DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

DELHI METRO RAIL CORPORATION LTD.

th
5 Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

CIVIL WORKS

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
CC-135: Construction of Simulator Building at Shastri Park, New Delhi

TECHNICAL SPECIFICATION CIVIL WORK

CLAUSE DESCRIPTION

1. GENERAL
2. EARTHWORK IN EXCAVATION AND BACKFILLING
3. FORMWORK
4. REINFORCING STEEL
5. CONCRETE : PLAIN AND REINFORCED
6. BRICK WORK
7. STONE WORK
8. CERAMIC GLAZED TILE CLADDING
9. WOOD WORK
10. METAL WORK
11. ALUMINIUM WORK AND GLAZING
12. FLOORING
13. SUSPENDED CEILINGS
14. WATER PROOFING
15. PLASTER
16. PAINTING AND POLISHING
17. MISCELLANEOUS
18. HORTICULTURE WORK
19. ROADS AND PAVEMENTS

DMRC/CC-135/Vol.-4/Tech. Spec./Civil Work

CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.0 GENERAL

1.1 Description of Work Site

Delhi Metro Rail Corporation Ltd. is constructing 304 nos. Staff Quarters at Bahadurgarh
of Type II (168 nos.), Type III (128 nos.), and Type IV (8 nos.), along with a Community
Centre, Sub Station, Time office and Parking space etc. to cater for housing of Operating
staff deputed on the Mundka – Bahadurgarh corridor. The project site is located at
Bahadurgarh, Haryana.
The location of the work and the general site particulars are shown in the Site Layout
enclosed in the tender drawings

1.2 Standard Specifications

a. The work in general shall be carried out as per CPWD specifications, 2009
(Volume I to II) unless specified in the nomenclature of the individual item or in the
particular specifications for civil works.
b. For the items not covered under the specifications as stated above, the work shall
be done as per relevant IS Codes, latest publications with correction slip.
c. For the items not covered under any of the specifications stated above, the work
shall be executed as per Manufacturer’s specifications/ General Engineering
Practice and/or as per direction of Engineer-in-charge.
d. In the absence of any definite provisions or any particular issue in the aforesaid
specifications, reference is to be made to the latest codes and specifications of
BIS, IRC, BS, ASTM, AASHTO and CAN/CAS in that order. Where even these are
silent, the construction and completion of works shall confirm to sound engineering
practice as approved by Engineer-in-Charge. In case, if any dispute arises out of
interpretation of the above, the decision of the Engineer-in-Charge shall be final
and binding on the Contractor.
e. Wherever reference is made in the Contract to specific standard codes to be met
by the materials, plants and other supplies to be furnished and work performed
and tested, the latest edition or revision of the relevant codes in effect shall apply,
unless otherwise explicitly stated in the contract. Wherever such standards and
codes are national, or related to a particular country of region, other internationally
recognized standards which ensure a substantially equal or higher performance
than the standards and codes specified will be accepted subject to the Engineer-
in-Charge’s prior review and written approval. Differences between standards must
be fully described in writing by the contractor and submitted to the Engineer-in-
Charge at least 15 days prior to the date when contractor desires the Engineer-in-
Charge’s approval.
If the Engineer-in-Charge determines that such proposed deviation do not ensure
substantially equal performance, the contractor shall comply with the standards
specified in the documents.
These Specifications contained herein shall be read in conjunction with other tender
documents.
i The Work shall be carried out in accordance with the "Good for Construction"
drawings and designs as would be issued to the Contractor by the Engineer duly
signed and stamped by him. The Contractor shall not take cognisance of any
drawings, designs, specifications, etc. not bearing Engineer's signature and stamp.
Similarly the Contractor shall not take cognisance of instructions given by any
other Authority except the instructions given by the Engineer in writing.

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ii The work shall be executed and measured as per metric units given in the
Schedule of Quantities, drawings etc. (FPS units where indicated are for guidance
only).
iii Absence of terms such as providing, supplying, laying, installing, fixing etc in the
descriptions does not even remotely suggest that the Contractor is absolved of
such providing, supplying etc unless an explicit stipulation is made in this contract.
The Owner shall bear no costs of materials, labour, equipment, duties, taxes,
royalties etc.
iv The specifications may have been divided into different sections / sub-heads for
convenience only. They do not restrict any cross-references. The Contractor shall
take into account inter-relations between various parts of works/trades. No claim
shall be entertained on the basis of compartmental interpretations.
v The classification of various items of works for purposes of measurements and
payments shall be as per bills of quantities (BOQ). Except where distinguished by
BOQ, the rates apply to all heights, depths, sizes, shapes and locations. They also
cater for all cuts and wastes. No floor wise separation shall be made for the rates.
Likewise all heights of centring, shuttering, staging, formwork and scaffolding,
trusses and erection methods are covered by the rates including multi stage
propping for heights greater than one floor as per drawings.

1.3 Abbreviations

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
BS British Standard
CPWD Central Public Works Department
DIN Deutsches Institut für Normung e.V.
IRC Indian Road Congress
IRS Indian Railway Standards
IS Indian Standards
JIS Japanese Industrial Standard
MORTH Ministry of Road Transport and Highways

1.4 Reference to the Standard Codes of Practice

The contractor shall make available at site all relevant Codes of practice as applicable.

1.5 Contractor to Provide

The Contractor shall provide and maintain at site throughout the period of works the
following at his own cost and without extra charge, except for the items specified in the Bill
of Quantities the cost being held to be included in the Contract Rates:
i General works such as setting out, site clearance before setting out and on
completion of works. All weather approach roads to the site office should also
be constructed and maintained in good condition.

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ii All labour, materials, plant, equipment and temporary works, Over head charges
as well as general liabilities, obligations, insurance and risks arising out of GCC,
required to complete and maintain the works to the satisfaction of the Engineer.
iii Adequate lighting for night work, and also whenever and wherever required by
the Engineer.
iv Temporary fences, barricades, guards, lights and protective work necessary for
protection of workmen, supervisors, engineers, General public and any other
persons permitted access to the site. Contractor shall provide proper signages
as directed.
All fences, barricade shall be painted with colour shades as specified by the
Engineer. The barricading should be of adequate height to ensure visual
obstruction of work from public view.
v All equipment, instruments, labour and materials required by the Engineer for
checking alignment, levels, slopes and evenness of surfaces measurements
and quality etc.
vi Design mixes and testing them as per relevant clauses of specifications giving
proportion of ingredients, sources of aggregates and binder along with
accompanying trial mixes. Test results to be submitted to the Engineer for his
approval before adoption on works.
vii Cost of Preparation and compliance with provision of a quality assurance
control programme.
viii Cost of safe guarding the environment.
ix A testing laboratory as specified by the Engineer equipped with the following
minimum apparatus, materials and competent trained staff required for carrying
out tests, as specified in the relevant sections of the specifications: -
a. One Set of standard sieves for testing grading of sand with mechanical
sieve shaker.
b. Sieves with openings respectively of 4.75mm, 10mm, 20mm, 25mm, 30mm
for testing and grading of aggregates.
c. Weighing Balance of capacity up to 10 Kg. reading up to 5 gm.
d. Electric Thermostat controlled oven and pans for drying of sand
andaggregates.
e. Glass measuring flasks of 1/2, 1 liter & 2 liter capacity.
f. Flask for determining moisture content of sand.
g. Slump cone with rod and V B Apparatus, flow table to measure slump or
DIN Specifications.
h. Apparatus to measure permeability of concrete as per Appendix 1700/II of
MOST Specifications.
i. Minimum 24 Nos. steel moulds for 150mm x 150mm x 150mm concrete
test cubes. It may be necessary to provide more steel cube moulds depending
upon concreting programme.
j. 25mm dia vibrator for compaction of concrete in test cubes and also
vibrating table.
k. Concrete cube testing machine of 200 tonnes capacity with 3 dial gauges
electrically operated.
l. Work benches, shelves, desks, sinks and any other furniture and lighting as
required by the Engineer.

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m. Abrasion Flakiness & Impact testing Equipment for testing coarse

aggregate.
n. Silt Testing Equipment.
o. Any other equipment specified by Engineer.
x Quality Assurance & Quality Control:
a The work shall conform to high standards of design and workmanship shall
be structurally sound and aesthetically pleasing. The Contractor shall
conform to the Quality standards prescribed, which shall form the
backbone for the Quality Assurance and Quality Control system.
b At the site, the Contractor shall arrange the materials, their
stacking/storage in appropriate manner to ensure the quality. The
Contractor shall provide all the necessary equipment and qualified
manpower to test the quality of materials, assemblies etc., as directed by
the Engineer. The tests shall be conducted at specified intervals and the
results of tests properly documented. In addition the Contractor shall keep
appropriate tools and equipment for checking alignments, levels, slopes
and evenness of the surfaces.
c The Engineer shall be free to carry out such tests as may be decided by
him at his sole discretion, from time to time, in addition to those specified in
this document. The Contractor may provide the samples and labour for
collecting the samples. Nothing extra shall be payable to the Contractor for
samples or for the collection of the samples.
- The test shall be conducted at the Site laboratory that may be established
by the Contractor or at any other Standard Laboratory selected by the
Engineer.
- The Contractor shall transport the samples to the laboratory for which
nothing extra shall be payable. In the event of the Contractor failing to
arrange transportation of the samples in proper time the Engineer shall
have them transported and recover two times the actual cost from the
Contractor's bills.
- All testing shall be performed in the presence of Engineer. Testing may be
witnessed by the Contractor or his authorised representative if permitted by
the Test House. Whether witnessed by the Contractor or not, the test
results shall be binding on the Contractor.
d The Engineer shall have the right at all times to inspect all operations
including the sources of materials, procurement, layout and storage of
materials, all equipment including the concrete batching and mixing
equipment, and the quality control system. Such an inspection shall be
arranged and the Engineer's approval obtained prior to starting of the
particular item of work. This shall however, not relieve the Contractor of his
responsibilities. All materials, which do not confirm to these specifications,
shall be rejected and shall be removed from the site immediately. The
Engineer shall have the powers to cause the Contractors to purchase and
use materials from any particular source, as may in the Engineer's opinion
be necessary for the proper execution of work.

1.6 Dimensions

Figured dimensions on drawings shall only be followed and drawings to a large scale shall
take precedence over those to a smaller scale. Special dimensions or directions in the
specifications shall supersede all others. All dimensions shall be checked on site prior to
execution.

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The dimensions where stated do not allow for waste, laps, joints, etc. but the Contractor
shall provide at his own cost sufficient labour and materials to cover such waste, laps,
joints, etc.
The levels, measurements and other information concerning the existing site as shown on
the drawings are believed to be correct, but the Contractor should verify them for himself
and also examine the nature of the ground as no claim or allowance whatsoever will be
entertained on account of any errors or omissions in the levels or the description of the
ground levels or strata turning out different from what was expected or shown on the
drawings.

1.7 Setting out of Works

The Contractor shall set out the Works indicated in the Conditions of Contract. The
Contractor shall provide suitable stones with flat tops and build the same in concrete for
temporary benchmarks. All the pegs for setting out the Works and fixing the levels
required for the execution thereof shall, if desired by the Engineer, likewise be built in
masonry at such places and in such a manner as the Engineer may direct. The Contractor
shall carefully protect and preserve all benchmarks and other marks used in setting out
the works. The contractor will make overall layout of complete work and get it checked
from engineer. The cost of all operations of setting out including construction of
benchmarks is deemed to be included in the quoted rates as per Bill of Quantities.
(a) All the survey work except levelling work shall be carried out using total stations
with one second accuracy. The levelling work shall be carried out using Auto level.
(b) The triangulations point given by DMRC before start of work shall be maintained
during execution and handed over back to DMRC after completion of work.

1.8 Materials

1.8.1 Source of Materials

It shall be the responsibility of the contractor to procure all the materials required f or
construction and completion of the contract. The contractor shall indicate in writing the
source of materials well in advance to the Engineer, after the award of the work and
before commencing the work. If the material from any source is found to be unacceptable
at any time, it shall be rejected by the Engineer and the contractor shall forthwith remove
the material immediately from the site as directed by the Engineer.

1.8.2 Quality

All materials used in the works shall be of the best quality of their respective kinds as
specified herein, obtained from sources and suppliers approved by the Engineer and shall
comply strictly with the tests prescribed hereafter, or where tests are not laid down in the
specifications, with the requirements of the latest issues of the relevant Indian Standards.

1.8.3 Sampling and Testing

All materials used in the works shall be subjected to inspection and test in addition to test
certificates. Samples of all materials proposed to be employed in the permanent works
shall be submitted to the Engineer at least 45 days in advance for approval before they
are brought to the site.

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Samples provided to the Engineer for their retention are to be labelled in boxes suitable
for storage. Materials or workmanship not corresponding in character and quality with
approved samples will be rejected by the Engineer.
Samples required for approval and testing must be supplied sufficiently in advance if
required quality and number to allow for testing and approval, due allowance being made
for the fact that if the first samples are rejected further samples may be required. Delay to
the works arising from the late submission of samples will not be acceptable as a reason
for delay in completion of the works.
Materials shall be tested before leaving the manufacturer’s premises, quarry or resource,
wherever possible. Materials shall also be tested on the site and they may be rejected if
not found suitable or in accordance with the specification, notwithstanding the results of
the tests at the manufacturer’s works or elsewhere or test certificates or any approval
given earlier. The contractor will bear all expenses for sampling and testing, whether at
the manufacturer’s premises at source, at site or at any testing laboratory or institution as
directed by the Engineer. No extra payment shall be made on this account.

1.8.4 Dispatch of materials

Materials shall not be dispatched from the manufacturer’s works to the site without written
authority from the Engineer.

1.8.5 Test certificates

All manufacturer’s certificates of test, proof sheets, etc showing that the materials have
been tested in accordance with the requirement of this specification and of the appropriate
Indian Standard are to be supplied free of charge on request to the Engineer.

1.8.6 Rejection

Any materials that have not been found to conform to the specifications will be rejected
forthwith and shall be removed from the site by the Contractor at his own cost within two
weeks or as instructed by the Engineer.
The Engineer shall have power to cause the Contractors to purchase and use such
materials from any particular source, as may in his opinion be necessary for the proper
execution of the work.

1.8.7 Storing of Materials at site

All materials used in the works shall be stored on racks, supports, in bins, under cover etc
as appropriate to prevent deterioration or damage from any cause whatsoever to the
entire satisfaction of the Engineer.
The storage of materials shall be in accordance with IS 4082 “Recommendation on
stacking and storage or construction materials on site” and as per IS 7969 “Safety code
for handling and storage of building materials”.
The materials shall be stored in a proper manner at places at site approved by the
Engineer. Should the place where material is stored by the Contractor be required by the
Employer for any other purpose, the Contractor shall forthwith remove the material from
that place at his own cost and clear the place for the use of the Employer.

1.9 Water

i Water from approved source

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Potable water only shall be used for the works. Contractor shall have his own source of
water duly approved by Engineer. The water shall be free from any deleterious
matter in solution or in suspension and be obtained from an approved source. The
quality of water shall conform to IS 456.
ii Storage
The Contractor shall make his own arrangements for storing water, if necessary, in
drums or tanks or cisterns, to the approval of the Engineer. Care shall be
exercised to see that water is not contaminated in any way.
iii Testing
Before starting any concreting work and wherever the source of water changes,
the water shall be tested for its chemical and other impurities to ascertain its
suitability for use in concrete for approval of the Engineer. No water shall be used
until tested and found satisfactory. Cost of all such Tests shall be borne by the
contractor.

1.9.1 Workmanship

All works shall be true to level, plumb and square and the corners, edges and arises in all
cases shall be unbroken and neat.
Any work not to the satisfaction of the Engineer or his representative will be rejected and
the same shall be rectified, or removed and replaced with work of the required standard of
workmanship at no extra cost.

1.10 Load Testing on Completed Structures

During the period of construction or within the defect liability period the Engineer may at
his discretion order the load testing of any completed structure or any part thereof if he
has reasonable doubts about the adequacy of the strength of such structure for any of the
following reasons:
a) Results of compressive strength on concrete test cubes falling below the
specified strength.
b) Premature removal of formwork.
c) Inadequate curing of concrete.
d) Over loading during the construction of the structure or part thereof.
e) Carrying out concreting of any portion without prior approval of the Engineer.
f) Honey combed or damaged concrete, which in the opinion of the Engineer is
particularly weak and will affect the stability of the structure to carry the design
load, more so in important or critical areas of the structure.
g) Any other circumstances attributable to alleged negligence of the contractor
which in the opinion of the Engineer may result in the structure or any part
thereof being of less than the expected strength.
All the loading tests shall be carried out by the contractor strictly in accordance with the
instructions of the Engineer, IS: 456 and as indicated hereunder. Such tests shall be
carried out only after expiry of minimum 28 days or such longer period as directed by the
Engineer.
The structure shall be subjected to a super-imposed load equal to 1.0 times the specified
superimposed load assumed in the design. This load shall be maintained for a period of
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24 hours before removal. During the test, struts strong enough to take the whole load shall
be placed in position leaving a gap under the members as directed. The deflection due to
the superimposed load shall be recorded by sufficient number of approved deflectometers
capable of reading up to 1/500 of a cm and located suitably under the structure as
directed by the Engineer.
The structure shall be deemed to have passed the test if the maximum deflection at the
end of 24 hours of loading does not exceed the deflection given by the following
expressions:
D = 0.001 L2/25 T, where,
D = max deflection due to imposed load only
L = span of the member under load test (the shorter span in case of slabs).
The span is the distance between centres of the supports or the clear distance between
the supports plus the depth of the member, whichever is smaller. In case of cantilever, this
shall be taken as twice the distance from the support to the end and deflection shall be
adjusted for movement of the support.
T = depth of member.
If within 24 hours of the removal of the superimposed load, the structure does not recover
at least 75% of the deflection under the superimposed load, the test loading shall be
repeated after a lapse of 72 hours. If the recovery after the second test is less than 80% of
the maximum deflection shown during the second test, the structure shall be considered
to have failed to pass the test and shall be deemed to be unacceptable.
In such cases the portion of the work concerned shall be taken down or cut out and
reconstructed to comply with the specifications. Other remedial measures may be taken to
make the structure secure at the discretion of the Engineer. However such remedial
measures shall be carried out to the complete satisfaction of the Engineer.
All costs involved in carrying out the tests (except integrity test for piles) and other
incidental expense thereto shall be borne by the contractor regardless of the result of the
tests. The contractor shall take down or cut out and reconstruct the defective work or shall
make the remedial measures instructed at his own cost.
If the load testing is instructed on any ground other than mentioned in a) to g) as
mentioned above, then the cost of the same shall be reimbursed if the result of the test
are found to be satisfactory.
In addition to the above load tests, non-destructive test methods such as core test and
ultrasonic pulse velocity test shall be carried out by the contractor at his own expense if so
desired by the Engineer. Non-destructive testing of piles will be paid as per BOQ. Such
tests shall be carried out by an agency approved by the Engineer and shall be done using
only recommended testing equipment. The acceptance criteria for these tests shall be as
specified by the testing agency or good engineering practice and as approved by the
Engineer.

1.11 Structural Work

i. Unless specified, only controlled concrete with design mix and weigh batching is
to be used for the work.
ii. Minimum cement content specified in CPWD specification 2009 (with upto date
corrections slip) is purely from durability point of view. Larger content of cement
shall have to provide if demanded by mix design.
iii. Provision of cement slurry to create bond between plain / reinforced concrete
surface and subsequent applied finishes shall not be paid extra.
iv. Mix design using smaller aggregates of 10mm down shall also be done in
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advance for the use in the junction having congested reinforcement.

v. Procedure of mixing the admixtures shall be strictly as per the manufacturer’s
recommendations if not otherwise directed by the Engineer.
vi. All the water tanks and other liquid retaining concrete structures shall undergo
hydro-testing.
vii. Special benches shall be provided at site for stacking reinforcement bars of
different sizes.
viii. Formwork for beams of RCC areas shall be designed in such a way that the
formwork of the adjacent slabs can be removed without disturbing the props /
supports of the beams.
ix. Wherever there are tension / suspended concrete members which are
suspended from upper level structural members, the shuttering / scaffolding of
such members at lower level shall have to be kept in place till the time the upper
level supporting members gain minimum required strength. Cost of such larger
duration of keeping in place the shuttering/scaffolding shall be deemed to be
included in the price quoted for respective structural members.
x. Formwork is required for full height at all locations. Special precaution for such
tall formwork shall be taken to ensure its safety. Extra costs for such formwork
shall be deemed to have been included in the price quoted against relevant
items.
xi. In the mobilisation period, the contractor shall carry out expeditiously and without
delay the following works:
(a) Material testing and mix designs of concrete as contemplated in the
specifications.
(b) Setting up of full fledged site laboratory as per the requirements of these
specifications.
(c) Any other pre-requisite items required for final execution.
(d) Site office for the use of the Engineer staff.
(e) Casting yard with full facilities.
xii. Casting yard to have following minimum facilities:
a) Casting beds as required.
b) All handling facilities for pre-cast elements.
c) Curing arrangements as required.
d) Stacking arrangements for pre-cast elements.
e) Storing of materials.
f) Proper drainage and approach roads.

1.12 Survey Work

The said work involves at the very start of work taking-over of reference point from the
Engineer, establishment of control points, triangulation points, bench marks, grid layout for
all the piers/column and other structures maintaining horizontal and vertical control within
the permissible limits, incorporating changes (if any), submission of full data in the
tabulation form and survey drawings including setting and layout of various works during
the progress of work.
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1.13 Transplantation of Trees

The item shall be carried out as per the approved plan by the Engineer after the
identification of the trees to be transplanted. The actual number of trees shall be finalized
after the necessary clearances by the concerned departments. The item is complete and
including all expenditures for carrying out all operations i.e. excavation, watering, feeding
of chemicals, back filling, lifting of trees by crane and transporting to the designated site
where it is to be transplanted and all necessary care to be taken for the specified initial
period till the tree gets settled at new site and up to the full satisfaction of the Engineer.
Measurements
The item shall be measured in numbers according to size of the tree as specified in the
item and the full payment shall be released only when the item is executed fully as per the
Scope of Work detailed out in the approved plan for transplantation of trees.
The rate shall include all required operations during the transplantation and specified
duration afterwards, clearances from the concerned authorities.

1.14 Finishing Work

1.14.1 Sub-Contractor

Works dealing with proprietary materials/ products may be carried out by the Contractor
through the Sub-Contractors as may be approved by the Engineer in writing. The Sub-
Contractors must be firms of repute and long standing, having adequate experience and
complete facilities to carry out all items of work required for completion as per
Specifications and expected quality to the satisfaction of the Engineer. The Sub-
Contractor must also have personnel experienced in preparing shop drawings. All such
works shall be carried out under the direct supervision of the manufacturers of the
proprietary materials/ products or their trained and accredited licensee. Works amounting
to minimum Rs. 10,00,000/- value could be sub-contracted after seeking approval from
the Engineer-In-Charge. Few of the works that could be sub-contracted are as follows:
Waterproofing
Caulking & Sealants
Seismic Joints
Expansion joints
Application of Silicone water repellent solution where specified.
Bearings

1.14.2 Guarantees and Building Maintenance for Finishes

The Contractor shall guarantee and undertake to maintain and rectify the various
components of the Civil Works for their successful performance for the periods as
specified below. The Contractor shall indemnify the Engineer for a similar period against
any damage to property and injury to persons on account of any defective work or
maintenance carried out by the Contractor. The format and text of the Guarantee and the
Indemnity Bond shall be as followed in CPWD or as approved by the Engineer.
Waterproofing for basements (which include raft, retaining walls, and
expansion/separation joints in retaining walls) and roofs shall be guaranteed for 7 years.
The waterproofing shall include all allied works on the roof such as concrete screed and
the China Mosaic roof finish/ stone cladding on the parapet between which the
waterproofing treatment shall be sandwiched.

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Waterproofing for the other areas such as toilets, kitchens, chhajjas etc. shall be
guaranteed for 7 years. The waterproofing shall include all allied works on the slab etc.
such as concrete/ mortar screeding, if any, floor finish between which the waterproofing
treatment shall be sandwiched.

1.14.3 Responsibility for Shop drawings, Samples and Mock-ups

Approval of shop drawings, samples and mock-ups for the various components shall not
absolve the Contractor of his responsibility of completing the work to the specifications,
standards, tests for performance and guarantees given in these documents and to a
quality of finish as desired by the Engineer.

1.14.4 Cleaning

Surfaces on which finishes are to be provided shall be cleaned with water jets or oil free
compressed air or power tools with wire brushes and detergents all as approved by the
Engineer.

1.14.5 Expansion bolts/ fasteners:

i. Unless specified otherwise all expansion bolts/ fasteners shall be fabricated from
stainless steel sheet, strip or plate conforming to ASTM A 240 Gr 304 or bar to
ASTM A 479 Gr 304 of approved make and design. The material of the bolt shall
not cause any bimetallic corrosion with the reinforcing bars of the RCC/ brickwork
or with any other fixings or doors or windows or skylights etc.
ii. For steel backings the fasteners shall be prevented from contact with other
metals, which would lead to bimetallic corrosion.
iii. For brick masonry backing the sleeves of the expansion bolts shall be fixed in
wedge shaped pockets having an area of 75mm x 75mm at the surface and
100mm x 100mm at the inner surface and shall be 125mm deep. The wedge could
also be as a truncated cone of 75mm dia / 100mm dia. The dimensions shall be
reviewed by the Engineer during execution of the work. The wedge shall be filled
with PCC 1:1:2 (1 Cement, 1 Sand and 2 Coarse Aggregate) mixed with non-
Shrink Compound in the proportion as recommended by the manufacturer.
iv. The holes drilled for the expansion fasteners shall be cleaned of all ground
material, dust, etc. before inserting the expansion sleeves.
v. All expansion bolts fixed into soffits shall be bonded to the backing with epoxy/
polyester resin of approved make.
vi. All expansion bolt fixings shall be tightened in accordance with the recommended
torque figures by the manufacturer. Where such values are not available the
Contractor shall test at least 6 samples to determine the safe torque values. All
bolts shall be tightened using torque spanner/ wrenches. All bolts shall be checked
24 hours (minimum) after installation and retightened if necessary.
No walls, terraces shall be cut for making any opening after water proofing has been done
without written approval of the Engineer. Cutting of waterproofing when authorised by the
Engineer in writing shall be done very carefully so that no other portion of the
waterproofing is damaged. On completion of the work at such places, the water proofing
membrane shall be made good and ensured that the opening / cutting is made fully water
proof as per specifications and details of water proofing approved by the Engineer at no
extra cost. No structural member shall be cut or chased without the written permission of
the Engineer.

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Provision of grooves in plaster, drip courses etc, if directed, at junction of walls-ceilings,

columns-walls, frames-plaster and such other generally typical locations shall not be paid
extra, including grooves in concrete, masonry, stonework.

1.14.6 Applicable Codes, Standards & Publications for Structural & Architectural
Work

The more important Codes, Standards and Publications to Contract are listed here under:

A General
IS: 875 (Part 3) Code of practice for design loads (other than
earthquake) for buildings and structures
IS: 1200 Methods of measurement of building and
Civil engineering works
IS: 1237 Specification for cement concrete flooring
tiles
IS: 1322 Bitumen felts for water proofing and damp-
proofing
IS: 1893 Criteria for earthquake resistant design of
structures
IS: 2185 (Part 1) Concrete masonry units: Hollow and solid
concrete blocks
IS: 2185 (Part 2) Concrete masonry units: Hollow and solid
light weight concrete blocks
IS: 2185 (Part 3) Concrete masonry units: Autoclaved cellular
aerated concrete blocks
IS: 2572 Code of Practice for construction of hollow
concrete block masonry
IS: 3414 Code of practice for design and installation of
joints in buildings
IS: 3462 Specification for unbacked flexible PVC
flooring
IS: 5318 Code of practice for laying of flexible PVC
sheet and tile flooring
IS: 6408 (Parts 1,2) Recommendations for modular co-ordination
in building industry – tolerances
IS: 8183 Bonded mineral wool
IS:10958 General check list of functions of joints in
building
IS:11817 Classification of joints in buildings for
accommodation of dimensional deviations
during construction
IS:11818 Method of test for laboratory determination of
air permeability of joints in buildings
IS:12440 Precast concrete stone masonry blocks
CPWD Specifications 96 with up-to-date correction
slips

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BS:476 (Part 7) Method for classification of the surface

spread of flame of products
BS:476 (Part 20) Method of determination of the fire resistance
of elements of construction (general
principles)
BS:476 (Part 22) Methods for determination of the fire
resistance of non-load bearing elements of
construction
BS: 1245 Specification for metal door frames (steel)
BS: 3261 Specification for unbacked flexible PVC
flooring
BS:3261:Part 1 Homogeneous flooring
BS:5215 Specification for one-part gun grade
polysulphide-based sealants
BS:5606 Guide to accuracy in building
BS:5725 (Part 1) Specification for panic bolts and panic
latches mechanically operated by a
horizontal push-bar
BS:6093 Code of practice for the design of joints and
jointing in building construction
BS:8200 Code of practice for the design of non-load
bearing external vertical enclosure of building
ASTM C 332 Specification for light weight aggregate for
insulating concrete
ASTM C 635 Specification for the manufacture,
performance and testing of metal suspension
systems for acoustical tile and lay-in panel
ceilings
SP 7 National Building Code of India
SP 23 (S&T) Hand Book on Concrete Mixes
B Bitumen
IS:702 Industrial Bitumen
IS:3384 Specification for bitumen primer for use in
waterproofing and damp-proofing
C Building Construction Practices
IS: 1838 Parts I and II. Specifications for preformed fillers for
expansion joint in concrete pavements and
structures.
IS: 1946 Code of Practice for use of fixing devices in
walls, ceilings, and floors of solid
construction.
IS: 3414 Code of Practice for design and installation of
joints in buildings.
IS: 6509 Code of Practice for installation of joints in
concrete pavements.
IS: 11134 Code of Practice for setting out of buildings.

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IS: 11433 Parts I and II. Specifications for one part Gun
grade polysulphide based joint sealant.
IS: 12200 Code of Practice for provision of water stops
at transverse contraction joints in masonry
and concrete dams
D Cement
IS: 269 33 grade ordinary Portland cement
IS: 455 Portland Slag Cement
IS: 650 Specification for standard sand for testing
cement.
IS: 1489 (Part 1) Portland pozzolana cement: Flyash based
IS: 1489 (Part 2) Portland pozzolana cement: Calcined clay
based
IS: 3535 Method of Sampling Hydraulic Cements
IS: 4031 (Parts 1 to 13) Methods of physical tests for
hydraulic cement.
IS: 4032 Method of chemical analysis of hydraulic
cement.
IS: 6925 Methods of test for determination of water
soluble chlorides in concrete admixtures.
IS: 8042 White Portland Cement
IS: 8112 Specification for 43 grade ordinary Portland
cement.
IS: 12269 Specification for 53 grade ordinary Portland
cement.
IS: 12330 Specification for sulphate resistant Portland
cement.
IRS: T 40
Indian Railways standard specifications for
special grade cement for use in concrete
sleepers
E Concrete
IS:456 Code of practice for plain and reinforced
concrete.
IS:457 Code of practice for general construction of
plain and reinforced concrete for dams and
other massive structures.
IS:460 (Parts I to III) Specification for Test Sieves
IS:516 Methods of test for strength of concrete.
IS:1199 Methods of sampling & analysis of concrete.
IS:1200 Method of measurement of building and civil
engineering
IS:1343 Code of practice for prestressed concrete
IS:1607 Method of Test Sieving
IS:2386 Parts I-VIII. Methods of tests for aggregates
for concrete.

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IS:2430 Methods of Sampling of Aggregates of

Concrete
IS:2438 Specification for roller pan mixer
IS:2514 Specification for concrete vibrating tables
IS:2571 Code of practice for laying in-situ cement
concrete flooring
IS:2645 Specifications for integral cement water
proofing compounds
IS:2722 Specifications for portable swing batchers for
concrete (double bucket type)
IS:2770 Methods of testing bond in reinforced
concrete part I pull out test
IS:3025 Methods of sampling and test (physical and
chemical) for water & waste water
IS:3370 Code of practice for concrete structures for
storage of liquids
IS:3935. Code of practice for composite construction
IS:4326 Code of practice for earthquake resistant
construction of building
IS:6925. Methods of test for determination of water
soluble chlorides in concrete Admixtures
IS:7242 Specifications for concrete spreaders
IS:7251 Specifications for concrete finishers
IS:7861 Parts I & II. Code of practice for extreme
weather concreting.
IS:7969 Safety code for handling and storage of
building materials
IS:8989 Safety code for erection of concrete framed
structures
IS:8142 Methods of test for determining setting time
of concrete by penetration resistance
IS:9103 Specifications for admixtures for concrete
IS:9013 Method of making, curing and determining
compressive strengths of accelerated cured
concrete test specimens
IS:9284 Method of test for abrasion resistance of
concrete
IS:10262 Recommended guidelines for concrete mix
design.
MORTH Specifications for Road and Bridge Works,
Ministry of Road Transport and Highways
(Roads Wing)
IRS Concrete Bridge Code
IRC 21-2000 Standard Specifications and Code of Practice
for Road Bridges Section III – Cement
Concrete (Plain & Reinforced)(First Revision)

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IRC:18-2000 Design criteria for Prestressed Concrete

Road Bridges (Post –Tensioned Concete)
Ready Mix Concrete
ASTM - C - 94
F Construction Plant and Machinery.
IS:1791 Specification for batch type concrete mixers.
IS:2505 General requirements for concrete vibrators:
Immersion type.
IS:2506 General requirements for screed board
concrete vibrators.
IS:3366 Specification for pan vibrators.
IS:3558 Code of Practice for use of immersion
vibrators for consolidating concrete.
IS:4656 Specifications for form vibrators for concrete.
IS:4925 Specification for concrete batching and
mixing plant.
IS:11993 Code of Practice for use of screed board
concrete vibrators.
G Formwork
IS:4990 Specifications for plywood for concrete
shuttering work.
IRC:87 Guidelines for the design and erection of
false work for road bridges.
IS:806 Code of practice for use of steel tubes in
general building construction.
IS:1161 Specification of steel tubes for structural
purposes.
IS:1239 Specification for mild steel tubes, tubulars
and other wrought steel fittings.
H Gypsum and Gypsum Board
IS:2095 Gypsum plaster boards
IS:2542 (Part 1/Sec 1 to Methods of test for gypsum plaster, concrete
12) and products: plaster and concrete
IS:2542 (Part 2/Sec 1 to Methods of test for gypsum plaster, concrete
8) and products: Gypsum products
IS:2547 (Part 1) Gypsum building plaster: Excluding premixed
lightweight plaster
IS:2547 (Part 2) Gypsum building plaster: Premixed
lightweight plaster
I Handling and Storage
IS:4082 Recommendation of Stacking and Storage of
construction materials
IS:8348 Code of practice for stacking and packing of
stone slabs for transportation
IS:8759 Code of practice for maintenance and
preservation of stones in building

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J Instruments For Testing Cement and

Concrete
IS:5513 Specification for vicat apparatus.
IS:5514 Specification for apparatus used in Le-
Chaterlier test.
IS:5515 Specification for compaction factor
apparatus.
IS:7320 Specification for concrete slump test
apparatus.
IS:7325 Specification for apparatus to determine
constituents of fresh concrete.
IS:10080 Specification for vibration machine.
IS:10086 Specification for moulds for use in tests of
cement and concrete.
IS:10510 Specification for vee-bee consistometer.
K Joint Fillers
IS:1838 (Part 1) Preformed fillers for expansion joint in
concrete pavements and structures (non
extruding and resilient type): Bitumen
impregnated fibre
L Paints and Coatings
IS:102 Ready mixed paint, brushing, red lead, non-
setting, priming
IS:109 Ready mixed paint, brushing, priming,
plaster, to Indian Standard Colour No. 361
and 631 white and off white.
IS:218 Creosote and anthracene oil for use as wood
preservatives
IS:347 Varnish, shellac, for general purpose.
IS:348 French Polish
IS:2074 Ready mixed paint, air drying, red oxide-zinc
chrome, priming
IS:4833 Methods of field testing of preservatives in
wood
IS:10013 (Parts 1 to 3) Water soluble type wood preservatives:
IS:10013 (Parts 1 to 3) (Part-1) Acid-copper-chrome preservative
IS:10013 (Parts 1 to 3) (Part-2) Copper-chrome-arsenic wood
preservative
IS:10013 (Parts 1 to 3) (Part-3) Copper-chrome-boron wood
preservative
BS:6496 Specification for powder organic coatings for
application and stoving to aluminium alloy
extrusions, sheet and preformed sections for
external architectural purposes, and for the
finish on aluminium alloy extrusions, sheet
and preformed sections coated with powder
organic coatings

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BS:EN:10152 Specification for electrolytically zinc coated

cold rolled steel flat products. Technical
delivery conditions
ASTM A 164-71 Specification for electrodeposited coatings of
zinc on steel

M Pigment for Cement

BS:1014 Specification for pigments for Portland
cement and Portland cement products
N Reinforcement & Structural Steel
IS:206 Code of Practice for use of Steel Tubes in
General Building Construction
IS:210 Grey Iron Castings
IS:280 Mild steel wire for general engineering
purposes
IS:432 Part I. Mild steel and medium tensile steel
bars. Part II Hard drawn steel wire.
IS:451 Technical Supply conditions for Wood
Screws
IS:806 Code of practice for use of steel tubes in
general building construction
IS:815 Classification coding of covered electrodes
for metal arc welding of structural steels
IS:1239 Specification for mild steel tubes, tubulars
and other wrought steel fittings
IS:1363 Black hexagon bolts, nuts and lock nuts and
black hexagon screws.
IS:1365 Slotted countersunk screws.
IS:1566 (Part I) Specifications for hard-drawn steel
wire fabric for concrete reinforcement.
IS:1786 Specification for high strength deformed steel
bars and wires for concrete reinforcement.
IS:2502 Code of Practice for bending and fixing of
bars for concrete reinforcement.
IS:2629 Recommended practice for hot-dip
galvanising of iron and steel.
IS:2751 Code of Practice for welding of mild steel
plain and deformed bars for reinforced
concrete construction.
IS:4759 Hot-dip zinc coating on structural steel and
other allied products.
IS:5525 Recommendations for detailing of
reinforcement in reinforced concrete works
IS:9417 Recommendations for welding cold-worked
steel bars for reinforced concrete
construction.

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IS:14268 Uncoated stress relieved low relaxation steel

class 2 for Prestressed concrete
IS:226 Structural steel (Standard Quality)
IS:800 Code of practice for use of structural steel in
general building construction.
IS:813 Scheme of symbols for welding.
IS:814 Covered electrodes for metal arc welding of
structural steel. (Part I & Part II)
IS:816 Code of practice for use of metal arc welding
for general construction in mild steel.
IS:822 Code of practice for inspection of welds.
IS:961 Structural steel (High Tensile)
IS:1024 Code of practice for use of welding in bridges
and structures subject to dynamic loading.
IS:1030 Carbon steel casting for General Engineering
Purposes
IS:1120 Coach Screws
IS:1367 Technical Supply Conditions for Threaded
Fasteners
IS:1161 Steel tubes for structural purposes.
IS:1182 Recommended practice for radiographic
examination of fusion welded butt joints in
steel plates.
IS:1915 Code of Practice for Steel Bridges
IS:2016 Plain Washers
IS:2062 Structural steel (Fusion welding quality)
IS:3063 Single Coil Rectangular Section Sprint
Washers for Nuts, Bolts and Screws
IS:3443 Crane Rail Sections
IS:3757 Specification for high tensile friction grip
bolts.
IS:5624 Specification for foundation bolts.
IS:3600 Code of practice for testing of fusion welded
(Part I) joints and weld metal in steel.
IS:4923 Hollow steel sections for structural use.
IS:6227 Code of practice for use of metal arc welding
in tubular structure.
IS:801 Code of practice for use of cold formed light
gauge steel structural members in general
building construction.

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IS:811 Specifications for cold formed light gauge

structural steel sections.
Structural Steel Micro alloyed (Medium and
IS:8500
high strength qualities)

IS:8910
General requirements of supply of weldable
structural steel
IS:9595 Recommendations for metal arc welding of
carbon & carbon-Mangnese steels

O Sand
IS:383 Coarse and fine aggregates from natural
sources for concrete.
P Scaffolding
IS:2750 Specification for steel scaffoldings
IS:3696 (Part 1) Safety Code of scaffolds and ladders:
Scaffolds
IS:3696 (Part 2) Safety Code of scaffolds and ladders:
Ladders
IS:4014 (Part 1) Code of practice for steel tubular scaffolding:
Definition and materials
IS:4014 (Part 2) Code of practice for steel tubular scaffolding:
Safety regulations for scaffolding
Guidelines for the design and erection of
IRC:87
falsework for road bridges
Q Sealants
IS:10959 Glossary of terms for sealants for building
purposes
IS:11433 (Part 1) One part grade polysulphide base joint
sealant: General requirements
IS:11433 (Part 2) One part grade polysulphide base joint
sealant: Methods of test
IS:13055 Methods of sampling and test for anaerobic
adhesives and sealants
BS:5889 Specification for one part gun grade silicone-
based sealants.
R Wood
IS:303 Plywood for General Purposes
IS:848 Synthetic resin adhesives for plywood
(phenolic and aminoplastic)
IS:1141 Seasoning of Timber – Code of Practice
IS:1328 Veneered decorative plywood
IS:1659 Block Boards
IS:2046 Decorative thermosetting synthetic resin
bonded laminated sheets

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IS:2202 (Part 1) Wooden flush door shutters (solid core type):

Plywood face panels
IS:2202 (Part 2) Wooden flush door shutters (solid core (type):
Particle face panels and hardboard face
panels
S Bearing
IRC:83Part-II Standard specifications and code of practice
for road bridges Elastomeric Bearings
Standard specifications and code of practice
IRC:83 Part-III
for road bridges Pot Bearings

T PILING

IS :2911 PART-I
IRC:78 Bored Cast in-situ Concrete Piles
Standard specifications and code of practice
for road bridges Foundation And
Substructure
U All Indian Railway Standards
V Metal
IS:276 Austenitic manganese steel castings
IS:733 Wrought aluminium and aluminium alloy bars,
rods and sections for general engineering
purpose.
IS:737 Specifications for wrought aluminium and
aluminium alloy sheet and strip for general
engineering purpose.
IS:3614 (Part 1) Specification for fire check doors: Plate metal
covered and rolling type
IS:3614 (Part 2) Specification for metallic and non-metallic fire
check doors: Resistance test and
performance criteria
IS:7196 Hold Fasts
ASME Sect 2 Part A Ferrous Material Specifications
ASTM B 221 Specification for aluminium-alloy extruded
bars, rods, wires, shapes, and tubes
BS:4873 Specification for Aluminium alloy windows
BS:7352 Specification for strength and durability
performance of metal hinges for side hanging
applications and dimensional requirements
for template drilled hinges
BS EN:10143 Specification for continuously hot-dip metal
coated steel sheet and strip. Tolerances on
dimensions and shape
W Glazing
BS:952 (Part 1) Glass for glazing: classification

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BS:952 (Part 2) Glass for glazing: Terminology for work on

glass
BS:4315 (Part 2) Methods of Test for Resistance to Air and
water penetration: Permeable walling
constructions (water penetration)
BS:5368 (Part 1) Method of testing Windows: Air permeability
test
BS:5368 (Part 2) Method of testing Windows: Watertightness
test under static pressure
BS:5368 (Part 3) Method of testing Windows: Wind resistance
tests
BS:5368 (Part 4) Method of testing Windows: Form of test
report
BS:5713 Specification for Hermetically sealed flat
double glazing units
BS:6262 Code of practice for glazing for buildings
BS:6262 (Part 4) Glazing for buildings: Code of practice for
safety, Human impact
BS:6375 (Parts 1) Performance of windows: Classification for
weathertightness (including guidance on
selection and specification)
BS:6375 (Parts 2) Performance of windows: Specification for
operation and strength characteristics
DIN:1249 (Part 12) Glass for use in building construction;
toughened glass; dimensions, working and
requirements
JIS:R 3203 Float and Polished Plate Glasses
ASTM E 283 Test method for determining the rate of air
leakage through exterior windows, curtain
walls, and doors under specified pressure
differences across the specimen
ASTM E 330 Test method for structural performance of
exterior windows, curtain walls, and doors by
uniform static air pressure difference
ASTM E 331 Test method for water penetration of exterior
windows, curtain walls, and doors by uniform
static air pressure difference
X Stone and Facings/ Linings
IS:1121-(Parts 1 to 4) Methods of test for determination of strength
properties of natural building stones
IS:1121-(Parts 1 to 4) (Part-1 Compressive strength)
IS:1121-(Parts 1 to 4) (Part-2 Transverse strength)
IS:1121-(Parts 1 to 4) (Part-3 Tensile strength)
IS:1121-(Parts 1 to 4) (Part-4 Shear strength)
IS:1122 Method of test for determination of true
specific gravity of natural building stones.
IS:1123 Method of identification of natural building
stones.

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IS:1124 Method of test for determination of water

absorption, apparent specific gravity and
porosity of natural building stones.
IS:1125 Method of test for determination of
weathering of natural building stones.
IS:1126 Method of test for determination of durability
of natural building stones.
IS:1127 Recommendations for dimensions and
workmanship of natural building stones for
masonry work.
IS:1128 Specification for Limestone (Slabs and Tiles)
IS:1129 Recommendation for dressing of natural
building stones.
IS:1130 Specification for marble (blocks, slabs and
tiles).
IS:1597 (Part 2) Code of practice for construction of stone
masonry: Ashlar masonry
IS:1706 Method for determination of resistance to
wear by abrasion of natural building stones
IS:1805 Glossary of terms relating to stones,
quarrying and dressing
IS:3620 Specification for laterite stone block for
masonry
IS:3622 Specification for Sandstone (slab & tiles)
IS:4101 (Part 1) Code of practice for external facing and
veneers: stone facing
IS:4101 (Part 2) Code of practice for external facing and
veneers: Cement concrete facing
IS:4101 (Part 3) Code of practice for external facing and
veneers: Wall tiling and mosaics
IS:4121 Method of test for determination of water
transmission rate by capillary action through
natural building stones
IS:4122 Method of test for surface softening of natural
building stones by exposure to acidic
atmospheres
IS:4348 Method of test for determination of
permeability of natural building stones
IS:5218 Method of test for toughness of natural
building stones
IS:8381 Recommended practice for quarrying stones
for construction purposes
IS:14223 (Part 1) Polished building stones: Granite
BS: 8298 Code of practice for design and installation of
natural stone cladding and lining

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2. EARTHWORK IN EXCAVATION AND BACKFILLING

2.1 General

These specifications shall be read in conjunction with the CPWD specifications 2009 with
up to date correction slips and other relevant specifications described under Standard
Specifications.
Excavation of rock may be carried out by chiselling, jack hammers, crow bars, wedging
and using cutting machine or by any other method approved by the Engineer. Use of non-
explosive demolition compounds shall also be permitted.
Open blasting is not permitted under scope of this contract but at discretion of the
Engineer, Controlled blasting may be permitted only in very special cases where all
alternative methods have failed to achieve the satisfactory results. Contractor shall take all
necessary precautions to prevent flying of blasted stones outside the excavation pit and
damage to adjacent structure etc by controlling spacing and quantity of explosive charge
and covering the sufficient area of blasting by steel plates loaded with adequate number
of sand bags. All operations of controlled blasting shall be carried out under the
supervision of a responsible authorised blasting agent. Contractor shall be responsible for
any damage arising out of blasting operation to workmen, public or any property.
Contractor shall obtain all necessary permission from Traffic Police and other concerned
authorities for blasting as required. Non-granting of permission for blasting by concerned
authorities will not be considered as reason for delay or any claim thereof.
Excavation for all works and of materials required for filling shall be to the exact width,
length and depth shown on the drawings or as directed by the Engineer. Where the nature
of soil or the depth of the trench and season of the year, do not permit vertical sides, the
contractor at his own expense shall put up the necessary shoring, strutting and planking
with due regard to the safety of personnel and works and to the satisfaction of the
Engineer.
If excavation is carried out to greater depth than required beyond the level specified, for
any reason whatsoever, such volume shall be made good by filling with PCC M15 having
coarse aggregates 40 mm and downgraded and brought to level to receive the levelling
course below foundations by the contractor at no extra cost to the employer. If excavation
is carried out to greater width and length, such extra width and length shall be filled in by
Jamuna sand by the contractor at his own cost. No claim in this regard will be entertained
Propping shall be undertaken when any foundation or stressed zone from an adjoining
structure is within a line of 1 vertical to 2 horizontal from the bottom of the excavation.
All excavations shall be carried out in conformity with the directions laid hereunder and in
a manner approved by Engineer. The work shall be so done that the suitable materials
available from excavation are satisfactorily utilised as decided upon beforehand.
The last 200mm depth of excavation shall be done not earlier than 36 hours before laying
the levelling course below foundations.
The Contractor shall make provision for all shoring, dewatering, dredging, bailing out or
draining water whether subsoil or rain or other water and the excavation shall be kept free
of water while the masonry work or concrete work is in progress and until the Engineer
considers the work well set (Refer IS: 3764 Safety Code for Excavation Work). The sides
of trenches shall be kept vertical and the bottom horizontal and shall be run level
throughout or properly stepped as directed by the Engineer.
Dewatering shall be carried out by suitable means with adequate stand-by arrangements
as may be approved by the Engineer. The level of ground water shall be maintained at
least 300mm below the lowest level of excavation during the laying of foundations. The
Contractor shall be deemed to have satisfied himself with regard to feasibility of all
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aspects of dewatering including site constraints due to existing structures. Though the
method of dewatering is left to the contractor, he shall be required to submit method
statement of dewatering scheme including requisite justifications to the Engineer and seek
his prior written approval. Approval of the Engineer however shall not relieve the
contractor of the responsibility of adequacy and appropriateness of dewatering and
protection arrangements for the quality and safety of the work. The contractor shall satisfy
the Engineer as to the capacity of the drains or disposal site to take the required quantity
and flow of water to be pumped out at various stages of excavation. The Contractor shall
obtain necessary approvals of local bodies for discharging the pumped out water. All the
dewatering pumps shall therefore also have dedicated D.G. Power supply which shall
come on automatically in case of failure of electrical supply from the mains. Monitoring of
water table shall be done using electronic probes located at least one each of the four
corner of excavation.
The Contractor shall erect and maintain during progress of works temporary fences with
all safety measures around dangerous excavations at contractor’s cost.
Near habitations and traffic prone areas, trenches and foundation pits or any other
excavation work shall be fenced, provided with proper caution signs and marked with red
lights, reflectors at night to avoid accidents. The contractor shall take all adequate
protective measures to see that excavation operations do not affect or damage adjoining
structures.
Excavation material required for filling shall be stacked or dumped where indicated by the
Engineer. Excavated material not required for filling and any surplus material shall be
removed or spread on the site as directed by the Engineer or carted away from the site as
directed by the Engineer. Dumping of this surplus material shall be in an orderly
environmental friendly manner using tarpoline cover, dumper, placer etc. and according to
the levels/grades as indicated by the Engineer. The cost of such removal and spreading
shall be borne by the Contractor and deemed to be included in the Contract Rates.
Necessary approval from the local authorities for carting and dumping surplus material is
to be obtained by the contractor.
The Contractor shall notify to the Engineer when the excavation is completed and no base
or Concrete or Masonry shall be laid until the Engineer has inspected and approved of the
soil conditions obtained for each individual footing or the full raft area.
The Contractor shall ensure the stability of the excavation so that the surrounding ground
and all adjoining structures and plants will be safe against settlement, subsidence and
damage and that there is no risk of injury to personnel.
In case any underground structures that need to be protected (like underground sewer
lines etc. ) are encountered, the Contractor shall bring the same to the notice of the
Engineer immediately and shall take all such steps as the Engineer may instruct for
protection of such structures. Such protective measures shall be done at the Contractor’s
cost. If any damage occur to such items which were required to be protected during
execution, the same shall be made good by contractor at his own cost otherwise client will
arrange to make it good at the risk and cost of contractor.
The Contractor may dispose off the surplus earth from the project site to a place/ places
as may be permitted by the Engineer. The transportation of the surplus earth shall be
done by mechanical means only. The Contractor shall at his own cost obtain necessary
clearances/ permissions statutory or otherwise needed for the purpose. Dumpers may be
used for transporting slushy, material excavated from pile boring / Open Foundation with
precautions for non spillage of muck.
In the foundation the backfilling shall be done in layers not more than 150mm thick and
shall be thoroughly watered and consolidated by approved method.

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2.2 Measurement and Payment

All excavation shall be measured net. Dimensions for purpose of payment shall be
reckoned on the plan PCC area of the excavation multiplied by the mean depth from the
surface of the ground in accordance with the Drawings. No extra payment is admissible
for any working space, beyond concrete dimensions and shuttering wherever required in
excavation. All over-excavation shall be made good by Contractor at his cost. No claim in
this regard will be entertained

2.3 Filling and Backfilling

2.3.1 General

All fill material will be subject to Engineer's approval. If any material is rejected by
Engineer, Contractor shall remove the same forthwith from the site at no extra cost to the
employer. Surplus fill material shall be deposited / disposed off as directed by Engineer
after the fill work is completed.
No earth fill shall commence until surface water discharges and streams have been
properly intercepted or otherwise dealt with as directed by Engineer.

2.3.2 Material

To the extent available, selected surplus spoils from excavated materials shall be used as
backfill. Fill material shall be free from clods, salts, sulphates, organic or other foreign
material. All clods of earth shall be broken or removed. Where excavated material is
mostly rock, the boulders shall be broken into pieces not larger than 150mm size, mixed
with properly graded fine material consisting of moorum or earth to fill up the voids and the
mixture used for filling.
Filling in pits and trenches around foundations of structures, walls etc.:
As soon as the work in foundations has been accepted and measured, the spaces around
the foundations, structures, pits, trenches etc. shall be cleared of all debris, and filled with
earth in layers not exceeding 150mm., each layer being watered, rammed and properly
consolidated, before the succeeding one is laid. Each layer shall be consolidated to the
satisfaction of Engineer. Earth shall be rammed with approved mechanical compaction
machines. Usually no manual compaction shall be allowed unless Engineer is satisfied
that in some cases manual compaction by tampers cannot be avoided. The final backfill
surface shall be trimmed and levelled to proper profile as directed by Engineer or
indicated on the Drawings.

2.3.3 Filling In Trenches

Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipe
and drains have been tested and passed. The backfilling material shall be properly
consolidated by watering and ramming, taking due care that no damage is caused to the
pipes. Same shall be applied for filling in trenches for cable ducting. Filling of the trenches
shall be carried out simultaneously on both sides of the trench to avoid unequal pressure.
Where the trenches are to be excavated in soil, the filling from the bottom of the trench to
the level of the centreline of the pipe shall be done by hand compaction with selected
approved earth in layers not exceeding 80mm; backfilling above the level of the centreline
of the pipe shall be done with selected earth by hand compaction or other approved
means in layers not exceeding 150mm.

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In case of excavation of trenches in rock, the filling up to a level 300mm above the top of
the pipe shall be done with fine materials, such as earth, murrum, etc. The filling up of the
level of the centreline of the pipe shall be done by hand compaction in layers not
exceeding 80mm whereas the filling above the centreline of the pipe shall be done by
hand compaction or approved means in layers not exceeding 150mm. The filling from a
level 300mm above the top of the pipe to the top of the trench shall be done by hand or
other approved mechanical methods with broken rock filling of size not exceeding 150mm
mixed with fine material as available to fill up the voids.
Filling of the trenches shall be carried simultaneously on both sides of the pipe to avoid
unequal pressure on the pipe.

2.3.4 Filling of Earth

(This specification is as per section 305.3 of MOST specification)

The thickness of each unconsolidated fill layer shall be as per BOQ description. Engineer
will determine the thickness of the layers in which fill has to be consolidated depending on
the fill material and equipment used.
2.3.4.1 Setting out: The limits of embankment/subgrade shall be marked by fixing batter
pegs on both sides at regular intervals as guides before commencing the earthwork.
2.3.4.2 Dewatering: If the foundation of the embankment is in an area with stagnant water,
and in the opinion of the Engineer it is feasible to remove it, the same shall be
removed by bailing out or pumping, as directed by the Engineer and the area of the
embankment foundation shall be kept dry. Care shall be taken to discharge the
drained water so as to cause damage to the works, crops or any other property. Due
to any negligence on the part of the Contractor, if any such damage is caused, it
shall be the sole responsibility of the Contractor to repair/restore it to original
condition or compensate the damage at his own cost. The limits of
embankment/subgrade shall be marked by fixing batter pegs
2.3.4.3 Compacting ground supporting embankment/subgrade:Where necessary, the
original ground shall be levelled to facilitate placement of first layer of embankment,
scarified, mixed with water and then compacted by rolling so as to achieve minimum
dry density as given in Table 300-2 of MOST.
Subgrade work shall not proceed until the foundations for subgrade have been
inspected and approved by the Engineer..
The embankment and subgrade material shall be spread in layers of uniform
thickness not exceeding 200 mm compacted thickness over the entire width of
embankment by mechanical means, finished by a motor grader and compacted as
per Clause 305.3.6. The motor grader blade shall have hydraulic control suitable for
initial adjustment and maintain the same so as to achieve the specific slope and
grade.
Moisture content of the material shall be checked at the site of placement prior to
commencement of compaction; if found to be out of agreed limits, the same shall be
made good. The water shall be added uniformly and thoroughly mixed in soil by
blading, discing or harrowing until a uniform moisture content is obtained throughout
the depth of the layer. Embankment and other areas of fill shall, unless otherwise
required in the Contract or permitted by the Engineer, be constructed evenly over
their full width and their fullest possible extent and the Contractor shall control and
direct construction plant and other vehicular traffic uniformly over them.
Whenever fill is to be deposited against the face of a natural slope, or sloping
earthworks face including embankments, cuttings, other fills and excavations
steeper than 1 vertical on 4 horizontal, such faces shall be benched as per Clause
305.4.1 immediately before placing the subsequent fill.

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2.3.5 Compaction:

Only the compaction equipment approved by the Engineer shall be employed to compact
the different material types encountered during construction. Smooth wheeled, vibratory,
pneumatic tyred, sheepsfoot or pad foot rollers, etc. of suitable size and capacity as
approved by the Engineer shall be used for the different types and grades of materials
required to be compacted either individually or in suitable combinations.
The compaction shall be done with the help of vibratory roller of 80 to 100 KN static
weight with plain or pad foot drum or heavy pneumatic tyred roller of adequate capacity
capable of achieving required compaction.
Each layer of the material shall be thoroughly compacted to the densities specified in
Table 300-2 of MOST specifications. Subsequent layers shall be placed only after the
finished layer has been tested according to Clause 903.2.2 of MOST specifications and
accepted by the Engineer. The Engineer may permit measurement of field dry density by
a nuclear moisture/density gauge used in accordance with agreed procedure and the
gauge is calibrated to provide results identical to that obtained from tests in accordance
with IS : 2720 (Part 28). A record of the same shall be maintained by the Contractor.
When density measurements reveal any soft areas in the subgrade/earthen shoulders,
further compaction shall be carried out as directed by the Engineer.
(For any specification that is not included in the above mentioned specification please
refer Section 305.3 of MOST specifications)

2.4 Lead

Lead for disposal of excavated material, shall be as specified in the respective item of
work. For the purpose of measurement of lead, the area to be excavated or filled or area
on which excavated material is to be deposited/disposed off shall be divided into suitable
blocks and for each of the blocks, the distance between centrelines shall be taken as the
lead which shall be measured by the shortest straight line route on the plan and not the
actual route taken by Contractor. No extra compensation is admissible on the grounds
that the lead including that for borrowed material had to be transported over marshy or
'katcha' land.

2.5 Measurement and Payment

Backfilling as per Specification on the sides of foundations of walls, etc. with excavated
material will be paid for separately unless specifically mentioned in the particular item of
Works. Quoted rates for that particular item should include backfilling where it would not
be paid for separately. As a rule, material to be backfilled shall be stacked temporarily
within the basic lead of 50 metres unless otherwise directed by the Engineer. If Engineer
directs / permits a lead of over 50m for such material, the conveyance of the material for
the extra distance over the basic lead of 50m for backfilling will be paid for.

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3. FORMWORK

3.1 General Description

3.1.1 General

This section covers the requirements for providing, fabricating and erecting formwork
including propping, bracing, shoring, strutting, tying, bolting, wedging etc. and all other
supports to the concrete during the process of setting, subsequent removal of forms.

3.1.2 Related Work Specified Elsewhere

Cast-in-place and pre-cast reinforced concrete.

3.1.3 Applicable Codes and Standards

IS: 456 CODE OF PRACTICE FOR PLAIN AND REINFORCED

CONCRETE
IS: 4990 PLYWOOD FOR CONCRETE SHUTTERING WORK
IS: 806 CODE OF PRACTICE FOR USE OF STEEL TUBES IN
GENERALBUILDING CONSTRUCTION.
IS: 1161 SPECIFICATION OF STEEL TUBES FOR STRUCTURAL
PURPOSES.
IS: 1239 SPECIFICATION FOR MILD STEEL TUBES.TUBULAR AND
OTHER WROUGHT STEEL FITTINGS.
IS: 2750 SPECIFICATION FOR STEEL SCAFFOLDINGS.

3.2 Submittals

3.2.1 Type of Formwork

Prior to start of delivery of material for formwork, the contractor shall submit samples of
different types of form work proposed and obtain approval of the Engineer.

3.2.2 Design of Forms

Before fabricating of forms, the contractor shall submit design calculations for proposed
formwork to the Engineer for his approval.
All design submittals of the contractor have to be verified and approved by an
independent agency appointed by the contractor at his cost before submitting to the
clients. Without such verification and approval, submittal by the contractor will be
considered as invalid.
Along with tender submission, contractor must send the name of independent agency and
qualifications that will be subject to DMRC approval.

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3.2.3 Tie Bolts

In case, the contractor proposes to use tie bolts running through the concrete, the location
and size of such ties bolts shall be submitted to the Engineer for his approval.

3.3 Materials

3.3.1 General

Formwork shall be of plywood, or steel capable of resisting damage to the contact

faces under normal conditions of erecting forms, fixing steel and placing concrete. The
selection of materials suitable for formwork shall be made by the contractor based on the
quality consistent with the specified finishes and safety.
All formwork supports (centering, props, scaffolds etc) shall only be in structural steel and
preferably of pipes conforming to IS:806, IS:1161, IS:1239, IS:2750, MORTH
specifications shall be applicable for details as found relevant by the Engineer.
Wooden ballies shall not be permitted as props. All props shall be properly braced using
X and K bracings.

3.3.2 Plywood

Plywood used for formwork shall be minimum 12 mm thick shuttering quality marine
plywood complying with IS :4990 and of make approved by the Engineer. Suitable
stiffeners and walers shall be provided depending on the shuttering design.

3.3.3 Steel

Steel formwork shall be made of 2 mm to 4 mm thick black sheets stiffened with angle iron
frame made out of M.S. Angles supported at suitable spacing to meet the design
requirement.

3.4 Design Criteria

Formwork shall be designed for the loads and lateral pressures due to dead weight of
concrete, superimposed live loads of workmen, materials and plants and for other loads
as indicated on the drawings.
Forms shall be designed to have sufficient strength to carry the hydrostatic head of
concrete as a liquid without deflection tolerances exceeding the acceptable limits.
Where necessary to maintain the tolerances indicated on the drawings, the formwork
shall be cambered to compensate for anticipated deflections due to the weight and
pressure of the fresh concrete, and also due to any other construction loads. Unless
otherwise shown or specified, the camber shall be provided as below:

Type of Member Compression Steel as Camber

% of Tensile Steel Coefficient

Simple span 0% 0.066

50% 0.037
Continuous 0% 0.032
Restrained span 50% 0.020

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3.5 Erection of Formwork

Forms shall be used wherever necessary to confine the concrete during vibration
and to shape it to the required lines. The formwork shall conform to shapes, lines,
levels, and dimensions of the concrete shown on the drawings.
Forms shall have sufficient strength to withstand the pressure resulting from
placement and vibration of concrete and shall be maintained rigidly in position.
Formwork shall be adequately supported by adequate number and size of struts,
braces, ties and props to ensure rigidity of forms during concreting. Where props rest on
natural or filled up ground, to avoid any settlement, the soil shall be thoroughly compacted
and bases of props shall be of sufficient size as to restrict the bearing pressure on the
ground to 5T/sqm.
Forms shall be tight enough to prevent loss of mortar from concrete and to produce a
dense, homogeneous and uniformly coloured concrete completely free from
honeycombing or surface roughness. Joints in formwork shall be designed to prevent
leakage, not only between individual elements forming the panels but also from the
horizontal and vertical junction between the panels themselves. At all joints of panels the
contractor shall provide foam rubber strips of suitable width and thickness to avoid
leakage.
If formwork is held together by bolts or wires, those shall be so fixed that no iron shall be
exposed on surface against which concrete is to be laid. The Engineer may at his
discretion allow the contractor to use tie bolts running through the concrete at his own
cost. Holes left in the concrete by these tie bolts shall be filled as specified by him at the
contractor's expense.
Formwork shall be constructed so as to facilitate loosening and permit removal without
jarring the concrete. Wedges, clamps and bolts shall be used wherever practicable
instead of nails.
All formwork erected shall be approved by the Engineer before concreting is started.

3.6 Cleaning and Oiling of Forms

At the time, concrete is placed in the forms, the surface of the forms in contact with the
concrete shall be free from encrustations of mortar, grout or other foreign material.
Temporary openings shall be left at the bottom of formwork to enable sawdust, shavings,
wire cutting and other foreign material to be worked out from the interior of the forms
before the concrete is placed.
The surface of the forms to be in contact with the concrete shall be coated with an
approved coating that will effectively prevent sticking and will not stain the concrete
surface. After each use the surface of forms in contact with concrete shall be cleaned,
well wetted and treated with form oil approved by the Engineer. Lubricating (machine)
oils shall not be used.
Oiling shall be done before reinforcement has been placed and care shall be taken that no
oil comes in contact with the reinforcement while it is being placed in position.
Immediately before concreting is commenced the formwork shall be carefully examined to
see that all dirt, shavings, sawdust and other refuse have been removed and the formwork
shall be wetted thoroughly to prevent absorption of water from concrete. The formwork
shall be kept wet during concreting and for the whole time that it is left in place.

3.7 Removal of Formwork

Formwork shall be removed carefully so as to prevent damage to the concrete. Wooden

wedges only shall be used between the concrete surface and the form if necessary while

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removal. Metal wedges, bars or tools shall not be used for this purpose. Any concrete
damaged in the process of removing the forms shall be repaired in accordance with the
provisions of concrete specifications.
All non-supporting forms shall be loosened and removed during regular working hours,
and as soon as the concrete has hardened sufficiently to prevent damage from the
removal of the forms. All false work and forms supporting concrete beams and slabs, or
other members subject to direct bending stress, shall not be removed or released until
the concrete has attained sufficient strength to ensure structural stability and to carry
both the dead and live loads including any construction loads which may be placed upon
it.
Unless otherwise permitted in writing by the Engineer, the forms shall not be stripped
before the minimum periods specified in IS:456. However the Engineer may increase the
above period if he considers it necessary for structural stability.
No construction loads exceeding the combination of superimposed dead loads plus
specified live load shall be supported on any unshored portion of the structure under
construction, unless analysis indicates adequate strength to support such additional loads.
Formwork shall be removed in such a manner so as not to impair safety and serviceability
of the structure. It shall be removed gradually to prevent sudden application of loads to
the concrete. All concrete to be exposed by form removal shall have sufficient strength so
as not to be damaged thereby.

3.8 Reuse of Forms

Immediately after the forms are removed, they shall be cleaned with jet of water and a soft
brush before they are reused.
The contractor shall not be permitted reuse of any forms which in the opinion of the
Engineer have worn out and have become unfit for formwork. The Engineer may in his
absolute discretion, order rejection of any forms he considers unfit for use in the works,
and order their removal from the site.

3.9 Formwork for exposed concrete surfaces

Where it is desired, directed or shown on the drawings to have original fair face finish of
concrete surface without any rendering or plastering, formwork shall be carried out by
using plywood or steel plates of approved quality and as per direction of engineer. The
contractor shall use one type of material for all exposed concrete surface and the forms
shall be constructed so as to produce a uniform and consistent texture and pattern on the
face of the concrete. Patches or forms for these surfaces will not be permitted. The
formwork shall be placed so that all horizontal form works are continuous across the entire
surface. If forms are constructed of lumber and are not panelled, the formwork joints shall
be staggered. To achieve a finish which shall be free of board marks, the formwork shall
be faced with plywood or equivalent material in large sheets. The sheets shall be
arranged in an approved pattern. Wherever possible, joints between sheets shall be
arranged to coincide with architectural features, sills, window heads or change in direction
of the surface. All joints between panels shall be vertical or horizontal unless otherwise
directed. Suitable joints shall be provided between sheets. The joints shall be arranged
and fitted so that no blemish or mark is imparted to the finished surfaces. To achieve a
finish which shall give the rough appearance of concrete cast against sawn board,
average 150 mm wide, formwork shall be securely jointed with tongued and grooved joints
if required to prevent grout loss. Sawn boards shall be set horizontally, vertically or at an
inclination shown in the drawings. All bolt holes shall be accurately aligned horizontally
and vertically and shall be filled with matching mortar recessed 5 mm back from the
surrounding concrete face.

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4. REINFORCING STEEL

4.1 General Description

This section covers the requirements for providing, fabricating, delivering, placing and
securing in position of steel reinforcement for all types of concrete work. These
specifications shall be read in conjunction with CPWD specifications 2009 with latest
correction slips MOST/MORTH Specifications and other relevant specifications described
in the section of these specifications.

4.1.1 4.1.1 Related Work Specified Elsewhere

Cast-in-situ and pre-cast reinforced concrete.

The following clauses are intended to amplify the requirements of the reference
documents listed above and the contractor shall comply with these clauses.

4.1.2 4.1.2 Applicable Codes and Standards

- IS: 280 MILD STEEL WIRES FOR GENERAL ENGINEERING

PURPOSES.
- IS: 432 PART I MILD STEEL AND MEDIUM TENSILE STEEL BARS.
PART II HARD DRAWN STEEL WIRE.
- IS: 456 CODE OF PRACTICE FOR PLAIN AND REINFORCED
CONCRETE.
- IS: 814 PARTS I & II ELECTRODES FOR METAL ARC WELDING OF
STRUCTURAL STEEL.
- IS : 816 CODE OF PRACTICE FOR USE OF METAL ARC WELDING FOR
GENERAL CONSTRUCTION IN MILD STEEL
- IS:1566 HARD-DRAWN STEEL WIRE FABRIC FOR CONCRETE
REINFORCEMENT.
- IS: 1786 SPECIFICATION FOR HIGH STRENGTH DEFORMED STEEL
AND WIRES FOR CONCRETE REINFORCEMENT.
- IS: 2502 CODE OF PRACTICE FOR BENDING AND FIXING OF BARS
FOR CONCRETE REINFORCEMENT.
- IS: 2751 CODE OF PRACTICE FOR WELDING OF MILD STEEL PLAIN
AND DEFORMED BARS FOR REINFORCED CONCRETE
CONSTRUCTION.
- IS: 9417 RECOMMENDATIONS FOR WELDING COLD-WORKED STEEL
BARS

All reinforcement work shall be executed in conformity with the drawings supplied and
instructions given by the Engineer and shall generally be carried out in accordance with
the relevant Indian Standard Specifications IS: 2502- Bending and Fixing of Bars for
Concrete Reinforcement. The reinforcement shall be thermo-mechanical treatment (TMT)

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of grade FE 500D and shall conform to IS 1786-2008. The reinforcement steel shall be
from primary producers and no re-rolled steel shall be supplied.

4.1.3 Mechanical couplers of threaded type with enlargement at connection by cold

forging may be used at appropriate locations after prior approval of engineer.

4.1.4In order to offer adequate resistance against corrosion, reinforcement bars shall be
provided with a coating of “ Truncated Inhibited Cement Slurry (Patent No. 109784/67
of CECRI, Karaikudi)” for non-aggressive environments (Mild and Moderate).

4.1.5 Protective coating of reinforcement rods shall conform to IS 9077 and it shall be
approved by the ENGINEER IN CHARGE. Standard IS: 9077 describes the following
methodology:

1. The reinforcement rods should be dipped in the derusting solution of approved

quality and the rods removed as soon as the rust is satisfactorily removed and a
bright surface is obtained. This should be immediately followed by cleaning the
rods with wet waste cloth and alkaline cleaning powder.
2. The rod should then be brushed with the phosphating jelly of approved quality by
means of fibre brush. The jelly should be left n the surface for a period of 45- 60
minutes and then removed by means of wet waste cloth. This should be followed
by brushing the inhibitator solution of approved quality 6 and the first coat of
cement slurry, prepared by mixing 500 cc of inhibitator for each 1000 gm of
Portland cement. All the above steps should be applied in the same day and after
12-24 hours of air –drying the sealing solution of approved quality should be
brushed followed by the second coat of cement slurry.
3. It should then be dried for 12-24 hours followed by a brush coat of the sealing
solution which should be applied again after 4 hours of air-drying.

4.2 Inspection & Testing:

The reinforcement shall be tested and inspected as per IS 1786-2008.Every bar shall be
inspected before assembling on the works and any defective, brittle, excessively rusted or
burnt bars shall be removed. Cracked ends of bars shall be cut out.
No work shall be commenced without the Engineer’s approval of the bar bending
schedule.
Manufacturer's Certificate shall be supplied for each lot of supply.
Specimens sufficient for three Tensile Tests for each different size of bar for each
consignment delivered, or for 10 tonnes of supply of that size, whichever is less shall be
sampled and tested by the Contractor. Batches shall be rejected if the average results of
each batch are not in accordance with the specifications.

4.3 Bar bending and Bar Bending Schedule:

All bars will be carefully and accurately bent by approved means in accordance with
IS:2502, and relevant drawings. It shall be ensured that depth of crank is correct as per
the bar cutting and bending schedule and bent bars are not straightened for use in any
manner that will injure the material.
Prior to starting bar bending work, the Contractor shall prepare bar bending schedule from
the structural drawings supplied to him and get the same approved by Engineer.

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Any discrepancies and inaccuracies found by the Contractor in the drawings shall be
immediately reported to the Engineer whose interpretation and decision there to, shall be
accepted.

4.4 Lapping & Welding:/Mechanical Splicing

1. As far as possible bars of the maximum length available shall be used. Laps shown
on drawings or otherwise specified by the Engineer will be based on the use by the
Contractor of bars of maximum length. In case the Contractor wishes to use shorter
bars, laps/couplers (approved make with permission of DMRC) shall be provided in
the manner and at the locations approved by the Engineer.
2. Bars having butt or lap welds shall be provided as specified in the drawings or as
instructed by the Engineer.

4.5 Spacing, Supporting and Cleaning:

1. All reinforcement shall be placed and maintained in the positions shown on the
drawings to be prepared by contractor.
2. The Contractor shall provide approved types of supports for maintaining the bars in
position and ensuring required spacing and correct cover of concrete to the
reinforcement as specified on the drawings. Cover blocks of required shape and
size, M.S. Chairs and spacer bars shall be used to ensure accurate positioning of
reinforcement. Cover blocks shall be cast well in advance and shall consist of
approved proprietary pre-packaged free flowing mortars (Conbextra HF of Fosroc or
equivalent). They shall be circular in shape for side cover and square for bottom
cover. The cost of cover block shall be deemed to have been included in the rates.
3. Bars must be cleaned, before concreting commences, of all scale, rust or partially
set concrete which may have been deposited there during placing of previous lift of
concrete.
4. Only TMT bars complying to IS:1786 shall be provided .
5. G.I. wire shall be used for binding reinforcement.

4.6 Welding:

1. Wherever specified all lap and butt welding of bars shall be carried in accordance
with IS: 2571. Only qualified welders shall be permitted to carry out such welding.
2. For cold twisted reinforcement welding operations must be controlled to prevent a
supply of large amounts of heat larger than that can be dissipated. The extreme non
twisted end portion shall be cut off before welding. Electrodes with rutile coating
should be used.
3. Bars shall be free from rust at the joints to be welded.
4. Slag produced in welding after alternative run should be chipped and removedby
brush.
5. Electrode should not be lighted by touching the hot bar.
6. The welding procedure shall be approved by the Engineer and tests shall be made
to prove the soundness of the welded connection.
7. E7018 electrode shall be used for Fe415 grade and E8018 electrode shall be used
for Fe500 above as per AWS (American Welding Society) standards.

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4.7 Measurement:

1. The weight of steel to be paid for at the contract rates shall be the weight of bars as
mentioned on the drawings or as instructed by the Engineer including stirrups, ties,
spacer bars, chairs and any other steel works specified as reinforcement but
excluding binding wire and cover blocks. Laps as specified on the drawings shall be
paid for. Laps required because of the contractor's use of shorter bars will not be
paid for.
2 The weight of any stirrup, tie bar shall be computed from the dimensions given on
the drawings or bending schedules. The weight in kg/metre shall be taken as 0.785
kg/metre per 100mm2 of cross section. The rate shall take into account the rolling
margin.

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5. CONCRETE: PLAIN AND REINFORCED

These specifications shall be read in conjunction with the CPWD specifications 2009 with
upto date correction slips, MOST/MORTH Specifications and other relevant specifications
described in the section 1.1 of these specifications.
Unless specifically mentioned in these specifications, it is to be understood that ALL
expenses incurred by the CONTRACTOR, including materials; tools; plants and
equipments; labour, cartage, conducting of related tests etc. in executing the work
according to these specifications are covered in the rates quoted by him for the items of
works.

5.1 Materials

Before bringing to the site, all materials for cement concrete shall be approved by the
Engineer. All approved samples shall be deposited in the office of the Engineer before
placing orders for the materials with suppliers. The materials brought on to the works shall
conform in every respect to their approved samples.
Fresh samples shall be deposited with Engineer whenever type or source of any material
changes. The contractor shall check fresh consignment of materials as it is brought on to
the works to ensure that they conform to the specifications and/or approved samples.
The Engineer shall have the option to have any of the materials tested to find whether
they are in accordance with specifications at the contractor’s expense. All bills vouchers
and test certificates which in the opinion of the Engineer are necessary to convince him
as to the quality of materials or their suitability shall be produced for his inspection as
and when required.
Any material, which has been found to conform to the specifications and not approved by
the Engineer, shall be rejected forthwith and shall be removed from the site by the
contractor at his own cost within the time stipulated by the Engineer. The Engineer shall
have the powers to cause the contractors to purchase and use materials from any
particular source, as may in his opinion be necessary for the proper execution of work.
Contractor shall also ensure that all constituents of exposed concrete shall be taken from
same sources to achieve a uniform colour and texture.

5.1.1 Cement

i. The cement used shall be one of the following types :

a) 43 grade Ordinary Portland Cement conforming to IS: 8112.
b) 53 grade Ordinary Portland Cement conforming to IS: 12269.
c) Portland Slag Cement confirming to IS:455.
For piling and foundation work, slab on grade, underground structures and all
structures in contract with earth, type of cement shall be as mentioned in section
8 on pile foundations.
ii. Whenever possible all cements of each type shall be obtained from one constant
source throughout the contract. Cement of different types shall not be mixed with
one another. Different brands of cement, or the same brand of cement from
different sources, shall not be used without prior approval of the Engineer.
iii. Packaged cement shall be delivered to the site in original sealed bags which shall
be labelled with the weight, name of manufacturer, brand and type. Cement
received in torn bags shall not be used. Cement shall be used in the order in
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which it is received. Cement in bags in storage for more than 3 months shall be
retested before use. A sample taken once for every 1000 bags shall be tested.
Contractor may obtain cement in bulk and store it in suitable silos of adequate
capacity. Each type of cement shall be stored in a separate silo and it shall be
ensured, that cements of different quality are not mixed up.
iv. All cement shall be fresh when delivered and at ambient atmospheric
temperature.
v. In fair faced elements, the cement used in the concrete for any complete element
shall be from a single consignment. All cement for exposed concrete shall be
from the same approved source and uniform in color.
vi. With each and every delivery of cement, the contractor shall provide
manufacturers certificate that the cement conforms to the relevant Indian
standard. The contractor shall provide complete facilities at site for carrying out
the following tests:
a) Setting time by vicat's apparatus as per IS:4031 and IS:5513.
b) Compressive strength of cement as per IS: 4031,IS:650, IS:10080.
vii. Total chloride content in cement shall in no case exceed 0.05 percent by mass of
cement. Also, total sulphur content calculated as sulphuric anhydride (SO3), shall
in no case exceed 2.5 percent and 3.0 percent when tri-calcium aluminates per
cent by mass is upto 5 or greater than 5 respectively.

5.1.2 Aggregates

Aggregates from natural sources shall be in accordance with IS:383. The contractor shall
submit to the Engineer certificates of grading and compliance for all consignments of
aggregate. In addition at site from time to time, the contractor shall allow for carrying out
such tests and for supplying test records to the Engineer. The aggregates shall be
procured from approved sources only as directed by the Engineer from time to time.
For fair faced concrete, the contractor shall ensure that aggregates are free from iron
pyrites and impurities, which may cause discoloration. Aggregates shall be stored on
paved areas in different compartments according to their nominal size.
8.1.1.1.1 a. Fine Aggregate

The contractor shall provide complete facilities at site for determining grading of
aggregates by sieves as per IS: 383, IS: 460, IS: 1607, and IS: 2386.
The fine aggregate shall be river sand pit sand, stone dust or other approved sand. It shall
be free from clay, loam, earth or vegetable matter, salt or other harmful chemical
impurities. It shall be clean, sharp, strong, angular and composed of hard siliceous
material.
If considered by the Engineer as necessary, the sand shall be washed in screw type
mechanical washers in portable water to remove silt, clay and chlorides. This shall be
done at least one day before using it in concrete. The washed sand shall be stored on a
sloping concrete platform and in such a manner as to avoid contamination. Such sand
washing, storing etc shall be at contractors cost.
The grading of fine aggregate when determined as described in IS: 2386 (part I), shall be
within the grading zones I, II, III.
The contractor shall provide complete facilities at site for carrying out the following tests:
A) Proportion of clay, silt and fine dust by sedimentation method as per IS: 2386
part II.
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B) Moisture content in fine aggregate as per IS: 2386 Part III.

C) Bulk density/ Bulkage.
8.1.1.1.2 b. Coarse Aggregate

The coarse aggregate shall be crushed stone.

Crushed gravel, natural gravel or a suitable combination thereof. Coarse aggregate
obtained from crushed or broken stone shall be angular, hard, strong, dense, durable,
clean and free from soft, friable, thin plate, elongated or flaky pieces and any deleterious
material.
River gravel or pit gravel shall be sound, hard, clean, non porous, suitably graded in size
with or without broken fragments and free from flat particles of shale, clay, silt, loam, and
other impurities.
Except where it can be shown to the satisfaction of the Engineer that a supply of properly
graded aggregate of uniform quality can be maintained over the said period of the works,
the grading of aggregate shall be controlled by obtaining the coarse aggregate in different
sizes and blending them in correct proportions as and when required. Aggregate shall be
stored in such a way as to prevent segregation of sizes and avoid contamination with
fines.
All coarse aggregate shall conform to IS: 383 and tests for conformity shall be carried out
as per IS: 2386, Parts I to VIII.
The maximum size of coarse aggregate shall be such that the concrete can be placed
without difficulty so as to surround all reinforcement thoroughly and fill the corners of
formwork. The grading of coarse aggregate shall be such that not more than 5% shall be
larger than the maximum size and not more than 10% shall be smaller than the smallest
size. Between these sizes the coarse aggregate shall be well graded. Unless otherwise
permitted by the Engineer the nominal maximum size shall not exceed 20 mm.

5.1.3 Water

Water used in the works shall be potable water and free from deleterious materials.
Water used for mixing and curing concrete as well as for cooling and/or washing
aggregate shall be fresh and clean free from injurious amounts of oil, salts, acids, alkali,
other chemicals and organic matter.
Water shall be from the source approved by the Engineer and shall be in accordance with
clause 5.4 of IS: 456 However, chloride content in water shall not exceed 500 mg/litre.
Before starting any concreting work and wherever the source of water changes, the water
shall be tested for its chemical and other impurities to ascertain its suitability for use in
concrete for approval of the Engineer. No water shall be used until tested and found
satisfactory. Cost of all such Tests shall be borne by the contractor.

5.2 Blending of aggregates

In order to obtain optimum workability, individual aggregates of nominal size 20mm,

10mm, 4.75mm and 2.36mm will be blended in such a way that the grading curve for all
aggregates will be a smooth curve from size 0.15mm to 25mm falling within the
established envelop grading curve. Contractor shall establish envelop grading curve for
each grade of concrete for given maximum size of aggregates and get it approved by
Engineer before finalising the mix design.

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5.2.1 Admixtures

Chemical admixtures are not to be used until permitted by the Engineer. In case their use
is permitted, the type, amount and method of use of any admixtures proposed by the
Contractor shall be submitted to the Engineer for approval. The minimum cement content
specified shall not be reduced on account of the use of the Admixtures.
The contractor shall further provide the following information concerning each admixture
to the Engineer
a. Normal dosage and detrimental effects if any of under dosage and over
dosage.
b. The chemical names of the main ingredients in the admixtures.
c. The chloride content, if any, expressed as a percentage by weight of
admixture. The admixtures shall be chloride free.
d. Whether or not the admixture leads to the entrainment of air when used in
the manufacturer's recommended dosage.
e. Where two or more admixtures are proposed to be used in any one mix, the
manufacturer's written confirmation of their compatibility.
In reinforced concrete, the chloride content of any admixture used shall not exceed 2
percent by weight of the admixture as determined in accordance with IS:6925 and the
total chloride and sulphate contents in concrete mix shall not exceed 0.15 and 4.0 percent
respectively by weight of cement.
The admixtures when used shall conform to IS: 9103. The suitability of all admixtures shall
be verified by trial mixes.
The addition of calcium chloride to concrete containing embedded metal will not be
permitted under any circumstances.
Retarding admixtures when used shall be based on ligno-sulphonates with due
consideration to clause 5.2 and 5.3 of IS: 7861.
Fibre reinforcement will be propex (fibermesh 300 e-3/fibermesh 150-e3) or equivalent
make polypropylene fibres, shall be added to ready mixed concrete whenever the material
is to be used for parapet, box girder .bar reinforcement is still considered primary
reinforcement, under normal condition, add to the ready mix at the plant in the quantity
recommended by the manufacturer subjected to the approval from Engineer-in-charge. If
job conditions warrant, fibre reinforcement may be added at the jobsite provided that
fibres are evenly distributed in the mix.

5.2.2 Batching Plants, Mixers and Vibrators

The primary item for concreting works has been considered from DSR 2012, where use of
Ready Mix Concrete from automatic batching plant has been specified. Due to various
factors of quality, transportation and time it is to be noted that use of Ready Mix Concrete
from fully automatic batching plant is to be replaced with fully automatic and computerized
weigh-batching plant of suitable capacity AT SITE with suitable capacity RO unit for all
structural concreting work by the Contractor. The plant used shall conform to IS: 4925.
Therefore, all clauses for concreting with fully Automatic Batching plant as per CPWD
Specifications 2009 would be applicable. And all Clauses for Ready Mix Concrete as per
CPWD Specifications 2009 would stand void or inapplicable. However, in any
circumstances, if Ready Mix Concrete is to be used for a particular section of work, all
clauses as per CPWD Specifications 2009 would be applicable.
The Contractor shall provide Concrete mixers (IS: 1791 – Batch type concrete mixers, IS:
2438 – Roller Pan Mixer) and Vibrators (IS: 2505 – Concrete Vibrators Immersion Type,

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IS: 2506 – Screed board concrete vibrators, IS: 4656 – Form Vibrators for Concrete)
supplied by recognised manufacturers.

5.2.3 Grade of Concrete

The concrete is designated as follows:

Concrete M 25 / 20
The letter M refers to the mix
The number 25 represents the characteristic compressive strength of 15cm cubes at 28
days in MPa (Mega Pascal: 1 MPa: 10 kg/cm2 approximately). M25 concrete thus has a
characteristic strength of 250 kg/cm2. Other mix design will also be denoted in same way.
The number 20 represents the nominal size of the aggregate in mm.

5.3 Mix Design

It is the complete responsibility of the Contractor to design the concrete mixes by

approved standard methods and to produce the required concrete conforming to the
specifications and the strength, workability requirements approved by the Engineer.
Mix Design Once approved must not be altered without prior approval of Engineer.
However, should the contractor anticipate any change in quality of future supply of
materials than that used for preliminary mix design, he should inform the Engineer quite in
advance and bring fresh samples sufficiently in advance, to carry out fresh trial mixes.
Design mix will indicate by means of graphs and curves etc., the extent of variation in the
grading of aggregates which can be allowed.

Limits of Water and Cement Contents

Maximum water/cement ratio
a) For RCC members including piles - 0.40
b) For PSC members - 0.40
For piling under water, 10% extra cement above the design mix or minimum cement
whichever is greater shall be provided.
Cement Content
Ordinary Portland cement (OPC) of 43 and 53 grade conforming to IS: 8112 and IS:
12269 respectively shall be used. The controlled concrete shall meet with the requirement
laid down in Table below. The aggregate cement ratio and water-cement ratio to be used
for obtaining the specified cube strength given in Table shall be determined in accordance
with the design of the mix. However for nominal mixes, CPWD specification and DSR
2012 will be followed.
Durability Requirements of Concrete

Grade of concrete Max Free Cement Water Min Cement

Ratio As per IS:456 Content
M 20 0.4 320 kg/ cum
M 25 0.4 360 kg/ cum
M30 0.4 400 kg/ cum
M 35 and above 0.4 430 kg/ cum

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Note: The maximum permissible cement content in concrete shall be 540 kg/cum. In the
case of M 30 and M 35 concrete used for water retaining structures min cement content
shall be limited to 450 kg/cum of concrete.
As regards trial mixes, acceptance criteria, acceptance specification, lot size, sampling
and testing and sampling size for all work of cast-in-situ and precast and general work, the
requirement of the relevant codes, standards and directions of the Engineer shall be
followed.

5.4 Additional tests for Concrete

As frequently as the Engineer may require, additional testing shall be carried out for
concreting in addition to mandatory test specified in CPWD specifications 2009 relevant IS
Code / MOST/MORTH Specifications.
Permeability test for Concrete
The concrete will be verified for permeability by the following procedure and shall confirm
to IS: 3085-1965 – ‘Permeability of Cement Mortar & Concrete’, Section 1716.5 of MOST
Specification and DIN 1048.
1 The Engineer shall select random batches of concrete for examination at
his discretion and sampling will generally be done at the point of discharge
from the mixer and at placing point.
2 From the batches thus selected two concrete cylinders shall be made in
accordance DIN 1048.
3 All cylinders shall be made, cured, stored, transported and tested in
accordance with clause 1716.5 of MOST Specifications. The tests shall be
carried out in a laboratory approved by the Engineer.
4 At least two cylinders shall be made on each day’s concreting until 60
cylinders have been made for each grade of concrete. The cylinders will be
tested as per the procedure, given in Clause 5 next.
5 Test Procedure:
The permeability of concrete will be verified by the following procedure:
i. Prepare a cylindrical test specimen 150 mm dia and 160mm high.
ii. After 28 days of curing, test specimen will be fitted in a machine such that
the specimen can be placed in water under pressure up to 7 bars. The
typical machine shall be similar to one shown in Appendix 1700/II of
MOST.
iii. At first a pressure of one bar is applied for 48 hours, followed by 3 bars for
24 hours and 7 bars for next 24 hours.
iv. After the passage of the above period, the specimen is taken out and split
in the middle by compression applied on two round bars on opposite sides
above and below.
v. The water penetration in the broken core is measured with scale and the
depth of penetration assessed in mm (max permissible limit 25 mm).
6 Acceptability Criteria:
The concrete shall pass the permeability test if it is properly compacted and is not
considered permeable when tested as per DIN, and the water penetration in the broken
core is less than 25mm.

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No extra payment shall be made for this test and cost of the same will be included in his
rate for concrete work.

5.5 Batching of Concrete Ingredients

Unless permitted by the Engineer, all concreting shall be either produced in automatic
weigh batching plant installed at site (Refer section 5.2.2).

5.6 Placing temperatures

During extreme hot or cold weather, the concreting shall be done as per procedures set
out in IS: 7861, Parts I & II.
In hot weather with temperature exceeding 40 degree C, the stock piles of fine and coarse
aggregates for concreting shall be kept shaded from direct rays of sun and the concrete
aggregates sprinkled with water for a sufficient time before concreting in order to ensure
that the temperature of these ingredients is as low as possible prior to batching. The mixer
and batching equipment shall be also shaded and if necessary painted white in order to
keep their temperatures as low as possible. The placing temperature of concrete shall be
as low as possible in warm weather and care shall be taken to protect freshly placed
concrete from overheating by sunlight in the first few hours of its laying. The time of day
selected for concreting shall also be chosen so as to minimise placing temperatures. In
case of concreting in exceptionally hot weather the Engineer may in his discretion specify
the use of ice either flaked and used directly in the mix or blocks used for chilling the
mixing water. In either case, the Contractor shall not be paid extra for cost of ice,
additional labour involved in weighing and mixing etc. All salt and saw dust shall be
removed from ice before use. Quality of water used for making ice shall confirm to IS: 456.

5.7 Transporting, Placing, Compacting and Curing

Transporting, placing, compacting and curing of concrete shall be in accordance with IS:
456.

5.7.1 Transporting

The mix after discharging from the mixer shall be transported by transit mixers, buckets,
pumps etc. or as approved by the engineer without causing segregation and loss of
cement slurry and without altering its desired properties with regard to water cement ratio,
slump, air content, cohesion and homogeneity. It should be ensured that the concrete is
moved to its final destination before it attains an initial set.
The transportation is to be done by agitating transit mixers, pumps or other approved
methods.

5.7.2 Placing

The method of placing shall be such as to prevent segregation by providing windows in

the formwork for pouring concrete or by Tremie pipe. The thickness of horizontal layers
shall not exceed 300mm. High velocity discharge of concrete causing segregation of mix
shall be avoided. The concrete shall be placed in the forms gently and not dropped from a
height exceeding 1.5m except in columns where the maximum allowed will be 2.0m. Each
layer of concrete shall be compacted fully before the succeeding layer is placed and
separate batches shall follow each other so closely that the succeeding layer shall be
placed and fully compacted before the layer immediately below has taken initial set.

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Concreting of any portion or section of the work shall be carried out in one continuous
operation and no interruption of concreting work will be allowed without approval of the
Engineer.

