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Design DivisionEngineering Services

ISO – 9001:2000

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MATERIAL AND CONSTRUCTION

SPECIFICATIONS

2 06-Mar-06 SS PSS PSS

1 22-Mar-05 PSS PSS PSS

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MATERIAL & CONSTRUCTION SPECIFICATIONS

1.0 GENERAL

1.1 These specifications establish and define the Material and Constructionalrequirements for Civil & Structural Works.

1.2 Contractor’s scope of Supply includes all the materials (consumables andnon-consumables), tools, tackles, labours etc. to complete the work in allrespect as per scope of work, specifications, codes, standards andstatutory requirements.

1.3 All materials shall be of standard quality and manufactured by renownedconcerns conforming to Indian Standards and shall be "ISI” mark as far aspossible unless otherwise approved by the Engineer-in-Charge. TheContractor shall get samples of all materials approved by the Engineer-in-Charge prior to their bulk procurement and use. Contractor shall furnishmanufacturer’s certificates, for the materials supplied by him when askedfor. Further to that he shall get the materials tested from an approved testhouse, if asked for by the Engineer-in-Charge. The cost of all tests shall beborne by the Contractor. Materials not conforming to specifications orconsidered defective by the Engineer-in-Charge shall not be used and shallbe promptly removed from the site by the Contractor at his own expense.

1.4 Whenever any reference to BIS Code is made, the same shall be takenas the latest revision (with all amendments issued thereto) at the time ofexecution.

1.5 The lump sum price quoted by the Contractor shall be inclusive of allincidental charges such as carriage, octroi, loading, unloading, storing, safecustody, watch & ward, returning back surplus materials to godown of issue(where applicable) etc.

1.6 Providing and operating necessary measuring and testing devices andmaterials (including all consumables) are included in the Contractor'sscope of work. The lump sum quoted price shall be inclusive of the cost ofall such tests, which are required to ensure achievement of specifiedquality. No separate payment for testing shall be made.


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2.0 MATERIALS / CONSUMABLES

2.1 General

2.1.1 The minimum requirements of various materials to be usedin Civil andStructural works are as below:

2.2 Water

2.2.1 Water used in construction for all civil & structural works shall be clean andfree from injurious amounts of oil, acids, alkalies, organic matters or otherharmful substances which may be deleterious to concrete, masonry or steel.The pH value of water sample shall be not less than 6. Potable water will beconsidered satisfactory. All requirements of IS:456, have to be met.

2.2.2 Tests on water samples shall be carried out in accordance with IS:3025 andthese shall fulfill all the guidelines and requirements given in IS:456.

2.2.3 Water for curing shall be of the same quality as used for concreting andmasonry works.

2.3 Aggregate (For Concrete)

2.3.1 General

a) Coarse and fine aggregates for Civil and Structural Works shall conform inall respects to IS:383 (Specification for coarse and fine aggregates fromnatural sources for concrete). Aggregates shall be obtained from anapproved source known to produce the same satisfactorily. Aggregatesshall consist of naturally occurring (crushed or uncrushed) stones, graveland sand or a combination thereof. These shall be chemically inert, hard,strong, dense durable, clean and free from veins, adherent coatings,

injurious amounts of alkalis, vegetable matter and other deleterioussubstances such as iron pyrites, coal, lignite, mica, shale, sea shells etc.

b) Aggregates which may chemically react with alkalis of cement or mightcause corrosion of the reinforcement shall not be used.

c) The maximum quantities of deleterious materials in the aggregates asdetermined in accordance with IS:2386 - Part II (Methods of Test foraggregates for concrete), shall not exceed the limits defined in IS:383.

2.3.2 Coarse Aggregates


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a) Coarse aggregates are the aggregates, which are retained on 4.75mm ISSieve. It shall have a specific gravity not less than 2.6 (saturated surface drybasis).

b) These may be obtained from crushed or uncrushed gravel or stone and maybe supplied as single sized or graded. The grading of the aggregates shallbe as per IS: 383 or as required by the mix design, to obtain densestpossible concrete.


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2.3.3 Fine Aggregates

a) Fine aggregates are the aggregates which pass through 4.75mm IS sievebut not more than ten percent (10%) pass through 150 micron IS sieve.These shall comply with the requirements of grading zones I, II and III ofIS:383. Fine aggregates conforming to grade zone IV shall not be usedfor reinforced concrete works.

b) Fine aggregates shall consist of material resulting from naturaldisintegration of rock and which has been deposited by streams or glacialagencies, or crushed stone sand or gravel sand. Sand from sea shores,creeks or river banks affected by tides, shall not be used for filling orconcrete works.

2.3.4 Sampling and Testing

The Contractor shall carry out all tests including mix designs of concrete, atthe start of work as well as during any stage of construction as per therequirement. Tests shall be carried out in accordance with IS:516-Methods

of test for strength of concrete and IS:2386-Methods of test for aggregatesfor concrete. The method of sampling shall be in accordance with therequirements given in IS: 2430.

2.3.5 Storage of Aggregates

a) Storage of all types of aggregates at the site of work shall be as specified inIS: 4082. Aggregates shall in no case be stored near excavated earth ordirectly over ground surface.

b) Fine aggregates delivered at the site in wet condition or becoming wet dueto rain or any other means, shall not be used for at least 24 hours. For theuse of such aggregates the contractor shall adjust the water content inaccordance with IS:2386 to achieve the desired mix.

2.4 Sand (For Masonry & Filling)

2.4.1 Sand for Masonry Mortars

a) The sand shall consist of natural sand, crushed stone sand or crushedgravel sand or a combination of any of these. The sand shall be hard,durable, clean and free from adherent coatings and organic matter and shall


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not contain the amount of clay, silt and fine dust more than specified inIS:2116.

b) The sand shall not contain any harmful impurities such as iron pyrites,alkalis, salts, coal or other organic impurities, mica, shale or similarlaminated materials, soft fragments, sea shells in such form or in suchquantities as to affect adversely the hardening, strength or durability of themortar.

c) The maximum quantities of clay, fine silt, fine dust and organic impurities in

the sand, when tested in accordance with IS:2386, shall not be more than5% by mass in natural sand, or crushed gravel sand or crushed stone sand.For organic impurities, when determined in accordance with IS:2386, colourof the liquid shall be lighter than that indicated by the standard solutionspecified in IS:2386.

2.4.2 Grading of Sand

The particle size grading of sand for use in mortars shall be within the limitsas specified below:

Gr ading Of Sand for Use in Masonry Mortars

In case of sand whose grading falls outside the specified limits due toexcess or deficiency of coarse or fine particles, this shall be processed tocomply with the standard by screening through a suitably sized sieve and/or

IS SieveDesignation IS:460(Part I)

Percentage PassingBy Mass

Reference ToMethod

4.75 mm 100 IS:2386 (Part-I)

2.36 mm 90 to 100

1.18 mm 70 to 100

600microns 40 to 100

300 microns 5 to 70

150 microns 5 to 15


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blending with required quantities of suitable sizes of natural sand particlesor crushed stone screening which are by themselves unsuitable. Thevarious sizes of particles of which the sand is composed shall be uniformlydistributed throughout the mass.

2.4.3 Sampling and Testing

The method of sampling shall be in accordance with IS: 2430. The amountof material required for each test shall be as specified in relevant parts of

IS:2386. All tests shall be carried out in accordance with the relevant partsof IS:2386. If further confirmation as to the satisfactory nature of thematerial is required, compressive test on cement mortar cubes (1:6) may bemade in accordance with IS:2250 using the supplied material in place ofstandard sand and the strength value so obtained shall be compared withthat of another mortar made with a sand of acceptable and comparablequality.

