness and slope with a straight
edge and spirit level and any unevenness corrected by adding some more mortar. When
batten beating is over the surface shall be beaten with wooden water thapies for about 5
days or till the surface becomes hard enough to rebound the thappy when the same is
struck on it. During the above beating, the surface shall be sprinkled with water and if
found necessary with lime water.
iii) As soon as the beating is over the surface shall be finished with a solution of Gur and
Gugal in the ratio of 0.5 kg. each for every 100 sq. metre of surface.The surface shall be
checked up, for slope and evenness with a straight edge and sprit level.
b) Dhar (Jodhpur Practice)
(i) First day unslacked lime 10cm in thickness shall be spread over the slabs and well
slacked and watered and then beaten with conical stones by hand so that no particles of
lime remain unslacked to cause blisters.
(ii) Second day it shall be well watered and raked up following the first day process.
(iii) Third day Hemp 250 gm (finely chopped), methi 750 gm finely powdered, p e r 10 sqm
shall be evenly and thoroughly mixed with the plastic lime.Washed stone broken metal
of size not more than 25 mm to 40mm cubical should be put in a layer of not less than 10
cm in thickness and then well beaten with conical stones by hand and the metal compactly
embedded.
(iv) Fourth day clean sharp stone, small gravel, 6 mm to 13 mm. cubicles shall then be put
over this big metal in 40 mm. thick layer and well beaten, first with stone beaters and
then by hand till they are well set. The thickness of thus prepared terrace shall not be
below 15 cm.
(v) After about a week later, fresh lime shall be slaked and passed through a very fine
sieve. At night it shall be well watered. In the morning this fine lime shall be spread and
rubbed over the roof terrace for full four hours or more. During the process of rubbing, a
decoction of gugal 250 gm., jaggery 65 gm per 10 sqm shall be sprinkled now and then
the surface rubbed with a wooden trowel and thus finished.
Note :- The Ralthal, Kharanja and dhar shall be laid over slabs right up to its edges on all wall
including under parapet.
13.1.7. Curing: The finished surface shall be covered with damp sand or jute bags kept moist, or the
surface may be sprinkled with water several times so as to keep it constantly wet for atleast a fortnight.
13.1.8. Removal of Props :After the completion of roof finish the props shall be removed.
13.1.9 Tests: The workmanship and material shall be such as to provide a leak proof roof and nothing
stated above shall absolve the contractor of responsibility from providing a water tight, leak proof
roof. In case any leakage occur, this shall be made good by contractor at his expense and labour.
13.1.10 Plastering and Pointing: The under ceiling shall either be plastered or pointed as specified
in the description of item in the schedule of quantities and shall conform to the relevant Specification.
a) The roof shall be measured in square metre, the thickness being specified. Roofing over clear
spans less than 2 metre shall be measured separately from those spanning 2 metre and above.
b) The clear measurements of roof between the walls shall be taken, when the walls over the
bearings are taken above roof level. In cases where the roof is continuous and no walls exists
over the walls the clear measurements of roof inclusive of wall thickness shall be measured.
c) Extra lift above 5 metre height of roof from the existing or proposed ground level whichever
is higher shall be paid separately in stages of 5 metre.
13.1.12 - Other types of Terracing-Mud Phuska: General
13.1.12.1 - Mud Phuska is a common type of insulating course in the roof used inshot dry regions of
the country, such as in Punjab, UP, Haryana, etc. where rainfall is not heavy. It is cheap, reasonably
durable and adds enough thermal insulation for maintaining relatively comfortable temperature in
the interior. Of course the reduction in temperature would be less than what can be obtained from
using polystyrene and other factory made products.
13.1.12.2- Materials :
a) Mud Phuska layer by itself is not sufficiently waterproof for the roof and it may be necessary to
provide beneath it a waterproofing layer or membrane like coat of hot bitumen (see Cl: 13.1.13)
to be effective in this respect. Care shall also be taken while doing roof finish work to compact
mud Phuska layer to maximum density.
i) Soil for mud Phuskashall be free from gravel and coarse sand of particle size greater than
2 mm, vegetable matter and KANKAR particles. The coarse material shall not exceed 25
percent by mass. The soil shall also be free from harmful and efflorescent salts. The
plasticity index of the soil shall be between 10 to 15 percent.
ii) Generally soil suitable for brick making is suitable for mud Phuska also. The plasticity
index will indicate a reasonable cohesive soil. Soil infected with white ants shall not be
used.
b) Soil for mud plaster and mud mortar shall be free from vegetable roots, gravel and coarse sand
of particle size greater than 2 mm. The coarse material shall not exceed 10 percent by mass and
the soil shall be free from harmful and efflorescent salts. The plasticity index shall be between
10 to 15 percent.
c) i) Mud plaster shall be prepared from soil prescribed in a(ii) . The dry soil shall be reduced to
fine powder and mixed with water in a pit, adding wheat straw 6 percent by mass and
cow dung 12 percent by mass. The mixture shall be allowed to rot for a period of not less
than 7 days. During this period it shall be pugged manually to get a homogeneous mass
free of lumps and clods. The wheat straw may be of any size since it would be broken to
small size during the period.
ii) The slump, when tested as per IS 1199 : 1959 shall be about 70 mm. Alternatively,
consistency of mortar may be adjusted by taking it in a trowel and observing as to how it
slides off the face of the trowel. The mortar shall readily slide off, but at the same time
shall not be so wet as to part into large drops before falling.
d) Cutback bitumen shall be prepared by adding 20 parts of kerosene oil and one part of paraffin
wax to 80 parts of 80/100 bitumen (see IS 217 : 1988) melted on gentle fire. The mixture shall
be worked to a homogeneous mass.
e) Mud mortar used as bedding under brick tile layer shall be prepared in the same-manner as mud
plaster but without any addition of fibrous reinforcing material and binding material. The mud
mortar may be used immediately without any rotting period. The mortar shall be mixedwith 2
percent bitumen cut back by mass of dry soil and worked to a homogeneous mass.
f) Leeping plaster (GOBRI LEEPING) shall be prepared by mixing soil with equal parts of cow
dung and adding the required quantity of water to make a thin paste; soil used shall be free
from coarse sand and gravel. The mixture shall then be worked into a homogeneous mass. Five
percent of cutback bitumen by mass of dry soil may be added to improve the water proofing
characteristics.
g) Brick tiles shall conform to IS 2690 (Part 1): 1993 and IS 2690 (Part 2) : 1992. Cement shall
conform to IS 269: 1989 or IS 455: 1989 or IS 1489 (Parts 1 & 2) : 1991 or any other as
specified. Sand and fine aggregate shall conform to IS 383: 1970, Burnt clay pozzolana shall
conform to IS: 1344-1981
h) Cement mortar for grouting shall be a 1:3 mix or any richer mortar as may be specified.
13.1.12.3- Preparatory Work :
i) The slope of terrace shall be such that all rainwater can be drained off, preferably the slope
shall be not less than 1 to 40. If the slope cannot be given in the mud Phuska layer, part of the
slope can be given in the sub-floor itself.
ii) The durability of the mud Phuska layer depends on how the protective layer, namely, the
mud plaster or brick tiles are maintained free of cracks.
iii) Where there is no rainfall and there is very little variation in temperature, paving with tiles
may not be necessary over mud Phuska layer.
iv) Waterproofing treatment as deemed necessary shall be done on the sub-floor.
13.1.12.4- Laying of Mud Phuska:
i) Preparation: The soil as described in (ii) shall be stacked in requisite quantities in about 300
mm high stacks over a level ground and the top surface divided into suitable compartments by
bunding. The estimated quantity of water corresponding to the optimum moisture contentshall
be added about 12 h before the use and allowed to soak. The stacks of soil shall then be worked
up with spades and hands to ensure proper distribution of moisture at the time of use of soil.
Note- Generally soil of this type will require an optimum moisture of about 145 Um3, Soil
suitable for good compaction should contain that much quantity of moisture, which when
moulded with hand to the shape of form, just retains its form.
ii) Laying:
a) The mud Phuska shall be laid loose to a thickness of not more than 150 mm. It shall be brought
to proper slope and then rammed manually with wooden THAPPIES so as to obtain maximum
density. The final thickness should not be less than 100 mm.
b) The surface shall be allowed to dry for a period of not less than 24 h. If any cracks appears,
they should be filled with a grout of the binder material that is used in the LEEPING(usually
GOBRI).
iii) Applying Mud Plaster:
a) On the mud Phuska, a layer of minimum 25 mm thick mud plaster shall be laid; the plaster may
be applied in single coat or two coats of 15 mm and 10 mm; two coats are preferable. Hair
cracks if any shall be grouted with the binder material of LEEPING. The surface level shall be
checked.
b) When the mud plaster coating has dried, a thin coat, not less than 3 mm, of LEEPING shall be
applied. The surface shall be allowed to dry and any hair cracks shall be grouted as before.
The LEEPING shall be finished with a trowel or float.
13.1.12.5- Paving with Brick Tiles:
a) The brick tiles, where necessary, shall be laid flat on a thin layer of mud mortar. The mud
mortar shall be used to the minimum extent to give a level surface. Tiles shall be laid close
together with a thickness of joint between 6 mm and 15 mm, it shall be ensured that the mud
mortar rises in the joints. The brickwork shall be allowed to dry for 24 h before grouting the
joints. Care shall be taken at the time of grouting that the tiles are not displaced.
b) While grouting with the 1:3 mix, ensure that all joints are filled. Allow the mortar to set for12
h before pointing, if it is to be done.
c) Check evenness and desired slope.
d) Cure the surface for not less than 7 days.
e) The junction between the roof finish and parapets shall be treated as specified / detailed on
the drawings.
13.1.12.6 - Maintenance: Annual maintenance is required when the roof is finished, only with
LEEPING, in such case the LEEPING shall be applied as necessary before monsoon. After
monsoon, grass if any shall be removed.
13.1.13 - Painting of Roof Slab With Hot Bitumen:
13.1.13.1 Preparing the Surface : The surface shall be painted only when it is thoroughly dry. The
surface to be painted shall be cleaned with wire brushes and cotton or gunny cloth. All loose
materials and scales shall be removed and the surface shall be further cleaned with a piece of cloth
lightly soaked in kerosene oil.
13.1.13.2-Paintingwith Bitumen: The contract or shall bring the bitumen to site in its original
packing and shall open and use it in the presence of the Engineer-in-Charge or his authorised
representative. The containers shall not be removed from the site until the painting job is completed
and the Engineer-in-Charge has satisfied himself regarding the quantity of bitumen actually used
and has given his permission to remove the empty containers.
13.1.13.3- The surface prepared and treated shall be painted uniformly with bitumen of approved
quality such as residual type petroleum bitumen of penetration 80/100, hot cutback bitumen or
equivalent as perspecifications of the manufacturer. The coat of bitumen shall be continued 15 cm
along the vertical surfaces joining the roof. Incase of parapet walls it shall be continued up to the
drip courses.
13.1.13.4- Residual type petroleum bitumen of penetration 80/100 shall be heated to a temperature of
not less than 180° C and not more than 190 degree C and shall be applied on the roof surface at not
less than 180° C. Similarly, hot cutback bitumen shall be heated to a temperature of not less than
165° C and not more than 170° C and shall be applied on the surface at not less than 165° C.
13.1.13.5- Care shall be taken to see that no blank patches are left. The quantity of bitumen to be
applied per 10 square metre of roof surface shall be 14 kg, unless otherwise stipulated in the
description of the item. It shall be carefully regulated so that the application is uniform at the
stipulated rate of 14 kg. per 10 square metre.
13.1.13.6- Spreading Sand: Immediately after painting, dry, clean sharp courses and at the rate of
60 cubic decimetre per 10 sqm. shall be evenly spread and levelled over the surface when the
bitumen is still hot.
13.1.13.7- Measurements: The superficial area of the surface painted shall be measured in square
metre. No deduction in measurements shall be made for unpainted areas of roof slab occupied by
chimney stacks, roof lights etc. of areas, each up to 40 sq decimetre. The measurements of length and
breadth shall be taken correct to a cm.
13.1.13.8- Rate: The rate shall include the cost of all materials and labour involved in all the
13.1.14 Rain Water Spouts: The sectional area of rainwater spouts provided shall be generally at
the rate of 1 square cm per 70 to 80 square decimetre (or one 100 mm dia. Pipe for 36 sq m of drained
area) of roof area drained. How ever in locations subject to excessive and high intensities of rainfalls,
the area of spouts provided may be suitably increased to suit local conditions. No spout shall be less
than 100 mm in dia meter. The spacing of spouts shall be arranged to suit the position of openings
in the wall. Encased PVC or CI pipes are suitable choices. PVC pipes if used up to the plinth
protection, should be encased in brick work.
13.1.14.1 -
a) Stone Ware Spouts: The spouts shall be 100 mm in diameter and 60 cm long. The stone ware
pipe shall be perfectly sound, free from fine cracks, imperfections of glazing etc. They
must be straight cylindrical and of standard nominal diameter and length and depth of socket as
given in IS 651. Full length of pipes shall be used on the work. They must be thoroughly salt
glazed inside and outside shall generally conform to IS 651-2007.
b) Fixing: These shall be provided at the mouths of khurras and shall be fixed in cement mortar 1:3
(1 cement : 3 coarses and) with the socket embedded in the masonry and the spigotend
projecting outside. The masonry around the pipe and socket shall be thoroughly wetted and the
holes shall be given a coat of cement mortar all-round. The S.W. pipe shall then be inserted
and fixed with a surround of mortar. Incase the hole has be come much larger than the size of
the pipe, cement concrete 1:2:4 (1 cement : 2 coarses and : 4 graded stone aggregate 12.5 mm
nominal size) shall be used to fill in the annular space. The spouts shall sloped own ward at the
rate of 1 in 6. The projection outside the wall shall be uniform and not less than 40 cm. The
entrance in to the pipe shall be smoothly rounded to meet the internal bore of the pipe to facilitate
easy flow. Care shall be taken to ensure that the vertical plane through the centre line of the
spouts is at right angles to the plane of the wall. Spouts in crow shall be true to line.
13.1.14.2- Measurements: Spouts shall be measured in numbers.
13.1.14.3- Rate: The rate shall include the cost of all materials and labour involved in all the
operations described above including scaffolding.
13.1.15- Water proofing of RCC roofs: By Applying Cement Slurry mixed with Armoucrete or
Tapecrete (MES specification).
13.1.15.1 Water Proofing Treatment to roofs: Water Proofing Treatment on Roof Slabs by
Applying Cement Slurry mixed with Armoucrete or Tapecrete, Second Layer of Fibre Glass Cloth.
13.1.15.2- Preliminaries to be Attended:
(i) Before taking up the waterproofing work the construction of parapet walls etc, including
finishing should be completed in all respects.
(ii) Similarly, the ancillary items like haunches, khurras, grooves to tack the fibre cloth layer, fixing
up of all down-take pipes, water pipes and electric conduits etc. should be completed and no
such work should be allowed on the area to be treated during the progress of water proofing
treatment or even later.
13.1.15.3 - Preparing Surface: There is no necessity of hacking the surface but the surface to be
treated shall be cleaned including chiseling the extra mortar sticking to the surfaces etc.
13.1.15.4 - Preparing Cement Slurry:
(i) Preparation of slurry is most important factor. The consistency of the slurry should be just that
of oil paint and the quantity of slurry prepared should be such as to cover the calculated and
desired area with just one coat of application and for that it is essential to calculate the correct
quantity of water to be mixed in the prescribed quantity of cement per sqm area.
(ii) This can be done only by trial and error method by preparing few samples with prescribed
quantity of cement and applying over few patches each of say 1/2 sqm area and thus the
required quantity of water per sqm area can be decided say X litres per sqm.
(iii) On deciding the correct quantity of water required per sqm area the required quantity of slurry
should be prepared which can be applied over the desired surface within 1/2 an hour of mixing
with 0.488 kg of grey cement + 0.253 kg of Armoucrete or Tapecreate + X litres
of water per sqm area and the required quantity of slurry thus prepared should only be used for
first application.
13.1.15.5 - Fibre Glass Cloth: The fibre glass cloth shall be of approved proprietary brand and shall
be thin, flexible uniformly bonded mat composed of chemically resistant borosilicate glass fibre
distributed in random open porous structure bonded together with a thermo-setting resin (Phenolic
Type).
13.1.15.6- Application of Slurry as First Layer: The First layer shall be applied with painting
brushes over the specified and dampened area with slurry prepared,very carefully including the
corners, holes on the surfaces and joints of pipes in concrete etc. and the application should continue
at least upto 150 mm height of fixtures of pipes from the surface. The surface on application shall
be air cured for just 4 hours.For projected pipes, slurry shall be applied just up to 100mm height
instead of 150mm height as prescribed. Also the slurry shall be applied up to a height of 300mm on
parapet walls and also the groove on top where the fibre glass cloth has to be tucked.
13.1.15.7 Spreading Fibre Glass Cloth:
(i) Immediately on applying the slurry on a sufficiently workable area when the slurry applied is
still green the fibre glass as specified shall be spread evenly on the surface without any kink
and pressed to see that no air spaces exist. The fibre glass cloth shall be taken up to a height of
300 mm on parapet walls and tucked in the groove specially prepared at that height.
(ii) A minimum overlap of 100mm width shall be provided when the fibre cloth has to be joined.
The joining of 1 0 0 = overlap shall be done with the same slurry used for the application on
surface as first layer. The fibre cloth shall also be extended up to a height of 100mm over pipes
projecting from the surface.
13.1.15.8- Preparing Cement Slurry Mixed with Sand for Third Layer:
(i) The quantity of water required to prepare slurry which can cover one sqm area of the surface
to be treated shall be calculated as described in clause 13.1.15.4and consider this quantity as
say X litres/sqm.
(ii) On deciding the correct quantity of water required, the slurry shall be prepared by mixing 1.289
kg of grey cement + 0.67 kg of Armoucrete or Tapecrete + 1.289 kg of coarse sand + X litres
of water. All above quantities are for preparing slurry to cover 1 sqm surface. Therefore, the
required quantity of slurry for the area to be covered within 1/2 an hour shall be prepared.
(iii) The consistency of the slurry shall be such that in one application with a brush 1.5 mm
thickness of slurry can be coated on the fibre glass cloth surface.
13.1.15.9 - Applying Final Coat of Slurry:
(i) The slurry specially prepared as explained above shall be applied evenly on the entire
surface covered with fibre glass cloth so that a layer of 1.5 mm thickness of slurry is formed.
(ii) The application of slurry shall be continued over the 300mm portions of parapet wall and
also the portion tucked in the groove on top.
(iii) The entire surface shall be allowed for air curing for 4 hours and later the surface shall be
cured with clean water for 48 hours.
(iv) On completion of curing the grooves where the fibre glass cloth is tucked shall be closed
neatly with cement mortar mixed with water proofing compound.
13.1.16 Brick Bat Coba: Integral Cement based Water Proofing treatment including preparation
of surface as required for treating roofs, balconies, Terraces etc. with Brick Bat Coba.
13.1.16.1- Preliminaries to be Attended : The preliminaries to be attended before taking up the
work shall be exactly same as described in clause 13.1.15.2
13.1.16.2 Preparing the Surface :It would be advantageous to roughen the surface by scraping the
surface when the slab is being cast, however the surface need not be hacked. In case the slab is
already cast and surface fairly finished, the same shall be cleaned neatly of all mortar droppings, loose
materials etc.
13.1.16.3 Blending Cement/Water with water Proofing Compound:
(i) Whenever the water proofing compound is to be used, it is advantageous to blend the same
with cement if the water proofing compound is in powder form and if the same is in liquid form
the required quantity of water blended with water proofing compound alone should be used for
preparing slurry/mortar.
(ii) The water proofing compound to be used shall conform to IS:2645 and be of reputed brand
with a clear ISI marked on the container which should be in the form of sealed tins or closed
packets.
(iii) The correct quantity of water proofing compound to be used per 50 kg grey cement shall be as
prescribed by the manufacturer on the tins/packets literature. However, not more than 3% of
water proofing compound shall be used per 50 kg of grey cement.
(iv) Blended cement with water proofing compound or water mixed with liquid water proofing
compound shall be used to prepare slurry/mortar.
13.1.16.4- Preparing of Slurry :
(i) The quantity of water required to prepare the slurry with 2.75 kg of cement to painted over an
area of 1 sqm shall be calculated exactly as described in clause13.1.15.4/13.1.15.8 para (i) and
(ii). Consider this quantity of water as x litres per sqm.
(ii) Depending upon the area of surface that has to be covered, the required quantity of slurry should
be prepared using 2.75 kg blended cement + x litres of water per sqm area to be covered, taking
particular care to see that only that much quantity of slurry shall be prepared which can be used
within 1/2 an hour of preparation.
13.1.16.5- Application of Slurry under Base coat:
(i) The slurry prepared as explained above shall be applied over the dampened surface with
brushes very carefully, including the joints between the floor slab and the parapet wall, holes
on the surfaces and joints of pipes in masonry/concrete.
(ii) The application of the slurry should continue up to a height of 300 mm over the parapet wall
and also to the groove as shown in Fig as below. The slurry should also be applied up to a
height of 150 mm over pipe projection etc.
13.1.16.6 - Laying Base coat 20 mm thick: Immediately after the application of slurry and when the
application is still green, 20mm thick cement plaster as base coat with cement mortar 1:4 (1 blended
cement: 4 coarse sand) shall be evenly applied over the concrete surface taking particular care to see
that all corners and joints are properly packed and the application of the base coat shall be continued
up to a height of 300 mm over the parapet wall as shown in Fig below
13.1.16.7- Preparing Brick-bat Concrete Mix
(i) Brick bat of size 25 mm to 100 mm out of over burnt bricks shall be used for the purpose of
brick bat coba.
(ii) Depending upon the area of concrete surface to be covered the calculated quantity of brick bats
to cover the area shall be heaped for mixing. Cement mortar 1:5 (1 blended cement: 5 coarse
sand) shall be prepared separately of half the quantity of brick bats, collected by volume.
(iii) The bricks bats shall be properly dampened (soaked in water) for six hours before the cement
mortar is added. The materials shall be thoroughly mixed by adding some water if needed and
the homogenous mix thus prepared should only be used. Under no circumstances dry brick bats
should be mixed with the mortar.
13.1.16.8 - Laying Brick-bat Coba:

(i) When the base coat takes initial set or preferably on the subsequent day the brick bat coba after
mixing as specified above shall be laid to required slope/ gradient. To ensure fixing up of proper
level/gradient correct level points should be fixed with brick bat coba mix only and the brick bat
coba shall be laid to the top of level points. The surface of brick bat coba shall be finished
neatly to proper slope.
(ii) The haunches/gola at the junction of parapet wall and the roof shall be formed only with
brick bat coba as shown in Fig above
(iii) In case the brick bat coba is laid on the base coat immediately on initial set there will be no
necessity of applying cement slurry over the base coat before laying the brick -bat coba.
However, if the brick bat coba is to be laid on the subsequent day, cement slurry prepared as
described in clause 13.1.16.4 shall be applied over the top surface of the base coat, then only
the brick bat coba shall be laid.
13.1.16.9 - Application of Slurry over Brick-bat Coba:
Immediately on laying brick-bat coba i.e when the initial set takes place, or at least on the subsequent
day cement slurry prepared as per clause 13.1.16.4 shall be applied on the surface of brick -bat coba.
The application of slurry shall be the same as described in clause 13.1.16.5 which should cover the
haunches/gola, and the remaining small portion of parapet wall and also
inside the groove as shown in the figure.
13.1.16.10 - Laying Finishing Layer (Protective Coat):
(i) Immediately on applying the cement slurry over the surface of the brick bat coba and when the
slurry applied is still green, a 20 mm thick layer of cement plaster, without leaving any joints
shall be applied with cement mortar 1:4 (1 blended grey cement: 4 coarse sand) over the entire
surface including the haunches/gola and the small portion on the parapet wall. The groove in
the parapet wall over the haunches shall also be filled neatly packing the mortar firmly in the
groove.
(ii) The surface of the finishing layer (protective coat) shall be neatly finished with cement slurry
prepared as per clause 13.1.16.4 The finished surface shall be allowed to dry for a while till a
string mark can easily be made on the surface, when 300mm x 300 mm square marks shall be
made over the entire surface.
13.1.16.11- Curing and Testing the Treatment: The entire surface thus treated shall be flooded with
water by making kiaries with weak cement mortar, water shall be made to remain on the roof slab
for a minimum period of two weeks during which it can be observed if there are any leakage or not.
Brick bat coba shall be provided as specified, however recommended average thickness is 120mm
and minimum at Khurra as 65 mm.
13.1.17 Reinforced Brick Roofing (IS: 10440-1983) :
13.1.17.1 - Terminology:
i) Reinforced Brick Slab (RB Slab) :- Reinforced brick slab is particularly same as reinforced
concrete slab in all its essential features except that brick work is substituted partly or fully for
cement concrete (see Fig. 2).
ii) Reinforced Brick Concrete Slab (RBC Slab) - These are reinforced brick slab using
concrete in the joints and on the top of bricks (see Fig. 2).
13.1.17.2-3. Materials:
i) Bricks - These shall he of at least Class 75 for RB and Class 35 for RBC construction and
conforming to IS: 1077-1976. Over burnt bricks having vitrified surface shall not be used.
ii) Cement Concrete:- Cement concrete used in filling the interstices in reinforced brick slabs and
for providing top decking of reinforced brick concrete slabs shall he of grade not less than M
15 and shallconform to IS: 456-2000. It shall contain just enough water to flowfreely without
segregation of the aggregates. The size of the aggregates may be suitably selected to suit the
construction.
iii) Reinforcement :- It shall conform to IS : 432 ( Part I )-1982: orlS : 1139-19664 or IS :
1786-1979/1. Reinforcements shall be free from rust scale or other coating.
iv) Centering and Formwork:- The formwork shall consist of steel possessing sufficient strength
so as to carry the superimposed load.Unless otherwise specified form work shall consist of
platforms composed steel sheets supported on runners or beams. The steel props and bracings
supporting the platform shall have sufficient lateral stability.
13.1.17.3 - Necessary Information:
i) For the efficient construction of the work, detailed information with regard to the following
is necessary:
a) Size and dimensions to be covered and loading conditions;
b) Type of supporting elements and restrictions if any to their arrangement; Level
c) to which the terrace should be brought to receive floor orroof finish; Treatment
d) of junctions with adjacent floors, walls, etc.,
e) Provision to be made for roof slope and other requirements for drainage; and
Provision for fixing of services, ceilings, etc.
(ii) All information as above shall be made available to those who are responsible for laying the
roof or floor. Necessary drawings and illustrations for preparatory work shall be given.
(iii) Arrangements shall also be made for proper exchange of information between those engaged
in laying the floor or roof and all others whose work will be affected.
13.1.17.4-. Preparatory Work:
a) Storage, Transport and Handling of Materials:-Necessary precautions shall be observed
in storage, transport and handling of cement, sand, bricks and aggregates.
The materials shall be stored on the building site in such a way as to prevent deterioration or
loss of their structural and other essential properties (see IS : 4082-1977).
b) Mixing of Cement Concrete:- Cement concrete shall be prepared in accordance with IS :
456-2000.
c) Cutting and Bending of Reinforcement: - Reinforcements shall be bent and fixed in
accordance with the procedure specified in IS : 2502-2004,and shall not be straightened in a
manner that will injure the material.
d) Preparation of Bricks: - Bricks shall be kept immersed in water for 4 to 6 hours and removed
about 15 to 20 minutes before they are used so that their skin is dry when cement concrete is
poured.
13.1.17.5-. Design Considerations:
i) The general design of RB and RBC slab shall be in accordance with IS:456-2000. In case of
RB slabs, working stress method of design may be followed.
ii) Compressive Strength of Brick Masonry: - All permissible stresses shall be related to the
compressive strength of bricks as given in Table-1 depending upon the crushing strength of
bricks.Alternatively, allowable stresses may be based on the results of prism test (see Appendix
B of IS:1905-1980), on masonry made from masonry units and mortars ,with the same bonding
arrangement as for the slab.
iii) Having determined the compressive strength, the permissible stresses to be followed in the
design shall be as given in Table 2.
iv) One way RB slabs with freely supported ends, shall be designed to resist a bending moment
near midspan of WL/8, where W is the total uniformly distributed load over the span and L is
the effective span. For slabs continuous over supports and for slabs spanning in two directions
at right angles, bending moment shall be calculated as given in IS : 456-2000.
v) RBC slab shall be designed in the same way as RCC slab as per IS: 456-2000.
NOTE- A continuous RBC slab at the support shall be designed like a RB slab and the bottom
reinforcement shall be continued over the support. Reinforcement for taking negative moment
over the support shall be provided in the top concrete.
13.1.17.6 - Reinforcement:
i) Design - The reinforcement in RB and RBC slabs shall be designed according to the provision
of IS: 456-2000 taking the spacing of bricks into consideration. The reinforcement in either
direction shall however not be less than 0.20 percent of the cross sectional area of the slab
where plain steel bars are used and not less than 0-16 percent where high strength deformed
bars are used.
ii) Spacing:- The horizontal distance between two parallel main reinforcement shall not be more
than three times the effective depth of the slab or 450 mm whichever is smaller.The pitch of
the distribution bars shall not be more than five times the effective depth or 450 mmwhichever
is smaller.
iii) Protection Against Corrosion:- Reinforcements shall be so placed that they do not touch
bricks at any point.A minimum cover of 25 mm shall be provided all round the
reinforcement.Further measures for preventing corrosion of reinforcements shall be taken as
recommended in IS: 9077-1979. In general, two bars shall not be used in the same joint.
13.1.17.7 - Construction of Reinforced Brick Roof or Floor:
i) Erection of Centering and Formwork: - Centering shall be erected to support the RB floor or
roof from below.The centering shall be smooth, clean and to correct alignment.The top surface
of form work shall be given an upward camber of 1 mm for every 150 mm of
span subject to a maximum of 30 mm to allow for initial settlement. Before laying the slab, the
formwork and the supports shall be checked to prevent undue sag and to ensure overall safety
and stability of theformwork.
ii) Detailing of Reinforcement: -All main and distribution reinforcement shall be placed in the
position shown in Fig; 1 and shall be completely embedded in concrete.They shall be rigidly
secured against any displacement and arrangement shall be made to ensure proper cover to the
reinforcements. Splices in adjacent bars, if needed shall be staggered.
iv) Spacing of Bricks: - The bricks prepared as in 13.1.17.4 (d) shall be laid between the RCC
beams in cement mortar 1:3 Preferably a minimum spacing of 60 mm in between the bricks
should be maintained for preventing corrosion.
Table 1 : Compressive Strength of Masonry.
S.No. Average Compressive Assumed compressive strength of
strength of Brick, N/mm2 masonry (fm )N/mm2
* ,
With Proper Control Without proper control

(1) (2) (3) (4)
i) 3.5 3.0 2.0
ii) 5.0 4.5 3.0
iii) 7.5 6.25 4.25
iv) 10.0 8.0 5.5
v) 15.0 9.5 6.5
vi) 17.5 11.0 7.5
vii) 21.0 12.25 8.25
viii) 25.0 13.25 9.0
ix) 28.0 14.0 9.5
x) 35.0 15.5 10.5
*In no case the assumed f shall be greater than the average compressive strength of mortar or grout
whichever is less.
Table 2 : Permissible stresses
S.No. Type of stress Permissible stresses, N/mm2
(1) (2) (3)
i) Flexural Compression 0.23 f
ii) Flexural Tension 0.10 f
iii) Shear (without shear reinforcement) 0.02 f
iv) Shear (with shear Reinforcement) 0.05 f
v) Bond: a) Plain Bars, 0.6
b) Deformed bars. 0.8
vi) Modulus of elasticity 1000 f but shall not exceed 2x104
13.1.17.8 - Laying of Bricks and Reinforcements :- The bricks for single brick thickness of floor
or roof shall be laid directly on the forms without bedding of any kind.After one row of bricks has
been laid the next row is similarly laid providing the gap for concrete joint.Concrete as prepared in
13.1.17.4 (b) shall be then poured in the gaps to fill the bottom of the joint to a uniform thickness
equal to the clear bottom cover to the reinforcing bars. Concrete should be poured into the joints
after the placement of reinforcement. Concrete shall be fluid enough to run freely around the
reinforcing bars and fill the joints completely. The joints shall be puddled sufficiently with a trowel
or a sharp ended I6 mm diameter rod to aid the flow of concrete to every corner and to fill any void
space left in the joint due to entrapping of air or otherwise. A typical cross section of RB and RBC
floor or roof is shown in Fig. 2. If a slab of two courses of brick is laid, a fresh layer of concrete
shall be spaced over the first course to make the middle horizontal joints and screeded properly to
the desired thickness of the joint.The top course of brick is then laid in the same manner as in the
first course.
13.1.17.9 - Curing: - The brickwork shall be kept wet by means of wet straw or wet sand or merely
by sprinkling water gently over the surface for about 24 hours after finishing. The slab shall then be
watered profusely and allowed to set for a period of atleast 10 days.
13.1.17.10 - Removal of Formwork :- The formwork for the RB and RBCfloor or roof shall not be
removed before 14 days after laying.
13.1.17.11 - Finishing :- The completed floor or roof shall be further finished with a water proofing
course of lime concrete (see IS : 3036-1980*) or MUD PHUSKA with tiles (see IS : 2115-19807).
The ceiling shall be rendered or plastered after drying with cement mortar (1:3 ) or lime mortar (1 :
2) as specified.The plaster may be in a single coat of 12 mm thick, and shall be done in accordance
with IS : 1661-1972. The finished surface of the floor or roof shall be cured with water for a period
of not less than 3 weeks.
13.1.17.12 - Inspection : Inspection shall be done at every stage to avoid unsatisfactory work. 13.2.
Corrugated Galvanised Steel Sheet Roofing:
13.2.1.Scope : This specification lays down requirements regarding materials, laying, fixing and
mode of measurement of galvanized corrugated steel sheet roofing. Only important aspects about G.S.
Sheets discussed under this clause, for more details for G.S. sheets refer Chapter 3.
13.2.2. Materials:
13.2.2.1. C.G.S. Sheets : Sheets shall conform in all respect to I.S. 277-1992. Ordinarily the sheets
used for roofing shall be of 1.0 mm to 0.63 mm thickness, 1.8 m. to 3.0 m. length, depending upon
the span of purlins, wind loads, and whether tiles used over sheets for insulation. The thickness shall
be stated in the schedule of quantities.The sheets shall be of 275 grade of coating (See Appendix-A)
unless otherwise specified in the descriptionofitem.
Hook bolts shall conform to IS 730:1978 steel bolts, nuts & washers shall be galvanized. Neoprene
washer, if used, shall conform to IS 8869: 1978.
13.2.2.2. Quality :- The sheet shall be free from twist or buckle and shall have uniform corrugation
true in depth & pitch and parallel to the sides of the sheet. The galvanizing shall be clean, even and
free from un- galvanized spots and other defects. The galvanizing shall be non-injured and in perfect
condition. The sheets shall not show signs of rust or white powdery deposits on the surface.
13.2.2.3. Zinc coating (IS:4736-1986) :- The weight of coating referred to in this specification
shall represent the total weight of zinc both sides inclusive. The following limits of zinc coating
shall apply to the different classes of sheets.
Class 1 :- Extra heavy coating of zinc shall on an average be not less than 750 gm/sgm. Class 2
:- Heavy coating of zinc shall on an average be not less than 600 gm/sgm. Class 3 :- Medium
coating of zinc shall on an average be not less than 450 gm/sgm. Class 4 :- Light coating of
zinc nominal 375 gm/sgm.
On any random sample selected from a delivery, in accordance with the I.S:277, the coating shall be
not less than 80% of the average specified for the class to which the sample belongs.
13.2.3. Purlin Spacing : Purlins of the specified material or M.S. rolled sections of requisite size shall
be fixed over the principal rafters. The purlin will be one at the ridge end other at the eaves the
spacing being not more than as given in Table-3 below :-
Table - 3 : Purlin Spacing
Purlin spacing
Sheet thickness in mm Roofing with Sheets only
(app. sheet gauge) Roofing with Mangalore Tiles
over sheets or any other
covering.
1.25 mm (18 gauge) 2.40 metre 1.80 m.
1.00 mm (20 gauge) 2.00 metre 1.50 m.
0.80 mm (22 gauge) 1.80 metre 1.40 m
0.63 mm (24 gauge) 1.60 metre 1.20 m.
The purlin should fall in the centre line of end laps. The ridge purlin should be placed in such a way
that the ridges can be fixed properly. Generally it shall be fixed 75 to 115 mm from apex of the roof.
The top surfaces of purlins shall be uniform & plane. The portion overhanging the wall support
should not be more than 1/4th of the spacing of the purlin. They shall be painted before fixing on
top. Embedded portions of wooden purlins shall be coaltarred with two coats.
13.2.4. Slope : The roof should be laid in a slope as provided in the drawing or as specified by the
Engineer. The normal pitch adopted shall usually be 1 vertical to 3 horizontal.
13.2.5. Laps:
(a) The end lap shall not be less than 15 cm and the side lap shall be two corrugation at each side.
The above minimum end lap of 15 cm shall apply to slopes of 1 vertical to 2 horizontal and
steeper slopes. For flatter slopes the minimum permissible end lap shall be 20 cm.
(b) The laps for the ridges, hips and valleys shall be a minimum of 20 cm. measured at right angles
to the line of the ridge, hip and valley respectively. These sheets shall be cut to suit the
dimensions or shapes of the roof, either along their length or their width or in a slant across
their lines of corrugations at hips and valleys. They shall be cut carefully with a straight edge
chisel to give a smooth and straight finish.
(c) Sheets shall not generally be fixed/ built into gables & parapets. They shall be bent up along
their side edges clone to the wall & junction shall be protected by suitable flashing or by a
projecting drip course, the later to cover the junction by at least 7.5 cm..
(d) Lapping in C.G.S. sheets shall be painted with a coat of approved steel primer and two coats of
painting with approved paint suitable for G.S. sheet, before the sheets are fixed in place.
13.2.6. Laying and Fixing of Galvanized Corrugated Steel sheets :
(a) The sheets shall be laid and fixed in the manner described below, unless otherwise shown in
the working drawings or directed by the Engineer-in-Charge.
(b) The sheets shall be laid on the purlins or other structural members as indicated, to a true plane,
with the lines of corrugation truly parallel or normal to the sides of the areas to be covered,
unless otherwise required as in special shaped roofs.
(c) The laying operation shall include all scaffolding work involved.
(d) Sheets shall be fixed to the purlins or other roof members such as hip or valley rafters etc. with
galvanized J or L hook bolts and nuts, 8 mm diameter, with bitumen and G.I. limpet washers
or with a limpet washer filled with white lead as directed by the Engineer-in-Charge. While J
hooks are used for fixing sheets on angle iron purlins, and L hooks are used for fixing the sheet
to R.S. joists, timber or precast concrete purlins. The length of the hook bolt shall be varied to
suit the particular requirements. The bolts shall be sufficiently long so that after fixing they
project above the top of the nuts by not less than 10 mm. The grip of J or L hook bolt on the
side of the purlin shall not be less than 25 mm. There shall be a minimum of three hook bolts
placed at the ridges of corrugations in each sheet on every purlin and their spacing shall not
exceed 30 cm. Coach screws shall not be used for fixing sheets to purlins.
(e) The galvanized coating on J or L hooks, and bolts shall be continuous and free from defects
such as blisters, flux stains, drops, excessive projections or other imperfections which would
impair service ability.
(f) The galvanized coating should conform to IS 4736-1986. The mass of coating per square
meter of the surface shall be as under:
Table 4 : Mass and Equivalent Thickness of Coating
Minimum Average Thickness Minimum Mass Individual Thickness
Mass ickness
(gIm2) (gm) (gIm2) (gm)
375 54 300 43
(g) Where slopes of roofs less than 21.5 degrees (1 vertical to 2.5 horizontal) sheets shall be joined
together at the side laps by galvanized iron bolts and nuts 25x6 mm size, each bolt provided
with a bitumen and a G.I. limpet washer or a G.I. limpet washer filled with white lead. As the
overlap at the sides extends to two corrugations, these bolts shall be placed zig-zag over the
two overlapping corrugations, so that the ends of the overlapping sheets shall be drawn tightly
to each other. The spacing of these seam bolts shall not exceed 60 cm along each of the staggered
rows. Holes for all bolts shall be drilled and not punched in the ridges of the corrugations from
the underside, while the sheets are on the ground.
(h) Laying of the sheets shall commence from the lower end (bottom) of roof. Longer length sheets
shall be fixed first and then shorter length sheets fixed towards the ridge. Minimum 300 mm
length of sheet should project beyond the edges of purlins. For alignment of sheets, one piece of
timber batten shall be fixed, projecting up to the depth of purlin, on the first and last structural
member (truss or rafter), and with both these batten pieces a thread shall be tied to check
straightness, etc., and then the sheets shall be fixed. First the bottom layer
of sheets shall be laid temporarily by 50 mm long nails. After laying all the sheets upto the
ridge, permanent fixing shall be done by means of J or L hook bolts.
(i) For fixing of sheets the cover shall not be less than 85 mm. The sheets shall be placed 'alternate',
that is, one sheet (the lower) being fixed with edges turning away from the bearer or purlin to
which the sheeting is fixed and the cover sheet on side being fixed with edges turning in towards
the bearer or purlin.
13.2.6.1. Holes :- Holes for receiving and fixing accessories shall be drilled (not punched from below
upwards, so that the arise shall be at the top. Care should be taken that the holes are on the ridges or
crown of the corrugations when the sheets are lald.The holes shall be made suiting the position of
purlins. For this it is necessary that the holes are drilled after the sheets are set in position. The holes
shall be one at each side lap and free edges, one in the centre of the width on either nearest ridge.For
jointing the sheet at the side laps the holes should not be more than 30 cm apart divided equally
according to the spacing of purlins. The sheet should also be joined at the ridge and eave ends and
the holes should be at 5 cm distance from the edges.
13.2.6.3. Fastenings :- At the ends the sheets shall be jointed with G.I. screws 5 cm. long (when
wooden Purlins are used) or hook bolt and nuts of 8 mm dia. or more, of proper length and lead
washer, unless otherwise specified. At the side laps the sheet shall be fastened with 20 mm. 6.3 mm.
mushroom headed bolts, nuts and lead washers. The bolts and screws etc. should be set in white
lead. When G.I. washers are used instead of lead washers a felt washer beneath them, shall be
provided.
J-hooks are used for fixing sheets on angle iron purlins & L-hooks are used for fixing to R.S. Joist
etc. The grip of J or L hooks bolt on the side of the purlin shall not be less than 25 mm. There shall
be a minimum of three hook bolts placed at the ridges of , corrugations in each sheet on every purlin
& their spacing shall not exceed 30 mm.
13.2.6.4. Ridges, hips and valleys :- The ridges and hips are to be of 0.80 mm thickness, plain
galvanized steel sheeting with 20 cm. lap on each side and securely fastened to the purlins ( The
length of the bolts or screws should be suitably increased) so as to prevent the rain from driving
under it. Valleys shall be 60 cm. wide and fixed as above. The ridges, hips and valleys shall be paid
for separately. The hips and ridges shall fit in squarely on the sheet. At least one hook should pass
through the end laps.
13.2.6.5. Wind ties :- In the windy or exposed positions it is necessary to fasten down the sheets at
the eaves and gables by continuous length of either wooden batten 5 cm x 2.5 cm or steel flat 4 0
mm x 6 mm. which shall be firmly fastened down to the purlins with the same hook bolts which
secure the sheets to the purlins. The ties shall be paid for separately unless described in the item of
roofing.
13.2.7. Mode of Measurement :
(i) The roofing shall be measured as the surface area along the incline in square metre. It shall be
measured flat and not along the girths of corrugation and shall be measured without any
allowance for laps and embedment into the wall excluding the laps for ridges, hips and valleys.
Openings up to 0.4 sqm. shall not be deducted and no cutting for forming such openings shall
be measured. For any opening exceeding 0.4 sqm in area, deduction in measurements for the
full opening shall be made and in such cases the labour involved in making these openings shall
be paid for separately. Cutting across corrugation shall be measured on the flat and not girthed.
No additions shall be made for laps cut through.
(ii) Portions of roof sheets embedded in walls shall not be measured.
(iii) Roof with curved sheets shall be measured and paid for separately. Measurements shall be taken
on the flat and not girthed. Sheeting bent to a curvature shall be measured separately.
(iv) Vertical sheeting and sheeting to a pitch exceeding 60° shall be measured separately.
(v) Ridges, hips, valleys, wind ties shall be paid separately in linear units.
13.2.8 Rate : The rate shall include the cost of all the materials and labour involved in all the
operations described above including a coat of approved steel primer and two coats of approved steel
paint on overlapping of C.G.S. sheets. This includes the cost of roof sheets, galvanized iron J or L
hooks, bolts and nuts, galvanized iron seam bolts and nuts, bituminous and galvanized iron limpet
washers etc.
13.3 Ridges and Hips of Plain Galvanised Steel Sheets:
13.3.1 Ridges and Hips: Ridges and hips of C.G.S. roof shall be covered with ridge and hip sections
of plain G.S. sheet with a minimum lap of 20 cm on either side over the C.G.S. sheets. The end laps
of the ridges and hips and between ridges and hips shall also be not less than 20 cm. The ridges and
hips shall be of 60 cm overall width plain G.S. sheet, 0.6 mm or 0.8 mm thick as given in the
description of the item and shall be properly bent in shape.
13.3.2 Fixing:
i) Ridges shall be fixed to the purlins below with the same 8 mm dia. G.I. hook bolts and nuts
and bitumen and G.I. limpet washers which fix the sheets to the purlins.
ii) Similarly, hips shall be fixed to the roof members below such as purlins, hip and valley rafters
with the same 8 mm dia. G.I. hook bolts and nuts and bitumen and G.I. limpet washers which fix
the sheets to those roof members. Atleast one of the fixing bolts shall pass through the end laps
of ridges and hips, on either side. If this is not possible extra hook bolts shall be provided.
iii) The end laps of ridges and hips shall be joined together with C.G.S sheet by galvanized iron
seam bolts 25x6 mm size each with a bitumen and G.I. washer or white lead as directed by the
Engineer-in-Charge. There shall be ateast two such bolts in each end lap.
iv) Surface of C.G.I. sheets of ridge and hip sections and the roofing sheets which overlap each
other shall be painted with a coat of approved primer and two coats of approved paint suitable
for painting G.S. Sheets before they are fixed in place.
13.3.3 Finish: The edges of the ridges and hips shall be straight from end to end and their surfaces
should be plane and parallel to the general plane of the roof. The ridges and hips shall fit in squarely
on the sheets.
13.3.4 Measurement : The measurements shall be taken for the finished work in length along the
centre line of ridge or hip, as the case may be, correct to a cm. The laps in ridges and hips and
between ridges and hips shall not be measured.
13.3.5 Rate: The rate shall include the cost of all labour and materials specified above, including
painting, cost of seam bolts and any extra G.I. hook bolts, nuts and washers, required.
13.4 Valley and Flashing of Plain Galvanised Steel Sheets:
13.4.1 Valley and Flashing: Valley shall be 90 cm wide over all plain G.S. sheet 1.6 mm thick or
other size as specified in the item bent to shape and fixed. They shall lap with the C.G.S. sheets not
less than 25 cm width on otherside. The end laps of valley shall also be not less than 25 cm. Valley
sheets shall be laid over 25 mm thick wooden boarding if so required. Flashing
shall be of plain G.S. sheet of 40 cm over all width 1.25 mm thick or 1.00 mm thick as specified in
the item bend to shape and fixed. They shall lap not less than 15 cm over the roofing sheets. The end
laps between flashing pieces shall not be less than 25 cm.
13.4.2 Laying and Fixing :
Flashing and valley sheets shall be fixed to the roof members below, such as purlins and valley
rafters with the same 8 mm dia. G.I. hook bolts and nuts and bitumen and G.I. limpet washers which
fix the sheets to those roof members.
Atleast one of the fixing bolts shall pass through the end laps of the valley pieces on otherside. If
this is not possible extra hook bolts shall be provided. The free end of flashing shall be fixed atleast
5 cm inside masonry with the mortar of mix 1:3 (1 cement : 3 coarses and).
13.4.3 Surface of G.S. sheets under overlaps shall be painted with a coat of approved primer and two
coats of approved paint suitable for painting G.S. sheets.
13.4.4 Finish: The edges of valley and flashing should be straight from end to end. The surfaces
should be true and without bulges and depressions.
13.4.5 Measurements: The length of the valleys and flashing shall be measured for the finished
work correct to a cm. The laps along the length of the valley or flashing pieces, including the portion
embedded in masonry, shall not be measured.
13.4.6 Rates : The rate for valleys, shall be for all the labour and materials specified above, including
painting, cost of seam bolts and the cost of requisite G.I. hook bolts, nuts and washers required over
and above those needed for connecting the roof sheets to the roof members. The rate for valleys shall
exclude the cost of boarding under neath which shall be paid for separately. The rate for flashing
shall be for all the labour and materials specified above, and shall include the cost of painting and
mortar for fixing in wall.
13.5 Gutters Made of Plain Galvanised Steel Sheets:

13.5.1 Gutters: Gutter shall be fabricated from plain G.S. Sheets of thickness as specified in the item.
Eaves gutters shall be of the shape and section specified in the description of the item. The overall
width of the sheet referred to there in shall mean the peripheral width of the gutter including the
rounded edges. The longitudinal edges shall be turned back to the extent of 12 mm and beaten to
form a rounded edge. The ends of the sheets at junctions of pieces shall be hooked in to each other
and beaten flush to avoid leakage.
13.5.2 Slope: Gutter shall be laid with a minimum slope of 1 in 120.
13.5.3 - Laying and Fixing:
13.5.3.1- Gutter shall be supported on and fixed to M.S. flat iron brackets bent to shape and fixed to
the requisite slope. The maximum spacing of brackets shall be 1.20 metre.
13.5.3.2 Where these brackets are to be fixed to the sides of rafters, they shall be of 40x3 mm section
bend to shape and fixed rigidly to the sides of rafters with 3 Nos. 10 mm dia. bolts, nuts and washers.
The brackets shall overlap the rafter not less than 30 cm and the connecting bolts shall beat 12 cm
centre.
13.5.3.3 Where the brackets are to be fixed to the purlins, the brackets shall consist of 50x3 mm
M.S. flat iron bent to shape with one end turned at right angle and fixed to the purlin face with 2
Nos. of 10 mm dia. bolts nuts and washers. The bracket will be stiffened by provision of 50x3
mm. M.S. flat whose over hung portion bent to right angle shape with its longer leg connected to the
bracket with 2 Nos. 6 mm dia. M.S. bolts, nuts and washers and its shorter leg fixed to face of purlin
with 1 No. 10 nun dia., bolt, nut and washer. The overhang of the vertical portion of the bracket from
the face of the purlin shall not exceed 22.5 cm with this arrangement. The spacing of the brackets
shall not exceed 1.20 metre.
13.5.3.4 The gutter shall be fixed to the brackets with 2 Nos. G.I. bolts and nuts 6 mm dia., each
fitted with a pair of G.I. and bitumen washers. The connecting bolts shall be above the water line of
the gutters.
13.5.3.5 For connection to down take pipes, a proper drop end or funnel shaped connecting piece
shall be made out of G.S. sheet of the same thickness as the gutter and riveted to the gutter, the other
end tailing into the socket of the rain-water pipe. Wherever necessary stop ends, angles etc., should
be provided.
13.5.4 Finish: The gutters when fixed shall be true to line and slope and shall be leak proof.
13.5.5 Measurements: Measurements shall be taken for the finished work along the centre line of
the top width of the gutter connection to a cm. The hooked lap portion in the junctions and gutter
lengths shall not be measured. The number of brackets which are fixed to purlins with stiffener flats
should be measured.
13.5.6 Rate: The rate shall include the cost of all labour and materials specified above, including all
specials such as angles, junctions, drop ends or funnel shaped connecting pieces, stop ends etc., flat
iron brackets and bolts and nuts required for fixing the latter to the roof members. Brackets of 50x3
mm flats fixed to purlins with stiffener flats will be paid extra.
13.6 Asbestos Cement Sheet Roofing:
13.6.1. Scope:
13.6.1.1. This specification lays down requirements regarding materials, handling, storage, laying
fixing and mode of measurement of Asbestos Cement Sheet Roofing.
13.6.2. Materials :The Asbestos cement sheets to be used shall be of the type (Big six or Trafford) as
specified by the Engineer or as shown in the drawings. The thickness shall be as specified in the
schedule of quantities and shall comply with the requirements of I.S. No. 459-1992. Fixing
accessories shall be as per 13.2.2.
The sheets shall be free from holes and cracks. The surface of the sheets shall be of uniform texture
and shall have neatly trimmed edges. Sheets and accessories - found to be cracked after fixing shall
be replaced by new ones, by the contractor without any extra charges.
13.6.3.Handling and Storage: The asbestos cement sheets shall be handled and stored in the manner
so as not to injure the sheets in any way. All damages caused due to careless handling or storing
shall be borne by the contractor. The sheets shall be stacked on firm and level ground laid on wooden
battens as per the methods specified by the manufacturers and protected from damages. When they
are stacked for good length of time, they shall be stored under cover.
13.6.4 Laps:
(a) The pitch of roof be preferably not less than 18 Degree. If steeper pitches are used, the end
lap lengths between adjacent sheets shall be increased.
(b) Purlins shall be so spaced to see that the sheets do not deflect; generally for 6 mm thick sheet,
the purlins should be spaced at 1.4 m for roof covering and 1.7 m for side cladding.
(c) Ridge purlins shall be fixed 75 mm to 115 mm from the apex of the roof, i.e. from the bolt
point.
(d) Additional trimmers shall be used between purlins at points where considerable traffic is likely
to occur, such as, adjoining valleys or gutters, etc. For smaller sheets, it is desirable to arrange
for closer purlin spacing at eaves rather than at edges.
(e) Hip and valley runners should be fixed flush with top face of the purlin and span between
them. The runners should be parallel to the edges of the sheeting to permit fixing of
accessories.
(f) The side lap should be half corrugation. For normal pitches, equal to and more than 18 degree,
the end lap shall not be less than 150 mm. For low roof pitches, less than 18 degree,
manufacturers shall be consulted for side laps; also for normal pitches in exposed conditions side
laps should be as per manufacturer's instructions.The side lap shall be away from the prevailing
wind direction. The free overhang at eaves, measured from lower edge to centre of bolt holes,
shall be not more than 300 mm.Wherever four corners of sheets overlap, two of them shall be
mitred to secure a perfect fit. To avoid undue width of flashing, the sheets should finish at
abutments with an upturned edge.
13.6.5. Spacing of Purlins: The following maximum spacing of Purlins for corrugated and semi-
corrugated sheets are recommended.
Table 5
Thickness of sheets Distance between purlins, centre to centre
mm '/4") 140 cm.
Nom. . 6 (Ye)
Nom. 7 mm (9/32 in.) 170 cm.
side the spacing recommended above should be increased by 30 cm. Similarly when a course of
short sheet necessitating closer purlin spacing is required to make up a roof slope, it shall be
preferable to arrange closer purlin spacing at the eaves rather than at the ridge for providing
additional support where it is most required.Additional trimmers or bridging shall be used between
purlins at all points where considerable roof traffic is likely to occur e.g. adjoining valley or box
gutters, below glazing and around chimneys, ventilators or other uptakes. This shall be done both on
new roof and while repairing existing roofs.
13.6.6 Laying and Fixing of A.C. Sheet Roofing:

13.6.6.1. Holes and Accessories:
(a) Holes in sheets shall be drilled and not punched and should be 2 mm larger than the diameter
of the hook bolt; they shall be at the crown of corrugation and not at the valleys.
(b) Holes for fixing sheeting shall be drilled in the centre of the end lap of sheets to suit, that is the
centre line of the purlins if these are of timber when square head coach screws are used; or as
close to the back of purlins, if J or L bolts are used with steel angles, precast concrete or timber
purlins. No hole shall be drilled nearer than 40 mm to any edge of sheet or an accessory.
(c) Galvanized iron J-hook bolts or cranked hook bolts and nuts bearing on galvanized iron
washers and bitumen washers shall be used for fixing sheets on angle iron purlins.
(d) Galvanized iron L-hook bolts and nuts bearing on galvanized iron washers and bitumen
washers shall be used for fixing sheets on RS joist, precast concrete or timber purlins.
(e) Galvanized iron coach screws bearing on galvanized iron washers and bitumen washers shall
be used for fixing sheets on timber purlins.
(f) Galvanized iron roof bolts and nuts bearing on galvanized iron flat washers and bitumen
washers shall be used for stitching on sheets, fixtures like ridge capping, corner pieces,
ventilators, north light curves, etc.
(g) Where sheets are laid on tubular purlins the fixing bolt should be designed to encompass at
least half the tube periphery and precautions should be taken to prevent its rotation.
(h) Direct fixing of sheets to drilled metal framework or by stud welding is undesirable as it
tends to restrain movement of sheets.
(i) Fixing bolts and screws shall be 8 mm or more in diameter and the nuts of the hook bolts shall
bear on galvanized iron washers which in turn shall be embedded on bituminous felt washers.
The screws and nuts shall be sufficiently tightened only to seat the bitumen washer over the
corrugations, so that natural movement in the substructure of the roof may not damage the
sheeting.
G) The length of J-bolt or crank bolt shall be 75mm longer than the depth of the purlin for single
sheet and 90 mm longer for double sheet or where ridges or other accessories have to be fixed.
k) The minimum length of square head coach screws for timber purlins shall be 110mm. The
number and length of bolts and washers shall be as given below :-
Table 6
Situation No. of Bolts, Washers Length of Bolts
1. At horizontal (end) laps of sheets; at Twice the number of Depth of purlin
eaves when filler pieces are used; at sheets in one horizontal plus 90 mm
ridge when sheet and ridge pieces are course
secured by the same bolt.
2. At eaves when filler not used; at Twice the number of Depth of purlin
ridge pieces are when sheet and sheets in one plus 75 mm
ridge pieces are not secured by the horizontal course
same bolt.
3. At intermediate purlins where Twice the number of Depth of purlin
horizontal laps do not occur. sheets in one plus 75 mm.
horizontal course.
1) The washers shall be 2 5 = in diameter and 1.6 mm thick for flat iron washers; 35 mm in
diameters and 1.5 mm thick for bitumen washers.
m) Ridge capping shall be secured to the ridge purlins by the same bolts which secure sheeting.
13.6.6.2 Laying of Sheets:
a) Check purlin spacing and length of sheets for securing the appropriate laps, overhang, etc.
b) Sheets shall be laid with smooth side upwards and with side and end laps as given in Fig.3.
The courses of sheets shall be so laid that the corrugations run in continuous straight lines. If
the building is in exposed position and is subject to driving rain and wind, it is advisable to
commence laying of sheets from the end opposite to the direction of wind.
(c) The sheets shall be laid starting either from eaves from left to right or right to left depending on
direction of prevailing wind, to avoid it. See Fig. 3 for laying sheets from left to right, for
details.The first sheet is laid uncut.
The remaining sheets in the bottom row shall have top left hand corners cut or mitred.
The sheets in the second and other intermediate rows shall have bottom right hand
corner and top left hand corner cut; the last sheet shall have only the top left hand corner
cut.
The last or top row of sheets shall have bottom right hand corner cut with the exception
of the last sheet which shall be laid uncut.
The whole sequence is reversed if laid from right to left.
The mitre is cut from a point 15 cm up the vertical side of the sheet to 4.5 cm along the
horizontal edge; this is necessary when four sheets meet at a lap.
d) Nuts and screws shall be tightened lightly at first and then fully tightened when a dozen or
more sheets are laid. One bolt or screw shall be used on each side of the lap.
13.6.6.3 Asbestos Accessories:

a) Moulded asbestos accessories should be selected as far as possible from the range of standard
patterns. Special fittings, if required shall be designed to conform closely to the sheet profile.
Roofing accessories should generally be secured to the roof or wall cladding by the same bolts
which secure the sheets.
b) Ridge capping should be secured to the purlins, as far as possible, by the same bolts which
secure the sheets, where this is not possible each wing of the ridge capping should be
adequately secured to the sheets by roofing bolts.
c)
1) Close fitting adjustable ridge capping shall be designed to fit the corrugations of sheets laid
with side lap of half corrugation and shall be fixed as in Fig. 4 and Fig. 5. Correct fitting
of ridge capping will be automatic, if a template is used when fixing roof sheets.
2. The work shall be started from left hand verge, placing first small roll wing (inner) and
positioning it in such a way that the first valley on the right hand side of the ridge fits
into the valley at side lap of roof sheeting. In case of large roll wing, it shall be so
positioned that the first valley of left hand side of the ridge wing fits into valley of side
lap of roof sheeting.
Typical One-
Piece Plain Angular Ridge
Fig. 21 Details Showing Fixing of Serrated Adjustable Ridge (Clause 13.6.6.3)
3. Serrated adjustable ridge capping's, supplied in pairs, are as shown in Fig. 21. The method of laying and
fixing of ridges shall be as shown in Fig. 21.
4. Fixing with a typical north light two piece adjustable ridge shall be as shown in Fig. 20.
c) Ridge finial in one piece should be secured to the ridge bolt through the crown. Two piece ridge finial should
be secured to the ridge capping and roof sheeting by one bolt through each wing of the fitting, in addition
they should be secured to the ridge capping by one roofing bolt at the crown. (see Fig. 21)
d) Hip capping or hip tiles - The roofing sheet at hips should be cut to the required mitred and be
close butted. The hip joint may be covered with two piece plain wind hip tiles (see Fig. 10),
one piece socketed plain wing angular hip tiles or heavy half round hip tiles. Alternatively, an
apron type capping may be used over the plain wing ridge should be secured through the roof
sheets to the hip runners, by one bolt on each side immediately above the socket. On timber
roof, the hip tile should be secured to the rafter by means of coach screws.
e) Eaves may be closed by piece as in Fig. 11, above glazing and at the bottom of vertical sheeting.
Alternatively, the sheeting at eaves may be bedded in mortar if the walls of the building are of
brick, block, or similar construction.
f) For top edges and abutments, apron flashings should generally be used (see Fig. 12) and
suitably fixed.
(g) Special moulded pieces may be used for ventilators and lights and suitably fixed. If roof lights
are required, purpose made roof light may be used either as fixed skylights or as adjustable
skylights. Alternatively, corrugated glass may be used.
h) Other asbestos cement fittings may be used as corner rolls, barge boards, etc. and secured to the
structure or sheeting.
13.6.6.4 Gutters and rain water pipes shall be fixed as per IS 2527: 1984
13.6.6.5 Expansion Joints: When corrugated sheets are to be used on large roofs in which there is
likely to be some movements of the structure due to variations in climatic conditions, it is important
that the expansion joints shall be inserted in the sheets to permit any such movement being taken up
at intervals as directed by the Engineer-in-charge. The same shall be paid for separately.
13.6.7 Asbestos Cement Sheets - Semi - Corrugated : All the provisions of 13.2.6 for corrugated
sheets and its sub-clauses shall apply for fixing semi-corrugated sheets except as modified below:
(a) Expansion joints shall be provided as per specifications, for large roofs where there is likely
to be some movements of the structure due to variation in climate conditions.
(b) The number and length of bolts, bituminous felt washers and galvanized iron washers shall
be as below:
Table - 7
S.No. Situation No. of Bolts and Washers Length of Bolts
1. At horizontal aps of sheets, SHORT BOLTS Depth of purlin + 75 mm
at caves with filler pieces; The number of sheets in
at ridges when sheets and one horizontal course+two
ridge pieces are screwed by
the same bolt
LONG BOLTS Depth of purlin + 90mm
The number of sheets in
one course less one
S.No. Situation No. of Bolts and Washers Length of Bolts
2. At eaves when pieces are Twice the number of sheets Depth of purlin + 75mm
not used; at ridge when in one horizontal course+
sheets and the ridge pieces one
are not screwed by the
same bolt
3. At intermediate purlins The number of sheets in Depth of purlin+75mm
where horizontal laps do not one horizontal course plus
occur. one.
c) The length of the mitre, when done, shall be 15mm and the width shall be equal to the width of
side lap.
13.6.8. Mode of Measurement:
(a) The corrugated and semi-corrugated sheeting shall be measured in square metres without any
allowance for laps. Vertical sheeting and sheeting laid to pitch exceeding 600 shall be
(b) Curved sheeting shall be measured separately.
(c) The ridges and hips shall be given in running metre and measured separately.
(d) Portions of roof covered by ridges and hips coverings shall be included in the measurements
of roof.
(e) Portions of roof covering embedded in wall shall not be measured.
(f) Opening up to 0.4 sqm. shall not be deducted & no cutting for forming such opening shall be
measured.
13.7 Poly Propylene Reinforced Cement Corrugated Sheet Roofing :
The sheets shall be of the approved quality and shall conform to IS 14871-2000. The sheets shall be
free from cracks, chipped edges or corners and other damages.
13.7.1 (a) General Composition of Sheets: The product shall be composed essentially of an in
organic hydraulic binder (see Note) oracalcium silicate binder formed by the chemical reaction of a
silicate binder formed by the chemical reaction of a siliceous (includes ground silica, pulverized fuel
ash and amorphous silica) and calcareous material reinforced by organic fibres and/or inorganic
synthetic fibres.
Pozzolanic materials process aids, fillers and pigments which are compatible with the fibre
reinforced cement may be added. The inorganic hydraulic binder shall be either 33 grade ordinary
Portland cement conforming to IS 269 or 43 grade ordinary Portland cement conforming to IS 8112
or 53 grade ordinary Portland cement conforming to IS 12269 or Portland pozzolana (flyash based)
cement conforming to IS 1489. (Part 1) or Portland pozzolana cement (Calcined clay based)
conforming to IS 1489 (Part2) or rapid hardening cement conforming to IS 8041 or Portland slag
cement conforming to IS 455. Fly ash used shall be conforming to IS 3812.
Note: Incase of Portland pozzolana cement and Portland slag cement, addition of pozzolanic
materials and slag shall not be permitted.
13.7.1 (b) Classification :- Sheets may be classified according to thickness as under:
Type A- The thickness of the sheets shall be approximately constant through out the width of
profile.
Type B- The thickness of the sheets shall vary regularly between the valley and the crown for
corrugated sheets or between the lower part and the upper part of ribs for a symmetrical section
sheets, in the same cross-section. The sheets shall be categorized based on height of corrugations,
`h' and minimum thickness è' as under:
Table 8 : Category and Class (Minimum Breaking Load N/m)
Category Min. Class
Thickness
'e'(m)
1 2 3 4 5 6 7 8 9 10
A (15 mm <h 600 800 1000 1400 - - - - - -
< 55mm)
B (25mm<h 4 1000 1400 2000 2500 3300 - - -
<55 mm)
C (40 = < h 4.5 - - - 1400 2000 2500 3300 4250 - -
<80 mm)
D (60 mm <h 5.5 - - - - - - 3300 4250 5600 7400
<150 mm)
13.7.1 .1 - Tolerances on dimensions: Following tolerances shall apply to nominal dimensions given by the manufacturer:
a) Tolerance on pitch, a : n
a<75mm + 4.0, -2.0 mm
75=<a< 180= + 6.0, -2.0 mm
1 8 0 = < a <260 mm + 8.0, -3.0 mm
260 = < a + 9.0, -3.0 mm
Tolerance for pitch of corrugation relates measurement over extreme corrugation.
b) Tolerance on height of corrugation, h : 1 5 =
<h<45=
4 5 = <h<150=
c) Tolerances on length
d) Tolerances on overall Width and effective width, we
+ 10,-5mm
e) Tolerance on nominal thickness, e: Out of squareness
± 10 percent but not more than ±0.6
mm of the nominal thickness.
of sheets: less than 10 mm.
Tolerance on height of edges: The producer shall specify this tolerance in their literature
when it is necessary to ensure the weather tightness of the roof, only for sheets having an
ascending edge one side and a descending edge on the other side.
13.7.1.2 - Mechanical Characteristics:
N o t e - For non-roofing and cladding applications, alternative mechanical characteristics may be
agreed between the manufacturer and the purchaser.
13.7.1.3 - Sampling and Testing etc.: As per IS 14871-2000
13.7.2 Slope : The roof shall not be pitched at flatter slope than 1 vertical to 5 horizontal. The
normal pitch adopted shall usually be 1 vertical to 3 horizontal.
13.7.3 Laying :
13.7.3.1 The sheets shall be laid on the purlins and other roof members as indicated in the working
drawings or as instructed by the Engineer-in-Charge.
13.7.3.2 The maximum spacing of purlins under the sheets shall be 1.40 metre in the case of 5.5 mm
thick sheets and these shall in no case be exceeded. Ridge purlins shall be fixed at 75 mm to 115
mm from the apex of the roof.
13.7.3.3 The top bearing surfaces of all purlins and of other roof members shall be in one plane so
that the sheets when being fixed shall not require to be forced down to rest on the purlins. The
finished roof shall present a uniform slope and the line of corrugations shall be straight and true. The
sheets shall be laid with the smooth side upwards.
13.7.3.4 The sheets shall be laid with a side lap of half a corrugation and an end lap of 15 cm
minimum in the case of roofs with a pitch flatter than 1 vertical to 2.5 horizontal (approx. 22 degree)
or in the case of very exposed situations, the minimum permissible end lap shall be 20 cm. Side laps
should be laid on the side facing away from the prevailing monsoon winds.
13.7.3.5 The free overhang of the sheets at the eaves shall not exceed 30 cm. Corrugated sheets shall
be laid from left to right starting at the eaves. The first sheet shall be laid uncut but the remaining
sheets in the bottom row shall have the top left hand corners cut or mitred. The sheets in the second
and other intermediate rows except the first and the last sheets, shall have both the top left hand
corner and bottom right hand corner cut. The last or top row sheets shall all have the bottom right
hand corner cut with the exception of the last sheet which shall be laid uncut. If for any reason such
as on considerations of the direction of prevailing winds, laying is to be started from the bottom right
hand corner, then the whole procedure should be reversed.
13.7.3.6 The `Mitred' described above is necessary to provide a snug fit where four sheets meet at a
lap. It is cut from a point 15 cm (or what ever the length of the end lap may be) up the vertical side
of the sheet to apoint 5 cm along the horizontal edge. This cutting may be done with an ordinary
wood saw at site.
Fig. 24 : Arrangement for Measurement of Length and Width of Sheet
13.7.4 Fixing:
13.7.4.1 Sheets shall be secured to the purlins and other roof members by means of 8 mm diameter
polymer coated iron J or L hook bolts and nuts. While, J hooks are used for fixing to angle iron
purlins, L hooks are used for fixing to R.S. joists, timber or pre cast concrete purlins.
The grip of the J or L hook bolt on the side of the purlin shall not be less than 25 mm. Each iron J or
L hook bolt shall have a bitumen washer and a galvanized iron washer placed over the sheet before
the nut is screwed down from above. On each purlin there shall be one hook bolt on the crown
adjacent to the side lap on either side. Bitumen washer shall be of approved manufacture.
Galvanizing of washers shall be as provided in para 13.2.6.3. Polymer coating of hooks, bolts and
nuts shall be as per IS code 14871.
13.7.4.2 The G.I. flat washer shall be 25 mm in diameter, 1.6 mm thick and the bitumen washer shall
be 35 mm in diameter and 1.5 mm thick. The length of J bolt or crank bolt shall be as specified in
Table 9 below.
Table-9
S.No. Situation No. of Bolts & Washers Length of Bolts
1. Athorizontal (end) laps of Sheets. Twice the No. of sheets in Depth of purlin
Ateaves when filler pieces areused. one horizontal course. plus 90 mm.
At ridge when sheets and ridge
pieces are secured by the same bolt.
2. At eaves when filler pieces are not Twice the No. of sheets in Depth of purlin
used. At ridge when corrugated the horizontal course. plus 75 mm.
sheets and ridge pieces are not
secured by the same bolt.
3. At intermediate purlins where Twice the No. of sheets in Depth of purlin
horizontal laps do not occur. the horizontal course. plus 75 mm.
13.7.4.3 Each nut shall be screwed lightly at first. After a dozen or more sheets are laid, d,the nuts
shall be tightened to ensure a leak proof joint.
13.7.4.4. Holes for hook bolts etc. shall be drilled and not punched, always through the crown of the
corrugation and not in valleys, in locations to suit the purlins while the sheets are on the roof in their
correct position. The diameter of holes shall be 2 mm more than the diameter of the fixing bolts. No
hole shall be nearer than 40 mm to any edge of a sheet or any accessory.
13.7.4.5 Roof ladders or planks shall always be used when laying and fixing the sheets, to avoid
damage to the sheets, and to provide security to the workmen.
13.7.5 Wind Ties:
Wind ties may be provided where the situation justify their provision. These shall be of 40 x 6 mm
flat iron section or of other size as specified. These shall be fixed at the eave ends of the sheets.The
fixing shall be done with the same hook bolts which secure the sheets to the purlins. Wind ties shall
be paid for separately unless described as included in the items of the roof work.
13.7.6 Finish: The completed roof shall present a neat and uniform appearance and be leak proof.
13.7.7.1 Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metre correct to two places of decimal.
13.7.7.2 The superficial area of roof coverings shall be measured on the flat with out allowance for
laps and corrugations. Portions of roof covering overlapping the ridge or hips etc. shall be included
in the measurements of the roof.
13.7.7.3 Roof with curved sheets shall be measured and paid for separately. Measurements shall be
taken on the flat and not girthed. The breadth of the roof shall be measured along the rest of the
curved sheets.
13.7.7.4 No deductions in measurements shall be made for opening up to 0.4 sqm and nothing extra
shall be allowed for forming such opening. For any opening exceeding 0.4 sqm in area, deduction in
measurements for the full opening shall be made and in such cases the labour involved in making these
openings shall be paid for separately. Cutting across corrugation shall be measured on the flat and
not girthed.
13.7.8 Rate: The rate shall include the cost of all the materials and labour involved in all the
operations described above except otherwise stated. This includes the cost of roof sheets, polymer
coated or L hook, bolts and nuts, bituminous and galvanized iron washers.
13.8 High Impact Poly Propylene Reinforced Cement Semi-Corrugated Sheet Roofing (IS :
14871 - 2000) :
13.8.1 These shall be of the specified thickness and of approved quality and shall conform to IS
14871 they shall be free from cracks, chipped edge corners or other damages.
13.8.2 Laying: The specifications for laying shall be the same as described in 13.7.3 except that (a)
the sheets shall be laid with the end stamped `Top' on the smooth side pointing towards the ridge,
(b) the sheets shall invariably be laid from right to left starting at the eaves with the procedure form it
ring etc. described under 13.7.3.5 and 13.7.3.6 reversed, (c) the side laps provided will be of one
corrugation, the left hand small corrugation of each sheet being covered by the right hand large
corrugation of the next sheet and (d) asbestos cement expansion joints shall be inserted every 45 metre
or so in the length of the roof. Specially manufactured expansion joint pieces shall be used for the
purpose. The end lap of expansion joints shall not be less than 150 mm. If the expansion joints may
be between the purlins, these should be stitched with seam bolts.
13.8.3 Fixing : The specifications shall be same as described in 13.7.4 except that along each line
of purlin there shall be a hook bolt in every vertical side lap corrugation and at the two verges and
there shall be an additional hook-bolt through one of the two intermediate corrugations on each sheet.
When sheets are supported over intermediate purlins as in the case of length over 1.40 metre for 5.5
mm thick sheets, fixing accessories are required on the intermediate purlins, through each side lap
and the verges only. The number and length of bolts and number of bituminous felt and galvanised
iron washers are given in Table 10.
Table-10
S.No. Situation No. of Bolts & Washers Length of Bolts

1. At horizontal (end) laps of Sheets. Short bolts: The number
At eaves when filler pieces are Depth of purlin
of sheets in one horizontal plus 75 mm
used.At ridge when sheets and ridge course plus two Long bolts:
pieces are secured by the same bolt. The number of sheets in Depth of purlin
one course less one. plus 90 mm.
2. At eaves when filler pieces are Twice the No. of sheets in Depth of purlin
not used. At ridge when sheets and one horizontal course plus 75 mm.
ridge pieces are not secured by the plus one.
same bolt.
3. At intermediate purlin when The No. of sheets in Depth of purlin
horizontal laps do not occur. one horizontal course plus plus 75 mm.
one.
13.8.4 Wind Ties & Finish : The specifications shall be as described in 13.7.5 and 13.7.6.
13.8.5 Measurements : It shall be as described in 13.7.7 in addition, the end lap of the sheets under
asbestos cement expansion joints where provided shall also be included in measurements. Gap
between the sheets under expansion joint shall not be measured. The expansion joint sheets shall be
measured for the finished work correct to one cm.
13.8.6 Rate : The rate shall include the cost of all the materials and labour involved in all the
operations described above except otherwise stated. This includes the cost of roof sheets, polymer
coated J or L hook bolts and nuts, bituminous and galvanised iron washers.
13.9 Ridges and Hips of Non-Asbestos High Impact Polypropylene Reinforced Cement (IS
14871-2000).
13.9.0 Ridges and hips shall be of the same manufacture as the corrugated or semi-corrugated sheets
used for roof, unless specifically permitted in writing by the Engineer-in-Charge. The sections shall
be free from cracks, chipped edges or corners or other damages.
Ridges shall be of the type specified in the item, such as: a)
Demarca
1. One piece plain angular.
2. Serrated or plain wing adjustable.
3. Close fitting adjustable.
4. North light adjus table and appropriate for the corrugated or semi-corrugated roof which is to
be covered `Plain Wing Angular' type ridges can be used only if the slope of the roof is exactly
30 degree. Hips shall be of ùnder-rated adjustable for `hips' sections.
5. Un-serrated adjustable.
13.9.1 Laying: The ridge sections shall be laid as per manufacturer's instructions with the rolls of
the two wings in the case of adjustable ridges fitting closely and with the serrations of serrated ridges
registering correctly with the sheets underneath. The stagger lapping or two wings of an adjustable
ridge section and the laps between adjacent pieces on the same wing of the ridges shall be as per
manufacturer's instructions. The end portions of the wings of the adjustable ridges which project
beyond the verges of the roof shall be cut and trimmed off neatly. Asbestos cement expansion joint
ridge pieces shall be provided every 45 metre (approx.) of ridge where the latter is of the semi-
corrugated serrated adjustable type. In laying hip pieces, serrations to suit the corrugations in the
sheets below should be cut in them so that they will be a snug fit over the sheets.
13.9.2 Fixing:
13.9.2.1 The wings of ridges shall be fixed to the sheets below with the seam bolts and nuts 8 mm
diameter polymer coated J or L hook bolts and nuts and bitumen and G.I. washers which fix the
sheets to the purlins. In additions, in north light adjustable ridges the curves of the two wings shall
be joined together at their crown with 8 mm dia. polymer coated seam bolts and nuts, at the rate of 2
numbers per pair of wings. Each seam bolt shall be provided with one bitumen and a pair of G.I.
washers.
13.9.2.2 Where `Plain wing angular' or `Plain wing adjustable' ridges are used, the gaps formed by
the roofing corrugations and the wings shall be filled with cement concrete 1:2:4 (1 cement : 2
coarses and : 4 graded stone aggregate 12.5 mm nominal size) up to the full length of the overlap.
The exposed face shall be finished perpendicular to the sheeting.
13.9.2.3 Wing of hips shall be fixed to the roof members below with the same 8 mm dia. polymer
coated or L hook bolts and nuts which fix the sheet to those members. In addition, they shall be
secured to the sheets below with 8 mm dia. polymer coated seam bolts, nuts and washers, so that
taken together with hook bolts there shall be bolt on each wing atleast every fifth corrugation of the
sheet below in the case of `Corrugation' and at least every second corrugation of the sheet below in
the case of `semi-corrugated' sheets. The seam bolts shall each be provided with one bitumen and a
pair of G.I. washers.
13.9.3 Measurements : The measurements for ridges and hips shall be taken for the finished work
along the centre line of the ridge and hip lines in length, correct to a cm.The laps in adjacent ridges or
hip pieces shall not be measured. The underlay of ridges under expansion joint pieces where the
latter are provided shall however be measured.
13.9.4 Rate: The rate shall include the cost of all materials and labour specified above, but does not
include (a) the cost of required polymer coated hook bolts and nuts and their washers, (b) the cost
of supplying and fixing expansion joint pieces, (c) the cost of closing the gaps between plain ridge
and the sheet corrugations with concrete. Item (a) above will be covered by the rate for the non-
asbestos cement sheet roofing while items (b) and (c) will be paid for separately unless specifically
included in the description of item of the ridge or hip item.
13.10 Other Roofing Accessories of Non-Asbestos High Impact Polypropylene Reinforced
Cement:
13.10.1 Accessories: The other accessories that may be required to be used on a roof are
(a) finishing pieces, eaves filler pieces, north light and ventilator curves, barge boards and
expansion joint sheets.
(b) ridge finials, cowl type ventilators, curved boards for north light, curves, roof light expansion
joints for ridge and expansion joints for north light curves and
(c) `S' type louver. The accessories shall be of the type appropriate for use with corrugated or
semi corrugated sheets which form the roofing.
The accessories shall be of the same manufacture as the corrugated or semi-corrugated sheets used
for the roof. The pieces shall be free from cracks, chipped edges or corners and other damages.
13.10.2 Laying & Fixing:
i) These shall be laid and secured with the same polymer coated hook bolts which secure sheets
to the roof members below where possible or with separate polymer coated hook bolts to the
roof members below and/ or with 8 mm dia. polymer coated seam bolts, nuts and washers to
the sheeting, generally as per manufacturers printed instructions and as ordered by the Engineer-
in-Charge. `S' type louvers shall be fixed to ventilators to timber, M.S. angle or flat iron
verticals spaced not more than 1.65 metre centre. The laps of adjacent pieces over the verticals
shall not beless than 10 cm. The upper flat of the top most row of louvers shall be fixed to the
vertical by 10 mm dia. polymer coated bolts and nuts and bitumen and polymer coated washers.
ii) The lower flats of the top and intermediate rows of louvers and the flat of the louvers pieces
below shall be secured together to the verticals behind by 10 mm dia. G.I. separating bolts
threaded at both ends and of suitable length. Each of these bolts shall be equipped with 2 pair
of nuts, G.I. and bitumen washers. The louver flats of the lowest line of louvers shall also be
fixed to the verticals at the proper distance from the same by the use of similar separating bolts
and nuts.
i) The accessories listed undergroup (a) in 13.10.1 shall be measured for finished work in
length correct to a cm. Laps between adjacent pieces shall not be measured.
ii) The accessories listed under group (b) in 13.10.1 shall be measured and paid for in number.
This applies in the case of finial too where the unit shall consist of a pair of inter locking
pieces.
iii) The `S' type louvers listed under group (c) in 13.10.1 shall be measured for the finished work
in length of each row of louvers correct to a cm. The laps, between adjacent pieces of louvers
will not be taken into account in the measurements.
13.10.4 Rate
13.10.4.1 The rates for supplying and fixing, non-asbestos cement accessories listed in groups (a) &
(b) of 13.9.4 shall include the cost of all materials and labour involved in all the operations described
above bolts, nuts, washers and other fixing accessories but does not include the members.
13.10.4.2 The rate for supplying and fixing roof lights shall not unless otherwise described in the
item, include the glazing which shall be paid for separately.
13.10.4.3 The rate for supplying and fixing `S' type louvers shall include all fixing accessories such
as ordinary and separating polymer coated bolts, nuts, and bitumen washers including drilling the holes
for the same in the vertical supporting member behind but shall not unless otherwise described in
the item the cost of supplying and fixing the supporting members which shall be paid for separately.
13.11 Eaves and Valley Gutters of Non-Asbestos High Impact Polypropylene Reinforced
Cement
13.11.1 Gutters and Accessories : Eaves gutters shall be of the type specified in the item such as
(1) plain ended eaves, (2) boundary wall, (3) socketed eaves ogee and (4) socketed half round. These
shall be of standard size as stipulated in the item. Valley gutters shall be of the `Plain' ended valley
types and of size as stipulated in the item.
These shall be of approved manufacture, approved by the Engineer-in-Charge. The gutter sections and
their accessories such as drop ends, stop ends, nozzles, angles and union clips shall be free from
cracks, chipped edges or corners and other damages.
13.11.2 Laying and Fixing:
13.11.2.1 Gutters shall be laid with a minimum slope of 1 in 120, which should be increased where
possible. Gutters shall be true to line and slope and shall be laid with the requisite accessories such as
dropends, stopends, nozzles, angles and union clips as shown in the working drawing or as ordered
by the Engineer-in-Charge.
13.11.2.2 The size of outlet of dropends and nozzles shall be of the same size as the size of the rain
water pipes in to which they shall be discharging the water.
13.11.2.3 Gutters and their accessories shall be supported by M.S. flat iron bracket. Where these
brackets are to be fixed to the sides of rafters, they shall be of 40x3 mm section bent to shape and
fixed rigidly to the sides of the rafter with 3 Nos. 10 mm dia meter bolts, nuts and washers. The
brackets shall over lap the rafter not less than 30 cm and the connecting bolts shall be 11.5 cm centre.
13.11.2.4 Where the brackets are to be fixed to the purlins they shall consist of 50x3 mm M.S. flat
iron bent to shape with one end turned at a right angle, and fixed to the purlin face with a 10 mm
dia. bolt, nut and washer. The per pendicular overhang portion of 50x3 mm bracket shall be stiffened
by another 50x3 mm flat, bent to rightangle shape with its lowerleg connected to the bracket with 2
Nos. 6 mm dia. M.S. bolts, nuts and washers and its shorter leg fixed to face of purlin with one
number 10 mm dia. bolt, nuts and washers. The over hang of the vertical portion of the flat iron
bracket from the face of the purlin shall not exceed by 22.5 cm with this arrangement.
13.11.2.5 The requisite slope in the gutters shall be given in the line of the bracket. The brackets
shall be placed at not more than 90 cm centre.
13.11.2.6 The gutters shall be fixed to the brackets with 2 Nos. 8 mm dia. polymer coated seam bolts
and nuts, each bolt and nut being equipped with a pair of bitumen and polymer coated washers.
These connecting bolts shall be above the water line of the gutters.
13.11.2.7 Spigot and socket ends of gutters of socketed eaves ornamental' or `socketed half round'
type and their accessories shall be connected together at their laps with one row of 8 mm dia. polymer
coated bolts and nuts, each bolt and nut being provided with a pair of bitumen and a pair of polymer
coated washers. The gap between the socket and spigot shall be packed with approved plastic roofing
compound, flanked on both sides with 6 mm dia. non-asbestos rope. The connecting polymer coated
bolts are then tightened so that the lapped joints become leak proof. The outer faces of the packed
non- asbestos rope shall not be farther than 6 mm from the edges of the spigot and socketed ends.
13.11.2.8 Where both ends of gutters and or their accessories to be connected together are of spigot
ends they shall be laid as butt joints with 1.5 mm gap in between over union clips (loose socket
pieces). The union clip shall be connected to the two butt ends of the gutter or other section on both
ends with two rows (one row per ends) of 8 mm dia. polymer coated bolts and nuts, each bolt and
nut being provided with a pair of bitumen and a pair of G.I. washers. The gap between the union
clips and the butt ends of the gutter sections or accessories shall be packed with approved plastic
roofing compound flanked at both edges by 6 mm dia. non-asbestos rope as before. The whole joint
shall be made leak proof by tightening the bolts.
13.11.2.9 The ends of `Plain' ended eaves or boundary wall type and `Plain' ended valley type gutters
and their accessories shall be laid with butt joints over union clips and connected together in the
same manner as for connecting spigot and socket ends described in the preceding sub-para.
13.11.2.10 The number of connecting bolts, nuts and washers and the quantities of 6 mm diameter
non- asbestos rope and plastic roofing compound required per spigot socket of òrnamental' and `half
round' gutters of different sizes and butt joint of plain ended `Boundary wall or eave' and `valley'
type gutters of different sizes shall be shown in Table 11.
Table 11 : Jointing Materials per Joint of Gutter
Type of Gutter Nominal 6 mm dia. Required per joint
Sizes-mm Asbestos
Plastic 8 mm G.I. Washer Bitumen
Rope
Roofing Dia.nuts 25 mm Washer
Compound and bolt dia. 25mm Dia.
Socketed 125 0.57m 170 g 1 No.45 mm 2 Nos. 2 Nos.
ornamental long
Socketed 200 0.98 m 255 g 3 Nos. 6 Nos. 6 Nos.
ornamental 45 mm long
Socketed 150 0.57 m 170 g 1 No. 2 Nos. 2 Nos.
half round 45 mm long
Socketed half 250 0.92 m 567 g 3 Nos. 6 Nos. 6 Nos.
round 45 mm long
Socketed half 300 1.07 m 709 g 3 Nos. 6 Nos. 6 Nos.
round 45 mm long
Plain ended 275x125 0.97m 737 g 8 Nos. 16 Nos. 16 Nos.
boundary wall x175 40 mm long
or eaves
Plain ended 300x150 1.15 m 850 g 8 Nos. 16 Nos. 16 Nos.
or eaves
Type of Gutter Nominal 6 mm dia. Required per joint
Sizes-mm Asbestos G.I.
Plastic 8 mm Bitumen
Rope Washer
Roofing Dia.nuts Washer
Compound and bolt 25 mm 25mm Dia.
dia.
or eaves
or eaves
valley x250 50 mm long
valley 50 mm long
13.11.3 Finish: The gutters and accessories when fixed shall be true to line and slope and shall be
ridged. All the joints shall be leak proof.
13.11.4 Measurements: The measurement of gutters shall be taken for the finished work in length
correct to a cm along the centreline of the gutters. The measured length of the finished gutters will
include the length over accessories such as drop ends, stop ends, nozzles and angles, though the rate
for the same shall not include the cost of the accessories unless specially described in the item. Laps
between the adjacent pieces of gutter and gutter section or between gutter section and accessories
shall not be measured. Accessories such as dropends, stopends, nozzles and angles shall be measured
and paid for separately. Union clips (loose sockets) shall not be measured separately as they are
included in the rate for gutters.
13.11.5 Rate : The rate for the gutters shall not, unless otherwise specified in the description of item,
include the cost of providing and fixing accessories such as drop ends, stop ends, nozzles and angles.
The rate shall include the cost of providing and fixing all union clips (loose sockets), all connecting
G.I. bolts, nuts and bitumen and G.I. washers, M.S. flat iron brackets and their fixture to the gutter
sections and to the roof members, non-asbestos rope and plastic roofing compound.
Extra over the rate for the gutter shall be paid for providing and fixing accessories, stop ends, drop
ends angles and nozzles. Where brackets of 50x3 mm size are provided in place of brackets of 40x3
mm size as indicated in para 13.11.2.4 extra rate will be paid for separately.
13.12. Jack-Arch Roofing:
13.12.1. Scope:
13.12.1.1 This specification lays down requirements regarding materials, centring, painting, laying,
curing and mode of measurement of Jack Arch Roofing.
13.12.2. Materials:
13.12.2.1. Joists: - The rolled steel Joists supporting Jack terracing shall generally be placed at a
distance of 1 to 1.4 metre apart but shall never exceed 2 metre according to the circumstances and
shall be of the section specified and free from rust and other defects. They shall conforms to IS 805
: 1968 steel tie rods should confirm to IS 432 (I) : 1982.
13.12.2.2. Bricks: - Only well burnt first class bricks shall be used for building, Jack-arches. They
shall conform to IS 1077: 1992.
13.12.3. Centring: The centring may be made on pillars built up from the ground or may be
suspended from the roof beams. In the later case, the cross timber carrying the centring shall be
suspended from the outer flanges of the beams by means of stout hook bolts of square cross sections,
to prevent the beams being displaced by the thrust of the arch due the centring under its load.
The top surface of the centring shall be smooth and to the correct curvature and shall be covered
with close boarding or such so as to prevent the mortar running through the joints. Concave templates
shall be provided by the contractor at his own expense for checking the curvature. The courses of
brick work shall be marked out on the surface of centring. No centring shall in any way be attached
to the tie rods nor shall any weight of the centring come on the tie rods.
13.12.4. Painting: All steel beams, tie rods, etc. shall be thoroughly freed from rust by means of
wire brushing. The portions of beams, tie rods and wall plates to be exposed before being erected
shall be painted with two coats of red lead paint. The parts of the roof beams, tie-rods and wall plates
which are to be embedded in masonry shall be completely set in and properly covered with neat
cement to prevent corrosion and the abutting course of masonry must be set in cement mortar or as
ordered by the Engineer. All steel joints where encased should be encased in cement concrete Grade
M 15 with a minimum cover of 4 cm.
13.12.5. Rise and Thickness : The jack-arch shall be built in the form of a segment of a circle with
a rise of about 1/8 of span. The thickness of the arch shall not be less than 10 cm, when built with
burnt clay bricks.
13.12.6. Tie Rods:
13.12.6.1. Tie rods shall be provided at designed spacing as shown in the drawing. Tie rods shall not
be less than 12 mm. in diameter. The exposed length of tie rods shall be painted.
13.12.6.2. The tie rods shall be placed generally not less than 7.4 cm. (3") above the bottom of the
joist and their spacing shall not exceed more than 20 times the width of the joist. These rods shall
be properly anchored.
13.12.6.3. For anchoring tie rods into the end walls, a separate encased beam may be used, in case,
the thickness of the walls is not sufficient to afford full anchorage by other means.
13.12.6.4. In a series of jack arches, the tie rods shall be provided in the end spaces only. When the
end spaces are shorter than the central span, the tie rods shall be provided for atleast two or more
spans near the ends.
13.12.6.5. Tie rods must be put in place and the nuts tightened up correctly before the centring are
fixed.
13.12.7. Springing:
The bricks for the springing course shall either be moulded to shape or cut to template on the
ground in sufficient number before the work is commenced.
13.12.8. Laying:
13.12.8.1. Brick work: The brick work shall comply in every respect with relevant specification on
Brick Work. In arches, brick shall be laid with their bed faces (19 cm.) normal to the thrust of the
arch in the mortar made of good hydraulic lime or fat lime mixed with Surkhi and clean coarse river
sand in equal proportion or cement mortar 1:4 or as specified by the Engineer In charge.
13.12.8.2. Top concrete: Over the bricks a layer of concrete which should be a minimum of (3")
7.5 cm. over the crown shall be laid. The haunches should be filled to make the top surface slopping
suitable for drawing water which should not be less than 1 in 60. The completed terrace may be
finished with flat Brick tiles laid in C.M. 1:3 mixed with crude oil.
13.12.9. Removal of Centring: The centring shall be removed a week after laying the final layer of
concrete.
13.12.10. Finish: The under surface of the arches shall be plastered as specified in the schedule of
quantities.
13.12.11. Curing: The work shall be kept cured while in progress & for a fort night after
completion.
The jack arch roofing including top layer of concrete, and centring shall be measured overall flat
(Plan area given in square metre).
The following shall be measured
separately:-Painting metal surfaces.

R.SJoist.
Lime plastering under surface.
Encasing R.S.J.
Tie rods.
13.13. Mangalore Tile-Roofing:
13.13.1. Scope:
13.13.1.1. This specification lay down requirements regarding materials, laying & fixing and mode
of measurement of MangaloreTile Roofing.
13.13.1.2. Mangalore tiles are machine made burnt-clay tiles widely used for roofing work in the
country. Its design incorporates corrugation for drainage and also an efficient interlocking system
between the tiles, enabling them when laid to form a leak proof layer. Depending on the degree of
protection needed from the roof, Mangalore tiles may be laid as such or with an under layer of flat
tiles or ceiling tiles, etc. A specific advantage of a tiled roof is the ease of maintenance since any
broken tile can be easily replaced. The design of Mangalore tile takes into account this aspect and
the tile as laid on the roof will be able to carry the weight of a man it is called on to support during
such repair. Though originally produced in areas near Mangalore, this tile is now manufactured and
used in many parts of the country.
13.13.2. Materials :
13.13.2.1. Tiles :- The tiles shall be of Mangalore pattern and of approved make. This shall conform
to the relevant specification in Chapter of building material. The class be as specified in the schedule
of quantities. Mangalore tiles shall conform to IS 654:1992. Ridge tiles shall conform to IS
1464:1992. Reapers shall be of any of the species given in IS 883:1970.
13.13.2.2. Specimen :- The tiles shall be in every way equal to the specimen approved by the
Engineer before the work commences and the same shall remain in the Engineer's custody. All
subsequent supply shall conform to this specimen.
13.13.3. Laying and Fixing
13.13.3.1. Preparatory work :
(a) The roof frame work shall be completed and the reapers nailed into position. The pitch of the
roof shall neither be less than 24 degree nor more than 45 degree.
(b) Spacing of reapers shall not normally exceed 600 mm; the size unless otherwise designed,
shall be normally 50 mm x 25mm for Mangalore tiles laid over flat tiles over reapers; and 50
mm x 15mm for Mangalore tiles laid over reapers or over ceiling tiles laid on reapers.
(c) Where ceiling board is adopted, it shall not be less than 12 mm thick and shall be tongued and
grooved. The boarding shall be nailed to the rafters first so as to form a continuous surface
from ridge to the eaves, and the reapers nailed over them. Alternatively the ceiling boarding
may be fixed direct to the purlins. The size of reapers shall not be less than 25mm x 25mm
fixed at suitable distances apart to suit the tiles spacing. The maximum spacing of sleepers shall
not exceed 750 mm.
d) Dimensional coordination be done between the various elements of Mangalore tiled roof to
avoid cutting of tiles.
e) No gutter on roof drainage shall discharge water from one roof to another, except from the
dormer.
0 Glass tiles, of the same shape and size as the Mangalore tiles may be fixed in the same manner
as other tiles.
g) While considering the strength of frame work the following dead loads shall be taken into
account :-
Table 12
Description Rise/Span Dead Load
Kg/sqm
Mangalore tiles embedded in mortar over tiles 1/4 to 1/2 110
Mangalore tiles with flat tiles without mortar for 1/4 to 1/3 80
embedment
Mangalore tiles alone 1/4 to 1/3 90
h) Flat tiles shall be immersed in water for 2 h and air driedbefore laying. The underside of the
flat tiles, if so specified, shall be dipped in whitewash mixed to a creamy consistency and then
the tiles dried.
i) Mangalore tiles shall be first soaked in water for at least 2 hours before laying.
13.13.3.2 Fixing of Reapers:
a) The reapers shall be fixed over the rafters at the specified spacing and nailed. The nails shall
penetrate at least 2 cm into the rafters. They shall extend at least three span lengths between
rafters; their length may be extended by a butt joint occurring on the rafters. The joints of two
adjacent rows of reapers shall not occur on the same rafter. At the eaves a tilting fillet shall be
fixed, if necessary
b) Where ceiling boards are used instead of reapers they shall be fixed as in 13.13.3.1(c).
13.13.3.3. Laying of Mangalore Tiles:
a) The tiles shall be laid from eaves towards the ridge properly interlocked according to the design
of the tile. The tiles shall be laid breaking joints, that is, the left channel of the upper tile shall
lie in the right channel of tile below. The hips and ridges of roof shall be covered with ridge
tiles which shall be edge-bedded in mortar. The mortar in edge bedding may be further finished
with plaster or paint to match the colour of the tiles. If the courses of roof tiles adjacent to the
hip or ridge do not fit exactly underneath the ridge tiles, either properly made tiles or tiles cut
to suitable shape may be use. At eaves the lower most course of tiles shall overhang the tiling
fillet by a distance sufficient to ensure that the water drained off from the roof, discharges clear
off the eaves into the gutter.
b) A suitable arrangement shall be made so that the lower most course of tiles are not blown away
by wind. The bottom most layer, or even more layers of tiles above it shall be tied to the reapers
or other roof elements by means of galvanized wire; or by a galvanized steel flat fixed to the
roof. Mortar bands 200 mm to 250 mm wide and 60 mm to 6 5 = deep may also be spread
over the tiled roof at a spacing of 2.5 m to 3 m for additional protection against wind.
c) Mangalore Tiles over a Flat Tile Undercover - The flat tiles shall be laid over the reaper; a
mortar layer 2 5 = thick shall be spread over the flat tile. Mangalore tiles shall then be laid
over the mortar and fully embedded. Where the pitch of the roof is more than 30 degree,
additional fillets shall be fixed at a spacing of about 1 m centre, so that the flat tiles laid between
them are retained in position. The Mangalore tiles may also be fixed over flat tiles without
mortar bedding, if so specified.
d) Mangalore Tiles over Ceiling Tiles - The ceiling tiles shall be laid over the reapers and the
Mangalore tiles shall be laid over them with appropriate interlocking between tiles in two
layers.
e) The eaves line and ridge - line shall be perfectly straight horizontal and parallel to each other.
f) The joints between hip and ridges shall be grouted so as to be leak proof. A metal saddle not
less than 45 cm' in area may preferably be used underneath such junctions as additional
protection against leakage.
h) A clear and unobstructed channel shall be formed in the valley. Undercover shall be provided
for the courses of tiles adjacent to the valley.
i) In case of chimney stacks and other similar features projecting through the roof, full tiles shall
be used around them and taken into masonry. In addition metal or bitumen flashing shall be
used to cover the intersection between the top edge of tiling and any projection through the
roof. The flashing shall be well tucked into either joints in masonry or grooves in concrete as
the case may be and shall be wedged and pointed.
j) At junctions of roof and wall, waterproofing treatment may be given as per relevant IS
Specification.
Where necessary tiles shall be let into the wall to a depth of 50 mm at least and a drip moulding shall
be provided at about 100 mm above the roof surface and the joints between the wall and roof be
grouted with waterproofing mortar.
13.13.3.4. Wind Ties: - At the eaves teakwood battens 50 mm x 13 mm or M.S. flats 30 mm x 3
mm shall be provided on the top, and fixed to the lower rafters with iron bolts or screws. This should
be paid separately.
13.13.3.5. General:- When the roof covering is completed, all the lines or the tiles must be perfectly
even and straight. The Contractor shall maintain and keep the whole roof watertight throughout one
whole monsoon.
13.13.4. Mode of Measurement
(a) Tile roofing shall be measured in square metre without any allowance for laps. Openings upto
0.4 sqm.shall not be deducted and no cutting for forming such openings shall be measured.
(b) Semi-circular ridges, hips and valleys shall be measured in running metre. If set in mortar, it
shall be so stated. Hip and ridges formed in plaster shall be given in running metre stating the
girth.
(c) Eave tiles bedded in mortar on walls shall be measured in running metre and paid separately,
describing mortar and the width of bedding. Filling ends and spaces between tiles at eaves with
mortar shall be given in running metre, stating the depth of filling. Screwing of tiles to battens
inclusive of drilling holes shall be measured in running metre stating the type and size of screws
and washers and their centre to centre distance.
(d) Straight cutting of tiles, hips, valleys, and skew verges, etc. shall be given in running metre.
(e) Any special tiles laid over roofing tiles for ventilators or other purpose shall be measured and
paid extra.
(f) Half tiles and one and a half tiles at verge shall not be measured separately but straight cutting
and waste at verge shall be allowed for the full length of the verge and given in running metre.
Tiles at verges embedded in mortar shall be measured in running metre and paid extra stating
the width of bedding.
13.14 Miscellaneous Items:
13.14.1. Paving over Mumty Roofs With Tile Bricks:
13.14.1.1 The roofs shall be paved with tile bricks laid flat and grouted with cement mortar.
13.14.1.2 - Tile Bricks : These shall conform to the detailed specifications.
13.14.1.3. Cement Mortar : The cement mortar shall be of 1 : 3 mix and of fine sand unless
otherwise specified in the description of the item and shall conform to the specifications described in
chapter for mortar.
13.14.1.4 - Preparing the surfaces : The surface shall be hacked, roughened and cleaned of all dust
and other foreign matter. It shall then be wetted before applying the mortar.
13.14.1.5. Paving and Grouting : Cement mortar shall be spread in 12 mm layer over the surface
evenly and to required slope. Tile bricks which had been soaked as in brick work in water for at least
an hour before hand shall then be laid open jointed and flat on the mortar and lightly pressed, and
set to plane surface true to slopes etc. using a trowel and wooden straight edge. The tile bricks shall
be laid with their joints not more than 10 mm wide. They shall be laid with their longitudinal lines
of joints truly parallel and horizontal and at right angles to the sloping edges of the roof.
Transverse joints in alternate rows should come directly in line with one another. Transverse joints
in adjacent courses shall not break joints by less than 5 cm. As soon as the paving is done, the open
joints shall be grouted with cement mortar 1:3 (1 cement: 3 fine sand ) cement used for grouting
mortar shall be mixed with 2 % (by unit of cement) water proofing compound conforming to IS:
2645. Care shall be taken to see that no joints are left unfilled or inadequately filled. The joints shall
be finished flush with the brick surface.
13.14.1.6Curing : The tile paving shall be cured for at least 7 days during which period it shall
be suitably protected from damage.
13.14.1.7 Measurements : Length and breadth shall be measured correct to a cm. Measurement
shall be taken for the finished work in superficial area covered.No deduction in measurement shall
be made for either opening or recesses for chimney stacks, roof lights, or for khurras, for areas upto
0.40 sqm nor any thing shall be paid for forming such openings.For similar areas exceeding 0.40
sqm deduction shall be made in measurements for all openings but nothing extra shall be paid for
13.14.1.8 - Rate : The rate shall include the cost of all materials and labour involved in all the
13.15. Lime Concrete Terracing with brick aggregate:
13.15.1. Materials : The nominal size of Brick aggregate shall not be more than 25 mm and also not
less than 20 mm. nominal size and lime mortar shall be 1:2 (1 lime putty : 2 surkhi) unless otherwise
specified in the description of the item.The volume of wet mortar to be used will be 50 % of stacked
volume of brick aggregate, unless otherwise specified in the description of item.
The brick aggregate shall be kept moist thoroughly for a period of not less than 6 hours before use
in the concrete mix.The specifications for the materials and method of preparation of mortar and
concrete shall conform in general to the specifications.
13.15.2. Laying :
a) Lime concrete shall be laid (and not thrown), in a single layer and spread and rammed with
wooden rammers of weight not exceeding 2 kg to the specified average thickness, slopes and
levels. The concrete shall be used when it is quite fresh concrete left over from the previous
days work shall in no circumstances, be used.
b) During this preliminary ramming, the surface shall be tested and kept perfectly true and even
by means of a trowel, straight edge and spirit level. The concrete shall then be further
consolidated by two rows of labourers sitting close and beating the concrete in with wooden
thappies ( weight 1 to 2 kg) across the entire width of the roof and thus slowly traversing the
length of the roof. Special care shall be taken to consolidate the concrete properly at its junction
with the parapet wall. This beating shall be continued for seven days or until the mortar is
almost set and the wooden thappies rebound from the surface readily when struck on it.
c) While the beating is in progress the surface shall be liberally sprinkled with a mixture of Gur
and boiled solution of Bael fruit, in the proportion of 1.75 kg of Gur to 1 kg bael fruit boiled
in 60 litre of water.
d) As soon as the beating is completed, the mortar that has come on top shall be softened by the
addition of the solution of Gur and Beal and smoothened with a float or trowel to a fine polish.
No plaster shall be used on any account for finishing the roof.
e) Curing : The concrete shall be kept wet after each day's work and for such period of time as
the Engineer-in-Charge may direct but shall not be less than ten days. The wetting shall be done
by spreading straw and watering very frequently from a watering cane through a perforated
hose, in moderate quantity, so as to ensure thorough wetting of the concrete. Water shall not
be poured on fresh concrete from large vessels as this may lead to damage to the finished
surface.
0 Finish : The slope of the finished terrace shall not be less than 1 in 50 unless a flatter slope is
expressly permitted by the Engineer-in-Charge in writing. The roof surfaces shall slope from
all sides towards the outlets.
The minimum thickness of the concrete at its junction with khurra shall be 5 cm. The lime concrete
shall overlap the cement concrete base of the khurra by 75 mm and shall be rounded to the edges of
the khurra. The lime concrete shall also be rounded at the junction of roof slab and parapet. The
finished lime concrete shall present a smooth surface with correct slopes and uniform rounding
wherever they occur. The concrete should be leak proof and free from cracks.
13.15.3 - Thickness : The average finished thickness of the laid concrete over the entire area shall
conform to the average thickness specified in the description of the item.The average thickness of
concrete shall be measured correct to 5 mm. In the above measurement the extra thickness at the
rounding with the junctions of wall shall not be taken into account.
13.15.4 - Measurements :
a) Length and breadth shall be measured correct to a cm. The area shall be calculated in square
metre for the finished work in superficial area of the specified average thickness,
upto two places of decimal.
b) No deduction in measurements shall be made for either openings or recesses for chimney
stacks, roof lights etc. or for khurra for areas upto 0.40 sqm. Nothing extra shall be paid either
for any extra material or labour involved in forming openings or recesses, or in rounding the
concrete junction of roof with parapet walls, chimney stack khurras etc. For similar areas
exceeding 0.40 sgm.deductions will be made in the measurements for the full openings but no
extra shall be paid for any extra labour, material etc. involved in forming such recesses and
openings and in rounding at the junctions aforesaid.
c) Where average thickness of concrete laid exceeds the average thickness specified in the item,
the extra depth shall not be paid for unless the same had been carried out under written orders
of the Engineer-in-Charge.
d) Where, however, such average thickness is found on measurements to fall short of the average
thickness specified in the item the contractor's rate will be reduced for the short fall in
thickness.
13.15.6 - Rate :The rate shall include the cost of all the materials and labour involved in all the
13.16 - Cement Concrete Gola:
13.16.1 - Cement Concrete : The specifications for concrete shall be the same as described in
chapter of concrete.
13.16.2 - Gola : A chase of 75 mm wide by 75 mm deep shall be cut in the parapet wall just above
the junction of mud phuska or lime concrete with parapet wall and it shall be filled with cement
concrete 1:2:4 (1 cement :2 coarse sand:4 stone aggregate 10 mm and down gauge) the external face
finish with a slope of 1 : 0.75 and the exposed surface of the gola shall be plastered with cement
mortar 1:3 (1 cement : 3 fine sand).
Expansion joint at every 3.5 to 4.5 metre shall be provided and filled with bitumen filler. The bitumen
filler shall be prepared by mixing bitumen, cement and coarse sand in the ratio of 80:1:0.25 (80 kg of
hot bitumen :1 kg of cement and 0.25 cum of coarse sand).
13.16.3 - Curing : The finished surface shall be cured for at least 7 days.
13.16.4 - Measurements : The length of the finished gola shall be measured at its junction with the
wall face correct to a cm. No deduction shall be made in measurements for gaps for water outlets.
13.16.5 - Rate : The rate shall include the cost of all materials and labour involved in all the
operations described above including the cost of bitumen filler in expansion joint, The rate includes
for all turnings and rounding at all the corners and risers.
13.16.6. Khurras for rain water disposal with terracing:
13.16.7- The khurras shall be constructed before the brick masonry work in parapet wall is taken up
and it shall be 45 cm x 45 cm unless otherwise specified in the description of the item and shall be
formed of cement concrete 1:2:4 mix (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm
nominal size) or other mix as stipulated in the description of the item.
13.16.7.1. Laying:
i). A PVC sheet 1 m x 1 m x 400 micron shall be laid under the khurra and then cement
concrete shall be laid over it to average thickness of 50 mm with its top surface lower than
the level of adjoining roof surface by not less than
(a) 20 mm in case of roof surface finished with lime concrete terracing.
(b) 70 mm in case of roof surface finished with lime concrete terracing covered with brick
tiles.
(c) 50 mm in case of roof surface finished with mud phuska with brick tile covering.
ii) The concrete shall be laid to a size greater than the stipulated size of the khurra in such a way that
the adjoining terracing whether of lime concrete or of the tile bricks shall overlap the concrete
on its three edges by not less than 7.5 cm. The concrete will slope uniformly from the edges to
the outlet, the slope being as much as possible and in no case less than 20 mm cement concrete
at the outlet. The concrete shall be continued at the same slope through the width of the wall
into the outlet opening to ensure a water tight joint.
iii). The khurras and the sides of the outlet shall then be rendered with 12 mm coat of cement plaster
1:3 mix (1 cement : 3 coarse sand) or other mix as stipulated in the description of the item. This
shall be done when the concrete is still green and shall be finished with a floating coat of neat
cement. The sides of the khurras and sides of the outlet opening shall be well rounded. The size
of the finished outlet opening shall be 10 cm wide by 20 cm high or as directed by the Engineer-
in-Charge.
iv). In cases where rain water is to be disposed off through rain water pipes, iron grating shall be
provided at the outlet as a safeguard against choking, if so directed by the Engineer-in-Charge.
Iron gratings where provided. shall be of overall size 20 x 25 cm. with an outer frame of 15 x
3 mm M.S. flat to which 4 Nos. M.S. bars of 10 mm dia. shall be welded in vertical direction
keeping equal clear spacing of 2.5 cm. or as directed by the Engineer in Charge.
13.16.7.2. Measurements : Khurras shall be counted in numbers.
13.16.7.3. Rate : The rate is for each completed khurra of the specified size and is inclusive of the
cost of all materials and labour involved in forming the khurras and outlet opening as described above,
except for iron gratings which shall be paid for separately.
13.17 Shell Roofs (Curved Roofs):
13.17.1 General: Shell roofs are cast in-situ or precast, they can be of single curvature or double
curvature. Reinforced concrete in-situ concrete shells covered by IS 2204 : 1962 are chosen
commonly for covering large clear column free areas, such as, factory buildings, godowns, power
stations, garages, island, platforms of railway stations, stadium, etc. Precast concrete doubly curved
shells, covered by IS 6332: 1984 also serves similar end uses. Shell units are effectively used for
replacing solid slabs; they may be used in conjunction with precast joists or battens or planks; or as
waffle shells by providing in-situ ribs in two directions. The shells are lighter in weight and save
reinforcing steel and concrete. It eliminates the use of shuttering fully and scaffolding partially. The
sizes of shells are chosen depending or handling facility. But shell construction is a specialized job
and the designers specifications should be adhered to.
13.17.2 Reinforced Concrete Shell Roof Cast In-Situ:
13.17.2.1 Shell Dimensions:
a) Chord width is the horizontal projection of the arc of the shell.
b) Radius R, at any point of the skin in one of two principal directions in the case of
cylindrical shells.
c) Rise is the rise of the shell at any section in vertical direction between the lower
springing level and the highest level or apex of shell.
d) Span is the distance between the centre lines of two adjacent end frames or traverses.
e) Semi-central Angle is half the angle subtended by the arc of a symmetrical circular
shell at the centre.
13.17.2.2 Type of Shells :There are many types of shells due to combination of geometric shapes,
such as, Barrel shells, Butterfly shells, Continuous cylindrical shells, Corrugated shells, Cylindrical
shells, Multiple cylindrical shells, North light cylindrical shells, Shells of evolution, Translation
shells, etc. Figures illustrating those are given in IS 2204:1962.
1. Barrel Shells :- Cylindrical shells which are symmetrical about the crown.
2. Butterfly Shells:- Butterfly shells are those which consist of twoparts of a cylindrical shell
joined together at their lower edges.
3. Continuous Cylindrical Shells:- Cylindrical shells which are longitudinally continuous
over the traverses.
4. Corrugated Shells:- Shells which have corrugations on their surface.
5. Cylindrical Shells:- Shells generated by a curve moving on a straight line or vice versa. Barrel
shells north light cylindrical shells, and butterfly shells are common examples of this type.
The common curves employed for the cross section of cylindrical shells are:- (a) arc of a
circle, (b) semi-ellipse, (c) parabola, (d) catenary and (e) cycloid .
NOTE -The semicircle, the semi-ellipse and the cycloid have the advantage that the tangents at
the ends are vertical and hence the horizontal thrusts transferred to the edge members are
negligible. but these shapes are somewhat difficult to construct.By far the most common curve
employed in modem cylindrical shell constructions the segment of a circle.
6. Multiple Cylindrical shells: - A series of parallel cylindrical shells which are traversely
continuous.
7. North-Light Cylindrical shells:- Cylindrical shells with the two springing at different
levels and built in single or multiple bays and having provisions for north-light glazing .
8. Ruled Surfaces: -A surface which can be generated entirely by a straight line, The surface is
said to be singly ruled if at every point a single straight line only can be ruled and `doubly ruled
' if at every point two straight lines can be ruled. Cylindrical shell and conoid are examples of
singly ruled surfaces, and .hyperbolic paraboloid and inverted umbrella are examples of doubly
ruled surfaces.Ruled surfaces have a practical advantage that they can be formed by straight
plank shuttering. Doubly ruled surfaces obviously have greater advantage for shuttering than
singly ruled surfaces.
9. Shells of Revolution:- Those generated by curves revolved about their is of symmetry.
Examples are segmental domes, (paraboloids of revolution and hyperboloids of revolution. The
term ('hyperboloid of revolution') unless otherwise qualified, will mean hyperboloid of
revolution of one sheet.
10. Shell Roof:-Curved surfaces in which the thickness is small ascompared to the radius and
other dimensions.
11. Translational Shell: -This is the surface generated when one curve moves parallel to itself
along another curve, the planes of the two curves being at right angles to each other. As a
special case, one or both the curves may be straight lines. Examples are `hyperbolic paraboloids'
(generated by a convex parabola moving over a concave parabola or vice versa), èlliptic
paraboloids' (generated by one parabola moving over another parabola, both being convex),
and "cylindrical shells'.
13.17.2.3 Design : For the efficient construction of shell roofs, detailed information with regard to
the following shall be furnished by the designer to the builder. Working drawings showing the
orientation and arrangement of shells, dimensions, details of reinforcement including exact
positioning, and other salient features, such as arrangement of north lighting, skylight, roof drainage,
construction joints and expansion joints, etc.
Before the construction, the builder shall give detailed consideration to the design and fabrication of
formwork and centring. The details of formwork and the sequence of erection and release of
formwork used in shell construction shall be as approved by the designer.
Design shall be according to relevant IS Codes. The thickness of singly-curved shells shall not
however be less than 5 cm, it is the usual practice to thicken the shell near the edges and the traverses.
The thickness of doubly-curved shells shall be not less than 4 cm; this minimum thickness is
adequate, as shells of double curvature are not developable and hence are more resistant to buckling;
more over flexural stresses are small. End frames or traverses are provided to preserve the shape of
the shell, it may a solid diaphragm, an arch rib, a portal frame or a bow string girder. Where a clear
soffit is required, especially where travelling form work is employed, the end frames may consist of
up-stand ribs.
a) Reinforcement shall not be less than 5 mm in diameter in the un-thickened portion of the
shell and shall not be greater than the following For shells from 4 cm upto less than 5 cm thick. 10 mm dia.
For shells from 5 cm upto less than 6.5 mm thick. 12 mm dia.

For shells from 6.5 cm and over 16 mm dia.
The maximum diameters specified in (a) apply only to the un-thickened portion of the shell. Larger
diameters for reinforcement will be permissible subject to the approval by the designer. The
maximum spacing of reinforcement in any direction shallbe limited to five times the thickness of the
shell and the area of unreinforced panel shall in no case exceed 15 d2 where d is the thickness of the
shell. The total depth occupied by reinforcement in the direction ofthickness in the un-thickened
portion of the shell shall not exceed three times the maximum permissible diameter for reinforcement
as specified in (a).
b) Mix Proportions for Concrete: Generally, a nominal mix of 1 : 2 : 4 (by nominal volumes)
maybe used for shells of medium dimensions and a nominal mix by volumeof 1 : 14 : 3 for
very large shells. In no case shall the nominal mix for concrete used in shell construction be lower
than 1 : 2 : 4. It is, however,desirable that the required strength for concrete is arrived at from
considerations of stresses in the shell and its elastic stability, and the mixes specified by
strength rather than by nominal volumes. Rich mixes will be generally undesirable as the
concrete shrinks more, giving rise to cracks. Wherever feasible, the maximum size of aggregate
shall be 20 mm. If there are difficulties in placing such a concrete, the maximum size may be
restricted to 12 nun provided the requirements for strength are satisfied.
NOTE- 20 mm maximum size of aggregate corresponds to 12 mm nominal size according to
IS : 383-1952 Specification for Coarse and Fine Aggregates from Natural Sources for Concrete.
It is advisable to use an air-entraining agent so that satisfactory workability is obtained without
increasing the water content of the mix.Concrete having excessive water contents should be
avoided as it is likely to slip down steep slopes.Concrete mix shall be as per IS 456:2000.
13.17.2.4 Sequence of Construction: Shells may have edge members which are designed to act in
unison with the shells; adjacent shells may also have been designed to take the loads in unison. For
ease and economy of construction, however, it is generally necessary to construct the various elements
separately. In order that the .final stress pattern in the completed structure may conform as closely as
possible to that assumed by the designer, it is necessary that the designer should specify the essential
conditions governing the sequence of construction. The actual sequence proposed by the builder
shall be subject to the designer's approval before construction starts on any of the elements of the
shell structure and this sequence shall not be varied without the designer's approval. In the type of shell
roofs, covered by this standard, the following sequence of construction may generally be used at
preliminary stages of planning the construction work:
Table 13
Type Stage Operation Remarks

a) Single Erection of formwork for Wherever economically
shell the edge members and feasible, consideration may
the traverses, fabrication be of the form work the
and placing of entire shell unit including the
reinforcement edge member and the
given to the erection traverse
and concreting with However, it shall be
such portion of shell ensured that the formwork for
reinforcement as the edge member and traverse
shown in the drawings. is not in any way connected
with the formwork of the shell
proper.
II Removal of formwork
leaving required supports.
III Erection of formwork for
the entire shell,
fabrication and placing
of steel there in and concreting.
W
Curing
V Removal of formwork.
VI Waterproofing and insulating.
VII Finishing.
b) Multiple shell : Multiple shells do not generally exceed four or at the most five in number in
one series depending on the designer's requirements for expansion joints. For multiple shells
the stages of construction will be the same as those for single shells. However,unless otherwise
provided for in the design, supports required for the edge beams, traverses and shells in one
series shall remain till the entire series is completed.
a) Formwork: Since shape is the essence of shell design and thicknesses are small, greater
care shall be exercised in the design and erection of formwork and special attention shall
be paid to minimizing the differential settlement of the centring and of the props
supporting them. Where repetitions justify, formwork in panels or mobile units may be
considered. Details for mobile units, if used, shall be worked out by the builder. If the
formwork is to be used a great number of times, the surface of the forms shall be of firm
construction to give the required repetitions. A hard and smooth surface for the form may
eliminate the need for plastering, thus effecting economy. Where no additional decorative
treatment is to be carried out, the designers may specify the general pattern to be left on
the intrados by the formwork. Formwork shall be designed and erected in such a manner
as to lend itself to be removable as specified in Decentring.
b) Placing of Reinforcement: The reinforcement in shell structure including edge
members,traverses, etc., shall be placed as shown in the drawing accompanying the
design. To ensure monolithic connection between shell and the edge members, the shell
reinforcement shall be adequately anchored into the edge members or vice versa, by
providing suitable bond bars from the edge members to the shell.
c) Reinforcement in the Shell: i)As far as possible, hooks shall be avoided in the shell and
adequate laps or welded joints as specified by the designer shall be provided in straight
lengths. If at all hooks are to be provided for reinforcement in the shell, they shall be kept
parallel to the plane of the shell. Only the minimum number of lengthening joints in the
bars shall be used and the joints shall be staggered.
NOTE- Welding is rarely adopted in the case of reinforcement placed within the thickness
of the shell. However, if it is required that the reinforcement shall be welded, only lap
welding shall be adopted.
ii) Reinforcement in edge members may be lapped, welded, orprovided with special
couplings with or without welding. If butt welding is used, it shall be done with
extreme caution for successfulresults. Provision of special couplings may be
advantageous in edge members of large spans as it would avoid congestion of bars
( see Note )due to laps and hooks. In such cases, the details and positioning of
couplings shall be decided by the designer.
NOTE- The problem of corrosion in reinforcement will, however, become less
serious with the use of prestressed concrete construction.
iii) A minimum cover of 12 mm shall be provided for the reinforcement.For regulating
the cover, accurately made and matured precast mortar or concrete pieces shall be
used. The reinforcement shall be correctly placed and firmly fixed. The
reinforcement may be securely tied or welded so that the spacing of the bars is
correctly maintained.
d) Mixing Concrete: The concrete shall be mixed in accordance with the requirements
specified for concrete in IS : 456-2000 Code of Practice for Plain and Reinforced Concrete
for General Building Construction ( Revised), and also the special instructions, if any, of
the designer.
Unless otherwise specified by the designer, the maximum size of the aggregates shall be
20 mm and the aggregate shall conform to IS : 383-1952 Specification for Coarse and
Fine Aggregates from Natural Sources for Concrete.
e) Casting of The Shell:
i) The full thickness of the shell shall be concreted in one operation. The positioning
of the construction joints shall be as indicated by the designer. The portion of an up-
stand member, if any, shall be concreted as soon as possible after the concreting of
the shell.Edge members and end frames shall be concreted first. A slump of 4 cm
for the concrete will be sufficient.
ii) For casting the shell either hand tamping or mechanical compaction by vibrators
may be used. The concrete shall have a slump of not less than 5 cm, if hand tamping
is used. Concreting may be done in panels of convenient dimensions and shape. In
the case of singly curved shells, the panel should be laid parallel
to the curved edge in order to limit the effect of shrinkage, each panel shall be
started at the lowest level and worked upwards. In the case of doubly curved shells,
the arrangement of panels shall be decided by the designer giving due consideration
to shrinkage effects. Mechanical compaction shall be done by using screed vibrators
generally. Needle vibrators may be used in thickened portions of the shell as
advised by the designer, however, use of needle vibrators shall be restricted to edge
members or thickened portions of the shell where the depth will be sufficient to
accommodate these vibrators.
iv) Concreting shall preferably be done in the cool hours of the morning or during the
night in summer. Special care shall be taken in tamping the concrete in down stand
stiffening members which are usually deep.Concrete shall be finished to the correct
curve as set by template.This may be done either continuously or by alternate-bay
method.
v) Thickness of the shell shall be regulated by using templates of corresponding
thickness. This thickness of the shell shall also be accurately checked at typical
points in between the thickness guides on the shell.
vi) Proper arrangements shall be made to avoid displacement of steel during placing
of concrete by providing walkways above the level of the finished concrete and
supported and free from the reinforcement at intervals so as to avoid disturbance of
the reinforcement.
vii) Construction Joints: -Construction joints shall invariably be along the curve.
They shall preferably be located along a line of zero shear stress, as for example,
along the directrix at mid-span. The construction joints shall be finished in such a
way that new concrete will effectively bond with the old. When the work is
commenced the next day, the joints shall be cleaned with wire brushes and slushed
with cement slurry.The surface of the concrete shall be finished with wooden
floats.The portions of the shell that are already cast shall be effectively protected
from exposure to sudden rains by means of tarpaulins and similar coverings.When
concreting proceeds, cubes of concrete shall be taken out from each day's work for
purpose of testing and verification of its quality.
f) Curing: In a shell roof, the ratio of the exposed area to the volume of concrete is
relatively much larger in comparison with normal reinforced concrete structures. Hence,
extreme care is required in keeping the surface sufficiently damp for curing. As soon as
concrete has sufficiently hardened to prevent damage to it, it shall be kept continuously
moist for the first 24 hours by covering the surface with wet canvas or gunny bags. There
after, the surface shall be kept continuously moist for a period of at least 10 days by
sprinkling water or by covering it with gunny bags or similar materials which are sprayed
over with water periodically, alternatively curing compounds may be used with the
approval of the engineer in-charge.
g) Decentering :The process of Decentering shall be gradual and without shock and so
controlled that the .overall stress pattern in the structure, at any stage of Decentering is
reasonably similar to the pattern expected in the design. Supports of adjacent edge
members may have to be lowered simultaneously with those of the shell. The Decentering
procedure to be actually adopted shall be subject to the designer's approval.
NOTE 1- As a general guide, the Decentering may commence when concrete has attained
a strength equal to twice the maximum dead load stress multiplied by a factor equal to Fc
/ Fb, where Fc = ultimate crushing strength of concrete, and
Fb = ultimate buckling strength of the concrete in the shell.
NOTE 2- Generally in the absence of test results on cubes, the centering of the shell may
be removed at the end of 14 days, and the Decentering the bottom shuttering of the edge
members and the end frames may be done at the end of 21 days. By casting the latter a
week in advance of the shell, it will be possible to strike the centering of the shell, the
edge members and the end frames on the same day.
h) Expansion Joints:Expansion joints shall be provided in accordance with the design and
specification of the designer (see relevant provisions of IS : 2210-1962 Criteria for the
Design of Reinforced Concrete Shell Structures and Folded Plates ). Complete structural
isolation of the roof members shall be effected at the expansion joints with a clear gap of
not less than 2 cm. It may also be necessary; some times, to have double columns. The gap
shall be filled with an elastic filler, and the waterproofing carried across the joint without
a break.
Lighting and Other Fixtures: Skylights, when provided, may be at the crown or on the
slope of the shell very near the crown.After completion of shells, no fittings shall be
embedded or suspended from the shell without the approval of the designer.
Thermal Insulation:Thermal insulation may be provided by the following methods:
a) By application of light-weight insulating concrete, foam concrete, cork, etc., over
the shell roof;
b) By providing an air gap between the shell and any rigid form of water proofing,
such as asbestos sheets;
c) By casting the shell over rigid boards that provide thermal and acoustic
insulation; and
d) By spraying on the underside of the shell a coating of insulating material, such as
asbestos.
Whatever type of thermal insulation is adopted, the net weight of the insulation layer
shall not exceed that assumed in the design, and the designer shall always specify
this weight.
k) Waterproofing: Waterproofing of shell roofs may be carried out by any of the following
methods or any other accepted method of flexible water proofing.
a) By application of bitumen-hessian process, bituminous felts, or cold bitumen;
b) By lining with aluminium foils; and
c) By lining with asbestos sheets.
Adequate slope for drainage of water shall be made in the water proofing.
Whatever method of water proofing is adopted, the net weight of the water proofing layer
shall not exceed that assumed in the design and the designer shall always specify this
weight.
1) Finishing: After completion of the shell, the inside may be given a rubbed finish,
if so required. The rubbing may be done with an abrasive stone.Since the construction of
shell is of utmost importance for its stability, the sequence, framework, placing of
reinforcement, etc., shall be carried out by an expert contractor. For guidance IS 2204:
1962 may be referred to.
13.18. Suspended Ceilings (False Ceiling):
13.18.1 Gypsum Board Suspended Ceiling :
13.18.1.1 Scope: Gypsum board suspended ceiling systems may be used to lower the height of rooms
and/form a void for services and to provide fire protection and sound insulation. They can also
provide sound insulation between adjacent rooms where sound resisting partitions are installed below
them.
13.18.1.2 Material:
(a) Gypsum Plaster Board : It consists of an created gypsum core treated with special additives,
covered on each face with a specially prepared durable paper liner which provides an ideal surface for
subsequent decoration or treatment and firmly binds the longitudinal sides of the board.
Consequently it is the ideal material to use for the construction of partitions wall lining & suspended
ceiling, both in new buildings and in the modification or alteration of existing ones.
Table 14 : Physical properties and performance.
Thickness Width Weight Thermal Thermal
(mm) (mm) (Kg/m2) Conductivity Resistance
(W/mk) (m2K/W)
11.5 610 & 1220 8.0 0.16 0.06
12.5 610 & 1220 10.50 0.16 0.08
15 1220 12.80 0.16 0.09
Nominal in a dry state=807.10 kg/m3
Density Standard
Gypboard conforms to IS 2542-1981& IS 2095-1982
Fire resistance 1 2 . 5 = = lh hour resistance. Material classified as class 1 Surface spread of
flame test as per BS476 PART-7 1971
Sound insulation The average rate of noise reduction between frequencies
of 100 Hz and 3,150 Hz is:
35.6 dB for a partition of 7 5 = or 9 7 = thickness with a 12.5 mm
board on each face.
38.5 dB for a partition as above but including 2 5 = of mineral wool
in the cavity.
42.5 dB for a 100 mm partition comprising of two layers of 12.5 mm
board on each side.
Resistance to knocking
and scuffing : Greater than that of Cement knocking and plaster work.
Gypsum is available with two different types of edge finish:
(i) tapered edge
The longitudinal edge may be tapered or square, depending on the type of application and the
convenience of using one or another finish. Tapered edge board gives an invisible joint, the gap
between each board being filled and finished in such a way that the linings or partitions present a
continuous, smooth, seamless surface. Square edge board can be used when a visible joint system is
required incorporation a surface joint strip, or where the board is required to be incorporated into a
metal grid suspended ceiling system.
(b) Dab Fixer:
A gypsum based adhesive to bond Gypboard to the background in back bond dry lining system,
Gypboard to Gypboard in compact wall system. It is supplied in normal 25 kg bags.
(c) Fixing Channel: A metal channel section used in metal framed partitions. It is fixed to the metal
studs at the required locations and is suitable for the attachment of heavy fixers to the partitions. The
fixing channel is 0.9mm thick, 99 mm wide and is supplied in 2440 mm lengths.
(d) Floor and Ceiling Channel: Used as the horizontal metal section at the ceiling and floor in
metal framed partition systems. The channel is 0.55 mm thick, in widths of 50 mm, 72mm and
146mm, all with a flange of 32 mm. Supplied in 3660 mm lengths.
(e) Stud Section: Used as the vertical member between the ceiling and floor channels of metal-
framed partition systems it is 0.55 mm thick with one 36 mm and one 34 mm flange and has cut-
outs along its length for services.
These are supplied in the following sizes :
Type Width(mm) Length(mm)
Studs 48 2440
2700
70 3050
Jumbo studs. 146 3660
(f) Batten section: A metal section used in the demountable partition system to fix Gypboard to the
metal stud frame and as a fixing base for external corner and skirting. It is 0.9 mm thick, 25 mm
wide, and 3050 mm long, predrilled at 150 mm centres.
(g) Steel Strapping : Galvanized steel strapping 0.55 mm thick, 40 mm wide. Used in the column
and beam encasement system to provide the basic fixing for steel angles and Gypboard lining.
Supplied in 25 m length.
(h) Steel Angle: Galvanized steel 90° angle, 0.55 mm thick with 25mm legs. Used with Gypboard
steel strapping in the column and beam encasement system at the flanges and for fixing the outer
layer of a double layer demountable partition at external angles. Supplied in lengths of 3050 mm &
3660 mm.
(h) Batten Trim: A rigid, white PVC extrusion that clips over and conceals the batten section and
fixings in demountable partitions. It forms the cover moulding at vertical and horizontal edges of
Gypboard, it is 27mm wide x 4mm deep and is supplied in lengths of 3050 mm.
(i) Drywall Screws: Zinc plated, self-drilling and self-tapping screws with counter sunk philips
heads. For fixing Gypboard to metal framing sections (upto 0.89 mm thickness). Available in length
of 25,35 and 45 mm and 1000 screws per box.
Board thickness Drywall screw
length (mm)
(mm)
9.5 25
12.5 25
15.0 25
23.0 35
second layer 12.5 35
second layer 15 45
(k) Joint Tape: A paper tape for reinforcing tapered edge joints and internal angles in systems. It
has a centre crease, chamfered edges and slit performance in four rows. Supplied in 120 m x 0.53
mm rolls.
(1) Angle Bead: A perforated, galvanized steel angle strip, used to reinforce external angles that
need maximum protection. Its arris is formed by a quarter-round metal bead which is left exposed. It
is 25 mm x 25 mm legs, suitable for all board thicknesses, and is supplied in 2440 mm and 3660 mm
lengths (fig. A).
(m) Edge Bead :A perforated galvanized steel channel section, used to form a positive perimeter
detail where cover strips are not used. It has a 25mm and a 10 mm short return leg. Supplied in
2440 mm & 3660 mm lengths, in two widths suitable for 9.5 & 12.5 mm Gypboard (Fig. B).
(n) Control Joint: Control joint is a G.I.cold rolled metal strip 0.38mm thick. It is 47mm wide and
is supplied in 3,3050 mm lengths. It is perforated on both flanges to ensure adhesion of applied
finishes, and the open slot is protected by plastic tape which is removed on completion. It weigh,
approximately 0.16 kg/m. (See figure C)
(o)
(o) Drywall Top Coat:
Specially formulated for use on the surface for direct decoration of Gypboard. Applied in one
application, after the jointing has dried, by brush or roller, it prepares the surface for paint and
wallpaper decoration. For paperhanging it allows the paper to be wet-stripped when redecorating. For
painting it primes,providing a consistent background for the first coat.Two coat application at the
recommended coverage also provides a vapour check treatment to the surface of the lining. A water
vapour resistance of at least 15MNs/g is achieved.Where Gypboard are to receive textured finishes,
or where decoration is delayed, it is strongly recommended that a primer such as top coat is used.
The primer should be applied as soon as possible after jointing & finishing is completed.
(i) Coverage: 8 to 9 litres/1OOm2 in single-coat application, 14 to 15 litres/100 m2 in two-
coat application supplied in 5 litre containers.
13.18.1.3 Fixing Procedure:

(a) P/F Suspended ceiling (Heavy duty): (i) Providing & fixing suspended false ceiling which
includes providing & fixing G.I.perimeter channels of size 27 mm, O.5mm thick having one
flange of 20 mm & another flange of 30 mm alongwith the perimeter of the ceiling, screw
fixed to the brick walUpartition with the help of nylon sleeves and screws at 600mm centre to
centre. Then suspending G.I.intermediate channels of size 4 5 0 . 9 mm thick with two flange
of 15mm each from the soffit at 900 mm centre with M.S .flat of 25x3mm fixed to the soffit
with G.I.cleat & expansion fasteners at 900 mm centre. Ceiling section of 0.5mm thickness
having knurled wedge of 51.5mm and two flanges of 26mm each with lips of 10.5mm are then
fixed to the Intermediate channel with the help of connecting clips and in direction
perpendicular to the Intermediate channel at 457 mm centres.9.5mm thick tapered/ square edge.
Gypboard with metalized polyester backing are then screwed to the ceiling sections with 25mm
dry wall screws at 230mm centre. The boards are fixed across to the ceiling section & joints
are staggered. Screw fixing is done mechanically either with screw driver or drilling machine
with suitable attachment.
After fixing first layer of Gypboards, second layer of 9.5mm tapered edge board is screw fixed
as above but the joints are staggered.Then tapered & square edges of the boards are filled &
finished with jointing compound, paper-tape, suitable for Gypsum plaster boards.
Finally a layer of veneer plaster 5mm thick is applied followed by two coats of top coat the
face board to give a smooth seemless finish.
Note: 1. For light fittings, grills diffusers,etc. cut outs have to be made with the frame of
perimeter channels of size 20 x 27 x 30 mm x 0.5 mm thick, supported suitably (extra).
2. Painting is to be considered extra.
(b) P/F false ceiling (light duty) : Providing and fixing suspended false ceiling, which includes
providing and fixing G.I.perimeter channels of size 27mm, 0.5mm thick having one flange of 20mm
and another flange of 30mm, along with perimeter of ceiling, screw fixed to brickwalU partition with
the help of nylon Rawl plugs and screws. Then suspending G.I.intermediate channels of size 45mm,
0.9mm thick with two flanges of 15mm each from the soffit at 1200 centre with ceiling angle of
width 25mm x25mmx0.5mm thick fixed to soffit with G.I.cleat and steel expansion fasteners. Ceiling
section of 0.5mm thickness having knurled wedge of 51.5mm and two flanges of 26mm each with
lips of 10.5mm are then fixed to the intermediate channel with the help of connecting clips and in
direction perpendicular to the intermediate channel at 457 mm centre. 12.5mm tapered edge
Gypboard is then screw fixed to ceiling section with 25mm drywall screws at 230mm centre.Screw
fixing is done mechanically either with screw driver or drilling machine with suitable
attachment.Finally, the tapered and square edges of the boards are jointed and finished to a flush with
requisite jointing compound, paper, tapes, and primer suitable for Gypsum plaster boards.
Note :
1. For light fittings, grills diffusers, etc. cut outs have to be made with the frame of perimeter
channels of size 20 x 27 x 30 mm x 0.5 mm thick, supported suitably. (extra).
Finally the face layer of the board are to be jointed and finished so as to have a flush look which
includes filling and finishing the tapered and square edges of the boards with jointing compound,
paper tapes and two coats of primer suitable for Gypboard.
13.18.1.4. Gyp board P/F suspended ceiling (light duty) feature joints:
i) Providing and fixing suspended false ceiling, which includes providing and fixing
G.I.perimeter channels of size 27mmx55mm thick having one flange of 20mm and another
flange of 30mm, along with perimeter of the ceiling, screw fixed to the brick wallpartition with
the help of nylon sleeves and screws at 610mm.c/c. Then suspending G.I.intermediate channels
of size 45mmx0.9mm thick with two flange of 15mm each from the soffit with G.I.cleat &
expansion fasteners at 900mm centre ceiling sections of 0.5mm thickness having knurled wedge
of 51.5mm and two flanges of 26mm each with clips of 10.5mm are then fixed to the
Intermediate channel with the help of connecting clips and in direction perpendicular to the
Intermediate channel at 610mm centre.
ii) Then the same size ceiling sections are screw fixed across to these ceiling sections by cutting
the flanges, to the bottom by steel screws to form a grid of 610 x 610mm, 12.5mm thick
Gypboard tiles are then screwed to the ceiling section leaving a groove of 4mm all around with
25mm dia. wall screws at 230mm centre.
Note :
1. For light fittings, grills diffusers, etc. cut outs have to be made with the frame of perimeter
channels of size 20 x 27 x 30 mm x 0.5 mm thick, supported suitably (extra).
13.18.1.5. General Assembly:
Jointing and finishing:
i) Jointing is carried out in three separate stages filling and tape bedding, fmishing and applying
a surface treatment to even out differences in surface texture and section.It is important to
ensure that all boards are securely and correctly attached. Protruding screws or nail heads
should be driven home. Gaps greater than 3 mm between the boards should be treated with
jointing compound pressed firmly into the gap so that it is completely filled. Jointing compound
used for this purpose should be stiffer than normal. It may also be necessary to repair scuffs
and minor damage to the boards.
ii) This is for the jointing compound filling, finishing of the joints and embedding the paper tape.
The powder is mixed by sprinkling it into water and stirring. The mixture should be allowed to
stand for 20 to 30 minutes before final stirring. A thick, creamy consistency is desirable. The
quantity mixed should be used within the 60 minute working time. The mixing utensil must be
thoroughly cleaned before re-use.
13.18.1.6. Tapered edge joints:
i) A continuous thin band of jointing compound is applied to the through of the tapered edge
joints. The joint tape is then pressed into the band of jointing compound, firmly embedded and
free from trapped air bubbles, with sufficient joint material under the tape to ensure good
adhesion.
ii) Immediately after the tape has been fixed, a new layer of material is applied over it, flush with
the surface of the board. Before the material begins to stiffen, the jointing sponge should be
moistened and surplus material wiped from the edges of the joint, without disturbing the main
joint filling. The sponge should be rinsed occasionally to prevent material setting in it. Once the
material has dried any slight depressions in the surface can be filled again and projections cut
back.
iii) When the material has dried about 1 hour after application, a thin layer of jointing compound
is applied in a broad band 200mm wide. The edges of this band should be immediately feathered
out with a slightly damp jointing sponge. When the joint material has completely dried, another
application is made,250mm wide and feathered out as before, it is important that the first coat
of finish is allowed to dry before the final coat is applied.
13.18.1.7. Cut edges: A finish similar to that achieved with tapered edge boards can be obtained
with cut edge boards or a cut edge and a tapered edge board. The cut edge should be lightly sanded
to remove any burrs. The edges of the adjoining boards are cut to make a `V' groove with a sharp
knife. The joint is filled flush with the face of the board, using jointing compound. The gap must be
filled solidly back to the framework. After the material is dried a thin layer of finish coat is applied
and joint tape bedded in it as tightly as possible, leaving sufficient material behind the tape to ensure
good adhesion and to eliminate air bubbles. Gypboard jointing compound is then applied over the
tape in a band 200mm wide, and the edges are feathered out with the damp jointing sponge. When
this has dried, a second application of finish coat is made 250mm wide and the edges are feathered
out. Wider feathering out of the joints will overcome slight misalignment of cut ends and edge joints.
13.18.1.8. Internal angles:Gaps between the boards are filled with jointing compound as described
earlier. A thin layer of jointing compound is applied with a brush to both sides of the angle. The
jointing tape is folded and pressed firmly into the angle to remove air bubbles. Sufficient joint
material should be left behind the tape to ensure good adhesion. A thin layer of jointing material
75mm wide is applied immediately and feathered out with the jointing sponge. Surplus material is
removed from the extreme edges as previously described. When this coat has dried, another
coat of same material 100 mm wide is applied to both sides of the angle and the edges feathered out
as before.When internal angles are formed at the junction of Gypboard and plastered walls or
ceilings, the above treatment is carried out.
13.18.1.9. External angles:
i) When external angles are formed, any cut edge of board should be marked by a bound edge.
External angles are reinforced with angle bead.
ii) Paper tape is creased firmly at the angles to lie close to the board surfaces. A 50 mm wide band
of jointing compound is applied to each side of the angle. The tape is pressed firmly into the
corner, making sure that the arris of the folded tape is straight immediately after bedding the
tape, a 125mm band of joint material is applied to both sides of the angle and the edges
feathered out with a moist sponge. After this coat of material has set a thin layer of same
material is applied and the edges again feathered out. When this is dry, the process is repeated.
iii) When maximum protection is required for the external angle, Gypboard angle bead should be
used. it is supplied in 3m lengths. When necessary it can be cut to required size with tin snips.
iv) Apply 50mm bands of jointing material to both sides of the angle formed by boards. The angle
bed is positioned on jointing compound with its flange covering the joint between boards. Press
firmly into place with the outer edges in contact with the board surface. Material which has been
squeezed through the holes and at the sides, should be struck off flush and the material allowed
to dry. Apply another layer 150mm wide and feather out. After this layer has dried a coat of
same material is applied to each side of the angle 25mm beyond the edge and feathered out
with the damp jointing sponge. When this has dried, another layer 200mm wide is applied and
feathered out as before.
13.18.1.10. N a and screw spotting: This process fills any indentations left by the hammer or
screwhead when fixing the board. With the layer of jointing compound which is struck off level with
the face of the board and allowed to dry. The operation is completed with one more application.
13.18.1.11. Surface treatment: When the jointing is dry, one coat of drywall top coat is applied to
the entire surface using a medium pile roller, cutting in edges and angles with a brush or entirely by
brush.
13.18.1.12. Cracks, causes & remedies:
Causes : Crack are found developed in the joints, mainly because of following reasons :
1. Various types of movements are passed on directly or indirectly to the joints:
a) Movement in the frame work of the system because of improper fixing arrangement.
 loose strap hanger/suspension medium or if it is not fixed straight vertical.
 suspension medium is not fixed rigidly to framework i.e. by means of nut and bolts.
2. Because of not adopting the practice of proper jointing and finishing
a) If paper tape is not used or embedded wrongly during first application of jointing and
finishing.
b) In case of square or cut edge joints, V-groove is not made and filled prior to embedding
of the paper tape.
3. At the joints of Gypboard and solid background or surface of different materials.
Remedies :
1. For taking care of the movements.
a) Suspension medium/strap hanger should be fixed firmly, rigidly and vertically straight
and tightly fixed to the frame work by means of nut and bolts as shown in Figure 27.
b) Nobody should be allowed to walk over the ceiling system. In case of regular M/F ceiling
system after the installation is completed. In case the movement above the ceiling is not
restricted, the design of the frame work should be modified to take care of such types of
movements. However, it is always recommended to use cat ladder or wooden planks
placed over the main member before somebody is allowed to walk.
c) Precautions should be taken to provide control joints in the ceiling/partition system,
where expansion joints of the building are located or to provide at 10 mfrs. max centre in
case of long partition runs or large ceiling area.
2. For Proper jointing and finishing
a) Only trained workers should be engaged so that embedding of paper tape in the joint
which is most important part should be done properly.
b) Also to take precaution of making V-groove and filled properly before embedding of
the paper tape.
c) Recommended jointing tool set should be used to achieve better finish. 3.
Joints between two different materials
a) Joint between Gypboard surface and solid background. The surface of solid background.
The surface of solid background should be made wet, absolutely rough and cleaned before
starting the jointing and finishing as per the recommended practice.Joint between
surfaces of Gypboard and other material, it depends upon the type of material. However,
in case the joint between Gypboard and Door or window frame, it is recommended to
provide edge bead etc. to protect the edge of Gypboard and to cover it by any type of
beadings.
13.18.1.13. Measurements: Length and breadth of the finished ceiling shall be measured correct to
a cm. The area shall be calculated in Sqm. Correct to two decimal places. No deduction shall be
made for making opening for electrical, air conditioning fire fighting fixtures nor shall be made
either for extra materials or Labour involved in making such openings.
13.18.1.14. Rates: The rate shall include the cost of all the materials and labour involved in all the
operations descrived above including scaffolding etc. frame work mentioned will be paid for
separately unless otherwise stipulated in the description of the items.
13.18.2 Ceiling With Insulating Building Boards:
13.18.2.1 Insulating Building Boards : The insulating building boards shall be of approved quality
as per IS code 3348 and, unless otherwise specified, shall have square edges. The dimension shall be
subjected to the tolerances given in the Table 15 below:
Table 15 : Dimensions and Tolerances
S. Type of Board Nominal Tolerance on Length Width Tolerance on
No. Thickness Thickness length and
mm mm cm cm width
(i) Fibreinsulation 9 ±0.75 365,300 180,150 120 cm and
board, ordinary or 12 ±0.75 270,240 120,100 below±3mm
flame retardant type 18 ±1.00 210,180 90, 60 Above120
25 ±1.25 150,120 45 and cm ± 6 mm
100,90 30
60, 45 and
30
13.18.2.2 Frame: Timber frame of the classof wood and sec on specifiedin the description of the
relevant item for the frame or as ordered by the Engineer-in-Charge shall be provided. The width of
the scantlings provided shall be sufficient to provide a minimum nailing surface of 50 mm. The
longitudinal and header scantlings shall be so arranged that (a) the boards can be fixed to form the
panel arrangements required as per drawings or as ordered by the Engineer-in-Charge,
(b) the longitudinal scantling to which the boards are mainly fixed are spaced at 30 to 45 cm centre,
the actual spacing selected depending on the width of the cut board in the panel arrangement,
(c) all edges of the cut board units are supported either on the longitudinal scantlings or on the
header scantlings.
The frame shall be given two coats of approved preservative paint (to be paid for separately) before
the board is nailed on M.S. angles or other sections shall be used for suspending the frame and will be
paid for separately.
Where the joints in the board are to be covered with beadings the framings centre should be 3 to 6
mm to allow for space between boards.
The framing and painting thereof shall be paid for separately unless specifically included in the
description of the ceiling item.
The bottom surface to the frame shall be checked and corrected to true planes and slopes.
13.18.2.3 Nails : The sheets shall be fixed to the frame scantling with G.I. headless nails 2.24 mm
dia. when the joints are to be left exposed. Where the joints will be covered with beadings, the sheets
are to be fixed to the frames scantlings with G.I. felt headed (clout) nails 2.5 mm dia. The length of
the nails shall generally be equal to thickness of sheet plus 25 mm so that their grip on the framing
members will not be less than 25 mm.
13.18.2.4 Fixing:
i) The boards shall be applied with lengths parallel to all joints centred over the framing members.
Where joints are to be covered, the boards may be spaced 3 to 6 mm apart as described in the
respective manufacturers' specifications. Where joints are to be left exposed the sheets shall be
butt laid with their edges abutting in moderate contact, but without having to force them into
place. The boards shall be supported and held tight to the grounds with timber pieces the later
being moved outwards as the nailing proceeds. The boards are first nailed to the intermediate
framing member proceeding from the centre of the board outwards, the edges being nailed last.
ii) Where the joints are to be left exposed, the outer rows of nails are placed at 10cm centre and
about 12mm from the edge of the sheet. In the rows in the middle of the sheets, the nails are
placed 20 cm apart. The nails should be counter sunk in the underside of board with a suitable
punch. Care shall be taken in driving the nails so that the sheets are not marked by hammer
blows.
iii) Where the joints are to be covered with beadings, felt headed (clout) nails shall be used instead
of lost head nails. The spacing of the nails in the interior rows in boards shall be the same as in
the proceeding Para. If the outer rows at edges to be covered by beadings, the nails will be
spaced at 20 cm centre in each row with the screws in the two rows staggered and passing
through beading, sheet and framing so that ultimately the spacing of the fixing (nails and screws
taken together) in each row will be at 10 cm centre so far as the sheets and frames are concerned.
13.18.2.5 Finishing: The exposed side of the board shall be truly level and plane without any local
bulges or sags. The joints shall be truly parallel and/or perpendicular to the walls. The width of joints
shall be uniformed. Care shall be taken to see that the uniformity of colour of the sheets is not spoilt
during the fixing operations.Where the joints required to be covered beadings of side, pattern and
material as ordered shall then be fixed with screws. These shall, however, be measured and paid for
separately, unless specifically included in the description of the ceiling item.The ceiling shall be
treated with distemper or painting if so required but such surface treatment will be paid for separately,
unless specifically included in the description of the ceiling item.
13.18.2.6 Measurement and Rate : These shall be the same as described in 13.18.1.
13.18.3 Hard Board/Particle Board/A.C. Sheet Ceiling:

13.18.3.1 Boards
13.18.3.1.1 Particle Board: The specifications for particle board shall be same as per 10.3.
13.18.3.1.2 Hard Board: The specifications for hard boards shall be same as per 10.3
13.18.3.1.3 A.C. Sheets: The specifications for A.C. sheets shall be same as per 10.3
13.18.3.2 Frame: The specifications as described in 13.18.2.2 shall apply except that the maximum
spacing of the longitudinal scantlings shall be 40 cm centre.
In the case of hard board the sheets shall be damped with water on the textured face before they are
fixed. This shall be carried out by brushing the textured face evenly and liberally with a sponge or
swab soaked in water. After this, the sheets are stacked with the damped sides against
each other, in pairs and left to remain for a period of 24 or 48 hours as recommended by the
respective manufacturers. During this conditioning the sheets should be sheltered from the sun and
strong heat.The specifications for cutting and chamfering etc. will be same as in 13.18.2.2.
13.18.3.3 Nails: The specifications shall be the same as in 13.18.2.3
13.18.3.4 Fixing: The specifications as in 13.18.2.4 shall apply.
13.18.3.5 Finishing: The specifications as in 13.18.2.5 shall apply with the exception that normally
no surface treatment like painting, varnishing etc. is necessary.
13.18.3.6 Measurements and Rate : These shall be the same as under 13.18.1
13.18.4. Plaster of Paris (Gypsum Anhydrous) Ceiling over Wooden Strips( Chapti Jali)
13.18.4.1 Frame : The frame work shall be of the specified wood wrought and framed. In case of
slopping roofs wooden battens of suitable section (depending upon the span and load to be carried)
shall be firmly fixed as main supports, to the under side of the tie beams of the trusses at required
centre by means of bolts and nuts of proper size. In case of flat roofs, the battens shall be securely
fixed to the walls and pillars by holding down bolts and shall be fastened to the slabs above with
iron straps or M.S. bars of suitable sections and pillars by holding down bolts and shall be fastened
to the slabs above with iron straps or M.S. bar of suitable sections and encroachedtherein. Cross
battens of 50 X 40 mm sections at 40 cm centre orso, shall then be fixed at right angles to the main
battens. The frame work shall be treated with approved wooden preservative before it is covered
with ceiling. The underside of the frame work shall be true to planes and slopes.The frame work for
ceiling shall be paid for separately unless specifically included in the description of the ceiling item.
13.18.4.2 Wooden Strips : Wooden strips 25 X 6 mm of first class kailwood, (unless otherwise
stipulates specifically in the description of the item) shall be fixed to the cross battens, in the parallel
rows with gaps of 10 mm in between adjacent rows, by means of felt headed (clout) nails. The strips
shall be fixed butt jointed and not overlapped. The joints shall be staggered. The minimum length of
strips to be used shall be 1.5 m depending upon the length of strips required.
13.18.4.3 Rabbit Wire Mesh: Rabbit Wire mesh shall then be fixed to the underside of wooden
strips and their junctions with the battens with nails at pitch of 15 to 20 cm as ordered by the Engineer
in charge. The rabbit wire mesh shall be straight, tight and perfectly true to planes and slopes and
without any sagging and shall be slightly below the underside of the laths to allow the plaster to
encase the metal round.
13.18.4.4 Plaster of Paris: The plaster of Paris shall be of the calcium-sulphate semi-hydrate
variety.Its fineness shall be such that when sieved through a sieve of IS sieve designation 3.35 mm
for 5 minutes after drying the residue left on it shall be not more than 1% by weight. It shall not be
too quick setting. Initial setting time shall not be less than 13 minutes. The average compressive
strength of material determined by testing 5 cm cubes after removal from mould, after 24 hours and
drying in an oven at 40 degree Centigrade till weight of the cubes is constant, shall not be less 84 kg
per square metre.
13.18.4.5 Applications: The material will be mixed with water to a workable consistency. Plaster of
Paris shall be applied to the underside of the laths over the rabbit wire mesh in suitable sized panels
and finished to a smooth surface by steel trowels. The plaster shall be applied in such a manner that
it fully fills the gaps between the laths and the thickness over the laths is specified in description of
the item. The joints shall be finished flush to make the ceiling in one piece. The finished surface
shall be smooth and true to plane, slopes or curves as required.
i) Lengths and breadth of superficial area of the finished work shall be measured correct to a cm.
Area shall be calculated in square meter correct to two places of decimal. No deduction will be
made of openings of areas upto0.40 sqm nor shall extra payments be made either for any extra
material or labour involved in forming such openings.
ii) For openings exceeding O. 40 sqm in area, deduction in measurements shall be made but extra
will be payable for any extra material or labour involved in making such openings.
iii) Curved surfaces shall be measured and paid for separately from flat surfaces. The work shall
be deemed to comprise of flat surfaces only unless specifically stated otherwise in the
description of the item.
iv) Any sunk or raised mouldings in the plaster shall be measured and paid for separately,
deductions being made from plastering on ceiling only if the width exceeds 15 cm. Ceiling at
a height greater than 5 metre shall be so described and measured separately stating the height.
operations described above including all scaffolding, staging etc. The frame work supporting the
ceiling will be paid for separately unless otherwise stipulated in the description of the item.The rate
does not include for any raised or sunk mouldings or for any patterned finishing of the surface which
will be measured and paid for extra over the plaster work.
13.18.5 Plain/Semi Perforated Particle Board Tiles Ceiling:
13.18.5.1 Frame: The framework shall consist of anodized aluminium T sections for main runners/
cross runners of size specified in the item with anodic coating of 15 micron and perimeter wall angle
of anodized aluminium section of size specified by the Engineer-in-charge with anodic coating of
15 micron fixed to the wall with M.S. screws 50 mm long and PVC raw plugs. The frame work shall
be executed in a manner so as to form a grid of 600 mm x 600 mm as specified in the item. The
frame work shall be suspended from ceiling by level adjusting hangers made of 6 mm dia. M.S. rods
fixed to slab by means of MS ceiling cleats. The ceiling cleats shall be fixed to the slab by means of
mechanical dash fasteners 6 mm dia. and 50 mm long. MS hangers and ceiling cleats shall be painted
with a coat of yellow zinc chromate primer and two coats of synthetic enamel paint.
13.18.5.2 Ceiling Tiles: Ceiling tiles shall be of 12 mm plaln/semi perforated or with design BWP
type phenol formaldehyde synthetic resin bonded particle board conforming to IS 3087 of required
size. Tiles shall be finished with a coat of aluminium primer on both side and edge sand two coats
of synthetic enamel paint of approved quality and shade on exposed faces of the tiles.
13.18.5.3 Fixing of Ceiling Tiles: The ceiling tiles shall be placed over the aluminium frame and fixed
to the frame with help of 25 mm long CP brass screws with minimum 2 screws on each side of the
grid. The CP brass screws shall be counter sunk star head screws.
13.18.5.4 Measurements: Length & breadth of the finished ceiling shall be measured correct to a
cm. The area shall be calculated in square metre correct totwo decimal places. No deduction shallbe
made for making openings for electrical, air conditioning, fire fighting fixtures nor shall extra
payment be made either for extra materials or labour involved in making such openings.
13.18.5.5 Rate : The rate shall include the cost of all the materials and labour involved in all the
operation described above including scaffolding etc. Aluminium frame work mentioned in
para 13.18.5.1 will be paid for separately unless otherwise stipulated in the description of the
items.
13.18.6 Translucent White Acrylic Plastic Sheet Ceiling:
13.18.6.1 Frame : It shall be as para 13.18.5.1
13.18.6.2 Ceiling Tiles: These shall be made of translucent white acrylic plastic sheet conforming to
IS : 14753 of thickness specified in the item.
13.18.6.3 - Fixing, Measurements & Rate : Same as per paras 13.18.5.3, 13.18.5.4, 13.18.5.5
respectively.
13.19 - Wooden Ceiling:
13.19.1 - Boards:
i) Boards shall be of the class of timber and of fuushed thickness as specified in the description
of the item and shall be in accordance with the general specifications for wood work. Only
selected boards of uniform width shall be used. Unless otherwise specified in the description of
the item or shown in the drawings, the width of boards selected for use shall not be less than
100 mm nor more than 150 mm.
ii) The specific width of boards once selected with in these two limits shall be maintained through-
out and shall not be varied except in the first and last lines of boards adjustment to the two
walls, where remaining odd width shall be adjacent equally on both sides. The maximum length
of the board in the finished work shall be 180 cm. The minimum length of board in the finished
work shall be such that it will span at least two spacing of the supporting framework except
where shorter lengths are unavoidable, depending on the arrangements of the lines of heading
joints which shall be carried out to the pattern ordered by the Engineer-in-Charge.
The boards shall be planed true on the exposed side.
iii) Unless stipulated otherwise in the description of the item, the longitudinal joints of the boards
shall be tongued and grooved, while the heading joints shall be of the square butt type and shall
occur under the centreline of the supporting joint. Heading joints in adjacent boards shall not
be placed over the same joists, those in alternate boards being arranged in the sameline, except
where the joints are to be concealed by headings.
13.19.2 Frame: Timber frame of the class of timber and section specified in the description of the
item or as ordered by the Engineer-in-Charge shall be provided. The width of the frame scantling
shall not be less than 50 mm. The arrangements and spacing of the frame scantling shall be as per
design furnished. The frame shall be given two coats of approved preservative paint before the
boarding is screwed. The frame and paints there of shall be paid for separately unless specifically
included in the description of the item. M.S. angles or other sections shall be used for suspending
the frame and paid for separately. The bottom surface of the frame shall be checked and corrected
to true plans and slopes.
13.19.3 Mild Steel Screws: Screws shall be got approved from the Engineer-in-Charge before
fixing. They shall be of the slotted counter sunk head type of length not less than the thickness of
the board plus 20 mm. The designation number shall not be less than 9 for screws of length 40 to 50
mm and shall not be less than 6 for screws of length 25 to 35 mm.
13.19.4 Fixing : The outerlines of boards shall be accurately fixed, parallel and close to the wall.
Each subsequent plank shall be carefully jointed up. The boards shall be fixed to the frame scantling
above with two screws at each of frame and one at every intermediate joist. The screws shall be
counter sunk and the screw holes filled with putty or sloping out wax. The unexposed faces of planks
shall be painted with wood preservative before fixing.
13.19.5 Finishing: The exposed side of the boards shall be truly level and plane. The joints shall be
truly parallel and/or perpendicular to the walls. Beadings shall then be fixed to the ceiling, to the size
and pattern required. These shall be measured and paid for separately unless specifically included in
the description of the ceiling item.
i) Length and breadth shall be measured correct to a cm. Areas shall be worked out to nearest
0.01 sqm. The superficial area of the finished work ceiling shall be measured in square metre.
ii) No deduction in measurements shall be made for openings of areas up to 0.40 sqm. Nothing
extra shall be payable either for any extra material or labour involved informing such openings.
For openings exceeding 0.40 sqm in area, deductions in measurements for the full opening will
be made and in such case any labour involved in making these openings shall be paid for
separately in running metre.
iii) Wooden ceiling of boarding fixed to curve surfaces in narrow widths shall be measured and
paid for separately and shall include making the joints to proper splay.
Circular cutting and waste shall be measured and paid for separately in running metre.
13.19.7 Rate : The rate shall include the cost of all materials and labour involved in all the
13.20 Rain Water Spouts:
13.20.0 The sectional area of rainwater spouts provided shall be generally at the rate of 1 square cm
per 0.70 to 0.80 sq m of roof area drained. However in locations subject to excessive and high
intensities of rainfalls, the area of spouts provided may be suitably increased to suit local conditions.
No spout shall be less than 80 mm in diameter. The spacing of spouts shall be arranged to suit the
position of openings in the wall.
13.20.1 Stone Ware Spouts: The spouts shall be 100 mm in diameters and 60 cm long.
13.20.1.1 The stone ware pipe shall be perfectly sound, free from fine cracks, imperfections of
glazing etc. They must be straight cylindrical and of standard nominal diameter and length and depth
of socket as given in IS 651. Full length of pipes shall be used on the work. They must be thoroughly
salt glazed inside and outside shall generally conform to IS 651.
13.20.1.2 Fixing: These shall be provided at the mouths of khurras and shall be fixed in cement
mortar 1:3 (1 cement : 3 coarses and) with the socket embedded in the masonry and the spigot end
projecting outside. The masonry around the pipe and socket shall be thoroughly wetted and the holes
shall be given a coat of cement mortar around. The S.W. pipe shall then be inserted and fixed with
a surround of mortar. In case the hole has become much larger than the size of the pipe, cement
concrete 1:2:4 (1 cement: 2 coarses and : 4 graded stone aggregate 12.5 mm nominal size) shall be
used to fill in the annular space. The spouts shall sloped own ward at the rate of 1 in 6. The projection
outside the wall shall be uniform and not less than 40 cm. The entrance into the pipe shall be
smoothly rounded to meet the internal bore of the pipe to facilitate easy flow. Care shall be taken to
ensure that the vertical plane through the centreline of the spouts is at right angles to the plane of the
wall. Spouts in a row shall be true to line.
13.20.1.3 Measurements: Spouts shall be measured in numbers.
operations described above including scaffolding.
13.21 Cast Iron in Water Pipes:
13.21.1 Cast Iron Pipes: Pipes shall conform to IS 1230 and shall be perfectly, smooth and
cylindrical, their inner and outer surfaces being as nearly as practicable concentric. These shall be
sound and of uniform castings, free from laps, pin holes or other imperfections and shall be neatly
finished and carefully fitted both inside and outside. The ends of pipes shall be reasonably square to
their axes.
13.21.2 Dimensions :
i) C.I. rainwater pipes shall be of the dia. specified in the description of the item and shall be in
full length of 1.8 metre including socket ends of the pipes, unless shorter lengths are required
at junctions with fittings. The pipe lengths shall be in each case be with socket. The pipes shall
be supplied without ears unless otherwise specifically mentioned.
ii) The pipes supplied shall be factory painted (with a bitumen base composition) both inside
and outside which shall be smooth and tenacious.
iii) Every pipe shall ring clearly when struck all over with a light hand hammer. When shorter
pipes are cut from full lengths they shall be cut with a hack saw. The sizes, weights, sockets and
tolerances of pipes shall be as shown in Table 16.
Table-16 : Dimensions and Weight of C.I. in Water Pipes
Nominal size of pipes 50 75 100 125 150
(Internal diameter in mm)
1. PIPE
(a) External diameter in mm 53 79 104 130 156
Tolerance in mm ±3 ±3 ±3.50 ±3.50 ±4.00
(b) Thickness in mm 3.00 3.00 3.00 3.00 4.00
Tolerance in mm ±1 ±1 ±1 ±1 ±1
(c) Nominal weight of 1800 mm 7.50 11.00 14.00 20.00 26.00
long pipe without ears in kg (-)10% (-) (-) (-) (-)
Tolerance in weight ±13.00 10% 10% 10% 10%
Tolerance in length in mm ±13.00 ±13.00 ±13.00 ±13.00
2. SOCKET
(a) Internal dia meter in mm 63 89 114 139 167
Tolerance in mm ±3.00 ±3.00 ±3.00 ±3.00 ±3.00
(b) Thickness in mm 4.00 4.00 4.00 4.00 4.00
Tolerance in mm ±1.00 ±1.00 ±1.00 ±1.00 ±1.00
(c) Internal depth in mm 60 65 65 75 75
Tolerance in mm ±10 ±10 ±10 ±10 ±10
Note:
1. All dimensions are in mm.
2. Pipes weighing more than the nominal weight may be accepted provided they comply in
every other respect with the requirements of this standard.
3. The above table applies only to rain water pipes fixed on wall face.
4. For pipes and fittings which are to be embedded in masonry, specifications shall correspond
with those of pipes for soil, waste, and vent pipes. For their weights, specifications under
chapter 19.0 shall be referred to.
13.21.3 Fixing and Jointing:
Pipes shall be either fixed on face of wall or embedded in masonry, as required in the
Plain pipes (without ears) shall be secured to the walls at all joints with M.S. holder bat clamps.
The clamps shall be made from 1.6 mm thick galvanized M.S. sheet of 30 mm width, bent to
the required shape and size so as to fit tightly on the socket of the pipe, when tightened with
screw bolts. It shall be formed out of two semi-circular pieces, hinged with
6 mm dia. M.S. bolt on one side and provided with flanged ends on the other side with hole to
fit by the screw bolt and nut, 40 mm long. The clamp shall be provided with a hook made out
of 27.5 cm long 10 mm diameter M.S. bar, riveted to the ring at the centre of one semi-circular
piece. The details of the clamps are shown in Fig. The clamps shall be fixed to the wall by
embedding their hook since ment concrete block 10x 10x 10 cm in 1:2:4 mix (1 cement : 2 coarse
sand : 4 graded stone aggregate 20 mm nominal size) for which necessary holes shall be made
in the wall at proper places. The clamps shall be kept about 25 mm clear off finished face of
wall, so as to facilitate cleaning and painting of pipes.
Note: Where G.I. sheet clamps are not provided, M.S. sheet clamps of 3 mm thick and 20 mm
wide shall be used for making the clamps.
iii) The pipes shall be fixed perfectly vertical or to the lines as directed. The spigot of the upper pipe
shall be properly fitted in the socket of the lower pipe such that there is a uniform annular space
for filling with the jointing material. The annular space between the socket and the spigot shall
be filled with a few turns of spun yarn soaked in neat cement slurry. These shall be pressed
home by means of caulking tool. More skins of yarn shall be wrapped if necessary and shall be
rammed home. The joint shall then be filled with stiff cement mortar 1:2 (1 cement : 2 fines
and) well pressed with caulking tool and finisheds mooth at top at an angle of 45 degree sloping
up. The joints shall be kept wet for not less than
7 days by tying a piece of gunny bag, four fold, to the pipe and keeping it moist constantly.
iv) Where pipes are to be embedded in masonry, these shall be fixed in masonry work as it proceeds.
In such cases care shall be taken to keep the pipes absolutely vertical or to the line as directed
by the Engineer-in-Charge. The pipe shall have a surrounding of 12 mm minimum thickness
of mortar at every portion of the external surface. The mortar shall be of the same mix as is
used in the masonry. The joint shall be caulked with lead as soon as the next length of pipe is
placed in position. The open end (socket end) of the pipe shall be kept closed till the next length
is fitted and jointed, to prevent any brick bats or concrete or pieces of wood falling in and
choking the pipe.
The depth of lead from the lip of socket shall be 25 mm minimum. In case of 100 mm dia. 75
mm and 50 mm pipes, the quantity of lead required per joint shall be 1.00 kg, 0.66 kg and 0.50
kg respectively for purpose of reckoning theoretical Consumption.
In order to ensure that required quantity of lead is poured into the joint and to control wastage
of lead, at the beginning, three or four samples shall be made and the quantum of lead per joint
The actual consumption of lead should be within ±5% of the approved sample job subject to
the provision that a variation of ± 20% shall be allowed over the theoretical quantity of lead
due to dimensional tolerances allowed as per Indian Standards. This variation includes
allowances of wastage also.
v) The spigot end shall butt the shoulder of the socket and leave no gap in between. The annular
space between the socket and the spigot will be first well packed in with spun yarn leaving 25
mm from the lip of the socket for the lead. The joint shall then be lead caulked as described in
detail under jointing of S.C.I soil, waste and vent pipes.
13.22 Cast Iron Accessories For in Water Pipes:
13.22.1 C.I. Fittings:
C.I. accessories such as bends of various degrees, heads, offsets of different projections, branches and
shoes shall conform to IS : 1230.
Bends shall be of the nearest standard degree as actually required at site. Heads shall be of the flat
or corner type as required. Offsets shall be of the projection as stipulated in the description of the
item. Branches shall be single or double as described in the item and shall be of the nearest standard
degree as actually required. Standard shoes shall be of over all vertical length, 180 mm for 75 mm
dia., 205 mm for 100 mm dia. and 275 mm for 150 dia. sized pipe from top of socket to lowest tip
of shoe. Shoes of longer lengths if used shall be in lengths 300 mm, 375 mm, 450 mm, or 600 mm
from top of socket to lowest tip of shoe of as actually required at site.
13.22.2 Dimensions: The fittings shall be of the diameter specified in the description of the item. The
thickness of the fittings and details of spigots and sockets shall be same as those of the corresponding
size of straight pipes. The fitting shall be supplied without ears unless otherwise specifically
mentioned in the item. The fittings shall be factory painted with a tar basis composition both inside
and outside which shall be smooth and tenacious. Every fitting shall ring clearly when struck all
over with a light hard hammer. The fittings shall be of standard size and their individual weights
shall conform to the weights given in the Table 17.
Table 17 : Weight of C.I. Rain Water Pipe Fittings