5.7.3 Compaction

Internal (needle) and surface (screed board) vibrators of approved make shall be used for
compaction of concrete.
Internal vibrators shall be used for compaction of concrete in foundations, columns,
buttresses arch section, slabs etc, and if required surface vibrators shall also be used.
Depending on the thickness of layer to be compacted, 25 mm, 40 mm, 60 mm and 75 mm
diameter internal vibrators will be used. The concrete shall be compacted by use of
appropriate diameter vibrator by holding the vibrator in position until:
i. Air bubbles cease to come to surface.
ii. Resumption of steady frequency of vibrator after the initial short period of
drop in the frequency, when the vibrator is first inserted.
iii. The tone of the vibrated concrete becomes uniform.
iv. Flattened, glistening surface, with coarse aggregates particles blended
into it appears on the surface.
v. Use of curing compounds may be permitted with specific approval of
Engineer.
After the compaction is completed, the vibrator should be withdrawn
slowly from the concrete so that concrete can flow in to the space
previously occupied by the vibrator. To avoid segregation during vibration
the vibrator shall not be dragged through the concrete nor used to spread
the concrete. The vibrator shall be made to penetrate, into the layer of
fresh concrete below if any for a depth of about 150mm. The vibrator
shall be made to operate at a regular pattern of spacing. The effective
radii of action will overlap approximately half a radius to ensure complete
compaction.
v. To secure even and dense surfaces free from aggregate pockets,
vibration shall be supplemented by tamping or rodding by hand in the
corners of forms and along the form surfaces while the concrete is
plastic.
vi. A sufficient number of spare vibrators shall be kept readily accessible to
the place of deposition of concrete to assure adequate vibration in case
of breakdown of those in use.
vii. Form vibrators whenever used shall be clamped to the sides of formwork
and shall not be fixed more than 450 mm above the base of the new
formwork and concrete shall be filled not higher than 230mm above the
vibrator. The formwork must be made specially strong and watertight
where this type of vibrator is used.
Care must be taken to guard against over vibration especially where the
workability of the concrete mix is high since this will encourage
segregation of the concrete.
viii. Plain concrete in foundations shall be placed in direct contact with the
bottom of the excavation, the concrete being deposited in such a manner
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as not to be mixed with the earth. Plain concrete also shall be vibrated to
achieve full compaction.
Concrete placed below the ground shall be protected from falling earth during and after
placing. Concrete placed in ground containing deleterious substances shall be kept free
from contact with such ground and with water draining there from during placing and for a
period of seven days or as otherwise instructed thereafter. Approved means shall be
taken to protect immature concrete from damage by debris, excessive loading, abrasion,
vibrations, deleterious ground water, mixing with earth or other materials, and other
influences that may impair the strength and durability of the concrete.

5.7.4 Curing

i. Curing of concrete shall be complete and continuous using potable water free
from chlorides and sulphates water that is free of harmful amounts of
deleterious materials that may attach, stain or discolour the concrete as per IS
456. Minimum wet curing will be for seven days by ponding water followed by
moist curing by spraying water which shall be maintained up to a total period for
at least 21 days from the date of casting.
ii. Immediately after compaction and completion of any surface finishes the
concrete shall be protected from the evaporation of moisture by means of
polythene sheathing, wet Hessian or other material kept soaked by spraying. As
soon as the concrete has attained a degree of hardening sufficient to withstand
surface damage moist curing shall be implemented and maintained for a period
of at least 15 days after casting.
iii. Method of curing and their duration shall be such that the concrete will have
satisfactory durability and strength and members will suffer a minimum
distortion, be free from excessive efflorescence and will not cause undue
cracking in the works by shrinkage.
iv. Curing compounds may be permitted with Engineer’s approval. However it is
required to be proved that using curing compound the concrete shall not have
less strength than concrete cured by water curing. It shall not leave any
discolouration on the structural concrete.

5.8 Construction Joints

Construction joints in all concrete work shall be made as directed by the Engineer. Where
vertical joints are required, these shall be shuttered as directed and not allowed to take
the natural slope of the concrete.
Before fresh concrete is placed against a vertical joint, the old concrete shall be chipped,
cleaned and moistened.
No separate payment shall be allowed to the Contractor for forming joints or chipping and
cleaning them. When a horizontal construction joint is formed, provision shall be made for
interlocking with the succeeding layer by the embedment of saturated wooden blocks or
wooden strips bevelled on four sides to facilitate their removal. Prior to the next pour the
wooden pieces shall be loosened and removed in such a manner as to avoid injury to the
concrete.
Construction joints in concrete walls and slabs for liquid retaining structures shall be
prepared in a similar manner to normal construction joints. If use of metal, rubber or
plastic water stops is specified, this shall be cast into joints. Measures shall be taken by
the Contractor to ensure that no displacement or distortion of water stops takes place
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during placing of concrete. The construction joints shall ensure proper bond and leak
proof joint.

5.9 Cracks

If cracks, which in the opinion of the Engineer may be detrimental to the strength of the
construction, develop in concrete construction, the Contractor at his own expense shall
test the structure as specified in clause 1.1.16 of ‘Loading Tests’ of these Specifications. If
under such test loads the cracks develop further, the Contractor shall dismantle the
construction, carry away the debris, replace the construction and carry out all
consequential work thereto.
If any cracks develop in the concrete construction, which in the opinion of the Engineer,
are not detrimental to the stability of the construction, the Contractor at his own expense
shall grout the cracks with neat cement grout or with other composition as directed by
Engineer and also at his own expense and risk shall make good to the satisfaction of the
Engineer all other works such as plaster, moulding, surface finish, which in the opinion of
the Engineer have suffered damage either in appearance or stability owing to such cracks.
The Engineer's decision as to the extent of the liability of the Contractor in the above
matter shall be final and binding.

5.10 Defective Concrete

Should any concrete be found honeycombed or in any way defective, such concrete shall
be cut out partially or wholly by the Contractor and made good at his own expense. If
Engineer feels that repaired structure will not be having same strength or shape or
uniformity with other exposed surface as original desired structure / original structure, the
same shall be rejected by Engineer and required to be dismantled and disposed by
contractor at his own cost as instructed by Engineer. Decision of the Engineer shall be
final and binding in this regard.

5.11 Exposed Faces, Holes and Fixtures

On no account shall concrete surfaces be patched or covered up or damaged concrete

rectified or replaced until the Engineer or his representative has inspected the works and
issued written instructions for rectification. Failure to observe this procedure will render
that portion of the works liable to rejection.
Holes for foundation or other bolts or for any other purposes shall be moulded, and steel
angles, holdfasts or other fixtures shall be embedded, according to the drawing or as
instructed by the Engineer.

5.12 Finishes

Unless otherwise instructed the face of exposed concrete placed against formwork shall
be rubbed down immediately on removal of the formwork to remove irregularities. The
face of concrete for which formwork is not provided other than slabs shall be smoothed
with a float to give a finish equal to that of the rubbed down face, where formwork is
provided. The top face of a slab which is not intended to be covered with other materials
shall be levelled and floated to a smooth finish at the levels or falls shown on the drawings
or as directed. The floating shall be done so as not to bring an excess of mortar to the
surface of the concrete. The top face of a slab intended to be surfaced with other material
shall be left with a spaded finish. Faces of concrete intended to be plastered shall be
roughened by approved means to form key.

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5.13 Concrete for flooring on grade

Concrete for flooring on grade shall be placed in alternate bays not exceeding more than
4m x 6m or as specified in the drawings including forming the joints or adjacent bays. The
stiff mix shall be thoroughly vibrated and finished to receive the floor finish.

5.14 Grouting of base plates & bolt holes

i Mixing
Dry grout should be mixed in a mechanical mixer: the conventional 200/400-litre capacity
concrete mixer can be used to mix four bags of dry grout; alternatively, paddle type mortar
mixers can be used. The quantity of grout to be mixed at one time should not exceed that
amount which can be placed in approximately 10 to 15 minutes.
ii Batching
Batching of grout by fraction of a bag is not allowed. The quantity of mixing water should
be the minimum commensurate with workability, compaction, and filling of the grout in all
corners and crevices. Mixing should be done for a minimum of three minutes to obtain a
fluid grout of uniform consistency.
iii Cleaning and preparation of the surface
The base concrete should be clean and strong, and its surface should be properly hacked;
all dust should be removed suction or compressed air. The surface should be thoroughly
wetted with water for several hours. Before the grout is poured, all free water should be
removed and the flat surfaces coated with a thin cement slurry.
iv Restraint
Heavy back-up blocks of timber or concrete should be fixed on all sided of the base plate
to prevent escape of the grout, when poured through the openings provided in the base
plate. Adequate restraint must be ensured on all the sides for a period of 7 days to obtain
effective expansion and shrinkage compensation.
v Curing
The grout should not dry out where external restraint is provided in the form of form-work,
the top opening and all stray openings should be covered with wet sack for at least 7
days.
vi Placing and Compaction
The grout should be placed quickly and continuously either through the holes in the base
plates or from one side only to ensure complete filling without entrapment of air. Grout
should be properly spread and compacted by rodding. Excessive vibration should be
avoided.
Below the bed plates the grout should be compacted using long pieces of doubled-over
flexible steel strapping or chains. The forward and backward movement of the strap or
chain will assist in the flow of the grout into place. Steps must be taken to keep the grout
in full contact with the underside of the bedplate until the grout sets; maintaining a small
head of fresh grout in the forms.
vii Shrinkage Compensated Grout
Shrinkage compensated grout or non-shrinkable grout of Associated Cement Companies
Limited or any other approved manufacturer (Fosroc, Roff, Sikka) should be used. The
batching shall be as per the manufacturer's specifications, other procedures being as
above.

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5.15 Pre-cast Concrete

The provision in this section shall be considered supplementary to general provisions for
reinforced concrete works.
Handling and Storage:
The pre-cast units shall be stored as directed by the Engineer. The area intended for the
storage of precast units should be surfaced in such a way that no unequal settlement can
occur.
To prevent deformation of slender units, they should be provided with supports at fairly
close intervals and should also be safeguarded against tilting. Lifting and handling
positions should conform to the Engineer's directions and drawings. In addition, location
and orientation marks should be put on the members, as and where necessary. During
erection the pre-cast units should be protected against damage caused by local crushing
and chafing effects of lifting and transport equipment.
Temporary Supports and Connections:
Temporary supports provided during erection should take into account all construction
loads likely to be encountered during the completion of joints between any combination of
precast and in-situ concrete structural elements. The supports should be arranged in a
manner that will permit the proper finishing and curing of any in-situ concreting and
grouting associated with the precast member being supported when the gaps of joints
have to be filled with concrete or mortar. They should first be cleaned and faces of the
joints should be wetted. The mixing, placing and compacting of cement and mortar should
be done with special care. Mortar of a dry consistency should be in the proportion of 1:1½
(1 part of cement to 1½ parts of sand) and should be placed in stages and packed hard
from both sides of the joint.
Tolerances:
The following tolerances apply to finished precast products at the time of placement in the
structure. The forms must be constructed to give a casting well within these limits:
1 Overall dimensions of members should not vary more than + 6mm per
3m length with a maximum variation of + 20mm.
2 Cross-sectional dimensions should not vary more than the following:
+ 3mm for sections less than 150mm thick
+ 4mm for sections over 150mm & less than 450mm
+ 6mm for sections over 450mm to 1000mm
+ 10mm for sections over 1000mm
3 Deviation from straight line in long sections should not be more than +
6mm up to 3m, + 10mm for 3m to 6m, + 12mm for 6m to 12m.

5.16 Ready Mix Concrete and Pumping

1 Ready-mixed concrete may be manufactured in a central automatic weigh

Batching plant and transported to the place of work in agitating transit mixers.
The maximum size of coarse aggregate shall be limited to one-third of the smallest inside
diameter of the hose or pipe used for pumping. Provision shall be made for elimination of
over-sized particles by screening or by careful selection of aggregates. To obtain proper
gradation it may be necessary to combine and blend certain fractional sizes of
aggregates. Uniformity of gradation throughout the entire job shall be maintained.
The quantity of coarse aggregate shall be such that the concrete can be pumped,

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compacted and finished without difficulty.

2. Fine aggregates
The gradation of fine aggregate shall be such that 15 to 30 percent should pass the 0.30
mm screen and 5 to 10 percent should pass 0.15 mm screen so as to obtain pumpable
concrete. Sands, which are deficient in either of these two sizes, should be blended with
selected finer sands to produce these desired percentages. With this gradation, sands
having a fineness modulus between 2.4 and 2.8 are generally satisfactory. However, for
uniformity, the fineness modulus of the sand should not vary more than 0.2 from the
average value used in proportioning.
3. Water, Admixtures and Slump:
The amount of water required for proper concrete consistency shall take into account the
rate of mixing, length of haul, time of unloading, and ambient temperature conditions.
Additions of water to compensate for slump loss should not be resorted to nor should the
design maximum water-cement ratio be exceeded. Additional dose of retarder be used to
compensate the loss of slump at contractor’s cost, when permitted by Engineer.
Retempering water shall not be allowed to be added to mixed batches to obtain desired
slump. The quantity of water added to the cement and aggregates during mixing shall be
such as to produce a concrete having sufficient workability to enable it to be properly
compacted to be worked into the corners of the shuttering and around reinforcement.
Reference may be made to IS:456, clause 6, for guidance with respect to workability.
Due account shall be taken of the variation of moisture content, within any
consignment of aggregate or any variations due to watering, exposure to rain or drying
weather. The contractor shall carry out regular moisture content Tests on stacked
aggregates as directed by the Engineer and results submitted to him.
In case of ordinary concrete, the maximum value of water cement ratio shall be 0.68
and in the case of controlled concrete the water cement ratio shall be determined by
the mix design subject to the requirements of durability requirement of concrete of these
specifications.
The contractor shall exercise particularly tight control of the water content for fair faced
concrete, the colour of which is sensitive to small variations of water in the mix.
When a suitable water cement ratio has been determined and agreed with the Engineer, it
shall be maintained throughout the corresponding part of works. Approved tests shall be
undertaken periodically by the contractor to satisfy the Engineer of the maintenance of the
consistency. However, the amount of water to be added to a mix other than for fair-faced
concrete may be reduced below the agreed design amount with the consent of the
Engineer if the contractor is able to demonstrate that such a reduction is consistent with
producing concrete of the required workability and characteristic strength.
Workability of cement concrete shall be checked at frequent intervals by slump test.
Where facilities exist and required by the Engineer, compaction factor test in accordance
with IS: 1199 shall also be carried out.
The degree of workability necessary to allow concrete to be well consolidated and to be
worked into corners of formwork and around reinforcement to give required surface finish
shall depend on the type and nature of the structure and shall be based on experience
and tests. The limits of consistency for structures are as specified in Table below:
Table : Limits of Consistency
Placing Conditions Degree of Values of Workability
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Workability
Concreting of shallow Very Low 20-10 sec veebee time or 0.75-
Sections with vibration 0.80 compacting factor
Concreting of lightly Low 10-5 sec veebee time or 0.80-0.85
reinforced sections with compacting factor
vibration
Concreting of lightly Medium 5-2 sec veebee time or 0.85-0.92
reinforced sections without compacting factor or 25mm-75mm
vibration, or heavily slump for 20mm aggregate
reinforced section with
vibration
Concreting of heavily High above 0.92 compacting factor or
reinforced sections without 75mm-125mm slump for 20mm
vibration aggregate
Notwithstanding the above, the range of slump to be obtained for various kinds of
concreting work in progress shall be as given in below or as per direction of Engineer.

Range of Slump Values (mm)

Kind of Concrete Slump (mm)
Pre-cast cement concrete 50 - 75
Pre-stressed concrete 75 - 100
Mass cement concrete and Plain cement concrete 25 - 75
Reinforced cement concrete 75 - 100
Underwater cement concrete 150 - 200
Grade Slabs 75 – 100
4. Transportation:
The method of transportation used should efficiently deliver the concrete to the point of
placement without significantly altering its desired properties with regard to water-cement
ratio, slump, and homogeneity.
The revolving-drum truck bodies of approved make shall be used for transporting the
concrete. The numbers of revolutions at mixing speed, during transportation, and prior to
discharge shall be specified and agreed upon. Reliable counters shall be used on
revolving-drum truck units. Standard mixer uniformity tests, conforming to ASTM
standards C 94-69 “Standard Specifications for Ready Mix Concrete”, shall be carried out
to determine whether mixing is being accomplished satisfactorily.
5 Pumping of concrete:
Only approved pumping equipment, in good working condition, shall be used for pumping
of concrete. Concrete shall be pumped through a combination of rigid pipe and heavy-duty
flexible hose of approved size and make. The couplings used to connect both rigid and
flexible pipe sections shall be adequate in strength to withstand handling loads during
erection of pipe system, misalignment, and poor support along the lines. They should be
nominally rated for at least 3.5 MPa pressure and greater for rising runs over 30 m.
Couplings should be designed to allow replacement of any section without moving other
pipe sections, and should provide full cross section with no construction or crevices to
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disrupt the smooth flow of concrete.

All necessary accessories such as curved sections of rigid pipe, swivel joints and rotary
distributors, pin and gate valves to prevent backflow in the pipe line, switch valves to
direct the flow into another pipe line, connection devices to fill forms from the bottom up,
extra strong couplings for vertical runs, transitions for connecting different sizes of pipe,
air vents for downhill pumping, clean-out equipment etc, shall be provided as and where
required. Suitable power controlled booms or specialized crane shall be used for
supporting the pipe line.
6 Field control
Sampling at both truck discharge and point of final placement shall be employed to
determine if any changes in the slump and other significant mix characteristics occur.
However, for determining strength of concrete, cubes shall be taken from the placement
end of line.
7 Planning
Proper planning of concrete supply, pump locations, line layout, placing sequence, and
the entire pumping operation shall be made and got approved. The pump should be as
near the placing area as practicable, and the entire surrounding area shall have adequate
bearing strength to support concrete delivery pipes. Lines from pump to the placing area
should be laid out with a minimum of bends. For large placing areas, alternate lines
should be installed for rapid connection when required. Standby power and pumping
equipment should be provided to replace initial equipment, should breakdown occur.
The placing rate should be estimated so that concrete can be ordered at an appropriate
delivery rate.
As a final check, the pump should be started and operated without concrete to be certain
that all moving parts are operating properly. A grout mortar should be pumped into the
lines to provide lubrication for the concrete, but this mortar shall not be used in the
placement. When the form is nearly full, and there is enough concrete in the line to
complete the placement the pump shall be stopped and a go-devil inserted and shall be
forced through the line by water under pressure to clean it out. The go-devil should be
stopped at a safe distance from the end of the line so that the water in the line will not spill
into the placement area. At the end of placing operation, the line shall be cleaned in the
reverse direction.

5.17 Testing Concrete Structures for Water Tightness & Acceptance Criteria

1. Underground Tanks, Pump Rooms and Sumps

In the case of structures whose external faces are submerged and are not accessible for
inspection, such as underground tanks, the structures shall be filled with water and after
the expiry of seven days after the filling, the level of the surface of the water shall be
recorded. The level of water shall be recorded again at subsequent intervals of 24 hours
over a period of seven days. Backfilling shall be withheld till the tanks are tested. The
total drop in surface level over a period for seven days shall be taken as an indication of
the water tightness of the structure.
A structure shall be deemed to be water tight if the total drop in the surface level over a
period of seven days does not exceed 40 mm.

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2. Roofs
The roofs of liquid-retaining structures shall be water-tight and shall be tested on
completion by flooding the roof with water to a minimum depth of 25 mm for 24 hrs. Where
it is impracticable, because of roof falls or otherwise, to contain a 25 mm depth of water,
the roof shall have water applied by a continuous hose of sprinkler system to provide a
sheet flow of water over the entire area of the roof for not less than 6 hrs. In either case
the roof shall be considered satisfactory if no leaks or damp patches show on the soffit.
Should the structure not satisfy either of these tests, then after completion of the remedial
work it should be re-tested in accordance with this clause. The roof insulation and
covering should be completed as soon as possible after satisfactory testing.
3. Contractor shall give warranty for leak tightness of joints for 10 years

5.18 Quality Control

1. The Engineer reserves the right to make changes in the mix proportions including
the increased cement content or/and a Change in the contractor's control
procedure, should the Quality control during progress of the works proves to be
inadequate in his opinion.
2. All the concrete work shall be true to level, plumb and square within the acceptable
tolerance. The corners, edges and arises in all cases shall be broken and finished
properly and carefully.
3. Tests required to be carried out shall be inclusive of following but not limited to:
Table: Quality Control
S. No. Material to be tested Type of test & explanation
1. Mix design A separate mix design for each grade of
concrete and for each type and brand of
ingredient eg cement, aggregate etc.
2. Cement Manufacturers certificates for each
consignment and brand of cement. Setting
time test at site for each consignment as per
relevant IS code.
Mortar cube strength test at site for each
consignment.
Comprehensive chemical analysis of
cement at an approved laboratory
3. Fine aggregates Sieve analysis for checking grading of
aggregates of each consignment.
Each consignment to be tested for
proportion of silt and fine dust by
sedimentation method Test for moisture
content as per for every day of
concreting.
Chloride content test by an approved
laboratory at every change of season and
as decided by the Project Manager for
each procurement.

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4. Coarse aggregates Composition of graded stone

aggregates to the satisfaction of the
Engineer
Chloride content test from an approved
laboratory at every change of season and
as decided by the Engineer for each
source of procurement.
5. Water Tests for fitness for use as constituent of
concrete as well as for curing at every
change of season and as decided by the
Engineer.
6. Admixtures & additives Each consignment to be tested at an
approved laboratory for chloride contents
and other physical and chemical
properties.
7. Total chloride content Calculations shall be shown by the
contractor in concrete to prove that total
chloride and sulphate contents are within
the limits specified in as per relevant IS
code of the specifications at regular
intervals and as directed by the Engineer.
8. Water cement ratio Calculations justifying water cement
ratio and workability taking due account
of moisture of aggregates, shall be
maintained for every day of concreting
for each grade.
Slump cone test to be performed for
every day of concreting as per the codal
requirements.
9. Concrete testing Testing of concrete cubes for each day of
concreting.
10. Formwork Contractor to provide obligatory proofs to
justify safety and soundness and control
of deflection of shuttering and scaffolding
in cases of doubts as instructed by the
Engineer.
11. Reinforcement Manufacturer's certificates of
reinforcement steel testing that the
material confirms to the requirements of
per relevant IS Codes and the
specification In case of any doubt,
material Should be separately tested at
an approved laboratory if instructed by
Engineer.
12. Curing compounds Manufacturer’s test Certificates required
13. Water stops Manufacturer's test Certificates required
14. Fasteners Pull out test on 10% subject to minimum 2
of each type and size of fastener.

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15. Pre-stressing hardware FIP testing of anchorages prior to their

use.
16. Pre-stress steel All physical and chemical tests prior to its
use.
17. Vacuum dewatered floor Mock up and demonstration to verify
efficacy of the system.

5.19 Site Laboratory

The contractor shall set up a full-fledged laboratory at the site so as to carry out at least
the various tests specifically indicated in these specifications. All equipment, instruments,
etc. to be used in the laboratory shall be proposed by the contractor and this shall be
subject to the approval of the Engineer. Various codes of practice indicated at the
beginning of various chapters of these specifications shall be stocked in an orderly fashion
in the site laboratory by the contractor for consultation by various persons connected with
the project.

5.20 Tolerances for Concrete Works

The acceptable tolerances for concrete works shall be as given below :

A. Wall / General Building - Cast-In-Place
A.1. Tolerance applying to concrete dimensions and locations only.
A.1.1. Plumb (allowable variation)
A.1.1.1. In the lines and surfaces of columns, piers, walls on any 3 m, 6 mm maximum for
the total height of the structure 25 mm
A.1.1.2. For exposed corner columns, control-joint grooves and other conspicuous lines:
In any 6m,6mm maximum for the total height of the structure 12 mm
A.2 Tolerance for finished slab surfaces
A.2.1 Surface finish tolerance
A.2.1.1 Depressions in floors between high spots shall not be greater than 8 mm below
a 3 m long straight edge for areas to receive carpets or the like floor finish
A.2.1.2. Depressions in floors between high spots shall not be greater than 12mm below
a 3 m long straight edge for all other areas.
A.2.2. Floor tolerance measurement shall be made the day after a concrete floor is
finished and the shoring is removed, in order to eliminate any, effects of
shrinkage, curling and deflection.
A.2.3 Variation from levels or the specified grades for slabs having over all length or
any two successive intermediate points separated by:
- 3m or less having exposed construction : 10mm
- More than 3m having exposed construction : 12mm
- For buried construction - Twice the limit specified above.

B. Precast concrete
B.1. Tolerances for precast non-pre stressed elements

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B.1.1 Length of element per 3 m of length  3 mm

Maximum for entire length 20 mm
B.1.2 Cross sectional dimensions
Sections less than 150 mm  3 mm
Sections 150 mm and less than 450 mm  5 mm
Sections 450 mm to 900 mm  6 mm
Sections over 900 mm 10 mm
B.1.3 Variation from straight line
In any 3 m of length + 3 mm
Maximum for the entire length 20 mm
B.1.4 Camber (variation from specified)
Per 3 m of span  3 mm
But not greater than 12 mm
B.1.5 Differential in camber between adjacent units in erected Position
Per 3 m of span  3 mm
But not greater than 12 mm
B.2. Precast panels
B.2.1. Casting tolerances
B.2.1.1. Height and width of panel
Basic dimension under 3 m 3 mm
3 m to 6 m  3 mm
 5 mm
over 6 m to 9 m  3 mm
 6 mm
Each additional 3 m increment in excess of 9 m 1.5 mm
B.2.1.2. Thickness  6 mm
3 mm
B.2.1.3 Skew-measured by the difference in length of the two diagonals
Per 1.8 m of diagonal length - 3 mm
+ 6 mm
B.2.1.4. Openings cast into panels
Size of opening  6 mm
Location of center line of opening  6 mm
B.2.1.5. Location of embedded items
Inserts, bolts, pipe sleeves, etc. 10 mm
Flashing reglets at panel edge  6 mm
Reglets for glazing gaskets  3 mm
Electrical outlets, hose bibs, etc. 12 mm

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B.2.2. After casting tolerances (monolithically cast panels)

B.2.2.1 with intermediate support
Bowing and warpage panel dimension 360
B.2.2.2 Without intermediate support panel
Bowing and warpage panel dimension  240
B.2.3. Erection tolerance
B.2.3.1 Distance between panels at face of panels. For panels with dimensions (normal
to the joint)
Of under 3 m  5 mm
Of 3 m to 6 m + 5 mm
- 6 mm
For each 3 m increment in excess of 6 m 1.5 mm
B.2.3.2. Joint taper (panel edges not parallel)
Per lineal foot of joint 0.6 mm
Minimum allowable 1.5 mm
Maximum for entire length 10 mm
B.2.3.3. Panel alignment
Alignment of horizontal and vertical joints 6 mm
Offset in exterior face of adjacent panels 6 mm
B.2.3.4. Location of openings in wall panels  6 mm
B.3. Erection tolerances
Refer to section a.1 for in-place tolerance of elements covered in sections B.1
and B.2
C. Materials
C.1 Reinforcing steel
C.1.1 Nominal mass Tolerances on nominal mass of bars shall be as per table-2 of
IS:1786-1985.
C.1.2. Placement for flexural members, walls, and compression members.
C.1.2.1 Tolerance in clear distance to formed soffit - 6 mm
C.1.2.2 Tolerance in depth `d' (where `d' is the distance from the extreme compression
fiber to the centroid of tension reinforcement)
Depth `d'
200 mm or less 10 mm
More than 200 mm 12 mm
C.1.2.3 Tolerance on minimum concrete cover
Depth `d'
200 mm or less - 10 mm
More than 200 mm - 12 mm
But not to exceed 1/3 specified concrete cover
C.1.2.4 Tolerance on minimum distance between bars - 6 mm
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C.1.2.5 Tolerance in uniform spacing of reinforcement

from theoretical location 50 mm
C.1.2.6 Tolerance in uniform spacing of stirrups
and ties from theoretical location 25 mm
C.1.2.7 Tolerance in longitudinal location of bends and ends of bars
General 50 mm
Discontinuous ends of members 12 mm
C.1.2.8. Tolerance in length of bar laps - 32 mm
C.1.2.9 Tolerance in embedded length
8 mm dia. To 36 mm dia - 25 mm
40 mm dia and above - 50 mm
C.2 Concrete Materials
C.2.1. Tolerance in measurement of quantity of materials for Batching concrete:

Batch weights greater than Batch weights less than 30

30 percent of Scale capacity percent of Scale capacity
Individual Cumulative Individual Cumulative
Batching Batching Batching Batching

Cement and +1% or +3% of not less than

Other scale capacity required
Cementations whichever is weight or
Materials greater more than4%
required
weight
Water by (volume 1% 1%
or by weight)
percent
Aggregates 2% 1% 2% 0.3%of scale
capacity+3%
required cumulative
weight whichever is
less
Admixtures 3% 3%
C.3 Concrete
C.3.1 Tolerance in slump (where no range Specified) 25 mm
C.3.2 Tolerance in air content by volume 1 1/2
mm %
4% minimum (where no range specified)
C.4 Embedded materials
C.4.1 tolerance from specified clearance relative to reinforcing 25 mm
C.4.2 tolerance from specified location  6 mm

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C.4.3 Deductions for openings, conduits, pipes, ducts, pockets, chases etc shall be made
provided each one of them is larger than 0.10 sqm in area. For each opening less
than or equal to 0.10sqm in area, no deduction shall be made.
C.4.4 No deduction shall be made for embedded fixtures including reinforcements,
sleeves, anchor bolts and similar items.

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6. BRICK WORK

6.1 FPS Brick work-

Refer Clause 6.2 of CPWD Specifications 2009.

6.2 Fly ash based products:

Fly ash based products such as Mechanized Autoclaved Sand Lime Fly ash Bricks/Fly
Ash Lime Gypsum Bricks/Autoclaved Aerated Concrete (AAC) Blocks have to be used in
construction activities as specified in Item of works of BOQ.

6.3 Mechanized Autoclaved Fly ash Lime Brick

These bricks shall be machine moulded and prepared in plant by appropriate proportion of
fly ash and lime. The autoclave fly ash bricks shall conform to IS 12894. Visually, the
bricks shall be sound, compact and uniform shape, free from visible cracks, warpage and
organic matters. The brick shall be solid with or without frog, and of 100/80 mm in length,
40 mm width and 10 to 20 mm deep one of its flat side as per IS 12894. The brick shall
have smooth rectangular faces with sharp corners and shall be uniform in shape and
colour. Fly ash shall conform to IS 3812 and lime shall conform to class ‘C’ hydrated lime
of IS 712.
Brick work with mechanized autoclaved fly ash lime bricks confirming to IS 12894:2002 of
class designation 10 (average compressive strength 100kg/cm2) in cement mortar 1:4.

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7. STONE WORK

7.1 Scope of work

The work shall include providing stone to internal and external area of the building
including pergolas, posts and railing, chhajjas, fascias, sides of beams / lintels / columns,
soffits of slabs / beams / lintels / chhajjas, parapets, copings, balconies, windows sills,
skirtings etc. whether to RCC or concrete or brick masonry or steel / metal all to design,
patterns, shapes and thicknesses, as specified or as directed by the Architect/Engineer-in-
Charge, complete in all respects to give the quality of finished work as desired by and to
the entire satisfaction of the Engineer.

7.2 Applicable Specifications

All work shall be in accordance with the CPWD Specifications 2009 with latest correction
slips and as detailed in clause 7.7 of CPWD Specifications -2009 - Stone Veneering
Work/Cladding and sub-clause there under except as modified hereunder and as per the
additional requirements given here under:
Stone cladding work using stone of thickness up to 18 mm shall be treated as stone
cladding work.

7.2.1 Materials

All stones used on one face of the work shall be from the same source of selected as per
approved sample of selected quality, uniform in colour, texture and grain free from cracks,
fissures and flaks with straight edges , perfect corners and from the same quarry.
The Contractor shall provide stones to match approved samples and they shall comply
with the following:
Stone shall be machine cut into slabs of required thickness and to the required sizes.
Stone shall be properly seasoned and brought to the proper condition for use.
Each worked stone shall be marked with the natural or quarry bed.
Stone shall be supplied to the work site with all shaping and machining completed at the
masonry yard. The mortises, sinkings perforations and notches for cramps, dowels and
corbel plates for supporting nibs shall be carefully formed, to ensure alignment of adjacent
stones, in accordance with approved working drawings. All holes, rebates, recesses, etc.
for providing fixings and inserts shall be pre-drilled and worked, using precision electric
machine tools.
Stone shall be finished, as specified, for all faces and returns etc. visible in the finished
work.
Stone shall be worked truly square from all face lines for the full width and thickness.
The minimum thickness of stone behind a cramp mortise shall not be less than that
specified.
Tolerance in thickness : upto 20 mm ± 2 mm
beyond 20 mm ± 3 mm
The compressive strength of common types of stones shall be as per Table 7-1 and the
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percentage of water absorption shall generally not exceed 5% for stones other than
specified.
Table 7-1 : Compressive strength of stones
Type of Stone Maximum Water Absorption Minimum Compressive
percentage by weight strength kg / sqcm.
Granite 3.50 500
Sand stone 4.00 300
Marble 0.40 500

Note 1: Test for compressive strength shall be carried out as laid down in IS: 1121 (Part
1).
Note 2: Test for water adsorption shall be carried out as laid down in IS: 1124.

The Contractor shall provide the Red Sand Stone machine cut (fine chisel and semi-
polished dressed stone) for the stone cladding work.

7.2.2 Materials for Mortar

Cement: Portland ordinary cement conforming to IS: 12269 only shall be used. The
cement shall be non-staining to the stone for cladding. The total chloride content of the
cement shall not exceed 0.05%.
White Cement: This shall conform to IS: 8042. The cement shall be non-staining to the
stone for cladding.
Sand: Crushed stone shall be used to match the stonework and shall be graded to
comply with the approved sample.
Coarse sand: Shall conform to IS: 383 and shall be used for grouting of the stonework.
Pigment: Shall conform to BS: 1014 or as per approved sample.
Water: Shall conform to the requirement of IS: 456.
Ancillary materials: cramps, dowels etc. as approved.
Note: Calcium chloride shall not be used.

7.2.3 Stone and Workmanship

(a) The Contractor shall provide various stones in sizes as required by the Architect
/Engineer. The stones shall be dressed as specified and directed by the
Architect/Engineer. Decision of the Architect/ Engineer in regard to the quality of
the stone and workmanship shall be final and binding on the Contractor.
(b) The Contractor shall submit three samples in sizes as may be indicated by the
Architect/ Engineer-in-Charge for keeping in the sample rooms.
(c) The Contractor shall ensure that the stone procured conforms to the approved
samples.
(d) The Contractor shall prepare samples of workmanship with stones procured in the
first lot. Wherein the workmanship of each stone shall be checked and approved,
including workmanship of mock-up of stone cladding of various elements. The
above sample work shall be to establish besides quality of workmanship, the
colour of the stone / mortar, finish, lines, levels, flatness, mortar type, sealing and
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the like and shall also include samples of fixings, sealant, silicone water repellent
application etc. for approval.
(e) The work shall be carried out there after, wherein the approved mock-up shall form
the minimum level of acceptable quality of workmanship.

7.2.4 Handling and Storing Materials

(a) The Contractor shall handle and stone materials such that any particular delivery
or consignment can be identified. Incompatible materials shall be stored
separately.
(b) All stone shall be stacked on a clean, dry, free-draining surface, be prevented from
contact with soil and shall be protected from extreme weather conditions. The
stone shall be covered with non-staining tarpaulins and protected from rain.
(c) The Contractor shall take steps to ensure that there is no danger of breaking and
damage to the stone. The storage areas shall be clear of all other operations.
(d) The Contractor shall prevent damage to the stone due to handling and transport.
Handling shall be planned and reduced to a minimum.
(e) The storage, handling, lifting and transporting methods shall be subjected to the
approval of the Engineer.

7.2.5 Dressing

To clause 7.7.2 of CPWD Specifications 2009 add the following:

(a) The edge of all stones at corners or junctions, soffits, projections etc. shall be fine
chisel dressed with single or double rebate, as shown in the drawings or as
directed. The edges of stones shall be fine chisel dressed with chamfer to form V-
groove of 6 mm or 8 mm as shown in the Construction Drawings or as directed.
Machine cutting shall be resorted to instead of hand cutting for all stone work.
(b) Preparation for Cladding Work - During the preparation for the stone cladding work
the Contractor shall consider the building as a whole while planning, detailing etc.
and not treat any face or part thereof in isolation.
(c) Matching Grains and Colour - All stone shall be sorted for colour and grains before
laying. The matching of grains / colour shall be carried out as approved by the
Engineer-in-Charge/Architect. No variation of type of grain or colour shall be
allowed in any one area.

7.2.6 Design and Pattern

All work shall be laid as per design, detail, pattern, colours, sizes and dimensions given on
the drawings. Any modification and variations at site shall be reflected in adjustment in
design as per the approval of the Architect/Engineer. All junctions, rebates, nosing,
corners shall have square, curved or shaped moulding as desired and as shown on the
drawings.

7.2.7 Service and Other Outlets

Before any work is to be taken up, the sizes and the pattern of stones shall be laid out,
together with the location of electrical, sanitary outlets and those of all other services and
approval sought from the Architect/Engineer. Thereafter the stones shall be laid out on
the floor showing patterns of grain, etc. and work shall only be carried out after obtaining

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approval of the Engineer.

7.2.8 Setting out

The Contractor shall set out the stone cladding work so as to achieve the following:
(a) Establish a benchmark or datum at each floor level for setting out.
(b) Establish a vertical centre line in each plain area.
(c) Establish the positions of movement joints.
(d) Avoid or minimize unsightly cutting.
(e) Obtain truly horizontal joint lines.
(f) Where opening and other features occur the work shall be done as per the
detailed drawings or as directed by the Architect/Engineer-in-Charge.

7.2.9 Laying and Jointing

The requirements given under clause 7.7.4 – Laying and 7.7.5 – Joints of CPWD
Specifications 96 shall be superseded by the requirements given hereunder. The term
laying shall be construed to include bedding where applicable.
a) Preliminary
The Contractor shall undertake everything necessary to obtain a satisfactory bond
between the backgrounds, and finishing / cladding. Such work shall include but not be
limited to the following:
i. Withholding application until curing and drying shrinkage of the structural
backgrounds are achieved.
ii. Fungicidal wash as approved to remove any organic growth.
iii. Removal of any greasy deposits by scrubbing with water and approved detergent.
iv. Final brushing to remove laitance, efflorescence or loose material.
v. Wetting to reduce suction or to obtain uniformity of suction.

b) Laying
The stone cladding shall be laid as follows:
i. All stones and all jointing surface shall be made perfectly clean and free of dirt,
dust, grease or other deleterious material.
ii. The stones shall be soaked in clean water for at least 30 minutes.
iii. The rendering shall be damped just sufficiently to prevent excessive water
absorption from stones.
iv. The bedding surfaces of small units shall be well wetted and the units stood on a
full bed of mortar and tapped home.
v. For very large or heavy units, a mortar bed shall be screeded level and full but
kept back 20 mm from the face, before the stone is lowered into place. All joints
shall be as completely filled as possible.
vi. Only sufficient mortar shall be spread to bed each stone.
vii. It shall be ensured that there are no hard lumps in the mortar that could prevent
even bedding.
viii. It shall be ensured that stones are flat and true by means of a straightedge.
Adjustments if necessary shall be made within 10 minutes of fixing.
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c) Jointing
i. The stone shall be fixed with consistent joint width by correct use of spacer lugs so
as to provide hairline (maximum 1 mm thick) joints.
ii. All joints shall be filled solid with 1:2 mortar (1 white cement with pigment: 2 sand)
except for projecting members of overhanging cornices which may be provided
with hollow bedding where approved by the Engineer-in-Charge. Excess mortar
shall be cleaned off immediately so that no mortar is visible on the face of the
stone cladding. The stone cladding shall be properly cured for at least 7 days.
iii. All stones shall be secured to the backing by means of Gun Metal cramps, pins,
anchors, fasteners and expansion bolts as shown on the drawings and approved
shop drawings and as directed by Architect/Engineer.
iv. All cramps, dowels etc. shall be fitted and grouted solid as the work proceeds.The
fixing shall be secured to concrete backing using expansion fasteners and bolts.
v. No stone shall bridge the expansion / separation gap provided in the structure.

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8. CERAMIC GLAZED TILE CLADDING

8.1 Scope of Work

The scope of work shall include Providing and fixing Ist quality ceramic glazed tiles
conforming to IS : 15622 of average thickness 15 mm of approved make like NITCO,
JOHNSON, SOMANY, KAJARIA, or equivalent make in all colours, shades except black
of any size as approved by Architect/Engineer-in-Charge in skirting and dados etc. or at
any other place as mentioned in the architectural drawings complete over 12 mm thick
bed of Cement Mortar 1:3 (1 cement : 3 coarse sand) and jointing with grey cement slurry
@ 3.3 kg. per sqm including pointing in white cement mixed with pigment of matching
shade complete .

8.2 Glazed Tiles

The tiles shall be of approved make and shall generally conform to IS 15622. They shall
be flat, and true to shape and free from blisters crazing, chips, welts, crawling or other
imperfections detracting from their appearance. The tiles shall be tested as per IS 13630.
Classification and Characteristics of pressed ceramic tiles shall be as per IS 13712.
The tiles shall be square or rectangular of nominal size. Table 1,3,5, and 7 of IS 15622
give the modular preferred sizes and table 2,4,6 and 8 give the most common non
modular sizes. Thickness shall be specified by the manufacturer. It includes the profiles
on the visible face and on the rear side. Manufacturer/supplier and party shall choose the
work size of tiles in order to allow a nominal joint width upto 2mm for unrectified floor tiles
and upto 1mm for rectified floor tiles. The joint in case of spacer lug tile shall be as per
spacer. The tiles shall conform to table10 of IS 15622 with water absorption 3 to
6%(Group BII).
The top surface of the tiles shall be glazed. Glaze shall be either glossy or matt as
specified. The underside of the tiles shall not have glaze on more than 5% of the area in
order that the tile may adhere properly to the base. The edges of the tiles shall be
preferably free from glaze. However, any glaze if unavoidable, shall be permissible on
only upto 50 per cent of the surface area of the edges.

8.3 Coloured Tiles

Only the glaze shall be coloured as specified. The sizes and specifications shall be the
same as for white glazed tiles.
a. Decorative Tiles
The type and size of the decorative tiles shall be as follows:
b. Decorated white back ground tiles
The size of these tiles shall be used as approved by Engineer-in-Charge.
c. Decorated and having coloured background
The size of these tiles shall be used as approved by Engineer-in-Charge.

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8.4 Preparation of Surface and Laying

8.4.1 Base concrete or the RCC slab on which the tiles are to be laid shall be cleaned,
wetted & mopped. The bedding for the tile shall be with cement mortar 1: 3 (1
cement: 3 coarse sand) or as specified The average thickness of the bedding shall
be 10 mm while the thickness under any portion of the tiles shall not be less than 5
mm.

8.4.2 Mortar shall be spread and corrected to proper levels and allowed to harden
sufficiently to offer a fairly rigid cushion for the tiles to be set and to enable the
mason to place wooden plank acre and squat on it.

8.4.3 Over this mortar bedding neat grey cement slurry of honey like consistency shall
be spread the rate of 3.3 kg of the cement per square meter over such an area as
would accommodate about twenty tiles. Tiles shall be soaked in water washed
clean and shall be fixed in this grout one after another, each tile gently being
tapped with a wooden mallet till it is properly bedded and in level with the adjoining
tile The joints shall be kept as thin as possible and in straight lines or to suit the
required pattern.

8.4.4 The surface of the flooring during laying shall be frequently checked with a straight
edge ape 2 m long, so as to obtain a true surface with the required slope.

8.4.5 Where full size tiles cannot be fixed these shall be cut (sawn) to the required size,
and the edge rubbed smooth to ensure straight and true joints.

8.4.6 Tiles which are fixed in the floor adjoining the wall shall enter not less than 10 mm
under the plaster skirting or dado.

8.4.7 After tiles have been laid surplus cement slurry shall be cleaned off.

8.5 Pointing and Finishing

The joints shall be cleaned off the grey cement slurry with wire/coir brush or trowel to a
depth of 2 m to 3 mm and all dust and loose mortar removed. Joints shall then be flush
printed with white cement added with pigment if required to match the colour of tiles. The
floor shall then be kept wet for 7 days After curing, the surface shall be washed and
finished clean. The finished floor shall not sound hollow' when tapped with a wooden
mallet.

8.6 Measurements

Length and breadth shall be measured correct to a cm before laying skirting, dado or wail
plaster an the area calculated in square metre correct to two places of decimal. Where
coves are used at the junction, the length and breadth shall be measured between the
lower edges of the coves. No deductions shall be made nor extra paid for voids not
exceeding 0.20sqm. Deductions for ends of similar material or other articles embedded
shall not be made for areas not exceeding 0.10sqm.

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8.7 Rate

The rate for flooring shall include the cost of all materials and labour involved in all the
operations described above. Nothing extra shall be paid for the use of cut (sawn) tiles in
the work.
Extra over and above the normal rate for white tiles shall be paid where coloured or any
other type of decorative tiles have been used.

8.8 Glazed Tiles in Skirting and Dado

8.8.1 The tiles shall be of approved make and shall generally conform to IS: 777. The
tiles shall be of earthenware covered by a glaze thoroughly matured and fitted to
the body. The tiles shall be sound, true to shape, flat and free from flaws and other
manufacturing defects affecting their utility The top surface of the tiles shall be
glazed. The underside of the tiles shall not have glaze on more than 5 per cent of
the area in order that the tile may adhere properly to the base. The edges of the
tiles shall be free from glaze, however, any glaze if unavoidable shall be
permissible on only upto 50 per cent of the surface area of edges.

8.8.2 The glaze shall be free from welts, chips, craze, specks, crawling or other
imperfections detracting from the appearance when viewed from a distance of one
meter. The glaze shall be either glossy or matt as specified. The glaze shall be
white in colour except in the case of coloured tiles when colours shall be specified
by the Engineer-in-Charge. There may be more than one colour on a tile.

8.9 Dimensions and Tolerances

8.9.1 Glazed earthenware tiles shall be made square or rectangular in sizes as specified
and shall be straight or cushion edge type.

8.9.2 Half tiles for use as full tiles shall have dimensions which shall be such as to make
the half tiles when jointed together (with 1 mm joint) match with dimensions of full
tiles. Tiles may be manufactured in sizes other than those specified above.

8.9.3 The thickness of the tiles shall be 5 mm as specified.

8.9.4 The dimensions of fittings associated with the glazed tiles namely cove base,
round edge tile, angles corner cups, ridge and legs, cornices and capping beads
shall be of the shape and dimensions as required and the thickness of fittings shall
be the same as the thickness of tiles given above.

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8.10 Tolerances

8.10.1 Facial Dimensions - The lengths of all the four sides of the tile shall be measured
to the nearest 0.1 mm. The average value of lengths/breadth shall not vary more
than ± 0.8 mm from the above specified dimension.

8.10.2 The variation of individual dimensions from average value of length/breadth shall
not exceed ± 0.5 mm.

8.10.3 Tolerances on thickness shall be ± 0.4 mm.

8.10.4 Tiles shall be checked for squareness and warpage as described therefore.

8.11 Trueness of Shape (Squareness)

Any variation from a right angle in the angle contained by any two adjoining sides shall be
limited so that if a builder's steel square is placed against the angle, the distance between
the inner edge of the square and the adjacent side of the tile or fitting shall not be more
than 0.5 mm per 100 mm run I above).

8.12 Performance Requirements Water absorption

8.12.1 The average water absorption of the tiles when tested and evaluated in
accordance with IS : 777 s not exceed 20 per cent.

8.12.2 Crazing: Tiles subjected to two cycles of crazing test as per IS: 777 shall not show
any sign crazing.

8.12.3 Impact Resistance: Tiles when tested for impact resistance as per IS: 777 shall
remain intact, apart from surface marking.

8.12.4 Chemical Resistance: When tested as per IS: 777, the glazed surface of tiles
and/or the fittings having a white or cream coloured glossy glaze shall show no
modification.

8.13 Preparation of Surfaces

The joints shall be raked out to a depth of at least 15 mm in masonry walls. In case of
concrete walls, the surface shall be hacked and roughened with wire brushes. The surf;
shall be cleaned thoroughly, washed with water and kept wet before skirting is
commenced.

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8.14 Laying

8.14.1 12 mm thick plaster of cement mortar 1: 3 (1 cement: 3 coarse sand) mix or as

specified shall applied and allowed to harden. The plaster shall be roughened with
wire brushes or by scratch diagonal at closed intervals.

8.14.2 The tiles should be soaked in water, washed clean, and a coat of cement slurry
applied liberally at back of tiles and set in the bedding mortar. The tiles shall be
tamped and corrected to proper plane and lines. The tiles shall be set in the
required pattern and jointed. The joints shall be as fine as possible. 1 of skirting or
dado shall be truly horizontal and joints truly vertical except where otherwise
indicated. Skirting and dado shall rest on the top of the flooring. Where full size
tiles cannot be fixed these shall cut (sawn) to the required size and their edges
rubbed smooth.

8.15 Curing and Finishing

The joints shall be cleaned off the grey cement grout with wire/coir brush or trowel to a
depth of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush
pointed with white cement added with pigments if required to match the colour of tiles. The
work shall then be kept wet for 7 days. After curing, the surface shall be washed and
finished clean. The finished work shall not sound hollow when tapped with a wooden
mallet.

8.16 Measurements

8.16.1 Length shall be measured correct to a cm. Height shall be measured correct to a
cm in the case of dado and 5 mm in the case of riser and skirting. The area shall
be calculated in square meter, correct to two places of decimal. Length and height
shall be measured along the finished face of the skirting or dado including curves
where specials such as coves, internal and external angles and beads are used.
Where cornices are used the area of dado shall be measured excluding the
cornices. Nothing extra will be paid for cutting (sawn) the tiles to sizes.

8.16.2 In addition to payment for areas of skirting and dado, specials such as coves,
internal and external angles and beads shall be measured separately and paid for
in running metres. Cornices shall also be similarly measured for payment in
running metres. Areas where coloured tiles or different types of decorative tiles are
used will be measured separately to be paid extra over and above the normal rate
for white tiles.

8.17 Rates

The rate shall include the cost of all material and labour involved in all the operations
described above. The specials such as coves internal and external angles and beading
shall be measured and paid for separately. The rate shall not include cost of cornices
which shall be measured and paid for is running metres separately.

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8.18 Glazed Tile Specials

The specials consist of coves, internal and external angles, beads cornices and their
corner pieces. Coves beads and angles shall be of thickness not less than the thickness
of the tiles with which they are used. The size of coves, beads, angles refer to the greatest
width of the special measured in a straight line. The stipulated size of cornices is their
height. The lengths of specials shall be 15 cm, 10 cm or other standard size available
conforming to the size of tiles available.

8.18.1 In other respects the general specifications described, in 11.15.1 of CPWD

specifications 96 with correction slips shall be applicable.

8.18.2 Preparation of Surface, Laying, Curing and Finishing shall be as specified in

11.16.2, 11.16.3 and 11.16.4 of CPWD specifications 96 with correction as far as
applicable.

8.19 Measurements

Special tiles to form coved internal angles of any radius, rounded external angles,
architraves moulding, ceiling ribs, cornices and the like shall each be measured in running
metres correct to a cm. Railing members and vertical members shall each be so
described. Ends, angles and internal sections shall be enumerated separately.

8.20 Rate

It shall include the cost of all materials and labour involved in all the operations described
above. Nothing extra shall be paid for corner pieces at junctions of coves, beads, cornices
etc. nor for using cut lengths of specials

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9. WOOD WORK

9.1 Scope of Work

The work shall include providing wood work for the building for doors/windows, cabinets,
handrail etc. and at any other location and situation as directed by the Architect/Engineer.
This includes providing and installation of the hardware/ ironmongery complete with
finishing, including glazing work in accordance with the design, patterns, shapes,
thicknesses, details, all as shown on the "Good for Construction" drawings or as specified
or as directed by the Architect/Engineer-in-Charge complete in all respects to give the
quality of finished work as desired by and to the entire satisfaction of the
Architect/Engineer. The work shall also include kiln seasoning, impregnation with
preservatives and providing all plant, equipment and appliances required to complete the
work.
The Contractor shall provide all the necessary wood working plant and equipment for use
at site for sawing, planning, sanding, rebating, moulding, groove cutting, dovetailing, etc.

9.2 Applicable Specifications

All work shall generally be in accordance with the CPWD Specifications 2009, ISI
specifications and as detailed in Part 9 - Wood Work of the same except as modified
herein under and as per the additional requirements given herein under.

9.2.1 Materials

Timber - The colour of timber shall be consistent. All timber in the entire building shall
have similar colour and grains. In any one area, the grains and colour shall be selected
and matched. All the timber shall be of the species specified. Only the selected quality of
timber shall be permitted on the work. Timber shall be of approved origin and shall be well
seasoned.
Block Board - Block boards shall be Grade 1 exterior grade. One sample for every 100
sqm or part thereof shall be taken and testing done as per IS: 303. All the samples tested
shall meet the requirement of physical and mechanical properties of plywood boards.

9.2.2 Seasoning and Preservative treatments of Timber

To Clause 9.1.7 of CPWD Specifications 2009 add the following:

9.2.1.1 All timber for woodwork shall be kiln seasoned. Tests shall be carried out for
moisture content on each lot. Test certificates from approved laboratory shall
be submitted to the Engineer. Up on delivery of each lot, for acceptance. Kiln
seasoning of timber shall be done as per IS: 1141 in plant approved by the
Engineer-in-Charge.

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9.2.1.2 Preservative Treatment shall be done for all timber to be used in the works,
which is not visible and is used only as framing to be covered by other work.
The treatment shall be done as per IS: 218 or IS: 10013 and tested as per IS:
4833.
9.2.1.3 The rate for timber work shall include provision of above treatments.

9.2.3 Samples

To Clause 9.1.7 of CPWD Specifications 2009 add the following:

Before proceeding with any work, the Contractor shall submit samples of timber and other
materials to the Engineer for approval. Samples and mock ups shall be made and put up
for approval for all frames, doors, panelling, skirting etc. before execution of the work is
taken up.

9.2.4 Shop Drawings

Shop drawings, with full size details shall be used for execution of the work. These
drawings shall be submitted to the Engineer-in-Charge. All work shall be carried out to the
dimensions shown on the drawings. Shop drawings prepared by the Contractor shall show
all details of joints, grooves, rebates, mouldings etc. in all respects and tolerances,
hardware, installation of ironmongery etc. complete.

9.2.5 Joinery and Carpentry

All joinery work shall be securely jointed, using appropriate joints- dovetailed, mortised
and tenoned, tongued and grooved- housed and glued with an adhesive of approved
quality (Araldite/ Fevicol etc.).
Bamboo and hard wood pins are to be used where directed by the Engineer-in-Charge.
Non-rusting screws shall be used in all work.
All wood work in contact with brick masonry or plaster or concrete shall be painted with
approved wood preservative paint.
All arises and angles shall be slightly rounded or square, as directed by the Engineer-in-
Charge.
All sizes of timber are specified as the finished sizes.

9.2.6 Pre-laminated Flush Doors

To Clause 9.7 of CPWD Specifications 2009 add the following:

35 mm thick both side pre-laminated flush doors having solid core of block board
construction, frame of first class hard wood with 25 mm thick teak wood lipping on all
edges, fully rebated not visible on face, well matched veneers of plywood all as per
drawings, specifications and as directed complete using .All flush doors shall be of
approved equivalent solid core type as specified, to confirm to IS: 2202 and IS: 1659. The
finished thickness of the shutter shall be as shown on the drawings.
Lamination on both the sides of the flush door shall be provided of the approved brand,
colour shade & texture by the Architect/Engineer with adhesive complete.
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The veneers shall be of such thickness that the core construction is not apparent when
the doors are decorated. An approved sample shall be deposited with the
Architect/Engineer for reference.

The solid core shall be prepared from best quality seasoned and treated wood, of one
species, having straight grains. The adhesive used for bonding/ cross-bonding and
plywood shall be Phenol Formaldehyde synthetic resin conforming to BWR (boiling water
proofing) type specified in IS: 848.
All edges of the core shall be lipped internally with first class teak wood battens of 25mm
minimum depth, glued and machine pressed along with the core. The lipping shall not be
visible on faces. Sample for approval must have such lipping. The lipping shall not be
measured and paid for separately but shall be deemed to be included in the rate for the
door. (This supersedes the provision made in clause 9.7.2, 9.7.4 of CPWD Specifications
2009.)
Flush doors shall have appropriate construction and the depth of top/bottom rail shall
be adequate to take concealed door closers/ floor springs. The depth of the lock rail
shall be appropriate to take the mortise locks. The Contractor shall provide mock-up to
demonstrate the above, for approval, before placing order for doors.
No defective door shall be accepted.
Doors having other face veneers or commercial veneers shall be as specified in the
Schedule of Quantities.

9.2.7 Timber Handrails

The handrails shall be of second class teakwood having moulding as per design fixed on
existing MS flat with necessary rustproof screws, proper jointing of the hand rail at turning
etc. complete French sprit polish two or more coats including a coat of wood filler.
The handrails shall be wrought, rebated and joined as per design and drawings, true to
shape with clear and sharply defined features. The handrails shall be rectangular, square,
chamfered, circular or curved in plan or in section or in both. The handrails shall be
securely fastened with screws or other approved fasteners to the balustrades.

9.2.8 Laminates

Laminates shall conform to IS: 5746 and shall also satisfy surface flame spread test as
per BS: 476 Part-7. The laminates shall be 1mm thick, having a density of approximately
1383 kg/cum. Laminates shall be of plain matt of approved brand, colour shade or
textured of approved makes on flush door with adhesive complete.

9.2.9 Holdfasts and Anchor Fasteners

Holdfasts shall be as per IS: 7196. The number of holdfasts used for each rough ground
of the door frames shall be as approved by the Engineer.
Expansion type anchor fasteners of approved size and manufacturer shall be used in
locations where holdfasts are not allowed for fixing frames.

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9.2.10 Ironmongery

All items of ironmongery and fittings, including door locks, hinges, hydraulic door closers,
floor springs, Sliding mechanism for sliding doors, all stops, latches, coat hooks etc.
together with their fixing accessories shall be of stainless steel ISI marked, procured and
fixed by the Contractor. The Contractor shall supply Catalogues and samples for approval
of the Architect/Engineer, and shall procure the same after obtaining the written approval
of the Engineer.
For doors, where Electric Strike, Electromagnetic locks and Magnetic Contacts are
proposed to be fixed as part of the Security and Access Control system, the Engineer-in-
Charge shall supply the same free of cost to the Contractor who shall fix the same at no
extra cost as per the instructions of the Engineer-in-Charge.

9.2.11 Termite, Wood Borer and Other Timber Pests

The Contractor shall obtain all timber and other timber based materials free from termites,
wood borer or other timber pests.
In the event of any evidence being found of infestation of wood work by pests, during the
Contract or Defects Liability Period, the Contractor shall replace all the wood work and
make good the same at no extra cost.

9.3 Acceptance Criteria

9.3.1 Acceptance of Work at Intermediate Stage

Clause 12.19.1.1 of CPWD Specification 2009 shall apply for woodwork.

9.3.2 Final Acceptance of Work

Clause 12.19.2.1 and 12.19.2.3 CPWD Specification 2009 shall apply for woodwork.

9.4 Protection

The Contractor shall protect the work at all times from any damage. All finished work
including ironmongery shall be protected by polythene-wrap or other approved means.
Doors which are in constant use by work people shall be kept open by means of a wedge.

9.5 Guarantee

Refer to 1.11.1 to Preamble to CPWD specifications 2009.

9.6 Measurements

CPWD Specifications 96/ISI specifications shall apply except that the timber frame and
the separate timber member notched into the frame (refer Clause 9.7 and for Flush door
clause 9.7.14, of CPWD Specifications 96 with correction slips if any ) shall be measured
separately, as if it were not fixed. The height and width shall be outside to outside of the

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frame (excluding the rough grounds).

Handrails to be measured in metre.
The rate quoted for the doors (other than Fire Doors) shall include the cost of providing
and fixing heavy duty stainless steel hinges and other items of Ironmongery which shall be
measured and paid for separately.
The rate quoted for fire doors shall include all cost of material and labour involved in all
the operations involved. However the door frames shall be measured under the item of
steel works and the ironmongery (excluding hinges), panic hardware and the vision panels
shall be measured and paid for separately.

9.7 Rate

Replace clause 9.3.5 of CPWD Specifications 2009 (with correction slips if any) by the
following:
The rate for wood work shall include the cost of materials and labour involved in all the
operations described above.

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10. METAL WORK

10.1 Scope of Work

The work shall include providing metal work in ferrous and non-ferrous metals in the
building for balustrades, handrails, railings, grill work, framework of skylights, inserts,
fasteners, lugs using plates, chequered and plain plates, flats, strips, squares, rounds,
tubes, pipes, angles, channels, tees, expanded metal, I-sections, etc. including cutting,
filing, grinding, drilling, mechanical fastening, welding, etc. at locations and situations as
directed by the Engineer-in-Charge in accordance with the design, patterns, shapes,
thicknesses, details, all as shown on the "Good for Construction" drawings or as specified
or as directed by the Engineer-in-Charge and also as per the Specifications, standards
and codes as given here in under, complete in all respects to give the quality of finished
work as desired by and to the entire satisfaction of the Engineer-in-Charge.

10.2 Applicable Specifications

All work shall be done as per CPWD Specifications 2009 with latest correction slips
except as modified herein under and as per the additional requirements given herein
under.

10.2.1 Shop drawings

All work shall be executed to approved shop drawings. The shop drawings shall inter-alia
show the complete details of the connections including the fixing arrangement to concrete
or brickwork or flooring, etc., the size of the welds/ bolts/ nuts/ washers/ grinding finish/
tolerances, etc.

10.2.2 Samples

The Contractor shall submit samples of all materials that are called for by the Engineer.
The Contractor shall prepare samples of workmanship and mock-up for approval.

10.3 Protection

The Contractor shall protect the work at all times from any damage. All finished work shall
be protected by polythene-wrap or other approved means.

10.4 Inserts

The Contractor shall fix all necessary inserts such as steel plates, pipe sleeves, bolts etc.
and make provision of holes, pockets, dowels etc. in the formwork to enable subsequent
fixing of supports, brackets, ceilings, precast members etc. as indicated on the drawings,
or called for in the Schedule of Quantities or as required by the Engineer.

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With the prior agreement of the Engineer, expansion type fasteners may be used by the
Contractor in hardened concrete.
The inserts shall be properly protected from damage, slurry leakage etc. by methods such
as applying grease, wrapping with burlap, plugging with hemp cloth etc. to the satisfaction
of the Engineer.

10.5 Steel Work in Built up Section (Welded)

The steel work in built up sections (welded) such as trusses, framed work etc. is specified
in this clause.

10.5.1 Laying out

It shall be as specified in 10.3.1 of CPWD Specifications 2009 and correction slips if any.

10.5.2 Fabrication

i Straightening, shaping to form, cutting and assembling, shall be as per clause10.3.2 of

CPWD Specifications - 2009 as far as applicable, except that the words "riveted or
bolted" shall be read as "welded" and holes shall only be used for the bolts used for
temporary fastening as shown in drawings.

ii Welding
Welding shall generally be done by electric arc process as/ IS: 816& IS: 823
The electric arc method is usually adopted and is economical. Where electricity for public
is not available generators shall be arranged by the contractor at his own cost unless
otherwise specified. Gas welding shall only be resorted to using oxyacetylene flame with
specific approval of the Engineer-in-Charge. Gas welding shall not be permitted for
structural steel work. Gas welding requires heating of the members to be welded along
with the welding rod and is likely to create temperature stresses in the welded members.
Precautions shall therefore be taken to avoid distortion of the members due to these
temperatures stresses

The work shall be done as shown in the shop drawings which should clearly indicate
various details the joint to be welded, type of welds, shop and site welds as well as the
types of electrodes to be used Symbol for welding on plane and shops drawings shall be
according to IS : 813.

As far as possible every effort shall be made to limit the welding that must be done after
the structure is erected so as to avoid the improper welding that is likely to be done to
heights and difficult positions on scaffolding etc. apart from the aspect of economy. The
maximum dia. of electrodes for welding work shall be as per IS: 814 and Appendix "B" of
IS: 823. Joint surfaces which are to be welded together shall be free from loose mill scale,

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rust, paint, grease or other foreign matter, which adversely affect quality of weld and
workmanship.

iii Precautions
All operations connected with welding and cutting equipment shall conform to the safety
requirements given in IS: 818 for Safety requirements and Health Provision in Electric and
gas, welding and cutting operations.

iv Operation, Workmanship and Process of Welding is described in Appendix B, of

Chapter 10 of CPWD Specifications 2009.

v Inspection and testing of welds shall be as per IS: 822.

vi Assembly
Before welding is commenced the members to be welded shall first be brought together
and firmly clamped or tack welded to be held in position. This, temporary connection has
to be strong enough to hold the parts accurately in place without any disturbance. Tack
welds located in places where final welds will be made later shall conform to the final weld
in quality and shall be cleaned off slag before final weld is made.

vii Erection
The specifications shall be as described in 10.3.3. of CPWD Specifications - 2009 and
correction slips if any except that while erecting a welded structure adequate means shall
be employed for temporary fastening the members together and bracing the framework
until the joints are welded. Such means shall consist of erection bolts, tack welding or
other positive devices imparting sufficient strength and stiffness to resist all temporary
loads and lateral forces including wind. Owing to the small number of bolts ordinarily
employed for joints which are to be welded temporary support of heavy girders carrying
columns shall be specially attended. Different members which shall be fillet welded, shall
be brought into as close contact as possible. The gap due to faulty workmanship or
incorrect fit if any shall not exceed 1.5 mm. If gap exceeds 1.5 mm or more occurs locally
the size of fillet weld shall be increased at such position by an amount equal to the width
of the gap.

viii Painting
Before the member of the steel structures are placed in position or taken out of the
workshop these shall be painted as specified in para 10.2.2 of CPWD Specifications 2009
and correction slips if any.

10.5.3 Measurements

The mode of measurements shall be the same as specified in 10.2.4 CPWD

Specifications -96 and correction slips if any except that weight of welding material shall

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not be added in the weight of members for, payment and nothing extra shall be paid for
making and filling holes for temporary fastening of members during erection before
welding.

10.5.4 Rate

The rate shall include the cost of all labor and materials involved in all the operations
described above

10.6 M.S. Sheet Sliding Shutters

These shall be manufactured as per drawings and specifications. These shall be

fabricated from mild steel sheets.

The shutters shall be double or single leaf shutter as specified. The shutters shall be
fabricated of specified size of M.S. angle iron frame Diagonally braced with the same size
of M.S. angle and riveted together with 3mm gusset plate at junction to form a rigid frame.
M.S. sheet of 1 mm thickness or as specified shall be fixed to the frame with rivets, as
approved by the Engineer-in-Charge. These shall also be provided with top and bottom
guide rails of specified. Size angles or T-irons and 25mm diameter pulley or 'with 25mm
diameter ball bearing at the bottom and guide back with steel pulleys at the top. The
shutters shall also be provided with locking arrangement, handles, stoppers, and
holdfasts, other fitting as specified in the description of the item.

The guide rails shall be sufficiently long and continued along the wall ort both ends so
that the sliding shutters can rest against the walls, giving full opening when so required.
Grills to be provided at the central portion of Rolling shutters for ventilation as per
Architect/Engineer.

10.6.1 Fixing

The guide rails shall be fixed to the floor by means of anchor bolts embedded in the
cement concrete floor. The steel section at the top shall be suitably supported from the
walls. Two channel sections shall be suitably fixed vertically below the extreme clamps in
the wall and floor to avoid the shutter from going out of the supports at top and bottom. A
suitable clamping arrangement will be provided at either end of the opening to avoid the
shutters from rolling back into the opening. All the adjoining work damaged in fixing shall
be made good to match the existing work.

10.6.2 Painting

All members of the sliding shutters including fittings shall be thoroughly cleaned of rust,
scales, dust etc. and given a priming coat of approved steel primer i.e., Red oxide zinc
chrome primer conforming to IS: 2074 before fixing them in position

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10.6.3 Measurements

Metal Work shall be measured in kgs unless indicated otherwise in the Schedule of
Quantities. The actual dimensions including any embedded portion shall be taken and the
weight calculated in kgs to the nearest second place of decimal using the standard
coefficients for converting the area/ length of the member to weight.
All wastage and variations are deemed inclusive in the item rate quoted by the Contractor
and nothing extra is admissible on this account. Payment will be made only for the
measured quantity of metal work incorporated in the work. Lugs of the inserts shall also
be measured under the item of Inserts.

10.6.4 Rate

The rate quoted shall include the cost of materials and labour involved in all the
operations described above.

10.7 Fire Check Door

i. Fire Rating
The steel fire doors
1. Procurement of 2 hr. fire rated door, should be tested and comply performance
criteria of Stability, Integrity and Insulation as per BS 476 Part 22 and IS 3614
Part II.
2. Frame should be made up of 1.6 mm Stainless steel with a single (6 bend)
rebate profile of 100 X 57 mm with holdfasts provided for grouting
3. Shutter of overall thickness 46 mm Flush design formed out of two outer skin
panels of 1.2 mm stainless steel sheets having lock seam joints for high
strength locking. Reinforcements shall also be provided at locking / hardware
area.
4. Premium quality SS Butt / SS Ball bearing hinges which are totally flushed with
the frame should be used..
5. The doors should be made using multibend construction technique using
special lock seam joints.
6. Proprietary Ceramic Based infill Material should be used.
7. The doors shall be procured in an assembled form with flexible hold fast and a
protective film coating.
8. The Mode of Packing shall be 5 Ply corrugated Box Flat packing.
ii. Standards
Doors should be manufactured strictly as per Indian and international standards
and tested as per BS 476 Part 22 and IS 3614 Part II
iii. Stability

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The door should not crumble.

iv. Integrity
In case of a fire, hot gases and flames would not propagate from one side to the
other.
v. Insulation

The door should prevent the cold face temperature from rising above 175 oC
even if the outside temperature goes as high as 1133oC.

Cautions

1. On receiving the door place the door on a flat ground with the "TOP" stamp
exposed and never in the free standing position prior to installation.
2. Bend the flush type hold fasts manually out for grouting during installation
Clean the door with a soft cloth and mild soap solution to cleanse dirt from the
surface
3. Do not place any heavy loads on the poor packing. This can lead to denting of
the door surface.
4. Do not unpack the door until installation. This will ensure protection of the door
at site prior to installation.
5. Bend the hold fasts only while installing the doors to avoid injury.
6. Do not scribe the door surface with any sharp objects on door (though doors is
chemically treated and painted properly this will make point of rusting).
7. Do not subject the door shutter to downwards cantilever pressure / force while
in open condition.
8. Do not remove plastic angle inserts between the doorframes and shutter till
the door has to be aligned. Ensure that the plastic angles are in place till the door
is in grouting / concreting stage.
9. Do not remove the stretch film till the painting on wall is completed (it is for the
protecting the paint surface during the installation).
10. Do not fill concrete / grout the door frame without aligning the door properly
General
The shutter of the door of approved make and shall be so designed so as to
provide the specified fire resistance when tested as per IS:3614 (Part 2): 1992 and
BS: 476 part 20 & 22 to suit the specified requirement and the manufacturer must
produce certificates of a recognized laboratory to the satisfaction of the Engineer.
Frame
Door frames of 16 SWG G.I. sheet formed to double rebate profile of suitable
section as per manufacturer with heat activated in tumescent fire seal strips of size

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10mm x 4mm (for smoke sealing) mounted in the groove in frame or EPDM gasket
to act as smoke seal suitable for mounting 120 minutes fire rated shutters with one
coat of anti-termite fire retardant primer.
Sill
The sill shall be of 16 SWG G.I. tube (not required in escape route doors).
Hardware/Fittings
(a) DOOR CLOSER:
Fire Rated Briton 121 or equivalent imported from Europe / USA having following
specifications:
Fixed Strength size 3, CE marked;
Certifier Approve CF390 – suitable for fire doors;
Strip steel arm set is pressed for increased rigidity;
Pressure Die Cast Aluminium body;
Hardened and ground steel rack and pinion mechanism for smooth and efficient
operation;
High Quality hydraulic fluid with built in temperature compensation ensure reliable
operation between -15degree C to +40degree C;
Independently certified for conformity to all requirements of EN1154, tested to
5,00,000 cycles;
Independently certified for conformity to all requirements of EN1634 fire test (upto
3hours);
Separate adjustments for both closing speed and latching speed;
Carries a manufacturer ten (10) year warranty.
MAKE – INGERSOLL RAND / DORMA / UNION/ GODREJ

(b) MORTICE LOCK :

Fire Rated Mortice Lock ME 60 / E-Series or equivalent imported From Europe/
USA having following specifications:
Lock case European Standard EN12209/DIN18251 and cylinder to EN1303
Grade 304 stainless steel faceplate to resist fire/corrosion
Non-handed and field reversible
Stainless steel 22mm throw deadbolt for high security
Lock case is in Steel
Latch/Deadbolt/Follower in Cast Stainless Steel
Follower suitable for 8mm spindles
MAKE – INGERSOLL RAND / DORMA / UNION/ GODREJ

(c) DOOR CO-ORDINATOR :

Ingersoll Rand make ‘IVES’ or equivalent Door Co-ordinator for Double Leaf door
co-ordination.
MAKE – INGERSOLL RAND / DORMA / UNION

(d) TOWER BOLT :

304 grade S. S. concealed tower bolt 300mm long Indian make.

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(e) Panic Bar/Exit Devices

These shall be of press type / pull type panic bars either single or triple latch. Briton
376 E series or equivalent imported from Europe / USA having the following
specifications:
Successfully tested for Panic Application and exceeds the requirement of EN
1125;
Successfully tested for Emergency Application to the requirement of EN 179;
Carries a manufacturer 5yrs. Warrantee certificate;
MAKE – INGERSOLL RAND / DORMA / UNION

(f) Seal
Heat activated in tumescent seal of size 10mm x 4mm of approved quality and make
or EPDM gasket shall be provided on all edges of door to check the spread of smoke
in case of fire.

10.8 Metal Railings

General
All complete steel/ aluminium railing elements, terminal sections, posts, and other fittings
shall be of shape, size and designation of approved material and make as given in the item
of work or as directed by Engineer. In case of steel railing all these elements shall be
painted with an approved paint. If straightening is necessary, it shall be done by methods
approved by Engineer.
The Contractor shall take every precaution against damage of the components during fixing
in position.
Damaged galvanised surfaces shall be cleaned and regalvanised. Special care shall be
taken to prevent staining of all products rust, mortar, etc. before it is put into use.
Fixing
The railing shall be carefully adjusted prior to fixing in place to ensure proper matching at
abutting joints, correct alignment and camber throughout their length.
Fixing shall be strictly as per fixing details shown on drawing or as directed by Engineer.
If sections are not galvanised, railing shall be given one shop coat of paint, and three coats
of paint after erection.

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11. ALUMINIUM WORK AND GLAZING

11.1 Scope of Work

The work shall include providing Powder Coated aluminium (minimum thickness of powder
coating 50 micron) and fixing glazing in aluminium door, window, ventilator shutters
skylights, semi-unitized structural curtain wall system, partitions etc. and at any other
locations and situations with PVC/neoprene gasket etc. complete as per the architectural
drawings and the direction of engineer-in-charge in accordance with the design, patterns,
shapes, thicknesses, details, all as shown on the "Good for Construction" drawings or as
specified or as directed by the Engineer-in-Charge and also as per the specifications,
standards and codes as given herein under, complete in all respects to give the quality of
finished work as desired by and to the entire satisfaction of the Engineer.
Aluminium work shall be provided with extruded built up standard tubular sections /
appropriate z sections and other sections of approved make conforming to IS : 733 and IS :
1285, fixed with rawl plugs and screws or with fixing clips, or with expansion hold fasteners
including necessary filling up of gaps at junctions, at top, bottom and sides with required
PVC/neoprene felt etc. Aluminium sections shall be smooth, rust fee, straight, mitred and
jointed mechanically wherever required including cleat angle, Aluminium snap beading for
glazing / panelling, C.P. brass/ stainless steel screws, all complete as per architectural
drawings and the directions of Engineer-in-charge (Glazing and panelling to be paid for
separately).
The work shall be carried out by an experienced specialist Sub-Contractor who shall be
appointed only after prior approval of the Engineer-in-Charge.

11.2 Materials

11.2.1 Aluminium

Aluminium shall conform to IS: 733, designation HE9-WP or HV9-WP alloy. Aluminium shall
be of superior quality extruded sections made by Indian Aluminium Co. or Hindustan
Aluminium or Jindal or an approved equivalent manufacturer, of a gauge suitable for the
work, powder coated to desired shade/colour, as specified.

11.2.2 Glass

Clause 9.2.9 of CPWD Specifiaction 2009 (with correction slips if any) of Wood Work shall
apply for the glass and with glass panes of 5.50 mm thickness (weight not less than 12.50
kg/sqm).

11.2.3 Powder Coatings

Powder coating (minimum thickness of powder coating 50 micron) for applications to

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aluminium alloys extrusion, sheets and preformed sections for architectural purposes and
their application, finish, performance etc. shall conform to BS: 6496 for powder coatings.
The coating (pure polyester) shall be as made by Berger or Nerocoat or Jenson &
Nicholson or approved equivalent.

11.2.4 Weather Stripping

Weather stripping shall be wool pile manufactured by Anand Reddiplex Limited or an

approved equivalent manufacturer. The profiles shall be as follows:

Application Base width Pile height

Casement windows 6.0mm 5.0mm
Swing doors 9.0mm 8.0mm

Gaskets shall be of with PVC / neoprene gasket etc. complete as per the architectural
drawings and the direction of engineer-in-charge of approved profile and manufacturer.

11.3 Handling and Storing Materials

11.3.1 Aluminium Work Fabrication and Components

All self-finished work shall be wrapped, taped or protected in an approved manner with non-
absorbent coverings.
These shall be delivered to a programme to reduce or eliminate site storage.
Coverings shall be removed just sufficient to enable jointing and assembling and shall be
replaced thereafter.

11.3.2 Glass

Glass shall be stored in dry, shaded and ventilated areas, on firm straight supports. Water
collection (condensation) between panes shall be prevented.
Different types of glasses shall be stacked separately with proper identification.

11.4 Workmanship

11.4.1 General

Aluminium Work shall be undertaken in accordance with sound engineering

practice and as follows:

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(a) Aluminium work shall be done as much as possible in the properly

equipped workshop.
(b) Site work shall be restricted to fixing and other operations that cannot be
undertaken in the workshop.
(c) Burrs, sharp edges and angles, coarse file marks, excess weld metal and
similar imperfections shall be removed.
(d) Work shall not be permitted to corrode or otherwise deteriorate between
fabrication and final treatment/ fixing.
(e) Aluminium work shall be fixed in the Works in a manner that prevents
corrosion due to contact with incompatible metals and other materials.

11.4.2 Bending and Joint Faces

Aluminium shall be shaped by bending with machine without weakening or otherwise

damaging the same.
Joint faces shall be formed to fit accurately in full contact. A suitable joint coating shall be
used for bolted or screwed connections.

11.4.3 Cutting Glass

All edge and surface treatment shall be done at the glass works after cutting to size. Glass
shall be cut to produce clean square edges. Any work to Toughened Glass shall be
undertaken by the glass manufacturer prior to the toughening process. The edge of multiple
glazed units shall not be nipped.

11.5 Design

The glazing for the building, including windows, skylights and doors, shall be designed by
the manufacturer as per BS: 6262 British Standard Code of Practice for Glazings for
Buildings, to withstand wind loadings as given by IS: 875 and provide seismic isolation and
restraint for buildings located in Seismic Zone-IV as per IS: 1893.
The Contractor shall submit complete design calculations for the design of the glazings for
the approval of the Engineer.
The Contractor shall order materials only after the designs are approved by the Engineer.

11.6 Performance

The performance of windows, glazing, doors, skylights shall be as given in BS: 6375 Parts 1
and 2 for weather tightness, operation and strength.

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11.7 Tests

Tests for performance shall be carried out by the Contractor as per following:
(a) BS: 5368 Part 1 - Air Permeability Test
(b) BS:5368 Part 2 - Water Tightness Test Under Static Pressure
(c) BS: 5368 Part 3 - Wind Resistance Test
The Engineer shall decide as to which windows shall be subjected to test.

11.7.1 Test Report

The test reports shall be submitted in quadruplicate as per the format given in BS: 5368
Part-4.

11.8 Sub Frames

All aluminium work shall be fixed to wooden sub frames. The sub frames shall be fixed to
brick work/concrete work using expansion bolts as directed by the Engineer-in-Charge.

11.9 Mock-up and Samples

Before preparation of shop drawings the Contractor shall submit samples of all preformed
and extruded sections proposed to be used. The Contractor shall also submit samples of
colours of coating, based on the colours requested by the Engineer. Once preliminary
approval is given and shop drawings are acceptable the Contractor shall submit final
samples of typical windows, complete in all respects.
Shop drawings shall be prepared by the contractor for each type of window / glazing giving
the details of all sections being used, their weights and fixing details, for approval of the
Engineer.
One complete sample of each type of window/glazing shall be erected at site for approval,
prior to mass execution.

11.10 Sealants

Structural grade and weathering grade silicon sealant ''Dow Corning'' or ''GE Silicon'' or
equivalent of approved colour and make shall be used as specified, as per the design
requirement.

11.11 Isolation

Where aluminium comes into contact with masonry, brick work, plaster or dissimilar metals,
it shall be coated with an insulating coat of lacquer, paint or tape to ensure that electro
chemical corrosion is avoided. The Contractor shall submit his proposal for the approval by
the Engineer-in-Charge before related materials are ordered.

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11.12 Protection

The Contractor shall protect the powder coated aluminium sections with clear or coloured
tape. The tape shall not disfigure the finish.
The Contractor shall protect installed work with suitable measures to the entire satisfaction
of the Engineer.

11.12.1 Protection against damage

Care shall be taken to avoid damage from any cause at all stages. Packing pieces used for
protection shall not disfigure or otherwise permanently mark the works.
Surface protection shall be afforded by careful handling and the avoidance of the use of
hooks, crowbars, or other implements that are likely to damage the stone, marble, granite
limestone, timber, doors, windows, metals, glass etc. Oils, grease, paint, cement slurry and
liquid agents liable to cause staining shall not be used in close proximity to the area in which
the materials are stacked.

11.12.2 Protection during Construction

Decorative surfaces shall be carefully protected during construction by a temporary cover of

adequate strength and durability.

11.12.3 Protection of finished work

At all stages of the Contract it is essential that all works are properly and effectively
protected.
Particular attention shall be given to permanently exposed surfaces, especially arises and
decorative features. The protection may be by timber strips, hessian or polyethylene, but
shall not be such as will damage, mark, or otherwise disfigure the work.
Polyethylene heavy duty sheeting may be used as protection against rain. It may be
necessary in certain cases to avoid contact of water with the materials.
Timber battens protecting sills or other arises shall be retained in position as long as
possible.
Suitable packing shall be used to ensure that scaffolding does not damage erected stone,
marble, granite or other finished works.
Work on the upper stages of the superstructure shall not be allowed to damage or disfigure
the work in the lower levels.
Unless special precautions are taken for winter working, the use of mortar shall be avoided
when the thermometer reads 2 degree and falling and the joints shall be protected.
Any disfigurement, discoloration or imperfection whatsoever due to any reason shall not be
accepted and the Contractor shall either remedy the same or redo the work at no extra cost.
The decision of the Engineer-in-Charge as to whether any work either in whole or in part is

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acceptable or not shall be final and binding on the Contractor.

11.13 Glazing

Adhesive labels for indicating "Glazing completed" shall be easily removable without
scraping. Marking with lime shall not be used for this purpose. Glass shall be protected
against mechanical damage. Any alkaline splashes shall be removed before they harden.

11.14 Tolerances

The size of aluminium work shall not vary by more than ±1.5mm.

11.15 Cleaning and Completion

On completion of the first area of aluminium work and glazing and the quality of work
accepted, the same shall be cleaned of all dust and other deposits.
This area of aluminium work and glazing shall be retained as a sample of the finished work,
wherein the effects of weather, movement and other conditions shall be reviewed over a
period not exceeding one month and the effects if found leading to unsatisfactory work, shall
be remedied by the Contractor, until a satisfactory sample of finished work is accepted. All
other work shall thereafter be completed to the same standard and quality as approved.

11.16 Ironmongery

For fixing ironmongery and friction hinges, if the wall thickness of the extruded aluminium
section is not adequate to take the threading of the screws, the Contractor shall provide
additional thickness with built-up sections etc. as required.
All Ironmongery including sliding gear for sliding glazings/ windows and the friction hinges
for side hung projected windows shall be supplied and installed by the Contractor. The
Contractor shall supply Catalogues and samples for approval of the Engineer.

11.17 Measurements

Aluminium work shall be paid by weight by calculating the actual weight of sections in the
window/glazing/door, before fixing of hardware, fixtures, glass etc.
Glass shall be measured on actual glass installed and nothing extra for wastage shall be
paid.

11.18 Rate

The rate shall include the cost of materials, labour involved in all the operations described
above. The cost for providing sealants shall not be paid separately.

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12. FLOORING

12.1 Scope of work

The work include laying of floor finishes for the building all as shown on the drawings or as
specified or as directed by the Architect / Engineer-in-Charge complete in all respects to
give the quality of finished work as desired by and to the entire satisfaction of the Architect /
Engineer-in-Charge. The work shall be carried out under the supervision of the
manufacturer / specialist Sub-Contractor who shall be appointed only after prior approval of
the Architect / Engineer-in-Charge.

12.2 Applicable specification

All work shall generally be in accordance with the CPWD Specifications 96/2009 and as
detailed in Part 11 – Flooring of the same except as modified here in under and as per the
additional requirements given hereunder.

12.3 General

All floor finishing materials such as stone slabs, kota, granite slabs or tiles, vitrified tiles,
timber floor boards / borders / bands, etc. shall be used in whole sizes. Wherever smaller
sizes than the whole is required as per design the same shall be prepared by machine
cutting after obtaining the permission of the Architect / Engineer-in-Charge. Manual cutting
shall not be permitted except for curved patterns.
All stone wherever used shall be from the same quarry.
All stone slabs shall be machine cut machine polished on all the sides as well as the edges.
All moulded edges shall be formed with edge moulding machines. All work of drilling, etc.
shall be done with power tools.
The thickness of 25 mm specified for stonework shall be with a tolerance of + 2 mm.
However, once one thickness is established or adopted the same shall be followed
throughout for the rest of the work.

12.4 Cement

Ordinary Portland Cement shall be used for all flooring work. White or coloured cement
shall be used for providing a floating coat behind the tiles before they are laid.

12.5 Surface Preparation

All contaminants such as dirt, oil, paint, wax grease, bitumen, forming, curing and release
agents efflorescence or other foreign matter shall be removed.

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12.6 Measurements

The area shall be calculated in sqm nearest to two decimals. Extra for cutting of stones in
curved portion shall be measured in Running Metre.

12.7 Rate

The rate quoted shall be applicable for flooring in different patterns, designs, in boarders in
one or more materials to form desired patterns, etc. All flooring shall be measured net
without any allowance for wastage.

12.8 Kota Stone Flooring

12.8.1 Kota Stone Slabs

i The slabs shall be of selected quality, hard, sound, dense and homogeneous in
texture free form cracks, decay, weathering and flaws. They shall be hand or
machine cut, to the requisite thickness. They shall be of the colour indicated in
the drawings or as instructed by the Engineer -in-Charge.
ii The slabs shall have the top (exposed) face polished before being brought to
site, unless otherwise specified. The slabs shall conform to the size required.
Before starting the work the contractor shall get the samples of slabs approved
by the Engineer-in-Charge.

12.8.2 Dressing

i Every slab shall be cut to the required size and shape and fine chisel dressed on
the sides to the full depth so that a straight edge laid along the side of the stone
shall be in full contact with it. The sides (edges) shall be table rubbed with coarse
sand or machine rubbed before paving. All angles and edges of the slabs shall
be true, square and free from chippings and the surface shall be true and plane.
ii The thickness of the slab after it is dressed shall be 20,25,30 or 40 mm as
specified in the description of the item. Tolerance of ± 2 mm shall be allowed for
the thickness. In respect of length and breadth of slabs Tolerance of ±5 mm for
hand cut slabs and ± 2 mm for machine cut slabs shall be allowed.

12.8.3 Preparation of Surface and Laying

The specification shall be as described in 11.18.3 of CPWD Specification 96 with correction

slips if any except that the edges of the slabs to be jointed shall be buttered with grey
cement, with admixture of pigment to match the shall of the slab.

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12.8.4 Polishing and Finishing

The specifications shall be described in 11.11.3 except that (a) first polishing with coarse
grade carborundum stone shall not be done, (b) cement slurry with or without pigment shall
not be applied on the surface before polishing of CPWD Specification 96 with correction
slips if any.

12.8.5 Measurements and Rates

These shall be as described in paras 11.18.5 and 11.18.6 of CPWD Specification 2009 with
correction slips if any.

12.9 Kota Stone in Risers of Steps, Skirting and Dado

a. Kota Stone Slabs and Dressing shall be as specified in 11.20.1 and 11.20.2
of CPWD Specifications-96/2009 except that the thickness of the slabs
shall be 25 mm or as specified in the description of the item. The slabs may
be of uniform size if required.
b. Preparation of surface shall be as specified in 11.19.2 of CPWD
Specification 2009 with correction slips if any.
c. Laying shall be as specified in 11.19.3 of CPWD Specification 96 with
correction slips if any except that the joints of the slabs shall be set in grey
cement mixed with pigment to match the shade of the slabs.
d. Curing, Polishing and finishing shall be as specified in 11.19.4 of CPWD
Specification 2009 with correction slips if any except that first polishing with
coarse grade carborundum stone shall not be done.

12.9.1 Measurements

Length shall be measured along the finished face of riser, skirting or dado correct to a cm.
Height shall be measured from the finished level of tread of floor to the top (the underside of
tread in the case of steps). This shall be measured correct to a mm in the case of risers of
steps and skirting and correct to a cm in the case of dado. The area shall be calculated in
'square metre correct to two places of decimal.
Lining of pillars etc. shall also be measured under this item.

12.9.2 Rate

The rate shall include the cost of all materials and labour involved in all the operations
described above.

12.10 Vitrified Tile flooring

The tiles shall be of approved make and shall generally conform to Table 12 of IS 15622
(Tiles with water absorption E ≤ 0.08 per cent Group BIa) and the joint thickness in flooring
shall not be more than 1mm. They shall be flat, and true to shape and free from blisters

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crazing, chips, welts, crawling or other imperfections detracting from their appearance. The
tiles shall be tested as per IS 13630. Classification and Characteristics of Vitrified Tiles shall
be as per IS 13712. The tiles shall be square or rectangular of nominal size. Table 1,3,5,
and 7 of IS 15622 give the modular preferred sizes and table 2,4,6 and 8 give the most
common non modular sizes. Thickness shall be specified by the manufacturer. It includes
the profiles on the visible face and on the rear side. Manufacturer/supplier and party shall
choose the work size of tiles in order to allow a nominal joint width upto 2mm for unrectified
floor tiles and upto 1mm for rectified floor tiles. The joint in case of spacer lug tile shall be as
per spacer. The tiles shall conform to table10 of IS 15622 with water absorption 3 to 6%
(Group BII).

12.10.1 Preparation of Surface and Laying

12.10.1.1 Base concrete or the RCC slab on which the tiles are to be laid shall be
cleaned, wetted and mopped. The bedding for the tile shall be with cement
mortar 1:4 (1 cement : 4 coarse sand) or as specified. The average thickness of
the bedding shall be 20 mm or as specified while the thickness under any portion
of the tiles shall not be less than 10 mm.

12.10.1.2 Mortar shall be spread, tamped and corrected to proper levels and allowed
to harden sufficiently to offer a fairly rigid cushion for the tiles to be set and to
enable the mason to place wooden plank across and squat on it.

12.10.1.3 Over this mortar bedding neat grey cement slurry of honey like consistency
shall be spread at the rate of 3.3 kg of cement per square metre over an area
upto one square metre. Tiles shall be soaked in water washed clean and shall be
fixed in this grout one after another, each tile gently being tapped with a wooden
mallet till it is properly bedded and in level with the adjoining tiles. The joints shall
be kept as thin as possible and in straight lines or to suit the required pattern.

12.10.1.4 The surface of the flooring during laying shall be frequently checked with a
straight edge about 2 m long, so as to obtain a true surface with the required
slope. In bath, toilet W.C. kitchen and balcony/verandah flooring, suitable tile
drop or as shown in drawing will be given in addition to required slope to avoid
spread of water. Further tile drop will also be provided near floor trap.

12.10.1.5 Where full size tiles cannot be fixed these shall be cut (sawn) to the
required size, and their edge rubbed smooth to ensure straight and true joints.
Tiles which are fixed in the floor adjoining the wall shall enter not less than 10
mm under the plaster, skirting or dado.

12.10.1.6 After tiles have been laid surplus cement slurry shall be cleaned off

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12.10.2 Pointing and Finishing

The joints shall be cleaned off the grey cement slurry with wire/coir brush or trowel to a
depth of 2mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush
pointed with white cement added with pigment if required to match the colour of tiles. Where
spacer lug tiles are provided, the half the depth of joint shall be filled with polysulphide or as
specified on top with under filling with cement grout without the lugs remaining exposed.
The floor shall then be kept wet for 7 days. After curing, the surface shall be washed and
finished clean. The finished floor shall not sound hollow when tapped witha wooden mallet.

12.10.3 Measurements

Length and breadth shall be measured correct to a cm before laying skirting, dado or wall
plaster and the area calculated in square metre correct to two places of decimal. Where
coves are used at the junctions, the length and breadth shall be measured between the
lower edges of the coves. No deduction shall be made nor extra paid for voids not
exceeding 0.20 square metre. Deductions for ends of dissimilar materials or other articles
embedded shall not be made for areas not exceeding 0.10 square metre.

12.10.4 Rate

The rate for flooring shall include the cost of all materials and labour involved in all the
operations described above, For tiles of sizes upto 0.16 sqm. unless otherwise specified in
the description of the item. Nothing extra shall be paid for the use of cut (sawn) tiles in the
work.
Extra over and above the normal rate for white tiles shall be paid where coloured or any
other type of decorative tiles have been used.

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13. SUSPENDED CEILINGS

13.1 Scope of Work

The work to install suspended ceilings for the building and shall include suspension grid
systems, accessories and other things necessary to complete the work, including providing
framing for all service outlets, fittings and fixtures, light fixtures, trap doors and access
panels etc., all as per design, pattern, details all as shown on the "Good for Construction"
drawings or as specified or as per the instructions of the manufacturer all as directed by the
Engineer-in-Charge complete in all respects to give the quality of finished work as desired
by and to the entire satisfaction of the Engineer-in-Charge. The work includes shaped
ceilings in plan & section.
The work shall be carried out by an experienced specialist Sub-Contractor who shall be
appointed only after prior approval of the Engineer.

13.2 Preparation

The Contractor shall ensure that the soffits and other backgrounds are clean and fit to
receive the suspension systems and perimeter work.
The Contractor shall coordinate closely with the work of other agencies.

13.3 Setting out

The Contractor shall set out the work so that;

(a) The correct ceiling level and profile are established.
(b) The panel centres and the joint lines are established including layout at
obstructions and in irregular areas.
(c) Cutting of ceiling panels is minimised or avoided.
(d) Mark the positions of access panels, luminaries, grilles, diffusers and other
service equipment, fire checks and everything else that affects the setting out.
(e) The locations of all fixing points are established.

13.4 Service Outlets

Service outlets such as for electric and lighting fittings, access panels, as shown on the
drawings and shall be shown on the shop drawings for the suspended ceilings. The shop
drawings shall also show the suspension arrangement from the structure, taking into
account ducting, piping and other services within the ceiling. Nothing extra shall be payable
for providing the service outlets.

13.5 Handling and Storage

All the components shall be stored under cover in clean and dry conditions in a dust free

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area and shall not be allowed to come into contact with cement, lime, plaster, mortar etc.
which can damage them. Special care shall be taken in stacking Plaster of Paris bags. They
shall be kept in dry conditions on a raised platform over wooden planks. The stacks shall be
kept away from the walls.

13.6 Cutting

Power tools shall be employed for the work. Manual work shall be done only under
exceptional circumstances with the prior permission of the Engineer-in-Charge.

13.7 Metal Sheet Ceiling

13.7.1 Scope of Work

The Metal Sheet suspended ceiling work of approved make shall be executed in flat,
tapered, curved or circular form, both in plan and in section together with coves, etc. as
required as per design.

13.7.2 General

Metal sheet suspended ceiling shall be of approved make together with all accessories and
fittings such as carrier and clip, carrier splice, edge cover profile and corner angles/splices,
cross "T" connection near to the wall, wall angles etc.

