TECHNICAL

SPECIFICATION
 A. SCOPE OF WORK

1.1 The scope of work shall cover, but shall not be exclusively limited to, the following:

a. Supply of all materials viz, raw steel, and paints

b. Supply of consumables like electrodes for welding, gases for gas cutting etc
c. Supply of plant & machinery, tools tackles, Hydra etc., instruments for fabrication,
machining of Structural Steel.
d. Providing facilities for testing of materials and conducting NDT if Required.
e. Providing facilities for transport and handing over the material to EPI yard at site.
f. Deploying requisite skilled and unskilled manpower for fabrication (Two coat
primer).
g. Sand Blasting, Fabrication of structures and transport to site
h. Application of paints at shop/site after fabrication
i. Providing all reasonable facilities for inspection by Bidder.
j. Conducting NDT as stipulated by the Owner and making test results available to
owner / Consultant for evaluation
k. Compliance with preliminary acceptance tests / inspection, liquidation of defects.

B. FABRICATION OF STEEL STRUCTURES

2.1 Material of Construction

All steel and other materials used for steelwork and in association with steelwork shall
conform to appropriate Indian standards. Only tested materials shall be used unless written
authority is obtained for the use of untested materials for certain secondary structural
members. Tentatively the following items shall be used for fabrication: Rolled Section Beams
(ISMB 200 – 300), Chanel (ISMC 75 – 250), Angel (ISA 50X50X6 and 75x75x8), Plates
(3.15mm, 6mm, 8mm, 10mm, 12mm) etc. The section of structural Steel is indicative only
and it may change during fabrication and as per fabrication drawing.

a) All rolled sections and plates up to & including 20 mm thickness shall conform to Grade
"A” as per IS : 2062.
b) Plates of thickness above 20 mm and Plated structures subjected to dynamic loading
shall conform to Grade "B” as per IS: 2062.
c) For High Tensile steel requirements, material conforming to IS: 8500 or SAIL- MA (HYA or
HYB) shall be used.

i. Steel sheets shall conform to IS: 1079.

ii. Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240)
iii. Translucent sheets shall be fibreglass reinforced polyester sheets of matching
profile as per IS: 12866.
iv. Colour coated sheets shall be as per appropriate standard.
v. Gutters shall be of copper bearing steel conforming to Grade "A" as per IS: 2062.
vi. Rails shall conform to IS: 3443.
vii. All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for
precision and semi precision hexagonal bolts) of property class 6.4 unless
otherwise specified. Washers shall conform to IS: 6610.
viii. All tapered washer shall be as per IS: 5372 for channels, and IS: 5374 for Joists.
Spring washers shall conform to IS: 3063.
ix. All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts
shall conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS:
6623 & IS: 6649 respectively.

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 x. Covered electrodes for arc welding shall conform to IS: 814.
xi. Certified mill test reports of materials used in the work shall be
2.2 Fabrication

2.2.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their
equivalent foreign national standard of the country of origin of supply unless
otherwise specified, and in conformity with various clauses of the Technical
Specification.

2.2.2 Wherever practicable and wherever perfect matching of parts is required at site,
members shall be shop assembled before despatch to minimise site work. Parts not
completely assembled in the shop shall be secured, to the extent possible, to prevent
damage during despatch.

2.2.3 All pieces shall be properly identified and bundled for transportation to work site.
Care shall be exercised in the delivery, handling and storage of material to ensure
that material is not damaged in any manner. Materials shall be kept free of dirt,
grease and foreign matter and shall be protected from corrosion. All materials shall
be stored properly on skids above the ground which shall be kept clean and properly
drained. Girders and beams shall be placed upright and stored. Long members such
as columns and chord members shall be supported on skids spaced near enough to
prevent damage due to deflection.

2.2.4 All fabricated pieces shall bear erection mark numbers painted/punched according to
appropriate erection and shop drawings at a prominent location on the structure for
easy identification.

2.2.5 All workmanship shall be in accordance with the best practice in modern structural
shops. Greatest accuracy shall be achieved in the manufacture of every part of the
work and all identical parts shall be strictly interchangeable.

2.2.6 Shearing or flame cutting may be used at the Contractor's option provided that a
mechanically controlled cutting torch is used for flame cutting and that the resulting
edges are clean and straight.

2.2.7 Unless clean square and true to shape all flame cut edges shall be planed/cleaned
by chipping or grinding. Where machine flame cutting is permitted for high tensile
steel, special care shall be taken to leave sufficient margin and all flame hardened
material shall be removed by machining/edge grinding.

2.2.8 Wherever shearing is used for cutting to size, sheared members shall be free from
distortions at sheared edge.

2.2.9 Each piece shall be distinctly marked before delivery, in accordance with an
approved marking diagram and shall bear such other marks as well to facilitate
erection. For easy identification at site a small distinguishing mark for each building
shall be painted at each end of every member before despatch from fabrication shop.
The fabricated steel work shall be despatched in sequence as per agreed
programme and for such portion as may be found convenient for erection or as
ordered by the Owner / Consultant.

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2.2.10 The Contractor shall provide suitable packing wherever necessary to guard against
damage during handling and transportation to site. All fabricated parts shall be
adequately braced to prevent damage during transit.
2.2.11 The tolerances for fabrication of steel structures shall generally conform to IS:7215
and to suit the technological requirements as specified by the equipment supplier.

2.2.12 Any fabrication work which is considered not to be in keeping with the Technical
Specification forming the Contract, or in absence of Technical Specification with
recognized good practice, shall be rectified /replaced /corrected at the Contractor's
expense as directed by the Owner / Consultant. Site fabrication work shall also
conform to all specifications, stipulations, terms and conditions applicable for shop-
welded structures as mentioned above.

