Vol II PDF

Government of Rajasthan
Public Health Engineering Department

(NIT No 10 /2018-19)
Work of Providing, laying, testing and commissioning of DI /

HDPE pipe line, Construction of RCC OHSR with allied civil
works with Defect Liability of One year and O&M for 5 years after
Defect Liability Period under Conversion of TSS into Piped Water
Supply Scheme, Sanjay Nagar, Tehsil Khetri, District Jhunjhunu
on SPR Turnkey basis.
Volume II
(Technical Bid)
Scope of work & Technical Specifications.
ESTIMATED COST
Rs 276.67 Lacs
Office of Additional Chief Engineer

Public Health Engineer Department, Jaipur Region-I,
Jyoti Nagar, Jaipur (Rajasthan)
Telephone no. 0141-2740170 Email: [email protected]

NIT No 10 / 2018-19 Conversion of TSS to Piped Water Supply Scheme of Sanjay Nagar
CHAPTER 1
SCOPE OF WORK
1.0 BACK GROUND
The purpose of the Work of Work of Providing, laying, testing and
commissioning of DI / HDPE pipe line, Construction of RCC OHSR with allied
civil works with Defect Liability of One year and O&M for 5 years after Defect
Liability Period under Conversion of TSS into Piped Water Supply Scheme,
Sanjay Nagar, Tehsil Khetri, District Jhunjhunu on SPR Turnkey basis is to
convert TSS to Piped Water Supply Scheme of Sanjay Nagar VIllage.
1.1GENERAL PRINCIPLES
The contractor shall carryout all works wholly in accordance with the terms and
conditions of the contract to fulfill all the requirements of the project and the
tender documents. All the material used, and the equipment installed shall be as
per the specifications defined in the contract and the work shall be executed with
good engineering practices.
Generally the following activities shall be carried out for each component of this
contract but shall not be limited to:
(i) Submission of all documents required according to the Contract
(security money/ guarantee, etc.).
(ii) Submission of Action Plan/ Execution Schedule in accordance with the
provisions of Special Conditions for approval of the Engineer in Charge.
(iii) Getting approval of all QAPs, design and drawings, material to be used,
equipment specifications and the samples prior to dispatching /
installing /commissioning of work on site. Unless mentioned otherwise,
if for any specific provision, references have been made in more than one
specification, the provision more stringent and which complies with
latest standards shall be applicable and the discrepancy shall be
explained by the EIC whose decision shall be final.
(iv) Submission of the design/ specifications, catalogs and the technical data
sheets of all the equipment, electrical/ instrumentation/ automation
system, design of the electrical components, taking into account the
interfaces to the other project components/packages and the future
extensions of the project.
(v) Preparation and submission of structural designs and reinforcement
drawings for all civil structures of the work. All expenses for this shall
be borne by the contractor.
(vi) All road cuttings and also their repairs are included in the scope of work
of the contractor. The contractor shall provide encasing of the pipeline in
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case of road crossing (WBM/ tar/ concrete/ stone slabs etc.) along with
re-aligning, re-grading, strengthening and restoring damaged road
section and associated lengths. For road/railway crossings, the
contractor himself shall contact the concerning department
(NHAI/PWD/Raiways, etc) and obtain sanction to do the road cutting,
crossing and repair of road-cutting. The repairing is to be done as per
specifications of the concerning department, to their satisfaction. The
maintenance of the repaired sections shall also be done by the contractor
during the one year defect liability period. The department may provide
assistance, for obtaining road cutting permission, as demanded by the
contractor, whenever required. The cost of shifting of electrical poles,
transformers, etc., if any, shall also be borne by the bidder. The bidder
shall be solely responsible for any damage occurred to the telephone
lines, OFC cables, cutting of trees, cables, distribution/ rising water
mains and gas pipes, drains while laying clear water pipeline, and shall
be liable to pay the amount levied by respective department(s) for the
repair and/ or damages so occurred.
(vii) To co-ordinate with concerned officers of PHED, NHAI, PWD, Forest,
Mining, Railway, electric supply company and personnel of local water
supply system (for carrying out the installation of new equipment), with
the district administrative offices and other offices for necessary
approvals and certificates.
(viii) Manufacturing, shop testing, pre-dispatch inspection, transportation to
site, providing transit insurance, storage, handling at site, installation,
sectional testing, pre-commissioning testing, commissioning and trial
runs for all components of the system and the system as a whole,
including the hydraulic, mechanical, electrical, Electro-Mechanical and
instrumentation equipment.
(ix) Construction of all buildings and water retaining structures, chambers,
thrust blocks, anchor blocks, saddle supports and other civil and
engineering structures required for completion of the work.
(x) Ancillary Civil works, campus development and Buildings as defined
herein after
(xi) For laying pipeline, the cost of shifting of electrical poles, transformers,
etc. shall be borne by the contractor. The bidder shall be responsible for
any damage occurred to the telephone lines, OFC cables, cutting of trees,
cables, distribution/rising water mains and gas pipes, drains while
laying clear water pipeline, and shall be liable to pay the amount levied
by respective department(s) for the repair and/ or damages so occurred.
(xii) Construction, testing & commissioning of all civil works, mechanical,
electrical and instrumental work as per scope of work, approved
drawings & detailed specifications.
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(xiii) Arrangement of adequate security, watch and ward of the system during
the execution period to safeguard the equipment and completed section
of the work from any type of mishandling, theft, fire and other hazards
etc. and all safety precautions at the time of storage of material,
execution of work and defect liability period and O&M period to avoid
any mishap.
(xiv) Restoration of PHED premises /Roads etc. after completion of the work.
(xv) Electrical design and electric load calculation, data sheet, QAP and
fulfillment of IEC requirement.
(xvi) Pre-commissioning test and inspections as per requirement.
(xvii) Commissioning of the whole system and optimization as per design
parameter after commissioning of all the component.
(xviii) The submission of the as-built drawings of the works is the precondition
for the final payment of execution part. The final drawings shall be
submitted in 5 copies on linen bound in an album of an approved size.
The contractor shall submit all the completion drawings and approved
design calculations on CD ROM / DVD in two copies with proper
directory structure.
1.2 MAJOR COMPONENTS OF WORK
a. Providing, laying, jointing, testing and commissioning of below mentioned
feeder pipe lines and distribution pipe lines with specials and
interconnections with existing system, road cut and repair as per requirement.
The work includes construction of anchor/thrust block, other civil work
required for stability of pipe line including earth work. the length are
indicative and may vary as per actual survet and alignment proposed and
approved by EIC.
S. Type and class of Pipe Size Length Feeder/Distribution
No
1. DI Pipe, K-7 100 mm 2200 M Feeder
2. DI Pipe, K-7 150 mm 1950 M Feeder
3. HDPE Pipe, PN-6 90 mm 26171 M Distribution
b. Construction and commissioning of following RCC storage reservoirs:
• RCC OHSR for Zone 1, capacity 300 KL, 18 M staging
• RCC OHSR for Zone 3, capacity 200 KL, 18 M staging
c. Civil work for following works;
• Valve Chambers – 4 Nos
• Road cutting and restoration work
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d. Operation and maintenance of the whole water supply scheme of RWSS

Sanjay Nagar including existing system for Five years after completion of
defect liability period of 12 months.
1.3 DETAILS OF MAJOR COMPONENT OF THE WORK
Detailed scope of major component of the work is as detailed below:-
a. Feeder Main & Distribution Pipe Line
The work of pumping mains includes preparatory works, survey, investigations,
hydraulic design & surge analysis of pipeline, manufacturing, testing at factory,
supply, delivery and storage at site, lowering, laying and jointing, sectional
testing, re-filling and commissioning of pipelines of various diameters, along
with supply of specials, pipe appurtenances and associated civil works so as to
achieve the objective of the project. D.I K-7 /HDPE PN 6 pipe shall be provided
in rising mains.
Pipes shall be laid along the roads as far as possible on the outer edge of the road
boundary. The alignment adopted in this contract has been taken along the
roads, wherever possible. However, during execution of the works, if a shorter
alternate and feasible route is found, the department may opt to lay pipeline
along that shorter route. Expenses on account of damages to field boundaries or
any other damages in field or of private property during laying of pipes shall be
borne by the contractor. The grade (i.e. L-section) in which the pipe shall be laid
shall be got approved by the department. The L-section shall be based on the
following principles:
• The change in slopes per km. length shall not be more than 10 in number.
• The slopes required shall be such that in normal conditions, the cover over
the laid pipe is not less than 0.6 meters. In general the cover should be 0.9
meters. However in general the limitation for cover shall be as given in
chapter ‘Specification of pipeline’.
The scope under the item shall consist of the following requirements;
(i) Manufacturing and Testing at works, transportation, packing, supply of
all sizes of DI-K7 / HDPE pipes, specials, jointing material etc to be
used. Stacking and/or storage of material, rehandling and to lay pipes
below ground by excavation and refilling the trench to ensure average
cover of 0.9 meters generally and construction of pedestals/portals for
pipe support to lay pipe above ground, if required and then to carry out
sectional testing, pre-commissioning checks, full completion tests and
trial runs. The water required for sectional testing after laying of pipe
shall be arranged by the contractor at his own cost.
(ii) Submission of L-section and plan for approval of Engineer-in-Charge
prior to commence the work and after approval take up the work and
submit As-built drawings after laying and testing of pipeline.
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(iii) Setting out of works, Laying and jointing of pipeline including lowering,
placing at proper alignment, cutting pipes, chamfering complete in all
respects. The work of laying and jointing of pipes and pipe
appurtenances should be done at required levels. The pipeline
alignment in general shall be kept on the outer edge of the existing/
proposed road boundaries. Wherever this is not possible, on approval
of Engineer-In-Charge, the pipe can be laid near the road or within the
carriageway. The alignment approved by the Engineer-In-Charge shall
be final and binding on the contractor.
(iv) Cutting of the vegetation for the purpose of excavation. However, it will
be contractor’s responsibility to obtain all kind of clearances, if required
to cut the vegetation for laying of pipe line and other civil works, if the
forest department will raise the amount against the cutting the said
vegetation, the amount will be deposited by the department, but the
contractor shall have to hand over the wood of damaged vegetation to
forest authorities as per directions at his cost.
(v)Excavation of trenches in ordinary soil/ hard dense soil/ hard dense
soil mixed with boulders/decomposed rocks/hard rock/saturated soil
for laying pipeline below ground as per the L-section approved by the
department. An average clear cover of 0.9 m shall generally be
maintained.
(vi) Preparation of trench bed, providing sand bedding where pipe is laid
below ground in stretches having boulders/rocky strata.
(vii) Refilling & compaction of trenches.
(viii) Providing support structures such as saddle supports or portal frames
for pipe laying above ground, wherever required.
(ix) Construction of thrust blocks at each deflection in horizontal and
vertical alignment of pipeline exceeding 5 degree for vertical bends and
10 degrees for horizontal bends.
(x) The pipeline above ground shall be suitably clamped, to prevent floating
of pipes in submerged conditions.
(xi) Interconnection of pipelines to existing pipelines, existing ESRs, existing
CWRs including providing all specials, civil & mechanical works.
(xii) To repair damage to pipelines, electrical poles, telephone poles, optical
fiber cables etc. and providing suitable structures for crossing the
existing other rising mains during laying clear water mains.
(xiii) Providing, testing and installing all materials such as bends, tees,
reducers with long radius, dismantling joints, insulating joints, rubber
rings, flanges, nuts & bolts, rubber sheets etc. of required specifications
for the installations.
(xiv) Providing anchor blocks wherever necessary.
(xv) Providing protection for foundations of pedestals/portals against soil
erosion.
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(xvi) Sectional testing of pipeline.

(xvii) Removal of defects in laying and jointing works of all pipelines, valves
and specials.
(xviii)Compliance of all safety rules at work sites.
(xix) Making connection of new pipes to existing pipes in transmission and
distribution as per directions of EIC.
(xx) Cleaning, Disinfections, testing and commissioning of all pipelines laid.
(xxi)Other ancillary works.
(xxix) Marking of laid pipelines on GIS Platform. The contractor shall submit
geo-referenced AUTOCAD drawings for the complete pipeline network
laid under the contract. Location of all valves and Tees, bends, junctions
and points of change in alignment of pipeline shall be determined using
differential GPS of 0.6 m accuracy or better. Attributes of pipeline, like
diameter, material, class etc shall be linked with GIS. The contractor shall
be responsible for getting the alignment of pipeline marked on to the GIS
platform of PHED.
(xxxiii)The work shall include all other items & accessories not specified above
but required to complete the work on turnkey basis to achieve the
intended objectives in safe, secure, reliable manner adopting best
engineering practices.
(xxii) The contractor shall take all safety precaution during execution of all
work i.e. P/L,CWR, OHSR and civil work etc
Road,Rail,River/Nallah Crossing :-
(i) For NH/SH/railway crossings, the department shall apply to respective

department for permission to carry out the crossing work. It shall be the
contractors’ responsibility to obtain approval from respective deptt. for
such crossing work . In case the respective deptt. does not allow the
contractor to do the work and carries the work themselves as a deposit
work, cost of such work shall be borne by the deptt. and withdraw these
work on the contractor scope.
(ii) NOC from the Municipalities/LSG bodies shall be obtained before
laying of pipe line in Municipal areas.
(iii) Encasing with MS pipe of carrier main, as DI/MS pipe line or as per
specifications of concerned department, shall be provided at all
Railway/canal/NH or SH Road/drain crossing and drawing and
specifications of concern department shall be adopted by contractor.
(iv) It shall be sole responsibility of the contractor to obtain permission for
Road/Rail crossing from concern authority by furnishing all
details/drawing/design and undertaking etc. required for the same
time to time. However department PHED may assist the contractor. Any
lapse/delay occur to the project due to late approval and there of
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execution shall be the contractor’s responsibility. The contractor shall be

responsible for any damage occurred to the telephone lines,
distribution/rising main water and gas pipe lines, sewerage pipe line,
roads, drains while laying pipeline and shall be liable to pay the amount
levied by respective department for the repair and / or damages so
occurred;
(v) The contractor should identify the number of crossings on
National/State highways and district roads etc. The scope under this
item includes all road crossings where pipelines are expected to cross
any road as finalized by EIC.
(vi) Providing a suitable designed and approved scour-proof bed for
crossing of pipeline below the scour depth of nallah, drain, canal or
river. For pipe crossings of drains above ground, the invert level of pipe
shall be kept 1 m above H.F.L / road level, using suitable support
structures. The structures must be protected by suitably planned river
training works. The crossing below the scour depth or above HFL has to
be decided in co-ordination of the EIC. Detailed drawing of crossing
arrangements proposed to be used shall be presented to Engineer-In-
charge for approval.
(vii) The laying of pipe shall not obstruct the flow of water in the natural
drains. The drains may be crossed underground at scour depth with MS
pipe in river crossing. The pipe shall be encased through pushing
method and or as per specifications of concern department. The
structures must be protected by suitably planned river training works.
(viii)The contractor is required to establish a field laboratory at each site
office for ensuring the timely inspection of the material and works.
(ix) The contractor shall carry out all works civil and/or mechanical work
which includes supply of specials, valves, tees, bends etc for
interconnecting the proposed pumping mains under this contract. The
pumping mains shall be connected to the outlet pipe from outlet
chamber of pumping stations at their upstream and shall be connected
to inlet pipe of existing/proposed ESRs & CWRs.
b. CONSTRUCTION OF RCC ELEVATED SERVICE RESERVOIR (ESR)
The work consists of construction of RCC elevated service reservoirs. The
Contractor shall be fully responsible for the soundness of the construction,
structural safety & water tightness of the structure based on the specifications,
sound engineering practices, and latest I.S. provisions.
The capacities of ESR(s) mentioned in scope of work are effective capacity. The
ESR shall be constructed in circular shape and top dome of ESR’s up to
capacity of 500 KL shall be dome roof and for capacity above 500 KL of
combination of flat & dome roof.
The scope of work includes:
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(i) Construction of reservoirs as per the provisions given in the

“Specifications for civil works”.
(ii) Supply and installation of puddle collars and duck foot bends for
installation of inlet, outlet, washout and overflow pipes.
(iii) Supply and installation of double flanged CI/DI pipes for inlet, outlet,
and washout (scour) and overflow with specials with minimum sizes as
listed below:
S. Item Material 300 KL, 18 200 KL 18 Valves
No M M
Inlet DI/CI 1 NRV, 1 Air
1 150 mm 100 mm
Pipe DF Valve
Resilient Seated
outlet DI/CI
2 150 mm 150 mm Sluice Valves- 2
pipe DF
Nos
To be connected
Overflow DI/CI with outlet pipe
3 150 mm 100 mm
pipe DF after supply
valves
Washout DI/CI Sluice Valve- 1
4 100 mm 100 mm
pipe DF No
(iv) Providing and installation of Electromagnetic flow meter at out let pipe
of 150 mm size.
(v) Interconnection of the inlet pipes to the feeder mains with pipe of equal
size using CI/DI double flanged pipes and required specials.
(vi) Interconnection of outlet pipes from the ESR to the feeders for zones
connected with ESR.
(vii) Providing & installation of at least two Resilient seated sluice valves on
each outlet, one sluice valve each on inlet & washout pipe for each
reservoirs. The sizes of the valves shall be equal to that of the main on
which they are to be installed.
(viii)Interconnection of the overflow pipe to the distribution or the outgoing
feeders as per the approval of Engineer-in-Charge using one sluice valve
of size equal to the size of overflow pipes as listed above, CI/DI double
flanged pipes and required specials.
(ix) Providing scour/washout pipes up to suitable length to drain the water
away from the structure in an environmental friendly manner, using a
sluice valve equal to the size of washout pipe as listed above, CI/DI
double flanged pipes and required specials.
(x) Providing float valve with auxiliary float with copper float ball, gun metal
ball cap, brass lever, brass split pin, gunmetal piston & piston cap, washer
of nitrile rubber with gun metal body in each CWR and ESR. The size of
float valve shall be same as of Inlet pipe. The pressure rating of valve
should be in accordance to the maximum designed pressure.
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(xi) The washout pipe will be of 150 mm dia. for all the CWRs and of 100 mm
dia. for all ESRs. up to 500 KL capacity and 150 mm dia for all above 500
KL Capacity.
(xii) Providing water level indicator as per specifications given in the chapter
of “Specifications for Civil Works” for all reservoirs.
(xiii)Excavation for all structures including working spaces, trench
excavation for pipes & other ancillary works in all sorts of soils, refilling &
disposal of surplus earth at suitable site & dressing as per direction of
Engineer-in-charge.
(xiv) Providing plinth protection works as per specifications and approved
drawings for all reservoirs.
(xv)Providing lightning arrestor on the top of ESR.
(xvi) Providing access to the top and inside the reservoir as per the
specifications given in the chapter of “Specifications for Civil Works”.
(xvii)The RCC stair shall start at a height of 4.5 Mtr from plinth level to
safeguard against unauthorized intruders.
(xviii)Providing ventilation for the reservoir as per the specifications given in
the chapter of “Specifications for Civil Works”.
(xix) Providing manhole/headroom for access inside the reservoir.
(xx) Providing 25mm diameter GI pipe in two rows in 50x50x6mm angle iron
railing along the top of reservoir, on the sides of the staircase and balcony,
and at other suitable points for the requirement of safety of maintenance
and execution staff.
(xxi) For each ESR, Providing a bypass arrangement to connect the incoming
rising main to the outgoing distribution line so as to enable supply to the
consumers through direct pumping in case of shut down of ESR.
(xxii) The inside surface of CWR/ESR shall be finished with plaster in CM 1:4
and using water proofing compound as per manufacturer’s
recommendation. The outer wall and surface of tanks above ground shall
be painted with cement paint of approved shade.
(xxiii) Testing of tank for water tightness and structural stability by filling it with
water and in accordance to the procedure laid down in tender document
as per I.S.S.
(xxiv) Painting the metallic surface with primer and enamel paint. Putting
slogan on tank as per direction of EIC.
(xxv) Final clearance of site before handing over the work, including leveling of
earth and disposal of surplus earth as per directions of the Engineer-in-
Charge.
(xxvi) The submission of as built drawings.
c. FIELD LABORATORY
The Contractor is required to establish a field laboratory at site office for
ensuring the timely inspection of the material and works. The laboratory will
be equipped with testing facilities sufficient to cope with the requirements of
the tests to be conducted on site. It should have at least the following
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equipment, which may be supplemented with additional equipment as may be

found necessary by the Engineer-in-charge/Contractor.
The Test Equipment, meters, instruments etc., used for testing shall be
calibrated at Recognized Test Laboratories at regular intervals and valid
certificates shall be made available to the Engineer in-charge. The calibration
certificates should be produced in advance for the approval of the Engineer-in-
charge and if necessary they shall be got recalibrated or substituted before
commencement of the tests.
List of Minimum Laboratory Equipment/Instrument

S. No. Name of Equipment/Instrument
A. General:
1 Balance 20 kg capacity-self indicating type
2 Electronic Balance 5 kg capacity accuracy 0.5 gm
3 Sieves analysis set of IS with lid and pan: 450 mm diameter:

63 mm, 53 mm, 37.5 mm, 26.5 mm, 13.2 mm, 9.5 .mm, 6.7 mm
and 4.75 mm size
4 Sieves analysis set of IS with lid and pan:200 mm diameter:

2.36 mm, 2.0 mm, 1.18 mm, 600 micron, 425 micron, 300
micron, 150 micron, and 75 micron
5 Measuring tape, vernier scale, Digital Screw Gauge, die for

concrete cubes, vibrating platform, tools and tackles
6 First aid box
C. For Cement and cement concrete:
1 Slump testing apparatus
2 Compression strength testing machine
D. For DI/HDPE Pipes:
1 Ultra sonic gauges for thickness measurement of coating,

lining and MS/DI pipe plate.
2 Equipment for Hydraulic sectional Testing with calibrated

pressure gauge
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d. OPERATION AND MAINTENANCE FOR 5 YEARS:

The scope of O&M for 5 years shall include operation and maintenance of all
works executed under this contract including rising mains (with all pipe
appurtenances), O&M of all reservoirs (ESRs) constructed under this contract
and O&M of distribution pipe lines shall be done by the contractor. The work
include O&M of electrical, instrumentation, bulk flow meters etc. as per
described standards. Apart from above operation and maintenance of RCC
OHSR, capacity 100 KL has to be done by the contractor.
The contractor shall update the O&M Systems and Procedures developed as
per department’s requirements. The same shall be submitted to the department
for approval along with other O&M documents like O&M Manuals, Log
sheets, Formats, etc. These shall be got audited annually throughout the O&M
period.
Within the frame work of the contractors responsibilities given above, the
contractor shall carry out the following activities, but these shall not limit
requirement of other activities, which otherwise are required as per term and
conditions of contract or to fulfill contractors responsibilities or are essential as
per good industrial practices. The contractor shall be responsible for:
a) Providing designed per day requirement of water to each ESR and from
each ESR to each zone. System shall be tested for design demand but shall
be run as per actual demand based on population as per directions of EIC.
b) Chlorination of water in CWR as per requirement for which Bleaching
powder shall be provided by the department.
c) To check the residual chlorine at the tail end of each zone. It should be as
per CPHEEO manual requirement.
d) Providing the minimum specified staff as specified during operation and
maintenance period and additional staff as per requirement during
periodic maintenance and in emergencies.
e) Providing all required consumables required for functioning/operation &
maintenance of equipment.
f) Metering is of utmost importance in this contract. Flow measurements of
meters at Pumping stations and at ESR will be recorded daily, and will be
signed by representatives of Department and Contractor.
g) Preventive/breakdown maintenance of all pumps, electrical, mechanical
& instrument equipment, installed under the contract. All costs including
costs of all material, equipment, etc required for operation and/or
maintenance (preventive and/or breakdown) to be borne by the
contractor.
h) Maintenance of the lighting fixtures and the lighting system of all areas
and replacement of all non-functional lighting fixtures within 24 hours.
i) Maintaining;
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• Repair history of all pipeline, mechanical, electrical and instrumentation

control equipment Logbooks:
• Every day power availability, input voltages, kWH meter, power factor
readings at pumping station.
• Daily Operation of pumps with every hour readings for operating
voltage, amperage and power factor, pressure on the manifold, pressure
at outlet of pumps and flow rate in manifold.
• Maintain record of net operating pressure, discharge and energy
consumption of each pump so as to arrive at the operating efficiency.
This record should be logged through the PLC installed in the pumping
station.
• Last periodic maintenance done for all reservoirs of the system.
• Observations made during patrolling of the pipeline.
j)In addition to maintenance of above logbooks, the contractor is required
to maintain one observation book at each pumping station. Observations
made in the observation book, by departmental officers, must be complied
with immediately and compliance report shall be sent monthly to EIC.
k) Providing tools and tackles and spares, at the start of the O&M period, as
per list given in price schedule (Vol. IV) and maintaining adequate
additional inventory of spares/accessories or equipment itself for repair
of system so that the electrical, mechanical, pipe and pipe appurtenances,
can work efficiently as per the guarantees given or minimum required
efficiencies asked for in the contract, without any additional costs to
department.
l) Providing manpower and materials for the required repairs of all facilities
along with the manpower and materials for repair of the buildings,
reservoirs and pipeline built under the contract.
m) Maintenance of the stores for the electrical, mechanical and
instrumentation equipment. The maintenance of stores will include but
shall not be limited to:
• Loading / unloading of materials received and issued for works.
• Proper arrangement of material in stores to ensure its safety and easy
availability.
• Maintaining store area neat and tidy.
• Keeping records and Accounting the incoming materials
• Keeping records and Accounting the consumed materials
n)The contractor shall be solely responsible for the safety and security of
the goods in the store and its accountability and will be responsible for
any loss or damages in stores for any reason. He may opt for insurance
cover against the value of the goods to be stored without any additional
costs on the Department.
o) Patrolling of the water mains laid in the contract, to identify and report
the damages / defects pipe and pipe appurtenances, CD works, en-route
structures.
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p) Emergency Maintenance/Periodic routine maintenance: Providing a fleet

consisting of suitable hauling machine, sufficient inspection/patrolling
vehicles and material hauling vehicles and any other
vehicles/machinery/equipment for adequate and timely repairs and/or
for routine/periodic maintenance /patrolling of the system.
q) Periodic routine maintenance of buildings & reservoirs constructed under
this contract. Such maintenance must ensure adequate cleanliness,
ventilation, illumination and structural safety. In addition to this, the
general hygienic standards must be maintained and adequate plantation
should be done.
r) Maintenance of road-cut repairs carried out under the contract.
s) Updating and periodic submissions of the operation and maintenance
manual as defined in specifications for O&M works. The contractor shall
take up all periodic maintenance works provided in the approved O&M
manual.
t) Submission of monthly report.
u) Co-ordination with other contractors and/ or agencies responsible for the
Execution, operation and maintenance for regional schemes and Electric
Supply Company.
The O&M period shall commence after complete execution of the project as
defined in contract document i.e. 12 months and one year defect liability after
award of work or actual date of completion of defect liability period whichever
is later. However, the part commissioning of the project on completion of
certain units, if possible, before completion of execution period, and if
Department desires to use these units, the same shall be put to O&M without
reckoning such period towards the 5 years period of O&M, however charges
for power shall be borne by the department during this period.
During Operation & Maintenance either after commencement of the O&M
period as mentioned above or during execution period i.e. part operation &
maintenance if required by department due to part handing over of the system
before completion of execution period of 24 months the following charges
towards O&M shall be paid by the Department / Contractor.
1. Power charges shall be paid by department. Any power factor surcharge
if levied by power supply agency shall be borne by the contractor.
2. Chemical i.e. Bleaching powder shall be provided by the department.
3. All other cost involved for O&M viz. cost of spares, staff,
communications, consumables, stationery, T&P, vehicles etc. shall be
borne by the contractor.
The duties of the contractor under this contract shall include the following
but shall not be limited to:
VOLUME-II Page 13
a) Identification and obtaining all the clearances required for the operation
of the facility and for the fulfillment of its obligations under the
Conditions of Contract.
b) Arrange all the necessary manpower & services for the operation and
maintenance of the system as per scope defined above including normal
watch & wards etc.
c) Make all necessary arrangements for the tools and plants, machinery,
equipments, furniture and transportation vehicles necessary for operation
and maintenance and timely repairs.
d) Procure and store all required materials, equipment, lubricants, inventory
for repair and operation and maintenance at such locations.
e) Be responsible for the security of the facility and comply with applicable
laws and/or statutory requirements as may be applicable in the land from
time to time.
f) Co-ordinate and communicate with other agencies like PWD, Railway,
JVVNL, Water Resources Deptt., Telephone Deptt. etc.
g) Be responsible to minimize wastage of water by attending to leakages of
pipe, air valve, scour valve etc. and breaches immediately and shall
repair/restore within 12 hours from the notice of such leakage / breach.
In no case the down time of the pipe/machine should exceed 12 hours.
h) The Contractor shall carry out his activities in the facility in such a
manner that water will not be wasted, leaked or spilled onto the site or
elsewhere. The Contractor shall bear the cost of correcting any adverse
consequences resulting from such wastage, leakage or spillage, and shall
maintain history of such event in history sheet.
i) The contractor shall keep records for daily water drawl from all pumping
stations which shall include Flow rates, pressure, operation state of
pumps at each head works, chlorine doses, flow & pressure at each ESR,
operational status of all mechanical, electrical & instrumentation
equipment. The record shall be kept in formats as approved by EIC.
Contractor shall submit these records to EIC on monthly basis.
j) The contractor shall submit report above operations regularly as
described here under daily / weekly / monthly through e-mail. Monthly
report should also be submitted in hard copies.
k) The plantation done on head works should be maintained and dead
plants should be replaced.
l) To keep the entire campus area, particularly toilets neat and clean and
dis-infected by using Phenyl, acid and other chemicals at all head works.
m) Up keeping and maintaining all illumination system, internal and
external at all head works by changing the default equipment
immediately.
Deployment of Minimum Staff for O&M
The minimum permanent staff to be deployed for each section by the

contractor for carrying out the O&M functions shall be as follows:
VOLUME-II Page 14
S. No. Category Total
1 Valve Man/Helper 2
2 Fitter 2
3 Helper for Fitter 4
Note:
• The above requirement is minimum only. The contractor will arrange extra
work force, as and when required, so as to smoothly run the repair and
maintenance including preventive maintenance, repairs etc. and general
cleanliness of the installations.
• The above staff strength is exclusive of leave/rest reserve required for
different category of staff. The contractor shall ensure, the personnel given
in the above table for all the seven days in a week.
• The contractor shall make appropriate arrangements for maintenance of
items like patrolling, vehicle operations and other activities defined to
fulfill its obligations under R&M contract.
Pipeline Works
a) Maintaining everyday observations including meter readings of all Flow

meters installed on the pipeline.
b) Repair of leakage’s, damage to any portion of pipes and pipe
appurtenances, pillars, thrust blocks etc., and shall be done to within 12
hours from identification.
c) Emergency Repair(s) of burst(s) for maintaining regular supplies
immediately.
d) Operation of all valves quarterly to check its functioning for operation.
Maintenance of all valves. Inspection of surge protection
equipment/system if any and repair them if required. Contractor shall
submit quarterly reports of all such activities done.
e) To maintain minimum level of inventory required for repair of pipe
leakage(s) and burst(s), valves (air valve, sluice valves, butterfly valves),
flow meters, surge protection devices or any other pipe appurtenances
or equipment(s) installed.
f) To maintain the valve chambers along the pipeline in clean and dry
conditions.
g) To make necessary arrangements for de-watering in situations
warranted for O&M.
VOLUME-II Page 15
h) To maintain the soil cover on the pipe damaged due to rains, run-off or
due to other reasons.
i) Maintaining clean conditions at pillars and fixity blocks along pipelines.
j) Maintain all the existing rising and distribution pipelines within the
project area.
Water Reservoirs (CWRs/ESRs/GLSR):
The Contractor shall carry out following maintenance work, during O & M
period:
a) Repair of damaged portions of reservoirs.
b) To operate and check all valves, instruments and automation systems
once in 3 months and do the required maintenance work to ensure their
smooth and proper functioning.
c) Cleaning and bleaching of the reservoir once in 6 months as per
direction of Engineer in Charge. The date of cleaning and bleaching shall
be painted on the signboard installed near the reservoir.
d) Repair of the damaged portions of the plinth protection works.
e) Repainting during the 5th year of O&M period
f) To maintain the reservoir, its surrounding and the campus in a neat and
tidy manner.
g) Other activities required for maintaining the tanks and their
surroundings in neat conditions.
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CHAPTER 2 : SPECIFICATIONS FOR PIPELINES