S. Description 75mmdia. 100 mm dia. 150 mm dia. Unit
No. (weight in kg) (weight in kg) (weight in kg)
1 2 3 4 5 6
1. Bends (Plain) 3.20 4.50 9.10 Each
2. Offsets (Plain)
(a) 55 nun projection 2.70 5.00 8.20 Each
(b) 75 mm projection 3.20 5.50 9.10 Each
(c) 115 mm projection 4.10 5.90 9.50 Each
(d) 150 mm projection 4.50 6.40 10.40 Each
(e) 225 mm projection 5.00 7.30 11.80 Each
(fj 300 mm projection 6.00 8.60 12.70 Each
3. Branches (Plain)
Single 5.00 7.30 14.50 Each
Double 6.80 10.00 19.10 Each
4. Standard shoes (Plain) 3.20 4.10 8.60 Each
S. Description 75mmdia. 100 mm dia. 150 mm dia. Unit
No. (weight in kg) (weight in kg) (weight in kg)
1 2 3 4 5 6
5. Longer shoes (Plain)
(a) 300 mm 4.10 5.00 - Each
(b) 75 mm 5.50 5.50 - Each
(c) 450 mm 7.30 6.40 - Each
(d) 600 mm 6.40 8.60 - Each
6. Heads Extras : 6.80 11.30 Each
7. (a) For ears cast on any 0.90 0.90 1.35 Each
fitting and short pipes
(b) For inspection doors 1.80 1.80 2.25 Each
fitted on any fitting
Note:
1. The above table applies only to rainwater fittings which are part of pipelines fixed on wall
face. Permissible tolerance in weight of fittings shall be 5%.
2. For fittings to be used with pipe lines to be embedded in masonry, specifications shall
correspond with those of pipe fittings for soil, waste and vent pipes. For their weights,
specifications under S.C.I. soil, waste and vent pipes may be referred to.
13.22.3 Fixing and Jointing : Fixing and jointing shall be as specified in 13.21.3.
13.22.4 Measurements: The fittings shall be measured by numbers. Where longer shoes are used in
lieu of standard shoes specified in the description of the item, they shall be measured as standard
shoes of 180 mm, 205 mm and 275 mm for 75 mm dia., 100 mm dia. and 150 mm dia. respectively
in number and the extra lengths of the shoes shall be measured and paid for under the corresponding
size of pipes.
13.22.5 Rate: The rate shall include in the case of fittings fixed on the face of wall, the cost of all
materials and labour involved in all the operations described above including jointing but excluding
the supply and fixing the M.S. holder bat clamps in walls and the anchoring concrete. Unless
otherwise specified in the description of the item, the rate shall apply for fittings without access
doors. In the case of fittings forming part of a rain water pipe line embedded in masonry, the rate
shall be for supplying and embedding the fittings in masonry but shall not include for the jointing
and lead caulking which shall be paid for separately.
13.23 Thermal Insulation for Roofing:
13.23.1 With Cellular Concrete:
13.23.1.1 Types and Grades : Cellular concrete is a light weight concrete formed by producing gas
or air bubbles in cement slurry or a cement sand slurry. Cellular concrete shall conform to IS 6598
and shall be of following two types depending on the manner of manufacture.
(i) Type I : High pressure steam cured (auto-claved) materials in the form of precast blocks.
(ii) Type II: Materials cured under natural conditions (that is under ambient pressure and
temperature) by water. The material may be either cast in situ or may be in the form of precast
blocks.
Grades- Each of these two types of the material shall have three grades, namely:
GradeA- Light weight cellular concrete; GradeB-
Medium weight cellular concrete and; GradeC-
Heavy weight cellular concrete. 13.23.1.2
Materials :
(a) Aggregate: A variety of siliceous fines, such as ground quarts sand shale, fly ash and
granulated slag may be used in the manufacture of cellular concrete.
(b) Water and binder shall conform to para 3.1.1 and 3.1.2 of CPWD Specifications 2009.
(c) Gassing Agents: Organic foaming agents based on resin soap, glue, surface active agents, or
finealuminium powder, zinc, dust, calcium carbide, calcium by chloride etc. may be used for
gassing the concrete.
13.23.1.3 Dimensions: The dimensions of the type I and type II precast cellular concrete block shall
be either 50 or 60 cm in length, 20, 25 or 30 cm in width and 7.5, 10, 15, 25 or 40 cm in thickness.
13.23.1.3.1 Tolerance: A tolerance of ±3 percent shall be allowed on width and height and ± 1
percent on thickness.
13.23.1.4 Requirement for Cellular Concrete:
Table- 18
S. Characteristics Grade Grade Grade Test reference
No. A B C
1. Densityin Upto 321 to 400 to IS 5688
kg/cum 320 400 500
2. Crushing Strength
in kg/sq. cm.
(type I) 7.0 12.0 20.0 -do-
(type II) 2.5 4.5 8.0
3. The Thermal
conductivity in
kw/cm° C 0.7 0.85 1.0 IS 3346
at 50° C mean
temperature
4. Capillary absorption not to exceed 20% in case of type I cellular concrete when tested as
per Appendix A of IS 6598.
13.23.1.5 Sampling : In a consignment, cellular concrete of the same type and grade and
manufactured approximately in the same period shall be grouped to form a lot. If it is in the form of
blocks, alot shall be made up of not more than 1000 blocks. If the material is in situ, not more than
10 tons of materials shall constitute alot. If the material is transported in lorries and received as such,
the material in lorry (or vehicle load) & may conveniently be termed as lot.
Each lot shall be tested for all the requirements separately.
If the lot is made up of precast blocks, the number of sample blocks to be tested shall be selected at
random as per the following Table. 19.
Table-19
Lot Size Sample size Permissible No. of defectives
(block to be sampled) (n) (visual and dimensional requirements) (a)
Upto 100 5 0
101 to 300 8 0
301 to 500 13 0
501 to 1000 20 1
13.23.1.6 General: Cellular concrete if done with precast blocks shall be laid on terrace slab after
thoroughly cleaning the surface. The blocks shall be laid over a layer of 12 mm average thick cement
mortar 1:4 (1 cement : 4 coarses and) and the joints shall also be filled properly with neat cement
slurry. The joints shall be staggered. Thickness of joints shall be as minimum as possible and not
more than 5 mm.
13.23.1.7 Measurements : Length and breadth of the roofing insulation shall be measured correct to
a cm and the surface are a worked out in square metre of the finished work. No deduction shall be
made for openings of areas up to 0.40 sqm. No extra payment will be made for any extra material
or labour involved in forming such openings. For openings exceeding 0.40 sqm in area, deduction
for the full opening will be made, but nothing extra will be paid for any extra material or labour
involved in forming such openings.
13.23.1.8 Rate : The rate shall include the cost of all materials and labour required in providing
cellular concrete.
13.23.2 With Resin Bonded Fibre Glass Wool (Bonded mineral Wool):
13.23.2.1 Material: The material shall be mineral wool made from rock slag or glass processed from
a molten state in to fibrous form and shall be bonded with a suitable binder. Bonded mineral wool
shall conform to specifications of group I of IS 8183.
13.23.2.2 Dimensions: The bonded mineral wool shall be supplied in width of 50, 60, 75 and 100
cm, and length of 100, 120 and 140 cm and the thickness of the bonded mineral wool shall be 25,
40, 50, 65 or 75 mm.
13.23.2.3 Tolerances: For width and length, the dimensional tolerances of the bonded mineral wool
slabs shall be - ½%. For nominal thickness in the range 25 to 75 mm the tolerance shall be - 2 mm.
An excess, in all dimensions is permitted.
13.23.2.4 Requirements for Fibre Glass Wool:
Table-20
S. Characteristics Group I Test Reference
No.
1. Bulk density 12 to 15 kg/cum IS 3144
2. Recovery after compression not less than Annex. A
90% of original thickness of IS 8183
3. Shot content max 500 micron-5% IS 3144
250 micron-15%
4. Moisture content and absorption not more than 2% IS 3144
5. Incombustibility Incombustible IS 3144
6. Thermalconductivitydeg.C 0.49 mw/cm° C IS 3346
at mean temperature 50°C
7. Sulphurcontent Not more than 0.6% IS 3144
13.23.2.5 General: Bonded mineral wool insulation can be either laid over false ceiling or
alternatively it can be fixed to the ceiling when the space above false ceiling is being used for
carrying return air. In the first case the bonded mineral wool can either be fixed with suitable
adhesive to the false ceiling board or else it can simply be rolled over the suspended false ceiling. In
the second case when space above false ceiling is to be used for carrying return air 1.5"x1.5" slotted
angle (3" length) shall be fixed to the ceiling by means of Rawl plugs at 2'0" spacing. Draw 14 gauge
tie wires from the slots. Make a mat of mineral wool insulation backed with scrim cloth with a light
coating of Plaster of Paris or polythene faced hessian and 24g x 1" wire mesh netting. The joints of
wire netting should be butted and tightly laced down with G.I.wire. Stretch them at tightly across
the angles holding it in place by means of tie wires.
i) Length and breadth of the roofing insulation shall be measured correct to a cm and the surface
area worked out in squaremetre of the finished work. No deduction shall be made for openings
of are as up to 0.40 sqm. No extra payment will be made for any extra material or labour involved
in forming such openings. For openings exceeding 0.40 sqm. in area, deduction for the full
opening will be made, but no extra will be paid for any extra material or labour involved in
ii) Boarding fixed to curved surfaces in narrow widths shall be measured and paid for separately.
Circular cutting and waste shall be measured and paid for separately in running metre.
13.23.2.7 Rate: The rate shall include the cost of all materials and labour required in providing
bonded mineral wool.
13.23.3 With Expanded Polystyrene:
13.23.3.1 Material: Expanded polystyrene shall conform to IS 4671. It is of two types as given
below:
(a) Type N-Normal
(b) Type SE - It shall be of self-extinguishing type when tested in accordance with Appendix E
of IS 4671.
13.23.3.2 Dimensions: The size of the finished boards shall be 1.0x0.5 m or as specified and
having a thickness of 15, 20, 25, 40, 50, 60, 75 or 100 mm.
13.23.3.2.1 Tolerances: The tolerances on length, width and thickness of the finished board shall
be ± 2 mm.
13.23.3.3 Requirements for Expanded Polystyrene for General Use:
Table : 21
S. Characteristics Requirements Test

No. ements at various nominal apparent Reference
densities in kg/cum
15 20 25 30 35
1. Thermal conductivity
(K.value) (a) at 0° C 0.34 0.32 0.30 0.29 0.28 IS 3346
(b) at 10° C 0.37 0.35 0.33 0.32 0.3
2. Compressive strength at 0.7 0.9 1.1 1.4 1.7 IS 4671
10% deformation in Kg/sq.
Max.
5. Thermal stability Percent 1 1 1 1 IS 4671
Max. (Appendix D)
6. Water absorption less than 0.5% by volume IS 4671
(after 24 hrs. immersion) (Appendix E)
13.23.3.4Sampling:Ina single consignment all theitems of the s sametype, shape and dimensions
belonging to the same batch of manufacture shall be grouped together to constitute got. For the
purpose of judging conformity to the requirements each lot shall be considered separately. The
number of sample items for this purpose shall depend on the size of the lot and shall be in accordance
with col. 1 & 2 of Table given below. The sample shall be taken at random from the lot.
Table-22
No. of items in the lot No. of sample items Permissible number of defective
sample items
1 2 3
Up to 25 3 0
26 to 100 5 0
101 to 300 8 0
301 to 1000 13 0
1001 to 3000 20 1
3001 and above 32 2
All the sample items selected from the lot shall be tested for all requirements of the specifications.
Any item failing in one or more of the requirements shall be regarded as defective.
13.23.3.5 General : Expanded polystyrene can either be fixed with suitable adhesive to the false
ceiling board or else it can simply be rolled over the suspended false ceiling.
13.23.3.6 Measurements : Length and breadth of the roofing insulation shall be measured correct
to a cm and the surface are a worked out in squaremetre of the finished work. No deduction shall be
made for openings of are as up to 0.40 sqm. No extra payment will be made for any extra material
or labour involved in forming such openings. For openings exceeding 0.40 sqm in area deduction
for the full opening will be made, but nothing extra will be paid for any extra materiaL1 labour
involved in forming such openings.
13.23.3.7 Rate :The rate shall include the cost of material and labour inproviding and fixing the
polystyrene boards.
13.23.4 With Exfoliated Vermiculite:
13.23.4.1 Material : Exfoliated vermiculite consists of vermiculite mineral which has been expanded
many times of its original volume after being subjected to high temperature (700° C to 1000° C). It
is utilised as a thermal insulation material after mixing it with a cementitious material.
13.23.4.2 Requirements of Exfoliated Vermiculite for General Use:
13.23.4.2.1 Exfoliated vermiculite in loose fill condition should conform to following:
Table-23
S.No Characteristics Type-I Type-II Type-III Type-IV
1. Density in Wm Min. 56 64 80 96
Max 12 128 144 160
2. Thermal conductivity at mean 0.72 0.72 0.72
0.72 temp. 25 deg. Cinmw/cm°C
3. Guarding : As per following table.
Accumulated % age retained on
sieves having square holes, by wt.
Table-24
Size 9.51 mm 4.76 mm 2.38 mm 1.19 mm 595 mm 297 mm 149 mm
designation
Mm Max Mm Max Min Max Min Max Mm Max Mm Max Min Max
Type-I 0 40 30 90 65 98 85 100 - - - - - -
Type-II - - 0 95 20 80 75 99 90 100 97 100 - -
Type-III - - - - 0 10 20 70 65 95 75 98 90 100
Type-IV - - - - - - 0 5 15 65 60 98 90 100
13.23.4.2.2 Exfoliated vermiculite after being mixed with a cementitious material should conform to
following:
Table-25
S.No. Characteristics Requirements
1. Consistency 35 to 45% or 178 to 229 mm
2. Dry covering capacity in sqm of 100 kg of 34 sqm
material 1 cm thick
3. Compressive strength at 5% deformation 103.5 KN/sqm
4. Liner shrinkage after 24 hrs. at 1800 Deg. 3%

F max.
5. Thermal conductivity max. at mean temperature 1.37 mw/cm° C.
95° C.
13.23.4.3 Sampling & Testing: If any of the test date obtained on the samples tested fail to
conform to the requirements given above, the material shall be rejected.
13.23.4.4 General: Exfoliated vermiculite alongwith cementitious material is mixed with water in
the required proportion (as specified by manufacturers). This mix is to be immediately spread over
the terrace slab in prescribed thickness. No curing need be done. After laying the insulation, the
entire surface shall be cement plastered with cement mortar 1:4 of 20 mm thickness.
i) Length and breadth of the roofing insulation shall be measured correct to a cm and the
surface are a worked out in square metre of the finished work.
ii) No deduction shall be made for openings of areas up to 0.40 sqm. No extra payment will be
made for any extra material or labour involved informing such openings. For openings
exceeding 0.40 sqm in area, deduction for the full opening will be made, but nothing extra will
be paid for any extra material or labour involved informing such openings.
iii) Boarding fixed to curved surfaces in narrow widths shall be measured and paid for
separately. Circular cutting and waste shall be measured and paid for separately in running
metres.
13.23.4.6 Rate : The rate shall include the cost of all materials and labour in providing exfoliated
vermiculite.
13.24 Unplasticised Polyvinyl Chloride Pipes And Fittings:
13.24.1 UPVC Pipes: Pipes shall conform to Type A pipes of IS 13592. The internal and external
surfaces of the pipes shall be smooth and clean and free from grooving and other defects. The end
shall be clearly cut and shall be square with the is of the pipe. The end may be chamfered on the
plain sides. Slight shallow longitudinal grooves or irregularities in the wall thickness shall be
permissible provided the wall thickness remains within the permissible limit.
13.24.2 - Colour of Pipe: Surface colour of the pipes shall be dark shade of grey or as specified.
13.24.3 - Marking: Each pipe shall be clearly and indelibly marked with the following informations
at intervals not more than 3 meter.
(a) Manufacturer's name or trademark.
(b) Nominal outside dia. of pipe.
(c) Type À'
(d) Batch number.
13.24.4 Dimensions:
13.24.4.1 Diameter and Wall Thickness:
i) Mean outside diameter, outside diameter at any point and wall thickness for type A
manufactured plain or with socket shall be as given in Table-lof IS 13592.
ii) UPVC rain water pipes shall be of the dia., specified in the description of the item and shall be
in nominal lengths of 2, 3, 4 or 6 metres either plain or with sliding/grooved socket unless
shorter lengths are required at junctions with fittings. Tolerances on specified length shall be +
10 mm and - 0 mm.
13.24.5 Fixing and Jointing:
i) Pipes shall be either fixed on face of wall or embedded in masonry as required in the
ii) Plain pipes shall be secured to the walls at all joints with PVC Pipes clips by means of 50 x 50
x 50 mm hard wood plugs, screwed with M.S. screws of required length including cutting brick
work and fixing in cement mortar 1:4 (1 cement : 4 coarses and). The clips shall be kep tab out
25 mm clear off finished face of wall, so as to facilitate cleaning of pipes. Pipes shall be fixed
perfectly vertical or to the lines as directed. The pipes shall be fitted to fittings with sealring
conforming to IS 5382 allowing 10 mm gap for thermal expansion.
13.24.6 Installation in Wall/Concrete: The walls/concrete slots should allow for as tress free
installation. Pipes and fittings to be inserted into the slots without a cement base have to be applied
first with a thin coat of PVC solvent cement followed by sprinkling of dry sand (medium size). Allow
it to dry. The process gives a sound base for cement fixation. This process is repeated while joining
PVC material to Cl/AC materials.
13.24.7 Fittings : Fittings used shall be of the same make as that of the PVC pipes Injection moulded
or fabricated by the manufacturer and shall have a minimum wall thickness of 3.2 mm. The fittings
shall be supplied with grooved socketed ends with square grooves and provided with Rubber Gasket
conforming to IS 5382. The plain ends of the fittings should be chamfered. The fittings shall be
joined with the help of Rubber lubricant. The details of fittings refer IS 13592-1992.
13.24.8 Measurements: The fittings shall be measured by numbers. The pipes shall be measured net
when fixed correct to a cm. excluding all fittings along its length.
described above including jointing but excluding the supply and fixing of wall plugs and PVC clips
which shall be paid for separately.
Note: These pipes shall be used only in shaft or unexposed location to avoid damage to these pipes
due to will full act.
LIST OF BUREAU OF INDIAN STANDARDS CODES
Si. No. IS Code Subject
1. I73 Specification for paving Bitumen.
2. 277 Galvanised steel sheets (plainand corrugated)
3 651 Glazed stone ware pipes and fittings
4. 702 Specification for industrial bitumen
5 1121 Transverse Strength of Stone Slab
6 1127 Stone Slabs Tolerance
7. 1199 Methods of sampling and analysis of concrete.
8. 1200(PT.IX) Method of measurements of engineering works:
Part-9 Roof covering.
9. 1200(PTX) Method of measurements of engineering works:
Part-10 ceiling, lining
10 1230 Cast iron rainwater pipes and fitting
11. 1367(PT-13) Supply conditions for steel fasteners pt.13 hot dip galvanized coating
12 2095(PT-1) Gypsum plaster boards (Pt.1) plain Gypsum plaster boards
13. 2115- Code of practice for flat roof finish: mud phuska
14. 2502-1963 Fabrication of Rein forcement for R.C.C.
15. 2633- Method of testing uniformity of coating on zinc coated articles
16. 2645 Specification for integral water proofing for cement mortar
and concrete
17. 2690(Pt-IIII) Specification for Brick Tiles: Pt. I-Burnt Clay , Pt. II- Burnt
Clay Hand Made
18. 3007(PT.1) Code of practice for laying of asbestos cement sheets:
part-1 corrugated sheets
19. 3007(PT.2) Code of practice for laying of A.C sheets part-2 semi-
corrugated sheets
20. 3087 Particle boards of wood and other lignocellulogic materials
(medium density) for general purposes-specifications
21. 3144 Methods of test for mineral wool thermal insulation materials
22. 3346 Method of the determination of thermal conductivity of
insulation materials.
19. 3348 Specification for fibre insulation boards
20. 3384 Specification for bitumen primer for water proofing and damp
proofing.
21. 4082-1977 Storage of Construction Materials at Site
22. 4671 Expanded polystyrene for thermal insulation purposes
23 5382 Specification for rubber sealing rings for gas mains, water
mains and sewers.
24. 5688 Methods of test of block type and pipe covering type thermal
insulations.
25. 6598 Cellular concrete for thermal insulation
26. 7193 Specification for glass fibre base coaltar pitch & bitumen felts
(Amendment I)
27. 8183 Bonded mineral wool
28. 10440-1983 Reinforced Brick Roofing
29. 13592 Unplasticised polyvinylchloride (UPVC) pipes for soil and
Waste discharge system for inside and outside building.
30. 14753 Specifications for Polymethy 1 Methacry late (Acrylic) sheets
31. 14871 Specifications for products in fibre rein forced cement-
Long corrugated or a symmetrical section sheets and fittings
for roofing and cladding.
CHAPTER No. 14
WHITE, COLOUR WASHING PAINTING &

OTHER FINISHES
CHAPTER No. 14 :
WHITE WASHING, COLOUR WASHING, PAINTING AND OTHER FINISHES.
CONTENTS
Clause No. Description Page No.
14.1 White Washing 3

14.2 Colour washing 7
14.3 Distempering 9
14.4 Painting 12
14.5 Varnishing 19
14.6 French Polishing 21
14.7 Wax Polishing 23

14.8 Cement Paint 24
14.9 Priming Coats on Wood , Iron or Plastered Surfaces. 25
14.10 New Painting Materials 27
Appendix À': Characteristics of plaster to paint Finish. 28
Appendix' B': Tests relating to fitness of plaster to painting 28
List of Relevant BIS codes 29
CHAPTER No. 14
WHITE WASHING, COLOUR WASHING, PAINTING AND
OTHER FINISHES.
14.1. White Washing:

14.1.1. Scope:
14.1.1.1. White washing of surfaces of buildings is necessary for both hygienic and aesthetic reasons.
In order to obtain a neat, clean and uniform finish it is necessary to prepare the surfaces, such as,
concrete, masonry or plaster.
14.1.1.2 This specification for white washing lays down the method of preparation of surface and
application of white wash over it and its mode of measurement. White wash may be applied over
unplastered brick-work, stone masonry and all plastered surfaces
14.1.2. Materials:
14.1.2.1. Lime shall conform to Class `C' (fat lime) of IS 712: 1984 and white in colour. Water shall
be clear, free from all organic and suspended impurities; potable water is suitable for this purpose.
Sodium chloride shall conform to IS 253 : 1985 or Grade II of IS 797 : 1982. Ultra marine blue or
indigo shall conform to IS 50 : 1970. ground to fine powder.Gum shall be of a quality approved by
the Engineer in charge.
14.1.3. Preparation of Surface:
14.1.3.1. New Surface: The surface shall be thoroughly cleaned of all dirt, dust, mortar drops and
other foreign matter before whitewash is to be applied. Cement plastered surfaces to be white washed
shall be left slightly rough and smooth finish by steel float shall not be obtained by rendering of pure
cement.
14.1.3.2. Old surfaces:
(a) The surface shall be prepared by brooming down all loose scale, dust, dirt and other foreign
matter or by scraping or by other suitable means to produce a clean surface . If the old surface
is colour washed, colour shall be entirely removed by brooming, steel wire brushing or scraping
or other means before white wash is applied.
(b) Old surface spoiled by smoke soot shall be scraped with steel wire brushes or steel scrapers.
These could also be rubbed with over burnt Surkhi or brick bats (khanjara) , broomed and
washed. Before the white wash, a priming coat of char coal powder mixed in white wash could
be applied for better results. The surface shall be broomed to remove all dust and dirt and shall
be washed with clean water.
(c) Oil and grease spots shall be removed by a suitable chemical and surface rubbed with wire
bruhes.
(d) All unsound portions of surface plaster shall be removed to full depth of plaster in rectangular
patches and plastered again after raking the masonry joints properly. Such portions shall be
wetted and allowed to dry. They shall be given one extra coat of whitewash . All wet surfaces
shall be allowed to dry for 48 hours before application of white wash. All unnecessary nails
shall be removed; and the holes and cracks shall be filled with lime putty or plaster of Paris to
make the surface smooth.
(e) When white washing old surfaces, if surfaces are found to be infected with mould growth, it
shall be treated as below.
Any growth of moulds, moss shall be removed by scraping with steel scraper and ammoniacal
copper solution consisting of 15 g of Copper Carbonate dissolved in 60 ml of liquor ammonia in
500 ml water, shall be applied to the surface and allowed to dry thoroughly before applying
colour wash or white wash. An alternative to ammoniacal copper solution treatment may
consist of 2 percent sodium pentachlorophenate solution in water.
(f) Local areas affected by efflorescence ( caused by the presence of soluble salts in excessive
quantiries in the bricks or mortar) shall be initially treated as described below and then applied
with whitewash or colour wash. Efflorescence will continue as long as there is sufficient water
in the structure backings to carry the soluble salts forward and it is useless to seal the moisture
by paint film on the surface. For removing efflorescence dry brushing appears to be the only
remedy. All types of efflorescence may not be removed by washing with water as it may carry
some salts back into the pores; on redrying efflorescence may be even worse than before if the
salts were still present in the structure. However, some salts in the effloresence can be removed
with repeated washings with water and brushing the face of masonry/plaster.. The treatment of
an old wall with hydrofuge silicone will frequently stop the efflorescence as the liquids block
the passage of moisture. In the case of efflorescence due to rising of salt solutions through
capillary action from sub-soil the only remedy is to provide bitumen or metallic seals in the
walls above ground level so that an effective barrier to capillary action is treated.
(g) Salts from small patches can be extracted by trowelling on the surface , a layer of slaked lime
about 6 mm thick. Which is made up of a stiff paste. This is left in place until dry, and then
removed , and wall brushed down.
(h) Salts from brick work can be removed with a solution of Zinc Sulphate and water. The
surface is brushed off when dry.
(i) A solution of 1 part Hydrochloric acid or Sulphuric acid and 5 parts of water is applied
vigorously with scrubing brushes , water being constantly sprayed on the work with a hose to
prevent penetration of acid. This will remove white or yellow blotches from floor or walls due
to efflorescence.
a) Cleaning of external brick walls after completion of the building can be done with a 5 percent
solution of `Muriatic acid'. The walls must be thoroughly washed with copious flow of clean
water before and after the application of the solution.
(k) A mortar can be made as follows which is water proof and will also be useful in preventing
efflorescence.
One part of Cement, 2 parts of sand to which is added 11.5 kg of Alum per cum of Sand, mix the
three and use adequate water to which is added 325 gm of per 3.5 lit. of water., and thoroughly mixed.
This mortar is applied as plaster.
14.1.4 Protective Measures: Surfaces of doors, windows, floors, articles of furniture, etc, and
such other parts of building not to be whitewashed or colour washed, shall be protected from being
splashed upon. Such surfaces shall be cleaned of whitewash or colour wash splashes, if any.
14.1.5. Scaffolding: Properly sized wooden ballies, bamboos or MS steel pipes shall be used for
scaffolding. Wooden planks to be used shall have minimum thickness of 40 mm. The ballies or
bamboos shall be tied with " moonj" or coconut fibre ropes and not with any metallic wire/ rope etc.
Wherever scaffolding is necessary, it shall be erected on double supports tied together by horizontal
pieces, over which scaffolding planks shall be fixed. No part of scaffolding shall rest against or touch
the surface to be white washed. Scaffolding shall be shod with gunny bags and top and bottom of
ladders be tied with pieces of old gunny bags , to prevent damage or scratches to the walls and floors.
In case of exposed brick work or tile work , double scaffolding having two sets of verticle supports
shall be used and got approved from Engineer-in-Charge in advance. For white washing the ceiling,
external walls etc. proper scaffoldings duly approved by the Engineer, shall be erected.
14.1.6. Preparation of White wash: Whitewash shall be prepared from fat lime conforming to IS
712 : 1984. The lime shall be slaked ( for 24 hours) at site and shall be mixed and stirred with about
5 Lit. of water for 1 kg of unslaked lime to make a thin cream. This shall be allowed to stand for a
period of 24 hours and shall be screened through a clean coarse cloth. Add 10 gm of gum dissolved
in hot water to each kg of unslaked lime. About 1.3 kg of sodium Chloride dissolved in hot water
may be added to every 10 kg of Lime. Small quantity of ultramarine blue (up to 3 g/kg of Lime)
shall also be added to the last two coats of whitewash solution and the whole solution be stirred
thoroughly (see Notes 1 and 2).
Notes:
1. The addition of sodium chloride (common salt) to lime wash helps in quick carbonation of
calcium hydroxie making the coating hard and rub-resistant.
2. For exterior work the white wash that will adhere well to stone and masonry surfaces may also
be prepared by scattering one part by weight of tallow in small lumps over 12 parts of quick
lime, slaking it with only just sufficient water to form a thick paste, stirring occasionally to
assist dispersing the tallow and allowing it to stand until cool. The resultant paste shall then be
let down to thin wash, which is strained through a coarse cloth. If tallow is not obtainable, then
Linseed oil or Castor oil about 10 percent by weight of dry lime may be used. If the oil does
not saponify and incorporate with lime, it should be heated up until the oil disappears. The oil
forms with lime an insoluble soap, which when once dry, will not wash off with heavy rain.
Use of linseed oil is likely to give slight yellow tinge to whitewash.
14.1.7. Application of White Wash: Whitewash shall be applied with Moonj brush or other brush
to the specified number of coats. The operation of each coat shall consist of a vertical stroke of the
brush given from the top downwards, another immediately from the bottom upwards over the first
stroke, and similarly one stroke horizontaly from the right and immediately another from the left
before it dries. Each coat shall be allowed to dry before the next coat is applied. No portion of the
surface shall be left out initially to be patched up later on. The brush shall be dipped in whitewash
pressed lightly against the wall of the container, and then applied lightly pressing against the surface
with full swing of hand.
(a) The ceiling should be white washed prior to the walls.
(b) For new work, a minimum of four coats shall be applied so that the surface presents a smooth
and uniform finish through which the plaster does not show. The finished dry surface shall not
show any signs of cracking and peeling the whitewash shall not come off readily on the hand
when rubbed.
(c) For old work, after the surface has been prepared as in 14.1.3, a coat of whitewash shall be
applied over patches and repairs. Then one or two or more coats of whitewash shall be applied
over the entire surface. The whitewashed surface shall present a uniform finish through which
the plaster patches do not show.
14.1.8. Finish: The surface when dry, shall present a smooth and uniform finish, free from brush
marks and any sign of cracking.
14.1.9.1. White washing shall include preparation of surface other than removal of film over the
entire surface by rubbing, scraping, providing of proper scaffolding and application of white wash
as specified above.
14.1.9.2. Work on old and new surfaces shall be measured separately in square metres, number of
coats applied being specified. Preparation of surface by removal of the film over the entire surface
by rubbing or scraping shall be measured as extra over item of white washing.
14.1.9.3. Unless specified otherwise specified repair works viz. removing of nails and making good
holes, cracks, patches etc. not exceeding 0.1 sq. metre each and not more than 0.5 % of the surface
in total shall be incident to the work of white washing and those exceeding 0.1 sq. metre each shall
be measured in square metre and paid in square metre.
14.1.9.4. Length and breadth shall be measured correct to a cm and area shall be calculated in Sqm.
Correct to two places of decimals. No deduction shall be made for ends of joints, beams, post, for
openings not exceeding 0.5 sq.m. each and no addition shall be made for reveals, joints, soffits,
jambs, sills etc. of these openings.
14.1.9.5. In case of opening exceeding 0.5 sq.m. but not exceeding 3 sq.m. each in area, deduction
shall be made for one face only, when both the faces of wall are treated with the same finish.
In case the faces are treated with different finishes the deduction for opening shall be made from the
finish on the side of frames of doors, windows etc. on which the width of reveal is less than that on
the other side: no deduction shall be made for the opening from other side.
14.1.9.6. For openings exceeding 3 sq.m. each in area deductions shall be made for both the faces of
the opening, and jambs, soffits, sills etc. shall be measured.
14.1.9.7. Corrugated surfaces shall be measured flat as fixed and not girthed. The quantities so
measured shall be increased by the following percentages:-
(i) Corrugated steel sheets 14%.
(ii) A.C. Sheets with large corrugations e.g. big sheets 20%
(iii) A.C. Sheets corrugated e.g. Trafford sheets 10%
14.1.9.8. Cornices and other Mouldings: These shall be girthed and white washing the cornices
and mouldings included with the general white washing.
14.1.9.9 Rate:
i) The rate shall include the cost of all materials and labour involved in all the operations
described above including preparation of surface by scraping, cleaning,scaffolding, etc.
ii) Where the quality of material is different from what is described in the item to get the tinge
required by the Engineer in charge, the difference in quality shall be subject to corresponding
adjustment in the rate for the item.
14.2. Colour Washing :
14.2.1. Scope : Colour washing of surfaces of buildings is necessary for both hygienic and aesthetic
reasons. In order to obtain a neat, clean and uniform finish it is necessary to prepare the surfaces,
such as, concrete, masonry or plaster. This specification for colour washing lays down the method of
preparation and application of colour wash. Colour wash may be applied over unplastered brick
work, stone masonry and all plastered surfaces.
14.2.2. Materials : Lime used shall conform to Class `C' (fat lime) to IS 712: 1984 and white in
colour. Water shall be clear, free from all organic and suspended impurities, potable water is suitable
for this purpose. Sodiumchloride shall conform to IS 253: 1985 or Grade II of IS 797:1982. Ultra
marine blue or indigo shall conform to IS 50 : 1970. Pigments of yellow and red ochre shall conform
to IS 44 : 1991; and pigments of blue vitriol shall be fresh crystals of anhydrous copper sulphate
(blue vitriol) and conform to 1S 261 : 1982 ground to fine powder. Premixed Lime colours as
vailable in the market may also be used.
14.2.3. Preparation of Surface:
14.2.3.1.New Surface: The surface shall be thoroughly cleaned of all dirt, dust, mortar drops and other
foreign matter before whitewash is to be applied.
14.2.3.2 Old surfaces :
(a) Surfaces, where the same colour wash is to be repeated, shall be broomed to remove all dust
and dirt. All loose scales of lime wash and other foreign matter shall also be removed. Where
heavy scaling has taken place the entire surface shall be scraped clean. This will also apply,
where a colour wash has to be given on an already white washed surface.
(b) For surfaces where different colour wash is to be applied, the old colour wash on surfaces shall
be entirely removed before white wash or different colour wash is applied. The surface shall be
prepared by brushing or by scraping or by other suitable means to produce a clean surface and
shall be broomed to remove dust, dirt, etc.
(c) Old surface spoiled by smoke soot shall be scraped with steel wire brushes or steel scrapers. -
The surface shall be broomed to remove all dust and dirt and shall be washed with clean water.
(d) Oil and grease spots shall be removed by a suitable chemical and surfaces rubbed with wire
brushes.
(e) All unsound portions of surface plaster shall be removed to full depth of plaster in rectangular
patches and plastered again after raking the masonry joints properly. Such portions shall be
wetted and allowed to dry. They shall be given one coat of whitewash. All unnecessary nails
shall be removed; and the holes and cracks shall be filled with lime putty or plaster of Paris to
make the surface smooth.
(f) When Colour washing old surfaces, if surfaces are found to be infected with mould growth, it
shall be treated as mentioned in white wash Para No. 14.1.3 (e).
(g) Local area affected by efflorescence shall be treated as mentioned in white wash Para No.
14.1.3 (f).
14.2.4. Preparation of Colour wash :
14.2.4.1. Sufficient quantity of colour wash enough for the complete job shall be prepared in one
operation to avoid any difference in shade. To the basic whitewash solution prepared in accordance
with 14.1.6, mineral colours not affected by Lime shall be added.
14.2.4.1.1. With yellow and Red Ochre : Solid lump, if any, in the powder, shall be crushed to
powder and solution in water prepared and then added to whit wash sieving it through a coarse cloth
mixed evenly and thoroughly to white wash in small quantities, till the required shade is obtained.
14.2.4.1.2. With Vitriol : Fresh crystals of Hydrous Copper sulphate (i.e. Blue Vitriol) shall be
ground to fine powder and dissolved in small quantity of water. Sufficient quantity of solution
enough to produce the colour wash of required shade shall be strained through a clean coarse cloth.
The filtrate being mixed evenly and thoroughly to the white wash.
14.2.4.1.3. Colour wash from other colouring pigments shall be prepared in accordance with the
instructions of the manufacturer.
14.2.5 Application of Colour Wash:
14.2.5.1 The colour wash shall be applied in accordance with the procedure laid down in 14.1.7. For
colour washing on new surfaces and old surfaces requiring a change of colour, after the surface has
been prepared as in 14.2.3, two coats of white wash shall be applied and the subsequent coats
(minimum two) shall be colour wash; the entire surface shall present a smooth and uniform finish.
To start with 0.1 sqm of the prepared surface shall be colour washed with the first coat of white wash
and subsequent coats of colour wash solution in full number of coats and the shade so obtained shall
be examined before the entire work of colour washing is taken up in hand. It shall then be noted that
small areas of colour wash will appear lighter in shade than when the same shades are applied to
larger surfaces. The finished dry surface shall not be powdery and shall not readily come off on the
hand when rubbed.
14.2.6. Priming Coats :
i) On old surfaces requiring a change of colour, two coat of white wash shall be applied before
the application of colour wash.
ii) No priming coat shall be needed for old surface bearing the colour of the same shade or a
good white wash.
14.2.7. Mode of Measurement :
i) The work of colour washing shall be measured in accordance with the rules for white
washing.
ii) The colour washing on new surfaces shall include the coats of white wash (priming coats).
iii) The colour washing on old surfaces shall be exclusive of any coats of white wash, the white
washing done on surfaces requiring a change of colour shall be measured separately.
14.2.8. Rate:
described above including preparation of surface by scraping,cleaning,scaffolding, etc.
14.3 Distempering :
14.3.1. Scope: The specification lays down the method of preparation of the surfaces and
application of distemper
14.3.2. Materials:
14.3.2.1. Distemper : Distemper of required colour and shade shall be obtained ready mixed of an
approved manufacture, conforming to the IS Standards :-
(i) I.S : 427-2005 : Specification for Dry Distemper.
(ii) I.S : 428-2000 : Specification for oil bound washable Distemper :
 Oil Emulsion.
 Plastic (Synthetic Polymer Emulsion based)
The distemper and primer shall be brought by the contractor in sealed tins in sufficient quantities at
a time to suffice for a fortnight's work.
14.3.2.2. Putty for filling holes etc. :
(i) For dry distemper : Whiting mixed with glue.
(ii) For oil bound distemper : Whiting mixed with petrifying liquid.
14.3.3. General :
14.3.3.1 Under no circumstances the distemper dry or oil emulsion should be applied on new cement
of newly plastered walls which have not dried out completely. Adequate time should be allowed for
the structure to dry out. If surface is prematurely sealed, the moisture will force the paint and the
plaster may be prevented from hardening properly.
14.3.3.2. Before the application of oil Bound washable distemper it is recommended to apply one
coat of petrifying liquid. But for alkaline surfaces some alkali resisting primer should be applied but
if the distemper is done after the wall surface is dried completely, distemper prior shall be used.
14.3.3.3. On dry porous surfaces use of a primer is essential to reduce porosity and for plastered
surfaces the primer should be alkali resistance.
14.3.3.4 The distemper can not be applied until the surface of the plaster is finished with Loi or
Sandia or by any other finishing work. The all surface should be finished with smooth finishing coat.
14.3.3.5. If the finishing of the surfaces can not be delayed then the surfaces should generally be
lime or colour washed and in exceptional cases distempered with distemper dry or white broken
whites and creams etc. as the dark shade would definitely be effected and show ugly patches.
14.3.4. Preparation of Dry-Distemper Surfaces.
14.3.4.1. Precautions against Moulds, Fungi, Algae and Lichens : Exterior surfaces of porous
building material liked brick, stone and cement rendering, especially if unpainted, may develop
growths of vegetation ranging from thick beds of moss to slimy streaks or patches of algae. Any such
growth shall be removed and ammoniacal copper solution (See Note) shall be applied to
the surface and allowed to dry thoroughly before painting.
Note :- A recommended composition and concentration of the ammoniacal wash shall consist 7 g of
Copper carbonate dissolved in 8 ml liquor ammonia and diluted one litre with water. Alternatively,
2.5 percent Magnesium silicofluoride solution may be used. To prevent recurrence of mould growth
on repainted surface the following procedure shall be adopted.
a. Remove the source of dampness and dry out the walls.
b. Improve ventilation, if necessary.
c. Remove the infected paint or paper, and
d. Sterilize the surface by applying any antiseptic wash, such as 2 percent Sodium
pentachlorophenate or any other suitable comparable material and allow to dry.
Many special problems regarding mould growth may require individual consideration and expert
advice may be sought when necessary.
14.3.4.2. All necessary nails should be removed. Fitting in plaster shall be made good with plaster of
pans mixed with dry distemper of colour to be used. The surface shall be rubbed down again with a
fine grade sand paper and made smooth. A coat of the distemper shall be applied over the patches.
The surface shall be allowed to dry thoroughly before the regular coat of distemper is allowed.
14.3.4.3. Undecorated surfaces : The surface shall be thoroughly brushed free from dust, dirt, green
mortar dripping and other foreign matter and sand papered smooth. The new plaster surface shall be
allowed to dry for atleast two months before applying distemper.
14.3.4.4. Decorated surfaces : All loose pieces and scales shall be removed by sand papering and
surface shall be cleaned of all green, dust, dirt etc. where heavy scaling has occured, the entire surface
shall be scrapped by means of steel scrapes so as to remove all accumulated distempering leaving
clean surface.
14.3.4.5. New Plastered surfaces : The surface shall be thoroughly cleaned of dust & dirts, green
and any foreign matter, the surface shall be sand papered with graces abrasive paper and dusted off
to achieve an even & smooth surface.
14.3.4.6. Old Surfaces : (Lime or colour wash for application of distemper dry or oil bound) : The
lime and colour wash if in good condition shall only be sand papered down if in bad condition shall be
removed completely by scrapping or rubbing.
14.3.4.7. Old Surfaces (Already distempered with dry distemper and required for application of dry
distempers) : If the old surface is in good or bad condition using simply be lightly sand papered with
fine sand paper and dusted off. The undesirable nails and holes should be filled and fitted with putty
and allowed to dry completely.
14.3.5. Primer Coat : A priming coat of whitening shall be applied over the prepared surface in case
of new work, if so specified no coat of white washing with lime shall be used as a primer coat for
distempering.
14.3.6. Preparation of Dry- Distemper: The dry distemper shall stored slowly in clean warm water
using (0.6 ltr.) of water per kg of distemper or in preparation as specified by the manufactures. It shall
be allowed to stand for atleast 30 minutes before application. The mixture shall be well stored before
and during use to maintain an even consistency. The distemper shall not be mixed in larger quantity
than is actually required for the days work.
14.3.7. Application of Dry Distemper: The application of distemper for the decorated surfaces,
after the primary coat has done, the surface shall be lightly sand papered taking care not to rub out
the priming coat and then dusted off with clean cloth. Prepared distemper shall than be applied in
minimum two coats with proper distemper brushes in horizontal stokes immediately followed by
vertical ones which together shall constituted one coat. The subsequent coats over the preceding one
shall be applied only after the previous coat has dried. For undecorated surfaces, the distemper shall
be applied in one coat or more over the prepared surface in the same manner as for decorated surface.
Distemper should be done in dry climates.
14.3.7.2. The finished surface shall be even and uniform without patches, brush marks, distemper
drops etc. The sufficient quantity of distemper shall be mixed to finish one room at a time. The
application of coat in each room shall be finished in one operation and no work will be started in
any room, which can not be completed the same day.
14.3.7.3. After each days work brushes shall thoroughly be washed in hot water and hang down to
dry, old brushes which are dirty or coated with distemper shall not be used.
14.3.8 Oil Bound Distemper:
14.3.8.1 Preparation of surfaces : The preparation for surfaces will be done as per specification
laid down for dry-distempering. Where unevenness is seen, it shall be made good by applying putty,
made of pans of plaster mixed with water on the entire surface including filling up with undulation
and the papering the same after it is dry.
14.3.8.2 Under the decorated surfaces, already dry distempered and required for applying oil bound
distempering, whether in good or bad condition shall be removed completely by washing even to
the last trace and allowed to dry completely and than sand papered smooth as per para 14.3.4.2.
14.3.9 Primer coat:
14.3.9.1 The Primer Coat, where used as on undecorated surface shall be alkali resistance primer or
distemper as specified in these shall be of the same manufacture as oil bound distemper.
14.3.9.2 If the wall surface plaster has not dried completely, cement primer shall be applied before
distempering the walls. But if distempering is done after the wall surface is dried completely,
distemper primer shall be applied.
14.3.9.3 Oil bound distemper is not recommended to be applied, within six months of the completion
of wall plaster. However, newly plastered surfaces if required to be distempered before a period of six
months shall be given a coat of alkali resistant priming paint conforming to IS : 109 and allowed to
dry for at least 48 hours before distempering is commenced.
14.3.9.4 For old work no primer coat is necessary.
14.3.10 Preparation of Oil-Bound distemper.
14.3.10.1 The distemper shall be diluted with water or any other prescribed thinner is a manner
recommended by the manufactures only sufficient quantity of distemper required for days work shall
be applied.
14.3.10.2 Application of distemper, for undecorated surface after the primer coat has dried for atleast
48 hrs. The surface shall be lightly sand papered to make it smooth for receiving the distemper,
taking care not to rub out the priming coat. All those particles shall be dusted off after
rubbing minimum two coats of distemper shall be applied with brushes in horizontal followed to
immediately by vertical which together shall constitute one coat. The subsequent coats shall be
applied after a time interval of atleast 24 hrs between consecutive coats to permit of the proper drying
of the preceding coat. For decorated surfaces, the distemper shall be applied in one coat or more
over the prepared surface in the same manner as for undecorated surface.
14.3.10.3 The finished surface shall be even and uniform without patches, brush marks, distemper
drops.
14.3.10.4 Sufficient quantity of distemper shall be mixed to finish one room at a time. The
application of a coat in each room shall be finished in one operation and no work shall be started in
any room which can not be completed the same day.
14.3.10.5 15 cm double bristled distemper brushes shall be used. After each day work, brushes will
be thoroughly washed in hot water with soap solution and hand down to dry. Old brushes which are
dirty and caked within distemper shall not be used on the work.
14.3.10.6 Surfaces of doors, windows, floors articles or furniture, etc. and such other parts of the
building shall not be distempered. Oil bound distempered shall be protected from being splashed
upon. Such surface shall be cleaned of distemper splashed, if any.
14.3.11.1 Distempering, shall include preparation of surface, providing of proper scaffolding, and
application of distemper of specified brand and colour, in a manner as specified above.
14.3.11.2 Distempering shall be measured in square metres in accordance with the rules for
measurement of white washing as per Para No. 14.1.9. Number of coats applied excluding the
Priming coat, and type of distemper used being specified.
14.3.11.3 Distemper priming coats required under various treatments as described under 14.3.2. to
14.3.5. shall be measured in square meteres separately, number of coats applied being specified.
14.3.12.Rate:
described above including preparation of surface by scraping,application of priming
coat,cleaning,scaffolding, etc.
required by the Engineer in charge , the difference in quality shall be subject to corresponding
14.4. Painting :
14.4.1. Scope : This Part will deal with painting, namely, oil paint, emulsion paint, cement paint,
synthetic gloss paints, bituminous paints, etc, on masonry, concrete and plaster surfaces (calcareous
surfaces), wooden, metallic.
14.4.2. Materials : Enamel interior and exterior paint shall confirm to IS 143 : 1993 and IS 2933:
1975 and cement paint to IS 5410 : 1992.
14.4.2.2 Ready Mixed Paints : These shall be of approved brand and brought to the site in original
sealed containers. As far as possible the paints used shall be obtained from a manufacturer covered
under I.S.I. certification scheme.
14.4.2.3 Paints Mixed at Site : Oil paints shall be prepared at site if so provided in the contract.
Utmost care shall be taken in preparing the paint which shall be got approved from the Engineer
before actual use.
14.4.2.4. Paint Removers : Paint removers, if approved for use in case of preparing old surfaces,
shall conform to I S: 430-1972.
14.4.2.5. Knotting : Knotting shall be prepared by one of the following methods :-
14.4.2.5.1. Patent Knotting: 125 g. of Shellac conforming to I S: 16-2008 shall be dissolved into
0.5 Litre of Methylated spirit (Denatured sprit ) conforming to I S: 324-1969. 15 g. Red lead is then
added and stirred well.
14.4.2.5.2. Size Knotting : 15 g of Red lead is ground in 2¼ Litre of water. Then 225 g. of glue is
added and heated and the hot solution applied as first coat. Second coat shall consist of red lead
ground in boiled linseed oil and thinned with turpentine oil. For softer types of wood quantity of glue
in first coat shall be increased as desired by the Engineer, and shall be 450 g. for Deodar wood.
14.4.2.6. Stopping : Bee's wax, Resin and Lac (orange in colour) in the proportion of 1:1:16 by
weight shall be melted down together in a suitable pot using slow heat the mix being kept well
stirred. Colouring materials to produce the required shade is added into molten mixture and stirred.
Stopping shall on cooling be rolled into stick forms for use.
14.4.3. Preparation of Surfaces :
14.4.3.1 Calcareous surfaces : General - In painting calcareous surfaces, careful consideration
shall be given to physical and chemical properties of the background and the backing materials which
are strongly alkaline. Concrete, lime and cement plasters are likely to cause alkali attack on paint.
This will have to be clearly distinguished from materials which are neutral or nearly so, as in the
case of calcium sulphate plasters. The characteristics of different calcareous surfaces are described in
Appendix -A.
14.4.3.2 Wood surface :
i) New Wood surfaces : The surface to be painted shall first be dusted off thoroughly to remove
all shavings, foreign matter etc. The surface shall then be rubbed and levelled smooth to fine
surface by using abrasive paper of grade 1 for first rubbing and grade zero for subsequent final
rubbings. The rubbing shall be done with steady reciprocative movement in the direction of
grains of wood.
ii) No scratch of sand paper shall be visible when final rubbing has been completed.
iii) The greasy spot if any still visible shall be removed by rubbing with a piece of clean white
muslin soaked in Benzine or Turpentine allowed to dry and glass papered if necessary.
iv) Knotting :- If the wood surface shows knots, and resinous patches these parts shall be given
two coats of either of the types of Knottings as specified in clause 14.4.2.5 and allowed to dry.
The surface shall then be lightly rubbed smooth with a abrasive paper. Knotting shall be done
before applying the primer.
14.4.33. Old wood work : If the old paint is oily and dirty but is firm and has not disintegrated, it
shall be cleaned down by washing with solution of alkaline soap and water. The surface shall then
be thoroughly rinsed with clean water to remove all soap and rubbed down with abrasive paper of
grade 1 care being taken to see that soap is removed from corner mouldings also. If the old paint film
is flaky, shows cracks, blisters it shall be completely removed by one of the following methods.
(a) By paint Removers : Paint removers of approved brand and quality shall only be used and
manufacturers instructions shall strictly be followed. The surface shall be washed thoroughly
and made smooth by rubbing with abrasive paper grade 1.
(b) Blow Lamp : The old paint shall be removed by burning it off with standard Blow -Lamp,
Playing the Lamp first on mouldings and carvings and then on flat surfaces, the paint being
scrapped off as soon as the film becomes soft. Care shall be taken to keep the blow lamp always
moving and never stationary, so as not to scorch the surface.
(c) By Scraping : The surface shall thoroughly be rubbed down with stiff bristle brushes. It shall
then be sand papered with Abrasive paper grade-I and water, until the paint film is removed
and the resulting surface is smooth .
14.4.3.2. Metal Surfaces:
14.4.3.2.1. New Metal Surfaces : The surfaces before painting shall be cleaned of all rust, scale,
dirt, and other foreign matter sticking to it, by bristle or metal brushes, scrapers, chisels and hammers
or other effective means. Oil and grease shall be removed by washing with petroleum or benzine
and surface allowed to dry.
14.4.3.2.2. Old Metal Surfaces : Where old paint has not deteriorated and is in good condition, the
under lying surface being free from corrosion, the surface shall be rubbed down with sand paper and
other abrasive materials. Oil and grease shall be removed by washing with petroleum, or benzine etc.
Where, complete removal of old paint is necessary, the surface shall be thoroughly cleaned of all old
paint, rust, scales, dirt, etc, by any of the following methods:
(a) Hand Cleaning :- The surface bearing loose paint, rust and mill scales shall be cleaned with
stiff bristle of metal brushes. Heavy layers of rust and scales shall be removed by scrapers and
chipping hammers. The surface shall be rendered smooth by rubbing with abrasive papers.
(b) Flame cleaning :- or to flame cleaning oil, grease or similar adherent matter shall be removed
by washing with suitable solvents and surface shall be allowed to dry. Oxy-acetylene flame shall
be traversed on the surface so as to burn off the old paint and the rust, scales etc. loosened. The
flame shall not be traversed too slow to create high temperature and to fuse the loose scales and
foreign matter to the metal surface. The surface shall then be rubbed with wire brushes and
loose debris and dust removed.
When the metal is still warm (but not hot a coat of suitable primer as specified by the Engineer
shall be applied).
(c) Paint Removers:- Paint Removers as specified in 14.4.2.4. shall be used strictly in accordance
with manufacturer's instructions. The surface shall then be rubbed with wire brushes, abrasive
paper and dusted off.
14.4.3.3. Plastered Surfaces :
14.4.3.3.1. New Plastered Surfaces :
i) In the case of new lime plaster, precautions with regard to the drying of background shall be
observed carefully as these will considerably effect the performance of the finish. In case of new
lime plaster, the essential principles with respect to drying of background will be the following.
ii) If possible lime plaster shall be left unpainted for the first few months so as to allow the
plaster to carbonate, harden and dry thoroughly.
iii) If the plaster has any tendency to craze or crack owing to shrinkage on drying, the movements
shall be allowed to occur before the surface is painted so as to enable provision of suitable
proprietary treatment. Heating the rooms, if accompanied by good ventilation, will assist
drying, but shall be cautiously adopted. Too rapid a drying may damage the plaster by causing
undue shrinkage and separation of the plaster coats.
iv) If there is any objection to leaving the plaster bare, a temporary decoration of soft distemper
may be applied. This may be removed easily at a later date and replaced by a more permanent
decoration. Other types of paint suitable for early application are cement paints, silicate paints
and washable distemper depending on the final decoration in view.
v) If the background of the plaster is one likely to contain large amounts of water, for example,
new brickwork, concrete or building blocks, no attempts shall be made to apply oil paint
(especially gloss finish) until there is every reason to believe that the walls are thoroughly
d'y
Some indication of the progress of drying can be obtained by means of tests described in Appendix
-B.
14.4.3.3.2. Old Surfaces : Old coating which are in bad condition, loose or flaky should be scrapped
off and the surface coated with suitable sealer before applying new paint, Surface previously finished
in water bound or or emulsion paints, if in good condition need not be washed down. But surfaces
finished "Size-Bond" distemper must be thoroughly washed to remove all traces of whiting and size.
The surface shall then be given treatment in similar way specified in under 14.4.3.3.1. above.
14.4.4. Application of Paint :
14.4.4.1General :
The paint shall not be applied on any surface during rain, frost, fog or to inside surface in the
presence of condensed moisture.
The ready mixed paint containers shall be well shaken to disturb settled pigments, and the paint
stirred with a metal rod to mix the settled pigments with the upper layers of paint to uniform
consistency, after which it shall be strained through a muslin cloth.
Paints, mixed at site, shall be prepared in sufficient quantity to cover up the whole work, and
strained through clean muslin cloth before use.
After the priming coat is applied all holes, cracks and joints in the wood shall be stopped with
hard stopping and the surface then rubbed down with abrasive paper grade 1.
Putty around the glass panes of doors, windows etc. shall also be painted without smearing the
glass .
For old surfaces, the number of coats of painting shall be as specified in schedule of quantities
or by the Engineer.
Each coat shall be allowed to dry thoroughly before the subsequent coat is applied. When dry
the surface shall be rubbed lightly with abrasive paper No. 1 & 0, after the priming and under
coats respectively and all dust wiped off with clean cloth.
viii) The work shall not be considered finished unitl an evenly and smoothly finished surface free of
hair marks, paint drops, etc. is achieved and all marks and traces of paint, from adjacent glass,
wood, floors etc. removed.
14.4.4.2. Application of paint with Brushes :
i) Painting brushes shall be checked before the commencement of brushing, for their being
cleaned and free from water, turpentine solvent and previous paints etc.
ii) Brush shall be dipped halfway into the paint container, moved back and forth to stirr the paint
evenly and pressed lightly against the wall of container to wipe off any excess paint, which
shall cause drippings. While brushing, a small portion shall be selected each time and painting
started at the top. proceeding towards bottom. The sequence of painting shall be as to paint,
picture rails first, then window panes, cup boards etc. and doors in the last.
iii) Each coat shall consist of reciprocating movement of brush from left to right followed by a
cross motion, vertical or transverse as the case may be. In case of wooden surfaces brush shall
be first applied in a direction perpendicular to that of the fibre grains and then along the grains.
Each coat shall be applied with a very light hand so as to spread the paint evenly all over the
surface without leaving any brush mark.
14.4.4.3. Application of paint with Spray Guns : The spray gun shall be adjusted to the fan shaped
flow at a correct pressure. The gun shall be coved from left to right parallel to the surface of
application at a distance of 20 to 30 cms. from the surface, and no space shall be left in between the
strokes. The trigger of gun shall be pressed and released at correct time to avoid any overlapping of
paint at the corners and edges,
14.4.5.1. General :
i) Preparatory work such as knotting, stopping and rubbing down, burning off or stripping shall be
described, the number of coats in addition shall be stated. Work on surfaces previously painted
shall be measured separately.
ii) Where special colours or other special finishes are required, it shall be so stated.
iii) Work on different surfaces shall be measured separately classified and included in the item.
(a) Smooth or non-absorbent surfaces such as on Steel & other metals.
(b) Semi-absorbent surfaces, such as wood, fibre board.
(c) Absorbent or rough surfaces, such as brick, stone, concrete, plaster etc.
iv) Painting, except where otherwise stated, shall be given in square metres.
v) No deduction shall be made for openings not exceeding 0.5 Sqm. each and no addition shall be
made for painting on beading, moulding, edges, jambs, soffits, sills etc. of such openings.
vi) Painting upto 10 cm. in width or in girth and not conjunction with similar painted work shall be
given in running metres.
Note:- Components e.g. trusses, compound girders, stanchions, lattices and similar work
shall, however, be given in square metres irrespective of the size of girth of members.
vii) Small articles upto 0.1 sq. m. of painted surfaces, where not in conjunction with similar
painted work, shall be enumerated.
14.4.5.2. Painting on different type of work shall be kept separate and the surfaces to be painted shall
be described, for example ,glazed joinery, weather boarding, roof battens, etc. It shall be stated
whether the measurements are flat or girthed. Alternatively, different surfaces may be grouped into one
general item, areas of uneven surfaces being converted into equivalent plain area in accordance with
Table-I.
Table -1: Equivalent Plain Areas of Uneven Surfaces
S. No. Description of work How Measured Multiplying Factor.
1 2 3 4
(i) Panelled or framed Measured flat (not girthed) 1.30 (for each side)
& braced joinery including chowkhat or frame.
Edges, chocks, cleats etc. shall
be deemed to be included in
the item.
(ii) Ledged and battened or Measured flat (not girthed) 1.30 (for each side)
ledged, battened and including chowkhat or frame.
braced. Edges
(iii) Flush Measured flat (not girthed) 1.20 (for each side)
including chowkhat or frame.
Edges
(iv) Fully glazed or gauzed Measured flat (not girthed) 0.80 (for each side)
including chowkhat or frame.
Edges
(v) Part panelled and Part Measured flat (not girthed) 1 (for each side)
glazed or gauzed. including chowkhat or frame.
Edges
(vi) Fully venetioned or Measured flat (not girthed) Edges 1.80 (for each
louvred. including chowkhat or frame. side)
(vii) Weather boarding. Measured flat (not girthed) 1.20 (for each side)
supporting frame work shall
not be measured separately.
(viii) Wood shingle roofing. Measured flat (not girthed) 1.10 (for each side)
(ix) Boarding with cover fillets Measured flat (not girthed) 1.05 (for each side)
& match boarding
(x) Tile and slate battening Measured flat overall, no 0.80 (for painting all
deduction shall be made for over)
open paces.
(xi) Trellis (or jaffri) work one Measured flat overall, no 2 (for painting all
way or two-way. deduction shall be made for over)
open spaces (Supporting
members shall not be
measured separately).
1 2 3 4
(xii) Guard bars, Balustrades, Measured flat overall, no 1 (for painting all
gratings and railings. deduction shall be made for over)
open spaces (Supporting
members shall not be
measured separately).
(xiii) Gates and open palisade -------------- do 1 (for painting all
fencing including standards, -------------- over)
braces, rails stays etc. (See Note)
(xiv) Carved or entiched work Measured flat 2 (for each side)
(xv) Steel roller shutter Measured flat (size of opening) 1.10 (for each side)
overall, jambs guides,
bottom, rails and locking
arrangments etc. shall be
included in the item (top
cover shall be measured
seperately
(xvi) Plain sheet steel door and Measured flat (not girthed) 1.10 (for each side)
window including framed, edges etc.
(xvii) Fully glazed or gauged Measured flat (not girthed) 0.50 (for each side)
steel door and windows including framed, edges etc.
(xviii) Partly panelled and partly Measured flat (not girthed) 0.80 (for each side)
glazed or gauged doors including framed, edges etc.
(xix) Collapsible gates Measured flat (size of opening) 1.50 (for each side)
Note:- The height shall be taken from the bottom of the lowest rail, if the palisades do not go below
it or form the lower end of palisades, if they project below the lowest rail, up to the top of palisades,
but not up to the top of standards, if they are higher than the palisades.
14.4.53. All other work shall be measured net on all visible painted surfaces:
14.4.5.3.1. When one or more coats are required to be applied to metal work before fixing, this
shall be stated and measured separately from painting applied after fixing.
14.4.5.3.2. Guard bars, balustrades, gates, gratings, grills expanded metal partitions and cages,
railings, steel palisading including standards, braces, rails, stays, etc, shall be measured flat over all
on one side only, when coated on all exposed surfaces. Height of steel palisading shall be measured
as described in the preceding paras regarding wood work.
14.4.5.3.3. Corrugated steel surfaces and Nainital pattern sheet roofs shall be measured flat (not
girthed) and given separately.
Alternatively, the areas of such surfaces (measured flat) may be included with plain surfaces after
increasing the areas by the following percentages:
(a) Corrugated sheets - 14 percent.
(b) Nainital pattern roof using plain sheets - 10 percent.
14.4.5.3.4. Painting on eaves, gutters, rain-water pipes soil and ventilating pipes and steel poles shall
be given in running metres stating the size or girth. fittings such as bends, shoes, branches, heads
etc. shall be included in the length.
14.4.5.3.5. Painting on small articles, such as gate and turn straps, metal ceiling/roses, metal switch
blocks head, and nuts of bolts, articles of builder's hardware and the like when picked out in a
different tint or not in conjunction with similar painted work shall be enumerated.
14.4.5.3.6. Flag staffs, steel chimney's aerial masts (not latticed), water tanks, flood lights, towers, over
head electric masts, spires and the like requiring special scaffolding shall be measured separately
stating the size, height and average girth.
14.4.5.4. The application of wood preservatives shall be given in square metres irrespective of the
girth of size and rules given in 14.4.5.2. shall be followed.
14.4.5.5. Letters, figures and similar itmes shall be enumerated stating the height and form or style,
namely block, italics, etc. stops, commas, hyphens, and the like shall be deemed to be included in
the item.
14.4.6 Precautions: All frunitures, fixtures, glazing, floors etc. shall be protected by covering and
stains, smears, splashings if any shall be removed and any damages done shall be made good by the
contractor at his cost.
14.4.7. Rate:
described above including preparation of surface by scraping,rubbing,application of priming
coat, cleaning, scaffolding, etc.
14.5 Varnishing :
14.5.1. Scope : This specification lays down the method of preparation of woods surfaces and
application of varnish there on.
14.5.2. Materials
14.5.2.1. Varnish :- Approved brand of Ready Mixed varnish conforming to I.S.I. standards shall only
be used. The varnish used shall be suitable for the purpose for which it is used, such as for exterior
or interior use, under ceating or finishing, and shall be clear or tinted, as approved by the Engineer.
The type of exterior Varnish that is type 1 or type 2 shall be as specified in the schedule of quantities
(type 1 refers to synthetic resin varnishes and the type 2 for natural resin varnishes). As per IS 524-
1983.
14.5.2.2. Putty and Stopping :- Same as specified for painting.
14.5.2.3. Glue Size : Thin solution of glue size shall be prepared by covering requisite quantity of
powdered 'Size' put in a pan with cold water . When size becomes soft, boiling water shall be added
and the mass stirred well. A solution containing water about 20 timer the weight of size shall be
suitable.
14.5.3. Preparation of Wood Surfaces:
14.5.3.1. New surfaces :
14.5.3.1.1. The surfaces shall be prepared in accordance with the provisions laid down under
specifications for painting. 80 grit, flint, coated abrasive paper shall be used for final rubbing.The
surfaces shall be frequently dusted off during rubbing.
14.5.3.1.2. Application of Putty : All holes and cracks shall be filled with the putty or stopping
prepared according to clause 14.5.2.2. Putty or stopping used shall be just sufficient to fill the holes
carefully and leave a smooth surface, care being taken to check that the surface around the holes &
Cracks do not get smeared with putty or stopping.
14.5.3.1.3. Filling :- The filling shall be done in accordance with the provisions laid down for french
polishing.
14.5.3.1.4. Sizing
:-
i) After filling the surface shall be given a thin coat of hot glue size solution prepared as specified
in 14.5.2.3. with soft brush. (If wood shows knots and resinous patches Multani mati or Ochre
shall be added to the glue size.) When dry it shall be rubbed down smooth with fine abrasive
paper and the surface again sized with same sizing.
ii) If staining of surface is specified, staining colour shall be mixed with second coat of glue.
iii) The object of application of the glue size is to seal the pores in wood to prevant absorption of
the oil in the varnish.
iv) Glue sizing is inadvisable on floors, table tops and other horizontal surface likely to carry wet
house hold utensils which are likely to distrub the size coatings and thus expose bare wood.
14.5.3.2. Old Surfaces : The provisions laid down under specifications for painting shall be
followed .
14.5.4. Application of Varnish :
14.5.4.1. General : Unless specified otherwise varnishing on new surfaces shall be in two coats (one
under coat and one finishing coat). The work shall be considered finished only when desired fine finish
obtained.
(a) The varnish shall be applied liberally with a full brush and spread evenly with short light stocks
to avoid frothing. If the work is vertical the varnish shall be crossed and recrossed and then laid
off, latter being finished on the upstrokes so that varnish, as it sets, flows down and eliminates
brush marks, the above process will constitute one coat. If the surface is horizontal, varnish
shall be worked in every direction, with light quick strokes and finish in one definite direction
so that it will set without showing brush marks. In handling and applying varnish care should
be taken to avoid forming froth or air bubbles. Brushes and containers shall be kept
scrupulously clean.
(b) Successive coats shall be applied after the previous coat is hard dry.
(c) Each coat except the last shall be lightly rubbed with fine abrasive paper before the next coat
is applied.
(d) The work of varnishing shall be carried in humid conditions.
(e) Surroundings of work shall be kept neat and clean to make dust free atmosphere.
(f) Putty round the glass panes of doors and windows shall also be varnished.
(g) The work after completion shall not be sticky to touch and no brush hair or any other material
shall be allowed adhering to it. It shall not show hair marks or drops on the surface.
(h) The adjacent glass, furniture, floor etc. shall be cleaned of all varnish marks or drops.
14.5.5. Mode of Measurement: The term varnishing shall include cleaning and preparation of
surface, stopping hoes and cracks filling sizing staining, furnishing of approved quality varnish,
application of varnish to the surface and protection of the work. Varnishing shall be measured in
square metres in accordance with the rule for painting wood work.
14.6. French Polishing:
14.6.1. Scope: This specification lays down the method of preparation of wood surfaces and
application of french polish thereon.
14.6.2. Materials :
14.6.2.1. French Polish : Pure shellac conforming to IS :16-2008 varying from pale orange to
lemon yellow colour, free from resin or dirt shall be dissolved in methylated spirit at the rate of 140
gm of shellac to 1 litre of spirit. Suitable pigment shall be added to get the required shade. Ready
made polish conforming to IS : 348-1952 can also be used.
14.6.2.2. Stain :
(a) Water Stain used for staining the wooden surface shall be prepared by mixing fine pumice to
powdered whiting & suitable colouring agent. Small amount of Turpentine oil may be added
to form fine paste. Alternately plaster of pans may be sprinkled on a pad of muslin moistened
with denatured spirit and by rubbing the pad across the grain.
(b) Sprit stain ready made stain apprived by the Engineer shall be used as per manufacturer's
instructions.
14.6.3. Preparation of Surface: The surface shall be cleared of all dirt, dust, laitance etc. The Plane
marks, Scratches, knots and other defects intensified by polishing process. The surface is then sand
papered with Abrasive paper of Grade 2 followed by grade 1, using cork blocks as a backing for
plane surface or rubbing the abrasive paper carefully with pressure of finger. During sand papering
the surface should be dusted frequently to remove dirt, shavings etc.
14.6.3.2. Colouring Staining :
(a) The surface so cleaned shall be stained with either 'Water Stain' or 'Spirit Stain' using suitable
colouring agent. Great care shall be taken so as to achieve the colour stain of the polish as per
sample approved by the Engineer.
(b) The 'Water Stain' Solution shall be applied with Rag or pad soaked in solution and rubbed
uniformly on the surface with a circulating motion on the surface. The surface shall be allowed
to dry and sand papered with Grade 1 abrasive paper, applying uniform pressure. The surface
when smooth shall be dusted with clean muslin cloth to remove all dirt.
14.6.3.3. Surface Oiling :- If so desired to achieve the dark colour of the final
polished surface, the surface so cleared may be wiped with a very light application of linced oil
(Oil should be very sparingly applied as the excess of it may produce defects in the final surface).
14.6.4. Application of Polish :
14.6.4.1. Bodying in :- The surface shall be applied with one or two rather liberal coats of polish
by working the rag or polishing pad across the grains using light pressure only. In the entire polishing
work surface shall not be continuously rubbed in no case must the coat be applied before the previous
one had dried. The surface shall be allowed to dry for about 2 hours.
14.6.4.2. Putty filling :
(a) All nail marks, holes, cracks etc. shall be filled with putty formed by mixing whiting. glue and
colouring agent. Alternately 'hard stopping' as per details in clause 14.4.2.6 may be used.
(b) The putty shall be applied with a straight flat metal edge and the surface made smooth taking
care just to fill the holes and not to smear the surface.
(c) The surface shall on drying be inspected to check up if the absorption has stopped. This is
indicated by the presence of a film of polish on the surface. If the absorption is indicated one
more coat of polish shall be applied and the surface allowed to dry.
(d) When the film of polish has hardened the surface shall be sand papered with zero Grade
abrasive paper to remove small lumps, irregularities, leaving the resultant surface smooth. Any
dirt that may be left behind by glass papering shall be dusted off and a coat of polish applied
in circular motion with light pressure. The polish pad shall be neither dry nor excessively wet.
Allow it to harden for a fairly long time say 12-24 hours.
(e) The surface at this stage should be continuous and free from patches indication that the grain
has been completely filled, if not more coats may be added.
14.6.4.3. Bodying up :
(a) When the previous film has hardened up it shall be glass papered with fine glass paper until a
perfectly mat surface is obtained. To prevent the introduction of scratches, very little pressure
should be applied after which the resulting dust should be carefully cleaned with a soft cloth.
The surface should then be given a light wipe over with Linseed oil applied by a rag, taking
care that only very little oil is used, otherwise the work may be spoiled.
(b) The polishing pad is now brought into use again using circular motion and the polish coat
applied on the surface. The pad should be hardly moist and the movement of the rubber should be
rather slow. The rubber will require a little lubricant to make it work satisfactorily and for this
purpose a drop or two of light linseed oil shall be applied on the sole of the rubber with finger
tips. The rubber shall be kept moving until it finally glides off. Care should be taken that the
surface is not over-rubbed otherwise foundation will be spoiled. No attempt should be made to
produce a brilliant lustre as at this stage we are not polishing but preparing to polish.
Allow the coat to dry, after which two more coats be added allowing time in between. The main
rule at this stage shall be to apply a series of thin coats at proper interval rather than heavy coat.
The number of coats to be applied at this stage would depend upon the condition of the wood, its
texture and general grain. Application of coats shall be continued till a fairly level and consistent
surface is secured which although not brilliant is fairly lustrous.
The surface shall be allowed to harden for 12-24 hours and kept covered with dust sheets. It
shall thereafter be examined and if lumpy or ridged, it shall be rectified.
14.6.4.4. Colour Matching : In order to obtain a uniform colour of the finished surface colour
matching maybe necessary. Dilute polish (Two part of Methylated spirit to one part of polish) to
which colouring media has been added as a corrective shall be applied with soft hair brush in very
light coats to achieve this and the colouring coats fixed with a light coat of transparent polish and
allowed to harden.
14.6.4.5. Spiriting Out :
(a) The film shall be glass papered using the finest grade of Sand paper (or even use sand paper)
with the lightest pressure and the polish pad worked up again using Methylated Spirit only. The
sole of the pad shall be just damp and nothing more as failure to do so may ruin the work. The
pad shall be worked up in the direction of the grains with a reciprocation movements and fairly
quickly, so that the surface is free from smear, rubber marks and other defects and is sufficiently
lustrous.
(b) In case a hard finish is desired, it shall be carried out as per approval of the Engineer-in
charge.
i) French Polishing shall include all preparatory works, bodying in, bodying up and spriting
out with specified polishes and colour staining in the manner and order specified above.
ii) The work shall be measured in square metres in accordance with the rule for painting wood
work. Alternatively the articles shall be described and enumerated.
14.6.6. Rate:
i) The rate shall include the cost of all materials and labour involved in all the perations described
above including preparation of surface by scraping,rubbing,application of priming
coat,cleaning,scaffolding (if required) etc.
14.7. Wax Polishing:
14.7.1 Scope : This specification lays down the method of preparation of wood surfaces and
application of was polish thereon.
14.7.2. Materials :
14.7.2.1. Wax polish shall be prepared from the following materials (mixed in the proportions
specified below) polish or different consistencies are required for different wood. (i) Commercial
Bee's wax, conforming to IS: 1504-1996.
(ll) Oil of Turpentine, conforming to IS: 533-1990.
(a) Preparation of wax polish:- Bee's wax shall be melted by heating it gently. After removing
the wax away from the fire, oil of turpentine shall be mixed and the mixture being well
stirred and allowed to cool down. Care should be taken while heating the wax and while
adding the turpentine as both are highly inflammable.
14.7.3. Preparation of Wood Surfaces: The surfaces shall be prepared as specified for french
polishing except that no grain filling is required generally unless specified in the schedule of
quantities. Grain filling with paste may be required for special work where the grain is particularly
over.
14.7.4. Application of Wax Polish :
14.7.4.1. The polish must first of all be thoroughly worked into the surface of the wood with a piece
of clean and fluffless coarse cotton cloth. The wax polish must be thoroughly rubbed into the surface
by shortish strokes backward and forward while considerable pressure is applied to the cloth piece.
Care should be taken that the wax is applied evenly. After well rubbing in one good coat of wax
polish the work should be covered with a dust proof sheet (cloth for preventing dust falling on the
work) and set aside to dry.
14.7.4.2. More coats may be similarly applied if required till the grain appears top well filled. The
final polish shall be done with clean fluffless soft cloth using long sweeping strokes. A fine surface
with an egg shell gloss should result after continued rubbing.
14.7.5. Mode of Measurement: The work shall be measure in Sqm. accordance with the
provisions laid down for painting. Alternatively the articles shall be described and enumerated.
14.7.6 Rate:
described above including preparation of surface by scraping,application of priming
coat,cleaning, etc.
14.8 Cement Paint :
14.8.1 Material:
i) The cement paint shall be (conforming to IS:5410-1992 ) of approved brand and manufacture.
ii) The cement paint shall be brought to the site of work by the contractor in its original container
in sealed condition. The material shall be brought in at a time in adequate to suffice for the
whole work or at least a fortnight's work.
14.8.2 Preparation of Surface: For New Work, the surface shall be thoroughly cleaned of all mortar
dropping, dirt, dust, algae, grease and other foreign matter by brushing and washing. Pitting in plaster
shall be made good and a coat of water proof cement paint shall be applied over patches after wetting
them thoroughly
14.8.3 Preparation of mix:
i) Cement paint shall be mixed in such quantities as can be used up within an hour of its mixing
as otherwise the mixture will set and thicken, affecting flow and finish, Cement paint shall be
mixed with water in two stages. The first stage shall comprise of 2 parts of cement paint and
one part of water stirred thoroughly and allowed to stand for 5 minutes. Care shall be taken to
add the cement paint gradually to the water and not vice versa. The second stage shall comprise
of adding further one part of water to the mix and stirring thoroughly to obtain a liquid of
workable and uniform consistency. In all cases the manufacturer's instructions shall be
followed meticulously.
ii) The lids of cement paint drums shall be kept tightly closed when not in use, as by exposure to
atmosphere the cement paint rapidly becomes air set due to its hygroscopic qualities.
iii) In case of cement paint brought in gunny bags, once the bag is opened, the contents should be
consumed in full on the day of its opening. If the same is not likely to be consumed in
full, the balance quantity should be transferred and preserved in an airtight container to avoid
its exposure to atmosphere.
14.8.4 Application:
14.8.4.1 The solution shall be applied on the clean and wetted surface with brushes or spraying
machine. The solution shall be kept well stirred during the period of application. It shall be applied
on the surface which is on the shady side of the building so that the direct heat of the sun on the
surface is avoided. The method of application of cement paint shall be as per manufacturer's
specification. The completed surface shall be watered after the day's work
14.8.4.2 The second 'coat shall be applied after the first coat has been set for at least 24 hours. Before
application of the second or subsequent coats, the surface of the previous coat shall not be wetted
14.8.4.3 For new work, the surface shall be treated with three or more coat of water proof cement paint
as found necessary to get a uniform shade
14.8.4.4 For old work, the treatment shall be with one or more coats as found necessary to get a
uniform shade.
14.8.5 Precaution : Water proof cement paint shall not be applied on surfaces already treated with
white wash, colour wash, distemper dry or oil bound, varnishes, paints etc. It shall not be applied on
gypsums, wood and metal surfaces.
If water proof cement paint is required to be applied on existing surfaces previously treated with
white wash, colour wash, etc., the surface shall be thoroughly cleaned by scrapping off all the white
wash, colour wash etc., completely. Thereafter, a coat of cement primer shall be applied followed
by two or more coats of water proof cement paint.
14.8.6 Scaffolding, Measurement & Rate: The specifications in respect of scaffolding, protective
measures, measurements and rate shall be as described under 14.1. The coefficient for cement paint
on RCC Jali shall be the same as provided in Table-1 under Para 14.4.5.2 for painting trellis for Jaffri
work
14.9 Painting Priming Coat on Wood, Iron or Plastered Surfaces:

14.9.1 Primer:
14.9.1.1 The primer for wood work, iron work or plastered surface shall be as specified in the
14.9.1.2 Primer for plaster/ wood work/ Iron & SteeU Aluminium surfaces shall be as specified
below :
Table -2
S. No. Surface Primer to be used
1. Wood work (hard and soft wood) nk mi
2. Resinous wood and plywood Pi c o n f o r n g to IS : 3536-1999
Aluminium primer conforming to IS : 3585-
1966
3. (a) Aluminium and light alloys Zinc chromate primer conforming to IS : 104
(b) Iron, Steel and Galvanized Red Oxide Zinc chromate Primer Conforming
steel to IS : 2074-1992
4. Cement/Concrte/RCC/ brick work, Cement Primer conforming to IS : 109
Plastered surfaces, asbestos
surfaces to receive oil bound
distemper or paint finish
9.1. 3 The primer shallbe ready mixed primer of app brand an d an and man ufacture.
14.9.1.4 Where primer for wood work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, white lead and double boiled Linseed oil in the ratio of 0.7 kg : 0.7 kg : 1 litre.
14.9.1.5 Where primer for steel work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, raw linseed oil and turpentine in the ratio of 2.8 kg : 1 litre: 1 litre.
14.9.1.6 The specifications for the base vehicle and thinner for mixed on site primer shall be as
follows:
(a) White Lead: The White lead shall be pure and free from adulterants li-ke barium sulphate
and whiting. It shall conform to IS : 103-1962.
(b) Red lead: This shall be in powder form and shall be pure and free from adulterants like brick
dust etc. It shall conform to IS : 102-1962.
(c) Raw Linseed Oil: Raw linseed oil shall be lightly viscous but clear and of yellowish colour
with light brown tinge. Its specific gravity at a temperature of 30 degree C shall be between
0.923 and 0.928.
Note: The oil shall be mellow and sweet to the taste with very little smell. The oil shall be of
sufficiently matured quality. Oil turbid or thick, with acid and bitter taste and rancid odour and
which remains sticky for a considerable time shall be rejected. The oil shall conform in all
respects to IS : 75-2010. The oil shall be of approved brand and manufacture.
(d) Double boiled linseed oil: This shall be more viscous than the raw oil, have a deeper colour
and specific gravity between 0.931 and 0.945 at a temperature of 30 degree C. It shall dry with
a glossy surface. It shall conform in all respects to IS : 77-2010. The oil shall be of approved
brand and manufacture.
(e) Turpentine: Mineral turpentine i.e. petroleum distillate which has the same rate of evaporation
as vegetable turpentine (distillate product of oleoresin of conifers) shall be used. It shall have
no grease or other residue when allowed to evaporate. It shall conform to IS : 533-1990.
14.9.1.7 All the above materials shall be of approved manufacture and brought of site in their
original packing in sealed condition
14.9.2 Preparation of Surface:
14.9.2.1 Wooden Surface: The wood work to be painted shall be dry and free from moisture.The
surface shall be thoroughly cleaned. All Unevenness shall be rubbed down smooth with sand paper
and shall be well dusted. Knots, if any shall be covered with preparation of red led made by grinding
red lead in water and mixing with strong glue sized and used hot. Appropriate filler material
conforming to IS : 345 with same shade as paint is applied. After obtaining approval of Engineer-
in-Charge for wood work, the priming coat shall be applied before the wood work is fixed in position.
After the priming is applied the holes and indentation on the surface shall be stopped with glazier's
putty or wood putty see Para No. 14.4.3.2 respectively. Stopping shall not be done before the priming
coat is applied as the wood will absorb the oil in stopping and the latter is therefore liable to crack.
14.9.2.2 Iron & Steel Surface: All rust and scales shall be removed by scrapping or by brushing
with steel wire brushes. Hard skin of oxide formed on the surface of wrought iron during rolling
which becomes loose by rusting, shall be removed. All dust and dirt shall be thoroughly wiped away
from the surface. If the surface is wet, it shall be dried before priming coat is undertaken.
14.9.2.3 Plastered Surface: The surface shall ordinarily not be painted until it has dried completely.
Trial patches of primer shall be laid at intervals and where drying is satisfactory, painting shall then
be taken in hand. Before primer is applied, holes and undulations, shall be filled up with plaster of
pans and rubbed smooth.
14.9.3 Application: The primer shall be applied with brushes, worked well into the surface spread
even and smooth. The painting shall be done by crossing and laying off as described in Para No.
14.4.4.
14.9.4 Treatment on Steel for Aggressive Environment:
14.9.4.1 A second coat of ready mixed red oxide/zinc chromate primer may be applied where
considered necessary in aggressive environment such as near Industrial Establishment and Coastal
regions where the steel members are prone to corrosion. The second coat (which shall be paid for
separately) is to be applied after placing the member in position and just before applying paint. The
second coat of primer is not necessary in case of painting with synthetic enamel paint as it is applied
over an under coat of ordinary paint.
14.9.4.2 The specifications described under 14.4 shall hold good so far as they are applicable.
14.9.5.Measurement:
14.9.6. Rate:
described above including preparation of surface by scraping, cleaning, scaffolding, etc.
ii) Where the quality of material is different from what is described in the item as required by the
Engineer in charge , the difference in quality shall be subject to corresponding adjustment in
the rate for the item.
14.10 - New Painting Materials: Many new painting materials are now available in the market with
different brand names. These can be categorized as internal and external. Most of these are synthetic
epoxy based.
APPENDIX - À'
CHARACTERISTICS OF CALCAREOUS SURFACES WITH REGARD TO PAINT

FINISH A-L CHARACTERISTICS OF LIME PLASTER
a) Lime plasters are highly alkaline and hence, until they are thoroughly dry and matured, they
are likely to cause alkali attack on oil containing paints and distempers and fading of
distempers. The severity of the attack varies with the proportion of soluble alkalis (soda and
potash) in lime used, but it is always wise to take full precautions against alkali attack
irrespective of the type of Lime used.
b) Lime plaster finishes have a moderately high suction. This may be encountered by suitable
adjustment of the priming coat.
c) Lime plaster develops efflorescence less quickly than other plaster finishes.
d) Lime plaster, if improperly gauged and worked, is likely to develop surface crazing. This defect
if present, may be reduced by special treatment to prevent cracks or their positions showing-
in the finished painted surface.
e) Lime plaster, being softer than other plasters, is liable to mechanical damage in certain
solutions. The plaster shall, however, be made to harden more quickly by suitable gauging.
APPENDIX - `B'
TESTS RELATING TO FITNESS OF PLASTER FOR PAINTING
B-1 Test for Alkalinity:
B-1.1 Representative areas of plaster shall be treated with an oil-gloss paint or other alkali-
sensitive paint (tinted with prussian blue) and left for at least a week. If at the end the lime
there is no sign of sponification or bleaching, conditions shall be reasonably safe for
permanent decoration. If on the other hand, bleaching and sponification has occurred, further
small areas shall be treated. This shall be repeated until sample areas remain undamaged.
B-1.2 Alternative Procedure Alkalinity may also be detected by the use of moistened red litmus
paper on the surface. If it turns blue the presence of alkaline background may be inferred.
B-2
Test for Efflorescence:
B-2.1
Small areas of plaster where the efflorescence is most conspicious shall be rubbed down
with a suitable abrasive followed by the application of damp (not wet) cloth and left for at
least one week. This process shall be repeated, if necessary, until no more salts appear.
Conditions shall then be reasonably safe for permanent painting. The test shall be carried
out under conditions of warmth and ventilation approximating those of occupational
conditions.
B-3 Test for Dryness:
B-3.1 It shall be noted that those tests covered in B-1 and B-2 are not sufficient since a plastered
wall may be neutral and show no signs efflorescence and yet be damp which is liable to cause
paint to fail in adhesion. Moisture metre for testing the dryness of walls may be
used in deciding when a surface has reached a condition to receive paint.
However, no form of test may indicate the condition of more than a small area and
since plastered wall seldom dries uniformly, the test shall be repeated at a number
of places. Again it shall be noted that deep seated moisture which is not always
detected by superficial tests may make its presence felt after the surface is painted.
LIST OF RELEVANT BIS CODES
S.No. IS Code No. Description

1 16(P-1&2)-2008 Specification for Handmade & Machine made Shellac
2. 44-1991 Pigments for Red and Yellow ochre
3 75-2010 Linseed oil Raw & Refined
4 77-2010 Double boiled Linseed oil
5 102-1962 Red Lead Primer
6 103-1962 White Lead
7 104-2009- Ready mix paint, brushing, zinc chromate primer
8 109-2009 Ready mix paint, brushing, priming, plaster to Cement Primer
9 143-1993 Synthetic Enamel Interior Paints.
10 253-1985 Sodium Chloride for White wash
11 348-1952 Ready Mixed Polish
12 427-2005 Specifications for Dry Distemper.
13 428-2000 Specifications for Oil Bound washable Distemper.
14 430-2009 Paint Removers Solvent Type flammable ordinary .
15 524-1983 Natural Resin Varnishes
16 533-1990 Turpentine oil
17 797-1982 Sodium Chloride Gr. II
18 1504-1996 Commercial Bee Wax
19 2074-1992 Red oxide Zinc Chromate Primer
20 2993-1975 Synthetic Enamel Exterior Paints
21 3536-1999 Ready mixed Paint, Brushing, Wood Primer
22 3585-1966 Specification for Ready Mixed Paint, Aluminium, Brushing,
Priming, Water Resistant, for Wood work.
23 5410-1992 Cement Paints-Specification.
CHAPTER No. 15
ALUMINIUM & P.V.C. WORK
CHAPTER No.15 : ALUMINIUM WORK & P.V.C. WORK
CONTENTS
15.1 Scope 3
15.2 Terminology 3
15.3 Material 3
15.4 Panelling Material 5
15.5 Aluminium Sheet 8
15.6 EPDM Gaskets 10
15.7 Sealant 10
15.8 Reflective Glass 11
15.9 Door, Window, Ventilator and Partition Frames 12
15.10 Door, Windows and Ventilator Shutters 13
15.11 Fittings 18
15.12 Louvers 19
15.13 Hermetically Sealed Unit 19
15.14 Brass Lock 20
15.15 Handing of Doors And Windows 20
15.16 Designation of Doors And Windows 20
15.17 Aluminium Work for Doors, Windows, Ventilators and Composite Units 21
15.18 General Specification And Tolerances for Aluminium Extrusions 21
15.19 Glazing Sheet, Glass or Frosted Sheet Glass 22
15.20 Removable Fly Screen 22
15.21 Anodizing Coating on Aluminium 23
15.22 Measurement 24
15.23 Rate 24
15.24 Floor Spring(Hydraulically Regulated) 24
15.25 Aluminium Decorative Grills 25
15.26 Providing& Fixing Machine Moulded Anodized Aluminium 26
Covering Over Expansion Joints
15.27 Aluminium Staircase Railings & Baluster 26
15.28 Aluminium Curtains Wall System 27
15.29 Structural Glazing 34
15.30 Aluminium Curtain Wall System Using Aluminium Composite Panel 30
15.31 UPVC Door Frames 35
15.32 PVC Door Shutters 36
15.33 PVC Door Frames 39
15.34 Panelled PVC Door Shutters 39
15.35 Fibre Glass Reinforced Plastic Door Frames 39
15.36 Fibre Glass Reinforced Plastic Shutters 40
15.37 Solid PVC Foam Profile Doors 40
15.38 Solid PVC Foam Profile Shutters 41
15.39 Factory Made Fibre Glass Reinforced Plastic Chajja 42
Illustration 43-64
CHAPTER No. 15
ALUMINIUM WORK AND PVC WORK
15.1 Scope: The specification covers material, fabrication, testing, dimensions and measurements of
use of Aluminum section and PVC materials. Diagrammatic details are placed as figures at page 43
to 65.
15.2 Terminology :
i) Bar: Any solid section, other than round with at least one dimension of 10mm or greater.
ii) Rod: Any round solid section with a diameter of 10mm or greater.
iii) Extruded Round Tube: A circular hollow extrusion of uniform wall thickness not subject
to cold drawing.
iv) Hollow Section: An extruded shape other than round tube, the cross section of which
completely encloses a void and which is not subject to cold drawing.
v) Floor spring (Hydraulically Regulated): A device used to close the door so as to slow down
its speed before it reaches in closed position, here in after called floor spring. Floor spring may
be single action or double action. Single action floor spring close the door in one direction only
whereas double action used to closed the door in both direction.
vi) Shoe : The device fixed to the bottom of the door leaf in order to hoist it to the floor spring.
vii) Top Centre Pivot : The device to secure the upper portion of the door leaf and the door
frame above.
viii) Right Hand Floor Spring: A floor spring suitable for use on an anticlockwise door, an
anticlockwise door is one which when viewed from above, rotates in anticlockwise direction
about its hinge while opening.
ix) Left Hand Floor Spring: The floor spring suitable for use on clockwise door a clockwise
door is one which, when viewed from above, rotates in clockwise direction about its hinge
while opening.
x) Sash: It is a complete window unit whether fixed or open type.
xi) Composite window: Window unit having two or more sashes joined together with one or
more coupling members.
xii) Centre Hung Ventilator: A ventilator horizontally pivoted at the centre on both sides. Top
half opens inwards and bottom half opens outwards.
15.3 Material 15.3.1
Aluminium:
i) Aluminium Sections: Aluminium sections used for fixed/openable windows, ventilators,
partitions, frame work & doors etc. shall be suitable for use to meet architectural designs to
relevant works and shall be subject to approval of the Engineer-in-Charge for technical,
structural, functional and visual considerations. The aluminium extruded sections shall conform
to IS:733-1983(Reaffirmed 2006) and IS:1285-2002(Reaffirmed 2013) for chemical
composition and mechanical properties. The stainless steel screws shall be of grade AISI 304.
The permissible dimensional tolerances of the extruded sections shall be as per IS:6477-1983
(Reaffirmed 2010) and shall be such as not to impair the proper and smooth
functioning/operation and appearance of door and windows.
Aluminium glazed doors, windows etc. shall be of sizes, sections and details as shown in the
drawings. The details shown in the drawings may be varied slightly to suit the standards
adopted by the manufacturers of the aluminium work, with the approval of Engineer-in-Charge.
Before proceeding with any fabrication work, the contractor shall prepare and submit, complete
fabrication and installation drawings for each type of glazing doors, windows, ventilators and
partition etc. for the approval of the Engineer-in-Charge. If the sections are varied, the
contractor shall obtain prior approval of Engineer-in- Charge and nothing extra shall be paid
on this account.
ii) Anodizing: Standard aluminium extrusion sections are manufactured in various sizes and
shapes in wide range of solid and hollow profiles with different functional shapes for
architectural, structural glazing, curtain walls, doors, window & ventilators and various other
purposes. The anodizing of these products is required to be done before the fabrication work
by anodizing/electro coating plants which ensures uniform coating in uniform colour and
shades. The extrusions are anodized up to 30 micron in different colour. The anodized
extrusions are tested regularly under strict quality control adhering to Indian Standard.
iii) Powder Coating:
a) Material: The powder used for powder coating shall be Epoxy Standard aluminium
extrusion sections are manufactured in various sizes and shapes in wide range of solid
and hollow profiles with different functional shapes for architectural, structural glazing,
curtain walls, doors, window & ventilators and various other purposes. The anodizing of
these products is required to be done before the fabrication work by anodizing/electro
coating plants which ensures uniform coating in uniform colour and shades. Anodizing
is electro coating of different colour like silver, champagne, bronze, black, white etc to
aluminium products. The extrusion are anodized up to 30 micron thickness in above
colour. The anodized extrusions are tested regularly under strict quality control adhering
to Indian Standard. Polyester powder of make approved by the Engineer-in-Charge. The
contractor shall give detailed programme for powder coating in advance, to facilitate the
inspection by Engineer-in-Charge or his authorized representative.
b) Pre-treatment: Each aluminium alloy extrusion or performed section shall be

thoroughly cleaned by alkaline or acidic solutions under the conditions specified by
chemical conversion coating supplier and then rinsed. A chemical conversion coating
shall be applied by treatment with a solution containing essentially chromate ions or
chromate and phosphate ions as the active components as applicable. The amount of the
conversion coating deposited depends on the type used by the conversion coating
chemical supplier. The conversion coating shall be thoroughly
rinsed either with the solution specified by the conversion coating chemical supplier or
with de-mineralized water and then dried at the temperature for the time specified by the
conversion coating chemical supplier. The contractor shall submit the detail specifications
and application procedure for application of conversion coating for approval of Engineer-
in-Charge. The metal surface after the conversion coating pretreatment and prior to the
application of the coating shall be free from dust or powdery deposits.
c) Process: The polyester powder shall be applied by electrostatic powder spray method.
Before start of powder coating the contractor shall submit detail specification for
application of polyester powder from manufacturer of the polyester powder for approval
of Engineer-in-Charge. The powder coating shall be applied as per the specification
approved by Engineer-in-Charge.
d) Thickness: The thickness of the finished polyester powder coating measured by micron
meter shall not be less than 50 micron nor more than 120 micron at any point.
e) Performance Requirements for the Finish:
(ei) Surface appearance: The finish on significant surfaces shall show no scratches when
illuminated and is examined at an oblique angle, no blisters, craters, pinholes or scratches
shall be visible from a distance of about 1 m. There shall not be any visible variation in
the colour of finished surfaces of different sections and between the colours of different
surfaces of same section.
(e ii) Adhesion: When a coated test piece is tested using a spacing of 2 mm between each of
the six parallel cuts (the cut is made through the full depth of powder coating so that
metal surface is visible) and a piece of adhesive tape, approximately 25 mm x 150 mm
approved by the Engineer-in-Charge is applied firmly to the cut area and then removed
rapidly by pulling at right angles to the test area, no pieces of the finish other than debris
from the cutting operation shall be removed from the surface of the finish.
iv) Protection of Powder Coated / Anodizing Finish : It is mandatory that all aluminium
members shall be wrapped with self adhesive non-staining PVC tape, approved by Engineer-
in-Charge.
v) Measurement: All the aluminium sections including snap beading fixed in place shall be
measured in running meter along the outer periphery of composite section correct to a
millimeter. The weight calculated on the basis of actual average (average of five samples)
weight of composite section in kilogram correct to the second place of decimal shall be taken
for payment. (Weight shall be taken after anodizing). The weight of cleat shall be added for
payment. Neither any deduction nor anything extra shall be paid for skew cuts.
vi) Rate: The rate shall include the cost of all the materials, labours involved in all the
operations as described in nomenclature of item and particular specification.
15.4 Panelling Material :
15.4.1 Pre-laminated Particle Board
A particles board laminated on both surfaces by synthetic resin impregnated base papers under
heat and pressure. Pre-laminated particle boards shall be of two grades, namely, Grade
I and II corresponding to each of the grades specified shall be of four types, namely, Types-
I, II, III, and IV classified by the surface abrasion characteristics specified in Table 1. The grade
and types of pre-laminated particle board shall be represented by symbols as follows:
Grade Type Designation

Grade I Type I PLB-11
Type II PLB-12
Type III PLB-13
Type IV PLB-14
Grade II Type I PLB-21
Type II PLB-22
Type III PLB-23
Type IV PLB-24
Table-1: Physical and Mechanical Properties

Si. Properties Flat Pressed Three Layer,
No. Multilayer and Graded
Grade-I Grade-II
(i) Density variation (Max.) Percent ± 10 ± 10
(ii) Water absorption (Max )
(a) 2 bows 7.0 15.0
(b) 24 hours 15.0 30.0
(iii) Thickness swelling (Max.), percent, 2 hours 5.0 8.0
(iv) Modulus of rupture (Min) N/mm2
(a) Up to 20 mm thickness 15.0 11.0
(v) Tensile strength perpendicular to surface (Min.)
N/m2
(a) Up to 20 mm thickness 0.45 0.3
(vi) Tensile strength perpendicular to surface (Min.)
N/mm2
(a) After cyclic test* 0.2 -
(b) After accelerated water resistance test** 0.15 -
(vii) Screw withdrawal strength (Min.), N:
(a) Face 1250 1250
(b) Edge 850 750
(viii) Abrasion resistance in number of revolutions
(a) Type I 450 450
(b) Type II 250 250
(c) Type III 80 80
Specifications 2014 PVC Work Page 6 of 65
umini
* Cyclic Test : Specimen are immersed in water at 27±2° C for a period of 72 hours, followed by
drying in air at 27 ± 2° C for 24 hours and then heating in dry air at 700 C for 72 hours. Three
such cycles are to be followed and then specimens are tested for tensile strength perpendicular
to the surface.
** Accelerated Water Resistance Test: Specimens are immersed in water at 27±2 0 C and water is
brought to boiling and kept at boiling temperature for two hours. Specimens are then cooled in
water to 27±2° C and tested for tensile strength perpendicular to the surface.
15.4.2 Particle Board: Synthetic resin bonded flat pressed three layers, multilayer and graded
particle board defined in IS 3087-2005(Reaffirmed 2010) having superfine surface shall be used for
production of prelaminated particle board. For ECO Marks the particle board shall also conform to
the requirements of ECO Mark specified in IS: 3087-2005(Reaffirmed 2010).
15.4.3 Impregnated Base Paper: Printed or plain coloured absorbent base paper having a weight of
60-140 g/m2 impregnated in a suitable synthetic resin and dried to a volatile content of 4-8 per cent
shall be used for pre-lamination on both surfaces of particle board.
15.4.4 Impregnated Overlay: An absorbent tissue, paper having a weight of 18-40 g/m2
impregnated in a suitable synthetic resin and dried to a volatile content of 4-8 per cent shall be used
for the manufacture of pre-laminated particle board.
15.4.5 Manufacture: Particle boards having superfine and closed surface with high face strength
and steep density gradient across the thickness is used for making prelaminated particle boards.
Impregnated base papers rich in a synthetic resin are placed on either side of the particle board and
the assembly is taken inside a short cycle single opening lamination press or a multi day light press.
Under heat and pressure the resin flows and forms a permanent bond with particle board.
The top surface of impregnated paper comes in contact with special surface chromium plates or steel
caulk plates and takes the impression of surface finish of these cauls. Hot boards are extracted out of
the short cycle press and cooled in air, whereas cooling of boards is done inside the dress in multiday
light type. Care should be taken to keep cycle times low in the press to avoid heat penetration to the
centre of the boar edge.
The impregnated overlay paper may be used by placing it over the impregnated base paper (IBP) on
one surface while using a normal IBP on the other surface and pressure. The impregnated overlay
becomes transparent after pressing. Such boards are used for high surface abrasion application.
In case of finished foil particle boards, the finished foil is pasted on both surfaces of particle board
after spreading suitable synthetic glue on board's surface and passing the assembly in a roller press
or a flat press under the influence of pressure and/or heat depending on the type of binder used.
15.4.6 Finish: The finish of the paper overlaid board depends on the surface of caulk plates used.
Common surface finishes in use are glossy, matt textured (soft, Swede, wood pore and leather), etc.
The surface finish of the foil finished boards depends on the original finish of the foil used.
15.4.7 Dimensions and Tolerances: Dimensions and tolerances shall conform to IS:12049-1987.
15.4.8 Testing: One sample for every 100 sqm. or part thereof shall be taken and testing done as
per IS:12823-1990(Reaffirmed 2009).For quantity less than 100 sqm, the test certificate from
manufacturer shall be relied upon. The Engineer-in-charge may ask for testing even if the quantity is
less than 100 sqm.
15.5 Aluminium Sheet:
15.5.1 Aluminium Sheets for use as panels shall be 1.25 mm thick aluminium alloy sheet conforming
to IS:737-2008(Reaffirmed 2013). Aluminium alloy sheet for use in general paneling work shall be of
types and thickness as specified and conforming to the requirement of IS:737-2008(Reaffirmed
2013). Aluminium sheets shall be of approved make and manufacturer. Aluminium panel may be
prefabricated units manufactured on modular or non-modular dimension.
15.5.2 Fixing: The required size of panel, keeping sufficient margin to be inserted inside the section,
shall be cut to correct size and fixed firmly in the frame with CP brass or aluminium or stainless
steel screws of star headed, counter sunk and matching size groove. Joints sealed with epoxy resin
or silicon sealant to make the unit water proof.
15.5.3 Float Glass:
i) The glass shall be clear float glass and should be approved by the Engineer in Charge. It shall
be clear, float transparent and free from cracks subject to allowable defects. The float glass
shall conform to the IS: 14900-2000 (Reaffirmed 2010).
ii) Thickness : The thickness of float glass shall depend on the size of panel. The tolerance in
thickness shall be as under:
Table-2
Nominal Thickness (in mm) Tolerance (in mm)
4.0 ± 0.3
5.0 ± 0.3
6.0 ± 0.3
8.0 ± 0.6
iii) Allowable Defects: The allowable defects shall be as per Table 3 below:
Table-3
S1.No. Defects Central Outer Remarks
1. Gaseous inclusion. Max 3.0 6.0 Separated by at least 30.0 cm
size, mm
2. Opaque gaseous inclusion. 3.0 6.0 Separated by at least 60.0 cm
Max. size. mm
3. Knots, dirt and stones, 1.0 1.0 Separated by at least 30.0 cm
Max. size. mm
4. Scratches, Rubs and Crush Faint Light Separated by at least 30.0 cm
5. Bow, percent. Max 0.5 0.5 See 15.5.3(iv) c
6. Reams, Strings and lines Light Light See 15.5.3(iv) d
7. Waviness Nil Nil See 15.5.3(iv) e
8. Sulphur stains Nil Nil
9. Corner breakage and chip Not more than
nominal thickness
of float glass
Specifications 2014 um & Work Page 8 of 65 PVC
iii) Allowable Cluster of Defects: The allowable cluster of defects mentioned under S1. No. 1,
2 & 3 of Table 3 shall be as per IS:14900-2000 (Reaffirmed 2010).
iv) Tests:
a) Thickness: The thickness of float glass shall be measured with micrometers or a caliper
which is graduated to 0.01 mm or with a measuring instrument having an equivalent
capacity.
b) Scratches, Rubs and Crush : Place the sample of float glass in a vertical position
approximately 50 cm from the viewer's position and look through it using either day light
without direct sunlight or a background light suitable for observing each type of defect.
Intensity of Scratches, Rubs, Crush Intensity Distance Limit
Faint Shall not be detectable beyond 50 cm
Light Detectable between 50-100 cm and not
beyond 100 cm.
c) Bow : Depending on the side on which bow is present, stand the sample vertically on a
wooden plank. Stretch a thread edge to edge. Measure the longest perpendicular.
Distance from the thread to the surface of float glass facing the thread and express it as
percentage of the length of float glass from edge along the thread.
d) Reams, Strings and Lines : Focus a light projector with a 500 W lamp and an objective
lens with an approximate 5 cm aperture and about 30 cm focal length on a flat white
projection screen placed about 760 cm from the light source in a dark room. Place the
float glass in a vertical position parallel to the screen between the light and the screen.
Move the glass slowly towards the screen with a vertical oscillating motion. The shadow
graph read out is the distance at which the distortion just blends with the general shadow
of the glass on the screen.
Table-4
Intensity of Reams, Strings and Lines Intensity Distance Limit
Light 7.5 cm
Medium 5.0 cm
Heavy 2.5 cm
e)Perspective Distort Distortion: When tested sted as per test procedure described bed below it shall
not give distorted vision of straight stripe pattern.
i) Test Procedure for Perspective Distortion
Perspective distortion shall be examined by looking through the specimen glass
which may be placed at about 4.5 m distance in such a direction that the incident
angle to it is 50 degree (4 mm or above) and by observing a screen set up
perpendicularly to the line of vision about 4.5 m further ahead of the specimen over
the total width of about middle part of the specimen from the horizontal direction.
The specimen glass shall be kept with the drawn direction at manufacture vertical and, on the
surface of the screen, the strip pattern of white and black parallel
straight lines of 25 mm width and inclined 45 degrees from the vertical shall be
provided and its surface shall be luster less.
15.6 EPDM - Gaskets:
The EPDM Gaskets shall be of size and profile as shown in drawings and as called for, to render the
glazing, doors, windows, ventilators etc. air and water tight. Samples of gaskets shall be submitted
for approval and the EPDM gasket approved by Engineer-in-Charge shall only be used. The
contractor shall submit documentary proof of using the above material in the work to the entire
satisfaction of Engineer-in-Charge.
The EPDM gasket shall meet the requirements as given in Table 5 below:
Table -5
S1. No. Description Standard Followed Specification

1. Tensile strength kg f/cm2 ASTM-D 412 70 Min.
2. Elongation at break % ASTM-D 412 250 Min.
3. Modulus 100% kg f/cm2 ASTM-D 412 22 Min.
4. Compression set % at 0° CC 22 Hrs. ASTM-D 395 50 Max.
5. Ozone resistance ASTM-D 1149 No visible cracks
15. 15.7 Se Sealant : i) The sealants of approved grade and colour shall only be used. The silicone for perimeter
joints (between Aluminium section and RCC/Stone masonry) shall be of make approved by
the Engineer in Charge.
ii) Method of Application:
a) Surface Preparation : Clean all joints and glazing pockets by removing all foreign
matter and contaminants such as grease, oil, dust, water, frost, surface dirt, old sealants or
glazing compounds and protective coatings.
b) Masking: Areas adjacent to joints shall be masked to ensure neat sealant lines. Masking
tape shall not be allowed to touch clean surfaces to which the silicone sealant is to adhere.
Tooling shall be completed in one continuous stroke immediately after sealant application
and before a skin forms and masking shall be removed immediately after tooling.
iii) Application: Install backer rod of appropriate size and apply silicone sealant in a continuous
operation using a positive pressure adequate to properly fill and seal the joint. The silicone
sealant shall be tooled with light pressure to spread the sealant against backing material and the
joint surfaces before a skin forms. A tool with convex profile shall be used to keep the sealant
within the joint. Soap or water shall not be used as a tooling aid. Remove masking tape as soon
as silicone joint is tooled.
iv) Tolerance: A tolerance of + 3 mm shall be allowed in the width of silicone joints. The depth
of the joints at throat shall not be less than 6 mm.
15.8 Reflective Glass:
15.8.1 Definitions:
(i) Shading Coefficient: The shading coefficient is the ratio of total solar transmittance to the
transmittance through 3.2 mm (1/8") clear glass. Windows with low shading coefficient values
improve comfort for building, lower the total cooling load of the building and help smooth out
of the difference in cooling loads between perimeter & core zones.
(ii) Luminous Efficacy Constant (Ke) indicates a windows relative performance in rejecting solar
heat-while transmitting day light. It is the ratio of the visible transmittance to the shading
coefficient; clear glass which lets in roughly equal amounts of visible light and solar near-
infrared energy has a Ke close to 1.0. The solar radiation contains about 50% invisible near-
infrared & ultra violet light. Therefore, a perfectly selective glazing, which would all allow
visible light pass through while blocking all of the invisible near-infrared & ultraviolet light,
would have Ke of about 2.0.
(iii) Resistance to Heat Conduction (R-valve): It is a measure of resistance to heat flow that occurs
because of temperature difference between the two sides of the windows. The inverse of R-value
is termed as U-value.
15.8.2 Reflective Glass : This is an ordinary float glass with a metallic coat to reduce solar heat.
Clear glass transmits most of the sunlight that shines upon it, and most of the solar heat as well; the
metallic coated glass i.e. reflective glass has better shading coefficients because they reflect rather
than absorb infrared energy. However, most of reflective glazing blocks day light more than solar
heat.
15.8.2.1 Types of Coatings: There are two types of reflective glass, Pyrlotic (Hard) coated and
vacuum (soft) coated.
(i) Pyroltic : It is a coating applied during glass manufacture. The coating is fused into the glass
at 1200°C.
(ii) Vacuum Coated Glass: It involves the deposition of metal particles on the glass surface by a
chain reaction in a vacuum vessel. It is often called a soft coat; because the coating is more
susceptible to damage than hard coat glass. Where toughening of product is required, the
product must be toughened first & then vacuum coated. Vacuum coated products have better
shading coefficient values than pyroltic products.
15.8.2.2 Performance of Reflective Glass: The performance of reflective glass 6 mm of nominal
thickness is given below:
S1.No. Parameter Threshold Ratio In % age
1. Visible Light
- Transmittance (%) 15-46
- Reflectance (%) 12-24
2. Total Solar Energy:
- Reflectance (%) 8-12
3. Ultra Violet Rays:
4. U-Value
- Summer 0.58
- Winter 0.45
5. Shading Coefficient 0.25-0.35
umini
Rajasthan P W D Building Specifications 2014 Chapter 15 : Al um & PVC Work Page 11 of 65
15.8.2.3 Testing: The reflective glass shall be tested for the followings:
(i) PhysicaUField Test: In a true reflective glass, when a pointed pencil is placed, then tip of
pencil (physical) & image should coincide.
(ii) Lab. Test: In the lab, the reflective glass shall be tested for the parameters specified in
15.8.2.2 above.
15.8.2.4 Fixing: Fixing of glass shall be done as specified.
15.9 Door, Window, Ventilator and Partition Frames:
15.9.1 Fabrication or Frame Work:
i) First of all the shop drawings for each type of doors/windows/ventilators etc. shall be prepared
by using suitable sections based on architectural drawings, adequate to meet the requirement/
specifications and by taking into consideration varying profiles of aluminium sections being
extruded by approved manufacturers. The shop drawings shall show full size sections of glazed
doors, windows, ventilators etc. The shop drawings shall also show the details of fittings and
joints. Before start of the work, all the shop drawings shall be got approved from the Engineer-
in-Charge.
ii) Actual measurement of openings left at site for different type of door/window etc. shall be
taken. The fabrication of the individual door/windows/ventilators etc. shall be done as per the
actual sizes of the opening left at site. The frames shall be truly rectangular and flat with regular
shape corners fabricated to true right angles. The frames shall be fabricated out of section which
have been cut to length, mitered and jointed mechanically using appropriate machines. Mitered
joints shall be corner crimped or fixed with self tapping stainless steel screws using extruded
aluminium cleats of required length and profile. All aluminium work shall provide for replacing
damaged/broken glass panes without having to remove or damage any member of exterior
finishing material.
15.9.2 Fixing of Frames:
i) The holes in concrete/masonry/wood/any other members for fixing anchor bolts/fasteners/ screws
shall be drilled with an appropriate electric drill. Windows/doors/ventilators etc. shall be placed
in correct final position in the opening and fixed to Sal wood backing using stainless steel
screws of star headed, counter sunk and matching size groove. of required size at spacing not
more than 250 mm c/c or dash fastener. All joints shall be sealed with approved silicone
sealants.
ii) In the case of composite windows and doors, the different units are to be assembled first. The
assembled composite units shall be checked for line, level and plumb before final fixing is
done. Engineer-in-Charge in his sole discretion may allow the units to be assembled in their
final location if the situation so warrants. Snap beadings and EPDM gasket shall be fixed as
per the detail shown in the shop drawings.
iii) Where aluminium comes into contact with stone masonry, brick work, concrete, plaster or
dissimilar metal, it shall be coated with an approved insulation lacquer, paint or plastic tape to
ensure that electrochemical corrosion is avoided. Insulation material shall be trimmed off to a
clean flush line on completion.
iv) The contractor shall be responsible for the doors, windows etc. being set straight, plumb,
level and for their satisfactory operation after fixing is complete.
Unit Size of Unit (Example) Size of Manufactured Unit
(mm) (Example) (mm)
Door 1050 x 2100 1025 x 2087.5
Window 1800 x 1350 1775 x 1325
Ventilator 900 x 600 875 x 575
15.9.3 Measurements: All the aluminium sections including snap beadings fixed in place shall be
measured in running meter along the outer periphery of composite section correct to a millimeter.
The weight calculated on the basis of actual average (average of five samples) weight of composite
section in kilogram correct to the second place of decimal shall be taken for payment (weight shall be
taken after anodizing). The weight of cleat shall be added for payment. Neither any deduction nor
anything extra shall be paid for skew cuts.
15.9.4 Rate: The rate shall include the cost of all the materials, labour involved in all the operations
as described in nomenclature of item and particular specification.
15.10 Door, Windows and Ventilator Shutters : Material, fabrication and dimensions of
aluminium doors, windows and ventilators manufactured from extruded aluminium alloy sections of
standard sizes and designs complete with fittings, ready for being fixed into the building shall be as
per IS 1948-1961(Reaffirmed 2011).
15.10.1 Terminology: The components of doors, windows and ventilators shall be detailed as in
Figures.
15.10.2 Standard Sizes, Tolerances and Designations:
The types and the overall sizes of Aluminium doors, windows and ventilators shall be as given in
Figures. Their sizes are derived after allowing 1.25 mm clearances on all the four sides for the
purpose of fitting the doors, windows and ventilators into modular openings.
15.10.3 Tolerances: The sizes for doors, windows and ventilators frames shall not vary by more
than ±1.5 mm.
15.10.4 Material: Aluminium alloy extruded sections used in the manufacture of extruded window
sections shall conform to IS:733-1983(Reaffirmed 2006). Hollow Aluminium alloy sections used
shall conform to IS:1285-2002 (Reaffirmed 2013). Dimension and weight per metre run of the
extruded sections shall be as given in Figures.
15.10.5 Glass Panes : Glass panes shall weigh at least 7.5 kg/m2 and shall be free from flaws, specks
or bubbles. All panes shall have properly squared corners and straight edges. The sizes of glass panes
for use in doors, windows and ventilators shall be as given in Table 6.
15.10.6Screws : Screws threads of machine screws used in the fabrication of aluminium doors,
windows and ventilators shall conform to IS:1362-1959.
15.10.7 Fabrication:
i) Frames: Frames shall be square and flat, the corners of the frame being fabricated to a true right
angle. Both the fixed and opening frames shall be constructed of sections which have been cut
to length, metered and welded at the corners. Where hollow sections are used with welded
joints, argon-arc welding or flash butt welding shall be employed (gas welding or brazing not
to be done). Subdividing bars of units shall be tennoned and riveted into the frame.
The location of the parts and details of construction of the doors, windows and ventilators are
indicated in Figures.
15.10.8 Side-hung Shutters:
i) For fixing aluminium alloy hinges, slots shall be cut in the fixed frame and the hinges inserted
inside and may be riveted to the frame. The hinges shall normally be of the projecting type 67
mm wide (Figures). The Aluminium alloy for cast hinges shall conform to IS Designation A-
5-M of IS:617-1999. Specification for Aluminium and Aluminium Alloy Ingots and Castings
for General Engineering Purpose and for extruded section of hinges to IS Designation HE10-
WP or HE30-WP of IS:733-1983. The pins for hinges shall be of stainless steel of non-
magnetic type or aluminium alloy HR30. Irrespective of hinges being anodized or not, the
aluminium alloy pins shall be anodized to a minimum film thickness of 0.025 mm shall be
sealed with oil, wax or lanolin. Non-projecting types of hinges may also be used where ever
required. (Figures).
Table-6 :
Glass Sizes (Clearance Allowed)
i) Frames: Frames shall be square and flat, the comers of the frame being fabricated to a true right
angle. Both the fixed and opening frames shall be constructed of sections which have been cut
to length, mitered and welded at the comers. Where hollow sections are used with welded
joints, argon-arc welding or flash butt welding shall be employed (gas welding or brazing not
to be done). Subdividing bars of units shall be tennoned and riveted into the frame.
The location of the parts and details of construction of the doors, windows and ventilators are
indicated in Figures.
15.10.8 Side-hung Shutters:
i) For fixing aluminium alloy hinges, slots shall be cut in the fixed frame and the hinges inserted
inside and may be riveted to the frame. The hinges shall normally be of the projecting type 67
mm wide (Figures). The Aluminium alloy for cast hinges shall conform to IS Designation A-
5-M of IS:617-1999. Specification for Aluminium and Aluminium Alloy Ingots and Castings
for General Engineering Purpose and for extruded section of hinges to IS Designation HE10-
WP or HE30-WP of IS:733-1983. The pins for hinges shall be of stainless steel of non-
magnetic type or aluminium alloy HR30. Irrespective of hinges being anodized or not, the
aluminium alloy pins shall be anodized to a minimum film thickness of 0.025 mm shall be
sealed with oil, wax or lanolin. Non- projecting types of
hinges may also be used where ever required.
ii) Frictions hinges may be provided for side-hung shutter windows, in which case peg stay may
not be required. The working principle of the friction hinges is illustrated in Figures.
iii) The handle for side-hung shutters shall be of cast aluminium conforming to IS Designation A-
5-M of IS:617-1999 and mounted on a handle plate welded or riveted to the opening frame in
such a way that it could be fixed before the shutter is glazed. The handle should have anodized
finish with minimum anodic film thickness of 0.015 mm. The handle shall have a two points
nose which shall engage with an aluminium striking plate on the fixed frame in a slightly open
position as well as in a fixed position (Figures). The height of the handles in each type of side-
hung shutters shall be fixed in approximate position as indicated in Figures.
iv) The peg stay shall be either of cast aluminium conforming to IS:617-1999 or folded from IS
Designation NS4 Aluminium alloy sheet conforming to IS:737-1983 specification for wrought
aluminium and aluminium alloys, Sheet and strip. It shall be 300 mm long, complete with peg
and locking brackets (Figures). The stay shall have holes for keeping the shutter open in three
different positions. The peg and locking bracket shall be riveted or welded to the fixed frame.
v) Alternatively, and if specifically required by the purchaser, side-hung shutters may be fitted
with an internal removable fly screen of 0.375 mm wire and equivalent to IS Sieve 100 in a
0.900 mm aluminium alloy sheet conforming to IS Designation NS3-1/2H of IS:737-1983
applied to the outer frame of the shutter by case or extruded aluminium alloy turn-buckle at the
jambs (Figures) and by aluminium or plated bronze shoes at the sill to allow of the screen being
readily removed, and with a rotor operator at the sill to permit the operation of the shutter
through an angle of 90° (Figures). On fly-screened shutters the peg stay is omitted and the
normal handle shall be replaced by a locking handle to hold the shutter in the fast position.
15.10.9 Top-Hung Ventilators: The Aluminium hinges for top-hung ventilators shall be either cast
or fabricated out of extruded sections and shall be riveted to the fixed rail after cutting a slot in it.
The Aluminium alloy for cast hinges shall conform to IS Designation A-5-M of IS 617-1999 and the
extruded section of hinge to IS Designation HE10-WP or HE30_WP of IS 733-1983.The pegs stay
shall be 300 mm long as in side-hung shutter (Figures). The locking bracket shall be fixed to the
fixed frame.
15.10.10 Centre-Hung Ventilators (Figures):
i) Centre hung ventilators shall be hung on two pairs of cup pivots of aluminium alloy to IS
Designation NS-4 of IS 737 and IS Designation A-5-M of IS 617 or on brass or bronze cup
pivots which should be either chromium or cadmium plated and riveted to the inner and outer
frames of the ventilators to permit the ventilator to swing through an angle of approximately
85°. The opening portion of the ventilator shall be so balanced that it remains open at any desired
angle under normal weather condition.
ii) Cast aluminium conforming to IS Designation A-5-M of IS 617 or bronze which shall be either
chromium- plated or cadmium-plated spring catch shall be fitted in the centre of the top bar of
the ventilators for the operation of the ventilator. This spring catch shall be secured to the frame
and shall close into aluminium catch plate riveted or welded to the
outside of the outer ventilator frame bar (Figures).
iii) Aluminium or cadmium plated brass cord pulley-wheel in an aluminium bracket shall be fitted
at the sill of the ventilator with aluminium or galvanized or cadmium plated steel screw or,
alternatively, welded together with an aluminium cord eye riveted or welded to the bottom inner
frame bar of the ventilator in a position corresponding to that of pulley (Figures).
15.10.11 Doors:
i) The outer fixed frame shall be of section Al-FX8. The shutter frame shall be of either hollow
sections Al-HFX5 and Al-HFX6 (Figures). The kick panels shall be of 1.25 mm aluminium
alloy sheet conforming to IS Designation NS3-1/2H of IS:737-1983 specification for Wrought
Aluminium and Aluminium Alloys, Sheet and strip and shall be screwed to the frame and the
glazing bar.
ii) Hinges -Cast of extruded aluminium alloy hinges for doors shall be of the same type as in the
windows but of larger size. The hinges shall normally be of the 50 mm projecting type
(Figures). Non-projecting type of hinges may also be used (Figures). The handle for doors may
be of the design indicated in Figures. A suitable lock for the door operable either from inside
or outside shall be provided.
Note: From the point of view of security, the lock which is operable from only one side is better
and in the case of such locks, a bolt shall be provided to make them inoperable from the other
side.
In double shutter doors the first closing shutter shall have a concealed aluminium alloy bolt at top
and bottom (Figures). It shall be so constructed as not to work loose or drop by its own weight.
Single and double shutter doors may be provided with a three-way bolting device (Figures). Where
this is provided in the case of double shutter door, concealed aluminium bolts may not be provided.
15.10.12 Composite Units: The doors shall be coupled to windows or side-lights by extruded
aluminium sections made from aluminium alloy conforming to IS Designation HE9-WP of IS 733-
2006. The coupling member should conform to the dimensions indicated in Figures.
15.10.13 Weather Bar: Where a coupling member is fitted over an external opening shutter, the
coupling member should incorporate an integrally extruded weather bar (Figures).
15.10.14 Position of Bolts, Fixing Screws and Lugs : Outer frames shall be provided with fixing
holes centrally in the web of the sections in the position (Figures). Moreover, any steel lugs coming
in contact with aluminium should be either galvanized or given one coat of bituminous paint. The
fixing screws and lugs shall be as given in Table-7.
Table-7
S1 . Place of Fixing Size of Screw or Lug
(i) To wooden frames rebated on the outside mm
30 x No. 10 galvanized
(ii) wood- screws.
-Do-
To plugs in concrete, stone or brick
work rebated on the outside
(iii) To plugs in concrete, stone or brick 45 mm x No. galvanized
work not rebated on the outside wood-screws
(that is plain or square jambs)
(iv) Direct to brick work or masonry Slotted steel adjustable lugs (natural
(that is plain or square jambs) finish) not less than 100x16x3 mm
countersunk galvanized machine
screws and nuts 19.0 x 6.3 mm
(v) To steel work Standard clips and 8 mm
galvanized bolts with hexagonal nuts.
15.10.15 Finish: Aluminium umdoors, windows and ventilators may be supplied in either matt,
scratch-brush or polished finish. They may, additionally, also be anodized, if so required by the
Engineer-in-charge. If colour anodizing is to be done then only approved light-fast shades should be
used. A thick layer of clear transparent lacquer based on Methacrylates or cellulose butyrate, shall
be applied on aluminium doors, windows and ventilators by the supplier to protect the surface from
wet cement during installation. This lacquer coating shall be removed after installation is completed.
15.10.16 Glazing: Glazing shall be provided on the outside of the frames. If required, glazing clips
may be provided as extra fittings. Four glazing clips may be provided per glass pane, except for door
type 8HS21 where the glazing clips shall be six per glass pane. In case of doors, windows and
ventilators without horizontal glazing bars the glazing clips shall be spaced according to the slots in
the vertical members, otherwise the spacing shall be 30 cm.
Note: Glazing clips are not usually provided for normal size glass panes. Where large size glass
panes are required to be used or where the door or the window is located in heavily exposed situation,
holes for glazing clips have to be drilled prior to fabrication and cannot be done at any later stage.
Use of glazing clips, where necessary, shall be specified while placing the order.
15.10.17 Packing: All doors, windows and ventilators shall be dispatched with the opening parts
suitably secured to preserve alignment when fixing and glazing. Fixing lugs, coupling fittings and
all hardware shall be dispatched separately. Composite windows shall be dispatched uncoupled.
15.10.18 Marking: All doors, windows and ventilators shall be suitably marked on the frames with
a mark identifying the manufacturer and the type. The units may also be marked with the BIS
Certification Mark.
15.11. Fittings :
15.11 .1 Stainless Steel Friction Stay:
The stainless steel friction stays of make approved by the Engineer-in-Charge shall be used. The
SS friction stays shall be of grade AISI-304 and of sizes specified in nomenclature of item.
15.11.2 Lockable Handles:
The lockable handle shall be of make approved by the Engineer-in-Charge and of required colour to
match the colour of powder coated /anodized aluminium window sections.
15.11.3 Hydraulic Floor Spring : The hydraulic floor spring shall be heavy duty double action
floor spring of make approved by the Engineer-in-Charge suitable for door leaf of weight minimum
100 kg. The top cover plate shall be of stainless steel, flushing with floor finish level. The contractor
shall cut the floor properly with stone cutting machine to exact size & shape. The spindle of suitable
length to accommodate the floor finish shall be used. The contractor shall give the guarantee duly
supported by the company for proper functioning of floor spring at least for 10 years.
15.11.4 Tubular Handle: The tubular handle bar shall be aluminium polyester powder coated
minimum 50 micron to required colour/anodized AC 15. Outer dia. of tube shall be 32 mm, tube
thickness 3.0 mm and centre to centre length 2115 mm ± 5 mm.
15.11.5 Measurement: Refer Para 15.9.3.
15.11.6 Rate : Refer Para 15.9.4.
15.12 Louvers: Aluminium extruded sections (anodized or powder coated) are used for providing
Louvers in aluminium door, window & partition for ventilation.
15.12.1 Fabrication: Refer Para 15.9.1.
15.12.2 Measurements: Refer Para 15.9.3.
15.12.3 Rate: Refer Para 15.9.4.
15.13 Hermetically Sealed Unit:
i) Insulating glass shall be a double glazed unit comprising two sheets of float glass panes separated
by a spacer, hermetically sealed using primary and secondary sealants. The design of insulating
glass system shall consist of:
(a) Hollow Spacer Bar :The hollow aluminium spacer bar shall be of required size and shape and
shall be colour anodized. The spacer bar shall have two lines of perforations in the inner
surface.
(b) Desiccant: The desiccant shall be Neftomol 3 A Chemetall or equivalent. The desiccant filled
in the aluminium spacer bar shall be synthesized crystalline compounds of Aluminium
Hydroxide, Caustic Soda and Sodium Silicate which absorbs water molecules. The desiccant
shall be of 3 A size (A means Angstrom). The quantity of desiccant used shall not be less than
35 g m length of spacer bar. Filled spacer bar frame shall not be stored for more than 6 hours
before assembly and sealing of the unit to ensure proper functioning of the desiccant. The
contractor shall submit documentary proof of using the above material in the work.
(c) Primary Sealant: The primary sealant shall be single component approved by the Engineer in
Charge, thermo plastic solvent free sealing compound based on polysosutylene. The sealant
surface shall be free from cavities, depression and other defects. The contractor shall submit
documentary proof of using the above material in this work.
(d) Secondary Sealant : The secondary sealant in double glazed unit shall be silicone sealant
approved by the Engineer in Charge. The contractor shall submit documentary proof of using
the above material in this work to the entire satisfaction of Engineer-in-Charge. Before
application of silicone/ polysulphide, the surface must be cleaned and free from oil, grease, dust
and other loose matter. The surfaces shall be cleaned with alcohol or other suitable solvents.
Detergent or soap shall not be used to clean the surfaces. The polysulphide shall be mixed and
applied mechanically using automatic mixing machine in the manner approved by Engineer-in-
Charge.
ii) Measurement: The height and width of double glazed/single glazed unit (the area of glass unit
outside the snap beading shall only be measured) as fixed in place shall be measured correct to
one centimeter and area calculated in sqm. correct to second place of decimal shall be taken for
payment.
iii) Rate: The rate shall include the cost of all the materials, labours involved in all the operations
as described in nomenclature of item and particular specification.
15.14 Brass Lock : This should generally conform to IS-2209-2006. The size of the lock shall be
denoted by the length of the body towards the face and it shall be 100 mm. the measured length shall
not vary more than 3 mm from the specified length. Ordinary lever mechanism with not less than 2
levers shall be provided. False lever shall not be used. Lever shall be fitted with one spring of
phosphor-bronze or steel wire and shall withstand the test as provided in IS-2209-2006. Locking-
bolt spring and strike plate shall conform to IS 2209-2006. Two keys shall be provided with each
lock.
15.15 Handing of Doors and Windows: The side-hung opening position of all doors shall be said
to be right hand or left hand according to the side on which they are hinged looking from the inside
as shown in figures.
15.16 Designation of Doors, Windows and Ventilators:
As per IS:1948-1961 (Reaffirmed 2011) Doors, windows and ventilators shall be designated by
symbols denoting their width, type and height in succession in the following manner.
(a) Width : It shall be indicated by the number of modules in the width of opening. The width
specified shall the width of opening and not the width of Joinery. One Modules = 10 Cm or 100
mm
(b) Type : It shall be indicated by the following letters of alphabet:
C = Centre hung shutters
F = Fixed glass panes
H = With Horizontal glazing bars
N = Without Horizontal glazing bars
S = Side hung shutters, and
T = Top hung shutters
(c) Height : It shall be indicated by the number of modules in the height of opening. The height shall
be height of opening and not the height of Joinery.
Example : A window of a width of 100 cm and Height 90 cm, having horizontal glazing bars and
side- hung shutters is designated by 10HS9. The width & height are the dimension of opening and not
of the Joinery which will be less as specified later.
15.17 Aluminium Work for Door, Windows, Ventilators and Composite Units:
15.17.1 General:
(i) The aluminium doors, windows and ventilators shall be fabricated by reputed work-shops using
aluminium extrusions manufactured by the renowned manufacturers. Fabrication of doors,
windows etc on site by local labour employed by the contractor shall not be permitted. The
fabricated materials in ready to fix position are subject to inspection by the Engineerin-charge.
(ii) General specifications and materials shall conform to the requirements as laid down in clause
15.2
15.17.2 Aluminium Alloy Extruded Section for Door, Windows & Ventilators :
As per IS :1948-1961(Reaffirmed 2011) Dimensions and weight per metre run of extruded section to
be used for manufacturing aluminium doors, windows & ventilators as recommended in IS : 1948-
1961 (shown in fig).
15.17.3 Aluminium Extruded Section for Doors, Windows & Ventilators : As per manufactures
of repute) Aluminium extruded section of difference dimension & weight other then IS : 1948-1961
are also manufactured by major companies. In case these are used as per direction of Engineerin-charge
than their weight & dimension shall be checked as per manufactures specification.
15.18: General Specification and tolerances for Aluminium Extrusion:
15.18.1 Circumscribing Circle Diameter (C.C.D):
(i) The product range can be broadly categorized as follows.
(a) For solids up to 190 mm
(b) For Hollows up to 135 mm
(ii) Sections with higher C.C.D can also be produced as per special inquiry.
15.18.2 : Manufacturing Tolerances :
Dimensional extrusions are normally manufactured as per Indian Standard / British Standard
Specification. Special tolerances shall be mutually agreed upon.
15.18.3 Tolerance on cut length:
(i) The standard cut length is 3.66 m. The tolerance on cut length shall be as follows.
Length Tolerance
Up to 6 metres +5.00mm
Over 6 metres +7.00mm
(ii) Section can also be supplied in random lengths between 1500 mm to 5000 mm.
15.18.4 Tolerance in Weight: Sectional weight per metre run shown for doors, windows and
ventilators under clause 15.7 is only for guideline. Actual weight will depend upon the functions like
tolerances and alloy. Generally a section will be supplied in ±10% weight tolerances.
15.18.5 Tolerance in Sizes: The sizes for doors, windows or ventilators frames shall not vary by
more than + 1.5 mm.
Unit Size of Unit (Example) (mm) Size of Manufactured Unit
(Example) (mm)
Door 1050 x 2100 1025 x 2087.5
Window 1800 x 1350 1775 x 1325
Ventilator 900 x 600 875 x 575
15.19 Glazing Sheet Glass or Frosted Sheet Glass:
(i) Sheet glass shall be of selected quality (SQ) or ordinary quality (OQ) as per IS : 2835-1998.
Glass shall be free from cracks, flaws, specks or bubbles. It shall be flat, transparent or frosted.
(ii) Glass panes shall weigh at least 7.5 kg /sqm. Sheet glass of 4 mm nominal thickness weighing
not less than 10 kg / sqm shall be used for glass panel of area up to 0.5 sqm. for panels
exceeding 0.5 Sqm. in area the nominal thickness of glass to be used shall be specified.
(iii) Nominal thickness and range of thickness of sheet glass shall be as per Table 8. Tolerance on
cut size (length & width) shall be ±2.0 mm.
Table 8 : Thickness and Weight of Sheet Glass

Normal Thickness (mm) Range of Thickness (mm) Weight (kg/sqm)
3.0 2.8 to 3.2 7.5
4.0 3.8 to 4.2 10.0
4.8 4.6 to5.1 11.9
5.5 5.2 to 5.8 13.5
6.3 6.0 to 6.6 15.5
(iv) In doors, windows and clerestory windows of bath, WC and lavatories frosted glass panes
may be used which shall weigh not less than 10 kg/sqm.
(v) Fixing of glass panes shall be done with aluminium beading fixed with CP brass or stainless
steel screws spaced not more than 10 cm from each corner and intermediate not more than 20
cm apart. When the glass panes are fixed with aluminium beading having mitered joints, epoxy
resin or silicon sealant shall be applied between glass panes and sash bars and also between
glass panes & the beading.
(vi) Glazing shall be provided on the outside of the frame unless otherwise specified.
15.20 Removable Fly Screen:
(i) If specified or directed by the Engineer-in-charge the side hung aluminium window shutters may
be fitted with an internal removable fly screen.
The fly screen shall be of 0.375 mm wire and equivalent of IS sieving 100 in a 0.9 mm
aluminium alloy sheet applied to the outer frame of the shutter by cast or with the help of
aluminium alloy turn buckle at the jambs.
(iii) Also an aluminium or plated bronze (gun metal) shoe at the sill shall be provided to allow for
the screen being readily removed with a rotor operator at the sill to permit the operation of the
shutter through an angle of 90° • (as shown in Figures.)
(iv) On fly screened shutters the peg stay is omitted and the normal handle shall be replace by a
locking handle to hold the shutter in fast position.
15.21 Anodic Coatings on Aluminium:
Anodic coating may be done over to Aluminium section to give them a protective and decorative
cover. This coating is produced by an electrolytic oxidation process by which the surface of
Aluminium is covered with a coating, generally an oxide, having protective, decorative or functional
properties. This should comply with requirements of IS:1868-2010.
15.21.1 : Thickness of coating : Anodic oxide coatings are graded by their thickness and are denoted
by the grade numbers shown in Table 2. The thickness of anodic coatings shall not be less than as
specified in Table 9.
Table 9 : Minimum Thickness of Anodic Coating
Grade Minimum Minimum Application
Average Local
Thickness in Thickness in
Micrometer Micrometer
AC25 25 20 For permanent installations, out doors and where
little or no deterioration of surface appearance are
tolerated, even with minimum maintenance.
AC15 15 12 For outdoor architectural use, for indoor
applications in arduous conditions and for graphic
application used for defense services and
professional equipment.
AC 10 10 8 May be used for outdoor in special applications
where cleaning is very frequent (for example,
decorative rim for vehicles) and also for certain
other indoor applications like refrigerator parts.
AC5 5 4 Generally used for indoor applications.
AC2.5 2.5 2 For some reflectors and as a base for paint.
NOTES:
1. All grades may be produced in electrolytes based primarily on sculptures or oxalic acid. With
most chromic acid electrolytes, only thinner coatings are obtainable. Barrier layer anodic
coatings used in capacitors as dielectrics produced in boric acid electrolytes are not included in
the table.
2. For control purposed, thickness may be determined by add current method or by breakdown
voltage test.
3. Minimum Average thickness shall be the average of five measurements as specified in IS
5523 : 2010
15.22 Measurement : 15.22.1 Frame Work:
1. Only after ascertaining that the aluminium doors/windows fixed on site are manufactured by
reducing the sizes as explained in clause 15.9 than the specified size of doors in the drawings
issued for construction, the length of each extruded section used for fabrication of the door
shall be measured correct to 1 mm. in cases the sizes of doors that are manufactured, happen to
be the sizes specified in the drawings only the theoretical dimensions arrived by reducing the
overall sizes should be considered.
2. The weight of material used shall be calculated on the basis of actual weight of extruded
sections used for fabrication and shall be compared with the weight given in the manufacturer's
catalogue subject to the condition that the variation in actual weight should not exceed + 10%
than the weights specified in manufacturer's catalogue. Payment shall be made for the actual
weight of the extruded section. The final weights shall be calculated in kg upto two place of
decimal.
15.22.2 Glazing : Length and width of opening for glazing inserts shall be measured correct to a
cm and area for payment shall be calculated in Sqm. Nearest to 0.01 sqm.
15.22.3 Panelling : The length and breadth of the panel inserts shall be measured correct to a cm
and the area calculated to the nearest 0.01 sqm. The weights of panel used shall be calculated
I). As per manufacturer's catalogue.
M. The actual weight of sheet used be found out and weight of panel actually used.(Actually
calculate weight shall be recorded subject to condition that variation in actual Weight shall not
exceed +10% than weight specified in the manufacturer's catalogue).
Least of above shall be considered for payment.
The actual weight shall be calculated in kg. to two places of decimal.
15.22.4 Fittings : All fittings for doors except hinges and handles shall be enumerated.
15.23 Rate:
I). The rate shall include the cost of material and labour for all operation described above except the
cost of glazing and paneling. It shall include screws expansion hold fastener, snap beading
including filling with necessary PVC/neoprene felt, cleats etc. the rate does not include the cost
of fittings except the hinges and handles.
M. The cost of glazing, paneling and additional fittings shall be paid under separate item, as
described herein.
15.24 Floor Spring (Hydraulically Regulated):
15.24.1 Type and Size of Floor Spring:
Typical details of a floor spring (Hydraulically regulated) are given in Fig. and shall confirm the
requirements of IS: 6315-1992.
15.24.2 Construction and Operational Details :
1) The floor springs shall be suitable for fixing to the doors weighing up to 125 kg without use
of additional door units.
2) The floor spring shall operate smoothly and easily without undue delay during the opening
and closing operations.
3) The oil check shall work satisfactorily at all temperatures between 49° and (-) 10° without
requiring any other change except by adjustment of the capstan nut.
4) The speed of the closing door shall be adjustable by means of a suitable controlling device.
Tension of the spring shall be increased or decreased by turning the capstan nuts clock-wise or
anti-clockwise. For exceptionally low temperature the adjustment in the speed could be made
by change in the grade of oil.
5) The shoe shall be fitted to the governing pivot of the floor spring by a square profile so that it
stands horizontally parallel with the top cover plate of the floor spring. Provisions shall be made
in the shoe for adjusting the door leaf to the final closing position by turning a screw.
6) When the door is opened at right angle, the door shall stand open till it is pushed to close.
15.24.3 Performance of floor Spring :
(i) The closing time of the floor spring shall be easily adjustable between 3 and 20 seconds for
which a suitable device to adjust the speed shall be provided.
After being fitted in position the door leaf shall be opened through 90° plus 5° and released. When
opened to an angle less than a right angle the door shall swing back automatically.
15.24.4 Workman ship: The floor spring shall be free from all mechanical defects, sharp edges
and other surface defect.
15.24.5 Quality Assurance: The floor spring should be with ISI mark for quality assurance.
15.24.6 Fixing : Suitable recess of the required size shall be cut in floor and the floor spring with
all its components viz. cover plate, outer box with slide plate etc. shall be embedded in floor.
15.24.7 Measurement : The floor spring shall be measured in numbers.
15.24.8 Rate : The rate shall include the cost of labour and material involved in all the operations
described above and making good the floor.
15.25 Aluminium Decorative Grill :
15.25.1 Aluminium grill is light weight (1/3 the weight of conventional iron grill) thereby facilitating
easier and quicker installation, ideally suited for ordinary/high rise buildings. It is rust proof and
suitable for any atmospheric condition. It has got elegance, aesthetic look. Apart from being used as
grill it is used in doors, partitions, fences and furniture.
15.25.2 Material: General specification and material shall conform to requirements laid in clauses
15.2.
15.25.3 Fabrications: It is prefabricated and available in different patterns and sizes thereby
minimizing the welding of joints. It is available in variable thickness such as 7.5 mm & 10 mm. It is
available in anodized, powdered coated colour, or clear resin coatings. However, grill of specified
thickness, colour shall be used. Typical pattern of grill are shown in Fig.
15.25.4 Measurement: Prefabricated anodized or of any specified colour aluminium decorative grill
(excluding frame work) shall be measured correct to 1 mm in both the directions and area for
payment shall be worked out in sqm. Correct to two places of decimal.
Different types of grill shall be measured and paid for separately.
15.25.5 Rate: Rate includes the cost of materials and labour involved in all the operations
described above. The frame work shall be as applicable either aluminium or timber. However, extra
shall be paid for providing molded beading where specified. Nothing extra shall be paid for plain
beading when specified in the drawings.
15.26 Providing and Fixing Machine Moulded Anodised Aluminium Covering Over Expansion
Joints:
15.26.1 General specification and material shall conform to requirement as laid in para 15.1, 15.1.2.
The aluminium sheet shall be of approved make and conforming to specifications laid IS :737-2008.
15.26.2 Aluminium sheet of required width and thickness shall be made out of wider sheet duly
machine cut. Machine moulded covering may be :
(i) 170mm under anodised aluminium sheet 2.5mm thick.
(ii) 210mm wide anodised aluminium sheet 2.5mm thick. Or of any
other width/thickness specified in the description of item.
15.26.3 Fixing: Aluminium sheet shall be machine-holed at required spacing. Staggered holes in the
receiving surface will be done with drilling machine and expandable plastic sleeve be provided in the
holes. Aluminium sheet shall be fixed with cadmium plated 4mm dia. 30mm long full threaded with
2mm thick anodised aluminium washer complete as per the direction of Engineerin-charge.
Anodising on the aluminium sheet and washer to be 15 micron thick.
15.26.4 Measurement: The length of aluminium sheet covering shall be measured in running metre
correct to 1cm. Payment shall be made for least of weight calculated on the basis of unit weight.
(i) Unit weight specified in manufacturer catalogue.
(ii) Actual weight per Sqm.
15.26.5 Rate: Rate includes the cost of material and labour involved in all the operations described
above. It shall include screws, plastic sleeves etc. complete.
15.27 Aluminium Staircase Railings and Baluster:
15.27.1 Aluminium being extensively used in building industry as such new types and designs are
constantly developed for extruded railings, baluster including fillets, brackets and attachments. These
are manufactured from appropriate aluminium alloys.
15.27.2 Materials: Aluminium extruded railing section, baluster section shall comply with the
chemical compaction and mechanical properties as laid down in para 15.1.1.
15.27.3 Hand rails: These are provided to render assistance in negotiating a stairway. Hand rails are
supported on baluster and normally run parallel to stair. Aluminium hand rails are light, convenient
to use and easy to maintain. Type of hand rail shall be as specified in the item.
15.27.4 Baluster: These are short vertical members of appropriate height, fixed between hand rail
and waste slab intended to support railing and protect the open space between railing and steps.
Baluster are of specified aluminium section, usually it is circular/square aluminium rod or a designer
pattern.
15.27.5 Fabrication and Fixing:
15.27.5.1 Baluster for specified failing height are cut from the stipulated aluminium section. These
are properly embedded in waste slab/step while its casting. Before concreting work is
started it shall be checked that balusters are truly in position and are vertical and top of all the baluster
are in proper line. Aluminium channels square filler or round fillet as specified in the item shall be
run connecting top of all the baluster, either by soldering, argon arc welding, wooden screwing as may
be applicable.
15.27.5.2 Specified extruded railing section in the contract is cut for the required length. The railing
section is fixed on the top of square/round fillet as specified in the item by soldering, brazing etc.
Precautions shall therefore be taken to avoid distortion of members. The work shall be completed as
shown in the drawings including cleats, brackets etc. Gap of any sort shall be filled with silicon
sealant complete.
15.27.6 Measurements: Length of each member
(i) Baluster (ii) Hand rail, (iii) Channel, Square fillet/ circular fillet, shall be measured correct to a
cm and payment shall be worked out in running metres correct to two places of decimals.
15.27.7 Rate: Rate includes the cost of material and labour involved in all operations described
above. It shall include cleats, silicon sealant etc. complete.
15.28 Aluminium Curtain Wall System :
15.28.1 General :
(1) This type of work is not an ordinary job which can be executed by the contractors doing the
general building works but this is a specialized job.
(2) The curtain glazing system which is mostly executed on the prestigious private sector
buildings, are normally executed under the supervision of the engineers, architects and
specialist consultants. The Government departments use this item in their prestigious projects.
(3) These structures are designed for the following effects:
Permanent Deformation, thermal expansion.

Wind and seismic load
Air and water infiltration or leakage.
Lateral deflection per floor height
(4) Normally for executing such works the design of the system is prepared by the specialized firm
and then the same is submitted to the client/department/architect for approval and only after
detailed scrutiny and checking design calculations and drawings, the design is accepted and the
firm is asked to take up the job.
(5) Sometimes neglecting all these formalities and factors ignorantly or otherwise, the works are
awarded to general building contractors who would just collect some ready-made units and
then see that the job is completed. Later lot of irreparable defects are noticed in such jobs.
(6) Therefore, this type of work must be got executed under L.S. contract system with contractor's
own design with full five years guarantee, making it obligatory for the contractor to execute
the work systematically and conduct the necessary mock-up unit tests, before taking up the
work to the satisfaction of client/department/architect.
(7) Hence the complete procedure to be adopted to execute this type of projects perfectly is
explained below.
15.28.2 Specification for Materials used for Curtain Wall
(1) Glazing As specified in the description of the item or as described
under clause 15.10
(ii) Framing system Aluminium anodized extruded sections manufactured by reputed manufacturers
and type shown under clause 15.22 For all types of members
like brackets, mullions, transome etc.
(3) Sealant As specified in the item or silicon sealant.
(4) Insulation 50 mm thick glass wool of minimum density 48 kg/cum
sandwiched with black polythene sheet 100 micron on one
side and aluminium foil of 100 micron on the other side or as
specified by manufacturer at spandrel area. The surface after
fixing insulation shall be plain without distortion.
(5)
Brown or Grey Colour of any shade approved by the client/
Engineer-in- Charge/Architect.
15.28.3 Aluminium Alloy Extruded Sections - Manufactured and supplied by reputed
companies: In absence of specific extruded sections available conforming to BIS specification,
extruded sections manufactured by reputed companies are used on works.
15.28.4 Components of Curtain wall system:
(i) The main components of a curtain wall system are shown in Fig.
15.28.5 General Specification and Tolerances for Aluminium Extrusions Produced by
manufacturers : Same as under Clause 15.8
15.28.6 Glazing : Same as under Clause 15.10.
15.28.7 Panelling: Same as under clause 15.11.1 and 15.11.2
15.28.8 Scope of Work:
15.28.8.1 Preliminary Requirements
(i) The contractor shall design, test, fabricate, deliver, install and guarantee all construction
necessary to provide a complete curtain wall system for the proposed building, all in
conformity with the drawings as shown.
(ii) Specification and all relevant construction regulations including providing any measures that
may be required to that end, notwithstanding any omissions or inadequacies of the drawings.
(iii) The curtain wall system shall also include the following activities:
(a) Metal frames, glass glazing, spandrels, ventilators, finish hardware, copings, metal
closure windows etc.
(b) All anchors attachments, reinforcement and steel reinforcing for the systems required
for the complete installations.
All thermal insulation associated with the system.
All fire protection associated with the system.
All copings and closure and metal cladding to complete the system.
All sealing and flushing including sealing at junctions with other trades to achieve
complete water tightness in the system.
Isolation of dissimilar metals and moving parts.
(g)
(h) Anticorrosive treatment on all metals used in the system.
(i) Polyester powder coating aluminium sections.
The contractor shall also be responsible for providing the following:
Engineering proposal, shop drawings, engineering data and structural calculations in
connection with the design of the curtain wall system.
Mock-ups, samples and test units.
Performance testing of the curtain wall framing and glazing assembly. Co-ordination
with the work of other trade.
Insulation with glass wool 48 kg/cum at spandrels area.
Protection.
All final exterior and interior cleaning and finishing of the curtain wall system. As built record
drawings and photographs.
Guarantees and warranties.
All hoisting, scaffolding, staging and temporary services.
Conceptualising and design of a suitable maintenance system for curtain glazing.
(v) The water tightness and structural stability of the whole curtain wall system are prime
responsibility of the contractor. Any defect or leakage found within the guarantee period shall
be sealed and made good all at the risk and cost of the contractor.
The curtain wall system shall be designed to provide for expansion and contraction of
components which will be caused by an ambient temperature range without causing buckling,
stress on glass, failure of joint sealants, undue stress on structural elements or other detrimental
effects, specific details should be designed to accommodate thermal and building movements.
15.28.8.2 Design Requirements:
(i) Curtain wall shall comply with all government codes and regulations, building bye-laws, if any.
All curtain walling, individual aluminium and glass components and all completed work shall
be designed and erected to comply with the following requirements.
15.28.8.2.1 Basic Requirement: The basic design and architectural requirements shall consist of the
size of window, net glass area, ventilator, configuration of windows and spandrels to be retained.
However the contractor may propose alternatives on the construction details provided that all basic
functional and architectural requirements are fulfilled.
15.28.8.2.2 Quality Consideration and other Activities:
(i) The contractor while submitting the detailed design calculations should submit the following
information on the quality of materials to be used and other aspects as detailed below:
(1) Metal quality, finishes and thickness
(2) Glass quality, coating and thickness and proposed manufacturer's brand names.
(3) Aluminium extruded sections including mullions and transoms together with structural
calculations and proposed manufacturer's brand name and also the name of agency
proposed for fabrication work.
Arrangement and jointing of components.
Field connections especially mullion to mullion and transom to mullion.
Fixing and anchorage system of typical wall unit together with structural calculations.
Drainage system and provision in respect of water leakage in the curtain wall system.
Provisions for thermal movements.
Sealant and sealing methods.
Glazing Method.
Wind load and seismic load and any other specific load considered in the design.
(ii) Design concept over lightning protection link-up system of the curtain wall for connection and
incorporation into the lightning conductor system of the building (Lightning conductor system
of the building to be done by any other agency).
(iii) The maximum permissible structural tolerances of the building that the system has been de-
signed to accommodate in case these tolerances exceed those specified in the specification.
15.28.8.2.3 Tolerances : Any parts of the curtain wall, when completed, shall be within the
following tolerances:
(1) Deviation from plumb, level or dimensioned angle must not exceed 3 mm per 3.5m length of
any member, or 6 mm in any total run in any line.
(2) Deviation from theoretical position on plan or elevation, including deviation from plumb,
level or dimensioned angle must not exceed 9 mm total at any location.
(3) Change in deviation must not exceed 3 mm for any 3.5 m run in any direction.
15.28.8.2.4 Samples : The contractor shall also submit samples of aluminium extruded sections,
mullion and transom sections in lengths of 300 mm with the same finish and workmanship as per
the tender proposals and 300 mm x 300 mm samples of glass (samples to include exposed screws
and other . exposed securing devices if any).
15.28.8.2.5 Ancillary Requirements to be fulfilled by the contractor:
(i) The contractor/sub-contractor shall submit a maintenance manual for the curtain wall system
inclusive of all metal parts, glass and finish etc.
(ii) During detailed design scrutiny and also during the actual execution of the work any additions
and extra provisions that will have to be made as per theoretical requirements or site conditions
shall be implemented and executed by the contractor at his own cost, without claiming any
thing extra under any circumstances.
15.28.9 Execution of Work:
15.28.9.1 Performance Testing:
15.28.9.1.1 General Requirements:
(i) Mock-up units shall be constructed by the contractor and tested to determine the structural
stability as well as air and water infiltration or leakage at glazing beads and all other joints
designed into the face of the building.
(ii) After the approval of structural calculations and the drawing for construction of the curtain
wall one test unit for performance testing of the curtain wall shall be constructed by the
contractor at an independent laboratory or at a laboratory approved by the Client/Engineerin-
Charge/Architect.
(iii) Erect mock-up under manufacturer's/Fabricator's direct supervision and employ workmen as
they would be employed during the actual erection at the job site.
(iv) The contractor shall submit to the Client/Engineer-in-Charge/Architect the test procedures to
be adopted, test schedule and location for testing before the work of actual testing is taken up.
(v) or to the fabrication of test units, the contractor shall submit shop drawings and design
calculations of the test unit for the approval of the Client/Engineer-in-Charge/Architect.
(vi) The contractor shall not start the work of erection of curtain wall on site till the approval for
the successful completion of the mock up test and clear instruction in writing to start the work
is received from the Client/Engineer-in-Charge/Architect.
(vii) The decision of the Client/Engineer-in-charge/Architect in respect of the procedure to be
adopted, in conducting the mock-Up test and the judgment over the net results, shall be final
and binding on the contractor.
15.28.9.2 Test of Wind Pressure:
(i) The equivalent load of wind pressure or wind suction shall be given to the test unit as
increasing or decreasing the inside pressure in the "pressure chamber" at which the test unit is
fixed.
(ii) The static wind pressure shall be applied up to 1.5 k pa at maximum wind pressure.
(iii) The variation of dynamic pressure shall be of any approximate sine curve line.
(iv) Deflection on each observational points of the test unit shall be observed and recorded under
static pressure as described above.
(v) Any damage and harmful permanent deformation on any parts except sealing materials shall
not be found at maximum wind pressure.
(vi) The deflection on the main structural parts in this condition shall not exceed:
(1) 1/175 of the span between supports or 20 mm, whichever is less for vertical elements.
(2) 1/250 of the span between supports for horizontal elements.
(3) The extent of recovery of deformation, 15 minutes after the removal of the test load, is
to be at least 95%.
15.28.9.3 Test of Lateral Deflection per floor height:
(i) Lateral deflection per floor height shall occur on the test unit, when the structural frame
which fixes the test unit is deflected horizontally.
The deflection of every ± 2.5 mm shall be increased up to ± 13 mm on the test unit (static
deflection test)
The dynamic deflection shall be applied up to ± 13 mm.
The variation of dynamic deflection shall be of an approximate sine curve line, one period of 3
seconds.
The dimensions of the deflection on each observational point of the test unit shall be measured
under the condition as described above and the damage shall be observed.
Any damage and harmful permanent deformation shall not be found in any parts of the curtain wall
except the damage to sealant at maximum deflection.
15.28.9.4 Water-tightness Test:
Water shall be sprinkled to the 'Test Unit' under wind pressure.

Pressure shall not be applied to the test unit.
The volume of the sprinkling water in one minute shall be 5litres per sqm minimum (0.1 gal/sq ft.).
All water leakage and drainage system at the joint and the openable sash of the curtain wall
system shall be observed from the outside of the chamber
Hold the test two times, in sequence as described below, conforming to the above mentioned
conditions.
Install the test unit.

Hold first water-tightness test.
Hold test of wind pressure as described above. Hold second
water-tightness test.
Lateral deflection test.
(vi) Water leakage shall not be observed inside at all parts of the test unit during first water-
tightness test.
15.28.9.5 Test Report: The contractor shall submit five copies of test report to the client/ Engineer-
in-charge/ Architect.
15.28.9.6 Cost of Performance Test:
(i) The contractor shall allow in his tender for the cost of the performance testing and fabrication,
erection, corrections to and demolition of the test units including any special provision
required in the, Testing laboratory for the tests mentioned above.
(ii) All reasonable travel and accommodation expenses incurred by the Client/Engineer-in-
Charge/Architect and that of the specialist consultant (Total number not exceeding 4 persons) in
attending any such test shall be borne by the contractor and the expenditure shall be deemed to
be included in his noted rates.
(iii) The contractor shall allow for amendments and adjustments to the mock-up unit as instructed
and required by the Client/Engineer-in-Charge/Architect or the consultant.
(iv) If the mock-up test unit fails to pass the initial testing, the contractor shall make the necessary
corrections to the test unit and shall get. the test unit retested by the testing laboratory until it
passes the test.
(v) Cost of corrections to the test unit and the cost of retesting shall be borne by the contractor.
(vi) The contractor shall be allowed six calendar months time after the work is awarded to set up
the Test unit and conduct the required test as described above to the satisfaction of the client/
engineer-in- charge /architect.
(vii) In case the contractor falls to conduct the necessary tests as described above or falls to meet
the required test results, without any genuine cause within the allotted period of six months the
Client/Engineer-in-charge/architect shall be free to rescind the contract with all costs including
the forfeiture of E.M.D. and any other securities deposited by the contractor under the condition
of contract.
15.28.9.7 Record of Test and Drawings:
(i) The testing laboratory shall keep the approved copy of the shop drawing and calculations of
the Test unit at testing laboratory during testing of test unit.
(ii) The testing laboratory shall accurately and nearly record on the above mentioned shop
drawings as changes, revisions, modifications etc. made to test unit, which shall become the
record drawing.
(iii) On completion of testing and after approval of the test reports the testing laboratory shall
submit 3 final record drawings to the clients/engineer-in-charge/architects .
15.28.9.8 Fabrication and Erection:
As described under clause 15.12.1 para (i) and (ii).
The grid for the curtain wall system shall be fabricated carefully with aluminium extruded sections
like mullions and transom in the exactly same pattern as per the final drawings with amendments if
any received from the laboratory after conducting the mock-up unit test.
The sizes of different members of the curtain wall system shall be exactly as adopted for the Mock-
up unit tests and the grid shall be fixed to the building member as shown in the drawing, received
after conducting the mock-up unit test.
Care should be taken to see that any gap between the frame and support and the frame itself is sealed
with silicon sealant.
Finish of grid frame shall be either anodized, organic coating, backed enamel finish or as specified
in the item of work, no visual variation in anodizing/colour shall be accepted.
Care shall be taken to see that the curtain wall system is not deformed, damaged during erection and
it shall be protected from direct contact with wet or intermittent wet cement concrete mortar etc.
A typical curtain wall system with the position of main members like mullions, transom glazing etc.
and other required details are shown in fig .
15.28.10 Representative of the contractor: Full time attendance of a qualified civil engineer with
sufficient experience in construction of curtain wall system shall be provided for erection of test
unit, for all testing and later on actual construction.
15.28.11 Performance Guarantee: The contractor shall provide a performance guarantee of
requisite value to be indicated in the general conditions of contract for a period of five years, to
provide for expenses to cover the risk and cost of rectification of defect, noticed during the five years
guarantee period. Guarantee period to start from the date of completion and handing over of the
project.
15.28.12 Measurements
(i) The breadth and the height of the finished work including the openable windows shall be
measured in metres and cm and the net quantity for payment shall be calculated in sqm up to
(ii) The area to be considered for measurement shall be the net area of the exterior face of the
curtain wall as fixed including the openable windows if any as part of the curtain wall.
15.28.13 Rate : The rate shall include the cost of all operations described above including the cost
of materials, labour, design shop drawings, erection and testing, mock-up test units, fabrication,
erection, finishing, scaffolding, undertaking performance guarantee. No other claims of any kind
pertaining to this work shall be entertained.
15.29 Structural Glazing:
15.29.1 Specification for Materials to be used in Structural Glazing: Same as described under
Clause 15.22
15.29.2 Aluminium Alloy Extruded Sections manufactured and supplied by reputed
manufactures: In absence of specific extruded sections available conforming to BIS Specification,
extruded sections manufactured by reputed companies.
15.29.3 General Specification and Tolerances for Aluminium Extrusions: Same as under Clause
15.8
15.29.4 Glazing: Same as under Clause 15.10
15.29.5 Scope of Work: Same as under Clause 15.28.8
15.29.6 Execution of Work:
Same as under Clause 15.28.9 except para (vii) and (viii) under clause 15.28.9.2
Though both the systems i.e. curtain wall system and structural glazing are very much similar still the
type and Shape of aluminium extruded sections that are used in this case are totally different.
Another noted difference between the two systems is that in elevation the structural glazing looks as
total glass surface without any beading visible externally, whereas in case of curtain wall system the
cover plate used on the surface is clearly visible in elevation.
A large quantity of sealant has to be used for the execution of the work of structural glazing with
the result the cost per sqm. of structural glazing works out to be much on higher side.
There is also a slight difference in the actual fabrication of the two systems though quantity of
materials required for execution in both the cases is same except the quantity of sealant.
A typical structural glazing system with the position of main members like mullion, transom, glazing
etc. (are shown in Fig.)
15.29.7 Representative of the Contractor : Same as under Clause 15.28.10.
15.29.8 Performance Guarantee : Same as under Clause 15.28.11.
15.29.9 Measurements : Same as under Clause 15.28.12.
15.29.10 Rate: Same as under Clause 15.28.13.
15.30 Aluminium Curtain Wall System (Using Aluminium Composite Panels):
15.30.1 Scope: It is an ultra modern product with contemporary architectural features. It is an
ideal option for interior inlay and external decor.
15.30.2 Materials : Specification for materials used for curtain wall as below :
15.30.2.1 Aluminium Composite Panels: It consist of two aluminium cover sheets (thickness
0.10mm to 0.50mm) and LDPE core. Its exterior surfaces is coated with PVDF paint (thickness 18
to 25 micron) or Super Polyester. It is available in 3mm, 4mm, 6mm thickness.
15.30.2.2 Framing System: Aluminium anodized extruded sections manufactured by reputed
manufactures for all type of member like brackets, mullions, transoms etc. are use for this.
15.30.2.3 Sealant : As specified in the item or silicon sealant.
15.30.3.1 The grid for the curtain wall system shall be fabricated carefully with Aluminium extruded
sections.
15.30.3.2 Care should be taken to see that any gap between the frame and support and frame
itself is sealed with silicon sealant.
15.30.3.3 Care shall be taken to see that the curtain wall system is not deformed, damaged during
erection.
15.30.3.4 After erection of frame ACP sheets are cut in desired sizes and fixed on frame by steel
screws. It is fixed on frame in two way.
 ACP Sheet cut in required shape and fixed on frame by steel screws. The gap between two
sheet i.e. joints in ACP sheets is filled with silicon sealant.
 Tray system- ACP Sheets are cut and prepared like tray shape before fixing on frame. These
trays are fixed on frame by aluminium cleats screwed both on tray and frame. The joints of
ACP sheets are filled with Backer road and silicon sealant.

15.30.4.1 The breadth and the height of the finished work shall be measured in meters and the
net quantity for payment shall be calculated in Sqm up to two places of decimal.
15.30.4.2 The area to be considered for measurement shall be the net area of the exterior face.
15.30.5 Rate :
The rate shall include the cost of all operation described above including the cost of materials, labour,
erection and testing, fabrication, finishing, scaffolding, etc. No other claims of any kind pertaining
to this work shall be entertained.
15.31 UPVC - Door Frames:
15.31.0 Material: Polyvinyl chloride Resin suspension grade is the basic raw material for forming
PVC compound. PVC resin then is mixed with chemicals like Calcium, Stearate, Hydrocarbon
Wax, Titanium Dioxide, Calcium Carbonate, Acrylic processing aids. Further, additives like impact
modifiers, pigments, epoxy plasticizer, UV stabilizer, lubricants, chemical blowing agent etc. are
added. The purpose of adding the chemicals and additives is to impart cellular structure, strength,
surface finish, colour and resistance to fading by light rays. These chemicals are mixed in the desired
proportion and shall be used in the formulation of PVC material and for free and smooth extrusion
of PVC profiles.
15.31.1 UPVC Door Frame: UPVC door frame shall be made of PVC material conforming to IS
10151. The door frame shall be made from extruded UPVC section having overall dimensions of 48
x 40 mm or 42 x 50 mm having wall thickness of 2.0 mm + 0.2 mm. Corners of the door frame to be
jointed by M.S. galvanized brackets. Joints mitred and plastic welded. The hinge side vertical outer
frames shall be reinforced by galvanized M.S. Tube of size 19x19 mm of wall thickness 1 mm + 0.1
mm and a tie rod shall be provided at the bottom of the frame. The frame shall be fabricated in
factory as per nomenclature of the item and directions of Engineer-in-Charge. (Fig.).
15.31.2 Fixing of Frames: The frames are to be fixed in prepared openings in the walls. All civil work
and tiling should be completed before the fixing of the frames. The frames are to be fixed directly
on the plastered wall. In case tiling is to be done in the place the frames are to be fitted, a 50 mm
strip should be left untied at the location where the frames are to be fitted. The frames are erected in
the prepared opening such that the vertical members of the door frame are embedded 50 mm in the
floor. The frame shall be fitted truly in plumb. A minimum of three anchor bolts or screws of size
65/100 shall be used to fix each vertical member. One bolt shall be fixed at 200 mm from the top
member and one bolt shall be fixed at 200 mm from the floor. The third anchor bolt shall be fixed
in the center. The top horizontal member shall be fixed using two 65/ 100 size anchor bolts or screws
at a distance of 200 mm from both the corners.
15.31.3 Measurements: The outer length of the vertical and horizontal members of UPVC door
frame shall be measured in running metres including embedded length in floor corrected up to a cm.
15.31.4 Rate: The rate includes the cost of the materials and labour involved in all the operations
described above. The cost of anchor bolts or screws for joining the frame is included in the rate. Any
other hardware, which may be required, shall be paid for separately.
15.32 PVC Door Shutters: The shutters shall be fabricated at factory as per nomenclature of the
item and directions of Engineer-in-Charge. Shutter shall be made of PVC material conforming to
relevant IS specifications.
15.32.1 24 mm thick PVC Door Shutters 15.32.2 30
mm Thick PVC Door Shutters 15.32.3 Sampling and
Criteria for Conformity: 15.32.3.1 General
Precautions:
i) The test specimens shall not have been exposed to a temperature below 40°C for 24 hours
immediately preceding the test and shall be free from all/visible moisture. The specimen shall
be inspected and any specimen with visible flaws shall be discarded.
ii) If any test specimen falls because of mechanical reason, such as failure of testing equipment
or improper specimen preparation, it shall be discarded and another specimen taken.
15.32.3.2 Sampling:
i) Sampling criteria for conformity shall be in accordance with IS 4020 (Part-I)-1998
ii) Lot in any consignment of shutters shall be of the same grade and type and manufactured
under similar conditions of production which shall be grouped together to form a lot.
The number of shutters to be selected at random from a lot shall depend upon its size and shall be
in accordance with Col. 1 and Col. 2 of Table 10.
Table 10: No. of Sample and Criteria for Conformity
SI. No. Sample size Permissible No. of Defects
(1) (2) (3)
26 to 50 8 1
51 to 100 13 1
101 to 150 20 1
151 to 300 32 1
301 to 500 50 2
501 and above 80 2
Note : For lot size 25 or less, number of samples to be taken for testing shall be as agreed to
between the manufacturer & Engineer-in-Charge.
Number of Tests : The samples selected as in column 2 of Table 10 shall be as agreed to between the
manufacturer & Engineer-in-Charge.
15.32.3.2.4 Criteria for Conformity : The lot shall be considered conforming to the requirements if
the number of samples failing to satisfy the requirements of characteristics does not exceed the
permissible number mentioned in col. 3 of Table 10.
15.32.4 Test: The door shutters shall be subjected to the following tests in accordance with IS 4020
(Part 1 to 16)-1998.
(a) Dimension and Squareness Test: Door shutters when tested in accordance with IS 4020 (Part
2)-1998. the dimensions of nominal width and height will be within a limit of + 5 mm. The
door shutter shall not deviate by more than 1 mm on a length of 500 mm. The thickness of the
door shutter shall be uniform throughout with the permissible variation of not more than 0.8
mm between any two points. The nominal thickness of the shutter shall be within a limit of +
1.5 mm.
(b) General Flatness Test: Door shutter, when tested in accordance with IS 4020 (Part 3)-1998
the twist, cupping and warping shall not exceed 6 mm.
(c) Local Plainness Test: Door shutters," when tested in accordance with IS 4020 (Part 4)-1998,
the depth of deviation measured at any point shall not be more than 0.5 mm.
(d) Impact Indentation Test: Door shutters, when tested in accordance with IS 4020 (Part 5)-
1998, shall have no defects such as cracking, tearing or delaminating and the depth of
indentation shall not be more than 0.2 mm.
(e) Edge Loading Test : Door shutters, when tested in accordance with IS 4020 (Part 7)-1998 the
deflection of the edge at the maximum load shall not be more than 5 mm. On removal
of the loads, the residual deflection shall not be more than 0.5 mm, failing which the test may
be repeated on the other edge in the reverse direction. Also there shall be no lateral buckling by
more than 2 mm during loaded condition and no residual lateral buckling after removal of the
load.
(f) Shock Resistance Test: Door shutters, when tested in accordance with IS 4020 (Part 8)-1998,
there shall be no visible damage in any part of the door after twenty five blows on each end.
(g) Buckling Test: Door shutters, when tested in accordance with IS 4020 (Part 9-1998), shall not
show any deterioration and any residual deformation more than 5 mm after 15 min. of
unloading and the initial deflection also shall not be more than 50 mm.
(h) Slamming Test: Door shutters, when tested in accordance with IS 4020 (Part 10)-1998, shall
not have any damage in any part of the door at the end of successive impacts. Door shutters,
when tested in accordance with IS 4020 (Part 10-1998), shall not have any visible damage in
part of the door at the end of 100 successive impacts.
(i) Misuse Test: Door shutters, when tested in accordance with IS 4020 (Part 11)-1998, there shall
not be any permanent deformation of the fixing or any other part of the door set in hindering
its normal working after the test.
(j) Screw Holding Test: Door shutters, when tested in accordance with IS 4020- Part 16-1998,
the load shall not be less than 1000 N.
(k) End Immersion Test : Door shutters, when tested in accordance with IS 4020- Part 13, the
shutter shall not show any delaminating.
(1) Knife Test: Door shutter, when tested in accordance with IS 4020 - Part 14, the grading shall
be standard & excellent.
(m) Glue Adhesion Test: Door shutters shall be tested in accordance with IS 4020 - Part 15. There
should be no delaminating.
15.32.5 Fixing of Shutters: PVC door shutter shall be side hung on three bolt hinges of size 100
mm, one at the centre and the other two at 200 mm from the top and bottom of the shutter. The flat
of the hinges shall be neatly counter sunk in to the recesses cut out to the exact dimensions of the hinge
flap. The door shall be drilled on the thickness to fit hinges. Screws for fixing the hinges shall be
screwed in with screwdrivers and not hammered. The length of the screws should be 8 mm/30 mm.
The hinges used should be of stainless steel.
15.32.6 Tolerance: The tolerance on the width and the height of the door shall be + 5 mm and the
tolerance on the nominal thickness of the door shall be + 2 mm.
15.32.7 Fittings: Fittings shall be provided as per schedule of fittings decided by Engineer-in-
Charge. In moisture prone areas M.S. fittings and screws should not be used. Hardware such as
handles, tower bolt, stopper, buffer etc. should be directly screwed (not pre-drilled) and fitted on the
door.
15.32.8 Measurements: Length and width of the shutters shall be measured to the nearest cm in
closed position covering the rebates of the frames but excluding the gap between the shutter and the
frame. Area is calculated to the nearest 0.01 sqm.
15.32.9 Rate: The specified rate include the cost of the door shutter and labour involved in fixing of
the shutter. Fittings & fixtures on the door shutter except hinges & screws shall be paid extra as
provided.
15.33 PVC Door frame: Solid PVC door frame and shutter shall be as per para 15.32.
15.33.1 Solid PVC Door Frames consisting of section 50 x 47 mm shall be fabricated from 5 mm
PVC sheet having density of 600 kg./cum. The sheet used may be in plain colour, printed design or
prelaminated veneer shade as approved by the Engineer-in-Charge. The weight per running metre
of the door frame including reinforcement should be a minimum of 1.5 kg./sq. m. The depth of the
rebate of door frame shall be 10 mm. Frames shall have smooth surface, without any warping or
bending in any member. All the parts of the door frame are to be joined to each other using solvent
adhesive conforming to IS 14182. A tolerance of + 3 mm shall be permitted in the specified
dimension of PVC section in the door frames. (Fig.) The solid PVC door frames shall be fabricated
in factory as per nomenclature of the item and directions of the Engineer-incharge.
15.33.2 Fixing of Frames : As per clause 15.31.2.
15.33.3 Measurements: As per clause 15.25.3.

15.33.4 Rate: As per clause 15.25.4.
15.34 Panelled PVC Door Shutter:
15.34.1 Panel PVC Shutters are factory made shutter and shall be brought to site fully assembled. The
Solid Panel PVC Door shall be fabricated from 5 mm PVC sheet. The sheets used may be in plain
colour, printed design or prelaminated veneer shade as approved by the Engineer-in-Charge. The
shutters shall be fabricated at factory as per nomenclature of the item and directions of the Engineer-
in-charge. (a) 30 mm thick panel PVC door shutters (Fig.).
15.34.2 Sampling and Criteria for Conformity: As per clause 15.32.3.
15.34.3 Tests: As per clause 15.32.4 except para (k), (1) & (m).
15.34.4 Fixing of Shutters: As per clause 15.32.5. In addition, it may be ensured that while fixing
hinges the screws pass through the two opposites surfaces of the M.S. reinforcement.
15.34.5 Tolerance: As per clause 15.32.6.
15.34.6 Fittings: As per clause 15.32.7.

15.34.7 Measurements: As per clause 15.32.8.
15.35 Fibre Glass Reinforced Plastic (FRP) Door Frames:
i) Door Frames shall be three legged of cross section 90 mm x 45 mm having single rebate of size
32 mm x 15 mm to receive shutter of 30 mm thickness. The frame shall be made of laminate
of thickness of 2 mm and shall be filled with wooden blocks of exterior grade MDF or seasoned
and treated hard wood inside the laminate in all the three legs of the frame. The frame to be
moulded by either hand lay up or resin transfer moulding process. The process shall consist of
laying gel coat at 1000 gms./m2 and laid over with layer of FRP Mat (CSM mat) gel coat and
FRP (CSM Mat) are defined in IS 14856. The CSM mat shall be bonded with Isophatholic resin
in the ratio not less than 1:2 (One part of Mat to two parts of Isopathlic resin and fillers &
additives) by weight. The edge shall be sealed with gel coat and FRP mat to obtain smooth
finish. Sufficient roving shall be laid in the corner to have smooth curve while laying the CSM
mat. (Figures.).
15.35.1 FRP door shall be manufactured as per specifications laid down in IS 14856-2011,
nomenclature of items & direction of Engineer-in-Charge.
15.35.2 Tolerance: Tolerance of size of frame to be + 2 mm and on size of rebate to be + 1 mm.
15.35.3 Finish: The surface of the moulded frame shall be free from any visible defects such as
small "pores, crazing, blistering, wrinkling, impurities, defective impregnation, colour blots and
aggregate defects, as mentioned in IS 14856-2011. Scattered pin holes duly repaired and finished by
applying resin and not noticeable shall be acceptable. Frame laminate shall be flat and shall have
smooth and level surface. Laminate shall be finished in colour & shade as approved by Engineer-in-
Charge.
15.35.4 Fixing of Frame: As per clause 15.31.2.
15.35.5 Measurement: As per clause 15.31.3.
15.36 Fibre Glass reinforced plastic (FRP) Shutters:
15.36.1 F.R.P. Shutters shall be manufactured conforming to the specifications as per IS 14856-
2011 and nomenclature of item & direction of Engineer-in-Charge. (Fig.)
15.36.2 Blocks of any seasoned hardwood of bulk density not less than 450 kg./m3 at 12 per cent
moisture content or any other material of sufficient thickness and length shall be provided inside the
shutter at suitable place to hold fittings and fixtures such as aldrop, tower bolt, handle, sliding door
bolt, mortice lock etc. Blocks for hinges shall be provided at three locations, unless otherwise
specified by the purchaser. One at the centre and other two at 200 mm from the top and the bottom
of the shutter. Blocks shall be provided at predetermined places in the shutter so as to fix hinges
mortice locks, tower bolts, aldrop, door closures, etc. The finished surface shall be buffed and
polished with wax.
15.36.3 Location of Fittings and Accessories: The lock rail of door shutters shall be so placed that
is centre line is at a height 850 + 5 mm from the bottom of the shutter. Door shutter shall be fixed to
the frame with three hinges, unless otherwise specified by the purchaser, of the type specified. These
locations shall be, one at centre and other two at 200 mm from the top and the bottom of the shutter,
where blocks have already been provided and suitable indication by depressing the profile has been
made. Screws for fixing the hinges shall be screwed in with screwdrivers & not hammered. The
length of screw should be 8/30 mm. The hinges used shall be stainless steel or aluminum.
15.36.4 Sampling & Criteria for Conformity Shall be as per clause 15.32.3.
15.36.5 Finish: As per clause 15.35.3.
15.36.6 Tests: As per para 15.32.4 except clause (j), (k), (I) & (m).
15.36.7 Fixing of Shutter: As per clause 15.32.5.
15.36.8 Tolerance: As per clause 15.32.6.
15.36.9 Measurement: As per clause 15.32.8.
15.37 Solid PVC foam profile doors:
15.37.1 Solid PVC Foam Profile Frame: Solid PVC foam profile frame doors are made from
solid PVC foam profiles 60 x 30 mm with integral skin cut to required size. Doors are provided with
naturally strong stiffener frame and sandwich panelled to offer sound and heat insulation with
pressure laminate/infill panel to provide scratch resistance surface. (Fig. 15.3). Supporting bar at
bottom side of frame shall be provided for maintaining frame in plumb. The frame shall be fabricated
in factory as per nomenclature of the item and directions of the Engineer-in-charge. PVC door frame
should have shore hardness more than 70.
15.37.2 Fixing of Frames: As per para 15.31.2.

