Zonal Railway Training Institute Bhusawal

Specification for Building Materials

Specification for Bamboos and Bamboo Matting

Bamboos- Bamboos shall be straight and free from splits, attacks of weevils and borer holes.
They shall be not older than about two to three years, well seasoned and not less than 4 meters
long. The girth at centre shall not be less than 13 cm for ordinary purposes.
Bamboo Matting – All matting shall be new and of the best, quality used locally. It shall not be
inferior to the sample approved by the Engineer. All edges of the matting shall be properly
bound. The matting shall be closely woven and shall be made from bamboo splits of nearly
uniform size.
When laying bomboo matting, side end laps of at least 15 cm shall be provided and the matting
shall be tied to supports in an approved manner. The second layer of matting if ordered, shall
be laid breaking joints with the first layer. When fillets of wood or bamboo are used for securing
matting, the fixing shall be done with nails driven through fillets, or tied by wire of approved
quality. If so ordered, all cut edges shall be properly bound to prevent fraying.

Specification for First Class Bricks

Clay - Clay used for brick manufacture must be free from gravel, coarse sand, kankar and roots
of grass and plants.
Bricks first class shall be wire cut, and table moulded with sand.
Preparation of clay- Tempering can be done in a pugging mill or by trodding upon by men or
animals.
Consistency- The approved consistency, which should not be so soft as to cause the raw brick
when turned out of the mould, to bulge in any way or to go out of shape by slumping.
Moulding - In moulding the brick, clay shall be dashed firmly into the moulds, which should be
kept well sprinkled with clean sand. The moulds should be washed after every 4 or 5 bricks
moulded. The mould used shall be of such a size, as will ensure bricks of correct nominal size
with variation of + 10 mm (1/8’’) in each case.
Burning should be done in pucca kilns.
Quality of Brick- Burnt brick shall be regular in size and shape, and shall have sharp square
corners and edges and parallel faces to ensure uniformity in thickness of the courses of the
brick work. The bricks shall be burnt so as to attain a uniform deep red, cherry or copper colour,
and burning should be thorough without any sign of verification.
The bricks must be free from any cracks, chipped surfaces and corners, flaws, stones or lumps
of any kind.
A sound well burnt first class brick should give a clear ringing sound when struck.
Brick should not absorb more than 20 % of its own dry weight, of water, when immersed for 24
hours.
A freshly burnt brick when thrown on firm ground or against other bricks should not break easily
Each standard Metric size brick should have a free on the upper face of either a rectangular
shape of size 4 cm x 2 cm x 1 cm (or 2 cm) deep or an oval shape of leading size of 6 cm x 4
cm x 1 cm (or 2 cm) deep.
The minimum compressive strength of brick should be 70 kg/cm. square.
The standard nominal dimensions of first class brick shall be 19 cm x 9 cm x 9 cm for metric
size bricks and 9" x 4 ¼" x 2 2/3" for inch size standard bricks.
Tolerance in size :- The actual dimensions of bricks when tested as described above shall be
within the following limits per 20 bricks.
Length 372 to 388 cm ( 380 ± 8 cm )
Width 176 to 184 cm ( 180 ± 4 cm )
Height 176 to 184 cm ( 180 ± 4 cm )

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Zonal Railway Training Institute Bhusawal

Specification for Second Class Bricks

Manufacture- The process of manufacture for second class bricks is the same as for first class
bricks with the following variations: -
(i) Table moulding is not necessary.
(ii) Tempering in a pugging mill is not necessary. Tempering by trodding with feet is sufficient.
(iii) The mould use should be of such size as will ensure burnt bricks of correct nominal size,
with variation of not more than + 5 mm in length and width and + 2 mm in thickness.
(iv) The burning of bricks may be carried out in kilns or country clamps.
Quality of Bricks - The second class bricks should be of regular in size and shape as possible
and should have fairly sharp corners and edges. The bricks should be free from cracks, larger
chipped surface and broken corners, stones and lumps, and inclusions of burnt kankar on the
surface.
Second class bricks may be slightly over-burnt and may show a slightly blue shade, but should
attain generally a red brown colour after burning and should not show any sign of verification.
Un-burnt bricks shall not be accepted under any circumstances.
A second class brick should, when struck with a piece of steel, give a ringing sound and should
not absorb more than 22% of its own dry weight, of water, when immersed for 24 hour.
The brick should have a minimum compressive strength of 35 kg/cm2.
Tolerance in size :- The actual dimensions of bricks when tested as described above shall be
within the following limits per 20 bricks.
Length 370 to 390 cm ( 380 ± 10 cm )
Width 175 to 185 cm ( 180 ± 5 cm )
Height 175 to 185 cm ( 180 ± 5 cm )

Specification For Country Kumbhar Bricks

Manufacture - The best local clay suitable for brick manufacture shall be used. The clay should
be free from gravel, coarse sand and roots of grass and plants.
Tempering can be done by trodding upon by men or animals.
Moulding - Moulding of country bricks can be done on the ground with the use of wooden
moulds.
The mould used should be of such a size, as will ensure a burnt brick size to be of the correct
nominal dimensions of 9" x 4 ¼" x 2 ¾", with a variation of + ¼" (6 mm) in all the dimensions. If
the nominal size of the brick is 9" x 4 ¼"x 1 ½" or 2”, the variation in thickness shall not exceed
+ 3/16" (4 mm).
The burning of the bricks can be done in country clamps with any available local fuel.
Quality - Country bricks must be free from cracks large chipped surfaces and broken corners
and stones and lumps.
The brick surface should be so hard as not to get scratched by the fingernail.
A country brick when struck with a piece of steel should give a fairly ringing and not dull earthy
sound.
It should not absorb more than 25% of its own dry weight, of water, when immersed for 24
hours.
When dropped on ground from a height of 1 m. it should not crack or break.
Country bricks may be slightly over-burnt but not under-burnt in any case. The colour may be
dull red or even reddish yellow.