2.1 DUCTILE IRON PIPES, FITTINGS AND SPECIALS
2.1.1Ductile Iron Pipes
The pipes will be centrifugally cast (spun) Ductile Iron pipes for Water and
Sewage confirming to the IS 8329: 2000 and shall be marked with BIS. The
pipes used will be either with push on joints (Rubber Gasket Joints) or
Flanged joints. All DI pipes shall conform to class K-7 and K-9 as specifically
indicated. For socket joint pipes, the minimum tensile strength shall be
420 N/mm2 and the minimum 0.2% proof stress shall be 300 N/mm2. The
minimum elongation after fracture shall be 10% for nominal diameters DN80
to 1,000 and 7% for nominal diameters DN1100 to DN2000. The Brinell
hardness testing shall not exceed 230 HB on the external un-machined
surface. Flanges for screwed on or Welded on K-7 or K-9 Pipes shall be of
Ductile Iron of 420 MPa minimum tensile strength and 5 percent minimum
elongation at break and maximum hardness 250 HB. The minimum classes of
screwed or welded flanges on K-7 and K-9 pipes shall be PN16. The size and
class of the pipes to be supplied shall be as Schedule of Prices.
Socketed joints shall be of the push-on type. Rubber gaskets confirming to IS:
5382 shall be used with push-on-joints or mechanical joints. Material of
rubber gaskets for push-on mechanical or flanged joints shall be compatible
with the fluid to be conveyed at the working pressure and temperature. For
Flanged joints, Rubber gaskets confirming to IS: 638 shall be used. Rubber
gaskets shall be stored in accordance with the relevant standard.
The quality of metal used for the manufacture of the pipes shall be of good
quality grey cast iron and subject to the various quality control tests as
specified in the relevant Standards.
The pipes shall be supplied in standard lengths of 6.00/5.50 meters with
suitably rounded or chamfered ends for socket and spigot. For flanged pipes,
the length shall be 5.50 meters. However in exceptional conditions, length of
pipe less or more than specified will be procured per instruction of the
Engineer.
2.1.2Ductile Iron Fittings and Specials
Ductile Iron Fittings shall be manufactured in accordance with IS:9523. The
metal used for the manufacture of casting shall conform to the appropriate
grade as specified in IS 1865, in commensurate with the requirements as laid
down in IS:9523. The minimum tensile strength shall be 420 N/mm2 and the
minimum 0.2% proof stress shall be 300 N/mm2. The minimum elongation
after fracture shall be 5%. The Brinell hardness testing shall not exceed 250
HBS on the external un-machined surface. All fittings and specials shall have
a minimum class of PN16.
All fittings shall also be subjected to a works leak-tightness test using water to
a pressure as given in IS:9523.
VOLUME-II Page 17
Socketed fittings, except collars, shall be supplied with push-on joints unless
otherwise called for. Collars shall be supplied with mechanical joints.
2.1.3Miscellaneous Materials
Miscellaneous materials includes any item other than a pipe, fittings or
specials which is used in a pipeline, such as rubber gaskets, bolts, nuts,
washers, lubricants, etc. Gaskets shall be free from extractable substances
which impart taste or odour and toxicity to water. Gaskets shall be made of
properly vulcanized virgin rubber compound containing no scrap or reclaim.
Gaskets shall be of such physical properties as to be capable of forming
permanent watertight joints against pressures up to the maximum test
pressure. Rubber sealing ring gaskets shall be fabricated as per IS: 5382 and
sheet rubber gaskets jointing and rubber insertion gaskets jointing shall be
fabricated as per IS: 638. Nuts, bolts and washers shall be of the best quality
bright steel, machined on the shank and under the head and nut. Studs, bolts
and nuts shall be galvanised. Bolts shall be of accurate length so that only one
thread shall show through the nut in the fully tightened conditions. Nuts and
bolts shall conform to IS: 1363 and IS: 1367. Lubricants only with indicated
brand name and accepted standard shall be supplied. The lubricant and its
compound should not have any implication on water quality.
Miscellaneous materials are preferably be manufactured by the manufacturer
of the pipes. In case they are not, it shall be the responsibility of the
Contractor of the pipes to have them manufactured from a suitable
manufacturer under it’s own supervision and have it tested at his/sub-
contractors premises as per the requirements. The Contractor shall be
responsible for the compatibility and quality of the products.
Miscellaneous materials shall be supplied with reasonable excess quantities.
2.1.4Protections of Pipes, Fittings and Specials

2.1.4.1 Internal Lining
All pipes, fittings and specials shall be delivered to site after applications of
appropriate lining and coatings. The internal wall of pipes shall be lined with
cement mortar as given in Annex B of IS: 8329 and for fittings as per Annex B
of IS: 9523. However, it is strictly required that the minimum Bore size of
pipes, fittings and specials after such internal lining shall not be less than their
respective nominal diameters. It is also mandatory to keep the minimum
required thickness of lining and the pipe walls as per the specifications.
At joints between cement mortar lined pipe (or specials) and valves, the
internal diameter of the pipe or special shall be finished to match the bore of
the valve by gradually decreasing or increasing the thickness of the lining in
the pipe or special, although the lining shall be nowhere less than 6 mm thick.
Any increase or decrease in the thickness of the lining shall be gradual and
smooth and the Contract Rates shall be deemed to include for all costs
incurred in providing such a lining.
VOLUME-II Page 18
Cement used for the lining shall conform to Portland cement (as per IS: 8 112
or IS: 455) mortar lining.
The cement mortar to be used for the lining shall be composed of cement,
sand and water. Additives, which shall be specified and approved, may be
used, provided that they do not prejudice the quality of the coating and that
of the transported water. The mortar shall be thoroughly mixed and shall
have a consistency which results in a dense and homogeneous lining. The
mortar shall contain by mass at least one part of cement to 3.5 parts of sand.
Applications and minimum thickness are as specified in the standard. At the
fittings ends, the lining may be reduced to values below the minimum
thickness. The length of the chamfer shall be as small as possible but, in any
case, shall be less than 50 mm.
The required thickness of the cement mortar lining and its tolerance as
stipulated in IS: 8329 and IS:9523 is in the following table:
Thickness of Cement Mortar

Nominal Lining (mm) Maximum crack width
Diameter
Nominal Limit Deviation* and radial Displacement
(DN)
Value
80 to 300 3 -1.5 0.8
350 to 600 5 -2 1.0
700 to 1200 6 -2.5 1.2
1400 to 2000 9 -3 1.5
* Only the lower limits are given
NOTE - Fittings ends may have a chamfer of maximum length 50 mm.
The lining shall be such that it cannot be dislodged with pressure of hand and
shall be free from corrugations or ridges that could reduce the thickness of the
lining to less than the minimum value.
2.1.4.2 External Coating
Pipes, fittings and specials shall be supplied to site after applications of
appropriate bituminous coatings to external surfaces as per Annex B of IS:
9523. Bituminous coatings are either hot applied or cold applied. Coating
shall not be applied to any pipe unless its surfaces are clean, dry and free
from rust. The coating material shall set rapidly with good adherence and
shall not scale off. The mean thickness of the coating shall be not less than 70
µm and the local and the minimum thickness shall be not less than 50 µm.
2.1.5Quality Assurance
The manufacturer shall be able to demonstrate the conformity of the products
to the requirements contained in this standard by controlling the
VOLUME-II Page 19
manufacturing process and carrying out the various tests as specified in the
standard. The manufacturer shall control the quality of the product during
manufacturing process by a system of process control in order to comply with
the technical requirements contained in the standard wherever possible
statistical sampling techniques should be used to control the process so that
the product is produced within the specified limits.
Batch sampling and mechanical testing of samples shall be made as per
procedures laid down in IS: 1608 for pipes and IS: 1500 for fittings. The tensile
testing machine shall have suitable holders or grips to suit the test bar ends so
as to positively apply the test load axially.
All pipes and fittings shall also be hydrostatically tested at specified pressures
and the test, shall be kept under pressure for 10 seconds. They shall withstand
the pressure lest without showing any sign of leakage, swealing or other
defect of any kind. The test shall be conducted before the application of
surface coating.
2.1.6Inspection
All works and materials under this specification will be rigidly inspected
during all phases of manufacture and testing and such inspection shall not
relieve the Contractor of his responsibility to furnish materials and perform
work in accordance with this specification.
The Contractor shall notify the Engineer-in-Charge or his representative, in
advance the production of materials and fabrication thereof, in order that the
employer may arrange for mill and shop inspection.
The Engineer-in-Charge or his representative may reject any or all materials
or work that do not meet with any of the requirements of the specifications.
The Contractor shall rectify or replace such rejected material / performed
work at his own cost, to the satisfaction of the Engineer-in-Charge or his
representative.
The Engineer-in-Charge or his representative shall have free access to those
parts of all plants or any other premises and sites that are concerned with the
furnishing of materials or the performance of work under this specification.
The Contractor shall furnish reasonable facilities to the Engineer-in-Charge or
his representative and space for inspection, testing and obtaining of any
information he desires in respect of the character of material used and the
progress and manner of the work.
The Contractor shall supply free of cost required specimen of materials for
testing by the Engineer-in-Charge or his representative at any time during the
progress of work and shall bear the cost of all such tests or re-tests to his
satisfaction.
The Contractor shall submit with the material, result of inspection and testing
as per standards specified on the material supplied to indicate its conformity
in respect of Chemical and physical properties per heat. All the tests shall be
VOLUME-II Page 20
carried out in manufacturer’s works. The Engineer-in-Charge or his

representative has the right to have the material tested independently to
confirm the quality/grades of the materials particularly, if there is no co-
relation between various test results or if required tests certificates are
notprovided.
2.1.7Defects and Rejection
Materials with defects at the place of manufacture or at site, or which prove to
be defective when properly applied in service shall be completely repaired or
shall otherwise be replaced at no cost to the Employer.
Defects shall include cracks, leaks, laminations, lack of complete penetration,
lack of complete fusion, dents exceeding one eighth of the specified wall
thickness and under cutting or reduction in the pipe wall thickness adjacent
to a weld exceeding 0.8 mm in depth.
Slag inclusions and gas pockets or voids shall be considered to be minor
imperfections and may be affected if the maximum size and distribution does
not exceed the limits shown in Table 9.3 and 9.4 and Figures 9.2 and 9.3 of
A.P.I. Standard 5L – 1991.
Any pipe or special which fails to pass the Hydraulic Pressure Test shall be
rejected.
Any pipe or special which has been rejected shall be marked in a distinctive
manner to preclude any possibility of its use in the Works. Such pipes and
specials may be submitted for re-test following the correction of any defects,
where such correction is permitted by the Engineer.
2.1.8Marking and Packing
The Supplier/ Contractor shall after proper rust preventing coating, wherever
necessary, pack all the material in a manner suitable for transport to a tropical
humid climatic region in accordance with the internationally acceptable
practices and in such a manner so as to protect it from damage and
deterioration in transit by road, rail and/ or sea and during storage at site till
the time of use which is approximately 6 months after delivery. The
Contractor shall be held responsible for all damages due to improper packing.
Each pipe and fitting shall be indelibly marked inside the bare pipe with the
following:
All pipes will be marked as per Clause 18 of IS 8329 and show as below:
•Manufacturer name/ stamp
•Nominal diameter
•Class reference
•All pipes shall be BIS Marked.
•A white ring line showing length of insertion at spigot end
Manufacturer’s distinguishing mark
Diameter (in mm)- outside or nominal dependant on material
Length of the pipe/angle of the bend (mm. degrees)
VOLUME-II Page 21
Works test pressure/Class

Actual weight of the pipe or special (Tons)
Sequential manufacturing number – to be consistent with works
manufacturing records
Where there is insufficient smooth surface area to accommodate the above
information, the marking shall be put on rust-proofed metal tags secured to
the item with galvanised wire.
The sequential manufacturing number shall be painted on the pipe and
stamped indelibly onto the inside of the socket. Clearly identifiable coloured
bands, as approved by the Engineer shall be used to differentiate between
sized and un-sized pipes.
The flanges of pipes and fittings shall be protected by wooden discs attached
by means of service bolts or by other approved means. Service bolts shall not
be incorporated in the Works.
All other pipe ends shall be protected against impact damage and entry of
foreign matter.
Small items, such as bolts, nuts, gaskets and other joint components shall be
crated for delivery. Each crate shall contain a detailed packing list in a
waterproof envelope. The outside of the crate shall bear a general description
of the contents and an identification mark relating it to the detailed packing
list.
2.1.9Certificate of Quality of Pipes and Specials
With every consignment of pipes and specials delivered under this contract
the Contractor shall furnish a certificate worded as follows:-
- “This is to certify that the quality of pipes and specials delivered in this
consignment is not inferior to the quality laid down in the
Specification”.
- No payment shall be made in respect of any consignment of pipes and
specials that is not accompanied by such a certificate.
The Contractor shall operate a Quality Assurance System, including:-
- Records of Tests performed by suppliers on materials brought in;
- Testing of materials for this Contract at various stages of manufacture
as herein specified, and preservation of the results of such testing;
- Sequential numbering of pipes and fittings.
The Quality Assurance System records shall be open to inspection by the
Engineer, and shall be maintained in such a way that any pipe or fitting is
identified by a unique sequential production number and can be uniquely
related to each stage of its manufacture including material origin and quality,
date and time of each operation, operator(s) involved and results of relevant
quality control tests.
On completion of the Contract, the Contractor shall pass a complete set of the
Quality Assurance records to the Engineer.
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2.2 HDPE PIPES

2.2.1 High Density Polyethylene Pipes (HDPE Pipes)
This specification covers the requirements of designing, manufacturing,
supplying, laying, jointing and testing of High Density Polyethylene Pipes
used for water supply at manufacturing and work site.
2.2.2 Applicable Codes
The manufacturing, testing, supplying, laying, jointing and testing of HDPE
pipes at work site shall comply with all currently applicable statutes,
regulations, standards and Codes. If requirement of this Specification conflicts
with the requirement of the standards / Codes, this Specification shall govern.
Codes, not specifically mentioned here but pertain to the use of HDPE pipes
shall form part of these Specifications.
2.2.3 Designation
Pipes shall be designated as per IS 4984, according to the grade of material,
followed by pressure rating and nominal diameter, for example, PE 63 PN 10
DN 200 indicates a pipe pertaining to material grade 63 having a pressure
rating 1.0 MPa and outside nominal diameter 200 mm.
2.2.4 Colour
For the purpose of identification of the pipes, each pipe shall contain minimum
three equi spaced longitudinal strips of width 3mm (min) in blue colour, these
strips shall be coextruded during pipe manufacturing and shall not be more
than 0.2 mm in depth. The material of the strip shall be of the same type as of
resin.
All HDPE Pipes of the same size, same pressure rating and same grade and
also manufactured essentially under similar conditions, shall constitute a lot.
2.2.5Marking
All pipes will be marked as per Clause of IS 4984 and as below:

• Manufacturer name/ stamp
• Batch No /Pipe no.
• Nominal diameter
• Class reference
• A white ring line showing length of insertion at spigot end
• ‘PHED Rajasthan’
VOLUME-II Page 23
2.2.6 Materials
The material used for the manufacturer of pipes should not constitute toxicity
hazard, should not support microbial growth, should not give rise to
unpleasant taste or odor, cloudiness or discoloration of water.
2.2.7 Raw Material

Raw material used to manufacture the HDPE pipes shall be 100% virgin PE
compound or Natural black PE resin confirming to IS: 4984, IS: 7328 and ISO:
4427; for this a certification has to be obtained by the pipe manufacturer from
the resin manufacturer as per clause 3.2.3 of IS: 4984. The resin proposed to be
used for manufacturing of the pipes should also comply with the following
norms as per ISO 9080.
Code No. Title/Specification
IS:4984 High Density Polyethylene Pipes for Water Supply
IS:2530 Methods of test for polyethylene moulding materials and
polyethylene compounds
IS:5382 Rubber sealing rings for gas mains, water mains and sewers.
Methods for random sampling
IS:7328 High density polyethylene materials for moulding and extrusion
IS:7634 Laying & Jointing of Polyethylene (HDPE) Pipes
IS:9845 Method of analysis for the determination of specific and/or overall
migration of constituents of plastics material and articles intended
to come into contact with foodstuffs
IS:10141 Positive list of constituents of polyethylene in contact with food
stuffs, pharmaceuticals and drinking water.
IS:10146 Polyethylene for its safe use in contact with foodstuff,
Pharmaceuticals and drinking water.
The resin should have been certified by an independent laboratory of

international repute for having passed 10,000 hour long term hydrostatic
strength (LTHS) test extrapolated to 50 years to show that the resin has a
minimum MRS of over 10MPa. Internal certificate of any resin manufacturer
will not be acceptable.
Certificate for having passed the full scale rapid crack propagation test as per
ISO 13478. High density Polyethylene (HDPE) used for the manufacture of
pipes shall conform to designation PEEWA-45-T-006 of IS 7328. HDPE
conforming to designation PEEWA-45- T-012 of IS 7328 may also be used with
the exception that melt flow rate (MFR) shall not exceed 1.10 g/10 min. In
addition, the material shall also conform to clause 5.6.2 of IS 7328.
VOLUME-II Page 24
The specified base density shall be between 941.0kg/ m³ and 946.0kg/ m³ (both
inclusive) when determined at 27°C according to procedure prescribed in
IS:7328 .The value of the density shall also not differ from the nominal value by
more than 3 kg/ m³ as per 5.2.1.1 of IS: 7328. The MFR of the material shall be
between 0.41 and 1.10 (both inclusive) when tested at 190°C with nominal load
of 5 kgf as determined by method prescribed in IS 2530. The MFR of the
material shall also be within ± 20 percent of the value declared by the
manufacturer.
The resin shall be compounded with carbon black. The carbon black content in
the material shall be within 2.5 ±0.5% and the dispersion of carbon black shall
be satisfactory when tested as per IS 2530.
2.2.8Anti-oxidant
The percentage of anti-oxidant used shall not be more than 0.3 percent by mass
of finished resin. The anti-oxidant used shall be physiologically harm less and
shall be selected from the list given in IS: 10141.
2.2.9Reworked Material
No addition of Reworked/ Recycled Material from the manufacturer‘s own
rework material resulting from the manufacture of pipes is permissible and the
vendor is required to use only 100% virgin resin compound.
2.2.10Maximum Quality of Pipe

The outside diameter of pipes, tolerance on the same and quality of pipe shall
be as given in table 2 of IS 4984. Quality shall be measured as the difference
between maximum outside diameter and minimum outside diameter
measured at the same cross section of the pipe, at 300 mm away from the cut
end. For pipes to be coiled, the quality shall be measured prior to coiling. For
coiled pipes, however, re-rounding of pipes shall be carried out prior to the
measurement of quality.
2.2.11Wall Thickness
The minimum & maximum wall thickness of pipe for the three grades of
materials, namely PE63, PE80, and PE100 shall be as given in table 3, 4, & 5
respectively in IS:4984.
2.2.12Length of Straight Pipe

The length of straight pipe used shall be more than 6 m or as agreed by
engineer in charge. Short lengths of 3 meter (minimum) up to a maximum of
10% of the total supply may be permitted.
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2.2.13CoIling
The pipes supplied in coils shall be coiled on drums of minimum diameter of
25 times the nominal diameter of the pipe ensuring that kinking of pipe is
prevented. Pipe beyond 110mm dia shall be supplied in straight length not less
than 6m.
2.2.14Workmanship / Appearance
Pipes shall be free from all defect including indentations, delaminating,
bubbles, pinholes, cracks, pits, blisters, foreign inclusions that due to their
nature degree or extent detrimentally affect the strength and serviceability of
the pipe. The pipe shall be as uniform as commercially practicable in colour
opacity, density and other physical properties as per relevant IS Code or
equivalent International Code. The inside surface of each pipe shall be free of
scouring, cavities, bulges, dents, ridges and other defects that result in a
variation of inside diameter from that obtained on adjacent unaffected portions
of the surface. The pipe ends shall be cut clearly and square to the axis of the
pipe.
2.2.15Handling, Transportation Storage and Lowering of pipes

During handling, transportation, storage and lowering, all sections shall be
handled by such means and in such a manner that no distortion or damage is
done to the section or to the pipes as a whole.
The following procedures should be followed so as to eliminate potential
damage to pipes and fittings and to maintain maximum safety during
unloading, lifting and lowering.
• Pipes must not be stored or transported where they are exposed to heat
sources exceeding 60oC.
• Pipes shall be stored sothat they are not in contact with direct sunlight,
lubricating or hydraulic oils, petrol, solvents and other aggressive
materials.
• Scores or scratches to a depth of greater than 10% or more of wall thickness
are not permissible; any pipes having such defects should be strictly
rejected.
• PE pipes should not be subjected to rough handling during loading and
unloading operations. Rollers shall be used to move, drag the pipes across
any surface.
• Only polyester webbing slings should be used to lift heavy PE (>315mm)
pipes by crane. Under no circumstances, chains, wire ropes and hooks be
used on PE pipes.
• Pipes shall not be dropped to avoid impact or bump. If any time during
handling or during installation, any damage, such as gouge, crack or
fracture occurs, the pipe shall be repaired if so permitted by the engineer in
charge before installation.
VOLUME-II Page 26
• During coiling, care should be taken to maintain the coil diameter at or

above the specified minimum to prevent kinks. Coiling shall be done when
the pipe attains the ambient temperature from the extruder. In uncoiling or
recoiling care should be taken so that sharp objects do not scour the pipe.
• When releasing coils, it must be remembered that the coil is under tension
and must be released in a controlled manner. The end of the coil should be
retained at all times, then the straps released steadily, one at a time. If the
coil has bands at different layers of the coil, then they should be released
sequentially starting from the outer layers. The amount of the energy
locked up in the coil will depend on the size of the pipe, the SDR of the
pipe, and the size of the coil.
• Straight lengths should be stored on horizontal racks giving continuous
support to prevent the pipe taking on a permanent set
• Bare coils shall be wrapped with hessian cloth for long distance (> 300Kms)
transportation. The truck used for transportation of the PE pipes shall be
exclusively used of PE pipes only with no other material loaded –
especially no metallic, glass and wooden items. The truck shall not have
sharp edges that can damage the Pipe.
• Pipes manufactured at factory are to be carried to the site of work directly
or stacked suitably and neatly along the alignment/road side/elsewhere
near by the work site or as directed by the Engineer.
• Damages during transit, handling, storage will be on the Contractor‘s
account and replacement for such pipes has to be made by the Contractor
without any extra cost as directed by the Engineer.
2.2.16 Lowering, Laying of Pipes

• Each pipe shall be thoroughly checked for any damages before laying and
only the pipes which are approved by the Engineer, shall be laid.
• While installing the pipes in trenches, the bed of the trench should be level
and free from sharp edged stones. In most cases, the bedding is not
required, as long as the sharp and protruding stones are removed, by
sieving the dug earth, before using the same as backfill material. While
laying in rocky areas, suitable bed of sand or gravel should be provided.
The filling of about 10 to 15 cm above the pipe should be with fine sand or
screened excavated material. Where hard rock is met with, bed concrete of
M15 or15 cm /20cm thick sand bed as approved by the engineer may be
provided
• As PE pipes are flexible, long lengths of fusion-jointed pipes having joints
made above ground, can be rolled or snaked into narrow trenches. Such
trenches can be excavated by narrow buckets.
• During the pipe laying of continuous fusion jointed systems, due care and
allowance should be made for the movements likely to occur due to the
thermal expansion/contraction of the material. This effect is most
pronounced at end connections to fixed positions (such as valves etc) and
at branch connections.
VOLUME-II Page 27
• Care should be taken in fixing by finishing the connections at a time the

length of the pipe is minimal (lower temperature times of the day.)
• For summer time installations with two fixed connection points, a slightly
longer length of PE pipe may be required to compensate for contraction of
the pipe in the cooler trench bottom.
• The final tie-in connections should be deferred until the thermal stability of
the pipeline is achieved.
• The flexibility of polyethylene pipes allows the pipe to be cold bend. The
fusion jointed PE pipe is also flexible as the plain Pipe. Thus the total
system enables directional changes within the trench without recourse to
the provision of special bends or anchor blocks. However, the pipe should
not be cold bend to a radius less than 25 times the OD of the pipe.
• The Installation of flanged fittings such as connections to sluice/air/gate
valves and hydrant tees etc., requires the use of stub ends (collars/flange
adaptors complete with backing rings and gaskets. Care should be taken
when tightening these flanges to provide even and balance torque.
• Provision should be made at all heavy fittings installation points for
supports (such as anchoring of the flange in the soil) for the flange joint to
avoid the transfer of valve wheel turning torque on to the PE flange joint.
• PE pipe is lighter than water. Hence care should be taken for normal
installations where there could be a possibility of flooding of the trench
thus the trench shall be kept free of water till the jointing has been properly
done
• When flooded, some soils may lose cohesiveness, which may allow the PE
pipe to float out of the ground. Several design checks are necessary to see if
groundwater flotation may be a concern. Obviously, if the pipeline
typically runs full or nearly full of liquid, or if groundwater is always
below the pipe, flotation may not be a significant concern. However,
weights by way of concrete blocks (anchors) are to be provided so that the
PE pipe does not float when suddenly the trench is flooded and the soil
surrounding the pipe is washed away. Thus site conditions study is
necessary to ensure the avoidance of flotation.
• Pipe embedment backfill shall be with stone-free excavated material placed
and compacted to the 95% maximum dry density.
2.2.17 Jointing of Pipes

•The pipe shall have a jointing system that shall provide for fluid tightness
for the intended service conditions. Appropriate jointing for HDPE pipe as
per IS :4984 shall be selected considering site and working condition,
pressure and flow of liquids
2.2.18Bedding, Backfilling and Compaction
Bedding
In case of sandy strata, no separate bedding is required. However the bottom face /
trench bed where pipe shall be placed shall be compacted to provide a minimum
compaction corresponding to 95% of maximum dry density. The pipe bedding
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should be placed so as to give complete contact between the bottom of the trench
and the pipe.
BACK FILLING
Backfilling should be placed in layers not exceeding 15cm thickness per layer, and
should be compacted to a minimum of 95% maximum dry density. The refilling
should be done on both sides of pipe together & height difference in earth fill on
each side should not be more to cause lateral movement of pipe.
Most of the coarse grained soil comprising of gravel or sand are acceptable.
However silty sand, clayey sand, silty and clayey gravel shall not be used unless
proposed to be used in conjunction with gravel or clean sand.
It is very important that the pipe zone backfill material does not wash away or
migrate in to the native soil. Likewise, potential migration of the native soil in to the
pipe zone backfill must also be prevented.
Heavy earth moving equipment used for backfilling should not be brought until the
minimum cover over the pipe is 90 cm in the case of wide tracked bulldozers or 120
cm in the case of wheeled roaders or roller compactors.
Compaction
Vibratory methods should be used for compaction. Compaction within distances of
15 cm to 45 cm from the pipe should be usually done with hand tempers. The
backfill material should be compacted not less than 95% of maximum dry density.
2.2.19Fittings & Specials

INJECTION MOULDED HDPE FITTINGS SHALL BE AS PER IS: 8008 (PART I TO IX). ALL
FITTINGS/SPECIALS SHALL BE MANUFACTURED BY INJECTION MOULDING AT FACTORY
ONLY. GENERAL REQUIREMENT OF INJECTION MOULDED HDPE FITTINGS CONFORMING TO
IS: 8008 PART I.
2.2.20Bends
HDPE bends shall be conforming to IS: 8008 Part II Specifications.
2.2.21Tees
HDPE Tees shall be conforming to IS: 8008 Part III Specifications.
2.2.22Reducers
HDPE Reducers shall be conforming to IS: 8008 Part IV Specifications.
2.2.23Flanged HDPE Pipe Ends
HDPE Stub ends shall be square ended conforming to IS: 8008 Part I & VI
Specifications. Stub ends will be welded on the pipe. Flange will be of slip on flange
type as described below:
2.2.24Slip-On Flanges
Slip-on flanges shall be metallic flanges covered by epoxy coating or plastic powder
coating. Slip-on-flanges shall be conforming to standard mating relevant flange of
valves, pipes etc. Nominal pressure rating of flanges will be PN10.
VOLUME-II Page 29
2.2.25Welding Procedure
Jointing between HDPE pipes and specials shall be done as per the latest IS: 7634
part II. Method of jointing between the pipes to pipes and pipes to specials shall be
with fusion welding using automatic or semi automatic, hydraulically operated,
superior quality fusion machines which will ensure good quality fusion welding of
HDPE pipes. If approved by the concerned Engineer, jointing with PP compression
fittings may be carried out for smaller diameters of PE pipes (up to 110mm).
2.2.26Tests to Establish Portability of Work

Pipe specimen shall be subjected to tests specified below in order to establish the
suitability of these pipes for use in carrying potable water:
I) Smell of the extract
II) Clarity of the colour of the extract
III) Acidity and alkality
IV) Global migration UV absorbing material Heavy metals
V) Un-reacted monomers (styrens) and Biological tests
2.2.27Hydraulic Testing
Pipes shall be given different hydraulic tests for ensuring quality of manufacture as
per clause 16.9.5.6.2 of this specification.
2.2.28Measurement
The net length of pipes as laid or fixed shall be measured in running meters correct
to a cm. Specials shall be excluded. No payment will be made for special as specials
payment included in pipe line.
2.2.29Rate
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 clause
Measurements‘, which shall be paid for separately.
VOLUME-II Page 30
2.3PIPE LAYING - GENERAL
Pipe shall be laid below ground level unless specified otherwise; the pipeline
shall be buried with minimum cover of 1.0 meter at top, as shown on tender
drawing. No material shall be installed unless approved by the engineer.
Pipes laid above ground on pedestals shall in general have minimum clear
height of 45 cm between the pipe invert and ground level. No HDPE pipes
shall be laid above ground level.
2.3.1Transportation /Storage of Pipes and Specials
The Contractor shall transport the pipes and other materials from
manufacturer to the site stores and from the site stores to the site of laying as
per the instructions given by the engineer-in charge. Pipes should be handled
with care to avoid damage to the surface and the socket and spigot ends,
deformation or bending. Pipes shall not be dragged along the ground or the
loading bed of a vehicle. Pipes shall be transported on flat bed
vehicles/trailers. The bed shall be smooth and free from any sharp objects.
The pipes shall rest uniformly on the vehicle bed in their entire length during
transportation. Pipes shall be loaded and unloaded manually or by suitable
mechanical means without causing any damage to the stacked pipes.
Transportation and handling of pipes shall be made as per IS 12288 for DI
pipes. All precautions set out shall be taken to prevent damage to the
protective coating and jointing surfaces or the ends of the pipes.
Whatever method and means of transportation is used, it is essential that the
pipes are carefully placed and firmly secured against uncontrolled movement
during transportation to the satisfaction of Engineer in Charge.
Damage to the lining must be repaired as per relevant IS code before pipe
laying. Laying shall be according to the instructions of the pipe manufacturer
after approval of EIC. Pipes shall not be thrown directly to the ground or
inside the trench.
When using mechanical handling equipment, it is necessary to employ
sufficient personnel to carry out the operation efficiently with safety. The
pipes shall be lifted smoothly without any jerking motion and pipe
movement shall be controlled by the use of guide ropes in order to prevent
damage caused by pipes bumping together or against surrounding objects.
Rolling or dragging pipes along the ground or over other pipes already
stacked shall be avoided.
Pipes shall be given adequate support at all times. Pipes shall be stored on a
reasonably flat surface free of stones and sharp projections so that the pipe is
supported throughout its length. During storage, pipe racks shall provide
continuous support and sharp corners of metal racks should be avoided.
Pipes shall not be stacked in a large piles of storage. Socket and Spigot ends of
VOLUME-II Page 31
the pipes shall be stacked in layers with sockets ends placed in an alternate of
the stack to avoid lop sided stacks.
The Contractor shall provide proper and adequate storage facility to protect
all the materials and equipment against damage from any cause whatsoever
and in case of any such damage /theft, the Contractor shall be held
responsible.
The Contractor shall lay the pipes along the alignments as per the approved
L-sections and layout. The layout shall include available information of
regarding existing services like water lines, sewer lines, telephone and electric
lines/cables. In the event some services fall in the alignment of lines to be
laid, the contractor shall have to shift the alignment or such services. The
contractor shall take all due care to avoid damage to any such services and in
case of any damage occurring to them in progressing the work, the contractor
shall make good the same at his own cost. No additional time and payment
shall be allowed on this account.
Rubber rings shall be handled and stored in their original packing, protected
against sunlight and contacts with petroleum products, solvents and paints.
The contractor shall provide suitable lifting equipment for loading, unloading
and laying of the pipes.
2.3.2Earth Work for Pipelines
2.3.2.1 General
The Contractor shall furnish all tools, plant, instruments, qualified
supervisory personnel, labour, materials, any temporary works, consumables,
any and everything necessary, whether or not such items are specifically
stated herein for completion of the work in accordance with the Employer’s
Requirements.
The Contractor shall survey the site before excavation and set out all lines and
establish levels for various works such as grading, basement, foundations,
plinth filling, roads, drains, cable trenches, pipelines etc.
The excavation shall be carried out to correct lines and levels. This shall also
include, where required, proper shoring to maintain excavations and also the
furnishing, erecting and maintaining of substantial barricades around
excavated areas and warning lamps at night.
Excavated material shall be dumped in low lying land, regular heaps, bunds,
riprap with regular slopes within the lead specified and levelling the same so
as to provide natural drainage to avoid formation of any puddle of water near
pipe alignment. Rock/soil excavated shall be stacked properly as approved
by the Engineer in Charge. As a rule, all softer materials shall be laid along
the center of heaps, the harder and more weather resisting materials forming
the casing on the sides and the top. Rocks shall be stacked separately.
Topsoil shall be stock piled separately for later re-use.
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2.3.2.2 Clearing
The area to be excavated/filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter.
If any roots or stumps of trees are encountered during excavation, they shall
also be removed. The material so removed shall be disposed off as approved
by the Engineer in Charge. Where earth fill is intended, the area shall be
stripped of all loose/ soft patches, top soil containing objectionable matter/
materials before filling commences.
2.3.2.3 Excavation
Excavation shall be taken out to such widths, lengths, depths and profiles as
are shown on the approved L-section or such other lines and grades as may
be agreed with the Engineer in Charge. Rough excavation shall be carried out
to a depth of 150mm above the final level. The balance shall be excavated
with special care.
Soft pockets shall be removed below the final level and extra excavation filled
up with lean concrete as approved by the Engineer in Charge. The final
excavation should be carried out just prior to laying the blinding course.
To facilitate permanent works, the Contractor may excavate, and also backfill
later, outside the lines shown on the drawings provided by the Contractor as
agreed with the Engineer in Charge. Should any excavation be taken below
the specified elevations, the Contractor shall fill it up with concrete of the
same class as in the foundation resting thereon, up to the required elevation
without extra cost to the Employer.
All excavations shall be to the minimum dimensions required for safety and
ease of working. Prior approval of the Engineer in Charge shall be obtained
by the Contractor in each proposed method of excavation, including
dimensions, side slopes, dewatering, disposal, etc. This approval shall not in
any way relieve the Contractor of his responsibility for any consequent loss or
damage. The excavation must be carried out in the most expeditious and
efficient manner. Side slopes shall be as steep as will stand safely for the
actual soil conditions encountered. Every precaution shall be taken to prevent
slips. Should slips occur, the slipped material shall be removed and the slope
need to be dressed to a modified stable slope.
2.3.2.4 Excavations for Laying pipe along the road
While laying pipeline below ground level along the road side, the Contractor
shall note the following:
➢The Contractor shall not take earth materials from the burrow pits excavate
if excavation required to take additional earth materials results in side
slopes steeper than 1:1 in clay dominating soil and 1:1.5 in case of silty
sand or sandy soils.
➢If invert of pipe is kept above the existing burrow pit level or part of pipe is
above it, the minimum side slopes of 1:1 in clay dominating soil and
1:1.5 in case of silty sand or sandy soils shall be provided on the side
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towards the burrow pit area so as to provide required cover. The side
slopes shall be properly compacted upto 90% of modified Procter
density.
➢If earth material is taken for providing required cover to pipe from the
burrow pits, the burrow pits shall be so graded upto the nearest drain
so that no impounding of water occurs in burrow pit area.
➢If the pipeline is laid just near the road section, as far as practical minimum
cover of 1.0 m shall be ensured. Whenever this requirement of cover
cannot be ensured, concrete casing of deigned thickness shall be
provided.
2.3.2.5 Excavation by the Use of Explosives
Unless otherwise stated herein, Specification of “IS:4081: Safety Code for
Blasting and related Drilling Operations” shall be followed. As far as possible
all blasting shall be completed prior to commencement of construction. At all
stages of excavation, precautions shall be taken to preserve the rock below
and beyond the lines specified for the excavation, in the soundest possible
condition. The quantity and strength of explosives used, shall neither damage
nor crack the rock outside the limits of excavation. All precautions, as
directed by Engineer in Charge, shall be taken during the blasting operations
and care shall be taken that no damage is caused to adjoining buildings or
structures as a result of blasting operations. In case of damage to permanent
or temporary structures, the Contractor shall repair the same to the
satisfaction of Engineer in Charge at his own cost. As excavation approaches
its final lines and levels, the depth of the charge holes and amount of
explosives used shall be progressively and suitably reduced.
The Contractor shall obtain a valid Blasting License from the concerned
Authorities. No explosives shall be brought near the work in excess of
quantity required for a particular section of blasting to be done; and surplus
left after blasting shall be removed to a magazine. As much as possible, the
magazine shall be built at far distant location from the area to be blasted.
Engineer in Charge’s prior approval shall be taken for the proposed location
of the magazine.
In no case blasting shall be allowed within 30 metres to any structure or
locations where concrete has just been placed. In the latter case, the concrete
shall be casted at least before 7 days.
For blasting operations, the following points shall be considered.
i) Contractor shall employ a competent and experienced supervisor
and licensed blaster in-charge of each set of operations, who shall be
held personally responsible to ensure that all safety regulations are
carried out.
ii) Before any blasting is carried out, the Contractor shall obtain written
approval of Engineer in Charge for such operations. In his request of
approval, the Contractor shall include the hours of blasting, the
VOLUME-II Page 34
nature of explosive to be used and the precautions taken for