13.7.3 Materials

The suspended ceiling to be provided in position at all heights and levels, to shapes,
inclinations , in straight lengths to achieve curve profiles design ceiling tiles (600mm x 600
mm) manufactured out of 0.50 mm coil coated RMP(regular modified polyester) coated
galvanized steel (Z180 Zcm - Zinc coated Mass/275 Mpa yield Stress) or Aluminum powder
coated ceiling panels.
Exposed side of the tile shall have 20 micron of polyster over 5 micron primer coat. Tiles
shall have bevelled/square edges produced on equipment. Two sides of each tile to be
raised piped and stopped to ensure positive engagement into the spring clip profile. Tile
shall be suspended from the roof with rigid suspension system, duly cross braced , in
tubes/flat/angles with ceiling brackets and hold on clamps etc. . Wall angles to be 25x25x0.6
mm thick coil coated steel matching with the colour of tiles. Tiles shall be micro-perforated
with holes 1.5 mm. dia. @2.5mmc/c with a backing of acoustics non-woven tissue which
shall be factory laminated and 25 mm thick fibre glass wood insulation of 24 kg/cum density
wrapped in 14 gauge polyethylene sheet shall be including.

13.8 Shop Drawings

Shop drawings shall be prepared for all suspended ceiling work by the Contractor. The shop
drawings shall show the entire installation system, including framing around light fixtures,

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ducts, grills, access panels, etc. Shop drawings shall be submitted to the Engineer for
approval. It will be the responsibility of the Contractor to coordinate with all the service
Contractors doing work in ceilings, to incorporate appropriate suspension systems free of
ducts, pipes, cable trays etc.

13.9 Approvals

The Contractor shall submit catalogues, samples of all items to be used in the ceiling and
samples of workmanship, for approval of the Engineer.

13.10 Measurements

To Clause 12.27.5 of CPWD Specifications 2009 add the following:

Nothing extra shall be paid for suspended ceiling curved in plan.

13.11 Rate

The rate shall include the cost of all materials, labour, scaffolding and all items mentioned in
the preceding clauses, except, cost of tiles which will be paid separately.

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14. WATER PROOFING

14.1 General

14.1.1 Description

This section covers the requirements for cement based water proofing treatment including
preparation of surface as required for treatment of roofs, balconies, terraces etc. by using
broken china /ceramic clay tiles on the top finished surface.

14.1.2 Applicable codes and standards

The codes and standards generally applicable to the work of this section is listed
hereinafter:
a) IS: 269 Ordinary and low heat Portland cement.
b) IS: 2645 Integral cement waterproofing compounds.
c) IS: 3067 Code of practice for general design details and preparatory
work for waterproofing of buildings.
The following clauses are intended to amplify the requirements of the reference
documents listed above and the Contractor shall comply with these clauses.

14.2 Submittals

14.2.1 Method

Before starting the water proofing treatment the contractor shall submit details of the he
proposes to adopt.

14.2.2 Treatment

The waterproofing treatment shall be carried out by a specialist agency approved by

Engineer-in-Charge according to the specifications. The horizontal and vertical treatment
shall comprise of the following main operations:
a) Applying and grouting a slurry coat of neat cement using 2.75 kg/sqm of cement
admixed with proprietary water proofing compound to IS.2645 over the RCC slab
including cleaning the surface before treatment.
b) Laying cement concrete using broken bricks/bricks bats 25 mm to 100 mm size
with 50% of cement mortar 1:5 (1 cement : 5 coarse sand) admixed with
proprietary water proofing compound conforming to IS : 2645 over 20 mm thick
layer cement mortar of mix 1:5 .
c) After two days of proper curing applying second coat of cement slurry admixed
with proprietary water proofing compound conforming to IS : 2645

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d) Finishing the surface by using broken china/ceramic clay tiles with 20 mm thick
joint less cement mortar of mix 1:4 (1 cement : 4 coarse sand) admixed with
proprietary water proofing compound conforming to IS : 2645 and finally finishing
the surface with trowel with neat cement slurry and making of 300 x 300 mm
square.

14.2.3 Testing

The whole terrace finished shall be flooded with water for a minimum period of two weeks
for curing and final test.

14.2.4 Guarantee

A written guarantee shall be furnished by the contractor to certify that the water proofing
treatment done shall be free from defects of materials and workman ship for a period of 10
years.
Leakage, failure to stay in place, cracking, undue expansion and contraction shall be
judged as defective work.

14.2.5 Rate

The contractors’ rates shall include the cost of labour and materials required for all the
operations described above at all heights / depths.

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15. PLASTER

15.1 Applicable Specifications

All work shall generally be in accordance with the CPWD Specifications 2009 except as
modified hereunder and as per the additional requirements.
Groves shall be made on external /internal wall plaster complete as per architectural
drawing.

15.2 Cement

Portland ordinary Cement conforming to IS: 1489 shall be used for all plaster work. The
total chloride content of the cement shall not exceed 0.05%.

15.3 Measurements

Plaster shall be measured as per clause 13.1.9 of CPWD Specifications 2009 except that
the visible surface area shall be measured and plaster bands irrespective of widths shall
also be measured as part of wall plaster.
Plaster for all floor levels and all heights shall be measured under the same item.

15.4 Rate

As per clause 13.1.10 of CPWD Specifications 2009.

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16. PAINTING AND POLISHING

16.1 Scope of Work

The finishing works shall include providing plastering, painting, sealing coats and
decoration to internal and external surfaces of the building, all as shown in the drawings
and as specified or as directed by the Engineer-in-Charge.

16.2 Applicable Specifications

All work shall generally be carried out as per CPWD Specifications 2009 Part 13 -
Finishing except as modified hereunder:

16.3 Materials

a) General
i) All materials shall be obtained only from approved shade, texture ,finish of
approved manufacturers of building paints; ICI, Berger, Jenson and Nicholson,
Nerolac, Asian Paints and Goodlass Nerolac.
ii) Paint containers shall not exceed 5 litres capacity.
iii) All paints and other materials shall be delivered in sealed containers bearing
information as per statutory requirements. The Contractor shall in addition
furnish a letter with each consignment from the manufacturer giving the
following data:
(a) Manufacturer's name or recognised trade Mark.
(b) The appropriate title and specification number.
(c) Whether priming, undercoat or finishing coat.
(d) Lead free, if required.
(e) Whether for interior or exterior use.
(f) The colour reference.
(g) The method of application.
(h) The batch number and date of manufacture.
iv) For containers of materials other than paints the above data shall be provided
to the extent that it is appropriate.
v) No paint shall be used after a period of 6 months from the date of manufacture
or the expiry period given by the manufacturer. If this period is exceeded, the
paint shall be removed forthwith from the site by the Contractor and nothing
extra shall be paid on this account.
vi) Only such number of containers as are required for immediate use shall be
opened.
vii) All brushes, paint rollers, spraying equipment, kettles etc., used in carrying out
the work shall be clean and dry. They shall be thoroughly re-cleaned before
being used for a different type or class of material.
viii) Cutting in shall be neatly and accurately performed.
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ix) No painting shall be done during inclement weather conditions, in dusty
atmosphere or when it is raining or when the temperature is less than 10°C or
when the humidity is high.
x) Sequence shall be properly planned such that finished work is not spoiled by
subsequent preparatory works.
xi) Flood coat shall be provided for preservatives.
xii) Successive coats of undercoat shall have different tints.
xiii) Paint shall be applied only to properly prepared, clean, sound and dry
surfaces.
xiv) Each coat of paint shall be thoroughly dry before the next coat is applied and
the surfaces of primers and undercoats shall be lightly rubbed down and
dusted off.
xv) Coats of paint shall be applied at proper intervals to secure maximum
adhesion. Where two hard gloss finishing coats are scheduled, the second
coat shall be applied within 48 hours.
xvi) The method of application by brush, roller or spray shall be decided by the
Engineer-in-Charge.

b) Paints from one manufacturer

Materials for the priming coat, putty undercoats and finishing coats of paint for any one
system shall be obtained from the same manufacturer.

c) Paints ,Primers and Distempers

i) Fire Retardant Enamel paint on Fire doors to provide class - I surface
spread of flame as per IS:12777 and BS:476 part - 7, two or more coats.
ii) Synthetic enamel shall be approved make and shade and it is to be spray
painted.
iii) Priming paints for steel work shall be red lead priming paint, conforming to
IS:102 or red oxide zinc chrome priming paint conforming to IS:2074.
iv) Distempering with oil bound washable distemper of approved brand and
manufacture to give an even shade New work (two or more coats) over and
including priming coat with cement primer.
v) Plaster of Paris Putty of 2 mm thickness over plastered surface to prepare the
surface even and smooth complete
vi) Textured coating of UNITILE'S unirock / SPECTRUM'S naturaplast or equal
approved make with two silicate undercoats and two coats of polyurethene top
coat with or without groves as per detail approved drawing over plaster
surface as per manufacture's recommendations and instructions and as
directed by the engineer at site
vii) Acrylic Emulsion shall be of approved make and shade.

d) Wood preservative
i) Oil type wood preservative solution conforming to IS:218 shall be flood
applied on all woodwork.

e) Oils
i) Oil for oiling hardwood shall be raw linseed oil.

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ii) Oil for use prior to wax polishing shall consist of two parts refined linseed oil,
one part of white spirit and one sixteenth part of gold size. All parts shall be
measured by volume.

f) Filler with Plaster of Paris

Interior plaster shall be filled, made even and smooth with Plaster of Paris, anhydrous
gypsum, conforming to IS:2547.

g) French spirit polish

French polish shall conform to IS:348. It shall be prepared by dissolving pure shellac
(conforming to IS:347) in methylated spirits. Also refer clause 13.50.1 of CPWD
Specifications 2009.

h) Colours
Paints for the work shall match the colours specified/ approved by the Engineer-in-
Charge. Blending of paints or tinting shall not be permitted.
The Contractor shall assume that multi-colour schemes of decoration will be adopted in
which changes of colour will occur only at internal or external angles of wall and ceilings.
Nothing extra shall be payable for use of more than one colour of paint in one
area/surface.

i) Samples
Samples for testing may be taken from the sealed containers, spray gun containers or
from the workmen's kettles on the works. In addition the Engineer at his discretion may
require sealed containers to be set aside for subsequent testing.
Any work found to be done with unsatisfactory materials or not done in an acceptable
manner shall be rejected. Such works shall be made good by the Contractor at no extra
cost, to the entire satisfaction of the Engineer.
If any paint that is delivered to site is found to be defective or unsatisfactory its use shall
be suspended and the manufacturer and the Engineer notified immediately.

j) Storage and Handling

Inflammable materials like thinners etc. shall be stored separately. An adequate number
of fire extinguishers of suitable type shall be kept in ready to use condition in the store.

k) Surface preparation Iron and steelwork

(a) Bare iron and steelwork including sheeting and pipes shall be thoroughly
prepared by removing all dirt, rust and loose mill scale to the entire
satisfaction of the Engineer-in-Charge.
(b) Preparation shall include the use of chipping hammers, scrapers, power
tools with mechanical wire brushes and Carborundum grinding discs. The
use of mechanical chisels and other impact tools may exceptionally be
ordered if in the opinion of the Engineer-in-Charge their use is necessary.

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(c) All rivets, welds, angles, joints and openings shall be properly cleaned.
(d) All tools shall be operated in such a manner that no sharp ridges or burrs
are left and no cuts made in the steel.
(e) Dust and other loose material shall be removed after cleaning. Oil and
grease shall be removed with white spirit.
(f) The priming coat shall be applied before any contamination or rusting
occurs.
(g) All surfaces shall be washed with mineral spirits to remove any dirt or
grease before applying paint. Where rust or scale is present, it shall be
wire brushed and cleaned with emery paper.
(h) Steelwork shall be given one shop coat of primer before delivery to site.
In case this gets damaged in transit the damaged areas shall be cleaned
off, wire brushed, and spot primed immediately after delivery. A second
coat of primer shall be applied at site after erection.

l) Precautions

(a) Old brushes, if they are to be used with emulsion paints, should be
completely dried of turpentine or oil paints by washing in warm soap
water. Brushes should be quickly washed in water immediately after use
and kept immersed in water in break periods to prevent the paint from
hardening on the brush.
(b) In the preparation of surfaces for plastic emulsion painting, no oil base
putties shall be used in filling cracks, holes, etc.
(c) Splashes on floors etc. shall be cleaned out without delay and definitely
everyday, as they will be difficult to remove after hardening.
(d) Washing of surfaces treated with emulsion paints shall not be done within
3 to 4 weeks of application.

m) Preparation of paint

i) Mixing:

(a) All liquid paints shall be thoroughly stirred using mechanical stirrers with
a minimum speed of 650rpm to a uniform consistency when containers
are opened and before being transferred to paint kettles.
(b) Paste paints shall be beaten up thoroughly as directed by the
manufacturer prior to thinning.

ii) Thinning

(a) Thinning for oil paints shall not normally be permitted. In exceptional
circumstances, the Engineer-in-Charge may permit thinning with up to

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5% of white spirit by volume or a thinner as recommended by the paint
manufacturer to maintain the paint in a working consistency.
(b) PVA emulsion paints shall be thinned with potable water for the first coat
only depending on the porosity of the surface to be painted. In any case,
the quantity of water shall not exceed 50% by volume. Subsequent coats
shall not be thinned.
iii) Straining
Any paint showing bittiness in application shall be strained through fine
gauze.
(a) Addition of other materials
With the exception of the thinners given in (b) above, no other materials
shall be added to the paints.
(b) Mixing of different paints together Mixing of different paints together shall
not be permitted.

n) Protection

(a) All ironmongery, finger plates, power points, lighting fixtures, grills,
diffusers, fixtures of other services, machinery, plant and equipment,
flooring, glazing etc. shall be protected using PVC sheets weighing
1000g/sqm and masking tapes. Flooring, wherever laid, even though it
may not have been polished shall be protected likewise.
(b) Masking tapes shall be used.
(c) Covering for protection shall be left in position upto completion, to the
satisfaction of the Engineer.

o) Method of Application

i) Brush painting

a) Paint shall be applied so that the finished surface is free from brush
marks.
b) All areas or parts shall be laid off correctly.

c) All paint edges shall be good, sharp and true to line.

ii) Primers

a) Priming coats shall be applied by brush to give a coat of adequate

thickness with no misses and to satisfy the porosity of the surface. The
priming shall be well worked into the surface, joints, angles and other
places where moisture is likely to collect.

b) Steelwork surfaces shall be primed immediately after cleaning. Priming

coats applied off-site that have suffered from exposure on the site or in

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transit shall be touched up or re-primed as necessary before
undercoating.

c) Where there is a doubt as to the adequacy of the primer to fully satisfy

the porosity of the surface, the Engineer-in-Charge shall be informed and
his directions taken.

iii) Undercoats
Undercoats shall be applied evenly over the whole surface to give a solid
film, care being taken to avoid uneven thickness of paint at edges and
angles.

iv) Finishing coats

a) Finishing coats shall be applied evenly over the whole surface to give a
solid film free from brush marks, sags, runs, peeling or other defects.

b) Finished work shall be uniform, of approved colour, smooth and free from
runs, sags, defective brushing and clogging. Edges of paint adjoining
other materials or colours shall be sharp and clean, to correct lines and
levels without overlapping.

c) Protection
All finished work shall be protected upto completion and handing over.

p) Cleaning

All areas shall be left in a neat, clean and tidy condition after the painting
work is over.

q) Scaffolding

Scaffolding shall be erected for all painting work. Ladders shall only be used in
exceptional circumstances where permitted by the Engineer-in-Charge. Care
shall be taken to avoid any damage to floors and walls.

r) Measurements

i) Painting shall be measured as per clause 13.25.6, 13.33.6 of CPWD

Specifications 96.
ii) Painting in small widths and girths, cornices etc., shall also be measured in
general painting. Painting for all floor levels and all heights shall be
measured under the same item.

S) Rate

As per clause 13.25.7 and clause 13.33.8 of CPWD Specifications 96.

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16.4 Oil Emulsion (Oil Bound) Washable Distempering

16.4.1 Materials

Oil emulsion (Oil Bound) Washable Distemper (IS:428) of Approved brand and
manufacture shall be used. The primer where used as on new work shall be cement shall
be primer or distemper primer as described in the item. These shall be of the same
manufacture as distemper. The distemper shall be diluted with water or any other
prescribed thinner in a manner recommended by the manufacturer. Only sufficient
quantity of distemper required for day’s work shall be prepared.
The distemper and primer shall be brought by the contractor in sealed tins in sufficient
quantities at a time to suffice for a fortnight's work, and the .same shall be kept in the joint
custody of the contractor and the Engineer-in-Charge. The empty tins shall not be
removed from the site of work, till this item of work has beeen completed and passed by
the Engineer-in-Charge.

16.4.2 Preparation of the Surface

For new work the surface shall be thoroughly cleaned of dust, old white or colour wash by
washing and scrubbing. The surface shall then be allowed to dry for at least 48 hours. It
shall then be sand papered to give a smooth and even surface. Any unevenness shall be
made good by applying putty, made of plaster of paris mixed with water on the entire
surface including filling up the undulations and then sand papering the same after it is dry.
. .
In the case of old work, all loose pieces and scales shall be removed by sand papering.
The surface shall be cleaned of all grease dirt etc.
Pitting in plaster shall be made good with plaster of Paris mixed with the colour to be
used. The surface .shall then be rubbed down again with a fine grade sand paper and
made smooth. A coat of the distemper shall be applied over the patches. The patched
surface shall be allowed to dry thoroughly before the regular coat of distemper is applied.

16.4.3 Application

16.4.3.1 Priming Coat

The priming coat shall be with distemper primer or cement primer, as required in the
description of the item. The application of the distemper primer shall be as described in
13.30.2.2.
Note: If the· wall surface plaster has not dried completely, cement primer shall be applied
before distempering the walls. But if distempering is done after the wall surface is dried
completely, distemper primer shall be applied.
Oil bound distemper is not recommended to be applied, within six months of the
completion of wall plaster. However, newly plastered surfaces if required to be
distempered before a period of six months shall be given a coat of alkali resistant priming

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paint conforming to IS : 109 and allowed to dry for at least 48 hours before distempering is
commenced.
For old work no primer coat is necessary.

16.4.3.2 Distemper Coat

For new work, after the primer coat has dried for at least 48 hours, the surface shall be
lightly sand papered to make it smooth for receiving the distemper, taking care not to rub
out the priming coat. All loose particles shall be dusted off after rubbing. One coat of
distemper properly diluted with thinner (water or other liquid as stipulated by the
manufacturer) shall be applied with brushes in horizontal strokes followed immediately by
vertical ones which together constitute one coat.
The subsequent coats shall be applied in the same way. Two or more coats of distemper
as are found necessary shall be applied over the primer coat to obtain an even shade.
A time interval of at least 24 hours shall be allowed between successive coats to permit
proper drying of the preceding coat.
For old work the distemper shall be applied over the prepared surface in the same manner
as in new work. One or more coats of distemper as are found necessary shall be applied
to obtain an even and uniform shade.
15 cm double bristled distemper brushes shall be used. After each days work, brushes
shall be thoroughly washed in hot water with soap solution and hung down to .dry. Old
brushes which are dirty and caked with distemper shall not be used on the work.
The specifications in respect of scaffolding, protective measures and measurements shall
be as described under 13.25.

16.4.4 Rate

The rate shall include the cost of all labour and materials involved in all the above
operations (including priming coat) described above.

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17. MISCELLANEOUS

17.1 BUILDING EXPANSION JOINTS

17.1.1 Specialised expansion joints consisting of extruded aluminum frame

assemblies of suitable profile to receive free floating cover plate of required shape and
profile / or elastomer suited to building applications shall be used. These will be provided
for covering the structural gap at expansion joints along the horizontal faces of slabs and
beams, vertical faces of retaining walls, etc. Necessary block-outs as per the
manufacturer's recommendations shall be provided in the structure which shall be filled in
the approved manner after placing the expansion joints. The base of the expansion joint
assembly shall be fixed onto the concrete base using anchor fasteners (not exposed to
top surface) as per manufacturer’s specifications. The joint shall have and anti-skid
serrated top plate with a free floating central plate. All aluminum in contact with concrete
shall have zinc chromate finish. The joint assembly shall be capable of accommodating
the specified movement without loss of cover and shall include all the necessary
accessories ,sealant etc as per manufacture’s drawings. The joint fixing shall be carried
out either by the main contractor under the supervision of supplier/manufacturing agency
of approved expansion joint . The expansion joint cover assemblies shall withstand a
minimum 500lb point load without damage or permanent deformation. The joint should be
water tight and test on same if required on direction of Engineer shall be conducted
without any extra payment for same.

Expansion Joint Filler Board

Expansion Joint Filler Board is a Cross linked Closed cell Polymer. It is widely known as
compressible Expansion Joint Filler Board and is flexible as well as has high
compression-recovery, therefore suitable for application at places which require readily
compressible low load. This filler board is non-tainting and therefore suitable for use in
potable water retaining and water excluding structures. It is very light weight and easy to
handle and install. It can withstand severe weathering conditions and shows no sign of
disintegration or degradation. It is a sheet form in semi-rigid, UV resistive, high
performance laminated closed cell polyethylene foam joint filler. It is suitable for use as
expansion joint filler in concrete, brick, block work and isolation joints where readily
compressible low load transfer joint filler is required.
Expansion Joint Filler Board is available of following tags i.e. ShaliTex board,
DURABoard, HD100, Capcell, Silflex
Joint closed cell polyethylene filler board should have the following properties :
1 Flexibility - 95% recovery after deflection (compression).
2 Weathering Test - Resilient and does not distort under low load transfer from wet
concrete
3 Closed cell structure - Extremely low water absorption thus non deteriorating and
durable
4 Bitumen free - Non-Staining
5 Chemically Resistant - Inert to most dilute acids, resistant to oil and hydrocarbons

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6 Hygienic - Rot proof and bacteria resistant
7 Simplicity - Easy to handle & install it

17.2 EXTERNAL DEVELOPMENT

17.2.1 PAVER

17.2.2 Material

60mm thick Premium finish paving blocks of M/s UniStone/Hindustan Tiles or equivalent
in approved design, size, thickness, pattern and colour,
Made from high vibratory technology and the pieces shall be cast in special plasticized
P.V.C moulds/ rubber moulds.
The composition of pavers block shall be of M-30 Grade concrete mix design. The
allowing variance should ±2mm in accordance with IS: 1237-1980.
The top layer of 12 to 15 mm to be made from ‘43’ Grade White Portland cement of JK or
equivalent.
The top surface of the paving blocks shall be sealed with acrylic lacquer resulting in
surface water absorption of tiles, less than 1% and water absorption by 24 hrs immersion
method, less than 8%.The bottom layer should consists of 43 Grades Grey Portland
cement of JK or equivalent, fine coarse aggregates, supper plasticizers, high strength
additives and water proofing compound.

17.2.3 Laying

Laying shall be done on 50mm thick compacted bed of course sand, filling the joints with
coarse sand and as per the direction of engineer in charge.

17.2.4 Measurements

Length and breadth shall be measured correct to a cm

17.2.5 PAVING TILE

17.3.5.1 Material
G.R.C glass reinforced concrete flooring / paving tiles Unistone/ Hindustan tiles or
equivalent tiles in sizes of 152mm x 152mm /305mm x 305mm. the thickness of the tiles
should range between 22 to 25mm, allowing variance of + - 5mm in accordance with
IS:1237-1980.
The tiles should be made with M-40 Grade concrete mix design having ’43’ grade white
Portland cement, reinforced with Alkali Resistant glass fiber and the pigmentation should
be done with exterior grade synthetic inorganic iron oxide pigments manufactured by
‘BAYFERROX (Germany)’ or equivalent with high vibration technology.

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The pigmentation should be homogeneous and in accordance with British standard BS
EN 12878:1999.
The other additives should be fine washed graded quartz, super plasticizers and
integrated water proffers agents and others.
The top surface of the tiles should be sealed with acrylic lacquer resulting in surface water
absorption of tiles, less then 1% and water absorption by 24 hrs immersion method, less
than 8%.

17.2.6 Laying

Laying shall be done over 20mm thick cement mortar bed 1:3 (1 cement : 3 coarse sand)
including filling the joints with white cement mixing with matching pigment.

17.2.7 Measurements

Length and breadth shall be measured correct to a cm.

17.3 STRUCTURAL GLAZING

a. Unitised System Based Structural Glazings: Fabricated out of Heavy Duty Aluminum
Extruded Profiles of approved make as per the Sections shown in the Profile
Combination Drawings enclosed, Comprising of Corners Mullion, Normal Mullion,
Top and Bottom Transom, Normal Transom and Single Glass Glazing Shutter; all
profiles conforming to Alloy 63400 WP with Chemical Composition and Mechanical
Properties as per IS-733; all profiles Pure Polyester Powder coated or Anodized in
approved shade with approved make and all profiles provided with Masking Tapes
to provide safety against external scratches at site (Masking Tapes to be removed
only at the time of handing over as per the instructions of Site-In-Charge / Architect).
b. The Unitised System Based Structural Glazing shall be designed for a Wind
Pressure of 175 Kgs. Per Sq.M. The Contractor must design the Semi Unitised
System Based Structural Glazing as per the prevalent site conditions and building
profiles. No extra claims shall be entertained at any stage for aluminum profile wall
thickness and size dimensions. The Contractor must quote rates accordingly.
c. The Contractor must provide details of Structural Calculations of the Mullion Member
Offered, and also provide drawings of individual members – Corners Mullion, Normal
Mullion, Top and Bottom Transom, Normal Transom and laminated Glass Glazing
Shutter; and also details of any other profiles that may be used – clearly indicating
all dimensions, wall thickness and weight (Kg./M).
d. The Anchoring / Bracing of the Unitised System Based Structural Glazings to the
RCC Beams / Columns shall be done with non-corrosive galvanised brackets of
approved design (galvanising to be done conforming to IS:4759 – 1996, up to 610
gms. Per Sq.M. – 80-90 Microns thickness). The Contractor to provide design
calculations for the Brackets to be used. Two Numbers of Brackets shall be
provided on each beam, one designed for load bearing and one designed for
expansion characteristics of the Mullion, including providing PVC spacers between
the Aluminum Mullion member and Bracket (including providing and fixing of
aluminum shims of various thickness behind the brackets to adjust the beam level
variations or designing and providing of extended brackets of required size as per
site requirements). Approved make flushed type fasteners and 10 x 100 mm
Stainless Steel Bolt shall be used for Anchoring the Brackets to provide a minimum

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anchoring depth of 50-80 mm in the concrete to withstand the dead load of the
Curtain Wall as well as stresses due to wind pressure etc.
e. All Screws, Bolts, Nuts and Washers used in the Semi-Unitised System Based
Structural Glazing shall be only Stainless Steel.
f. The glazing framework shall be aligned for the entire height of each mullion and for
the entire width of each Transom by LAZER BEAM equipment to ensure Cent per
Cent ‘X’ axis and ‘Y’ axis alignment.
g. The Transom to Mullion joints must be properly sealed with weather silicon sealant
to make the joint water tight. The Expansion Joints between two Mullion at every
beam level should be created by inserting 300 mm long Aluminum Expansion
Sleeve Tube and bolted with the main mullion member, and the Expansion Joint gap
should be minimum 10 mm to 20 mm. The Expansion Joint must be properly sealed
all around with weather sealant to make it water tight. The details for the Expansion
Joint to be submitted by the Contractor and got approved by the Architect.
h. EPDM Gaskets of suitable profiles shall be provided at all required positions to make
the glazing air tight.
i. The glazing shutter profile shall be properly designed to accommodate 23 mm thick
Hermetically Sealed Double Insulated Glass units of 6 mm thick Toughened
blue/smoke grey Glass on the outside and 5 mm thick Clear Float Glass on the
inside of required specifications. The panel after being fabricated shall be cleaned
for removing any dust or frost and 2 sided Structural Adhesion tape shall be applied
and the glass duly surface cleaned shall be stuck to the glazing panel. Subsequently
the Structural Silicone shall be applied. The glazed panel shall be given adequate
time for curing – as per the manufacturers’ specifications.
j. The Contractor must design the Structural Bite using the specified wind load, panel
size and the sealant design strength of 138 kPa. And the Structural Bite as well as
the glueline thickness must be a minimum of 6 mm, however, the Structural Bite
must be equal to or greater than the glueline thickness in the ratio between 1 : 1 and
3 : 1. The Structural Sealant applied in the joint must be able to be filled using
standard caulking practices and must not move during cure with adequate exposure
to atmospheric air to cure. The load calculations for the designing of the dead load
should be based on the design strength of structural sealant as 700 Kgs per Sq.M
for dead load. The weight of the panel divided by the silicone contact area must not
exceed the dead load design strength of the sealant.
k. The Contractor must ensure that the surface used for application of Structural
Silicone should have a minimum of an Aldine finish and therefore should be
anodised for a minimum thickness of 15 microns.
l. The peripheral gaps between the top and bottom transoms shall be sealed both from
inside and outside to make the glazing water tight - gaps up to 10 mm between the
peripheral aluminum member and masonry/R.C.C./Stone shall be sealed by
inserting Backer Rod and weather silicon; and the peripheral gaps between the
corner mullions wherever the gaps are expected to be more than 10 mm, shall be
sealed by providing and fixing of 2 mm thick aluminum sheet flashings bent to
required profile as per approved design duly anodized in approved colour.
m. The Unitised System Based Structural Glazings shall be complete in all respects as
per the elevation and accommodated as per the site conditions as per the dimension
details given.

17.4 GRC SCREENS/JAALI

General

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Materials used for making the GRC unit shall generally comply with relevant Indian
Standards and Codes. Where materials are not fully covered by this specificationor
alternative materials are offered, the Contractor shall forward to the Construction Manager
prior to commencing the work, details of those he proposes to usetogether with supporting
evidence indicating that the finished product will be capable of meeting theperformance
requirements of this specification.
Workmanship
a. Weighing and Batching
Dry ingredients shall be batched by weight using calibrated weighing equipment capable
of an accuracy of ± 2% of the stated batch weight. Liquids should be weighed, volume-
batched or automatically dispensed. The producer must demonstrate that the method
employed will give an accuracy of ± 2%.
b.Mixing
The cement slurry should be mixed in a high-speed shear mixer, or other high-speed
mixer which can achieve a good and even dispersion of all slurry ingredients.
c.Application
Application shall be by spraying, using purpose-built equipment which allows the
simultaneous deposition and uniform mixing of the glassfibre and cement matrix.The glass
fibre and cement slurry shall be metered to the spray head at rates to achieve the desired
mix proportion and glass content. These shall be checked for each spray pump at least
once per day and prior to commencing spray production after each stoppage. Distribution
of fibre in the mix shall be controlled by the operator in such a way as to be as uniform as
possible. Cleanliness of equipment and working areas shall be maintained at all times.
d. Shape and Finish
The panels are to be formed of GRC in moulds to achieve the profiles indicated by the
architectural drawings. The manufacturer shall provide a means for producing a
replacement panel at any time during the building contract. Moulds shall be adequately
cured to eliminate shrinkage and distortion and shall be properly braced. The exposed
face of the GRC panels surfaces shall be free of blowholes, cracks, undulation or similar
imperfections.
e.Shop Drawings
Prior to commencing manufacturing work, the manufacturer shall submit for approval
detailed shop drawings showing the following information:
■ layout (sectional plan and elevation) of complete wall panelling;
■ full-size section of typical panel and support members;
■ method of assembly and supports and fixings to the existing structure and provision to
withstand imposed stresses;
■ method of installation, caulking, flashing and provision for vertical and horizontal
expansion;
■ junction and trim to adjoining surfaces; and
■ fittings and accessories,
The submission of shop drawings shall be supported by engineering design computations
to show that cladding and supports comply with the design criteria specified.
Demoulding and Curing

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Once the initial set has taken place, GRC elements should be covered with polythene for
their protection and to prevent them from drying out fully. They must not be moved again
until they are ready for demoulding. The GRC elements must not be demoulded until they
have gained sufficient strength to be removed from the mould and transported within the
factory, without being overstressed. If the GRC elements are too large to be demoulded
by hand, special demoulding sockets or loops should be embedded in the panel during
manufacture, and demoulding should be assisted with a lifting frame. This procedure
should be agreed with the engineer. During demoulding, the panels shall be uniformly
supported in a manner which avoids undue stresses in the panels. If polymers are used in
the mix to avoid wet curing, the panels should be stored under cover for a minimum of 7
days at a temperature of between 5°C and 35°C. If polymers are not used in the mix,
curing shall be continued after demoulding under conditions which shall provide free water
on the surfaces of the panels at a temperature not exceeding 50°C for a period of not less
than 7 days (including the initial cure in the mould).
Identification of Elements
All panels shall be identified individually to indicate the panel type and date of
manufacture. At the time of preparation of shop drawings the manufacturer shall indicate
his required order of delivery.
Handling, Transportation and Installation
The products shall be handled, transported and installed using methods which ensure that
no damage or marking of architectural surfaces occurs and so that the panels are not
subject to undue stress. The safety and protection of GRC units shall be ensured
throughout the whole of the contract works.Site access and, if necessary, storage space
shall be provided by the main contractor. The main contractor shall also provide true, level
and clean support surfaces and shall provide for the accurate placement and alignment of
connection hardware on the structure.
Weatherproofing
Responsibility for the weatherproofing of the whole installation of GRC panels rests with
the GRC manufacturer. The joint details shown on the drawings represent the appearance
required and their minimum standard of weatherproofing acceptable.
Joints shall be weather-sealed with closed-cell polyethylene compressible backing rods
and caulked with 2-part polysulphide sealant or other approved sealant in selected
colours, installed completely in accordance with the sealant manufacturer’s
recommendations with regard to joint dimension, priming, substrates, mixing, curing,
masking, cleaning and the like.
The GRC manufacturer shall submit details of the proposed sealant and the application
recommendations for approval by the construction manager prior to commencement of
the contract works.
Joints located and indicated on the drawings are those required for sealing the GRC
cladding against adjacent materials and those required for architectural purposes for
division of the panels into the design modules. Should the GRC manufacturer or
contractor propose to subdivide the cladding into smaller panels for ease of casting,
handling and erection, additional joints may be introduced in the design, provided the
location proposed is discreet. The
GRC manufacturer shall submit proposed locations and designs of additional panel joints
with their tender

17.5 INTERIOR PAINTING WITH PLASTIC EMULSION PAINT

a. The plastic emulsion Paint is not suitable for application on external, wood and iron
surface and surfaces which are liable to heavy condensation. These Paints are to
be used on internal surfaces except wooden and steel.

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b. Plastic Emulsion Paint as per IS 5411 of approved brand and manufacture and of
the required shade shall be used.
c. Painting on New Surface
i. The wall surface shall be prepared as specified in 13.23.3 of CPWD Specifications
2009.
ii. Application : The number of coats shall be as stipulated in the item. The Paint will
be applied in the usual manner with brush, spray or roller. The Paint dries by
evaporation of the water content and as soon as the water has evaporated the film
gets hard and the next coat can be applied. The time of drying varies from one
hour on absorbent surfaces to 2 to 3 hours on non-absorbent surfaces. The
thinning of emulsion is to be done with water and not with turpentine. Thinning with
water will be particularly required for the under coat which is applied on the
absorbent surface. The quantity of water to be added shall be as per
manufacturer’s instructions.
The surface on finishing shall present a flat velvety smooth finish. If necessary
more coats will be applied till the surface presents a uniform appearance.
d. Precautions
(i) Old brushes if they are to be used with emulsion Paints, should be completely
dried of turpentine or oil Paints by washing in warm soap water.
Brushes should be quickly washed in water immediately after use and kept
immersed in water during break periods to prevent the Paint from hardening on the
brush.
(ii) In the preparation of wall for plastic emulsion painting, no oil base putties shall be
used in filling cracks, holes etc.
(iii) Splashes on floors etc. shall be cleaned out without delay as they will be
difficult to remove after hardening.
(iv) Washing of surfaces treated with emulsion Paints shall not be done within 3 to 4
weeks of application.

e. Other details shall be as specified in 13.23 as far as they are applicable.

17.6 EXTERIOR PAINTING ON WALL

TEXTURED PAINT AND ACRYLIC SMOOTH PAINT

a. Material
The paint shall be (Textured exterior paint/Acrylic smooth exterior paint/premium acrylic
smooth exterior paint) of approved brand and manufacture. This paint shall be brought to
the site of work by the contractor in its original containers in sealed condition. The material
shall be brought in at a time in adequate quantities to suffice for the whole work or at least
a fornight’s work. The materials shall be kept in the joint custody of the contractor and the
Engineer-in-Charge. The empty containers shall not be removed from the site of work till
the relevant item of work has been completed and permission obtained from the Engineer-
in-Charge.
b. Preparation of Surface
For new work, the surface shall be thoroughly cleaned off all mortar dropping, dirt dust,
algae, fungus or moth, grease and other foreign matter of brushing and washing, pitting in
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plaster shall make good, surface imperfections such as cracks, holes etc. should be
repaired using white cement. The prepared surface shall have received the approval of
the Engineer in charge after inspection before painting is commenced.
c. Application
Base coat of water proofing cement paint
i. All specifications in respect of base coat of water proofing cement paint shall be as
described under 13.21 of CPWD Specifications 2009.
ii. Before pouring into smaller containers for use, the paint shall be stirred thoroughly
in its container, when applying also the paint shall be continuously stirred in the
smaller containers so that its consistency is kept uniform. Dilution ratio of paint
with potable water can be altered taking into consideration the nature of surface
climate and as per recommended dilution given by manufacturer. In all cases, the
manufacturer’s instructions & directions of the Engineer-in-charge shall be
followed meticulously. The lids of paint drums shall be kept tightly closed when not
in use as by exposure to atmosphere the paint may thicken and also be kept safe
from dust.
iii. Paint shall be applied with a brush on the cleaned and smooth surface. Horizontal
strokes shall be given, First and vertical strokes shall be applied immediately
afterwards. This entire operation will constitute one coat. The surface shall be
finished as uniformly as possible leaving no brush marks.
iv. The first coat to be applied by brush or wool roller as a base coat, diluted with
sufficient water and the final coat (Undiluted) to be applied by trowel and finished
with acrylic trowel to maintain with or without groOves, as per details in drawings.

The thickness of both coats should be 1.0 to 1.5mm. the water repellence of the product
shall be >= 86gm/m2 as per test method IS:5410-1969,
The specifications in respect of scaffolding, protective measures, measurements and
rate shall be as described under 13.14 of CPWD Specifications 2009.
d. Composition
Texture paint should consist of ACRYLIC copolymer resigns combined with quartz, silica,
mineral, aggregates, synthetic inorganic pigments, bactericide, fungicides and various
other additives, giving the product water repellent properties.

e. No of coats : Two coats

f. Measurements
Length and breadth shall be measured correct to a cm.

17.7 Glazed Tiles in Skirting and Dado

I. The tiles shall be of approved make and shall generally conform to IS: 777. The
tiles shall be of earthenware covered by a glaze thoroughly matured and fitted to
the body. The tiles shall be sound, true to shape, flat and free from flaws and other
manufacturing defects affecting their utility The top surface of the tiles shall be
glazed. The underside of the tiles shall not have glaze on more than 5 per cent of
the area in order that the tile may adhere properly to the base. The edges of the
tiles shall be free from glaze, however, any glaze if unavoidable shall be
permissible on only upto 50 per cent of the surface area of edges.
II. The glaze shall be free from welts, chips, craze, specks, crawling or other
imperfections detracting from the appearance when viewed from a distance of one
meter. The glaze shall be either glossy or matt as specified. The glaze shall be

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white in colour except in the case of coloured tiles when colours shall be specified
by the Engineer-in-Charge. There may be more than one colour on a tile.

17.8 Dimensions and Tolerances

I. Glazed earthenware tiles shall be made square or rectangular in sizes as specified

and shall be straight or cushion edge type.
II. Half tiles for use as full tiles shall have dimensions which shall be such as to make
the half tiles when jointed together (with 1 mm joint) match with dimensions of full
tiles. Tiles may be manufactured in sizes other than those specified above.
III. The thickness of the tiles shall be 5 mm as specified.
IV. The dimensions of fittings associated with the glazed tiles namely cove base,
round edge tile, angles corner cups, ridge and legs, cornices and capping beads
shall be of the shape and dimensions as required and the thickness of fittings shall
be the same as the thickness of tiles given above.

17.9 Tolerances

I. Facial Dimensions - The lengths of all the four sides of the tile shall be measured
to the nearest 0.1 mm. The average value of lengths/breadth shall not vary more
than ± 0.8 mm from the above specified dimension.
II. The variation of individual dimensions from average value of length/breadth shall
not exceed ± 0.5 mm.
III. Tolerances on thickness shall be ± 0.4 mm.
IV. Tiles shall be checked for squareness and warpage as described therefore.

17.10 Trueness of Shape (Squareness)

Any variation from a right angle in the angle contained by any two adjoining sides shall be
limited so that if a builder's steel square is placed against the angle, the distance between
the inner edge of the square and the adjacent side of the tile or fitting shall not be more
than 0.5 mm per 100 mm run I above).

17.11 Performance Requirements Water absorption

I. The average water absorption of the tiles when tested and evaluated in
accordance with IS : 777 s not exceed 20 per cent.
II. Crazing: Tiles subjected to two cycles of crazing test as per IS: 777 shall not show
any sign crazing.
III. Impact Resistance: Tiles when tested for impact resistance as per IS: 777 shall
remain intact, apart from surface marking.
IV. Chemical Resistance: When tested as per IS: 777, the glazed surface of tiles
and/or the fittings having a white or cream coloured glossy glaze shall show no
modification.

17.12 Preparation of Surfaces

The joints shall be raked out to a depth of at least 15 mm in masonry walls. In case of
concrete walls, the surface shall be hacked and roughened with wire brushes. The surf;

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shall be cleaned thoroughly, washed with water and kept wet before skirting is
commenced.

17.13 Laying

I. mm thick plaster of cement mortar 1: 3 (1 cement: 3 coarse sand) mix or as

specified shall applied and allowed to harden. The plaster shall be roughened with
wire brushes or by scratch diagonal at closed intervals.
II. The tiles should be soaked in water, washed clean, and a coat of cement slurry
applied liberally at back of tiles and set in the bedding mortar. The tiles shall be
tamped and corrected to proper plane and lines. The tiles shall be set in the
required pattern and jointed. The joints shall be as fine as possible. 1 of skirting or
dado shall be truly horizontal and joints truly vertical except where otherwise
indicated. Skirting and dado shall rest on the top of the flooring. Where full size
tiles cannot be fixed these shall cut (sawn) to the required size and their edges
rubbed smooth.

17.14 Curing and Finishing

The joints shall be cleaned off the grey cement grout with wire/coir brush or trowel to a
depth of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush
pointed with white cement added with pigments if required to match the colour of tiles. The
work shall then be kept wet for 7 days. After curing, the surface shall be washed and
finished clean. The finished work shall not sound hollow when tapped with a wooden
mallet.

17.15 Measurements

I. Length shall be measured correct to a cm. Height shall be measured correct to a

cm in the case of dado and 5 mm in the case of riser and skirting. The area shall
be calculated in square meter, correct to two places of decimal. Length and height
shall be measured along the finished face of the skirting or dado including curves
where specials such as coves, internal and external angles and beads are used.
Where cornices are used the area of dado shall be measured excluding the
cornices. Nothing extra will be paid for cutting (sawn) the tiles to sizes.
II. In addition to payment for areas of skirting and dado, specials such as coves,
internal and external angles and beads shall be measured separately and paid for
in running metres. Cornices shall also be similarly measured for payment in
running metres. Areas where coloured tiles or different types of decorative tiles are
used will be measured separately to be paid extra over and above the normal rate
for white tiles.

17.16 Rates

The rate shall include the cost of all material and labour involved in all the operations
described above. The specials such as coves internal and external angles and beading
shall be measured and paid for separately. The rate shall not include cost of cornices
which shall be measured and paid for is running metres separately.

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17.17 Glazed Tile Specials

The specials consist of coves, internal and external angles, beads cornices and their
corner pieces. Coves beads and angles shall be of thickness not less than the thickness
of the tiles with which they are used. The size of coves, beads, angles refer to the greatest
width of the special measured in a straight line. The stipulated size of cornices is their
height. The lengths of specials shall be 15 cm, 10 cm or other standard size available
conforming to the size of tiles available.
I. In other respects the general specifications described, in 11.15.1 of CPWD
specifications 2009 with correction slips shall be applicable.
II. Preparation of Surface, Laying, Curing and Finishing shall be as specified in
11.16.2, 11.16.3 and 11.16.4 of CPWD specifications 2009 with correction as far
as applicable.

17.18 Measurements

Special tiles to form coved internal angles of any radius, rounded external angles,
architraves moulding, ceiling ribs, cornices and the like shall each be measured in running
metres correct to a cm. Railing members and vertical members shall each be so
described. Ends, angles and internal sections shall be enumerated separately.

17.19 Rate

It shall include the cost of all materials and labour involved in all the operations described
above. Nothing extra shall be paid for corner pieces at junctions of coves, beads, cornices
etc. nor for using cut lengths of specials.

17.20 Glass Reinforced concrete tiles cladding on External Wall (GRC) -

laying

Fixing of Glass Reinforced Concrete tile cladding of 15 mm thick (Average) Riverdale

Walling (Cladding), approved make/product of approved Colour/Shade, exterior grade as
per approved pattern.
I. Plaster the surface to be tiled with cement mortar (1 Cement: 3 Coarse Sand) as
specified in the manufacturer’s specifications.
II. Fix the tile with grey cement Slurry and jointed with white cement slurry mixed with
pigments of required colour on exterior walls as shown in elevations/drawings
including PU Coating as specified in the manufacturer Specification (to be secured
to the backing by means of cramps already provided in the tiles which shall not be
paid separately.
III. If tiles are square or rectangular in shape, set the right angles for the rooms and
place the first tile along the right angle lines and place it on base mortar. Tap
gently only with a cloth covered wooden / rubber mallet to obtain perfect levels.
IV. Clean the surface of the tile with clean water immediately after laying with wet
sponge. Ensure that the base mortar cement which squeezes through joints does
not settle on the tile.

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V. In sites where multiple levels are encountered, wherever level changes occur, the
tiles on the ride will have to be adequately protected with mortar cushion.
VI. When large span tiles have to be laid on curved substrate, it is suggested that the
tiles be cut to take the contour of the slope ensuring proper bedding.

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18. HORTICULTURE WORK

Specifications for Landscaping and Horticulture items described in schedule of quantities

shall be as per CPWD specifications 1996, and as given below.

18.1 Plant Materials

Plant materials shall be well formed and shaped true to type and free from disease, insect
and defect such as knots, sun-cold, windburn, injuries, abrasion or disfigurement.
All plant materials shall be healthy, sound, vigorous, free from plant diseases, insect
pests, or their eggs, and shall have healthy well-developed root systems. All plants shall
be hardy under climatic conditions similar to those in the locality of the project. Plants
supplied shall conform to the names listed on both the plan and the plant list. No plant
materials will be accepted if branches are damaged or broken. All material must be
protected from the sun and weather until planted.

All nursery stock shall have to be inspected and approved by the Landscape Architect
before planting.
All plants shall conform to these requirements specified in the plant list. Except that plants
larger than specified may be used if approved, but use of such plants shall not increase
the contract price. If the use of the larger plant is approved the spread or roots or ball of
earth shall be increased in proportion to the size of the plant.
Deliver plants with legible identification labels.

18.2 Topsoil (Good Earth)

Topsoil or good earth shall be a friable loam; typical of cultivated topsoil’s of the locality
containing at least 2% of decayed organic matter (humus). It shall be taken from a well-
drained arable site. It shall be free of subsoil, stones, earth sckides, sticks roots or other
objectionable extraneous matter or debris. It shall contain no toxic materials. No topsoil
shall be delivered in a muddy condition.

18.3 Fertiliser

Dry sludge or cow dung or similar shall be used. Measurement of manure shall be in
stacks with 8% reduction for payment. It shall be free from extraneous matter harmful
bacteria, insects or chemicals.

18.4 Root System

The root system shall be conducive to successful transplantation. Where necessary, the
root ball shall be preserved by support with Hessian or other suitable material. On soils
where retention of good ball is not possible, the roots should be suitably protected in some
other way, which should not cause any damage to roots.

18.5 Condition

Trees and shrubs shall be substantially free from pests and diseases, and shall be
materially undamaged. Torn or lacerated roots shall be pruned before dispatch. No roots
shall be subjected to adverse conditions, such as prolonged exposure to drying winds or
subjection to water logging, between lifting and delivery.
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18.6 Supply and Substitution

Upon submission of evidence that certain materials including plant materials are not
available at time of contract, the contractor shall be permitted to substitute other material
and plants with an equitable adjustment of price. All substitutions shall be of the nearest
equivalent species and variety to the original specified and shall be subject to the approval
of the Engineer.

18.7 Packaging

Packaging shall be adequate for the protection of the plants and such as to avoid heating
or drying out.

18.8 Marking

Such specimen of tree and shrub, or each bundle shall be legibly labelled with the
following particulars:
Its name;
The name of the supplier, unless otherwise agreed;
The date of dispatch from the nursery.

18.9 Tree and General Shrub Planting

Trees should be supplied with adequate protection as approved after delivery. If planting
is not to be carried out immediately, balled plants should be placed cheek to cheek and
the ball covered with sand to prevent drying out. Bare rooted plants can be heeled in by
placing the roots in a prepared trench and covering them with earth, which should be
watered in to avoid air pockets around the roots.

18.9.1 Digging of Pits

Tree pits shall be dug a minimum of three weeks prior to backfilling. The pits shall be
90 x 90 x 90 cm. While digging the pits, the topsoil upto a depth of 30 cms may be kept
aside if found good (depending upon site condition), and mixed with the rest of the soil.
If the soil is bad below, it shall be replaced with the soil mixture as specified further herein.
If the soil is normal it shall be mixed with manure; river sand shall be added to the soil if it
is heavy.
The bottom of the pit shall be forked to break up the sub soil.

18.9.2 Backfilling

The soil is backfilled; watered through and gently pressed down, a day previous to
planting to make sure that it may not further settle down after planting. The soil shall be
pressed down firmly by tread it down, leaving a shallow depression all round for watering.

18.9.3 Planting

No tree pits shall be dug until final tree position has been pegged out for approval.
Care shall be taken that the plant sapling when planted is not buried deeper then in the
nursery or in the pot.

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Planting should not be carried out in waterlogged soil.
It is most important to plant trees at the original soil depth; the soil mark on the stem is an
indication of this and it should be maintained on the finished level allowing for setting of
the soil after planting. All plastic and other imperishable containers should be removed
before planting. Any broken or damaged roots should be cut back to sound growth.
The bottom of the planting pit should be covered with 50mm to 75mm of soil. Bare roots
should be spread evenly in the planting pit; a small mound in the center of the pit on which
the roots are placed will aid an even spread. Soil should be placed around the roots,
gently snaking the tree to allow the soil particles to shift into the root system to ensure
close contact with all roots and to prevent air pockets. Backfill soil should be firmed as
filling proceeds layer by layer care being taken to avoid damaging the roots. Organic
material should be applied, according to soil requirements.

18.9.4 Stacking

Newly planted trees must be held firmly although not rigidly by staking to prevent a pocket
forming around the stem and newly formed fibrous roots being broken by mechanical
pulling as the tree rocks.
Methods:
The main methods of staking shall be:
A single vertical stake 900mm longer than the clear stem of the tree, driven 600mm to
800mm into the soil.
Two stakes as above driven firmly on either side of the tree with a crossbar to which the
stem is attached. Suitable for bare - rooted or balled material.
A single stake driven in at an angle of 45 degrees and leaning towards the prevailing
wind, the stem just below the lowest branch being attached to the stake. Suitable for small
bare - rooted or balled material.
For plant material 3m to 4.5m high with a single stem a three wire adjustable guy system
may be used in exposed situations.
The end of stake should be pointed and the lower 1m to 1.20m should be coated with
a non injurious wood preservative allowing at least 150mm above ground level.

18.9.5 Tying

Each tree should be firmly secured to the stake so as to prevent excessive movement.
Abrasion must be avoided by using a buffer, rubber or hessain, between the tree and
stake. The tree should be secured at a point just below its lowest branch, and also just
above ground level; normally two ties should be used for each tree. These should be
adjusted or replaced to allow for growth.

18.9.6 Watering

The contractor shall allow for the adequate watering in of all newly planted trees and
shrubs immediately after planting and he shall during the following growing season, keep
the plant material well watered.
All shrubs which are supplied pot grown shall be well soaked prior to planting.
Watering in and subsequent frequent watering of summer planted container - grown
plants is essential.

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18.10 Shrub Planting In Planters and Bed

All areas to be planted with shrubs shall be trenched to a depth of 400-600mm.

Tall shrubs may need staking; which shall be provided if approved by the Contracting
Architect, depending upon the conditions of individual plant specimen. Shrubs and ground
cover shrubs in beds and planters. Positions of shrubs to be planted shall be marked out
in accordance with the planting plan. Shrubs are set out, precautions should be taken to
prevent roots drying. Planting holes 40cm dia. and 40cm deep should be excavated for
longer shrubs. Polyethene and other non perishable containers should be removed and
any badly damaged roots carefully pruned. The shrubs should then be set in holes so
that the soil level, after settlement, will be at the original soil mark on the stem of the
shrub. The hole should be backfilled to half its depth and firmed by treading. The
remainder of the soil can then be returned and again filled by treading.

18.11 Grassing

18.11.1 Preparation

During period prior to planting the ground shall be maintained free from weeds.
Grading and final levelling of the lawn shall be completed at least three weeks prior
to the actual sowing. Regular watering shall be continued until sowing by dividing the
lawn area into portion of approx 5 m. Square by constructing small bunds to retain water.
These `bunds' shall be levelled just prior to sowing of grass plants. At the time of actual
planting of grass, it shall be ensured that the soil has completely settled.

18.11.2 Soil

The soil itself shall be ensured to the satisfaction of Landscape Architect to be a good,
fibrous loam, rich in humus.

18.11.3 Sowing the Grass Roots

Carpet grass (Cynodon dectylon or a local genus approved by the landscape architect)
shall be obtained from a grass patch, seen and approved before hand.
The grass stock received at site shall be manually cleaned of all weeds and water sprayed
over the same after keeping the stock in a place protected from sun and dry winds.
Grass stock received at site may be stored for a maximum of three days. In case
grassing for some areas is scheduled for a later date fresh stock of grass roots shall be
ordered and obtained.

18.11.4 Execution

The Carpet grass shall be laid over a leveled and compacted area with no bald patches
left.

18.11.5 Maintenance

As soon as the grass is approximately an inch high it shall be rolled with a light woodier
roller in fine and dry weather and when it has grown to 2 to 3 inches above the ground,
weeds must be removed and regular cutting with the scythe and rolling must begun. A top
dressing of announce of guano to the square yard on well decomposed well broken
sludge manure will help on the young grass. The scythe must continue to be used for
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several months until the grass is sufficiently secure in the ground to bear the mowing
machine. It should be possible to use the inch above the normal level for the first two or
three cuttings. The grass should be cut so that it is from 1 to 2 inches in length, instead of
the 1/2 to 3/4 of an inch necessary for mature grass.
In the absence of rain the lawn shall be watered every ten days heavily, soaking the
soil through to a depth of at least 25 cms.
Damage failure or dying back of grass due to neglect of watering especially for seeding
out of normal season shall be the responsibility of the contractor.
Any shrinkage below the specified levels during the contract or defects liability period shall
be rectified at the contractor's expense.
The contractor is to exercise care in the use of rotary cultivator and mowing machines to
reduce to a minimum the hazards of flying stones and brickbats. All rotary mowing
machines are to be fitted with safety guards.

18.11.6 Rolling

A light roller shall be used periodically, taking care that the lawn is not too wet and
sodden.

18.11.7 Edgings

These shall be kept neat and must be cut regularly with the edging shears.

18.11.8 Fertilizing

The lawn shall be fed once a month with liquid manure prepared by dissolving 45 grams
of ammonia sulphate in 5 litres or water.

18.11.9 Watering

Water shall be applied daily during dry weather. Watering whenever done should be
thorough and should wet the soil at least upto a depth of 20 cms.

18.11.10 Weeding

Prior to regular mowing the contractor shall carefully remove rank and unsightly weeds.

18.12 Maintenance

The landscape contractor shall maintain all planted areas within the landscape contract
boundaries until the period of one year after the complete plantation. Maintenance
shall include replacement of dead plants. Watering, weeding, cultivating, control of
insects, fungicide and other diseases by means of spraying with an approved insecticide
or fungicide, pruning and other horticulture operations necessary for the proper growth of
the plants and for keeping the landscape sub-contract area neat in appearance.

18.12.1 Pruning & Repairs

Upon completion of planting work on the landscape sub-contract all trees should be
pruned and all injuries repaired where necessary. The amount of pruning shall be limited
to the minimum necessary to remove dead or injured twigs and branches and to

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compensate for the loss of roots and the results of transplanting operations.
Pruning shall be done in such a manner as not to change the natural habit or special
shape of the trees.

18.12.2 Tree Guards

Where tree guards are necessary, care should be taken to ensure that they do not impede
movement or restrict growth.

18.12.3 Nursery Stock

Planting should be carried out as soon as possible after reaching site. Where planting
must, of necessity, be delayed, care should be taken to protect the plants from pilfering or
damage from people or animals. Plants with bare roots should be healed in as soon as
received or otherwise protected from drying out, and others set closely together and
protected from the wind. If planting should be unpacked, the bundles opened up and
each group of plants heeled in separately and clearly labelled. If for any reason the
surface of the roots becomes dry the roots should be thoroughly soaked before
planting.

18.12.4 Protective Fencing

According to local environment shrubs may have to be protected adequately from

vandalism until established.

18.12.5 Completion

On completion the ground should be formed over and left tidy. Defective plants or plants
dying within one year have to be replaced free of cost.

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19. ROADS AND PAVEMENTS

19.1 Granular Sub-Base

19.1.1 Scope

This work shall consist of laying and compacting well-graded material on prepared
subgrade in accordance with the requirements of these Specifications. The material shall
be laid in one or more layers as sub-base or lower sub-base and upper sub-base (termed
as sub-base hereinafter) as necessary according to lines, grades and cross-sections
shown on the Drawings or as directed by the Engineer.

19.1.2 Materials

The material to be used for the work shall be natural sand, moorum, gravel, crushed
stone, or combination thereof depending upon the grading required. Materials like crushed
slag, crushed concrete, brick metal and kankar may be allowed only with the specific
approval of the Engineer. The material shall be free from organic or other deleterious
constituents and conform to one of the three gradings given in Table 8-1. While the
grading in Table 8-1 are in respect of close-graded granular sub-base materials, one each
for maximum particle size of 75 mm, 53 mm and 26.5 mm.

19.1.3 Physical requirements

The material shall have a 10 percent fineness value of 50 kN or more (for sample in
soaked condition) when tested in compliance with BS: 812 (Part III). The water absorption
value of the coarse aggregate shall be determined as per IS: 2386 (Part 3): if this value is
greater than 2 percent, the soundness test shall be carried out on the material delivered to
site as per IS: 383. For Grading II and III materials, the CBR shall be determined at the
density and moisture content likely to be developed in equilibrium conditions which shall
be taken as being the density relating to a uniform air voids content of 5 per cent.
Table 20.1
Grading For Close-Graded Granular Sub-Base Materials
IS sieve Per cent by weight passing the IS sieve
Designation Grade I Grading II Grading III
75.0 mm 100 - -
53.0 mm 80-100 100 -
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20

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Note: The material passing 425 micron (0.425 mm) sieve for all the three gradings when
tested according to IS:2720 (Part 5) shall have liquid limit and plasticity index not more
than 25 and 6 per cent respectively.

19.1.4 Strength of Sub-base

It shall be ensured prior to actual execution that the material to be used in the sub-base
satisfies the requirements of CBR and other physical requirements when compacted and
finished.
When directed by the Engineer, this shall be verified by performing CBR tests in the
laboratory as required on specimens remoulded at field dry density and moisture content
and any other tests for the “quality” of materials, as may be necessary.

19.1.5 Construction Operations

a. Preparation of subgrade
Immediately prior to the laying of sub-base, the subgrade finished as per clause 301 or
305 MORTH specifications as applicable shall be prepared by removing all vegetation
and other extraneous matter, lightly sprinkled with water if necessary and rolled with two
passes of 80-100 kN smooth wheeled roller.

b. Spreading and compacting

The sub-base material of grading specified in the Contract shall be spread on the
prepared subgrade with the help of mortar grade of adequate capacity, its blade having
hydraulic controls suitable for initial adjustment and for maintaining the required slope and
grade during the operation or other means as approved by the Engineer.
When the sub-base material consists of combination of materials, mixing shall be done
mechanically by the mix-in-place method.
Manual mixing shall be permitted only where the width of laying is not adequate for
mechanical operations, as in small-sized jobs. The equipment used for mix-in-place
construction shall be a rotator or similar approved equipment capable of mixing the
material to the desired degree. If so desired by the Engineer, trial runs with the equipment
shall be carried out to establish its suitability for the work.
Moisture content of loose material shall be checked in accordance with IS:2720 (Part 2)
and suitably adjusted by sprinkling additional water from a truck mounted or trailer
mounted water tank and suitable for applying water uniformly and at controlled quantities
to variable widths of surface or other means approved by the Engineer so that, at the time
of compaction, it is from 1 per cent above to 2 per cent below the optimum moisture
content corresponding to IS:2720 (Part 8). While adding water, due allowance shall be
made for evaporation losses. After water has been added, the material shall be processed
by mechanical or other approved means like disc harrows, rotavators until the layer is
uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not
exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a
compacted single layer upto 225 mm. The compaction shall be done with the help of
vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot drum or
heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre
pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required
compaction. Rolling shall commence at the lower edge and proceed towards the upper
edge longitudinally for portions having unidirectional crossfall and super elevation and
shall commence at the edges and progress towards the centre for portions having
crossfall on both sides.
Each pass of the roller shall uniformly overlap not less than one-third of the track made in
the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and
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any high spots or depressions which become apparent, corrected by removing or adding
fresh material. The speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum
dry density for the material determined as per IS:2720 (Part 8). The surface of any layer of
material on completion of compaction shall be well closed, free from movement under
compaction equipment and from compaction planes, ridges, cracks or loose material. All
loose, segregated or otherwise defective areas shall be made good to the full thickness of
layer and re-compacted.

19.1.6 Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause 902 of
MORTH Specifications for Road and Bridge Works.
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900 of MORTH Specifications for Road and Bridge Works

19.1.7 Measurements for Payment

Granular sub-base shall be measured as finished work in position in cubic metres.

The protection of edges granular sub-base extended over the full formation as shown in
the Drawing shall be considered incidental to the work of providing granular sub-base and
as such no extra payment shall be made for the same.

19.1.8 Rate

The contract unit rate for granular sub-base shall be payment in full for carrying out the
required operations including full compensation for:
Furnishing all materials to be incorporated in the work including all royalties, fees,
where necessary and all leads and life; All labour; tools, equipment and incidentals to
complete the work to the Specifications; Carrying out the work in part widths of road
where directed; and Carrying out the required tests for quality control.

19.2 SUB-GRADE

19.2.1 Scope

In sub-grade composed of clay, fine sand or other soils that may be forced up into the
coarse aggregate during rolling operation, an insulation layer of suitable thickness of
granular materials or over size brick aggregate not less than 10 cm thick shall be provided
for blanketing the sub-grade, which shall be paid for separately, unless otherwise
specified.
In slushy soils or in areas that are water logged, special arrangements shall be made to
improve the sub-grade and the total pavement thickness shall be designed after testing
the properties of the subgrade soil. Necessary provision for the special treatment required
shall be made in the project and paid for separately.

19.2.2 Preparation of Sub-Grade

The surface of the formation for a width of sub-base, which shall be 15 cm more on either
side of base course, shall first be cut to a depth equal to the combined depth of sub-base

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and surface courses below the proposed finished level (due allowance being made for
consolidation). It shall then be cleaned of all foreign substances. Any ruts or soft yielding
patches that appear due to improper drainage conditions, traffic hauling or from any other
cause, shall be corrected and the sub-grade dressed off parallel to the finished profile.

19.2.3 Consolidation

The sub-grade shall be consolidated with a power road roller of 8 to 12 tonnes. The roller
shall run over the sub grade till the soil is evenly and densely consolidated and behaves
as elastic mass (the roller shall pass a minimum of 5 runs on the sub grade). All
undulations in the surface that develop due to rolling shall be made good with material or
quarry spoils as the cases may be and the sub-grade is rerolled.

19.2.4 Surface Regularity

The finished surface shall be uniform and conform to the lines, grades and typical cross
section shown in the drawings, when tested with the template and straight edge, the
variation shall be within the tolerances specified in Table 20.2.
TABLE 20.2
Permissible Tolerances of Surface Evenness of Sub Grade
Longitudinal profile maximum Cross profile maximum permissible
permissible undulation when variation from specified profile when
measured with a 3 metre straight measured with a camber template
edge
24 mm 15 mm

Where the surface irregularity of the sub grade falls outside the specified tolerances, the
contractor shall be liable to rectify these with fresh material or quarry spoils as the case
may be, and the sub-grade rerolled to the satisfaction of Engineer-in-Charge.

19.2.5 Measurements

The lengh and width shall be measured correct to a cm. The area shall be worked out in
square metre, correct to two places of decimal.

19.2.6 Rate

The rate for preparation and consolidation of sub grade shall include the cost of materials
and labour involved for all the operations mentioned in above unless otherwise specified.

19.3 WATER BOUND MACADAM WITH STONE AGGREGATE

19.3.1 Scope

Stone aggregate of specified size is used. This is a standard sub base/base and is used
where stone aggregate is available at reasonable rates. This consists of clean crushed
coarse aggregate mechanically interlocked by rolling and voids thereof filled with
screening and binding material with the assistance of water, laid on a prepared sub grade,
sub-base, base or existing pavement as the case may be. Water bound macadam may be
used as a sub base, base course or surfacing course.

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19.3.2 Quantities of Materials

Quantities of coarse aggregate, screening and binding material required to be stacked for
100 mm approximate compacted thickness of W.B.M. for 10 sqm shall be as per table
16.12 for stone aggregate of the size 90 mm to 45 mm. For stone aggregate of other size,
63 mm to 45 mm and 53 mm to 22.4 mm quantity of coarse aggregate and stone
screening for 75 mm approximate compacted thickness of WBM base for 10 sqm. shall be
as per Table 20.4.
TABLE 20.3

Coarse Aggregate Binding

Stone Screenings
Material

Grading/
Classificati Size Net
Classification and Quantity Quantity
on Range Quantities
size

90 mm 1.21 cum Type A 0.27 cum to 0.08 cum to

Grading I to to 1.28
13.2 mm 0.30 cum 0.10 cum
45mm cum
Note: Net quantity = Loose quantity measured in stacks minus 7.5%.
TABLE 20.4

Coarse Aggregate Stone Screenings

Grading/ For W.B.M.
Classificatio Size Net For W.B.M. Base
Classificatio Surface
n Range Quantity Course
n and size Course
0.91 cum Type A
63-45 0.12 cum to 0.15 0.10 cum to
Grading 2 to 0.96
mm 13.2 mm cum 0.12 cum
cum
0.91 cum Type B
63-45 0.20 cum to 0.22 0.16 cum to
Grading 2 to 0.96
mm 11.2 mm cum 0.18 cum
cum
0.91 cum Type B
63-45 0.18 cum to 0.21 0.14 cum to
Grading 3 to 0.96
mm 11.2 mm cum 0.17 cum
cum
* Note: The quantity of metal measured in stacks and reduced by 7.5%.

The quantity of binding material required for 75 mm (approximate) compacted thickness

will be 0.09 cum/10 sqm in the case of W.B.M. base course and 0.13 cum/10 sqm when
the W.B.M. is to function as a surface course.

19.3.3 Preparation of Foundation

In the case of an existing unsurfaced road, where new materials is to be laid, the surface
shall be scarified and reshaped to the required grade, camber and shape as necessary.
Weak places shall be strengthened, corrugations removed and depressions and pot holes
made good with suitable materials, before spreading the aggregate for W.B.M.
Where the existing surface over which the sub base of W.B.M. is to be laid is black
topped, to ensure effective internal drainage, furrows 50 mm x 50 mm (depth of furrows
increased to reach bottom of bituminous layer where necessary) at one metre intervals

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shall be cut in the existing bituminous surface at 45 degree C to the central line of the
carriageway before the W.B.M. is laid.

19.3.4 Provision of Lateral Confinement of Aggregates

Before starting with W.B.M. construction, necessary arrangements shall be made for
lateral confinement of aggregates. One method is to construct side shoulders in advance
to a compacted layerof the W.B.M. coarse. Inside edges may be trimmed vertical and the
included area cleaned off all spilled materials thereby setting the stage for spreading the
coarse aggregate.
The practice of laying W.B.M. after excavating a trench section in the finished formation
must be completely avoided.

19.3.5 Spreading Aggregate

The coarse aggregate shall be spread uniformly and evenly upon the prepared base in
required quantities with a twisting motion to avoid segregation. In no case shall these be
dumped in heaps directly on the area where these are to be laid nor shall their hauling
over a partly completed base be permitted. The aggregates shall be spread uniformly to
proper profile by using templates placed across the road six metres apart. Where
specified, approved mechanical devices may be used to spread the aggregates uniformly.
The levels along the longitudinal direction upto which the metal shall be laid, shall be first
obtained at site to the satisfaction of Engineer-in-Charge, and these shall be adhered to.
The surface of the aggregate spread shall be carefully trued up and all high or low spots
remedied by removing or adding aggregate as may be required.
The W.B.M. sub-base shall be normally constructed in layer of 100 mm compacted
thickness and W.B.M. base shall be normally constructed in layers of 75 mm compacted
thickness. No segregation of large or fine particles shall be allowed and the coarse
aggregate as spread shall be of uniform gradation with no pockets of fine material.
The coarse aggregate shall normally not be spread in lengths exceeding three days
average work ahead of the rolling and blending of the proceeding section.

19.3.6 Rolling

Immediately following at spreading of the coarse aggregate, it shall be compacted to the

full width by rolling with either the three-wheel-power-roller of 8 to 10 tonnes capacity or
an equivalent vibratory roller. Initially, light rolling is to be done, which shall be
discontinued when the aggregate is partially compacted with sufficient void space in them
to permit application of screenings.
The rolling shall begin from the edges with the roller running forward and backward and
adding the screenings simultaneously until the edges have been firmly compacted. The
roller shall then progress gradually from the edges to the centre, parallel to the centre line
of the road and overlapping uniformly each preceding rear wheel track by one half width
and shall continue until the entire area of the course has been rolled by the rear wheel.
Rolling shall continue until the road metal is thoroughly keyed with no creeping of metal
ahead of the roller. Only slight sprinkling of water may be done during rolling, if required.
On superelevated curves, the rolling shall proceed from the lower edge and progress
gradually continuing towards the upper edge of the pavement.
Rolling of sub base shall not be done when the sub-grade is soft or yielding or when the
rolling causes a wave like motion in the sub-base or sub-grade. When rolling develops
irregularities that then aggregate added to or removed from it as required and the area
rolled until it gives a uniform surface conforming to the desired cross-section and grade.
The surface shall also be checked transversely by template for camber and any

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irregularities corrected in the manner described above. In no case shall the use of
screenings to make up depressions be permitted.

19.3.7 Application of Screenings

After the coarse aggregate has been lightly rolled to the required true surface, screenings
shall be applied gradually over the surface to completely fill the interstices. Dry rolling
shall be continued while the screenings are being spread so that the jarring effect of the
roller causes them to settle into the voids of the coarse aggregates. The screenings shall
not be dumped in piles on the coarse aggregate but shall be spread uniformly in
successive thin layers either by the spreading motion of the hand, shovels or a
mechanical spreader.
The screenings shall be applied at a slow rate (in three or more applications) so as to
ensure filling of all voids. Rolling and brooming shall continue with the spreading of the
screenings. Either mechanical brooms or hand brooms or both may be used. In no case
shall the screenings be applied, so fast and thick as to form cakes, ridges on the surface
making the filling of voids difficult, or to prevent the direct bearing of the roller on the
coarse aggregates. The spreading, rolling and brooming of screenings shall be performed
on sections which can be completed within one day’s operation and shall continue until no
more screenings can be forced into the voids of the coarse aggregate. Damp and wet
screenings shall not be used under any circumstances.

19.3.8 Sprinkling and Grouting

After spreading the screening and rolling the surface shall be copiously sprinkled with
water, swept and rolled. Hand brooms shall be used to sweep the wet screening into the
voids and to distribute them evenly. The sprinkling, sweeping and rolling operations shall
be continued and additional screenings applied where necessary until the coarse
aggregates are well bonded and firmly set for the entire depth and until a grout has been
formed of screenings and water that will fill all voids and form a wave of grout ahead of the
wheels of the roller. The quantity of water to be used during the construction shall not be
excessive so as to cause damage to the sub-base or sub-grade.

19.3.9 Application of Binding Material

After the application of screenings and rolling, a suitable binding material shall be applied
at a uniform and slow rate in two or more successive thin layers. After each application of
binding material, the surface shall be copiously sprinkled with water and the resulting
slurry swept in with hand brooms or mechanical brooms or both so as to fill the voids
properly. The surface shall then be rolled by a 8-10 tonne roller, water being applied to the
wheels in order to wash down the binding material that may get stuck to the wheels. The
spreading of binding material, sprinkling of water, sweeping with brooms and rolling shall
continue until the slurry that is formed will, after filling the voids form a wave ahead of
wheels of the moving roller.

19.3.10 Setting and Drying

After final compaction of the course, the road shall be allowed to cure overnight. Next
morning defective spots shall be filled with screenings or binding material, lightly sprinkled
with water, if necessary and rolled. No traffic shall be allowed till the macadam sets.

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19.3.11 Surface Evenness

The surface evenness of completed W.B.M. sub-base in the longitudinal and transverse
directions shall be as specified in Table 20.5 for sub base with stone aggregate of size 90-
45 mm and above.

TABLE 20.5

The longitudinal profile shall be checked using a 3 meter long straight edge and graduated
wedge at the middle of each traffic lane along a line parallel to the Centre line of the road.
The transverse profile shall be checked with adjustable template at intervals of 10 meters.
For base with stone aggregate of size 63 to 45 mm and 53 to 22.4 mm surface evenness
to be as per Table 20.6.

TABLE 20.6

The longitudinal profile shall be checked with a three metre long straight edge and
graduated wedge at the middle of each traffic lane along a line parallel to the centre line of
the road. The transverse profile shall be checked with adjustable templates at intervals of
10 metres.

19.3.12 Rectification of Defective Construction

Where the surface irregularity of the W.B.M. sub-base course exceeds the tolerances
specified in Table 16.14 or where the course is otherwise defective due to sub grade soil
mixing with the aggregates, the layer to its full thickness shall be scarified over the
affected area, reshaped with added material or removal and replaced with fresh materials
as applicable, and re-compacted. The area treated in the aforesaid manner shall not be
less than 10sqm. In no case shall depressions be filled up with screenings and binding
materials.

19.3.13 Meaurements

The length and breadth shall be measured to the nearest centimetre. The depth of
consolidated layer shall be computed to nearest half centimetre by taking average of
depths at the centre and at 30 cm from the left and right edges at a cross section taken at
100 metre interval or less as decided by the Engineer-in-Charge by making small pits. The

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consolidated cubical contents shall be calculated in cubic metres correct to two places of
decimal. The cubical contents shall be compared with net quantity of stone aggregates
paid (that is stacked quantity – 7.5%). If the cubical contents are within (±) 5% of the paid
net stacked quantity of stone aggregates, the work shall be treated as acceptable. If the
cubical contents is short of net stacked quantity by more than 5% then the payment shall
be restricted to the quantities derived from cubical content.

19.3.14 Rate

The rate shall include the cost of all labour and materials involved in all the operations
described above, except cost of stone aggregate, kankar moorum, screenings and bajri,
for which separate payments shall be made. Where W.B.M. is to be laid over an existing
road, scarifying and consolidation of the aggregate received from scarifying shall be paid
for separately.

19.4 PRIME COAT OVER GRANULAR BASE

19.4.1 Scope

This work shall consist of the application of a single coat of low viscosity liquid bituminous,
material to a porous granular surface preparatory to the superimposition of bituminous
treatment or mix.

19.4.2 Materials

a. Primer
The choice of a bituminous primer shall depend upon the porosity characteristics of the
surface to be primed as classified in IRC: 16. These are:
(i) Surfaces of low porosity; such as wet mix macadam and water bound
macadam,
(ii) Surfaces of medium porosity; such as cement stabilised soil base,
(iii) Surfaces of high porosity; such as a gravel base.

b. Primer viscosity
The type and viscosity of the primer shall comply with the requirements of IS 8887, as
sampled and tested for bituminous primer in accordance with these standards. Guidance
on viscosity and rate of spray is given
Table 20.7.

Table 20.7
Viscosity Requirement and Quantity Of Liquid Bituminous Primer
Type of surface Kinematic Viscosity of Quantity of Liquid
Primer at
Bituminous Material
60*C(Centistokes)
per 10 Sqm.(kg)
Low porosity 30-60 6 to 9
Medium porosity 70-140 9 to 12

High porosity 250-500 12 to 15

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c. Choice of primer
The primer shall be bitumen emulsion, complying with IS 8887 of a type and grade as
specified in the Contract or as directed by the Engineer.
d. Weather and Seasonal Limitations
Bituminous primer shall not be applied to a wet surface or during a dust storm or when the
weather is foggy, rainy or windy or when the temperature in the shade is less than 10
degree Centigrade. Surfaces which are to receive emulsion primer should be damp, but
no free or standing water shall be present.

19.4.3 Construction

a. Equipment
The primer distributor shall be a self-propelled or towed bitumen pressure sprayer
equipped for spraying the material uniformly at specified rates and temperatures. Hand
spraying of small areas, inaccessible to the distributor, or in narrow strips shall be sprayed
with a pressure hand sprayer, or as directed by the Engineer.
b. Preparation of road surface
The surface to be primed shall be prepared in accordance with Clauses 501.8. and 902 of
MORTH specifications as appropriate. Immediately prior to applying the primer the
surface shall be carefully swept clean of dust and loose particles, care being taken not to
disturb the interlocked aggregate. This is best achieved when the surface layer is slightly
moist (lightly sprayed with water and the surface allowed to dry) and the surface should be
kept moist until the primer is applied.
c. Application of bituminous primer
The viscosity and rate of application of the primer shall be as specified in the Contract, or
as determined by site trials carried out as directed by the Engineer. Where a geosynthetic
is proposed for use, the requirements of Clauses 703 .3.2 and 703.4 of MORTH
specifications shall apply. – The bituminous primer shall be sprayed uniformly in
accordance with Clause 501 of MORTH specifications. The method for application of the
primer will depend on the type of equipment to be used, size of nozzles, pressure at the
spray bar and speed of forward movement. The Contractor shall demonstrate at a
spraying trial, that the equipment and method to be used is capable of producing a
uniform spray, within the tolerances specified.
d. Curing of primer and opening to traffic
A primed surface shall be allowed to cure for at least 24 hours or such other period as is
found to be necessary to allow all the volatiles to evaporate before any subsequent
surface treatment or mix is laid. Any unabsorbed primer shall first be blotted with an
application of sand, using the minimum quantity possible. A primed surface shall not be
opened to traffic other than that necessary to lay the next course. A very thin layer of
clean sand may be applied to the surface of the primer, to prevent the primer picking up
under the wheels of the paver and the trucks delivering bituminous material to the paver.

19.4.4 Tack coat

Over the primed surface, a tack coat should be applied in accordance with Clause 503
MORTH specifications.

19.4.5 Quality Control of Work

For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 of MORTH specifications shall apply.

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19.4.6 Arrangements for Traffic

During construction operations, arrangements for traffic shall be made in accordance with
the provisions of Clause 112 of MORTH specifications.

19.4.7 Measurement for Payment

Prime coat shall be measured in terms of surface area of application in square metres.

19.4.8 Rate

The contract unit rate for prime coat with adjustments as described in Clause 8.5.7 shall
be payment in full for carrying out the required operations including full compensation for
all components listed in Clause 401.8 (i) to (v) of MORTH specifications and as applicable
to the work specified in these Specifications. Payment shall be made on the basis of the
provision of prime coat at an application rate of 0.6 kg per square metre, with adjustment,
plus or minus, for the variation between this amount and the actual amount approved by
the Engineer after the preliminary trials.

19.5 TACK COAT WITH BITUMEN—EMULSION

19.5.1 Materials

Bitumen: This shall be Bitumen emulsion (Medium Setting) of specified grade and
consistency conforming to IS 8887 specifications.

19.5.2 Construction Operation

a. Preparation of surface
Cleaning:
Prior to the application of bitumen, all vegetation, loose sealing compound, caked mud,
animal dung, dust, dirt and foreign material shall be removed from the entire surface of the
pavement and from existing dummy, construction and expansion joints (wherever existing)
by means of mechanical sweepers and blowers, otherwise with steel wire brushes, small
picks, brooms or other implements as approved by the Engineer-in-Charge. The material
so removed shall be disposed off as directed by the Engineer-in-Charge.

b. Weather and Seasonal Limitations

The tack coat shall not be applied nor any bitumen work done during rainy weather or
when the surface is damp or wet or when the atmospheric temperature in the shade is not
more than 16o C.
c. Applying Tack Coat
Heating: Bitumen shall be heated in a boiler to a temperature of 165 deg. C to 175 deg. C
and maintained at that temperature. Temperature shall be checked at regular intervals
with the help of a thermometer.
Application of Bitumen: Hot bitumen shall be applied evenly to the clean, dry surface by
means of a pressure sprayer at specified rate. Even and uniform distribution of bitumen
shall be ensured. Bitumen shall be applied longitudinally along the length of the pavement
and never across it. Excessive deposits of bitumen caused by stopping or starting of the
sprayer or through leakage or any other reason shall be suitably rectified.

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19.5.3 Measurements

Length and breadth shall be measured correct to a cm, along the surface of pavement.
Area shall be worked out in sqm correct to two places of decimal.

19.5.4 Rate

Bitumen emulsion (Medium Setting) of specified grade and consistency to be used at

room temperature at following rate.
1. on w.b.m @ 0.4kg/sqm.
2. on bituminous surface @ 0.25 kg/sqm.

19.6 DENSE BITUMINOUS MACADAM

19.6.1 Scope

Dense Bituminous Macadam (DBM) is used mainly for in base/binder and profile
corrective courses. DBM is also used as road base material. This work shall consist of
construction in a single or multiple layers of DBM on a previously prepared base or sub-
base. The thickness of a single layer shall be 50 mm to 100 mm.

19.6.2 Materials

a. Bitumen
The bitumen shall be paving bitumen of penetration Grade VG-30 @ 5% (percentage by
weight of total mix) and lime filler @ 2% (percentage by weight of total mix) and lime filler
@ 2% (percentage by weight of Aggregate) conforming to IS 73 or as otherwise specified
in the item.
b. Coarse aggregates
The coarse aggregates shall consist of crushed rock, crushed gravel or other hard
material retained on the 2.36 mm IS Sieve. They shall be clean, hard, durable, or cubical
shape, free from dust and soft or friable matter, organic or other deleterious substance.
Before approval of the source, the aggregates shall be tested for stripping. The
aggregates shall satisfy the physical requirements specified in Table 20.8, for dense
bituminous macadam.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of
the crushed material retained on the 4.75 mm IS Sieve shall have at least two fractured
faces.
TABLE 20.8
Physical Requirements for Coarse Aggregate for Dense Bituminus Macadam

Property Test Specification

Max 5% passing 0.075mm
Cleanliness (dust) Grain size anlysis1
sieve.
Flakiness and Elongation
Particle shape Max 30%
Index (Combined)2
Los Angeles Abrasion
Strength* Value3 Max 35%
Max 27%
Aggregate Impact Value4

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Soundness5
Durability Sodium Sulphate
Max 12%
Magnesium Sulphate Max 18%
Water Absorption Water Absorption6 Max 2%
Coating and stripping of
Minimum retained coating
Stripping Bitumen aggregate 95%
Mixtures7
Water sensitivity** Retained Tensile Strength8 Min 80%

c. Fine Aggregates
Fine aggregates shall consist of crushed or naturally occurring mineral material, or a
combination of the two, passing the 2.36 mm IS Sieve and retained on the 75 micron
sieve. They shall be clean, hard, durable, dry and free from dust and soft or friable matter,
organic or other deleterious matter. The fine aggregate shall have a sand equivalent value
of not less than 50 when tested in accordance with the requirements of IS 2720 (Part 37).
The plasticity index of the fraction passing the 0.425 mm IS Sieve shall not exceed 4,
when tested in accordance with IS 2720 (Part 5)
.Note:
1. IS: 2386 Part 1
2. IS: 2386 Part 1
(The elongation test to be done only on non-aggregate in the sample)
3. IS 2368 Part 4*
4. IS 2368 Part 4*
5. IS 2386 Part 5
6. IS 2386 Part 3
7. IS 6241
8. AASHTO T283**
* Aggregate may satisfy requirement of either of these two tests.
** The water sensitivity test is only required if the minimum retained coating in
the stripping test is less than 95%.

d. Filler
Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or
cement approved by the Engineer-in-Charge. The filler shall be graded within the limits
indicated in Table 20.9.
TABLE 20.9
Grading Requirements for Mineral Filler
IS Sieve (mm) Cumulative percent passing by weight of total aggregate
0.6 100
0.3 95-100
0.075 85-100

The filler shall be free from organic impurities and have a plasticity index not greater than
4. The Plasticity Index requirements shall not apply if filler is cement or lime.

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19.6.3 Aggregate Grading and Binder Content :

When tested in accordance with IS 2386 Part 1 (wet sieving method), the combined
grading of the coarse and fine aggregates and added filler for the particular mixture shall
fall within the limits shown in Table 20.10 for dense bituminous macadam.
TABLE 20.10
Composition of Dense Graded Bituminous Macadam Pavement Layers

Note: The combined aggregate grading shall not vary from the low limit on one sieve to
the high limit on the adjacent sieve.

19.6.4 Mixture Design

Requirement for the Mixture: The mixture shall meet the requirements as given in
Table20.11

TABLE 20.11
Requirements for Dense Bituminous Macadam
Minimum stability (kN at 600C) 9.0
Minimum stability (kN at 600C) 2
Maximum flow (mm) 4
Compaction level (number of blow) 75 blows on each of the two faces of the
specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate See Table 20.12
(VMA)
Per cent voids filled with bitumen (VFB) 65-75

The requirements for minimum percent voids in mineral aggregate (VMA) are given in
Table 20.12.
TABLE 20.12
Minimum Percent Voids in Mineral Aggregate (Vma)

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Note:
1. The nominal maximum particle size is one size larger than the first sieve to retain more
than 10 percent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values
between those listed.

19.6.5 Binder Content

The binder content shall be optimized by using Marshall method for determining the
optimum binder content shall be adopted as described in the Asphalt Institute Manual MS-
2, replacing the aggregates retained on the 26.5 mm sieve by the aggregates passing the
26.5 mm sieve and retained on the 22.4 mm sieve.

19.6.6 Job Mix Formula:

The contractor shall inform the Engineer-in-Charge in writing, at least 20 days before the
start of the work, of the job mix formula proposed for use in the works, and shall give the
details of Source and location of all materials, their sizes, grading and test results.
Approval of the job mix formula shall be based on independent testing by the Engineer-in-
Charge for which samples of all ingredients of the mix shall be furnished by the Contractor
as required by the Engineer-in-Charge. Job mix formula shall be revised if there is a
change in source of material and be got approved by Engineer-in-Charge.

19.6.7 Plant Trials – Permissible Variation in Job Mix Formula:

Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials
at the mixer to establish that the plant can be set up to produce a uniform mix conforming
to the approved job mix formula. The permissible variations of the individual percentages
of the various ingredients in the actual mix from the job mix formula to be used shall be
within the limits as specified in Table 20.13.
TABLE 20.13
Permissible Variations from the Job Mix Formula

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19.6.8 Laying Trials:

Once the plant trials have been successfully completed and approved, the Contractor
shall carry out laying trials, to demonstrate that the proposed mix can be successfully laid
and compacted.

19.6.9 Construction Operations

 Prime Coat : Where the material on which the dense bituminous macadam is to
be laid is other than a bitumen bound layer, a prime coat shall be applied, as
specified, in accordance with the provisions, or as directed by the Engineer-in-
Charge.

 Tack Coat : Where the material on which the dense bituminous macadam is to be
placed is bitumen bound surface, a tack coat shall be applied as specified, in
accordance with the provisions, or as directed by the Engineer-in-Charge.

 Mixing and Transportation of the Mixture: The provisions are as specified in

item and MORTH specification.

 Spreading: MORTH specification shall apply. The paver finisher shall be fitted
with electronic sensor device.

 Rolling: The compaction process shall be carried out as per MORTH

Specification.

 Opening to Traffic: The newly laid surface shall not be open to traffic for at least
24 hours after laying the completion of compaction, without the express approval
of the Engineer-in-Charge in writing.

 Surface Finish and Quality Control of Work: The surface finish of the completed
construction shall conform to the requirements of section 900 of MORTH
specifications. For control of the quality of materials supplied and the works carried
out the relevant provisions of Section 900 of MORTH specifications.

 Arrangement for Traffic: During the period of construction, arrangements for

traffic shall be made in accordance with the provisions of specification and as per
direction of Engineer-in-Charge.

19.6.10 Measurement

Dense Bituminous Materials shall be measured as finished work in cubic meters, correct
to two places of decimal.

19.6.11 Rate

The rate includes the cost of all materials, labour and equipment, in all the operation
described above.

19.7 BITUMINOUS MACADAM

19.7.1 Scope

Bituminous Macadam (BM) is more open graded than DBM and consists of single course
or multiple courses of compacted crushed aggregates premixed with bituminous binder.

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19.7.2 Materials

a. Bitumen:
The bitumen shall be paving bitumen of penetration Grade of specified consistency and
content conforming to IS 73 or as otherwise specified in the item.
b. Coarse Aggregates
The coarse aggregates shall consist of crushed rock, crushed gravel or other hard
material retained on the 2.36 mm IS Sieve. They shall be clean, hard, durable, or cubical
shape, free from dust and soft or friable matter, organic or other deleterious substance.
Before approval of the source, the aggregates shall be tested for stripping. The
aggregates shall satisfy the physical requirements specified in Table 20.6, for dense
bituminous macadam, except for strength which shall be max 40% for Los Angeles
Abrassion value and aggregate impace value of max 30%.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of
the crushed material retained on the 4.75 mm IS Sieve shall have at least two fractured
faces.
c. Fine aggregates
Fine aggregates shall consist of crushed or naturally occurring mineral material, or a
combination of the two, passing the 2.36 mm IS Sieve and retained on the 75 micron
sieve. They shall be clean, hard, durable, dry and free from dust and soft or friable matter,
organic or other deleterious matter. The fine aggregate shall have a sand equivalent value
of not less than 50 when tested in accordance with the requirements of IS 2720 (Part 37).
The plasticity index of the fraction passing the 0.425 mm IS Sieve shall not exceed 4,
when tested in accordance with IS 2720 (Part 5)
Aggregate grading and binds content aggregate grading, quantity of bitumen and
appropriate thickness are as per Table 20.14.
TABLE 20.14
Composite of Bituminous Macadam

19.7.3 Measurement:

BM shall be measured as furnished work in cubic meters correct to two places of decimal.

19.7.4 Rate:

The rate includes the cost of all material labour and equipments in all the operations
described.

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19.8 DENSE BITUMINOUS CONCRETE

19.8.1 Scope

The Dense Bituminous Concrete (DBC) is used in wearing and profile corrective courses,
in a single or multiple layers on a previously prepared bound surface. A single layer shall
be 25 mm to 100 mm in thickness.

19.8.2 Materials

Bitumen:CRBM or PMB as specified.

Coarse Aggregates: The coarse aggregates shall be generally as specified in the
Table 20.15.
TABLE 20.15
Physical Requirements of Coarse Aggregates for Bitumen Mastic

Fine Aggregates:The fine aggregates shall consist of crushed hard rock or natural sand
or a mixture of both. The grading of fine aggregates inclusive of filler material passing 75
micron shall be as given in the Table 20.16

TABLE 20.16
Grading of Fine Aggregate I/C Filler

Filler: The filler shall be limestone powder passing 75 micron and shall have a calcium
carbonate content of not less than 80 per cent when determined in accordance with IS
1514.
Aggregate Grading and Binder Content : When tested in accordance with IS 2386 part 1
(wet grading method), the combined grading of the coarse and fine aggregates and added
filler shall fall within the limits shown in Table No. 20.12 for grading 1 or 2 specified in the
contract.

19.8.3 Mixture Design

Requirements for the Mixture:

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Apart from conformity with the grading and quality requirements for individual ingredients,
the mixture shall meet the requirements set out in Table 20.17 except loss of stability of
immersion in water at 60°C. The requirements for minimum percent voids in mineral
aggregate (VMA) are as per the Table 20.18

TABLE 20.17
Requirements for Dense Bituminous Macadam
Minimum stability (kN at 600C) 9.0
Minimum stability (kN at 600C) 2
Maximum flow (mm) 4
Compaction level (number of blow) 75 blows on each of the two faces of the
specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate See Table 20.18
(VMA)
Per cent voids filled with bitumen (VFB) 65-75

TABLE 20.18
Minimum Percent Voids in Mineral Aggregate (Vma)

Note:
1. The nominal maximum particle size is one size larger than the first sieve to retain more
than 10 percent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values
between those listed.

Binder Content:
The Marshall method for determining the optimum binder content shall be adopted as
described in the Asphalt Institute Manual MS-2, replacing the aggregates retained on the
26.5 mm Sieve and retained on the 22.4 mm Sieve, where approved by the Engineer-in-
Charge.

Job Mix Formula:

The contractor shall inform the Engineer-in-Charge in writing, at least 20 days before the
start of the work, of the job mix formula proposed for use in the works, and shall give the
details of Source and location of all materials, their sizes, grading and test results.

Approval of the job mix formula shall be based on independent testing by the Engineer-in-
Charge for which samples of all ingredients of the mix shall be furnished by the Contractor
as required by the Engineer-in-Charge.

Job mix formula shall be revised if there is a change in source of material and be got
approved by Engineer-in-Charge.

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Plant Trials – Permissible Variation In Job Mix Formula:
Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials
at the mixer to establish that the plant can be set up to produce a uniform mix conforming
to the approved job mix formula. The permissible variations of the individual percentages
of the various ingredients in the actual mix from the job mix formula to be used shall be
within the limits as specified in Table 20.19.

TABLE 20.19
Permissible Variations from the Job Mix Formula

Laying Trials:
Once the plant trials have been successfully completed and approved, the Contractor
shall carry out laying trials, to demonstrate that the proposed mix can be successfully laid
and compacted.

19.8.4 Construction Operations

TABLE NO. 20.20

Composition of Bituminous Concrete Pavement Layers
Grading 1 2
Nominal aggregate size 19 mm 13 mm
Layer Thickness 50-65 mm 30-45 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate passing
45 - -
37.5 - -
26.5 100
19 79-100 100
13.2 59-72 79-100
9.5 52-79 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-0
Bitumen content % by mass 5.5% or specified in item or 5.5% or specified in item or
of total mix2 directed otherwise directed otherwise
Specified in item or directed Specified in item or directed
Bitumen grade (pen) otherwise otherwise
Note:
1. The combined aggregate shall not vary from the low limit on one sieve to the high limit
on the adjacent sieve.
2. Determined by the Marshal method.
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19.8.5 Tack Coat:

Where specified in the Contract, or otherwise required by the Engineer, a tack coat
shall be applied.

