Technical Specification
Technical Specification
Technical Specification
D.6.1.1 Scope
This specification covers requirements for materials, dimensions, classification,
testing for pressure and non-pressure pipes made from glass fibre reinforced
thermosetting resin with or without on aggregate filler. Specification also covers
supplying, lowering, laying, joining and testing Glass-fibre Reinforced Plastic (GRP)
pipes at work site used for the conveyance of industrial wastewater of highly acidic and
corrosive nature.
D.6.1.2 Applicable Codes
a)
National Standards
The manufacturing, testing, supplying, joining and testing at work site of GRP
pipes shall comply with all currently applicable statues, regulations, standards
and codes. In particular, the following standards unless otherwise specified here
in, shall be referred. In all cases, the latest revision of the codes shall be referred
to. If requirements of this specification conflicts with the requirements of the
codes and standards, this specification shall govern.
(i)
(ii)
(iii)
plastics. (iv)
(vi)
Signature of Bidder
Glass fibre chopped strand mat for the reinforcement of polyester resin
systems.
b)
International Codes
Wherever for certain specific requirements the information given in above
mentioned IS codes is found to be inadequate, following international codes shall
be referred to. However, in case of any discrepancy, decision of Owner /
Engineer shall be final and implemented by the Contractor.
(i)
ASTM D 2412 :
W Standard test method for determination of external loading characteristics of
plastic pipe by parallel plate loading.
(ii)
ASTM D 3262 :
Standard specification for reinforced plastic mortar sewer pipe.
(iii)
ASTM D 3517 :
Standard specification for glass fibre reinforced thermosetting resin pressure
pipe.
(iv)
ASTM D 3618 :
Test for chemical resistance of reinforced thermosetting resin pipe in a deflected
condition.
(v)
ASTM D 3839 :
Standard practice for underground installation of flexible
thermosetting resin pipe and reinforced plastic mortar pipe.
(vi)
reinforced
ASTM D 4161:
Standard specification for Fibre glass (glass-fiber reinforced thermosetting
resin) pipe joints using flexible elastomeric seals.
(vii)
ASTM D 477 :
Standard specification for elastomeric seals (Gaskets) for joining plastic
pipe. (viii)
ASNI/AWWA C 950-88
Design
Pressure Rating
GRP pipes used will be having pressure rating as follows :
Pressure class
(PN)
300
600
900
12
15
(1 Kpa = 0.102 metres of Water column)
1200
1500
Note : The working pressure rating may be changed for use at fluid temperature
greater than 43.5 deg. C in accordance with the manufacturers
recommendation.
D.6.1.4 Manufacturing
(a)
General
The method of manufacturing of GRP pipes shall be such that the form and the
dimensions of the finished pipes are accurate within the limits specified in
relevant Clauses of IS : 14402 and ASTM 3262. The surfaces and edges of the
pipes shall be well defined and true and shall have squareness of pipe ends as
specified in IS : 14402 and ASTM D 3262.
The GRP pipes and joints shall be systematically checked for any manufacturing
defects by experienced supervisors so as to maintain a high standard of quality.
Each pipe should have permanent ISI mark.
Owner/Engineer shall at all reasonable times have free access to the place where
the pipes and joints are manufactured for the purpose of examining and testing
the pipes and joints and of witnessing the test and manufacturing.
All tests specified either in this specification or in the relevant clauses of Indian
Standards or International Standards shall be performed by Supplier/ Contractor
at his own cost and in presence of Owner / Engineer if desired. For this,
sufficient notice before testing of the pipes shall be given to Owner/ Engineer.
If the test is found unsatisfactory, Owner/Engineer may reject any or all pipes of
that lot. The decision of Owner/Engineer shall be final and binding on Contractor
and not subject to any arbitration or appeal.
(b)
Dimensions
Pipes shall be designated by nominal standard diameters. The nominal
diameters, minimum wall thickness, length of barrel, joints etc. shall be within
the tolerance limits specified in IS: 14402, ASTM D 3262 and ASTM D 3517.
The relevant requirements are specified in Data Sheet A.
(c)
(b)
Beam Strength
The pipe shall meet or exceed the minimum longitudinal tensile / compressive
strength as per relevant clauses of IS: 14402, ASTM D 4262 and ASTM D 3517.
(c)
Soundness
(N)
Upto 50
51 to 100
13
Each pipe shall be checked for dimensions, soundness, workmanship finish and
deviation from straight.
The lot shall be declared as conforming to the requirements of this specification, if
the sample pipes taken from the lot meets the requirements of all the tests, otherwise no t.
Testing
GRP pipes manufactured by the above process shall be subjected to the following tests.
(a)
After selecting pipe specimens randomly from the lot as per clause no. 1.7 above
they shall be tested at factory for following tests.
(b)
Critical dimensions
All pipes will be measured for compliance with critical dimensions as specified
in relevant clauses of IS : 14407, ASTM D 3262 and ASTM D 3517 after
allowing for the specified tolerances. The dimensions shall include diameter,
wall thickness, sqareness and length. Pipes not in compliance will be rejected.
(c)
Visual Acceptance
Generally the pipe shall be free from all defects, including de-laminations,
bubbles, pinholes, cracks, pits, blisters, foreign inclusions and resin-starved areas
that due to their nature, degree or extent, detrimentally affect the strength and
serviceability of the pipe.
The pipe shall be as uniform as commercially
practicable in colour, capacity, density and other physical properties.
(d)
(e)
(f)
3517. The sample size shall be selected as per clause 1.7 above. If may sample
should fail to meet the requisite value specified in the IS/ASTM codes, five (5)
further samples should betaken and tested.
If the results comply with
requirement, all pipes will then be acceptable. However, if these five samples
fail then all pipes from that lot will be rejected unless individually proven
acceptable.
(g)
(h)
(i)
D.6.1.8
Marking
Both ends of each length of pipe and fitting shall be marked at least in letters not less
than 12 mm in height and of bold type style in a colour and type that remains legible
under normal handling and installation procedures. The marking shall include the
following :
(a)
Internal diameter
(b)
(c)
(d)
(e)
Handling
The manufacturer / Supplier (M/S) shall be responsible for safe delivery of pipes and
fittings as per order place and as per the schedule. If the contractor for works is other
than manufacturer / supplier, then M/s shall submit a complete manual of instruction/
guide./ procedure for handling of pipe before installation. Broadly following
instructions/ procedures shall be followed.
D.6.1.10
Fire Safety
GRP pipes manufactured using petrochemicals and are inflammable.
Hence
manufacturer/supplier/contractor (m/s/c) shall take utmost precaution while handling,
transporting, storing, loading/unloading, installing, and testing, etc. at all stages,
against fire hazard. Care must be taken to avoid exposure of the pipe to welders
sparks, cutting-torch flames or other heat / flame / electrical sources which could
ignite the pipe material.
D.6.1.11
Transportation
All pipe sections shall be supported on flat timbers spaced on a maximum of 4 mete
rs centres with a maximum overhand of 2 metres in trucks. No pipes shall be in
contact with other pipes while transportation.
Maximum stack height will be approximately 2 meters. Pipes shall be strapped to the
vehicle over the support points using pliable straps or ropes, Steel cables or chains
shall not be allowed for strapping without adequate padding, stacking pipes shall
limit the deflection as follows:
3.0% o9f diameter for stiffness class SN 1250.
2.5% of diameter for stiffness class SN 2500
2.0% of diameter for stiffness class SN 5000
1.5% of diameter for stiffness class SN 10000
D.6.1.12
Storing
Pipes may be stored on ground or on flat timbers. When storing on ground the
ground shall be flattened and made free of potential damaging debris. All pipes shall
be choked to prevent rolling.