ensuring safety.
iii) Contractor shall ensure that all workmen and the personnel at site
are excluded from an area within 200 m radius from blasting point,
at least 15 minutes before blasting time by sounding warning
whistle. The area shall also be given a warning by sounding a
distinguishing whistle.
iv) The blasting of rock near any existing buildings, equipment or any
other property shall be done under cover and Contractor shall make
all such necessary muffling arrangements. Covering may preferably
be done by MS plates with adequate dead weight over them.
Blasting shall be done with small charges only and where directed
by Engineer in Charge, a trench shall be cut by chiseling prior to
blasting operation, separating the area under blasting from the
existing structures.
v) Blasting shall be supervised by a Supervisor and not more than 6
(six) holes at a time shall be set off successively. If the blasts do not
tally with the number blasted, the non-blasted holes shall be
carefully located after half an hour and when located, shall be
exploded by drilling a fresh hole along the non-blasted hole (but not
closer than 600 mm from it) and by exploding a new charge.
vi) A wooden tamping rod with a flat end shall be used to push
cartridges home and metal rod or hammer shall not be permitted.
The charges shall be placed firmly into place and not rammed or
pounded. After a hole is filled to the required depth, the balance of
the hole shall be filled with stemming which may consist of sand or
stone dust or similar inert material.
vii) Contractor preferably detonate the explosives electrically.
viii) The explosives shall be exploded by means of a primer which shall
be blasted by detonating a fuse instantaneous detonator (F.I.D) or
other approved cables. The detonators with F.I.D. shall be connected
by special nippers.
ix) In dry weather and normal dry excavation, ordinary low explosive
gunpowder may be used. In damp rock, high explosive like gelatin
with detonator and fuse wire may be used. Underwater or for
excavation in rock with substantial accumulated seepage, electric
detonation shall be used.
x) Holes for charging explosives shall be drilled with pneumatic drills.
The drilling pattern being so planned that rock pieces after blasting
will be suitable for handling without secondary blasting.
xi) When excavation has almost reached the desired level, hand
trimming shall be done for dressing the surface to the desired level.
Any rock excavation beyond an over break limit of 75 mm shall be
filled up as instructed by Engineer in Charge, with concrete of grade
VOLUME-II Page 35
not less than M10. Finishing level of rock excavation shall be done
by hand trimming.
xii) Contractor shall be responsible for any accident to workmen, public
or Employer’s property due to blasting operations. Contractor shall
also be responsible for strict observance of rules, laid by Inspector of
explosives, or any other Authority duly constituted under the State
and / or Union Government as applicable at the place of excavation.
2.3.2.6Stripping Loose Rock
All loose boulders, detached rocks partially and other loose material which
might move therewith not directly in the excavation but so close to the area to
be excavated as to be liable, in the opinion of Engineer in Charge, to fall or
otherwise endanger the workmen, equipment, or the work shall be stripped
off and removed from the area of the excavation. Overall the use of
explosives for rock excavation shall ensure not to render unstable or unsafe
the rocks or structures, which was originally sound and safe.
Any material not requiring removal in order to complete the permanent
works, but which, in the opinion of Engineer in Charge, is likely to become
loose or unstable later, shall also be promptly and satisfactorily removed.
2.3.2.7Timber Shoring
Wherever required close timbering shall be done by completely covering the
sides of the trenches and pits generally with short, upright members called
'polling boards'. These shall be of minimum 25 cm x 4 cm sections or as
approved by the Engineer in Charge. The boards shall generally be placed in
position vertically side by side without any gap on each side of the excavation
and shall be secured by horizontal walling of strong wood at maximum of 1.2
metre spacing, strutted with ballies or as approved by the Engineer in Charge.
The length of the ballie struts shall depend on the width of the trench or pit. If
the soil is very soft and loose, the boards shall be placed horizontally against
each side of the excavation and supported by vertical walling, which in turn
shall be suitably strutted. The lowest boards supporting the sides shall be
taken into the ground and no portion of the vertical side of the trench or pit
shall remain exposed, so as to render the earth liable to slip out.
Timber shoring shall be 'close' or 'open' type, depending on the nature of soil
and the depth of pit or trench. The type of timbering shall be as approved by
the Engineer in Charge. It shall be the responsibility of the Contractor to take
all necessary steps to prevent the sides of excavations, trenches, pits, etc. from
collapsing.
Timber shoring may also be required to keep the sides of excavations vertical
to ensure safety of adjoining structures or to limit the slope of excavations, or
due to space restrictions or for other reasons. Such shoring shall be carried
out, except in an emergency, only under instructions from the Engineer in
Charge.
The withdrawal of the timber shall be done carefully to prevent the collapse
of the pit or trench. It shall be started at one end and proceeded with,
VOLUME-II Page 36
systematically to the other end. Concrete or masonry shall not be damaged

during the removal of the timber.
In the case of open timbering, the entire surface of the side of trench or pit is
not required to be covered. The vertical boards of minimum 25 cm x 4 cm
sections shall be spaced sufficiently apart to leave unsupported strips of
maximum 50 cm average width. The detailed arrangement, sizes of the timber
and the spacing shall be subject to the approval of the Engineer in Charge. In
case of large pits and open excavations, where shoring is required for
securing safety of adjoining structures or for any other reasons and where the
planking across sides of excavations/pits cannot be strutted against, suitable
inclined struts supported on the excavated bed shall be provided. The load
from such struts shall be suitably distributed on the bed to ensure non-
yielding of the strut.
2.3.2.8Dewatering
The Contractor shall ensure that the excavations/trenches are free from water
during excavation and laying and shall take all necessary precautions and
measures to exclude ground/rain water so as to enable the works to be
carried out in reasonably dry conditions in accordance with the construction
programme. Sumps made for dewatering must be kept clear of the
excavations/trenches required for further work. The method of pumping
shall be approved by Engineer in Charge, but in any case, the pumping
arrangement shall not make movement of subsoil or blowing in due to
differential head of water during pumping. Pumping arrangements shall be
adequate to ensure no delays in construction. The dewatering shall be
continued for at least (7) seven days after the last pour of the concrete. The
Contractor shall, however, ensure that no damage to the structure results on
stopping of dewatering.
The Contractor shall study the sub-soil conditions carefully and shall conduct
any tests necessary at the site with the approval of the Engineer in Charge to
test the permeability and drainage conditions of the sub-soil for excavation,
concreting etc., below ground level.
The method of dewatering and disposal of water shall be approved by the
Engineer in Charge. The Contractor shall suitably divert or drain the
dewatered water from such areas of work where a build-up of water in the
opinion of the Engineer in Charge obstructs the progress of the work and
leads to retards the progress of construction. Management of dewatered
water is detrimental to the safety of men, materials, structures, equipment
and avoiding the unsanitary conditions that will occur by stagnation.
When there is a continuous inflow of water and the quantum of water to be
handled is considered in the opinion of Engineer in Charge, to be large, a well
point system- single stage or multistage, shall be adopted. The Contractor
shall submit to the Engineer in Charge, details of his well point system
including the stages, the spacing, number and diameter of well points,
headers etc., and the number, capacity and location of pumps for approval.
VOLUME-II Page 37
2.3.2.9Rain Water Drainage

Grading in the vicinity of excavation shall be such as to exclude rain/ surface
water draining into excavated areas. Excavation shall be kept clean of rain
and such water as the Contractor may be using for his work by suitably
pumping out the same. The method of pumping and discharging of such
water shall be approved by the Engineer in Charge.
2.3.2.10Bench mark
Before starting works in any section of the works, the Contractor shall fix
permanent benchmarks, at least four in every Kilometer. These benchmarks
shall be fixed away from the field of work so as not to be disturbed during the
execution and shall be securely fixed in concrete.
2.3.2.11Fencing, Watching and Lightening
The posts of the fencing shall be of timber, securely fixed in the ground not
more than 2.5 m. apart. They shall not be less than 10 cm in dia. or not less
than 1.25 m above the surface of ground. There shall be two rails, one near the
top of the posts and the other about 0.5 m above the ground and each shall be
of 5 cm to 10 cm in dia. and sufficiently long to run from post to post which
they shall be bound with strong ropes. The method, of projecting rails beyond
the posts and tying together where they meet will not be allowed on any
account. All along the edges of the excavated trenches, a bund of earth about
one metre high shall be formed where so required by the Engineer-in-Charge
for further protection. Proper provision shall be made for lighting at night
and watchman shall be kept to see that this is properly done and maintained.
In addition to the normal lighting arrangements, the Contractor shall provide
wherever such work is in progress, battery operated blinking light (6 volts) in
the beginning and end of a trench with a view to provide suitable indication
to the vehicular traffic. The contractor shall provide and display special
boards printed with fluorescent paints indicating the progress of the work
along the road. The Contractor shall be held responsible for payment of all
claims for compensation as a result of accident or injury to any person or
property due to improper fencing, inadequate lighting or non-provision of
red flags. The Contractor shall at his own cost provide all notice boards before
opening of roads as directed by the Engineer-in-Charge. The Contractor shall
make arrangements to direct traffic whenever work in through fare is in
progress.
2.3.3Pipe Laying Below ground
2.3.3.1 Trench excavation
The earth work shall be carried out as specified above.
Before excavating the trench the alignment of pipeline and L-section shall be
approved by Engineer-in-charge. The work of trench excavation shall be
commensurate with laying and jointing of the pipelines. It should not be
excavated in advance for a length greater than 3 days ahead of work of laying
VOLUME-II Page 38
and jointing of pipeline unless and otherwise directed by the Engineer in

charge. It is proposed to ensure the following:-
➢ Safety precautions have to be incorporated in the work progress,
➢ Inconvenience to the public shall be minimized,
➢ The trench shall not be allowed to erode,
➢ The trench must not be filled with water,
➢ The trench must not be refilled before laying of the pipes,
➢ The bed for the laying of the pipes has to be prepared according to the L-
section immediately before laying of the pipes.
The trench excavation of pipeline shall be in accordance with relevant
standards. Pipe trenches shall be excavated to the lines and levels shown on
the drawings and as directed by the Engineer. The depth of the excavated
trench shall be as given in the drawings and directed by the Engineer. The
trench shall be of adequate width to allow the burial of pipe, while being as
narrow as practical. For HDPE pipes, the width of trench shall provide a
clearance of 150mm on either of the pipe as per IS 7634 (Part 2):2012 for both
supported and unsupported trenches. For DI pipes, the width of the trench at
bottom between the 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.
No pipe shall be laid in a trench until the section of trench in which the pipe is
to be laid has been approved by the Engineer.
The depth should be sufficient to provide a cover not less than 1000 mm so
that the pipe line will not interfere with the cultivation of land. It may be
necessary to increase the depth of pipeline to avoid land drains or in the
vicinity of roads, railways or other crossing. Care shall be taken to avoid
spoiling of bank caused by an accumulation of rain water.
The bottom of the trench shall be trimmed and leveled to permit even
bedding of the pipes. It should be free from all extraneous matter, which may
damage the pipe or the pipe coating. Additional excavation shall be made at
the joints of the pipes, so that the pipe is supported along its entire length.
All excavated material shall be stacked in such a distance from the trench
edge that it will not endanger the work or workmen and it will avoid
obstructing footpaths, roads and drive ways. Hydrants under pressure,
surface boxes, fire or other utility controls shall be left unobstructed and
accessible during the construction work. Gutters shall be kept clear or other
satisfactory provisions made for street drainage, and natural water – courses
shall not be obstructed.
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 work and until it is
safe for traffic to use the roadways. All materials, piles equipment and pipes
VOLUME-II Page 39
which may serve as obstruction to traffic shall be enclosed by fences or

barricades and shall be protected by illuminating proper lights when the
visibility is poor.
As far as possible, the pipe line shall be laid below existing services, like
water and gas pipes, cables, cable ducts and drains but not below sewers,
which are usually laid at greater depth. Where it is unavoidable, pipeline
should be suitably protected. A minimum clearance of 150 mm shall be
provided between the pipeline and such other services.
Trees, shrubbery fences, poles, and all other property and surface structures
shall be protected. Tree roots shall be cut within a distance of 50 cm from pipe
joints in order to prevent roots from entering them. 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 provided. The structures, which will be disturbed shall be
restored after completion of the work.
Wherever necessary to prevent caving, trench excavations in soils such as
sand, gravel and sandy soil shall be adequately sheeted and braced. Where
sheeting and bracing are used, the net trench width after sheeting shall not be
less than that specified above. The sides of the excavation shall be adequately
supported at all times and, except where described as permitted under the
Contract, shall not be battered.
The Engineer in co-operation with the Contractor shall decide about the
sheeting / bracing of the trench according to the soil conditions in a particular
stretch and taking into account the safety requirements of the Contractor’s
and Engineer – In – Charge’s staff. Generally, safety measures against caving
have to be provided for trenches with vertical walls if they are deeper than 2.0
m.
2.3.3.2 Bedding of the Pipes
The DI pipeline shall generally be laid in ordinary sandy soil for which no
extra bedding shall be provided. In such case, while doing the excavation, the
bottom of the trench shall be prepared in a manner so as to match the
curvature of the pipe as far as possible subtending an angle of about 120o at
the center of pipe. Wherever the bottom of the trench is of such a nature (i.e.
any type of rock / hard soil/ boulder) which is likely in the opinion of the
Engineer-in-Charge to cause damage to the pipe or coating or an unsuitable
material is encountered which cannot support the pipe, the Contractor shall
excavate the trench to an additional depth below the required depth and shall
refill to required level with suitable material such as loose soil/ sand, to be
approved by the Engineer-in-Charge. The bedding thickness shall be not less
than 15 cm under the barrel of the pipes. The complete pipe has to be covered
and surrounded by the same material as used for bedding so that a total cover
VOLUME-II Page 40
of 30cm above the barrel can be achieved. The excavated hard/dense soil can
be refilled after bedding and covering of the pipe with the loose soil/sand.
The bedding shall be compacted with a light hand rammer. Adding sand
during ramming shall make up any reduction in thickness due to compaction.
During the work of providing sand bedding and laying the pipeline, loose
material from the sides or edges of the trench shall be prevented from falling
inside the trench, by providing shoring and taking other measures. Also
where necessary, trench shall be kept dry by pumping out seepage water
continuously.
For HDPE pipes, bedding shall generally be done as per IS 7634 (Part 2):2012.
No special bed preparation will be required 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. Any large rocks, hard pan, or stones larger than 20 mm
should be removed and 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.
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.
2.3.3.3 Stringing of pipes along the alignment
The pipes shall be laid out properly along the proposed alignment in a
manner that they do not create any significant hindrance to the public and
that they are not damaged.
Stringing of the pipes end to end along the working width should be done in
such a manner that least interference is caused in the land crossed. Gaps
should be left at intervals to permit the passing of equipment across the
working area. Pipes shall be laid out that they remain safe where placed and
that no damage can occur to the pipes and the coating until incorporated in
the pipeline. If necessary, pipes shall be wedged to prevent accidental
movement. Precautions shall be made to prevent entrance of soil, mud etc. in
the pipe.
Generally, the pipes shall be laid within two weeks from the date of their
dispatch from the manufacturer / store.
2.3.3.4 Lowering and Jointing pipes
The laying of DI pipes shall be as per IS 12288 ; however the specific
references given herein shall prevail on the provisions of the standards.
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Pipes should be lowered into the trench with tackle suitable for the weight of
pipes. For smaller sizes, up to 200mm nominal bore, the pipe may be lowered
by the use of ropes but for heavier pipes, suitable mechanical equipment have
to used.
The pipes shall be cleaned in the whole length with special care of the spigot
and sockets ends on the inside / outside to ensure that they are free from dirt
and unwarranted projections. The whole of the pipes shall be placed in
position singly and shall be laid true to profile and direction of slope
indicated on longitudinal sections. The pipes shall be laid without deflection
in a straight alignment between bends and between high and low points.
Vertical and horizontal deflections between individual pipes need the
approval of the Engineer. In no case the deflection shall be more than 75% of
those recommended by the manufacturer.
Before pipes are jointed they shall be thoroughly cleaned of all earth lumps,
stones, or any other objects that may have entered the interior of the pipes,
particularly the spigot end and the socket including the groove for the rubber
ring.
Pipes and the related specials shall be laid according to the instructions of the
manufacturers and using the tools recommended by them.
Cutting of pipes shall be reduced to a minimum required to conform with the
drawings. Cutting shall be made with suitable tools and according to the
recommendations of the manufacturer. The spigot end shall be chamfered
again at the same angle as the original chamfered end. Cutting shall be
perpendicular to the centre line of the pipe. In case of ductile iron pipes the
cut and chamfered end shall be painted with two coats of epoxy paint. If there
is no mark for the insertion depth on the spigot end of the (cut) pipe it shall be
marked again according to the instructions of the manufacturer.
Before pipes are jointed they shall be thoroughly cleaned off all earth lumps,
stones, or any other objects that may have entered the interior of the pipes,
particularly the spigot end and the socket including the groove for the rubber
ring. End caps, if any, shall be removed only just before laying and jointing.
The socket and spigot ends of the pipes shall be brushed and cleaned. The
chamfered surface and the end of the spigot end has to be coated with a
suitable lubricant recommended by the manufacturer of the pipes. Oil,
petroleum bound oils, grease or other material which may damage the rubber
gasket shall not be used as lubricant. The rubber gasket shall be inserted into
the cleaned groove of the socket. It has to be checked for correct positioning.
All specials like bends, tees etc. and appurtenances like sluice or butterfly
valves etc. shall be laid in synchronization with the pipes. The Contractor
VOLUME-II Page 42
shall ensure that the specials and accessories are ready in time to be installed
together with the pipes.
At the end of each working day and whenever work is interrupted for any
period of time, the free ends of laid pipes shall be protected against the entry
of dirt or other foreign matter by means of approved plugs or ends caps.
When pipe laying is not in progress, the open ends of installed pipe shall be
closed by approved means to prevent entrance of trench water and dirt into
the line.
No pipe shall be laid in wet trench conditions that preclude proper bedding,
or when, in the opinion of the Engineer, the trench conditions or the weather
are unsuitable for proper installation.
Where a pipeline crosses a water course, the design and method of
construction should take into account the characteristics of the water course
to ascertain the nature of bed, scour levels, maximum velocities, high flood
levels, seasonal variation, etc. which affect the design and laying of pipeline.
The assembly of the pipes shall be made as recommended by the pipe
manufacturer and using suitable tools.
For DI pipes, two pipes shall be aligned properly in the pipe trench and the
spigot end shall be pushed axially into the socket either manually or with a
suitable tool specially designed for the assembly of pipes and as
recommended by the manufacturer. The spigot has to be inserted up to the
insertion mark on the pipe spigot. After insertion, the correct position of the
socket has to be tested with a feeler blade.
The pipe laid shall be absolutely straight unless planned otherwise. The
accuracy of alignment shall be tested before starting refilling with the help of
stretching a string between two ends of the straight stretch of pipes to rectify
possible small links in laying.
Deflection of the pipes if any shall be made only after they have fully been
assembled.
On gradients of 1:15 or steeper, precautions shall be taken to ensure that the
spigot of the pipe being laid does not move into or out of the socket of the laid
pipe during the jointing operations. As soon as the joint assembly has been
completed, the pipe should be held firmly in position while the trench is back
filled over the barrel of the pipe.
Designed anchorage shall be provided to resist the thrusts developed by
internal pressure at bends, tees, etc.
Precautions against Floatation
VOLUME-II Page 43
When the pipeline laid underground or above ground in a long narrow

cutting gets submerged in water collected in the trench of cutting it is
subjected to an uplift pressure due to buoyancy and is likely to float if
completely or partly empty. In the design of pipelines, provision is to be
made to safeguard against floatation providing sufficient overburden or by
providing sufficient dead weight by means of blocks, etc. Pipe shall be
protected against floatation by providing anchor blocks. Factor of safety for
calculations and checking against floating shall be taken as 1.5.
In the case of works extending over one or more monsoon seasons, however,
special care and precautions are necessary during the progress of work on
this account. The work of providing blocks, refilling the earth to the required
level, compacting the same, etc. shall always be done as soon as the pipeline
in the cutting has been laid.
The Contractor shall ensure that water shall not be allowed to accumulate in
open trenches. Where work is in an incomplete stage, precautionary work,
such as blank-flanging in the open ends of the pipeline and filling the pipeline
with water etc. shall be taken up as directed by the Engineer.
Such works shall be to the Contractor's account and no separate payment
shall be made for the same. The Contractor's rate for pipe laying shall be
deemed to include such precautionary measures against floatation.
Protection of the pipeline against floatation during the Contract Period shall
be the responsibility of the Contractor. Should any section of the pipeline float
due to his negligence, etc. the Contractor shall rectify or lay the pipes again to
the correct line and level at his cost.
2.3.3.5 Fill Materials, Backfilling and Site Grading
a) DI Pipes
Trenches shall be backfilled with approved selected excavated material only

after the successful testing of the pipeline. The tamping around the pipe shall
be done by hand or light vibrating machinery means but not directly above
the pipes. The water content of the soil shall be as near the optimum moisture
content as possible. Filling of the trench shall be carried out simultaneously
on both sides of the pipe in such a manner that unequal pressure does not
occur. Each layer shall be consolidated by watering, ramming and care shall
be taken to avoid damage to the pipeline.
VOLUME-II Page 44
Fill Materials,
General
All fill materials shall be subject to the Engineer in Charge’s approval. If any
material is rejected by Engineer in Charge, the Contractor shall remove the
same forthwith from the site. Surplus fill material shall be deposited and
excess material shall be disposed off as directed by Engineer in Charge after
the fill work is completed.
No earth fill shall commence until surface water discharges and streams have
been properly intercepted or otherwise dealt with to the approval of the
Engineer in Charge.
Material
To the extent available, selected surplus soil from excavations shall be used as
backfill. Backfill material shall be free from lumps, organic or other foreign
material. All lumps of earth shall be broken or removed. Where excavated
material is mostly rock, the boulders shall be broken into pieces not larger
than 150 mm size, mixed with properly graded fine material consisting of
murum or earth to fill the voids and the mixture used for filling.
If fill material is required to be imported, the Contractor shall make
arrangements to bring such material from outside borrow pits. The material
and source shall be subject to prior approval of the Engineer in Charge. The
approved borrow pit areas shall be cleared of all bushes, roots of trees, plants,
rubbish, etc. Topsoil containing foreign material shall be removed. The
materials so removed shall be disposed of as directed by Engineer in Charge.
The Contractor shall provide the necessary access roads to borrow areas and
maintain the same if such roads do not exist.
Sand Filling
Where backfilling is required to be carried out with local sand, it shall be

clean, medium grained and free from impurities. The filled-in-sand shall be
kept flooded with water for 24 hours to ensure maximum consolidation. The
surface of the consolidated sand shall be dressed to required level or slope.
Construction of floors or other structures on sand fill shall not be started until
the Engineer in Charge has inspected and approved the fill.
Refilling of trenches
VOLUME-II Page 45
On completion of the pipe laying operations in any section, for a length of

about 100m and while further work is still in progress, refilling of trenches
shall be started by the Contractor with a view of restricting the length of open
trenches. Pipe laying shall closely follow the progress of Trench Excavation
and the Contractor shall not permit unreasonably excessive lengths of trench
excavation to remain open while awaiting testing of the pipeline. If the
Engineer considers that the Contractor is not complying with any of the
foregoing requirements, he may prohibit further trench excavation until he is
satisfied with the progress of laying and testing of pipes and refilling of
trenches. Only soft earth and murrum of good quality free from stones
boulders, roots, vegetation etc., shall be utilised after the lumps are broken for
filling in around the pipes for atleast 30cm all around for pipes. Filling shall
be done in layers not exceeding 150 mm and compacted to 70 to 80% of max.
dry density percent of the maximum dry density as per part VII of IS:2720.
The excavated material nearest to the trench shall be used first. Care shall be
taken during backfilling, not to damage the coatings or disturb the pipes,
joints, etc. Filling shall be carried out simultaneously on both sides of the
pipes so that unequal pressure does not occur. Walking or working on the
completed pipeline shall not be allowed unless the trench has been filled to
height of at least 30cm over the top of the pipe except as may be necessary for
tamping etc., during backfilling work.
The remaining portion of the trench may be filled in with a mixture of hard
and soft material free from boulders and clods of earth larger than 150mm in
size if sufficient quantity of good earth and murrum are not available. Filling
in shall be done in layers not exceeding 150 mm in thickness accompanied by
adequate, ramming etc., so as to be compacted to 70 to 80% of the maximum
dry density as per part VII of IS:2720. Water contents of the soil shall be as
near the optimum moisture content as possible. The trench shall be refilled so
as to build up to the original ground level, keeping due allowance for
subsequent settlement likely to take place.
The Engineer in Charge shall, at all times, shall decide which portion of the
excavated materials shall be for filling and in which portion of the site and in
what manner it shall be so used.
If any material remains as surplus it shall be disposed of as directed by the
Engineer, which includes loading, unloading, transporting and spreading as
directed within a distance of 1 km. If the Contractor fails to remove the earth
from site within 7 days after the period specified in a written notice, the
Engineer may arrange to carry out such work at the Contractor's risk and cost
VOLUME-II Page 46
or may impose such fine for such omission as he may deem fit. Particular care
shall be taken to keep the trench dry during the entire refilling operation.
No mechanical plant other than approved compacting equipment shall run
over or operate within the trench until backfilling has reached its final level or
the approval of the Engineer has been obtained.
In case of excavation of trenches in rock, the filling upto a level 30 cm above
the top of the pipe shall be done with fine materials such as earth, murum,
etc. The filling up to the level of the centre line of the pipe shall be done by
hand compaction in layers not exceeding 8 cm whereas the filling above the
centre line of the pipe shall be done by hand compaction or approved means
in layers not exceeding 15 cm. The filling from a level 30 cm above the top of
the pipe to the top of the trench shall be done by hand or other approved
mechanical methods with broken rock filling of size not exceeding 15 cm
mixed with fine material as available to fill up the voids.
Filling of the trenches shall be carried out simultaneously on both sides of the
pipe to avoid unequal pressure on the pipe.
Subsidence in filling: Should any subsidence take place either in the filling of
the trenches or near about it during the maintenance period of 12 months
from the completion of the Contract Works, the Contractor shall make good
the same at his own cost or the Engineer may without notice to the
Contractor, make good the same in any way and with any material that he
may think proper, at the expense of the Contractor. The Engineer may also, if
he anticipates occurrence of any subsidence, employ persons to give him
timely notice of the necessity of making good the same, and the expenses on
this account shall be charged to the Contractor.
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:
Zone A:
From the bottom of the Back-filling by hand with sand, fine gravel or
trench to the level of other approved material placed in layers of 150
the centre line of the mm and compacted by tamping. The back-
pipe filling material shall be deposited in the trench
for its full width of each side of the pipe,
specials and appurtenances simultaneously.
Special care shall be taken to avoid damage of
the pipe and the coating or moving of the pipe.
Zone B:
VOLUME-II Page 47
From the level of the Back-filling and compaction shall be done by

centre line of the pipe hand or approved mechanical methods in
to a level 300 mm layers of 150 mm, special care shall be taken to
above the top of the avoid damage of the pipe and the coating or
pipe moving of the pipe.
Zone C:
From a level 300 mm Back-filling shall be done by hand or approved
above the top of the mechanical methods in 15 cm layers after
pipe to the top of the compacting and carried to the level necessary to
trench. allow for the temporary restoration of road and
path surfaces, and also for hard-core (if and
where ordered) on roads or to such level as will
leave the requisite space for the top soil, road
surface etc. to be reinstated as directed by the
Engineer.
In case of agricultural or waste land and after
approval by the Engineer back-filling may be
made in thicker layers and with less compaction
up to 200 – 300 mm above the initial ground
level.
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 IS 12288.
The excavated material may be used for back-fill in the following cases,
provided it complies with IS 12288:
a)In Zone C: In cases where settlement is unimportant back-fill shall be neatly
rounded over the trench to a sufficient height to allow for settlement to
the required level.
b)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 Engineer.
All excavations shall be backfilled to the level of the original ground surfaces
unless otherwise shown on the drawings or ordered by the Engineer, and in
accordance with the requirements of the specification. The material used for
backfill, the amount thereof, and the manner of depositing and compacting
shall be subject to the approval of the Engineer, but the Contractor shall be
VOLUME-II Page 48
responsible for any displacement of pipe or other structures, any damage to

surfaces, or any instability of pipes and structures caused by improper
backfilling of backfill materials.
Trenches shall be backfilled with selected material placed in layers not
exceeding 15 cm in thickness after compacting, wetted and compacted to a
density of not less than 90 percent of the maximum dry density at optimum
moisture content for zone A, zone B and zone C of the surrounding material.
Any deficiency in the quantity of material for backfilling the trenches shall be
supplied by the Contractor at his expense. Water for compaction shall be
arranged by the contractor at his cost.
The Contractor shall at his own expense make good any settlement of the
trench backfill occurring after backfilling and until the expiry of the defects
liability period.
Trenches crossing a road shall be backfilled with selected material placed in
layers not exceeding 15cm in thickness after compacting wetted and
compacted to a density of not less than 90 percent of the maximum dry
density at optimum moisture content of the surrounding material. Any
deficiency in the quantity of material for backfilling the trenches shall be
supplied by the Contractor at his expenses.
On completion of pressure and leakage tests, exposed joints shall be covered
with approved selected backfill placed above the top of the pipe and joints in
accordance with the requirements of the above specifications. The Contractor
shall not use backfilling for disposal of refuse or unsuitable soil.
2.3.3.6Sequence of Works for ensuring good pipe laying
1.The required fittings, valves and jointing material should be carefully
worked out at the beginning. First of all, these materials should be
received in full to the site and stored as pre-directions of manufacturer
or as directions given elsewhere in this specification.
2.The pipes shall be received on site only after the above fittings, valves and
materials for joints have been received and all necessary preparation for
laying has been made.
3.The material received should be checked for inspection certification as per
Contract and damage during transportation. All damaged should be
separated and not used.
4.The pipes received should be stored strictly as per directions of the
manufacturer or as mentioned elsewhere in this manual in this or
standards.
5.The pipes and other material should be again inspected for any damage
before use in the trench.
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6.The fittings and valves should be installed in sequence with the laying of
pipes without leaving any gaps.
7.It is desirable to lay the pipelines from the end from where it can be
connected to the water source to enable regular flushing of laid pipes.
8.The entry of dirt or any foreign material in the pipe should be religiously
prevented.
9.Each joint should be carefully checked for its completeness before covering
up.
10.There should be a commensurate progress in trench excavation, laying and
jointing of pipes, fittings, valves etc and testing of laid pipes in sections
so as to complete testing of all pipes laid in quick follow up of
completing laying and jointing.
2.3.4Pipe laying above ground
The procedure described above for handling, lowering and jointing the pipes
for underground described above shall be followed for lifting, laying and
jointing of pipes on supports or on ground. Subjected to approval of
Engineer, the pipe may rest on ground if the soil is non-aggressive. The
ground should, however, be dressed to match the curvature of the pipe shell
for an arch length subtending an angle of 120° at the centre of pipes.
Alternatively, the pipeline shall be laid either on saddle or roller and rocker
supports as specified by the Engineer.
The Contractor shall design and submit L-section of the pipeline for the
section concerned. The Contractor shall also prepare details of the type of
saddles/concrete pedestals/ring girders to be provided before the actual
work of casting is taken in hand.
Before execution, the Contractor shall submit detailed designs and drawings
and all supports such as portal frames, saddles, ring girders etc for approval
of the EIC.
Pipe laying above ground shall generally start from the fixed or restrained
support on either side and the expansion joints being provided in the last.
Fixed or restrained supports are constructed at all anchor blocks. Where such
blocks are not required for long lengths, fixed supports shall be achieved by
fixing the pipeline to the special type of R.C.C. or steel saddles/ concrete
pedestals as specified above. Usually the distance between successive fixed
supports are about 300m, but shall be designed based on the particularity of
the material and submitted for approval of Engineer. Expansion joints shall
always be provided between two fixed supports or anchorages.
Anchor blocks shall be constructed before commencing the pipe laying work
in any section. The construction of the blocks shall be carried out in 3 stages
VOLUME-II Page 50
in the first stage the lower part upto 150 mm below the invert of the pipeline
including concrete chairs to support it shall be constructed; in the second
stage the pipeline on this part of the block shall be laid; and lastly, the
remaining block around and over the pipeline shall be constructed.
The support saddles/ concrete pedestals and ordinary saddles/ concrete
pedestals shall be cast-at least 3 weeks before the pipeline is laid on them.
After all saddles/ concrete pedestals between successive fixed supports have
been cast, a line plan showing the actual position thereof shall be prepared,
after taking levels and measuring distances. In case of any errors in casting
the pedestals, corrections shall be applied. The pipe laying work shall then
start from the fixed support and shall proceed towards the expansion joints.
The method of jointing the pipes and erecting them on previously cast R.C.C.
saddles/ concrete pedestals shall be determined by the Contractor depending
upon the type of plant equipment.
The pipe strakes shall be jointed in position on the saddles/ concrete
pedestals either by the cranes, portable gantries, shear legs or any other
equipment approved by the Engineer-in-Charge. Normally, not more than
two pipes shall be aligned, tacked and kept in position on temporary
supports. During jointing, the pipeline shall be supported on wooden sleepers
and wedges, with the free end of the pipeline held in position by slings to
avoid deflection due to temperature variations during the day.
2.3.5General Site Grading/Reinstatement

