Municipal Administration & Urban Development

Department (MA&UD)

Andhra Pradesh Urban Finance and Infrastructure Development

Corporation (APUFIDC)

PROJECT DEVELOPMENT AND MANAGEMENT

CONSULTANTS for AMRUT (REGION-1)

QUALITY ASSURANCE & QUALITY CONTROL

MANUAL FOR AMRUT PROJECTS
QUALITY ASSURANCE & QUALITY CONTROL MANUAL
FOR AMRUT PROJECTS REGION-1
ANDHRA PRADESH
 Quality Assurance & Quality Control Manual

Contents
CHAPTER 1 ........................................................................................................................................................... 7
INTRODUCTION ................................................................................................................................................ 7
1.1 Quality Definition ......................................................................................................................................... 7
1.2 QA / QC Manual ............................................................................................................................................ 8
1.2.1 Key Parameters of Quality Assurance ................................................................................................ 8
1.3 Health Safety & Environment ...................................................................................................................... 8
CHAPTER 2 ......................................................................................................................................................... 10
CONSTRUCTION QUALITY CONTROL ...................................................................................................... 10
2.1 Introduction .................................................................................................................................................. 10
2.2 Testing ........................................................................................................................................................... 10
2.3 Inspections of Sites ...................................................................................................................................... 12
2.3.1 Everyday Supervision: ....................................................................................................................... 12
2.3.2 Periodical Inspection for Quality...................................................................................................... 12
2.3.3 Random Checks .................................................................................................................................. 14
CHAPTER 3 ......................................................................................................................................................... 15
CONTROL OF MATERIALS AND EQUIPMENT ......................................................................................... 15
3.1 General .......................................................................................................................................................... 15
3.2 Mandatory Tests Performed at Site ............................................................................................................ 15
CHAPTER 4 ......................................................................................................................................................... 18
MATERIALS AND EQUIPMENTS TO BE CERTIFIED BY MANUFACTURER ....................................... 18
CHAPTER 5 ......................................................................................................................................................... 19
DEPARTMENTAL INSPECTIONS .................................................................................................................. 19
5.1 Materials and Equipment to be Inspected by Departmental Team at the Factory................................ 19
CHAPTER 6 ......................................................................................................................................................... 20
CONTROL OF CIVIL / STRL. WORKS AND WATER RETAINING STRUCTURES............................... 20
6.1 Proportions of Cement Concrete ................................................................................................................ 20
6.2 Proportions of Cement Mortar .................................................................................................................... 21
6.3 Construction of Water Retaining Structures ............................................................................................. 21
CHAPTER 7 ......................................................................................................................................................... 26
SOURCE OF WATER AND TREATMENT UNITS OF CANAL BASED WS SCHEMES ......................... 26
7.1 Water Works Units including WTP ........................................................................................................... 26
CHAPTER 8 ......................................................................................................................................................... 28
TESTING OF MATERIALS ............................................................................................................................... 28
CHAPTER 9 ......................................................................................................................................................... 29
PROCEDURE OF SAMPLING AND TESTING OF MATERIALS............................................................... 29
9.1 Cement........................................................................................................................................................... 29
9.1.1 Sampling Procedures and Sample Collections............................................................................... 29
9.1.2 Tests for Cement ................................................................................................................................ 30
A. Test for Fineness .......................................................................................................................... 30
B. Test for Compressive Strength.................................................................................................... 30

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9.2 Aggregates..................................................................................................................................................... 32
9.2.1 Sampling Procedures and Sample Collections............................................................................... 32
A. Tests for Fine Aggregate (Sand) ................................................................................................ 33
B. Tests for Coarse Aggregate (Stone Grit).................................................................................... 36
9.3 Bricks ............................................................................................................................................................. 38
9.3.1 Sampling Procedures and Sample Collections............................................................................... 38
9.3.2 Tests for Bricks IS: 1077-1992............................................................................................................ 38
A. Visual............................................................................................................................................. 38
B. Dimensions ................................................................................................................................... 39
C. Water Absorption ......................................................................................................................... 39
D. Efflorescence................................................................................................................................. 40
E. Compressive Strength ................................................................................................................. 41
9.4 Cement Concrete .......................................................................................................................................... 42
9.4.1 Sampling Procedures and Sample Collections............................................................................... 42
9.4.2 Tests of Cement Concrete ................................................................................................................. 42
A. Slump Test .................................................................................................................................... 42
B. Compressive Test:......................................................................................................................... 43
9.5 Reinforcement Steel & Structural Steel ..................................................................................................... 44
9.5.1 Sampling Procedures and Sample Collections ................................................................................ 44
9.5.2 Tests of Steel for Reinforcement IS: 1786-2008 ................................................................................ 44
9.5.3 Mild Steel (Structural)........................................................................................................................ 46
A. Tensile strength of structural steel............................................................................................. 46
9.6 Pipes for Water Supply & Sewerage .......................................................................................................... 46
9.6.1 Sampling Procedures and Sample Collections............................................................................... 46
9.6.2 Tests of UPVC Pipes for Potable Water Supply IS: 4985-2000 ...................................................... 46
9.6.3 Tests of UPVC Pipes for Drainage / Sewerage Work..................................................................... 47
9.6.4 Tests of Glazed Stone Ware Pipes IS: 651-2007 .............................................................................. 48
9.6.5 Tests of R.C.C Pipes........................................................................................................................... 49
9.6.6 Tests of HDPE Pipes .......................................................................................................................... 50
9.6.7 Tests of G.I Pipes ............................................................................................................................... 51
CHAPTER 10 ....................................................................................................................................................... 52
WATER FOR CONSTRUCTION PURPOSES ................................................................................................ 52
10.1 Sampling of Water...................................................................................................................................... 52
CHAPTER 11 ....................................................................................................................................................... 53
TESTS & STANDARDS FOR TIMBER ........................................................................................................... 53
11.1 Surface Electrode Test................................................................................................................................ 53
11.2 Knife Electrode Test ................................................................................................................................... 53
CHAPTER 12 ....................................................................................................................................................... 54
TESTS & STANDARDS FOR OTHER CONSTRUCTION MATERIALS ................................................... 54
12.1 Terracing ..................................................................................................................................................... 54
12.2 Precast Concrete Manhole Covers and Frames ....................................................................................... 54
12.3 Plastic Encapsulated Footrests .................................................................................................................. 54
12.4 LDPE Sheet ................................................................................................................................................. 55

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CHAPTER 13 ....................................................................................................................................................... 56
DRINKING WATER SAMPLING .................................................................................................................... 56
13.1 Sampling for Physical and Chemical Analysis ....................................................................................... 56
13.2 Sampling for Bacteriological Analysis ..................................................................................................... 56
13.3 Bacteriological Guidelines ........................................................................................................................ 58
CHAPTER 14 ....................................................................................................................................................... 59
CHECKS AND TESTS OF FINISHED WORKS ............................................................................................. 59
14.1 Damp Proof Course .................................................................................................................................... 59
14.2 Brick Masonary ........................................................................................................................................... 59
14.3 RCC Works .................................................................................................................................................. 59
14.4 Plastering ..................................................................................................................................................... 59
14.5 Thickness of Floors .................................................................................................................................... 59
14.6 Chaukhats.................................................................................................................................................... 59
14.7 Steel Windows ............................................................................................................................................ 59
14.8 Paint, Distemper Plastic Emulsion (One test for each brand of paint) ................................................. 59
14.9 Fittings ......................................................................................................................................................... 60
14.10 Distempered Surface ................................................................................................................................. 60
14.11 Glass Panes................................................................................................................................................. 60
14.12 Sal Wood for Chaukhats ........................................................................................................................... 60
14.13 Timber for Shutters ................................................................................................................................... 60
14.14 Thickness of Shutters................................................................................................................................ 60
CHAPTER 15 ....................................................................................................................................................... 61
HYDROSTATIC TESTS OF PIPELINES ......................................................................................................... 61
CHAPTER 16 ....................................................................................................................................................... 62
TEST REPORT FORMATS ................................................................................................................................ 62
16.1 Test Certificate for Cement ....................................................................................................................... 63
16.2 Test Certificate for Coarse Aggregate ...................................................................................................... 64
16.3 Test Certificate for Fine Aggregate........................................................................................................... 65
16.4 Test Certificate for Construction Water (For saline zone only)............................................................. 66
16.5 Compressive Strength of Concrete ........................................................................................................... 67
16.6 Concrete Slump Test .................................................................................................................................. 68
16.7 Hydrostatic Test for Non Pressure Pipes ................................................................................................. 69
16.8 Hydrostatic Test for Pressure Pipes.......................................................................................................... 70
16.9 Leak Test for Under Ground RCC Structures ......................................................................................... 71
16.10 Leak Test for Elevated RCC Structures................................................................................................... 72
16.11 Water Absorption of Bricks...................................................................................................................... 73
16.12 Silt Content ................................................................................................................................................ 74
CHAPTER 17 ....................................................................................................................................................... 75
RECORDS TO BE MAINTAINED AT CONSTRUCTION SITE.................................................................. 75
17.1 Site Order Book .......................................................................................................................................... 75
17.2 Material Register ........................................................................................................................................ 76
17.3 Daily Progress Report ................................................................................................................................ 77
17.4 Concrete Pour Record ................................................................................................................................ 78
17.5 Test Record.................................................................................................................................................. 79

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17.6 Design and Drawing Record ..................................................................................................................... 80

17.7 Non-Conforming Item Record .................................................................................................................. 81
CHAPTER 18 ....................................................................................................................................................... 82
QUALITY ASSURANCE BY DEPARTMENTAL ENGINEERS DURING INSPECTION ........................ 82
CHAPTER 19 ....................................................................................................................................................... 84
CHECK LIST GUIDES FOR VARIOUS WORKS........................................................................................... 84
20.1 Check List for Laying and Jointing of Pipe Lines, Back Filling, Hydrotesting ................................... 84
20.2 Check List for Disinfecting Plant ............................................................................................................. 86
20.3 Check List for Pump Chamber.................................................................................................................. 87
20.4 Check List for Development of Water Works ......................................................................................... 90
20.5 Check List for OHSR ................................................................................................................................. 92
20.6 Check List for Water Treatment Plant...................................................................................................... 96
20.7 Check List for Sewer Laying & Treatment Plant .................................................................................... 98
20.8 Check List for Control Panel for 3-Phase Pump & Motor .................................................................... 102
20.9 Check List for Centrifugal Pump, Motor & Delivery Pipe in Pump Chamber ................................. 104
20.10 Quality Certification ............................................................................................................................... 106
CHAPTER 20 ..................................................................................................................................................... 107
PROJECT IMPLEMENTATION ARRANGEMENTS .................................................................................. 107
20.1 Responsibilities of Key Organizations .................................................................................................. 107
CHAPTER 21 ..................................................................................................................................................... 111
QA / QC DUTIES OF CONTRACTORS ........................................................................................................ 111
20.1 QA / QC Duties......................................................................................................................................... 111
CHAPTER 22 ..................................................................................................................................................... 116
DESIGN REQUIREMENTS ............................................................................................................................ 116
22.1 Design Requirements for Reinforced or Plain Concrete Structures: .................................................. 116
22.2 Materials in General ................................................................................................................................ 118
22.2.1 Samples and Tests of Materials ................................................................................................... 119
22.3 Standards................................................................................................................................................... 119
22.4 General Arrangement of Plant ................................................................................................................ 123
22.4.1 Orientation.................................................................................................................................... 123
22.4.2 Buildings and Structures ............................................................................................................. 123
22.5 Roadways, Pathways & Hard standings ................................................................................................ 130
22.6 Specn. for Anti-Corrosive Internal Coating/Lining protection of Conc. Surfaces ............................ 132
22.7 Hydraulic Testing of Liquid Retaining Structures ............................................................................... 139
22.8 Non Destructive Testing of RCC Structures ......................................................................................... 140
22.9 Rain water harvesting system. ................................................................................................................ 140
22.9.1 Need for Rain water Harvesting.................................................................................................. 140
22.9.2 Components of the Rain Water Harvesting Scheme................................................................. 141
22.9.3 Integration with Storm Water Drains ......................................................................................... 141

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ABBREVIATIONS
Sl. No. Abbreviation Description
1 AC Asbestos cement
2 BIS Bureau of Indian standard
3 BOQ Bill of quantities
4 0C Degree Celsius temperature
5 CCDU Communication and capacity development unit
6 CI Cast iron
7 Cm Centimeter
8 3 Cubic meter
Cum/ M
9 CWR Clear water reservoir
10 Dia Diameter
11 E.E. Executive Engineer
12 FC Fully covered
13 Fig Figure
14 GC Galvanized corrugated
15 GI galvanized iron
16 Gm Gram
17 GPWSC Gram Panchayat Water Supply Committee.
18 HDPE High density poly ethylene
19 HRD Human resources development
20 ISI Indian Standard Institution
21 ITP Inspection test plan
22 J.E. Junior Engineer
23 Kg Kilogram
24 Kl Kilo Litre
25 Km Kilo meter
26 M Meter
27 MC Manufacturer Certificate
28 MH Manhole
29 Ml Milliliter
30 Mm Millimeter
31 m3 Cubic meter
32 M&E Monitoring and evaluation
33 NC Not covered
34 No. Number
35 OHSR Over head service reservoir
36 O&M Operation and Maintenance.
37 PC Partially covered

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Sl. No. Abbreviation Description

38 PHE Public Health Engineering.
39 PVC Poly vinyl chloride
40 P.W.D. Public works department
41 QAC Quality Surveillance and control
42 QA/QC Quality assurance /Quality Control
43 QAP Quality assurance plan
44 QCF Quality control format
45 QC-M Quality control of material
46 QC-P Quality control Process
47 QMSW Quality management and surveillance wing
48 QS Quality system
49 RCC Reinforced cement concrete
50 Re / Rs Rupee / Rupees
51 STP Sewage treatment plant
52 SW Stone ware
53 SW Ap Sector wide approach
54 T Tonne
55 TOR Terms of reference
56 TMT Thermo mechanically treated
57 TP Third party
58 WQM&S Water quality monitoring & surveillance
59 WS &SM Water supply & sanitation monitoring
60 WTP Water treatment plant

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CHAPTER 1
INTRODUCTION

This Quality Assurance Quality Control Manual is prepared for the use of Department of
PUBLIC HEALTH ENGINEERING/ULB/APUFIDC. It is based on Various Quality Assurance
practices, PWD specifications, requirement of the tender document for test of materials,
Field/laboratory testing and relevant IS: codes. This will provide a base document outlining
policy, procedure, responsibilities, compliance acceptance criteria and documentation for
carrying out tasks related to inspection, testing and reporting on various materials, items
involved for the satisfactory completion of the work. In all cases however, it is important to
understand that the contract documents including the technical specifications are the basis for
execution of the construction. Quality Assurance Quality Control (QA/QC) Manual provides a
guide lines for supervision of construction project. A QA/QC Manual establishes a standard
guideline for enabling supervisory staff to check different activities of construction in respect
of technical specifications. Quality assurance plan serve as a road map to supervisory staff to
ensure quality of project works.
The contractor has been prepare a Construction Quality Control / Quality Assurance Manual
for the type of construction generally carried out for public health engineering department
and sanitation, and also to describe the responsibility and accountability of the supervisory
staff. Reporting system shall also be covered in the Manual.
1.1 Quality Definition
Quality is the totality of features and characteristics of a product for service that bears on its
ability to satisfy the projects functional requirements. The quality of output is always agreed
upon between the supplier and the client (In project work, Contractor and the employer,
respectively), and the quality objective is to achieve zero defects with best quality of the
project works. This is possible only by ensuring quality control at every stage during progress
of construction.

Quality is conformity to standards and requirements to achieve excellence. The following are
some definitions pertaining to quality and how to achieve it.

Quality control (QC): The operational techniques or a system of maintaining

standards by reviewing, checking, inspecting and testing.
Quality Assurance (QA): The planned and systematic actions and implementations
necessary to provide adequate confidence that the work will satisfy quality requirements.
Quality System (QS): A set of documented processes, which seek to provide satisfaction
that the project outputs will fulfill all the requirements for which it is being planned. The
Quality System should fully incorporate the organization, human resources, materials,
equipment, processes, inspections, testing and other parameters of the project. A key
element of QS is the QA/QC Manual.
Quality Surveillance: This normally covers two aspects.
At the project level, a review is required to ensure that the quality practices are
implemented and documented to ensure in relation to the quality system.

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At the contract package level, inspection and testing is required to ensure that the works
executed meet the required quality standards.

1.2 QA / QC Manual
This QA/QC Manual focuses on the implementation activities of the project following
contract award, primarily on supervision and quality control of construction works. The
QA/QC Manual is intended to be used as guide line for supervision of construction activities,
primarily by the field staff of the ENGINEER INCHARGE AND RE/ APUFIDC and the
Design and Supervision Consultants.
It will provide a base outline towards, procedure, responsibilities, compliance acceptance
criteria and documentation for carrying out inspection, testing and reporting on various
materials, items involved for the satisfactory execution of the project work. In all cases,
somehow, it is most important to understand that the technical specifications as specified in
the contract document / agreement are the guidelines for any construction activity.
The QA/QC Manual for the Construction activity does not attempt to suggest technical
specifications, since these are stated in the contract documents. Its aim is to ensure that the
works are executed as per specifications to achieve best results. Test results shall be
interpreted as applicable for individual package, in accordance with the technical
specifications as specified in the conditions of contract.
1.2.1 Key Parameters of Quality Assurance
Quality system involves the various key tools which are generally practiced in the field for
Quality Assurance System. The well designed quality assurance system will provide
confidence that the project outputs will fulfill all the requirements for which it is being
planned. The quality assurance system should have the following basic parameters.

Site documents
Mandatory and optional testing
Availability of field and departmental laboratories
Manufacturing test certificates
Departmental team inspections
Checklist guide form works
Site inspections
Post quality testing of finished works
Quality certification
Monthly reporting and review meetings
1.3 Health Safety & Environment
The Health and Safety of any project site also plays an important role and is also a part of the
quality control of any project work. The HSE audits have to be conducted at the Project Sites
for the various work areas generally encountered in the projects being executed. The following
activities are to be maintained under HSE.

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Display of Notices
Warning tape, lighting arrangement at location of any excavated trench,
electrical installation or mechanical erection.
Fire Prevention and Protection
Environment & Health
House Keeping
Lighting
Monsoon Precaution
Noise and Vibration
Personnel protective equipment (PPE) for field staff.
Health, Safety and Environmental aspects are given in detail in the separate HSE manual.

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CHAPTER 2
CONSTRUCTION QUALITY CONTROL

This section provides an overview of construction quality control activities, including testing
and site inspection. Materials control requirements are presented in detail here while specific
testing and inspection requirements for each category of works are presented in Chapters 10 to
15 of this Manual.
2.1 Introduction
Construction Quality Control (CQC) is intended to provide a comprehensive, common and
consistent framework for quality control across various contract packages. CQC comprises two
main elements of quality control:

Testing
Inspections
Testing control covers the type of tests to be carried out, frequency of testing and stage of
testing.
Inspection control covers the timing of inspections, what to be inspected and the inspection
procedures. QC should be affected at five stages:

Input Materials and Equipment Components

In-process Activities
Stage Completion
Interfacing (of special importance in water and sewerage contract packages)
Final completion
The contractor is responsible for informing EIC giving sufficient notice time so that
they can witness the tests.
2.2 Testing
Various field tests on materials and works are required to be carried out by the contractor
during construction. A well-equipped and properly operating field test laboratory is an
important feature of quality assurance plan. A list showing typical testing equipment to be
provided in the contractor’s site laboratory is presented in Table 2.1. It should be made
mandatory as per provision in the technical / contract bid.
Table: 2.1 List of Equipment Required for Testing
Sl. No. Equipment Purposes

1 Compression testing machine Cube and brick

2 Sieve set complete Aggregates

3 Measuring jars Silt

4 Screw gauge Thickness of pipes

5 Vernier caliper Dia. Of pipes

6 Balance Mass of pipe/steel etc

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Sl. No. Equipment Purposes

7 Slump cone Workability
8 Cube mould - 2 sets. Testing of C.C.

9 Hydraulic testing machine Testing of pipe

The contractor shall set-up the site laboratory within 15 days after getting letter to proceed
and inform the EIC for conducting inspections. Laboratory equipment shall be properly
calibrated, and certificates and its updating as and when required should be kept at the
laboratory for review by ULB’S and GPWSC as necessary. Specialized tests at outside
laboratories shall only be undertaken with the prior approval of the ULB’S. Zonal
laboratories one in each zone shall also be established for quality testing of materials used by
the contractor. The tests to be conducted in the Zonal laboratory are given in Table 2.2.
Table: 2.2 Tests to be Conducted in the Zonal Laboratory
Sl. No. Material Tests to be conducted Equipment
1 Cement Consistency Vicat apparatus

Soundness Le Chatelier apparatus

Vicat apparatus
Setting time
2 Aggregate Bulk density Bulk density apparatus

Flakiness/Elongation Thickness and length

gauge.

Crushing value Crushing value

apparatus
3 Concrete (fresh) Cube test Compression testing
machine
Post concrete Compressive strength of Rebound hammer
post concrete
4 Bricks Compressive strength Compression testing
machine
5 Pipes Hydraulic testing of pipes Hydraulic pump

Tests should be performed in accordance with the contract documents. The control of test
reports shall be done as stipulated in Section 10 of this Manual. All test samples should be
preserved in a sealed container, with proper identification numbers, test log reference, test
date, and other applicable information. These samples must be stored at contractor’s
office/laboratory by the contractor.
In addition to tests performed on site, the contractor is responsible for external tests which
are performed at approved laboratories as per the contract document.

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2.3 Inspections of Sites

Inspections of sites must be carried out to ensure that the construction activities and
construction materials conform to the relevant standards. Site inspections can be divided into
everyday supervision and periodical quality inspection. The suggestions in respect of these
two have been elaborated herein.

2.3.1 Everyday Supervision:

Everyday site supervision of all construction activities shall be carried out by the ULB’S. This
includes checking of lines, layouts and levels and other relevant checks. Daily Progress
monitoring shall also be carried out by the ULB’S. The Supervising team of the ULB’S shall
ensure that materials that have been rejected or for which a non- conformance report has not
yet been issued are not used in works.
Equipment to be used in construction is point of concern in quality assurance system. The
equipment requirements have been laid out in the Contract documents. It is necessary that
the ULB’S check the adequacy of the equipment used by the contractor for construction as
per the prescribed standards and specifications.
GPWSC involvement in the procurement will be limited to the extent that the materials being
used by the contractor should be checked visually from time to time for its quality and to be
associated during sampling and its testing.
2.3.2 Periodical Inspection for Quality
Officers/ Engineer of ULB’S& GPWSC shall carry out periodic quality inspections during in-
process, stage completion, interfacing and final completion, and during all critical activities
component wise as per the following examples in Table 2.3.

Table: 2.3 List of Critical Activities Component Wise

Sl. No. Component Critical Activities
1 Pipe line Excavation
Completion of excavation Trenches for Pipe
laying
Laying and jointing of pipes in correct
alignment.
Pressure/leakage Testing of pipe line
2 OHSR/UGSR Backfillingand
Centering in layers and watering
shuttering for R.C.C. works
Placing of reinforcing steel
Concrete mixing, vibrating and pouring
Testing for water tightness
Curing
3 Electro Mechanical Installation of electrical and mechanical
equipment such as Pump & Machinery and
Disinfecting units etc.
Testing, trial runs and commissioning of
electro- mechanical equipment and plants

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Sl. No. Component Critical Activities

4 Tube Well Drilling
Lowering of Assembly
Verticality Test
5 Pump Chamber Mortar proportion in Brick masonry
Centering and shuttering for R.C.C. works
Placing of reinforcing steel
Concrete mixing, vibrating and pouring
Curing
6 Canal Based Water Mortar proportion
Treatment Plant with Centering and shuttering for R.C.C. works
units as; Placing of reinforcing steel
i) Intake works and Concrete mixing, pouring and vibrating
inlet channel Curing
ii) Storage cum Grading of filter media
Sedimentation tank LDPE sheets
iii) Suction cum scour Water tightness
well Hydraulic losses
iv) High Level Tank Efficiency of plant
v) Filter beds
vi) Clear water tank

7 Sewage Treatment Mortar proportion

Plant with units as; Centering and shuttering for R.C.C. works
i)Collecting tank Placing of reinforcing steel
ii)Facultative pond / Concrete mixing, pouring and vibrating
Maturation pond Curing
iii)Sludge Drying LDPE sheets and Thickness of lining
Beds Water tightness
iv)Sludge Curing Hydraulic losses
Platform v)Composting Efficiency of plant
Pits etc.

The ULB’S and GPWSC shall also inspect the materials certified by manufacturers, materials
and equipment components upon delivery to the site. The contractor shall give advance notice
to the ULB’S and GPWSC when critical activities are proposed or major equipment items are to
be delivered. On completion of one stage of the construction and before proceeding to the next
stage the engineer in charge of ULB’S shall inspect and certify the quality of the works
completed before granting approval for the next stage of the works to start. The final inspection
shall encompass tests on completion and trial runs. The certification of quality will be based on
the documents and the periodic site visits. The ULB’S representative and the GPWSC
representative should witness all the tests conducted by the contractor.

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2.3.3 Random Checks

The concept of Random Checks has been adopted to have an external review of quality of
works executed. The checks should be conducted jointly by the ULBs and GPWSC. A fixed time
table is not suggested for this. The tentative agenda for the random checks is described as
follows:

Physical inspection of the works under execution and inspection of quality of

workmanship:
Review of site documentation and contractor compliance:
Sample verification of test reports and quality certificates:
Review of issues, constraints and lacunae in quality system implementation:
Preparing of action plans for improving the quality: and
Performance appraisal of the contractors.
If any non-conformance is observed, the details will be recorded in Performa C/QRF-7.