If it is necessary to stack pipes, flat timber supports at maximum 6 metre spacing
with chocks shall be used. If it is available, the original shipping dunnage shall be
used. The stacks shall be stable against wind or other horizontal forces. Maximum
stack height allowable shall be approximately 2 metres. Pipes larger than 1400 mm
diameter shall not be stacked. The permissible deflection shall be as per clause 1.15.
Rubber ring gasket shall be shipped separately from the couplings and shall be stored
in the shade in their original packaging and shall not be exposed to sunlight except
during utilisation. The gaskets shall also be protected from exposure to greases and
oils which are petroleum derivatives and from
solvents and other deleterious
substances.
Gasket lubricant shall be carefully stored to prevent damage to the container.
Partially used buckets shall be prevented from contamination of the lubricant.
D.6.1.13
D.6.1.14
Jointing Pipes
Pipe sections shall be jointed utilising double bell couplings and shall be assembled
as indicated in the following paragraphs and as per the relevant clauses of ASTM D
3517, STM D 4161. The gasket used for jointing purpose shall be as per ASTM F
447, specification for Elastomeric Seals (gasket) for joining plastic pipes.
(a) Clean Coupling
Double bell coupling grooves and rubber gasket ring shall be thoroughly cleaned
to make sure no dirt or oil is present.
(b) Install Gaskets
The gasket shall be inserted into the grooves, leaving two to four uniform loops
of rubber extending out of the groove. There should be a minimum of one loop
for each 450 mm of gasket ring circumference.
(c) Lubricate Gaskets
Uniform pressure shall be applied to push each loop of the rubber gasket into the
gasket groove. Then using a clean cloth, a thin film of lubricant shall be applied
to the rubber gasket. Normal amount of lubricant consumed per joint shall be as
follows :
0.1 Kg
0.15 Kg
0.20 Kg
0.25 Kg
0.30 Kg
0.35 Kg
Nom.
Angular
deflection
(Degrees)
3.0
2.5
2.0
1.5
1.25
1.00
Nom. Radius of
Curvature (m)
Section Length
3m
6m
12 m
57
115
229
69
137
275
86
172
344
115
229
458
138
275
550
172
344
688
D.6.1.15
it shall be assured that the coupling area is properly bedded and backfilled after
the joint assembly is completed.
(b) Backfilling Pipe
Backfilling shall be done immediately after joining pipes. Proper selection,
placement and compaction of pipe zone backfill shall be ensured to control the
vertical deflection. Installed pipes shall have initial deflection less than the
values to be given by the tenderer depending on the type of soil to encountered
with, the pipes shall have no bulges, flat areas, or other abrupt changes of
curvature.
(c) Pipe Zone Backfill
Pipe zone for backfilling shall be defined as the zone from the bed upto 300 mm
above the pipe crown.
Most coarse grained soils are acceptable. This shall be composed of gravel or
clean sand. However, silty sand, clayey sand, silty gravel and clayey gravel shall
not be used unless proposed to be used in conjunction with gravel or clean sand.
The selection of backfill material would require the approval of the Engineer
-in- charge.
Compatibility of the backfill material and the native soil shall be checked. Sieve
analysis shall be carried out at selected sections to ensure that between two
adjacent soils D85 finer is grater than 0.2 D15 coarser where D85 percentile size
of finer soil and D15 is the 15 percentile size of coarser soil.
Where native soil is shown in the pipe zone the soil shall be granular, free of
debris and organic materials and rocks and soil clumps grater than 2 times the
maximum gravel size.
Maximum size of grain for the backfill material shall be :
Upto 1600 mm dia.
19 mm
For 1800 mm to 2400 mm dia. 25 mm
Backfill shall not be onto the pipe from the top of the trench. During backfilling,
it shall be made certain that the granular material flows completely under the
pipe to provide full support. A board or other blunt toll may be used to push and
compact the backfill under the pipe. Proper completion of this step is a very
important phase of backfilling the pipe.
Proper backfilling shall be done in 150 mm to 300 mm lifts, depending on
backfill material and compaction method. Between each lift. The proper
compaction shall be attained to ensure that the pipe will have adequate side
support. Compaction of sandy (Vs. Gravel) backfill is accomplished most easily
when the material is at or near its optimum moisture content. When backfilling
reaches pipe spring line (half of diameter), all compaction shall be done first near
the trench sides and proceed towards the centre.
Alternate Installations
When the combination of pipe stiffness, cover depth, and native soil characteristics
places the installation required in the alternate category, following options are
available.
1) Use a higher stiffness pipe to permit a standard installation.
2) Increase the trench width
The specific requirement for standard and alternate installation are given in
Data
Sheet A.
D.6.1.17
D.6.1.18
Flooded Trench
When the ground water table is above the trench bottom, the water level shall be
lowered to at least the trench bottom (preferably about 200 mm below) prior to
preparation of the pipe bed. If the water level can not be maintained below the top of
the bedding, special installation methods shall be adopted at no extra cost to achieve
proper pipe support. Specification of an appropriate procedure shall require the
approval of Engineer-in-charge. If the pipe is empty in a flooded trench, a minimum
cover of one pipe diameter of dense soil (1,900 kg/cu.m. or more) will be normally
sufficient to prevent pipe flotation.
D.6.1.19
D.6.1.20
Avoid pumping long distances through the backfill materials or native soils,
which could cause loss of support to previously installed pipes due to removal of
material or migration of soil.
Do not turn off the dewatering system until sufficient cover depth has been
reached to prevent pipe flotation.
1
Hard & Very
Stiff
Very Dense
& Dense
30
3.0
2
Stiff
3
Medium
4
Soft
Medium
Loose
Very Loose
16-30
3.0
6-15
2.5
3-5
2.0
Checking to insure that the above initial requirements MUST be done for each pipe
immediately after completion of installation (typical within 24 hours after reaching
maximum cover).
While initial deflection in Table above area acceptable for pipe performance, a value
more than 2% indicates the installation intended has not been achieved and shall be
improved for future pipes (i.e. increased pipe zone backfill compaction, coarser
grained pipe zone backfill materials, or wider trench etc.
Following procedure shall be adopted for checking the initial diametrical deflection
for installed pipes :
Complete backfilling shall be done to require grade.
The temporary sheeting (if used) shall be completely
removed.
x 100
Actual
D.6.1.21
I. D.
Vertical I. D. + Horizontal I. D.
2
OR
I. D. (1) + I. D. (2)
2
Re-backfill the pipe zone in lifts with the appropriate material, compacting each
layer ad required by the cover depth to limit the pipe deflection.
Backfill to grade and check the pipe deflections to verify they have not
exceeded the values in Clause 8.1.
(b) For Pipe Deflected Greater than 8% Pipe Diameter
Pipes over 8% deflections shall be replaced completely.
No attempt to jack or wedge the installed over-deflected pipe into a round
condition shall be made to avoid damage to the pipe.
D.6.1.22
D.6.1.23
Concrete Encasement
When encasement of pipes in concrete has been specified to carry unusual loads,
specific limitations in the installation procedures shall be observed.The concrete
surround must be placed stages allowing sufficient time layers for the cement to set
(no longer exert buoyant forces). Maximum lift height is variable with nominal pipe
stiffness as shown below :
D.6.1.24
SN 5000
SN 10000
Measurement
All GRP pipes shall be measured according to the work actually done and no
allowance will be made for any waste in cutting to the exact length required. The
measurement for pipes shall be in running meters nearest to a centimeter of length
along the centre line of pipe as actually laid at work site.
The rate for providing, lowering, laying and jointing of GRP pipes and fittings shall
be deemed to include cost of joining material such as couplings, gaskets, lubricants,
equipment and tools for making joints, testing as specified and as directed and the
extra excavation required for bedding of pipes and fittings / couplings etc.