19.8.6 Mixing and Transportation of the Mixture:

The provisions as specified in item and MORTH specification shall apply.

19.8.7 Spreading:

The MORTH specification shall apply. The paver finisher shall be fitted with
electronic sensor device.

19.8.8 Rolling:

The compaction process shall be carried out as per MORTH Specification..

19.8.9 Opening to Traffic:

The newly laid surface shall not be open to traffic for at least 24 hour after laying
and completion of compaction, without the express approval of the Engineer-in-
Charge in writing.

19.8.10 Surface Finish and Quality Control:

The surface finish of the completed construction shall conform to the requirements
of section 900 of MORTH specifications. For control of the quality of materials
supplied and the works carried out the relevant provisions of Section 900 of
MORTH specifications.

19.8.11 Arrangements for Traffic:

During the period of construction, arrangements for traffic shall be made in

accordance with the provisions of specification and as per direction of Engineer-in-
Charge.

19.8.12 Measurement for Payment:

DBC measured as finished work in cubic meters, correct to two places of decimal.

19.8.13 Rate:

The rate includes the cost of material, labour and equipments, involved in all the
operations described above.

19.9 CEMENT CONCRETE PAVEMENT

Specifications for CC pavement should be read in conjunction with the

Methodology for Vacuum Dewatering in CC pavement on pg 148 item no. 17.1.
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Cement concrete to be compacted by screed board vibrator of the type approved
by Engineering- Charge and by vacuum dewatering process complete as per
directions of Engineer-in-charge.

19.9.1 Measurements:

It shall be measured in cubic meters correct to two place of decimal.

19.9.2 Rates:

The rate shall include the cost of material, labour and machinery involved in all the
operations described above.

19.10 KERB STONE (PRECAST)

19.10.1 Laying:

Trenches shall first be made along the edge of the wearing course of the road to
receive the kerb stones of cement concrete of specified grade. The bed of the
trenches shall be compacted manually with steel rammers to a firm and even
surface and then the stones shall be set in cement mortar of specified proportion.

The kerb stones with top 20 cm. wide shall be laid with their length running parallel
to the road edge, true in line and gradient at a distance of 30 cm. from the road
edge to allow for the channel and shall project about 12.5 cm. above the latter.
The channel stones with top 30 cm. wide shall be laid in position in chamber with
finished road surface and with sufficient slope towards the road gully chamber.
The joints of kerb and channel stones shall be staggered and shall be not more
than 10 mm. Wherever specified all joints shall be filled with mortar 1:3 (1 cement :
3 coarse sand) and pointed with mortar 1:2 (1 cement: 2 fine sand) which shall be
cured for 7 days.
The necessary drainage openings of specified sizes shall be made through the
kerb as per drawings or as directed by the Engineer-in-Charge for connecting to
storm water drains.

19.10.2 Finishing:

Berms and road edges shall be restored and all surplus earth including rubbish
etc. disposed off as directed by the Engineer-in-charge. Nothing extra shall be paid
for this.

19.10.3 Measurements:

Cement It shall be measured in cubic meters with Length of the finished work (for
specified width and height of stone) shall be measured in running metre along the
edge of the road correct to a cm.

19.10.4 Rates:

The rate shall include the cost of all the materials and labour involved in all the
operations described above.

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SPECIFICATIONS FOR NON DSR ITEMS

Item No 5.11 is for Wooden Storage Cabinetry, wherein all the Material
Specifications are covered in DSR/CPWD Specifications. In addition, the
Item is providing all necessary details.

Item No 5.16, 5.18 (a to f) relate to SS Hardware Items, whose specifications are

as/CPWD.

Item No 6.04 is for Temporary barricading of the site & is derived from Item No of
DSR.

Item No 7.08, 7.12 & 7.22, are for Granite cladding, grooves & skirting, for which the
material specifications are already covered in CPWD Schedule.

Item No 7.20 Supply and installation of Heterogeneous vinyl sheet flooring areas in
sheet form. The total thickness would be 4.5mm and thickness of wear layer would
be 0.45mm. The product should be multi layered consisting of wear layer with PUR
coating, PVC layer, fiber glass layer and foam layer. It shall conform to shock
absorption of ≥28%, ball bounce of ≥95%, sound insulation of 20-22dB, Impact
resistance of ≥8N/m as per DIN 18032, abrasion resistance of ≥7mm, indentation
resistance of 0.6mm as per EN1016, friction coefficient of 0.6 as per GB/T14833-
1993, Rebound coefficient of 0.86 as per GB/T14833-1993 . Rate to include skirting,
end profile, pvc cove former on edges .

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ATHLETA
Sports Floor

Technical Details
Thickness 4.5 mm
Wear Layer Thickness (mm) 0.45
Roll Width in meters 1.8
Roll Length in meters 20
Weight kg./sqm 3.03 ~ 6.1

Technical Characteristics 4.5 mm

Shock Absorption % >28
Sliding Co-efficient (range) 0.45 – 0.65
Energy Return 0.38 m/s
Ball Bounce >97%
Vertical Deformation 2.3 mm
Fire Resistance (grade) Cfl
Chemical Resistance FINE
Sound Insulation 20-22 db

Test Items Test Method Result

Surface Treatment Resistance to staining PUR coating with UV
Treatment
Impact Resistance DIN 18032 N/M ≥8
Abrasion Resistance Mm ≤ 10 7
Indentation Resistance EN1016 Mm ≤ 0.6
Friction Co-efficient GB/T14833-1993 0.45 – 0.65 0.6
Rebound Co-efficient GB/T14833-1993 ≥ 0.85 0.86

Chemical Detection
Soluble Cadmium limits mg/m² ≤20 0.050
Volatile Content mg/m² ≤75 24
Vinyl Chloride Monomer mg/kg ≤5 0.5
Soluble Pb limit mg/m² ≤20 0.45

Item No 7.21 Providing and fixing carpet sheet/roll 4.3mm thick floor covering, pile
material 100% nylon 6.6 having resilient water proof backing material and total
weight of carpet should be 1.8 Kg/sqm and anti sound absortion of 0.10 approved
shade in flooring and skirting in approved pattern on a smooth top and damp proof
base using adhesive of approved quality and manufacture including rolling with light
wooden roller and the cost of levelling the surface with self levelling adhessive etc.
all complete as per manufacturer's specification. ( Make Flotex or Equivalent)

TECHNICAL SPECIFICATION SHEET

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Performance Specification

EN1307:2005 Wear Class 33

Fire Test
Europe Euro classification

EN13501-1 Class Bƒl s1

US Radiant panel – ASTM

E648 Class 1

Acoustic Tests

Impact Noise ISO 140 - 8 ALw = 20 dB

Noise absorption ISO 354 Noise reduction coefficient = 0.10

Appearance Retention
Tests
Hexapod ISO 10361 4.0 after 12,000 cycles

Suitable for continuous use under

Castor Chair Test EN 985 castors

Thermal resistance to ISO

8302 0.09 m2/Kw

Dimensional Stability Tests

EN434 <0.2% change in dimensions

Wear Test
Lisson EN 1963 <30 gr loss of pile (pass)
Wira abrasion Minimum of 60,000 cycles

Antistatic Test

Walk ISO 6356 <2 kV

Vertical ISO 10965 <1010 ohms

Friction Slip Resistance

Tests

EN 14041 Class DS

Dry and wet results > 0.70

DIN 51097 (Spec > 0.40)
UK SGR Pendulum Dry - Very low slip
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Wet - Low slip

Colour Fastness Typical values

To dry rubbing EN ISO 105
X12 4
To wet rubbing EN ISO 105
X12 4

To light EN ISO B02 6

To water EN ISO 105 E01 5

Guarantee 10 year wear guarantee

Product Specification

Flocked textile floor

Construction covering

Pile material 100% Nylon 6.6

(density) (approx. 80 million
fibres/m22/70 million
fibres/yd )
Resilient waterproof
Backing material backing
30 lm/98.4' (60
2
m2 per
Roll length roll/71.76 yd )
Roll width 200 cm / 6'6"

. Total weight: ISO 8543

2
Approx 1.8 kg/m
2
Sheet (3.32 lbs/yd )
Total thickness: Approx. 4.3 mm
ISO 1765 Sheet (0.17")

Item No 9.13 is for Chicken wire mesh at junctions, for which the material
specifications are covered in CPWD.

Item No 9.16 Providing and fixing Glass Reinforced Concrete (G.R.C) Screens in
approved size,pattern, design, thickness and color of M/S UniStone make or
equivalent. The Screens should be made from ‘53 grade’ White Portland Cement
manufactured by ‘JK Cement’ or equivalent, Quartz, Fine Silica Sand, Alkali
Resistant Glass Fiber manufactured by ‘Saint Gobain’ or equivalent, Super
Plasticizers manufactured by ‘BASF’ or equivalent, Polymers manufactured by
‘BASF’ or equivalent and U.V resistant Synthetic inorganic pigments should be used
for pigmentation manufactured by YFERROX (Germany)’ or equivalent. The material
casting should take ace in Synthetic Rubber / FRP Mould manufactured by ‘Reckli’
or equivalent. The fixing of Screens should be ‘Dry fixing’ i.e. to be done with
Stainless Steel (SS – 304) ‘L’ shaped Clamps, dash fasteners and pins.

GRC Composition

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S. No Material Percentage Manufacturer

Name

1 White Cement 50% Birla white/JK

2 Quartz fine silica sand( graded & 50%
selected)
3 Alkali resistant glass Fiber 3% to 4% Saint gobain or
equivalent
4 Super Plasticizer 0.30% to 0.50% BASF, Germany
5 Polymer 0.5% to 1.0% BASF, Germany
6 FRP mould Reckli Germany
7 Polystyrene As per requirement
8 UV & Alkali resistant, Synthetic Dose as per Bayer-Germany
inorganic pigments approved color

Technical Specification

Dry Density : > 1800 Kg/M3

Water Absorption : Less than 6% of dry weight by immersion

over a period of 24 hours

Compressive Strength : > 400 Kg. / CM2 (M - 40 Grade)

Wet Transverse Strength : > 7 N/ mm

Abrasion Resistance : Less than 2.0 for E.H.D.

Thermal Conductivity : 1.63 W/MK at 3% moisture content

1.80 W/MK at 5% moisture content

GRC Screens fixing details

The fixing of GRC Screens requires structural member support in following forms. It
can be M.S Support structure; S.S. Brick work or R.C.C. The structural support is
required on either of two sides of the screen, horizontally or vertically. The fixtures
used for fixing these screens are made of S.S. 304 quality and the no. of fixtures
used generally depends on size, weight, thickness and the site fixing conditions. The
fixtures used are well capable of taking the load of the screen and wind pressure at
heights. The actual fixing details for this product vary from site to site, as per the site
conditions. For instance, for high rise buildings or for fixing a large piece of screen
i.e. 20’ X 10’, Tower Crain and hydra are used to lift the piece, for fixing. The fixing
takes place only after physical verification of measurements of opening where the
product is supposed to be fixed.

Item No 11.04 is for AAC Block filling in sunken areas, wherein the material
specifications are covered in CPWD Specifications.

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Item No 12.02 pertains to Paneling work, for which the Item provides complete &
detailed specifications, as required.

Item No 12.03 pertains to Acoustic ceiling work, for which the Item provides
complete & detailed specifications, as required.

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Name of Work : DMRC Simulator Building at Shastri Park, Delhi

LIST OF APPROVED MAKES OF MATERIALS ( CIVIL)

S.No. Description Approved Make / Manufacturers

1. Silicon Sealant GE / Wacker / Dow coning

2. Waterproof Cement paint Snowcem, Asian , Burger

3. Adhesive for Door Fevicol/Vamicol/Dunlop

Work
4. Float Glass Saint Gobain Pilkington or ASAI

5. Anti – Termite Pest Control India Ltd. In case PCI is not

Treatment able to undertake the work, it should be
done by permanent members of IPCA as
approved by Engineer-in-Charge.

6. Glass Mirror Modiguard or Atul

7. Aluminium Accessories Classic/Argent/Oxford /Newlite /Crown

and Hardware /EBCO /Earl Bihari
8. Toughened Glass GSC or Pilkington or Gold Plus or Asahi

9. Anchor Fastner Hilti / Fischer /Bosch

10. Aluminium extrusion Indalco or Hindalco or Jindal

members

11. Fireproof Hardware Fittings Dorma / Marshal/Briton/Duprin

12. uPVC Windows Finesta/Rehau/NCL Wintech

13. Fire seal Astroflame UK or approved equivalent

14. Flush Door Shutters Green ply/ Merino/Duro

15. Plywood, Veneer, particle Green ply/ Merino/Duro/Archidply

Board, MDF board
16. Compact laminate cubical Merino/Greenlam

17. Gypsum board Partition Lafarge Boral Gypsum / India Gypsum Ltd.

18. SS Hardware fittings Godrej/Doorset/Kitch

19. Fire resistant door Navair /Sukri/ Promat /Pacific

frame/shutter

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20. Cement JK/AMBUJA/ ACC/L&T/LAFARGE

21. Reinforcement steel TATA/SAIL

22. Structural steel TISCO/SAIL

23. Ceramic Tiles SOMANY /KAJARIA/Orientbell

24. Vitrified Tile Somany/Kajaria /Orientbell

25. Gypsum false ceiling Lafarge Boral Gypsum or India Gypsum

26. White cement based JK cement/Birla/Unicrete

wall putty
27. Ceramic tiles Adhesive Pidilite/BalEndura/Unicrete

28. Paint, Distemper ICI, Jenson & Nicolson, Asian, Berger

29. Concrete Sika /STP/CICO/Pidilite / Fosroc /

Admixtures/pigments

30. Waterproofing Compound Dr. Fixit /FOSROC, Sika

31. PVC water stopper Sintex Industries Ltd /Superplast / Fixopan

32. Stainless steel Hardware Godrej/Doorset/Ozone

Fittings
33. Mortice locks Godrej/Doorset

34. Door Windows Aluminium Everite / Argent / Classic/ Crown / Earl

hardware fittings Bihari
35. E.P.D.M Gaskets Anand Reddiplex / Enviro Seals

36. GRC screens/GRC tiles Unistone/Ashirwad GRC/Delhi GRC

37. Fire Rated Glass Schott/Saintgobain/pyrogaurd

Pilkington/Glaverbel

38. Fire Retardant Paint Viper FRS 881, Nullifire, Burger

39. Fire Seal Sealz, Alstroflam, Abacus

40. Fire: D-Type Pull Becker Fire Solution, Dorma, Hardwin

Handles
41. Fire: Hinges, Becker Fire Solution, Inersoll Rand,
Dorma .
42. Fire: Panic Exit Device Dorma / Marshal/Briton/Duprin

43. Fire: Tower Bolts Dorma/Marshal/Briton

44. Modular SS Railing System JINDAL Architecture

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Or
Kich
45. Extruded Vitrified clay tiles Unistone/Prakriti Ceramics/Jindal mechno
Bricks Pvt. Ltd.
46. Extruded Aluminium Hunter douglas or equivalent
Louvers
47. Garbage Chute Echotech/ MetalKraft /Horizon Chutes Pvt.
Ltd/Tenny Design Tech (P) Ltd.
48. AAC Block Adhesive Laticrete/Unicrete

NOTE :

The Contractor shall produce samples before procurement of the material for approval of
the Engineer-in-charge, at-least one month before execution for all materials required for
works. In respect of materials for which approved makes are not specified as above,
the same shall be decided by the Engineer-in-charge and sample got approved from
Engineer-in-charge before procurement.

The Contractor shall produce samples before procurement of the material for approval of
the Engineer-in-charge at-least one month before execution for all materials required for
works. The material of makes out of the above shall be used on the work.

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 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

PLUMBING & SANITATION WORKS

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.0 SPECIFICATIONS FOR PLUMBING & SANITATION WORKS

1.1 General

1.1.1 Scope of work

The scope of work comprises supply, installation, commissioning and testing of water supply,
sewerage and drainage, sanitary fixtures and fittings, water pumping, water treatment system &
solar heating system for Proposed Simulator Building for DMRC at Shastri Park The scope
of work includes supply of all materials as per specifications and drawings, laying, fitting, fixing,
installation and commissioning the same.

1.1.2 All the water supply, drainage and sanitary works shall be carried out strictly as per printed
central PWD Specifications, 2009 Vol. (II) with upto date corrections for water supply,
sewerage and drainage, sanitary fixtures and fittings. Water pumping, water treatment system
& solar heating system shall be carried out as per relevant sections of these Specifications.

1.1.3 All the water supply and sanitary works shall be carried out by the licensed plumbers approved
by the Local Authorities and skilled workmen, experienced in the trade.

1.1.4 All works shall be completely concealed either within shafts or chases or in fills and dropped
ceilings unless specifically shown in drawings or required otherwise.

1.1.5 All works shall be adequately protected, to the satisfaction of the Engineer, so that the whole
work is free from damage throughout the period of construction upto the time of handing over.

1.1.6 No work shall be covered without approval of the Engineer.

1.1.7 The Contractor shall be responsible for coordinating the work with works of other trades
sufficiently ahead of time to avoid unnecessary hold-ups. Hangers, sleeves, recesses, etc.
shall be left in time as the work proceeds whether or not these are shown in drawings.

1.1.8 All clamps, screws, brackets, hangers and all miscellaneous steel work needed in the work
shall be fully galvanised.

1.1.9 Only specified brand of material will be used subject to the approval of the sample.

1.1.10 The Contractor shall submit as directed by the Engineer samples, manufacturer's drawings,
equipment characteristics and capacity data etc. of all equipment, accessories, devices, etc.
that he proposes to use in the installation, to the Engineer for approval.

1.1.11 The Contractor shall prepare and submit to the Engineer for approval before the work is
commenced, all shop drawings.

These shop drawings in triplicate must be submitted by the contractor as soon as possible after
the order is placed to give ample time for all the parties concerned to study and make comment
thereon.

The work shall commence only after the shop drawings are approved by the Engineer.

1.1.12 On completion of work the contractor shall submit to the Engineer one original and two copies
of as-built drawings.

1.1.13 Before the work is handed over, the Contractor shall clean all fixtures removing all plaster,
stickers, rust stains and other foreign matter of discolouration of fixtures, leaving every part in
acceptable condition and ready for use, to the satisfaction of the Engineer.

1.1.14 All sanitaryware and fittings shall conform to I.S. standards. The Contractor shall submit
samples of all fittings and fixtures proposed to be used to the Engineer for his approval. The

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approved samples shall remain with the Engineer till the completion of the work.

1.1.15 All workmanship shall conform to Indian Standard Codes of Practice. The fixing and finishing
shall be neat, true to level and plumb. Manufacturer's instructions shall be followed closely
regarding installation and commissioning.

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1.2 SANITARY FIXTURES AND FITTINGS

1.2.1 Workmanship

All sanitary-ware shall be fixed in a neat workmanlike manner, true to level and plumb.
Manufacturer's instructions shall be followed closely regarding installation and commissioning.

1.2.2 Protection of Fixtures

Fixtures shall be protected throughout the progress of the work from damage. Special care
shall be taken to prevent damage and scratching of chromium plated fittings. Tool marks on
chromium fixtures, etc. shall not be accepted.

All fixtures shall be fixed with chromium plated brass screws with washers whenever
necessary.

Protective paper on fixtures shall be removed with hot water only at the final completion of
work.

1.2.3 Sanitaryware

All porcelain sanitaryware shall be of first quality, free from warps, cracks and glazing defects.
All sanitaryware, fittings and fixtures shall be as shown in drawings and indicated in Bill of
Quantities.

1.2.4 Testing

When the installation has been completed to the satisfaction of the Engineer it shall be tested
in the following manner:

a) The entire system shall be slowly filled with water, allowing any trapped air to escape.

b) When all outlets are closed the system shall be checked for water tightness.

c) Each outlet shall then be checked for rate of flow and correct operation.

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1.6 LIST OF APPROVED MAKES FOR PLUMBING AND SANITATION MATERIALS

Engineer-in-Charge reserve the right to select the any of the brand out of the Brands listed in list of
approved makes. Contractor to obtain written approval of Brand and model prior to procurement of
material.

SL. NO. MATERIALS BRAND NAME

1. VITREOUS CHINA AND FIRECLAY HINDWARE

SANITARYWARE PARRYWARE
CERA

2. PLASTIC W.C. SEATS COMMANDER

DIPLOMAT
ADMIRAL

3. STAINLESS STEEL SINKS KINGSTON

JAYNA
NIRALI

4. C.P. FITTINGS & ACCESSORIES JAQUAR

PARKO
KINGSTON

5. C.P. WASTE, SPREADERS, URINAL JAQUAR

FLUSH PIPES PARKO
KINGSTON

6. SOIL, WASTE & RAIN WATER PIPES

& FITTINGS

A) CI PIPES & FITTINGS NECO

SKF
RIF

7. CENTRIFUGALLY CAST SPUN ELECTROSTEEL

DUCTILE IRON PIPES & FITTINGS JINDAL
TATA

8. RCC PIPES PRAGATI CONCRETE

UDYOG.
JAIN SPUN PIPE CO.
MANYA CONCRETE

9. CPVC PIPES & FITTINGS AJAY

ASTRAL
ASHIRVAD

10. G.I. PIPES JINDAL HISSAR

SURYAPRAKASH
TATA

11. G.I. FITTINGS R-BRAND

(MALLEABLE CAST IRON) KS-BRAND
ZOLOTO

12. BALL VALVES ZOLOTO

HONEYWELL

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AIP

13. BUTTERFLY /NRV VALVES ZOLOTO

HONEYWELL
AIP

14. WATER METRES CAPSTAN

KRANTI
ANAND

15. STONEWARE PIPES & PERFECT

GULLY TRAPS BURN
RK

16. C.I. MANHOLES NECO

COVERS AND FRAMES SKF
RIF

17. RCC MANHOLE COVER & FRAMES

& GULLY GRATINGS KK MANHOLE
MANYA CONCRETE
SHRI BALAJI SPUN PIPE

18. FASTNERS HILTI

CANON
FICHER

19. PIPECOAT IWL LIMITED

SHALIMAR
RESTECK

20. AIR RELEASE VALVE ENERGY

SANT
KARTAR

21. WATER HEATER RACOLD

VENUS
HAVELLS

22. HOT WATER NEOPRENE INSULATION ARMAFLEX

UP TWIGA
LLOYD

23. CP GRATINGS NEER

CHILLY
CAMRY

24. MIRROR MODI FLOAT GLASS

ATUL

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2.0 SPECIFICATINS FOR WATER SUPPLY PUMPS & WATER TREATMENT

SYSTEM

2.1 Scope of Work

The Scope of work in this subhead shall consist of furnishing all labour, materials, equipment
and appliances necessary and required to completely do all work relating to the supply,
installation, testing & commissioning of water pumping and water treatment as described
hereinafter and shown on the drawings.

The work shall include the following :-

Supply, installation, testing & commissioning of

a) Water supply pumps & drainage pumping system.

b) Water filtration system.

c) Electrical works related with water supply pumps & water treatment plant.

d) Painting of equipment and piping.

e) Unloading of the equipment and placing in position at site.

f) Foundation of equipments as required.

2.2 Contractor’s Experience

2.2.1 Contractors quoting for this work shall be engaged in the manufacture, work testing and
installation of Pumping Systems and Water Treatment Plants.

2.2.2 Contractor must have sufficient experience in the execution of turn-key projects.

2.2.3 Contractor must submit with the tender a list of similar jobs carried out by him in the last five
years along with the name of works, name and address of clients, year of execution,
capacity of plant and value of work.

2.3 Technical Information

2.3.1 Contractor shall submit along with the tender copies of detailed specifications, cuts, leaflets,
and other technical literature of equipment and accessories offered by him.

2.3.2 Contractor’s attention is specially invited to the special conditions and other clauses in the
agreement which required the contractor to :-

a. To Submit detail shop drawings.

b. Use material of specific makes and brands.
c. Obtain approval from various authorities as necessary and required.

d. Execute the entire work on a turn-key basis so as to provide a totally operating plant.

2.4 Exclusions

2.4.1 Work under this contract does not include the following work:-

2.4.2 Electrical cables upto incoming motor control centre.

2.5 Site Accessibility

2.5.1 The equipment are to be located in pump house located within the substation building.

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2.5.2 The equipment must be carried from the goods receiving station to the site in an extremely
careful manner to prevent damage to the equipment building or existing services.

2.5.3 Contractor must visit the site and familiarize himself with above problems to ensure that the
equipment offered by him are of dimensions that they can be carried and placed in position
without any difficulty.

2.6 General Requirements

a) All materials shall be new and of the best quality conforming to specifications and
subject to the approval of the Engineer.

b) All equipment shall be of the best available make manufactured by reputed firms.

c) All equipmens shall be installed on suitable foundations, true to level and in a neat
workmanlike manner.

d) Equipment shall be so installed as to provide sufficient clearance between the end

walls and between equipment to equipment.

e) Piping within the pump house shall be so done as to prevent any obstruction in the
movement within the pump house.

2.7 Pumping System

2.7.1 Pumping sets

Water supply pumps shall be monoblock online vertical, single or multistage stainless steel
pumps suitable for clean filtered water.

2.7.2

2.7.3 Drainage Pumps

All drainage pumps shall be portable submersible monoblock non clog pumps with totally water
& dust proof motor compact in design. The motor portion shall be isolated from the pump by
intermediate casing with double mechanical seal in oil chamber. The shaft shall be with die
cast rotor on motor side & shaft protection sleeves on pump side and shall be with grease
packed bearings and greesing pump. The motor housing shall be suitable for IP 68 protection.
The motor shall be provided with built in temperature sensor enabling tripping of motor if temp
rises above 150 Deg.C and restart at 80 Deg.C giving complete dry run protect.

The pump shall be of capacities & head as given in Bill of Quantities.

2.7.4 Level Controller/Indicator

Contractor shall provide and install low voltage transistorised level controllers/indicator as
specified in Bill of Quantities. Each level controller/indicator shall be provided with required
number of PVC sheathed stainless steel probes with necessary wiring and conducting.

2.7.5 Neoprene flexible pipe connectors

Suction and delivery lines of the pumps shall be provided with double flanged reinforced
Neoprene flexible pipe connectors. Connectors shall be suitable for a working pressure of
each pump as specified in Bill of Quantities.

2.7.6 Piping

Pipes for suction and delivery line shall be galvanised steel tubes to IS:1239 (Heavy Class).
Fittings shall be melleable cast iron fittings as per IS:1879.

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2.7.7 Valves

a) Butterfly valves

Butterfly valves shall be of centric disc construction with single piece body of Cast Iron with disc
of aluminium bronze with nitrile seat. Shaft shall be stainless steel with teflon bearing butterfly
valve shall conform to PN 1.6 rating and shall be provided with suitable matching flanges
compatible with PN 1.6 rating of valves.

b) Non-return valve

Non-return valves shall be cast iron spring action swing check type. An arrow mark in the
direction of flow shall be marked on the body of the valve. The valves shall bear IS: 5312
certification.

The valves shall be of cast iron body and cover. The internal flap shall be of cast iron and
hinged by a hinge pin of high tensile brackets of stainless steel. Cast iron parts shall conform
IS:210 / 70, grade 200/ 260 type.

The gasket shall be of high quality rubber and flap seat ring of leading gun metal to BS:1400
LG 2C. At high pressure of water flow the flapper shall seat tightly to the seat. The valve shall
be capable of handling pressure up to 7kg / sq. cm.

c) Ball valves

Ball valves shall be lever operated, screwed type of bronze body as per IS:318 with SS ball and
SS stem with mild steel lever.

2.7.8 Joints

All G.I. pipes and fittings shall be provided with screw joints unless otherwise instructed.

2.7.9 Testing

All G.I. pipes shall be tested hydrostatically for a period of two hours to a pressure of 14.0
Kg/Cum. without drop in pressure.

2.8 Water Treatment System

2.8.1 Water Filter

a) Water filter shall be dual media pressure filter / activated carbon filter suitable for a rate
of filtration given in Bill of Quantities. The design fabrication and construction shall
conform to the requirement of IS:2825.

b) Filter shall be vertical type skid mounted of required diameter. The shell shall be
fabricated from M.S. plates conforming to IS:2041 suitable to withstand as design
pressure given in Bill of Quantities. The minimum thickness of shell shall be 6 mm
and dished ends shall be 6 mm which shall include corrosion allowance and mill
allowance respectively. The scaling allowance on dished ends to be considered by the
bidder as per requirement of IS:2825. The filter shall have atleast one pressure tight
manhole cover. Each filter shall be provided with screwed or flanged connection for
inlet, outlet, individual drain connections necessary and required. Filter shall be
painted inside with minimum two coats of non-toxic corrosion resistant paint and one
coat of red oxide primer outside.

c) Under Drain System

Each filter shall be provided with an efficient under drain system comprising of

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collecting pipes, polypropylene nozzle's of manufacturer design. The entire under

drain system shall be supported on M.S. plate or cement concrete supports provided
by the contractor.

d) Face Piping

Each filter shall be provided within interconnecting face piping comprising of inlet,
outlet and back wash complete with valves. Pipes shall be GI heavy class (65 mm &
below). Pipe 80 mm dia and above shall be CI (LA) double flanges pipes with
matching fittings.

e) Accessories

i) Air release valve with connecting piping.

ii) 100 mm dia Dial Bourden type gun metal pressure gauges with gun metal
isolation, cock and connecting piping on inlet and outlet, causing shall be with
cast aluminium stored enamel black finish cases.

iii) Sampling cocks on low water inlet and filtered water outlet.

iv) Connection with valve for air scouring.

f) Each filter shall be provided with clean and washed filter media of type and depths as
recommended by the manufacturer.

g) Back Wash

Backwash flow rate shall be 400 gallons/hr./sq.ft which shall be achieved by reversal of
flow from water supply pumps through the pressure filter. Backwash shall be done
once in 48 hours subject to the recommendations of manufacturer.

2.8.2 Chemical Dosing Pumps (for Chlorination)

a) Chemical dosing pumps shall be reciprocating type with PVC or Ebonite head and
adjustable stroke with 0-100% adjustment.

b) Pump shall be driven by a totally enclosed vertical spindle motor suitable for 400/440
volts, 3 phase, 50 cycles, A.C. supply.

c) Capacity of the pump shall be as per manufacturer’s recommendation.

d) As the dose rate is likely to vary depending upon the quality of water select a pump of
which operating capacity can be exceeded by further 50%.

2.8.3 Solution Tanks for Chlorination

Provide one PVC/Rubber lined M.S. tank of minimum one day storage capacity for each pump
considering the extended capacity of the pump.

2.8.4 Piping for Water Treatment Plant

a) Pipes shall be M.S. galvanised steel conforming to IS:1239 (Heavy class) with
matching malleable cast iron fittings.
b) Valves 65 mm dia and below shall be lever operated Ball valves, screwed type of
bronze body as per IS:318 with SS ball and SS stem with mild steel lever.
c) Non-return valve 65mm and below shall be of gunmetal confirming to IS : 778.
d) Valves 80 mm dia and above shall be cast iron lever operated butterfly valve.
e) Non return valve 80 mm dia and above shall be cast iron double flanged to IS:5312.

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2.8.5 Flow Measurement

The contractor shall provide one bye-pass type Rota meter reading LPH on delivery line of filter
and softener.

2.8.6 The contractor shall supply one complete set of test kit for water treatment system.

2.8.7 Painting and Clean-up

a) One completion of the installation contractor shall scrub, clean all pumps, piping, filter,
softener and other equipment and apply one coat of primer.

b) Apply minimum two coats of synthetic enamel paint. Type/make of paint shall be as
per Engineer approval.

c) Provide painted identification legend and direction arrows on all equipment and piping
as directed by the Engineer.

d) On final completion of the work, contractor shall clean up the site and pump room of all
surplus materials, rubbish and leave the place in a broom clean condition.

2.9 Electrical Works

2.9.1 Cables

a) Contractor shall provide all power and control cables from motor control centre to
various motors, level controllers and other control devices.

b) Cables shall conform to IS:1554 and carry ISI mark.

c) Wiring cables shall conform to IS:694.

d) All power cables shall be aluminium conductor PVC insulated/PVC sheathed FRLS
armoured cables of 1100 volts grade.

e) All control and wiring cables shall be copper conductor PVC insulated armoured and
PVC sheathed 600 volt grade.

f) All cables shall have stranded conductors. The cables shall be in drums as far as
possible and bear manufacturer's name.

2.9.2 Motor Control Centres

Cubicles switch board of floor mounted and shall be fabricated from 16 gauge M.S. sheet with
dust and vermin proof construction. It shall be painted with stove enamelled paint of approved
make and shade. It shall be fitted with suitable etched plastic indentifications plates for each
motor. The cubicles shall in general comprise of the following :

(A) Incoming and outgoing MCCB’s of required capacity with rotary handle.

(B) PVC Colour coaded TPN Aluminium busbar having current density 0.8Amp/sq.mm.

(C) Isolation switch fuse unit one for each motor.

(D) Fully automatic DOL/Star Delta starters appropriate for motor rating with ON/OFF push
buttons and on/off indicating neon lamps for individual motor.

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(E) Single phase preventor of appropriate rating for each motor.

(F) Selector switch for pump operation.

(G) Panel type ampere meters of appropriate rating one for each motor.

(H) Panel type voltmeter on incoming main with rotary selector switch to read voltage
between phase to neutral and phase to phase.

(I) Rotary switch for manual or auto operation for each pump.

(J) Space for liquid level controllers specified separately in this contract.

The panel shall be prewired with colour coded wiring. All interconnecting wiring from
incoming main to switch gear, meters and accessories with in the switch board panel.

2.10 Installation, Commissioning & Guarantees

2.10.1 Installation

a) Contractor shall supply three copies of foundation drawings giving weight, vibration
and other loads required for the proper designing of the foundations.

b) All equipment shall be installed in a true workman like manner true to level and grade
in accordance with the best current practice.

c) Contractor shall employ sufficient and proper equipment for lifting and placing of heavy
equipment and in a manner which shall not strain or cause damage to the existing
structures. If any damage is done, the same shall be made good to the satisfaction of
the Engineer without any additional cost.

d) The contractor shall submit detailed shop drawings showing detailed layout of the
system showing dia piping, valves etc. for approval of the Engineer. The work shall be
started only after approval of shop drawings submitted by the contractor.

2.10.2 Commissioning

a) On completion of the work in all its aspects, the contractor shall start up the plant in a
manner normally done for the continuous operation for a period of not less than 48
hours and shall rectify and adjust the equipment for leakages and balancing the
system.

b) After satisfactory commissioning of the plant, the contractor shall conduct performance
tests on the pumps to satisfy the Engineer that all equipments are performing to the
rated outputs any or all pumps and equipment shall be rectified or replaced if the same
is not performing in accordance with the specifications.

2.10.3 Guarantees

a) On award of the work contractor shall submit a guarantee covering the quality and
performance of all materials supplied and installed under the contract. This guarantee
shall cover each and every material whether manufactured by the contractor or not.

b) Contractor shall specify a suitable procedure to test the rated performance of the
equipment and shall provide all necessary equipment, guages etc. for conducting such
tests.

c) The guarantee shall cover a period of one year from the date of installation and
handing over and commissioning of plant.

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2.10.4 Completion

On completion of the job, the contractor shall hand over to the Engineer the following:

a) One flow chart drawn in ink on thick paper and mounted in a glass frame showing the
flow diagram of the process including legend showing valves to be normally open or
closed and instructions for operation and maintenance of the pumping equipment.

b) Five sets of operating and maintenance instructions with spare parts list and their
manufactures and/or suppliers.
c) Five sets of catalogues and drawings for all equipment supplied.

On final commissioning of the plant, contractor shall provide the services of one trained
supervisor for period of two calendar weeks to train the Owners' staff in the operation and
maintenance of the plant.

2.11 LIST OF APPROVED MAKES FOR PUMPS AND WATER TREATMENT SYSTEM

Engineer-in-Charge reserve the right to select the any of the brand out of the Brands listed in list of
approved makes. Contractor to obtain written approval of Brand and model prior to procurement of
material.

SL. NO. MATERIALS BRAND NAME

1. VERTICAL IN LINE PUMPS - DP PUMPS

& HYDROPNEUMATIC SYSTEM - GRUNDFOS
- EBARA

2. MONOBLOCK SUBMERSIBLE
DRAINAGE PUMPS - DP PUMPS
- GRUNDFOS
- EBARA

3. G.I/M.S PIPES - JINDAL HISSAR

- PRAKASH SURYA
- TATA

4. G.I. FITTINGS - R-BRAND

(MALLEABLE CAST IRON) - KS-BRAND
- ZOLOTO

5. BALL VALVE /BUTTERFLY VALVE - ZOLOTO

- HONEYWELL
- AIP

6. NON-RETURN VALVE - ZOLOTO

- HONEYWELL
- AIP

7. CI STRAINERS - LEADER
- SANT
- AIP

8. Y-STRAINERS - ZOLOTO
- HONEYWELL

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- AIP

9. MOTORIZED BUTTERFLY VALVE - AIP

- HONEYWELL
- DANFOSS

10. PRESSURE GAUGE - H GURU

- FIEBIG
- EMERALD

11. PRESSURE SWITCH - DANFOSS

- SWIZER
- INDFOSS

12. WATER METERS - KAPSTAN

- KRANTI
- ANANAD

13. ELECTRIC MOTORS - KIRLOSKAR

- NGFE
- SIEMENS

14. ELECTRICAL SWITCHGEAR & STARTERS - GE POWER

- L&T
- CONTROL & SWITCHGEAR

15. CABLES - SKYTONE

- POLYCAB
- GRANDLAY

16. LIQUID LEVEL CONTROLLERS - AUTOLIFT

LIQUID LEVEL INDICATORS - TECHNICA
- MV INSTRUMENTS

17. FILTER - ION EXCHANGE

- THERMAX
- ENVIROTECH UTILITY

18. CHLORINATOR - MILTON ROY

- SEKO
- PENTAIR

19. ELECTRICAL CONTROL PANEL - AS PER APPROVED BY CPRI

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6.0 PREAMBLE TO THE PRICING OF BILL OF QUANTITIE FOR PHE & FIRE FIGHTING WORKS

6.1 GENERAL

6.1.1 This section shall be applicable for item rate work and for variations.

6.1.2 This preamble covers water supply, sewerage, drainage, sanitary fittings, pumping systems,
water treatment, solar heating system & fire fighting works.

6.1.3 This preamble shall be read in conjunction with the specifications, condition of contract,
drawings and all other documents accompanying the tender papers.

6.1.4 For all items of work the rates shall be comprehensive and all inclusive. The rates shall
include for all matters and things necessary for satisfactory completion and maintenance of
the work in proper working order and to the satisfaction of the Engineer-in-Charge, including
testing, making samples, etc., and all that have been indicated in the specifications or other
Tender Documents either directly or indirectly, and cover for all obligation of the Contractor
under the Contract. No claim for additional payment shall be allowed for any error or
misunderstanding by the contractor of the work involved.

6.1.5 Unless otherwise mentioned in the description of the item, this Bill of Quantities shall be
applicable for work in any height, position or condition.

6.1.6 Unless otherwise stated, method of measurement as described in the latest editions of I.S.
1200 with its parts corresponding to different sections of work shall be followed. In case of
any dispute in this matter, the decision of Engineer-in-Charge shall be final, binding and
conclusive.

6.1.7 The following notations have been used throughout the Bill of quantities.
m - Metre
mm - Millimetre
2
m - Square Metre
2
mm - Square Millimetre
3
m - Cubic Metre
No. - Number/Numbers
Dia - Diameter
Kg. - Kilogramme/s
T - Metric Tonne
L.S - Lumpsum
Pt. - Point/Points
Set - Set/Sets
C/C - Centre to Centre
@ - At the rate of
V - Volt/Volts
A - Ampere/s
SWG - Standard Wire Gauge

6.1.8 The Contractor shall be deemed to have full knowledge of all his obligations under the
Contract and shall be deemed to have made full allowance for complying with all such
obligations in his offer.

6.2 TRADE PREAMBLE

6.2.1 Sanitary Installation, Water Supply Pipes & drainage

All sanitary installations, water supply and drainage works shall be measured as per CPWD
specifications -2009 Vol.-II.

6.2.2 Mechanical Equipments

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All mechanical equipment e.g Filter, Chlorinator, Pumps, solar panel & electric Panels etc.
shall be measured in number and the rate shall include all items of work as given in
specifications & Bill of Quantities. The cost of construction of suitable foundations duly
approved by the Engineer-in-Charge is also deemed to be included in the rate of the
particular equipment.

6.2.3 Internal Fire Hydrants Pipes

Specified pipes for fire hydrant system shall be measured in running meter along the centre
line of the pipe lines and the rate shall include the cost of all necessary fittings, supports,
clamps, cutting chases and holes in walls, floors and making necessary excavation,
backfilling and disposal of surplus earth, where required. The rate shall be inclusive of the
cost of necessary fittings, painting, testing and commissioning of the pipe lines, as specified.

6.2.4 Accessories for Fire Fighting Systems

All accessories for fire fighting system e.g. fire hydrants, RRL hoses, hose reels, branch
pipes fire hose cabinets, air valves etc. shall be measured in numbers and shall include all
items as given in the Bill of Quantities.

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 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

ELECTRICAL WORKS

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1 LV MAIN SWITCHBOARD INCLUDING DB

1.1 GENERAL

1.1.1 Simulator buildings are provided with Electrical Panels for receiving and distribution of
power supply to various usages as defined in various clauses at voltage level of 415
V/50 Hz. The usages are generally lighting, air conditioning system, ECS system, PD
area and all other type E&M work which come building coverage. Switch boards and
panels as per following list are provided for power supply distribution at Stimulator
building and in depots.

1.1.2 The bidders shall refer the BOQ and drawing for incoming feeders, outgoing- feeders,
indications, metering and protection details along with quantity and type of each.

1.1.3 The manufacturing , testing , installation and commissioning of complete 415 V, 3

phase, 4 wire and 50 Hz low voltage main switchboard is as defined in IEC/EN
61439-1, built up from compartments to housebusbars , terminal blocks, internal and
control wiring, instrumentation, relays, interlock and padlocking facility, emergency
push buttons, equipment for BMS/ SCADA /RS 485/ Mod bus connectivity of
communicable ACB/MCCB interface, indication lamps, control and auxiliary
switches, contacts, control power supply, air circuit breaker, MCCB, MCB, CTs and
PTs, APFCsand any other items considered necessary to deliver the functions of
incoming and outgoing power supply as detailed in BOQ and drawing.

1.1.4 The equipments installed in each of the Electrical Panel are defined in the BOQ.

1.2 GOVERNING SPECIFICATIONS

1.2.1 Electrical Panels along with equipments shall conform to the latest standard or
harmonize as per the respective standard as given below or specified along with the
equipment in the specification.

1.2.2 In case of any conflict between specifications & the standards, the
instructions/decision of the Engineer' or Employer's authorized representative shall
be binding.

1.3 STANDARDS:

1.3.1 Low voltage Electrical Panels shall satisfy the following requirements and shall also
comply with standards in force when Electrical Panel units are manufactured,
particularly which are in the following table (Unless otherwise stipulated in the
specification, the latest version of the standards shall be applicable)
STANDARD DESCRIPTION
ISO STANDARD

ISO 9001 Quality systems- model for quality

assurance in design/development,
production, installation and servicing
IEC STANDARD

IEC 60228 Conductors of insulated cables

IEC 60255 Measuring relays and protection
equipment
IEC 60529 Degrees of protection provided by
enclosures (IP Code)
IEC 60831 Shunt power capacitors of the self-

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

healing type for a.c. systems having a

rated voltage up to and including 1000 V
IEC 60871 Shunt capacitors for a.c. power systems
having a rated voltage above 1000 V
IEC 60898 Electrical accessories – Circuit-breakers
for over current protection for household
and similar installations
IEC 60947-6-1/EN 60947-6-1 Specification for low-voltage and control
gear Multiple function equipment.
Automatic transfer switching equipment.
IEC 60947-2/EN 60947-2 Specification for low-voltage switchgear
and control gear circuit breakers
IEC 60947-1 Specification for low-voltage switchgear
and control gear. Contactors and motor-
starters. Electromechanical contactors
and motor-starters.
IEC 61008 Residual current operated circuit-
breakers without integral over current
protection for household and similar uses
(RCCBs)
IEC 61439-3/EN 61439-3 Specification for low-voltage switchgear
and control gear assemblies. Particular
requirements for low-voltage switchgear
and control gear assemblies intended to
be installed in place.
IEC 61439 Specification for low-voltage switchgear
and control gear assemblies
IEC 62262 Degrees of protection provided by
enclosures for electrical equipment
against mechanical impacts(IK code)
IEC 61641 Enclosed low-voltage switchgear and
control gear assemblies - Guide for
testing under conditions of arcing due to
internal fault
IEC 61869/BSEN 61869 Instrument transformers
IS STANDARD
IS 13779 ac Static Watt-hour Meters, Class 1 and
2
IS 13947-5-2 Low-Voltage Switchgear and Control
gear, Part 5: Control Circuit Devices and
Switching Elements, Section 2: Proximity
Switches
IS 13947-5-1 Low-Voltage Switchgear and Control
gear, Part 5: Control Circuit Devices and
Switching Elements, Section 1:
Electromechanical Control Circuit
IS 13947-4-1 Low-Voltage Switchgear and Control
gear : Part 4 - Contractors and Motor-
Starters
Is 13947-3 Low voltage switchgear and control gear,
part 3: switches, disconnectors, switch-
disconnectors and fuse combination units

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

IS 13947-2
A Low-Voltage Switchgear and Control
C gear, Part 2: Circuit Breakers
B
IS 13947-1 Low-voltage switchgear and control
- gear, Part 1: General rules
A
IS 5553i Reactors – Specification
BS STANDARDS
r
BS 381 C Colour chart
BS 4800c Colour
i
BSEN60742/BS 3535/BS 61558 Isolating Transformers
BS 1432r Specification for Copper for electrical
c purpose high conductivity copper
u
rectangular conductor with drawn or
i
t rolled edges.
BS 951 Electrical earthing. Clamps for earthing
b and bonding. Specification
r
e
BS 7430a Code of practice for protective earthing of
k electrical installations
e
BS ENr 13601 copper and copper alloys - copper rod,
bar and wire for general electrical
purposes
IEC/BS EN 60947-4-1 Specification for low-voltage switchgear
 and control gear. Contactors and motor-
 starters. Electromechanical contactors
 and motor-starters.
BS EN 10025 Hot rolled products of structural steels
BS EN 50525 Electric cables. Low voltage energy
 cables of rated voltages up to and
 including 450/750 V (U0/U)






1.4 ABBREVIATIONS

 ALTS- Automatic load transfer switch

 APFC-Automatic power factor correction
 ATS- Automatic transfer switch
 DB- Distribution board
 EMC- Electromagnetic compatibility
 LEP- Local Electrical Panel
 LMCP- Local motor control panel
 LT- Low Tension
 LVDB-low voltage distribution board
 ELECTRICAL PANELS- Low Voltage main switch board
 MCB- Miniature circuit breaker
 MCCB-Moulded case circuit breaker
 MFM- Multi function meter

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 MPCB-Motor protection circuit breaker

 RCCB- Residual current circuit breaker
 RCBO-Residual Current Circuit Breaker with Over-current
 RTU- Remote terminal unit
 SELECTRICAL PANELS- Sub Main Distribution Board
 TB- Terminal block
 VFC- Volt free contact

1.5 GENERAL AND TECHNICAL REQUIREMENTS OF ELECTRICAL PANELS

1.5.1 The Electrical Panel shall be same as low- voltage switchgear and control-gear
assemblies defined in IEC 61439-1 or EN 61439-1 built up from compartments
housingcircuit breakers, control gear, relays, bus bars, controls and other equipment as
defined in BOQ.
1.5.2 All panels should be factory built of proven design with OEMs as well as switchboard
manufacturer approved as covered by clause 3.10 of IEC 61439-1.
1.5.3 The Electrical Panel shall pass the internal arc fault containment tests in accordance
with IEC 61641 for fault current ratings as defined in BOQ for a minimum time of 0.3
sec.
1.5.4 The degree of Ingress Protection for Electrical Panels shall be IP 54 for Simulator
Building unless otherwise specified in BOQ, as defined in IEC 60529 which shall not
deteorate with time.
1.5.5 The Electrical Panels and the associated equipment, including switchgear and control
gear assemblies shall be certified for the category of duty specified as per Annex A of
IS/IEC 60947-1.
1.5.6 The main circuit as defined in vide clause 3.1.3 of IEC 61439-1 shall have an insulation
voltage of 1000 V AC or as specified in the BOQ.
1.5.7 The ambient temperature and ambient humidity for Electrical Panel shall be as per IEC
61439-1 (clause 7.1.1 and 7.1.2 of IEC 61439-1) and Switchgear shall be as per IEC
60947(Clause 6.1.1 and 6.1.3 of IEC 60947).
1.5.8 The secure service life of Electrical Panels shall be at least 30 years as defined in
General Scope of Work. The design features to secure the service life of 30 years shall
be submitted at the time of design approval.
1.5.9 The Electrical Panel shall have a rated short time withstand current of 70 kA, 65 kA, 50
kA and 35 kA for 1 second as per BOQ.
1.5.10 The Electrical Panels shall be a minimum of Form 4b Type 5 in accordance with BS EN
61439-2/IEC 61439-2 & Eiema’s Guide to Forms of Sepration.

1.6 ELECTRICAL PANEL CONSTRUCTION

1.6.1 The panels shall be of the approved design to suit local conditions as prevailing at
different stimulator buildings.
1.6.2 The Electrical Panel ( other than DB) shall be designed for indoor use in the form of free
standing, floor mounting extendible, self contained, flush fronted cubicles and
sectionalized as necessary to face easy transportation and erection, containing all the
equipment indicated on the Drawing, BOQ and specified hereinafter.
1.6.3 The cubicle section shall be constructed of angle iron types frames or folded sheet steel
or fully welded/bolted construction with all necessary removable covers. Removable
lifting lugs shall be provided on the top of the cubicles. Cubicle sections shall be
provided with bolts or devices for insuring that they are correctly aligned when being
coupled together. The bus bar chamber shall be fitted with removable end cover plates
secured by mild steel captive screws.

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1.6.4 It shall be finished to provide a rigid shell type of enclosure in accordance with BS
EN 10025.

1.6.5 The load bearing parts of the entire electrical panel assembly shall be 2 mm CRCA
thick sheet whereas other partition parts shall be constructed of minimum 1.6 mm
CRCA thick sheet steel.

1.6.6 The Electrical Panels shall be mounted on a robust base frame made up of steel
channel with a minimum height of 100mm and the maximum height of Electrical
Panel shall not exceed 2.40 meter including base frame. The base frame shall be
able to withstand the static and dynamic loads of the Electrical Panels. The steel
channels shall be painted with epoxy polyester paint. The main contractor shall
ensure that the maximum height of the Electrical Panel at the site of installation shall
not exceed 2.6 meter including foundation if any.

1.6.7 Electrical panel shall have provision for top/bottom in-coming and bottom/top out-
going to suit site conditions of cable entries.

1.6.8 Non-magnetic gland plates of not less than 5 mm thick of suitable size shall be
provided at the top and bottom of the LV main switchboards for the termination of
incoming and outgoing power cables of size 120 sq. mm or more or bus ways and 3
mm thick for cables of size less than 120 sq. mm. Where armoured multi- core
cables terminate inside the switchboard enclosure, glanding plates or glanding
brackets shall be provided for securing the cables to the switchboard.

1.6.9 Glanding plates, glanding brackets and extension boxes shall be removable and
shall be of adequate size for the particular cables to be terminated. The cables shall
not put any stress on to the glanding plate and shall be secured adequately.

1.6.10 All relays and indicating instruments shall be at least 300 mm and not higher than1.8
m from base frame. The clearance in front, back and side of all assemblies of
switchgear and control gear shall be as per IE Rule 51.

1.6.11 Various units comprising a complete Electrical Panels shall be grouped in a multi-
tier arrangement including a cabling and wiring chamber of ample dimensions to
accommodate terminal blocks, cable boxes and gland plates.

1.6.12 The equipment shall be arranged within each compartment such that all normal
maintenance can be carried out through hinged access doors or removable covers,
and where possible from the front.

1.6.13 Adequate maintenance access shall be provided to equipment within the Electrical
Panels. Demountable panels shall be provided at the back of the Electrical Panels
that can be handled by a single person. Every demountable panel shall be provided
with a pair of handles for easy removal and fixing.

1.6.14 Front access door shall be fixed with concealed hinges and interlocked with the
switch mechanism. The door panel can be opened only if the switchgear is in the
"OFF position” or the switchgear should switch off if the panel door is opened.

1.6.15 Ventilating louvers along with filter, where required, shall ensuring compliance of IP
of panel. It shall be provided in such a way that it is easily accessible for cleaning or
self cleaning filters shall be proved.

1.6.16 Anti-condensation heaters shall be provided at the rate of 60 W for each vertical of
the Electrical Panels, incase the volume is greater than 1 cubic meter of one vertical
then 2x60 W heater shall be provided. The heaters shall be of an enclosed tubular
pattern, each separately fused/ MCBs and switch. Each heater shall be controlled by
means of a step adjustable humidistat.

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1.6.17 Adequate arrangements for air circulation shall be made within each compartment of
the Electrical Panels, if required. The Contractor shall ensure that the internal
temperature of the Electrical Panels will be well within the operating ranges as
specified by IEC 61439-1 of all electric components including switchgear, control
gear, bus bars, relays, wiring and timers inside the Electrical Panels.

1.6.18 All the incoming / outgoing terminations shall be extended via copper connections
into a separate termination chamber adjacent to the switchboard. When busbars are
used between switchboards, the internal busbars of the switchboard shall be of
tinned copper bars sizes of copper shall be as per tested design. No linking of
busbar or incoming/outgoing terminals with switchgeras/functional units shall be
permitted with cable except in case of MCCBs./MCBs below or equal to 100 Amps
rating.

1.6.19 The switchgear assembly/sub-assemblies or panels shall be termite and rodent

proof.

1.6.20 The switchboard shall have sufficient space to house all electrical equipment
allowing spare Space capacity of 10% for the future expansion if specifically asked in
BOQ

1.6.21 Spare feeder shall be provided as per BOQ. Any Panel which comprises an
assembly of similar modules shall be constructed such that further similar modules
can be added at either end.

1.6.22 All similar items of the Electrical Panels and their component shall be
interchangeable. Spare parts shall be manufactured to originals and shall fit all
similar items of the Electrical Panels. Where machining may be needed before fitting
renewable parts, the machining fits and the associated tolerances shall be shown on
the drawings accompanying the instruction manuals.

1.6.23 The Electrical Panel shall operate without excessive vibration and with a minimum of
noise as per best of engineering practice and shall also operate without excessive
temperature rise at the rated load conditions.

1.6.24 The style and finish of the workmanship shall be consistent throughout the Works.
Unless otherwise specified, Engineer shall decide the final colours for all paintwork
and other finishes to be applied to the Electrical Panels.

1.7 ELECTRICAL PANEL EARTHING AND SAFETY ARRANGEMENT

1.7.1 All non-current carrying metallic components shall be permanently connected to

earth.

1.7.2 Material used for the earthing busbar shall be same as the main busbar.

1.7.3 The tin-plated copper/aluminium earthing busbar inside the panel shall have cross-
sectional area as per calculation given in Annex B.

1.7.4 A continuous earthing busbar shall be provided along the whole length of each
Electrical Panels and shall be provided with terminals for connection to the metal
housing of incoming busways, cable trunking and cladding or armouring of all
incoming and outgoing cables and to the substation earth.

1.7.5 Switchboards shall be provided with two earthing terminals, one at each end, for the
connection of external earth conductor for earthing. The earthing bars shall be fixed
at rear interior bottom portion throughout the length of the switchboard, bonding all

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

gland plates, and other component parts of the switchboard to a main earth point
adjacent to the intake position in accordance with BS 951 and BS 7430.

1.7.6 All terminals, connections, relays and other components which may remain live when
access doors are open shall be screened. It shall not be possible to obtain access to
an adjacent cubicle when any door is opened.

1.7.7 Where several outgoing circuits occupy a common cabling chamber, all copper work,
cable lugs, terminations and terminal blocks shall be fully segregated by
compartmentation to enable work on any one circuit to be carried out with other
circuits remain live.

1.7.8 Protection against shock in normal service shall be achieved by the provision of
barriers or enclosures both vertical and horizontal and between adjacent units to
ensure segregation and prevent accidental contact with live parts, or by complete
insulation of all live parts Control cables shall be segregated from primary
conductors.

1.7.9 The protective earthing configuration shall be TN-S unless otherwise specified.

1.8 EQUIPMENT INSTALLED INSIDE ELECTRICAL PANELS

Electrical panels consist of Low Voltage Switchgear, control wiring and all other parts
which are defined below.

1.8.1 Busbar

1.8.1.1 Busbars shall be of rectangular section hard drawn high conductivity tinned copper
bare type conform to BS 1432/13601 or aluminium as per BOQ, adequately rated
for designed value and fault level of load as per BOQ and supported by non-
tracking moulded insulators spaced at suitable intervals. The complete assembly
shall be capable of withstanding the maximum mechanical stresses to which it may
be subjected to under fault conditions.

1.8.1.2 Sizing of the busbar shall comply with IEC 60890 for temperature rise assessment by
extrapolation and in case of copper busbar temperature rise as per Copper
Development association latest formula, may also be used.

1.8.1.3 Bus bar rating shall be same through out the length of panel and shall be as per BOQ
type tested design and recommendation of IEC 61439. The bus bar shall be
designed for easy extension in future at either end.

1.8.1.4 Busbars and busbar connections shall be constructed in accordance with the
requirements of IEC 61439-1. The short-time withstand current rating shall be as
mentioned in BOQ for 1 second at 415 V.

1.8.1.5 Connection in Bus bars shall be made as approved and proven design of original
manufacturer.

1.8.1.6 The maximum temperature of the bus bars and the bus connections shall be as per
IEC 61439 standard.

1.8.1.7 The main busbars shall be so positioned and arranged that all busbar risers and
droppers can be brought onto the main busbars without undue bending. Busbars
shall be and supported with appropriate clearances in air to the requirement of
providing full insulation.

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1.8.1.8 Busbar chambers of similar rating shall be capable of coupled together using busbar
coupling links, in accordance with the manufacturer's recommendation. Coupling
links shall be approved by the Engineer before use.

1.8.1.9 Interconnecting conductors between busbar chambers and switchgear shall be as per
rating of switchgear and type tested design.

1.8.1.10 Switchgear shall be joined to busbar chambers by means of properly designed

busbar chamber connection flanges or conduit couplers and male bushes.
Connection flanges shall be manufactured from galvanized sheet steel or CRCA
and finished grey.

1.8.1.11 Busbars shall be coloured for phase identification at location of bus inspection
points with the approval of site Engineer. The material for phase identification shall
be non-fading colour of proven design to be decided by the Engineer and use of
adhesive label shall not be acceptable.

1.8.1.12 The front cover and end plates of busbar chamber shall be removable and normally
held in position by non-ferrous metal screws
1.8.2 POLARITY

1.8.2.1 The polarity of all apparatus shall be arranged as follows when viewed facing the front
of the Electrical Panels:

1) For two pole apparatus, phase pole and neutral pole when reading from
top to bottom or left to right; and
2) For three or four pole apparatus, red, yellow and blue phases and
neutral when reading from top to bottom or left to right.

1.8.2.2 All cables shall be so connected within the Electrical Panels such that the correct
sequences are preserved throughout.
1.8.3 Control supply

1.8.3.1 Separate control bus of suitable rating made of copper shall be provided throughout
the panel length, and the control bus should be accessible from the front of the
panel. Control voltage taping for different feeder shall be done with proper clamp.

1.8.3.2 The control circuit shall be separated from other auxiliary circuits, i.e. indicating circuit,
heater and lighting circuits, with dedicated circuit protective devices.

1.8.3.3 240V control supply will be available from the building UPS with standby utility or as
decided by engineer at site. DP MCB protection shall be provided at incoming.

1.8.3.4 240V Volt sensing relay with volt free contacts shall be provided for sensing the
control supply for local and remote indication to BMS/SCADA.
1.8.4 Instrumentation
1.8.4.1 Electrical meters shall conform to IS 13779 / IEC - 1036, 687, 1286 suitable for single
phase /three phase supply system in all respects. Accuracy of meters shall be of
class as specified in BOQ.
1.8.4.2 All meters shall be digital type and multifunction meters should be with RS 485
connectivity to suit BMS System wherever mentioned in BOQ. Suitable memory and
software for logging the information along with real time metering information must
be available. The meters must have required level of protection and sufficient
number of auxiliary contacts.
1.8.4.3 Meters shall be suitable for continuous operation as per IEC 898.
1.8.4.4 Meter shall be suitable for 3 phase, 4 wire systems, balanced as well as unbalanced
load. All instruments and associated apparatus shall be capable of carrying their full-

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

load current without undue heating. They shall not be damaged by the passage of
fault currents up to the rating of the associated switchgear through the primaries of
their associated instrument transformers. The instrument meter shall be earthed by a
conductor of not less than 2.5 mm2 cross-sectional area.
1.8.4.5 Energy meters shall be two / three element, switch board mounting type suitable for
unbalanced loads. In case of two incoming feeders, a summation C.T. shall be
provided with the meter.
1.8.4.6 The display for meters i.e. ammeter, voltmeters or multifunction meter shall be auto-
ranging type.
1.8.4.7 Selector switches shall be inbuilt in Voltmeter such that voltmeters can read voltages
between phase and phase and between phase and neutral.
1.8.4.8 Ammeters shall normally be suitable for 5 A secondary of current transformers
1.8.4.9 Voltmeter circuits shall be provided with protection through MCB as required.
1.8.4.10 Separate current transformers for a feeder shall be provided for protection device
and for instrumentation.
1.8.5 Current Transformers (CTs) and Voltage Transformers (VTs)

1.8.5.1 CTs and VTs shall comply with IEC 61869/BSEN 61869 and CTs shall be of the
epoxy resin encapsulated ring type. The ratings specified on the Drawings are
indicative only and it shall be contractor/manufacturer's responsibility to ensure that
the ratings offered are adequate for the relays/meters provided considering lead
resistance, etc.

1.8.5.2 Current transformers shall comply with approved standard and shall be compatible
with and provide the necessary accuracy, over current factors, characteristics,
performance and VA rating for the satisfactory operation of the relevant protection
devices, instruments and meters.

1.8.5.3 All CTs shall have a short-time current rating as specified in IEC 60044-1.

1.8.5.4 CTs for protection shall be compatible with the protection relays to ensure that the
CTs will not be saturated up to the maximum prospective fault current.

1.8.5.5 CTs designed for unit protection schemes shall be able to withstand a stability of not
less than the maximum through-fault of the units.

1.8.5.6 In balanced circuits, the spill current with maximum stability conditions shall not
exceed one quarter of the operating current of the relay.

1.8.5.7 CTs for use in conjunction with protection relays shall be of class 5P accuracy or
better. CTs for use in conjunction with measuring instruments shall be of Class 1
accuracy. The product of rated accuracy limit factor and rated output of the
protection CTs shall not be less than 20 times the total rated burden of the trip circuit
including the relay, connection leads and O/C release where applicable.

1.8.5.8 All CTs shall have output ratings adequate to cater for the burden connected to them.
The Contractor shall demonstrate to the satisfaction of the Employer representative.
By calculation or by test, that each group of the CTs, when installed and having the
secondary burden connected, is capable of operating the relays and other measuring
instruments in accordance with the manufacturer's published characteristics and the
requirements of the system, with a reasonable margin of safety.

1.8.5.9 Measuring CTs shall be connected to test terminal block. The test blocks shall be
provided with easily removable links and designed to facilitate connection of testing
instruments on load without open-circuiting the CTs.

1.8.5.10 The secondary circuit of each set of CTs shall be earthed at one point only through a
disconnectable copper link at a readily accessible position for testing.

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1.8.5.11 Multi-ratio CTs (where used) shall have a label clearly indicating the connections
required for the alternative ratios. These connections shall be shown on panel wiring
diagrams.

1.8.5.12 Identification labels shall be fitted, mentioning type, ratio, rating, output and serial
numbers.

1.8.5.13 VTs shall be provided with adequately rated primary and secondary fuses.

1.8.5.14 Instruments shall be similar in appearance throughout the whole of the Electrical
Panels. All instruments meters shall be of flush pattern, dust and moisture proof,
suitable for the environment in which they are installed.

1.8.5.15 All instruments and meters shall be completely segregated in instrument

compartments. Compartments containing these devices shall not contain any
terminals or equipment operating at higher voltages with the approval of site
Engineer.

1.8.5.16 The housing shall be of steel or phenolic mould. Design and manufacture of meters
shall ensure prevention of fogging of instrument glass. Selector switches shall be
provided for ammeters and voltmeters used in three-phase system. This selector
shall be of built-in type with meters.
1.8.6 Relays

The relays are having in-built function with protective gears such as ACB, MCCB
and MCB and MPCB etc. In case any relay is required for additional protection as
stated in BOQ or otherwise, the same shall be provided to ensure full protection to
the system.
1.8.7 Emergency push button (EPB)

Emergency lock and key type push buttons shall be installed wherever required or
specified in BOQ to de-energize the Electrical Panels in the event of an emergency. The EPB
shall be button type with flat surface protection guard ring and pressed-in design with key
reset so that accidental triggering and vandalism shall be avoided as far as possible.
Transparent hinged cover shall be provided in front. Unless otherwise specified on the
Drawings, the EPB shall be mounted at 1300 + 100 mm above finish floor level. The button
design and the installation details shall be submitted for approval.
1.8.8 Interlock and padlocking facilities

1.8.8.1 Mechanical key interlocks shall be provided wherever applicable or as specified in

BOQ and shall be so designed as to avoid mal-operation at the point of manual
application. The scheme shall be such that attempts to remove a captive key shall
not result in tripping or opening of the device.

1.8.8.2 The tripping of the ACB(s) shall be via local hard wiring control and in Signal(s) shall
also be generated from circuit breaker(s) upstream of the corresponding Electrical
Panels and the switchboard interconnected section ACB.

1.8.8.3 Electrical interlocks on withdrawable equipment shall be so arranged that if the

equipments are withdrawn, the complete operation of the withdrawn equipment shall
be independent of the remote interlocking contacts. In addition, interlocks shall not
be defeated leading to damages or unsafe operations of Electrical Panels due to the
withdrawing of equipment.

1.8.8.4 Locking facilities shall be provided where appropriate for switches and isolators in
order that they may be locked in the open position. Switchgear cubicle access doors
shall be equipped with integral type locks, preferably incorporated in the handles of
the equipment.

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1.8.8.5 Where locking facilities are of the integral barrel type, the key for each lock shall be
unique to the associated lock unless otherwise specified.

1.8.8.6 Two keys shall be provided for every lock supplied. The keys shall be fitted with rings
with identification labels, and cabinets with glazed front- opening doors shall be
provided. The cabinets shall be adequate in size and equipped with hooks to house
all keys when not in use, and shall be mounted in positions to be decided.
1.8.9 Internal and control wiring

1.8.9.1 All equipment shall have adequate provision for the entry and termination of all
associated power and auxiliary cables.

1.8.9.2 Cable entry shall in all cases, except where otherwise specifically approved, and be
at the base of the equipment. All cabling and wiring within the Electrical Panels shall
be neatly run and fitted in or upon such cable trays, trunkings and conduits as may
be appropriate to the layout and equipment. Cable trays, trunkings, conduits and
cleats shall be non - metallic and shall be of the low smoke halogen free material.A
metallic cleat is acceptable with the approval of site engineer.

1.8.9.3 FRLSZH Cables shall be as per BS 6724-multicore cable and BS 7211 for single
core cable. All internal and control wiring shall be Fire retundant Low Smoke Zero
Halogen (FRLSZH) copper conductor wires rated at 450/750 V complying with BS
EN 50525. All control wiring within the Electrical Panels shall be with single core
minimum 2.5 mm2 for CT and balance as per approved manufacturer design.
Insulation shall have a glossy finish, be resistant to oil and be incapable of
supporting combustion. Fire survival cables shall be provided where required as per
BOQ.

1.8.9.4 Wiring from the fixed part of the switchboard to the movable part such as hinged
door shall be enclosed by flexible tubing made of Fire retundant Low smoke Zero
Halogen material. Exposed live terminals shall be suitably shrouded or covered.

1.8.9.5 Wiring passing out to fully accessible positions shall be run in non-metallic Fire
retundant low smoke halogen free flexible tubes or conduits.

1.8.9.6 All internal wiring shall be neatly run and securely fixed in non-metallic cleats in such
a manner that, wherever practicable, wiring can be checked against diagrams
without removal of the cleats.

1.8.9.7 Access opening shall be fitted with a suitable long lifegrommet where inter-panel
wiring passes through panel side sheets etc.

1.8.9.8 Bus-wires shall be fully insulated. Bus-wires terminals shall be fully accessible from
the point of entry to each enclosure. MCB and links shall be provided to enable all
control circuits within the Electrical Panels to be isolated from the bus-wires.

1.8.9.9 All control circuits shall be protected by a MCB.

1.8.9.10 There shall be no joints in conductors between terminal points.

1.8.9.11 Terminations for terminals shall be of the crimped-on ring type. Terminations of
stranded conductors to clamp type terminals shall be of the crimped-on solid rod
type.

1.8.9.12 No more than one core of either internal or external wiring shall terminate on any
outgoing terminal. Where duplication of terminal blocks is necessary, suitable solid
bonding links shall be incorporated in the design of block selected.

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1.8.9.13 Wiring for all known future equipment shall be provided and all wires shall be
terminated.

1.8.9.14 All wires between the terminals of two equipment shall be given a unique number
according to an approved system. A wire number shall not change solely by virtue of
passing through, say, a marshalling terminal block.

1.8.9.15 In the interests of uniformity, the wire-numbering system shall be approved by the
Engineer.

1.8.9.16 Identification markers shall be fitted to all wires and multicore cable tails within
enclosures in accordance with the diagram for apparatus concerned. Cable and
core makers shall be of insulation material, colored according to the wire numbering
system with a glossy finish, be resistant to oil and be incapable of supporting
combustion. Numbers shall not be duplicated unless the corresponding wires are
directly in series or parallel

1.8.9.17 Different insulation colours shall be provided to distinguish the various circuits. All
wiring shall conform to the colour and ferrule codes to be approved by Engineer.

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1.8.10 Terminal blocks

1.8.10.1 Both incoming and outgoing cable shall have top or bottom entry depending on site
requirement.
1.8.10.2 Each terminal block compartment shall have not less than 20 % or 4 spare
terminals whichever is greater.
1.8.10.3 Terminal blocks for low voltage wiring shall be moulded from high-grade non-
hygroscopic melamine, comprise bank ofrail-mounted blocks with all live parts fully
shrouded, screw- clamp, spring loaded insertion, solder-lug or stud type terminals
as appropriate to the design and duty of the cables to be terminated. Pinch-type
screws, where the screw is in direct contact with the conductor, shall not be used.
1.8.10.4 Each terminal shall be provided with claw-type washers, crimp lugs or other
approved means for connection of the wires. Plain and spring washers, nuts and
lockouts shall be electro-tinned.
1.8.10.5 Terminals shall be assembled in banks and each terminal shall be complete with
marking tags to fit into moulded tag slots.
1.8.10.6 Terminals for final connections for indication, instrumentation and metering circuitry
shall have test probe facilities and an integral disconnecting device to facilitate
testing.
1.8.10.7 Terminations shall be grouped according to function and no more than two wires
Connected to one terminal. Labels shall be provided adjacent to the terminal block
to identify the function and voltage of each group.
1.8.10.8 All terminals to which 240 V or 415 V AC circuits are connected, where they are in
individual terminal blocks, shall be provided with a transparent insulated cover
which in addition to any other form of identification and shall have a label engraved
suitably indicating the voltage.
1.8.10.9 Terminals for the control supply which may be still alive when the main equipment
is isolated from the mains supply shall be suitably labelled to reduce the risk of
accidental contact.
1.8.10.10 All terminals shall bear a permanent identification number or letter.

1.8.11 Marshaling unit

1.8.11.1 In main distribution Electrical Panels separate marshalling chamber shall be
provided for BMS interfaces terminals or wherever required as per BMS
requirement.
1.8.11.2 Single location interface for different LV components of main distribution panel or
other Electrical panel where ever necessary or as per BOQ shall be provided
through marshalling chamber for BMS interface.
1.8.11.3 All interface terminals and ports for BMS shall be wired up to the marshalling
chamber. Necessary marking and ferruling shall be provided for individual
termination.
1.8.11.4 Control command interface and other terminals having potential should have due
separation from VFC interface terminals. Control and signal cable wiring from
different relays, sensors, transducer, controller and contactor releases shall be
through separate wiring bunch to avoid fault current or external magnetic/ electric
interface.

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1.8.11.5 Necessary multi dropping and single point interface provision shall be done
through suitable short links. Communicable devices using standard protocol
communication shall be looped as per BMS requirement.
1.8.11.6 Marshalling chamber should have provided with necessary mounting arrangement
or space provision for BMS remote I/O module/ PLC equipment along with its
associated interface equipment and power supply unit or as per BOQ.
1.8.11.7 Junction box for control wires to suit four poles of ACB connection shall be
provided as per requirement.
1.8.11.8 Connecting cable with connector between ACB communication unit and junction
box shall be provided.
1.8.11.9 24V DC source unit or as required (Incoming supply shall be taped form the
control supply available in the panel) for communication of ACB/MCCB with
SCADA/BMS system.
1.8.11.10 Panel manufactures shall provide the required termination and interface detail for
BMS work. In case of requirement of supervision and guidance during BMS
commissioning, same shall be inclusive to the panel manufacture's scope of work.
It is the responsible of panel manufactures to provide necessary interface detail
such as data point register address during BMS commissioning or supervise as
appropriate during installation and testing of BMS system.
1.8.11.11 Marshalling box shall comply with EMC (electromagnetic Compliance) and
protected from any electrical or magnetic interface. Required protection against
any BMS or panel component has to be inclusive to respective contractor’s scope
of work.
1.8.11.12 Any specific interface requirement not specified here with shall be wired upto the
marshaling chamber interface terminal. BMS/SCADA interface point should only
confine to marshalling box.

1.8.12 BMS interface

1.8.12.1 Electrical contractor shall cross reference the requirement of BMS remote control
and monitoring interface as required for electrical equipment’s and shall provide the
necessary volt free contact and remote control interface for BMS.
1.8.12.2 Serial interface as applicable for ACB/MCCB and digital meters or MFMs shall be
strictly on standard protocol communication (preferable with MODBUS-RTU, RS485,
2 wire communication). Necessary interface detail and drawing shall be provided to
BMS contractor during commissioning.
1.8.12.3 All terminals and BMS interface terminal and ports shall be wired to a separate
chamber with adequate number of ITBs and with proper marking as per interface
document.
1.8.12.4 No such change in contact or pseudo signal shall be provided for critical alarms
control interface.
1.8.12.5 BMS and PLC interface for control command shall be pulse type close contacts for
single command output / double command output or a variable voltage/current (i.e.
0V- 10V or 4mA - 20 mA) for analog output command.

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1.8.12.6 There shall be one interface for control open and one for control close operations.
The Contractor shall provide appropriate equipment to sense and latch the remote
control signal for performing the open/close control function. The BMS digital output
(DO) &analog output (AO) signal shall be as stipulated.
1.8.12.7 Contacts shall be rated to adequately make and break and carry continuously not
less than 5A at 250V AC or 2A at 11O V DC.Volt-free contacts for sequence of event
(SOE) and alarms shall firmly close and seat in position once activated. The contacts
shall not bounce or vibrate due to internal or external causes
1.8.12.8 Required data point as per BMS requirement shall be configured in respective
controller or equipment by panel manufactures as required with necessary hardware
and software for above said serial link communication.

1.8.13 Indicating lamps

1.8.13.1 Indicating lamps shall be multiple LED type. All indicating lamps shall be suitably
rated so that the indication is clearly visible from the side and front at a distance of
not less than 3 m in a room.
1.8.13.2 The colours of indicating lamps for red, yellow, blue phases, ACB on, off and trip
shall be red, yellow, blue, red, green and amber respectively.

1.9 LOW VOLTAGE SWITCHGEAR

1.9.1 Air circuit breakers (ACB)

1.9.1.1 ACB should be mechanically robust of compact design, air break horizontal and
withdrawable type, confirming to IS/IEC 60947-2 and EN 60947-2.
1.9.1.2 Air Circuit Breaker is provided in transformer incomer, outgoing feeder,
Interconnector Bus-Section and essential/semi-essential circuit breaker as defined in
BOQ.
1.9.1.3 Manual charging as well as by 240 V AC motor with charged spring closing
mechanism complete with anti-pumping relay, discharge resistor, auxiliary switch,
etc.
1.9.1.4 240 V A.C shunt-trip coil shall be operable, within operational voltage range of 70%
to 110% of rated voltage as per Clause 7.2.1.3 of IEC 60947-1.
1.9.1.5 The operating mechanism shall be trip-free.
1.9.1.6 Maximum number of circuit breaker auxiliary switches, spare auxiliary switches to be
equally divided between normally open and normally closed. At least 4 spare pairs of
N.O. and N.C. volt free contacts shall be provided.
1.9.1.7 Indicating lamps for on, off, tripped on fault and trip supply healthy with all necessary
push buttons, panel wiring, bus wiring, terminals, fuses, etc.
1.9.1.8 Power and control cable terminals with undrilled gland plates for outgoing power
cables and multi-core cables.
1.9.1.9 Electrical connection between the breaker and switchboard shall be of plug and
socket type with automatic screening shutters.An interlock to prevent withdrawal
when the breaker is closed.
1.9.1.10 Number of Poles shall be as per BOQ.

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1.9.1.11 Local/auto control selecter switch shall belockable in all positions. The automatic
control shall be defeated when the selector switch is put at local or OFF position as
per drawing and BOQ
1.9.1.12 Remote indication and alarm facilities shall be provided for Circuit-breaker open,
Circuit-breaker closed, Circuit Breaker is ready to close, Circuit-breaker tripped on
fault, and Switch position of local/remote control selector switch.
1.9.1.13 Control switch for air circuit breakers shall be as follows:

a) Air Circuit breakers shall be fitted with operative switches of the pistol grip type.
The handles of control switches for air circuit breakers shall turn clockwise for
closing and anti - clockwise for tripping.
b) The control switch shall be clearly labelled as CIRCUIT BREAKER OPEN -
NEUTRAL - CLOSE, with spring return to the neutral position. Mechanical
interlock shall be fitted to prevent repetitive closing without moving first to the trip
position, and shall be capable of padlocking in the neutral or trip position.

1.9.1.14 Set of terminals wired to provide for connection to the following:

 Automatic changeover and interlocking as shown on the drawing

 Operation of emergency push button as per requirement or as per BOQ.
 Signal cables wired to terminal block for remote monitoring to SCADA.

1.9.1.15 Electrical Characteristics:

 Rated Insulation Voltage: 1000 V

 Rated Frequency: 50 Hz
 Rated ambient temperature: As per Clause 6.1.1 and 6.1.3 of IEC 60947
 Utilization category: B or as per drawing or BOQ.

1.9.1.16 Rated uninterrupted current: as shown on Drawings, however the contractor must
provide breaker after taking into account of the installation conditions and derating
for ambient temperature, based on selected make during preparation of working
drawings.
1.9.1.17 Current Ratings shall be as follows:

 Rated short-time withstand current (lcw): 50 kA for 1 second (minimum)

 Rated ultimate short circuit breaking capacity(Icu): 50 kA based on actual fault
level or as per BOQ.
 Rated service short-circuit breaking capacity (Ics): 100% of Icu, and
 Rated short-circuit making capacity: shall be at least 2.1 times of ultimate short
circuit breaking capacity at 0.25 power factor or as per BOQ.

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1.9.1.18 Protection: ACB shall have microprocessor based protection releases for type of
faults with selective over current (long time, short time & instantaneous) & earth fault
protection, measurement of electrical parameters and with communication capability
with SCADA/BMS system. Any other additional protection as mentioned in BOQ.
ACB shall have an LED/LCD display to show true RMS current in all the three
phases and highest current among these phases. The release shall be equipped
with self diagnostic feature with indication. The release shall have zone selective
interlocking andbe capable through Modbus over Serial (RS 485 port)
communication as defined in drawing where applicable. The overload and short
circuit characteristics should be front adjustable and password protected or suitable
arrangement to pevent unauthorised entry with the approval of Engineer.
1.9.1.19 The release should have an internal fault indication for faster fault diagnosis/self
diagnostic feature is required.
1.9.1.20 The release should have fault indications by which discrimination of fault is possible.
1.9.1.21 Control relays and wiring for automatic changeover interlocking and other breaker
operation as shown on the Drawings.
1.9.1.22 Fire resistant transparent covers shall be provided over ACB’s to achieve IP-54
protection and door interlock so that ACB access door shall not open if ACB is ON
otherwise it will automatically OFF if Door is opened.
1.9.1.23 Electrical interlock for the two incoming circuit breakers and interconnector bus -
section circuit breaker to prevent paralleling of different power supply sources at any
one time as shown on the Drawings
1.9.1.24 Following shall be provided for ACB connected to the transformer incomer:

1) Four Protection Current Transformers (three in panel, one in loose to be

mounted in transformer neutral), a Restricted Earth Fault Relay and a
Standby Earth Fault relay as specified for the interface with high voltage
switchgear.
2) Two ways inter-tripping relay shall be provided with the associated HV feeder
circuit breaker by interfacing with the Power Supply Contactor.
3) Voltage sensing relay and associated relays for automatic changeover and
interlocking operation as detailed on the Drawings.

1.9.1.25 Interlocks and Test Operation Facilities

All ACBs shall be provided with interlocks to ensure that:

1) The ACB cannot be plugged in or isolated while it is closed,

2) The ACB cannot be closed until it is fully plugged in or completely isolated
3) The ACB cannot be closed in the service position without completing the
auxiliary circuits between the fixed and moving portions
4) With manual charged and motor charged spring mechanisms the springs
cannot be discharged until they have been fully charged and until the means
for charging has been removed or disconnected,
5) Facilities shall be provided for testing the ACB operation when in the isolated
and withdrawn positions by the normal means as in service, and
6) Where control circuits are provided and interlock circuits are broken via plugs
on withdrawal of the ACB, a minimum of one jumper lead and plug assembly
of each size and type shall be provided to facilitate testing in the withdrawn
position.
7) The neutral shall be rated for 100%

1.9.1.26 Safety Shutters

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1) A set of shutters with padlocking facilities shall be provided to cover each three
phase group of stationary isolating contacts. The shutters shall be independent
and operated automatically by a positive drive from the ACB withdrawal
mechanism
2) In order to prevent unauthorized operation, the withdrawable air circuit
breakers shall be provided with padlock facilities to secure them in their
connected, test and isolated positions.

1.9.2 Moulded case circuit breakers

1.9.2.1 MCCBs shall comply with and be type-tested to IS/IEC 60947-2 or EN 60947-2.
Each MCCB shall be of fixed or withdrawable type, as specified in the BOQ and have
all the mechanical and live parts completely enclosed in an insulated moulded case.
Withdrawable pattern circuit breakers shall be designed that their electrical equipment
can be safely disconnected from or connected to the main circuit whilst the circuits are
live.
1.9.2.2 MCCB shall be suitable for isolation as per Annexure 7.1.2 of IEC 60947-2
1.9.2.3 MCCBs shall meet the following requirements:

a) Number of poles: double-pole, triple-pole or four poles as specified on the

Drawings or Design or BOQ
b) Rated operational voltage: 240 / 415 V AC, as per drawing or BOQ
c) Rated insulation voltage: 660 V AC, higher voltage acceptable
d) Rated uninterrupted current (In): as shown on the Drawings or BOQ, but after
taking into account the installation conditions and temperature duration
deration.
e) Rated frequency: 50 Hz,
f) Rated short-circuit making capacity (Icm): shall be at least 2.1 times of ultimate
short circuit breaking capacity at 0.25 power factor,
g) Rated ultimate short-circuit breaking capacity (Icu): 50/35 kA (min),
h) Rated: service short-circuit breaking capacity (Ics): 50/35 kA Further, Ics must
be equal to 100% Icu for the selected breaker,
i) Utilization category: A or B as appropriate,
j) Degree of protection: IP 3X to IEC 60529 or EN 60529, and
k) Rated ambient temperature: As per IEC 60947-2
l) Impulse Withstand Voltage - 8KV
m) 0 - t - CO - t - Co type of Duty i.e. Ics=lcu.
n) MCCB's to be provided in LV Main Switchboard shall be stored energy type
motorized and Suitable for Remote Closing by BMS.

1.9.2.4 All MCCB's should have front adjustable microprocessor based releases with
adjustment in the range of 40 - 100% for nominal overloads and adjustable setting
for short circuit faults. MCCB's for network/feeder Protection shall have releases with
earth Fault Protection features, wherever and as indicated in Bill of quantities or
drawings.
1.9.2.5 In case of 4 pole MCCB, neutral shall be defined and capable of offering protection
upto full rating with possibility of adjustment at site in the neutral setting.
1.9.2.6 Mechanical endurance shall be as specified in latest IEC standard.
1.9.2.7 MCCB's shall have an electrical endurance operation cycles as per latest IEC
standard 60947.

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1.9.2.8 All MCCB's shall be arranged for padlocking in OFF positions with lock provided. A
shunt trip coil shall be provided to facilitate automatic tripping and local manual
tripping. The manual trip device shall be fitted with the means of padlocking. The
shunt trip coil shall be suitable for operation within a voltage range of 70% to 110%
of the rated AC power supply voltage.
1.9.2.9 Electronic trip units shall comply with the requirements as specified in Appendix F
(EMC /EMI Compatibility) of IEC 60947-2 or EN 60947-2.
1.9.2.10 The trip unit shall be easily replaceable in the same MCCB without changing the
MCCB.
1.9.2.11 The time delay on overload tripping shall be inversely proportional to the over current
up to a threshold value of approximately six to seven times the rated current at rated
working temperature.
1.9.2.12 Handle position shall give positive indication of 'ON' ‘OFF’ or 'TRIPPED', thus
qualifying to disconnection as per IEC 60947-3 indicating true position of all the
contacts.
1.9.2.13 The operating mechanism of MCCB's shall be Independent of the operating speed of
the over centre toggle and the MCCB shall be of current limiting type and comprise
of Quick make and Quick break switching. Contacts shall be non-welding type. The
operating mechanism should be trip-free and provided with mechanical “ON", OFF"
and "TRIPPED indicator. The MCCB shall be designed for both vertical and
horizontal mounting, without any adverse effect on electrical performance.
1.9.2.14 Remote closing and tripping coil should be of continuous duty cycle. Wherever
interlocking or remote controlling required, all Motorised MCCB shall be considered
without any cost addition.
1.9.2.15 MCCB's shall have common field fittable auxiliaries for the entire range and above
250 A the accessories like copper spreaders and phase barriers should be the
integral part of the MCCB's.
1.9.3 Miniature circuit breakers (MCB)
1.9.3.1 MCBs shall comply with and be type-tested to IEC 60898 or EN 60898.
1.9.3.2 MCBs shall meet the following requirements:

a) Number of poles: single-pole, double-pole, triple-pole or four-pole as specified

in the BOQ or Drawings
b) Protection against external influences: Enclosed-type,
c) Method of connection: Bolted type or clip-on type,
d) Rated operational voltage and frequency240 / 415 V AC and 50 Hz.
e) Rated current: 6 A, 10 A, 16 A, 20 A, 25 A, 32 A, 40 A, 50 A, as shown on the
Drawings. Above 50A, MCCB as specified above must be used.
f) Range of instantaneous tripping current: MCB's shall be current limiting Type
Class 3 with range of instantaneous tripping current B, C or D type as
appropriate oras specified,
g) Rated short-circuit breaking capacity: not less than 10 kA (M3) unless
otherwise specified in BOQ
h) I2t characteristic: suitable for load and circuit being protected,
i) Degree of protection: IP-20 for MCB's
j) Reference ambient temperature: as per IEC 60898.
k) MCB's shall have minimum power loss (Watts) per pole as per the IEC and
should be proven by published value by manufacturer.

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1.9.3.3 The load handling contacts shall be silver/tungsten or proven material and the
contacts and operating mechanism shall be designed so as to give a wiping action
both at make and break. Thebreaker operating mechanism shall be of trip-free type.
The breaker operating dolly shall be clearly indicated for the "ON" and "OFF"
positions. It should be of Quick make and Quick break type.
1.9.3.4 Circuit protection against overload and short-circuit conditions shall be provided by
means of thermal-magnetic device. Double-pole, triple-pole, and four pole MCBs shall
be integral units and interlocked internally so that an over current through any pole
shall trip all the poles of the MCB simultaneously. An assembly of two or three or four
single-pole units mechanically strapped together is not acceptable.
1.9.3.5 Housing shall be heat resistant and having high impact strength. All DP, TP and FP
circuit breaker shall have a common trip bar and should be mechanically coupled
through a pin. It shall have an electrical endurance of the order of 10000 operation
cycle for current rating of up to 50A.

1.9.4 Residual current circuit breaker(RCCB)

1.9.4.1 RCCBs shall be double pole or four-pole current-operated, housed in a totally
enclosed moulded case, manufactured and tested in compliance with IEC 61008 or
EN 61008.
1.9.4.2 RCCBs shall meet the following requirements:

a) Number of poles: double-pole or four-pole as specified on the Drawings,

b) Rated current (In): as shown on the Drawings,
c) Rated residual operating current: 30 mA or 100 mA or 300 mA as shown on
drawings or as per approval of the Engineer.
d) Rated voltage: 240/415 V AC,
e) Rated frequency: 50 Hz,
f) Rated short-circuit capacity: not less than 1.5 kA unless otherwise specified in
BOQ
g) Operating characteristics in case of residual currents with DC components: as
specified,
h) Method of mounting: distribution board type,
i) Method of connection: connection shall be made with propre size of thimbles
and number ferruling for circuit identification,
j) I2t characteristic: suitable for equipment and circuit being protected
k) Degree of protection: IP 3X to IEC 60529 or EN 60529, and
l) Reference ambient temperature: As per IEC.

1.9.4.3 The tripping mechanism shall be of trip-free so that the unit cannot be held closed
against an earth fault. Tripping devices utilizing electronic amplifiers or rectifiers are
not acceptable.
1.9.4.4 Provision shall be made for testing the automatic earth - leakage tripping by an
integral test device. A device shall be fitted for prevention against reclosing after the
device has tripped on earth leakage.

1.9.5 RCBO (Residual Current Circuit Breaker with Over-current) protection

1.9.5.1 RCBOs shall be double pole or four-pole current-operated, housed in a totally
enclosedmouldedcase, manufactured and tested in compliance with IEC 61009 -1,
IS 12640(part 2) 2008 and ISI marked.
1.9.5.2 RCBOs shall meet the following requirements:

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a) Number of poles: double-pole or four-pole as specified on the Drawings,

b) Rated current (In): as shown on the Drawings,
c) Rated residual operating current: 30 mA or 100 mA or 300 mA as shown on
drawings or as per approval of the Engineer.
d) Rated voltage: 230/415 V AC,
e) Rated frequency: 50 Hz,
f) Rated short-circuit capacity: 10kA
g) Operating characteristics in case of residual currents with DC components: as
specified,
h) Method of mounting: distribution board type,
i) Method of connection: connection shall be made with propre size of thimbles
and number ferruling for circuit identification,
j) I2t characteristic: suitable for equipment and circuit being protected
k) Degree of protection: IP 2X, and
l) Reference ambient temperature: As per IS 12640-1
m) The tripping mechanism shall be of trip-free so that the unit cannot be held
closed against an earth fault. Tripping devices utilizing electronic amplifiers or
rectifiers are not acceptable.
n) Provision shall be made for testing the automatic earth - leakage tripping by an
integral test device. A device shall be fitted for prevention against reclosing
after the device has tripped on earth leakage
o) A mechanical flag indicator on RCBO for faster identification of fault trip
condition i.e. earth leakage or over-current for faster fault diagnosis and
preventive measures.

1.9.6 Discrimination
1.9.6.1 Selection of ACB, MCCB and MCB shall be of same make. Total discrimination up to
the design fault level must be available between the various elements of switchgear
(ACB, MCCB, MCB etc) selected. Supplier must provide test certificates from
acceptable, accredited and reputed laboratories or submit published discrimination
charts/tables to prove the same. In view of Standardization and Uniformity, mixing of
two series of switchgear (even from the same manufacturer) for either MCCB or ACB
will not be permitted.
1.9.6.2 In case higher frame sizes rating of switchgear(than those specified In the BOQ) is
required to be provided to achieve the above requirement, due to selection of a
particular make, the same shall be provided at no extra cost if other makes are able
to achieve the same with the specified frame size.

1.9.7 Remote monitoring

1.9.7.1 The following critical status and alarms for each Electrical Panels shall be sent to
BMS for remote monitoring via volt-free contacts or serial interface over standard
protocol communication as approved but not limited to:

a) Individual ACB/MCCB open/close status,

b) Common alarm for ACBs/MCCBs trip on fault/lock out,
c) Common alarm for any local/remote or local/auto selector switch in local mode
d) Control supply failure,
e) ACB ready to close indication.
f) Emergency push button (EPB) operated, and
g) Busbar voltage ,current , frequency and energy parameter
h) Electrical Panels under voltage alarm and cause of tripping.

1.9.8 Motor starter

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1.9.8.1 Every motor starter shall be designed to perform the following functions efficiently and
safety:

a) To start the motor without damage to the drive or driven equipment whilst
regulating the starting current to the satisfaction of the requirements of this
Specification and ensuring that at all stages of starting, the motor will develop
sufficient torque to accelerate the load.
b) To stop the motor.
c) To prevent damage to the motor due to overload, disconnection of one phase
etc.
d) To prevent damage to reduced and danger to personnel due to resumption of
the electricity supply following a failure.
e) To prevent the damage to the motor due to stalling or internal electrical or
mechanical faults by quickly disconnecting the supply.
f) To prevent damage to the motor or the starter itself due to improper, unskilled
or hesitant operation or failure to complete a starting sequence once it is
connected.
g) To enable the motor and starter to be completely isolated from the main supply
and from all control supplies for inspection and repairs by means of fixed type
unit for each starter circuit.

1.9.8.2 Each motor starter assembly shall comprise MCCB/MPCB, contactors, protection
relays, electronic circuitry, control switches, lamps and instruments and accessories
as specified hereinafter. It shall include control devices for automatic control
systems. The whole unit shall be enclosed in the cubicle, from which no access can
be gained to adjoining cubicles.
1.9.8.3 The specified starter types are based on estimated motor ratings. The final selection
of starter shall be based on the installed motor rating. Starters and associated over-
load devices shall be selected in accordance with the run-up time of the associated
motor driven load, the maximum thermal capacity of the motor and frequency of
starting, and the duty cycle. All starters shall have suitable protection for phase-to-
phase, phase-to-neutral and phase-to-earth faults, over-loads, and single phasing,
with additional protection measures as specified. Overload relays releases as
specified shall have inverse time delay characteristics compatible with the motor
drive to which they are applied for all protective devices the short-circuit capacity
(Isc) shall be capable of withstanding a fault current of the panel, as a minimum.
1.9.8.4 The specifications of incoming and other circuit breakers (ACB/MCCB etc.) shall be
as per clause 1.9, as relevant.
1.9.8.5 All starters shall be in accordance with section 7.2 of IEC 60947-4-1 or EN 60947-4-
1, and shall be adequately rated for conditions in which it shall operate.
1.9.8.6 All starters shall be type tested by a competent and internationally recognized testing
authority for type 2 co-ordinations in accordance with IEC 60947-4-1 or EN 60947-4-
1.
1.9.8.7 All contactors shall be electro-magnetic type with utilization category AC - 3 to IEC
60947-1.
1.9.8.8 All starter shall be of electrically held on pattern and shall not release until the over
voltage falls below 70% of nominal.
1.9.8.9 Control circuits shall generally be operated on main supply derived from the LMCP,
suitably protected by MCB type 2, as specified in clause 1.9. The control circuit shall
be of self-holding and latching design.