Specification For Bullies

Defects - All bullies shall be reasonably straight and sound and without bark. All branches and
large knots must be trimmed flush with the surface of the bullies. The bullies shall be free from
spongy, brittle, flaky or brushy condition. Also they shall be free from Bee holes, Bird holes,
Buttressee, Flutes, Rot, Splits, Spongy on hollow heart, Twist, Wounds.

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Knots - Sound, live and tight knots up to diameter of 1/3 of the diameter of the bully at the spot
may be permitted, if not more in number than one per every 250 cm length.
Cracks - Sun cracks not more than 2 mm deep and not continuous for more than 60 cm may be
permitted.
Taper - 2 cm variation in the diameter of a bully per 3 meters of length may be permitted. The
diameter of the centre of a bully shall not be less than the nominal diameter specified. The
diameter at the smaller end shall not be less than the nominal diameter, by more than 1.5 cm.
Heart shake - A shake not touching the periphery on any side, and limited well within the centre
not exceeding 1/4th of the diameter of the bully in size, may be permitted.
Bend - 1.5 cm out of the straight in the last quarters towards ends may be permitted. No bend
at the middle two quarters of the bullies may be permitted.

Specification For Stones

Crushing strength - Crushing strength should be greater than 1000 kg / sq.cm.
Appearance - Stones, which are to be used for face work, should be decent in appearance and
they should be capable of preserving their colour uniformly for a long time.
Facility of dressing - Stones should be such that they can be dressed easily and economically.
Fracture - Edges of Building stone fracture should be sharp, even and clear.
Hardness - Coefficient of hardness, as worked out in hardness test, should be greater than 17.
Percent-age wear - In attrition test wear should be equal to or less than 2 percent.
Resistance of fire - Minerals composing stone should be such that shape of stone is preserved
when a fire occurs.
Seasoning - Stones should be well seasoned before putting into use. When stones contain
quarry sap. Stones should be dried or seasoned before they are used in structural work.
Specific gravity - For a good building stone, its specific gravity should be greater than 2.7 .
Texture - A good building stone should have crystalline structure. Stones with such texture are
strong and durable.
Toughness index - In impact test the value of toughness index comes 19.
Water absorption - For a good stone, percentage absorption by weight after 24 hours should
not exceed 5%.
Weathering - A good building should possess better weathering qualities. It should be capable
of withstanding adverse effects of various atmospheric and external agencies such as rain,
frost, wind, etc.

Specification For Water

General - Water used for all purposes in all classes of masonry, reinforced & mass concrete
work, shall be free from earthy, vegetable or organic matter, oils acids & alkaline substance in
solution or suspension and impurities potable water is generally considered satisfactory for
mixing concrete.
Properties and their limit of water –
To neutralize 200 ml. sample of water using phenolphthalein as an indicator, it should not
require more than 2 ml. of 0.1 normal NaOH.
To neutralize 200 ml. sample of water using methyl orange as an indicator, it should not require
more than 10 ml of 0.1 normal HCl.
Mineral oil (not mixed with animal or vegetable oils) in concentrations greater than 2% by weight
of cement may reduce the concrete strength by more than 20% water containing sugar in
excess of 500 ppm may affect the setting time of cement.
The pH value shall generally be not less than 6.
Sea Water - Mixing or curing of concrete with sea water is not recommended because of
presence of harmful salts in sea water. Under unavoidable circumstances, seawater may be

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used for mixing or curing in plain concrete or such reinforced concrete constructions, which are
permanently under sea water.
Water found satisfactory for mixing is also suitable for curing concrete. However, water used for
curing should not produce any objectionable stain or unsightly deposit on the concrete surface.
The presence of tannic acid or iron compounds in objectionable.

Specification For Sand

Quality of Sand –
Sand shall be coarse in texture and clean and gritty to the touch and composed of hard grains.
It shall be free from clay, coal, any animal vegetable and bituminous matter, any soluble
sulphates, gypsum, soft or flaky particles and other deleterious matter.
Fine sand drift of sand likely to be mixed with salt or mica, should on no account be used. If
sand is dirty, it shall be washed and dried before use. Sea sand will not, under any
circumstances, be allowed to be used for any description of mortar or concrete.
Properties of good sand: - Following are the properties of good sand: -
i. It should be chemically inert.
ii. It should be clean and coarse. It should be free from any organic or vegetable matter.
iii. It should container sharp, angular and durable grains.
iv. It should not contain salts which attract moisture from the atmosphere.
Test for Sand - For detecting the presence of organic impurities in sand, solution of sodium
hydroxide or caustic soda is added to sand and it is stirred. If colour of solution changes to
brown, it indicates the presence of organic matter.
A glass of water is taken and some quantity of sand is placed in it. It is then vigorously shaken
and allowed to settle. If clay is present is sand, its distinct layer is formed at top of sand.
Sand is actually tested and from its taste, presence of salts is known.
Sand is taken from a heap and it is rubbed against the fingers. If fingers are stained, it indicates
that sand contains earthy matter.
Size and grading –
The following limits of grading may be regarded as a guide.
If sand is not graded within the limits laid above, the Engineer may order washing, removing or
adding sand of a particular size to bring it to the specification.
Item of work % of sand retained on IS Sieve Slit
any
4.75 mm 2.36 mm 1.18 mm 600 300 150 clay
micron micron micron

Plastering (Base Max. 0 2 20 70 95 100 Not

Coat) Min. 0 0 5 15 50 90 more
than
Plastering Max. 0 0 5 70 95 100 8%
(Finishing Coat) Min. 0 0 0 15 50 90

Mortar Max. 2 20 40 70 95 100

Min. 0 0 0 0 35 85
Stacking - All sand required for mortar, plaster, concrete etc. shall be so stacked as to prevent
any dirt and foreign matter being mixed with it.
Measurement - Sand bulks to a substantial extent when partially wet measurement of sand
should therefore be taken, when the sand in stacks is completely dry.