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CHAPTER 3
CONTROL OF MATERIALS AND EQUIPMENT

This section on control of materials and equipment gives an overview of control requirements
for construction materials and equipment including field testing, manufacturer’s certification,
departmental team inspection for materials, efficiency of equipment and calibration of
equipment.
3.1 General
General Control and approval of construction materials and equipment to be incorporated in
the works shall be based on the following;
Test reports for materials tested at site, such as cement, sand, water, and aggregate; the
contractor will perform all tests. The designated ENGINEER- IN-CHARGE and RE
representative and APUFIDC representative shall witness as per Chapter 1. They shall sign
the report in token of witnessing.
Manufacturer’s certificates and IS mark for manufactured items are as indicated in Table 4.1 or
as stipulated in the contract;
3.2 Mandatory Tests Performed at Site
For mandatory tests the list of materials if to be performed at site is given in Table 3.1. Types of
tests are presented in Tables 3.2 to 3.5 under the referenced procedure number. Test report
formats are included in Chapter 16. The reports are to be maintained in a bound register, where
in 3 copies of report will be prepared, two copies to be submitted with monthly report to
ENGINEER-IN-CHARGE and RE & APUFIDC and third copy to be retained by contractor.

Table: 3.1 List of materials to be tested on site

Identification
Sl. No Material
Number

1 Cement QC-M -01

Fine aggregate
2 QC-M -02
(Sand)

3 Bricks QC-M -03

Coarse aggregate for

4 QC-M -04
concrete works

5 Pipe line works QC-M -05

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Table: 3.2 Types of Tests for Cement

CEMENT QC-M-01

Procedures
Sl. No. Type of Test Frequency of Test Timing of Test / Inspection
(Page No.)
1 Fineness Clause One for each On receipt of material at
10.1 source of 10 T or site and before using as
(60) part thereof and directed by the Engineer.
when called for by Test certificate to be
the Engineer. produced to the Engineer
Sampling should before use.
comply with
2 Compressive Clause IS: 3535 – 1986
strength – 72 hrs, 10.1
168 hrs, 672 hrs. (60)

OPC 43 shall conform to

IS: 8112:1989
OPC 53 shall conform to
IS: 12269 - 1987
PPC shall conform to IS:
1489 – 1991

Table: 3.3 Types of Tests for Sand

FINE AGGREGATE (SAND) QC -M-02

Sl. Procedures Timing of Test /

Type of Test Frequency of Test
No. (Page No.) Inspection

1
Particle Size and shape Clause 10.2 One test for 20m3 or
IS: 2386 -Part-(I)-1963 ( 62-63) part thereof. On receipt at site and
test certificate to be
produced to the
Engineer before use.
Clause 10.2
2 Fineness modulus
( 62-63) One test for 20m3

3 Bulking test
Clause 10.2 One test per 20m3
( 64) or part thereof

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FINE AGGREGATE (SAND) QC -M-02

Sl. Procedures Timing of Test /

Type of Test Frequency of Test
No. (Page No.) Inspection

Silt content IS: 2386 - Clause 10.2

4
Part(II)-1963 ( 64) One test for 20m3

Table: 3.4 Types of Tests for Bricks and Brick Tiles

BRICKS & BRICK TILES QC-M-03

Sl. Procedures Timing of Test /

Type of Test Frequency of Test
No. (Page No.) Inspection
Compressive Clause 10.3
1
strength ( 70-71)
Physical Clause 10.3
2
properties ( 68-69) One test for each
On receipt at site
Water Clause 10.3 source.
3
absorption test ( 69)
Clause 10.3
4 Efflorescence
( 69-70)

Table: 3.5 Types of Tests for Coarse Aggregate for Concrete

COARSE AGGREGATE FOR CONCRETE QC-M-04
Sl. Procedures Timing of Test /
Type of Test Frequency of Test
No. (Page No.) Inspection

Particle size
Clause 10.4
1 distribution IS One for each source of 40
(66)
2386(I)-1963 cum. Or part thereof and
On receipt of
10% Fine when called for by the
material at site
value as per IS ENGINEERING
2 Lab INCHARGE.
2386- Part (IV
)-1963

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CHAPTER 4
MATERIALS AND EQUIPMENTS TO BE CERTIFIED BY MANUFACTURER

Acceptance of certain manufactured materials and equipment components, as stipulated in

the contract, shall be based on test certificates from the manufacturer conforming to IS
calibration certificates for equipment issued by NABL authorities and also on visual
inspection. These items shall bear the IS mark. ENGINEER INCHARGE AND RE shall review
the manufacturers’ certificates for conformance to contract requirements before these items are
delivered to the site. Upon their delivery and before their installation or otherwise
incorporation in the works ENGINEER INCHARGE AND RE and APUFIDC shall inspect the
condition of these items. Inspection criteria shall be decided jointly by ENGINEER
INCHARGE AND RE and APUFIDC. They may decide to have the material additionally
tested in Laboratory. The cost of such tests will be borne by the contractor.
The reference numbers are allocated for different materials /equipment as given in Table 4.1
which are meant for references only, to be used while listing the manufacturer’s certificates.

Table: 4.1 List of Materials and Equipment to be Certified by the Manufacturer

Reference
Sl. No Description
Number
1 Cement MC-1
2 Steel for Reinforcement and structural steel MC-2
3 Pipe such as GI , PVC ,MS,CI,DI,SW ,RCC etc. MC-3
4 Manhole covers and Footrest MC-4
5 AC/GI/Fiber glass sheets MC-5
6 Electrical cables/fans and fixtures MC-6
7 Switches/sockets and boards MC-7
8 Flow measuring devices MC-8
9 Control Panel MC-9
10 Lightening arrestor MC-10
11 Water Level indicator and controllers. MC-11
12 Disinfection Units MC-12
13 Pump and Motor MC-13
14 All type of specials such as PVC, GI, CI etc. MC-14
15 All types of valves such as sluice valve, Air valve etc. MC-15
16 Any other item as per agreement MC-16

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CHAPTER 5
DEPARTMENTAL INSPECTIONS

5.1 Materials and Equipment to be Inspected by Departmental Team at the Factory

Materials and equipment to be inspected by Departmental Team vary from package to package,
as stipulated in the contract documents. DT inspection would normally take place at the factory
during or upon completion of manufacture. Upon delivery and before installation or
incorporation in the works, ENGINEER-IN-CHARGE and RE and APUFIDC shall inspect the
physical condition of these items and, if necessary, test them on site. Inspection criteria should
be stipulated in the contract document. Refer to Table 5.1 for a list of materials and equipment
suggested for inspection by DT inspections.

Table: 5.1 Materials and Equipment to be Inspected by

Departmental Team at the Factory
Sl. No. Description
1 Pipes such as DI, CI, PVC, MS, SW, HDPE / MDPE
2 Pumps, Motors & D.G. Sets
3 Manhole Frames and covers
4 R.C.C. Pipes

Departmental Team (DT) shall have one SDE from ENGINEER-IN-CHARGE & RE and one AE
from other division.

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CHAPTER 6
CONTROL OF CIVIL / STRUCTURAL WORKS AND WATER RETAINING STRUCTURES

This section of the Quality assurance and Quality control Manual covers the testing of works
working procedures and sequences for general civil and structural works. The key elements
to be inspected in these works are concreting brickwork and finishes. The requirements for
testing and control of materials for these works are already described in previous section.

6.1 Proportions of Cement Concrete

As per IS:456-2000 Nominal mix concrete may be used for concrete of M20 or lower. The
proportions of materials for nominal mix concrete shall be in accordance with provision of BIS
as given in Table 6.1
Table: 6.1 Proportions of Nominal Mix Concrete

Total Quantity of dry

Aggregate by Mass per 50 kg Quantity of
Proportion of Fine
Grade of of cement, to be taken as the water per 50
Aggregate to Coarse
Concrete sum of the individual masses kg of cement,
Aggregate( By mass)
of Fine and Coarse Aggregate, Max.in liter.
Kg, Max.

M5 800 60
Generally 1:2 but
M 7.5 625 45
subject to upper limit
M 10 480 34
of 1: 1.5 and a lower
M 15 330 32
limit of 1:2.5
M 20 250 30

NOTE- The proportions of the fine to coarse aggregate should be adjusted from upper limit to
lower limit progressively as the grading of the aggregates becomes finer and the maximum
size of the coarse aggregate becomes larger. Graded coarse aggregate shall be used.
For an average grading of the fine aggregate (that is, Zone II of Table 4 of IS 383), proportions
shall be 1:1.5, 1:2 and 1:2.5 for maximum size of aggregates 10 mm, 20mm and 40mm
respectively.

The cement content of the mix specified in above Table for any Nominal mix shall be
proportionately increased if the quantity of water in a mix has to be increased to overcome the
difficulties of placement and compaction, so that the water – cement ratio as specified is not
exceeded.
The Civil engineering Hand Book provides strength expected to be attained by concrete of
different proportions and the permissible stresses are laid down as given in Table 6.2.

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Table: 6.2 Strength of Concrete of Different Proportions

Grade of Characteristic Compressive strength In kg / cm2

concrete
At 7 days At 28 days

M10-1:3:6 70 100

M15- 1:2:4 100 150

M20-1:1.5:3 135 200

M25-1:1:2 170 250

6.2 Proportions of Cement Mortar

IS: 2250- 1981 provides different grades of mortar for use in masonry work as given in Table 6.3.
Table: 6.3 Grades of Masonry Mortar
Compressive strength at 28 days in
Grade Cement: Sand
N/mm2

MM – 0.7 0.7-1.5 1:8

MM – 1.5 1.5-2.0 1:7

MM – 3 3-5 1:6

MM – 5 5-7.5 1:5

MM – 7.5 7.5 and above 1:4

M – 7.5 7.5 and above 1:3

The selection of mortar will be governed by the strength required by the masonry and
reference may be made in IS: 1905- 1987 for knowing the suitability of combination of various
types of mortars and grade of bricks for the different strength required for the masonry.
6.3 Construction of Water Retaining Structures
In the case of Reinforced Cement Concrete (RCC) retaining structures, only concrete mix
proportions by volume shall be used. The associated quarry and source of sand and aggregate
shall be approved by Engineer after satisfactory tests of aggregates. Mechanical mixing with
mixtures is mandatory. Mechanical vibrators in sufficient number should be used for
compaction of concrete. Hand compaction cum manual compaction is not permitted under any
circumstances. Adequate mixtures and vibrators, including standby should be available at site
well before the start of concrete work.
Shuttering quality should be of good standard, as approved by the Engineer well before the
fixing of any shuttering. Shuttering should be fixed in such a manner that no slurry or water
seeps through the jointing or box outs. For this plastic tape, Plaster of Paris (POP), putty other
suitable sealants should be used at joints of shuttering.

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The concrete should be kept moist throughout 24 hours a day for the specified number of days
for adequate curing by flooding with water, or by putting moist gunny bags. Adequate
separate labor and supervisor should be deployed for curing work, in ensuring that this
important component of the work is satisfactorily conducted.

Table: 6.4 List of Tests for Civil Works and Liquid Retaining Structures
Material
Sl. No. Activity Type of test (Page Test & Sampling
Name
No.) Procedure (Page No.)
1 Pump chamber
1.1 Earth Bedding Earth/Soil QC-P-01 (35) Lab
Coarse Aggregate QC-M-04 (30) Clause 10.2 (62)
1.2 Gravel Bedding Cement QC-M-01 (29) Clause 10.1 (58)
Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
Cement QC-M-01 (29) Clause 10.1 (58)
Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
1.3 Masonry
Water Lab
Bricks QC-M-03 (30) Clause 10.3 (68)
Cement QC-M-01(29) Clause 10.1 (58)
Coarse Aggregate QC-M-04 (30) Clause 10.2 (62)
1.4 Horizontal DPC
Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
Bitumen Lab
Cement QC-M-01(29) Clause 10.1 (58)
Coarse Aggregate QC-M-04 (30) Clause 10.2 (62)
1.5 RCC Slab Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
Water Lab
Steel MC -2 (30) Lab
Cement QC-M-01(29) Clause 10.1 (58)
1.6 Mortar Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
Water Lab
2 Water retaining structures
Cement QC-M-01(29) Clause 10.1 (58)
Coarse Aggregate QC-M-04 (30) Clause 10.2 (62)
2.1 RCC works Fine Aggregate QC-M-02 (30) Clause 10.2 (62)
Water Lab
Steel MC -2 Lab

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Material
Sl. No. Activity Type of test (Page Test & Sampling
Name
No.) Procedure (Page No.)
3 Completion of Stage Completion Test Field
Liquid Retaining
Structures (Wet
Wells, Storage
Reservoirs,
UGSR/ OHSR,
Pretreatment
Units, RCC Open
Channels, etc.)

The QC-P-01 to QC-P-06 are Reference Numbers given to various quality control process of
works to be executed as mentioned in Table: 6.5.
Table: 6.5 Identification Numbers Given to Various Quality Control Processes
Sl. Type of work Reference
1 Bedding QC-P-01
2 Concreting QC-P-02
3 Cement sand mortar QC-P-03
4 Liquid retaining structure QC-P-04
5 Completion of pipe line and QC-P-05
6 Manholes and valve chambers QC-P-06
The formats below provide the types of tests, frequency of tests and time of tests etc.

Table: 6.6 Types of Tests for Earth Bedding

Earth Bedding QC-P-01

Sl. Test Timing of Test /

Type of Test Frequency of Test
No. Performed at Inspection

Moisture content One test for each

1 as per IS: 2720- Lab
250m3 of soil During
1983
execution of
Field density test One test for each work
2 as per Lab 100m2 of compacted
IS: 2720- 1983 area

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Table: 6.7 Types of Tests for Concreting

Concreting QC-P-02

Sl. Test Report Timing of Test /

Type of Test Frequency of Test
No. Format No. Inspection

One test for 1-5 m3 of

concrete.
Two tests for 6-15 m3of
concrete. Test samples to be
Compressive A/TR-5 taken while pouring.
strength as per Three tests for 16-30 m3 of
1 Clause 10.4 Tests to be done as
concrete. specified in the
IS: 516 -1959
3
Four tests for 31-50 m of contract.
concrete + one set every
50 m3of additional
concrete work.
Random checks
A/TR-6
Slump test per throughout concreting Before pouring
2 Clause 10.4
IS :1199- 1959 period as directed by the concrete
Engineer
Steel
reinforcement Daily Before pouring
3 Before pouring concrete
placement and Report concrete
bending
Concrete Pour Immediately after
4 C/QRF-4 When pouring is done
Report pouring

Table: 6.8 Types of Tests for Cement Sand Mortar

Mortar QC-P-03
Test Timing of Test/
SI.NO. Type of Test Frequency of Test
Performed at Inspection
One sample for
Test samples to be
Compressive every 2 m3 of
taken while placing.
strength as per mortar subject to a
1 Site/ Lab Tests to be done as
IS: 2250-1981 minimum of three specified in the
samples for a contract.
day’s work
Consistency as per
2 Lab ----- do ----- ------ do -----
IS: 2250- 1981

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Table: 6.9 Types of Tests for Liquid Retaining Structures

Testing of Liquid Retaining Structures QC-P-04

Timing of
SI. Test Report Frequency
Type of Test Test/
No. Format No. of Test
Inspection

Water tightness for One test per

1 A/TR-9
underground structures structure On completion
Water tightness for One test per of stage
2 A/TR-10
elevated structures structure

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CHAPTER 7
SOURCE OF WATER AND TREATMENT UNITS OF CANAL BASED WATER
SUPPLY SCHEMES

Public health engineering department schemes are based on surface source or ground
water source. Surface water is drawn from irrigation canals. Depending upon the
availability of potable water in the region the source of water supply is selected as
surface or ground water.
7.1 Water Works Units with proposal of WTP included in the Water Supply Scheme
The water works units required for utilization of various water sources including the
proposal of conventional Water Treatment Plant and their purpose are given in Table: 7.1.
Table: 7.1 Water Works Units
Sl.
Description Purpose
No.

For withdrawal of water from surface source and to

1 In take works
ensure entrance velocity of 0.60- 0.90cm/sec.

For conveyance of raw water to sedimentation and

2 Inlet channel storage tank and it should be laid at correct gradient/
alignment.
Storage cum
3 It should be made water tight to reduce losses
Sedimentation tank
Underground suction Collection chamber for pumping water should be
4
cum scour well tested for water tightness .

To house machinery and other equipment and shall

5 Pump chamber
be constructed as per standard departmental design.

Centrifugal pumps as per IS: 9542-1980 are installed

6 Pumping plants for pumping raw water to high level Tank and clear
water to O H S R.
For distribution of raw water to filter units and should
7 High Level Tank have scour and overflow arrangement.
The structure should be tested for water tightness.

Provided for filtration of water. The structure is

Slow sand filter/ Rapid provided with under drainage, filter media, inlet
8
sand filter outlet channels as per specifications. The structure
should be tested for water tightness.

For storage of clear water, and is provided with

9 Clear water reservoir scour/over flow pipes. Structure should be tested for
water tightness.

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Sl.
Description Purpose
No.

Elevated R.C.C. Storage Tank to supply water to

consumer at minimum residual pressure of 12m
10 OHSR head. The staging of tank will be as Guided by IS:
11682-1985 foundation design shall depend on
bearing capacity of soil.

Disinfection of water shall be carried out by

11 Disinfection Mechanical chlorinator using chlorine Solution or
silver ionization based plant.

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CHAPTER 8
TESTING OF MATERIALS

All the materials proposed to be used in the works must have been tested by the contractor and
approved by the ENGINEER INCHARGE AND RE well before the start of work at site. The
contractor shall submit the concrete pouring report to the ENGINEER INCHARGE AND RE
and APUFIDC as and when concreting is done and shall obtain the approval of the ENGINEER
INCHARGE AND RE when a particular stage is completed and before proceeding to the next
stage.

Tests for general civil and structural works are listed in Table: 6.4. Test processes are
presented in Table 6.6, 6.7, 6.8 under the referenced test numbers. Required materials tests
are also indicated (materials testing processes are presented in Chapter 9). Test report
formats are included in Chapter 16. Testing of liquid retaining structures is given in Table
6.9. The contractor shall be responsible for conducting tests as stipulated.

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CHAPTER 9
PROCEDURE OF SAMPLING AND TESTING OF MATERIALS

Sampling procedures, sample collection, test to be conducted and acceptable test results of
widely used materials in the projects are covered as under;

9.1 Cement
9.1.1 Sampling Procedures and Sample Collections
The sample collected represents the typical of average properties of material to be tested. Such
sample is said to be the representative sample. Much care and systematic sampling procedure
is required to be followed, which are now standardized by the relevant BIS.

Sampling instrument should be clean and dry when used.

Precautions should be taken to protect the sample from contamination.
Sample containers should be of such a size that they are almost completely filled
by the sample.
Sample container shall be sealed air tight after filling and marked with full
particulars are of the material and the date of sampling.
Quantity of cement offered at one time is called a lot.
This lot is normally divided in to sub lots depending upon its total weight. Quantity of
cement taken by a single operation is called increment. Aggregates of all these increments
from the same sub lot is called gross sample. When these gross samples of each sub lot are
reduced by suitable procedures for laboratory testing, they are called laboratory samples.
Equal quantities of cement from each laboratory sample representing sub lots, are mixed to
form composite samples.
The method of sampling from bags is described below;

Divide the entire lot in to sub lots. Sub lots should consist of equal No. of bags.

From each sample at least 2% bags should be sampled.

These bags are to be chosen at random. To ensure randomness following

procedure should be followed. For example, if a lot consists of 600 bags that is 30
tons, divide this lot into 3 sub lots i.e. 200 bags each. Thus N=200. Since at least, 2%
bags are to be sampled, then n=4 bags. Therefore, r=200/4=50. Thus starting from
th
any one point, every 50 bag is to be removed.

Increments are to be taken by inserting a tube sampler as per IS: 3535. The material so
collected from each bag is 0.75kg.

Material so collected should be placed in to air tight containers. Cans, plastic bags
may be used. These containers shall be sealed immediately. Gross- samples thus
obtained have to be reduced to laboratory samples by quartering. Reduction should be
continued till about 7-10 kg material required for laboratory sample are obtained.

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Equal quantities of material shall be taken from each laboratory sample

representing the sub lot and mixed together to constitute composite sample
representing the lot as a whole. The weight of the composite sample shall be about
7 kg to 10kg.

All laboratory samples and composite samples should be sealed in an air tight
moisture proof container.
9.1.2 Tests for Cement
The cement is the important ingredient of mortar and concrete used for construction purposes.
The various physical and chemical test should be conducted as per prescribed frequency.
Following are the tests to be conducted to judge the quality of cement.
1. Consistency
2. Fineness
3. Soundness
4. Initial and Final Setting Time Of Cement
5. Compressive strength
A. Test for Fineness
To determine the fineness of cement by dry sieving as per IS: 4031 (Part 1) – 1996. The
principle of this is that we determine the proportion of cement whose grain size is larger
than specified mesh size. The apparatus used are 90µm IS Sieve, Balance capable of weighing
10g to the nearest 10mg, A nylon or pure bristle brush, preferably with 25 to 40mm, bristle,
for cleaning the sieve.
Procedure to Determine Fineness of Cement

i) Weigh approximately 10g of cement to the nearest 0.01g and place it on the sieve.
ii) Agitate the sieve by swirling, planetary and linear movements, until no more fine
material passes through it.
iii) Weigh the residue and express its mass as a percentage R1, of the quantity first
placed on the sieve to the nearest 0.1percent.
iv) Gently brush all the fine material off the base of the sieve.
v) Repeat the whole procedure using a fresh 10g sample to obtain R2. Then calculate
R as the mean of R1 and R2 as a percentage, expressed to the nearest 0.1 percent.
When the results differbymorethan1percentabsolute, carry out a third sieving and
calculate the mean of the three values.
Reporting of Results
Report the value of R, to the nearest 0.1 percent, as the residue on the 90µm sieve.
B. Test for Compressive Strength
Method
1) Gauge a mixture of cement and regarded identified Indian Standard sand in the
proportion of 1:3 by weight using (P/4+3.0) percent of water where P is the percentage
of water required to produce a paste of standard consistency.

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2) Fill the cube moulds (70.6mmx70.6mm) by compacting it for 2 minutes on a vibrating

machine at a speed of 12,000±) 400 vibrations per minute. Smoothen the top surface of the
cubes with flat side of a trowel.
3) Immediately upon completion of mould, place the cube moulds in an atmosphere of
270C ± 20C and relative humidity over 90%. After, 24 hours, remove the specimens
from the moulds and keep them in water till testing.
4) Test the cubes at 3 days and 7 days age in the compression testing machine at such a
rate that maximum load is reached in 80-100 seconds.
Report the average compressive strength in N/mm2 (kg/cm2)./ mpa. The reporting is to be
made on format A/TR-1.

CEMENT (PPC) IS: 1489 (1)-1991 FLY ASH BASED

Ref
Test Frequency Acceptance Standard
Codes
1.Chemical Tests
(i) Loss on ignition, Once for every As per IS: i) 5.0% max
percent by mass source approval 4032- ii) 6.0% max
(ii) Magnesia (Mgo), Once for every lot, 1985 iii) 3.0% max
percent by mass Once for every 3 iv) x + 4.0(100-x)/100
(iii) Sulphuric anhydride months where x is the declared % of
(So3) Percent by mass flyash in the given Portland
(iv) Insoluble material, Pozzolona cement
percent by mass
2. Physical Tests Once for every i) Min.30min.
(a) Setting Time source approval ii) Max.600min.
(i) Initial Once for every lot
(ii) Final 10mm (max.)
(b) Soundness (Le- 0.8% (max) by Autoclave
Chatelier Expansion) method
(c) Compressive
Strength Once for every 3 Not less than 16 MPa strength
(i) At 72±1hr months Not less than 22 MPa strength
(ii) At 168±2hrs Not less than 33 MPa strength
(iii) At 672±4 hr
(d)Fineness Specific surface shall not be
(e) Drying shrinkage less than 300 M2/kg
Not be more than 0.15%

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CEMENT (OPC-43 GRADE) IS: 8112-1989

Test Frequency Ref Codes Acceptance / Standard
1.Chemical Tests Once for every As per
Chlorides (as Cl) source IS: 4032- 0.05 % max
Ratio of Alumina to approval. 1985 0.66 % min
that of Iron Oxide Once for every lot.
Magnesium (MgO) Once for every 3 6.0 % max
Total Sulphur content months 3.0 % max
(SO3) 5.0 % max
Loss on Ignition 2.0 %
Insoluble residue Lime max
saturation factor 0.66- 1.02
2. Physical Tests Once for every
(a) Setting Time source approval Not less than 30 min.
(i) Initial Once for every Not less than 600 min
(ii) Final lot As per
IS : 4031- 10mm (max.)
(b)Soundness (Le- Once for every 3 1988 and 0.8% (max) by Auto clave
Chatelier Expansion) months method
(c)Compressive
Strength Not less than 23 MPa
(i) At 72±1hr strength Not less than 33
(ii) At 168±2 hrs MPa strength Not less than
(iii)At 672±4hr 43 MPa strength
(d)Fineness (Blain’s
air permeability 225 M2/kg Minimum Residue
method) not to exceed 10 %
By sieving on 90µ
sieve

9.2 Aggregates
9.2.1 Sampling Procedures and Sample Collections
The method of sampling from stacks on site is described below;
Divide the lot in sub lots.
Minimum weight of gross samples is the minimum No. of increments.
Increments should be drawn with the help of scoop.
Sampling of aggregate from the stacks should be carried out, as for as possible,
during making of the stack.
Number of increments should be equally distributed over the sub-lot.
When it becomes necessary to sample a stationary stack, trench sampling method
may be used.