15.37.3 Test in PVC Foam Profiles: Tests on PVC Foam Profiles shall be as per Table 11 below:
Table-11
S. No. Property Test Method Unit Acceptable
Value
1. Density (at 27°C) ASTM D 792 gm/cc 0.5-0.7
2. Tensile strength at yield ASTM D 638 PSI % 2000
(B) Elongation at Break ASTM D 638 20
3. Tensile Modulus (Modulus ASTM D 638 N/Sq.mm 200
of Elasticity)
4. Impact strength (ch'arpy ASTM D 256 ftlb/sq.ln 7
Unnotched)
5. Durometer Hardness DIN 53505 Shore D 70
6. Vicat Softening Point ASTM D 1525 C 75
(at ION Load)
7. Flammability UL94 Self
Extinguishing
15.37.4 Measurements:As per clause 15.31.3.
15.37.5 Rate : As per clause 15.31.4.
15.38 Solid PVC foam profile shutters:
i) Solid PVC foam shutters are made from solid PVC foam profiles with integral skin. Doors are
provided with naturally strong stiffener frame and sandwich panelled to offer sound and heat
insulation with pressure laminate/infill panel provides scratch resistance surface. Door shutters
can be nailed, screwed, drilled, glued, sawn lapped or welded just like wood and characterized
by excellent screw holding strength (200 kg f.).
15.38.1 28 mm Thick Door Shutters: Profile is cut in required length to make vertical & horizontal
stile. Mitered cut joint are made using solvent based PVC adhesive & epoxy solvent. G.I. 'C stiffener
39 x 19 x 19 or 40 x 20 x 19g. M.S. Pipe is fixed in the grooves made in frame. Telescopic polymeric
corners are provided at corners for better rigidity. Infill panel 3 mm thick HPL sheet is fixed with
csk screws of required size to the profile frame as specified. Mirror image of shutter frame is joined
using solvent based PVC adhesive as well as csk type sheet metal screws of required size at four
corners at top & bottom. Additional bonding strength is
provided by using silicone sealant epoxy sealant at joints. Lock rail is provided by using PVC profile
& C type G.I. stiffener 40 x 10 in the groove & fixed with adhesive to frame & infill. Decorative
corner moulding is fixed to impart elegant look.(Fig. ).The fabrication shall be done in factory as
per nomenclature of the item and directions of Engineer-in-Charge.
15.38.2 Sampling and Criteria for conformity: As per clause 15.32.3.
15.38.3 Tests : As per clause 15.32.4.

15.38.4 Fixing of Shutters: As per clause 15.32.5.
15.38.5 Tolerance: As per clause 15.32.6. Fittings:
15.38.6 As per clause 15.32.7. Measurements : As
15.38.7 per clause 15.32.8. Rate : As per clause
15.38.8 15.32.9.
15.39 Factory made fibre glass reinforced plastic chajja:

F.R.P. chajja shall be 4 mm thick of required colour/size, design and drawing as approved. The
chaja shall have smooth gradual slope curvature for easy drainage of water & shall be factory
manufactured as per nomenclature of item & directions of Engineer-in-Charge. (Fig. 15.50).
15.39.1 Material:
Glass Fibre (chopped strand mat) shall be as per IS 11551
Unsaturated Polyester Resin shall be as per IS 6746
Surface Burning Characteristics of Building Material - ASTM E 84-77a
Unsaturated Polyester Resin Gel coat shall be as per IS 6746 Curing Agents -
Cobalt Napthanate and MEKP
Test of products - IS 14425
Glass Fiber Roving - IS 11320
The F.R.P. chajja laminate shall be water and chemical resistant and shall have very high transit
strength to weight ratio and high modulus of elasticity, good textile processing and excellent fiber
reinforcement properties. The laminate shall have low coefficient of thermal expansion and a high
thermal conductivity and high dielectric constants. The F.R.P. laminate shall be diversion ally
stable, shall have moisture and corrosion resistance.
15.39.3 Tolerance: Tolerance of +10 mm in overall size of FRP chajja is permissible.
15.39.4 Finish: The F.R.P. laminate to be finished with polyurethane based or equivalent paint as
final coat or gloss or mat followed by clear lacquer coat to get the shine of required shade.
15.39.5 Tests: Frequency of tests as per direction of Engineer-in-Charge & tests to be conducted as
per pars 15.32.4.
15.39.6 Measurement and Rate: The width and length to be measured in centimetre and area to
be calculated as square metre correct up to two places of decimal. The rate includes cost of all the
materials, labour scaffolding, fittings & fixing up to all heights etc. involved in operations described
above, but excludes the cost of paint.
LIST OF RELEVANT BIS CODES
S1. No. IS Code Subject
1. 617-1994 Aluminium Alloys cast Hinges
2. 733-1983 Wrought Aluminium and Aluminium Alloys, Bars, Rods and
(Re.2006) Sections
(For General Engineering Purposes) -Specification
3. 737-2008 Wrought Aluminium and Aluminium alloy sheet and strip for
(Re.2013) general engineering purposes -Specification
4. 1285-2002 Wrought Aluminium and Aluminium Alloy, Extruded Round
(Re.2013) Tube
5. 1362-1959 Screws threads for Fabrication of Aluminium Door, Windows
& Ventilators
6. 1868-1996 Anodic coating on Aluminium and its Alloys-Specification
(Re.2010)
7. 1948-1961 Specification for Aluminium Doors, Windows and Ventilators
(Re.2011)
8. 2209-1976 Brass Vertical Mortice Lock
7. 3087-2005 Pre-laminated particle board -Specifications.
(Re.2010
8. 3908-1986 Specification for Aluminium equal leg angles
(Re.2013)
9. 3909-1986 Specification for Aluminium unequal leg angles
(Re.2013)
10. 3965-1981 Dimensions for wrought Aluminium and Aluminium Alloys
(Re.2006) bars, rods and sections.
11. 4020-1998 Test of Door Shutters
12. 5523-1983 Method of testing anodic coating on aluminium and its alloys.
(Re.2010)
13. 6012-1992 Measurement of coating thickness by Eddy Current Method
(Re.2010)
14. 6315-1992 Floor springs (Hydraulically regulated) for heavy doors-
(Re.2012) Specifications
15. 6477-1983 Dimensions of extruded hollow section and tolerances
(Re.2010)
16. 6746-2005 Unsaturated Polyester Resin systems
17. 10151- PVC Door Shutters
18. 11551-2001 Glass Fibre (Chopped Strand Mat)
19. 12049-1987 Dimension & Tolerances relating to Wood based Panel Materials
20. 12823-1990 Wood products- Pre-laminated particle board -Specifications.
(Re.2009)
21. 14425-1997 Guide for manufacture of glass reinforced polyester resin
moulding
22. 14856-2000 Specification for glass fibre reinforced plastic (FRP) panel
(Re.2011) type door
23. 14900-2000 Specifications for transparent float glass
(Re.2010)
CHAPTER No. 16
REPAIRS AND MAINTENANCE OF

BUILDINGS
CHAPTER No.16 : REPAIRS & MAINTENANCE OF BUILDINGS
CONTENTS
Clause No. Description Page No.
16.1 Scope 3
16.2 Repair of Plaster 3
16.3 Fixing Door Windows or Clerestory Window Chowkhat in 4
Existing Opening
16.4 Making Opening in the Masonry Construction and 5
Fixing Chowkhat for Doors, Windows & Clerestory Windows
16.5 Repair/Replacement of Doors and Windows Shutters 6
16.6 Providing & Fixing Wooden Cleats to Doors and Windows 7
16.7 Renewing Glass Panes With Putty and Nails 7

16.8 Renewing Glass Panes With Wooden Fillets 8
16.9 Providing New Wooden Fillets 9
16.10 Renewal of Old Putty of Glass Panes 9
16.11 Fixing Fan Clamps in Existing R.C.C. Slabs 9
16.12 Regrading of Mud Phuska 10
16.13 Replacing of Sand Stone Slabs in Roofing 11
16.14 Guniting to Damaged R.C.C. Column and Beams 11
16.15 Repair to Brick on Edge Flooring in C.M. 12
16.16 Repair to C.C. Flooring 13
16.17 Repair to C.C. Flooring (of Red Oxide of Iron) 14
16.18 Repair to Terrazzo Flooring (Marble Chips) Laid in Situ 14
16.19 Repair to Terrazzo Tile Flooring 14
16.20 Repair to Terrazzo Tiles(Glazed Tiles) Work in Dado 15
16.21 Precautions to Prevent Cracks in Buildings 15
CHAPTER No. 1 6
REPAIR & MAINTENANCE OF BUILDINGS
16.1 Scope :
The Specification shall apply to all items of repairs to building work required to be carried out under
the contract or as directed by the Engineer in charge. These work shall be carried out in conformity
with the relevant specifications to the required level.
16.2 Repair to Plaster: The work includes cutting the patch and preparing the wall surface. Patches
of 2.50 square metres and less in area shall be measured under item of 'Repairs to Plaster' under this
sub-head Plastering in patches over 2.5 square metres in area shall be paid for at the rate as applicable
to new work under subhead "Finishing".
1.6.2.1 Scaffolding: Scaffolding as required for the proper execution of the work shall be erected. If
work can be done safely with the ladder or jhoola(wooden platform suspended with pulley and rope
arrangement) these will be permitted in place of scaffolding.
16,2,3 Cutting: The mortar of the patch, where the existing plaster has cracked, crumbled or sounds
hollow when gently tapped on the surface, shall be removed. The patch shall be cut out to a square
or rectangular shape at position marked on the wall as directed by the departmental staff. The edges
shall be slightly under cut to provide a neat joint.
16.2.3 Preparation of Surface: The masonry joints which become exposed after removal of old
plaster shall be raked out to a minimum depth of 10 mm in the case of brick work and 20 mm in the
case of stone work. The raking shall be carried out uniformly with a raking tool and not with a basuli,
and loose mortar dusted off. The surface shall then be thoroughly washed with water, and kept wet
till plastering is commenced. In case of concrete surfaces, the same shall be thoroughly scrubbed
with wire brushes after the plaster had been cut out and pock marked, as described in relevant Chapter
. The surface shall be washed and cleaned and kept wet till plastering is commenced.
16.2.4 Application of Plaster: Mortar of specified mix with the specified sand shall be used. The
method of application shall be as described for single coat plaster work of the specified mix and
under relevant Chapter . The surface shall be finished even and flush and matching with the old
surrounding plaster. All rounding necessary at junctions of walls, ceilings etc. shall be carried out in
a tidy manner as specified in relevant Chapter 9. All dismantled mortar etc. shall be disposed of as
16.2.5 Protective Measure: Doors, windows, floors, articles of furniture etc. and such other parts
of the building shall be protected from being splashed upon. Splashing and droppings, if any, shall
be removed by the contractor at his own cost and the surface cleaned. Damages, if any, to furniture or
fittings and fixtures shall be recoverable from the contractor.
16.2.6 Curing : Curing shall be done as for plaster work with special reference to the particular
type of plaster mix as described under Chapter 9.
16.2.7 Finishing: After the plaster is thoroughly cured and dried the surface shall be white washed or
colour washed to suit the existing-finishing as required unless specified otherwise.
16.2.8 Measurements : Length and breadth shall be measured correct to a cm. The area shall be
calculated in square metre correct to two places of decimal. Patches below 0.05 square metre in area
shall not be measured for payment. Pre-measurements of the patches to be plastered shall be recorded
after the old plaster has been cut and wall surface prepared.
16.2.9 Rate : The rate includes the cost of all the materials and labour involved in all the operations
described above including lead for disposal of old dismantled plasters.
163 Fixing Door, Window or Clerestory Window Chowkhat in Existing Opening in Masonry/
R.C.C. Wall :
16.3.1 Making Holes:
16.3.1.1 In case of door frames without sills, holes 40 mm deep shall be made in the floor for fixing
the lower end of verticals of the frames. For doors with sills, the sill plates shall be partly fixed in
the floor so that they project above the floor to the height as directed by the Engineerin-Charge.
163.1.2. For embedding hold fasts/ fasteners of doors, windows or clerestory windows, the requisite
number of holes at the correct positions shall be cut out in the masonry/R.C.C. walls. The size of the
holes shall be such that the chowkhat with the hold-fasts/fasteners can be conveniently erected in
position. Where necessary, masonry/R.C.C. shall be chipped uniformly to facilitate easy insertion of
the frame in the opening.
16.3.1.3 Special care shall be taken when holes are made in load bearing pillars or wall portions
separated by openings to ensure that beams etc. supported by them are properly propped up. In such
portions cutting holes shall be done on one side at a time. The sides of the holes shall be truly parallel
and perpendicular to the plane of the wall. Due care shall be taken, not to disturb the adjoining
masonry and the masonry under the bearings of lintels and arches etc. spanning the opening. The
holes shall then be cleaned of all dust, mortar and brick bats or stone pieces and thoroughly wetted.
16.3.2 Fixing:
i) The sides of chowkhat of door, window or clerestory window abutting against or to be
embedded in masonry shall be painted with two coats of coal tar before being placed in position.
The chowkhat shall then be inserted in position with their hold-fasts bolted tight. The chowkhat
shall then be adjusted to proper line and plumb and secured in position by temporary bracing
which shall not be disturbed or removed until the hold fasts are embedded in the masonry and
the concrete block has set. The concrete to be used for embedding hold-fasts shall be cement
concrete 1:3:6 mix (1Cement: 3 Coarse Sand: 6 Graded Stone Aggregate 20 mm nominal size).
ii) The minimum size of concrete block in which the hold-fasts will be embedded shall be 30 x 10
x 15 cm for 35 cm long holdfasts. The concrete of the block shall completely fill the hole made
in the masonry for the purpose. The chase cut in the floor shall be cut square and construction
joint shall be provided, filled in with cement concrete 1:2:4 (1 cement: 2 coarse sand : 4 graded
stone aggregate 20 mm nominal size) and rendered smooth at the top and finished to match the
existing type of floor.
16.3.3 Finishing : After the surface surrounding the hold-fasts has sufficiently dried it shall be
cleaned of dust etc. and wetted. It shall then be plastered with cement mortar 1: 4 (1 Cement: 4 Fine
Sand) flush and matching with the surrounding plaster work. In case of exposed brick work, stone
work, the finishing shall be done to match the surrounding. Any other portion of the wall opening,
if damaged, shall be repaired in similar way. After the cement plaster patches have been thoroughly
cured and have dried, they shall either be white washed or colour washed as required unless otherwise
specified. All waste material and debris obtained from cutting etc. shall be disposed off to the nearest
dumping ground.
16.3.4 Measurements: The chowkhat of doors, window and clerestory windows shall be
enumerated separately.
16.3.5 Rate: The rate shall apply irrespective of the size of the chowkhat up to a maximum area of
opening 3.75square metres for doors, 2.5 square metres for windows and 1.2 square metres for
clerestory windows. The rate is inclusive of labour and materials involved in all the operations
described above, excluding the cost of chowkhat but including the cost of supplying and fixing the
hold-fasts/ fasteners and C.C. block & bolts.
16.4 Making opening in the Masonry Construction and Fixing Chowkhat for Doors, Windows
and Clerestory Windows:
16.4.1
(a) Before making opening it is necessary to examine that the wall exclusive of opening is adequate
to take the load coming on the structure. All the structural members supported on the walls
which have, direct bearing over the area in which opening is to be made, shall be properly
supported with props to relieve the load from masonry wall till, the lintel over the opening is
strong enough to take the load. Care should also be taken not to disturb the adjoining masonry.
(b) All precautions as explained in the relevant Chapters (Demolition and Dismantling) should be
followed in case of dismantling the external walls. The portion to be dismantled may be clearly
marked on both sides of the wall. Dismantling shall be carried out from top to bottom within
the marked area-. The sides of the opening shall be as far as possible, parallel and perpendicular
to the plane of wall.
16.4.2 Making Opening:
16.4.2.1 The openings for fixing door/window frames shall be to the extent of accommodating the
holdfast. The holdfasts shall be fixed in cement concrete 1: 3: 6 (1 Cement : 3 Coarse sand : 6 Stone
aggregate 20mm nominal size) or in masonry as required. Where only opening is to be made in the
masonry, the width of the opening shall be such that the sides of the masonry can be built true to line
and plumb and such masonry built shall conform to the specifications of the particular type of
masonry in which the opening is made with particular reference to size of corner stones etc. In order
to get continuity with old masonry, proper key shall be provided. The height of the opening shall be
such that it can accommodate the required depth of the RCC lintel also.
16.4.1.2 The sides of opening in masonry shall be cleaned of all dust, mortar, brick bats/loose stones,
chips etc. and the surface left rough and thoroughly wetted.
16.4.1.3 The lintel shall be invariably cast first in the opening made for the purpose. One side of
the shuttering shall be kept open in the beginning till the concrete is laid. The shuttering shall
then be fixed for half of the opening and concreting completed.
16.4.1.4 Curing of lintel cast shall be done for a minimum period of 7 days.
16.4.1.5 Precast RCC lintel or R.S. Joist may also be used when directed by the Engineer-in-
Charge.
16.4.2 Fixing Chowkhat: Fixing of chowkhat shall be done as specified in 16.3.2
16.4.3 Finishing:
16.4.3.1 After the surface of the sides of masonry opening and lintel are sufficiently dry and set, it
shall be cleaned free of dust, loose mortar etc. and wetted thoroughly. It shall then be plastered or
pointed as required flush with the surrounding masonry work. Any other portion of the wall if
damaged shall be finished in similar manner.
16.4.3.2 After the cement plaster/pointing has been thoroughly cured and have dried the surface shall
be either white or colour washed/painted as required. The surface of the wall which is spoiled due
to splashing of mortar shall be cleaned.
16.4.4 Measurements: The opening made for doors, windows, clerestory windows shall be counted
by numbers separately.
16.4.5 Rate: The rate shall apply irrespective of the size of the opening up to a maximum area of
3.75 square metres for doors, 2.50 square metres for windows and 1.20 square metres for clerestory
windows. The rate is inclusive of labour and material involved in all the operations described above.
Cost of Chowkhat, cost of CC blocks, cost of supplying the hold-fasts, bolts, cost of R.C.C. lintel or
R.S. Joist which shall be paid for separately.
16.5 Repair/Replacement of Door and Window Shutters :
16.5.1 The damaged shutter shall be carefully examined by the Engineer-in-Charge to decide
whether entire shutter along with panels and fittings is to be replaced or only a part of the shutter is
required to be replaced. Keeping in view the condition and remaining life of the portions to be
retained.
16.5.2 If the entire shutter is to be replaced, the shutter in question should be removed from the
existing frame without damage to the frame and the hinges fittings should be removed for reuse in
the new and shutter proposed to be fixed.
16.5.3 The new shutter shall be of the same class of timber as the dismantled one unless otherwise
decided by the Engineer-in-Charge. The specifications for manufacture and fixing of the new shutter
shall be as specified ( refer relevant chapter).
16.5.4 At the time of fixing the shutter in the frame, minor damages to the rebates in the frame shall
be made good to ensure proper fitting of the shutter and fixing of hinges may be done with new
wood screws in new locations slightly away from the original location to ensure proper fixing of the
hinges to the frames.
16.5.5 Any old fitting of the dismantled door which are worn out or damaged may be replaced with
new one as directed by the Engineer-in-Charge.
16.5.6 When so directed by the Engineer-in-Charge only a portion of the shutter viz. rails or styles
may be replaced with new member of the same class of timber with shape and size matching the
portions retained. The dismantling of the member shall be done with care so that mortise or Tenon
of the existing member is not damaged and the new member fixed carefully and properly
as specified ( refer relevant chapter).
16.5.7 Measurements: Measurements shall be made as per the specifications ( refer relevant
chapter) if entire shutter has been replaced. The overall length and width of the framework of the
shutters shall be measured nearest to a cm in fixed position (overlaps not to be measured in case of
double leaved shutters) and the area calculated in square metres correct to two places of decimeter.
No deduction shall be made to form panel openings or louvers. No extra payments shall be made for
shape, joints and labour involved in all operations described above. If only panelling or part of
panelling has been replaced, measurements shall be measured correct to a cm before fixing the
beading and the area shall be calculated to the nearest 0.01 sqm. The portions of the panel inserts or
glazed panel inside the grooves or rebates shall not be measured for payment. If styles and rails are
only to be replaced, measurements shall be made correct to a cm before fixing the beading and the
area shall be calculated to the nearest 0.01 sqm.
16.5.8 Rate: The rate shall include the cost of material and labour involved in all the operations
described above. The frame work and panelling of each type or glazed panels shall be paid separately.
The rate for frame work includes the cost of butt hinges and necessary screws. However, extra shall
be paid for providing moulded beading where specified. Nothing extra shall be paid for plain
beading.
16.6 Providing and Fixing Wooden Cleats to Doors and Windows:
16.6.1 Cleats: The cleats to match the existing size or of 100 mm x 75 mm x 50 mm shall be made
of the class of wood described in the item. The shape of the cleat shall be as approved by the
Engineer-in-Charge. The cleats shall properly fit in the rebates of the chowkhat to effectively stop
the shutters from closing. The surface of cleats shall be painted, varnished or bees waxed, etc. to
match with the finish of the existing door or window.
16.6.2 Fixing: Recesses shall be cut in the frame of the chowkhat and in the cleat to the exact size
and depth for counter sunk the hinges. The cleats shall be fixed with 50 mm butt hinges of brass or
mild steel as specified. The screws used shall be of the same material and finish as the hinges and
these shall be 20 mm long of designation No. 6. Cleats shall be fixed as far as possible in the original
position.
16.6.3 Measurements: Cleats of each class of wood shall be enumerated by numbers.
described above. The rate shall also include the cost of hinges and screws required for fixing the
cleats, cost of painting, varnishing or bees waxing to match with the finish of existing door or
window.
16.7 Renewing Glass Panes with Putty and Nails:
16.7.1 Removing Broken Glass Panes: Old putty shall be raked out with hack knife. The brad
(small nails without head) and pieces of broken glass shall be removed from the rebates of the sash
bars. The pieces of glass panes as found useful shall be handed over to the Engineer-in-Charge of
the work. No glass shall be inserted in frames until they have been primed and prepared for painting
so that the wood may not draw oil out of the putty.
16.7.2 Glass Panes : The glass panes shall conform to specifications described in (to refer relevant
chapter)
16.7.3 Fixing:
i) The glass panes shall be so cut that it fits slightly loose in the frame. A thin layer of Putty
conforming-to IS: 419 shall be prepared by mixing one part of white lead with three parts of
finely powdered chalk and then adding the boiled linseed oil to the mixture to form a stiff paste
and adding varnish to the paste @ 1 liter of varnish to 18 kg. of paste. The putty so prepared in
the form of a stiff paste shall be drawn along the inner edge of the rebate, for bedding the back
of the glass panes. The glass pane shall then be put in position, pressed home against the thin
layer of the putty, and secured in rebate by new brads. The brads shall not be spaced more than
7.5 cm from each corner and not more than 15 cm apart. The putty shall then be applied in the
rebate uniformly sloping from the inner edge of the rebate. In doing this care shall be taken to
keep the putty a little within the inner edge of the rebate and surplus putty removed so that none
of it is seen through the glass from the inside. The putty so filled in the rebates shall be levelled
smooth and finished in a straight line. When dried the putty shall be covered with a coat of
paint of approved quality and shade to match the existing finish of joinery work.
ii) The glass panes shall be cleaned with ethylated spirit. All splashing or droppings of washing
and paints shall be removed. All rubbish and unserviceable materials shall be disposed off to
the dumping ground.
Note : Frosted glass panes should be replaced with frosted glass panes. These shall be fixed
with frosted face on the inside
16.7.4 Measurements: Length and breadth of glass panes shall be measured correct to a cm. The
area of the glass panes as fixed shall be calculated in square meter correct to two places of decimal.
16.7.5 Rate : The rate shall include the cost of labour and materials involved in all the operations
described above.
16.8 Renewing Glass Panes with Wooden Fillets:
16.8.1 Removing Broken Glass Panes: The specifications shall be the same as in para 16.7.1 except
that the wooden fillets including nails shall be taken out carefully.
16.8.2 Glazing :
i) The specifications for glass panes and their fixing shall be the same as given in relevant chapter
. The fillet shall either be fixed flush or projected uniformly to match with the existing work
by mean of nails (brads).
ii) The new fillet provided shall be painted or finished otherwise to match with the existing
finish of the joinery work.
iii) The glass panes shall be cleaned with ethylated spirit of all sorts of splashing and droppings
of wash and paints.
iv) All rubbish and unserviceable materials shall be disposed off in the dumping ground.
16.8.3 Measurements: Length and breadth of glass panes shall be measured correct to a cm. The
area of the glass panes as fixed shall be calculated in square metre correct to two places of decimal
including necessary nails (brads). The new wooden fillets fixed shall be measured in running metres
correct to a cm.
16.8.4 Rate: The rates shall include the cost of labour and material involved in all the operations
described above except that the cost of new wooden fillets used in the work and their finishing shall
be paid for separately.
16.9 Providing New Wooden Fillets: The fillets shall be of wood, as specified in the item of
work, these shall be cut and planed smooth to the required shape and dimensions.
16.9.1 Fixing:
i) The specifications for glass panes and their fixing shall be the same as given in (to refer
relevant chapter). The fillet shall either be fixed flush or projected uniformly to match the
existing work.
ii) The fillet shall be painted or finished otherwise to match with the existing finish of the
joinery work.
iii) The glass panes shall be cleaned with ethylated spirit of all sorts of splashing and dropping
of wash and paints.
16.9.2. Measurements: The fillets shall be measured in running metres. The lengths shall be
measured correct to a cm.
16.9.3. Rate: The rate shall include the cost of all labour and materials involved in all the operations
described above. The rate shall also include the cost of removal of worn out fillets, when these are
met with in old work. The rate shall vary according to the class of wood used.
16.10 Renewal of Old Putty of Glass Panes:
16.10.1 The old putty shall be removed as specified in 16.7.1 and new putty fixed as specified in
16.7.3
16.10.2 Measurements: The work shall be measured in running metres. The length along the
rebate shall be measured correct to a cm.
16.10.3 Rate: The rate shall include the cost of labour and materials involved in all the operations
described above.
16.11 Fixing Fan Clamps in Existing R.C.C. Slabs:
16.11.1 The fan clamps to be fixed in an existing R.C.C. slab shall be of specified type. These shall
be made of 16 mm dia. M.S. bar (Fig. 1).
16.11.2Fixing:
i) A 15 x 17.5 cm size chase shall be cut from the ceiling to expose the reinforcement and up to
2.50 cm clear round the reinforcement bar as directed. This shall be done without any damage
to adjoining portion of the ceiling.
ii) The two arms at the ends of the clamps shall be passed through the space over the reinforcement
bar from the bottom of the slab. Then the two arms shall bent down about 1.5 cm by means of
a crow bar. The clamp shall be held in position and chase in the ceiling filled with cement
concrete 1:2:4 (1 cement: 2 coarse sand : 4 graded stone aggregate 20 mm nominal size). The
ceiling shall then be finished to match the existing surface and properly curded.
iii) The exposed portion of the clamp shall be given two or more coats of paint including one
priming coat of shade as ordered by the Engineer-in-charge.
16.11.3 Measurements and Rate: Clamps shall be counted in numbers. The rate per fan clamp shall
include the cost of labour and materials involved in all the operations described above. The rate shall
apply irrespective of the thickness of the slab.
DRAWING NOT TO SCALE ALL

DIMENSIONS ARE IN MM
Fig.1 Repairs of Fan Clamps
16.12 Regrading of Mud Phuska Terracing:

16.12.1 Dismantling:
i) The specified area of roof as directed by the Engineer-in-Charge shall be dismantled carefully
so that the minimum of tiles or bricks are damaged. The serviceable tiles or bricks shall be
cleaned and stacked on places as directed by the Engineer-in-Charge, or on the parapet wall if
convenient and safe or otherwise carried to ground and stacked as directed by the Engineer-in-
Charge.
ii) All unserviceable tiles and debris shall be disposed off to the dumping ground as directed by
the Engineer-in-Charge. Suitable earth shall be stacked separately for reuse.
16.12.2 Laying: Mud phuska shall be removed, cleaned of all foreign matter and brought to the
ground. After approval of the Engineer-in-Charge it shall then be reduced to fine powder and then
mixed with additional soil for regarding and additional fibrous reinforcing materials such as chopped
straw or fresh bhusa at the rate of 8 kg/cum of mud mortar shall be mixed with old earth. The
chopping used shall not be more than 20 mm in length. A pit shall be dug where the mixture shall
be added and allowed to mature for a period of not less than 7 days. During this period the mixture
shall be worked up at interval with feet and spades so as to get pugged into homogenous mass free
from lumps and clods. The consistency of the mortar shall be adjusted by taking it in a trowel and
observing how it slides off from the face of the trowel. The mortar shall readily slide off, but at the
same time it shall be so wet as to part into large drops before falling.
16.12.3 Leaping Plaster: It shall be prepared by mixing soil which is free from coarse sand with
approximately equal volume of cow dung and adding the required quantity of water. The mixture
shall work to a homogeneous mass. The quantity of gobar used in Gobri leaping shall not be less
than 0.30 cum per 100 sq m of plaster area.
16.12.4 Laying Tile Bricks and Grouting: The specifications shall be as described in (to refer
relevant chapter) except that new tile as necessary to replace the broken tiles shall be used. Half or
cut brick tiles shall not be used except where necessary to complete the bond. New work shall
be finished in level with surrounding surface.
16.12.5 Curing and Measurements: Shall be as specified in relevant chapter.
16.12.6 Rate: The rate shall include the cost of all materials and labour involved in all the
operation described above. Except for new tiles or bricks which shall be paid for separately.
16.13 Replacing Sand Stone Slabs in Roofing :
16.13.1 Dismantling of roof:
i) The general specifications given in the relevant chapter shall apply. The cracked or decayed Stone
slab as marked by the representative of the Engineer-in-charge shall be removed after dismantling the
tile covering with mud phuska etc. over it if any, or any other type of covering over the stone slabs.
Mud phuska terracing with tile brick or any other type of covering shall be dismantled as per 16.12.1
over the specified cracked or decayed tiles to an area extending 15 cm on all sides of stone slabs.
This area may be increased by the Engineer-in-Charge, if found necessary. Stone slabs shall then be
dismantled and carried down and stacked properly.
In case the Stone slabs are not covered at top with mud phuska or lime terracing or any other type
of covering, the decayed or cracked stone slabs shall be dismantled and carried down or lowered
with ropes and stacked properly.
16.13.2 Relaying of Stone Slab Roofing:
i) Before placing the Stone slab the condition of the existing wooden battens or supporting walls
shall be checked by suitable methods and replaced if required as per direction of Engineer-in-
Charge. The upper surface of the wooden battens and beams or walls supporting the Stone slab,
shall be painted with two coats of coal tar if not already treated and with one coat of coal tar if
originally treated or with plaster of required strength on the top of the wall etc..
ii) The specifications for stone slabs, laying, finishing and curing, shall be as described under the
relevant chapter.
16.13.3 Relaying of Mud Phuska with Tile: The specifications shall be as described in 16.12.2 to
16.12.4 and shall be paid for separately.
16.13.4 Curing and Measurements: Shall be done as described in relevant clause of Chapter on
Roofing.
16.13.5 All unserviceable material shall be disposed off to the dumping ground as directed by the
Engineer-in-Charge.
described above, except the cost of wooden battens which shall be paid for separately.
16.14 Gumting to Damaged R.C.C. Columns and Beams:
16.14.1 R.C.C. columns and beams which have cracked or where reinforcements have deteriorated
shall be repaired by Guniting. Where necessary centring for the beams and slab and shoring for the
columns in both the planes shall be provided before Guniting is started. Sequence of strengthening
work shall be as under:
16.14.1.1 Strengthening of first floor beams and column from the footings up to the middle, of the
second storey.
16.14.1.2 Strengthening of beams of second floor and columns from the middle of second storey to
middle of third storey.
16.14.1.3 Strengthening of beams of 3rd floor and terrace beams and columns from the middle of
3rd storey up to terrace level.
16.14.1.4 At least 7 days strength shall be attained by the Gunited beams before any load from top
floor is transferred to the floor beams. The members which are to be strengthened shall be relieved
of the dead load. The repair work shall be done from ground floor upward.
16.14.2 Preparation of surface: Before strengthening the structural members by guniting the
surface of the existing members shall be prepared as under.
16.14.2.1 Concrete Surface: Any existing plaster on R.C.C. work shall be removed and R.C.C.
surfaces shall be roughened with foot marks at least 6 mm deep at close intervals not more than 1
cm centres to form a bond for the cement gunite plaster. In case of masonry walls all plaster, if any,
shall be completely removed and joints raked out to a depth of 20 mm. All cracks shall be opened
out to maximum depth possible in V shape and the surface shall be cleaned of all loose mortar and
foreign matter.
16.14.2.2 Reinforcement : The reinforcement bars shall be cleaned properly to remove all the scales
and rust by wire brushing and by rubbing with emery paper. A coat of neat cement slurry shall be
applied on the existing reinforcement after cleaning it as mentioned above just before the Guniting
is done.
16.14.3 Placing Additional Reinforcement: The additional reinforcement based on actual design
shall be placed in position by fixing it to the existing concrete by fastening with wires tied to nails
driven into the concrete and secured rigidly and supported so that reinforcement does not get
displaced when guniting is done. In any case clear spacing between the reinforcement bars shall not
be less than 50 mm.
16.14.4 Precaution: Guniting shall be continuously inspected to check the materials, forms,
reinforcement running of equipment, application of guniting and curing. Any defective area found
shall be removed and got redone.
16.14.5 Gumting :Gunite is a mixture of cement and sand deposited in the form of cement plaster
ranging from 12 to 50 mm thick for walls and 100 mm for floors ejected under a pressure of 2 to 3
kg/square cm from a machine called cement gun. The cement and sand are mixed almost dry and
screened through a sieve of specified designation, and mixture is blown dry through a hose and water
just sufficient for the purpose of hydration added at the nozzle. A separate hose carries the water to
the nozzle. Under a pressure of 1 to 1.5 kg/square cm unless otherwise specified by the manufacturer
of the gun and the nozzle man regulates the quantity by means of a hand operated valve.
16.14.6 Measurements: Breadth and length in face of repaired/gunited surface shall be measured
correct to a cm and area shall be calculated in sq m correct to two places of decimal.
16.14.7 Rate: The rate shall include the cost of all materials and labour described above, excluding the
cost of additional reinforcements required, which shall be paid separately.
16.15 Repairs to Brick on Edge Flooring in Cement Mortar :
16.15.1 The new bricks used for repair shall be of the class specified and the specifications for the
bricks to be used in the work shall be as laid down in (to refer relevant chapter)
16.15.2 Brick required for flooring shall be adequately soaked in stacks by profusely sprinkling with
clean water at regular intervals for a period not less than six hours so as to keep them wet, except for
dry brick flooring.
16.15.3 The bricks laid in the portion under repair should be removed carefully so that as many full
bricks as possible are taken out for reuse. After the bricks and old mortar is removed, base concrete
i.e. sub-grade shall be properly cleaned and coated with thick cement slurry so as to get a good bond
between sub-grade and flooring.
16.15.4 The brick shall be laid in the existing pattern. These should be laid frog downward. Old
brick reused shall be used in one continuous stretch.
16.15.5 Bricks shall be laid on 12 mm thick mortar bed of specified proportion of the ingredients
and each brick shall be properly bedded and set home by gentle tapping, with handle of trowel or
wooden mallet, its inside faces shall be buttered with mortar, before the next brick is laid and pressed
against it. The newly laid surface should be in the same plane and loose of the existing surface,
16.15.6 After the bricks have been laid, mortar should be scrapped out from the joints to a depth of
20 mm, cement grouted and then cement pointed. After pointing the whole surface should be kept
moistened by covering with wet absorbent material.
16.15.7 Measurements: Length and breadth shall be measured correct to a cm before laying
skirting, dado or wall plaster. The area of the repaired brick flooring shall be measured as laid in
square metre correct to two places of decimal. No deductions shall be made nor extra paid for any
opening in the floor area up to 0.1 square metre (10 dm sq). Nothing extra shall be paid for laying
the floor at different levels in the same room or court yard. Brick flooring when laid in diagonal
herring bone bond or other pattern as specified or directed shall be measured separately. The area
where old bricks are reused shall be measured and paid for separately.
16.15.8. Rate: The rate shall include the materials and labour required for work of dismantling &
repairing the existing flooring in addition to what is specified in the item of work.
16.16 Repair to Cement Concrete Flooring:
16.16.1 The flooring to be replaced should be dismantled carefully without damaging the base and
the dismantled material disposed off as directed by the Engineer-in-Charge.
16.16.2 The panels of the flooring to be repaired shall be adjusted according to the existing pattern
and proper slope as per the existing floor slope shall be maintained. No damage shall be done to the
existing floor panels. Edges of the adjoining panels shall be repaired and strengthened and surface
shall be made smooth to get straight vertical joint.
16.16.3 The specifications given in (to refer relevant chapter) shall generally apply.
16.16.4 Measurement: Length and breadth shall be measured correct to a cm and its area as laid
shall be calculated in sq m correct to two places of decimal, length and breadth shall be measured
before laying skirting dado or wall plaster. No deduction shall be made nor extra paid for any
opening in the floor of area up to 0.10 sq m.
16.16.5 Rate: The rate shall include the materials and labour required for work of dismantling &
repairing the existing flooring in addition to what is specified in the item of work.
16.17. Repairs to Cement Concrete Flooring (of Red Oxide of Iron):
16.17.1 The flooring to be replaced should be dismantled carefully without damaging the base and
the dismantled material disposed off as directed by the Engineer-in-Charge.
and proper slope as per existing floor shall be maintained, edges of the adjoining panels shall be
repaired and strengthened and surface shall be made smooth to get straight vertical joints.
16.17.3 Sample of cement concrete flooring with red oxide topping shall be prepared and got
approved from the Engineer-in-Charge before laying the cement concrete flooring to match the
colour of the existing flooring.
16.17.4 The specifications given in the relevant chapter shall generally apply.
16.17.5 Measurements: Length and breadth shall be measured correct to a cm and its area laid shall
be calculated in sq m. correct to two places of decimal, length and breadth shall be measured before
laying skirting, dado or wall plaster. No deduction shall be made nor extra paid for any opening in
the floor of area up to 0.10 sq m.
16.17.6 Rates: The rate shall include the materials and labour required for work described above
for repairing &dismantling the existing flooring .
16.18 Repairs to Terrazzo (Marble Chips) Flooring Laid in Situ:
16.18.1 The flooring to be replaced should be dismantled carefully without damage to the base and
dismantled materials disposed off as directed by the Engineer-in-Charge.
and proper slope as per existing floor shall be maintained. Edges of the adjoining panels shall be
repaired and strengthened and surface shall be made smooth to get straight vertical joints.
16.18.3 Samples of terrazzo (marble chips) flooring conforming to shade texture and pattern of the
existing flooring shall be prepared and got approved from the Engineer-in-Charge before
commencing the work.
16.18.4 Cement slurry shall be applied to the edge of existing flooring before fixing of glass strips.
16.18.5.Terrazzo tile flooring shall be laid higher than the level of existing flooring to make
allowance for rubbing and polishing.
16.18.6 The specifications given in (to refer relevant chapter) shall generally apply.
16.18.7. Measurements: Measurements shall be made as per relevant Chapter on Flooring.
16.18.8. Rates: The rate shall include the materials and labour required for work described above for
repairing &dismantling the existing flooring .
16.19 Repair to Terrazzo Tile Flooring:
16.19.1 The flooring to be replaced should be dismantled carefully without damage to the base and
the dismantled materials disposed off as directed by the Engineer-in-charge.
16.19.2 The patches of terrazzo tile flooring to be repaired shall be adjusted according to the
existing pattern and proper slope as per existing floor shall be maintained.
16.19.3 Samples of terrazzo tile shall be got approved from Engineer-in-Charge before to start
of the to match the shade texture and pattern of the existing terrazzo tile flooring. 16.19.4
The specifications given in (to refer relevant chapter) shall generally apply.
16.19.5. Measurements: Measurements shall be made as per para ( refer relevant Chapter) for the
area more than 0.40 square metre and shall be measured in number for the area equal to or less than
0.40 square metre.
16.19.6 Rates: The rate shall include the work of dismantling the existing flooring in addition to
what is specified ( refer relevant Chapter).
16.20 Repairs to Terrazzo Tiles/Glazed Tile Work in Dado:
16.20.1 The portion of dado to be replaced should be dismantled carefully without damage to the
base the dismantled materials disposed off as directed by the Engineer-in-Charge.
16.20.2 Samples of terrazzo file/glazed tile matching the existing tiles in dado in respect of texture
shade size and pattern may be got approved by the Engineer-in-Charge before starting the work.
16.20.3. The specifications given in (to refer relevant chapter) as applicable shall apply.
16.20.4. Measurements: Measurements shall be done as per para ( refer relevant chapter) as
applicable for the area more than 0.40 square metre and will be measured in number for the area
equal to or less than 0.40 square metre.
16.20.5 Rates: The rate shall include the work of dismantling the existing dado and disposal of the
dismantled material in addition to what is specified in (refer relevant Chapter) as applicable.
16.21 Precautions to Prevent Cracks in Buildings: In order to minimise cracks in building the
following measures shall be adopted subject to approval of the Engineer-in-Charge.
16.21.1 Cracks in General:
16.21.1.1. Masonry work shall be proceeded systematically and uniformly at all levels.
16.21.1.2. The plaster work in wall shall be deferred as much as possible so as to let shrinkage in
RCC and masonry take place before plastering.
16.21.1.3. Where required as per working drawings 12 mm wide gap shall be provided and filled
with impregnated fibre base or bituminous filler as specified, when two slabs butt against each other
and both on an internal wall. Such expansion joints should always be provided at ridges (and not in
valleys).
16.21.1.4. Ceiling plaster shall be done first and then the wall plaster. When the ceiling plaster is
done shall be finished with a chamfered edge at an angle at its junction with the wall at bearings
with a trowel when the plaster is still green. Similarly when the wall plaster is being done, it shall
be kept separate from the ceiling plaster by a thin straight groove drawn with a trowel at an angle
with the wall, while the plaster is still green .
16.21.1.5 RCC or plain cement concrete 1:2:4 bed plate with smooth surface and a thick coat of lime
wash or laid with Kraft paper shall be provided under the beam. The plaster of wall and the bed plate
shall be kept separated from that of the beam . Minimum thickness of RCC bed plate shall be 10 cm
and that of plain concrete 20 cm.
16.21.2 Horizontal Crack in Masonry and Plaster:
(i) At the floor or roof slab level.
(ii) At junction of sun shade and wall.
16.21.2.1. A smooth bearing for RCC slabs and beams on the wall with 6 mm cement
plaster 1: 3 (1 cement : 3 fine sand), finished with a floating coat of neat cement shall be
provided and then finished with a thick coat of lime wash or craft paper. The sides of top
of slabs and beams in contact with walls shall be painted with thick coat of hot bitumen.
16.21.2.2. Unless otherwise shown in drawings, the slab shall bear on external wall with a
setback of half the thickness of wall from the external face of the wall.
16.21.3 Vertical Cracks at the Bearings of RCC Beams or Pillars:
These cracks occur when RCC beam has an expansion over the masonry pillar. These can
be avoided by designing a continuous beam or the pillar. Where, however, expansion
joint in beams is essential a RCC bed plate may be provided over the pillar for its full
length and width.
16.21.4 Transverse Cracks in RCC Slab of Sun-Shades, Verandas and Rooms:
Expansion joints shall be allowed at 5 to 6 metres intervals in case of sun shades 12 to 15
metres in case of covered veranda slabs and 12 to 15 metre in case of slab continuous
over rooms in a row of quarters. To prevent cracks in the masonry below or above the
expansion joints, the following measures shall be taken.
16.21.4.1 Sun Shades : In this case, the expansion joints shall not extend to the portion
embedded in masonry but shall start from 5 cm from the face of the wall and the
distribution reinforcement in the embedded portion and in the 5 cm portion of the chajja
slab where there is no expansion joint, shall be increased to 40% of main reinforcement.
The gap of the expansion joint in the projected portion shall not be filled with any
materials.
16.21.4.2. Verandas Slab: In this case, the expansion joint shall be a neat butt joint which
shall be finished straight. The joint shall be carried right through the portion embedded
in the masonry also. It is desirable to provide a vertical butt joint in the masonry
supporting the veranda slab at the expansion joints right from plinth level. Where this is
not possible RCC or plain cement concrete bed plates shall be provided on the bearing .
To prevent cracks in the masonry above, the longitudinal wall shall have also a butt joint
with gap running in the same vertical plane as the joint in the slab. The gap in the case of
roof slabs can be sealed by aluminium cradles as shown in drawings.
16.21.4.3. Room Slabs:
i) In load bearing structures expansion joint in room slabs shall be similar to that in
veranda slabs. Where slab is combined with T-beams, the expansion joint shall be
provided by substituting one of the T-beams, with rectangular beam and slabs.
ii) In RCC framed structure, the expansion joint is generally provided in conjunction
with twin beams and twin columns . The expansion joint shall be provided with
aluminium cradle and its top filled with bituminous material. The underside of the
beam shall be provided with sheet of asbestos or any other suitable materials, which
shall be fixed on one side and shall be free to. move on the other. side within oval
shaped holes, in case of twin-columns, the expansion joint is similarly covered on
the inside and outside.
iii) The gap between the twin columns and the gap below aluminium cradle twin beams
need not be filled. However before, the joints are covered on the outside with
asbestos or other suitable material as specified, the gap should be cleaned thoroughly
of all rubbish or mortar dropping etc, in case of larger expansion joints (Generally
more than 10 cm).
iv) In case of gap between the twin columns and gap below Aluminium in twin beams
should be filled up with impregnated fibre board in all the floors so that rubbish or
mortar droppings etc. may not enter into the expansion joints.
CHAPTER No. 17
DISMANTLING AND DEMOLITION
CHAPTER No. 17 : DISMANTLING AND DEMOLITION
CONTENTS
17.0 Scope 3
17.1 Terminology 3
17.2 Planning for Dismantling/Demolition. 3
17.3 Precautionary Measures to be taken while Dismantling/ Demolition. 4
17.4 Protection to the public 6
17.5 Sequence of Demolition operations. 7
17.6 Removal of materials. 7
17.7 Stairs, Passage ways and Ladders. 9
17.8 Demolition of walls. 9
17.9 Demolition of floors. 10
17.10 Demolition of steel structures. 10
17.11 Catch platform 10
17.12 Mechanical Demolition. 11
17.13 Recommendations for demolition of certain special types 11
and elements of structures
17.14 Mode of measurements. 13
17.15 First Aid. 17
17.16 Rates. 17
Appendix 1: Note on Present Techniques of Demolition 18
List of relevant BIS Codes 21
C H A P T E R No. 17
DISMANTLING AND DEMOLITION
17.0 : Scope:
This specification covers the method and mode of measurement of Demolition and Dismantling.
17.1 :Terminology:
17.1.1: Dismantling:
The term Dismantling implies carefully separating the parts and removing without damage, the parts
of a building/structure. This may consist of dismantling one or more parts of the building as specified
or shown on the drawing.
17.1.2: Demolition:
The term "Demolition" implies breaking up. This shall consist of demolishing whole or part of
work including all relevant items as specified or shown on the drawings.
17.2 : Planning:
17.2.1- Before beginning the actual work of demolition, a careful study shall be made of the structure
which is to be dismantled or pulled down and also of all its surroundings. This shall, in particular,
include study of the manner in which the various parts of the building to be demolished are supported
and how far the stage by stage demolition will affect the safety of the adjoining structure. A definite
plan of action / procedure for the demolition work, depending upon the manner in which the loads
of the various structural parts are supported, shall be prepared and approved by the engineer-in-
charge and this shall be followed as closely as possible, in actual execution of the demolition work.
Before the commencement of each stage of demolition, the Junior/Assistant Engineer shall brief the
workmen in detail regarding the safety aspects to be kept in view and be present at the site to
supervise the operations. A sequence and safety plan for the operation should be drawn by the
Engineer-in-charge.
17.2.2 - The demolition work shall be proceeded with in such a way that it causes the least damage
and nuisance to the adjoining building and ensures the safety to the public . First-aid equipment shall
be kept available at all demolition works of any magnitude. Also, by prior arrangement, a qualified
doctor shall be available at call.
17.2.3 -Dismantling shall be done in a systematic manner. All materials which are likely to be
damaged by dropping from a height or by demolishing roofs, masonry etc. shall be carefully removed
first. Chisels and cutters may be used carefully as directed. The dismantled articles shall be removed
manually or otherwise, lowered to the ground (and not thrown) and then properly stacked as directed
by the Engineer-in-Charge. Where existing fixing is done by nails, screws, bolts, rivets, etc.,
dismantling shall be done by taking out the fixing with proper tools and not by tearing or ripping off.
17.2.4 -No structure or any part of the structure or any floor or temporary support or scaffold, side
wall or any device for equipment shall be loaded (with men and equipment) in excess of
the safe carrying capacity, in its then existing condition.
17.2.5- Any serviceable material, obtained during dismantling or demolition, shall be separated out
and stacked properly as directed by the Engineer-in-Charge within a lead of 50 metre. All
unserviceable materials, rubbish etc. shall be disposed off as directed by the Engineer-in-Charge.
The contractor shall maintain/disconnect existing services, whether temporary or permanent, where
required by the Engineer-in-Charge.
17.3- Precautionary measures to be taken while dismantling / demolition:
The demolition shall always be well planned before hand and shall generally be done in reverse order
of the one in which the structure was constructed. The operations shall be got approved from the
Engineer-in-Charge before starting the work. Due care shall be taken to provide and maintain the
safety measures specified in IS : 4130.
17.3.1- No demolition work should be carried out at night especially when the building or structure to
be demolished is in an inhabited area.
17.3.2- When work of demolition is to be taken up the area should be cleared and barred for all
outsiders. No one should be allowed up to 50 m from the place of demolition. Helmets must be worn
by all the workers/ supervisors engaged in dismantling work. The place should be strictly guarded at
night with red lights at prominent places, and watchman should be posted round the clock.
17.3.3 - On every demolition job, danger signs shall be conspicuously pasted all around the structure
and all doors and openings giving access to the structure shall be kept barricaded or manned except
during the actual passage of workmen or equipment. However, provisions shall be made for at least
two independent exits for escape of workmen during any emergency.
17.3.4- The Demolition shall always be well planned before being taken into hand and shall generally
be done in reverse order of the one in which the structure was constructed. The operations shall be got
approved from the Engineer-in-Charge before starting the work.
17.3.5- Necessary propping, shoring and under pinning shall be provided to ensure the safety of the
adjoining work or property before dismantling and demolishing is taken up and the work shall be
carried out in such a way that no damage is caused to the adjoining work or property. Moreover, the
nuisance effect of the demolishing work on the use of the adjacent buildings should be kept to the
minimum. Wherever specified, temporary enclosures or partitions shall also be provided, as directed
by the Engineer-in-Charge. Temporary shoring or any arrangement as desired by the Engineer shall
be carried out for the safety of portions required to be pulled out or of adjoining property or
temporary enclosures or partitions. But these instructions of the Engineer shall in no way relieve the
contractor of his obligation under the contract to carry out the job in a workman like way. The
contractor shall keep the employer /Engineer, indemnified against all claims for damages to other
properties or personals.
17.3.6- Necessary precautions shall be taken to keep down the dust nuisance to the minimum through
watering etc.. Articles shall be passed by hand where necessary and lowered to the ground and not
thrown. Where these are fixed by nails, screws, bolts etc., dismantling shall be done by taking out
the fixture with proper tools and not by tearing or ripping off.
17.3.7- Dismantling shall be done in a systematic manner. All materials which are likely to be
damaged by dropping from a height or by demolishing roofs, masonry etc. shall be carefully removed
first.
17.3.8- Any serviceable material, obtained during dismantling or demolition, shall be separated out
and stacked properly as directed by the Engineer-in-Charge within a lead of 50 meters, all
unserviceable materials rubbish etc. shall be disposed off as directed by the Engineer-in-Charge.
17.3.9- During nights, Red lights shall be placed on or about all the barricades.
17.3.10- The power on all electrical service lines shall be shut off and all such lines cut or
disconnected at or outside the property line, before the demolition work is started. or to cutting of
such lines, the necessary approval shall be obtained from the electrical authorities concerned. The
only exception will be any power lines required for demolition work itself.
17.3.11- All gas, water steam and other service lines shall be shut off and capped or otherwise
controlled at or outside the building line, before demolition work is started.
17.3.12- If a structure to be demolished has been partially wrecked by fire, explosion or other
catastrophe, the walls and damaged roofs shall be shored or braced suitably.
17.3.13- or to commencement of work, all materials of fragile nature like glass shall be removed.
17.3.14- No demolition work should be carried out at night especially when the building or structure
to demolished is in an inhabited area.
17.3.15- No demolition work shall be carried out during storm and heavy rain.
17.3.16-Goggles preferably made of celluloid lens and shall be worn at the time of demolition of
walls, floors, tearing of plaster, etc, especially when instruments like jack hammers are employed in
demolition work, to protect the eyes from injuries from flying piece, dirt, etc. that may be blown up
by the wind.
17.3.17- Insurance: The contractor shall provide a third party / property comprehensive insurance
cover to indemnify the Engineer against all damage to workmen, property, injuries, hospitalization,
losses or death etc. on the site or on the adjoining properties.
17.3.18- It is desirable that leather or rubber gloves should be worn by the workers while
demolishing RCC work or removing steel work, etc, where the hands of the workers are likely to be
injured.
17.3.19- Safety belts shall be used by labourers while working at higher level to prevent falling from
the structure.
17.3.20- Walkways and passageways shall be provided for the use of the workmen who shall be
instructed to use them and all such walkways and passageways shall be kept adequately lighted, free
from debris and other materials.
17.3.21- Construction sheds and tool boxes should be located away from areas of falling debris to
avoid injuries to users.
17.3.22- Screens shall be placed, where necessary, to prevent flying pieces from injuring the fellow
workmen.
17.3.23- Water may be used to reduce dust while tearing down plaster from brickwork. If this is
impracticable, workmen shall cover the face and nose with piece of muslin or alternatively
respirators.
17.3.24- No unnecessary work shall go on below when demolition is in progress above. When some
work is to be done at the lower level, adequate protection shall be provided for all the workmen so
engaged.
17.3.25-- When there is a possibility of fire breaking out, appropriate portable first-aid fire
appliances (See IS 2190 : 1979 ) shall be kept at hand.
17.4 :Protection to the Public :
17.4.1- Before any demolition work is started, every sidewalk or road adjacent to the work likely to
be affected shall be closed or protected. Screens shall be placed where necessary to prevent injuries
due to falling pieces. Water may be used to reduce dust while tearing down plaster from brick work.
17.4.2-Children and members of the public shall be kept out of the building and the adjoining yard.
17.4.3- If the structure to be demolished is more than two Storeyed or 7.5 m high, measured from the
sidewalk or street which cannot be closed or safely diverted, and the horizontal distance from the
inside of the sidewalk to the structure is 4.5 m or less a substantial sidewalk shed shall be constructed
over the entire length of the sidewalk adjacent to the structure of sufficient width with a view to
accommodating the pedestrian traffic without causing congestion. The sidewalk shed shall be lighted
sufficiently to ensure safety at all times.
17.4.4- A toe board of at least 1 m high above the roof of the shed shall be provided on the outside
edge and ends of the sidewalk shed. Such boards may be vertical or inclined outward at not more
than 45 degrees.
17.4.5- Except where the roof of a sidewalk shed solidly abuts the structure, the face of the sidewalk
shed towards the building shall be completely closed by providing sheeting / planking to prevent
falling material from penetrating into the shed.
17.4.6- The roof of sidewalk sheds shall be capable of sustaining a load of 73 N/mm 2. Only in
exceptional cases, say due to lack of other space, the storing of material on a sidewalk shed may be
permitted in which case the shed shall be designed for a load of 146 N/mm2. Roof of sidewalk shed
shall be designed taking into account the impact of the falling debris. By frequent removal of loads
it shall be ensured that the maximum load, at any time, on the roof of work shed is not more than
6000 N/m2. The height of sidewalk shed shall be such as to give a minimum clearance of 2.4 m.
17.4.7- Sidewalk shed opening. for loading purposes, shall be kept closed at all time except during
actual loading operations.
17.4.8- The deck flooring of the sidewalk shed shall consist of plank of not less than 50 mm in
thickness closely laid and deck made watertight. All members of the shed shall be adequately braced
and connected to resist displacement of members or distortion of framework.
17.4.9- When the horizontal distance from the inside of the sidewalk to the structure is more than
4.5 m and less than 7.5 m, a sidewalk shed or fence may be built or in place of such a shed or fence
a substantial railing shall be constructed on the inside of the sidewalk or roadway along the entire
length of the demolition side of the property with movable bars as may be necessary for the proper
execution of the work.
17.4.10- Where worker's entrances to the building being demolished are not completely protected by
sidewalk sheds, all such entrances shall be protected by canopies extending from the face of the
building to a point not less than 2.5 m from it. In such case such overhead protection shall be at least
0.6 m wider than the building entrance or opening and every canopy shall be as strong
as the sidewalk shed, specified in 17.4.5
17.5 : Sequence of Demolition Operations:
17.5.1 The demolition work shall be proceeded with in such a way that:
(a) It causes the least damage and nuisance to the adjoining building and the members of the
public, and
(b) It satisfies all safety requirements to avoid any accidents.
17.5.2- All existing fixtures required during demolition operations shall be well protected with
substantial covering to the entire satisfaction of the rules and regulations of the undertakings or they
shall be temporarily relocated.
17.5.3- Before demolition work is started, glazed sash, glazed doors and windows, etc, shall be
removed. All fragile and loose fixtures shall be removed. The lath and all loose plaster shall be
stripped off throughout the entire building. This is advantageous because it reduces glass breakage and
also eliminates a large amount of dust producing material before more substantial parts of the
buildings are removed.
17.5.4- All wall openings which extend down to floor level shall be barricaded to a height of not
less than one metre above the floor level. This provision shall not apply to the ground level floor.
17.5.5- All floor openings and shafts not used for material chutes shall be floored over and be
enclosed with guard rails and toe boards.
17.5.6 The demolition shall always proceed systematically storey by storey in descending order and
the work on the upper floors shall be completely over before any of the supporting members or other
important portion on the lower floor is disturbed. These requirements shall not prohibit the
demolition of structure in sections, if means are taken to prevent injuries, to persons or damage to
property.
17.6: Removal of Materials:
17.6.1-General:
Dismantled materials may be thrown to the ground only after taking all due/adequate precautions. The
material shall preferably be dumped inside the building. Normally such materials shall be lowered
to the ground or to the top of the sidewalk shed where provided by means of ropes or suitable tackles
(See also 17.4.6 ).
17.6.2-Through Chutes
17.6.2.1- Wooden or metal chutes may be provided for removal of materials. The chutes shall
preferably be provided at the centre of the building for efficient disposal of debris.
17.6.2.2- Chutes, if provided at an angle of more than 45° from the horizontal, shall be entirely
enclosed on all the four sides, except for opening at or about the floor level for receiving the
materials.
17.6.2.3- Opening for the chutes (See 17.6.3 ) shall not exceed 1.20 m in height measured along the
wall of the chute and in all storeys below the top floor such opening shall be kept closed when not
in use.
17.6.2.4-To prevent the descending material attaining a dangerous speed, chute shall not extend in
an unbroken line for more than two storeys. A gate or stop shall be provided with suitable means for
closing at the bottom of each chute to stop the flow of materials.
17.6.2.5-Chutes at an angle of less than 45° to the horizontal may be left open on the upper side
provided that at the point where such a chute discharges into a chute steeper than 45° to the
horizontal, the top of the steeper chute shall be boarded over to prevent the escape of materials.
17.6.2.6- Any opening into which workmen dump debris at the top of chute shall be guarded by a
substantial guard rail extending at least one metre above the level of the floor or other surface on
which men stand to dump the materials into the chute.
17.6.2.7-A toe board or bumper, not less than 50 mm thick and 150 mm high shall be provided at
each chute opening, if the material is dumped from the wheel barrows. Any space between the chute
and the edge of the opening in the floor through which it passes shall be solidly planked over.
17.6.3: Through Holes in the Floor:
17.6.3.1- Debris may also be dropped through holes in the floor without the use of chutes. In such a
case the total area of the hole cut in any intermediate floor, one which lies between floor that is being
demolished and the storage floor shall not exceed 25 percent of such floor area. It shall be ensured
that the storage floor is of adequate strength to withstand the impact of the falling material.
17.6.3.2- Openings in all the floors below the floor from which materials are being removed, shall
be protected by standard railings and toe boards or preferably planked over if the holes are not being
used for dumping materials.
17.6.3.3- All intermediate floor openings for passage of materials shall be completely enclosed with
barricades or guard rails not less than one metre high and at a distance of not less than one metre
from the edge of general opening. No barricades or guard rails shall be removed until the storey
immediately above has been demolished down to the floor line and all debris cleared from the floor.
17.6.3.4- When the cutting of a hole in an intermediate floor between the storage floor and the floor
which is being demolished makes the intermediate floor or any portion of it unsafe, then such
intermediate floor shall be properly shored. It shall also be ensured that the supporting walls are not
kept without adequate lateral restraints.
17.6.4: Removal of Debris/Malba:
17.6.4.1- As demolition work proceeds, the released serviceable materials of different types shall be
separated from the unserviceable lot (hereafter called `Malba') at suitable time intervals and properly
stacked/stocked clear of the spots where demolition work is being done.
17.6.4.2- The Malba obtained during demolition shall .be collected in well-formed heaps at properly
selected places, keeping in view safe conditions for workmen in the area. The height of each Malba
heap shall be limited to ensure its not toppling over or otherwise endangering the safety of workmen
or passers by.
17.6.4.3- The Malba shall be removed from the demolition site to a location as required by the local
civil authority. Depending on the space available at the demolition site, this operation of conveying
Malba to its final disposal location may have to be carried out a number of times during the
demolition work. In any case, the demolition work shall not be considered as completed and the area
declared fit for further occupation till all the Malba has been carried to its final disposal location and
the demolition area tidied up.
17.6.4.4- Materials which are likely to cause dust nuisance or undue environmental pollution in any
other way, shall be removed from the site at the earliest and till then they shall be suitably covered.
Such materials shall be covered during transportation also.
17.6.4.5- Unauthorized use of the debris or Malba in any work shall not be permitted. The released
materials classed as `serviceable' shall be inspected by a competent person before being used.
17.7 :Stairs, Passageways and Ladders:
17.7.1- Stairs and stair railings, passageways and ladders shall be left in place as long as possible.
17.7.2- For the use of ladders, provisions laid down in IS 3696 ( Part 2) : 1991 shall be followed.
17.7.3- All stairs, passageways and ladders to be used by workmen during the process of demolition
shall be maintained in a safe condition.
17.7.4- Ladders or their side rail extend not less than 1.0 m above the floor or platform to which
such ladder gives access.
17.7.5- All ladders shall be secured against, slipping out at the bottom and against movement in
any direction at the top.
17.8 :Demolition of Walls:
17.8.1- While walls of sections of masonry are being demolished , it shall be ensured that they are
not allowed to fall as single mass upon the floors of the building that are being demolished so as to
exceed the safe carrying capacity of the floors. Overloading of floors shall be prevented by removing
the accumulating debris through chutes or by other means immediately. The floor shall be inspected
by the Engineer-in-charge before undertaking demolition work and if the same is found to be
incapable to carry the load of the debris, necessary additional precautions shall be taken so as to
prevent any possible unexpected collapse of the floor.
17.8.2- Walls shall be removed part by part. Stages shall be provided for the men to work on if the
walls are less than one and a half brick thick and dangerous to work by standing over them.
17.8.3- No section of wall whose height is more than 15 times of thickness, shall be permitted to
stand without lateral bracing unless such wall is in good condition and was originally designed to
stand without such lateral bracing or support.
17.8.4- Structural or load supporting members on any floor shall not be cut or removed until all the
storeys above that floor have been demolished and removed.
17.8.5- Before demolishing any interior or exterior wall within 3 m of the opening in the floor
immediately below, such opening shall be substantially planked over, unless access is denied to
workmen to that portion of the area of the floor immediately below the opening, in the floor of the
storey being demolished, where any debris pieces passing through this opening may fall.
17.8.6- In framed structures, the steel frame may be left in place during demolition of masonry work.
Where this is done, all steel beams, girders, etc, shall be cleared of all loose materials as the
demolition of masonry work progress downward provided it is still strong enough to stand as an
independent structure.
17.8.7- Walkways shall be provided to enable workmen to reach or leave their work on any scaffold
or wall. Such walkways shall be not less than 3 planks, nor less than 0.8 m in width.
17.8.8- At the completion of each day's work, all walls shall be left stable to avoid any danger of
getting overturned.
17.8.9- Foundation walls which serve as retaining walls to support earth or adjoining structure, shall
not be demolished until such an adjoining structure has been underpinned or braced and the earth
removed by sheet piling or sheathing.
17.9:Demolition of Floors:
17.9.1- In cutting holes in a floor which spans in one direction, a slit of width not exceeding 300 mm
shall be cut at the first stage for the entire length of the slab along which its spans. The opening shall
thereafter be increased to the desired width by suitable installments.
17.9.2- When floors are being removed, no workmen shall be allowed to work in the area, directly
underneath and such area shall be barricaded to prevent access to it.
17.9.3- The demolition of floor shall be started only after the floor in question and the surrounding
floor area for a distance of 6.0 m have been entirely cleared of persons, and the debris and other
unnecessary material removed.
17.9.4- Stringers of ample strength shall be installed to support the planks where necessary and the
ends of such stringer shall be supported by floor beams, girders and not by floor slab alone.
17.9.5- Planks used for temporary protection shall be sound and at least 50 mm thick. They shall be
laid close together with the ends having at least 100 mm bearing over solid support to prevent tipping
under load. If corrugated GI Sheets are used for temporary protection, it shall be secured to the solid
support with suitable framework.
17.10 :Demolition of Steel Structures :
17.10.1- When a derrick is used, care shall be taken to see that the floor on which it is supported is
amply strong for the loading so imposed. If necessary heavy planking shall be used to distribute the
load to floor beam and girders.
17.10.2- Overloading of equipment shall not be allowed.
17.10.3- Tag lines shall be used on all materials being lowered or hoisted up and a standard signal
system shall be used and the workmen instructed on the signals.
17.10.4- No person shall be permitted to ride the load line.
17.10.5- No beams shall be cut until precautions have been taken to prevent it from swinging
freely and possibly striking any worker or equipment to any part of the structure being demolished.
17.10.6- All structural steel members shall be lowered from the building and shall not be allowed to
drop.
17.11 : Catch Platform:
17.11.1- In demolition of exterior walls of multistory structures, catch platform of sufficient strength to
prevent injuries to workers below and public shall be provided, when the external walls are more
than 20 m in height.
17.11.2- Such catch platform shall be constructed and maintained not more than 3 storeys below the
storey from which exterior wall is being demolished. When demolition has progressed to within 3
storeys of ground level, catch platform will not be considered necessary.
17.11.3-Catch platform shall be capable of sustaining a live load of not less than 6100 N/m2
17.11.4- Materials shall not be dumped on the catch platform nor shall they be used for storage
materials.
17.11.5- Catch platforms shall not be less than 1.5 m in width, measured in a horizontal direction
from the face of the structure and shall consist of outriggers and planks. Planks shall be laid tight
together, without openings between them and the walls. Catch platform shall be provided with a
continuous solid parapet along its outer edge of at least 1 m height. The parapet shall be constructed
of the same specification as the platform.
17.11.6- Catch platform can be constructed of material other than wood also, provided such
material is of equal strength.
17.11.7-The outriggers shall be of ample strength and shall not be spaced more than 3 m apart.
17.12 :Mechanical Demolition: When demolition is to be performed by mechanical devices, such
as weight ball and power shovels, the following additional precautions may be observed:-
(i) The area shall be barricaded for a minimum distance of 1.5 times from the height of the wall.
(ii) While the mechanical device is in operation, no workmen shall be allowed to enter the
building being demolished,
(iii) The device shall be so located as to avoid falling debris; and
(iv) The mechanical device when being used shall not cause any damage to adjacent structure,
power line, etc.
17.13 : Recommendations for Demolition of Certain Special Types and Elements of
Structures:
17.13.1 : Roof Trusses:
17.13.1.1-If a building has a pitched roof, the structure should be removed to wall plate level by hand
methods. Sufficient purlin and bracing should be retained to ensure stability of the remaining roof
trusses while each individual truss is removed progressively.
17.13.1.2- Temporary bracing should be added, where necessary to maintain stability. The end frame
opposite to the end where dismantling is commenced, or a convenient intermediate frame should be
independently and securely guyed in both directions before work starts.
17.13.1.3-On no account should the bottom tie of roof trusses be cut until the principal rafters are
prevented from making out ward movement.
17.13.1.4-Adequate hoisting gears suitable for the loads shall be provided. If during demolition any
thing is to be put on the floor below the level of the truss, it shall be ensured that the floor is capable
of taking the load
17.13.2: Heavy Floor Beams:
Heavy blocks of timber and steel beams should be supported before cutting at the extremities and
should then be lowered gently to a safe working place.
17.13.3: Jack Arches:
Where tie rods are present between main supporting beams, these should not be cut until after the
arch or series of arches in the floor have been removed. The floor should be demolished in strips
parallel to the span of the arch rings (at right angles to the main floor beams).
17.13.4: Brick Arches:
17.13.4.1-Expert advice should be obtained and at all stages of the demolition, better/closer
supervision should be given by persons fully experienced and conversant in the type of work to
ensure that the structure is stable at all times.
17.13.4.2- As much dead load as possible may be removed provided it does not interfere with the
stability of the main arch rings, but it should be noted that the load carrying capacity of old arches
relies on the filling between the spandrels. On no account should the restraining influence of the
abutments be removed before the dead load of the spandrel fill and the arch rings are removed.
17.13.4.3-
(a) A single span arch can be demolished by hand by cutting narrow segments progressively from
each springing parallel to the span of the arch, until the width of the arch has been reduced to
a minimum which can then be collapsed.
(b) Where it is impossible to allow debris to fall to the ground below, centering designed to carry
the load should be erected and the arch demolished progressively. The design of the centering
should make appropriate allowance for impact.
17.13.4.4-Where deliberate collapse is feasible, the crown may be broken by the demolition ball
method working progressively from edges to the centre.
17.13.4.5-Collapse of the structure can be affected in one action by the use of explosives. Charges
should be inserted into bore holes drilled in both arch and abutments.
17.13.4.6-In multi-span arches, before individual arches are removed, lateral restraint should be
provided at the springing level. Demolition may then proceed as for single span; where explosives are
used it is preferable to ensure the collapse of the whole structure in one operation to obviate the
chance of leaving unstable portion standing.
17.13.5 - Cantilever (Not Part of a Framed Structure):
Canopies, cornices, staircases and balconies should be demolished or supported before tailing
down load is removed.
17.13.6 :In-situ Reinforced Concrete:
Before commencing demolition, the nature and condition of the concrete, the condition and position
of reinforcement, and the possibility of lack of continuity of reinforcement should be ascertained.
Attention should be paid to the principles of the structural design to determine which parts of the
structure depend on each other to maintain overall stability.
17.13.7: Reinforced Concrete Beams:
A supporting rope should be attached to the beam. Then the concrete should be removed from both
ends by pneumatic drill and the reinforcement exposed. The reinforcement should then be cut in such
a way as to allow the beam to be lowered under control to the floor.
17.13.8 : Reinforced Concrete Columns:
The reinforcement should be exposed at the base after restraining wire guy ropes have been placed
round the member at the top. The reinforcement should then be cut in such a way as to allow it to be
pulled down to the floor under control.
17.13.9 :Reinforced Concrete walls : These should be cut into strips and demolished as for
columns.
17.13.10: Suspended Floors and Roofs :
The slab should be cut into strips parallel to the main reinforcement and demolished strip by strip.
Where ribbed construction has been used, the principle of Design and method of construction should
be determined before demolition is commenced.
17.13.11: Precast Reinforced concrete:
Due precautions shall be taken to avoid toppling over of prefabricated units or any other part of the
structure and whenever necessary temporary supports shall be provided.
17.13.12: Prestressed Reinforced Concrete:
Before commencing of the demolition work, advice of an engineering expert in such demolition
shall be obtained and followed.
17.13.13: Chimney and Spires:
Before commencing of the demolition work, involving such structures, advise of an engineer
expert in such demolition shall be obtained and followed.
17.14: Mode of Measurements:
All work shall be measured net in the decimal system, as fixed in its place, subject to the following
limits, unless otherwise stated hereinafter.
(a) Dimensions shall be measured correct to a cm.
(b) Areas shall be worked out in sqm correct to two places of decimal.
(c) Cubical contents shall be worked out to the nearest 0.01 cum
(d) Parts of work required to be dismantled and those required to be demolished shall be
(e) Measurements of all work except hidden work shall be taken before demolition or
dismantling and no allowance for increase in bulk shall be allowed.
(f) Specifications for deduction for voids, openings etc. shall be on the same basis as that
adopted for new construction of the work.
(g) Work executed in the following conditions shall be measured separately.
(i) Work in or under water and/or liquid mud
(ii) Work in or under foul position
The provision contained in IS 1200:Part-XVIII (Demolition and Dismantling) (Latest Version)
should be adopted with regards to mode of measurements.
17.14.1 : General Points:
All works shall be measured net in the decimal system, as fixed in its place, subject to the
following limits, unless otherwise stated hereinafter.
(a) Dimensions shall be measured correct to a cm.
(b) Area shall be worked out in sqm correct to two places of decimal.
(c) Cubical contents shall be worked out to the nearest 0.01 cum.
17.14.2- Parts of work required to be dismantled and those required to be demolished shall be
17.14.3-Measurements of all work except hidden work shall be taken before demolition or
dismantling and no allowance for increase in bulk shall be allowed.
17.14.4-Specifications for deduction for voids, openings etc. shall be on the same basis as that
adopted for new construction of the work.
17.14.5-Work executed in the following conditions shall be measured separately.
Work in or under water and / or liquid mud.
Work in or under foul position.
Work under tides, and
Work in Snow
17.14.6- Bill of Quantities /Item of Work - Item of work shall fully describe the materials and
workmanship and represent the work to be executed.
17.14.7- Measurement in Stages - Work shall be measured under the following categories in
convenient stages stating the height or depth :
(a) Below ground/datum level, and
(b) Above ground/datum level.
Note - The ground/datum level shall be defined in each case.
17.14.8- Demolition and Dismantling -Works required to be demolished and those required to be
dismantled shall each be measured separately.
17.14.9: Lead:
The description shall include separation of serviceable material from the unserviceable, stacking
within 100 m and disposal of debris. Removal of materials beyond 100 m shall be measured
separately.
The distance for removal shall be measured over the shortest practicable route and not necessarily
the route actually taken.
Distances exceeding 100 m and up to 1 km shall be measured in units of 100 m and those
exceeding 1 km in units of 500 m.
17.14.10- Works laid dry and with mortar shall be measured separately and the type of mortar shall
be stated. Framed and unframed measured separately
17.14.11- Disconnecting/Maintaining of Services -Attention shall be directed to any necessary
disconnecting or maintaining of services, whether temporary or permanent, and an item shall be
provided for making good if required.
17.14.12 : Roofs:
17.14.12.1 - Roof coverings generally including battens boarding, mats, bamboo jaffari or other
subsidiary supports shall be measured in square metre except lead sheet roof covering which shall
be measured in quintals and stone slab roof covering which shall be measured in cubic meters.
Ridges, hips and valleys shall be girthed and included with the roof area. Corrugated or semi
corrugated surfaces shall be measured flat and not girthed.
17.14.12.2 - Mud phuska on roofs shall be measured in cubic metre.
17.14.12.3 - Lead sheets in roofs shall be measured in kilograms and hips, valleys, flashings,
lining to gutter etc. shall be included in this weight.
17.14.12.4 - R.B. or R.C.C. roofs shall be measured as specified in 17.14.17.
17.14.12.5 - Supporting members, such as rafters, purlins, beams, joists, trusses etc. where of wood
shall be measured in cubic meters and steel or iron sections in kilograms.
17.14.13 : Ceiling: The stripping of ceiling shall be measured in square metre.
17.14.13.1 - Dismantling of Supporting joists, beams, etc. shall be measured in cubic metre or in
kilogram as specified in 17.14.12.5.
17.14.13.2 - Height above floor level, if it exceeds 3.5m shall be paid for separately.
17.14.14 : Floors and Paving:
Dismantling of floors (except concrete and brick floors) shall be measured in cubic metre and mode
of fixing shall be described. Concrete paving shall be measured in square meter stating their
thickness.
17.14.15: Concrete and Brick Roofs and Suspended Floors:
Demolition of floors and roofs of concrete or brick shall be measured in cubic metre. 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.
17.14.16: Walls and Piers:
17.14.16.1- Taking down walls and independent piers or columns of brick, stone or concrete shall be
measured, in cubic metre. All copings, corbels cornices and other projections shall be included with
the wall measurements. In measuring thickness of plastered walls, the thickness of plaster shall be
ignored.
17.14.16.2- Ashlar face stones, dressed stone work, precast concrete articles, etc. if required to be
taken down intact shall be so stated and measured separately in cubic metre.
17.14.16.3- Cleaning bricks stacking or measurements including all extra handling and removal
and disposing off the rubbish as stated shall be enumerated in thousand of cleaned bricks.
17.14.16.4- Cleaning stone obtained from demolished/dismantling stone masonry of any description
including ashlar facing dressed stone work, stone slabs or flagging and precast concrete blocks
including all extra handling and disposing off the rubbish as stated shall be measured in cubic metre
of cleaned stone.
17.14.16.5- Honey comb works or cavity walls or bricks stone or concrete shall be measured as
solid.
17.14.17 : Reinforced Concrete and Brick Work:
Reinforced concrete structure and reinforced brick roofs and walls shall be measured in cubic
metre and if reinforcement is required to be salvaged, it shall be so stated.
Where reinforcement is required to be separated, scraped and cleaned the work shall be measured
separately in kilograms of salvaged steel.
17.14.18 : Partitions, Trellis Work Etc.:
Partitions or light walls, of lath and plaster, trellis work, expended metal, thin concrete or terracotta
slabs and other similar materials including frame work if any shall be measured in square metre
stating the overall thickness.
17.14.19 : Wood work:
All wood work including karries (tree trunks) averages 40 sqcm or over in section, shall be measured
in cubic metre, while that under 40 sq cm in section, in running metre. Ballis shall be measured in
running metre.
Boarding including wooden chajjas and sun shades along with supports shall be measured in
square metre in its plane.
17.14.20: Steel and Iron Work:
17.14.20.1-All steel and iron work shall be measured in kilograms. The weight shall be computed
from standard tables unless the actual weight can readily be determined.
17.14.20.2-Riveted work, where rivets are required to be cut, shall be measured separately.
17.14.20.3-Marking of structural steel required to be re-erected shall be measured separately.
17.14.20.4-In framed steel items, the weight of any covering material or filling such as iron sheets
and expended metal shall be included in the weight of the main article unless such covering is not
ordered to be taken out separately.
17.14.21: Doors and Windows:
Dismantling of doors, windows, clearstory windows, ventilators etc. (wood or metal) whether done
separately or along with removal of wall by making recess in the wall shall be enumerated. Those
exceeding 3 sqm each in area shall be measured separately. The item shall include removal of
chowkhats architraves, hold fasts and other attachments.
If only shutters are to be taken out it shall be measured separately.
17.14.22: Water Pipe Lines and Sewer Lines:
17.14.22.1-Water pipe lines including rain water pipes with clamps and special, sewer lines (salt
glazed ware or concrete) etc. shall be described by their internal diameter and length measured in
running metre inclusive of joints.
17.14.22.2 - If the joints, special and fittings etc. are required to be separated, it shall be so stated
and enumerated.
17.14.22.3-Pucca drains shall be measured under relevant items.
17.14.22.4 -Valve, cistern, public fountain, platform, fire hydrants, etc. shall be enumerated.
17.14.22.5- Manholes and inspection chambers shall be enumerated stating the size and depth of
manhole/ inspection chamber. They shall be classified into different groups depending upon the
depth, in unit of half and one metre depth. The depth of the manhole shall be the distance between the
top of manhole cover and invert level of the drain.
17.14.22.6-Ventilating shafts, gully traps, flushing cisterns and other appurtenant items of work
shall be enumerated.
17.14.23 : Posts and Struts:
Posts or struts (wood, steel or RCC) of any section including taking out embedded portion shall be
measured in running metre.
17.14.24 : Fencing Wire Mesh:
Wire mesh fencing of any type with frame shall be measured in square metre.
17.14.25 :Glazing:
Taking out any portion of serviceable glass except polished plate, from old sashes, skylights etc.
(any thickness, weight or size) raking out old putty, etc. shall be measured in square metre. Irregular
or circular panes shall be measured as rectangle or square. The width and heights being measured
correct to the nearest 0.5 cm.
17.15: First Aid:
17.15.1- A copy of all pertinent regulations and notices concerning accidents, injury and first-aid
shall be prominently exhibited at the work site.
17.15.2- Depending on the scope and nature of the work a person, qualified in first-aid shall be
available at work site to render and direct first-aid to casualties. He shall maintain a list of individuals
qualified to serve in first-aid work. Enough first-aid kit, including a stretcher and cot with accessories
shall be provided at site. A telephone may be provided to first-aid assistant with telephone numbers
of the hospitals prominently displayed.
Complete reports of all accidents and action taken thereon shall be forwarded to the competent
authorities.
17.16 : Rates :
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 and disposing off unserviceable material within a distance of 50 metre.
The rate shall also include for temporary shoring for the safety of portions not required to be pulled
down, or of adjoining property, and providing temporary, enclosures or partitions, where considered
necessary.
Appendix - 'A'
Notes on Present methodologies for Demolition of structures:
Demolition is the tearing-down of buildings and other structures. Demolition contrasts with
dismantling, which involves taking a building apart while carefully preserving valuable elements for
re-use.
For small buildings, such as houses, that are only two or three stories high, demolition is a rather
simple process. The building is pulled down either manually or mechanically using large hydraulic
equipment: elevated work platforms, cranes, excavators or bulldozers. Larger buildings may require
the use of a wrecking ball, a heavy weight on a cable that is swung by a crane into the side of the
buildings. Wrecking balls are especially effective against masonry, but are less easily controlled and
often less efficient than other methods. Newer methods may use rotational hydraulic shears and
silenced rock-breakers attached to excavators to cut or break through wood, steel, and concrete. The
use of shears is especially common when flame cutting would be dangerous.
The tallest building demolished by nonterrorist methods was the 47-story Singer Buildin _ in New
York City, which was built in 1908 and torn down in 1967-1968 to be replaced by One Liberty Plaza.
A wrecking ball in action at the demolition of the Rockwell Gardens.
A high-reach excavator is used to demolish this tower block.

Before any demolition activities, there are many steps that need to take place - including but not
limited to performing asbestos abatement, removing hazardous or regulated materials, obtaining
necessary permits, submitting necessary notifications, disconnecting utilities, rodent baiting, and
development of site-specific safety and work plans. The typical razing of a building is accomplished
as follows:
Hydraulic excavators may be used to topple one- or two-story buildings by an undermining process.
The strategy is to undermine the building while controlling the manner and direction in which
it falls. The demolition project manager/supervisor will determine where undermining is necessary so
that a building is pulled in the desired manner and direction. The walls are typically undermined at a
building's base, but this is not always the case if the building design dictates otherwise. Safety and
cleanup considerations are also taken into account in determining how the building is undermined
and ultimately demolished. Hoe rams are typically used for removing the concrete road deck and
piers during bridge demolition, while hydraulic shears are used to remove the bridge's structural
steel.
In some cases a crane with a wrecking ball is used to demolish the structure down to a certain
manageable height. At that point undermining takes place as described above. However crane
mounted demolition balls are rarely used within demolition due to the uncontrollable nature of the
swinging ball and the safety implications associated.
High reach demolition excavators are more often used for tall buildings where explosive demolition is
not appropriate or possible. Excavators with shear attachments are typically used to dismantle steel
structural elements. Hydraulic hammers are often used for concrete structures and concrete
processing attachments are used to crush concrete to a manageable size, and to remove reinforcing
steel.
To control dust, fire hoses are used to maintain a wet demolition. Hoses may be held by workers,
secured in fixed location, or attached to lifts to gain elevation.
Loaders or bulldozers may also be used to demolish a building. They are typically equipped with
"rakes" (thick pieces of steel that could be an I-beam or tube) that are used to ram building walls.
Skid loaders and loaders will also be used to take materials out and sort steel.
The technique of Verinage is used in France to weaken and buckle the supports of central floors
promoting the collapse of the top part of a building onto the bottom resulting in a rapid, symmetrical,
collapse.
The Japanese company Kajima Construction has developed a new method of demolishing buildings
which involves using computer-controlled hydraulic jacks to support the bottom floor as the
supporting columns are removed. The floor is lowered and this process is repeated for each floor.
This technique is safer and more environmentally friendly, and is useful in areas of high population
density.
Building implosion : Main article: Building implosion
Demolition of a chimney at the former brewery "Henninger" in Frankfurt am Main, Germany, on 2

December 2006
The demolition of the New Haven Coliseum in New Haven, Connecticut
Large buildings, tall chimneys, smokestacks, and increasingly some smaller structures may be
destroyed by building implosion using explosives. Imploding a building is very fast - the collapse itself
only takes seconds - and an expert can ensure that the building falls into its own footprint, so as not
to damage neighboring structures. This is essential for tall structures in dense urban areas.
Any error can be disastrous, however, and some demolitions have failed, severely damaging
neighboring structures. The greatest danger is from flying debris which, when improperly prepared
for, can kill onlookers.
Even more dangerous is the partial failure of an attempted implosion. When a building fails to
collapse completely the structure may be unstable, tilting at a dangerous angle, and filled with un-
detonated but still primed explosives, making it difficult for workers to approach safely.
A third danger comes from air overpressure that occurs during the implosion. If the sky is clear, the
shock wave, a wave of energy and sound, travels upwards and disperses, but if cloud coverage is low,
the shock wave can travel outwards, breaking windows or causing other damage to surrounding
buildings.
Stephanie Kegley of CST Environmental described shock waves by saying, "The shock wave is like
a water hose. If you put your hand in front of the water as it comes out, it fans to all sides. When
cloud coverage is below 1,200 feet, it reacts like the hand in front of the hose. The wave from the
shock fans out instead of up toward the sky."
While a controlled implosion is the method that the general public often thinks of when discussing
demolition due to its spectacularity, it can be dangerous and is only used as a last resort when other
methods are impractical or too costly. The destruction of large buildings has become increasingly
common as the massive housing projects of the 1960s and 1970s are being leveled around the world.
At 439 feet (134 m) and 2,200,000 square feet (200,000 m2), the J. L. Hudson Department Store and
Addition is the tallest steel framed building and largest single structure ever imploded.
Preparation :
It takes several weeks or months to prepare a building for implosion. All items of value, such as
copper wiring, are stripped from a building. Some materials must be removed, such as glass that can
form deadly projectiles, and insulation that can scatter over a wide area. Non-load bearing partitions
and drywall are removed. Selected columns on floors where explosives will be set are
drilled and high explosives such as nitroglycerin, TNT or C4 are placed in the holes.
Smaller columns and walls are wrapped in detonating cord. The goal is to use as little
explosive as possible; only a few floors are rigged with explosives, so that it is safer (fewer
explosives) and less costly. The areas with explosives are covered in thick geotextile
fabric and fencing to absorb flying debris.E61 Far more time-consuming than the
demolition itself is the clean-up of the site, as the debris is loaded into trucks and hauled
away.
Deconstruction : Deconstruction (building)
A new approach to demolition is the deconstruction of a building with the goal of
minimizing the amount of materials going to landfills. This "green" approach is applied
by removing the materials by type material and segregating them for reuse or recycling.
With proper planning this approach has resulted in landfill diversion rates that exceed
90% of an entire building and its contents in some cases. In addition, it also vastly reduces
the CO2 emissions of the removing of a building in comparison to demolition.
The development of plant and equipment has allowed for the easier segregation of waste
types on site and the reuse within the construction of the replacement building. On site
crushers allow the demolished concrete to be reused as type 1 crushed aggregate either as
a piling mat for ground stabilization or as aggregate in the mixing of concrete. Timber
waste can be shredded using specialist timber shredders and composted, or used to form
manufactured timber boards, such as MDF or Chipboard. Safety is paramount, a site
safety officer is usually assigned to each project to enforce all safety rules and regulations.
List of Relevant BIS Codes

S.No. BIS Code No. Description
1. IS: 1200 (P-18) Methods of Measurements of Demolition and Dismantling.
2. IS;2190-1979 First Aid appliances
3. IS:3696(P-2)-1991 Ladders etc. for Demolition
4. IS:4130-1991 Safety measures in Dismantling.
CHAPTER No. 18
MISCELLANEOUS BUILDING WORKS
CHAPTER No.18 : MISCELLANEOUS BUILDING WORKS
CONTENTS
18.1 Cement Concrete Plinth Protection 3
18.2 Brick work Plinth Protection 4
18.3 Urinal Partitions 4
18.4 Cup Board 5
18.5 Providing and Fixing Aluminium Strip Edging to Stairs 6
18.6 Water Proofing Treatment (W.P.T.) 7
18.7 Providing Water Stops 20
18.8 Water Proofmg Treatment on Roof slabs by applying cement Slurry
Mixed with Armoucrete or Tapecrete, second layer of Fibre
Glass cloth 22
18.9 Integral Cement Based Water Proofing Treatment (including
Preparation of Surface as required for Treating Roofs,
Balconies, Terrace, etc.) with Brick Bat Coba 24
18.10 Water Proofing with Bitumen Felt 27
18.11 Water Proofing with Glass Fibre Tissue Reinforced Bitumen 34
18.12 Applying Bituminous Solution Primer on Roof and Wall Surface 35
18.13 Grading of Roof for Water Proofing Treatment 35
18.14 Water Proofing Treatment with A.P.P. Membrane 39
18.15 Water Proofing Membrane with A.P.P. modified Prefabricated 44
Membrane Five Layered
18.16 Extra for Covering of A.P.P. modified Prefabricated Water Proofing 47
Membrane with Geo Textile
18.17 Composite Roof Insulation and Water Proofmg with Rigid
Polyurethane Foam 48
18.18 Expansion Joints 51
18.19 Barbed wire fencing 51
18.20 Miscellaneous Brick Work 54
18.21 Cutting Rebates, Holes, Openings ,Grooves etc. in Dressed
Stone Work Concrete and Brick Work 55
18.22 Cut Stone Door & Window frames 56
18.23 R.C.C. Door and Window Frame 58
18.24 Wall Covering 59
18.25 Cast in Place Voided Slabs 63
18.26 Cement Concrete Block Flooring over
Cement Concrete Bedding 63
18.27 Shotcrete 64
Appendix À' Bitumen Felts (Fibre Hessian Base) 69
Appendix 'B' Glass Fibre Base Bitumen Felt 71
Appendix 'C' Safety at Construction site 72
Figures 83-98
List of Bureau of Indian Standards (BIS) Codes 99
CHAPTER No. 18
MISCELLANEOUS BUILDING WORKS
18.1 Cement Concrete Plinth Protection:

18.1.1 Scope:
(a) Plinth protection shall be provided in building to safe guard of entry of rainwater in
foundation & plinth
(b) Plinth protection shall be provided, as specified, to required width. It comprises 5 cm thick
cement concrete 1 : 3 : 6 (1 cement: 3 coarse sand : 6 graded stone aggregate 20 mm nominal
size) over 7.5 cm bed of dry brick aggregate 40 mm nominal size, grouted with fine sand. The
outer edge shall be lined with 2nd class bricks laid on edge and joints laid in cement mortar
1:4(1 cement: 4 fine sand). Plinth protection shall be laid with a minimum outward slope of 1
in 50.
18.1.2-Preparing Ground: The ground, where plinth protection is to be laid shall first be prepared
to the required slope. The high portions of ground shall be excavated, hollows and depressions filled
up to the required level with the excavated earth and watered and rammed to give uniform outward
slope. Preparation of any area involving cutting and filling up to a depth of 15 cm shall not be paid
for separately. Cutting and filling beyond 15 cm shall be paid for separately. The bed shall be watered
adequately and rammed with iron rammers. Surplus earth, if any, obtained shall be disposed off
within a lead of 50 metres or as directed by the Engineer-in-Charge.
18.1.3 Brick Edging : The edging shall be of bricks of grade as specified in the item.. Trenches of
required depth and width shall first be made along the edge of the plinth protection to receive the
bricks for edging. The bed of trenches shall be compacted to a firm and even surface. The brick shall
be laid true to line in cement mortar 1:4(1 cement: 4 fine sand) with length parallel and abutting the
plinth protection. The top face of the brick edging shall be in one level, to conform to the finished
level or the plinth protection adjacent to the edging. After the concreting is done, no portion of the
brick edging shall project above the adjacent concrete surface. Cement mortar shall conform to the
specifications described in (to refer relevant reference)
18.1.3.1 Sub-grade: The sub-grade shall consist of a bed of dry brick aggregate of 40 mm nominal
size. brick aggregate shall be spread evenly over the prepared surface to 7.5 cm depth
(unconsolidated) and given a minimum outward slope of 1 in 50. The aggregate shall be carefully laid
and packed, bigger size being placed at the bottom. The brick aggregate shall be consolidated dry with
heavy iron rammers. After the brick aggregate has been consolidated the surface shall be checked
with a straight edge and any depressions etc. filled up and consolidated. The aggregate shall then be
grouted evenly with fine sand @ 0.06 cubic metres/10 sqm area, adequately watered to ensure filling
of the voids by sand and again rammed with heavy iron rammers. The finished surface shall give
uniform appearance.
18.1.4 Cement Concrete Topping: After the sub-grade has-been compacted and prepared as
under (to refer relevant reference), 5 cm thick cement concrete 1:3:6 (1 cement: 3 coarse sand
: 6 graded stone aggregate 20 mm nominal size as specified in the item) shall be laid in one operation
as described (to refer relevant reference), except that the top shall be finished with only wooden
floats. The concrete surface shall not be finished with mortar. The length of each panel shall not be
more than 5 m. The finished surface shall have a minimum outward slope of 1 in 50.
18.1.5 Curing : Specification shall be as described in Chapter 5 : Concrete
18.1.6 Measurements: The length and breadth of cement concrete topping shall be measured correct
to a cm and the area calculated in sqm correct to two places of decimal. No deduction shall be made
not anything extra paid for any openings for pipes etc. up to 0.1 sqm . Brick edging shall be measured
in running metre correct to a cm and paid for separately.
18.1.7 Rate: The rate shall include cost of materials and labour described above except for brick
edging which will be paid for separately.
18.2 Brick Work Plinth Protection : Plinth protection shall be provided as specified, to the required
width. It shall consist of a layer of bricks of grade specified in the relevant item, in cement mortar
1:6(1 cement: 6 fine sand) over a bed of dry graded brick aggregate of 40 mm nominal size laid,
compacted and grouted with fine sand. The top brick on edge layer shall be finished with pointing
in Cement mortar 1:2 (1 cement: 2 fine sand). Plinth protection shall be laid with a minimum outward
slope of 1 in 50.
18.2.1 The specifications for 'Preparing ground' and 'Sub-grade' shall be as described in 18.1.2 and
18.1.3 respectively.
18.2.2.Brick Topping : After the sub-grade had been compacted thoroughly, brick flooring with
bricks of class designation 75 in cement mortar 1:6 (1 cement: 6 fine sand) shall be laid to the
required slope. The bricks shall be laid in herring bone bond or as described in the item..
18.2.3 Pointing: The pointing which shall be in 1:2 cement mortar (1 cement : 2 fine sand) shall
conform to the specifications given in 'Pointing' under sub-head 'Finishing'.
18.2.4 Curing: Specification for curing (minimum for 7 days) shall be as described in chapter of
Brick work.
18.2.5 Measurements: Length and breadth shall be measured correct to a cm and area calculated in
sqm correct to two places of decimal. No deduction shall be made nor anything extra paid for any
openings for pipes etc. up to 0.1 sqm.
described above.
18.3 Urinal Partitions:
18.3.1 Reinforced Cement Concrete Partition : The partition shall be of precast reinforced cement
concrete slab, suitably embedded in the wall and the exposed surfaces finished in terrazzo. The size of
the slab shall be 105 cm high and 60 cm width (overall). The thickness of the RCC slab, excluding
finishing, shall be 32 mm. The cement concrete for the slab shall be of mix 1:2:4 (1 cement: 2 coarse
sand : 4 graded stone aggregate 10 mm nominal size). The slab shall have reinforcement of mild steel
bars 6 mm dia. at 20 cm centre to centre both ways. The specifications for R.C.C. work shall be as
described in chapter 6.
18.3.1.1 Fixing : The partitions shall be fixed in the wall 60 cm apart between the centre of slabs
or as specified in the relevant drawings, with cement concrete 1:2:4 (1 cement: 2 coarse sand :
4 graded stone aggregate 6 mm nominal size) in the vertical recesses cutlet for this purpose. The size
of the recess shall be 11.5 cm wide and 11.5 cm deep. The slab shall project 50 cm from the face of
the wall, unless otherwise specified. The lower edge of the slab shall be kept 45 cm above the
standing level unless otherwise specified. The partition slab shall be fixed and set in position true to
plumb. The lower edges of all slabs fixed in one wall shall lie in one horizontal plane, similarly the
top edges. The front edges shall be in one plane.
183.1.2 Finishing: All the exposed surfaces of the slab shall be finished with 6 mm thick terrazzo
plaster in cement mortar 1:2 (1 part of cement and 2 parts of marble chips of 3 mm size and down)
over an under coat of 6 mm thick cement plaster in cement mortar 1:3 (1 cement: 3 coarse sand).
The finishing of all slabs in one lavatory block shall be done at one time to ensure uniform colour
of the finished terrazzo work and uniform size of marble chips.
The specifications in general shall be as in chapter 12 on flooring except that the thickness of under
coat shall be 6 mm instead of 12 mm. The finished thickness of slab shall be 56 mm with a tolerance
of ±3 mm.
18.3.1.3 Curing : Curing shall be as specified (minimum 10 days) or as per direction of Engineer in
charge.
18.3.1.4 Measurements : The partitions shall be enumerated.
18.3.1.5 Rate: The rate shall include the cost of labour and material involved in all the operations
described above, including the leaving /cutting of recess in the wall.
18.3.2 Marble Slab Partitions : The partitions shall be of marble slab, embedded in the wall. The
size of the marble slab shall be 105 cm high and 60 cm wide. The finished thickness shall be 25 mm.
The specifications for marble work, in general, shall be as per the chapter 12 on Marble work, except
that the marble shall be of approved source unless otherwise specified. The marble shall be cut into
slabs of required thickness and shall be in one piece.
18.3.2.1 Finishing : The partition of the slab to be embedded in the masonry shall be rough dressed.
Dressing and rubbing of the exposed portion of the slab shall be as described. The dressed slab shall
be of the thickness as specified with a tolerance of ±1.5 mm. The slab shall be got approved from
the Engineer-in-Charge before procurement.
18.3.2.2 Fixing shall be as in 18.3.1.1 except that the recess shall be 7.5 cm wide.
18.3.2.3 Measurement shall be as in 18.3.1.4.
18.3.2.4 Rate : The rate shall include the cost of labour and materials involved in all the operations
described above including the leaving/cutting of recess in the wall.(see Fig.13)
18.4: Cup Board:
i) The work shall be carried out as per drawing or as directed by the Engineer-in-Charge. The timber
shall conform to the specifications given (to refer relevant reference).
18.4.1 Frame Work: Frame work shall be made to the sizes and shape as shown in the drawings, or
as specified. The specifications given (to refer relevant reference) shall be applicable to frame work.
18.4.2 Shutters: The quality and the thickness of the shutters shall be as specified or as shown in
the relevant drawings. The shutters shall be flush/panelled/glazed or panelled and glazed as specified
or as shown in the drawings. Specifications for flush shutters shall be as described (to refer relevant
reference). Specifications for panelled glazed or panelled and glazed shutter shall
be as described (to refer relevant reference).
18.4.3 Shelves : The number, size and thickness of the shelves shall be as shown in the relevant
drawings or as specified. The planks for shelves shall be of specified timber or hard board and planed
on all faces and edges. The shelves shall rest on wooden supports, 25 x 25 mm, for their full depth.
The wooden supports shall be fixed in the wooden enclosure or in masonry by means of wooden
plugs and screws, at suitable intervals. The shelves shall be fixed to the supports with wood screws
of suitable size at 100 mm centre to centre. The shelves, when fixed, shall be truly horizontal.
18.4.4 Internal Partitions: Where specified or shown in the drawings, the vertical partition of
timber of size and thickness shown shall be provided and shall be of one piece. It shall be secured to
shelves by means of screws to avoid slipping or lateral movement. The partition, when fixed, shall be
truly vertical.
18.4.5 Hanger-rod: The hanger rod, where specified or shown in the drawing, or as directed by the.
Engineer-in-Charge, shall be provided at the top of cupboard. The clear gap above the rod shall be
not less than 8 cm. The rod shall be of single piece. The diameter of wooden / PVC rod shall be 25
mm while that of metal shall be 20 mm, unless otherwise specified. The end supports shall consist
of brass or C. P. brass, PVC bracket of approved quality fixed to the side masonry of the cupboard
with suitable plugs and screws.
18.4.6 Fittings: These shall be provided and fixed as per specifications and schedule of fittings given
in the contract/drawings, unless otherwise specified. The fittings shall be as per samples approved
by the Engineer-in-charge.
18.4.7 Finishing: All the wood work shall be painted or finished as specified. After fixing the plugs
for supports, the plaster should be neatly repaired with cement mortar 1: 4 (1 cement: 4 coarse sand)
where wood lining is not specified, the inside plaster portion shall be finished with two coats of oil
bound distemper or flat wall paint of approved colour, as specified. When required, the inside of the
cupboard shall be lined with wooden planks/ply wood of specified quality where shown on the
drawings or specified in the description of the item. Specifications for wood lining shall be as
described (to refer relevant reference) except that the lining shall be directly fixed without any
patterns of the masonry surface by means of plugs and screws spaced at not more than 20 cm apart
in both directions. The finishing of the exposed surface of the lining shall be as specified above in
this clause.
18.4.8 Measurement : The cupboard shall be measured in numbers for each size .
18.4.9 Rate :
a) Payment will be made at the rate specified in the contract. Separate rates shall be payable for
each type of cupboard, depending upon the size, materials, shelves, finishing and other
features.
b) The rate shall include the cost of all materials and labour involved in all the above operations.
However, the rate does not include any brick work, plastering, R.C.C. work, flooring and
holdfasts for frames, which shall be paid for separately under relevant items, if executed.
18.5. Providing and Fixing Aluminium Strip Edging to Stairs :
18.5.1 Aluminium Sections : Size and shape of aluminium sections shall be as specified in the
relevant items of work/drawings. These shall be provided to RCC/wooden or masonry steps as
specified.
18.5.2 Fixing:
a) A suitable recess shall be provided in the step, both in tread and riser portions, to receive the
step edging so that, after fixing, the top surface of the edging and the top surface of the tread
shall be perfectly in one level. Similarly the outer face of the vertical leg of the edging shall be
flush with the finished surface of the riser.
b) In cases where the finish over the risers and treads consists of plain cement concrete flooring
and cement/lime cement mortar respectively, the edging shall be fixed after the flooring/
plastering are completed. Where the finish consists of marble chip flooring marble chips
plastering, the edging shall be fixed after the polishing of the flooring/plastering.
c) The recess shall be thoroughly cleaned of all loose material, mortar droppings etc. before fixing
the edging. The surface recess shall be given a coat of cement slurry and a thin layer of cement
mortar 1:3 (1 cement : 3 coarse sand) Holes shall be drilled in the leg of the edging coming on
the tread to receive the screw of specified size. The edging shall be kept in position, tapped
gently to make it sit firmly on the mortar bedding and then fixed in position with necessary 25
mm size wood screws. Each edging shall be in one piece only after the work is completed and
the mortar has set, no hollow sound shall be given when the edging the tapped. Any edging
giving hollow sound shall be taken out and refixed properly. Wooden plugs of suitable size at
approximately 20 mm apart shall be fixed at desired level during laying of cement concrete in
steps for fixing the edging. The fixing may be done using rawl plugs/detefix also, instead of
wooden plugs.
18.5.3 Measurements: The length of aluminium step edging shall be measured in running metre
correct to a cm.
18.5.4 Rate: The Rate shall including the cost of labour and the material required for all the
operations described above include making holes, providing wooden plugs/ rawl plugs etc.
18.6 Water Proofing Treatment (WPT):
18.6.1 Terminology:
i) Blended Cement : Cement mixed with water proofing compound in liquid or powder form.
ii) Coating or Covering: Protective material applied over the polyurethane foam for absorption
of ultra violet rays and for water shedding.
iii) Core Density : The weight per unit volume of a single layer of foam excluding skins that
may be formed.
iv) Expansion Joints; Joints provided in the structure to allow for thermal expansion/
contraction.
v) In place Density: The weight per unit volume of the cross-section of foam including skins
that may be formed.
vi) Low Parapet Walls : Parapet walls of height less than 45cm.
vii) Water Bars :Water bars are preformed strips of impermeable materials which are embedded
in the concrete during construction.
18.6.2 Integral Cement based Treatment for Water Proofing on Horizontal Surface:
a) Water Proofing Horizontal Surfaces of Under Ground Water Tanks, Swimming Pools or
Basements from Outside (Fig..1)
b) External Water Proofing Treatment of Under Ground Water Tank with Cylindrical Shell Roof
on Top.
18.6.2.1 Preparing the Surface:
(a) Preparing the Surface of Lean Concrete/Levelling Course: The Water Proofing treatment
over the lean concrete/levelling course surface as shown in Fig.1 should adhere to the surface
firmly, the surface of levelling course should be roughened when the concrete is still green. In
case the surface is not made rough in the initial stages itself i.e. before the concrete is set, the
work of water proofing should not be permitted till proper key is provided for the 25 mm thick
base layer. This key cannot be achieved by hacking the already set concrete surface instead a
spatter-dash key should be provided without any extra cost, as it is the responsibility of the
contractor to roughen the surfaces properly over which plaster or similar coat is to be laid.
(b) Preparing the horizontal surface of the offset of the slab: Same as explained above.
18.6.2.2 Blending Cement/Water with Water Proofing Compound: Usual method of mixing
water proofing compound in powder or liquid form, to already prepared cement mortar should be
discouraged, the correct method is to use the blended cement/ water proofing compound to prepare
the cement mortar for use in water proofing works.
(a) Blending Cement with Water-Proofing Compound i.e. Preparing blended cement:
(i) The required quantity of cement bags to be used for a particular portion of work should be
sorted out and the contents of each bag should be emptied on a suitable dry platform.
Water proofing compound in powder form manufactured by reputed manufacturer
bearing ISI mark conforming to IS 2645-2003 should be mixed with the contents of each
bag. The quantity of water proofing compound to be mixed should be as prescribed by
the manufacturer but not exceeding 3% by weight of cement.
ii) The requirements for integral waterproofmg compounds for cement mortar and
concrete which shall be assessed by :
The permeability to water of the specimen made from cement sand mortars, with and
without addition of waterproofing compound under test, by measuring the percolation of
water through standard specimen cylinders. The permeability to water of the standard
cylindrical specimen prepared with the recommended proportions of water proofing
compound shall be less than half of the permeability of similar specimen prepared
without the addition of the compound when tested in accordance with the method given
in Annex B of IS 2645-2003.
The physical tests of setting time and compressive strength of cement by admixing the
recommended proportions of the mortar/ concrete waterproofing compound and
comparing the results of similar tests on the same cement without addition of the
compound.
iii) Setting Time : The setting time of the cement admixed with the recommended
proportion of the waterproofing compound when tested according to IS 4031 (Part 5),
keeping time of gauging not less than 5 Mn nor more than 6 Mn shall conform the
following requirements :
Initial setting time : Not less than 30 min nor the reduction in the initial setting time
shall be more than 25 percent of the actual initial setting time of cement used for testing.
Final setting time: Not more than 600 min. nor the increase in the final setting time shall
be more than 25 percent of the actual final setting time of cement used for testing.
b) Compressive Strength : The average compressive strength of 3 mortar cubes, prepared, stored
and tested in accordance with the method described in IS 4031 (Part 6), using the recommended
proportion of integral waterproofing compound as admixture to the cement shall be as follows:
i) Compressive strength at 3 days (72 ± 1 h) -Not less than the minimum specified 3 days
compressive strength of the grade of ordinary Portland cement used nor less than 90
percent of the 3 days compressive strength of mortar cubes prepared with same cement
and sand only.
ii) Compressive strength at 7 days (168 ± 2 h) -Not less the minimum specified 7 days
compressive strength of the grade of ordinary Portland cement used nor less than 90
percent of the 7 days compressive strength of mortar cubes prepared with same cement and
sand only.
c) Chloride Content: The chloride content determined in accordance with IS 6925 in the product
shall be declared by the manufacturer. Further, it should not exceed 2.0 percent by mass of the
product.
(iv) The quantity of cement (50 kg) the water-proofing compound in powder form thus mixed
should be thoroughly blended by employing skilled labourers and the cement thus blended
should again be packed in gunny bags so that the material can be readily used for preparing
mortar/slurry for the water proofing works, to achieve best results.
(v) Blending Water with Liquid Water Proofing Compound:
(a) In case the water proofing compound to be used is in liquid form then instead of blending
cement with water-proofing compound the water to be used in the particular mix should
be blended with water proofing compound.
(b) This can be done by taking the just required quantity of water to be mixed in the particular
batch of dry cement mortar. The required quantity of water thus collected per batch of
dry cement mortar to be prepared should be mixed with liquid water-proofing compound
from sealed tins with ISI mark and manufactured by reputed manufacturer.
(c) The water thus mixed with water-proofing compound shall be thoroughly stirred so that
the water is blended with water proofing compound nicely.
(d) The quantity of blended water thus prepared should only be used per batch of dry cement
mortar/dry cement to make slurry to be used for water-proofmg works to achieve the best
results.
Note : The use of cement mixed with water-proofing compound has been referred as
"blended cement" in some references, which shall mean use of water proofing compound
in powder/liquid form for use in cement mortar/slurry.
18.6.23 Rough Kota Stone/Sand Stone Slabs:
(i) The stone slabs to be used for this item shall be in thickness of 22 mm to 25 mm. Larger size
of stone slabs i.e. 550 mm x 550 mm or 550 mm x 850 mm shall be used to minimise the
number of joints.. Stones with varying thicknesses ( less than 22mm or more than 25 mm) shall
not be permitted to be used.
(ii) General requirement of Kota stone/Red Sand Stone shall be as laid down in chapter 3.
18.6.2.4 Preparation of Cement Slurry: Cement slurry shall be prepared with 2 kg to 2.2 kg of
cement /sqm having viscous honey like consistency. Each time only that much quantity of slurry
shall be prepared which can be covered on the surface and the surface in turn would be covered with
25 mm thick cement mortar base within half an hour. Slurry prepared and remained un-used for more
than half an hour shall be rejected.
18.6.2.5 Preparation of Cement Mortar :The Cement mortar 1:3 (1 blended cement: 3 coarse sand)
shall be prepared with cement/water duly blended as explained in clause 18.6.2.2 para (a). Each time
only that much quantity of cement mortar that can be consumed within half an hour, shall be
prepared. Any quantity of cement mortar that is prepared and remains unused for more than half an
hour shall be rejected.
18.6.2.6 Laying Water Proofing Course with rough Kota stone/Sand stone:
(1) First Layer: 25 mm Thick Base Course in cement mortar 1:3.
(i) Before laying the first course of cement mortar 1:3 base, the lean concrete surface shall be
cleaned neatly with water and cement slurry prepared as per clause 18.6.2.4 shall be applied only
on the area of the concrete surface, that can be covered with the cement mortar (1:3) base course
within half an hour.
(ii) The cement slurry should cover every spot of the surface and no place shall remain uncovered.
(iii) Just after the application of cement slurry on the surface, the cement mortar prepared as per
clause 18.6.2.5 should be used for laying the base course.
(iv) For laying base course to a perfect level at least 3 Nos. 25 mm high wooden strips with 3 legs
(tripod) shall be placed on the concrete surface at suitable distances and the cement mortar shall
be laid to the exact level of the strips and tamped gently. The top surface should be finished
neatly and later scratched when green with a suitable instrument.
(v) Before the base course dries and gets hard that is just before the base course takes up initial set,
the 2nd layer of Rough Kota Stone/Red Sand Stone slab cladding shall be taken up
immediately.
Note: As far as possible work of different layers of this water proofing treatment shall be taken
up in immediate succession without allowing any time gap in between the layers, otherwise it
would be difficult to achieve homogenous treatment, which is the basic necessity.
(2) Second Layer: 20 mm thick Rough Kota Stone Slab/Red Sand Stone Slab
(i) When the 25 mm thick base course is just getting set the cement slurry prepared as per clause
18.6.2.4 should be spread over the base course up to the area that shall be covered with just
two to three stone slabs.
(ii) The cement slurry shall be spread in such a way that the area of base course to be covered
immediately shall be covered with slurry without any gap, or dry spots.
(iii) Each time only the area that is required to clad two to three sand stone slabs shall be taken up
for spreading the slurry and only after fixing the stone slabs over the slurry further area shall
be taken up.
(iv) Immediately on applying cement slurry on the base course the Rough Kota stone Slabs/Red
Sand stone slabs shall be laid over the base course and pressed gently so that the air gap can
be removed.
(v) The slurry applied on the surface which gets spread when the stone slab is pressed shall get
accumulated in the joints of adjacent stone slabs and if any gap still remains between the stone
slabs the same should also be filled with additional quantity of cement slurry.
(vi) For laying the stone slabs in perfect level, two stone slabs at adjacent corners/ends shall be
fixed firmly to the required level and a string stretched over the two slabs, the intermediate slabs
shall then be set to the level of the string.
(3) Third Layer: 25 mm thick course in cement mortar 1:3.
(i) On filling all the joints of the Rough Kota Stone Slabs/Red Sand Stone slabs with cement
slurry and after a gap of 6 to 8 hours the area of stone slabs shall be cladded with cement
mortar 1:3.
(ii) The surface of stone slabs shall be cleaned and lightly watered. The cement mortar (1:3)
prepared as per clause 18.6.2.5 shall be used for laying this course, no cement slurry need be
used and the mortar can be laid on the slab surface directly.
(iii) For laying this course in perfect level, 25 mm high wooden strips with legs (tripod) used for
laying base course shall be used and the top surface shall be finished smooth without using
additional cement or slurry.
(4) Fourth Layer: Top Finish with Stone Aggregates 10 to 12 mm Size
(i) Immediately after laying 3rd course and before the cladded mortar takes the initial set, stone
aggregate of 10 mm to 12 mm nominal size shall be pressed in to the finished surface @ 8
cudm/sgm.
(ii) The aggregates though embedded shall be clearly visible on the surface, i.e. the stone
aggregates shall not be embedded totally inside the mortar.
Note:- This treatment is provided over the surface which are originally in slope or in level &
no attempt under any circumstances shall be made to provide any slope by altering the 25 mm
thickness of base course, to lay water proofing course in slope.
In case a slope is to be provided for the water proofing layer on a surface which is in perfect level,
grading with additional cement concrete/cement mortar shall be provided and then the water-
proofing layer shall be laid on the graded surface.
18.6.2.7 Curing:
(a) Water Proofing on Lean Concrete Surface: Immediately after completing the fourth layer,
arrangements shall be made to lay the top RCC slab as quickly as possible and in the mean time
till the top slab is concreted the water proofing treatment shall be kept wet continuously. In case
the concreting of slab gets delayed for more than 2 weeks the curing can be stopped after 14
days.
(b) Water Proofing on Horizontal Surface of the offset of floor slab: The water proofing
treatment done on the offset of the floor slab shall be kept wet continuously for 14 days
minimum.
18.6.2.8. Measurement: Length and breadth shall be measured along the finished surface correct to
a cm and area shall be worked out to nearest 0.01 sqm.
18.6.2.9 Rate : The rate shall include the cost of labour & materials involved in all the operations
described above.
18.6.3 External Water Proofing Treatment for Under Ground Water Tank Covered with
Top RCC Slab (Fig. 1)
18.6.3.1 Preparing the Surface:
(a) Preparing the Surface of Lean Concrete/Levelling Course. Same as explained under clause
18.6.2.1 para (a).
(b) Preparing the horizontal surface of the offset of Floor slab. Same as explained under clause
18.6.2.1 para (b).
(c) Preparing the surface of top of RCC Slab.
The top surface of the RCC roof slab shall be made rough by hacking the surface with a specifically
made hacking tool when the concrete is just laid and the initial set starts taking place. Alternatively,
the surface should be roughened by providing spatter dash key as explained under clause 18.6.2.1 para
(a).
18.6.3.2 Blending Cement/Water with Water-Proofing Compound: Same as explained under
clause 18.6.2.2 para (a) & (b)
18.6.3.3 Rough Kota Stone Slab/Red Sand Stone Slab Same as explained under clause 18.6.2.3.
18.6.3.4 Preparation of Cement Slurry: Same as explained under clause 18.6.2.4 18.6.3.5 Laying
Water Proofing Course Same as explained under clause 18.6.2.6. 18.6.3.6 Curing:
(a) Water proofing on Lean Concrete Surface: Same as explained under clause 18.6.2.7 para (a).
(b) Water proofing on Horizontal Surface of the offset of flooring Same as explained under
clause 18.6.2.7 para (b).
(c) Water proofing on Top Roof Slab: Same as explained under clause 18.6.2.7 para (b).
18.6.3.8 Measurement :Same as clause 18.6.2.8.
18.6.3.9 Rate : Same as clause 18.6.2.9.
18.6.4 External Water Proofing Treatment for Basements:
Water proofing treatment, measurement and rate for basements shall be done exactly as specified for
the water proofing treatment for underground water tank with cylindrical shell roof on top as shown
in Fig.l and explained under clause 18.6.2.
18.6.5 Water Proofing Horizontal Surfaces of Under Ground Water Tanks, Swimming Pools,
or Basements from Inside:
18.6.5.1 Internal Water Proofing Treatment for Under Ground Water Tank with Cylindrical Shell
Roof on Top (Fig. 2)
Note:-
1. The only difference between the external water proofing treatment of this type of structure as
dealt under clause 18.6.2 and the internal water proofmg treatment for the same structure as in
this case is that the water proofing treatment for the floor slab in the previous case is for the
bottom face of the floor slab whereas in this case the water proofing treatment for the same
floor slab shall be for the top exposed face.
2. Unlike in case of water proofing treatment provided from outside, as shown in Fig.1 where the
offset of floor slab is also treated, in this particular case as the water proofing treatment is given
to the inner faces of the tank no water proofing treatment is required to be provided for the
offset of floor slab.
3. Water Proofing treatment for inside slab of water tank shall be done well before casting of
slab/shell roof so that water treatment is properly set. Care shall be taken that each vertical prop
scaffolding rests on strong and proper size of sole piece so that load on each prop is spread over
greater area and it does not spoil the horizontal water proofing layer. In case roof slab is cast
before water proofing, then working for water proofmg layer through manhole shall be very
difficult.
18.6.5.2. Preparing the Surface:
As the water proofing has to be provided for the exposed face of the RCC floor slab cast with rich
mix, the surface of the slab must be made rough by hacking the surface with a specially made hacking
tool immediately after initial set takes place in the concrete.
Hacking the already hardened surface of richer mix concrete will not be possible and in that case the
key required to be provided for the base course to be laid on top, shall be done by providing spatter
dash key.
Under no circumstances the water proofing treatment shall be done on a plain surface or a surface
simply scratched with wire brushes etc.
18.6.5.3. Blending Cement/Water with Water Proofing Compound Same as explained in clause
18.6.2.2 para (a) & (b).
18.6.5.4 Rough Kota Stone Slab/Red Sand Stone Slab Same as explained in clause 18.6.2.3.
18.6.5.5 Preparation of Cement Slurry Same as explained in clause 18.6.2.4.
18.6.5.6 Preparing Cement Mortar Same as explained in clause 18.6.2.5.
18.6.5.7 Laying Water-Proofing Course :Same as explained in clause 18.6.2.6 including the Notes
there in.
18.6.5.8. Curing:
(i) In this case just after the water proofing work on top of floor slab is completed, the water
proofing for the vertical faces of the side walls from inside shall also be taken up immediately.
Till the water proofing work on vertical faces is in progress, the water proofing work done on
floor slab shall be kept wet for a minimum period of 14 days.
(ii) Immediately on completion of water proofing on the vertical faces of side walls, the water
tank shall be gradually filled with water for testing.
18.6.5.9. Measurement: Length and breadth shall be measured along the finished surface correct to
18.6.5.10 Rate : The rate shall include the cost of labour and materials involved in all the
18.6.1.2.2 Internal Water Proofing Treatment for Under Ground Water Tank covered with RCC
Slab (Fig. 3)
a) Water Proofing to Horizontal Surface of floor slab: Same as explained in clauses 18.6.2.
b) Water Proofing to Top RCC slab: Same as explained in clauses 18.6.3
c) Measurement and Rate: Same as clauses 18.6.2.8 and 18.6.2.9 respectively.
18.6.6. Water-Proofing Horizontal Surfaces of Basement from Inside (Fig. 2): Same as
explained under clause 18.6.2.1 to 18.6.2.9
18.6.7 Integral Cement Based Treatment for Water Proofing on the Vertical Surface/Faces:
18.6.7.1 Water Proofing Vertical Surfaces of Under Ground Water Tanks, Swimming Pools or
Basements from Outside:
18.6.7.1.1 External Water Proofing Treatment of Under Ground Water Tank with Cylindrical
Shell Roof on Top (Fig. 1):
18.6.7.1.1.1 Preparing the Surface and Providing Ancillary Arrangements:
(i) The surface of the structure to be treated shall be roughened properly either by raking joints
when the mortar is still green in case of brick/stone masonry structures, or by hacking the
cement concrete surface with a specially made hacking tool just after removing the shuttering.
(ii) In case the raking joints/hacking concrete surface is not done properly the only alternative
method to make the surface rough is providing spatter dash key.l This treatment shall be got
done from the contractor without paying any extra cost.
(iii) It should be very clearly understood that the vertical water proofing treatment either from
inside or outside shall be undertaken only when the entire work is structurally complete.
(iv) For doing the water proofing treatment from outside or inside around scaffolding shall be
erected which shall be strong enough to support the stone slabs.. Also proper strong scaffold
boards strong ladders and coir ropes shall be made available for using while erecting the stone
slabs. Similarly, while doing the water proofmg to vertical faces from inside a particular care
shall be taken to see that the water proofing layer of floor slab shall not get damaged while
resting the vertical props of scaffolding. As a precaution it is advised to rest the bailies on the
strong and proper size sole piece placed on the horizontal water-proofing treatment of the floor
slab.
Alternatively water proofing for vertical surface shall be provided before horizontal floor slab water
proofing. In order to arrest any leakage through junction of vertical/horizontal water proofmg a proper
haunch (Fig.7) in cement concrete shall be provided.
18.6.7.1.1.2. Blending Cement/Water with Water-Proofing Compound: Same as explained in
clause 18.6.2.2 including the Note therein.
18.6.7.1.13. Rough Kota Stone/Sand Stone Slabs:
(i) Same as explained clause 18.6.2.3 para (i) and (ii).
(ii) For the stone slabs that are used for arresting the leakages, while executing this type of water
proofing treatment, the first and foremost mandatory condition is that the number of
joints in the portion covered by the stone slabs shall be minimum and this condition can be
achieved only by using the maximum possible size of stone slabs. Normally the size of stone slabs
used for the purpose is 600 x 600 mm or 600 x 900 mm each stone slab weighing approximately 16
kg and 25 kg respectively.
The Rough Kota Stone slabs/Red Sand stone slabs used for such works though are basically rough on
the surface still that much roughness will not be sufficient for the stone slabs to remain in vertical
position held by cement slurry.
Therefore the grip for the stone slabs has to be increased and this can easily be done by planting 12
mm to 15 mm nominal size stone aggregate fixed with araldite on the face of each stone slab as
shown in fig.3.
A 20 mm thick clear gap has to be formed between the masonry/concrete surface and the stone
slabs erected in vertical position for pouring the cement slurry as shown in Fig. 3.
This gap can be maintained by fixing with araldite the 20 mm x 20 mm cover blocks made out of
rich cement mortar on the four corners of the stone slabs and also at centre as shown in Fig 3.
18.6.7.1.1.4. Preparation of Cement Slurry: Same as explained in clause 18.6.2.4.
18.6.7.1.1.5. Preparation of Cement-Mortar (1:4): Same as explained in clause 18.6.2.5 except that
the proportion of cement mortar shall be 1:4 (1 Blended Cement: 4 Coarse sand) instead of 1:3 (1
Blended Cement: 3 Coarse sand),
18.6.7.1.1.6. Fixing Water-Proofing Courses on Vertical Surfaces as Shown in Fig.3.
Note :
(i) Normally the item of work prescribes executing the first layer as base course with cement
slurry, second layer fixing rough Kota stone/sand stone slab third layer as plastering the surface
and the fourth layer as finishing surface with neat cement punning but in actual execution a gap
of 20 mm width has to be formed for pouring cement slurry. The 20 mm wide gap can be
formed by erecting the 20 mm thick Rough Kota Stone Slab/Red Sand Stone slab at a distance
of 20 mm from the Masonry/concrete surface over which the cement slurry is to be cladded and
can be termed as first step for construction.
(ii) Hence for all practical purpose we will consider the chronology of layers as per actual
construction i.e. as laid in particular serial and not as actually formed later. Mainly to avoid
confusion and to distinguish between the two different layers laid and the actual work that is
executed we will term the actual working as Step I, Step II etc.
Step I : Erecting Rough Kota Stone Slab/Red Stone Slab forming 20 mm wide gap :
(i) The Rough Kota Stone Slab/Red Sand Stone slab duly fixed with 20 mm x 20 mm cover blocks
and 12 mm to 15 mm size stone aggregate on the surface as explained in clause 18.6.7.1.1.3
para (iv), (v) & (vi) and shall be erected against the masonry/concrete surface to be treated by
abutting the 20 mm thick cover block against the surface thus forming a clear gap of 20 mm.
(ii) The stone slabs thus erected shall be supported with ballies/pipes to the scaffolding already
erected for the purpose.
(iii) The joints of stone slabs shall be temporarily closed from outside with cement mortar so that
the cement slurry poured in the gap does not escape through the joints. the bottom
portion of the stone slab shall also be closed with cement mortar.
(iv) While erecting the stone slabs proper care shall be taken to see that stone slab are of uniform
size. In case smaller width slabs are used it shall be ensured that these are not fixed at the
corners but the same should be at the middle portion.
(v) Another important point to be noted is that one should be very careful in interlinking the Rough
Kota Stone Slabs/Red Sand Stones of horizontal layer of water-proofing with this vertical layer
of water proofing and the method of interlinking shall be strictly followed.
(vi) The Rough Kota Stone Slab/Red Sand Stone slab shall be erected in perfect plumb and the
stone slabs thus erected and fixed in position can be considered as 2nd layer of water proofing
on completion.
(vii) Further lifts of Rough Kota Stone Slabs/Red Sand Stone slabs up to the full height of the
masonry/concrete wall shall be erected only after filling the gap of each lift erected, with
cement slurry.
Step II : Filling Cement Slurry in the gap formed by erecting Rough Kota Stone Slabs/Red
Sand Stone Slabs:
(i) When the first lift of stone slabs are erected and checked to be in perfect plumb, cement slurry
prepared as per clause 18.6.7.1.1.4 shall be poured in the gap till the gap is filled completely.
(ii) The further filling of slurry in the second lift shall be done when the second lift of stone slabs
are erected in position and thus the work on 2nd and 1st layer of the item shall be completed
simultaneously till the cladding over the entire height of the wall is complete.
(iii) Thus on completion of filling cement slurry and erecting stone slabs for the entire height of the
wall it can be considered that the first layer i.e. the layer of cement slurry and the second layer
i.e. the layer of erecting Rough Kota Stone Slabs/Red Sand Stone Slabs is complete as per the
item.
Step 111/3rd Layer: Plastering Over 2nd layer with Cement Mortar 1:4 (1 Blended Cement : 4
Coarse Sand)
(i) Immediately on completion of the work of cladding the entire masonry/concrete wall with
Rough Kota Stone Slab/Red Sand Stone slab the cement mortar applied over the joints shall be
removed and the joints exposed.
(ii) The entire surface cladded with stone slabs shall be cleaned with water neatly to start the
work of plastering.
(iii) Cement mortar 1:4 (1 blended cement: 4 coarse sand) prepared as per clause 18.6.7.1.1.5
shall be used for the purpose.
(iv) Care shall be taken to see that the 20 mm thickness of cement plaster over the entire surface
shall be maintained correctly.
(v) The work of plastering shall be taken up immediately on completion of cladding the wall
surface rather it should be a continuous process from the day of starting the erection of stone
slabs till the finishing work of plastering is done.
(vi) The plastering shall be taken up from top to bottom without leaving any joint. As far as possible
the joints in plaster shall be minimum, still in case a joint has to be left to continue the work on
the subsequent day, cement slurry prepared as explained under clause 18.6.7.1.1.4
shall be applied over the entire joint and then only the work of plastering shall be taken up.
Step IV/4th Layer : Finishing with Neat Cement Punning:
(i) When the surface of plastering is still green, the cement slurry prepared as per clause
18.6.7.1.1.4 shall be applied over the plastered surface and the surface shall be finished neatly
to a smooth surface with specially made semi-round thappies.
(ii) The surface should show a smooth and neat finish without any undulations.
18.6.7.1.1.7 Curing and Testing: On completion of water proofing course from outside, the tank shall
be cleaned from inside, scaffoldings shall be removed and tank is gradually filled with water for
testing which shall commence within two to three days. The exposed faces of the water proofing
course shall be kept wet for 14 days. No back filling shall be done before expiry of 14 days from the
date of completing the water proofing course from outside.
18.6.7.1.1.8 Measurement: Length, width/height shall be measured along the finished surface
correct to a cm and the area shall be worked out correct to nearest 0.01 sqm.
18.6.7.1.1.9 Rate: The rate shall include the cost of all labour and materials involved in all the
operations described above and all heights.
Note:
(i) This water-proofmg treatment though very costly when compared to other types of treatments
as explained in Explanatory Notes and Comments under clause 18.6.1.1 still it has its own
advantages. It is a permanent water proofing treatment. If successfully done no further major
repair/replacement/maintenance would be needed as in case of all other water proofing
treatments.
(ii) However, this treatment is not normally executed by any specialized agencies and the
contractor has to get the work executed with his own labour and supervising staff who will be
normally ignorant about the correct procedure of execution.
(iii) At the same time the execution of the work is complicated and cannot be followed easily even
by an experienced civil engineer and unless the work is executed perfectly and carefully the
structure will not be water tight and the water proofing treatment done would be un repairable;
thus the huge amount spent on the treatment would be a shear waste.
(iv) Though this is a very old method of water proofing treatment, the same has not been explained
in any of the codes published by Bureau of Indian Standards or PWD Specifications and no
detailed literature on the subject is available and thus, the execution of the item is mainly based
on the specification of the experienced foreman/mistry on site.
(v) Hence the actual execution of this item has been explained step by step in detail with number
of figures and valuable suggestions, so that a Site Engineer, even with very little experience, can
follow the correct procedure of execution of the item and get the quality work executed without
difficulty and ultimately producing a water tight structure.
18.6.7.1.2 External Water Proofing Treatment on Vertical Surfaces of Under Ground Water
Tank Covered With RCC Slab (Fig. 3)
(i) The treatment for vertical surfaces shall be exactly same as explained in clause 18.6.7.1.
(ii) The treatment for Horizontal surface of top RCC slab shall be exactly as explained in clause
18.6.7.1.1.
(iii) Measurement and Rate: Shall be same as in clause 18.6.2.8 and 18.6.2.9 respectively.
18.6.7.1.3 External Water Proofing Treatment for Basements (Fig.1) : The treatment,
measurement and rate for vertical surfaces shall be exactly as explained in clause 18.6.7.1.
18.6.7.2 Water-Proofing Vertical Surfaces of Under Ground Water Tanks, Swimming Pools or
Basement from inside:
18.6.7.2.1 Internal Water Proofing Treatment for Under Ground Water Tank with Cylindrical
Shell Roof on Top :
18.6.7.2.1.1 Preparing the surface and providing Ancillary Arrangements: Same as explained
in clause 18.6.2.1.
18.6.7.2.1.2 Blending cement/ water with waterproofing compound: Same as explained in
clause 18.6.2.2.
18.6.7.2.13 Rough Kota Stone Slab/Sand Stone Slab: Same as explained in clause 18.6.2.3.
18.6.7.2.1.4. Preparation of Cement Slurry : Same as explained in Clause 18.6.2.4. 18.6.7.2.1.5.
Preparation of Cement Mortar 1:4 : Same as explained in clause 18.6.2.5.
18.6.7.2.1.6 Fixing Water Proofing Courses on Vertical Surfaces as shown in Fig. 3 : Same as
explained in clause 18.6.7.1.1.6.
18.6.7.2.1.7. Curing and Testing: On completion of water proofing course from inside the
scaffoldings shall be removed and the tank shall be cleaned from inside perfectly and the tank shall
be filled gradually with water for testing. The exposed surface of the water proofing treatment shall
be kept wet till the water being filled does not touch the surface. In this case there shall not be any
objection to do the back filling from outside even before the commencement of the water proofing
treatment.
18.6.7.2.1.8 Measurement: Same as clause 18.6.7.1.1.8.
18.6.7.2.1.9 Rate : Same as clause 18.6.7.1.1.9.
18.6.7.2. Internal Water Proofing Treatment of Under Ground Water Tank Covered with
RCC Slab at Top (Fig. 2): Same as given in clause 18.6.7.2.1.
18.6.7.3. Internal Water Proofing Treatment for Basements (Fig. 2) : Same as explained in
clause 18.6.7.2.1.
18.6.8. Water Proofing Treatment to Vertical and Horizontal Surfaces of Depressed/Sunken
Portion of W.C, Kitchen and the Like (fig.4):
18.6.8.1 Preliminaries to be attended:
(i) Completion of internal plaster for ceiling and walls of W.C. block leaving the portion for
dado/skirting.
(ii) Completion of grooving/chasing for doing the concealed work of G.UC.I pipes/Electrical
conduits to be executed in W.C.
(iii) Cleaning the depressed/sunken portion of W.C. of all debris, extra mortar sticking to the
vertical and horizontal surfaces etc.
(iv) Completion of making necessary holes for "P" trap/ Nahani trap A/water escape pipe etc.
18.6.8.2 Preparing Surface and Fixing Pipes and Fittings:
(i) The key to successful water proofing treatment is providing proper key in the concrete
surface and this can be achieved only when the surface of the bottom slab of the depressed/
sunken portion is hacked by a specially made hacking tool, after the concrete slab is cast and
just before the same gets set.
(ii) Similarly, in case of vertical surfaces of the depressed/sunken portion, the same should be
hacked with a hacking tool the moment the shuttering is removed, if delayed it will not serve
any purpose.
(iii) If the contractor does not attend to these activities, the water proofing treatment on such
surfaces shall not be permitted unless the contractor at his own cost provides spatter-dash key.
(iv) All ancillary works like fixing the 'P' trap in position and all other pipes including the water
escape pipe shall be fixed properly and the holes should be plugged carefully before taking up
the waterproofing work
18.6.8.3. 1st Course:
(i) Only grey cement duly blended with water proofing compound as explained in detail in
clauses 18.6.2 shall be used for preparing the cement slurry.
(ii) In case liquid water proofing compound is proposed to be used the same should be mixed with
the water collected for preparing the slurry and only this water mixed with water proofing
compound shall be used to prepare the slurry.
(iii) Particular care should be taken to see that the consistency of the slurry should be such that 4.4
kg of blended cement with water proofing compound is used per sqm area of surface to be
treated. The slurry should be applied on the vertical faces till the bottom of floor up to which
the waterproofing treatment has to be done as shown in Fig. 4. Particular care should be taken
to see that the slurry is applied to corners without leaving any gap.
18.6.8.4. 2nd Course:
(i) Immediately on applying the blended cement slurry on the surface to be treated cement plaster
20 mm thick in CM. 1:3 (prepared with coarse sand and blended with cement-water proofing
compound) shall be applied both on vertical and horizontal surfaces taking particular care to
complete the entire depressed/sunken portion of W.C. within a day so that the plaster can be
done without any joint. The surface of the plaster shall be left rough but finished in one plain
and cured for a week.
(ii) On completion of the curing period both horizontal and vertical surfaces shall be cleaned
properly and gently and allowed to dry.
18.6.8.5 Final Course:
(i) Only after the surface is completely dried the blown type petroleum or residual bitumen shall
be applied as specified/prescribed (to refer relevant reference). The bitumen shall be applied
taking particular care to see that not less than 1.7 kg of bitumen is consumed per sqm. area of
application over which PVC sheet 400 micron thick shall be spread evenly without any kink
immediately, so that the PVC sheet sticks to the surface firmly.
(ii) Special care should be taken while overlapping the PVC sheet where a minimum overlap of
150 mm width should be maintained, duly pasting the overlapped sheet with an application of
bitumen @ 1.7 kg/sqm.
(iii) The projections of pipes and 'P trap outlet etc. inside the depressed/sunken portion of W.C
shall also be cladded with water proofing treatment layer up to a length of 150 mm, using a
coat of bitumen with PVC Sheet.
(iv) Figure 18.6.15 shows clearly the position of surfaces to be treated and accordingly the specified
filling material has to be filled directly on the PVC sheet cladded to the surfaces and also the
base concrete has to be laid abutting the vertical surfaces cladded with PVC sheet. Therefore
the entire activity of filling the specified materials and laying the base concrete shall be done
very carefully so that the PVC sheet cladded on the surfaces does not get punctured and
damaged.
(v) The surfaces of depressed/sunken portion of W.C. shall not be left without covering with
specified filling material and base concrete, otherwise the PVC sheet layer may be tampered by
the labour working in the vicinity.
(vi) At least, fixing up of W.C. pan, filling specified material and the top base concrete should be
done as quickly as possible and the top horizontal layer of water proofing may be taken up
later i.e. just before laying the floor tiles.
18.6.8.6 Measurement: Length and breadth shall be measured along the finished surface correct to
18.6.8.7 Rate: The rate shall include the cost of all labour and materials involved in all the operations
described above.
18.7. Providing Water-Stops (conforming to IS : 3370 Part I):
18.7.1 Water stops are essential components provided in RCC hydraulic structure. Provision
contained in IS: 3370 Part I deals with this.
18.7.2 Types of Joints for which Water bars are Provided: The water bars are provided only for
the movement joint in a water retaining structure : Different types of movement joints are as detailed
below:
(a) Complete Contraction Joint: This is a movement joint with deliberate discontinuity both in
concrete as well as the reinforcements but no initial gap is maintained between the concrete on
either side of the joint. This joint is intended to accommodate the contraction of the concrete.
(Fig.5).
(b) Partial Contraction Joint: This is a movement joint with deliberate discontinuity in concrete
but no water bar is provided and no discontinuity is provided in steel. No initial gap is
maintained between the concrete on either side of joint:
Note :- No water bar is used for this joint
(c) Expansion Joint: This is also a movement joint with complete discontinuity in both
reinforcement and concrete. It is intended to accommodate either expansion or contraction of
the structure. In general such joint requires the provision of an initial gap between the adjoining
parts of the structure which by closing or opening accommodates expansion or contraction of
the structure.
18.7.3 Types and Performance of Water Bars:
(i) Water bars are preformed strips of impermeable material which are embedded in the concrete
during construction so as to span across the joint and provide a permanent watertight seal
during the whole range of joint movement.
(ii) The most usual forms of water bars are strip with a longitudinal corrugation.
(iii) Another form of water bar of metallic type is Z shaped strip.
(iv) Water bars of copper, sheet lead, natural or synthetic rubber and plastic such as polyvinyl
chloride (PVC) are also used . These bars comprise of central longitudinal hollow tube with thin
walls and stiff wings of about 150 mm width.
(v) Out of the metals available copper is most suitable as regards ductility, resistance to corrosion
in air, water and concrete. However, it may be attacked by some wastes. If sheet lead is used it
should be insulated from concrete by a good coat of bituminous or suitable composition.
Natural, synthetic rubbers and plastics have very considerable advantage in handling, splicing
and in making intersections.
(vi) Galvanised iron sheets may also be used with the specific permission of the Engineer-in-Charge
provided the liquid stored or the atmosphere around the liquid retaining structure is not
excessively corrosive i.e. sewage.
(vii) The strip water bars described as above, while placing in position has to be passed through the
end shutter of the first placed concrete with the result the shuttering at this point should be
perfectly watertight otherwise cement slurry may escape from the concrete being laid and will
ultimately weaken the structure. Therefore to avoid the above problem one can prefer newer
type of water bar .
(viii) The design of the moulded water bar with several projections need not be passed through the
end shutter while placing the same in position. Another main advantage of this water bar is that
since it occupies bigger proportion of the thickness of the joint it would lengthen the shortest
alternative water path through the concrete.
18.7.4 Fixing Water Bar:
1. The water bar should have such shape and width that the water path through the concrete
around the bar shall not be unduly short.
2. It is important to ensure proper compaction of concrete around the water bar.
3. Proper cover to all the reinforcements shall be maintained.
4. Sometimes to increase the bond the holes are provided in the copper water bars but in the long
run it proves to be disadvantageous as it shortens the path of water through concrete.
5. Water bars should be placed at the centre of the wall or if it is to be provided away from the
centre it's distance from either face of the wall shall not be less than half the width of water
bar.
18.7.5 Cover Plates for Joints:
Sometimes joint cover plates have to be used to expansion joints mainly to avoided the risk of
a fault in the water bar which is embedded.
The plates to be used should be either copper or sheet lead. In case the copper plates are to be
used, it should be clamped to the concrete face on each side of the joint. To ensure water
tightness suitable gasket shall be used.
Joint cover plates of sheet lead are also used and fixed on the joints. In this case the edges may
return in to grooves formed in the concrete and can be made completely water tight by lead
caulking. Faces of the concrete to which sheet lead is to be fixed should be painted with
bituminous or other suitable composition and the lead sheet should be similarly coated before
fixing.
18.7.6 Spacing of Joints:
(i) In Reinforced Concrete floors movement joints should be spaced at not more than 7.5 m apart
in two directions at right angles. The wall and floor joints should be in line except where sliding
joints occur at the base of the wall in which case corresponding vertical joint is not important.
(ii) In concrete walls, the vertical movement joints should normally be placed at a maximum
spacing of 7.5 m in reinforced walls. The maximum length desirable between vertical
movement joints will depend upon the tensile strength of the walls and may be increased by
suitable reinforcements.
(iii) Amongst the movement joints in floors and walls as mentioned above, expansion joint should
normally be provided at a spacing of not more than 30 m between successive expansion joints
or between the end of the structure and the next expansion joint, all other joints being of the
contraction type.
Note : Thus on examining the spacing of movement joints where the water bars are used, it is
very clear that the small size water-retaining structures constructed in towns and cities mostly
on private and Government projects will not require the provision of movement joints either
for compression or expansion, thus no water bar would be needed to execute such small works.
The water bars shall be used only for large RCC water reservoirs, RCC ducts conveying water and
for the subways provided the whole structure is constructed in a water logged area.
18.7.7. In case of expansion joints, the filling of these with bitumen filler, bitumen felt or any such
material etc. shall be paid for separately in running metre. The measurement shall be taken up to two
places of decimal stating the depth and width of joint.
In case joint cover plates either of copper or sheet lead with ancillaries are provided, these shall be
measured and paid for separately.
18.7.8 Measurement: Length shall be measured correct to a cm and net quantities shall be calculated
up to two places of decimal. Each category of water stops/bars such as PVC, copper specifying
width, thickness shall be measured and paid for separately.
18.7.9 Rate: The rate shall include all labour and materials in all the operations described above.
18.8 Water Proofing Treatment on Roof Slabs by applying Cement Slurry Mixed with
Armoucrete or Tapecrete, Second Layer of Fibre Glass Cloth:
18.8.1 Preliminaries to be Attended:
(i) Before taking up the waterproofing work the construction of parapet walls etc. including
finishing should be completed in all respects.
(ii) Similarly, the ancillary items like haunches, khurras , grooves to tack the fibre cloth layer,
fixing up of all down take pipes, water pipes and electric conduits etc. should be completed and
no such work should be allowed on the area to be treated during the progress of water proofing
treatment or even later.
18.8.2 Preparing Surface: There is no necessity of hacking the surface but the surface to be treated
shall be cleaned including chiselling the extra mortar sticking to the surfaces etc.
18.8.3 Preparing Cement Slurry: The cement slurry shall be prepared as prescribed as under:
(i) Preparation of slurry is most important factor. The consistency of the slurry should be just that
of oil paint and the quantity of slurry prepared should be such as to cover the calculated and
desired area with just one coat of application and for that it is essential to calculate the correct
quantity of water to be mixed in the prescribed quantity of cement per sqm area.
(ii) This can be done only by trial and error method by preparing few samples with prescribed
quantity of cement and applying over few patches each of say 1/2 sqm area and thus the
required quantity of water per sqm area can be decided say x litres per sqm.
(iii) On deciding the correct quantity of water required per sqm area the required quantity of slurry
should be prepared which can be applied over the desired surface within 1/2 an hour of mixing
with 0.488 kg of grey cement + 0.253 kg of Armoucrete or Tapecrete + x litres of water per
sqm area and the required quantity of slurry thus prepared should only be used for first
application.
18.8.4 Fibre Glass Cloth: The fibre glass cloth shall be of approved proprietary brand and shall be
thin, flexible uniformly bonded mat composed of chemically resistant borosilicate glass fibre
distributed in random open porous structure bonded together with a thermosetting resin (Phenolic
Type).
18.8.5 Application of Slurry First Layer The slurry should be applied in the same manner as
described below, except that over projected pipes etc. slurry shall be applied just up to 100 mm
height instead of 150 mm height as prescribed in that clause. Also the slurry shall be applied up to a
height of 300 mm on parapet walls and also the groove on top where the fibre glass cloth has to be
tucked.
The second layer shall be applied over the first layer after a gap of 4 hours after application of
the first layer.
The slurry for application of second layer shall be prepared as per method described and the
application shall be exactly the same as for first layer. The applied surface shall be allowed to
air cure for 4 hours and thereafter water curing shall be done for full 48 hours.
It will be advantageous accordingly, it is desirable to undertake the work of filling the
prescribed filling material in the depressed portion, fixing W.C. pan and laying base concrete etc.
The top of base concrete shall also be given the same treatment as described before the work
of filling is taken up.
In case no further work as described above is to be taken up immediately on completion of
water proofing treatment due to any reason whatsoever it is advised to protect the treated
portion with cement plaster 1:4 as a protective layer for which separate payment shall be made
to the contractor.
18.8.6 Spreading Fibre Glass Cloth:
(i) Immediately on applying the slurry on a sufficiently workable area when the slurry applied is still
green the fibre glass as specified shall be spread evenly on the surface without any kink and
pressed to see no air spaces exist. The fibre glass cloth shall be taken up to a height of 300 mm
on parapet walls and tucked in the groove specially prepared at that height,
(ii) A minimum overlap of 100 mm width shall be provided when the fibre cloth has to be joined.
The joining of 100 mm overlap shall be done with the same slurry used for the application on
surface as first layer. The fibre cloth shall also be extended up to a height of 100 mm over pipes
projecting from the surface.
18.8.7 Preparing Cement Slurry Mixed with Sand for Third Layer:
(i) The quantity of water required to prepare slurry which can cover one sqm area of the surface
to be treated shall be calculated as described in clause 18.8.5. and consider this quantity as say
x litres/sqm.
(ii) On deciding the correct quantity of water required, the slurry shall be prepared by mixing 1.289
kg of grey cement + 0.67 kg of Armoucrete or Tapecrete + 1.289 kg of coarse sand + x litres
of water. All above quantities are for preparing slurry to cover 1 sqm surface. Therefore, the
required quantity of slurry for the area to be covered within 1/2 an hour shall be prepared.
(iii) The consistency of the slurry shall be such that in one application with a brush 1.5 mm
thickness of slurry can be coated on the fibre glass cloth surface.
18.8.8 Applying Final Coat of Slurry:
(i) The slurry specially prepared as explained above shall be applied evenly on the entire
surface covered with fibre glass cloth so that a layer of 1.5 mm thickness of slurry is formed.
(ii) The application of slurry shall be continued over the 300 mm portions of parapet wall and
also the portion tucked in the groove on top.
(iii) The entire surface shall be allowed for air curing for 4 hours and later the surface shall be
cured with clean water for 48 hours.
(iv) On completion of curing the grooves where the fibre glass cloth is tucked shall be closed
neatly with cement mortar mixed with water proofing compound.
18.8.9 Fourth and final layer of brick tiling with specified cement mortar shall be paid for
separately:
18.8.10 Measurement: Length and breadth shall be measured along the finished surface correct to
a cm and area shall be worked out to nearest 0.01 sqm. Overlaps and tucking in to flashing grooves
shall not be measured. No item in measurements shall be made for either opening or recess or
chimney stack, roof lights or Khurras of area up to 0.40 sqm, nor anything extra shall be paid for
forming such openings, recess etc. For area exceeding 0.40 sqm deduction will be made in the
measurement for the full openings and nothing extra shall be made for making such opening.
18.8.11 Rate: The rate shall include the cost of labour and material involved in all the operations
described above.
18.9. Integral Cement based Water Proofing Treatment (Including Preparation of Surface as
required for Treating Roofs, Balconies, Terraces etc.) with Brick Bat Coba:(Fig.6)
18.9.1 Preliminaries to be attended: The preliminaries to be attended before taking up the work
shall be exactly same as described in clause 18.8.1.
18.9.2 Preparing the Surface : It would be advantageous to roughen the surface by scraping the
surface when the slab is being cast, however the surface need not be hacked. In case the slab is
already cast and surface fairly finished, the same shall be cleaned neatly of all mortar droppings,
loose materials etc. with brooms/cloth.
18.9.3 Blending Cement/Water With Water Proofing Compound:
(i) Whenever the water proofing compound is to be used, it is advantageous to blend the same
with cement if the water proofing compound is in powder form and if the same is in liquid form
the required quantity of water blended with water proofing compound alone should be used for
preparing slurry/mortar.
(ii) The water proofing compound to be used shall conform to 1S:2645 and be of reputed brand
like Cico, Impermo etc. with a clear ISI mark on the container which should be in the form of
sealed tins or closed packets.
(iii) The correct quantity of water proofing compound to be used per 50 kg grey cement shall be as
prescribed by the manufacturer on the tins/packets literature. However, not more than 3% of
water proofing compound shall be used per 50 kg of grey cement.
(iv) Preparing blended cement with water proofing compound or preparing water mixed with liquid
water proofing compound to be used to prepare slurry/mortar shall be exactly as described in
clause 18.8.2, hereinafter in this item referred as "Blended Cement".
18.9.4 Preparation of Slurry:
(i) The quantity of water required to prepare the slurry with 2.75 kg of cement to painted over an
area of 1 sqm shall be calculated exactly as described in clause 18.8.3 para (i) and (ii). Consider
this quantity of water as x litres per sqm.
(ii) Depending upon the area of surface that has to be covered, the required quantity of slurry should
be prepared using 2.75 kg blended cement + x litres of water per sqm area to be covered, taking
particular care to see that only that much quantity of slurry shall be prepared which can be used
with in 1/2 an hour of preparation i.e. before the initial setting time of cement.
18.9.5 Application of Slurry Under Base Coat:
(i) The slurry prepared as explained above shall be applied over the dampened surface with
brushes very carefully, including the joints between the floor slab and the parapet wall, holes
on the surfaces, and joints of pipes in masonry/concrete.
(ii) The application of the slurry should continue up to a height of 300 mm over the parapet wall
and also in the groove . The slurry should also be applied up to a height of 150 mm over pipe
projections etc.
18.9.6 Laying Base Coat 20 mm thick: Immediately after the application of slurry and when the
application is still green, 20 mm thick cement plaster as base coat with cement mortar 1:5 (1 blended
cement: 5 coarse sand) shall be evenly applied over the concrete surface taking particular care to see
that all corners and joints are properly packed and the application of the base coat shall be continued
up to a height of 300 mm over the parapet wall.
18.9.7 Preparing Brick-bat Concrete Mix:
(i) Brick bat of size 25 mm to 115 mm out of over burnt bricks shall be used for the purpose of
brick bat coba.
(ii) Depending upon the area of concrete surface to be covered the calculated quantity of brick
bats to cover the area shall be heaped for mixing. Cement mortar 1:5 (1 blended cement:
5 coarse sand) shall be prepared separately of half the quantity of brick bats, collected by
volume.
(iii) The brick bats shall be properly dampened for six hours before the cement mortar is added. The
materials shall be thoroughly mixed by adding some water if needed and the homogenous mix
thus prepared should only be used. Under no circumstances dry brick bats should be mixed with
the mortar.
18.9.8 Laying Brick bat Coba:
(i) When the base coat takes initial set or preferably on the subsequent day the brick bat coba after
mixing as specified above shall be laid to required slope/gradient. To ensure fixing up of proper
level/gradient correct level points should be fixed with brick bat coba mix only and the brick
bat coba shall be laid to the top of level points. The surface of brick bat coba shall be finished
neatly to proper slope.
(ii) The haunches/gola at the junction of parapet wall and the roof slab shall be formed only with
brick bat coba as shown in Fig. 6..
(iii) In case the brick bat coba is laid on the base coat immediately on initial set there will be no
necessity of applying cement slurry over the base coat before laying the brick-bat coba.
However if the brick bat coba is to be laid on the subsequent day, cement slurry prepared as
described in clause 18.9.4 shall be applied over the top surface of the base coat, then only the
brick bat coba shall be laid.
18.9.9 Application of Slurry Over Brick-bat Coba: Immediately on laying brick-bat coba i.e.
when the initial set takes place, or at least on the subsequent day cement slurry prepared as per clause
18.9.4 shall be applied on the surface of brick-bat coba. The application of slurry shall be the same
as described in clause 18.9.5 which should cover the haunches/gola, and the remaining small portion
of parapet wall and also inside the groove as shown in the figure.
18.9.10 Laying Finishing Layer (Protective Coat):
(i) Immediately on applying the cement slurry over the surface of the brick-bat coba and when the
slurry applied is still green, a 20 mm thick layer of cement plaster, without leaving any joints
shall be applied with cement mortar 1:4 (1 blended grey cement : 4 coarse sand) over the entire
surface including the haunches/gola and the small portion on the parapet wall. The groove in
the parapet wall over the haunches shall also be filled neatly packing the mortar firmly in the
groove.
(ii) The surface of the finishing layer (protective coat) shall be neatly finished with cement slurry
prepared as per clause 18.9.4. The finished surface shall be allowed to dry for a while till a
string mark can easily be made on the surface, when 300 mm x 300 mm square marks shall be
made over the entire surface.
18.9.11 Curing and Testing the Treatment:
i) The entire surface thus treated shall be flooded with water by making kiaries with weak cement
mortar, water shall be made to remain on the roof slab for a minimum period of two weeks
during this period it can be observed for any leakages are there or not.
ii) Brick bat coba shall be provided as specified in item, however recommended average
thickness is 120 mm and minimum at Khurra as 65 mm.
iii) Note The brick bat coba on laying should be cured for two days, there after finishing coat
should be taken up. In our opinion this proposition is without any convincing reasoning or
authenticity. On the other hand this may cause more harm.
iv) The whole treatment is supposed to be integral one i.e. it should be homogenous treatment, as
such by delaying the process and splitting the layers the very basic requirement will be
negated.
v) Putting the surface of Brick-bat coba for curing just for two days and then covering the same
with a protective layer carries no meaning and purpose, on the other hand when the Brick-bat
coba is covered immediately with a protective layer and whole area is being flooded immediately
there is absolutely no chance that the brick bat coba shall loose its water content by evaporation,
which is the main purpose for curing operation.
18.9.12 Measurement: The measurement shall be taken along the finished surface of treatment
including the rounded and tapered portion at junction of parapet wall. Length and breadth shall be
measured correct to a cm and area shall be worked out to nearest 0.01 sqm. No deduction in
measurement shall be made for either openings or recesses or chimney stack, roof lights or Khurras or
area up to 0.40 sqm., nor any thing extra shall be paid for forming such openings, recesses etc. For
areas exceeding 0.40 sqm deduction will be made in the measurements for the full openings and
nothing extra shall be paid for making such openings.
described above.
Notes:
(1) The work is to be got done through a specialised agency.
(2) The item carries a ten year guarantee against leakage and bad workmanship. Guarantee Bond
is to be executed and submitted by the contractor in the prescribed Performa, which is also to
be signed by the specialised agency.
18.10 Water Proofing With Bitumen Felts:
Water proofing treatment with self finished felt shall be four courses or six courses as described in
the item. Four courses water proofing treatment with self finished felt is a normal duty treatment
suitable for buildings where the cost of roof treatment is required to be restricted.
Six course water proofing treatment with self finished felt is a heavy duty treatment suitable for
important structures.
18.10.1 Materials:
18.10.1.1. Self finished felt (Appendix A and B) : The self finished felt shall be of brand and
manufacture conforming to the type and grade given in the description of the item. This shall be one
of the following types:
(a) Type 2 grade 1 is a glass fibre base bitumen felt conforming to IS : 7193.
(b) Type 2 grade 1 is a fibre (vegetable or animal) base felt conforming in all respects to IS:
1322.
(c) Type 2 grade 2 is a fibre (vegetable or animal) base felt conforming in all respects to IS:
1322.
(d) Type 3 grade 1 is a Hessian base felt conforming in all respects to IS : 1322.
18.10.1.2 Bonding Materials
This shall consist of blown type petroleum bitumen conforming to IS : 702 or residual petroleum
bitumen conforming to IS : 73 or mixture thereof. The bonding material shall be so selected as to
withstand the local condition of temperature and gradient satisfactorily. The penetration of bitumen
used shall not exceed 40 in any case. Suitable residual type petroleum bitumen is of penetration
30/40 (IS grade S-35).
Generally, blown type petroleum bitumen of S-90 shall be used for the base and intermediate layers
of bonding material and for flashing, while residual type petroleum bitumen with higher penetration
and low softening point shall be used for the finishing layer. Suitable blown type petroleum bitumen
is of IS grade 85/25 or 90/15 of approved quality shall be used.
Where proprietary brands of bonding materials are proposed to be used by the contractor they shall
conform in all respects to the specifications in the preceding para
Table Showing the quantity of Bonding Materials to be used over per Sqm Area of Surface to be
treated for Different Courses, in four course and six course treatments
1st course 3rd course 5th course