Site grading shall be carried out as approved by the Engineer in Charge.
Filling and compaction shall be carried out as per specifications and
elsewhere unless otherwise indicated below.
If no compaction is called for, the fill may be deposited to the full height in
one operation and levelled. If the fill has to be compacted, it shall be placed in
layers not exceeding 225 mm and levelled uniformly and compacted as
indicated above before the next layer is deposited.
To ensure that the fill has been compacted as specified, field and laboratory
tests shall be carried out by the Contractor.
Field compaction tests shall be carried out in each layer of filling until the fill
to the entire height has been completed. This shall hold good for
embankments as well. The fill will be considered as incomplete if the desired
compaction has not been obtained.
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The Contractor shall protect the earth fill from being washed away by rain or
damaged in any other way. Should any slip occur, the Contractor shall
remove the affected material and make good the slip.
If so specified, the rock as obtained from excavation may be used for filling
and levelling to indicated grades without further breaking. In such an event,
filling shall be done in layers not exceeding 50 cms approximately. After rock
filling to the approximate level, indicated above has been carried out, the void
in the rocks shall be filled with finer materials such as earth, broken stone, etc.
and the area flooded so that the finer materials fill up the voids. Care shall be
taken to ensure that the finer fill material does not get washed out. Over the
layer so filled, a 100 mm thick mixed layer of broken material and earth shall
be laid and consolidation carried out by a 12 ton roller. No less than 12 ton
passes of the roller shall be accepted before subsequent similar operations are
taken up.
2.3.6Damage to Public Utilities
All precautions shall be taken during excavation and laying operations to
guard against possible damage to any existing structure/pipeline of water,
gas, sewage etc. After excavation of trenches, pipe shall not be lowered unless
the dimensions of trenches and bedding for work for pipes at the bottom of
the trenches are approved by Engineer-in-Charge. Pipes and fittings/specials
shall be carefully lowered in the trenches. Special arrangements such as
cranes, tripods with chain pulley block for lowering the pipes and
fittings/specials shall be made by Contractor. In no case pipes and
fittings/specials shall be dropped. The Contractor shall be responsible for any
damages occurring during the laying of pipeline.
2.3.7Reinstatement of Road/ Footpath
Wherever the road is required to be cut, the Contractor shall obtain prior
permissions for road crossing and/or laying pipeline along the road from
concerned Authorities and prepare a negotiable diversion, at his cost, before
taking up road cutting. The Employer shall assist the Contractor in obtaining
such permission by endorsing letter(s) to relevant authorities. The Contractor
shall pay all fee, charges, levies in relation to permission for laying of pipeline
along and across the road, that shall be reimbursed to the Contractor as per
actual against proof of such payment.
After the pipes are laid and the trench refilled to the original level, the traffic
may be allowed to pass through. The road must be properly re-graded and
the damaged portion of road as well as the re-graded portions must be
constructed upto the sub-grade level as per the specifications of the concerned
Authorities. If the rules/guidelines/directions of relevant authorities do not
VOLUME-II Page 52
permit contractor to restore the roads, then the Contractor shall deposit such
road restoration charges to the relevant authorities. The Contractor shall
allow such costs in his bidding and no separate payment is admissible for
road restoration charges.
2.3.8Clearing the Site
All surplus materials, and all tools and temporary structures shall be removed
from the site as directed by Engineer-in-Charge and the construction site left
clean to the satisfaction of Engineer-in-Charge.
2.3.9Protection against scouring of foundation

•Providing pitching:
Wherever the pipeline pedestal or portal foundation are located near a
nallah or across a nallah, the Contractor shall provide a cut-off wall upto
the scour depth all around the footing/ foundation at a distance of 2
times the depth of foundations below the existing ground level. The
portion between the cut-off wall and the foundation shall be filled with
compacted soil and 30cm thick stone pitching shall be done with weight
of stone not less than 40 kg. The minimum section of cut-off wall shall
be of 0.3m in width and minimum 2m in depth. The cut-off wall shall be
of RR masonry in cement mortar 1:4 laid on 1:3:6 Cement concrete mix
minimum 15cm thickness.
•Providing longitudinal walls and cross walls:
Wherever pipe is laid on pedestal across a nallah/drain or in ravines
with drain flowing across the pipe alignment, longitudinal check wall or
curtain wall shall be provided on both sides of the pipe foundations.
The cut-off wall on the upstream side of nallah/drain shall be taken at
least up to 2m depth from the general ground level or up to the scour
depth whichever is more. The downstream side of cut off wall shall be
taken 2.5 m in depth. The area between two walls shall be filled with
compacted soil and a gentle slope shall be provided for drainage of
water in case of minor drain, but a flexible apron shall be provided for
bigger nallah. The minimum width of cut off walls shall be 0.3m. The
wall shall be of RR stone masonry in cement mortar 1:4 and the exposed
top face shall be provided 25mm cement coping in M-15 grade or grade
as per IS 456 concrete. The base course shall be of 1:3:6 mix concrete of
minimum 15 cm thickness.
VOLUME-II Page 53
2.3.10Anchoring of the pipeline

Thrust blocks shall be provided at each bend, tee, taper, end piece to prevent
undue movements of the pipeline under pressure. They shall be constructed
as per actual design and approval of Engineer in Charge according to the
highest pressure during operation or testing of the pipes, the safe bearing
pressure of the surrounding soil and the friction coefficient of the soil.
Nominal steel shall be provided as per the provisions of CPHEEO manual
and the construction of block shall be done in M15 grade of concrete.
2.3.11Documentation
MEASUREMENT AND LOGGING:
The Contractor shall prepare a special logbook detailing all the relevant data
of individual pipe and pipe coating, diameter, length, wall thickness, defects,
pipe number, lot/batch or materials used for each pipe. Sampling and testing
at site test results at manufacturer's plant(s), tests conducted by independent
agency, damages, repairs, rejects and any other information that Engineer-in-
Charge considers to be relevant and required for all incoming bare pipes and
Engineer-in-Charge approved outgoing coated pipes as applicable.
Contractor shall submit this information in the form of a report at the agreed
intervals.
2.3.12Field Hydraulic Test
• The Field Hydrostatic test pressure shall be as described in following
related paras & provisions in the IS codes.
• The working pressure and surge pressure shall be calculated for
ultimate flow i.e. pumping for demand of design year.
• Before start of the testing, the pipe shall be kept filled at low pressures
for minimum 24 hours to allow absorption of water by lining.
• Pressure building shall be gradual.
• The duration of the test shall be 3 hours after attaining full pressure.
• Rebuilding of pressure up to the testing pressure shall be done after
every fall of 10% from the testing pressure.
• Length of a section for testing preferably shall not be more than 1.5 km
and as per directions of EIC.
• Joints shall be kept open during testing. Adequate anchorages shall be
provided to avoid any movement of pipes.
• All the equipment and water required for field hydraulic test of pipeline
shall be arranged by the Contractor for which no additional payment
shall be made.
VOLUME-II Page 54
The contractor shall provide and maintain all requisite facilities, instruments,
for the field testing of the material. All pipes, specials, valves and civil works
shall be replaced by the Contractor free of cost if damaged during testing.
2.3.13Testing of Pipelines
2.3.13.1 Sectional Tests
After laying and jointing, the pipeline shall be tested for tightness of barrels
and joints, and stability of thrust blocks in sections approved by the Engineer
in Charge. The length of the sections depends on the topographical
conditions. Preferably the pipeline stretches to be tested shall be between two
chambers (air valve, scour valve, bifurcation, and other chamber).
The water required for testing shall be arranged by the Contractor himself.
The Contractor shall fill the pipe and compensate the leakage during testing.
The Contractor shall provide and maintain all requisite facilities, instruments,
etc. for the field testing of the pipelines. The testing of the pipelines generally
consists in three phases: preparation, pre-test/saturation and test,
immediately following the pre-test. Generally, the following steps are
required which shall be monitored and recorded in a test protocol if required:
(a)Sectional field testing of pipeline should be done only after constructing
thrust block at bends as well as at dead ends of pipelines. In case of
permanent dead end, thrust block should be constructed before testing
and at temporary dead end, temporary anchor should be provided to
take complete thrust.
(b)The length of pipeline should be tested may initially be kept as 500
meter, which can be increased in subsequent test by engineer in charge.
(c)During filling of pipeline with water, air should be released from air
vent pipes and care should be taken to close air vents only when
complete air has been removed from the pipeline and smooth flow of
water starts.
(d)In case of pipeline with internal cement mortar lining the water is to be
kept filled in the pipeline for 48 hours before sectional testing.
(e)Effort should be made to install the pressure gauge of 150 mm dial
diameter and of appropriate ratings at the lowest point of the pipeline
and if it is not possible than an allowance should be made for the
difference in static head between the lowest point and point of
measurement to ensure that the maximum pressure is not exceeded at
the lowest point.
(f)The water for this purpose shall be reasonably clear and free of solids
and suspended matters, water should be filled in pipeline section
having lowest RL.
VOLUME-II Page 55
(g)The testing conditions for the pipeline shall be as per the test pressures
mentioned above and conditions laid out in IS: 12288:1987(amended
up to date) and CPHEEO manual on water supply and treatment.
(h)The test pressure shall be gradually raised at the rate of 1 kg/cm 2/min.
while inspecting the thrust block and the temporary anchoring.
(i)Starts the test by maintaining the test pressure at the desired level, if a
drop occurs in the test pressure make it the same by adding more
water, record the water added and the pressure in interval of 15
minutes at the beginning and 30 minutes at the end of test period.
(j)Rebuilding of pressure up to the testing pressure shall be done after
every fall of 10% from the testing pressure.
(k)Water required for pipeline testing is to be arranged by the contractor
himself at his own cost.
The testing conditions for the pipelines are summarized as follows:

DI Pipes
Acceptance Criteria
(i)Quantity of water added during the test of 6 Hours should not exceed 0.1 litre
per mm of pipe diameter per KM of pipeline per day for each 30 meter head
of pressure applied. Allowable leakage during testing for various size of
pipelines for test pressure of 12 kg/cm2 and 18 kg/cm2 is shown in table
below and for any other test pressure quantity of leakage can be calculated
on average basis.
Allowable leakage during testing of pipeline@ 0.1 litter per mm of pipe dia per
KM of pipeline per day for 30 meter head of pressure.(as per CPHEEO manual
cl 6.4.4.2)
Allowable leakage in litre during
Dia of pipe Test duration in test duration and field test pressure
S.No. in mm hour in meter head per KM of pipeline
12 kgf/cm2 18 kgf/cm2
1 100 6 10 15
2 125 6 12.5 18.75
3 150 6 15 22.5
4 200 6 20 30
5 250 6 25 37.5
6 300 6 30 45
7 350 6 35 52.5
8 400 6 40 60
9 450 6 45 67.5
VOLUME-II Page 56
10 500 6 50 75
11 600 6 60 90
12 700 6 70 105
13 750 6 80 120
14 800 6 90 135
15 1000 6 100 150
(ii)If leakage is greater than the specified the defective pipe(s) or joint(s) shall be
repaired/replaced until the leakage is within the specified allowance.
(iii) Water used for testing should not be carelessly disposed off on land which
would ultimately find its way to trenches.
(iv)One register for testing pipeline should be maintained and all tests including
failures test should be recorded.
2.3.13.2 Failure to pass the test
All pipes or joints which are proved to be in any way defective shall be
replaced or remade and re-tested as often as may be necessary until a
satisfactory test are obtained. Any work, which fails or is proved by test to be
unsatisfactory in any way shall be redone by Contractor. No payments shall
be made against replacement or remade and retested pipeline.
The pipes shall be accepted to have passed the pressure test satisfactorily, if
the quantity of water required to restore the test pressure does not exceed the
amount ‘Q’, calculated by the above formula for DI and if the pressure
remains steady within 5% of the target value for 1 1/2 hr for HDPE.
If it is required to test a section of a pipe line with a free end, it is necessary to
provide temporary support against the considerable end thrust developed by
the application of the test pressure. The end support can be provided by
inserting a wooden beam or similar strong material in a short trench
excavated at right angle to the main trench and inserting suitable packing
between the support and pipe end.
No section of the pipe work shall be accepted by the Engineer until all
requirements of the test have been obtained. The test also includes for:
•Closing of the valves against full static or dynamic pressure.
•Operation of all valves including scour valves (open-close-open).
•Operation of all air valves.
•Operation of all locking arrangements of valve chambers.
On completion of a satisfactory test any temporary anchor blocks shall be

removed. Backfilling of the pipeline shall be completed.
VOLUME-II Page 57
CHAPTER 3
SPECIFICATIONS OF VALVES
3.0 GENERAL
This chapter describes the minimum requirements for the provision of Sluice Valves,
Gate Valves, Check Valves and Air Valves. Prior to the procurement of valves the
Contractor shall obtain the Engineer in charge’s approval for the materials to be
used.
• General applicable Standards to be applied to the Works under this Section shall
be Indian Standards and British Standards or other approved International
Standard.
• As far as practicable all valves of the same type shall be from the same
manufacturer.
• Valves for pipeline installation shall comply with the relevant provisions of the
appropriate BS, IS and other international standards.
• A certificate from the manufacturer’s shop testing shall be provided for review
by the Engineer in charge.
• Before delivery to Site all working surfaces shall be thoroughly cleaned and if
metal protected with grease. The initial charges of oil, grease and similar
materials necessary for the correct setting to work and operation of valves and
penstocks shall be provided by the Contractor. Packing must be sufficient to
ensure complete protection of the fitting during transit and storage and all valves
are to have their openings sealed until installation.
• The valve stem, thrust washers, screws, nuts and all other components exposed
to the water shall be of a corrosion resistant grade of stainless steel. Valves shall
be free from sharp projections. Butterfly valves shall be provided with bypass
arrangement having rising spindle gate valves. Bypass may be integral with
valve or connected between pipes. Minimum size of by pass for valves in main is
150 mm.
• All valves shall be protected against corrosion. Minimum required application
shall be factory applied food grade epoxy system 250 microns thick.
• Provision for indicator tags shall be made for identification / location of valves.
Marking shall be either cast on the bonnet or the body and shall show the
following:
Manufacturer’s name or mark
Year of valve casting
Size of valve
Designation of working pressure
VOLUME-II Page 58
Number of turns to open, with the direction of closing clearly indicated on the
hand wheel or body as appropriate.
Client’s Name
• Gaskets shall be of Nitrile rubber and ready made matching with respective
flanges. Gaskets cut out from rubber sheets are not acceptable.
3.1 INSTALLATION
• All valves, gates, operators and appurtenances shall be installed in accordance
with the manufacturer’s recommendations and as per the specifications laid for
pipe laying, and to the locations indicated on the drawings.
• The installation shall be true to alignment and rigidly supported.
• As soon as installation and operating conditions permit, all valves and
appurtenances shall be given a field test to be witnessed by the Engineer in
charge to demonstrate that they meet all requirements and operating conditions.
• Valves shall be PN rating 1.0, 1.6, 2.0 and 2.5 (as required) based on hydraulic
considerations as per the sum of the hydraulic working pressure and design
surge pressure at the point of installation.
3.2 OPERATION
• All sluice valves and butterfly valves on pipeline shall be manually operated and
they shall be provided with suitable hand wheel or key. For valves greater than
400 mm diameter gear operators shall be used. The direction of closing shall be
clearly indicated on the hand wheel or body as appropriate.
• All sluice valves and butterfly valves in the pumping stations shall be electrically
operated with provision of manual operation. The direction of closing shall be
clearly indicated on the hand wheel or body as appropriate.
• Manual operation of valves shall be so that the torque effort required operating
the hand wheel manually, lever or chain shall not exceed 20 kg-m applied by an
operator.
• Valves shall be provided with operating hand wheels, caps, extension spindles
and valve boxes as required. Extended valve spindles shall have spindle guides
and operating caps.
• For sluice valves up to 600 mm diameter installed in underground chamber or
otherwise not easily accessible, the Contractor shall furnish extension spindles
and/or keys, or chains with extension oil cups or such similar fittings or
appliances as may be required to permit easy access for proper operation,
lubrication etc. Valves shall be suitable for frequent operation as well as
operation after long periods of idleness in either open or closed position.
• Unless detailed otherwise all hand wheels shall have the words “open” and
“close” cast in English with arrows indicating the direction of rotation. All hand
wheels shall be of a solid cast type.
VOLUME-II Page 59
• Operation must be possible by one man against maximum design working

pressure. For butterfly valves the gearbox shall be provided with self locking
devices. A locking facility shall be provided for the BF valve in either the fully
open, fully closed or intermediate position. Gate valves and butterfly valves shall
be provided with position indicators, to show whether the valve is in the open or
close position.
• Scour valves shall be provided with extension spindle with supports for
operation from operating level / ground level, as required.
3.3 DI SOFT SEATED GATE VALVE/SLUICE VALVE
Manufacturing, supply and delivery of DI, D/F non-rising spindle soft seated
glandless Gate Valves with body and bonnet of Ductile cast iron of grade GGG-
40, wedge with fully encapsulated EPDM rubber W-270 (approved for drinking
water) and seals of NBR. The valves should be with replaceable stem nut and
replaceable sliding shoes. Valve stems shall be of single piece thread rolled.
Valve shall have 3 “O” rings of NBR for stem sealing. Gate valve shall be
compatible for buried applications without valve chamber. Face-to-face
dimensions as per BS 5163-89/IS 14846-PD/EN 558F4 and flange connections as
per IS 1538, Maximum Valve operating torque should be at least 40% less than
the torque as stated in the standard EN 1074. Electrostatic epoxy powder/liquid
coating (EP-P) inside and outside surface of valve shall be color blue RAL 5005
with minimum coating thickness of 250 microns. The EPDM rubber & Epoxy
Powder should be approved by W 270. (EP-P it is a resi-coat powder approved
for drinking water application, applied through fusion bonding technology
process by dipping the shot-blasted casted components heated up to 200 deg C).
MATERIAL OF CONSTRUCTION:
Body, Bonnet Ductile Iron GGG 40 (EN-JS- 1030)

Wedge (fully Ductile Iron GGG 40 (EN-JS- 1030) encapsulated with
rubber EPDM rubber - W270 approved grade.
encapsulated)
Spindle/Stem SS: IS: 6603 12Cr13/22, Cr 13; AISI 410/AISI 420, rolled
thread
Stem Nut Brass
Bonnet Gasket EPDM rubber - W270 approved grade
Internal Fasteners Stainless Steel SS316/304
Stem Sealing Toroidal NBR sealing rings (Min 03 ‘O’ Rings)
Coating Electro Static epoxy powder coated; DFT
minimum 250 micron, shade RAL 5005 (BLUE)
VOLUME-II Page 60
SLUICE VALVES (AS PER IS 14846)
1 This section covers the requirements for non-rising stem type sluice valve as
per IS 14846. The valves will be used for water supply on line installations in
upright positions, up to 450 C working temperature, with double flange and
cap or hand wheel, for manual operation. Manually operated sluice valves
shall be provided as indicated in drawing according to the diameter and of
class PN 1.0. The valves shall be installed between flanges. Dismantling shall
be possible by the use of rigid or flexible dismantling pieces or flange
adopter at one side
2 Nominal pressure and dimensions
Dimensions and mass of the sluice valves shall be in accordance with IS
14846. The flanges and their dimensions of drilling shall be in accordance
with IS: 1538 (part-I to XXII).
3 Material
The material for different component parts of sluice valve shall conform to
requirements given below:
1. Standard IS 14846:2000. And ISI marked.

2. Size, range, and
quantity As per Appendix to the data sheet
3. Fluid Water
4. Rating PN : 1.0 ( 10 Kg. / cm ² )
5. Stem Non rising
6.
Flanged, flat faced flanges as per IS-1538 Table IV &
Ends VI having off center bolt holes
7. Bonnet Bolted
8. Disc. Solid wedge
9. Operation Hand wheel
10. Seat Body - Renewable Disc - Renewable
11. Other Valves shall close in clockwise rotation of the hand
requirements wheel.
12. Body / bonnet C.I. IS 210 GR 260
13. Disc C.I. IS 210 GR 260
14. Stem S.S. AISI – 410
15. Body seat Bronze IS 318 GR LTB 2
16. Disc seat Bronze IS 318 GR LTB 2
VOLUME-II Page 61
17. Stem nut Bronze IS 318 GR LTB2

18. Stuffing box C.I. IS 210 GR 260
19. Gland C.I. IS 210 GR 260
20. Packing Graphite Asbestos
21. Carbon Steel IS 1367 Class 4.6 / 4
Bolts, studs
& nuts
22. Shell test 15 Kg / Cm²
23. Seat test 10 Kg / Cm²
24. Back seat test 10 Kg / Cm²
4 Coating
All sluice valves shall be coated by dipping in a bath of tar base
composition as given in clause 7 of IS: 780 for sizes from 50 mm to 300 mm
and clause 8 of IS : 2906 for sizes from 350 mm to 600.
All components susceptible to corrosion attack shall be coated internally
and externally. Protective coating shall always be applied to the individual
components before they are assembled, following shot blasting to give
good adhesion.
5 Marking, testing and inspection
The standard marking and packing of the valves shall be done as per clause
10 and 11 of IS: 780. The direction of rotation for OPEN, CLOSE position
shall be marked on the hand wheel and on the bonnet of the valve.
Testing of sluice valve shall be done for close end in accordance with IS:
780 for sizes from 50
mm to 300 mm and IS : 2906 for sizes from 350 mm to 600.
All the valves shall be inspected for flow detection test in accordance with
IS : 780. for sizes
from 50 mm to 300 mm and IS : 2906 for sizes from 350 mm to 600.
3.4 SPECIFICATION OF CAST IRON AIR VALVE
SCOPE
This specifications covers the supply of single and double air valves conforming
to fig. H-4 and H-40 of G.K. Catalogue in size 25mm to 200mm.
SINGLE AIR VALVES (25mm)
C.I. small orifice type single air valve in size 25mm conforming generally to
fig.H-4 of G.K. Catalogue. The BUOYANT ball will rest on a bronze/extruded
VOLUME-II Page 62
brass orifice nipple. The BUOYANT ball will have a timber core with rubber
covering. It shall have G.M./Brass screwed nipple at bottom with 1” BSP thread.
The dimensions/pressures etc. shall be as under.
Ball dia Dimensions in inches Max. W.P. App. Wt.

min in
A. B. C. Kg/Cm 2 Kg. H-4
3 7/8" 10" 5 3/4 1 10 10.5

Sq (25mm)
Assemblies tested hydraulically for strength to 20 Kg/Cm2

DOUBLE AIR VALVES ; (Size 40 mm to 200mm)
The Air Valve shall be of double orifice type conforming to Fig. H-40 of G.K.
Catalogue. The small orifice BUOYANT ball for high pressure chamber will rest
on a bronze/ Extruded Brass orifice nipple. The BUOYANT ball will have a
timber core with rubber covering. The large orifice ball for low pressure
chamber will rest on Neoprene moulded seat. The ball shall have a timber core
with valcanite covering.
The air valve shall be provided with an integral screw down type isolating
valve. The operating rod
shall be made from extruded high tensile brass of quality grade HT-1 as per
IS:320-1980 (430 Mpa is minimum tensile strength and minimum elongation of
20% on 5.65 50 gauge length.)
All Flanges shall be drilled conforming to IS:1538-1976.
The dimension, size of valve, parts, test pressure, weight of different

components ferrous and non-ferrous and total weight shall be as under.
Valve Ball Dia. Dimensions in inches Max Total Wt. of Suitable

Size A. Large small B Max. C Min. D Min. W.P Wt. Non For mains
orifice orifice Kg/ Kg. ferrous MM dia.
40 mm 2 1/2" 3 1/8" 14 5/8" 7 5/8" 16 1/6" 10 24.5 0.900 Up to 100

50 mm 3" 3 7/8" 16 1/2" 7 5/8" 16 1/2" 10 40.0 1.250 125 to 200
80 mm 3 7/8" 3 7/8" 18 1/4" 8 5/8" 18 1/4" 10 54.0 1.750 225 to 350
100 mm 5" 5" 21 7/8" 10 3/4" 23 7/8" 12 83.0 2.600 400 to 500
150 mm 8" 5" 26 1/2" 17" 32 3/8" 12 153.0 3.600 600 to 900
200 mm 10" 5 1/2" 32 1/8" 20" 38 3/8" 12 317.0 5.000 1000 to 1200
VOLUME-II Page 63
Assemble tested Hydraulically for strength to 20 Kg/cm
The cast iron for various parts shall be of grade FG-200 of IS 210/1973
(Amended upto date).
The non-ferrous parts except the orifice plug and spindle shall be made from
Gunmetal as per IS: 318-1981 Grade LTB-2.(Amended up to date)
MANUFACTURE: (Applicable for single & Double Air Valves)
The Air Valves shall be manufactured according to modern workshop practice

to give good finish high quality. The design of orifices and vents should ensure
properly regulated flow of air.
Tolerance in weight -5% & + no limit.
TESTING
The valve should be tested to a hydrostatic test pressure, non shock type, of 20
Kg./Sqcm. for two minutes, before despatch. There shall be no permanent
distortion of any component part under this test.
The Air Valve should be suitable for a working pressure 10Kg/Cm.
COATING:
Immediately after casting and before machining all cast iron parts shall be
thoroughly cleaned and before rusting commences shall be coated with a
composition having a tar base.
The coating shall be such that it shall not impart any taste, or smell to water. It
shall be smooth, glossy, tenacious, sufficiently hard so as not to flow when
expose to a temperature of 77 C and not so brittle at a temperature 15 C . As to
chip off when scratched lightly with the point of a penknife.
Alternatively two coats of black Japan paint conforming to type 8 of IS: 341-1971
or paint conforming to type 2 of IS: 158-1968 shall be applied.
MARKING:
Each Valve shall have cast on it the following information:

a)Manufacturer's name or trade mark.
b)Size of valve.
c)Year of manufacturing
3.5 SPRING LOADED DUAL PLATE CHECK VALVE