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1.9.8.10 Where the control voltage is not 240V it shall be derived from transformers to BS
3535/BS 61558. Transformers shall be rated at the total control circuit load plus a
minimum of 10% spare capacity. Transformer primary windings shall be protected by
MCB's in the line connection(s) and a removable neutral link shall be provided where
the neutral is required. The supply shall be taken from downstream of the main
incoming Circuit Breaker. One end of the transformer secondary shall be connected
directly to the main earth bar. This connection shall be upstream of the control circuit
neutral link.The supply from the other end-of the winding shall be protected by MCB.
1.9.8.11 The type of starters for other mechanical equipment such as plumbing, drainage, fire
services pump and other motor circuits shall be as specified in this clause subject to
rating of the motors selected during working drawing production as per clause
4.16.3. The starters shall also comply with the requirements laid down in the Code of
Practice of electricity (Wiring) Regulations. Voltage for motors shall be 415V 3-phase
or 240V 1-phase, as required. Motors rated 0.37kW and larger shall have a rated
voltage of 415V, 3 phase, 50Hz. Motors rated smaller than 0.37 kW shall be
operated at 240V 1-phase. Direct-online motor starters shall be used for motors up
to and including 3.75 kW at 415 volts, 3 phase. All motors over this limit shall be
equipped with reduced voltage starters of the star-delta or soft starter type as
indicated in BOQ.

Motor size (M)Load Maximum starting current in multiple

of full load current (phase of motors)
M≤ 0.37 kW 6 (single phase motor)
0.37 kW < M< 3.75 kW 6 (three phase motor)
3.75 kW ≤ M 6-7 (three phase motor)
1.9.8.12 Tolerance in the above currents shall be of the order of ±20%
1.9.8.13 The direct-on-line starters shall be provide based on condition given in Clause
1.9.8.11 and shall include, but not be limited to, the following:

a) MPCB as specified,
b) Triple pole air break contactor,
c) MPCB wherever specified or required shall be provided with inbuilt
Thermal/Magnetic and single-phasing protection. MCCB, wherever specified/
required shall be of Electronic Trip Unit type with single phasing preventer unit.
d) All Current transformers with suitable ratio, output and accuracy for motor
protection,
e) Local/off/remote control selector switch lockable in each position,
f) Set of start and stop push button,
g) Set of indicating lamps for motor running, off and tripped on fault,
h) Set of digital input (dry contacts) interface wired to terminals for wiring
connection to stimulator building services controllers,
i) One set of terminals wired to the following:
 Emergency stop push button, effective in all positions of the
local/remoteswitch if any.
 Remote start/stop of the motor, effective only in the remote position of
the selector switch.
 Hour run meter,
 Lamp test button,
 Any other items required to affect satisfactory motor starting and
control asspecified in this Specification, and
 Double pole contractor and motor protection unit for single phase DOL
type starter.

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j) Interposing relays/contactor for remote close and remote open whenever

required.
k) Leakage Protection for DOL starters shall be provided with 25 / 40 A, 4 Pole
RCCB with sensitivity of 100/300 mA as specified.

1.9.8.14 Star-delta starters shall be provided to limit the maximum starting current within
2.5 times the rated motor full load current. The star-delta starters shall be equipped
as per direct-on-line starters specified above, with the following additional provisions:

a) Star-delta starters shall be of the automatic type and shall comply with BS
EN60947-4-1. Triple pole air break star and delta contactors shall be
electrically interlocked so that they cannot close or be closed at the same time.
In all types ofstar-delta starters the correct phase relationship between the star
and delta connections to minimize disturbance on changeover shall be
maintained.
b) Rated and adjustable solid state timer for automatic star-delta transition, and
c) Automatic changeover timers shall be adjustable from 1 second to 30 seconds.
Timers shall incorporate a fixed delay of between 20 ms between the star
contact or opening and the delta contactor closing.
d) MPCB /MCCB as specified in drawings /Schedules shall be used. MCCB shall
be as specified in clause 1.9 with the difference that the Electronic trip Units
shall be suitable for Motor Protection against Over Load (Adjustable) and Short
Circuit. For requirement of Earth fault/Earth Leakage protection, Clause
1.9.8.17 referred to.

1.9.8.15 Reversing Starters

Forward and reverse contactors will be mechanically and electrically

interlocked. Reversing starters will be in accordance with BS EN 60947 and be
suitable for AC 4 utilization category.

1.9.8.16 Incoming Supplies

The isolation devices for assemblies with duplicated supplies shall be

interlocked (electrically and mechanically) to prevent simultaneous closure.

1.9.8.17 Earth Leakage/Earth Fault Protection

For Earth Leakage /earth fault Protection for Circuits with Star-delta starters
(wherever required, based on calculations done during working drawings
Production Stage). Add- on Modules to MCCB (based on current rating of
MCCB) shall be provided with continuous adjustment from 30 mA to 10 A
range with adjustable time delay.

1.9.8.18 Status/Alarm

a) Indicating lamps shall be provided on each phase of the main incoming supply.
b) All assemblies incorporating automatic control systems shall be equipped with
suitable status/ alarm annunciation facilities. If these are not available directly
from the automatic control system then a separate status/alarm annunciator
shall be provided. Status/alarm enunciators shall provide indications for all
starting devices of 'ON', 'OFF'and 'TRIPPED' conditions.
c) The status/alarm annunciator equipment shall be mounted in the same cubicle
as the automatic controls. Volt-free contacts shall be provided for each
condition in each starter cubicle, which shall be wired internally to the
status/alarm annunciator, via terminals at each end.

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d) The schematic diagrams as indicated in the Working Drawings shall be shown

and the operating status of all equipment shall also be indicated. Status
indicating lights shall exhibit run/stop or open/close and fault conditions. The
Contractor shall provide test buttons for the indicating lights. The layout, color,
symbols and arrangement of the mimic diagram shall be submitted to the
Engineer for review prior to manufacture.
e) Suitable interfaces shall be built into each channel to relay signals to remote
locations, by means of volt-free contacts.
f) Hours-run meters shall be fitted as specified and not be resettable.

1.9.8.19 Control Circuits

a) In each individual starter, the control circuit shall be provided with MCB, a
neutral link, a means of disconnection and, where specified, a disconnection
over ride switch.
b) Neutral links shall comprise a solid copper link mounted in a white coloured
fuse base and carrier, which shall not be interchangeable with control or power
fuse carriers.
c) The control circuit supply shall be connected via an auxiliary contact on the
starter isolator.
d) Where automatic changeover systems are specified for duty/standby
operation, the control circuit for the changeover controls shall be independent
of both starters.
e) Start delay timers shall be incorporated for sequential operation of starters
where specified. The failure of one timer or starter to operate shall not prevent
operation of the remaining starters.

1.9.8.20 Interlocking

a) The control circuit of a dependent starter shall be wired via auxiliarymotor

contactor in the lead starter. In the case of reduced voltage starter, the
contacts shall be on the full voltage contactor.
b) Should the lead starter be shut down either intentionally or by a fault condition,
the dependent starter shall drop out immediately.
c) A time delay shall be incorporated in the interlock circuit to delay the operation
of the dependent starter where specified. Such time delays shall be in addition
to the interlock circuits.

1.9.8.21 Auxiliary contacts

a) Two normally open and two normally closed auxiliary contacts shall be
provided for each starter as spares unless otherwise specified. These contacts
shall be in addition to contacts used for the control of the starter.

1.9.9 MPCB (Motor Protection Circuit Breaker)

1.9.9.1 Motor circuit breakers shall comply with the general recommendations of standard
IEC 60947-1,-2 and -4-1.

a) The devices will be in utilization category A, conforming to IEC 60947-2 and

AC3 conformingto IEC 60947-4-1.
b) Rated operational voltage of 690V AC (50/60 Hz)
c) Rated insulation voltage of 690V AC (50/60 Hz)
d) Isolation conforming to standard IEC 60947-2,
e) Rated impulse-withstand voltage (Uimp) of 6 kV.

1.9.9.2 MPCB shall meet following requirement:-

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Mounting:

The motor circuit breakers will be designed to be mounted vertically or

horizontally without derating Power supply will be from the top or from the
bottom.

Contacts:

In order to ensure maximum safety, the contacts will be isolated from other
functions such as the operating mechanism, casing, releases, auxiliaries, etc,
by high performance thermoplastic chambers.

Operating mechanism

The operating mechanism of the motor circuit breakers must have snap action
opening and closing with free tripping of the control devices. All the poles will
close, open, and trip simultaneously.

Button:

The motor circuit breakers will be actuated by a rotary operator clearly

indicating the position ON (I), OFF (O), trip

Isolation:

In order to ensure isolation with clearly visible breaking conforming to standard

IEC 60947-2 paragraph 7.2.7:
a. The mechanism will be designated so that the different types of
operator will only be in position (O) if the main contacts are physically
separated,
b. In position (0) the operating devices will indicate the isolated position.
c. Isolation is enhanced by the double break of the main circuit.

Padlocking

a. Motor circuit breakers will accept a padlocking device in the "isolated"

position.
b. Trip
c. The motor circuit breakers will be equipped with a "PUSH TO TRIP"
device on the front enabling the correct operation of the mechanism
and poles opening to be checked.

Limitation, Durability

a. The motor circuit breakers will be current limiting for a mains voltage of
400 V, the maximum let-through energy (IZt) on short circuit being
extremely low.
b. The motor circuit breakers will have a high electrical and mechanism
durability of at least 5 times that required by the standard.

Protection functions

1.9.9.3 General recommendations: The motor circuit breakers will be equipped with releases
comprising a thermal element assuring overload protection and a magnetic element
for short-circuit protection.

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1.9.9.4 In order to ensure safety and avoid unwanted tripping, the magnetic trip threshold
(fixed) will be factory set to an average value of 12 Ir.

a) All the elements of the motor circuit breakers will be designated to enable
operation at an ambient temperature as per IEC without derating.
b) The thermal trips will be adjustable on the front by a rotary selector.
c) The adjustment of the protection will be simultaneous for all poles.

1.9.10 Switch fuse units & disconnects/isolators (where applicable)

1.9.10.1 Switch fuse units shall have quick-make; quick-break silver plated preferably double
break contacts with operating mechanism suitable for rotary operation in the case of
cubicle mounting. All switches shall be rated according to the equipment schedule or
drawings and shall withstand the system prospective fault current let through. Cam
operated rotary switches with adequate terminal adaptors up to 25A are acceptable
but for all higher rating switch fuse units shall be heavy-duty type.
1.9.10.2 Fuses shall be HRC cartridge type conforming to IS: 13703 - 1993 with a breaking
capacity corresponding to system fault level. Fuses shall be link type with visible
indication. Screw type fuses are not acceptable for any ratings.
1.9.10.3 All disconnects shall consist of switch units quick-make, quick-break type with silver
plated contacts. The switches shall preferably have double breaks. The switches
shall preferably have sheet steel enclosure, which in turn is mounted on suitable
angle iron frame work. In wet locations enclosures shall be IP56 rated. Disconnects
shall have a minimum breaking capacity of 5KA at 415 Volts.
1.9.10.4 Switch contacts shall be designed with arc repelling features to extinguish the arc
quickly to provide long contact life.

1.9.11 Isolators
1.9.11.1 Isolators shall be fixed on wall, on self-supported galvanized angle iron frame work
as required and mounted as near to the motor as possible. Where several motors
are installed, isolators if required shall be provided at a central location on a common
frame work with prior approval at site. The Isolator shall be provided in IP 65
enclosures from the Isolator manufacturer only.
1.9.11.2 Painting, earthing and labels shall be provided as generally indicating for MV
Switchgear and as shown on drawings.

1.9.12 Contactors
1.9.12.1 Contactors shall comply with IS/IEC 60947-4-1 or EN 60947-4-1.
1.9.12.2 Contactors shall be electro-magnetically controlled, double air-break type.
Contactors shall be four-pole, triple-pole, double-pole or single-pole as shown on the
Drawings.
1.9.12.3 The mechanical endurance of the contactors shall not be less than 3 million no. load
operating cycles.
1.9.12.4 Contactors shall be silver-faced.

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1.9.12.5 The contactor should be modular in design with minimum inventory requirements
and built -in mechanically interlocked wherever required. They should be suitable for
the addition of auxiliary contacts and other electrical auxiliaries without any
compromise on the performance or the operation of the contactors. The contactors
from 4KW to 400kW shall be associated with the same 10 auxiliary contact block
range or as per BOQ.
1.9.12.6 The control contactors for power factor correction equipment shall be of quick break
and have a high arc resistance during switching operation. Contactors shall be of
utilization category AC-6b for this application and specifically designed for switching
directly connected capacitor banks.
1.9.12.7 The contactors for other applications shall have an un-interrupted rated duty and
utilization category of at least AC3 at 415V and 50 Hz. The contacts should be of fast
opening and fast closing type.
1.9.12.8 The making and breaking capacity values of the contactors should be as follows (as
per IEC 60947-4)

For AC3 duty:

a) Making capacity equal to or more than 10 Ie
b) Braking Capacity equal to or more than 8 Ie,
For AC4 duty:
a) Making capacity equal to or more than 12 Ie,
b) Braking Capacity equal to or more than 10 Ie,

1.9.12.9 The contactors should be capable of frequent switching and should operate
withoutderating at 60°C for AC3 applications. They should be climate proof. The coil
of the contactor should have class H insulation to support frequent switching. Class
F insulation is also acceptable with the approval of site Engineer.
1.9.12.10 The rated voltage of the contactor and the rated insulation voltage shall be 690V.
The rated Impulse voltage of the contactor should be at least 8 KV.
1.9.12.11 Wherever DC control is required, the contactor should have wide range (0.7 to 1.25
Uc) DC coil with built in interference suppression as required.
1.9.12.12 The control and power terminals should be at separate layers preferably with colour
coding (black for power and white for control). All contactors power connection shall
be finger safe (IP 2X)
1.9.12.13 They should be capable of being integrated into automated system (PLCs)
without any interposing components in the minimum operating conditions.
1.9.12.14 Contactors used with surge suppressor.

1.9.13 Auxiliary switches and contacts

1.9.13.1 Auxiliary switches provided for indication, protection, metering, control, interlocking
supervisory purposes shall be readily accessible at the front of the Electrical Panels.
Adequate secondary contacts shall be included to enable the auxiliary switch to be
wired to the fixed portion of the equipment.
1.9.13.2 For each control compartment, spare auxiliary contacts with a minimum of two NO
and two NC contacts shall be provided and wired to suitably identify spare terminals.
1.9.13.3 Auxiliary contacts for all applications shall be rated at 240 V AC or 110 V DC with
contact rating of at least 6 A AC or DC and operating life of atleast one million on on-
load operations at 0.4 power factor inductive load.

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1.9.14 Power factor correction equipment

1.9.14.1 Power factor correction equipment and its installation shall comply with IEC 60831/IS
13340. Each power factor correction equipment shall consist of capacitors,
switchgears, cables, cable gland; micro-processor based intelligent power factor
control relays, CTs and contactors etc.
1.9.14.2 Capacitor banks shall consist capacitors of variable capacity i.e. 5 kVAR, 10 kVAR,
15 kVAR, 25 kVAR or fixed type as per BOQ. Capacitor bank with total capacityas
shown on the drawings or BOQ shall be provided and connected to the designated
switchgear in the LV main switchboard to improve the overall power factor to not less
than 0.98 lagging. The system shall ensure that a leading PF does not occur.
1.9.14.3 The Contractor shall ensure that the power factor correction equipment shall not
cause harmonic resonance in the LV electrical network
1.9.14.4 The capacitor bank shall be of floor standing type built up from static primary
capacitor units. The capacitor shall be mounted on the lower and de-tuned inductor
on the upper part of the panel so that the temperature of capacitor environment is
lower than the average temperature in the panel.In case, ventilating fan is required to
maintain the desired temperature in the capacitor panel, the same shall switch on
and off depending upon the set temperature and only when at least one capacitor is
in service. The thermostate temperature shall be provided with step adjustment
features if considered necessary as per design.
1.9.14.5 Each three phase capacitor unit shall be MPP self healing type with total losses not
greater than 0.5 W/kvar. The primary capacitor unit shall comply with the
requirement of IEC 60871-1 or BS 1650.
1.9.14.6 The capacitor unitshall be usable for indoor application with permissible overloadsas
below:

a) Voltage overloads shall be 10% for continuous operation and 15% for 30
minutes in a 24 hours cycle
b) Current overloads shall be 15 % for continuous operations and 50% for six
hours in a 24 hours cycle.
c) Over load of 35% continuously and 45%for six hours in a 24 hours cycle.
d) All capacitors involved shall be disconnected instantaneously, and
reconnected step by step at intervals after the supply is restored.
e) Each capacitor bank shall be fitted with an automatic discharge assembly
which shall discharge the entire capacitor bank from the peak alternating
voltage to a voltage level not exceeding 50 V measured at the capacitor bank
terminals one minute after disconnection from the supply.
f) The automatic power factor control relay (APFCR) shall be a microprocessor
based static unit with output relays equal to the no. of capacitor steps.
Minimum no. of relays shall be six/eight (6/8) or as specified in BOQ. The
switching ON and OFF of the capacitor unit shall be done in a sequence so
that even wear takes place on the contactors and relays over one week of
operation.
g) The APFC relay shall be intelligent to ensure balancing of duty cycle of the
capacitors.
h) APFC relays shall provide all necessary function of relay, controls, protection,
annunciation and condition monitoring. A no-volt and single phasing protection
shall be provided.
i) Local/off/auto selector switch and visual indication of energized capacitor with
red lamps, etc shall be provided.
j) Type tests for the equipment shall include operating voltage, temperature
cycling and repeated switching.

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k) Overcurrent shall be 1.8 x In.

l) Peak inrush current withstand capacity shall be 250 x In

1.9.14.7 DETUNED FILTER

a) Detuned harmonic filter reactors shall be used as per BOQ along with power
capacitors to mitigate harmonics amplification and to avoid electrical
resonance in LV electrical networks.
b) The reactors shall be made of high grade copper windings, having a three
phase, iron core construction suitable for indoor use. The reactor are air
cooled and the layout shall be in accordance with IEC 60289 / IS 5553.
c) The permitted tolerance of inductance is ± 3% of rated inductance value.
d) Reactor tuning factor shall be 7 % (189 Hz) and the current rating of the
reactor shall include the effects of harmonics and other possible over-currents
e) The limit of linearity of inductance of the filter reactor is: 1.8*In with L=0.95*LN.
f) Allreactors shall be fitted with a temperature sensitive micro-switch in the
centre coil (normally open) for connection to trip circuits in case of high
operating temperatures

1.9.15 Automatic load transfer switches (ALTS)

1.9.15.1 Automatic load transfer switches shall be composed of paired ACBs or MCCBs.
ACBs and MCCBs used in Automatic Load Transfer switches shall be used as
specified in this specification.
1.9.15.2 Paired ACBs or MCCBs (as specified above) shall be provided with motorized
mechanisms for "ON/OFF" operation.
1.9.15.3 Each automatic load transfer switch shall be equipped with, but not be limited to,
thefollowing:

a) Illuminated indicator for "Normal Supply On" and "Standby Supply On" to be
provided at the front cover of the compartment housing the changeover
switches.
b) Transfer mechanism to facilitate automatic/ manual changeover from the
normal source to the standby source.
c) Automatic/manual change-over selector switch shall be provided. It shall be
possible to manually operate the circuit breakers in the event of absence of
control voltage.
d) ALTS should have electrical interlocking along with mechanical interlocking
through base plate to ensure that two MCCBs shall not be ON simultaneously.
e) Interlocking facility to insure that normal breaker tripped on fault will not cause
standby breaker to close or vice versa, unless the breaker are reset manually.
f) A test switches to simulate mains power failure and indicate the changeover
sequence to allow on load testing.
g) Auxiliary relay and contacts to facilate main power source failure for routine
testing of the automatic change-over operation.
h) 2 nos. each NO and NC volt free dry contacts shall be provided for each
change-over circuit breaker unit.
i) The change-over function shall work without auxiliary power supply with fail
safe operation.
j) All indications for all operations viz. ON, OFF, TRIP.

1.9.15.4 The changeover system between the normal and standby sources shall be as
follows:

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a) 3 phase sensing circuits with adjustable time delay facility in the range of 0 to
15 seconds shall be provided to monitor the voltage condition of the normal
and standby source.
b) Failure of one or more phases of normal main supply or are reduction of
voltage to a value of 90% to 70% (adjustable) of nominal value shall initiate the
timing device. If the failure persists at the expiry of this present time delay, the
changeover section will be affected provided that the voltage of the standby
source reaches 90% of the nominal value.
c) Upon restoration of the normal power supply, which has been determined
stable after a time delay, the changeover switch shall automatically be restored
to the normal supply. It shall also be able to switch the load back to the normal
supply under manual control.

1.9.16 Automatic Transfer Switches (ATS)

1.9.16.1 General

This covers scope to provide automatic transfer switches (ATS) and enclosed
ATS, comprising an ATS with a microprocessor controller for auto-operation
and, with amperage, voltage, number of poles ( 3 and 4 poles ) and withstand
values as per the Schedule of Quantities. The automatic Transfer switching
equipment is designed to be used in low voltage power systems for Open
transition transfer applications, with simultaneous closing of all 4 poles (three
phases and neutral).

1.9.16.2 Design Prerequisite

a) The transfer switch unit shall be electrically operated and mechanically

held.The electrical operator shall be a motorized unit or a double solenoid
mechanism, momentarily energized.
b) The switch shall be mechanically interlocked on a single shaft. The system
shall incorporate switch position indicator, with provision of manual emergency
operation, having 3 stable positions – Normal, Isolated and Emergency. To
prevent source overlapping the transfer is operated through distinct isolated
position.
c) The sensing and logic shall be built-in microprocessor for maximum reliability
and with option of serial communications feature. To facilitate flexibility of
installation there shall be provision of Line/ Load reversibility.
d) ATS system shall have following characteristics:-

System Operational Voltage 415 V

Rated Insulation Voltage 1000 V
Impulse withstand Voltage 12 KV
Thermal Rating of Switch At 40 deg. C
Storage temperature -20 to +70°C
Operating temperature -20 to +70 ° C

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1.9.16.3 Standards & Codes

STANDARDS DESCRIPTIONS
IEC60947-1 Low-voltageswitchgear and controlgear-
Generalrules

IEC60947-6-1 Multiplefunctionequipment–
TransferswitchingEquipment

IEC60947-3 Low-voltageswitchgear and controlgear–

Switches&disconnectors

EmissionGeneralstandard
EN55022 ConductorEmissions
EN55022 RadiatedEmissions
Immunity GeneralStandard
EN61000-4-2 ElectrostaticDischarge (ESD)
EN61000-4-3 Radiatedelectromagnetic field
EN61000-4-4 Electricalfast transient(EFT)
EN61000-4-5 Surges
EN61000-4-6 Conductedradio frequency field
EN61000-4-8 Powerfrequency magnetic field
EN61000-4-11 Voltagedips,shortinterruptionsandvariations

EN61000-4-13 Harmonicsandinterharmonics
IEC61010-1 Electromagnetic compatibility

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1.9.16.4 Normal / Emergency sequences must integrate following timers:

Loss of Mains Timer to validate Main source failure before starting loss of
Mains sequence Delay to transfer Timer (Emergency source availability Timer)
to validate emergency source stability before transferring.Cool Down Timer in
case of Genset application, to allow genset cooling down period after
transferring back the load to the Main source It shall be possible to block the
re-transfer operation (from Emergency to Main source) via programming.

1.9.16.5 Safety

An in-built Auto/Manual selector must inhibit any automatic command in

manual position it must also be possible to equip the product with a key
selector to allow secure accesstothe operational mode selection, Padlocking of
the product in Isolation position must be included, and padlocking of the
system in all 3 positions must be possible on request

1.9.16.6 Construction and Design Requirements

a) Transfer Switch
I. The Switching contacts of ATS must be silver plated and of the self
cleaning type, which optimizes the quality of the contacts during
operation and also to render a maintenance free system.
II. A manual operating handle made of one piece only shall be
provided for emergency transfer purposes. The handle shall be
located on the ATS itself to ensure ease of locating that and for
quick operation for maximum efficiency during power outages.
Manual transfer shall be possible on load
III. Manual retransfer function must be possible either locally or from
remote.
IV. The switch shall have simultaneous closing of all 4 poles of ATS to
minimize effect of transient voltages
V. The Neutral pole of ATS shall be fully rated (100% rating for all 4
poles).
b) Controller
I. ATS Controller should have selectable Single phase or Three
phase control on Sources
II. The control unit shall direct operation of the switch. The controller’s
sensing and logic shall be a built-in microprocessor for maximum
reliability, minimum maintenance and to facilitate serial
communication capabilities
III. It shall be possible to block the re-transfer operation when selected.
The transfer back operation to the main source must be voluntarily
validated
IV. The Frequency setting shall be possible in steps of 0.10 % whereas
Voltage to be settable in steps of 1%
V. It shall be possible to have Voltage sensing on all three phase as
well as for single phase
VI. There shall be 300 distinct nominal voltage settings, for precise
settings over a wide voltage band
c) Settings
I. Both Voltage and Frequency settings shall be field adjustable either
Locally though display and keypad, or remotely through serial
communication ( voltage in 1% steps and frequency in 0.1% steps )
d) Events & Alarms

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I. It shall be possible to programme the minimum and maximum

voltage and frequency thresholds, and associated hysteresis levels
to avoid any nuisance triggering of the switch operation. It shall also
be possible to closely monitor Phase rotation of both the sources to
check for any flaws. It shall be possible to configure unbalance level
for both Mains and Backup source to ensure phase loss detection

1.10 DISTRIBUTION BOARDS

1.10.1 Distribution boards for miniature circuit breakers shall be of sheet steel construction
with aminimum thickness of 1.6 mm, suitably braced to form a rigid structure.
Exterior corners and edges shall be rounded to give a smooth overall appearance.
Hinged swing doors shall be fitted with gaskets and shall be easily removable to
simplify installation. DBs shall be provided with suitable size of surge protection. DBs
shall be fixed with bottom at 1200 mm from finished floors. DBs shall be fixed
properly, fitted square with the frame and with holes correctly positioned. DBs shall
be fastened to the walls with suitable grouted studs of not less than 12-mm diameter.

1.10.2 IP ratings for distribution boards shall be IP 54(used for Lights & small power).

1.10.3 All boards shall be meggered phase to phase and to neutral using 1000/500V
megger with all switches in closed position. The megger value should not be less
than 2.5 M Ohm between phases and 1.5 M Ohm between phase and neutral.
Testing of minimum 10 kA short-circuit current otherwise specified in BOQ required.

1.10.4 Each distribution board shall be arranged for top and bottom cable entry and shall be
provided with ample cable termination plates and chambers to enable cables to be
neatly glanded with tails grouped and terminated on to appropriate internal
terminations.

1.10.5 Distribution boards shall be wall mounted and shall, where specified, incorporate
doublepole or triple pole all insulated switches as appropriate, which shall be front of
panel operated with an "ON/OFF" indicator and capable of being padlocked in the
"OFF" position. Distribution boards shall incorporate combinations of single pole,
double pole, triple pole and four pole miniature circuit-breakers (MCBs/MCCBs) as
specified.

1.10.6 Each bank of MCB's shall be clearly identified with its appropriate phase colours
code, and the mounting framework for the banks of MCB's shall be easily removable
to simplify installation. Adequate phase barriers and shields shall be fitted to ensure
that after installation and wiring, all bare terminals and wires are covered to prevent
accidental contact with live conductors during the normal procedure of resetting
MCB's.

1.10.7 Each distribution board shall be supplied complete with a permanent circuit
identification chart, preferably mounted within the front door. This chart shall be
permanently and legibly filled in as circuits are completed, including the circuit
description, the MCB rating and theidentification of upstream source of the
distribution board.

1.10.8 Each distribution board shall be clearly labeled indicating its service and all 3- phase
distribution boards shall be fitted with standard labels as per relevant IS.

1.10.9 In the top and bottom, of each distribution board a 32 mm clear hole in addition to
other requirements shall be provided. These spare holes shall be fitted with 32 mm
stopping plugs and locknuts.

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1.10.10 Spare MCB's shall be provided on the basis of one per four ways or part thereof for
every distribution board ensuring that spares are provided in numbers and rating
proportional to the numbers and ratings in the installation.

1.10.11 Distribution boards shall comply with best industry practice.

1.10.12 All busbars shall be of hard drawn tinned copper having ratings as specified
complying to relevant clauses given under clause 4.1 as relevant, and shall be
electro-tinned. Neutral busbars shall be of thesame cross-sectional area as the
phase busbars and shall have adequate number of terminals for all outgoing circuits
including spare ways.

1.10.13 The configuration of the busbars, busbar supports and busbar mounting
arrangement) shall be rated at 415 V. It shall be type tested and certified to a short
time withstanding current which is not less than 10 kA for 1 sec at voltage of 415 V.

1.10.14 Multi-terminal connectors shall be provided within the distribution board for
connection of protective conductors of all outgoing circuits including spare ways.

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1.11 FINISHES
1.11.1 Sheet Steel materials used in the construction of these units should have undergone a
rigorous rust proofing process comprising of alkaline degreasing, descaling in dilute
sulphuric acid and a recognized phosphating process.
1.11.2 The steel work shall then receive two dip-coats of oxide filler/primer before final
painting. Castings shall be scrupulously cleaned and fettled before receiving a similar
oxide primer coat. The manufacturer is required to have 7 tank treatment facility for this.
1.11.3 All exposed metal surfaces, both internal and external, shall be thoroughly cleaned of all
dust, oil, grease, scale, rust or any other contaminants and shall be epoxy powder
coated immediately at the manufacturer's factory. In case of any doubt, the painting
procedure, paint samples and process shall be approved prior to commencement of
painting.
1.11.4 The epoxy powder coating shall be not less than 50 micron thick and with colour in
accordance with BS 381C or BS 4800 as approved by Engineer.
1.11.5 Every care shall be taken to protect the surface of the panel from damages during
transportation and installation. In case, there is any damage, the same shall be made
good by the method as approved by the site engineer which may also include change of
the panel.
1.11.6 Size of the DB shall be optimized precisely by proper utilization of points on MCB.
Proper utilization of points reduces the space acquired by DB as well. If the numbers of
points are few on MCB then it shall be avoided by adjusting the same on other MCB
having sufficient free points. MCB rating shall be as per the number of points to be
included. Circuit for areas other than critical rooms e.g. SER, TER,SCR etc. shall be
clubbed according to the rating of MCB. While designing DBs, efforts shall be made in
such a way that each circuit shall have not more than 800 Watts connected
load.However, In case of LED Points where load per point may be less, number of
points may be suitably increased.

1.12 NAMEPLATES AND LABELS

1.12.1 NAMEPLATES
Each Electrical Panels shall have permanently attached to it in a conspicuous
position labels upon which shall be engraved or stamped with the manufacturer's
name, type and serial number, date of manufacture, designation of each Electrical
Panels, details of the loading and duty at which the item of the Electrical Panels has
been designed to operate. Such labels shall be of non-hygroscopic material.

1.12.2 LABELS

a) Labels shall be provided for every panel to describe the duty of or otherwise
identify every instrument, relay or item of control equipment mounted
externally and internally.
b) The designation on these labels shall be clear and shall, where applicable,
incorporate the device number along with concise descriptive wording in
English.
c) Externally fitted panel labels shall be of Perspex or other approved transparent
plastic with letters and numbers rear engraved and filled with black.
d) Internally fitted panel labels shall be finished in white with engraved letters and
numbers filled with black, laminated material such as Trifoliate or rear
engraved and filled plastic may be used. Embossed materials and techniques
will not be accepted or any latest technology which provides same result as
mentioned above shall be applicable.

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e) Labels shall be provided in conformity with the above requirements or by other

approved means wherever necessary to designate panels or panel sections.
To describe or identify circuits or circuit components, to provide warnings or
reminders of dangerous or potentially dangerous circumstances and wherever
called for elsewherein this Specification.
f) Safety labels "Danger 415 V in both English and Hindi shall be provided on
both the front and rear of the Electrical Panels. The safety labels shall have
graphic symbolsexactly as per IS standards. The design of all such signs shall
be submitted for approval. Similar labels shall be provided for other panels at
different voltages.
g) Labels shall not be less than 45 mm high. Lettering shall be of not less than 10
mm high. All labels shall be securely fixed to the panels by bolts and nuts.
h) Details of proposed inscription, including the English and Hindi wordings, and
samples of the labels shall be submitted for approval before any labels are
manufactured.
i) Circuit labels, one on the front of the panel and one on the rear of the panel
suitably engraved.

1.13 FOUNDATION (IF REQUIRED) AND INSTALLATION

1.13.1 The location of each foundation shall be correctly set out in accordance with the
approved foundation layout drawing. Base channels shall be grouted, levelled in
cement concrete pad for switchgear and other cubicle panels, etc. with reference to
a bench mark in the building. Pedestal type panels and superstructures shall be
erected by grouting foundation bolts into the foundation in cured holes left in
foundation blocks. For concreting on existing floors, a proper bonding surface shall
be made by chipping the floor. The final finish to the surface of the floor shall be
given after all equipment has been installed. If floor is broken for installation of
equipment, it shall be restored to original finish after completion of installation.

1.13.2 The concreting shall be done in accordance with the provision of Indian Standard
Code of Practice for Plain and Reinforced Concrete, IS 456-2000. Concreting IS:
383-1970 Specification for coarse and fine aggregates from natural sources for
concrete IS: 269-1989 Specification for 33 grade ordinary portland cement IS: 516-
1959 Method of test for strength of concrete

1.13.3 Suitable grooves or niches shall be provided in the foundation block at the time of
casting to enable embodiment of earth strips without calling for chipping of the
blocks. Subsequently conduits of appropriate size shall be embedded in the
foundation blocks for cabling, in the first instance, wherever required.

1.13.4 All foundations shall be cast in the presence of the Employer's representatives. All
foundation and grouted bolts shall be cured for a minimum period of 48 hrs.

1.13.5 Foundations shall be prepared as per manufacturers drawing, shall be leveled,

checked for accuracy and the switchboards installed. Busbar connections shall be
checked with a feeler gauge after installation. Tightness of accessible bolted bus
joints shall be checked using calibrated torque wrench. Sealing of cable and boxes
to prevent moisture entry shall be checked. Switchboard earth bars shall be
connected to the earth grid.

1.13.6 Fabrication drawings of all panels shall be approved by the Employer's

representative before fabrication

1.13.7 The Electrical Panels shall be installed in the locations as approved by the Engineer.
Electrical Panels shall be secured, plumbed and levelled and in true alignment with
related adjoining work,

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1.13.8 The rigid galvanized U-channels with adjustable levelling screws to ensure effective
fixing of the Electrical Panels on the uneven floor shall be provided.
1.13.9 Anchor bolts and anchorage items shall be provided where required and field checked
to ensure proper alignment and location. Templates, layout drawings, and
supervision on Site shall be provided to ensure correct placing of anchorage items in
concrete.
1.13.10 Supporting members, fastenings, framing hangers, bracing, brackets, straps, bolts,
angles, shall be installed as required to set and rigidly connect the work.
1.13.11 Temporary bracing, gauge, or other devices shall be provided as required to
accomplish erection and to provide safety and stability until the ELECTRICAL
PANELS is in its final and approved position.
1.13.12 Erection tolerance requirements shall be controlled so as not to impair the strength,
safety, serviceability, or appearance as Approved.
1.13.13 After installations are complete, all places where the shop applied coating is
abraided, all bare steel, including bolts, nuts, washers, and welds shall be thoroughly
cleaned. Each item shall be painted with the same paint as used for shop coating in
the corresponding location.

1.14 OTHER PROVISIONS

1.14.1 The Electrical Panels shall be provided with all necessary cable lugs etc., fixed in
positions on mounting plates and straps, to suit the types and directions of entry of the
cables as shown on the Drawings or as specified.
1.14.2 Cable conductors for all circuits within the Electrical Panels shall be arranged in a tidy
manner and mechanically secured at regular intervals such that any movement
occurring to the conductors, either under normal operation conditions (e.g. thermal
expansion, vibration, etc.) or due to short circuit in any one of the circuits, shall not
cause any damage or short circuit to any healthy bare live parts in the Electrical Panels.
1.14.3 Each Electrical Panels shall be supplied complete with all operating handles jigs, etc.
required for the normal charging, closing, opening, racking in and out operations of all
circuit breakers of the Electrical Panels and shall be properly fixed in a neat manner on
a board with brass hooks inside the switch room/plant room where the Electrical Panels
is installed.
1.14.4 Each Electrical Panels shall be provided with two rubber mats of ribbed surface,
complying with BS 921 or equivalent Indian standards, laid in front of and at the rear of
the switch board. The rubber mats shall be continuous sheets of minimum thickness of
10 mm, each of same length as the switchboard and minimum width of not less than
1000 mm or the width of the space between the fronts or back of the switchboard to the
adjacent wall.
1.14.5 Hydraulic operated handling truck suitable for handling all sizes of air circuit breakers for
the Electrical Panels shall be provided as indicated in the BOQ.

1.15 SPECIAL CONDITION:

1.15.1 The Switchboard shall be complete with all components and accessories, which are
necessary or usual for their efficient performance and satisfactory maintenance under
the various operating and atmospheric conditions. Such parts shall be deemed to be
included within the scope of supply whether specifically included or not in the
specifications or in the tender schedules. The contractor shall not be eligible for any
extra charges for such accessories etc.

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1.16 RELIABILITY, MAINTENANCE, SPARES AND LIFE

1.16.1 The electrical panel shall be designed for reliable and safe working. It shall be
designed for a maintenance free secure service life of switchboards, sub-assemblies
and components for at least 30 years.

1.16.2 The manufacturer shall submit the list of spares which are required to be replaced as
a must change item along with interval.

1.17 MATERIAL AND MANUFACTURING:

1.17.1 All similar items of the Electrical Panels and their component interchangeable. Spare
parts shall be manufactured originals and shall fit all similar items of the Electrical
Panels. Where machining may be needed before fitting renewable parts, the
machining fits and the associated tolerances shall be shown on the drawings
accompanying the instruction manuals.

1.17.2 All parts which are susceptible to wear or contaminated by dust shall enclosed in
dust-proof housings.

1.17.3 The style and finish of the workmanship shall be consistent throughout the Works.
Unless otherwise specified, Engineer shall decide the final colours for all paint work
and other finishes to be applied to the Electrical Panels.

1.18 TESTING

1.18.1 The firm shall submit valid type test not more than 5 years old of the equipment
conducted at accredited/authorised/reputed/nominated by DMRC laboratory. The
type test shall be as per the governing specification.

1.18.2 DMRC will carry out Routine and factory acceptance tests as prescribed in the
specification with following additional test

1.18.3 The manufacturer shall not change the Bill of Material used in the manufacturing of
samples used for Type testing. In case the bill of material is changed then Engineer-
in-charge may ask for the repetition of those type tests which he considers relevant.

1.19 INDICATIVE LIST OF ITEMS TO BE INCLUDED IN FAT PLAN FOR ELECTIRCAL PANELS

(This list is an indicative List for the inspectors to be conducted during FAT of Power Panels. However,
the detailed FAT plan needs to be developed for the specific Panel based on approved GADs and
Contract Specifications and as per the tests defined in Clause – 11 of IEC 61439 -1 (Routine
Verification)/as per the relevant Standards as applicable.)
S. No Description Type of Check Remarks
GENERAL
A All items/components (switchgears, cables, Visual Check & Obtain
wires, meters, relays etc.) used are as per the Certification before confirmation
Approved Makes, Vendors and ratings. Call letter from Panel
Manufacturer
B Obtain the Factory Test reports of Verify for each
Incoming/Raw Material Panel duly
C Obtain the Internal Test reports/Manufacturer Review verified by the
Test Report of Internal Quality Tests done on Main
Panel offered for Inspection as per ISO 9001. Contractor.
D Confirmation from Panel Manufacturer that For record
Penel has been manufactured strictly as per
approved GADs.

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E List of tools required for Inspection and copy Check for Validity
of their Calibration Certificates from
independent Labs/Authorities.
Note: All the above are to be made part of this FAT
report
Panel must be of Modular construction as per
PS. The Inspection team shall carry the
approved GAD, approved Bill of materials,
Contract Specification, relevant standards,
copy of Approvals and approved FAT Plan
from the office before proceeding for the FAT
inspection to the factory promises.
Physical/Dimensional Checks (as per approved GADs).
1 Check the Length, Breadth and Height of the Measurement
complete Panel.
2 Check dimensions of each Sections and Measurement
Cubicles.
3 Check Number and dimensions of Space for Measurement
future additions as per Specifications & Bod.
4 Check dimensions of the Doors/back Panels, Measurement
etc. (Note: Back Panel sections should not be
too bulky to handle by one individual. May be
taken care during GAD and checked during
FAT).
5 Check height/dimensions of all front Mounting Measurement
Accessories (such as indicators. Measuring
instruments, knobs, etc.)
5.1 EPB (Emergency Push Button) at 1300 mm Measurement
where applicable.
5.2 All Relays & indicating instruments between Measurement
300 to 1800 mm
5.3 Max. Operating Height should not be more Measurement
than 1800 mm
5.4 Blank Space between the Floor of Switch Measurement
board and bottom unit (Min. 200 mm or as per
PS)
6 Check size/height of Base Frame (may be Measurement
min. 100 mm. or as per PS).
6.1 The make of the manufacturer of bought out
items is clearly displayed on the items where
possible.
6.2 Check that all materials used in the
manufacturing of the electrical panel are fire
retardant, low smoke & zero halogen.
7 Verify Material and Thickness of Load bearing Certificate/
and Non-Load Bearing Member of Panel
Enclosure: Measurement
7.1 Panel Structure
7.2 Bus bar Section
7.3 Cable Alley
7.4 Switchgear/feeder sections
7.5 Doors

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7.6 Gland Plate

8 Check Quality of Sheet Metal Painting and Visual/Measurement
Colour used. It should be as per the
Specification/Approved drawings.
9 Check for the Quality of Sheet Metal Visual
Workmanship. There shall not be any sharp
edges, burrs, dents, etc. on the panel.
10 Check Number and Quality of the Door Visual
Hinges. Ensure that doors are strongly
supported and should not have any unwanted
deflection/shakiness. When door is closed, it
is latched at adequate places with adequate
crushing of gasket on metal frame.
11 Check Quality of the Door handles, Locks etc. Visual
12 Check interlocking of Doors, Switchgears, Verify and Visual
incomers, outgoings and couplers as per the Check
design logic and drawing
13 Check and compare the sealing arrangements Verify and Visual
all around the panel to ensure intended Check
ingress Protection is achieved and compare
with the Type test reports.
13.1 Simple Paper insertion test for IP54. Insert a
paper in the gasket and metal frame, close the
door and pull the paper. It should not pull out.
13.2 Check Quality of Gaskets/sealing rubber, etc.
for the Doors. The arrangement shall be such
that it is replicable during maintenance.
13.3 Check Quality of Gaskets/sealing rubber, etc.,
around the cut-outs for Measuring & indicating
instruments, Switchgears, Relays etc.
13.4 Proper sealing of knock-outs/cut-outs/gaps for
control cabling bus bar, etc., between different
feeders/sections within the Panels.
14 Check the Lifting arrangements (Hooks etc.) Visual
are provided.
14.1 Adequate Number of Lifting points/Hooks
14.2 Adequate Strength of Lifting Points/Hooks
15 Check proper identification markings, Visual
numbering labelling, tags have been provided.
15.1 For the Panel
15.2 For each incoming and Outgoing Feeders
15.3 For Measuring and indicating instruments
15.4 Danger Plates/Signages
16 Check for rust, any sign of initiation of Visual
corrosion, oxidation, etc., on the support
members/nut bolts/bus bars/terminal points,
etc. Initiation is an indication of use of
defective material.
CABLE ALLEYS
17 Check for Cable Entry Arrangement (top Visual
entry/Bottom entry) as per GADs.

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18 Check for Maintenance/Working space in Visual/

Cable Alleys, etc. Measurement
19 Check for adequate Space for Visual/
accommodating Cable Loops, etc. Measurement
20 Provision for securing/clamping cables in Visual
Cable alley for proper dressing of cables.
21 Check for Knock outs for Glanding of different Visual
smaller sizes of Cables in Marshalling box (to
be used for BMS cables).
22 Thickness of Glanding Plates should be Measurement
minimum 5.0 mm & strong enough to take the
simultaneous load/forces of cables glanded on
to it. The Cables shall be well supported and
not exert any force on the glanding plate
23 Proper dressing/harnessing of internal control Visual
cables and wiring within the Panel.
24 Provision of identification tags/ferrules on the Visual
internal control cables and wiring within the
Panel.
EARTHING ARRANGEMENT
25 Check that Material of Earth Bus provided in Visual
Panel is as per PS.
26 Check the Size of continuous Earth Bus Measurement
provided in the Panel as per IEC.
27 Check if the Earth Bus is properly supported Visual
and connected to the outside terminals.
28 Check that proper earthing has been provided Visual
throughout the Panel and all non-current
carrying parts are properly earthed.
29 All the Gland plates have been earthed Visual
properly
30 All Doors and openable sections must be Visual
earthed through flexible wires/jumpers (dual if
required as per Specs)
31 Cases of all instruments and apparatus shall Visual
be earthed by a conductor of suitable size (but
not less than 2.5 sq. mm)
32 Check that the Frame of Switchgear is Visual
earthed, when racked in to the Cubicle.
BUS BAR SECTION
33 Check Bus bar dimensions as per Approved Measurement
GAD (Only rectangular Busbar is permitted)
34 Neutral bus shall be of full size Measurement
35 Material of the busbar shall be as per Visual/ Certificate
approved specification
36 Quality (Conductivity) of the Material of the Certificate/
busbar (Copper/Aluminium) shall be as per Measurement
approved specification
37 Check the quality of conducting material used Certificate/
for Bus bar and the Quality of Tinning on the Measurement/Visual
Copper Bus bar.

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37.1 Factory tinned Bus bars to be used. Obtain

the Factory Test certificate and attach the
report.
37.2 Tinning of Bus Bar edges after cutting/sizing
also to be checked.
38 Check that the Bending of Bus Bars should be Confirmation &
on Rollers of adequate diameter to avoid Cross-Check
undue bending stresses
39 Check the fixing/mounting arrangements of Visual
Main bus bar to ensure that there are no
undue stresses due to misalignment of fixing
arrangements. (Focus on the location where
Panel is divided in to different sections to
ensure that the Bus Bar sections match
properly).
39.1 Check the proven design of bus bar
connections of OEM & its compliance in the
manufactured product
40 Bus bar must be color coded for Phase Visual
identification
Note: In case, sleeve is to be provided over
the Bus bar for color coding as per PS, then
the material of the sleeve must be as per the
relevant clauses of PS.
41 Check the distance between Bus bar supports Measurement
and compare with Type tested
assemblies/Approved GADs.
42 Bus Bar Supports should be of approved Confirmation
material.
43 Measure minimum Electrical clearances Measurement
between the bus bars for different Phases,
Neutral and Earth.
(Main Bus as well as Tap off Bus bars)
(Minimum clearance will be between Live
parts and Earth)
44 Check the interconnecting / Tap - off links Measurement
between Main Bus and bus sections for
proper tightnessetc. (connection with the
double split cast brass clamp is permitted)
45 Interconnection between Bus Bar and Visual
Switchgear - must be high conductivity
Copper Bar and must be insulated and Colour
coded
46 Proper compartmentation at locations where Visual
connecting Links enter the Switchgear
section, bus bar sections and Cable Alley
must be ensured.
(Form - 4 b, Type - 5 to be ensured, for
Stimulator building section)
For elevated, separate compartments for
incoming and Outgoing cable terminations, to
be ensured.

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47 Proper Shrouding of Bus bar joints / tap off Visual

points to be ensured. Material to be as per PS
of the Contract.
48 Proper clearances and segregation must be Measurement
maintained between Terminals / Tap - offs of
different feeders from Main Bus Bars.
INTERNAL WIRING, TERMINAL BLOCK
49 Check if the Wiring for all power and Control Verify Material Test
circuit is being provided as per Approved GAD Certificate
/ Specifications.
Note:- Internal Wiring in LT panels to be
FRLSZH / FS as per Specs for Stimulator
buildings.

50 Termination arrangements
50.1 Terminal blocks should be of Non - Verify Material
Hygroscopic of Melamine
50.2 At terminal points - Plain and Spring Washers Visual
with electro - tinning to be used
50.3 Check the tightness of wiring termination Visual
50.4 Terminal should have test probe facility Visual
50.5 All Live parts of Terminal blocks must be fully Visual
shrouded
50.6 Spare Capacity of Terminals Visual
50.7 Cable terminations should be with lugs of Visual
adequate size and with proper crimping
50.8 No more than two wire to be connected to the Visual
Terminal
50.9 Terminals should have identification Labels. Visual
50.1 All cables should have identification ferrules Visual
50.11 Check if the adequate size of the cables / Measurement
wires is being used for the control wiring
50.11 All the internal wiring shall be properly Visual
dressed and randomly check the traceability
of the wires from the wiring diagram
50.12 Check Provision of Protection for Control Visual
wiring as approved
MARSHALLING BOX for BMS (if applicable)
51.1 MarshallingBox / Separate chamber for the Visual
BMS connection is provided as per the
Approved GAD
51.2 Check the BMS points have been provided as Visual
per the approved I/O schedule
51.3 Provision of Soft links points for the control Visual
shall be checked
51.4 All the terminals for the BMS shall be properly Visual
secured and identification mark along with the
voltage level shall be provided
51.5 Randomly check voltage level at the BMS Measurement
points for any leakage voltage etc (at Potential
free contacts)

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51.6 No power wiring / cable should pass through Visual

marshalling box
SWITICHGEARS, PROTECTIONS, INDICATIONS, ANNUNICATIONS AND MEASURING
INSTRUMENTS
52 Detailed Check list for these items of the Factory Test
Panel may be prepared based on the GADs / Certificates and Test
Contract Specifications during FAT

53 Test Certificates / Calibration Certificates for Factory Test

Measuring instruments to be ensured Certificates
54 Check Surge Arresters (if applicable) have Visual &
been provided Manufacturer's Test
Reports
55 Separate CTs for Measurement and Visual &
Protection of relevant Class and Burden as Manufacturer's Test
per PS to be ensured Reports
56 Check Control Logics, Interlocks and Visual, Simulation,
Protections Schemes in detail as per the Primary & Secondary
approved plan / arrangement. Injection etc

57 Check the working of ALTS & Controls Visual, Simulation,

provided for safe operation. Primary & Secondary
Injection etc

MISCELLANEOUS
58 Check the lights, sockets, anti-condensation Visual
heaters and air circulation means provided in
the Panels as per GADs.
59 All the Control and power wiring must per Visual
properly segregated.
60 Padlocks and interlock provision and Visual
Functions to be checked for the safety for
each.
61 Check for extendibility of the Panels (including Visual
Bus Bars) on either side.
62 Check provision of entry for Fire Trace Tube
and internally with in the various cubicles and
adequate sealing arrangements.
63 Ensure that there are No Joints in the cables
used
64 The tests defined in Clause - 11 of IEC 61439
- 1 (Routine Verification)/as per the relevant
Standards as applicable are also to be
performed for which separate Test sheet may
be prepared.
65 The make of the manufacturers of bought out
items is clearly displayed on the items where
possible.

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66 Check that all materials used in the

manufacturing of the electrical panel are fire
retardant, low smoke & zero halogen.
APFC PANEL
67 Ensure that material/equipment of only one
make is used in the entire Electrical Panel
assembly.
68 Check the make, rating and specification of
capacitors used.
69 Check the functioning of APFEC relay as
defined in the operating manual of the relay.
70 Check the installation of capacitor & inductor
as per the form & specification.
71 Check the working of cooling fans only when
temperature goes above set value and at least
one capacitor in service.
72 Check the sizing of the filter used to ascertain
the cleaning frequency for continuous working
of cooling fan.

1.20 DATA SHEET

S. Values
Unit
No. Description

Length marking: Length shall be marked with number at one meter intervals on the sheath.

*Bidder to furnish the data

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2 MV CABLING

2.1 SCOPE

The Medium Voltage cables are used at stimulator building for E& M applications for
power supply and control for various equipments. This specification takes care of the
design, manufacturing, testing and installation requirements of the Cables. There are two
types of cables namely PVC insulated as per IS: 1554 (Part-1):1988 and XLPE insulated
PVC sheathed as per IS 7098 (Part-1): 1988. XLPE cables are generally used for power
supply application and PVC insulated for control application.

2.2 STANDARD

2.3.1 All equipment’s, components, materials and entire work shall be carried out in conformity
with applicable and relevant IS/BS/IEC Standards and Codes of Practice. In addition
relevant clause of Indian electricity act 2003 and Indian electricity rule 1956 amended up
to date shall apply.
2.3.2 It is to be noted that updated and current standards shall be applicable irrespective of
dates mentioned along with IS in the tender documents.
STANDARDS DESCRIPTION
IS:1554 (Part-I) – 1988 PVC insulated (heavy duty) electric cables: Part 1 For
working voltages up to and including 1100 V
IS:7098 Part-I 1988 Cross-linked polyethylene insulated PVC sheathed
cables: Part 1 For working voltage up to and including
1100 V
IS 1255 – 1983 Code of practice for installation and maintenance of
power cables up to and including 33 kV rating
IS 8130 – 1984 Conductors for insulated electric cables and flexible
cords
IS 10418 –1982 Drums for electric cables
IS 10810 Methods of test for cables (All latest)
IS 3961 Recommended current rating for cables (All latest)
IS 5819 –1970 Recommended short circuit rating of high voltage PVC
cables
BS:7671 – 2001 Requirements for electrical installations. IEE Wiring
Regulations

- Sixteenth edition.
BS 4579 Specification for performance of mechanical and
compression joints in electric cable and wire.
BS 6121 Mechanical cable glands
IS 5831 PVC Insulation and sheath of electric cables.
2.3.3 All Codes and standards mean the latest.Where not specified otherwise the installation
shall generally follow the Indian standards/British Standards Codes of Practice/IEC
standards.
2.3.4 Cables up to size 10-sqmm conductor size shall be copper conductor & beyond size 10-
sqmm shall be aluminium. All conductors shall be stranded.

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2.4 ABBREVIATIONS

S. No. Abbreviation Description

1. PVC Poly-vinyl Chloride
2. XLPE Cross-Linked Polyethylene
3. FRLSH Flame Retardant Low Smoke and Halogen
4. LV Low Voltage
5. MV Medium Voltage
6. HV High Voltage
7. HT High Tension
8. MS Mild Steel
9. GI Galvanized Iron
10. RCC Reinforced Cement Concrete
11. UPVC UnPlasticised Poly Vinyl Chloride
12. FRLSZH Flame Retardant Low Smoke Zero Halogen

2.5 TECHNICAL REQUIREMENTS

2.5.1 PVC Cables
2.5.1.1 Medium voltage cables shall be 1100 Volt grade aluminium/copper
conductors, PVC insulated, PVC sheathed with flame retardant low smoke
and halogen (FRLSH) compound and armoured conforming to IS: 1554 Part-
l. Cables shall be rated for 1100 Volts.
2.5.1.2 The insulation shall be of Type A PVC compound conforming to the
requirements of IS 5831.
2.5.1.3 The conductor of all cables shall be stranded. Sector shaped stranded
conductors shall be used for cables of 50-sqmm and above.
2.5.2 XLPE Cables
2.5.2.1 The cables shall be 1100 Volt grade XLPE insulated with PVC inner sheath,
steel armouring and with an outer protective sheath of flame retardant low
smoke and halogen(FRLSH) compound, conforming to IS: 7098 (Part I).
Cables shall have high conductivity stranded aluminium or copper conductors
and cores colour coded to the Indian Standards.
2.5.2.2 A common covering (bedding) shall be applied over the laid up cores by an
extruded sheath of unvulcanised compound. Armouring shall be applied over
this extruded sheath. The outer sheath shall bear the manufacturer's name
and trade mark at every meter length. Cores shall be provided with following
colour scheme of PVC insulation

1 Core Red / Black/Yellow/ Blue

2 Core Red and Black
3 Core Red, Yellow and Blue
3.5Core: Red, Yellow, Blue and Black
The colour of the outer sheath shall be Black or as required by the Engineer.

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2.6 DELIVERY, STORAGE AND HANDLING

a) Storage and handling shall conform to section 7 of IS 1255.

b) All cables shall be new without any kinks or damage, marked with DMRC,
manufacturer's name, insulating material, conductor size and voltage class on
cable surface at every 1000 mm approx.
c) Cable drum conforming to IS: 10418 shall be stored on a well-drained, well-
ventilated area protected from sun and rain on hard surface, preferably of
concrete, so that the drums do not sink in ground causing rot and damage to the
cable drum.
d) For transportation over long distance, the drums shall either be mounted on drum
wheels, trailers and pulled by ropes, unloaded preferably by crane and rolled
down carefully on suitable ramps. While transferring cable form one drum to
another, the barrel of the new drum shall have diameter not less than the original
drum

2.7 INSTALLATION
2.7.1 While shortest practicable route shall be preferred, cable runs shall follow fixed
development such as roads, footpaths etc. with proper offsets so that future maintenance
and identification are rendered easy.
2.7.2 Whenever cables are laid along well demarcated or established roads, the LV/MV cables
shall be laid further from the line than HV cables.
2.7.3 Cables of different voltages and also power and control cable shall be kept in different
trenches with adequate separation. Where available space is restricted, LV/MV cables
shall be laid above HV cables.
2.7.4 Where cables cross one another, the cables of higher voltage shall be laid at a lower level
than the cables of lower voltage.
2.7.5 Power and communication cables shall as far as possible, cross at right angles, where
power cables are laid in proximity to communication cables the horizontal and vertical
clearances shall not normally be less than 600 mm.
2.7.6 Cables shall be laid in the routes marked in the drawings. Where the route is not marked,
the contractor shall mark it out on the working drawings after deciding in consultation with
Engineer. Cables shall be laid in masonry trenches, directly on walls / ceiling, inside shafts
/ cable trays, directly buried in ground or in pipes/ducts as elaborated below. Cables of
different voltages and also power and control cables shall be laid, in different trenches with
adequate separation. Wherever available space is restricted such that this requirement
cannot be met, medium voltage cables shall be laid above HT cables as approved.
2.7.7 Cables shall be so laid that the maximum bending radius is 12 times the overall diameter
of the cable for medium voltage cables and 15 times the overall diameter for 11 kV cables
or in accordance with the manufacturer's recommendations whichever is higher.
2.7.8 In the case of cables buried directly in ground, the cable route shall be parallel or
perpendicular to roadways, walls etc. Cables shall be laid in an excavated, graded trench,
over a sand or soft earth cushion to provide protection against abrasion. Cables shall be
protected with brick or cement tiles as shown on Drawings. Width of excavated trenches
shall be as per code of practice and drawings.
2.7.9 The general arrangement of cable laying shall be as per drawings. All cables shall be full
runs from panel to panel without any joints or splices.

2.8 CABLES LAID IN MASONRY TRENCHES

2.8.1 Wherever so specified, cables shall be laid in indoor/outdoor masonry/RCC trenches with
chequered plate/RCC covers to be provided by contractor. Cables shall be laid on GI
supports of approved design grouted in trench walls at intervals not exceeding 600 mm. If
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required, cables shall be arranged in tier formation inside the trench. Cables shall be
dressed properly so that the clear spacing between the cables shall not be less than the
diameter of the cable. Suitable clamps, hooks and saddles shall be used for securing the
cables in position. Complete details of this support work shall be shown in working
drawings to be prepared by the Contractors and submitted for approval of Engineer before
execution. Works shall be carried out only as per approved working drawing. Wherever so
specified, trenches shall be filled with fine sand.

2.9 CABLE LAID ON TRAYS/WALLS

2.9.1 Where numbers of cables are run, necessary perforated cable trays shall be provided
wherever shown. Ladder cable trays shall be galvanized MS as specified in the BOQ.

2.9.2 After laying and securing the cables in a cut-out, suitable water tight sealant shall be
applied as per requirement to prevent any ingress of water.

2.9.3 Cables shall be secured in position and dressed properly by means of suitable clamps,
hooks, saddles etc. Clamping of cables shall be at minimum intervals as below:
Type of Cables Size Clamping by Fixing intervals
MV Up to and Purpose made, 300 mm
including 25- approved GI
sqmm clamp minimum 2
mm thick 19 mm
wide
MV&HV 35-sqmm to 120- Clamps 3 mm 600 mm
sqmm thick 25 mm -
wide
MV&HV 150-sqmm and Clamps 3 mm 600 mm
above thick 40 mm -
Wide
Note: The fixing intervals specified apply to straight runs. In the case of bends,
additional clamping shall be provided at 30 cm from the centre of the bends on both
sides.

2.10 BURIED DIRECTLY IN GROUND

2.10.1 Cables should be so laid that they will not interfere with underground structures.

2.10.2 All water pipes, sewage lines or other structures which become exposed by excavation
shall be properly supported and protected from injury until the filling has been rammed
solidly in places under and around them. Cables shall be laid and protected at such
locations.

2.10.3 Any telephone or other cables coming in the way are to be properly shielded as
directed by Engineer.

2.10.4 Surface of the ground shall be made good so as to conform in all respects to the
surrounding ground to the satisfaction of Engineer.

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2.11 ROUTING OF THE CABLE RUNS

2.11.1 Before cable laying work is undertaken, the route of the cables shall be decided in
consultation with Engineer.
2.11.2 While shortest practicable route shall be preferred, cable runs shall follow fixed
development such as roads, footpaths etc. with proper offsets so that future maintenance
and identification are rendered easy.
2.11.3 Whenever cables are laid along well demarcated or established roads, the LV/MV cables
shall be laid further from the kerb line than HV cables.
2.11.4 Cables of different voltages and also power and control cables shall be kept in different
trenches with adequate separation. Where available space is restricted, LV/MV cables
shall be laid above HV cables.
2.11.5 Where cables cross one another, the cables of higher voltage shall be laid at a lower level
than the cables of lower voltage.
2.11.6 Power and communication cables shall as far as possible cross at right angles. Where
power cables are laid in proximity to communications cables the horizontal and vertical
clearances shall not normally be less than 600 mm

2.12 WIDTH OF TRENCH

2.12.1 The width of trench shall be determined on the following basis:

a) The minimum width of masonry trench for laying single cables shall be
350 mm or as specified in BOQ.
b) Where more than one cable is to be laid in the same trench in horizontal
formation, the width of trench shall be increased such that the inter-axial
spacing between the cables except where otherwise specified shall be at
least one cable diameter.

2.12.2 There shall be a clearance of at least 150 mm between axis of the end cables and the
sides of the trench.
2.12.3 The space between multiple cables laid in same trench shall be laid as prescribed by the
manufacturer of the cable or as recommended in standards.

2.13 DEPTH OF TRENCH

2.13.1 Where cables are laid in single tier formation, in ground the total depth of the trench shall
not-be less than 750 mm for cables up to 1.1 kV and 1250 mm for cables above 1.1 kV.
When more than one tier of cables is unavoidable and vertical formation of laying is
adopted, the depth of trench shall be increased by 300 mm for each additional tier to be
formed.

2.14 EXCAVATION OF TRENCHES IN GROUND

2.14.1 The trenches shall be excavated in reasonably straight lines. Wherever .there is a change
in direction, suitable curvature of 12 times the overall diameter of the largest MV cable and
15 times the overall diameter for 11·kV HT cable shall be provided. Where gradients and
changes in depths are unavoidable, these shall be gradual. Excavation should be done by
any suitable manual or mechanical means. Excavated soil shall be stacked firmly by the
side of the trench such that it may not fall back into the trench.
2.14.2 Adequate precautions shall be taken not to damage any existing cables, pipes or other
such installations during excavation. Wherever bricks, tiles or protected covers or bare
cables are encountered, further excavation shall not be carried out without the approval of
the Engineer. The Contractor shall use a cable detector along the route of excavation and
identify existing live cables along the route and exercise caution during excavation.

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2.14.3 Existing property exposed during trenching shall be temporarily supported or propped
adequately as directed by the Engineer. The trenching in such cases shall be done in
short lengths, necessary pipes laid for passing cables therein and the trench refilled as
required. If there is any danger of a trench collapsing or endangering adjacent
structures, the sides shall be well shored up with timbering and / or sheathing as the
excavation proceeds. Where necessary these may even be left in place when
backfilling the trench.

2.14.4 Excavation through lawns shall be done in consultation with the Engineer. Bottom of
the trench shall be level and free from stone, brick, etc. The trench shall be provided
with a layer of dean dry sand cushion of not less than 80 mm in depth before laying of
cables.

2.15 LAYING OF CABLE IN TRENCH IN GROUND

2.15.1 The cable drum shall be properly mounted on jacks or on a cable wheel at a suitable
location. It should be ensured that the spindle, jack etc. are strong enough to carry the
weight of the drum without failure and that the spindle is horizontal in the bearing so as
to prevent the drum creeping to one side while rotating.

2.15.2 The cable shall be pulled over rollers in the trench steadily and uniformly without jerks or
strains. The entire cable length shall, as far as possible, be laid in one stretch. However
when this is not possible the remainder of the cable shall be removed by flaking i.e.
making one long loop in the reverse direction.

2.15.3 After the cable is uncoiled and laid over the rollers, the cable shall be lifted slightly over
the rollers beginning from one end by helpers standing about 10 meters apart and drawn
straight. The cable should then be taken off the rollers by additional helpers lifting the
cables and then laid in the trench in a reasonably straight line.

2.15.4 For short runs and cable sizes up to 50-sqmm 1.1 kV grade, the alternative method of
direct handling can be adopted with the prior approval of the Engineer. If two or more
cables are laid in the same trench, care should be taken to preserve relative position. All
the cables following the same routes shalt be laid in the same trench. Cables shall not
cross each other as far as possible. When the cable has been properly straightened, the
cores shall be tested for continuity and insulation resistance. The cable shalt be
measured thereafter.

2.15.5 Suitable moisture sealing compound tape shall be used for sealing of the ends of cables
laid in the trench. All the cables remaining in drums after laying shall be sealed in a dust
and moisture proof manner.

2.15.6 The trench shall be provided with a layer of clean dry sand cushion of not less than 80
mm in depth before laying of cables. Cable laid in trenches in a single tier formation shall
have a covering of clean dry sand of not less than 170 mm above the base cushion of
sand before the protective cover is laid. If additional tiers are formed each of the
subsequent tiers also shall have a sand cushion of 300 mm and the top most cable shall
have a final sand covering not less than 170 mm before the protective cover is laid. A
final protection to cables shall be laid to provide warning to future excavators of the
presence of the cable and also to protect the cables against accidental mechanical
damage. Such protection shall be with second class bricks of not less than 225 mm x
100 mm x75 mm (normal standard size) laid breadth wise for the full length of the cable
to the satisfaction of the Engineer. Where more than one cable is to be laid in the same
trench this protective covering shall cover all the cables and project at least 50 mm over
the sides of the end cables. In addition bricks on edge shall be placed along the entire
run on either side of the cable run.

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2.15.7 The trenches shall then be back filled with excavated earth free from stones or other
sharp edged debris and shall be rammed and watered in successive layers not
exceeding 300 mm. Unless otherwise specified a crown of earth not less than 50 mm in
the center and tapering towards the side of the trench shall be left to allow for
subsidence. The crown of earth should however not exceed 100 mm so as not to be a
hazard to vehicular traffic.

2.15.8 Where road berms or lawns have been cut or kerbstones displaced the same shall be
repaired and made good to the satisfaction of the Engineer and all surplus earth and
rocks removed to places as specified.

2.16 ROUTE MARKERS

2.16.1 Route markers shall be provided along straight runs of the cables at locations approved
and generally at intervals not exceeding 25 meters. Markers shall also be provided to
identify change in the direction of the cable route and also for location of every
underground joint.

2.16.2 Route markers shall be made out of 100mm x 100mm x 5mm GI/aluminium plate welded
or bolted onto 35 mm x 35 mm x 6 mm angle iron 600 mm long duly painted with anti-
corrosive paint/ embossed. Such plate markers shall be mounted parallel to and 300.mm
or so away from the edge of the trench/pipe/duct, or as directed at site.

2.16.3 Plastic identification tags shall be provided at every 30m. Cables shall be identified at
end terminations indicating the feeder number and the Panel/Distribution board from
where it is being laid.

2.17 LAYING IN PIPES / CLOSED DUCTS

2.17.1 In locations such as road crossings, entry to buildings/ poles in paved areas etc. cables
shall be laid in pipes or closed ducts. Spun reinforced concrete/GI pipes or UPVC ducts
shall be used for such purposes and the pipe shall not be less than 100 mm in diameter
for a single cable and not less than 150 mm for more than one cable. These pipes shall
be laid directly in ground without any special bed. Unless otherwise specified the top
surface of pipes shall be at a minimum depth of 1000 mm from the ground level when
laid under roads, pavements etc.

2.17.2 The pipes for road crossings shall preferably be on the skew to reduce the angle of bend
as the cable enters and leaves the crossing. Pipes shall be continuous and clear of
debris or concrete before cable is drawn. Sharp edges at ends shall be smoothened to
prevent injury to cable insulation or sheathing.

2.18 LAYING OF CABLES IN FLOORS

2.18.1 Laying of cables directly in floors shall be avoided and GI pipes of adequate size shall
be used wherever necessary. However if the cables have to be laid direct in the floor
specific written approval ofshall be obtained and the Contractor shall cut chases, lay
the cables and make good the chases to original finish.

2.19 CABLE ENTRY INTO BUILDINGS

2.19.1 Cable entry into buildings shall be made through RCC pipes recessed in the floor. RCC
Hume pipes shall be provided well in advance for service cable entries. The pipe shall
be filled with sand and sealed at both ends with bitumen mastic to avoid entry of water.
Suitable size manholes shall be provided wherever required to facilitate drawing of
cables as per requirements. The Contractor shall submit a written request to Engineer
for inspection of following works for cabling:
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a) On excavation and provision of sand bed at bottom of trench

b) On laying of cables, and provision of sand bed over the cables
c) On provision of protective cover & back filling
d) On commencing termination of cable

2.19.2 These requests shall be serially numbered and shall be in an approved format out of
one or two formats to be submitted by the Contractor.

2.20 CABLE JOINTS

2.20.1 Cable joints shall be resorted to and permitted only if length of cable route is more than
standard cable drum length. Cable joints shall not be permitted in any other
circumstances. Wherever unavoidable these joints shall be made with specific approval
of Engineer, and shall from a part of cable run /laying. Cable Jointing shall be done
only of approved make cable joints. No extra cost shall be paid for jointing of cables.

2.21 CABLE LOOPS

2.21.1 At the time of the installation approximately 3 meters of surplus cable shall be left .as
below or as directed by Engineer-In-charge

a) at each end of the cable

b) on each side of underground straight through/tee/termination joints
c) at entries to buildings

2.21.2 This cable shall be left in the form of a loop. Wherever long runs of cable length are
installed cable loops shall be left at suitable intervals as specified by the
architect/clients.

2.22 TERMINATION / JOINTING OF CABLES

2.22.1 All cable terminations should be nut-bolt type; irrespective of the cable size and shall
have tinned copper compression lugs. The end terminations shall be insulated with a
minimum of six half-lapped layers of PVC tape. Cable armouring shall be bonded at
both ends.

2.22.2 Soldered jointing/ termination shall be totally avoided. Solder-less terminations by using
crimping tools, suitable lugs and double compression brass glands shall be used. In the
case of aluminium conductors, it is to be ensured that the conductor oxidation is
cleaned by means of emery paper and then a thin coat of tin is applied before
termination.

2.23 MATERIAL AND MANUFACTURING

2.23.1 The material used in the manufacturing shall not deviate from the one used in the
manufacturing of sample piece of which the type test results submitted for vendor
approval.
2.23.2 The routine and acceptance test result shall not vary widely as compared to the type test
results.
2.23.3 The manufacturers shall be able to demonstrate to the inspecting official the sourcing of
material and process as per the system described in ISO document for continuous quality
control.

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2.24 TESTING
2.24.1 Type test results as per the relevant standards mentioned herewith and not more
than one year old shall be submitted along with the vendor approval request. In case the
engineerso desires, a repeat of the type test from the accredited lab may be asked for.
2.24.2 FRLSH, PVC insulated Cables shall be subjected to type tests and acceptance
test as per IS: 1554 Part-1 1988 carried out in accordance with appropriate parts of IS:
10810.
2.24.3 FRLSH, XLPE cables shall be tested as per IS: 7098 Part-1 and IS: 10810.
2.24.4 Acceptance Test for XLPE and PVC shall be carried as per the proforma given at
annexure A1 and A2 respectively of Paragraph 2.37 of this specification.The prescribed
values as per relevant IS and type results as available on record shall preferably filled by
inspecting official before the inspection.
2.24.5 Test at Siteafter receipt and installation shall be carried as per the proforma
given at annexure B.All type, acceptance and site test readings records shall form part of
the completion documentation.Underground Cable routes shall be got verified with the
help of cable detector.

2.25 CABLE TRAYS

2.25.1 Cable trays of sizes as per BOQ and drawings shall be of doubled bend channel
design unless otherwise stated.Cable trays shall be fabricated from minimum 2 mm thick
perforated hot dip galvanised sheet steel and shall be complete with tees, elbows, risers,
and all necessary hardware. Cable trays shall be hot dipped galvanized as specified.
Cable trays shall be erected in perfect level.
2.25.2 Widths of cable trays, thickness of steel, flanges of trays, and bends or tees,
shall be nominally as follows:
Width of Tray (mm) Thickness of Steel (mm) Flanges of Tray (mm)
300 & below 2 50/40
300-450 2 50/40
450-900 2 50/40
1000 2 50/40

2.25.3 Trays shall not have sharp edges, burrs or projections injurious to cable
insulation. Trays shall include fittings such as bends, risers etc. for changes in direction
and elevation. Each run of cable tray shall be completed before laying of cables. Cable
trays shall be exposed and accessible. All bends & tees should be factory made.
2.25.4 Trays shall be supported adequately at minimum 1 m distance from the building
structure by means of painted / galvanized (as specified) MS structural members secured
to the structure by dash fasteners or by grouting. This support should be capable of
withstanding the weight equivalent of 3m length of the cables that can be laid in the trays.
At turns the support has to be double and at both ends of the bend. The entire cable tray
system shall be rigid. Cost of support arrangement shall be included in the rates quoted
for supply and installation of trays. Complete details of this support arrangement shall be
shown in working drawings to be prepared by the Contractors and submitted for approval
of Employer's representative before execution. Works shall be carried out only as per
approved working drawing. Minimum support should be 40 X 40 X 5mm GI angle. Anchor
fasteners of suitable size to be provided.

2.25.5 All bends and tees shall be used as factory made to the extent possible.In case of any
deviation; the same shall get approval by the engineer before use.

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2.25.6 Cable tray shall be required to be marked for identification as approved by

engineer/employers representative.

2.26 CABLE TRAY EARTHING

2.26.1 Each Cable Tray joint shall have tinned copper/GI bond bolted to each adjacent tray to
ensure electrical continuity.

2.27 Termination
2.27.1 The terminating kits shall be suitable for termination of the cables on an indoor switchgear
or equipment. These shall be of proven design and shall be type-tested as per relevant
Indian or International Standards. Type test certificates shall be submitted. The cable and
wire terminations shall avoid any possibility of loose joint and wire snapping. Cable
conductor termination shall be by means of a heavy-duty solder less cable lug for
terminating aluminium cable to copper busbar or vice-versa. The lug shall be of high
conductivity copper, electro- tinned and applied to the conductor by means of a hydraulic
crimping tool. All such crimping should meet the requirements of BS 4579.
2.27.2 The cable sheath shall be clasped by means of a gland of compression type based on BS
6121 or equivalent Indian standard with a compression washer, which will hold the cable
sheath securely. A cable shroud shall be fitted to cover the body of the compression
gland.
2.27.3 All wires shall be terminated with an Approved type of connector.

2.28 CABLE GLANDS AND ACCESSORIES

2.28.1 Non-Armoured Cables

2.28.2.1 All cable glands and accessories shall be approved to BS 6121 or

equivalent Indian standard.

2.28.2.2 The cable glands shall have a watertight seal when fitted to a cable.

2.28.2.3 Each cable gland shall be supplied with a brass gland locknut and a flame
retardant low smoke halogen free outer gland shroud. The shroud shall
totally enclose the gland body and form an effective seal against the
cable sheathing.

2.28.2.4 The Gland shall be flame proof.

2.28.3 Armoured Cables

2.28.3.1 All cable glands and accessories shall be approved to BS 6121 or

equivalent Indian standard.

2.28.3.2 The cable glands shall have a watertight seal when fitted to a cable.

2.28.3.3 Cables shall be terminated in a gland fitted with an armour clamp and an earth tag. The
gland body shall be provided with an internal conical seal to receive the armour
clamping cone, and a clamp nut, which shall secure the armour-clamping cone, and
conical armour seal. The spigot of the gland body shall be threaded to suit standard
conduit accessories. A flame retardant low smoke halogen free shroud shall be fitted to
cover the gland body.

2.29 CABLE TIES

2.29.2 Cable ties shall be made from corrosion resistant, flame retardant and ultra violet
stabilised materials. At locations where cables are installed above tracks or in areas
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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

subjected to significant and constant vibration, cable ties shall be of metal construction
type and coated with a corrosion resistant, low smoke halogen free and flame retardant
insulation material.

2.30 CABLE JOINTS

2.30.1 The straight through jointing kits shall be suitable not only for conditions of high
humidity encountered in Metro sub-way, but also for underground buried installation
with uncontrolled back-fill and possibility of flooding by water. These shall be of proven
design and shall be type-tested asper relevant Indian or International standards. Type
test certificates shall be submitted.

2.30.2 The jointing kits shall match the cable specifications. Joints shall not be permitted in the
fire survival cables in case the joint does not meet the fire survival conditions.

2.30.3 Every connection at a cable joint shall be mechanically and electrically sound, be
protectedagainst mechanical damage and any vibration, shall not impose mechanical
stress on the fixings of the connection and shall not cause any mechanical damage to
the cable conductor.

2.30.4 The appropriate tools specified by the joint manufacturer shall be used when
jointingcables.

2.30.5 The outer casing/outer sheath of the cable joint shall be fabricated from a low smoke
halogen free material.

2.30.6 No cable joints shall be allowed without the prior Approval of the Engineer / Engineer.
Alljoints, accessories and cable joint locations shall be submitted to the Engineer for
Approval prior to any jointing of cables. All cable jointing shall be performed by a
qualified jointer andpreferably by the manufacturer of the jointing kits.

2.31 CABLE LOOPS

2.31.1 At the time of the installation approximately 3 meters of surplus cable shall be left as
below or as directed by Employer's representative or Engineer-in-charge.

a) At each end of the cable

b) On each side of underground straight through/tee/termination joints.
c) At entries to buildings

2.31.2 This cable shall be left in the form of a loop. Wherever long runs of cable length are
installed cable loops shall be left at suitable intervals as specified by the
architect/clients.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

2.32 CABLE IDENTIFICATION

2.32.1 Identification strips/tags of metal or plastic should be attached to the cable, particularly if
several are laid in parallel 8 to 10 m apart .Identification tags should also be attached at
every point into the buildings and at the cable end termination.
2.32.2 Cable identification shall be assembled from elliptical profiled low smoke halogen
freemarkers, carrier strip and cable ties.
2.32.3 Every single core cable and every core of a multi-core cable shall be provided
withidentification at its terminations in the form of sleeves or ferrules of appropriate
colours or as specified for signalling cables.

2.33 Technical literatures and test certificates to be furnished by Contractor before execution of
work at site.
2.33.1 Contractor shall furnish following minimum technical particulars:

a) Name of manufacturer
b) Standard governing specification
c) Manufacturer’s type designation
d) Rated system voltage in kV
e) Rated continuous current in amps
f) Max. permissible current in amps at 400C
g) Short circuit current for 1 sec. in kA
h) Minimum permissible bending radius in mm
i) Overall diameter of cable/wire in mm
j) Max. permissible length of cable in drum
k) Weight of cable and drum including cable
l) Resistance of Conductor/100m length
m) High voltage with-stand test result in kV
n) Insulation resistance
o) Thickness and material of
I. Insulation
II. Inner sheath
III. Armouring
IV. Outer Sheath.
p) Compound used for FRLS properties
q) Chemicals used for protection against rodent and termite attack.
r) Shelf life of cable accessories for the ambient temperature specified.
s) Catalogues and brochures giving technical and physical details of the cable such
as current rating, de-rating factors, etc.
t) Type test certificates and special test results for cables offered.
u) Shelf life of cable accessories for the ambient temperature specified.
v) Type test certificates for cable & accessories.
w) De-rating factor with the proposed method of cable laying.

2.34 Material and Manufacturing

2.34.1 The material used in the manufacturing shall not deviate from the one used in the
manufacturing of sample piece of which the type test results submitted for vendor
approval.
2.34.2 The routine and acceptance test result shall not vary widely as compared to the type test
results.
2.34.3 The manufacturers shall be able to demonstrate to the inspecting official the sourcing of
material and process as per the system described in ISO document for continuous quality
control.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

ANNEXURE
ANNEXURE-A1: Acceptance test report for XLPE cables:

Acceptance Test Report

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 7098 Pt-1 & Data Sheet Specified Values Type Test Values Observed Values
Type test Values shall
(Specified Values shall
be the same as
Test Descriptions Unit be as per IS 7098 Pt-1 DRUM No.:
submitted at the time
S. and the Cable selected)
of Vendor approval
No.
Core Idenditification Red, Yellow, Blue & Black Red, Yellow, Blue & Black Red Yellow Blue Black

Colour of Inner Sheath & Outer Sheath Black/Black Black/Black Black/Black

Dimentional Check -
i) Thickness (Main) mm
(Neutral) mm
1 ii) Thickness of Inner Sheath mm

iii) Thickness of Outer Sheath mm

iv) Overall Dia of Cable mm

Tests on Conductor (As per IS 8130) -
No. of Wires in Conductor (Class-
i) -
2)(M/N)
o
Conductore Resistance at 20 C
ii) Ohm/Km
2 (M/N)

iii) Tensile strength (Before ageing) N/mm2

iv) Wraping Test (Before ageing) -
v) Annealing Test (Before stranding) %
Test on Insulation (As per IS-7098-1) -
i) a) Volume resistivity (at 27 oC) Ohm cm
b) Volume resistivity (at 90 oC) Ohm cm

ii) a) Tensile strength (Before ageing) N/mm2

3 b) Elongation at break (Before
%
ageing)
o
Hot set test (at 200+ 3 C for 15
iii) -
min.)
a) Elongation under load %
b) Permanent Elongation %
Test on Armouring (as per IS- 3875) -
4
i) Strip Dimension mm
Test on Outer Sheath (as per IS- 5831) -

i) a) Tensile strength (Before ageing) N/mm2

5
b) Elongation at break (Before
%
ageing)
Test on Complete Cable -
6 High Voltage Test ( for each
i) -
connection)
Visual Inspection
i) Embossing over outer Sheath
7
Sequential Length Marking at every
ii)
meters

Date and Signature:

(Manufacturer) (Contractor) (DMRC Inspecting officer)

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

ANNEXURE A2: Acceptance test report for PVC cables:

Acceptance Test Report

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 1554 Pt-1 & Data Sheet Specified Values Type Test Values Observed Values
(Specified Values shall Type test Values shall
be as per IS 1554 Pt-1 be the same as
Test Descriptions Unit DRUM No.:
and the Cable submitted at the time
S.
selected) of Vendor approval
No.
Core Idenditification Red, Yellow, Blue & Black Red, Yellow, Blue & Black Red Yellow Blue Black

Colour of Inner Sheath & Outer Sheath Black/Black Black/Black Black/Black

Dimentional Check -
i) Thickness (Main) mm
(Neutral) mm
1 ii) Thickness of Inner Sheath mm
iii) Thickness of Outer Sheath mm

iv) Overall Dia of Cable mm

Tests on Conductor (As per IS 8130) -
No. of Wires in Conductor (Class-
i) -
2)(M/N)
o
Conductore Resistance at 20 C Ohm/K
ii)
2 (M/N) m

iii) Tensile strength (Before ageing) N/mm2

iv) Wraping Test (Before ageing) -
v) Annealing Test (Before stranding) %
Test on Insulation (As per IS-1554-1) -
i) a) Volume resistivity (at 27 oC) Ohm cm
b) Volume resistivity (at 90 oC) Ohm cm
ii) a) Tensile strength (Before ageing) N/mm2
3 b) Elongation at break (Before
%
ageing)

iii) Hot set test (at 200+ 3 oC for 15 min.) -

a) Elongation under load %

b) Permanent Elongation %
Test on Armouring (as per IS- 3875) -
4
i) Strip Dimension mm
Test on Outer Sheath (as per IS- 5831) -
i) a) Tensile strength (Before ageing) N/mm2
5
b) Elongation at break (Before
%
ageing)
Test on Complete Cable -
6 High Voltage Test ( for each
i) -
connection)
Visual Inspection
i) Embossing over outer Sheath
7
Sequential Length Marking at every
ii)
meters

Date and Signature:

(Manufacturer) (Contractor) (DMRC Inspecting officer)

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

ANNEXURE C

Cable Installation Checklist

1 Insulation Resistance(500 V)
(in MΩ)
R-Y
Y-B
B-R
R-N
Y-N
B-N
R-PE
Y-PE
B-PE
N-PE
2 Continuity
Yes/No
R
Y
B
N
PE
3 Visual Inspection
Yes/No or
Remarks

a. No cracks and physical damage observed on cable

b. Properhook, clamp and saddle provided as per spec.

c. Bending radius as per specification and provision of additional

support at bends

d. Proper offsets and loop provided for future maintenance

e. Proper distance maintained between the control and LV cables

f. Proper Phase sequence

g. Armour of the cable earthed properly at both ends

h. Route Marker provided as per specification

i. Distance between the LV/MV and HV cables, if exists together

j. Identification tags provided as per specification

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

k. Cable termination has been completed as per the specification

l. Underground cable routes verified with the help of cable detector

Verified By(DMRC)
Checked
By(Contractor)

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

3 CONDUIT WIRING& ASSOCIATED ACCESSORIES

3.1 SCOPE

3.1.1 The scope of the specification covers supply of wires/conduits/sockets etc, installation,
testing and commissioning of the wire in conduit with related works, earthing of
distribution/sub-distribution boards, plug sockets, Conduit Fittings,associated
accessories etc.

3.2 GOVERNING SPECIFICATIONS

3.2.1 Electrical wiring along with other related items shall conform to the latest standard or
harmonize as per the respective standard as given below or specified along with the
equipment in the specification.

3.2.2 In case of any conflict between specifications & the standards, the instructions/decision
of the Engineer' or Employer's authorized representative shall be binding.

3.3 STANDARDS

3.3.1 All equipment, components, materials and entire work shall be carried out in conformity
with applicable and relevant IS/BS/IEC Standards and Codes of Practice. In addition
relevant clause of Indian electricity act 2003 and Indian electricity rule1956 amended up
to date shall apply.

3.3.2 It is to be noted that updated and current standards shall be applicable irrespective of
dates mentioned along with standards in the tender documents

STANDARD DESCRIPTION
IS 694:2010 Polyvinyl chloride insulated sheathed and unsheathed cables
with rigid and flexible conductor for rated voltages up to and
including 450/750 V
IS 732:1989 Code of practice for electrical wiring installations (third
revision)
IS 2309:1989 Code of practice for protection of buildings and allied
structures against lightning (second revision)
IS 5831:1984 PVC insulation and sheath of electric cables (first revision)
IS 8130 Conductors for insulated electric cables and flexible cords
(second revision)

3.3.3 Codes and standards mean the latest. Where not specified otherwise the installation
shall generally follow the Indian standards/British Standards/IEC standards.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

3.4 ABBREVIATIONS

S. No. Abbreviation Description

1 PVC Poly-vinyl Chloride
2 XLPE Cross-Linked Polyethylene
3 FR Fire Retardant
4 FRLS/H Flame Retardant Low Smoke/Halogen
5 MS Mild Steel
6 GI Galvanised Iron

3.5 TECHNICAL REQUIREMENT

a) PVC Cables/Wires for rated voltages up to 450/750 V.

b) Electrical wires shall confirm to IS 694-2010. Generally there are three types of
electrical wires used in Metro system described at Sl No. 17, 19 and 20 of the
specification IS 694-2010.

Sl. No. 17 of specification IS 694-2010.: Single core non-sheathed cables with flexible
conductors for general purpose with maximum temperature of 70ºC, 450/750 V grade

 FR-PVC insulated (Type A vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
 Stranded Copper conductors class 5 as per IS 8130
 Size and purpose
 Light and Fans: 2.5 mm 2 multi-strand copper conductors or as specified in
BOQ
 6/16 socket and group wiring of lighting and fan circuits: 4/6 mm2 multi-
strand copper conductors or as specified in BOQ.

Sl. No. 19:Multi-core sheathed cables with flexible conductors for general purpose with maximum
temperature of 70ºC

 450/750 V grade
 FR-PVC insulated (Type A vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
 Stranded Copper conductors class 5 as per IS 8130
 Sheath shall be PVC of type ST1 with 70ºC PVC compound confirming to IS
5831 Table 2
 Size and purpose
 Size: 4 to 300 mm2 as specified in BOQ
 Number of Conductors: 1,2,3,4 and 5 core as specified in BOQ

Sl. No. 20: Multi-core sheathed cables with flexible conductors for general purpose with
maximum temperature of 70ºC

 450/750 V grade
 FR-PVC insulated (Type A vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
 Stranded Copper conductors class 5 as per IS 8130
 Sheath shall be PVC of type ST1 with 70ºC PVC compound confirming to IS
5831 Table 2
 Size and purpose
 Size: 0.5 to 2.5 mm2 as specified in BOQ
 Number of Conductors: 6 to 25 cores as specified in BOQ
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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

3.6 INSTALLATION REQUIREMENT

3.6.1 Wiring diagram

3.6.1.1 Before execution of works, the Contractor shall submit the copies of drawings which are
necessary to ensure correct supply of equipment, components, fittings and material
and to enable correct erection of the installation for satisfactory and trouble free
performance as detailed in the specifications. All drawings for approval shall be
prepared and submitted by the Contractor in standard size as approved by engineer
and multiples thereof as required by the engineer.

3.6.1.2 Revision and modification: Approval for any revision and / or modification in
job specifications shall be taken from the Engineer before implementation.

3.6.1.3 Change in construction drawings: Any change required during and / or after approval of
detailed construction drawings on account of functional requirements or in the interest
of efficient running of the system, keeping the basic parameters unchanged, shall be
carried out by the Contractor at no extra cost.

3.7 GUIDELINES FOR DRAWING OF WIRES

3.7.1 Bunching Of Wires

3.7.1.1 Wires carrying current shall be so bunched in conduits that the phase and neutral wires
are drawn into the same conduit. Wires originating from two different phases shall not
be run in the same conduit.
3.7.2 Termination / Jointing Of Wires

3.7.2.1 Wiring shall be carried out in looping system. Joints shall be made only at distribution
board terminals, switches/buzzers and at ceiling roses/connectors/lamp
holder’s terminals of lights/fans/socket outlets. No joints shall be made inside conduits
or junction/draw/inspection boxes.

3.7.2.2 Wiring conductors shall be continuous from outlet to outlet. Joints where unavoidable,
due to any specified reasons shall be brought to the notice of Engineer and made by
approved connectors only with his permission. Specific prior permission from Engineer
in writing shall be obtained before making such joint.

3.7.2.3 Insulation shall be shaved off for a length of 15 mm at the end of wire and it shall not be
removed by cutting it square or wringing. Strands of wires shall not be cut for
connecting terminals.

3.7.2.4 Conductors having nominal cross sectional area up to 10-sqmm shall be cage clamped.

3.7.2.5 Heat-shrinkable sleeves of good quality of relevant standard as approved by the

Engineer shall be used on thimble connections.

3.7.2.6 At all bolted terminals, current carrying or non-current carrying shall be provided with
adequately sized flat and spring washer as per the requirements. Brass nuts and bolts
shall be used for all current carrying connections.

3.7.2.7 The pressure applied to tighten terminal screws shall be just adequate, and should not
dent or damage or cut any strand of the conductor.

3.7.2.8 Switches controlling lights, fans, socket outlets etc. shall be connected to the phase wire
of circuits only.

3.7.2.9 Only certified and licensed wire-men shall be employed to do wiring / jointing work.
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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

3.7.2.10 Load Balancing - Balancing of circuits in three-phase installation shall be planned

before the commencement of wiring and shall be strictly adhered to. Distribution of
circuits in three phase installation shall be as per distribution chart indicated
in drawings.

3.7.2.11 Colour Code of Conductors· All wires shall be colour coded as follows:
PHASE COLOUR OF WIRE
R Red
Y Yellow
B Blue
N Black
Earth control, if any Green

3.8 PRECAUTIONS DURING DRAWING OF WIRES

3.8.1 The drawing of wires shall be executed with due regard to the following:
3.8.2 No wire shall be drawn into any conduit, until all work of any nature that may cause
damage to wires is completed. Care shall be taken in pulling the wires so that no damage
occurs to the insulation of the wire. Bushes shall be provided at conduit edges.
3.8.3 Before the wires are drawn, conduits shall be thoroughly cleaned of moisture, dust, dirt or
any other obstruction by forcing compressed air through the conduits if necessary.

3.9 POINT WIRING

3.9.1 System of wiring

3.9.1.1 Group wiring shall be used for the lighting circuits except for individual rooms and other
small cubicles where light points may be wired individually. Each group shall cater for a
load of approx. 800 watts and wiring shall be done by Loop in - Loop out at each fitting
as per drawing.

3.9.1.2 The wiring shall be carried out strictly as per IE Rules / Indian Standard Code of Practice
for electrical wiring installation IS: 732-1989. The wiring shall be done on distribution
system with distribution and sub-distribution boards located at convenient points.

3.9.1.3 Wires as specified aboveof nominal size 2.5-sqmm shall be used for wiring of single light
points, fans and 6 A plug sockets or as specified for group wiring of light points. For
6/16 A sockets, the minimum conductor size used shall be 4-sqmm nominal.
3.9.2 Parameters

3.9.2.1 Point wiring shall be carried out as per following parameters in concealed/surface
conduit system unless otherwise stipulated.

3.9.2.2 Only looping system of wiring shall be adopted through-out. All accessories shall
be flush type unless otherwise stated.

3.9.2.3 For estimation of load, following loads per point shall be assumed:

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1 Light points As per load of fixture

2 6 Amps socket outlet points 100 Watts
3 Fan points 60 Watts
4 Exhaust fan points 300 Watts or as specified
5 16 Amp socket outlet points 500 Watts

3.9.2.4 Light points, fan points and 6 amp socket outlet points may be wired on a
common circuit.Each circuit shall have not more than 800 Watts connected
load.However, In case of LED Points where load per point may be less, number of
points may be suitably increased. Wiring from DB to the first switch in each such circuit
is defined as circuit wiring.

3.9.2.5 Power circuits shall normally have maximum two 16-amps socket outlet
unless otherwise stated. Separate circuit shall be run for each geyser, kitchen
equipment, window air conditioners and similar appliances.

3.9.2.6 Point wiring rates shall include cleaning of dust; splashes of colour wash or paint from all
fixtures, fans, fittings, etc. at the time of taking over of the installation.
3.9.3 Inspection, checks and tests

3.9.3.1 Prototype tests on electrical wire shall be submitted by the vendor seeking approval.
Factory acceptance tests for wire shall be carried out by Contractor along with witness
by DMRC representative as per the proforma given at annexure A.