2.3 Material Preparation

2.3.1 Cut edges shall be finished smooth by grinding or machining wherever necessary.
Sufficient allowance (3 mm to 5 mm ) should be kept in the items in case machining
is necessary.
2.3.2 Cutting may be affected by gas cutting, shearing, cropping or sawing. In gas cutting
of high tensile steel, special care is to be taken to leave sufficient metal to be
removed by machining so that all metal that has been hardened by flame is removed.
2.3.3 Sufficient shrinkage allowance (@ 1mm/M) shall be kept wherever heavy welding is
involved.
2.3.4 Straightening and bending shall be done in cold condition as far as practicable.
2.3.5 If required, straightening and bending may be done by application of heat between
900°C and 1100°C. Cooling down of the heated item shall be done slowly.

2.4 Drilling and punching of holes

2.4.1 Drilling and punching of holes for bolts shall be done as per IS:800:1984, unless
otherwise specified by the Owner.
2.4.2 Drifting of holes for bolts during assembly shall not cause enlargement of holes
beyond permissible limit or damage the metal.
2.4.3 Holes for bolted connection should match well to permit easy entry of bolts. Gross
mismatch of holes shall be avoided.
2.4.4 Permissible deviation in holes for mild steel bolts of normal accuracy and high
strength bolts are given in the ANNEXURE-A.

2.5 Assembly for fabrication

2.5.1 Fabrication of all structural steelwork shall be in accordance with IS:800-1984 and in
conformity with various clauses of this specification, unless otherwise specified in the
drawings.
2.5.2 Fabrication of structures shall preferably be taken up as per the sequence of
erection.
2.5.3 All erection units shall bear erection mark no. and reference drg no. at a prominent
location on the structures for easy identification at site.
2.5.4 Fabricated structures shall conform to tolerance as specified in this standard and in
IS:7215-1974. In case of contradiction, tolerances specified in this standard shall
prevail.
2.5.5 All the components of structures shall be free from twist, bend, damage etc,
2.5.6 Assembly of structures shall be carried out by using suitable jigs and fixtures in order
to obviate distortion during welding.

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2.5.7 Surface, wherever machining is specified, shall be either planed or milled or ground
to ensure maximum contact.
2.5.8 If end-milling or machining is planned after the assembly is over, sufficient allowance
(5 mm to 15 mm) shall be kept in the items where milling/machining is to be done.
2.5.9 If pre-bending of the plate is required to avoid welding distortion, it shall be done in
cold condition.
2.5.10 Sufficient trial assembly of fabricated components (despatch elements) shall be
carried out in the fabrication works to control the accuracy of workmanship.
2.5.11 Where necessary, washers shall be tapered or otherwise suitably shaped to give the
heads of nuts and bolts satisfactory bearing.
2.5.12 The threaded portion of each bolt shall project through the nut at least by one thread.
2.5.13 Permissible deviations from designed (true) geometrical form of the despatch
elements shall be in accordance with IS:7215-1974.

2.6 Method of Construction

2.6.1 The size of fillet welds shall not be less than 5mm for load-bearing joints.
2.6.2 Main structural elements shall be welded continuously. Intermittent welds shall be
used only on secondary members, which are not exposed to weather or other
corrosive influence.
2.6.3 Connections and splices shall be made by welding, or by bolting with appropriate
property class. Black bolts shall be used in connections and attachments of
secondary members such as purlins, wall girts, etc. Bolts shall be prevented from
loosening by means of lock nuts, single coil spring washers or similar devices.
2.6.4 Method of splicing shall be similar to the method of construction adopted for
structures. All splices shall be full-strength splice unless exception is specified.
2.6.5 Roof and wall sheets shall be fixed to purlins and wall girts by stainless steel top
speed screws with neoprene washers. The connections shall ensure water-tightness
into the buildings. The spacing of these screws/bolts shall be sufficient to prevent
uplift of sheets by suction. The roof and wall sheets shall be stitched together at their
edges by using screws. The end and side overlaps of sheeting shall be sufficient to
prevent ingress of rainwater. End lap shall not be less than 75mm and side lap shall
not be less than one and half corrugation for GCS sheets. For troughed aluminium
sheets manufacturer’s recommendations shall be followed.

2.7 Despatch Instructions

2.7.1 Each despatchable structure shall bear mark no. along with reference drawing
number at two prominent locations (e.g. on flange and bottom of base plate of a
column).
2.7.2 Control assembly of important structures shall be done in the shop floor before
despatch to avoid mismatching. For all such important structures, match marking
shall be given at the control assembly stage in the shop floor and such match
markings shall be made clearly visible while assembling the structures at site.
2.7.3 Centre lines of column flanges and both sides of web shall be punched, preferably at
top and bottom to facilitate alignment after erection.

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 C. PAINTING OF BUILDING STEEL STRUCTURES

All steel structural work shall be painted as follows unless otherwise stated in the drawing
/ Technical Specification. Relevant section of the GS shall be referred for further
guidelines on painting.

3.1 General

This specification covers the materials, tools, facilities and quality requirement for
surface preparation and painting of steel structures, equipment, piping, ducts, chutes,
wood work etc.

The complete paint system for any item includes the following basic activities

i. Proper Surface preparation

ii. Applications of Primer Coats
iii. Applications of Finished Coats

All the above coats shall be of quality paint products and of approved
make. The scope of work shall also include supply of All paint materials as per
Specification described herein.

3.2 Surface Preparation

Surface preparation required for paint application, shall be such as to clean the surface
thoroughly y of any material which will be conducive to premature failure of the paint subs t
rates.

All surfaces shall be cleaned of loose substances, and foreign materials, such as dirt, rust,
scale, oil, grease, welding flux, etc. in order that the prime coat is rigidly anchored to the
virgin metal surface. The surface preparation shall confirm to pictorial representation of
surface quality grade of Swedish Standards Institution SIS – 055900 or equivalent standards
such as SSPC – VIS – 1.67 or DIN 55928(Part 4) or BS 4232 or IS 1477 – 1971 (Part I)

The acceptable surface preparation quality / grade are described under each paint system.
The procedures include solvent c leaning, hand tool cleaning, power tool cleaning, blast
cleaning, wood surface cleaning, flame cleaning and pickling. This will ensure surface quality
as required by the Specific primer paint. For ready reference surface preparation Quality
grade to be adopted in respect of SIS 055900 and DIN 55928 (par t -4) is given in Annexure-
01.