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Each gross sample should be reduced separately. Reduction may be done by

quartering method.
Each laboratory sample so obtained is carefully packed, great care being taken to
prevent the loss of any fine material. Each container should have card giving the
following information:
(a) Name of the quarry pit, river bed etc. and address.
(b) Proposed use of material.
(c) Geographic location and shipping facilities.
A. Tests for Fine Aggregate (Sand)
Sand is extensively used for masonry and concrete works. Therefore mandatory test of sand
is needed for quality control. The various test required are given below.
Sieve Analysis & Fineness Modulus
Method
6nos. of I S. sieves as specified in the standards given below are used for determination of
percentage of weight of sand retained on each sieve. A sample of about 1000 gms of sand is
weighted and then it is passed successively through the set of sieves specified below. The
weight of sand retained on each sieve is weighted and tabulated and Fineness Modulus is
calculated.
The sample shall be brought to an air-dry condition before weighing and sieving. This may
be achieved either by drying at room temperature or by heating at a temperature of 100
degree to 110 centigrade. The air dry sample shall be weighed and sieved successively on the
appropriate sieves starting with the largest. Care shall be taken to ensure that the sieves are
clean before use. Each sieve shall be shaken separately over a clean tray until not more than a
trace passes but in any case for a period of not less than two minutes. The shaking shall be
done with avaried motion backwards and forwards, left to right, circular clockwise and anti-
clockwise and with frequent jarring, so that the material is kept moving over the sieve
surface in frequently changing directions. Materials shall not be forced through the sieve by
hand pressure but on sieves coarser than 20 mm. Placing of particles is permitted. Lumps of
fine material, if present may be broken by gentle pressure with fingers against the side of the
sieve. Light brushing of underside of the sieve with a soft brush may be used to clear the
sieve openings.
Light brushing with a fine camel hair may be used on the 150 micron IS sieve to prevent
segregation of powder and blinding of apertures. Still or worn out brushes shall not be used for
this purpose and pressure shall not be applied to the surface of the sieve to force particles
through the mesh. On completion of sieving the material retained on each sieve together with
any material cleaned from the mesh shall be weighed. The cumulative percentage by weight of
the total sample passing each of the sieves, to the whole number is reported on Format A/TR-2.

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STANDARDS
Ref. of
Test Frequency Acceptance/Standard
Codes
1. Particle Once for IS: 383- Fine aggregates should be grading for as given
Sizes every 1970 below
a) Sieve source IS: 2386 IS
Analysis approval (Part I)– Sieve
Percent by weight passing for
Once in 1963 Design-
a month IS: 1542- ation
1992 Zone-I
Zone II Plaster
IS: 2116- (High Masonry
(Stand. IS:
1980 strength IS: 2116
Conc.) 1542
Conc.)
10mm 100 100 100

4.75mm 90-100 90-100 95-100 100

2.36mm 60-95 75-100 95-100 90-100

1.18mm 30-70 55-90 90-100 70-100

600 15-34 35-59 80-100 40-100

300 5-20 5-20 20-65 5-70

150 0-10 0-10 0-15 0-15

For crushed stone sands, crushed gravel sand the permissible limit on 150 micron I S sieve
is increased to 20 %. Tolerance of ± 5 % is allowed except on 600 for sand used in
concrete.
Silt Test
Method
A sample of sand to be tested shall be placed without drying in a 200 ml measuring cylinder.
The size of the sample shall be such that it fills the cylinder up to 100 ml mark. Water shall be
added to 150 ml mark. The mixture shall then be shaken vigorously and allowed to settle for 3
hours.
The height of silt visible as settled layer above the sand shall be expressed as percentage
the height of sand settled below the jar.
The reporting is to be made on format No. A/TR-12 .
Standards
Not more than 8% by weight in natural sand.
Not more than 10% by weight in case of crushed stone sand.

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Organic Impurities
Method
Fill a 350 ml clear glass medicine bottle up to 70 ml mark with a 3% solution of caustic soda or
sodium hydroxide. The sand is next added gradually until the volume measured by the sandy
layer is 125 ml. The volume is then made up to 200 ml by addition of more of solution. The
bottle is then Stoppard and shaken vigorously and allowed to stand for 24 hours. At the end of
this period, the color of the liquid will indicate whether the sand contains a dangerous amount
of matter.
Standards
A colorless liquid indicates a clean sand free from organic matter.
A straw colored solution indicates some organic matter but not enough to be seriously
objectionable. Darker color means that the sand contains injurious amounts and should not be
used unless it is washed, and a retest shows that it is satisfactory.
Bulkage of Sand
Method
Take a measuring cylinder and fill it with damp sand (consolidated by shaking) to its four fifth
capacity. Let the volume of damp sand in the cylinder be X, then pour water in the cylinder
and stir the sand well. The water shall be sufficient to submerge the sand completely. Let the
volume of consolidated sand be Y. The percentage of bulk age of damp sand shall be
calculated from the formula:

Percentage Bulkage =
STANDARD
Test Frequency Ref. Codes Acceptance/Standard
1.Deleterious Once for every IS: 383-1970 Deleterious Percentage by
materials source approval IS: 2386 Material weight (Max.)
Once in a month (Part Coal and Lignite 1
II) – 1963 Clay and Lumps 1
Material finer that 3
75 micron IS Sieve
Soft Fragment -
Shale 1
Total % of all. 5
2.Silt Content Once for every Maximum 8% or as specified in
source approval Agreement
Once daily
3.Specific Gravity Once for every IS: 383-1970 Test is required for maintaining
and Density source approval IS: 2386 uniformity of material brought from
Once every 3 (Part III) – the source
months 1963

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Test Frequency Ref. Codes Acceptance/Standard

4.Water Once for every IS: 383-1970 Test required for adjusting the water
Absorption source approval IS: 2386 content in the mix design before
Once Daily (Part III) – starting any concrete mixing
1963
5.Soundness Once for every IS: 383-1970 Maximum average loss of weight after 5
source approval IS: 2386 cycles
Once every 3 (Part V) – (i) Tested with Sodium Sulphate
months 1963 - 10%
(ii) Tested with Magnesium Sulphate
- 15%

B. Tests for Coarse Aggregate (Stone Grit)

Coarse aggregate is most important constituent in concrete, which mainly imparts
strength to concrete structure. The various test required are given below to judge the
hardness of coarse aggregate.
Impact Test
Crushing Test
Abrasion Test
10% fine Value
Sieve Analysis & Fineness Modulus Test
Method
The stone ballast for use in all types of cement concretes work shall meet the grading
requirements specified below. I.S. sieve of sizes as given below are used and weight retained
on each sieve is found out with the help of balance. The reporting is to be made on format No.
A/TR- 2.

STANDARDS

TEST Frequency Ref. of Acceptance / Standard

codes
1. Particle Size Once for IS:383- Percentage
IS Sieve
(a) Sieve Analysis every 1970 Grading passing (by
Designation
source IS: weight)
approval 2386 20mm
40mm 100
Once Nominal size
(Part I)
in a 20mm 85 – 100
– 1963
week 10 mm 0 – 20
4.75 mm 0–5
12.5mm Nominal
16 mm 100
size
12.5 mm 85 – 100
10 mm 0 – 45

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TEST Frequency Ref. of Acceptance / Standard

codes
4.75 mm 0 – 10
10.0 mm Nominal
12.5 mm 100
size
10 mm 85 – 100
4.75 mm 0 – 20
2.36 0 -- 5
(b)Flakiness Index and 35% Maximum value of combined Elongation and
Elongation Index Flakiness Index
2) Deleterious IS: Deleterious Material Percentage by weight
Materials (crushed 383- (Max.)
aggregate) 1970 (i) Coal and Lignite 1
IS:2386 (ii) Clay and Lumps 1
(PartII)
(iii) Material finer that 3
– 196375 micron IS Sieve
(iv) Soft Fragment --
(v) Shale --
Total % of all. 5
3. Specific Gravity and Once for IS: 383- Test is required for maintaining uniformity of
Density every 1970 material brought from the source
source IS:2386
approval (Part
Once in a III)–
fortnight 1963
4. Mechanical
properties
(a) Aggregate Once for IS: 45% maximum by Weight 45%
Crushing Value every 383- maximum by Weight
(b) Impact Value source 1970 Not less than 5 tonnes 50%
approval IS:2386 maximum by Weight
(Part
(c) 10 percent Fines IV) –
Once for 1963
(d) Abrasion Value every
source
approval
5. Soundness Once for IS:383- Maximum Average Loss of weight after 5 cycles
every 1970 (i) Tested with Sodium Sulphate - 12%
source IS:2386 (ii) Tested with Magnesium Sulphate - 18%
approval (Part
V) –
1963

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TEST Frequency Ref. of Acceptance / Standard

codes
6. Surface Moisture Once for
content every IS: Test required adjusting the water content in the mix
source 383- design before starting any concrete mixing.
approval 1970
At every IS:
change of 2386
mix design (Part
III) –
1963
7. Alkali Reactivity Once for IS: 383- Innocuous Aggregate
every 1970
source IS: 2386
approval (Part
VII) –
1963

9.3 Bricks
9.3.1 Sampling Procedures and Sample Collections
The sample may be drawn by random sampling.
The stack shall be divided into a number of real or imaginary sections and the
required number of bricks is drawn from each sections. For this purpose bricks in
the upper layers of the stack shall be removed to enable units to be sampled from
places with in the stack.
The bricks shall be selected and inspected for each lot separately for ascertaining
their conformity to the requirement of the relevant specification.
9.3.2 Tests for Bricks IS: 1077-1992
Following tests are required for bricks;
Visual,
Dimension,
Absorption,
Efflorescence,
Compressive strength.
A. Visual
Method:
20 bricks shall be selected at random out of 50,000 bricks of each class, then color and
shape is observed. Two bricks are struck back to back with each other and sound observed
is recorded.

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STANDARDS:
All Classes for masonry Over Burnt for road

Shall have a uniform deep cherry red Shall have a deep copper color, and
color, and shall be thoroughly burnt and shall be over-burnt and regular in
not over burnt. The bricks must give a shape. The bricks should emit a clear
clear ringing sound on being struck. ringing sound when struck. The bricks
They may be free from cracks, chips, must be free from cracks, chips, flaws
flaws and stones lumps of any kind. and stones or lumps and spongy
matter.

B. Dimensions
Method
20 whole bricks shall be selected at random and their dimensions shall be measured
by spreading the bricks in contact with one another, length, breadth and height wise
on a level surface. These dimensions should be within the tolerance limits specified
below:

All Classes Non Modular Bricks (In mm)

Length 4600 ± 80

Standard size of one brick

Width 2200 ± 40
Length : 230 mm
Width : 110 mm
1400 ± 40 for 70 mm high Height : 70 mm or 30 mm
Height
600 ± 40 for 30 mm high

Straight Over Burnt Bricks

Length 177.5’’ to 182.5’’ Standard size of one brick
Width 85’’ to 87.5’’ Length : 8’ 7/8’’
Width : 4’ 1/4’’
Height 52.5” to 55.0’’ Height : 2’ 5/8’’

Modular Bricks
Length 3800 ± 80 mm
Standard size of one brick
Width 1800 ± 40 mm Length : 190 mm
Width : 90 mm
1800 ± 40 cm for 90 mm high
Height Height : 90 mm or 40 mm
± 40 for 40 mm high

C. Water Absorption
Method
5 whole dry bricks shall be selected at random from the sample obtained. The test specimen

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shall be weighted and shall then be completely immersed in clean water at room temperature
and allowed to remain in this state for a period of 24 hours. The specimen shall then be taken
out, wiped with damp cloth and then weighed immediately.

Absorption percentage by weight =

A : Weight of dry specimen
B : Weight of the specimen after 24 hours immersion in cold water. The reporting is to be
made on format A/TR 11.

STANDARD

Sl.
Class Ref. codes Limit
No.

1 For Masonry IS : 3495(II)-1992 Not more than 20% by weight

Straight over burnt

2 Not more than 10% by weight
for road work

D. Efflorescence
Method
Five dry bricks shall be selected at random from the sample of bricks obtained. Each brick
shall be placed on end in a flat bottom dish containing distill water. The depth of emersion of
the brick being not less than 2.5 cm. The whole arrangement shall be allowed to stand in a
warm room (i.e. 18 to 30oC ) and well ventilated room until all the water in the dish
evaporate. When the water is absorbed and the bricks appear to be dry, a similar quantity of
distilled water shall again be placed in the dishes and the same allowed to evaporate as
before. At the end of this period the bricks shall be examined for efflorescence.
STANDARDS:
The liability to efflorescence shall be reported as per following definitions:

Sl. No Standard Definition Ref. code

When there is no perceptible deposit of IS : 3495(II)-1992

1 Nil
efflorescence

When not more than 10% of area of the

2 Slight
brick is covered with a thin deposit of salt.

When there is a heavier deposit than

under slight and covering up to 50% of the
3 Moderate
brick surface but unaccompanied by
powdering of flaking of the surface.

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Sl. No Standard Definition Ref. code

When there is a heavy deposit of salts

covering up to 50% or more of the brick
4 Heavy
surface but unaccompanied by powdering
of flaking of the surface.

When there is a heavy deposit of salts

accompanied by powdering and flaking of
5 Serious
the surface and tending to increase with
repeated weathering of the specimens.

E. Compressive Strength
Method:
The bricks when used in masonry are subjected to compressive stresses due to load
transferred. So in order to enable them to sustain the load coming on them, they should be
tested for their compressive strength.
5 whole bricks shall be selected at random from the sample of bricks. The bricks shall be
0
immersed in water at 25 to 29 C for 24 hours. They shall then be removed and allowed to dry
at room temperature for about 5 minutes and wiped free from surplus moisture. Their frogs
shall be filled with mortar composed of one part Portland cement and three parts clean sand
graded to 3 mm and down. The bricks shall then be stored under damp sacks for 24 hours.
After the expiry of this period, they shall be immersed in water for 3 days.
At the end of 3 days the sample of bricks shall be taken out, wiped dry and placed with the
flat surface horizontal and the mortar filled face facing upwards between 2 or 3 plywood
sheets
Approximate 3 mm thick and carefully centered between the plates of the compression testing
machine. The compression plate of the testing machine shall have a ball seating in the form of
a portion of a sphere, the centre of which coincides with the centre of the face of the plate. The
load shall be applied axially at a uniform rate of approximately 140 kg/cm2 per minute until
2
failure occurs. The compressive strength of bricks shall be expressed in kg/cm or N/mm2.
During testing of bricks if any brick is found to have strength more than 20% of the group, it
shall be limited to +20%only for calculating the average strength.
STANDARD

Class Average compressive strength not less than

Ref. IS codes
Designation
N / mm2 Kg / cm2
35 35 350 IS : 3495 (I) – 1992
30 30 300
25 25 250
20 20 200
17.5 17.5 175

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Class Average compressive strength not less than

Ref. IS codes
Designation
N / mm2 Kg / cm2
15 15 150
12.5 12.5 125
10 10 100
7.5 7.5 75
5 5 50
3.5 3.5 35

The first class bricks as per technical specifications should have strength of 10.5 N/ mm2

9.4 CEMENT CONCRETE

9.4.1 Sampling Procedures and Sample Collections

3
From mixer: At least three approximately equal sample increments totaling 0.02m (20
liters) shall be taken from a batch during its discharge. Each sample increments are to be
collected by passing clean dry receptacle across a stream of concrete. Receptacle should
be such as to avoid segregation. Buckets of 7to 10 liters capacity of G.I. will serve the
purpose.
From batch: Sample shall be taken while a batch of concrete is being prepared or
immediately after it has been discharged on site. Sample shall be collected at not less
than five well distributed position, avoiding edge of the mass where segregation may
have occurred.
The composite sample obtained by either of the methods mentioned above shall be
mixed on a non-absorbent base either with a shovel or trowel to ensure uniformity.
These samples can then be used for conducting:

(a) Slump test,

(b) Preparation of cube for strength test.

9.4.2 Tests of Cement Concrete

A. Slump Test
Method
This test is carried out in the field during the course of concreting. The slump test
apparatus as per IS: 7320- 1974 is used for determination of slump of fresh concrete. The
cone (30x20x10cm) is placed on a flat non-absorbent surface and then filled with concrete
mix in four different layer of equal thickness. Each layer is template 25 times by the 16
mm diameter bullet pointed 60 cm length iron pinning rod. The stroke are applied
uniformly over the entire area with a force that the rod just penetrates the full depth of the
layer compacted. After the filling is completed the conical vessel or mould is removed by
raise vertically and the molded concrete is allowed to subside. The subsidence height of
the specimen is measured in mm and recorded in terms of slump. The reporting is to be

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made on format A/TR-6.

STANDARDS
Sl. Ref. Degree of Slump
Placing Conditions
No. codes workability in mm
1 Blinding concrete; Shallow IS: 456 – Very low < 25
sections; Pavement using 2000
pavers IS: 1199–
1959
2 Mass concrete; Low 25 - 75
Lightly reinforced sections in slabs,
beams, walls, columns;
Floors;
Hand placed pavements; Canal
lining;
Strip footings
3 Heavily reinforced sections in Medium 50 – 100
slabs, beams, walls, columns;
Slip form work; Pumped
concrete 75 – 100
4 Trench fill; High 100 – 150
5 In-situ piling Tremie Very high > 150
concrete

B. Compressive Test:
Method
The 150 mm cube moulds as per IS: 10086 -1982 are used for this purpose. Six specimens shall
be taken for each sample to be tested for 7 and 28 days. The mould is filled with concrete mix
in 3 layers of equal thickness. Each layer is template 25 times by the 16 mm diameter bullet
pointed 60 cm length iron pinning rod. The test shall be made at the edge of concrete
corresponding that to for which the strength specified, Compression tests shall be made
immediately upon removal of the concrete test specimens from the curing room i.e. the test
specimens shall be loaded in damp condition. The dimensions of the test specimens shall be
measured in millimeters accurate to 0.5.The metal bearings plates of the testing machine shall
be place in contact with sides of the test specimens.
Cushioning material shall not be used in the machine. In the case of cube, the test specimen
shall be placed in the machine in such a manner that the load is applied to the sides of the
specimen. An adjustable bearing block shall be the used to transmit the load to the test
specimen. The size or lower section of the bearing block shall be kept in machine as the head
of the testing machine is brought to a bearing on test specimen.

The load shall be applied axially without shock at the rate of approximately 140 kg/ cm2 per
minute. The total load indicated by the testing machine at failure of the test specimen shall be
recorded and the unit compressive strength calculated from the measured dimensions of the
test specimen. The type of failure and appearance of the concrete shall be noted. The reporting

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is to be made on format A/TR-5.

STANDARDS OF CHARACTERISTIC STRENGTH
Compressive strength on 15 cm cubes for
Group Grade
work test In N/mm2
Designation
Min at 7 days Min at 28 days
Ordinary Concrete M10 7.0 10
M15 10.0 15
M20 13.5 20
Standard Concrete M25 17.0 25
M30 20.0 30
M35 23.5 35
M40 27.0 40
M50 50
M55 55
High strength M60 60
Concrete M65 65
M70 70
M75 75
M80 80

9.5 Reinforcement Steel & Structural Steel

9.5.1 Sampling Procedures and Sample Collections
Take sufficient rods, at random, from each lot to obtain desired number of samples.
If more than one rod is needed, they must be taken from different bundles.
Using a hacksaw, cut off as many one-meter long pieces as are needed for the test
from the sampled rod or rods.
Tie the cut-off pieces from each lot together with wire and mark properly.
Every bundle of steel samples must be identified with a proper label and be sent to
the laboratory under cover of a sample data from giving:

Type of steel
Nominal size
Cross-section
Grade and mould number
Test to be done on the samples.
9.5.2 Tests of Steel for Reinforcement IS: 1786-2008
Method
The steel should be got tested in authorized laboratories before it is used for work at site.
Following tests should be conducted for reinforcement steel,

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Mass per meter/diameter

Yield stress ( 0.2% Proof stress)
Ultimate tensile strength
Elongation
Cold bend re bend test
Chemical composition
Three pieces of 100 cm. length in each size should be drawn out of 10 ton lot. After
measuring the diameter in mm and weight in kg the strength test and elongation is carried
out in Universal testing machine.
Chemical test could be done on one sample only for each manufacturer.
STANDARDS
Test Frequency Ref Codes Acceptance / Standard
1. Chemical Tests
Carbon Once for every IS : 228 (1- 0.30 Max.
Sulphur source approval 24)- 0.06 Max.
Phosphorus Once for every lot 1987 0.06 Max.
Sulphur+Phosphorus 0.11 Max.
2. Physical Tests Once every IS: 1786: - 10% more than the actual 0.2% proof
3 months 1985 stress but not less 485MPa
Ultimate tensile Once for every IS : 1608- Min. - 415MPa
strength source approval 2005 Min.- 14.5 %
Once for every lot To be satisfactory To
0.2% proof stress be satisfactory
IS :1599- 6.31 ±3% for 32 mm Dia., 4.830
% Elongation Bend Once every 1985 ±3% for 28 mm dia.,
Test 3 months 3.85 ± 3% for 25 mm dia.,
Re-bend Test IS :1786- 2.470 ±3% for 20 mm Dia.,
2008 1.580 ±5% for 16 mm Dia.,
Mass per meter run 0.888 ±5% for 12 mm Dia.,
(kg) 0.617 ±7% for 10mm dia.,
0.395 ±7% for 8mm dia.,
0.222 ±7% for 6 mm dia.

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9.5.3 Mild Steel (Structural)

STANDARDS
Ref
Test Frequency Acceptance/Standard
Codes
Desig Carbon
1.Chemi Once for IS:2062 Grade C Mn S P Si
equal value
nation
- cal every -2006 max.
Compos source A Fe410 WA 0.23 1.5 0.05 0.05 0.04 0.42
ition approval
Once in B Fe410 WB 0.22 1.5 0.046 0.045 0.04 0.41
a project
C Fe410 WC 0.20 1.5 0.040 0.04 0.04 0.39
for each
source Nitrogen Content 0.02 %
Nb, V and Ti content (all or any) 0.2 %

A. Tensile strength of structural steel

Sl.
Test Standards
No.

1 Yield strength 250 MPa

2 Ultimate strength 400 MPa

3 Density 7.8 g/cm3

9.6 Pipes for Water Supply & Sewerage

9.6.1 Sampling Procedures and Sample Collections
All pipes in a single assignment of the same class, same size and manufactured under
essentially similar conditions shall constitute a lot.
For ascertaining conformity of the lot to the requirements of the standards, sample
shall be tested from each lot separately.
These pipes shall be selected at random from the lot and in order to ensure the
randomness of the selection, a random number tables IS: 4905 may be referred to.
In the absence of random number table, the following procedure may be adopted;
Starting from any pipe in the lot, count 1, 2, 3 ….and so on up to r, where r is the
integral part of N/n , N being the number of pipes in lot, and n the number of pipes in
the sample. Every rth pipe so counted shall be withdrawn so as to constitute the
required sample size.

9.6.2 Tests of UPVC Pipes for Potable Water Supply IS: 4985-2000
Methods and Standards
The dimension test should be carried out in the field and other types should be carried out
in the laboratory before use.

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Pipes of 1.0 m length each size should be sampled out for test.

Ref.
Field tests Standards
codes
Length of pipe IS: As per Table-1
Mean outside dia.(Min/Max) 4985- ,,
Diameter at any point.(Min/Max) 2000 ,,
Wall Thickness .Average (Min/Max)
Visual appearance ,,
Smooth, clean, both end square cut
Dimensions of sockets Ls = 0.5dn + 6mm
Ls = minimum socket length
dn = nominal outside dia of pipe

REF.
LAB TEST STANDARDS
CODES
IS: Shrinkage not more than 5%
Reversion test 12235(5)-
2004 Pipe shall not fail during the
Short term hydro static pressure test prescribed test duration.
4.19xPN( MPa) at 27oC for one hour TIR not more than 10%
IS: 12235 VST of specimen shall not be less than
Resistant to external blows at (8)-2004 800 C

0oC Vicat softening temperature Density of pipe shall be between 1.40

Density and 1.46gm/cc
IS: 12235 11.0 % ( Max.)
(9)-2004

Sulphated ash content

IS: 6307-
1985

IS:
13360 (3)
9.6.3 Test of UPVC Pipes for Drainage / Sewerage Work
Methods and Standards
The dimension test should be done in field on receipt of pipes using ball ended screw
gauge/and caliper for other test sample as above should be sent to approved laboratory and
it should be used only after the result are found satisfactory as per relevant standards.

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STANDARDS
Field test Ref. codes Standards
1) Dimension IS: 1) IS 15328- 2003 Table-1
(i)Mean outside dia. 15328- ---- do ----
(ii)Outside dia. at any point 2003 IS 15328- 2003 Table-3
(iii)Wall thickness 2) The internal & external surface of the pipe
shall be smooth clean and free from any
2) Visual appearance
other ducts
3) The color shall be dark (any shade of
3) Color brown) uniformly colored throughout the
entire wall, slight variations in the
appearance of the color are permitted.

Lab test Ref. codes Standards

4). Vicat softening temp.
IS:12235 4)Not less than 79oC
5) Longitudinal Reversion test (V)-2004
5)Maximum ±5%
6) Resistant to external IS:12235
(IX)-2004 6)TIR not more than 10%
blows at 0oC IS:12235
7) Resistance to Internal (VIII)-2004 7) Pipe shall not fail ( seep, crack, bulge or
hydrostatic pressure. burst) during the prescribed test duration
and shall meet the requirement of IS: 15328
Table-6
Minimum one Pipe of 1.0 m length each size should be Sampled out for test.

9.6.4 Tests of Glazed Stone Ware Pipes IS: 651-2007

Methods and Standards
The dimension test of pipe should be conducted in the field after the sampling is done by
ENGINEERING-IN-CHARGE. Hydraulic and other tests should be got done in the approved
laboratory before use. The material should conform to relevant specifications.