3.9.3.2 Installation test of conduit wiring shall be carried out by Contractor along with witness by
DMRC representative during the process of installation and completion of the
installation as per the proforma given at annexure B as stipulated in special conditions
of contract.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Annexure A:

Acceptance Test Report

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 694:2010 & Data Sheet Specified Values Type Test Values Observed Values
Test Descriptions Unit (Specified Values shall Type test Values DRUM/COIL No.:
be as per IS 694:2010 shall be the same as
and the Cable selected) submitted at the
S. No.
time of Vendor
Core Idenditification
Colour of Outer Sheath Black Black Black
1 Maximum size of Conductor mm
Conductor Resistance (ohms/km -
2
corrected at 20 oC)
Annealing Test (for Copper Wires After
3
stranding)
Thickness of Insulation mm
4

Thickness of Outer sheath mm

5

Overall dia of core mm

6

Test on Insulation (As per IS-5831-1984) -

Type of compound
i) a) Volume resistivity (at 27 oC) Ohm cm
7 b) Volume resistivity (at 90 oC) Ohm cm
ii) a) Tensile strength (Before ageing) N/mm2
b) Elongation at break (Before %
ageing)
Test on Outer Sheath (as per IS- 5831- -
1984)
Type of compound
8
i) a) Tensile strength (Before ageing) N/mm2
b) Elongation at break (Before %
ageing)
9 Routine High Voltage test at R. temp.
FR Test -
10 i) Oxygen Index Test
ii) Temperature Index Test -
11 Flammability test
i) As per IS 10810 (Pt 53)
ii) Time of burning after removal the
flame

Date and Signature:

(Manufacturer) (Contractor) (DMRC Inspecting officer)

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Annexure B:

S. NO. DESCRIPTION REMARKS

Checks to be done before Drawing of Wire in Conduits as per the Specification for
supply & installation of conduits, associated fittings & accessories Specification No.
DMES-E/0001/DMRC-E-E&M-CONDUIT-01
1 Steel wire of 1.6 sqmm size shall beleft in all conduit
runs to facilitate drawing of wires as per clause no. 3.9.1
2 Check for any mechanical stress on the conduit.
3 Check for use of approved quality metallic flexible
conduits at expansion joints of the building
4 Check allowance for running earthing wire as per clause
no. 3.9.1
5 Conduit should be kept within 300mm of floors and
ceiling when running parallel to them
6 Ensure conduit runs must not exceed 8 m or have more
than two right angle bends.
7 Check conduits from different Distribution Boards must
not be connected to same junction box
8 Check the water tightness of the Conduit system as per
the ‘Method Statement including Tests’ submitted by the
contractor.As per the specification of conduit.
9 Check the coupling used in conduit system, conduits
must be coupled using couplers or via boxes as per
clause no. 3.9.3
10 Check the joints and terminations of the conduits,
conduit-threads must not be exposed and if unavoidable
then must be treated as per section 4(b) of the
specification.
11 Check the conduit bends as per approval given by the
Engineer at site.
In Recessed Conduit and Outlet Boxes
12 Ensure minimum of 12mm of concrete must cover the
conduit and outlet box.
13 Ensure that the conduit must be tied to the reinforcement
with steel wire(dia 1.5 mm) at an interval of maximum 1
m.
14 Check the space between the concealed conduits
entering the draw-in box must be minimum 25mm
In Case Of Conduit Recessed In Brick
15 Ensure 10 mm space must be available between
conduits and depth must be sufficient so that minimum
thickness of plaster over conduit is 6 mm
16 Check the Heavy duty pressed steel clamps screwed to
MS flat strip saddled at maximum 600mm must be
provided where chase has been cut for conduiting
17 Ensure Galvanised Chicken wire mesh of 0.6 mm thick
with 10 to 15 mm aperture must be provided for full
length of the chase in the plaster
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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

18 Ensure that all boxes for accessories and draw/junction

boxes must have outer rim flushed in the finished
surface, in case of concealed conduits
In Case Of Surface Conduiting
19 Check for approved make spacer saddle at an interval
not exceeding 600 mm and 300 mm from the fittings.
20 Good quality of workmanship must be ensured in case of
surface conduiting
21 Check that the loop earthing wire must be connected to a
screwed earth stud inside outlet boxes to make an
effective contact with the metal body.
22 Ensure that all outlets and switch boxes shall be
provided with temporary covers and plugs before plaster
and concreting work to safeguard against filling up with
mortar/plaster etc.
23 Check entire conduit system including outlets and boxes
must be thoroughly cleaned after completion of erection
and before drawing of wires.
24 Check loop earthing is provided by means of insulated
stranded copper conductor wires of sizes as per BOQ
laid along with wiring inside the conduits for all wiring
outlets.
Checks to be done after Drawing of Wire in Conduits as per the Specification for
Conduit Wiring of Simulator building Specification
25 Check the phase and neutral must be drawn in the same
conduit.
26 Ensure two different phases must not run in same
conduit.
27 Check the wiring, no joint must be present in the
conduits or junction/draw/inspection boxes, except with
prior written approval from Engineer at site.
28 Check all bolted terminals, brass approved flat washer of
large area must be used.
29 Check that good quality heat shrinkable sleeves are
used at the terminations.
30 Check the switches controlling lights, fans, socket outlets
etc. must be connected to the phase wire of circuit only.
31 Ensure bushes must be provided at the conduit edges
and proper care must be taken so that no damage
occurs to the insulation of the wire.
32 Insulation resistance must be tested. This must not be
less than 50 divided by the number of points in the circuit
in mega ohms.(50/no. of circuits)
33 Check the earth continuity of various equipments
installed.
34 Measure current and voltage of all the lighting circuits at
the sub-distribution board with all the lamps switched on
to ensure that these are within design values, in case of

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3-phase the load must be balanced reasonably.

35 Measure the minimum and maximum illumination levels
after installation of all the lamps along with the supplier
of lamp/luminaries and shall and shall complywith the
designed value
36 Check the phase sequence to ensure correct phase
sequence.

*Note: The test for insulation resistance must be carried out when all the equipment are
disconnected from the circuit.

Date & Sign

(Contractor) (MMRDA
representative)

3.10 Supply and Installation of Rigid Steel Conduits, Associated Fittings and Accessories:

3.10.1 Conduit is a part of closed wiring system of circular or non- circular cross-section for
conductors and/or cables in electrical installations allowing to draw them in and/or to
replace them. However, in this document the word ‘conduit’ shall refer to circular cross-
section only. Conduits shall be sufficiently closed- jointed so that the conductors can
only be drawn in and not inserted laterally. The conduits shall be rigid Steel type.

3.10.2 Conduit Fittings referred to in this document is a device designed to join or terminate one
or more portions of a conduit installation which shall be of metal (Galvanized Steel) only.

3.10.3 Conduit Accessories are the parts other than fittings used in fixing steel conduits.The
specifications contained herein are applicable to Stimulator buildings, Depots, Staff
Quarters and office Complex etc.

3.11 GOVERNING SPECIFICATION FOR THE CONDUIT, ASSOCIATED FITTINGS AND

ACCESSORIES

3.11.1 The conduits, associated fittings and accessories shall satisfy the requirements given
below and shall also comply with standards mentioned particularly in the table below
unless otherwise stipulated in the specifications. The latest version of standards shall
be applicable.
STANDARD DESCRIPTION
Specification For Conduits For Electrical Installations: Part I IS: 9537 : Part I, 1980
General Requirements,
IS: 9537: Part II, 1981
Part II Rigid Steel Conduits

Specification For Accessories For Rigid Steel Conduits For IS: 3837 : 1976
Electrical Wiring
Conduit Fittings for Electrical Installations: Part1 General IS: 14768 Part-1, 2000
Requirements

Part 2: Metal Conduit Fittings

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IS: 14768 Part-2, 2003

Specification for Flexible Steel conduits for electrical wiring IS: 3480 : 1966
Code of practice for electrical wiring installations IS: 732 : 1989
National Electrical Code, 2011
National Building Code, 2005
Central Electricity Authority (Measures relating to Safety and
Electricity Supply) Regulations, 2010
Plugs And Socket-Outlets of Rated Voltage up to and IS: 1293 : 2005
Including 250 Volts And Rated Current up to and Including 16
Amperes — Specification
Switches for domestic and similar purposes IS: 3854 : 1997
General Requirements for Enclosures for Accessories for IS: 14772:2000
Household and Similar Fixed Electrical Installations –
Specification
Code of practice for electrical installation fire safety of IS: 1646: 1997
buildings
Recommendations on safety procedure and practices in IS: 5216 : 1982
Electrical works
Specification for Hot-dip Zinc coating on mild steel tube IS: 4736 : 1986

Methods For Determination of Mass of Zinc Coating on Zinc IS: 6745 : 1972
Coated Iron and Steel Articles
Plugs, Socket-Outlets and Couplers for Industrial Purposes, IS: 60309-2
Part 2: Dimensional Interchangeability Requirements for Pin
and Contact-Tube Accessories
Degrees of protection provided by Enclosures (IP Code) IS: 60529
Recommended Practice for hot-dip galvanizing of Iron and IS: 2629
Steel
Zinc Ingot- Specifications IS: 209
Hot Rolled Carbon Steel Sheet and Strip Specifications IS: 1079
Standard Test Method for Surface Burning Characteristics of ASTM E84
Building Materials
Standard Test Methods for Fire Tests of Building Construction ASTM E119
and Materials
Standard Test Method for Fire Tests of Penetration Fire stop ASTM E814
System
3.11.2 Note: The latest edition of the standards shall be used. Wherever Indian Standards are
not available, relevant latest British and/or IEC Standards shall be applicable.

3.12 ABBREVIATIONS

 IS- Indian Standard

 IEC- International Electrotechnical Commission
 ERW- Electric Resistance Welding
 GI- Galvanized Iron
 MS- Mild Steel
 NEC- National Electrical Code
 NBC- National Building Code
 ASTM- American Society for Testing and Materials

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Note: The term ‘Approved’ in this specification means that the approval of the Engineer-in-
Charge shall be taken.

3.13 REQUIREMENT
3.13.1 Rigid Galvanized Steel Conduits (IS: 9537, Part I & II)

3.13.1.1 These shall be galvanized steel with minimum wall thickness of 1.6mmup to 32mm
diameter and 2.0mm for sizes above 32mm diameter, electric resistance welded
(ERW), electric threaded type, with both ends screwed having perfectly circular tubing.
Conduits shall show no appreciable unevenness and shall be free from burrs, fins and
the like which may cause damage to cable insulation. These rough internal edges shall
be removed by means of a proper reamer. Conduits shall be precision welded and
shall be fabricated from tested steel strips of required thickness by electric resistance
welding. Welds shall be smooth and consistently of high quality to ensure crack proof
bending. The conduit shall be galvanized according to IS 4736-1986. All conduits used
in this work shall be marked according to IS: 9537 Part-2 and also with ISI certification
mark. Other requirements for the conduits shall be as per IS: 9537, Part-1 and Part-2.
3.13.2 Flexible Conduits (IS: 3480)

3.13.2.1 The usage shall be restricted to only those areas where it is not possible to use Rigid
Steel Conduits. All final connections especially to vibrating equipments shall be made
through flexible conduits. Flexible steel conduits shall be as per latest edition of IS:
3480. Where flexible steel conduit is employed, the length shall not exceed 2.5 metres
and shall be provided with an earth continuity conductor of copper size not less than
2.5mm².
3.13.3 Galvanized Steel Bends (IS: 14768)

3.13.3.1 Large right angle bends (as per IS: 14768 but more than 75mm radius) or non-right
angle bends (as per IS: 14768) in conduits runs shall be made by means of conduits
bending machines carefully so as not to cause any crack in the conduit. Small right
angle bends in conduits runs can be made by standard conduit accessories
(solid/inspection bends/elbows). Facilities such as draw-in boxes must be provided so
that cables are not drawn round more than two right-angle bends or their equivalent.
The radius of bends must not be less than the standard normal bend. Bends in multi
runs of conduits shall be parallel to each other and neat in appearance, maintaining the
same distance as between straight runs of conduits.
3.13.4 Standard Fittings & Accessories IS: 3837 & IS: 14768, Part-1 and Part-2.

3.13.4.1 Heavy Protection Class Galvanized (IS 4736 & IS 6745) standard conduit fittings and
accessories like standard/extra-deep circular boxes, looping in boxes, junction boxes,
solid / inspection elbows, solid/inspection tees, couplers, nipples, saddles, check nuts,
earth clips, bushes etc. shall be of superior quality and of approved makes. The covers
screwed with approved quality screws shall be used that can withstand hard use or
wear. Samples of all conduits fittings and accessories shall be got approved by
Engineer-in-Charge before use. Conduit fittings and Accessories shall be as per IS:
3837 and IS: 14768, Part-1 and Part-2.

3.13.4.2 Conduit boxes and covers shall have a minimum degree of protection as follows:

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Description Against Corrosion Enclosure Surface or

Concealed
Outside buildings Heavy Protection both inside IP 54 Surface
and outside

Plant rooms and Heavy Protection both inside IP 41 Surface

service ducts, Switch and outside
Rooms, Store Rooms,
Ceiling Voids
Below Ground Heavy Protection both inside IP 44 -
and outside
All other locations Heavy Protection both inside IP 41 Concealed
and outside

3.13.4.3 The contractor shall submit for approval the ‘Method Statement including Tests’ to
ensure above degree of ingress protection. In case no testing facility is available, the
contractor shall comply with this clause by submitting design and installation features.
3.13.5 Fabricated Fittings & Accessories

3.13.5.1 Wherever required, outlet/ junction boxes of required sizes shall be fabricated from
1.6mm thick MS sheets except ceiling fan outlet boxes which shall be fabricated from
minimum 3mm thick sheets. The outlet boxes shall be galvanized and of approved
quality, finish and manufacture. Suitable means of fixing connectors etc., if required,
shall be provided in the boxes. A screwed brass stud shall be provided in all boxes
except circular junction boxes as earthing terminal.
3.13.6 Outlet Boxes for Light Fittings

3.13.6.1 These shall be minimum 75mm x 75mm x 50mm deep and provided with required
number of threaded collars for conduit entry. For ceiling mounted fluorescent fittings,
the boxes shall be provided 300mm off center for a 1200mm fitting and 150mm off
center for a 600mm fitting so that the wiring is taken directly to the down rod. 3mm thick
Perspex/hylam sheet cover of matching color shall be provided.
3.13.7 Outlet Boxes for Ceiling Fans

3.13.7.1 Outlet boxes for ceiling fans shall be fabricated from minimum 3mm thick MS sheet
steel and galvanized. The boxes shall be hexagonal in shape of minimum 100 mm
depth and 60mm sides. Each box shall be provided with a recessed fan hook in the
form of one 'u' shaped 15 mm dia rod welded to the box and securely tied to the top
reinforcement of the concrete slab for a length of minimum 150 mm on either side.
3mm thick Perspex/hylam sheet cover of matching colour shall be provided.
3.13.8 Boxes for Modular Wiring Accessories

3.13.8.1 Boxes for housing modular wiring accessories (switches, switched socket outlets,
telephone/computer / TV outlets, bell pushes, electronic fan regulators etc.) shall be
fabricated from minimum 1.6mm thick MS sheets provided with rust inhibiting
galvanization. The MS boxes shall be suitable for a grid plate being fixed over it for
mounting wiring accessories leaving ample space at the back and on the sides for
accommodating wiring conductors, MS boxes shall be provided with a brass earth
terminal. The MS boxes shall have knockout holes for conduit entry which shall be
secured in position by check nuts and provided with bushes.

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3.13.8.2 In case the number of switches in one box is not tallying with that available in standard
manufacturer range, the box accommodating the next higher number of switches shall
be provided without any extra cost.
3.13.9 Wiring Capacity of Conduits

3.13.9.1 Conduits shall be of ample sectional area to facilitate simultaneous drawing of wires
and permit future provision also. Total cross section of wires measured overall shall not
normally be more than half the area of the conduit. No cables installed in conduits shall
be laced.Maximum number of wires which could be drawn in various sizes of conduits
shall be as given in table below:

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N
Note: The above table shows the maximum capacity of conduits for a simultaneous
drawing in of cables as per DMRC’s requirements.

a) The columns headed ‘S’ apply to runs of conduits which have distance not
exceeding 4.25 m between draw in boxes and which do not deflect from the
straight by an angle of more than 15 degrees. The columns headed ‘B’ apply to
runs of conduit, which deflect from the straight by an angle of more than 15
degrees.
b) Conduit sizes are the nominal external diameters.

3.13.10 Modular Cover Plated Mounted Wiring Accessories

3.13.10.1 Switches

All 6 A, 16 A and 20A switches shall be of the modular enclosed type flush mounted
250 volt AC of the best quality and standard approved by Engineer-in- Charge. The
housing of switches shall be made from high impact resistant and flame retarding
plastic material. The switch controlling the light point shall be connected on to the
phase wire of the circuit. Lighting switches used on AC supplies shall be of “AC only”
type and not de-rated when used with fluorescent or inductive loads. Lighting
switches used on DC supplies shall be of “double-pole” quick make-and-break type,
with pillar type terminals and earthing straps. Every switch controlling an appliance
shall be labeled with the name of the appliance it controls and shall be fitted with an
indicating lamp. The switch shall govern to 250 V grade as per IS 3854:1977
Amendment No. 6, Aug 2011 and IS 1293 respectively. Brands namely Crabtree, MK
Electric, CPL-obsession, Legrand, Schneider, SSK, ABB shall be used.

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3.13.10.2 Molded Cover Plates

Switches, receptacles and telephone system outlets in wall shall be provided with
molded cover plates of shape, size and colour approved by the Engineer- in- Charge
made from high impact resistant, flame retarding and ultra violet stabilized
engineering plastic material, and secured to the box with counter sunk round head
chromium plated brass screws. Where two or more switches are installed together,
they shall be provided with one common switch cover plate as described above with
notches to accommodate all switches either in one, two or three rows.

One and two gang switch cover plate, telephone outlet cover plate, 6 A and 16 A
switched / unswitched plates, shall have the same shape and size. Three and four
gang switch cover plates shall have the same shape and size. Six and eight gang
switch cover plates shall have the same shape and size. Nine and twelve gang switch
cover plates shall have the same shape and size. Wherever five switches, seven
switches, ten switches and eleven switches are to be fixed the next higher sizes of
gang switch cover plate to be used and openings shall be provided with blank-off
covers at no extra cost.

3.13.10.3 Wall Socket Outlets

All 6/16 A wall sockets outlets unless otherwise mentioned on the drawings shall be
switched, with round pins and fitted with automatic linear safety shutters to ensure
safety from prying fingers. Unswitched 6/16 A wall socket outlets where called for in
the drawings shall be of three pin type.

The socket outlets shall be made from high impact resistant, flame retarding and ultra
violet stabilized engineering plastic material. Socket outlets mounted externally or in
damp areas shall be weatherproof and shall have a degree of protection of IP54.

The switch and sockets shall be located in the same plate. The plates for 6A switched
/ unswitched plugs and telephone outlets shall be of the same size and shape. All the
switched and unswitched outlets shall be of the best standard. Mounting boxes shall
be galvanized steel. The switch controlling the socket outlet shall be on the phase
wire of the circuit. An earth wire shall be provided along the cables feeding socket
outlets for electrical appliances. The earth wire shall be connected to the earthing
terminal screw inside the box. The earth terminal of the socket shall be connected to
the earth terminal provided inside the box.

3.13.10.4 Industrial Socket Outlets

Industrial plugs, connectors, socket outlets and appliance inlets shall be provided to
meet IS 60309-2. Heavy- duty three phase socket outlets shall be 32A, complying with
IS 60309-2. For interior use such as plant room unit shall be rated to IP44. Externally
or in wet environments such as Tunnel and Undercroft level the protection shall be
IP66.

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3.14 CONDUIT INSTALLATION (IS: 732 AND RELEVANT CLAUSES OF NEC, 2011)
3.14.1 System

3.14.1.1 The whole conduit system shall be installed to comply fully with relevant provision in
Indian Standard Specifications, National Electrical Code, 2011. Conduits shall be laid
either recessed in walls and ceilings or on surface on walls and ceilings or partly
recessed and partly on surface, as required. Same rate shall apply for recessed and
surface conduiting in this contract. Steel wire of 1.6 mm2 size to serve as a fish wire
shall be left in all conduit runs to facilitate drawing of wires after completion of
conduiting. No conduit shall be under mechanical stress. When crossing through
expansion joints in building, the conduit sections across the joint shall be through
approved quality metallic flexible conduits (as per IS 3480) of the same size as the rigid
conduit. Allowance shall be made for running an earth wire of size not less than the
largest conductor contained between each terminal fitted in the nearest conduit boxes
on each side of the telescopic/ flexible conduit joint.
3.14.2 Layout

3.14.2.1 Conduits layout and routes shall be submitted for Engineer-in-Charge's approval prior
to execution. Allowance for adjustments due to site conditions shall be provided with no
extra cost.

3.14.2.2 Conduit routes shall be chosen for easy, straight runs with a minimum of bends and
crossing. Generally they shall follow the structure of building, running at right angles or
in parallels to floors and ceiling. Conduit shall be kept within 300mm of floors and
ceiling when running parallel to them.

3.14.2.3 Outlets boxes for housing accessories shall be used as draw boxes. The total number
of draw boxes shall be kept to a minimum and shall be provided so that conduits runs
do not exceed 8m or have more than two right angle bends.

3.14.2.4 Conduits from different distribution boards shall not be connected to the same junction
box. Each run of conduit shall be assembled complete with draw in wires.
3.14.3 Joints and Terminations

3.14.3.1 Conduit threads shall be thoroughly cleaned and the conduits tightly screwed. The
conduit system shall be watertight after installation. The contractor shall submit for
approval the ‘Method Statement including Tests’ to ensure the above requirement.

3.14.3.2 Conduits shall be connected using couplers or via boxes. With a coupler, the ends of
the conduit shall be butted close together and the running coupler is screwed tightly on
and tightened by a locknut.

3.14.3.3 Conduits terminating into boxes provided with spouts shall be threaded so that there
are no exposed threads. For boxes with no spouts, the termination shall be made using
a brass bush and a coupler. The conduit is pushed through the knockout or drilled entry
and the bush is screwed tightly onto its end. The coupler is screwed to butt firmly
against the exterior wall of the box.

3.14.3.4 Where conduits are not jointed or terminated in boxes, they shall be terminated in a
screwed brass bush.

3.14.3.5 In all joints and terminations, conduits threads shall not be exposed. Where this cannot
be avoided as in a running coupler, the exposed threads shall be treated as given in
Section 4(b) of this specification.

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3.14.4 Bends (IS: 14768-2)

3.14.4.1 Conduits shall be bend cold with an approved type of bending block or bending
machine, without altering the dimensions of their sections. The approval for the
bending block or bending machine proposed to be used at site shall be taken from the
Engineer-in- Charge.
3.14.4.2 All conduits bends shall be such as to permit compliance to the requirements for bends
in the IS regulations.
3.14.4.3 Bends shall be made with as large a radius as the position of the conduit within the
building permits. Where the bend is more than 90 degree, circular or rectangular
junction boxes shall to be used for connecting conduits.

3.14.5 Recessed Conduiting

3.14.5.1 Conduits recessed in concrete members shall be laid before casting, in the upper
portion of slabs or otherwise as may be instructed, so as to embed the entire run of
conduits and ceiling outlet boxes with a cover of minimum 12mm concrete. Conduits
shall be adequately tied to the reinforcement with steel wire of not less than 1.5mm
diameter to prevent displacement during casting at intervals of maximum 1 metre. No
reinforcement bars shall be cut to fix the conduits. Suitable flexible joints shall be
provided at all locations where conduits cross expansion joints in the building. Spacing
between concealed conduits entering the draw-in boxes shall not be less than 25mm to
allow concrete aggregate to pass and set between conduits.

3.14.5.2 Conduits recessed in brick work shall be laid in chases to be cut by electrical contractor
in brick work before plastering. The chases shall be cut by a chase cutting electric
machine.

3.14.5.3 The chases shall be of sufficient width (minimum 10mm spacing between adjacent
conduit) to accommodate the required number of conduits and of sufficient depth to
permit full thickness of plaster (minimum 6mm) over conduits.

3.14.5.4 The conduits shall be secured in the chase by means of heavy duty pressed steel
clamps screwed to MS flat strip saddles at intervals of maximum 600 mm.The chases
shall then be filled with cement and coarse sand mortar (1:3) and properly cured by
watering. Galvanized chicken wire mesh of 0.6mm thick with 10 to 15mm aperture shall
be provided for the full length and width of the chase in the plaster to prevent cracking.

3.14.5.5 Junction boxes intended for facilitating drawing of wires in conduiting system shall be
located in accessible locations to permit redrawing of wires in future. Open ends of
conduits laid in slabs and walls shall be suitably plugged before pouring
concrete/plastering to prevent ingress of water / debris in to the conduits.

3.14.5.6 Entire recessed conduit work in concrete member and in brick work shall be carried out
in close coordination with progress of civil works. Conduits in concrete member shall be
laid before casting and conduits in brick work shall be laid before plastering. If it
becomes necessary to embed conduits in already cast concrete members, suitable
chase shall be cut in concrete for the purpose. For minimizing this cutting, conduits of
lesser diameter than 25mm and outlet boxes of lesser depth than 50mm could be used
by the contractor for such extensions only after obtaining specific approval from
Engineer-in-Charge. For embedding conduits in finished and plastered brick work, the
chase would have to be made in the finished brick work. After fixing conduit in chases,
chases shall be made good in most workmanlike manner to match with the original
finish.

3.14.5.7 Cutting chases in finished concrete or finished plastered brick work for recessing
conduits and outlet boxes etc. shall be done by the Contractors without any extra cost.
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3.14.5.8 In the concealed conduit system, all boxes for accessories & draw/junction boxes shall
be installed such that outer rim is flush with the finished surface of the wall. Sockets
near skirting level shall be fed from the floor above rather than the floor below, because
in the latter case it would be difficult to avoid traps in the conduit

3.14.5.9 Where surface mounted distribution boards are used with a sunk conduit,a flush
adaptable box shall be fitted in the wall behind the distribution board and to take the
flush conduits directly into it. Holes can be drilled in the back of the distribution board
and bushed. Spare holes should be provided for future conduits. Distribution boards
must be bonded to the adaptable boxes and unused holes should be sealed.
3.14.6 Surface Conduiting

3.14.6.1 Wherever so desired, conduit shall be laid in surface over finished concrete and/or
plastered brickwork. Suitable spacer saddles of approved make and finish shall be
fixed to the finished structural surface along the conduit route at intervals not exceeding
600mm (except from fitting where 300mm).

3.14.6.2 Fixing of standard bends or elbows shall be avoided as far as practicable and all
curves maintained by bending the conduit pipe itself with a long radius which will permit
easy drawing-in of conductors.

3.14.6.3 Holes in concrete or brick work for fixing the saddles shall be made neatly by electric
drills using masonry drill bits. Conduits shall be fixed on the saddles by means of good
quality Galvanized steel clamps meant to withstand hard use and wear screwed to the
saddles by counter sunk screws.

3.14.6.4 Neat appearance and good workmanship of surface conduiting work is of particular
importance. The entire conduit work shall be in absolute line and plumb. Conduits
above false ceiling shall be fixed on suitable hangers supported from structural ceiling.

3.14.6.5 All surface conduits shall be run in a vertical or horizontal direction. Diagonal runs shall
not be permitted.
3.14.7 Penetration in Walls

3.14.7.1 Where proprietary cable transits are required, they shall be installed strictly in
accordance with the manufacturer’s recommended procedures. Where cables pass
through walls, floors, or fire partitions, sleeves shall be installed to facilitate installation
and subsequent withdrawal of the cable.

3.14.7.2 After installation of the cables, the hole(s) through which the cables pass shall be
sealed with fire resisting material to achieve the fire rating as the structure through
which they pass. Details of the proposed sealing method shall be submitted for
approval prior to implementation. Cables passing through external walls shall
additionally be sealed with appropriate additional weather protection to prevent the
ingress of water.

3.14.7.3 The fire resisting material shall intumesce to form a hard char that tightly seals
penetrations against flame spread, smoke and toxic fumes. The fire resisting material
shall be tested according to ASTM E119, ASTM E814 and ASTM E84. Test
certification and test report shall be submitted.

3.14.7.4 The materials shall not emit toxic gases on exposure to fire. The materials shall be
easy to dismantle and replace in case of rearrangement and also withstand vibration
due to rail operation and seismic tremor.

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3.14.8 Fixing of Conduit Fittings and Accessories

3.14.8.1 For concealed conduiting work, the fittings and accessories shall be completely
embedded in walls/ceilings leaving top surface flush with finished wall/ceiling surface in
a workman like manner.

3.14.8.2 Loop earthing wire shall be connected to a screwed earth stead inside outlet boxes to
make an effective contact with the metal body.
3.14.9 Protection of Conduit

To safeguard against filling up with mortar / plaster etc. all the outlet and switch boxes
shall be provided with temporary covers and plugs, which shall be replaced by
sheet/plate covers as required. All screwed and socketed joints shall be made fully water
tight with white lead paste.

3.14.10 Cleaning of Conduit Runs

The entire conduit system including outlets and boxes shall be thoroughly cleaned after
completion of erection and before drawing in of cables. For cast in-situ conduits, it shall
be checked for freedom from blockage and continuity as soon as the shuttering is
removed. All conduit shall be swabbed through before wiring is commenced and cables
hall not be drawn into any section of the system until all conduits and draw boxes for that
particular section are fixed in position. The contractor shall submit for approval the
‘Method Statement including Tests’ to ensure the above requirements of cleaning of
conduit runs.

3.14.11 Loop Earthing

Loop earthing shall be provided by means of insulated stranded copper conductor wires
of sizes as per bill of quantities laid along with wiring inside conduits for all wiring outlets
and sub mains. Earthing terminals shall be provided inside all switch boxes, outlet boxes
and draw boxes etc. To satisfy requirements for earth fault loop impedance, the layout of
conduit, trunking and ducting and routing of cables, contractor shall ensure that the
maximum circuit lengths allowable are not exceeded.

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3.15 ADDITIONAL REQUIREMENTS

a) All conduits shall be electrically and mechanically continuous and substantially

water tight after installation. Electrical continuity and resistance of steel conduit
systems intended to be encased in concrete shall be tested immediately prior to
pouring.
b) Where an exposed galvanized surface has been cut or otherwise damaged, it
shall be repaired by application of a zinc rich epoxy primer with a generous
overlap on the existing sound metal coating. Exposed threads and connections
shall be similarly treated. The epoxy primer shall be used strictly in accordance
with the manufacturer’s instructions.
c) The use of inspection elbows and tees shall be avoided, as there is insufficient
room for drawing in cables and, in addition the installation presents a shoddy
appearance. Round boxes in accordance with relevant Indian Standards may be
used. For conduits up to 25 mm diameter, the small circular boxes should be
used. Circular boxes are not suitable for conduits larger than 32 mm, and for
these larger sizes rectangular boxes should be used to suit the size of cables to
be installed.
d) All circular boxes shall be provided with long spouts, internally threaded,
incorporating a shoulder for the proper butting of the conduit.
e) An indelible display shall identify the cables laid along with the conduits at each
conduit junction/ termination etc. for identification during any future handling.
f) The contractor shall submit ‘Method Statement’ for Installation, Testing and
Commissioning of the conduit system as per the requirements of this
specification. The ‘Method Statement’ shall also cover the aspect of quality and
safety during Installation, Testing and Commissioning of the system.
g) For Stimulator buildings, switches shall be single pole and rated not less than
20A, for use on AC systems, including fluorescent or inductive loads.
h) All boxes and conduit accessories shall be fully weatherproof when used in
outdoor locations and tunnels. Weatherproof boxes and conduit accessories shall
also be used in locations other than outdoors where specified.
i) Covers for external application shall have machined faces, and shall be provided
with neoprene type gaskets. No box shall be fixed in such a position as to be
inaccessible on the completion of the building structure or other services.

3.16 SAFETY

The conduit system shall follow the relevant clauses of Central Electricity Authority
(Measures relating to Safety and Electricity Supply) Regulations, 2010, National
Building Code, 2005 and National Electrical Code, 2011 for the safety precautions to
be adopted. In addition to this, following conditions should be adhered to:

a) All conduits shall be kept clear of gas and water pipes. In particulars, conduits
shall be at least 150mm away from gas pipe. Where proximity to these pipes is
unavoidable, they shall be effectually segregated e.g. using rubber or other
insulating material to prevent appreciable voltage difference at possible points of
contact. Segregation from extra low voltage circuits and telecommunication
circuits shall also apply unless these are wired to that same voltage requirement
as lighting and power circuits.
b) Emergency power sockets for Fire Services Department shall be provided in
headwall units, tail-wall units and other locations shown on the drawings. The
socket outlet shall be 32A, three phase, 5 pin socket outlets, in red colour, to
IP54.

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c) The materials used in the conduit system shall be fire retardant, shall not emit
toxic gases and smoke on exposure to fire. The materials shall be easy to
dismantle and replace in case of rearrangement and also withstand vibration due
to rail operation and seismic tremor.
d) No timber or inflammable material shall be used for any supports.
e) No sharp edges or portion shall be present which may cause injury during
handling or installation.

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4 LIGHTING & FANS

4.1 LED Lights

A. General

1. The scope of work shall cover the supply, installation and testing and commissioning of the
lighting system. Relevant codes and standards upto latest revision shall be applicable. This
specification covers the LED lighting that shall be used for general lighting in DMRC.
2. The lumen maintenance of the LED fittings (of the system not chip) shall not be less than
70% after 50000hrs i.e. [L70; B50.].
3. The luminaries shall comply with L-70, B-50 standards and the required illumination shall
be maintained till the end of contract period.
4. The product shall be of proven design, shall have type test certificate/performance
certificate from the accredited laboratory.
5. The lighting fixtures and accessories shall give continuous trouble free operation and the
material should not deteriorate with time.
6. Luminaire shall have a warranty of 5 years after the delivery and the warranty will be seen
in-line with L-70, B-50 and other standards, failing to meet the required lux level as
mentioned in addition to complete failure of the fixture.
7. Lighting layout with selection of approved light fittings to be submitted by the
bidder/contractor for review by DMRC and based on the final layout dialux reports (with all
parameters) to be submitted for the confirmation of the design meeting the lux level given in
the lux chart. The lighting design shall also meet the best level of uniformity ratio.
8. The KW loading and LPD (Light Power Density) in W/m2 shall comply with the latest
NBC/ECBC requirements.
9. The tolerances in the wattage/efficacy/harmonics and other parameters shall be as per the
latest IEC/IS.
10. The light fittings or its paint shall not emit toxic/corrosive gases in case of fire and shall be
non combustible and fire resistant type.
11. The emergency lighting installation shall fully comply with NBC or other relevant safety
standards.
12. 25% of the total lights distributed uniformly shall be connected to emergency source i.e.
UPS/DG.
13. Luminaire shall be embossed with ‘For DMRC’ with following legends:
Type of fitting /Manufacturer name /Manufacturing year /wattage /Lumen /Efficacy

B. LED Standards
1. The luminaries shall have conformation standard of luminaries as per IEC 60598/10322
and shall have electrical safety as per IEC 61000, 61547-2-13, 61347, 62471, 60958,
62560, 60838-2-2 and it.
2. IEC 62471-Standard for Eye and Skin /Photoboilogical Safety.
3. IEC 62031-Safety Standard for LED Module.
4. IEC 61347-2-13-Standard for Led Drivers.
5. IEC62560-Stanadard for Self Ballasted LED Lamps.
6. IEC 60838-2-2-Stanadard for Particular Requirement on LED Connectors.
7. EC DIRECTIVE 2002/95/EC and Related Commission.

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8. IEC 61000-3-2 "Electromagnetic compatibility (EMC) - part 3-2: limits - limits for harmonic
current emissions (equipment input current ≤ 16 a per phase)" is an international standard
concerning the harmonics emitted by electric equipment.
9. 61547-2-13 “Specifies particular safety requirements for electronic control gear for use on
DC or AC supplies up to 1000 V (a.c. at 50 Hz or 60 Hz) and at an output frequency which
can deviate from the supply frequency, associated with LED modules.
10. CISPR 15. Limits and Methods Of Measurement of Radio Disturbance Characteristics Of
Electrical Lighting And Similar Equipment
11. IEC 61000-4-11.
12. LED Characteristics standards- LM79, LM-80 L-70 B-50 TM-21.
13. IS 1239: Part 1: 2004S Steel Tubes, Tubulars and Other Wrought Steel Fittings -
Specification - Part 1: Steel Tubes.
14. IS 1239 : Part 2 : 1992Mild steel tubes, tubulars and other wrought steel fittings, Part 2 Mild
steel tubulars and other wrought steel pipe fittings
15. All codes and standards mean the latest. Where not specified otherwise the installation and
requirements shall generally follow the Indian standards codes of practice or the relevant
British Standard codes of Practice in the absence of standards.

C. LED MAKE AND SPECS

1. The approved makes for the LED chips are Nichia, Philips-Lumileds, Osram and Cree or
as approved by DMRC
2. Manufacturer should have LM-80 report and IS file of the luminaries to be supplied for
different applications areas.
3. Manufacturer has to submit the test report along with relevant documents.

D. LED chip specification

1. LED efficacy at the chip level shall be >120 lumen/watt.
2. The system luminous efficacy(Actual lumen coming out of LED Luminaries)of the led
luminaries (of the system) shall be as under
i) For Down lighter = min 120Lm/W.
ii) For Platform edge type fittings-140Lm/W
iii) For any Tube or Module/Panel type Fixture = min 140Lm/W.
iv) For Highbay/ Flood Light/ Pole Light/ or any External lighting=Min 120Lm/W.
3. The minimum view angle of the LED shall not be less than 120⁰.
4. The product shall be available in the colour temperature range of 4000K-6000K.
5. It shall have an SDCM (standard deviation in colour maintenance) of <5.
6. The LED efficiency shall be more than 85% at a junction temperature of 85ºC.
7. It shall have CRI >80 for indoor except tunnel, flood light and high bay and CRI> 70 for
outdoor applications.

E. LED DRIVER AND CONTROL CIRCUIT SPECIFICATION

1. The led driver shall be constant current type.
2. The driver shall be able to withstand surge (EFT+ESD interference) of minimum 4 KV with
a rise time of 20 nanoseconds. Luminaire with wattage >50w and all external luminaire
shall have surge protection devices of min 8KV.
3. The driver shall have under voltage, over voltage, short circuit and earth fault protection.
4. Output over voltage protection of 125V DC.
5. The high voltage test shall be done on the drivers as per the latest standards.
6. Output voltage ripple shall be within 3%.

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7. Total harmonic distortion shall be <15%.

8. The LED driver should comply to CISPR 15 for limits and method of measurement of Radio
Interference Characteristics.
9. The control gear shall compliant to IEC 61347-2-13, IEC 62384.
10. The driver shall have an efficiency >85%.
11. It shall have a power factor >.9.
12. It should give consistent performance in the input voltage range of 165V-270V at 50 Hz.
13. The Current Waveform Shall Compliant To EN 61000-3-2
14. The equipments shall comply with IEC 61547 for EMC immunity requirements.
15. The control gear shall be compliant to IEC 61347-2-13,IEC 62031 and IEC 62384.
16. The Output Voltage of the Driver Shall Be Designed To Meet The Power Requirement Of
The System.

F. LIGHT FIXTURE SPECS.

1. The fixture shall be surface suspended or recessed type depending on the application area.
2. The housing shall be made of Extruded aluminium/Pressure Die cast aluminium
(PDCA)/.5mm thick CRCA conforming to relevant standards and shall have U.V. and
corrosion resistance protection.
3. The luminaries shall have a high quality clear toughened glass or non yellowish
polycarbonate or PMMA diffuser with diffused reflection having a minimum trasnsmitivity of
85%.
For the outdoor applications it shall have a clear toughened glass or clear U.V. stabilized
polycarbonate cover.
4. It shall have a proper thermal management to dissipated heat. The heat sink should be
made of extruded aluminium/latest trends as applicable having high conductivity.
5. Reflector (if) shall be a high quality aluminium reflector and shall have efficiency more than
85% to achieve a wide light distribution. The anodic film shall have a minimum thickness of
2.5 micron.
6. The fixture shall be suitable to work in diverse atmospheric condition like humid, dust,
corrosive etc.
7. The fixture shall have a minimum ingress (IP) and impact protection (IK) rating depending
upon the area of application.
8. The power factor of the overall system shall be >.9.
9. The fixture shall be provided with separate wiring channel with cover plate and earth
terminal.
10. Provision shall be made for main connection directly at the back of housing.
11. The internal wiring of the fixture shall be of LSH type.

G. AREAWISE SPECIFIC REQUIREMENT

Platform/Subway/Stairs/ Entrances/Basements

1. It shall have IP 54 protection.

2. It shall have impact protection of rating min 06 i.e.IK-06.
3. It shall have adjustable height arrangement provision and shall have easy installation and
alignment feature.

Enclosed Concourse/indoor/BOH

1. It shall have a minimum IP-20 protection.

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External/Pole/Highbay lighting

1. It shall have minimum of IP-65 protection.

2. It shall have impact protection of rating min 05 i.e. IK-05.
3. It shall have a UV stabilized clear polycarbonate cover or clear toughened glass.

H. Area wise lux requirement for different activity centers:

APPLICATION AVERAGE DESIGNED LUMINANCE (LUX)

Common Area
Circulating and Parking Area 30
Entrance/Exit/Stairs/Escalators 250
Corridor/Passages/Toilet 200
Lifts 150
Operation rooms
Staff working area/Control room 250
Telecommunication/UPS/Battery/Pu 200
mp/Chiller/Auxiliary
Substation/TSS/DG Room/LT panel
etc. (All plant room)
Stores Room 200
Administrative Offices
Office 200

4.2 EXTERNAL LIGHTING

A. General
The steel tubular street lighting poles used for lighting of approach roads, traffic lanes and
walkways in the circulating area, shall be erected at a distance of 300 mm from the edge of
the road/walkway. The foundation for the poles shall be of 1:2:4 concrete. This shall be
done by the Contractor as a part of the contract work as per the approved drawing. The
pole with its base plate shall be grouted in the foundation which shall be provided with
muffing. Galvanized down pipes/sleeves of suitable diameter shall be embedded in the
concrete for the incoming and outgoing feeder cables. Contractor should follow CPWD
specification for mounting of MCBs.

B. Street and Flood Lighting Fixture

In addition to the specifications given above the external luminaire should have minimum of
IP-65 protection impact protection of rating min 05 i.e. IK-05, UV stabilized clear
polycarbonate cover or clear toughened glass. The light fixture construction shall be of die-
cast/extruded aluminium.

C. Street Lighting Poles

1. The lighting poles shall be octagonal / round type poles as per IS 2713 (PART 2) –1980,
hot dip galvanized as per drawings and as specified. The pole shall have a base plate, a
large access panel, and necessary fixture mounting bracket at top and 2 nos. 1.5m length
of 40mm diameter bent GI pipes for cable loop-in loop-out to be provided. The access panel
shall provide easy access to a multi-way porcelain connector and fuse board, to be
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mounted inside the pole. The access shall be specially fabricated with adequate
reinforcement and weather gasket to prevent ingress of moisture and vandal proofed. Poles
shall have large diameter entries for incoming and outgoing cable and two earth studs. The
pole fabrication shall conform to the drawings and where such drawing is not available; the
contractor shall make drawing and have it approved before fabrication.
2. The octagonal / round poles shall be made from steel of minimum tensile strength 490
N/mm2.
3. Grade of foundation bolts shall be 6.8 & confirming to IS: 1367 (Part-III) – 2002.
4. Foundation – adequate size M30 grade RCC foundation with 100mm raft including
excavation are included in the rates of street light poles. Contractor shall submit design
calculation in support of size of RCC foundation for external lighting poles.
5. The pole shall be provided with a 20mm hole for wiring of street light pole and two
nos.20mm studs are to be welded for earthing.
D. Junction Boxes and Connecting Cable
1. Each pole shall be complete with an MS junction box of pole-mounting type/fitted inside the
pole, manufactured from MS sheet of 14 sheet gauge painted with oil paint over red oxide
zinc chromate primer. The junction box shall have a water proof lockable cover (IP55) of
size 300 x 100 mm. It shall be fitted with 6A MCB and 6-way, 20A connector strip, a neutral
link, earthing studs and suitable down pipes for the incoming and outgoing cable-lead. The
junction box shall generally comply with the requirements of IS: 2675-1983. The supply of
pole shall be complete with 3 x 4-mm2 copper FR / cable,PVCinsulated, PVC sheathed
drawn from the junction box to the luminaire terminal.
2. Pole shall have a concrete coping of 200mm height and 300mm diameter in M30.
E. Cable laying
1. Cabling shall be generally as specified in the section ‘CABLING.’
2. Cables shall be terminated in a 6-way terminal block inside the pole or attached therewith
as shown on drawings.
3. Cable route shall be as shown on the drawings or the contractor shall mark out the route
and lay the cables only upon approval of the route.
F. Earthing
All street light fixtures and poles shall be earthed as specified under section ‘EARTHING.’
In each pole a through hole of 14mm diameter shall be provided at a height of 300mm for
earthing. Every lighting pole shall be earthed by connecting it to the continuity earth of the
feeder cable from the feeder pillar. In addition, every 7th pole shall be connected to locally
provided earth electrode as per approved drawing.
G. Feeder pillars (as applicable)
1. Suitable feeder pillars, 3-phase 415 V outdoor type, with a fixed canopy shall be
provided for power distribution to masts & streetlights. The feeder pillar shall have IP: 54
degree of protection. It shall be provided with weather-proof lockable door, incoming and
outgoing cable glands, earthing studs and other accessories.
H. Testing and commissioning
1. The lighting installation shall be tested as per approved schedule and the instructions of
Engineer and shall include but not be limited to the following:

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a) Insulation resistance of each circuit shall be measured without the lamps being in
place. Itshould not be less than 500000 ohms to earth.
b) Current and voltage of all the outdoor lighting circuits shall be measured at the
Main Distribution Board with all the lamps switched on to ensure that these are
within designed values and in the case of 3-phase circuits, the load shall be
balanced if required.
c) Earth continuity shall be checked for all the circuits.
d) After inserting all the lamps and switching on all the circuits, minimum and
maximum illumination levels shall be measured in all areas and their conformity
with designed levels established. The test results shall be entered in the
approved pre-commissioning proforma and submitted to the Engineer for
approval before final commissioning.

4.3 PLUG-SOCKETS

4.3.1 The 3-pin 6A/16A plug Universal socket shall be combination socket and switch and
switch (on the live side) suitable for use with either 6A plug or 16A plug. The switches
and sockets shall be enclosed type flush mounted switches of 230 volt ac grade. These
shall be provided with approved poly carbonate modular cover plates, secured to the
box with counter sunk screw. Where more than one switch occurs in same location,
they shall be installed in gangs under one cover plate.

4.4 TIME SWITCHES

a) Spring reserve 24 hour dial time switches shall be suitable for operation on a 230
volt 50Hz ac supply and shall be driven by a self-starting synchronous motor with
a spring reserve mechanism which will enable the clock to continue to function
for a period of at least 30 hours after interruption of the supply. Separate motor
and switch terminals shall be provided. Switch contacts shall be rated at 20
amperes
b) Spring reserve - solar dial time switches shall be suitable for operation on a 230
volt 50Hz ac supply and shall be driven by a self-starting motor with a spring
reserve mechanism which will enable the clock to continue to function for a
period of at least 30 hours after interruption of the supply.
c) Separate motor and switch terminals shall be provided. Switch contacts shall be
rated at 20 amperes.
d) The time switch shall be fitted with a 24-hour dial complete with one set of ON
and OFF levers. A selective day omitting device shall also be provided. The time
switch shall be provided with an "ON-OFF" by-pass switch to completely over-
ride pre-set switching functions.
e) For safety reasons, where lighting switches occur in different phases they must
be separated by a distance of not less than 2.0 m unless phase barrier type
switches are used. This type of switch is only to be used when shown on the
drawing or on the specific instruction of the Employer's representative.

4.5 Ceiling, Wall Fans & Exhaust fans

4.5.1 Ceiling fans shall be energy efficient highest BEE rated of latest notification of
1400mm/1200mm sweep conforming to IS: 374-1979 complete with fan suspension
stem, canopies and regulators. 30-cm suspension stem shall be standard accessory and
stems shall be heavy-duty steel tubes to IS: 1239-2004. The stem shall be painted with
enamelled paint. The fan shall have a junction box with MS hook of minimum size 150-
mm diameter fixed in recess of ceiling and covered with sun-mica sheet of minimum 3-
mm thickness.

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4.5.2 The fan clamp shall be fabricated from new metal and shall be as close fitting as
possible. The suspension rod shall be seamless steel tube mounted on a pre-embedded
hook with hard rubber isolator. Regulators shall be step type mounted in the switch box.
The box in all such cases shall be large enough to accommodate the regulator and
switches. Air circulators of suitable size & sweep as specified, 1440 rpm, suitable for 230
V, 1-phase, Low noise level of 80-90dB or as stipulated in Indian Standards and
approved shall be provided at suitable location.
4.5.3 Exhaust fan – The exhaust fan shall be of size 300/450-mm as specified and required and
900 rpm and shall conform to IS: 2312-1967 (as reaffirmed in 2005). The fans shall be
robust, having double ball bearings and low noise.

4.6 Inspection & tests

4.6.1 Prototype tests/routine tests as required shall be carried out by the contractor and
witnessed by employer’s representative as stipulated in Special Conditions of contract.

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5 PROTECTIVE EARTHING

5.1 Detailed description and Application

5.1.1 The earthing protection is an integral part of any electrical system and is required
to:

a) Protect personal and equipment from electrical hazards.

b) Achieve a reduction in potential to the systems neutrals.

c) Reduce or eliminate the effects of electrostatic and electromagnetic interference on

the Signaling and Telecom equipment arising from auxiliary electrical systems.
5.2 REFERENCES

This specification requires the reference to the following documents:

IS 3043-1987 Indian standard code of practice for earthing

IEEE 80 IEEE guide for safety in AC sub-station grounding
IEEE 837 Standard for qualifying permanent connections used in
Substation grounding.

Wherever, reference to any specification appears in this document, it shall be taken as a

reference to the latest version of that specification unless the year of issue of the specification is
specifically stated.

5.3 APPLICATIONS

Earthing systems covered in this document shall be for providing effective grounds for

5.31 Sub-Stations

5.32 Main LT panel

5.33 Transformer and Generator neutral earths

5.34 Lightning arrester earths

5.35 Equipment earths including panels

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5.4 SELECTION OF EARTH SYSTEM

S.N. Installations/ IR Value Soil Type/ Resistivity Earth System

Current Capacity Required

Normal Soil/ upto 50

1. House hold 8 ohm ohm-mtr Single Electrode
Sandy Soil/ between 50
earthing/ to Single Electrode
3kA 2000 ohm-mtr
Rocky Soil/ More than
2000 Multiple Electrodes
ohm-mtr
Normal Soil/ upto 50
2. Commercial 2 ohm ohm-mtr Single Electrode

Sandy Soil/ upto 2000

premises ohm-mtr Multiple Electrodes

Office buildings/ Rocky Soil/ More than

2000 Multiple Electrodes
5kA
ohm-mtr
Normal Soil/ upto 50
3 Transformers, 1 - 2 ohm ohm-mtr Single Electrode

substation Sandy Soil/ upto 2000

ohm-mtr Multiple Electrodes

earthing, LT line Rocky Soil/ More than

2000 Multiple Electrodes
equipment/ 15kA
ohm-mtr
Normal Soil/ upto 50
4 Transformers, less than 1 ohm-mtr Single Electrode

substation ohm Sandy Soil/ upto 2000

ohm-mtr Multiple Electrodes

earthing, HT line Rocky Soil/ More than

2000 Multiple Electrodes
equipment/ 40kA
ohm-mtr
Normal Soil/ upto 50
5 Lightning less than 1 ohm-mtr Single Electrode

arresters, extra ohm Sandy Soil/ upto 2000

ohm-mtr Multiple Electrodes

high current Rocky Soil/ More than

2000 Multiple Electrodes
applications etc./
ohm-mtr
50kA

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5.4.1 TYPE OF SOILS

Soil can be classified in to various types, though based on the size of the particles it
contains:

5.4.2 Normal soil

Black cotton soil, vegetable soil, garden soil, loamy garden, soil shallow black , soil
medium black soil ,deep black soil and marshy soil etc having low soil resistivity
value ( up to 50 ohm meter)

This type has the big particles and the size of the particles does determine the degree
of aeration and drainage that the soil allows. It is granular and consists of rock and
mineral particles that are very small. Therefore the texture is gritty and sandy soil is
formed by the disintegration and weathering of rocks such as limestone, granite, quartz
and shale, thus resulting in over-drainage. It warms very fast in the spring season.
Coastal area, silt soil, red sandy soil, sandy clay and coastal alluvium etc having soil
resistivity up to 2000 ohm-meter are considered as sandy soil.

5.4.3 Rocky soil

The area containing rocks, pebbles, uneven hard surface laterite soil, lime stone, sand
stone, gravel, granite and chalk etc having soil resistivity more than 2000 ohm-meter is
considered as rocky soil. This type of soil does not absorb moisture and are extremely
poor conductor.

5.5 LOCATION OF EARTH ELECTRODE

Where there is option, site should be chosen in one of the following types of soil in the
order of preference given:-

a. Wet marshy ground;

b. Clay, loamy soil, arable land.

c. Clay and loam mixed with varying proportions of sand, gravel and stones;

d. Damp and wet sand, peat.

Dry sand, gravel chalk, limestone, granite, very stony ground and all locations where
virgin rock is very close to the surface should be avoided,

5.6 MEASUREMENT OF EARTH ELECTRODE RESISTANCE

The earth resistance shall be measured using fall of potential method as per para 37 of
IS:3043.

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5.7 EARTHING SYSTEM

The earthing system includes earth electrode, installation of earth electrode in suitable pit size,
construction of earth pit with cover for the installation, connection of earth electrode with
equipotential earth bus and connection of equipment to equipotential earth bus.

5.8 Earth electrode

The earth electrode is the main component of the earthing system which is in direct contact with
the ground and thus provides a means of releasing or collecting any earth leakage currents.
The material should have good electrical

conductivity and should not corrode in a wide range of soil conditions. For an effective earthing
system, two types of earth electrodes can be used as described here:

5.8.1 Rod earth electrode

5.8.1.1 High tensile-low carbon steel rod having diameter not less than 17mm complying with
requirements of BS 4360 Grade 43A or EN10025:2-004 S275JR, molecularly bonded by
99.99% pure high conductivity copper on outer surface with copper coating thickness
250 micron or more, Length 3000 mm (minimum). Length of the electrode may be
increased in multiple of 1 meter to reduce earth resistance if required. To increase the
length, pieces of similar rod shall be either exothermally welded to basic 3 meter
electrode or connected using socket of suitable size. These sockets shall also be
molecularly bonded by 99.99% pure high conductivity copper on inner & outer surface
with copper coating thickness 250 micron or more.

5.9 Copper bus bar of size 250 mm x 50mm x 6 mm having electrical conductivity of
101% IACS, minimum 99.9% copper content shall be exothermically welded to rod
with 4 holes of 12 mm dia. (2 on each side) for connecting earthing conductor.

5.10 Current carrying capacity: The design of the electrode should be such as to have
more than 15kA current carrying capacity for 1 second.

5.10.1 Concentric pipe earth electrode:

5.10.1.1 Primary conductor

MS pipe with 25 - 50 mm diameter, class B, ISI mark as per IS-1239, Length 2000 or 3000 mm
as per table at para 8.1.2.7.

5.10.1.2 Secondary conductor

MS pipe with 40-100 mm diameter, class B, ISI mark as per IS-1239, Length 2000 or 3000 mm
as per table at para 8.1.2.7.

5.11 Conductive mixture

For hermetically filling inside the cavity i.e. between secondary conductor & primary conductor,
crystalline compound is to be injected in the electrode assembly. It is a combination of high
conductivity metal alloys, copper & aluminium powder, conductive carbon/cement and bonding

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material etc. mixed in different proportion. The mixture is forced (pressurized) filled inside the
earth electrode in the paste form and after solidification of the same, the end caps are welded.
The metal alloys shall help in conducting the current and conductive carbon gives anti corrosive
property. Bonding material should provide strength to the mixture. Resistivity of the mixture
shall be less than 0.2 ohm-meter. Resistivity shall be tested by making a 20cm cube of the
material and checking resistance across the opposite face of the cube.

5.11.1 Complete electrode shall be molecularly bonded by 99.99% pure, high conductivity
copper on outer surface with copper coating thickness 300 micron or more.

5.11.2 Its surface shall be clean and free from any visible oxide layer or foreign material.

5.11.3 Copper bus bar of size 250 mm x 50mm x 6 mm having electrical conductivity of 101%
IACS, minimum 99.9% copper content shall preferably be exothermically welded to
earth electrode or connected with the help of two number stainless steel nut bolts of
appropriate size having 4 holes of 12 mm dia. (2 on each side) for connecting
earthing conductor.

5.12 Current carrying capacity: The design of the electrode should be such as to have more
than following current carrying capacity in kA (for 1 second):

S.N. Current Primary Electrode dimensions

Conductor (dia. x length)
Capacity
diameter

1. 3 kA 25 mm 40 mm x 2000 mm

2. 5kA 25 mm 40 mm x 3000 mm
3 15kA 25 mm 50 mm x 3000 mm
4 40kA 40 mm 80 mm x 3000 mm
5 50kA 50 mm 100 x 3000 mm

5.13 Earth enhancement material:

Earth enhancement material is a superior conductive material that improves earthing

effectiveness, especially in areas of poor conductivity (rocky ground, areas of moisture
variation, sandy soils etc.). It may contain conductive cement, graphite, hydrous aluminium
silicate, sodium montmorillonite etc and shall not contain bentonite. It improves conductivity of
the earth electrode and ground contact area. It shall have following characteristics-

i) It should have low resistivity preferably bellow 0.2 Ohm-meters. Resistivity shall
be tested by making a 20cm. cube of the material and checking resistance
across the opposite face of the cube.

ii) It shall not depend on the continuous presence of water to maintain its
conductivity.

iii) It should be a little alkaline in nature with pH value >7 but <9, test certificate from
NABL approved laboratory to be provided for the composition so designed.

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iv) It should have better hygroscopic properties to absorb moisture. It should absorb
and release the moisture in dry weather condition and help in maintaining the
moisture around the earth electrode.

v) It should have capacity to retain >10% moisture at 105ºC. Test certificate from
NABL approved lab to be submitted for the composition so designed.

vi) It should have water solubility < 5%. Test certificate from NABL approved lab be
submitted for the composition so designed.

vii) It should be granular with granule size 0.1 mm to 3 mm.

viii) It should be non toxic, non reactive, non explosive & non corrosive.

ix) It shall be thermally stable between -10 degree centigrade to +60 degree
centigrade ambient temperature.

x) It shall not decompose or leach out with time.

xi) It shall not pollute the soil or local water table and meets environmental friendly
requirement for landfill.

xii) It should expand & swell considerably and removes entrapped air to create
strong connection between earth electrode and soil.

xiii) It should be diffuses into soil pores and creates conductive roots enlarging
conductive zone of earth pit.

xiv) It shall be permanent & maintenance free and in its “set form”, maintains
constant earth resistance with time.

xv) It shall not require periodic charging treatment or replacement.

xvi) It shall be suitable for any kind of electrode and all kinds of soils of different
resistivity.

xvii) It shall not cause burns, irritation to eye, skin etc.

xviii) Minimum quantity of earth enhancement material to be supplied :

For 5’ x5’x 10’ earth pit – Min. 75 kgs per pit

For 300mm bore type earth pit – Min 50 kgs per pit

xix) The Earth enhancement material shall be supplied in sealed, moisture proof
bags. These bags shall be marked with Manufacturer’s name or trade name,
quantity, batch no & date of manufacture.

5.13 Backfill material

Normally the excavated soil shall be used if it is free from sand, gravel and stones. In
case the excavated soil contains sand, gravel and stones these shall be removed by
appropriate methods such as hand picking, sieving etc. Small proportion of sand in the
soil may be permissible. Material like sand, salt, coke breeze, cinders and ash shall not

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be used because of its acidic and corrosive nature. If the excavated soil contains sand,
gravel and stone in large proportion and it is not feasible to remove these economically,
good quality soil from other place may be used for backfilling.

While backfilling the soil shall be thoroughly compacted with at least 5 kg compactor. In
case the soil is dry, small quantity of water may be sprinkled only to make it moist
enough suitable for compacting. Large quantity of water may
make the soil muddy which is not suitable for compacting and after drying the soil may
contain voids which may permanently increase earth resistance.

5.14 Equipotential bus & Earthing Conductor

5.14.1 A copper bus bar of size 300mm x 25mm x 6mm to be installed in the equipment room
as equipotential bus and must be connected with preferably copper strip of 25mm x
3mm (suitable length) from instrument to the bus bar . The connecting terminal of the
earth electrode to the bus bar must be connected by copper strip of 25mm x 3mm
(suitable length) buried inside a trench of 300mm width x 600mm depth (from the earth
pit to the nearest wall) .It shall be duplicated. However, it shall be ensured that only
minimum required length is used and any extra length is cut away to keep the earth
impedance minimum.

5.14.2 It shall be high conductivity copper having electrical conductivity of 101% IACS i.e.
minimum 99.9% copper content The maximum specific resistance of the copper strip
earthing conductor shall be 17.241 x 10-7 ohm cm at 20ºC.
(iii) At a temperature of 20ºC, its density shall be 8.89 gm/cm3
(iv) Its surface shall be clean and free from any visible oxide layer or foreign
materials.
(v) It shall preferably be connected to earth electrode and earth bus bar with the
help of exothermic welding or at least two number stainless steel nut bolts of
appropriate size.
(vi) Normally a single length of copper strip shall be used for each duplicate copper
strip earthing conductor and no joint should be used. However in situation
requiring greater length one joint in each copper strip shall be permitted. The
joints shall be made by exothermic welding of at least 10mm overlapping portion
of the strips.
5.15 Construction of unit earth.
i) Make 5ft x 5ft x 10ft earth pit. If it is not possible to make such a pit due to non
availability of clear space at locations like ATM, High mast lighting tower,
Passenger information systems, PRS etc. or in rocky soil, min. 300 mm bore up
to 10 ft deep can be made using earth auger or any other method. Earth pit
larger than specified size can be made, if required.
ii) Sleeve the soil digged and remove the gravels and stones. If soil quality is good
(without Murum and rocks) then add some quantity of earth enhancement
material in the soil for using as backfill.
iii) If the soil seems unusable (containing large quantity of gravel, stones, murum,
sad etc.) then replace the soil with black cotton soil.
iv) Insert the electrode at the centre of the earth pit and arrange to keep it vertical in
the pit.
v) Arrange for adequate quantity of water supply for the earth pit. (Approx. 600
litres)
vi) Fill the pit with the backfill and keep on adding the earth enhancement material
surrounding the electrode and simultaneously watering the pit.
vii) With a steel bar or pipe, keep on poking the soil gel and stirring intermittently for
removing the air pockets and proper settlement of the pit.
viii) The procedure to be repeated till completion of the filling of the earth pit along
with the packing material and sufficient watering adequate ramming.
ix) The pit should be very compactly rammed and watering for 2-3 days and

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addition of soil if required be done.

x) Make trench of 600 mm (depth) x 300 mm (wide) from the earth pit to the nearest
point of connection.
xii) Construct inspection chamber with cover for the installation.
xiii) Measure the earth resistance as per IS 3043:1987 code of practice. Earth
resistance value shall be less than 1 ohm in non-rocky/non-sandy surface by
single electrode Installation and in rocky surface by multiple electrode installation
(not more than three electrodes & its individual earth pits). For earthing purpose,
if solid rocky layer is found within 10 feet from ground level while digging the
earth pit then it is considered rocky surface. Coastal area, silt soil, red sandy soil
and sandy clay are considered as sandy surface.
xiv) If required resistance is lower than the resistance of single earth electrode then
multiple earths can be constructed and interconnected.

5.15.1 Inspection chamber

i) A 300X300X300 mm (inside dimension) concrete box (wall thickness min. 50 mm)
with smooth cement plaster finish shall be provided on the top of the pit. A concrete
lid 25 to 50 mm. thick, with pulling hooks, painted black shall be provided to cover
the earth pit. PVC sleeve of appropriate size shall be provided in concrete wall to
take out earthing connections.
ii) The masonry work shall be white washed inside and outside.
iii) Care shall be taken regarding level of the floor surrounding the earth so that the
connector is not too deep in the masonry or projecting out of it.
iv) On backside of the cover, date of the testing and average resistance value shall be
written with yellow paint on black background.

5.16 MARKING:

The marking shall be clear, distinct and visible to the naked eye from a distance of
about 1 meter; the size of marking shall be of minimum 25 mm. Following information
shall be legibly and indelibly marked on the packed sets:

a) Specification no.
b) Name of the manufacturer
c) Batch no. & Date of manufacturer
d) Current carrying capacity

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5.17 TESTS-

Following tests shall be done on one sample-

5.17.1 Corrosion Test: As per IS: 2119, salt spray test for analysis of effect of corrosion for
the specific electrode shall be done through NABL approved testing lab, preferably for
500 hrs. or more.

5.17.2 Exothermic weld material shall be tested as per provisions of IEEE 837.
5.17.3 Electrical properties test on conductive mixture.
5.17.4 Physical, chemical & electrical properties test on earth enhancement material
5.17.5 Toxic content tests for cadmium, lead, mercury, hexavalent chromium,
polybrominated biphenyls (PBBs) & polybrominated diphenyl ethers (PBDEs) on
conductive mixture & earth enhancement material.

Certificates from NABL approved laboratories shall be submitted with test results of
above tests. Test certificates shall not be more than three years old.

For dimension, weight and specific resistance average of 3 readings shall be taken.
Average value shall be within specified limits and individual values shall not go
beyond double of tolerances.

5.18 ACCEPTANCE TESTS

5.18.1 Following shall constitute acceptance tests and shall be done on 100% sample basis
for all the tests mentioned below except where otherwise indicated–
5.18.2 Physical check for earth electrode for rod type electrode and concentric pipe type
electrode.
5.18.3 Physical check for copper bus bar for rod type electrode and for concentric pipe type
electrode.
5.18.4 Dimensional and construction feature tests of inspection chamber
5.18.5 Earth enhancement material
5.18.6 Earth resistance measurements

5.19 INSPECTION:

All the gauges/ test & measuring instruments shall be under calibration control at the
time of inspection and proof to this office shall be produced.

Inspection and testing shall be carried out by the inspecting authority nominated by
the purchaser to ensure that all the requirements of this specification are complied
with for the acceptance of the materials offered by the supplier for inspection.

The purchaser or his nominee shall have right of free access to the works of the
manufacturer and to be present at all reasonable times and shall be given facilities by
the manufacturer to inspect the manufacturing process at any stage of manufacture.
He shall have the right to reject whole or part of any work or material that does not
conform to the terms of this specification or any other specification or requirement
applicable and may order the same to be removed / replaced or altered at the
expense of the manufacturer. All reasonable/complete facilities considered necessary
by the inspecting authorities for the inspection shall be supplied by the manufacturer
free of cost.

The manufacturer shall at his own cost prepare and furnish the necessary test pieces
and appliances for such testing as may be carried out at his own premises in
accordance with the specification. Failing the existence of facilities at his own
premises for the prescribed tests, the manufacturer shall bear the cost of carrying out
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the tests in an approved laboratory, workshop or test house.

5.19 COMPLETION REPORT & CERTIFICATION:

a. The last documents for the completion of the procedure will be submission of the work
completion report to the concern Railway authority. After testing the earth values of
the pits and proper recording in presence of Railway authority, certified grounding self
adhesive certificate shall be provided for all installations and the same will be
displayed / pasted at the place of installation.
b. The complete layout with dimensions of the earthing & bonding system shall be
submitted by the supplier in appropriate size (in three copies) after commissioning
showing commissioning date, earth resistance, specification no. and manufacturer’s
name.

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6. LIGHTNING PROTECTION

6.3 Detailed description and Application

6.4.1 The external Lightning Protection system is intended to intercept direct lightning flashes
to the structure, including flashes to the side of the structure and conduct the lightning
current from the point of strike to the ground. It should also disperse this current into the
earth without causing thermal or mechanical damage. The scope of work shall cover
supply, installation and testing of air and earth terminations and down conductors.
Protection of buildings against lightning shall be done to include the provision of a
parallel path lightning system complete with air terminal conductors, ground terminals
interconnecting conductors and other fittings required for the complete system.

6.5 Governing Specifications

6.5.1 The Lightning Protection system shall comply with standards mentioned particularly in
the table below unless otherwise stipulated in the specifications. The latest version of
standards shall be applicable.
IS: 2309 – 2005 Code of practice for the protection of buildings and
allied structures against lightning
IS: 3043 – 1987 Code of practice for earthing
IEC-62305 Protection against lightning

All codes and standards mean the latest. Where not specified otherwise the
installation shall generally follow the Indian Standard Codes of practice or any other
relevant standard.

6.6 Requirements
6.6.1 Air terminations: Air termination systems can be composed of any combination of the
following elements:
a) Rods
b) Meshed conductors
The individual air termination should be connected together at roof level. The air
termination shall be multiple point type of copper/brass material. The stem and multi-
point head shall be erected on the roof with a 150 x 150 x 6mm stainless steel (SS)
base plate with a threaded socket of the same material welded to it. The base plate
shall be embedded in a concrete block to hold the elevation rod in a vertical position.
Air termination shall be one single rod without any joints.
6.6.2 Positioning of Air-terminations
Air termination components installed on a structure shall be located at corners,
exposed points and edges in accordance with one or more of the following acceptable
methods:
 Protection angle method
 Rolling sphere method
 Mesh method
6.6.3 Down Conductor
The down conductors should be of SS and to be arranged such that:
6.6.3.1 The down conductor shall follow the most direct path possible between the air
termination and the earth termination and several parallel current paths exist.
6.6.3.2 The down conductor shall be free of sharp bends, upturns and kinks and clamped to
the stem of the air termination by means of gun metal clamps. Each down conductor
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shall have an independent earth termination and length of the current paths is kept to
a minimum.
6.6.3.3 The down conductor shall be clamped to the building outer wall at 600-mm centers. All
joints shall be tinned, soldered or double-riveted.

6.7 Additional Requirements

6.7.1 A testing link shall be provided for each down conductor.
6.7.2 The entire lightning protective system shall be mechanically strong to withstand the
mechanical forces produced in case of a lightning stroke.
6.7.3 Horizontal air terminations shall be coursed along contours such as ridges, parapets
and edges of flat roof, and where necessary over flat surfaces in such a way as to join
each air termination to the rest and should themselves form a closed network.
6.7.4 All metallic finials, chimneys, ducts, vent pipes, railings, gutters, metallic flag staff etc.
on or above the main surface of the roof of the structure shall be bonded to, and form
part of the air-termination network. If portions of a structure vary considerably in height,
any necessary air termination or air termination network of the lower portions shall be in
addition to their own conductors, be bonded to the down conductors of the taller
portions.
6.7.5 Each down conductor shall have an independent earth pit. The interconnection of all the
earth termination shall be done. It should be capable of isolation for testing purposes by
“testing joints” of GI provided in suitable enclosures.

6.8 Safety: Not applicable.

6.9 Energy efficiency: Not applicable.

6.10 Maintenance and life:

 The service life of the system shall be at least 30 years.

 The manufacturer should also submit Annual Maintenance cost rates for the full
service life of the system.

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6.11 Material and manufacturing

6.11.1 Quality Assurance and Controls: The Contractor’s Management Systems shall
emphasize quality assurance and controls. The programme shall be adequate to ensure
an acceptable level of quality of the equipment supplied. The concept of total quality
assurance shall be based on the principle that quality is a basic responsibility of the
Contractor’s organization, and shall be visible by:
a) Firm procurement and job performance specifications.
b) Firm procedures for transmission of information and data to their
Subcontractors and ensuring their compliance.
c) Adequate testing to ensure repetitive product conformity to design
requirements and Total programme of surveillance and verification of physical
performance and configuration accountability.
 Adequate records shall be kept by the Contractor to provide evidence of quality and
accountability. These records shall include results of inspections, tests, process
controls, certification of processes and personnel, discrepant material, and other quality
control requirements.
6.11.2 The manufacturer shall ensure use of best manufacturing practice like quality
of bends, no sharp corners, and no metallic parts with sharp edges, use of quality
gasket at appropriate loss to damp vibrations and sealing etc.
6.11.3 The manufacturer shall study the environmental pollution data prevailing near
the Depot where its equipment is going be installed.The manufacturer shall take
adequate precaution either during manufacturing or installation to prevent any damage
to the equipment or loss of life arising due to prevailing pollution level.

6.12 Testing
6.12.1 The entire installation shall be tested in accordance with the Indian Standard
Code (IS 2309) and the ground resistance values shall be recorded for each earthing
Terminal.
6.12.2 The whole of the lightning protective system shall have a combined resistance
to earth not exceeding 10Ω.

6.13 Training
6.13.1 On completion of installation, the manufacturer shall supply two sets of well
bound handing over manuals duly approved by Consultants/Engineer-in-charge. Each
set shall include:-
 As Built Drawings.
 Do’s and Don’ts for the maintenance and operating staff.
 Extracts of the warrant/DLP.
 Soft copy of the entire document.

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7 THREE PHASE INVERTER

7.1 Scope
7.1.1 This specification covers requirement for design, supply, installation, testing &
commissioning of Inverter for Charkop Depot only.
7.1.2 Any material and component not specifically stated in this but necessary for trouble free
operation of the equipment and accessories specified herein shall deemed to be
included.

7.2 Standards
7.2.1 The Inverter shall be designed to comply with all applicable provision of current Indian
standards/IES Where Indian Standards are not available, International Standards, which
ensure performance equivalent or superior to Indian Standards, shall be followed.
Nothing in this specification shall be constructed as to relieve the supplier of the
responsibility for correctness of the design and construction of the equipment. All the
standards being followed shall be listed out in the tender. Where any foreign standard is
being followed, the copy of the same shall be provided with the tender. Wherever
service conditions and requirements laid down in this specification differ from applicable
standards, the conditions specified herein shall prevail.
7.2.2 The Inverter shall comply with all the latest applicable statutory rules, regulations, acts
and safety codes which may be in force during the period of execution and which are
related with design, construction and operation of equipment in the locality where the
equipment is to be installed.
7.2.3 The application acts and statutory regulations are as under:

 The Indian Electricity Act.

 Indian Electricity rules
 National Fire Code
 NationalBuilding Code of India
 Bureau of Indian standards

7.2.4 It will operate with existing 24/48 volts lead acid batteries suitable for 120 minute
backup.

7.3 Technical particular of Inverter

DESCRIPTION PARAMETERS
Rating 10 KVA
AC INPUT 415V + 15% -20% Three Phase
Frequency 50Hz ± 3%
DC VOLTAGE 24 /48 VDC
Charging Time 120 Hours for 90% of full Capacity
Charger Type CVCC Internal Controlled Rectifier type
Technology IGBT
Output Voltage 440 Volt AC Three Phase
Voltage Regulation ± 2% for DC input variation & output load variation
Frequency 50Hz ± 1.5Hz
Waveform PWM Sine wave
Harmonic Distortion Less than 3%
Inverter Efficiency > 92%
Power Factor >0.8
Overload 150% for 60 sec

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Phase Displacement 120Degree ± 1Degree

Audible Noise Less than 45 dB at 1 Meter
Microprocessor based DigitalLCD Meter R,Y,B Output Voltages, Output currents
for &Frequency, DC Voltage , Battery and Load
Percentage
PROTECTIONS Output Overload & Short circuit, Output Under
&Overvoltage, DC Under & Overvoltage Input
Under & Overvoltage, Single Phasing & Phase
unbalance
Operating temperature 0 degree centigrade to 50 degree centigrade
Humidity Max 95%, Noncondensing
INDICATIONS & ALARMS:  Mains on Indication
 Inverter on Indication
 DC Low Indication & Alarm
 Fault Indication & Alarm
 Output Overload Indication & Alarm

Changeover Static Switch Bi-directional

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List of Approved Makes:

This list is indicative and not restrictive.

S.No. ITEMS APPROVED MAKES

LV MAIN SWITCHBOARD INCLUDING DB
MV/LV Switchboards Tricolite Electircal Industries, L&T, GE, Schneider,
1
Unilec, Neptune, Adlec, ABB,Siemens
2 415 Volts ACBs L&T, Siemens, ABB, Schneider
Moulded case Circuit L&T, Siemens, ABB, Legrand, Schneider
3
Breakers(MCCB)
Distribution boards L&T Hager, Legrand, Siemens, ABB, Havells, GE,
4 Tricolite, Schneider, Unilec, Neptune, Adlec, Sudhir
Gensel Ltd,
5 RCBO/RCCB L&T Hager, Legrand, Siemens, ABB, Schneider
Miniature circuit L&T Hager, Legrand, Siemens, Schneider, ABB
6
breakers (MCB)
Switch fuse units with L&T, GE, Siemens, Controal & Swicthegear ltd, ABB,
HRC fuses Merlin-Gerin, Crompton-Greaves
7

8 Protective relays Alstom (AREVA), ABB, L&T, Siemens, Schneider

Capacitors Crompton, Mehar(Schneider), L& T, Siemens, Ducati,
9
ABB
Cast resin current AE,Kappa,control & Switchgear, Precise, G&M
10
transformers (Gilbert & Maxwel)
Meters (digital) MECO,DUCATI,Allen-
11 Bradely,Motwane,AE,Enercon,HPL,Schneider,L&T,Se
cure
12 Selector Switches Kaycee,L&T(Salzer), BCH,Teknic,Schneider,ABB
Indicating lamps and L&T,BCH,Vaishno,Siemens,TEKNIK,RAAS,Schneider
13
push buttons
14 APFC realy Enercon, L&T, DUCATI, EPCOS
15 ATS ASCO, Cummins
MV CABLING
1 XLPE Cables (FRLS) Finolex, Asian/RPG,KEI, Havells, Bonton, Polycab
Copper/Aluminium, Dowells, Jainson
(Crimping Type) cable
2
lugs for 1100 volt
grade cables
Compression glands Peeco, Comet, Dowells
3 for 1100 volt grate
cables
4 Copper conductor KEI, Finolex, Havell, Bonton, Polycab

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FR/FRLS PVC
insulated wires ISI
marked
Terminal blocks & ELMEXX, PHOENIX,WAGO, CONNECTWEL or
5
cage clamps equivalent
6 Cable Tray Bharati, Unitech,Steelways,MEM,BEC and equivalent
CONDUIT WIRING & ASSOCIATED ACCESSORIES
GI conduit pipes ISI BEC,AKG, Steelkraft and other equivalent ISI marked
1
marked
Modular system Crabtree, MK Electric, CPL obsession, legrand,
switches, socket Schneider, SSK,ABB
2 outlets, and wiring
accessories with
moulded cover plates
GI Conduit Conforming to BIS/ISI as per approved samples
3
accessories
LIGHTING & FANS
Light fittings Phillips, Bajaj, Surya, Crompton, Stellar,
1
Instapower(High mast LED), WIPRO
2 Ceiling Fans Crompton Greaves,Orient,Khaitan,Alstom
3 Lamps Philips,Osram
4 Lighting Poles Paruthi, Bajaj, Phillips, Crompton
5 LED Chips Philips, Nitchia, Cree, Seoul Semiconductors
6 Area lighting masts Philps,Bajaj,Crompton,GE,METEL COATS (KLITE)
UNINTERRUPTED POWER SUPPLY (UPS) & INVERTER
UPS System Tata
1 Liebert,Numeric,APC,Seimens,Piller,Schneider,GE,Ar
os-PCI
UPS Battery Exide,Farukawa,Standard,Panasonic,Amara
2
Raja,HBL-Nife or equivalent
Battery and battery RDSO Approved vendor
3
charger
4 Inverter Luminous, Micro Tek, Su-Kam
COMPACT SANDWITCH TYPE BUS DUCT & LV LIGHT BUS TRUNKING
1 Busduct& Light Bus EAE,Henikwon,Schneider,Siemens,L&T,C&S,
Trunking Legrand, MK
2
FIRE ALRAM & DETECTION SYSTEM
1 FACP Notifier, Simplex( Tyco)
Smoke and heat Edwards, Phillips, Appolo, Cerberus,
2
detectors Tyco,Notifier,System Sensor
FIRE HYDRANT & FIRE FIGHTING SYSTEM
1 Pumps Kirloskar/Mather & platt
Motors Kirloskar/ABB/siemens/ngef/gec/alsthom/jyothi/cromp
2
ton greaves

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Starters, As per LV MAIN SWITCHBOARD INCLUDING DB

3 switches/switch fuse list
units
Voltmeter & ammeter As per LV MAIN SWITCHBOARD INCLUDING DB
4
list
5 Pressure switch Indfoss/Switzer/Morley/System Sensor
6 Pressure gauge Fiebig/H.guru/Newage/Sukan/Waaree/Wika
7 Pipes (MS & GI) Tata/Jindal
8 Fittings
a) MS/GI forged steel Vs/suru/B&M/equivalent
fittings
9
b) MS/GI butt welded Deccan metal/equivalent
ERW fittings
10 Sluice valve Kirloskar/leader
Gunmetal/stainless Zolota/ leader/ Sant/ Advance
11 steel valves (full way
& check valves)
12 Non-return valves Kirloskar/leader
13 Butterfly valve Audco/Advance
14 Hydrant valve Newage/minimax
HOSE REEL TUBE KESARA PLAST/SYNTEX/Mitra /New Age
15 (Thermoplastic
synthetic reinforced)
Hose pipe (RRL type) Jayashree/Newage/CRC/Jyoti/Maruti/Dunlop/Minimax
16
/Safex/Zenith
Branchpipe with Newage/Safeguard/Minimax
17
nozzle
Hose box Reputed make as per is specification subject to
18
DMRC approval
19 Paints exposed pipes Assian paints/Berger/Shalimar
20 Anchor fasteners Hilti/hi-tech supports/Fisher
Wraping & coating I w l (pypkote)/equivalent
21 materials for
underground pipes
Primer/paints for Shalimar bitumanstic paints/equi.
22 painting for above
ground pipes
23 Y-type/suction strainer Kirloskar/leader /Sant
Foot valve with Kirloskar/leader/zoloto/sarkar
24
strainer
25 Sprinklers Tyco/spraysafe (uk)/ reliable (usa)/grinnel/star
Alarm valve Hd fire/mather & platt/spraysafe/central
26
(installation valve)
Water motor gong & Hd fire/mather & platt/spraysafe/central
27
trims

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Flow switches Switzer/forbes

28 marshall/viking/gem/macdonald/grinnel/system
sensor/morlay ias
29 Air release valve Newage/kirloskar
30 Ball valve TBS/IBP/equivalent
Cast iron non-return Kirloskar/leader/kalpana
31
vlave double flanged
Rubber gasket Reputed make as per is specification subject to dmrc
32
approval
Clean Agent Gas Fire trace/Sevo
33
Flooding
Portable fire Minimax/niti/safex/zenith/safeguard
34
extinguisher
35 Welding electrode Advani oerlikan/L&T
Anti Vibration Resistroflex, flenonics (USA), GERB
36
Mounting
AIR-CONDITIONING AND VENTILATION SYSTEM
Circulator Crompton Greaves,Orient,Khaitan,Alstom,Almonard
1
fans/Exhaust fans
Air conditioning Carrier,Bule Star,LG,Daikin,Toshiba,Hitachi
2
system
Variable refrigerant Dalkin, Mitsubishi,York,Hitachi,LG
3
volume/flow units
Dehumidification BRYAIR
4 Unit STULZ
EQUIVALANT
AIR QUALITY & ACTIVE BUILDINGS by PiRhoAlpha
5 CONTROL IAQ PURE AIR
MAGNETO
ECS
1 AHU Waves Aircon, System air India, ETA, Bluestar
2 Centrifugal Fan Kruger , Greeneck, Comfrei, Nicotra
3 Air Filter Spectrum
4 FCU Waves Aircon, ETA, Bluestar
5 Air Cooled Chiller Trane, York,Dunhambush
6 Pump Set Kirloskar, ITT
7 GI Sheet Tata, Jindal
Rolastar, Radiant air systems,
8 Prefabricated Duct
Techno fabri duct, Techno Aircon
Motorised Fire
9 Ruskin India, Greenheck India
Damper
Fusible Link Fire
10 Ruskin India, Greenheck India
Damper
11 Motor Operated Systemair India, Caryaire

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works 4

CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Damper
12 Manual Damper Systemair India
Volume Control
13 Systemair India
Damper
14 Grills Systemair India, Caryaire
15 Diffuser Systemair India, Caryaire
16 Fire rated Paint Firespray International Ltd
Insulation (Non fire
17 UP Twiga
rated)
18 Insulation (Fire rated) Rockwool India Pvt ltd, Lloyd Insulation ltd
19 Cooing Tower Paharpur India
20 MS & GI Pipes Jindal, Tata
21 Balancing Valve Advance India
22 Check Valve Advance India
Butterfly Valve (Non-
23 Advance India, Kitz Japan
motorised)
Butterfly Valve
24 Belimo, Kitz Japan
(Motorised)
25 PICV – AHU Flowcon
26 PICV – FCU Flowcon, Pettiranaroli
27 Y – strainer Emerald, Sant
Axial Flow Fans
28 Kruger Singapore, Systemair Malaysia
(ECS)
29 Propeller fan Kruger Singapore, Systemair Malaysia
30 Flexible Coupling Resistoflex
ECS Sound
31 Systemair, Ruskin
Attenuator
32 Motor ABB, Crompton, Siemens, Alstom
Automatic Expansion
33 Anergy/CIMM/TACO
Tank
34 Automatic Air Vent Anergy/Flamco
35 Temperature Gauge Waree
36 Pressure Gauge Waree
37 VFD ABB, Danfoss
Water Treatment
38 Thermax
System
39 Anti Fouling Device Danfoss
DG SETS
1 Diesel Engine Cummins, Perkins, Caterpillar
2 Alternator Stamford, Leroy-Somer
Woodward, Power-R-CON, DIEF, Schneider, Allen
3 PLC Make
bradely, Siemens
Tricolite, ECS, L&T, GE, Associated
4 AMF Panels Switchgears,Schneider, Unilec, Neptune, Anand
Power, Adlec, ABB, Sudhir Genset Ltd.

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works 5

CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Neilson or any other equivalent confirming to CPCB

5 Silencers
norms.

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works 6

 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

FIRE ALARM SYSTEMS

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

8 CONVENTIONAL FIRE DETECTION AND ALARM SYSTEM

8.1 THE SPECIFICATION COVERS GENERAL REQUIREMENTS OF

MICROPROCESSOR BASED FIRE ALARM CONTROL AND INDICATING
EQUIPMENT.

a) The Fire detection system shall comprise of a central unit, connected by two wires to
field devices. Including fire detection devices, alarm devices and control devices, located
throughout the protected building area. The control unit shall continuously monitor the
status of all sensing devices, and initiate action when a fire or smoke condition is
present.
b) The alarm management shall be field configurable from the control panel via a keypad to
enable the system and to permit future changes. This configuration shall be maintained
under power failure conditions.
c) The Fire alarm panel shall be designed to communicate with the sensors and field
devices. It shall be a microprocessor based unit, and shall incorporate all hardware and
software to enable it to make decisions upon information received from sensors, and
operate appropriate outputs to initiate required alarm and signals. The panel shall
comply with IS 2189 code of practice. The control unit shall have a front panel
comprising of indicating LED’s, control keyboard, and LCD display.
d) The panel shall have 32 characters LCD monitoring & programming setup through menu
option and shall also have provision for viewing events like, Fire, Fault, Disable etc.,
e) The Panel shall be protected against unauthorised operation by means of Password and
shall have two levels of access into the system menu via keypad.
f) These are to be as follows:

Level 1: USER
Level 2: ADMIN

g) Signaling and annunciation shall be by zone, displayed on LED indicators, and on the
LCD text display. Fire, Fault, maintenance, and device/zone disabled signals shall be
indicated visually by LCD text display, and audibly, in the control unit.

h) The display must show the total number of alarm events currently in the system. Fire
alarms shall take priority when displaying. However, it must be possible to view all
events currently in the system, including, fire alarms, faults, disable devices
information’s.

i) The visual indications must be arranged so that the different warning are clearly
distinguished.(i.e. amber for fault, red for alarm) The internal audible signal device may
be the same for all alarms, but either tone variation shall be used to differentiate the
signals. Outputs shall be provided for audible alarms, control functions and remote
repeater.

7.1.1 Programmable Trouble Reminder: The system shall provide means to automatically
initiate a reminder that troubles exist in the system. The reminder will appear on the system
display and (if enabled) will sound a piezo alarm.

8.2 Fire Alarm Panel Indicators

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

All visual indicators shall be LED’s and no incandescent lamps are to be used.

The following LED’s must be provided:

Zone wise Fire

Zone wise Fault
Zone wise Supervisory
Disable/walk test
Common Fire
Common Fault
Common Supervisory

8.3 Panel Displays

The LCD text display must be able to simultaneously display a minimum of the following
information in each display mode.

Zone Display Mode:

- Type of alarm (zone wise & common)

- Alarm count
- Total number of alarms
- 32 Character LCD display

Device Display Mode:

- Alarm count
- Zone in alarm
- Detector in alarm
- Alarm type (zone wise)

The LCD must be at least a 32 character display.

8.4 Panel Controls

The panel is to incorporate a keyboard and push-button with the following functions:

System reset button

Alarm Acknowledge button / silence alarm button
Lamptest button
Menu button
Enter button
Evacuate button
Left / Right Arrow button
Change button

The panel shall have potential free contact form C relay ( 2 for fire and 1 for fault/supervisory)

8.5 Optical Smoke Detector:

The conventional type optical smoke detector shall confine to the relevant standards having the
following features:

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

a. The Smoke detector shall have a unique protocol chamber designed to sense smoke.
b. It shall have sensitivity of 0.09 to 0.14 dB /m.
c. All the detectors shall have a visible LED to indicate the healthiness/ trouble/ alarm
condition of the detector.
d. The LED shall be located in such a way that it shall be visible from the 360° from the
below visual. In some cases where the visibility of the detector is obstructed by cable
trays, false ceiling etc. Facility for connecting the detector to a response indicator has to
be present. The response indicator derives the power to glow from the zone.
e. The detector shall provide a blow out the dust/dirt using a blower.
f. Sleek low-profile housing design with regular 100mm base.
g. The detector shall be capable of detecting both smoldering fires and open fires and shall
be UL approved.

8.6 Heat Detector (Thermal Fixed & ROR):

The conventional type thermal detector shall confine to the relevant standards having the
following features:

a The Heat detection system shall be of Rate of rise of temperature and Fixed
Temperature.
b These detectors will raise an alarm when the detector reaches 59 ° C (Fixed) or when
the change in temperature exceeds the rate of rise of 11O C / min.
c All the detectors shall have a visible LED to indicate the healthiness/ trouble/ alarm
condition of the detector.
d The LED shall be located in such a way that it shall be visible from the 360° from the
below visual. In some cases where the visibility of the detector is obstructed by cable
trays, false ceiling etc. Facility for connecting the detector to a response indicator has to
be present. The response indicator derives the power to glow from the Zone.
e The detector shall provide a blow out the dust/dirt using a blower.
f Sleek low-profile housing design with regular 100mm base.
g The detector shall be capable of detecting both smoldering fires and open fires and shall
be UL approved.

8.7 Multi Sensor (Optical &Thermal) Detector:

The conventional type optical thermal detector shall confine to the relevant standards having the
following features:

a It shall be combination of Smoke and heat detection. The smoke detection system shall
work on and the Heat detection system shall be of Rate of rise of temperature and Fixed
Temperature.
b It shall have sensitivity of 0.09 to 0.14 dB /m.
c All the detectors shall have a visible LED to indicate the healthiness/ trouble/ alarm
condition of the detector.
d The LED shall be located in such a way that it shall be visible from the 360° from the
below visual. In some cases where the visibility of the detector is obstructed by cable
trays, false ceiling etc. Facility for connecting the detector to a response indicator has to
be present. The response indicator derives the power to glow from the loop.
e The detector shall provide a blow out the dust/dirt using a blower.
f Sleek low-profile housing design with regular 100mm base.
g The detector shall be capable of detecting both smoldering fires and open fires and shall
be UL approved.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

8.8 Manual Call Point

The Manual Call Point shall be Conventional type to define the location.

 It shall operate on 24 Volts DC.

 It shall be red in colour ABS Plastic.
 The Manual Call Point shall be with a Resettable type front glass.
 The switch rating shall be for minimum 1 amp.
 There shall be a 5 mm RED LED to glow if the Call Button is activated.
 The cable termination in the call button shall be with 6A rated terminals.
 It shall be compatible with all type of conventional panel.

8.9 Sounder:

The Sounder shall be Conventional type:

 It shall operate on 24 Volts DC.

 It shall be red in colour ABS Plastic.
 The Sounder shall be tested at site for continuous operation of 15 minutes.
 The sounders shall be conventional and wired in a separate NAC.
 Operating Current : 40mA
 Sound Level : 100dB@1m
 Operating Temperature : 0 - 49° C / 32-120° F.
 Sounder Type : Piezo Electric Type
 Tone Type : Fire Engine Siren.

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 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

CCTV SYSTEM

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
CC-135: Construction of Simulator Building at Shastri Park, New Delhi

TECHNICAL SPECIFICATIONS FOR IP CCTV SURVEILLANCE SYSTEM

1 INSPECTION OF SITE:

The bidder should inspect and examine the site and its surrounding and shall satisfy as to
the quantities and nature of work, materials necessary for completion of the work and in
general to obtain all necessary information as to risks, contingencies and other
circumstances which may influence or affect his offer. No extra claim consequent on any
misunderstanding or otherwise shall be allowed.

1.1 IP CCTV SURVEILLANCE SYSTEM

SCOPE OF WORK:

a) Supply, installation, testing and commissioning high quality fast-acting IP CCTV

surveillance system along with power supply, power distribution and required accessories in
the different blocks of ICPAC Headquarters •

b) The entire system shall be as per the drawing and technical specifications enclosed with
tender documents.

c) The price quoted by the vendor should include all the expenses incurred in commissioning
of all cameras with power supply, accessories and other devices complete with software.

d) The CCTV surveillance system should consist of IP Fixed dome cameras (indoor type),
fixed box cameras (outdoor type), software, server, power supply and cables.

e) Video management software shall offer both video stream management and video stream
storage management. Recording frame rate and resolution in respect of individual channel
shall be programmable.

f) The system is presently designed for 21 cameras where as not limited to the same and
scalable up to unlimited cameras if required in the future.

g) Provide an independent network that can be integrated to the purchaser’s network without
degrading the perfosupervisory specialists and technicians at the job to assist in all phases
of system installation, start up and commissioning.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

h) Cat 6cable/fiber cable connectivity with all required hardware up to purchaser’s networking
switches of LAN, locations of networking switches.

i) 230 volts AC Power supply distribution from UPS to each location of cameras along with
DBs ,JBs, cabling work etc. with required accessories.

j) Power supply unit as required for cameras.

k) Training & handing over of all materials, equipment and appliances.

l) Any other items/accessories required for installation, testing and commissioning of CCTV
system.

m) No extra cost shall be paid for miscellaneous items if required to complete the work as per
the design concept.

1.2 SUBMITTALS:

a) Drawings:

b) The system supplier shall submit all shop drawings, and bill of materials.

c) Installation drawing

d) Bill of Materials

e) Cable connectivity drawings and cable schedule.

f) Power distribution scheme

g) Specifications and data sheet for each item

h) List of software and software licenses,

i) Test certificates, Internal test reports etc.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

j) System Documentation

k) System configuration diagrams in simplified block format.

l) Manufacturer's instructions and drawings for installation, maintenance and operation of all
purchased items.

m) Overall system operation and maintenance instructions—including preventive maintenance

and troubleshooting instructions.

n) A list of all functions available and a sample of function block programming that shall be
part of delivered system.

o) Quality Assurance Plan

p) Operation and maintenance manuals.