3.3 Hand Tool Cleaning

The surface shall be cleaned manually by vigorous wire brushing as per grade St -2 quality
of Swedish Standard Institution SIS 055900 and DIN 555928. This method effectively
removes loosely adherent materials, but would not affect residues of rust or mill scales that
are intact are firmly adherent. Finally the surface is to be cleaned with a vacuum cleaner or
with clean compressed air or with clean brush. After preparation the Surface shall have a
faint metallic shine. The appearance shall correspond to the prints designated St – 2.

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3.4 Power Tool Cleaning

The surface shall be cleaned by electric or pneumatic tools, such as brushes, sanding
machines, disc abrasive grinder, rotary disc scalar etc. to St – 3 quality. The tools shall be
used carefully to prevent excessive roughening of surface and formation of ridges and burrs.
This method will remove loosely adherent materials but would not affect residues of rust or
mill scales that are firmly adherent and intact.

3.5 Blast Cleaning

The surface shall be cleaned by impingement of abrasive materials, such as graded sand at
high velocity created by clean and dry compressed air blast as per the grade according to
Swedish Standard Institution SIS 055900.This method will remove loosely adherent
materials as well as adherent scales and mill scales. Prior to application of blast, heavy
deposit of oil and grease are removed by solvent cleaning excessive surface scales are
removed by hand tools or power tool cleaning. The extent of removal of adherent scales is
varied, depending on the application and is defined by the surface quality grades Sa1, Sa2,
Sa2.5 and Sa3 in the order of increasing cleanliness. The blast c leaning is not
recommended for sheet metal work.

3.6 Flame Cleaning

The surface is c leaned by rapid heating by means of oxyacetylene flame to loosen the
adherent scales, followed immediately by wire brushing. This method will remove loosely
adherent materials as well as most of the adherent scales and mill scales. In order to
minimize or prevent distortion flame cutting shall not be used on members having thickness
of 6 mm and lower.

3.7 Paint Application

3.7.1 Paints

(i) Paint shall be applied in accordance with paint manufacturer ’s

recommendations. The work shall generally follow IS 1477 – 1971 ( Part II ) for jobs
carried out in India and SSPC- PA- 1 or DIN 55928 or equivalent for jobs
carried out outside India.
(ii) General compatibility between primer and finishing paints shall be established by the
paint manufacturer supplying the paints.
(iii) In the event of conflict between this general procedure on painting and the paint
manufacturer’s specification, the same shall be immediately Brought to the notice of
the Purchaser. Generally in cases of such Conflicts, manufacturer’s specification /
recommendations shall prevail.
(iv) Before buying the paint in bulk, i t is recommended to obtain sample of paint and
establish “Control Area of Painting”. On Control Area, surface preparation and
painting shall be carried out.
(v) If required, samples of paint shall be tested in laboratories to establish quality of paint
with respect to:

a) Viscosity
b) Adhesion/Bond of paint in steel surfaces
c) Adhesion/Simulated salt spray test.
d) Chemical analysis (percentage of sol ids by weight)
e) Normal wear resistance as encountered during handling & erection.

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 f) Resistance against exposure to acid fumes, etc.

(vi) Whole quantity of paint for a particular system of paint shall be obtained from the same
manufacturer.
(vii) The main Contractor shall be responsible for supply of paints and this Responsibility
shall not be passed on to the sub-contractor
(viii) The painting materials as delivered to the Contractor, must be in the manufacturer’s
original container bearing thereon manufacturer’s name brand and description. Paint
/Painting material in containers without labels or with illegible labels shall be rejected,
removed from the area and shall not be used.
(ix) Thinners wherever used shall be those recommended by the paint manufacturers and
shall be obtained in containers with manufacturer ’s name and brand name of thinner
legibly printed, failing which the thinner is liable to be rejected and shall not be used.
(x) All paint containers shall be clearly labelled to show the paint identification, date of
manufacture, batch number, Special Instruction, Shell life etc, the container shall be
opened only at the time of use.
(xi) All paints shall be stored in accordance with the requirements of laid down procedure
by the paint manufacturer.
(x) All ingredients in a paint container shall be thoroughly mixed to break –up lumps and
disperse pigments before use and during application to maintain homogeneity.
(xi) The make of Paint – SHALIMAR, BERGER, ASIAN PAINTS, ICI or approved by
MCL/EPI.
(xii) The colour code of the finishing paint to be followed shall be intimated to the
successful Tenderer after finalisation of order. The undercoat shall have different tint
to distinguish the same from the finishing coat.
(xiii) The Contractor shall furnish paint manufacturer ’s test report or technical data sheet
pertaining to the paint selected. The data sheet shall indicate among other things the
relevant standards, if any, composition in weight percent of pigments, vehicles,
additives drying time, Viscosity spreading rate, flash point , method of application ,
quality of surface preparation required, corrosion resistance properties and colour
shades available.

3.8 General

3.8.1 Each coat of paint shall be continuous, free of pores and of even film thickness
without thin spots.
3.8.2 Each coat of paint shall be sufficiently dry before application of next coat.
3.8.3 Paint shall be applied at manufacturer ’s recommended rates. The number of coats
shall be such that the minimum dry f i lm thickness specified is achieved. The dry film
thickness of painted surfaces shall be checked with ELCOMETER of measuring
gauges to ensure application of specified DFT.
3.8.4 Zinc rich primer paints which have been exposed several months before finishing
coat is applied shall be washed down thoroughly to remove soluble zinc salt
deposits.
3.8.5 The machine finished surfaces shall be coated with white lead and tallow before
shipment or before being put out into the open air.
3.8.6 Areas which become inaccessible after assemble shall be painted before assembly
(after obtaining painting clearance from the inspecting authority) after requisite
surface cleaning as specified.
3.8.7 Paint shall not be applied when the ambient temperature is 5 deg C and below or 45
deg C and above. Also paint shall not be applied in rain, wind, fog or at relative
humidity of 80 % and above unless the manufacturer ’s recommendations permit.