DATA SHEET A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
:
:
:
:
:
:
PN 6 Bar
6 kPa = 61.2 m wc
12 kPa = 122.4 m wc
As per Clause 1.24
12.0 m
Stiffness Class
stiffness
KPA.
248
12
30 mm
(8) Joints
The GRP pipes shall be joined by utilizing Double Bell Couplings.
In special cases as per the manufacturer / suppliers instructions the following
types of joints may be allowed by Owner / Engineer.
a)
Flexible steel coupling with anyone of
i)
Epoxy or PVC coated steel mantle
ii)
Stainless steel mantle, or
iii)
b)
c)
(9) Width of trench (Bt) from the invert level of pipe upto ground level above the top
of pipe. Width of trench shall be as per drawing given in tender document.
(11)Bedding and backfilling for pipes: As per Clause 1.16.
D.6.5
D.6.5.1 It will be necessary to give connections of the new 2000 mm dia. GRP pipes with
Existing manhole near Ambedkar Bridge East side near pumping station.The connection will
be made with all jointing materials etc. complete. The payment will be made on item
completed as stated above.
Trenches shall be kept free from water until the pipes are installed and the joints
have hardened.
2904. BEDDING FOR PIPE
The bedding surface shall provide a firm foundation of uniform density throughout the
length of the pipe, shall conform to the specified levels and grade, and shall be as specified
here:
First Class bedding: Under first class bedding, the pipe shall be evenly bedded on a continuous
layer of well compacted approved granular material, shaped concentrically to fit the lower part
of the pipe exterior for atleast ten per cent of its overall height or as otherwise shown on th e
drawings. The bedding material shall be well graded sand or another granular material passing
5.6 mm sieve suitably compacted/rammed. The compacted thickness of the bedding layer
shall be as shown on the drawings and in no case shall it be less than 75 mm.
2905. LAYING OF PIPE
No pipe shall be laid in position until the foundation has been approved by the Engineer.
Where two or more pipes are to be laid adjacent to each other, they shall be separated by a
distance equal to at least half the diameter of the pipe subject to a minimum of 450 mm.
The arrangement for lifting, loading and unloading concrete pipes from factory/yard and
at site shall be such that the pipes do not suffer any undue structural strain, any damage due to
fall or impact. The arrangement may be got approved by the Engineer.
Similarly, the arrangement for lowering the pipe in the bed shall be got approved by the
Engineer. It may be with tripod-pulley arrangement or simply by manual labour in a manner
that the pipe is placed in the proper position without damage.
The laying of pipes on the prepared foundation shall start from the outlet and proceed
towards the inlet and be completed to the specified lines and grades. In case of use of pipes
with bell-mouth, the belled end shall face upstream. The pipes shall be fitted and matched so
that when laid in work, they form a uniform gradient with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed at the cost of the
Contractor.
2906. JOINTING
The pipes shall be jointed either by collar joint or socket spigot joint. In the former
case, the collars shall conform to IS 14402-1966 and having the same strength as the pipes to be
jointed. Jointing and Gluing space shall conform to various standards laid in Indian standard as
well as British standards according to the diameter of the pipe
For jointing pipe lines under light hydraulic pressure, the recess at the end of the pipe
shall be filled with suitable approved compound. Pipes shall be so jointed that the ring of one
pipe shall set into the recess of the next pipe.The ring shall be thoroughly compressed by
jacking or by any other suitable method.
All joints shall be made with care so that their interior surface is smooth and consistent
with the interior surface of the pipes. After finishing, the joint shall be kept covered and damp
for at least four days.
2907. BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid and the jointing
material has set. The backfill soil shall be clean, free from boulders, large roots, excessive
amounts of sods or other vegetable matter, and lumps and shall be approved by the Engineer.
Backfilling up to 300 mm above the top of the pipe shall be carefully done with approved graded
gravelly material and the soil thoroughly rammed, tamped or vibrated in layers not exceeding
300 mm, particular care being taken to thoroughly consolidate the materials under the haunches
of the pipe. Approved pneumatic or light mechanical tamping equipment can be used.
Filling of the trench shall be carried out simultaneously on both sides of the pipe in
such a manner that unequal pressures do not occur.
In case of high embankment, after filling the trench up to the top of the pipe in the
above said manner, a loose fill of a depth equal to external diameter of the pipe shall be placed
over the pipe before further layers are added and compacted.
2908. MANHOLES AND OTHER ANCILLARY WORKS
Manholes and other ancillary works shall be constructed in accordance with the
details shown on the drawings or as directed by the Engineer.
2909. OPENING TO TRAFFIC
No traffic shall be permitted to cross the pipe line unless height of filling above the top
of the pipe line is at least 1200 mm.
2910. MEASUREMENTS FOR PAYMENT
Glass Fiber Reinforced Plastics (GRP) pipes shall be measured along their
centre between the inlet and outlet ends in linear meters.
Selected granular material for pipe bedding shall be measured as laid in cubic meters.
Ancillary works like Construction of manholes etc., shall be measured as provided for under
the respective Sections.
2911. RATE
The Contract unit rate for the installing Glass Fiber Reinforced Plastics (GRP) pipes
shall include the cost of pipes including loading, unloading, hauling, handling, storing, laying in
position and jointing complete and all incidental costs to complete the work as per these
Specifications.
Ancillary works such as excavation including dewatering & backfilling, concrete
and masonry shall be paid for separately, as provided under the respective Clauses.
304.3.5. Slips and slip-outs: If there are any slips or slip-outs in the excavation,
these shall be removed by the Contractor at his own cost.
304.3.6. Public safety: Near towns, villages and all frequented places, trenches
and foundation pits shall be securely fenced, provided with proper caution signs and
marked with red lights at night to avoid accidents. The Contractor shall take adequate
protective measures to see that the excavation operations do not affect or damage
adjoining structures. For safety precautions, guidance may be taken from IS : 3764.
304.3.7.
Backfilling: Backfilling shall be done with approved material after
concrete or masonry is fully set and carried out in such a way as not to cause undue thrust
on any part of the structure. All space between foundation masonry or concrete and the
sides of excavation shall be refilled to the original surface in layers not exceeding 150
mm compacted thickness. The compaction shall be done with the help of suitable
equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary
watering, so as to achieve a density not less than the field density before excavation.
304.3.8. Disposal of surplus excavated materials: Clause 301.3.11 shall apply.
304.4.Measurements for Payment
Excavation for laying of pipes and manhole shall be measured in cu. m. for each
class of material encountered, limited to the dimensions shown on the drawings or as
directed by the Engineer, Excavation over increased width, cutting of slopes, shoring,
shuttering and planking shall be deemed as convenience for the Contractor in executing
the work and shall not be measured and paid for separately.
Foundation sealing, dewatering, including pumping is included in the above rates
and will not be paid separately.
304.5 Rates
304.5.1. The Contract unit rate for the items of excavation for structures shall be
payment in full for carrying out the required operations including full compensation for :
(i)
setting out;
(ii)
(iii)
removal of all logs, stumps, grubs and other deleterious matter and
obstructions, for placing the foundations including trimming of bottoms of
excavations;
(iv)
(v)
backfilling, clearing up the site and disposal of all surplus material within
all lifts and leads up to 2000 m or as otherwise specified; and
(vi)
304.5.2. Deleted.
The Contract unit rate for transporting material from the excavation for
structures shall be full compensation for all labour, equipment,
tools, and
incidentals necessary on account of the additional haul or
transportation involved beyond the initial lead of 2000 m.
1101. DESCRIPTION
1101.1. This work shall consist of construction of all types of piles for structures
in accordance with the details shown on the drawings and conforming to the
requirements of these specifications.