3.5.1 GENERAL
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The valve shall be of flanged type suitable for mounting on a horizontal pipeline.
Valves shall possess high speed closing characteristics and be designed for
minimum slam condition when closing.
Dual plate check valves conform to API 594 and API 598. They shall have resilient
sealing. The spring action shall optimise the equal closing rates of each plate
especially when the friction coefficients are uneven due to one plate resting upon
one another. The plates shall not drag on the seat while opening. The plates shall not
vibrate under full or partial flow condition.
The minimum body-wall thickness shall conform to those given in Table 1B of API
Standard 594.
The face-to-face dimensions of valves (including valves with ring-joint facings) shall
conform to those mentioned in Table 2B of API Standard 594.
The valve body shall be furnished with a clearly visible cat, forged, machined-in, or
die-stamped arrow to indicate the direction of flow through the valve.
3.5.2 CONSTRUCTIONAL FEATURES
Double Flanged quick closing non slam spring loaded dual plate, generally
conforming to API 594 for pressure rating as per requirement at particular section, of
size equivalent to the delivery pipe, shall be provided with following material of
construction:
3.5.3MATERIALS OF CONSTRUCTION
(a) Rating As per requirement at particular
section
(b) Body CI to IS 210 Gr FG 260 for PN 1.0 and
CS/MS for PN 2.0
(c) Plate CS : A 216 Gr WCB
(d) Hinge Pin /Stop Pin SS. AISI 431
(e) Springs SS. AISI 316
(f) Body & Plate Seat 13% Chromium overlay.
(g) Seal EPDM
(h) Retainer Carbon Steel
(i) Body Bearing SS AISC 316
(j) Plate Bearing SS AISC 316
3.6 NON-RETURN VALVES
3.6.1CONSTRUCTIONAL FEATURES
Non-return valves shall double flanged and be installed on the delivery side of the
pumps, and shall be suitable for installation in a horizontal pipeline. Rapid natural
closing to be non-slam by suitable design of spring return mechanism, to ensure that
the valve will rapidly fully close the moment forward flow of the water ceases i.e. on
pump shutdown, external counter weights will not be acceptable. To prevent
excessive head loss, larger diameter non-return valves will be provided with several
VOLUME-II Page 65
smaller and lighter flaps in a single bulkhead. In this case stopper to be provided for
the upper door to avoid contact with shell.
3.6.2MATERIALS OF CONSTRUCTION
Body CI to IS Gr FG 200
Door CI to IS Gr FG 200
Spring Spring steel BS:970
Body ring S S. AISI 304
Door ring SS. AISI 304
Hinge pin AISI 410 /431 Hardened and ground
3.6.3 Flanges
➢ The nominal size and thickness of the flanges shall be as defined for pressure
rating 1.0, 1.6 and 2.5 N/mm2 conforming to IS 6392. The pressure rating of
the flanges shall be equivalent to the valve with which they are being
installed. The selection of the flange out of these three ratings shall be based
on the design pressure at the place of installation.
➢ Valves shall be flanged and the flange face at right angles to the valve
centerline. Backside of valve flanges shall be machined or spot faced for
proper seating of the head and nut.
➢ Flanges shall be machined on faces and edges to IS 6392 or BS 4504. Flange
drilling shall conform to IS 1538.
➢ No new or additional holes shall be drilled on site. Tapped holes are not
acceptable in flanges.
3.7 NUT, BOLTS, WASHERS
The jointing material such as nuts, bolts, washers, pig lead, rubber packing, etc. shall
be provided by the Contractor.
Nuts and bolts shall be of the best quality bright steel, machined on the shank and
under the head and nut. Studs, bolts and nuts shall be galvanised. Bolts shall be of
accurate length so that only one thread shall show through the nut in the fully
tightened conditions. Nuts and bolts shall conform to IS 1363 and IS 1367.
Washers, locking devices and anti-vibration arrangements shall be provided where
necessary.
Where there is a risk of corrosion, bolts, nuts and studs shall be designed so that the
maximum stress does not exceed half the yield stress of the material under any
conditions. All bolts, nuts and screws which are subject to frequent adjustment or
removal in the course of maintenance and repair shall be made of nickel bearing
stainless steel.
The Contractor shall supply all holding down, alignment leveling bolts complete
with anchorages, nuts washers and packing required to fix the plant to its
foundations, bed plates, frames and other structural parts.
VOLUME-II Page 66
The Contractor shall procure and keep at site, reasonable excess quantities to cover
wastage of those materials which will be normally subject to waste during erection,
commissioning and setting to work.
Throughout erection, the valves shall be supported properly on wooden sleepers,
etc. and shall be concreted immediately thereafter, as directed. Before the valves are
actually fixed, they shall be cleaned and greased and it should be seen that all parts
are in perfect working condition. In the case of air valves, the Contractor shall take
special care of the dexine joints and the ebonite and /or vulcanite balls until they are
fixed in position. They shall be kept immersed in water in suitable containers.
3.10INSPECTION AND TESTS
The following Inspection and Testing procedures shall be carried out for all the
equipment as applicable:
(i) Visual Inspection.
(ii) Material Certificates for all the specified material shall be furnished.
(iii) Welding Qualifications.
(iv) Dimension Checking.
(v) Stage Inspections (in process inspection).
(vi) Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test
wherever applicable.
(vii) Operation check.
(viii) Liquid penetrating tests or magnetic particle tests for all machined
surfaces of pressure parts.
(ix) Ultrasonic test for forging materials viz.,
(x) Plates of thickness 20mm and above for pressed / formed parts such as
heads, etc.
(xi) Plates, flanges and bars of thickness / diameter 40mm and above used for
fabrication of pressure and load bearing members and rotating parts.
(xii) Radiographic testing for all but welded parts, as per applicable codes.
(xiii) Hardness tests for all Hardened surfaces.
The Contractor shall maintain proper identification of all materials used, along with
reports for all internal / stage inspection work carried out, based on the specific job
requirement and or based on the datasheets / drawings / specifications.
Requirement of shop tests for Valves are listed below:
a) During testing there shall be no visible evidence of structural damage to any of
the valve components.
b) Each valve operated actuator shall be shop-operated at least three times from the
fully closed to the fully opened position, and the reverse, under no-flow
condition, to demonstrate that complete assembly is workable.
VOLUME-II Page 67
The tests mentioned below shall be hold points and to be witnessed by a duty
authorized representative of the Employer:
The following tests shall be carried out for butterfly valves in line with IS 13095:
a. Seat leakage test. Seat test shall be carried out in each direction and the valve
shall be drop tight.
b. Body hydrostatic test
c. Disc strength test at body test pressure in each direction.
d. Valve operation with and without actuator
The following tests shall be carried out for sluice valves in line with IS 14846:
a. Seat leakage test
b. Body hydrostatic test
c. Valve operation
The material certificates, physical properties, heat treatments and shop test
certificates of valve body, disc, wedge and shaft shall be duly approved and certified
by the manufacturer and these shall be subject to review & approval by the
Engineer.
Notwithstanding the above requirement for inspection and quality control, the
following inspection and quality control measures shall be carried out by
manufacturer:
a. Magnetic particle tests on body and disc/door.
b. Dye penetration tests on metal seats.
c. Ultrasonic tests on shafts.
d. Overload Torque Test shall be carried out on the gear boxes of the valves. The
test shall be carried out by applying 1.5 times the rated torque.
VOLUME-II Page 68
CHAPTER 4
SPECIFICATIONS FOR CIVIL WORKS
4.1. General
4.1.1. This part of the specification covers the design loads to be considered,
specifications of material and workmanship for the civil works. Material
used and workmanship for the civil works of campus development,
repair/new works of buildings, civil works associated with pipeline laying
etc. to be done under the contract will adhere to the provisions laid down in
this chapter.
4.1.2. For materials used other than those specified, the material must conform to
the requirement of respective Indian Standards/International Standard
and/or good engineering practices. The contractor shall get prior approval
of the materials proposed to be used under the contract as per the provisions
of Special Conditions of Contract, from the Engineer-in-Charge.
4.2. Design Considerations:
4.2.1.DESIGN SUBMISSIONS
4.2.1.1.The contractor shall be responsible for the safety of structures, correctness
of design and drawings, even after the approval of the same by Engineer-
in-Charge.
4.2.1.2.Complete detailed design calculations of foundations and superstructure
together with general arrangement drawings and explanatory sketches
shall be submitted to the Engineer-in-charge. Separate calculations for
foundations or superstructures submitted independent of each other shall
be deemed to be incomplete and will not be accepted by the Engineer-in-
charge.
4.2.1.3.The design considerations described hereunder establish the minimum
basic requirements of plain and reinforced concrete structures, masonry
structures and structural steel works. However, any particular structure
shall be designed for the satisfactory performance of the functions for
which the same is being constructed.
4.2.2.DESIGN STANDARDS
All designs shall be based on the latest Indian Standard (I.S.) Specifications
or Codes of Practice unless otherwise specified. The design standards
adopted shall follow the best modern engineering practice in the field
based on any other international standard or specialist literature subject to
such standard reference or extract of such literature in the English language
is being supplied to and got approved by the Engineer-in-charge. In case
of any variation or contradiction between the provisions of the I.S.
VOLUME-II Page 69
Standards or Codes and the specifications given in the tender document,

the provision given in this specification shall be followed.
4.2.3.DESIGN LIFE
The design life of all structures and buildings shall be 60 years.
4.2.4.DESIGN LOADING
All buildings and structures shall be designed to resist the worst combination of
the following loads/ stresses under test and working conditions; these include
dead load, live load, wind load, seismic load, stresses due to temperature
changes, shrinkage and creep in materials, dynamic loads:
Dead Load
This shall comprises all permanent construction including walls, floors, roofs,
partitions, stairways, fixed service equipments and other items of machinery. In
estimating the loads of process equipment all fixtures and attached piping shall
be included.
Live Load
Live loads shall be in general as per I.S. 875. However, the following minimum
loads shall be considered in the design of structures:
i) Live load on roofs : 2.00 kN/m2
ii) Live load on floors supporting equipment : 10.00 kN/m2

such as pumps, blowers, compressors,
valves etc.
Iii) Live load on all other floors walkways, : 5.00 kN/m2

stairways and platforms
In the absence of any suitable provisions for live loads in I.S. Codes or as given
above for any particular type of floor or structure, assumptions made must
receive the approval of the Engineer-in-charge prior to starting the design work.
Apart from the specified live loads or any other load due to material stored, any
other equipment load or possible overloading during maintenance or erection/
construction shall be considered and shall be partial or full whichever causes the
most critical condition.
Wind Load
Wind loads shall be as per I.S. 875. Part 3
Earthquake Load
This shall be computed as per I.S. 1893 taking into consideration soil foundation
system, importance factor appropriate to the type of structure, basic horizontal
seismic coefficient/ seismic zone factor & average acceleration coefficient.
Dynamic Load
VOLUME-II Page 70
Dynamic loads due to working of plant items such as pumps, blowers,

compressors, switch gears, travelling cranes, etc. shall be considered in the
design of structures
4.2.5.JOINTS
Movement joints such as expansion joints, complete contraction joints, partial
contraction joints and sliding joints shall be designed to suit the structure.
However contraction joints in buildings shall be provided at specified locations
spaced not more than 7.5 m in both right angle directions for walls and rafts.
Expansion joints of suitable gap at suitable intervals not more than 40 m shall be
provided in walls, floors and roof slabs of water retaining structures, as per IS-
3370.
The positions of construction joints should be specified by the designer &
indicated on the drawings. If there is a need on site to revise any specified
position or to have additional joints, the proposed positions should be agreed
with the designer.
The concrete at the joint should be bounded with that subsequently placed
against it, without provision for relative movement between the two concrete
should not be allowed to run to a feather edge & vertical joints should be formed
against stop edges.
Expansion joints for non liquid retaining structures shall be provided as per IS
3414.
Requirements for Construction of RCC Reservoirs
General
The RCC reservoirs are to be constructed as per the type and size detailed in the
“Scope of Work” defined in this Volume II of tender document. The conceptual
drawings of CWR/ ESR are given in the drawings in Volume III of the tender
document which are for general understanding of department requirements but
shall have no bearing on the submissions for approval, the requirements as
given in this document are required to be fulfilled. The facilities and general
arrangements of the reservoirs shall be as shown in the drawings in Volume III.
The contractor shall submit detailed general arrangement drawings, structural
drawings and design of each structure for the approval of Engineer in charge.
The designs shall adhere to the provisions given in this chapter. The design shall
be got approved from the agencies defined in the contract before submission to
the Engineer-in-Charge.
The ESRs shall be of Intze type shape, supported on raft foundation. The
arrangements for lightening arrestor, conductors and earthing system shall be
made by the contractor.
The construction of reservoirs shall be carried out in accordance with the
specifications mentioned herein and relevant IS amended upto date. The general
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arrangement drawings of the piping system and other drawings like layout plan
of site, structural drawings and designs, working drawings, etc shall be
submitted by the contractor for approval of the department prior to start of
work. In cases where the specifications given below are silent about any aspects
in respect of any item, the work shall be carried out as per the relevant IS code
of practice in the latest version and/or as per sound engineering practice after
approval of Engineer-in-Charge.
Preparatory Works
The Contractor shall provide and maintain a benchmark with a level at a

location approved by the Engineer in Charge at each reservoir construction sites.
All levels shall be deemed to refer to that benchmark. The Contractor may
establish other secondary benchmarks on the site.
Soil & Geo Technical Investigation
For RCC ESR: SBC tests shall be got done through MNIT Jaipur/ BITS Pilani/
IIT Delhi. For foundations to be laid on sandy strata, the structural design and
reinforcement drawings shall be prepared assuming maximum SBC of soil as 8
T/Sqm even if the SBC testing is found to be 8 T/Sqm or more at foundation
depth. If the SBC testing is found to be less than 8 T/Sqm at foundation depth,
the structure shall be designed on the basis of actual SBC found on testing for
which no extra payment will be made to contractor.
For GLR: Foundation shall be designed for SB equal to 10 t/sqm
Material of Construction
The building/construction material to be used shall be as per the specifications

given in this chapter. The pipes & specials to be used shall be as per the
specifications given in Chapter for Pipes. The valves and instruments shall be as
per the specifications given in this volume II containing specifications for Valves
and Instrumentation respectively.
Design Considerations for Reservoirs
GENERAL PRINCIPLES:
1. Maximum height of live storage in water reservoirs shall be 4.0 meters.
2. Height of dome shall be 1/5th to 1/6th of span of dome.
3. Minimum Free board shall be kept as 0.3 meters.
4. Staging in case of overhead reservoirs is defined as the difference of levels

between the finished ground level and bottom of the water retaining
structure (top of the bottom ring beam of bottom dome).
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Design Requirements
The following are the design requirements for all reinforced or plain concrete
structures.
Cement concrete ( plain or reinforced ) shall comply with the requirement of
specifications of Rajasthan PWD (B&R) Specification and Explanatory Notes for
Building and House Drainage except in so far as these are not altered or
modified by specific stipulations as given in the specifications herein.The
concrete grades to be used shall not be leaner than the following :
Water bearing structure, beam, platform in the

- reservoir and roof M 35
for ESR & CWR
Water bearing structure, beam, platform in the
- reservoir and roof M 25
for GLR
- Other structural concrete M 25
- Lean concrete in foundation M 15
Concrete mix of richer than M20 shall be got designed form MNIT Jaipur/
BITS Pilani/ IIT Delhi at contractors cost.
The The Synthetic Polyolefin (Polypropylene and Polyethylene) Fiber shall
be used as admixture.
The fibre shall be as per enclosure. The dose shall be as per design
approved.
The reinforced concrete for water retaining structures shall have a
minimum cement content of 300 kg/m3 with a maximum 20 mm size
aggregate and 330 kg/m3 with a maximum 40 mm size
Aggregate.
The minimum reinforcement in walls, floors and roofs in each of two
directions of right angles within each surface zone shall be as per 7.1 of IS:
3370 part 2.
The nominal cover of concrete for all steel, including stirrups, links,
sheathing and spacers shall be as per 7.2 of IS : 3370 Part 2 for liquid
retaining structures and as per IS:457 for other structures.
Suitable admixtures may be used with the approval of engineer in charge.
Construction of floors and walls of Liquid Retaining structures shall be as per IS:
3370 Part 1.
VOLUME-II Page 73
Design requirement of RCC liquid retaining structures / grade of concrete /

minimum cement content and for other provisions, these shall be governed by
the provisions of latest IS 456 and IS 3370 amended upto date, whichever is
more stringent.
Loads
All loads shall be considered as per the provisions of IS 875 and other references
as defined in this chapter.
The design shall be suitable for the worst possible conditions of loading during
construction and operation.
Concrete Grade, cover, minimum cement content and thickness
Grade of concrete to be used for the reservoirs shall be as per the provisions of
IS 456 for moderate environmental exposure conditions. The minimum cement
content for reservoir members shall be 360 Kg/cum. For other works such as
plinth protection etc.., the minimum cement content shall be as per the
respective codes. Minimum cover as prescribed in IS 456 shall be provided. The
minimum thickness of reservoir members shall be in accordance to the
provisions of IS 456 and IS 3370. However the following minimum thicknesses
shall be provided for different reinforced concrete members, irrespective of
design thicknesses as follows:
Walls for liquid retaining structures 150 mm
Spherical Dome/Flat roof slab of RCC
reservoirs 125 mm
Bottom slabs of CWRs 150 mm
Floor slabs including roof slabs, walkways,
canopy slabs 150 mm
Wall of cables/ pipe trenches, underground
pits etc. 125 mm
Wall of cables/ pipe trenches, underground
pits etc. 125 mm
Column footings 150 mm
Parapets, Chajja 75 mm
Pre-Cast trench cover 50 mm
Free board depth to be provided 300 mm
Dead storage depth 100 mm
Thickness of lean concrete below foundation 100 mm
Depth of foundation for ESR 3000mm or on solid rock.
Depth of foundation for CWR 1000mm or on solid rock.
Age factor shall not be more than 1(one)
The above dimensions are minimum prescribed. In case of any code

requires them to on higher side, the provision of that IS code shall prevail
VOLUME-II Page 74
Final Finishing
The contractor will ensure that the entire structure along with all its installations
are in a finished and in new and fully operative condition when handed over,
after the D.L.P. period is over. He shall have repaired and removed all signs of
damage that might have been done during the course of installation and fixing
of equipment. He shall also see that all the exterior has been finished properly
and the entire site is cleared of all extra construction material, debris and
excavated soil. This shall have to be done to the satisfaction of the Engineer in
Charge.
Miscellaneous Items of Reservoirs
Puddle collars
Puddle collars shall be used for connecting the inlet, outlet, overflow & washout
pipes to the reservoir. All puddles shall be fixed at right angle to the RCC wall
during casting of wall. All puddle collars shall be of C.I. The minimum length
shall be at least 100 mm more than the total finished thickness of the walls and
size of the puddle collars shall be equal to the size of the respective pipe.
Pipes
The working length of double flange CI pipes shall be 0.5m, 1m, 1.5m, 2m, 2.75m
and 3.0m. The pipes shall be ISI marked, and shall be straight and permissible
deviation from straight line shall be in accordance with IS : 7181. The pipes of
heavier mass than the maximum shall be accepted provided they comply in
every other respect with the requirement of IS: 7181. The pipes shall be supplied
with the required bolts, nuts and rubber gaskets. The flanges and their
dimensions of drilling shall be in accordance with IS: 1538.
The working pressure for the double flanged pipes shall be 10 kg/cm2 (1Mpa).
The pipes shall be tested hydrostatically at a specified pressure in accordance
with IS : 7181. The pipes shall not show any sign of leakage, sweating or other
defect of any kind. The factory test pressure for pipe sizes up to and including
300 mm shall be 25 kg/cm2 and for pipe sizes over 300 mm up to and including
600 shall be 20 kg/cm2.
The pipes shall be internally and externally coated with hot applied (dip)
bituminous paint in accordance with IS: 7181.
Alternatively Ductile iron D/F pipe class K-9 as per IS 8329 may be used.
All flanged Specials
The cast iron flanged specials (all flanged tee, flanged tapers, bends, blank
flanges, and Puddle collar) shall be according to IS: 1538.
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The specials shall be internally and externally coated with hot applied (dip)
bituminous paint.
All flanged specials shall be used for nominal pressure of 10 kg/cm2 (1Mpa).
Flanged specials shall be supplied with the required bolts, nuts and rubber
gaskets. The nut & bolts shall be supplied in jute bag; rubber gasket shall be
supplied in polyethylene bags.
The length and size of the puddle collars to be fixed at different places of the
structures shall be decided by the Engineer in Charge. Pipe make shall be got
approved from Executive Engineer, District Division I Jaipur before using it on
site.
Ladder
M.S. ladder 450 mm wide, made up of 50mm x 50mm x 6mm M.S. angle iron
and 25mm M.S. bars welded at 300mm c/c shall be provided outside from the
balcony to top dome in ESR. MS cage shall also be provided on this ladder.
Similarly MS ladder/RCC Staircase shall be provided at CWR for access to the
top dome. M.S. ladder with all its components should be suitably painted as per
approval of EIC.
The ladders in all type of reservoirs (i.e. CWR & ESR) from top dome roof to
inside platform and from platform to bottom dome in the container shall be of
aluminium. Its drawing shall be got approved from EIC before dispatch.
Railing
Hand railing shall be provided along the stairs of ESR and on the top dome of
ESR. Hand railing around the platforms, Balcony, stairs and landings shall be
consisting of 25 mm diameter medium B class GI pipes in two rows (one at the
top and other at middle level) and 750mm high vertical post 50x50x6 mm angle
iron @> 750mm centre to centre properly embedded in the concrete(At least two
vertical angles are to be provided wherever distance is less) with all accessories
like elbows, tees etc. including welding, threading and embedding in cement
concrete floor. Railing shall be protected against corrosion after welding. The
pipe shall pass through hole in the vertical angle.
Water level indicator
Water level indicator shall be installed on the ESR. Water level indicator
consisting of an approved copper float and iron counter weight and connected
by steel flexible wire passing over aluminium pullies fixed on 25mnm GI
medium class pipe which is installed as indicated in the drawing shall have to
be provided. The scale shall be calibrated in centimeters and should consist of
M.S. sheet 20 gauge fixed over wooden plank with an M.S. angle iron frame of
35mm x 35mm x 5mm and painted with white enamel base, letters in black and
VOLUME-II Page 76
red. The scale shall be located and fixed with RCC column at 2m above the
ground for ESR.
RCC Ventilator
RCC Ventilators shall be provided for all reservoirs. The size of ventilator shall
be approved by EIC in consideration to the tank size. The drawing of ventilator
shall be got approved from EIC. For smaller reservoirs CI vent pipes of dia as
per approval of EIC shall be provided.
Lightening arrester
Lightning arrester shall be of copper bar of 25mm dia and 2m long to be

provided at the top of ESR. This is to be connected by a GI strip 25 mm wide &
3mm thick. This conductor strip shall be connected to a 450
(i) x 450mm x 3mm thick copper plate to be embedded below the average
ground level by digging a pit. The earthing system shall comply with Indian
Electricity Rules and shall confirm to IS 3043. The pit shall be refilled by
alternate layers of salt and coke and balance shall be filled with loose soil. The 40
mm dia GI watering pipe shall be provided in the pit. Care shall be taken that
earth pit does not sink.
Plinth Protection
Plinth protection works for ESR and CWR is to be provided all around each
reservoir in a 1 m circular strip. It shall consist of laying lean concrete 100 mm
thick in M10, over compacted soil. Over the lean concrete brick on edge flooring
or RR stone flooring in 1:4 cement sand mortar shall be provided. Along this
plinth protection provision of toe wall of M15 grade cement concrete 150 mm
wide over the base of lean concrete of M10 shall be provided. Side slope of
plinth protection shall be 1 in 50 outward & peripheral slope should be 1 in 500.
Plinth protection works to be constructed below the OH Service Reservoir, shall
be extended up to 1m from fall of balcony or edge of raft slab, whichever is
more, all around service reservoir. It shall consist of laying lean concrete 100 mm
thick in M10, over compacted soil.
The minimum free space between plinth protection and the first bracing of
the ESR shall be 1.60 meters. Slogan and logo
The contractor shall paint on the vertical wall of the tank portion by using 3
coats of plastic emulsion paint of shade as approved by engineer in charge to
form a base for writing the slogan. The Size & shade for painting the slogan will
be approved and directed by Engineer in Charge. The logo should indicate the
name of the project, name of the village and the capacity of the reservoir. The
slogan shall be as directed by the Engineer-in-charge.
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Pipe Clamp
At least two clamp on one staging shall be provided of 6mm thick 50mm wide
MS flat fixed on pipe & column.
Man Hole Cover
Square manhole cover 600X600 mm shall be provided. The cover shall be made
of 5 mm thick MS flat. The frame shall be made of MS angle 50*50*6. The cover
shall be connected to this frame by using two nos. strung hinges. Locking
arrangement shall be provided.
Ladder
Aluminum ladder from top dome to the bottom, 450 mm wide, made up of
aluminium section of sufficient size as per design approved by Engineer in
charge with horizontal sections provided at with at 300mm c/c shall be
provided..
Gate
To prevent the unauthorized entry to structure, the gate of height 2.1 m, made
up of Angle iron and MS Sheet, shall be installed at stair case first landing above
3 m height from plinth protection work. The Angle shall be 35x35x5 mm size
and sheet shall be of 20 gauge. The frame for the gate shall be made up of angle
50x50x5 mm. The gate shall be grouted in the concrete. The gate shall be
accompanied by a cover made up of Angle Iron and MS Sheet. The enclosure
shall be 2 meter in length. It shall be fabricated and installed as per directions of
Engineer In Charge.
Jali (at the delivery pipe of RCC ESR)
The CI Jali of suitable size shall be provided on the Delivery Pipe to prevent
entry of any unwanted material in the pipe.
Treatment of Joints in continuous portion
Two hours after pouring the concrete, the slurry would be washed with high
pressure water jet & air jet. Before pouring the next layer of concrete the old
surface shall be brushed, painted with approved joining compound.
Water bar of G.I. sheet 150 mm wide 20 gauge shall be provided as per IS 3370
Part-I 1965 as construction joints in vertical wall. Overlaps in sheets shall be 300
mm. Alternatively water stopper of HDPE can be used.
Valves
The material to be supplied under this sub-section shall include but not be
limited to the following:
VOLUME-II Page 78
(i) All necessary fittings including bolts, nuts, gaskets, backing rings, counter
flanges, jointing material, strainers etc. as required.
(ii) Valves to start/stop and regulate flow
(iii) Painting, anti-corrosive coating etc., inside and outside of the valves.
The design, construction material, manufacture, inspection, performance and

testing shall comply with all applicable Indian Standards and Codes. Nothing in
the specification will be construed to relieve the supplier of this responsibility.
Testing for water tightness
The contractor shall carry out a water tightness test as per IS: 3370 for the
maximum water head condition i.e. with the water standing at full supply level.
All cost of testing shall be borne by the contractor. This test shall be carried out
in accordance with the procedure given below
a. For water tightness test, before the filling operations are started, the
reservoirs shall be jointly inspected by the Engineer in Charge and the
representative of the Contractor and condition of surfaces of wall,
construction joints etc. shall be inspected and noted and it shall be
ensured that jointing material filled in the joints is in position and all
openings are closed. The contractor shall make necessary arrangement for
ventilation and lighting of reservoir by way of flood lights, circulators etc.
for carrying out proper inspection of surfaces and internal conditions if so
desired by the Engineer in Charge.
b. The water retaining structures shall be filled with water gradually at the
rate not exceeding 30 cm. rise in water level per hour and shall extend for
a period of 72 hours. Records of leakages starting at different level of
water in the reservoirs, if any, shall be kept.
c. The reservoirs once filled shall be allowed to remain filled for a period of
7 days before any readings or drop in water level is recorded again at 7
days. The total drop in surface level over a period of 7 days shall be taken
as indication of the water tightness of the reservoir, which for all practical
purposes shall not exceed 40mm. There shall be no indication of leakages
around the puddle collars or on the wall and bottom of the reservoir.
d. If the structure does not satisfy the test requirements, and the daily drop
in water level is decreasing, the period of test may be extended for further
seven days and if the specified limit is not exceeded, the structure may be
considered as satisfactory.
e. In case the drop in water level exceeds the permissible limit with the
stipulated period of test, the Contractor shall carry out such additional
works and adopt such measures as may be directed by the Engineer in
charge to reduce the leakage in the permissible limit. The entire
VOLUME-II Page 79
rectification work that shall be carried out in this connection shall be at

Contractor’s cost.
If the test results are unsatisfactory, the Contractor shall ascertain the cause and
make all necessary repairs and repeat the water retaining structures test
procedures, at his own cost. Should the re-test results still be unsatisfactory after
the repairs, the structure will be condemned and the Contractor will dismantle
and reconstruct the structure, to the original specification, at his own cost.
4.3. MATERIALS & STANDARDS
The term “materials” shall mean all materials, goods and articles of every kind
whether raw, processed or manufactured and equipment and plant of every
kind to be supplied by the Contractor for incorporation in the Works.
Except as may be otherwise specified for particular parts of the works the
provision of clauses in “Materials and Workmanship” shall apply to materials
and workmanship for any part of the works.
All materials shall be new and of the kinds and qualities described in the
Contract and shall be at least equal to approved samples.
Materials and workmanship shall comply with the relevant Indian Standards
(with amendments) current on the date of submission of the tender.
Where the relevant standard provides for the furnishing of a certificate to the
Engineer-in-charge, at his request, stating that the materials supplied comply in
all respects with the standard, the Contractor shall obtain the certificates and
forward it to the Engineer-in-charge.
The specifications, standards and codes listed below are considered to be part of
this Bid specification. All standards, specifications, codes of practices referred to
herein shall be the latest editions including all applicable official amendments
and revisions.
In case of discrepancy between two standards the provisions more stringent
shall be followed. In case of discrepancy between the Bid Specification and the
Standards referred to herein, the Bid Specification shall govern.
IS No. Title
CONSTRUCTION PLANNING AND STORAGE OF MATERIALS
4082 : Recommendation on stacking and storage of construction

materials at site (first revision)
IS No. Title
7969 : Safety code for handling and storage of building materials
EARTHWORK
VOLUME-II Page 80
3764: 1992 Excavation work - Code of safety (first revision)
4081 Safety code for blasting and related drilling operations
FOUNDATIONS
269 : 33 grade ordinary Portland cement.
432 (Part 1) Mild steel and medium tensile steel bars and hard-drawn steel
wire for concrete reinforcement : Part 1 Mild steel and medium
tensile steel bars (third revision)
456 Code of practice for plain and reinforced concrete (Reaffirmed

1991)
2974 (Part 1) Code of practice for design and construction of machine

foundations : Part 1 Foundations for reciprocating type
machines

foundations : Part 2 Foundations for impact type machines
(hammer foundations)
2974 (Part 3) Design and construction of machine foundations - Code of

practice : Part 3 Foundations for rotary type machines (medium
and high frequency)

foundations : Part 4 Foundations for rotary type machines of
low frequency

foundations :
Part 5 Foundation for impact machines other than hammers
(forging and stamping press, pig breakers, drop crusher and
jolter)
6403 Code of practice for determination of bearing capacity of

shallow foundations.
PLAIN AND REINFORCED CONCRETE
269 33 grade ordinary Portland cement
383 Coarse and fine aggregates from natural resources for concrete
456 Code of practice for plain and reinforced concrete
VOLUME-II Page 81
516 Method of test for strength of concrete
875 (Part 1) Code of practice for design loads (other than earthquake) for
buildings and structures : Part 1 Dead loads -Unit weights of
building material and stored materials
buildings and structures : Part 2 Imposed loads
buildings and structures : Part 3 Wind loads
buildings and structures : Part 4 Snow loads
buildings and structures : Part 5 Special loads and load
combinations
650 Standard sand for testing of cement
1199 Methods of sampling and analysis of concrete
1786 High strength deformed steel bars and wires for concrete
reinforcement
2502 Code of practice for bending and fixing of bars for concrete
reinforcement
2505 Concrete vibrators - Immersion type - General requirements
4926 Ready mixed concrete
8112 43 grade ordinary Portland cement
9012 Recommended practice for Concreting
9103 Admixtures for concrete
10262 Recommended guidelines for concrete mix design
12269 53 Grade ordinary Portland Cement
STEEL CONSTRUCTION
104 Ready mixed paint, brushing, zinc chrome, priming
123 Ready mixed paint, brushing, finishing, semi-gloss, for general

purposes to Indian Standard Colours No.445, 446, 448, 449, 451,
VOLUME-II Page 82
473 and red oxide
800 Code of practice for general construction in steel
7205 Safety code for erection of structural steel work
FLOORS AND FLOOR COVERINGS
1237 Cement concrete flooring tiles
1443 Code of practice for laying and finishing of cement concrete

flooring tiles
8042 White Portland cement
WHITE WASHING, COLOUR WASHING AND PAINTING OF MASONRY,

CONCRETE AND PLASTER SURFACES (CALCAREOUS SURFACES)
44 Iron oxide pigments for paints
109 Ready mixed paint, brushing, priming, plaster, to Indian