2.4.4 Sand for Filling

Sand for filling shall meet the requirements of IS:383 and shall be natural

sand, hard, strong, free from any organic and deleterious materials. Sandobtained from sea shores, creeks or river banks affected by tides, shall notbe used for filling. Fine aggregates suitable for concreting works shall besuitable for filling also. No sand below grading zone-III as per IS: 383 shallbe allowed for filling.

2.5 Cement

Unless otherwise specifically called for, cement3 for RCC and PCC/leanconcrete works shall be one of the following:

33 grade ordinary or low heat Portland cement IS: 26943 grade ordinary Portland cement IS: 8112Portland slag cement IS: 455Portland Pozzolana cement (fly ash based) IS: 1489 (Part-1)(The type of cement selected shall be appropriate for the intended use).

Portland Pozzolana cement (calcined clay based) IS:1489 (Part-2)Sulphate resisting Portland cement IS: 12330High alumina cement IS: 6452

For masonry applications the use of Masonry cement (conforming toIS:3466) can be made.


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2.6 Steel

2.6.1 General

All steel bars, sections, plates, and other miscellaneous steel materials, etc.shall be free from loose mill scales, rust as well as oil, mud, paint or othercoatings. The materials, construction specifications such as dimensions,shape, weight, tolerances, testing etc, for all materials covered under thissection, shall conform to respective BIS codes.

2.6.2 Reinforcement Bars

High strength deformed (HSD) TMT steel bars of minimum grade Fe 415,conforming to IS:1786 shall be used.

2.6.3 Structural Steel

Structural steel sections shall conform to following BIS codes:

Steel tubes for structural purposes IS: 1161Mild Steel Tubes, tubular and other wrought steel fittings IS: 1239

Steel for general structural purposes (Grade A) IS: 2062Hollow steel sections for structural use. IS:4923

2.6.4 Miscellaneous Steel Materials

Miscellaneous steel materials shall conform to the following BIS codes:

Expanded Metal Steel Sheets for General purposes IS:412Specification for mild steel and medium tensilesteel bars and hard drawn steel wire for concretereinforcement (Grade I)

(For mild steel bars of anchor bolts, rungs, metal inserts,grating etc.) IS: 432Hexagonal head bolts, screws & nuts of product Grade C. IS:

1363Cold formed light gauge structural steel sections. IS: 811Technical supply conditions for threaded steel fasteners. IS:

1367Plain washers IS:

2016Steel wire ropes for general engineering purposes IS:

2266


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Thimbles for wire ropes. IS:2315

Bulldog grips. IS:2361

Mild Steel Tubes, tubular and other wrought steelfillings. (For Hand rail tubular sections) IS:

1239Drop forged sockets for wire ropes for generalengineering purposes IS:

2485Steel chequered plates IS:

3502Hexagonal bolts and nuts (M42 to M150). IS:

3138

2.6.5 Anchor Bolts

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves andplates etc. shall be as per relevant BIS codes mentioned above underClauses 5.6.4.

2.7 Brick

2.7.1 General

Bricks for masonry works shall conform to IS:1077 - Specification forcommon burnt clay building bricks and shall be Avval variety of class 5.0(with minimum compressive strength of 5.0 N/mm2). Physical requirements,quality, dimensions, tolerances etc. of common burnt clay building bricksshall conform to the requirements of IS:1077. Bricks shall be hand-mouldedor machine-moulded and shall be made from suitable soils. The bricks shall

have smooth rectangular faces with sharp corners and shall be well burnt,sound, hard, tough and uniform in colour. These shall be free from cracks,chips, flaws, stone or humps of any kind.

Testing of the bricks shall be done as per IS:5454 and IS:3495. Waterabsorption shall not be more than 20% by its dry weight when soaked incold water for 24 hours. Locally available bricks of non modular size(230x115x75mm) in place of bricks of modular size (190x90x90mm) can beused in case the bricks satisfy the other requirements of IS:1077(corresponding class as defined above).

2.8 Stone


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2.8.1 General

All Stones used for masonry works shall conform to the requirements offollowing BIS codes.

Method of identification of natural building stones IS:1123Recommendations for dimensions and workmanship of natural buildingstones for masonry work IS:1127 Recommendations for dressing of naturalbuilding stones IS:1129

2.8.2 Quality of Stones

Stones shall be hard, dense, strong, sound, durable, clean and uniform incolour. They shall also be free from veins, adherent coatings, injuriousamounts of alkalis, vegetable matters and other deleterious substancessuch as iron pyrites, coal, lignite, mica, sea shells etc. As far as possiblestones from one single quarry shall be used for anyone work. The strengthof stones should be adequate to carry the imposed load and shall meet allthe requirements of IS: 1905, taking into account the appropriate crushingstrength of stone and type of the mortar used. The percentage of water

absorption, when tested in accordance with IS: 1124, shall not exceed 5percent.

The length of the stone shall not exceed 3 times the height. Width of stoneon base shall not be less than 150mm and in no case exceed 3/4 ththickness of the wall. Height of the stone shall not be more than 300mm.

2.9 Admixtures

2.9.1 General Requirements for Admixtures

a) All concrete admixtures shall comply with the following Indian standards:Specification for integral cement water proofing compounds. IS:2645Specification for other admixtures for concrete. IS:9103 In case of non-availability of any IS code for testing and acceptability criteria, relevant American, British or German Code shall be applicable.

b) No admixture shall impair the durability of the concrete nor combine with theingredients neither to form harmful compounds nor increase the risk ofcorrosion of reinforcement. Use of admixtures shall not reduce the drydensity of concrete. Once the proportion of admixtures has beenestablished, strict check shall be maintained not to alter the proportions ofingredients and water-cement ratio of the Design Mix during execution.


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c) The chloride contents in admixtures shall not exceed 2% by mass of theadmixture or 0.03% by mass of the cement.

d) Admixtures which do not meet the requirements stipulated in this documentshall not be used.

2.9.2 Water Proofing Compounds

a) The permeability of the specimen with the admixture shall be less than half

of the permeability with a similar specimen without the use of thesecompounds. These compounds shall be used in such proportion asrecommended by manufacturer but in no case it shall exceed 3% by weightof cement.

b) The initial setting time of the cement with the use of these compounds shallnot be less than 30 minutes and final setting time shall not be more than 10hours. Tests shall be carried out in accordance with IS:4031.

c) Compressive strength of the specimen at 3 days shall not be less than160kg/cm2 nor 80% of the 3 days compressive strength of mortar cubes

prepared with same cement and sand only, whichever is higher. Similarlycompressive strength at 7 days shall not be less than 220 kg/cm2 nor lessthan 80% of the 7 days compressive strength prepared with the samecement and sand only, whichever is higher. The test to determine thecompressive strength shall conform to IS: 4031.

2.10 Water Bars (Water Stops)

2.10.1 PVC water bars shall be used in reinforced concrete construction of liquidretaining structures or any other structure to safeguard them fromhydrostatic pressure and water leakage and any relative movementbetween two parts of the structure due to thermal loading shrinkage ordifferential movement of foundations. These shall be preformed and shallprovide a permanent water tight seal along the entire joint in the pouredconcrete structures. These shall also be flexible enough to withstanddeflection/ displacements at joints arising due to variation of temperaturesor settlement of foundations.