1101.2. The construction of pile foundations requires a careful choice of the piling
system depending upon subsoil conditions and loading characteristics and type of
structure. The permissible limits of total and differential settlements, unsupported length
of pile under scour, impact/entanglement of floating bodies and any other special
requirements of project are also equally important criteria for selection of the piling
system. The method of installing the piles, including details of the equipment shall be
submitted by the Contractor and got approved from the Engineer.
1101.3. The work shall be done as per IS : 2911 except as modified herein.
1102. SUBSURFACE INVESTIGATION
1102.1. The complete subsurface investigation of strata in which pile
foundations are proposed shall be carried out in advance and by insitu pile tests. For
details of geotechnical subsurface explorations reference may be made to Section 2400.
At least one borehole for every foundation of the bridge shall be executed. Borings
should be carried upto sufficient depths so as to ascertain the nature of strata around the
pile shaft and below the pile tip. However, depth of boring shall not be less than:
1) 1.5 times estimated length of pile in soil but not less than 15 m beyond the
probable length of pile
2) 15 times diameter of pile in weak/jointed rock but minimum 15 m in such
rock
3) 4 times diameter of pile in sound, hard rock but minimum 3 m in such rock
1102.2. The subsurface investigation shall define adequately stratification of
sub-strata including the nature and type of strata, its variation and extent and specific
properties of the same. The investigation shall be adequate for the purpose of selection of
appropriate piling system and for estimating design capacities for different diameters and
length of piles.
1102.3. Pressure meter tests may be used in the case of rock, gravel or soil for
direct evaluation of strength and compressibility characteristics. Though these tests are of
specialised nature they are most appropriate for difficult/uncertain substrata especially
for important projects.
1102.4. For piles socketed into rocks, it is necessary to determine the uniaxial
compressive strength of the rock and its quality.
The investigation shall also include location of ground water table and other
parameters including results of chemical tests showing sulphate and chloride content and
any other deleterious chemical content in soil and/or ground water, likely to affect
durability.
1103. TYPE OF PILES
The piles may be of reinforced concrete, prestressed concrete, steel or timber. The
piles may be of solid or hollow sections or steel cased piles filled with concrete. Co
ncrete piles may be driven cast-in-situ or precast or bored cast-in-situ or precast piles
driven into performed bores. The shape of piles may be circular, square, hexagonal,
octagonal, H or I Section.
1104. MATERIALS
1104.1. The basic materials shall conform to the specifications for materials given
in Section 1000. The specifications for steel reinforcement, structural concrete,
prestressed concrete and structural steel to be used in pile foundations shall be as given in
the relevant sections.
1104.2. Concrete in Piles
Grade of concrete to be used in cast-in-situ piles shall not be less than M 20 and
the cement content shall not be less than 400 kg per cubic meter of concrete. Grades of
concrete for precast reinforced and prestressed concrete piles shall not be less than M 25
and M 35 respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ piles
and 0.45 for precast piles.
The minimum slump of concrete for driven cast-in-situ piles shall be 100 mm to
150 mm to 200 mm and that of bored cast-in-situ piles 150 mm to 200 mm. The slump
should not exceed 200 mm in any case.
Concrete mix should have homogeneous mixture with required workability for the
system of piling adopted. Suitable and approved admixtures may be used in concrete mix
where necessary.
Where piles are exposed to action of harmful chemicals or severe conditions of
exposure due to presence of sulphate, chloride etc. it may be preferable to opt for higher
grades of concrete restricting water cement ratio to 0.45. Special types of cement, such as
sulphate resistant cement may be used where considered appropriate.
such that the older piles can be withdrawn without disturbing newer
piles. Separate stacks shall be provided for different lengths of piles.
Where piles are stacked in layers, the number of layers shall not exceed
three. Whenever curing is needed during storage, arrangements shall be
made to enable the piles to be watered. For detailed precautions with
regard to curing operations specifications for structural concrete given in
Section 1700 shall apply.
Before the operation of handling and driving the piles, the minimum periods
counted from the time of casting shall be allowed for as indicated in Table 1100-1.
Prestressed piles shall not be lifted or handled until fully stressed.
TABLE 1100-1 TIME FOR CURING PRECAST PILES
Type of cement Minimum periods from time of casting
used in casting
Strike side
End of wet
Lift from
the pile
shutters
curing (days)
casting bed
(hours)
(days)
Ordinary Portland
24
7
10
Rapid hardening
Portland
12
Drive (days)
28
10
displacing the material laterally. The two types of piles are termed as bored piles and
driven piles respectively. Cast-in-situ concrete piles may be cast in metal shells which
may remain permanently in place. However, other types of cast-in-situ concrete piles,
plain or reinforced, cased or uncased, may be used if in the opinion of the Engineer the
soil conditions permit their use and if their design and the methods of placing are
satisfactory.
The metal casing shall be of sufficient thickness and strength to hold its original
form and show no harmful distortion after it and adjacent casings have been driven and
the driving core, if any, has been withdrawn.
Cast-in-situ concrete driven piles shall be installed using a properly designed
detachable shoe at the bottom of the casing. Certain specific requirements of cast-in-situ
driven piles shall be as per Clauses 1110 and 1111.
Any liner or bore-hole which is improperly located or shows partial collapse that
would affect the load carrying capacity of the pile, shall be rejected or repaired as
directed by the Engineer at the cost of the Contractor.
Wherever practicable, concrete should be placed in a clean dry hole. Where
concrete is placed in dry and there is casing present, the top 3 m of the pile shall be
compacted using internal vibrators. The concrete should invariably be poured through a
tremie with a funnel so that the flow is directed and concrete can be deposited in the hole
without segregation.
Where the casing is withdrawn from cohesive soils for the formation of cast-insitu pile, the concreting should be done with necessary precautions to minimise the
softening of the soil by excess water. Where mud flow conditions exist, the casing of
cast-in-situ piles shall not be allowed to be withdrawn.
Care shall be taken during concreting to prevent as far as possible the segregation
of the ingredients. The displacement or distortion of reinforcement during concreting and
also while extracting the tube shall be avoided.
If the concrete is placed inside precast concrete tubes or consists of precast
sections, these shall be free from cracks or other damage before being installed.
The concrete shall be properly graded, shall be self-compacting and shall not get
mixed with soil, excess water, or other extraneous matter. Special care shall be taken in
silty clays and other soils with the tendency to squeeze into the newly deposited concrete
and cause necking. Sufficient head of green concrete shall be maintained to prevent
inflow of soil or water into the concrete.
The placing of concrete shall be a continuous process from the toe level to the top
of the pile. To prevent segregation, a tube or tremie pipe as appropriate shall be used to
place concrete in all piles.
General requirements and precautions for concrete under water are as follows:
(a)
(b)
The concrete should be coherent, rich in cement with high slump and
restricted water cement ratio.
(c)
The tremie pipe will have to be large enough with due regard to the size of
aggregate. For 20 mm aggregate the tremie pipe should be of diameter not
less than 150 mm and for large aggregate, larger diameter tremie pipes
may be necessary.
(d)
The first charge of concrete should be placed with a sliding plug pushed
down the tube ahead of it to prevent mixing of water and concrete.
(e)
The tremie pipe should always penetrate well into the concrete with an
adequate margin of safety against accidental withdrawal if the pipe is
surged to discharge the concrete.
(f)
(g)
The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150
mm. Any defective concrete at the head of the completed pile shall be cut away and made
good with new concrete. The clear cover between the bottom reinforcement in pile cap
from the top of the pile shall be not less than 25 mm. The reinforcement in the pile shall
be exposed for full anchorage length to permit it to be adequately bonded into the pile
cap. Exposing such length shall be done carefully to avoid damaging the rest of the pile.
In cases where the pipe cap is to be laid on ground, a leveling course of M 15 nominal
mix concrete 100 mm thick shall be provided. Defective piles shall be removed or left in
place as judged convenient without affecting the performance of adjacent piles or pile
cap. Additional piles shall be provided to replace the defective piles.