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Silt Content – The sand shall not contain more than 8% of silt as determined by field test with
measuring cylinder.
Bulking of Sand – Dry & saturate sand almost have the same volume but damp sand increase
in volume depending upon moisture content. Due allowance for bulking for any samples of
sand should be determined as per IS : 2386 ( Pt III ) 1963.
Relation between moisture contents & bulking of Sand
Moisture content % by Bulking % age by Moisture content % by Bulking % age by
weight Volume weight Volume
2 15 4 25
3 20 5 30

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Specification For Surkhi

i. Surkhi for mortar or concrete shall be made from over brunt clay or bricks.
ii. It shall pass through IS sieve 3.35 mm and not more than 10% is retained on IS sieve 90
micron.
iii. Clay bricks used for surkhi shall be free from under burnt lime, soluble sulphates
gypsum etc.
iv. The sample of bricks to be used for making surkhi shall be got approved by the
Engineer.
v. Surkhi shall be free from admixtures.
vi. Surkhi must be stored under cover in a rainproof shed with a brick floor

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Specification For Lime

Classification - For use of Railway works, two kinds of lime shall be used.
"A”: - FAT LIME: - This is lime with a high calcium oxide content which depends solely on
absorption of carbon dioxide from air, for setting. This shall be used in preparation of neeru for
plastering, for whitewash and for use in lime-coal ash lime-cement, or lime-coal ash cement
gauged composite mortars for masonry and plaster work. This shall correspond in quality to
Class "C.
"B”: - HYDRAULIC LIME: - This is lime containing small quantities of silica and alumina and/or
iron oxide, which are in chemical combination with some of the calcium oxide contents, giving a
putty or mortar, which has the property of setting and hardening under water by chemical
reactions. This shall be used for plaster or masonry work, but never in combination with cement
or for the preparation of Neeru. This shall correspond in quality to class 'B'.
Properties –
Chemical Composition: -
i. The percentage of magnesium oxide shall not exceed 5.
ii. The percentage of insoluble residue in sodium carbonate solution, shall not exceed 5.
iii. Cementation value should be between 0.3 and 0.6 for hydraulic lime.
iv. Minimum total percentage of Silica, Alumina and Ferric Oxide should be 15 in the case of
Hydraulic lime.
v. Minimum total percentage of calcium and magnesium oxides should be 70 for Hydraulic
Lime and 85 for fat lime.
Physical properties: -
i. Hydrated fat lime shall leave no residue on IS Sieve 850 micron not more than 5 per cent.
ii. Hydrated Hydraulic lime, shall leave on IS Sieve 2.36 mm not more than 5 per cent.

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Zonal Railway Training Institute Bhusawal

iii. For hydraulic lime, expansion in 'Le Chateliar' moulds shall not exceed 10 mm.
iv. For hydraulic lime, minimum compressive strength of 1: 3 lime sand mortar after 14 days
shall be 12.5 kg. per cm2 and after 28 days, 17.5 kg. per cm2.
Manufacture - Lime shall be burnt in such kilns and with such fuel as the Engineer may
approve. It shall be picked over after burning in order to remove un burnt materials and
impurities. Lime shall be slaked by spreading it on a suitable platform to a depth of not more
than 15 cm and watered through rose sprinklers. It shall be thoroughly slaked, i.e. until further
addition of water to a representative sample produces no further chemical action or heat. No
free water should run from the lime slaking platform.
Field test - The following field tests may be adopted to determine the quality of lime.
i. Fat lime should have pure white colour. Hydraulic lime is generally of dirty white colour. A
porous lumpy form indicates quicklime, and close grained lumpy structure indicates un
burnt lime.
ii. Hydrochloric acid of 50% strength should be added to powdered lime in a test tube. If
there is abundant effervescence, lime has not been burnt / stored properly. If there is
excessive insoluble residue, a large proportion of inert material is indicated.
iii. If after 24 hours, a very thick gel is formed above the insoluble residue, the lime it
eminently hydraulic. If the gel is not quite thick, the lime is feebly hydraulic. If no gel is
formed, the lime is non-hydraulic or fat.

Specification For Cement

Cement - The cement shall be any of the following -
i. Ordinary and low heat Portland cement conforming to IS: 269-1976.
ii. Portland slag cement conforming to IS: 455-1976.
iii. Portland Pozzolona cement conforming to IS: 1489-1976.
iv. High alumina cement for structural use conforming to IS: 6452-1972.
v. Super sulphated cement conforming to IS: 6909-1973.
vi. Rapid hardening Portland cement conforming to IS:8041-1978.
vii. White Portland cement conforming to IS:8042-1978.
viii. Hydrophobic Portland cement conforming to IS: 8043-1978.
ix. High strength ordinary Portland cement conforming to IS: 8112-1976.
Properties of cement - The type of cement selected should be appropriate to the intended use.
The different types of cements are generally made by the adjustment in relative proportions of
chemical compounds and fineness to suit the particular requirement.
Alumina & Iron oxide should be 1.02 and 0.66. Magnesia not to be more than 5%. Sulphur
content not to be more than 2.75%.
Total chloride content in cement shall not exceed 0.05% by mass for cement used in
prestressed concrete structure and long span reinforced concrete structures (method of test for
determination of chloride content in cement is given in IS 12423:1988).
Physical requirement - Following are the physical and chemical requirement of the cement
shall be satisfied.
Fineness - When tested for fineness the 33, 43 & 53 grade cement by blains Air permeability
2
with the method given in IS: 4032-1985, the specific surface shall not be less than 225m /kg.
Soundness - When tested by Le-chatelier and autoclave test as per the IS: 4031 (part 3)-1988
33, 43 & 53 grade cement, unaerated cement shall not have an expansion of more than 10 mm.
Setting time - The setting time of cements 33,43 & 53 when tested by the Vicat apparatus
method described in IS: 4031(Part-5)-1988 shall conform to the following requirements:
Initial setting time in minutes, not less than 30.
(b) Final setting time in minutes, not more than 600.