Standard Colour No. 361 and 631 White and off white
133 Enamel, interior : (a) undercoating, (b) finishing
158 Ready mixed paint, brushing, bituminous, black lead-free, acid

alkali and heat resisting
168 Ready mixed paint, air drying, for general purpose
427 Distemper, dry, colour as required
428 Distemper, oil emulsion, colour as required
2395 (Part 1) Code of practice for painting concrete masonry and plaster
surfaces : Part 1 Operation and workmanship
2395 (Part 2) Code of practice for painting concrete masonry and plaster
surfaces : Part 2 Schedule
5410 Cement paint
6278 Code of practice for whitewashing and colour washing
9862 Ready mixed paint, brushing, bituminous, black lead-free, acid

alkali, water and chlorine resisting
4.4. SAMPLES AND TESTS OF MATERIALS

The Contractor shall submit samples of such materials as may be required by
VOLUME-II Page 83
the Engineer-in-charge and shall carry out the specified tests directed by the
Engineer-in-charge at the Site, at the supplier’s premises or at a laboratory
approved by the Engineer-in-charge.
Samples shall be submitted and tests carried out sufficiently early to enable
further samples to be submitted and tested if required by the Engineer-in-
charge.
Approval by the Engineer-in-charge as to the placing of orders for materials or
as to samples or tests shall not prejudice to any of the Employer’s powers
under the Contract.
4.5. STANDARDS
Materials and workmanship shall comply with the relevant Indian Standards
(with amendments upto date).
Where the relevant standard provides for the furnishing of a certificate to the
Engineer-in-charge, at his request, stating that the materials supplied comply in
all respects with the standard, the Contractor shall obtain the certificates and
forward it to the Engineer-in-charge.
The specifications, standards and codes listed in this chapter are considered to be
part of this Bid specification. All standards, specifications, codes of practices
referred to herein shall be the latest editions including all applicable official
amendments and revisions.
4.6. EARTHWORK FOR BUILDINGS/RESERVOIRS
4.6.1. GENERAL
The Contractor shall furnish all tools, plant instruments, qualified supervisory
personnel, labour, materials, any temporary works, consumables, any and
everything necessary, whether or not such items are specifically stated herein for
completion of the work in accordance with the Department’s Requirements.
The Contractor shall survey the site before excavation and set out all lines and
establish levels for various works such as grading, basement, foundations, plinth
filling, roads, drains, cable trenches, pipelines etc. Such survey shall be carried
out by taking accurate cross sections of the area perpendicular to established
reference/grid lines at 8 m in case of buildings and 30 m in case of roads and
pipe lines works intervals or nearer, if necessary, based on ground profile and
thereafter properly recorded.
The excavation shall be carried out to correct lines and levels. This shall also
include, where required, proper shoring to maintain excavations and also the
furnishing, erecting and maintaining of substantial barricades around excavated
areas and warning lamps at night.
Excavated material shall be dumped in regular heaps, bunds, riprap with regular
slopes and levelling the same so as to provide natural drainage. Rock/soil
excavated shall be stacked properly as approved by the Engineer-in-charge. As a
rule, all softer material shall be laid along the centre of heaps, the harder and
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more weather resisting materials forming the casing on the sides and the top.
Topsoil shall be stock piled separately for later re-use.
4.6.2. CLEARING
The area to be excavated/filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If
any roots or stumps of trees are encountered during excavation, they shall also be
removed. The material so removed shall be disposed off as approved by the
Engineer-in-charge. Where earthfill is intended, the area shall be stripped of all
loose/ soft patches, top soil containing objectionable matter / materials before fill
commences.
4.6.3. EXCAVATION
Excavation for permanent work shall be taken out to such widths, lengths,
depths and profiles as are shown on the approved drawings or such other lines
and grades as may be agreed with the Engineer-in-charge Rough excavation shall
be carried out to a depth of 150 mm above the final level. The balance shall be
excavated with special care. Soft pockets shall be removed below the final level
and extra excavation filled up with material as approved by the Engineer-in-
charge. The final excavation should be carried out just prior to laying the
blinding course.
To facilitate the permanent works the Contractor may excavate, and also backfill
later, outside the lines shown on the approved drawings or as agreed with the
Engineer-in-charge. Should any excavation be taken below the specified
elevations, the Contractor shall fill it up with material as approved by EIC upto
the required elevation at no cost to the department.
All excavations shall be to the minimum dimensions required for safety and ease
of working. Prior approval of the Engineer-in-charge shall be obtained by the
Contractor in each individual case, for the method proposed for the excavation,
including dimensions, side slopes, dewatering, disposal, etc. This approval, shall
not in any way relieve the Contractor of his responsibility for any consequent
loss or damage. The excavation must be carried out in the most expeditious and
efficient manner. Side slopes shall be as steep as will stand safely for the actual
soil conditions encountered. Every precaution shall be taken to prevent slips.
Should slips occur, the slipped material shall be removed and the slope dressed
to a modified stable slope.
4.6.4. ROCK
STRIPPING LOOSE ROCK
All loose boulders, detached rocks partially and other loose material which might
move therewith not directly in the excavation but so close to the area to be
excavated as to be liable, in the opinion of Engineer-in-charge, to fall or otherwise
endanger the workmen, equipment, the work shall be stripped off and removed
from the area of the excavation. The method used shall be such as not to render
unstable or unsafe portion, which was originally sound and safe.
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Any material not requiring removal in order to complete the permanent works,
but which, in the opinion of Engineer-in-charge, is likely to become loose or
unstable later, shall also be promptly and satisfactorily removed.
4.7. FILL, BACKFILLING AND SITE GRADING
4.7.1.GENERAL
All fill material shall be subject to the Engineer-in-charge’s approval. If any
material is rejected by Engineer-in-charge, the Contractor shall remove the same
forthwith from the site. Surplus fill material shall be deposited/disposed off as
directed by Engineer-in-charge after the fill work is completed.
4.7.2.MATERIAL
To the extent available, selected surplus soil from excavations shall be used as
backfill. Backfill material shall be free from lumps, organic or other foreign
material. All lumps of earth shall be broken or removed unless otherwise stated.
Where excavated material is mostly rock, the boulders shall be broken into pieces
not larger than 150 mm size, mixed with properly graded fine material consisting
of murrum or earth to fill the voids and the mixture used for filling.
If fill material is required to be imported, the Contractor shall make
arrangements to bring such material from outside borrow pits. The material and
source shall be subject to the prior approval of the Engineer-in-charge. The
approved borrow pit areas shall be cleared of all bushes, roots of trees, plants,
rubbish, etc. Top soil containing foreign material shall be removed. The
materials so removed shall be disposed of as directed by Engineer-in-charge. The
Contractor shall provide the necessary access roads to borrow areas and maintain
the same if such roads do not exist.
4.7.3.FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES, WALLS,
ETC.
The spaces around the foundations, structures, pits, trenches, etc., shall be
cleared of all debris, and filled with earth in layers not exceeding 15 cm, each
layer being watered, rammed and properly consolidated to the satisfaction of
Engineer-in-charge. Earth shall be rammed with approved compaction
mechanism. Usually no manual compaction shall be allowed unless the
Engineer-in-Charge is satisfied that in some cases manual compaction by
tampers cannot be avoided. The final backfill surface shall be trimmed and
leveled to a proper profile to the approval of the Engineer-in-charge.
The filling shall be done after the concrete or masonry is fully set and done in
such a manner as not to cause undue thrust on any part of the structure.
4.7.4.PLINTH FILLING
Plinth filling shall be carried out with approved material such as soil, sand or
murum as in layers not exceeding 15 cm, watered and compacted with approved
compaction mechanism. When filling reaches the finished level, the surface shall
be flooded with water, unless otherwise directed, for at least 24 hours, allowed to
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dry and then the surface again compacted as specified above to avoid settlement
at a later stage. The finished level of the filling shall be trimmed to the
level/slope specified.
Compaction of large areas be carried out by means of 12 ton rollers smooth
wheeled, sheep-foot or wobbly wheeled rollers. In case of compaction of
granular material such as sands and gravel, vibratory rollers shall be used. A
smaller weight roller may be used only if permitted by the Engineer-in-charge.
As rolling proceeds, water sprinkling shall be done to assist consolidation. Water
shall not be sprinkled in case of sandy fills.
The thickness of each unconsolidated fill layer can in this be upto a maximum of
300 mm. The Contractor will determine the thickness of the layers in which fill
has to be consolidated depending on the fill material and equipment used and
the approval of the Engineer-in-charge obtained prior to commencing filling.
The process of filling in the plinth, watering and compaction shall be carried out
by the contractor in such a way as not to endanger the foundation columns,
plinth walls etc. already built up. Under no circumstances Black cotton soil shall
be used for plinth in filling.
For mechanical compaction rolling shall commence from the outer edge and
progress towards the centre and continue until compaction is to the satisfaction
of Engineer-in-charge, but in no case less than 10 passes of the roller will be
accepted for each layer.
The compacted surface shall be properly shaped, trimmed and consolidated to an
even and uniform gradient. All soft spots shall be excavated, then filled and
consolidated.
At some locations/ areas, it may not be possible to use rollers because of space
restrictions, etc. The Contractor shall then be permitted to use pneumatic
tampers, rammers, etc. and he shall ensure proper compaction.
4.7.5.SAND FILLING IN PLINTH AND OTHER PLACES
Where backfilling is required to be carried out with local sand it shall be clean,
medium grained and free from impurities. The filled-in-sand shall be kept
flooded with water for 24 hours to ensure maximum consolidation. The surface
of the consolidated sand shall be dressed to required level or slope. Construction
of floors or other structures on sand fill shall not be started until the Engineer-in-
charge has inspected and approved the fill.
4.8. GENERAL SITE GRADING
Site grading shall be carried out as indicated in the approved drawings.
Excavation shall be carried out as specified in the Department’s Requirements.
Filling and compaction shall be carried out as specified elsewhere unless
otherwise specifications indicated below.
If no compaction is called for, the fill may be deposited to the full height in one
operation and levelled. If the fill has to be compacted, it shall be placed in layers
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not exceeding 200 mm and levelled uniformly and compacted as indicated above
before the next layer is deposited.
To ensure that the fill has been compacted as specified, field and laboratory tests
shall be carried out by the Contractor.
Field compaction tests shall be carried out in each layer of filling until the fill to
the entire height has been completed. This shall hold good for embankments as
well. The fill will be considered as incomplete if the desired compaction has not
been obtained.
The Contractor shall protect the earth fill from being washed away by rain or
damaged in any other way. Should any slip occur, the Contractor shall remove
the affected material and make good the slip.
4.8.1. FILL DENSITY
Unless otherwise specified the compaction, where so called for, shall comply
with minimum 90% compaction by Standard Proctor at moisture content
differing not more than 4% from the optimum moisture content. The Contractor
shall demonstrate adequately by field and laboratory tests that the specified
density has been obtained.
4.8.2. TIMBER SHORING
The provisions of relevant ISS shall apply.
4.8.3. DEWATERING
The Contractor shall ensure at his cost that the excavation and the structures are
free from water during construction and shall take all necessary precautions and
measures to exclude ground/ rain water so as to enable the works to be carried
out in reasonably dry conditions in accordance with the construction
programme. Sumps made for dewatering must be kept clear of the excavations/
trenches required for further work. The method of pumping shall be approved
by Engineer-in-charge, but in any case, the pumping arrangement shall be such
that there shall be no movement of subsoil or blowing in due to differential head
of water during pumping. Pumping arrangements shall be adequate to ensure
no delays in construction. The dewatering shall be continued for at least (7)
seven days after the last pour of the concrete. The Contractor shall, however,
ensure that no damage to the structure results on stopping of dewatering.
The Contractor shall study the sub-soil conditions carefully and shall conduct
any test necessary at the site with the approval of the Engineer-in-charge to test
the permeability and drainage conditions of the sub-soil for excavation,
concreting etc., below ground level.
The scheme for dewatering and disposal of water shall be approved by the
Engineer-in-charge. The Contractor shall suitably divert the water obtained from
dewatering from such areas of site where a build up of water in the opinion of
the Engineer-in-charge obstructs the progress of the work, leads to unsanitary
conditions by stagnation, retards the speed of construction and is detrimental to
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the safety of men, materials, structures and equipment.

When there is a continuos inflow of water and the quantum of water to be
handled is considered in the opinion of Engineer-in-charge, to be large, a well
point system-single stage or multistage, shall be adopted. The Contractor shall
submit to the Engineer-in-charge, details of his well point system including the
stages, the spacing number and diameter of well points, headers etc., and the
number, capacity and location of pumps for approval.
If any foundation pits are filled due to accumulation of surface flow during the
progress of work or during rainy season, or due to any other cause all pumping
required for dewatering the pits & removing silt shall be done without extra cost.
4.8.4. RAIN WATER DRAINAGE
Grading in the vicinity of excavation shall be such as to exclude rain/ surface
water draining into excavated areas. Excavation shall be kept clean of rain and
such water as the Contractor may be using for his work by suitably pumping out
the same. The scheme for pumping and discharge of such water shall be
approved by the Engineer-in-charge.
4.9. CONCRETE
4.9.1. GENERAL
The Engineer-in-Charge shall have the right at all times to inspect all operations
including the sources of materials, procurement, layout and storage of materials,
the concrete batching and mixing equipment and the quality control system.
Such an inspection shall be arranged and the Engineer-in-Charge’s approval
obtained, prior to starting of concrete work. This shall, however, not relieve the
Contractor of any of his responsibilities. All materials which do not conform to
the Specifications shall be rejected.
Materials should be selected so that they can satisfy the design requirements of
strength, serviceability, safety, durability and finish with due regards to the
functional requirements and the environmental conditions to which the structure
will be subjected. Materials complying with codes/standards shall generally be
used. Other materials may be used after approval of the Engineer-in-Charge and
after establishing their performance suitability based on previous data,
experience or tests.
4.9.2. MATERIALS
4.9.2.1. CEMENT
Unless otherwise called for by the Engineer-in-charge, cement shall be ordinary
Portland cement (Grade33, Grade 43, Grade 53) conforming to IS : 269, IS : 8112
or IS : 12269 or Super Sulphated cement conforming to IS 6909 or super resistant
Portland cement conforming to IS 12330 or Pozzolana Portland Cement
conforming to IS 1489(part 1)
Sulphate resistant cement conforming to IS 12330 shall be used for all cement
concrete works below ground level if the soil resistivity is less.
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Only one type of cement shall be used in any one mix. The source of supply,
type or brand of cement within the same structure or portion thereof shall not be
changed without approval from the Engineer-In-Charge.
Cement which is not used within 90 days from its date of manufacture shall be
tested at a laboratory approved by the Engineer-In-Charge and until the results
of such tests are found satisfactory, it shall not be used in any work.
4.9.2.2. AGGREGATES (GENERAL)
It shall comply with requirement of IS 383 and as specified in IS 456-2000.
Aggregates shall consist of naturally occurring stones (crushed or uncrushed),
gravel and sand. They shall be chemically inert, strong, hard, clean, durable
against weathering, of limited porosity, free from dust/slit/organic
impurities/deleterious materials such as iron pyrites, cod, mica, slate, clay alkali,
soft fragments, sea shells and conform to IS : 383. Aggregates such as slag,
crushed over burnt bricks, bloated clay aggregates, sintered fly ash and tiles shall
not be used.
Aggregates shall be washed and screened before use where necessary or if
directed by the Engineer-in-Charge.
Aggregates containing reactive silica shall not be used.
The maximum size of coarse aggregate shall be as stated on the drawings but in
no case greater than ¼ of the minimum thickness of the member.
Plums 160 mm and above of a reasonable size may be used in mass concrete fill
where directed. Plums shall not constitute more than 20% by volume of the
concrete when specifically permitted. The plums shall be distributed evenly and
shall not be closer than 160 mm from the surface. For heavily reinforced
concrete members as in the case of ribs of main beams the nominal maximum
size of aggregate shall be restricted to 5 mm less than minimum clear distance
between the main bars or 5 mm less than the minimum cover to reinforcement
whichever is smaller. Coarse and fine aggregates shall preferably batched
separately, specially for design mix concrete.
The largest possible size, properly graded should be used in order to reduce
water demand.
Graded aggregate shall confirm to requirements in Table 1, 2, 3 & 4. All in
aggregate shall confirm to requirements in Table 5.
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Table 1
Graded Aggregate
IS Sieve Percentage Passing for Normal size of Aggregate
Designation
Mm 40 mm 20 mm 16 mm 12.5 mm
80 100 - - -
40 95-100 100 - -
20 30-70 95-100 100 100
16 - - 90-100 -
12.5 - - - 90-100
10 10-35 25-55 30-70 40-85
4.75 0-5 0-10 0-10 0-10
2.36 - - - -
Table 2
Single Sized Aggregate (Ungraded)
Designatio
n
Mm 63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
80 100 - - - - -
63 85-100 100 - - - -
40 0-30 85-100 100 - - -
20 0-5 0-20 85-100 100 - -
16 - - - 85-100 100 -
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Designatio
n
12.5 - - - - 85-100 100
10 0-5 0-5 0-20 0-30 0-45 85-100
4.75 - - 0-5 0-5 0-10 0-20
2.36 - - - - - 0-5
Table 3
Making Single Sized to Graded Aggregate
Cement Nominal Part of Single Size Aggregate to be Mixed to Get Graded

Concret size of Aggregate (by Volume)
e Mix Graded
Aggregat
e 50 mm 40 mm 20 mm 12.5 mm 10 mm
Required
1:6:12 63 9 - 3 - -
40 - 9 3 - -
1:5:10 63 7.5 - 2.5 - -

40 - 7.5 2.5 - -
1:4:8 63 6 - 2 - -
40 - 6 2 - -
1:3:6 63 4.5 - 1.5 - -

40 - 4.5 1.5 - -
20 - - 4.5 - 1.5
1:2:4 40 - 2.5 1 - 0.5

20 - - 3 - 1
12.5 - - - 3 1
VOLUME-II Page 92
Cement Nominal Part of Single Size Aggregate to be Mixed to Get Graded

Concret size of Aggregate (by Volume)
e Mix Graded
Aggregat
e 50 mm 40 mm 20 mm 12.5 mm 10 mm
Required
1:1.5:3 20 - - 2 - 1
Note : Proportions indicated are by volume. If single sized aggregate specified is not
available, the volume of single sized aggregates shall be varied with a view to obtain the
graded aggregate.
Table 4
Grading of Fine Aggregates
IS Sieve Percentage Passing for
Designation
Grading Zone Grading Zone II Grading Zone Grading Zone

I III IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 90-100
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 : For crushed stone sands, the possible limit on 150 micron IS sieve is
increased to 20 percent. This does not affect 5 percent allowance permitted to
other sieves.
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Table 5
All-in-Aggregate Grading
IS Sieve Percentage Passing All-in-Aggregate Grading of
Designation
Mm 40 mm Nominal Size 16 mm Nominal

Size
80 100 -
40 95-100 95-100
20 45-75 95-100
4.75 mm 25-45 30-50
600 micron 8-30 10-35
150 micron 0-6 0-6
Fine aggregates are divided into 4 zones. Typical good sand falls in Zone II
grading, however, finer or coarse sand may be used with suitable adjustment in
the ratio of quantities of coarse to fine aggregates.
Very fine sands as included in Zone IV grading should not be used except when
the concrete is closely controlled by design mixes.
4.9.2.3. WATER
Water used for both mixing and curing shall conform to IS : 456-2000 and free
from injurious amounts of oils, acids, alkalis, salts, sugar, organic materials that
may be deleterious to concrete or steel. The pH value of water shall not be less
than 6.
4.9.2.4. REINFORCEMENT
Reinforcement shall be any of the following :
High strength deformed bars and wires to IS 1786.
Rolled steel Grade A made from structural steel to IS 2062.
All reinforcement shall be free from loose mill scales, loose rust and coats of
paints, oil, mud or other coatings which may destroy or reduce bond.
4.9.2.5. ADMIXTURES
Accelerating, retarding, water reducing and air entraining admixtures shall
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conform to IS : 9103 and integral water proofing admixtures to IS : 2645.

Admixtures may be used in concrete as per manufacturer’s instructions only
with the approval of the Engineer-in-Charge. An admixture’s suitability and
effectiveness shall be verified by trial mixes with the other materials used in the
works. If two or more admixtures are to be used simultaneously in the same
concrete mix, their interaction shall be checked and trial mixes done to ensure
their compatibility. There should also be no increase in risk of corrosion of the
reinforcement or other embedments.
Calcium chloride shall not be used for accelerating set of the cement for any
concrete containing reinforcement or embedded steel parts. When calcium
chloride is permitted such as in mass concrete works, it shall be dissolved in
water and added to the mixing water by an amount not exceeding 1.5 percent of
the weight of the cement in each batch of concrete. The designed concrete mix
shall be corrected accordingly.
4.9.3. SAMPLES AND TESTS
All materials used for the works shall be tested before use.
Manufacturer’s test certificate shall be furnished for each batch of cement /steel
and when directed by the Engineer samples shall also be got tested by the
Contractor in a laboratory approved by the Engineer-in-Charge.
Sampling and testing shall be as per IS : 2386 under the supervision of the
Engineer-in-Charge.
Water to be used shall be tested to comply with requirements of IS : 456.
The Contractor shall furnish manufacturer’s test certificates and technical
literature for the admixture proposed to be used. If directed, the admixture shall
be got tested at an approved laboratory at no extra cost.
4.9.4. CONCRETE
4.9.4.1. GENERAL
Concrete grade shall be as designated on approved drawings. In concrete grade
M15, M20 etc. the number represents the specified characteristic compressive
strength of 150 mm cube at 28 days, expressed in N/sq. mm as per IS: 456. Concrete
in the works shall be “DESIGN MIX CONCRETE” or “NOMINAL MIX
CONCRETE”. All concrete works of grade M5, M7.5, M10, and M15 shall be
NOMINAL MIX CONCRETE. Grade M20 can be nominal or design mix as per the
requirement whereas all other grades, above M20 necessarily be DESIGN MIX
CONCRETE.
4.9.4.2. DESIGN MIX CONCRETE
The mix design shall produce concrete having reduced workability (consistency)
and strength not less than approximate values given in table below. Workability
shall be controlled by direct measurement of water content and checking it at
frequent intervals by method prescribed in IS 1199.
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4.9.4.3. MIX DESIGN AND TESTING

For Design Mix Concrete, the mix shall be designed according to IS: 10262 and SP
23 to provide the grade of concrete having the required workability and
characteristic strength not less than appropriate values given in IS: 456. The
design mix shall be cohesive and does not segregate and should result in a dense
and durable concrete and also capable of giving the finish as specified. For liquid
retaining structures, the mix shall also result in watertight concrete. The
Contractor shall exercise great care while designing the concrete mix and
executing the works to achieve the desired result.
The minimum cement content for Design Mix Concrete shall be as per IS: 456.
The minimum cement content stipulated above shall be adopted irrespective of
whether the Contractor achieves the desired strength with less quantity of
cement. The Contractor’s quoted rates for concrete shall provide for the above
eventuality and nothing extra shall become payable to the CONTRACTOR in this
account. Even in the case where the quantity of cement required is higher than
that specified above to achieve desired strength based on an approved mix
design, nothing extra shall become payable to the CONTRACTOR.
It shall be the Contractor’s sole responsibility to carry out the mix designs at his
own cost. He shall furnish mix design to the Engineer-in-Charge well in advance
of the concreting operations, a statement of proportions proposed to be used for
the various concrete mixes and the strength results obtained. The strength
requirements of the concrete mixes ascertained on 150 mm cubes as per IS : 516
shall comply with the requirements of IS : 456.
Grade of Concrete Minimum Specified Characteristic
Compressive Compressive Strength
Strength N/sq. mm at 28 days
N/sq.mm at 7 days
M15 10.0 15.0

M20 13.5 20.0
M25 17.0 25.0
M30 20.0 30.0
M35 23.5 35.0
M40 27.0 40.0
Grades lower than M20 shall not be used for reinforced concrete (general).
Grading lower than M25 shall not be used for reinforced concrete in liquid
retaining structures.
A range of slumps which shall generally be used for various types of
construction unless otherwise instructed by the Engineer-in-Charge is given
below:
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Structure / Member Slump in millimeters
Maximum Minimum
Reinforced foundation walls and footings 75 25
Plain footings, caissons and substructure 100 25

walls
Slabs, Beams and reinforced walls 75 25
Pump & miscellaneous Equipment

Foundations 100 25
Building columns 50 25
Pavements 50 25
Heavy mass construction 50 25
4.9.5. Batching & Mixing of Concrete

Proportions of aggregates and cement, as decided by the concrete mix design,
shall be by weight. These proportions shall be maintained during subsequent
concrete batching by means of weigh batchers capable of controlling the weights
within one percent of the desired value.
Amount of water added shall be such as to produce dense concrete of required
consistency, specified strength and satisfactory workability and shall be so
adjusted to account for moisture content in the aggregates. Water-cement ratio
specified for use by the Engineer-in-Charge shall be maintained. Each time the
work stops, the mixer shall be cleaned out and while recommencing, the first
batch shall have 10% additional cement to allow for sticking in the drum.
Arrangement should be made by the Contractor to have the cubes tested in an
approved laboratory or in field with prior consent of the Engineer-in-Charge.
Sampling and testing of strength and workability of concrete shall be as per
IS:1199, IS : 516 and IS : 456.
4.9.5.1. NOMINAL MIX CONCRETE
Mix Design & Testing
Mix Designing and preliminary tests are not necessary for Nominal Mix
Concrete. However works tests shall be carried out as per IS : 456. Proportions
for Nominal Mix Concrete and w/c ratio may be adopted as per Table 9 of IS :
456. However it will be the Contractor’s sole responsibility to adopt appropriate
nominal mix proportions to yield the specified strength.
Batching & Mixing of Concrete
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The Proportions of materials used for concrete of grades shall be as given below :
Proportions for Nominal Mix of Concrete
Grade of Total Quantity for Dry Proportion of Fine Quantity of

Concrete Aggregate by Mass per Aggregate to Coarse Water per
50 kg of Cement Aggregate 50 kg of
Cement,
(as Sum of Fine and (by Mass)
Max in
Coarse Aggregates), in
Litres
kg, Max
M5 800 Generally 1:2 60

Subject to an upper
limit of 1:1.5 and a
lower limit of 1:2.5
M 7.5 625 -do- 45
M 10 480 -do- 34
M 15 350 -do- 32
M 20 250 -do- 30
NOTES
The proportions of the fine to coarse aggregates should be adjusted from

upper limit to lower limit progressively as the grading of the fine
aggregates becomes finer and maximum size of coarse aggregate becomes
larger. Graded coarse aggregate (see Table 5.1) shall be used.
Example: For an average grading of fine aggregate (that is, Zone II of IS
383 :1970, Table 4) 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.
This table envisages batching by weight,. Volume batching when done the
nominal mixes would roughly be 1:3:6, 1:2:4 and 1:1.5:3 for M 10, M 15
and M 20 respectively.
For underwater concreting the quantity of coarse aggregate, either by
volume or mass, shall not be less than 1.5 times nor more than twice that
of the fine aggregate.
Mixing
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Concrete shall be mixed in a mechanical mixer conforming to IS 1791. The

mixing shall be continued until there is uniform distribution of materials and the
mass is uniform in colour and consistency. If there is segregation after
unloading, the concrete should be remixed.
4.9.6. FORMWORK
Formwork shall be all inclusive and shall consist of but not be limited to shores,
bracings, sides of footings, walls, beams and columns, bottom of slabs etc.
including ties, anchors, hangers, inserts, falsework, wedges etc.
The design and engineering of the formwork as well as its construction shall the
responsibility of the Contractor. However, if so desired by the Engineer-in-
Charge, the drawings and calculations for the design of the formwork shall be
submitted to the Engineer-in-Charge for the approval.
Formwork shall be designed to fulfill the following requirements:
Sufficiently rigid and tight to prevent loss of grout or mortar from the concrete at
all stages and appropriate to the methods of placing and compacting.
Made of suitable materials.
Capable of providing concrete of the correct shape and surface finish within the
specified tolerance limits.
Capable of withstanding without deflection the worst combination of self weight,
reinforcement and concrete weight, all loads and dynamic effects arising from
construction and compacting activities, wind and weather forces.
Capable of easy striking out without shock, disturbance or damage to the
concrete.
Soffit forms capable of imparting a camber if required
Soffit forms and supports capable of being left in position if required
Capable of being cleaned and/or coated if necessary immediately prior to casting
the concrete; design temporary openings where necessary for these purposes and
to facilitate and the preparation of construction joints.
The formwork may be of timber, plywood, steel, plastic or concrete depending
upon the type of finish specified. Sliding forms and slip form may be used with
the approval of the Engineer-in-Charge. Timber for formwork shall be well
seasoned, free from sap, shakes, loose knots, worm holes, warps and other
surface defects. Joints between formwork and structures shall be sufficiently
tight to prevent loss of slurry from concrete, using seals if necessary.
The faces of formwork coming in contact with concrete shall be cleaned and two
coats of approved mould oil applied before fixing reinforcement. All rubbish,
particularly chippings, shavings, sawdust, wire pieces dust etc. shall be removed
from the interior of the forms before the concrete is placed. Where directed,
cleaning of forms shall be done by blasting with a jet of compressed air at no
extra cost.
VOLUME-II Page 99
Forms intended for reuse shall be treated with care. Forms that have deteriorated
shall not be used. Before reuse, all forms shall be thoroughly scraped, cleaned,
nails removed, holes suitably plugged, joints repaired and warped lumber
replaced to the satisfaction of the Engineer-in-Charge. The Contractor shall
equip himself with enough shuttering to allow for wastage so as to complete the
job in time.
Permanent formwork shall be checked for its durability and compatibility with
adjoining concrete before it is used in the structure. It shall be properly anchored
to the concrete.
Wire ties passing through beams, columns and walls shall not be allowed. In
their place bolts passing through sleeves shall be used. Formwork spacers left in-
situ shall not impair the desired appearance or durability of the structure by
causing spalling, rust staining or allowing the passage of moisture.
For liquid retaining structures, sleeves shall not be provided for through bolts
nor shall through bolts be removed if provided. The bolts, in the latter case,
shall be cut at 25 mm depth from the surface and the hole made good by cement
mortar of the same proportion as the concrete just after striking the formwork.
Where specified all corners and angles exposed in the finished structure shall
have chamfers or fillets of 20 mm x 20 mm size.
Forms for substructure may be omitted when, in the opinion of the Engineer-in-
Charge, the open excavation is firm enough (in hard non-porous soils) to act as a
form. Such excavations shall be larger, as approved by the Engineer-in-Charge,
than that required as per drawing to compensate for irregularities in excavation.
The Contractor shall provide adequate props carried down to a firm bearing
without overloading any of the structures.
The shuttering for beams and slabs shall be so erected that the side shuttering of
beams can be removed without disturbing the bottom shuttering. If the
shuttering for a column is erected for the full height of the column, one side shall
be built up in sections as placing of concrete proceeds or windows left for placing
concrete from the side to limit the drop of concrete to 1.0 m or as approved by the
Engineer-in-Charge. The Contractor shall temporarily and securely fix items to
be cast (embedments/ inserts) in a manner that will not hinder the striking of
forms or permit loss of grout.
Formwork showing excessive distortion, during any stage of construction, shall
be repositioned and strengthened. Placed concrete affected by faulty formwork,
shall be entirely removed and formwork corrected prior to placement of new
concrete at Contractor’s cost.
4.9.7. PREPARATION PRIOR TO CONCRETE PLACEMENT
Before concrete is actually placed in position, the inside of the formwork shall be
cleaned and mould oil applied, inserts and reinforcement shall be correctly
positioned and securely held, necessary openings, pockets, etc. provided.
VOLUME-II Page 100

All arrangements- formwork, equipment and proposed procedure, shall be

approved by the Engineer-in-Charge. Contractor shall maintain separate Pour
Card for each pour as per the approved format.
4.9.8. CHECK FOR REINFORCEMENT AND CONCRETING
All reinforcement shall be checked and recorded prior to pouring of concrete by
an authorised representative of the engineer in Charge. Similarly the entire
concrete pouring work shall be done in the presence of authorised representative.
The contractor shall therefore give a notice of a minimum three days to the
engineer in Charge or his representative such that the works can be checked by
him or his authorised representative.
4.9.9. TRANSPORTING, PLACING AND COMPACTING CONCRETE
Concrete shall be transported from the mixing plant to the formwork with
minimum time lapse by methods that shall maintain the required workability
and will prevent segregation, loss of any ingredients or ingress of foreign matter
or water. During hot or cold weather, concrete shall be transported in deep
containers or by other suitable measures to reduce loss of water by evaporation
and heat loss in cold weather may also be adopted.
In all cases concrete shall be deposited as nearly as practicable directly in its final
position to avoid rehandling. To avoid segregation, concrete shall not be
rehandled or caused to flow. For locations where direct placement is not possible
and in narrow forms, Contractor shall provide suitable drops and “Elephant
Trunks”. Concrete shall not be dropped from a height of more than 1.0 m. Care
shall be taken to avoid displacement of reinforcement or formwork.
Concrete shall not be placed in flowing water. Under water, concrete shall be
placed in position by tremies or by pipeline from the mixer and shall never be
allowed to fall freely through the water.
While placing concrete the Contractor shall proceed as specified below and also
ensure the following:
Continuously between construction joints and pre-determined abutments.
Without disturbance to forms or reinforcement
Without disturbance to pipes, ducts, fixings and the like to be cast in; ensure that
such items are securely fixed. Ensure that concrete cannot enter open ends of
pipes and conduits etc.
Without dropping in a manner that could cause segregation or shock.
In deep pours only when the concrete and formwork designed for this purpose
and by using suitable chutes or pipes.
Do not place if the workability is such that full compaction cannot be achieved
Without disturbing the unsupported sides of excavations; prevent contamination
of concrete with earth. Provide sheeting if necessary in supported excavations,
withdraw the linings progressively as concrete is placed.
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If placed directly onto hardcore or any other porous material, dampen the
surface to reduce loss of water from the concrete.
Ensure that there is no damage or displacement to sheet membranes.
Record the time and location of placing structural concrete.
Concrete shall normally be compacted in its final position within thirty minutes
of leaving the mixer. Concrete shall be compacted during placing with approved
vibrating equipment without causing segregation until it forms a solid mass free
from voids thoroughly worked around reinforcement and embedded fixtures
and into all corners of the formwork. Immersion vibrators shall be inserted
vertically at points not more than 450 mm apart and withdrawn slowly till air
bubbles cease to come to the surface, leaving no voids. When placing concrete in
layers advancing horizontally, care shall be taken to ensure adequate vibration,
blending and melding of the concrete between successive layers. Vibrators shall
not be allowed to come in contact with reinforcement, formwork and finished
surfaces after start of initial set. Over-vibration shall be avoided; under vibration
is likewise harmful.
The vibrator should penetrate rapidly to the bottom of the layer and atleast 15 cm
into the preceding layer if there is any. It should be held generally 5 to 15 sec.
until the compaction is considered adequate and then withdrawn slowly at
thereof about 8 cm/s.
Concrete may be conveyed and placed by mechanically operated equipment after
getting the complete procedure approved by the Engineer-in-Charge. The slump
shall be held to the minimum necessary for conveying concrete by this method.
When concrete is to be pumped, the concrete mix shall be specially designed to
suit pumping. Care shall be taken to avoid stoppages in work once pumping has
started.
Except when placing with slip forms, each placement of concrete in multiple lift
work, shall be allowed to set for at least 24 hours after the final set of concrete
before the start of subsequent placement. Placing shall stop when concrete
reaches the top of the opening in walls or bottom surface of slab, in slab and
beam construction, and it shall be resumed before concrete takes initial set but
not until it has had time to settle as approved by the Engineer-in-Charge.
Concrete shall be protected against damage until final acceptance.
4.9.10. MASS CONCRETE WORKS
Sequence of pouring for mass concrete works shall be as approved by the
Engineer-in-Charge. The Contractor shall exercise great care to prevent
shrinkage cracks and shall monitor the temperature of the placed concrete if
directed.
4.9.11. CURING
Curing and protection shall start immediately after the compaction of the
concrete to protect it from
VOLUME-II Page 102

• Premature drying out, particularly by solar radiation and wind;