Additional intermediate steel straps shall be placed at not more than 3 metres centre
measured along the length of the pile.
Timber piles which are to be capped shall be separately cut off so that true
bearing is obtained on every pile. Piles inaccurately cut off shall be replaced. Splicing of
timber piles shall not be permitted except by written permission of the Engineer.
1110.Driving Equipment
Piles or their casings may be driven with any type of drop hammer, diesel
hammer or single-acting steam or compressed air hammer, provided they penetrate to the
prescribed depth or attain the designed resistance without being damaged. The weight or
power of the hammer should be sufficient to ensure a penetration of at least 5 mm per
blow, unless rock has been reached. It is always preferable to employ the heaviest
hammer practicable and to limit the stroke, so as not to damage the pile. The minimum
weight of the hammer shall be 2.5t. In the case of precast concrete piles the mass of the
hammer shall be not less than 30 times the mass of 300 mm length of pile.
Stream or air hammers shall be furnished along with boiler or air compressor of
capacity at least equal to that specified by the manufacturer of the hammers. The boiler
or air compressor shall be equipped with an accurate pressure gauge at all times. The
valve mechanism and other parts of steam, air or diesel hammers shall be maintained in
first class condition so that the length of stroke and number of blows per minute for
which the hammer is designed, will be obtained. Inefficient steam, air or diesel hammers
shall be removed from the work.
1111. DRIVING
1111.1. General Procedure
Details of the equipment and the method proposed for driving the piles shall be
submitted with the tender for scrutiny and approval of the Engineer. Piles shall be
installed from firm ground or from temporary supports or from fixed platform. The
arrangement shall provide sufficient rigidity to ensure accuracy of pile driving under all
conditions of tide, stream flow or hammer drop.
During driving the top of pile shall be protected by a suitable helmet of substantial
steel construction. The helmet shall provide uniform bearing across the top of the pile and
shall hold the pile centrally under the hammer. No pile shall be driven unless inspected
and approved by the Engineer.
Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of
driving within specified tolerances. Forces producing undue bending or torsional stresses
in piles shall not be applied during driving. The force of the hammer shall be directed
centrally and axially during driving.
The stroke of a single acting or drop hammer shall be limited to 1.2 m unless
otherwise permitted by the Engineer. A shorter stroke may be necessary when is danger
of damaging the pile.
Piles shall not be bent or sprung into position but shall be effectively guided and
held on-line during the initial stages of driving. Attempts to correct any tendency for the
pile to run off-line by the application of significant horizontal restraint will not be
permitted. Shortly after the commencement of driving and at regular intervals throughout
the driving operation, checks shall be made to ensure that the pile frame does not exert
any undue lateral force on the pile due to restraint within the helmet.
If the indications are that a pile will finish outside the specified tolerances, driving
operations on that pile will cease. The pile shall be withdrawn, the hole filled and the pile
re-driven at no extra cost.
To avoid the possibility of premature set-up pile driving shall be continuous in
the later stages, without any deliberate stops. (Delays of an hour or less may lead to
significant set-up in piles i.e. resistance to further driving increases after driving is
stopped).
If any pile is damaged in any way during driving, it shall be repaired or replaced
as directed by the Engineer, at no extra cost. If during driving, the head of a pile is
damaged to the extent that further driving is not possible, the head shall be cut off and
driving continued. The cost of cutting off shall be borne by the Contractor and where, as
a result of such cutting off the head, the pile is too short, the Contractor, shall, at his own
cost, supply and splice on sufficient length of pile to restore the pile to its correct length.
Piles should be driven to the minimum acceptable penetration shown on the
drawings. This may require preboring and/or jetting as indicated in these specifications
with the full approval of the Engineer.
Piles shall be driven to nominal refusal or the required ultimate dynamic capacity
nominated on the drawings or until the top of the pile is at the level required and
specified on the drawing whichever gives the lowest toe elevation. The Engineers
decision in these matters shall be final. Nominal refusal shall be taken as equivalent to 25
mm total penetration for the final 20 blows using a hammer of driving energy as specified
and shall be used as the criterion for acceptance for piles founded on rock. Severe driving
which results in an average set per blow less than 0.5 mm will not be permitted.
Where hard drilling is encountered because of dense strata or obstructions located
above the predetermined pile tip level, nominal refusal shall not be considered to have
been achieved unless the Engineer is satisfied that the total number of blows, as the
average driving resistance specified for nominal refusal, indicates that further driving will
not advance the pile through dense strata or obstructions.
The maximum depth of the preboring shall be such that the specified set (or less)
is obtained when the toe of the pile is at founding level. Preboring shall be as approved
by the Engineer and shall not extent below one metre above the founding level and the
pile shall be driven to at least one metre below the prebored hole. To ensure that the pile
is properly supported laterally in the hole, any space remaining around the pile at the
ground level after driving is finished shall be backfilled with approved granular material.
When water jetting is used, at least two jets shall be attached to the pile
symmetrically when this type of technique is used. The volume and pressure of water at
the outlet nozzles shall be sufficient to freely erode material adjacent to the toe of the
pile. The maximum depth of jetting shall be such that the specified set (or less) is
obtained when the toe of the pile is at founding level. Jetting shall cease as directed by
the Engineer and shall not proceed below one metre above the founding level and the pile
shall be driven at least one metre below the pre-bored hole.
To avoid very hard driving and vibration in materials such as sand, jetting of piles
by means of water may be carried out only by express permission of the Engineer and in
such a manner as not to impair the bearing capacity of the piles already in place, the
stability of the soil or the safety of any adjoining buildings. Details of the arrangement
for jetting shall be got approved from the Engineer in advance.
If, for jetting, large quantities of water are used, it may be necessary to make
provision for collection of water when it comes to the ground surface, so that the stability
of the piling plant is not endangered by the softening of the ground.
Jetting shall be stopped before completing the driving which shall always be
finished by ordinary methods. Jetting shall be stopped if there is any tendency for the pile
tips to be drawn towards the pile already driven owing to the disturbance to the ground.
1112. RAKER (INCLINED) PILES
The maximum rake to be permitted in piles shall not exceed the following:
i)
above ii)
iii)
1113.1. General
The bearing capacity of a single pile may be determined from test loading a pile.
The load test on a concrete pile may not be carried out earlier than 28 days from the time
of casting of the pile.
There shall be two categories of test on piles, namely, initial tests and routine
tests. Initial tests should be carried out on test piles which are not be incorporated in the
work. Routine tests shall be carried out as a check on working piles. The number of initial
and routine tests on piles shall be as determined by the Engineer depending upon the
number of foundations, span length, type of superstructure and uncertainties of founding
strata. In any case, the initial load tests shall not be less than 2 in number, while the
routine load tests shall not be less than 2 percent of the total number of piles in the
structure nor less than 2 in number.
The above stipulations hold good for both vertical as well as lateral load tests on
pile foundations.
However, both initial and routine tests may be suitably increased for important
structures or cases with large variation in the sub-surface strata.
The methodology of carrying out load tests and of arriving at safe load on piles
shall conform to IS : 2911 (Part IV).
In case of any doubt of workmanship or load carrying capacity of working piles
not subjected to routine tests, or when ordered by the Engineer, or when provided in the
contract, load tests on working piles may be supplemented by non-destructive testing.
Such tests may include Integrity Testing of concrete in the installed pile and utilisation
of Pile Driving Analyser which gives an indication of pile capacity in end bearing and
side friction.
1114. PILE CAP
Pile Caps shall be of reinforced concrete. A minimum offset of 150 mm shall be
provided beyond the outer faces of the outer most piles in the group. If the pile cap is in
contact with earth at the bottom, a levelling course of minimum 100 mm thickness of
M 15 nominal mix concrete shall be provided.