Kg /sqm kg/sqm kg/sqm
I. Four course treatment : 1.45 1.45 -
R. Six course treatment
(a) With type 3 grade 1 hessian
base self finished bitumen felt 1.45 1.20 1.45
(b) With felts other than type 3 grade 1 1.45 1.20 1.70
hessian base
18.10.1.3 Stone Grit and Pea-sized Gravel: Stone grit shall be as specified (to refer relevant
reference) and shall be 6 mm and down size. Where pea-sized gravel is used it shall be hard, round
and free from dust, dirt etc. The stone grit or pea-sized gravel shall not be spread over vertical and
sloping faces of flashings and at drain mouths. At these places the surface shall be painted with two
coats of bituminous solution.
The quantity of stone grit or pea-sized gravel required for the final course of four or six course
treatment with hessian base self finished bitumen felt type 3 grade 1 shall be 6 cubic decimetre/ sqm.
For six course treatment with felt other than type 3 grade 1, the stone grit or pea sized gravel at 8
cubic decimetre per sqm shall be used.
i) The surface to be treated shall have a minimum slope of 1 in 120. This grading shall be carried
out with lime concrete, cement concrete or cement plaster with coarse sand, as ordered, to the
average thickness required and finished smooth. Such grading shall be paid for separately. The
correct method of executing the item of grading is explained in clause 18.13.
ii) Junctions between the roof and vertical faces of parapet walls, chimneys etc. shall be cased by
running triangular fillets 7.5 x 7.5 cm size, in lime concrete or cement concrete. At the drain
mouths, the fillets shall be suitably cut back and rounded off for easy application of
water proofing treatment and easy flow of water. Lime concrete where used shall conform to
specifications described (to refer relevant reference) except that the brick aggregate shall be 20
mm nominal size. Cement concrete where used shall be 1: 2 : 4 mix (1 Cement: 2 Coarse Sand
: 4 graded stone aggregate 20 mm Nominal Size). The provision of fillets shall be deemed to
be covered by the item of water proofing and shall not be measured or paid for separately.
iii) In existing roof where gola and drip course are provided at the junction of roof and vertical
face of parapet wall, chimney stacks etc., these shall be dressed suitably and finished smooth so
as to ensure an easy and gradual turning of the flashing. Any dismantlement or forming and
finishing smooth the junction for forming the base of the flashing shall not be measured or paid
for separately and shall be deemed to form part of the preparation of the surface in the water
proofing treatment.
iv) While the grading of roof surface is being done, it shall be ensured that the outlet drain pipe
have been fixed and mouth at the entrance have been eased and rounded off properly for easy
flow of water.
When any pipe passes through the roof to be treated, angular fillet of shape , shall be built
around it for the water proofing treatment to be taken over it. These fillets shall not be measured
or paid for separately.
vi) For carrying over and tucking in the water proofing felts into the parapet walls, chimneys stacks
etc. a horizontal groove 6.5 cm deep, 7.5 cm wide section with its lower edge at not less than
15 cm above the graded roof surface shall be left on the inner face of the same during
construction if possible. When such groove has not been left, the same shall be cut out neatly
and the base at rear of the groove shall be finished smooth with cement plaster 1:4(1 cement: 4
coarse sand). Such cutting of the groove and its finishing smooth shall be deemed to be part of
the water proofing item and shall not be measured or paid for separately. No deduction shall be
made either for not making the groove or when the later has already been left in the masonry
by the construction agency.
vii) Tucking in the water proofing felt will be required where the parapet wall exceeds 45 cm in the
height from the graded surface. Where the height is 45 cm or less, no groove will be required
as the water proofing treatment will be carried over the top of the parapet wall to its full
thickness. In the case of low dividing walls of height 30 cm or less, outlets therein shall be cut
open for full height and the bottom and sides shall be rendered smooth and corners rounded
and such treatment shall not be measured and paid for separately.
viii) Where expansion joints are left in the slab, the provision of dwarf walls and/or RCC slabs for
covering them and finishing the smooth surface shall be the responsibility of the construction
agency, which had laid the roof slab and will not be included in the operation of water proofing.
ix) The graded surface of the roof and concrete fillets and the faces of walls shall be thoroughly
cleaned with wire brushes and all loose scales etc. removed. The surface shall then be dusted
off. Any crack in the roof shall be cut to 'V section, cleaned and filled up flush with cement
mortar slurry 1: 4 (1 cement : 4 coarse sand) or blown type petroleum bitumen of IS grade
85/18, or approved quality conforming to IS : 702. Such cleaning of the surface or treating the
cracks shall not be paid for separately.
18.10.3 Priming Coat: Where so specified, or required by the Engineer-in-Charge for example
under slightly damp conditions a priming coat consisting of a bitumen primer conforming to IS 3384
should be applied with brush on the roof and wall surface at 0.24 litres per sqm to assist adhesion of
the bonding material (i.e. bitumen).
Such application of primer shall be paid for separately, unless specifically included in the water
proofing item.
18.10.4 Underlay:
i) Where a floating treatment of water proofing with self finished bitumen felt is required i.e.
where water proofing treatment is required to be isolated from the roof structure, a layer of
bitumen saturated felt (underlay) shall be spread over the roof surface and tucked into the
flashing groove. No bonding material shall be used below the underlay in order to keep the
underlay free of the structure. The adjoining strips of the underlay shall overlap to a minimum
of 7.5 cm at sides and 10 cm at ends. The overlaps shall be sealed with the same bonding
material as used for the self finished felt treatment. Unless specifically included in the water
proofing item, the underlay treatment shall be paid for separately.
ii) The underlay shall be of type 1 saturated felt conforming to IS: 1322 in all respects and having
a total minimum weight of the finished bitumen felt in dry condition with mica dusting powder
@ 6.8 kg per 10 sqm. The roll shall not be damaged or crack on being unrolled on a fairly
smooth and flat surface.
iii) It should be clearly noted that no bonding material is to be laid below the underlay but the
"Initial Layer" i.e. the first layer of the bonding material either for the four course treatment or
for the six course treatment shall be laid directly over the underlay considering the same as the
base of the four course/six course water proofing treatment. The underlay should be provided
over the graded surface only when specifically prescribed in the item of work. This item is
proposed only in very rare cases and not at all for the regular waterproofing treatment works.
18.10.5 Treatment:
18.10.5.1 The water proofing shall consist of a four or six course treatment, as given in the
description of the item, each layer of bonding materials, self finished bitumen felt or stone grit or
pea sized gravel being counted as a course.
18.10.5.2 The choice of a four or six course treatment will depend on the climatic condition, the
importance of the building, the durability required, cost and other relevant considerations.
18.10.5.3 A four course treatment shall consist of the following layers :
(i) Initial layer of bonding material applied hot at specified weight per unit area.
(ii) 2nd layer of self finished bitumen felt of specified brand and manufacture conforming
to the type and grade given in the description of the item.
(iii) Third layer of bonding material.
(iv) Final layer of stone grit of pea sized gravel spread at specified volume of material per
unit area.
Note : In this case the layer of stone grit or pea sized gravel is not provided
18.10.5.4 In a six course treatment, the first, second and third layer shall be the same as in the
four course treatment. The fourth and fifth layer shall consist of self finished felt and bonding
material respectively. The sixth layer shall consist of stone grit or pea sized gravel.
18.10.5.5 The primer or underlay where required to be provided shall not count against the number
of courses specified.
18.10.6 Laying:
18.10.6.1 Bitumen bonding material of required grade shall be heated to the working temperature
specified for the particular grade by the bitumen manufacturers and conveyed to the roof in buckets or
pouring canes in weighed quantities.
Suitable working temperature for different grades of bitumen are as under:
(i) Blown type petroleum bitumen of IS grade 85/25 or 90/15 180 degree C.
(ii) Residual type petroleum bitumen of penetration 30/40 - 180 degree to 190 degree C (IS
grade S-35).
Drain outlets shall be given a four or six course treatment as specified for the roof in the description
of the item in the manner specified for the flat roof surface. Water proofing treatment shall be carried
into the drain pipe or outlets by at least 10 cm. The water proofing treatment laid on the roof surface
shall overlap the upper edge of the water proofing treatment in the drain outlets by at least 10 cm.
18.10.6.2 The self finished felt shall be cut to the required length, brushed clean of dusting material
and laid out flat on the roof to eliminate curls and subsequent stretching. The felt shall normally be
laid in length at right angles to the direction of the slope and laying shall be commenced at the lowest
level and worked up to crest. The felt shall not be laid in single piece of very long lengths as they
are likely to shrink; 6 to 8 m are suitable lengths. The roof surface shall be cleaned and dry before
the felt treatment is begun. Each length of felt shall be laid in position and rolled up for a distance
of half its length. The hot bonding material shall be poured on the roof across the full width of the
rolled felt as the later is steadily rolled out and pressed down. The pouring shall be so regulated that
the correct weight of bonding material per unit area is spread uniformly over the surface. Excess
bonding material that gets squeezed out at the ends shall be levelled up as laying proceeds. When
the first half of the strip of felt has been bonded to the roof, the other half shall be rolled up and then
unrolled on the hot bonding material in the same way. Subsequent strips shall also be laid in the
same manner. Each strip shall overlap the preceding one by at least 7.5 cm at the longitudinal edges
and 10 cm at the ends. All overlaps shall be firmly bonded with hot bitumen. Streaks and trailings of
bitumen near edges of laps shall be levelled by heating the overlap with a blow lamp and levelling
down unevenness.
The third layer of bonding material in the four course treatment shall be carried out in a similar
manner after the flashing has been completed.
18.10.6.3 In a six course treatment the third and fourth layers of bonding material and self finished felt
shall be laid in the manner already described, taking care that laps in the felt are staggered from those
in the second layer. The fifth layer of bonding material shall be carried out after the flashing is done.
18.10.6.4High Parapet Walls, Chimney Stacks etc.:
i) Felts shall be laid as flashings wherever junctions of vertical and horizontal surfaces occur.
Longitudinal laps shall be 10 cm. The lower layer of flashing felt in a six course treatment
shall overlap the roof water proofing by not less than 20 cm while the upper layer shall overlap
the roofing felt by 10 cm. The minimum overlap of the flashing felt in four course specification
over the roofing felt shall be 10 cm.
ii) The flashing shall consist of the same four or six course treatment as for the roof except that
the final course of stone grit or pea-sized gravel shall be replaced by an application of
bituminous solution of approved quality in two coats on the vertical and sloping faces only, of
the flashing. The overlap along the length of flashing shall stagger with those in the second
layer of flashing felt (in a six course treatment and with the joints in the roof felt).
iii) The upper edge of the flashing felt shall be well tucked into the flashing grooves in the parapet,
chimney stacks etc. to a depth of not less than 6.5 cm. Corresponding applications of bonding
material shall also be made. The flashing treatment shall be firmly held in place in the grooves
with wood edges at intervals and the grooves shall be filled up with cement mortar 1:4 (1
cement: 4 coarse sand) or cement concrete 1: 2 : 4 (1 cement: 2 coarse sand : 4 graded stone
aggregate 6 mm nominal size) and surface finished smooth with the rest of the wall. The cement
work shall be cured for 7 days. When dry, the exposed plaster joints of grooves shall be painted
with bitumen and two coats of bituminous solution shall be applied on the vertical and sloping
surface of flashing.
iv) After the top flashing felt layer has been fixed, the penultimate layer of bonding material shall
be applied over the roofing felt and the horizontal overlaps and vertical and sloping surfaces of
the flashings at the specified rate. Stone grit or pea sized gravel shall then be spread uniformly
over the hot bonding material on the horizontal roof surface at the specified quantity per unit
area and pressed into it with a wooden roller.
18.10.6.5 Low Parapet Walls: Where parapet walls are of height 45 cm or less, bitumen felt
flashings shall be provided in the same manner as for flashings in the case of high parapet walls
except that the upper edge shall be carried up to the full height of the wall and taken right across the
top of the parapet and down on the external vertical faces to a minimum distance of 5 cm.
18.10.6.6 Low Dividing Walls :
i) Where low dividing walls or inverted beams are met with, the same shall be covered with a
four or six layer treatment as for the main roof, the latter bearing carried down both sides of
the wall and overlapping the roofing treatment as in the case of flashing of high parapet walls.
ii) Drain outlets where formed in the low dividing walls, shall be given water proofing treatment
of the same number of courses as specified for the flat roof surface. The bottom and sides shall
be so treated that all overlaps are in the direction of flow of drainage.
18.10.6.7 Expansion Joints :
i) Where the expansion joints are provided in the slabs, the joints and their cover slabs shall be
suitably treated with water proofing. A typical sketch of an expansion joint with the RCC slabs
on either side of the joint turned vertically up and covered with precast RCC cover slabs. The
cover slabs shall cover the vertical turned up dwarf walls by not less than 7.5 cm and are
provided with throating on their underside along their length. The water proofing treatment
shall be taken up the sloping junction fillets and the vertical faces of the walls to the underside
of the cover slabs. The cover slabs are given the water proofing treatment like the roof slabs,
after the cross joints between adjacent cover \ slabs are first
sealed with 15 cm width of roofing felt struck to them with bitumen. The water proofing
treatment shall be carried down the sides of the cover slabs to their full thickness. Care shall be
taken to see that overlaps if any in the roofing over the cover slabs stagger with the joints
between cover slabs.
ii) The formation of the expansion joints and provision of cover slabs shall be the responsibility of
construction agency. The formation of the junction fillets and the water proofing treatment of the
joint and cover slabs shall be carried out by the water proofing agency. No extra shall be paid for
the junction fillers or for the sealing of the cross joints in the cover slab with 15 cm width of
bitumen strips.
18.10.6.8 Pipes:
i) Where vertical pipe outlets are met with, 7.5 x 7.5 cm fillets of lime or cement concrete of the
type and section shall be provided and flashing of four or six course treatment, same as for the
roofing treatment shall be laid.
ii) The upper edge of the flashing shall be laid sloping down forward and butted against the pipe
and annular depression so formed shall be filled with hot bitumen. A circular metal collar in
the shape of an inverted truncated cone shall be fixed on the pipe to throw off the rain water
clear of the flashing and this shall be paid for separately.
18.10.6.9.Terrace : Where roof surfaces are expected to be used, precast cement concrete tiles or
40 mm thick cement concrete shall be laid on the water proofing treatment. In such cases, the final
course of stone grit or pea sized gravel shall not be laid in the water proofing treatment. Suitable
adjustment in the rates will be effected for not providing the stone grit or pea sized gravel layer.
Cement concrete in situ flooring shall be laid in panel not exceeding 0.4 square metres each. Precast
tiles or in situ concrete flooring where laid shall be paid for separately unless included in the
description of the water proofing item.
i) Length and breadth shall be measured correct to a cm. The area shall be calculated in square
metres correct to two places of decimal.
ii) Measurements shall be taken over the entire exposed area of roofing and flashing treatment
including flashing over low parapet walls, low dividing walls and expansion joints and at pipe
projections etc. Overlaps and tucking into flashing grooves shall not be measured.
iii) Vertical and sloping surfaces of water proofing treatment shall also be measured under the
four or six course treatment as the case may be, irrespective of the fact that the final course of
grit or pea sized gravel is replaced by bitumen primer.
iv) Primer or saturated felt underlay, where provided, shall also be measured in the same manner
as the water proofing treatment and paid for separately. No deduction in measurements shall
be made for either openings or recesses for chimney stacks, roof lights and the like, for areas
up to 40 square decimetre (0.4 sqm) nor anything shall be paid for forming such openings.
v) For similar areas exceeding 40 sq. decimetre deductions will be made in measurements for
full opening and nothing extra shall be paid for forming such openings.
described above and the particular specifications given under the different items, with the corrections
noted in the relevant sub-para.
18.11 Water Proofing with Glass Fibre Tissue Reinforced Bitumen: In-situ water proofing
treatment of roofs with glass fibres tissue reinforced bitumen shall be of five-course, seven-course
or nine-course type as specified. In selecting the combinations of layer of glass fibre tissue membrane,
consideration shall be given to the type and construction of buildings, climatic and atmospheric
conditions and the degree of permanence required. Five-course treatment is a normal duty treatment
suitable for moderate rainfall conditions (less than 50 cm), seven-course treatment is a heavy duty
treatment suitable for severe conditions of rainfall (50 to 150 cm) and nine-course treatment is extra
heavy duty treatment suitable for very heavy conditions of rainfall (more than 150 cm).
18.11.1 Materials:
i) Bitumen Primer: The primer shall conform to the requirements laid down in IS : 3384. Unless
otherwise specified, each coat of bitumen primer shall be applied at the rate of 0.40 kg per
square metre of the surface area.
ii) Glass Fibre Tissue: The glass fibre tissue shall be thin, flexible, uniformly bonded mat
composed of chemically resistant borosilicate staple glass fibre distributed in a random open
porous structure, bonded together with a thermosetting resin (Phenolic type) and reinforced
with continuous filament glass yarn at 10 mm pitch in the longitudinal direction. The minimum
weight of the tissue shall be 40 gm per square metre and the nominal thickness shall be 0.50 ±
0.1 mm. The minimum tensile strength of the tissue shall be 45 kg/150 mm width in the
longitudinal direction.
iii) Bonding Material: This shall consist of blown type bitumen conforming to IS : 702 or residual
bitumen conforming to IS : 73 heated to the correct working temperature. The penetration of
the bitumen shall not be more than 40 when tested in accordance with IS: 1203. Unless
otherwise specified, each coat of bonding material shall be of blown type bitumen of grade
85/25 heated to a working temperature of 180 degree C and applied at the rate of 1.60 kg per
18.11.2. Surface finish : Surface finish shall depend upon whether the roof is flat or sloping and
whether the terrace is accessible or not. Pea size gravel, stone grit, burnt clay tiles, cement concrete
flooring tiles, broken pieces of ceramic glazed tile or bitumen based aluminous mastics may be used
as specified. Pea size-gravel/stone grit, where specified, shall be spread at the rate of 0.006 cubic
metre per square metre of the surface area. Materials used for surface finish shall be dry and free
from dust.
18.11.3. Preparation of Surface: The preparation of the surface shall be done as specified in
18.6.8.2 except that water proofing felt wherever mentioned shall mean glass fibre tissue. To ensure
good adhesion between the structural surface and water proofing treatment, suitable methods to dry
the surface shall be adopted wherever necessary.
18.11.4 Treatment:
a) The water proofing treatment shall be five, seven or nine-course as specified. The first coat of
bitumen primer, each coat of bonding material, each layer of glass fibre tissue and the top layer
of surface finished shall be counted as a course.
b) A five course treatment shall consist of the following :
1. First coat of bitumen primer
2. Second coat of bonding material
3. Third layer of glass fibre tissue
4. Fourth coat of bonding material
5. Fifth and top most layer of surface finish as specified.
c) In seven-course treatment, the first four courses shall be the same as for five course treatment.
The fifth course shall be a layer of glass fibre tissue. The sixth course shall be a coat of bonding
material and the top most seventh course shall be of specified surface finish.
d) In nine course treatment, the first six courses shall be the same as for seven course treatment.
The seventh course shall be layer of glass fibre tissues, the eighth course shall be a coat of
bonding material and the top most ninth course shall be of specified surface finish.
18.11.5 Laying: Laying shall be done as specified except that the glass fibre tissue shall be used
instead of self finished felt and the first course shall be a coat of bitumen primer followed by
subsequent courses as per the treatment required.
18.11.6 Measurements & Rates: Measurements and rates shall be as specified in 18.10.7 and
18.10.8 respectively except that the rate shall be inclusive of the first coat of bitumen primer.
18.12 Applying Bituminous Solution Primer on Roof and Wall Surface (at 0.24 Litre Per
Sqm.):
18.12.1 Preparation of the Surface: The surface to be painted shall be cleaned with wire brushes and
cotton or gunny cloth. All loose material and scales shall be removed and dusted off.
18.12.2 Application: As specified in item of work or required by the Engineer-in-Charge under
slightly damp conditions, priming coat consisting of a between primer conforming to IS : 3384 is
applied with a brush on the roof and wall surface at 0.24 litres per sqm to asset adhesion of the
bonding materials (i.e. bitumen).
18.12.3 Measurement: Length and breadth shall be measured along the finished surface correct to
18.12.4 Rate: The rate shall include the cost of labour and materials involved in all the operation
described above. Such application of prima shall be paid for separately unless specially included in
the water proofing item.
18.13 Grading of Roof for Water Proofing Treatment:
18.13.1 Grading with Lime Concrete:
18.13.1.1 Materials: Brick aggregate shall not be more than 18 mm and also not less than 20 mm
nominal size and lime mortar shall be 1: 2 (1 lime putty: 2 surkhi) unless otherwise specified in the
The volume of wet mortar to be used will be 50% of stacked volume of brick aggregate, unless
otherwise specified in the description of item. The brick aggregate shall be kept moist thoroughly for
a period of not less than 6 hours before use in the concrete mix.
The specifications for the materials and method of preparation of mortar and concrete shall conform
in general to the specifications described (to refer relevant reference).
18.13.1.2. Laying:
18.13.1.2.1 Lime concrete shall be laid (and not thrown), in a single layer and spread and rammed
with wooden rammers of weight not exceeding 2 kg to the specified average thickness, slopes
and levels. The concrete shall be used when it is quite fresh, concrete left over from the previous
days work shall in no circumstances, be used.
18.13.1.2.2 During this preliminary ramming, the surface shall be tested and kept perfectly true and
even by means of a trowel, straight edge and spirit level. The concrete shall then be further
consolidated by two rows of labourers sitting close and beating the concrete in unison with wooden
thappies (weight 1 to 2 kg) across the entire width of the roof and thus slowly transversing the length
of the roof. Special care shall be taken to consolidate the concrete properly at its junction" with the
parapet wall. This beating shall be continued for seven days or until the mortar is almost set and the
wooden thappies rebound from the surface readily when struck on it.
18.13.1.3. Curing: The concrete shall be kept wet after each day's work and for such period of time
as the Engineer-in-Charge may direct but shall not be less than ten days. The wetting shall be done
by spreading straw and watering very frequently from a watering cane through a perforated rose, in
moderate quantity, so as to ensure thorough wetting of the concrete. Water shall not be poured on
fresh concrete from large vessels as this may lead to damage to the finished surface.
18.13.1.4 Finish: The slope of the finished grading shall not be more than 1 in 120 unless a steeper
slope is expressly permitted by the Engineer-in-Charge in writing. The roof surfaces shall slope from
all sides towards the outlets/parapet walls.
The minimum thickness of the concrete at its junction with khurra or parapet shall be 5 cm. The lime
concrete shall overlap the cement concrete base of the khurra by 75 mm and shall be rounded to the
edges of the khurra. The lime concrete shall also be rounded at the junction of roof slab and parapet.
The finished lime concrete shall present a smooth surface with correct slopes and uniform rounding's
wherever they occur. The concrete should be free from cracks.
18.13.1.5 Thickness: The average finished thickness of the laid concrete over the entire area shall
conform to the average thickness specified in the description of the item. The average thickness of
concrete shall be measured correct to 5 mm. In the above measurement, the extra thickness at the
rounding with the junctions of wall shall not be taken into account.
18.13.1.6 Measurements
i) Length and breadth shall be measured correct to a cm. Area shall be worked out to nearest 0.01
sqm, and the cubical contents of consolidated lime concrete shall be worked out to nearest 0.001
cum. Concrete laid in excess of the dimension shown in the drawing shall not be measured.
ii) Where average thickness of concrete laid exceeds the average thickness specified in the item,
the extra depth shall not be paid for unless the same had been carried out under written orders
of the Engineer-in-Charge.
iii) Where, however, such average thickness is found on measurements to fall short of the average
thickness specified in the item the contractor's rate will be reduced for the shortfall in thickness.
iv) No deduction in measurements shall be made for either openings or recesses for chimney
stacks, roof lights etc. or Khurra for areas up to 0.1 sqm (1000 sq cm.). Nothing extra shall be
paid either for any extra material or labour involved in forming such opening or recesses or in
rounding the concrete at junction of roof with parapet walls, chimney, stacks, Khurras etc.
18.13.1.7 Rate: The rate shall include the cost of all the materials and labour involved in all the
Note:
a) Preparation of Surface:
(i) If the RCC slab is to be treated with waterproofing treatment which would need grading the
surface of the roof, then the same shall be made rough in the initial stages only when the
concrete laid is still green. This can be easily done by scratching the surface with a scratching
tool immediately after finishing the slab. However, the surface should not be hacked.
(ii) In case the grading is to be done over the slab which is already cast and attained it's full strength,
then the only alternative to roughen the surface is not by hacking with a hacking tool but by
treating the surface with spatter dash key.l
(iii) The method of preparing the surface for grading prescribed above shall be followed for
executing any type of grading.
18.13.2 Grading with Cement Concrete 1:2:4 (Fig. 8):
18.13.2.1 Materials: Cement, coarse sand and graded stone aggregate 20 mm nominal size, shall be
used as specified in the item.The specifications for the materials and method of preparation of
concrete shall conform in general to the specification described in (to refer relevant reference)
18.13.2.2 Laying:
(i) Before laying cement concrete for grading, the level markings (Thiya) to the required slope/
gradient shall be made only with cement concrete on the surface of the slab at suitable spacing
with the help of string and steel tape (Measuring tape) so that the mason can lay the concrete
to the required thickness, slope/ gradient easily in between the two level markings.
(ii) On getting the level markings approved by the Site Engineer the surface should be sprinkled
with thick cement slurry and the concrete should be laid carefully, without throwing from
height, in predetermined strips.
(iii) As no vibrator can be used for consolidating such small depths, the concrete should be
consolidated by specially made wooden tamping beams operated by two labours on two ends.
After the tamping is done the surface should be finished to required slope/gradient with wooden
trowels without leaving any spots of loose aggregates etc.
(iv) The cement concrete that is mixed must be laid in position, within half an hour of its mixing
with water; therefore, every time small batches shall be mixed i.e. a quantity which an be laid
within half an hour. In case any quantity of concrete remains unused for more than half an hour
the same should be rejected and removed from site.
18.13.2.3 Finishing: The slope of finished terrace shall not be more than 1 in 120 unless a steeper
slope is expressly permitted by the Engineer-in-Charge in writing.
The minimum thickness of the concrete at its junction with Khurra or parapet shall be 5 cm. The
concrete shall be rounded at the junction of roof slab and parapet. It is desirable to provide a
haunch/gola/fillet at the junction of the parapet wall and the roof slab.
The finished concrete surface shall present a smooth surface with correct slopes and uniform
rounding's wherever they are provided. The concrete should be free from cracks. Excess trowelling
shall be avoided."
18.13.2.4 Thickness: Average thickness shall be as per clause 18.13.1.5
18.13.2.5 Curing: Curing shall be done either by spreading straw/hessian cloth over the graded
surface, keeping the same wet for full 10 days or flooding the graded area with water by making
kiaries with weak cement mortar, keeping the water over the surface for full 10 days. Occasional
curing by simply spraying water now and then shall not be permitted under any circumstances.
18.13.2.6 Measurement:
i) Length and breadth shall be measured correct to a cm. Area shall be worked out to nearest 0.01
sqm and the cubical contents of consolidated concrete shall be worked out to nearest 0.001
cum. Concrete laid in excess of the dimension shown in the drawing shall not be measured.
ii) Where average thickness (see clause 18.13.1.5) of concrete laid exceeds the average thickness
specified in the item, the extra depth shall not be paid for unless the same had been carried out
underwritten orders of the Engineer-in-Charge.
iii) Where, however such average thickness is found on measurements to fall short of the average
thickness specified in the item, the concrete rate will be reduced for the shortfall in thickness.
iv) No deduction in measurements shall be made for either opening or recesses for chimney stacks,
roof lights etc., Khurra for area up to 0.1 sq m (1000 sq. cm). Nothing extra shall be paid either
for any extra material or labour involved in forming such opening or recess or in rounding the
concrete function of roof with parapet walls, chimney stack, khurra etc.
18.13.2.7 Rate: The rate shall include the cost of all the materials and labour involved in all the
operation described above.
Note :- Preparation of Surface:
(i) If the RCC slab is to be treated with waterproofing treatment which would need grading the
surface of the roof, then the same shall be made rough in the initial stages only when the
concrete laid is still green. This can be easily done by scratching the surface with a scratching
tool immediately after finishing the slab. However the surface should not be hacked.
(ii) In case the grading is to be done over the slab which is already cast and attained it's full strength,
then the only alternative to roughen the surface is not by hacking with a hacking tool but by
treating the surface with spatter dash key.
(iii) The method of preparing the surface for grading prescribed above shall be followed for
executing any type of grading.
18.13.3 Grading Roof with Cement Mortar 1:3/1:4 (Fig. 9):
18.13.3.1 Limitations on Operating the Item on Grading with Cement Mortar
(i) Grading on roofs with cement mortar cannot be done on roof slabs of large width/length as
laying more than 50 mm thickness of grading with cement mortar shall not be stable and
economical.
(ii) Unlike the provision of a minimum 50 mm thickness of grading with Lime Concrete/Cement
Concrete, the minimum thickness for grading with cement mortar shall be just 20 mm to 18
mm as it is not desirable to increase the maximum thickness more than 50 mm.
(iii) Therefore the maximum length/width that can be achieved with this restriction of thickness is
the length/width that can be covered with cement mortar. Recommended width shall be 6 m if
the slope of grading is in two directions and 3 m in case the slope is in one direction.
(iv) Thus, the grading with cement mortar can be used for slabs of smaller spans, cantilevers,
chhajja, balconies etc.
18.13.3.2 Materials: Cement and coarse sand shall be as specified in the item of work or as
described (to refer relevant reference)
18.13.3.3 Cement Mortar: Cement mortar 1:3 (1 cement: 3 coarse sand)/1:4 (1 cement: 4 coarse sand)
shall be as specified in the item of work conforming to the specification described (to refer relevant
reference)
18.13.3.4 Preparing the Surface :The surface shall be cleaned properly with brooms brush, cloth
to remove all dirt's, dust, mortar droppings.
18.13.3.5 Laying: Same as described in clause 18.13.2.2, except that cement mortar shall be
tamped with wooden and steel trowel and surface finished with steel trowel.
18.13.3.6 Finishing:
(i) The slope of finished surface shall not be more than 1 in 120 unless a steeper slope is
specified in the item of work or ordered by the Engineer-in-Charge in writing.
(ii) The finished surface of the grading shall present a smooth surface with correct slopes and
uniform rounding's wherever they are provided. The mortar surface shall be free of cracks.
Excess trowelling shall be avoided.
18.13.3.7 Thickness:
(i) The minimum thickness of cement mortar grading at the junction with khurra or parapet wall
shall be 20 mm to 18 mm. The cement mortar shall be rounded at the junction of roof slab and
parapet. It is desirable to provide a haunch/gola/fillet at the junction of parapet wall and the
roof slab.
(ii) The maximum thickness that shall be adopted for grading with cement mortar shall be 50 mm.
It is not at all desirable to lay the cement mortar grading for greater thickness and in that case
it is advised to go in for grading with Lime Concrete/Cement Concrete.
(iii) The average thickness shall be as shown in Fig. 9.
18.13.3.8 Curing : Curing for the grading with cement mortar shall be done exactly as described in
clause 18.6.11.2.5.
18.13.3.9 Measurement: Same as specified in clause 18.13.2.6 except that cement mortar may be
read instead of cement concrete.
18.13.3.10 Rate : The rate shall include the cost of labour and material involved in all the
18.14 Water Proofing Treatment with APP (Atactic Polypropylene Polymeric) Membrane
(Fig.11):
In-situ water proofing treatment of roofs with APP (Atactic Polypropylene) modified polymeric
membrane shall be five course, seven course type as specified. In selecting the combinations of
layer of APP membrane, consideration shall be given to the type and construction of buildings,
climate and atmospheric conditions and the degree of permanence required. Five course treatment is a
normal duty treatment suitable to moderate rainfall conditions (less than 50 cm), seven course
treatment is a heavy duty treatment suitable for severe conditions of rainfall (50 to 150 cm) and
seven course treatment with APP modified polymeric membrane 2.00 mm thick and weight 3.00
kg/sqm, suitable for very heavy condition of rainfall (more than 150 cm).
18.14.1 Materials:
i) Bitumen Primer: The primer shall conform to the requirements laid down in IS:3384. Unless
otherwise specified, each coat of bitumen primer shall be applied at the rate of 0.40 kg per
ii) Atactic Polypropylene modified polymeric membrane : It is a polymeric water proofing
membrane manufactured to high standards. It is five layered APP modified polymeric
membrane with centre core as 20 micron HMHDPE/100 micron HMHDPE High Molecular
High Density Polyethylene Film, this centre core is the heart of the membrane and protects
against water and moisture. The centre core is sandwiched on both sides by high quality
polymeric mix with properties of high softening point, high heat resistance and cold resistively
to make it ideal for all water proofing treatment. The polymeric mix is protected on both sides
with 20 micron HMHDPE film. This is available in variable thickness and weights, usually
width is 1.0 m. Important physical and chemical parameter of the membrane shall be as given
in Table for guidance.
Table
Centre Core Thickness Weight
20 micron HMHPDE 20 micron HMHPDE 1.5 mm 2.25 kg/sqm
100 micron HMHPDE 20 micron HMHPDE 2.00 mm 3.00 kg/sqm
Where
proprietary brands Atactic Polypropylene modified polymeric membrane is proposed to
be used by the contractor, they shall conform in all respects to the specification in the preceding
para and manufactured by Bengal Bitumen Co. Ltd. or a company of repute.
iii) Bonding Material: This shall consist of blown type bitumen conforming to IS: 702 or residual
bitumen conforming to IS : 73 headed to the correct working temperature. The penetration of
the bitumen shall not be more than 40 when tested in accordance with IS : 1203, unless
otherwise specified each coat of bonding material shall be of blown type bitumen of grade 85/25
heated to a working temperature of 180 degree C and applied @ 1.20 kg per square metre of
the surface area.
iv) Surface Finish: Surface finish shall be with brick tiles of class designation 100 grouted with
cement mortar 1:3 (1 cement: 3 fine sand) with 2% integral water proofing compound by weight
of cement over a 12 mm thick layer of cement mortar 1:3 (1 cement: 3 fine sand) and finished
neat, as shown in Fig. 10.
Note : Surface finish shall be measured and paid for separately under relevant item.
i) The preparation of surface shall be done as specified in 18.10..2 except that water proofing
felt wherever mentioned shall mean Atactic Polypropylene modified polymer membrane.
To ensure good adhesion between the structural surface and water proofing treatment, suitable
method to dry the surface shall be adopted where necessary.
ii) The surface to be treated shall have a minimum slope of 1 to 120. This grading shall be
carried out with cement concrete or cement plaster with coarse sand, as desired, to the average
thickness required and finished smooth. Such grading shall be paid for separately.
iii) Junctions between the roof and vertical faces of parapet walls, chimneys etc. shall be chased
by running triangular fillets 7.5 x 7.5 cm. size, cement concrete. At the than mouths, the fillets
shall be suitably cut back and rounded off for easy application of water proofing treatment and
easy flow of water. Cement concrete where shall be 1:2:4 mix (1 Cement: 2 Coarse sand: 4
Graded stone aggregate 20 mm. Nominal size). The provision of fillets shall be deemed to be
covered by the item of water proofing and shall not be measured or paid for separately.
iv) In existing roof where gola and drip course are provided at the junction of roof and vertical
face of parapet wall, chimney stacks, etc. These shall be dressed suitably and finished smooth
so as to ensure an easy and gradual turning of the flashing. Any dismantlement or forming and
finishing smooth the junction for forming the base of the flashing shall not be measured or paid
for separately and shall be deemed to form part of the preparation of the surface.
v) While the grading of roof surface is being done, it shall be ensured that the outlet than pipe
have been fixed and mouth at the entrance have been eased and rounded off properly for easy
flow of water. When any pipe passes through the roof to be treated, angular fillet of shape
shown in Fig.10 shall be built around it for the water proofing treatment to be taken over it.
These fillets shall not be measured or paid for separately. For carrying over and tucking in the
water proofing felts into the parapet walls, chimneys stacks etc. a horizontal groove 6.5 cm.
deep, 7.5 cm. wide section with its lower edge at not less than 15 cm. above the graded roof
surface shall be left on the inner face of the same; during construction if possible. When such
groove has not been left, the same shall be cut out neatly and the base at rear of the groove shall
be finished smooth with cement plaster 1:4 (1 cement: 4 coarse sand). Such cutting of the
groove and its finishing smooth shall be part of the water proofing or paid for separately. No
deduction shall be made either for not making the groove or when the latter has already been
left in the masonry by the construction agency. Tucking in the water proofing felt will be
required where the parapet wall exceeds 45 cm. in the height from the graded surface. Where
the height is 45 cm. or less, no groove will be required as the water proofing treatment will be
carried over the top of the parapet wall to its full thickness. In the case of low dividing walls of
height 30 cm. or less, outlets therein shall be cut open for full height and the bottom and sides
shall be rendered smooth and corners rounded and such treatment shall not be measured and
paid for separately. Where expansion joints are left in the slab the provision of dwarf walls
and/or RCC slabs for covering them and finishing the surface smooth shall be the responsibility
of the construction agency, which had laid the roof slab and will not be included in the operation
of water proofing. The graded surface of the roof and concrete fillets and the faces of walls
shall be thoroughly cleaned with wire brushed and all loose scales etc. removed. The surface
shall then be dusted off. Any crack in the roof shall be cut to V section, cleaned and filled up
flush with cement mortar slurry 1:4 (1
cement : 4 coarse sand) or blown type petroleum bitumen of IS grade 85/25, or approved quality
conforming to IS 702. Such cleaning of the surface or treating the cracks shall not be paid for
separately.
18.14.3 Treatment: The water proofing treatment shall be five, seven course as specified. The first
coat of bitumen primer, each coat of bonding material, each layer of Atactic Polypropylene modified
Polymeric membrane and the top layer of surface finished shall be counted as a course.
A five course treatment shall consist of the following:
(i) First coat of bitumen primer
(ii) Second coat of bonding material
(iii) Third layer of APP modified polymeric membrane of specified thickness and weight.
(iv) Fourth coat of bonding material
(v) Fifth and top most layer of surface finish as specified.
In seven-course treatment, the first four courses shall be the same as for five course treatment. The
fifth course shall be a layer of APP modified polymeric membrane. The sixth course shall be a coat
of bonding material and the top most seventh course shall be of specified surface finish.
18.14.4 Laying: Laying shall be done as specified except that APP modified polymeric membrane
shall be used instead of self finished felt and the first course shall be a coat of bitumen primer
followed by subsequent course as per treatment required. The method of laying different courses is
shown in Fig. 11.
(a) First course shall be a coat of bitumen primer @ 0.40 kg per sq m followed by subsequent
course as per treatment required.
(b) Drain outlets shall be given a four or six course treatment as specified for the roof in the
description of the item in the manner specified for the flat roof surface. Water proofing
treatment shall be carried into the drain pipe or outlets by at least 10 cm. The water proofing
treatment laid on the roof surface shall overlap the upper edge of the water proofing treatment
in the drain outlets by at least 10 cm.
(c) The APP modified polymeric membrane shall be cut to the required length, brushed clean of
dusting material and laid out flat on the roof to eliminate curls and subsequent stretching. The
membrane shall normally be laid in length in the direction of the slope and laying shall be
commenced at the lowest level and worked up to crest. The membrane shall not be laid in single
piece of very long lengths as they are likely to shrink; 6 to 8 m are suitable lengths. The roof
surface shall be cleaned and dry before starting the membrane treatment. Each length of
membrane shall be laid in position and rolled up for a distance of half its length. The hot
bonding material shall be poured on the roof across the full width of the rolled membrane as
the latter is steadily rolled out and pressed down. The pouring shall be so regulated that the
correct weight of bonding material per unit area is spread uniformly over the surface. Excess
bonding material that gets squeezed out at the ends shall be levelled up as laying proceeds.
When the first half of the strip of felt has been bonded to the roof, the other half shall be rolled
up and then unrolled on the hot bonding material in the same way. Subsequent strips shall also
be laid in the same manner.
Each strip shall overlap the preceding one by at least 7.5 cm. at the longitudinal edges
and 10 cm. at the ends. All overlaps shall be firmly bonded with a blow lamp and levelling
down unevenness. The fourth layer of bonding material in the five course treatment shall be
carried out in a similar manner after the flashing has been completed.
(d) In a seven course treatment the fifth layers of membrane shall be laid in the manner already
described, taking care that laps in the membrane are staggered from those in the earlier layer.
The sixth layer of bonding material shall be carried out after the flashing is done.
(e) High Parapet Walls, Chimney Stacks etc.: Membrane shall be laid as flashing wherever
junctions of vertical and horizontal surfaces occur. Longitudinal laps shall be 10 cm. The lower
layer of flashing membrane in a six course treatment shall overlap the roof water proofing by
not less than 20 cm. while the upper layer shall overlap the roofing felt by 10 cm. The minimum
overlap of the flashing membrane in five course treatment over the roofing membrane shall be
10 cm.
The flashing shall consist of the same five or seven course treatment as for the roof except that
the final course shall be replaced by an application of 12 mm thick cement plaster 1:3 on the
vertical and sloping faces only, of the flashing. The overlap along the length of flashing shall
stagger with those in the second layer of flashing membrane (in a seven course treatment and
with the joints in the roof membrane).
The upper edge of the finishing membrane shall be well tucked into the flashing grooves in the
parapet, chimney stacks etc. to a depth of not less than 6.5 cm. Corresponding applications of
bonding material shall also be made. The flashing treatment shall be firmly held in place in the
grooves with wood edges at intervals and the grooves shall be filled up with cement mortar 1:4
(1 cement: 4 coarse sand) or cement concrete 1:2:4 (1 cement: 2 coarse sand : 4 graded stone
aggregate 6 mm nominal size) and surface finished smooth with the rest of the wall. The cement
work shall be cured for 7 days. When dry, the exposed plaster joints of grooves shall be painted
with bitumen and two coats of bituminous solution shall be applied on the vertical and sloping
surface of flashing.
After the top flashing membrane layer has been fixed, the penultimate layer of bonding material
shall be applied over the roofing membrane and the horizontal overlaps and vertical and sloping
surfaces of the flashing at the specified rate.
(f) Low Parapet Walls: Where parapet w a s are of height 45 cm. or less, membrane flashings
shall be provided in the same manner as for flashings in the case of high parapet walls except
that the upper edge shall be carried up to the full height of the wall and taken right across the
top of the parapet and down on the external vertical faces to a minimum distance of 5 cm.
(g) Low Dividing Walls: Where low dividing walls or inverted beams are met with, the same shall
be covered with a four or six layer treatment as for the main roof, the latter bearing carried
down both sides of the wall and overlapping the roofing treatment as in the case of flashing of
high parapet walls.
Drain outlets where formed in the low dividing walls, shall be given water proofing treatment
of the same number of courses as specified for the flat roof surface. The bottom and sides shall
be so treated that all overlaps are in the direction of flow of drainage.
(h) Expansion Joints: Where the expansion joints are provided in the slabs, the joints and their
cover slabs shall be suitably treated with water proofing. A typical sketch of an
expansion joint with the RCC slabs on either side of the joint turned vertically up and dwarf
walls by not less than 7.5 cm. and are provided with throating on their underside along their
length. The water proofing treatment shall be taken up the sloping junction fillets and the
vertical faces of the walls to the underside of the cover slabs. The cover slabs are given the
water proofing treatment like the roofs slabs, after the cross joints between adjacent cover slabs
are first sealed with 15 cm width of roofing felt struck to them with bitumen. The water proofing
treatment shall be carried down the sides of the cover slabs to their full thickness. Care shall be
taken to see that overlaps if any in the roofing over the cover slabs stagger with the joints
between cover slabs.
The formation of the expansion joints and provision of the cover slabs shall be the responsibility of
the construction agency. The formation of the junction fillets and the water proofing treatment of the
joint and cover slabs shall be carried out by the water proofing agency. Nothing agency extra shall
be paid for the sealing of the cross joints in the cover slab with 15 cm. width of bitumen strips.
(i) Pipes: Where vertical pipe outlets are met with, 7.5 x 7.5 cm fillets of lime or cement concrete of
the type and section shown in Fig. 11 shall be provided and flashing of four or six course
treatment, same as for the roofing treatment shall be laid.
The upper edge of the flashing shall be laid sloping down forward and butted against the pipe
and annular depression so formed shall be filled with hot bitumen. A circular metal collar in
the shape of an inverted truncated cone shall be fixed on the pipe to throw off the rain water
clear of the flashing and this shall be paid for separately.
18.14.5 Measurement: Length and breadth shall be measured correct to a cm. The area shall be
calculated in square metres correct to two places of decimal. Measurements shall be taken over the
entire exposed area of roofing and flashing treatment including flashing over low parapet walls, low
dividing walls and expansion joints and at pipe projections etc. Overlaps and tucking into flashing
grooves shall not be measured. Vertical and sloping surfaces of water proofing treatment shall also
be measured under the five or seven course treatment as the case may be, irrespective of the fact that
the final course is replaced by bitumen primer. No deduction in measurements shall be made for
either openings or recesses for chimney stacks, roof lights and the like, for areas up to 0.4 sq m nor
anything shall be paid for forming such openings. For areas exceeding 0.40 sq m deduction will be
made in measurements for full opening and nothing extra shall be paid for forming such openings.
18.14.6 Rate: Rate shall be as specified in 18.10.8 except that the rate shall be inclusive of the first
coat of bitumen primer but excluding the surface finish which shall be paid under relevant schedule
item.
18.15 Water Proofing Membrane with Atactic Polypropylene Polymer Modified Prefabricated
Membrane Five Layered (Fig. 12) :
Atactic Polypropylene Polymer modified prefabricated five layer water proofing membrane shall be
of thickness as specified. In selecting thickness of membrane due consideration shall be given to the
type and construction of building, climate and atmospheric condition and permanence required. Five
layered treatment 2.00 mm thick with glass fibre is with a normal duly treatment suitable for pitched
roofs. Five layered 3.00 mm thick with glass fibre matt treatment is suitable for moderate condition
of rainfall (50 to 150 mm) and fine layered 3.00 mm thick with non-woven polyester matt treatment
is suitable for heavy condition of rainfall (more than 150 cm).
18.15.1 Materials:
i) Bitumen Primer: Bitumen primer for bitumen membrane manufactured by the same
manufacturer shall have density at 25°C in the range of 0.87-0.89 kg/litre and viscosity of 70-
160 CPS primer shall be applied at the rate of 0.40 litre/sqm.
ii) Atactic Polypropylene Polymer modified prefabricated membrane: It is a polymeric water
proofing membrane manufactured to high standard. This shall be one of the following types:
(a) 2 mm thick with glass fibre matt
(b) 3 mm thick with glass fibre matt
(c) 3 mm thick with non-woven polyester matt.
It is prefabricated five layered black finish water proofing membrane comprising of centre core of
50 to 60 gsm glass fibre matt/ 170 gsm non woven polyester matt sandwiched on both sides by APP
polymer modified bitumen which is protected on both sides by 20 micron thermo fusible
polyethylene sheet. Composite thickness of the membrane including all five layers shall be 2/3 mm
with glass fibre matt and 3 mm with non-woven polyester matt manufactured by Bitumat Co. Ltd.
or a company of repute. It is available in 1 m width and variable length.
Important physical and chemical parameters of the membrane shall be as given in table:
Table
SI. No. of Layers Thick- Joint strength in Softening Cold
Elongation Tear Strength
No. ness longitudinal and point flexibility
at 23°C in in
Transverse
longitudinal longitudinal
transverse direction Transverse
direction direction
1 2 3 4 5 6 7 8
1. Five layered 2 mm 3 N/5 cm 350/300 N/5cm 60/80N 150° -2°C
reinforced with
fibre glass
2. Five layered 3 mm 3.3 N/5 cm 350/300N/5 cm 60/80N 150° -3°C
reinforced with
fibre glass
fibre glass
3. 3 mm 40/50N/ 650N/450N/5cm 300/250 N 150° -2°C
Five layered
5cm
reinforced with
non-woven
polyester mart.
Wh When tested in accordance with ASTM, D-5147wherepropriet ary brandAtactic polypropylene

modified black finished is proposed to be used by the contractor they shall conform to all respects to
the specification in the preceding para. However, contractor should be advised to get the work done
through authorised applicator.
18.15.2 Preparation of Surface: The surface to be treated shall have a minimum slope of 1 in 100
or as specified, as far as applicable provision specified in clause 18.10.2 shall apply for preparation
of surface except for pitched roof where surface shall be cleaned off any loose paint
etc. To ensure good adhesion between the surface and water proofing treatment suitable method to
dry the surface shall be adopted where necessary. All hair line cracks in the surface should be filled
with the approved sealant.
18.15.3 Treatment: The water proofing shall consist of prefabricated five layered 2mm/3 mm
membrane as shown in Fig. 12. The choice of 2 mm or 3 mm membrane will depend on the type of
roof i.e., pitched or flat and importance of building, durability, cost etc.
18.15.4 Laying:
i) Bitumen primer of required grade shall be applied to the prepared roof, drain and any other
surface wherever polymer modified membrane is to be laid over the primary coat the five
layered water proofing membrane shall be laid using Butane torch and sealing all joints and
preparing the surface complete.
ii) Drain outlets shall be given same treatment as specified for the roof in the description of the
item in the manner specified for the flat roof surface. Water proofing treatment shall be carried
into the drain pipe or outlets by at least 10 cm. The water proofing treatment laid on the roof
surface shall overlap the upper edge of the water proofing treatment in the drain outlets by at
least 10 cm.
iii) The APP polymer modified prefabricated water proofing membrane shall be cut to the required
length. Water proofing membrane shall normally be laid in length at right angles to the direction
of the slope and laying shall be commenced at the lowest level and worked up to crest. APP
water proofing membrane shall be laid in 6 to 8 m lengths. The roof surface shall be cleaned
and bitumen primer shall be applied in the correct quantity, over this specified water proofing
membrane shall be laid with butane torch after allowing 24 hours for primer to dry. Each strip
shall overlap the preceding one by at least 10 cm at the longitudinal edges and 15 cm at the
ends. All overlaps shall be firmly bonded with bitumen primer and levelled by heating the
overlap with butane torch.
iv) If the roof is accessible the treatment is protected by brick tiles laid over a 12 mm thick cement
mortar bedding and joints sealed with cement mortar or plain cement concrete, which shall be
measured and paid for separately.
v) High parapet walls, chimney stacks etc. : APP water proofing membrane shall be laid as
flashing wherever junction of vertical and horizontal surfaces occur. Longitudinal laps shall be
10 cm. The upper edge of flashing membrane shall be well tucked into the flashing grooves in
the parapets, chimney stack etc. to a depth of not less than 6.5 cm; corresponding applications of
primer coat shall also be made. The flashing treatment shall be firmly held in the grooves and
it shall be sealed with the approved sealant after terminating the membrane.
vi) Low Parapet Walls : Where parapet walls are of height 45 cm or less APP water proofing
membrane flashings shall be provided in the same manner as for splashing in the core of high
parapet walls except that upper edge shall be carried up to the full height of the wall and taken
right across the top of the parapet and down on the external vertical faces to a minimum distance
of 5 cm.
vii) Low Dividing Walls: Where low dividing walls or inverted beams are met with, the same
treatment shall be provided as for the main roof, the lateral bearing carried down both sides of
the wall and overlapping the roof treatment. Drain outlets where formed in the low dividing
walls, shall be given water proofing treatment same as for the main roof.
viii) Expansion Joints: a) Where the expansion joints are provided in the slabs, the joints and their
cover slabs shall be suitably treated with water proofing treatment. A typical sketch of an
expansion joint with the RCC slabs on either side of the joint turned vertically up and covered
with precise RCC cover slabs. The cover slabs shall cover the vertical turned up dwarf walls
by not less than 7.5 cm and are provided with throating on their underside along their length.
The water proofing treatment shall be taken up the slopping junction fillets and the vertical
faces of the walls to the underside of the cover slabs are given the water proofing treatment like
the roof slabs, after the cross joints between adjacent cover slabs are first sealed with 15 cm.
width of roofing felt struck to them with bitumen. The water proofing treatment shall be carried
down the sides of the cover slabs to their full thickness. Care shall be taken to see that overlaps
if any in the roofing over the cover slabs stagger with the joints between cover slabs.
b) The formation of the expansion joints and provision of cover slabs shall be the responsibility
of construction agency. The formation of the junctions fillets and the water proofing
treatment of the joint and cover slabs shall be carried out by the water proofing agency.
No extra shall be paid for the junction fillets or for the sealing of the cross joints in the
cover slab with 15 cm. width of bitumen strips.
For general guidance refer para 18.10.6.7
18.15.5 Measurements: Length and breadth shall be measured correct to a cm. The area shall be
calculated in square metres correct to two places of decimal.
Measurements shall be taken over the entire exposed area of roofing and flashing treatment including
flashing over low parapet walls, low dividing walls and expansion joints and at pipe projections etc.
overlaps and tucking into flashing grooves shall not be measured.
No deduction in measurements shall be made for either openings or recesses for chimney stacks,
roof lights and the like, for areas up to 40 square decimetre (0.4 sqm) nor anything shall be paid for
For similar areas exceeding 40 sq decimetre, deductions will be made in measurements for full
opening and nothing extra shall be paid for forming such openings.
described above. Preparation of surface shall be measured and paid for separately.
Note:- Instead of brick tiles plain cement concrete can also be used as a finishing layer on Geo textile.
18.16. Extra For Covering of Atactic Polypropylene Polymeric Modified Prefabricated Water
Proofing Membrane with Geo Textile:
i) If the water proofing treatment of flat roof has been done with APP modified five layered
membrane and the roof is accessible, a separation layer i.e. top of membrane should be laid
before any protected treatment is done. Brick tiles in cement mortar or 18 mm thick cement
concrete 1:2:4 shall be laid as final layer as shown in Fig. 12 above.
ii) Geo textile 120 gm non woven 100% polyester of thickness 1 to 1.18 mm manufactured by a
company of repute used.
iii) Geo textile of the specified thickness is bonded to the water proofing membrane with
intermittent touch by heating the membrane by Butane torch as per manufacturing
recommendations.
18.16.1 Measurements: Length and breadth shall be measured correct to two places of decimal,
measurement shall be taken over the entire exposed area of roofing keeping in view the provision laid
in clause 18.15.5.
18.16.2. Rate: The rate shall include the cost of all labour and materials involved in all the operation
described. Final layer of brick tiles or 18 mm thick cement concrete shall be measured and paid for
separately.
18.17. Composite Roof Insulation and Water Proofing with Rigid Polyurethane Foam:
i) 30 mm thick joint less sprayed foam (Lloyd foam) or equivalent..
ii) Composite roof insulation and water proofing treatment serves the purpose of water proofing
and roof insulation. It is strong light weight treatment, thereby reducing the dead weight on the
building.
iii) Efficient thermal insulation property reduces heat to travel and therefore air conditioning
losses are quite less.
iv) This treatment can be applied to flat surface and is ideal for pitched roof, where very high
disbanding stresses (such as leeward wind forces) are to be countered by the insulation curved,
corrugated and irregular surfaces. Apart from external use, spray foam can be applied internally
as long as building is suitable, having easy, convenient access for application and good
ventilation. The foam can be sprayed on the underside of roofs on suspended floors and on the
inner surface of walls.
v) Although this forms a weather resistance membrane, in addition final coating is required as an
additional protection against sun rays. Liquid applied polyurethane foam should adhere strongly
to any surface and should not sag, buckle while in use.
18.17.1 Materials:
i) Polyurethane Foam: Rigid Polyurethane Foam United Nations Office for Project Services
(UNOPS) Certified (CFC Free) shall conform to IS : 13205. A rigid cellular plastic material
formed by catalysed reaction between poly-isocynate and a poly- hydroxyl compound (Polyol)
with foaming agent which is normally a Chlorofluoro-carbon gas. The foam shall be composed
substantially of urethane linkages which are basically straight chain structures.
Salient properties of polyurethane foam for guidance are given below:
Density = 42 ± 2 kg/m3 Thermal Conductivity = 0.023 W/mk (design)
Compressive strength = 300 kpa Water absorption (7 days) = 0.2 kg/m3
Tensile Strength = 280 kpa Temperature limit = 100 degree C (Max.)
Shear Strength = 210 kpa Closed Cell content = 92% vol.
There are two methods of application of polyurethane foam:
a) In Situ Pouring Method :- A method adopted for complicated shapes for minimizing the
number of joints or for strengthening the structures to be insulated by pouring (or
injecting). This is also known as foam on foam or layer by layer application of rigid foam
insulation. This is useful for thermal insulation of storage tanks, vessels, columns, piping,
flanges, valves etc.
b) In-situ Spray Method: This method is applicable for insulating large areas in short time
where PUR foam system is sprayed on the surface to be insulated to form a foam insulation.
ii) Isothane EMA:
a) Elastomeric membrane is a liquid applied coating. It is urethane pre polymers based which
cures by reaction with atmospheric moisture to give a continuous film which is rubbery and
elastic. It contains leafing aluminium which gives excellent U. V resistance. It shall have higher
viscosity than a conventional paint and is designed to give a high build film. It can be applied
with brush and should not be diluted.
b) It cures to a permanently flexible, seamless membrane, which by virtue of its chemical
reactivity in wet state has good adhesion as a base course to a wide range such as asphalt
roofing, slates, tiles, asbestos concrete, brick, wood, glass and metals. Unlike traditional
bitumen based product, it should not become brittle due to age or exposure to ultra violet
radiation or weathering. It should not be effected by extremities of temperature variation.
c) Coverage rate varies with the texture, porosity of the surface. On average coverage of Isothane
special primer shall be 6-10 m2/litre and that of Isothane BMA @ 1 Kg/m2 and shall provide
an adequate film thickness of 1 mm.
d) For guidance salient properties are given below:
Specific gravity 1.18
Solid % min 95
Application limit 0-70°C
Approximate Dry time 12-20 Hrs. touch dry
(20 degree, 50% RH) 7 days full cure
Elongation % = 500
Tensile strength = 2.07 N/mm2
Accelerated weathering = No appreciable
deterioration (12000 Hrs.)
Resistance to ultraviolet rays, hydrolysis, and
industrial environment = Excellent
Resistance to mechanical damage = Good
Storage/Shelf stability = 9 months
e) It shall be stored in a cool, covered and well ventilated space. Under no circumstances should
the drum be kept in open or water be allowed to come in contact with the chemicals.
Unnecessary opening of can should be avoided. Once opened it starts to cure and form skin. The
cured skin should be removed to use the material below.
f) Handling of Foam System: Material should be stored as stated above and as per the instruction
of chemical supplier. The supply shall be taken in sealed commercial container bearing the
label of manufacturer with the following information.
(i) Indication of source of manufacture (ii) Name of contents (iii) Net Weight of contents (iv)
Lot or batch number (v) Recommended storage temperature range (vi) A caution label
indicating strict instruction for handling and storage temperature range (vii) Mixing instructions
(viii) Expiry date or shelf life and recommended maximum pot-life after opening of container.
g) Surface Finish:
i) If the roof is not accessible, First coat urethane based Isothane Elastomeric water proofing
membrane (EMA) over the entire surface @0.5Kg/sqm is applied on P.U. foam. Second
coat Isothane EMA @0.5 Kg/ sqm is applied on the First coat.
ii) If the surface is accessible brick tiles in cement mortar 18 mm thick plain cement concrete 1:2:4
(1 cement: 2 coarse sand : 20 mm nominal graded stone aggregate) shall be laid in chequered
2.5 m x 2.5 m panels with 24 SWG x %" chicken wire mesh interposed in between and finished
smooth. All joints between the panels shall be sealed with polymerized mastic.
Note:- Surface finish which is accessible shall be measured and paid for separately under
relevant item.
18.17.3 Preparation of Surface: As far as applicable provision specified in 18.10.2 shall apply for
preparation of surface. Roof slab should be free from all profusion and depression having proper
slope and free flow of water. Remove all loose materials by vigorous brushing by wire mesh if
necessary. Surface should be thoroughly dry, any moisture is to be dried.
18.17.4 Treatment:
a) Composite roof insulation and water treatment shall consist of a four course treatment or with
a wearing course of brick tiles or 18 mm thick plain cement concrete 1:2:4, as given in the
b) The choice of four course or with a wearing course treatment shall depend whether roof is un
accessible/accessible.
c) A four course treatment shall consist of the following:
(i) Polyurethane primer
(ii) 2nd layer of 30 mm thick Rigid polyurethane foam.
(iii) 3rd Layer (First coat) of urethane based Isothane Elastomeric water proofing
membrane.
(iv) Final layer (2nd coat) of Isothane EMA.
For accessible roof a wearing course of 18 mm thick cement concrete 1:2:4 shall be laid as final
layer over the four courses treatment mentioned above.
18.17.5 Laying:
i) Over the cleaned surface apply polyurethane primer over the entire roof area @ 5 - 6 sqm/ litre.
ii)2nd layer of 30 mm thick Rigid Polyurethane Foam 'United Nations Office for Project Services
(UNOPS) certified (CFC Free) - Lloyd foam or equivalent conforming to IS:13205 with density
of foam being 40-45 g/m3. This is a seamless and monolithic treatment. Application of
rigid/polyurethane by spray eliminates separate fixing procedure. Foam is sprayed with the help
of two component Gusmer machine which are capable of maintaining the mix ratio within ±
2% accuracy and controlling the temperature at precisely the opinion range.
iii) 3rd layer (First coat) of Isothane EMA elastomeric membrane coating @ 0.50 kg/sqm is applied,
average maximum thickness of 0.50 mm. Before laying this layer fill cracks and voids with
mastic sealant if required.
iv) 4th layer (2nd coat) of isothane EMA : The first coat should be touch dry in 12 to 48 hours (in
some conditions this might be delayed) and the 2nd coat of isothane @ 0.50 kg/sqm should be
applied average maximum thickness of 0.5 mm with 24 hours to ensure good adhesion. Due to
some reason or otherwise if it is not possible to lay 2nd coat within 24
hours of laying of first coat, prime the entire surface with special primer and allow to dry before
2nd coat is laid within 4 to 8 hours. An overlap of 150mm shall be provided. Total thickness
of First and 2nd coat shall not be diluted.
v) All completed works shall be cleaned to remove any spills of chemicals. Aromatic
hydrocarbon solvent should be used to clean equipment.
vi) If the surface is accessible the treatment is protected by brick tiles in cement mortar or 18 mm
thick plain cement concrete with 24 SWG x 3/4" chicken wire mesh interposed in between as
per the recommendation of execution agency which shall be measured and paid for separately.
18.17.6 High Parapet Walls: Water proofing layer shall be laid as flashing wherever junction of
vertical and horizontal surface occur.
18.17.7 Low Parapet Walls: Where parapet walls are of height 45 cm or less the same treatment as
for the main roof shall be carried out and taken right across the top of parapet and down on the
external vertical faces to a minimum distance of 5 cm.
18.17.8.Low dividing walls, drain outlets : Where low dividing walls or inverted beams are met
with, the same treatment shall be provided as for the main roof.
18.17.9 Expansion Joints :- Where expansion joint are provided in slabs, the joints are provided
in slabs, the joints and their cover shall be suitably treated with water proofing treatment.
18.17.10 Precautions: Precautions to be taken while handling volatile chemical substances (i)
Protective work clothes; (ii) Safety glasses preferably with side protection; (iii) Protective gloves
which are impermeable to liquids; (iv) Chemical resistant work shoes; (v) Water containers and
dispensers to wash parts of the body which may accidentally be exposed to spills; (vi) Bottles of eye
cleansing lotion in case of accidental splashing to the eyes of personnel; and (vii) Clothes should not
be allowed to get saturated with chemicals, in case it happens, proper washing be carried to prevent
the remote possibilities of skin contact and irritation caused thereby. Work place must be ventilated
at all times.
18.17.11 Measurements: Measurements shall be as specified in 18.15.5.
18.17.12 Rate: The rate shall include the cost of labour and materials involved in all the operation
described above. For accessible roofs wearing course of brick tiles/18 mm thick cement concrete
shall be measured and paid for separately.
Note : The job is to be carried out by reputed agency like Lloyd Insulations (India) Ltd. or a
company having sufficient work experience.
18.18 Expansion Joints: For details refer clause 6.4.5 of Chapter 6.
18.19. Barbed wire fencing:
18.19.1. Scope: This specification lays down requirement regarding materials, fixing and mode of
measurement of barbed wire fencing.
18.19.2. Materials
a) Barbed wire : For fencing it shall be galvanised steel barbed wire and shall conform to I.S. 278.
Some of the requirements for this are given below :-
Type. Number of Dia. of Dia. of Bard
line wire Line Wire. Point Wire. spacing.
A 2 2.50 mm 2.50 mm 7.50 cm.
B 2 2.50 mm 2.50 mm 15.00 cm.
C 2 2.00 mm 2.50 mm 7.50 cm.
D 2 2.00 mm 2.50 mm 15.00 cm.
b) Fencing Posts :
i) Bally Posts :Ballies shall be new and as nearly straight as possible, Portion inside and
up to 10cm. above ground shall be coal tarred . (See Drawing. 18.8.-2)
ii) Sal wood Posts : Sal wood shall be structural Timber of grade I conforming to relevant
specification on timber. Portion inside and up to 10 cm. above ground shall be coal tarred.
iii) Mild Steel Angle Iron Posts : Mild steel angle iron posts shall be of structural steel
ordinary quality. A hole of 6 mm. Dia. with or without a side cut as directed by the
Engineer shall be board at wire spacings for holing up the wire in position.
iv) Precast Reinforced concrete Posts : Precast concrete posts shall be of cement concrete
of Grade M. 15 conforming to relevant specification. for "Cement Concrete " The posts
shall be of square cross- section at the top, which shall be uniformly enlarged in section
up to ground level. The section of the portion in foundation shall remain uniform. The
post shall be reinforced with 4 numbers of 6 mm. dia. bars one at each corner. Holes of
30 mm dia. shall be left in the intermediate posts and 12 mm. dia. for 10t' corner and
starting posts.
v) Sizes and sections : For fencing heights of 110, 150 and 180 cm. the minimum
permissible sizes and sections shall be as per table below. for other heights, these shall
be as specified by the Engineer.
TABLE
SIZES AND SECTIONS FOR FENCING POSTS.
S. Type of Height of Height of Girth of Girth of 10th. Depth of
No. Fencing Fencing Fencing posts intermediate posts corner & starting foundation
posts. (Cms.) including part and stays posts. (cms)
in foundations.
(Cms.)
1. Bally post 110 150 22.0 cm Av. Girth 22.0 cm Av. girth 40
150 195 22.0 cm Av. Girth 22.0 cm Av. girth 45
180 230 30.0 cm Av. Girth 30.0 cm Av. girth 50
2. Sal wood. 110 150 5.0x5.0 cms 75x7.5 cms. 40
150 195 6.0x6.0 cms 75x7.5 cms. 40
180 230 7.5x7.5 cms 10xlO cms. 40
3. MS Angle Iron 110 150 50x50x3 mm 50x50x6mm 40
150 195 50x50x3 mm 50x50x6mm 45
180 230 55x55x3 mm 65x65x8mm 50
4. Precast cement 110 150 7.5x7.5 to 9x9cms. - do - 40
concrete 150 195 7.5x7.5 to - do - 45
10x10cms
180 230 10x10 to - do - 50
13xl3cms.
c) Stays : The posts shall be provided with stays of similar sections, at every 10th and first,
last, and first, last, and corner posts. The stays shall be fixed to the fencing posts.
d) Straining bolts : M.S. Straining bolts of 10 mm. Dia. of the shapes as shown in drawings
.11 shall be used.
18.19.3. Foundation :
i) Foundations for 10t'', first last and corners fencing posts and stays shall be filled in cement
concrete of Grade M 10 or Lime concrete 1:2 in accordance to relevant specification. The
dimensions, of the foundation block shall be as shown in drawings (enclosed).
ii) Type of foundation for intermediate posts other than M.S. angle iron shall be specified by the
Engineer. this can either be filled with earth, rammed and compacted. or in 1:2 Lime concrete or in
cement concrete of Grade M 10 depending on the type of the soil available. M.S. angle iron posts
foundations shall be filled in Lime concrete 1:2 or in cement concrete of grade M 10.
18.19.3.1 Size of foundation : The size of foundation block for different heights of posts shall be
as follows :-
(a) For 110 cm. high posts 20x20x40 cms.
(b) For 120 cm high posts 30x30x45 cms .
(c) For 150 cm. high posts. 30x30x45 cms.
(d) For 180 cm. high posts. 30x30x60 cms.
18.19.4. Preparation of Ground : The ground 30 cm. wide along the fencing shall be cleaned of
all obstructions, loose stones, brush woods etc. Portions of ground raised by more than 10 cm.
causing obstruction to the lower most fencing wire, shall be scrapped off.
18.19.5. Fixing of Barbed wire :
i) The spacing of posts shall be three meters centre to centre unless or otherwise specified or as
directed by Engineer in charge. The dimensions of the area to be fenced. Every 15th last but
one end & corner posts shall be strutted on both sides and end posts on one side only. The
number of fencing wires and their spacings shall be adjusted according to the height of the
fencing required as per Table given below:-
TABLE
Height of fencing above G.L. (Measured up No. of fencing Spacings of wires
to the top most wire) wires (respectively)
110 cms. 6,5,4, 20,25,33 cms.
150cm. 8,7,6, 20,23,28 cms.
180 cm. 10,8,7,6, 19,24,28,34 cms.
ii) The bottom most line shall be fixed at 10 cms. above the ground level, and the top most at 5
cms. below the top end of post.
iii) If specified diagonal lines shall also be tied across the top most and bottom most line wires.
iv) M.S. straining bolts 10 mm. &a. shall be provided at every 10t''. Corner and starting and last
post to keep the barbed wire in position and tight. Either of the two types of straining bolts as
specified in the schedule of quantities (details shown in drawings) shall be used.
v) Barbed wire shall be tied to the straining bolt of the starting post and stretched to such length as
to reach the next straining bolts, to which it shall be tied and enough tension is induced in the
full length, to keep it tight and straight without sag, by proper adjustment of the nut. Similarly
the procedure shall be repeated for next and subsequent parts of the fencing. After this the wire
shall be fixed in position to every intermediated posts with the fixing accessories in a manner
given below
18.19.5.1. For bally and sal wood posts : One number M.S. nails 3.15 mm dia. and 70 mm long
shall be driven in to the posts at the specified spacing below the wire and shall be bent to envelop the
barbed wire.
18.19.5.2. Angle Iron posts : If only holes are provided in the flange than the barbed wire will be
held in position by G.I. Wire 1.60 mm dia. (1/16") If the bore is accompanied with a cut in the flange
than the wire shall be pushed into the hole and the cut portion hammered back to its original position.
18.19.5.3. Precast R.C. Post : Wire shall be passed through the holes and stretched to tighten it
sufficiently. Wire at every 3rd post shall be tied with 1.60 mm dia. G.I. wire.
18.19.5.4. Painting : All iron work (un galvanised) shall be painted white or green as per relevant
specification for painting .
(a) Fencing wires shall be measured in running metres. Type of wire and fixing accessories shall
be stated. Straining bolts shall be included with this item.
(b) Fencing posts, shall be enumerated and shall include foundation, coal tarring. The type of
foundation shall also be stated.
(c) Stays shall be enumerated and shall include foundation, coal tarring. Type of foundation
shall also be stated.
(d) Preparation of ground shall be measured separately.
18.20. Miscellaneous Brick Work:
Miscellaneous brick work, such as corbels, string course, projections, pilasters, aprons, friezes, fire
places, under pinning, fair cutting, edging, filleting, tile brick work, etc.
18.20.1. Scope : This specification covers the mode of measurement of miscellaneous work, under
brick work.
18.20.2.1. Corbels, String courses etc: Corbels, string courses, projections, pilasters, aprons and
friezes shall be measured separately and given in running metres.
18.20.2.2 Fire places chimneys etc: Brick work (excluding fire brick work) in chimney breasts,
chimney stacks, smoke or air flues not exceeding 0.25 sq. m. in sectional area shall be measured as
solid, and no extra measurement shall be made for pargetting and coring such flues. Where flues
exceed 0.25 sq m. in sectional area, deduction shall be made for the same and par-getting and coring
flues given in running metres stating the size of the flue. Apertures for fireplaces shall not be
deducted and extra labour shall not be measured for splaying of jambs & throating.
18.20.2.3. Pilasters : The pilasters shall be measured for their net volume and fully described. Where
pillars of different sections and shapes are involved, they shall be in addition enumerated separately.
18.20.2.4. Backing to masonry : Brick work in backing to masonry shall be measured separately, the
description shall include all cutting and waste for bonding. The thickness shall be taken as the average
thickness of brick work.
18.20.2.5. Underpinning : Brick work in underpinning shall be measured separately and an item
for extra labour and material in wedging up on top of underpinning shall be given in square metres
measured as the length into width of the top course.
18.20.2.6. Fair cutting not exceeding 10 cm. in width or in girth, such as in splays, chamfers, etc.
shall be given in running metre. Circular fair cutting shall be measured separately.
18.20.2.7. Brick Edging : Brick edgings, such as those to roads, and the like shall be described and
given in running metres.
18.20.2.8. Filleting : Filleting in mortar, such as flashing on rooms shall be described and given in
running metres stating the shape and sectional area of fillets.
18.20.2.9. Fire brick work :
i) The bricks and fire clay mortar shall be described and the work shall be measured separately
and given in cubic metres. Work in linings to chimney shafts shall be measured separately and
shall include forming the cavity between fire brick lining and brick work.
ii) Purpose made fire bricks shall be enumerated as extra- over.
18.20.2.10. Broken glass coping : Broken glass coping shall be given in square metres and described
stating the thickness of mortar and weigh to broken glass per sq .m. of coping
18.20.2.11. Brick work around steel joists : Extra labour in cutting and fitting and brick work
round steel joists, stanchions, girders, etc. Shall be given in square metres, the girth of the joists,
girders, etc. being measured.
18.20.2.12. Sills, cornices etc: Sills and cornices and other projections, etc. of splayed, bull nosed
or any other type of purpose made or cut bricks, shall be fully described and given in running metres
stating the depth and width of the projection.
18.20.2.13. Tile Brick work : Tile brick work shall be measured separately and the rules for
measuring ordinary brick work shall be followed.
18.21. Cutting Rebates, Holes, Openings, Grooves etc. in Dressed Stone Work, Concrete and
Brick Work:
18.21.1. Scope: This specification covers dressing, finishing and mode of measurement of cutting
rebates, holes, openings, grooves, etc. in dressed stone work, concrete and brick work.
18.21.2. Size: The size of rebates, holes etc. shall be as shown in drawing.
18.21.3. Dressing and Finishing : Unless otherwise specified the dressing of the rebates, chamfers,
splays etc. shall be the same as for the abutting plain faces of work. Templates of sheet metal or
wood shall be prepared as per drawing to ensure correct dimension and shape. All the angles, curves,
splays should be correct at all points both in cross sections and longitudinally as per drawing having
no uneven edges and surfaces.
a) For dressed stone work:- Following measurements will be given in square metres when
exceeding 7.5 cms. in girth or in width unless otherwise included in the item.
(i) Sunk work to faces, beds and joints as in arch, Voussoirs and key blocks, splays,
batters, weathering, etc.
(ii) Moulded work as in cornices etc. (girth or moulding measured)
b). Following measurement shall be done separately, and given in running metres when not
exceeding 7.5 cms. in width or girth.
(i) Chamfers, arries or splays exceeding 1.25 cm. in width.
(ii) Chamfers, arrieses or splays exceeding 1.25 cm. but not exceeding 7.5cm. in width.
(iii) Rounded bull nose-angle or moulding or hollow angles.
(iv) Rebates, grooves (square, hollowed or dove tailed) in face work.
(v) Rebates, grooves (square, hollowed or dove tailed) for joints, tongues of sills etc.
(vi) Cutting chisel draft margin, cutting rectangular or dove tail mortises in dressed stones
shall be enumerated stating the size in cubic cm. The fixing with cement or leas shall be
described. Internal and external mitres and stops to chamfers moulding etc. shall be
reckoned as one running metre multiplied by the girth of moulding if the work is
measured superficially, and as one running metre, if the work is measured linearly. The
quantity thus arrived at, shall be added to main item.
c). Drilling or cutting holes shall be enumerated stating the diameter of the hole and its depth.
d). Figures, letters etc. cut into stone shall be described and enumerated stating the height.
18.21.5. For Existing Stone Walling or Concrete of Brick Works:
18.21.5.1.Cutting chase rebates, throating, grooves etc. in existing walling shall be given in running
metres and classified according to the girth as follows, except in case of throating which shall be
Not exceeding 15 cm. girth.
Exceeding 15 cm. but not exceeding 30 cm. girth.
Exceeding 30 cm. girth.
18.21.5.2. Cutting holes through existing walling and making good shall be given per cm. of depth
of cutting and shall be classified as follows :
(i) Holes up to and including 250 sq. cm. in area.
(ii) Holes exceeding 250 sq. cm. and up to and including 0.1 sq. m. in area.
18.21.5.3. Cutting openings exceeding 0.1 sq. m. area shall be given in cubic metres and the item
shall include the provision for fixing and removal of requisite shoring and temporary supports.
18.21.5.4. When new walls are bonded to existing walls, an item of labour and material in cutting,
toothing and bonding shall be given in square metres, measured on the vertical face in contact with
new work only. The spacing, size and toothing required to be cut in existing work shall be described
.
18.22. Cut Stone Door and Window Frames:
18.22.1. Scope: This specification covers the materials, sizes, dressing, fixing and mode of
measurement of cut stone door, window and ventilator frames.
18.22.2 Materials:
i) Stones :-Stones shall be as specified under specification for stone sills.
18.22.3 Size, Dressing and Fixing:
18.22.3.1 Size :-
The sections of the frames for windows, doors, and ventilators shall be as given in the contract.
The sections normally used are given below Fig.
(a) Doors and Windows :-
(i) Single paitam 75x75mm 100x75 mm
(ii) Double paitam 100x75 mm 125x75 mm 125x100 mm
(b) Ventilators :
(i) Single paitam 75 x 50 mm 125x50 mm 100x75 mm The
width of the rebate shall be equal to the thickness of shutters and the depth shall be 13 mm.
18.22.3.2 Dressing : Unless otherwise specified every member of the frame shall be fine tool
dressed on all the exposed faces including rebates. The face in contact with the wall may be left
undressed.
18.22.33 Jointing and fixing : The members of the frame shall be fixed with cement mortar 1:4 of
the type and quality as per relevant specification. The projections of the top and bottom member
which shall not be less than 15 cm., shall be well built into the. wall at both ends. The vertical
members of the frame shall be well fixed into the top and bottom horizontal members and shall have
mason's mortise and Tenon joint. The size of the Tenon shall be as shown in the Drawing. Any small
space left at the joint shall be filled with neat cement slurry. Where bottom horizontal member is not
provided, the vertical members shall be embedded at least 30 mm. deep in the stone sills or in cement
concrete sills. The fixing of the frames shall be carried out along with the work of masonry and shall
not be left to be done later on. The frame shall be well protected from damages due to other
operations connected with the construction work.
18.22.4. Fixing of Hinges:

18.22.4.1 Fixing arrangement of Hinges: The hinges can be fixed to the frame in the following
manner:
i) In this method a recess is made in the frame for fixing of wooden block 15 cm. x thickness of
shutter x width of frame, to which the hinges are fixed as for wooden frames.
18.22.4.2 Holes : The number of through holes to be left in the frame (position as shown on the
drawings) shall be as under :
2 Nos.10 mm dia. for each binge.
2 Nos. 10 mm dia. for each tower bolt
Any other holes required for other fittings and grills shall be left as shown in the drawings or as
directed by the Engineering charge. These additional holes shall be measured and paid separately.
18.22.43 Number of Hinges : The number of hinges should be as per schedule of fittings given in
relevant chapter, but at least 3 hinges should be provided for fixing one door shutter leaf and 2 hinges
for fixing of window and ventilator shutter leaf.
18.22.5 Finishing : After completion of the work, the frames shall be washed with washing soda or
any other material to remove any stains of lime, white washing or paint etc. If desired by the
Engineering charge, they may be white or colour washed, for which no additional payment shall be
made.
(a) The measurement shall be recorded in running metres. The bearings required for fixing the
frame in the wall or sills, shall not be measured.
(b) Making holes, and recesses for housing of hinges and tower bolts etc. is included in the rate
for the item and shall not be paid separately.
(c) Any extra holes required for fixing iron grills shall be measured separately.
(d) The curved frames shall be measured separately.
18.23 R.C.C. Door and Window Frames:
18.23.1. Scope:
18.23.1.1 This specification covers the materials, sizes, method of construction, fixing and mode of
measurement of R.C.C. door, window and ventilator frames.
18.23.2 Materials :
a) Cement concrete :-Unless otherwise specified, the cement concrete shall be of 1:2½:3½ mix
by volume, conforming to relevant specification. The cement, coarse, and fine aggregates and
water shall conform to the standards prescribed in relevant Specification The maximum size of
coarse aggregate shall be 10 mm.
The quantity of material required for 1 m3 of concrete shall be as follows;
(i) Cement 0.2 m3 or 61 bags. (ii) Sand - 0.534 m3 (iii) Coarse aggregate 0.748. m3
b) Reinforcement :- The reinforcement, and dowel bars shall be mild steel rods conforming to
IS 432-1960.
18.23.3 Size: As per relevant specified shall apply.
18.23.4 Reinforcement and its Fabrication:
i) The main reinforcement shall be 4 Nos. 5 mm. diameter bars, The stirrups shall be of 3 mm
diameter wires spaced 15 cm. centres.
ii) The fabrication shall be done as specified for R.C. work.
18.23.5 Casting:
a) Mould :The mould shall generally be of steel. Wooden moulds may also be permitted at the
discretion of Engineer in charge.
b) Casting : Before filling the concrete in the moulds these shall be thoroughly cleaned and then
oiled with mould oil and reinforcement skeleton placed ill the moulds in proper position. The
covers shall be as shown in the Drawings. The concrete shall be mixed as specified for plain
concrete in the relevant chapter and shall be gradually filled into the moulds and kept
continuously compacted by rodding and tamping until the mould is full. Any extra concrete
shall be struck off level with a straight edge. Alternately the compaction may be done on a
vibration platform.
c) Removal of mould : The sides of the moulds may be removed carefully by sliding after about
4 hours and any defects noticed be rectified. The R.C. frame be removed from the mould after
16 hours for curing.
d) Making depressions for Hinges & Holes :The depressions and holes for fixing up of hinges,
tower bolts, and grating etc. should be made as per drawings at the time of casting.
e) Curing: Immediately after the frames are removed from the moulds, these shall be covered
with wet canvas tip the first 24 hours from the time of casting have elapsed, Afterwards these
shall be shifted to a curing yard or placed in an immersion tank where these shall be kept
continuously moist for at least 21 days. When cured in an immersion tank the water of the tank
shall be changed every forth day.
f) Drying : After the curing period is over the units shall be stored in a shed and allowed to dry
gradually for at least 2 weeks before these are used in the construction.
g) Finishing the exposed faces with special finishes: Terrazzo or marble chips or any other
special finishes shall be provided if desired. The terrazzo layer 6 mm. thick shall be provided on
the exposed faces, after the sides have been removed (after about 4 hours). The terrazzo finish
may be in plain cement or colours added to the ordinary or white cement as the case may be.
The work of terrazzo finish shall be carried out as per specification of terrazzo flooring.
18.23.6 Fixing: The relevant chapter shall apply, but instead of Tenon and mortise joint, a dowel 12
mm. diameter 15 cm long shall be embedded 10 cm. in the vertical member and shall project 5 cm
above it. The projected portion shall fit in the hole provided in the horizontal member. The hole shall
be plugged with cement mortar 1:4.
(a) Same as for cut stone frames.
(b) Special finishes on R.C. frames shall be measured separately and paid accordingly.
18.24 Wall Covering:
18.24.1 Scope: This specification covers materials, fixing, jointing and mode of measurement of
the following :
(i) Gypsum wall boards.
(ii) Fibre building boards,
Plywood and block boards.
(iv) Chip boards and wood waste boards.
(v) Asbestos wall boards.
(vi) Other miscellaneous types bf wall boards (including plastic boards and reed, boards.)
18.24.2 Materials:
a) Gypsum wall boards:- This shall conform to I.S. Specification for Gypsum wall boards.
b) Fibre building boards :-This shall conform to 1.S. 1658-1960.
c) Plywood:- This shall conform to 1.S. 1328-1958.
d) Block boards :- This shall conform to 1.S. 1659-1960.
e) Chip boards :- This shall conform to 1.S. Specification for chip boards.
f) Asbestos wall boards :-Corrugated A. C. sheet used as wall covering shall conform to I.S.
459-1955. Plain A.C. Sheet shall conform to IS. 459-1962.
g) Nails :-Nails used as fixing accessories for wall coverings shall conform to IS 723.
h) Fixing:- These shall conform to the requirements recommended in the relevant I.S. Code of
practice for use of fixing devices in walls or ceilings.
18.24.3 Storage and Handling of Boards:
a) Gypsum boards : The boards shall be kept dry in transit and stored flat in, a clear dry place.
b) Fibre board plywood etc.: The boards shall be stored and handled in accordance with the
manufacturers instructions. They shall be stored in the room where they are to be used for a
minimum period of 24 hours before use.
18.24.4 Supporting Walls and Framework: The supporting walls and frame work for the coverings
shall be completed before the work is started. Timber or steel-stud-framing for partitions or fittings
attached to a wall shall be done in accordance with the detailed drawings and shall conform to the
specifications for wood and steel work. The assembled components such as doors, windows etc. shall
be installed in position before the wall covering work is commenced.
18.24.5 Fixing Coverage:
18.24.5.1 Fixing Gypsum wall boards:
i) The detailed drawings for fixing shall be supplied. It shall be ensured in the first instance that the
moisture content of the timber back ground is such that dimensional changes will not be serious
to cause distortion or cracking in the covering fixed on it. The nails size their spacing are given
Table No. 1 in The nailing shall be done starting from the centre of the row working outwards.
ii) Jointing: The boards shall be fixed with a joint thickness of about 6 mm. All Vertical joints shall
be staggered particularly where both sides of the wall are covered. The joints shall be filled
with Gypsum plaster. After filling the joints a thick skin of the Gypsum shall be spread about
5 cm. wide on either side of the joint and to it shall be trowelled dry a reinforcing scrim cloth
about 10 cm. wide. When metal scrim is used a stiffer plaster will be used to enable the
trowelling of scrim down to the board. The joints may be left open also if desired.
18.24.5.2 Fixing Fibre building board :
a) All fibre boards are subject to slight movement due to moisture and temperature changes and
this shall be allowed for in fixing.
b) Frame work : The frame work shall generally be of wood, Planed battens 4 cm.x2 cm. shall
be used on solid walls. The battens shall be plugged to the wall at intervals of 30 cm. On uneven
wall face the battens shall be plugged and fitted with packing pieces at the back where
necessary. If there is any possibility of dampness the battens shall be treated with odour less
preservative.
c) The size and spacing of nails is given in Table 1. The nails shall be rust less where nail heads
are exposed. Special nail recommended by the, manufacturers shall generally be used. The nails
shall be driven skew wise at about 60° inclinatidn to the direction perpendicular
to the board in alternate directions. Near the edges there shall be a minimum clear space of
12mm. from the nail to the edge of the board.
d) Joints : The type of joint shall be as per detailed drawings
(i) An open butt joint shall have at least 3 . clearance.
(ii) Joints shall not 'normally be filled with plaster but where low or medium density fibre
board is to be plastered the joints shall be left with a gap of about 6 mm. which shall be
covered with scrim bedded in plaster before the finishing coat of plaster is applied.
(iii) The uncovered joints may be bevelled or parallel grooved, using plane and chisel but is
quicker and better to use special fibre board cutter. Edges shall be rounded with glass
paper or with a rasp.
(iv) The edges if rebated for fixing purpose shall not be nailed through the rebates.
(v) Open joints may also be covered with strips of various materials. The' cover strips shall
be nailed or screwed along the centre so that the fixing passes through the open joints.
(e) Wood cover strips shall be 4.5 cm. x 1.5 cm. Wood mouldings, fibre board or hard board
can 'also be used. Plain strips cut from standard sheets can also be used for the purpose.
(f) Metal cover strips made of aluminium. chromium plated, brass moulded, plastic, linen
backed adhesive paper strip and other types of metal sections specially shaped for the
purpose I may also be used as cover strips. Linen backed adhesive board is fixed by
wetting it and pressing it over the edges of the boards.
18.24.5.3 Fixing of ply wood block boards etc. :
18.24.5.3.1 General : The plywood shall be used in the form of panels with or without stiffening.
When stiffened the same shall be done with narrow strips of class I teak wood size as given in the
detailed drawings or as directed by the Engineer in charge.
18.24.5.3.2 Protection of edges and Treatment for dampness : The edges of plywood panels shall
be protected before fixing with a suitable sealer, where there is any possibility of dampness. The back
of the plywood and also the supporting wood shall either be treated with odourless preservative or
by giving a priming coat of paint followed by a sealing coat. Both vertical as well as horizontal
panelling is possible with plywood and the one as given in the detailed drawings or as directed by
the Engineer in charge shall be followed. In horizontal panelling with plywood in large rooms, the
work may preferably be done in bays not exceeding 2.7 metres, in length. In vertical panelling the
width of panels may be 0.9 to 1.2 m.
18.24.5.3.3 Joints : The vertical joints shall always be staggered. The type of joint for plywood and
block board shall be as per detailed drawings. Where it is desired to make a butt joint in the block
board, both the edges shall be grooved and a separate tongue glued. In long lengths this joint shall
be strengthened by dowels of size and spacings as approved.
18.24.5.4 Fixing chip boards and wood waster boards : The fixing shall be done in the same
manner as for the fibre boards described in relevant chapter and spacing of supports shall be as
described in table No.1
18.24.5.5 Fixing Asbestos cement wall boards:
i) Frame : The frame shall be of wood.
ii) In fixing A.C. sheets care should be taken to avoid rigid fixing as this may cause cracking of
sheets if the supporting structure expands or shrinks. The holes for fixing shall be drilled not
punched and drilled slightly larger than the screw. The size of the screws and spacing shall be
as given in table No. 1 Corrugated sheets shall also be fixed with the same precautions as for flat
sheets but a lap over the corrugation shall be given over the joint.
iii) Jointing : In case of plain sheets the thickness of the joints shall be about 6 mm. The joint may
be covered with strips of various materials as described for fibre building boards described in
relevant chapter. The one to be used shall be as given in detailed drawings or as approved by
the 'Engineer-in charge.
18.24.5.6 Fixing a multiple layer of coverings :
i) When the number of coverings to be fixed is more than one, the first covering shall be nailed
or other wise fixed as described in relevant chapter and further coverings with suitable adhesive
as specified by the manufacturer.
ii) In the case of some covering such as fibre boards, the second or the subsequent layers may
also be nailed but the nails shall be longer than the one used for the lower covering by the
thickness of the lower coverings.
iii) For better stability and strength the successive layers may be fixed in perpendicular directions.
(that if one is horizontal the other immediately above or below it may be vertical). The joints
of the preceding layer(that is the joints shall be staggered).
iv) When bonding is done with adhesive, temporary supports shall be given to the succeeding layer
till the adhesive has set. The temporary supports may be nail driven at about 30 cm. centres
both horizontally and vertically or wood framing may be applied to the boards. When the
adhesive has set the temporary supporting nails shall be counter sunk to a depth equal to the
thickness of the face layer or wall board or any wood framing used shall be removed.
18.24.6 Mode of Measurements:
(i) The supporting members shall be measured separately.
(ii) All work unless otherwise described shall be given in square metres.
Works formed to circular surfaces shall be measured separately.
(iv) No deduction shall be made for openings not exceeding 0.4 Sq. metres.
(v) All straight and raking cutting and waste shall be included with the item concerned.
(vi) Cover strips (cover fillets) over joints shall be measured separately and given in
running
metres, materials, width and thickness of strip or fillet being stated. Edges of rounded or
chamfered shall be measured separately.
(vii) Sealing joints of Gypsum or fibre boards shall be measured in running metres giving
the type of scrim (cloth or metal).
(viii) Chamfering or rounding edges of fibre boarding and cutting "V" groove in the same
shall be given in running metres.
(ix) Treating the framework and sheets for prevention of dampness shall be measured as
specified for painting.
18.25 Cast in Place Voided Slabs:
a) Voided slabs can be either in reinforced concrete or in prestressed concrete.
b) Voids can be either circular or rectangular in shape. Void formers may be manufactured
from steel sheets, fibre reinforced cement, expanded polystyrene, HDPE, etc. They are
generally corrugated to attain sufficient rigidity in order to prevent distortion or collapse
during concreting. They should also be leak tight.
c) Void formers shall be suitably tied down in order to prevent floatation during concreting.
Care shall be taken during placement of concrete to ensure that the concrete flows fully
into the space beneath the void formers.
18.25.1 Measurement for Payment: Concrete & Steel shall be measured in accordance with the
specified item based on the quality ordered or as shown on the drawing.
18.25.2 Rate: The contract unit rate for the construction shall cover the cost of all materials including
transportation, laying, compacting, all labour, tools, equipment, sampling and testing, supervision
and all incidentals necessary for completing the work according to these specifications.
18.26 Cement Concrete Block Flooring over Cement Concrete Bedding :
18.26.1 The work shall consists of constructing cement concrete block flooring over cement concrete
(M15) bedding.
18.26.2 Construction Operations: Excavation for laying the bedding and floor protection works shall
be carried out as per specifications under proper supervision. Before laying the foundation and
protection walls, the excavated trenches shall be inspected by the Engineer to ensure that:
a) There are no loose pockets and unfilled depressions left in the trench.
b) The soil at the founding level is properly compacted to true lines and level so as to have an
even bedding.
c) All concrete and other elements are laid in dry bed.
d) Bedding of cement concrete nominal mix (M15) of 300mm thickness shall then be laid in
accordance with specifications except that the surface of the concrete shall not be given a
smooth finish.
e) Flooring shall consists of 150 mm thick cement concrete block M 15 grade
conforming to the specifications. On a layer It shall be bedded on a layer of cement
mortar (1:3) prepared as per specifications. Spalls shall be used to fill in the voids.
The joints shall be filled with cement mortar and finished neat. The stone shall break
joints and the thickness of joints shall not exceed 20 mm. The top of flooring shall
be kept 300 mm below the lowest bed level.
18.26.3 Measurement for Payment: Cement Concrete block flooring and cement concrete bedding
shall be measured in cubic metres for each class of material. Preparation of base for laying the
flooring shall be deemed incidental to the work.
18.26.4 Rate: The contract unit rate for the construction shall cover the cost of all materials including
transportation laying, compacting, all labour, tools, equipment, sampling and testing, supervision
and all incidentals necessary for completing the work according to these specifications.
18.27 Shotcrete : 18.27.1General :
18.27.1.1 Shotcrete is mortar or concrete conveyed through a hose and pneumatically projected at
high velocity onto a surface. The force of jet impinging on the surface compacts the material.
Generally a relatively dry mixture is used, and so the material is capable of supporting itself without
sagging or sloughing, even for vertical and overhead applications.
18.27.1.2 Shotcrete is generally referred to as gunite, pneumatically applied mortar or concrete,
sprayed concrete, air blown mortar and concrete, etc. However, the term `Shotcrete' will be used
throughout this part as the term is accepted internationally.
18.27.1.3 Shotcrete is suitable for a variety of new construction and repair work, but its properties are
to a great extent dependent on the conditions under which it is placed, the capability of the particular
equipment selected and in particular on the competence of the operating staff. Shotcrete can be either
plain or reinforced.
18.27.1.4 Shotcrete is done by two processes, namely, dry-mix process and wet-mix process.
Pneumatically conveyed shotcrete in which most of the mixing water is added at the nozzle is dry-
mix process. Shotcrete wherein all the ingredients, including mixing water, are mixed in the
equipment before introduction into the delivery hose in wet-mix process; the shotcrete mix may be
conveyed pneumatically or moved by displacement.
18.27.2 Materials:
18.27.2.1 Cement, aggregates, water, admixtures and reinforcement are as per Chapter 3 & 6
volume I except as mentioned as under:
18.27.2.1.1 Aggregates:
a) Fine aggregate (sand) - Sand for concrete shall comply with the requirements of IS 383 : 1970
and graded evenly from fine to coarse as per Zone II and Zone III grading. Sand failing to
satisfy this grading may however be used if pre-construction testing gives good results
(see18.27. 5). Further sand for finish or flash coats may be finer from the above grading.
However, the use of finer sands results in greater drying shrinkage, and coarse sands in more
rebound.
b) Coarse aggregate - Coarse aggregates, when used, shall comply with IS 383: 1970. It shall
conform to one of the grading given in. Chapter 3 Building materials.
18.27.3 Shotcreting Process:
18.27.3.1 General: The two basic processes are:
a) Dry-mix process, and
b) Wet-mix process.
18.27.3.2 Dry-Mix Process : In this process, a mixture of cement and moist sand is conveyed
through the delivery hose to a nozzle where most of the mixing water is added, under pressure (see
Fig. 22). The process consists of the following steps:
a) The cement and moist sand are thoroughly mixed;
b) The cement-sand mixture is fed with a special mechanical feeder or gun.
c) The mixture is forced into the delivery hose by a feed wheel or a distributor;
d) The mixed material is carried in suspension of compressed air through the delivery hose to a
nozzle, which is filled inside with a perforated manifold through which water is introduced
under pressure and intimately mixed with other ingredients; and
e) The mortar is jetted from the nozzle at high velocity on to the surface to be shotcreted.
18.27.3.3 Wet-Mix Process : In this process, all the ingredients including water are mixed before they
enter the delivery hose. It consists of the following steps:
a) All the ingredients, including mixing water, are thoroughly mixed;
b) The mortar or concrete is introduced into the chamber of the delivery equipment;
c) The mixture is forced into the delivery hose and conveyed by compressed air or other means
to a nozzle;
d) Additional air is injected at the nozzle to increase the velocity and improve the shooting
pattern; and
e) The mortar or concrete is jetted from the nozzle at high velocity on to the area to be
shotcreted.
18.27.3.4 Shotcrete may be produced by either of the processes for normal constructional
requirements.
However, difference in cost of equipment, maintenance and operational features may make one or
the other method more attractive for a particular application.
18.27.4 Properties of Shotcrete :
18.27.4.1 Shotcrete, if properly applied, is a structurally adequate and durable material capable of
excellent bond with concrete, masonry, steel, and other materials. However, these favourable
properties of sound shotcrete are contingent on proper planning and supervision, and on the skill and
continuous attention by the operating staff.
18.27.4.2 The water cement ratio for shotcrete in place normally falls within a range of 0.35 to 0.50
by mass which is somewhat lower than for most conventional concrete mixes. In general, the
physical-properties of sand shotcrete in place are comparable to those of conventional mortar or
concrete of the same composition. Most reported values for 28 days strength are in the range of 20
to 50 N/mm2 (200 kg/cm2 to500 kg/cm2). It is recommended that strength higher than 25 N/mm2
(250 kg/cm2) be specified only for the most carefully executed shotcrete jobs.
18.27.4.3 The drying shrinkage of shotcrete depends, somewhat on the mix proportions used, but
generally falls within the range of 0.06 to 0.08 percent. This is rather higher than most low slump
conventional concrete, which is generally placed in heavier sections using larger aggregates and
leaner mixes. It will tend to give more shrinkage, cracking and may require a closer joint spacing. The
durability of shotcrete is good.
18.27.4.4 Shotcrete offers advantages over conventional concrete in a variety of new construction and
repair works. It is frequently more economical because of lesser forming requirements and because
it requires only a small portable plant for manufacture and placement.
18.27.5 Pre-Construction Testing:
18.27.5.1 Testing shall be done prior to the commencement of the work in order to check the
operation of equipment, skill of the operating staff and the quality of shotcrete. The procedure is
detailed in 18.27.5.2 to 18.27.5.7.
18.27.5.2 Test panels shall be fabricated, simulating actual job conditions, by the operating staff
using the equipment, materials and mix proportions proposed for the job.
18.27.5.3 For the dry-mix process, the amount of water added at the nozzle is adjusted so that the in
place shotcrete appears to be adequately compacted and neither sags nor shows excessive rebound.
Where justified by the size and importance of the job or lack of previous experience with the
materials, it may be advisable to test two or three mixes, generally within the range of 1 part of
cement to 3 to 4; parts of sand, before deciding on the final mix proportions.
18.27.5.4 The procedure for wet-mix process is similar to the dry-mix process (see18.27.5.3), except
that the entire concrete mix is premixed to give a workability judged to be appropriate for the work,
before it is introduced to the chamber of delivery equipment. Tests on more than one mix design are
usually recommended where it is desired to include coarse aggregate in the mix. Normally 20 to 40
percent of coarse aggregate is first tried with subsequent mixes adjusted to reflect the results of the
first trial.
18.27.5.5 The panels are fabricated by gunning on to a back form of plywood. A separate panel shall
be fabricated for each mix design being considered, and also for each gunning position to be
encountered in the structure, that is, slab, vertical and overhead sections. At least part of the panel
shall contain the same reinforcement as the structure, to show whether sound shotcrete is obtained
behind the reinforcing rods, The panel shall be large enough to obtain all test specimens needed, and
also to indicate what quality and uniformity maybe expected in the structure. Generally, the size of the
panel shall be not less than 75 cm x 75 cm. The thickness shall be the same as in the structure, except
that it shall normally be not less than 7.5 cm.
18.27.5.6 Cubes or cores shall be taken from the panels for testing. The cores shall have a minimum
diameter of7.5 cm and length diameter ratio of at least one if possible. The specimens shall be tested
in compression at the age of 7 or 28 days or both.
18.27.5.7 The cut surfaces of the specimens shall be carefully examined and additional surfaces shall
be exposed by saving and breaking of the panel when it is considered necessary to check the
soundness and uniformity of the material. All cut and broken surfaces shall be dense and free from
laminations and sand pockets.
18.27.6 Mixing:
18.27.6.1 Dry-Mix Process :
a) Batching by mass is preferred.
b) The moisture content of the sand shall generally be within 5 to 6 percent to permit flow at a
uniform rate.
c) The mixing equipment shall be capable of thoroughly mixing the sand and cement insufficient
quantity to maintain continuity of placing. The mixing time shall be not less than a minute in a
drum type mixer. The mixer shall be thoroughly cleaned to prevent accumulations of batched
materials.
d) Supply of clean dry air under pressure should be ensured through an air compressor. The air
pressure should be uniformly steady (non-pulsating).The operating pressure shall drive the
material from the delivery equipment into the hose.
e) For length of hose up to 30 m, the operating pressure shall be 0.3 N/mm 2 (3 kg/cm2) or more,
for each additional 15 m length of hose pressure may be increased by 0.035 N/mm2,
(0.35 kg/cm2) and the same increase allowed for each 7.5 m that the nozzle is raised before
the gun.
f) Water under pressure shall be supplied; the water pressure shall be sufficiently greater than the
operating air pressure at the discharge nozzle. Water pressure shall also be steady and non-
pulsating.
18.27.6.2 Wet-Mix Process :
a) Batching by mass is preferred. Aggregates may be batched by volume of periodic checks are
made to ensure that the masses are maintained within the required tolerance. Water may be
batched either by volume or by mass.
b) The mixing time will depend on the mix being used and the efficiency of the mixer.
c) The other details are as per dry mix.
18.27.7 Application of Shotcrete:
18.27.7.1 Surface Preparation:
a) Shotcrete shall not be placed on any surface which is frozen, spongy or where there is free-
water.
b) Surfaces shall be kept damp for several hours before shotcreting.
c) In case of repairs, all existing deteriorated concrete shall be removed. The final cut surface
shall be examined to make sure that it is sound and perfectly shaped, all edges shall be tapered.
The surface shall be cleaned of a loose and foreign materials.
d) Exposed reinforcement shall be free of rust, scales, etc.
18.27.7.2 Formwork: Forms may be plywood sheeting or other material, true to line and dimension.
They shall be so constructed as to permit the escape of air and rebound during gunning operations.
Forms shall be oiled and dampened just before gunning. Short removable bulkheads may be used at
intersections. Appropriate scaffolding shall be erected to permit suitable positions for holding the
nozzle.
18.27.7.3 Reinforcement:
a) Reinforcement shall be so placed as to cause least interference to gunning operations.
b) Minimum clearance may be 12 mm to 50 mm between formwork and reinforcement for
mortar work and concrete mix respectively.
c) Clear spacing between bars shall be not less than 65 mm.
d) As far as possible, bars shall be so arranged as to permit shooting from the opposite side.
e) Lapped reinforcing bars shall not be tied together; they shall be separated by at least 50 mm.
f) For repair work, existing work may be fixed with reinforcement by nails.
g) All detailing shall be as per IS 456 : 1978.
18.27.7.4 Alignment Control: Adequate ground wires shall be installed to ensure thickness and
surface planes of shotcrete build up.
18.27.7.5 Placing of Shotcrete:
a) Shotcrete may be built up in layers. Shotcrete shall be forced behind bars. When bars are closely
spaced more than one bar may be shot from each position of the nozzle. Avoid
building up on the front face of the bar.
b) The first layer shall completely embed the bar for walls, columns and beams, beginning at the
bottom.
18.27.7.6 Rebound :
a) Rebound is aggregate and cement paste which ricochets off the surface during the
application of shotcrete. Rebound may be as below:
Surface Percentage of Rebound
Floors or slabs 5-15
Sloping and vertical walls 15-30
Overhead work 25-50
b) Rebound shall not be worked back in to concrete .it shall not be included in later batches.
18.27.7.7 Preparation for Succeeding Layers :
The earlier layer shall be allowed to take initial set before the second layer is commenced. Then
laitance, loose material and rebound shall be removed. The surface shall be thoroughly sounded with
a hammer for drummy areas resulting from rebounding pockets or lack of bond. Drummy areas shall
be cut off and replaced with succeeding layers. Surfaces to be shot shall be damp.
18.27.7.8 Construction Joints: Construction joints shall generally follow the principles as laid
down in Chapter 6 (Vol. 1).
18.27.7.9 Finishing: The natural gun finish is preferred both from structural and durability
considerations. Finishing may be difficult for dry-mix work.
18.27.7.10 Suspension of Work:
a) The work shall be suspended when exposure to high wind, breezing or rain is likely.
b) When work is stopped, the shotcrete shall be sloped off to a thin edge and then the work
resumed after cleaning the surface.
18.27.7.11. Curing: The surfaces shall be kept continuously wet for at least 7 days.
APPENDIX À'
BITUMEN FELTS (FIBRE HESSIAN BASE)
A-1 Weights: The weights of the ingredients used in the manufacture of bitumen felts per 10 sqm
shall be not less than those specified in Table A-1.
Table - A-1 : Minimum Weights of Bitumen Felts

S. Type of felt for 10 sqm
No. Untreated Saturant Coatent Bitumen Total weight of the
Base content finished bitumen Felt
in dry
condition with
mica Dusting powder
Min.
kg kg kg kg kg
Fibre Base
(i) Type 2 Grade 1 5.0 4.5 12.9 11.9 22.6
(ii) Type 2 Grade 2 4.0 4.5 21.8 17.1 30.8
Hessian Base
(iii) Type 3 Grade 1 2.3 1.8 17.7 12.1 23
(iv) Type 3 Grade 2 2.3 1.8 31.8 20.2 37.1
Note : 1. The weight of the untreated base shall be taken en as in the dry condition.
2. Includes allowance for 0.5 kg minimum mica dusting powder in dry condition.
A-2 Testing:
A-2.1 Frequency of test shall be decided by the Engineer-in-charge depending on quantum of work.
From each of the rolls one piece 3 m long and the full width of the felt shall be cut out for preparing
test specimens. The first 2M. of the roll shall not be selected for this purpose. The lengths of felt so
selected shall be free from abnormal defects and shall be truly representative of the whole
consignment. The selected pieces of felt shall be dispatched without breakage or distortion, wrapped
up in water proof paper or other similar materials so as to cause no damage to the material during
transit. In case the material has stuck together, no heat shall be applied to separate the layer but the
whole roll shall be sent for testing and the fact shall be reported.
The samples, when tested as per IS:1322 shall conform to the requirements given in Table A-II.
Table A-II : Sample Size
No.. of rolls in No. of rolls to be selected Permissible no. of Sub-sample
the lot in the sample defective rolls sizes, no. of
rolls to be selected
1 2 3 4
Up to 100 5 0 2
101 to 150 8 0 3
151 to 300 13 0 4
301 to 500 20 1 5
501 to 1000 32 2 6
1001 to 3000 50 3 8
3001 and above 80 5 10
: - 1. All the rolls taken as per columns 2 shall be inspected for width, length and visible external
defects.
2. The rolls taken as per column 4 shall be tested for breaking strength, pliability, storage sticking,
heat resistance, water absorption and pressure head.
These rolls shall be taken at random from the lot, and in order to ensure randomness of selection,
random number tables may be used. In case random number tables are not available, the
following procedure may be adopted for the selection of the rolls.
Starting from any roll in the lot count them as 1,2,3... r and so on, in one order. Every r th roll
thus counted may be selected till the requisite number of rolls for the sample is obtained, r
being the integral part of N/n, where N is the number of rolls in the lot and n the number of
rolls to be selected in the sample.
A-2.2 From each of the rolls one piece 3 m long and the full width of the felt shall be cut out for
preparing test specimens. The first 2 m of the roll shall not be selected for this purpose. The lengths
of felt so selected shall be free from abnormal defects and shall be truly representative of the whole
consignment. The selected pieces of felt shall be despatched without breakage or distortion, wrapped
up in water proof paper or other similar materials so as to cause no damage to the material during
transit. In case the material has stuck together, no heat shall be applied to separate the layer but the
whole roll shall be sent for testing and the fact shall be reported.
A-3 Tests: The samples, when tested as per IS : 1322 shall conform to the requirements given.
A-4 Criteria for conformity: The lot shall be considered to be in conformity with the
requirements of the standard if the following conditions are satisfied :
(a) The number of rolls found defective with respect to width, length and visible external defects
do not exceed the corresponding number given in column 3 of table II
(b) From the observed values of breaking strength, the average X and the range R are calculated
for each direction (that is, warp way and weft way) separately and the value of the expression X
- 0.6 R is found to be greater than or equal to the applicable specified value.
Note 1. Average X is the value obtained by dividing the sum of the observed values by the
number of observed values.
Note 2. Range R is the difference between the maximum and minimum in a set of observed
values.
(c) For all the other characteristics (except breaking strength) all the test pieces satisfy all the
requirements of the characteristics individually.
APPENDIX 'B'
GLASS FIBRE BASE BITUMEN FELT
B-1 Weight: The weight of the ingredients used in the manufacture of glass fibre felts for 10
square metre shall not be less than those specified in Table B-I.
Table B-1: Minimum Weight Of Bitumen Glass Fibre Base Felt
For 10 Square Metres
S. Type of felt Untreated Treated base Coatant Total weight in dry
No. base (kg) (kg) (kg) condition including
surfacing materials (kg)
1. Type 2 Gr. 1 - 0.4 15.3 18.0
B-2 Sampling: All the rolls of the same type and grade and from the same batch of manufacture, in
one consignment shall constitute a lot. The conformity of the lot to the requirements of this standard
shall be determined on the basis of the inspection and test carried out on the samples selected from
the lot. The number of rolls to be selected from a lot shall depend upon the size of the lot and shall
be in accordance with Table B-II.
Table B-II: Sample Size and Criterion of Conformity

No. of rolls in No. of rolls to be selected Permissible no. of Sub-sample
the lot in the sample defective rolls sizes, no. of
rolls to be selected
1 2 3 4
Up to 100 5 0 2
101to150 8 0 3
151 to 300 13 0 4
301 to 500 20 1 5
501 to 1000 32 2 6
1001 to 3000 50 3 8
3001 and above 80 5 10
Note : 1. All the rolls taken as per columns 2 shall be inspected for width, length and visible
external defects.
2. The rolls taken as per column 4 shall be tested for breaking strength, pliability, storage
sticking, heat resistance, water absorption and pressure head.
These rolls shall be taken at random from the lot and in order to ensure randomness of selection,
random number tables may be used. In case random number tables are not available, the following
procedure may be adopted for the selection of the rolls.
Starting from any roll in the lot count as 1, 2, 3...r and so or in one order. Every rth roll thus counted
may be selected till the requisite number of rolls for the sample is obtained, r being the integral part
of N/ n, where N is the number of rolls in the lot and n the number of rolls to be selected in the
sample.
From each of these rolls one test sample 3 m long and the full width of the felt shall be cut out for
preparing test specimens. Test samples shall not be taken from damaged portion of the rolls, if any,
the required number of test specimens shall be taken from each of the test sample and subjected to
the corresponding tests.
B-3 Tests: The sample, when tested as per IS : 7193 shall conform to the requirements given.
B-4 Criteria for conformity The lot shall be considered to be in conformity with the requirements
of the standard if the following conditions are satisfied :
(a) The number of rolls found defective with respect of width, length and visible external
defects, do not exceed the corresponding number given in column 3 of table .
(b) From the obsessed values of breaking strength, the average X and the Range R are calculated
for each direction (that is, warp way and weft way) separately and the value of the expression
X-0.6 R is found to be greater than or equal to the application specified value.
Note : 1. Average X is the value obtained by dividing the sum of the observed value by the number
of observed value.
2. Range R is the difference between the maximum and minimum is a set of observed
values.
(c) For all the other characteristics (except breaking strength), all the test pieces satisfy all the
requirements of the characteristics individually.
APPENDIX : `C'
Safety at Construction Sites.
C-1: As per PWD Manual (Clauses as per Manual)
3030 Construction site Safety Code as per PWD Manual:
30.30.1 General -
(i) Suitable scaffolds should be provided for workmen on all works that can not safely be done
from the grounds or from solid construction except such short period work as can be done
safely from ladders. When a ladder is used an extra Mazdoor shall be engaged for holding the
ladders and if the ladder used for carrying materials as well, suitable foot holds and hand holds
shall be provided on the ladder and the ladder shall be given an inclination not steeper than 1/4
to 1 (1/4 horizontal and 1vertical).
(ii) Scaffolding or staging more than 12 ft. above the ground or floor, swung or suspended from an
overhead support or erected with stationary support shall have a guard rail properly
attached, bolted braced and otherwise secured at least 3 feet high above the floor or platform of
such scaffolding or staging and extending along the entire length of the outside the ends thereof
with only such opening as may be necessary for the delivery of materials. Such scaffolding
staging shall be fastened as to prevent it from swaying from the building or structure.
(iii) Working Platform, Gangways, and Stairways should be so constructed that they should not sag
unduly or unequally, and if the height of the platform or the Gangway or the Stairway is more
than 12 feet above ground level or floor level, they should be closely boarded should have
adequate width should be suitably fenced, as described in (ii) above.
(iv) Every opening in the floor of a building or in a working platform be provided with suitable
means to prevent the fail of persons or materials by providing suitable fencing or railing whose
minimum height shall be 3' 10".
Safe means of access shall be provided to a working platform and other working places. Every ladder
shall be securely fixed. No portable single ladder shall be over 30 feet in length, while the width
between side rails in rang ladder shall in no case be less than 11½" for ladder up to and including 10
ft. in length and for longer ladders this width should be in-respect at least 1/a" for each additional feet
of length, uniform step spacing shall into exceed 12". Adequate precautions shall be taken to prevent
danger from electrical equipment. No material on any of the sites of works shall be so stacked or
placed as to cause danger or inconvenience to any person or the public. The contractor shall also
provide all necessary fencing and lights to protect the Public from accident and shall be bound to
bear the expenses of defence of every suit. Action or other proceedings at law that may be brought
by any person for injury sustained owing to neglect of the above precautions and to pay any damages
and cost which may be awarded in any such suit, action or proceeding to any such person or which
may with the consent of the contractor be paid to compromise any claims by any such person.
30.30.2 Excavation and Trenching -All trenches four feet or more in depth shall at all times be
supplied with at least one ladder for each 100 feet length or fraction thereof. Ladder shall be extended
from bottom of the trench to at least 3" above the surface of the ground. The sides of the trenches
which are 5' or more in depth shall be stepped back to give suitable slope, or securely held by timber
bracing, so as to avoid the danger of sides to collapse. The excavated materials shall not be placed
within 5' from the edge of the trench or half of the depth of the trench whichever is more. Cutting
shall be done from top to bottom. Under no circumstances under mining or undercutting shall be
done.
30.30.3 Demolition : Before any demolition work is commenced and also during the process of the
work
(a) All roads and open areas adjacent to the work site shall either be closed or suitably protected.
(b) No electric cable or apparatus which is liable to be a source of danger over a cable or
apparatus used by the operator shall remain electrically charged.
(c) All practical steps shall be taken to prevent such danger to persons employed from risk of fire
or explosion of flooding. No floor, roof, or other part of the building shall be so overloaded
with debris or materials to render it unsafe.
30.30.4 Miscellaneous -All necessary personnel safety equipment as considered adequate by the
Engineer-In-Charge should be kept available for the use of persons employed on the site and
maintained in a condition suitable for immediate use and the contractor should take adequate steps
to ensure proper use of equipment by those concerned.
(a) Workers employed on mixing Asphaltic materials, Cement and lime mortars shall be
provided with protective footwear and protective goggles.
(b) Those engaged in white washing and mixing or stacking of cement bags or any material
which is injurious to the eye shall be provided with protective goggles.
(c) Those engaged in welding works shall be provided with welders protective eye shields.
(d) Stone breakers shall be provided with protective goggles and protective clothing and seated
at sufficiently safe intervals.
(e) When workers are employed in sewers and manholes, which are in use, the contractor shall
ensure that the manhole covers are opened and are ventilated at least for an hour before the
workers are allowed to get into the Manholes, and the Manholes so opened shall be cordoned of
with suitable railing and provided with warning signals or boards to prevent accident to the
public.
(f) The contractor shall not employ men below the age of 18 years and women on the work of
painting with products containing lead in any form. Whenever men above the age 18 are
employed on the work on lead painting the following precaution should be taken.
1. No paint containing lead or lead products shall be used except in the form of paste or
ready made paint.
2. Suitable face masks should be supplied for use by workers when paint is applied in the
form of spray or surface having lead paint dry rubbed and scraped.
3. Over rails shall be supplied by the contractor to the workmen and adequate facilities shall
be provided to enable the working painters to wash during and on cessation of work.
(ix) When the work is done near any place where there is risk of drawing, all necessary equipment
should be provided and kept ready for use and all necessary steps taken for prompt rescue of
any person in danger and adequate provision should be made for prompt first aid treatment of all
injuries likely to be sustained during the course of the work.
(x) Use of Hoisting mechanical and tackle including their attachments, anchorage and supports
shall conform to use of following standard or conditions.
(a) These shall be of good mechanical construction, sound materials and adequate strength
and free from patent defect and shall be kept in good repair and in good working order.
(b) Every rope used in hoisting or lowering of materials or as a means of suspension shall
be of durable quality and adequate strength, and free from patent defects.
(2) Every crane driver or of hoisting appliances operator shall be properly qualified and no
persons under the age of 21 years should be in charge of any hoisting machine including
any scaffolding or give signal to the operators.
(3) In case of every hoisting machine and of every chain ring hook, shackle swivel and pully
block used in hoisting or lowering or as mean of suspension the safe working load shall
be ascertained by adequate means-Every hoisting machine and all gear referred to above
shall be plainly marked with the safe working load. In case of a
hoisting machine having a variable safe working load, each safe working load of the
conditions under which it is applicable shall be clearly indicated. No part of any machine
or any gear referred to above in this paragraph shall be loaded beyond the safe working
load except for the purpose of testing.
(4) In case of departmental machines the safe working load shall be notified by the Electrical
engineer in charge. As regard contractors machines, the contractors shall notify the safe
working load to the machine to the Engineer-In-Charge, whenever he brings any
machinery to site of work and get it verified by the electrical engineer concerned.
(xi) Motors, Gearing, Transmission, Electric Wiring and other dangerous parts of hoisting
appliances should be provided with efficient safe guards. Hoisting appliances should be
provided with such means as will reduce to the minimum risk of accidental descent of the load.
Adequate precautions should be taken to reduce to the minimum risk of any part of a suspended
load becoming accidentally displaced. When workers employed in electrical installations which
are already enogised insulating mats, wearing apparel, such as Gloves, Sleeves and boots as
may be necessary should be provided. The workers should not wear any rings, watches and
carry keys or other materials which are good conductors of electricity,
(xii) All scaffolds, ladders and other safety devices mentioned or described herein shall be
maintained in safe condition and no scaffold. ladder or equipment shall be altered or removed
while it is in use. Adequate washing facilities shall be provided at near places of work.
(xiii) These safety provisions should be brought to the notice of all concerned by display on a notice
board at a prominent place at the work spot. The person responsible for compliance of the safety
code shall be named therein by the contractors.
(xiv) To ensure effective enforcement of the rules and regulations relating to Safety Precaution the
arrangements made by the contractor shall be open to inspection by the Labour Officer,
Engineer-In-Charge of the department or their representatives.
(xv) Notwithstanding the above clauses from (i) to (xiv) there is nothing in these to exempt the
contractor, to exclude the operations of any other Act or Rules in force in the Republic of India.
C2: As per SP 70: Hand Book on Construction Safety Practices (Published by BIS)
Construction Safety Practices:
1 Excavation:
1.1 Fencing:
1.1.1 Where deep excavation is going on and there is likelihood of the public or cattle frequenting the
area, suitable protective fencing should be erected and also sufficient number of notice boards and
danger signals should be provided to prevent accidents by falling of persons in excavated trenches/
pits. For excavated sites close to public roads/pathways, the area and the notice boards should have
danger lights during darkness hours.
1.1.2 Barriers or coverings should be provided to excavations, shafts, pits and openings having a
vertical fall distance of more than 2 m, except during the period necessary for the access of persons
and movement of plant equipment and materials. A structure made of timber or other suitable
material should be erected for excavating and earthwork operations in order to prevent
any fall of rock or displacement of earth or other material adjacent to or forming the sides of the
excavations.
1.2 Shoring :
1.2.1 Timber has been used traditionally for shoring. Aluminium shores using hydraulic jacks to
hold them in place are also used these days. They are economical and lightweight, can be installed and
dismantled easily and have a longer life. They are also more safe than timber to use.
1.2.2 Installation :
As far as possible, the installation of shores should be done from the surface that is, vertical shores
should be placed from surface and the first horizontal brace should be installed just below the surface
from above. The operator should go down in the trench with the help of a ladder which is long
enough to install the next lower brace or trench jack, etc. Thus, the trench is made safe for him to
descend to install additional horizontal braces. The trench jack or horizontal braces should never be
used as a ladder for getting in or out of a trench as they are not designed to take vertical load.
1.2.3 Removal :
i) When the removal of shoring is planned, the possible collapse of trench sides should be
anticipated. The newly installed utility line will then be safeguarded in the normal course by
being covered with loose or compact fill before shores are removed. If the trench is likely to
cave in on removal of the shores, it can be filled up to the bottom of the horizontal brace. It is
a safe way for the worker to go down on the ladder and remove this brace, after which additional
trench space can be filled up to the next horizontal brace or screw jack.
ii) If the trench is to stay after the removal of shoring, the latter should not be removed till all work
within the trench is completed and the newly installed utility line has been protected or covered.
iii) A worker can then use a ladder to descend to the bottom of the horizontal trench jack and
remove it. The remaining horizontal jacks should be removed as he ascends the ladder. The
removal of shoring is a hazardous work. A worker should never be permitted to engage in this
work single handed.
1.2.4 Loose Site Material : The most serious safety problem associated with deep highway cut is
that of landslides. This may occur during the work or any time after completion. Damages include
loss of life or body injury, more often after heavy rains when the soil loosens and becomes heavy with
water. All loose stones, projecting lumps or earth should be removed from the trenches. The
excavated sides of a trench should be adequately guarded.
1.2.5 Minimum Check and clear Edge of Trench: There is a tendency to dump the excavated
material just on the edge of the trench where excavation is done manually. The material may slide
back into the trench or apply additional load on shoring. A provision of clear berm of a width not
less than one-third of the final depth of excavations is recommended. In areas where this width of
the berm is not feasible, the reduced berm width of not less than 1 m should be provided. It is always
better to provide substantial toe board to prevent `roll back' into the trench.
13 Plant and Machinery: The excavation may be done manually or with the help of equipment
depending on the volume of work and site conditions. The risk of accidents in mechanical
excavations are more due to the speed of excavation and dumping of the material. The following
safety measures are recommended.
1.3.1 The excavating equipment should be parked at a distance of not less than the depth of the
trench, or at least 6 m away from excavated sides for trenches deeper than 6 m.
1.3.2 With the use of power shovels and draglines, the banks of trenches become unstable and thus
dangerous for persons working nearby. These conditions should be watched and suitably remedied.
1.3.3 The vehicles should not be permitted to be driven too close to the pit. Care should be taken for
locating roads leading to or from the pit. While loading manually, the vehicle should not be taken
too near the wall of the pit. Use of spot logs will reduce risk of accidents where the vehicle is reversed
for loading.
1.3.4 Workers should be provided with proper tools Maximum hardness is the primary requirement
for cutting edges and striking faces of tools. Overlooking the importance of providing the right tools
for the job is perhaps the most serious risk to workers.
1.3.5 Workers using tools should guard against the danger arising out of the sudden movement of
material which may throw them off balance. They should be adequately spaced to avoid being
accidentally struck by tools of others working nearby.
1.4 Access and Escape: The workers should be able to escape fast in the event of any mishaps during
excavation. It is recommended that one ladder should be provided for every length of 15 m or fraction
thereof in the case of hazardous work, and 30 m of length or fraction thereof in the case of relatively
less hazardous work. Quite often the pathways become slippery due to accumulation of mud, sand
or gravel. This should be avoided. Further, the pathways should be strong enough to withstand the
intended use. Similarly, gangways should be of superior construction. The planks used should be
strong, laid parallel to the length of the gangway and fastened together against displacement. They
should be thick and have cleats for safe walking. Gangways should be kept clear of excavated
material and other obstruction.
1.5 Other Precautions:
i) Many accidents occur due to falls in unfenced trenches. Such accidents are more common
during the rainy season. Fences, guards or barricades should be erected to prevent persons or
livestock from falling into them. At night time, all public sidewalks and walkways should be
adequately illuminated, and warning lights placed at proper sites to ensure safety of pedestrian
and vehicular traffic. Sidewalks tend to become unstable during monsoons. They should be
braced in the wet season. During excavation, the excavated sides should have the provision of
steps or gradual slopes to ensure safety of men and machines in the area. It is possible that
harmful gases and fumes are present in a trench. Gases, vapours and their metabolizes absorbed
by a human organ create morphological abnormalities and the individual develops symptoms of
poisoning. To prevent such mishaps, dilution and exhaust ventilation system should be used to
reduce the concentration of gaseous matter to the recommended hygiene standards.
ii) Explosive mixed gases may also be present in the trenches. Air containing more than 1.5
percent of flammable gases by volume is dangerous. Gases and fumes should be rendered
harmless or discharged at points that are sufficiently remote from the trenches.
iii) Internal combustion engines emit hydro-carbon, carbon monoxide and nitrogen oxides, which
are dangerous to health. Hence no internal combustion engine should be operated in a trench
unless adequate precautions are taken.
iv) Burrowing or mining or what is known as `gophering' should not be allowed. In any trench
where such methods are being followed, the cavity belt should be eliminated by cutting it back
to the bare slope before removing any further material from the section of the trench.
v) Workers normally take their lunch under the shade near their work sites. If shade is not
available, they tend to sit in the shade or undercut of the trench. This practice should be
prohibited. While excavating near or below the building foundations, the latter should be
supported by shoring, bracing or underpinning as long as the trench remains open.
1.6 Common Hazards : Vibrations caused by the operation of machinery at sites adjacent to the
excavated pits may cause collapse of walls unless they are properly braced. Further, quick sand is a
dangerous phenomenon which necessitates the use of continuous steadying.
Damp sand is non-stable and for proper support it may need bracing. (see Table 1). 1.7
Responsibility of Supervisor:
1.7.1 Safety Check: Experienced and qualified supervisors should be put in charge of the excavation
work. They should understand their responsibilities and the details of all safety rules. A supervisor
should have the authority to enforce all safety rules at site, prevent the use of defective safety
appliances, rigging of tools and materials and to disallow any worker to handle jobs for which he is
not qualified. The supervisor should brief workers about the working plan before the start of the
work and explain potential hazards to them. The excavation work should be inspected by a qualified
engineer once a week and after every heavy spell of rain or storm. Defects, damage or dangers found
should be reported immediately to the site incharge and corrective action taken. He should pay a
special attention to water pipelines, electric cables lying below the surface or during excavations of
underground structures. The supervisors should ensure that all workers working under him are
provided with safety appliances and protective equipment, and that they use it. The format of the
Supervisor's Monthly Safety Report is given as Annex À'. The worksheet for observation is attached
as Annex `B'. General instructions for shoring and timbering of trenches is given in table 1.
3. Piling and Deep Foundations:

3.1 General: A basic step in safety in piling is that one must know the elements of machinery and
equipment, how they can cause accidents and what steps should be taken by the operator to avoid
accidents. Machines and equipment differ widely, depending upon the process and mode of piling,
manufacturer's specialties, specification and allied factors. The safety requirements of each machine
should be understood.
3.2 Piling Rigs : The legs of the tripod should be properly spiked in the ground. This will prevent
accidents due slipping up of the tripod legs when rested on a paved ground or sleepers. The shear
legs and bases become thin and fatigued with usage. They should be replaced frequently. The failure
of a pulley due to shearing of bolt or pin is quite common. Therefore, frequent check-ups of the
pulley are essential. The wire rope forms the link between the main piling tools and the winch.
Following regular checks are required in this respect.
a) Check for loose strands and wear, deformation, corrosion and breakage of wires.
b) Check whether the end of the rope has become loose or has slipped wire clips or wire
sockets.
c) Check against slippage of rope from the sleeve during work.
d) Check if there is any occurrence of torsion while working and if so, rewind it normally at
once.
e) Check if there are any adhesions like mud, earth, etc., on the rope. If so, clean with wire
brush or compressed air.
f) Check if the grease applied on the rope is adequate
g) Check for wear and cracks on the lining of the clutches and brake band; and the engine
condition.
3.3 Field Operations : The common hazards in various field operations such as sheet piling, well
foundation are mentioned below:
3.3.1 Sheet piling are normally used for construction of cassion or cofferdam to permit the de-
watering of water for efficient under water working. They are handled manually, lifted by cranes
and lowered by hammer or vibrostroker. The accidents due to drowning and injuries while handling
are very common. These can be minimized by adopting the following precautions:
a) Hand ropes should be tied to controUprevent the movement of steel sheet sections that are
transported.
b) Stirrups should be provided to workers engaged in interlocking the sheets.
c) Adequate pumping facilities shall be provided at cofferdam. Also adequate means of escape,
such as ladders and boats shall be provided at cofferdams for protection of workers in case of
flooding.
d) Adequate supplies of life saving equipment shall be provided for workers employed on
cofferdams. When sheet sections are being removed their movement shall be controlled by
cables and other effective means.
BIS Codes on Construction Safety:

S. No. Title
818:1968 Code of practice for safety and health requirements in electric and gas
welding and cutting operations first revision)
930:1977 Wooden extension ladders for fire brigade use (first revision)
1197:1970 Code of practice for laying of rubber floors (first revision)
1902:1993 Code of practice for preservation of bamboo and cane for non-structural
purposes (jlrst revision)
1904:1986 Code of practice for design and construction of foundations in soils:
General requirements (third revision)
1905:1987 Code of practice for structural use of un-reinforced masonry (third
revision)
1989 Leather safety boots and shoes:
2171:1999 Portable fire extinguishers, dry powder (cartridge type) (third revision)
2190:1992 Selection, installation and maintenance of portable first-aid fire
extinguishers - Code of practice (second revision)
S. No. Title
2750:1964 Steel scaffoldings
2925:1984 Specification for industrial safety helmets (second revision)
3016:1982 Code of practice for fire precautions in welding and cutting operations
first revision)
3696 Safety code of scaffolds and ladders
(Part 1) :1987 Scaffolds
(Part 2) :1991 Ladders
3764:1992 Excavation work - Code of safety first revision)
4014 Code of practice for steel tubular scaffolding:
(Part 1): 1967 Definitions and materials
(Part 2) :1967 Safety regulations for scaffoldings
4082:1996 Recommendation on stacking and storage of construction materials at
site (second revision)
4130:1991 Demolition of buildings - Code of safety (second revision)
4571:1977 Specification for aluminium extension ladders for fire brigade use (first
revision)
4770:1991 Rubber gloves for electrical purposes (first revision)
4912:1978 Safety requirement for floor and wall openings, railings and toe boards
(first revision)
5121:1969 Safety code for piling and other deep foundation
5216 (Part 1) : Guide for safety procedures and practices in electrical work: Part 1 General
(first revision)
1982
5916:1970 Safety code for construction involving use of hot bituminous materials
6194:1971 Intermittent positive pressure respirator, bag type, manually operated
6922:1973 Criteria for safety and design of structures subject to underground blasts
6994 (Part 1): Specification for safety gloves: Part 1 Leather and cotton gloves
1973
7205:1974 Safety code for erection of structural steel work
7293:1974 Safety code of working with construction machinery
7969:1975 Safety code for handling and storage of building material
8758:1993 Recommendations for fire precautionary measures in the construction of
temporary structures and pandals (first revision)
8989: Safety code for erection of concrete frame structure
9457:1980 Safety colours and safety signs.
13415:1992 Code of safety for protective barriers in and around buildings
S. No. Title
13416 Recommendations for preventive measures against hazards at work places:
(Part 1) :1992 Falling material hazards prevention
(Part 2) :1992 Fall prevention
(Part 3) :1994 Disposal of debris
(Part 4) :1994 Timber structure
(Part 5) :1994 Fire protection
13430:1992 Code of practice for safety during additional construction and alteration
to existing buildings.
S.No. IS No. Subject

1. 2645-1975 Specifications for integral cement water proofing compounds.
2. 702-1988 Specifications for Industrial Bitumen (2nd Revision).
3. 1322-1993 Specifications for Bitumen felts for water proofing and damp
proofing (4th Revision).
4. 3384-1986 Specifications for bitumen primer for water proofing and damp
proofing (Reaffirmed 1990) (1st Revision).
5. 13205-1991 Code of practice for the application of Polyurethane insulation by
the situ pouring method. (Reaffirmed 2001).
6. 73-1992 Specification for Paving Bitumen (2nd Revision).
7. 7193-1994 Specification for Glass Fibre base coal tar Pitch Bitumen felts
(Amendment) (1st Revision).
8. 12432 (Part 3) Application for spray applied insulator - Code of safety : Part 3
Polyurethane/ Polyisocyarurate.
9. 3370 (Part -I) Code of practice for concrete structures for storage of liquid : Part
1 General Requirements.
10. 12200 Provision of Water Stops at Transfers Construction Joints in
Masonry and Concrete Dams - Code of Practice.
CHAPTER No. 19
SANITARY INSTALLATIONS
CHAPTER No. 19 : SANITARY INSTALLATIONS
CONTENTS
19.1 Scope 3
19.2 Terminology 3
19.3 Water Closet 6
19.4 Urinals 10
19.5 Flushing Cisterns 13
19.6 Foot Rest 18
19.7 Wash Basin 18
19.8 Towel Rail 19
19.9 Sink 20
19.10 Draining Board 20
19.11 Shelves For Wash Basin 21
19.12 M.S.Stays & Clamps 21
19.13 Mirror 22
19.14 Bath Tub 22
19.15 Pillar Taps 24
19.16 Toilet Paper Holder 24
19.17 Showers 25
19.18 Construction of Septic Tank 25
19.19 Soak Pit 27
19.20 Dispersion Trench 27
Appendix À' Methods of inspection for Defects of
Bath Tubs 28
Appendix `B'Recommended Sizes of Septic Tanks 29
Figures 31-63
Rajasthan PWD Building Specifications 2014 Chapter 19 : Sanitary Installations Page 1 of 65


CHAPTER No. 19
SANITARY INSTALLATIONS
19.1 Scope:
All Vitreous Sanitary Appliances (Vitreous China) shall conform to IS: 2556 (Part-I) 1994 for
general requirements and relevant IS codes for specific requirements.
19.2 Terminology:
a) Antisiphon Pipe: A ventilating pipe connected to or close to the outlet side of a trap seal.
b) Automatic Flushing Cistern (Fig 20): A flushing cistern arranges to discharge its content by
siphonage at regular intervals, determined by the rate at which water is fed into the cistern.
c) Ba11 Cock: A faucet opened or closed by the fall or rise of a ball floating in the surface of
water.
d) Ba11 Valve: A simple non return valve consisting of a ball resting on a cylindrical seat
within a fluid passageway.
e) Bell Mouth: An expanded rounded entrance to a pipe or orifice.
f) Bend: Length of pipe bent or cast into an angle shape
g) Bib Tap: A tap with a horizontal inlet and nozzle bent to discharge in a downward direction.
h) Blister: A raised portion of the surface protruding not more than one millimeter above the
surface and not greater than 3mm in its greatest dimension.
i) Box Union: A device for joining two threaded pipes.
j) Branch:
A special form of vitrified sewer and cast iron pipe used for making connections to a
sewer or water main. The various types are called T, Y, T-Y, double Y, and V branches,
according to their respective shapes.
Any part of piping system other than a main.
Branch Vent: A vent connecting one or more individual vents with a vent stack or stack
vent.
Building combined Drain or Sewer: A building drain or sewer which conveys sewage
and storm water.
Building (House) Drain: That part of the lowest piping of a drainage system which
receives the discharge from soil, waste and other drainage pipes inside the walls of the
building and conveys it to the building (house) sewer beginning 0.9 m outside the
building wall.
iii) Building (House) sewer: That part of the horizontal piping of a drainage system which
extends from the end of the building drain which receives the discharge of the building
drain and conveys it to a public sewer, private sewer, individual sewage

disposal system or other point of disposal. Also called a house connection.
iv) Building (House) Trap: A device, fitting or assembly of fittings installed in the building
drain to prevent circulation of air between the drainage system of the building and the
building sewer.
v) Building Sanitary Drain: A building drain which conveys sewage but does not convey
storm water.
vi) Building ( Sanitary) Sewer: A building sewer which conveys sewage but does not
carry storm water.
vii) Building (Storm) Drain : A building drain which conveys storm water but does not
convey sewage.
viii) Building (Storm) Sewer : A building sewer which conveys storm water but does not
convey sewage.
1) Caulked:
i) The Process of driving, pouring or forcing lead, oakum, plastic or other material into a
joint to make it leak proof.
ii) The material used in the caulking process.
Caulked Joint: A spigot and socket joint in which the jointing material is compacted
by means of caulking tool and hammer.
m) Chase: A continuous recess in wall, floor or ceiling for the purpose of holding pipes and
conduits.
n) Cistern: A fixed container for water in which the water is at atmospheric pressure. The
water is usually supplied through a ball valve.
o) Collar: A pipe fitting in the form of sleeve for jointing the spigot ends of two pipes in the
same alignment.
p) Cowl: A Hood on the top of a vent pipe or soil stack.
q) Craze or Crazing: Fine cracks in the glaze.
r) Cross: A pipe fitting used for connecting four pipes at right angles.
s) Fittings: Coupling, flange, branch, bend, tee, elbow, union, waste plug, P or S trap with vent,
ferrule, stop tap, bib tap, pillar tap, globe tap, ball valve, cistern, storage tank, baths, water
closets, boiler geyser, pumping set with motor and accessories, meter, hydrant valve and any
other article used in connection with water supply, drainage and sanitation.
t) Float Valve: A valve in which the closer to an opening such as a plug or gate, is actuated by
a float to control the flow in to a tank.
u) Flush Bend: A bend located at the bottom of low level flushing cistern for the purpose of
flushing pedestal type water closet and similar fixture.
v) Flushing Cistern (Fig 20): A cistern provided with a device for rapidly discharging the
contained water and used in connection with a sanitary appliance for the purpose of cleaning the
appliances and carrying away its contents into a drain.
w) Gasket: A piece of compressible material used to make a joint between two flat surfaces.
x) Oakum: Hemp or old hemp rope soaked in oil to make it water proof.

y) One Pipe System: In this a single soil waste pipe conveys both soil and waste directly to the
building drain.
z) Pinhole: A hole in the body, less than 1.5 mm in its maximum dimension.
aa) Reducer: A pipe fitting with inside threads larger at one end than at the other. All such fittings
have more than one size are reducers because of the custom of stating the larger size first.
bb) Sanitary Appliances: The appliances for the collection and discharge of soil or waste matter are
called sanitary appliances.
cc) Single Stack System: This is the name given to a simplified one pipe system wherein all
ventilation pipes are omitted. The stack itself is made to cater (or provide) for all the vent
requirements by restricting the flow into the stack to certain predetermined limits.
dd) Sink (Fig 26): A shallow fixture, ordinarily with a flat bottom, that is usually used in kitchen or
in connection with the preparation of food, laboratory purposes and for certain industrial
process.
ee) Socket: The female part of spigot and socket joint.
ff) Soil Pipe: A pipe which conveys to drain the discharge from a water closet or urinals. In one pipe
and `single stack' system the soil pipe also conveys to a drain the discharge from bath, wash
basins, sinks, and similar appliances.
gg) Speck: Area of the finished surface with contrasting colour less than one millimeter maximum
dimension.
hh) Spigot: The male part of a spigot and socket joint.
ii) Spigot and Socket Joint: Joint in which the end of the one pipe enters the enlarged end of the
next pipe.
jj) Stack: A main vertical discharge or ventilating pipe.
kk) Trap: A fitting or device so designed and constructed as to provide, when properly vented, a
liquid seal which will prevent the back passage of air without materially affecting the flow of
sewage or waste water through it.
ll) Two Pipe System : In this, the soil pipe conveys discharges from water closets, urinals, and
similar so appliances directly to the drainage system and the waste pipe conveys waste from
ablutionary and culinary appliances to the drainage system directly or through trapped gully
where desired.
mm) Union: A pipe fitting used for joining the ends of two pipes neither of which can be turned.
nn) Valve: A device used for controlling the flow of liquid in a line of pipe.
oo) Ventilating Pipe (Vent Pipe): The pipe which provides a safe outlet into the atmosphere for
the foul gases in the drain or sewer.
pp) Warpage: Distortion of original shape during manufacturing process.
qq) Water Seal: The depth of water which should be removed from a fully charged trap before air
can pass through the trap.
rr) Waste Pipe: A pipe used to convey liquid waste not containing human excreta.
ss) Waste Stack:A vertical pipe used to convey liquid waste not containing human excreta.

19.3. Water closet (Fig no 8) : General: All vitreous sanitary appliances (Vitreous China) shall
conform to IS: 2556 (Part-I) general requirements. All sanitary and plumbing work shall be carried
out through licensed plumbers. On completion of the work the site shall be cleaned and all rubbish
disposed off as directed by the Engineer-in-Charge.
19.3.1 Squatting Pans (Indian Type W.C.):
a) Patterns of squatting pans:
(i). Long pattern conforming to IS:2556 (Part III)- 1994 Fig 1
(ii). Orissa Pattern conforming to IS:2556 (Part-III)- 1994 Fig 2
(iii). Rural Pattern conforming to IS:2556 (Part III)- 1994 Fig. 3
(iv). Integrated type conforming to IS:2556 (Part XIV)1995 Fig.4
Preferably ORISSA type pan should be used, however squatting pan may be of other
patterns and sizes satisfying the requirements laid in relevant Indian Standards where so
agreed upon by Engineer-in-Charge.
b) Squatting Pan Material: Squatting pans shall be of white vitreous china conforming to IS: 2556
Part-I for General Requirements and relevant IS codes for each pattern as described below:
i) Squatting pan shall be of white (or many other colour as agreed upon by the Engineerin-
Charge) vitreous china conforming to IS: 2556 PartI-1994 for General Requirements and
relevant IS codes for each pattern of pan.
ii) Each pan shall have an integral flushing rim of suitable type. Rural pattern, however, shall
have no integral flushing rim. Squatting pan both long and Orissa pattern, of 630 mm size
shall be of the box rim type. Squatting pans of sizes smaller than 630 mm may be made
either box rim or open rim type. The flushing rim shall have an inlet or supply horn for
connecting the flush pipes as shown in fig. 1 to 4. The flushing rim and inlet shall be of
self draining type. It shall have weep hole at the flushing inlet of the pan. The flushing
inlet, for the long pattern pan may be located either at the narrow end or broad end or at
both the ends as directed by the Engineer-in-Charge. The inside of the bottom of the pan
shall have sufficient slope from the front towards the outlet and the surface shall be uniform
and smooth to enable easy and quick disposal while flushing. The exterior surface of the
outlet below the flange shall be unglazed surface which shall have grooves at right angles
to the is of the outlet. The pan when sealed at the outlet and vent (if fitted) with watertight
seal shall be capable of holding not less than 10 litre of water between normal water level
and the highest possible water level of pan as installed.
c) Trap: In all cases a pan shall be provided with a self-cleansing (100 mm) "P" or "S" type trap of
the same material as the pan with approximately 50 mm water seal, and 50 mm dia. vent horn
where required by the Engineer-in-Charge conforming to IS: 2556 (Part 13)-1995. The trap
shall be glazed inside.
d) Footrest: If specified the squatting pan shall be provided with a pair of footrests of the same
material as the pan.
e) Dimensions & Tolerances: Squatting pans shall be made in any of the following sizes: Long
pattern 580 and 630 mm

Orissa pattern 580x440 and 630x450 mm
Rural Pattern 480mm
Integrated pattern 500 mm(long pattern)
The functional & connecting dimensions of squatting pans shall conform to those given in the
Fig. 1 to 4. The top surface of long pattern pan shall not at any point vary from the designed
plane or contour by more than 6 mm for size 580 mm and more than 10 mm for size 630 mm
and measured vertically. This value shall not exceed 10 mm in any case of Orissa pattern pans.
The tolerances shall be as laid down in IS: 2556 (Part I)-1994.
f) Fixing:
i) The pan shall be fixed in position as shown on the drawing. The pan shall be sunk into
the floor and embedded in a cushion of average 15 cm thick cement concrete 1:5:10 (1
cement: 5 coarse sand:10 graded brick ballast 40 mm nominal size). The concrete shall
be left 115 mm below the top of the pan, so as to allow flooring and its bed concrete.
ii) The pan shall normally be at the floor level, unless otherwise specified with a floor
slope of about 3 to 5 mm towards the pan.
iii) The pan shall be fixed to the trap by means of a leak proof joint with cement mortar 1:1
(1 cement: 1 fine sand) as in case of S.W. pipes and the entire job carried out so that the
effective seal is always kept maintained, the vent of the trap being connected to Anti-
Siphonage pipe.
iv) Any making or breaking of wall /floor carried out to fix the soil or vent pipes shall be
v) While laying flooring, a section about 1 x1.5 m or less of the part of the floor where W.C.
is to be fixed shall be left out. This shall be finished only after the pan has been fixed and
laid in position, this work of flooring being measured separately. The flooring shall, unless
otherwise specified, be of terrazzo finish.
g) Protection: The pan shall be kept suitably protected against all damages.
h) Measurements: Squatting pans shall be enumerated.
i) Rate: Rate shall include the cost of labour and material involved in all the operation described
above including the cost of both pan and trap, as well as their fixing and connection including
cutting and making good the wall and floor, but excluding the pair of footrest and the concrete
laid.
19.3.2 Water Closet (European type):
i) The water closets shall be of white (or any other colour as agreed upon by the Engineerin-
Charge) vitreous china conforming to IS: 2556 (Part I)-1995 and other relevant IS Code. Wash
down type water closets with pedestal conforming to IS: 2556 (Part II)-1995 shall be either of
the two patterns and sizes as shown in Fig. 6 and 7.
ii) The closet shall be of one piece construction. Each water closet shall have not less than two
holes in pedestal having a minimum diameter of 6.5mm for fixing to floor and shall have an
integral flushing rim of suitable type. It shall also have an inlet or supply holes for connecting
the flushing pipe of dimensions conforming to "B" in table in fig. 6 & 7. The flushing rim may
be boxed or open type. In the case of box rims, adequate number of holes

on each side together with a slot opposite the inlet shall be provided. The flushing rim and inlet
shall be of the self draining type. The water closet shall have a weep hole at the flushing inlet.
iii) Each water closet shall have an integral trap with either "S" or "P" outlet with at least 50 mm
water seal. For "P" trap, the slope of the outlet shall be 20 degree below the horizontal. When
required the water closet shall have an antisiphonage 50 mm dia. vent holes on the outlet side
of the trap with dimensions conforming to those given in fig.6 and on either right or left hand
or centre as specified, set at an angle of 45 degree and invert of vent hole not below the central
line of the outlet. The inside surface of water closets and traps shall be uniform and smooth in
order to enable an efficient flush. The serrated part of the outlet shall not be glazed externally.
The water closet when sealed at the bottom of the trap in line with the back plate shall be
capable of holding not less than 15 litres of water between the normal water level and the
highest possible water level of the water closet as installed.
19.3.2.1Syphonic water closet:
i) Single or Double Trap Pattern, wash down water closet for close coupled suit, P or S or
concealed S trap, horizontal outlet W.C. for closed coupled suite as shown in Fig. 8 toll
conforming to IS:2556 (Part-8)-1995 may be provided as directed by Engineer-in-Charge.
ii) The water closet may be wall hung type (bracket fitting) if so directed by the Engineer-in-
Charge.
iii) The closets may also be provided in any other pattern and size as per manufactures
specification as agreed upon by the Engineer-in-Charge. However except for functional
dimensions, all other requirements as laid down in relevant IS code shall be complied with.
19.3.2.2. Universal Water Closets (Anglo-Indian type): This type of closet is suitable both as
squatting pan of the Indian type or as a sitting pan of the European type. Universal water closets
conforming to IS: 2556 (Part 15)-1995 shall be either of the two sizes as shown in fig. 12.
19.3.2.3 Fixing: The work shall be carried cut, complying in all respects with the requirements of
relevant bye- laws of the local body in whose jurisdiction the work is situated. The closet shall be
fixed to the floor, at the position as shown on the drawing by means of 75 mm long, 6.5 mm dia.
Countersunk bolts & nuts embedded in floor concrete with rubber or fibre washers so as not to allow
any lateral displacement. The outlet shall be fixed to the soil pipe by means of a cement mortar joint
as in the case of S.W. pipes.
Wall hung W.C.'s, shall be fixed according to manufacturer's specifications.
19.3.2.4 Seat and Cover (Fig.13) :
i) The water closet shall be provided with plastic seat and seat cover conforming to IS: 2548
(Part I & II)-1983. Unless otherwise specified these shall be of closed pattern.
ii) Thermosetting plastic used shall conform to grade 2 or 3 of IS: 1300 when it is phenolic or
IS: 3389 when of urea formaldehyde.
iii) Thermo plastic material used may be of Polypropylene, Appendix A of IS: 2548 (Part II)-1983.
In public buildings where rough and heavy use of seats and covers are common, plastic seats
shall be moulded out of thermosetting material, phenolic or urea formaldehyde only and the
under side of the seat shall be flat with solid moulding.
iv) The seat shall be fixed to the pan by means of two corrosion resistant hinges both with a

minimum length of shank 65 mm and threaded to within 25mm of the flange supplied by the
manufacturer along with the seat. Each bolt shall be provided with two suitably shaped washers
of rubber or other similar materials for adjusting the level of the seat while fixing it to the pans.
In addition, one non-ferrous or stainless steel washer shall be provided with each bolt. The
maximum external diameter of the washer fixed on the underside of the pan shall not be greater
than 25mm. The hinging device shall be bronze or brass with nickel chromium plating
confirming to IS: 2548 and the seat shall have not less than three rubber or plastic buffers unless
otherwise specified. The cover shall be fitted with the same number of buffers as provided for
the seat. Alternative hinging v) devices as supplied by the manufacturer of the seat can also be
used for fixing with the approval of Engineer-in-Charge.
vi) Seats shall have a smooth finish and shall be non- absorptive and free from cracks and crevices.
They shall be capable of being easily cleaned and shall not be adversely affected by common
solvents or household cleanser.
vii) Strength: The seats shall withstand without permanent distortions of the seat or hinge fittings
and damage to any finish, a load of 1150 N for 30 minutes, applied in the manner prescribed in
IS: 2548.
Wooden seats as per manufacturer's specifications may be provided as directed by the
Engineer-in-Charge.
19.3.2.5. Protection: The closet shall be kept suitably protected against all damages till the work is
completed.
19.3.2.6. Measurements: The water closets shall be enumerated and grouped according to the type
and the types of traps used. The seat and cover shall be measured separately and classified according
to the material.
19.3.2.7. Rate: Rate shall include the cost of labour and material involved in all the operations
described above including the cost of WC pan, "P" or "S" traps, as well as their fixing and cutting
and making good the walls and floor, but excluding the seat and cover. Any damage caused to the
building, or to electric, sanitary, water supply or other, installations etc. therein, either due to
negligence on the part of the contractor, or due to actual requirements of the work, shall be made
good and the building or the installation shall be restored to its original condition by the contractor.
Nothing extra shall be paid for such restoration works except where otherwise specified. For making
good the damage to the under mentioned items of work, the specifications as given in the following
paras shall apply, unless directed otherwise.
(a) Masonry Work: The masonry work shall be made good by using the same class of bricks,
tiles or stones as was damaged during the execution of the work. The mortar used shall be
cement mortar 1:5 (1 cement: 5 fine sand) or as directed by the Engineer-in-Charge.
(b) Plain Concrete Work: Concrete work for sub-grade of the flooring, foundations and other
plain concrete works shall be cement concrete 1:5:10 (1 cement : 5 coarse sand : 10 graded
stone aggregate 40 mm nominal size). A coat of neat cement slurry shall be applied at the
junction with old work, before laying fresh concrete.
(c) Cement Concrete Flooring and R.C.C. Work: Cement concrete 1:2:4 (1 Cement: 2 Coarse
sand: 4 graded stone aggregate 20 mm nominal size) shall be used after applying a coat of neat
cement slurry at the junction with old work, and the surface finished to match with the
surrounding surface.

d) Plastering: Cement plaster 1:4 (1 cement: 4 sand) shall be used. The sand shall be fine or coarse,
as used in the original work. The surface shall be finished with two or more coats of white
wash, colour wash, distemper or painting as required, but where the surface is not to be white
washed, colour washed, distempered or painted, it shall be finished as required to match with
the surrounding surface.
(e) Other Items: Damage to any other item shall be made good as directed by the Engineerin-
Charge.
Note: In all the above operations the damaged portion shall be cut in regular geometric shape
and cleaned before making good the same.
19.4. Urinals:
19.4.1. Bowl Type (Fig.14):
i) Urinal basins shall be of flat back or corner wall type lipped in front and white (or any other
colour agreed upon by the Engineer-in-Charge) vitreous China conforming to IS:2556 (Part
VI)-1995 of sizes shown in Fig. 14. The urinals shall be of one piece construction. Each urinal
shall be provided with not less than two fixing holes of minimum dia. 6.5 mm on each side.
Each urinal shall have an integral flushing rim of suitable type and inlet or supply horn for
connecting the flush pipe. The flushing rim and inlet shall be of the self draining type. It shall
have a weep hole at the flushing inlet of the urinals.
ii) At the bottom of the urinal an outlet horn connecting to an outlet pipe shall be provided. The
exterior of the outlet horn shall not be glazed and the surface shall be provided with grooves at
right angles to the is of the outlet to facilitate fixing to the outlet pipe. The inside surface of the
urinal shall be uniform and smooth throughout to ensure efficient flushing. The bottom of the
pan shall have sufficient slope from the front towards the outlet such that there is efficient
draining.
The following tolerances may be allowed on the dimensions:
(a) On dimension 50 mm and over ± 4 percent
(b) On dimension less than 50mm ± 2mm
(c) On all angles ± 3 degree
19.4.1.1 Stall Urinals (Fig. 15):
The stall urinal and its screen shall be of white (or any other colour agreed upon by Engineerin-
Charge) glazed fine clay conforming to IS: 771 (Pt. 3 Sec.2). The stall shall be 1190 mm high
and 460 mm wide with 400 mm overall depth at the base.
Where specified, screens which shall be 1190 mm high and 15 cm wide (overall) and projecting
50 cm after suitable embedment in the wall, shall be provided as directed by the Engineer-in-
Charge. In case of a range of two or more urinals, there shall be further division screens as shown
in Fig. 15. The end screen shall also be suitably fixed as directed by the Engineer-in-Charge.
The range shall have 15 cm deep standard pattern tread plates of fire clay or black granite as
specified or otherwise directed by the Engineer-in-Charge. The inside surface of the stall and
its screens shall be regular and smooth throughout to ensure efficient flushing.

19.4.1.2 Half Stall Urinals (fig. 16):
i) These shall be of white (or any other colour agreed upon by engineer-in-Charge) vitreous china
conforming to IS: 2556 (Part VI, Sect 2) -1994. They shall be of one piece construction flat back
or angle back with or without an integral flushing box rim and provided with slots or alternative
fixing arrangement at the flat back end. They shall be provided with ridges where integral
flushing rim is not provided in the sides of the interior of the bowl, to divert the water towards
the front line of the urinal where integral flushing box rim is specified. Water spreaders
provided shall conform to IS: 2556 (Part VI sec. 6)-1974.
ii) These shall be of vitreous China of one piece construction with integral flush inlet.
iii) The tolerance of ± 4 percent may be allowed on the dimensions specified.
19.4.1.3 Mini Stall: Mini stall urinals shall be of Vitreous China conforming to manufacturers
specifications.
19.4.1.4 Slab urinals: Slab urinals shall conform to IS:771 (Part III, Sec. I)-1979. Slab urinals
shall be one of the following pattern and sizes:
(a) Batter slab:
1000x600 mm
1000x450 mm
(b) End slab:
1000x360 mm
The dimension of slab urinal shall be as shown in Fig.17
The urinals may be provided in other pattern and sizes where so agreed upon by the
Engineer-in-Charge.
19.4.1.5 Urinal Partition slabs: Urinal partition slabs shall be provided as specified in Fig.19.
19.4.1.6 Squatting Plate Urinal (Fig. 18): The plates shall be of white (or any other colour agreed
upon by the Engineer-in-Charge) vitreous china conforming to IS: 2556 (Part-I) and IS: 2556 (Part
VI) Section 3 with internal flushing rim with front or side inlet. Squatting plate shall be of one piece
construction. Each urinal shall have integral longitudinal flushing pipe of suitable type which may be
connected to flush pipe. The following tolerances may be allowed on the dimensions:
(a) On dimensions 50 mm and over ± 4 percent
(b) On dimensions less than 50 mm ± 2 mm
There shall be 100 mm dia. glazed vitreous china channel with stop and outlet piece in front.
19.4.1.7. Angle back urinals shall be provided as directed by the Engineer-in-Charge. 19.4.2
Fixing:
19.4.2.1. Bowl type and Half-Stall (Single or range), Lipped urinals:
i) Urinals shall be fixed in position by using wooden plugs and screws. It shall be at a height of 65
cm from the standing level to the top of the lip of the urinal unless otherwise directed by the
Engineer-in-Charge. The size of wooden plugs shall be 50mmx50mm at base tapering to
38mmx38mm at top and of length 5cm. These shall be fixed in the wall in cement mortar

1:3 (1 cement: 3 fine sand). After the plug fixed in the wall the mortar shall be cured till it is
set.
ii) Each urinal shall be connected to 32 mm dia. G.I. waste pipe which shall discharge into the
channel or a floor trap. The connection between the urinal and flush or waste pipe shall be made
by means of putty or white lead mixed with chopped hemp.
19.4.2.2 Stall Urinal (Single or Range): The floor slab shall be suitably sunk to receive the stall
urinal. Where the floor slab is not sunk, the stall urinal shall be provided over a platform. The lip of
the stall urinal shall be flush with the finished floor level adjacent to it. The stall urinal shall be laid
over a fine sand cushion of average 25mm thickness. A space of not less than 3 mm shall be provided
around, in front sides and filled with water proofing plastic compounds. Care shall be taken that after
the sub-grade for the floor is cast, one week should lapse before urinals are installed. Generally
fixing of the tread plate has been specified . The traps & fittings shall be fixed as directed by
Engineer-in-charge. Payment for the floor and its sub grade shall be made separately.
19.4.2.3 Squatting Plate (Single or Range):
i) The floor slab shall be suitably sunk to receive the squatting plate. Where the floor slab is not
sunk, the plate shall be provided over a platform. The top edge of the squatting plate shall be
flush with the finished floor level adjacent to it. It shall be embedded on a layer of 25mm thick
cement mortar 1:8 (1 cement: 8 coarse sand) laid over a bed of cement concrete 1:5:10 (1
cement: 5 coarse sand: 10 graded brick aggregate 19 mm nominal size).
ii) There shall be 100 mm dia. white glazed vitreous china channels with stop and outlet pieces
suitably fixed in the floor in cement mortar 1:3: (1 cement: 3 course sand) and joint finished with
white cement. The squatting plates shall have 1190 mm high and half brick thick wall in front
and on either side of the squatting plate. The brick work for the walls shall be paid separately.
The exposed surface of walls shall be lined with white glazed tiles with proper corners and
angles set in neat cement mortar, the face of the joints shall be gone over with whiting so as to
match with the color of the tiles. The tiles shall be 15cm square. Space if any, left between the
side walls and squatting plate shall be finished white to match the color of the squatting plate.
The trap and fittings shall be fixed as directed by the Engineerin-Charge. The vitreous china
channel shall discharge into a 65mm dia. standard urinal, Cl trap with vent arm having 6 5 =
CP brass outlet grating.
19.4.3 Flushing: The flushing of urinal shall be either by:
(i) Automatic flushing cistern, or
(ii) Manually operated flushing cistern, or
(iii) Manually operated flushing valve.
Flushing valve if used shall be C.P. brass stop valve, the valve being fixed on each urinal. This shall
not be used in places of assembly. The capacity of flushing cistern and relevant size of flush pipes for
urinals in a range shall be as per Table 1

Table-1:
No. of Urinals Capacity of Size of flush pipe Chromium Diameter of
in range Flushing Plated (GI.) C.I Traps
cistern
Main Distribution
One 5 Litres 15 mm 15 mm 50 mm
Two 10 Litres 20 mm 15 mm 50 mm
Three 15 Litres 25 mm 15 mm 80 mm
Four 15 Litres 25 mm 15 mm 80 mm
19.4.4 Measurements: The uri urinal shall begrouped according to the type and enumerated.
described above.
19.5 Flushing Cisterns:
19.5.1 Capacity: The cistern shall be denoted by the capacity. For water closets, the capacity shall
be 5 to 10 litres.
19.5.2. Types:
i) Flushing cisterns shall be automatic or manually operated, high level/ low level coupled or dual
flush type as specified for water closets and urinals. A high level cistern is intended to operate
with a minimum height of 125cm and a low level cistern with a maximum height of 30 cm
between the top of the pan and under side of the cistern.
ii) Cistern shall be of cast iron, vitreous China, Pressed Steel, Plastic (IS: 774 for Flushing type
and IS: 2326-1987 for Automatic flushing cisterns and IS: 7231- 1994 for Plastic flushing
cisterns).
19.5.3 Material:
19.5.3.1. Cast Iron Type: The thickness of the body including cover shall be not less than 5 .
19.5.3.2. Vitreous China: The thickness of the body including cover shall be not less than 6 .
19.5.3.3. Pressed Steel: The body of the pressed steel cistern shall be of seamless or welded
construction. The body and cover of the pressed steel cistern shall be of thickness not less than 1.6
mm and 1.3 mm respectively before coating and shall be vitreous enameled or otherwise protected
against corrosion by equally efficient coating.
19.5.3.4. Plastic Type (PVC): Plastic flushing cisterns for WC and Urinals shall be as per IS
7231.The thickness of the body including cover at any point shall not be less than 2 mm for GRP
and not less than 3 mm for other plastic materials. The cistern shall be free from manufacturing faults
and other defect affecting its utility. The materials for manufacturing various components of the
flushing cisterns shall conform to the requirements given in Table 2 below:

Table 2 : Materials for Various Components of Flushing Cisterns
S No. Components Material Conforming to
(1) (2) (3) (4)
1. Cistern High Density Polyethylene (HDPE), IS: 7328
or Polystyrene, high impact, or IS: 2267
Polypropylene,orl
Acrolonitrile-butadiene- styrene
2. Flush Pipe Steel tube, seamless or welded,
medium or light, completely
protected inside and outside by
hot dip galvanizing, electroplating
or vitreous enameling, or, IS: 1239
Lead Pipe, or, IS : 404
Copper Alloy
3. Cover Same material as that of the body
4. Chain Hot dip galvanized steel wires, or,
Inter-locked nonferrous metal.
5. Overflow pipe High Density Polyethylene, or, IS: 4984
Unplasticised PVC, or, IS: 4985
Any other corrosion resistant material
6. Siphon! Valve High density polyethylene, or IS: 7328
Polypropylene, or, IS: 2267
Polystyrene, high impact, or
Glass fibre reinforced plastic (GRP), or
Acrylonitrile- butadiene-styrene
7. Operating mechanism! Non-ferrous metal or any other
lever corrosion- resistant material
8. Float Valve As specified in IS 1703, or
IS 12234, or IS 13049
9. Polyethylene float for As specified in IS 9762
float valve
10. Coupling nut and Non-ferrous metal, or
lock-nut Hot-dip galvanised steel, or
Hot-dip galvanized malleable iron,
or Any other non-corrosive metal, or
Injection-moulded HDPE/polyacetal
Note: Where the requirements for the material of any component or the relevant Indian Standard
designation for any material are not specified, these shall be as directed by the Engineer-in-Charge.
Talc as filler, if used shall not exceed 20%
19.5.3.5. The outlet of each syphon or stand pipe shall be securely connected to the cistern by

means of lock nut. The cistern shall be free from manufacturing faults and other defects affecting their
utility. All working parts shall be designed to operate smoothly and efficiently. Cistern shall be
mosquito proof only if there is no clearance anywhere which would permit a 1.6 mm wire to pass
through in the permanent position of the cistern i.e. in the flushing position or filling position. The
breadth of a low level cistern shall be such that the cover or seat or both, of water closet pan shall
come to rest in a stable position when raised.
19.5.3.6. Cover: A cistern shall have a removable cover which shall fit closely on it and be secured
against displacement. In designs where the operating mechanism is attached to the cover this may
be made in two sections, but the section supporting the mechanism shall be securely bolted or
screwed to the body.
19.5.3.7. Flush Pipe and its connection:
i) The outlet fitting of each cistern shall be securely connected to the cistern. The normal internal
dia. of cistern outlet shall not be less than 32mm and 38mm for high level and low level cisterns
respectively. The length of the outlet of the cistern shall be 32 ± 2 mm. All joints shall be
completely water light.
ii) Flushing pipe shall be of (a) medium quality galvanized iron having internal dia. of 32±1 mm
for high level cistern and 38±1 mm for low level cistern. The flush pipe shall be of suitable
length with bends etc. as required for fixing it with front or back inlet of WC Pan (b)
Polyethylene pipes, low density, conforming to IS: 3076 or high density conforming to IS:
4984 (c) Unplasticised PVC pipe conforming to IS: 4985. For high density polyethylene and
unplasticised PVC pipes, the outside diameter of the pipes shall be 40mm. When PVC
plumbing pipes are used the outside dia. of the pipe shall be 40mm for high level cisterns and
50mm for low level cisterns. In case of low level cistern the flush pipe shall be a vertical pipe
30 cm long and having a nominal internal dia. 38 ± 1 mm (except plastic flush pipes).In case
of high level cisterns, the flush pipe shall be a vertical pipe 125cm long and having a nominal
internal dia. 32± 1mm (except plastic flush pipes) and in case of low level cistern 30 cm long
and 38± 1 mm dia. (except plastic flush pipes
19.5.3.8 Overflow pipe:
(i) G.I. Overflow pipe shall be of not less than 20 mm nominal bore and shall incorporate a non
corrodible mosquito proof brass cover having 1.2 mm dia. perforations, screened in a manner
which will permit it to be readily cleaned or renewed when necessary. No provision shall be
made where by the overflow from the cistern shall discharge directly into the water closet or
soil pipe without being detected.
(ii) The invert of the overflow pipe in the case of high level and low level cistern shall be 20 mm
minimum above the working water level. In case of overflow due to any means water should
drain out through the overflow pipe and not through the syphon pipe.
The plastic overflow pipes shall be manufactured from high density polyethylene conforming to
IS : 4984 or unplasticised P.V.C. conforming to IS: 4985.
19.5.3.9. Inlet & overflow holes:
The cisterns shall be provided with inlet and overflow holes situated one at each end which shall be
capable of accommodating an overflow pipe of not less than 20mm nominal bore and 15mm size
ball valve. The holes shall be clearly cast or drilled and the adjacent surfaces shall be smooth.
19.5.3.10. Pull & Chain: In case of high level manually operated cistern, the lever arm of the

cistern shall have a suitable hole near the end through which a split ring or a (S) hook shall pass. A
chain shall be attached to the ring or the hook. The chain shall be of G.I. and strong enough to sustain
a suddenly applied pull of 10 kg. a dead load of 50 kg. without any apparent or permanent deformation
of the shape of the ring. The chain shall terminate in suitable handle or pull which shall be of pottery,
galvanized iron, nonferrous metal or a moulding in any heat resisting and non absorbent plastic. The
finish shall be smooth and free from burrs. In case of low level cisterns, the handle shall be of a
chromium plated brass or it shall be push button operated.
19.5.3.11. Ball valve: Ball valve shall be of screwed type 15mm in dia. and shall conform to IS:
1703 or IS 12234 or IS 13049. The float shall be made of polyethylene as specified in IS: 9762. (The
design shall permit the cistern to fill in rapidly and close effectively when the level of water reaches
the working water level.)
19.5.4 Syphonic Action: In case of manually operated cisterns the symphonic action of the flushing
cistern shall be capable of being rapidly brought into action by the operating lever, but shall not self-
syphon or leak. When tested according to IS: 774, the discharge rate shall be 10±0.5lit. in 6 sec., and
5±0.5 lit in 3 sec. for cistern of capacity 10 litre and 5 litre respectively. The cistern shall be so designed
that there is not appreciable variations in the force of flush during the discharge of the required quantity
of water. The cistern shall have discharge capacity of 5 to 10 litres as specified. When required to
give a full flush, these shall discharge 5 litres to 10 litres with variation of 0.5 litres.
19.5.4.1 Operational and Performance Requirements:
a) Flushing Arrangement: The cistern under working conditions and with the float valve in
closed position shall operate on a single operation of the operating mechanism/lever without
calling for a sudden jerk in pulling. If a valve is used instead of siphon for flushing purposes,
the valve shall be completely leak proof.
b) Working Water Level: The working water-level shall be a minimum of 6.5 cm. below the
effective top edge of the cistern and shall be legibly and permanently marked on the inside of
the cistern. Effective top edge shall be taken on edge after top of the body without considering
bead.
c) Freedom from Self Siphonage: The siphonic system shall be capable of being rapidly brought
into action when the water is at the working water level, but shall not self siphon or leak into
the flush pipe when the water is up to 1 cm above the invert of the overflow pipe.
d) Reduced Water Level: The discharge shall operate satisfactorily when the cistern is filled to
a level up to 1 cm. below the working water level.
e) Special Requirements : Distortion Resistance Test: The cisterns, complete with its fittings,
shall be installed and filled with water to the marked water line and observed for any distortion.
The cistern shall not budge more than 6 mm and the cover shall not be dislodged.
i) Dead Load Test: When the flushing mechanism incorporates chain pull or hand operated
lever, the cistern, complete with its fittings, when installed and filled with water to the
marked water line and tested by the application of a dead load of 230 N applied 6 mm
from the end of the operating lever arm for 30 seconds, shall not distort to such an extent
that any part becomes detached. In the case of other operating mechanism, the dead load
applied shall be a mass equivalent

to the operating force required to overcome the normal hydrostatic head; Thirty seconds
after the load is removed, the function and appearance of the cistern shall not be impaired.
ii) Front Thrust Test: The front thrust test shall be applied only to cisterns intended for
low level use. The cistern complete with its fittings, when installed and filled with water
to the marked water line and tested by the method described in IS 7231, shall not distort
to such an extent as to be inoperable or unsightly when the load is removed.
iii) Impact Test: The cistern, complete with its fittings, when installed and filled as described
in IS 7231 shall show no defect after one impact. Repeat the test but with the cistern
empty. The cistern shall show no defect after the further impact.
19.5.5 Fixing:
19.5.5.1. High level cistern: The cistern shall be fixed in two C.I. cantilever brackets which shall be
finally embedded in the wall in cement concrete (1:2:4) block 100x75x150mm. These shall be
properly protected by suitable impervious paint. Alternatively the cisterns shall have two holes in
the back side above the overflow level for screwing into the wall, supplemented by two cast iron
wall supports. A 5 litre cistern, however, may be supported by larger brackets cast on the body of
the cistern. The cistern shall be provided with 19 mm nominal bore G.I. overflow pipe 185cm long
with fittings. The outlet or flush pipe from the cistern shall be connected to the pan by means of
cement or putty joint. The flush pipe shall be fixed to wall by using holder bat clamps of required
shape and size so as to fit tightly on the pipes when tightened with screwed bolts. The clamps shall
be embedded in brick work in cement mortar 1:3 (1: cement: 3: coarse sand). If connection between
cistern and pan is made with G.I. pipe, the bends and offsets shall be made cold.
19.5.5.2. Low level cistern: Clause 19.5.5.1 shall apply except that connections between cistern and
closet shall be made by means of 40 mm dia. flush bend with rubber or G.I. inlet connection as
specified.
19.5.5.3. Automatic cistern: Clause 19.5.5.1 shall apply except that C.P Brass stop cock shall be
provided for cistern having a capacity of more than 5 litres. The main and distribution flush pipe
shall be fixed to the wall by means of standard pattern holder bat clamps as shown in Fig. 20.
19.5.6 Painting:
i) The inside of cast iron cistern and fitting shall be painted with an approved bitumastic paint
and the outside of cistern, brackets, flush pipe etc. shall be painted with a priming coat of red
oxide (or other approved protective paint) and finished with two coats of aluminum paint
(except for glazed cistern which do not require any painting). Alternatively, it may be desired
to be finished in zinc paint in the tint matching the surround walls.
ii) All exposed G.I., C.I. or lead pipes and fittings shall be painted with approved quality of paint
and shade as specified. The painting work shall conform to specification described under SH:
Painting.
19.5.7 Measurements: Flushing cistern including all fittings shall be enumerated, classified into
high level and low level and grouped according to size and type of material used.

19.5.8 Rate: The rate shall include the cost of labour and material involved in all the operations
described above including providing and fixing pull and chain brackets flush and overflow pipes and
their connection as well as painting as described above.
19.6 Footrest:
19.6.1 Material: Foot rest shall be of vitreous china conforming to IS: 2556 (Part X) - 1974. Foot
rests which are rectangular shall meet minimum requirements and dimensions shown in Fig. 21 and
may be of different designs where so specified. Foot rest of different shapes and sizes shall also be
allowed subject to approval of Engineer-in- Charge.
19.6.2 Fixing: After laying the floor around the squatting pan as specified a pair of foot rests shall
be fixed in cement mortar (1:3) (1 cement: 3 coarse sand). The position of foot rests with respect to
pan shall be as per Fig. 21.
19.6.3 Measurements:Pair of Foot rests shall be enumerated.
19.6.4 Rate: The rate shall include the cost of all the material and labour involved in all the
19.7 Wash basin:
19.7.1 Material:
19.7.1.1. Basin:Wash basins shall be of white (or any other colour as agreed upon by the Engineerin-
charge) vitreous China conforming to IS: 2556 (Part I)-1994 and IS: 2556 (Part IV)-1994. Wash
basins either flat back or angle back as specified shall be of one piece construction, including a
combined overflow. (Fig. 22 to 25). All internal angles shall be designed so as to facilitate cleaning.
Each basin shall have a rim on all sides, except sides in contact with the walls and shall have a
skirting at the back. Basins shall be provided with single or double tap holes as specified. The tap
holes shall be 28 mm square or 30 mm round or 25mm round for pop up hole. A suitable tap hole
button shall be supplied if one tap hole is not required in installation. Each basin shall have circular
waste hole to which the interior of basin shall drain. The waste hole shall be either rebated or beveled
internally with dia. of 65mm at top. Each basin shall be provided with a non-ferrous 32mm waste
fitting. Stud stop to receive the brackets on the under side of the wash basin shall be suitable for a
bracket with stud not exceeding 13 mm dia. 5 mm height and 305 mm from the back of basin to the
centre of the stud. The stud slots shall be of depth sufficient to take 5mm stud. Every basin shall
have an integral soap holder recess or recesses, which shall fully drain into the bowl. A slot type of
overflow having an area of not less than 5cm2 shall be provided and so designed as to facilitate
cleaning of the overflow.
19.7.1.2. Pedestal:
i) Glazed pedestals for wash basins, where specified shall be provided. The quality and colour of
the glazing of the pedestal shall be exactly the same as that of the basin along with which it is to
be installed. It shall be completely recessed at the back to accommodate supply and waste pipes
and fittings. It shall be capable of supporting the basin rigidly and adequately and shall be so
designed as to make the height from the floor to the top of the rim of basin 75 to 80 cm. All the
waste fittings shall be brass chromium plated, or as specified.
ii) The following tolerances may be allowed on dimensions specified:
(a) On dimension 75mm and over ±4 percent
(b) On dimension less than 75mm ±2mm

(c) Diameter of the waste hole ± 3mm
19.7.1.3. Waste fittings:
i) The waste fittings shall be of Nickel Chromium plated brass with thickness of plating not less
than service grade 2 of IS: 4827 which is capable of receiving polish and will not easily scale off.
The fitting shall conform in all respect to IS: 2963-1979 and shall be sound, free from laps,
blow holes and pitting and other manufacturing defects. External and internal surfaces shall be
smooth and clean. They shall be neatly dressed and be truly machined so that the nut smoothly
moves on the body.
ii) Waste fitting for basins shall be of nominal size 32mm.
19.7.2 Fixing:
i) The basin shall be supported on a pair of C.I. cantilever brackets conforming to IS: 775-1979
and be embedded in cement concrete (1:2:4) block 100x75x150mm. Use of M.S. angle or Tee
sections as bracket is not permitted. Brackets shall be fixed in position before dado work is
done. The brackets have been shown in Fig. 28. The brackets shall be painted with two or more
coats of approved paint. The wall plaster on the rear shall be cut to rest over the top edge of the
basin so as not leave any gap for water to seep through between wall plaster and skirting of
basin. After fixing the basin, plaster shall be made good and surface finished to match with the
existing one. C.I floor traps conforming to IS: 1729-1979 having 50 mm water seal (min. 35mm
in two pipe system with gully trap) should be used. Bottle traps may be provided if directed by
the Engineer-in-Charge. Waste pipes laid horizontally should have gradient not flatter than 1
in 50 and not steeper than 1 in 10.
ii) The waste water from wash basin shall be discharged directly to a floor trap and finally to the
vertical stack. (Fig.24) on upper floors and in case of ground floor, the waste water shall be
discharged either directly to the gully trap or through the floor trap (Fig. 23). C.P. brass trap
and on are not to be used in such situations.
iii) If waste pipe is concealed or crosses the wall, waste water shall be discharged through non-
ferrous trap like PVC Engineering plastic or C.P. brass union (Fig. 24) to vertical stack. The
C.P. brass trap and union shall be paid for separately.
iv) When so specified a 20mm G.I. puff pipe terminating with a perforated brass cap screwed on
it on the outside of the wall or connected to the anti-syphon stack shall be provided.
v) Where oval shaped or round shaped wash basins (VANITY Basins) are required to be fixed,
these shall be fixed preferably in RCC platform with locally available stone topping either fully
sunk in stone top or top flush with the stone topping or overtopping stone top, as directed by
19.7.3 Measurements: Wash basin shall be enumerated according to size and type. C.P. Taps, Stop
cocks and lead connection as provided be measured extra.
19.7.4 Rates: The rate shall include the cost of material labour involved in all the operations
described above including fixing complete with the brackets, waste fittings and waste pipe fittings.
19.8 Towel rail:
19.8.1 Material: The towels Rail shall be of:
(a) C.P. Brass with two C.P. brass brackets with nickel chromium plating of thickness not less than
grade no.2 of IS: 4827-1983

(b) Anodized aluminum fluted surface (1.25mm thick) with two anodized aluminum brackets.
(c) Plastic towel rails and Towel rings as per manufacturer's specifications.
19.8.2 Fixing: It shall be fixed in position by means of C.P. brass screws on wall surface by PVC
dash fasteners, firmly embedded in wall.
19.8.3 Measurements: Towel rail shall be enumerated.
19.8.4 Rate: Rate shall include the cost of material and labour involved in all the operations
described above.
19.9 Sink:
19.9.1 Kitchen Sink: Kitchen sink (Fig. 26) shall be of glazed fire clay conforming to IS: 771 (Part
II)-1985, The kitchen sink shall be in one piece construction with or without rim but without overflow.
19.9.1.2 Laboratory Sink: Laboratory sink shall be of one piece construction made of vitreous
china conforming to IS: 2556 (Pt. V)-1994 or of glazed fire clay conforming to IS 771 (Part II)-1985
with overflow as shown in Fig. 26.
19.9.1.3. Stainless Steel Sink:
i) Wherever specified stainless steel kitchen sink of size as specified conforming to IS : 13983-
1994 shall be provided.
ii) The floor of the sink shall gently slope towards the outlet. The outlet shall in all cases be
suitable for waste fittings having flanges of 88 mm diameter and the waste hole shall have a
minimum diameter of 65 mm at the bottom to suit the waste fittings. The waste hole shall be
either rebated or beveled having a depth of 10 mm. Each sink shall be provided with a
nonferrous 50 mm dia. waste fitting. The 50 mm long shank of the waste shall be threaded to the
full length to the under side of flange in each case.
iii) The waste fittings shall be of nickel chromium plated brass of nominal size 50 mm. The sink
shall be provided with 40 mm CP brass or PVC union. CI Brackets for supporting sink shall
conform to IS : 775-1970.
19.9.2 Fixing:
i) The fitting shall consist of assembly of sink, C.I. brackets, union and G.I. or P.V.C. waste
pipe.
ii) The sink shall be supported on C.I. cantilevers brackets, embedded in cement concrete (1:2:4)
block of size 100x75x150mm, Brackets shall be fixed in position before the dado work is done.
The C.P. brass or P.V.C. union shall be connected to 40 mm nominal bore G.I. or PVC waste
pipe which shall be suitably bent towards the wall and shall discharge into a floor trap. The
height of front edge of sink from the floor level shall be 80 cm.
19.9.3 Measurements: The sinks shall be enumerated.
19.9.4 Rate: Rate shall include the cost of material and labour involved in all the operations
described above including cutting and making good the walls.
19.10 Draining board:
19.10.1 Material: Draining board manufactured from stainless steel or vitreous china as per
manufacturer's specifications, as agreed upon by Engineer-in-charge shall be provided.

19.10.2 Fixing: One end of the board shall rest on sink and the other end shall be supported on C.I.
or Rolled Steel brackets as specified, embedded, or fixed in position by means of wooden plugs and
screws. The bracket shall be painted to the required shade as specified.
19.10.3 Measurements: The drain boards shall be grouped according to their size and material
and enumerated.
19.10.4 Rate: The rate shall include the cost of material and labour involved in all the operations
described above, including cutting and making good the walls.
19.11 Shelves for wash basins:
19.11.1. Material:
19.11.1.1. Glass Shelf: Glass shelf shall consist of an assembly of glass shelf, with anodized
aluminum angle frame to support the glass shelf. The shelf shall be of glass of best quality with
edges rounded off and shall be free from flaws, specks or bubbles. The size of the shelf shall be
60x12 cm unless otherwise specified and thickness not less than 5.5 mm.
19.11.1.2. PVC Shelf: P.V.C. shelf as per manufacturer's specifications and size as specified shall be
provided.
19.11.1.3. Vitreous China Shelf: Vitreous china shelf as per manufacturer's specifications and
size 30 to 60 cm long, as specified, shall be provided.
19.11.2. Fixing:
i) The shelf shall have C.P. Brass brackets which shall be fixed with C.P. brass screws to rawl
plugs or wooden cleats firmly embedded in the walls.
ii) The height of the glass shelf above the floor level shall be 115 cm, unless otherwise or as
shown in the drawings.
19.11.3. Measurements: The glass shelf shall be grouped according to their size, material and
enumerated.
19.11.4. Rates: The rate shall include the cost of material and labour involved in all the operations
19.12 M.S. Stays and clamps:
19.12.1. Materials: The clamps shall be made from 1.5mm thick M.S. flat of 32mm width, bent to
the required shape and size to fit tightly on the socket when tightened with nuts and bolts. It shall be
formed of two semicircular pipes with flanged ends on both sides with holes to fit in the screws,
bolts and nuts 40mm long. The stay shall be minimum one meter long of 10mm dia. M.S. bar. One
end of the stay shall be bent for embedding in wall.
19.12.2. Fixing (Fig. 29): The stay shall be embedded in the wall in cement concrete block of size
19x 10x l Ocm in 1:2:4 (1 cement: 2 coarse aggregate: 4 graded stone aggregate 20mm nominal size).
The block shall be finished to match with the surrounding surface.
19.12.3. Mode of Measurement: M.S. Stays and clamps shall be grouped according to their type &
size and enumerated.
19.12.4. Rate: The rate shall include the cost of material and labour involved in all the operations

19.13 Mirror:
19.13.1. Materials: The mirror shall be of superior sheet glass, with edges rounded off or beveled, as
specified. It shall be free from flaws, specks or bubbles. The size of the mirror shall be 60x45 cm,
unless specified otherwise and its thickness shall not be less than 4mm. It shall be uniformly silver
plated at the back and free from silvering defects. Silvering shall have a protective uniform covering
of red lead paint. Where beveled edge mirrors are not available, fancy looking mirrors with PVC
beading/border, or Aluminum beading or stainless steel /border, based on manufacturer's
specifications be provided. Nothing extra shall be paid on this account. Backing of mirrors shall be
provided with environmental friendly material.
19.13.2. Fixing: Mirror shall be fixed in position by means of 4 C.P. brass screws and C.P. brass
washers, over rubber washers and wooden plugs firmly embedded in walls. C.P. brass clamps with
C.P. brass screws may be an alternative method of fixing where so directed. Unless specified
otherwise, the longer side shall be fixed as horizontal. The height of the bottom edge of mirror shall
not be less than 120cm above the floor level, unless otherwise specified or shown in drawings.
19.13.3. Measurements: Mirrors shall be enumerated according to their size.
19.13.4. Rate: The rate shall include the cost of all the material and labour involved in all the
19.14 Bath Tub:
19.14.1. Material: Bath Tub shall be of
(i) Enameled Steel Bath tub conforming to IS 3489-1985.
(ii) Gel- coated Glass Fibre Reinforced Polyester Resin conforming to IS: 6411-1985.
19.14.1.1. Bath Tub Enameled Sheet Steel:
i) The Bath Tub shall conform to IS: 3489-1985. Fig. 30 shows the patterns of Bath Tub. The
bath tub must have finished surface free from undulations, drawing lines and other defects,
deleterious to the provision of a satisfactory enamel coating.
ii) The interiors of the bath tub shall be adequately and evenly coated with vitreous enamel. The
enameling shall conform to IS: 772-1973. Thickness of the enamel shall not be less than 0.2mm
and not more than 0.5mm. External surface of the bath tub shall be given one ground or primer
enamel coating. Gloss, colour and capacity shall be uniform and visually satisfactory.
iii) A bath tub shall be liable to rejection if the finish shows any of the following defects:
(a) Crazing
(b) Dimples, Rundown sagging- unless not readily attracting attention when viewed from
normal eye level under natural light.
(c) Blisters-Not more than two in number on the interior surface shall be permitted
provided they can not be broken by a pressure of a finger nail.
(d) Pin holes- Pinholes not more than two in number for coloured bath tubs and not more
than four for white enameled bath tubs shall be permissible. There shall be no grouping of
pinholes and they shall not o penetrate in to the metal.
(e) Specks- Specks shall be less than one millimeter in size and maximum five in number
and there shall be no grouping. Specks less than 0.25 mm in size shall not be treated

as defect unless in sufficient number to form discolourisation.
iv) Warpage of edges set against wall or floor and edges of roll rims shall not exceed 5mm/ m,
warpage of all other edges shall not exceed 7.5 mm/m.
v) For the safety of users, bath tubs shall be as flat bottomed as practicable. The fall along the
bottom head end to outlet shall be adequate for complete emptying. The waste hole shall be so
formed as to be suitable for receiving a 40mm waste fitting. The bath tubs shall be provided at
the tap end, with effective means of attaching an earth continuity conductor. With each bath
tub, two spacing washers of suitable thickness to take up the difference between the thickness
of the metal of the bath tub and the depth of the seating on pillar taps shall be supplied. In
addition, two fibre or lead washers for each tap shall be supplied for fitting above and below
the tap roll to prevent the enamel from crazing when the taps are tightened in position.
vi) The maximum permissible variation from the dimensions specified in Fig.30 shall be ± 4
percent in all cases except overall width and overall length, where the variation shall not
exceed ± 1 percent.
Supports made of cast iron, mild steel or any other suitable material, as specified, shall be
provided. The support shall be non-adjustable type, as indicated in chain dotted line in Fig. 30
for use on bath tubs without panels. This shall include two sizes:
a) For bath tubs to which a trap with 35mm min. seal is to be fitted.
b) For bath tubs to which a trap with 70mm min. seal is to be fitted. 19.14.1.2
Bath Tub Gel- coated Glass Fibre Reinforced Polyester Resin (Fig. 28):
i) Bath tub shall conform to IS: 6411-1985. The fibre glass used in manufacture of bath tubs shall
be non-alkaline conforming to È' type or À' type Grade. The proportion of glass fibre shall not
be less than 25 percent of the glass fibre reinforced polyester layer including gel coated layer.
Unsaturated polyester resin used in the manufacture of bath tubs shall be resistant to hot water
and weathering. The bath tub shall possess a uniform gel-coat on the working surface. The resin
used in the gel-coat shall be isophthalic grade of polyester or epoxy resin or an equally suitable
chemical resistant grade of resin. The gel-coat shall not be less than 0.25 mm thickness nor
more than 1.00 mm thickness.
ii) Bath tub shall be one piece unit with an opening for waste outlet with floor sloping towards the
outlet. An overflow shall normally be provided on the side near the waste outlet. A side panel
may be provided integrally or separately with the bath tub. The waste opening shall be suitable
for the proper installation of waste fittings which are ordinarily used for the purpose. The bath
tub shall be provided with a supporting structure integral to the unit in between the space
between the bottom of the bath tub and the floor of the building on which the bath tub rests,
unless otherwise specified. The materials of the supporting structure shall be at least equal to the
material of the bath tub in resistance to deterioration with age and shall meet the requirements
of fungus and of vermin.
iii) In forming the roll, the outer edges shall be flanged or rolled back underneath sufficiently to
prevent exposure of sharp edges. The vertical height of the flanged or rolled edges shall be not
more than 30mm. At the top end of the roll, there shall be a level area within a radius of at least
25mm from the centre of each tap hole.
19.14.2. Bath Tub shall be inspected as per Appendix À' of Chapter 19.