1.3 QUALITY ASSURANCE:

a) The entire system shall be installed and commissioned from a single vendor to assure
reliability and continued service.

b) The vendor shall be required to train and instruct client's personnel in the correct use,
operation and supervision of the system, preferably prior to the handing over of the project.

c) The supplier shall be responsible for inspection and Quality Assurance (QA) for all
materials and workmanship

1.4 TESTING:

a) Component Testing: Maximum reliability shall be achieved through extensive use of high-
quality, pre-tested components. Each and every component shall be individually tested by
the manufacturer prior to shipment.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

b) Tools, Testing and Calibration Equipment: The supplier shall provide all tools, testing, and
calibration equipment necessary to ensure reliability and accuracy of the system.

1.5 POWER SUPPLY:

a) 230 V + 10 %, 50 Hz + 5% shall be made available for UPS input. Bidder’s scope shall
include complete power distribution for IP CCTV including complete cabling work, DBs and
required electrical accessories with suitable protection devices from UPS (in bidder’s
scope) and UPS output to IP CCTV cameras .

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

2 TECHNICAL SPECIFICATIONS:

IP CCTV SURVEILLANCE SYSTEM

2.1 IP Video System Overview:

a) Transmit and Receive H.264 and MPEG-4 Video and bi-directional Audio.

b) Video and alarm management software under one single front end and should be on open
platform with support to renowned IP camera brands.

c) Support for multi user and multi user group environment in addition to user hierarchy

d) System should allow to be used as a distributed or central architecture with support to any
number of cameras and any number of clients that may be added in future.

e) System Guarantees Bandwidth & Frame rate control.

f) Provides Activity Controlled Frame rate, which in turn reduces the Bandwidth and the
Storage requirements.

g) Provides Broadcast quality Video across IP network including Internet.

h) Provides multiple failover and network resilience.

i) Provides real time recording at 25fps with no frame loss.

j) Provides PTZ Camera Controls & Binary INPUT/OUTPUT controls.

k) Supports Multiple IP Video Streams.

l) Secured recording for evidence purposes and user authentication to protect data integrity.

m) Video Stream bit rate selectable from 32 to 4096kbps.or better

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

n) All the IP cameras shall have Micro SD card slot for recording in SD card when network is
down/fail

2.2 IP Fixed Box Camera (Outdoor Type)

a) Camera must provide at least 704x576 (PAL) active pixels @ 25 fps

b) Color Resolution 540 TV Lines/ 704x576 pixels or better for sharp pick up of live video.

c) Minimum Sensitivity of Day: 0.5 Lux; Day/Night: 0.5 lux in color / 0.05 lux mono

d) Gain Control Automatic

e) White Balance Mode: Auto; Fluorescent; Indoor; Outdoor

f) Shutter Speeds 1/60 to 1/10000 (NTSC), 1/50 to 1/10000 (PAL) or Auto

g) Operating voltage: Power over Ethernet (802.3AF); 12V/24V AC/DC

h) The IP Camera should support a Receiver Driver Unit or a motorized zoom lens

i) The hardware architecture must incorporate multiple processors to ensure best video
quality and other functions even at maximum processor load.

j) The IP Camera system must offer a choice of either MPEG-4 Advanced Simple Profile
or H.264 video compression standards, by just upgrading the firmware over the network
without dismantling the camera.

k) The IP Camera must run Window 10 Operating system for reliability.

l) The camera must have a built in firewall - SSL and other non-IP address specific
security measures are deemed insufficient

m) Should support and allow configuration of the following video resolutions or better.

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CC-135:
Construction of
Simulator
Building at
Shastri Park, New
Delhi

o 352X 288 (SIF)

o 704 X 576 (4 SIF)

o 704 X 288 (2 SIF)

n) When running on MPEG-4 / H.264 compression, the video codec should support atleast
2 simultaneous streams at resolutions between 4SIF and SIF.

o) Each of these streams must be independently configurable to view and record at

different frame rate and resolutions simultaneously.

p) Each Video stream should in turn allow for TCP connections, UDP connections and an
unlimited number of Multicast connections.

q) Each stream must allow independent configuration of bit rate, frame rate, I frame
interval, rate control mode and motion data.

r) All streams must guarantee full frame (25fps) rate under high motion, PTZ operation and
all conditions. A certification from the manufacturer is required to prove this and will need
to be shown during demonstration.

s) The IP Camera must support Capped Bit Rate (CBR) control, to enable users to keep
bandwidth utilization under a certain value without compromise on image quality
irrespective of the level of motion in the scene.

t) The IP Camera must support Activity Controlled Frame Rate control to automatically
adjust frame rate depending on motion in the scene. During periods of negligible motion,
the frame rate must drop to 1fps and when motion occurs the frame rate will return to full

DMRC/CC-
135/Vol.-4/Tech.
Specifications/
Electrical, FF, LV &
HVAC Works/CCTV
System
Page 7 of 15
CC-135: Construction of Simulator Building at Shastri Park, New Delhi

frame rate (30fps/25fps) within 100ms. It must be configurable using a Region of Interest
editor (ROI) that can select regions of the scene where motion will be ignored.

u) Support network protocol 802.3 and IETF Standards10/100 Base-T Ethernet,

RTP/RTCP, TCP, UDP, ICMP, SNMP, HTTP, FTP, TELNET, MULTICAST, ARP and
IGMP

v) Each stream Bit-rate should be user configurable from 32 to 4096 Kbps or better

w) The IP Camera will have a built in web server, making it accessible for configuration
using a standard Internet browser.

x) The IP Camera must be compatible to support advanced analytics software which

should be able to perform the following:

a. Intelligent Motion Detection - Virtual trip wire

b. Left item detection - Theft detection

c. Object tracking

d. Counter flow detection

y) Must have minimum 1 alarm inputs and 1 relay outputs

z) The IP Camera must support redundant recording by streaming to multiple recorders at

the same time.

aa) Should be able to detect motion based on localized area, object size & direction

bb) It must be possible to reset a unit back to Factory Default configuration without losing IP
address information.

cc) Video Output PAL

a) Composite Video Serial Data Port supporting RS232/ RS422/ RS485

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

b) Password protected Web interface for administration

c) Should have onboard diagnostics facility for serial, Video & Network interface. System
logging shall be possible to a remote IP address, the console port or the unit itself.

d) The system MUST be able to use one particular frame rate and resolution at Day time
and automatically switch to another frame rate/resolution profile when low light
conditions occur

e) The system MUST allow for Telnet/FTP access into the units and also this
access MUST be configurable, wherein when active access is allowed and when
deactivated access MUST not be allowed.

2.3 IP Fixed Dome Camera (Indoor Type)

a) Latest Camera Ex View 1/3 “ or 1/4" interlaced imager or better

b) Camera must provide atleast 752x582 (PAL) active pixels

c) Color Resolution 540 TV Lines or better for sharp pick up of live video.

d) Minimum Sensitivity of Day: 0.5 Lux; Day/Night: 0.5 lux color / 0.05 lux

e) White Balance Mode: Auto; Fluorescent; Indoor; Outdoor

f) Verifocal /Auto Iris DC drive lens options of 3.8 – 9.5mm or 9 – 22mm

g) Shutter Speeds 1/60 to 1/10,000 (NTSC), 1/50 to 1/10,000 (PAL) or Auto*

h) Operating voltage: Power over Ethernet (802.3AF); 12V/24V AC/DC.

i) The hardware architecture must incorporate multiple processors to ensure best video
quality and other functions even at maximum processor load

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

j) The IP Camera must offer a choice of either MPEG-4 Advanced Simple Profile or H.264
video compression standards, by just upgrading the firmware over the network without
dismantling the camera.

k) The IP Camera must run Windows 10 Operating system for reliability.

l) The camera must have a built in firewall - SSL and other non-IP address specific
security measures are deemed insufficient

m) Should support and allow configuration of the following video resolutions

n) 352 X 288 (SIF )

o) 704 X 576 (4 SIF)

p) 704 X 288 (2 SIF)

q) When running on MPEG-4 / H.264 compression, the video codec should support at least
2 simultaneous streams at resolutions between 4SIF and SIF.

r) Each Video stream should in turn allow for TCP connections, UDP connections and an
unlimited number of Multicast connections.

s) Each stream must allow independent configuration of bit rate, frame rate, I frame
interval, rate control mode and motion data.

t) All streams must guarantee full frame (25fps) rate under high motion and all conditions.
A certification from the manufacturer is required

u) The IP Camera must support Capped Bit Rate (CBR) control, to enable users to keep
bandwidth utilization under a certain value without compromise on image quality
irrespective of the level of motion in the scene.

v) The IP Camera must support Activity Controlled Frame Rate control to automatically
adjust frame rate depending on motion in the scene. During periods of negligible motion,
the frame rate must drop to 1fps and when motion occurs the frame rate will return to full
frame rate (30fps/25fps) within 100ms. It must be configurable using a Region of Interest
editor (ROI) that can select regions of the scene where motion will be ignored.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

w) Support network protocol 802.3 and IETF Standards 10/100 Base-T Ethernet,
RTP/RTCP,TCP, UDP, ICMP, SNMP, HTTP, FTP, TELNET, MULTICAST, ARP and
IGMP

x) Each stream Bit-rate should be user configurable from 32 to 4096 Kbps or better

y) The IP Camera will have a built in web server, making it accessible for configuration
using a standard Internet browser.

z) The IP Camera must be compatible to support advanced analytics software which

should be able to perform the following:

o Intelligent Motion Detection - Virtual trip wire

o Left item detection - Theft detection

o Object tracking

o Counter flow detection

aa) Must have minimum 1 alarm inputs and 1 relay outputs

bb) The IP Camera must support redundant recording by streaming to multiple recorders at
the same time.

cc) Camera should be able to detect motion based on localized area, object size & direction.

dd) It must be possible to reset a unit back to Factory Default configuration without losing IP
address information

2.4 Video Output PAL

a) Composite Video Serial Data Port supporting RS232/ RS422/ RS485

b) Password protected Web interface for administration

c) Should have onboard diagnostics facility for serial, Video & Network interface. System
logging shall be possible to a remote IP address, the console port or the unit itself.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

d) The system MUST be able to use one particular frame rate and resolution at Day time
and automatically switch to another frame rate/resolution profile when low light
conditions occur

e) The system MUST allow for Telnet/FTP access into the units and also this access MUST
be configurable, wherein when active access is allowed and when deactivated access
MUST not be allow.

3 Video Operation Codec Management, Recording and Processing Software

(VOCMRPS)

a) VOCMRPS will be a highly scalable, enterprise level software solution. It must offer
a complete Video Surveillance solution that will be scalable from one to hundreds of
cameras that can be added as and when required. It should allow for seamless integration
of third party security infrastructure where possible. The system MUST be capable of
working on latest Windows OS and Windows Server platforms. Should support client-
server architecture.

b) The software must come as one unit and not multiple loadable units and should support
free distribution of multiple clients to multiple machines.

c) The software must not have operator seat based licensing. It must allow for any number of
user seats/installations on the IP video network to be added for future scalability at no
management software cost or licensing cost.

d) The manufacturer supplied management software pack should be on open platform/

standard media player.

e) The VOCMRPS should allow for video to be streamed on a video mosaic wall.

f) All upgrades and releases should be made available free of cost during warranty period.

g) The system shall allow operation with/without a PC keyboard or mouse with touch screen
PC monitors. Once system configured, virtual matrix functions can be carried out using
CCTV keyboards and should have capability to configure with HDTV.

h) The VOCMRPS shall provide the following:

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

i. Automatic search of components of proposed system on the network. They can be

Cameras, Monitors, Alarm panels, NVRs.It should also capture video from various
source like webcam, USB cam etc.

ii. The system should allow for live view, playback and system configuration of the IP video
system.

iii. The system should allow for creation of multiple users and user groups and assign tasks
to each.

iv. Drag & Drop functions for most functions on the system and also for set up of connection
between cameras and monitors and also support to create custom layout by grouping of
cameras from different server/ locations into groups for more efficient monitoring.

v. Several simultaneous live picture connections of camera in network. It should be

capable of showing video pane layouts including 2x2, 3x3, 4x4, 5x5,8X8 various Hot
Spots (1+5, 1+7, 1+9, 1+12, 1+16) and custom layouts

vi. It shall be possible to display video and audio bit rates; frame rate and resolutions on
each video pane as overlays.

vii. The live view must be capable of highlighting motion as green rectangle overlays and
displaying real-time alarm information overlaid on the live video feed.

viii. It shall be possible to listen to audio from individual codec (cameras) or Receivers.

ix. Audio must be simultaneously transmitted from the Operator to allow a two-way
conversation.

x. It must be possible to establish bi-directional audio connection on alarm. The user

should also be able to disable listen when speaking to prevent feedback through the
microphone.

xi. System setup for pre-defined surveillance tasks to be invoked at pre-defined times in the
day.

xii. Programming of automatic recording events on NVR, maybe based on events such as
alarms and video analysis

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

xiii. Remote maintenance of IP Video components

xiv. Off line construction of site ‘tree’ and addition of devices

xv. It shall be possible to show text on screen display (OSD) when video is displayed on a
Receiver/Decoder.

xvi. The location of the OSD must be configurable on the screen.

xvii. The system should provide Video Lockout facility where a super-user can prevent all
other users from viewing live video and divert recorded video to another Networked
Video Recorder. The super-user shall also be able to release the video lockout and
restore the system to its original state. It should also support software watchdog for
advance detection of problem & recovery at server.

i) The VOCMRPS shall allow the following: - Live display of cameras

a. Live display of camera sequences, salvos and guard tours - Playback of archived
Video at speeds of x1/4 – x16

b. Retrieval of archived Video using normal playback, thumbnails (motion, event or

time based) - Instant Replay of Live Video

c. Use of site maps and Google map - Configuration of system settings

j) For each camera set up bit rate, frame rate, and resolution shall be set independent of
other cameras in the system.

k) Altering the setting of one shall not affect the settings of other cameras.

l) Should allow up to 21 cameras to be replayed simultaneously from one NVR

m) Auto-protecting of video recording on post and pre ‘alarm’ images.

n) Exported recordings will be protected by an invisible watermark using hashing function with
a 1024 bit key.

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o) Should have facilities for play, forward, rewind, pause along with fast forward and rewind for
reviewing the recorded videos.

p) The application should allow for time-synchronized playback of different cameras together
in the same video panel. This will enable the operator to watch playback of an event in an
area covered by multiple cameras from different angles as the event happens.

q) The system must support absolute redundancy with 1 to N, N to 1 and N to N redundancy

configurations. All this should be provided without a licensing model.

r) The system must support video bookmarks, where the system allows the user to create
textual bookmarks at various places in a recorded footage and allow access to these
bookmarks through an intelligent bookmark management system.

s) The system must allow application of sorting and searching filters on bookmarks for faster
retrieval and access to incidents in recorded footage.

3.1 Network Video Recorder

a) NVR shall be installed on a Linux/Windows PC.

b) The NVR/NAS should have no limitations on the kind of storage to be used (RAID, NAS,
etc).

c) The NVR/NAS must be capable of recording 50 cameras simultaneously.

d) The NVR/NAS must be providing for a disk management system which will automatically
reap old recordings to overwrite with new ones when max disk usage is reached.

e) The storage on a minimum Disk of 8TB

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 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

FIRE FIGHTING

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1 FIRE HYDRANT & FIRE FIGHTING SYSTEM

1.1 General
1.1.1 The scope of this section comprises the supply, installation, testing and
commissioning of the entire fire fighting system.
1.1.2 All M.S pipes and other accessories shall be cleaned thoroughly before application
of primer coats. Two coats of primer shall be applied and thereafter two coats of
enamel paint shall be applied. Each enamel paint coat should be given minimum 24
hours drying time. No thinner shall be used. The work shall be done in professional
manner and to the satisfaction of the Engineer. No extra amount shall be paid for
this work and price may be included with the relevant item itself opr as per BOQ.
1.1.3 All items provided in this specification shall be provided by the Contractor and no
extra payment shall be made.
1.1.4 All power and control cables in the fire system shall be Fire Retardant Low Smoke
low halogen (FRLS) cables.
1.1.5 The Contractor shall obtain approval from Local Fire Department. No extra amount
shall be paid for this work and price may be included in the rates.
1.1.6 All nuts, bolts, washers etc. shall be of Galvanized iron for fitment of pipes, valves
and other accessories unless and otherwise specified.
1.2 Scope of Work
1.2.1 The scope of work shall cover supply, fabrication, installation, testing and
commissioning of the fire hydrant system covering the following but not limited to:
a) Fire Hydrant electric pumps as shown in the BOQ, drawings and as required.
b) Jockey pump, electric driven as shown in the equipment schedule, drawings and as
required.
c) Hydrant mains, external ring and yard hydrants.
d) Wet risers in the building as specified and shown on drawings.
e) Landing valves, hose reels, hose cabinets etc.
f) Firebrigade breaching, siamesec onnectionsand connections to pumps and
appliances.
g) The Fire Suppression System shall comprise the Fire Hydrants System, the Sprinkler
System (Wet type), Fire extinguishers, Gas flooding system etc.
h) The Hydrant System and the Sprinkler System, under normal conditions, shall be
pressurized by means of the electric motor driven Jockey Pump.
i) The Hydrant System and Sprinkler System shall be provided with two electric motor
driven main pump (1 Working + 1 Standby).
j) The starting and stopping of the Jockey pump shall be automatic based on the
pressure switches at preset low and high pressure.
k) The electric motor driven Hydrant Pump starts automatically at preset pressure by
means of a pressure switch. As soon as the Hydrant Pump starts, the Jockey Pump
stops. If for any reason the electric motor driven Hydrant Pump does not start at the
preset pressure or is unable to maintain the pressure, the stand by electrical driven
Hydrant Pump starts at the preset pressure.
l) The hydrant pump, electric motor driven shall be stopped only manually.
m) Contractor shall ensure that all false ceiling voids greater than 800 mm are provided
with sprinklers.
n) Contractor shall ensure Hydro Testing for the complete system.
o) The contractor shall include submission and obtain necessary approval of relevant
drawings, schèmes and documents from local / fire authorities and also obtain all
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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

necessary permissions and NOC for execution of work as wellas getting final
approvals from the concerned fire officers along with relevant “NOC” for occupation of
building. No extra payment shall be made on account of getting the approval.
p) The contractor shall get the Fire Fighting System approved by the Fire Authority
having Jurisdiction.Without which the work will not be taken over by the Employer. All
expenses on this account shall be borne by the Contractor.
1.3 Standards

1.3.1 The fire hydrant installation shall conform to and meet with the requirements set out by
the following:

STANDARDS DESCRIPTION
Code of practice for installation of internal fire
IS: 3844-1989
hydrant.
National Building Code Part-IV: Fire Safety
NBC Part-IV
System
IS: 5290 – 1993 Specification for landing valves
Specification for Thermoplastic Hoses
IS : 12585
Specification for Wet Riser system and
CPWD
sprinkler system

a) All the standards mentioned above as well as referred to in the document

elsewhere shall be latest
b) SHOP DRAWINGS The Contractor shall prepare and furnish all shop drawings
in quadruplicate at no extra cost for approval by the Engineer-in-Charge before
commencing fabrication/manufacture of the equipment. Such shop drawings
shall be based on the Architect drawings and requirements laid down in the
specifications and as per site conditions. The manufacture of equipment shall be
commenced only after the shop drawings are approved in writing by the
Engineer-in-Charge. Such drawings shall be co-ordinated with all disciplines of
work.
c) COMPLETION/ AS BUILT DRAWINGS: On completion of the work and before
issuance of certificate of completion, theContractor shall submit to the Engineer-
in-Charge, General layout drawings, drawn at approved scale indicating layout
of pump house piping and its accessories “As installed ". These drawings shall
in particular give the following:
d) General layout of pump house.
e) Panels and other equipment location and sizes etc.
f) Complete Schematic as installed.
g) Location of Hydrants, Earth pipes, route of earthing conductors etc.
h) Route of all cables and pipes run along with detail sizes and mode of
installation.
1.3.2 Documents
1.3.2.1 The Contractor shall submit to the Engineer-in-Charge, the following documents on
completion of the work and before issuance of completion

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

a) Warranty for equipment installed.

b) Test certificates.
c) History sheets of the equipments.
d) Catalogues.
e) Operation and Maintenance manuals.
f) List of recommended spares and consumables.
g) Reconciliation statement. viii. All approvals and sanctions.
1.3.2.2 Sanction/approvals from statutory authorities/local fire department

1.3.3 The Contractor shall be fully responsible and shall carry out following activities :-
a) Submission of working drawing.
b) Obtaining the approval of drawings.
c) Arranging inspection of site by officials of the Authority.
d) Obtaining the final no objection/completion certificate after submitting required
documents.
e) Any other statutory approvals required.

1.4 Fire Pump

a) The fire pump shall be single stage /double stage suction centrifugal type and direct
driven conforming to IS: 1520 by electric motor or diesel engine as specified. The
pumprating and performance shall conform to the equipment schedule and meet
the TAC duty requirements. The pumps should be with mechanical seal of reputed
make.
b) Pump casing shall be of close-grained cast iron (grade FG 200, IS 210) with bronze
impeller. The shaft sleeve shall be brass or SS 304/SS410and the trim shall be
brass or bronze.
c) Pump shall be capable of delivering 150% of the rated capacity at 65% of the rated
head and the no-delivery head shall be not more than 140% (150% in case of end
suction type) of the rated delivery head. The pump casing shall withstand 1.5 times
the no-delivery pressure or 2 times of the duty pressure whichever is higher.
d) The pump shall be electrically driven with direct flexible coupling.
e) The electric drive motor shall be squirrel cage induction conforming to IS: 325-1996
and rated for continuous duty (S1). Motor shall have not less than class F insulation
and minimum enclosure of IP22. The starter shall be air-cooled fully automatic star
delta or autotransformer type. Starters shall conform to relevant IS standard and
rated for AC-3 duty conditions.
f) Drive rating shall be based on the largest of the following:
i. Rated pump discharge at rated head
ii. 150% of rated discharge @ 65% of rated head
iii. Maximum power absorbed by the pump in its operating range i.e. no-
delivery to free discharge.
g) The pumps shall be directly coupled to the motor shaft through a flexible coupling
protected by a coupling guard.
h) The pump and motor shall be mounted on a common base plate fabricated from
mild steel section. The base plate shall have rigid, flat and true surfaces to receive
the pump and motor/diesel engine mounting feet. The pump will be perfectly
aligned with the motor so as to avoid any vibration during operation.
a) The pump Heads Specified on the Drawings and/or equipment Schedules are for
guidance and information only are calculated based on assumed equipment pressure
drops. The Exact pump head based on the pipe run and the offered equipment.
Calculation shall be submitted for approval. No modification to the piping System shall be
allowed without prior approval. Any additional cost for modification of the
system(pumps,motors,switchgears,cables,panelboards,switchboard etc) necessary to
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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

meet the specified duties, special conditions and the offered equipment shall be provided
at no extra cost to the Employer)

1.5 Pump Foundation

Foundation of pumps in Fire Pump rooms should be of considerable height so that
these are not submerged in case of overflow.

1.6 Accessories
1.6.1 The Fire Pumps shall be complete with the following accessories:
a) Suction and discharge eccentric reducers
b) Pump coupling guard
c) Common base frame, fabricated mild steel or cast iron.
d) Pressure gauge at discharge side between pump and the non-return valve.
1.6.2 Each pump shall have independent set of pressure switches. The pressure switch
shall be snap action SP DT switch rated 10A @ 230 V operated through a stainless
steel diaphragm. The switch shall have a pointer for manual adjustment of set point,
and all electrical connections shall be terminated in a screwed terminal connector. The
entireunit shall be encased in a cold drawn steel (heavy gauge) enclosure. The
diaphragm shall be designed for a maximum operating pressure of the system. Each
pressure switch shall be provided with a pressure gauge in parallel as shown on the
drawings and all gauges and pressure switches shall be mounted in an instrument
panel with necessary control piping and drainage facility.
1.6.3 Anti vibration mounting
Suitable vibration mounting duly approved by Engineer shall be employed for mounting
the unit so as to minimize transmission of vibration to the structure. The isolation
efficiency achievable shall be clearly indicated.

1.6.4 Rubbermat

Rubber mat shall be provided in front to cover the full length of all panels. Where back
space is provided for working from the rear of the panel, rubber mat shall also be
provided to cover the full length of panel. 1000 mm wide of required length as required
for 1100 voltage.

1.7 System operation and control panels

1.7.1 The fire pump shall be started automatically on loss of pressure and the operation
sequence of the booster and fire pumps shall be as follows:
Description Cut in Cut out
Main Fire Electric Pump 5.00 Kg/sqcm Manual
Standby Pump(Electric driven) 4.00 Kg/sqcm Manual

1.7.2 The motor starters (direct on line or star-delta) shall consist of electrically actuated
contactors. The starter shall be complete with ON-OFF push buttons, timers and
auxiliary contacts and shall be fully automatic. There shall be an indicating lamp with
each of the pumps and an ammeter and selector switch with the fire pumps. Fire
pump starting shall be annunciated through an electric siren.
1.7.3 The starter along with isolator shall be housed in a 14 SWG MS box duly rust inhibited
through a process of degreasing and phosphating.
1.7.4 All cabling to and from the pumps to starter and control switch shall be carried out
through armoured PVC cables of approved makes. Cables shall be laid in accordance
with section "MV CABLING". The pump motors and panels shall be double earthed in
accordance with IS 3043- 1987 or as shown on drawings and as approved.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.7.5 All power and control cables in the fire system shall be Fire Retardant Low Smoke low
halogen (FRLS) cables.
1.7.6 Installation
a) The pump and motor assembly shall be mounted and arranged for ease of
maintenance and to prevent transmission of vibration and noise to the building
structure or to the pipe work.
b) The pump and motor assembly shall be installed on suitable RCC foundation.
The length and width of the foundation shall be such that 100 mm. space is left
all around the base frame. The height of foundation shall be so decided that the
total weight of foundation block is 1.5 times the operating weight of the pump
assembly. The foundation shall be isolated from the floor by vibration isolating
pads. Angle iron frame of size 35 mm x 35 'mm x 3 mm shall be provided on the
top edges of the foundation.
c) More than one pump and motor assembly shall not be installed on a single base
or cement concrete block.
d) The suction/discharge pipe shall be independently supported and their weight
shall not be transferred to the pump. It should be possible to disconnect any
pump for repairs without disturbing the connecting pipe line.
e) A minimum clearance of 1 m. around the main pumps shall be provided.
1.7.7 Drainage pump
a) Drainage sump pumps shall be vertical type suitable for drainage and solids
upto 12mm size. Pumps shall be wet pit/submersible type, grease lubricated
and having ample support arrangement for suspension from sump top slab.
Impeller shall be cast iron with open vanes.
b) Pumps shall be provided with necessary support plates and M.S. sections.
Pumps shall operate with high water level in sump and stop at low water level by
means of an electronic level controller or auto float.
c) Pump shall have all accessories suitable for operation on 230 V, single
phase/415 V 3 phase, 50 Hz. AC supply complete with starter for automatic
operation including water level sensing device, inter connection with
submersible cable etc. common electrical panel with alternative operation of
pumps including all cabling, wiring etc. The scope will also include GI piping
work including bend connectors, etc. for drainage, complete in all respects

1.8 Fire hydrants and hose reels

1.8.1 Fire hydrant design
1.8.1.1 Various pipe sizes of dia – 250mm, 200mm, 150mm, 100mm, 80mm, 65mm, 50mm,
40mm, 32mm and 25mm shall be used and these are purely for contractor's
guidance. The contractor shall beresponsible for selection of sizes as per detailed
engineering to be done by him and submit calculation (Hydraulic Calculation as per
standard) for approval to Employer/DDC. Plumbing design to bedone by the
contractor shall incorporate the following:
a) Butterfly/sluice valves shall be provided at suction and delivery sides of pumps
(If positive suction is not provided, valve at suction is not to be provided).
b) External hydrant
c) Fire service connection/inlet.
d) Test valve.
e) Drain connections.
1.8.1.2 For testing the system healthiness and automatic operation on daily basis, one test
pipe with butterfly/sluice valve shall be provided in common discharge header. For
avoiding wastage of water, this pipe shall discharge water in the tank.
1.8.1.3 Non return valve shall be provided at the delivery of each pump and fire service inlet.
This shall be of swing type.
1.8.1.4 Air release valves with ball valve shall be provided in the piping system for venting
trapped air with a size of 25 mm for pipes upto 100 mm and 40 mm for larger pipes.
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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.8.2 Hydrants shall be provided internally and externally as shown on the drawings.
Internal hydrants shall be provided at each landing of and escape staircase and
additionally depending on the floor area as shown on drawings. Landing valve shall be
single headed SS (stainless steel) valve with 63 mm diameter outlets and 80mm inlet
conforming to IS 5290-1993. Landing valve shall have flanged inlet and instantaneous
type outlets and mounted at 1.0m above the floor level. Instantaneous outlets for the
hydrants shall be of standard pattern approved and suitable for 63mm diameter fire
brigade hoses. The landing Valve shall be fitted to a T connection of the Risers at the
Landing in such a way that the valves is in the centre of the internal hydrant operation.
The valve base shall be Vertical and the valve facing outside, so there shouldbe no
hinderence in the operation of wheel. Wherever necessary, pressure reducing orifices
plate shall be provided so as to limit the pressure to 3.5 kg/cm2 or any other rating as
required by the LocalFire Authority.
a) Each landing valve shall have a hose reel cabinet as shown on drawings.
b) Landing valve with single 63 mm diameter outlet and 80 mm diameter inlet.
c) First-aid hose reel shall be with 45 m long 25 mm diameter (for Stations) and 30 m
long 20 mm diameter (for Depot) high pressure thermo plastic (IS: 12585 marked)
with Ball Valve and 7 mm shutoff nozzle. The entire assembly is mounted on a wall
bracket and can swing 180 degree. The water inlet is connected to the riser pipe by
means of a socket and valves. The hose tube can be pulled out easily for the
purpose of discharge of water
d) nos. 15-meter long38mmdiametersynthetichoseswithSSISmarked instantaneous
couplings.
e) Branch Pipe and Nozzle:- Branch Pipes with nozzle are mounted at the end of hose
pipe . Branch pipe is properly finished and free from sharp edges. During
operation.a fireman has to hold the branch pipe. One end of branch pipe is fixed
with hose coupling and the other end is threaded to fit the nozzle. Nozzle is tapered
pipe with one end threaded internally which is fixed on branch pipe. The size of
other end i.e. nozzle shall be 20 mm (nominal internal diameter).
f) The First Aid Hose pipe shall conform to IS: 12585 and be wound on a heavy-duty
circular hose drum confirming to IS: 884 – 1985 with a bracket. The hose shall be
permanently connected on one end to the Wet Riser through a 25m Ball Valve with
necessary hose adapter and a SS nozzle at the other end.
g) Hoses shall be in two lengths of 15 m each, of synthetic type ( UL listed ) with
instantaneous couplings, neatly rolled into bundles and held in position with steel
brackets. Hoses shall be tested and certified by the manufacturer to withstand an
internal water pressure of not less than 35 kg/cm2 without bursting. The hose shall
also withstand a working pressure of 7-kg/ cm2 without leakage.
h) The internal hose cabinet shall be fabricated from mild steel sheet / stainless steel
sheet / aluminium sheet. The cabinet shall have double flap-hinged doors with 5.5
mm clear glass and shall have necessary openings for riser main and brackets for
all internals. The cabinet shall be provided with suitable and robust locking
arrangement, the hose cabinet shall be of size to accommodate the following.
i. Landing valves (Single / double headed).
ii. Hose pipe.
iii. Hose reel (45 mtr.).
iv. Branch pipes, nozzles (2 sets).
v. Fire man’s axe and hand appliances.
vi. Universal locking arrangement.
i) The Hose Cabinet shall be fabricated from any of the following ( as per BOQ ):

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

i. 2 mm thick MS sheet duly rust inhibited through a process of degreasing

and phosphating and painted in red colour.
ii. 2 mm thick stainless steel sheet.
iii. 3mm thick aluminium sheet powder coated to red colour.
j) External hydrants shall be as per IS: 5290 with hand wheel control and an 80 mm
diameter pipe stand post. Hydrants shall be located at least 2m away from and
within 15m from the building wall.
k) Each hydrant shall be provided with a hose cabinet containing 2 x 15m 38 mm
diameter synthetic hoses with couplings. The cabinet shall contain a branch pipe
and nozzle. The cabinet shall be 900 x 600 x 450 mm fabricated out of 2 mm
stainless steel sheet or powder coated 3 mm thick aluminium sheet. The cabinet
shall be wall-mounted or freestanding with its own steel legs depending on the site
conditions and as shown on drawings and as approved.
i. Single / Double headed yard hydrant valve.
ii. Hose pipe (2 lengths of 15 m).
iii. Branch pipes, nozzles (2 sets).
iv. Fire man’s axe (20,000 volts for a period of 60 sec. as per IS : 926).
v. Universal locking arrangement fabricated from 3 mm thick aluminium
sheet and postal red coated with 6 mm thick plain glass in front.
l) The fire brigade connection shall consist of four headed inlets, as specified in BOQ,
63mm diameter outlets with built-in check valve and drain plugs connected to a
150mm diameter outlet connection to the water reservoir or to the hydrant main.
The fire brigade collecting head shall conform material and performance to IS: 904-
1983 “Specification for 2-way & 3-way suction collecting heads for fire fighting
purposes”. These are provided for connection of fire service hose pipes for either
directly pressurizing the system with their pumps or filling water in the tank from a
distance. In the first case non return valve with butterfly valve shall be provided for
holding water pressure. Fire service inlet shall be provided with each wet
riser/down comer and the ring main. The typical arrangement shall be as per
CPWD specification part V (Wet Riser and Sprinkler System). These are fixed to
150 mm dia pipe and located in MS Box made of 2 mm thick mild steel sheet with
open able glass cover.these shall be as pere IS 904
m) Fire man’s axe.

1.8.3 Testing and commissioning

1.8.3.1 The Jockey & fire pump starting and stopping shall be tested by opening the test
valve and record the following and the valves should be as furnished below:
Jockey pump start / stop
System pressure at start-up
System pressure at stop
Time elapsed from start to stop
Hydrant / Sprinkler Main Pump
System pressure at start-up

1.8.3.2 Maintained system pressure while discharging the landing valve at the highest
point.
Highest outlet 3.5 kg/cm2

1.8.3.3 All the operating tests shall be carried out to the satisfaction of Compliance with the
local fire brigade and the enforcing authorities as specifically ladid down by the local
fire authorities.
1.8.3.4 Mode of measurement

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

a) Hydrant pump with mounting frame excluding concrete foundation shall be

measured per unit.
b) Jockey pumps - same as hydrant pump.
c) Instrument panel with pressure gauges, pressure switches, control piping etc.
shall be measured as one unit.
d) Control cabling from pressure gauge panel to the respective starters shall be
measured in running meter and paid at unit rates.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.9 PIPING FOR FIRE FIGHTING SYSTEM

1.9.1 Scope

The scope of work covers supply, fabrication, laying, testing, painting and
commissioning of the entire piping system for the fire fighting installation i.e. fire
hydrant and sprinkler systems.

1.9.2 Standards

The following standards shall be applicable:

STANDARDS DESCRIPTION

IS – 8757 Glossary of terms associated with Fire safety.

IS – 884 Specification for first aid hose reel for fire fighting.

Specification for coupling, double male and double female

IS – 901
instantaneous pattern for fire fighting.

IS – 902 Specification for suction hose couplings for fire fighting purposes.

Specification for fire hose delivery couplings, branch pipe, nozzles

IS – 903
and nozzle spanner.

Specification for two-way and three-way suction collecting heads

IS – 904
for fire fighting purposes.

Specification for suction strainers, cylindrical type for fire fighting

IS – 907
purposes.

IS – 908 Specification for fire hydrant, stand post type.

IS – 909 Specification for ground fire hydrant.

IS –636 Non percolating flexible fire fighting delivery hose.

IS –7637 Glossary of terms for fire fighting equipments.

Specification for washers for water fittings for fire fighting

IS –937
purposes.

Code of practice for fire safety of building (general) :

IS –1641 Generalprinciples for fire grading and classifications.

IS –1642 Code of practice for fire safety of building (general): Details of

construction.
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IS –1643 Code of practice for fire safety of building (general) :Exposure

hazard.

IS –1644 Code of practice for fire safety of building (general): Exit

requirements and personal hazard.

IS –1646 Code of practice for fire safety of building (general) : Electrical

Installation.

IS –2871 Specification for branch pipe, universal for fire fighting.

IS –2930 Functional requirements for hose laying tender for fire brigade
use.

IS –8090 Specification for coupling, branch pipe, nozzle, used in hose reel
tubing for fire fighting.

IS –8442 Specification for stand post type water monitor for fire fighting.

IS –9972 Specification for automatic sprinkler heads.

IS –11101 Specification for extended branch pipe for fire brigade use.

IS –12349 Fire Protection sign.

IS –12407 Graphic symbols for protection plan.

IS –9668 Code of practice for provision and maintenance of water supplies

and fire fighting.

IS –3844 Code of practice for installation and maintenance of internal fire

hydrants and hose reel on premises.

IS –10221 Code of practice for coating and wrapping of under ground mild
steel pipe lines.

IS –15105 Design and installation of fixed automatic sprinkler fire

extinguisher system – Code of Practice.

IS –325 Three phase induction motors.

IS –1822 Motor starter for voltage not exceeding 1000 volts.

IS –3624 Burden tube pressure and vacuum gauges.

IS –1520 Horizontal centrifugal pumps for clear, cold, fresh water.

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IS –1239 Mild steel tubes, tubular and other wrought steel fittings.

IS –3589 Electrically welded steel pipes for water, gas and sewage.

IS –6392 Steel pipe flanges.

IS –778 Gunmetal gate, globe and check valves for general purpose.

IS –2592 Recommendation for methods for measurement or fluid flow be

means of orific plates and nozzles.

IS –732 Code of practice for electrical wiring and fitting of building.

IS –900 Code of practice for installation and maintenance of induction

motor.

IS –1248 Direct acting electrical indicating instruments.

IS –2516 A.C. circuit breakers for voltages not exceeding 1000 volts.

Heavy duty air break switches and composite units of air break
IS –4047
switches and fuses for voltage not exceeding 1000 volts.

IS –2208 HRC cartridge fuse links upto 650 volts.

IS –1554 PVC insulated (heavy duty) electric cable for working voltage upto
and including 11000 volts.
(Part II)
IS –1536 Centrifugally Cast Iron Pipe.

IS –1537 Vertically Cast Iron Pipe.

IS –1538 Cast Iron Pipe Fitting.

IS –780 Sluice valve for water works purpose (50 to 300 mm size ).

IS –13095 Butterfly valves.

All the standards mentioned above as well as referred to in the document elsewhere shall be
latest.

1.9.3 Hydrant Mains

External
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a) Mild steel pipes, when laid underground, shall be protected against corrosion by
a 4 mm thick bituminous tape with minimum 12 mm overlap over the entire
length including fittings. Fittings shall be weldable wrought iron; suitable for butt-
welding and 10% of the welded joints shall be radiographically tested and found
in order. The welded joints shall be random selected for testing in consultation
with the Engineer-in- charge. All flanges shall be slip-on welded type to IS: 6392
– 1971 with a 3mm fiber- reinforced EPDM gasket and rated for 2.0 N/ mm2.
b) Underground mains shall be laid not less than 750 mm below the ground level.
All excavation for pipe laying shall be carried out with sufficient width for making
proper joints. Backfilling shall be done only after the piping is hydro-statically
pressure tested. Piping shall be constantly kept clean till tested.
c) All valves shall be housed in brick masonry chambers over 150mm cement
concrete (1:3:6) foundation. The brick walls of the chamber shall be plastered
inside and outside with 20mm cement sand plaster 1:4 with a floating coat of
neat cement. Chambers shall be 650 x 650 mm clear for depths up to 1200 mm
and 1000 x 1000 mm for depths beyond. Each chamber shall have a cast iron
surface box approved by the Engineer incharge.
d) Piping laid above ground shall be supported on cement concrete (1:2:4)
pedestals raising the bottom of the pipe at least 150mm over the ground level
and held to the pedestals with galvanized clamps. Pedestals shall be made at
3.0m centre to centre and as shown on drawings. Cement concrete 1:2:4 thrust
anchors shall be provided at all tee-off points and change of direction as shown
on drawings and as required. Pipes laid on walls and ceiling shall have
galvanized steel brackets.
e) If pipe shall be buried then the Pipe material shall be replaced by Ductile pipe
with Double flange subject to approval of Engineer in charge.

Internal

a) All internal pipes shall be, unless otherwise specified, heavy quality mild steel
tubes to IS: 1239 using wrought steel heavy-duty fittings. Flanges shall be
provided to matewith valves and other equipment and shall conform to IS: 6392.
Flanges shall be rated for 2.0 N/ mm2.
b) Valves shall be suitable for external piping.
c) All pipes shall be of approved make and best quality without rust marks. Pipes
and fittings shall be fixed in a manner as to provide easy accessibility for repair,
maintenance and shall not cause obstruction in shafts, passages etc. Pipes and
fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat
workmanship manner. Pipes shall be securely fixed to walls and ceilings by
suitable supports at intervals specified. Only approved type of anchor fasteners
shall be used for RCC ceiling and walls.
d) All pipes shall be adequately supported from ceiling or walls through structural
supports fabricated from mild steel support structures e.g. rods, channels,
angels and flats generally as shown on drawings. Fasteners shall be shear type
anchor fasteners in concrete walls and ceilings and wrought steel spikes of at
least 75mm long in brick walls. All pipes supports shall be painted with 1 coats of
red oxide primer and two coats of black enamel paint.
e) All low point loops in the piping shall be provided with 25mm Ball Valves for
draining the system. All valves shall have screwed brass caps. Likewise 25mm
gunmetal air vents shall be provided at all high point loops to prevent air locking.
f) All piping shall have welded joints.

Pipe Jointing

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a) All pipes shall be provided with threaded / welded joints. Hold tite shall be used
for sealing for threaded joints.
b) Joints between valves and MS pipes shall be made by providing a suitable
flange.
c) Flanges shall have appropriate number of holes and shall be fastened with nuts,
bolts and 1.5mm thick EPDM gasket.
d) All nuts, bolts, washers etc. shall be of Galvanized iron for fitment of pipes,
valves and other accessories unless and otherwise specified.
e) Mild steel flanges shall be in accordance with Table - 17 of IS : 6392 "Plate
Flanges for Welding" and flange thickness shall be as under. Gasket thickness
shall not be less than 3 mm.

Pipe dia Flange Thickness

200 mm 24 mm
150 mm and 125 mm 22 mm
100 mm and 80 mm 20 mm
65 mm 18 mm
40 mm and below 16 mm

f) The type of fiiting required for pipes upto 50mm dia will be screwedfitting and
above 50mm dia will be butt welded fitting.
1.9.4 Valves and other accessories

Gate Valves

a) Sluice / Gate valves shall be used for isolation of flow in pipelines. For sizes up
to 65 mm, gate valves shall be outside screw non rising spindle type and shall
be as per IS: 778 Class-I and Class-II, as applicable. For sizes 80 mm to 300
mm, gate valve shall be as per relevant IS, PN=1.6 and shall be of inside screw
and non rising type and cast iron double flanged.
b) Gate valves shall be provided with a hand wheel, draining arrangement of seat
valve and locking facility (as required). Gate valves shall have back setting bush
to facilitate gland renewal during full open condition.
c) The Body, bonnet, Stuffing Box, cap and hand wheel shall be of cast iron to IS:
210 - 1970, grade FG 200 / 260. The non-rising spindle shall be of solid forged
high tensile brass or carbon steel to AISI 304 construction. The Body seating
and wedge ring shall be of solid leaded gunmetal. The Bonnet gasket shall be of
high quality rubber.
d) The Valve shall be PN 1.6 rated and shall be tested in accordance with relevant
BS/IS/API standard. The ends shall be flanged. The batch number of the valve
shall be punched on the top of the flange. The spindle shall be removable type,
and shall be easily rotated.

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Pressure Switch

a) The Pressure switches shall be employed for starting and shutting down
operation of pumps automatically, dictated by line pressure. The Pressure
Switch shall be diaphragm type. It shall be suitable for line pressures up to 15 kg
/ cm2. The scale range for cut in and cut out shall be from 0 to 10 kg / cm2.
b) The Switch shall be suitable for consistent and repeated operations without
change in values. It shall be provided with IP: 66 water and environment
protection.
c) The enclosure shall be of aluminium and pressure element and wetted parts
shall be of stainless steel. The switch shall be snap acting type with 1 number
NO / NC contact.

Air Vessel and Air Release Valve

a) Air vessel shall be fabricated from 6 mm thick, 300mm x 1000mm MS plate

suitable for 7kg/cm2 working pressure complete with air release valve, safety
valve, pressure gauge etc. as required. The air vessel shall be continuous
welded construction and painted with two coats of Postal red enamel outside
over a coat of primer and cast paint inside.
b) Air Release Valve shall be gun metal/brass and minimum test pressure of 20
bar.

Pressure Vessel

a) The Pressure Vessel shall be provided to compensate for slight loss of pressure
in the system and to provide an air cushion for counter acting pressure surges
whenever the pumping set comes into operation. It shall be normally partly full of
water, the remaining being filled with air, which will be under compression when
the system is in normal operation.
b) Pressure vessel shall be fabricated from 8-10 mm thick MS plate with dished
ends and suitable supporting legs. It shall be provided with a 50 mm diameter
flanged connectionsfrom pump, one 25 mm drain with ball valve, one water level
gauge and 25 mm sockets for pressure switches. The pressure vessel shall be
hydraulically tested as required.
c) The Pressure Vessel shall be for Hydrant Systems. The Pressure Switches shall
be mounted on the drain end of each Vessel. The Vessel shall also be provided
with an air release valve mounted at the top.

Pressure Gauge

a) The Pressure Gauge shall be constructed of die cast aluminium and stove
enamelled. It shall be weather proof with an IP 55 enclosure. It shall be a
stainless steel Bourdon tube type Pressure Gauge with a scale range from 0 to
16 Kg / cm2 and shall be constructed as per IS: 3624 - 1987. Each Pressure
Gauge shall have a siphon tube connection. The Shut off arrangement shall be
by Ball Valve.

Ball Valve

a) The Ball Valve shall be made from die cast brass and tested to 14 Kg/cm2
pressure. The valve shall be internally threaded to receive pipe connections.
b) The Ball shall be made from brass and machined to perfect round shape and
subsequently chrome plated. The seat of the valve body- bonnet gasket and
gland packing shall be of Teflon.
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c) The handle shall be of chrome-plated steel with PVC jacket. The handle shall
also indicate the direction of `open' and `closed' situations. The gap between the
ball and the Teflon packing shall be sealed to prevent water seeping up to 14 Kg
/ cm2 pressure.
d) The handle shall also be provided with a lug to keep the movement of the ball
valve within 90 degree. The lever shall be operated smoothly and without
application of any unnecessary force.

Non Return Valve

a) Non-return valves shall be cast iron spring action swing check/dual platetype.
An arrow mark in the direction of flow shall be marked on the body of the valve.
The valve shall bear IS certification.
b) The Valve shall be of cast iron body and cover. The internal flap in the direction
of water shall be of cast iron and hinged by a hinge pin of high tensile brass or
stainless steel. Cast iron parts shall conform to IS: 210 – 1970, grade 200 / 260
type.
c) The gasket shall be of high quality rubber and flap seat ring of leaded gunmetal.
At high pressure of water flow the flapper shall seat tightly to the seat. The Valve
shall be capable of handling pressure up to 15 kg / cm2.
d) Testing shall as per reluctant IS/BS/API Standard.

Butterfly Valve

a) The Butterfly Valve shall be suitable for waterworks and tested to minimum of 16
kg / cm2 pressure. The Valves shall fulfil the requirements of IS 13095.
b) The body shall be of cast iron to IS: 210 in circular shape and of high strength to
take the minimum water pressure of 10 kg / cm2. The disc shall be heavy-duty
cast iron with anti-corrosive cast or nickel coating.
c) The valve seat shall be of high-grade elastomer or nitrile rubber. The Valve in
closed position shall have complete contact between the seat and the disc
throughout the perimeter. The elastomer rubber shall have a long life and shall
not give away on continuous applied water pressure. The shaft shall be of EN 8
grade carbon steel.
d) The Valve shall be fitted between two flanges on either side of pipe flanges. The
Valve edge rubber shall be projected outside such that they are wedged within
the pipe flanges to prevent leakage.
e) The Valves shall be supplied with manual gear operated opening.
f) Butterfly valves above 150mm shall be wheel operated type.

Strainers

a) Stainless steel (Y type) strainers shall have minimum 1 mm thick screen with 3
mm perforations. Strainers shall be provided with flanges.

Orifice Plates

a) For restricting pressure at lower levels in the sprinkler system, orifice plates of
appropriate sizes shall be fitted at different floor levels, at the branching points
form Riser Main. The Diameter of such orifice shall not be less than 50% of the
dia of pipe into which it is to be fitted, which shall not be less than 50 mm dia.
These orifice plates must be of stainless steel with plain central hole without
burrs. Such orifice plate must have a projecting identification tag.
b) The orifice plate shall fitted not less than two pipes internal diameters
downstream of the outlet from any elbow or brand.

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c) Contractor shall submit the design and identify location on drawing before
installation

Pressure relief valve

a) Each System shall be provided with a Pressure Relief Valves. The Valve shall
be spring actuated and set to operate as per field requirement.
b) The Valve shall be constructed of bronze and provided with an open discharge
orifice for releasing the water. The Valve shall be open lift type

Anchor / thrust block

a) Contractor shall provide suitably designed anchor blocks in cement

concrete/steel support to cater to the excess thrust due to work hammer and
high pressure.
b) Thrust blocks shall be provided at all bends, tees and such other location as
determined by the Engineer. Exact location, design, size and mix of the concrete
block/steel support shall be as shown on the drawings or as directed by the
Engineer prior to execution of work.
1.9.5 Pipe supports

All pipes whether horizontal or vertical shall be suitably supported using GI clamps /
painted MS angles as approved by Engineer in Charge.

Vertical Pipes

a) The pipes running vertical shaft shall be supported by galvanized mild steel rigid clamps
fixed to wall with anchor bolts and studs.

Horizontal Pipes

a) Pipes running horizontal shall be supported from structural beam/slab by using

appropriate GI clamps / MS angles with anchor fastener, bolts etc as approved by
Engineer in Charge.
b) The spacing of supports shall be as follows:

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GI Pipes/MS Pipes
Internal Dia (mm) Spacing (mm)
15 1800
20,25 2400
32 2700
40-50 3000
65-80 3600
100 4000
150 4500

c) Supports for horizontal piping longer than 15m in a stretch shall be provided with
swivel clamps. Otherwise, the clamps shall be universal clamps or rigid clamps
as required by the project engineer-in-charge.
d) Fixing of clamps/rails etc. - All clamps, rails and accessories shall be fixed to the
structure (beam, slab, walls etc.) by using approved good quality anchor
fasteners of appropriate size.
1.9.6 Installation
a) The installation work shall be carried out in accordance with the detailed drawings
prepared by the contractor and approved by the Engineer.
b) In pipe above ground level, expansion loops or joints shall be provided to take care of
expansion or contraction of pipes due to temperature changes.
c) Tee-off connections shall be through equal or reducing tees, otherwise ferrules welded to
the main pipe shall be used. Drilling and tapping of the walls of the main pipe shall not be
resorted to.
d) Open ends of piping shall be blocked as soon as the pipe is installed to avoid entrance of
foreign matter.
e) Piping installation shall be supported on or suspended from structure adequately. The
contractor shall provide clamps and hangers .Proper lines and levels shall be maintained
while installing exposed pipes.
f) Extra supports shall be provided at the bends and at heavy fittings like valves to avoid
undue stress on the pipes.
g) Pipe sleeves of diameter larger than the pipe by least 59 mm shall be provided wherever
pipes pass through walls and the annular spaces shall be filled with felt and finished with
retaining rings.
h) Vertical risers shall be parallel to walls and column lines and shall be straight and in
plumb. Risers passing from floor to floor shall be supported at each floor by clamps as
per Para 3.20.
i) The space in the floor cut outs around the pipe work shall be closed using cement
concrete (1:2:4 mix) or steel sheet, from the fire safety considerations, taking care to
seethat a small annular space is left around the pipes to prevent transmission of
vibration to the structure.
j) Riser shall have suitable supports at the lowest point.
k) Where mild steel pipes are to be buried under ground the same shall be treated in
accordance with Para 3.19 before laying. The top of the pipes shall be not less
than100cms below the ground level. Where this is not practicable, permission of the
Engineer shall be obtained for buried the pipes at lesser depth. Masonry (with 1:4 plaster
i.e. cement or sand) or C.C. (1:2:4 for cement, sand & concrete) blocks shall be provided
for supporting the pipes at interval in accordance with Para 3.17(vi). After the pipes have
been laid, the trench shall be refilled with the excavated soil in layers of 20 cm. and
rammed and any extra soil shall be removed from the site of work by the contractor.
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l) Underground pipe shall be laid at least 2 m. away from the face of the building preferably
along the roads and foot paths. As far as possible laying of pipes under road, pavement
and large open spaces shall be avoided. Pipes shall not be laid under building and
where unavoidable, these shall be laid in masonry trenches with removable covers.
m) To facilitate detection of leak and isolation of defective portion of pipe, valves shall be
provided in underground pipe at suitable locations. As far as possible such valves shall
be provided over ground. If the valves are to be provided below ground, suitable
masonry chamber with cover plate shall be provided with the approval of the Engineer.
Locations where vehicles can pass shall be avoided for provision of valve below ground.
n) Pipe over ground shall be painted in red colour shade no. 536 of IS: 5. Suitable
identification shall be provided to indicate the run of underground pipe wherever the
route of underground pipe cannot be ascertained from the location of yard
hydrant/isolating valves.
o) It shall be made sure that proper noiseless circulation is achieved in the system. If proper
circulation is not achieved due to air-bound connections, the contractor shall rectify the
defective connections. He shall bear all the expenses for carrying out the above
rectification, including the tearing up and refinishing of floors, walls etc. as required.
1.9.7 Painting
1.9.7.1 All exposed piping for fire fighting shall be distinctly painted `Fire red' shade 536 to
IS: 5-2004. Pipes shall first receive two coats of red oxide primer uniformly applied
and two coats of oil paint applied thereafter. All pipes supports shall be painted black
as specified for support & clamps.
1.9.7.2 Painting Schedule - All equipment and piping shall be painted in accordance with the
following colour code:
1.9.7.3 All surfaces to be painted shall be thoroughly cleaned with wire brush to remove
completelyrust and other extraneous substances. Over the cleaned surfaces one
coat of red oxide primershall be applied completely covering the exposed surfaces.
Finishing coat of enamel paint shall be applied one day after the prime coat, after
ensuring that the paint is dry. The second coat shall be done before the installation is
handed over and after approval to do so from the Engineer-in-charge.
1.9.7.4 Corrosion protection tape shall be wrapped on M.S. Pipes to be buried in ground.
This corrosion protection tape shall comprise of coal tar/asphalt component
supported on fabric of organic or inorganic fiber and minimum 4 mm. thick and
conform to requirement of IS: 10221-Code of practice for coating and wrapping of
underground mild steel pipe line. Before application of corrosion protection tape all
foreign matter on pipe shall be removed with the help of wire brush and suitable
primer shall be applied over the pipe thereafter.
1.9.7.5 The primer shall be allowed to dry until the solvent evaporates and the surface
becomes tacky. Both primer and tape shall be furnished by the same manufacturer.
Corrosion protection tape shall then be wound around the pipe in spiral fashion and
bounded completely to the pipe. There shall be no air pocket or bubble beneath the
tape. The overlaps shall be 15 mm. and 250 mm. shall be left uncoated on either end
of pipe to permit installation and welding. This area shall be coated in-situ after the
pipe line is installed. The tapes shall be wrapped in accordance with the
manufacturer's recommendations. If application is done in cold weather, the surface
of the pipe shall be pre- heated until it is warm to touch and traces of moisture are
removed and then primer shall be applied and allowed to dry.

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S.No. Equipment Colour Distinguishing Mark

a. Pump motors Fire Red Shade No.536
to IS: 5 -2004
b. Internal piping - do -
c. Landing valves & Hose reel - do -
cabinets
d. External Hydrants - do -
e. Fire brigade connection - do -
f. Priming tank - do -
g. Air vessel - do -
h. Electric panels Black & Red
i. Fire Alarm Panel Black & Red
j. Repeater panel Black & Red
k. Break Glass Unit Fire Red
l. Hooters/Speakers Fire Red
m. Sprinkler pipes Fire Red

1.9.8 Testing & commissioning

1.9.8.1 All piping after installation shall be tested for a hydrostatic test pressure of 10.5
kg/cm2 or1.5 times the working pressure (whichever is less) maintained for 24
hours. All joints and valves shall be checked for leaks and rectified and retested.
During testing all valves except drain & air valves shall be kept fully open.
1.9.8.2 Piping repaired subsequent to the above pressure test shall be re-tested in the
same manner.
1.9.8.3 System may be tested in sections and such sections shall be securely capped.
1.9.8.4 Pressure gauges may be capped off during pressure testing of the installation.
1.9.9 Makes of materials

For makes of materials refer to list of approved makes of material.

1.9.10 Mode of measurement

1.9.10.1 All external piping shall be measured along the centre line of the pipe and paid
per unit length and shall include
a) All pipes & fittings
b) Bituminous coating
1.9.10.2 All internal piping shall be measured similarly but shall include for the pipe
supports and clamps.
1.9.10.3 All valves, air valves, drain valves together with flanges or tail pieces shall be
measured per unit.
1.9.10.4 All excavation and concrete supports and thrust blocks shall be measured as
per drawing and paid for per cum.
1.9.10.5 The cost of pipe supports described above form part of the rate quoted for piping
and no extra shall be payable on the account.
1.9.10.6 All painting shall form part of the cost of equipment piping etc. No separate
payment shall be admissible.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.10 PORTABLE FIRE EXTINGUISHERS

1.10.1 Scope

The scope of work covers the supply and installation of portable fire extinguishers.The
following types are envisaged in these specifications and provided as shown in the
schedule of portable fire extinguishers.

a) Dry powder extinguisher

b) Carbon-dioxide extinguisher
c) Mono ammonia phosphate extinguisher
d) Water expelling type.
1.10.2 Standards

The latest standards and rules and regulations shall be applicable:

Fire protection manual of the tariff advisory committee, Fire Insurance Association of
India

STANDARD DESCRIPTION

IS: 15683 Portable Fire Extinguisher Dry Powder Type

IS: 15683 Portable Fire Extinguisher Cabon dioxide Type

1.10.3 Extinguishers
1) Dry powder type
a) The extinguishers shall be 2, 6, 10 kg capacity and cartridge type unless specified
otherwise. The body shall be of cold rolled carbon steel grade D and 1.5mm thick up
to 5 kg and 2mmfor 10 kg. The construction shall be similar to `Soda Acid type' but of
the following dimensions.

Capacity (kg) Outside diameter (mm) Filler opening (mm)

2.00 100 45
6.00 150 45
10.00 175 45

b) The discharge fitting shall be with 500mm 10mm diameter hose up to 5 kg and 750
mm
c) 12.5 mm diameter for 10 kg with a trigger controlled nozzle capable of discharging
85% of the contents as follows:

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Capacity (kg) Time (sec) Throw (m)

2.00 8 – 10 2
6.00 15 – 20 4
10.00 23 - 30 6

d) A carbon dioxide cartridge conforming to IS: 4947 - 1985 shall be fitted in a cartridge
holder with an inner shell. A spring loaded piercing device shall be provided in the
cap for piercing the seal of the gas cartridge. A syphon tube of copper or PVC shall
be provided for upright operation.
e) All internal and external components and surfaces shall receive anti-corrosive
coating of not less than 12 microns shall be applied uniformly as indicated below:
Body Mild steel Tin alloy
Cage for acid bottle and Brass sheets Lead or tin alloy
spring
Discharge fittings Leaded – Tin Bronze Tin alloy
Strainer Brass sheets Lead or Tin alloy

2) Carbon dioxide type

a) The extinguishers shall be rated for 2.0 and 4.5 kg by weight of carbon dioxide,
unless stated otherwise. The contents shall be with a filling ratio not exceeding
0.667.
b) The body shall be steel cylinder made according to IS: 7285 - 2002 and
approved by the chief controller of explosives.
c) The discharge head shall be simple and safe to operate conforming to IS: 3224 -
2002 with a safety release to IS: 5903 - 1970 set to 18.0 to 20.0 N/mm2. A
syphon tube of copper or PVC shall be fitted. A non-conducting discharge horn
and a high-pressure hose (27.5 N/ mm2 pressure) shall be fitted with each
extinguisher.
d) The discharge system shall be designed toexpel 95% of the contentsin
continuous discharge as follows:

Capacity (kg) Time (Sec.)

2.0 8 – 18
3.0 10 – 20
4.5 10 - 24

3) Water CO2 Fire Extinguishers

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a) The extinguishing medium shall be primarily water stored under normal

pressure, the discharge being affected by release of carbon dioxide gas from a
60 gms cylinder.
b) The capacity of the cylinder when filled shall be 9 liters ± 5 %.
c) The cylinder shall be fabricated from MS sheet, welded at seams, with dish and
dome, being of same thickness and of size not exceeding the diameter of the
body. The neck shall be externally threaded with leaded tin bronze.
d) The cap shall be of leaded tin bronze. The siphon tube shall of brass or GI. The
cartridge holder, knob, discharge fittings and plunger shall be of leaded tin
bronze and plunger of stainless steel with spring also of stainless steel. The
discharge tube shall be of braided nylon, of 10 mm diameter and 600 mm length
with a brass nozzle.
e) The extinguisher shall be treated for anti-corrosion internally and externally and
painted fire red externally. The cartridge shall be IS marked. The Extinguisher
body shall be tested to 25-bar pressure for 2 minutes. The Extinguisher shall be
IS: 15683 marked.
1.10.4 General Requirements
a) All extinguishers shall be standard products approved by the Authority having
Jurisdiction andmanufactured and tested strictly in accordance with the relevant
Indian Standard. All markings and test results shall be stamped in the
appropriate colour markings accordingly to the Indian Standards.
b) All extinguishers shall have a structurally designed galvanized steel handle and
also a suitable wall-mounting bracket.
1.10.5 Mode of measurement
a) Each extinguisher with its mounting bracket shall be measured per unit and paid
for.
1.10.6 Makes of materials
a) For makes of materials refer to list of approved makes of material.

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works/ Fire Fighting Page 22 of 22
 DELHI METRO RAIL CORPORATION LIMITED

Construction of Simulator Building at Shastri Park, New

Delhi

CONTRACT NO: CC-135

TENDER DOCUMENTS

VOLUME - 4

TECHNICAL SPECIFICATIONS

HVAC

DELHI METRO RAIL CORPORATION LTD.

5th Floor, A-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1 AIR-CONDITIONING AND VENTILATION SYSTEM FOR SIMULATOR

BUILDING

1.1 GENERAL SCOPE OF WORK

Scope of work under this contract shall include but not limited to the design,
manufacture, testing at manufacturer’s workshop, supply, storage, erection, site testing
and commissioning of the Air-conditioning & Ventilation System training of DMRC staff
mainly comprising of:

1.1.1 Outdoor and indoor units of VRV/ VRF/ High performance air-conditioning system
along with refrigerant piping and drain piping etc.

a) Ventilation fans
b) Air distribution system
c) Drain Piping
d) Electrical works

1.1.2 Any other item required to complete the work except the specified items
mentioned under para “works & services to be arranged by other than HVAC
Contractor”.
1.1.3 Scope of work shall also include the following:

a) De-mobilisation, clearing of all temporary works and facilities after

completion of job.
b) The Contractor shall include the supply of entire materials in accordance
with this specification and the whole of the work necessary for the
complete installation as set down in this Specification and with the
accompanying schedules and drawings. Materials and components not
specifically stated in the specifications and/or bill of materials or noted on
the drawings but which are necessary for satisfactory installation and
operation of the system shall be deemed to have been included in the
scope of work.

1.2 QUALITY ASSURANCE OF MATERIALS AND WORKMANSHIP

1.2.1 Materials

a. The contractor will supply the equipment’s as indicated in the list of approved
makes in the tender.
b. Furthermore, all equipment’s must strictly conform to the relevant IS code
specified in the tender document. However, the contractor shall submit Vendors
data in the approved format.
c. The contractor shall furnish test certificates of the materials procured for the work.
Testing of materials shall also have to be done at contractors cost as and when
necessary and required by the Engineer. If the test result of any material does not
comply with the results stipulated in the relevant latest IS code, the materials shall
be rejected and no claim shall be entertainedon any account what so ever. All the
rejected material should be removed from the siteof work, without delay.
d. Where manufacturer have furnished specific instructions relating to the materials
used in this job and covering points not specifically mentioned in these
documents, manufacturer’s instructions shall be followed.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.2.2 Quantum of Materials to be ordered

The Schedule ofQuantities shall not be used as a basis for ascertaining the
quantumof materials to beordered and these are for guidanceonly. The
Contractor shall assess the quantitiesof materials to beordered as per
requirement and shall be entirely responsible for the same. The
design/drawingsof the layouts/system shall be approved from theemployers’
representative.

1.2.3 Manufacturer Instruction

Where manufacturers have furnished specific instructions relating to the

materials and equipment used in this project, covering points not specifically
mentioned in these documents, such instructions shall be followed in all cases.

1.3 INSTALLATION, INSPECTIONS & TESTING

When the installation is deemed by the Contractor to be complete, he

shall arrange with the Engineer for inspection and testing of the installation. Test
results shall be recorded in the format approved by the Engineer. An installation
shall not be accepted until the Engineer is satisfied about its compliance with the
requirements of the specifications and performance of the system.The
Contractor shall cause interim/stage inspection during execution of the works as
and when so called for and carry out any rectification / modification as may be
suggested by the Engineer.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.3.1 Soon after the work is completed, the Contractor shall inform in writing to the
Engineer for getting the complete system including all sub-systems and
instrumentation, control panels etc., thoroughly inspected and tested for
satisfactory performance. After satisfactory completion of tests of the system, the
Contractor shall carryout all start up trials of the system provided by him.
1.3.2 Any defect noticed during these tests shall be speedily rectified for testing and
shall be the responsibility of the contractor.
1.3.3 All instruments and materials including consumables required for testing shall be
the responsibility of the Contractor.
1.3.4 Balancing of all air and water systems and all tests shall be carried out by the
contractor in accordance with the specifications and relevant local codes if any.
Performance test shall consist of seven days operation of system for each season.
1.3.5 Testes shall be carried out in peak summer and monsoon season.
1.3.6 The results for summer/monsoon and winter air conditioning in duplicate shall be
submitted for scrutiny. Two copies of the certified manufacturer’s performance
curves for each piece of equipment shall be submitted along with the test results.
The contractor shall also provide two copies of record of all safety and automatic
control settings for the entire installation.
1.3.7 The contractor shall arrange all necessary balancing and testing equipments,
instruments, materials, accessories, refrigerant and the requisite labour. Any
defects in materials and/or in workmanship detected in the course of testing shall
be rectified by the contractor, to the satisfaction of the Employer.
1.3.8 The installation shall be tested again after removal of defects and shall be
commissioned only after approval by the Employer. All tests shall be carried out in
the presence of the representatives of the Employer.

1.4 STANDARD OF WORK

1.4.1 The work shall be carried out to the satisfaction of the Employer and in
accordance with the regulations of the Electricity Supply Authority, Electricity
Rules and other local Regulations and the enclosed specifications.

1.5 SHOP DRAWINGS

1.5.1 Before proceeding with the work, the Contractor shall submit for approval, general
layout and assembly drawings and such additional assembly and sub-assembly
detailed drawings as necessary to demonstrate fully that all parts of the apparatus
to be furnished will conform to Specifications. These Drawings will include plant
room layouts, required to complete the project as per specifications and as
required by the Engineer. These drawings will contain details of construction, size,
and arrangement, operating clearances, performance characteristics and capacity
of all items of equipment, as also the details of all related items of work by other
Contractors. Each item of equipment proposed shall be a standard catalogue
product of an established manufacturer as per specifications.
1.5.2 When the Engineer makes any amendments in the above drawings, the
Contractor shall supply fresh sets of drawings with the amendments duly
incorporated, along with the drawings on which corrections were indicated.
1.5.3 The Contractor shall furnish for checking and scrutiny advance sets of prints of the
layout, assembly and erection drawings. No modifications shall be made in the
drawings after they have been approved by the Engineer without his prior consent.
All drawings necessary for assembly, erection, maintenance, repair and operation

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

of the equipment shall be furnished. Different parts shall be suitably numbered for
identification and ordering of spare parts.
1.5.4 No material or equipment may be delivered or installed at the job site until the
Contractor has in his possession, the approved Shop Drawings for that particular
material or equipment.
1.5.5 The Shop Drawings shall be submitted for approval sufficiently in advance of the
planned delivery and installation of any materials, to allow the Engineer ample
time for scrutiny. No claims for extension of time shall be entertained because of
any delay in the work due to his failure to produce Shop Drawings at the right
time, in accordance with the approved program
1.5.6 Approval of Drawings by the Engineer shall not relieve the Contractor of any part
of his obligation to meet all the requirements of the Contractor of the correctness
of his drawings. The Contractor shall be responsible for any pay for all alterations
of the works due to discrepancies or omission in the drawings or other particulars
supplied by him, whether such drawings have been approved by the Engineer or
not.
1.5.7 The drawings prepared, and the allocated position for equipments represents a
feasible scheme in the machine room and equipment room. The layout in the
machine room and the equipment room may be rearranged only in the allocated
space, subject to the approval of the Engineer.
1.5.8 Where the work of the Contractor has to be installed in close proximity to, or will
interfere with the work of other trades, the Contractor shall assist in working out
space conditions to make a satisfactory adjustment. If so directed by the Engineer,
the Contractor shall prepare composite working drawings and sections at a
suitable scale, clearly showing how his work is to be installed in relation to the
work of other trades. If the Contractor installs his work before coordinating with
other trades, or so as to cause any interference with work of other trades, he shall
make all the necessary changes without extra cost to the purchaser.

1.6 VIBRATION ISOLATION AND NOISE LEVEL

1.6.1 All equipment shall operate under all conditions of load without any sound or
vibration which is objectionable in the opinion of the Engineer. In case of rotating
machinery, sound or vibration noticeable outside the room in which it is installed,
or annoyingly noticeable inside its own room, shall be considered objectionable.
The provision shall be made for vibration isolation of minimum 90% efficiency.
Abnormal vibration and noise level conditions shall be corrected by the Contractor
at his own expense.

1.7 GUARANTEE
1.7.1 The contractor shall guarantee that all the material, machinery and components
supplied, fabricated, designed and installed by him shall be free from defects due
to fault design material and/or workmanship, that the plant shall perform
satisfactorily specifically the successful performance of the system in monsoon
and summer and the efficiency of the system and all the components shall not be
less than the values laid down in the specifications and the capacities shall be
within +/- 5%of the specified values, in case of deviation greater than +/- 5%, the
contractor shall replace the necessary components.

1.8 MAINTENANCE & TRAINING

1.8.1 The Contractor shall associate, during the erection and during the Defects Liability
Period with the purchaser staff to familiarize them with the operation and
maintenance of the plant.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.8.2 If required by the Engineer the Contractor shall agree to train members of the
purchaser maintenance staff either at his or manufacturer’s work or at such other
place or places as may be considered suitable by the Engineer.
1.8.3 On completion, supply of two sets of well bound handing over manuals duly
approved by
1.8.4 Consultants/Engineer. Each set shall include “As Built Drawings”

1.9 TECHNICAL DATA

1.9.1 The tenderer must submit the technical data along with catalogue, literature, and
manufacturer’s manual for all items as listed in tender(Technical specifications) in
the indicated format, and submit along with their tenders.
1.9.2 Failure to furnish technical data with tenders may result in summary rejection of
tenders.

1.10 WORKS & SERVICES TO BE EXECUTED BY OTHER AGENCIES

1.10.1 The following associated works and services are excluded from scope of this
contract and shall be executed by other agencies in accordance with
contractors approved shop drawings.
1.10.2 Insulation to exposed roofs with50mmthick expanded polystyrene or
equivalent insulation.
1.10.3 All civil works like foundations for the equipment, breaking and making good
of openings for pipes and ducts. However minor openings shall be carried
out by Air- conditioning contractor.
1.10.4 Provisionof415 volt,3 phase power near each outdoor units and220 volt
single phase supply near each indoor units for VRV system.
1.10.5 Provisionof415 volt,3 phase power near each outdoor units for high
performance unit.
1.10.6 False ceiling work.

1.11 BASIS OF DESIGN

1.11.1 AIR-CONDITIONING

The following areas in depot shall be air-conditioned.

II. TECHNICAL SPECIFICATIONS

a) Location:

Site Location : NEW DELHI

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

b) Outdoor Design Conditions:

Outdoor Design Conditions considered for Srinagar are as follows:

Summer

Dry Bulb Temperature : 110 Deg F (43.3 Deg. C)

Wet Bulb Temperatures : 75.0Deg F (23.8 Deg. C)

c) Indoor Design Conditions:

Dry Bulb Temp : 71.6+2 Deg. F (22.0 + 1.1Deg. C)

Relative Humidity : Not exceeding 60%

d) Perimeter Heat Gain

Roof (Exposed to sun) with Thermal

insulation Consisting of 75 mm thick
extruded polystyrene.

U = 0.09 BTU/HR/SFT/DEGF

Glass (Hermetically sealed double Solar Transmission

glass
U = 0.59 BTU/HR/SFT/DEGF

e) Noise Level Design Criteria

In accordance with Design Standards and Criteria, permissible noise level in various spaces,
considered when unoccupied, shall be as follows:

S.No. Area Acceptable Noise Levels

(db)

a. CONDITIONED AREA 45

b. Corridor 52

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

The average lighting load may vary as per actual lighting loadof the particular premises
13.16 Ducting (For Air-Conditioning)

Maximum air velocity 1500 ft/min,460 mtrs/min

Maximum friction 0.1 INWG per100Ft run
Maximum velocity at exhaust air 500 ft/min, 152 mtrs/min
grille

Ducting (For Ventilation)

Maximum air velocity 2000 ft/min, 600mtrs/min

Maximum friction 0.1INWGper100 Ft run
Maximum velocity at exhaust air 600 ft/min, 183mtrs/min
grille

1.12 VARIABLE REGRIGERANT FLOW SYSTEM

Detailed description and Application

ESTIMATED AIRCONDITIONING LOAD

VRF HVAC EQUIPMENT SELECTION - DMRC STIMULATOR BUILDING

BASIS OF DESIGN REQUIREMENT SELECTION

S.N. AREA SQ.FT Occup Eqpt CFM REF. Indoor Qty Total TR Equipment
ancy Load in REQD TR Unit in Selected
KW TR.

VRF + Dx
GROUND FLOOR

.
1 TRAINING COORDINATOR. 1086 10 3.00 2129 5.2 6.40 1 6.40 DUCTED
2 SPARE ROOM 377 2 0.50 838 1.9 3.20 1 3.20 CASSETTE
3 WAITING LOUNGE 366 9 0.25 557 1.6 2.00 1 2.00 CASSETTE
4 PRINCIPAL ROOM 434 12 0.50 899 2.5 3.20 1 3.20 CASSETTE
5 ENTRANCE FOYER SECURITY
1564 0.50 0.00 0.00 NOT REQUIRED
& RECEPTION
6 TECHNICAL ROOM & UPS
384 8 14.52 3481 6.3 4.00 3 12.00 CASSETTE Wkg
ROOM
Cassette DX
4.00 3 12.00
Standby
7 SPACE FOR MMI'S
MAINTENANCE SIMULATOR & 3939 60 14.85 7394 17.4 8.00 3 24.00 DUCTED
STORAGE ROOM

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

FIRST FLOOR

.
8 ATS TRAINING SIMULATOR
1297 30 6.00 4382 9.5 6.40 2 12.80 DUCTED
ROOM
9 MSM ROOM-1 831 10 4.50 2213 4.9 6.40 1 6.40 DUCTED
10 MSM ROOM-2 892 10 4.50 2041 4.6 6.40 1 6.40 DUCTED
11 MSM ROOM-3 890 10 4.50 2040 4.6 6.40 1 6.40 DUCTED
12 MSM ROOM-4 892 10 4.50 2085 4.7 6.40 1 6.40 DUCTED
13 MSM ROOM-5 892 10 4.50 2041 4.6 6.40 1 6.40 DUCTED
14 MSM ROOM-6 890 10 5.50 2520 5.5 8.00 1 8.00 DUCTED
15 TRAINING COORDINATOR 385 4 0.50 1030 2.3 3.20 1 3.20 CASSETTE

SECOND FLOOR

16 LIBRARY 5365 100 5.00 10667 26.7 8.00 4 32.00

DUCTED
0 0.00
17 6 GMSM + CBT ROOM 849 20 8.70 3158 6.8 8.00 1 8.00 DUCTED
2.00 1 2.00 CASSETTE
18 TRAINING COORD. ROOM 431 4 0.50 986 2.3 3.20 1 3.20 CASSETTE
19 TRAINING MANAGER ROOM 377 4 0.50 1023 2.3 3.20 1 3.20 CASSETTE
THIRD FLOOR
20 CONFERENCE ROOM 1797 100 2.00 5725 17.5 8.00 2 16.00 DUCTED
21 REFRESHMENT AREA 891 15 1.00 1599 4.1 2.00 1 2.00 CASSETTE
3.20 1 3.20 CASSETTE
22 TRAFFIC CONTROLLER 892 10 2.50 1808 4.4 3.20 2 6.40 CASSETTE
23 R33 DESKTOP SIMULATOR 1736 10 2.50 3218 7.8 3.20 3 9.60 CASSETTE

24 ECS/TVS SIMULATOR 931 5 1.25 1931 4.5 6.40 1 6.40 DUCTED

25 TRANING MANAGER 355 4 0.50 860 2.0 3.20 1 3.20 CASSETTE
26 MODEL SCR & TC/SIMULATOR 377 4 1.00 1114 2.5 2.00 2 4.00 CASSETTE
Total 29121 471 65742 43 218 TOT IDU
TOT VRF ODU
236.0
HP
3 Nos. Dx
10.8 Cassette Unit
3.6 Tr.
De-humidifier to have its own
Note cooling system so no load
included in the heatload..

Outdoor Unit Selection

 CIRCUITS

4 # 44 HP,

1 # 60 HP

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

 Dx Units

3 x 3.6 Tr Cassettes

NOTE:

1. 3 NOS. 3.6 Tr. AS DX TYPE CASSETTE UNITS FOR STANDBY.

2. ALL EQUIPMENTS CONSIDERED WITH 100% INVERTER COMPRESSORS

3. De-humidifier to have its own cooling system so no load included in the heatload.

4. Higher number of compressors are preferred for redundancy in the system.

The scope of work related to Variable Refrigerant Flow Air-conditioning

System shall generally comprise of but not limited to the following :

 Manufacturing
 Testing at manufacturer’s works
 Supply and storage
 Installation at station
 Site testing and commissioning
 Training of DMRC staff

The VRF type air-conditioning system shall generally consist of:

 Outdoor and Indoor units along with refrigerant piping, its nitrile insulation
with aluminium cladding and cable tray/raceway. The cabletray/raceway
used for refrigerant pipe and electrical cables will be a part of the VRF
system and no separate payment is to be made. Each refrigerant circuit
from Outdoor Unit to Indoor Unit will run on separate cable tray.
 Air distribution system when ducting is provided as per BOQ
 Drain Piping.
 Electrical works.
 Materials and components not specifically stated in the specifications
and/or bill of materials or noted on the drawings but which are necessary
for satisfactory installation and operation of the system.

1.12.1 Governing Specifications
1.12.1.1 The VRF type air-conditioning system shall comply with standards
mentioned particularly in the table below unless otherwise stipulated in
the specifications. The latest version of standards shall be applicable.

AHRI-1230 (or the latest)

ASHRAE latest standard and guidelines.
UL-94- V0
Indian Electricity Rules- 2005
ASTM B 280

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Japanese Industrial Standard JIS H :3300

1.12.2 Requirements

The VRF system shall be designed to meet the following minimum

requirements:

1.12.2.1 Design Parameters

The following parameters shall be considered for the design

Outside Conditions for Cooling

DB WB
Ambient Temperature 43.3deg C 28.3

Inside Conditions

Inside temperature 22.0 ± 1 deg C

Condition
(Relative humidity not exceeding 60%)

Fresh Air: As per ASHRAE.

Lighting Load: 1.2 W/Sq ft.

Ducting(For Air conditioning)

Maximum Air velocity 460 mtrs/min

Maximum Friction 1 cm WG per 100 mtrs run
Maximum velocity at exhaust air grille 152 mtrs/min
1.12.3 Functional Requirements

VRF

The Variable Refrigerant Flow (VRF) System should be air cooled, consisting of
modular condensing outdoor units connected to multiple indoor units. Each
indoor unit shall have the capability of individual set point control. Each modular
condensing unit should have 100% Inverter Compressors (minimum 2
compressors for 12HP and above units) to obtain 10% to 100%step less
capacity control to match the air-conditioning load. The VRF unit shall be
capable of operating within a wide range of temperatures. The system shall be
designed for automatic cyclic operation for a bank of VRF units with settable
time feature including providing all related microprocessor, cabling. The
refrigerant used should be environmental friendly and latest. The manufacturer
shall take a note of the ambient air pollution prevailing in Delhi/NCR region and
shall provide proven protection against corrosion to all the components of VRF
module. The VRF air conditioning system shall consist of the following sub-
systems:-

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Outdoor unit

The outdoor unit shall be a factory assembled unit housed in a sturdy weather
proof casing constructed from rust-proofed mild steel panels coated with a
baked enamel finish. There should be no scaling, corrosion or any other physical
deformation on the body of Outdoor unit. The outdoor unit shall be modular in
design and thickness of the sheet used for manufacturing the body shall be such
that it shall not deform during handling and may use corrugation to strengthen
the body structure. It should be possible to place the ODU’s side by side. The
ODU must deliver the rated capacity (within the acceptable tolerance as
specified in AHRI 1230) at outdoor ambient 43.3deg C (DB). The minimum IEER
should be as below:-
ODU Capacity IEER (Minimum)
All capacities 18

The outdoor unit should be able to operate even in case of breakdown of one of
the compressor (for 18 HP and above units).The Outdoor unit shall at least have
the following sub-components:-
 Compressor
The compressor shall be highly efficient and capable of capacity
modulation with inverter scroll/Twin rotary design.
 Heat Exchanger
The heat exchanger shall be constructed with copper tubes mechanically
bonded to aluminium fins to form a cross fin coil. The heat exchanger
and condenser fins must be coated with Anti-corrosive treatment Fan
Motor Speed Control
The condensing unit fan motors to have at least two speed operations to
maintain constant head pressure control at all ambient temperatures and
modes of operation.
 Refrigerant Circuit
The refrigerant circuit shall include an accumulator, liquid and gas shut
off valves and a solenoid valves or pulse width modulation valve. The
equipment must have inbuilt refrigerant stabilization control for proper
refrigerant distribution
 Oil Recovery System

Each unit shall be equipped with an oil separator to ensure stable

operation with long refrigerant piping.

Indoor unit

Indoor unit shall be Wall mounted/Ceiling mounted/floor mounted/ AHU (as per
requirement) with metallic body with factory fabricated body, each complete with
coil, pre-filter, etc. including necessary steel supporting structure. Indoor unit
should have flexibility for duct extension (if required)

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It shall have electronic control valve to control refrigerant flow rate in response to load
variations of the room.The fan shall be dual suction multi blade type and statically and
dynamically balanced to ensure low noise and vibration free operation. The indoor unit
should be designed such that in case of failure/ trip of one indoor unit, the working of ODU
and other indoor units should not be affected. The indoor unit fan shall be direct driven.
The indoor unit casing shall be fully insulated and sealed to prevent condensation. Each
indoor unit shall have the capability of individual set point control. The indoor unit should
be provided with corded remote control as a standard accessory. The address of the
indoor unit shall be set automatically in case of individual and group control. In case of
centralized control, centralized remote controller shall set it.
 Electronic Expansion Valve

Each indoor unit shall be fitted with an electronic expansion valve to control the refrigerant
flow in response to the load variations in the room. The electronic expansion valve is to be
controlled via a computerized control sensing the return air temperature, refrigerant inlet
and outlet temperatures. During the cooling operation the electronic expansion valve shall
control the refrigerant superheat degree at the evaporator.

Cooling Coils Shall be direct expansion, constructed from copper tubes

expanded into aluminium fins to form a rigid mechanical bond.

 Unit Control Board

It shall Include in the indoor unit a printed circuit board complete with,
address switches for a variety of operation controls, emergency operation switch and fault /
operation indication LED’s. The fan motors shall be thermally protected.

Centralized system remote controller

A multifunctional compact centralized system remote controller shall be provided with the
system. The System Controller shall provide proven air conditioning management system
to give complete control of VRF air conditioning equipment. It should be user friendly.

It should be able to control at least 64 indoor units connected at a station, The

centralized system remote controller shall perform the following minimum
functions:

I. Starting/stopping of Air conditioners as a zone or group or individual

units.
II. Temperature setting for each indoor unit or zone.
III. Switching between temperature control modes, switching of fan speed
and direction of airflow, enabling/disabling of individual remote controller
operation.
IV. The address of the indoor unit shall be set automatically in case of
individual and group control.
V. Monitoring of operation status such as operation mode & temperature
setting of individual indoor units, maintenance information, trouble-
shooting information.
VI. Scheduling of both Indoor and Outdoor units as per the requirement.
VII. The controller shall be user friendly. A provision of wiring the centralized
system controller to the indoor unit, up to a distance of 1 km shall be
made.

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VIII. In case of power fluctuation or power failure, the addressing and other
settings such as temperature of individual indoor units should not be
affected. Alpha- numeric addressing of each indoor unit should be
possible to facilitate the location of individual indoor unit.

Refrigerant pipe work

 All interconnecting pipe-work between the condensing unit & indoor units
shall have quality seamless copper tubes with brazed connections and
the appropriate distribution joints and headers shall be used. The piping
should be routed at site in such a manner, that brazed joints in the
Refrigeration Piping are kept to a minimum. All interconnecting piping,
joints and U bends within the condensing unit shall be painted with two
coats of clear transparent coating of suitable material for protection
against corrosion from ambient air pollution.
 Each coat shall have dry film thickness of 35 micron or more. The
coating shall be strong, flexible and durable. It shall have good adhesive
and abrasion resistance. It shall be resistant to moisture, UV, acid alkali
and other chemicals. All suction & liquid lines of the Refrigerant pipe
work shall be insulated with Nitrile rubber /expanded polyethylene pipe
sections as specified to avoid condensation.
 The exposed piping insulation shall be painted with U/V paint. The
refrigerant pipe shall be thermally insulated by proven materials having
low thermal conductivity, high mechanical strength, non-combustible,
resistance to Fungi, ozone, UV and any other environmental pollutant.
Moulded tee joints of thermal insulating material shall be used at
bends.The exposed piping insulation shall be painted with U/V paint.
 The refrigerant piping shall be extendable minimum 165 m with 50 m
level without any oil trap. Distribution refrigeration pipe joints and
headers shall be installed in an appropriate orientation to enable correct
distribution of refrigerant. The Distribution joints shall be factory/site
insulated. All pipe-work must be kept clean and free from contamination
to prevent breakdown of the system. All pipe ends shall be kept sealed
until immediately prior to making a joint.
 Refrigerant charge must be calculated based on the actual length of the
refrigerant pipe work. The refrigerant charging process must be carried
out with an appropriate charging station and under supervision of
manufacturer or his representative.
 The insulated refrigerant piping and electrical conduit shall run on GI tray
properly supported by GI rods. The exposed tray on terrace shall be
covered by open able GI covers.
 The OD & wall thickness of copper refrigerant piping shall be as follows:

Size Thickness Specification
6.35mm (1/4 in) 24 G C1220T-O (ANNEALED)
9.52mm (3/8 in) 24 G C1220T-O (ANNEALED)
12.70mm (1/2 in) 22 G C1220T-O (ANNEALED)
15.88mm (5/8 in) 22 G C1220T-O (ANNEALED)
19.05mm (3/4 in) 20 G C1220T-1/2 H (HALF-HARD)
22.23mm (7/8 in) 20 G C1220T-1/2 H (HALF-HARD)
25.40mm (1 in) 20 G C1220T-1/2 H (HALF-HARD)
28.58mm (1 1/8 in) 18 G C1220T-1/2 H (HALF-HARD)

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31.75mm (1 1/4 in) 18 G C1220T-1/2 H (HALF-HARD)

38.10mm (1 1/2 in) 16 G C1220T-1/2 H (HALF-HARD)
44.45mm (1 3/4 in) 16 G C1220T-1/2 H (HALF-HARD)
50.8mm (2 in) 14 G C1220T-1/2 H (HALF-HARD)

The size of the pipe may vary depending on the site conditions.

 Test certificates for copper pipes used in the refrigerant circuit(as per JIS
H 3300) from an accredited laboratory should be submitted.

Drain piping

The indoor units shall be connected to vertical drainage insulated UPVC pipe.
The pipes shall be laid in proper slope for efficient drainage of condensate
water. Drain pipes carrying condensate water shall be insulated with 6 mm
Nitrile rubber having a ‘K’ value of 0.036W/mk at a mean temperature of 20 0C
and a minimum density of 55 Kg/Sqm. The joints shall be properly sealed with
synthetic glue to ensure proper bonding of the ends.

Noise Level

The Noise level of outdoor unit shall not be more than 68 dB(A)at normal
operation. The Noise Level of indoor unit shall not be more than 42 dB(A) for
non ductable type and not more than52dB(A) for ductable/AHUunit type. The
noise level shall be measured at a distance of 1m away(horizontally) and 1.5m
aboveground.

Input Voltage & Frequency

All the outdoor unit shall be suitable for operation with 415 V ±10%, 50±3% Hz,
3Ph 4 wire AC supply where as all indoor units should be with 230 V± 10%,
50Hz ±3 % Single Phase supply or 415 V ±10%, 50±3% Hz, 3Ph 4wire.

1.12.4 Additional Requirements

a. The power/control/communication cable between indoor and outdoor

units shall run in GI conduits or armoured cable to be used.
b. The insulated refrigerant piping and cable between indoor and outdoor
unit shall run in a Galvanized Steel raceway/Cable tray with proper
supporting arrangement.
c. All galvanized support beams, galvanized legs, galvanized hangers,
anchor bolts, vibration isolators, and ductworks shall be provided for the
installation of the units, assembly and its sub-assembly.
d. The VRF type air conditioning units shall be mounted on vibration
isolators and installed in accordance with the manufacturer’s
recommendation such that no disturbing vibration or noise is being
transmitted to the nearby structure.
e. The centralized system Controllershall be located in a properly sized box
with lock and key facility along with its battery/adapter unit. The power
supply cable for the controller shall be taken in a conduit from the
nearest 230V socket. A guidance manual of the controller shall be
located in this unit.

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f. Joints in refrigerant piping should be kept as minimum as possible, for

this following consideration to be taken into account:
 One end expanded copper tube should be preferred over plain
ended copper tube.
 If possible bending of semi-hard/hard copper pipe should be
preferred instead of using elbow.

1.12.5 Safety

All necessary safety devices shall be provided in the indoor and outdoor
units to ensure the safety operation of the system. The design of the
safety system shall be such that the equipment is protected and defect of
one unit shall not lead to consequential damage to any other units. The
safety and protection design shall be submitted with the offer and shall be
a part of the training course to DMRC official.

The following safety devices shall be part of the outdoor unit:

a. High Pressure Switch

b. Low Pressure Switch
c. Fan Motor Safety thermostat
d. Over Current Relay
e. Fusible Plug
f. Fuse
g. Overload protection
h. Protection for indoor fan motor.

All the material used in the manufacturing of VRF system shall be fire
retardant. The indoor unit shall be in conformance to UL-94 guidelines.
The manufacturer shall submit UL compliance certificate with the offer.

1.12.6 Energy efficiency

Only the best manufacturing practices i.e. the units with maximum IEER
as per AHRI-1230 standard with addendum will be accepted. The
contractor shall study the best available designs and offer the best IEER
available in industry. However, the VRF unit should provide a minimum
IEER of18. The formula used for the calculation of IEER shall be as
follows:

IEER= [(0.02* COP at 100% loading) + (0.617* COP at 75% loading) +

(0.238* COP at 50% loading) + (0.125* COP at 25% loading)]* 3.41

In case if the IEER is less than 18, a consolidated penalty shall be paid
by the contractor, according to the following formula :

Cost= [ 0.02(1/COPm1 – 1/COPr1) + 0.617* 0.75 (1/COPm2 – 1/COPr2) +

0.238 * 0.5 (1/COPm3 – 1/COPr3) + 0.125 * 0.25 (1/COPm4 – 1/COPr4)] *
16 hrs * 365 days * Rs 7/kWh * 10 years* 3.51* TR rating

Where, COPr1, COPr2, COPr3, COPr4 are reference COP’sand are taken
as 4, 5, 6 and 5.5corresponding to IEER= 18and COPm1, COPm2, COPm3,
COPm4 are the COP’s declared by the manufacturer corresponding to
100%, 75%, 50% and 25% respectively at 350 C.

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Alternatively :

Cost of energy consumption of each18HP outdoor unit with IEER of 18

running for 16 hrs a day and energy cost at Rs.7 per unit comes to
approx Rs.26.4 lac for 10 years and it comes to Rs.27.65 lac with IEER
of 17, which means for every drop of 1% IEER additional cost of energy
consumption for 10 years comes to Rs.0.22 lac. Therefore for every drop
of 1% IEER of the offered VRF system below 18, a consolidated penalty
of Rs.0.22 lac shall be paid by the contractor. This shall also apply to
ODUs of 20 HP and 24 HP.

Successful bidder shall submit the COP at AHRI conditions also of the
proposed VRF system at all four loading conditions, i.e. 100%, 75%, 50%
and 25% along with supporting documents. COP at the time of FAT will
be measured by DMRC or the representative of DMRC and if IEER is
found to be less than 5% of declared value, penalty at double the rate as
per para 6.2willbeimposed.

1.12.7 Maintenance and life

a. The service life of the VRF system shall be at least 15 years, with
average 12-16hours working per day during the year.
b. The manufacturer shall submit the list of those items whose life does
not match with the service life of VRF. The life of such spares shall
be advised with a certificate from the original manufacturer of the
spares. The firm shall supply purchase specification of these items.
c. The manufacturer should also submit Annual Maintenance cost rates
for the full service life of the system.
d. The manufacturer shall provide free service and guarantee for 24
months from the date of taking over the metro station by the
purchaser.
e. The manufacturer will submit an undertaking that the spare parts will
be available for the entire service life of the product.

1.12.8 Special Condition

Quality Assurance and Controls: The Contractor’s Management Systems

shall emphasize quality assurance and controls. The programme shall be
adequate to ensure an acceptable level of quality of the equipment
supplied. The concept of total quality assurance shall be based on the
principle that quality is a basic responsibility of the Contractor’s
organization, and shall be visible by:

a. Firm procurement and job performance specifications.

b. Firm procedures for transmission of information and data to their
Subcontractors and ensuring their compliance.
c. Adequate testing to ensure repetitive product conformity to design
requirements and Total programme of surveillance and verification of
physical performance and configuration accountability.
d. Adequate records shall be kept by the Contractor to provide
evidence of quality and accountability. These records shall include
results of inspections, tests, process controls, certification of
processes and personnel, discrepant material, and other quality
control requirements.
e. Complaint Handling and commitment towards customer satisfaction.