2.10.2 Performance requirements of PVC water bars shall meet the requirementsof IS:12200. These shall be of an approved make and ofribbed/serrated/plane type with a bulb at the centre. The thickness andwidth of water bars shall in no case be less than 5mm and 150mm


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respectively. However, for concrete sections greater than 300mm thick, thewidth of water bars shall not be less than 230mm

2.11 Bitumen/bituminous Materials

Bitumen to be used for various types of work shall meet all the requirementsof relevant BIS codes as given below:

Specification of Paving Bitumen. IS: 73

Specification for bitumen mastic for flooring. (Grade IV) IS:1195Specification for Bitumen felts for water proofing and damp proofing IS:

1322Specification for Bituminous compounds for water proofingand caulking purposes. IS:

1834Specification for preformed fillers for expansion jointin concrete pavements and structures. IS:

1838Specification for bitumen mastic for use in water proofing of roofs IS:

3037Specification for bitumen primer for use in water proofingand damp proofing. IS:

3384Specification for Bitumen Mastic for Tanking and damp proofing. IS:

5871Specification for Glass fibre based coal tar pitch & bitumen felts IS:

7193Code of practice for damp proofing using bitumen mastic IS:

7198Specification for bitumen Mastic, Anti Static and

electrically conducting grade. IS:8374

(Tests and acceptable criteria shall be as per relevant BIS codes.)

2.12 PVC Pipes

PVC Pipes shall conform to the requirements of IS:4985.

2.13 Wood/timber


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2.13.1 Wood recommended for platforms of cold vessels or below cold vessels/exchangers shall be hard and shall be of group A, grade I, and shall havesafe permissible stress of 7N/mm2 in compression, perpendicular to grainson outside location as per IS:883. General characteristics like durability,treatability etc. shall conform to IS:883 and IS:3629.

2.13.2 Timber required to be used for form work shall be fairly dry before use. Itshould maintain its shape during the use and even when it comes intocontact with moisture from the concrete. Storage of Wood/Timber shall be

as per the requirements of IS: 4082.

For proper identification and selection of suitable timber for form work,following codes shall be referred. Classification of commercial timbers andtheir zonal distribution IS:399 Specification for ballies for general purposesIS:3337

Specification for Ply wood for concrete shuttering work IS:4990

2.14 Anti-termite Compounds

2.14.1 Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall beused for treatment of soil for protection of buildings against attack bysubterranean termites.

2.15 Polysulphide Sealants

2.15.1 All Polysulphide Sealants shall conform to IS:12118. Test conditions andrequirements shall be as given in the above referred BIS code.


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STANDARD SPECIFICATION

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STRUCTURAL STEELWORK

(FABRICATION / ERECTION)



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TABLE OF CONTENTS

CL. NO.D E S C R I P T I O N

1.0.0 SCOPE

2.0.0 GENERAL

2.1.0 WORK UNDER CONTRACTOR‟S SCOPE

2.2.0 WORK BY OTHERS

2.3.0 CODES AND STANDARDS

2.4.0 CONFORMITY WITH DESIGNS

2.5.0 MATERIALS

2.6.0 STORAGE OF MATERIALS

2.7.0 QUALITY CONTROL

2.8.0 SHOP DRAWINGS

3.0.0 WORKMANSHIP

3.1.0 FABRICATION

3.2.0 RIVETED AND BOLTED CONSTRUCTION

3.3.0 WELDED CONSTRUCTION

3.4.0 FINISH

3.5.0 FINAL CLEANING UP

3.5 SLAB BASES AND CAPS

3.6 LACING BARS

3.7 SEPARATOR

3.8 BEARING PLATE

3.9 ARCHITECTURAL CLEARENCES

3.10 SHOP CONNECTIONS

3.11 CASTING


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3.12 METHOD AND SEQUENCE OF ERECTION

4.0 PAINTING AFTER ERECTION

5.0 FINAL CLEANING UP

6.0INSPECTION, TESTING, ACCEPTANCE CRITERIA ANDDELIVERY

7.0 DELIVERY OF MATERIALS


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1.0 SCOPE

This specification covers supply of material fabrication, testing, painting anddelivery to site and erection after assembly of structural steelwork includingsupply of all consumable stores and rivets, bolts, nuts, washers, electrodesand other materials required for fabrication and field connection of allstructural steelwork complete as per design / drawings / specificationsunder the scope of the contract.

2.0 GENERAL

The designs shall be carried out as per the specifications specified in the“Civil Design criteria” attached with the bid document and elsewher e in thebid document.

2.1. Any mismatch of any structural assembly or any mismatch during erection,the contractor shall submit rectification proposal (with due concurrence ofDesigner) for approval of the Company. Rectification Work shall be taken upas per approval.

2.2 Work by others

No sub-contracting (including preparation of fabrication drawings) under thisspecification will be allowed, unless specifically mentioned elsewhere in thecontract / approved by the EIC.

2.3 Codes and Standards

All work including materials supplied for temporary / permanentincorporation in this work under this specification shall, unless otherwisespecified in the contract, conform to the requirements of the latest revision

and/or replacements of the following or any other relevant Indian Standardspecifications and codes of practice. In case any particular aspect of thework is not covered by an Indian Standard Specification, the Contractorshall submit a procedure for the same and obtain approval of EIC.

BIS : 226 - Structural Steel (Standard Quality)BIS : 813 - Scheme of symbols for welding.BIS : 815 - Classification and coding of covered electrodes

for metal arc welding of mild steel and low alloyhigh tensile steel.

BIS : 817 - Code of practice for training and testing metal


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arc welders.BIS : 818 - Code of practice for safety and health

requirements inelectric and gas welding and cutting operations.

BIS : 822 - Code of practice for inspection of welds.BIS : 919 - Recommendations for limits and fits for

Engineering.BIS : 961 - Structural Steel (High Tensile).BIS : 1148 - Rivet bars for structural purposes

BIS : 1149 - High tensile rivet bars for structural purposes.BIS : 1161 - Steel Tubes for Structural purposes.BIS : 1200 - Method of measurement of steelwork and

ironwork (part 8).BIS : 1239 - Mild Steel Tubes.BIS : 1363 - Black hexagon bolts, nuts and lock nuts

(dia 6mm to 24mm).BIS : 1364 - Precision and semi-precision hexagon bolts,

screws, nutsand locknuts (dia range 6 to 39 mm).

BIS : 1367 - Technical supply conditions for Threaded

Fasteners.BIS : 1442 - Covered electrodes for the metal arc welding of

high tensilestructural steel.

BIS : 1608 - Method for tensile testing of steel productsother than sheetstrip, wire and tube.

BIS: 1730 - Dimensions for steel plate, sheet and strip forstructural andgeneral engineering purposes.

BIS : 1731 - Dimensions for steel flats for structural andgeneralengineering purposes.

BIS : 1852 - Rolling and cutting tolerances for hot rolledsteel products.

BIS : 1977 - Structural steel (Ordinary quality) ST-42-0.BIS : 2062 - Structural steel (fusion welding quality).BIS : 2074 - Ready mixed paint, red oxide Zinc chromate

priming.BIS : 2629 - Recommended practice for Hot-dip galvanizing

of Iron and

Steel.


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BIS : 3757 - High Tensile Friction Grip bolts.BIS : 4759 - Specifications for Hot-Dip Zinc Coatings

Structural Steeland other Allied products.

BIS : 7215 - Tolerances for fabrication of steel structures.BIS : 823 - Code of procedure for Manual Metal ARC

welding of MildSteel.

BIS : 1024 - Code of practice for use of welding in Bridges

andStructures subjected to Dynamic loading.

BIS : 1365 - Slotted counter sunk Head and slotted Raisedcounter sunkHead screws (Dia 1.6 to 20mm).

BIS : 1447 - Code of Practice for Finishing of Ferrous MetalsinBuildings Painting and Allied finishes.