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Compressive Strength - The Average Compressive strength of at least 3 mortar cubes (Area
of face 50 cm2) composed of one part of cement, three parts of standards sand (conforming to
IS 650: 1966) by mass and P/4+3%(of combined mass of cement plus sand) water and
prepared, stored and tested in the manner described in IS 4031 (Part - 6): 1988 shall be as
follows: -
Sr. No. Time after which test is done 33 gr 43 gr 53 gr

(a) 72 ± 1 hrs. 16 MPA 23 MPA 27 MPA

(b) 168 ± 2 hrs 22 MPA 33 MPA 37 MPA

(c) 672 ± 4 hrs. 33 MPA 43 MPA 53 MPA

Tensile strength - Minimum tensile strength of standard briquettes.
1 day 20 kg/cm2 for rapid hardening cement
3 days 20 kg/cm2 for ordinary Portland cement
30 kg/cm2 for rapid hardening cement
7 days 25 kg/cm2 for ordinary cement.
Delivery - The Cement shall be packed in bags (Jute jacking bag conforming to IS 2580:1982,
double hessian bituminized (CRI) type, multi wall paper conforming to IS 11761: 1986,
polythene lined (CRI type) Jute, light weight jute conforming to IS 12154:1987, woven, HDPE.
Conforming to IS 11653:1986, jute synthetic union conforming to 12174:1987.
Packing - The cement shall be packed in bags 50 kg. The permissible tolerance on the weight
of supplied in bags shall be 2.5% per bag with an overall tolerance of ± 1/2 % per wagon load of
20/25 metric tonnes.
Field Tests Of Cement`
1. Colour uniform greenish gray.
2. Cool feeling when hand is thrusted into cement bag ( No warm feeling )
3. Smooth feeling when rubbed between fingers.
4. When touch should not feel oily.
5. When handful cement thrown in bucket containing water, initially it should float and then sink.
6. Lumps should not be there.
Stacking and Storage –
Cement in bags shall be stored and stacked in ashed which is dry, leak proof and as moisture
proof as possible. Flooring of the shed shall consist of the two layers of dry bricks laid on well
consolidated earth to avoid contact of cement bags with the floor. Stacking shall be done

Period of storage %age of 28-days Strength

Fresh 100%
3 months 80%
6months 70%
12months 60%
24 months 50%

Rejection - Cement may be rejected if; it does not comply with any of the requirements of the
specification.
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Specification for Ballast

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Quality of stone – Stone ballast shall consist of had durable stone, not inferior the approved
sample. A ballast sample when tested for physical properties –
Aggregate abrasion test – Water abrasion maximum 30 % relaxable up to 35%.
Aggregate impact test – Impact value maximum 20% relaxable up to 25%.
The total percentage of deleterious substances in course aggregate shall not exceed five
subject to the maximum % of individual substances as given below –
Coal & lignite - 1 %
Clay Lumps - 1 %
Soft fragment - 3 %
Material finer than IS sieve 75 microns - 3 %
Test – When so ordered coarse aggregates shall be subjected to the following test
1. Particle size test. 2. Standard test for determination of clay fine silt and fine dust in fine
aggregates. 3. Sieve analysis. 4. Soundness . 5. Organic impurities. 6. Strength test.
Grading of aggregates – The fine and course aggregates should be mixed in such proportions
that the grading of the combined aggregate falls within the limits.
Limits of grading of coarse aggregates-
IS Sieve Percentage by wt. Passing through sieves for maxi. Size of aggregate.
Designati 10mm 20mm 40mm 80mm
on A B C A B C A B C A B C
4.75 mm 0 0 0 0 0 0 0 0 0 0 0 0
10 mm 100 100 100 49 70 84 40 56 77 44 56 77
20 mm - - - 100 100 100 59 75 88 54 - -
40 mm - - - - - - 100 100 100 67 79 90
80 mm - - - - - - - - - 100 100 100
Categories – Cyclopean aggregate or cobbles of size 7.5 cm to 15 cm. These may be used with
the permission of the Engineer in mass concrete.
Coarse aggregate of size 5 mm to 75 mm used for all mass concrete work.
Aggregates of a porous nature shall not be permitted ( Wt not exceeding 10% of dry wt after
immersion for 24 hrs. )
Aggregates shall be stored in such a manner as to avoid contamination with dust and with
organic or inorganic impurities.
Aggregates of different grads shall be stacked separately.

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Specification of Ist Class Brick Masonry.

General - Brickwork, 1st sort, shall be built with whole bricks, 1 st sort, laid in mortar. No cut or
broken bricks shall be used except where necessary to complete bond.
Bond - English bond shall be used throughout.
Soaking - Bricks shall be soaked in water before use for a period of at least 2 hours for the
water to just penetrate the whole depth of the bricks. Alternatively bricks may be adequately
soaked in stacks by profusely spraying with clean water at regular intervals for a period not less
than six hours.
Laying - Each course shall be laid level both longitudinally and transversely. The walls of all
structures shall be carried up regularly in all cases, not leaving any part more than 1 meter
lower than the other. When circumstances render it necessary to carry on the same section of a
o
building at different levels, the bricks shall be stepped to an angle of 45 . The work shall be
carried up vertical or to the batter intended. The height of brickwork raised in one day shall not
exceed 1 metre.