• leaching out by rain and flowing water;
• rapid cooling during the first few days after placing;
• high internal thermal gradient;
• low temperature of frost;
• vibration and impact which may disrupt the concrete and interfere with its
bond to the reinforcement
After the concrete has begun to harden i.e. 1 to 2 hr. after laying curing shall be
started.
All concrete, unless approved otherwise by the Engineer-in-Charge, shall be
cured by use of continuous sprays or ponded water or continuously saturated
coverings of sacking, canvas, hessain or other absorbent material for the period of
complete hydration with a minimum of 10 days. The quality of curing water
shall be the same as that used for mixing.
Where a curing membrane is approved to be used by the Engineer-in-Charge, the
same shall of a non-wax base and shall not impair the concrete finish in any
manner. The curing compound to be used shall be approved by the Engineer-in-
Charge before use and shall be applied with spraying equipment capable of a
smooth, even textured coat.
When concrete is used as subgrade for flooring, the flooring may be commenced
before the curing period of subgrade is over, but curing of subgrade shall be
continued along with the top layer of flooring for a minimum period of 10 days.
Curing may also be done by covering the surface with an impermeable material
such as polyethylene, which shall be well sealed and fastened.
4.9.12. CONSTRUCTION JOINTS AND KEYS
The position and arrangement of construction joints shall be as indicated by the
contractor in his working drawings dually approved by the department.
Concrete shall be placed without interruption until completion of work between
construction joints. If stopping of concreting becomes unavoidable anywhere, a
properly formed construction joint shall be made with the approval of the
Engineer-in-Charge.
Dowels for concrete work, not likely to be taken up in the near future, shall be
coated with cement slurry and encased in lean concrete as indicated on the
drawings or as approved by the Engineer-in-Charge. Before resuming concreting
on a surface which has hardened all laitance and loose stone shall be thoroughly
removed by wire brushing/hacking and surface washed with high pressure
water jet and treated with thin layer of cement slurry for vertical joints and
horizontal layers. When concreting is to be resumed on a surface, which has not
fully hardened, all laitance shall be removed by wire brushing, the surface
wetted, free water removed and a coat of cement slurry applied. On this, a layer
VOLUME-II Page 103

of concrete not exceeding 150 mm thickness shall be placed and well rammed
against the old work. Thereafter work shall proceed in the normal way.
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 concrete mix. This cement
slurry or mortar shall be freshly mixed and applied immediately before placing
concrete.
4.9.13. FOUNDATION BEDDING
All earth surfaces upon which or against which concrete is to be placed, shall be
well compacted and free from standing water, mud or debris. Soft or spongy
areas shall be cleaned out and filled with either soil-cement mixture, lean
concrete or clean sand compacted as approved by the Engineer-in-Charge. The
surfaces of absorptive soils shall be moistened.
Concrete shall not be deposited on large sloping rock surfaces. The rock shall be
cut to form rough steps or benches by picking, barring or wedging. The rock
surface shall be kept wet for 2 to 4 hours before concreting.
Excavation, in clay or other soils that are likely to be affected by exposure to
atmosphere, shall be concreted as soon as they are dry. Alternatively, unless
otherwise mentioned the bottom of the excavation shall be protected
immediately by 8 cm thick layer of cement concrete not leaner than M10 or in
order to obtain a dry hard bottom, the last stretch of excavation of about 10 cm
shall be removed just before concreting.
4.9.14. REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE
Immediately after the shuttering is removed, all defective areas such as honey-
combed surfaces, rough patches, holes left by form bolts etc, shall be inspected by
the Engineer-in-Charge who may permit patching of the defective areas or reject
the concrete work.
All through holes for shuttering shall be filled for full depth and neatly plugged
flush with surface.
Rejected concrete shall be removed and replaced by the Contractor at no
additional cost to the Employer.
For patching of defective areas all loose materials shall be removed and the
surface shall be prepared as approved by the Engineer-in-Charge.
Bonding between hardened and fresh concrete shall be done either by placing
cement mortar or by applying epoxy. The decision of the Engineer-in-Charge as
to the method of repairs to be adopted shall be final and binding on the
Contractor. The surface shall be saturated with water for 24 hours before
patching is done with cement sand mortar. The use of epoxy for bonding fresh
concrete shall be carried out as approved by the Engineer-in-Charge.
4.9.15. HOT WEATHER REQUIREMENTS
Concreting during hot weather shall be carried out as per IS 7861 (Part I).
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Adequate provision shall be made to lower concrete temperatures which shall

not exceed 40 deg C at time of placement of fresh concrete.
Where directed by the Engineer-in-Charge, the Contractor shall spray non-wax
based curing compound on unformed concrete surfaces at no extra costs.
4.9.16. COLD WEATHER REQUIREMENTS
Concreting during cold weather shall be carried out as per IS: 7861(Part II).
The ambient temperature during placement and upto final set shall not fall below
5 deg. C. Approved antifreeze/accelerating additives shall be used where
directed.
For major and large scale concreting works the temperature of concrete at times
of mixing and placing, the thermal conductivity of the formwork and its
insulation and stripping period shall be closely monitored.
4.9.17. LIQUID RETAINING STRUCTURES
The Contractor shall take special care for concrete for liquid retaining structures,
underground structures and those others specifically called for to guarantee the
finish and water tightness.
The Contractor shall make all arrangements for hydro-testing of structure, all
arrangements for testing such as temporary bulk heads, pressure gauges, pumps,
pipe lines etc.
The Contractor shall also make all temporary arrangements that may have to be
made to ensure stability of the structures during construction.
Any leakage that may occur during the hydro-test or subsequently during the
defects liability period or the period for which the structure is guaranteed shall
be effectively stopped either by cement/epoxy pressure grouting, guniting or
such other methods as may be approved by the engineer-in-charge. All such
rectification shall be done by the contractor to the entire satisfaction of the
engineer-in-charge at no extra cost to the department.
4.9.18. WATERSTOPS
4.9.18.1. MATERIAL
The material for the PVC waterstops shall be a plastic compound with the basic resin
of polyvinyl chloride and additional resins, plasticizers, inhibitors, which satisfies
the performance characteristics specified below as per IS : 12200. Testing shall be in
accordance with IS : 8543.
a) Tensile strength : 3.6 N/mm2 minimum
b) Ultimate elongation : 300% minimum
c) Tear resistance : 4.9 N/mm2 minimum
d) Stiffness in flexure : 2.46 N/mm2 minimum
VOLUME-II Page 105

e) Accelerated extraction
Tensile strength : 10.50 N/mm2 minimum
ii) Ultimate elongation : 250% minimum
f) Effect of Alkali : 7 days

Weight increase : 0.10% maximum
Weight decrease : 0.10% maximum
iii) Hardness change : ± 5 points
g) Effect of Alkali : 28 days

Weight increase : 0.40% maximum
Weight decrease : 0.30% maximum
iii) Dimension change : ± 1%
PVC waterstops shall be either of the bar type, serrated with centre bulb and
end grips for use within the concrete elements or of the surface (kicker) type
for external use.
PVC waterstops shall be of approved manufacture. Samples and the test
certificate shall be got approved by the Engineer-in-Charge before procurement
for incorporation in the works.
4.9.18.2. WORKMANSHIP
Waterstops shall be cleaned before placing them in position. Oil or grease shall
be removed thoroughly using water and suitable detergents.
Waterstops shall be procured in long lengths as manufactured to avoid joints as
far as possible. Standard L or T type of intersection pieces shall be procured for
use depending on their requirement. Any non-standard junctions shall be made
by cutting the pieces to profile for jointing. Lapping of waterstops shall not be
permitted. All jointing shall be of fusion-welded type as per manufacturer’s
instructions.
Waterstops shall be placed at the correct location/level and suitably supported at
intervals with the reinforcement to ensure that it does not deviate from its
intended position during concreting and vibrating. Care shall also be taken to
ensure that no honey-combing occurs because of the serrations/ end grips, by
placing concrete with smaller size aggregates in this region. Projecting portions
of the waterstops embedded in concrete shall be thoroughly cleaned of all
mortar/concrete coating before resuming further concreting operations. The
projecting waterstops shall also be suitably supported at intervals with the
reinforcement to maintain its intended position during concreting so as to ensure
that it does not bend leading to formation of pockets. In addition, smaller size
aggregates shall be used for concreting in this region also.
VOLUME-II Page 106

4.9.19. PREFORMED FILLERS AND JOINT SEALING COMPOUND

4.9.19.1. MATERIALS
Preformed filler for expansion / isolation joints shall be non-extruding and
resilient type of bitumen impregnated fibres conforming to IS : 1838 Part I or IS
1838 Part 2.
Bitumen coat to concrete/masonry surfaces for fixing the preformed bitumen
filler strip shall conform to IS:702. Bitumen primer shall conform to IS : 3384.
Sealing compound for filling the joints above the preformed bitumen filler shall
conform to Grade ‘A’ as per IS:1834.
Other organic solvents such as polysulphate based joint sealents to IS:1433 Part 1
or IS 12118 Part 1 may be used with the approval of Engineer-In-Charge.
4.10.STRUCTURAL STEEL WORK
4.10.1. FABRICATION
4.10.1.1. GENERAL
As much fabrication work as is reasonably practicable work shall be completed
in shops, where steel work is fabricated.
All workmanship and finish shall be of the best quality and shall conform to the
best-approved method of fabrication. All materials shall be finished straight and
shall be machined/ground smooth true and square where so specified. All holes
and edges shall be free of burrs. Shearing and chipping shall be neatly and
accurately done and all portions of work exposed to view shall be neatly
finished. Tolerances for fabrication of steel structures conform IS 7215.
Tolerances for erection of steel structures shall conform to IS 12843.
4.10.1.2. MINIMUM THICKNESS OF METAL - CORROSION PROTECTION
Unless, otherwise specified, the thickness of steel section shall be governed as
below:
Steel work exposed to weather
Where steel work is directly exposed to weather and is fully accessible for
clearing and repairing the thickness shall not be less than 6 mm; and where steel
is exposed to weather and is not accessible for cleaning and painting, the
thickness shall not be less than 8 mm. This shall not apply for hot rolled sections
covered by Indian Standards.
Steel work not directly exposed to 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 to Indian Standards, the mean thickness of flange
be considered and not the web thickness.
The requirements (a) and (b) above does not apply to light structural work or
sealed box section or to steel work in which special provision against corrosion
VOLUME-II Page 107

has been made and also in case of steel work exposed to highly corrosive fumes
or vapour in which case the thickness shall be as approved by the Engineer-In-
Charge.
4.10.1.3. DRAWINGS PREPARED BY THE CONTRACTOR
The contractor shall prepare all fabrication working and erection drawings for
the entire work. The drawings shall preferably be of one standard size and the
details shown there in shall be clear and legible.
All fabrication drawings shall be submitted to the Engineer-In-Charge for
approval.
No fabrication drawings will be accepted for Engineer-In-Charge’s approval
unless checked and approved by the contractor’s qualified structural engineer
and accompanied by an erection plan showing the location of all pieces detailed.
The CONTRACTOR shall ensure that connections are detailed to obtain ease in
erection of structures and in making field connections.
Fabrication shall be started by the contractor only after Engineer-In-Charge’s
approval of fabrication drawings. Approval by the Engineer-In-Charge of any of
the drawing shall not relieve the contractor from the responsibility for
correctness of engineering and design of connections, workmanship, fit of parts,
details, material, errors or omissions or any and all work shown thereon.
The drawings prepared by the contractor and all subsequent revisions etc. shall
be at the cost of the contractor for which no separate payment will be made.
4.10.1.4. WELDING
Welding shall be in accordance with IS 816, IS 819, IS 1024, IS 1261, IS 1323 and
IS 9595 as appropriate.
Welding procedure shall be submitted to the Engineer-in-Charge for approval.
Welding shall be entrusted to qualified and experienced welders who shall be
tested periodically and graded as per IS 817, IS :7310 (Part 1) and IS :7318 (Part
1).
For welding any particular type of joints, welders shall give evidence acceptable
to Engineer-In-Charge of having satisfactorily completed appropriate tests as per
IS 817 Part 1, IS 1393, IS 7307, IS 7310 Part 1 and IS 7318 Part 1 as appropriate.
While fabricating plated beams and built up members, all shop splices in each
component part shall be made before such component part is welded to other
parts of the members. Wherever weld reinforcement interferes with proper fit-
up between components to be assembled off welding, these welds shall be
ground flush prior to assembly.
Approval of the welding procedure by the Engineer-in-Charge shall not relieve
the Contractor of his responsibility for correct and sound welding without
undue distortion in the finished structure.
No welding shall be done when the surface of the members is wet nor during
period of high wind.
VOLUME-II Page 108

Each layer of a multiple layer weld except root and surfaces runs may be
moderately penned with light blows from a blunt tool. Care shall be exercised to
prevent scaling or flaking of weld and base metal from overpeening.
No welding shall be done on base metal at a temperature below -5 Deg. C. Base
metal shall be preheated to the temperature as per relevant IS codes.
Electrodes other than low-hydrogen electrodes shall not be permitted for
thicknesses of 32 mm and above.
All welds shall be inspected for flaws
The correction of defective welds shall be carried out in a manner approved by
the Engineer-in-Charge without damaging the parent metal.
4.10.2. PAINTING
All fabricated steel material, except those galvanised shall receive protective
paint coating as prescribed in IS 1477 Parts 1 & 2.
All surfaces to be painted, oiled or otherwise treated shall be dry thoroughly
cleaned to remove all loose scale and loose rust.
Shop contact surfaces need not be painted unless otherwise specified.
Surfaces not in contact but inaccessible after shop assembly shall receive full
specified protective treatment before assembly. This does not apply to interior
of hollow seatings.
Chequered plates shall be painted after the details of painting are approved by
the Engineer-In-Charge.
In case of surfaces to be welded, steel shall not be painted within a suitable
distance of any edges to be welded if paint would be harmful to the welder or
impair the quality of welds.
Welds and adjacent parent metal shall not be painted prior to slugging,
inspection and approved.
Parts to be encased in concrete shall not be painted or oiled.
4.10.2.1. SURFACE TREATMENT
All the surfaces of steel work to be painted shall be thoroughly cleaned of all
loose mill scale, rust, grease, dirt and other foreign matter. The type of surface
treatment shall be as specified in the respective item of work. The workmanship
shall generally conform to the requirements of IS 1477- Part I.
4.10.2.2. PAINTING OF FERROUS SURFACE
Unless and otherwise mentioned, all MS fabricated items used in the project
shall be painted with any of the three options given for interior or external
works. The specifications adopted for every component must be got approved
from the Engineer-in-Charge, before use.
VOLUME-II Page 109

Sr. Final Primer Undercoat Finishing Number and Thickness

No. Finish Coat of Coating
Requir
ed
(1) (2) (3) (4) (5) (6)
A. FOR INTERIORS
(i) Full IS 102: IS 133:1993 IS 133:1993 For optimum results,

gloss 1962 (B)1) (B)1) two coats of primer,
(enamel (see IS 2933:1975 IS 2933:1975 one undercoat, and
gloss) two finishing coats are
Note) (B, S)1) (B, S)1)
recommended. The
IS total film thickness
207:19 shall be not less than
64 100 microns.
(ii) Oil gloss Same IS 133:1993 Same as for (i)

as for (B)
(i) OR
IS 144:1950
(S)
(iii) Metallic Same - IS 2339:1963 One coat of primer and

finishes as for (B) two finishing coats; if
(i) IS 2339:1963 bituminous aluminium
paint is used, three
(S)
coats will be necessary.
OR
Bituminous
aluminium
paints
(iv) Bitumen Same - IS 158:1981 Three coats of bitumen

as for shall be used.
(i)
B. FOR EXTERIORS
(v) Full IS 102: IS IS For optimum results,

gloss 1962 2933:19751) 2933:19751) two coats of primer,
one undercoat, and
(see
two finishing coats are
Note)
recommended. The
VOLUME-II Page 110

Sr. Final Primer Undercoat Finishing Number and Thickness

No. Finish Coat of Coating
Requir
ed
(1) (2) (3) (4) (5) (6)

total film thickness
shall be not less than
100 micron.
(vi) Oil gloss Same - IS 117:1964 Same as for (vii)

as for
OR
(v)
IS 128:1962
(vii Metallic Same - IS 2339:1963 One coat of primer and

) finishes as for two finishing coats; if
OR
(v) bituminous aluminium
Bituminous paint is used, three
aluminium coats will be necessary.
paint
NOTE – Paint primer conforming to IS 102:1962 may be used only where

special precautions for drying of the primer coat taken and where satisfactory
drying conditions is ensured before application of further coats.
Each of these Indian Standards cover both undercoating and finishing paints, and
paints appropriate for the function shall be used.
(B) in brushing.
is spraying.
4.10.2.3. MATERIALS
All the materials shall be of the best quality from an approved manufacturer.
contractor shall obtain prior approval of the engineer-in-charge for the brand of
manufacturer and the colour/shade prior to procurement for usage in the
works.
Primer and finish paints shall be compatible with each other to avoid cracking
and wrinkling. As such it is recommended that the primer and finish paint shall
be from the same manufacturer.
The colour and shade shall conform to IS Standards referred to in Appendix ‘D’
of IS 1477-Part II. To facilitate choosing the correct shade/number from the
alternatives available, contractor shall adopt trial painting in small patches in
consultation with and as directed by the engineer-in-charge.
All paint delivered to the fabrication shop/site shall be ready mixed, in original
sealed containers, as packed by the manufacturer. Thinner shall not be
VOLUME-II Page 111
permitted for usage unless specifically directed by the engineer-in-charge.

Paints shall be stirred thoroughly to keep the pigment in suspension.
Contractor shall at his own cost arrange for testing of paints as per relevant
Indian Standard laboratory whenever engineer-in-charge wants the tests to be
carried out for each batch of paints. Test results shall be submitted to the
engineer-in-charge for obtaining approval.
The type and the number of coats of the primer paint and finish paint shall be as
specified in the respective items of work.
Painting shall be carried out only on thoroughly dry surfaces.
No painting shall be done in frosty/foggy weather or when the humidity is high
enough to cause condensation on the surface to be painted. Paint shall not be
applied when the temperature of the surface to be painted is at 50 0 C or lower.
Primers shall adhere to the surface firmly and offer a key to the subsequent
coats.
The application of paint film serve the twin purpose of protecting the steel from
corrosion and giving the decorative appearance. A paint which gives the steel
adequate protection over a long period together with good appearance shall
therefore be adopted.
Workmanship shall generally conform to requirements specified in IS 1477-Part-
II.
It is essential to ensure that immediately after preparation of the surfaces, the
first coat of primer paint shall be applied by brushing and working it well to
ensure a continuous film without “holidays”. After the first coat becomes hard
dry a second coat of primer shall be applied by brushing to obtain a film free
from holidays.
Structural steel surfaces shall be given the first coat of primer at shop and the
second coat after it is erected in position. Further, any abraded surfaces of the
first coat during transport from shop to site and during erection shall be
provided with a touch up coat of the primer.
The dry film thickness of each coat of primer shall be not less than 25 microns.
Application of finishing paints shall be carried out within the shortest possible
time interval after primer since the primer coats are too thin to give adequate
corrosion protection to the steel surface over a long duration.
Filler coats shall be applied to fill dents and to obtain a smooth finish wherever
necessary. Only factory prepared filler suitable for steel work shall be used.
Filler prepared by whiting and linseed oil by craftsmen at site shall never be
used as such fillers may be unbalanced and incompatible with primer and
finishing coats. Application of filler shall be done with good putty knife and
necessary skill. Filler applied shall be just sufficient to fill the depression or
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unevenness and it shall be restricted to the minimum. It shall be applied in thin

layers. In filling depression or unevenness, due as many coats as are necessary
may be applied allowing each layer to dry hard. The hardened coat shall be cut
down by wet rubbing before the subsequent coat is applied. Where necessary,
filler coats shall be applied over the undercoats also.
Painting shall be carried out either by brushing or by spraying. contractor shall
procure the appropriate quality of paint for this purpose as recommended by the
manufacturer.
After the second coat of primer is hard dry, the entire surface shall be wet
rubbed cutting down to a smooth uniform surface. When the surface becomes
dry, the undercoat of paint of optimum thickness shall be applied by
brushing/spraying with minimum of brush marks. The coat shall be allowed to
hard-dry. The under coat shall then be wet rubbed cutting down to a smooth
finish, taking adequate care to ensure that at no place the undercoat is
completely removed. The surface shall then be allowed to dry.
The first finishing coat of paint shall be applied by brushing or by spraying and
allowed to hard dry. The gloss from the entire surface shall then be gently
removed and the surface dusted off. The second finishing coat shall then be
applied by brushing or by spraying.
At least 24 hours shall elapse between the application of successive coats. Each
coat shall vary slightly in shade and this shall be got approved by the engineer-
in-charge.
Minimum dry film thickness of each coat of finish paint of synthetic enamel shall
be 25 microns. Minimum dry film thickness of other finish paints shall be as
specified in the respective item of work.
Epoxy primer and epoxy paint shall be applied within the specified pot life all as
per recommendations of the manufacturer.
Surfaces inaccessible after assembly shall receive two coats of primer prior to
assembly.
Surfaces inaccessible after erection, including top surfaces of floor beams
supporting grating or chequered plate shall receive one additional coat of finish
paint over and above the number of coats specified prior to erection.
Portion of steel members embedded to be encased in concrete shall not be
painted. Joints to be site welded shall have no shop paint for atleast 50 mm from
the welding zone. Similarly, the steel surfaces shall not be painted in areas
where connection is by use of friction grip bolts. On completion of the joint, the
surfaces shall receive the painting as specified.
Maintenance painting of steel structures will become necessary if the painting
already carried out shows signs of chalking, hairline cracking, deep checking,
fine checking, peeling, blistering and rusting. The breakdown of a paint film is
progressive from the top finish paint to the primer coat and the object of
maintenance painting is to renovate periodically to effectively check the
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breakdown and protect the steel surfaces from corrosion. It is essential that
same quality of paint as specified earlier need be adopted to ensure
compatibility. The general workmanship for maintenance painting shall
conform as per Clause 7 of IS 1477 - Part II.
Contractor shall provide suitable protection as necessary to prevent paint
finishes from splashing on equipment, floors, walls etc.
4.11.CIVIL WORKS DETAILS
4.11.1. BRICKWORK
4.11.1.1. MATERIALS
Bricks used in the works shall conform to the requirements laid down in IS : 1077,
IS 2180, IS 2222, IS 2691, IS 3952, IS 6165. The class of the bricks shall be as
specifically indicated in the respective items of work prepared by the Contractor.
Bricks shall have following dimensions :
Length Width Height

Mm mm mm
Non Modular Bricks 230 110 70
230 110 30
Common burnt clay bricks are classified on the basis of compressive strength as
given below:
Class 10 7.5 5 3.5

designation
Avg. 10 7.5 5 3.5

compressive
strength N/ mm2
Bricks shall be sound, hard, homogenous in texture, well burnt in kiln without
being vitrified, hand/ machine moulded, deep red, cherry or copper coloured, of
regular shape and size and shall have sharp and square edges with smooth
rectangular faces. The bricks shall be free from pores, cracks, flaws and nodules
of free lime. They shall have smooth rectangular faces with sharp corners and
shall be uniform in colour, tolerance of brick dimension shall be  3% for
designation 10 & above and  8% for lower designation. Hand moulded bricks
shall be moulded with a frog and those made by extrusion process may not be
provided with a frog. Bricks shall give a clear ringing sound when struck.
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THE SAMPLE SIZE FOR ALL THE TESTS SHALL BE AS FOLLOWS :
Brick Lot size Sample Size
Class 10 more than 50000 20 bricks

bricks
7.5, 5, 3.5 more than 100000 20 bricks

bricks
The sampling shall be at random & samples shall be stored in a dry place until
tests are done.
4.11.1.2. 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 be less than
20 % of the specified value.
4.11.1.3. WATER ABSORPTION :
Five bricks shall be tested for water absorption and shall not exceed 20 % by
weight upto class 12.5 & 15% by weight for higher classes.
4.11.1.4. EFFLORESCENCE :
Five bricks shall be tested for efflorescence. The efflorescence shall be ‘nil’ to ‘
moderate’
Sample bricks shall be submitted to the Engineer-in-Charge for approval and
bricks supplied shall conform to approved samples. If demanded by Engineer-
in-Charge, brick samples shall be got tested as per IS : 3495 by Contractor. Bricks
rejected by Engineer-in-Charge shall be removed from the site of works within 24
hours.
Mortar for brick masonry shall consist of cement and sand.
Mortar leaner than 1.5 and richer than 1:3 shall not be used.
Materials
Water :
Water used shall be clean and reasonably free from injurious or deleterious
materials such as oils, acids, alkalis, salts. The pH value of water shall not be less
than 6.
Cement :
Cement shall conform to any of the following :
33 Grade Ordinary Portland Cement IS : 2697
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Sand :
Sand for masonry mortars shall confirm to IS 2116
4.11.1.5. PREPARATION OF MORTARS :
Mortars shall be prepared and tested as per IS 2250. Mixing of cement mortar
shall be done in a mechanical mixers.
Workmanship of brick work shall conform to IS : 2212. All bricks shall be
thoroughly soaked in clear water for at least one hour immediately before being
laid. The cement mortar for brick masonry work shall be as specified in the
respective item of work prepared by the Contractor. Brick work 230 mm thick
and over shall be laid in English Bond unless otherwise specified. 100mm/ 115
mm thick brickwork shall be laid with stretchers. For laying bricks, a layer of
mortar shall be spread over the full width of suitable length of the lower course.
Each brick shall be slightly pressed into the mortar and shoved into final position
so as to embed the brick fully in mortar. Only full size bricks shall be used for
the works and cut bricks utilised only to make up required wall length or for
bonding. Bricks shall be laid with frogs uppermost.
All brickwork shall be plumb, square and true to dimensions shown. Vertical
joints in alternate courses shall come directly one over the other and be in line.
Horizontal courses shall be levelled. The thickness of brick courses shall be kept
uniform. In case of one brick thick or half brick thick wall, atleast on e face
should be kept smooth and plane, even if the other is slightly rough due to
variation in size of bricks. For walls of thickness greater than on e brick both
faces shall be kept smooth and plane. All interconnected brickwork shall be
carried out at nearly one level so that there is uniform distribution of pressure on
the supporting structure and no portion of the work shall be left more than one
course lower than the adjacent work. Where this is not possible, the work be
raked back according to bond (and not saw toothed) at an angle not exceeding 45
deg. But in no case the level difference between adjoining walls shall exceed one
meter. Brick work shall not be raised more than one metre per day.
Bricks shall be so laid that all joints are well filled with mortar. The thickness of
joints shall not be less than 6 mm and not more than 10 mm. The face joints shall
be raked to a minimum depth of 10 mm/ 15 mm by raking tools during the
progress of work when the mortar is still green, so as to provided a proper key
for the plastering/ pointing respectively to be done later. When plastering or
pointing is not required to be done, the joints shall be uniform in thickness and
be struck flush and finished at the time of laying. The face of brickwork shall be
cleaned daily and all mortar droppings removed. The surface of each course
shall be thoroughly cleaned of all dirt before another course is laid on top.
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During harsh weather conditions, newly built brick masonry works shall be
protected by tarpaulin or other suitable covering to prevent mortar being washed
away by rain.
Brickwork shall be kept constantly moist on all the faces for at least seven days
after 24 hrs of laying. The arrangement for curing shall be got approved from the
Engineer-in-Charge.
Double scaffolding having two sets of vertical supports shall be provided to
facilitate execution of the masonry works. The scaffolding shall be designed
adequately considering all the dead, live and possible impact loads to ensure
safety of the workmen, in accordance with the requirements stipulated in IS :
2750 and IS : 3696 (Part - I). Scaffolding shall be properly maintained during the
entire period of construction. Single scaffolding shall not be used on important
works and will be permitted only in certain cases as decided by the Engineer-in-
Charge. Where single scaffolding is adopted, only minimum number of holes, by
omitting a header shall be left in the masonry for supporting horizontal
scaffolding poles. All holes in the masonry shall be carefully made good before
plastering/ pointing.
In the event of usage of traditional bricks of size 230 mm x 115 mm x 75 mm, the
courses at the top of the plinth and sills as well as at the top of the wall just below
the roof/ floor slabs and at the top of the parapet shall be laid with bricks on
edge.
All brickwork shall be built tightly against columns, floor slabs or other
structural members.
To overcome the possibility of development of cracks in the brick masonry
following measures shall be adopted.
For resting RCC slabs, the bearing surface of masonry wall shall be finished on
top with 12 mm thick cement mortar 1:3 and provided with 2 layers of Kraft
paper Grade 1 as per IS : 1397 or 2 layer of 50 micron thick polyethylene sheets.
RCC/ steel beams resting on masonry wall shall be provided with reinforced
concrete bed blocks of 150 mm thickness, projecting 150mm on either sides of
the beam, duly finished on top with 2 layer of Kraft paper Grade 1 as per IS :
1397 or 2 layers of 50 micron thick polyethylene sheets.
Steel wire fabric shall be provided at the junction of brick masonry and concrete
before taking up plastering work.
Bricks for partition walls shall be stacked adjacent to the structural member to
predeflect the structural member before the wall is taken up for execution.
Further, the top most course of half or full brick walls abutting against either a
deshuttered slab or beam shall be built only after any proposed masonry wall
above the structural member is executed to cater for the deflection of the
structural element.
Reinforced cement concrete transomes and mullions of dimensions as indicated
in the construction Drawings to be prepared by the Contractor are generally
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required to be provided in the half brick partition walls.

Where the drawings prepared by the Contractor indicate that structural steel
sections are to be encased in brickwork, the brickwork masonry shall be built
closely against the steel section, ensuring a minimum of 20 mm thick cement-
sand mortar 1:4 over all the steel surfaces. Steel sections partly embedded in
brickwork shall be provided with bituminous protective coating to the surfaces
at the point of entry into the brick masonry.
4.11.2. UNCOURSED RANDOM RUBBLE MASONRY, IN FOUNDATION PLINTH AND
SUPERSTRUCTURE
4.11.2.1. MATERIALS
Stones for the works shall be of the specified variety which are hard, durable, fine
grained and uniform in colour (for superstructure work) free from defects like
cracks, sand holes, patterns of soft / loose materials veins, other defects. Quality
and work shall conform to the requirements specified in IS : 1597 (Part-I). The
percentage of water absorption shall not exceed 5 percent as per test conducted
in accordance with IS: 1124. The Contractor shall supply sample stones to the
Engineer-in-Charge for approval. Stones shall be laid with its grains horizontal
so that the load transmitted is always perpendicular to the natural bed.
Cement-stand mortar for stone masonry works shall be as per IS 2250.
4.11.2.2. SCAFFOLDING
Type of scaffolding to be used shall be as specified in the section of brick
masonry.
For all works below ground level the masonry shall be random rubble uncoursed
with ordinary quarry dressed stones for the hearting and selected quarry dress
stones for the facing.
For all R.R. masonry in superstructure the masonry shall be well bounded, faced
with hammer dressed stones with squared quoins at corners. The bushing on the
face shall not be more that 40 mm on an exposed face and on the face to be
plastered it shall not project by more than 12 mm nor shall it have depression
more than 10mm from the average wall surface.
Face stones shall extend back sufficiently and bond well with the masonry. The
depth of stone from the face of the wall inwards shall not be less than the height
or breadth at the face. The length of the stone shall not exceed three times the
height and the breadth on base shall not be greater than three-fourths the
thickness of wall nor less than 150 mm. The height of stone may be upto a
maximum of 300 mm. Face stones or hearting stones shall not be less than 150
mm in any direction.
Chips and spalls shall be used wherever necessary to avoid thick mortar joints
and to ensure that no hollow spaces are left in the masonry. The use of chips
and spalls in the herating shall not exceed 20 percent of the quantity of stone
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masonry. Spalls and chips shall not be used on the face of the wall and below
hearting stones to bring them to the level of face stones.
The maximum thickness of joints shall not exceed 20 mm. All joints shall be
completely filled with mortar. When plastering or pointing is not required to be
done, the joints shall be struck flush and finished as the work proceeds.
Otherwise, the joints shall be raked to a minimum depth of 20 mm by a raking
tool during the progress of the work while the mortar is still green.
Through or bond stones shall be provided in wall upto 600 mm thick and in case
of wall above 600mm thickness, a set of two or more bond stones overlapping
each other by at least 150mm shall be provided in a line from face to back. Each
bond stone or a set of bond stones shall be provided for every 0.5 sq.m of wall
surface.
All stones shall be sufficiently wetted before laying to prevent absorption of
water from the mortar. All connected walls in a structure shall be normally
raised uniformly and regularly. However if any part of the masonry is required
to be left behind, the wall shall be raked back (and not saw toothed) at an angle
not exceeding 45 deg. Masonry work shall not be raised by more than one metre
per day.
Green work shall be protected from rain by suitable covering. Masonry work
shall be kept constantly moist on all the faces for a minimum period of seven
days for proper curing of the joints.
4.11.3. DAMP - PROOF COURSE
4.11.3.1. MATERIALS AND WORKMANSHIP
All the walls in a building shall be provided with damp-proof course covering
plinth to prevent water from rising up the wall. The damp-proof course shall run
without a break throughout the length of the wall, even under the door or other
opening. Damp-proof course shall consist of minimum 50mm thick cement
concrete of 1:2:4 nominal mix with nominal reinforcement and approved water-
proofing compound admixture conforming to IS: 2645 in proportion as directed
by the manufacturer. Concrete shall be with 10mm down graded coarse
aggregates.
The surface of brick work/stone masonry work shall be levelled and prepared
before laying the cement concrete. Side shuttering shall be properly fixed to
ensure that slurry does not leak through and is also not disturbed during
compaction. The upper and side surface shall be made rough to afford key to the
masonry above and to the plaster. Damp-proof course shall be cured properly for
at least seven days after which it shall be allowed to dry for taking up further
work.
4.11.4. MISCELLANEOUS INSERTS, BOLTS ETC.
All the miscellaneous inserts such as bolts, pipes, plate embedments etc., shall be
accurately installed in the building works at the correct location and levels, all as
detailed in the construction Drawing to be prepared by the Contractor.
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Contractor shall prepare and use templates for this purpose, if so directed by the
Engineer-in-Charge. In the event, of any of the inserts are improperly installed,
contractor shall make necessary arrangement to remove and reinstall at the
correct locations/levels all as directed by the Engineer-in-Charge.
4.11.5. BASE CONCRETE
The thickness and grade of concrete and reinforcement shall be as specified in
items of works prepared by the Contractor.
Before placing the blinding concrete, the sub-base of rubble packing shall be
properly wetted and rammed. Concrete for the base shall then be deposited
between the forms, thoroughly tamped and surface finished level with the top
edges of the forms. Two or three hours after the concrete has been laid in
position, the surface shall be roughened using steel wire brush to remove any
scum or laitance and swept clean so that the coarse aggregates are exposed. The
surface of the base concrete shall be left rough to provide adequate bond for the
floor finish to be provided later.
4.11.6. CEMENT PLASTERING WORK
4.11.6.1. MATERIALS
The proportions of the cement mortar for plastering shall be 1:4 (one part of
cement to four parts of sand). Cement and sand shall be mixed thoroughly in
dry condition and then just enough water added to obtain a workable
consistency. The quality of water and cement shall be as per relevant IS
standards. The quality and grading of sand for plastering shall conform to IS:
1542. The mixing shall be done thoroughly in a mechanical mixer unless hand
mixing is specifically permitted by the Engineer-in-Charge. If so desired by the
Engineer-in-Charge sand shall be screened and washed to meet the
Specifications. The mortar thus mixed shall be used as soon as possible
preferably within 30 minutes from the time water is added to cement. In case the
mortar has stiffened due to evaporation of water this may be re-tempered by
adding water as required restoring consistency but this will be permitted only
upto 30 minutes from the time of initial mixing of water to cement. Any mortar
which is partially set shall be rejected and removed forthwith from the site.
Droppings of plaster shall not be re-used under any circumstances.
Preparation of surfaces and application of plaster finishes shall generally
conform to the requirements specified in IS: 1661 and IS: 2402.
Plastering operations shall not be commenced until installation of all fittings and
fixtures such as door/ window panels, pipes, conduits etc. are completed.
All joints in masonry shall be raked as the work proceeds to a depth of 10 mm /
20mm for brick/ stone masonry respectively with a tool made for the purpose
when the mortar is still green. The masonry surface to be rendered shall be
washed with clean water to remove all dirt, loose materials, etc., Concrete
surfaces to be rendered shall be roughened suitably by hacking or bush
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hammering for proper adhesion of plaster and the surface shall be evenly wetted
to provide the correct suction. The masonry surfaces should not be too wet only
damp at the time of plastering. The dampness shall be uniform to get uniform
bond between the plaster and the masonry surface.
4.11.6.2.1. Interior plain faced plaster
This plaster shall be laid in a single coat of 12 mm thickness. The mortar
shall be dashed against the prepared surface with a trowel. The dashing of
the 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. The coat shall be
trowelled hard and tight forcing it to surface depressions to obtain a
permanent bond and finished to smooth surface. Interior plaster shall be
carried out on jambs, lintel and sill faces, etc. as shown in the drawing and as
directed by the Engineer-in-Charge.
4.11.6.2.2. Plain Faced Ceiling plaster
This shall be applied in a single coat of 6 mm thickness. Application of
mortar shall be as stipulated in above paragraph.
Exterior plain faced plaster
This plaster shall be applied in 2 coats. The first coat or the rendering coat shall
be approximately 14 mm thick. The rendering coat shall be applied as stipulated
above except finishing it to a true and even surface and then lightly roughened
by cross scratch lines to provide bond for the finishing coat. The rendering coat
shall be cured for atleast two days and then allowed to dry. The second coat or
finishing coat shall be 6mm thick. Before application of the second coat, the
rendering coat shall be evenly damped. The second coat shall be applied from
top to bottom in one operation without joints and shall be finished leaving an
even and uniform surface. The mortar proportions for the coats shall be as
specified in the respective item of work. The finished plastering work shall be
cured for atleast 7 days.
Interior plain faced plaster 20 mm thick if specified for uneven faces of brick
walls or for random/ coursed rubble masonry walls shall be executed in 2 coats
similar to the procedure stipulated in above paragraph.
For external plaster, the plastering operation shall be commenced from the top
floor and carried downwards. For internal plaster, the plastering operations for
the walls shall commence at the top and carried downwards. Plastering shall be
carried out to the full length of the wall or to natural breaking points like doors/
windows etc. Ceiling plaster shall be completed first before commencing wall
plastering.
Double scaffolding to be used shall be as specified in clause 6.6.1.8.
The finished plaster surface shall not show any deviation more than 4mm when
checked with a straight edge of 2 m length placed against the surface.
To overcome the possibility of development of cracks in the plastering work
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following measures shall be adopted.