BIS : 2016 - Plain Washers.BIS : 3664 - Code of practice for Ultrasonic Testing by Pulse

Echo

Method.BIS : 5334 - Code of practice for Magnetic Particle Flow

Detection ofwelds.

BIS : 7318 - Approved Test for welders when weldingprocedureapproval is not required.

BIS : 7318 - Fusion Welding of Steel.

2.4 Conformity with Designs

Except where the standard connection details are furnished, thecontractor shall design all connections, supply and fabricate all steelwork and furnish all connection materials in accordance with theapproved drawings and/or as instructed by the Engineer-in-Chargekeeping in view the maximum utilization of the available sizes andsections of steel materials.

2.5 Materials to be used

2.5.1 General


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All steel materials required for the work will be supplied by the contractorunless otherwise specified elsewhere in the contract. Steel used forconstruction shall be free from rust and pitting. Steel shall be as fresh aspossible. The steel material shall be free from mill scales, slag inclusions,lamination, pitting, rust, etc. On receipt of steel material, the contractor shallsubmit Mill test Certificate of the material and offer for inspection ofmaterial. During inspection the Steel shall be identified / verified for HeatNo. / Cast No., bar or bloom number, plate number, supply condition.

Dimensions, grade of steel (basic specification) along with Mill TestCertificate. Whenever the materials are required to be used fromunidentified stocks, if permitted by the Engineering-charge, a randomsample shall be tested at an approved laboratory from each lot of 50 tonnesor less of any particular section.

The arc welding electrodes shall conform to the relevant Bureau of IndianStandard Codes of Practice and Specifications and shall be of heavycoated type. The thickness of the coating shall be uniform and concentric.With each container of electrodes, the manufacturer shall furnishinstructions giving recommended voltage and amperage (Polarity in case of

D.C. supply) for which the electrodes are suitable.

2.5.2 Steel / Fasteners / Welding electrodes / paints etc.

2.5.2.1 The above materials to be used in construction within the purview of thisspecifications shall comply with the applicable Indian StandardSpecifications referred at 2.3.0 above.

2.5.2.2 In case of imported steel materials being used, these shall conform tospecifications equivalents to any of the above as may be applicable.

2.5.2.3 Where high tensile steel is specified for rivets, steps shall be taken toensure that the rivets are so manufactured that they can be driven andheads formed satisfactorily without the physical properties of steel beingimpaired.

2.5.4 Bolts and Nuts

Materials for Bolts and nuts under the purview of this contract shall complywith any of the following Indian Standard Specifications as may beapplicable.


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(a) Mild Steel : All mild steel for bolts and nuts when tested inaccordance with the following Indian Standard Specification shall have atensile strength of not less than 44 kg/mm

2 and a minimum elongation of 23

percent on a gauge length of 5.4 A, where „A‟ is the cross sectional area ofthe test specimen.

(b) High Tensile Steel (Structural Quality) : The material used for themanufacture of high tensile steel bolts and nuts shall have a minimumtensile strength 58 Kg/mm

2. Other mechanical properties shall conform to

grade HT of BIS:961.

(c) High Tensile Steel (Special Quality) : The material used for themanufacture of special quality high tensile steel bolts and nuts shall havethe mechanical properties appropriate to the particular class of steel as setout in IS:1367 or as approved by the Engineer-in-Charge.

2.6 Storage of Material

2.6.1 General

All materials shall be so stored as to prevent deterioration and to ensure thepreservation of their quality and fitness for the work. Any material which hasdeteriorated or has been damaged shall be removed from the contractor‟syard immediately, failing which, the Engineer-in-Charge shall be at liberty toget the material removed and the cost incurred thereof shall be realizedfrom the contractor. The contractor shall maintain upto date accounts inrespect of receipt, use and balance of all sizes and sections of steel andother materials. In case the fabrication is carried out in Contractor‟sfabrication yard / shop, all materials meant for use in this contract shall bestacked separately with easily identifiable marks.

2.6.2 Yard

The Contractor will have to establish a suitable yard in an approved locationat site for storing the fabricated steel structures and other materials whichwill be delivered to him by the Vendor according to the contract. The yardshall have proper facilities like, drainage, lighting, suitable access for largecranes, trailers and other heavy equipments. The yard shall be fenced allaround with security arrangement and shall be of sufficiently large area topermit systematic storage of the fabricated steel structures withoutovercrowding and with suitable access for cranes, trailers and otherequipment for use in erection work in proper sequence in accordance with

the approved programme of work.


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2.6.3 Covered Store

All field connection materials, paints, cement etc. shall be stored on welldesigned racks and platforms off the ground in a properly covered storebuilding to be built at the cost of the Contractor.

2.6.4 Steel

The steel to be used in fabrication and the resulting sub piece shall be

stored in separate stacks off the ground section wise and lengthwise so thatthey can be easily inspected, measured and accounted for at any time. Ifrequired by the Engineer-in-Charge, the materials may have to be storedunder cover and suitably painted for protection against weather.

2.6.5 Electrodes

The electrodes for electric arc welding shall be stored in a properlydesigned racks, separating different types of electrodes in distinctly markedcompartments. The electrodes shall be kept in a dry and war, condition ifnecessary by resorting to heating.

2.6.6 Bolts, Nuts and Washers

Bolts, nuts and washers and other fastening materials shall be stored onracks off the ground with a coating of suitable protective oil. These shall bestored in separate gunny bags or compartments according to diameter,length and quality.

2.6.7 Paints

Paints shall be stored under cover in air tight containers. Paints supplied insealed containers shall be used up as soon as possible once the container

is opened.

2.7 Quality Control

The Contractor shall establish and maintain quality control procedures fordifferent items of work and materials to the extent necessary to ensure thatall work is performed in accordance with this specification. In addition to theContractor‟s quality control procedures, all materials and workmanship shallbe subject to inspection at the contractors fabrications shop (whetherlocated at site / elsewhere) by the Engineer-in-Charge or his representative.The Contractor shall co-operate with the Engineer-in-Charge or his


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representative in permitting access for inspection to all places where workis being done and in providing free of cost all necessary help in respect oftools and plants, instruments, labour and materials required to carry out theinspection. The inspection shall be so scheduled as to provide the minimuminterruption to the

work of the contractor .

Materials or workmanship not in conformance with the provisions of this

Specification may be rejected at any time during the progress of the work.

The quality control procedure shall cover but not be limited to the followingitems of work :-

(1)Steel :Quality, Mill Test Certificate, test reports ofrepresentative sample of materials from unidentifiedstocks if permitted to be used.

(2)Rivets, Bolts :Mill test certificate Nuts & washers dimension checks,material testing.

(3)Electrodes :Mill test certificate thickness and quality of flux coating.

(4)Welders :Qualifying Tests.

(5)Welding sets :Performance Tests.

(6)Welds :Visual inspection, Destructive / non destructive testssuch as Radiography, Ultrasonic tests etc. asapplicable.

(7)Paints :Mill test certificate physical inspection reports.

(8)Galvanizing :Tests in accordance with IS:2633 Method for testinguniformity of coating on Zinc coated Articles andIS:4759 Specification for Hot-Dip Zinc coatings onStructural Steel and other allied products.

9)Erection :Clearing levels, grades, plumbs, joint characteristicsincluding tightness of bolts.


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10)Grouting :Cleaning and roughness of foundation, quality ofmaterials used for grouting, admixtures, consistencyand strength of grout.

11)Painting :Preparation of surface for painting, quality of primersand paints, thinners, application and uniformity of coats.