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Laying Procedure - Mortar is spread on the top of the foundation course, over an area to be
covered by the edge of the wall. The depth of spread of mortar may be about 1 cm.
The corner of the wall is constructed first. For that, one brick is laid first at the corner, and
pressed, with hand so that the thickness of bed joint remains only about 6mm. The first closer
is covered with mortar on its side and then pressed against the first corner brick, such that 6 mm
thick vertical joint is obtained. The excess mortar from the sides will squeeze out, which is
cleaned off with trowel.
The level and the alignment is checked. Few headers and stretchers are then laid in the first
course. After having laid the first course at the corner, mortar is laid and spread over the first
course, to a depth of about 1 cm and end stretcher is laid first, by pressing it into the mortar and
then hammering it slightly so that the thickness of bed joint is 6 mm.
Striking joints - In case where no pointing or plastering is required, the green mortar shall be
neatly struck flush. Where pointing and plastering is required the joints should be racked out to
a depth of not less than 10 mm.
Curing – The Brick work shall be constantly kept moist on all faces for a minimum period of
seven days.
Jointing cold brick work with new brick work - Jointing shall be done in such a way that
there shall not be any hump or projection at the joint. The thickness of each course of new work
shall be made equal to the thickness of the corresponding course of the cold work by adjusting
thickness of horizontal mortar joints, and the wall where necessary shall be made exactly to the
same thickness by adjusting the thickness of vertical joints.
Toothing - The usual practice in joining new cross-wall to old main weal is to cut out a number
of rectangular recesses in the main wall equal in width to the width of the cross-wall. Three
courses in height, and half a brick depth, a space of three courses being left between the
sinkings. The new cross-wall is bonded into the recesses with cement mortar to avoid any
settlement. It is necessary that the sinkings should not be less than 225 mm apart, as in the
cutting portion is likely to become shaken and cracked.
Scaffolding –
Scaffolding must be double if not possible-scaffolding poles shall rest in a hole provided in a
header but not allowed in pillars under 90 cm in width.
Supervision of brickwork - The following points should be kept in mind while supervising brick
masonry :-
i. The bricks should be properly laid on their bed.
ii. The bricks, while laying, should be pushed sideways, to have uniform thickness of vertical
joints. For thicker walls, the joints should be grouted in every course in addition to the
bedding and flushing.
iii. The brickwork should be carried out perfectly in line.
iv. The brickwork should be perfectly in level.
v. The brickwork should be truly in plumb.
vi. Use of brick bats should be minimum.
vii. At plinth, window sill, floor or roof level and at the top of the parapet wall, the brick course
should be laid with brick on edge.
viii. When piers are tied up or buttresses counter-forts are used with wall, they should be built
up course by course so as to maintain proper bond with the main wall.
ix. It is desirable to provided about 18 mm to 25 mm thick expansion joints after every 30 to
45 m length of the wall.
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Specification for IInd Class Brick masonry & Country Kumbhar Brick Masonry

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Brickwork second sort –

Brick work second sort shall be the same as Brick work first sort with the exception that: -.
i. It shall be built with second sort bricks,
ii. vertical and bed joints up to 1 cm thick will be allowed,

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Brick work with country (kumbhar) bricks -

Brick work with Country (Kumbhar) bricks shall be the same as Brick Work Second Sort
described in above, with the exception that it shall be built with country (Kumbhar) bricks. As
the size of these bricks may vary within the specified limits, care should be taken while
constructing masonry, to ensure that the face of masonry which is to be subsequently pointed or
left un plastered, is in plumb and in an even plane.

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Specification for Cement Plaster

1. Scaffolding – Double scaffolding shall be provided. Single scaffolding shall be permitted in

such cases the inner end of the horizontal scaffolding pole shall rest in a hole provided only in
the header. Such holes not be allowed in pillers / columns less than one meter in width. Above
10 meters height steel scaffolding shall be provided.
2 Preparatory Works –
i. All service pipes, conduits, cables etc., that are to be embedded in masonry work and
covered with plaster.
ii. All joints shall be raked out to a depth of 20 mm.
iii. All dirt, must, oil, paint or any other material.
iv. The surface shall be brushed and washed with fresh water.
3. Mortar - The mortar of the specified mix shall be used. Mortar shall be conform to
specification and must be used within 30minutes.
4. Application of Plaster –- For all plaster patches of plaster 15 cm  15 cm shall be put on
about 2 m apart as thickness specified. Plastering up to 15 mm thick shall be done in single
coat. Plastering above 15 mm up to 20 mm thick shall be done in two coats. Plastering above
25 mm thick shall be used with the approval of DEN. Plaster shall be started from the top and
worked down towards the floor. The mortar shall be applied in a uniform surface slightly more
than the specified thickness. The plaster shall be than brought to a true surface by working a
wooden straight edge. All corners, arrises, angles and junctions shall be truly vertical or
horizontal. Rounding or chamfering corners, arrises, provision of grooves at junction etc. The
plaster work shall be closed at the end of the day on the body of wall and not nearer than 15 cm
to any corners or arrises.
5. Finish – The plaster shall be finished to true and plumb surface to the proper degree of
smoothness as required. The work shall be tested frequently as the work proceeds with a true
straight edge not less than 2.5 m long and with plumb bobs.
6. Thickness – The thickness of the plaster shall be measured exclusive of the thickness of
key, grooves or open joints in brick masonry. The average thickness of plaster shall not be less
than the specified thickness. The minimum thickness over any portion of the surface shall not be
less than specified thickness by more than 3 mm.
7. Watering and curing - All plaster work shall be kept damp continuously for a minimum
period of 7 days.
8. Control of Cracking - The main reasons for cracking of plaster are as follows,