19.14.3. Measurements: The bath tub shall be grouped according to the size and material used.
G.I. piping for supply as well as lead connection and taps shall be measured separately.
19.14.4. Rates: Rate shall include the material and labour involved in all the operations described
above including fixing.
19.15 Pillar taps: 19.15.1 Materials:
i) Pillar taps shall be of chromium plated brass and shall conform to IS: 1795-1982. The nominal
sizes of the pillar tap shall be 15 mm or 20 mm as specified. The nominal size shall be
designated by the nominal bore of the pipe outlet to which the tap is to be fitted. Finished
weights of 15mm and 20 mm pillar taps shall be as prescribed in Table 2.
Table 2: Minimum finished weights of pillar taps
Particulars eight for

Weight
15 mm size (gms.) 20 mm size (gms.)
Body 255 505
Washer Plate Loose Valve 15 28
Back nut 40 50
Tap 650 1175
Casting shall be sound and free from laps, blow and pitting . External and internal surfaces
shall be clean, smooth and free from sand and be neatly dressed. The body, bonnet and other
parts shall be machined true so that when assembled, the parts shall be axial, parallel and
cylindrical with surfaces smoothly finished.
ii) The area of waterway through the body shall not be less than the area of the circle of diameter
equal to the bore of the seating of the tap. The seating of pillar tap shall be integral with the body
and edges rounded to avoid cutting of washer. Pillar taps shall be nickel chromium plated and
plating shall be capable of taking high polish which shall not easily tarnish or scale.
iii) Every pillar tap, complete with its component parts shall withstand an internally applied
hydraulic pressure of 20 kg/ sq. cm maintained for a period of 2 minutes during which period
it shall neither leak nor sweat.
19.15.2.Measurements: Pillar taps shall be grouped according to their type & size and shall be
enumerated.
19.15.3. Rates: The rate shall include the cost of material and labour involved in all the operations
described above including fixing etc. complete.
19.16 Toilet paper holder:
19.16.1. Material: The toilet paper holder shall be of C.P. brass or vitreous china as specified and
of size and design as approved by the Engineer-in-charge.
19.16.2. Fixing: The toilet paper holder shall be fixed in position by means of C.P. brass screws
and rawl plugs or wooden cleats embedded in the wall.

19.16.3. Measurements: The toilet paper holders shall be grouped according to their material, size
and enumerated.
19.16.4. Rate: The rate shall include the cost of material and labour involved in all the operations
described above.
19.17 Showers:
19.17.1. Material:
19.17.1.1. Shower Head:
i) The shower head shall be made of Chromium plated brass or vitreous china as specified in the
schedule of quantities. The size of the shower head shall be as specified, the normal sizes being
100 mm dia. and 150 mm dia.
ii) The shower head shall be provided with perforation to break up the water into a fine spray.
The number of holes shall be about one hole of one millimeter diameter each, in one sq. cm.
area of the shower head. Thus:
(a) For a shower of 100mm dia, about 70 holes of one mm dia each.
(b) For a shower of 150 mm dia about 150 holes of one mm dia each.
iii) Inlet connection of each shower shall be screwed female in the case of metallic showers and
shall be of brass. The size of the inlet shall be as specified below:
(a) For 100mm shower face 12mm dia. inlet.
(b) For a 150 mm dia shower face 20mm dia. inlet.
19.17.1.2. Pipe fittings and Specials: All pipe work including specials shall be of G.I. pipe 12
mm dia. and shall be as per specification of G.I. pipe work.
19.17.2. Control of water supply:
i) When a shower is arranged for cold water supply only each shower shall be controlled by 12
mm screw down stop valve. This valve shall be measured separately.
ii) The shower shall be arranged for hot and cold water supplies blended manually by means of
a mixing valve conforming to IS: 1701, "Specifications for mixing valve for ablutionary and
domestic purposes". This valve shall be measured separately.
19.17.3. Fixing:
i) Unless otherwise specified or shown in drawings, the height of the shower fan shall be 2 to
2.20 m from floor level.
ii) The distance of the inner face of the shower from the wall shall be at least 45 cm unless
otherwise specified. The shower arm shall be fixed truly at right angles to the wall face unless
19.17.4. Measurements: Showers shall be classified on the basis of materials used, grouped
according to size and enumerated.
19.17.5 Rates: Rate shall include the cost of material and labour involved in all the operations
described above.
19.18. Construction of Septic Tank (Fig. 34 & 35):

19.18.1 Scope:
a) In area having no central sewage system, every house shall have arrangements for its sewage
being treated in septic tank, effluent from which should be given secondary treatment either in
a biological filter or on the land, or in a sub-surface disposal system.
b) Surface and sub-soil water should be excluded from finding way into the septic tank. Waste
water may be passed into the septic tank provided the tank and the means for effluent disposal
are designed to cope up with this extra liquid. Depending on the location of the water table and
the nature of the strata, the type of disposal for the effluent from the septic tank shall be decided.
19.18.2 Dimensions: Septic tanks shall have minimum width of 75 cm, minimum depth of one metre
below water level and a minimum liquid capacity of one cubic metre. Length of tanks shall be 2 to 4
times the width. Suitable sizes of septic tanks for use of 5, 10, 15, 20 and 50 persons based on certain
assumptions are given in Appendix `B' of Chapter 19.
19.18.3 Cover and Frame: Every septic tank shall be provided with C.I. cover of adequate strength.
The cover and frames shall be 500 mm dia. (M.D.) minimum or 610 mm x 455 mm (LD). The
specification for frames and cover given shall apply.
19.18.4 Ventilating Pipe:
Every septic tank shall be provided with C.I. ventilating pipe of at least 50 mm diameter. The top
of the pipe shall be provided with a suitable cage of mosquito proof wire mesh.
The ventilating pipe shall extend to a height which would cause no smell nuisance to any
building in the area. Generally the ventilating pipe may extend to a height of about 2 m, when
the septic tank is at least 15 m away from the nearest building and to a height of 2 m above the
top of the building when it is located closer than 15 meters. The ventilating pipe may also be
connected to the normal soil ventilating system of the building where so desired.
19.18.5 Disposal of Sludge: The sludge from septic tanks may be delivered into covered pit or into
a suitable vehicle for removal from the site. Spreading of sludge on the ground in the vicinity shall not
be allowed.
19.18.6 Testing: Before the tank is commissioned for use, it shall be tested for water-tightness by
filling it with water and allowing it to stand for 24 hours. It shall then be topped up, if necessary,
and allowed to stand for a further period of 24 hours during which time the fall in the level of the
water shall not be more than 1.5 cm.
19.18.7 Commissioning of Septic Tank: The tank shall be filled with water to its outlet level before
the sewage is let into the tank. It shall, preferably, be seeded with small quantities of well digested
sludge obtained from septic tanks or sludge digestion tanks. In the absence of digested sludge a small
quantity of decaying organic matter, such as digested cow dung, may be introduced.
19.18.8 Sub-surface Absorption System: The effluent from a septic tank shall be disposed of by a
soak pit or a dispersion trench depending on the position of the sub-soil water level, soil and sub-
soil conditions and the size of the installation.
19.18.9 Measurements: Septic tank shall be enumerated.
19.18.10 Rate: The rate shall include the cost of materials and labour involved in all the operation,
except Sub-Surface absorption system which shall be paid for separately.

19.19 Soak Pit 2.5 m dia. x 3 m deep (Fig. 36):
19.19.1 Construction: The earth excavation shall be carried out to the exact dimensions as shown in
the figure. In the soak pit shall be constructed a honey-comb dry brick shaft 45x45 cm and 292.5 cm
high. Round the shaft and within the radius of 60 cm shall be placed well burnt brick bats. Brick
ballast of size from 50 to 80 mm nominal size shall be packed round the brick bats upto the radius
of 90 cm. The remaining portion shall be filled with brick ballast of 40 mm nominal size. The
construction of shaft and filling of the bats and the ballast shall progress simultaneously.
19.19.2 Cover and Drain: Over the filling shall be placed a single matting which shall be covered
with minimum layer of 7.5 cm earth. The shaft shall be covered with 7.5 cm thick stone or R.C.C.
slab 10 cm wide and 10 cm deep brick edging with bricks of class designation 75 shall be provided
round the pit. The connection of the open surface drain to the soak pit shall be made by means of
100 mm diameter S.W. pipe with open joints,
19.19.3 Measurements: Soak pit shall be enumerated.
19.19.4 Soak Pit 1.2 x 1.2 x 1.2 M:
19.19.4.1 Construction: The earth excavation shall conform to the general specifications for earth
work. After the excavation is complete the soak pit shall be filled with brick bats. The brick bats shall
be from properly burnt bricks. 10 cm wide and 10 cm deep brick edging with bricks of class
designation 75 shall be provided round the soak pit.
19.19.4.2 Measurements:Soak pits shall be enumerated.
19.19.4.3 Rate: Rate shall include the cost of labour and materials involved in all he operations.
19.20 Dispersion Trench (Fig. 37) :
19.20.1 It shall be provided when the sub-soil water level is within 180 cm from the ground level.
Dispersion trenches are not recommended in areas where fibrous roots of trees or vegetation are likely
to penetrate the system and cause blockages.
19.20.2 Construction:
a) Dispersion trenches 50 to 100 cm deep and 30 to 100 cm wide shall be excavated to a slight
gradient and shall be provided with 15 to 25 cm of washed gravel or crushed stones. Open
jointed pipes placed inside the trench shall be made of unglazed earthenware clay or concrete and
shall have minimum internal diameter of 75 to 100 mm. Each dispersion trench should not be
longer than 30 m and trenches should not be placed closer than 1.8 m.
b) The covering for the pipes on the top shall be with coarse aggregate of uniform size to a depth
of approximately 15 cm. The aggregate above this level may be graded with aggregate 12 to 15
mm to prevent ingress of top soil while the free flow of water is no way retarded. The trench
may be covered with about 30 cm of ordinary soil to form a mound and turned over. The
finished top surface may be kept at least 15 cm above ground level to prevent direct flooding
of the trench during rains.
19.20.3 Measurements:The length of dispersion trench shall be measured in running metre nearest
to a cm.
described above.

APPENDIX - À'
METHOD OF INSPECTION FOR DEFECTS OF BATH TUBS
i) The surface of the bath tubs shall be visually inspected for blemishes from a distance of 600
mm after being inked. The light source shall be partially diffused daylight supplemented, if
necessary, with diffused artificial light to provide illumination comparable to that usually
available within short distance of the outside window facing north, but not in direct sunlight.
The illumination shall have an intensity of 1,000 to 2,000 lux. Blemishes other than given in
Table A-2 shall not be allowable.
ii) Ink Test: To do the visual examination of the surface of the bath tub, ink is applied to the
area to be inspected as follows:-
(a) Wash the entire area to be inspected with a water soluble ink.
(b) Rinse the surface with fresh water and dry. Ink will remain entrapped in cracks pits
etc.
All references to visible defects shall refer to defects apparent to the eye upon close
inspection, after the surface has been ink tested.
iii) The defects which cannot be permitted are listed in Table below:
Table A-1 : Defects which cannot be permitted
Part Non-permissible Defects

Upper rim, inner wall, bottom apron, Small pores, wrinkle craze, bubbles, defective
other visible faces. impregnation, superficial defects, injuries,
aggregate defects.
Obscure faces Defective impregnation, Superficial defects.
iv) The permissible range of various defects a r e T a b l e b e l o w :

Table A-2: Permissible Defects
Defects/Parts Upper Inner Apron Bottom Other Readily
Rim Wall Visible Parts
Traces of mending 2 2 2 2 Not conspicuous
Impurities 2 3 2 3 -do-
Pinholes 2 3 2 3 -do-
Colour bolt Should not be Conspicuous
Unevenness Should not be Conspicuous
Deformity The horizontal section of the upper rim shall drain off water readily. The bend of the
section in content with wall shall be less than 5 mm. Deformities of the other sections of the bath
tub shall not be conspicuous.

Table A-3 : Functional Dimensions of Long and Orissa Patterns
Si. Description Ref. in Long Pattern of Orissa Pattern of
No. Fig. 1 Size Size
and 2 580 630 580x440 630x450
1. 2. 3. 4. 5. 6. 7.
i) Length A 580 630 580 630
ii) Length of opening, Min B 480 530 470 500
iii) Height F 300+10 319+10 300+10 319+10
iv) Width of opening, small end H 170+10 170+10 180+10 180+10
v) Width of opening, wide end J 260+10 260+10 210+10 210+10
vi) Slope of bottom of Pan, Min ? 15° 15° 15° 15°
vii) Distance between the centre L 70 70 70 70
of outlet to the inside face of
flushing rim at the back, Max.
viii) Width N - - 440 450
ix) Length of foot rest P - - 310+10 310+10
v) Tolerances where not specified
shall conform to Part I of
IS: 2556
APPENDIX `B'
RECOMMENDED SIZES OF SEPTIC TANKS
RECOMMENDED SIZES OF SEPTIC TANKS FOR UPTO 20 USERS

No. of Length Breadth Liquid depth (Cleaning interval of)
users 1 year 2 year
no. m m m m
5 1.5 0.75 1.0 11.05
10 2.0 0.90 1.0 1.40
15 2.0 0.90 1.0 2.00
20 2.3 1.10 1.0 1.80
Note: 1. The capacities are recommended on the assumptions that discharge from only WC will
be treated in the septic tank.
2. A provision of 300 mm should be made for free board.
3. The sizes of septic tanks are based on certain assumptions, while choosing the size of
septic tank exact calculation shall be made.

RECOMMENDED SIZES OF SEPTIC TANKS FOR RESIDENTIAL COLONIES
No. of Length Breadth Liquid depth (Cleaning interval of)
users 1 year 2 year
no. m m m m
50 5.0 2.0 1.0 1.24
100 7.5 2.65 1.0 1.24
150 10.0 3.0 1.0 1.24
200 12.0 3.3 1.0 1.24
300 15.0 4.0 1.0 1.24
Note:
2. The sizes of the septic tank are based on certain assumptions while choosing the size of
septic tank, exact calculation shall be made.
3. For population over 100, the tank may be divided into independent parallel chambers for
ease of maintenance and cleaning.
RECOMMENDED SIZES OF SEPTIC TANKS FOR HOSTEL

AND BOARDING SCHOOLS
No. of Length• Breadth Liquid depth (D) for intervals of sludge
users stated
no. withdrawal
in Once
a year in 2 years
m m m m
50 5.0 1.6 1.3 1.4
100 5.7 2.1 1.4 1.7
150 7.7 2.4 1.4 1.7
200 8.9 2.7 1.4 1.7
300 10.7 3.3 1.4 1.7
Note :-
2. The sizes of the septic tank are based on certain assumptions while choosing the size of
septic tank exact calculation shall be made.
3. For population over 100, the tank may be divided into independent parallel chambers for
ease of maintenance and cleaning.

Table: F-5 : Dimensions and Permissible Tolerance of Pattern 2 Water Closets
S. Description Ref. in Dimensions Tolerance
No. Fig. 7
(1) (2) (3) (4) (5)
i) Height A 390 ± 20
ii) Height Of Centre Line Of Flush Inlet B 350 ± 20
iii) Height Of Centre Line Of Outlet For P-Trap Cl 180 ± 10
Only
iv) Distance From End Of Trap To Floor For C2 20 ±5
S-Trap Only
v) Internal Dia Meter Of Outlet Min* D 80 -
vi) External Dia Meter Of Outlet Max* D 110 -
vii) Internal Diameter Of Flush Inlet Socket E 50 ±3
viii) Depth Of Flush Inlet Socket F 30 ±3
ix) Distance From End Of Flush Inlet Socket To G 45 -
Outside Of Outlet, Min.
x) Depth Of Water Seal Min H 50 -
xi) Water Surface Area Max - 7500 mm2 -
xii) Length From Seat Bolt Holes To Front Rim L 430 -
xiii) Diameter Of Seat Bolt Holes M 13 -
xiv) Distance Between Centre Of Seat Bolt N MAX 175 -
Holes MIN 160
xv) Width Of Opening,Min P 240 -
xvi) Length Of Opening Min Q 290 -
xvii) Length Of Serrated Part Of Outlet R 50 -
xviii) Overall Length Max S 500 to 573 -
xix) Trap Inlet Depth T MAX 75 -
MIN 90
xx) Angle Of Back Plate 90° to 135° -
XXI Angle Of Outlet q 104° -
*Ovality Permissible Within The Dimensions For Inlet And Outlet Diameters.

SI IS No. Subject
1. 771-1979 Glazed Fire-Clay Sanitary appliances: Part 1: General requisites (2 Rev.)
(Amdt.1) (Reaffirmed 1992)
2. 771-1985 Glazed fire-Clay Sanitary appliances: Part 2 Specific requirements of
kitchen and laboratory sinks (3rd revision) Reaffirmed 1990).
3. 771-1979 Glazed fire Clay Sanitary appliances: Part 3/Sec. I Specific requirements
of urinals: Slab Urinals (2nd revision) (Reaffirmed 1992)
4. 771-1985 Glazed fire Clay Sanitary Appliances: Part 3/Sec. II Specific requirements
of urinals: Stall Urinals (3rd revision) (Reaffirmed 1990)
5. 772-1973 General requirements for enameled cast iron sanitary appliances (2nd
Rev.)(Amdt.I) (Reaffirmed 1992)
6. 774-1984 Flushing cisterns for water closets and urinals (other than plastic cistern)
(4th Rev.) (Amdt.3) (Reaffirmed 1990)
7. 775-1970 Cast iron brackets and supports for wash basins and sinks (2nd Rev.)
Reaffirmed 1990)
8. 1300-1994 Phenolic moulding materials.
9. 1703-1989 Copper alloy float valves (horizontal plunger type) for water supply
fittings (3rd revision)
10. 1729-1979 Sand cast iron spigot and socket soil waste and ventilating pipes, fittings
and accessories (1St revision) (Reaffirmed 1991)
11. 1795-1982 Pillar taps for water supply purposes (2"d revision) (Reaffirmed 1992)
12. 2267-1972 Polystyrene moulding materials (1St revision (Reaffirmed 1991)
13. 2326-1987 Automatic flushing cisterns for urinals (1St revision)
14. 2548-1983 Plastic seats and covers for water-closets: Part I. Thermo set seats and
covers (4th revision)- (Amendments 3) (Reaffirmed 1990)
15. 2548-1983 Plastic seats and covers for water - closets: Part II. Thermo Plastic seats
and covers (4th revision) (Amendments 2) (Reaffirmed 1990)
16. 2556 Specification for vitreous sanitary appliances (vitreous China)
16A. 2556-1994 -do- R. I General requirements (3rd revision)
16B. 2556-1994 -do- R. II Specific requirements of wash down water-closets (4th rev.)
16C. 2556-1994 -do- R. III Specific requirements of squatting pans (4th revision)
16D. 2556-1994 -do- R. IV Specific requirements of wash basins (3rd revision)
16E. 2556-1994 -do- R. V Specific requirements of laboratory sinks (3rd revision)
16F. 2556-1979 -do- Pt. VI Specific requirements of urinals, Sec. 1. Bowl type (3rd rev.)
16G. 2556-1974 -do- R. VI Specific requirements of urinals Sec. 2. Half stall urinals (2"d
Rev.) (Amdt.1) (Reaffirmed 1992)

SI IS No. Subject
16H. 2556-1974 -do- R. VI Specific requirements of urinals Sec. 3 squatting plates (2"d
16 I. 2556-1974 -do- R. VI Specific requirements or urinals, Sec.4. Partition slabs (2"d
16 J 2556-1995 -do- Part VIII Specific requirements of pedestal close coupled wash down
and symphonic water closets.
16K. 2556-1995 -do- R. X Specific requirements of foot rests (2°d revision) (Amendment
16L. 2556-1974 -do- R. X1V Specific requirements of integrated squatting pans (Amdt.2)
(Reaffirmed 1992)
16M 2556-1974 -do- Pt. Pt. XV Specific requirements of universal water closets
17. 2963-1979 Copper alloy waste fittings for wash basins and sinks (Pt Rev.)
(Reaffirmed 1992)
18. 3076-1985 Low density polyethylene pipes for potable water supplies (2nd Rev.)
19. 3389-1994 Urea formaldehyde moulding material (Pt revision)
20. 3489-1985 Specification for enameled steel bath tubs (Pt revision (Reaffirmed 1990)
21. 3989-1984 Specification for centrifugally cast (spun) iron spigot and socket soil,
waste and ventilating pipes, fittings and accessories (2nd revision)
(Amendment 2) (Reaffirmed 1991).
22 4827-1983 Electroplated coatings of nickel and chromium on copper and copper
alloys (with drawn)
23 4984-1987 High density polyethylene pipes for potable water supplies, sewage and
industrial effluents (3rd Rev.)
24 4985-1988 Specification unplasticised PVC Pipes for potable water supplies (2"d
Rev.) (Amendment 1)
25 6411-1985 Specification for gel-coated glass fibre reinforced polyester resin bath
tub (Pt Rev.) (Reaffirmed 1990)
26 7231-1984 Plastic flushing cisterns (valves siphonic type) for water closets and
urinals.(Reaffirmed 1990)
27 13983-1994 Stainless Steel sinks for domestic purposes-specifications.
CHAPTER No. 20
HORTICULTURE AND LANDSCAPING
CHAPTER No. 20 : HORTIULTURE AND LANDSCAPING
CONTENTS
20.0 Terminology and Definitions 3
20.1 Horticultural Works 8
20.2 Materials 8
20.3 Supplying and stacking of Materials. 8
20.4 Trenching in ordinary soil. 10
20.5 Good Earth 10
20.6 Fine dressing of ground. 11
20.7 Excavation and trenching for preparation of beds for 11
Hedge and Shrubbery.
20.8 Mixing Good Earth and Manure. 12
20.9 Uprooting rank vegetation and weeds and preparing 12
the ground for planting "Doob Grass".
20.10 Grassing with Doob grass. 13
20.11 Renovating Lawns. 13
20.12 Specifications for Lawn Mowers. 14
20.13 Digging pits for planting trees. 15
20.14 Tree Guards. 16
20.15 Earthen Flower Pots 17
20.16 Garden Tools. 19
20.17 Boundary Hedges. 21
20.18 Campus Road side Tree Plantation 21
20.19 Planning Trees and Grasses. 23
20.20 Method of collection, maintenance and sowing of seeds. 23
20.21 Nursery 25
20.22 Manure 26
20.23 Species/Planting trees on road side 26
20.24 Growing Annuals. 29
20.25 Plantation/Avenue plantation/median plantation, 30
transplantation, care and maintenance of trees
on urban roads.
20.26 Trees suitable for plantation in Rajasthan 32
20.27 Choice of the type of trees. 32
20.28 Fencing etc. 32
Rajasthan PWD Building Specifications 2014 Chapter 20 : Horticulture. Page 1 of 33


CHAPTER No. 20
HORTICULTURE AND LANDSCAPING
20.0 Terminology and Definitions : For the purpose of this standard, the following definitions
shall apply.
1) Absorption : The process of taking up water and holding in pores or open spaces as a
sponge.
2) Aeration: Any method which facilitates the entry of air into the interstices of the soil.
3) Autogamy When a flower is fertilized by its own pollen.
4) Auxin : A substance synthesized by a plant and able to influence growth at some point other
than the point of synthesis; comparable to a harmone in animals.
5) Bark Ringing : The removal of a narrow strip of bark from a part or whole of the
circumference.
6) Bedding : The planting of flowering or foliage plants in beds to give massive decorative
displays.
7) Blending : (a) Blending of grasses for a lawn. (b) Blending the plants in herbaceous borders.
(c) Mixing of colours in annual border to avoid clash of colours.
8) Brush Harrowing : The use of an implement on which brushes are mounted for
improvement of the surface condition of grass areas and removal of dry leaves.
9) Brushing : Manual or mechanical use of a brush for the improvement of the condition of the
surface.
10) Burn off : The destruction of vegetable growth above or at ground level by burning.
11) Charring : Protection from decay by the effect of fire used to carbonize the surface of wood.
12) Chlorosis : A diseased condition shown by loss of green colour that is chlorophyll.
13) Cleistugamy : Self pollination without the flower opening. .
14) Compatibility :
(a) Of sex cells, the ability to unite and form a fertilized egg that can grow to maturity.
(b) Congeniality as determined by the degree of success of the union between stock and
scion.
15) Composting : (a) The process of converting waste vegetable matter into humus. (b) The
application of compost of the soil.
16) Cross Raking : Cultivation by raking in two or more transverse directions.
17) Cultivate (Verb) :To till the soil by ploughing or other mechanical means.
18) Cutting Back : The removal of unwanted growth to a specific point, either. to protect the
plant from diseases or to have desired shape of the plant.

19) Cutting Down : In running, removal of top growth usually of multi-stemmed shrubs and
other plants to encourage fresh growth from old wood.
20) Cuffing Out: In pruning, the removal of dead or diseased wood or any unwanted growth.
21) Cuttings : The portion of a plant used for multiplication.
22) Damping Down : (a) The moistening of paths and paving to settle dust. (b) The moistening
of paths, and staging's usually in a greenhouse to maintain or increase humidity.
23) Die back : A disorder of tree, bush and vine fruits characterized by killing back of the
younger growth.
24) Soaking : The application of water to plants in open ground pots or containers to the extent
of saturating the soil about the roots.
25) DE blossoming : The cultural practice of removing completely the flowers from a growing
plant.
26) Defoliation : The cultural practice of causing the leaves to fall from a growing plant.
27) DE heading : The removal of faced flower or seed heads.
28) Digging : Breaking or loosening the soil by lifting with a spade or fork.
29) Digging in : The incorporation of additional material, such as organic material, fertilizers
and soil conditioners into the soil by digging.
30) Digging over : Cultivation of the soil by a fork to a shallow depth.
31) Digging Single (One Spit Digging): Digging to the full depth of a spade or fork.
32) Disbudding : The removal of unwanted buds.
33) Dividing : A method of multiplying plants or improving established herbaceous plants either
by cutting away or by Separating rooted plant plumps.
34) Infertile : Soils having a very limited capacity to produce vegetation.
35) Infilling : The correcting of irregularities in a surface by filling depressions with a suitable
material.
36) Interfertility : The ability of one variety to set fruit and produce seeds that will germinate
when pollinized by another variety.
37) Knife Ringing : A single circumferential knife cut in the stem or branch of a tree.
38) Latent Bud : A bud, usually concealed, more than one year old, which may remain dormant
indefinitely or may develop under certain conditions.
39) Layering : The method by which stem of a plant is pegged down and covered with a layer of
soil so that it takes root and can be detached.
40) Leaf Mould :Vegetable moulds obtained from leaves and weeds which have decayed well.
41) Lifting : The loosening and raising of the root ball of a tree or plant by manual or
mechanical means.
42) Liming : The application of lime to the soil.
43) Make Good : To rectify defective work, to replace dead, drying or inferior plants, turf, etc.
44) Manuring : The enrichment of soil with farmyard manures or any organic or inorganic
fertilizers.

45) Mesophyte : A plant that grows naturally under conditions of moderate humidity, and
neither requires nor will survive culture in water or extreme drought.
46) Minimal Cultivation : The reduction of physical cultivation methods by the application of
chemicals.
47) Mound-up : To cover up the lower part of the stem of a plant with soil usually to protect
tubers or for support or blanching.
48) Mowing : The cutting of grass by manual or mechanical means.
49) Mulching : The application of a layer of a suitable material to the surface of the soil to protect
the roots of the plants, to conserve moisture, reduce weed growth and reduce fluctuations in
soil temperature.
50) Naturalize : The practice of growing certain plants in simulated wild conditions and
allowing them to adopt natural habits and associations.
51) Netting (Verb) : The application of protective nets as netting to plants to prevent damage,
by mammals, birds, vermin or weather.
52) Nicking: (a) To give a horizontal incision below a bud or lateral shoot to control the flow of
sap. (b) The removal of a small piece of the coat of hard seed to assist germination.
53) Notching : The removal of a small crescent or triangle of bark to control the flow of sap to a
bud or lateral shoot.
54) Over Sowing : The repair of thin areas of sward by lightly cultivating the surface and
sowing additional seed.
55) Parthenocarpy : The production of fruit without true fertilization.
56) Pedicel : The support of a single flower of an inflorescence.
57) Pegging Down : A form of training by which shoots are brought down to a horizontal or
arched position and held by pegs driven into the soil.
58) Perennial : A plant which lives for more than two years.
59) Plashing (Pleaching) : A form of training in which branches and twigs of adjoining plants
are roughly intertwined in the form of a screen.
60) Photoperiodism :The influence of light on direction of growth.
61) Peduncle : The support of an inflorescence or a flower stalk.
62) Polyembryony : The production of more than one embryo in an avule.
63) Prickling: The light disturbance of soil surface with a fork.
64) Pricking-Off : Removal of seedlings from*an overcrowded seed pan or nursery bed.
65) Proliferation : A rapid and repeated production of new parts, as the formation of leafy parts
from floral parts.
66) Pruning : The cutting of trees and shrubs to improve their growth and appearance.
67) Pulverising : Breaking the soil from lumps or clods down to finer state, either mechanically
or by manual methods.
68) Raking (Raking Over): (a) Final cultivation by a rake to produce a fine filth and bring to a
true even surface prior to sowing, planting, or turfing. (b) Drawing a rake across a surface to
remove unwanted material, for example, raking stones from soil. (c) Drawing of

a spring tine rake or similar tool across turf to remove moss, leaves and litter.
69) Raking In :The incorporation of additional material, such as seed, fertilizers, and chemical
compounds into the surface layer of the soil by raking.
70) Rank (Adjective) : The unwanted vegetative growth.
71) Re-setting : Replanting.
72) Respiration: Gaseous exchange by which the plant absorbs oxygen and gives off carbon
dioxide.
73) Ridging : A method of cultivation in which the soil is thrown up into ridges.
74) Rolling : Passing a roller over a surface to crash or consolidate the material or to form a
better surface.
75) Rotary Mowing : The mowing of grass by a rotary type machine.
76) Rotation : A succession of different crops on a piece of ground.
77) Rotavating : Tilling the soil with a rotary action by means of a mechanical rotavator.
78) Rough Cutting : Maintenance of grass areas by hand-scythe, motor-scythe or similar tools.
79) Score : To cut or slit to a pre-set depth, that is, the vertical cutting of turf prior to lifting.
80) Screening (Sifting or Sieving) : The separation of materials, such as soil, compost, wood ash,
leaf soil and peat into various grades of particle size by using either hand or mechanical sieves
or screens. The finer materials are shifted from coarse, the degree of fineness depending on the
number and size of mesh of the sieves or screens used (the choice of synonym depending upon
the implement used).
81) Scything: (a) The cutting of grass with a scythe. (b) Usually the cutting of long grass, either
with a scythe or by a reciprocating knife or machine.
82) Seasonal Bedding : The planting of flowering or foliage plant in beds to give massive
decorative displays.
83) Smother: A-cultural practice of controlling close growing weed growth by skimming the
surface and turning with a spade to cover the green top growth with root, mat and soil.
84) Sod Culture : A method of orchard soil management in which a permanent perennial crop is
grown between the trees, season and then allowed to remain on the ground. A limited area
around the trees is hoed, spaded or otherwise tilled.
85) Sod-Sowing :The restoration of an existing grass sward by re-sowing after scarification or
chemical destruction.
86) Sour Sap: A sour or fermented condition of the sap often associated with a high water table
or other root disturbance and usually followed by the death of the tree.
87) Spiking : Perforation of turf with a solid tined implement.
88) Spit : A layer of soil in depth, equal to the blade of a spade.
89) Sponging : The treatment of plants by washing or wiping leaf surfaces and sterns with soft
water or insecticide, for display, routine maintenance or pest control.
90) Spraying : The application of water, other liquids or liquid mixtures containing insecticides
or fungicides in the form of fine droplets produced under pressure.

91) Spring Bedding : The planting of flowering or foliage plants in beds to give massive
decorative displays during springs.
92) Springing: The easing of soil compaction, usually under turf, by lightly levering with a fork.
93) Staking : The supporting of trees or shrubs against movement by attachment to one or more
posts of wood or metal.
94) Sterility : The inability to produce seeds that will germinate.
95) Summer Fallow : Allowing land to lie idle for a season to conserve water for use the
following season.
96) Sunburn : The killing of bark near the ground surface due to reflected heat rays, a form of
sunscald.
97) Sweeping : The removal of leaves or debris by a brush, broom, or machine.
98) Top-Dress : To apply fresh soil, peat, compost or other material fertilizers or conditioners to
the surface of soil or turf.
99) Topiary Work : The clipping of shrubs or small trees to train them into ornamental or
fanciful shapes.
100) Topping of Grass : Lightly mowing.
101) Topping of Hedges and Plants : The shortening of leading shoots.
102) Topping of Trees : The shortening of leading shoots to encourage branching and to obtain
better shape.
103) Training : The shaping of a plant by pruning, tying-in or other means to produce a desired
form.
104) Trenching : A type of terracing Where small trenches are constructed across the land slope in
order to intercept and either to drain it-safely or to conserve it on land, particularly for
improving soil condition of the degraded land slopes where afforestation of pasture
development programme are taken. When the trenches are made on contour, it is called contour
trenching and when the trenches are provided with a gradient across land slope, it is called
graded trenching.
105) Trimming : Slightly clipping upon any plant material to align edge or shape.
106) Turfing : Laying a lawn with the turfs lifted from an established lawn.
107) Turf-Perforation :The operation of making a series of holes through a grass sward into the
soil beneath with a spiked peat or hollow tined implement to improve the free passage of air,
moisture and nutrients.
108) Twig Staking : Supporting of plants by twigs of brushwood inserted into the ground.
109) Under fill : Packing soil beneath sunken turf to raise it to the desired level.
110) Weed : Undesirable or unwanted plants.
111) Weeding : The manual, mechanical or chemical removal of weeds.
112) Weeding Out : The removal of undesirable or unwanted plants.
113) Wind Burn : A disorder of the leaves in which first their edges and later perhaps the entire
leaf dries out and presents a scorched appearance.

114) Witches Broom : A disorder of the stem or it's branches in which there is an extreme amount
of branching,. Resulting in a very brushy condition, sometimes caused by fungus attack.
115) Working In: Any method of incorporating into the upper levels of the soil or into turf any
substance for its improvement.
116) Xerophyte : A plant that can endure extreme drought.
20.1 Horticultural Works: Horticultural operations shall be started on ground previously levelled
and dressed to require ground formation levels and slopes. In case where unsuitable soil is met
with, it shall be either removed or replaced or it shall be covered with good earth to a thickness
suitable for the plants and decided by the Horticulture-in-Charge.
In the course of excavation or trenching during horticultural operations, any walls, foundations,
etc. met with shall not be dismantled without pre-measurement and prior to the written
permission of the Engineer-in-charge.
20.2.: Materials:
a) Grass
(1) Mandawri Doob (grass), and Calcutta Doob (Grass)
(2) Bermuda, and Selection No.1
(3) Carpet.
b) The area from where the grass roots are to be obtained shall be specified by the Horticulture-
in Charge at the time of execution of the work and no royalty etc. shall be charged on this
account from the contractor. Grass is to be arranged by contractor (cost of grass to be paid
separately). The grass shall be fresh, free from weed and rank vegetation but having # Rhizome
# with sufficient nodes and shall be approved by Horticulture-in-Charge before planting.
20.2.1 Measurement: The area of grassing shall be measured in sqm as laid as per specifications.
20.2.2 Rate: It shall include all materials, tools, plants and labour. The payment shall be in Rs./
sqm
20.3 Supplying and Stacking of Materials
20.3.1 Manure: Farm Yard Manure : It shall be well decayed, free from grits and any other
unwanted materials. It shall be transported to the site in lorries with efficient arrangement to prevent
spilling enroute. It shall be stacked at site. Each stack shall not be less than 50 cm height and volume
not less than 3 cum.
a) Measurements: Length, breadth and depth of stacks shall be measured correct to a cm. The
volume of the stack shall be reduced by 8% for looseness in stacking and to arrive at the net
quantity for payment.
b) Rate : The rate shall include the cost of manure, transportation, all labour and T&P involved
in all operations described above, including carriage up to one km. The rate shall also include
royalty if payable.
20.3.2 Good Earth: The soil shall be suitable for gardening free from kankar, Moorum shingle, rocks,
stones, brick bats, building rubbish and any other foreign matter. The earth shall be free from clods
or lumps or sizes bigger than 75 mm in any direction. It shall have pH Value ranging

between 6 to 8.5. The earth shall be stacked at site in stacks not less than 50 cm high and of volume
not less than 3.0 cum.
a) Measurements : Length, breadth and height of stacks shall be measured correct to a cm. The
volume of the stacks shall be reduced by 20% for voids before payment, unless otherwise
described.
b) Rate : The rate shall include the cost of excavating the earth from areas lying at distances not
exceeding one km from the site, transporting the same at site breaking of clods and stacking at
places indicated. The rate shall also include royalty if payable.
20.3.3 Oil Cake (Neem/Castor): The cake shall be free from husk, dust, grit and any other foreign
matter. It should be un-decorticated and pulverised. The material shall be packed in old serviceable
gunny bags of 50 kg capacity approximately. The quality of cake should be got approved by the
Horticulture-in-Charge before supply.
a) Measurement : The arrangement for weighing shall be made at site of work by the
department. The gunny bags shall be the property of the government.
b) Rate: The rate shall include the cost of material and labour involved in all the operations
described above, including carriage to and stacking at the site of work with all leads and lifts,
taxes, weighing etc.
20.3.4 Supply and Stacking of Sludge : It shall be transported to the site in lorries with efficient
arrangement to prevent spilling enroute. It shall be stacked at site. Each stack shall not be less than
50 cm height and volume not less than 3 cum.
a) Measurements : Length, breadth and depth of stacks shall be measured correct to a cm. The
volume of the stack shall be reduced by 8% for looseness in stacking and to arrive at the net
quantity for payment.
b) Rate: The rate shall include the cost of labour and material involved in all operations described
above, including carriage up to one km. The rate shall also include royalty if payable.
20.3.5 Goat Dung Manure: Dried and pulverised is a good manure vegetation. It shall be stacked
at site. Each stack shall not be less than 50 cm height and volume not less than 3 cum. Measurement
and rate as per farm yard manure.
20.3.6 Vermin compost:
a) Vermicompost is an organic manure (bio-fertilizer) produced as the vermicast by earth worm
feeding on biological waste material, plant residues. This compost is an odourless, clean,
organic material containing adequate quantities of N, P, K and several micronutrients essential
for plant growth. Vermicompost is a preferred nutrient source for organic farming. It is eco-
friendly, non-toxic, consumes low energy input for composting and is a recycled biological
product.
b) Vermicompost is nothing but the excreta of earthworms, which is rich in humus and nutrients.
We can rear earthworms artificially in a brick tank or near the stem / trunk of trees (specially
horticultural trees). By feeding these earthworms with biomass and watching properly the food
(bio-mass) of earthworms, we can produce the required quantities of Vermicompost.
Advantages of Vermicompost:
1. Vermicompost is rich in all essential plant nutrients.

2. Provides excellent effect on overall plant growth, encourages the growth of new shoots / leaves
and improves the quality and shelf life of the produce.
Vermicompost is supplied in PVC bags with instructions on dosage and use.
20.4. Trenching in Ordinary Soil
a) Trenching of soil is done in order to loosen the soil, and turn over and buried the top layer
containing weeds etc. in the base and to bring up the lower layers of good earth-to form a
proper medium for grassing, regrassirig, hedging and shrubbery.
b) Trenching shall be done to the depth ordered by the Superintendent -in-charge. The depth is
generally 30 cm. for grassing and 60 cm. for regrassing in good soil.
c) The trenched ground shall, after rough dressing, be flooded with water by making small kiaries
to enable the soil to settle down. Any local depression unevenness etc. shall be made good by
dressing and or filling with good soil.
d) Weeds or other vegetation which appear on the ground are then -uprooted and removed and
disposed off and paid for separately. The surface when hard enough is fine dressed. These
operations when carried out are, however, payable separately from trenching.
20.4.1 Trenching:
Trenching shall consist of the following operations:
1. The whole plot shall be divided into narrow rectangular strips of about 1.5 m width or as
2. These strips shall be sub-divided lengthwise into about 1 m long sections. Such sections shall
be excavated serially and excavated soil deposited in the adjacent section preceding it.
3. In excavating and depositing care shall be taken that the top soil with all previous plant growth
including roots, get buried in the bottom layer of trenched area, the dead plants so buried
incidentally being formed into humus.
4. The excavated soil shall be straight away dumped into the adjoining sections so that double
handling otherwise involved in dumping the excavated stuff outside and in back filling in the
trenches with leads is practically eliminated.
20.4.2 - Measurements
Length and breadth of the plot shall be taken correct to 0.1 m and depths correct to cm. Cubical
contents shall be calculated in cubic meters, correct to two places of decimal. No deduction shall be
made nor extra paid for removing stones, brick bats and other foreign matter met with during
excavation up to initial lead of 50 m and stacking the same.
20.4.3 Rate
The rate shall include the cost of all labour and material involved in the operations described above,
including cost of all precautionary measures to be taken for protections and supporting all services
etc. met with during trenching. It does not include the cost of mixing of earth, sludge/ manure.
20.5. Good Earth : The good earth supplied shall be stacked at site in stacks not less than 50 cm
high and of volume not less than 3 cum
20.5.1 Measurements: Length, breadth and height of stacks shall be measured correct to a cm.

The volume of the stacks shall be reduced by 20% for voids before payment, unless otherwise
described..
20.5.2 Rate: The rate shall include the cost of excavating the earth from areas lying at distance not
exceeding one km. from the site, transporting the same at site breaking of clods and stacking at
places indicated. The rate shall also include royalty if payable.
20.5.3 Spreading Good Earth
Good earth sludge shall be removed from stacks by head load and spread evenly over the surface to
the thickness ordered by the Horticulture-in-charge. It shall be spread with a twisting motion to avoid
segregation and to ensure that spreading is uniform over the entire area.
20.5.4-Measurements: The quantity of good earth spread shall be determined by the difference in
the volume of good earth in stacks before and after spreading duly reduced for looseness- in stacking
by 20% of good earth.
20.5.5 Rate : The rate shall include the cost of all labour, T&P, and materials involved in all the
operations described above, but does not include the cost of the good earth which shall be paid for
separately unless specifically described in the item.
20.5.6 Uprooting Weeds from Trenched Areas:
After 10 days and within 15 days of flooding the rough dressed trenched ground with water, the
weeds appearing on the ground, shall be rooted out carefully and the rubbish disposed off as directed
by the Horticulture-in-Charge.
a) Measurements: Length and breadth shall be measured correct to 0.1 metre. Superficial area
of the weeded ground shall be measured for the purpose of payment.
b) Rate: The rate shall include the cost of all labour and tools & equipment /materials involved
in all the operations described above.
20.6 Fine Dressing the Ground:
Slight unevenness, ups and downs and shallow depressions resulting from the settlement of the
flooded ground, in drying and from the subsequent weeding operations, shall be removed by fine
dressing the surface to the formation levels of the adjoining land as directed by the Horticulture
Inspector/Superintendent Gardens, and by adding suitable quantities of good earth brought from
outside, if necessary. Such supply and spreading of good earth stacked at site is however, payable
separately.
20.6.1 Measurements:- Length and breadth of the dressed ground shall be measured correct to 0.1
metre. The area shall be calculated in sqm. correct to two places of decimal.
20.6.2 Rate:- The rate shall include the cost of all labour, T&P, and materials involved in all the
operations described.
20.7 Excavation and Trenching for Preparation of Beds for Hedge and Shrubbery:
i) Beds for-hedges and shrubbery are generally prepared to width of 60cm to 125 cm- and 2 to 4
metre respectively. Beds for hedges and shrubbery shall be prepared in the following manner:-
ii) The beds shall first be excavated to a depth of 60 cm. and the excavated soil shall be stacked
on the sides of the beds. The surface of the excavated bed shall then be trenched to a further
depth of 30 cm. in order to loosen the soil, in the manner described in

measurement for Trenching. No Flooding will be done at this-stage but the top surface shall be
rough dressed and levelled. The excavated soil from the top 60 cm. depth of the bed stacked at
the site shall then be thoroughly mixed with sludge or manure in the proportion 8:1 by volume
(8 parts of stacked volume of earth after reduction by 20% to 1 part of stacked volume of sludge
or manure after, reduction by 8%) or other proportion as described in the item. The mixed earth
and manure shall be refilled over the trenched bed, levelled neatly and profusely flooded so
that the water reaches-even the bottom most layers of the trenched depth of the bed. The surface
after full subsidence shall again be refilled with the earth and manure mixture, watered and
allowed to settle and finally fine dressed to the level 50 mm to 75 mm below the adjoining
ground or as directed by the Horticulture / Superintendent-in-charge. Surplus earth if any shall
be disposed off as directed by the Superintendent-in-charge. Any surplus earth if removed
beyond initial lead shall be paid for separately.
iii) Stones, brick bats and other foreign matter if met with during excavation or trenching shall be
removed and stacked within initial lead and lift, such material as is declared unserviceable by the
Horticulture / Superintendent -in-charge shall be disposed by spreading and levelling at places
ordered by him. If disposal is outside the initial lead and lift, then the transport for the extra
leads will be paid for separately. If a large proportion of material unsuitable for the hedging
and shrubbery operations is met with and earth from outside is required to be brought in for
mixing with manure and filling, the supply and stacking of such earth will be paid for
separately.
20.7.1 Measurements - Length, breadth and depth of the pit excavated and trenched shall be
measured correct to a cm. The cubical contents shall be calculated in cubic metre correct to two
place of decimal.
20.7.2 Rate - The rate shall include the cost of all labour and materials involved in all the operations
described above with the exceptions noted above. The rate shall not include the cost of supplying
and stacking sludge or manure unless the same is specifically included in the description of the item.
20.8 Mixing of Good Earth and Manure:
The stacked earth shall, before manual mixing, be broken down to particles of sizes not exceeding-6
mm. Good earth shall be thoroughly mixed manually with sludge or manure in specified proportion
as described in the item or as directed by the Superintendent -in-charge. The mixing shall be spread
at the surface and for 75 mm depth below, shall be broken down to particle size not more than 10
mm in any direction.
20.8.1 Measurements:- The quantity of good earth and sludge or manure mixed shall be determined
by the difference in the volume of good earth, sludge or manure in stack, before and after spreading
duly accounted for voids and looseness in stacks.-
20.8.2 Rate -The rate shall include the cost of all labour and materials involved in all the operations
described above, but does not include the cost of good earth sludge or manure which shall be paid
for separately, unless otherwise described in the item.
20.9 Uprooting Rank Vegetation and Weeds and Preparing the Ground for Planting Doob
"grass" :
i) Initially the area shall be dug up to a depth of 30 cm and weeds and rank vegetation with

roots removed there from by repeated forking. The whole area then shall be retrenched to a
depth of 60 cm.
ii) Clods of excavated earth shall then be broken up to the size not more than 75 mm in any
direction. The area shall then -be flooded with water and after 10 days and within 15 days of
flooding, weeds that germinate again shall be uprooted carefully..
iii) The rubbish arising from the above operations shall be-removed and disposed off in a manner
directed by the Horticulture-in-Charge, away from the site. The earth shall then be rough
dressed and fine dressed.
20.9.1 Measurements:- The length and breadth of uprooted area shall be measured correct to 0.1
metre. The area shall be calculated in sqm correct to two places of decimal.
20.9.2 Rate:- The rate shall include the cost of all labour and materials involved in all the operations
described above.
20.10 Grassing with 'Doob Grass':
i) The area from where the grass roots are to be obtained shall be specified by the Horticulturein-
Charge at the time of execution of the work and no royalty shall be charged on account from
the contractor.
ii) The soil shall be suitably moistened and then the operation of planting grass shall be
commenced. The grass shall be dibbled at 10 cm., 7.5 cm., 5 cm apart in any direction or other
spacing as described in the item. Dead grass and weeds shall not be planted. The contractor
shall be responsible for watering and maintenance of levels and the lawn for 30 days or till the
grass forms a thick lawn free from weeds and fit for mowing whichever is later. Generally
planting in either direction at 15 cm, 10 cm spacing is done in the case of large open spaces, at
7.5 cm spacing in lawns.
iii) Precautions -During the maintenance period, any irregularities arising in ground levels due to
watering or due to trampling by labour, or due to cattle straying thereon, shall be constantly made
up to the proper levels with earth as available or brought from outside as necessary. Constant
watch shall be maintained to ensure that dead patches are replanted and weeds are removed.
20.10.1 Measurements:- Length and breadth of the lawn grassed shall be measured correct to 0.1
metre and the area shall be calculated in square metre correct to two places of decimal.
20.10.2 Rate:- The rate shall include the cost of all labour and materials involved in all the operations
described above, excluding supply of the requisite quantity of good earth if so needed for properly
maintaining the levels of the lawns.
20.11 Renovating Lawns:
i) The area shall be first weeded out of all undesirable growth. The entire grass shall be scrapped
(cheeled) without damaging roots and levels of the grounds. Slight irregularities in surface shall
be levelled off and the area shall then be forked so as to aerate the roots of the grass without,
however up-rooting them.
ii) Specified quantity of manure shall then be spread uniformly with wooden straight edge (phatti)
as directed by the Horticulture-in-Charge. The area shall then be slightly sprinkled with water
so as to facilitate proper integration of the manure or sludge with-the soil and later flooded.
The contractor shall be responsible for watering,

iii) proper maintenance and tending of the lawn for 30 days or till the grass forms a
lawn fit for mowing, whichever is later.
iv) During the above operations, all undesirable growths shall be constantly weeded
out and all rubbish removed and disposed off as directed by the Horticulture-in-
Charge.
20.11.1 Measurements:- Length and breadth of the-lawn renovated shall be measured
correct to 0.1 m. The area shall be calculated in sqm correct to two places of decimal.
20.11.2 Rate:- The rate shall include the cost of all labour and T&P (excluding RH
Pipe/grass) involved in all-the operations described above, including the supply of the
requisite quantity of good earth if so needed for proper maintenance of the levels of the
lawns. The cost of the sludge or manure shall be measured and paid for separately,
unless its supply is specifically included in the description of the item.
20.12 Specification For Power Lawn Mower:
20.12.2 Cylinder Type Hand Lawn Mowers Part II - Roller Type: For the purpose
of this standard, the mowers shall be of the following two types.
Type A : The mower (See Fig.1) which requires one man or two men, one for
controlling and other for pulling.

Type-B: The mower (see Fig.2) which requires one man to control it and two men or animal(s) to
pull it.
20.13. Digging Pits for Planting Trees:
Digging pits in ordinary soil & refilling the same with the excavated earth mixed with manure in the
ratio of 2:1 by volume (2 parts of stacked volume of earth after reduction by 20% 1 parts of stacked
volume of manure after reduction by 8%) flooding with water and dressing including removal of
surplus earth (Cost of manure or extra good earth if needed to be paid separately) pit dia. 60 cm x
60 cm deep.
20.13.1-Measurement : Holes shall be enumerated.
20.13.2-Rate : The rate shall include the cost of all labour and materials involved in all the
operations described above excluding the cost of supplying and stacking the requisite quantity of
manure/sludge and oil cake.
20.13.3 In Soil Other than Ordinary Soil
i) Where pits are dug in (a) Hard soil (b) Ordinary rock or (c) hard rock, the above soils occurring
_ independently or in conjunction with each other and/or ordinary soil in any hole, the different
excavated soils shall be stacked separately. Excavation in hard rock shall be carried out by
chiselling only.
ii) The stack measurement of ordinary or hard rock shall be reduced by 50% and of hard soil by
20% to arrive at the excavated volume. These excavations shall be paid for as extras over the
rate for holes dug in ordinary soil above, at rates appropriate to the particular soil concerned.
iii) Sufficient quantity of good soil to replace the solid volume of stones, brick bats, unsuitable
earth and other rubbish, all roots and other undesirable growth, ordinary and hard stacks shall
be brought and stacked at site but the supply and stacking of such earth shall be paid for
separately.
iv) The useless excavated stuff shall be disposed off by spreading at places ordered by the
Horticulture-in-Charge. If such places are outside initial lead, carriage for the extra lead shall
be paid for separately.
21.13.4 Measurements: The pits shall be enumerated. The volume of excavation in soil other than
ordinary soil shall be determined by reducing the stack volume of the relevant soil with the respective
percentage deduction for voids.
21.133 Rate: The rate shall include the cost of labour and material involved in all the operations
described above including mixing, refilling, watering dressing etc.
20.14. Tree Guards:
20.14.1 Ornamental Circular Iron Tree Guard with Bars (Fig. 3).
(i) The tree guard shall be 50 cm. in diameter. The tree guards shall be formed of (i) 3 Nos. 25 x
25 x 3 mm angle iron verticals 2.00 m long excluding splayed outward at lower end up to an
extent of 10 cm. (ii) 3 Nos. 25 x 5 mm MS flat rings fixed as per design (iii) 15 Nos. 1.55 metre
long 6 mm dia. bars. Each ring shall be in two parts in the ratio of 1:2 and their ends shall be
turned in radially for a length of 4 cm at which they are bolted together with 8 mm dia. and 30
mm long MS bolts and nuts.
(ii) The vertical angle irons shall be welded to rings along the circumference with electric plant.15
Nos. bars shall be welded to rings at equal spacing along the circumference of ring. The lower
end of the angle iron verticals shall be splayed outwards up to an extent of 10 cm. The lower
end of the flat of lower ring shall be at a height of 45 cm. and upper end of the flat of top ring
shall be at the height of 2.00 metres. The middle ring shall be in the centre of top and lower
ring. The bars shall be welded to rings as shown in the drawing. The entire tree guard shall be
given two coats of paint of approved brand and of required shade over a priming coat of ready
mixed primer of approved brand. The design of the tree guard shall be as shown in the drawing.
20.14.2 Measurements : The tree guard shall be enumerated.
20.14.3 Rate : The rates shall include the cost of all labour and materials involved in all the
perations described above.
20.14.4 Tree Guards with MS angle, flat and welded wire mesh:
i) The tree guards shall be formed of (i) 3 Nos. 25 x 25 x 3 mm angle iron verticals 2.00 m
long excluding splayed outward.at lower end up to an extent of 10 cm. (ii) 3 Nos. 25 x 5
mm MS flat rings fixed as per design (iii) 15 Nos. 1.55 metres long 6 mm dia. bars. Each
ring shall be in two parts in the ratio of 1:2 and their ends shall be turned in radially for a
length of 4 cm at which they are bolted together with 8 mm dia. and 30 mm long MS bolts
and nuts.
ii) The vertical angle irons shall be welded to rings along the circumference with electric
plant.15 Nos. bars shall be welded to rings at equal spacing along the circumference of ring.
The lower end of the angle iron verticals shall be splayed outwards up to an extent of 10
cm. The lower end of the flat of lower ring shall be at a height of 45 cm. and upper end of
the flat of top ring shall be at the height of 2.00 metre. The middle ring shall be in the centre
of top and lower ring. The bars shall be welded to rings as shown in the drawing. The entire
tree guard shall be given two coats of paint of approved brand and of required shade over a
priming coat of ready mixed primer of approved brand. The design of the tree guard shall be
as shown in the drawing.
20.14.5 Measurements: The tree guard shall be enumerated.
20.14.6 Rate : The rates shall include the cost of all labour and materials involved in all the

20.14.7 Brick work tree guards: Honeycombed B.W. in various designs can an attractive and
economic tree guard. These can be painted in lime colours to add to the landscape. These can be
enumerated and can be paid as one complete item.
20.14.8 Earthen pit as a tree guard : Space permitting, a large (1.5 m dia and 1 m deep) pit can
also serve as a temporary tree guard. The soil dug is formed in to an earthen wall to protect the plant
from cattle. It needs better maintenance. It can be enumerated and paid as one complete item.
20.15. Earthen flower Pots
i) The earthen pots shall be moulded with good earth. These shall be thoroughly baked without being
vitrified, regular in shape and size. All the posts shall be free from visible defects such as cracks
chips, stones and flaws of any kind. The pots shall give a clear ringing sound when struck
together or with a light stick.
ii) Size: The sizes ( height) of the earthen pots are given in table as below:
(a) Earthen pot 150 mm size
(b) Earthen pot 225 mm size
(c) Earthen pot 300 mm size
(d) Earthen pot 350 mm size
iii) Tolerance : A margin for variation of 1.5 cm for pots of size 20 cm and above and a margin of
1 cm for pots of size 15 cm and below will be permitted.
iv) The. pots shall be stacked properly in a countable manner but not in more than 3 layers. The net
quantity for payment will be arrived- after deducting the broken pots, improperly baked or
otherwise damaged in any form assessed by physical appearance etc.
20.15.1 Measurement: The Earthen flower pots shall be enumerated for each size.
20.15.2 Rate: The rate shall include the cost of all the labour and material required, including
carriage to the site of work or the place specified.
20.15.3 Filling of Polythene Bags/Earthen Pots with Manure and Good Earth as Specified :
Filling of mixture of good earth and sludge or manure in polythene bags or earthen pots/cement
mosaic pots or any other containers.
20.15.4 Operations : Mixing:
i) The separately stacked earth and manure or sludge shall before mixing, be broken down to
particles of sizes not exceeding 6 mm in any direction. Good earth shall be thoroughly mixed
with sludge or manure in specified proportion as. directed in the item of as directed by the
Superintendent Garden-in-Charge.
ii) During the process of preparing the mixture as above and before actual filling in
bags/containers etc. required quantity of water should be sprinkled to keep mixture cool and
damp.
iii) The polythene bags/containers thus filled in, shall be arranged in countable manner in
properly prepared beds/ground as directed within 50 m lead.
20.15.5 - Measurement : In numbers.
20.15.6 Rate The rate shall include the cost of all labour etc. involved in all the operations
described above, but does include the cost of good earth, manure polythene bags and containers
which shall be paid separately unless specifically described in the item.
20.16 Garden Tools :
20.16.1 Specifications For Budding & Grafting Knife Combined :
The budding and grafting knife is one of the essential tools for a horticulturist who specializes in
evolving new varieties of crops with improved characteristics by using the budding and grafting
technique. This knife as the name suggests, has two blades meant for the two different purposes-
budding & grafting, riveted to either end of a common handle. Such knives are used extensively in
orchards, vegetable gardens and plantation nurseries.
The nomenclature of various parts of the knife shall be as given in fig.
Assembly of Budding and Grafting Knife, Combined

20.16.2 Specification For Spades & Seprangs:
Scope: Spades & seprangs (Narrow spades with long handles) are used in gardens and plantation.
Type The spades shall be of following four types- (a) Garden Spades (b) Draining Spades (c)
Grafting Spades and (d) Trenching Spades
The seprangs shall be of the following two types :
(a) short handled seprangs & long handled seprangs.
20.16.3 Specification For Pruning & Slashing Knives, Hooked & Curved:
i) Scope : Pruning & slashing knife is a hooked shape or a curved knife forged from one piece &
fitted with handle secured firmly with metallic rivets.

20.16.04 Specification For Hedge Shears Straight Edge Type Scope:
Hedges & shears are used for pruning of Hedges
20.17 Boundary Hedges : Hedging:

The main requirements of hedges are : (I) they must be long lived, healthy and not susceptible to
pest disease, (ii) they should be capable of withstanding cutting and hardy (frost resistant), (iii) they
should be cheap to produce because the cost is directly related to the ease of propagation of the plants,
(iv) they should be of close branching type and twiggy.
20.17.1 Layout of Boundary Hedges:
The hedges which are planted to form the highway boundary, should be normally protected by a
fence. The method of planting applicable to the varieties like quick-thorn, beech, hornbeam and privet
are common.
20.17.2 Methods of Planting: Initially, dig pits, insert the plant after spreading the roots carefully. As
the pit is filled back, shake the plant, to ensure that the soil is perfectly mixed with the root system.
Fill the pit slightly more and make the filling firm by treading with foot taking special care that the
foot is kept straight and the heel does not break roots from the root ball, or scrape bark from the stem
of the plant.
20.17.3 Cutting : Hawthorn (quick) hedging in particular, develops too much top growth and
therefore requires frequent cutting otherwise it tends to develop tree like trunks and looses its lower
growth, and hence its value as a hedge. The remedial work is done by the process known as hedge
laying.
20.18 Campus Road Side Tree-Plantation :
i) For planting of trees the location' is the most important factor. If the tree is to be planted on
the edge of the road ensure that the planting is not done under an overhead cable etc.

Similarly the period of planting is also equally important. The planting of trees can be
preferably done when the tree is dormant i.e. normally between the months of November to
March. The condition of weather should also be favourable and especially during frosty
weather no planting should be undertaken.
ii) A pit of sufficient width and depth which can accommodate satisfactorily the root system, when
spread, should be dug and the selected spots to plant the tree. The root system of the tree to be
planted should be carefully checked to ensure that it has not been too severely pruned or
damaged.
A fine filth added if necessary, with fertilizer to the extent of about 0.25 kg of bone meal, should
be forked at the bottom 01 the pit. Drive a wooden stake at suitable point in the pit, so that it can
support the tree.
Insert the tree in the pit, prepared as prescribed above, and place the same suitably, spreading the
roots carefully. The most important point to be noted in the case of placing the tree in its correct
position i.e. the tree should be placed at the same depth of placing as was before being moved
and this can be achieved by making the mark on the trunk of the tree and while refilling the pit
the top of filled earth should coincide with the mark on the trunk of the tree.
v) After placing the tree in the correct position the pit should be refilled with the excavated soil
liberally mixed with peat which will assist the growth of the plant. While the refilling is in
progress the tree should be shaken so as to ensure that the soil is mixed properly with the roots.
vi) The refilling of the pit should be slightly overfilled and the top of the filling should be firmed
by treading with foot keeping the leg straight and taking particular care not to damage the roots
or bark. On firming the soil tie the trunk of the tree to the wooden stake, using two plastic ties.
vii) Lastly place a mulch of 50 mm thick over the top refilled portion of the pit, and make a ridge
of peat around the plan. It should be particularly noted that when a tree is moved whilst
growing/in leaf in should be watered at regular intervals until the tree gets established to the
changed location.
Note: When the tree is to be moved whilst in leaf, the roots should be well watered before it is lifted
and the root ball kept well together while lifting, by wrapping tightly with hessian. The above
wrapping is removed only when the tree is placed in the new location.
20.19 Details about Planting Trees and Grassing : Different Methods of Planting Trees
i) There are a number of methods by which trees are propagated in addition to direct sowing of
seeds. Some of the most common ones are described below.
ii) Transplanting from Nurseries : The job of planting has to be done with great care, any
negligence would result in the failure of the plant. While planting out operation care should be
taken to see that the root system is not disturbed or injured. This' can be achieved by carefully
digging out seedlings at the tine-the soil is wet and removing would be easy. The seedlings are
removed along with a ball of earth along the roots. They are then transferred to the new place
by putting them just as they were in their original position. A particular care that one should
take is during transplanting the stem should be kept in a vertical position and the roots point
downwards in their natural direction without twisting or turning.
iii) Although the trees may be brought up by direct sowing the seeds in practice, however it is
found convenient, to grow plants of various suitable species in a nursery, then after two to three
years transplant the nursery cultured seedlings, when their roots get developed, so as to get
established in the new soil.
iv) The best period for transplanting is at the outbreak of the rainy season when after a good
shower the soil is soaked. The stem of the plants to be transplanted should at least be having
20 mm dia and 1.0 m to 1.5 m height.
v) However, some trees can be transplanted in winter when the leaves are fallen. The plants that
can be easily grown in the nursery & transplanted are Neem, Jamun, Shisham, Mulberry & Sins.
Out of these plants shisham needs plenty of water, and mulberry, neem & sins need
considerably less water and the species kikar can be tried in drier places.
vi) In case of plants like eucalyptus etc. if grown in pots the roots are sure to be pot bound, in such
cases the pots are carried to the new site and the seedlings roots bared of earth are lowered
down into the hole dug for them. This will facilitate their further growth.
20.19.1 Propagation by Cuttings :
Generally 1.5 m. to 3 m. long cuttings with lower end cut obliquity is planted about 600 mm to 900
mm in the hole prepared in the ground, taking care to plaster the upper end with cow dung & clay.
The cutting normally is done in rainy season or winter.
20.19.2 Grafting :
i) The action of laying base the growing portion between the back and wood of a branch with a
sharp knife is called grafting. The -real season for grafting is spring i.e. when the fresh growth
takes-place.
ii) Layering : This-is a method where the- branches of a tree are bent downward until they are
brought down in contact with the soil. The tree is then left alone for one full season when it
would be noticed that most branches so treated take root in the soil where they are in contact.
Mostly mangoes and some other similar trees are grown in this method.
20.20. Method of Collection, Maintenance & Sowing of Seeds
i) The seeds should be collected only when they are ripe, and just before they begin to fall.

A rough test which is quite practical to ensure soundness is heat an iron plate red hot, and place
some of the seeds on this hot plate, the sound seeds will be those which will burst before
burning..
ii) An alternative method is to collect the seeds in an earthen pot and keep them moist and put
the pot in a warm dark place, the sound seeds will immediately start germinating.
iii) The seeds should be collected in dry weather and spread out in the shade for drying. The dried
seeds should be cleared and the outer cover removed. It should be a point that only fresh seeds
should be used for sowing, i.e. almost as soon as they are collected and are still oily. Under no
circumstances wet seeds should be used.
iv) The plants differ with each other very much in the time the seeds can be stored. The seeds must
be stored properly as they are liable to be attacked by insects or moisture. The dried seeds
should be stored in an air tight tins or well closed bottles with naphthalene balls so that they
can be saved from the attacks of insects.
v) The ideal season for sowing is the beginning of monsoon. The method-of sowing differs from
one type of seed to the other, but still all seeds need warmth, moisture and oxygen hence as far
as possible they should be provided with light & heat of the sun. The general practice is to sow
a seed up to a depth of twice or three times the diameter of the seed and 75mm depth in hard
soil, below the ground surface.
vi) However, the method for small seeds is bit different. Here the seeds are mixed with charcoal
or sand and disseminated in boxes or pots. Later when the seeds are large enough to handle
singly, they are put to required depth in soil. Again very small seeds are scattered as evenly as
possible and covered with finer soil to protect the seeds during watering.
20.20.1 Maintaining the Level of Plantation:
1. If the land is sufficiently high and is well drained then the tree can be planted flush with the
surrounding soil.
2. In case the trees are to be planted on the side of an embankment no special arrangement need
be done as the water would escape down the slope.
3. In low lying areas the tree should be planted on a minimum 300 mm high and 900 mm dia.
mound with all sides sloping.
20.20.2 Digging Pits for Planting:
The pits can be of any shape however the top should be 1200 mm wide, and the bottom 900 mm.
The height can be 900 mm. If the original soil is not very rich then it is advisable to have a goat body
of rich soil to help the growth of the tree. The portion 300mm below the surface is the best and
should alone be used for mixing with manure for filling near the plant. Only one tree should be
planted in each pit. The real procedure is that the pits should be dug few days in advance and on
planting the soil is mixed with manure and refilled in pits & allowed to weather by rains or irrigation.
20.20.3 Method of Watering:
Water is required more frequently in early stages i.e. twice or thrice a week, but when the plants
grow to a height of 1.2 m to 1.5 m the watering can be done once a week, taking care that the watering
is required more frequently in dry hot months and less frequently in winter. Also particular care should
be taken during watering to see that the water reach deep down till the roots. Pouring

little quantity of water more frequently will not be helpful. Also the soil should be invariably
worked during planting as well as watering.
20.20.4 Treatment with Matching:
i) This is done during the commencement of the dry season. The earth around the stem about 600
mm wider than the shade at noon is dug to a depth of 75mm and covered with leaf mould. This
process is called mulching. Watering is done over this portion which will retain moisture for a
longer time, and the soil with neither cake nor crack.
ii) Another method is where the earthen pitchers with holes are buried in the ground by the side
of the plant, and the pot is kept filled with water from which water percolates & feeds the
plant.
iii) One should remember that it is not the stem that needs water but the roots, hence, to facilitate
the water to reach the roots properly the surface soil is to be kept loose up to 300 mm to 600
mm around the plant to effect proper watering. Also it is advisable to heap the earth around the
stem and hollow out the surrounding portion into a circular ditch so that when watering is done
the stem remains surrounded with water.
20.20.5 Protection of Young Trees:
Providing tree guards immediately after planting the plants are to be protected from grazing animals,
The best method of protection is the construction of tree guards. The tree guards are generally made
of Bamboos, old tar drums or brick jali. Roughly 250 No. of bricks are required for a brick-guard
described under Clause 20.14.7. The details of RCC tree guards as per Indian standard specification
is given separately. Similarly, under Clause 20.14.1 & 20.14.4 detailed description with figures of
manufacturing different types of ornamental tree guards with steel is given."
20.21 Nursery
i) The site for nursery should be a level land and of sandy loam soil, and plenty of water should
be available. The location of nursery should be convenient for inspection as well as
transplantation of plants. Trenches with the width at top as 300mm and bottom width as 200mm
and a height of 230 to 300 mm should be dug, 1800 mm apart or as required as per the
requirement of the plant. Berms on both sides of the excavated trench are formed by dumping
the excavated soil about 300 mm away on both sides of the trench. The berms are used for
sowing the seeds: The berms thus formed should be made level prior to sowing is taken up.
Normally the work on nursery should be completed before the end of March. In practice the
seedlings grow faster over ' ridges than in beds & even the transplanting would be easy. The
seedlings in any nursery are raised from seeds but in case of certain species which do not grow
from seeds they will have to be raised from cutting or grafting. The plants should be retained -
in the nursery flit they are sufficiently hard to withstand the planting out operation at the same
time they should not be kept for a longer time in the nursery, with the result the roots of the
plant will unduly cramp for space.
ii) When the plants are too he carried over long distances for transplanting the earthen ball around
the roots should be neatly wrapped with leaves, grass, Matting or polythene sheets, or the balls
may be packed in boxes or baskets with empty space filled by good earth and kept moist by
sprinkling water.
iii) The nursery should have a good provision for paths, trenches and fallow. As a matter of

fact failure rate of plants can be considered as 25%. Also as per general practice about one third
or one fourth area available, should be used in rotator., every year. The actual size of nursery
will mainly depend upon the number of seedlings to be produced, and the age of seedling to be
supplied, during the year. The most important factor is the period of keeping the plants in the
nursery.
20.22 Manure:
20.22.1 Chemical Manure : This manure is made by the mixture of equal parts of Ammonium
Sulphate and bone meal or super phosphate of lime. Usually when. the plant grows about 150mm
height the manure is applied.
In case of cow dung or sheep dung is most useful. The horse dung is less rich in manure. The manure
out of dung should never be used fresh but should be thoroughly rotted, otherwise the grubs
contained in the manure will attack the plant roots
The dung thus collected -should not be exposed to the atmosphere as other wise we may not be in a
position to prevent the escape of valuable gasses. Hence the dung should also be collected in a pit
covered with earth, we can also add urine but after diluting the same with a quantity of water four
times the quantity of urine. Normally the compost should be about 2 years old but in hot places the
compost takes lesser time to mature. The quantity of composed that is used is about 3 to 4 kg per
sqm.
20.22.2 Leaf Moulds :
i) This is a best addition to the nursery soil :A pit of 600mm to 900 mm depth is dug in a shady
place. This pit is filled with fallen leaves of avenue trees particularly at the time when the fruit
trees shed their leaves. After a lapse of nearly one to one and half year the leaves thus collected
in the pit will be converted into invaluable manure.
ii) The decay can be quickened if the pit is thoroughly soaked two or three times during the hot
season. The manure will be containing worms and other vermin's which should be removed
completely before the same is used.
20.23 Planting trees on road-side : Species:
i) The trees for road side planting should be selected very carefully. The most common and
evergreen one would be mango or nearly evergreen like margosaindica or neem. The trees
should be suitable for the atmospheric condition. Mostly shady trees which do not spread
sending large branches should be selected. In short the trees should be fairly hardy and robust
and should not be of a variety which grows very fast and ultimately dies fast. Generally the trees
that grow about 3m to 4m in a straight direction and spread are most suitable ones. Similarly
the roots of the trees should go deep because shallow rooted trees would spoil the pavement as
it would absorb the moisture from the sub-grade.
ii) Trees with thin and small leaves like tamarind or margosaindica etc. should be preferred-as
they need less water and withstand the' drought very well.
iii) Trees with thick and broad level require more moisture and water. Similarly, trees producing
valuable fruits or timber or even a babool tree which sheds thorns are not at all suitable one.
Certain trees which shed their leaves during the month of April May should not be preferred at
all. One should bear in mind the nature of the road i.e. if the road has to run close to the houses
just like in a colony etc. the thick growing large trees would not be suitable.

iv) It is a common knowledge that in summer the trees-dry up the soil almost up to 6% with the
result the volume of the subgrade gets reduced and the pavements crack. Hence in heavy clayey
soils the fast growing trees should be planted at least 15m away from the road.
v) Only mixed planting should be resorted to so that plants flower & bear fruits in different
seasons and also the shedding of leaves takes place in different parts of the season. Also by mix
planting. only -some of the trees get uprooted during storms and h e . To serve as an effective
land mark, tall growing varieties with straight stem may be, planted at selected spots. Planting
the trees of divergent habits like banyan, babool and cork etc. should be avoided.
vi) The trees on opposite side of the road should be planted in staggered fashion i.e. each tree
should not come in line with the tree on the opposite side but should be located at middle
portion. The planting of the tree should be 2m to 3m away from the edge of the shoulder/ berm.
vii) It is mandatory to take particular care that the trees do not interfere with the traffic on the road
and the same should be free from off shoot of the branches at least for a height of 3.5m to 4m on
high ways & little more on streets in towns. In case the branches grow horizontally they should
be cut maintaining a minimum height as 3.5m. The trees should be pruned in such a manner
that the natural shape is retained.
viii) Telephone & telegraph poles should be so fixed that there will not be any interference due to
the growth of tree. However they can be fixed at least 1.5m outside the road edge or preferably
at the boundaries of the road.
ix) A major precaution that should be taken is a tree of less than 1.5m height should not be planted
on the road side. It has been observed that most of the failures on the road side planting is due
to the use of small seedlings or trees which have not had their roots formed fully before being
transplanted from the nursery.
20.23.1 Spacing of trees:
i) On an average, tree planting on road sides in our country is about 80 to 90 trees per km.
Generally distance between two trees kept at 5 m to 10 m, is suitable. -
ii) However, at places where rainfall is less the trees can be planted at 15m apart and fast growing
trees are planted in between so that some shade would be available in between. The
intermediate trees can be trimmed or cut down once the main trees grow to more than 3.5 to
4m height.
iii) A particular care should be taken while planting the trees on curves so that it does not obstruct
the vision. The roots of the trees spread wildly hence no tree should be planted within 6 m of
any masonry work. The above distance should be increased depending upon the type of tree.
The distance may be kept between 20m to 25m as the roots of trees, like pipal, gular, pilkhan
and barged grow into the masonry joints and create the damage. The distances that can be
maintained for the different types of trees is given below.
iv) Numbering Trees : The trees should be numbered carefully. They should be numbered at a
height of 1.25m-above the ground level in a specially made space of 150mm X150mm by
scraping the bark. Only dry scales Should be scrapped without peeling the tree. The numbers
should be written in black colour over the white background.

v) Maintenance of Trees : In spite of providing all equipment like pipes etc. still on an average we
will need one Gardner to maintain about 2 to 2.5 km. road side trees. The length will be
drastically reduced' if the Gardner has to in addition attend the plantation in the divider portion
as well.
S. No. Name of tree Safe spacing

1. Teak 10m to 15m.
2. Pipal 17m to 20m.
3. Neem 8m to 10m.
4. Siris 12m to 15m.
5. Goldmohar 12m to 15m.
6. Mango 10m to 12m.
7. Jacranda 12m to 15m.
8. Cassia fistula 10m to 15m.
9. Cassia renizira 10m to 12m.
10. Cassia jawanica 12m to 18m.
11. Cassia nodusa 10m to 12m.
12. Bahunia 10m to 12m.
13. Silver oak 5m to 8m.
vi) Controlling the Attack by Pests : This can be done by spraying chemicals as follows:
(a) Dissolve 50gm. of copper sulphate in a litre of boiling water and this mixture is added to
four times the quantity of lime water just before spraying. Spraying this mixture is very
effective.
(b) Boil 100 gm of well dried tobacco leaves in one litre of water for one full hour. Dissolve
25 gm of hard soap in this tobacco water, and before use add 6 litres of cold water and
this mixture can be sprayed to arrest the pests.
(c) For any tree a parasitic plant is most dangerous. Hence the parasite plant should be
removed completely with roots and destroyed. The affected branch or a dead branch
should be cut to save the main tree. The cutting or removing a branch should not be done
in a haphazard manner. The most systematic method would be as follows :
(d) The cutting of a branch should not be done by an axe but a cut should be made with a
sharp knife/saw close to the affected portion taking care not to leave the stub of amputed
branch on the good limb or the tree trunk.
(e) If one has to remove a large heavy branch the same should be done as follows:
The branch should be cut keeping a distance of about 350mm from the trunk. The bark
around should be cut with a pruning knife. Then leaving about 300 m. space cut the-
under side with a saw lo a distance of- half the dia., then cut the remaining half; so that
the bark-will not be torn off-Small branches can be-cut with the. pruning knife. The
wounds or cuts caused should be protected against moisture or decay,-& this can

be easily done' by painting the cut portion with tar: The-more systematic method is as
follows :
Treat the woody portion with a dilute solution of any good wood preservative or tar &
the stripped bark should be treated with a solution of lac in methylated spirit.
20.23.02 Cavity filling :
i) Sometimes due to careless pruning a cavity gets formed in the trunk and this should not be left
untreated. The damage to the tree can be prevented with following method. The dead wood
should be scraped very carefully, and the hollow portion should be washed thoroughly with a
strong solution of permanganate of potash and then fill up the entire gap with cement concrete 1:
2 : 4 well packed & finished neatly till below the level of the bark.
ii) As a matter of fact good maintenance will help prolong the fife of a tree. No excavation should
be allowed to be done near the tree unless totally unavoidable as if may disturb the roots. The
stem should be coal tarred up to 600mm height from the ground at least once in two years. The
pruning should be done regularly & wounds if any treated properly.
20.23.03 Pruning a Tree :
i) The pruning should be started when the tree is about 2 years old. The pruning will help the
growth of a tree in a straight direction -and keep it healthy. The best season for pruning is end
of cold season or say beginning of the month of March. This is the period when the leaves just
appear and the growth in a tree is least active. On the contrary if the pruning is done, in summer
i.e. when the trees are in full growth & the wounds bleed which will not allow the use of tar &
bitumen to adhere properly.
ii) To keep the tree healthy only two rows or tiers of branches should be removed in a year. Axe
should not be used for the purpose of pruning, one can choose the different types of tools.
20.23.04 Felling Trees :
When a tree is cut a hollow should be dug around the base & the trunk cut as low down as possible.
The hollow portion is then filled properly.
20.24 Growing Annuals :
i) The first step in readying a flower bed - Break up the soil of the seed bed by driving a spading
fork into the soil the full depth of its tines, then pull back. If you are right-handed, apply
pressure to the fork with your left foot to avoid having to step aside when you pull back on the
handle.
ii) Turn over the soil with the fork, removing stones and debris, break up clods by hitting them
with the back of the fork. Then cover the soil with 2 or 3 inches of peat moss, compost or
manure, followed by a thin layer of low-nitrogen fertilizer.
iii) After thoroughly mixing the soil, peat moss and fertilizer with the spading fork, rake over the
seed bed several times until it reaches a fine consistency. Then add a thin layer of
superphosphate to stimulate root growth and rake it in thoroughly.
iv) To set seeds in order to space plants properly and simplify weeding, first mark of the bed in a
grid by pressing a hoe handle into the soil. Separate the grid lines by the distance specified for
mature plants.

v) Place several seeds at each of the points where the lines intersect. Sow large seeds individually
and cover them to the depth called for in the instructions on the seed packet; tap small seeds
from the packet and do not cover them. Firm the soil around the seeds.
vi) Sowing seeds only at the grid intersections marks it easy to identify weeds- anything that
sprouts elsewhere must be a weed. When hoeing weeds, clear the area in front of you before
working farther into the bed to avoid trampling on young plants.
vii) When the seedling produce their first true leaves, thin the bed by removing all but the most
robust plant in each clump. Pull out the weak seedlings carefully. Be sure the soil is moist so
they can be pulled without disturbing the roots of the remaining plant.
20.25 : Plantation in Urban areas: Special Considerations:
i) Urban roads offer the opportunity for planting under a variety of situations:
a) Median planting for screening of head light glare.
b) Screening of undesirable views.
c) Screening for noise.
d) Planting for beautification and unification of landscape.
ii) The following points should be kept in view while planning and executing plantation in
urban areas.
a) The plantation should be such that it can grow well under harsh environment of the
city. In large cities, the plants should be smog resistant.
b) Adequate should be available for utility services.
c) For urban roads, shade and beauty should be the main criteria as regards tree selection.
Where the space available is limited, and only one row of trees can be grown on each
side, flowering trees may be alternated with shade trees. The trees should be small or
medium sized.
d) Where sufficient land is available, double rows of avenue trees may be adopted -the
outer row being of shade type and the inner row of flowering type.
e) Plantation in medians: The essential purpose is to cut off headlight glare from the traffic
in opposite direction. Flowering plants and shrubs (1-1.5 m high) are eminently suited for
the purpose. These are best planted in baffles if the median is a minimum 3 m wide,
otherwise in a continuous line. The median should be fenced to prevent horizontal or
vertical overgrowth beyond the edge of the median.
f) Avenue plantation : On long avenues on building projects, suitable trees can be planted
in rows, at 10-15 m c/c on the road side, duly staggered on both sides. These will be
shady trees suiting the landscape of the drive way.
g) Requirements of the trees to survive in populated areas. These requirements are
necessary to ensure healthy growth and longevity. These are as under :
i) Soil aeration: Roots need oxygen for growth, and for this depend upon soil environment.
Proper soil aeration requires diffusion of air in to spaces between the soil particles. This
calls for a loose, friable soil with good drainage that will prevent it from being water
logged.

ii) Oxygen dissolved in water which percolates in to the soil. Rainwater is highly oxygenated
and hence efforts should be made to trap as much rain water as possible. On road sides,
therefore, road crust layers, BT or CC should exclude the drainage basins of the trees.
Openings should be left in the kerb to allow the flow of rain water in to the trees. Provide
perforated slabs around the tree trunk or perforated bricks for access of water to the roots.
May also provide loose paving slabs around tree basins with wide enough gaps between
slabs for grassing or ground cover planting especially on footpaths and esplanades.
iii) Pruning and treating damages to established trees : Trees be pruned regularly and the
foliage should not obstruct the road way. All decayed wood is cut out and cavities if any
are washed with a solution of mercuric chloride or copper sulphate and lime. The cavity
is filled hard with cement mortar and edges of the cavity are also cut smooth so the
cambium may grow freely and cover the cavity after it is filled.
iv) Maintenance for preservation, repair of established trees and transplanting. Damage
caused by cut and fill of soil. Already established trees are likely to be adversely affected
by construction works. Many a times it causes amputation, die-break, imbalance in
anchorage and affecting their stability, nutritional deficiencies leading to death in many
cases.
v) Similarly, piling up of excavated debris over the roots even to a thickness of 150 mm
would cause serious damage to the trees. This should be avoided.
vi) On construction of new roads, the existing trees be saved through environment friendly
alignment. If any tree is to be cut, these should be compensated with planting ten more
trees. Dry retaining walls could be constructed around the existing trees to protect their soil
and roots.

vii) Transplanting: Transplanting is needed to save a tree from being cut & lost. Trenches are
dug in small segments along the (lm radius) circumference of the tree and the roots are
pruned. After a few weeks the segments are dug and roots pruned. Finally the tree is
uprooted and carried away to the transplantation site and planted and watered there. It
needs a well coordinated effort.
20.26 Trees suitable for plantation in Rajasthan :

Ashoka for avenue plantation,
Gul Mohar : Suitable for town avenues.
Jamun or Indian cherry : Suitable for highway avenues.
Mango: -do-
 Margosa or Neem: Good for arboriculture on highways in dry areas.
 Mowa or Mahua: -do-
 Tarmind or Imli: Good avenue tree for dry regions.
 Siris: Suitable for highway avenue.
Babul: For village or less important roads.
 Shisham: Very good for Highway avenues.
 Other species: Amaltas, Akasi Neem, Cassia Nodosa, cassia Ranny Gera, Goolar,
Khera, Karanj, and Sahejena.
20.27 Choice of the type of tree : Trees should be evergreen type, having small size long
leaves, capable of developing straight bole about 3-4 m high from ground level, should be fairly
hard, fast growing and resistant to wind. The species should have deep roots.
20.28 Fencing : Wherever, the plantation is to be fenced, it may be done with chain link fencing of
MS Angle posts at 3 m c/c, or MS sections as per design. The design should not contain sharp metal
shapes which can injure the user. PVC net, honeycombed Brick work can be used as fencing on
nurseries and protected areas. Selection shall be based on importance of the area.

CHAPTER No. 21
WATER SUPPLY WORK

CHAPTER No. 21 : WATER SUPPLY WORK
CONTENTS
21.0 Scope 3
21.1 Terminology 3
21.2 General Requirements 10
21.3 Basic Guidelines 13
21.4 Design Consideration 33
21.5 Pipes 46
21.6 Water Meter (Domestic Type) 77
21.7 Water Storage Tank 80
21.8 Valves. 85
21.9 Cocks 87
21.10 Fire Hydrants 89
21.11 Pillar and Posts for Hydrants 90
21.12 Surface Box 91
21.13 Service Connection 91
21.14 Making Connection of G.I Distribution Branch with G.I. Main 92
21.15 Pumps 93
Appendix À' 95
Figures 96 to 121
List of BIS Codes 122
Rajasthan PWD Building Specifications 2014 Chapter 21 : Water Supply Works Page 1 of 126
CHAPTER No. 21
WATER SUPPLY WORK
21.0 Scope: The specification covers the water supply systems including procurement, distribution
and disposal for Buildings.
21.1 Terminology:
1) Air Gap: The unobstructed vertical distance through the free atmosphere between the lowest
opening from any pipe or fitting supplying water to a tank or other device and the flood level
rim of the receptacle in a water supply system and or the distance between the lowest joint of a
water inlet or feed pipe to an appliance and the spill over level (or the overflowing level) of the
appliance
Air Valve: A valve that releases air from a pipe line automatically without loss of water, or
introduces air into a pipe line automatically, if the internal pressure becomes less than that of the
atmosphere.
Authority having jurisdiction: The Authority which has been created by an statute for
administering the provisions and which may authorise a committee or an official to act on its
behalf; hereinafter called the "Authority"
Available Head: The head of water available at the point of consideration due to main's pressure
or overhead tank or any other source of pressure.
Approved: Accepted or acceptable under an applicable specification stated or cited or accepted
as suitable for the proposed use under procedures and powers of the Administrative Authority.
Back flow: (a) The flow of water or other liquids, mixtures or substances into the distributing
pipes of a system of supply of potable water from any source or sources other than its intended
source.
(b) The flow of a liquid in a direction reverse of that intended.
(c) Backflow connection: Any arrangement whereby back flow can occur.
Backflow Prevention Device: Any approved measure or fitting or combination of fittings
specifically designed to prevent backflow or back siphonage in a water service.
Back Siphonage: The flowing back of used contaminated or polluted water from a plumbing
fixture /fitting or vessel into a water supply due to a reduced pressure in such pipe (see
Backflow).
Barrel: That portion of a pipe in which the diameter and the wall thickness remain uniform
throughout.
Base: The lowest portion or lowest point of a stack of vertical pipe.
Ball Cock: (Fig. 1) A faucet opened or closed by the fall or rise of a ball floating on the
surface of water.
b) Barrel: That portion of a pipe in which the diameter and wall thickness remain uniform
throughout.
9) Branch: (Fig. 1):
(a) A special form of cast iron pipe used for making connections to water mains. The various
types are called T, Y. T-Y, double Y, and V branches, according to their respective
shapes.
(b) Any part of a piping system other than a main.
(c) Branch, Interval: A length of soil or waste stack corresponding , in general to a storey
height but in no case less than 2.4 m within which the horizontal branches from one floor
or storey of a building are connected to the stack.
(d) Branch Vent: A vent connecting one or more individual vents with a vent stack or
stack vent.
(e) Building combined Drain or Sewer : A building drain or Sewer which conveys both
sewage and storm water.
(f) Building (House) Drain: That part of the lowest piping of a drainage system which
receives the discharge from soil, waste and other drainage pipes inside the walls of the
building and conveys it to the building (house) sewer beginning 0.9 m outside the building
outer wall.
(g) Building (House) sewer: That part of the horizontal piping of a drainage system which
extends from the end of the building drain which receives the discharge of the building
drain and conveys it to a public sewer , private sewer, individual sewage disposal system
or other point of disposal. Also called house connection.
(h) Building (House) Trap: A device, fitting or assembly of fittings installed in the building
drain to prevent circulation of air between the drainage system of the building and the
building sewer.
(i) Building Sanitary Drain : A building drain which conveys sewage but does not
convey storm water.
G ) Building (Sanitary) Sewer : A building sewer which conveys sewage but does not
convey storm water.
( k ) Building (Storm) Drain : A building sewer which conveys storm water but does not
convey sewage.
(1) Building (Storm) Sewer : A building sewer which conveys storm water, but does not
convey sewage.
10) Capacity: The storage capacity of the storage or flushing cistern or a tank when filled up to
the water line.
11a) Collar: A pipe fitting in the form of a sleeve for jointing the spigot ends of two pipes in the
same alignment.
b) Common vent: A vent connecting at the junction of the two fixture drains and serving as a
vent for both fixtures.
c) Communication Pipe: The part of the service pipe, extending from the water main up to
and including the stop cock, which is under the control of the authority.
12) Coupling: A pipe fitting with inside threads only, used for connecting two pieces of pipe.
13) Cross: (Fig. 1) A pipe fitting used for connecting four pipes at right angles.
14) Communication Pipe: (Fig. 3) That part of a pipe which vests in the water supply line from
the mains. It is the water main to the building and terminates at a designed point.
15) Consumer: Any person who uses or is supplied water or on whose application such water is
supplied by the Authority.
16a) Consumer Pipe: The portion of service pipe used for supply of water and which is not the
property of the Authority.
b) Continuous Vent: A vertical vent that is a continuation of the drain to which it connects. 17)
Cover:
(a) A removable plate for permitting access to a pipe, fitting, vessel or appliance.
(b) The vertical distance between the top of the barrel of a buried pipe or other construction
and the surface of the ground.
(c) Cross Connection: A connection between two normally independent pipelines which
permits flow from either pipeline into the other.
18a) Deep Manhole: A manhole of such depth that an access shaft is required, in addition to the
working chamber.
b) Degreasing: The process of removing greases and oils from sewage, waste sludge or
garbage.
c) Depth of manhole: The vertical distance from the top of the manhole cover to the
outgoing invert of the main drain channel.
d) Diameter: The nominal diameter of a pipe.
e) Direct Tap: A tap which is connected to a supply pipe and subject to water pressure
from the water main.
f) Downtake Tap : A tap connected to a system of piping not subject to pressure from the
water mains.
g) Drainage: The removal of any liquid by a system constructed for the purpose.
h) Dry Vent : Any vent that does not carry water or water-borne waste.
i) Dwelling Unit: One or more rooms with provisions for living, sanitary and sleeping
facilities arranged for use of one family.
19a) Elbow: (Fig. 1) A pipe fitting for providing a sharp change of direction in a pipe line.
b) Existing Building or Use: A building structure or its use before the commencement of the code
and which does not conform to the code.
20) Factory: A place to which the provisions of the Indian Factories Act of 1948 and
amendments thereto from time to time apply.
21) Feed Cistern: A storage vessel used for supplying cold water to a hot water apparatus,
cylinder or tanks.
22) Ferrule: (Fig. 1) A pipe fitting for connecting a service pipe to a water main.
23) Fire Hydrant: (Fig. 1) A device connected to a water main and provided with necessary
valve and outlets to which a fire hose may be attached for discharging water at a high rate for the
purpose of extinguishing fires, washing down streets, or flushing out the water main.
24) Flange: (Fig. 1) A projecting flat rim on the end of a valve, pipe etc.
25) Flanged pipe: (Fig. 1) A pipe provided with flanges so that the ends can be joined together
by means of bolts.
26) Float Valve: A valve in which the closure to an opening such as a plug or gate is actuated by
a float to control the flow into a tank.
27a) Fitting: Anything fitted or fixed in connection with the supply, measurement, control,
distribution, utilization or disposal of water like Coupling, flange, branch, bend tees, elbows,
unions waste with plug, P or S trap with vent, stop ferrule, stop valve, bib tap, pillar tap, globe
tap, ball valve, cistern storage tank, baths water-closets, boiler geyser, pumping set, with motor
and accessories, meter, hydrant, valve and any other article used in connection with water
supply and sanitation.
b) Fixture Branch: In a water supply system, the water supply pipe between the fixture supply
pipe and the water distribution pipe.
c) Fixture Drain: The drain from the trap of a fixture to the junction of that drain with any
other drain pipe.
d) Fixture Supply: A water supply pipe connecting the fixture with the fixture branch.
e) Fixture Unit: A quantity in terms of which the load producing effects on the plumbing system
of different kinds of plumbing fixtures is expressed on some arbitrary chosen scale.
f) Fixture Unit Flow Rate: The total discharge flow in litre/second of a single fixture which
provides the flow rate of that particular plumbing fixture as a unit of flow . Fixtures are rated
as multiples of this unit of flow.
28a) Float Operated Valve: Ball valves or ball taps and equilibrium by valves operated by means
of a float.
b) Flooded : A fixture is flooded when the liquid there in rises to the flood level rim or overflows
on to the floor.
29a) Flushing Cistern: A cistern provided with a device for rapidly discharging the contained water
and used in connection with a sanitary appliance for the purpose of cleansing the appliance and
carrying away its contents into a drain.
Note: The nominal size of a cistern is the quantity of water discharged per flush.
b) Fresh Air Inlet: A connection to the drainage system to permit the circulation of air through
the system.
30a) General Washing Place: A washing place provided with necessary sanitary arrangement and
common to more than one tenement.
b) Geyser: An apparatus for heating water with supply control on the inlet side and delivering it
from an outlet.
c) Gulley Trap: A fitment with a trap and a screen through which the discharge from an open
drain is taken to a sewer.
d) Horizontal Branch: A branch drain extending laterally from a soil or waste stack, leader,
house drain or house storm drain with or without vertical sections or branches, which receives
the discharge from one or more fixture drains or plain water inlets and conducts it to the soil
or waste stack or to the house drain or the house storm drain.
e) Horizontal Pipe : Any pipe which makes an angle of more than 45° with the vertical.
f) House Drain: That part of the lowest horizontal piping of a building drainage system including
the horizontal branch from the base of a stack connected to the main house drain which receives
the discharge from soil, waste or other drainage pipes in the building and conveys it to the
existing lateral, main sewer cesspool of septic tanks.
g) House Storm Drain : A drain used for conveying rain water, ground water, subsurface water,
condensate, cooling water or similar discharge to the existing lateral or main sewer.
h) Individual Vent: A pipe installed to vent a fixture trap and which connects with the vent
system above the fixture served or terminates in the open air.
i) Industrial Wastes: Liquid wastes, resulting from the processes employed in industrial
establishments and are free of faecal matter.
j) In- sanitary: Contrary to sanitary principles or injurious to health
31). Junction Pipe: A pipe incorporating one or more branches. 32a)
Lagging: Thermal insulation on pipes.
b) Leader ( Downspout) : The water conductor from the roof of gutter drain to the house storm
drain or other piping serving as a storm drain including but not limited to a `downspout' or a `rain
water conductor'.
33a) Licensed Plumber: Person licensed under the provisions of this Code.
b) Main Sewer: Any sewer owned or maintained by the public authority.
c) Minor Repairs : The repairing of an existing plumbing fixture , including the replacement
of faucets or valves or parts thereof.
34) Nipple: (Fig. 1) A tubular pipe fitting usually threaded on both ends and less than 300 mm
long used for connecting pipes or fittings.
35) Non return Valve: (Fig.2) A device provided with a disc hinged on one edge so that it
opens in the direction of normal flow and closes with reversal of flow.
36) Offset: A Pipe fitting used to connect two pipes whose axes are parallel but not in line.
37) Period of Supply: The period of the day or night during which water supply is made
available to the consumer.
38) Pipe Work: Any installation of piping with its fitting.
39) Plinth: The portion of a structure between the surface of the surrounding ground and surface
of the floor immediately above the ground.
40) Plumbing:
(a) The pipes, fixtures and other apparatus inside a building for bringing in the water
supply and removing the liquid and water borne wastes:
(b) The installation of the foregoing pipes, fixtures and other apparatus.
41) Plumbing fixtures : Installed receptacles, devices or appliances which are supplied with water
or which receive or discharge liquids or other liquid-borne wastes with or without discharge
into the drainage system with which they may be directly or indirectly connected.
42) Plumbing System: The plumbing system shall include the water supply and distribution pipes;
plumbing fittings and traps; soil, waste, vent pipes and anti-siphonage pipes; building drains and
building sewers including their respective connection, devices and appurtenances within the
property lines of the premises, and water-treating or water-using equipment.
43) Potable Water: Water which is satisfactory for drinking, culinary and domestic purposes
and meets the requirements of the Authority.
44) Premises: Premises shall include passages, buildings and lands of any tenure, whether open or
enclosed, whether built on or not, and whether public or private in respect of which a water rate
or charge is payable to the Authority or for which an application is made for supply of water.
45) Public Building: A building used or intended to be used either ordinarily or occasionally as a
church, chopal, temple, mosque or any place of public worship, Dharmshala, College, School,
theatre, cinema, public concert room, public hall, public bath, hospital, hotel, restaurant, lecture
room or any other place of public assembly.
46) Residual Head: The head available at any particular point in the distribution system.
47) Return Offset: A double offset installed so as to return the pipe to its original alignment.
48a) Rim : The unobstructed open edge of a fixture.
b) Riser : A water supply pipe which extends vertically one full storey or more to convey water to
branches or fixtures.
49a) Reflux valve: A non-return valve used in a pipe line at a rising gradient to prevent water that
is ascending the gradient from flowing back in the event of a burst lower down.
b) Roof Drain: A drain installed to receive water collecting on the surface of a roof and to
discharge it into the leaser (downspout).
c) Roughing-in : The installation of all parts of the plumbing system which can be completed
prior to the installation of the fixtures. This includes drainage, water supply and vent piping, and
necessary fixture supports.
50a) Sanitary Sewer : A sewer which carries sewage and to which storm, surface and ground waters
are not intentionally admitted.
b) Service Pipe: Pipe that runs between the distribution main in the street and the riser in the case
of a multistoried building or the water in the case of an individual house and is subject to water
pressure from such main.
c) Sewer Branch : A sewer which receives sewage from a relatively small area and discharges
in to a main sewer.
d) Sewer, combined : A sewer receiving both surface runoff and sewage.
e) Sewer Common : A sewer in which all owners of abutting properties have equal rights.
f) Sewer Private : A sewer privately owned and used by one or more properties.
g) Sewer, storm : A sewer, which carries storm water and surface water, street wash or other
wash waters or drainage but excludes sewage and industrial wastes.
51) Sluice Valve (Gate Valve): A valve in which the flow of water is cut off by means of a circular
disc., fitting against machine-smoothed faces, at right angles to the direction of flow. The disc
is raised or lowered by means of a threaded stem connected to the handle of the valve; the
opening in the valve is usually as large as the full bore of the pipe.
52a) Socket: (Fig. 1) The female part of the spigot and socket joint.
b) Soil waste : The discharge from water closets, urinals, slope sinks, stable or cowshed gullies
and similar appliances .
53) Spigot: (Fig. 1) The male part of a spigot and socket joint.
54a) Stack : The vertical main of a system of soil, waste or vent piping.
b) Stop cock: A cock fitting in a pipeline for controlling the flow of water.
c) Stop Tap : A device which includes stop cock, stop valve, or any other device for stopping the
flow of water in a line or system of pipes at will. A control valve fixed at the end of a
communication pipe which controls the supply from the water main.
55a) Storage tank: A tank or a cistern for storage of water which is connected to the water main
by means of a supply pipe.
b) Sump : A tank or pit which receives sewage or liquid water, located below the normal grade
of gravity system and which must be emptied by mechanical means.
c) Supports: Supports, hangers and anchors or devices for supporting and securing pipe and
fittings to walls, ceilings, floors or structural members.
56) System of Drainage :
a) Combined System: A system in which foul water ( sewage) and surface water are
conveyed by the same sewers and drains.
b) Separate system : A system in which foul water (sewage) and surface water are
conveyed by the separate sewers and drains.
c) Partially Separate System: A modification of the separate system in which part of the
surface water is conveyed by the foul (sanitary) sewers and drains.
57) Systems of Plumbing:
a) One-Pipe system : The system of plumbing in which the waste connections from sink,
baths and wash basins, and the soil pipe branches are all collected in to one main pipe
which is connected directly to the drainage system. Gully traps and waste pipes are
completely dispersed with but all the traps of water closets, basins etc., are completely
ventilated to preserve the water seal.
b) One-Pipe system - Partially Ventilated : Also called single stack, partially ventilated.
A system in which there is one soil pipe in to which all water closets, baths, sink and
basins discharge. In addition, there is a relief vent which ventilates only the traps of water
closets.
c) Two-Pipe System : The system of plumbing in which the soil and waste pipe are distinct
and separate, the soil pipes being connected to the drain direct and waste pipes through a
trapped gully. All traps of all appliances are completely ventilated in this system.
d) Single Stack System: The one pipe system in which there are no trap ventilation.
e) Single Stack-Partially Ventilated : Same as one pipe system partially ventilated. A via
media between the one-pipe system and the single stack system.
58a) Tenement: A room (s) in the occupation of or meant for the occupation of one tenant. b)
Terminal Pressure : The residual head at the end of distribution system.
59) Union: (Fig. 1) A pipe fitting used for joining the ends of two pipes neither of which can be
turned.
60) Valve: A device used for controlling the flow of water in a pipe line.
61). Vertical Pipe: Any pipe which is installed in a vertical position or which makes an angle of
not more than 45° with the vertical.
62) Warning Pipe: An overflow pipe so fixed that its outlet, whether inside or outside a building, is
in a conspicuous position where the discharge of any water there from can be readily seen.
63a) Washout Valve: A device located at the bottom of the tank for the purpose of draining a tank
for cleaning, maintenance etc.
b) Waste Water (Sullage) : Spent water from baths, washbasins, sinks, and similar appliances,
which does not contain human or animal excreta.
c) Water Level : The designed top water level of the cistern.
64) Water Line: A line marked inside a cistern to indicate the highest water level at which the
supply valve should be adjusted to shut off.
65) Water Main (Street Main): A water supply pipe for public or community use which vests in
the Authority. It refers to the pipe for the general conveyance of water as distinct from
communication pipe for the conveyance of water for individual premises.
66). Water Outlet: A water outlet, as used in connection with, the water distributing system is the
discharge opening for the water (a) to a fixture/fitting (b) to atmospheric pressure (except into an
open tank which is part of the water supply system), (c) a boiler or heating system: and (d) to
any water-operated device or equipment requiring water to operate, but not a part of the
plumbing system.
67) Water Supply System: Water supply system of a building or premises consists of the water
service pipe, the water distribution pipes, and the necessary connecting pipes, fittings, control
valves, and all appurtenances in or adjacent to the building or premises.
68) Water works: Water works for public water supply include a lake, river, spring, well, pump
with or without motor and accessories reservoir, cistern, tank, duct whether covered or open
sluice, water main, pipe culvert, engine and any machinery, land, building or thing used for
storage, treatment and supply of water.
21.2 General Requirements:
21.2.1 Any damage caused to the building or to electric, sanitary water supply or other installations
etc. therein either due to negligence on the part of the contractor or due to actual requirements of the
works shall be made good and the building or the installations shall be restored to its original
condition by the contractor.
Nothing extra shall be paid for it, except where otherwise specified.
21.2.2 All water supply installation work shall be carried out through licensed plumbers.
21.2.3 It is most important to ensure that wholesome water supply provided for drinking and culinary
purposes, is in no way liable to contamination from any less satisfactory water. There shall, therefore,
be no cross connection what so ever between a pipe or fitting for conveying or containing wholesome
water and a pipe or fitting for conveying or containing impure water or water liable to contamination
or of uncertain quality of water which has been used for any purpose. The provision of reflux or non-
return valves or closed and sealed valves shall not be construed a permissible substitute for complete
absence of cross connection.
21.2.4 Where a supply of wholesome water is required as an alternative or standby to supply of less
satisfactory water or is required to be mixed with the latter, it shall be delivered only into a cistern,
and by a pipe or fitting discharging into the air gap at a height above the top edge of the cistern equal
to twice its nominal bore, and in no case less than 15 cm.
21.2.5 No piping shall be laid or fixed so as to pass into, through or adjoining any sewer, scour outlet
or drain or any manhole connected there with nor through any ash pit or manure-pit or any material
of such nature that would be likely to cause undue deterioration of the pipe.
21.2.6 Where the laying of any pipe through fouled soil or previous material is unavoidable, the
piping shall be properly protected from contact with such soil or material by being carried through an
exterior cast iron tube or by some other suitable means. Any piping or fitting laid or fixed which
does not comply with the above requirements, shall be removed and re-laid in conformity with the
above requirements.
21.2.7 The design of the pipe work shall be such that there is no possibility of backflow towards the
source of supply from any cistern or appliance whether by siphonage or otherwise, and reflux or non-
return valves shall not be relied upon to prevent such backflow.
21.2.8 All pipe work shall be so designed, laid or fixed, and maintained such that it remain
completely watertight, thereby avoiding wastage of water, damage to property and the risk of
contamination of the water conveyed.
21.2.9 In designing and planning the layout of the pipe work, due attention shall be given to the
maximum rate of discharge, required economy in labour and materials, protection against damage and
corrosion, protection from frost, if required, and to avoidance of airlocks, noise transmission and
unsightly arrangement.
21.2.10 To reduce frictional losses, piping shall be as smooth as possible from inside. Methods of
jointing shall be such as to avoid internal roughness and projection at the joints, whether of the
jointing materials or otherwise.
21.2.11 Change in diameter and in direction shall preferably be gradual rather than abrupt to avoid
undue loss of head. No bend or curvature in piping shall be made which is likely to reduce the cross-
section.
21.2.12 Underground piping shall be laid at such a depth that it is unlikely to be damaged by frost
or traffic loads and vibrations. It shall not be laid in ground liable to subsidence, but where such
ground cannot be avoided, special precautions shall be taken to avoid damage to the piping. Where
piping has to be laid across recently disturbed ground, the ground shall be thoroughly consolidated
so as to provide a continuous and even support.
21.2.13 Where the service pipe is of diameter less than 50 mm the stop valves shall be of the screw
down type and shall have loose washer plates to act as non-return valves. Other stop valves in the
service line may be of the gate type.
21.2.14 In flats and tenements supplied by a common service pipe a stop tap shall be fixed to control
the branch of each separately occupied part. In large buildings a sufficient number of stop valves shall
be fixed on branch pipes, and to control groups of ball valves and draw off taps, so as to minimize
interruption of the supply during repairs, all such stop valves shall be fixed in accessible positions
and properly protected from being tampered with, they may be of the gate type to minimize loss of
head by friction.
21.2.15 Water for drinking or for culinary purposes as far as possible shall be on branch pipes
connected directly to the service pipe.
21.2.16 Pumps shall not be allowed on the service pipe as they cause a drop of pressure on the
suction side thereby affecting the supply to the adjoining properties. In cases where pumping
required, a properly protected storage tank of adequate capacity shall be provided to feed the pump.
21.2.17 Service pipes shall be so designed and constructed as to avoid air-locks, so that all piping and
fittings above ground can be completely emptied of water to facilitate repairs. There shall be drinking
taps or draw-off (not underground) taps at the lowest points, from which the piping shall rise
continuously to draw-off taps, ball valves cistern, of vents (where provided at the high points).
21.2.18 Service pipes shall be designed so as to reduce the production and transmission of noise as
much as possible. Appliances which create noise shall be installed as far distant as possible from the
living rooms of the house. High velocity of water in piping and fittings shall be avoided. Piping shall
be confined, as far as possible, to rooms where appliances are fixed, it shall have easy bends, and
where quietness is particularly desired, holder bats or clamps shall be insulated from the piping by
suitable pads.
21.2.19 The rising pipe to the storage cistern, if any or to any feed cistern shall be taken as directly
as possible to the cistern and shall be fixed away from windows or ventilators.
21.2.20 All pipe work shall be planned so that the piping is accessible for inspection, replacement and
repair. To avoid it being unsightly, it is usually possible to arrange it in or adjacent to cupboards,
recesses, etc. provided there is sufficient space to work on the piping with the usual tools.
Piping shall not be buried in walls or solid floors. Where unavoidable, piping may be buried for short
distances provided that adequate protection is given against damage and that no joints are buried. If
piping is laid in ducts or chases, these shall be roomy enough to facilitate repairs and shall be so
constructed as to prevent the entry of vermin. To facilitate removal of pipe casing, floor boards
covering piping shall be fixed with screws or bolts.
21.2.21 When it is necessary for pipe to pass through a wall or floor, a sleeve shall be fixed therein
for insertion of the pipe and to allow freedom for expansion and contraction and other movement.
Piping laid in wooden floor shall, where possible, be parallel with the joists.
21.2.22 Where storage tanks are provided to meet overall requirements of water, connection of
service pipe with any distributing pipe shall not be permitted except one direct connection for
culinary or drinking requirements.
21.2.23 No service pipe shall be connected to any water closet or urinal. All such supplies to flushing
cisterns shall be from storage tanks.
21.2.24 No service or supply pipe shall be connected directly to any hot water system or to any
apparatus used for heating other than through a feed cistern thereof.
21.3 Basic Guidelines:
21.3.1 Materials, Fittings and Appliances:
21.3.1.1 Standards for Materials, Fittings and Appliances: All materials used in the construction
of any of the works or any of the appliances described in this code shall conform to the relevant
Indian Standards where available in so far as these standards are applicable, where no such standards
exist, the materials shall be of the quality and workmanship acceptable to the Authority, and shall be
open to inspection at the manufacture's work before dispatch.
21.3.1.2 Materials for pipes: Pipes may be of any of the following materials:
(a) Cast iron vertically cast or centrifugally (spun) Cast;
(b) Steel (lined or coated with bitumen or bituminous composition and out-coated with cement
concrete or mortar, where necessary);
(c) Reinforced Cement Concrete
(d) Pre-stressed Reinforced concrete
(e) Mild steel tubes or tubulars (galvanized)
(f) Copper
(g) Brass
(h) Wrought iron
(i) Asbestos cement
(j) Lead
(k) Polyethylene ( low and high density)
(1) Un-plasticized PVC (UPVC) Pipes
(m) PE-AL-PE composite pipes.
(n) Polyvinyl Chloride (rigid PVC).
(o) Chlorinated Polyvinyl Chloride (CPVC) Pipes
(p) 3-Layer PPR
21.3.1.3 Choice of pipe material:
a) General technical factors affect the fmal choice of pipe materials including internal pressures,
hydraulic and operating conditions, maximum permissible diameter, external corrosion and any
special conditions of laying. In choosing the material for piping and fittings, account shall be
taken of the character of the water to be conveyed through it, the nature of the soil/ ground in
which the piping is to be laid and the relative cost as compared with its useful life. The material
shall be resistant to corrosion, both inside and outside or shall be suitably protected against
corrosion.
b) Due to its strength and corrosion resistance, CI can be used in soils and for waters of slightly
aggressive character. Their disadvantage lies in their being unsuitable for corrosive soils unless
special steps are taken to combat them, their weight adding to the transportation problems in hilly
and difficult terrains. Coating inside and outside of the pipe is always preferred. They are well
suited for pressure mains and laterals where tapings are made for house connections.
c) Cl pipes are vertically cast or spun and the ends for joints can be flanged or Socket & Spigot.
Spun pipes are preferable to vertically cast (IS 1537-1976) Cl pipes. This specification (IS: 1537)
covers pipes of nominal dia. from 80 to 1500 mm and lengths from 3.66 m to 5.5 m. Up to 600
mm dia , the socket and spigot pipes are in 2 classes. Class À' is for a test pressure of 2.0 MPa
( 20kgf/cm2) and class `B' is for a test pressure of 2.5 MPa (25kgf/cm2 ). For sizes 600 mm to
1000 mm, the test pressure for the two classes À' and `B' is reduced to 1.5 to 2 MPa.
respectively. For sizes over 1000 mm to 1500 mm, the test pressure for the two classes À' and
`B' is 1.5 is further reduced to 1 and to 1.5 MPa. respectively.
d) Cast ( spun) iron pipes for water, gas and sewage are governed by IS 1536-1976. This
specification (IS: 1536) covers pipes of nominal dia. from 80 to 1000 mm and lengths from
3.66 m to 6 m. The classification of pipe is according to the thickness of the pipe. For spigot
and socket pipes, Class LA is the basis for the series of pipes . Class À' allows for a 10%
increase in thickness over class `LA' and Class `B' allows for a 20% increase in thickness over
class `LA'. For special uses C,D and E, etc. special classes may be arrived at after allowing
corresponding increase in thickness of 30, 40 and 50% etc. over class LA. The thickness of
pipe barrel for class LA=10/12x (7+0.02DN), where DN is the nominal diameter of the pipe.
e) A uniform hydrostatic test pressure of 3.5 M Pa ( 35kgf/ cm2) at works for all classes of pipes
has been specified while the hydrostatic after installation for LA, A and B classes are fixed at
1.2, 1.8 and 2.4 MPa (12. 18 and 24 kg f/ cm2) respectively. For flanged pipes, the
corresponding test pressures are slightly less.
f) The metric pipe sizes have same external barrel diameter for any size irrespective of the classes
. Also the internal socket dia. is same for the same size irrespective of the class. Cl flanged
pipes and fittings are usually cast in larger diameters. Smaller sizes have loose flanges screwed
on the end of double spigot spun pipes.
g) Steel main pipes being light in weight are used for large dia. especially larger than 900 mm
where Cl pipes become very heavy and costly. In undulating areas and where subsidence is
likely to occur, they can be used because of their resilience but they are more subject to internal
and external corrosion as compared to other pipes.
h) Steel pipes of small diameter can be made from solid bar sections by hot or cold drawing
process and these tubes are referred to as seamless. The large sizes are made by welding
together the edges of suitably curved plates, the sockets being formed later in a press. The
thickness of the steel used is often controlled by the need to make the pipe stiff enough to keep
its circular shape during storage, transport and laying as also to prevent excessive deflection
under the load of the trench back filling. The thickness of a steel pipe is, however considerably
less than the thickness of the corresponding vertically cast or spun Iron pipe owing to the higher
tensile strength of the steel making it possible for steel pipes to be more than twice the length
of CI pipe of the same class, with consequent saving in transport, pipe laying and jointing costs.
i) Specials of all kinds can be fabricated without difficulty to suit the different site conditions.
Due to their elasticity, steel pipes adopt themselves to changes in relative ground level without
failure and hence are very suitable for laying in ground liable to subsidence . However, steel
mains need protection from corrosion.
J) Electrically welded steel pipes for water gas and sewage for sizes from 150 to 2000 mm nominal
dia. are covered by IS:3589-1981. The pipes are designated by the method of manufacture
followed by a number corresponding to the minimum tensile strength in MPa e.g. E 4 1 0
indicates electric fusion (arc) welded steel pipes having a minimum tensile strength of 410
MPa. The steel pipes shall have minimum specified wall thickness as given in Table 1 as under:
Table 1 : Minimum Specified Thickness of Steel Pipes
Nominal Dia.of Pipes-mm Minimum

thickness
of plate-mm
200 to 400 5
450 to 700 6
800 to 900 7
1000 to 1200 8
1400 to 2000 10
h) Prestressed Concrete pipes are ideal for a pressure range of 0.5 to 2.0 MPa ( 5 to 20 kg f/cm2)
where CI and Steel are not economical.
i) Lead piping shall not be used to convey domestic water supply as most of the water in India
are plumb solvent and are liable to cause lead poisoning. Lead piping may, however, be used
for flushing and overflow pipes. It is liable to corrosion on contact with fresh cement mortar or
concrete and shall be protected by wrapping with a protective material which will also permit
movement due to expansion and contraction.
i) Copper piping may be used particularly in hot water installations provided water is not capable
of dissolving an undue amount of copper.
j) Asbestos cement pipes are relatively more corrosive resistant than steel or CI, light and easy to
handle, and these are used in lateral and minor distribution systems. However, these pipes
cannot take high internal pressures. In soils containing sulphates, RCC and AC pipes are liable
to corrode. These pipes also require adequate safeguards while laying / baclfilling.
k) Mild steel tubes used in plumbing system shall be of medium class conforming to IS: 1239
(Part I) 1990.
1) PVC, Polyethylene pipes : Being more flexible and more corrosive resistant compared to metallic
and concrete pipes, Unplasticized PVC and Polyethylene pipes can be extensively used in hotels
and house service connections as also plumbing systems. The plasticized PVC is not
recommended because of the uptake of lead by the water. PVC pipes are well suited for use in
mountainous terrain and undulating areas. They have the advantage of easy and simple jointing
unlike polyethylene. Polyethylene pipes can be used successfully in river crossings. PVC pipes
should not be laid on hot surfaces or in too close a proximity of hot water pipes. Care should
also be taken to avoid location where they are likely to be exposed to atmospheres charged with
coal gas.
21.3.2 Conveyance and Distribution of Water within the Premises:
21.3.2.1 Basic Principles: Some of the details of plumbing which are considered necessary for
properly designed, acceptably installed and adequately maintained plumbing systems are given
in 21.3.2.2 to 21.3.2.9. Through the details of construction may vary, the basic sanitary and safety
principles are the same, and they merit serious study. Furthermore, in the event of any unforeseen
situation not covered by specific provisions in this Schedule, the principles enumerated may serve
as useful guides.
21.3.2.2 Wholesome water supply provided for drinking and culinary purposes shall not be liable to
contamination from any less satisfactory water. There shall, therefore, be no cross-connection
whatsoever between a pipe or fitting for conveying or containing wholesome water and a pipe or
fitting for containing impure water or water liable to contamination or of uncertain qualify or water
which has been used for any purpose. The provision of reflux or non-return valves or closed and
sealed stop valves shall not be construed as a permissible substitute for complete absence of cross-
connection.
21.3.2.3 The design of the pipe work shall be such that there is no possibility of backflow towards the
source of supply from any cistern or appliance whether by siphonage or otherwise. Reflux or non-
return valves shall not be relied upon to prevent such backflow.
21.3.2.4 Where a supply of wholesome water is required as an, alternative or stand-by to a supply of
less satisfactory water or is required to be mixed with the latter, it shall be delivered only into a
cistern, and by a pipe of fitting discharging into the air gap at a height above the top edge of the
cistern equal to twice its nominal bore, and in no case less than 150 mm. It is necessary to maintain
a definite air gap in all appliances or taps used.
21.3.2.5 All pipe work shall be so designed, laid or fixed, and maintained as to be and to remain
completely watertight, thereby avoiding waste of water, damage to property and the risk of
contamination of the water conveyed.
21.3.2.6 No piping shall be laid or fixed so as to pass into, through or adjoining any sewer, scour
outlet or drain or any manhole connected therewith nor though any ash pit or manure pit or any
material of such nature that would be likely to cause undue deterioration of the pipe, except as
permitted in 21.3.2.8.
21.3.2.7 Where lines have to be laid in close proximity to electric cables or corrosive soils, adequate
precautions should be taken to avoid electrical accidents and corrosion.
21.3.2.8 Where the laying of any pipe through corrosive soil or pervious material is unavoidable, the
piping shall be property protected from contact with such soil or material by being carried through
an exterior cast iron tube or by some other suitable means as approved by the Authority. Any existing
piping or fitting laid or fixed which does not comply with the above requirements, shall be removed
immediately by the consumer and re-laid by him in conformity with the above requirement and to
the satisfaction of the Authority.
21.3.2.9 No boiler for generating steam or closed coilers of any description or any machinery shall
be supplied water directly from a service or supply pipe. Every such boiler or machinery shall be
supplied from a feed cistern.
21.3.3 General Requirements for pipe work: (Fig. 3):
21.3.3.1 Mains: The following principles shall apply for the mains:
a) Service mains shall be of adequate size to give the required rate of flow.
b) The mains shall be divided into sections by the provisions of sluice and other valves so that
water may be shut off for repairs.
c) To avoid dead ends, the mains shall be arranged in a grid formation or in a network
d) Where dead ends are unavoidable, a hydrant shall be provided to act as a wash-out.
e) The wash-out valve shall not discharge directly into a drain or sewer, or into a manhole or
chamber directly connected to it, an effectively trapped chamber shall be interposed, into
which the wash-out shall discharge.
f) Air valves shall be provided at all summits, and wash-out at low points between summits.
g) Mains need not be laid at unvarying gradients, but may follow the general contour of the
ground. They shall, however, fall continuously towards the air valves. The gradient shall be
such that there shall always be a positive pressure at every point under working conditions.
h) The cover for the mains shall be at least 900 mm under roadways and 750 mm in the case of
footpaths. This cover shall be measured from the top of the pipe to the surface of the ground.
i) The mains shall be located sufficiently away from other service lines like electric and telegraph
cables to ensure safety and where the mains cannot be located away from such lines, suitable
protective measures shall be accorded to the mains.
21.3.3.2 Communication Pipes:
a) Every premise that is supplied with water by the Authority shall have its own separate
communication pipe. In the case of a group or block of premises belonging to the same owner
the same communication pipe may supply water to more than one premises with the prior
permission of the Authority.
b) The communication pipe between the water main and the stop-cock at the boundary of the
premises shall be laid by the Authority.
c) Connections up to 50 mm diameter may be made on the water main by means of screwed
ferrules, provided the size of the connections does not exceed one-third the size of the water
main. In all other cases, the connection shall be made by a T-branch off the water main.
d) As far as practicable, the communication pipe and the underground service pipe shall be laid at
right angles to the main and in approximately straight lines to facilitate location for repairs. It
is also recommended that the communication pipe be laid in a pipe in pipe sleeve of larger dia.
made of non-corrosive material to protect the communication pipe.
e) Every communication pipe shall have a stop-cock and meter inserted in it. The waterway of
each such fitting shall not be less than the internal sectional of the communication pipe and the
fittings shall be located within the premises at a conspicuous place accessible to the Authority
which shall have exclusive control over it.
21.3.3.3 Consumer Pipes:
a) No consumer pipe shall be laid in the premises to connect the communication pipe without
the approval of the Authority.
b) The consumer pipe within the premises shall be laid underground with a suitable cover to
safeguard against damage from traffic and extremes of weather.
c) To control the branch pipe to each separately occupied part of a building supplied by a
common service pipe, a stop tap shall be fixed to minimize the interruption of the supply
during repairs. All such stop valves shall be fixed in accessible positions and properly
protected. To supply water for drinking or for culinary purposes, direct taps shall be provided
on the branch pipes connected directly to the consumer pipe. In case of multi-storied
buildings, down take taps shall be supplied from overhead tanks.
d) Pumps shall not be allowed on the service pipe, as they cause a drop in pressure on the suction
side, thereby affecting the supply to the adjoining properties. In cases where pumping is required,
a properly protected storage tank of adequate capacity shall be provided to feed the pump.
e) No direct boosting (by booster pumps) shall be allowed from the service pipes
(communication and consumer pipes).
f) Consumer pipes shall be so designed and constructed as to avoid air-locks. Draining tap shall
be provided at the lowest points from which the piping shall rise continuously to draw-off taps.
g) Consumer pipes shall be so designed as to reduce the production and transmission of noise as
much as possible.
h) Consumer pipes in roof spaces and unventilated air spaces under floors or in basements shall
be protected against corrosion.
i) Consumer pipes shall be so located that they are not unduly exposed to accidental damage and
shall be fixed in such positions, as to facilitate cleaning and avoid accumulations of dirt.
j) All consumer pipes shall be so laid as to permit expansion and contraction or other
movements.
21.3.3.4 Prohibited Connections:
a) A service pipe shall not be connected into any distribution pipe, such connection may permit
the backflow of water from a cistern into the service pipe, in certain circumstances, with
consequent danger of contamination and depletion of storage capacity. It might also result in
pipes and fittings being subjected to a pressure higher than that for which they are designed, and
in flooding from overflowing cisterns.
b) No pipe for conveyance or in connection with water supplied by the Authority shall
communicate with any other receptacle used or capable or being used for conveyance other
than water supplied by the Authority.
c) Where storage tanks are provided, no person shall connect or be permitted to connect any
service pipe with any distributing pipe.
d) No service or supply pipe shall be connected directly to any water-closet or a urinal. All such
supplies shall be from flushing cisterns which shall be supplied from storage tank.
e) No service or supply pipe shall be connected directly to any hot water system or to any other
apparatus used for heating other than through a feed cistern thereof.
21.3.4 Laying of Mains and Pipes on Site:
21.3.4.1 Excavation and Refilling: The bottoms of the trench excavations shall be carefully
prepared so that the barrels of the pipes, when laid, are well bedded for their whole length on a firm
surface and are true to line and gradient. The width of the excavation shall be sufficient
to allow the pipes to be properly laid and jointed, joint holes being made where necessary.
21.3.4.2 In the refilling of the trenches, the pipes shall be surrounded with fine selected material,
well rammed so as to resist subsequent movement of the pipes. No stones shall be in contact with the
pipes, and when the excavation is in rock, the bottom shall be cut deep enough to permit the pipes
to be bedded on a layer of fine selected material, or (especially where there is a steep gradient) on a
layer of concrete.
21.3.4.3 Preparing Pipes for Laying Underground: The pipes shall be carefully cleared of all
foreign matter before being laid. They shall be thoroughly brushed out-internally with a well-fitting
hard brush, and after laying the open end shall be temporarily plugged to prevent ingress of water,
soil, etc. precaution shall be taken to prevent floatation of the plugged pipes, should the trench
become flooded.
21.3.4.4 Any coating, sheathing or wrapping of the pipes shall be examined for damage and repaired,
where necessary, and shall also be made continuous over the joints.
21.3.4.5 Concrete Pipes and Cast Iron Pipes: These should be laid in accordance with the
requirements given in IS: 783-1985 and IS: 3114-1994, respectively.
21.3.4.6 Laying Underground Mains: Where the trench is on a slope, pipe laying shall proceed in
an 'uphill' direction to facilitate joint making.
21.3.4.7 Except in the case of small pipe under low pressure, thrust blocks of concrete shall be
formed at all bends to transmit the hydraulic thrust on to undisturbed ground and to spread it over a
sufficient area. Where the hydraulic thrust is in upward direction, anchor-blocks of sufficient weight
shall be provided to which the pipes shall be secured with steel straps.
21.3.4.8 Surface Boxes: Iron surface boxes shall be provided to give access to valves (see IS: 3950-
1979) and hydrants, and shall be supported on concrete or brickwork which shall not be allowed to
rest on the pipes and transmit traffic loads to them, allowance being made for settlement. Vertical iron
guard pipes may be provided to enclose the spindles of sluice valves. It is not generally necessary to
enclose entirely the valves and hydrants in brick or concrete chambers, but if the later are provided ,
they shall be of sufficient dimensions to permit repairs being carried out to the fittings. (Fig.19,
Fig.20)
21.3.4.9 If the surface box, mounted on a guard pipe, is fixed over the underground stop valve merely
to give access for operating the latter, the limited space provided by this arrangement will not permit
the repacking of the stop valves gland or other repairs to be carried out with excavation. The guard
pipe may be supported on bricks, and should not rest on the supply pipe.
21.3.4.10 Meters: If the service pipe is to be metered, the meter may be provided and fixed by the
Authority. Private meter of approved type may be permitted to be used subject to such conditions as
the Authority may prescribe. Meters of domestic type shall conform to the requirements of IS: 779-
1994. Meters of bulk type shall conform to the requirements of IS: 2373-1981. The meter shall be
installed in accordance with IS: 2401-1973. The meter shall be fitted beyond the stopcock with unions
to facilitate the necessary periodic changing of the meter. If fitted in an exposed position outside the
building, the meter shall be housed in water meter boxes conforming to IS: 2104-1981. (Fig.2)
21.3.4.11 Laying Service Pipes: Service pipes of less than 50 mm bore may be connected to mains
by means of right-angled screw-down ferrule of non-ferrous metal conforming to IS: 2692-1989, but
the ferrule itself shall not be more than 25 mm bore. Ferrule of 20 mm bore and above
shall not be used in mains of less than 100 mm bore. The main is drilled and tapped and the ferrule
screwed in. In case of large sized trunk mains, this may be done by a tapping under pressure machine,
which will obviate any interference with the use of the main.
21.3.4.12 Service pipes of 50 mm bore and upward shall be connected to special T-branches which
have to be inserted into the line of the main. Special branch pipes shall also be used for service pipes
of less than 50 mm bore where the bore of the main is not greater than thrice that of the service pipe.
21.3.4.13 In the process of installing or repairing any part of a plumbing installation, the finished
floors, walls, ceilings, tile work or any other part of the building or premises, which shall be changed
or replaced, shall be left in a safe structural condition in accordance with the requirements of the
relevant codes and any building bye-laws approved by the Authority. All exterior openings provided
for the passage of pipe shall be properly sealed.
21.3.4.14 Precautions against contamination of the mains shall be taken when making a connection,
and where any risk exists, the main shall be subsequently disinfected. The underground water service
pipe and the building sewer or drain shall be kept at a sufficient distance apart to the satisfaction of
the Authority so as to prevent contamination of water. Water service pipes or any underground water
pipes shall not be run or laid in the same trench as the building sewer or drainage pipe. Where this
is unavoidable, the following conditions shall be fulfilled:
(a) The bottom of the water service pipe, at all points, shall be at least 30 cm above the top of
the sewer line at its highest point.
(b) The water service pipe shall be placed on a solid shelf excavated at one side of the common
trench.
(c) The number of joints in the service pipe shall be kept to a minimum.
(d) The materials and joints of sewer and water service pipe shall be installed in such a manner and
shall possess the necessary strength and durability so as to prevent the escape of solids, liquids,
and gases there from due to temperature changes, settlement, vibrations and superimposed
loads.
21.3.4.15 The service pipe shall pass into or beneath the building at a depth below the external
ground level of not less than 0.75m (provided the foundation is deeper than 0.75m) and at its point
of entry through the structure should be accommodated in a sleeve which should have previously
been solidly built in. The space between the pipe and the sleeve shall be filled with bituminous or
other suitable material for a minimum length of 15 cm at both ends.
21.3.4.16 Care shall be taken to ensure that before the pipeline is charged all piping and fittings are
clean internally, and free from particles of sand or soil, metal fittings, chips, etc. which besides causing
obstructions may lead to failure by corrosion.
21.3.4.17 Securing and Supporting of Pipes: Lead piping of not more than 25 mm bore, in vertical
runs, may be secured direct to brick walls (other than external walls) by iron pipe clamps driven into
the wall joints or may be secured to wooden battens or other wood work by iron or brass clips with
ears for screw fixing, the clamps or clips or holder bats being at not more than 90 cm interval.
Damage to the piping by the clamps shall be prevented by the insertion of small lead pads.
21.3.4.18 Copper piping shall be secured by copper or copper-alloy clips direct to wood work, or
by similar bracket-clips built-in to walls or screwed to plugs.
21.3.4.19 Wrought iron and steel piping shall be secured in a manner similar to that used for copper
piping, except that the clips shall be of iron or steel.
21.3.4.20 Plastic pipes should be secured and supported in accordance, with the recommendations
given in IS: 7634 (Part 2)-1975 and IS: 7634 (Part 3)-1975 and German Standards DIN for
Polypropylene Random Copolymer Type-3.
21.3.4.21 Pipes Laid Through Ducts, Chases, Notches or Holes: Ducts or chases in walls for
piping shall be provided during the building of the walls. If they are cut in existing walls, they shall
be finished sufficiently smooth and large enough for fixing the piping. In the case of lead pipes, the
joints may be wiped outside the duct, and the pipes eased back into the duct after jointing.
21.3.4.22 Wherever possible back boards shall be provided in chases for fixing the piping, otherwise
lead piping shall be protected from contraction with lime or cement by use of building paper or felt.
Where covers are provided to chases, they shall be fixed with screws for easy removal.
21.3.4.23 Piping laid in notches or holes shall not be subjected to external pressure, and shall be free
to expand and contract without noise due to friction on the wood.
21.3.4.24 Lagging for pipes: Where lagged piping outside buildings is attached to walls, it shall be
entirely covered all round with waterproof insulating material and shall not be in direct contract with
the wall. Where it passes through a wall, whether into a building or not the lagging shall be continued
along the pipe throughout the thickness of the wall, and where it emerges from the ground, the
lagging shall be continued into the ground until the depth of 0.75 m is reached.
21.3.4.25 Lagged piping connected to cisterns, enclosed by insulating casing shall pass at right
angles through the casing and be bagged independently of the casing if the piping is sandwiched
between the cistern and the casing, it will probably, not be sufficiently insulated.
21.3.4.26 The minimum thickness of insulating material or lagging hot-water piping inside buildings
shall be 12 mm in the case of glass in fibre form, compressed felt, and felted slag or mineral wool
and 20 mm in the case of asbestos, 85 percent magnesia, compressed backed cork and granulated
cork (raw or backed).
21.3.4.27 All lagging exposed to moist conditions shall be waterproof or covered with a waterproof
wrapping.
21.3.4.28 Spacing of Fixing for Internal Piping: Fixing on internal pipes shall be spaced at regular
intervals.
21.3.5 Jointing of Pipes:
21.3.5.1 Cast Iron Pipes: The spigot and socket joints of cast iron pipes are usually caulked with lead.
The common form of joint is made by first caulking in spun yarn, then filling the space left in the
joint by running in molten lead (at proper temperature), taking care that the joint is made with one
continuous pour filling of the entire joint space with solid lead such that no dross enters the joint,
and then thoroughly caulking the lead. The spun yarn shall be clean and sterile and the lead shall
conform to IS: 782-1978. The lead need not extend into the joint further than the back of the groove
formed in the socket. Molten lead joints are not favoured and the alternatives to such jointing are as
under:
i) Tyton Joint: This is a patented joint and involves the manufacture of spun C.I pipes with
modified socket design and the use of a special rubber gasket to effect a sound and efficient
joint. A rubber gasket of a special type with a bulb and groove is kept compressed between the
spigot and socket with a projecting head from the socket pressing against the groove in the
gasket. The rubber ring is of two different qualities cast monolithic and provides water tightness
by its shape and flexibility. This joint is now generally adopted in all projects.
ii) Screwed gland flexible joint: Here the jointing is essentially a screwing arrangement to hold
the rubber ring in position. Screw threads are cast inside the socket of the pipe and on the
outside of the CI gland. A flexible rubber ring is inserted in the joint and when the CI gland is
screwed on to the socket, the rubber ring is pressed tight in the annular space between the spigot
and socket. The flexibility is claimed only up to 3° against 5° in the case of Tyton joint.
iii) Electrolite joint: This is similar to Tyton joint but with a difference. In the Tyton joint, a
projecting ring or head from the socket presses against a groove in the rubber gasket
compressed between the socket and spigot. In the Electrolite joint, however, a projecting head
or lug in the rubber ring presses against a groove in the socket. The efficiency is yet to be
established.
iv) CI detachable joint after cutting the socket ends: In this method, the socket ends are cut and
the pipes jointed in the same way as AC pressure pipes with CI detachable joints. The use is
recommended where the working pressure is more than 30 m.
v) Cement Joints: The joint is made with Jute or hemp yarn with stiff cement paste (15 kg Portland
cement and 1 lit. of water) like in case of SW pipes. The joints are caulked with special tools
and cured for 10 days before subjecting to pressure. These joints are rigid and necessitate a firm
foundation for the pipe line for minimizing movements. Lead joints are used at suitable
intervals to give flexibility. These joints are suitable where the working pressure is less than 30
m.
21.3.5.2 The spun yarn is used to centre the spigot in the socket, to prevent the flow of molten lead
into the bore of pipe, to reduce the amount of lead required to complete the joint and to make the
joint watertight. Spun yarn may become infected with bacteria, which may contaminate the water
and, therefore, shall be effectively sterilized before use by being exposed to the vapours of 40 percent
formaldehyde in an air-tight chamber for not less than 3 hours. Alternatively, proprietary brands of
sterilized spun yam may be used. Threaded lead or lead wire or strip may be used instead of spun
yarn, thus producing a solid lead joint. Lead covered yarn may also be used which does not have the
disadvantages of plain yarn. Cold lead may be caulked into the joint space first followed by spun
yarn, and the joint then completed with cold or molten lead. Rubber ring joints may also be suitable
wherever there is a provision for them in the spigot made by the manufacturer.
21.3.5.3 Caulking may be done with pneumatic tools or with a hand hammer weighing not less than
2 kg. When working with lead wool, it is very important to use caulking tools of appropriate
thickness to fill the joint space and to thoroughly consolidate the material from the back to the front
of the socket lead run joint shall be preferably finished 3 mm behind the socket face.
Note: Attention is also drawn to IS: 3114-1994 for jointing of cast iron pipes, quantity of lead and
spun iron for different sizes of pipes, etc.
21.3.5.4 Cast iron pipes may also be joined by means of flanges of cast iron and steel pipes with
flanges welded-on.
21.3.5.5 Flanged joints shall be made with rings of good quality, smooth, hard, compressed fibre
board (not less than 1.5 mm thick) and of such width as to fit, inside the circle of bolts. The rings
shall be smeared thinly with graphite paste. Alternatively, the jointing rings may be of rubber or
rubber insertion or gutta-percha, or may be corrugated non-corrosive alloy together with a suitable
jointing paste. The nuts shall be carefully tightened in opposite pairs, until the joint ring is only just
sufficiently compressed between the targets to ensure water tightness of the joint under the desired
water pressure.
21.3.5.6 Several proprietary flexible joints are available for jointing cast iron pipes and these may
be used with the specific approval of the Authority. However, they shall be used strictly in
accordance with the manufactures instructions.
21.3.5.7 For joints in small diameter wrought iron or steel piping and cast iron piping, Cooper-alloy
screwed unions or ferrules shall be used and for large diameters, the joints shall be made by flanged
connecting pieces.
21.3.5.8 Welded Steel Pipes: Plain ended steel piping may be joined by welding except where the
piping is provided with a lining which would be damaged by heat.
21.3.5.9 Wrought Iron and Steel Screwed Pipes:Screwed wrought iron steel piping is jointed with
screwed and socketed joints, using screwing fittings of wrought iron, steel or malleable cast iron.
Care shall be taken to remove any burr from the end of pipes after screwing. A jointing compound,
which may be one of the many proprietary makes, may be used according to the maker's instructions
together with a grummet of a few strands of fine yam, but compounds containing red lead shall not
be used because of the danger of contamination of the water. Any threads exposed after jointing shall
be painted, or in the case of underground piping, thickly coated with bituminous or other suitable
composition to prevent corrosion.
21.3.5.10 Screwed wrought iron or steel piping may also be jointed with screwed flanges of wrought
iron, steel or cast iron.
21.3.5.11 Asbestos Cement Pipes: Asbestos cement pipes are jointed with flexible joints supplied by
the pipe makers.
21.3.5.12 Copper Pipes: Screwed copper piping shall be jointed with screwed copper-alloy fittings.
The screw threads of the pipe shall be cleaned out and the joint made by screwing the fittings on
after first treating the threads with raw linseed oil or other suitable jointing compound alternatively,
the screw threads of the pipe and the fittings may be lined, and the joint heated to the melting point
of the solder when being screwed.
21.3.5.13 Plain copper piping shall be jointed with compression (manipulative or non-manipulative)
or with capillary joints, in each case using copper-alloy fittings, or by welding. Only manipulative
compression joints, that is, joints in which the pipe ends are flanged, belled or swaged, are suitable for
use with fully annealed copper piping.
21.3.5.14 In the case of capillary joint, the pipe end and the interior of the socket of the fitting shall
be cleaned with steel wool, fluxed, and fitted together, and the joint then heated to just above, the
melting point of the solder, which is either provided in the fitting or is touched into the joint with a
solder stick, and which then flows by capillarity to fill the joint space. If the pipe is of fully annealed
copper, its ends shall be made truly round before jointing.
21.3.5.15 It is important that the correct size of fittings is used to suit the nominal size of the pipe.
21.3.5.16 Copper piping may be autogenously welded or bronze welded, the latter giving the
stronger joint. The piping may be jointed directly or by the use of weldable copper or copper alloy
fittings. The welding may be done by an oxy-acetylene blow pipe, using filler rod of copper or bronze
and a suitable flux. Bronze rod shall be genuine bronze which is not likely to fall by dezincification.
Copper piping may be welded to cast brass fittings by this method. Copper to be welded shall be
deoxidized copper and not tough pitch copper. Welding shall be done by skilled craftsman only.
21.3.5.17 Copper piping of small diameter shall be jointed to cast iron, wrought iron, or steel piping
by the use of copper-alloy screwed unions or ferrules. For screwed copper piping of diameter, larger
than about 40 mm, a flanged joint shall be used, the copper pipe shall have a copper alloy flange
screwed, brazed or welded on, and this shall be jointed to the iron or steel flange by alloy bolts or
nuts.
21.3.5.18 Lead Pipes: Lead and lead alloy piping shall be jointed with wiped solder joints or by
other suitable methods.
21.3.5.19 Lead and lead alloy piping shall be jointed to cast iron, wrought iron, steel or copper
piping by the use of copper alloy screwed unions or ferrules.
21.3.5.20 Concrete Pipes: Concrete pipes shall be jointed in accordance with the
recommendations given in IS: 783: 1985.
21.3.5.21 Polyethylene and Unplasticized PVC Pipes: These pipes shall be jointed in accordance
with the recommendations given in IS: 7634 (Part 2)-1975 and IS: 7634 (Part 3) - 1975, respectively.
21.3.6 Storage of Water:
21.3.6.1 Purposes for providing Storage: In a building, provision is required to be made for
storage of water for the following reason:
(a) To provide against interruptions of the supply caused by repairs to mains, etc;
(b) To reduce the maximum rate of demand on the mains;
(c) To tide over periods of intermittent supply, and
(d) To maintain a storage for the fire fighting requirement of the building (see page 4 'Fire and
Life Safety' of National building code 2005).
21.3.6.1.2 The water may be stored either in overhead tanks (OHT) and/or underground tanks
(UGT).
21.3.6.3 Materials Used: Reservoirs and tanks for the reception and storage of water shall be
constructed of reinforced concrete brick masonry, Ferro-cement precast, mild steel, stainless steel or
plastic.
21.3.6.4 Tanks made of steel may be of welded, riveted or pressed construction. The metal shall be
galvanized coated externally with a good quality anti-corrosive weather-resisting paint. Lead-based
paint shall not be used in the tank. Lead lined tanks shall not be used Rectangular pressed steel tanks
shall conform to good practice [9-1 (3) of NBC 2005].
21.3.6.5 Each tank shall be provided with the following:
a) Manholes- Adequate number of manholes for access and repair. The manholes shall be
made of corrosion resistant material (for example, cast iron, reinforced cement concrete, steel
fibre reinforced concrete galvanized steel, high density polyethylene, fibre glass reinforced
plastic or such other materials acceptable to the Authority). Manholes shall be provided with
locking arrangement to avoid misuse and tampering.
b) Catch Rings and Ladders- Tanks higher then 900 mm depth shall be provided with corrosion
resistant catch rings, steps or ladders according to the depth to enable a person to reach the
bottom of the tank.
c) Overflow Pipe- Each tank shall be provided with an overflow pipe terminating above the
ground/terrace level to act as a 'Warning Pipe' to indicate overflow conditions. The size of the
overflow pipe shall be adequate to accept the flow. Normally the overflow pipe size shall be
one size higher than the inlet pipe. When the inlet pipe diameter is large, two or more overflow
pipes of equivalent cross-section may be provided.
d) Vent Pipes- Tanks larger than 5000 litre capacity shall be provided with vent pipes to prevent
development pressure in the tank which might result in 'NO FLOW' condition or inward
collapse of the tank.
e) Scour Pipe- Each tank shall be provided with a scour pipe with an accessible valve for
emptying the tank.
f) Connection of Overflow and Scour Pipe- Under no circumstances tank overflow and scour pipe
shall be connected to any drain, gully trap or manhole to prevent back flow and contamination
of the water. All such connections shall be discharged over a grating with an air gap of 50 mm.
All overflow and vent pipes shall be provided with mosquito proof brass grating to prevent
ingress of mosquito, vermin and other insects.
g) The top slab of the tank must be suitable sloped away from its centre for proper drainage of
the rainwater.
h) Tanks on terraces and above ground shall be supported by appropriate structural members so
as to transfer the load of the tank and the water directly on the structural members of the
buildings.
21.3.6.6 Storage tank shall be easily accessible and placed in such a position as to enable through
inspection and cleaning to be carried out. If the storage capacity required is more than 5000 litre, It
is advantageous to arrange it in a series of tanks so interconnected that each tank can be isolated for
cleaning and inspection without interfering with the supply of water. In large storage tanks, the outlet
shall be at the end opposite the inlet to avoid stagnation of the water.
21.3.6.7 The outlet pipe shall be fixed 50 mm to 75 mm above the bottom of the tank and fitted with
a strainer, preferably of brass.
21.3.6.8:
a) In the case of underground storage tanks, the design of the tank shall be such as to provide for
the draining of the tank when necessary and water shall not be allowed to collect around the
tank. The tank shall be perfectly water-proof and shall be provided with a cement concrete cover,
having a manhole opening, with a properly fitting hinged cast iron cover on a leak proof cast
iron frame.
b) The underground tanks should not be located in low lying areas or near any public or private
sewer, septic tank, leaching pool or soakage pit to prevent any contamination. The overflow
of the tank should be well above (preferably 600 mm) the external surface level and terminate
as a warning pipe with a mosquito proof grating. Care must be taken to prevent backflow of
local surface water into the tank in case of local flooding. Otherwise the overflow must be
terminated in a safer manner as per the site conditions. For tanks with at least one side exposed
to a basement, it is safer to discharge the overflow into the basement level.
c) The tank top slab shall also be designed to carry the load due to fire tender movement where
anticipated as in the case of an extended basement. There should be no common wall between
the tanks storing safe water and tanks storing water from unsafe sources.
21.3.6.9 In case of overhead tanks, bottom of the tanks shall be placed clear off the terrace slab such
that the elevation difference between the outlet pipe of the tank and the highest fixture at the top
floor of the building is minimum 2 m, which shall also prevent leakage into the structural slab. In
tall buildings, the top of the tank shall be provided with the safe ladder or staircase. The top slab
shall be provided with railing or a parapet wall.
21.3.6.10 For jointing steel pipe to a storage tank, the end of the pipe shall be screwed, passed
through a hole in the tank and secured by back nuts, both inside and outside. The pipe end shall be
flush with the face of the inside back nut. For jointing copper pipe to steel or copper tank, a connector
of non-ferrous material shall be used. The connector shall have a shoulder to bear on the outside of
the tank and shall be secured by a back nut inside.
21.3.6.11 The quantity of water to be stored shall be calculated taking into account the following
factors:
a) hours of supply at sufficiently high pressure to fill up the overhead storage tanks;
b) frequency of replenishment of overhead tanks, during the 24h;
c) rate and regularity of supply; and,
d) consequences of exhausting storage particularly in case of public building like hospitals.
If the water supply is intermittent and the hours of supply are irregular, it is desirable to have a
minimum storage of half a day's supply for overhead tanks. For additional requirement of water storage
for firefighting purposes, reference may be made to Part 4 'Fire and Life Safety of NBC2005'
Note- General guidelines for calculation of capacity of these storage tanks are as follows:
a) In case only OHT is provided, it may be taken as 33.3 to 50 percent of one day's requirement;
b) In case only UGT is provided, it may be taken as 50 to 150 percent of one day's requirement;
and
c) In case combined storage is provided, it may be taken as 66.6 percent UGT and 33.4 percent
OHT of one day's requirement.
21.3.6.12 When only one communication pipe is provided for water supply to a building, it is not
necessary to have separate storage for flushing and sanitary purposes for health reasons. In such
cases when only one storage tank has been provided, tapping of water may be done at two different
levels (the lower tapping for flushing) so that a part of the water will be exclusively available for
flushing purposes.
21.3.7 Water Fittings and Appliances:
21.3.7.1 Bath, Lavatory and Mixing Taps: Bath, lavatory and mixing taps shall generally comply
with the requirements specified for bib taps in IS: 781-1984. Combination taps, mixing valves
(see IS 1701-1960) or blenders for mixing hot and cold water and discharging the mixture through a
single outlet shell be fed with both hot water and cold water under pressure only from cisterns at the
same level or from the same cistern; the cold water should not be supplied directly from a service
pipe as otherwise, there is also desirable that the feed pipe does not also feed other fittings.
21.3.7.2 Position where Self-closing Taps are Permissible: Self closing taps and other special
fittings of makes approved by the Authority may be permitted to be used on direct pipes and
distributing pipes from tanks. Self-closing taps shall be of non-concussion type and shall comply
with IS: 1711-1984.
21.3.7.3 Water Closet Flushing Cistern: All water closets and urinals shall be supplied with water
from proper flushing cistern or from other equally efficient and suitable waste preventing apparatus.
Flushing cisterns having 10 litre discharge capacity and discharging at an average rate of 5 litre/sec
are considered suitable for wash-down water closets and squatting pans IS: 2556 (Part2)-1994 and
IS: 2556 (Part 3) 1994.
21.3.7.4 Water-closet Flush Valves: No person shall fix, fit or use upon any premises any flush
valves, or similar apparatus through which water supplied by the Authority is intended to pass unless
previous permission of the Authority is obtained. Such flush valves or flushing apparatus shall be of
the self-closing type and shall be allowed on water-closet only. The design of the flushing valve or
flushing apparatus of similar type shall be such that no single flush shall exceed 15 litre. All flush
valves shall be fitted with regulating stop cock or valve in addition to the regulating screw on the
top of the valve which shall be sealed by an authorized officer. Every flush valve shall be provided
with a suitable and approved type of stop cock on the upstream side of the flush valve.
21.3.7.5 Urinal Flushing Cistern: Every urinal flushing cistern, in which water supplied by the
Authority is used, shall have an efficient waste preventing apparatus so constructed as to prevent
discharge of more than 5 litre of water to each stall, basin or compartment at each flush (see IS:
2326- 1987).
21.3.7.6 Use of Automatic Flushing Cisterns: Flushing apparatus capable of discharging
automatically (see IS: 2326-1987) may be allowed to be fitted on water-closets.
21.3.7.7 Use of Ball Valves: Ball valves shall be of one of the classes, namely high pressure or low
pressure and shall conform to the requirements specified in IS: 1703-1989.
21.3.7.8 Silencing Pipes of Ball Valves: A silencing pipe may be fitted to a ball valve when
permitted by the Authority and in such cases anti-siphonage holes shall be provided in the pipe or in
the body of valves and these holes shall be above the overflow level.
21.3.8 Cleaning and Disinfection of the Supply System:
21.3.8.1 All water mains, communication pipes service and distribution pipes used for water for
domestic purposes should be thoroughly and efficiently disinfected before being taken into use and
also after every major repair. The method of disinfection shall be subject to the approval of the
Authority. They shall also be periodically cleaned at intervals, depending upon the quality of water
and the treatment it receives before use. It is, however, desirable that the communication pipes and
the storage cisterns are thoroughly cleaned at least once every year in order to remove any suspended
impurities that may have settled in the pipe or the tanks.
21.3.8.2 Disinfection of Storage Tanks and Down take Distribution Pipe: Storage tanks and
down take distribution pipes shall be disinfected as follows:
i) The storage tanks and pipes shall first be filled with water and thoroughly flushed out. The storage
tanks shall then be filled with water again and disinfecting chemical containing chlorine added
gradually while the tanks are being filled, to ensure thorough mixing. Sufficient chemical shall
be used to give the water a dose of 50 parts of chlorine to one million parts of water. If ordinary
bleaching powder is used, the proportion will be 150 g of powder to 1,000 litre of water. The
powder shall be mixed with water to creamy consistency before being added to the water in the
storage tank. If a proprietary brand of chemical is used, the proportions shall be as specified by
the makers. When the storage tank is full, the supply shall be stopped and all the taps on the
distributing pipes opened successively, working progressively away from the storage tank. Each
tap shall be closed when the water discharge brings to smell of chlorine. The storage tank shall
then be topped up with water from the supply pipe and with more disinfecting chemical in the
recommended proportions. The storage tank and pipe shall then remain charged at least for
three hours. Finally the tank and pipes shall be thoroughly flushed out before any water is used
for domestic purposes.
21.3.9 Inspection and Testing:

21.3.9.1 Testing of Mains-Before Commencing Work: All pipes, fittings and appliances shall be
inspected, before delivery at the site to see whether they conform to accepted standards. All pipes
and fittings shall be inspected and tested by the manufactures at their factory and shall comply with
the requirements of this Section. They shall be tested hydraulically under a pressure equal to twice
this maximum permissible working pressure or under such greater pressure as may be specified. The
pipes and fittings shall be inspected on site before laying and shall be sounded to disclose cracks;
Any defective items shall be clearly marked as rejected and forthwith removed from the site.
21.3.9.2 Testing of Mains after Laying: After laying and jointing, the main shall be slowly and
carefully charged with water by providing a 25 mm inlet with a stop-cock, so that all air is expelled
from the main. The main is then allowed to stand full of water for a few days if time permits, and
then tested under pressure. The test pressure shall be 0.5 N/mm2 or double the maximum working
pressure, whichever is greater. The pressure shall be applied by means of a manually operated test
pump, or in the case of long mains or mains of a large diameter, by a power-driven test pump,
provided the pump is not left unattended. In either case, due precaution shall be taken to ensure that
the required test pressure is not exceeded. Pressure gauges shall be accurate and shall preferably have
been recalibrated before that test. The pump having been stopped, the test pressure shall maintain itself
without measurable loss for at least 5 mm. The mains shall be tested in sections as the work of laying
proceeds; it is an advantage to have the joints exposed for inspection during the testing. The open
end of the main may be temporarily closed for testing under moderate pressure by fitting a water-tight
expanding plug of which several types are available. The end of the main and the plug shall be secured
by struts or otherwise, to resist the end thrust of the water pressure in the mains.
21.3.9.3 If the section of the main tested terminates into a sluice valve, the wedge of the valve shall
not be used to retain the water, instead the valve shall be temporarily fitted with a blank flange, or,
in the case of a socketed valve with a plug, and the wedge placed in the open position while testing.
The end of the main and the plug shall be secured by struts or otherwise, to resist
the end thrust of the water pressure in the mains.
21.3.9.4 Testing of Service Pipes and Fittings: When the service pipe is complete, it shall be slowly
and carefully be charged with water, allowing all air to escape, care being taken to avoid all shock
or water hammer. The service pipe shall then be inspected under working conditions of pressure and
flow. When all draw-off taps are closed, the service pipe shall be absolutely water-tight. All pipes
(piping), Fittings and appliances shall be checked for satisfactory support, and protection from
damage, corrosion and frost. Because of the possibility of damage in transit, cisterns shall be re-
tested for water-tightness on arrival at the site, before fixing.
21.3.9.5 In addition to the provisions given in 21.3.9.1 provisions given in 21.3.9.2 to 21.3.9.4 shall
also apply to hot water supply installations in regard to inspection and testing.
21.3.9.6 Testing of the system after installation: After the hot water system, including the hot
water heaters has been installed, it shall be carefully charged with water, so that all air is expelled from
the system. The entire system shall then be hydraulically tested to a pressure of 0.5 N/mm2 or twice
the working pressure, whichever is greater, for a period of at least half an hour after a steady state is
reached. The entire installation shall then be inspected visually for leakages, and sweating. All
defects found shall be rectified by removing and remaking the particular section. Caulking of
threads, hammering and welding of leaking joints shall not be allowed.
21.3.9.7 Hot water testing: After the system has been proved water-tight, the hot water heaters shall
be commissioned by connecting the same to the electrical supply. The system shall then be observed
for leakage in pipes due to expansion or overheating. The temperature of water at outlets shall be
recorded. The thermostats of the appliances shall be checked and adjusted to temperatures specified
in Table 7.
21.3.9.8 Electrical Connection: For relevant provisions regarding general and safety requirements
for household and similar electrical appliances, reference may be a good practice [9-1 (14) of NBC
2005]. The metal work of the water heating appliances and installation other than current carrying
parts shall be bound and earthed in conformity with the good practice [9-1(14) of NBC2005]. It
should be noted that screwing of an immersion heater into a tank or cylinder cannot be relied upon to
effect a low resistance earth connection, a satisfactory separate earthing of heater should be affected.
21.3.10 Maintenance :
21.3.10.1 Storage tanks shall be regularly inspected and shall be cleaned out if necessary. Tanks
showing signs of corrosion shall be emptied, thoroughly wire brushed to remove loose material (but
not scrapped), cleaned and coated with anti-corrosive paint of inert composition not liable to impart
taste or odour or otherwise contaminate the water. Before cleaning the cistern, the outlet shall be
plugged to prevent debris entering the pipe. The tank shall be examined for corrosion and water
tightness after cleaning.
21.3.10.2 Record drawings showing pipe layout and valve positions shall be kept up to date and
inspection undertake to ensure that any maintenance work has not introduced cross-connections or
any other undesirable feature.
21.3.10.3 Any temporary attachment fixed to a tap or outlet shall never be left in such a position
that back-siphonage of polluted water into the supply system may occur.
21.3.10.4 All valves shall be periodically operated to maintain free movement of the working
parts.
21.3.10.5 All taps and ball valves shall be inspected for water tightness, glands shall be made good,
washers shall be replaced and mechanism of spring operated taps and ball valves shall be repaired
where required.
21.3.10.6 All overflow pipes shall be examined and kept free from obstructions.
a) Pressure vacuum breaker,
b) Double check valve, and,
c) Reduced Pressure backflow device.
21.3.10.7 The installation shall not adversely affect drinking water,
a) by materials in contact with the water being unsuitable for the purpose;
b) as a result of backflow of water from water fittings, or water using appliances into pipe work
connected to mains or to order fittings and appliances;
c) by cross-connection between pipes conveying water supplied by the water undertaker with
pipes conveying water from some other source; and,
d) by stagnation, particularly at high temperatures.
21.3.10.8 No pump or similar apparatus, the purpose of which is to increase the pressure in or rate
of flow from a supply pipe or any fitting or appliance connected to a supply pipe, shall be connected
unless the prior written permission of the water supplier has been obtained in each instance. The use
of such a pump or similar apparatus is likely to lead to pressure reduction in the upstream pipe work
which, if significant, increases the risk of backflow from other fittings.
21.3.10.9 The water shall not come in contact with unsuitable materials of construction.
21.3.10.10 No pipe or fitting shall be laid in, on or through land-fill, refuse, an ash pit, sewer,
drain, cesspool or refuse chute, or any manhole connected with them.
21.3.10.11 No pipe susceptible to deterioration by contact with any substance shall be laid or
installed in a place where such deterioration is likely to occur. No pipe that is permeable to any
contaminant shall be laid or installed in any position where permeation is likely to occur.
21.3.10.12 If a liquid (other than water) is used in any type of heating primary circuit, which
transfers heat to water for domestic use, the liquid shall be non-toxic and non-corrosive.
21.3.10.13 A backflow prevention device shall be arranged or connected at or as near as practicable
to each point of delivery and use of water. Appliances with built-in backflow prevention shall be
capable of passing the test. All backflow prevention devices shall be installed so that they are
accessible for examination, repair or replacement. Such devices shall be capable of being tested
periodically by the Authority to ensure that the device is functioning efficiently and no backflow is
occurring at any time.
21.3.11 Quality Requirements of Water Supply:
21.3.11.1 General: The water supplied should be free from pathogenic organisms, undesirable taste
and odour, and minerals, which could produce undesirable physiological effects. It should be clear,
palatable, of reasonable temperature neither corrosive nor scale forming.
21.3.11.2 Physical and Chemical Standards: The physical and chemical quality of water should
not exceed the limits prescribed in the Table-1
21.3.11.3 : Bacteriological Standards: Water entering the distribution system should satisfy all
the following requirements.
a) E- coli count in 100 ml sample should be zero.
b) Coliform organism not more than 10 per 100 ml sample shall be present in any sample.
c) Coliform organisms should not be detectable in 100 ml of any two consecutive samples or
more than 50 percent of the samples collected for the year.
If coliform organisms are found re-sampling should be done. The repeated finding of 1 to 10 coliform
organisms in 100 ml samples or the appearance of higher number in any sample should necessitate
investigation into both the efficacy of the purification process and the method of sampling Source
of pollution should be removed forthwith.
21.3.11.4 Virological Aspects: 0.5 mg per litre of free chlorine residual for one hour is sufficient to
inactivate virus, even in water that was originally polluted. This free residual chlorine is to be insisted
in all disinfected supplies in areas suspected of wide prevalence of infective hepatitis. The free
chlorine residue also takes care of the safety of the water supply from bacteriological point of view.
21.3.11.5 Hardness of Water:
i) Free carbon dioxide in underground water combines with chalk or limestone to form calcium
bicarbonate, which is soluble in water. It causes temporary hardness, which can be cured by
boiling the hard water. Calcium and magnesium Sulphate and chloride cause permanent
hardness in water.
ii) When soap is dissolved in hard water it reacts with minerals in the water to form a scum on the
surface before it combines with water to form leather. The excessive rubbing required to form
lather together with the scum formed is the reason for describing the water as 'hard'. More soap
is required to form lather in hard water than in soft water. It is advantageous therefore to treat
hard water to reduce the hardness for washing purposes. Water having concentration in excess
of 200 mg/litre is hard and requires treatment. Moreover, hard water causes formation of scales
on the heating element in the cattle, geyser, etc. so that progressively more fuel is required to
heat the water, thus wasting energy.
21.3.11.6 Water Treatment: Two methods are used:
a) Lime or lime with soda is added to the water which brings about changes to the hardness
compounds so that they become insoluble and precipitate by settlement or in filters,
b) The nature of hardness is changed in a Base Exchange softener. A natural or synthetic zeolite
is used to convert compounds of calcium and magnesium to sodium carbonate-bicarbonate and
sulphates that do not cause hardness. For domestic treatment small Base Exchange equipment
is generally used.
21.3.11.7 pH Value of Water:
i) Rainwater and water that contains decomposing organic matter such as peat, is acid water. It
is corrosive to iron and steel and will take lead into solution, which leads to cumulative
poisoning.
ii) Alkaline water contains calcium bicarbonate, which is the constituent of temporary hardness.
Pure water consists of hydrogen and oxygen and a small number of positive and negative ions.
The measure of the acidity or alkalinity of water is pH, which indicates the concentration
of hydrogen ions. Acid water has a pH value of less than 7.00 and alkaline water has a pH
value above 7.0.
Table-1(b): Physical and Chemical Standards of Water Supply
S. No. Characteristic Acceptable Cause for
rejection (*)
1. Turbidity (Units on J.T.U. Scale) 2.5 10
2. Colour (units on platinum cobalt scale) 5.0 25
3. Taste and odour unobjectionable
4. pH 7.0-8.5 <6.5 and >9.2
5. Total dissolved solids (mg/1) 500 1500
6. Total hardness (as CaCO3,) (mg/1) 200 600
7. Chlorides (as Cl) (mg/1) 200 1000
8. Sulphates (as SO4) (mg/1) 200 400
9. Fluorides (as F) (mg/1) 1.0 1.5
10. Nitrates (as NO3) (mg/1) 45 45
11. Calcium (as Ca) (mg/1) 75 200
12. Magnesium (as Mg) (mg/1) not > 30 150
(If there are 250 mg/l of sulphates, Mg content
can be increased to a maximum of 125 mg/1
with the reduction of sulphates @ 1 unit per
every 2.5 units of sulphates).
13. Iron (as Fe) (mg/1) 0.1 1.0
14. Manganese (as Mg) (mg/1) 0.05 0.5
15. Copper (as Cu) (mg/1) 0.05 1.5
16. Zinc (as Zn) (mg/1) 5.0 15.0
17. Phenolic compounds (as phenol) (mg/1) 0.001 0.002
18. Anionic detergents (as MBAS) (mg/1) 0.2 1.0
19. Mineral oil (mg/1) 0.01 0.3
20. Arsenic (as As) (mg/1) 0.05 0.05
21. Cadmium (as Cd) (mg/1) 0.01 0.01
22. Chromium (as hexavalent Cr) (mg/1) 0.05 0.05
23. Cyanides (as CN) (mg/1) 0.05 0.05
24. Lead (as Pb) (mg/1) 0.1 0.1
25. Selenium (as Se) (mg/1) 0.01 0.01
26. Mercury (total as Hg) (mg/1) 0.001 0.001
27. Poly nuclear aromatic hydrocarbons (PAH) 0.2 mg/1 0.2 mg/1
28. Gross alpha activity 3 pCi/1 3 pCi/1
29. Gross beta activity (pCi- pico Curie) 30 pCi/l 30 pCi/l
(*) The figures indicated under the Column àcceptable' are the limits up to which the water is
generally acceptable to the consumers. Figures in excess of those mentioned under 'acceptance'
render the water unsuitable, but still may be tolerated in the absence of alternative source up to the
limits indicated under the column 'cause for rejection' above which the supply will have to be
rejected.
If there are 250 mg/1 of sulphates, Mg content can be increased to a maximum of 125 mg/1 with the
reduction of sulphates at the rate of 1 unit per every 2.5 units of sulphates.
Note 1: The figures indicated under the column 'acceptable' are the limits up to which the water
is generally acceptable to the consumers.
Note 2: It is possible that some mine and spring water may exceed the radioactivity limits and
in such cases it is necessary to analyze the individual radio nuclides in order to assess the
acceptability or otherwise for public consumption.
21.4 Design Consideration:
21.4.1 Water supply Requirements for Buildings:
21.4.1.1 Water supply for Residences: a) A minimum of 70 to 100 litre per head per day may be
considered adequate for domestic needs of urban communities, apart from non-domestic needs as
flushing requirements. As a general rule the following rates per capita per day (Table-2) may be
considered minimum for domestic and non-domestic needs:
Table-2
a) For communities with population up to 20000 and without flushing system:
1) water supply through stand post 40 lphd, Min.
2) water supply through house service connection 70 to 100 lphd
b) For communities with population 20000 to 100000
together with full flushing system 100 to 150 lphd
c)
For communities with population above 100000
together with full flushing system 150 to 200 lphd
NOTE: Thevalueof water supply given as 150 to 200 litreper head per day may be reduced to 135
litre per head per day for houses for Lower Income Group (LIG) and Economically Weaker Section
of Society (EWS), depending upon prevailing conditions.
b) Out of the 150 to 200 litre per head per day, 45 litre per head per day may be taken for flushing
requirements and the remaining quantity for other domestic purposes.
21.4.1.2 Water Supply for Buildings other than Residences: Minimum requirements for water
supply for buildings other than residences shall be in accordance with Table 3.
21.4.1.3 Water Supply for Fire Fighting Purposes: The Authority shall make provision to meter the
water supply requirements for firefighting in the city/area depending on the population density and
types of occupancy.
21.4.1.4 Provision shall be made by the owner of the building for water supply requirements for
firefighting purposes within the building, depending upon the height and occupancy of the building,
(in conformity with the requirements laid down in part 4 'Fire and Life Safety'. of NBC2005)
Table-3 : Water Requirements for Buildings other than Residences
21.4.2 Water Sources and Quality:
21.4.2.1 Sources of water : The origin of all sources of water is rainfall. Water can be collected as
it falls as rain before it reaches the ground; or as surface water when it flows over the ground or is
pooled in lakes or ponds; or as ground water when it percolates into the ground and flows or collects
as ground water, or from the sea into which it finally flows.
21.4.2.2 The quality of water to be used for drinking shall be as per good practices [9-1(2) of
NBC2005].
21.4.2.3 For purposes other than drinking, water if supplied separately, shall be absolutely safe from
bacteriological contamination so as to ensure that there is no danger to the health of the users due to
such contaminants.
21.4.2.4 Waste Water Reclamation: Treated sewage or other waste water of the community may be
utilized for non-domestic purposes such as water for cooling. flushing, lawns, parks, firefighting and
for certain industrial purposes after giving the necessary treatment to suit the nature of the use. This
supply system shall be allowed in residences only if proper provision is made to avoid any cross
connection of this treated waste-water with domestic water supply system.
21.4.2.5 Wherever a building is used after long intervals, the water quality of the stored water must
be checked so as to ensure that the water is safe for use as per water quality requirements specified
in this Schedule.
21.4.3 Estimate of Demand Load: Estimates of total water supply requirements for buildings shall
be based on the occupant load consistent with the provisions of 21.4.1.
21.4.3.1 For residential buildings, the requirements of water shall be based on the actual number
occupants, where this information is not available; the number of occupants for each residential unit
may be based on a family of five. For assessing the population in other occupants, reference may be
made to Part 4 'Fire and Life Safety' of NBC 2005.
21.4.3.2 In making assessment of water supply requirements of large complexes, the future occupant
load shall be kept in view. Use may be made of the following methods for estimating future
requirements.
a) demographic method of population projection,
b) arithmetic progression method,
c) geometrical progression method,
d) method of varying increment or incremental increase,
e) logistic method,
f) graphical projection method, and
g) graphical comparison method.
21.4.4 Design of Distribution Systems:
21.4.4.1 Rate of Flow: One of the important items that needs to be determined before the sizes of
pipes and fittings for any part of the water piping system may be decided upon is the rate of flow in
the service pipe which, in turn depends upon the number of hours for which the supply
is available at sufficiently high pressure. If the number of hours for which the supply is available is
less, there will be large number of fittings in use simultaneously and the rate of flow will be
correspondingly large. The data required for determining the size of the communication and service
pipes are:
a) the maximum rate of discharge required;
b) the length of the pipe; and,
c) the head loss by friction in pipes, fittings and meters.
21.4.4.2 Discharge Computation: Design of consumer's pipes based on future unit:
The design of the consumer's pipes or the supply pipe to the fixtures is based on the number and
kind of fixtures installed;
a) the fixture unit flow rate; and,
b) the probable simultaneous use of these fixtures.
The rates at which water is desirably drawn into different types of fixtures are known. These rates
become whole numbers of small size when they are expressed in fixture unit.
The fixture units for different sanitary appliances or groups of appliances are given in Table 4 and
Table 5.
21.4.4.3 Probable simultaneous demand:
The possibility that all water supply taps in any system in domestic and commercial use will draw
water at the same time is extremely remote. Designing the water mains for the gross flow will result
in bigger and uneconomical pipe mains and is not necessary. A probability study made by Hunter
suggests the relationship shown in Fig. 4, 5 and Table 6. In the absence of similar studies in India,
the curves based on Hunter's study may be followed. In making use of these curves, special
allowances are made as follows:
a) Demands for service sinks are ignored in calculating the total fixture demand.
b) Demands of supply of supply outlets such as house connections and air conditioners
through which water flows more or less continuously over a considerable length of time
must be added to the probable flow rather than the fixture demand.
Fixtures supplied with both hot and cold water exert reduced demands upon main hot water and
cold water branches (not fixture branches).
Table-4 : Fixture Unit for Different Types of Fixtures with Inlet Pipe Diameter.
S. Type of Fixture Fixture Unit (FU) as Minimum Normal Size
No. Load Factor of Fixture Branch, mm
1 Ablution tap 1 15
2 Bath tub supply by spout Shower 3 15
over tub does not add to the load.
3 Shower stall domestic 2 15
4 shower in groups per head 3 15
5 Wash basin domestic use 1 15
6 Wash basin public use 2 15
7 wash basin surgical 2 15
8 scrub station in hospitals per outlet 3 15
9 Drinking water fountain/water cooler 0.5 15
10 Water-closet with cistern (single/ 1 15
double flush)
11 Water-closet with flush or magic eye 8 25/32
operated valve
12 Urinals with auto flushing cisterns 4 15/20
13 Urinals with flush or magic eye 2 15/20
operated valve
14 Kitchen sink (domestic use) 2 15/20
15 Washing machine 3 15/20
Table 4 (1) : Recommended Storage Capacities

S. No Type of Building Per Storage in Litre
1. Dwelling Houses Resident 70
2. Hostels -do- 90
3. Hotels -do- 135
4. Commercial Buildings without canteen Head 35
5. Commercial Buildings with canteen Head 45
6. Restaurants Meal 7
7. Day Schools Head 25
8. Boarding Schools Resident 90
9. Nurses Homes and Medical Quarters. -do- 135
Table 4 (2) : Storage for Flushing Purposes
S. No.. Classifi of Building Storage Capacity
1. For Tenements having common 900 litre/WC seat
conveniences
2. For residential premises other than 270 litre net for one WC seat and
tenements having common conveniences 180 litre for additional seat in the
same flat
3. For factories and Workshops. 900 litre for WC seat and 180 lit
per urinal seat
4. For Cinemas, Public Assembly halls etc. 900 litre for WC seat and 350 lit
per urinal seat
Table - 5: FixtureUnitfor Different
if ferent Types of Fixtures Based on Pipe or Trap Diameter
S. No. Drain or Outlets () Fixture Unit (FU)
(1) (2) (3)
1. 32 or smaller 1
2. 40 2
3. 50 3
4. 65 4
5. 75 5
6. 100 6
NOTE - Before usingthe above figures check the actualflow from the outlets of special equipment, for
example, small period high discharges, for example, from washing machines boiler blow downs
filter backwash and water tank emptying operations.
Table-6 : Probable Simultaneous Demand
No. of System with Flush Tanks Demand System with Flush Valves Demand
Fixture (Based on Future Units) (After Hunter)
Units
Unit Rate of Flow in Litre per Unit Rate of Flow in Litre per
Flow Minute Flow Minute
(1) (2) (3) (4) (5)
20 2.0 56.6 4.7 133.1
40 3.3 93.4 6.3 178.4
60 4.3 121.8 7.4 209.5
80 5.1 144.4 8.3 235.0
100 5.7 211.4 9.1 257.7
120 6.4 181.2 9.8 277.5
140 7.1 201.0 10.4 294.5
210 7.6 215.2 11.0 311.5
PWD Building 2014 Page 38 of 126