2.7.1 Standard dimensions, forms and weights

The dimensions, forms, weights and tolerances of all rolled shape rivets,bolts, nuts, studs, washers, etc. and other members used in the fabricationof any structure shall, wherever applicable, conform to the requirements ofthe latest relevant Indian Standards, wherever they exist, or, in the absenceof Indian

Standards, to other equivalent standards.

2.8 Shop Drawings

The sequence of submission of shop drawings for approval shall match withthe approved fabrication and erection schedule. The shop drawings will besubmitted for review / approval for ascertaining / verifying the generalconformity with the design requirements / specifications so as to ensure thecorrectness of general arrangement for centerline dimensions and levels,section sizes, and adequacy of connections including splice joints as to theno. of bolts weld length, size of gusset/enc plates. Ensuring the correctnessof all other details like cutting lengths, matching of holes, notch dimensions,match markings, bill of materials, bolt list etc. will be entirely theContractor‟s responsibility.

The shop drawings shall include but not be limited to the following :-

(a) Assembly drawings giving exact sizes of the sections to be used andidentification marks of the various sections.

(b) Dimensional drawings of base plates, foundation bolt location etc.

(c) Comparison sheets to show that the proposed alternative section, ifany, are as strong as the original sections shown on the Design Drawings.

(d) Any other drawings or calculations that may be required for theclarification of the works or substituted parts thereof.


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(e) These drawings shall give all the necessary information for thefabrication, erection and painting of the steelwork in accordance withprovisions of this specification. Shop drawings shall be made in accordancewith the best modern practice and with due regard to sequence, speed andeconomy in fabrication and erection. Shop drawings shall give completeinformation necessary for fabrication of two various components of thesteelwork, including the location, type, size and extent of welds. These shallalso clearly distinguish between shop and field rivets, bolts and welds andspecify the class of bolts and nuts. The drawings shall be drawn to a scale

large enough to convey all the necessary information adequately. Notes onthe shop drawings shall indicate those joints or groups of joints in which it isparticularly important that the welding sequence and technique of weldingshall be carefully controlled to minimize the locked-up stresses anddistortion. Welding symbols used shall be in accordance with therequirements of the Indian Standard Specification BIS : 813.

3 WORKMANSHIP

3.1 Fabrication

3.1.1 General

All workmanship shall be equal to the best practice in modern structuralshops, and shall conform to the provisions of the Indian Standard IS:800 – Code of Practice for use of Structural Steel in General Building Constructionand other relevant Indian Standards or equivalent.

3.1.2 Straightening Material

Rolled materials before being laid off or worked, must be clean free fromsharp kinds, bends or twists and straight within the tolerance allowed by theIndian Standard Specification BIS:1852 – Specification for rolling andcutting tolerance for hot-rolled steel products. If straightening is necessary,it may be done by mechanical means only. Straightening by heating is notpermitted. Removing distorted portion and use of remaining portion ispermitted.

3.1.3 Cutting


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Cutting shall be effected by shearing, cropping or sawing. Use of amechanically controlled gas cutting torch may be permitted for mild steelonly. Gas cutting of high tensile steel may also be permitted providedspecial care is taken to leave sufficient metal to be removed by machining,so that all metal that has been hardened by flame is removed. Gas cuttingwithout a mechanically controlled torch may be permitted if special care istaken and done under expert hand, subject to the approval of the Engineer-in-Charge.

To determine the effective size of members cut by gas, 2mm shall bededucted from each cut edge. Gas cut edges, which will be subject tosubstation stress or which will be subjected to substantial stress or whichare to have weld metal deposited on them, shall be reasonably free fromgauges, occasional notches or gauges not more than 4mm deep will bepermitted. Edges greater than 4 mm that remain from cutting shall beremoved by grinding. All reentrant corners shall be shaped notch free to aradius of at least 12mm. Shearing, cropping and gas cutting shall be clean,reasonably square and free from any distortion.

3.1.4 Planing of edges

Planing or finishing of sheared or cropped edges of plates or shapes or ofedges gas cut with a mechanically controlled torch shall not be required,unless specifically required by design and called for on the drawings,included in a stipulation for edge preparation for welding or as may berequired after the inspection of the cut surface. Surface cut with hand flameshall generally be ground, unless specifically instructed otherwise by theEngineer-in-Charge.

3.1.5 Clearances

The erection clearance for cleated ends of members connecting steel tosteel shall preferably be not greater than 2mm at each end. Wherever theerection clearance greater than 3mm at each end, for practical reasons isnecessary, suitably designed cleatings shall be provided.

3.2 Riveted and bolted construction

3.2.1 Holes

Holes through more than one thickness of material for members, such ascompound stanchions and girder flanges, shall be drilled after the members

are assembled and tightly clamped or bolted together. Punching may be


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permitted before assembly, if the thickness of the material is not greaterthan the nominal diameter of rivet or bolt plus 3mm subject to a maximumthickness of 16mm provided that the holes are punched 3mm less indiameter than the required size and reamed after assembly to the fulldiameter.

Holes for rivets or black bolts shall not be more than 1.5mm or 2.0mm(depending on whether the diameter of the rivet or bolt is less or more thanor equal to 25mm) larger in diameter than the nominal diameter of the rivet

or black bolt passing through them.

Holes for turned and fitted bolts shall be drilled to a diameter equal to thenominal diameter of the shank or barrel subject to tolerance grade of H8 asspecified in BIS:919. Parts to be connected shall be firmly held together bytacking welds or clamps and the holes drilled through all the thickness inone operation and subsequently reamed to size. Holes not drilled throughall thickness in one operation shall be drilled to a smaller size and reamedout after assembly.

Holes for rivets or bolts shall not be formed by gas cutting process.

3.2.2 Assembly

All parts or riveted members shall be well pinned or bolted and rigidly heldtogether while riveting. Drifting to enlarge un-matching holes shall notgenerally be permitted. In case drifting is permitted to a slight extent duringassembly, it shall not distort the metal or enlarge the holes. Holes that mustbe enlarged to admit the rivets or bolts shall be reamed. Poor matching ofholes shall be cause for rejection. The component parts shall be soassembled that they are neither twisted not otherwise damaged, and shallbe so prepared that specified chambers, if any are maintained.

Rivets shall ordinarily be hot driven, in which case their finished heads shallbe approximately hemispherical in shape and shall be of uniform sizethroughout the work for rivets of the same size full, neatly finished andconcentric with holes. Rivets shall be heated uniformly to a temperature notexceeding 1065˚ C, they shall nor be driven after their temperature hasfallen below 540˚ C.

Rivets shall be driven by power riveters, of either compression or manuallyoperated type, employing pneumatic, hydraulic or electric power. Handdriven rivets shall not be allowed unless in exception cases specifically

approved by the Engineer-in-Charge. After driving, rivets shall be tight, shall


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completely fill the holes and their heads shall be in full contact with thesurface. In case of countersunk rivets, the countersinking shall be fully filledby the rivet, any protudness of the countersunk head being dressed of flush,if required.

Riveted members shall have all parts firmly drawn and held together beforeand during riveting and special care shall be taken this respect for all singleriveted connections. For multiple riveted connections a service bolt shall beprovided in every third or fourth hole.

All loose, burnt or otherwise defective rivets shall be cut out and replacedand special care shall be taken to inspect all single riveted connections.Special care shall also be taken in heating and driving long rivets. Thecontractor shall prove the quality of riveting by cutting some rivets chosen atrandom by the Engineer-in-Charge. No extra payment will be made to thecontractor for such cutting and replacing to the extent of ten sound rivet perfive hundred done. Riveting work, for any particular section or group, will beconsidered satisfactory when at least 90% of the corresponding cut rivetsare found to be sound. If the ratio is below 75%, all the rivets in theparticular section or group shall be cut, removed and replaced and tested

again at the contractor‟s expense.