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i. Quick drying of the mortar due to hot weather and low atmospheric humidity.
ii. When a strong mix has been used on a weak background.
iii. Lack of bond with the background.
iv. Masonry underneath has not undergone initial shrinkage.
v. Lack of proper raking of joints, and
vi. Discontinuity in backgrounds, such as change from wall to ceiling from concrete to
brickwork from clay brickwork to concrete block work, etc.
9. Precautions aga1nst cracking and crazing - Large surfaces should be done in alternate
squares or strips keeping joints at convenient places coinciding with architectural breaks,
otherwise cracks will appear in the plaster. The contractor shall obtain detailed instructions from
the Engineer in this respect before starting the work.
10. Measurements - Length and width shall be measured correct to a cm and its area shall be
calculated in sq. m. correct to two places of decimal.

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Specification for Cement Pointing

1. Scaffolding – Shall be provided as for plaster.

2. Preparation of surface – The joins shall be raked out properly. Dust and loose mortar shall
be brushed out. The surface shall than be thoroughly washed with water, cleaned and kept wet
before pointing.
The joins shall be raked to such a depth that minimum depth of the new mortar measured from
either the sunk surface of the finished pointing or from the edge of the brick shall not be less
than 12 mm.
3. Mortar - The mortar of the specified mix shall be used. Mortar shall be conform to
specification and must be used within 30minutes.
4. Application and Finishing – The mortar shall be pressed into raked joint with a pointing
trowel, either flush, sunk or raised, according to the type of pointing. The jointing shall than be
finished with the proper tool.
5. Flush Pointing – The mortar shall be pressed into the joints and shall be finished off flush
and level with the edges of the bricks.
6. Ruled Pointing – The joints shall be initially formed as for flush pointing and then while the
mortar is still green a groove of any shape shall be formed by running a forming tool straight
along the center line of the joints.
7. Tuck Pointing - Tuck Pointing shall project from the wall facing with its edges cut parallel so
as to have a uniformly raised band about 6 mm raised and width 10 mm or more.
8. Curing - The pointed face shall be kept well wetted for at least 7 days..
9. Measurements - Length and width shall be measured correct to a cm and its area shall be
calculated in sq. m. correct to two places of decimal.

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Specification for White Wash

1. Scaffolding - Double scaffolding shall be provided. Above 10 meters height steel scaffolding
shall be provided. If ladders are used, pieces of old gunny bags shall be tied on their tops.
2. Preparation of surface. - ( a ) For New work – The surface shall be thoroughly brushed free
from droppings and foreign matter.

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( b ) For old work – All loose particles and scales shall be scrapped off. The surface shall be
prepared by brooming down, steel wire brushing, scrapping or other means as may be ordered
to produce an approved clean and fair surface.
After cleaning the surface as specified above, nails shah be removed and all nail holes, plug
holes, cracks and crevices stopped with the materials similar in composition to the surface to be
stopped.
3. Preparation of Wash. - The wash shall be prepared from fresh stone white or shell lime (fat)
slaked with sufficient water to make a thin cream. This shall be allowed to stand for a period of
24 hours and then shall be screened through a clean until if attains the consistency of thin
cream coarse cloth. 40 grams of gum dissolving in hot water, shall be added to each 10 cubic
decimeter of the cream. The approximate quantity of water to be added in making the cream will
be 5 liters of water to one kg of lime. Neel up to 3 gm per kg of lime dissolved in water shall than
be added.
4. Application. - The white wash shall be applied with moonj brushes to the specified of coats.
One coat consists of a, stroke of the brush from the top downwards, plus another stroke from
the bottom upwards over the first stroke, plus one stroke from the right and another from the left
over the first brush before if dries. White washing with spray machines shall not be permitted.
Each coat shall be allowed to dry before the next one is applied.
5. Protective Measure - Doors, windows, floors and articles of furniture etc, shall be
protected from being splashed upon covering with dust sheets.
6.Measurement - Length and width shall be measured correct to a cm and its area shall be
calculated in sq. m. correct to two places of decimal.

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Specification for Colour Wash

1. Specification - The Specification for white washing shall apply to work also, the only
difference being that the specified mineral colours, not affected by lime, shall be added to
white-wash solution. Neel not be added.

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Specification for Distempering

1. Specifications. - The following Indian Standards shall apply :

(a) IS : 427-1953- for Distemper, Dry, Colour as Required ;
(b) IS : 428-1953- Specification for Distemper, Oil Emulsion, Colour as Required ;
The distemper shall be of approved make and colour.
2. Mixing. –
i. Distemper shall not be mixed in a larger quantity than actually required for a day's work.
ii. The dry distemper shall be stirred slowly in clean water using 0.6 liters of water per kg. of
distemper.
iii. Oil bound distemper shall be diluted with water or any other prescribed thinner in a
manner.
iv. Distempers should be applied in dry weather with a broad stiff brush, and after the first
Coat has thoroughly dried, another should then be laid on.
v. Old brushes which are dirty and eked with distemper shall not be used on the work.
3. Preparation of Surface for Application -