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 Applications of paint shall be only be spraying or brushing as per IS 486 – 1983 and
IS 487 – 1985.
3.8.8 Primer paint shall be applied not later than 2 – 3 hours after preparation of surface,
unless specified otherwise.
3.8.9 Edges, corners, crevices, depress ions, joints and welds shall receive special at tent
ion to ensure that they receive painting coats of the required thickness.
3.8.10 Surfaces which cannot be painted but require protect ion shall be given a coat of rust
inhibitive grease according to IS 958 – 1975 or solvent deposited compound
according to IS 1153 – 1975 or IS 1674 – 1960.
3.8.11 Surfaces in contact during shop assembly shall not be painted. Surfaces which will
be inaccessible after assembly shall receive minimum two coats of specified primer.
3.8.12 Surfaces to be in contact with wood, brick or other masonry shall be given one shop-
coat of the specified primer.

3.9 Site / Field Painting

3.9.1 Wherever shop primer painting is scratched, abraded or damaged, the surface shall
be thoroughly cleaned using emery paper and power driven wire brush wherever war
ranted, and touched up with corresponding primer. Touching up paint shall be
matched and blended to eliminate conspicuous marks.

3.9.2 If more than 50% of the painted surface of an item requires repair, the Entire item
shall be mechanically cleaned and new primer coats shall be applied followed by
intermediate and finishing coats as per painting specification.
3.9.3 All field welded areas on shop painted items shall be mechanically cleaned (including
the weld area proper, adjacent areas contaminated by weld spatter or fumes and
areas where existing primer paint is burnt). Subsequently, new primer and finishing
coats of paint shall be applied as per painting specification.
3.9.4 The first coat of finish paint at site shall be applied preferable within three months of
the shop paint.

3.10 Structural

3.10.1 All fabricated steel structure, fabricated steel pipes, etc. shall have a minimum of
two coats of primer paint before dispatch to site.
3.10.2 Parts of steel structures embedded in concrete shall be given a protective coat of
Portland cement slurry immediately after fabrication and after surfaces of this part is
thoroughly cleaned from grease, rust, mill scales, etc. No paint shall be applied on
this part.
3.10.3 All structures shall receive appropriate number of primer and finishing coats in order
to achieve over All DFT as per design drawings/ specification.

3.11 Painting Schemes

3.11.1 Legend

SP - Surface preparation quality as per SIS standard

2P1 - Two (2) coats of Primer paint type P1
2F1 - Two (2) coats of Finish paint type F1
DFT - Dry Film Thickness in microns developed
CRT- Clean and Retouch

3.12 PAINT MATERIALS

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3.12.1 PRIMER PAINTS (P)

Primer paint products shall be applied only on dry and clean surfaces.

A. Primer Paint – P1 (Phenolic – Alkyd Based)

A single pack air drying phenolic modified alkyd composition with zinc phosphate as a primer
paint conforming generally to IS : 2074.
Air drying time - About 60 minutes (touch dry)

- Overnight (hard dry)

Dry film thickness (DFT)/Coat - 40 microns (min)

Temperature resistance - Upto 100 deg C dry heat

B. Finish Paints (F)

Finish paint costs shall be applied over primer coats and intermediate coats after proper
cleaning and touch up of primed surface.

C. Finish Paint – F1

A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably
pigmented.
Air drying time - 3 to 4 hours (touch dry)

- 24 hours (hard dry)

DFT/Coat - 25 microns (min)

Temperature resistance - Upto 100 deg C dry heat

Compatible with - Primer P1

Intermediate I1

Colour - Generally all shades

3.12.2 Surface Preparation Grade

Annexure-01
Sl No. Surface Preparation Swedish Std. DIN Std. Din

SIS 055900 55928 (Part 4)

1 Blast cleaning to white metal

Sa 3 Sa 3

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 Removal of all visible rusts, mill-scales,
paint and foreign matters.

2 Blast cleaning to near white metal:

95% of any section of surface area is Sa 2.5 Sa 2.5

free from all rusts, mill-scales and visible
residues.

3 Blast cleaning to commercial quality:

At least 2/3 of any section of the surface

Sa 2 Sa 2
area is free from all rusts, mill-scales and
visible residues.

4 Brush-off blast cleaning:

Removal of all loose mill-scales, rust and Sa 1 Sa 1

foreign matters etc.

5 Power tool cleaning:

Very thorough scrapping and wire

brushing to
St 3 St 3
remove loose mill-scale, rust and foreign
matters to have pronounced metallic
shine.

6 Hand tool cleaning:

Removal by hand brushing of loose mill- St 2 St 2

scale, loose rust and foreign matters.

3.12.3 Painting Scheme

Annexure-02
Sl No Description Painting Scheme Total DFT
At Shop At Site
1.0 Steel Structures
(Temp. not exceeding
800C)
Technological steel
structures for plant and
equipment
2P1 2F1 130

Indoor

Outdoor

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3.12.4 COLOUR CODE
Annexure-03
Si No Items Painted Colour Colour No.of IS
:5
1 Building frames including Aircraft grey 693
bracings, side girts, louvers etc.

2 Crane girders Azure blue 104

3 Crane stops Post office red 538

4 Gutters Black bituminous -
aluminium
5 Fire escape platforms ladders, Single Red 537
etc.
6 General hand railing, top Lemon Yellow 355
runners
7 Rung ladders Lemon Yellow 355

8 All members blocking passages Lemon Yellow 355

for

Movement
Trestles, towers and pipe Dark admiralty grey 632
9 bridges
10 Conveyor gallery structures Aircraft Grey 693
11 Steel chimneys Aluminium -

N.b- Mention colour code is tentative. The final colour code will be decided
during execution of work by MCL/CMPDI/EPIL.