For cases between 75% and 90% the Engineer-in-Charge shall have theoption to instruct cutting and replacing any number of further rivets at theContractor‟s cost as he deems necessary.

Bolted construction shall be permitted only in case of field connections ifcalled for on the Drawings and is subjected to the limitation of particularconnections as may be specified. In special cases, however, shop boltconnections may be allowed if directed by the Engineer-in-Charge.

Washers shall be tapered or otherwise suitably shaped, where necessary,to give the heads and nuts of bolts a satisfactory bearings. The threadedportion of each bolt shall project out through the nut at least one thread. Inall cases the bolt shall be provided with a washer of sufficient thicknessunder the nut to avoid any threaded portion of the bolt being within thethickness of the parts bolted together. In addition to the normal washer onespring washer or lock-nut shall be provided for each bolt for connectionssubjected to vibrating forces or otherwise as may be specified on theDrawings.

3.3 Welded construction


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3.3.1 General

Welding shall be in accordance with relevant Indian Standards and assupplemented in the Specification. Welding shall be done by experiencedand good welders who have been qualified by tests in accordance withBIS:817.

3.3.2 Preparation of Material

Surface to be welded shall be free from loose scale, slag, rust, grease,paint, and any other foreign material except that mild scale whichwithstands vigorous wire brushing may remain. Joint surfaces shall be freefrom fins and tears. Preparation of edges by gas-cutting shall, whereverpracticable, be done by a mechanically guided torch.

3.3.3 Assembling

Parts to be fillet welded shall be brought in as close contact as practicableand in no event shall be separated by more than 4mm. If the separation is1.5m or greater, the size of the filled welds shall be increased by the

amount of the separation. The fit of joints at contact surfaces which are notcompletely sealed by welds, shall be close enough to exclude water afterpainting. Abutting parts to be butt-welded shall be carefully aligned.Misalignments greater than 3mm shall be corrected and in making thecorrection the parts shall not be drawn into a sharper slope than twodegrees (2 deg.)

The work shall be positioned for flat welding whenever practicable.

3.3.4 Welding Sequence

In assembling and joining parts of a structure or of built-up members, theprocedure and sequence of welding shall be such as will avoid needlessdistortion and minimize shrinkage stresses. Where it is impossible to avoidhigh residual stresses in the closing welds of a rigid assembly, such closingwelds shall be made in compression elements.

In the fabrication of cover-plated beams and built-up members, all shopsplices in each component part shall be made before such component partis welded to other parts of the member. Long girders or girder sections maybe made by shop splicing not more than three sub-sections, each made inaccordance with this paragraph.


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When required by the Engineer-in-Charge, welded assemblies shall bestress relieved by heat treating in accordance with the provisions of therelevant Indian Standard or any other Standard approved by the Engineer-in-Charge.

3.3.5 Welding technique

All complete penetration groove welds made by manual welding, exceptwhen produced with the aid of backing material not more than 8mm thick

with root opening not less than one-half the thickness of the thinner part joined, shall have the root of the initial layer gauged out on the back sidebefore welding is started from that side, and shall be so welded as to securesound metal and complete fusion throughout the entire cross section.Groove welds made with the use of the backing of the same material as thebase metal shall have the weld metal thoroughly fused with the backingmaterial. Backing strips need not be removed. If required, they may beremoved by gauging or gas cutting after welding is completed, provided noinjury is done to the base metal and weld metal and the weld metal surfaceis left flush or slightly convex with full throat thickness.

Groove welds shall be terminated at the ends of a joint in a manner that willensure their soundness. Where possible, this should be done by use ofextension bars or run-off plates. Extension bars or run-off plates need notbe removed upon completion of the weld unless otherwise specifiedelsewhere in the contract.

To get the best and consistent quality of welding, automatic submerged arcprocess shall be preferred. The technique of welding employed, theappearance and quality of welds made, and the methods of correctingdefective work shall all conform to the relevant Indian Standards.

3.3.6 Temperature

No welding shall normally be done on parent material at a temperaturebelow (-)5˚C. However, if welding is to be undertaken at low temperature,adequate precautions as recommended in relevant Indian Standard shall betaken. When the parent material is less than 40mm thick and thetemperature is between (-)5˚C and 0˚C, the surface around the joint to adistance of 100mm or 4 times the thickness of the material, whichever isgreater, shall be preheated till it is hand warm. When the parent material ismore than 40mm thick, the temperature of the area mentioned above shallbe in no case be less than 20 deg C. All requirements regarding preheating


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of the parent material shall be in accordance with the relevant IndianStandard.

3.3.7 Peening

Where required, intermediate layers or multiple-layer welds may be peenedwith light blows from a power hammer, using a round-nose tool. Peeningshall be done after the weld has cooled to a temperature warm to the hand.Care shall be exercised to prevent scaling of flaking of weld and base metal

from over peening.

3.3.8 Equipment

These shall be capable of producing proper current that the operator mayproduce satisfactory welds. The welding machine shall be of a type andcapacity as recommended by the manufacturers of electrodes or as may beapproved by the Engineer-in-Charge.

3.4 Finish

Column splices and butt joints of compression members depending oncontact for stress transmission shall be accurately machined and close-butted over the whole section with a clearance as specified elsewhere in thebid document.. In column caps and bases, the ends of shafts together withthe attached gussets, angles, channels etc., after welding/riveting together,should be accurately machined so that the parts connected butt over theentire surfaces of contact. Care should be taken that those connectingangles or channels are fixed with such accuracy that they are not reduced inthickness by machining by more than 1.0 mm.

3.5 Slab bases and caps

Bases and caps fabricated out of steel slabs, except when cut from materialwith true surface, shall be accurately machined over the bearing surfaceand shall be in effective contact with the end of the stanchion. A bearingface which is to be grouted direct to a foundation need not be machined ifsuch face is true and parallel to the upper face.

To facilitate grouting, holes shall be provided, where necessary instanchion bases for the escape of air.

3.6 Lacing bars


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The ends of Lacing bars shall be neat and free from burns

3.7 Separators

Rolled section or built-up steel separators or diaphragms shall berequired for all double beams except where encased in concrete, in whichcase, pipe separators shall be used.

3.8 Bearing Plates

Provision shall be made for all necessary steel bearing to take up reactionof beams and columns and the required stiffeners and gussets whether ornot specified in Drawings.

3.9 Architectural Clearances

Bearing plates and stiffener connections shall not be encroached upon the

permitted architectural clearances.

3.10 Shop Connections

(a) All shop connections shal1 be either riveted or welded as specified onthe Drawings.

(b) Heads of rivets on surfaces carrying brick walls shall be flattened to 10mm thick projection.

(c) Certain connections, specified to be shop connections, may be

changed to field connections if desired by the Engineer-in-Charge for convenience of erection and the Contractor will have

to make the desired changes at no extra cost to the ONGC.

3.11 Castings

Steel castings shall be annealed.

3.12 Method and sequence of erection


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3.12.1 The method and sequence of erection shall have the prior approvalof the Engineer-in-Charge. The Erector shall arrange for most economicalmethod and sequence available to him consistent with the Drawings andspecifications and such information as may be furnished to him prior to theexecution of the Contract.

3.12.2 Safety and Security during Erection

The contractor shall comply with BIS : 7205 for necessary safety and

adhere to safe erection practices and guard against hazardous as well asunsafe working conditions during all stages of erection.