The attachment of the pile head to the cap shall be adequate for the transmission
of loads and forces. A portion of pile top may be stripped of concrete and the
reinforcement anchored into the cap. Manual chipping may be permitted after three days
of pile casting, while pneumatic tools for chipping shall not be used before seven days
after pile casting. The top of pile after stripping shall project at least 150 mm into the pile
cap. A layer of surface reinforcement may be provided with a cover of 25 mm to retain
the integrity of concrete below the main cap reinforcement which is to be laid 25 mm
above the pile top.
Concreting of the pile cap shall be carried out in dry conditions. The bottom of
the pile cap shall be laid preferably as low as possible taking account of the water level
prevalent at the time of casting.
The top of concrete in a pile shall be brought above cut-off level to permit
removal of all laitance and weak concrete before pile cap is laid. This will ensure good
concrete at the cut-off level.
1115.
ii)
iii)
iv)
v)
The liquid limit of bentonite not less than 400 per cent
(ii)
The tremie shall be water-tight throughout its length and have a hopper
attached at its head by a water-tight connection.
(iii)
The tremie pipe shall be large enough in relation to the size of aggregates.
For 20 mm aggregate the tremie pipe shall be of diameter not less than
150 mm and for larger size aggregate tremie pipe of larger diameter is
required.
(iv)
The tremie pipe shall be lowered to the bottom of the bore-hole, allowing
water or drilling mud to rise inside it before pouring concrete.
(v)
The tremie pipe shall always be kept full of concrete and shall penetrate
well into the concrete in the bore-hole with adequate margin of safety
against accidental withdrawal if the pipe is surged to discharge the
concrete.
1115.2.6. For very long or large diameter piles, use of retarding plasticiser in
concrete is desirable.
1115.2.7. For large diameter piles, it may be essential to conduct non-destructive
pile integrity tests to evaluate integrity of the pile.
1115.2.8.Where possible, it may be desirable to grout the base of pile with cement
slurry under suitable pressure after concrete in the pile attains the desired strength. For
this purpose, conduit pipes with easily removable plugs at the bottom end should be
placed in the bore alongwith reinforcement cage before concreting.
1116. TOLERANCES
1116.1. Permissible Tolerances for Pile
(i)
(ii)
: 5 mm
: 25 mm
: 5mm
: Pile Length in
mm 1000
Driven Piles
(a)
(b)
(c)
(d)
(iii)
Bored Piles
(a)
(b)
(c)
: + 50 mm, -10 mm
: 1 in 50
: 50 mm
(d)
: 25 mm
Variation in dimensions
Misplacement from specified position in
plan
Surface irregularities measured with 3 m
straight edge
Variation of levels at the top
The materials shall be tested in accordance with these Specifications and shall
meet the prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed
standards of acceptance.
1118.
For supply of precast concrete, timber or steel piles of specified cross-section, the
measurement shall be in metres of the length of piles ordered in writing by the Engineer
measured from the head to the butt of the shoe or the tapered point. Reinforcement in
precast concrete piles shall not be measured for payment.
For cast-in-situ driven and bored concrete piles of specified cross-section, the
measurement shall be the length in metres of the accepted pile that remains in the
finished structure complete in place. Reinforcement in cast-in-situ driven and bored
concrete piles shall be measured for payment as per Section 1600.
Routine and Initial Pile Load Tests shall not be measured for payment.
For installation of the pile, i.e. by driving in the case of precast concrete, timber,
steel and cast-in-situ driven piles, and by boring in the case of cast-in-situ bored piles the
measurement shall be the length in metres that remains in the finished structure complete
in place, limited to that shown on drawings or ordered by the Engineer. No distinction
shall be made for penetration through hard strata or rock and socketing into rock.
For steel liners/casing shown on the drawings to be permanently left in place, the
measurement shall be by weight in tonnes that remains in the finished structure complete
in place, limited to that shown on drawings or ordered by the Engineer.
For the pile cap, the quality of concrete shall be measured in cubic metres as per
Section 1700. While reinforcement in pile cap shall be measured in tonnes as per Section
1600.
1119. RATE
The contract unit for supplying precast concrete, timber or steel piles shall inclu
de cost of all labour, materials, tools and equipment, and other work involved in making
or fabricating the pile complete as shown on the drawing, and where required its
loading, transport, delivery to site unloading and stacking it at the place indicated by the
Engineer. The cost of reinforcement as per Section 1600 in precast concrete piles shall
be deemed to be included in the quoted rate for supply of piles.
The contract unit rate for cast-in-situ driven and bored piles shall include the cost
of concrete and all other items as per Section 1700. The contract unit shall also include
costs of all labour, materials, equipments and all other incidentals involved in conducting
routine and initial pile load tests including installation of piles for initial loa d tests.
The contract unit rate for reinforcement in cast-in-situ driven and bored piles shall
be as per Section 1600.
The contract unit for installation of piles shall include full compensation for
furnishing all labour, materials, tools and equipment, and incidentals for doing all the
works involved in driving timber, precast concrete and steel piles, driving or making
bores for cast-in-situ driven and bored concrete piles, cutting off pile heads, all complete
in place to the specified penetration of piles. Providing temporary liner/casing and its
withdrawal and placing reinforcement in position shall also be deemed to be included in
the rate for installation of piles and no additional payment shall be made for the same.
The contract unit rate for permanent steel liners shall include cost of all labour,
fabrication and placing the steel liner to the required depth as shown on the drawings and
as ordered by the Engineer.
The contract unit rate for concrete in pile cap shall cover all costs of labour, materials,
tools, plant and equipment, formwork and staging including placing in position,
sampling and testing and supervision, all as per Section 1700. Reinforcement in the pile
cap shall
be paid for separately as per Section 1600.
1601. DESCRIPTION
This work shall consist of furnishing and placing coated or uncoated mild steel or
high strength deformed reinforcement bars (untensioned) of the shape and dimensions
shown on the drawings and conforming to these Specifications or as approved by the
Engineer.
1602. GENERAL
Steel for reinforcement shall meet with the requirements of Section 1000.
Reinforcements may be either mild steel/medium tensile steel or high strength
deformed bars. They may be uncoated or coated with epoxy or with approved protective
coatings.
1603. PROTECTION OF REINFORCEMENT
Uncoated reinforcing steel shall be protected from rusting or chloride
contamination. Reinforcements shall be free from rust, mortar, loose mill scale, grease,
oil or paints. This may be ensured either by using reinforcement fresh from the factory or
thoroughly cleaning all reinforcement to remove rust using any suitable method such as
sand blasting, mechanical wire brushing, etc., as directed by the Engineer.
Reinforcements shall be stored on block, racks or platforms and above the ground in a
clean and dry condition and shall be suitably marked to facilitate inspection and
identification.
Portions of uncoated reinforcing steel and dowels projecting from concrete, shall
be protected within one week after initial placing of concrete with a brush coat of neat
cement mixed with water to a consistency of thick paint. This coating shall be removed
by lightly tapping with a hammer or other tool not more than one week before placing of
the adjacent pour of concrete. Coated reinforcing steel shall be protected against damage
to the coating. If the coating on the bars is damaged during transportation or handling and
cannot be repaired, the same shall be rejected.
1604. BENDING OF REINFORCEMENT
Bar bending schedule shall be furnished by the Contractor and got approved by
the Engineer before start of work.
Reinforcing steel shall conform to the dimensions and shapes given in the
approved Bar Bending Schedules.
Bars shall be bent cold to the specified shape and dimensions or as directed b y
the Engineer using a proper bar bender, operated by hand or power to obtain the correct
radii of bends and shape.
Bars shall not be bent or straightened in a manner that will damage the parent
material or the coating.