D. WELDING SPECIFICATIONS

4.1 General

4.1.1 The welding and welded work shall conform to IS:816 and other relevant codes unless
otherwise specified. Electrodes shall conform to IS:814 and shall be approved by the
Owner / consultant.
4.1.2 Welding shall be done by Electrical Arc Process. Automatic welding shall be
employed for important structures as specified in the drawings. Generally,
submersed arc, Automatic & Semi-automatic welding shall be employed. Only where
it is not practicable, Manual Arc welding may be resorted to. In case of Manual Arc
Welding, recommendations of electrode manufacturer are to be strictly followed
4.1.3 Welding shall not be done under such weather conditions which might adversely
affect the efficiency of the welding and where necessary, effective protection and
other safeguards shall be provided.
4.1.4 Only qualified welders suitable for the job shall be employed. The Owner / Consultant
at his discretion can order periodic tests in accordance with IS:817 of the welders
and / or of the welds produced by them at no extra cost. Welding shall be done using
requisite jigs and fixtures to avoid distortions or damage to members during / after

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 welding. Welds on exposed work shall be finished uniformly smooth to present a neat
appearance.
4.1.5 The layouts and sequence of operations shall be arranged so as to eliminate
distortion and shrinkage stress to the satisfaction of the Inspector. Welding work shall
be under constant supervision of competent welding supervisor and shall be done in
a properly organized manner with the approved quality welding sets and with
automatic welding machines. Detailed welding procedure shall be submitted to the
Owner / Consultant and approval of the same shall be obtained before fabrication is
commenced.

4.2 Welding Procedure

4.2.1 Welding procedure to be prepared by the Contractor shall include the following :

i) Type and size of electrodes.

ii) Current and arc voltage.(for automatic welding)
iii) Length of run per electrode, or (for automatic welding) speed of travel.
iv) Number and arrangement of runs in multi-run welds.
v) Position of welding.
vi) Preparation and set-up of parts.
vii) Welding sequence.
viii) Pre or, post-heating.
ix) Specification and thickness of steel
x) Welding process ( manual arc / submerged arc welding )
xi) Thickness of components meeting at a joint
xii) Pre and post heating requirement
xiii) Weather condition – restrictions thereof xiv) Use of jigs and fixtures
xiv) Type of non-destructive testing to be carried out
xv) Inspection procedure to be followed
xvi) Sequence and process to be followed in different multiple-pass butt welding
for different plate thicknesses.

The welding procedure shall be subject to Owner’s / Consultant’s approval.

4.2.2 The welding procedure shall be arranged to suit the details of the joints as indicated
in the drawings and the positions in which the welding is to be carried out. The welds
shall meet the requirements of quality specified.
4.2.3 All electrodes for use in the work to which the specification relates shall be kept
under dry conditions. Electrodes which are damaged by moisture shall not be used
unless it is certified by the manufacturer that when it is properly dried there shall be
no detrimental effect. Any electrode which has part of its flux coating broken away or
is otherwise damaged shall be discarded.
4.2.4 Low hydrogen electrodes and flux for submerged arc welding shall be dried at 250-
300 deg. C for one hour in drying oven before use.
4.2.5 At site, the electrodes shall be kept in proper coves while using them for welding
4.2.6 All metal arc welding shall be as per IS : 9595
4.2.7 Submerged arc welding of mild steel and low alloy steel shall be as per IS : 4353
4.2.8 For multi-run weld deposit the succeeding run shall be done only after the preceding
run is cleaned of all slag and flux deposits.
4.2.9 The Contractor shall prepare the edges with an automatically controlled flame cutting
torch followed by grinding correctly to the shape, size and dimensions of the groove,
prescribed in the design and shop drawings. in case of U-groove joint, the edges

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 shall be prepared with an automatic flame cutting torch in two passes following a
bevel cut with a gouging pass, or by machining.
4.2.10 The welding surfaces shall be smooth, uniform and free from fins, tears, notches or
any other defect, which may adversely affect welding. Welding surfaces or the
surrounding surfaces within 50 mm of weld shall be free from loose scale, slag, rust,
grease, paint, moisture or any other foreign material. Pre-bending of plates for three
plate welded sections shall be done where found necessary.
4.2.11 Manipulators may be used where necessary and shall be designed to facilitate
welding and to ensure that all welds are easily accessible to the operators. Where full
strength butt welds are specified run-on and run-off pieces shall be used. The
welding shall be such that the face of weld deposit shall at all places be proud of the
surfaces of the parent metal by 1 to 1.5 mm. Where a flush surface is required, the
surplus weld metal shall be ground and dressed off.
4.2.12 After completing each run of weld, all slag shall be thoroughly removed, and the
surface cleaned before starting the next run of weld. The weld metal, as deposited
(including tack welds if to be incorporated) shall be free from cracks, slag, inclusions,
gross porosity, cavities and other deposition faults. The weld metal shall be properly
fused with the parent metal without serious undercutting or overlapping at the toes of
the weld. The surfaces of the weld shall have a uniform and consistent contour and
uniform appearance.
4.2.13 All weld runs found defective shall be cut by using either chipping hammer, gouging
torch, or suitable grinding wheel in such a manner that adjacent material is not
injured in any way. Peeling of the welds involving deformation of the weld surface
either during de- slagging or thereafter shall not be allowed.
4.2.14 Arc-strikes on parent surfaces of structures shall be strictly avoided.

4.3 Control in Welding

4.3.1 The extent of quality control in respect of welds for structural elements for both
statically and dynamically loaded structures shall be as follows and shall be
conducted by the contractor at his own cost:-

A. Visual Examination - All welds shall be 100% visually inspected to check

the following:

i. Presence of undercuts
ii. Visually identifiable surface cracks in both welds and base metals.
iii. Unfilled craters
iv. Improper weld profile and size
v. Excessive reinforcement in weld
vi. Surface porosity
Before inspection, the surface of weld metal shall be cleaned of all slag, spatter
beads, scales etc. by using wire brush or chisel.

B. Dye Penetration Test (DPT) - This shall be carried out for all important fillet
welds and groove welds for both statically and dynamically loaded structures
to check the following
i. Surface cracks
ii. Surface porosities

Dye Penetration Test shall be carried out in accordance with American

National Standard ASTME 166.