Proper access, platform and safety arrangement shall be provided forworking and inspection (at no extra cost wherever required )

3.12.3 Temporary bracing

Unless adequate bracing is included as a part of the permanent framing, theerector during erection shall and install, free of cost to the Owner, temporaryguys and bracings where needed to secure the framing against loads suchas wind or seismic forces comparable in intensity to that for which thestructure has been designed, acting upon exposed framing as well as loadsdue to erection equipment and erection operations.

If additional temporary guys are required to resist wind or seismic forcesacting upon components of the finished structure installed by others duringthe course of the erection of the steel framing, arrangement for theirinstallation by the erector shall be made free of cost to the ONGC.

3.12.4 Temporary floors for buildings

It shall be the responsibility of the Contractor to provide free of cost plankingand to cover such floors during the work in progress as may be required bythe Act of parliament and /or bylaws of state, Municipal or other localauthorities.

3.12.5 Setting out


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Positioning and leveling of all steelwork, plumbing of stanchions and placingof every part of the structure with accuracy shall be in accordance with theapproved Drawings and to the satisfaction of the Engineer-in-Charge. TheContractor shall check the positions and levels of the anchor bolts, etc.before concreting and get them properly secured against disturbance duringpouring operations. He shall remain responsible for correct positioning. Anyminor modification in the positioning including chipping, cutting and makinggood, adjusting of Anchor Bolts etc. if necessary shall be carried out by thecontractor at his own expense. The positioning and leveling of all steel work

including plumbing of columns and placing of every part of the structure withaccuracy shall be in accordance with drawing and approval of Engineer-in-Charge. For heavy columns, etc. the Contractor shall set proper screedbars if desired by the Engineer-in-Charge, to maintain proper level, withoutany extra cost.

Each tier to column shall be plumbed and maintained in a true verticalposition to the limits of tolerance allowable under this Specification.

No permanent field connections by riveting, bolting or welding shall becarried out until proper alignment and plumbing has been attained.

3.12.6 Field riveting

All rivets shall be heated and driven with pneumatic tools. Hand passing or„throwing„of rivets are desirable. Any other method of convening hot rivetsfrom the furnace to the driving point must be approved by the Engineer-in-Charge.

No cold rivets shall be driven. All other requirements of riveting in includingquality and acceptance criteria shall be in accordance with the relevantportions of the specification for Fabrication of Structural Steel work of theProject.

3.12.7 Field bolting


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All relevant portions in respect of bolted construction of the specificationfor fabrication of Structural Steel work applicable to the Project shall alsobe applicable for field bolting in addition to the following:

Bolts shall be inserted in such a way so that they may remain in positionunder gravity even before fixing the nut. Bolted parts shall fit solidlytogether when assembled and shall not be separated by gaskets or anyother interposed compressible materials. When assembled, all jointsurfaces, including those adjacent to the washers shall be free of scales

except tight mill scales. They shall be free of dirt, loose scales, burns andother defects that would prevent solid seating of the parts. Contactsurfaces within frication-type joints shall be free of the oil, paint, lacquer orgalvanizing.

All high tensile bolts shall be tightened to the required minimum bolttension by any of the following methods.

a) Turn-of-nut method

When the turn-of-nut method is used to provide the bolt tension, there

shall fir st be enough bolts brought to a “ snug tight “ condition to ensurethat the parts of the joint are brought into good contact with each other. “Snug tight “ is defined as the tightness attained by a few impacts of anordinary or the full effort of a men using an ordinary spud wrench.Following this initial operation, bolts shall be placed in any remainingholes in the connection and brought to snug tightness. All bolts in the jointshall then be tightened additionally by the applicable amount of nutrotation specified in Table-1 with tightening progressing systematicallyfrom the most rigid part of the joint to its free edges. During this operationthere shall be no rotation of the part not turned by the wrench.

T A B L E –I

Bolts length notexceeding 8”or 200 mm

Bolt lengthexceeding 8”or 200 mm

Remarks

1/2 turn 2/3 turnNut rotation is relative to boltregardless of the element (nut orbolt) being turned. Tolerance onrotation 30 degrees over or under


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SPECIFICATION FOR

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Bolts may be installed without hardened washers when tightening is doneby the turn-of-nut method. However, normal washers shall be used.

Bolts tightened by the turn-of-nut method may have the outer face of the nutmatch-marked with the protruding bolt point before final tightening, thusaffording the inspector visual means of noting the actual nut rotation, suchmarks can be made by the wrench operator by suitable means after the

bolts have been brought up snug tight.

b) Torque wrench tightening

When torque wrenches are used to provide the bolt torque the bolts shall betightened to the torques specified in TABLE-II. Nuts shall be in tighteningmotion when torque is measured. When suing torque wrenches to installseveral bolts in a single joint, the wrench shall be returned to touch up boltspreviously tightening, which may have been loosened by the tightening ofsubsequent bolts, until all are tightened to the required tension.

TABLE –IINominal Bolt

Diameter (mm)Torque to be applied (Kg.M) for

bolt class 8.8 of I.S : 136720 59.9422 81.6324 103.73

In either of the above two method, if required for bolt entering and wrenchoperation clearances, tightening may be done by turning the bolt while thenut is prevented from rotating.

Impact wrenches if used shall be of adequate capacity and sufficientlysupplied with air to perform the required tightening of each bolt inapproximately ten seconds.

Holes for turned bolts (to be inserted in the field) shall be reamed in thefield. All drilling and reaming for turned bolts shall be done only after theparts to be connected are assembled. Tolerances applicable in the fit of thebolts shall be in accordance with relevant Indian Standard Specifications. Allother requirements regarding assembly and bolt tightening shall be inaccordance with this sub clause.


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3.12.8 Field welding

All field assembly and welding shall be carried out in accordance with therequirements mentioned in the bid document. Where the fabricatedstructural steel member have been delivered painted, the paint shall beremoved before field welding for a distance of at least 50 mm on either sideof the joints. Holes for all erection bolts removed after final erection shall beplugged by welding.

3.12.9 Holes, cutting and fitting

No cutting of sections, flanges, webs, cleats, rivets, bolts, welds etc. shallbe done unless specification approved and /or instructed by the Engineer-in-Charge.

The erection shall not cut drill or otherwise alter the work of other trades, orhis own work to accommodate other trades, unless such work is clearlyspecified in the Contract or directed by the Engineer-in-charge. Whereversuch work is specified the Contractor shall obtain complete information as tosize location and number of alternations prior to carrying out any work. The

contractor shall not be entitled for any extra cost on account of any suchwork.

3.12.10 Drifting

Correction of minor misfits and reasonable amount of reaming and cuttingof excess stock from rivets will be considered as permissible. For this,light drifting may be used to draw holes together and drills shall be usedto enlarge holes as necessary to make connections. Reaming, thatweakens the member or makes it impossible to fill the holes properly or toadjust accurately after reaming, shall not be allowed.

Any error in shop work which prevents the proper assembling and fittingof parts by moderate use of drift pins and reamers shall immediately becalled to the attention of the Engineer-in-Charge and approval of themethod of correction obtained. The use of gas cutting torches at erectionsite is prohibited.

3.12.11 Grouting of stanchion bases and bearings of beams and girders onstone, brick or concrete (plain or reinforced) :

Grouting shall be carried out as specified elsewhere in the bid document.


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Whatever method of grouting is employed the operation shall not becarried out until steel work has been finally leveled and plumbed thestanchion bases being supported meanwhile by steel wedges, andimmediately before grouting, the space under steel shall be thoroughlycleaned.