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New Walls - The plastered walls to be distempered shall have a fine densely trowelled shining
surface and shall be absolutely dry and shall be sand-papered thoroughly, and then one coat of
Priming shall be applied.
Old Walls - If the old walls are covered with distemper, the same shall be removed by washing
lightly with soft cloth with plenty of warm water. But in case the walls are coloured or white
washed, the wash must be removed thoroughly first and all depressions filled with gypsum,
which shall be allowed to set and dry completely before distempering is done. The walls shall
then be sand papered and a coat of white chalk mixed with glue or sizing, may be applied and
the surface then distempered.
4. Application. - Distemper shall applied in dry weather. Only after the first coat is thoroughly
dry, another coat shall be laid on. The first coat shall always be of a lighter tint. In applying, the
brush shall be dipped in the distemper and stroked cross-ways on the walls, and immediately
afterwards, applied perpendicularly. It is recommended that two men shall work together, one
going round the room applying distemper from the ceiling downwards as far as be can reach;
and the second man following him applying the distemper below. In this way, it is easier to join
up and avoid patchy overlap.
Proper distemper brushes (broad and stiff) shall be used, and these shall be washed daily after
use and hung up to dry. Brushes with soaked distemper on them shall not be allowed. Brushes
shall never be allowed to rest on the bristles.
The rate for distempering shall include all the preliminary work of brooming down, wire-brushing,
scraping, washing, stopping and also subsequent cleaning of splashes on timber, glass, paint,
floor, furniture, etc.

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Specification for Cement Wash

1. Cement - The relevant clauses of the Specification on "Cement", shall apply to this work
also.
2. Preparing Surface - The surface shall be prepared as "White washing."
3. Cement Wash The cement wash shall be prepared by mixing neat Portland cement with
water. The quantity of cement to be used will be used will depend upon the shade of the wash
required; 140 gms of cement per sq.m of surface should give a good finish.
As much cement wash shall be prepared at, a time as can be used within half an hour.
4. Workmanship - Cement wash shall be applied in prescribed number of coats with brush, the
coats being laid on vertical and horizontally. Each coat must be allowed to dry and shall be
subject to inspection before the next coat is applied.

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Specification for Snow Cem

1. Cement paint - Cement paints are suitable for use on exterior and interior cement concrete
and stucco surface not subjected to mechanical abrasion. Cement paints are recommended
where it is desired to decorate or reduce the water permeability of exterior walls built of porous,
open textured concrete, such as concrete block masonry. They may also be used where the
concrete or stucco is damp at the time of painting or may become damp subsequently. They are
not well suited for interior surfaces requiring frequent and thorough cleaning as coating of these
paints are not easily washed and tend to erode with vigorous scrubbing.

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Zonal Railway Training Institute Bhusawal

The water proof cement paint shall be an approved manufacture such as snowcem, permacem
or other equal and approved quality and shall be brought to the site in original, airtight
containers with seals intact.
2. Preparatory work - Surfaces shall be thoroughly cleaned free from dirt, dust, etc. by
brushing and washing down with clean water. any grease oil, oil paint, varnishes and oil-bound
washable distemper shall be removed.
Lime wash and water bound distemper shall be thoroughly removed by washing, brushing and
by steel wire brushing or scraping.
Rough cast and pebble dash shall be thoroughly brush to remove dirt and dust.
3. Mixing - The dry cement paint shall be thoroughly mixed with clean fresh water so as to
produce a paint of required consistency which for normal work shall be that of ordinary paints.
Paint for application by brush shall be strained through a paint strainer, and paint for spraying
shall be twice strained.
The paint shall be kept well strained during use and no paint which-has been mixed for a longer
period than one hour shall be used.
4. Application - The paint to surfaces other than rough cast may be applied by means of
brushes or spraying with low pressure pot sprayer if Spraying, however, may only be carried out
if the Engineer approves. Paint applied to roughcast and pebbledash shall be by means of
spraying.
Absorbent surfaces shall be thoroughly damped so as to give even suction. In dry weather,
freshly paint surfaces hall be kept damp for at least 2 days.
5. Coats - When more than one coat is ordered, subsequent coat shall not be applied until the
preceding coat has thoroughly hardened, inspected and approved.

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Specification for Timber

1. Terms & definitions. –

Centre heart - The core of a log including the pith.
Cup - A curvature in a piece of timber across the grain or width of the piece.
Gkain - A descriptive term applied to the alignments of cells and tissues.
Insects holes - Ccavities caused by insects.
Knot - A branch base embedded in the tree of timber.
Pith - Soft tissues found near about the centre of the log.
Sapwoop - Outer layers of the log, which in the growing tree contain living cells. The sap is
usually lighter in colour.
Shake - Partial or complete separation between adjoining layers in tissues.
Split - A crack extending from one face to another face.
Spring - Edge-wise deviation from straight line drawn from end to end of a piece.
Taper - Progressive diminution in girth along the length from the butt end to the top.
Twist - A spiral distortion.
Wane - The original rounded surface of a tree remaining on a piece of converted timber.
Warp - A deviation in sawn ttimber from true plane surface.
2. Timber to be free from defects - The timer shall be free from warp, cup, large knots, dead
knots, spring, twist or bend (subject to tolerances permitted), free from spongy, brittle flaky or
brushy condition. All timber shall be free from decay, rot, harmful fungus and insect attacks, and
from any other damage of harmful nature. The planks shall be straight, sawn parallel, square
edged and square trimmed at ends.
3. Permissible Tolerances in Defects -.