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 C. Ultrasonic- testing: Ultrasonic test shall be conducted for all groove welds
and heat affected zone in dynamically loaded structures and for other
important load bearing butt welds in statically loaded structures as desired by
Owner, to detect the following

i. Cracks
ii. Lack of fusion
iii. Slag inclusions
iv. Gas porosity

Ultrasonic testing shall be carried out in accordance with American National

Standard ANSI/AWS DI.1-96. Before ultrasonic test is carried out, any
surface irregularity like undercuts, sharp ridges etc. shall be rectified.
Material surface to be used for scanning by probes must allow free
movement of probes. For this purpose, surface shall be prepared to make it
suitable for carrying out ultrasonic examination.

D. Radiographic Testing (X-ray and & Gamma-Ray Examination)

This test shall be limited to 2% of length of welds for welds made by manual
or semi- automatic welding and 1% of length of weld if made by automatic
welding machines. The location and extent of the following defects :

i. Gas porosity
ii. Slag inclusions
iii. Lack of penetration
iv. Lack of fusion
v. Cracks

Radiographic testing shall be conducted in accordance with American

National Standard ANSI/AWSDI.1-96. Any surface irregularity like undercuts,
craters pits etc. shall be removed before conducting radiographic test. The
length of weld to be tested shall not be more than 0.75 x focal distance. The
width of the radiographic film shall be width of the welded joint plus 20 mm on
either side of the weld.

4.3.2 The Contractor shall provide testing equipment for conducting non-destructive tests
for confirming the integrity of welding wherever necessary as directed by the Owner /
consultant.

4.4 Acceptable Limits of Defects of Weld

Limits of Acceptability of welding defects shall be as follows:

a) Visual inspection & Dye Penetration Test

The limits of acceptability of defects detected during visual inspection and Dye
Penetration Test shall be in accordance with American National Standard ANSI/AWS
D1.1-96.
b) Ultrasonic Testing - The limits of acceptability of defects detected during ultrasonic
testing shall be in accordance with American National Standard ANSI/AWS D1.1-96.

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 c) Radiographic testing - The limits of acceptability of defects detected during
Radiographic testing shall be in accordance with American National Standard
ANSI/AWS D1.1-96.

4.4.1 Rectification of Defects in Welds

In case of detection of defects in welds, the rectification of the same shall be done as
follows

i) All craters in the weld and breaks in the weld run shall be thoroughly filled with
weld.
ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so as to
provide smooth transition of weld to parent metal.
iii) Welds with cracks and also welds with incomplete penetration, porosity, slag
inclusion etc. exceeding permissible limits shall be rectified by removing the
length of weld at the location of such defects plus 10 mm from both ends of
defective weld, and shall be re-welded. Defective weld shall be removed by
chipping hammer gouging torch or grinding wheel. Care shall be taken not to
damage the adjacent material.

6.1 Inspection Of Structures

6.1.1 The Owner / Owner’s Inspector shall have free access at all times to those parts
of Contractor's or his Sub- Contractor's works which are concerned with the
fabrication of steel works and shall be afforded all reasonable facilities at all
stages of preparation, fabrication and trial assemblies for satisfying himself that
the fabrication is being undertaken in accordance with the provisions of relevant
specification.
6.1.2 All gauges and templates, tools, apparatus, labour and assistance for checking
shall be supplied by the contractor free of charge. The Owner / Inspector may at
his discretion, check the test results obtained at the Contractor's works, by
independent test at the Government Test House or elsewhere, and should the
material so tested be found to be unsatisfactory, the cost of such test shall be
borne by the Contractor.
6.1.3 Contractor shall make all necessary arrangements for stage inspection by
Owner/Inspector during the fabrication at shop and incorporate all on-the-spot
instructions / changes conveyed in writing to the Contractor.
6.1.4 Material improperly detailed or wrongly fabricated shall be reported to the
Owner/Inspector and shall be made good as directed. Minor misfits which can be
remedied by moderate use of drift pins, and moderate amount of reaming and
slight chipping may be corrected in that manner, if in the opinion of the Owner /
Inspector the strength or appearance of the structure shall not be adversely
affected. In the event the Owner / Inspector directs otherwise, the items shall be
rejected and a completely new piece shall be fabricated. The cost of correcting
errors shall be to the account of the Contractor.

6.1.5 The Owner / Owner’s Inspector shall have the power :

a) To declare, before any structure is submitted for inspection, that the same is
not in accordance with the contract, owing to the adoption of any unsatisfactory
method of fabrication and the same will be rejected.

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 b) To reject any structure as not being in accordance with specifications &
drawings.

c) To insist that no structure or parts of the structure once rejected is

resubmitted for inspection/test, except in cases where the Owner / Inspector
authorised representative considers the defects as rectifiable.
6.1.6 If, on rejection of structure by the Owner/Inspector the Contractor fails to make
satisfactory progress within the stipulated period, the Owner / Inspector shall be
at liberty to cancel the contract and fabricate or authorise the fabrication of the
structures at any other place he chooses, at the risk and cost of the Contractor,
without prejudice to any action being taken in addition to terms of General
Conditions of Contract.
6.1.7 The Owner / Inspector's decision regarding rejection shall be final and binding on
the Contractor.
6.1.8 The specifications prescribe various tests at specified intervals for ascertaining
the quality of the work done. If the tests prove unsatisfactory, Owner/Inspector
shall have liberty to order the Contractor to re-do the work, done in that period
and/ or to order such alterations and strengthening that may be necessary at the
cost of the Contractor and the contractor shall be bound to carryout such orders
failing which the rectification/redoing shall be done by the Owner through other
agencies and the cost recovered from the Contractor.
6.1.9 Notwithstanding any inspection at the workshop the Owner/Inspector shall have
the liberty to reject, without being liable for compensation any fabricated
members or materials brought to site that do not conform to specifications /
drawings.
6.1.10 All rejected materials shall be removed from the site of fabrication by the
Contractor at his own cost and within the time stipulated by the Owner/Inspector.