If required by the Engineer-in-Charge, certain admixtures like aluminumpowder, “ironite” or equivalent, may be required to be added to the groutto enhance certain desirable properties of the grout at no extra time/cost

implication to ONGC.

The grout mixture shall be poured continuously (without any interruptiontill completion) by grouting pumps from one side of the base plate andspread uniformly with flexible steel strips and rammed with rod, till thespace is filled solidly and the grout mixture carried to the other side of thebase plate.

The grout mixture shall be allowed to harden for a period as decided bythe Engineer-in-Charge. At the end of this period, the shims/wedges/packplates may be removed and anchor bolts tightened uniformly. The

alignment of the structure shall now be rechecked and if found correct,the voids left by the removal of shims / wedges / pack plates (if removed)must be filled up with a similar mixture of grout. In case after checkingserious misalignment is indicated the grout shall be removed completelyand fresh grouting shall be done after making appropriate correction ofalignment.

4 PAINTING AFTER ERECTION

Field Painting wherever required is to be carried out as per normalpainting procedure adopted for shop painting. Field painting shall be

carried out for all construction / erection joints, portion damaged due totransportation & erection process, etc. Contractor shall make allarrangement for field painting to get the desired quality to complete thework.

Touch up painting making good any damaged shop painting andcompleting any unfinished portion of the shop coat shall be carried out bythe erection Contractor free of cost to the Owner. The materials andspecification for such painting in the field shall be in accordance with therequirements of the specification for fabrication of structural steel workapplicable for the project.


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Painting shall not be done in frosty or foggy weather or when humidity issuch as to cause condensation on the surfaces to be painted. Beforepainting of steel, which is delivered unpainted, is commenced all surfacesto be painted be dried and thoroughly cleaned from all loose scale andrust.

All field rivets, bolts welds and abrasions to the shop coat shall be spotpainted with the same paint used for the shop coat. Where specified,surfaces which will be in contact after site assembling shall receive a coat

of paint (in additional to the shop coat, if any) and shall be broughttogether while the paint is still wet. Surface which will be inaccessibleafter field assembly shall receive the full-specified protective treatmentbefore assembly. Bolts and fabricated steel members which aregalvanized or otherwise treated and steel members to be encased inconcrete shall not be painted.

The specification for paint and workmanship shall be in accordance withthe requirements of the specification for fabrication of structural steel workapplicable to the project. The number of coats and the shades to be usedshall be as specified or as directed by the Engineering-in-Charge.

5 FINAL CLEANING UP

Upon completion of erection and before final acceptance of the work bythe Company, the contractor shall remove temporary support, scaffolding,installation aid, grouting aids, tools & equipment for construction &erection, all surplus material from site, etc. and cleaning of site andsurroundings. Costs of all these activities are deemed to be included inthe contract

6 INSPECTION, TESTING, ACCEPTANCE CRITERIA

AND DELIVERY

6.1 Inspection

Unless specified otherwise, inspection of all work shall be made bythe Engineer-in-Charge or his representative at the place of manufactureprior to delivery. The Engineer-in-Charge or his representative shall havefree access at all reasonable times to those parts of the manufacturer'sworks which are concerned with the fabrication of the steelwork under thisContract and he will be provided all reasonable facilities for satisfying


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himself that the fabrication is. being done in accordance with theprovisions of this Specification.

The contractor shall provide free of charge, such as labour, materials,electricity, fuel, water, stores, tools and plant apparatus and instrumentsas may be required by the Engineer-in-Charge to carry out inspectionand/or tests in accordance with the contract.

6.2 Testing and Acceptance Criteria for Fabrication

6.2.1 General

The contractor shall carry out sampling and testing in accordance with therelevant Indian Standards and as supplemented herein for the followingitems at his own cost, unless otherwise specified in the Contract. Thecontractor shall get the specimens tested in a laboratory approved by theEngineer-in-Charge and submit to the Engineer-in-Charge the test resultsin triplicate within 3(three) days after completion of the test.

6.2.2 Steel

All steel supplied by the contractor shall conform to the relevant Bureau ofIndian Standards and as specified elsewhere in the bid document.

All material shall be free from all imperfections, mill scales, slag intrusions,laminations, pittings, rusts etc. that may impair their strength, durability andappearance.

6.2.3 Welding

All electrodes shall be procured from reliable manufacturers with testcertificates. The correct grade and size of electrode which has notdeteriorated in storage shall be used. The inspection and testing of weldingshall be performed in accordance with the provisions of the relevant IndianStandards or other equivalents. For every 50 tones of welded fabrication,the engineer-in-Charge may ask for 1(one) test-destructive or non-destructive including x-ray, ultrasonic test or similar, the cost of which shallbe borne by the contractor. In cases of the test results showing deficiency,the Engineer-in-Charge shall have option to reject or instruct any remedialmeasures to be taken free of cost to the Owner.


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6.2.4 Rivetts, bolts, nuts and washers shall be procured from approvedsupplier and shall conform to the relevant Indian Standards. If desired bythe Engineer-in-Charge, representative samples of these materials mayhave to be tested in an approved laboratory and in accordance with theprocedure described in relevant Indian Standards, cost of all such testingshall have to be borne by the contractor. In addition to testing the rivets byhammer, 2% (two percent) of the rivets done shall be cut off by chisels toascertain the fit, quality of material and workmanship. The removal of thecut rivets and reinstalling new rivets shall be done by the contractor at his

own cost.

6.3 TESTING AND ACCEPTANCE CRITERIA FOR ERECTION

6.3.1 General

Loading tests shall be carried out on erected structures, if required by theEngineer-in-Charge, to check adequacy of fabrication and/or erection. Anystructure or a part thereof found to be unsuitable for acceptance as a resultof the test shall have to be dismantled and replaced with suitable memberas per the Contract, and no payment towards the cost of the dismantled

portion and any connected work shall be made to the Contractor. In courseof dismantling, if any damage is done to any other parts of the structure orto any fixtures the same shall be made good free of cost by the Contractorto the satisfaction of the Engineer-in-Charge. The cost of the tests specifiedhereinafter shall be borne by the contractor. Any extra claim due to loss oftime, idle labour, etc. arising out of these testing operations shall be borneby contractor.

The structure or structural member under consideration shall be loaded withits actual dead load for as long a time as possible before testing and thetests shall be conducted as indicated in the following sub-clauses 6.3.2,

6.3.3, and 6.3.4. The method of testing and application of loading shall beas approved by the Engineer-in-Charge.

6.3.2 Stiffness Test

In this test, the structural or member (identified by the Engineer-in-Charge)shall be subjected, in additional to its actual dead load, to a test load equalto 1.5 times the specified superimposed load, and this loading shall bemaintained for 24 hours. The maximum deflection attained during the testshall be within the permissible limit. If, after removal of the test load, themember or structure does not show a recovery of at least 80 per cent of the


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maximum strain or deflection shown during 24 hours under load the testshall be repeated. The structure or member shall be considered to havesufficient stiffness, provided that the recovery after this second test is notless than 90 per cent of the maximum increase in strain or deflectionrecorded during the second test. The tests shall be carried out as perrelevant codes and standards.

6.3.3 Strength Test

The structure or structural member (identified by the Engineer-in-Charge)under consideration shall be subjected in additional to its actual dead load,to a test load equal to the sum of the dead load and twice the specifiedsuperimposed load and this load shall be maintained for 24 hours.

In the case of wind load, a load corresponding to twice the specified windload shall be applied and maintained for 24 hours either with or without thevertical test load for more severe condition in the member under or thestructural as a whole. Complete tests under both conditions may benecessary to verify the strength of the str

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