Field test Ref. codes Standards

1.Dimensions
Length
Internal diameter
Mean thickness
Internal depth of socket As per IS
Excess shoulder measurement : 651- +4%.-1.5%
Length of grooving 2007 As per IS : 651-2007 Table 1

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Lab test Ref. codes Standards

2 Hydraulic test IS : 651- Should sustain minimum 0.15 Mpa (1.50
2007 kg/cm2) for 5 seconds
3 Alkali test No evidence of pitting, softening, spalling or
cracking should be observed
4 Other test Internal SP-1 SP-2 SP-3
dia in mm KN/m KN/m KN/m
(a) Crushing strength Upto 150 16 18 21
200-300 16 21 24
350-450 16 26 32
500-800 16 32 60
(ii) Absorption Thickness in mm Increase in mass
Up to 20 6%
Over 20 up to 25 7%
Over 20 up to 32 8%
Over 20 up to 38 9%
Over 38 10%
(iii) Acid resistant test Loss in mass 2.5 % maximum

9.6.5 Tests of R.C.C Pipes

Methods and Standards
It shall be as per IS: 458-2003 and should also conform the test requirements as per IS: 3597-
1998.
Test Frequency Ref. Code Acceptance/ Standard
1. Tolerances in At the start of IS: 458- Up to and including 30 mm + 2mm, -
Dimensions work for source 2003 1mm Over 30 mm and up to and
approval Once for including 50mm + 3mm, - 1.5 mm
Wall Thickness every Lot for each Over 50 mm and up to and including
size 65mm+ 4mm,- 2.0 mm
Over 65 mm and up to and including
80mm+ 5mm, - 2.5 mm
Over 80 mm and up to and including
95mm+ 6mm, - 3.0 mm
Over 95 mm + 7mm, - 3.5 mm
Internal Dia. Of IS: 458- Up to and including 300 mm ± 3mm
pipe or socket 2003 Over 300 mm and up to and including
600 mm ± 5mm
Over 600 mm ± 10 mm
Overall Length IS: 458- ±1% of standard Length
2003
2. Three Edge IS: 458- Shall withstand the design Load
Bearing 2003

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Test Frequency Ref. Code Acceptance/ Standard

3. Water IS : 3597- After 10 minutes, 2.5 % of dry Mass
absorption 1998 Max, and total absorption at the end
of 24 Hours shall not exceed 6.5% of
dry mass
4. Hydrostatic No leakage under the design pressure
test
5. Straightness The deviation from straightness when
tested by means of rigid straight edge
parallel to the longitudinal axis of the
pipe shall not exceed 3 mm for every
m length
6. Reinforcement IS: 458- On breaking the Pipe and extracting
2003 the reinforcement, it shall be as per
the provision

9.6.6 Tests of HDPE Pipes

Methods and Standards
The HDPE pipes shall conform to IS: 4984-1995

Ref.
Test Frequency Acceptance / Standard
code
1.Dimensions As per Table
(i) Out side Dia.
(ii) Wall thickness No localized swelling, leakage, weeping, or
1. Hydraulic bursting during subjecting to internal pressure
Characteristics creep test.
2. Reversion Test Longitudinal reversion shall not be more than
3%
3. Density 940.5 to 946.4Kg/m3 at 270C and shall not differ
from the nominal value by more than 3kg/ m3

4. Melt Flow Rate 0.41 to 1.10 at 1900C with nominal load of 5kg
(MFR) and shall be within 20% of the value declared by
the manufacturer.

5. Carbon Black
Content and 2.5+ 0.5% with uniform dispersion.
Dispersion

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9.6.7 Tests of G.I Pipes

Methods and Standards
It shall conform to IS: 1239 (I) -2004 with respect to dimension, weight per meter and
Hydraulic test pressure. The Galvanizing of pipes shall also conform to relevant IS : Codes
as given below:

Test Frequency Ref Codes Acceptance/Standard

1. Mass of Zinc One test per lot IS: 6745-1972 400 g/m2 minimum total mass of Zinc
Coating (inside and outside) per surface area
(inside and outside) of the coated surface.
The Zinc coating shall be free from
2Visual Test One test per lot IS: 2629-1985 imperfection like flux, ash and dross
inclusions, bare patches, black spots,
pimples, lumpiness, rums, rust, blister,
white deposit etc.

Minimum 1m pipe length for each size should be sent for lab test.

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CHAPTER 10
WATER FOR CONSTRUCTION PURPOSES

Water used for mixing and curing shall be clean and free from injurious amounts of oil,
acids, alkalis, salts, sugar, organic materials or other substances that may be deleterious to
concrete or steel. Potable water is generally considered satisfactory for mixing concrete.
10.1 Sampling of Water
The containers of glass or other inert material like polythene must be carefully cleaned
before use. Minimum one liter sample should be collected for lab test.
Methods and Standards
Water should be tested as per relevant IS Codes as shown below, and shall conform to IS: 456 -
2000 and IS: 10500-1991. The reporting is to be made on format A/TR-4.

Ref.
Test Frequency Acceptance/Standard
Codes
1. Chemical Analysis Once for every
source approval IRC: 21-
(a) PH value Every Quarterly 2000 a) Minimum6
Chemical tests daily
in the site b) 2000mg/L for concrete
(b) Chlorides (as Cl) Laboratory with IS: 3025 not containing
testing kits (Part 32) - embedded steel and
1987 500mg/L for RCC and
PSC
(c) Sulphates (as SO3) IS: 3025 c) 400mg/L
(Part 28)
(d) Neutralization with
-1987 d) Max. 5 ml of 0.2 normal
NaoH (with
IS: 3025 NaOH to neutralize 100
phenolphthalein as
(Part 22) ml. sample of water
indicator)
-1987
2. Physical Analysis
(a) Suspended Matter Once for every IS: 3025 a) 2000 mg/ l max.
(b) Organic Matter source approval (Part 23)
(c) Inorganic Matter Every Quarterly -1987 b) 200 mg/ l max.
IS: 3025
(Part 17) c) 3000mg/l max.
IS: 3025
(Part 18)
IS: 3025
(Part 19)
- 1987

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CHAPTER 11
TESTS & STANDARDS FOR TIMBER

All the mechanical properties of seasoned timber vary with moisture content, and
therefore, it is necessary that the moisture content of timber be determined. It can be
measured by moisture meter using electrode. When moisture content of timber is checked by
oven drying method, the result of electrical moisture meter shall be ignored.
Methods
11.1 Surface Electrode Test
For surface measurement of moisture content of veneers, plywood and finished wood ware
item as there are no needles or knives to be driven into the timber, it does not spoil the
fabricated articles, just press lightly on the surface of the wood and you get an instantaneous
reading of the moisture content.
11.2 Knife Electrode Test
For measuring the moisture content of planks and boards, the knives are en -headed in a
plastic material, which can stand light hammers for driving the knives up to about 8mm into
the timber. This will give the average moisture content of a plank from 25 to 40 mm thick.

STANDARD

Sl. No. Description Ref. Codes Limit as per zone I

1 Allowable moisture content for doors and

windows
IS: 287-1993 10% Max.
(i)Thickness 50 mm and above

IS: 1708(1)-1986 8% Max.

(ii) Thickness below 50mm

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CHAPTER 12
TESTS & STANDARDS FOR OTHER CONSTRUCTION MATERIALS

12.1 Terracing
Method
When terracing is completed and curing is done for a period of 7 days, the roof shall be tested
by filling of 10 cm deep water for 72 hours. The seepage shall be watched and results entered
in site register of checks. Standard required is as mentioned hereunder:
STANDARD
The roof surface as completed shall be even and true to slope of 1 in 48 or as specified and
should be leak proof.

12.2 Precast Concrete Manhole Covers and Frames

Precast Manhole covers and Frames and cover shall conform to IS: 12592- part (I-II)- 1988.
Manufactures certificate with test report should be taken before it is used for the work. 16 mm
bars may be used in heavy duty and 12 mm dia bars in light duty with minimum embedment
of 20 cm on both sides of the hook duly welded with the main reinforcement of the cover.
Manhole covers shall be of the following four grades and types;

Grade Ref. Load in

Grades Type/shape of cover frame
designation codes tones

Light Duty LD-2.5 IS: 12592 2.5 Circular, Square,

Medium MD-10 1988 10 Rectangular Circular,
Duty Heavy HD -20 20 Rectangular Circular,
Duty Extra EHD-35 35 Square, Rectangular
heavy Duty Circular, Square,
Rectangular

Concrete weaker than M-30 shall not be used. Compaction of concrete shall be done by
machine vibrations.
12.3 Plastic Encapsulated Footrests
Orange color safety footrest of minimum 6 mm thick plastic encapsulated as per IS : 10910-
1984 on 12 mm dia. steel bar conforming to IS : 1786-2008 having minimum cross section as 23
mm x 25 mm and overall minimum length 263 mm and width as 165 mm with minimum 112
mm space between protruded legs having 2 mm tread on top surface ribbing or chequering
besides necessary and adequate anchoring projections on tail length on 138 mm as per
standard drawing and suitable to with stand the bend test and chemical resistant test as per
specifications and having manufacturer’s permanent identification mark to be visible even
after fixing. The step shall be tested at a load of 225 Kg. as per IS : 5455-1969.

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12.4 LDPE Sheet

LDPE plastic film shall be made of genuine virgin raw material (polymer) having a density
3 0
between 0.913 to 0.923 gm/cm at 27 C. The film shall have IS certification regarding its
quality as per IS: 2508 – 1984. The film shall be of the specified thickness and shall be supplied
in the form of flat sheet. The length of the single roll shall not be less than 30m.

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CHAPTER 13
DRINKING WATER SAMPLING

Physical, chemical and bacteriological analysis are necessary for drinking water. All samples
of water should be properly labeled and should be accompanied by complete and accurate
identifying and descriptive data. Data should include date and time of collection, type of
source of the sample and temperature of water at the time of collection.
13.1 Sampling for Physical and Chemical Analysis
The containers of glass or other inert material like polythene must be carefully cleaned before
use. It can be rinsed with alkaline permanganate solution followed by oxalic acid solution.
After having been cleaned, should be rinsed thoroughly with tap water and then with distilled
water. About 2.5 liters of the sample is required for analysis. Prior to filling, the sample bottle
should be rinsed out two or three times with water to be collected. Care should be taken to
obtain a sample that is truly representative of existing conditions and to handle it in such a
way that it does not deteriorate or become contaminated before it reaches the laboratory. The
sample should reach the place of analysis as quickly as possible with in 72 hours of collection.
The sample should only be collected after the well has been pumped for a sufficient time to
ensure that the sample will be representative of the groundwater.

13.2 Sampling for Bacteriological Analysis

Sterilized glass bottles provided with round glass stopper having an overlapping rim should
be used. The stopper and the neck of the bottle should be protected by brown paper. The
sterilization is carried out in an autoclave at 1 kg/cm2 pressure for 15 minutes or by dry heat
0
at 160 C for 1 hour. The sample should be representative of the water to be tested and they
should be collected with utmost care to ensure that no contamination occurs at the time of
collection or prior to examination. The sample bottle should not be opened till the time of
filling. The stopper with the cap should be removed with care to eliminate soiling. During
sampling, the stopper and the neck of the bottle should not be touched by hand and they
should be protected from contamination. The bottle should be held near the base, filled
without rinsing and the stopper replaced immediately. The bottle should not be filled
completely but sufficient air space left for shaking before analysis. Then the brown paper
warping should be tied to protect the sample from contamination. The volume of the sample
should be sufficient for carrying out all the tests required and in no case, it should be less than
250ml.
STANDARD
Recommended Guidelines for Physical and Chemical Parameters as per Water Manual (GoI)
**Cause for
Sl. No. Characteristics *Acceptable
rejection
1 Turbidity (NTU) 1 10
2 Colour (Units on Platinum Cobalt scale) 5 25
3 Taste and Odour Unobjectionable Unobjectionable
4 Ph 7.0 to 8.5 <6.5 or> 9.2
5 Total dissolved solids (mg/I) 500 2000
6 Total hardness (as CaCO3) (mg/I) 200 600

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**Cause for
Sl. No. Characteristics *Acceptable
rejection
7 Chlorides (as CI) (mg/I) 200 1000
8 Sulphates (as SO4) (mg/I) 200 400
9 Fluorides (as F) (mg/I) 1.0 1.5
10 Nitrates (as NO3) (mg/I) 45 45
11 Calcium (as Ca) (mg/I) 75 200
12 Magnesium (as Mg) (mg/I) 30 150
If there are 250mg/I of Sulphates, Mg content can be increased to a maximum of 125mg/I
with the reduction of Sulphates at the rates of 1 unit per every 2.5 units of sulphates.
13 Iron (as Fe) (mg/I) 1.0 1.0
14 Manganese (as Mn) (mg/I) 0.05 0.5
15 Copper (as Cu) (mg/I) 0.05 1.5
16 Aluminum (as AI ) (mg/I) 0.03 0.2
17 Alkalinity (mg/I) 200 600
18 Residual Chlorine (mg/I) 0.2 >1.0
19 Zinc (as Zn ) (mg/I) 5.0 15.0
20 Phenolic compounds (as Phenol) 0.001 0.002
21 Anionic detergents (as MBAS ) (mg/I) 0.2 1.0
22 Mineral Oil (mg/I) 0.01 0.03
TOXIC MATERIALS
23 Arsenic (as As ) (mg/I) 0.01 0.05
24 Cadmium (as Cd ) (mg/I) 0.01 0.01
25 Chromium (as hexavalent Cr ) (mg/I) 0.05 0.05
26 Cyanides (as CN ) (mg/I) 0.05 0.05
27 Lead (as Pb ) (mg/I) 0.05 0.05
28 Selenium (as Se ) (mg/I) 0.01 0.01
29 Mercury (total as Hg ) (mg/I) 0.001 0.001
30 Polynuclear aromatic hydrocarbons (PAH) (µg/I) 0.2 0.2
31 Pesticides (total, mg/I) Absent Refer to WHO
guidelines for
drinking water
Quality Vol. I-1993
RADIO ACTIVITY+
32. Gross Alpha activity (Bq/I) 0.1 0.1
33. Gross Beta activity (Bq/I) 1.0 1.0
Notes:
* The figures indicated under the column “Acceptable” are the limits up to which water is
generally acceptable to the consumers.

** Figures in excess of those mentioned under “Acceptable “ render the water not
acceptable, but still may tolerated in the absence of an alternative and batter source but up
to the limits indicated under column “Cause for Rejection” above which they have to be
rejected.

+ It is possible that some mine and spring waters may exceed these radioactive limits and
in such cases it is necessary to analyze the individual radio nuclides order nuclides
order to asses the acceptability or otherwise for public consumption.

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13.3 Bacteriological Guidelines

The recommended guidelines for bacteriological quality are given in the following Table.

BACTERIOLOGICAL QUALITY OF DRINKING WATER

Organisms Guideline value

All water intended for drinking

E. coli or thermo tolerant Coli form bacteria must not be detectable in any 100-ml sample

Treated Water entering the distribution system

E. coli or thermo tolerant Coli form bacteria must not be detectable in any 100-ml sample

Total Coli form bacteria must not be detectable in any 100-ml sample

Treated Water entering the distribution system

E. coli or thermo tolerant Coli form bacteria must not be detectable in any 100-ml sample

must not be detectable in any 100-ml sample.

In case of large of supplies, where sufficient
Total Coli form bacteria samples are examined, must not be present in
95% of samples taken throughout any 12
month period.

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CHAPTER 14
CHECKS AND TESTS OF FINISHED WORKS

14.1 Damp Proof Course

The thickness has to be checked at every 10 M length. It should be ensured that there
are no joints in DPC. Results of thickness checked be recorded in the register of
checks. DPC shall be cured for at least for 7 days, after which it shall be allowed to
dry.
14.2 Brick Masonary
th
Every 10 layer of brick masonry be checked to see that joints and frogs of bricks are
filled with mortar. These should be at every 10 m length in long wall and 3 m in cross
wall. Mortar from joints be scraped out and sent to district lab for test of mix. Results of
check and result of test of mix be entered in register of checks and test to be maintained
at site.1 kg of sample is required for chemical tests.
14.3 RCC Works
The surface of every structure member laid in R.C.C. should be checked to see whether
it is porous. Where porosity is suspected a portion be chipped off to see its extent the
results be recorded in site register of checks. It should be checked to see that no
reinforcement bars are visible. For testing of post concrete 1 kg of sample is required
for chemical tests.

14.4 Plastering
The finished plaster surface be cut out 10x10 cms in size and thickness be checked and
recorded in site register of checks. Such cut outs should be in each wall of every room.
1 kg of sample is required for chemical tests.
14.5 Thickness of Floors
Cut out of size 5x5 cms will be made in the corner of each room and thickness of floor
will be measured and recorded in the site check register.
14.6 Chaukhats
The section of the chaukhats be checked and dimensions recorded in the site register of
checks. Each chaukhat be checked by J.E. in token of having been checked. The
dimensions of sections should be within the prescribed tolerances.

14.7 Steel Windows

The steel iron sections thickness of all windows will be measured and recorded in the
site register of checks.

14.8 Paint, Distemper Plastic Emulsion (One test for each brand of paint)
Approved paint will be obtained in container and each container will be opened in the
presence of J.E. who will sign the container in token thereof. Such container when
empty will be kept in his custody and counted when all painting work is completed to
ascertain that the spreading capacity has been maintained as laid down by the
manufacturers. The results be noted in the site register for checks.

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14.9 Fittings
The fittings for doors and windows shutters will be checked to see that they are in
according to specifications, designs and results are entered in the register of checks. It
should also be ensured that the fittings are fixed with the specified number and quality
of screws.

14.10 Distempered Surface

Where oil bound distemper of plastic emulsion has been used an area of 1 m x 1 m on
each wall be washed with water and checked to see if the paint washes off. Results
should be entered in the site register of checks.

14.11 Glass Panes

The thickness of 5% of the glass panes to be fixed will be checked with calipers and
recorded in the site register of checks. It should also be seen that the panes are fixed
with specified number and quality of screws.
14.12 Sal Wood for Chaukhats
No individual hard and sound knot shall be more than 2.5 cm diameter and the
aggregate area of all knots shall not exceed 1% area of the piece. There shall not be less
than 5 growth rings per 2 cm width. Air dry wood shall weight at an average of about
3
0.8 to 0.9 gms / Cm .
14.13 Timber for Shutters
No individual hard and sound knot shall be more than 2.5 cm diameter and the
aggregate area of all knots shall not exceed 1% area of the piece. Air dry wood shall
3
weight at an average of about 0.56 gms / Cm .
14.14 Thickness of Shutters
The thickness of all the shutters shall be measured with caliper and recorded in the site
register of checks. The thickness of shutters shall be within the prescribed tolerances.

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CHAPTER 15
HYDROSTATIC TESTS OF PIPELINES

After a new pipe has been laid, jointed and back filled (or any valve section thereof), it shall
be subjected to the following two tests:
i) Pressure test at a pressure of at least double the maximum working pressure-pipe
and joints shall be absolutely water tight under the test.
ii) Leakage test (to be conducted after the satisfactory completion of the pressure test)
at a pressure to be specified by the authority for duration of two hours.
The portions of the line shall be tested by subjecting to pressure test as the laying progresses
before the entire line is completed. In this way any error of workmanship will be found
immediately and can be corrected at a minimum cost. Usually the length of the section to be
tested shall not exceed 500m.
Where any section of a main is provided with concrete thrust blocks or anchorages, the
pressure test shall not be made until at least five days have elapsed after the concrete is cast.
If rapid hardening cement has been used in these blocks or anchorages, test shall not be
made until at least two days have elapsed.
Prior to testing, enough back fill shall be placed over the pipe line to resist upward thrust. All
thrust blocks forming part of the finished line shall have been sufficiently cured and no
temporary bracing shall be used.
The open end of the section shall be sealed temporarily with an end cap having an outlet
which can serve as an air relief vent or for filling the line, as may be required. The blind face of
the end cap shall be properly braced during testing by screw jacks and wooden planks or steel
plate. The section of the line to be tested shall be filled with water manually or by a low
pressure pump. Air shall be vented from all high spots in the pipe line before making the
pressure strength test because entrapped air gets compressed and causes difficulty in raising
the required pressure for the pressure strength test.
The test pressure shall be gradually raised at the rate of approximately one Kg,/sq. cm. /min.
the duration of the test period if not specified shall be sufficient to make a careful check on the
pipe line section.
The pipe shall be judged to have passed the test satisfactorily if the quantity of water required
to restore the test pressure does not exceed 1.5 liters per 10 mm of nominal bore for a length of
1 km.

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CHAPTER 16
TEST REPORT FORMATS

All the essential test report formats for implementation of QA/QC procedures are
given and are listed below;

Test Certificate for Cement

Test Certificate for Coarse Aggregate
Test Certificate for fine Aggregate
Test Certificate for water (where water is brackish)
Compressive Strength of Concrete
Concrete Slump Test
Hydrostatic Test for NP Pipes
Hydrostatic Test for pressure Pipes
Leak Test for Under Ground RCC Structures
Leak Test for Elevated RCC Structures
Water absorption of bricks
Silt content of fine aggregates

TEST REPORT FORMATS

Sl. No Test Report Title Ref. IS Code Form No. Remarks
1489 - 1991
1 Test Certificate for Cement A/TR -1
8112 -1989
383- 1970
2 Test Certificate for Coarse Aggregate A/TR -2
2386 – 1963
383 - 1970
3 Test Certificate for fine Aggregate A/TR -3
2386- 1963
4 Test Certificate for water 3205 – 1987 A/TR -4
456 - 2000
5 Compressive Strength of Concrete A/TR -5
516 – 1959
6 Concrete Slump Test 1199 -1959 A/TR -6
7 Hydrostatic Test for NP Pipes Manual A/TR -7
8 Hydrostatic Test for pressure Pipes Manual A/TR -8
9 Leak Test for Under Ground RCC Strs. 3370 – 2009 A/TR -9
10 Leak Test for Elevated RCC Structures 3370 -2009 A/TR -10
11 Water absorption of bricks 3495 – 1992 A/TR -11
12 Silt content of fine aggregate 383(III) – 1963 A/TR -12

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16.1 Test Certificate for Cement

Form No A/TR-1
Name of work :
Contract Agreement No :
Name of contractor :
Source of supply ;
Date of sampling &
Quantity :
Material description :

CONSISTENCY
Trial Weight of Weight Percentage of Reading of Consistency
No. cement of water water indicator (P) Remarks

SETTING TIME
Time recorded when Time recorded at
Setting Time water added set Setting time Remarks
Initial
Final
FINENESS
Weight of Retained on 0.075
cement used Percentage retained Remarks
Sieve

COMPRESSIVE STRENGTH
Crushing
Room Date of Date of Age of Crushing strength
temperature casting testing specimen load (T) Remarks
kg/cm2

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………… Dated ……………………

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16.2 Test Certificate for Coarse Aggregate

Form No A/TR-2
Name of work :
Contract Agreement No :
Name of contractor :
Source of supply :
Date of sampling & Quantity :
Material description :

A - 20 mm Nominal size

Sieve Cumulative Remarks /

Weight weight Cumulative % Cumulative %
size in Standards
retained (g) retained retained passing
mm % Passing
40 mm 100
20 mm 85-100
10 mm 0-20
4.75 mm 0-5
Pan
TOTAL

B - 10 mm Nominal size
Cumulative Remarks /
Sieve size Weight weight Cumulative Cumulative
Standards
in mm retained (g) retained % retained % passing
% Passing
12.5 mm 100
10 mm 85-100
4.75 mm 0-20
2.36 mm 0-5
Pan
TOTAL

Fineness modulus of coarse aggregate = C is cumulative % retained

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………….. Dated …………………….

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16.3 Test Certificate for Fine Aggregate

Form No A/TR-3

Name of work :
Contract Agreement No :
Name of contractor :
Source of supply :
Date of sampling & Quantity:
Material description :

Cumulative Standards
Sieve Weight Cumulative
weight Cumulative Zone II
size in retained % (wt)
retained % retained Passing
mm (g) passing
limits
4.75mm 90-100
2.36 mm 75-100
1.18 mm 55-90
600 µ 35-59
300 µ 8-30
150 µ 0-10
Pan
TOTAL

Fineness modulus of fine aggregate=

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.…………………………………………..Dated …………………….

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16.4 Test Certificate for Construction Water (For saline zone only)
Form No. A/TR-4

Name of work :
Contract Agreement No :
Name of contractor :
Source of supply :
Date of sampling & Quantity :
Material description :

Inorganic
Sl. PH Organic Sulphates Chlorides Suspended
Solids
No. Color Value Solids (mg/l) (mg/l) (mg/l) matter (mg/l)
(mg/l)
PCC < 2000
Limits >6 < 2000 < 3000 < 500 < 2000
RCC < 1000
1
2
3
4
5

Remarks/
Recommendations……………………………………………………………………..

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………..Dated …………………….

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16.5 Compressive Strength of Concrete

Form No. A /TR-5

Name of work :
Contract Agreement No :
Name of contractor :
Sampling done By :
Date of sampling & Quantity:
Description of structural member

Test No.
Sl. No. Particulars Unit
1 2 3
1 Identification Mark
2 Weight Kg
3 Length Cm
4 Breadth Cm
5 Height Cm
6 Area Cm2
7 Crushing Load Kg
8 Compressive strength Kg/cm
2

Average compressive strength of concrete = ………………………kg/cm2

Remarks /
Recommendations. ………………………………………………………………..

Signature :
Name :
Date :
For Contractor

Name of ULB / Department

Representative present
at the time of testing ……………………………………………….