Bars bent during transport or handling shall be straightened before being used on
work and shall not be heated to facilitate straightening.
1605. PLACING OF REINFORCEMENT
a)
b)
c)
methods:
(i)
In case of beam and slab construction, industrially produced polymer
cover blocks of thickness equal to the specified cover shall be placed between the
bars and formwork subject to satisfactory evidence that the polymer composition
is not harmful to concrete and reinforcement. Cover blocks made of concrete may
be permitted by the Engineer, provided they have the same strength and
specification as those of the member.
(ii)
In case of dowels for columns and walls, the vertical reinforcement shall
be kept in position by means of timber templates with slots cut in them
accurately, or with cover blocks tied to the reinforcement. Timber templates shall
be removed after the concreting has progressed upto a level just below their
location.
(iii)
d)
(iv)
(v)
Bars coated with epoxy or any other approved protective coating shall be
placed on supports that do not damage the coating. Supports shall be
installed in a manner such that planes of weakness are not created in
hardened concrete. The coated reinforcing steel shall be held in place by
use of plastic or plastic coated binding wires especially manufactured for
the purpose. Reference shall be made to Section 1000 for other
requirements.
e)
1606.2.2. While welding may be permitted for mild steel reinforcing bars
conforming to IS : 432, welding of deformed bars conforming to IS : 1786 shall in
general be prohibited. Welding may be permitted in case of bars other than S 240 grade
including special welding grade of S 415 grade bars conforming to IS : 1786, for which
necessary chemical analysis has been secured ad the carbon equivalent (CE) calculated
from the chemical composition using the formula:
CE = C + Mn + Cr+Mg+V + Ni + Cu
6
5
15
is 0.4 or less.
1606.2.3. The method of welding shall conform to IS : 2751 and IS : 9417 and to
any supplemental specifications to the satisfaction of the Engineer.
Welding may be carried out by metal arc welding process. Oxyacetylene welding
shall not be permissible. Any other process may be used subject to the Engineer and
necessary additional requirements to ensure satisfactory joint performance. Precautions
on over heating, choice of electrode, selection of correct current in arc welding etc.,
should be strictly observed.
All bars shall be butt welded except for smaller diameter bars (diameter of less
than 20 mm) which may be lap welded. Single-V or Double-V butt joints may generally
be used. For vertical bars single bevel or double bevel joints may be used.
Welded joints shall be located well away from bends and not less than twice the
bar diameter away from a bend.
Generally, shop welding in controlled conditions is to be preferred, where
feasible. Site welding where necessary shall, however, be permitted when the facilities,
equipment, process, consumables, operators, welding procedure are adequate to produce
and maintain uniform quality at par with that attainable in shop welding to the
satisfaction of the Engineer.
Joint welding procedures which are to be employed shall invariably be
established by a procedure specification. All welders and welding operators to be
employed shall have to be qualified by tests prescribed in IS : 2751. Inspection of welds
shall conform to IS : 822 and destructive or non-destructive testing may be undertaken
when deemed necessary. Joints with weld defects detected by visual inspection or
dimensional check inspection shall not be accepted.
Suitable means shall be provided for holding the bars securely in position during
welding. It must be ensured that no voids are left in welding. When welding is done in 2
or 3 stages, previous surface shall be cleaned properly. Bars shall be cleaned of all loose
scale, rust, grease, paint and other foreign matter before carrying out welding. Only
competent and experienced welders shall be employed on the work with the approval of
the Engineer. No welding shall be done on coated bars.
M.S. electrodes used for welding shall conform to IS : 814.
1606.2.4. Welded joints shall preferably be located at points where steel will not
be subject to more than 75 per cent of the maximum permissible stresses and welds so
staggered that at any on section, not more than 20 per cent of the bars are welded.
1606.2.5. Welded pieces of reinforcement shall be tested. Specimens shall be
taken from the site and the number and frequency of tests shall be as directed by the
Engineer.
1606.3. Mechanical Coupling of Bars
Bars may be jointed with approved patented mechanical devices as indicated on
the drawing or as approved by the Engineer e.g. by special grade steel sleeves swagged
on to bars in end to end contact or by screwed couplers. In case such devices are
permitted by the Engineer, they shall develop at least 125 per cent of the characteristic
strength of the reinforcement bar.
1607. TESTING AND ACCEPTANCE
The material shall be tested in accordance with relevant IS specifications and
necessary test certificates shall be furnished. Additional tests, if required, will be got
carried out by the Contractor at his own cost.
The fabrication, furnishing and placing of reinforcement shall be in accordance
with these specifications and shall be checked and accepted by the Engineer.
1608. MEASUREMENTS FOR PAYMENT
Reinforcement shall be measured in length including hooks, if any, separately for
different diameters as actually used in work, excluding overlaps. From the length so
measured, the weight of reinforcement shall be calculated in tonnes on the basis of IS :
1732. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and
annealed steel wire or other methods for binding and placing shall not be measured and
cost of these items shall be deemed to be included in the rates for reinforcement.
1609. RATE
The contract unit rate for coated/uncoated reinforcement shall cover the cost of material,
fabricating, transporting, storing, bending, placing, binding and fixing in position as shown on the
drawings as per these specifications and as directed by the Engineer, including all l abour, equipment,
supplies, incidentals, sampling, testing and supervision.
The unit rate for coated reinforcement shall be deemed to also include cost of all
material, labour, tools and plant, royalty, transportation and expertise required to carry
out the work. The rate shall also cover sampling, testing and supervision required for the
work.
1701. DESCRIPTION
The work shall consist of furnishing and placing structural concrete and incidental
construction in accordance with these specifications and in conformity with the lines,
grades and dimensions, as shown on the drawings or as directed by the Engineer.
1702. MATERIALS
All materials shall conform to Section 1000 of these Specifications.
1703. GRADES OF CONCRETE
1703.1. The grades of concrete shall be designated by the characteristic strength
as given in Table 1700-1, where the characteristic strength is defined as the strength of
concrete below which not more than 5 per cent of the test results are expected to fall.
TABLE 1700-1.
Grade Designation
M 15
M 20
M 25
M 30
D.6.1.30
M 35
M 40
M 45
M 50
M 55
1700-2.
a) PCC members
b) RCC members
c) PSC members
Exposure conditions
(kg/cu.m.)
360
400
400
Normal
Severe
0.45
0.45
0.40
0.45
0.40
0.40
Conditions of Exposure
Moderate
M 25
M 35
M 35
Severe
M 30
M 40
M 40
a) PCC members
b) RCC members
Exposure conditions
Exposure conditions
Normal
250
310
Severe
310
400
Normal
0.50
0.45
Severe
0.45
0.40
Conditions of Exposure
Moderate
M 15
M 20
Severe
M 20
M 25
(ii)
(iii)
Severe conditions of exposure shall mean alternate wetting and drying due
to sea spray, alternate wetting and drying combined with freezing and
buried in soil having corrosive effect.
(iv)
The cement content shall be low as possible but not less than the quantities
specified above. In no case shall it exceed 540 kg/cu.m. of concrete.
1703.3. Concrete used in any component or structure shall be specified by
designation along with prescribed method of design of mix i.e. Design Mix or
Nominal Mix. For all items of concrete, only Design Mix shall be used, except where
Nominal Mix concrete is permitted as per drawing or by the Engineer. Nominal Mix
may be permitted only for minor bridges and culverts or other incidental construction
where strength requirements are upto M 20 only. Nominal Mix may also be permitted
for non-structural concrete or for screed below open foundations.
1703.4. If the Contractor so elects, the Engineer may permit the use of higher
grade concrete than that specified on the drawing, in which event the higher grade
concrete shall meet the specifications applicable thereto without additional compensation.