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Defects –cracks - (a) Cracks, shakes or splits in any face and the ends, will be admissible only
up to 1.3 cm or 25% in depth, which ever is less, provided they do not reach or are likely to
reach the other face.
(b) End cracks, shakes or splits will be permissible only up to 6.0 cm per metre length of the
piece.
Bend - 0.7 cm per metre length shall be admissible.
Grain - Oblique grain running diagonally from one end to the other of the piece shall not be
permissible.
Knots - (a) Sound live tight knots will be permissible only upto a diameter of 5.0 cm or 1/3 of the
width, whichever is less, the diameter being measured along the greatest diameter of the
section of the knot exposed on the face of the wood, provided that such knot does not occur
within 6 mm of the edge of any piece or that the knots do not exceed 5 in number per square
metre of either side faces.
(b) Dead knots only upto 2.0 cm in dia. And only upto 5 in number per square metre of either
side faces will be permissible, provided they are not within 6 mm of the edges.
Pith and centre heart - (a) Centre heart will be pemissible if it is not within 2.5 cm from any
edge on the end face, or is well placed within middle third belt of the section. Any centre heart
running diagonally from one wide face, to the other wide face, starting from one end, to other,
end, affecting more than 50% of the length of the piece will not be permissible.
(b) Pith to the extent of 3 mm deep and 25% of length of the piece in length will be permissible.
Sap wood - Sap wood, shall be permissible only to the extent of 25% of any face in teak wood,
10% in hard woods and 25 % in case of timbers suitable for packing cases etc.
Wane - Wane to the extent of 10% of width and thickness of 2.5 cm whichever is less, and 1 cm
in length per every 12 cm length of the piece, will be permissible.
Taper - A difference of 2 mm in thickness and 3 mm in width causing a tapered surface will be
admissible. The number of pieces having such tapers, shall not exceed 10% of the total number
of pieces accepted,
Insect holes - (a) Insect holes up to 10 mm dia. not running at an angle of more than 45° will be
acceptable, provided they are not more than 1 per every 60 cm length.
(b) Pin borer holes just like needle holes will not be accepted, unless they are very widely
scattered.
4. Hiding defects - Any effort at plugging, painting, using any adhesives, resinuous materials to
hide defects in any piece, shall render not only the piece, but also the whole supply rejectable.
Timber presented for inspection shall be clean and free from dust, mud, paint or other material.
5. Seasoning. - The timber supplied should have been well-seasoned in the log before being
cut into scantlings, and thereafter also in scantlings for as long a period as possible. No timber
which is warped or carcked during the seasoning process, will be acceptable. The seasoning of
timber shall be judged from its moisture content us laid down in IS: 287-1960.

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Specification For Asbestos Corrugated Sheets

1. Specification - The ridge purlins should be fixed at 8 cm to 11 cm from the apex of the roof.
A. C. sheet shall conform to IS: 459-1970 or as updated time to time.
2. Strength - The roofing sheets shall be capable of withstanding a distributed test load of 400
kg. per square metre with purlins spaced at up to 1.7 m. Centre.
3.1. Cutting and drilling where necessary - Asbestos cement materials shall be cut with a
wooden saw and drilled with brace and twist drill and the holes shall on no account be punched
as this will not only splay out the aperture but also weakening the materials at vulnerable points,
The holes shall be 2 mm larger than the diameter of the fixing bolts and shall always be drilled
through the crown of the corrugations and never on the flats or valleys.

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3.2. Holes - The holes for fixing the sheets shall be drilled in the exact position to suit the
purlins, i.e. on the centre line of the purlins
3.3. To avoid fracture, sheets must not be rigidly fixed.
3.4. Screws and hooks should be supplied with cup-shaped or limpet washers by approved
manufacturers. It is also essential to make the bolt-holes watertight by using bitumen washers.
4. Fixing - Joints should have a half corrugation lap only. The end lap should be 15 cm. Where
four sheets meet at a lap, mitering of sheets is necessary to provide a snug fit. The maximum
free overhang at the eaves should not exceed 40 cm.
The length of the 'J' bolt or crank bolt shall be 75 mm longer than the depth of purlin for single
sheet fixing and 90 mm longer than depth of the purlin where two sheet over lap or where ridges
or other accessories are to be fixed with the sheet. The minimum length of square head coach
screw for timber purlins shall be 110 mm when corrugated sheet is laid it shall be 115 mm when
semi-corrugated sheet is laid.
5. Cracked Sheets - All sheets and accessories found to be cracked after fixing shall be
replaced by new ones.
5.1 Mitres - Unless otherwise specified in the manufacturers' instructions, where 4 corners of
sheets overlap, two of them MUST be mitred (cut off).
6.1. Handling and Storage at Site - The asbestos cement sheets shall be handled and stores
in the best possible manner so as not to damage the sheets in any way. The sheets shall be
stacked to a height of not more than one metre on firm and level ground laid on wooden battens
according to the stacking methods specified by the manufacturers and protected from damage.
When, they are stacked for any length of time they shall be stored under cover.
6.2. Asbestos cement materials of same variety and size shall be stacked together. Damaged
materials shall not be stacked with sound materials. All damaged materials shall be salvaged
as early as possible.

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Specification For Asbestos Flat Sheets

1. Specification - Asbestos flat sheets for ceilings shall be of specified manufacture and
thickness.
1.1. The sheets should be screwed on to the framework with 35 mm galvanized countersunk
head screws 15 cm apart, leaving 6 mm clearance to joint edges to permit expansion and
contraction of the timber without damaging the sheets. The screws in the adjoining sheets
should be side by side and not staggered, and shall not be lees than 10 mm from the edge.
Screws shall be uniformly and symmetrically placed over the entire surface. Fixing with screws
shall be done from centre of boards outwards, and screws driven slightly below the board
surface with care, so as not to project above the sheet surface.
2. Cover strips - The Asbestos Cover Skips to joints should be fixed by 6 cm copper or brass
wood screws, 30 cm apart. Before fixing the cover strips, the gap between the joining sheets
should be slightly grooved with a carpenter's file. It should be ensured, that the joint between
the sheets comes square on the timber panelling.
3. Payment. - The finished surface area is only to be paid for. No extra payment is to be made
for cover strips, laps, etc.

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