Works Rajasthan Specifications
(1) (2) (3) (4) (5)
180 8.2 232.2 11.6 328.5
200 8.6 243.5 12.3 348.3
220 9.2 260.5 12.7 359.6
240 9.6 271.8 13.1 370.9
300 11.4 322.8 14.7 421.2
400 14.0 396.4 17.0 481.4
500 21.7 472.9 19.0 538.0
600 19.4 549.3 21.1 597.5
700 21.4 606.0 23.0 651.3
800 24.1 682.4 24.5 693.7
900 26.1 739.0 26.1 739.0
1000 28.1 795.7 28.1 795.7
1500 36.1 1022.2 36.1 1022.2
2000 43.9 1243.1 43.9 1243.1
2500 51.1 14469 51.1 1446.9
3000 57.8 2136.7 57.8 2136.7
Unit rate of flow = Effective fixture units.
21.4.4.4 Pipe Size Computation: Commercially available standard sizes of pipes are only to be
used against the size arrived at by actual design. Therefore, several empirical formulae are used,
even though they give less accurate results. The Hazen and William's formula and the charts based
on the same may be used without any risk of inaccuracy in view of the fact that the pipes normally
to be used for water supply are of smaller sizes. Monogram of Hazen and William's equation has
been provided in Annex `F' of NBC 2005.
21.4.5 Distribution Systems in Multi-Storied Buildings:
21.4.5.1 There are four basic methods of distribution of water to a multi-storied building
a) Direct supply from mains to ablutionary taps and kitchen with WCs and Urinals supplied by
overhead tanks.
b) Direct Pumping Systems.
c) Hydro-pneumatic Systems
d) Overhead Tanks Distribution.
21.4.5.2 Direct Supply System: This System is adopted when adequate pressure is available round
the clock at the topmost floor. With limited pressure available in most city mains, water from direct
supply is normally not available above two or three floors. For details of this system, reference may
be made to good practice [9-1 (5) of NBC 2005].
21.4.5.3 Direct Pumping:
a) Water is pumped directly into the distribution system without the aid of any overhead tank,
except for flushing purposes. The pumps are controlled by a pressure switch installed on the
line. Normally a jockey pump of smaller capacity installed which meets the demand of water
during low consumption and the main pump starts when the demand is greater. The start and
stop operations are accomplished by a set if pressure switches are installed directly on the line.
In some installation, a timer switch is installed to restrict the operating cycle of the pump.
b) Direct pumping systems are suitable for buildings where a certain amount of constant use of
water is always occurring. These buildings are all centrally air conditioned buildings for which
a constant make up supply for air conditioning cooling towers is required.
c) The system depends on a constant and reliable supply of power. Any failure in the power
system could result in a breakdown in the water supply system.
d) The system eliminates the requirements of overhead tanks for domestic purposes (except for
flushing) and requires minimum space (Fig. 6).
21.4.5.4 Hydro-pneumatic Systems: Hydro-pneumatic system is a variation of direct pumping
system. An air-tight pressure vessel is installed on the line to regulate the operation of the pumps. The
vessel capacity shall be based on the cut-in and cut-out pressure of the pumping system depending
upon allowable start/stops of the pumping system. As pumps operate, the incoming water is the
vessel, compresses the air on top. When a predetermined pressure is reached in the vessel a pressure
switch installed on the vessel switches off the pumps. As water is drawn into the system pressure,
the air in the pressure tank slowly reduces the volume due to dissolution in water and leakages from
pipe lines. An air compressor is also necessary to feed air into the vessel so as to maintain the
required air-water ratio. The system shall have reliable power supply to avoid breakdown in the
water supply.
21.4.5.5 There is an alternate option of providing variable speed drive pumping system where a
pump with a large variation in its pressure-discharge and speed of the pump is efficiently used to
deliver water at rates of flow as required by the system by changing its speed by varying it with the
assistance of an electronic device which will reduce the rate of flow from speed of the motor from
960 rpm to 3000 rpm. With this arrangement the same pump is able to deliver water as required at
different times of the day. The system consumes energy in proportion to the work done and save
considerable amount of power as compared to the fixed speed pumps used conventionally.
21.4.5.6 Hydro-pneumatic system generally eliminates the need for an over head tank and may
supply water at a much higher pressure than available from overhead tanks particularly on the upper
floors, resulting in even distribution of water at all floors (Fig. 7).
21.4.5.7 Overhead Tank Distribution: This is the most common of the distribution systems
adopted in various types of buildings. The system comprises pumping water to one or more overhead
tanks placed at the top most location of the hydraulic zone. Water collected in the overhead tank is
distributed to the various parts of the building by a set of pipes located generally on the terrace.
Distribution is accomplished by providing down takes to various fixtures (Fig. 8).
21.4.6 Hot Water Supply Installations: Design Consideration:
21.4.6.1 General: Hot water is needed for several purposes in residential buildings and in industrial
establishments. Hot water supply is an essential need under cold climate conditions. Heating of water
is done with electric power, oil, gas, solar and other fuels. The designs of hot water supply
system / heating temperatures and its appliance is done as per IS : 7558-1974.
a) In electric water heating practice for domestic purposes, the accepted method is to use storage
heaters in which water is steadily heated up to a predetermined temperature and stored until
required for use. The heating by electricity of a large quantity of water, such as water required
for a hot bath, within the time normally taken to run the water into the bath, requires a heater
of too high a rating to be practicable in normal domestic premises.
b) In modern hotels and apartment blocks and service apartments, centralized storage and
distribution systems are adopted, where other energy sources such as oil, gas, solar panels, etc.,
may be used for the generation of hot water as these options prove more economical and
convenient in heating large volumes of water for storage.
c) When water supplied to the buildings contains dissolved salts resulting in hardness of water,
measures such as installation of water softening plants etc. shall be taken to avoid formation of
scales in the hot water installations.
21.4.6.2 Storage Temperature: The design of hot water supply system and its appliances shall be
based on the temperatures at which water is normally required for the various uses. Refer Table 7.
Table-7
Scalding 65° C
Supply to Sink 60° C
Supply for Hot bath 43° C as run, for use at 41° C
Supply for Warm bath 37° C
Supply for Tepid bath 29.5° C
Supply to wash basins 55°C
Hot water storage temperature (may be increased to 60°C
65° C when soft water is used).
21.4.6.3 In order to minimize the danger of scaling, precipitationof scale from hard water, standing
heat losses, risk of steam formation and the possibility of damage to percolation or order fittings and
to surface finishes, a storage temperature of 60° C is recommended. If storage capacity is limited, a
higher temperature up to 65° C may be adopted when soft water is used.
21.4.6.4 Storage Capacity: The size of the storage vessel is governed by the maximum short time
demand of the domestic premises. Depending on local conditions this shall be 501 to 751 at 60° C
in a dwelling with a bath tub and 251 at 60° C for a shower or a tap (for bucket supply). The capacity
of the storage vessel shall not be less than 20 percent in excess of the required maximum short time
demand. In larger houses where a single hot water heater is intended to supply hot water to more
than one bathroom or kitchen or both, the maximum short time demand shall be estimated and the
capacity decided accordingly. Small electric or gas storage heaters of 151 to 251 capacity may be
used to supply one or two points of draw off depending on the use of hot water. Values of volume
of hot water required for a bath, when cold water is mixed with it are given in Table 8.
Table-8 : Volume of Hot Water Required for a Bath
When Cold Water is Mixed with It.
Storage temperature, °C 75 70 65 60 55 50
Percentage of hot water required 51 55 60 73 82.5
Quantity of hot water in litre required for 59 63 69 76 84 95
a 115 litre bath
NOTE-Hotbath,temperatureat41°Candcoldwateratabout5to5.5°C 21.4.6.5RateofFlow:Withstoragetypeinstalationtherecommendedendedminimumratesofflow
for different types of fixtures are given in Table 9.
Table-9 : Rate of Flow of Hot water
S. No Fixtures Rate of Flow litre/
I. Bath tub 22.5
II. Kitchen sink 18
M. Wash basin 7
W. shower (spray type) 7
21.4.6.6 Design of Storage Vessel: Storage tanks shall be oblong or cylindrical in shape and shall
be installed, preferably with the long side vertical in order to assist the effective stratification or
`layering' of hot or cold water. The ratio of height to width or diameter shall not be less than 2:1. An
inlet baffle should preferably be fitted near the cold inflow pipe in order to spread the incoming cold
water.
21.4.6.7 Materials for Storage Vessel and Pipes:
i) Under no circumstances shall un-galvanized (black) mild steel pipes and fittings, such as
sockets, bushes, etc. be used in any part of a hot water installation, including the cold feed pipe
and the vent pipe. Materials resistant to the chemical action of water supplied shall be used in
construction of vessels and pipes. Each installation shall be restricted to one type of metal only,
Materials such as tinned copper, certain other materials such as monel (silvery corrosion resistant
alloy) metal or all galvanized mild steel are suitable for the storage vessels. When water supplied
is known to have appreciable salt content, galvanized iron vessels and pipes shall not be used.
To minimise corrosion due to electrolytic action, each installation shall, as far as practicable,
be restricted to one type of metal only such as all Copper or all galvanised mild steel. However,
it is advisable to avoid use of lead pipes in making connection to wash basins. Where required
it is also advisable to use vessels lined internally with glass, stainless steel, etc.
ii) In general tinned copper and other metals such as model metal etc. are suitable for most types
of water. The suitability of galvanized mild steel for storage tanks depends upon the pH value
of the water and the extent of its temporary hardness. For values of pH 7.2 or less galvanized
mild steel should not be used. For values of pH 7.3 and above, galvanized mild steel may be
used provided the corresponding temporary hardness is not lower than those given below
(Table-10).
Table-10
pH Value Minimum Temporary Hardness Required ( m e )
7.3 >210
7.4 >150
7.5 140
7.6 110
7.7 90
7.8 80
7.9-8.5 70
21.4.6.8 Location of Storage Vessel:
a) The loss of heat increases in proportion to the length of pipe between the storage vessel and the
hot water outlet since each time the water is drawn, the pipe fills with hot water which then
cools. The storage vessel shall therefore be so placed that the pipe runs to the most frequently
used outlets are as short as possible.
b) Thermal insulation: To ensure efficiency and economy in operation, the hot water storage
vessel and pipes should be adequately insulated wherever necessary, to minimise the heat loss.
The whole external surface of the storage vessel including the cover to the handle should be
provided with a covering equivalent, at least to 75 mm thickness of thermal insulating material
having a conductivity not exceeding 0.043 kcal /m2 / h / °C / mm
21.4.6.9 Immersion Heater Installation: If a domestic storage vessel is to be adapted to electric

heating by the provision of an immersion heater and thermostat, the following precautions shall be
observed:
a) Location of immersion heaters- The immersion heater shall be mounted with its is horizontal,
except in the case of the circulation type which is normally mounted with its axis
approximately vertical.
b) In a tank with a flat bottom, a space of not less than 75 mm below the immersion heater and
50 mm below the cold feed connection shall be provided to allow for accumulation of sludge
and scale, where it will not affect the working of the immersion heater.
c) In a cylindrical storage vessel with inwardly dished bottom, the inlet pipe shall be so arranged
that the incoming cold water is not defected directly into the hot water zone. The lowest point
of the immersion heater shall be 25 mm above the centre line of the cold feed inlet, which, in
turn, is usually 100 mm above the cylinder rim.
d) Location of thermostat: Where the thermostat does not form an integral part of the immersion
heater, it shall be mounted with its edges horizontal, at least 50 mm away from and not lower
than the immersion heater.
e) Dual heater installations: If desired, the principle of the dual heater may be adopted. In this
case, one heater and its thermostat shall be installed at a low level as indicated in (b) and (c).
The second heater and its thermostat shall be similarly disposed in the upper half of the
cylinder at a level depending on the reserve of hot water desired for ordinary domestic use.
The bottom heater shall be under separate switch control.
f) Clearance around storage vessel: Adequate clearance shall be provided between the tank and the
cupboard, door or walls to allow convenient insertion and adjustment of the immersion heater
and thermostat and to give space for thermal insulation.
21.4.6.10 Rating of Inunersion Heaters: The rating of an immersion heater shall be determined
according to the following factors:
a) proposed hot water storage capacity (the maximum with cold water as indicated in 21.4.6.3
shall be taken into account),
b) rate of utilization (draw off frequency),
c) permissible recovery period, and
d) inlet water temperature.
For details regarding rated input of water, refer to good practice [9-1 (14) of NBC 2005].
21.4.6.11 Thermal Insulation: The hot water storage vessel and pipes shall be adequately insulated
wherever necessary to minimize heat loss. The whole external surface of the storage vessel including
the cover to the hand hole shall be provided with a covering equivalent to not less than 75 mm
thickness of thermal insulating material having a conductivity of not more than 0.05 W/ (m2.°C)/mm
at mean temperature of 50° C.
21.4.6.12 Cold Water Supply to Heaters: A storage water heater (pressure type) shall be fed from
a cold water storage tank and under no circumstances connected directly to the water main, except
the type which incorporates a feed tank with ball valves and overflow pipe arrangement (cistern type
heaters) or non-pressure type heaters.
21.4.6.13 Storage cisterns:
a) The storage capacity of a cold water tank shall be at least twice the capacity of the hot water
heater. The capacity of the storage tank may, however, be 1.5 times when the number of heaters
connected to one common tank exceeds 10.
b) The storage tank for supply of cold water to hot water heaters shall be separate, if practicable.
In the case of a common tank which also supplies cold water to the fixtures, this cold water
supply connection shall be so arranged that 50 percent of the net capacity, worked out as above
shall be available for supply to the hot water heaters.
c) In the case of multi-storied buildings where a common overhead tank over the stair/lift well is
generally installed, it is advisable to have one or more local tanks for supply to the hot water
heaters. This arrangement shall help in reducing the length of the vent pipes (Fig. 8).
d) In tall multi-storied buildings where the static pressure increases with the height, the total static
pressure on the hot water heaters on the lowest floor shall not exceed the rated working pressure
of the hot water heater installed. Should the height of the building so require, additional tanks
shall be provided on the intermediate floors to restrict the static head to permissible limits (Fig.
9).
e) As an alternative to the arrangements stated in. (c) and (d) above, an individual storage tank
in each flat may be provided for supply to hot water heaters (Fig.-11).
21.4.6.14 Cold Water Feed:
a) The feed pipe connecting cold water tank with the hot water heater shall not be of less than 20
mm bore and it shall leave the cold water tank at a point not less than 50 mm above
the bottom of the tank and shall connect into the hot water heater near its bottom. The feed pipe
shall not deliver cold water to any other connection, but into the hot water cylinders only.
b) In the case of multi-storied buildings, a common cold water feed pipe may be installed, but
each hot water heater shall be provided with a check valve (horizontal-type-check valve shall
be preferred to vertical type for easy maintenance).
c) Care shall be taken in installing the point to prevent air locks in the piping and negative
pressure in the hot water heater. Cold water feed pipe shall not be cross connected-with any
other source of supply under pressure (Fig.12).
21.4.6.15 Hot Water Piping: Expansion pipe or vent pipe:
a) Each pressure type hot water heater cylinder shall be provided with a vent pipe of not than 20 mm
bore. The vent pipe shall rise above waterline of the cold water tank by at least 150 mm plus
10 mm for every 300 mm height of the water above the bottom of the heater. The vent shall
discharge at a level higher than the cold water tank supplying to the hot water tank. Care shall
be taken to ensure that any accident discharge from the vent does not hurt or scald a passerby
or persons in the vicinity.
 The vent pipe shall be connected to a highest point of the heater vessel and it shall project
downwards inside it, as otherwise air may trapped inside, resulting in surging and consequent
noises.
 At no point, after leaving the vessel, shall the vent pipe dip below the level of its connection
at the vessel. A vent pipe may, however, be used for supply of hot water to any point between
the cold water tank and the hot water heaters. The vent pipe shall not be provided any valve
or check valves.
 Hot water heaters: The common hot water delivery pipe shall leave the hot water heater near
its top and be of not less than 20 mm bore generally, not less than 25 mm bore if hot water
taps are installed on same floor as that on which the hot water heater situated.
 Hot water taps shall be of such design that would cause the minimum friction. Alternatively
oversized tap may be provided, such as a 20 mm tap on a 15 mm pipe.
The hot water distributing system shall be so designed as to ensure that the time lag between
opening of the draw-off taps and discharge of hot water is reduced to the minimum to avoid
wastage of undue amount of water which may have cooled with water standing in the pipes, when
the taps are closed. With this end in view, a secondary circulation system of flow and return
pipes from the hot water tank shall be used where justified. Whether such a system is used or
not, the length of pipe to a hot water draw-off tap, measured along the pipe from the tap to the
hot water tank or the secondary circulation pipe, shall not exceed the lengths given in Table 11.
g) Wherever mixing of hot and cold water is done by a mixer fitting, that is, hot and cold stop-cocks
deliver to a common outlet of mixed water (like, showers, basin or bath supply fittings), the
pressure in the cold and hot water systems shall be equal. This can be achieved by connecting
the cold water supply from an overhead tank at the same static height as the overhead tank
supplying cold water to the hot water heaters. In case this is not possible, hot and cold water
should be supplied to the fixtures by separate supply taps.
Table-11
S. No. Largest Internal Diametereter of Pipe Length m
i) Not exceeding 20 mm 12
ii) Exceeding 20 mm but not exceeding 25 mm 7.5
iii) Exceeding 25 mm 3.0
NOTE- In the case of a composite pipe of different diameters, the largest diameter is to be
taken into consideration for the purpose of this table.
4.6. 16 Types of Hot Water : The v various types of water heaters used for preparation
of hot water are as follows:
(a) Electric Storage-Heaters:
(i) Non-pressure or open outlet type,

(ii) Pressure type
(iii) Cistern type, and
(iv) Dual heater type
(b) Gas Water Heaters:
(i) Instantaneous type, and
(ii) Storage-type
(c) Solar Heating Systems (IS: 12933 (P-I), IS: 12976):
(i) Independent roof mounted heating units, and
(ii) Centrally banked heated system.
(d) Central Hot Water System:
fired, and
Electrically heated.
Heating in oven coil, Heating
by steam in a boiler
21.4.6.17 The quality and construction of the different types of hot water heaters shall be in
accordance with good practice [9-1 (15) of NBC 2005]. Typical arrangement of water heaters is
shown in (Fig. 11). Requirements in regard to inspection and testing of hot water supply installations
shall be in accordance with Clause 21.3.9.
21.5 Pipes:
21.5.1 Galvanized Iron Pipes:
21.5.1.1 Materials: The pipes (tubes) shall be galvanized mild steel hot finished seamless (HFS) of
welded (ERW) HRIW or HFW screwed and socketed conforming to the requirements of IS: 1239
Part-I-1990 for medium grade. They shall be of the diameter (nominal bore) specified in the
description of the item, the sockets shall be designated by the respective nominal bores of the pipes
for which they are intended.
21.5.1.2 Galvanizing shall conform to IS: 4736-1986. The zinc coating shall be uniform adherent,
reasonably smooth and free from such imperfections as flux, ash and dross inclusions, bare batches,
black spots, pimples, lumping, runs, rust stains, bulky white deposits and blisters. The pipes and
sockets shall be cleanly finished, well galvanized in and out and free from cracks, surface flaws,
laminations and other defects. All screw threads shall be clean and well cut. The ends shall be cut
cleanly and square with the axis of the tube.
21.5.1.3 The dimension and weights of pipes and sockets and tolerances shall be as prescribed in
Appendix 'A'.
21.5.1.4 All screwed tubes and sockets shall have pipe threads conforming to the requirements of
IS: 554-1985. Screwed tubes shall have taper threads while the sockets shall have parallel threads.
21.5.1.5 All tubes shall withstand a test pressure of 50 kg/Sq.cm. without showing defects of any
kind.
21.5.1.6 Fittings: The fittings shall be of mild steel tubular or wrought steel fittings conforming to
IS: 1239 (Part II) - 1992 or as specified. The fittings shall be designated by the respective nominal
bores of the pipes for which they are intended.
21.5.1.7 Laying and jointing of pipes and fittings (for laying of all types of pipes): Unloading:
The pipes shall be unloaded where they are required.
21.5.1.8 Unloading (except where mechanical handling facilities are available): Pipes weighing up
to 60 kg. shall be handled by two persons by hand passing. Heavier pipes shall be unloaded from the
lorry or wagon by holding them in loops, formed with ropes and sliding over planks set not steeper
than 45 degree. The planks shall be sufficiently rigid and two ropes shall always be used to roll the
pipes down the planks. The ropes should be tied on the side opposite the unloading. Only one pipe
shall be unloaded at a time.
21.5.1.9 Under no circumstances shall the pipes be thrown down from the carriers or be dragged or
rolled along hard surfaces.
21.5.1.10 The pipes shall be checked for any visible damage (such as broken edges, cracking or
splitting of pipe) while unloading and shall be sorted out for reclamation. Any pipe which shows
sufficient damage to preclude it from being used shall be discarded.
21.5.1.11 Storing: The pipes and specials shall be handled with sufficient care to avoid damage to
them. These shall be lined up on side of the alignment of the trench, socket facing upgrade when
line runs uphill and upstream when line runs on level ground.
21.5.1.12 Each stack shall contain pipes of same class and size, consignment or batch number and
particulars of suppliers, wherever possible, shall be marked on the stack.
21.5.1.13 Storage shall be done on firm, level and clean ground, Wedges shall be provided at the
bottom layer to keep the stack stable.
21.5.1.14 Cutting: Cutting of pipes may be necessary when pipes are to be laid in lengths shorter than
the lengths supplied, such as while replacing accessories like tees, bends, etc. at fixed position in the
pipe lines.
21.5.1.15 A line shall be marked around the pipe with a chalk piece at the point where it is to be cut.
The line shall be so marked that the cut is truly at right angle to the longitudinal is of the pipe. The
pipe shall be rigidly held on two parallel rafters nailed to cross beams, taking care that the portion
to be cut does not overhang and the cut mark is between the two rafters. The pipe shall be neatly cut
at the chalk mark with carpenter's saw or hacksaw having a long blade, by slowly rotating the pipe
around its longitudinal is so as to have the uncut portion on top
for cutting. Cutting of the pipe at the overhang should, as far as possible, be avoided, as an
overhanging end is liable to tear off due to its weight before the cutting is complete.
21.5.1.16 Trenches:
a) The trenches shall be so dug that the pipes may be laid to the required alignment and at
required depth.
b) Cover shall be measured from top of pipe to the surface of the ground.
c) The bed of the trench, if in soft or made up earth, shall be well watered and rammed before
laying the pipes and the depressions, if any, shall be properly filled with earth and consolidated
in 20 cm. layers.
d) If the trench bottom is extremely hard or rocky or loose stony soil, the trench shall be excavated
at least 150 mm below the trench grade. Rocks, stone or other hard substances from the bottom
of the trench shall be removed and the trench brought back to the required grade by filling with
selected fine earth or sand (or fine moorum if fine soil or sand is not available locally) and
compacted so as to provide a smooth bedding for the pipe. Where excavation requires blasting
operation, it shall be ensured that no pipes have been stacked in the vicinity and completed pipe
line in the vicinity has already been covered before starting of blasting operations. This is
necessary to prevent damage to the exposed pipes in the vicinity by falling stones as a result of
blasting.
e) After the excavation of the trench is completed, hollows shall be cut at the required position to
receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the
barrels of the pipes shall rest throughout their entire length on the solid ground and the sufficient
spaces left for jointing the underside of the pipe joint. These socket holes shall be refilled with
sand after jointing the pipe.
f) Roots of trees within a distance of about 0.5 metre from the side of the pipe line shall be
removed or killed with a coating of Bitumen.
g) The excavated materials shall not be placed within 1metre or half of the depth of the trench
whichever is greater from the edge of trench. The materials excavated shall be separated and
stacked so that in refilling they may be re-laid and compacted in the same order to the
satisfaction of the Engineer-in Charge.
h) The trench shall be kept free from water. Shoring and timbering shall be provided wherever
required. Excavation below water table shall be done after dewatering the trenches.
i) Where the pipe line or drain crosses existing road, the road crossing shall be excavated half at
a time, the 2nd half being commenced after the pipes have been laid in the first half and the
trench refilled. Necessary safety measures for trench as directed shall be adopted.
j) All types of water mains cables etc. met within the course of excavation shall be carefully
protected and supported. Care shall be taken not to disturb the electrical and communication cable
met with during course of excavation, removal of which, if necessary, shall be arranged by the
Engineer-in-Charge.
21.5.1.17 Laying:
a) The pipes shall be lowered into the trench by means of suitable pulley blocks, sheer legs, chains,
ropes etc. In no case the pipes shall be rolled and dropped into the trench. One end of each rope
may be tied to a wooden or steel peg driven into the ground and the other end
held by men which when slowly released will lower the pipe into the trench. After lowering, the
pipes shall be arranged so that the spigot of one pipe is carefully centered into the socket of the
next pipe, and pushed to the full distance that it can go. The pipe line shall be laid to the levels
required. Specials shall also be laid in their proper position as stated above.
Where so directed, the pipes and specials may be laid on masonry or concrete pillars. The pipe laid
on the level ground shall be laid with socket facing the direction of flow of water.
The pipes shall rest continuously on the bottom of the trench. The pipes shall not rest on lumps
of earth or on the joints. Four metre long wooden templates may be used to check the level of
bed. Clearance of approximately 100 mm in depth and width equal to length of the collar plus
30 mm on both sides shall be provided at the joint which shall be refilled from sides after the
joint is made.
In unstable soils, such as soft soils and dry lumpy soils, it shall be checked whether the soils can
support the pipe lines and if required suitable special foundation shall be provided.
Some clayey soils (for example black cotton soil) are drastically affected by extremes of
saturation and dryness. In changing from saturated to a dry condition, these soils are subjected to
extraordinary shrinkage which is usually seen in the form of wide and deep cracks in the earth
surface and may result in damages to underground structures, including pipe materials. The clay
forms a tight gripping bond with the pipe, subjecting it to excessive stresses as the clay shrinks.
It is recommended that in such cases an envelope of a minimum 100 mm of tamped sand shall
be made around the pipe line to avoid any bonding.
f) In places where rock is encountered, cushion of fine earth or sand shall be provided for a depth
of 150 mm by excavating extra depth of the trench, if necessary, and the pipes laid over the
cushion. Where the gradient of the bed slopes is more than 30 degree it may be necessary to
anchor a few pipes against sliding downwards (Fig.12A).
g) Thrust blocks (Fig.12A) :
i) Thrust blocks are required to transfer the resulting hydraulic thrust from the fitting of
pipe on to a larger load bearing soil section.
ii) Thrust blocks shall be installed wherever there is a change in the direction/size of the
pipe on to a larger load bearing soil section.
iii) Thrust blocks shall be constructed taking into account in pipe size, water pressure, types
of fitting, gravity component when laid on slopes and the type of soil. The location of
thrust blocks for various types of fittings is given in Fig. 12A.
iv) When a fitting is used to make a vertical bend, it shall be anchored to a concrete thrust
block designed to have enough weight to resist the upward and outward thrust. Similarly
at joints, deflected in vertical plane, it shall be ensured that the weight of the pipe, the
water in the pipe and the weight of the soil over the pipe provide resistance to upward
movement. If it is not enough, ballast or concrete shall be placed around the pipe in
sufficient weight to counteract the thrust.
v) When the line is under pressure there is an outward thrust at each coupling. Good soil,
properly tamped is usually sufficient to hold pipe from side movement. However, if soft
soil conditions, are encountered, it may be necessary to provide side thrust blocks or other
means of anchoring. In such cases only pipe on each side of the deflected
coupling shall be anchored without restricting the coupling.
vi) Pipes on slopes need be anchored only when there is a possibility of the back fill around
the pipe sloping down the hill and carrying the pipe with it. Generally for slopes up to 30
degree good well drained soil carefully tamped in layers of 100 mm under and over the
pipe, right up to the top of trench will not require anchoring.
vii) For steeper slopes, one out of every three pipes shall be held by straps fastened to
vertical supports anchored in concrete.
21.5.1.18 Back Filling and Tamping:
i) Back filling shall follow pipe installation as closely as possible to protect pipe from falling
boulders; eliminating possibility of lifting of the pipe due to flooding of open trench and
shifting pipe out of line by caved in soil.
ii) The soil under the pipe and coupling shall be solidly tamped to provide firm and continuous
support for the pipe line. Tamping shall be done either by tamping bars or by using water to
consolidate the back fill materials.
iii) The initial back fill material used shall be free of large stones and dry lumps in stony areas.
The material for initial back fill can be shaved from the sides of the trenches. In bogs and
marshes, the excavated material has usually little more than vegetable matter and this should not
be used for bedding purposes. In such cases gravel or crushed stone shall be hauled in.
iv) The initial back fill shall be placed evenly in a layer of about 100 mm thick. This shall be
properly consolidated and this shall be continued till there is a cushion of at least 300 mm of
cover over the pipe.
v) If it is desired to observe the joint or coupling during the testing of mains as they shall be left
exposed. Sufficient back fill shall be placed on the pipe to resist the movement due to pressure
while testing. Balance of the backfill need not be so carefully selected as the initial material.
However, care, shall be taken to avoid back filling with large boulders, which might damage
the pipe when the back fill is spaded into the trench. Pipes in trench on a slope shall have extra
attention to make certain that the newly placed back fill will not become a blind drain in effect
because until back fill becomes completely consolidated there is tendency for ground or surface
water to move along this looser soil resulting in a loss of support to the pipe. In such cases the
back fill shall be tamped with extra care and the tamping continued in 100 mm layers+ right up
to the ground level.
21.5.1.19 Hydrostatic tests: After a new pipe has been laid, jointed and back filled (or any valved
section thereof), it shall be subjected to the following two tests:
(a) Pressure test at a pressure of at least double the maximum working pressure-pipe and joints
shall be at maximum working pressure-pipe and joints shall be absolutely water tight under the
test.
(b) Leakage test (to be conducted after the satisfactory completion of the pressure test) at a
pressure to be specified by the authority for a duration of two hours.
(c) Hydrostatic Tests Procedure:
i) The portions of the line shall be tested by subjecting to pressure test as the laying progresses
before the entire line is completed. In this way any error of workmanship will be found
immediately and can be corrected at a minimum cost. Usually the length
of the section to be tested shall not exceed 500 m.
ii) Where any section of a main is provided with concrete thrust blocks or anchorages, the
pressure test shall not be made until at least five days have elapsed after the concrete is
cast. If rapid hardening cement has been used in these blocks or anchorages, test shall
not be made until at least two days have elapsed.
iii) Prior to testing, enough back fill as described in 21.5.1.2.6 shall be placed over the pipe
line to resist upward thrust. All thrust blocks forming part of the finished line shall have
been sufficiently cured and no temporary bracing shall be used.
iv) The open end of the section shall be sealed temporarily with an end cap having an outlet
which can serve as a relief vent or for filling the line, as may be required. The blind face
of the end cap shall be properly braced during testing by screw jacks and wooden planks
or steel plate as shown in (Fig.13).
v) The section of the line to be tested shall be filled with water manually or by a low pressure
pump. Air shall be vented from all high spots in the pipe line before making the pressure
strength test because entrapped air gets compressed and causes difficulty in raising the
required pressure for the pressure strength test.
vi) The test pressure shall be gradually raised at the rate of approximately one kg/sq. cm/
min. The duration of the test period if not specified shall be sufficient to make a careful
check on the pipe line section.
21.5.1.20 Laying and Jointing of G.1. Pipes (External Work): The specifications for GI pipe as
described in Cl. 21.5.1.2 shall apply, as far as applicable.
i) Trenches: The galvanized iron pipes and fittings shall be laid in trenches. The widths and depths
of the trenches for different diameters of the pipes shall be as in Table 12.
Table-12
Dia. of Pipe (mm) Width of Trench (mm) Depth of trench (mm)
15 to 50 300 600
65 to 100 450 750
Minimum cover under road up to the top of pipe shall be 1.2 m.
ii) At joints the trench width shall be widened where necessary. The work of excavation and
refilling shall be done true to line and gradient in accordance with general specifications for
earth work in trenches.
iii) When excavation is done in rock, it shall be cut deep enough to permit the pipes to be laid on
a cushion of sand minimum 75 mm thick.
iv) Cutting and Threading: Where the pipes have to be out or rethreaded, the ends shall be
carefully filed out so that no obstruction to bore is offered. The end of the pipes shall then be
carefully threaded conforming to the requirements of IS: 554-1985 with pipe dies and tapes in
such a manner as will not result in slackness of the joints when the two pieces are screwed
together. The taps and dies shall be used only for straightening screw threads which have become
bent or damaged and shall not be used for turning of the threads so as to make them slack, as
the later procedure may not result in a water tight joint. The screw threads of pipes and fitting
shall be protected from damage until they are fitted.
v) Jointing: The pipes shall be cleaned and cleared of all foreign matter before being laid. In
jointing the pipes, the inside of the socket and the screwed end of the pipes shall be oiled and
rubbed over with white lead and a few turns of spun yarn wrapped round the screwed end of
the pipe. The end shall than be screwed in the socket, tee etc. with the pipe wrench. Care shall
be taken that all pipes and fittings are properly jointed so as to make the joints completely water
tight and pipes are kept at all times free from dust and dirt during fixing. Burr from the joint
shall be removed after screwing. After laying, the open ends of the pipes shall be temporarily
plugged to prevent access of water, soil or any other foreign matter.
vi) Thrust Blocks (Fig. 12): In case of bigger diameter pipes where the pressure is very high,
thrust blocks of cement concrete 1:2:4(1 cement: 2 coarse sand: 4 graded stone aggregate of 20
mm nominal size) of adequate size and shape shall be provided on all bends to transmit the
hydraulic thrust to the ground, spreading it over a sufficient areas depending upon the type of
soil met with.
vii) Painting: The pipes shall be painted with two coats of anticorrosive bitumastic paint of
approved quality.
viii) Testing of joints: The pipes and fittings after they are laid jointed shall be tested to hydraulic
pressure of 6 Kg/sq. cm (60 meter). The pipes shall be slowly and carefully charged with water
allowing all air to escape and avoiding all shocks or water hammer. The draw off tapes and stop
cocks shall then be closed and specified hydraulic pressure shall be applied gradually. Pressure
gauge must be accurate and preferably should have been recalibrated before the test. The test
pump having been stopped, the test pressure should be maintained without loss for at least half
an hour. The pipes and fittings shall be tested in sections as the work of laying proceeds, having
joints exposed for inspection during the testing. Pipes or fittings which are found leaking shall
be replaced and joints found leaking shall be redone, without extra payment.
ix) Trench filling: The pipes shall be laid on a layer of 7.5 cm sand and filled up to 15 cm above
the pipes. The remaining portion of the trench shall then be filled with excavated earth. Surplus
earth shall be disposed off as directed.
x) Measurements: The lengths shall be measured in running metre correct to a cm for the finished
work, which shall include G.I. pipe and G.I. pipe fittings such as bends, tees, elbows, reducers,
crosses, plugs, sockets, nipples and nuts, but exclude brass or gun metal taps (cocks), valves,
union, lead connection pipes and shower rose. All pipes and fittings shall be classified
according to their diameters, method of jointing and fixing substance, quality and finish. In case
of fittings of an equal bore, the pipe shall be described as including all cuttings and wastage. In
case of fittings of unequal bore, the largest bore shall be measured.
xi) Rate: The rate shall include the cost of labour and materials involved in all the operations
described above. The rate shall include excavation and refilling in trench but exclude painting
of pipes and sand filling all round the pipes, unless otherwise specified.
21.5.1.21 Laying and Jointing of G.I. Pipes (internal work):
a) For internal work the galvanized iron pipes and fittings shall run on the surface of the wall or
ceiling (not in chase) unless otherwise specified. The fixing shall be done by means of standard
pattern holder bat clamps, keeping the pipes about 1.5 cm clear of the wall. When it is found
necessary to conceal the pipes, chasing may be adopted or pipes fixed in the
ducts or recess etc., provided there is sufficient space to work on the pipes with the usual tools.
The pipes shall not ordinarily be buried in walls or solid floors. Where unavoidable, pipes may
be buried for short distances provided adequate protection is given against damage and where so
required joints are not buried. Where directed by the Engineer-in-Charge, a M.S. tube sleeve
shall be fixed at a place the pipe is passing through a wall or floor for reception of the pipe and
to allow freedom for expansion and contraction and other movements. In case the pipe is
embedded in walls or floors it should be painted with anticorrosive bitumastic paints of
approved quality. The pipe shall not come in contact with lime mortar or lime concrete as the
pipe is affected by lime. Under the floors the pipes shall be laid in layer of sand filling as done
under concrete floors.
b) All pipes and fittings shall be fixed truly vertical and horizontal unless unavoidable. The pipes
shall be fixed to walls with standard pattern holder bat clamps of required shape and size so as
to fit tightly on the pipes when tightened with screwed bolts, these clamps shall be embedded
in brick work in cement mortar 1:3 (1 cement: 3 coarse sand), and shall be spaced at regular
intervals in straight lengths as shown in Table 13.
Table - 13
Dia. mm Horizontal length-m Vertical length-m
of pipe
15 () 2.0 2.5
20 2.5 3.0
25 2.5 3.0
32 2.5 3.0
40 3.0 3.5
50 3.0 3.5
65 3.5 5.0
80 3.5 5.0
The clamps ampsshall be fixed at shorter lengths nearthe fittings as directed by the Engineerin-
Charge.
c) For G.I. pipes 15 mm diameter, the holes in the walls and floor shall be made by drilling with
chisel or jumper and not by dismantling the brick work or concrete. However, for bigger
dimension pipes the holes shall be carefully made of the smallest size as directed by the
Engineer-in-Charge. After fixing the pipes the holes shall be made good with cement mortar
1:3 (1 cement: 3 coarse sand) and properly finished to match the adjacent surface.
d) Unions will be provided to facilitate connections, additions and alterations as well as for
maintenance and for change of pipes. The locations where unions are to be provided will be
decided with prior written approval of the Engineer-in-Charge.
e) Measurements: The lengths shall be measured in running metre correct to a cm for the finished
work, which shall include G.I. pipe and G.I. fittings such as bends, tees elbows, reducers,
crosses, plugs, sockets, nipples and nuts, but exclude brass or gun metal taps (cocks), valves,
unions, lead connection pipes and shower rose. All pipes and fitting shall be classified
according to their diameter, method of joining and fitting, quality and finish. In case of fittings
of an equal bore the pipe shall be described as including all cuttings and
waste. In case of fittings of unequal bore, the largest bore shall be measured. Pipes laid in
trenches (or without supports) and pipes fixed to walls, ceilings, etc. with supports shall be
f) Rate: The rate shall include the cost of labour and material involved in all the operations
described above. The rate shall include the cost of cutting holes in walls and floors and making
good the same. This shall not however, include concealed pipe work in which case cutting of
chase and making good shall be paid separately. It shall not include painting of pipes and
provide sleeves, unless specified otherwise.
21.5.2: Asbestos Cement Pipes (Pressure Pipes): Materials
a) These shall be made from a through and homogenous mixture of ordinary Portland cement
conforming to IS: 269-1989 and asbestos fibre free from loading and from organic fibres. The
pipes shall conform to IS: 1592-1989. The pipes shall be classified according to the test
pressure as detailed in Tablel4. The maximum working pressure, under which each pipe shall
be used, shall not exceed half the test pressure for that class of pipe.
Table : 14
Class Test Pressure
Class-5 5 kg/sqcm (50 m head)
Class-15 15 kg/sq.cm (150 m head)
b) The nominal diameter of pipe shall be 50 mm, 80 mm, 125 mm, 150 mm, 200 mm, 250 mm,
300 mm, 450 mm, 600 mm, 900 mm and 1000 mm. The variation of the internal diameter shall
not be more than 10% of the nominal internal diameter. The interior of pipes shall have a
smooth finish and regular surface and regular internal diameter. It shall be straight within
tolerance limits.
c) Specials: Plain ended, cast iron, specials shall be used to suit the diameter of pipe.
d) Laying and jointing of asbestos cement pressure pipes (External work): The
specifications described in 21.3.2 shall apply as far as applicable.
e) Storage:
i) The stack shall be in pyramid shape or the pipes laid lengthwise and crosswise in alternate
layers. The pyramid stack is advisable for smaller diameter pipes for conserving space in
storing them. The height of the stack shall not exceed 1.5 metre.
ii) Cast iron detachable joints and fittings shall be stacked under cover and separated from
the asbestos cement pipes and fittings.
iii) Rubber rings shall be kept clean, away from grease, oil, heat and light.
21.5.2.1 Trenches:
a) The width of the trench above pipe level shall be as small as possible but shall provide sufficient
space necessary for jointing the pipes. The trench width shall be such as to provide a space of
300 mm in either side of the pipe.
b) The Pipes, shall have a minimum soil cover of 750 mm, when laid under foot paths and side
walks, 900 mm, when laid under roads with light traffic or under heavy traffic when the soil
has a poor bearing capacity and is subjected to heavy traffic, the pipes shall be laid on a bed
provided for each jointing pit.
c) Jointing: Before commencing jointing, the pipes, joints and ends of the pipes shall be
cleaned, preferably with a hard wire brush to remove loose particles.
i) Cast iron Detachable Joints (Fig.14): The joint shall consist of a central collar, two
rubber rings, two flanges of cast iron and the required number of bolts and nuts. One
flange and rubber ring shall be placed on end of the pipe already laid, and the other flange,
rings and central collar shall be slipped on to the pipe to be assembled. The rubber ring
shall be kept positioned at half the collar width less 2.5 mm from the end of the pipe
already laid. A site gauge (Fig. 14.) may be used for convenience. The other pipe shall
be brought nearer leaving a gap of 5 mm between the two pipe ends. This gap will
facilitate maneuvering of deflection at joints after assembly and will take care of any
expansion in the pipe line. The collar shall be sided to sit square around the rubber ring
on pipe no.1 and then the rubber ring shall be rolled on pipe 2 to sit around the collar.
The flanges shall be moved on both ends to enclose rubber rings. The fastening bolts
shall be inserted through the holes of the flanges and the bolts shall be tightened
alternately and evenly for proper sitting of the joint.
ii) Asbestos Cement pipe Coupling: This joint shall consist of three rubber rings and an
asbestos cement coupling machined on the inside. The rubber rings shall be seated in
respective grooves, after cleaning the coupling shall be suitably lubricated with a soft
soap solution or other lubricant which is not detrimental to rubber rings of drinking water.
Then, the assembly shall be made by pushing with a crowbar (Fig. 14.) or using a pipe
puller. The joints shall be made by keeping the pipes in one line. Any permissible
deflection at the joint shall be made after completion of the joint only. Wherever
necessary, change over front cast iron pipe to asbestos cement pipes and vice versa shall
be done with the help of suitable adapter shown in (Fig. 14.).
iii) Special Cast iron Fittings and Accessories: Normally when pipe line is laid. A certain
number of cast iron fittings such as tees, bends, reducers, etc. and special fittings such as
air or sluice valves are required.
iv) Laying of Fitting: All cast iron fitting shall be plain ended to suit the class and diameter
of pipe manufactured. Cast iron fittings are jointed by cast iron detachable joints only.
Cast iron specials having flanges are jointed in the pipe line with cast iron flange adapters
having one and flanged and other plain ended.
v) Anchorages: a) It shall particularly be noted that the cast iron joints do not hold pipe
ends within firmly. During working of test pressure there will be a tendency for the pipe
ends or specials ends to slip out of the joint. More so in case of blank end cap used for
closure of pipe line and in case of degree bends and tees. In order to keep them firmly in
the pipe line, anchoring of these specials are necessary against the directions of thrust.
b) The anchorage shall consist of either concrete cast in-situ or masonry built in cement
mortar. The anchors shall be extended to the firm soil of the trench side. The shape of the
anchors will depend on the kind of specials used. They shall be spread to the
full width of trench and carried vertically by the side and over the special to about 15 cm.
The bearing area on sides of the trench shall be proportional to the thrust and to the
bearing capacity of the sides of the trench (Fig 12).
21.5.2.2 Hydrostatic Tests:
a) The Asbestos Cement pipes shall be tested as specified in IS: 5913-1989 in the factory and hence
the purpose of field testing is to check the quality of workmanship and also to check whether
the pipes have been damaged in transit. As such, the test pressure shall be kept as two times the
actual operating pressure unless a higher test pressure is specified. However, it may be noted
that the test pressure during the field test shall not exceed the values given in Table 15.
Table-15 : Test Pressure For A.C. Pressure Pipes
Class of pipe Maximum field test pressure kg f/sq cm
5 3.75
10 7.50
15 11.25
20 15.00
25 18.75
b) Asbestos cement pipes always absorb a certain amount of water. Therefore, after the line, is
filled, it shall be allowed to stand for 24 hours. Before pressure testing and the line shall be
again filled.
c) Measurements: The net length of pipes as laid or fixed shall be measured in the running metre
correct to a cm. Specials shall be excluded and enumerated and paid for separately. The portion
of the pipe, within the collar at the joints, shall not be included in the length of pipe work.
d) Excavation refilling: Shoring and timbering in trenches, masonry or concrete pillars and
thrust blocks, wherever required, shall be measured and paid for separately, under relevant
items of work. The joints shall be enumerated and paid for separately.
e) Rate : The rate shall include the cost of materials and labour involved in all the operations
described above except for the items measured/enumerated and paid separately as stated
above.
21.5.3 Cast Iron Pipe Centrifugally Cast Spun:
21.5.3.1 Materials:
a) The spun iron pipes shall conform to IS: 1536-1989. The spun iron pipes. Shall be of cast iron
cast centrifugally and vary in diameters from 80 mm to 750 mm. These shall be of class LA,
class A and class B, as specified. These pipes shall be used for water pressures up to half the
hydraulic test pressure as detailed in Table 16. The tolerances shall be as prescribed.
Table-16 : For Centrifugally cast Socket and Spigot Pipes.
Ty pes of Pipes Hydrostatic Test Pressure for
works
Class LA in kg/sqcm
Class A Class B
Flanged pipes up to 600 mm dia.(DN) 35.69 35.69 35.69
Spigot and Socket pipe in 700 mm 15.29 20.39 25.49
diameter (DN) and above.
Hydrostatic Test pressure for Centrifugally cast pipes screwed on Flanges.
with
Up to 300 DN NA NA 25.49
350 to 600 DN NA NA 16.32
b) Hydrostatic Test: DI Pipes: Pipes shall be tested hydrostatically at the pressure specified in
the Table 16 above. To perform the test, the pressure shall be applied internally and shall be
steadily maintained for a period of minimum 10 seconds. The pipes shall withstand the pressure
test and shall not show any signs of leakage, sweating or other defects. As far as possible the
hydrostatic test shall be conducted before coating the pipes with cement mortar. Suggested
maximum pressure (inclusive of surge) and maximum hydrostatic test pressure after
installation for socket and spigot pipes and flanged pipes are given as under for information :
Hydrostatic Test Pressure and Hydraulic working pressure for DI pipes as per Annex. `B'
of IS 1536-2001 (Table 12.2)
Nominal Description Suggested Suggested
Diameter-DN maximum maximum
Hydrostatic site Hydraulic working
test pressure in pressure in MPa/
MPa/ kg/sqcm kg/sqcm
(1) (2) (3) (4)
80-600 Spigot and Socket spun pipes Class LA 1.6/16.31 1.0/10.197

80-600 Spigot and Socket spun pipes Class A 2.0/20.39 1.25/ 12.75
80-600 Spigot and Socket spun pipes Class B 2.5/25.49 1.6/16.31
700-1050 Spigot and Socket spun pipes Class LA 1.5/15.29 1.0/10.197
700-1050 Spigot and Socket spun pipes Class A 2.0/20.39 1.2/12.24
700-1050 Spigot and Socket spun pipes Class B 2.5/25.49 1.5/15.29
80-300 Flanged Pipes Class B 2.5/25.49 1.6/16.31
350-600 Flanged Pipes Class B 2.0/20.39 1.6/16.31
When pipes are required for higher test pressures, test pressures are subject to special
agreement between the purchaser and the manufacturer.
c) Specials: The specials shall conform to IS: 1538. The hydraulic test pressure of each class
shall be as detailed in Table 16 and 17.The tolerances shall be as prescribed in Appendix ' .
21.5.3.2 Laying and jointing of cast Iron pipes and Fitting (External Work): Specifications: It
shall be done as per IS 3114-1985, salient procedures are as under.
a) Excavation and Preparation of Trench : General : a) The trench shall be so dug that the
pipe may be laid to the required alignment and at the required depth. When the pipeline is under
a roadway, a minimum cover of 1.0 m is recommended for adoption, but it may be modified to
suit local conditions by taking necessary precautions. The trench shall be excavated only so far
in advance of pipe laying as specified by the Authority. The trench shall be so braced and
drained that the workmen may work therein safely and efficiently. The discharge of the trench
dewatering pumps shall be conveyed either to drainage channels or to natural drains and shall
not be allowed to be spread in the vicinity of the work site.
b) Trenching by Machine or by Hand : Hand methods for excavation shall be employed in
locations shown on the drawings given by the Authority. In other places excavation may be
done by hand or by machine.
c) Width of Trench : The width of the trench at bottom between faces of sheeting shall be such
as to provide not less than 200 mm clearance on either side of the pipe except where rock
excavation is involved. Trenches shall be of such extra width, when required as will permit the
convenient placing of timber supports, strutting and planking, and handling of specials.
d) Provisions for Joints : Additional width shall be provided at positions of sockets and flanges
for jointing to be made properly. Depths of pits at such places shall also be sufficient to permit
finishing of joints.
e) Pipe Clearance in Rocks: Ledge rock, boulders and large stones shall be removed to provide
a clearance of at least 150 mm below and on each side of pipes, valves and fittings for pipes 600
mm in diameter or less, and 200 mm for pipes larger than 600 mm in diameter. The specified
minimum clearances are the minimum clear distances which will be permitted between any
part of the pipe or appurtenance being laid and any part, projection or point of such rock,
boulder or stone.
f) Limits of Excavation Relative to Gradients : Except where special foundations are to be
provided for specific reasons, the trench shall be excavated in accordance with one of the
following alternatives as may be considered appropriate by the Authority:
i) The trench shall be excavated to the exact gradient specified so that no making of the
sub-grade by backfilling is required and the pipe rests on solid and undisturbed ground
when laid;
ii) When the bottom of the trench at the specified gradient is found to be unstable or to
include ashes and cinders, all types of refuse, vegetable or other organic material, or large
pieces or fragments of inorganic material, they shall be removed to the satisfaction of the
Authority; and
iii) Where the excavation is in rock or boulders, the designed clearance shall be provided.
g) Trimming of Trench Bottoms: Where rock and large stone or boulders are encountered, the
trench shall be trimmed to a depth of at least 150 mm below the level at which the bottom of
the barrel of the pipe is to be laid, and filled to a like depth with granular material to pass through
a sieve of 12.5 mm aperture size [see IS 2405 (Part 2) : 1980] and well rammed to form a fair
and clean bed for pipe.
h) Finish of Surfaces : In all cases there shall be a uniform and continuous bearing and support
for the pipe at every point between the sockets or flanges except that it will be permissible to
disturb and otherwise damage the finished surface over a maximum length of 450 mm near the
middle of each pipe length by the withdrawal of pipes lings or other lifting tackle. The finished
sub-grade shall be prepared accurately by means of hand tools. The sub-grade beneath the
centerline of the pipe shall be finished to within one cm of a straight line between the pipe joints
or batten boards.
i) Special Foundation in Poor Soil : Where the bottom of the trench and sub-grade is found to
consist of material which is unstable to such a degree that, in the opinion of the Authority, it
cannot be removed and replaced with an approved material thoroughly compacted in place to
support the pipe properly, a suitable foundation for the pipe, consisting of piling, timbers or
other materials, in accordance with plans prepared by the Authority shall be constructed.
j) Previous Excavations: Where the trench passes over a sewer or other previous excavation, the
trench bottom shall be sufficiently compacted to provide support equal to that of the native soil
or conform to other regulatory requirements in a manner that will prevent damage to the existing
installation.
21.5.3.3 Rock Excavation : The term 'rock' wherever used in this standard shall have the same
meaning as given under terminology in IS 1200 (Part 1) : 1974.
a) Blasting : Blasting for excavation shall be permitted only after securing the approval of the
Authority and only when proper precautions are taken for the protection of persons or property.
The hours of blasting shall be fixed by the Authority. The procedure of blasting shall conform
to the requirements of local controlling Authority.
b) Braced and Sheeted Trenches : Open-cut trenches shall be sheeted and braced as required by
any governing state laws and municipal regulations and as may be necessary to protect life,
property or the work. When close sheeting is required, it shall be so driven so as to prevent
adjacent soil from entering the trench either below or through such sheeting.
c) The Authority shall have the right to order the sheeting to be driven to the full depth of the
trench or to such additional depths as may be required for the protection of the work. Where the
soil in the lower limits of a trench has the necessary stability, the Authority at discretion, may
permit stopping of the driving of sheeting at some designated elevation above the trench
bottom.
d) Sheeting and bracing which have been ordered to be left in place should be removed for a
distance of 900 mm below the established street level or the existing surface of the street,
whichever is lower. Trench bracing, except that which should be left in place, may be removed
when the back filling has reached the respective levels of such bracing. Sheeting, except that
which has been left in place, may be removed after the backfilling has been completed or has
been brought up to such an elevation as to permit its safe removal. Sheeting and bracing may
be removed before filling the trench, but only in such manner as will ensure the adequate
protection of the completed work and adjacent structures.
e) Care of Surface Material for Re-use : All surface materials which in the opinion of the
Authority, are suitable for re-use in restoring the surface shall be kept separate from the general
excavation material as directed by the Authority.
f) Stacking Excavated Material: All excavated material shall be stacked in such a manner that
it will not endanger the work or workman and it will avoid obstructing footpaths and roads,
driveways. Hydrants under pressure, surface boxes, fire of other utility controls shall be left
unobstructed and accessible until the work is completed. Gutters shall be kept clear or other
satisfactory provisions made for street drainage, and natural water-courses shall not be
obstructed.
g) Barricades, Guards and Safety Provisions: To protect persons from injury and to avoid
damage to property, adequate barricades, construction signs, torches, red lanterns and guards as
required shall be placed and maintained during the progress of the construction work, and until
it is safe for traffic to use the roadways. All materials pipes, equipment and pipe which may
serve as obstructions to traffic shall be enclosed by fences or barricades and shall be protected
by proper lights when the visibility is poor. The rules and regulations of the local authorities
regarding safety provisions shall be observed.
h) Maintenance of Traffic and Closing of Streets: The work shall be carried in such a manner
which will cause the least interruption to traffic, and the road/street may be closed in such a
manner that it causes the least interruption to the traffic. Where it is necessary for traffic to
cross open trenches, suitable bridges shall be provided. Suitable signs indicating that a street is
closed shall be placed and necessary detour signs for the proper maintenance of traffic shall be
provided.
i) Structure Protection: Temporary support, adequate protection and maintenance of all
underground and surface structures, drains sewers and other obstructions encountered in the
progress of the work shall be furnished under the direction of the Authority. The structure which
may have been disturbed shall be restored upon completion of the work.
j) Protection of Property and Surface Structures: Trees, shrubbery fences, poles and all other
property and surface structures shall be protected unless their removal is shown on the drawings
or authorised by the Authority. When it is necessary to cut roots and tree branches, such cutting
shall be done under the supervision and direction of the Authority.
k) Interruption of Service : No valve or other control of the existing services shall be operated
without the permission of the Authority.
21.5.3.4 Laying:
a) Unloading of Pipes: While unloading, pipes shall not be thrown down from the trucks on hard
roads. Unloading them on timber skids without a steadying rope and thus allowing the pipes to
bump hard against one another should not be allowed. In order to avoid damage to the pipes
and specially to the spigot end, pipe should not be dragged along concrete and similar
pavements with hard surfaces.
b) Detection of Cracks in Pipes : The pipe and fittings shall be inspected for defects and be rung
with a light hammer preferably while suspended to detect cracks. Smearing the outside with
chalk dust helps the location of cracks. If doubt persists further confirmation may be obtained
by pouring a little kerosene on the inside of the pipe at the suspected spot; if a crack is present
the kerosene seeps through and shows on the outer surface. If a pipe is mishandled either
accidentally or due to carelessness during unloading or lowering it should be thoroughly
inspected before laying and shall be rejected if found unsuitable by the Authority.
c) Lowering of Pipes and Fittings: Proper implements, tools and facilities satisfactory to the
Authority shall be provided and used for the safe and convenient execution of the work. All
pipes, fittings, valves and hydrants shall be carefully lowered into the trench, piece by piece,
by means of a derrick, ropes or other suitable tools or equipment, in such a manner as to prevent
damage to pipes materials and protective coatings and linings. Under no circumstances shall
pipes materials be dropped or dumped into the trenches. Pipes over 300 mm diameter shall be
handled and lowered into trenches with the help of chain pulley blocks. Tripod supports used
for this purpose shall be regularly checked to prevent all risks of accidents.
d) Cleaning of Pipes and Fittings : All lumps, blisters and excess coating material shall be
removed from the socket and spigot end of each pipe and the outside of the spigot and the inside
of the socket shall be wire-brushed and wiped clean and dry and free from oil and grease before
the pipe is laid.
21.5.3.5 Laying of Pipes :
a) Every precaution shall be taken to prevent foreign material from entering the pipe while it is being
placed in the line. If the pipe laying team cannot put the pipe into the trench and in place without
getting earth into it, the Authority may require that before lowering the pipe into the trench, a
heavy, tightly woven canvas bag of suitable size shall be placed over each end and left there
until the connection is to be made to the adjacent pipe. During laying operations, no debris,
tools clothing or other materials shall be placed in the pipe.
At times when pipe laying is not in progress, the open ends of pipe shall be closed by a
watertight plug or other means approved by the Authority.
Joints of pipe in the trench which cannot be poured shall be caulked with jointing materials to
make them watertight. Alternatively, flanged pipe/threaded pipe may be used.
Number of Pipes Laid Before Jointing : Wherever the jointing material specified is cement,
six or more lengths of pipe shall be laid in place ahead of each joint before such a joint is
finished.
Cutting of Pipe : The cutting of pipe for inserting valves, fittings or closure pieces shall be
done in a neat and workmanlike manner without damage to the pipe or cement lining so as to
leave a smooth end at right angles to the is of the pipe. For this purpose use of a pipe cutting
machine is recommended.
When pipe cutting machine is not available for cutting pipes of large diameters, the electric-
arc cutting method may be permitted using a carbon or steel rod. Only qualified and
experienced workmen shall be employed on this work.
When the pipe cutting machine is not available and the site conditions do not permit pipe
cutting by machines, the pipe can be cut using chisels.
The flame cutting of pipe by means of an oxyacetylene torch shall not be allowed.
Direction of Laying of Socket End : On level ground, the socket ends should face the
upstream. When the line runs uphill the socket ends should face the upgrade.
Permissible Deflection at Socket and Spigot Joints: Where necessary to deflect pipe from a
straight line, either in the vertical or horizontal plane, to avoid obstructions or where long radius
curves are permitted, deflection at joint shall not exceed the following:
Lead joints 2.5°
Rubber joints
For nominal bore 80 to 300 mm 50
For nominal bore 350 to 400 mm 4°
For nominal bore 450 to 750 mm 3°
21.5.3.6 Pipelines Crossing Railway Line : The Authority should consult the railways before
preparing plans and specifications for this part of the work.
a) Where the pipes run beneath tram tracks or are located in areas where similar vibratory effects
are likely, care should be taken to avoid any direct transmission of the vibrations to the pipes
itself. Adequate cover with soft well-packed filling is essential.
b) Conditions Unsuitable for Laying of Pipe: No pipe shall be laid in or when, in the opinion
of the Authority, trench conditions are unsuitable.
c) Casing Pipes : When the pipes run beneath the heavy loads, suitable size of casing pipes/
culverts may be provided to protect the carrier pipe or when required by the Authority.
d) Clearance : When crossing existing pipelines or other structures, alignment and grade shall be
adjusted as necessary, with the approval of the Authority to provide clearance as required by state
or local regulations or as deemed necessary by Authority to prevent future damage or
contamination of either structure.
21.5.3.7 Usage of Anchor and Thrust Blocks in Pipe Lines
a) General : High pressure mains need anchorages at dead ends and bends, as appreciable thrust
occur which tend to cause 'draw' and even blowout of joints. Where the thrust is appreciable,
concrete blocks should be installed at all points where movement may occur.
b) Hydrants : The bowl of each hydrants shall be well braced against a sufficient area of un
excavated earth at the end of the trench with stone slab or concrete backing, or it shall be tied
to the pipe with suitable metal tic rods, clamps, or restrained joints as shown or directed by the
Authority.
c) Tie rods, clamps or other components of dissimilar metal shall be protected against corrosion
by hand application of a bituminous coating.
d) Pipelines : Anchorages are necessary to resist the tendency of the pipes to pull apart:
i) at bends or other points of unbalanced pressure, or
ii) when they are laid on step gradients and the resistance of their joints to longitudinal
(shearing) stresses is either exceeded or inadequate. They are also used to restrain or
direct the expansion and contraction of rigidly joined pipes under the influence of
temperature changes.
iii) It is advisable to avoid sharp bends above 45° and in soft ground it is better not to put
two bends together but to separate them by at least a length of straight pipe. If the
pressures are high enough to merit it and sleeve joints are being used, the joints on the
bends and on two pipes either side of them should be fully welded inside and outside, and
the trench, refilled with concrete to 150 mm above these pipes and bends. Pipes laid on
steep inclines should be anchored or transversed blocks or other precautions taken to
prevent slippage and measures to overcome unbalanced pressures provided.
iv) Anchor or thrust blocks shall be designed in accordance with IS 5330: 1984. Thrust
resistant design pressure should be equal to the test pressure.
v) Restrain Materials : Vertical and horizontal reaction backing shall be made of
concrete of grade M15 conforming to IS 456 : 1978.
21.5.3.8 Jointing of Pipes :
a) Jointing of Socket and Spigot Pipes Jointing may be done with any of the following materials:
Molten lead (under dry conditions),

Lead wool (under wet conditions),
Cement, and
Tarred yarn (for sewers only where considered necessary).
b) Yarning or Packing Material: Yarning or packing material shall consist of one of the
following:
i) Spun yarn,
ii) Moulded or tubular natural or synthetic rubber rings,
iii) Asbestos rope, or
iv) Treated paper rope.
NOTE- In sewerage system the usage of natural or synthetic rubber rings may be decided
by the Authority taking into consideration the characteristics of effluent.
c) All the materials mentioned in (b) shall be handled with care in order to prevent contamination
and shall be dry when put into place in the joint. The material used shall be free of oil, tar or
greasy substances. In cement joints, the yarning materials may be omitted if so specified.
NOTE- Spun yarn used as a jointing material shall be of sterilized quality. It shall have been
exposed to vapours of 40 percent formaldehyde in air-tight chamber for three hours before
using it in water main.
d) Placing of Yarning Material : The yarning material shall be placed around the Spigot of the
pipe and shall be of proper dimensions to centre the spigot in the socket. When the spigot is
shoved home, the yarning material shall be driven tightly against the inside base or hub of the
socket with suitable yarning tools.
e) When a single strand of yarning material is used, it shall have an overlap at the top of not more
than 50 mm. When more than a single strand is required for a joint, each strand shall be cut to
sufficient length so that the ends will meet without causing overlap. The ends of the strands
shall meet on opposite sides of the pipe and not on the top or at the bottom. Successive strands
of yarning material shall be driven home separately.
f) Lead Joints: Lead for caulking purposes should conform to IS 782: 1978.
g) Quantity of lead for joints : The quantity of lead required for different sizes of pipes are
given in Table 18.
h) Heating and pouring of lead : Lead shall be heated in a melting pot kept in easy Reach of the
joint to be poured so that the molten metal will not be chilled in being carried from the melting
pot to the joint and shall be brought to a proper temperature so that when stirred it will show a
rapid change of colour. Before pouring, all scum shall be removed.
Each joint shall be made with one continuous pour filling of the entire joint space with solid lead.
Spongy or imperfectly filled joints shall be burnt /chiseled out and re-poured.
Position of joint runner: The joint runner shall fit snugly against the face of the socket and
the outside of the pipe shall be dammed with clay to form a pouring lip to provide for filling
the joint flush with the face and to the top of the socket.
Procedure for caulking of socket and spigot joints :The common form of joint is made by
first caulking in spun yarn then filling the remainder of the joint space by running in molten
lead, taking care that no dross enters the joint, and then thoroughly caulking the lead. The lead
need not extend into the joint further than the back of the groove formed in the socket. The
spun yarn is used to centre the spigot in the socket, to prevent the flow of molten lead into the
bore of the pipe, to reduce the amount of lead required to complete the joint and to make the
joint watertight. Spun yarn may become infected with bacteria, which may contaminate the
water and, therefore, shall be effectively disinfected before use. [see Note under 21.5.3.8 (b)].
Alternatively, proprietary brands of sterilized spun yarn may be used. Shredded lead or lead
wire or strip may be used instead of spun yarn, thus producing a solid lead joint. Lead covered
yarn may also be used which does not have the disadvantages of plain yarn. Cold lead may be
caulked into the joint space first followed by spun yarn, and the joint then completed with cold
or molten lead. Caulking maybe done with pneumatic tools or with a hand hammer weighing
not less than 2 kg. When working with lead wool, it is very important to use caulking tools of
appropriate thickness to fill the joint space, and to thoroughly consolidate the material from the
back to the front of the socket. Lead run joints shall be preferably finished 3 mm behind the
socket face.
k) Quantity of lead wool and spun yarn for joints : The quantity of lead wool and spun yarn
required for different sizes of pipes are given in Table 19. As lead wool jointing is mostly done
in difficult site conditions, higher tolerances may be permitted in practice from the quantities
specified in Table 19.
1) Cement Joints : Where cement joints are used for cast iron gravity sewers, cement as permitted
in IS 456: 1978 may be used.
m) Procedure : Closely twisted spun yarn gasket of such diameter as required to support the spigot
of the pipe at the proper grade and make truly concentric joints, and in one piece of sufficient
length to pass around the pipe and lap at the top, shall be thoroughly saturated in cement paste.
This gasket shall be laid in the socket for the lower third of the circumstances of the joint and
covered with cement mortar (1 cement: 1 coarse sand). The spigot of the pipe shall be
thoroughly cleaned with a wet brush, inserted and carefully driven home, after which a small
amount of mortar shall be inserted in the annular space around the entire circumference of the
pipe and solidly rammed into the joint with a caulking tool, the mortar previously placed being
driven ahead of the gasket. The remainder of the joint shall then be completely filled with
mortar and bevelled off at an angle of 45 degrees with the outside of the pipe. On pipes of 450
mm in diameter or larger, the joints shall be pointed and smoothed from the inside. While
making cement joints, one lead joint shall be introduced for every ten cement joint.
n) The inside of the pipe shall be cleaned after the mortar sets slightly by dragging a large gunny
wrapped block of wood or straw through the pipe. Care is, however, necessary to
see that this block is not left in the sewer when the work is interrupted or completed.
o) Time interval before filling pipe : Pipe laid with cement joints shall not be filled with water
until a lapse of twelve hours after the last joint in any valved section has been made, and
pressure shall not be permitted in the pipe until all joints have aged as provided in 7.4.
P) Rubber Ring Joints: In the case of rubber ring joints or push on joints, the groove and the socket
shall be thoroughly cleaned before inserting the rubber gasket. While inserting the gasket it
shall be made sure that it faces the proper direction and that it is correctly seated in the groove.
After cleaning dirt or foreign materials from the plain end, lubricant shall be applied in
accordance with the pipe manufacturer's recommendations. See Table 19.
q) The contractor shall make sure that the plain end is bevelled as square or sharp edges may
damage or dislodge the gasket and cause a leak. When the pipe is cut at site, the plain end shall
be bevelled with a heavy file or grinder to remove all sharp edges.
r) The plain end of the pipe shall be pushed into the socket of the pipe and while pushing, the pipe
shall be kept straight. If any deflections are to be made in the alignment, it may be made after
the joint is assembled. A timber header shall be used between the pipe and crowbar or jack to
avoid damage to the pipe while the plain end of the pipe is pushed into the socket either with a
crow bar or jack, or lever puller.
21.5.3.9 Flanged Joints : Cast iron pipes may also be joined by means of flanges.
a) The gaskets used between flanges of pipes shall be compressed fibre board or natural / synthetic
rubber (see IS 638 : 1979) of thickness between 1.5 to 3 mm. The fibre board shall be
impregnated with chemically neutral mineral oil and shall have a smooth and hard surface. Its
weight per square metre shall be not less than 112 g/mm thickness.
b) Each bolt should be tightened a little at a time taking care to tighten diametrically opposite
bolts alternatively. The practice of fully tightening the bolts one after another is highly
undesirable.
c) Several proprietary flexible joints are available for jointing cast iron pipes and these may be
used with the specific approval of the Authority; however, they shall be used strictly in
accordance With the manufacturer's instructions.
21.5.3.10 Hydrostatic Tests:
a) Types of Tests : After a new pipe has been laid, jointed and back filled as specified, it (or
any valved section thereof) shall be subjected to the following two tests:
i) Pressure test at a pressure as specified in (b), and
ii) Leakage test at a pressure to be specified by the Authority for a duration of two hours.
b) Procedure for Pressure Test : Pressure Test : The field test pressure to be imposed shall be
not less than the greatest of the following:
i) One and a half times the maximum sustained operating pressure,
ii) One and a half times the maximum pipeline static pressure, and
iii) Sum of the maximum static pressure and surge pressure subject to the works test
pressure.
c) Where the field test pressure is less than two-thirds the works test pressure, the period of
test should be increased to at least 24 hours. The test pressure shall be gradually raised at the
rate of nearly 0.1N/mm2 per minute.
d) If the pressure measurements are not made at the lowest point of the section, an allowance
should be made for the static head between the lowest point, "and the point of measurement to
ensure, that the maximum pressure is not exceeded at the lowest point. If a drop in pressure
occurs, the quantity of water added in order to re-establish the test pressure should be carefully
measured. This should not exceed 0.1 litre per mm of pipe dia per km of pipeline per day for
each 30 metre head of pressure applied.
e) Pressurization: Each valved section of pipe shall be filled with water slowly and the specified
test pressure, based on the elevation of lowest point of the linear section under test and corrected
to the elevation of the test gauge, shall be applied by means of a pump connected to the pipe in
a manner satisfactory to the Authority.
f) Examination Under Pressure: All exposed pipes, fittings, valves hydrants and joints should
be carefully examined during the open-trench test. When the joints are made with lead, all such
joints showing visible leaks shall be recaulked until tight. When the joints are made with
cement and show seepage or slight leakage, such joints shall be cut out and replaced as directed
by the Authority. Any cracked or defective pipes, fittings, valves or hydrants discovered in
consequence of this pressure test shall be removed and replaced by sound material and the test
shall be repeated until accepted by the Authority.
21.5.3.11 Procedure for Leakage Test :

a) A leakage test shall be conducted concurrently with the pressure test. Leakage is defined as the
quantity of water to be supplied into the newly laid pipe, or any valved section thereof within
0, (135 N/mm"- of the specified leakage test pressure after the air in the pipeline has been
expelled and the pipe has been filled with water.
b) No pipe installation shall be accepted untill the leakage is less than the number of cm3/h as
determined by the formula:
qL= NDV 3.3

where
qL = the allowable leakage in cm3/h,
N = number of joints in the length of the pipeline,
D = Diameter in mm, and
P = the average test pressure during the leakage test in kgf/cm
Variation from Permissible Leaking : Where any test of pipe laid indicates leakage greater
a) than that specified above, the defective joints shall be repaired until the leakage is within the
specified allowances.
b) Pre-requisite to Test : Where any section of a main is provided with concrete thrust blocks or
anchorages in accordance with 21.5.3.7 (a) and (b), the pressure test shall not be made until at
least five days have elapsed after the concrete was cast. If rapid hardening cement has been
used in these blocks or anchorages, the test shall not be made until at least two days have
elapsed.
e) Back-Filling : Before testing, the trench may be partially back filled, if required by site condition,
except at the joints in accordance with 21.5.3.12 Such back-filling shall be done after obtaining
the permission from the Authority.
f) Time for Testing of Lead Jointed Pipe : If the requirements of (d) above have been complied with,
a lead jointed pipe may be subjected to hydrostatic pressure, inspected and tested for leakage
at any convenient time after the trench has been back-filled in accordance with (e) above.
g) Time for Testing of Cement Jointed Pipe : After the requirements of (d) above have been
complied with and the trench back-filled in accordance with (e ), the main shall be filled with
water in the manner specified in 21.5.3.8 (o) and 21.5.3.10 (b) , and shall not be subjected to
hydrostatic pressure inspected and tested for leakage till at least 36 hours have elapsed
thereafter. The pipe shall remain full of water until all tests have been made.
h) In case where there are no valves, or valved sections are too long, the testing may be permitted to
be carried out in suitable segments with the permission of the Authority.
21.5.3.12 Back-Filling :
a) For the purpose of back-filling, the depth of the trench shall be considered as divided into the
following three zones from the bottom of the trench to its top:
i) Zone A : From the bottom of the trench to the level of the centre line of the pipe,
ii) Zone B: From the level of the centre line of the pipe to a level 300 mm above the top of
the pipe, and
iii) Zone C : From a level 300 mm above the top of the pipe to the top of the trench.
b) Back-Fill Material : All back-fill material shall be free from cinders, ashes, Slag, refuse,
rubbish, vegetable or organic material, lumpy or frozen material, boulders, rocks or stone or
other material which in the opinion of the Authority, is unsuitable or deleterious. However,
material containing stones up to 200 mm as their greatest dimension may be used in Zone C
unless specified otherwise herein.
c) Back-Fill Sand : Sand used for back-fill shall be a natural sand complying with 8.2, graded
from fine to coarse. The total mass of loam and clay in it shall not exceed 10 percent. All
material shall pass through a sieve of aperture size 20 mm [see IS 2405 (Part 2) : 1980] and not
more than 5 percent shall remain on IS Sieve of aperture size 6.30 mm.
d) Back-Fill Gravel : Gravel used for back-fill shall be natural gravel, complying with 8.2 and
having durable particles graded from fine to coarse in a reasonably uniform combination with no
boulders or stones larger than 50 mm in size. It shall not contain excessive amount of loam and
clay and not more than 15 percent shall remain on a sieve of aperture size 75 micron.
e) Back-Filling in Freezing Weather: Back-filling shall not be done in freezing weather except
by permission of the Authority, and it shall not be made with frozen material. No fill shall be
made where the material already in the trench is frozen.
f) Back-filling in Zone A shall be done by hand with sand, fine gravel or other approved material
placed in layers of 150 mm and compacted by tamping. The back-filling material shall be
deposited in the trench for its full width of each side of the pipe, fittings and appurtenances
simultaneously.
g) Back-filling in Zone B shall be done by hand or approved mechanical methods in layers of 150
mm, special care being taken to avoid injuring or moving the pipe. The type of back-fill material
to be used and the method of placing and consolidating shall be prescribed by the Authority to
suit individual locations.
Back-filling in Zone C shall be done by hand or approved mechanical, methods. The types of
back-fill material and method of filling shall be as prescribed by the Authority.
Back-Fill Under Permanent Pavement : Where the excavation is made through permanent
pavements, curbs, paved footpaths, or where such structures are undercut by the excavation,
the entire back-fill to the subgrade of the structures shall be made with sand in accordance with
(c) above Paved footpaths and pavements consisting of broken stone, gravel, slag or cinders
shall not be considered as being of a permanent construction. Method or place and consolidating
the back-fill material shall be prescribed by the Authority.
j) Back-Fill with Excavated Material : The excavated material may be used for back-fill in the
following cases, provided it complies with (b) above.
i) In Zone C, in cases where settlement is unimportant and when shown on the drawings
or specified, the back-fill shall be neatly rounded over the trench to a sufficient height to
allow for settlement to the required level.
ii) In any zone when the type of back-fill material is not indicated or specified provided
that such material consists of loam, clay, sand, fine gravel or other materials which are
suitable for back-filling in the opinion of the Authority.
k) Concrete Slabs Over Pipes : When pipes are laid under roads and pavements subjected to heavy
traffic loads, the trenches may be covered with reinforced concrete slabs of suitable design.
21.5.3.13 Flushing and Disinfection of Mains before Commissioning :
a) The mains intended for potable water supplies should be disinfected before commissioning
them for use.
b) Disinfection of New Mains : Special care should be taken to ensure disinfection of new mains.
Among possible sources of contamination are sewer drainage, contaminated soil in the trench,
contamination from workmen and or their equipment and of course unavoidable foreign
material present in the trench during construction.
c) Education of crew members as to need for avoiding contamination of the main during
construction is fundamental. Contractors and workmen should be thoroughly familiar with all
pertinent state and local requirements governing installations of mains. All sewers, water mains
and other underground conduits should be located prior to construction and relocated, if
necessary, to prevent contamination during construction. Pipe should be strung on high ground.
At all times when construction is not actually in progress, watertight plugs should be installed
in all pipe openings. Gunny sacks and rags are not adequate. Provision should be made to pump
out any other water that might collect in the trench. Special care should be taken to avoid
contamination of valves, fittings, and pipe interiors, both before and during construction, each
should be inspected and, if necessary cleaned before installation. After pressure testing the
main, it should be flushed with water of sufficient velocity to remove all dirt and other foreign
materials. When this process has been completed, disinfection (using liquid chlorine, sodium
or calcium hypochlorite) can proceed by one of the
recommended methods as described in (d) and (e ).
d) Continuous Feed : In this method, water from the distribution system or other approved source
and the chlorine from selected are fed at constant rate into the new main at a concentration of
at least 20 to 50 mg/litre. A properly adjusted hypochlorite solution injected into the main with a
hydrochlorinator liquid chlorine injected into the main through a solution feed chlorinator and
booster pump may be used. The chlorine residual should be checked at intervals to insure that
the proper level is maintained. Chlorine application should continue until the entire main is filled.
The water should remain in the main for a minimum of 24 hours, during which time all valves,
hydrants etc., along the main should be operated to ensure their proper disinfection. Following
the 24 hours period not less than 10 mg/1 chlorine residual should remain in the main.
(e) Slug Method : In this method a continuous flow of water is fed with a constant dose of chlorine
(as in the previous method) but with rates proportioned to give a chlorine concentration of at
least 300 mg/1. The chlorine is applied continuously for a period of time to provide a column of
chlorinated water that will contact all interior surfaces of the main for a period of at least three
hours. As the slug passes tees, crosses, etc., proper valves must be operated to ensure their
disinfection. This method is used principally for large diameter mains where continuous feed
is impractical.
f) Regardless of the method used, it is necessary to make certain that back flow of the strong chlorine
solution into the supplying line does not occur. Following the prescribed contact period
chlorinated water should be flushed to waste until the remaining water has a chlorine residual
approximating that throughout the rest of the system. Bacteriological tests as prescribed by the
authorities should be taken, and if the results fail to meet minimum standards, the disinfecting
procedure must be repeated and the results again tested before placing the main in service.
21.5.3.14 Removal, Restoration and Maintenance of Paved Footpaths, etc., after laying of pipe:
a) Allowable Removal of Pavement : Pavement and road surfaces may be removed as a part of
the trench excavation, and the amount removed shall depend upon the width of trench specified
for the installation of the pipe and the width and length of the pavement area required to be
removed for the installation of gate valves, specials, manholes or other structures. The width
of pavement removed along the normal trench for the installation of the pipe shall not exceed
the width of the trench specified by more than 150 mm on each side of the trench. The width
and the lengths of the area of pavement removed from the installation of gate valves, specials,
manholes or other structures shall not exceed the maximum linear dimensions of such structures
by more than 150 mm on each side. Wherever, in the opinion of the Authority, existing conditions
make it necessary or advisable to remove additional pavement, it shall be removed as directed
by the Authority.
b) Restoration of Damaged Surfaces and Property : Where any pavement, trees, shrubbery
fences, poles or other property and surface structures have been damaged, removed or disturbed
during the course of work, such property and surface structures shall be replaced or repaired
after completion of work.
c) Replacement of Pavement and Structures : All pavements, paved footpaths, curbing, gutters,
shrubbery, fences, poles sod or other property and surface structures removed or
disturbed as a part of the work shall be restored to a condition equal to that before the work
began, furnishing all labour and materials incidental thereto. In restoring the pavement, sound
granite blocks, sound brick or asphalt paving blocks may be re-used. No permanent pavement
shall be restored unless and until, in the opinion of the Authority, the condition of the back-fill
is such as to properly support the pavement.
d) Cleaning Up: All surplus materials, and all tools and temporary structures shall be removed from
the site as directed by the Authority. All dirt, rubbish and excess earth from the excavation shall
be hauled to a dump and the construction site left clean to the satisfaction of the Authority.
Table-18 : Quantity of Lead for Different Sizes of Pipes
Nominal size of pipe mm. Lead per joint Depth of lead joint mm.
kg.
(1) (2) (3)
80 1.8 45
100 2.2 45
125 2.6 45
150 3.4 50
200 5.0 50
250 6.1 50
300 7.2 55
350 8.4 55
400 9.5 55
450 14.0 55
500 15.0 60
600 19.0 60
700 22.0 60
750 25.0 60
NOTE:
1. The quantity of lead given in the table is on average basis and a variation of 10 percent is
permissible.
2. Before pipes are jointed on large scale, three of four sample joints shall be made and the average
consumption of lead per joint shall be got approved by the Engineer-in-Charge. Only required
quantity of spun yam shall be put so as to give the specified depth of lead in the joint.
Table-19: Quantity of Lead Wool or Lead Yam for Different Sizes of Pipes
Diameter of pipe mm. Weight of wool or lead Depth of lead wool or lead
yarn (kg) yarn (mm)
80 0.80 19
100 0.90 19
125 1.25 20
150 1.60 23
200 2.05 23
250 2.95 25
300 3.50 29
350 4.65 31
400 5.70 32
450 6.70 33
500 8.30 35
600 10.00 36
700 11.80 36
750 13.60 38
800 15.40 40
900 21.80 40
Note: i) An allowance of fiveper cent variation in the specified weights and depths is permissible.
Note: ii) Under special circumstances the Engineer-in-Charge may decide the quantities of lead
wooUspun yarn depending upon the site conditions.
a) The net length of pipes as laid or fixed, shall be measured in the running metre correct to a cm
Specials shall be excluded and enumerated and paid for separately. The portion of the pipe
within collar at the joints shall not be included in the length of pipe work.
b) Excavation, refilling, shoring and timbering in trenches, masonry or concrete pillars and thrust
blocks, wherever required, shall be measured and paid for separately, under relevant items of
work.
c) Lead caulked joints shall be measured and paid for separately.
21.5.3.16 Rate: The rate shall include the cost of materials and labour involved in all the operations
described above except for the items measured/ enumerated separately under various para's which
shall be paid for separately.
21.5.4 Plastic pipes:
21.5.4.1 Materials: The plastic pipes commercially available in the country are that of (i) low-
density polyethylene (LDPE) conforming to IS: 3076-1985 (ii) High-density polyethylene (HDPE)
conforming to IS: 4984-1995 and (iii) Rigid (unplasticised) polyvinyl chloride (UPVC) conforming to
IS: 4985-1988 (iv) Polythelene/ Aluminium / Polythelene Composite Pressure Pipes for Hot And
Cold Water Supplies conforming to IS: 15450-2004 (v) Chlorinated Polyvinyl Chloride (CPVC)
Pipes for Potable Hot and Cold Water Distribution Supplies conforming to IS: 15778-2007 (vi) 3-
Layer PPR conforming to DIN:8077-1977, DIN: 8078-1996. These pipes are corrosion resistant and
light in weight, and have been found suitable for cold water services. Plastic materials perform on their
own merits, and each of these plastic pipes has its own limitations and advantages for a particular
application under conditions of use. Relevant Indian standard specifications have been laid down for
these pipes.
21.5.4.1.2 Low Density Polyethylene (LDPE): It is flexible now it is well established that this
material is used for pipes with diameter up to 63 mm, generally recommended for use in long runs
e.g. for point to point conveyance of water, because of its flexibility, and fact that LDPE pipes require
closer spacing for horizontal and vertical runs, their use has not been found practical for installation
of internal water supply system.
21.5.4.1.3 High Density Polyethylene (HDPE): It is rather tougher as compared to low-density
polyethylene. Pipes up to 2100 mm diameter have been produced out of this material. In India
however, HDPE pipes are available from 21 mm to 400 mm dia. Use of these pipes in small diameters
for internal water supplies has not found ready acceptance because of practical problems like on-site
jointing, and taking out of various connections in plumbing. Their use in larger diameters for
conveyance of water/effluents and in long runs from point to point has been found very suitable and
has been readily accepted by the Public Health Engineering and similar departments in the country.
21.5.4.1.4 Polyethylene pipes: These are normally available in black colour. These are resistant to
most chemicals, except nitric acid, and very strong acids, fats and oils and certain solvents
particularly chlorinated ones. There is a phenomenon called environmental stress cracking which
means that if polyethylene is stressed at normal temperatures and comes into contact with certain
materials then it will crack and eventually fail. The material includes detergents, organic acids,
esters, aldehydes, ketone, amides, nitro compounds, and alcohols (but not beer). The HDPE is worse
than LDPE in this respect.
21.5.4.1.5 Rigid (un-plasticized) PVC Pipes:
i) These are widely accepted for applications such as cold water services internal /external water
supply systems, water mains, rain water system, soil waste piping system, and underground
(sewage pipes) drainage piping system. Rigid PVC is three times as rigid as polyethylene, it is
also much stronger and will withstand much higher pressure for a given wall thickness. Joints
can easily be made in rigid PVC pipes by solvent welding, and a whole range of moulded
matching fittings and specials are available for these pipes. Rigid PVC pipes are normally
available in the following shades: i) White /cream, ii) Light to dark gray, Black
ii) In general, rigid PVC is resistant to most inorganic acids, alkalis and salts, as well as many
organic chemicals. It is quite resistant to most effluents, salt water and plating solutions,
corrosive fumes, soils and the like which lead to its applications over a wide field. The
material is also perfectly safe with potable water whether hard or soft, and in the former case
it tends to retard the formation of scale. Those materials which do attack it include concentrated
oxidizing acids, esters, ketones, aromatic and chlorinated hydrocarbons, organonitro
compounds, organo-amino compounds, lacquer solvents and acetic anhydride.
iii) The pipes shall be reasonably round and shall be supplied in straight lengths with socketed ends.
The internal and external surfaces of pipes shall be smooth & clean, free from grooving and other
defects. The end shall be cleanly cut and square with the is of the pipe. The pipe shall be
designated by external diameter and shall conform, to IS: 4985-1988 revised in all respects.
The dimensions and tolerances of rigid PVC pipes shall be as prescribed.
21.5.4.1.6 Fittings: Fittings used shall be of the same make as that of PVC pipes. Injection moulded
or made in cast iron and shall conform to Indian Standard wherever available.
21.5.4.2 Laying and Jointing of P.V.C. Pipes: (Internal Work):
21.5.4. 2.1 Clamping: The pipes shall be laid & clamped to wooden plugs fixed above the surface
of the wall as shown in Fig. 22. Alternatively plastic clamps of suitable designs, wherever
manufactured, shall be preferred. Provision shall be made for the effect of thermal movement by not
gripping or districting the pipe at supports between the anchors for suspended pipes. The supports
shall allow the repeated longitudinal temperature movement to take place without abrasion. Line or
point contact with the pipe shall be avoided. Heavy components such as metal valves shall be
individually supported.
21.5.4.2.2. Supports: P.V.C. pipes require supports at close interval. Recommended support spacing
for un-plasticised P.V.C. pipes are given in Table 20. This spacing may be increased by 50% for
vertical runs support:
Table-20
Pipe Dia. mm. Support spacing mm
20 700
25 750
32 825
40 975
50 975
It is essential that P.V.C. pipes shall be aligned properly before fixing them on the wooden plugs
with clamps. Even if the wooden plugs are fixed using a plumb line, P.V.C. pipes shall also be
checked for its alignment before clamping. The pipe line will be wavy if the clamps are not fixed
keeping the pipe plumb.
21.5.4.2.3 Connection to a Water Tap: Connection to the water tap shall be made by means of a
G.I. adopter as shown in the Fig. 22 G.I. adopter shall preferably be supplied by the same
manufacturer as that of P.V.C. pipe. In any threaded coupling between P.V.C. and G.I. it is preferable
that P.V.C. is fitted inside the G.I. fitting. If however greater projection in desired, same shall be
achieved by joining a short piece of a G.I. pipe (Nipple) as shown in Fig. 22.
21.5.4.2.4 Connection to a Shower Rose: Shower rose connection shall be of G.I. pipes as shown in
Fig. 22.
21.5.4.2.5 Connection from masonry/ concrete water tank: Solvent cement shall be coated on the
section of the pipe to be embedded in concrete. Fine dry sand and cement mixture shall be sprinkled
uniformly around the pipe. This shall give a rough surface which can be safely embedded in concrete;
water proofing cement shall be used to close the gap properly.
21.5.4.2.6 Measurements: The length shall be measured in running metre correct to a cm for the
finished work which shall include P.V.C. fittings such as bends, tees, elbows, reducer, crossed, plugs,
sockets, nipples and nuts, but exclude, taps valves, etc. All pipes and fittings shall be classified
according to their outside diameters and pressure ratings. Fittings of unequal outside diameter shall
be measured along with the larger diameter pipe.
21.5.4.2.7 Rate: The rate shall include the cost of labour and material in all the operations described
above, except metal pipe used for encasing P.V.C. pipe and anchor blocks, unless otherwise
specified.
21.5.4.3 Laying and Jointing of Un-plasticised P.V.C. Pipes (External Work)
21.5.4.3.1 Handling and Storage:
i) Un-plasticised P.V.C. pipes are of light weight material. Reasonable care shall be taken in
handling and storage of these to prevent damages. On no account the pipes shall be dragged
along the ground. Pipes shall be given adequate support at all times. They shall not be stacked
in large piles, especially under warm temperature conditions as the bottom pipes may distort,
thus giving rise to difficulty in pipe alignment and jointing.
ii) For temporary storage in the field, where racks are not provided care shall be taken that the
ground is level and free from loose stones. Pipes stored thus shall not exceed three layers and
shall be so stacked as to prevent movement. The pipes shall preferably be stored under shade.
iii) For satisfactory service performance of plastic pipes under conditions of use, the following
points must be kept in view while undertaking installation of plastic piping system:
(a) The plastic materials are `thermoplastic' in nature, and must not be used in contact with
hot surfaces (or hot water),
(b) They must be supported at regular intervals for above ground installations,
(c) Allowance must be made, during installation for their expansion, particularly by using
loose clips/clamps,
(d) A range of specials and matching fittings must be identified and their manufacturers/
suppliers listed.
Rigid P.V.C. pipes up to 600 mm dia. have been produced. However, in India these are available
from 21mm to 315 mm.
In these specifications only the use of rigid (un-plasticised) P.V.C. pipes for cold water supplies is
covered.
21.5.4.3.2 Trenches: The trench bottom shall be carefully examined for the presence of hard objects
such as flints, rock projections or tree roots etc. Pipes shall be bedded in sand or soft soil free from
rock and gravel. Back fill 15 cm above the pipe shall also be of fine sand or soft soil. Pipes shall not
be painted. The width of pipe plus 30 cm in case of gravel soils Pipes shall be laid at least 90 cm
below the ground level (measured from surface of the ground to the top of the pipe)
21.5.4.3.3 Jointing:
21.5.4.3.3.1 Solvent Welded Joints (Fig 15) Non heat application Method:
i) In this method, instead of forming a socket on one pipe and an injection moulded socket fitting
or coupler is used, with a provision to take in the pipes at both ends. The solvent cements are
applied on the surfaces to be jointed and the joint is made at ambient temperature. Injection
moulded fittings only shall be used in preference to fabricated fitting, only solvent
recommended by the manufacturers of the pipes shall be used and full load on the joints applied
only after 24 hours. The pipe shall be cut perpendicular to the is of the pipe length with a metal
cuttings saw or an ordinary hand saw with small teeth. Pipe ends have to be beveled slightly
with a beveling tool (Reamer) at an angle of about 30 degree. The total length of insertion
socket (injection moulded socket of couplet) shall be marked on the pipe and checked how far
the pipe end could be inserted into the fitting socket. Attempt shall be made to push the pipe to
the marked distance; if not possible it shall at least be pushed for 2/3 of this distance.
ii) Dust, oil, water grease etc. shall be wiped out with a dry cloth from the surface. Further the
grease should be thoroughly removed with a suitable solvent such as ethylene chloride or as an
alternative the outside surface of the pipe and the inside of the fitting may be roughened with
emery paper.
Generous coatings of solvent cement shall be evenly applied on the inside of the fitting all
round the circumference for the full lengths of insertion and on the outside of the pipe end upto
the marked line with non-synthetic brush of suitable dimension. The pipe shall be pushed into
the fitting socket and held for 1 or 2 minutes as otherwise the pipe may come out of the fitting
due to the slippery quality of cement and the tapering inside bore of the fitting. The surplus
cement on the pipe surfaces shall be wiped out. If the solvent cement has dried up too much or
the tapering of the socket is too steep, jointing will not be proper and pipe will come out of the
fitting.
iii) In summer months joints shall be made preferably early in the morning or in the evening when
it is cooler. This will prevent joint from pulling apart when the pipe cools off at night. Heat
application method for jointing shall not be allowed.
21.5.4.3.3.2 Flanged Joints: For jointing P.V.C. pipes particularly of larger sizes to valves and
vessels and larger size metal pipes where the tensile strength is required the joint is made by the
compression of a gasket or ring seal set in the face of C.I. flange. Flanges solvent welded to the
P.V.C. pipes shall be supplied by the manufacturer.
21.5.4.3.3.3 Rubber Ring Joints: Rubber ring joints can provide a water tight seal but do not resist
pull. As such these may be used only as repair collar and for jointing pipes larger than 110mm. Such
joints may be provided on pipes which are buried in the ground and supported throughout on bedding
so that they are not subjected to movement and longitudinal pull. The material of rubber ring shall
conform to IS: 5382-1985. Where aggressive soils are met with, synthetic rubbers perform better for
jointing. The ring shall be housed in a groove formed in plastic or metallic housing. The rubber is
compressed and makes a seal between the pipe and the housing. The ring shape and the method of
compressing the ring vary considerably in different types of joints. Most joints often require the
application of lubrication paste which shall be procured from the manufacturer of P.V.C. pipes.
Rubber rings shall be supplied by the manufacturers.
The rubber ring joints can be either of:
1. with spigot and socket, or
2. with separate collar pieces having two rubber rings, one at either end.
21.5.4.3.4 Crossing road or drain: (Fig. 16) :Where the pipe crosses a road or a drain, it shall be
through C.I. or R.C.C. pipe.
21.5.4.3.5: Supports for valve and hydrant: Valve and hydrant tees shall be supported as shown in
Fig. 18 so that the torque applied in operating a valve is not transmitted to the pipe line.
21.5.4.3.6.Inspection and Testing :
i) Solvent welded pipe shall not be pressure tested until at least 24 hours after the last solvent
cement joint has been done.
ii) All control valves shall be positioned open for the duration of the test and open end closed
with water tight fittings. The testing pressure on completion of the work shall not be less than
one and a half times the working pressure of the pipes as indicated in Table 16.
iii) Pressure shall be applied either by hand pump or power driven pump. Pressure gauges shall be
correctly positioned and closely observed to ensure that at no time are the test pressures
exceeded. The systems shall be slowly and carefully filled with water to avoid surge pressure or
water hammer. Air vents shall be open at all high points so that air may be expelled from the
system during filling.
iv) When the system has been fully charged with water and air displaced from the line, air vent
shall be closed and the line initially inspected for seepage at joints and firmness of supports
under load. Pressure may then be applied until the required test pressure is reached.
v) Without any additional requirement of make-up-water the test pressure should not fall more
than 0.2kg/sq.cm at the end of one hour test duration.
21.5.4.3.7 Measurements: The length shall be measured in running meter correct to a cm for the
f s h e d work which shall include P.V.C. fittings such as bends, tees, elbows, reducers, crosses, plugs,
sockets, nipples and nuts, but exclude, taps, valves, etc. unless otherwise specified. All pipes and
fittings shall be classified according to their outside diameters and pressure ratings. Fittings of
unequal outside diameter shall be measured along with the larger diameter pipe.
21.5.4.3.8 Rate: The rate shall include the cost of labour and material in all the operations described
above except excavation in trenches, sand filling around the pipes, metal pipes used for encasing
P.V.C. pipe and anchor blocks, unless otherwise specified.
21.5.5 Copper Pipes:
21.5.5.1 Materials:
21.5.5.1.1 Copper plumbing is used, mainly for concealed plumbing purposes in toilets/bathrooms and
kitchens i.e. for 15 mm (½ inch) plumbing pipes. Copper plumbing material shall conform to
following specifications:
1) Seamless copper tubes to BS: 2871 Part -1 (Tubes for water, gas and sanitation).
2) Copper capillary fittings to BS: 864 Part -II.
3) Bronze capillary fittings to BS: 1400 LG2 and ISO-1438.
4) Solder to BS: 215 G and ISO: 2021
21.5.5.1.2 The copper pipes dimensions are 15 mm O.D. x 0.7 mm thick for hard pipes and 15 mm
O.D. x 0.9 mm thick for annealed or bending quality pipes. Other sizes may be used as per
manufacturer's specification and as agreed upon by the Engineer-in-Charge.
21.5.5.2 Fixing: Fittings recommended for use are copper capillary fittings and bronze capillary
fittings for threaded joints. Brass fittings are not recommended since brass is prone to
dezincification.
Solders used for soldering copper pipes and fittings should be lead-free as lead solders can cause
toxicity, Lead free Tin/Silver solders may be used.
21.5.5.3 Measurements: The lengths shall be measured in running metre correct to a cm for the
finished work, which shall include copper pipes and copper fittings including soldering and all
cuttings and wastage.
21.5.5.4 Rate: The rate shall include cost of labour and material involved in above work. The rate
shall include the cost of cutting chases, holes in walls & floors and making good the same.
21.6 Water Meter (Domestic Type):
21.6.1 Materials:
21.6.1.1 Water meters (Fig.2):Water metre conforming to IS: 779-1994 shall be selected according
to the flow to be measured and not necessarily to suit a certain size of main. The following points shall
govern the selection of meters.
a) The maximum flow shall not exceed the nominal capacity of the meter.
b) The continuous flow shall be not greater than the continuous running capacity rating.
c) The minimum flow to be measured shall be within minimum starting flows.
21.6.1.2 Inferential water meter has the same accuracy as the semi-positive type at higher flow; it
passes unfiltered water better than a semi-positive meter and is lower in cost.
21.6.1.3 Special care is necessary in selecting the most suitable meter where large rates of flow may
exist for short periods. The normal working flow shall be well within the continuous running capacity
specified in IS: 779, as high rate of flow over a short period may cause excessive wear of the meter
chosen, if it is too small for the duty.
21.6.1.4 Owing to the fine clearance in the working parts of meters, they are not suitable for
measuring water containing sand or similar foreign matter, and in such cases a filter or dirt box of
adequate effective area shall be fitted on the upstream side of the meter (Fig. 2). It shall be noted
that the normal strainer fitted inside a meter is not a filter and does not prevent the entry of small
particles such as sand.
21.6.1.5 Water meters and their parts, especially parts coming in continuous contact with water shall
be made of materials resistant to corrosion and shall be non-toxic and non-training. Use of dissimilar
metals in contact under water shall be avoided as far as possible in order to minimize electrolytic
corrosion.
21.6.1.6 Body: The body of water meter shall be made either from Type A or Type B materials as
specified below:
type A: The body of water meters shall be made from bronze, brass or any other corrosion resistant
material e.g. Grey iron castings, blackheart malleable iron, spherodial graphite iron casting.
type B : The body of the water meters shall be made from suitable plastics.
Note: Plastics shall have following qualities:
i) It shall not affect the potability of water.
ii) Elongation, 15 percent, Min. on a specimen of lengths 150 mm (for procedure of
determination of elongations).
iii) Water absorption on immersion for 24 hours should not exceed 0.6 percent by weight (for
procedure of determination of water absorption).
iv) Shall be capable of withstanding temperature up to 55°C without undergoing deformation or
softening and becoming unsatisfactory in performance.
21.6.1.7 Registration Box: Registration box of water meters of Type A shall be made from bronze,
brass, aluminum alloy or suitable plastics. Registration box of water meters of Type B shall be made
from suitable plastics or aluminum alloys. The registration box of dry dial water meters shall be
provided with one or two escape holes for minimizing the accumulation of condensed water.
21.6.1.8 Cap: Cap of water meters of Type A shall be made from brass, bronze, aluminum alloy or
suitable plastic. The cap of water meters of Type B shall be made of plastics or aluminum alloy.
Where the cap and registration box are integral, the materials for cap may be the same as used for
registration box. The cap shall be so designed and fixed to the registration box as to avoid entry of
water and dirt. The transparent window which covers the dial shall be inserted from the inside into
the cap. The protective lid shall be secured by a robust hinge or other suitable method of robust
construction.
21.6.1.9 Locking arrangement: Provision shall also be made to lock the lid. The provision shall be
such that the lock is conveniently operated from the top. Where the provision is designed for use in
conjunction with padlocks, the hole provided for padlocks shall be of a diameter not less than 4 mm.
21.6.1.10 Wiper: Where so required for dry-type water meters the transparent window covering the
dial shall be provided with a wiper on the inner side for wiping off condensed water.
21.6.1.11 Connecting Arrangements: The meter casing shall be fitted in the pipe line by means of
two conical or cylindrical nipples or tail pieces with connecting nuts which shall be provided with
each meter. The nipples of water meters of Type A shall be made of the same materials as specified
for body. Nipples of water meters of Type B shall be made of the same materials as specified for the
body where they are integral with the body of the water meters; where they are separate, they shall
be made of malleable iron, galvanized steel or suitable plastics. The nuts shall be of the same material
as used for nipples. The internal diameter of the nipple where it connects the pipe line shall be equal
to that corresponding to the nominal size of the meter. The threads on the connection shall conform
to IS: 779-1985. The minimum lengths of the threads shall be as given in Table 21.
Table-21: Minimum Length of Thread (All dimensions in millimeter)
Nominal size of meter Minimum length of thread
15 13
20 14
25 16
40 20
50 25
21.6.1.12 Strainers: Water meters shall be provided with strainers. Strainers shall be of a material
which is not susceptible to electrolytic corrosion. They shall be of plastics or other corrosion-
resistant materials for both Type A and Type B meters. They shall be rigid, easy to remove and
clean, and shall be fitted on the inlet side of the water meter. It shall be possible to remove and clean
the strainer in such a way as not to permit disturbing the registration box or tampering with it. The
strainer shall have a total area of holes not less than twice the area of the nominal inlet bore of the
pipe to which the meter is connected, however, in the case of meters provided with internal strainer
involving opening of the registration box for cleaning, an additional external strainer shall be fitted
on the inlet side satisfying the above requirements.
Overall dimension of water meters shall be as specified in Table 22.Screw & studs shall be of
brass or other corrosion resistant material.
Table-22: Overall Dimensions of Water Meters
Nominal size of Overall length Overall width. Overall height
Meter including nipples (Max.) (Max.)
pples
15 250 100 180
20 290 130 240
25 380 170 260
40 430 210 300
50 470 270 300
(All di dimensions in mm ) Tolerance on the overall length shall ± 5 mm. 21.6.1.13 Capacity on
Short period rating or nominal capacity: The nominal capacity of the
water meters shall be as specified in Table 23. The meter shall be capable of giving minimum
discharge as stated in the table without the head loss exceeding 10 m within the meter.
21.6.1.14 Yarn (Spun) :
Spun yarn shall be of clean hemp and of good quality. It shall be soaked in hot coal tar or bitumen
and cooled before use.
Table-23: Nominal Capacity of Water Metre
Discharge per hour
Nominal size of meter (mm) Semi positive Type (Litre) Inferential Type (litre)
15 2000 2500
20 3400 3500
25 5500 5500
40 10000 16000
50 15000 23000
21.6.2 Instal Installation ofWater Meter (Fig.2):
21.6.2.1 The G.I. line shall be cut to the required length at the position where the meter and stop
cock are required to be fixed. The ends at of pipe shall then be threaded. The meter and stop cock shall
be fixed in position by means of connecting pipes, G.I. jam nut and socket etc. A stop cock shall be
fixed near the inlet to the water meter. The paper disc inserted in the nipples of the meter shall be
removed and the meter installed exactly horizontal or vertical in the flow line in the direction shown
by the arrow cast on the body of the meter. Care shall be taken that the factory seal of the meter is
not disturbed. Wherever the meter shall be fixed to newly fitted pipe line, the pipe line shall have to
be completely washed before fitting the meter. For this purpose a piece of pipe equal to the length of
the meter shall be fitted in the new pipe line. The water shall be allowed to flow completely to wash
the pipe line, and then the meter installed as described above by replacing the connection piece.
21.6.2.2 Testing of Joints:Testing of joints shall be done as described in Cl. 21.5.1.2.8
21.6.3 Measurements: The work of fixing meters and stop cocks shall be enumerated according to
the diameters.
described above, but excluding the cost of stop cock and water meter.
21.7 Water Storage Tanks:
21.7.1 Polyethylene Water Storage Tanks (Fig.29):
21.7.1.1 Material: Polyethylene water storage tanks shall conform to IS : 12701-1996. Polyethylene
used for manufacture of tanks and manhole lids may be of high density (HDPE), low density (LDPE)
or linear low density (LLDPE) and shall conform to IS: 10146-1982. Polyethylene shall be
compounded with carbon black so as to make the tank resistant to ultra violet rays from the sun. The
percentage of carbon black content in polyethylene shall be 2.5± 0.5 and it shall be uniformly
distributed. The materials used for the manufacture of tank, manhole lid and fittings shall be such
that they neither contaminate the water nor impart any taste, colour, odor or toxicity to water.
21.7.1.2 Manufacture and Finish: The tanks shall be manufactured by rotational moulding process.
Each tank and the manhole lid shall be single piece having arrangement for fixing and locking the
manhole lid with the tanks. Excess material at the mould parting line and near the top rim shall be
neatly cut and finished. The internal and external surface of the tanks shall be smooth, clean and free
from hidden internal defects like air bubbles, pit and metallic or other
foreign material inclusion. Capacity of the tank, minimum weight of the empty tank (without
manhole lid) and the manufacturer brand name shall be embossed on the top surface of the tank near
manhole.
21.7.1.3 Shape, Size and Capacity: The tank shall be cylindrical vertical with closed top having a
manhole. Diameter and height of the tank of various capacities shall be as per manufacture's
specifications and a tolerance of ±3 percent shall be permitted on these dimensions. Net capacity of
the tank shall be net volume of water contained between the lowest level of the inlet and lowest
specified level. Net capacity of the tank in litre shall be specified. Extra capacity, if any, shall be
ignored.
21.7.1.4 Weight and Wall Thickness: Minimum weight of the empty tank (exclusive of manhole lid
fittings) and minimum wall thickness of top, bottom and sides shall be as specified in Table 24. Wall
thickness shall be checked beyond 150 mm of the edge where the direction of the plane of tank
surface changes.
Table - 24
S. No. Capacity Minimum Wall thickness- Minimum Weight of
(litre) mm empty Tank-(kg)
1 200 ()
4.4 7.8
2 300 4.4 9.0
3 400 5.5 15.0
4 500 6.0 18.0
5 700 6.6 23.5
6 1000 7.0 33.0
7 1250 7.0 40.0
8 1500 7.0 47.0
9 1700 7.0 54.0
10 2000 8.2 64.0
11 2500 8.2 81.0
12 3000 8.8 96.0
13 4000 10.4 138.0
14 5000 10.7 191.0
15 6000 10.7 209.0
21 7500 10.7 250.0
17 10000 11.5 363.0
18 15000 11.5 550.0
19 20000 13.2 814.0
Note: Gross capacity of the tanks shall be at least 5 percent in excess of the minim umnet capacity.
21.7.1.5 Installation and Fittings: The flat base of the tank shall be fully supported over its whole
bottom area on a durable rigid flat and level platform sufficiently strong to stand without deflection
the weight of the tank when fully filled with water. Depending upon the capacity and
location tanks may be suitably anchored as per the directions of the Engineer-in-Charge. For inlet,
outlet, and other connections fully threaded G.I, HDPE or PVC connections with hexagonal check
nuts and washers on either side of the tank wall shall be provided. Holes for threaded connections
shall be drilled and not punched. Pipes entering or leaving the tank shall be provided with unions and
suitably supported on a firm base to avoid damage to the tank walls.
21.7.1.6 Manhole lid: The lid shall rest evenly and fit over the rim of the manhole so as to prevent
the ingress of any foreign matter into the tank. The lid shall be provided with suitable arrangement
for locking it with the tank.
21.7.1.7 Hoisting: The hoisting of tanks into position, as directed by the Engineer-in-Charge, shall
be carried out so that no part of the tank or of the structure is damaged in the operation. The tank
shall be installed in position truly level. The supports for the tanks shall be provided as ordered and
shall be measured & paid for separately.
21.7.1.8 The tank and its components shall conform to the local bye-laws for prevention of mosquito
menace.
21.7.1.9 Measurements: Dimensions shall be measured to the nearest cm. and weight of the empty
tank shall be recorded to the nearest 100g. Capacity of the tank as shown in Table 24 shall be counted
in numbers according to the capacity for the complete job.
21.7.2 Masonry Water Storage Tanks on Terraces (Fig.17):
21.7.2.1 Tank shall be located nearest to the fitting to which water is to be supplied so that long
horizontal length of G.I. delivery pipe is avoided. It should not be visible, as far as possible, from the
main road and compound of the buildings. The over flow pipe shall discharge at a convenient and
visible point so that it does not damage the building and does not prove a nuisance, should the tank
go out of order. A bottom clearance of not less than 30 cm shall be provided to permit easy clearance
of the terrace below the tank.
21.7.2.2 The suggestive sizes of tanks, with a free board of 15 cm are given as under in Table 25.
Net capacity (litre) Internal size (L x B x H) ( cm)
L B H
300 70 70 75
600 90 90 90
900 105 105 90
1200 120 120 100
1400 120 120 115
1800 120 120 120
2100 130 130 125
Where more than anone tank is to be provided atone place , a larger ger t ankof combined net capacity
may be built with suitable internal partitions to achieve an economical design.
21.7.2.3 All the fittings except float valve and mosquito proof coupling shall be fixed during
construction of slab and side walls as the work proceeds and no subsequent piercing of tank slab and
walls shall be permitted.
21.7.2.4 Bottom Slab:
The bottom slab of the tank shall be of reinforced cement concrete 1: 1.5:3 (1 cement: 1.5 coarse
sand: 3 stone aggregate 20 mm nominal size). This shall be supported on structurally adequate
supports of brick masonry walls/RCC beams or rolled steel section and shall be given a mild slope
towards scour pipe outlet. The slab thickness shall be 10 cm for sizes given above; reinforcement
detail shall be as given in (Fig.17). For sizes other than those given above, or a combination of tanks,
the structural details, shall be supplied by the Engineer-in-Charge. When the slab is supported on
brick masonry walls, the top to the walls shall be provided bearing plaster as for suspended floors.
When the slab is supported on RCC beams this can be either integral or simply supported as the
situation may warrant. A slab with simply supported conditions on the beam is preferable. If it is to
be simply supported, the beam top shall be rendered and finished with a coat of neat cement and
provided with a thick coat of lime wash.
21.7.2.5 Walls: The walls shall be of brick masonry in cement mortar 1:3 (1 cement: 3 coarse sand)
of class 75 bricks. First course of brick masonry shall be laid immediately after concreting of the
base slab i.e. when the concrete is still green. The remaining masonry shall be raised and completed
within a week of laying the slab.
21.7.2.6 Fittings:
21.7.2.6.1 Scour Pipe: A 40 mm dia. G.I. pipe, joined with 40 mm G.I. `T' to prevent slipping, shall
be embedded inside wall to serve as a scour pipe. The end of this scour pipe shall be provided with
a G.I. socket and plug. Details of scour pipe shall be as shown in Fig. 17.
21.7.2.6.2 Delivery Pipe: Delivery pipe shall be of 20 mm dia. fixed with G.I. tee to prevent slipping.
This shall be fixed at least 30 mm above the bottom slab of the tank to prevent silt at the bottom of
tank entering it.
21.7.2.6.3 Over Flow Pipe: This shall be of 25 mm G.I. socket at the internal end and shall be fixed
at the free board level of the tank at a convenient point to drain out overflow. The length of pipe
including G.I. socket shall be 30 cm. The outer end of the overflow pipe shall be threaded.
21.7.2.6.4 Inlet Pipe: This shall be 20mm G.I. Pipe with 20 mm socket at internal end and socket or
elbow at the outer end as required. It shall be fixed at the free board level.
21.7.2.6.5 Mosquito Proof Coupling: Mosquito Proof coupling of rigid P.V.C. or any other suitable
material as per approved design and approved by the Engineer in charge with sieve No. 425 dia.
perforations shall be provided to the over flow pipe.
21.7.2.6.6 Ball Valve: Ball valve with a plastic float of specified size and pressure shall be provided
to each tank. The ball valve shall be of brass. It shall be securely fixed to the tank in continuation of
the inlet pipe and set in such a position that body of the ball valve does not submerge when the tank
is full up to water line. The ball valve shall be so adjusted as to limit the level of the water in the
tank at 25 mm below the lip of overflow pipe. Specification of ball valve shall be as given in
C1.21.8.4
21.7.2.6.7 Mosquito Proof C.I. hinged cover: Each tank shall be provided with 425 mm dia.
standard mosquito proof C.I. hinged cover weighing 8.15 kg. and frame weighing 6.80 kg. with
locking arrangement. The frame shall be fixed to the top slab while pre-casting the same. This shall
be provided in one corner convenient to the position of the ball valve as per the direction of the
Engineer-in-Charge.
21.7.2.7 Plaster:
21.7.2.7.1 The base slab and the side walls will be plastered from inside with 15 mm thick cement
mortar 1:3 (1 cement: 3 fine sand). This plaster shall be done within one week of construction of the
side walls. The junctions of the wall and the base slab in the interior and those between walls shall be
rounded with mortar 1:3 while doing internal plaster all the joints of the inlet, delivery, scour and
over flow pipes shall be made completely leak proof.
21.7.2.7.2 A coat of neat cement punning shall be applied to the plaster on the surface of the walls
under the base slab on the inner side of the tank. This plaster and neat cement punning shall also be
carried over the top of the side of the tank. This plaster and neat cement punning shall also be carried
over the top of the side walls of the tank to serve as bearing plaster for the top side.
21.7.2.7.3 The external wall of the tank shall be plastered with 12 mm thick cement mortar 1:4 (1
cement: 4 fine sand).
21.7.2.8 Curing: Curing of R.C.C. and brick work and plastering shall be done as per norms. The
tank shall be filled with water after 28 days of completion of brick work for half the capacity and to
the full level a day thereafter. In order to prevent cracks developing in concrete due to shrinkage, the
water in the tank shall be kept till such time the tank is put into use when it shall be properly scoured.
21.7.2.9 Top Slab: The top slab shall be of pre-cast reinforced cement concrete of 1:1½:3 mix 5 cm
thick. The details of reinforcement shall be as per design. The size of the top slab shall be such that
it projects by 15 mm on all sides beyond the external finished faces of the tank wall. The top of the
slab shall be rendered smooth while casting. The frame of the C.I. hinged cover shall be kept ready
before hand so that it is embedded in concrete while casting the slab.
21.7.2.10 Connection from masonry water tank: Solvent cement shall be coated and fine dry sand
and cement mixture shall be sprinkled uniformly on the section of the pipe to be embedded in
masonry.
21.7.2.11 Testing: The tank shall be tested for water tightness at full supply level. The requirement
of the test shall be deemed to be satisfied, if the external faces show no sign of leakage and remain
apparently dry over the period of observation of seven days, after allowing a seven day period for
absorption after filling. If the structure shows signs of wetness, necessary rectification shall be
carried out till it becomes leak proof after further leasing.
21.7.2.12 Measurements: Water storage tanks shall be enumerated according to the size.
21.7.2.13 Rate: Unless otherwise specified the rate shall include the cost of materials and labour
involved in all the operations described above including centering and shuttering etc. but excluding
the supporting structure.
21.7.3 R.C.C. Water Storage Tanks:
21.7.3.1 These tanks shall be cast in situ, circular/rectangular in shape and of the capacity as directed
by the Engineer-in-Charge. These shall be as per approved design and drawing.
The mix of R.C. C. shall not be less than M 20 for members either coming in contact with water or
enclosing the water surface.
Minimum cover and other design and drawing details shall conform to IS: 3370-part 1 1965, IS:
3370-part II 1965.
21.7.3.2 Fittings: Clause 21.7.2.6 shall apply.
R.C.C. Water Storage Tank shall be measured under respective items of works.
21.7.3.4 Rate:
The rate shall include the cost of materials and labour involved in above operations and shall be
paid under respective items of work.
21.8 Valves:
21.8.1 Sluice Valves - Brass/Gun Metal (Fig.2):
21.8.1.1 Material: The sluice valves are used in a pipe line for controlling or stopping flow of water.
These shall be of specified size and class and shall be of inside non raising screw type up to 300 mm
size and raising or non-raising screw type above 300 mm with either double flange or double socket
ends and cap or hand wheel. These shall in all respects comply with the Indian Standard Specification
IS: 780-1984 for valves 50 to 300 mm size and for valves above 300 mm size. Class II sluice valves
are used for maximum working pressure of 15 kg/sq.cm (150 metre head).
The body, bonnet, wedge gate and stuffing box shall be of good quality gray cast iron, The spindle
of bronze, the nut and valve seats of leaded tin bronze. The bodies, spindles and other parts shall be
truly machined with surface smoothly finished. The area of the water way of the fittings shall be not
less than the area equal to the nominal bore of the pipe.
The valve shall be marked with an arrow to show the direction of turn for closing of the valve.
21.8.1.2. Installation of Sluice Valve: The valve shall be fully examined and cleared of all foreign
matter before being fixed. The fixing of the valve shall be done by means of bolts, nuts and 3 mm
rubber insertions or chemically treated compressed fiberboard 1.5. mm minimum thickness and of
weight not less than 0.183 gm / sqcm., with the flanges of spigot and the socketed tail pieces drilled
to the same specification in case of spigot and socketed pipes and with flanges in case of flanged
pipes. The tall pieces shall conform to IS: 1938.These shall be jointed of the pipe line by means of
lead caulked joints.
21.8.2 Non-return Valve or Check valve: Non return valve or check Valve-Brass (Fig. 2):
A non-return valve permits water to flow in one direction only and is provided on the ascending part
of the main to check return flow. The non-return valve shall be of brass and shall be of horizontal or
vertical flow type as specified.
The valves shall be of quality approved by the Engineer-in-Charge and shall have the weight
specified in Table 26 with a tolerance of 5 percent.
21.8.2.2 Non-Return valve or check valve-Gun metal (Fig.2): Specification description in
21.8.2.1, shall apply except that non-return valve shall be of gun metal and shall generally conform
to IS: 778-1984.
Table-26 : Weights of Non-Return / Check Valves
mm Horizontal type (kg.) Vertical type (kg.)
Diameters ()
15 0.30 0.25
20 0.55 0.36
25 0.90 0.75
32 1.25 0.90
40 1.70 1.20
50 2.90 1.45
65 5.25 2.15
80 7.70 4.10
21.8.3 Full way valve:
21.8.3.1 Full Way Valve with Wheel--Brass: Full way is a valve with suitable means of connection
for insertion in a pipe line for controlling or stopping the flow. The valve shall be of brass fitted with
a cast iron wheel and shall be of gate valve type conforming to IS: 778-1984 opening full way and
of the size as specified. The valves shall be of best quality as approved by the engineer in charge and
shall approximately have the weights specified in Table 27 with a tolerance of 5 percent.
21.8.3.2 Full Way Valve with Wheel - Gun Metal: Specification described in the clause 21.8.3.1
shall apply except that the full way valve shall be of gun-metal and of the size .specified, these shall
generally conform to IS:778-1984 and their weights shall be as specified in Table 27.
Table-27: Weights of Full Way Valves
Size( mm) Flanged ends (kg.) Screwed ends (kg.)
15 1.021 0.567
20 1.503 0.680
25 2.495 1.077
32 3.232 1.559
40 4.082 2.268
50 6.691 3.232
65 10.149 6.804
80 12.381 8.845
21.8.4 Copper Alloy Float/ Ball Valves: The float Than valve shall be of brass or Gunmetal as
specified conforming to IS: 1703-1989 (Fig. 1). The ball valve shall be of following two classes:-
a) High Pressure: Indicated by the abbreviation 'HP' for use on mains having pressure of 1.75
kg/sq. cm. and above. These shall remain closed at a test pressure of 10.5 kg/sq.cm.
b) Low Pressure: indicated by the abbreviation `LP' for use on mains having a pressure up to
1.75 kg/sq.cm. These shall remain closed at a test pressure of 3.5 kg/sq.cm.
The float valve shall be of following nominal sizes 15 mm, 20 mm, 25 mm, 32 mm 40 mm and 50
mm. The nominal size shall correspond with the nominal bore of the inlet shanks, Polyethylene floats
shall conform to IS: 9762-1994. Diameter of spherical floats are specified in Table 28.
Table-28
S. Nominal size of ball valve
No.
15 mm 20 mm 25 mm 32 mm 40 mm 50 mm
1 Diameter of spherical 127 152 203 229 254 305
Float (mm) High
pressure
2 Low pressure 114 127 178 203 203 251
3 Minimum weight of ball 283 446 823 1445 1589 1852
valve including back nut,
body and piston (gm)
21.8.4.1 Polyethylene Float:It shall conform to IS: 9762. 21.8.5 Other Valves:
21.8.5.1 Fancy Stop Valve: These are available in nominal sizes of 15 and 20 mm. Inlet and outlet
connection threads shall have internal or external threads. Typical fancy stop valve is shown at (D)
and (E) in (Fig.23) It is also called open stopcock as opposed to concealed stopcock. (IS: 8931-
1993)
21.8.5.2 Angle Stop Valve: It is a valve with inlet and out-let at right angles to each other. It is
provided to stop the supply of water to geyser, flushing cistern, and the wash basin, etc.: so that
necessary servicing of water fittings or appliances can be carried out without having to shut off
complete water supply of the house. Typical angle stop valve is shown at (F) in (Fig.23) (IS: 8931-
1993).
21.8.5.3 Concealed Stop Valve: It is used to regulate the supply of hot and cold water to shower,
mixer, etc. in a concealed plumbing line. It is shown at (C) in (Fig.23) It has internal threads only. (IS:
8931 - 1993)
21.9 Cocks: Copper Alloy Bib Cock and Stop Cock (Fig. 2, Fig.28): A bib cock (bib tap) is a
draw off tap with a horizontal inlet and free outlet and a stop cock (stop tap) is a valve with a suitable
means of connections for insertion in a pipe line for controlling or stopping the flow. They shall be
of specified size and of screw down type and conform to IS: 781-1984 or IS: 8931-1978. The closing
device shall work by means of a disc carrying a renewable non-metallic washer which shuts against
water pressure on a seating at right angles to the is of the threaded spindle which operates it. The
handle shall be either crutch or butterfly type securely fixed to the spindle. Valve shall be of the loose
leather seated pattern. The cocks (taps) shall open in anti-clock wise direction. The bib cock and
stop cock shall be polished bright. The minimum finished weight of bib tap (cock) and stop tap
(cock) shall be as specified in Table 29.
Table - 29 : Minimum Finished weight of Bib Cock/Stop Cock
Size (mm) wt
Minimum
Bib cock finished .(kg)
Stop cock
8 0.25 0.25
10 0.23 0.35
15 0.40 0.40
20 0.75 0.75
In case these are required to be nickel plated, the plating shall be of the first quality with a good thick
deposit of silvery whiteness capable of taking high polish which will not easily tarnish or scale.
21.9.1.1 Plastic Bib Tap (IS: 9763-1981) : They are available in sizes of 15 and 20 mm and shall
be tested under and internal hydraulic pressure of 2 MPa for a duration of 5 minutes (min.).
21.9.2 Pillar Cock (Fig.27a, 27b): A pillar cock (tap) is a draw-off tap with a vertical inlet and an
uplifted or a horizontal free outlet. The nominal size of pillar tap shall be 1 5 = and 20mm.
Pillar taps shall have screwed shanks not less than 50 mm long from the underside of the flange and
shall be provided with back nut. These shall comply to IS: 1795-1982 or IS: 8934-1978.
21.9.2.1 Quarter-turn Tap (Fig.27b): Modern taps use a system of discs to open and close the
water supply. The lower disc is fixed and the top disc can be turned through 90 degrees as illustrated
in Figure 11.21. When the two ports or holes in the top disc coincide with those in the bottom fixed
disc the water flows. A lever when turned or depressed operates a spindle to effect the necessary
quarter turn to open the tap for water to flow. The advantage of these taps is that the polished ceramic
discs will last as long as the tap itself without need of replacement.
21.9.2.2 Self-closing Taps (IS: 1711 - 1970): A self-closing tap is a draw-off tap, which remains in
the open position so long as a lever handle or a push button is kept pressed in and closes when the
lever handle or push button is released. It may incorporate a device, which closes the tap even without
the release of line handle after a fixed quantity of water is discharged; these are available in two
nominal sizes of 15 and 20 mm. It is tested under an applied hydraulic pressure of 2 Mpa minimum
for a duration of 2 minutes (minimum).
21.9.2.3 Combination Tap Assemblies: These are of the following two types (IS: 8931 - 1993):
21.9.2.3.1 Pillar Mounting Combination Tap Assembly: It has a vertical inlet and a nozzle
arranged to discharge in a downward direction (such as, single hole, two hole and three hole
combination tap assemblies for wash basin) and is suitable for mounting on a horizontal surface as
shown in (Fig.24).
21.9.2.3.1 Wall Mounting Combination Tap Assembly: It has a horizontal inlet and a nozzle
arranged to discharge in a downward direction (such as, bath and sink combination tap assemblies)
and is suitable for mounting on a vertical surface (wall) as shown in (Fig.25).
The basic requirements of casting are the same as for a stop valve.
21.9.2.4 Mixing Valve (IS : 1701 - 1960): It is an appliance into which hot and cold water entering
through separate valve ports are mixed in a specially formed chamber and then diverted through a
nominal range by the operation of a single handle. Mixing valves are sizes 15, 20 and 25 mm. A
typical mixing valve is illustrated in (Fig.26). The size of a mixing valve shall be
denoted by the nominal size of the bore of the inlets which shall always be of equal diameter.
21.9.3 Shower Rose: Shower rose shall be of chromium-plated of 100 mm size when measured
across the diameter; the inlet connection shall be 15 or 20 mm as required. The number of holes in
the rose shall be 145 + 10. The diameter of each hole in the rose shall be 1.2 mm with + 10 percent
tolerance. The holes shall be suitably spaced so as give a uniform shower.
21.9.4 Diverter: is a combination tap assembly for concealed fitting with built-in non - return valve,
a 4-way diverter can divert water to either bath spout, or shower or flexible cord telephone shower
from its closed position .
21.9.4.1 Flow straightening and Aerating Device: consists of molded plastic fitted at the outlet
with in the nozzle of the tap. They incorporate multiplicity of orifices in a perforated plate and should
be easily removable for cleaning purposes. When aerators are fitted there is usually a reduction of
flow.
21.9.5 Drinking Water Fountain (IS: 1700-1973): It discharges water in a jet for direct drinking
purposes and is installed in schools, parks and other public places. The jet is preferably inserted at
the side. The arrangement shall be such that, when the fountain is operating without hindrance under
normal conditions, the stream falls appreciably within area of waste outlet.
The jet of the fountain shall issue from a nozzle, which shall be set at an angle from the vertical so
as to prevent the backflow of water in the jet of the orifice. The nozzle shall be circular in cross-
section and the length of the nozzle shall not exceed 2.5 times the diameter of the supply pipe and
the diameter of the nozzle end shall be protected by a corrosion-resistant guard to prevent the mouth
and nose of persons using the fountain from coming in contact with the nozzle.
21.9.5.1 Measurements: All valves cocks shall be enumerated according to their types & size.
21.9.5.2 Rate: Unless otherwise specified the rate shall include the cost of material and labour
involved in all the operations described above.
21.10 Fire Hydrant:
21.10.1 Fire Hydrants (Fig.1): The hydrants shall be of spindle type with 65 mm outlet combined
with sluice valve, unless otherwise specified. The hydrant shall conform to IS: 909-1992 and shall
consist of the following components:
(a) One sluice valve class 1 type, conforming to IS: 780-1984.
(b) A duck foot bend,
(c) A 65 mm male coupling instantaneous pattern; and
(d) Cast iron cap permanently secured to the duck foot bend by means of a chain. Where the fire
service requirement of coupling differs from the above, the requisite coupling shall be
provided at no extra cost.
The body and cover shall be of good quality cast iron, spindle of bronze and the nut and the valve seat
of leaded tin bronze. The bodies, spindle and other parts shall be truly machined with surface smoothly
finished.
21.10.2 Installation of the fire hydrants: The hydrant shall be fully examined and cleaned of all
foreign matter before being fixed. The fixing shall be done on the water main which shall be of
minimum 80 mm dia. The flanged end of the hydrant shall be fixed to the flanged outlet of a tee in
the water main by means of bolts, nuts and 3 mm rubber insertion of chemically treated
compressed fiber board 1.50 mm minimum thickness and of weight not less than 0.183 gm. per
sq.cm. This can also be fixed by means of flanged tall piece which may be connected to the water main
by C.I. specials.
21.10.3 Measurements: Fire hydrant shall be enumerated.
21.10.4 Rate: Unless otherwise specified the rate shall include the cost of materials and labour
involved in all the operations described above against relevant item of work.
21.11 Pillars and Posts for Hydrants: 21.11.1
R.C.C. Post for Hydrant (Fig 18):
21.11.1.1 Hydrant: The R.C. C. post for a hydrant shall be of the size 25x25 cm at the bottom and
15 x 15 cm at the top. A pipe of specified size shall be provided during casting in the centre of the
post. The post shall be of 170 cm height, out of which 60 cm shall be kept below ground level.
21.11.1.2 Earthwork: The excavated earth shall be disposed of as directed by the Engineer-in-
Charge.
21.11.1.3 Reinforced cement concrete work: The post shall be made of cement concrete 1:2:4 (1
cement: 2 coarse sand: 4 graded, stone aggregate 12.5 mm nominal size) and reinforced with 4 Nos.
10 mm dia. bars at corners. 6 Nos. squares stirrups of 6 mm diameter bars shall be provided for
keeping the vertical reinforcement in position.
21.11.1.4 Finishing: The R.C.C. post shall be plastered with 6 mm thick cement plaster with c.m.
1:4 (1 cement: 4 fine sand) on all the exposed surfaces and up to a depth of 15 cm below ground
level. The plastered surface shall be finished with a floating coat of neat cement.
21.11.1.5 Measurements: The R.C.C. posts shall be enumerated.
21.11.1.6 Rate: The rate shall include the cost of labour and materials required for all the operations
described above including providing and embedding of the pipe in the post.
21.11.2.1 Masonry Pillar for Hydrant (Fig 18):
21.11.2.1.1 Pillar: The section of the pillar shall be one and half brick square or one brick square as
specified. The height of the pillar above ground shall be 110 cm.
21.11.2.1.2 Earth Work: The excavated earth shall be disposed of as directed by the Engineerin-
Charge.
21.11.2.1.3 Concrete Work: Foundation concrete shall consist of 15mm thick cement concrete
1:5:10 (1 cement :5 fine sand: 10 graded stone aggregate 40 mm nominal size)
21.11.2.1.4 Brick Work: The masonry shall be with bricks of class designation 75 in cement mortar,
1.4 (lcement: 4 coarse sand). The brick masonry shall be kept up to a height of 100 cm above ground
level. The hydrant pipe shall pass through the pillar or shall be fixed to the pillar with G.I. holder
bat clamps as directed by the Engineer-in-Charge.
21.11.2.1.5 Finishing: The pillar masonry shall be plastered with 12 mm cement plaster 1:4 (1
cement: 4 fine sand) finished with a floating coat of neat cement. The top of the masonry pillar shall
have 10 cm thick cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 12.5 mm
nominal size) coping with edges rounded off. The concrete of the coping shall be rendered smooth
with neat cement.
21.11.2.1.6 Measurements: Hydrant pillars shall be enumerated according to the size.
21.11.2.1.7 Rate: The rate shall include the cost of labour and materials required for all the
operations described above except providing and fixing of pipe which shall be paid separately.
21.11.2.2 Masonry Platform for Stand Post (Fig 18:):
21.11.2.2.1 Platform: The internal dimension of the platform shall be 120 x 120 cm or 90 x 90 cm
as specified.
21.11.2.2.2 Earth Work: Earth work shall be done true to dimensions as shown in the drawing.
The excavated earth shall be disposed of as directed by the engineer-in-Charge.
21.11.2.2.3 Concrete Work: Foundation for the platform shall consist of 10 cm thick cement
concrete 1:5:10 (1 cement: 5 coarse sand: 10 graded stone aggregate 40 mm nominal size).
21.11.2.2.4 Kerbing: The kerbing for the platform shall be of half brick thick with bricks of class
designation 75 in cement mortar 1:4 (1 cement: 4 fine sand). The kerb shall be plastered on top and
sides with 12 mm thick cement plaster with C.M. 1:4 (1 cement: 4 fine sand) finished with a floating
coat of neat cement. The junctions and comers of the kerbing and the floor shall be rounded off.
21.11.2.2.5 Flooring: Flooring shall consist of 40 mm thick cement concrete 1:2:4 (lcement: 2 coarse
sand: 4 graded stone aggregate 20mm nominal size) which shall be finished with a floating coat of
neat cement. The floor shall be given proper slopes as directed by the Engineer-in-Charge.
21.11.2.2.6 Measurements: Platforms for stand posts shall be enumerated according to the size.
21.11.2.2.7 Rate: Rate shall include the cost of labour and materials required for all the operations
described above.
21.12 Surface Box:
21.12.1 Materials: This shall be of cast iron, well made and free from casting and other defects. All
sharp edges shall be removed and finished smooth. The shape and dimensions of surface boxes for
stop cocks, sluice valves, fire hydrants, water metre etc. shall be as specified in (Fig. 19. and Fig.20).
The C.I. surface boxes shall be coated with a black bituminous composition except in case of fire
hydrants where the cover of the surface box shall be painted with two coats of rust resisting bright
luminous yellow paint for clear visibility during night.
21.12.2 Fixing: The C.I. surface box shall be fixed on the top of masonry chamber in plain or
reinforced cement concrete 1:2:4(1cement:2 coarse sand: 4 graded stone aggregate 20 mm nominal
size) as the case may be.
21.12.3 Measurements: Surface boxes shall be enumerated and unless otherwise specified masonry
chambers shall be paid under relevant items of work.
21.12.4 Rate: The rate shall include the cost of materials and labour involved in all the operation
described above.
21.13 Service Connection:
21.13.1 Either metal or P.V.C. saddles, as specified, shall be used for the off take of service
connections from larger bore pipes (50mm diameter and above). The saddle consists of two half
round sections of metal or P.V.C. straps which envelops the portion of pipe from where connection is
to be given, and are bolted together or held round the pipe by wedge grips (Fig.11) the hole of
required size shall be drilled through the pipe and the box provided in the top strap. Ferrule piece
shall be connected after making threads in the box and pipe. Suitable rubber packing shall be used
between the straps and the pipe to provide cushioning as well as sealing against leakages
as shown in fig. 8. A seal is formed between the saddle and the pipe by rubber round o-ring
compressed between the pipe and the under surface of the upper section. The service connection is
taken from a boss on the upper section.
21.13.2 The size of the hole drilled in the pipe shall be limited to those given in the Table 30.
Table-30 : Size of Hole Drilled in Pipe
Pipe S i z e ( m m ) Maximum size of drilled hole (mm)
80 and 100 20
125 and 150 25
200 35
250 and above 50
21.13.3 Conventional equipment for tapping under pressure may be used with PVC pipe service
connections using a special trepanning cutter to pierce the poise wall. Ferrules shall not be screwed
directly into pipes without the introduction of saddle piece. A typical illustration of a ferrule
connection is shown in (Fig. 21).
21.13.4 Ferrules : The ferrules for service connection shall generally conform to IS: 2692-1989. It
shall be of non- ferrous materials and shall be of nominal bore as specified, the ferrules shall be
fitted with a screw and plug or valve capable of completely shutting off the water supply to the
communication pipe, if and when required.
For fixing ferrules the empty main shall be drilled and tapped at 45 degree to the vertical and ferrule
screwed in. The ferrule must be so fitted that bon portion of the shank shall be left projecting within
the main into which it is fitted.
21.13.5 Measurements: Connections shall be enumerated.
described above excluding the cost of ferrule.
21.14 Making Connection of G.I Distribution Branch with G.I. Main:
21.14.1 Preliminary Work: A pit of suitable dimensions shall be dug at the point where the
connection is to be made with the main and earth removed up to 15cm below the main. The flow of
water in the water main shall also be disconnected by closing the sluice or wheel valves on the mains.
21.14.2 Making Connection: For cutting and jointing 21.5.1.7 and 21.5.1.14 shall apply. The G.I.
main shall first be cut. Water, if any, collected in the pit shall be balled out and ends of the G.I. pipes
threaded. The connection of distribution pipe shall then be made after fixing G.I. tee of the required
size to the G.I. main and fittings such as jam nut, G.I. socket connecting piece etc.
21.14.3 Testing of Joints: After laying and jointing, the pipes and fittings shall be inspected under
working condition of pressure and flow. Any joint found leaking shall be redone and all leaking
pipes removed and replaced without extra payment. The pipes & fittings after they are laid shall be
tested to a hydraulic pressure of 6 kg/sq.cm. (60m) the pipes shall be slowly and carefully charged
with water allowing all air to escapes and avoiding all shock of water hammer. The draw of laps and
stop cocks shall then be closed and specified hydraulic pressure shall be applied gradually. Pressure
gauge must be accurate and preferably should have been recalibrated
before the test. The test pump having been stopped, the test pressure should be maintained without
loss for at least half an hour. The pipes and fittings shall be tested in sections as the work laying
proceeds. Having the joints exposed for inspection during the testing.
21.14.4. Finishing: The portions of the pipe in the pit shall be painted with bitumastic paint and
encased with sand 15 cm around. The pit shall be filled with earth in level with the original ground
surface watered, rammed and the area dressed.
21.14.5 Measurements: The work of making connections shall be enumerated.
described above.
21.15 Pumps:
21.15.1 Pumps to be used for drinking water supply shall be one of the followings:
1. Pumps Driven by a prime mover :
Horizontal centrifugal pumps

Submersible pumps
Vertical turbine pumps
Jet centrifugal pump combination units conforming to IS: 12699-1989
2. Hand pumps:
Shallow well hand pump conforming to IS: 8035-1976
Deep well hand pumps-conforming to IS: 9301-1990
Deep well hand pumps (VLOM) conforming to IS: 13056-1991

Extra Deep well hand pumps conforming to IS: 13287-1992 Direct
Action Hand Pumps
21.15.2 Guidelines for selection of Pumps: The type of pumps to be used for drinking
water supply shall depend on the water quantity requirement, water source from where the water is
to be supplied and operating conditions under which pump is required to work. Weightage should
also be given to the initial cost, operational cost and maintenance cost of the pump, types of prime
mover available, cost of installation, maintenance and efficiency of pump, its applicability and space
required by it in its selection.
(A) Comparative analysis of the advantages and limitation of the types of pumps with respect to
some of the main factors important from the selection point of view is presented in Table 31.
21.15.3 Installation: Correct installation is one of the most important factors for successful
operation of pumps. A pump, if correctly installed, requires less maintenance, has fewer shut downs,
longer operating life and lower maintenance cost.
21.15.3.1 Horizontal Centrifugal Pumps: Installation of these pumps shall be according to IS:
9694 (Part-II) 1980. Factors such as location, foundation, grouting, alignment and piping should by
given due importance during installation.
21.15.3.2 Submersible Pumps: For proper installation of submersible pump sets, guidelines
provided in IS: 8034-1989 and manufacturer's recommendations shall generally be followed, since
the motor and pump are directly coupled, or close coupled, the manufacturer shall indicate
the minimum size of the bore hole in which the submersible pump set shall be erected and
suspended freely.
21.15.3.3 Jet Centrifugal Pump combination: For installation of jet centrifugal pump
combinations, guidelines given in IS: 12699-1989 shall be followed. Jet centrifugal pump
combinations can be installed either horizontally or vertically according to space availability.
21.15.3.4 Deep Well Hand Pumps (India Mark-II): Installation of deep well hand pumps (India
Mark-II) shall be according to IS: 11004-Part-I, 1992. The location of the bore well is of prime
importance and it shall be located away from source of actual pollution. The area shall be easily
approachable to users. The bore well shall be of size 100 to 150 mm and the minimum recharge of
the bore well shall not be less than 15 litre /minute.
21.15.3.4 Measurements: Pumps shall be enumerated according to their type, prime movers and
other specifications.
21.15.3.5 Rate: The rate shall include the cost of material and labour involved in all the operations
described above, including the cost of prime mover if taken.
APPENDIX À'
PROCEDUCRE FOR PRESSURE TEST
1. Each valve section of the pipe shall be slowly filled with water and all air shall be expelled
from the pipe through hydrants and blow offs. If these are not available at high places,
necessary tapping may be made at points of highest elevation before the test is made and plugs
inserted after the tests have been completed.
2. If the trench has been partially back-filled the specified pressure based on the elevation of the
lowest point of the line or section under test and corrected to the elevation of the test gauge,
shall be applied by means of a pump connected to the pipe in a manner satisfactory to the
engineer-in-Charge. The duration of the test shall not be less than 5 minutes.
3. Examination under Pressure: All exposed pipes, fittings, valves, hydrants and joints should
be carefully examined during the open-trench test. When the joints are made with lead, all
such joints showing visible leaks shall be re-caulked until tight. When the joints are made with
cement and show seepage or slight leakage, such joints shall be cut out and replaced as
directed by the authority. Any cracked or defective pipes, fittings, valves or hydrants
discovered in consequence of this pressure test shall be removed and replaced by sound
material and the test shall be repeated until satisfactory to the Engineer-in-Charge.
4. If the trench has been back-filled to the top, the section shall be first subjected to water pressure
normal to the area and the exposed parts shall be carefully examined. If any defects are found,
they shall be repaired and the pressure test repeated until no defects are found. The duration
of the final pressure tests shall be at least one hour.
Procedure for Leakage Test
5. Leakage is defined as the quantity of water to be supplied in to the newly laid pipe, or any
valved section thereof, necessary to maintain the specified leakage test pressure after the pipe
has been filled with water and the air expelled. No pipe installation shall be accepted until the
leakage is less than the number of cm3/h determined by the formula :
ND √P
q1=
3.3
Where q1 = the allowable leakage in cm3/h

N = number of joints in the length of the pipe line. D
= diameter in mm, and
P = the average test pressure during the leakage testing kg/cm2
6. Variation from Permission Leakage: Should any test of pipe laid in position discloses
leakage greater than that specified in Para 5 the defective joints shall be repaired until the leakage
is within the specified allowance.
Fig. 16 : P.V.C. Piping
LIST OF BUREAU OF INDIAN TANDARDS (BIS) CODES
S.No. BIS Code No. Subject
GENERAL
1. 1172-1983 Code of basic requirements for water supply, drainage and
sanitation.
2. 1200(p-19)-1981 Methods of measurement for water supply, plumbing and drains
(third revision)
3. 2065-1983 Code of practice for water supply in buildings (second revision)
4. 2379-1963 Specifications for colour code for the identification of pipe lines.
5. 6295-1971 Code of practice for water supply and drainage in high altitudes
and or/subzero temperature regions.
6. 7022(P-1)-1973 Glossary of terms relating to water sewerage and industrial
effluents.
7. 7558-1974 Code of practice for domestic hot water installations.
8. 10446-1983 Glossary of terms relating to water supply and sanitation.
9. 12183 (P 1) 1987 Code of practice for plumbing in multi storied buildings : Part
1 water supply.
10. SP 35 : 1987 Handbook on water supply & drainage.
11. NBC2005 National Building Code of India 2005 Part-9 Plumbing Services
PIPES, SPECIALS, FITTINGS AND LAYING
1. 404(P-1-2)-1979 Specification for lead pipes
2. 458-1971 Specification for concrete pipes with and without reinforcement
3. 554-1985 Dimensions for pipe threads where pressure tight joints are
required on the threads (3 rd revision) (Reaffirmed 1990).
4. 651-1980 Specification for salt glazed stone ware pipes and fittings.
5. 782-1979 Specification for caulking lead (3 rd revision) ( R e = e d 1992)
6. 783-1959 Code of practice for laying of concrete pipes.60
7. 784-1978 Specification for prestressed concrete pipes (including fittings)
(first revision)
8. 806-1968 Code of practice for use of steel tubes in general building
construction.
9. 1230-1979 Specifications for cast iron pipes and fittings.
10. 1239 (Part I):1990 Specification for mild steel tubes tubulars and other wrought steel
fittings, Part I mild steel tubes (5th revision) ( R e = e d 1985)
11. 1239 (P II): 1992 Specification for mild steel tubes tubulars and other wrought steel
fittings, Part II mild street tubulars and other wrought steel pipe
fitting (3rd revision) (Amendment I)
12. 1536-1989 Specification for centrifugally cast (spun) iron pressure pipes for
water gas and sewage (3 rd revision) (Amendment II) (Reaffirmed
1993)
13. 1537-1976 Specification for vertically cast iron pressure pipes for water, gas
and sewage (1st revision ) (Amendment 5) (Reaffirmed 1991)
14. 1538-1993 Specification for cast iron fittings for pressure pipes for water,
gas and sewage, (3rd revision) superseding IS 1538 (Parts 1 to
24)
15. 1592-1989 Specification for Asbestos cement pressure pipes (3rd revision).
16. 1626(P-1)--1980 Specification for Asbestos cement building pipes and pipe fittings,
gutter and gutter fittings.
17. 1729-1979 Specifications for sand cast (spun) iron spigot and socket, soil,
waste and ventilating pipes, fitting and accessories.
18. 1742-1983 Code of practice for building drainage.
19. 1879(P1-10)-1975 Specifications for malleable cast iron fittings.
20. 1916-1963 Specification for steel cylinder reinforced concrete pipes.
21. 2501-1985 Specification for copper tubes for general Engineering purposes.
pipes for water gas and sewage (3rd revision) (Amendment II)
(Reaffirmed 1993)
22. 3006-1979 Specification for chemically resistant glazed stone ware pipes and
fittings.
23. 3076-1985 Specification for low density polyethelene pipes for potable water
supplies. (second revision).
24. 3114-1985 Code of practice for laying of cast iron pipes.
25. 3486-1966 Specifications for cast spigot and socket drain pipes .
26. 3589-1981 Specifications for electrically welded steel pipes for water, gas
and sewage 9200 mm to 2000 mm nominal diameter)
27. 3597-1985 Method of test for concrete pipes ( first revision).
28. 3989-1984 Specifications for centrifugally-cast (spun) iron spigot and socket
soil, waste and ventilating pipes, fittings and accessories.
29. 4127-1983 Code of practice for laying of glazed stone ware pipes.
30. 4270-1983 Specifications for steel tubes used for water wells.
31. 4350-1967 Specifications for concrete porous pipes for under drainage.
32. 4736-1986 Hot-dip Zinc Coatings on mild steel tubes (1st revision)
(Amendment I) (Reaffirmed 1992)
33. 4984-1987 Specification for high density polyethylene pipes for potable water
supplies, sewage and industrial effluents (3rd revision)
34. 4827-1083 Electroplated coatings of nickel and chromium on copper and
copper alloys (1st revision) (withdrawn)
35. 4984-1978 Specification for high density ployethylene pipes for potable
water supplies, sewage and industrial effluents (second revision).
36. 4985-1988 Specification for unplasticised PVC pipes for potable water
supplies (2nd revision) (Amendment I)
37. 5531(P{ 1-3)-1977 Specification for cast iron specials for asbestos cement pressure
pipes for water gas and sewage.
38. 5822-1970 Code of practice for laying of welded steel pipes for water supply.
39. 5913-1989 Method of test for asbestos cement products (1st revision)
40. 6163-1978 Specifications for centrifugally cast (spun) iron low pressure pipes
for water gas and sewage,
41. 6392-1971 Specifications for steel pipe flanges.
42. 6418-1971 Specifications for cast iron and malleable cast iron flanges for
general engineering purposes. pipes for water gas and sewage,
43. 6530-1972 Code of Practice for Laying of Asbestos Cement Pressure Pipe
44. 6631-1972 Specifications for steel pipes for hydraulic purposes.
45. 7181-1974 Specifications for horizontally cast iron double flanged pipes
for water gas and sewage,
46. 7319-1974 Specification for perforated concrete pipes.
47. 7322-1983 Specification for specials for steel cylinder reinforced concrete
pipes.
48. 7634-1975(P 1-3) Code of Practice for Plastic Pipe Works for Potable Water Supply
49. 7834 (P 1-8)-1975 Specification for injection moulded PVC socket fittings with
solvent cement joints for water supplies.
50. 8008( P1-7)-1976 Specification for injection moulded high density ployethelene
(HDPE) fittings for potable water supplies pipes for water gas
and sewage (3rd revision) (Amendment II) (Reaffirmed 1993)
51. 8112-1989 Specification for 43 grade ordinary Portland cement
52. 8329-1977 Specifications for centrifugally cast (spun) ductile iron pressure
pipes for water gas and sewage,
53. 8794-1988 Specification for Cast Iron Detachable Joints for use with Asbestos
Cement Pressure Pipe
54. 12288-1987 Code of Practice for use and Laying of Ductile Iron Pipes.
55. 15450-2004 Polythelene/Aluminium/Polythelene Composite Pressure Pipes for
Hot And Cold Water Supplies
56. 15778-2007 Code of practice for Chlorinated Polyvinyl Chloride (CPVC) Pipes
for Potable Hot And Cold Water Distribution Supplies
57. IS 15801 Polypropylene-Random Copolymer Pipes for hot and cold water
supplies-Specifications
58. DIN 8077-1977 D1N8078-1996 PP Pipe Dimensions PP Pipes General Quality
Requirements and Testing. PP Pipe fitting. (DIN 21962)
SPECIALS AND OTHERS
1. 778-1984 Specification for copper alloy gate, and check valves for water
works purposes (4' revision) (Amendment 2) (Reaffirmed 1990)
2. 779-1978 Specification for water meters (domestic type) (5th revision)
(Amendments 3) (Reaffirmed 1991)
3 780-1984 Specification for sluice valves for water works purposes (50 to
300 mm size) (6th revision) (Amendments 3) (Reaffirmed 1990)
4. 781-1984 Specification for cast copper alloy screw down bib taps and stop
valves for water services (3rd revision) (Amendment 1)
(Reaffirmed 1990)
5 909-1992 Specification for underground fire hydrant, sluice valve type (3rd
revision)
6. 1701-1960 Specification for mixing valves for ablutionary and domestic
purposes.
7. 1703-1989, Specification for copper alloy float valves (horizontal plunger
1703-2000 type) for water supply fittings (3rd revision)
8. 2104-1981 Specifications for Water Meter Boxes (Domestic Type)
9. 2373-1981 Specification for water meters bulk type (third revision).
10. 2401-1973 Code Of Practice for Selection, Installation and Maintenance of
Domestic Water Meters.
11. 2556 (P XI) 1979 Specification for vitreous sanitary appliances (vitreous China) Part
XI specific requirements for shower rose (lst revision) (Reaffirmed
1990)
12. 2685-1971 Code Of Practice for Selection, Installation and Maintenance of
Sluice Valves.
13. 2692-1989 Specification for ferrules for water services (2'd revision)
(Amendment I)
14. 2800-1979 (P1&2) Code of practice for Construction & Testing of Tube well/Bore
well
15. 2906-1984 Specification for sluice valves for water works purposes (350 to
1200 mm size) (3rd revision) (Amendment 3) (Reaffirmed 1990)
16. 3042-1965 Specification for single faced sluice gates (200 to 1200 mm size).
17. 3370-1965 Code of practice for concrete structures for storage of liquids
Part-I General requirements (Amendment-1) Part-II pin forced
concrete structures (Amendment-2)
18. 3370-1965 Code of practice for concrete structures for storage of liquids
Part-I General requirements Part-IV Design tables (Amendment-
2)
19. 3950-1979 Specification for surface boxes for sluice valves
20. 4038-1979 Specification for foot valves for water works purposes.(first
revision).
21. 4097-1967 Code of practice for Gravel for use as Pack in Tube-well.
22. 5290-1983 Specification for landing valves (second revision)
23. 5312-1984 Specification for Swing Check Type Reflux(NON RETURN)
valves for water works purpose PART-1(Single Door Pattern)
24. 5382-1985 Rubber sealing rings for gas mains, water mains and sewers (1st
revision) (Amendment I) (Reaffirmed 1994)
25. 6784-1984 Method for performance testing of water meters (domestic type)
(first revision).
26. 6908-1975 Specifications for asbestos pipes and fittings for sewerage and
drainage.
27. 9762-1994 Specification for polyethylene floats (spherical) for float valves
28. 9763-1988 Specification for Plastic Bib taps and Stop Valves (Rising Saddle)
for Cold Water Services.
29. 10146-1982 Polyethylene for its safe use in contact with food stuffs,
pharmaceuticals & drinking water.
30. 10299-1982 Specification for Cast lion saddle Pieces or Service Connection
from Asbestos Cement Pressure Pipe.
31. 12701-1996 Rotations moulded polyethylene water storage tanks- specification
(Revision-I)
Fire Fighting
1. 901-1975 Specification for Couplings double male and double female,
instantaneous pattern for firefighting ( second revision).
2. 903-1984 Specification for fire hose delivery Couplings branch pipe, nozzles
and nozzle spanner ( third Revision).
3. 906-1972 Specifications for branch with revolving head for firefighting
purposes (second revision).
4. 908-1975 Specifications for fire hydrant , stand post type (second revision)
5. 909-1975 Specifications for underground fire hydrant, sluice valve type
(second revision).
6. 910-1980 Specifications for combined key for hydrant, hydrant cover and
lower valve (second revision).
7. 952-1969 Specifications for fog nozzle for fire brigade use.
8. 2546-1974 Specifications for Galvanised mild steel fire bucket(first revision).
9. 2871-1983 Specifications for branch pipe universal, for firefighting purposes.
(First revision).
10. 3844-1966 Code of practice for installation of internal fire hydrants in
multistory buildings.
11. 5132-1969 Specifications for hydrant stand pipe for firefighting(first revision).
12. 9668-1980 Code of practice for provision and maintenance of water supplies
for firefighting.
CHAPTER No. 22
DRAINAGE WORK
CHAPTER No. 22 : DRAINAGE WORK
CONTENTS
22.1 Scope 3
22.2 Terminology 3
22.3 General Requirements of Design of Drainage System 7
22.4 Appurtenances/ Materials 8
22.5 Laying and Jointing Stone Ware Pipes 16
22.6 Drainage Appurtenant structures 19
22.7 Constructing Drop Connection 23
22.8 Construction of Open Surface Drain 24
Figures 25-36
Appendix 'A': Laying & Jointing of P.E. pipes. 37
List of Bureau of Indian Standards (BIS) Codes 56
Rajasthan PWD Building Specifications 2014 Chapter 22 : Drainage Work Page 1 of 56


CHAPTER No. 22
DRAINAGE WORK
22.1-Scope:
The scope of drainage and sewerage in respect of buildings shall cover the disposal of waste ( foul)
water, recycling of water, rain water harvesting, disposal of solid waste, disposal of sanitary waste
through sewerage/septic tanks and soakage pits etc. While disposal of foul water, sanitary waste etc.
is covered in the Chapter 19-Sanitary installation, rainwater harvesting in chapter 23-Tube wells and
water harvesting work, recycling of water can be considered for housing / institutional/ Industrial
complexes etc. The Specifications for each one of these shall apply to all items of drainage works as
required to be carried out under the contract or as directed by Engineer-in-charge in execution of
drainage work a reference is to be made to IS code for guidance & compliance, wherever applicable.
Wherever not clear, good Engineering practice shall be adopted in construction to the satisfaction of
the Engineer.
22.2 Terminology
1. Authority: The Authority which has been created by an statute for administering the provisions
and which may authorise a committee or an official to act on its behalf, herein after called the
"Authority" An individual, an office, a board, a department or an agency established and
authorized by Union or State Government or any Statutory body created by law who undertakes
to administer and enforce the provision of this code as adopted or amended.
1.1 Approved: Accepted or acceptable under an applicable specification stated or cited or
accepted as suitable for the proposed use under procedures and powers of the
Administrative Authority.
2. Barrel: That portion of a pipe in which the diameter and wall thickness remain uniform
throughout.
3. Bedding: The material on which the pipe is laid and which provides support for pipe.
4. Benching: The sloped floor of a manhole or an inspection chamber on both sides and above
the top of the channel.
5. Building combined Drain or Sewer : A building drain or Sewer which conveys both sewage
and storm water.
6. Building (House) Drain: That part of the lowest piping of a drainage system which receives
the discharge from soil, waste and other drainage pipes inside the walls of the building and
conveys it to the building (house) sewer beginning 0.9 m outside the building outer wall.
7. Building (House) sewer: That part of the horizontal piping of a drainage system which extends
from the end of the building drain which receives the discharge of the building drain and
conveys it to a public sewer , private sewer, individual sewage disposal system or other point of
disposal. Also called house connection.
8. Building (House) Trap: A device, fitting or assembly of fittings installed in the building drain
to prevent circulation of air between the drainage system of the building and the building sewer.

9. Building Sanitary Drain : A building drain which conveys sewage but does not convey
storm water.
10. Building (Sanitary) Sewer : A building sewer which conveys sewage but does not convey
storm water.
11. Building (Storm) Drain : A building sewer which conveys storm water but does not convey
sewage.
12. Building (Storm) Sewer : A building sewer which conveys storm water, but does not
convey sewage.
13. Chair: A bed of concrete or other suitable material on the trench floor to provide a support
for the pipes at intervals.
14. Cover :
a). A removable plate for permitting access to a pipe or pipe fitting vessel or appliance.
b). The vertical distance between the top of the barrel of a buried pipe or other construction
and the surface of the ground.
15. Channel: The open waterway through which sewage, storm water or other liquid waste flow
at the invert of a manhole or an inspection chamber.
16. Cleaning Eye: An access opening having a removable cover to enable obstructions to be
cleared by means of a drain rod.
17. Connections: The junction of a foul water drain, surface water drain with public sewer,
cesspool Soak-way or other water courses.
18. Curb, Kerb: The stone margin of a side walk.
19. Diameter: The nominal internal diameter of a pipe.
20. Dispersion Trench: A trench in which open jointed pipes surrounded by coarse aggregate
media and overlaid by fine aggregate are laid. The effluent from septic tank gets dispersed
through the open joints and is absorbed in the surrounding soil.
21. Depth of Manhole: The vertical distance from the top of the manhole to the outing invert of
the main drain channel.
22. Deep Manhole: A manhole of such depth that an access shaft is required, in addition to the
working chamber.
23. Drain: A line of pipes including all fittings and equipment, such as manholes traps, gullies and
floor traps used for the drainage of a building, or a no. of buildings or yards appurtenant to the
building, within the same curtilage. Drain shall also include open channels used for conveying
surface water.
24. Drainage: The removal of any liquid by a system constructed for the purpose.
25. Drop connection: A branch drain of which the last length of piping of the incoming drain,
before connection to the sewer, is vertical.
26. Drop Manhole: A manhole incorporating a vertical drop for the purpose of connecting a
sewer or drain, at high level, to one at lower level.
27. Drainage Work: The design, construction of a system of drainage.

28. Effluents:
(a) Tank effluent: The supernatant liquid discharge from a septic tank.
(b) Filter effluent: The liquid discharge from a biological filter.
29. Formation: The finished level of the excavation at the bottom of a trench or heading
prepared to receive the permanent work.
30. Flushing Tank: Tank used to flush the sewer line/manholes.
31. French Drain or Rubble Drain: A shallow trench filled with coarse rubble, clinker, or
similar material with or without field drain pipes.
32. Gully Chamber: The chamber built of masonry around a gully trap, for housing the same.
33. Gully Trap: A trap water seal provided in a drainage system in a suitable position to collect
waste water from the scullery, kitchen sink, wash basins, baths and rain water pipes.
34. Haunching: Concrete bedding with additional concrete at the sides of the pipe.
35. Highway Authority: The public body in which is vested, or which is the owner of a highway
repairable by the inhabitants collectively, otherwise the body of persons responsible for the
upkeep of the highway.
36. House Drain: That part of the lowest horizontal piping of a building drainage system including
the horizontal branch from the base of a stack connected to the main house drain which receives
the discharge from soil, waste or other drainage pipes in the building and conveys it to the
existing lateral, main sewer cesspool of septic tanks.
37. House Storm Drain : A drain used for conveying rain water, ground water, subsurface
water, condensate, cooling water or similar discharge to the existing lateral or main sewer.
38. Inspection Chamber: A water tight chamber constructed in any house drainage system which
takes wastes from gully traps and disposes off to manhole, with access for inspection and
maintenance.
39. Interceptor Manhole (Interceptor Chamber): A manhole incorporating an intercepting
trap, and providing means of access thereto and equipped with a fresh air inlet on the upstream
side of the trap.
40. Invert: The bottommost level of flow (under gravity) in a pipe / sewer or drain.
41. Junction pipe: A pipe incorporating one or more branches.
42. Invert: The lowest point of the interior or a sewer or drain at any cross section.
43. Manhole: Any chamber constructed on a drain or sewer so as to provide access thereto for
inspection testing or the clearance of obstruction.
44. Plinth: The portion of a structure between the surface of the surrounding ground and surface
of the floor immediately above the ground.
45. Puff Ventilation: The ventilation provided for waste traps in two-pipe system, in order to
preserve the water seal.
46. Rest Bend (Duck Foot Bend) : A bend supported in a vertical position by a foot formed at
its base.
47. Saddle: A purpose made fitting, so shaped as to fit over a hole cut in a sewer or drain, and
used to form connections.

48. Sewer: a closed drain carrying night soil and other water borne waste.
49. Sanitary Sewer : A sewer which carries sewage and to which storm, surface and ground
waters are not intentionally admitted.
50. Service Pipe: Pipe that runs between the distribution main in the street and the riser in the case
of a multistoried building or the water in the case of an individual house and is subject to water
pressure from such main.
51. Sewer Branch : A sewer which receives sewage from a relatively small area and discharges
in to a main sewer.
52. Sewer, combined : A sewer receiving both surface run off and sewage.
53. Sewer Common : A sewer in which all owners of abutting properties have equal rights.
54. Sewer Private : A sewer privately owned and used by one or more properties.
55. Sewer, storm : A sewer, which carries storm water and surface water, street wash or other
wash waters or drainage but excludes sewage and industrial wastes.
56. Soffit: The highest portion of the interior of a sewer or drain at any cross-section.
57. Soil Waste: The discharge from water closets, urinals, slope sinks, stable or cowshed gullies
and similar appliances.
58. Soil pipe: Which receives the discharges from soil fitments, such as water closets. Urinals,
and slope sinks.
59. Stack: The vertical main of a system of soil waste or vent piping.
60. Sullage Waste Water: Spent water from baths. wash basins, kitchen sinks, and similar
appliances which does not contain human or animal excreta.
61. Surface Water Drain: A drain conveying surface water.
62. Surface Water: The run off from precipitation other water that flows over surface of the
ground including storm water.
63. Sub Soil Water: Water occurring naturally below the surface of the ground.
64. Sludge: The settled solid matter in the semi-solid condition.
65. Soak Pit: A pit through which effluent is allowed to seep or leach into the surrounding soil.
66. Septic tank: A water tight single storied tank in which sewage is retained sufficiently long to
permit sedimentation of suspended solids and partial digestion of settled sludge by anaerobic
bacteria.
67. Scum: The greasy and other substances floating on the surface of the sewage.
68. Vent Pipe: A pipe line installed to provide flow of air to or from a drainage system or to
provide circulation of air within such system to protect trap seals from Siphonage and back
flow.
69. Systems of Drainage:
a. Combined System: A system of drains or sewers in which foul water and surface
water are conveyed by the same sewer pipes/ drains.
b. Separate System: A system of drains or sewers in which foul water and surface water
are conveyed by the separate sewer pipes and drains.

c. Partially Separate System: A modification of the separate system in which part of the
surface water is conveyed by the foul sewers and drains.
70. Trade Effluent : Any liquid either with or without particles of matter in suspension therein,
which is wholly or in part produce in the course of any trade or industry, carried at trade
premises. It includes farm wastes but does include domestic sewage.
71. Vent Pipe: An open ended pipe, in s hot water apparatus, for the escape of air and for the
safe discharge of any steam generated.
72. Ventilating Pipe: A pipe in a sanitary pipe work system which facilitates the circulation of
air
within the system and protects trap seals from excessive pressure fluctuation.
73. Waste Water: The discharge from wash basins, sink and similar appliance, which does not
contain human excreta.
74. Waste pipe: In Plumbing, any pipe that receives the discharge of any fixtures, except water
closets or similar fixtures and conveys the same to the house drain or soil or waste stack. When
such pipe does not connect directly with a house drain or soil stack, it is called an indirect waste
pipe.
22.3 General Requirements of Design of Drainage System:
22.3.1 In designing a drainage system for building(s), the aim shall be to design for / provide the
pipes/conduits to have self-cleansing velocity for the conveyance of soil waste, surface or subsurface
waters and for the removal of such wastes speedily and efficiently to a sewer or other outlet, without
risk of nuisance and hazard to health.
22.3.2 The discharge of water through a domestic drain is intermittent and limited in quantity and
therefore, small accumulations of solid matter are likely to form in the drains between the building and
the public sewer. There is usually a gradual shifting of these deposits as discharge take place. Gradients
shall be efficient to prevent these temporary accumulations building up and blocking the drains.
22.3.3 Normally, the sewer shall be designed for discharging three times the dry weather flow
flowing half-full with a minimum self-cleansing velocity of 0.75 metre per second. The approximate
gradients which give this velocity for the sizes of pipes likely to be used in building drainage and
the corresponding discharges when flowing half-full are given in Table 1. The size and slopes shall
conform to Local Municipal Bye Laws.
22.3.4 In cases, where it is practically not possible to conform to the minimum gradients, a flatter
gradient may be used but the minimum velocity in such cases shall on no account be less than 0.61
meter per second.
22.3.5 On the other hand, it is undesirable to employ gradients generating a velocity of flow greater
than 2.4 meter per second. Generally PVC pipes are more suitable but where it is unavoidable, cast
iron pipes may be used. The approximate gradients which give a velocity of 2.4 meter per second for
the various sizes of pipes and the corresponding discharge when flowing half-full are given in Table
1.
22.4 Appurtenances/ Materials:
22.4.1 Flushing Tank (Fig. 1):
Flushing tank is an independent tank or chamber in which water is stored and discharged into sewer
at intervals for flushing sewer.

22.4.1.1 Subject to the minimum size of 100 mm, the sizes of pipes shall be decided in relation to the
estimated quantity of flow and the available gradient.
22.4.1.2 C.I. Cover: C.I. Cover shall be of 560 mm dia. and shall be medium duty or heavy duty
depending upon the locations of the tank. It shall conform in all respects to IS: 1726 (Part IV and
Part II) respectively. Weight of cover and frame shall conform to IS: 1726.
22.4.1.3 Syphon: Syphon shall be automatic syphon made of cast iron with trapped outlet for
flushing. The syphon for flushing a sewer line shall be 65 mm, 80 mm or 100 mm dia. as specified.
22.4.2 Manholes:
22.4.2.1 C.I. Covers: The covers and frames shall conform to IS: 1726 and shall be of the following
grades and types:-
(a) Heavy duty: These shall be denoted by the letters HD circular solid type for use under
heavy vehicular traffic condition and shall conform to IS: 1726 (Part-II).
(b) Medium duty: These shall be denoted by the letters MD circular or rectangular solid type for
use under light traffic condition such as foot paths, carriage drives and cycle tracks. These
shall conform to IS: 1726 (Part IV& V).
(c) Light duty:
i) these shall be denoted by the letter LD of rectangular size for use in domestic premises
or where they are not subjected to wheeled traffic loads. These shall conform to IS: 1726
(Part VI) - Square types shall conform to IS: 1726 (Part-VII).
ii) The covers and frames shall be cleanly cast and they shall be free from air and sand holes
and form cold shuts. They shall be neatly dressed and carefully trimmed. All castings shall be
free from voids whether due to shrinkage, gas inclusion or other causes. Covers shall have
a raised chequered design on the top surface to provide an adequate non-slip
i•
g p
iii) The cover shall be capable of easy opening and closing and shall be fitted in the frame
in workmanship like manner.
iv) The cover shall be gas tight and water tight. The covers used in manholes in sewer lines
invariably bear the word 'SEWER' on the top and those used for storm water drains shall
bear the word 'STORM'. These markings shall be done during casting of the covers.
v) The sizes of covers specified shall be taken as the clear internal dimensions of the frame.
vi) The approximate weights of the various types of manhole covers and frames shall be as
per IS: 1726. Covers and frames shall be coated with a black bituminous composition.
The coating shall be smooth and tenacious. It shall not flow when exposed to a temperature
of 63°C and shall not be brittle as to chip off at temperature of 0°C .
Table 1 :Gradients for Sewers Generating a Maximum Velocity of 2.4 m / second
Diameter Minimum Gradient / Discharge Maximum Gradient / Discharge
Gradients Discharge Gradients Discharge
cum/min cum/min
100 1in57 0.18 1in5.6 0.59
150 1 in 100 0.42 1 in 9.7 1.32
200 1 in 145 0.73 1 in 14 2.4
230 1 in 175 0.93 1 in 17 2.98
250 1 in 225 1.10 1 in 19 3.60
300 1 in 250 1.70 1 in 24.5 5.30
22.4.2.2 Precastconcrete manhole covers & frames: Precast reinforced cement concrete manhole
covers intended for use in sewerage and water works shall generally conform to IS: 12592 (Part I &
II) Detailed specifications are as under. The different grades and types of manhole covers may be used
are as follows:
(a) LD-2.5: Rectangular, Square or Circular types. These are suitable for use within residential
and institutional complexes/areas with pedestrian but occasional LMV traffic. These covers may
also be used for Inspection chambers.
(b) MD-10- These are suitable for use in service lanes/roads, car parking areas etc.
(c) HD-20: Suitable for use in institutional/commercial areas/carriage ways with heavy duty
vehicular traffic like buses trucks etc.
EHD-35: Circular, Square, or rectangular (scrapper manhole) types. These are suitable for use on
carriage way in commercial industrial/port areas/near ware houses / godowns where frequent
loading and unloading of trucks/ trailers is common, with slow to fast moving vehicular traffic of the
types having wheel loads up to 11.5 tonne irrespective of the location of the manhole chambers.
22.4.23 : Lifting Device:
The minimum diameter of mild steel rod used as lifting device shall be 10 mm for light and 12 mm for
medium duty covers and 16 mm for heavy and extra heavy duty covers. The lifting device shall be
protected from corrosion by galvanizing or epoxy coating or any other suitable coating.