Ref No.………………………………………………… Dated……………………

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16.6 Concrete Slump Test

FORM No. A/TR –6

Name of work :
Contract Agreement No. :
Name of contractor :
Source of supply :
Date of sampling & Quantity:
Material description :

Sl. Test Number

Particulars Unit
No. 1 2 3
1 Weight of cement Kg
2 Weight of Coarse aggregate Kg
3 Weight of fine aggregate Kg
4 Water / cement ratio
5 Weight of water Kg
6 Slump mm

Average slump of concrete ………………………………….. mm

Remarks / Recommendations.
………………………………………………………………..
Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………….. Dated …………………….

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16.7 Hydrostatic Test for Non Pressure Pipes

Form No. A / TR –7

Name of work :

Contract Agreement No. :

Name of contractor :

Source of supply :

Material description :

Volume of water
Internal Time
Sl. Water level to restore to
diameter in Stretch Length (m)
No. drop (mm) original level
(mm) hours
(liters)
10 min 30 min 10 min 30 min

Remarks / Recommendations
……………………………………………………………………..

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………….. Dated …………………….

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16.8 Hydrostatic Test for Pressure Pipes

Form No. A/TR –8

Name of work :

Contract Agreement No. :

Name of contractor :

Source of supply :
Material description :

Applied
Internal test
Sl. Material Length
diameter Stretch pressure Time (hours) Observations
No. of pipe (m)
(mm)
kg/cm2
1 2 3

Remark / Recommendation.
……………………………………………………………………..

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.……………………………………….. Dated …………………….

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16.9 Leak Test for Under Ground RCC Structures

Form No. A/TR –9
Name of work :

Contract Agreement No. :

Name of contractor :

Material description :

Date of Filling: Initial Water level:

Observation Date of Water level
Drop (mm) Remark
no. observation (m)
1.
2.
3.
4.
5.
6.

Remark / Recommendation.
……………………………………………………………………..

Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………….. Dated …………………….

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16.10 Leak Test for Elevated RCC Structures

Form No. A/TR –10

Name of work :
Contract Agreement No. :
Name of contractor :
Description :

Date of Filling: Water Level

Observation Date of
Initial Final Time
no. observation
1.
2.
3.
4.
5.
6.

Remark / Recommendation.
……………………………………………………………………..
Signature : Signature :
Name : Name :
Date : Date :
For Contractor For Department

Ref No.………………………………………….. Dated …………………….

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16.11 Water Absorption of Bricks

Form No. A/TR –11
Name of work :

Contract Agreement No. :

Name of contractor :

Description :

Brand ……………………

Quantity of sample : ……………………….

Weight of Water
Weight of Dry Dimensions
Sl. No. water Bricks Absorption
bricks (Kg) - A (mm)
(Kg) - B (B-A) / A x 100
1

Limit: It should not be more than 20%

Remark / Recommendation.
……………………………………………………………………..
Signature : Signature :
Name : Name :

Date : Date :

For Contractor For Department

Ref No.……………………………………….. Dated …………………….

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16.12 Silt Content

Form No. A/TR –12
Name of work :

Contract Agreement No. :

Name of contractor :

Description :

Brand : ……………………

Quantity of sample :……………………….

Observations Sample - 1 Sample - 2 Average Standards

It should not
Height of sand
be more
layer (A)
than 8 %

Height of silt
layer (B)

Silt content (%)

B x 100 / A

Remark / Recommendation.
……………………………………………………………………
Signature : Signature :
Name : Name :

Date : Date :

For Contractor For Department

Ref No.……………………………………….. Dated …………………….

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CHAPTER 17
RECORDS TO BE MAINTAINED AT CONSTRUCTION SITE

The contractor shall be responsible for a site order book, in triplicate, at the site of work at all
time, and this shall be open for inspection by authorized representative of ULB’S. The site
order book has two primary purposes to record day today instruction to the contractor and
the contractor’s compliance with these instructions, and to record the inspections and
expectations of work completion stages along with issuing approvals to the contractor to
proceed with the next stage of constructions.
As noted above the status of the contractor’s compliance with instructions issued is to be
summarized in the site order book, Format No. C/QRF-1 given below, and reviewed monthly
by the ULB’S and during the periodic squad checks. In cases where the contractor has failed to
comply with the instructions the reasons therefore shall be determined and necessary
remedial action required to be taken.

The ULB’S will maintain a file of site orders issued to contractor for record and compliance.

17.1 Site Order Book

Form No C/QRF-1
Date :
Name of work :
Place/Site :
Agreement No :
Name of Contractor :

COMMENTS ON THE PROGRESS AND QUALITY

Whether Sufficient labour on Site :
Whether Sufficient Equipment on Site :
Overall Quality of Materials :
Overall Quality of Workmanship :
Instructions To The Contractor

Compliance

*(3 copies per set- one copy each to be sent to ULBs by the contractor, one copy to be
retained at site)

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17.2 Material Register

Form No C/QRF-2
Name of Work :
Contract Agreement No. :
Name of Contractor :
Name of Item :
Total Quantity Required :
Source :
Minimum Size of One Lot :

Addition Balance
Cumulati Cumu Present Signature
Sl. Previous Invoice/ al Issued / Out
Date ve lative require of
No. Quantity Bill No Quantity consumed standing
Quantity Issue ment contractor
Quantity

*To be maintained item wise in ledger form, to be filled daily by contractor.

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17.3 Daily Progress Report

Form No C/QRF-3

Name of Work :
Contract Agreement No. :
Name of Contractor :

Date :

EQUIPMENT AT SITE
Available :

Under Repair :

Sl. Name of Item Quan- Loca- Labour engaged

No. compo- Execu- Tity tion
Skilled Non- Fitter Mason Others
nent ted
skilled
1

Any Special Difficulties/ happenings:

Signature : Signature :

Name : Name :

Date : Date :

For Contractor For Department

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17.4 Concrete Pour Record

Form No C/QRF-4

Name of Work :
Contract Agreement No. :
Name of Contractor :
Steel checked By :
Form work Checked By :
Scaffolding checked By :
Slump checked By
Cube filled in the presence of

Name of
Mix Approved Time of Cement Time of
Date compo Structural Qty. Laid
nent Member Proportion By Start bags used completion

Concreting done in the presence of:

Signature : Signature :
Name : Name:
Designation: Designation:
For Contractor For Department

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17.5 Test Record

Form No C/QRF-5
Name of Work :
Contract Agreement No. :
Name of Contractor :

Status of Date Sign.

Status of Sign.
Sl. Description Date of Size of Name of Manufactur and of
DT of
No. of sample sampling sample Laboratory ing Result contr
Inspection ULB
Certificate of Test ator

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17.6 Design and Drawing Record

Form No C/QRF-6

Name of Work :

Contract Agreement No. :

Name of Contractor :

Status of
Date of
Sl. Drawing Contractor’s S.D.E./E.E.
Details of Drawing Title/ No Receipt of
No. (Original/ Signature Signature
Drawing
Revised )

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17.7 Non-Conforming Item Record

Form No.C/QRF-7

Name of Work :

Contract Agreement No. :

Name of Contractor :

Brief details of item :

Name and designation of the Authority deciding the non-

conformation:
Name……………………………..
Designation…………………………….

Reason for non-conforming :

Nature of non-conforming-

Comments:

i) Whether the item is structurally sound.

ii) Whether the item is acceptable with in Specified tolerance limits at reduced rates.
iii) Whether the item requires demolition and re-execution.

Signature : Signature :

Name : Name :

Date : Date :

For contractor : For Department :

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CHAPTER 18
QUALITY ASSURANCE BY DEPARTMENTAL ENGINEERS DURING INSPECTION

The tenders are on turnkey basis and all the material is procured by the contractor, hence to
have a proper quality control and to improve the quality of work, the departmental engineer’s
at various level will ensure thekey parameters of quality assurance during inspections as per
Table 18.1. Such tools are not covered up in the Manual of orders. These inspections shall not
impinge the existing responsibilities of the officers/ engineers as laid down in the Manual of
orders.

Table: 18.1 Quality Assurance By Departmental Engineers During Inspection

Sl.
Key parameters of Quality Assurance
No
1 SITE DOCUMENTS
1.1 Site Order book
1.2 Material Register
1.3 Daily Progress Report.
1.4 Concrete pour Record
1.5 Test Record
1.6 Design and Drawing Record
1.7 Non Conforming Item Record
1.8 Cube test record
2 MANDATORY TESTING
2.1 Cement
2.2 Fine aggregate
2.3 Coarse aggregate
2.4 Concrete ( Slump, Cube test)
2.5 Steel bars
2.6 Bricks
2.7 Timber
2.8 Hydro testing of sewer
2.9 Hydro testing of pipeline
2.10 Water for construction
AVAILABILITY OF FIELD
3
AND LAB EQUIPMENTS
4 MANUFACTURING CERTIFICATES
4.1 Cement
4.2 Steel for Reinforcement and structural
GI Pipe / GI Fittings/ PVC /MS
4.3
/SW /RCC Pipes
4.4 Manhole covers and Footrest
4.5 AC/GI/Fiber glass sheets
4.6 Electrical cables/fans and fixtures
4.7 Switches/sockets and boards
4.8 Flow measuring devices
4.9 Control Panel
4.10 Lightening arrestor
4.11 Level indicator and
controllers.

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Sl.
Key parameters of Quality Assurance
No
4.12 Silver ionization plant
4.13 Any other item as per agreement
DEPARTMENTAL TEAM
5
INSPECTION
5.1 DI, CI,PVC,
5.2 Pumps , Motors & D.G. Sets
5.3 Manhole Frames and covers
5.4 R.C.C. Pipes
CHECK LIST GUIDE FOR
6
WORKS
Laying and jointing of pipeline, Back
6.1
filling, Hydro testing
6.2 Pump & machinery of
6.3 Disinfecting plant
6.4 Pump chamber
6.5 Development of water works
6.6 O.H.S.R / U.G.S.R
6.7 Water treatment plant (canal based)
6.8 Sewer laying & treatment
6.9 Control panel for 3 phase pump & motor
6.10 Centrifugal pump and motor
PERIODICAL SITE
7
INSPECTIONS
POST QUALITY INSPECTION OF
8
FINISHED WORKS
9 QUALITY CERTIFICATION
MONTHLY REPORTING AND
10
REVIEW MEETINGS

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CHAPTER 19
CHECK LIST GUIDES FOR VARIOUS WORKS

20.1 Check List for Laying and Jointing of Pipe Lines, Back Filling, Hydrotesting

FORM No. B/CL-1

1. Name of work :
2. R.B. No. :
3. Contract Agreement No. :
4. Name of contractor :

Sl.
Description Yes/No/NA Remarks
No.
A. Stage 60% Payment schedule: - Supplying of pipe and valves, excavation, laying,
jointing, and fixing of valves.
1 a) Whether pipes are of proper specifications and as per
approved make as per DNIT?
b) Whether pipes have been tested at manufacturer’s
premises and has been inspected by two officers deputed as
per instructions of the department and test certificates are
available?

2 Whether the Sluice Valve/Air Valves etc. are as per

specification and MC has been obtained?

3 Whether the CI/GI/PVC specials are as per specification and

MC has been obtained?

4 Whether the trenches have been excavated to correct depth as

per specifications and dimensions?

5 Whether the pipe line has been laid true to the alignment
with proper bedding made as per specifications?

6 Whether Jointing material used as per specification?

7 Whether all the lanes are provided with pipe lines as per
approved drawing?

8 Whether the completion drawing of pipe line prepared and

submitted with running bills?

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Sl.
Description Yes/No/NA Remarks
No.
B. Stage 40% Payment schedule: - Completion, testing and commissioning.

1 Any busting of pipeline noticed in the village.

2 Whether all the leakages observed during testing have been

repaired properly?
3 Whether the trenches were backfilled in layers, and properly
watered and consolidated as per specifications?
4 The filling is carried out to required level and without any
settlement?
5 Field compaction / density test conducted?

6 Whether the road metal was separately collected and all type
of roads reinstated properly after laying of pipes?

7 Whether GPWSC/Panchayat are satisfied with restoring of

roads and streets and a certificate to this effect has been given
by the GPWSC/ Panchayat before clearing payments of brick
paving/ cement concrete restoration work?
8 Whether the valve chambers constructed as per drawing and
tested for water tightness?

9 Whether the distribution system hydraulically tested?

10 Whether the distribution system properly disinfected before

providing connections to consumers?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :

Name : Name :
Date : Designation :
Date :

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20.2 Check List for Disinfecting Plant

FORM No. B/CL-2
1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/NA Remarks

SILVER IONIZATION PLANT

1 Whether the Silver ionization is auto switch on and off

with pump?
2 Is Silver Ionization feed water pump working properly and
as per I.S: 8472- 1998?
3 Whether Silver Ionization flow meter installed as per IS :
779- 1994?
4 Whether the water chamber of electrodes is constructed of
stainless steel with SS 304?
5 Whether the dosing automatic set constant bythe
microprocessor when the power goes and come back
6 again?
Whether the flip/ flop technology of changing polarity
within 30 seconds working?
7 Whether Silver Ions Test kits available at site?

8 Whether MC has been obtained and DT inspection

conducted?
CHLORINATOR
1 Whether chlorinator and accessories is as per specification?

2 Whether MC has been obtained and DT inspection

conducted?
3 Whether the chlorinator is installed and working properly?

4 Whether Testing kit for residual chlorine test available for

water sample testing?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :
Name : Name :
Date : Designation :
Date :

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20.3 Check List for Pump Chamber

FORM No. B/CL-3
1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :
4. R.B. No :

Sl.
No. Description Yes/No/NA Remarks

A. Stage 40% Payment schedule :- Up-to roof level

UPTO PLINTH LEVEL

1. Whether Bench Mark pillars are fixed and layout is correct as
per approved drawing for excavation of foundation?
2. Whether Depth of foundation is correct as per approved
drawing?
3. Whether Earth bedding condition checked?

4. Whether following materials used are as per specifications

and Test for materials conducted as per frequency?
Bricks
Fine aggregate
Coarse aggregate
5. Whether following manufactured materials used are as
per specification and Test for materials conducted and
MC obtained?
Cement
Steel for reinforcement

6. Whether Concrete bedding laid as per specification?

7. Whether proper arrangement of curing and curing period

maintained as per specification?
8. Whether Istclass Brick work in foundation and plinth is as
per Specifications and necessary test for mix proportion of
mortar conducted?
9. Whether Horizontal / vertical D.P.C. provided as per
specifications?

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Sl.
No. Description Yes/No/NA Remarks

UPTO ROOF LEVEL

10. Whether Istclass brick work in super structure is as
per Specifications and proper wet bricks are used. Test for
mix proportion of mortar conducted?
11. Whether Brick work in super structure is in true plumb and
top of all walls are in level?
12. Whether Thickness of joints in brickwork is kept 1 cm± 20 %?
13. Whether All horizontal and vertical joints are being filled
correctly?
14. Whether proper curing period maintained as per
specification?
15. Whether size of doors/windows and other joinery work as
per Drawing has been kept?
16. Whether proper section and gauge of hollow pressed
steel chowkhats have been provided with proper
grouting?
17. Whether foot rest provided as per drawing and specification?

B. Stage 60% Payment schedule: - Completion & finishing

1. Whether Proper Centering and shuttering has been provided
for R.C.C. slab?
2. Whether steel Reinforcement laid as per design and drawing?

3. Whether R.C.C. Slab is laid of required thickness and in level?

4. Whether proper size of Girder (proper I-section) has been

provided (Medium weight)?
5. Whether proper size of opening in the roof has been provided
with cover as per drawing for lowering of pump?
6. Whether surface cleaned of all loose mortar and efflorescence
before plastering?
7. Is the finishing of plaster inside/outside is proper and mix is
as per required proportion?
8. Whether the floor has been laid in panels, correct thickness
and proper sand filling done under floor?
9. Whether proper underground conduit for electric cable has
been provided for machinery etc?

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Sl.
No. Description Yes/No/NA Remarks

10. Whether electrical fixtures installed are as per approved

specifications and quantity?
11. Whether top finishing and slope of floor is correct?

12. Whether proper tile terracing has been done on roof as per
specification?
13. Whether proper quality and type of wood has been used with
correct thickness of shutters as per specification?
14. Whether thickness of Glass used in window panes is correct
as per specification?
15. Have grills been provided as per standard drawings?

16. Whether Gravel Pit of proper size has been constructed,

channels grouted and MS Sheet cover provided as per
drawing?

17. Whether V-notch houdi with proper specifications has been

constructed according to drawing?
18. Whether Quality of distemper/cement based paint (Snow
cem) is as per specification?
19 Whether Quality of paint used on wood work/steel work and
on other components is as per contract?

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20.4 Check List for Development of Water Works

FORM No. B/CL-4

1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/NA Remarks

1 Whether Bench Mark pillars are fixed and layout is

correct as per approved drawing for excavation of
foundation?
2 Whether Depth of foundation is correct as per
approved drawing?
3 Whether Earth bedding condition checked?
4 Whether following materials used are as per
specifications and Test for materials conducted as per
frequency?
Bricks
Fine aggregate
Coarse aggregate
5 Whether following manufactured materials used are
as per specifications and Test for materials conducted
and MC obtained?
Cement
Structural steel
6 Whether Concrete bedding laid as per specification?
7 Whether Istclass Brick work in foundation and plinth
is as Per specifications and necessary test for strength
of mortar conducted?
8 Whether D.P.C. provided as per specifications?
9 Whether Ist class brick work in super structure is as
per Specifications and proper wet bricks are used. Test
for mix proportion and strength of mortar conducted?
10 Whether Brick work in super structure is in true
plumb and top of all pillars in level?
11 Whether Thickness of joints in brickwork is kept 1 cm±
20%?
12 Whether All horizontal and vertical joints are being
filled correctly?

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Sl. No. Description Yes/No/NA Remarks

13 Whether proper curing period maintained as per

specification?
14 Whether Gate Pillars and corner Pillars have
been Constructed as per drawing?

15 Whether proper size and number of Iron pickets has

been embedded in PCC of approved mix as per
drawing?
16 Whether proper size/ type of D-hooks have been
provided as per drawing?

17 Whether barbed wire provided as per IS: 278-2009 and

is of proper gauge and fully stretched in correct
alignment?
18 Whether proper size of iron Gate has been fixed with
proper fittings and in alignment as per drawing?

19 Whether paths at water work has been constructed

according to proper section and camber as per
drawing?
20 Whether Quality of paint on steel work and on
other components is as per specification?
21 Whether proper sign board according to
specifications has been installed?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :

Name : Name :
Date : Designation :
Date :

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20.5 Check List for OHSR

FORM No. B/CL-5
1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :
4. .R.B. No. :

Sl. No. Description Yes/No/NA Remarks

A. Stage 30% Payment schedule:- Foundation and column up-to ring beam

1. Is Soil Bearing Capacity has been got checked from

approved/ reputed institute?
2 Whether Bench Mark pillars and center pillar were fixed and
layout/depth of foundation is correct as per approved
drawing?
3 Earth bedding condition checked for any filled up soil.
4 Is suitable mechanical arrangement for curing of RCC work
(electrical motor/diesel engine operated device) is available
at site which is capable of lifting water up to top dome of
OHSR.?

4 Whether following materials used are as per specifications

and W Test for materials conducted as per frequency?
Fine aggregate
Coarse aggregate
5 Whether following manufactured materials used are as per
specifications and Test for materials conducted and MC
obtained?
Cement
Steel for reinforcement
6 Whether all requisite tests have been conducted for the
following items as per frequency?.
Excavation and bedding
Plain cement concrete
R.C.C. ( Slump test, Compressive strength)
7 Whether PCC laid as per drawing and specifications?

8 Whether proper steel centering and dent less shuttering is

being used?

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Sl. No. Description Yes/No/NA Remarks

9 The reinforcement in the following members provided is as
per drawing/design and whether it has been checked by
EE/SDE?
Foundation
Columns
Braces
10 Whether Concrete Mixer/Vibrator was used at site and
standby arrangement made?
11 Whether Concrete pours Register with date of casting each
bit of concrete is being maintained?
12 Whether R.C.C. in the following members laid as per
dimensions given in approved drawing with desirable
smooth finishing?.
Foundation
Columns
Braces
13 Whether verticality of R.C.C. columns checked before and
after pouring of concrete?

14 Whether proper curing period maintained as per

specification?

B. Stage 30% Payment schedule: - From ring beam up-to roof slab and completion of stair
case.
1 Is the reinforcement in the following members provided is as
per drawing/design and whether it has been checked by
EE/SDE?
Bottom Ring beam
Bottom dome and gallery
Tank wall
Top ring beam
Top dome
Staircase and landings

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Sl. No. Description Yes/No/NA Remarks

2 Whether R.C.C. in the following members laid as per
dimensions given in approved drawing with desirable
smooth finishing?
Bottom Ring beam
Bottom dome and gallery
Tank wall
Top ring beam
Top dome
Staircase and landings

3 In Stair Case whether G.I. Pipe railing and angle iron

pickets is as per drawing and specification?
4 Whether Bell Mouth Puddle collars, Double Flanged Puddle
Collars have been fixed in position and are of proper
specifications and approved make?
5 Whether proper curing period maintained as per
specification?
C. Stage 40% Payment schedule: - Arrangement and erection of C.I D/F pipe and specials, all
balance work including plinth protection, automatic water level controller and testing of
structure etc.

1 Whether the CI/ DI/ DF pipes are as per specifications and

MC obtained and pipes have been fixed in true plumb?

2 Whether inlet and overflow pipes have been properly

installed in the tank so as to ensure proper working depth of
OHSR and a free board of 0.60 mtr?

3 Whether following C.I. valves, specials have been fixed in

position and are of proper specifications and approved make?
3.1 Duck Foot Bends (IS 13382-1992)

3.2 Sluice Valves

3.3 Expansion Joints (IS 1536-1989)

3.4 M.S. Clamps

3.5 Joining Material (Nut Bolts/Rubber insertion)
4 Is pipes extended by 2.75 mtr. Length beyond Duck Foot
Bends?

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Sl. No. Description Yes/No/NA Remarks

5 Is overflow pipe further extended by providing D/F Bend at
its end and vertical pipe of 2 mtr? Length and a D/F Bend
duly fitted with expanded metal mesh of 10 mm sq.
provided at end?
6 Whether angle posts are painted in two coats after primer?
7 Whether R.C.C. roof ventilator is provided with proper ail
(mesh) cover as per drawing?
8 Is water level indicator with proper specification and
polythene ball of minimum 30 cm dia. Has been provided as
per drawing and Whether plumb/ indicator is as per size
and specifications? Or if, Electronic float system is provided
it is as per specification and working properly?

9 Whether water sealed Manhole Cover of suitable size with

proper specifications / Drawing with locking arrangement
have been provided?
10 Whether Lightening Conductor with proper earth electrode
and specifications and drawing has been provided?
11 Whether Steel Ladder from balcony landing to top of the
Dome provided as per drawing and specification?
12 Whether Aluminum Ladder inside the tank provided as per
specifications and drawings and one end fixed to the top
dome and other end with the bottom dome?
13 Whether vertical pipes, clamps, railings, steel ladder and
fittings are painted with two coats of paints after applying
primer coat?
14 Whether the OHSR has been tested for water tightness and
found no leakage or seepage?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :
Name : Name :
Date : Designation :
Date :

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20.6 Check List for Water Treatment Plant

FORM No. B/CL-6

1. Name of work : 4.R.B. No. :

2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/NA Remark

1 Whether Bench mark Pillars constructed for every
units and the foundation, invert, hydraulic and
formation levels have been ensured as per drawing?
2 Whether following materials used are as per
specifications? Whether Test for materials conducted
as per frequency?
Bricks
Fine aggregate
Coarse aggregate
Filter media
3 Whether following manufactured materials used are
as per specifications? Whether requisite Tests for
materials conducted and MC obtained?
Cement
Steel for reinforcement
LDPE sheet
Manhole cover and Footrest
Vent pipes
4 Whether all requisite tests have been conducted for
the following items as per frequency?.
Excavation and bedding
Plain cement concrete
Cement Mortar
R.C.C. ( Slump test, Compressive strength)
5 Whether Intake chamber has been constructed as per
drawing with screen?
6 Whether the sedimentation cum storage tank has
been constructed to correct dimensions as per
drawing/ specifications and tested for water
tightness? Whether the float arm has been provided
as per drawing /specification and working properly?

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Sl. No. Description Yes/No/NA Remark

7 Whether the scour cum suction well has been
constructed to correct dimensions as per drawing/
specifications and tested for water tightness?
8 Whether the high level tank has been constructed to
correct dimensions as per drawing/ specifications
and tested for water tightness?
9 Whether the filter beds has been constructed to
correct dimensions as per drawings /specifications
and tested for water tightness?
10 Whether Filter Media is from approved quarry and
placed in filter beds to correct position and thickness
as per drawing and specification?
11 Is the clear water tank has been constructed to
correct dimensions as per drawing / specification
and tested for water tightness?

12 Whether the Valves and specials are as per

specifications and MC obtained?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :

Name : Name :

Date : Designation :
Date :
Note : Check list for components namely OHSR, Pump chamber, Centrifugal pump and
motor, Control panel, Development of water works compound and Disinfecting unit shall be
required to be filled separately on prescribed format .

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20.7 Check List for Sewer Laying & Treatment Plant

FORM No. B/CL-7
1. Name of work : 4.R.B. No.:
2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/NA Remarks

A : SEWER LAYING JOINTING AND APPURTENENT WORKS

1 Whether Bench mark Pillars for site rail constructed for
every line and the foundation, invert levels have been
ensured as per drawing?

2 Whether following materials used are as per

specifications and Test for materials conducted as per
frequency?
Bricks
Fine aggregate
Coarse aggregate

3 Whether following manufactured materials used are as

per specifications? Whether Test for materials conducted
and MC obtained?
Cement
Steel for reinforcement
Manhole cover and Footrest
Ventilating shaft
4 Whether following manufactured materials used are as
per specifications? Whether Departmental Inspection
for materials conducted and MC obtained?
PVC / SW /CI /DI / RCC pipes etc.
Manhole cover and Footrest

5 Whether all requisite tests have been conducted for the

following items as per frequency?.
Foundation bedding
Plain cement concrete
Cement Mortar
6 Whether the alignment of sewer is in accordance with
the approved plan?
7 Whether the trenches has been excavated as per
specifications?