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The manufacturer shall ensure use of best manufacturing practice like

quality of bends, no sharp corners, and no metallic parts with sharp
edges, use of quality gasket at appropriate loss to damp vibrations and
sealing etc.

The manufacturer shall study the environmental pollution data prevailing

near the Metro Station where its equipment is going be installed. The
manufacturer shall take adequate precaution either during manufacturing
or installation to prevent any damage to the equipment or loss of life
arising due to prevailing pollution level.

1.12.9 Testing

a. The unit shall be tested for capacity and IEER as per AHRI conditions
at manufactures premises or at an accredited laboratory. The
capacity of ODU and IDU’s shall be as per the BOQandrated100%
capacity(within the acceptable tolerance as specified in AHRI 1230) .
b. The manufacturer shall also submit the deration graph for different
ambient conditions in the performance of their VRF system starting
from the maximum ambient temperature conditions as specified in this
specification.
c. Before delivery, owner/ their representative reserve the right to
witness the test in presence of tenderers and manufacturer’s
representative.
d. The manufacturer shall submit Installation guidelines duly approved by
Engineer-in-charge. The manufacturer shall ensure compliance of
installation guidelines and shall sign the installation certificate before
commissioning of the plant to start.
e. After complete installation of refrigerant piping, it shall be pre-
pressure tested and repaired if necessary and further pressure tested
to 3,800 Pa, to hold for a minimum 24 hours with dry nitrogen prior to
insulating the joints.
f. After satisfactory testing, the refrigerant pipe shall be evacuated and
dehydrated to (- 755 MM HG) and held for one to four hours
depending on the pipe length.
g. The FAT plan for VRF equipment shall be as per Annexure-A.

1.12.10 Training

The contractor shall ensure training of DMRC staff as decided by DMRC

at DMRC workplace or at his workplace as considered necessary.

On completion of installation, the manufacturer shall supply two sets of

well bound handing over manuals duly approved by
Consultants/Engineer-in-charge. Each set shall include:-

 As Built Drawings.
 Do’s and Don’ts for the maintenance and operating staff.
 Working details of VRF system.
 Operating manual.
 Extracts of the warrant/DLP.
 Details of service center.

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 List of staff trained on the said design of the VRF.

 The first page of the booklet shall be signed by the manufacture,
contractor and DMRC Engineer.
 Soft copy of the entire documents.
1.12.11 DXSPLIT AIR CONDITIONERS
1.12.12 General

 The contractor shall supply and install split system air conditioner with5
star rating wherever indicated. The system shall be complete in all
respects and comply with the specifications as given.
 All split units shall be eco friendly type.

1.12.13 Condensing units

a. Each condensing unit shall be complete unit with high EER hermetic
scroll compressors, air cooled condenser, condenser fans with motors,
internal piping, switches and internal wiring and shall be enclosed in
weatherproof outdoor type housing.
b. The compressor shall be hermetic, with enclosed gas cooled motor. The
compressors shall be suitable forR410A.
c. The condenser coil shall be air cooled type with aluminium sine wave
fins and copper tubes and necessary refrigerant connections. The
copper tubes shall not be less than1/2” O.D.
d. The condenser air fans shall be propeller type direct driven, each
complete with motor. The air quantity and area of the condenser shall
be adequate for working in the specified outdoor conditions.
e. The casing shall be fabricated from galvanized steel and finished with
powder coated paint. The casing shall make the whole unit fully weather
proof. Suitable for outdoor installation.
f. The unit shall include a remote control assembly with thermostat and
starter and speed switches.
g. The necessary charge of refrigerant gas and lubricated oil shall be
provided to run the system.

1.12.14 Cooling unit (Duct able)

a. The cooling unit shall be matched to the respective condensing unit and shall
consist of cooling coil, blower, filters,outer casing, drain pan, accessories etc.
b. The cooling coil shall have copper tubes of not less than1/2” O.D. and continuous
aluminium sine wave fins with integral collars. The tubes shall be staggered in the
direction of the air flow.
c. The fan section shall compriseof1 No. statically and dynamically balanced
centrifugal blower, motor, drive package, mounting arrangement etc.
d. The unit casing shall be made of galvanized steel, the casing shall be insulated to
lower the noise level and eliminate condensation.

1.12.15 Cooling unit (Non-Duct able (Cassettes, High walls))

a. The cooling unit shall be matched to the respective condensing unit and shall
consist of cooling coil, blower, filters,outer casing, drain pan, accessories etc.
b. The cooling coil shall have copper tubes of not less than1/2” O.D. and continuous
aluminium sine fins with integral collars. The tubes shall be staggered in the
direction of the air flow.

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c. The fan section shall compriseof1 No. statically and dynamically balanced
centrifugal blower, motor, drive package, mounting arrangement etc.
d. The unit casing shall be made of galvanized steel, the casing shall be insulated to
lower the noise level and eliminate condensation.
e. Indoor unit should be as per UL-94.

1.12.16 Refrigerant piping

The condensing unit and evaporator unit shall be interconnected by type`L’

seamless refrigerant liquid and suction lines using flared or brazed fittings.
Necessary accessories shall be incorporated in the circuit.

a) The suction and liquid line shall be insulated with13 mm thick expanded
polyethylene/ Nitrile rubber insulation and the discharge/gas line shall be
insulated with19mm thick insulation.
b) Necessary chases and holes in walls and floor etc for laying the piping
work shall be done by contractor, after completion of work necessary
repair work shall be done by contractor and brought to its original finish

1.12.17 Miscellaneous

a. The unit shall have control panel, housing the starting switches, contactor, relays
etc. Isolation pads shall be provided under the units.
b. Insulated drain line shall be provided from indoor unit up to drain trap. (to be
priced separately).
c. Suitable M.S. channel supporting frame shall be provided for the condensing unit
and supporting arrangement for the indoor units.
d. Interconnecting power and control cabling shall be provided between condensing
unit and evaporator unit.
e. PVC flexible sleeves shall be provided to cover the insulated refrigerant piping
and electrical cabling from indoor to outdoor units.
f. Compressor current should not flow through indoor unit.
g. Inbuilt protection in indoor unit against electric fault to be provided.

1.12.18 Installation

The split type air conditioner shall be mounted on vibration isolators and
installed in accordance with the manufacturer’s recommendation such that no
disturbing vibration or noise is being transmitted to the nearby structure.

a) Refrigerant pipes that exposed to outdoor shall be covered with UV

coating to protect insulation from direct UV exposure.
b) Anti corrosion protective coating on refrigerant pipes, Bents, Joints of
indoor & outdoor unit to be done to avoid leakages.

All galvanized support beams, galvanized legs, galvanized hangers, anchor

bolts,vibration isolators,ductworks and shall be provided for the installation of
the units.

1.12.19 Testing and commissioning

After installations are completed, all air-conditioning system shall undergo test
run. Any adjustments that are needed shall be made to assure that all air-
conditioning system

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willoperateeithertherequiredperformance.Reportformstocontainfollowingminimu
mdata listings shall include design and actual conditions for each Item
mentioned below:

a) Date and time of test.

b) Air-conditioning unit make, type, name and serial number.
c) Fan rpm.
d) Fan motor amperage
e) Rated motor amperage, starter number and ampere rating.
f) Fan CFM
g) Fresh air CFM in case of duct able units
h) Outside conditions (DB and WB)
i) Entering coil conditions (mixing) (DB andWB)
j) Leaving coil conditions (DB andWB)

During test run, the air filters of testing sets shall be used.

1.13 FANS
1.13.1 General

a) This Section specifies the manufacture and installation of all ventilation

fans as shown on Drawings.
b) The fan external total pressure resistance figures specified on the
Equipment Schedules and/or Drawings are for guidance and information
only and are calculated based on assumed resistance figures of
equipment. The exact fan total pressure based on the duct run and the
offered equipment shall be carefully checked and re-calculated for each
fan before ordering the equipment. Calculation shall be submitted for
Approval. No modification to the ductwork system shall be allowed
without prior Approval. Any additional cost for the modification of the
system (fans, motors, switchgears, cables, panel boards, switchboards,
etc.) necessary to meet the specified duties, spatial conditions and the
offered equipment shall be provided at no extra cost to the Employer.
c) Allowance shall be made for the effects on fan performance of all
installation conditions including coils, eliminators, sound attenuator,
plenums, enclosures, inlet and discharge arrangements so that actual
installed fan performance equals that specified.
d) Proprietary bell mouth and wire guard shall be provided for fans without
ductwork connection. Bell mouth is not required for propeller fans.

1.13.2 Quality control

a) Reference Codes and Standards

AMCA Standard 210: Laboratory Methods of Testing Fans for Rating

BS 848: Fans for General Purposes

IS / IS / IEC 60034 for design, performance and efficiency of motors

ISO 5801: Industrial Fans – Performance Testing using Standardized

Airways

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b) Codes and regulations of the jurisdictional authorities.

c) All fans, drives and accessories shall be designed, constructed, rated
and tested in accordance with the recommendations and standards of
AMCA / ISO.
d) Fan tests shall conform to the requirements of AMCA Standard 210 or
ISO 5801 or to an Approved equal standard.
e) Sound ratings shall conform to AMCA standard test code for sound rating
of air moving devices or BS 848: Part 2.

1.13.3 Technical and installation requirements

a) Description

i. Fans shall have non-overloading characteristic, except for

forward curved centrifugal, over their entire operating range.
The characteristic curves shall be such that the fan operating
point falls between the no flow static pressure and the
maximum mechanical efficiency. The fan characteristic shall
also be such that for a 15 % increase in total pressure over the
specified value, the fan shall deliver not less than 85 % of the
specified air volume flow rate. The stability of fan operation shall
not be affected under such situation.
ii. All axial flow fans with nominal rating above 7.5 kW shall have a
minimum efficiency of 70%. The manufacturer’s best efficient
fans shall be selected through manufacturer’ software by
engineer in charge during approval.
iii. Each fan unit including motor and drive shall be supplied from
the manufacturer as a completely factory-assembled package
and all guarantees and test certificates shall be deemed to
apply to the entire assembly.
iv. All fans shall be capable of withstanding the pressures and
stresses developed during continuous operation at the selected
duty. Additionally, all belt driven fans shall be capable of
running continuously at 15% in excess of the selected duty
speed.
v. Lifting eye/Flanges shall be provided on all centrifugal and axial
fans.
vi. All fans shall be statically and dynamically balanced.
vii. All centrifugal fan shafts shall have the ends drilled to receive a
tachometer.
viii. Motor speed shall not exceed 1495 rpm unless otherwise
specified.
ix. Nominal motor nameplate rating shall be higher than the peak
operating power of the selected fan curve for non-overloading
characteristic. The motor rating shall be a minimum of 15%
higher than the motor operating point at design conditions
unless otherwise specified.
x. All fans and motors offered shall be of minimum vibration and
noise level during operation. Should the vibration and noise
level be excessive and not within acceptable standards,
additional vibration isolation and sound attenuation shall be

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provided at no extra cost to the Employer to the satisfaction of

the Engineer.
xi. All fans are required to be hot dip galvanised/ galvanised.

b) Propeller Fans

i. The impeller shall be designed to give maximum volume with

minimum noise level and minimum power consumption and
shall be made of steel or aluminium alloy. The hub shall be
steel with grey stove epoxy finish or aluminium alloy. The fan
shall be complete with anti-vibration mount.
ii. The motor shall be dust and moisture protected to IP54 and of a
totally enclosed construction with permanently lubricated ball
bearings suitable for running in ambient temperatures of up to
50°C and relative humidity of up to 100%.
iii. Wire guards made of heavy gauge steel wire or rod with all
joints and crossings welded and shall be fitted to impeller side
or motor side or both where appropriate.
iv. Propeller fans shall be diaphragm mounted on not less than
3mm thick steel mounting plate with stove epoxy grey finishes.
v. Provided with seal permanently lubricated bearings.
vi. With tip speed not exceeding 17.5m/s

c) Axial Flow Fans (Vane Type)

i. Provide axial flow, direct drive aerofoil fans as specified on the

Equipment Schedules and/or Drawings.
ii. Fan Casing

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 Casing shall enclose the motor and impeller.

 Fan casings shall be fitted with matching flanges on
the inlet outlet ends with spigots for attachment of
flexible connections.
 Inspection doors or sight ports to enable direction of
rotation to be established shall be provided.
 Terminal boxes welded to the casing shall be provided
for electrical connection using metallic flexible conduits
to fan motor complying with BS 4999: Part 20 for dust
and weatherproof conditions.
 Grease nipples shall be brought to the outside of the
casing in the most accessible position and fitted with
lubrication tube made of copper or other Approved
material.
 Gasketed access doors shall be provided in each fan
housing or connecting ductwork, suitable for access to
adjust or replace blades. For smoke extraction fans,
the gaskets shall be suitable for continuous operation
in an air stream temperature of 250 °C for not less
than two hours.

iii. Impeller.

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 Impellers shall be of die-cast aluminium alloy.

 For hub size of 315mm (dia.) and above, blades shall
be manual adjustable without removing the wheel.
 Positive locking shall be provided for securing the
impeller blades into the hub. Spun aluminium hub
caps shall be fitted.
 The blades shall be counter-balanced and mounted on
a thrust bearing for vertically installed fans.

iv. Except smoke extraction fans and unless otherwise specified,

drive motors shall be of class F insulation (BS 4999 and BS
2757) totally enclosed type and rated for continuous operation
in ambient temperature of 50 °C. Performance and rating shall
comply with BS 5000 and IEC 34-1 with protection to IP55. All
motors shall be of efficiency class IE-2.
v. Factory bell mouth shall be provided where no duct connection
is required. Fans shall be fitted with bell mouth inlets. Flow
cores and bell mouth inlets shall be fabricated in steel and
provided with flanges drilled and rigidly bolted to the fans.
vi. Provide wire guards on fan outlet/inlet not connected to
ductwork and shall be made freely accessible for maintenance.
vii. Fans shall be provided with mounting feet and spring isolators.
viii. The bearing life of the fan motor assembly shall be of 40,000
hours (L-10 life).
ix. Stationary, curved guide vanes shall be located on the outlet
side of the fan to straighten the motion of the air leaving the
blades to improve operating efficiency if required.
x. For smoke extraction fan, adequate clearance shall be provided
between blade tips and housing at all points to allow for
expansion and contraction over a continuous operation in an air
stream temperature range from 0 °C to 250 °C without
developing interference to the specified flow capacity. The
fabrication/shop drawings shall show the clearance at over a
continuous operation in an air stream temperature range from 0
°C to 250 °C as well as any point of minimum clearance in
between. The motors in case of smoke extraction fans shall be
fire rated for 250°C, 2 hours.

d) Centrifugal Fans

i. Provide forward/backward curved fans as specified on the

Equipment Schedules and/or Drawings. Back ward curved type
shall be non-over loading.
ii. Unless otherwise indicated, centrifugal fans consuming more
than 7.5kW at the fan shaft shall be of the backward bladed
type having a fan total efficiency not less than 80%. Centrifugal
fans with shaft power exceeding 15kW shall be of the aerofoil
backward curve type.
iii. Fan Casing

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 Fan casing shall be of sheet steel construction

adequately stiffened and braced and shall be entirely
free from vibration or drumming during normal
operation. The steel required to be galvanised / hot dip
galvanised.
 All fans with an inlet eye diameter exceeding 300mm
shall have a bolted access door on the scroll for
access purposes. The size of access panels shall be
such as to facilitate cleaning and maintenance of the
impeller.
 Drain sockets or holes with copper drain pipe brought
out to an accessible point, valved and plugged, shall
be provided.
 Fan casings shall be fitted with flanges on the outlet
connection suitable for connection of discharge
ductwork and flexible connections as shown on the
Drawings.
 Where the inlet side of the fan is connected to
ductwork, matching flanges for connection of flexible
connections shall be provided
 Inspection doors or sight ports to enable direction of
rotation to be established shall be provided.

iv. Fan Impellers

 Impellers shall be double inlet, double width or single

inlet, single width as shown on the Equipment
Schedule and/or Drawings and shall be mounted on
substantial hubs.
 Fan impellers shall be backward/forward sloping
blades as specified on the Equipment Schedule and/or
Drawings.
 Impellers shall be rigidly fixed to solid bright steel
shafts adequately sized and proportioned to ensure
that the maximum operating speed is not more than
60% of the first critical speed. The shaft shall be
protected by reliable anti-rust coating.
 Impellers shall be of steel, electro-galvanized after
fabrication (or aluminium where indicated), of riveted
or welded construction, with spiders or hubs, of robust
design and shall be capable of running continuously at
15% in excess of normal speed.
 All forward curved fans shall be selected for use with
speed not exceeding 1200rpm and backward curved
fans shall be selected not to exceed 2000rpm, unless
otherwise specified.

v. Unless otherwise specified, drive motors to Class F insulation

shall be totally enclosed and rated for continuous operation in
an ambient temperature of 50°C. Performance and rating shall
comply with IEC 60034. All motors shall be of efficiency class
IE-2.

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vi. The fan and motor shall be mounted on rigid galvanized steel
channel base. Provide slide rails for adjustable mounting of
motors.
vii. The driven V-belt shall be rated at 150% of the operating motor
power input. Provide adjustable sheaves on the motor, capable
of 20% adjustment in fan speed, with the design fan capacity
settling at approximately the midpoint of the adjustment. Belt
speed shall not exceed 25m/s.
viii. Type of V-belt shall be in accordance with the "Standards for
Light-duty or Fractional-Horsepower V-Belts" of Rubber
Manufacturers Association.
ix. Belt guards shall be of heavy gauge steel framing with
expended mesh screen.
x. All belt guards shall have access openings at the shaft ends to
enable tachometer readings to be taken.
xi. Vibration isolators shall be provided in accordance with
"Acoustic Treatment and Vibration Control" section of this
Specification.
xii. The shafts shall be carried in ring lubricated self-aligning sleeve
bearings for shafts of 150mm diameter and larger. Each bearing
shall have large oil storage capacity to ensure efficient
lubrication. On shafts of sizes smaller than 150mm diameter,
grease lubricated self-aligning ball bearings resiliently mounted
to reduce noise transmission shall be used.
xiii. The shafts shall be extended beyond the drive-side bearing and
keyed for overhung pulley in all cases.
xiv. For centrifugal fans used in air handling units (AHUs) and
primary air handling units (PAUs), one coat of corrosion-proof
coating shall be applied to all non-working surfaces of shafts at
the factory.
xv. The bearing life of the fan motor assembly shall be of 40,000
hours (L-10 life).

e) Smoke Extraction and Pressurization Fans

i. In addition to the aforesaid requirements stipulated in this M&W

Specification, all fans used for smoke extraction and
pressurization shall comply with additional requirements
specified in this Clause.
ii. Smoke extraction fans shall be rated to deliver the designed
flow rate and pressure for continuous operation in an air stream
temperature of 250° C for not less than 2 hour.
iii. Not used
iv. All finishes shall be factory-applied and certified by the
respective manufacturer that the finishing materials are capable
of withstanding exposure continuously to an air stream
temperature of 250 °C for not less than 2 hours without
producing smoke or any toxic fumes.

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v. Motor winding of smoke extraction fans shall be insulated to

permit motor operation at design conditions for continuous
operation in an air stream temperature of 250 °C for not less
than 2 hour. The smoke extraction fans shall be performance
tested at factory for the performance and operating condition
before delivery. Type test certificates shall be submitted to the
Engineer for Approval.

f) Installation

i. All belts, pulleys, chains, gears, couplings, projecting set

screws, keys and other rotating parts shall be adequately
guarded so that any person can safely come in close proximity
thereto.
ii. Fit fans and appurtenances to the space provided and make
readily serviceable.
iii. Provide support beams, support legs, platforms, hangers and
anchor bolts required for the proper installation of equipment as
shown on the Drawings or as recommended by the
manufacturer and Approved by the Engineer.
iv. Provide permanently attached lifting eyes of sufficient number
for on Site installation and future dismounting of fan units.
v. Provide factory inlet bells and other accessories for fan units as
shown on the Drawings or otherwise required for a complete
and efficient installation.
vi. Where corrosion can occur, appropriate corrosion resistance
materials and installation methods shall be used including
isolation of dissimilar metals against galvanic interaction.
vii. Thoroughly clean the entire system before installing filters or
operating the fans.
viii. For systems containing filters, install filters and permanently
seal the filter frame air-tight before operating the fans. Replace
all dirty filters and filter media before handing over the system to
the Employer.
ix. Means of protection against over current in the motor shall be
incorporated in the control equipment when the motor rating
exceeds 0.37 kW.
x. A hole in the blanking off plate shall be provided for the cables
leading to the fans. The hole shall be sealed around the cables
with material suitable for sealing the hole effectively and
continuously exposed to an air stream temperature of 250 °C
for not less than 2 hours rating if the fans are used for smoke
extraction.

DATA SHEET FOR AXIAL FLOW FANS

Type Vane/Tube Axial (Long Casing Type)
Reference Code / Standard AMCA 210, ISO5801, BS848
Capacity As per BOQ

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Flow Unidirectional
Noise 85 dBA at 1 meter
Total Pressure As per BOQ
FAN
Blade Aerofoil Construction, Dynamically Balanced
Material Aluminum alloy
Bearings Totally sealed type Ball Bearing
Hub Cast Aluminium Alloy
Casing Rolled Steel Sheet, Heavy Gauge
Shaft Solid Steel
Mounting Shaft Key And Positive Locking Device
Drive Arrangement Direct Drive
Motor
Type TEFC, IE-2, Induction Motor, Continuous Duty
Design As Per IEC 60034
Three Phase, 415 V, 50 Hz, AC Power Supply
Power Supply
IP 55 Protected
Mounting Arrangement Suitable Bracket For Ceiling Suspension
Lifting Eye At Suitable Location And Number or
Lifting Arrangement
as per manufacturer standard.
Synthetic Paint (Not required in case of 275
Paint
GSM or above, as per standard)
1. Lifting eyes / Flanges shall be provided for the lifting of fans.
2. Should be provided for spring isolators & to install fans as per manufacturer
standard.
3. Flanges on the fans have sufficient strength to lift the fans.
4. Fans shall be provided with Flexible connections(Fire Rated in case of Fire
Rated) with spring washers on both the side.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.14 AIRWASHER
1.14.1 The packaged air washers shall be cabinet type of sheet metal sectionalized
constructions and shall include fan section, cooling pad section, motor, drive etc.

a) Air Washer enclosure / housing (double skin)

i. The air washer housing shall be made of double skin design

with main structure made of Extruded aluminium frame work in
different sections. The panels shall be double skin sand witch
type with 0.8mm precoated galvanized sheet on outside and
0.8mm precoated sheet on inside with 40mm thick phenolic
foam insulation material in between. All sections shall be bolted
to each other with neoperence rubber gasket and fixed with
stainless steel screw in between them for perfect air light joint.

b) Fan Section

i. The fan impeller shall be fabricated from GI sheets complete

with multiple, double inlet double width forward/backward
curved blades. It shall be both statically and dynamically
balanced.
ii. The fan housing shall be fabricated from 16 GA GI sheet of
sturdy construction and with smooth air inlets.
iii. The impeller shall be mounted on suitably sized steel shaft and
heavy duty ball /roller two bearings, one on either side. The
shaft should have key for fixing the drive pulley.
iv. The fan section shall be complete with multi ‘ V’ groove,
balanced pulleys ‘V’ belts and TEFC drive motor, along with
adjustable base for mounting the motor, inside the fan section.
However, direct driven plug fans shall be preferred.
v. The fan section shall have weatherproof light for illumination.
vi. The fan access door shall be equipped with micro-switch
interlocked with fan motor to enable switching off the fan motor
automatically in the event of door opening. The access door
shall further have wire mesh screen.

c) Cooling Pad

i. The cooling pads shall be of rigid cross fluted honey comb

design, having highly water absorbent cellulose media,
impregnated with anti sot insoluble chemicals. It shall provide
extended and sufficient wetted surface to provide a water
absorbing efficiency of 90% with air velocity not exceeding 500
FPM (2.5 M/Sec.) Suitable GI sheet moisture eliminator shall
be provided in the pad section.
ii. The cooling pads section and tank shall be fabricated from 18
Gauge SS sheets with bolted construction.
iii. The section shall be complete with FRP water distribution
header having ports and sized for uniform and adequate water
flow.

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iv. The tank shall be fitted ¾” (20mm) float valve of commercial

grade brass.
v. The pad section shall have provision for fixing one or two sets
of air filters as specified later.

d) Pumps

i. The water distribution pumps shall be of heavy duty, vertical

type mounted inside the tank. It shall be complete with
adjustable bleed off arrangement to prevent concentration of
undesirable salts.

e) Air Filters

i. The standard pre-filters shall be meeting eurovent class EU-4

with filter media non-woven synthetic with GI/ AI mesh Filters
shall be flange type.
ii. The unit shall also have fine dust filters having an efficiency of
95% measured by atmospheric dust spot efficiency. The filters
shall be meeting euro vent class EU-8/9. These filters shall be
optional and shall provided when specified.
iii. The above set of filters shall be fixed in filter frames, shaped to
prevent air leakage. The filters shall be easily removable. The
filter section may form part of the pad section or may be bolted
separately to the pad section. Above stated filters, (EU-4 or
8/9) shall be flange type.

f) Motors and Starters

i. The motor for each blower, shall be totally enclosed, fan cooled,
squirrel cage induction type.(IP-55)
ii. The motor starters wherever required and stated shall be “direct
on line” type upto 5 HP. All larger starters shall be of fully
automatic star delta type.
iii. The pumps shall be provided with single phase, self tripping
starter.

g) Miscellaneous

i. All the required accessories shall be provided wherever

necessary for proper operation and shall also include the
following:

 Necessary GI-B class piping for water circulation.

 Vibration isolators for the blowers and pumps.
 Canvas connections at the outlet of each fan.
 Nuts, bolts, shims etc., as required for the grunting of the
equipment.
 Float valve in the air washer tank, along with quick fill
connection.
 Gate valves in drain, make up, quick fill line etc. as required.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

 Built in isolator switches for the fan and pump motor and
wiring from the isolators upto the respective motors.

h) Limitation

i. The air velocity limits are as follows:-

 Velocity across air washer-not exceeding 2.5 m/s (500 FPM).

 Velocity at blower outlet-not exceeding 10 m/s (2000 FPM).

1.15 WET SCRUBBER

1.15.1 In general specifications shall be as per Air washer given above whereas specific
constructions shall be as given below in subsequent paragraph.

a) Air Scrubber shall be fabricated out of 18 gauge MS sheet internal

coated with FRP linned or equal.
b) Air Scrubber spray nozzles shall be brass material.
c) Air Scrubber eliminator shall be 4 bend PVC/GI.
d) The exhaust air from kitchen shall be subjected to single / two stage
spray section. Spray nozzles and piping shall be PP/HDPE material.
e) Scrubber efficiency shall be atleast 75% down to filtration upto 5 micron
dust particles. Spray nozzle shall be Hi – pressure type.
f) The wet scrubber shall be made to take care of the kitchen exhaust
which shall comprise mainly of Black soot, un-burnt oil and odour of
roasted food from tandoor etc.

1.16 DEHUMIDIFIERS

1.17 The Dehumidifier should have the capacity to maintain 65±5% RH at a temperature of
71.6 °F inside room.

The Dehumidifier will maintain only the required RH and the temperature will be
maintained with separate air conditioning system unit to be considered in the
contractor scope of supply and the rate quotes shall include this cost.

There has to be a separate programmable Humidistat for each unit for controlling and
maintaining the desired Humidity.

They should be compact in size.

SPECIFICATIONS AND GENERAL FEATURES FOR DEHUMIDIFIERS:

* High efficiency and reliability Easy to operate

* Certified as per standard EN ISO12100-1:2003,

* Suitable for continuous operation EN ISO12100-2:2003,EN60204-1:2006+A1 2009

* Auto / manual selector switch.

* Meeting essential requirements of European directives

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

* Power on, heater on and fault status indications Low Voltage directive 2006/95/EC

* Independent blower and motor for each airflow machine directive 2006/42/EC (Process
& Reactivation)

* A totally self contained unit

* Volume control damper for both (Process & Reactivation).

* CNC fabricated unit(s) with powder coated finish air flow.

* Rotor media has high performance metal silicates Easy to install synthesized in situ.

* Several mounting and installation options.

* Rotor incorporates robust internal structure with stainless.

* Small footprints; low volume/weight per CMH. steel perimeter flange for industrial
quality, durability and Easy to maintain easy serviceability.

* Quick and easy to service.

* Rotor perimeter flange extends media and seal life.

* Rotor is water washable.

* Edge hard face coating on rotor ensures long life and Options good sealing for media
and seals.

* Humidity control through humidistat on/off.

* Rotor is non-flammable with organics < 2%.

* Stainless steel construction

* Process and reactivation air flow sectors are insulated

* Micro processor controller Necessary control and safeties

* Differential air pressure switch for providing react air flow.

* Reactivation cool down safety device.

* Electrical interlocking of fan motors, heaters and rotor drive.

* Unique PTFE bonded bulb seal design; minimized air leakage

Product Special Features:

Rotor: High performance metal silicate

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

High performance metal silicate (High RH)

High performance molecular sieve (Low RH)

Process : High capacity metallic mesh filter

External box fitted with EU5 / filter

External box fitted with EU7 / filter

Higher static fan

Reactivation : High capacity metallic mesh filter

External box fitted with EU5 / filter

External box fitted with EU7 / filter

Higher static fan

Energy :Electric reactivation

External box fitted with steam reactivation

Construction :Cold rolled powder coated steel Stainless steel

Control : Single stage On/Off humidistat

Double stage On/Off humidistat

Proportional humidity sensor with SSR Digital display panel

Microprocessor control Touch/Push button panel

Performance Charts : Performance Charts to be submitted for Approval.

IAQ Measurement and Analytics

Indoor Air quality monitoring system and Data Analysis for :

Occupant Centric KPIs – Analytics platform analyses the IEQ data collected at
important regions of the building to provide occupant centric performance indicators.
These indicators outline the Thermal Comfort, Air Quality and Visual Comfort levels of
the regions monitored.

FM operations support – Real time data plots and analytics provides insights into day to
day behaviour of the building interiors. The rich data would help the FM team
understand certain interventions that can be tested to improve FM operations.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Effective BMS usage – Get recommendations for optimal utilization of your HVAC and
Lighting systems for improving air quality, thermal comfort and reduce energy
consumption.

Recommendations for improvement – Our platform has a rich library of effective

solutions for IEQ improvement. Based on the condition of the Air, Thermal and Visual
aspects of the interior space, the report would include customized recommendations for
improving the environment quality.

Recommendations include the technologies as well as vendors for the solutions.

A plug-n-play WiFi/ZigBee/2G/LTE Enabled device packed with Industrial Sensors for

monitoring indoor environment. Can be customized as per requirements

IT SHOULD BE ABLE TO MONITOR:

 TEMPERATURE
 HUMIDITY
 TVOC
 NOx
 PM10
 PM2.5
 CO2
 Light Levels

The system generated Data should be compared with the Standards defined on the
basis of ISHRAE 10001:2016 for Indoor Environment Quality

DUCTWORKS, DAMPERS, DIFFUSERS AND ACCESSORIES-

1.17.1 General

a) Description

i. This Section specifies the manufacture and installation of

ductwork, diffusers, registers, grilles, dampers, guide vanes,
cleaning of air system, access panels and accessories.
ii. All ductwork and distribution accessories delivered to Site shall
be new and indelibly stamped to identify different grades,
materials and manufacturers.
iii. Provide all ductwork, diffusers, registers, dampers and grilles
generally in accordance with the Drawings to be performed
during final design stage.
iv. Diffusers, registers and grilles shall be selected to meet the
requirements of noise control as described elsewhere in this
Specification.

b) Quality control

i. Relevant Codes and Standards

 HVCA, DW/144: Specification for Sheet Metal Ductwork, Low,
Medium and High Pressure/Velocity Air Systems

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 IS 277 : Galvanized steel sheets (plain and corrugated) -

Specification
 BS 476: Fire Tests on Building Materials and Structures
 BS 729: Hot Dip Galvanised Coatings on Iron and Steel
Articles
 UL 555: Fire Dampers
 UL 555S: Leakage Rated Dampers for Use in Smoke Control
Systems
ii. SMACNA: HVAC Duct Construction Standards, metal and
Flexible and Rectangular Industrial Dust Construction
Standards (Note: SMACNA standards shall be applied only if
any part of the duct installation standards are not covered by
DW/144).
iii. Technical and installation requirements.

c) Sheet Metal Ductwork

i. All sheet metal and stainless steel ducting shall be constructed

to the recommendations of DW/144. The pressure class rating
shall also be in accordance with DW/144.
ii. Ductwork shall be constructed of galvanised steel sheets
complying to DW144 for sheet thickness and IS277 for
galvanization requirements. The galvanization requirements as
per IS277 are as follows:
Thickness of sheet (mm) Galvanization (GSM)
0.18 to 0.28 (both
200
inclusive)
0.30 to 0.55 (both
220
inclusive)
0.63 to 1 (both inclusive) 275
Above 1 350
iii. Provide volume control dampers, complete with adjusting
handle or similar device to all branches of the supply air ducts
to regulate air flows along the main duct and the branch ducts.
Provide opposed blade type volume control dampers to all
branch.
iv. Provide flexible connectors of not less than 100 mm long
between primary air handling units/air handling units/fans and
related ductwork to prevent transmission of vibration to adjacent
elements. Flexible connectors shall also be provided at
building/station expansion and movement joints.
v. The material used for the flexible connections shall withstand
the specified conditions of temperature and air pressure, and
shall comply with the standards of air-tightness. The material
shall be fire resistant.
vi. Provide flanged joints to plant and elsewhere as necessary to
facilitate maintenance.
vii. All flanged joints in ductworks shall be made up with rubber
gaskets or suitable mastic material. These joints should also be

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connected with suitable material for earthing. Proper sized

electrical continuity jumpers (min. 2 per joint) are required to be
provided for making the duct work continuous. The gaskets
provided should be fire retardant and should not emit toxic
gases in case of fire.
viii. Apply sealant, adhesives, tapes to joints for sealing. All such
material shall comply with the requirements of DW/144.
ix. Balancing dampers of appropriate types shall be provided for air
balancing.
x. Short radius rectangular and square elbows in air ducts shall be
equipped with double thickness turning vanes. Long radius
elbows shall be used wherever possible.
xi. The transition ductwork between silencers and fans shall be
constructed of not less than 1.2mm thick galvanised steel sheet.
The transition shall be aligned with the fans and shall be
connected with angle flanges.
xii. The ducts and supports in the stations must be adequate for
minimum 100mm wg static pressure or the system pressure
whichever is higher.
xiii. Duct crossing for duct strength at 450mm or as per SMACNA.
xiv.
DATA SHEET FOR NON FIRE RATED DUCT MATERIAL AND DUCT WORK
Duct Material Galvanized Sheet Steel Of Lock Forming Quality
Zinc Coating As per IS277
Reference codes / Standards Duct Construction DW 144 / SMACNA(only for
parts not covered in DW144), IS277
Duct All Duct Sections Will Be Cross Broken
Guide Vanes At All the Bends To Be Made From The Same
Material As The Duct
Thickness Of Sheet And Type As per DW144
Of Joint for Rectangular Duct
Traverse Joint
Large side upto 1000mm TDF type Flange
Large side 1000mm and Slip On Flange
above
Bracing/Support Indicative support arrangement is given in tender
drawing, final drawing shall be approved by
engineer in charge
Duct Accessories
For Joints Hexagonal Nuts – Bolts / Washers Zinc Coated
Rivets Galvanized Iron / Magnesium Aluminium Alloy
Gaskets Fire retardant– size as per flange requirement
Screws Self Tapping Screws Will Not Be Used
Support Arrangement As Per SMACNA/DW144
Support From Wall / Ceiling Anchor Fastener Of Required Rating Not Less Than
2.5 Times the Load of the Duct

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Paint Flanges And Supports Treated For Corrosion And

Painted With Zinc Rich Paint Of Approved Quality
Flexible Connection Fire Proof Material To Be Screwed Or Clip Band
circular Spigots With Adjustable Screw Or Toggle Fitting
Flexible Connection Fire Proof Material To Be Flanged And Bolted With
Rectangular Ducts Backing Flat Or Bolted To Mating Flange With
Backing Flat
Flexible Connection 150 mm Length Between Two Faces (Minimum)

1.17.2 Flexible Ducts

a) Flexible ducts shall be neatly fixed and adequately supported.

b) Flexible ducting used to connect the air distribution accessories and main
ductworks shall comply with Part 7 of DW/144.
c) Flexible duct length shall not exceed 3.7m in length. Sheet metal duct
branch off shall be provided in case the maximum length of flexible duct
permitted is not long enough to reach the air terminal.
d) Bending radius shall be sufficient to prevent undue tensioning of the
outside of the bend and restriction of the throat likely to cause
deformation and/or leakage. The ratio between the bending radius and
the duct diameter shall be less than 2. In no case shall flexible ductwork
be used to connect misaligned ducts.
e) Flexible duct shall consist of flexible corrugated metal tubing of stainless
steel, aluminium, tin plated or aluminium coated steel and suitable for an
operating temperature range of –5 to 9°C.
f) The frictional resistance to air flow per unit length of flexible duct shall not
exceed 150% of the frictional resistance per unit length of galvanised
steel duct of similar diameter.
g) Flexible duct shall be insulated and wrapped with a minimum 25mm thick
24kg/m3 density fibre glass blanket.
h) Flexible duct shall not be used for any system which is designed for
handling smoke or being part of a smoke control system.

1.17.3 Fusible Link Fire Dampers (FLFD)

a) Provide fire dampers in air ducts where ducts penetrate fire

compartments.
b) Fire dampers shall fully comply with the requirements of DW/144.
c) Fire dampers shall be constructed to the same standards of air tightness
as the rest of the system.
d) Fire damper casings and blades shall be constructed of galvanised sheet
(275 GSM) and provided with a galvanised steel angle frame to each
side of wall or floor.
e) Fire damper casings shall be flanged to suit the ductwork which they are
fitted and the cross-sectional area shall not be less than that of the
ductwork.
f) Blade and fusible link shall be accessible for servicing through air-tight
inspection doors placed upstream or downstream of the air path
whichever provides the better access.
g) Provide UL Listed fusible link set at 68°C / 74°C or else as approved to
all fire dampers unless otherwise specified. Fusible link shall be arranged
in an exposed position and at upstream of the damper.
h) Details and position of all fire damper and associated access doors shall
be submitted for Approval prior to installation on Site.
i) Provide all necessary fixing framework for the installation of fire dampers.

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j) Provide fire rated material to seal off the clearance between the fire
dampers and wall.

DATA SHEET FOR FIRE DAMPER

Type Fusible Link Snap Acting (FLFD)
Reference Code / UL 555 BS 476 Part 20.,UL Classified
Standard
Fire Rating Two Hour @ 2500 C
Fusible Link Rated @ 680 C /740 C
Service Continuous Duty
Mounting Horizontal Or Vertical
Construction In Single / Two Module
Differential Pressure 1000 Pascal
Damper Free Area 80 % Of Damper Face Area
Damper Operating As per manufacturer standard complying UL555
Mounting Bracket
Open / close Limit Switch With Each Module
Indication
Leakage Max 5% Of The Rated Air Flow Across Damper In Open
Position
Frame Construction As per manufacturer standard complying UL-555
Blade
Pressure Drop 38 Pascal @ 10 Mtr. / sec. Air Velocity
Construction Material As per manufacturer standard complying UL-
555

Design – Aerofoil Design OR 3V-Type Design

Type Opposed/parallel Blade as per requirements

Blade Thickness For Aerofoil Design – Min 1.6mm

For 3V-Type Design – Min 1.5mm

Both complying UL-555

Linkages As per manufacturer standard complying UL-555
Shaft As per manufacturer standard complying UL-555
Bearing As per manufacturer standard complying UL-555

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1.17.4 Paint/Covering for Fire Rated Ductwork(As applicable)

a) Where shown on the Drawings, fire rated ductwork or equipment

enclosure shall be fabricated from fire rated material to the requirements
of BS 476 Part 24 or ISO 6944.
b) The construction of the ductwork or enclosure shall take into account the
structural strength, noise isolation as required and the requirements of
Class C duct in accordance with DW/144.
c) All necessary supports, and other accessories required for the complete
installation of fire rated ductwork, Sealent, Gasket, including additional
material for fire stopping at wall/ceiling penetration, shall be supplied by
the same manufacturer as the fire rated duct material and shall be
assembled in accordance with all the manufacturer’s recommendation
regarding all aspects of construction and installation shall be certified by
the manufacturer.
d) The applicable smoke temperature shall be 250 deg C. The ductwork
system shall be fire-rated for two hours and shall maintain mechanical
stability, fire resistant integrity, and thermal insulation criteria to BS 476:
Part 24 as per the ISO Cellulosic Fire Curve at temperature of 1029 C,
for both vertical and horizontal duct arrangements, for both inside and
outside fire exposures. Restriction of the duct due to twisting or buckling
after the fire test shall not cause 25 % or more reduction in cross-
sectional duct area.
e) The performance shall not be affected by moisture absorption.
Mechanical strength shall be maintained and the fire resistance material
shall not de-laminate or the fire resisting properties shall not deteriorate
even under water saturation. The material shall also be "Class-One"
surface spread of flame as defined in BS 476: Part 7. Additional
insulation, if required, shall be used as per the manufacturer’s
recommendation.
f) Whether BS 476 thermal insulation criterion is applicable or not, fire rated
air-conditioning supply, return, and exhaust ductwork shall be complete
with thermal insulation and vapour barrier.
g) The fire resistant material shall not attract pests and shall not rot or
support the growth of mould.
h) All fire resistant ductwork or enclosure, apart from its fire resisting quality,
shall be capable of resisting accidental damage and shall require to pass
the hard body impact test section of BS 5669: Part 1 / BS EN 1128 with
the weight being dropped through not less than 1m.
i) Smoke extraction system ductwork shall be made from suitable material
with adequate thickness. Rivets or self sealing screws used shall not be
of aluminium. Where ductwork (including sealant, flexible connection,
gasket and accessories) for smoke extraction / purge systems penetrate
the fire compartment walls or floors of the room which they serve, the
portion of the ductwork that traverses outside of the compartment wall or
floor shall have a fire rating equal to the fire rating of the compartment
wall or floor which it traverses through or of not less than two hours
whichever is the higher.

j) Fire resistant and acoustically sealed access panels shall be provided in

the above-mentioned enclosures for the access and maintenance of
equipment and fire dampers.

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DATA SHEET FOR FIRE RATED DUCT MATERIAL AND DUCT WORK
Duct Material Galvanized Sheet Steel Of Lock Forming Quality
Fire Rating Two Hour @ 2500 C
Zinc Coating As per IS277
Reference codes / Duct Construction BS 476 PART 24, ISO 6944.
Standards
Duct All Duct Sections Will Be Cross Broken
Guide Vanes At All the Bends To Be Made From The Same Material As
The Duct
Thickness Of As per DW144
Sheet And Type Of
Joint for
Rectangular Duct
Traverse Joint
Large Side upto TDF Type
1000 mm
Large Side 1001 – Slip on flange
2250 mm
Bracing Indicative support arrangement is given in tender drawing,
final drawing shall be approved by engineer in charge
Duct Accessories
For Joints Hexagonal Nuts – Bolts / Washers Zinc Coated
Rivets Galvanized Iron / Magnesium Aluminium Alloy
Gask Material Fire Rated For 2500 C 2 hours
ets Thicknes As per flange requirements
s
Screws Self Tapping Screws Will Not Be Used
Joint Strength Should With Stand 1.5 Times the Operating Pressure With
Out Deformation Or Failure
Support As Per SMACNA/DW144
Arrangement
Joint Strength Should With Stand 1.5 Times the Operating Pressure With
Out Deformation Or Failure
Support As Per SMACNA/DW144
Arrangement
Support From Wall Anchor Fastener Of Required Rating Not Less Than 2.5
/ Ceiling Times the Load of the Duct
Paint Flanges And Supports Treated For Corrosion And Painted
With Zinc Rich Paint Of Approved Quality
Flexible Fire Proof Material To Be Screwed Or Clip Band With
Connection Adjustable Screw Or Toggle Fitting
circular Spigots
Flexible Fire Proof Material To Be Flanged And Bolted With
Connection Backing Flat Or Bolted To Mating Flange With Backing
Rectangular Ducts Flat
Flexible 150 mm Length Between Two Faces (Minimum)
Connection
Duct Material Fire Rated To Comply With BS – 476 Part 24 And ISO –

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

6944
Reference BS 476 Part 24, ISO – 6944
Standard
Flame And Fire Class O (BS 476 Part 6 & 7)
Spread
Fire Duct Work Manufactured to HVCA Standard DW-144
Function Smoke Extraction
Duct Material Resistant to Water Impingement From Any Sprinkler
System
Impact Resistance BS EN 1128
Stability And Must Retain at least 75% of its overall Cross Sectional
Integrity Area

(BS – 476 Part 24 (1987)

Leak Test HVCA Specification DW – 143
Sealant Flame Retardant

Duct Accessories
Supports And Should Have 8000 C Melting Point And Tensile Stress is
Angle 15 N / mm2 For min 2Hour
Hangers And
Stiffeners
Flanges
Gasket And Nut /
Bolts
Duct Work Seals As Per BS – 476 Part 24, ISO – 6944

1.17.5 Motor Operated Dampers (MOD) - (As applicable)

a) All motor operated dampers shall be suitable for installation in either a vertical
plane or a horizontal plane.
b) The dampers shall be operated by electric actuators and shall be readily
assembled on Site from modular panels. Each motor operated damper panel
shall be of the multiple-parallel-blade type, with an independent channel frame;
and shall be factory-assembled complete with frames, blades, shafts, bearings,
seals, linkage, and all accessories required to erect the panels into composite
dampers. Motor operated dampers shall be provided with all structural support
members and hardware required for installation with additional framing or trims as
required to complete the installation.
c) Motor operated damper actuator shall be mounted outside of the damper frame.
d) Spring-return type damper actuator shall be provided either to open or close
damper as required in the event of power failure.
e) All motor operated dampers shall be the product of a single manufacturer; and all
like components shall be provided by a single supplier.
f) Motor operated damper module assembly shall have a net free face area of not
less than 80 % measured to the inside of the frames.
g) Dampers shall be based on standard air having a density of 1.20 kg/m3. This
shall apply to MOD and MSFD/MFD.
h) The motor operated damper manufacturer shall carry out factory tests to verify
that when the dampers are fully-closed and holding against a differential pressure

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

of 1000 Pa, air leakage through the damper will not exceed 8 CFM per square
feet of net damper face area.
i) When the dampers are in the fully-open position and air is flowing across the
damper at a uniform velocity of 10 m/s and the static-pressure drop across the
damper shall not exceed 38 Pa.
j) The motor operated dampers and their associated structural-supporting systems
shall, when the dampers are in the fully - closed position, be capable of
withstanding a differential pressure across the dampers of not less than 1.5 kPa.
k) The motor operated damper blade and shaft assemblies shall be supported at
each end by means of heavy duty, permanent self-lubricating bronze or stainless
steel bearings.
l) All motor operated damper-blade seals and damper-frame seals shall be
fabricated of a flexible material suitable for the specified operating conditions as
Approved. The seals shall be factory-installed in dovetail grooves incorporated for
this purpose in the design of the blade and frames to facilitate a tight closure
between the blades, and between the blades and frame. All seals shall sit
securely in the closed damper position. Alternative design of the seals will be
subject to the Approval of the Engineer. Noise due to resonance of spring-type
seals or any other source shall be rejected.
m) Each module of damper with only two operating positions should have one limit
switch with two contacts to monitor its open/closed status. If any one module of
the damper fails to operate, the damper shall be considered not functioning
properly. For each module of damper with three operating positions, two or more
limit switches shall be provided.
n) Motor operated damper linkage shall consist of stainless steel (SS-316),
extending through bearings inserted in brackets fabricated of stainless steel. The
linkage bearings shall be fabricated from bronze or other material suitable for the
specified operating conditions as Approved. The linkage brackets shall either be
attached to the damper-blade shafts or be side-mounted and mechanically inter-
connected with the shafts. Set screws shall not be used in the linkage assembly.
The linkage for MFD shall be as per manufacturing standard complying UL555
and UL555S.
o) Motor operated damper frames shall be a channel cross-section with not less
than a 100 mm web and 40 mm flanges, and shall be fabricated of hot-dipped
galvanised steel plate (min. 275 GSM) to BS EN 10142. However, the web and
frame for MFD shall be as per manufacturing standard complying UL555 and
UL555S. Reinforcing bosses and dove-tail grooves for mounting frame seals shall
be integral parts of the channel configuration. The corners of the frames shall be
either welded or reinforced by means of riveted gusset plates.
p) All screws, bolts, nuts, washers, expansion anchors, and/or other hardware
required to complete the installation shall be fabricated from stainless steel grade
316, and all intermediate supports, framing members, and hardware required for
assembly/installation of the damper shall be fabricated of hot-dipped galvanised
steel to BS 729.
q) The motor operated dampers shall be installed using fastening devices and
structural support elements herein specified, and in accordance with the
published instructions of the damper manufacturer.
r) Motor operated damper blades shall have an aerofoil or 3V design with minimum
thickness of 2mm, and shall be fabricated of hot-dipped galvanised steel plate (
min. 275 GSM) to BS EN 10142 . The width of the blades, measured in the
direction of airflow shall not be less than 100 mm and shall not be greater than
200 mm. For MFD, blades shall be aerofoil design (min 1.6mm) or 3V design (min
1.5mm).
s) Motor operated damper-blade shafts shall be fabricated of stainless steel SS-
316,. The design of the shafts shall incorporate the devices required for securely

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

locking the blades onto the shafts. For MFD, shafts shall be as per manufacturing
standard complying UL555 and UL555S requirements.
t) All VCDs, and MDs shall also comply with above specifications to the extent
applicable. VCDs shall have provision to set & lock the damper at any desired
position, whereas, MDs shall have a two position set and lock facility only. These
would be made of GSS (275 GSM) with 2 mm frame and blades.

DATA SHEET FOR MOTORISED SMOKE & FIRE DAMPERS

Type Motorized Damper
Reference Code / Standard UL 555S, UL 555, BS 476 Part 20.
Fire Rating Two Hour @ 2500 C
Service Continuous Duty
Mounting Horizontal Or Vertical
Construction Each module With Dedicated Motor Actuator
Differential Pressure 1500 Pascal
Damper Free Area 80 % Of Damper Face Area
Damper Operating Mounting As per Manufacturing standard complying UL555 &
Bracket UL555S
Open / close Indication Limit Switch With Each Module
Leakage Leakage as per Class 1 of UL555S
As per Manufacturing standard complying UL555 &
Frame Construction
UL555S
Blade
Pressure Drop 38 Pascal @ 10 Mtr. / sec. Air Velocity (As per size)
Material - As per Manufacturing standard complying
UL555 & UL555S
Construction
Design – Aerofoil Design OR 3V Design
Type Parallel/ Opposed Blades
For Aerofoil Design – Min 1.6mm

For 3V-Type Design – Min 1.5mm

Blade Thickness
Both complying UL555 & UL555S

As per Manufacturing standard complying UL555 &

Linkages
UL555S
As per Manufacturing standard complying UL555 &
Shaft
UL555S
Bearing Self-Lubricated Sleeve Bearing
Bearing Rating OneHour @ 2500 C
As per Manufacturing standard complying UL555 &
Crank Arms
UL555S
Actuator Assembly

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

Capacity 50% In Excess Of The Rated Capacity

Differential Pressure 1500 Pascal
Temperature Rating of
Two Hour @ 2500 C
actuator assembly
Motor Type Single Phase, 220 V, 50 Hz, AC Supply
Accessories Space Heater
Indication Power On – Off
1. Sleeve thickness of dampers shall be same as the frame thickness
1.17.6 Guide Vanes

a) Guide vanes shall be provided as required to maintain an acceptable

system pressure loss.
b) All blanking plates and sealing plates shall be provided for a complete
installation.
c) Vanes, supports, stiffeners, flanges, washers, bolts and welding filler
shall be of galvanised steel (275 GSM) and constructed to the
recommendations of DW/144.
d) Vanes shall be of continuous seam welded construction, except for
stiffening ribs, which may be stitch welded. Welding shall be in
accordance with relevant British Standards.
e) Curved sections shall be rolled or alternatively formed by a series of
creases in a break press as long as the creases are closely spaced, not
obstructive and form a smooth profile of air flow. If a break press is to be
used, a sample of a section of vane shall be submitted for Approval.

1.17.7 Ductwork Installation

a) Provide complete ductwork systems and ensure that the installation can
be adjusted to the designed flow rates to the satisfaction of the Engineer.
b) Check all the Drawings provided in regard to structural requirements and
other finishes before detailing the ducting system. Allowance shall be
made for the detailed development and on Site co-ordination.
c) Submit all drawings to indicate the fabrication and installation of ductwork
for Approval before fabrication commences.
d) Replace damaged ductwork and other appurtenances at no additional
cost to the Employer.
e) Provide hangers and supports (Slotted rail), fabricated of hot-dipped
galvanised steel, for the proper installation of ducts in accordance with
DW/144. Hanger rods shall be 10 mm or 13 mm in diameter, depending
on size of duct. All such hangers shall be provided with screwed lengths
on lower end for adjustment of ducting runs to level. All nuts shall be
provided with washers and with lock-nuts, and projecting ends of bolts
shall be cut off.
f) Supports shall not be riveted or bolted to the air ducts.
g) Install dampers and splitters in a manner so that they can be adjusted at
any time after completion of the work.
h) Install dampers without strain or distortion of any part of the dampers.
i) Adjust moving parts to move freely without binding.
j) Caulk dampers airtight around frames.
k) Adjust dampers and splitter adjusting rods to operate freely, between the
open and closed position.
l) Install flexible connections in accordance with Part 7 of DW/144.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

m) All ductwork shall be manufactured according to the dimensions taken on

Site. Provision shall be allowed to accommodate any discrepancies
between the Drawings and the Site dimensions.
n) All branches and openings in ducts shall be purpose made prior to
erection of the ductwork.
o) Cross-breaking will be permitted on low velocity ductwork only and in no
case where rigid external insulation shall be applied.
p) Internal roughness, sharp edges or obstructions to air flow shall not be
allowed.
q) External edges and corners formed from cleated joints shall be neatly
dressed down with air tight joints.
r) Provide at least 75 mm clearance from ductwork to walls, ceiling and
obstructions where a high standard of cleanliness shall be maintained.

1.17.8 Diffusers, Registers and Grilles Installation

a) Install diffusers, registers and grilles so that they can be key adjusted
from the face directly without special tools.
b) Unless otherwise specified, install vanes, volume control dampers and
multiple-blade extractors so that they can be removed through the
diffusers and registers for access to the duct.
c) Install diffusers, grilles, registers and louvers with frame connected to the
ductwork and provide soft gaskets inserted under the frame or otherwise
so arranged so as to avoid air leakage around the diffusers and grilles.

1.17.9 MOD Installation - (As applicable)

a) Each damper shall be installed so as to provide smooth operation,

opening and closing without shock in accordance with the manufacturer’s
recommendations.
b) Undue flexing or bending of connecting rods and linkage will not be
acceptable. Such connecting rod or linkage shall be replaced with either
a corrected design, higher strength material or increased size of such a
component at no extra cost to the Employer.
c) Dampers shall be supported independently of the ductwork.
d) Wall and floor mounted dampers: All slight, unavoidable spaces and
purpose-provided spaces between the damper frames and the structure
shall be sealed as required or as Approved. Blanking-off plates for such
purpose shall be considered as part of the damper assembly and shall
be provided at no additional cost to the Employer.
e) Damper module installations shall be fully sealed by gaskets between the
module frame and the mounting frame. The gasket material for
MSFD/MFD shall meet the continuous operation in an air stream
temperature of 250°C for not less than one hour criteria. Identification of
damper position is required on easy visible and accessible position, and
the damper setting position after balancing shall be marked in a
permanent manner.

1.17.10 Air Duct Cleaning points

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

a) The Contractor shall supply and install air duct cleaning points access
doors at suitable locations to the duct work system. The cleaning points
shall be installed at fully accessible locations. The contractor shall also
supply proprietary type compressed air lance, disinfection application
lance and ambling probe which shall be suitable for use with the cleaning
points. All joints must be air/water tight to prevent leakage.

1.17.11 Grills and Diffusers

a) All grills and diffusers shall be designed and rated in accordance with
ASHRAE 32-7/ASHRAE 70.
b) All grills and diffusers shall be of pure polyester finish aluminium unless
otherwise specified. Colour of grills and diffusers shall be selected by the
Engineer. Samples of finishes shall be submitted for approval.
c) All supply, return and exhaust diffusers shall be complete with opposed
blade dampers, suitable for mounting with appropriate diffuser and shall
be fitted with concealed adjustment devices. Straighter grids are required
before diffusers except for the last diffuser on the route. Each supply air
grille shall be complete with an opposed blade multi-leaf damper. One
set of tool for every 10 grilles or diffuser shall be provide for volume
adjustment.
d) The inside of all components and surfaces of all diffusers and grilles shall
be painted matt black. The drawings show provisional locations of
diffusers and grilles but in each instance outlets shall be installed in
accordance with the final detail drawings and reflected ceiling plans.
e) Velocities, net airways and distribution patterns shall give satisfactory air
distribution and temperature equalisation, be free of draughts
stratification or noise nuisance. The contractor shall make final
adjustments to air patterns when balancing.
f) The sizes of the grilles (including linear grille) indicate on drawings imply
the neck sizes of the fittings. Whereas the sizes of ceiling diffusers on
drawings imply overall external dimensions.
g) Square ceiling Diffusers
 Diffusers constructed of extruded aluminium shall be power coated
polyester finish to a colour approved by the Engineer.
 Diffusers with removable cores shall have square necks or alternatively
round necks. Diffuser sizes are shown on the drawings.
 Provide aluminium or steel opposed blades volume control dampers of
black colour with concealed adjustment lever. In general, dampers will
not be required for fan coil unit system having supply diffuser.
 Provide galvanised steel sheet painted black at the front view to seal off
dummy parts of diffuser.
 Diffusers ring or frames shall be compatible with the ceiling construction
in which they are installed. A transition piece shall be provided to
connect the diffuser to the duct. All edges exposed to view shall be
rolled or otherwise stiffened and rounded. Internal parts shall be
removable to permit cleaning of the diffuser and provide access to the
duct.
 Baffles, turning vanes or other devices shall be provided for the
required air distribution pattern. Equalising grids shall be provided for
ceiling diffusers.
 Volume control dampers shall be equipped and factory fabricated by
the diffuser manufacturer. The adjustment position shall be easily
accessed.

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 Square and rectangular diffusers shall comply with the following

performance requirements at design flow :

 Maximum pressure drop : 30 Pa

 Throw : 4m
 Noise criteria : NC 30
 Maximum air velocity at diffuser neck : 4 m/s
 Maximum terminal velocity : 0.5 m/s

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

h) Supply and Transfer Air Grilles and Register for general use.
 Double deflection supply air grilles/register shall be
tapped from top or bottom of ducts with provision for
tamper proof adjustment of air pattern spread along its
width. Adjusting tool shell be provided by the
manufacturer. Grilles/register shall have a minimum of
80% free area.
 Provide grilles/registers to meet the size and
capacities as shown in the drawings required to
connect ducts to grilles and registers.
 Grilles and register shall be factory assembled with
opposed blade volume control dampers operable
through the grilles face. The adjustment shall be by a
key through the face of the register and the volume
control damper shall be group operated or opposed
blade type. The operating mechanism shall not project
through any part at the register face.
 Diffusers constructed of the extruded aluminium shall
be pure polyester finish o a colour approved by the
Engineer.
 All grille cores shall be capable of being removed
easily from the duct work of access to dampers.
 All edges exposed to view shall be rolled or otherwise
stiffened and rounded. All edges shall be equipped
with air tight, non-combustible neoprene or sealing
stips to prevent leakage. The register ring of frames
shall be compatible with ceiling construction in which
they are installed.
 Multi-blade volume extractors shall be of the air
deflecting and air straightening type with blades
spaced a maximum of 50mm apart.
 Supply air registers shall comply with the following
performance requirements at design flow as :

o Maximum pressure drop : 30 Pa

o Throw : 4m
o Noise criteria : NC 30

i) Return/Exhaust Grilles and Registers for General use

 Grilles shall have single set of fins which shall be
vision proof to effectively mask the return opening.
Grilles shall have 450 inclined fins spaced
approximately 19 mm apart.
 Free area of grille core shall be at least 80%.
 Grilles and registers will be fixed type.
 Return air diffusers shall match the supply diffusers in
appearance and shall be constructed of the same
material and identical in surface finish as approved by
the Engineer.
 Register rings or frames shall be compatible with the
ceiling construction in which they are installed.
j) Linear Air Diffusers

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

 Each diffusers shall be of single/multi-slotted

vertical/horizontal discharge, ceiling mounted type
fitted into a field-insulated boot with spigot for
receiving supply air duct as detailed on the drawings.
 Diffusers of extruded aluminium shall be power coated
polyester finish to a colour as approved by the
Engineer.
 Number of slots and lengths of diffusers and capacity
shall be as indicated on the drawings.
 Provide air boot to the diffusers as shown on the
drawings. Air boot casing shall be constructed of 0.6
mm thick galvanised steel with interior surfaces
insulted to prevent erosion. Insulation and air boot
shall be extended to cover the collar of diffuser.
Volume control dampers shall be provided in the air
boot spigot.
 Subject to the ceiling panel design, the flanges of the
diffusers shall be designed to support “drop in “ ceiling
pane.
 Provide suitable support points independent of
suspended ceiling for the air boots and the associated
diffusers.
 Air boot spigot location and dimensions shall generally
be as indicated on the drawings.
 Provide galvanised steel sheet painted black at the
front view to seal off the dummy part of the diffusers.
 Linear air diffuser shall comply with the following
performance requirements at design flow as :

 Maximum pressure drop : 30 Pa

 Throw : 6m
 Noise criteria : NC 35
 Minimum terminal velocity : 0.5 m/s

k) Nozzle/Jet Diffusers
 Nozzle/Jet diffuser assembly shall consist of round
diffuser element which shall be fitted to square or
rectangular back plate, opposed blade volume damper
and duct collar.
 Each nozzle/Jet diffuser assembly shall consist of the
diffuser element and shall be compatible with the
architectural design in which they are installed.
 Individual diffuser element shall be capable of
adjusting the air deflection upto 300 from any plane
perpendicular to the face. Adjustment shall be
accomplished from front or back of the diffuser without
tools.
 Volume control dampers shall be provided for the
diffusers.
 The Nozzle/Jet diffuser shall comply with the following
performance requirements as design flow :

 Maximum pressure drop : 60 Pa

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 Throw : 15m
 Noise criteria : NC 35

DATA SHEET FOR GRILLS AND DIFFUSER

Function Air Distribution
Standard Air Diffusion Council
Requirement For Supply Air, Return Air And Air Extraction
Grills Linear Flow / Double Deflection Registers
Diffuser Four Way Rectangular / Square / Round
Construction Material Aluminium
As per manufacturer standard
Flange
Suitable For Continuous Joint With Alignment
Strips
Design Extruded section
Blade / Louvers Adjustable Front and Rear
Bars
Front Aluminium
Rear Aluminium
Damper
Type Adjustable Lever Operated
Fire Rating Non Fire Rated
Finish Black Anodized
Material Duly Treated for corrosion And Anti
Paint
Corrosive Paint
Noise Generation Should Have Very Low Air Noise Generation

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.17.12 Access Door- (As applicable)

a) Gasketed airtight access doors shall be provided at the duct for access,
inspection and maintenance of fans, equipment, dampers, filters, smoke
probes and controls.

b) Doors shall be hinged type complete with minimal of two sash locks and
shall be made of same metal thickness as ducts. Doors shall have
suitable size to access.

c) Access doors for insulated ductwork shall be of double skin construction

with insulation in between. The insulation for the access doors shall be of
the same type and thickness as the adjacent ductwork.

d) The door panels shall be made of suitable material and they shall have
not less than 12 mm wide neoprene rubber gasket around the entire
perimeter to ensure air tightness. It shall have the same fire rating as the
adjacent duct construction.

e) The access doors shall be hung on approved heavy duty hinges and
provided with suitable quantity with locks. The locks shall be able to
operate both from inside and outside. Where it is impracticable to use
hinge doors, the access doors may be fixed in position with wedge type
locks on opposite sides with suitable quantity per door. The section of the
duct where the access door is located shall be reinforced with suitable
material.

f) Where the duct is of smaller dimensions than the access door specified,
the door shall be of the full width of the duct Sealant and gasket used
shall be in accordance with the recommendations of HVCA, DW/144
Specification.

1.17.13 Manual Damper & Volume Control Damper

DATASHEET FOR MANUAL DAMPER & VOLUME CONTROL DAMPER

Type Manual Damper
Lever Arrangement, For Adjustment And
Operation
Locking At Any Position
Service Continuous Duty
Mounting Horizontal Or Vertical
Construction Splitter, Butterfly Type
Damper Free Area 80 % Of Damper Face Area
Damper Operating Mounting
Galvanized Steel
Bracket
Less than 0.1m3/s/sqm of net damper face
Leakage
area
Frame Construction Galvanized Steel
Blade
38 Pascal @ 10 Mtr. / sec. Air Velocity or as
Pressure Drop
per manufacturer standard
Construction Aerofoil design/3V design, Galvanized Steel

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For Manual Damper - Parallel/OpposedBlade

Type
For VCD – Opposed Blade
Material Galvanized Steel
Thickness 2.0 mm Thick
Linkages Stainless Steel – 316
Shaft Stainless Steel – 316,
Bearing
Type Bush Bearing
Material Brass
Suitably Supported For Ease of Movement,
Handle sufficient strength and shall be made of similar
material and shall be easy to operate.
1. Damper shall be factory tested for fully closed position and holding against a
different pressure of 1000 Pa and air leakage through the damper shall not exceed
0.1m3/s/sqm of net damper face area as per specification.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.18 INSULATION
1.18.1 Scope

Supply and fix thermal insulation for piping, ducting and equipment’s as per
the specification described in this section.

1.18.2 Materials of insulation

The following insulating materials shall be used:

a) For Refrigerant Piping

i. All suction pipes and low temperature/ pressure liquid pipes of the
Refrigerant pipe work shall be insulated with slip on Closed Cell
Elastomeric Nitrile Rubber fire retardant pipe insulation having a
wall thickness of not less than13 mm. The thermal conductivity of
the insulation material shall not exceed0.032W/mK at0 degree C
mean temperature. The density of the insulation material shall not
be less than33+3 Kg/cum.
ii. All joints of the insulation shall be sealed with100 mm widthx3
mm thick self-adhesive tape of the same material as insulation
and shall be of the same make as the basic insulation material.
Insulation material exposed to atmosphere shall be of the
material as described above and shall be provided with UV
protective coating/lamination. The joint sealing tape shall also be
provided with identical UV protective coating/lamination. Where
indoor refrigerant pipe work is located in roof spaces or spaces
where temperature may exceed30 degree C and RH may
exceed80%, the thickness of pipe insulation shall be selected
accordingly.
iii. The insulated refrigerant pipe shall be cladded with GI flexible
pipe between each set of indoor and outdoor unit.

b) For Ducting-

 Clean the surface with a wire brush and make it free from rust
and oil.
 Apply two coats of synthetic glue to the surface.
 Wrap the duct with insulation sheets of the thickness mentioned
above.
 The joints shall be sealed with synthetic glue to form a seamless
bond. The duct joints shall be additionally covered with a 150mm
strip of insulation material.

c) Duct Acoustic Lining-

 The duct surface shall first be cleaned from inside.

 Then frame of 25 mm square section made of 18 Ga (1.2 mm)
thick G.I. sheet should be fixed on both ends of the duct piece.
 The insulation slabs should be fixed between these sections of
ducts using adhesive compound and self adhesive stick pins.
 The insulation shall the be covered with RP tissue, sealing all
joint so that no fibre is visible.

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CC-135: Construction of Simulator Building at Shastri Park, New Delhi

 The insulation shall then be covered with 0.5 mm perforated

aluminium sheets.
 The sheet of insulation shall be secured to the duct by means of
stick pins as mentioned above.

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 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

1.19 ELECTRICAL WORK

1.19.1 General

These specifications cover all types of motors used for pumps, air washer,
Scrubber, Fans, machines etc. The motor installation, wiring, control shall be
carried out strictly in accordance with the specification here in after laid down.

1.19.2 MOTORS

General

a) This Section specifies the manufacture and installation of motors.

b) Unless otherwise specified or approved, all motors shall be of the totally
enclosed fan-cooled type with Class F insulation. Motors for fire services
pumps shall be of class H insulation and of IP 55 construction. Motors for
fire rated operation shall be designed for continuous operation in an air
stream temperature of 250°C for not less than two hour and shall be
totally enclosed squirrel cage induction, fan cooled guarded to IP55 with
Class H insulation. Insulation materials shall be suitable for the climatic
conditions available in the city. Particulars of all motors shall be
submitted for Approval.Motors shall be with IE2 Class.
c) Motors shall be adequately rated to meet the service demands of
associated driven units under all conditions and as limited by electrical
and mechanical protective devices. The cooling fan of the motor shall be
aluminium and protected by a metal fan cover.
d) The type, design and manufacture of all motors shall be subject to
Approval. Motors powered by AC shall comply with IS / IEC 60034 and
shall be of squirrel cage, induction type. Voltage for motors shall be 415V
3-phase or 240V 1-phase, as required. Motors rated 0.37kW and larger
shall be rated 415V, 3-phase, 50Hz. Motors rated smaller than 0.37 kW
shall be operated at 240V 1-phase. Starters for motors shall include
individual unit control transformers. Direct-on-line motor starters shall be
used for motors up to and including 3.75 kW at 415 volts, 3 phase. All
motors over this limit shall be equipped with reduced voltage starters of
the star delta or autotransformer, two-step, closed transition type.
e) The starting current shall not exceed 6 times of the full load current when
direct-on-line starting at full voltage is applied.
f) All motors shall be capable of accelerating the driven plant from standstill
to rated speed with a terminal voltage of 80% of the nominal supply
voltage at 50Hz in less than 4 seconds. All motors shall be capable of
operating continuously or, for short-time rated motors, for the duration of
the short-time period, at rated torque at any supply voltage between 90%
and 110% of the nominal supply voltage at 50Hz. They shall be capable
of delivering the rated torque when running at 70% of the nominal
voltage for a period of 10 seconds without injurious overheating and
under these conditions the slip shall not exceed 10%.
g) All motors shall be capable of operating continuously without injurious
effect and capable of driving the driven units at their rated output at any
frequency between 48Hz and 52Hz together with any voltage between
90% and 110% of the nominal voltage.
h) Vertically mounted motor shafts shall be supported by Approved thrust
bearings.
i) All bare steel internal parts except bearings shall be painted unless
otherwise protected against corrosion.

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j) Motors shall be designed for low shaft current and shall have adequate
provision to prevent bearing damage by shaft current.
k) An auxiliary marshalling box, electrically and mechanically separated
from the power supply terminal boxes, shall be securely mounted on the
motor frame for marshalling all small wiring for motor control or
monitoring.
l) For axial fans, external copper grease leads shall be provided for
lubrication of motor bearings unless totally sealed bearings are used.
m) The maximum motor efficiency shall be at the normal operating
condition. Motors in all cases shall be entirely suitable for the duty
intended. A margin of not less than 5% for compressors, 15% for fans
and 10% for water pumps shall be provided for equipment over the
continuous rating of the motor (without over-loading) under the normal
operating condition unless otherwise specified. The motor shall have
efficiency class IE2.
n) The power factor of motors shall not be less than 0.85 lagging at the
operating condition. Otherwise suitable power factor correction facilities
shall be provided to improve the power factor. For two-speed fans, the
requirement shall be achieved at both high speed and low speed
operating condition.
o) All steel works, supporting brackets and members, which are required for
the pump motor installation, shall be hot-dipped galvanized. Motors shall
be factory-painted to the appropriate finish. The paint used shall be
capable of withstanding continuous operation in an air stream
temperature of 250°C for not less than two hours without emitting smoke
or toxic fumes.
p) unless otherwise specification in this M&W Specified, in normal ambient
conditions bearings shall be designed for 40,000 hours operating service
(L10 life, Anti-Friction Bearing Manufacturer's Association) and provided
with a grease outlet connection for in service lubrication. Grease fittings
shall be brought to outside of fan housing and provided with covers
which shall effectively exclude water and dirt. Grease outlet is not
required if totally sealed type bearings are used.
q) Motor terminals shall preferably be of the stud type, totally enclosed both
from atmosphere and from the motor winding and be fully insulated from
the frame. Rubber insulation shall not be used for connections between
the windings and the terminals.
r) Each motor terminal box shall be fitted with sealing chamber, conduit
gland or adaptor plate, as required, together with the necessary fittings to
suit the cable entry. Terminal markings and rating plates shall be
provided. The terminal box shall be large enough for the specified cable
sizes of the respective motor.

1.19.3 Standards

a) Reference Codes and Standards

i. IS / IEC 60034 – for design, performance and efficiency of

motors
ii. IS 1271 / IEC 60085 / NEMA – For insulation class rating

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1.19.4 Technical and Installation Requirements

a) General

i. Motors of intake and exhaust fans of the axial type taking in

100% outside air shall be suitable for operation in atmosphere
of up to 95% RH.
ii. Noise level shall meet BS EN 60034-9.
iii. The degree of protection of the motors shall conform to IP55 20
with the following additional requirements:

 Motor frames shall be steel or aluminium alloy or cast

iron for motors inside station areas as appropriate.
 Motor frames shall be cast iron for motors in tunnels
and Ancillary Buildings.
 Earthing terminal shall be provided.
 Unless otherwise specified, red oxide zinc chromate
primer with two finish coats of grey paint shall be
painted.
 All motors shall be squirrel type and shall be suitable
for DOL or reduced voltage starting as specified on the
Equipment Schedules and/or Drawings.

iv. Termination boxes of adequate size shall be die cast aluminium

alloy or cast iron diagonally split type and suitably gasketed to
prevent ingress of moisture and dirt with the following additional
requirements:

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 Rotatable in any of the four 90 degree positions;

 Threaded holes suitable for mounting brass cable
glands;
 Stud type terminals for terminating electric cables as
specified; and
 Internal wiring connections to the main terminal boxes
and auxiliary marshalling boxes.
 Bearings shall be double shields and have the
following additional requirements:
 Ball or roller bearings with grease fittings and
minimum pressure relief fittings for in service
lubrication. Totally enclosed type bearings are also
acceptable.
I. Guide and thrust bearings for vertical motor drive units shall
be subject to Approval.

 Lifting eyes shall be provided for motors with a weight

of 20kg and above.
 Tests shall be carried out before shipment to
demonstrate that the equipment complies fully with
specified requirements. Test certificates shall be
provided for Approval.
b) Installation

i. Motors shall be installed as required by the driven equipment.

ii. Lifting equipment shall be provided for the installation of motors.
iii. Any additional steel works, supporting brackets and members
which are required for the motors installation shall be provided
by the Contractor at no extra cost to the Employer.
iv. The frames and supports shall be accurately set and leveled.
v. Each motor shall be provided with an emergency stop push
button at the Approved location. For outdoor installation, all
emergency stop push buttons shall be of weatherproof type.
vi. All moving or rotating parts of motors, which can be accessed
by personnel, shall be properly covered by steel wire mesh
guards.

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1.19.5 Switchboard: same as above subhead: 1(electrical works)

1.19.6 Electrical cabling: same as above subhead: 3 (electrical works)

1.20 TESTING OF AIR-CONDITIONING SYSTEM

a) Routine and types tests for the various items of equipment shall be
performed at the manufacturer’s workshop by the contractor in presence
of consultant and client and test certificates shall be furnished. Functional
tests shall be conducted at site.
b) The performance tests to determine whether or not the full intent of the
specification is meant shall be conducted by the contractor. After
notification to the employers that the installation has been completed and
the plant has run continuously for a period of at least two weeks, the
contractor shall conduct under the direction of the consultants and in the
presence of the employer’s representatives tests such tests as specified
to establish the capacity of various equipment supplied and installed by
the contractor.
c) The contractor shall operate, test and adjust the air conditioning
appliances including adjustment of regulators, dampers, etc.
d) All test equipment, labour, operating personnel, oil and refrigerant
required for these tests shall be furnished by the contractor to enable the
plant to be put in continuous running test for a period of two days after all
other tests and adjustments have been made.
e) The performance tests shall be conducted during peak summer and peak
monsoon.

1.20.1Procedure

Design Conditions

The inside and outside conditions will be recorded for24 hours duration on
hourly basis. The outside and inside dry bulb and wet bulb temperatures shall
be recovered by means of a sling psychrometer with mercury thermometers.
The relative humidity shall be computed from the psychometric chart. The
inside dry bulb temperature and relative humidity shall fall within the specified
limits.

Capacity of the Air-conditioning System

The following aspects shall be checked before conducting the performance

tests:

a) The outside conditions shall be as close to the design values as possible.

The tests shall be arranged during the peak summer and monsoon
b) The internal loads of various spaces shall be close to the design values
as far as possible. Otherwise, internal loads shall be simulated to a value
required to satisfy the design condition.
c) Hourly readings of pressure, temperature, electrical current, and voltage
and power factor shall be properly recorded. The capacity of the system
and various other equipment and accessories shall be ascertained as
follows:

1.20.2 Cooling Coils of Indoor units

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a) The flow of air over the cooling coil will be measured by recording the
velocity of air across each filter placed before the cooling coil. The
velocity shall be measured by means of an anemometer.
b) The wet bulb temperature of air entering the coil and that leaving the coil
shall be measured. The enthalpy of entering and leaving air shall be
noted from the psychometric chart, corresponding to the WB temperature
recorded. Single thermometer shall be used.
c) Same pressure gauge and thermometer shall be used for different
measurement of pressure and temperatures. The capacity of the
compressor shall be computed from the performance chart supplied by
the manufacturer. Bhp/ton of the compressor shall be computed from
above readings.

1.20.3 Air Balancing

After the desired inside conditions are achieved the quantity of air through
every outlet shall be measured. Air balancing should be done as per design
conditions.

1.20.4 Functional tests

Electrical Equipment:

a) All the cables shall be tested for continuity and absence of cross
phasing. Insulation resistance between the phase conductors and the
earth be measured shall with the help ofa500-V megger.
b) Motors:
i. Starting current shall be recorded every time the motor is started.
ii. Starter operation shall be checked for single phasing by removing
one of the phases.
iii. Overload protection shall be checked by altering the starter
thermal overload setting.

1.20.5 Test reading

The following readings shall be recorded hourly during the tests and capacity
of the plant shall be computed.

Indoor Units :
Air velocity M/Hr (FPM)
Coil face area M2 (SFT)
Air quantity M3/Hr (CFM)
Entering air temp. DB OC (OF)
Entering air temp. WB OC (OF)
Leaving air temp. DB OC (OF)
Leaving air temp. WB OC(OF)
Cooling capacity K Cal./ Hr (TR)
Motor
Rated horse power HP
Rated volts Volts
Rated current Amps
Actual current Amps
Actual volts Volts

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Control, Interlocks etc.

The observations of the test shall be recorded for each item separately.

1.21 NOISE CONTROL

1.21.1 Scope

The scope of this section comprises of the supply, installation, testing and
commissioning of noise and vibration control equipment and accessories.

1.21.2 Standards

The testing of all noise control equipment and the methods used in measuring
the noise rating of air conditioning plant and equipment shall be in
accordance with the relevant sections of the following British Standards,
unless otherwise stated:

STANDARDS DESCRIPTION
BS4718: 1971 Methods of Test of Silencers for Air
Distribution Systems.
BS2750 Parts1-9:1980 Laboratory and Field Measurement of
Airborne Sound Insulation of Various
Building Elements.
Recommendations for Field Laboratory
Measurement of Airborne and Impact
Sound Transmission in Buildings.

BS3638: 1987 Methods of Measurement of Sound

Adsorption in a Reverberation Room
BS4773 Part2: 1976 Acoustic Testing.

BS4856 Part2: 1976 Acoustic performance without additional

ducting of forced fan convection
equipment.
BS4773 Part5: 1976 Acoustic performance with additional
ducting of forced fan convection equipment
BS4857 Part2:1978 (1983) Acoustic Testing and Rating of High
Pressure Terminal Reheat Units.
BS4954 Part2:1978 (1987) Acoustic Testing and Rating of Induction
Units
BS5643: 1984 Glossary of Refrigeration, Heating,
Ventilating and Air Conditioning Terms
Note: British standards shall also be applicable for noise control.

1.21.3 General

Mechanical services shall generally be designed and installed with provisions

to contain noise and the transmission of vibration, generated by moving plant
and equipment at source where illustrated on the tender drawings and plant
and equipment schedules to achieve acceptable noise rating specified for
occupied areas.

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In addition to the provisions specified in the Specification, particular attention

must be given to the following details at time of ordering plant and equipment
and their installation :-

a) All moving plant, machinery and apparatus shall be statically and

dynamically balanced at manufacturers works and certificates issued.
b) The isolation of moving plant, machinery and apparatus including lines
equipment from the building structure.
c) Where duct work and pipe work services pass through walls, floors and
ceilings, or where supported shall be surrounded with a resilient acoustic
absorbing material to prevent contact with the structure and minimise the
outbreak of noise from plant rooms.
d) The reduction of noise breakout from plant rooms and the selection of
externally mounted equipment and plant to meet ambient noise level
requirements of the Specifications.
e) Electrical conduits and connections to all moving plant and equipment
shall be carried out in flexible conduit and cables to prevent the
transmission of vibration to the structure and nullify the provisions of anti-
vibration mountings.
f) All duct connections to fans shall incorporate flexible connections, except
in cases where these are fitted integral within air handling units.
g) Duct work connections to the fan inlets/outlets shall be concentricity
aligned so that the flexible connections are not subjected to any strain
and not used as a means of correcting base misalignment.
h) All resilient acoustic absorbing materials shall be non flammable, vermin
and rot proof and shall not tend to break up or compress sufficiently to
transmit vibration or noise from the equipment to the structure.
i) Where practicable, silencers shall be built into walls and floors to prevent
the flanking of noise the duct work systems and their penetrations sealed
in the manner previously described.

Where this is not feasible, the exposed surface of the duct work between the
silencer and the wall subjected to noise infiltration shall be acoustically clad
as specified.

1.21.4 Anti-vibration mountings

a) All items of rotating and reciprocating plant and equipment shall be

isolated from the structure by the use of anti-vibration materials,
mountings or spring loaded supports fixed to either concrete bases,
inertia blocks or support steels as indicated.
b) Centrifugal fans and motors within air handling units shall be isolated
from the frame of the air handling unit by suitable anti-vibration
mountings. Fan discharge air connections shall be fitted with approved
flexible connections internally isolating the fan scroll from the air handling
unit casing.
c) Axial flow fans shall be mounted on steel legs as diaphragm plates
supported on neoprene in shear anti-vibration mountings, or suspended
using spring loaded hangers to suite the application.
d) Centrifugal pumps shall be mounted on inertia bases consisting of
reinforced concrete sub- base, anti-vibration mountings and concrete
filled steel upper plinth. The Contractor shall be responsible for issuing
the steel upper plinth and mountings to the Contractor for building-in.

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e) Pipe work connections to circulating pumps, chillers, cooler coils and

other equipment shall be made with flexible connections as per
Specifications.
f) The construction of the anti-vibration mountings shall generally comply
with the following: - Enclosed Spring Mounting( Caged or Restrained
Springs)
g) Each mounting shall consist of castor fabricated telescopic top and
bottom housing enclosing one or more helical steel springs as the
principle isolation elements, and shall incorporate a built- in levelling
device.
h) The springs shall have an outside diameter of not less than75%of the
operating height, and be selected to have at least50%overload capacity
before becoming coil bound.
i) The bottom plate of each mounting shall have bonded to it a neoprene
pad designed to attenuate any high frequency energy transmitted by the
springs.
j) Mountings incorporating snubbers of restraining devices shall be
designed so that the snubbing damping or restraining mechanism is
capable of being adjusted to have no significant effect during the normal
running of the isolated machine.
k) Restrained isolator shall be provided on chillers subject to approval by
the manufacturers.

1.21.5 Flexible connections

a) Flexible connections shall be provided on all duct work connections to

fans, rotating plant and equipment isolated from structure and anti-
vibration materials or mountings. Pipe work and duct work crossing
building movement or construction joints shall be installed with flexible
connections.
b) Flexible connections on duct work to fans etc., shall be a minimum/
maximum free length of 100 mm/200 mm. respectively to minimise noise
transmission and noise breakout. They shall be completely free from
stress and shall not be required to accept any weight.
c) Thickness and strength of flexible connection materials shall be suitable
to withstand the positive and negative fan pressures to which they will be
subjected to and shall not allow perceptible leakage. The materials shall
be durable, non flammable having food acoustical quality.
d) Flexible connections shall be fitted to all pump suction and discharge
connections, and other vibrating equipment and where anti-vibration
mounts and inertia basis are fitted.
e) Flexible connections shall allow freedom of movement of plant in all
plans.
f) Matching flanges to pipe work flexible connections shall be of the smooth
faced weld-nick type.
g) Rubber Bellows shall be fitted as close to the source of vibration as
practicable. The pipe at the other end of the bellows shall be a fixed
point.
h) Rubber bellows shall be single convolution of multiply reinforced EPDM
rubber with wire reinforced cuffs. Flanges shall be able to swivel and be
removable. The date of manufacture shall be moulded on the bellows.
For traceability membranes shall have an indelible identification showing
manufacturer, country of origin, the type and a batch number.
i) Tie bars with rubber top hat washers shall be used on bellows.

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j) For working temperatures up to70ºC the rubber bellows shall be high

tensile synthetic fibre reinforced.
k) For working temperature between70ºC and100ºC the bellows carcase
shall be steel wire mesh reinforced throughout. Steel reinforced bellows
shall be manufactured and approved to the Standards.
l) For temperatures above100ºC bellow shall be multiply stainless steel
with Van Stone ends swivel flanges. The overall length shall not
exceed130 mm.
m) Flexible connections with screwed connections shall be reinforced EPDM
rubber hoses and shall have at least one full union to avoid torque ingon
installation.

1.22 GRAVENT - NATURAL VENTILATION SYSTEMS

1.22.1 Ridge type GRAVENT including all fastneners, sealants, flashing and caps etc. as
detailed below.

a) The gravity Ventilation System shall conform to the following

specifications:
i. Material of construction 0.50 mm thk. Pre-painted GI sheet.
ii. The ventilator shall be self-supporting over its dimensions.
iii. Bird screens shall be Netlon.
iv. All fasteners shall be aluminium / Galvanised as required
v. All sealants to be RTV-Silicones with a guaranteed continuous
high temperature rating of 200°C.
vi. The entire ventilator is to be mounted on roof purlins.
vii. The “Filler blocks” will have to be provided & fixed.

1.23 WIND DRIVEN TURBO VENTILATORS- NATURAL VENTILATION SYSTEMS

1.23.1 Aluminium Built 24” Turbine Technical Specification

Material Used Totally Aluminium Built

Number of Vanes 0.5 mm thickness, 38 Numbers

Centre Shaft Stainless Steel

Bearing NSK 2 RS (2 Nos)

Rivets Aluminium Pneumatic Rivets

Turbine Doom Thickness 1.2 mm

Turbine Outer Dia 680 mm

Turbine Doom Dia 372 mm

Turbine Rotor Dia 650 mm

Turbine Throat Dia 610 mm

Turbine Height 350 mm

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Turbine Weight 3.8 Kgs

1.23.2 24” FRP Molded Base Specification

Raw Materials Used CSM Mat, G.P. Resin, Waxpol, PVA,

Accelerator, Catalyst

Thickness 2 mm

Length 1500 mm

Width 1000 mm

Throat Dia 600 mm

Throat Height 310 mm

Suction Dia 700 mm

Weight 7.5 Kgs

1.24 MODE OF MEASUREMENTS (AS APPLICABLE)

1.24.1 Units Prices in the Schedule of Quantities:

a) The item description in the schedule of quantities is in the form of a

condensed resume. The unit price shall be held to include everything
necessary to complete the work covered by this item in accordance with
the specifications and drawings. The sum total of all the individual item
prices shall represent the total price of the installation ready to be
handed over.
b) The unit price of the various items shall include the following:
i. All the labour required to supply and installation the complete
installation in accordance with the specifications.
ii. Use of any tools, equipment, machinery, lifting tackle, scaffolding,
ladders etc. required by the contractor to carry out his work.
iii. All the necessary measures to prevent the transmission of
vibration.
iv. The necessary material to isolate equipment foundations from the
building structure, wherever necessary.
v. Storage and insurance of all equipment, apparatus and materials.
c) The contractor’s unit price shall include all equipment, apparatus,
materials and labour indicated in the drawings and/or specifications in
conjunction with the item in question, as well as all additional equipment,
apparatus, material and labour used and necessary to make in question
on its own (and within the system as a whole) complete even though not
specially shown, described or otherwise referred to.

1.24.2 Measurements of sheet metal ducts, grilles/diffusers etc.

a) Sheet Metal Ducts:

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i. All duct measurements shall be taken as per actual outer duct

surface area including bends, tees, reducers, collars& other
fittings. Gaskets, nuts, bolts,vibration isolation pads are included
in the basic duct items of the BOQ. These shall be treated as
ordinary duct pieces with their length measured along their centre
line.
ii. The unit of measurements shall be the finished sheet metal
surface area in metres squares.
iii. No extra shall be allowed for lapse and wastage.
iv. No measurements of vanes, splitters, duct dampers, deflectors,
access door etc which are required to be installed in duct shall be
made and the same shall be deemed to be part of duct work.
v. The unit duct price shall include all the duct hangers and
supports, exposing of concrete reinforcement for supports and
making good of the same as well as any materials and labour
required to complete the duct frame.
b) Grilles/Diffusers
i. All measurements of grills/diffusers shall be the actual outlet size
excluding the outer flanges.
ii. The square or rectangular grilles/diffusers shall be measured in
plain Sqm.
iii. All round diffusers shall be measured by their diameters in cm.
iv. All linear diffusers shall be measured as per actual length in
meters.
v. The grill/diffuser frame shall be constructedof16 gauge and blade
shall be constructedof18 gauge of extruded aluminium sections
either anodized or powder coated.

1.24.3 Measurements of piping, fittings, valves, fabricated items

a) Pipe
i. All pipes shall be measured in linear meter (to the nearest CM)
along the axis of the pipes and rates shall be inclusive of all
fittings E.G. tees, bends, reducers, elbows etc. Deduction shall be
made for valves in the line.
ii. Exposing reinforcement in wall and ceiling and floors of possible
and making good the same or installing anchor fasteners and
inclusive of all items as specified in specifications and schedule of
quantities.
iii. Rates quoted shall be inclusive of providing and fixing vibration
pads and wooden pieces, wherever specified or required by the
project coordinator.
iv. Flexible connections, wherever required or specified shall be
measured as part of straight length of same diameter, with no
additional allowance being made for providing the same.
v. The length of the pipe for the purpose of payment will be taken
through the centreline of the pipe and all fittings (E.G. tees,
bends, reducers, elbows etc.) as through the fittings are also
presumed to pipe lengths. Nothing extra whatsoever will be paid
for over and above for the fittings for valves and flanges.
b) Structural Supports

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i. Structural supports including supports fabricated from pipe

lengths for pipes shall be measured as part of pipe line and
hence no separate payment will be made. Rates shall be
inclusive of hoisting, cutting, jointing, welding, cutting of holes and
chases in walls, slabs or floors, painting supports and other items
as described in specifications, drawings and schedule of
quantities or as required at site by project coordinator.
c) Copper Connections for Indoor Units
i. Copper connection assembly for making connections to the
indoor units shall be measured, as part of the indoor units price
and shall include brass flare nuts, brass straight connector, brass
tees, brass reducer fittings, fixing of automatic 3 way valve,
making connections and leak testing, complete assembly as per
specifications and drawings. Nothing extra shall be payable on
account of any variation in the length of copper pipe.

1.24.4 Insulation

a) The measurement for vessels, piping, and ducts shall be made over the
bare uninsulated surface area of the metal.
 Pipes
 The measurements for installation of piping shall be made in
linear metres through all valves, flanges, and fittings.
Pipes/bends shall be measured along the centreline radius
between tangent points. If the outer radius is R1 and the inner
radius is R2. The centre line radius shall be measured as
(r1+R2)/2. Measurement of all valves flanges and fittings shall
be measured with the running metre of pipe line as if they are
also pipe lengths. Nothing extra over the above shall be
payable for insulation over valves, flanges and fittings in pipe
line/routing. Fittings that connect two or more different sizes of
pipe shall be measured as part of the larger size.
 Ducts
 The measurements for insulation of ducts shall be made in
actual square metres of bare uninsulated duct surface through
all dampers, flanges and fittings. In case of bends the area
shall be workedout by taking an average of inner and outer
lengths of the bends. Measurements for the dimension for the
connecting duct, nothing extra over the above shall be
payable for insulation over dampers, flanges and fittings in
duct routing.
 Acoustic Duct Lining
 In case of acoustic lining of air ducts, measurements of the
bare inside duct surface in square metres shall be final for
billing purposes.
 The insulation/acoustic panels shall include cost of channel,
supports, adhesives, vapour, proofing, finished
tiles/boards/sheets as well as additional labour and materials
required for completing the work.

1.25 TECHNICAL DATA

It is mandatory to fill given below data sheet at the time of tender quoting and
at the time of proposal.

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1.25.1 VARIABLE REFRIGERANT VOLUME AIR COOLED UNITS

Outdoor Unit

a) Outdoor Units Make and Model

b) Type (Cooling or heat pump)
c) Dimension of unit (Overall)
d) Actual capacity (TR) at specified conditions
e) Permissible length of refrigerant piping
f) Type of compressor
g) No. of compressor (each unit)
h) No. of digital compressor Electrical characteristics
i) Power consumption at ARI conditions for each capacity
100%
75%
50%
25%

Indoor Unit

a) Manufacturer Type
b) Nominal capacity (TR)
c) Airflow Min/Max (CFM) Sound level (Hi/Lo)
d) Overall dimensions (L x W x H)
e) Unit weight (Kg)
f) Remote controller for each indoor unit (Yes/No)

Centralized Controller

a) No. of controllers
b) Features
c) Power consumption
d) Technical brochures to be attached.

Galvanised steel sheets

a) Make
b) Thickness/Gage
c) Class of Galvanizing

Grilles/diffusers/dampers

a) Make material and gaugeof the following

b) Fire damper, rating, makeof damper motor
c) Smoke damper, rating, makeof damper motor
d) Grilles/Diffuser
e) Slot Diffuser
f) Duct Damper
g) FA Damper
h) Access Panel.

INSULATION

a) Manufacturer

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works/ HVAC Page 68 of 69

 CC-135: Construction of Simulator Building at Shastri Park, New Delhi

b) Duct acoustic lining material& density

c) Duct insulation material& density
d) Pipe insulation material& density

1.25.2 SPLIT AIR CONDITIONERS

General

a) Make
b) Dimension( L x H x D) inMM
c) Weight in Kg

Compressor

Manufacturer -
Model -
Type -
Refrigerant -
Power consumption KW
Refrigeration Capacity Nominal TR
Refrigeration Capacity actual at 44ºC air TR
entering

Cooling Coil

Tube diameter MM
Face area Sq m
No. of rows No.
No. of fins/cm No.

Tube material -

Condenser

Face area Sq m
No. of rows No.
No. of fins/cm No.
Tube material -
Fin material -
Tube diameter MM
Type & no. of fans No.
Fan motor rating KW.

DMRC/CC-135/Vol.-4/Tech. Specifications/ Electrical, FF, LV & HVAC Works/ HVAC Page 69 of 69