22.4.2.4 : Finishing & Coating:
To prevent any possible damage from corrosion of steel the under side of the covers shall be treated
with anticorrosive paint. The top surface of the covers shall be given a chequered finish. In order to
protect edges of the covers from possible damage at the time of lifting and handing, it is necessary that
the manhole covers shall be cast with a protective mild steel strip/flat of minimum 2.5 mm thickness
around the periphery of the covers. Exposed surface of mild steel strip / flat shall be given suitable
treatment with anticorrosive paint or coating.
22.4.2.5: Physical Requirements:
(a) General: All cover units shall be sound and free from cracks and other defects which interfere
with the proper placing of the unit or impair the strength or performance of the units. Minor
chipping at the edge/ surface resulting from the customary methods of handling during delivery
shall not be deemed for rejecting.
(b) Load Test: The breaking load of individual units when tested in accordance with the method
described in IS: 12592 shall not be less than the values specified in Table 2
Table : 2
Grade of Cover Type Load in tonne Diameter of
Blocks in mm
EHD- 35 (Extra Heavy Duty) Circular, Square or 35 300
Rectangular
HD- 20 (Heavy Duty) Circular, Square or 20 300
Rectangular
MD- 10 (Medium Duty) Circular, or 10 300
Rectangular
LD- 2.5 (Light Duty) Rectangular, Square 2.5 300
or Circular
(c) Fixing: The frame of manhole covers shall be firmly embedded to correct alignment and level
in RCC slab or plain concrete as the case may be on the top of masonry which shall be paid as
extra unless specified otherwise.
(d) Rates: The rate shall include the cost of materials and labour involved in all the operation
described above except fixing of frames and covers which shall be paid as extra unless specified
otherwise in the item.
22.4.3 Pipes and Specials: Pipes and specials may be of any of the following types as specified:
Cast iron centrifugally cast (spun) - IS 1536
Galvanised steel - IS 1239 & IS 4736
PE-AL-PE Pipes - IS 15450
PP-R Pipes - IS 15801
CPVC pipes - IS 15778
RCC pipes as per IS 458
SW pipes as per IS 651, IS 4127

In choosing the material for piping and fittings, account shall be taken of the character of the water to
be conveyed through it, the nature of the ground in which the pipes are to be laid and the relative
economics.
a) Cast iron (centrifugally cast) pipes and specials shall confirm to the I.S. 1536 Specifications. The
spun iron pipes shall be of cast iron cast centrifugally and vary in diameters from 80 mm to
750 mm. These shall be of class LA, class A and class B, as specified. Pipes shall be tested
hydrostatically at the pressure specified in table 3 & 4. Tolerances on specified dimensions
shall be as prescribed in IS 1536.
Specials: The specials shall conform to IS 1538. The hydraulic test pressure of each class shall be as
detailed in Table 5. Tolerances on specified dimensions shall be as prescribed in IS 1536.
Table : 3
Hydrostatic Test pressure for centrifugally cast spigot pipes in MPa
Hydrostatic Test pressure for works in MPa
Class Up to DN 600 DN 700 & above
LA 3.5 1.5
A 3.5 2.0
B 3.5 2.5
Table 4 : Hydrostatic Test pressure for centrifugally cast pipes

with screwed on Flanges in MPa
Class Up to DN 600 DN 700 & above.
B 2.5 1.6
Table 5 : Hydrostatic Test pressure for fittings in MPa (N/mm2) (meter head)
Nominal - Diameter Fitting without branches or Fitting with branches greater
with branches not greater than than half the principal
half the principle diameter. Diameter.
Up to and including 300 mm 2.5 (25) 2.5 (25)
Over 300 mm and up to and 2.0 (20) 2.0 (20)
including 600 mm
Over 600 mm and up to and 1.5 (15) 1.0 (10)
including 1500 mm
b) Pipes-Galvanised Iron/Steel :
i) The pipes (tubes) shall be galvanised mild steel hot finished seamless (HFS) or welded ( E M
HRIW or HFW screwed and socketed conforming to the requirements of IS 1239 Part-I for
medium grade. They shall be of the diameter (nominal bore) specified in the description of the
item, the sockets shall be designated by the respective nominal bores of the pipes for which they
are intended. (see Chapter 21 on water supply)
ii) Galvanising shall conform to IS 4736: The zinc coating shall be uniform adherent, reasonably
smooth and free from such imperfections as flux, ash and dross inclusions, bare

batches, black spots, pimples, lumping runs, rust stains, bulky white deposits and blisters. The
pipes and sockets shall be cleanly finished, well galvanised in and out and free from cracks,
surface flaws laminations and other defects. All screw threads shall be clean and well cut. The
ends shall be cut cleanly and square. For laying, jointing etc., refer to Chapter 21 on Water
supply.
(c) PE-AL-PE Pipes - IS 15450 : These are Polyethylene-Aluminium-Polyethylene pipes .These
are essentially meant for cold and hot water Supply under pressure. Reference be made to IS 15450
for details.
(d) PP-R Pipes - IS 15801 : The PP-R is a bonded, multilayer pipe consisting of
different layers of the pipe:-
(i) The inner-most layer of the pipe to be Anti - bacterial to prevent bacteria growth inside pipe
surface.
(ii)The middle layer to be of plain PP-R which is neither in contact with Water and nor under
direct effect of the atmospheric conditions.
(iii) The outer-most layer to be of U.V. stabilized PP-R to prevent the pipe surface from sunlight
under exposed atmospheric conditions.
The pipes should in general be conforming to the requirements of IS 15801 except that specified
with in nomenclature of the item. The pipes should have smooth inner surface with non-contracting
diameters. The pipes shall be cleanly finished, free from cracks and other defects. The pipes shall be
clean and well cut along ends after taking into consideration the desired length, using the pipe
scissors. The Polypropylene used for manufacturing the pipe shall conform to the requirements of IS
10951 and IS 10910. The specified base density shall be between 900 kg/ m3 and 910 kg/m3 when
determined at 27°C. The resin should be mixed with sufficient quantity of colour master batches.
The colour master batch should be uniform throughout the pipe surface. The standard dimension
ratio (SDR) i.e. ratio of the nominal outer diameter of a pipe to its nominal wall thickness should be
7.4/11 as given in the item. These are also primarily water supply pressure pipes. Reference be made
to relevant IS codes.
(e) CPVC pipes - IS 15778: CPVC pipes & fittings used in hot & cold potable water distribution
system shall conform to requirement of IS 15778. The material from which the pipe is produced
shall consist of chlorinated polyvinyl chlorides. The polymer from which the pipe compounds are to
be manufactured shall have chlorine content not less than 66.5%. The internal and external surfaces
of the pipe shall be smooth, clean and free from grooving and other defects. The pipes shall not have
any detrimental effect on the composition of the water flowing through it.
22.4.3.1 Cement Concrete Pipes (with and without Reinforcement):

The pipes shall be as per diameters and barrel thickness as per IS 458, with or without reinforcement as
required and shall be of the specified class ( Table 6) . These shall conform to IS: 458. The reinforced
cement concrete pipes shall be manufactured by centrifugal (or spun) process while unreinforced
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 imperfect grading of the aggregate
mixing or moulding. Concrete used for the manufacture of unreinforced and reinforced concrete
pipes and collars shall not be leaner than nominal CC 1:2:4 (icement: 2 coarse sand : 4 graded stone
aggregate). The maximum size of aggregate should not exceed one

third of the thickness of the pipes or 20 mm whichever is smaller. The reinforcement in the reinforced
concrete pipes shall extend throughout the length of the pipe. The circumferential and longitudinal
reinforcements shall be adequate to withstand the specified hydrostatic pressure and bear with
bending stresses due to the weight of water when running full plus three times its own weight, across
a span equal to the length of pipe.
Table 6 : CONCRETE PIPES

Class Description Test pressure Conditions where normally used
(Hydrostatic)
NP1 Un-reinforced concrete 0.7 kg/sqcm For drainage and irrigation use,
non pressure pipes (7 metre head) above ground or in shallow trenches.
NP2 Reinforced concrete light -do- For drainage and irrigation use,
duty, non-pressure pipes for culverts carrying light traffic.
NP3 Reinforced concrete, -do- For drainage and irrigation use,
medium-duty non- for culverts, carrying heavy traffic.
pressure pipes
NP4 Reinforced concrete, -do- For drainage and irrigation use,
heavy duty non-pressure for culverts, carrying very heavy
pipes traffic, such as railway loading.
P1 Reinforced concrete 2.0 kg/sqcm For use on gravity mains, the
pressure pipes (20 metre head) design pressure not exceeding
two-third of the test pressure.
P2 Reinforce concrete 4.0 kg/sqcm For use on pumping mains, the
pressure pipes (40 metre head) design pressure not exceeding half
of the test pressure.
P3 Reinforce concrete 6.0 kg/sqcm -do-
pressure pipes (60 metre head)
The minimum cover for reinforcement of spun pipes and for all other pipes shall be as given in
Table 7
Table 7 :
Cover for
Pipe thickness
Spun Pipes- mm Other than spun pipe- mm
Less than 30 mm 9 12
30mmto75mm 12 16
75 mm and over 18 18
22.4.3.2 Laying and Jointing of Cement concrete pipes and Specials:
a) Trenches: The trenches shall be so dug that the pipes may be laid to the required alignment and at
required depth. Where the pipes are to be bedded directly on soil, the bed shall be suitably rounded
to fit the lower part of the pipe, the cost for this operation being included in the rate for

laying the pipe itself.
b) Laying:
i) Loading, transporting and unloading of concrete pipes shall be done with care. Handling shall
be such as to avoid impact. Gradual unloading by inclined plane or by chain pulley block is
recommended. All pipe sections and connections shall be inspected carefully before being laid.
Broken or defective pipes or connections shall not be used. Pipes shall be lowered into the
trenches carefully. Mechanical appliances may be used. Pipes shall be laid true to line and grade
as specified. Laying of pipes shall proceed upgrade of a slope.
ii) If the pipes have spigot and socket joint, the socket ends shall face upstream. In the case of
pipes with joint to be made with loose collars, the collars shall be slipped on before the next pipe
is laid. Adequate and proper expansion joints shall be provided where directed.
iii) In case where foundation conditions are unusual such as in the proximity of trees or holes, under
existing or proposed tracks manholes etc. the pipe shall be encased all-around in 15 cm chick
cement concrete 1:5:10 (1 cement: 5 fine sand: 10 graded stone aggregate, 40 mm nominal size)
or compacted sand or gravel.
iv) In case where the natural foundation is inadequate, the pipes shall be laid either in concrete
cradle supported on proper foundations or on any other suitably designed structure. If concrete
cradle bedding is used, the depth of concrete below the bottom of the pipe shall be at least 1/ 4 '
of the internal dia. of the pipe subject to the min. of 10 cm and a maximum of 30 cm. The concrete
shall extend up to the sides of the pipe at least to a distance of 1/4' of the outside diameter for
pipes 300 mm and over in dia. The pipe shall be laid in this concrete bedding before the concrete
has set. Pipes laid in trenches in earth shall be bedded evenly and firmly and as far up the
haunches of the pipe as to safely transmit the load expected from the backfill through the pipe to
the bed. This shall be done either by excavating the bottom of the trench to fit the curve of the
pipe or by compacting the earth under around the curve of the pipe to form an even bed.
Necessary provision shall be done for joints wherever required.
v) When the pipe is laid in a trench in rock, hard clay, shale or other hard material the space below
the pipe shall be excavated and replaced with an equalizing bed of concrete, sand or compacted
earth. In no case shall pipe be laid directly on such hard material.
vi) When the pipes are laid completely above the ground the foundations shall be made even and
sufficiently compacted to support the pipe line without any material settlement. Alternatively the
pipe line shall be supported on rigid foundations at intervals. Suitable arrangements shall be made
to retain the pipe line in the proper alignment, such as by shaping the top of the supports to fit
the lower part of the pipe. The distance between the supports shall in no case exceed the length
of the pipe. The pipe shall be supported as far as possible close to the joints. In no case shall the
joints come in the centre of the span. Care shall be taken to see that super imposed loads greater
than the total load equivalent to the weight of the pipe when running full shall not be permitted.
Suitably designed anchor blocks at change of direction and grades for, pressure lines shall be
provided where required.
22.4.3.3 Jointing: Joints are generally of rigid type. Where specified flexible type joints may also be
provided.
a) Rigid Spigot and Socket Joint (Fig. 10):
The spigot of each pipe shall be slopped home well into the socket of the pipe previously laid and

adjusted in the correct position. The opening of the joint shall be filled with stiff mixture of cement
mortar in the proportion of 1:2 (1 cement: 2 fine sand) which shall be rammed with caulking tool. After
a day's work any extraneous materials shall be removed from the inside of the pipe and the newly
made joint shall be cured well.
b) Rigid Collar Joint (Fig. 10) :
The two adjoining pipes shall be butted against each other and adjusted in correct position. The collar
shall then be slipped over the joint, covering equally both the pipes. The annular space shall be filled
with stiff mixture of cement mortar 1:2 (1 cement: 2 fine sand) which shall be rammed with caulking
tool. After a day's work any extraneous materials shall be removed from the inside of the pipe and the
newly made joint shall be cured.
c) Semi Flexible Spigot and Socket Joint (Fig. 10):
The joint is composed of specially shaped spigot and socket ends on the concrete pipes. A rubber
ring shall be placed on the spigot which shall be forced into the socket of the pipe previously laid. This
compresses the rubber ring as it rolls into the annular space formed between the two surfaces of the
spigot and the socket, stiff mixture of cement mortar 1:2 (1 cement : 2 fine sand) shall then be filled
into the remaining annular space and rammed with a caulking tool. After day's work any extraneous
materials shall be removed from the inside of the pipe and the newly made joint shall be cured.
d) Semi Flexible collar Joint (Fig. 10):
This is made up of a loose collar which covers two specially shaped pipe ends as shown in the Fig. 10.
Each end shall be fitted with a rubber ring which when compressed between the spigot and the collar,
seal the joint. Stiff mixture of cement mortar 1:2 (1 cement: 2 fine sand), shall then be filled into the
remaining annular space and rammed with a caulking tool. After day's work, any extraneous material
shall be removed from the inside of the pipe and the newly made joint shall be cured.
e) Internal Flush Joint (Fig. 10):
The joint is generally used for culvert pipe of 60 cm dia. and over. The ends of the pipe are specially
shaped to form a self-centering joint with an internal jointing space 1.3 cm wide, the finished joint is
flush with both inside and outside with the pipe wall as shown in Fig. 10. The jointing space is filled
with cement mortar 1:2 (1 cement: 2 fine sand) mixed sufficiently dry to remain in position when
forced with a trowel or rammer. After day's work, any extraneous material shall be removed from the
inside of the pipe and the newly made joint shall be cured.
I) External Flush Joint:
i) This joint is suitable for pipes which are too small for jointing form inside. The joint is composed
of specially shaped pipe ends as shown in Fig. 10. Each end shall be butted against each other
and adjusted in correct position. The jointing space shall then be filled with cement mortar 1:2
(1 cement: 2 fine sand) sufficiently dry and finished off flush. Great care shall be taken to ensure
that the projecting ends are not damaged as no repairs can be readily affected from inside the
pipe.
ii) In all pressure pipe lines, the recess at the end of the pipe line shall be filled with jute braiding
dipped in hot bitumen or other suitable approved compound. Pipes shall be so jointed that the
bitumen ring of one pipe shall set into the recess of the next pipe. The ring shall be thoroughly
compressed by jacking or by any other suitable method.

iii) The number of pipes that shall be jacked together at a time shall depend on the diameter of the
pipes and the bearing capacity of the soil, for small pipes up to 25 cm diameter, six pipes can be
jacked together at a time.
iv) The quantity of jute and bitumen in the ring shall be just sufficient to fill the recess in the pipe
when pressed hard by jacking or by any other suitable method. Before and during jacking care
shall be taken to see that there is no offset at the joint.
22.4.3.4 Testing: For pressure pipe, the completed pipeline shall be tested for pressure (Known as site
test pressure) which shall not be less than the maximum pipeline operating pressure plus the
calculated surge pressure, but in no case shall it exceed the hydrostatic test pressure. For non-
pressure pipes the joints shall be tested as per procedure laid down under para 22.6.4.
22.4.3.5 Refilling of Trenches: In case where pipes are not bedded on concrete, special care shall be
taken in refilling trenches to prevent the displacement and subsequent settlement at the surface
resulting in uneven street surfaces and dangers to foundations etc. The backfilling materials shall be
packed by hand under and around the pipe and rammed with a shovel and light tamper. This method
of filling will be continued up to the top of pipe. The refilling shall rise evenly on both sides of the
pipe continued up to 60 cm above the top of pipe so as not to disturb the pipe. No tamping shall be
done within 15 cm of the top of pipe. The tamping shall become progressively heavier as the depth of
the backfill increases.
22.4.3.6 Measurements: The lengths of pipes shall be measured in meter nearest to a cm laid or
fixed from inside of one manhole to the inside of the other manhole. The length shall be taken along
the centre line of the pipes over all fittings such as bends, collars, junctions, etc. which are not be
Excavation, refilling, shoring and timbering in trenches, and cement concreting wherever required
shall be measured separately under relevant items of work.
described above.
22.5 Laying and Jointing Stone Ware Pipes:
a) For all sewers and drains, glazed stoneware pipes shall be used as far as possible in preference
to other types of pipes. These are suitable, particularly where acid effluents or acid sub-soil
conditions are likely to be encountered.
b) All pipes with spigot and socket ends and fittings shall conform to IS:651. These shall be sound,
free from visible defects such as fire cracks or hair cracks. The glaze of the pipes shall be free
from crazing. The pipes shall give a sharp clear tone when struck with a light hammer. There
shall be no broken blisters. The thickness of pipes shall be as given in the Table 8.

Table 8 : STONE WARE PIPES
Internal diameter Thickness of the barrel and socket
mm mm
100 12
150 16
200 17
230 19
250 20
300 25
350 30
400 35
450 38
The length of pipes shall be 60, 75, 90 cm exclusive of the internal depth of the socket. The pipes
shall be handled with sufficient care to avoid damage to them.
22.5.1 Trenches:
22.5.1.1 Specifications described in following para's shall apply, as far as possible.
22.5.1.2 The trench shall be so dug that the pipe can be laid to the required alignment and at the
required depth. When the pipe line is under a roadway, a minimum cover of 90 cm is recommended
for adoption but it may be modified to suit local conditions. The trench shall be excavated only so far
in advance of pipe laying as specified by the Engineer-in-Charge. The trench shall be so shored and
drained that the workmen may work therein safety and efficiently. The discharge of the trench
dewatering pumps shall be conveyed either to drainage channels or to natural drains.
22.5.1.3 The excavation shall be carried out with manual labour or with suitable mechanical
equipment as approved by the Engineer-in-Charge.
22.5.1.4 Unless otherwise specified by the Engineer-in-Charge, the width at bottom of trenches for
different diameters of pipes laid at different depths shall be as given below:
(a) For all diameters, up to an average depth of 120 cm, width of trench in cm=diameter of pipe
+ 30 cm.
(b) For all diameters for depths above 120 cm, width of trench in cm=diameter of pipe + 40 cm.
(c) Notwithstanding (a) and (b) the total width of trench shall not be less than 75 cm for depths
exceeding 90 cm.
22.5.2 Laying
22.5.2.1: All pipes shall be laid on a bed of cement or lime concrete with thickness and mix as
specified, projecting on each side of the pipe to the specified width of the trench. The pipes with
their crown level at 1.20 m depth and less from ground shall be covered with 15 cm thick. Concrete
above the crown of the pipe and sloped off to meet the outer edges of the concrete, to give a minimum
thickness of 15 cm all-around the pipe (Fig. 11). Pipes laid at a depth greater than 1.20 m at crown
shall be concreted at the sides up to the level of the centre of the pipe and sloped off from the edges to
meet the pipe tangentially (Fig. 11).

22.5.2.2: The pipe shall be carefully laid to the alignments, levels and gradients shown on the plans
and section. Great care shall be taken to prevent sand etc. from entering the pipes. The pipes between
two manholes shall be laid truly in a straight line without vertical or horizontal undulation. The pipes
shall be laid with socket up the gradient. The body of the pipe shall for its entire length rest on an even
bed of concrete and places shall be created in the concrete to receive the socket of the pipe.
22.5.2.3 Where pipes are not bedded on concrete, the trench floor 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, the desired levels shall be made up with concrete
1:5:10 (1 cement: 5 fine sand: 10 graded stone aggregate 40 mm nominal size) for which no extra
payment shall be made.
22.5.2.4 If the floor of the trench consists of rock or very hard ground that cannot easily be excavated
to smooth surface the pipe shall be laid on a leveling course of concrete as desired.
22.5.2.5 When S.W. pipes are used for storm water drainage, no concreting will normally be
necessary. The cement mortar for jointing will be 1:3 (1 cement: 3 fine sand).
22.5.2.6 Jointing:
a) Tarred gasket of hemp yarn soaked in thick cement slurry shall first be placed round the spigot
of each pipe and the spigot shall then be slipped home well into the socket of the pipe previously
laid. The pipe shall then be adjusted and fixed in the correct position and the gasket caulked
tightly home so as to fill not more than 1/4th of the total depth of the socket.
b) The remainder of the socket shall be filled with stiff mixture of cement mortar in the proportion
of 1:1 (1cement: 1 fine sand). When the socket is filled, a fillet be formed round the joint with a
trowel forming and angle of 45 degree with the barrel of the pipe.
c) After a day's work any extraneous material shall be removed from the inside of the pipe. The
newly made joints shall be cured for at least seven days.
22.5.3 Hydraulic Testing of Joints:
a) Stoneware pipes used for sewers shall be subjected to a test pressure of 2.5 m head of water at
the highest point of the section under test. The tolerance of two litre per centimeter of diameter
per kilometer may be allowed during a period of 10 minutes. The test shall be carried out by
suitably plugging the lower end of the drain and the ends of the connection if any and filling the
system with water. A knuckle bend shall be temporarily jointed in at the top end and a sufficient
length of vertical pipe jointed to it so as to provide the required test head, or the top may be
plugged with a connection to a hose ending in a funnel which could be raised or lowered till
the required head is obtained and fixed suitable for observation.
b) Before commencing the hydraulic test, the pipelines shall be filled with water and maintained
full for 24 hours by adding water, if necessary, under a head. of 0.6 m of water. The test shall be
carried out by suitably plugging the low end of the drain and the ends of connections, if any,
and filling the system with water. A knuckle bend shall be temporarily jointed in at the top end
and a sufficient length of vertical pipe jointed to it so as to provide the required test head or,
the top end may be plugged with a connection to a hose ending in a funnel which could be raised
or lowered till the required head is obtained and fixed suitably for observation.
c) Subsidence of the water may be due to one or more of the following causes:
i) Absorption by pipes and joints,

ii) Sweating of pipes or joints,
iii) Leakage at joints or from defective pipes, and
iv) Trapped air.
d) Allowance shall be made for (i) by adding water until absorption has ceased and after which
the proper test should commence. Any leakage will be visible and the defective part of the work
should be cut out and made good. A slight amount of sweating which is uniform may be
overlooked, but excessive sweating from a particular pipe joint shall be watched for and taken
as indicating a defect to be made good.
e) If any leakage is visible, the defective part of the work shall be cut out and made good. A slight
amount of sweating which is uniform may be overlooked, but excessive sweating form a
particular pipe or joint shall be watched for and taken as indicating a defect to be made good.
f) Any joint found leaking or sweating, shall be rectified or embedded into 15 cm layer of
cement concrete (1:2:4) 30 cm in length and the section retested.
g) Refilling: In cases where pipes are not bedded on concrete, special care shall be taken in
refilling trenches to prevent the displacement and subsequent settlement at the surface resulting in
uneven street surfaces and dangers to foundation etc. The backfilling materials shall be packed
by hand under and around the pipe, and rammed with a shovel and light tamper. This method of
filling will be continued up to the top of pipe. The refilling shall rise evenly on both sides of the
pipe continued up to 60 cm above the top of pipe so as not to disturb the pipe. No tamping should
be done within 15 cm of the top of pipe.
h) Measurements: :The lengths of pipes shall be measured in running meters nearest to a cm as
laid or fixed, inside of one manhole to the inside of the other manhole. The length shall be taken
along the centre line of the pipes over all fittings such as bends, junctions, etc. which shall not
be measured separately. Excavation, refilling, shoring and timbering in trenches, and cement
concreting wherever required shall be measured separately under relevant items of work.
i) Rate: The rate shall include the cost of materials and labour involved in all the operations
described above excluding the cost of concrete which shall be paid for separately.
22.6 : Drainage Appurtenant Structures :
22.6.1 Road Gully Grating : Constructing Road Gully Chamber with Grating:
22.6.1.1 Road Gully chamber with Horizontal Grating (Fig. 13 & 14)
The chamber shall be of brick masonry of specified class and shall have a C.I. grating with frame
fixed in 15 cm thick cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm
nominal size) at the top. The size of the chamber shall be taken as the clear internal dimensions of the
C.I. frame. The chamber shall have a connection pipe, the length of which in metre between the road
gully chamber and the manhole of the drain shall not be less than one by forty (1/40) times the nominal
diameter of pipe in mm (i.e. for 150 mm connection pipe, length shall not be less than 3.7 m and for
250 mm connection pipe length shall not be less than 6.25 m). The chamber shall be built at the location
fixed by the Engineer-in-Charge. Generally the spacing of the chambers shall be 18 to 36 m depending
upon the grading of the road channel and the area of the drainage. R.C.C. gully grating shall be fixed
in cement mortar 1:2 (1 cement: 2 coarse sand) as shown in Fig. 13. The

casting of the grating and frames shall be the same as that for manhole covers. The Gully grating
cover shall be hinged to the frame to facilitate its opening for cleaning and repairs.
22.6.1.2 Road Gully Chamber with Vertical Grating (Fig. 14):
The chamber shall be of 230 mm thick brick masonry in cement mortar 1:4. 12 mm dia. round bar
shall be fixed in cement concrete block at the bottom. The bars at the top shall be welded or riveted
to M.S. flat 40 x 6 mm as shown in Fig. 14. The specifications shall be same as described in 22.9.1.
Presently FRP covers and gratings are also available which are more adoptable.
22.6.1.3 Road Gully Chamber with Horizontal and Vertical Grating:
The details of typical road gully chamber of brick masonry shall be same as shown in Fig. 14.
22.6.1.4 Measurements: Road gully chambers shall be enumerated.
described above except the cost of excavation and connection pipes.
22.6.2: S.W. Gully Trap: Gully traps shall conform to IS: 651. These shall be sound, free from
visible defects such as fire or hair cracks. The glaze of the traps shall be free from crazing. They
shall give a sharp clear tone when struck with light hammer. There shall be no broken blisters.
Each gully trap shall have one C.I. grating of square size corresponding to the dimensions of inlet of
gully trap. It will also have a water-tight C.I. Cover with frame inside dimensions 300 x 300 mm; The
CI cover weighing not less than 4.50 kg and the frame not less than 2.70 kg. The grating, cover and
frame shall be of sound and good casting and shall have truly square machined seating faces.
22.6.2.1 Excavation: The excavation for gully traps shall be done true to dimensions and levels as
indicated on plans or as directed by the Engineer-in-charge.
22.6.2.2 Fixing: The gully traps shall be fixed on cement concrete foundation 65 cm square and not
less than 10 cm. thick. The mix for the concrete will be 1:5:10 (1 cement: 5 fine sand: 10 graded stone
aggregate 40 mm nominal size). The jointing of gully outlet to the branch drain shall be done similar
to jointing of S.W. pipes described in 22.7.3.
22.6.2.3 Brick Masonry Chamber:
a) After fixing and testing gully and branch drain, a brick masonry chamber 300 x 300 mm (inside)
in brick work of specified class in cement mortar 1:5 (1 cement: 5 fine sand) shall be built with
a half brick thick brick work round the gully trap from the top of the bed concrete up to ground
level. The space between the chamber walls and the-trap shall be filled in with cement concrete
1:5:10 (1 cement: 5 fine sand: 10 graded stone aggregate 40 mm nominal size). The upper
portion of the chamber i.e. above the top level of the trap shall be plastered inside with cement
mortar 1:3 (1 cement: 3 coarse sand), finished with a floating coat of neat cement. The corners
and bottom of the chamber shall be rounded off so as to slope towards the grating.
b) C.I. cover with frame 300 x 300 mm (inside) shall then be fixed on the top of the brick masonry
with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm nominal
size) and rendered smooth. The finished top of cover shall be left about 4 cm above the
adjoining ground level so as to exclude the surface water from entering the gully trap.
22.6.2.4 Measurements: The work shall be enumerated. Excavation shall be measured separately
under relevant item of earth work.

described above, except earth work which shall be paid for separately.
22.6.3 Construction Manholes (Fig. 3 to 7) :
22.6.3.1
a) At every change of alignment, gradient or diameter of a drain, there shall be a manhole or
inspection chamber. Bends and junctions in the drains shall be grouped together in manhole as
far as possible. The maximum distance between manholes shall be 30 m.
b) Manholes of different types and sizes as specified shall be constructed in the sewer line at such
places and to such levels and dimensions as shown in the drawings or as directed by the Engineer-
in-charge. The size specified shall indicate the inside dimensions between brick masonry faces
of the manholes.
c) Where the diameter of the drain is increased, the crown of the pipe shall be fixed at the same
level and necessary slope give in the invert of the manhole chamber. In exceptional cases and
where unavoidable, the crown of the branch sewer may be fixed at lower level but in such cases
the peak flow level of the two sewers shall be kept the same.
d) Sewers of unequal sectional area shall not be jointed at the same invert in a manhole. The invert
of the smaller sewer at its junction with main shall be at least 2/3 the diameter of the main
above the invert of the main. The branch sewer shall deliver sewage in the manhole in the
direction of main flow and the junction must be made with care so that flow in main is not
impeded.
e) No drain from house fittings, e.g. gully trap or soil pipe, etc. to manhole shall normally
exceed a length of 6 m unless it is unavoidable.
0 Manholes 90 x 60 cm is generally constructed within compound for house drainage only and near
the buildings for house drainage. Manholes 1.2 m x 90 cm are generally constructed for main
drainage work for depths less than 1.5 m.
g) Manhole 1.4 m x 90 cm are of the arched type and are generally constructed for main drainage
works where depth is 1.50 m or more The width of manholes shall be increased more than 90 cm
on bends or junctions or pipes with diameter greater than 450 mm and that the benching width
on either side of the channel is minimum 20 cm.
h) Manholes 1.4 m internal diameter are generally constructed for main drainage works where
depth is 2.45 m or more as an alternative to manholes of arch type. The diameter shall be
increased suitably, for pipes with diameter greater than 450 mm in the same manner as in the
case of rectangular manholes.
i) Before deciding size of manholes, Local Municipal Bye Laws shall be consulted. As a general
guide some typical type designs of manholes have been shown in Fig. 3 to 8. When manholes are
constructed on foot path, these shall be provided with cover of medium duty casting and when
built within the width of the road under vehicular traffic, these shall be provided with cover of
heavy duty casting.
22.6.3.2 Excavation : The excavation for manhole shall be true to dimensions and levels shown on
the plans or as directed by the Engineer-in-charge.
22.6.3.3 Bed Concrete: The manhole shall be built on a bed of cement concrete 1:4:8 (1 cement: 4
coarse sand: 8 graded stone aggregate 40 mm nominal size) unless required by local authorities.

The thickness of the bed concrete shall be 20 cm for manholes up to 4.25 m depth and 30 cm for
depths beyond 4.25 m unless otherwise specified or directed by the Engineer-in-charge. In bad
ground, special foundations as suitable shall be provided.
22.6.3.4 Masonry: Brick Work:
a) The brick work shall be with class 75 brick in cement mortar 1:4 (1 cement: 4 coarse sand).
The external joints of the brick masonry shall be finished smooth, and the joints of the pipes with
the masonry shall be made perfectly leak proof. For arched type and circular manholes, brick
masonry in arches and arching over the pipes shall be in cement mortar 1:3 (1 cement: 3 fine
sand). In the case of manholes of circular type the excess shaft shall be corbelled inwardly on
three sides at the top to reduce its size to the cover frame to be fitted.
b) The walls shall be built of one brick thickness for depths up to 4.00 m. In ordinary subsoil
below a depth of 4.00 m the wall thickness shall be increased to one and half brick and at 9.75
m below or more ground two brick thick walls shall be built.
22.6.3.5 Stone Work: R.R. Stone masonry in CM 1:6 (icement: 6 coarse sand) shall be used for
constructing walls of manhole. Minimum thickness of walls may be kept 450 mm. The internal sides
of walls should be plastered in CM 1:6 (1 cement: 6 coarse sand) having thickness 20 mm. The joints
of the pipes with the masonry shall be made perfectly leak proof.
22.6.3.6 Plaster and Pointing: The wall of the manholes shall be plastered inside with 12 mm thick
cement plaster 1:3 (1 cement: 3 coarse sand) finished smooth. In the case of arched type manhole
the walls of the manhole shall be plastered inside all around only up to the crown level, and flush
pointed for the shaft with cement mortar 1:2 (1 cement : 2 find sand). Where the saturated soil is met
with, also the external surface of the walls of the manhole shall be plastered with 12 mm thick cement
plaster 1:3 (1 cement: 3 coarse sand) finished smooth up to 30 cm above the highest sub-soil water
level with the approval of the Engineer-in-charge. The plaster shall further be water proofed with
addition of approved water proofing compound in a quantity as per manufacturer's specifications. In
case the designs/Local Authorities/Bye Laws specify richer specifications, the same shall be
adopted.
b) For earth work excavation, bed concrete, brick work, plaster and pointing, R.C.C. work and
refilling of earth, respective specifications shall be followed.
22.6.3.7 Benching: The channels and benching shall be done in cement concrete 1:2:4 (1 cement: 2
coarse sand: 4 graded stone aggregate 20 mm nominal size) and rendered smooth with neat cement. The
depth of channels and benching shall be as given in Table 9.
Table : 9
Sizes of drain Top of channel at the centre Depth of benching at side
above bed concrete wall above bed concrete
mm cm cm
100 15 20
150 20 30
200 25 35
250 30 40
300 35 45
350 40 50
400 45 55
450 50 60

22.6.3.8 Foot Rests (MH steps) :
a) All manholes deeper than 0.8 m shall be provided with M.S. foot rests. These shall be embedded
20 cm deep in 20x20x10 cm blocks of cement concrete 1:3:6 (1 cement: 3 coarse sand: 6 graded
stone aggregate 20 mm nominal size). The concrete block with M.S. foot rest placed in its centre
shall be cast in situ along with the masonry and surface finished with 12 mm thick cement
plaster 1:3 (1 cement: 3 coarse sand) finished smooth.
b) Foot rests which shall be of 20 mm sq M.S. bars as shown in Fig. 7 shall be fixed 40 cm apart
vertically and staggered laterally and shall project 10 cm beyond the surface of the wall. The top
foot rest shall be 45 cm below the manhole cover. Foot rests shall be painted with coal tar, the
portion embedded in the cement concrete block being painted with thick cement slurry before
fixing.
22.6.3.9 Manhole Covers and Frames: The frame of manhole shall be firmly embedded to correct
alignment and levels in R.C.C. slab or plain concrete as the case may be on the top of the masonry.
After completion of the work, manhole covers shall be sealed by means of thick grease.
22.6.3.10 Measurements: Manholes shall be enumerated under relevant items. The depth of the
manhole shall be reckoned from the top level of C.I. cover to the invert level of channel. The depth
shall be measured correct to a cm. The extra depth shall be measured and paid as extra over the
specified depth.
22.6.3.11 Rate :The rate shall include the cost of materials and labour involved in all the operations
described above but excludes the cost of (i) excavation, (ii) M.S. foot rests and (iii) 12 mm thick
cement plaster with water proofing material applied at the external surface of the manhole if required.
These items shall be paid for separately under relevant items of work. Payment for extra depths of
manholes shall be made separately under relevant items of work.
22.7 Constructing Drop Connection (Fig. 7):
22.7.1 General :
a) In cases where branch pipe sewer enters the manhole of main pipe sewer at a higher level than
the main sewer, a drop connection shall be provided. The work shall be carried out as per Fig. 7
S.C.I. pipes and special conforming to IS: 1729 shall be of the same size as that of the branch
pipe sewer.
b) For 150 and 250 mm main line, if the difference in level between the water line (peak flow
level) and the invert level of the branch line is less than 60 cm, a drop connection may be
provided within the manhole by giving suitable ramp. If the difference in level is more than 60
cm, the drop shall be provided externally.
c) The main lines up to 350 mm dia. are designed for half depth of flow, from 350 mm to 900
mm for 2/3 depth of flow and beyond 900 mm for 3/4 depth of flow.
22.7.1 Excavation : The excavation shall be done for the drop connection at the place where the
branch line meets the manhole the excavation shall be carried up to the bed concrete of the manhole
and to the full width of the branch line.
22.7.2 Laying : At the end of branch sewer line, S.C.I. cross shall be fixed to the line which shall be
extended through the wall of the manhole by a horizontal piece of SCI pipe to from an inspection or
cleaning eye. The open end shall be provided with chain and lid. The SCI drop pipe shall be connected
to the cross at the top and to the SCI bend at the bottom. The bend shall be extended through the

wall of the manhole by a piece of C.I. pipe which shall discharge into the channel. Necessary channel
shall be made with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm
nominal size) and finished smooth to connect the main channel. The joint between SCI pipe and
fittings shall be each caulked as specified. The joint between SCI cross and S.W. branch line shall
be made with cement mortar 1:1 (1 cement: 1 fine sand) The exposed portion of the drop connection
shall be enclosed all around with minimum 15 cm the concrete 1: 5: 10 (1 cement: 5 fine sand: 10
graded stone aggregate 40 mm nominal size) and cured. For encasing the concrete around the drop
connection, the necessary centering and shuttering shall be provided. The holes made in the walls of
the manhole shall be made good with brick work in cement mortar 1:4 (1 cement: 4 coarse sand) and
plastered with cement mortar 1:3 (1 cement: 3 coarse sand) on the inside of the manhole wall. The
excavated earth shall be back filled and compacted in the trench in level with the original ground level.
Drop connection shall be enumerated. The depths beyond 60 cm shall be measured in running
meters correct to a cm under relevant items.
described above but excluding the cost of excavations and refilling.
22.8 Construction of Open Surface Drain (Fig. 11)
22.8.1 The open drains shall be of the size and shape as specified in the item and laid to such
gradients and in such locations as may be shown in the relevant drawing or as directed by the
Engineer-in-Charge. The Masonry of the drain shall be in CM 1:4, the CC floor in PCC M 15 and
Plaster on the effluent side in CM 1:4. The section of the masonry and the thickness of plaster shall
be as per design/drawing.
22.8.2 Measurements: The drains shall be measured for individual items of excavation, PCC,
Masonry and plaster. The drains shall have a coping as specified.
22.8.3 Rate: The rate shall include the cost of labour and materials required for all the operations
described above.

Drawing not to Scale
All Dimensions are in mm.

APPENDIX'A'
Laying and Jointing of PE Pipes

1. Jointing Techniques:
1.1 General: Polyethylene pipes are made by continuous extrusion process and are generally available in
factory cut lengths and in form of coils. PE pipes conforming to IS 4984, as they are UV protected (due
to carbon black content in the pipe), may be stored either in open or covered.
1.1.1 The commonly used joints are as follows:
a) Fusion welding:
1) Butt fusion welding;
2) Socket fusion welding; and
3) Electro fusion welding;
b) Insert type joints;
c) Compression fittings/push fit joints;
d) Flanged joints; and
e) Spigot and socket joints.
1.2 Fusion Welded Joints:
a) The principle of fusion welding is to heat the two pipe surfaces to a designated temperature
and then fuse them together by application of sufficient force. This force causes the melted
materials to flow and mix, there by resulting in fusion.
b) Fusion welding of PE pipes must be carried out with welding equipment having temperature
and pressure (where applicable) display arrangements. PE pipes and PE fittings, to be joined by
face-to-face (butt fusion) welding must be of the same wall thickness and the ends must be cut
square. However, in some cases of fusion, where face-to-face contact is not involved the jointing
pipes/fittings wall thicknesses need not be same. The integrity of the fusion joint is dependent
on the cleanliness, temperature control and designated equipment that has been properly
maintained.
c) The pipe ends shall be dry and free of dust. Mating surfaces shall be planed/scraped before
fusion to remove surface material as polyethylene (PE) oxidizes on exposure to air. These
prepared (scraped) surfaces should not be touched, as there is a risk of contamination of the
surface, which may affect the weld efficiency. The site conditions must be protected against bad
weather influences such as moisture and temperatures below 5°C.
d) The fusion welding procedure described here is suitable for welding polyethylene pipes and
fittings falling in melt flow rate (MFR) range of 0.1-1.2 g/10 min at 190°C with nominal load of
5 kgf.

1.2.1.1 Butt fusion equipment : Basic welding machine shall be self-supporting such as guides and
clamps to suit the stability of the basic machine and with sleeves as per the size requirement along
with the following accessories:
a) Non-stick coated with poly tetra flouroethylene (PTFE), heating plate with thermostat and
temperature indicator,
b) Chamfering (Planing) tool - electrical/manual as appropriate, and
c) Electro-hydraulic power pack (for sizes greater than 125 mm) unit with pressure indicator,
bypass arrangement and accumulator.
d) The butt fusion equipment shall incorporate a facility for supporting the heating plate and
planing tool (necessary to square cut the pipe end) when in use. The machine shall be robust
enough to withstand normal field use.
e) Butt welding machines can be manual (for diameters up to 125 mm), hydraulic or pneumatic.
However, a locking system to hold the fusion force is to be ensured in all the systems, and the
equipment shall be protected against exerting over-pressure on the pipe. It shall be able to
maintain the required interface force on the pipe or fittings end as long as necessary.
1.2.1.2 Butt welding procedure (see Fig. A-1)
a) Clamp the pipes/fitting in the butt fusion machine.
b) Wipe the ends to be welded, inside and out, with a clean cloth to remove water, dirt, mud, etc.
c) Welding ends should be squared. In case of pipe, plane both ends by a planer (mechanical/
electrical for pipe diameters greater than 160 mm) until they are perfectly square. Fittings,
ends can be re-cut square, where necessary.
d) Remove the plastic shavings from the vicinity of the ends without touching the prepared
surface as any contamination will be detrimental to the welding process. Re-clean the surface
with proper solvent.
e) Bring together the two ends and ensure they are aligned.
f) Check the hot plate (mirror) temperature (range 200-230°C) and make certain the plate
surfaces
are clean. It is good practice to make `dummy' welds daily, prior to welding sessions as a
means of cleaning the mirror. That is, the weld procedure should be taken to the heat soak
stage, when the process can be aborted. The hot plate surface must not be touched with hand,
metal implements or tools. A damaged or dirty hot plate will result in a poor joint. Heating
mirror is nothing but a metallic plate heated up to the required temperature by electrical coil
embedded inside. The word `mirror' has come into vogue because the heating plate radiates
heat.
g) or to heating, levelling of the pipes/fittings is essential to ensure square plane face over the
heat surface [see 1.2.1.2 (c)].
h) Move the pipe/fitting ends into contact with hot plate and a steady pressure of 0.15 ± 0.01
MPa shall be applied while a uniform bead forms around the circumference of the both ends.
This procedure is to ensure that the entire face of the Weldable portion heats uniformly through
the surface contact with the mirror.
j) After the bead height is formed as per Table 1relieve the pressure but maintain contact
pressure between the plate and the ends of the heated surfaces as per pressure build up time
mentioned in Table 1.
k) Push back the pipe/fitting ends away from the mirror after the above operation. When
removing the mirror, make sure it is not brushed across the molten pipe ends.
m) Bring the molten ends together and follow the recommended pressure as per the requirement
of the pipe/fitting wall thickness (see Table 1). This pressure should be applied by building up
gradually to avoid squeezing out too much of the melt. Do not disturb the joint during the
required cooling time. Follow the pressure-time diagram as given in Fig. A-2.
n) Relax the pressure and carefully remove the clamps only after ensuring that cooling time has
elapsed.
p) Inside or outside bead removal after the weld joint cools, shall have no affect on the weld
performance.
1.2.1.3 Caution : It is essential to ensure the pressure-temperature chart and the corresponding
timing table is followed. While jointing, the pressure should be maintained as mentioned in Table 1.
After the pressure is relieved, the joint is allowed to cool to ambient temperature. Under no
circumstance the weld should be forcibly cooled (no quenching).

Table 1 : Values of the Recommended Bead Width and Timing for Butt Fusion Welding
S. Nominal Bead Height Heating Change
No. wall on the up-s over-s Jointing and cooling
thickness- heated Pressure Cooling Cooling
mm tool-mm Build up Time under Time
time -s pressure.-s. During
pressure
(1) (2) (3) (4) (5) (6) (7) Relaxation-S
(8)
i) Up to 4.5 0.5 45 5 5 6 300
ii) 4.5-7 1.0 45-70 5-6 5-6 6-10 600
iii) 7-12 1.5 70-120 6-8 6-8 10-16 900
iv) 12-19 2.0 120-190 8-10 8-11 16-24 1200
v) 19-26 2.5 190-260 10-12 11-14 24-32 1500
vi) 26-37 3.0 260-370 12-16 14-19 32-45 1800
vii) 37-50 3.5 370-500 16-20 19-25 45-60 2100
viii) 50-70 4.0 500-700 20-25 25-35 60-80 2700
NOTE-Bend strap testing is suggested on a sample ample to verifyfusion joint integrity and to qualify
the welding technicians. The specimen shall be made by the cutting the pipe longitudinally into strips
of 1 or 1.5 times the wall thickness wide and by about 300 mm or 30 times the wall thickness in
length with the fusion centred strip (see Fig. A-3). The fusion sample should be bent till the ends meet
and visually inspected. The sample should be free of cracks and breaks and shall have seamless joint
surface. Testing shall be done on the each size of the pipe being used at the site, to qualify various
machines and the technicians that are likely to be employed at the site.
1.2.2 Socket Fusion (see Fig. A-4) : This technique consists of simultaneously heating the external
surface of the pipe and the internal surface of the socket fitting until the material reaches fusion
temperature; inspecting the melt pattern; inserting the pipe end into the socket; and holding it in
place until the joints cools.
1.2.2.1 Socket fusion procedure :
a) Prepare the pipe - cut at right angles and trim;

b) Chamfer pipe end. Remove burrs and chips from inside pipe ends;
c) Utilize proper depth gauge to ensure correct insertion depth and pipe roundness;
d) Clean pipe and fitting with cloth to remove all the contaminants,
e) Verify proper heater plate temperature. Temperature should be 200-230°C;
f) Force fitting and pipe onto a heater surface. Be sure to insert pipe completely into female
socket and the fitting completely onto the male socket;
g) Apply the heat on the surface of the pipe;
h) Remove the pipe and fitting from the heater. Care should be taken for not to apply torque or
twist the pipe or fitting;
j) Quickly insert heated portion of the pipe into the heated socket of the fitting and ensure
coaxial alignment of the pipe and fitting;
k) Allow joint to cool for proper cooling time. Be sure to maintain pressure while cooling;
m) Allow joint to cool to room temperature before moving the joint; and
n) Inspect joint for weld integrity.
1.2.3 Electro Fusion (see Fig. A-5) : Electro fusion is a heat fusion process where a coupling or
fitting containing an integral heating source (resistance wire) is used to join the pipes and fittings. The
jointing areas, that meets the pipe surface and the inside the fittings are overlapped and the resistance
wires inside the fitting are heated by electric current.
During heating, fitting and pipe materials melt, expand and fuse together. Heating and cooling cycles
are automatically controlled by the bar code arrangement on the fittings and the machinery used.

The welding equipment or its accessory shall be able to supply the required voltage for the electro
fusion joint. The device must switch off as soon as the necessary heat has been fed to the welding zone.
The welding machine must be calibrated and timing adjusted to the electro fusion fitting's bar code
data (the fitting and machinery manufacturer recommendations shall be followed).
Electro fusion is the only heat fusion procedure that does not require longitudinal movement of the
joinable surfaces. It is frequently used where both pipes lengths are constrained, such as for repairs or
tie-in joints in the trench. Joints between dissimilar polyethylene grades and different wall
thicknesses can also be made using electro fusion, as the procedure readily accommodates
polyethylene grades with different melt flow rates and is independent of the pipe wall thickness.
1.2.3.1 Electro fusion welding procedure

a) Prepare the pipe - Cut at right angles and trim;
b) Remove the outer film of pipes using scraper;
c) Clean pipe surfaces with cleaner (as recommended by the electro fusion fittings supplier);
d) Mark the insertion depth on the pipe;
e) Remove the fittings from the packaging without touching the fusion surface;
0 Firmly push-in the pipe until the centre stop or marking;
g) Mount and fix assembly attachment;
h) Slide in the second pipe up into the fitting to centre stop or marking;
j) Firmly fasten the integrated clamp to ensure no movement while welding;
k) Follow operating instructions of the machine and fitting manufacturer or read the bar code;
m) Check the fusion indicator on the fittings and then remove cable; and
n) Wait for cooling to remove the assembly (follow the fusion guidelines of the fusion fittings
supplier or what is given in the bar code data).
1.2.4 Insert Type Joint (see Fig. A-6):
1.2.4.1 Insert type of fittings are available in both plastic and metal for use with PE pipes. These are
commonly used for the delivery pipe connections of bore/tube well pumps.
1.2.4.2 In corrosive locations plastic/stainless steel insert fittings are preferred. In less corrosion
conditions gunmetal fittings may be used and in normal or slightly corrosive environments, brass
fittings may be employed. The insert moulding plastic fittings with metallic inserts are also available.
The outer serrations of PE/metal insert type fittings - slightly over sized - lock into the pipes to
prevent their coming out under sudden pressure surge. The pipe bore is expanded by immersion in oil
bath (130°C) where the heat of the oil bath would soften the pipe to enable insertion of fitting.
1.2.4.3 The insertion of these fittings into the bore of the pipe is done with by hand pressure only. A
worm driven type clip while the surface of the pipe is relatively warm should be tightened over the
pipe to ensure the grip. Bolting or riveting the inserted fitting onto the pipe wall is also recommended
for carrying heavy weight, such as submersible pump.
1.2.4.4 This type of jointing is used normally for diameter pipes up to 110 mm and internal pressure
below 0.4 MPa. Load carrying capacity of this assembly depends on the pull force applied by the
weight of the total assembly including the weight of the hung item (say a submersible pump) and
media weight inside the pipe. The pipe manufacturers' recommendations are to be followed for
allowable total pull force on a given pipe with insert type connection. The elongation of PE pipe is
very high (over 600 percent), hence these recommendations attain significance. More so, if the load on
to the assembly is very high such as in the case of submersible pump lowered with PE pipe as a delivery
pipe with this type of connection.
1.2.5 Compression Fittings (see Fig. A-7 and Fig. A-8)
1.2.5.1 Compression fittings are detachable joints and are made of metal or plastics [polypropylene
(PP)] or a combination of both. Compression fittings form a tight seal by applying a compressive
force to the pipe and pipe fitting. The fitting is compressed against the pipe with a force sufficient to
eliminate all space remaining in the joint, thus preventing the fluid from leaking.
1.2.5.2 It is critically important to the integrity of the fitting that excessive force is avoided in
tightening the nut. If the fitting is over tightened, the gripper (clip ring) will deform and cause leaks.
Over tightening is the most common cause of leaks in compression fittings. As a general rule, a
compression fitting should be `finger tight' and then tightened one turn with a wrench. The fitting
should then be tested, and if slight weeping is observed, the fitting should be slowly tightened a bit
more until the weeping stops.
1.2.5.3 Compression fittings are also available as metal fitting such as the type of fitting commonly
used for copper tubes. In this type of joint the dimensions of the pipe are generally not altered. The
joint is affected by an internal liner and a compression ring or sleeve which shrinks and therefore
compresses the pipe wall on the liner, thus gripping to the wall of the pipe. The liner and compression
sleeve may also be an integral unit.

1.2.5.4 Compression fittings with collar/pipe ends and flat gaskets:
Aluminum alloy or brass fitting with male and female coupling parts may also be used for jointing
with metallic fittings. The male and female ends of the coupling are welded face to face on two ends
with hot plate or electric coil. The two collars are brought together and the female end of the coupling
is tightened on the male end. A water tight seal is made between the flanges. This is the detachable
type of jointing and is practicable up to 50 mm diameter pipes.
1.2.5.5 Compression fittings do not require fusion. They work at higher pressures and even with
toxic media. Compression fittings are especially useful in installations that may require occasional
disassembly or partial removal for maintenance, etc., since these joints can be detached and re-joined
without affecting the integrity of the joint. They are also used in situations where a heat source, in
particular a heating plate, is prohibited and inside bead formation by butt fusion is not preferred.
1.2.5.6 For coiled polyethylene pipes, of small diameters (<110 mm) where the working pressure do
not exceed 1.6 MPa, jointing by polypropylene (PP) compression fittings is generally recommended
over fusion jointing.
1.2.5.7 Various varieties of PP compression fittings such as couplers, bends, tees, reducers and
threaded/flanged adapters to connect to valves /tanks/ non-PE pipes are available.
1.2.5.8 Polypropylene compression fittings are easy to fit requiring no special skills, have no
possibility of infiltration (seepage) from outside or leaks from inside and therefore, are most ideal for
domestic service connections enabling easy threaded connections to the ductile/cast iron/PVCU/PE
pipe ferrules/saddles of the main lines.
1.2.6 Flanged Joints (see Fig. A-9)
1.2.6.1 These are used for jointing the PE pipes particularly of larger size to valves and vessels and
large size metal pipes, and where non-PE pipes are to be joined with PE pipes.
1.2.6.2 It contains slip-on metallic/polyethylene flanges with collar/stub ends. The collar/stub end is
welded by butt, socket or electro fusion, as per procedures (see 1.2.1.2, 1.2.2.1 and 1.2.3.1) to the pipe.
In case polyethylene flanges are used a suitable metallic backing plates shall be used to support the
polyethylene flanges so that the bolt force does not deform the plastic flange. Injection moulded
polyethylene flanges without backing flanges conforming to IS 8008 (Part 7) may also be used.
Sealing is improved by incorporating a natural or synthetic rubber gasket between flanges.

1.2.7 Spigot and Socket Joint (see Fig. A-10):
1.2.7.1 Any joint that permits sliding of the free end (spigot end) inside the socket with a rubber or
suitable gasket, without leakage is called a spigot and socket joint.
1.2.7.2 The socket (bell) could be an integral part of the pipe at one end or a special coupler, into
which the free ends (spigot ends) of the pipes are pushed to achieve a water tight joint. Various types
of Ò' rings are available in the market and the user may check with the manufacturer about the
suitability of the same as per site conditions.
1.2.7.3 These joints are normally weak in longitudinal pull and hence need anchoring wherever such
a tendency of longitudinal pull is likely in the pipe line. The supports of the side connection should
ensure that excessive lateral bending does not occur. In small diameter, the coupler itself could be
modified to have a split, threaded, grip type gasket of hard materials in addition to Ò' ring to prevent
loosening because of longitudinal pull. Special type of rubber gasket (for water tightness) to prevent
any slipping out of the free end of the pipe shall be used.
1.2.7.4 This type of joint is best used for non-pressure applications, such as gravity lines and for
encasing cables or smaller diameter pipes.
2. BENDING
2.1 Cold Bending (see Fig. A-11): Polyethylene pipes have a degree of flexibility such that a
substantial radius may be set up within a length of pipe itself without heating and causing residual
stress. This enables gradual curves to be negotiated without the need for special bends or flexible
couplings. However the radius of the bend shall be as per Table 2. Cold bending should only be used
on pipes at ambient temperature.
Table 2 : Allowable Bend Radius for Various SDRs
(Clause 2.1)
S.No. Pipe SDR Minimum Bending Radius
(1) (2) (3)
i) SDR = 9 10 times diameter
ii) 9 < SDR = 13.6 13 times diameter
iii) 13.6 < SDR= 21 17 times diameter
iv) SDR > 21 20 times diameter
NOTE- SDR (Standard Dimension Ratio) is defined as: SDR = Outside diameter, mm/Minimum
wall thickness, mm
Building Specifications 2014 Chapter 22 : Drainage Work Page 47 of 56

2.2 Hot Bending:
2.2.1 Forming of small radius bend may easily be done by the application of heat either by hot air oven
or by immersion in a suitable liquid at an appropriate temperature. For lower density polyethylene
pipe, the temperature range is 100 to 110°C and suitable liquids
are water, glycerol or a solution of calcium chloride. Higher density polyethylene pipe should be
heated in an inert liquid, such as glycerol at a temperature of 130°C. Electrical heating coils or plates
may be used only by experienced technicians.
2.2.2 In preheating operations, the low thermal conductivity of PE should be kept in mind.
Overheating can usually be recognized by surface discolouration and distortion. On the other hand
bending operations should not be performed at too low a temperature.
2.2.3 At higher temperature, the bore of the pipe tends to collapse and therefore requires support
during the bending operation. Internal support should be affected before heating by packing the bore
of the pipe with warm fine dry sand or by inserting rubber pressure hose, rubber rod or a flexible
spring. After the pipe is uniformity heated it should be bent around a sample jig and held in the correct
position until the form is cooled.
2.2.4 It is recommended that radius of the bend for pipe up to 50 mm size should not be less than
three times the outside diameter of the pipe for lower density PE and five times the outside diameter
for higher density PE. Pipes of large diameter will require an increase in radius. General
recommendations of the bend radius given in Table 2 are to be followed. The pressure compatibility
of the bend is to be tested before using the same in the field.
3. Pipe Laying:
3.1 The pipe line may be laid alongside of the trench and jointed there. There after the jointed
pipeline shall be lowered into the trench carefully without causing undue bending. The pipeline shall
be laid inside the trench with a slack of up to 2 m/100 m of pipe line.
3.2 Polyethylene pipes conforming to IS 4984, being black in colour, when subjected to direct
sunlight or warm ambient temperature may become warmer than the ground temperature. When
placed inside the trench, the pipe will contract in length as it cools to the surrounding soil temperature.
If the pipe is connected to sub-surface structures (such as preset valve, etc.) before it is cooled
sufficiently, excessive pull forces could develop. Allow the pipe to cool to ambient temperature
prior to making a connection to an anchored joint.
3.3 Polyethylene pressure piping systems jointed by butt welding, electro fusion and flanges do not
require external joint restraints or thrust block joint anchors.
3.4 Polyethylene pipes are non-metallic, so once buried, metal detector type locators are ineffective.
To facilitate locating a buried PE pipe, metallic locating tapes or copper wires can be placed alongside
the pipe. Locating tapes/wires are placed slightly above the crown of the above before the final back
fill.
3.5 Because of high integrity of properly made fusion joints, PE pipes can be used with special
installation techniques such as horizontal directional drilling, pipe bursting, micro tunneling methods
of trench less technologies.
4. Earth Work And Pipe Support (Trenching):
4.1 Trench width and depth shall be as per Fig. A-12 and Table 3.
Table 3 : Trench Dimensions
(Clauses 4.1 and 4.4.1) - All dimensions in millimeter
S.No. Size of pipe- Width of trench- Initial back fill- Range of depth of
mm mm mm cover-mm
(1) (2) (3) (4) (5)
i) 20-110 300 150 900-1100
ii) 125 425 150 900-1100
iii) 140 440 150 900-1100
iv) 160 460 150 900-1100
v) 180 480 150 900-1100
vi) 200 500 150 900-1100
vii) 225 525 150 900-1100
viii) 250 550 150 900-1100
ix) 315 615 150 900-1100
x) 355 655 150 900-1100
xi) 400 700 150 900-1100
xii) 450 750 150 900-1100
xiii) 500 800 150 900-1100
xiv) 560 860 150 900-1100
xv) 630 930 150 900-1100
xvi) 710 1010 150 900-1100
xvii) 800 1100 150 900-1100
xviii) 900 1200 150 900-1100
xix) 1000 1300 150 900-1100

Notes: 1. Width may be increased where jointing inside the trench becomes necessary because of
site conditions.
2. Under national/state highways, a concrete/ hume pipe shall be covered over the pipe.
3. Depth is to be measured over the crown of the pipe.
4. In case of mole-plough technique of pushing the coils of diameters 20-100 mm in am
narrow trench the width of 300 mm is not mandatory.
5. Initial back fill material shall be as per this standard.
6. For gravity lines SDR more than 22, manufacturers should be consulted for allowable
deformation calculations under dynamic traffic load.
4.2 Flexibility : For rigid pipes such as concrete, etc., the pipe alone has to take the main vertical
forces acting on the pipe, while flexible PE pipe makes use of the horizontally acting soil support
accumulating as a result of the deflection of the pipe. This aspect improves the load bearing capacity
of PE pipe especially useful property in gravity pipe design where there is no internal pressure to
ensure the pipe circularity.
4.3 Trench Bedding: Polyethylene pipe requires no special bed preparation for laying the pipe
underground, except that there shall be no sharp objects around the pipe. However, while laying in
rocky areas suitable sand bedding should be provided around the pipe and compacted.
4.4 Trench Depth:
4.4.1 The trench depth shall be as per Table 3. The initial back fill up to 150 mm above the crown of
the pipe should be compacted with screened excavated material free of sharp stones or objects or with
fine sand where no such material is available.
4.4.2 The excavated soil from the trenches should be placed such that it shall not interfere with
stringing and jointing of the pipes.
4.4.3 In all cases, 150 mm above the top of the crown of the pipe is to be compacted either by
mechanical or manual means. Wherever road crossing with heavy traffic is likely to be encountered a
concrete pipe encasing is recommended.
4.4.4 Polyethylene pipes can be jointed inside or outside the trench, as per site conditions. However, in
case of jointing inside the trench, the width of the trench may be suitably increased to ensure work
space.

Fig. A-12B : For Soil having Sharp Rocks and Unconsolidated Material that are Made Up of Rocks
Fragments > 20 mm Diameter
FIG. A-12 : TRENCH LAYOUT
4.5 Water in the Trench (see Fig. A-13) :The pipe shall be laid on a stable foundation. Where
water is present or where the trench bottom is unstable, excess water should be removed
before laying the pipe. In case there is a chance of floatation because of likely flood, the pipe shall
be encased with concrete weights as per the buoyancy calculations.
4.6 Under Water Installations (see Fig. A-14): Polyethylene pipes are frequently used for carrying
potable water across rivers/canals/lakes. Even water filled PE pipe is lighter than water. Thus the pipe
can be aligned along the recommended route over the water surface and then submerged with suitable
weights (see Fig. A-13). Submerged installations require permanent concrete ballast rings attached
around the pipe to ensure submergence and stable system once it is submerged. Concrete block design
depends on type of installation, tidal flows and wave actions.
4.7 Service Connection (see Fig. A-15-A and Fig. A-15-B)
4.7.1 New service connections can be made on PE pipes with mechanical saddles or electro fusion
saddles. Mechanical saddles are similar to those available for PVC-U and ductile iron.

4.7.2 Installation of mechanical saddle is similar to techniques used to install saddles on other piping
materials, however care has to be taken as excessive tightening of the side bolts may make the pipe
oval. Mechanical saddles should have wide straps to distribute compressive forces and must be
installed as per manufacturer's recommendations.
4.7.3 Installation of electro fusion saddle shall be as per the electro fusion jointing procedure detailed
in 1.2.3.1.
4.7.4 Mechanical saddles can also be used for PE to metal connection as a transition tapping. 5.
Installation:
5.1 Lowering:
5.1.1 When jointed outside of the trench the jointed pipeline shall be lowered into the trench (for
underground installations) carefully (preferably with mechanical handling equipment for sizes greater
than 160 mm) without causing undue bending that can cause kinking. The pipeline shall be laid
inside the trench. with a slack of up to 2 m/100 m of the pipeline (pipe
line to be laid in a sinuous alignment).
5.1.2 Bending of pipe inside the trench involves excavating the trench to the desired bend radius.
Exposed black PE pipe to ambient temperature greater than 30°C will have very high surface
temperature that makes it difficult to handle. Proper precautions shall be taken to ensure safety at work
site.
5.2 Thermal Expansion
5.2.1 For exposed PE pipes, provisions shall be made for the effects of thermal movement. The
support anchors for exposed PE pipes should not grip or distort the pipe (see Fig. A-16), but should
allow free movement of the pipe due to temperature variation.
5.2.2 Plastics pipe clamps may be used to support the pipe. Standard pipe clips may also be used but
care shall be taken not to over tighten and cause the clips to bite into the pipe. Pipe clips should be
correctly aligned and should provide a smooth flat surface for contact with pipe. Sharp edged supports
should be avoided.
5.3 Painting: Plastics pipes in general need not be painted. Painting may disguise its character.
Hazard might occur by mistaking this pipe for metal one in using it for load bearing support or, for
electrical grounding.
Precaution: Polyethylene pipes shall not be installed near hot water pipes or near any other heat
sources.

5.4 Valve Anchoring (see Fig. A-17): All types of manual controls and valves in particular should be
anchored firmly so as to avoid the turning torque imparted by the operation of the hand wheel of the
valve onto the pipe. In short the valve should not be `hung' on the pipe, as is normally done for metallic
pipes.
5.5 Support Spacing :Suitable supports as agreed to between the buyer and the supplier for horizontal
over ground run of PE pipe with pipe clamps/brackets should be used. At >40°C, continuous support is
recommended, if the pipe is carrying heavier liquids.
5.6 Effect of Temperature:
5.6.1 Expansion and Contraction: The co-efficient of expansion is about fourteen times than that for
expansion experienced with metal pipes. This also holds good for contraction due to fall in temperature.
5.6.1.1 In underground pipe the normal changes in the direction of the pipe provide an adequate
means of accommodating expansion/contraction.
5.6.1.2 In the continuous straight runs of exposed pipe it is necessary to insert units to absorb the
expansion. Expansion loops, bellows or sliding gland expansion joints may be used.
5.6.1.3 Care should be taken in, to account for the high increase in surface temperatures of these
pipes in cases of exposed laying or laying in the close proximity of artificial heat sources.
5.7 PE Fittings :Polyethylene pipe fittings conforming to IS 8008 (Parts 1 to 9) and IS 8360 (Parts 1
to 3) may be used for connecting the pipes and other system appurtenances. These fittings can also
be used for connecting to metallic valves (sluice, scour and air), tanks, pipes and other mechanical
equipment (pumps, etc.). However, where there is a likely hood of vibrations and turning torques in
such connections, the fitting wall thickness shall be minimum one rating higher than the corresponding
pipe.
5.8 Concrete Encasement: Polyethylene pipes may be encased in concrete, wherever necessary.
Compressible padding material at least 3 mm thick and at approximately 150 mm.
from the face of concrete shall be provided around pipes at the entry and exit points to eliminate any
potential sharp edges from rubbing against the pipe wall. Pipeline shall not be filled with water until
the concrete has developed sufficient strength.
6. Laying The Pipe in Trenches:
6.1 Trench Filling:
6.1.1 On completion of the pipe laying operations up to a length of about 1 000 m while further
laying work is still in progress, refilling of trenches of this stretch shall be carried out up to 300 mm
above pipeline. Pipe laying shall follow closely the progress of trench excavation. Only soft earth
and gravel of good quality free from boulders, roots vegetable matter, etc., shall be used first. If
sufficient quantity of suitable (sharp edge stone free) excavated earth is not available, the trench shall
be filled by borrowed gravel or material up to 300 mm above top of the pipe.
6.1.2 Care shall be taken during back filling for not to damage the pipe or joints. Filling has to be
carried out simultaneously on the both sides of the pipes so that unequal pressure does not occur.
Load on the buried pipeline shall not be permitted unless the trench has been filled to the height of at
least 300 mm over the top of the pipe. Filling shall be done in layers of 150 mm, with the first layer
watered and compacted by stamping or by mechanical means. The trench shall be refilled so as to build
up the original ground level, keeping due allowance for subsequent settlement likely to take place.
7. Field Testing of Pipeline : The pipeline to be tested shall be filled with water slowly allowing for
splurging the entrapped air. Air valves at high points should be open to allow air to escape while
water is being filled. Before pressure is applied, the pipeline section under test shall be restrained
against movement. The following procedure is recommended for PE pipe testing:
a) Polyethylene pipelines shall be pressure tested at ambient temperature. After filling with
water the pipeline shall be left to stabilize for a period of 1 h.
b) Fusion joints may be covered during testing. Flanged joints shall be kept open for visual
inspection. The pipeline shall be filled with water and pressure tested from the lowest point.
c) During the test period, make-up water is continuously added to maintain the pressure.
d) The test pressure shall be 1.5 times the rated pressure of pipes or of the proposed maximum
design pressure of the section. Apply the pressure by continuously pumping at a constant rate.
e) Under no circumstance, air is to be used instead of water for testing.
f) Tests should be performed on reasonable lengths of pipelines. Long lengths more than 2 000
m may make leak detection more difficult.
g) Acceptance criteria - If the pressure remains steady (within 5 percent of the target value) for
11 h, leakage is not indicated. Flanged connections shall be visually inspected.
h) If the test is not complete because of leakage or equipment failures, the test section shall be
depressurized and allowed to relax for at least 8 h, before starting the next testing sequence.
j) Testing outside the trench is to be avoided, as pipe rupture may involve safety issues.
8. Repair and Maintenance (See Fig. A-18)
8.1 A perfectly welded fusion jointed PE pipes is totally leak proof. A good compression fitting also
ensures total integrity of the system. However, there may be external conditions that necessitate
repairs and maintenance of the system. Various methods may be employed for repairing leakages or

damage to sections of PE pipes.
8.2 In general, the best way is to cut the damaged portion and to replace it by a new pipe or pre-
fabricated flanged replacement section. The connections of new pipe to either ends of the old pipe
may also be done by insert type of fittings (subject to their pressure limitations) and by electro fusion
fittings. Butt fusion inside the trench for repairs is not recommended as the movement of the pipe for
attaining the required facial pressure for good weld integrity may not be possible. When failure or
damage occurs in a welded joint, the original weld shall be removed entirely before re-welding. No
patch work is recommended.
9. General Guidance:
9.1 Freezing: Freezing of water inside the PE pipes does not fracture it, as the pipe expands to allow
the extra volume. However, direct application of intense heat, such as a torch or open flames should
not be used to de-freeze.
9.2 Pressure Check: In any application where polyethylene pipe is attached to a pressure source,
which is greater than the pressure rating of the polyethylene pipe being installed, adequate pressure
reduction devices shall be installed. Whenever, such devices are installed a regular check of such
devices should be made to ensure their continued proper functioning as a protection to the PE pipe.
9.3 Surge Pressure: Polyethylene pipes, by their visco-elastic nature and creep properties, can
withstand much higher short term loads, that is, 2.3 times the working pressures. This property
enables PE pipe to be able to withstand repetitive water hammer surges of pumping mains, without
any need for any extra correction factor. However, for velocities higher than 1.5 m/s a surge check is
necessary.

Note: The saddles shown in Fig. A-15-A and A-15-B can also be used as repair sleeves.
9.4 Slack in Laying: When PE pipes are laid inside the trench, up to 2 percent slack is
permitted.

S.No. IS No. Subject
1. 458-1988 Precast Concrete pipes (with and without reinforcement) (3rd
Rev) (Amendment 2).
2 651-1992 Specification for salt glazed stone ware pipes and fitting (5th
revision).
3. 783-2010 Code of Practice for Laying Concrete Pipes
1536-2001 Cast Iron spun pipes
4. 1726 ( Partl-7) 1991 Specification for cost Iron manhole covers and frame (3rd
revision)
5. 1729-1797 Specification for sand cost Iron spigot and socket soil waste
and ventilating pipes fitting and accessories
6. 4111-1986(P-1-4) Code of practice for Ancillary structure system for sewerage.
7. 4127-1983 Code of Practice for Laying of Glazed Stone Ware Pipes
8. 4885-2001 Specifications for Sewer Bricks
9. 5455-1969 Specifications for Cl steps for Man Holes.
10. 7634(P-2)-2012- Laying and jointing of PE pipes.
11. 12592-2002 Pre-cast Concrete Manhole Covers and Frames:
Specifications
CHAPTER No. 23
TUBE WELLS &
WATER HARVESTING WORK
CHAPTER No.23
TUBE WELLS & WATER HARVESTING WORK
CONTENTS
23.1 Scope 3
23.2 Terminology 3
23.3 Development of Tube Well 5
23.4 Type of Tube Well 5
23.5 Drilling Methods 5
23.6 Accessories 8
23.7 General Requirements 8
23.8 Disinfection 9
23.9 Grouting & Sealing 10
23.10 Surface Apron 10
23.11 Measurement of Tube Well Depth 10
23.12 Measurement of water level 10
23.13 Verticality & Alignment 11
23.14 Testing for yield & Draw Down 12
23.15 Quality of Water 12
23.16 Information to be furnished by the owner of the Tube Well 13
23.17 Information to be furnished by the Drilling Agency 13
23.18 Handing Over of Tube Well after Construction/testing 13
23.19 Handing Over document of Tube Well after testing 14
23.20 Rain Water Harvesting 14
Appendix À' 26
Appendix `B' 27
List of Relavent IS Codes 28
Rajasthan PWD Building Specifications 2014 Chapter 23 : Tube Well & RWH Page 1 of 28
CHAPTER No. 23
TUBE WELLS & WATER HARVESTING WORK
23.1 Scope :
This Specification applies to drilling, construction and testing of tube wells for agriculture, drinking
water, industrial, rain water harvesting and other allied purposes.
23.2 Terminology:
For the purpose of this standard, defmitions of the terms generally used in tube well drilling technology
(specified in IS 9439: 1980) shall apply.
i) Tube Well: A tube well is a type of water well in which a long 100-200 mm (4 to 8 inch) wide
steel tube or pipe is bored into an underground aquifer. The lower end is fitted with a strainer,
and a pump at the top lifts water for irrigation etc. The required depth of the well depends on
the depth of the water table.
ii) Temporary reservoir: A small reservoir of water is made at the outlet of the tube well. This
reservoir is used for different usage of water by the local population.
iii) Drive mechanism : In the past, the pump was driven by large diesel engines. However, now
a days electric motors are used, as they are a much cheaper source of power.
iv) Casing: The tube well casing houses the inlet, cylinder, piston valves and rising main of a
"down-the-hole" type hand pump. Casing to support the external surfaces of the borehole
against collapse may be needed, either temporarily or permanently, and is often made of PVC
pipe, which is both cheap and inert. Seepage down the tube well bore is prevented by the
sanitary seal. Seepage from the ground above the aquifer is excluded by the lengths of plain
casing. Water to be pumped is admitted through slots in the lower lengths of casing. Water
abstracted from aquifers in relatively soft ground usually contains sand or silt particles, which
are liable to cause rapid wear to pump valves and cylinders (and dissatisfaction among
consumers). Methods of preventing these particles from reaching the pump are of two general
types, screening and sand/gravel packing.
v) Screening: The drawing shows slots in the PVC casing which can be cut on site, using a
hacksaw. More elaborate, and far more compact, screens are available commercially, some can
be bolted on to pump inlets. Materials used include woven wire and man-made fabric, the later
can be wrapped around the pump inlet assembly. Screening is nearly always needed in some
form.
vi) Sand/gravel packing: The drawing shows graded sand and gravel, which is placed from the
top of the borehole. More compact, pre-bonded, packs of sand and/or gravel are available
commercially, some of these can also form part of the pump inlet assembly. Sand and/or gravel
packing is meant to eliminate particles from the water before they reach the screen and would
otherwise have passed through the screen.
vii) Ground Water Safety: The introduction of tube wells has led to major Arsenic poisoning in
Bangladesh. High concentrations of Arsenic occur naturally in the soil in some areas of
Bangladesh. The wells were drilled into aquifers which contained high levels of this naturally
occurring Arsenic.
Aquifer : Aquifers are the permeable formations having structures which permit appreciable
quantity of water to move through them under ordinary field Conditions. Thus these are the
Geologic formations in which ground water occurs. (i.e. Sand & Gravels).
Aquicludes : Aquicludes are the impermeable formations which contain water but are not
capable of transmitting of supplying a significant quantity(e.g. clays).
 Aquifuge: Aquifuge is an impermeable formation which neither contains water nor transmits
any water.
Probably 90 % of all developed aquifers consists of unconsolidated rocks, chiefly gravel and sand.
Sands are composed of microscopic particles that are rounded(bulky ) or angular in shape. They
drain easily, do not swell, posses insignificant capillary potential and when dry exhibit no
shrinkage, clays on the other hand are composed of microscopic particles of plate like shape. They
are highly impervious, exhibit considerable swelling, posses a high capillary potential and
demonstrate considerable volume reduction upon drying.
 Porosity : Porosity is defined as the ratio of the volume of openings or pores or voids in the
material to its total volume and is expressed as percentage.
 Specific yield : The capacity of a formation to contain water is measured by porosity .However
a high porosity does not indicate that an aquifer will yield large volume of water to a well. The
only water which can be obtained from the aquifer is that which will flow by gravity. The
specific yield of an aquifer is defined as the ratio expressed as a percentage, of the volume of
water which after being saturated, can be drained by gravity to its volume. Specific yield is an
indication of water yielding capacity of an unconfined aquifer.
xiii) Specific Retention : Specific yield is always less than porosity since some water will
be retained in the aquifer by molecular and surface tension forces. The specific retention of an
aquifer is the ratio, expressed as a percentage, of volume of water it will retain after saturation
against the force of gravity to its own volume.
xiv) Water Table : The saturated zone is bounded at the top by either a limiting surface of saturation
or overlying (confining) impermeable strata, and extends down to underlying impermeable
strata. In the absence of the confining impermeable layer, the static level of water in wells
penetrating the zone of saturation is called the water table. The water table is the surface of
water body which is constantly adjusting itself towards an equilibrium condition. If there were
no recharge to or outflow from the ground water in basin, the water table would eventually become
horizontal.
xv) Unconfined Aquifer : Unconfined aquifer or water table aquifer is the one in which a water
table serves as the upper surface of the zone of saturation . It is also some times known as the
phreatic or non artesian aquifer. In such an aquifer, the water table varies in undulating form and
in slope. Rises and falls in water table correspond to changes in the volume of water in storage
with in the unconfined aquifer.
xvi) Confined Aquifer or Artesian Aquifer : Confined Aquifer or Artesian Aquifer is the one in
which ground water is confined under pressure greater than atmospheric by overlying,
relatively impermeable strata. Artesian aquifer are analogous to pipelines. The static pressure at
a point with in the artesian aquifer is equivalent to the elevation of the water table in the
recharge area less the loss in head through the aquifer to the point under consideration. In a
well penetrating such an aquifer, the water level will rise to the level of the local static pressure or
artesian head. Water enters a confined aquifer in an area where the confining bed rises to the
surface or ends underground and the aquifer becomes unconfined. Artesian aquifer usually have
relatively small recharge areas as compared with unconfined aquifers. When water is
withdrawn from an artesian well, a local depression of the piezometric surface results. This
decrease in pressure permits a slight expansion of the water and in some cases a compaction of
the aquifer.
xvii) Flowing well and Artesian well : When a tube well penetrates a confined aquifer, water rises
in the well to the level of local static pressure or artesian head. If this artesian pressure is
sufficient to raise the water above the ground level, a flowing well occurs. If, however, the water
level in such a well is below the ground level, but is above the local water table, it is known as
the artesian well.
Perched aquifer is a special type of unconfined aquifer, and occurs where a ground water body is
separated from the main ground water by a relatively impermeable stratum of small aerial extent
and by the zone of aeration above the main body of ground water.
23.3 Development of Tube well:
i) The drilled well shall be developed by any of the methods specified in IS 11189: 1985 depending
upon the site conditions in order to get maximum sand free yield. The development process shall
be continued until the stabilization of sand and gravel pack has taken place.
ii) The development of the tube well by over pumping should be done at I5 percent to 25 percent
higher discharge than the expected discharge from the tube well. The final discharge should be
free from sand with a maximum tolerance of 20 parts of sand in one million parts of water by
volume after 20 minutes of starting the pump.
iii) In case of tube wells for drinking water, the discharge shall be totally sand free. If the discharge
is not sand free after 20 minutes of starting the pump, the well shall be redeveloped. In case the
discharge is still not sand free even after re-development, the pump set of lesser discharge
capacity may be installed to get sand free water suitable for drinking. The turbidity and hardness
of water of wells used for drinking purposes, shall be as specified in IS 10500: 1983.
iv) After completion of development by over pumping, the well shall be tested for its performance
that is yield characteristics and efficiency. This shall be achieved by conducting a step draw
down test-determine draw downs at the end of the hour by pumping at 3 to 4 different rates of
discharge.
v) The company should be equipped with 1100 to 450 CFM and 150 to 600 PSI capacity
compressors for development of Tube Well. The 550 CFM at 600 PSI, compressor has been
introduced for the first time in India ,in Tube well industry for quick and effective development
of Tube well of depth up to 1500 feet by direct lowering of airline. In addition the Tube wells are
developed by submersible pumps to make the discharge silt free. Step draw down test is
conducted to determine operational discharge and well efficiency. Screw air compressor of
1100 CFM@350 PSI is also used for drilling.
vi) Drilling machines are available in bench ,pillar and gang type ,which cover a wide range of
operations such as Tube well drilling, Development of Tube well and ground water exploration.
23.4 Type of Tube wells:
23.4.1 Type 1 (Cavity Well) : Cavity wells are generally shallow wells drilled in alluvial formations.
These are wells with casings resting in thick, hard impervious clay layer above the aquifer. It is a
pre-requisite that the impervious clay layer should be of adequate thickness to support the well and
should not disintegrate when water is pumped out.
23.4.2 Type 2 (lobe well ): Tube wells are generally constructed in alluvial formations comprising a
casing pipe, a housing pipe (if need be) and an intake section either screen or slotted pipe with or
without gravel packing (artificially packed or naturally packed wells. These wells may be either
under water table conditions or under artesian conditions.
23.4.3 Type 3 (Bore well in Hard Rock Formation ): The over-burden in such wells is encased to
eliminate the risk of caving in. Drilling is further carried out in rock formation and the bore is left
normally unsupported to allow the water to flow from crevices and fishers into the bore except in
cases where caving formations are encountered.
23.5 Drilling Methods:
23.5.1 Auger Drilling: The drilling is done with a spiral or worm auger connected to square rods
turned manually with rod tillers, the cuttings produced as a result of drilling are removed with a sand
shell. Steel casing pipes with drive shoes at the bottom are lowered as the drilling progresses. This
method is employed where very shallow drilling in alluvium formation is involved.
23.5.2 Water Jet Boring: A drill bit with nozzles is attached to the drill pipes at its bottom and
through which water is pumped at high pressure. The water on its return flow through the annular space
between the bore and the drill pipe, brings out the cutting along with it to the surface. Casing pipe is
simultaneously used to avoid caving-in. The method is suitable for drilling shallow wells in loose
sandy formations.
23.5.3 Calyx Drilling: A bit made from hollow steel tube with two inclined slots called `shot bit' is
connected below another tube ( core barrel) which is further connected to the drill rods. These are
rotated mechanically. Chilled shots are fed to the bottom of the bit through the drill string along with
water. These are ground by the shot bit to form abrasive material with sharp edges which cuts into the
consolidated formation forming an annular ring to form a core inside the core barrel, which is then
taken out from well by grouting the core with quartz chips, etc. This method is successful for shallow
tube wells drilling in consolidated formations with large diameter holes.
23.5.4 Percussion Drilling: A heavy bit attached with a drill stem, a drilling jar to a cable is given up
and down spudding motion, either manually or by power. Water is added to dissolve the cuttings which
are lifted out by means of a bailer. Steel casing pipes with drive shoes are used as the hole progresses.
This method of drilling is suitable for drilling in bouldery formations.
23.5.5 Rotary Drilling:
23.5.5.1 Direct Circulation Method:
i) In direct mud rotary drilling method, the bore hole is advanced dry rapid rotation of a drill bit
mounted on the end of the drill rods. The bit cuts and breaks the material at the bottom of the hole
into small pieces (cuttings). The cuttings are removed by pumping drilling fluid enhancer, such
as bentonite, down through the drill rods. The drilling fluids also serves to cool the drill bit and
stabilize the bore hole wall, to prevent the flow of fluids between the bore hole and surrounding
earth materials, and to reduce cross contamination between aquifers.
ii) Despite these obstacles, direct mud rotary drilling can be the best alternative, especially for deep
wells or wells completed into well - Lithified rocks, when direct mud rotary methods are used,
hole diameters should be 3 inches to 5 inches larger than the outer dia. of the well casings to
allow effective placement of filter and sealing materials. Two inch dia. monitoring wells should
therefore installed with in 5.5 inch or larger holes.
23.5.5.2 Reverse Circulation Method:
i) Reverse circulation is achieved by blowing air/water down the rods , the differential pressure
creating air lift of the water and cuttings up the inner tube which is inside of each rod. It reaches
the bell at the top of the hole, and then moves through a sample hose which is attached to the top
of the cyclone The drill cutting trowel around the inside of the cyclone until they fall through an
opening at the bottom and are collected in a sample bag.
ii) Reverse circulation is air powered , water is also used to reduce dust , keep the drill bit cool
and assist in pushing cutting back upwards, but also when collaring a new hole. A mud called
liquid pool is mixed with water and pumped into the mud string , down the hole. This helps to
bring up the sample to the surface by making the sand stick together , occasionally 'super foam'
(quick foam)is also used to bring all the very fine cuttings to the surface and to clean the hole
around the rods ,when the drill reaches soil , a collar is put down the hole around rods which is
normally PVC piping , occasionally the collar may be made from metal casing , collaring a hole
is needed to stop the walls from caving in and bogging the rod string at the top of the hole .Collars
may be up to 60m deep depending upon the ground.
iii) Reverse circulation rigs set ups usually consists of a support vehicle ,an auxiliary vehicle , as
well as the rig itself .The support vehicle ,normally a truck, holds diesel and water tanks for
resupplying the rig .It also holds other supplies needed for maintenance on the rig .The auxiliary is
a vehicle , carrying an auxiliary engine. These engines are connected to the rig by high pressure
air hoses .Although Reverse circulation rigs have their own booster and compressor to generate
air pressure ,extra power is needed which usually supplied by the rig due to lack of space for
these large engines.
iv) A setting of drill pipes with a drill bit at the bottom is rotated by mechanical means. Plain water
or a fluid of gelling quality depending on the strata conditions is allowed to flow into the bore
hole, when drill cuttings along with water are sucked through the drill pipes by a centrifugal
pump and thrown into the setting pit. The hole remains intact under the hydrostatic pressure of
the drilling fluid, the level of which is maintained continuously. Large diameter holes can be
drilled in alluvium formations by this method.
23.5.6 Down the Hole Hammer ( DTH ) Drilling :
i) The method is used for fast and economical drilling in hard formations. Compressed air is
utilized for rapid impacting action by the hammer to the bit thus crushing the formation into small
chips which are flushed out through the annular space between the bore and the drill pipes by
the upcoming compressed air.
ii) The drilling bits generally used during the drilling by direct circulation method and by reverse
circulation method are tri cone rock roller bits, diamond drilling bits, reaming bits and thin wall
core bits. Their use depends upon the type of soil formations such as soft, medium hard and hard
formations. The bits used for percussion drilling are California pattern bits and for DTH drilling
are button bits and drag bits.
23.6 Accessories: The accessories commonly used for tube well construction, their description/
functions and the typical material for their manufactures are given in Table 1.
Table 1 :Nomenclature of Tube well Parts

Si. Name of Part Description/Function of Part Typical Materials
No. IS Code nos.
(i) Bail plug or A closed socket provided at the bottom most end IS 226 : 1975
bottom plug of the pipe assembly. A simple mild steel plate
welded at the bottom end.
(ii) Bail plug hook Inverted Ù' hook attached to the `bottom plug or IS 226 : 1975
a bar fitted across the blind pipe.
(iii) Casing pipe Placed against strata from which water is not to be IS 4270 : 1983 or
tapped. IS 12818 : 1989
(iv) Screens/slotted Have openings to permit entrance of water from IS 8110 : 1985
pipes the aquifer.
(v) Centralizer The centralizing guides are fitted to the well IS 226 : 1975
assembly except the housing pipe at suitable
spacing to keep the assembly in the centre of the
hole so that an even thickness of gravel packs.
(vi) Taper/reducer A taper/reducer is intended to connect the IS 226 : 1975
housing pipe with lower diameter assembly down
below.
(vii) Housing pipe This is the upper portion of the case section of IS 4270 : 1983
the well and serves as housing for the pumping
equipment and is a vertical conduit through which
water flows from the aquifer to the pump. It is
water tight and extends downwards from ground
surface to a depth below the anticipated pumping
water level.
(viii) Clamp Fixed at the top of the tube well for supporting IS 226 : 1975
the well assembly.
(ix) Well Cap Used to keep the tube well closed after its IS 226: 1975
completion until the pump set is installed. It is
either threaded to be screwed to top of the
housing or simply a plate is spot welded so as to
be easily removed when required.
23.7 General Requirements:
23.7.1 Design and Lowering of Pipe Assembly:
23.7.1.1 Design of Pipe Sizes and Lengths: The length and diameter of the casing pipe is selected on
basis of static water level, the draw down, the discharge expected from the well and the size of pump
to be installed. The size and length of slotted/strainer pipes are selected according to the actual
requirement according to the strata met with, the expected discharge and the depth of tube
well. The casing pipes shall generally conform to IS 4270: 1983 and the slotted/strainer pipes shall
conform to IS 8110: 1985.
23.7.1.2 Design of Screen Slots: The entry of water in the tube well shall be either through screens
or slotted pipes. Following are the various types of well screens and slotted pipes used in water wells
depending upon the type and size of well:
Plain slotted pipe,
Bridge slotted pipes,
Mesh wrapped screens,
Cage type wire wound screens,
Pre-packed resin bonded gravel screens, and
Brass screens.
The design, selection and type of screen or slotted pipe, size and distribution of slots shall be as
specified in IS 8110: 1985.
23.7.2 Gravel Packing:
23.7.2.1 All gravel to be, used as pack in tube well construction shall be as specified in IS 4097:
1967. The thickness of the gravel shroud around the screen shall generally be not less than 10 cm.
23.7.2.2 In percussion method of drilling, gravel is fed into the annular space between the casing
pipe and the assembly pipe up to 3 m above the bottom of the slotted pipe. The well is developed
using compressed air or by bailers and as the water becomes clear, surging or backwashing is done to
make the development more perfect. More gravel is fed, if necessary, and when the water becomes free
from sand, the casing pipe is jacked up to some height, and the process is repeated until all the aquifers
are gravel packed.
23.7.2.3 In rotary method, the pipe assembly is lowered into position and gravel packing may be
done up to a suitable depth below the bottom of the housing pipe in the first instance. Thereafter the
gravel packing up to the required depth is completed after keeping the housing pipe vertical within
limits. To achieve uniform gravel packing around the pipe assembly inverted cones should be used.
23.7.2.4 A provision for a well base to eliminate the possibilities of subsidence of the well structure
may be incorporated. If the bottom of the well is in a soft formation, the well should be provided
with an artificial base for the casing and screen by over drilling the hole about 1 to 2 m and filling the
extra depth with concrete or gravel.
23.8 Disinfection:
23.8.1 The well shall be disinfected after completion of test for yield. All the exterior parts of the
pump coming in contract with the water shall be thoroughly cleaned and dusted with powdered
chlorine compound. In fact it should be disinfected every time a new pump is installed or the one
replaced after repairs.
23.8.2 A stock solution of chlorine may be prepared by dissolving free chlorinated lime. For obtaining
an applied standard concentration of 50 ppm. One litre of the stock solution should be used to treat
300 litres of water.
23.8..3 In case of water wells for drinking water purposes, the quality of water should be as laid
down in IS 10500: 1983.
23.9 Grouting and Sealing:
23.9.1 Grouting and sealing of tube well may be done, if required by the owner, depending upon the
site conditions and quality of the discharge of the strata encountered. To ensure that the grout will
provide a satisfactory seal, it should be applied in one continuous operation. Sealing of the tube well
may be done by grouting the annular space between bore and the housing pipe, thickness of grouting
depending upon the quality of water. In case of tube wells for drinking purposes, grouting and sealing
shall always be done to ensure safe sanitary conditions.
23.9.2 It is desirable to plan an oversize bore hole of 7.5 to 15 mm more than the diameter of the
well casing to an adequate depth during the design of well itself. The depth to be grouted varies with
geologic and site conditions but a depth of 3 to 4.5 m from the surface is generally adequate.
23.10 Surface Apron: An apron around the well and sloping away from it protects the well from
pollution caused by contaminated water flowing back into it and prevents muddy pools' of standing
water forming around the well.
23.11 Measurement of Tube well Depth:
23.11.1 Measurement by Means of Cable or Rods: This method is suitable for measurement of
depth of tube wells on a consolidated formation. The bottom of tube well shall first be cleaned and the
depth measured by :
a) Twisted metallic cable strained by a plumb-bob, and
b) means of rigid rods.
With any of the above methods three distinct measurements shall be taken and effective one will be
the average reading of the three.
If the depth of tube well does not exceed 100 m, the accuracy of measurement is ± 0.5 percent. If the
depth exceeds 100 m, the accuracy of measurement shall be agreed between contractor and owner.
23.11.2 Measurement by Means of Casing: This method also applies to unconsolidated formation
and is used for any tube well with casing. The depth of tube well shall be deemed to be equal to
length of the pipes lowered, after the deduction of the screwed ends. Each pipe should be measured
to an accuracy of ± 0.1 percent. The accuracy of measurement is ± 0.3 percent.
23.12 Measurement of Water Level:
23.12.1 Direct Measurement - This is carried out by a steel tape or cable with a suitable sinker
attached at the ends. The steel tape or cable is wound round a rotating drum. Measurements shall be
done by measuring the length of tape or cable. Depth of immersion of sinker shall be taken into
account in the measurement. A set of three readings shall be taken and effective will be their average.
Any measurement which deviates from the average by more than ± 0.3 percent shall be discarded and
new measurement to be taken in place. Accuracy of measurement shall be as agreed between the
drilling agency and owner.
23.12.2 Electric Measurement (Double Pole Contact ):
i) Double Pole Contact, a sufficiently rated battery, a reel with a length of twin electric cable and an
electrical indicating instrument as a high resistance voltmeter or a mili ammeter are required. The
items should be adjusted as shown in the figure. One end of the cable shall be permanently
connected to voltmeter/ammeter and the other end to be connected through battery. As the cable
is lowered into the tube well, the circuit is completed as soon as the two electrodes
strike the water and the instrument indicated. The depth of water level is obtained by measuring
the twin cable from the electrodes to the top of tube well.
ii) Where electric power is more easily available, battery may be replaced with the power supply
mains. In this case, single pole method may be used. For single pole contact, the apparatus is
similar to as described for two pole contact with the difference that the contact casing is fitted
with one electrode and a single cable. The circuit is completed through the rising main as soon
as the electrode touches the water. Measurement is similar to two pole contact method. This
method shall be employed only when the casing extends from the top of the bore hole to below
the water surface to be measured.
23.12.3 Air Pressure Line Method: This consist of:

a A tube positioned between casing and the outlet pipe and extending to below the depth of water.
b A calibrated pressure gauge graduated in meters of water or in MN/m2' and
c An air pump and non return air valve.
All above items should be adjusted as shown in IS: 2800 (Part II)-1979. For example, if water level
`L' is to be determined, air is pumped into the air tube, until maximum reading is obtained on the
pressure gauge. The complete air tube will be filled with air and the pressure reading corresponds to
À' . At the time of setting, distance `B' should be noted. The required depth `C' will be the difference
of `B' and' A' readings.
23.13 Verticality and Alignment:

23.13.1 If a turbine well pump is to be installed in a well, the well should be true to line from its top
to a point just below the maximum depth at which it is proposed to set a pump. A tube well out of
alignment and containing as and bends or cork-screw should be rejected because such deviations
cause severe wear on the pump shaft, bearings and discharge casing and in a severe case, might make
it impossible to get a pump in or out. If an air lift or a suction pump is used for pumping, alignment
is not so important and the same is applicable to the submersible type of pump.
23.13.2 In case of gravel surrounded tube wells if the pipe assembly is found inclined in a slant
position before completing the gravel pack, the assembly should be pulled in a desired direction by
suitable methods with a view to rectify slantness and bringing the pipe assembly within the pernussible
limits of verticality. The gravel pack should be completed immediately after the verticality has been
tested and rectified.
23.13.3 The verticality of the tube well shall be tested by using plumb or a plunger, 6 mm smaller in
diameter within the inside diameter of the well casing. The plumb may be made from a piece of sheet
steel or a short piece of pipe. Whichever is used, it shall be heavy enough to keep the plumb line taut.
The hub of the ring shall not be solid as the water shall through it as it is lowered in the well. The
hole from which the plumb line passes shall be in the exact centre of the ring. Knots or marks shall
be made every 3 m on the plumb line to indicate the depth to which the ring has been lowered in the
well. The plumbing shall be suspended from the guide pulley where it shall be at least 3 m above
the top of the well. The guide pulley is fixed on a tripod or frame. The vertical centre of the pulley
shall be so located that the plumb line comes off its outer edge exactly over the centre of well casing.
23.13.4 For tube wells encased with pipes up to 350 mm diameter the verticality of the tube well
shall be measured in terms of clear cylindrical space available within the housing pipe after the
construction of the tube well.
23.13.4.1 Verticality of the tube well shall have a deviation so as to provide clear cylindrical space not
less than clear cylindrical space available in a hypothetical tube well of the same size but having
deviation of 10 cm per 30 m in one direction and in one place only.
23.13.4.2 The verticality of the tube well is to be tested as given in 23.13.3. After the necessary
computation is made, cross sections of housing pipes at different depths are drawn on a graph and clear
cylindrical space is determined. This cylindrical space of the actually constructed tube well shall be
referred as `G' in the following paragraphs.
23.13.4.3 Cross sections of hypothetical tube well identical in dimensions to the actual tube well but
having deviation of 10 cm per 30 m in one direction and in one. Plane are drawn on the graph sheet
and the minimum allowable cylindrical space is determined
23.13.4.4 If the cylindrical space `G' of the actually constructed tube well is equal to more than the
cylindrical space `H' of the hypothetical tube well (having deviation 10 cm in 30 m in one direction
or one plane ) the tube well actually constructed shall be considered within the permissible limits of
verticality as given in this standard.
23.13.4.5 For example cross sections of two tube wells G1 and G2 having 300 mm diameter of
housing pipe have been drawn after computation of verticality results and space G1 is found more than
space `H', while space G2 is less than space `H'. Therefore tube well G1 shall be considered within
the limits of verticality while G2 is not within the limits verticality as per the provisions of these
specifications.
23.14 Testing For Yield and Drawdown:
23.14.1 The drawing off of water through tube well results in a lowering of water level. This
drawdown creates a hydraulic gradient in the water bearing material with the result that underground
flow into the tube well takes place. The rate of inflow depends upon the hydraulic gradient,
permeability and saturated thickness of water bearing material and of tube well construction.
23.14.2 After the well has been completely constructed and cleaned out of the depth of the well
accurately measured, this test should be carried out.
23.14.3 This test is conducted by installing a test pump in the tube well temporarily and pumping out
water. At each rate of discharge, pumping is carried out at least for 30 minutes. If the water level
discharge are found to be fluctuating, development is carried out some more hours until the discharge
becomes steady and sand content is within tolerable limits. The specific capacity of the well for
various pumping rates is computed based on drawdown test data. Discharge may be measured by
any method detailed in IS: 5120-1977 `Technical requirements for roto dynamic special purpose
pumps (first revision).'
23.14.4 Since the yield is influenced by a number of factors such as geological formation, rainfall,
neighbouring tube wells, etc, the pumping rate shall in general, not exceed 60 percent of the yield
determined by test. It is recommended that geological advice should be obtained on the percentage to
be adopted for each location.
23.15 Quality of Water:
23.15.1 In the construction of the well, due precautions shall be taken by the drilling agency to
maintain the premises in a sanitary condition and to avoid as much as practical, the entrance of
contaminated water into the safe water bearing formations. Any water of materials used should be free
of contamination and, if their nature permits, should be adequately disinfected with chlorine before
use. The slush pit should be constructed so that no material there from will enter the well, except
mud reused when the construction is by rotary method. In such cases the slush pit and mud return
channels should be protected against contamination from surface water or any other sources.
23.15.2 Water shall be collected during aquifer performance test and analyses chemically as desired
by the owner, for different constituents depending on the ultimate use to which water will be put.
23.16 Information to be Furnished by the Owner of the be well: The
owner shall furnish the following information to the drilling agency:
a) Information regarding tube wells and dug well, existing near his land. Their depth, formation
encountered and discharge, etc, may be furnished as far as possible;
b) Static water level;
c) Expected yield;
d) Purpose for which the water is needed, such as irrigation, industrial or domestic purpose, etc;
and
e) Any other information. 23.17 Information to be
Furnished by Drilling Agency:
When offering to sink a tube well, the drilling agency shall furnish the owner with the following
information:
a) Suitability of the site proposed by the owner (if a more suitable site, other than the one
proposed by the owner is available, it should be suggested);
b) Whether a test bore hole is proposed and if so, its diameter and depth, and also depth of
production tube well proposed;
c) Likelihood of increase or decrease of the depth given at (b) above;
d) Method of drilling with size of bore in different depths;
e) Types of plain pipe with size, wall thickness and slotted/strainer pipes with opening, may be
mentioned;
0 Guarantee with regard to the verticality of tube well and sand content (ppm) in the discharge
from the well at the time of handing over;
g) Development methods to be adopted may be stated; and
h) Any other information and conditions,
23.18 Handing over of Tube well after Construction / testing:
The following information should be furnished by the testing agency to the owner on completion of
testing of the tube well:
a Result of the tube well depth and water level measurements
b Report on the chemical and bacteriological analysis of water, and
c Result of development and drawdown test as Table 2.
Table 2 : Test Results
A. Normal Test
S. Rated Depression Specific Total Hours Sand in ppm Static Water Pumping
No. Discharge at Rated Yield 2/3 Run at End of Level Water Level
Discharge Test
1 2 3 4 5 6 7 8
B. Discharge at 1.2 times normalyield or 1. times theno rm al depression

Specific Yield Discharge Drawdown Total Sand in Static Water Pumping
Hours ppm at Level Water
Run End of Test Level
1 2 3 4 5
23.19 Handing over Document for Tube well after Testing: The tube well should be handed over
to the owner in a complete shape. The housing pipe should be closed by a well cap for the period
between the completion of the tube well and the installation of the pump set. The following
information shall be furnished by the drilling agency on completion of the tube well:
a) Total depth of tube well drilled,
b) Strata chart of the tube well indicating different type of soil formations met with at different
depths and indicating the depth of each type of soil formation,
c) Samples of strata collected, neatly packed and correctly marked in sample bays,
d) Position of every joint in well assembly,
e) Method used for development,
0 Total hours of development done,
g) Developed discharge in L.P.S.,
h) Discharge is totally sand free or presence of sand particles is there,
i) P.P.M. and turbidity after development,
j) Pumping water level at developed discharge, and
k) Static water level.
23.20. in Water Harvesting :
23.20.1 Scope:
i) Record droughts and water-supply worries have served as catalysts for state to consider
legislation legalizing the catchment and use of rainwater for use in households and for lawns.
ii) There has been increased interest over the past five years in State allowing, defining, and
clarifying when rainwater harvesting can occur. Rainwater harvesting is the act of utilizing a
collection system to use rainwater for outdoor uses, plumbing, and, in some cases gation
consumption also. State must ensure water-quality standards and public health concerns are
met.
iii) Allows financial institutions to consider making loans for developments that will use
harvested rainwater as the sole source of water supply.
iv) Requires rainwater harvesting system technology for potable and non potable indoor use and
landscape watering be incorporated into the design and construction of each new state building
located in an area of the state in which the average annual rainfall is at least 20 inches.
v) Requires the development of rules regarding the installation and maintenance of rainwater
harvesting systems that are used for indoor potable purposes and connected to a public water
supply system, prior to this it could only be used for non potable purposes.
vi) Requires a person who intends to connect a rainwater harvesting system to a public water
supply system for potable purposes to give written notice to the municipality or the owner or
operator of the public water supply system. A municipality or public water supply system may
not be held liable for any adverse health effects allegedly caused by the consumption of water
collected by a rainwater harvesting system that is connected to a public water supply system and
is used for potable purposes if the municipality or the public water supply system is in
compliance with the sanitary standards for drinking water.
vii) Encourages each municipality and Urban development authority to promote rainwater
harvesting at residential, commercial, and industrial facilities through incentives such as the
provision at a discount of rain barrels or rebates for water storage facilities. Requires the Urban
Development Authority to ensure that training on rainwater harvesting is available for the
members of the permitting staffs of municipalities and Public Health Department at least
quarterly. School ,districts authority are strongly encouraged to implement rain water harvesting
systems.
viii) Prohibits a municipality or UIT from denying a building permit solely because the facility
will implement rainwater harvesting.
23.20.2 Rainwater Harvesting -Terminology:
a) The term rainwater harvesting is being frequently used these days; however, the concept of
water harvesting is not new for India. Water harvesting techniques had been evolved and
developed centuries ago.
b) For conservation & harvesting rain in order to recharge alarmingly receding ground water
tables. Rain water harvesting systems that comprises collection and storage of rain water for
different needs. This collected rain water is stored and subsequently used for meeting the
irrigation demands of domestic as well as agricultural applications. Further these can also be used
for recharging ground water.
c) The rain water harvesting includes collecting, storage, and efficient use of rain water , which
reduce the cost of public water supply.
d) Ground water resource gets naturally recharged through percolation. But due to indiscriminate
development and rapid urbanization, exposed surface for soil has been reduced drastically with
resultant reduction in percolation of rainwater, thereby depleting ground water resource.
Rainwater harvesting is the process of augmenting the natural filtration of rainwater in to the
underground formation by some artificial methods. "Conscious collection and storage of
rainwater to cater to demands of water, for drinking, domestic purpose & irrigation is termed as
Rainwater Harvesting."
ii) Auxiliary Water System: The term means any water system on or available to the premises other
than the water works. The Auxiliary water may include water from a source such as wells, lakes or
streams or process fluids or used water.
iii)Grey water: It means treated waste water from bath tubs, showers, lavatory, fixtures, wash
basins, washing machines, and laundry tubs .It does not include waste water from toilets, urinals,
kitchen sinks, dish washers, or laundry water from soiled diapers.
iv) Potable Water: It means water fit for human consumption & domestic use that is safe & normally
free of minerals, organic substances & toxic agents in excess of reasonable amounts for domestic
usage in the area served & normally adequate in quantity & quality for a minimum health requirements
of the persons serviced.
v) Reclaimed Water: It means water resulting in the treatment of domestic, municipal or industrial
waste water that is suitable for a water reuse that would not otherwise occur. Specifically excluded
from this definition is "Grey water".
vi) Storm Water: It means precipitation that is discharged across the land surface or through
conveyances to 1 or more waterways & that may include storm water runoff, snow melt runoff, &
surface runoff & drainage.
vii) Storm Water Management Facility: It means a device that control storm water runoff &
changes the characteristics of that runoff, including but not limited to, the quantity, the period of
release or the velocity of flow.
viii) Water Works: It means a system that serves piped water for drinking of domestic use to:
a) The public
b) At least 15 connections, or
c) An average of 25 individuals for at least 60 days out of the year. The term "Water Works"
include all structure, equipment & appurtenance used in the storage, collection, purification,
treatment & distribution of pure water, except the piping & fixtures inside the building where
such water is delivered.
23.20.3 Why harvest rainwater: This is perhaps one of the most frequently asked questions, as to
why one should harvest rainwater. There are many reasons but following are some of the important
ones:
i) Relief of strain on other water supply
ii) Ability to build or farm in areas with no other water supply
iii) Cleaner water
iv) Increased independence and water security
v) Lower water supply cost
vi) Improved plant growth
vii) Greater sensitivity and connection with natural cycles
viii) To arrest ground water decline and augment ground water table
ix) To beneficiate water quality in aquifers
x) To conserve surface water runoff during monsoon
xi) To reduce soil erosion
xii) To inculcate a culture of water conservation
23.20.4 How to harvest rainwater: Broadly there are two ways of harvesting rainwater:
(i) Surface runoff harvesting
(ii) Roof top rainwater harvesting
23.20.4.1: Surface runoff harvesting: In urban area rainwater flows away as surface runoff. This
runoff could be caught and used for recharging aquifers by adopting appropriate methods.
23.20.4.2: Roof top rainwater harvesting (RTRWH): It is a system of catching rainwater where it
falls. In roof top harvesting, the roof becomes the catchments, and the rainwater is collected from the
roof of the house/building. It can either be stored in a tank or diverted to artificial recharge system.
This method is less expensive and very effective and if implemented properly helps in augmenting
the ground water level of the area.
23.20.4.3 Components of the Rainwater harvesting system: Rain water harvesting system should
be designed and sized based on a number of factors that are specific to the site, structures) and
use(s).The design should include an evaluation of the catchment surface, gutters, pre treatment
devices, storage, pumps, piping, and appropriate treatment. There are a number of resources that can
be used to guide individuals in this process. The system mainly constitutes of following sub
components:
(i) Catchment Surface :
a) The surface that receives rainfall directly is the catchments of rainwater harvesting
system. It may be terrace, courtyard, or paved or unpaved open ground. The terrace may
be flat RCC/stone roof or sloping roof. Therefore the catchments are the area, which
actually contributes rainwater to the harvesting system
b) Rain water is typically captured from a structure or building roof. Rain water can also be
captured from a constructed conveyance specifically designed to intercept the rainwater
for collection. Other impervious surfaces, such as driveways, parking areas, etc. are
generally not suitable for rainwater harvesting but may be appropriate for storm water
management.
c) The roof material will impact the quality and quantity of captured rainwater. Smooth
metal or slate surfaces are most efficient. Clay and concrete tiles may collect less rainwater
due to porosity ,inefficient flow and evaporation. Calculators used to estimate quantity and
component sizes may include a "Rooftop Runoff Coefficient" to account for differences
in catchment surface materials. Composite shingles, and tar and gravel roofmg may leach
chemicals into the water, so these should be considered as a part of the design and intended
use of the harvested rainwater.
(ii) Gutters, Downspouts & Drains (Transportation): Gutters are used to capture rainwater all the
eaves of a building, and should be sloped towards the down spouts. Their size depends on the
roof configuration. surface area, roof slope, number of down spouts and intensity of rainfall.
Rainwater from rooftop should be carried through down take water pipes or drains to
storage/harvesting system. Water pipes should be UV resistant (ISI HDPE/PVC) pipes, vinyl,
aluminium, and galvanised steel, of required capacity. Water from sloping roofs could be caught
through gutters and down take pipe. At terraces, mouth of the each drain should have wire mesh
to restrict floating material.
(iii) Pre Treatment, Free First Flush Diverters, Roof Washers :
a) Leaves and other debris can be prevented from entering the collected rainwater along the
gutters using leaf screens or "gutter guards" ,or in the down spouts with downspout filters
or strainer baskets. Other pre-treatment devices such as cylindrical screens and filter
socks may be installed at the outlet of the downspouts or inlet to the storage tank.
b) A first flush diverter is designed to re-route the initial rain water runoff that may contain
contaminants such as dust, pollen, bird and rodent feces from the harvested water storage
tank. One diverter is recommended for each downspout and there are several designs
available. The diverted water should ideally be routed to a previous area to allow for
filtration. The recommended amount of rain water diverted depends on roof surface,
amount of debris, and number of antecedent dry days.
c) A roof washer is another device for filtering small debris just ahead of the storage tank.
Roof washers are commercially available and consist of a 30-50 gallon box tank, which
are usually equipped with a 30 micron filter or other strainer.
d) First flush is a device used to flush off the water received in first shower. The first shower
of rains needs to be flushed-off to avoid contaminating storable/rechargeable water by
the probable contaminants of the atmosphere and the catchments roof. It will also help in
cleaning of silt and other material deposited on roof during dry seasons Provisions of first
rain separator should be made at outlet of each drain pipe.
There are also devices which combine the functions of first diversion and a roof washer.
All treatment devices require regular maintenance and cleaning.
(iv) Storage Tanks: Storage tanks or cisterns are selected based on size, location, and material of
construction . Algae growth should be prevented by using opaque tanks, and minimizing light
penetration from any openings. Proper screening of all inlets, outlets and overflows is necessary
to protect from vectors such as mosquitoes, insects and rodents.
(v) Pumps & controls: Submersible pumps, suction or jet pumps are common in rain water
harvesting systems. They are often used in conjunction with a pressure tank and switch for
pump control . A floating pump intake equipped with a filter is recommended to withdraw
water a few inches below the water surface.
23.20.5 Treatment to Harvested water:
(a) Treatment Goals & Water Quality Standards: The safe drinking water act has established
chemical, physical, radiological and microbiological standards for public drinking water .These
standards have been adopted by the water works department. The public drinking water
standards cover contaminants that pose acute and chronic health concerns. These guide lines
recommended that harvested rainwater be restricted to non potable activities. In setting with a
high potential for human exposure or contact, the primary area of concern is microbial
contamination. The public health goal in these setting is to maintain an absence of :
 Bacteria, including Escherichia coli, legionella
 Protozoans, including Giardia lamblia, Cryptosporidium - Viruses
(b) Treatment Processes: It is important that potential users understand the need for treatment in
order to minimize risk to those that may come in contact with harvested rainwater Pre treatment
devices (described in the previous section are recommended for all rainwater
harvesting systems. Additional treatment processes maybe necessary, depending on the intended
use. Treatment effectiveness can only be established through a regular water testing program, in
conjunction with routine maintenance of the rainwater harvesting system.
(c) Filter: (el) There is always some scepticism regarding Roof Top Rainwater Harvesting since
doubts are raised that rainwater may contaminate groundwater. There is remote possibility of this
fear coming true if proper filter mechanism is not adopted. Secondly all care must be taken to
see that underground sewer drains are not punctured and no leakage is taking place in close
vicinity. Filters are used for treatment of water to effectively remove turbidity, colour and
microorganisms. After first flushing of rainfall, water should pass through filters. There are
different types of filters in practice, but basic function is to purify water.
(c2) Filtration devices are used to remove particulate matter that may clog piping valves, plumbing
fixtures other devices, stain sinks, toilets and tubs, and harbour pathogenic microorganism.
Cartridge filters of synthetic fibre, ceramic media filters, and activated carbon filters should be
used as appropriate. Filters that are certified to meet standards help ensure that the filter does
not impart undesirable contaminants into the water.
( 6 ) The efficiency of the filter is related to the opening size. A recommended size for non-potable use
often cited is 5 microns. The intended use of the harvested rainwater should determine the type
and opening size of the filter.
(c4) Granular activated carbon (GAC) filters provide an additional benefit in absorbing organic
compounds, some of which may impart undesirable water characteristics such as odour. GAC
filters are generally used in series with another sediment filter. GAC filters must be installed
upstream of chlorine disinfection.
(c5) Synthetic membrane filters with smaller openings, such as reverse osmosis units, may also be
considered, depending on the proposed use.
(i) Sand Gravel Filter: These are commonly used filters, constructed by brick masonry and filled by
pebbles, gravel and sand as shown in the figure. Each layer should be separated by wire mesh.
(ii) Charcoal Filter: Charcoal filter can be made in-situ or in a drum. Pebbles, gravel, sand and
charcoal as shown in the figure should fill the drum or chamber. Each layer should be separated by
wire mesh. Thin layer of charcoal is used to absorb odour if any.
(iii) PVC Pipe Filter: This filter can be made by PVC pipe of 1 to 1.20 m length. Diameter of pipe
depends on the area of roof. Six inches dia. pipe is enough for a 1500 Sq. Ft. roof and 8 inches dia.
pipe should be used for roofs more then 1500 Sq. Ft. Pipe is divided into three compartments by
wire mesh. Each component should be filled with gravel and sand alternatively as shown in the
figure. A layer of charcoal could also be inserted between two layers. Both ends of filter should have
reduce of required size to connect inlet and outlet. This filter could be placed horizontally or vertically
in the system.
(iv) Sponge Filter: It is a simple filter made from PVC drum having a layer of sponge in the middle
of drum. It is the easiest and cheapest form filter, suitable for residential units.
(d) Neutralization: Neutralization of rainwater may be necessary to raise the pH to acceptable
levels. This is particularly important if the water will contact metal surfaces, pipe, etc. To prevent
corrosion. A neutralizing filters/contactors with calcium carbonate media, sometimes blended with
magnesium oxides, can also be used to raise the pH.
(e) Disinfection: Non potable water used indoors should be disinfected. Disinfection of non potable
water prevents microbial growth (such as Legionella and E coli), odour and fouling of fixtures. All
disinfection methods shall follow filtration. The disinfection methods most commonly referenced are
Chlorine, Ultra violet (UV) light, and ozone. VDH recommends that a qualified professional
engineer design the system and provide operational recommendations for the appropriate treatment
and delivery of harvested rain water.
i) Chlorine is a powerful oxidant chemical that is generally used in conventional drinking water
disinfection. Chlorine disinfection may be achieved in various ways, and generally leaves a
residual in finished water to inhibit growth of bacteria. Chlorine disinfection can be achieved
through the use of flow through chlorinators using calcium hypochlorite tablets or pallets .An
automated, sodium hypochlorite solution feed system using metering pump and injector may also
be used. Chlorine compounds having standard certification are recommended. Do not use
commercial bleaches or chlorine products that contain fragrances or UV stabilizers
(particularly cyanide based UV stabilizers designed for swimming pools). A total chlorine
residual of 0.2 mg/L is recommended.
ii) UV light disinfection devices for potable water must meet standards class A. Non potable water
disinfection devices should meet standards class B, as a minimum. UV light system must be
rated for the system design flow rate.
iii) Ozone is a powerful oxidant that is highly reactive and does not leave a residual disinfectant in
the water. In addition to disinfecting microorganisms, it also reduces colour, taste and odours.
Ozone gas can be a health hazard if inhaled, and accumulation of ozone may pose a risk of
explosion.
23.20.6 Methods of Roof Top Rainwater Harvesting:
23.20.6.1 Storage of Direct use: In this method rain water collected from the roof of the building is
diverted to a storage tank. The storage tank has to be designed according to the water requirements,
rainfall and catchments availability. Each drainpipe should have mesh filter at mouth and first flush
device followed by filtration system before connecting to the storage tank. It is advisable that each
tank should have excess water over flow system.
Excess water could be diverted to recharge system. Water from storage tank can be used for secondary
purposes such as washing and gardening etc. This is the most cost effective way of rainwater
harvesting. The main advantage of collecting and using the rainwater during rainy season is not only
to save water from conventional sources, but also to save energy incurred on transportation and
distribution of water at the doorstep. This also conserve groundwater, if it is being extracted to meet
the demand when rains are on.
23.20.6.2 Recharging Ground water Aquifers: Ground water aquifers can be recharged by various
kinds of structures to ensure percolation of rain water in the ground instead of draining away from the
surface. Commonly used recharging methods are :
a) Recharging of bore wells
b) Recharge pits,
c) Soak bays or recharge shafts,
d) Recharging of dug wells,
e) Recharge trenches,
f) percolation tanks.
a) Recharging of Bore wells: Rain water collected from roof top of the building is diverted through
drain pipes to settlement or filtration tanks. After settlement, filtered water is diverted to bore
wells to recharge deep aquifers. Abandoned bore wells can also be used for recharge.
Optimum capacity of settlement tank/filtration tank can be designed on the basis of area of catchments,
intensity of rainfall and recharge rate as discussed in design parameters. While recharging, entry of
floating matter and silt should be restricted because it may clog the recharge structure. "First one or
two showers should be flushed out through rain separator to avoid contamination. This is very
important and all care should be taken to ensure that this has been done".
b) Recharge Pits: Recharge pits are small pits of any shape rectangular, square or circular, contracted
with brick or stone masonry wall with weep hole at regular intervals. Pit can be covered with
perforated covers. Bottom of pit should be filled with filter media.
The capacity of the pit can be designed on the basis of
catchments area, rainfall intensity and recharge rate of soil Usually the dimensions of the pit may
be of 1 to 2 m width and 2 to 3 m deep depending on the
depth of pervious strata. These pits are suitable for
recharging of shallow aquifers, and small houses.
c) Soak bay or Recharge Shafts: Soak away or recharge shafts are provided where upper layer of
soil is alluvial or less pervious. These are bored hole of 30 cm dia. up to 10 to 15 m deep,
depending on depth of pervious layer. Bore should be lined with slotted/perforated PVC/MS pipe
to prevent collapse of the vertical sides. At the top of soak away required size sump is constructed
to retain runoff before the filters through soak away. Sump should be filled with filter media.
Perforated pipe
d) Recharging of dug wells: Dug well can be used as recharge structure. Rainwater from the rooftop
is diverted to dig wells after passing it through filtration bed. Cleaning and desalting of dug well
should be done regularly to enhance the recharge rate. The filtration method suggested for bore
well recharging could be used.
e) Recharge Trenches:
Recharge trench in provided where upper impervious layer of soil is shallow. It is a trench excavated
on the ground and refilled with porous media like pebbles, boulder or brickbats. it is usually made for
harvesting the surface runoff. Bore wells can also be provided inside the trench as recharge
shafts to enhance percolation. The length of the trench is decided as per the amount of runoff
expected. This method is suitable for small houses, playgrounds, parks and roadside drains. The
recharge trench can be of size 0.50 to 1.0 m wide and 1.0 to 1.5 m deep.
f) Percolation tanks: Percolation tanks are artificially created surface water bodies, submerging a land
area with adequate permeability to facilitate sufficient percolation to recharge the ground water. These
can be built in big campuses where land is available and topography is suitable.
Surface run-off and roof top water can be diverted to this tank. Water accumulating in the tank
percolates in the solid to augment the ground water. The stored water can be used directly for
gardening and raw use. Percolation tanks should be built in gardens, open spaces and roadside green
belts of urban area.
23.20.6.3 Testing: Harvested rain water should be tested at the storage unit (cistern or tank) to
determine the microbial and chemical quality of the water, prior to any subsequent treatment. If
treatment is installed, then the harvested water should also be tested downstream of all treatment
units to ensure that the treatment is working.
23.20.6.4 Operation and Maintenance : The owner of a rain water Harvesting system is responsible
for the ongoing operation and maintenance. Duties may include any of the following :
 Monitor tank levels
 Clean gutters and pre-treatment devices
 Repair and maintain mechanical and electrical equipment
 Remove sediment build up in tanks
 Periodically backwash filters or replace the filter media
 Replenish neutralizing filter media
 Replace spent GAC media
 Clean UV light bulb and quartz sleeve, replace bulbs as needed
 Replenish chlorine disinfectant (tablets, pellets or solution)
 Regularly test bacteriological water quality
Owners of rainwater harvesting systems with extensive water treatment equipment may consider
contracting maintenance oversight from the system designer or equipment supplier. At a minimum,
specific manufacturer's literature should be consulted for more detailed operation and maintenance
information.
23.20.6.5 Do's and Dont's:

Harvested rainwater is used for direct usage or for recharging aquifers. It is most important to ensure
that the rainwater caught is free from pollutants. Following precautionary measures should be taken
while harvesting rainwater:-
Roof or terraces uses for harvesting should be clean, free from dust, algai plants etc.
 Roof should not be painted since most paints contain toxic substances and may peel off.
 Do not store chemicals, rusting iron, manure or detergent on the roof.
 Nesting of birds on the roof should be prevented.
 Terraces should not be used for toilets either by human beings or by pets.
 Provide gratings at mouth of each drainpipe on terraces to trap leaves debris and floating
materials.
 Provision of first rain separator should be made to flush off first rains.
 Do not use polluted water to recharge ground water.
 Ground water should only be recharged by rainwater.
 Before recharging, suitable arrangements of filtering should be provided.
 Filter media should be cleaned before every monsoon season.
 During rainy season, the whole system (roof catchments, pipes, screens, first flush, filters, and
tanks) should be checked before and after each rain and preferably cleaned after every dry period
exceeding a month.
 At the end of the dry season and just before the first shower of rain is anticipated, the storage
tank flushed off all sediments and debris.
RECHARGE TABLE OF RAIN WATER AVAILABLE FROM ROOFS

Rain fall
100 200 300 400 500 600 700 800 900 1000
in mm
Area of
Roof RECHARGE WATER IN CUM.
(Sq m.)
20 1.4 2.9 4.3 5.8 7.2 8.7 10.1 11.6 13.0 14.5
30 2.2 4.3 6.5 8.7 10.8 13.0 15.2 17.3 19.5 21.7
50 3.6 7.2 10.5 14.5 18.1 21.7 25.3 28.9 32.5 36.1
100 7.2 14.5 21.7 28.9 36.1 43.4 50.6 57.8 65.0 72.3
150 10.8 21.7 32.5 43.4 54.2 65.0 75.9 86.7 97.5 108.4
200 14.5 28.9 43.4 57.8 72.3 86.7 101.2 115.6 130.1 144.5
250 18.1 36.1 54.2 72.3 90.3 108.4 126.4 144.5 162.6 180.6
RWH
Rajasthan PWD Building Specifications 2014 Chapter 23 : Tube Well & Page 25 of 28
12 Top of tube well above/below ground level ................................................................................
13 Size of gravel ...................... Quantity used before development ............. Quantity used during
development .............................................................................................................................
14 Method used for development ......................................................................................................
Total hours of testing ...............................................................................................................
15 Development discharge ...............................................................................................................
16 Turbidity ......................................................................................................................................
17 Further details appended:
a) Samples of strata, neatly packed in sample bags,
b) Chart of pipe assembly lowered, and
c) Results of mechanical analysis of samples of unconsolidated strata.
18 Remarks:
Owner ...................................................... Driller ..................................................................
APPENDIX `B'
INFORMATION TO BE FURNISHED BY DRILLING AGENCY TO OWNER ON
COMPLETION OF TUBEWELL
1 Agency conducting the test .....................................................................................................
2 Location of the tube well ........................................................................................................
3 Date of starting .......................................................................................................................
4 Date of completion ...................................................................................................................
5 Total depth of tube well ..........................................................................................................
Method adopted .......................................................................................................................
6 Depth of water level ...............................................................................................................
Method adopted .......................................................................................................................
7 Result of verticality and alignment test .........................................................................................
8 Drawdown test: Time of test ..................................................................................................
Speed rev/min ........................... Discharge ...................... Period run ...................................
9 Rated discharge in P/min ........................................................................................................
10 Depression head of the production well ......................................................................................
11 Sand contents in ppm at the rated discharge after 20 minutes of the start of the pump or 20
percent in excess of the rated discharge (if 50 percent extra depression cannot be arranged) ........
12 Recommendation with regard to a suitable pump ......................................................................
13 Further details appended :
Chemical and bacteriological analysis of tube well water
14 Remarks:
Owner ..................................................................Driller .......................................................
LIST OF RELAVENT INDIAN STANDARD CODES
S.No. IS Code No. Title
1 2800 (Part 1) : 1991 Code of practice for construction and Testing of tube wells
2 2800 (Part 2) : 1991 Code of practice for construction and Testing of tube wells
3 226 : 1975 Structural steel (standard quality) (fifth revision)
4 4097 : 1988 Gravel for use as pack in tube wells
5 4270 : 1983 Steel tubes used for water wells (first revision )
6 8110 : 1985 Well screens and slotted pipes (first revision )
7 9439 : 1980 Glossary of terms used in water well drilling technology
8 10500 : 1983 Drinking water
9 11189 : 1985 Methods for tube well development
10 12818 : 1989 Unplasticized PVC ribbed screen casing and plain casing pipes
for bore/tube wells - Specification
CHAPTER No. 24
PLANNING AND DESIGNING

OF BUILDINGS
CHAPTER No. 24 : PLANNING AND DESIGNING OF BUILDINGS
CONTENTS
24.1 Scope 3
24.2 Terminology 3
24.3 Land Use Classification and uses permitted 11
24.4 Means of Access 12
24.5 Educational Facilities 14
24.6 Requirements of Plots 21
24.7 Classification of Buildings 23
24.8 Open Spaces (with in Plots) 23
24.9 Area and Height Limitation 29
24.10 Requirements of Parts of Buildings. 34
24.11 Fire and Life Safety 41
24.12 Design and Construction. 41
24.13 Lighting and Ventilation. 42
24.14 Electrical and Allied Installations. 42
24.15 Air-conditioning, Heating and Mechanical Ventilation. 42
24.16 Acoustics, Sound Insulation and Noise Control 42
24.17 Heat Insulation. 42
24.18 Installation of Lifts and Escalators. 42
24.19 Plumbing Services and Solid Waste management. 42
24.20 Special Requirements for Planning of Public Buildings
for use of Physically Challenged Persons. 43
24.21 General Building Requirements (Home stead) 55
24.22 Special Requirements for Development Planning in Hilly Areas. 58
Rajasthan PWD Building Specifications 2014 Chapter 24 : Planning & Designing of Buildings Page 1 of 62
CHAPTER No. 24
NORMS OF PLANNING & DESIGNING OF BUILDINGS
24.1 Scope:
This Part deals with the development control rules and general building requirements to ensure
health and safety of the public.
24.2 Terminology:
For the purpose of this part, the following definitions shall apply:
1. Access: A clear approach to a plot or a building.
2. Accessory Use: Any use of the premises subordinate to the principal use and customarily
incidental to the principal use.
3. Alteration: A change from one occupancy to another, or a structural change, such as an
addition to the area or height, or the removal of part of a building, or any change to the structure,
such as the construction of, cutting into or removal of any wall, partition, column, beam, joist,
floor or other support, or a change to or closing of any required means of ingress or egress or
a change to the fixtures or equipment.
4. Approved: Approved by the Authority having jurisdiction.
5. Authority Having Jurisdiction: The Authority which has been created by a statute and which
for the purpose of administering the Code/Part may authorize a committee or an official or an
authorised agency to act on its behalf, hereinafter called the 'Authority'.
6. Back-to-Back Cluster: Clusters when joined back to back and/or on sides see Fig.1).
7. Balcony: - A horizontal projection, with a handrail or balustrade or a parapet, to serve as
passage or sitting out place.
8. Basement or Cellar: - The lower storey of a building below or partly below ground level.
9. Building: Any structure for whatsoever purpose and of whatsoever materials constructed and
every part thereof whether used as human habitation or not and includes foundation, plinth,
walls, floors, roofs, chimneys, plumbing and building services, fixed platforms, VERANDAH,
balcony, cornice or projection, part of a building or anything affixed thereto or any wall
enclosing or intended to enclose any land or space and signs and outdoor display structures.
Tents, Shamianahs, tarpaulin shelters, etc, erected for temporary and ceremonial occasions with
the permission of the Authority shall not be considered as building.
10. Height of Building: The vertical distance measured in the case of flat roofs, from the average
level of the ground around and contiguous to the building or as decided by the Authority to the
terrace of last liveable floor of the building adjacent to the external walls, and in the case of
pitched roofs, up to the point where the external surface of the outer wall intersects the finished
surface of the sloping roof, and in the case of gables facing the road, the mid-point between the
eaves level and the ridge. Architectural features serving no other function except that of
decoration shall be excluded for the purpose of measuring heights.
11. Building Envelope: The horizontal spatial limits up to which a building may be permitted to
be constructed on a plot.
12. Building Line: The line up to which the plinth of a building adjoining a street or an extension
of a street or on a future street may lawfully extend. It includes the lines prescribed, if any, in
any scheme. The building line may change from time-to-time as decided by the Authority.
13. Cabin: A non-residential enclosure constructed of non-load bearing partition.
14. Canopy: A projection over any entrance.
15. Carpet Area: The covered area of the usable rooms at any floor level (excluding the area of
the wall).
16. Chhajja: A sloping or horizontal structural overhang usually provided over openings on
external walls to provide protection from sun and rain.
17. Chimney: An upright shaft containing one or more flues provided for the conveyance to the
outer air of any product of combustion resulting from the operation of heat producing
appliance or equipment employing solid, liquid or gaseous fuel.
18. Chowk or Courtyard: A space permanently open to the sky, enclosed fully or partially by
building and may be at ground level or any other level within or adjacent to a building.
19. Chowk, Inner: A chowk enclosed on all sides.
20. Chowk, Outer: A chowk one of whose sides is not enclosed.
21. Closed Clusters: Clusters with only one common entry into cluster open space (Fig. 2).
22. Cluster: Plots or dwelling units or housing grouped around an open space (Fig. 3). Ideally
housing cluster should not be very large. In ground and one storeyed structures not more than
20 houses should be grouped in a cluster. Clusters with more dwelling units will create
problems in identity, encroachments and of maintenance.
23. Cluster Court Town House: A dwelling in a cluster plot having 100 percent or nearly 100
percent ground coverage with vertical expansion, generally limited to one floor only and
meant for self use.
24. Cluster Plot: Plot in a cluster.
25. Cooking Alcove : A cooking space having direct access from the main room without any
intercommunicating door.
26. Covered Area: Ground area covered by the building immediately above the plinth level. The
area covered by the following in the open spaces is excluded from covered area (see Table 3):
a) Garden, rockery, well and well structures, plant nursery, water pool, swimming pool (if
uncovered), platform round a tree, tank, fountain, bench, CHABUTRA with open top
and unenclosed on sides by walls and the like;
b) Drainage culvert, conduit, catch-pit, gully pit, chamber, gutter and the like;
c) Compound wall, gate, un-storeyed porch and portico, canopy, slide, swing, uncovered
staircase, ramps areas covered by CHHAJJA and the like; and
d) Watchmen's booth, pump house, garbage shaft, electric cabin or sub-stations, and such
other utility structures meant for the services of the building under consideration.
NOTE- For the purpose of this Part, covered area equals the plot area minus the area
due for open spaces.
27. 'Cul-de-Sac' Cluster : Plots/dwelling units when located along a pedestrianised or. vehicular
'cul-de-sac' road (see Fig. 4).
28. Density: The residential density expressed in terms of the number of dwelling units per
hectare.
NOTE- Where such densities are expressed exclusive of community facilities and provision of
open spaces and major roads (excluding incidental open spaces), these will be net residential
densities. Where these densities are expressed taking into consideration the required open space
provision and community facilities and major roads, these would be gross residential densities
at neighbourhood level, sector level or town level, as the case may be. The provision of open
spaces and community facilities will depend on the size of the residential community.
Incidental open spaces are mainly open spaces required to be left around and in between two
buildings to provide lighting and ventilation.
29. Detached Building: A building detached on all sides.
30. Development : 'Development' with grammatical. variations means the carrying out of building,
engineering, mining or other operations, in, or over, or under land or water, on the making of
any material change, in any building or land, or in the use of any building, land and includes
re-development and layout and subdivision of any land and 'to develop' shall be construed
accordingly
31. Drain: A conduit, channel or pipe for the carriage of storm water, sewage, waste water or
other water borne wastes in a building drainage system.
32. Drainage : The removal of any liquid by a system constructed for the purpose.
33. Dwelling Unit/Tenement : An independent housing unit with separate facilities for living,
cooking and sanitary requirements.
34. Escalator: A power driven, inclined, continuous stairway used for raising or lowering
passengers.
35. Exit : A passage, channel or means of egress from any building, storey or floor area to a
street or other open space of safety.
36. External Faces of Cluster: Building edges facing the cluster open spaces.
37. Fire Separation: The distance in metres measured from the external wall of the building
concerned to the external wall of any other building on the site, or from other site, or from the
opposite side of a street or other public space for the purpose of preventing the spread of fire.
38. Floor : The lower surface in a storey on which one normally walks in a building. The general
term 'floor' unless specifically mentioned otherwise shall not refer to a 'mezzanine floor'.
39. Floor Area Ratio (FAR): The quotient obtained by dividing the total covered area (plinth
area) on all floors by the area of the plot:
Total covered area of the floors
Plot area
FAR = 40. Gallery: An intermediate floor or platform projecting from a wall of
an auditorium or a hall providing extra floor area, additional seating accommodation, etc. It
shall also include the structures provided for Seating in Stadia.
41. Garage, Private: A building or a portion thereof designed and used for parking of private
owned motor driven or other vehicles.
42. Garage, Public: A building or portion thereof, other than a private garage, designed or used
for repairing, servicing, hiring, selling or storing or parking motor driven or other vehicles.
43. Group Housing: Housing for more than one dwelling unit, where land is owned jointly (as in
the case of co-operative societies or the public agencies, such as local authorities or housing
boards, etc) and the construction is undertaken by one Agency.
44. Group Open Space: Open space within a cluster.
Group open space is neither public open space nor private open space. Each dwelling unit
around the cluster open space have a share and right of use in it. The responsibility for
maintenance of the same is to be collectively shared by all the dwelling units around.
45. Habitable Room : A room occupied or designed for occupancy by one or more persons for
study, living, sleeping, eating, kitchen if it is used as a living room, but not including bathrooms,
water closet compartments, laundries, serving and store pantries, corridors, cellars, attics, and
spaces that are not used frequently or during extended periods.
46. Independent Cluster: Clusters surrounded from all sides by vehicular access roads and
pedestrian paths (see Fig. 5).
47. Interlocking Cluster : Clusters when joined at back and on sides with at least one side of a
cluster common and having some dwelling units opening onto or having access from the
adjacent clusters.
Dwelling units in such clusters should have at least two sides open to external open space.
Houses in an interlocking cluster can have access, ventilation and light from the adjacent cluster
"and should also cater for future growth (see Fig. 6).
48. Internal Faces of Cluster: Building edges facing the adjacent cluster open space (as in case
of interlocking cluster) of the surrounding pedestrian paths or vehicular access roads.
49. Ledge or Tand : A shelf-like projection, supported in any manner whatsoever, except by
means of vertical supports within a room itself but not having projection wider than 1 m.
50. Lift: An appliance designed to transport persons or materials between two or more levels in a
vertical or substantially vertical direction by means of a guided car or platform. The word
'elevator' is also synonymously used for 'lift'.
51. Loft: A structure providing intermediate storage space in between two floors with a
maximum height of 1.5 m, without having a permanent access.
52. Mezzanine Floor: An intermediate floor between two floors of any storey forming an
integral part of floor below.
53. Occupancy or Use Group: The principal occupancy for which a building or a part of a
building is used or intended to be used; for the purposes of classification of a building according
to occupancy, an occupancy shall be deemed to include subsidiary occupancies which are
contingent upon it.
54. Occupancy, Mixed: The occupancy, where more than one occupancy are present in
different portions of the building.
55. Open Clusters: Cluster where cluster open spaces are linked to form a continuous open
space (see Fig. 7).
56. Open Space : An area, forming an integral part of the plot, left open to the sky.
N o t e - The open space shall be the minimum distance measured between the front, rear and
side of the building and the respective plot boundaries.
57. Open Space, Front: An open space across the front of a plot between the building line and
front boundary of the plot.
58. Open Space, Rear: An open space across the rear of a plot between the rear of the building
and the rear boundary of the plot.
59. Open Space, Side: An open space across the side of the plot between the side of the
building and the side boundary of the plot.
60. Owner: Person or body having a legal interest in land and/or building thereon. This includes
free holders, leaseholders or those holding a sub-lease which both bestows a legal right to
occupation and gives rise to liabilities in respect of safety or building condition. In case of lease
or sub-lease holders, as far as ownership with respect to the structure is concerned, the structure
of a flat or structure on a plot belongs to the allottee / lessee till the allotment/ lease subsists.
61. Parapet : A low wall or railing built along the edge of a roof or floor.
62. Parking Space: An area enclosed or unenclosed covered or open sufficient in size to park
vehicles, together with a drive-way connecting the parking space with a street or alley and
permitting ingress and egress of the vehicles
63. Partition : An interior non-load bearing barrier, one storey or part-storey in height.
64. Plinth- The portion of a structure between the surface of the surrounding ground and surface
of the floor, immediately above the ground.
65. Plinth Area: The built up covered area measured at the floor level of the basement or of any
storey.
66. Porch: A covered structure supported on pillars or otherwise for the purpose of pedestrian or
vehicular approach to a building.
67. Room Height: The vertical distance measured from the finished floor surface to the finished
ceiling surface. Where a finished ceiling is not provided underside of the joists or beams or tie
beams shall determine the upper point of measurement.
68. Row Housing/Row Type Building: A row of buildings, with only front, rear and interior
open spaces where applicable.
69. Semi-Detached Building: A building detached on three sides.
70. Service Road/Lane: A road/lane provided adjacent to a plot(s) for access or service
purposes as the case may be.
71. Set-Back Line : A line usually parallel to the plot boundaries and laid down in each case by
the Authority, beyond which nothing can be constructed towards the plot boundaries.
72. Site (Plot): A parcel (piece) of land enclosed by definite boundaries.
73. Site, Corner : A site at the junctions of and fronting on two or more intersecting streets.
74. Site, Depth of: The mean horizontal distance between the front and rear site boundaries.
75. Site' Double Frontage: A site, having a frontage on two streets, other than a corner plot.
76. Site' Interior or Tandem: A site access to which is by a passage from a street whether such
passage forms part of the site or not.
77. Stair cover (or Mumty): A structure with a roof over a staircase and its landing built to
enclose only the stairs for the purpose of providing protection from weather and not used for
human habitation.
78. Storey: The portion of a building included between the surface of any floor and the surface of
the floor next above it, or if there be no floor above it, then the space between any floor and
the ceiling next above it
79. Storey, Topmost : The uppermost storey in a building whether constructed wholly or partly
on the roof.
80. Street : Any means of access, namely, highway, street, lane, pathway, alley, stairway,
passageway, carriageway, footway, square, place or bridge, whether a thoroughfare or not, over
which the public have a right of passage or access or have passed and had access
uninterruptedly for a specified period, whether existing or proposed in any scheme, and
includes all bunds, channels, ditches, storm-water drains, culverts, sidewalks, traffic islands,
roadside. trees and hedges, retaining walls, fences, barriers and ' railings within the street lines.
81. Street Level or Grade : The officially established elevation or grade of the central line of the
street upon which a plot fronts and if there is no officially established grade, the existing grade
of the street at its mid-point.
82. Street Line: The line defining the side limits of a street.
83. To Abut: To abut on a street boundary such that any portion of the building is on the road
boundary.
84. To Erect : To erect a building means:
a) To erect a new building on any site whether previously built upon or not, and
b) To re-erect any building of which portions above the plinth level have been pull down,
burnt or destroyed.
85. Tower-like Structures : Structures shall be deemed to be tower-like structures when the
height of the tower-like portion is at least twice the height of the broader base at ground level.
86. Verandah: A covered area with at least one side open to the outside with the exception of
1 m high parapet on the upper floors to be provided on the open side.
87. Volume to Plot Area Ratio (VPR) : The ratio of volume of building measured in cubic
metres to the area of the plot measured in square metres and expressed in metres.
88. Water-Closet (WC): A water flushed plumbing fixture designed to receive human excrement
directly from the user of the fixture. The term is used sometimes to designate the room or
compartment in which the fixture is placed.
89. Window: An opening to the outside other than a door, which provides all or part of the
required natural light or ventilation or both to an interior space.
24.3 Land use Classification and uses Permitted: The land use classification may be as indicated
below:
S1. No. Use Zone (Level 1) Use Zone (Level 2)
1 2 3
i) Residential (R) (3) Primary Residential Zone (R-1)
Mixed Residential Zone (R-2)
Unplanned/Informal Residential Zone (R-3)
ii) Commercial (C) (3) Retail Shopping Zone (C-1)
General Business and Commercial District/Centres (C-2)
Wholesale, Godown, Warehousing/Regulated Markets (C-3)
iii) Manufacturing (M)(3) Service and Light Industry (M-1)
Extensive and Heavy Industry (M-2)
Special Industrial Zone Hazardous, Noxious and Chemical (M-3)
iv) Public and Semi- Government/Semi-Government/Public Offices (PS-1)
Public (PS) (7) Government Land (use determined) (PS-2)
Educational and Research (PS-3)
Medical and Health (PS-4)
Social, Cultural and Religious (PS-5)
Utilities and Services (PS-6)
Cremation and Burial Grounds (PS-7)
v) Recreational (P)(4) Playgrounds/Stadium/Sports Complex (P-1)
Parks and Gardens - Public Open Spaces (P-2)
Special Recreational Zone - Restricted Open Spaces (P-3)
Multi-Open Space (Maidan) (P-4)
vi) Transportation and Roads (T-1)
Communication (T)(7) Railways (T-2)
Airport (T-3)
Seaports and Dockyards (T-4)
Bus Depots/Truck Terminals and Freight
Complexes (T-5)
Transmission and Communication (T-6)
vii) Agriculture and Water Agriculture (A-1)
Bodies (6) Forest (A-2)
Poultry and Dairy Farming (A-3)
Rural Settlements (A-4)
Brick Kiln and Extractive Areas (A-5)
Water Bodies (A-6)
viii) Special Area (5) Old Built-up (Core) Area (S-1)
Heritage and Conservation Areas (S-2)
Scenic Value Areas (S-3),
Village Settlement (S-4)
Other Uses (S-5)
Note
a) Areas of informal activities may be identified in the above land use categories at Level 2.
b) Mixed use zone may be identified at the development plan level, having more than one use
zone with mixed activities of such use zones.
c) In all, there could be 38 use zones at the development plan level within eight land use
categories at the perspective plan level as given in the above table.
d) Use of premises for different activities could be provided at the project/action plan level or
with the approval of the Authority as the case may be.
e) Use of zone regulations for the use permissibility could be decided by the town planner
depending upon the requirement/ feasibility.
24.3.1 The various building uses and occupancies permitted on the various zones shall be as given
in the Master Plan.
24.3.2 Uses to be in Conformity with the Zone: Where the use of buildings or premises is not
specifically designated on the Development Plan or in the absence of Development Plan, shall be in
conformity with the zone in which they fall.
24.3.3 Uses as Specifically Designated on Development Plan: Where the use of a site is
specifically designated on the Development Plan, it shall be used only for the purpose so designated.
24.3.4 Non-conforming Uses: No plot shall be put to any use, occupancy or premises other than
the uses identified in 24.3.1 except with the prior approval of the Authority.
24.3.5 Fire Safety: Buildings shall be so planned, designed and constructed as to ensure fire safety
and this shall be done as per Part 4 'Fire and Life Safety'.
24.4 Means of Access:
24.4.1 Every building/plot shall abut on a public/private means of access like streets/roads duly
formed.
24.4.2 Every person who erects a building shall not at any time erect or cause or permit to erect any
building which in any way encroaches upon or diminishes the area set apart as means of access
required in the Code. No buildings shall be erected so as to deprive any other building of the means
of access.
24.4.3 Width of Means of Access:
The residential plots shall abut on a public means of access like street/road. Plots which do not abut
on a street/road shall abut/front on a means of access, the width and other requirements of which
shall be as given in Table 1.
Table 1
Width and Length of Means of Access
S. No. Width of Means of Access -m Length of Means of Access-m
(1) (2) (3)
i) 6.0 75
ii) 7.5 150
iii) 9.0 250
iv) 12.0 400
v) 18.0 1 000
vi) 24.0 above 1000
Note :- If the develop development is only on one sideof the means of access the p prescribed widths may
be reduced by 1 m each case.
In no case development on plots shall be permitted unless it is accessible by a public street of width
not less the 6 m.
24.4.3.1 Other Buildings
For all industrial buildings, theatres, cinema houses, assembly halls, stadia, educational buildings,
markets, other buildings which attract large crowd, the means of access shall not be less than the
following:
Width of Means of Access-m Length of Means of Access-m

12.0 200
15.0 400
18.0 600
24.0 above 600
Further, in no case shall the means of access be lesser in width than the internal access ways in
layouts and subdivision.
24.4.3.2 Pathways
a) The approach to the buildings from road/street/internal means of access shall be through paved
pathway of width not less than 1.5 m, provided its length is not more than 30 m.
b) In the case of special housing schemes for low income group and economically weaker section
of society developed up to two storeyed row/cluster housing scheme, the pedestrian pathway
width shall be 3 m subject to provisions of 24.9.4.1(a). The pedestrian pathway shall not serve
more than 8 plots on each side of the pathway, the length of the pathway shall be not more than
50 m.
24.4.3.3 The length of the main means of access shall be determined by the distance from the farthest
plot (building) to the public street. The length of the subsidiary access way shall be measured from
the point of its origin to the next wider road on which it meets.
24.4.3.4 In the interest of general development of an area, the Authority may require the means of
access to be of larger width than that required under 24.4.3 & 24.4.3.1
24.4.3.5 In existing built-up areas in the case of plots facing street/means of access less than 4.5
m in width, the plot boundary shall be shifted to be away by 2.25 m from the central line of the
street/means of access way to give rise to a new street/means of access way of 4.5 m width
24.4.4 The means of access shall be levelled, metalled, flagged, paved, sewered, drained, channelled,
lighted, laid with water supply line and provided with trees for shade to the satisfaction of the
Authority free of encroachment by any structure or fixture so as not to reduce its width below the
minimum required under 24.4.3 and shall be maintained in a condition to the satisfaction of the
Authority.
24.4.4.1 If any private street or any other means of access to a building is not levelled, metalled,
flagged or paved, sewered, drained, channelled, lighted or laid with water supply line or provided with
trees for shade to the satisfaction of the Authority, who may, with the sanction of the Authority, by
written notice require the owner or owners of the several premises fronting or adjoining the said
street or other means of access or abutting thereon or to which access is obtained through such street
or other means of access or which shall benefit by works executed, to carry out any or more of the
aforesaid requirements in such manner as he shall direct.
24.4.4.2 If any structure or fixture is set upon a means of access so as to reduce its width below the
minimum required, the Authority may remove the same further and recover the expenses so incurred
from the owner.
Also refer National Building Code Clauses 4.5 to 5.5 on these issues. 24.5
Educational Facilities :
S.No. Facility Min. Land
Area Required
(ha.)
a) Pre-Primary to Secondary Education
1. Pre-primary, nursery school (1 for every 2500 population)
i) Area per school 0.08 ha.
ii) Location of pre-primary/nursery school Near a park
2. Primary school (class 1 to 5) (1 for every 5000 population)
i) Strength of school - 500 students
ii) Area per school 0.40 ha.
a. School building area 0.20 ha.
b. Play field area (with a minimum of 18 m x 36 m to be ensured for
effective play) 0.20 ha.
3. Senior secondary school (class 6 to 12) (1 for every 7500
population)
i. Strength of the school - 1000 students
Area
Required(ha.)
ii Area per school 1.80 ha.
b. Play field area (with a minimum of 68 m x 126 m to be ensured for
effective play) 1.00 ha.
c. Parking area 0.20 ha.
4 Integrated school without hostel facility (class 1 to 12)
(1 for every 90000 to 100000 population)
I Strength of the school-1500 students
a School building area 0.70 ha.
b Play field area 2.50 ha.
c Parking 0.30 ha.
5 Integrated school with hostel facilities (class I to 12)
(1 for every. 90000 to 100000 population)
i Strength of school - 1500 students
b. Play field area 2.50 ha.
c. Residential (including hostel area) 0.40 ha.
d. Parking area 0.30 ha.
6 School for physically challenged (class 1 to 12)
(1 for every 45000 population)
i) Strength of school - 400 students
ii) Area per school 0.70 ha.
b. Play field area 0.30 ha.
c. Parking area 0.20 ha.
b) Higher Education - General
1) College (1 for every 125000 population)
i Student strength of college- 1000 to 1500 students
4 Integrated school without hostel facility (class 1 to 12)
I Strength of the school-1500 students
Area
Required(ha.)

c Parking 0.30 ha.
5 Integrated school with hostel facilities (class I to 12)
(1 for every. 90000 to 100000 population)
c Residential (including hostel area) 0.40 ha.
D Parking area 0.30 ha.
6 School for physically challenged (class 1 to 12)
(1 for every 45000 population)
c Parking area 0.20 ha.
b) Higher Education - General
1) College (1 for every 125000 population)
i Student strength of college- 1000 to 1500 students
ii Area per college 5.00 ha.
a College building area 1.80 ha.
c Residential (including hostel area) 0.40 ha.
d Parking area 0.30 ha.
2) University campus/centre area 10.00 ha.
3) New university area 60.00 ha.
C Technical Education
1) Technical education centre (A) (1 for every 1000000
population to include one ITI and one polytechnic)
i Strength of ITI - 400 students
ii Strength of polytechnic - 500 students
iii Area per technical education centre 4.00 ha.
a Area for ITI 1.60 ha.
B Area for polytechnic 2.40 ha.
Area
Required (ha.)
2) Technical education centre (B), one for every 1000000
population to include one ITI, one technical centre and
1 coaching centre).
Area per technical education centre 4.00 ha.
a Area for ITI 1.60 ha.
b Area for technical centre 2.10 ha.
c Area for coaching centre 0.30 ha.
d) Professional Education
1) Engineering college one for every 1000000 population.
i Strength of the college- 1500 students
ii Area per college 6.00 ha.
2) Medical college (1 for every 1000000 population)
Area of site including space for general hospital 15.00 ha.
3 Other professional colleges (1 for every 1000000 population)
i Area of site for students strength upto 250 students 2.00 ha.
ii Additional area of site for every additional 100 students or
part thereof up to total strength of 1 000 students 0.50 ha.
iii Area of site for strength of college - From 1000 to 1500 students 6.00 ha.
24.5.1 Health Care Facilities
1) Dispensary (1 for every 15000 population) Area 0.08-0.12 ha.
2 Nursing Home, child welfare and maternity centre
i Capacity 25 to 30 beds-Area 0.20-0.30 ha.
3 Poly-clinic with some observation beds
(1 for every 100 000 population). Area 0.20-0.30 ha.
4 Intermediate hospital (category B) (1 for every 100000 population)
i Capacity 80 beds (initially the provision may be for
50 including 20 maternity beds)
ii Total area 1.00 ha.
a Area for hospital 0.60 ha.
b Area for residential accommodation 0.40 ha.
5) Intermediate hospital (category A) (1 for every 100000 population)
i Capacity 200 beds (initially the provision may be for 100 beds)
ii Total area 3.70 ha.
a. Area for hospital 2.70 ha.
Area
Required(ha.)
b Area for residential accommodation 1.OO ha.
6 General hospital (1 for every 25OOOO population)
i Capacity 5OO beds (initially the provision may be for 3OO beds)
ii Total area 6.OO ha.
a Area for hospital 4.OO ha.
7 Multi-specialty hospital (1 for 1OOOOO population)
ii Total area 9.OO ha.
a Area for hospital 6.OO ha.
8 Speciality hospital (1 for every 1OOOOO population)
ii Total area 3.7O ha.
a Area for hospital 2.7O ha.
24.5.5.2 Socio-Cultural Facilities
1 Community room (1 for every 5OOO population) area: 75O m2
2 Community hall, mangal karyalaya / kalyana mandapam / barat ghar
/ library (1 for every 15OOO population). Area 2OOO m2
3 Recreational club (1 for every 1OOOOO population) Area : 1OOOO m2
4 Music, dance and drama centre (1 for every 1OOOOO population).
Area: 1OOO m2
5 Meditation and spiritual centre (1 for every 1OOOOO population).
Area : 5OOO m2
6 Socio-cultural centre (1 for every 1OOOOOO population) Area. 15 ha.
24.5.5.3
Distribution Services
1 Petrol/diesel filling and servicing centre
May be permitted in central as well as sub-central business district,
district centres, community centres (only filling station), residential
and industrial use zones in urban areas, along the national highways,
state highways, villages identified as growth centres, freight complex
and on proposed major roads.
Shall not be located on the roads having right of way less than 3O m
Shall be approved by the explosive/fire department.
Area
Required(ha.)
Area/Size
Only filling station 30m x 17m
Filling-cum-service station 36m x 30m
Filing-cum-service station-cum-workshop 45m x 36m
Filling station only for two and three wheelers 18m x 15m
2. Compressed natural gas (CNG)/filling centre
Permitted in all use zones (except in regional parks and Developed
District Parks) and along the national highways, state highways and
villages identified as growth centres, freight complex and on
proposed major roads
Shall not be located on the road having right of way less than 30 m.
Shall be approved by the explosive/fire department.
Area/size for mother station (building component-control room/ 1080 m2
office/dispensing room, store, pantry and W.C. (36mx30m)
3. LPG godown /Gas godown 1 for every 40000 to, 50000 population
The major concern for its storage and distribution is the location
which shall be away from the residential areas and shall have open
spaces all around as per the Explosive Rules
Capacity - 500 cylinders or 8000 kg of LPG 520 m2
i) Area (inclusive of chowkidar hut) (26mx20m)
4. Milk distribution (1 milk booth for every 5000 population)
Area inclusive of service area 150 m2
24.5.5.4 Police, Civil Defence and Home Guards Land Area
Required,Min
1) Police station (1 for every 90000 population)
Area (inclusive of essential residential accommodation 0.05 ha,
additional to be provided for civil defence and home guards) 1.50 ha.
2) Police post (1 for every 40000 to 50000 population) (not served
by a police station)
Area (inclusive of essential residential accommodation) 0.16 ha.
3) District office and battalion (1 for every 1000000 population)
i) Area for district office 0.80 ha.
ii) Area for battalion 4.00 ha.
iii) Total area 4.80 ha.
4) Police line (1 for every 2000000 population) -Area 4.- 6.00 ha.
5) District Jail (1 for every 1000000 population)-Area 10.00 ha.
6) Civil defence and home guards (1 for every 1000000 population),
Area 2.00 ha.
24.5.5.5 Fire
One fire station or sub fire station within 1 km to 3 km
(for every 200000 population)
i Area for fire station with essential residential accommodation 1.00 ha.
ii Area for sub-fire station with essential residential accommodation 0.60 ha.
24.5.5.6 Telephone, Telegraphs, Postal and banking facilities Land Area
Required,Min.
a Telephone and Telegraphs
b Telephone exchange of 40000 lines (1 for every 400000
population) Area 4.00 ha.
2 Postal
i) Post office counter without delivery (1 for every 15000 population)
ii) Floor area to be provided in local shopping centre 85 m2
3) Head post office with delivery office (1 for 250000 population),
Area 750 m2
4) Head post office and administrative office (1 for 500000
population), Area 2 500 m2
b) Banking
c) Extension counters with ATM facility (1 for every 15000
population)
i) Floor area for counters 75 m2
ii) Floor area for ATM 6 m2
5 Bank with locker, ATM and other banking facilities (1 for 100000
population) area 2500 m2
24.5.5.7 Sports Activity
1 Divisional sports centre (1 for 1000000 population)- Area 20.00 ha.
2) District sport centre (1 for 100000 population)-Area 8.00 ha.
3) Neighbourhood play area (I for 15000 population)-Area 1.50 ha.
4) Residential unit play area (1 for 5000 population)-Area 5 000 m2
24.5.5.8 Shopping Land Area
Required,Min
1) Convenience shopping (1 for 5000 population)-Area 1 500 m2
2) Local shopping including service centre (1 for 15000 population),
Area 4 600 m2
3) Community centre with service centre (1 for 100000 population),
Area 5.00 ha.
4) District centre (1 at district leveUl for 500000 population), Area 7.5 ha.
5) Local wholesale market (1 for 1000000 population), Area 10.00 ha.
6) Weekly markets (1 to 2 locations for every 100000 populations with
300 to 400 units per
a) Parking and other open spaces within the commercial centres could
be so designed that weekly markets can operate in these areas
during non-working hours. Area per location 0.40 ha.
7) Organized informal sector eating places (1 for 100000 population).
The area of informal sector should have
Suitable public conveniences and solid waste
Disposal arrangements. 2000 m2
24.5.5.9 Religious
1 Religious campus (1 for 100000 population) 5.00 ha.
24.5.10 Electrical Sub Station
1 11 kV Sub-station (1 for 15000 population) Area 500 m2
2 66 kV Sub-station (2 for 100000 population)
Area for each Sub-station (that is 60 m x 100 m) 6000 m2
3 220 kV Sub-station (1 for 500000 population), Area 4.00 ha.
24.5.5.11 Transport
1 Three wheeler and taxi stand (1 for 15000 population). Area: 500 m2
2 Bus terminal (1 for 100000 population), Area 4000 m2
3 Bus depot (1 for 500000 population), Area 2.00 ha.
24.5.5.12 Cremation/Burial Ground
The site shall be identified in locations, which are not proximous to
residential areas
1 Electric crematorium (1 for large size towns) Area 2.00 ha.
2 Cremation ground (1 for 500000 population) Area 2.50 ha.
3 Burial ground (1 for 500000 population) Area 4.00 ha.
24.5.5.13 Dhobi Ghats
1. Dhobi ghat with appropriate arrangements for water and drainage
facilities and it shall be ensured that the water bodies are not
polluted as a result of such activities (1 for 100000 population) 5000 m2
24.5.6 Every layout of sub division shall take into account the provisions of
development plan and if the land is affected by any reservation for
public purposes, the authority may agree to adjust the location of
such reservations to suit the development.
24.6 Requirements of Plots
24.6.1 No building shall be constructed on any site, on any part of which there is deposited refuse,
excreta or other offensive matter objectionable to the Authority, until such refuse has been removed
there form and the site has been prepared or left in a manner suitable for building purposes to the
satisfaction of the Authority.
24.6.2 Damp Sites
Wherever the dampness of a site or the nature of the soil renders such precautions necessary, the
ground surface of the site between the walls of any building erected thereon shall be rendered damp-
proof to the satisfaction of the Authority.
24.6.3 Surface Water Drains
Any land passage or other area within the curtilage of a building shall be effectively drained by
surface water drains or other means.
24.6.3.1 The written approval of the Authority shall be obtained for connecting any sub-soil or
surface water drain to a sewer.
24.6.4 Distance from Electric Lines
No VERANDAH, balcony, or the like shall be allowed to be erected or re-erected or any additions or
alterations made to a building within the distances quoted below in accordance with the current Indian
Electricity Rules as amended from time-to-time between the building and any overhead electric
supply line.
S.No. Power Distribution Lines Vertically-m Horizontally-m
1 2 3 4
a Low and medium voltage line and service 2.5 1.2
line
b High voltage lines up to and including 3.7 1.2
11000 v
c High voltage lines above 11OOO v upto
and 3.7 2.0
and including 33000 v
d Extra high voltage line beyond 33000 v 3.7 2.0
(plus 0.3 m for (plus 0.3 m for
every additional every additional
33 000 V or 33 000 V or
part thereof) part thereof)
24.6.5 Distance of site from thenormal edge of water course/areamaybe specifiedbytheAuth Authority,
keeping, in view the normal maximum flood/tide level.
24.6.6 Size of Plots:
24.6.6.1 Residential : Each plot shall have a minimum size/frontage corresponding to the type of
development as given below:
Type of Development Plot Size Sqm. Frontage m.
1 2 3
Detached building Above 250 Above 12
Semi-detached building 125-250 8 to 12
Row type building 50-125 4.5 to 8
N o t e - For low income housing see Clause 12.20 of NBC.
a) The minimum size of the site for group housing development shall be as given in the Master
Plan and local development control rules.
24.6.6.2 Industrial : The size of the plot shall not be less than 300 m2 and its width shall not be
less than 15 m.
24.6.6.3 Other Land Uses : The minimum size of plots for buildings for other uses not covered
under 24.5 shall be as decided by the Authority.
24.7 Classification of Buildings :
24.7.0 Buildings are classified based on occupancy and types of construction.
24.7.1 For the purpose of the Code, the following shall be the occupancy classification and types of
construction, for more detailed information, reference may be made to Part 4 'Fire and Life Safety'
of C.
24.7.1.1 Occupancy Classification:
a) Residential;
b) Educational;
c) Institutional;
d) Assembly;
e) Business; 0 Mercantile (will include both retail and
wholesale stores)
g) Industrial (will include low, moderate and high fire hazards);
h) Storage and J)
Hazardous
24.7.1.2 Types of Construction:
a) Type 1,
b) Type 2,
c) Type 3, and
d) Type 4. 24.8 Open Spaces
(Within a Plot):
24.8.1 General: Every room intended for human habitation shall abut on an interior or exterior
open space or an open VERANDAH open to such interior or exterior open space.
24.8.1.1 The open spaces inside and around a building have essentially to cater for the lighting and
ventilation requirements of the rooms abutting such open spaces, and in the case of buildings abutting
on streets in the front, rear or sides, the open spaces provided shall be streets in the front, rear or
sides, the open spaces provided shall be sufficient for the future widening of such streets.
24.8.1.2 Open Spaces Separate for each Building or Wing:
The open spaces shall be separate or distinct for each building and where a building has two or more
wings, each wing shall have separate or distinct open spaces for the purposes of lighting and
ventilation of the wings.
However, separation between accessory and main buildings more than 7 m in height shall not be
less than 1.5 m, for buildings up to 7 m in height no such separation shall be required.
24.8.13 The open space shall be the minimum distance measured between the front, rear and side of
the building and the respective plot boundaries. The front, rear and side of the building shall be the
point of the building nearest to the boundary.
24.8.2 Residential Buildings:
24.8.2.1 Exterior Open Spaces; Front open space:
a) Every building fronting a street shall have a front space, forming an integral part of the site as
below:
S.No Front Open Space, Min.-m Width of Street Fronting the Plot-m
(1) (2) (3)
i) 1.5 Up to 7.5
ii) 3.0 7.5 to 18
iii) 4.5 18 to 30
iv) 6.0 Above 30
i) For buildings up to a maximum height of 7 m.
Note-In case a building abuts two or more streets, the value of open spaces is to be based on the
average width of streets, subject to a minimum of 1.8 m for cases (ii), (iii) and (iv) above.
b) For streets less than 7.5 m in width, the distance of the building (building line) shall be at least 5
m from the centre line of the street. (see 24.4.3.5).
Note-This limiting distance has to be determined by the Authority for individual road/street widths
taking into account the traffic flow.
24.8.2.2 Rear open space:
a) Every residential building shall have a rear open space, forming an integral part of the site, of
an average width of 3 m and at no place measuring less than 1.8 m, except that in the case of a
back-to-back sites, the width of the rear open space shall be 3 m throughout. Subject to the
condition of free ventilation, the open space left up to half the width of the plot shall also be
taken into account for calculating the average width of the rear open space. For plots of depths
less than 9 m, for buildings up to 7 m in height, the rear open space may be reduced to 1.5 m.
b) Rear open space to extend the rear wall : The rear open space shall be co-extensive with the
entire face of the rear wall. If a building abuts on two or more streets, such rear open space shall
be provided throughout the face of the rear wall. Such rear wall shall be the wall on the opposite
side of the face of the building abutting on the wider street unless the Authority directs
otherwise.
c) In case of corner plots less than 300 m2 in area, the rear open space should be 2.4 m
minimum.
24.8.2.3 Side open space:
a) Every semi-detached and detached building shall have a permanently open air space, forming an
integral part of the site as below:
1) For detached buildings there shall be a minimum side open space of 3 m on both the
sides.
N o t e - For detached residential buildings up to 7 m in height on plots with a frontage less than 12
m (see 24.6.6.1), one of the side open spaces may be reduced to 1.5 m.
2) For semi-detached buildings, there shall be a minimum side open space of 3 m on one
side.
N o t e - For semi-detached buildings up to 7 m in height on plots with a frontage less
than 9 m (see 24.6.6.1), the side open spaces may be reduced to 1.5 m.
3) For row-type buildings, no side open is required.
b) In the case of semi-detached buildings, the. open spaces provided on one side shall be as in
24.8.2.3 (a) and all habitable rooms shall abut either on this side open space or front and
rear open spaces or an interior open space (see 24.8.2.5).
24.8.2.4 The provisions of 24.8.2.2 and 24.8.2.3 are not applicable to parking lock-up garages up to
3 m in height located at a distance of 7.5 m from any street line or front boundary of the plot.
24.8.2.5 The open spaces mentioned in 24.8.2.2 to 24.8.2.3 shall be for residential buildings up to a
height of 10 m.
24.8.2.6 For buildings of height above 10 m, the open spaces (side and rear) shall be as given in
Table 2. The front open spaces for increasing heights of buildings shall be governed as under:
Where a building height is not covered by Table 3 (page 30), the maximum height shall be limited
according to the width of the street as follows:
a) The maximum height of building shall not exceed 1.5 times the width of road abutting plus
the front open space,
b) If a building abuts on two or more streets of different widths, the building shall be deemed to
face upon the street that has the greater width and the height of the building shall be regulated
by the width of that street and may be continued to this height to a depth of 24
m along the narrower street subject to conformity of Cl. 8 of NBC.
Table 2 : Side and Rear Open Spaces for Different Heights of Buildings
SI Height of Side and Rear Open Spaces to
No. Buildings-m be Left Around Building-m
(1) (2) (3)
i) 10 3
ii) 15 5
iii) 18 6
iv) 21 7
v) 24 8
vi) 27 9
vii) 30 10
viii) 35 11
ix) 40 12
x) 45 13
xi) 50 14
xii) 55 and above 16
Notes:
1) For buildings above 24 m in height, there shall be a minimum front open space of 6 m.
2) Where rooms do not derive light and ventilation from the exterior open space, the. width of
such exterior open space as given in col 3 may be reduced by 1 m subject to a minimum of 3
m and a maximum of 8 m. No further projections shall be permitted.
3) If the length or depth of the building exceeds 40 m, add to col (3) 10 percent of length or
depth of building minus 4.0 m.
24.8.2.7 For tower-like structures, as an alternative to 24.8.2.6, open spaces shall be as below:
a) Up to a height of 24 m, with one set-back, the open spaces at the ground level, shall be not
less than 6 m
b) For heights between 24 m and 37.5 m with one set-back, the open spaces at the ground level,
shall be not less than 9 m;
c) For heights above 37.5 m with two set-backs, the open spaces at the ground level, shall be
not less than 12 m, and
d) The deficiency in the open spaces shall be made good to satisfy 24.8.2.3.1 through the setbacks
at the upper levels; these set-backs shall not be accessible from individual rooms/ flats at these
levels.
24.8.2.8 The front open space would govern the height of the building (see 9.4 of NBC).
24.8.2.9 Interior Open Spaces:
a) Inner courtyard : In case the whole of one side of every room excepting bath, WC and store
room is not abutting on either the front, rear or side open spaces, it shall abut on an inner courtyard,
whose minimum width shall be 3 m.
Further, the inner courtyard shall have an area, throughout its height, of not less than the square of
one-fifth the height of the highest wall abutting the courtyard. Provided that when any room
(excluding staircase bay, bathroom and water-closet) is dependent for its light and ventilation on an
inner courtyard, the dimension shall be such as is required for each wing of the building. Where only
water-closet and bath room are abutting on the interior courtyard, the size of the interior courtyard
shall be in line with the provision for ventilation shaft as given in 24.8.2.6
b) Ventilation shaft: For ventilating the spaces for water-closets and bath rooms, if not opening on
to front, side, rear and interior open spaces, these shall open on the ventilation shaft, the size of
which shall not be less than the values given below:
Height of Size of Ventilation Minimum One Dimension
Buildings-m Shaft- m2 of the Shaft-m
(1) (2) (3)
Up to 10 1.2 0.9
12 2.8 1.2
18 4.0 1.5
24 5.4 1.8
30 8.0 2.4
Above 30 9.0 3.0
Notes:
1) For buildings of height above 30 m, a mechanical ventilation system shall be installed

besides the provision of minimum ventilation shaft.
2) For fully air-conditioned residential buildings for lodging purposes, the ventilation shaft need
not be insisted upon, provided the air-conditioning system works in an uninterrupted manner,
also, provided there is an alternative source of power supply.
c) Outer courtyard: The minimum width of the outer courtyard (as distinguished from its depth)
shall be not less than 2.4 m. If the width of the outer courtyard is less than 2.4 m, it shall be
treated as a notch and the provisions of outer courtyard shall not apply. However, if the depth
of the outer courtyard is more than the width, the provisions of 24.8.1.2 shall apply for the open
spaces to be left between the wings.
24.8.2.10 Joint Open Air Space: Every such interior or exterior open air space, unless the latter is
a street, shall be maintained for the benefit of such building exclusively and shall be entirely within
the owner's own premises.
a) If such interior or exterior open air space is intended to be used for the benefit of more than one
building belonging to the same owner, the width of such open air space shall be the one
specified for the tallest building as specified in 24.8.2.3 abutting on such open air space.
b) If such interior or exterior open air space is jointly owned by more than one person, its width shall
also be as specified in Clause 8.2 of the "National Building Code" (NBC), provided every such
person agrees in writing to allow his portion of such joint open air space to be used for the
benefit of every building abutting on such joint open air space and provided he sends such
written consent to the Authority for record. Such common open air space shall thenceforth be
treated as a permanently open air space required for the purposes of the Code. No boundary
wall between such joint open air space shall be erected or raised to a height of more than 2.0
m.
24.8.3 Other Occupancies:
24.8.3.1 Open spaces for other occupancies shall be as below:
a) Educational buildings: Except for nursery schools, the open spaces around the building
shall be not less than 6 m.
b) Institutional buildings : The open spaces around the building shall be not < 6 m.
c) Assembly buildings- T h e open space at front shall be not less than 12 m and the other open
spaces around the building shall be not less than 6 m.
NOTE: However, if assembly buildings are permitted in purely residential zones, the open
spaces around the building shall be not less than 12 m.
d) Business, mercantile and storage buildings: The open spaces around the building shall be
not less than 4.5 m. Where these occur in a purely residential zone or in a residential with
shops line zone the open spaces may be relaxed.
e) Industrial buildings : The open spaces around the building shall be not less than 4.5 m for
heights up to 16 m, with an increase of the open spaces of 0.25 m for every increase of 1 m or
fraction thereof in height above 16 m.
N O T E - Special rules for narrow industrial plots in the city, namely plots less than 15 m in width,
and with appropriate set-backs from certain streets and highways, shall be applicable.
1) Hazardous occupancies: The open spaces around the building shall be as specified for
industrial buildings [see 24.8.3.1 (e)].
24.8.4 Exemption to Open Spaces : Projections into Open Spaces:
Every open space provided either interior or exterior shall be kept free from any erection thereon
and shall be open to the sky, except as below:
a) Cornice, roof or weather shade not more than 0.75 m wide;
b) Sunshades over windows/ventilators or other openings not more than 0.75 m wide;
c) Canopy not to be used as a sit out with clearance of 1.5 m between the plot boundary and the
canopy;
d) Projected balcony at higher floors of width not more than 1.2 m. and
e) Projecting rooms/balconies [see (d)] at alternate floors such that rooms of the lower two floors
get light and air and the projection being not more than the height of the storey immediately
below.
However, these projections into open spaces shall not reduce the minimum required open spaces.
24.8.4.1 Accessory building: The following accessory buildings may be permitted in the open
spaces:
a) In an existing building, sanitary block of 2.4m in height subject to a maximum of 4 m2 in the
rear open space at a distance of 1.5 m from the rear boundary may be permitted, where facilities
are not adequate.
b) Parking lock up garages not exceeding 2.4 m in height shall be permitted in the side or rear
open spaces at a distance of 7.5 m from any road line or the front boundary of the plot, and
c) Suction tank and pump room each up to 2.5 m2 in area.
24.8.4.2 Projection into Street: In existing built-up or congested areas, no projection of any sort
whatsoever, except sunshades (see 24.8.4.2.3) extending more than 23 cm below a height of 4.3 m,
shall project over the road or over any drain .or over any portion outside the boundaries of the site
projection arising out of the vertical past the water pipe may be permitted in accordance with the
drainage plan.
24.8.4.3 Porticos in existing developed area:
Porticos in bazaar areas of existing developed areas may be permitted to project on road land
subject to the following limitations:
a) Porticos may be allowed on such roads leaving a minimum clear space of 18 m between
kerbs;
b) The porticos shall not be less than 3 m wide;
c) Nothing shall be allowed to be constructed on the portico which shall be used as an open
terrace:
d) Nothing shall be allowed to project beyond the line of arcades, and
e) The space under the portico shall be paved and channelled according to the directions of the
Authority.
24.8.4.4 Sunshades over windows and ventilators:
Projections of sunshades over windows or ventilators in existing built-up or congested areas when
permitted by the Authority shall fulfil the following conditions:
a) No sunshade shall be permitted over the road or over any drain or over any portion outside
the boundaries of the site below a height of 2.8 m from the road level;
b) Sunshades provided above a height of 2.8 m from the ground level shall be permitted to project
up to a maximum width of 60 cm, if the road over which they project exceeds 9m in width,
and
c) No sunshade shall be permitted on roads less than 9 m in width or on roads having no
footpaths.
24.8.5 Limitations to Open Spaces: Safeguard against reduction of open space:
No construction work on a building shall be allowed if such work operates to reduce an open air
space of any other adjoining building, belonging to the same owner to an extent less than what is
prescribed at the time of the proposed work or to reduce further such open space if it is already less
than that prescribed.
24.8.5.1 Additions or Extensions to a Building:
Additions or extensions to a building shall be allowed, provided the open spaces for the additions/
extensions satisfy 24.8.2 after such additions/extensions are made.
24.9 Area and height limitations:
24.9.1 General : The limitation of area and height of buildings of different occupancy classes and
types of construction shall be achieved by specifying it in terms of FAR, which shall take into
account the various aspects that govern in specifying FAR as given below:
a) Occupancy class;
b) Types of construction;
c) Width of street fronting the building and the traffic load;
d) Locality where the building is proposed and the density;
e) Parking facilities;
0 Local fire fighting facilities; and
g) Water supply and drainage facilities.
24.9.2 The comparative FAR's for different occupancies and types of construction are as given in
Table 3 and the Authority shall select a basic FAR for one occupancy and a type of construction and
arrive at the FAR values for other combinations taking into account the other local factors (Refer Cl.
9.1 of National Building Code-NBC).
24.9.2.1 Unlimited Areas: The minimum fire separation on all sides of buildings of unlimited
areas (see Table 3) and of Type 1 construction shall be 9 m.
24.9.3 Street Width: The area limits shall apply to all buildings fronting on a street or public space
not less than 9 m in width accessible to a public street.
24.9.4 Height Limit: The height and number of storey's shall be related to FAR and the provisions
of 24.8.
24.9.4.1 Where a building height is not covered by Table 3, the maximum height shall be limited
according to the width of the street as follows:
a) The maximum height of building shall not exceed 1.5 times the width of road abutting plus the
front open space;
b) If a building abuts on two or more streets of different widths, the building shall be deemed to
face upon the street that has the greater width and the height of the building shall be regulated by the
width of that street subject to other provisions of the Cl. 8 of the NBC.
Table 3: Comparative Floor Area Ratios for Occupancies Facing

One Public Street of at Least 9 m Width
Occupancy Classification Type of Construction