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Sl. No. Description Yes/No/NA Remarks

8 Whether the shoring and strutting has been done as per
specifications?
9 Whether the excavated earth has been kept away from
trench as per specifications?
10 Whether the suitable diversion has been made for
proper movement of traffic?
11 Whether the sewer has been laid true to the alignment
and gradient with proper bedding in all streets as per
drawing and specifications?
12 Whether the jointing material used as per specification
and joint tested before backfilling?
13 Whether Oblique junctions are laid against each house?
14 Whether the trenches were backfilled in layers, and
properly watered and consolidated as per specifications?
15 Field compaction / density test conducted?

16 Whether all type of roads metal was separately collected

and road reinstated properly after laying of sewers?
17 Whether the manhole chambers constructed as per
drawing and specifications and tested for water
tightness?
18 Whether Ventilating shaft are erected at suitable places
as per drawings?
19 Whether the completion drawing of sewer line with L-
section prepared and submitted with running bills?
B : SEWAGE TREATMENT PLANT
1 Whether Bench mark Pillars constructed for every units
and the foundation, invert, hydraulic and formation
levels have been ensured as per drawing?
2 Whether following materials used are as per
specifications and Test for materials conducted as per
frequency?
Bricks
Fine aggregate
Coarse aggregate

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Sl. No. Description Yes/No/NA Remarks

3 Whether following manufactured materials used are as
per specifications? Whether Test for materials conducted
and MC obtained?
Cement
Steel for reinforcement
LDPE sheet
Vent pipes
4 Whether all requisite tests have been conducted for the
following items as per frequency?.
Excavation in foundation
Plain cement concrete
Cement Mortar
R.C.C. ( Slump test, Compressive strength)
5 Whether following units of sewage treatment plant are
constructed as per approved design drawing and
specifications?
Collecting tank/sump
Pump chamber as per checklist B/CL-5
Facultative pond / Maturation pond
Sludge Drying Beds
Sludge Curing Platform
Composting Pits etc.
6 Whether construction of rest room including toilet as per
type design, drawing and specification has been
constructed?
7 Whether the sewage pumps, control panels are as per
specifications and installed properly?
8 Whether Sluice valve and reflux valve are ISI marked
and as per specifications & the MC has been obtained?
9 Whether the pipes and specials, rubber packing, nut and
bolts are as per specifications?
10 Is there any leakage from fittings?
a) Inside the pump chamber
b) Outside the pump chamber
11 Is Valves and fittings installed properly?
12 Whether the efficiency of the plant checked?
13 Whether Generating set has been installed as per
required capacity/specifications on proper foundation?

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Sl. No. Description Yes/No/NA Remarks

14 Completion drawing with actual hydraulic line
prepared and submitted with running bill?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :
Name : Name :
Date : Designation :
Date :

Note : Check list for components namely Pump chamber, Development of water works
compound shall be required to be filled separately on prescribed format .

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20.8 Check List for Control Panel for 3-Phase Pump & Motor
FORM No. B/CL-8
1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/N/A Remarks

1 Whether the main switch is of suitable capacity of L&T or
any other reputed make?
2 Whether the MCB/ MCCB units are of specified make?

3 Whether the 3 Phase starter is of suitable capacity L&T or

any reputed make?
4 Whether the single phase preventer of L&T or reputed
make is provided and working properly?
5 Whether the panel box is of approved thickness and has
been power painted?
6 Whether it is suitable for 415 V AC. With variations up
to 6% on either side?
7 Whether Shunt Capacitor is of proper KVAR capacity
and of reputed make, or approved by PSEB?
8 Whether Ampere meter is of suitable range and of L&T
make or any other reputed make?
9 Whether Volt meter is of suitable range (500V) and of
L&T make or any other reputed make?
10 Whether the ELCG is of L&T /Havel or reputed make?

11 Whether three phase Indicators lamps are of

L&T/Alstom (22.5mm Led type or equivalent reputed
make?
12 Whether Fuse bases and HRC fuses are of L&T/Havel
make or equivalent?
13 Whether selector switch for Ammeter and Voltmeter are
of L&T, Kaycee make or equivalent?
14 CT for Ammeter is of AE, EE, GE make or equivalent?
15 Contractor’s relays and timers are of L&T, Siemens make
or equivalent?
16 Switch fuse unit is of L&T, Siemens, GE make or
equivalent?

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Sl. No. Description Yes/No/N/A Remarks

17 Wires are of Finolex, Kent, Plaza make or equivalent?

18 Whether MC has been obtained and DT inspection

conducted?
19 Whether the control panel has been fitted properly?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :
Name : Name :
Date : Designation :
Date :

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20.9 Check List for Centrifugal Pump, Motor & Fittings of Delivery Pipe in Pump
Chamber
FORM No. B/CL-9

1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :

Sl. No. Description Yes/No/N/A Remarks

1 Whether the pumping set is of reputed make as per technical
specifications, MC obtained and DT inspection conducted?
2 Whether the shaft, impeller and bearing are as per technical
specifications?
3 Whether the speed of motor is as per specifications?

4 Whether the actual discharge of pump is as per specifications?

5 Whether the alignment of the shaft is correct?

6 Whether it is suitable for 415 V AC. with variations up to 6% on

either side?
7 Whether combined efficiency of pump set is as per specifications?
8 Whether head and discharge are correct as per
specifications?
9 Whether foundation and base plate are as per specifications and
foundation bolt are of proper size and length?
10 Whether the pump set has been power painted?

11 Whether the suction lift is within the limit (4.5 m IS: 9694 Part-I)?
12 Whether the suction pipe joints are airtight and pump starts
without priming?
13 Whether Sluice valve, reflux valve and Air valve are ISI marked
and as per specifications & the MC has been obtained?
14 Whether the pipes and specials, rubber packing, nut and bolts are
as per specifications?
15 Is there any leakage from fittings?
a)Inside the pump chamber
b) Outside the pump chamber
16 Is Air Valve/Non Return Valve installed properly?
17 Is double earthling done for machinery and is in order?
18 Is there any excess vibrations observed on running of Pump?

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Sl. No. Description Yes/No/N/A Remarks

19 Is there any overheating of bearings?

20 If the velocity in suction and delivery pipe is within the limit(Less

than 1.5m not exceed 2m)?

FOR CONTRACTOR FOR DEPARTMENT

Signature : Signature :
Name : Name :
Date : Designation :
Date :

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20.10 Quality Certification

FORM NO.B/CL-10

1. Name of work :
2. Contract Agreement No. :
3. Name of contractor :
4. Name of Structure/Location:

QUALITY CERTIFICATE

This is to certify that we have inspected the conduct of the works in accordance with
established Quality Control procedures and that the items included in this Interim
Payment Certificate satisfy the required quality of works and are acceptable with regard
to the specifications and standards as prescribed under the Contract. Requisite Test
Certificates are attached.

Enclosures
1
2
3
4
5
6
7
8
9
10

Signature/Date:

Date: ---------------------- RE. .

[ULB]
Note: This Quality Certificate shall be completed and attached to each Interim Pay before
payment is made.

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CHAPTER 20
PROJECT IMPLEMENTATION ARRANGEMENTS

1. ULB’S has created a State Project Management Cell for overall programme planning,
fund flow management, capacity building , IEC, Quality Control, monitoring of physical
and financial progress and reporting.
2. Quality Management and Surveillance Wing have been created for technical audit of
different activities of construction at various stages during progress of project work.
3. Department of water supply and sanitation (ULB’S) have 3 Chief Engineer, 11
Superintending Engineer and team of Executive Engineers, Sub Divisional Engineers
(SDE), and Junior Engineers (J.E.) for project planning, supervision of projects in the
state and O&M of MV schemes.
4. A consultant has been engaged for providing technical support.
5. Consultant has also been appointed for Water Quality Monitoring, Remote sensing and
source studies.
6. District Project Management Cell (DPMC) has been created in all the 20 Districts for the
support to the GPWSCs and responsible for planning and monitoring of programme
activities in the district.
7. Consultant for IEC and MIS development has been engaged.
8. A consultant for preparing QA/QC manual and its implementation, capacity building
with strategic supervision has also been appointed.
9. GPWSCs are formed for participation as owner’s representative towards monitoring of
the water supply and sanitation schemes to be implemented for single village and intra
villages and ensure O&M of assets.
20.1 Responsibilities of Key Organizations
Table20 1 identifies the responsibilities of each organization’s to avoid any
misunderstanding.
Table: 20.1 Responsibilities of Key Organizations
Sl.
Task Activities Unit
No.
1 TECHNICAL APPROVAL OF DESIGN Approval
DRAWING AND COST ESTIMATES.
2 TENDER, ALLOTMENT AND UPKEEP OF Invitation,
CONTRACT DOCUMENTS. Receive tenders,
evaluation

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3 CONTRACT ADMINISTRATION AND OVERALL SUPERVISION.

3.1 Administration and management of Management

contracts including interpretations of
technical specifications.
3.2 Revised drawings and designs Submission,
review and
approvals
3.3 Provide layouts / levels for works. Primary
Checking of levels and layouts. Secondary
3.4 Adequacy of the input such as material, Primary
labor, equipment with reference to technical Secondary
requirement.
3.5 Material register Documentation
Review
3.6 Maintain work site in neat, orderly and Primary
safe manner. Secondary
3.7 Minimize inconveniences to the public. Primary
Secondary
3.8 Inter departmental coordination.

3.9 Continuous on sites supervision during Primary

construction and ensuring safety. Secondary
3.10 Monitoring of progress, find cause of delay, Primary
remedial measures and issue instructions to Secondary
contractor.
3.11 The contractor fulfills all contractual Primary
obligation, proper storage of materials, Secondary
regulations , contract conditions,
specifications and instructions.

3.12 Ensuring that site order book are properly Primary

maintained. Secondary

3.13 Test records and results are available for Primary

review and assessment. Secondary
3.14 Contractor prepares and submits monthly
progress report in time.
3.15 Preparation of drawing of completed Primary
works. Secondary

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4 QUALITY ASSURANCE AND INSPECTIONS

4.1 Training on using manual to contractor Training

staff.
4.2 Provide effective supervision of the works Primary
in order to ensure the quality and Secondary
conformity with the standards and
specifications prescribed in the contract.

4.3 Inspect all work sites regularly to ensure Primary

that the work is being implemented in Secondary
accordance with the approved standards
and that the quality control procedures set
forth under the contract are followed.
4.4 Take samples and test independently Primary
testing

wherever considered necessary. Insure that Secondary

proper records of the tests conducted are
maintained.
4.5 Inspect interim work as required to accept Primary
or reject completion stages before Secondary
permitting the contractor to proceed with
further works. Enter all approvals in the site
4.6 order book
Inspect the and have it signed
completed works by allparties.
insuring that Primary
any defects in materials or workmanship are Secondary
properly identified in a timely manner.
4.7 Conduct monthly inspections and site Primary
coordination meetings for all works to Secondary
review the overall progress and quality of
the works.
4.8 If any work item or construction material Primary
issue standard or unacceptable, deduct such Secondary
work or supply of material from the
progress payment or defer payment until
the contractor rectifies the deficiencies.

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5 MEASUREMENT AND PREPARING BILLS AND PAYMENTS

5.1 Conduct joint measurements of the works Primary

with the contractor and record them in the Secondary
stipulated format for payment.

5.2 Prepare necessary release order of security Prepare and

and payment after completion of the defect verified Hand
liability period as per the contract. receipt

6 REPORTING
6.1 Submit monthly project progress report. Submission

6.2 Prepare and submit Monthly Progress Submission

Reports in the approved format that
includes Quality Control Status, physical
and financial progress.
6.3 Submit a quarterly progress report. Submission

7 INTER DEPARTMENTAL AFFAIRS

7.1 Identify power connection, road crossings, Primary
pipe line inter connections with existing Secondary
system, permission for use of land, etc.
7.2 Obtain permissions from other Primary
departments and organizing the works as Secondary
required through them.

8 OTHER RESPONSIBILITIES

8.1 QA/QC Training module for ULB’S Training

engineers
8.2 QA/QC Training module for contractors Training

8.3 QA/QC Training to REs Training

8.4 QA/QC Module Linked to MIS

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CHAPTER 21
QA / QC DUTIES OF CONTRACTORS

These procedures are prepared with a view of ensuring stream lime action in various activities
that might have over lapping responsibilities. These are only clarifications on the responsibilities
as prescribed in the department. in case of variance, the contract documents will prevail over the
stipulations above.
20.1 QA / QC Duties
The contractor’s QA/QC duties are summarized in Table: 21.1. Apart from these other duties
shall be performed as per the contract documents or directed by the Engineer. It is essential to
keep certain documents at site for making a permanent record of each and every item related to
the project. Such items may include tests conducted at site, test certificates, instructions issued to
contractor, record of drawings issued to the contractor, inventory of the material at site. All such
site documents play an important role not only in assuring the quality of the work, but also in
making the project management comparatively easier. All these documents with a definite
identification number have been listed in Chapter-3.
Table: 21.1 List of Contractor’s QA/QC Duties
Activity/Item Contractor’s QA/QC Duties
Designs/Drawings Maintain design / drawing register at site
for contract Use only approved drawings for construction

Intimate GPWSC /ULB’S the details, date of

Test laboratory completion with requisite manufacturers’ and
and equipment calibration certificates of equipments.
Maintain the equipments in good condition and
calibrate as necessary
Enter receipts in material register
Materials to be tested only in approved laboratories
Prepare concrete mix proportions as per volume as
Material required by contract and submit test results to GPWSC
receipts /ULB’S.
Materials Take test samples in presence of GPWSC /ULB’S when
testing requested
Perform material tests
Submit test reports to GPWSC /ULB’S with monthly
reports Maintain test log

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Activity/Item Contractor’s QA/QC Duties

Entries to be made in material register at site
Tag and record all rejected materials
Rejected materials
Intimate GPWSC /ULB’S in writing the proposed date of
removal of material from site and confirm after removal
Enter daily consumption of materials in material
Material
register and indicate balance quantity
consumption
Intimate GPWSC /ULB’S the details, date of
Construction mobilization along with requisite insurance certificate
equipment Maintain equipments in good working condition
Intimate breakdown of construction equipments
Intimate GPWSC /ULB’S in writing when construction is
going to commence and what activities are proposed to be
undertaken
Intimate GPWSC/ULB’S in advance when critical works,
Construction such as concreting, embankment, paving, pipeline laying
and jointing, testing, etc., would be undertaken, along with
the test certificates of the materials proposed to be used in
these works. No critical activity shall start unless the
material is tested. Certificates are verified and approved by
the Engineer.
Concreting to take place only after pour card is signed.
To provide any other necessary QA/QC requirement.
Daily work To maintain in daily log.
progress Perform tests as per contract requirements.
Testing of works
Submit test reports tools.
in progress
Maintain test log during the execution of works.
Intimate GPWSC/ULB’S in writing the proposed date of
Rejected work removal from site and confirm after removal.
items Rectify defective work and invite GPWSC/ULB’S forre-
inspection.
Enter change orders, site instructions, letter and
Instructions
minutes of meetings issued by the Engineer and
from Engineer
Consultants in the Instruction Log.
Take instructions in Site Order Book.
Inspection of
Intimate ULB’S of compliance.
Engineer

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Activity/Item Contractor’s QA/QC Duties

Progress Prepare and maintain project schedules and undertake

scheduling and work in accordance with approved schedule.
control
Reporting Prepare and submit Monthly Progress Reports and other
reports as per contractual requirements.

Maintain the following records on

Site/Contractor’s Office/Laboratory as given
in Annexure C.
Site Order book
Material Register
Records Daily Progress Report.
Concrete pour Register
Test Record
Design &Drawing Record
Non conforming item record
Cube test record

All the work executed against the contract shall be of

Workmanship
good workmanship.
All the Debris should be disposed of properly after
Disposal Of Debris
completion of construction work.

Table 21.2 Brand of Material and Equipment

Sl. No. Material / Equipment Make / Brand
1 Cement OPC Grade 43 ACC, Ambuja, UltraTech, JK Lakshmi, Binani

2 Bricks Ordinary clay bricks of any brand conforming to

IS : 1077
3 Reinforcement steel TISCON,SAIL, Rathi, Kamdhenu, RINL

4 Structural steel IISCO,TISCO,SAIL, Rathi, Kamdhenu, Ispat

5 Water proofing Cico, Dr. Fixit, Dr. Forex

6 White cement JK White, Birla

7 Bitumen Shalimar
8 AC Sheets Everest, Armco, Charminar, Uppal

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Sl. No. Material / Equipment Make / Brand

9 SW pipes Burn & Co., Perfect Potteries, Girco, Navroji,
Oriental ceramics
10 CI/DI pipes Jindal saw, Electrosteel, Electrotherm

11 MS pipes SAIL, Jindal ,Tata, Surya, EST or equivalent

12 UPVC pipes & fittings Supreme, Polygold, Finolex, Devendra, Diplast,

Prakash, Swastika, Tirupati
13 GI pipes Jindal, Tata, TTC, TST, Tirupati

14 HDPE Pipes Dura line

15 Oil distemper and other paint Shalimar, British paint, any Asian brand, Berger

16 Water proof cement Snowcem, Asian, Berger

17 Metallic Red oxide primer Shalimar, Asian brand, Berger

18 Paint Nerolac, Jhonson Nicholson, Asian, Berger

19 CI valves Kirloskar, IVC

20 CI fittings BRM/HSCC/ Electrosteel/

Oriental/Upadhyay/Birla
21 GI fittings UNIK, SVW, NMC

22 Sluice gates and screens Jash

23 Flush Doors Dura, Green Ply, Euro

24 Ply Board Dura, Green Ply, Euro

25 Door fittings Classic (Al.) ,304 (S&S)

26 Glass pane Santgobin, Modi guard, AIS

27 Ceramic Tiles Somany, Jonson& Jonson, Perry, Kajaria

28 Sanitary ware Perry ware, Hindustan, Cera , Jonson

29 CP fitting Jaquar , Roca, ARK

30 Storage tank Syntex , Polycon

31 SS Strainer Johnson, Super or equivalent

32 Filter media From Pathankot or other approved source

Conforming to IS: 8419 ( 1 ).
33 LDPE Film Conforming to IS : 2508

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Sl. No. Material / Equipment Make / Brand

34 Electric motors Crompton greeves, Kirloskar, Siemen, Jyoti, ABS

35 Pumps KSB, BS, Crompton, WIPL

36 Cables Asian/ FGI/ Dalton/ FCI / CCI/ Universal

37 Three Phase Starter L&T/ Unilec/ Kilburn/ Siemen/ ABB/ GE

38 Switch gear L&T/ Siemen

39 Shunt Capacitor GE/ Asian/CGL/ Madhav or approved by PSEB

40 MCB up to 10 HP Havells/ Datar/

MCCB above 10 HP S&SCS Havells/
Datar/ S&SCS

41 Contractors, Relays and Timers L&T / Siemen

42 Indicating lamps L&T /Alstom/ Siemen,( 22.5mm Led Type )

43 Ampere meter/ Voltmeter GE, EE, L&T, AE

44 Transformer NGEF, KEC, Kanohar, Marson

45 Panel board L&T , Havell, GE

46 ELCB L&T, Havell, MDS

47 Fuse bases Havell, L&T, GE

48 HRC fuses Havell, L&T, GE

49 Selector switch for ammeter L&T, Kaycee

and voltmeter
50 CT for ammeter AE, EE, GE

51 Wire Finolex, Kent, Plaza

52 Thimbles Dowell,

53 Single phase preventor L&T, Minillec

54 Switch fuse unit L&T, Siemen, GE

55 Chlorinating Plant Aqus ,Servel

56 Silver Ionization Plant Jet clear, Bharti water

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CHAPTER 22
DESIGN REQUIREMENTS

22.1 Design Requirements for Reinforced or Plain Concrete Structures:

a) All blinding and level the concrete shall be a minimum 100 mm thick in concrete grade
M10 with a maximum 10mm aggregate size.
b) All liquid retaining reinforced concrete structures, concrete shall be of a minimum M30
grade with a maximum 20 mm aggregate size for all structural members and for Buildings,
reinforced concrete shall be of a minimum M25 grade (Footings, Plinth Beams, Columns,
Slab and beams, etc., i.e. which are other than liquid retaining structures) with a maximum
20 mm aggregate size for all - structural members. Further, if there are any liquid retaining
RCC tanks coming up with in the buildings, concrete shall be of minimum M30 grade for
such RCC tanks also.
c) The reinforced concrete for all structures shall have a minimum cement content of 375
kg/m3 with a maximum 20 mm size aggregate. Grade of Cement for all structures to be as
per IS: 456. Reinforced concrete shall have maximum slump of 100mm with maximum
water cement ratio of 0.48.
d) As a design consideration to control crack, though general requirements of IS 3370 shall be
followed, All liquid retaining structures shall be designed based on the serviceability crack
width limit state (i.e. 0.1 mm crack width) and other limit state requirements also to ensure
an adequate degree of safety and serviceability.
e) The minimum cover to the main reinforcing bars for different members for:
1. Non-liquid retaining structures shall be as follows unless stated otherwise:
Slab (Floor, Roof, Canopy, Chajjas and Staircase) 25 mm
Beams (Sides, Bottom & Top) 40 mm
Lintels (all around) 30 mm
Columns
i) For column width 200 40 mm
ii) For column width 230 & above 50 mm
Pedestals (in contact with earth) 50 mm
Basement wall, retaining walls
i) Face in contact with earth 50 mm
ii) Interior face 40 mm
Foundations (Top, Bottom and sides) 50 mm
2. Liquid retaining structures shall be as follows unless stated otherwise:
Walls - Face in contact with earth 60 mm
Walls - Face in contact with Water 60 mm
Base Slab in contact with Water 60 mm
Base Slab in contact with Soil 60 mm
Launders/Gutter Slabs 45 mm

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f) In general, reinforcement for buildings and sewage treatment units shall be TMT-CRS
(Corrosion Resistant Steel) of Grade Fe 500D. All physical and chemical properties of
this Fe 500 grade steel shall conform to IS: 1786-2008. Welded wire fabric shall conform
to IS: 1566 as shown or specified on the drawing. The CRS (corrosion resistant steel)
index shall be at least 1.35 when tested for Salt Spray test as per "ASTM B 117 - 2009 test
procedure for 120 hours when compared with the Fe 500D normal reinforcement bars
and with same bar diameter. All test results (including physical and chemical properties
and salt spray tests) have to be produced for the respective bar diameter for each
consignment of steel delivered at site and at a frequency of every 20 Metric Tons.
Reinforcement bars and structural steel to be procured only from Primary steel
producers with Integrated Steel such as TATA/ SAIL/ RINL/ JSW/ SHYAM STEEL/
EQUIVALENT using iron ore as the basic raw material and having in-house iron
making facilities followed by production of liquid steel and crude steel with in-house
rolling, adopting BF-BOF route or DRI-EAF technology as per Ministry of Steel
guidelines. No Re-rolled material/secondary steel will be accepted or allowed for any
structural works.
Only those firms are eligible who are primary steel producer and should have
integrated steel plant in single premises.
Certificate issued by ministry of steel of primary steel producer and integrated steel
plant having infrastructure in single premises for producing sponge iron, billet and TMT
reinforcement bars using iron ore as base material. The steel manufacturing company
should have latest ISO accreditation for Quality Management System.
g) The minimum amount of reinforcement in each of the two directions at right angles
within each surface zone should be provided as per clause 8.1 of IS 3370 (Part 2):2009.
Definition of surface zones is clearly shown in Figure 1 and Figure 2 of IS 3370 (Part 2):
2009. For slabs, minimum of 10 mm dia bars shall be used to avoid any deformation of
lesser diameter bars under loads prior to construction.
h) All buildings shall have a minimum 1 meter wide, 100 mm thick plinth protection
paving in M15 grade concrete or stone slabs/tiles. All plinth protection shall be
supported on well compacted strata.
i) All pipes and ducts laid below the structural plinth and road works shall be surrounded
with concrete of grade M15 having minimum 150 mm thick concrete or D/4 (D = outer
dia. of pipe) thickness whichever is more with proper reinforcement.
j) Use of pressure relief valves to reduce uplift pressure due to ground water table shall
not be allowed.
k) Detailing of the reinforcement shall be considered as per latest Indian code of practices
and special publications as applicable.