6 Quality System And Third Party Inspection.

6.1 General

Inspection shall be carried out at the works of the Contractor during fabrication and on
final product to ensure conformity of the same with the acceptable criteria of technical
specifications, approved fabrication drawings and indicated standards.

This specification is in addition to the provisions laid down in Owner's General Condition
of Contract (GCC) and special instructions to Contractor, if any.

6.2 Quality System Requirements.

The Contractor must recognise the importance of quality and follow the defined quality
programme in all manufacturing and quality control activities of the product. The
Contractor shall define and implement the tasks and controls that shall provide needed
assurance in case manufacturing of product is sub-contracted either partly or fully and / or
for the procured components of the product. All bought-out components, if any, shall be
procured from approved list of vendors issued by the Project Authority.

Owner reserves the right to verify the quality programme and entire product
characteristics to assure the intended and specified quality of the product.

6.3 Quality Assurance Plan (QAP)

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 Approved QAP will be provided later after obtaining approval from
MCL/CMPDI.

6.4 Calibration Of Measuring Equipment.

6.4.1 All the measuring equipment used for inspection & testing shall be calibrated and
appropriate accuracy class of measuring equipment shall be used. Calibration
standards used for calibration of measuring equipment shall be traceable to
national standards of National Physical Laboratory (NPL), New Delhi with
unbroken chains of comparison
6.4.2 Calibration Certificate of All Measuring Equipments.

Valid calibration certificates for all measuring equipments used during inspection
and testing with traceability to national standards of NPL / NPL accredited
laboratories shall be furnished along with inspection call prior to undertaking
inspection by Owner.

Calibration certificates shall also indicate reference number of calibration

standards calibrated by NPL / NPL accredited laboratories and copies of such
calibration certificates of calibration standards shall also be furnished when asked
for.

6.5 Test Certificates And Documents.

6.5.1 For each of the items being fabricated, the following test certificates and
documents, as applicable, in requisite copies including original shall be
submitted to Inspection Agency. All test certificates must be endorsed by the
Contractor with linkage to project, purchase order and acceptance criteria.

i) Raw materials identification & physical and chemical test certificates for all
materials used in fabrication of the component (except IS 2062-1992).
ii) WPS, PQR & WPQ Documents as per applicable code.
iii) Details of stage-wise inspection & rectification records for fabricated items and
machined articles.
iv) Control dimension chart with records of alignment, trueness of shape, etc.
v) Details of heat-treatment and stress relieving charts as per specification.
vi) Non-Destructive Test reports as per respective code.
vii) Hardness test certificate.
viii) Performance Test Certificates for all characteristics.
ix) Geometric accuracy and repeatability test reports of machine tools.
x) Surface preparation and painting certificates.
xi) Certificates from competent authority for the items coming under statutory
regulations.

6.5.2 The Inspection Agency shall have the right to be present and witness all tests
being carried out by the Contractor at their own laboratory or approved
laboratories. Also, the Inspection Agency shall reserve the right to call for
confirmatory test on samples, at his discretion.

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 6.6 Manufacturing And Inspection Schedule

The Contractor shall submit the schedule for fabrication and inspection indicating
components/ assembly / sub-assembly, date of approval of drawings / data sheets,
address of Fabricator with contact person and scheduled date of inspection. Such reports
shall be submitted to Owner with a copy to Inspection Coordinating Office once in a
month. These monthly reports shall state the planning for next three months. Submission
of first report must commence one month prior to commencement of fabrication activities
of the component.

6.7 Internal Inspection By Contractor

6.7.1 The Contractor in accordance with approved drawings, T.S., Owner Order, and
approved QAP shall carry out inspection and tests. The Contractor shall maintain
records of each inspection and test carried out and signed documents shall be
submitted to Owner for verification.
6.7.2 The Contractor shall carry out their internal inspection & obtain clearance from
statutory bodies e.g. IBR, CCE, TAC, Weights & Measures, safety, IE rules etc.
as and where applicable, prior to offering any component for Owner's inspection
in accordance with approved QAP.
6.7.3 The Contractor shall ensure use of appropriate calibrated measuring equipment
during their internal inspection, as well as, make available the same during
Owner's inspection and tests. Also, they shall make necessary arrangement for
access and use of Owner owned measuring equipment during inspection.
6.7.4 The Contractor shall identify all the inspected component / raw materials & shall
maintain the record of status of inspection viz. inspected & found acceptable,
require rectification / rework, rejected etc.
6.7.5 The Contractor shall establish and maintain procedures to ensure that product
that does not conform to specified requirements, is prevented from inadvertent
use or installation. The description of non-conformity that has been accepted
subsequently by Owner by concession and / or of repairs shall be recorded.

Repaired and reworked product shall be offered for re-inspection to Owner along
with records of corrective action taken.

6.7.6 The Contractor shall not despatch any equipment till receipt of despatch
clearance from Owner.

6.8 Method Of Undertaking Inspection &Testing By Owner.

6.8.1 Agency Responsible:-

Inspection / Waiver of component shall be undertaken by EPI/CMPDI/MCL

depending upon the location of manufacturers.

6.8.2 Method of Issuing Inspection Call to EPI/CMPDI/MCL

i) Inspection call shall be given only on readiness of the assembly / sub-

assembly and approval of all relevant drawings and QAP. In case
assembly sub - assembly offered for inspection are found not ready, all
the cost of visit of Owner's personnel shall have to be borne by the
Contractor. Also, if the assembly / sub-assembly after inspection found

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 not acceptable, require rework and involve Owner's re-inspection, all the
cost of such re-inspections shall also be borne by the Contractor.
ii) Inspection call shall be floated to Owner with ten days clear margin,
enclosing all documents like test Certificates, Internal Inspection Reports,
Purchase Order, Sub-Purchase Order, T.S., Approved QAP, approved
GA drawings/ data sheets and fabrication drawings with a copy of call
letter to Inspection Co-ordinating Office. Inspection calls without above
documents shall be ignored.
iii) The supplier shall offer substantial quantities for economical inspection
consistent with the size of order.