Type 1 Type 2 Type 3 Type 4
(1) (2) (3) (4) (5)
Residential UL 2.0 1.4 1.0
Educational UL 2.0 1.4 1.0
Institutional UL 1.5 1.0 0.8
Assembly UL 1.0 0.7 0.5
Business UL 2.9 2.3 1.6
Mercantile 8.0 1.8 1.4 10
Industrial 7.5 1.9 1.6 1.3
Storage (see Note 4) 6.0 1.5 1.3 1.0
Hazardous (see Note 4) 2.8 1.1. 0.9 NP
UL - Unlimited, NP - Not Permitted
Notes:
1 This table has been prepared, taking into account the combustible content in the different
occupancies as well as the fire resistance offered by the type of construction (also see Part
4 'Fire and Life Safety').
2 This table shall be modified by the Authority, taking into account the other aspects as given
below (see 24.9.1):
a) Density in terms of dwelling unitslhectare;
b) Traffic considerations;
c) Parking spaces;
d) Local fire fighting facilities; and
e) Water supply, drainage and sanitation requirements.
3 The FAR specified may be increased by 20 percent for the following;
a) A basement or cellar and space under a building constructed on stilts and used as a
parking space, and air-conditioning plant room used as accessory to the principal use.
b) Electric cabin or sub-station, watchman's booth of maximum size of 1.6 m2 with
minimum width or diameter of 1.2 m, pump house, garbage shaft, space required for
location of fire hydrants, electric fittings and water tank;
c) Projections and accessory buildings as specifically exempted (see 24.8.4.1); and
d) Staircase room and lift rooms above the topmost storey, architectural features, and
chimneys and elevated tanks of dimensions as permissible under the Code, the area of the
lift shaft shall be taken only on one floor.
4. In so far as single storey storage and hazardous occupancies are concerned, they would be
further governed by volume to plot area ratio (VPR), to be decided by the Authority.
24.9.4.2 Height Exceptions : Roof structures:
The following appurtenant structures shall not be included in the height of the building unless the
aggregate area of such structures, including penthouses, exceeds one-third of the area of the roof of
building upon which they are erected:
a) Roof tanks and their supports (with support height not exceeding 1 m);
b) Ventilating, air-conditioning, lift rooms and similar service equipment;
c) Stair cover (MUMTY) not exceeding 3 m in height, and
d) Chimneys, parapet walls and architectural features not exceeding 1.2 m in height.
24.9.4.3 The building height for different occupancy types shall not exceed the maximum height
prescribed in Part 4 'Fire and Life Safety' of C.
24.9.5 Restrictions in the Vicinity of Aerodromes : For buildings in the vicinity of aerodromes,
the maximum height of such buildings shall be decided in consultation with the Civil Aviation
Authorities. This shall be regulated by the rules for giving no objection certificate for construction of
buildings in the vicinity of aerodromes of Directorate General of Civil Aviation. However, the latest
rules of Directorate General of Civil Aviation shall be followed in all cases of buildings coining up
in the vicinity of an aerodrome.
24.9.5.1 For the purpose of 24.9.5 new buildings, structures which rise to 30 m or more in height and
are to be located within 20 km of the aerodrome reference point, shall be constructed only if no
objection certificate has been obtained from the Directorate General of Civil Aviation.
24.9.5.2 In the case of buildings to be erected in the vicinity of defence aerodromes, the maximum
height of such building shall be decided by the Defence Authority.
24.9.5.3 This will apply specially to new constructions, overhead high voltage/medium voltage
lines, telephones/telegraph lines, factories, chimneys, wire/ TV antennas.
24.9.5.4 No new chimneys or smoke producing factories shall be constructed within a radius of 8
km from the aerodrome reference point (ARP).
24.9.5.5 Overhead high voltage/medium voltage lines telephone/telegraph lines shall not be
permitted in the approach/take-off climb areas within 3000 m of the inner edge of these areas.
24.9.5.6 A 3 m margin shall be allowed in new constructions for wireless/TV antennas, cooling
towers and MUMTIES.
24.9.5.7 Group Housing : Group housing development may be in low rise house clusters or
multi-storeyed apartments for high density development.
a) No limit to floors and height shall be applicable, but the coverage and floor area ratio for various
densities may be as given in Table 4 unless otherwise provided in the Master Plan and local
development control rules.
Table 4 : Floor Area Ratio and Coverage for Group Housing
S.No. Net Residential Maximum Coverage Floor Area Ratio
Dwelling Units/ Hectare in percent
(1) (2) (3) (4)
i) 25 25 0.50
ii) 50 30 0.75
iii) 75 33 0.90
iv) 100 35 1.00
v) 125 35 1.25
vi) 150 35 1.50
vii) 175 35 1.75
N O T E - The coverage shall be calculated on the basis of the whole area reserved erved for group
housing.
24.9.5.8 The minimum size of the site for group housing multi-storeyed apartment shall be 3000
m2.
24.9.5.9 The number of dwelling units are calculated on the basis of the density pattern given in
the Development Plan taking into consideration a population of 4.5 persons per dwelling unit.
24.9.5.10 The basement may vary between 33.33 to 50 percent of the plot area and is to be used for
parking, servicing and for essential household storage without counting in FAR.
24.9.5.11 One car parking space for every two flats up to 90 m2 floor area and one for every flat for
100 m2 or more shall be provided.
24.9.5.12 With a view to providing adequate parking for occupancies and the vehicular load,
appropriate off street parking provisions have to be made in the building / on-site. This could also
be permitted in basement areas and the footprint for the basement parking can exceed the ground
coverage of the building subject to no basement building construction to cross the building line and
all other safety features for structural, fire, health and public safety being ensured.
24.9.5.13 Off-Street Parking Spaces : The off-street parking (on-site parking) spaces in a plot to
be provided shall be in accordance with Annex B of NBC. The spaces given in Annex B shall be
considered by the Authority in conjunction with the Development Rules, in force, if any. The spaces
to be left out for off-street parking as given in 24.9.5.3. to 24.9.5.6 shall be in addition to the open
spaces left out for lighting and ventilation purposes as given in Cl. 15 of NBC.
24.9.5.14 Further 50 percent of the open spaces required around buildings may be allowed to be
utilized for parking or loading or unloading spaces, provided a minimum distance of 3.6 m around the
building is kept free from any parking, loading or unloading spaces subject to the provisions
of Part 4 `Fire and Life Safety' of C.
24.9.5.15 Each off-street parking space provided for vehicles shall be as follows:
a) For car, the minimum parking space to be 3 m x 6 m when individual parking space is
required and 2.75 m x 5 m when common parking space is required.
b) Space for scooter/two wheeler and bicycle to be not less than 1.25 m2 and 1.00 m2
respectively.
c) Area for each equivalent car space inclusive of circulation area is 23 m2 for open parking, 28
m2 for ground floor covered parking and 32 m2 for basement.
24.9.5.16 For buildings of different occupancies, off-street parking space for vehicles shall be
provided as stipulated below:
a) Motor Vehicles: Space shall be provided as specified in Annex B of NBC for parking motor
vehicles (cars).
b) Other Types of Vehicles: For non-residential building, in addition to the parking areas
provided in (a) above, 25 to 50 percent additional parking space shall be provided for parking
other types of vehicles and the additional spaces required for other vehicles shall be as decided
by the Authority, keeping in view the nature of traffic generated in the city.
24.9.5.17 Off-street parking space shall be provided with adequate vehicular access to a street; and
the area of drives, aisles and such other provisions required for adequate maneuvering of vehicle
shall be exclusive of the parking space stipulated in these provisions.
24.9.5.18 If the total parking space required by these provisions is provided by a group of property
owners for their mutual benefits, such use of this space may be construed as meeting the off-street
parking requirements under these provisions, subject to the approval of the Authority.
24.9.5.19 In buildings of mercantile (commercial), industrial and storage type, in addition to the
parking spaces provided, a space at the rate of 3.5 m x 7.5 m, shall be provided for loading and
unloading activities, for each 1000 m2 of floor area or fraction thereof.
24.9.5.20 Parking spaces shall be paved and clearly marked for different types of vehicles.
24.9.5.21 Apart from parking at ground level, provision of underground or multi-storeyed parking may
be permitted. The parking of vehicles at different level may also be mechanized. In the case of
parking spaces provided in basement(s), at least two ramps of adequate width and slope shall be
provided, located preferably at opposite ends. In case of underground multi-storeyed parking, special
measures with regard to fire safety shall be taken (see Part 4 `Fire and Life Safety' of NBC).
24.9.6 Greenbelts, Landscaping and Water Conservation:
a) General: Greenbelts and landscaping including plantation of shrubs and trees help to certain
extent in enhancing the environmental quality.
b) Planting of trees in streets and in open spaces should be done carefully to take advantage of
both shades and sunshine without obstructing the flow of wind circulation and sight. Their
advantage for abating glare and for providing cool and or warm pockets in developed areas
should also be taken.
c) Norms for Planting of Shrubs and Trees : Suitable provisions may be made for greeneries
including plantation of shrubs and trees as a part of environmental protection in general. This
aspect shall be taken care of from the initial stage of town and country planning, zoning and
planning of development of particular area and group housing. Finally, this aspect shall also be
taken into account in planning individual building of different occupancies.
d) The types of plants, the distance between trees/ plants from the building and the distance
between plants shall be carefully worked out keeping in view the structural safety and aesthetic
requirements of buildings.
e) Trees shall be numbered area-wise, plot-wise and road-wise by the concerned authority and
they shall be checked periodically.
Cutting and pruning of trees in public as well as private areas shall be suitably regulated. Trees
shall be cut only after obtaining the permission of the Authority designated for this purpose.
g) The landscape planning and design shall be done in accordance with Part 10 "Landscaping,
Signs and Outdoor Display Structures, Section 1 Landscape Planning and Design" of the NBC.
h) Water conservation and augmentation: In view of critical shortage of water, conservation
of water by rain water harvesting and by use of recycled water to the maximum extent possible
will be required. In this regard the following provisions may be adopted.
i) The local authority preparing a town-planning scheme or a development plan should see that
the local water bodies are preserved, and if dry, are activated by directing water-courses
appropriately. If required, the same should be enlarged, deepened, etc.
j) The water body should be protected by ensuring that no permanent /temporary construction
development takes place around it up to a distance of 50 m from the edge of the water body and
the same shall be suitably landscaped. Further, the public shall have easy access to the water
body.
k) The rain water run-off shall be suitably directed to Recharging Wells in plots belonging to
the local authority and of appropriate design.
1) The local authority should encourage for collection of rain water from roofs and terraces and
direct the same either to a storage tank or to a recharging well.
m) Buildings having central air-conditioning plants requiring water for cooling purposes may
not be allowed to use fresh water for the purpose.
n) Commercial or residential multi-storey complexes may use recycled water for flushing of
toilets. Separate storage tanks and separate distribution pipes shall be provided for the purpose.
o) Butcheries, tanneries and solid waste disposal sites shall not be permitted within 10 km from
the aerodrome reference point.
24.10 Requirements of parts of buildings:
24.10.1 Plinth : Main Buildings:
a) The plinth or any part of a building or outhouse shall be so located with respect to the
surrounding ground level that adequate drainage of the site is assured. The height of the plinth
shall be not less than 450 mm from the surrounding ground level.
b) Interior Courtyards and Covered Parking Every interior courtyard shall be raised at least 150
mm above the determining ground level and shall be satisfactorily drained.
24.10.2 Habitable Rooms : Height:
a) The height of all rooms for human habitation shall not be less than 2.75 m measured from the
surface of the floor to the lowest point of the ceiling (bottom of slab). In the case of pitched
roof, the average height of rooms shall not be less than 2.75 m. The minimum clear head room
under a beam, folded plates or eaves shall be 2.4 m. In the case of air-conditioned rooms, a height
of not less than 2.4 m measured from the surface of the floor to the lowest point of air-
conditioning duct or the false ceiling shall be provided.
b) The requirements of (a) apply to residential, business and mercantile buildings. For
educational and industrial buildings, the following minimum requirements apply:
a) Educational Buildings- Ceiling height 3.6 m for all regions, in cold regions, 3 m.
b) Industrial Buildings- Ceiling height 3.6 m, except when air-conditioned, 3 m (Factory
Act 1948 and Rules therein shall govern such heights, where applicable)
24.10.2.1 Size : The area of habitable room shall not be less than 9.5 m2, where there is only one
room with a minimum width of 2.4 m. Where there are two rooms, one of these shall not be less than
9.5 m2 and the other not less than 7.5 m2, with a minimum width of 2.1 m.
24.10.3 Kitchen :
a) Height : The height of a kitchen measured from the surface of the floor to the lowest point in the
ceiling (bottom slab) shall not be less than 2.75 m, except for the portion to accommodate floor trap
of the upper floor.
b) Size: The area of a kitchen where separate dining area is provided, shall be not less than 5.0 m2
with a minimum width of 1.8 m. Where there is a separate store, the area of the kitchen may be
reduced to 4.5 m2. A kitchen, which is intended for use as a dining area also, shall have a floor area of
not less than 7.5 m2 with a minimum width of 2.1 m.
24.10.3.1 Other Requirements:
Every room to be used as kitchen shall have:
a) unless separately provided in a pantry, means for the washing of kitchen utensils which shall
lead directly or through a sink to a grated and trapped connection to the waste pipe;
b) an impermeable floor;
c) a flue, if found necessary; and
d) a window or ventilator or opening of size not less than as specified in 24.13.1.1 subject to
increase in area of opening in accordance with Note 3 of 24.13.1.2.
24.10.4 Bathrooms and Water-Closets :
a) Height : The height of a bathroom or water-closet measured from the surface of the floor to the
lowest point in the ceiling (bottom of slab) shall not be less than 2.1 m.
b) Size : The area of a bathroom shall not be less than 1.8 m2 with a minimum width of 1.2 m.
The floor area of water-closet shall be 1.1 m2 with a minimum width of 0.9 m. If bath and water-
closet are combined, its floor area shall not be less than 2.8 m2 with a minimum width of 1.2 m.
c) Other Requirements : Every bathroom or water- closet shall:
i) be so situated that at least one of its walls shall open to external air;
ii) not be directly over or under any room other than another water-closet, washing place, bath
or terrace, unless it has a water-tight floor;
iii) have the platform or seat made of water-tight non-absorbent material;
iv) be enclosed by walls or partitions and the surface of every such wall or partition shall be
finished with a smooth impervious material to a height of not less than 1 m above the floor of
such a room;
v) be provided with an impervious floor covering, sloping towards the drain with a suitable
grade and not towards VERANDAH or any other room; and
vi) have a window or ventilator, opening to a shaft or open space, of area not less than 0.3 m2
with side not less than 0.3 m.
d) No room containing water-closets shall be used for any purpose except as a lavatory and no
such room shall open directly into any kitchen or cooking space by a door, window or other
opening. Every room containing water-closet shall have a door completely closing the entrance
to it.
24.10.5 Ledge or Tand/Loft: a) Height : The minimum head-room of ledge or Tand/loft shall be
2.2 m. The maximum height of loft shall be 1.5 m.
b) Size :A ledge or Tand/loft in a habitable room shall not cover more than 25 percent of the area of
the floor on which it is constructed and shall not interfere with the ventilation of the room under any
circumstances.
24.10.6 Mezzanine Floor :
a) Height :It shall have a minimum height of 2.2 m.
b) Size : The minimum size of the mezzanine floor, if it is to be used as a living room, shall not be
less than 9.5 m2. The aggregate area of such mezzanine floor in a building shall in no case exceed
one-third the plinth area of the building.
24.10.6.1 Other Requirements:
A mezzanine floor may be permitted over a room or a compartment provided:
a) it conform to the standard of living rooms as regards lighting and ventilation in case the size
of mezzanine floor is 9.5 m2 or more.
b) it is so constructed as not to interfere under any circumstances with the ventilation of the
space over and under it;
c) such mezzanine floor is not sub-divided into smaller compartments;
d) such mezzanine floor or any part of it shall not be used as a kitchen; and
e) in no case shall a mezzanine floor be closed so as to make it liable to be converted into
unventilated compartments
24.10.7 Store Room:
a) Height : The height of a store room shall be not less than 2.2 m.
b) Size : The size of a store room, where provided in a residential building, shall be not less than
3m2
24.10.8 Garage:
a) Height : The height of a garage shall be not less than 2.4 m.
b) Size: The size of garages shall be as below:
i) Private Garage: 3.0 m x 6.0 m, minimum; and
ii) Public Garage: Based on the number of vehicles parked, etc. (see Cl. 10 of NBC).
24.10.9 Basement:
a) The basement shall not be used for residential purposes.
b) The construction of the basement shall be allowed by the Authority in accordance with the
land use and other provisions specified under the Development Control Rules.
c) The basement to be constructed within the building envelope and subject to maximum
coverage on floor 1 (entrance floor) may be put to only the following uses:
i) Storage of household or other goods of ordinarily non-combustible material;
ii) Strong rooms, bank cellars, etc;
iii) Air-conditioning equipment and other machines used for services and utilities of the
building; and
iv) Parking spaces. 24.10.9.1 The basement shall have the
following requirements:
a) Every, basement shall be in every part at least 2.4 m in height from the floor to the underside
of the roof slab or ceiling;
b) Adequate ventilation shall be provided for the basement. The ventilation requirements shall be
the same as required by the particular occupancy according to byelaws. Any deficiency may be
met by providing adequate mechanical ventilation in the form of blowers, exhaust fans, air-
conditioning systems, etc;
c) The minimum height of the ceiling of any basement shall be 0.9 m and the maximum, 1.2 m
above the average surrounding ground level;
d) Adequate arrangements shall be made such that surface drainage does not enter the
basement;
e) The walls and floors of the basement shall be watertight and be so designed that the effects of
the surrounding soil and moisture, if any, are taken into account in design and adequate damp
proofing treatment is given; and
The access to the basement shall be separate from the main and alternative staircase providing
access and exit from higher floors. Where the staircase is continuous in the case of buildings
served by more than one staircase, the same shall be of enclosed type serving as a fire separation
from the basement floor and higher floors. Open ramps shall be permitted if they are
constructed within the building line subject to the provision of (d).
The exit requirements in basements shall comply with the provisions of Part 4 'Fire and Life
Safety' of the NBC.
24.10.10 Chimneys: The chimneys shall be built at least 0.9 m above flat roofs, provided the top of
the chimneys is not below the top of the adjacent parapet wall. In the case of sloping roofs, the chimney
top shall not be less than 0.6 m above the ridge of the roof in which the chimney penetrates.
24.10.11 Parapet: Parapet walls and handrails provided on the edges of roof terraces, balcony,
VARANDAH, etc shall not be less than 1.0 m and not more than 1.2 m in height from the finished
floor level.
24.10.12 Cabin: The size of cabins shall not be less than 3.0 m2 with a minimum width of 1.0 m.
The clear passages within the divided space of any floor shall not be less than 0.75 m and the distance
from the farthest space in a cabin to any exit shall not be more than 18.5 m. In case the sub-divided
cabin does not derive direct lighting and ventilation from any open spaces, mechanical means, the
maximum height of the cabin shall be 2.2 m.
24.10.13 Boundary Wall : The requirements of the boundary wall are given below:
a) Except with the special permission of the Authority, the maximum height of the compound wall
shall be 1.5 m above the centre line of the front street. Compound wall up to 2.4 m height may
be permitted if the top 0.9 m is of open type construction of a design to be approved by the
Authority.
b) In the case of a corner plot, the height of the boundary wall shall be restricted to 0.75 m for a
length of 10 m on the front and side of the inter-sections and the balance height of 0.75 m if
required in accordance with (a) may be made up of open type construction (through railings) and
of design to be approved by the Authority.
c) However, the provisions of (a) and (b) are not applicable to boundary walls of jails. In industrial
buildings, electric sub-stations, transformer stations, institutional buildings like sanitaria,
hospitals, industrial buildings like workshops, factories and educational buildings like schools,
colleges, including hostels, and other uses of public utility undertakings and strategically
sensitive buildings, a height up to 2.4 m may be permitted by the Authority.
24.10.14 Wells: Wells, intended to supply water for human consumption or domestic purposes,
where provided, shall comply with the requirements of 24.10.14.1 and 24.10.14.2.
24.10.14.1 Location : The well shall be located:
a) not less than 15 m from any ash pit, refuse pit, earth closet or privy and shall be located on a
site upwards from the earth closet or privy;
b) not less than 18m from any cess pit soak way or borehole latrine and shall be located on a
site upwards from the earth closet or privy;
c) that contamination by the movement of subsoil or other water is unlikely; and
d) not under a tree or otherwise it should have a canopy over it, so that leaves and twigs may
not fall into the well and rot
24.10.14.2 Requirements : The well shall
a) have a minimum internal diameter of not less than 1 m;
b) be constructed to a height not less than 1 m above the surrounding ground level, to form a
parapet or kerb and to prevent surface water from flowing into a well, and shall be
surrounded with a paving constructed of impervious material which shall extend for a distance
of not less than 1.8 m in every direction from the parapet from the kerb forming the well head
and the upper surface of such a paving shall be sloped away from the well.
c) be of sound and permanent construction (PUCCA) throughout. Temporary or exposed
(KUTCHA) wells shall be permitted only in fields or gardens for purposes of irrigation, and
d) have the interior surface of the lining or walls of the well be rendered impervious for a depth
of not less than 1.8 m measured from the level of the ground immediately adjoining the well-
head.
24.10.15 Septic Tanks : Where a septic tank is used for sewage disposal, the location, design and
construction of the septic tank shall conform to requirements of 24.10.15.1 and 24.10.15.2 [see also
Part 9 Plumbing Services, Section 1 Water Supply, Drainage and Sanitation (Including Solid Waste
Management)' of NBC].
24.10.15.1 Location of the Septic Tanks and Subsurface Absorption Systems: A sub-soil
dispersion system shall not be closer than 18 m from any source of drinking water, such as well, to
mitigate the possibility of bacterial pollution of water supply. It shall also be as far removed from
the nearest habitable building as economically feasible but not closer than 6 m, to avoid damage to
the structures.
24.10.15.2 Requirements:
a) Dimensions of septic tanks - Septic tanks shall have a minimum width of 750 mm, a minimum
depth of 1 m below the water level and a minimum liquid capacity of 1 m3. The length of
tanks shall be 2 to 4 times the width;
b) Septic tanks may be constructed of brickwork, stone masonry, concrete or other suitable
materials as approved by the Authority;
c) Under no circumstances shall effluent from a septic tank be allowed into an open channel
drain or body of water without adequate treatment.
d) The minimum nominal diameter of the pipe shall be 100 mm. Further, at junctions of pipes in
manholes, direction of flow from a branch connection shall not make an angle exceeding 45°
with the direction of flow in the main pipe;
e) The gradients of land drains, under-drainage as well as the bottom of dispersion trenches and
soak ways shall be between 1:300 and 1:400;
0 Every septic tank shall be provided with ventilating pipe of at least 50 mm diameter. The top of
the pipe shall be provided with a suitable cage of mosquito-proof wire mesh.
The ventilating pipe shall extend to a height which would cause no smell nuisance to any
building in the area. Generally, the ventilating pipe may extend to a height of about 2 m, when
the septic tank is at least 15 m away from the nearest building and to a height of 2 m above the
top of the building when it is located closer than 15 m;
g) When the disposal of septic tank effluent is to a seepage pit, the seepage pit may be of any suitable
shape with the least cross-sectional dimension of 0.90 m and not less than 1.00 m in depth
below the invert level of the inlet pipe. The pit may be lined with stone, brick or concrete blocks
with dry open joints which should be backed with at least 75 mm of clean coarse aggregate.
The lining above the inlet level should be finished with mortar. In the
case of pits of large dimensions, the top portion may be narrowed to reduce the size of the RCC
cover slabs. Where no lining is used, specially near trees, the entire pit should be filled with
loose stones. A masonry ring may be constructed at the top of the pit to prevent damage by
flooding of the pit by surface runoff. The inlet pipe may be taken down a depth of 0.90 m from
the top as an anti-mosquito measure, and
h) When the disposal of the septic tank effluent is to a dispersion trench, the dispersion trench shall
be 0.50 m to 1.00 m deep and 0.30 m to 1.00 m wide excavated to a slight gradient and shall
be provided with 150 mm to 250 mm of washed gravel or crushed stones. Open jointed pipes
placed inside the trench shall be made of unglazed earthenware clay or concrete and shall have
a minimum internal diameter of 75 mm to 100 mm. Each dispersion trench shall not be longer
than 30 m and trenches shall not be placed closer than 1.8 m.
24.10.16 Office-cum-Letter Box Room: In the case of multi-storeyed multi-family dwelling

apartments constructed by existing and proposed Cooperative Housing Societies or Apartment
Owners Associations, limited companies and proposed societies, an office-cum-letter box room of
dimension 3.6 m x 3 m shall be provided on the ground floor. In case the number of flats is more
than 20, the maximum size of the office-cum-letter box room shall be 20 m2.
24.10.16.1 Business Buildings: Provision shall be made for letter boxes on the entrance floor as per
the requirements of the postal department.
24.10.17 Meter Rooms :For all buildings above 15 m in height and in special occupancies, like
educational, assembly, institutional, industrial, storage, hazardous and mixed occupancies with any
of the aforesaid occupancies having area more than 500 m2 on each floor, provision shall be made
for an independent and ventilated meter (service) room, as per requirements of electric (service)
supply undertakings on the ground floor with direct access from outside for the purpose of
termination of electric supply from the licensee's service and alternative supply cables. The
door/doors provided for the service room shall have fire resistance of not less than two hours.
24.10.18 Staircase/ Exit Requirements:

24.10.18.1 The minimum clear width, minimum tread width and maximum riser or staircases for
building shall be as given in 24.10.18.1.1 to 24.10.18.1.3 ( see also Part-4 `Fire and Life Safety' of
NBC)
24.10.18.2 Minimum width - The minimum width of staircase shall be as follows:
a) Residential buildings (dwellings) 1.0 m
NOTE : For row housing with 2 storeys, the minimum
width shall be 0.75 m.
b) Residential hotel buildings 1.5 m
c) Assembly buildings like auditoria, theatres and cinemas 2.0 m
d) Educational building 1.5 m
e) Institutional buildings 2.0 m
0 All other buildings 1.5 m
24.10.18.3 Minimum tread: The minimum width of tread without nosing shall be 250 mm for
residential buildings. The minimum width of tread for other buildings shall be 300 mm.
24.10.18.4 Maximum riser: The maximum uniform height of riser shall be 190 mm for residential
buildings and 150 mm for other buildings and these shall be limited to 12 per flight.
24.10.18.5 The minimum head-room in a passage under the landing of a staircase shall be 2.2 m. The
minimum clear head-room in any staircase shall be 2.2 m.
24.10.18.6 Exit Requirements: All aspects of exit requirements for corridors, doors, stair cases,
ramps, etc. in respect of widths, travel distance shall be as per Part 4 'Fire and Life Safety' of NBC.
24.10.19 Roofs:
24.10.19.1 The roof of a building shall be so designed and constructed as to effectively drain water
by means of sufficient rain-water pipes of adequate size, wherever required, so arranged, jointed and
fixed as to ensure that the rain-water is carried away from the building without causing dampness in
any part of the walls, roof or foundations of the building or an adjacent building.
24.10.19.2 The Authority may require rain-water pipes to be connected to a drain or sewer to a
covered channel formed beneath the public footpath to connect the rain-water pipe to the road gutter
or in any other approved manner.
24.10.19.3 Rain-water pipes shall be affixed to the outside of the external walls of the building or in
recesses or chases cut or formed in such external walls or in such other manner as may be approved
by the Authority,
24.10.19.4 It is desirable to conserve rain water using suitable rain water harvesting techniques
including by roof water collection. In this context, reference may be made to Part 9 'Plumbing
Services, Section 1 Water Supply, Drainage and Sanitation (Including Solid Waste Management of
NBC).
24.10.19.5 Special Requirements of Low Income Housing : shall be as given in Annex C of NBC.
For detailed information in this regard, reference may be made to the accepted standards [3(1)].
24.10.19.6 Special Requirements for Physically Challenged: Special requirements for planning of
buildings and facilities keeping in view the needs of the physically challenged, applicable particularly
to public buildings meant for their use, are given in Annex D of NBC.
24.10.19.7 Special Requirements for Cluster Planning for Housing : Special requirements for
cluster planning for housing shall be as given in Annex E of C.
24.10.19.8 Special Requirements for Low Income Habitat Planning in Rural Areas: Special
requirements for low income habitat planning in rural areas shall be as given in Annex F of NBC.
24.10.19.9 Special Requirements for Development Planning in Hilly Areas: Special
requirements for development planning in hilly areas is given in Annex G.
24.11 Fire and Life Safety: For requirements regarding fire and life safety for different occupancies,
reference shall be made to Part 4 'Fire and Life Safety' of NBC
24.12 Design and construction : For requirements regarding structural design, reference shall be
made to Part 6 'Structural Design' and for construction (including safety) reference shall be made to
Part 7 'Constructional Practices and Safety' of National Building code.
24.13 Lighting and ventilation : For requirements regarding lighting and ventilation for different uses
and occupancies reference shall be made to Part 8 'Building Services Section 1: Lighting and
Ventilation' of National Building Code .
24.13.1.1 Lighting and Ventilation of Rooms : Rooms shall have, for the admission of light and air,
one or more openings, such as windows and ventilators, opening directly to the external air or into
an open VERANDAH.
24.13.1.2 Notwithstanding the area of openings obtained through the minimum aggregate area (see
Notes 1 to 3) of such openings, excluding doors inclusive of frames, shall be not less than:
a) one-tenth of the floor area for dry hot climate;
b) one-sixth of the floor area for wet hot climate;
c) one-eighth of the floor area for intermediate climate; and
d) one-twelfth of the floor area for cold climate.
NOTES
1 If a window is partly fixed, the openable area shall be counted.
2. No portion of a room shall be assumed to be lighted, if it is more than 7.5 m away from the
opening assumed for lighting that portion.
3. The area of openings as given in (a) to (d) above shall be increased by 25 percent in the case
of a kitchen [see 24.10.3.1(d)].
24.14 Electrical and allied installations (including lightning protection of buildings) : For
requirements regarding electrical installations in buildings including lightning protection of
buildings, reference shall be made to Part 8 'Building Services, Section 2 Electrical and Part 8
'Building Services, Section 2 Electrical and Allied Installations' of National Building code.
24.15 Air conditioning, heating and mechanical ventilation : For requirements regarding design,
construction and installation of air conditioning, heating and mechanical ventilation systems,
reference shall be made to Part 8 'Building Services, Section 3 Air Conditioning, Heating and
Mechanical Ventilation' of National Building code.
24.16. Acoustics, sound insulation and Noise control : For requirements regarding the desired
noise levels and sound insulation in different occupancies, reference shall be made to Part 8Building
Services, Section 4 Acoustics, Sound Insulation and Noise Control' of National Building code.
24.17 Heat Insulation : For calculation of solar radiation on buildings and recommended limits of
thermal transmittance of roofs and walls for different parts of the country and heat transmission losses
due to different constructions, reference may be made to good practice.
24.18 Installation of lifts and escalators :Provision for lifts shall be made for buildings 15 m or
more in height. For requirements regarding planning, designing and installation, etc of lifts and
escalators, reference shall be made to Part 8 'Building Services, Section 5 Installation of Lifts and
Escalators' of National Building code.
24.19 Plumbing services and solid waste management : For requirements regarding water supply,
drainage and sanitation (including solid waste management) and gas supply, reference shall be made
to Part 9 'Plumbing Services' of National Building code.
24.20 Special Requirements for Planning of Public Buildings Meant For Use of Physically
Challenged Persons:
24.20.1 General :
a) These requirements apply to all buildings and facilities used by the public. These apply to
temporary or emergency conditions as well as permanent conditions. It does not apply to
private residences.
b) These requirements are concerned with non ambulatory disabilities, semi-ambulatory
disabilities, sight disabilities, hearing disabilities, disabilities of in co-ordination, aging,
allergies, heart and lung diseases, epilepsy, haemophilia, incontinence and enterostomy.
c) It is intended to make all buildings and facilities used by the public accessible to, and functional
for the physically challenged through and within their doors, without loss of function, space or
facility where the general public is concerned. It supplements the general requirements of the
Code, and reflects greater concern for safety of life and limb. In cases of practical difficulty,
unnecessary hardship, or extreme differences, the Authority may grant exceptions from the literal
requirements of this Annex or permit the use of other methods or materials, but only when it is
clearly evident that equivalent facilities and protection are thereby secured.
24.20.1.1 For the purpose of this Annex, the following definition shall apply.
a) Aging : Those manifestations of the aging processes that significantly reduce mobility, flexibility,
co-ordination, and perceptiveness but are not accounted for in the categories mentioned in 24.20.2.1
to 24.20.2.9
24.20.1.2 Appropriate Number: The number of a specific item that would be necessary, in
accordance with the purpose and function of building or facility, to accommodate individuals with
specific disabilities in proportion to the anticipated number or individuals with disabilities who
would use a particular building or facility.
24.20.2 Disabilities:
24.20.2.1 Non-ambulatory disabilities: Impairments that, regardless of cause or manifestation, for
all practical purposes, confine individuals to wheelchairs.
24.20.2.2 Semi-ambulatory disabilities: Impairments that cause individuals to walk with difficulty
or insecurity. Individuals using braces or crutches, amputees, arthritis, spastics and those with
pulmonary and cardiac ills may be semi-ambulatory.
24.20.2.3 Sight disabilities: Total blindness or impairments affecting sight to the extent that the
individual functioning in public areas is insecure or exposed to danger.
24.20.2.4 Hearing disabilities: Deafness or hearing handicaps that might make an individual
insecure in public areas because he is unable to communicate or hear warning signals.
24.20.2.5 Disabilities of in co-ordination: Faulty co-ordination or palsy from brain spinal, or
peripheral nerve injury.
24.20.2.6 People with allergies: People with allergies may be sensitive to dust, mildew, pollen,
animal hair, formalin, turpentine, etc. Some are sensitive to contact with substances and materials, such
as, nickel, chromium and rubber.
24.20.2.7 People with heart and lung diseases: People with heart and lung diseases may only be
able to walk short distances and may be unable to climb stairs. The requirements of these people are
similar to those with impaired mobility.
24.20.2.8 People with epilepsy, haemophilia, etc.: The requirements of those with epilepsy,
haemophilia, etc, are related primarily to the design of buildings and the need to minimize the risk
of injury caused by falling or encountering obstacles.
24.20.2.9 People with incontinence, enterostomy operations, etc.: The requirements of people
with incontinence, enterostomy operations, etc. (colostomies, ileostomies and urostomies) are
mainly related to bathroom provision. In certain circumstances, for example, in public water-closet
compartments, it may be desirable to provide a special sink for emptying urine bags.
24.20.2.10 Fixed Turning Radius, Front Structure to Rear Structure: The turning radius of a
wheelchair, left front-foot platform to right rear wheel, or right front-foot platform to left rear wheel,
when pivoting on a spot.
24.20.2.11 Fixed Turning Radius Wheel: The tracking of the caster wheels and large wheels of a
wheelchair when pivoting on a spot.
24.20.2.12 Involved (Involvement) : A portion or portions of the human anatomy or physiology, or
both, that have a loss or impairment of normal function as a result of genesis, trauma, disease,
inflammation or degeneration.
24.20.2.13 Ramps, Ramps with Gradients: Because the term 'ramp' has a multitude of meanings and
uses, its use in this text is clearly defined as ramps with gradients (gradual slope joining two level
surfaces) that deviate from what would otherwise be considered the normal level. An exterior ramp,
as distinguished from a 'walk', would be considered an appendage to a building leading to a level
above or below the existing ground level.
24.20.2.14 Walk, Walks :Because the terms 'walk' and 'walks' have a multitude of meanings and
uses, their use in this standard is clearly defined as a predetermined prepared surface, exterior
pathway leading to or from a building or facility, or from one exterior area to another, placed on the
existing ground level and not deviating from the level of the existing ground immediately adjacent.
24.20.3 Site Development : Almost any building can be made accessible to physically challenged
persons by so planning the site that the terraces, retaining walls and winding walks are used
effectively.
24.20.3.1 Site development is the most effective means to resolve the problems created by
topography, definitive architectural designs or concepts, water table, existing streets, and typical
problems, singularly or collectively, so that aggress, ingress and egress to buildings by physically
challenged may be facilitated while preserving the desired design and effect of the architecture.
24.20.4 Walks: Public walks should be at least 1 200 mm wide, and should have a gradient not
greater than 1 in 20.
24.20.4.2 It is essential that the gradient of walks and /driveways be less than that prescribed for
ramps, since / walks would be devoid of handrails and kerbs and would be considerably longer and
more vulnerable to the elements. Walks of near maximum grade and considerable length should have
level areas at intervals for purposes of rest arid safety. Walks or driveways should have a non-slip
surface
24.20.4.3 Such walks shall be of a continuing common surface not interrupted by steps or abrupt
changes in level
24.20.4.4 Wherever walks cross other walks, driveways, or parking lots they should blend to a
common level.
24.20.4.5 This requirement, does not require the elimination of kerbs, which, particularly if they
occur at regular intersections, are a distinct safety feature for all of the challenged, particularly the
blind. The preferred method of meeting the requirement is to have the walk incline to the level of the
street. However, at principal intersections, it is vitally important that the kerbs run parallel to the
street, up to the point where the walk is inclined, at which point the kerb would turn in and gradually
meet the level of the walk at its highest point. A less preferred method would be to gradually bring
the surface of the driveway or street to the level of the walk. The disadvantage of this method is that
a blind person would not know when he has left the protection of a walk and has entered the hazards
of a street or driveway (see fig. 9).
24.20.4.6 A walk shall have a level platform at the top which is at least 1500 mm long, if a door
swings out onto the platform or towards the walk. This platform shall extend at least 300 mm beyond
each side of the doorway.
24.20.4.7 A walk shall have a level platform at least 900 mm deep, if the door does not swing onto
the platform or towards the walk. This platform shall extend at least 300 mm beyond each side of the
doorway.
24.20.5 Parking Space:
24.20.5.1 Spaces that are accessible and approximate to the facility should be set aside and identified
for use by individuals with physical disabilities.
24.20.5.2 A parking space open on one side, allowing room for individuals in wheelchairs or
individuals on braces and crutches to get in and out of an automobile onto a level surface, is adequate.
It should have a minimum width of 2700 mm preferably 2800 mm for ambulant disabled and minimum
3000 mm preferably 3300 mm for wheel chair users.
24.20.5.3 Parking spaces for individuals with physical disabilities when placed between two
conventional diagonal or head-on parking spaces should be 3.6 m to 3.8 m wide and the length of
the aisle should 7.3 m, 6.1 m and 6.5 m for head-on, 90° and 60° parking respectively.
24.20.5.4 Care in planning should be exercised, so that individuals in wheelchairs and individuals using
braces and crutches are not compelled to wheel or walk behind parked cars.
24.20.5.5 Consideration should be given to the distribution of spaces for use by the disabled in
accordance with the frequency and persistency of parking needs.
24.20.5.6 Walks shall be in conformity with 24.20.4.
24.20.6. Buildings:
24.20.6.1 Ramps with Gradients : Where ramps with gradients are necessary or desired, they
shall conform to the following requirements (see Fig. 10). And
a) A ramp when provided should not have a slope greater than 1 in 20 or maximum of 1 in 10
for short distance up to 9000 mm.
b) A ramp shall have handrails on at least one side, and preferably two sides, that are 900 mm
high, measured from the surface of the ramp, that are smooth; and that extend 300 mm beyond
the top and bottom of the ramp. Where major traffic is predominantly children, the handrails
should be placed 760 mm. high.
Notes :
1. Where handrails are specified to be of heights other than 80 cm, it is recommended that
two sets of handrails be installed to serve all people. Where major traffic is predominantly
children, particularly physically disabled children, extra care should be exercised in the
placement of handrails, in accordance with the nature of the facility and the age group or
groups being serviced (see also D-3 of Annexure D of the Development Control Rules
and general Building requirements of NBC).
2. Care should be taken that the extension of the handrails is not in itself a hazard..
Extension up to 300 mm may be made on the side of a continuing wall.
c) A ramp shall have a surface that is non-slip surface and if length is 3500 mm, the minimum
width shall be 1500 mm.
d) The provision of non-slip surfaces on ramps greatly assists the challenged persons with semi
ambulatory and ambulatory disabilities. Non-slip surfaces. are provided by many finishes and
materials. The surfaces of the concrete ramps can be made non-skid by brooming the surface
or by finishing with an indenting roller.
e) A ramp shall have a level platform at the top which is at least 1800 mm long, if a door swings
out onto the platform or toward the ramp. This platform shall extend at least 300 mm beyond
each side of the doorway (see Fig. 11).
f) Each ramp shall, have at least 1800 mm of straight clearance at the bottom.
g) Ramps shall have level platforms at 10 m to 10 m intervals for purposes of rest and safety,
and shall have platforms minimum 1.5 m length wherever they turn.
h) For visually impaired people, ramps may be colour contrasted with landing.
i) To minimize rise to wheelchair users, ramps should be equipped with herbs approximately
50 mm high at exposed sides.
24.20.6.2 Entrances :
a) At least one primary entrance to each building shall be usable by individuals in wheelchairs
(see Fig. 12 A) and shall be indicated by a sign (see Fig. 12 B).
b) At least one entrance usable by individuals in wheelchairs shall be on a level that would
make the elevators accessible.
24.20.63 Doors and Doorways : Door width
a) To enable wheelchair users to pass through doors, the minimum clear width should be 900 mm
and shall be operable by a single effort. In certain cases the clear width should be 900 mm to
1000 mm, for example, if the wheelchair has to be turned in the doorway, where there is a door-
closer or at entrance doors to public buildings and in other situations where there is considerable
traffic.
have a horizontal handle approximately 800 mm from the floor. Self-closing doors should be
equipped with an easy gripped vertical pull-handle with a length of at least 300 mm, and with
the lower end approximately 800 mm above floor. For many people and specially those with
impaired vision, it is helpful to make clear whether doors are to be pulled or pushed (see Fig.
14).
24.20.6.4 Windows: Windows should be designed to avoid the glare which is a particular problem for
people with impaired vision. Large glass areas close to circulation spaces should be marked a little
below eye-level with a coloured band or frame. To enable wheelchair users to see through a window
comfortably, the sill should be not higher than 800 mm from the floor. Windows should be easy to
open and close. Their controls should be placed in the zone 900 to 1200 mm from the floor to open
and close. (see Fig. 15)
24.20.6.5 :
a) Stairs should not be the only means of moving between floors. They should be supplemented
by lifts or ramps.
b) Straight flights of steps are preferred by ambulant disabled people. Treads should be
approximately 300 mm deep and risers not higher than 150 mm. Steps should be of a consistent
height and depth throughout the stair. Projecting nosing and open stairs should be avoided to
minimize the risk of stumbling.
c) Handrails should be provided to both sides of any stairway. They should be continuous and
extend not less than 300 mm beyond the top and bottom step (otherwise it is difficult for the
disabled to use the rail at the first and last step; see Fig. 16).
d) For people with impaired vision, there should be a colour contrast between landings, and top
and bottom steps of a flight of steps, or the front edge of each step should have a contrasting
colour.
24.20.6.6 Floors:
a) Floors shall have a non-slip surface.
b) Floors on a given storey shall be of a common level throughout or, be connected by a ramp
in accordance with D-3.1.1 to D-3.1.8. (Annexure D of NBC).
c) A gentle slope up to 10 mm may be given between the level of the floor of the corridor and
the level of the floor of the toilet rooms.
d) There should not be a difference between the level of the floor of a corridor and the level of
a meeting room, dining room, or any other room, unless proper ramps are provided.
24.20.7 Sanitary Facilities: It is essential that sanitary facilities, in accordance with the nature and
use of a specific building or facility, be made accessible to, and usable by, the physically challenged.
24.20.7.1 Sanitary facilities shall have space to allow traffic of individuals in wheelchairs (see Fig.
17 and 18).
24.20.7.2 Sanitary facilities shall have at least one water-closet cubical for the ambulant disabled
(see Fig. 19 and 20), that:
a) is 900 mm wide;
b) is at least 1500 mm, preferably 1600 mm deep;
c) has a door (where doors are used), that is, 800 mm wide and swings out;
d) has handrails on each side, 780 mm high and parallel to the floor, 40 mm clearance between
rail and wall, and fastened securely at ends and centre; and
e) has a water-closet with the seat 500 mm from the floor.
N o t e - The design and mounting of the water-closet is of considerable importance. A wall-
mounted water-closet with a narrow under structure that recedes sharply is most desirable. If a
floor mounted water-closet must be used, it should not have a front that is wide and
perpendicular to the floor at the front of the seat The bowl should be shallow at the front of the
seat and turn backwards more than downwards to allow the individual in a wheelchair to get
close to the water-closet with the seat of the wheelchair.
24.20.7.3 Sanitary facilities shall have wash basins with narrow aprons, which when mounted at
standard height are usable by individuals in wheelchairs, or they shall have wash basins mounted
higher, when particular designs demand, so that they are usable by individuals in wheelchairs.
24.20.7.3.1 The drain pipes and hot-water pipes under a sanitary appliance shall be covered or
insulated so that a wheelchair individual do not find it inconvenient.
24.20.7.4 Some mirrors and shelves shall be provided above the wash basins at a height as low as
possible and not higher than 1 m above the floor, measured from the top of the shelf and the bottom
of the mirror.
24.20.7.5 Sanitary facilities for men shall have wall-mounted urinals with the opening of the basin
460 mm from the floor, or shall have floor-mounted urinals that are on level with the main floor of
the toilet room.
24.20.7.6 Toilet rooms shall have an appropriate number of towel racks, towel dispensers, and
other dispensers and disposal units mounted not higher than 910 mm from the floor.
24.20.8 Drinking Fountains:
a) An appropriate number of drinking fountains or other water-dispensing means shall be
accessible to and usable by the physically disabled.
b) Drinking water fountains or water coolers shall have up front spouts and control
c) Drinking water fountains or water coolers shall be hand-operated or hand and foot-operated.
d) Conventional floor mounted water coolers may be convenient to individuals in wheelchairs
if a small fountain is mounted on the side of the cooler 800 mm above the floor.
e) Fully recessed drinking water fountains are not recommended.
0 Drinking water fountains should not be set into an alcove unless the alcove is wider than a
wheelchair.
24.20.9 Public Telephones: May not be required with the advent of mobile phones.
24.20.10 Handrails : Handrails are used as a locational and mobility aid by blind and visually
impaired people, and as a support for people with mobility impairments. The handrail should be
securely fitted to the wall to withstand heavy pressure. Handrails should turn in towards the wall at
either end.
24.20.10.1 Handrails should be approximately 900 mm from the floor. The rail should be easy to
grip, having a circular section with a diameter of approximately 40 mm and fixed as shown in Fig.
21.
24.20.10.2 To aid identification, the colour of the rail should contrast with the wall behind
24.20.11 Elevators :In a multi-storey building, elevators are essential to the successful functioning
of physically disabled individuals. They shall conform to the requirements given above.
24.20.11.1 Elevators shall be accessible to, and usable by the physically disabled on the level that
they use to enter the building, and at all levels normally used by the general public.
24.20.11.2 Elevators shall allow for traffic by wheelchairs as recommended by the C.
24.20.12 Controls :It is advantageous for wheelchair users if controls are placed at low level. For
visually impaired people, they should be at eye-level.
24.20.12.1 To enable wheelchair users to reach controls while not placing them too low for visually
impaired people, controls should be in the zone 900 mm to 1200 mm from the floor. It is
advantageous if controls in, for example, lifts are placed at an angle of approximately 45° to the wall
so that they are easier to read and operate. To cater for wheelchair users, controls should be placed
not less than 400 mm from room comers. All the power and electric points should be placed at one
metre above the floor level and should not project outside walls.
24.20.12.2 Again, to cater for visually impaired people, controls should be colour-contrasted with
backgrounds. Information should preferably be in relief for tactile reading.
24.20.12.3 To aid operation for people with impaired co-ordination or impaired vision, switches,
etc., should have large push plates.
24.20.12.4 Controls for powered door openers to hinged doors should be located so that the doors
do not conflict with wheelchairs, sticks, walking aids, etc.
24.20.12.5 To facilitate operation for people with limited strength in arms and hands, handles
should be easy to grip and turn.
24.20.13 Identification: Appropriate identification of specific facilities within a building used by the
public is particularly essential to the blind.
24.20.13.1 Raised letters or numbers shall be used to identify rooms or offices.
24.20.13.2 Such identification should be placed on the wall to left of door preferable at a height
1500 mm from the floor.
24.20.13.3 Doors that are not intended for normal use, and that might prove dangerous if a blind
person were to exit or enter by them, should be made quickly identifiable to the touch by knurling the
door handle or knob (see Fig. 22).
24.20.14 Warning Signals:
24.20.14.1 Audible warning signals shall be accompanied by simultaneous visual signals for the
benefit of those with hearing disabilities.
24.20.14.2 Visual signals shall be accompanied by simultaneous audible signals for the benefit of
the blind. To assist blind people, lettering and symbols on signs should be in relief for tactile reading.
24.20.143 Signs should be designed and located so that they are easy to read. For visually impaired
people, signs should preferably be at eye-level and it should be possible to approach them closely. Text
and symbols should be colour-contrasted with the background. The letters should not be less than 12
mm high.
24.20.14.4 Signs should be well illuminated and surfaces should not cause mirroring or reflections.
Signs should not be behind glass or similar materials.
24.20.14.5 Information based on colour codes only should be avoided; colour blind people may
find them difficult to understand.
24.20.15 Work Bench :This should be at least 800 mm wide, 600 mm deep and 650 mm to 700
mm high. For wheelchair users, the convenient height of work tops is between 750 mm and 850
mm, flexible provision is preferred. Further, for wheelchair access to a work bench, wash basin or
table, a clear space for knees and footrests is needed.
24.20.16 Hazards:Every effort shall be exercised to obviate hazards to individuals with physical
disabilities.
24.2O.16.I Access panels or manholes in floors, walks, and walls may be extremely hazardous,
particularly when in use, and should be avoided.
24.20.16.2 When manholes or access panels are open and in use, or when an open excavation exists
on a site, particularly when it is in proximity of normal pedestrian traffic, barricades shall be placed
on all open sides, at least 8.5 m from the hazard, and warning devices shall be installed in accordance
with D-3.14.2.(Annexure as referred above)
24.20.16.3 Low-hanging door closers that remain within the opening of a doorway, when the door
is open or that protrude hazardously into regular corridors or traffic ways when the door is closed,
shall be avoided.
24.20.16.4-Low-hanging signs, ceiling lights, and similar objects or signs and fixtures that protrude
into regular corridors or traffic way shall be avoided. A minimum height of 2.1 m measured from the
floor is recommended.
24.20.16.5 Ramps shall be adequately lighted.
24.20.16.6 Exit signs shall be in accordance with good practices.
24.20.16.7 Equipment and materials causing allergic reactions should as far as possible be avoided in
dwellings and buildings.
24.20.17 Designing For Children:
24.20.171 The dimensions given are for adults of average stature. In designing buildings for use by
children, it may be necessary to alter some dimensions, such as, height of handrails, in accordance
with accepted standards as per NBC.
24.20.17.2 For additional information regarding other facilities and conveniences required in
buildings meant for use of physically challenged, reference may be made to accepted standards as
per NBC.
24.21 General Building Requirements (Homestead):
24.21.1 General : The requirements of parts of buildings shall be as given in 24.21.1 to 24.21.10
24.21.2 Plinth :The minimum height of plinth shall be regulated on the basis of environmental and
topographical condition and higher plinth height may be required in areas prone to flooding.
24.21.3 Size of Room:
24.21.3.1 Habitable Room:
a) Every dwelling unit to be provided should have at least two habitable rooms. Even if one room
house is provided initially it should be capable of adding a new second room in future. In a
house of two rooms, first room shall not be less than 9.0 sqm. with minimum width of 2.5 m
and second room shall not be less than 6.5 sqm. with a minimum width of 2.1 m provided the
total area of both the rooms is not less than 15.5 sqm. In incremental housing the bigger room
shall always be the first room.
b) To facilitate incremental housing in case of flatted development or otherwise, habitable space
at mezzanine level may be permitted. The minimum size of such a mezzanine floor should not
be lesser than 6.5 sqm. and such a floor should occupy not more than 50 percent of the room
area of which it is a part. Such a mezzanine floor should have appropriate
openings to facilitate light and ventilation as per 24.21.8 Minimum clear height below and
above the mezzanine floor should be 2.4 m and 2.1 m respectively.
As far as possible mezzanine floor should have direct ventilation from the external face of the
building. Where this is not possible ventilation through main room may be allowed provided
total area of openings in the main room is provided taking into consideration area of mezzanine
floor. Such mezzanine floor may be accessible through the main room by a ladder, whose
minimum angle with vertical plane should be 22½°. Height of the riser should be less than 250
mm.
24.21.4 Water-Closet/Bathroom:
a) The size of independent water-closet shall be 0.9 m2, with minimum width of 90 cm.
b) The size of independent bathroom shall be 1.2 m2 with minimum width of lm, and
c) The size of combined bath and water closet shall be 1.8 m2 with minimum width of 1 m.
24.21.5 Kitchen :The size of a cooking alcove serving as cooking space shall not be less than 2.4
m2 with a minimum width of 1.2 m. The size of individual kitchen shall not be less than 3.3 m2 with
a minimum width of 1.5 m. Semi-open spaces with low walls and roof may also be provided for
cooking in areas where such provision is suitable with respect to climatic comfort. Provision for
smokeless working environment shall be made in all kitchens considering fuel efficiency and health
hazard due to smoke inhalation.
24.21.6 Balcony: The minimum width of individual balcony, where provided, shall be 0.9 m and
shall not be more than 1.2 m and it shall not project beyond the plot line and on roads or pathway.
24.21.7 Minimum Height: The minimum height of rooms/spaces shall be as follows:
Habitable room 2.75 m
Kitchen 2.6 m
Bath/water-closet 2.2 m
Corridor 2.1 m
24.21.7.1 In the case of sloping roofs, the average height of roof for habitable rooms shall be 2.75
m and the minimum height at eaves shall be 2.10 m.
24.21.8 Lighting and Ventilation: The openings through windows, ventilators and other openings
for lighting and ventilation shall be in accordance with Cl. 5.4 of Part 8, section 1, of NBC,
N o t e - The windows and other openings shall abut onto open spaces either through areas left open
within the plot or the front, side and rear spaces provided in the layouts which shall be deemed to be
sufficient for light and ventilation purposes. Wherever ventilation/lighting is provided by means of
JALI or grill of any material, total area of openings shall be calculated excluding solid portion of the
JALI or grill.
24.21.9 Stairs:
The following criteria shall be adopted for internal individual staircase:
a) Minimum width
1. 2 storied-straight 0.60 m
2. 2 storied-winding 0.75 m
3. 3 or more storied-straight 0.75 m
4. 3 or more storied-winding 0.90 m
b) Riser 190 mm, Max
c) Tread
1 2 storeyed 225 mm, Min
2 3 storeyed or more 250 mm, Min
Note: This could be reduced to 200 mm as the clear tread between perpends, with possibility of
open riser as well as nosing and inclined riser to have an effective going of 225 mm.
24.21.10 Water Seal Latrine:
a) No building plan shall be approved and no building shall be deemed to have been completed
and fit for human occupation unless provision is made for water seal latrine. No dry latrine shall
be allowed. Water seal latrines can also be provided on the basis of community toilets or shared
toilets as per the recommendation.
b) Where leaching pits are used, it should be constructed within the premises of the households as
it would be economical as well as facilitate their cleaning. However, where, due to space
constraint, construction of pits within the premises may not be possible, pits may be constructed
in places like lanes, streets and roads.
c) In case the pit is located under the road, street or foot path, the inverted level of the pipe
connecting the latrine pan with the pit shall be at least 1.1 m below ground level or below the
bottom of the water main existing within a distance of 3 m from the pits whichever is more.
Construction of such pits may be in accordance with C.
d) The water seal latrine should be properly maintained and kept in sanitary condition by the
owner or the occupier. The contents of the septic tanks, soak pits, leach pits, etc, should be
periodically emptied.
e) The leach pits should be cleaned only after 2 years of their being put out of service after they
were full.
f) Location of sanitary facility either as part of the house or separately shall be decided on the
basis of felt perceptions.
24.21.10.1 The house site shall provide space for storage of food grains and keeping cattle. A manure
pit having a minimum area of 1.0 m2 shall also be catered for. This will take care of composting of
biodegradable waste.
24.21.11 Other Requirements:
24.21.11.1 Requirements of fire safety, structural design, building services and plumbing services shall
be as specified in relevant parts of the Code.
24.21.11.2 One water tap per dwelling unit may be provided, where adequate drinking water supply
is available. If supply is inadequate, public hydrants shall be provided. In the absence of piped water
supply, hand pumps may be used for provision of water supply.
24.21.12 Drainage System :
a) Water from drains shall be connected to village ponds and appropriate eco-friendly methods
like growing of duck weed plants shall be adopted to treat waste water.
b) This treated water may be used for irrigation and agriculture.
c) Appropriate methods (namely conservation, ground water recharging, rain water harvesting,
etc.) should be employed to ensure effective water management.
24.21.13 Community Facilities:
24.21.13.1 A community ha1UBARAAT GHAR shall be established.
24.21.13.2 Rural Development Centre shall include PANCHAYAT GHAR, a MAHILA KENDRA
that may also serve as a vocational training centre.
24.21.13.3 School, health centre, post office, police post, shopping, work sheds for the artisans,
telephone facilities, etc should also be established.
24.21.13.4 The use (to the extent possible) of locally available building materials and cost effective
substitutes for scarce building materials. Appropriate technology inputs shall be introduced for
improving the local materials or conventional or traditional practices for improved efficiency.
24.21.13.5 The concept of 'aided self-help' shall be ensured for active participation of the prospective
users and association in the construction and development of dwelling units and other community
building.
24.21.13.6 The special needs of women headed households/ single and working women/woman in
difficult circumstances should be addressed. The specific requirement of women in terms of
providing necessary facilities in homes to lessen their drudgery would be given sufficient attention.
24.21.13.7 Protecting and promoting our cultural heritage, architecture and traditional skills should be
given due importance
24.22 Special Requirements For Development Planning In Hilly Areas:
24.22.1 General : a) These guidelines provide requirements relating to development planning and
design of buildings in hilly areas. Any area above 600 m in height form mean sea level may be
classified as hilly, or any area with average slope of 30° may also be classified as hilly, considering
the sensitive and fragile eco-system of hills and mountains. However, the State Governments may
identify and notify areas to be covered under 'Hilly Area', which need to be dealt with special
consideration, when developmental activities are taken up.
24.22.1.1 Hilly areas have one of the most fragile ecosystems, which need to be conserved. Therefore
planning and development strategies for hilly areas shall have to be designed with added sensitivity
and stress on integrated development. The development approach shall comprise sound land use
planning and settlement planning.
24.22.1.2 Settlement planning in the hill areas has extremely large implications on the environment.
For planning of the new settlements or working out the strategies for the growth of the existing
settlements, it is necessary to conduct detailed environmental inventory/impact assessment. The
inventory would involve geological investigations, slope analysis, soil, flora and fauna analysis,
climatic inventories, vulnerability to natural disasters, etc. In addition to this the aesthetic factors,
cultural, architectural and historical heritage, scenic/landscape value should also be taken into
consideration. Keeping in view the scarcity of good buildable land and also the high cost of the
construction, it is necessary to optimize the use of land and at the same time, use cost effective,
appropriate building materials and technologies.
24.22.2 Land Use Planning:
24.22.2.1 The following land use structure shall be adopted in Development Planning in Hilly
areas:
Land Use Percentage of Developed Area

(i) Small Towns (2) Medium Towns (3) Large Cities (4)
Residential 50-55 48-52 45-50
Commercial 2-3 2-3 4-5
Industrial 3-4 4-5 5-7
Public and semi-public 8-10 8-10 10-15
Recreational 15-18 15-18 18-20
Transport and commerce 5-6 5-6 6-8
Ecological 8-10 8-10 8-10
24.22.3 Open Spaces:
24.22.3.1 The following standards shall be adopted in Development Planning in Hilly areas
Type Area Area per Remarks
Range 1000
Population
(in ha) (in ha)
(1) (2) (3) (4)
Tot lot 0.03-0.05 Minimum width 15 m
Playground 0.50-1.00 0.12 to 0.20 One for every 5000 may be
combined with schools.
Parks 1.20-2.00 0.12 to 0.20 One for every 10 000 population.
City parks / playgrounds /
exhibition grounds/cultural
Gathering grounds 0.12 to 0.20 For the entire town at one of
more sites, depending upon
design and space availability.
Botanical garden 10-20 One for every town
Recreational complex 10-12 One for every settlement with
including zoo tourist potential
24.22.4 Roads and Paths:
24.22.4.1 Street orientation shall preferably be East-West to allow for maximum South sun to enter
the buildings. The street shall be wide enough to ensure that the buildings on one side do not shade
those on the other side.
24.22.4.2 The following road widths shall be adopted for urban roads in Hilly areas.
Road Type Width (in m)
Open Areas Built-up Areas Plains
Arterial road 18-24 15-18 50-60
Sub-arterial road 15-18 12-15 30-40
Collector road 9-12 7.5-9 20-30
Local street 4.5-6 3-6 10-20
Loop street (maximum 4.5 4.5 9
length = 500 m)
Cul-de-sac (maximum 4.5 4.5 7.5
length = 500 m)
Pedestrian path 1.5-2.5 1-15 1.5-4.5
24.22.4.3 Hill Road Manual (IRC:SP:48-1998), a publication of the Indian Roads Congress shall
be referred to for detailed guidelines for planning roads in Hilly areas.
24.22.5 Community Facilities And Services
24.22.5.1 The following standards shall be adopted for community facilities and Services in Hilly
areas.
Type Population Distance Area Range
1 2 3 4
A. Educational 4000 1-2 0.20-0.30
Primary school 15000 5-7 0.30-0.50
Secondary school (10+2) --- 8-12 0.30-0.60
Industrial training centre 30000 8-12 2.00 -3.00
College
B. Health
Health sub-centre 3000 2-4 0.025-0.067
Primary health centre 25-50 beds) 20000 16-20 0.105-0.210
Hospital (200-250 beds) 80000 16-20 0.840-2.100
Veterinary centre 1000 16-20 0.050-0.100
C. Other Facilities
Community Welfare Centre 16000 5-7 0.10 -0.15
D. Services
Fire station 50000 - 0.30 - 0.80
General post office 50000 10-15 0.20- 0.40
Post office 10000 5-7 0.10-0.15
Rural post office 2000 2-4 0.025-0.050
Rural post office 1000 1-2 --
Bank (tribal areas) 10000 16-20 0.100-0.150
Telephone exchange 50000 10-15 0.20-0.40
Electric sub-station (66 kV) - - 1.00
Electric sub-station (11 kV) - - 0.05
LPG godown - - 0.15
24.22.6 General Building Requirements:
24.22.6.1 General : The provisions contained in this Part shall apply excepting for the specific
provisions given hereunder.
24.22.6.2 Siting :
a) No house shall preferably be located closer than 1 m to another house.
b) No house shall be located closer than 10 m to a steep slope.
c) No house shall be built on a landfill or the edge of a slope known to have been levelled.
d) Buildings in hills shall be clustered together to minimise the exposure to cold winds. Open
spaces provided shall allow for maximum South sun.
e) Buildings shall be located on the south slope of a hill or mountain for better exposure to solar
radiation. At the same time, exposure to cold winds may be minimized by locating the building
on the leeward side.
24.22.63 Passive Systems for Climatic Control :
a) Appropriate solar passive methods, such as orientation, double-glazing, trombe walls and solar
collectors, shall be adopted to achieve climatic comfort with little use of conventional energy.
b) Care shall be taken in siting and design of buildings to provide passive controls to modify
the effect of strong / cold winds.
24.22.6.4 Flat land is normally not available in hilly regions.-The houses are required to be
constructed on partially sloping land made available by cutting and filling. It shall be necessary to
protect the house by building retaining walls/breast walls [see 3(8)] to avoid landslides occurring at
time of earthquakes or heavy rains.
24.22.6.5 Disaster Resistance: All necessary steps shall be taken in designing and building in hilly
regions to achieve disaster resistance as per the relevant codes and Part 6 'Structural Design' of NBC.
All natural disasters likely to affect the locality shall be taken into consideration, namely earthquakes,
cyclones, avalanches, flash floods, landslides etc.
LIST OF BIS CODES

The following list records those standards which are acceptable as 'good practice' and 'accepted
standards' in the fulfilment of the requirements of the Code. The latest version of a standard shall be
adopted at the time of enforcement of the Code.
S.No. IS No. Title
1. 3792 : 1978 Guide for heat insulation of non-industrial buildings (first
revision) 11907 : 1986 Recommendations for calculation of
solar radiation on buildings.
2. 4838 : 1990 Anthropometric dimensions for school children age group
5-17 years (second revision)
3. 4878 : 1986 Bye laws for construction of cinema buildings (first revision)
4. 4963 : 1987 Recommendations for buildings and facilities for the
physically challenged (first revision)
5. 8888-1993 Guide for requirements of low (Part 1): 1993 income
housing: Part 1 Urban area (first revision)
6. 10314 : 1987 Code of practice for sanitation for leaching pits for rural
community
7. 13727:1993 Guide for requirements of cluster planning for housing
8. 14458-1998/1997
Guidelines for retaining walls for bill area:
(Part 1): 1998 Selection of type of wall
(Part 2): 1997 Design of retaining/breast walls
9. NBC National Building Code 2005 or revisions thereof.
CHAPTER No. 25
FIRE PROTECTION WORKS

CHAPTER No. 25 : FIRE PROTECTION WORKS
CONTENTS
25.1 Scope 3
25.2 Terminology 3
25.3 Classification of Buildings based on occupancy (For Fire Prevention) 6
25.4 Types of Construction 7
25.5 System Engineering 10
25.6 Functional Requirements 12
25.7 Electric Fire Pump 16
25.8 Diesel Fire Pump 17
25.9 Auxiliary Pumping Equipments 20
25.10 Piping for Wet Riser & Sprinkler System 21
25.11 Power and Control Panel & other Control Compounds 24
25.12 Electric Works and Earthings 27
25.13 Installation and Testing of Wet Riser Sprinkler System 28
25.14 Fire Detection 31
25.15 Fire Alarm System 34
25.16 Fire Drill and Fire orders 40
Figures 50-52
Appendix À' 53
Rajasthan PWD Building Specifications 2014 Chapter 25 : Fire Protection Works Page 1 of 55
CHAPTER No. 25
FIRE PROTECTION WORKS
25.1. Scope:
i) These general specifications cover the details of equipment, inspection as may be necessary
before dispatch, delivery at site, installation, testing and commissioning and handing over in
working condition of the wet riser system, sprinkler system and fire detection system for Fire
Protection works.
ii) These technical specifications shall be read in conjunction with the standard conditions of
contract for electrical works with all correction slips as are relevant for commercial aspects as
well as schedule and drawings and requirements under these specifications.
iii) In the event of any discrepancy between these specifications and inter-connected contract
documents, the technical requirements as per the contract specifications shall be followed and
deemed to be having over-riding value.
iv) These technical specifications shall be read in conjunction with the National Building Code.
v) This chapter covers the requirements for fire prevention, life safety in relation to fire and fire
protection of buildings. The Code specifies construction, occupancy and protection features
that are necessary to minimize danger to life and property from fire.
25.2. Terminology: For the purpose of this chapter, the following definitions shall apply.
a) Automatic Fire Detection and Alarm System: Fire alarm system comprising components
for automatically detecting a fire, initiating an alarm of fire and initiating other actions as
appropriate.
NOTE: The system may also include manual fire alarm call points.
b) Automatic Sprinkler System: A system of water pipes fitted with sprinkler heads at suitable
intervals and heights and designed to activate automatically, control and extinguish a fire by
the discharge of water.
c) Building : Any structure for whatsoever purpose and of whatsoever materials constructed and
every part thereof whether used as human habitation or not and includes foundation, plinth,
walls, floors, roofs, chimneys, plumbing and building services, fixed platforms, verandah,
balcony, cornice or projection, part of a building or anything affixed thereto or any wall
enclosing or intended to enclose any land or space and signs and outdoor display structures.
Tents, shamianahs, tarpaulin shelters, etc., erected for temporary and ceremonial occasions
with the permission of the Authority shall not be considered as building.
d) Height of Building : The vertical distance measured in the case of flat roofs, from the average
level of the ground around and contiguous to the building or as decided by the Authority to the
terrace of the last livable floor of the building adjacent to the external wall, and in the case of
pitched roofs, up to the point where the external surface of the outer wall intersects the finished
surface of the sloping root and in the case of gables facing the road,
the mid-point between the eaves level and the ridge. Architectural features serving no other
function except that of decoration, shall be excluded for the purpose of measuring heights.
Combustible Material : The material which either bums itself or adds heat to a fire, when
tested for non-combustibility in accordance with accepted standard.
Covered Area: Ground area covered by the building immediately above the plinth level. The
area covered by the following in the open spaces is excluded from covered area
i) garden, rockery, well and well structures, plant nursery, water pool, swimming pool (if
uncovered), platform round a tree, tank, fountain, bench, chabutara with open top and
unenclosed on sides by walls and the like,
ii) drainage culvert, conduit, catch-pit, gully pit, chamber, gutter and the like,
iii) compound wall, gate, unstoreyed porch and portico, slide, swing, uncovered staircases,
ramp areas covered by chhajja and the like,
iv) watchman's booth, pump house, garbage shaft, electric cabin or sub-stations, and such
other utility structures meant for the services of the building under consideration.
NOTE: For the purpose of this Part, covered area equals the plot area minus the area due
for open spaces in the plot.
g) Down-comer : An arrangement of fire fighting within the building by means of down-comer
pipe connected to terrace tank through terrace pump, gate valve and non-return valve and
having mains not less than 100 mm internal diameter with landing valves on each floor/landing.
It is also fitted with inlet connections at ground level for charging with water by pumping from
fire service appliances and air release valve at roof level to release trapped air inside.
h) Dry Riser : An arrangement of firefighting within the building by means of vertical rising
mains not less than 100 mm internal diameter with landing valves on each floor landing which
is normally dry but is capable of being charged with water usually by pumping from fire service
appliances.
i) Emergency Lighting: Lighting provided for use when the supply to the normal lighting fails.
j) Emergency Lighting System : A complete but discrete emergency lighting installation from
the standby power source to the emergency lighting lamp(s), for example, self- contained
emergency luminaries' or a circuit from central battery generator connected through wiring to
several escape luminaries.
k) Escape Lighting : That part of emergency lighting which is provided to ensure that the escape
route is illuminated at all material times, for example, at all times when persons are on the
premises, or at times the main lighting is not available, either for the whole building or for the
escape routes.
1) Fire Door : A fire-resistive door approved for openings in fire separation.
m) Fire Exit : Away out leading to an escape route having panic bar hardware provided on the
door.
n) Fire Lift: The lift installed to enable fire services personnel to reach different floors with
minimum delay, having such features as required in accordance with this Part.
o) Fire Load : Calorific energy, of the whole contents contained in a space, including the
facings of the walls, partitions, floors and ceilings.
p) Fire Load Density : Fire load divided by floor area.
q) Fire Resistance Rating: The time that a material or construction will withstand the standard
fire exposure as determined by fire test done in accordance with the standard methods of fire
tests of materials/structures.
r) Fire Resistance: Fire resistance is a property of an element of building construction and is the
measure of its ability to satisfy for a stated period some or all of the following criteria:
i) resistance to collapse,
ii) resistance to penetration of flame and hot gases, and
iii) resistance to temperature rise on the unexposed face up to a maximum of 180°C and/ or
average temperature of 150°C.
s) Fire Separation: The distance in metre measured from the external wall of the building
concerned to the external wall of any other building on the site, or from other site, or from the
opposite side of street or other public space for the purpose of preventing the spread of fire.
t) Fire Separating Wall : The wall provides complete separation of one building from another
or part of a building from another or part of a building from another part of the same building
to prevent any communication of fire or heat transmission to wall itself which may cause or
assist in the combustion of materials on the side opposite to that portion which may be on fire.
u) Fire Stop: A fire resistant material, or construction, having a fire resistance rating of not less
than the fire separating elements, installed in concealed spaces or between structural elements
of a building to prevent the spread/propagation of fire and smoke through walls, ceilings and
like as per the laid down criteria.
Fire Tower : An enclosed staircase which can only be approached from the various floors
through landings or lobbies separated from both the floor areas and the staircase by fire-
resisting doors, and open to the outer air.
Fire Resisting Wall: A fire resistance rated wall, having protected openings, which restricts the
spread of fire and extends continuously from the foundation to at least 1 m above the roof.
 Floor Area Ratio (FAR): The quotient obtained by dividing the total covered area (plinth
area) on all floors by the area of the plot
FAR= Total covered area of all floors / Plot area
High Rise Building: For the purpose of this Part, all buildings 15 m or above in height shall
be considered as high rise buildings.
 Horizontal Exit: An arrangement which allows alternative egress from a floor area to another
floor at or near the same level in an adjoining building or an adjoining part of the same building
with adequate fire separation.
 Means of Egress: A continuous and unobstructed way of travel from any point in a building
or structure to a place of comparative safety.
ab) Occupancy or Use Group: The principal occupancy for which a building or a part of a building
is used or intended to be used; for the purpose of classification of a building according to the
occupancy, an occupancy shall be deemed to include subsidiary occupancies which are
contingent upon it.
ac) Plinth Area: The built-up covered area measured at the floor level of the basement or of any
storey.
ad) Pressurization: The establishment of a pressure difference across a barrier to protect a
stairway, lobby, escape route or room of a building from smoke penetration.
ae) Pressurization Level: The pressure difference between the pressurized space and the area
served by the pressurized escape route, expressed in Pascal (Pa).
af) Roof Exits : A means of escape on to the roof of a building, where the roof has access to it from
the ground. The exit shall have adequate cut-off within the building from staircase below.
ag) Site Plot: A parcel (piece) of land enclosed by definite boundaries.
ah) Stack Pressure: Pressure difference caused by a temperature difference creating an air
movement within a duct, chimney or enclosure.
ai) Tavel Distance: The distance to be travelled from any point in a building to a protected escape
route, external escape route or final exit.
aj) Ventilation: Supply of outside air into, or the removal of inside air from an enclosed space.
ak) Venting Fire : The process of inducing heat and smoke to leave a building as quickly as possible
by such paths that lateral spread of fire and heat is checked, firefighting operations are
facilitated and minimum fire damage is caused.
al) Volume to Plot Area Ratio (VPR): The ratio of volume of building measured in cubic metre
to the area of the plot measured in square metre and expressed in metre.
am) Wet Riser: An arrangement for firefighting within the building by means of vertical rising
mains not less than 100 mm nominal diameter with landing valves on each floor/landing for
firefighting purposes and permanently charged with water from a pressurized supply.
253 Classification of Building Based on Occupancy (for Fire Prevention):
25.3.1. General Classification: All buildings, whether existing or hereafter erected
shall be classified according to the use or the character of occupancy in one of the following
groups:
Residential
Educational
Group A Institutional
Group B Assembly
Group C
Group D Business
Group E Mercantile
Group F Industrial
Group G Storage
Group H
Group J Hazardous
25.4.Types of Construction:
25.4.1 General:
i) The design of any building and the type of materials used in its construction are important
factors in making the building resistant to a complete burn-out and in preventing the rapid
spread of fire, smoke or fumes, which may otherwise contribute to the loss of lives and
property.
ii) The fire resistance of a building or its structural and non-structural elements is expressed in
hours against a specified fire load which is expressed in K cal/m2, and against a certain intensity
of fire. The fire-resistance test for structural element shall be done in accordance with good
practice. For the purpose of the Code, the types of construction according to fire resistance
shall be classified into four categories, namely,
iii) Type 1 Construction, Type 2 Construction, Type 3 Construction and Type 4 `Construction'.
The fire resistance ratings for various types of construction for structural and non-structural
members shall be as given in Table 1.
Table 1: Fire Resistance Ratings of Structural and Non-Structural Elements (Hours)

Type of Construction
S. No. Structural Element 'hype 1 Type 2 Type 3 Type 4
Hours Hours Hours Hours
1. Exterior walls:
a) Fire separation less than 3.7 m 4 2 2 1

(i) Bearing 2 1.5 1 1
(ii) Non-bearing
b) Fire separation of 3.7 m or more but
less than 9 m
(i) Bearing 4 2 2 1
(ii) Non-bearing 1.5 1 1 1
c) Fire separation of 9 m or more
(i) Bearing
(ii) Non-bearing 4 2 2 1
1 1 1 1
2. Fire resisting walls 4 2 2 2
3. Fire separation assemblies
(like fire check doors) 4 2 2 2
4. Fire enclosures of exit ways, hallways
and stairways 2 2 2 2
5. Shaft other than exit ways, elevator and
hoist ways 2 2 2 2
6. Exit way access corridors 1 1 1 1
7. Vertical separation of tenant spaces 1 1 1 1
pe
S. No. Structural Element Ty of Construction
Type 1 Type 2 Type 3 Type 4
Hours Hours Hours Hours
8. Dwelling unit separation 1 1 1 1
Non-load bearing partitions ------- Least half an
9. At hour
Interior bearing walls, bearing partitions, ------
columns, girders, trusses (other than
roof trusses) and framing
i) Supporting more than one floor 4 2 2 2
ii) Supporting one floor only 3 1.5 1 1
iii) Supporting a roof only
3 1.5 1 1
10. Structural members support walls 3 1.5 1 1
11. Floor construction including walls 3 1.5 1 1
12. Roof construction
i) 5 m or less in height to lowest 2 1.5 1 1
member
ii) More than 5 m but less than 6.7m 1 1 1 1
in height to lowest member
iii) 6.7 m or more in height to lowest 0 0 0 0
member
iv) For buildings 15 m in height or above non-combustible materials should be used for
construction and the internal walls of staircase enclosures should be of brick work or
reinforced concrete or any other material of construction with minimum of 2 h rating.
The walls for the chimney shall be of Type 1 and Type 2 Construction depending on whether the
gas temperature is above 200°C or less.
v) It is required that an elementlcomponent shall have the requisite fire resistance rating when
tested in accordance with the accepted standard .For various data regarding fire resistance
ratings of various building components such as walls, columns, beams and floors. Fire damage
assessment, post fire structural safety assessment of various structural elements of the building
and adequacy of the structural repairs can be done by the fire resistance ratings mentioned in
Tables 2 to18 of National Building Code. Fire resistance ratings for few nature of Construction
and materials is in Table given below:
Fire Resistance (Hours) Masonry Walls: Solid
(Required to Resist Fire from One Side at a Time)
S. Nature of Construction Minimum Thickness (mm), Excluding any Finish for a
No. and Materials Fire Resistance (Hours) of
Load Bearing Non-load Bearing

1 1.5 2 3 4 1 1.5 2 3 4
1 Reinforced' cement 120 140 160 200 240
concrete (25)2 (25)2 (25)2 (25)2 (25)2
2 Unreinforced cement 150 175
concrete
3 No-fines concrete with:
a) 13 mm cement/sand
or gypsum!sand _ _ _ _ _ 150 150 150 150 150
b) 13 mm light weight
aggregate gypsum _ _ _ _ _ 150 150 150 150 150
plaster
4
Bricks of clay:
a) Without finish 90 100 100 170 170 75 90 100 170 170
b) With 13 mm 90 90 90 100 100 75 90 90 90 100
lightweight aggregate
gypsum plaster
5 Bricks of sand lime
a) Without finish 90 100 100 190 190 75 90 100 170 170
b) With 13 mm 90 90 90 100 100 75 90 90 90 100
lightweight
aggregate gypsum
plaster
6 Blocks of concrete:
a) Without finish 90 100 100 _ _ 75 90 100 140 150
b) With 13 mm 100 100 75
90 90 90 75 75 90 100
lightweight
aggregate
gypsum plaster
c) With 13 mm
cementlsand or 75 90 90 100 140
gypsum/sand
') Walls containing at least 1 percent of vertical reinforcement. 2)

Minimum thickness of actual cover to reinforcement.
25.4.2 A high rise building during construction shall be provided with the following fire protection
measures, which shall be maintained in good working condition at all the times:
a) Dry riser of minimum 100 mm diameter pipe with hydrant outlets on the floors constructed
with a fire service inlet to boost the water in the dry riser and maintenance should be as per the
requirements laid down in good practice.
b) Drums tilled with water of 2000 litre capacity with two fire buckets on each floor, and
c) A water storage tank of minimum 20000 litre capacity, which may be used for other
construction purposes also. The open spaces around or inside a building shall conform to the
requirements of `Development Control Rules and General Building Requirements'.
25.4.3 For high rise buildings, the following additional provisions of means of access to the building
shall be ensured `Development Control Rules and General Building Requirements' :
a) The width of the main street on which the building abuts shall not be less than 12 m and one
end of this street shall join another street not less than 12 m in width;
b) The road shall not terminate in a dead end, except in the case of residential building, up to a
height of 30 m.
c) The compulsory open spaces around the building shall not be used for parking, and
d) Adequate passageway and clearances required for fire fighting vehicles to enter the premises
shall be provided at the main entrance, the width of such entrance shall be not less than 4.5 m.
If an arch or covered gate is constructed, it shall have a clear head-room of not less than 5 m.
25.5 System Engineering : General: The wet riser and sprinkler systems is a combination of
equipment like fire pumps (electric/diesel driven) pressurization pump, automatic priming
arrangements (where required), charged water main (inside and outside the building) hydrants, hose
reels and hose pipes, valves, control panel etc. individually engineered in each case. Underground
water storage static tank of required capacity is provided for all wet riser installations.
25.5.1. The scope of wet riser system shall generally comprise the supply, installation, testing and
commissioning of the following:-
Electric motor driven fire pump
Diesel engine driven fire pump
Pressurization pump set
Priming pump set and automatic arrangement
Water charged pipe lines and air vessel(s)
(vi) Yard hydrants and landing hydrants including landing valves, hose pipes, hose reels, branch
pipe, nozzles
(vii) Terrace pump for pressuring the down comer
(viii) Electric power and control panel
(ix) Cables and earthing
(x) Misc. items like pressure switches, turbine type alarm, level indicators, fire brigade
connections etc.
(xi) Minor building works
(xii) Underground static water storage tank
( i i ) Terrace tank
(xiv) Shafts for wet Riser/Down comer pipes
(xv) Pump house
25.5.2. Locations and Requirements:
(a) Underground static storage tank and pump house: Following aspects shall be considered in
deciding the location of the underground static water storage tank and the wet riser pump house
:-
(i) Easy accessibility for firefighting operations;
(ii) Proximity of fire pump house to the static tank;
(iii) Ease in bringing and removing equipment;
(iv) Pump house not being prone to flooding by rain water or subsoil water
(v) Protection of the pump house from any falling masonry and the like, occasioned by fire;
(vi) Adequate ventilation for engine/aspiration and to limit the temperature rise in pump
house on continuous operation;
(vii) Aesthetics
The pump house should preferably be located at least 6m away from the building to be
protected. Where this is not possible, this shall be enclosed with suitable masonry
structure as a part of the building to prevent spread of fire into the pump room and provide
safe operation.
The fire pump house should be located, such that the suction for the pump is flooded.
Where this is not practicable, the pump house may be constructed with negative suction for
pumps, with suitable automatic priming arrangement. The size of the fire pump house
should be 5.5 m x 8 m x 3.5m, where engine driven fire pump, electric motor driven fire
pump, and pressurization pump are installed.
The capacity and design of the static tank shall be in accordance with the provisions of
National Building code part-IV Fire protection and the Bye-laws, as applicable
(b) External piping and hydrants: - External hydrants shall be within 2 to 15m from the building
to be protected such that they are accessible & may not be damaged by vehicles. A spacing of
about 45m between hydrants is generally adopted.
(c) The wet riser shaft: The wet riser shafts shall be located on the following considerations:-
Easy accessibility to the firefighting personnel;

Feasibility to cover the floor areas in the firefighting operation, using standard hose
reels of 1 x 7.5m and 1 x 15m length taking a range of 15m for water jet.
Segregated from electrical installations: Normally one riser for every 1000 sqm. or part
thereof area in each floor is found to be adequate.
For multi-storeyed building more than 24m high, calling for more than one riser,
additional width shall be suitably provided.
(iv) Terrace tank: The terrace tank shall be located so as to easily accessible and for
convenient connections to the pressurization pump for the down comer. The location
should be acceptable aesthetically and structurally. The capacity of the terrace tank shall
be in accordance with the provisions of National building code part IV fire protection
and the local by laws as applicable.
(v) Power supply Arrangement: The provisions of National building code Part IV and the
local bye-laws, if any, shall be complied with in deciding the arrangement of electric power
supply to the fire pump house. The feeder to the power and control panel in the wet riser
pump house shall be controlled by a HRC fuse switch unit/ circuit breaker with over-load
and short circuit protection, having a continuous current rating of 600% the full load
current of the pump/electric motor. The switch gear controlling the fire pump at the power
and control panel in the wet riser pump house shall be continuously rated to atleast 250%
of the full load current of the fire pump motor and with short circuit protection only and
without any overload protection. The feeder shall be independent, protected by a circuit
breaker without under voltage/ no volt protection.
vi) Conformity with statutory Act, rule regulations standards and safety codes.
a) Indian Electricity Act and Rules: All electrical works in connection with
installation of wet riser system shall be carried out in accordance with the provision
of Indian Electricity Rules, 1956 amended up to date.
b) PWD Specifications - The Electrical works shall also conform to PWD general
specifications for electrical works - 2000 or other latest revised versions.
c) Indian Standards - The wet riser system equipment, materials, accessories and their
installation shall conform to relevant Indian Standards amended up to date and also
to the National building code Part IV fire protection.
d) Fire Regulations - The installation shall be carried out in conformity with the local
fire regulation and rules there under wherever they are in force. Provision in local
by-laws, if any, shall be complied with.
vii) Other Acts and Rules - The installation shall also comply with the following-
(i) Indian Petroleum Act, 1937 and Petroleum Rules, 1974 wherever applicable.
(ii) Any other Acts or rules in force.
viii) Care of Buildings: Care shall be taken, while handling/ installing the equipment to avoid
damage to the building. On completion of the installation, the contractor shall arrange to
repair all damages to the building caused during installation so as to bring to the original
condition. He shall also arrange to remove all unwanted waste materials form pump room
and other areas used by him.
ix) Painting and Protection: All equipment supplied shall be given final coat of paint over
the primer after necessary treatment at the works before dispatch. All damages to painting
during transport and installation shall be set right or repainted to the satisfaction of the
department before handing over.
25.6. Functional Requirements:
25.6.1 Scope:
i) This section covers the detailed functional requirements of the Wet Riser System & Sprinkler
System including the associated components viz., pressurization pump and priming pump.
ii) Normally one electric pump and one diesel pump will be installed in the pump house. Where
standby diesel generating set of adequate capacity is available or where duplicate electric
supply from two independent sources is available, the provision of diesel engine driven pump
set may be dispensed with and an additional electric motor driven pump set may be provided,
with the approval of the local authority.
iii) The pumps shall only be direct coupled to the prime movers.
iv) There shall be of test valve, operation of which will simulate the operation of the landing valve/
external hydrant. This will enable testing the healthiness of the equipment, availability and its
control. Where the wet riser pump house is situated below ground level the test valve shall be
located outside the pump house.
v) Operation of test valve or operation of any yard or landing hydrant shall initiate, through fall
of water pressure to a pre-set value in the system (about 1kg/ cm2), provide the control panel
status for both the fire pumps is at "automatic" position.
vi) An electric pressurization pump shall be installed in the fire pump house, to re-pressurize the
system automatically due to gradual fall in pressure in the wet riser as a result of any leakage.
vii) The pressurization pump shall automatically start, when set to auto-status, when the water
pressure in the wet riser system falls to a pre-set valve (about 0.35kg/cm2 below the normal
system pressure) and shut down when the system pressure reaches the set value. Both the limits
shall be adjustable on the appropriate control in the pump room.
viii) Where flooded suction is not provided or is not possible for the fire and pressurization pumps,
an automatic priming system complete with a pump shall be provided. The priming pump shall
operate whenever the water level in priming tank goes down to a preset lower level and shut
down when the tank is filled up to a preset higher level. The arrangement of tapping from the
fire pump to fill the priming tank, instead of the priming pump, may be provided only where
so specified.
25.6.2 Operating Sequence :
i) First the electric fire pump will start by the sudden fall of pressure in the system due to
operation of the pressure switch and feed the water to the system.
ii) If within a pre-set period the electric pump has not come up to speed and the pump has not
started pumping water, the control system shall shut down the electric pump and initiate the
start up of the standby pump. The main electric pump shall then be locked out. The above
sequence shall also operate if water is not pumped due to any reason such as failure of
electricity supply.
iii) Automatic pressurization pump and automatic priming pump where provided shall be shut
down automatically when the fire pump, electric or diesel, is operating. Necessary integration of
pipe work and controls shall be provided for the purpose. A timer may be employed where
necessary to distinguish between slow fall of pressure due to system leaks and sudden fall of
pressure due to fire duty by opening of valves and thus prevent parallel start up of both
pressurization and fire pumps.
The power and control panel for the system shall incorporate the following functional
requirements:
 The control panel shall have status selection for each of the pumps for àutomatic' as well
as `manual' operation.
 Pumps when under `manual' status shall be operated manually through relevant push buttons.
 The fire pumps once started shall not be stopped automatically except due to low water
level in the underground storage tank.
The fire pumps shall be locked out for operation both for `manual' & àutomatic' operations, once
the low water control operates and furnish an audio and visual alarm on the panel. The audio
alarm can be silenced by accepting the alarm. The visual alarm shall be individual for each
equipment. It shall be flashing type and on acceptance remain steady. A reset button shall be
provided for each pump for returning the pump for fire duty.
 Overload or under voltage/ no volt trip devices for electric fire pump shall not be provided
in the starter. Tell-tale lamps to indicate the availability of power shall be provided.
 Once tripped, the electric fire pump shall remain locked out for operation irrespective of the
position of its operational status selection switch. Lock out indication shall be available on the
panel.
 Return to normal operation availability shall be feasible only by manual re-set of locked
out units by operation of appropriate push buttons.
 When fire pumps are brought into operation an audible tone from turbine type alarm operated
by water flow in the mains shall be provided to indicate the healthiness of the system. The
healthy running alarm shall not be silenced till the fire pump is shut down, but the tone may be
mellowed by the operator if required.
 Terminal facilities for repeat indication of various audio and visual indications on a slave
panel at a remote location shall be available.
25.6.3 Wet Riser Cum Down Comer:
i) Where terrace pumps, terrace tanks and wet riser-cum-down comer pipes are provided the
following shall be the functional requirements.
ii) There shall be 2 no. electric pump sets each of capacity 450/900 litres per minute as specified,
capable of developing a pressure of not less than 3kg per cm2. at the farthest top most hydrant.
iii) These pumps shall be located on the terrace with suction from the terrace tank and discharge
connected to the down comer.
iv) These pumps shall be started and stopped manually. Necessary electrical inter-lock shall be
provided so that these cannot be operated when fire pump or pressurization pump is operated.
v) The control and power supply board for these pumps shall be at the Ground floor at a
convenient location near the entrance to the building. Additionally, the pumps shall be
provided for manual starting and stopping from terrace level also.
vi) There shall be a selector switch so that either of the pump sets could be put on the fire duty.
vii) The power supply to the pumps shall preferably be from the generating set where provided.
viii) An audio visual alarm shall be provided in the control panel for low water level in the terrace
tank.
25.6.4. Sprinkler System Description:
i) The building shall have sprinkler protection as per the design requirements and specifications.
ii) Generally, wherever possible extended throw sidewall sprinkler heads shall be employed.
Areas with false ceiling shall have pendant sprinklers.
iii) There shall be one number installation control valve controlling the complete system. This shall
be located at the point of tapping off of the supply from the pump house and the overhead tank.
iv) The primary source of water for the sprinkler system shall be the overhead tank which through
a down comer shall be connected directly to the sprinkler header.
v) Pendant type sprinkler head.
vi) Sprinkler heads shall be of quartzoid bulb type with bulb, valve assembly, yoke and the deflector.
The sprinkler shall be of approved make and type with 15 mm nominal dia. outlets.
vii) The bulb shall be made of corrosion free material strong enough to withstand any water pressure
likely to occur in the system. The bulb shall shatter when the temperature of the surrounding air
reaches at 68°C.
viii) The nominal bore shall be 15mm dia. and colour of liquid shall be Red.
ix) The sprinkler head shall be as specified.
x) Extended throw sidewall sprinkler head.
xi) These sprinklers shall be of fast response type with fusible alloy melting at 69°C - 71°C and
snapping open the outlet. The material shall be of Gun metal/ Stainless Steel. The coverage shall
be up to max. 20 sqm with forward throw up to 6m and side wise 2m either side with spray
pattern of 120 degrees minimum. The fast response shall be achieved by quick heat absorbing
metal fins or any other technology and the sprinkler shall be listed as per the standards.
25.6.5 Upright Type Sprinkler Head:
i) Upright sprinkler heads shall be similar to pendent type in material construction and performance
but designed to throw water droplets upwards in umbrella fashion, to cool the underside of ceiling
and extinguish any fire involving combustibles above false ceiling.
ii) The sprinkler head shall be as per specifications. The nominal bore shall be 15mm dia. and the
colour of liquid shall be red.
iii) Piping: For piping the specifications as laid down for Hydrant piping shall be followed except
for pipe fittings below 50 mm dia. where only screwed heavy grade GI fittings or forged steel
fittings shall be used. Teflon tape shall be used in all jointing between pipe to sprinkler. `Holdtite'
shall be used in pipe to pipe seals. Pipe supports shall be at every 3.0 M (including all horizontal
turns) for pipes up to 50 mm dia. pipe supports shall be at intervals of 4.5 M for pipes above 50
mm dia.
iv) Flow Control Sprinkler: It shall have a body and deflector etc. of forged Gun metal/ chrome
plated. The housing shall be gun metal and discharge of Teflon/ rubber. The orifice size shall be
15mm and end connection shall be same. The orifice size shall be a fusible
alloy pellet set to fuse at 63°C and a snap disc of by-metallic type to snap at 71°C to allow
water to flow through the orifice. When the temperature reduces to 35°C, the snap disc shall reset
itself to close water flow, but shall re-open again when the temperature rises to 71°C. There
shall be 3 nos. of small thin circular fins one above other at the bottom, which shall be of metal
with heat conductivity. It shall withstand a test pressure upto 10.5 kg/ cm2. The Auto-flow
control sprinkler head shall be approved by competent authority.
v) Concealed type sprinkler head: The exposed part of the sprinkler shall be concealed by means
of cover plate assembly which shall be mounted flush with the Use ceiling. It shall be rated at
71°C and shall withstand pressure up.to 10.5kg/ cm2. The sprinkler shall be provided with a
matching escutcheon plate. The ceiling plate shall absorb heat and transfer the heat to a fusible
alloy hinge, which at the rated temperature shall melt and expose the sprinkler head to the heat
below.
vi)Installation Control Valve : The installation control valve shall be double seated clapper
type check valve. The body and cover shall be made from cast iron to conform IS: 210 Grade
FG 200. The seat and seat clamp shall be made from bronze conform to IS: 318, LTB II Grade.
The sealing to be seat, shall be neoprene gasket. The hinges pin and ball shall be of stainless
steel.
 It shall be vertically mounted and the direction of water travel shall be indication on the
surface. It shall be rated to 12kg/ cm2 and tested to 25kg/ cm2 pressure.
 A bypass check valve shall be fitted to adjust minor and slow variations in water pressure
for balancing so as to avoid any false alarm.
The valve shall also be provided with a Test Control Box. The bod shall house a lever to test
and operate the ICV. A brass strainer shall also be provided at the point of water supply to the
alarm gong. A retarding chamber shall also be provided.
 The chamber shall be able to balance the water pressure in cause of water line surges.
 Each installation control valve shall have two sets of pressure gauges with brass ball valve
type shut off.
 A water motor alarm shall also be provided. This shall be mechanically operated by discharge
of water through an impeller. The drive bearing shall be weather resistant. A strainer shall be
provided on lines before the nozzle. The gong piece shall be constructed from bronze to IS: 318,
2TB II Grade and base of cast iron. The motor housing, rotor and housing cover shall be pressure
die cast aluminium.
xiii) A brass automatic ball drop valve with the retard chamber shall also be provided.
25.7. Electric Fire Pump:
25.7.1 Scope: This section covers the details of requirements of the motor, starter and pump for the
electrically operated fire pump.
25.7.2. General: The electrical fire pump shall be suitable for automatic operation complete with
necessary electric motor and automatic starting gear, suitable for operation on 415 volts, 3phase, 50
Hz. A.C. system. Both the motor and the pump shall be assembled on a common bed plate, fabricated
M.S. channel type or cast iron type.
25.7.3. Drive : The pump shall be only direct driven by means of a flexible coupling. Coupling
guard shall also be provided.
25.7.4. Fire Pump:
i) The fire pump shall be horizontal split casing centrifugal type. It shall have a capacity to deliver
1800/ 24001pm as specified, developing adequate head so as to ensure a minimum pressure of
3kg per cm2 at the highest and the farthest outlet. The delivery pressure at pump outlet shall be
not less than 7 kg. per cm2 in any case. The pump shall be single stage or multi stage as
specified.
ii) The pump shall be capable of giving a discharge of not less than 150 per cent of the rated
discharge, at a head of not less than 65 per cent of the rated head. The shut off head shall be
within 120 per cent of rate head.
iii) The pump casing shall be of cast iron to grade FG 200 to IS: 210 and parts like impeller, shaft
sleeve, wearing ring etc. shall be of non-corrosive metal like bronze/ brass/ gun metal. The shaft
shall be of stainless steel.
iv) Bearings of the pump shall be effectively sealed to prevent loss of lubricant or entry of dust
or water.
v) The pump shall be provided with a plate indicating the suction lift, delivery head, discharge,
speed and number of stages.
vi) The pump casing shall be designed to withstand 1.5 times the working pressure.
vi) Motor : The motor shall be squirrel cage A.C. induction type suitable for operation on 415 volts
3 phase 50 Hz. System.
vii) The motor shall be totally enclosed fans cooled type conforming to protection clause IP 21 vide
I.S. 4691. The class of insulation shall be B. The synchronous speed shall be 1500/ 3000 RPM
as specified. The motor shall be rated for continuous duty and shall have a horse power rating
necessary to drive the pump at 150 per cent of its rated discharge with at least 65 per cent rated
head. The motor shall conform to IS: 325.
25.7.5. Motor Starter: The motor starter shall be automatic star delta type conforming to IS: (latest
edition). The unit shall include suitable current transformer and ammeter of suitable range on one
line to indicate the current. The starter shall not incorporate under voltage no voltage trip overload
or SPP.
The starter assembly shall be suitably integrated in the power and control panel for the wet riser
system.
25.8 Diesel Fire Pump:
25.8.1. Scope: This section covers the details of requirements of the standby fire pump, operated by
a diesel engine.
25.8.2. General: The diesel pump set shall be suitable for automatic operation complete with
necessary automatic starting gear, for starting on wet battery system and shall be complete with all
accessories. Both engine and pump shall be assembled on a common bed plate, fabricated mild steel
channel type.
25.8.3. Drive: The pump shall be only direct driven by means of a flexible coupling. Coupling guard
shall also be provided. The speed shall be 1500/ 1800 RPM as specified.
25.8.4. Fire Pump:
i) The fire pump shall be horizontal split casing centrifugal type. It shall have a capacity to
deliver 1800/ 24001pm as specified, developing adequate head so as to ensure a minimum
pressure of 3kg per sq. cm. at the highest and the farthest outlet. The delivery pressure at the
pump outlet shall be not less than 7 kg per sq. cm. in any case. The pump may be single stage
or multi stage as specified. The pump shall be capable of giving a discharge of not less than
150% of the rated discharge at a head of not less than 65% of the rated head. The shut off head
shall be within 120% of the rated head.
ii) The pump casing shall be of cast iron to grade FG 200 to IS 210 and parts like impeller shaft
sleeve, wearing-ring etc. shall be of non-corrosive metal like bronze/ brass/ gun metal. The shaft
shall be of stainless steel. The pump shall be provided with mechanical seal.
iii) The pump casing shall be designed to withstand 1.5 times the working pressure.
iv) Bearings of pump shall be effectively sealed to prevent loss of lubricant or entry of dust or
water.
25.8.5. Diesel Engine:
a) Environmental conditions- The engine shall be required to operate under the conditions of
environment as specified.
b) Engine Rating: - The engine shall be cold starting type without the necessity of preliminary
heating of the engine cylinders or combustion chamber (for example, by wicks, cartridge,
heater plugs, etc.) The engine shall be multi cylinder/ vertical 4 stroke cycle, water cooled,
diesel engine, developing suitable HP at the operating speed specified to drive the fire pump.
Continuous capacity available for the load shall be exclusive of the power requirement of
auxiliaries of the diesel engine and after correction for altitude, ambient temperature and
humidity for the specified environmental conditions. This shall be at least 20% greater than the
maximum HP required to drive the pump at its duty point. It shall also be capable of driving
the pump at 150% of the rated discharge at 65% of rated head. The engine shall be capable of
continuous non-stop operation for 8 hours and at least 3000 hours of operation before major
overhaul. The engine shall have 10% overload capacity for one hour in any period of 12 hours
continuous run.
The engine shall accept full load within 15 seconds from the receipt of signal to start. The
diesel engine shall conform to BS 649/ IS: 10002, all amended up to date.
c) Engine Accessories - The engine shall be complete with the following accessories:-Fly
wheel dynamically balanced.
Direct coupling for pump and coupling guard.
Radiator with hoses, fan, water pump, drive arrangement and guard.
Corrosion Resister.
Air cleaner, oil bath type/ Dry type.(vi) Fuel service tank support, semi-rotary pump
and fuel oil filter with necessary pipe work.
Pump for lubricating oil and lub, oil filter.
Elect. starting battery (2 x 12v).
Exhaust silencer with necessary pipe work.
Governor
Instrument panel housing all the gauges, including Tachometer, hour meter and starting
switch with key (for manual starting)
(xii) Necessary safety controls
(xiii) Winterisation arrangement, where specified.
d) Cooling System:- The engine cooling system shall be radiator water cooled system. The
radiator assembly shall be mounted on the common bed plate. The radiator fan shall be driven
off the engine as its auxiliary with a multiple fan belt. When half the belts are broken, the
remaining belts shall be capable of driving the fan. Cooling water shall be circulated by means
of an auxiliary pump of the engine in a closed circuit.
e) Fuel System:-
i) The fuel shall be gravity fed from the engine fuel tank to the engine driven fuel pump.
The engine fuel tank shall be mounted either over or adjacent to the engine itself or
suitably wall mounted on brackets at a height not less than 60cm above the fuel injection
pump. The fuel filter shall be suitably located to permit easy servicing.
ii) All fuel tubing to the engine shall be with copper, with flexible hose connections where
required. Plastic tubing shall not be permitted.
iii) The fuel tank shall be of welded steel construction (3mm thick) and of capacity sufficient
to allow the engine to run on full load for at least 8 hours. The tank shall be complete
with necessary floor mounted supports, level indicator (protected against mechanical
injury) inlet, outlet, overflow connections and drain plug and piping to the engine fuel tank.
The outlet should be so located as to avoid entry of any sediments into the fuel line to the
engine.
iv) A semi rotary hand pump for filling the daily service tank together with hose pipe 5 m
long with a foot valve etc. shall also form part of the scope of work.
Lubricating Oil System:- Forced feed lubricating oil system shall be employed for positive
lubrication. Necessary lubricating oil filters shall be provided, located suitably for convenient
servicing.
Starting System:- The starting system shall comprise necessary batteries (2 x12v), 24 volts
starter motor of adequate capacity and axle type gear to match with the toothed ring on the fly
wheel. Bi-metallic relay protection to protect starting motor from excessively long cranking runs
suitably integrated with engine protection system shall be included within the scope of the
work. The capacity of the battery shall be suitable for meeting the needs of the starting system.
The battery capacity shall be adequate for 10 consecutive starts without recharging with cold
engine under full compression.
h) Exhaust System:- The exhaust system shall be complete with silencer suitable for out-door
installation and silencer piping including bends and accessories needed for a run of 5 metre
from the engine manifold. (Adjustment rates for extra lengths shall also be given). The total
back pressure shall not exceed the engine manufacturer's recommendation. The exhaust piping
shall be suitably lagged.
i) Engine shut down mechanism:- This shall be manually operated and shall return
automatically to the starting position after use.
j) Governing System:- The engine shall be provided with an adjustable governor to control the
engine speed within 5% of its rated speed under all conditions of load upto full load. The
governor shall be set to maintain rated pump speed at maximum pump load.
k) Engine Instrumentation:- Engine instrumentation shall include the following-
(i) Lubricating Oil pressure gauge
(ii) Lub. Oil temperature gauge
(iii) Water pressure gauge
(iv) Water temperature gauge
(v) Tachometer
(vi) Hour meter The instrumentation panel shall be suitably resident mounted
on the engine.
m) Engine Protection Devices:- Following engine protection and automatic shut down facilities
shall be provided:-
Low lubricating Oil pressure
High cooling water temperature
High Lub. Oil temperature Over
speed shut down
n) Pipe work:- All pipe lines with fittings and accessories required shall be provided for fuel oil,
lub. Oil and exhaust systems, copper piping of adequate sizes shall be used for Lub. Oil and
fuel oil M.S. piping will be permitted for exhaust.
o) Anti Vibration Mounting:- Suitable vibration mounting duly approved by engineer-incharge
shall be employed for mounting the unit so as to minimize transmission of vibration to the
structure. The isolation efficiency achievable shall be clearly indicated.
p) Battery Charger:- Necessary float and boost charger shall be incorporated in the control
section of the power and control panel, to keep the battery under trim condition. Volt-meter to
indicate the state of charge of the batteries shall be provided.
25.9. Auxiliary Pumping Equipment:
25.9.1. Scope: This section covers the details of requirements of the auxiliary equipment necessary for
the operation of the fire pumps and the wet-riser system and terrace pump of the wet-riser cum down
comer. While pressurization pump shall be installed in all installations priming pump and terrace
pump shall be provided only where specified.
25.9.2. General: The pump shall be suitable for automatic operation complete with necessary
electric motor and automatic starting gear, suitable for operation on 415 volts 3 phase 50 Hz A.C.
system. Both the motor and the pump shall be assembled on a common base plate, fabricated mild
steel channel type or cast iron type.
25.9.3 Drive: The pump shall be directly driven from the electric motor flexible coupling and
coupling guard shall be provided for pressurization pump and terrace pump. The priming pump may
be monobloc type.
25.9.4 Auxiliary Pumps:
i) The discharge of the pressurization pump shall be 10% of rated discharge of the main fire pump.
The head at this discharge shall be about 90% of the main fire pump. The discharge of the
terrace pump shall be 450/900 as specified and of such head as to provide 3kg/ Sq. cm. at the
top farthest outlet of the down come. The priming pump shall have a discharge
such that the priming tank is filled up in 5 minutes and head to suit the location of the priming
tank and the sump.
ii) Pressurization pump and terrace pump shall be horizontal split casing type, single stage or
multi-stage as specified. The pump casing shall be of cast iron and parts like impeller, shaft
sleeve, wearing ring, etc. shall be of non-corrosive metal like bronze, brass or gun metal. The
shaft shall be of stainless steel.
iii) Bearings of the pump shall be effectively sealed to prevent loss of lubricant or entry of dust/
water.
iv) The pump casing shall be designed to withstand 1.5 times the working pressure.
25.9.5. Motor: The motor shall be squirrel cage A.C. induction type suitable for operations on 415
volts 3 phase 50 Hz. System. The motor shall be totally enclosed fan cooled type conforming to
protection clause IP 21 of IS: 4691. The class of insulation shall be B or E, the later being preferred.
The synchronous speed shall be 3000 RPM/ 1500 RPM as specified. The motor shall conform to IS:
325- latest edition and rated for continuous duty.
25.9.6. Motor Starter: The motor starter shall be automatic star delta type above 7.5 HP rating and
DOL type upto 7.5 HP rating with overload trip, but without under voltage/ no volt trip. An
independent single phasing preventer shall be provided for each motor. The unit shall include
ammeter of suitable range on the one line to indicate the current with current transformer as
necessary. Starter shall conform to IS: 1822. The starter shall be integrated in the power and control
panel for the wet riser system.
25.9.7. Automatic Priming Arrangement:
i) Where positive suction is not available for fire pumps and pressurization pump, an automatic
priming arrangement shall be provided. This comprises electric motor driven priming pump to
the pump to the sump and the priming tank and the priming tank to the different pumps, drain,
overflow, etc.. Where specifically indicated, the priming tank may be filled appropriately by a
tap on the riser system when the pump is running the overflow being returned back to the
underground storage tank. The priming pump shall start automatically when water in the
priming tank goes below a pre-set and stops when the water reaches a higher pre-set level.
ii) The priming tank shall be of welded steel construction with 3mm thick sheets, supported on
suitable pedestal. The tank shall be of capacity equivalent to at least 3 times the volume of the
suction line up to foot valve. The tank shall be complete with high and low level switches,
water in and out connections and drain and overflow connections.
25.10. Piping for Wet Riser & Sprinkler System:
25.10.1. Scope: This section covers the details of requirements of piping used in wet riser & sprinkler
system, including the associated auxiliary equipment.
25.10.2. General: The wet riser & sprinkler system piping shall comprise M.S. pipe work, with
necessary M.S. fittings and accessories. C.I. pipes may be used in locations where unavoidable, to
connect the underground C.I. piping system to the riser in the form of distant piece. The wet riser
sprinkler piping system shall remain pressurized at all times during operation and as such the piping
work shall be carried out to withstand the same.
25.10.3. Pipes and Pipe work:
i) M.S. pipes and accessories and fittings shall be of "Heavy class" conforming to IS: 1239 Part
1/1974 and Part IU 1979, the pipe joints shall be butt welded for 50mm and larger sizes, sawed
up to 40mm.
ii) C.I. pipes shall be of "class B" to IS: 1537-1976 (vertically cast iron pipes) and fittings shall
be of "Heavy Grade" to IS: 1538-1993. The flanges shall be smooth faced.
iii) M.S. pipes for automatic priming arrangement overflow & than connection shall be heavy
class to IS: 1239 Part 1/1970 and Part W 1972.
iv) The pipe sizes shall be as specified. However, the size of the initial delivery pipe shall in any
case not be less than the internal diameter of the delivery outlet of the pump. The suction pipe
shall be sized such that the water velocity therein at rated pump discharge is not more than
90m/min for negative suction and 1 0 0 n for positive suction arrangement.
v) Where screwed joint becomes necessary in M.S. piping such as the joint between the flange
and piping, they shall be taper threaded.
vi) The joint between a C.I. pipe and a G.I. pipe shall be of flanged type.
vii) Packing sheets between flanges shall be of rubber or asbestos compound and shall with stand
test pressure of 1-1/2 times the working pressures in the pipe line.
25.10.4 Air Vessel and Air Release Valve: Air vessel on top of each wet riser piping shall be
fabricated of at least 6 mm thick steel to withstand the pressure, with dished ends and supporting
legs. This shall be of 250 mm dia. and 1m high. This shall be complete with necessary flange
connection to the wet riser piping and air release valve with necessary piping to meet the functional
requirement of the system. The air vessel shall be of continuous welded construction. This shall be
tested for twice the working pressure.
25.10.5. Valves, gauges and orifice plates:
i) Sluice valves above 65mm shall be of cast iron body and bronze/ gunmetal seat. They shall
conform to type PN 1.6 of IS: 780-1980, valves up to 65mm shall be of gunmetal construction.
Valve wheels shall be of right hand type and have an arrow head engraved or cast thereon
showing the direction for turning open and closing.
ii) Non return valves shall be of cast iron body and bronze/ gun metal seat. They shall conform to
Class I of IS: 5312 and have flanged ends. They shall be swing check type in horizontal runs
and lift check type in vertical runs of piping. They shall not be spring loaded type.
iii) Pressure gauge of suitable range shall be installed on the discharge side of each pump-vacuum
gauge shall be provided on suction side for pumps with negative suction. The dial size shall
be 150mm. The gauges shall be with necessary cocks.
iv) Orifice plates shall be of 6mm thick stainless steel to reduce pressure on individual hydrants to
operating pressure of 7kg/ Sq.cm. Design of the same shall be given by the contractor as per
location and pressure condition of each hydrant.
25.10.6. External Yard Hydrants:
i) External Yard Hydrants shall be of `Stand Post' type conforming to I.S.:908-1975 and comprise
Stand Post for single outlet, duck foot bend flange riser and single headed brass/ gunmetal valve
conforming type A of I.S. 5290-1973.
ii) The stand post column shall be cast iron, cast in one piece, conforming to Grade 20 of I.S.
210-(latest edition). The internal diameter at the top shall be at least 80 mm
iii) The outlet shall be angled towards ground, with instantaneous spring lock type gunmetal
female coupling of 63 mm dia. for connecting to hose pipe.
25.10.7. Internal Hydrants:
i) The internal hydrants outlet shall comprise "double headed double outlet gunmetal landing
valve" conforming to type `B' of I.S. 5290-1973. Separate valves one on each of the two heads
shall form part of the landing valve construction.
ii) A cap with chain is provided on one head of the outlet which will have an instantaneous pattern
female coupling for connecting to hose pipe, and adaptor on the other head for first lid hose
reel connection.
iii) The landing valve shall be fitted to a Tee connection on the wet riser at the landing.
25.10.8. First Aid Hose reel equipment:
i) First aid Hose reel equipment shall comprise reel, hose guide fixing bracket, hose tubing globe
valve, stop cock and nozzle. This shall conform to IS 884-1969. The hose tubing shall conform
to IS:444 (latest edition)
ii) The hose tubing shall be 20 mm dia. and 36.5 m long. The nozzle and globe valve shall be of
25 mm size.
iii) The fixing bracket shall be of swinging type. Operating instruction shall be engraved on the
assembly.
iv) First-aid firefighting appliances shall be provided and installed in accordance with good
practice. The firefighting equipment and accessories to be installed in buildings for use in
firefighting shall be in accordance with the accepted standards contained in and shall be
maintained periodically so as to ensure their perfect serviceability at all times.
v) In addition to wet riser or down-comer, first-aid hose reels shall be installed on all the floors
of buildings of 15 m in height or more and shall be in accordance with accepted standards. The
first-aid hose reel shall be connected directly to the riser/down-comer main and diameter of
the hose reel shall not be less than 19 mm.
25.10.9 Hose Pipes, Branch pipes and Nozzles:
a) Hose Pipes:
i) Hose pipes shall be rubber lined woven jacketed and 63 mm in diameter.
ii) They shall conform to Type 2 (Reinforced rubber lined) of I.S. 636 (latest edition). The
hose shall be sufficiently flexible and capable of being rolled.
Each run of hose pipe shall be complete with necessary coupling at the ends of match
with the landing valve or with another run of hose pipe or with Branch pipe. The
couplings shall be of instantaneous spring lock type.
b) Branch Pipe: Branch pipe shall be of copper, gunmetal or aluminium alloy 63 mm dia. and
be complete with male instantaneous spring lock type coupling for connection to the hose pipe.
The branch pipe shall be externally threaded to receive the nozzle.
c) Nozzle:-i) The nozzle shall be copper or gunmetal, 20 mm in (internal) diameter. The
screw
threads at the inlet connection shall match with the threading on the branch pipe, the inlet
end shall have a hexagonal head to facilitate screwing of the nozzle on to the branch pipe
with nozzle spanner.
End couplings, branch pipes, and nozzles shall conform to IS:903-1985.
Two hoses of 15m length with couplings shall be provided with each external (yard)
hydrant. Two hoses of 7.5m/15m length, as specified, with couplings shall be provided with
each internal hydrant. One nozzle and one branch pipe with coupling shall be provided
with each yard hydrant and internal hydrant.
25.10.10. Hose Cabinet:
i) The hose cabinet to accommodate the hose pipes, branch pipe nozzle and the hydrant outlets
shall be fabricated from 1.5mm thick sheet steel. In case of internal hydrants, this shall
accommodate the hose reel equipment also. This shall have lockable, centre opening glazed
doors. Where the niche for wet riser is provided with shutters, separate hose cabinet as above
may be dispensed with. This shall be specified in the schedule of work.
ii) The scope of work includes provision of masonry or steel frame structure, as specified for
installation.
iii) The hose cabinet shall be painted red and stove enamelled.
iv) Fire Brigade Inlet Connections
v) One set of 4 way collector head Fire Brigade connection shall be provided near the pump
house, and individual wet risers as specified.
This shall comprise 4 instantaneous mate inlet couplings, plugs and chains at pump house and
2 way at other locations.
vi) The inlet to the wet riser shall be with 150mm dia. sluice valve and non-return valve. The
scope shall include necessary reducers, tees, bends and special fittings as required.
vii) Necessary enclosure of sheet metal with support shall be provided, as in the case of hose
cabinets.
25.10.11 Hydraulic Siren: A siren shall be provided in the system, to indicate the flow of water in
the sprinkler system. This shall be turbine type.
25.11. Power and Control Panel and Other Control Components:
25.11.1. Scope: This section covers the detailed requirements of the power and the control panel
for the wet riser sprinkler system, and also for the various control components in the system.
25.11.2 Power and Control Panel (Constructional Requirements):
a) General Features: The power and control panel shall be totally enclosed, free standing, floor
mounted cubicle type, fabricated out of sheet steel not less than 2mm thick. Where necessary,
additional stiffening shall be provided by angle iron frame work. General construction shall be
of compartmentalization and sectionalisation such as mains incomer, electric fire pump, diesel
fire pump, pressurization pump, priming pump and control, so that there is no mix up of power
and control wiring and connections in the same sections as far as possible. The panel shall be
front operated type with all connections accessible from the front. Front doors shall be hinged
type. Back doors shall be hinged type or removable type for inspection. The door hinges shall
be of concealed type. The doors shall be provided
with quick fixing doors knobs with indication. The general arrangement of the panel shall be got
approved before fabrication. The cubicle construction shall be to IP 21 as per IS:2147.
b) Cable entries and gland plates:- All cable entries shall be through gland plates which are
removable and sectionalized. Necessary compression type glands shall also be provided. Where
heavy cables are brought in and terminated, suitable clamps shall be incorporated to relieve the
stress on the glands due to the weight of the cable. Cable entries may be from top or bottom
depending on the equipment layout and cable scheme as approved.
c) Bus bar and Connections:- The bus bars shall be air insulated, and of aluminium of high
conductivity electrolytic quality (grade E 91 E to IS: 5082) and of adequate cross section.
Current density shall not exceed 130 amps per sq. cm. All connections to individual, circuits from
the busbars shall preferably be with solid connections. The busbars and the connections shall be
suitably covered with PVC sleeves or in an approved manner. Busbars shall suitably supported
using non hygroscopic insulated supports such that they may stand 50 KA RMS symmetrical
current for one second. High tensile bolts and spring washers shall be provided at busbar joints.
d) Earthlings Arrangements: GI strip 25mm x 5mm shall be run at the rear of the board, bonding
all the sections suitably. 2Nos. earth terminals shall be provided at the ends of the GI strip for
connection to earth system. Earth terminals shall be with a flexible loop and the hardware shall
be of G.I..
e) Terminal Blocks and Small Wiring: Terminal blocks shall be of heavy duty type and
generally not less than 15 amps 250 V grade up to 100 V, and 600 V grade for the rent of the
functions. They shall be easily accessible for maintenance. All control wiring inside the panel
shall be with PVC insulated copper conductor of 2.5 sq. mm size and 600 V grade conforming
to IS: 694. Suitable colour coding may be adopted. Wiring harness shall be neatly formed and
run preferably function wise, and as far as possible segregated voltage wise. Identification
ferrules shall be used at both ends of the wires.
f) Instruments and lamps: All indication lamps and instruments shall be flush mounted type in
front of the panel. The voltmeter and ammeters shall be of size 100 mm conforming to clause
1.5 of IS 1248 for accuracy. Current transformers shall be provided with ammeters, wherever
necessary. Indicating lamps to indicate the availability of electric supply shall be provided at
the incoming section. Necessary indicating lamps for alarm indications and battery charging
shall be provided in the respective sections. All indicating lamps and voltmeter shall be
protected with HRC cartridge type fuses.
g) Labels:- All internal components shall be provided with suitable identification labels. Suitably
engraved labels shall be fixed at the panel for all switches, instruments, push buttons,
indicating lamps etc.
h) Painting:-
The entire panel shall be given a primer coat of red lead after degreasing and phosphate
treatment, and 2 coat of final paint of approved shade before assembly of various items.
The panels for the terrace pump shall be of cubicle design. The specifications of power
and control panel for the wet riser shall be applicable for those panels, with controls and
indications.
i) Equipment Requirements: General - The power and control panel shall comprise individual
section for the various equipment of the system and controls, in a combined cubicle type design.
Where particularly specified, totally independent panels for each equipment shall be provided in
cubicle design, and the main electric panel and the individual panels in such a case shall
incorporate isolating arrangement of appropriate capacity. All switch fuse/fuse switch units shall
be to AC 23 duty to IS: 4064.
j) Incomer Section- The incomer section shall comprise:-

(i) Fuse switch unit with HRC fuses, ammeter, voltmeter, selector switch, set of phase
indication lamps and fuses. (Fuse rating to suit consideration (iii) below).
(ii) Aluminium busbars
(iii) TP & N outgoing switch fuse unit with HRC fuses for electric fire pump. (Fuse
rating to take continuously 250% of full load current of fire pump motor).
TP & N outgoing switch fuse units with HRC fuses for pressurization pump, priming pump
and terrace pump (where specified) and for local lighting control.
(v) TP & N fuse unit with HRC fuses for Battery charger unit control.
(vi) TP&N switch fuse unit with HRC fuses outgoing (spares, as specified).
Lot:- Terminal blocks, inter-connections labels etc. as necessary.
2511.3. Electric Fire Pump Section:- The section shall incorporate the following facilities:-
TP & N isolator
Control system components and equipment such as relays, contractors, timers etc, for
automatic operation.
Starter unit, current transformer and ammeter
Indication lamps, their fuses, terminal blocks, push buttons, control and selector switches etc.,
as are required
Pump lock out devices due to faults or abnormalities as specified
Visual/audio alarms, indications and communication facility as specified
(vii) Necessary inter-connection control and power cable work; cable glands, lugs and internal
wiring and connections etc.
25.11.4. Engine Section:- The engine section shall incorporate the following facilities:
(i) Control system components and equipment such as relays, contractors, timers etc. for
automatic operation
(ii) Instruments, indicator lamps, fuses, terminal blocks, push buttons, control and selector
switches etc. as are required
(iii) Engine shut down and block out devices due to faults or abnormalities as specified
(iv) Visual /audio alarm indication and enunciator facility as specified
(v) Inter-connection control and power cable work, cable glands, lugs, all internal wiring and
connections etc.
25.11.5. Auxiliary Pump Sections:- Each of the auxiliary pump section for pressurization and
priming pump shall incorporate the following :-
(i) TP&N
(ii) Control system components such as relays, timers, contractors, etc. as are necessary for
functional requirements
(iii) Starter unit, current transformer and ammeter
(iv) Indication lamps, fuses, terminal blocks, push buttons, selector switch etc as required
(v) Inter-connections, power and control cable work, cable glands, lugs, internal wiring and
connections.
(vi) Low water level alarm for terrace tank, where provided 25.11.6. Control
Section:- This sections shall incorporate the following :-
(i) Control components integrating the various sections, so as to satisfy the functional
requirements
Battery charger unit with boost/float charge facility with voltmeter, capable of independently
charging 2 sets of batteries at a time
Visual /Audio alarms, not covered in individual sections
Lamps healthy test facility
Instruments, indicating lamps, push buttons, fuse terminal blocks etc. as required Test
facility to simulate operation of hydrants
25.11.7. Other Control Components:

a) Pressure Switches: Pressure Switches shall be provided for switching on and off the
pressurization pump at present pressures and also for switching on the fire pump at preset pressure.
Being the main component for initiating the signal for the operation of the pumps, the pressure
switches shall be totally reliable, sturdy in construction and of long life. The pressure settings shall
be adjustable.
b) Low Water Level Indicator and Switch: To prevent the dry running of fire pumps due to
emptying of the static tank, a water level indicator and switch shall be provided. This shall trip the
electric motor or stop the diesel engine, as the case may be when the water level goes below a present
level. This shall also furnish a distinct low water level audio visual alarm. This should indicate the
level of water at different stages in the Power and Control Panel.
c) Power Supply for Controls: In order to ensure that the control system remains operational at
all times, the control system shall be designed for 24 VDC operation, fed from 24 V wet battery.
This shall be independent of the starting battery for the engine i.e. battery shall remain trickle
charged at all times from the common battery charger at the control section.
25.12. Electrical Work and Earthings:
25.12.1. Scope:
i) This section covers the detailed requirements of electrical works including earthling, for the
wet riser installation.
ii) Electric power supply shall be terminated in the incoming switch gear of the Power and Control
Panel by the Department. all further connections to the various components of the wet riser
system shall be the responsibility of the contractor, for a complete and working system,
satisfying all the functional requirements.
iii) The scope shall particularly include the following:
a) Power and Control Panel(s) shall be as specified.
b)
All inter-connections with multi-core armoured copper cables of size as approved
between various control units and control panel(s).
c) All power cable connections with multi core armoured aluminium cables of size as
approved between panels motors etc. either clamped on wall, run on cable trays or laid
in duct etc. as the case may be. Trays clamps, supports and all labour shall be inclusive
within the quoted cost.
iv) Necessary earthlings with 2 No. G.I. pipe electrodes and loop earthings.
v) The work shall be carried out conforming to General Specifications for Electrical Works
(Internal) amended up to date and (External) amended up to date.
25.13. Installation and Testing of Wet Riser Sprinkler System:
25.13.1. Scope:-
a) This section covers the requirements of installation of the various components of the wet riser
sprinkler system. Survey of the site of work shall be made by the contractor before preparation
of the detailed drawings for submission to the department for approval. The installation shall
be carried out strictly in accordance with the approved drawing.
b) The scope of installation work shall include the following, whether or not expressly
mentioned in the Schedule of Work.
(i) Cement concrete (1:2:4 mix) foundation for all pump sets.
(ii) Vibration isolation arrangement for all pump sets
(iii)Filling up the hole in flooring with cement concrete, after laying the wet riser pipes
(iv) Necessary supports for pipes in the wet riser pump room
(v) Necessary supports and clamps for wet riser plumbing inside the building
(vi) Supporting bracket/frame work for the fuel oil tank of the engine
(vii) Excavation of the earth, consolidation and refilling after laying of wet riser piping in
ground
(viii) Provision of necessary brick base or intermediate supports, as required in approved
manner in case of soils which are not strong enough to support the pipes, thereby likely
to cause differential settlement.
(ix) Necessary anchor block of ample dimensions in 1:2:4 cement concrete at all bends, Tee
connections, foot of the wet riser, and other places as required to stand the pressure thrusts
in pipes.
(x) Necessary masonry work/steel work for supporting hose cabinets near external (yard)
hydrants
(xi) Valve chambers of approved design, where specified
(xii) Ground level hydrants of approved design, where specified
(xiii) Cutting and making good the damages for the installation work of the wet riser
system
(xiv) Strainers and foot valves for pumps with negative suction, and strainers for pumps with
positive suction
(xv) All the required control piping, exhaust piping (15 m long) from engine, oil piping for
fuel oil and lubricating oil for the engine, drain piping from the pumps to the drain point
in the pump room, overflow piping from priming tank to the sump. The piping work shall
include all necessary fittings, valve and accessories for effective functional requirements.
(xvi) Inter-connecting cable work with controls, control panel, batteries etc. including battery
leads.
(xvii) Orifice plates at individual hydrants, as required
25.13.2. Pipe Work Associated with Diesel Engine:
i) Pipe works for fuel system, lub. Oil system and exhaust system shall be complete with all
necessary fittings and accessories and all required supports, clamps, hangers etc, for a
complete work.
ii) Fuel feed is by gravity and the fuel tank shall be located at least 60 cm above the fuel
injection pump.
iii) Fuel pipe of copper shall not be soldered but brazed or welded.
iv) No valves or cocks shall be provided in the fuel feed line to the engine from the fuel tank.
v) Precautions shall be taken to prevent any air locks in any part of the fuel system. No air relief
cock shall be permitted and where inescapable, screwed plugs shall be provided for the purpose.
The installation of the fuel supply system shall be such that a completely primed condition is
maintained, free from air lock.
vi) Filter's shall be provided in fuel oil and lubricant, oil circuits allocations that are easily
accessible for maintenance.
25.13.3. Wet Riser Pipe Work:
i) The suction line for each pump shall be independent.
ii) No sluice valve shall be provided in suction line, where the pump is located above the water
level in the sump, foot valve and strainer shall however be provided.
iii) Sluice valve shall be provided in suction line, where the pump is located below the water
level in the sump, strainer at the suction end shall be provided.
iii) Each external (yard) hydrant shall be controlled by a sluice valve at ground level.
iv) Sluice valve and non-return valve shall be provided at ground floor level for each vertical
riser.
v) Sluice valves shall be kept in open position and the scope of work includes provision of
necessary leather strap and pad lock, so as to prevent unauthorized closing of valve.
vi) The installation work includes provision of all clamps, supports, anchors etc.
Spacing between vertical supports shall not exceed 1.5m, Clamps shall be provided on either
side of the Tee joints for internal hydrants. Necessary anchors/thrust pads shall be provided as
approved at locations of bends, Tee etc, as required, within the scope of work.
vii) Underground pipes of the wet riser & sprinkler system shall be laid 1m below ground level
and at least 2m away from the face of the buildings. The run of piping shall be preferably along
roads and foot-paths and shall not be under buildings. Where specifically indicated
to cross building, these shall be laid in masonry trenches with removable covers. (trenches and
covers to be made by the Department) with cut off valves at the entry and exit points.
viii) Where provision of M.S. pipe below ground become inescapable, it shall be protected from
soil corrosion by 2 coats of coal tar hot enamel paint and 2 wraps of reinforced fibre glass
tissue or bituminised hessian.
ix) Each CI pipe M.S. pipe shall be subjected to hydraulic pressure test before installation, in
presence of the Engineer-in-charge or his authorized representative.
x) External (Yard) hydrants shall be located to have the outlet at about 1m above ground level.
xi) External (Yard) hydrants shall be located at least 2m away from the face of buildings but not
more than 15m and be accessible.
xii) Where external hydrants below ground level are specifically indicated in tender specifications,
there shall be enclosed in masonry or cast iron structure of size 75 cm square and 8cm above
ground level. The hydrant shall be within 8cm from the top of the enclosure.
xiii) Necessary facility for draining the rise pipe shall be provided at ground floor level with
40mm size gate valve.
xiv) Internal hydrants at each floor shall be located at about 1m above floor level.
xv) Valve chambers shall be of 1m square in size, with cover.
25.13.4. Hoses and Hose cabinets:
i) All hoses shall be numbered and a record submitted with completion plan. The number and
length shall be easily recognizable on each hose pipe.
ii) External hose boxes shall be installed such that the hose is not exposed to sun rays.
25.13.5. Painting:
i) Painting of the entire wet riser piping over the Ground shall be done with an anticorrosive
primer and 2 coats of approved paint. The colour shall be red to shade No. 536 of IS 5 paint shall
conform to IS 2932.
ii) The pumps and engine shall be painted after installation with a coat of approved paint to
similar shade as per original supply.
25.13.5 Testing of the system:
i) After laying and joining, the entire piping shall be tested to hydrostatic test pressure. The pipes
shall be slowly charged with water so that the air is expelled from the pipes. The pipes shall be
allowed to stand full of water for a period of not less than 24 hours and then tested under
pressure. The test pressure shall be at least 1.5 times the operating pressure. The test pressure
shall be applied by means of manually operated test pump or by a power driven test pump to
be provided by the contractor. In either case precautions shall be taken to ensure that the
required test pressure is not exceeded.
ii) The open end of the piping shall be temporarily closed for testing.
iii) Test shall be conducted on each pump set after completion of the installation with respect of
delivery head, flow and B.H.P. The test shall be carried out by the contractor at his own cost
except for water and electricity which will be provided by the Department free.
iv) All leaks and defects in different joints noticed during the testing and before commissioning
shall be rectified to the satisfaction of Engineer-in-charge.
v) Testing of fittings/equipment shall be carried out either at site or at works in the presence of a
representative of the Department. Test certificates shall also be furnished by the contractor.
vi) The automatic operation of the system, for the various functional requirements and alarms as
laid down in this specification shall be satisfactorily carried out on presence of the Engineer-
in-charge.
25.13.6. Approval by local bodies: It shall be the responsibility of the contractor to obtain the
approval of drawings and to get the installation inspected and passed by the concerned agencies, as
may be necessary as per local bye laws. Any fee payable to the local bodies for such activities shall
also be borne by the contractor.
25.14. Fire Detection:
25.14.1 Analogue addressable fire alarm system:
25.14.1.1 Scope of work: The scope of work under this head shall include designing, supplying and
installing of analogue addressable fire alarm and detection system. The work under this system shall
consist of furnishing all materials, equipment and appliances and labour necessary to install the said
system, complete with manual call box, detectors, control panel, speakers, relays etc. for
disconnecting other system such as A H Us and electric supply etc. wherever required.
25.14.2. Preamble:
i) Since each bidder will have his own technical terms for the equipment offered, in order to bring
commonality the bidder will be required to give his equivalent name for the terms indicated
here under. The Bidder shall in all his communications shall state the equipment/ product by
the name indicated in this document. He may give his equivalent within brackets next to the term.
In case his equipment does not match the general terms of this specification, the Bidder shall be
required to state specifically how his equipment is different but that it meets the requirements
of the specifications.
ii) The Bidder may note that he should not insist on using his own patented name only because
the equipment offers more functions than indicated herein.
iii) The following terms are being used:-
a) Ionization type Smoke Detector:- The detector shall be analogue addressable type
with switches/ codes etc. to define the detector.
b) Photo electric type Smoke Detector:- The detector shall be analogue addressable type
with switches/ codes etc. to define the detector.
c) Heat Detector:- The detector shall be analogue addressable type with switches/ codes
etc. to define the detector.
d) Manual Call Box Station: The manual call box station shall be addressable type with
switches/ codes etc to define the station. Function shall be similar to that of a
conventional manual call box.
e) Hooter:- The Hooter shall be able to give hooting alarm through it and controlled from
the Fire Alarm Panel.
f) Fault Isolator:- This equipment shall be placed in the electrical wiring and shall be able
to isolate electrical short circuiting and loose wiring. The isolator shall be able to keep
the part of the electrical circuit in operation that is connected directly to the Fire Alarm
Panel.
g) Fire Alarm Panel:- This refers to the microprocessor based panel that shall be connected
to the various detector loops. There shall be multiple looping/ zoning as indicated on the
drawing. The panel shall be able to check individual detectors for performance as well as
to give pin point location of fire alarm. Hooter Alarm as well as facility for cutting off of
A H Us and electrical power may also be included. No transponders or zone-wise
microprocessor based panels shall be used.
h) Loop:- A Loop or a zone shall mean a 2 wire circuit connecting at least 90 analogue
addressable detectors/ units.
i) Addressable Unit:- This term indicates the complete group of addressable detectors,
addressable manual call boxes, addressable hooters, addressable fault isolators,
addressable switches etc.
j) Switches:- Contacts or relays for tripping of A H Us, power supply etc as required.
Any switch shall be able to trip an individual A H Us if so required.
25.14.3. Specification:
i) The design, supply and installation and testing of the entire fire alarm system shall conform to
BS: 5839 or NFPA 71 and 72. the detectors shall conform to relevant codes for Fire Alarm
Systems.
ii) A general line diagram showing the circuit and spacing of detectors shall be enclosed with
tender drawings. However, this line diagram is mainly for guidance of the Bidders and
wherever it may be at variance with the BS: 5839 or NFPA 71 and 72, the latter shall be
followed.
25.14.4. Rate of Rise cum Fixed Temperature Heat Detector:
i) The Heat Detector shall be intelligent analogue addressable detector with its own manually set
digital code and be able to give a single digitized output to the Fire Alarm Panel regarding its
condition. The detector shall employ the thermostat principle for heat sensing and the fixed
temperature setting shall be at 60 degrees centigrade. It shall be able to communicate with the
Fire Alarm Panel by the pulses emitted from the Panel.
ii) The base of the detector shall be interchangeable with other Smoke Detector and the
construction shall be of poly carbonate or any approved proprietary flame retardant material.
LEDs shall be provided to indicate locally alarm condition. The enclosures shall meet IP 22
protection grade.
iii) It shall be able to withstand temperature varies from 0 degree centigrade to 50 degree
centigrade. Further, relative humidity (noncondensing type) up.to 95% shall not hamper its
performance. The voltage rating shall be from 17 V DC to 28 V DC, though the voltage may
be changed depending upon the working voltages of a proprietary Fire Alarm Panel.
iv) The detector shall meet the requirements of either En 54/ FM/ UL or VDs. It shall be possible
to test the detector's working both from the panel as well as locally by means as designed by
the Bidder. The approved coverage per detector for unhampered areas shall not
be less than 50 sq. metre. The detector shall be resettable type.
25.14.5. Ionization Type Smoke Detector:
i) Smoke detectors shall be working on ionization principle and shall be of dual chamber and dual
source type. They shall be completely solid state with LED indication at the base. The
radioactive source used in the detector shall not emit beta or gamma rays and the strength of
the radioactive source shall not exceed 1 micro curie.
ii) The detector shall be able to sense incipient fire by detecting the presence of visible and
invisible products of combustion. The detector shall be suitable for low voltage (17 to 28 volts
DC) two wire supply. The detector shall be provided with response indicator (LED) and the
sensitivity of the detector shall not vary with change in ambient temperature, humidity, pressure
of voltage variation.
iii) Its performance shall be not affected by air current upto 10 m per second. The detector shall be
suitably protected against dust accumulation/ ingress and it shall be free from maintenance and
functional test at intervals. All detectors shall be identical in construction design and
characteristics to facilitate easy replacement. The detector housing shall be damage resistant
made of polycarbonate or proprietary self- extinguishing material.
iv) The coverage per smoke detector shall be as per BS: 5445 or as listed with under writers
Laboratory, U.S.A., subject to a minimum of 70 sqm. This coverage area will reduce depending
upon structural configurations or partitions etc. It shall be possible to connect Smoke Detector
with Heat Detector or Manual Push Buttons in the same circuit. The sensitivity of detector shall
be set adjusted by the supplier to suit the site requirement. It shall have in-built safety device
to monitor the removal and pilferage of the detector. The detector also must have facility for
remote indication. The quiescent current flow must not exceed 50 milliamps. and alarm
condition current shall be maximum 60 milliamps.
v) The Ionization type Smoke Detector shall be intelligent analogue addressable detector with its
own manually-set digital code and be able to give analogue output to the Fire Alarm Panel
regarding its condition. It shall be able to communicate with the Fire Alarm Panel by the pulses
emitted from the panel.
vi) The base of the detector shall be interchangeable with other Smoke or Heat Detectors. The
enclosure shall meet IP 22 protection grade.
vii) It shall be able to withstand temperature variations from 0 degree centigrade to 60 degree
centigrade. Further, Relative Humidity (noncondensing type) up to 95% shall not hamper its
viii) The Detector shall meet the requirements of either En 54/ FM/ UL/ VDs or LPC. It shall be
possible to test the Detector's working both from the Panel as well as locally by means as
designed by the Bidder.
ix) It shall be possible to mount the detectors in Duct Casting Units for sampling of supply air
from the A H Us is so required.
25.14.6 Photo Electric Smoke Detector:
i) The Photo Electric smoke Detector has an optical sensing chamber that operates on the light
scattering principle and responds to those particles that form optically dense smoke.
When smoke enters the sensing chamber it scatters light which is received by a photo cell. The
signal is amplified and digitized for reception by the panel. The detector shall activate on
receiving smoke particles in the 0.5 to 10 micro metre range. The detector shall be completely
solid state with LED indication at the base.
ii) The detector shall be able to sense incipient fire by detecting the presence of visible and
invisible products of combustion. The detector shall be suitable for low voltage (17 to 28 V D
C) two wire supply. The detector shall be provided with response indicator (LED) and the
sensitivity of the detector shall not vary with change in ambient temperature, humidity, pressure
of voltage variation.
iii) Neither its performance shall be affected by air current up to 10 m per second. The detector
shall be suitably protected against dust accumulation/ ingress and it shall be free from
maintenance and functional test at intervals. All detectors shall be identical in construction
design and characteristic to facilitate easy replacement. The detector housing shall be damage
resistant made of polycarbonate or proprietary self extinguishing material.
iv) The coverage per smoke detector shall be up to a minimum of 70 M sq. This coverage area will
reduce depending upon structural configurations or partitions etc. It shall be possible to connect
Smoke detector with Heat Detector or Manual Push Buttons in the same circuit. The sensitivity
of detector shall be set adjusted by the supplier to suit the site requirements.
v) It shall have in-built safety device to monitor the removal and pilferage of the detector. The
detector also must have facility for remote indication. The quiescent current flow must not
exceed 50 milliamps and alarm condition current shall be maximum 60 milliamps.
vi) The photo electric type smoke detector shall be intelligent analogue addressable detector with
its own manually set digital code and be able to give analogue output to the Fire Alarm Panel
regarding its condition. It shall be able to communicate with the Fire Alarm Panel by the pulses
emitted from the Panel.
The base of the Detector shall be interchangeable with other Smoke or Heat Detectors. The
enclosure shall meet IP 22 protection grade.
It shall be able to withstand temperature variations from 0 degree centigrade to 50 degree
centigrade. Further, relative humidity (noncondensing type) up to 95% shall not hamper its
ix) The detector shall meet the requirements of either EN 54/ FM/ UL/ VDs or LPC. It shall be
possible to test the detector's working both from the panel as well as locally by means as
designed by the Bidder.
x) It shall be possible to mount the detectors in Duct Casting Units for sampling of supply air
form the A H Us. If so required.
25.15. Fire Alarm System:
i) The Fire Alarm System shall conform to BS: 5839 or EN 54 or NFPA 71/72 or Underwriter's
Laboratory in respect of design and installation and it shall give Audio/ Visual Alarm signals
when initiation from Manual Call Box or the temperature in case of Heat Detector or smoke
density in case of Ionization or Photo Electric Detector exceeds the pre-set limit. The system
shall give pin point location of fire with warning system and voice communication for
commands and instruction if required.
Each Zone shall have a minimum of 9 0 detectors in a circuit. The Fire Alarm Panel itself
shall have the mother boards/ transponders/ interface of each zone built-in.
Annunciation (Hooter Alarm) facility shall also be inbuilt into the panel, the panel being able
to initiate alarm signal for any particular set in this case a floor- hooter as required.
The system shall be fully supervised for all fault conditions with distinctive alarms operated for
fault and fire conditions. Test push buttons features shall be provided to test the electronic
circuits and detector conditions.
The Panel shall be so programmed that when a particular Manual Call Box or detector or group
of detectors give a fire signal the Panel should be able to trip an individual A H U automatically,
if so required by the owner at a later date.
25.15.1. Hooter:
i) The Hooter shall be of electronic type and shall give discontinuous/ intermittent audible alarm
whenever any detector or call box operates. It shall be possible to control the hooter audible
alarm in case it is not required to sound the alarm except for the panel.
ii) It shall be complete with electronic oscillations, magnetic coil (sound coil) and accessories,
ready for mounting (fixing).
iii) The sound output from the Hooter should not be less than 100 decibels at the source point.
Hooter shall be 4W each and enclosed in an MS stove enamelled box of 16 gauge thickness.
25.15.2. Manual Call Box:
i) Manual Push Button shall be of break glass or pull down type units, completely encased in a
cast aluminium housing or in16 gauge MS, with provision for cable or conduit coupling. The
manual push button shall have the word prescribed in clear bold letters on facia window "in case
of Fire Break Glass/ Pull Down".
ii) The Manual Call Box station shall be fully addressable with its own set code and operated by
digitized signals sent form the panel. The voltage range shall be from 15 V to 28 V. It shall
have protection as per IP 33. The operating temperature range shall be from 0 degree C to 50
degree C. Relative Humidity (noncondensing) range for performance parameters shall be
between 0 to 9 5 % . Further, it shall conform to BS 5839 or EN 54/ FM/ UL/ VDS/ LPC.
25.15.3. Fire Alarm Control Panel:

i) The fire alarm control panel shall be microprocessor based fully analogue addressable analogue
control unit which shall control all analogue addressable detectors, manual call stations and
switching system (for disconnecting A H U and power supply) connected to it.
ii) All addressable units shall be connected to the panel through the loop cards and shall be
addressed through individualized numbers. The panel shall be able to obtain analogue value
for all detectors in the circuit through a pulsed digitalized current data. The panel shall be able
to analysis all analogue inputs from all addressable units and through its own software and
ambient level screening the panel shall be able to identify fire, possible fire or fault conditions.
The unit supervision shall be dynamic and continuous.
iii) The Fire Alarm Panel shall itself have all zone cards in it. No isolated mother board or
transponder shall be considered. Each loop shall be able to access a minimum of 90
addressable units.
iv) The panel shall also give adequate warning signal whenever there is dust accumulation in
detectors and up to the point of its replacement it should be possible to change the level of
ambient alarm calibration condition either by the use of software programme operable by the
owner or by resetting the detector.
iv) Short circuiting, loose wiring or missing units shall also be reported at the panel with pin point
or segment-wise location. In such cases, the system through the use of Fault Isolators shall be
able to isolate that segment between the two fault isolators.
v) The panel shall have a Liquid Crystal Display Alpha- Numeric type on it to indicate
immediately all conditions. In case of testing of the system from the panel, the display shall be
able to give readouts of analogue value of all detectors being tested. The panel shall also be
able to carry out continuous self-monitoring when in normal condition.
vii) The panel shall have either an in-built or external printer coupled to the panel which shall log
all events with time. The printout shall clearly indicate the event - Fire/ Pre Alarm/ Fault etc.
the Unit address and time.
viii) The panel shall also be able to discriminate between false alarms and fire conditions, as well
as priority selection of alarm address in case alarm activates in two or more remotely located
units simultaneously. In such cases, the manual call box shall be reported first, group of
sequentially laid detectors (in one room for example) second and a detector with the greatest
obscuration over a period of time third.
ix) The panel shall also be able to actuate switches automatically in case of Fire condition, that of
A H Us and power supply or other systems such as piped pressurized gas supply. The contractor
will be required to design and install the system in operation in coordination with the relevant
contractors. The contractor will not be allowed to charge extra on this account and such charges
shall be included in his package.
x) In this respect the contractor is required to take note of clause relating to cutting off of A H Us
given above. The contractor shall indicate in his Bid what facilities shall need to be provided
by the Client for completing this mechanism.
xi) The system shall be fail safe and adequate safe guards should be under taken that in the event
of a failure of a part of the system it shall not handicap the complete system. The mother board
shall be of modular construction.
xii) The contractor shall undertake the responsibility of the complete installation, commissioning,
user trials, training and maintenance of the system as required. The contractor shall take all
responsibility for preparation and installation of system software into the panel. The software
shall be such so as to be easily operated by the client's personnel, is secured against software
errors, ability to be upgradable so as to incorporate more detector units or replacement/
changing of detector units, can incorporate more features at a later date such as illumination
control, security etc.
xiii) The panel shall have its own battery backup of a minimum of 12 hours run. The battery shall
be sealed maintenance free of 54 Ah capacity or as required.
xiv) It shall be able to withstand temperature variations from 0 degree centigrade to 50 degree
centigrade. Further, relative humidity (noncondensing type) up to 95% shall not hamper its
be changed depending upon with working voltages of a proprietary Fire Alarm Panel.
xv) The panel shall be totally enclosed dust and vermin proof type made of minimum 16 gauge
dust inhibited sheet with even baked finish. The panel shall be of completely solid state design.
xvi) The logic circuitry shall be based on high noise immunity solid state hardware employing
modular condition. Logic cards shall be of epoxy fibre glass construction.
xvii) The system shall meet the BS 5839/ EN 54/ NFPA 71 & 72 standards and all equipment
excluding cabling and wiring shall be listed with UL/ FM/ VDS or LPC.
25.15.4. Power Supply:
i) The control panel shall derive 230 volts power from main supply. A standby power supply shall
be immediately available in the event of failure of normal supply and shall automatically be connected
so as to maintain the equipment in condition such that fire alarm originating from the operation
of detector can be given. The standby battery as secondary supply shall be such that when charged
by associated battery charging equipment it can operate independently for a period of 12 hours.
It shall have enough power supply to cope with additional load resulting in alarm originated from
two separate zones for the one hour.
Suitable arrangements shall be incorporated to prevent secondary batteries from discharging
through the charging equipment in the event of its breakdown or as failure in the supply.
Necessary automatic changeover from normal to standby DC supply in case of main supply
failure shall be provided by the contractor.
In addition to the batteries, a battery charger suitable for operation on the auxiliary power
available in the office as specified above shall be supplied. The capacity of the charger shall be
such that the same can boost charger the battery (within 8 hrs) while supplying the rated load of
the fire detection and annunciation system. Facilities shall be provided to limit the voltage
supplied to fire detection and alarm system to their rated values during the time of boost charging.
The charger shall normally supply the battery trickle charging current and the DC loads of the
fire detection and alarm system. In case the AC supply on the input side of the charger fails the
necessary power for the complete fire detection and alarm system including P A shall be supplied
by the battery.
v) Switches, fuses, overloaded devices, voltmeter, ammeter and earth fault indicating device
shall be furnished for the power supply system.
vi) Visible and audible annunciation for troubles or failure in the power supply system like
"Charger Failure", "Battery Low Voltage", etc. shall be provided.
vii) Battery earth/ fault indication/ annunciation shall be included in the panel.
vii) The electronic cards to be used in the battery chargers shall be of PCB type with male/ female
type plug-in-contacts.
viii) Automatic boost/ trickle charging facility shall be included in chargers.
25.15.5. Conduit:
i) These shall be 16 G Mild steel welded and having perfectly circular tubing and capable of being
cleaned and tight fitting joints. Conduits shall be laid either surface or in recessed as required
and it shall be protected from rust by one coat of iron oxide and one coat of Red enamel paint.
ii) Above false ceiling cables shall be drawn off from the conduits laid on the slab. The cables
shall be drawn through flexible PVC conduits including all necessary supports, clamps etc. as
required.
iii) Where conduits have to be installed under RCC slabs, the contractor shall use dri11 guns and
PVC dash fasteners for screwing of saddles for exposed conduits.
25.15.6. Fault Isolator:
i) The fault isolator shall be able to detect wire short circuit/ loose wiring and similar conditions
and shall be able to isolate that segment from the circuit, so that the rest of the circuit continues
to operate.
ii) The fault isolators shall operate in pairs in any loop and whenever any short circuit occurs
between any two of them, both immediately shall switch to an open circuit state and isolate the
length of wiring between them. The isolators should automatically return to the closed circuit
as soon as the short circuit is corrected.
iii) The fault isolator shall be addressable so as to provide indicate of its changed state. It shall
also have an inbuilt LED to give local alarm.
25.15.7. Switch:
i) The switches shall be addressable and command able Units controlled from the Fire Alarm
Panel that shall automatically energize circuits to disable electrical circuits for A H Us or
Power supply etc.
ii) The contractor shall take note of relevant clauses given above. He shall be required to
specifically inform the owner about what facilities he shall require from the owner or the Air
conditioning agency working at site for tripping off the A H Us.
25.15.8. Duct Casting Unit:
i) The duct casting units are to be directly installed in the air conditioning ducts for detecting
any hazardous quantity of products of combustion being carried through the ducts.
ii) The complete unit shall consist of Aluminium housing to accommodate a lonisation or optical
detector with plug-in facility and sampling tubes, one for air inlet and the other as the air outlet.
iii) The inlet tube shall extend into and across the duct width (from 0.5 meter to 3.0 meter), the
outlet tube shall be of fixed length of 7.5cm length.
iv) When the A H U blower fans shall operate a continuous cross sectional sampling of air from
the duct shall flow through the housing containing the detector. The outlet tube shall return
the sampled air into the duct.
v) The functional requirements of the Duct Casting Unit shall be: a) Uniform
Sensitivity irrespective of air velocity- up to 1200 meters per minute.
b) It shall function on the Venturi principle, with Aluminium Venturi tubes.
c) The Duct Casting Unit shall be compact, easy to install and with the facility to dismantle the
cover or detector for maintenance purposes.
d) The housing shall be mounted outside the duct, the tubes shall be inserted through the duct
by...
e) The Duct Casting unit shall be FM/ UL/ VDS/ LPS approved. No indigenous Duct Casting
unit shall be accepted.
25.15.9. Amplifier:
i) The amplifier shall be as specified in schedule of quantities with an additional amplifier as
standby. All terminals should be soldered firmly on to solder tags or terminated on good quality
connector strips. The amplifiers shall be Multi channel mixing type and capable of running on
240 V AC or 12/24 V DC. The amplifier shall have dual tone control, level indicators and cater
to complete frequency range.
ii) The amplifier shall be Rack Mounted within the housing of the Fire Alarm Panel. It shall have
Microphone Channel Volume Control, Microphone/ Auxiliary Selector, Volume, Bass and
Treble Control with LED type level Bar graph.
iii) The Audio Signal Quality shall have a Frequency Response from 80 Hz to 20000 Hz.
Distortion shall be less than 5%.
iv) Output for loud speakers should be operable from a 100 V Terminal for Line Matching
Transformer type speakers. The amplifier shall also have the facility of direct dial-in and talk
for certain restricted office telephones.
25.15.10 P A System Accessories:
i) The P A system shall have a 15 zone floor selector console. The zones shall be solid state card
type, rack mounted in card slots. The console shall be fabricated from 16 gauge M S sheet and
stove enamelled. All cards shall have push button controls. The console shall also have push
button type all call facility. The console shall be prewired and connected to the fire alarm panel
through the amplifier for automatic alarm/ voice announcements through the Hooter/ Speaker.
ii) Other accessories shall be a goose neck cardioids microphone, professional grade cassette deck,
change over panel for transfer from hooting to voice, mains panel for power supply and
monitor panel all mounted in a rack of 16 gauge and enamelled complete as required.
25.15.11 Cables and Wires:
i) Cables shall be PVC insulated 1100 V grade for armoured and unarmoured and shall conform
to IS: 1554. The conductor shall be stranded/ solid core as required copper and insulation shall
be extruded PVC conforming to IS: 5831. The cable shall have outer shall of a material with an
oxygen index not less than 29 and temperature index of 250 degree C. The cables shall have
Fire Resistance Test Properties as per IEC: 332.
ii) The entire installation shall be tested to Electricity Rules and as per IS: 732 (1973) with
amendments. The cables shall be laid as per IS:1255 (1967).
iii) Loop cabling shall be 2 core 1.5 sq. mm. solid copper conductor cable rated at 1100 volts and
conforming to IS: 1554 including the latest amendments.
iv) Armoured cabling shall be used and fixed to the roof through the use of GI saddles. Thimbles
shall be used at all terminations.
v) In case conventional fire detection and above system is require, it shall conform to IS: 2189
(amended up to date).
25.16. Fire Drills and Fire Orders: Fire notices/orders shall be prepared to full- fill the
requirements of firefighting and evacuation from the buildings in the event of fire and other
emergency. The occupants shall be made thoroughly conversant with their actions in the event of
emergency, by displaying fire notices at vantage points and also through regular training. Such notices
should be displayed prominently in broad lettering.
25.16.1. Guidelines for Fire Drill and Evacuation Procedures for High Rise Buildings :
a) Introduction: In case of fire in a high rise building, safe evacuation of its occupants may present
serious problems unless a plan for orderly and systematic evacuation is prepared in advance
and all occupants are well drilled in the operation of such plan. These guidelines are intended
to assist them in this task.
b) Alarms: Any person discovering fire, heat or smoke shall immediately report such condition to
the fire brigade, unless he has personal knowledge that such a report has been made. No person
shall make, issue, post or maintain any regulation or order, written or verbal, that would require
any person to take any unnecessary delaying action prior to reporting such condition to the fire
brigade.
c) Drills:
i) Fire drills shall be conducted, in accordance with the Fire Safety Plan, at least once every
three months for existing buildings during the first two years. Thereafter, fire drills shall
be conducted at least once every six months.
ii) All occupants of the building shall participate in the fire drill. However, occupants of the
building, other than building service employees, are not required to leave the floor or use
the exits during the drill.
iii) A written record of such drills shall be kept on the premises for a three years period and
shall be readily available for fire brigade inspection.
d) Signs and Plans:
i) Signs at Lift Landings: A sign shall be posted and maintained in a conspicuous place on
every floor at or near the lift landing in accordance with the requirements, indicating that
in case of fire, occupants shall use the stairs unless instructed otherwise. The sign shall
contain a diagram showing the location of the stairways except that such diagram may be
omitted, provided signs containing such diagram are posted in conspicuous places on the
respective floor.
A sign shall read "IN CASE OF FIRE, USE STAIRS UNLESS INSTRUCTED
OTHERWISE". The lettering shall be at least 12.5 mm block letters in red and white
background. Such lettering shall be properly spaced to provide good legibility. The sign
shall be at least 250 mm x 300 mm, where the diagram is also incorporated in it and 62.5
mm x 250 mm where the diagram is omitted. In the latter case, the diagram sign shall be
at least 200 mm x 300 mm. The sign shall be located directly above a call-button and
squarely attached to the wall or partition. The top of the sign shall not
be above 2 m from the floor level.
ii) Floor Numbering Signs A sign shall be posted and maintained within each stair enclosure
on every floor, indicating the number of the floor, in accordance with the requirements
given below.
The numerals shall be of bold type and at least 75 mm high. The numerals and
background shall be in contrasting colours. The sign shall be securely attached to the stair
side of the door.
iii) Stair and Elevator Identification Signs Each stairway and each elevator back shall be
identified by an alphabetical letter. A sign indicating the letter of identification shall be
posted and maintained at each elevator landing and on the side of the stairway door from
which egress is to be made, in accordance with the requirements given below:
The lettering on the sign shall be at least 75 mm high, of bold type and of contrasting
colour from the background. Such signs shall be securely attached.
iv) Stair Re-entry Signs: A sign shall be posted and maintained on each floor within each
stairway and on the occupancy side of the stairway where required, indicating whether
re-entry is provided into the building and the floor where such re-entry is provided, in
accordance with the requirements given below:
The lettering and numerals of the signs shall be at least 12.5 mm high of bold type. The
lettering and background shall be of contrasting colours and the signs shall be securely
attached approximately 1.5 m above the floor level.
v) Fire command station shall be provided with floor plan of the building and other
pertinent information relative to the service equipment of the building.
e) Fire Safety Plan:
i) A format for the Fire Safety Plan shall be as given in clause h.
ii) The applicable parts of the approved Fire Safety Plan shall be distributed to all tenants
of the building by the building management when the Fire Safety Plan has been approved
by the Fire Authority.
iii) The applicable parts of the approved Fire Safety Plan shall then be distributed by the
tenants to all their employees and by the building management to all their building
employees.
iv) Where the owner of the building is also an occupant of the building, he shall be
responsible for the observance of these rules and the Fire Safety Plan in the same manner
as a tenant.
v) In the event there are changes from conditions existing at the time the Fire Safety Plan
for the building was approved, and the changes are such so as to require amending the Fire
Safety Plan, within 30 days after such changes, an amended Fire Safety Plan shall be
submitted to the fire brigade for approval.
f) Fire Command Station: A Fire Command Station shall be established in the lobby of the building
on the entrance floor. Such command station shall be adequately illuminated.
g) Communications and Fire Alarm: A means of communication and flue alarm for use during
fire emergencies shall be provided and maintained by the owner or person in charge of the
building.
h) Fire Safety Plan Format:
i) Building Address:
Street and Pin Code Number: .................................
Telephone Number: ................................................
ii) Purpose and Objective:
1. Purpose: To establish method of systematic, safe and orderly evacuation of an area
or building by its occupants in case of fire or other emergency, in the least possible
time, to a safe area by the nearest safe means of egress; also the use of such available
fire appliances (including sounding of alarms) as may have been provided for
controlling or extinguishing fire and safeguarding of human life.
2. Objective: To provide proper education as a part of continuing employee
indoctrination and through a continuing written programme for all occupants, to
ensure prompt reporting of fire, the response of fire alarms as designated, and the
immediate initiation of fire safety procedures to safeguard life and contain fire until
the arrival of the fire brigade.
3. Fire Safety Director:
i) Name
ii) Regularly assigned employment
iii)Regularly assigned location
iv) How is he notified when at regular location?
v) How is he notified when not at regular location?
vi) Normal working hours
vii) Duties of Fire Safety Director
4. Deputy Fire Safety Director:
Name
Regularly assigned employment
Regularly assigned location
How is he notified when at regular location? How is
he notified when not at regular location? Normal
working hours
vii) Duties of Deputy Fire Safety Director
5. Fire Wardens and Deputy Fire Wardens:
a) Are their names on Organization Charts for each floor and floor tenancy?
b) Submit typical completed Organization Chart for Fire Drill and Evacuation
Assignment.
c) Duties of Fire Wardens and Deputy Fire Wardens.
6. Building Evacuation Supervisor:
a) Name
b) Regularly assigned employment - Title
c) Regularly assigned location
d) How is he notified when at regular location?
e) How is he notified when not at regular location?
f) Normal working hours
g) Duties of Building Evacuation Supervisor
7. Fire Party:
a) Submit a completed Organization Chart for
b) Fire Parties naming person in charge, and his title in the building. Indicate
standards of selection from building employees based on background and
availability.
c) How are they notified?
d) How are they notified when they are not at their regular locations?
e) Means of responding
f) Duties of each member of Fire Party
8. Occupants Instructions: Distribution of instructions to all tenants, tenants'
employees and building employees.
9. Evacuation Drills:
a) Frequency of drills
b) How conducted?
c) Participation: Who participated? How?
d) Controls and supervision
e) Recording of details of drills
10. Fire Command Station:
a) Location
b) Requirements
1) Adequate illumination.
2) Adequate communication to mechanical equipment room and elevator
control room on each floor
3) Copy of Fire Safety Plan
4) Copy of Building Information Form
5) Representative floor plans showing location of signs, floor remote
station, communications, etc.
11. Signs:
a) Signs at elevator landings, Floor diagrams
b) Floor numbering
c) Stairway identification
d) Elevator identification
e) Stair re-entry
12. Fire Prevention and Fire Protection Programme see cl.25.16.6
13. Building Information Form see cl.25.16.7
14. Representative Floor Plan see cl. 25.16.8
15. Fire Safety Plan Prepared by see cl.25.16.9
a) Date when prepared.
b) Date when revised.
25.16.2 Duties:
25.16.2.1. Fire Safety Director's Duties:
i). Be familiar with the written Fire Safety Plan providing for fire dri11 and evacuation
procedure in accordance with orders on the subject.
ii). Select qualified building service employees for a The Party and organize, train and supervise
such Fire Brigade.
iii). Be responsible for the availability and state of readiness of the Fire Party.
iv). Conduct fire and evacuation drills.
v). Be responsible for the designation and training of a Fire Warden for each floor, and
sufficient Deputy Fire Wardens for each tenancy in accordance with orders on the subject.
vi). Be responsible for a daily check for the availability of the Fire Wardens, and see that up-to
date organization charts are posted.
NOTE: If the number of Fire Wardens and Deputy Fire Wardens in the building is such that it
is impractical to individually contact each one daily, a suggested method to satisfy the
requirements is to make provisions for the Fire Warden, or a Deputy Fire Warden in the absence
of the Fire Warden, to notify the Fire Safety Director when the Fire Warden or required number
of Deputy Fire Wardens are not available. In order to determine the compliance by the Fire
Warden and Deputy Fire Wardens, when this method is used, the Fire Safety Director shall
make a spot check of several different floors each day.
vii). Notify the owner or some other person having charge of the building when any designated
individual is neglecting his responsibilities contained in Fire Safety Plan. The owner or the
other person in-charge of the building shall bring the matter to the attention of the firm
employing the individual. If the firm fails to correct the condition, the Fire Department shall
be notified by the owner/person in-charge of the building.
viii). In the event of fire, shall report to the Fire Command Station to supervise, provide for and
coordinate:
a) Ensure that the Fire Department has been notified of any fire or fire alarm.
b) Manning of the Fire Command Station.
c) Direction of evacuating procedures as provided in the Fire Safety Plan.
d) Reports on conditions on fire floor for information of Fire Department on their arrival.
e) Advise the Fire Department Officer in-charge in the operation of the Fire Command
Station.
ix). Be responsible for the training and activities of the Building Evacuation Supervisor.
25.16.2.2 Deputy Fire Safety Director's Duties:
i). Subordinate to the Fire Safety Director.
ii). Perform duties of Fire Safety Director in his absence.
25.16.23. Fire Wardens and Deputy Fire Wardens Duties: The tenant or tenants of each floor
shall, upon request of the owner or person in charge of buildings, make responsible and dependable
employees available for designation by the Fire Safety Director as Fire Warden and Deputy Fire
Wardens.
a). Each floor of a building shall be under the direction of a designated Fire Warden for the
evacuation of occupants in the event of fire. He shall be assisted in his duties by the Deputy
Fire Wardens. A Deputy Fire warden shall be provided for each tenancy. When the floor area
of a tenancy exceeds 700 m2 of occupiable space, a Deputy Fire Warden shall be assigned for
each 700 m2 or part thereof.
b). Each Fire Warden and Deputy Fire Warden shall be familiar with the Fire Safety Plan, the
location of exits and the location and operation of any available fire alarm system.
c). In the event of fire, or fire alarm the Fire Warden shall ascertain the location of the fire, and
direct evacuation of the floor in accordance with directions received and the following
guidelines:
i) The most critical areas for immediate evacuation are the fire floor and floors immediately
above. Evacuation from the other floors shall be instituted when instructions from the
Fire Command Station or conditions indicate such action. Evacuation shall be via
uncontaminated stairs. The Fire Warden shall try to avoid stairs being used by the Fire
Department. If this is not possible, he shall try to attract the attention of the Fire
Department Personnel before such personnel open the door to the fire floor.
ii) Evacuation to two or more levels below the fire floor is generally adequate. He shall
keep the Fire Command Station informed regarding his location.
iii) Fire Wardens and their Deputies shall see that all occupants are notified of the fire, and
that they proceed immediately to execute the Fire Safety Plan.
iv) The Fire Warden on the fire floor shall, as soon as practicable, notify the Fire
Command Station of the particulars.
v) Fire Wardens on floors above the fire shall, after executing the Fire Safety Plan, notify
the Fire Command Station of the means being used for evacuation and any other
particulars.
vi) In the event that stairways serving fire floor and/or floors above are unusable due to
contamination or cut off by fire and/or smoke or that several floors above fire involve
large numbers of occupants who must be evacuated, consideration may be given to using
elevators in accordance with the following:
1) If the elevators servicing his floor also service the fire floor, they shall not be
used. However, elevators may be used if there is more than one bank of elevators,
and he is informed from the Fire Command Station that one bank is unaffected by
the fire.
2) If elevators do not service the fire floor and their shafts have no openings on the
fire floor, they may be used, unless directed otherwise.
3) Elevators manned by trained building personnel or firemen may also be used.
4) In the absence of a serviceable elevator, the Fire Warden shall select the safest
stairway to use for evacuation on the basis of the location of the fire and any
information received from the Fire Command Station. The Fire Warden shall check
the environment in the stairs prior to entry for evacuation. If it is affected by smoke,
alternative stair shall be selected, and the Fire Command Station notified.
5) The Fire Warden shall keep the Fire Command Station informed of the means
being employed for evacuation by the occupants of his floor.
d) Ensure that an alarm has been transmitted.
25.16.2.4. Organization Chart for Fire Drill and Evacuation Assignment: A chart designating
employees and their assignments shall be prepared and posted in a conspicuous place in each tenancy
and on each floor of a tenancy that occupies more than one floor and a copy shall be in the possession
of the Fire Safety Director.
25.16.2.5 Keep available an updated listing of all personnel with physical disabilities who cannot use
stairs unaided. Make arrangements to have these occupants assisted in moving down the stairs to
two or more levels below fire floor. If it is necessary to move such occupants to a still lower level
during the fire, move them down the stairs to the uppermost floor served by an uninvolved elevator
bank and then remove them the street floor by elevator. Where assistance is required for such
evacuation, notify Fire Safety Director.
25.16.2.6 Provide for Fire Warden identification during fire drills and fires, such as using arm band,
etc.
25.16.2.7 Ensure that all persons on the floor are notified of fire and all are evacuated to safe areas.
A search must be conducted in the lavatories to ensure all are out. Personnel assigned as searchers
can promptly and efficiently perform this duty.
25.16.2.8 Check availability of applicable personnel on Organization Chart and provide for a
substitute when the position on a chart is not covered.
25.16.2.9 After evacuation, perform a head count to ensure that all regular occupants known to have
occupied the floor have been evacuated.
25.16.2.10 When alarm is received, the Fire Warden shall remain at a selected position in the vicinity
of the communication station on the floor, in order to maintain communication with the Fire
Command Station and to receive and give instructions.
25.163. Building Evacuation Supervisor's Duties :A building Evacuation Supervisor is required at
all times other than normal working or business hours when there are occupants in the building and
there is no Fire Safety Director on duty in the building.
1. He should be capable of directing the evacuation of the occupants as provided by the Fire Safety
Plan.
2. During fire emergencies, the primary responsibility of the Building Evacuation Supervisor shall
be to man the Fire Command Station, and the direction and execution of the evacuation as
provided in the Fire Safety Plan. The Building Evacuation Supervisor's training and related
activities shall be under the direction of the Fire Safety Director in accordance with these rules,
and the Fire Safety Plan. Such activities shall be subject to Fire Department control.
25.16.4 Fire Party Duties :On receipt of an alarm for fire the Fire Party shall:
a) report to the floor below the fire to assist in evacuation and provide information to the Fire
Command Station.
b) after evacuations of fire floor, Endeavour to control spread of fire by closing doors, etc.
c) attempt to control the tire until arrival of the Fire Department, if the fire is small and
conditions do not pose a personal threat.
d) leave one member on the floor below the fire to direct the Fire Department to the fire
location and to inform them of conditions.
e) on arrival of the Fire Department, the Fire Party shall report to the Fire Command Station for
additional instructions.
f) have a member designated as runner, who shall know the location of the nearest telephone, and
be instructed in its use. Such member shall immediately upon receipt of information that there
is a fire or evidence of fire, go to the telephone, transmit an alarm and await the arrival of the
Fire Department and direct such department to the fire.
NOTE : A chart designating employees and their assignments shall be prepared.
25.16.5 Occupant's Instructions:
a) The applicable parts of the approved Fire Safety Plan shall be distributed to all tenants of the
building by the building management when the Fire Safety Plan has been approved by the Fire
Commissioner.
b) The applicable parts of the approved Fire Safety Plan shall then be distributed by the tenants
to all their employees and by the building management to all their building employees.
c) All occupants of the building shall participate and cooperate in carrying out the provisions of
the Fire Safety Plan.
25.16.6. Fire Prevention and fire Protection Programme :
a) A plan for periodic formal inspections of each floor area, including exit facilities, fire
extinguishers and housekeeping shall be developed. A copy of such plan be submitted.
b) Provision shall be made for the monthly testing of communication and alarm systems.
25.16.7. Building Information Form:
It shall include the following information:
a) Building address .................................................................................. Pin Code ................
b) Owner or person in-charge of building- Name, Address and Telephone Number.
c) Fire Safety Director and Deputy Fire Safety Director's Name and Telephone Number.
d) Certificate of occupancy. Location where posted, or duplicate attached.
e) Height, area, class of construction.
0 Number, type and location of fire stairs and/ or fire towers.
g) Number, type and location of horizontal exits or other areas of refuge.
h) Number, type, location and operation of elevators and escalators.
i) Interior fire alarms, or alarms to central stations.
j) Communications systems and/or w e - talkie, Mobile telephones, etc.
k) Standpipe system, size and location of risers, gravity or pressure tank, fire pump, location of
connections, name of employee with certificate of qualification and number of certificate.
1) Sprinkler system, name of employee with Certificate of Fitness and certificate number.
Primary and secondary water supply, fire pump and areas protected.
m) Special extinguishing system, if any, components and operation.
n) Average number of persons normally employed in building. Daytime and night time.
o) Average number of handicapped people in building. Location. Daytime and night time.
p) Number of persons normally visiting the building. Daytime and night time.
q) Service equipment such as:
1) Electric power, primary, auxiliary;
2) Lighting, normal, emergency, type and location;
3) Heating, type, fuel, location of heating unit;
4) Ventilation - with fixed windows, emergency means of exhausting heat and smoke;
5) Air-Conditioning Systems - Brief description of the system, including ducts and floors
serviced;
6) Refuse storage and disposal;
7) Fire fighting equipment and appliances, other than standpipe and sprinkler system, and
8) Other pertinent building equipment.
r) Alterations and repair operations, if any, and the protective and preventive measures necessary to
safeguard such operations with attention to torch operations.
s) Storage and use of flammable solids, liquids and /or gases.
t) Special occupancies in the building and the proper protection and maintenance thereof. Places of
public assembly, studios, and theoratical occupancies.
25.16.8. Representative Floor Plan: A floor plan, representative of the majority or the floor designs
of the entire building, shall be at the Command Post, in the main lobby, under the authority of the Fire
Safety Director. One copy of a representative floor plan shall be submitted to the Fire Department
with the Fire Safety plan.
25.16.9. Fire Safety Plan: In planning, evaluate the individual floor layouts, the population of floors,
the number and kinds of exits, the zoning of the floor by area and occupants. Determine the
movement of traffic by the most expeditious route to an appropriate exit and alternative route for
each zone, since under fire conditions one or more exits may not be usable. This format is to be used
in the preparation of the Fire Safety Plan. Nothing contained in this Fire Safety Plan
format is to be construed as all inclusive. All rules and other requirements are to be fully complied with.
25.16.10. Personal Fire Instruction Card: All the occupants of the building shall be given a
Personal Fire Instruction Card giving the details of the floor plan and exit routes along with the
instruction to be followed in the event of fire. A typical Personal Fire Instruction Card shall be as follows:
PERSONAL FIRE INSTRUCTION CARD
SEAL
NAME OF THE ORGANIZATION
ADDRESS OF THE ORGANIZATION
NAME: .............................................................................................................................................
DESIGNATION: ..............................................................................................................................
FLOOR NO.: ....................................................................................................................................
DATE: ..............................................................................................................................................
FIRE WARDEN
INSTRUCTIONS
FOR YOUR OWN SAFETY YOU SHOULD KNOW
1. Two push button fire alarm boxes are provided per floor. You should read the operating
instructions.
2. You should read the operating instructions on the body of the fire extinguishers provided on your
floor.
3. The nearest exit from your table.
4. Your assembly point on ground floor (check with your Fire/Deputy Fire Warden).
5. FOR YOUR OWN PROTECTION YOU SHOULD REPORT TO YOUR FIRE/ DEPUTY FIRE
WARDEN
a) If any exit door/route is obstructed by loose materials, goods, boxes, etc.
b) If any staircase door, lift lobby door does not close automatically, or does not close
completely.
c) If any push button fire alarm point, or fire extinguisher is obstructed, damaged or
apparently out of order.
IF YOU DISCOVER A FIRE
1. Break the glass of the nearest push button fire alarm and push the button.
2. Attack the fire with extinguishers provided on your floor. Take guidance from your Wardens.
3. Evacuate if your Warden asks you to do so.
IF YOU HEAR EVACUATION INSTRUCTIONS
1. Leave the floor immediately by the south/ north staircase.
2. Report to your Warden, at your predetermined assembly point outside the building.
3. Do not try to use lifts.
4. Do not go to cloakroom.
5. Do not run or shout.
6. Do not stop to collect personal belongings.
7. Keep the lift lobby and staircase doors shut.
YOUR ASSEMBLY POINT IS ...................................................................................................................
APPENDIX'A'
TABLE: SIZE OF MAINS
SIZE OF THE MAINS TYPE OF BUILDING HEIGHT OF BUILDING

BUILDING
1 2 3
1 5 0 = as single outlet 1) Residential buildings (A)
landing
i) *Lodging or rooming houses

ii) Dormitories
iii) One or two family private 15m or above and not
dwellings exceeding 45m
iv) Apartment houses (flats)
v) With shopping area not
Less than 15m
exceeding 500m2
vi) Hotels
15m or above in height but not
-do- 2) Educational buildings (B) 15m or above but not
exceeding 30m
-do- 3) Institutional buildings (C)
a) For hospitals and sanatorium 15m or above but not
exceeding 30m
b) For custodial institutions 15m or above but not exceeding
30m and mental institutions
-do- 4) Assembly buildings (D 15m or above but not exceeding
30m and total floor area not
exceeding 500m2/ floor (above
30m, not to be permitted)
-do- 5) Business buildings (E) 15m or above but not
exceeding 30m
-do- 6) Mercantile buildings (F) 15m or above but not
exceeding 30m
(above 35m, not to be permitted)
-do- 7)Industrial buildings (G) 15m or above but not exceeding
18m2
1 5 0 = with twin outlet 8) All buildings classified valves Above 45m
Landings under (i) to (iv)
9) All buildings classified Above 15m
under (v) above with shopping
area exceeding 500m2
-do- exceeding 10) All buildings classified Above 30 m and area 500 m2
under 1(v) above
SIZE OF THE MAINS TYPE OF BUILDING HEIGHT OF BUILDING
BUILDING
1 2 3
150mm with twin outlet 11) Hotels Above 30m
under 2 and 3 above
under 5 above
14) All storage buildings (H) Above 10m but not
exceeding 15m
15) All Hazardous buildings (J) Above 10m but not
exceeding 15m
*Buildings above 15m in height not permitted in case of high hazard industrial buildings.
LIST OF BUREAU OF INDIAN STANDARDS CODES

S.No. IS Code No. Particulars
1 201-1993 Grey iron castings (third revision)
2 318-1981 Leaded tin, bronze ingots and castings (second revision)
388- Hose tubing
3 325-1996 Three-phase induction motors (fourth revision) (with
Amendment No.1)
4 636-1988 Specification for firefighting hose (second revision)
5 636-1990 PVC insulated cables for working voltages up to and
including 1100 volts
6 780-1984 Sluice valves for water works purposes (50 to 300mm) size
(fifth revision)
7 778-1984 Specification for first-aid, hose-reel for firefighting (for fixed
installations)
8 901-1988 Specification for couplings, double male and double female,
instantaneous pattern for fire fighting
9 904-1983 Specification for two-way and three-way suction collecting
heads for firefighting purposes (revised) (with Amendments
No.1 & 2)
10 905-1980 Specification for delivery breaching, dividing and collecting
pattern for fire fighting
11 906-1992 Specification for branch with revolving head for firefighting
purposes
12 908-1975 Specification for fire hydrant, stand post type
S.No. IS Code No. Particulars
13 884-1985 Specification for underground fire hydrant, sluice valve type
14 1648-1961 Code of practice for fire safety of buildings (General)
firefighting equipment and its maintenance
15 3844-1989 Code of Practice for installation of internal fire hydrants in
multi-story buildings
16 4038- Foot valves for water-works purposes.
17 10221 Anticorrosion treatment for underground MS pipes.

Pwd Specifications for Building Works 2014 (All Chapters i.e. 1 to 25)

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DISCLAMER

The “PWD SPECIFICATIONS FOR BUILDING WORKS 2014” has

J.C. Mohanty, i.a.s

Jaipur. Dated : 03.06.2014

The revised/updated specifications are being published in twenty five Chapters

Er. R.P. Khandelwal

Volume 1 Chapter No. Description

Jaipur. Dated : 03.06.14

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 Preparation of all detailed construction/Installation drawing and methodology for trenchless

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7. Necessary permissions from all concerned authorities shall be obtained by Engineer-in-

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Technical Proceedings of Seminar on Trenchless Technology organized by HQ CE Delhi Zone

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2.4.19 Doors, Windows and Ventilators:

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