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l) Sliding layer or slip layer shall be provided between sub base and structural slab (Raft).
Polythene sheets of 500 microns shall be provided as sliding layer as per IS specification.
m) Water tightness testing of water retaining structures shall be done in accordance with IS:
3370, (Part I) - 2009. It is described in Clause 10.22 of this document. The depth of water
for testing shall be up to the soffit of the covering slab.
The following minimum thicknesses shall be used for different reinforced concrete members,
irrespective of design requirements:
(i) Walls for liquid retaining structures : 250 mm
(ii) Roof slabs for liquid retaining structures : 150 mm
(Other than flat slabs)
(iii) Bottom slabs for liquid retaining structures : 300 mm
(iv) Floor slabs including roof slabs, walkways,
Canopy slabs : 125 mm
(v) Walls of cables / pipe trenches,
Baffle walls, Underground pits etc. : 200 mm
(vi) Column footings : 300 mm
(vii) Parapets : 100 mm
(viii) Precast trench cover, chajja and all fascias : 125 mm
(ix) Column Dimensions
a) Exceptional case (Based on any specific requirements)
i) To match with width of Block masonry wall : 200mm
ii) To match with width of Brick masonry wall : 230mm
b) In general case : 300 mm
(x) Beams (To match with width of Block masonry wall) : 200 mm
(xi) Launder Base Slab : 200 mm
(xii) Launder Vertical Wall, Baffle Wall, Gutter Slab : 150 mm
(xiii) Grade Slabs : 150 mm

22.2 Materials in General

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.
As soon as practicable after receiving the order to commence the Works, the Contractor shall
inform the Engineer of the names of the suppliers from whom he proposes to obtain any
materials but he shall not place any order without the approval of the Engineer which may be
withheld until samples have been submitted and satisfactorily tested. The Contractor shall

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thereafter keep the Engineer informed of orders for and delivery dates of all materials.
Materials shall be transported, handled and stored in such a manner as to prevent deterioration,
damage or contamination failing which such damaged materials will be rejected and shall not
be used on any part of the Works under this contract.
22.4.1 Samples and Tests of Materials
The Contractor shall submit samples of such materials as may be required by the Engineer and
shall carry out the specified tests directed by the Engineer at the Site, at the supplier's premises
or at a laboratory approved by the Engineer.
Samples shall be submitted and tests carried out sufficiently early to enable further samples to
be submitted and tested if required by the Engineer.
The Contractor shall give the Engineer seven days' notice in writing of the date on which any of
the materials will be ready for testing or inspection at the supplier's premises or at a laboratory
approved by the Engineer. The Engineer shall attend the test at the appointed place within
seven days of the said date on which the materials are expected to be ready for testing or
inspection according to the Contractor, failing which the test may proceed in his absence unless
instructed by the Engineer to carry out such a test on a mutually agreed date in his presence.
The Contractor shall in any case submit to Engineer within seven days of every test such
number of certified copies (not exceeding six) of the test results as the Engineer may require.
Approval by the Engineer as to the placing of orders for materials or as to samples or tests shall
not prejudice any of the Engineer's powers under the Contract.
The provisions of this clause shall also apply to materials supplied under any nominated sub-
contract.
22.3 Standards
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, at his
request, stating that the materials supplied comply in all respects with the standard, the
Contractor shall obtain the certificate and forward it to the Engineer.
The specifications, standards and codes listed below are considered to be part of this
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 the Specification and the Standards referred to herein, the
Specification shall govern.
a) Materials
IS: 269 - Specification for 33 grade ordinary Portland cement
IS: 278 - Specification for Galvanized Steel Barbed wire & Fencing
IS: 383 - Spec. for coarse and fine aggregates from natural sources for concrete
IS: 428 - Specification for distemper, oil emulsion, colour as required

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IS: 432 - Specification for mild steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement (Parts 1 & 2)
IS: 455 - Specification for Portland slag cement
IS: 458 - Specification for precast concrete pipes (with and without reinft.)
IS: 650 - Specification for standard sand for testing of cement
IS: 651 - Specification for salt glazed stoneware pipes and fittings
IS: 808 - Specification for dimensions for hot rolled steel beam, column channel
and angle sections
IS: 814 - Specification for covered electrodes for manual metal arc welding of
Carbon and Carbon Manganese steel
IS: 1003 - Specification for timber panelled and glazed shutters (Parts 1 & 2)
IS: 1038 - Specification for steel doors, windows and ventilators
IS: 1077 - Specification for common burnt clay building bricks
IS: 1398 - Specification for packing paper, water proof, bitumen laminated
IS: 1489 - Specification for Portland pozzolana cement (Parts 1 & 2)
IS: 1566 - Specification for hard drawn steel wire fabric for concrete reinft.
IS: 1580 - Specification for bituminous compounds for water proofing and caulking
purposes
IS: 1786 - Specification for high strength deformed steel bars and wires for concrete
reinforcement
IS: 1852 - Specification for rolling and cutting tolerances for hot rolled steel products
IS: 1948 - Specification for aluminium doors, windows and ventilators
IS: 1977 - Specification for Low Tensile structural steel (Ordinary quality)
IS: 2062 - Specification for steel for general structural purposes (Hot Rolled Low,
Medium and High Tensile Structural Steel).
IS: 2185 - Specification for concrete masonry units (Parts 1, 2 & 3)
IS: 2202 - Specification for wooden flush door shutters (Parts 1 & 2)
IS: 2645 - Specification for integral cement water proofing compounds
IS: 2721 - Specification for Galvanized Steel Chain Link Fence Fabric
IS: 2750 - Specification for steel scaffoldings
IS: 2835 - Specification for flat transparent sheet glass
IS: 3384 - Spec. for bitumen primer for use in waterproofing and damp proofing
IS: 3502 - Specification for steel chequered plates
IS: 4021 - Specification for timber door, window and ventilator frames
IS: 4350 - Specification for concrete porous pipes for under drainage
IS: 4351 - Specification for steel door frames
IS: 4990 - Specification for plywood for concrete shuttering work
IS: 8112 - Specification for 43 grade ordinary Portland cement
IS: 9862 - Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali,
water and chlorine resisting
IS: 10262 - Recommended guidelines for concrete mix design
IS: 12269 - Specification for 53 grade ordinary Portland cement
IS: 12330 - Specification for sulphate resisting Portland cement

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IS: 12709 - Glass fibre reinforced plastics (GRP) pipes, joints and fittings for use
for potable water supply
b) Tests
IS: 516 - Method of test for strength of concrete
IS: 1182 - Recommended practice for radiographic examination of fusion-welded
butt joints in steel plates
IS: 1199 - Methods of sampling and analysis of concrete
IS: 2386 - Methods of test for aggregates for concrete (Parts 1 to 8)
IS: 2720 - Methods of test for soils (Parts 1 to 39)
IS: 2911 - Code of Practice for design and construction of Pile foundations (Part 4)
IS: 3025 - Methods for sampling and test (physical and chemical) for water and
wastewater (Parts 1 to 56)
IS: 3495 - Method of test for burnt clay building bricks (Parts 1 to 4)
IS: 3613 - Acceptance tests for wire flux combination for submerged arc welding
IS: 4020 - Methods of tests for wooden flush doors shutters: Type tests
IS: 4031 - Methods of physical tests for hydraulic cement (Parts 1 to 15)
IS: 5807 - Method of test for clear finishes for wooden furniture (Parts 1 to 6)
IS: 7318 - Approval tests for welders when welding procedure approval is not
required (Parts 1 and 2)
IS: 13311 - Methods of Non-destructive testing of Concrete- Part 1 & Part 2
c) Codes of Practice for design / detailing
IS: 456 - Code of practice for plain and reinforced concrete
IS: 783 - Code of practice for laying of concrete pipes
IS: 800 - Code of practice for general construction in steel
IS: 806 - Code of practice for use of steel tubes in general building construction
IS: 816 - Code of practice for use of metal arc welding for general construction in
mild steel
IS: 817 - Code of practice for training and testing of metal arc welders
IS: 875 - Code of practice for design loads (other than earthquake) for building
structures (Parts 1 to 5)
IS: 1081 - Code of practice for fixing and glazing of metal (steel and aluminum)
doors, windows and ventilators
IS: 1172 - Code of practice for basic requirements for water supply, drainage and
sanitation
IS: 1477 - Code of practice for painting of ferrous metals in buildings (Parts 1 & 2)
IS: 1597 - Code of practice for construction of stone masonry (Parts 1 & 2)
IS: 1742 - Code of practice for building drainage
IS: 1893 - Criteria for earthquake resistant design of structures
IS: 1904 - Code of Practice for Design and Construction of Foundation in Soils:
General Requirements.
IS: 2065 - Code of practice for water supply in buildings
IS: 2212 - Code of practice for brickwork

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IS: 2338 - Code of practice for finishing of wood and wood based materials
(Parts 1 & 2)
IS: 2394 - Code of practice for application of lime plaster finish

IS: 2395 - Code of practice for painting, concrete, masonry and plaster surfaces
(Parts 1 & 2)
IS: 2470 - Code of practice for installation of septic tanks (Parts 1 & 2)
IS: 2502 - Code of practice for bending and fixing of bars for concrete reinft.
IS: 2571 - Code of practice for laying in-situ cement concrete flooring
IS: 2595 - Code of practice for radiographic testing
IS: 2751 - Recommended practice for welding of mild steel plain and deformed
bars for reinforced construction
IS: 2911 - Code of Practice for design and construction of Pile foundations
IS: 2974 - Code of practice for design and construction of machine foundations
(Parts 1 to 4)
IS: 3114 - Code of practice for laying of Cast Iron pipes
IS: 3370 - Code of practice for concrete structures for the storage of liquids
(Parts 1 to 4)
IS: 3414 - Code of practice for design and installation of joints in buildings
IS: 3558 - Code of practice for use of immersion vibrators for consolidating
concrete
IS: 3658 - Code of practice for liquid penetrant flaw detection
IS: 3935 - Code of practice for composite construction
IS: 4000 - Code of practice for High strength bolts in steel structures
IS: 4014 - Code of practice for steel tubular scaffolding (Parts 1 & 2)
IS: 4111 - Code of practice for ancillary structures in sewerage system (Parts 1 to 5)
IS: 4127 - Code of practice for laying of glazed stoneware pipes
IS: 4326 - Code of practice for Earthquake Resistant Design and Construction of
Buildings
IS: 4353 - Recommendations for submerged arc welding of mild steel and low alloy
steels
IS: 5329 - Code of practice for sanitary pipe work above ground for buildings
IS: 5334 - Code of practice for magnetic particle flaw detection of welds
IS: 5822 - Code of practice for laying of welded steel pipes for water supply
IS: 7215 - Tolerances for fabrication of steel structures
IS: 9595 - Recommendations for metal arc welding of carbon and carbon
manganese steel
IS: 10005 - SI units and recommendations for the use of their multiples and of certain
other units
SP: 16 - Design Aids for Reinforced Concrete To IS: 456
SP: 34 - Handbook on Concrete Reinforcement and Detailing
SP: 38 - Handbook of Typified Design of Structures with Steel Roof Trusses

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d) Construction Safety
IS: 3696 - Safety code for scaffolds and ladder (Parts 1 & 2)
IS: 3764 - Safety code for Excavation work
IS: 7205 - Safety code for erection of structural steel work

22.4 General Arrangement of Plant

The following general guidelines shall be followed in the preparation of general arrangement of
Plant:
Sufficient room shall be allowed between items of plant and adjacent Plant or fixed
structures to permit safe and convenient access for operation and maintenance;

An area adjacent to all mechanical Plant shall be provided as maintenance lay down
area;
Fixed runways, lifting eyes or other means shall be provided to permit the removal of
Plant that may be required to be removed during the course of its normal operational
life for maintenance or any other purpose;
Areas where leakage is likely to occur whether in normal use or during maintenance
shall be provided with covered drainage channels which shall direct spillage either to a
suitable plant drain or to a sump from where it can be pumped to plant drain;

22.4.1 Orientation
The works shall be laid out within the confines of the Site in order to interface to the existing
infrastructure of roadways and inlet and outlet pipe work. Underground services requiring to
be relocated in order to accommodate the proposed site layout shall, with the approval of the
Engineer, be relocated by the Contractor.

22.4.2 Buildings and Structures

All the building and structure works shall generally comply with the following Employer's
Requirements unless otherwise specified elsewhere:
1) All building works shall be of reinforced concrete framework (Concrete Grade of M25
as a minimum).
2) All external walls shall be in solid cement concrete blocks of concrete grade M15 and
shall be provided as per IS: 2185 (Latest Revision) and shall be 200 mm thick. 50mm
thick DPC (1:1.5:3) with water proofing admixture shall be provided at plinth level
before starting masonry work.
3) All internal partition walls shall be in solid cement concrete blocks of concrete grade
M15 and shall be provided as per IS: 2185 (Latest Revision). All internal walls shall be
200mm thick except for toilets. Toilet partition walls shall be in 100 mm thick solid
concrete block.

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.4) (a) Finishes to concrete liquid retaining structures shall be :

F1 - External surfaces, buried
F2 - External surfaces exposed and up to 300 mm below ground level
F2 - Internal surfaces
(b) Finishes to other concrete structures shall be :
F1 - Buried
F1 - Exposed, where plastering is specified
F2 - Exposed
The type of finishes are explained in Chapter 4 of Part 10A "Standard Basic Specifications for
Civil and Structural Works"
5) All internal masonry and ceiling surfaces finish shall have 12 mm and 6 mm thick plain
faced cement plaster respectively in cement mortar (1:4) with neat cement finish on top.
Over this, one coat of primer and two coats of plastic emulsion paint of approved
quality and shade shall be provided.
6) All external masonry and concrete with rough board finish shall have 20 mm thick sand
faced cement plaster in two coats, base coat 12 mm thick in cement mortar 1:4 and
finishing coat 8 mm thick in cement mortar 1:4. Waterproofing compound of approved
make and quality shall be added to the cement mortar in proportions as specified by the
manufacturer.
7) All external surfaces above ground level shall have one coat of primer and two coats of
waterproof cement based paint of approved quality and shade. A coat of silicone water
repellent paint shall also be applied thereon.
8) Toilet areas, walls and ceilings, shall have one coat of primer and two coats of plastic
emulsion paint.
9) Toilet floor slab shall be filled with brick bat coba (broken bricks in lime) and provided
with waterproofing as per the specifications of an approved specialist waterproofing
company.
10) The finished floor level in toilet areas shall be 25 mm below general finished floor level
elsewhere in the building. Sunken floor shall be provided with damp proofing
treatment.
11) The flooring in all areas except toilets, staircases, pumping stations, chlorination
building, centrifuge building, chemical building, Digester Building, Gas Generation
room, Boiler Building, workshop, D.G.Room shall be in 18 mm thick mirror polished,
machine cut granite slab of approved shade and pattern placed in cement mortar (1:4).
150mm high skirting shall be provided in these areas.
12) The flooring in the pumping stations, chlorination building, centrifuge building,
chemical building, Digester Building, Gas Generation room, Boiler Building, workshop,
D.G. Room and loading/unloading bay shall be 60mm thick cement concrete flooring
with Metallic concrete hardener topping, under layer of 42mm thick cement concrete

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1:2:4 (1 cement : 2 coarse : 4 graded stone aggregate 16mm thick nominal size) and top
layer of 18mm thick metallic concrete hardener consisting of mix 1:2 (1 cement : 2 stone
aggregate 6mm nominal size) by volume & mixed with metallic hardening compound of
approved quality @ 3 kg/m2. Including cement slurry and rounding off edges. In
chemical building alum storage area and preparation area, battery room and areas
coming in contact with acid / alkali spillage / fumeto be provided with Acid resistant
tiles. Dado of acid / alkali resistant tiling as per IS:4457 shall be provided to a height of
2100 mm set in potassium silicate mortar and joints pointed with resin bonded mortar
13) The flooring in Operator's room, Security room, Control room, MCC cum Electrical
Panel room shall be in 18 mm thick mirror polished, machine cut granite slab of
approved shade and pattern placed in cement mortar (1:4). 150mm high skirting shall be
provided in these areas.
14) Toilet areas shall have 450 mm x 450 mm x 25 mm thick polished Anti-Skid resistant
ceramic /Kota stone tiles placed in cement mortar 1:4 to give an overall thickness of 50
mm. 2100 mm high dado, in 250 mm x 250 mm x 6 mm thick glazed tiles (approved
make, shade and pattern) placed in cement mortar 1:3 shall also be provided in these
areas.
15) The flooring along with skirting in administration cum laboratory building shall be 18
mm thick mirror polished, machine cut granite slab of approved shade and pattern
placed in cement mortar (1:4). 150mm high skirting shall be provided in these areas.
Granite stone shall be provided for laboratory platforms fixed over double sandwiched
cuddappah support as directed and the edges of granite is to be embedded into the wall.
16) The toilet facilities shall include at least :
(i) 2 Nos. Water closets with white Vitreous china clay European Type
(ii) 2 Nos. Urinals of sizes 600 mm x 400 mm x 300 mm flat back type in Vitreous china clay
separated by a marble partition of size 680 mm x 300 mm.
(iii) 2 Nos. wash basins of size 510 mm x 400 mm in Vitreous china clay with inlet, outlet and
Overflow arrangements.
(iv) 2 Nos. mirror of size 400 mm x 600 mm wall mounted type fitted over wash basins.
(v) 2 Nos. plastic liquid soap bottles
(vi) 2 Nos. chromium plated brass towel rails minimum 750 mm long.
(vii) All stopcocks, valves and pillar cocks shall be heavy duty chromium plated brass.
(viii) All fittings such as `P' or `S' traps, floor traps, pipes, downtake pipes etc.
(ix) The sewage from toilet blocks shall be led to the wet well of terminal sewage pumping
station if present or included under this contract or to the closest gravity sewer or with
soak pit with septic tank with necessary arrangements.
17) All staircases shall have granite/concrete tiles for treads and risers of approved make
and shade and half tile skirting to be provided. All concrete stairs shall have aluminium
nosing over 2 mm thick rubber strip of width same as nosing for the full length of the
tread. Nosing shall be fixed with countersunk screws.

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18) Stairways shall be provided to permit access between different levels within buildings.
Staircase shall be minimum 1200mm wide, minimum Tread = 250 mm, maximum Riser
= 175 mm and maximum 15 number of steps per flight unless specified otherwise.
Staircases in general shall not be steeper than 40°. Staircases having space constraints
may be steeper than 400. The maximum vertical run for a single flight of stairs shall be
3.0 M.
19) All roof tops and overhead tanks shall be made accessible with ladder provision.
Vertical step ladders fitted with landing point extensions will be permitted where
considered appropriate by the Engineer to access areas not frequently visited.
20) Steel staircases shall be constructed of standard channel stringers with M.S. grating
treads 25mm thick with non skid nosing. Steel Ladders shall be minimum 600mm wide
and shall not exceed 6m of straight run. The ladders shall be painted with epoxy paint.
21) All hand railing shall be provided with 6063-T6 Aluminium Alloy 40mm Outer
Diameter of 3mm wall thickness with an ultimate tensile strength of at least 207 MPa
and yield strength of at least 172 MPa. The minimum height of hand railing shall be
1.2m and maximum spacing of verticals shall be 1.2 m. Number of horizontal rails shall
be 3 (1 top, 1 intermediate and 1 bottom) with a 146x80 x12 thk toe plate at the bottom
along with necessary accessories..
22) The reinforced concrete roofs shall be made waterproof by application of an approved
roof polythene / bitumen membrane / brick bat coba/chemical or Tarfelt. The finished
roof surface shall have adequate slope to drain quickly the rain water to R.W down take
inlet points.
23) All roof floors shall have minimum 750 mm height solid concrete block parapet wall.
24) For roofing drainage, cast iron oru PVC rainwater down takes with C.I. bell mouth or
uPVC bend and C.I. or uPVC grating at top shall be provided. For roof areas up to 40 sq
m minimum two nos. 100 mm diameter down take pipes shall be provided. For every
additional area of 40 sq m or part thereof, at least one no. 100 mm dia. down take pipe
shall be provided.
25) Top surfaces of chajjas and canopies shall be made waterproof by providing a screed
layer of adequate slope or application of an approved roof membrane and sloped to
drain the rain water.
26) Building plinth shall be minimum 450 mm above average finished ground level around
building or high flood level whichever is more.
27) All doors, windows, rolling shutters shall have lintels above. Chajja protection to lintels
on external walls shall be such as to prevent the rain water splashing into the building.
Chajja projection of minimum 750 mm for rolling shutters, 600 mm for doors and
windows shall be provided to prevent the rain water splashing into the building. Chajja
shall be projected 300 mm on either side from size of doors/windows/rolling shutters.

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28) All windows and ventilators shall have 25 mm thick Kota stone sills bedded in cement
mortar (1:3).
29) All Aluminium Doors, windows and Ventilators sections shall have powdered coated to
a minimum of 50-60 microns with exterior durable polyester grade powder of approved
quality.
30) All doors, windows and ventilators shall be made of aluminium confirming to latest
version of IS: 1948. All fixtures for doors, windows and ventilators shall also be of
aluminium. Aluminium grills shall be provided in all the windows and ventilators with
necessary coatings. Doors shall be in two panel and both panels shall be
glazed/unglazed. Minimum weight of aluminium doors & windows shall be as follows
I. Single Glazed Window: (Weights indicated shall be aluminum)
a) Openable
Outer Frame : Weight 0.70 kg/m
Shutter Frame : Weight 0.97 kg/m
Intermediate Mullion : Weight0.97 kg/m
Beading : Weight 0.31 kg/m
b) Fixed Louvers windows/ventilators
Outer Frame : Weight 0.46 kg/Rmt
II. Double Glazed Window
Outer Frame : Weight 0.72 kg/Rmt
Shutter Frame : Weight 0.97 kg/Rmt
Intermediate Mullion : Weight0.98 kg/Rmt
Beading : Weight 0.31 kg/Rmt
III. Sliding Windows
Bottom & Top Frame : Weight 0.70 kg/m
Shutter Frame : Weight 0.42 kg/m
Interlocking Section : Weight 0.47 kg/m
IV. Aluminium Door
Outer Frame : Weight 2.508 kg/Rmt
Shutter Frame : Weight 2.508 kg/Rmt
Bottom Stile : Weight 2.508 kg/Rmt
Glazing shall be 5.5wired mm thick glass as per IS: 2835 for Doors and windows.
Glass louvers shall be provided for ventilators with frame weight of 0.46kg/m.
31) Openings of the windows & ventilators shall be minimum 25% of the external wall area.
32) Ventilator shall be provided where height of floor is more than 3m.
33) All windows and ventilators shall have wire mesh. Frame of doors, windows and
ventilators shall be of aluminium of standard rolled section. Doors, Windows and
Ventilators shall be of size as per schedule to be submitted by the Contractor for
approval of Engineer. The minimum size shall be as per below:

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Door of opening size 1.2m x 2.1m

Door of opening size 0.75m x 2.1m for toilets
Glazed windows of minimum size 1.2m x 1.2m
Ventilators of minimum size 0.6m x 0.6m
34) Rolling shutters shall be made of 80 x 1.25 mm MS laths. Rolling shutter shall be of
minimum size 5.0m wide x 5.0m high with motorised. Rolling shutter shall be provided
in MCC cum panel room, chlorine tonner shed, at entry and exit of the pump house for
access to pumps, motors, valves, panels and as wherever required.
35) All concrete channels and ducts used for conveying liquid shall have inside finish of
type F2. The width of concrete channels shall not be less than 500 mm. All open channels
shall be provided with 6063-T6 Aluminium Alloy hand railing to a minimum height of
1.2 m from the access surface elevation. All concrete surfaces of structures conveying
raw sewage or primary effluent upstream of the aeration tanks shall be protected from
corrosion with an approved internal lining as specified in Clause 10.21 of this document.
36) Kerbs to be provided below the hand railing on the catwalks/pathways should be as per
relevant sections of Factory Act. It shall not be less than 150mm.
37) All exposed surfaces of inserts embedded in concrete shall be painted with two coats of
enamel paint over one coat of red oxide zinc chrome primer. Surfaces in contact with
concrete shall not be painted.
38) All structural steel members shall be painted with two coats of enamel paint over one
shop and one field coat of red oxide zinc chrome primer.
39) All rooms in the treatment plant buildings shall be provided with appropriate sign
boards indicating the function of the rooms involved written in Kannada and English
Languages.
40) The roof of the buildings shall be provided with Solar Panels of approved make as per
approval of Employer for sustainable development and meeting basic lighting system
load from solar power.
41) The design of buildings shall reflect the climatic conditions existing on site. Process
buildings shall as far as is possible permit the entry of natural light , and the use of
glazed panelling shall be kept to a minimum and preference given to wall openings
protected by weather canopies.
42) Emergency exit doorways shall be provided from all buildings in order to comply with
local and international regulations .Stairways and paved areas shall be provided at the
exit points.
43) Toilet blocks in process buildings and control blocks shall be provided with a sink with
two drinking water taps of 20 mm size with adequate inlet and outlet connections.
44) All the walkways shall have minimum 1.2 m clear width and shall be covered with
Granite /concrete tiles. Walkways to be provided with 6063-T6 Aluminium Alloy hand
railings.

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45) Material of construction for Advanced Sludge Treatment Units shall be in RCC (M-30)
grade concrete.
46) Anaerobic Sludge Digesters and Sludge Tank with Gas Holders shall be built in RCC. A
top dome of digesters and Gas Holders shall be made of Steel with full Epoxy Coating as
per the specification given in Clause 10.21 of this Part-10 and top surface Ring Beam and
top 2m wall of the digester shall also be coated with Epoxy Coating. Contractor may
submit his proposal for the alternative materials which can be used for digester dome
and gas holder along with all technical details. Employer will approve the type of
material which shall be used for the construction of gas holders and digester domes
depending upon the durability, corrosion resistivity, strength, ease in operation,
functional requirements, economy, etc.(if included in this contract)
47) All concrete structures in contact with sewage and/or sludge upstream of the Aeration
Basins shall be provided with full interior corrosion protection linings and/or coatings
of appropriate material and thickness. This also applies to all concrete structures in
contact with any type of sewage sludge anywhere in the plant. For Aeration Basins,
interior lining shall extend from the top of wall down to 1.0 meter below the lowest
operating water level.
48) For structures containing water or process liquid, the top of the wall shall be atleast 0.5m
higher than the maximum water surface level calculated at high flood level and peak
plant flow. Finished Ground level will be 0.5m above the High flood level.
49) If the High flood level is more than Ground Level then road shall be constructed on the
Earthen Embankments/Engineered Embankment. Earthen Embankments/ Engineered
Embankment shall be constructed with side slope of atleast 2 horizontal to 1 vertical.
Stone pitching shall be provided at both sides of the embankment as per IS: 8237. Top
width of embankment shall be taken as 6.0m. Top level of embankment shall be 0.5m
above high flood level. Good quality of filling materials can be used for embankment
construction as approved by Engineer/as suggested in relevant Geotechnical
Investigation Report recommendations as applicable.
50) Engineered Embankments for plant structures in Swampy/Water logged areas shall be
considered in compliance with relevant Geotechnical Investigation Report
recommendations as applicable.
51) All requirements for Engineered Embankments and all other associated works
connected to this system (i.e. like, all controlled filling requirements, Type & suitability
of materials, Methodologies, Testing, Protective systems, Aprons, Proper slopes,
Stability, Specifications, Quality control, and all other requirements pertaining to this
system of works, etc.,) shall be considered in compliance with relevant Geotechnical
Investigation Report recommendations as applicable. Also to enlist the services of an
experienced & specialized agency for all related design aspects considerations,
equipment specifications, and implementation methodology, etc., as an advice for the
same (Refer to 46 & 47).