6.9 Obligations Of Contractor

6.9.1 The Contractor shall provide all facilities and ensure full and free access of the
Inspection Engineer of Owner to the Contractor's or their Sub-Contractor's
premises at any time during contract period, to facilitate him to carry out
inspection & testing of the product during or after manufacture of the same.
6.9.2 The Contractor shall delegate a Representative / Co-ordinate to deal with Owner
/ Consultant on all inspection matters. Also, Contractor's Representative shall be
present during all inspection at Sub-Contractor's works.
6.9.3 The Contractor shall comply with instructions of the Inspection Engineer fully and
with promptitude.
6.9.4 The Contractor / Sub-Contractor shall provide all instruments, tools, necessary
testing & other inspection facilities to Inspection Engineer free of cost for carrying
out inspection.
6.9.5 The cost of testing welds by ultrasonic, radiographic and dye penetration tests
etc. in the fabrication workshop shall be borne by the Contractor.
6.9.6 The Contractor shall ensure that the assembly / component of the plant and
equipment required to be inspected, are not dismantled or despatched before
inspection.
6.9.7 The Contractor shall not offer equipment for inspection in painted condition
unless otherwise agreed in writing by Owner / Consultant.
6.9.8 The Contractor shall ensure that the equipment and materials once rejected by
the Inspection Engineer are not re-used in the manufacture of the plant and
equipment. Where parts rejected by the Inspection Engineer have been rectified,
as per agreed procedures laid down in advance, such parts shall be segregated
for separate inspection and approval, before being used in the work.

6.10 Stamping And Issue Of Inspection Documents.

Inspection Memo: -

For stage inspection & for rejected items / items which do not conform to Technical
Specification in one or more quality characteristics requiring rectification / rework, Inspection
Memo shall be issued in standard form indicating therein the details of observation &
remarks. Fabricator shall indicate all the non-conformities with respect to specification of the
product in the Inspection Memo for further control.

Inspection Certificate: -

On satisfactory completion of final inspection & testing by Owner / Third Party Inspector, all
accepted material shall be stamped suitably and the Inspection Engineer for the accepted
items shall issue Inspection Certificate in standard form.

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Inspection Waiver Certificate: -

For the waiver category of items identified in the approved QAP, Owner shall issue
Inspection Waiver Certificate after scrutiny of Contractor's Internal Inspection Report, Test
Certificates and other Documents as identified in QAP.

6.11 General Clauses

6.11.1 Inspection & tests carried out by Owner / Third Party Inspector shall not absolve
the responsibility of the Contractor to provide acceptable product nor shall it
preclude subsequent rejection and any fault found after inspection/issue of
inspection certificate shall not absolve the bidder of its responsibility for
correctness of fabricated items and any fault found at later stage shall be
rectified by bidder without any extra cost.
6.11.2 Owner / Third Party Inspector reserves the right to inspect any product at any
stage of manufacturing without prior notice to Contractor beyond pre-identified
stages & hold points of approved QAP.

6.12 Permissible Deviation In Assembly Of Welded Joints

A) SQUARE BUTT-JOINT
a) Gap between the ends of plates : + 1.0 mm
b) Stepping of one plate over the other : + 1.0 mm
B) SINGLE VEE-GROOVE JOINT
a) Bevel angle : + 5 deg
b) Gap between two plates : + 1.0 mm
c) Stepping of one plate over the other : + 2.0 mm
d) Root thickness : + 1.0 mm
C) LAP JOINT
a) Over lap : + 5.0 mm
b) Gap between the surfaces : + 1.0 mm
D) TEE FILLET JOINT
a) Gap between the edge of the web and
the surface of the flange : + 2.0 mm
E) DOUBLE VEE-GROOVE JOINT
a) Stepping of plate over one another : + 2.0 mm
b) Deviation in value of root thickness : + 1.0 mm
c) Deviation in bevel angle : + 1.0 mm
d) Deviation in value of gap : + 1.0 mm

6.13 Inclusion In Price

6.13.1 No idle labour payment and idle plant & machinery payment will be given to
bidder under any circumstances.
6.13.2 Bidder price shall include all costs of plant & machinery, tools and tackles,
consumables etc. including their insurance, safety, security etc. that may be
necessary to complete the work in all respect in time.
6.13.3 Bidder price shall all include all costs of manpower (i.e engineers, supervisors
and labours) including their accommodation, communication, conveyance,

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 Sanitary facilities, first aid, medical, safety PPE, incidental expenses, safety,
security etc. required to complete work in all respect in time.
6.13.4 Rectifications, if any due to fault of bidder, shall be done by bidder immediately
within the Defect Liability Period. If the bidder fails to carry out required
rectification on account of fault of bidder, EPI at its discretion may get the job
done and debit the same to the bidder.
6.13.5 Bidder has to carry out all kind of Punch List Work identified by EPI/MCL to the
fullest satisfaction of them.

E. GENERAL SPECIFICATIONS

Providing, Fabrication, Sand Blasting & Painting of structures.

1. The Welder Qualification Test is mandatory for all welders. Only qualified welders
shall be allowed to work. All welding shall be as per IS 823 USING Approved
Electrodes of ESAB, ADOR, D&H or approved by MCL/EPI.
2. All welding shall be conforming to IS : 814 for Mild Steel Structures using
Electrode no. E6013 and E7018 .For E7018 Electrodes, use baking / holding/
carrying oven as per the standard guideline of welding. Rectifier Set shall do welding
of the plates more than 10mm thickness.
3. All holes in the structural steel sections shall be made by proper drilling and no
holes by gas cutting shall be allowed during Erection work at site.
4. All sharp edges of the fabricated structures shall be made smooth by proper
grinding so that while handling of the same, any untoward incident can be avoided.
5. Before painting, proper surface preparation by blasting/ wire brushing / emery
paper etc. is required as per painting specification.
6. All surfaces of the structural fabricated items shall be dry cleaned in order to
remove any dirt, grease, oil etc. by Wire Brushing, Scraping and sand Blasting before
application of Primer.
7. Approved Make for Structural Steel: SAIL / TISCO / RINL / JINDAL

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