Plastering work shall be deferred as much as possible so that fairly complete drying
shrinkage in concrete and masonry works takes place.
Steel wire fabric shall be provided at the junction of brick masonry and concrete to
overcome reasonably the differential drying shrinkage/ thermal movement.
Ceiling plaster shall be done, with a trowel cut at its junction with wall plaster.
Similarly trowel cut shall be adopted between adjacent surfaces where discontinuity
of the background exists.
4.11.7. CEMENT POINTING
4.11.7.1. MATERIALS
The cement mortar for pointing shall be in the proportion of 1:3 (one part of
cement to three parts of fine sand). Sand shall conform to IS : 1542 and shall be
free from clay, shale, loam, alkali and organic matter and shall be of sound, hard,
clean and durable particles. Sand shall be approved by Engineer-in-Charge and
if so directed it shall be washed/ screened to meet specification requirements.
Where pointing of joints in masonry work is specified, the joints shall be raked at
least 15 mm/ 20 mm deep in brick/ stone masonry respectively as the work
proceeds when the mortar is still green.
Any dust/ dirt in the raked joints shall be brushed out clean and the joints shall
be washed with water. The joints shall be damp at the time of pointing. Mortar
shall be filled into joints and well pressed with special steel trowels. The joint
shall not be disturbed after it has once begun to set. The joints of the pointed
work shall be neat. The lines shall be regular and uniform in breadth and the
joints shall be raised, flat, sunk or ‘V’ as may be specified in the respective items
of work. No false joints shall be allowed.
The work shall be kept moist for atleast 7 days after the pointing is completed.
Wherever coloured pointing has to be done, the colouring pigment of the colour
required shall be added to cement in such proportions as recommended by the
manufacturer and as approved by the Engineer-in-Charge.
4.11.8. WATER-PROOFING ADMIXTURES
Water-proofing admixtures shall conform to the requirements of IS: 2645 and
shall be of approved manufacture. The admixture shall not contain calcium
chloride. The quantity of the admixture to be used for the works and method of
mixing etc. shall be as per manufacturer’s instructions and as directed by the
Engineer-in-Charge.
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CHAPTER 5
PRE-DISPATCH INSPECTIONS
1.1 PRE-DISPATCH INSPECTIONS AND TESTS
The contractor shall submit a Quality Assurance Programme (QAP) for each item for
approval of Engineer-in-Charge. Actual manufacturing shall start only after
approval of QAP.
It is proposed to get the equipment and material listed in the table below, inspected
prior to dispatch to work-site through third party/project consultants/departmental
engineer(s).
S. No. Equipment/Material
1. All Pipes and specials
2. All Valves
3. All pumps, motors , DG Set and Transformers
4. Electro Magnetic Full Bore Meters, Turbine Type bulk meters
5. Equipment for PLC
The Contractor shall notify Engineer-in-Charge at least 4 weeks in advance for

carrying out the Pre-Dispatch inspection, and tests before the dispatch of materials.
Failure to Pre-Dispatch inspection/tests, the contractor shall be liable for all costs
incurred against such dispatches. No material scheduled or notified for pre-dispatch
shall be accepted until inspection/have been successfully carried at manufacturers
or other selected premises and the inspection report has been approved by Engineer-
in-Charge and he has given consent for dispatch of material.
In addition to the pre-dispatch inspections, the Engineer-in-Charge may ask for
additional tests/certificates from manufacturer to satisfy with the quality of material
used and for the compliance to respective standards.
For all materials and equipments not listed above, the contractor shall produce
manufacturers test certificates for material, performance, efficiencies, workmanship
and standard compliance etc. as directed by the Engineer-in-Charge, to satisfy with
the quality of the material to be received.
The Engineer-in-Charge may also ask for Pre-Dispatch inspections for any other
item(s) not shown in the list of items requiring pre-dispatch inspection, for which the
contractor shall make necessary arrangements, without any additional costs to the
Department.
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Considering the less quantity of material to be got tested at manufacturer’s work, the
EIC may condone such pre-dispatch inspection after obtaining manufacturer’s test
certificates for satisfactory completion of tests for pre-dispatch as mentioned
hereinafter. The Contractor shall thereafter be responsible for the equipment
performance at site for given duty conditions. Pre-dispatch inspection and its
approval shall also not relieve the Contractor from its responsibility of performance
of material in design conditions during execution and maintenance.
1.2 TESTING AND INSPECTION OF PIPES & SPECIALS

The pipes and specials will only be dispatched after necessary certification by the
Department's representative or third party is obtained regarding satisfactory
completion of inspection. The Engineer-in-Charge may also ask for repetition of
some tests, even after successful testing by the Department's representative in his
presence or in front of a third party authorised by the Department. The contractor in
such cases will co-operate and provide all necessary facilities for re-testing, without
any additional costs to the Department.
1.3 INSPECTION AND TESTING FOR BUTTERFLY VALVES

During testing there shall be no visible evidence of structural damage to any of the
valve component.
The following test shall be carried out for butterfly valves:
i) Seat leakage test at rated pressure
ii) Body hydrostatic test at 1.5 times the rated pressure
iii) Disc strength test at body test pressure
iv) Valve operation with and without actuator
v) For effort Required in manual operation of valve
vi) Crack opening test under tension
vii) Other tests specified in BS 5155 or relevant IS
viii) Identification and properties of material of body
ix) General construction features of gear box as per requirement given in
specification.
Valves to be tested with actuators shall be tested with actuators, with a differential
head equivalent to their maximum working pressure, to prove that the actuators
are capable of opening and closing the valves under maximum unbalanced head
condition within the specified opening or closing period.
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1.4 INSPECTION AND TESTING FOR SLUICE VALVES

valve component. Following tests shall be carried out.
I) Seat leakage test at rated pressure
ii) Hydrostatic test at 1.5 times the rated pressure
iii) Valve operation
iv) For effort Required in manual operation of valve
v) Identification and properties of material of body
vi) General construction features of gear box as per requirement given in TD
Valves to be tested with actuators shall be tested with actuators, with a differential
head equivalent to their maximum working pressure, to prove that the actuators are
capable of opening and closing the valves under maximum unbalanced head
condition within the specified opening or closing period.
1.5 INSPECTION AND TESTING FOR DUAL PLATE CHECK VALVES/NON-RETURN

VALVES
valve component.
ii) Body hydrostatic test at 1.5 times rated pressure
iii) Other tests specified in API 598/other applicable standards
1.6 INSPECTION AND TESTING FOR AIR VALVES

valve component.
ii) Operation
iii) Test report from FCRI for air intake/discharge capacity
iv) As per relevant ISS
1.7 INSPECTION AND TESTING OF PUMPS

The performance and hydraulic tests of the pumps shall be made with their
respective duty motors and frequency drive. The following inspections/tests shall be
carried out:
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1. Non Casing - Dye penetration test on critical area,

destructive Impeller -Dye penetration test on critical area, Shaft -
special test Ultrasonic test,
2. Hydrostatic 1.5 times the shut-off head

Test
3. Performance As per IS 5120 & IS 9137 at reduced speed as approved by

Test Engineer-in-Charge.
Head v/s Discharge characteristic -
Power absorbed v/s Discharge -
Efficiency v/s Discharge -
Readings for the above tests shall be taken at duty points.
4. Strip Test Clearances within tolerance limits and no signs of cavitation

evident.
5. Mechanical As per IS: 11723, Gr 6.3 or better.

Balancing
6. Other Tests i) For Vibration levels of Shafts

ii) For noise levels
7. Visual Pumps shall be offered for visual inspection before shipment.

Inspection The pump components shall not be painted before inspection.
1.8 INSPECTION OF MOTORS

Motors shall be subject to full performance tests, (including Power factor) which
may be witnessed by the authorised person / agency of the department at the Motor
manufacturer’s works. Motors of 5.0 kW to 20 kW site rating shall be subject to
performance tests but will not be witnessed. Motors under 5.0 kW site rating shall be
subject to “type test” standards. Type test certificates that shall include the following
shall be provided for all motors:
i.Motor testing shall be carried out in accordance with the requirements of IS 325.
ii.Acceptance Tests - Full load test to determine efficiency, power factor and slip
shall be conducted on all the motors. No negative tolerance shall be permitted
on the tested motor efficiency
iii.All type test certificates conducted on similar motors.
1.9 INSPECTION OF LV DISTRIBUTION PANEL
VOLUME-II Page 126

All routine tests on all panels.

All type test certificate conducted on similar panels to be forwarded.
1.10 OTHER EQUIPMENTS

All the items listed below shall be inspected before dispatch for the general
requirement of testing in the standards to which they conform, the Department’s
requirement as given in the specifications, the general arrangements and for
workmanship.
Electro Magnetic Full Bore Meters, Turbine type meters.
1.11 MANUFACTURE’S CERTIFICATIONS

For other items to be used for the work, the department may ask for relevant
certificate of the manufacturer.
VOLUME-II Page 127

CHAPTER 6
TESTING - COMMISSIONING AND TRIAL RUN
2.1 INSPECTION AND TEST AFTER ERECTION
In addition to the progressive supervision and inspection by the Engineer-in-Charge
the Contractor shall offer for inspection to Engineer in Charge, the complete, erected
System or its Parts on which tests are to be carried out. After such inspection by
Engineer in Charge, each equipment/subsystem shall be tested by the Contractor in
accordance with the applicable standards in the presence of Engineer in Charge.
It is not the intent to specify herein all details about the commissioning activities.
However the commissioning checks in brief are given as guidance.
The pre-commissioning test results shall be documented for record purposes and
compared with the shop test certificates.
2.2 TEST INSTRUMENTATION
All required test instrumentation, for the performance and efficiency tests, shall be
supplied by the Contractor and shall be retained by him upon satisfactory
conclusion of all such tests at the site. All costs associated with the supply,
calibration, installation and return of the test instrumentation shall be included in
the contract price. The test instrumentation for the performance tests shall be in
accordance with the code. All test instrumentation shall be as per Indian Standards
as approved by the Engineer in Charge. All calibration procedures and standards
shall be subject to the Engineer in Charge's approval. Batch calibration will not be
accepted.
2.3 PIPE LINE
The sectional testing of pipeline shall be done as per provisions laid in the Chapter
of “Specifications for Pipes” along with the laying of pipelines. The tested pipeline
will be joined by gap pieces to complete the total physical completion of works.
The laid pipeline will be joined with respective manifold through valves. Just before
the commissioning the complete main will be checked for:
(i) All the valves in the system will be inspected for proper lubrication,
manual operation.
(ii) All air valves shall be inspected for proper fitting and operation of
isolating valves.
(iii) All flange joints will be checked for tightness of all bolts, clamps, etc.
(iv) The entire transmission shall be checked for proper soil cover.
(v) The structures will be checked for any constructional defects.
(vi) The valve chambers and their surroundings will be checked for its
cleanliness.
2.4 VALVES OF ALL KIND
VOLUME-II Page 128

PRE-COMMISSIONING CHECKS
a) Check dimensional details and alignment
b) Check tightness of all bolts, joints, etc.
c) Check manual operation; in case of motor driven valves check electrical operation
d) Check for duration of full closure and opening cycles
COMMISSIONING CHECKS
a) Check operation in the starting and stop routine of the related pumps
b) Check for operation from control panel
c) Check for leakage of shaft glands, joints
2.5 INSTRUMENTATION
SITE CALIBRATION
Standard calibration procedures shall be used for calibrating all field instruments. All
reference equipment, used for calibration, shall be certified from an authorised
certifying agency, to be arranged by the Contractor at his own cost. At the time of
calibration, standard calibration norms shall be adopted and the same will be
documented for record purposes.
Calibration shall be performed in the presence of the Engineer in Charge or his
representative. The instrumentation shall be calibrated while being commissioned.
The Contractor will monitor and check the instrument calibration throughout the
Operation and Maintenance period.
1.0.1INSTRUMENTATION INSTALLATION & PRE-COMMISSIONING CHECKS
a) Check the exact location of the instrument with reference to the Pipe &
Instrumentation diagram and/or the General Arrangement drawing.
b) Check the model No. and instrument type with reference to the technical
specification requirements.
c) Check all mounting and fixing arrangements and required accessories such as
isolation valve, nuts & bolts, siphon etc.
d) Check that the instrument installation is as per the installation drawing.
e) Check the cable type, connections for power supply as well as signal cables.
f) Check the loop continuity for every circuit. While this is being done, the power
supply to the instrument shall be cut-off.
g) Site calibration of the instruments shall be compared with the manufacturer’s
factory test reports.
h) After switching on the instrument/system, it shall be monitored hourly and the
data obtained shall be recorded and compared with the reference norms to
ascertain whether any recalibration is required. If recalibration is required it shall
be carried out using standard reference equipment/instruments at no extra cost.
VOLUME-II Page 129

1.0.2INSTRUMENTATION COMMISSIONING
a) Each control loop and interlock shall be tested independently, in manual mode
first and then in auto mode. The operation shall be checked for conformity with
the approved block logic in both modes.
b) Annunciation system shall be checked as performance testing by simulating the
condition and by passing in actual mode and then individual loop will be checked
for annunciation system. All motorised valves shall be checked in manual mode
first, from controls on the control panel and feed-back from the field for valve
on/off shall be checked on the mimic and panel. All pump control ON/OFF shall
be checked in manual mode first.
2.6 TESTS FOR WATER TIGHTNESS OF WATER-RETAINING STRUCTURES
The contractor shall carry out a water tightness test as per IS: 3370 for the maximum
water head condition i.e. with the water standing at full supply level. All cost of
testing shall be borne by the contractor. This test shall be carried out in accordance
with the procedure given below
-For water tightness test, before the filling operations are started, the reservoirs shall
be jointly inspected by the Engineer in Charge and the representative of the
Contractor and condition of surfaces of wall, construction joints etc. shall be
inspected and noted and it shall be ensured that jointing material filled in the joints
is in position and all openings are closed. The contractor shall make necessary
arrangement for ventilation and lighting of reservoir by way of flood lights,
circulators etc. for carrying out proper inspection of surfaces and internal conditions
if so desired by the Engineer in Charge.
-The water retaining structures shall be filled with water gradually at the rate not
exceeding 30 cm. rise in water level per hour and shall extend for a period of 72
hours. Records of leakages starting at different level of water in the reservoirs, if any,
shall be kept.
-The reservoirs once filled shall be allowed to remain filled for a period of 7 days
before any readings or drop in water level is recorded again at 7 days. The total drop
in surface level over a period of 7 days shall be taken as indication of the water
tightness of the reservoir, which for all practical purposes shall not exceed 40mm.
There shall be no indication of leakages around the puddle collars or on the wall and
bottom of the reservoir.
-If the structure does not satisfy the test requirements, and the daily drop in water
level is decreasing, the period of test may be extended for further seven days and if
the specified limit is not exceeded, the structure may be considered as satisfactory.
-In case the drop in water level exceeds the permissible limit with the stipulated
period of test, the Contractor shall carry out such additional works and adopt such
measures as may be directed by the Engineer in charge to reduce the leakage in the
permissible limit. The entire rectification work that shall be carried out in this
connection shall be at Contractor’s cost.
VOLUME-II Page 130

- If the test results are unsatisfactory, the Contractor shall ascertain the cause and
make all necessary repairs and repeat the water retaining structures test procedures,
at his own cost. Should the re-test results still be unsatisfactory after the repairs, the
structure will be condemned and the Contractor will dismantle and reconstruct the
structure, to the original specification, at his own cost.
2.7 DOCUMENTATION
Set of documents shall be prepared and maintained by the Contractor and one set of
the latest revised documents shall always be kept at site. The following documents
shall be prepared by the Contractor:
• Data sheets for instrument specification and selection
• Instrument Schedule
• Instrumentation schedule
• Instrumentation cable schedule
• Loop drawings for instruments in the field and control panel
• Instrument test and calibration report
• Instrument installation drawings
• As built drawings and G.A. Drawings for equipment and instrument installation
The Contractor shall keep on site, two sets of the latest revised Operation,
Maintenance and Calibration manuals for all field instruments and sub systems,
annunciation system, data loggers, indicating controllers and PLC system etc.
2.8 PERFORMANCE TESTS AT SITE
1.0.3EXECUTION OF THE TESTS
As soon as possible after the equipment has been installed and after physical
completion of the work, performance tests shall be carried out as per relevant test
requirements and mutually agreed/specified Codes and Standards. These tests may
repeat the tests carried out at the manufacturer's works and/or his sub-vendor/sub-
contractor's works and any other tests the Engineer in Charge may require in order
to determinate that the equipment and works are in accordance with the
specifications and guarantees.
Performance tests for individual items of Equipment, shall be conducted on all
equipment supplied by the Contractor.
A program for conducting the performance tests shall be submitted to the Engineer
in Charge, for approval, at least fourteen days before the commencement of the tests.
If the Contractor so desires, the equipment may be run for a reasonable time,
immediately before the performance test is conducted. A request for this run, stating
duration and operating point must be made, in writing to the Engineer in Charge at
least three days before the performance test.
VOLUME-II Page 131

During the period of any test, the conditions shall be held as steady as possible,
compatible with safe and effective operation.
The power consumption of all continuously running auxiliary equipment shall also
be measured and recorded during the performance tests.
After the results of the performance tests have been submitted to and approved by
the Engineer in Charge, a summary of the test readings and the performance
calculations shall be incorporated in the final version of the Operating and
Maintenance Instruction Manuals.
1.0.4REJECTION OF THE SYSTEM OR SYSTEM COMPONENTS
If the performance tests indicate the computed values of performance parameters
have deviated from the guaranteed values and the Contractor is unable, within 21
days or such extension of time as may be allowed by the Engineer in Charge, to
remedy such deficiency, then the Engineer-in-Charge shall have the right to reject
the component or the system.
2.9 COMMISSIONING
1.0.5GENERAL
After successful checks and after erection and pre-commissioning tests, the entire
system shall be commissioned by the Contractor.
During commissioning, the Contractor shall supply all material and labour to
supervise, operate, keep in operation, adjust, test, service, repair and do all things
necessary to keep the System running to the satisfaction of the Engineer in Charge.
This shall include labour on a 24 hour-a-day basis during the test period and for
such other period of continuous operation, as the Engineer in Charge may consider
necessary to establish the efficient operation of the System.
If any test results/operations show noticeable variation from the Specification
requirements for the System or any particular item of the System, the Contractor
shall immediately take steps to rectify the deficiency without any extra cost to
Department.
1.0.6SYSTEM COMMISSIONING
The Contractor shall be responsible for trial runs, testing and commissioning of the
entire system under design and operating conditions or under conditions which the
Engineer in Charge may define and which in no case shall exceed the design and
operational conditions. The System commissioning shall commence after the work
has been physically completed to the satisfaction of the Engineer in Charge. The
design and operation conditions are as follows:
a) Design capacity of the pumps
b) Starting of pumps against closed/ open valves
c) Stopping of pumps after closure/ opening of delivery header valves
VOLUME-II Page 132

d) Power cut and sudden stop of all pumps under design flow conditions
e) Closing of the line valves against full static pressure
f) Operation of all valves (manual and motorised/ manual)
g) Operation of all air valves
h) Operation of Air vessel if any
i) Operation of all measuring instruments
The timing of the commissioning tests will depend on the availability of water and
power.
The Contractor shall prepare the entire system for the execution of the tests complete
with all required taps, branches with blank flanges, etc. All these provisions have to
be of a durable nature so that the tests can be repeated even after several years. He
has to provide all the equipment for the execution of the tests and for the measuring
and recording of:
a) pressure at various points within the pump station and the pipeline, precision 1 m
(0.1 bar)
b) head losses across different valves and fittings
c) overall energy efficiency of the pumping system at the prescribed flow rates
d) performance of the non-return valves
e) other tests required for the verification of the performance data of the pump
station system in conjunction with the pipeline system
f) Loss of water in mains
The Contractor may engage an institution for the execution of the required tests and
their monitoring at his own cost. The institution has to be approved by the Engineer
in Charge.
The system shall be treated as commissioned only when the entire system has been
successfully operated over a period of time as follows:
• 36 hours uninterrupted, continuous running for three days, at design flow/ flow
notified by Engineer-in-Charge.
or
• Short duration operation of 8 hours with a 8 hour stop and a further 4 hours
pumping totaling 12 hours working per day for a three day period, at design
flow/ flow notified by Engineer-in-Charge.
Any repairs or replacement required during this period shall be done by the
Contractor at his own cost.
The Contractor shall allow for commissioning to be conducted at any time during
the O &M Period without extra charges under the Contract.
VOLUME-II Page 133

The operation of the system solely for the purpose of maintaining partial supply by
or on behalf of the Department shall not be taken as evidence that any work has
fulfilled the commissioning tests, or has been taken over unless the Engineer in
Charge specifically states so in writing.
2.10 TRIAL RUNS
The Contractor shall run and maintain the System for 30 days at a stretch, or any
other stipulated periods and conditions prescribed by the Engineer-in-Charge, from
the date of commissioning. During the trial run all components of the system must
function in a synchronized manner so as to give all desired outputs at efficiencies
guaranteed or as stipulated in the specifications, failing which the Engineer-in-
Charge may extend the period of trial run, till a date the entire system functions to
the complete satisfaction of Engineer-in-Charge.
Standard test reports shall be compiled at all stages of installation, pre-commissioning
and commissioning. Any modifications or changes shall be incorporated and marked
on the respective reference drawings and the Engineer in Charge shall be advised.
The necessary protocol must be maintained for record purposes, jointly with
Engineer in Charge and/or the authorised Representative of the Department.
2.11 PERFORMANCE DURING OPERATION AND MAINTENANCE PERIOD
The Department reserves the right to carry out further tests to check the
performance and efficiency of the Plant at the end of the O&M period. Such
adjustments to the plant, as may be considered part of normal operating routine,
shall be carried out prior to these tests.
Should the results of such repeat tests, carried out by the Department, indicate that
performance values deviate from guaranteed values or the auxiliary power
consumption exceeds 1.0% of guaranteed value, then the Contractor shall be given
the opportunity to take corrective measures and carry out further tests, all at his own
expense. Should the test indicate performance and auxiliary power consumption
values below the guaranteed value then the Contractor’s security deposit may be
forfeited.
VOLUME-II Page 134

CHAPTER 9
Specifications for Operation and Maintenance
3.1 GENERAL
This section of specifications applies to the specifications of materials used for
operation and maintenance, the workmanship, period for routine maintenance,
specifications for the acceptable quality of treated water, maintenance of records,
and responsibilities during operation and maintenance period.
The Contractor shall operate and maintain the entire system all buildings
constructed in the project as per the scope of work, campus areas for the entire
period specified in the Contract.
3.2 SPECIFICATIONS
The specification of materials used for repairs shall be the one used in the original
work. If not used during execution, specifications for such materials, which were not
used during construction, shall be got approved by the department, prior to
commencement of operation and maintenance period and must be incorporated in
the O&M manual. Without being limited by this clause, during O&M period, the
contractor shall use appropriate material for repairs even if the material required for
such repair is not approved earlier, and no delay in repairs shall be subjected to such
limitation. But subsequent to such use of material, the contractor shall submit
proposals for the approval of the specifications of such material. The submissions
and approval of material shall be done in accordance to the conditions laid down in
the special conditions of contract. The approved material, will subsequently form a
part of the O&M manual.
3.3 EXPERIENCE AND QUALIFICATION OF STAFF
For all operation and maintenance works, the contractor shall provide skilled staff,
who have adequate qualifications and sufficient experience of similar works. The
minimum qualifications and experience required for minimum staff to be deployed
by the contractor shall be as per scope of work for carrying out the O&M functions.
3.4 LUBRICATION
A complete schedule of recommended oils and other lubricants shall be furnished by
the Contractor, in the operation and maintenance manuals. The number of types of
lubricants shall be kept to a minimum. In case of grease lubricated bearings for
electric motors, a lithium base grease is preferred.
The Contractor shall indicate the brand name of indigenously available equivalent
lubricants with complete duty specification, in the O&M manual. The Contractor
shall also furnish the schedule of quantities for each fill, frequency of filling and
annual requirement in O&M manual.
Where lubrication is effected by means of grease, preference shall be given to a
pressure system which does not require frequent adjustment or recharging.
Frequent, for this purpose means more than once in a month.
VOLUME-II Page 135

Where more than one type of special grease is required, a grease gun for each special
type shall be used.
All lubricant systems shall be designed so as not to cause a fire or pollution hazard.
The Contractor shall supply flushing oil for such lubrication system when an item of
plant is ready for preliminary running.
3.5 SPARE PARTS
All spare parts used for the equipment in the maintenance of the system must be
from the manufacturer of the equipment or if the equipment itself has been made
with parts of other manufacturer the parts must be of the same make as used in the
equipment supplied and installed.
All spare parts shall be packed for long storage under the climatic conditions
prevailing at the site. Each spare part shall be labelled on the outside of its packing
with its description, number and purpose and, if more than one spare is packed in a
single case, a general description of the case contents shall be shown on the outside
and a packing list enclosed.
3.6 PARTICULAR REQUIREMENTS DURING O&M
The workmanship observed for all repair and maintenance work must be in
accordance to “Good Engineering Practices”.
3.7 PIPELINE
The MS clamps, pipe sections used must have thickness as per design requirement at
the point of installation and shall be coated internally and externally as specified for
MS pipes in the chapter of “Specifications for Pipes”.
The rubber gaskets/ rings, nut & bolts etc. to be used shall be as per specifications
given for respective items in the Chapters of “Specifications for Pipes” and
“Specifications for Valves”.
After each repair the damaged coating of pipes must be repaired and if in trench
conditions, the trench must be filled with approved soil so as to provide minimum
cover of 0.90 meters.
Stretches along pipe alignments where cover is washed out or removed due to other
reasons must be rehabilitated so that the minimum cover required is always
maintained.
All cracks in pipe supporting structures, valve chambers and their edges must be
racked, filled and made good with cement sand mortar 1:2.
3.8 OPERATIONS AND MAINTENANCE MANUAL
The comprehensive manual to be submitted before the operation and maintenance
period, i.e. during execution stage as defined in special conditions, of contract
containing the contents as specified in Chapter – 2 of “scope of work” given in
Volume II of bid document, must be updated, not limited to, on principals listed
below:
VOLUME-II Page 136

1. Up-dating any changes in the procedures existing in the O&M manual,

deemed necessary to be changed due to limitation observed during the
maintenance period and incorporating the procedures for maintenance
of other repairs/break downs not incorporated in the maintenance but
faced during O&M period.
2. Procedures for repair of leaks/burst in different types of pipes must be
provided, with supporting drawings as provided in the O&M manual
must be updated if any differences are observed during O&M contract.
3. Frequency of spares used in maintenance of valves (air-valve, sluice
valves and butterfly valves), expansion joints, equipment installed for
surge protection and protection against corrosion must be recorded for
updating the contents of manual.
4. Record of trouble shooting points and details of events causing
troubles (break down’s) during maintenance of pumps / motors /
measuring equipment(s), / electric panel and accessories there in must
be maintained and used for updating the contents of manual.
5. The record of Inventory used must be maintained and the relevant
portion of O&M manual must be updated to list out the requirement of
Inventory for maintaining the system for 12 months.
6. The provisions in the manual must incorporate every aspect of good
industrial practices even if not elaborated here or in other parts of the
bid documents. The provisions in the approved operation and
maintenance document shall only be valid and binding for both the
parties during operation and maintenance along with the additions
and deletions made.
7. The manual so prepared must be updated after the end of every year of
operation and maintenance, giving effect to the experience gained and
the observations made by the Department during the maintenance
period.
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Government of Rajasthan

Public Health Engineering Department

Work of Providing, laying, testing and commissioning of DI /

Office of Additional Chief Engineer

Telephone no. 0141-2740170 Email: [email protected]

d. Operation and maintenance of the whole water supply scheme of RWSS

(xvi) Sectional testing of pipeline.

(i) For NH/SH/railway crossings, the department shall apply to respective

execution shall be the contractor’s responsibility. The contractor shall be

The scope of work includes:

(i) Construction of reservoirs as per the provisions given in the

equipment, which may be supplemented with additional equipment as may be

List of Minimum Laboratory Equipment/Instrument

1 Balance 20 kg capacity-self indicating type

2 Electronic Balance 5 kg capacity accuracy 0.5 gm

3 Sieves analysis set of IS with lid and pan: 450 mm diameter:

4 Sieves analysis set of IS with lid and pan:200 mm diameter:

5 Measuring tape, vernier scale, Digital Screw Gauge, die for

6 First aid box

C. For Cement and cement concrete:

1 Slump testing apparatus

2 Compression strength testing machine

D. For DI/HDPE Pipes:

1 Ultra sonic gauges for thickness measurement of coating,

2 Equipment for Hydraulic sectional Testing with calibrated

d. OPERATION AND MAINTENANCE FOR 5 YEARS:

• Repair history of all pipeline, mechanical, electrical and instrumentation

p) Emergency Maintenance/Periodic routine maintenance: Providing a fleet

The minimum permanent staff to be deployed for each section by the

S. No. Category Total

a) Maintaining everyday observations including meter readings of all Flow

Water Reservoirs (CWRs/ESRs/GLSR):

CHAPTER 2 : SPECIFICATIONS FOR PIPELINES

2.1.4Protections of Pipes, Fittings and Specials

Thickness of Cement Mortar

carried out in manufacturer’s works. The Engineer-in-Charge or his

Works test pressure/Class

2.2 HDPE PIPES

All pipes will be marked as per Clause of IS 4984 and as below:

2.2.7 Raw Material

The resin should have been certified by an independent laboratory of

2.2.10Maximum Quality of Pipe

2.2.12Length of Straight Pipe

2.2.15Handling, Transportation Storage and Lowering of pipes

• During coiling, care should be taken to maintain the coil diameter at or

2.2.16 Lowering, Laying of Pipes

• Care should be taken in fixing by finishing the connections at a time the

2.2.17 Jointing of Pipes

2.2.19Fittings & Specials

2.2.26Tests to Establish Portability of Work

2.3PIPE LAYING - GENERAL

nature of explosive to be used and the precautions taken for

systematically to the other end. Concrete or masonry shall not be damaged

2.3.2.9Rain Water Drainage

and jointing of pipeline unless and otherwise directed by the Engineer in

which may serve as obstruction to traffic shall be enclosed by fences or

Precautions against Floatation

When the pipeline laid underground or above ground in a long narrow

Trenches shall be backfilled with approved selected excavated material only