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52) Suitable River flow training systems/Flow diversion to be adopted at required

locations/places in compliance with relevant Geotechnical Investigation Report
recommendations as applicable.

22.5 Roadways, Pathways & Hard standings

A comprehensive network of roadways shall be provided the around treatment plant to link in
with the existing road network and permit access to the plant for necessary maintenance,
delivery of consumables and personnel access. All roads shall be of Wet Mix Macadam and
minimum 6 metres wide excluding shoulders and drains. Vehicular access shall be provided for
all Plant structures and buildings. All roads shall be provided with drainage and shall be
constructed to prevent standing water.
Paved access ways of 3m width shall be constructed with interlocking concrete blocks of 40 mm
minimum thickness to provide a network of logical routes interlinking plant areas. Damage to
any existing roads on account of their use by the Contractor shall be made good to the
satisfaction of the Engineer.
Hard standing areas with shading facility shall be provided to permit the parking of vehicles
involved in the delivery of consumables from blocking site roadways during unloading or
loading. The road system shall be designed such that vehicles involved in the delivery of
consumables can follow a continuous route through the works and out again.
Site Drainage
The Contractor shall provide a site drainage system. The system shall comprise of the
following:
- Storm Water Drainage
- Foul Drainage
Storm Water Drainage
Storm water drains adjacent to the existing and proposed roads (under this Contract) shall be
sized for a rainfall intensity of 50 mm/hr, allowing for 100% runoff. Drains adjacent to roads
shall be in stone masonry in CM (1:4) of appropriate thickness, topped with 75 mm thick M10
concrete and internally flush pointed in cement mortar (1:4), 20 mm thick. The minimum width
of drain shall be 450mm.
The storm water drainage system shall also be designed to cater the run-off from the existing
plot areas and structures, if necessary depending upon the site topography.
All drains inside the building shall have minimum 40 mm thick grating covers. In areas where
heavy equipment loads would be coming, pre cast RCC covers shall be provided in place of
steel grating. These drains shall lead the water to drain sump.
Garland drains shall be provided around all buildings to receive the drainage water from roof
and floor and lead them to the plant storm water drainage system.

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Foul Drainage
The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be conveyed to either wetwell of the terminal sewage
pumping station wherever exist or proposed under this contract or nearest public sewer
wherever exist or with septic tank and soak pit arrangement.
Cable and Pipe work Trenches
Cable and pipework trenches shall generally be constructed in reinforced concrete.
All floor cut-outs and cable ducts, etc. shall be covered with M25 precast concrete covers (Heavy
Duty) or MS grating as per direction of Engineer in outdoor areas and M.S. chequered plates,
suitably painted of adequate thickness in indoor areas. All uncovered openings shall be
protected with hand railing. The pipe, cable trenches shall be suitably sloped to drain off
rainwater to a suitable location.
Layout of trenches outside the buildings shall allow space for construction of future trenches
where necessary with due consideration for planning for future developments. This aspect shall
be brought to the notice of the Engineer while planning the works.

Pipes and Ducts

R.C.C ducts for drainage shall have minimum 1 metre pre-cast cover (M25 concrete, Heavy
duty) while laid under roads. Access shafts of size not less than 600 mm x 1000 mm shall be
provided.
All drains (except storm water drains adjacent to roads) shall be covered and designed
structurally for appropriate loads.

Boundary wall, Retaining wall & Main Gate

Boundary wall / Compound wall
Compound wall shall consist of RC precast slab panels (M25) with minimum 60mm thick Logo,
RC post at regular intervals including plinth beam as supports for the panels and necessary RC
foundation system for the same along with barbed wire stretched between MS angles fixing at
the top of the precast panels with necessary fixtures etc.,
All structural designs and Specifications shall confirm to relevant codal provisions.
Retaining wall
1. Retaining wall shall be RCC with M25 grade of concrete. Wall foundations shall be
placed on virgin soil and not on backfilled soil. Foundations shall extend to a depth of at
least 1.0 metre below finished ground level.
2. Expansion joints shall be provided in the retaining wall.
3. In retaining walls, 100 mm dia weep holes shall be provided at 1 m vertically and
horizontally. The lowest weep hole shall be at about 30 cm above the ground level. All
weep holes shall be surrounded by loose stones and shall have sufficient fall to drain out
the water quickly.

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Main Gate
Proposed treatment plant shall have one main gate to access the plant irrespective of existing
gate at the premises of existing plant site. Minimum width of main gate shall be 6.5m. Main gate
shall have 1.5m wide wicket gate. Main gate shall have as external framework of GI pipes and
internal framework of MS flats. Gate shall be fixed on RCC columns. The design and pattern of
gate with drawing shall be submitted for approval of the Engineer. The gate shall have all
necessary hinges, locking arrangement, rolling arrangement and painting complete, as
approved by the Engineer.
Landscaping
The site shall be landscaped once the Works are substantially complete. Landscaping area shall
be marked in the layout plan of STP site.
Landscaping shall include planting of suitable trees and development of lawn/grassed areas.
Landscaping in general shall meet ecological and environmental conditions of the site. Road
widths shall determine the size of the tree height and spread to be selected for planting. Trees
suitable for local conditions shall be selected as approved by the Engineer. Medicinal and fruit
trees shall be avoided. Landscaping shall be maintained in good condition till the completion of
the contract.
Area for landscaping will be equal to total area of project site minus area for the treatment plant
units and the area required for roads, sidewalks and drains.

Tree Planting
Pits dug a few days in advance of actual planting shall be allowed to weather and be filled with
top soil mixed with manure. Size of the pit shall be as per standard requirement. Only one tree
shall be planted in each pit. A guard made of bamboo with wire mesh or bricks or M.S. ring as
approved by Engineer, shall be provided.

22.6 Specification for Anti-Corrosive Internal Coating/Lining protection of Concrete

Surfaces
Application limits of Anti-Corrosion Internal Coating/Lining for Concrete Surfaces:
1. All units upstream of and including Primary Clarifiers will have to be provided with
internal coating/lining for the full internal surface area (Walls and base slab)
2. For the units - Anaerobic Zone, Anoxic Zones, Aeration Zones and Aeration Basin
Effluent Channels, internal coating/lining shall be provided on the walls only from the
top of the structure to 1.0 m below the lowest operating liquid level
3. For the units handling the solids part such as: Gravity Sludge Thickener, Anaerobic
Sludge digester and Digested Sludge and Biogas Storage tank, internal lining shall be
provided for the entire internal surface area.
Contractor shall adopt any one of the following materials for internal coating/lining and submit
his methodology for approval of Engineer.

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Intertol Poxitar or equivalent

This is a two component reaction hardening coating of low solvent content based on a coal tax
epoxy combination with mineral fillers manufactured by Sika India Pvt Ltd, which is provided
for long term protection to concrete and steel structures against chemical corrosion. This
component has excellent resistant to water and chemicals. It has resistant to microbes also.
Application Methodology
For steel structure, sand blasting or wire brushing is essential. Surface of steel shall be free from
oil, dirt and grease. For Concrete structure, remove cement skin, loose particle from the surface.
Cavities, pin holes should be levelled.
For Concrete structure, surface shall be primed using 1 part of Inertol Poxitar and 5% Sika
Thinner DS. Surface shall be primed using above materials at a rate of 0.20 kg/ m2.
As seal coat, two coats of Inertol Poxitar is applied with rate of 0.20 kg/ m2 per coat. Inertol
Poxitar is basically consisting of two parts Part-A & part-B. Part A and part-B are mixed in 16:84
ratios (by weight).
For Steel Structure, surface shall be primed with Fraizinc-R with the rate of 0.20 kg/ m2. After
this, two coats of Inertol Poxitaris applied over the primer with the rate of 0.20 kg/ m2 per coat.
Part-A & part-B are mixed thoroughly with electric stirrer with up and down movement. These
shall be mixed for at least 3 minutes. Apply mix with by brush or roller. Over coating shall be
done after minimum 4 hours or maximum 7 days.

Properties of Inertol Poxitar are given below:

Colour : Black
Solids by weight : 77%
Mixed Density : 1.50 at 27 C
Pot Life : At 30 C 120 Minutes
Over-coating Time : Subs Temp Min Max
10 C 16 hours 7 days
20 C 8 hours 7 days
30 C 4 hours 7 days
Mixing Ratio : Part A : part B =16:84 (by Weight)
Curing Time : 7 days
Shalipoxy-CTE or equivalent
Shalipoxy-CTE is a two component Coal Tar Epoxy coating manufactured by Shalimar Tar
Product limited, black in colour, used to protect steel, concrete structures in corrosive
environment. It cures to a hard smooth surface and possesses exceptional resistance to the effect
of water immersion, salt water, oils, acids, minerals, crude oils etc.

Application Methodology
For Concrete Structures- Mechanical grinding or other suitable surface preparation is
recommended for obtaining best results on concrete. Compressed air is used to remove residual

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dust or use brush to remove dust completely. Compressed air should be oil free. Apply only to
dry surface.
For Steel Structures- Steel structures which are to receive Shalipoxy-CTE coating should be
prepared by sandblasting or power tool or mechanical cleaning to a commercial Grey metal
finish. If moisture or other contaminants contaminate prepared surface, they should be
reblasted. Use suitable Shali Zinc Epoxy primer over the prepared surface.
Mix (by volume) 4 parts of Component A to 1 part of Component B by stirring thoroughly for at
least 3 minutes. Allow the mix to stand for 10 minutes before application.
Apply two coats of Shalipoxy-CTE by brush, roller or spray. First coat should be allowed to dry
tack before application of second coat. The second coat should be applied within 72 hours, wipe
first coat with MIBK and wipe dry with cloth before second coat.
Covering capacity of Shalipoxy-CTE for concrete structure shall be 4 m2 per litre per coat and
for Steel structures it shall be 6 m2 per litre per coat.

Properties of Shalipoxy-CTE are given below:

Colour : Black
Solids by weight : 76%
Pot Life : At 30 C 240 Minutes
Over Coating Time : 12 Hours
Curing Time : 7 days
Dry Film Thickness , in two Coats : 300 Microns
Master Seal-SP120 or equivalent
The high build , pitch extended epoxy coating shall be MASTERSEAL SP 120 manufactured by
BASF Construction Chemicals, a 100% solids, solvent free, tough abrasion resistant protective
coating. The product shall exhibit excellent bond strength with the substrate at least exceeding
2.5 MPa, when tested as per ASTM D4541. The product shall be formulated have high build
thickness exceeding 150 microns per coat on average and shall be applied to achieve overall
thickness of 300 microns in two coats. The product shall be formulated to resist exposure to
accelerated weathering test as per ASTM D4587 and shall not exhibit any flaking or blistering.
Application Methodology
Concrete Structure- First it shall be ensured that concrete shall be at least 28 days old and
sound. Oil, grease, mould release agent, curing membrane and such other contaminants must
be removed by mild detergent and water, and by thoroughly scrubbing with a soft brush. If the
wall surface is damp or water is seeping out, stop the leakage before coating. Even out all
unevenness such as blow holes , pin holes and other surface defects with CONCRESIVE 2200
manufactured by BASF Construction Chemicals India Private Limited , before application of
coating.
Steel Structures-Remove all previous treatments and corrosion products by sand/shot blasting
to bright metal finish. Do not allow long time gap between surface preparation and the coating
to prevent re-oxidising of metal before application of product.

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Master Seal SP120 is two component products, Master Seal SP120 Base and Master Seal SP120
Hardener. Both these products are mixed in ration 1:1 (by weight) Mix both the components for
3 minutes with a slow speed drill and wing style mixing paddle at 300-400 rpm until a
homogeneous colour is achieved. Keep the paddle below the surface to avoid entrapping air.
This shall be applied in two coats, each at a W.F.T. of 150 microns. The second coat applied after
first coat has dried (4-6 hours) and at right angles to it. Should the application of second coat be
delayed, abrade the previous coat to give an adequate mechanical key and wipe with SOLVENT
NO 2 before application.
Properties of Master Seal SP120 are given below:
Colour : Black viscous liquid
Solids by volume : 100%
Mixed Density: 1.65 Kg/l at 27 C
Pot Life : At 25 C 60 Minutes
At 40 C 30 Minutes
Over Coating Time : 12 Hours at 25 C
Mixing Ratio : Part A : part B =1:1 (by Weight)
Curing Time : 5 days
Dry Film Thickness , in two Coats : 300 Microns
10.21.4 Nitocote ET550 or equivalent
Nitocote ET 550 is aEpoxy tar based high performance resin coatingThixotropic pitch extended
epoxy amine adduct formulation containing reinforcing inert fillers and special blend of
solvents. The product is supplied as a two-component system comprising a special blend of an
epoxy resins and a separate low viscosity amine hardener.Nitocote ET 550 is applied as a two
coat application. It is generally applied at a wet film thickness of 265 micron per coat (175
microns DFT per coat). The product shall exhibit excellent bond strength with the substrate
when tested as per specification.
Application Methodology
All surfaces to be treated with Nitocote ET550 must be clean and free from dust or loose
material.
Concrete Structure- All laitance must be removed by grit blasting or other suitable removal
methods. The general standard of surface preparation should be in accordance with ACI 503R-
89, Chapter 5 paragraph 5.4. Following the preparation of a concrete structure, care should be
taken to ensure that any surface irregularities are filled with Nitomortar FC
Steel Structures- Any metal surface should be grit blasted to a bright finish, meeting the
requirements of Swedish Standards SA 21/2. BS4232, First Quality .All metal surfaces should
be coated immediately after preparation.
Mixing
Nitocote ET550 should always be mixed in an open, well ventilated area. The contents of the
base shall be stirred thoroughly to disperse any settlement. The entire contents of the hardener

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shall be poured into the base container ensuring that the sides and bottom of the container are
well scraped. The two components should be mixed mechanically using a mixing paddle fitted
on a heavy duty, slow speed electric drill. The mixing should be carried out continuously for 3-5
minutes, until a uniform consistency is achieved.
Application: Brush application
Nitocote ET550 should be applied in two coats. The thoroughly mixed material should be
applied with a suitable brush. The first coat must be firmly applied and be well scrubbed into
the surface, ensuring a uniform coating with a wet film thickness not less than 265 microns, be
allowed to dry for not less than 16 hours at 20°C. The second coat should be applied as above,
again achieving a wet film thickness of 265 microns. The number of coats to achieve a total wet
film application of 530 microns.

Properties of Nitocote ET550 are given below:

Sr.no Property Allowable Standard Method
1 Dry Film Thickness , in two Coats
2 Adhesive bond strength :>1.5 N/mm2 ASTM D 4541
3 Hardness Test
a) Gauge Hardness H to 6H ASTM-D 3363-92a
b) Scratch Hardness H to 6H ASTM-D 3363-92a
Chemical Test
Specimens Immersed for 30 days in
1) H2 SO4 1% ASTM-C 210-92
2) NaOH 1 % ASTM-C 210-92
3) Deionsed water ASTM-C 210-92
4) HNO3 10% No attack
5) NaOH 30% No attack
6) Period of Exposure to methane at 2.0 kg/sq.cm pressure for 720 hours BS 5493
No attack means no signs of swelling, scratches, peeling or discoloration of Epoxy Tar specimen
Inter zone 954
Two-component, high build modified epoxy barrier coat - hydrocarbon modified epoxy cured
with a cycloaliphatic amine adduct curing agent, and formulated to give good barrier protection
in both immersed and external atmospheric exposure conditions. The product is supplied as a
two-component system comprising of a pigmented epoxy base and a clear amine curing agent.
The product is supplied as a two-component system comprising a special blend of an epoxy
resins and a separate low viscosity amine hardener. The coating can be applied as a single coat
system achieving a dry film thickness of 500 microns (588 microns wet film thickness) sprayed
in one coat.
Application Methodology
Surface Preparation
Concrete Structure- Surfaces must be clean, dry and free from curing compounds, laitance,

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releasing compounds, oil, grease, dirt, chalk, or previously applied coatings. Laitance must,
therefore, be removed by sweep blasting or other means prior to coatings application. Ensure
that the concrete is sufficiently dry to receive coatings; use a moisture meter. The 6% maximum
moisture content shall be permissible. A primer coat of a solvent-free epoxy primer must be
applied at a thickness of 40-50microns before application of the topcoat.
Steel Structures- All surfaces to be coated must be clean and free from dust or loose material.
Interzone 954 can be applied directly to blasted steel as per SSPC/SP-6, a minimum surface
profile of 50- 75 microns is recommended.
Previously Painted Surfaces - Remove all rust, rust scale, other corrosion products, loose or
heavy chalk and loose or scaling paint by 'Hand or Power Tool Cleaning" (SSPC-SP2 or 3
respectively / AS 1627 St2 or St3). 'Feather' thick edges of existing coating. Sand or sweep blasts
any glossy areas until dull. Spot prime bare areas as recommended.
Mixing
The mixing ratio of Base (Part A) to Curing Agent (Part B) is 4:1. Material is supplied in two
containers as a unit. Always mix a complete unit in the proportions supplied. The product, once
mixed, must be used within the working pot life specified.
1. Agitate Base (Part A) with a power agitator
2. Combine entire contents of Curing Agent (Part B) with the Base (Part A) and mix
thoroughly using a power agitator.
Application: Airless Spray Application
Airless spray is the preferred method of application as air spray techniques will not produce
satisfactory film build without the need for "multiple pass" applications. The pump should have
a minimum ratio of 45:1. It is also advisable to check that adequate air volume is present.
Airless Spray
Tip Range: 0.53-0.66mm (21-26 thou)
Total Output: Minimum 176kg/cm2
Fluid Pressure: 2500 p.s.i

Properties of Inter zone 954 are given below:

Sr.no Property Allowable Standard Method
1 Dry Film Thickness , in a single coat 500 microns DFT gauge
2 Adhesive bond strength Not less than 10MPa (10 N/mm2) ISO 4624
3 Tensile Strength An average of 11MPa (11 N/mm2) ASTM D2370
4 Abrasion Resistance Average of 88mg weight loss per 1000 cycles using CS10 wheels
and a 1Kg loading. ASTM D4060
5 Immersion No film defects after 1 year of exposure ISO 2812 Part 2 -
"Resistance to water
immersion @ 40°C"
6 Impact Resistance Direct Impact Resistance - 2.5 Joules ASTM D2794

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Chemical Test
Specimens Immersed for 30 days in
1) H2SO4 1% No attack ASTM-C 210-92
2) NaOH 1 % No attack ASTM-C 210-92
3) Deioninsed water No attack ASTM-C 210-92
4) Period of Exposure to methane at 2.0 kg/sq.cm pressure for 720 hours
*No attack means no signs of swelling, scratches or peeling of coating specimen

Application Methodology
Surface Preparation
Concrete Structure- Surfaces must be clean, dry and free from curing compounds, laitance,
releasing compounds, oil, grease, dirt, chalk, or previously applied coatings. Laitance must,
therefore, be removed by sweep blasting or other means prior to coatings application. Ensure
that the concrete is sufficiently dry to receive coatings; use a moisture meter. The 6% maximum
moisture content shall be permissible. A primer coat of a solvent-free epoxy primer must be
applied at a thickness of 40-50microns before application of the topcoat.
Steel Structures- All surfaces to be coated must be clean and free from dust or loose material.
Inter zone 954 can be applied directly to blasted steel as per SSPC/SP-6, a minimum surface
profile of 50- 75 microns is recommended.
Previously Painted Surfaces - Remove all rust, rust scale, other corrosion products, loose or
heavy chalk and loose or scaling paint by 'Hand or Power Tool Cleaning" (SSPC-SP2 or 3
respectively / AS 1627 St2 or St3). 'Feather' thick edges of existing coating. Sand or sweep blasts
any glossy areas until dull. Spot prime bare areas as recommended.
Mixing
The mixing ratio of Base (Part A) to Curing Agent (Part B) is 4:1. Material is supplied in two
containers as a unit. Always mix a complete unit in the proportions supplied. The product, once
mixed, must be used within the working pot life specified.
1. Agitate Base (Part A) with a power agitator
2. Combine entire contents of Curing Agent (Part B) with the Base (Part A) and mix
thoroughly using a power agitator.
Application: Airless Spray Application
Airless spray is the preferred method of application as air spray techniques will not produce
satisfactory film build without the need for "multiple pass" applications. The pump should have
a minimum ratio of 45:1. It is also advisable to check that adequate air volume is present.
Airless Spray
Tip Range: 0.53-0.66mm (21-26 thou)
Total Output: Minimum 176kg/cm2
Fluid Pressure: 2500 p.s.i

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Properties of Inter zone 954 are given below:

Sr.no Property Allowable Standard Method
1 Dry Film Thickness, in a single coat 500 microns DFT gauge

2 Adhesive bond strength Not less than 10MPa (10 N/mm2) ISO 4624

3 Tensile Strength An average of 11MPa (11 N/mm2) ASTM D2370

4 Abrasion Resistance Average of 88mg weight loss per 1000 cycles using CS10 wheels
and a 1Kg loading. ASTM D4060
5 Immersion No film defects after 1 year of exposure ISO 2812 Part 2 -
"Resistance to water
immersion @ 40°C"
6 Impact Resistance Direct Impact Resistance - 2.5 Joules ASTM D2794
Chemical Test
Specimens Immersed for 30 days in
1) H2SO4 1% No attack ASTM-C 210-92
2) NaOH 1 % No attack ASTM-C 210-92
3) Deionised water No attack ASTM-C 210-92
4) Period of Exposure to methane at 2.0 kg/sq.cm pressure for 720 hours
*No attack means no signs of swelling, scratches or peeling of coating specimen

22.7 Hydraulic Testing of Liquid Retaining Structures

In addition to the structural test of structures as applicable, the liquid retaining structures shall
also be tested for water tightness test at full supply level as described in clauses 12.1,12.1.1,
12.1.2 and 12.1.3 of latest version of IS 3370 (Part I).
On completion of the structure and before its commissioning, the Contractor shall carry out a
water tightness test for the maximum water head condition i.e. with the water standing at Full
Supply Level (FSL). This test shall be carried out preferably in dry season and prior to internal
coating/lining in accordance with the procedure given below:
The water tightness test shall be carried out when the construction of liquid retaining structure
is done and when it is possible to fill the structure and ensure that uniform settlement of the
structure as a whole or as directed by the Engineer. Before the filling operations are started the
structure shall be inspected by the Engineer and the Contractor's Representative and the
condition of surfaces of walls, contraction joints shall be noted and it shall be ensured that the
jointing material filled in the joint is in position and all openings are closed. The Contractor
shall make necessary arrangement for ventilation and lighting of the structure by way of
floodlights, circulators etc. for carrying out proper inspection of the surfaces and inner
conditions if so desired by the Engineer. Records of leakages starting at different levels of water
in the reservoir, if any, shall be kept.
The liquid retaining structure once filled shall be allowed to remain so for a period of seven
days before any readings of drop in water level are recorded. The level of the water shall be

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recorded against the subsequent intervals of 24 hours over a period of seven days. The total
drop in surface level over a period of seven days shall be taken as an indication of the water
tightness of the structure, which for all practical purposes shall not exceed 40 mm. Also there
shall be no indications of the leakages around the opening or on the walls.
If the structure does not satisfy the condition of test and the daily drop in water level is
decreasing, the period of test may be extended for a further period of seven days and it the
specified limit is then reached the structure may be considered as satisfactory.
The external faces of structure shall not show any signs of leakage and shall remain apparently
dry over the period of observation of seven days after allowing a seven day period for
absorption after filling.
In case the drop in level exceeds the permissible level limit and signs of leakage 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 to reduce the leakage within the permissible
limits. The entire rectification work that shall be carried out in this connection shall be at the
Contractor's cost. The water required for subsequent testing shall be supplied to the Contractor
free of cost, if the same is available near the site. Contractor shall have to make arrangement for
filling emptying the structure at his own 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.
During testing and during defect liability period the impression marks created due to seepage
shall be rectified and made good.
No separate payment shall be made for water tightness test and the cost thereof shall deem to
be covered in the rates quoted of different items of work of Treatment Plant.

22.8 Non Destructive Testing of RCC Structures

Non Destructive Testing (NDT) shall be carried out as per latest version of IS: 13311 codes as
per the instruction given by Employer.

22.9 Rain water harvesting system.

22.9.1 Need for Rain water Harvesting

Rainwater harvesting at STP site shall be carried out in view of the following:
a) Conserving rainwater
b) Possibility of integrating the storm water drainage scheme of the STP with rain water
conservation.
c) The convenient and economical way of achieving the same is by adopting roof water
harvesting methodologies.

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22.9.2 Components of the Rain Water Harvesting Scheme

Rainwater harvesting carried out for enriching the groundwater resources essentially consists
a) common collection tank; and
b) pipe line(s)
Following are the main components proposed for the roof water harvesting system at the STP
including their location in the project area:
a) Rainwater pipes from the roofs of all the Buildings;
b) First flush piping system
c) Storm water drains adjoining the roads of the plant;

22.9.3 Integration with Storm Water Drains

The roof water from all Buildings, etc. shall be collected and integrated with all storm water
drains of the main plant area.

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