1704. PROPORTIONING OF CONCRETE
Prior to the start of construction, the Contractor shall design the mix in case of
Design Mix Concrete or propose nominal mix in case of Nominal Mix Concrete, and
submit to the Engineer for approval, the proportions of materials, including admixtures to
be used. Water-reducing admixtures (including plasticisers or super-plasticsers) may be
used at the Contractors option, subject to the approval of the Engineer. Other types of
admixtures shall be prohibited, unless specifically permitted by the Engineer.
1704.1. Requirements of Consistency
The mix shall have the consistency which will allow proper placement and
consolidation in the required position. Every attempt shall be made to obtain uniform
consistency.
The optimum consistency for various types of structure shall be as indicated in
Table 1700-4, or as directed by the Engineer. The slump of concrete shall be checked as
per IS : 516.
TABLE 1700-4.
TYPE
1
SLUMP(mm)
25
25
40 50
50 75
75 125
100 200
(i)
(ii)
Where there is insufficient data to satisfy the above, the current margin for
the initial design mix shall be taken as given in Table 1700-5:
TABLE 17005.
Concrete Grade
M 15
M 20
M 25
M 30
M 35
M 40
M 45
M 50
M 55
Current Margin
(MPa)
10
10
11
12
12
12
13
13
14
The initial current margin given in the Table 1700-5 shall be used till sufficient
data is available to determine the current margin as per sub-clause (i) above.
1704.2.2. Trial mixes
The Contractor shall give notice to enable the Engineer to be present at the
making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare
trial mixes, using samples of approved materials typical of those he proposes to use in the
works, for all grades to the Engineers satisfaction prior to commencement of concreting.
The initial trial mixes shall generally be carried out in an established laboratory approved
by the Engineer. In exceptional cases, the Engineer may permit the initial trial mixes to
be prepared at the site laboratory of the Contractor, if a full fledged concrete laboratory
has been established well before the start of construction, to his entire satisfaction. In all
cases complete testing of materials forming the constituents of proposed Design Mix
shall have been carried out prior to making trial mixes.
Sampling and testing procedures shall be in accordance with these specifications.
When the site laboratory is utilised for preparing initial mix design, the concrete
plant and means of transport employed to make the trial mixes shall be similar to that
proposed to be used in the works.
Test cubes shall be taken from trial mixes as follows. Fir each mix, set of six
cubes shall be made from each of three consecutive batches. Three cubes from each set of
six shall be tested at an age of 28 days and three at an earlier age approved by the
Engineer. The cubes shall be made, cured, stored, transported and tested in accordance
with these specifications. The average strength of the nine cubes at 28 days shall exceed
the specified characteristic strength by the current margin minus 3.5 MPa.
1704.2.3. Control of strength of design mixes
a)
Adjustments to mix proportions arrived at in the trial mixes shall be made subject to the
Engineers approval, in order to minimise the variability of strength and to maintain
the target mean strength. Such adjustments shall not be taken to imply any change
in the current margin.
b)
When required by the Engineer, the Contractor shall recalculate the current margin in
accordance with Clause 1704.2.1. The recalculated value shall be adopted as
directed by the Engineer, and it shall become the current margin for concrete
produced subsequently.
c)
During production, the Contractor shall carry out trial mixes and tests, if required by the
Engineer, before substantial changes are made in the material or in the proportions
of the materials to be used, except when adjustments to the mix proportions are
carried out in accordance with sub-clause (a) above.
1704.3. Requirements of Nominal Mix Concrete
Requirements for nominal mix concrete unless otherwise specified, shall be as
detailed in Table 1700-6.
TABLE 1700-6. PROPORTIONS FOR NOMINAL MIX CONCRETE
Concrete
Grade
M 15
350
M 20
250
1704.4.
Additional Requirements
Concrete shall meet with any other requirements as specified on the drawing or as
directed by the Engineer. Additional requirements shall also consist of the following
overall limits of deleterious substances in concrete:
a)
Prestressed Concrete
0.3 percent
b)
1704.5.
The Contractor shall submit the following information for the Engineers
approval:
a)
b)
concrete c)
d)
(i)
(ii)
Statement giving the proposed mix proportions for nominal mix concrete.
Any change in the source of material or in the mix proportions shall be subject to
the Engineers prior approval.
1705. ADMIXTURES
Use of admixtures such as superplasticisers for concrete may be made with the
approval of the Engineer.
As the selection of an appropriate concrete admixture is an integral part of the mix
design, the manufacturers shall recommend the use of any one of his products only after
obtaining complete knowledge of all the actual constituents of concrete as well as
methodologies of manufacture, transportation and compaction of concrete proposed to be
used in the project.
1706. SIZE OF COARSE AGGREGATE
The size (maximum nominal) of coarse aggregates for concrete to be used in
various components shall be given as Table 1700-7.
TABLE 1700-7.
Components
i) RCC well curb
ii) RCC/PCC well steining
iii) Well cap or Pile Cap Solid type piers and
abutments
iv) RCC work in girders, slabs, wearing coat,
kerb, approach slab, hollow
piers and abutments, pier/abutment
caps, piles
v) PSC work
vi) Any other item
Maximum nominal size of aggregates shall also be restricted to the smaller of the
following values:
a)
b)
Measurement of Water
x)
Tremies
size 25 mm to 70 mm
minimum 500 watts
full width of carriageway
(upto two lanes)
All formwork and reinforcement contained in it shall be cleaned and made free
from standing water, dust, snow or ice immediately before placing of concrete.
No concrete shall be placed in any part of the structure until the approval of the
Engineer has been obtained.
If concreting is not started within 24 hours of the approval being given, it shall
have to be obtained again from the Engineer. Concreting then shall proceed continuously
over the area between the construction joints. Fresh concrete shall not be placed against
concrete which has been in position for more than 30 minutes unless a proper
construction joint is formed.
Except where otherwise agreed to by the Engineer, concrete shall be deposited in
horizontal layers to a compacted depth of not more than 450 mm when internal vibrators
are used and not exceeding 300 mm in all other cases.
Concrete when deposited shall have a temperature of not less than 5 degrees
Celsius, and not more than 40 degrees Celsius. It shall be compacted in its final position
within 30 minutes of its discharge from the mixer, unless carried in properly designed
agitators, operating continuously, when this time shall be within 1 hour of the addition of
cement to the mix and within 30 minutes of its discharge from the agitator. It may be
necessary to add retarding admixtures to concrete if trials show that the periods indicated
above are unacceptable. In all such matters, the Engineers decision shall be final.
Concrete shall be thoroughly compacted by vibration or other means during
placing and worked around the reinforcement, tendons or duct formers, embedded
fixtures and into corners of the formwork to produce a dense homogeneous void-free
mass having the required surface finish. When vibrators are used, vibration shall be done
continuously during the placing of each batch of concrete until the expulsion of air has
practically ceased and in a manner that does not promote segregation. Over vibration
shall be avoided to minimise the risk of forming a weak surface layer. When external
vibrators are used, the design of formwork and disposition of vibrator shall be such as to
ensure efficient compaction and to avoid surface blemishes. Vibrations shall not be
applied through reinforcement and where vibrators of immersion type are used, contact
with reinforcement and all inserts like ducts etc., shall be avoided. The internal vibrators
shall be inserted in an orderly manner and the distance between insertions should be
about one and a half times the radius of the area visibly affected by vibration. Additional
vibrators in serviceable condition shall be kept at site so that they can be used in the event
of breakdowns.
Mechanical vibrators used comply with IS: 2502, IS: 2506, IS: 2514 and IS: 4656.
1710. CONSTRUCTION JOINTS
Construction joints shall be avoided as far as possible and in no case the locations
of such joints shall be changed or increased from those shown on the drawings, except
with express approval of the Engineer. The joint shall be provided in a direction
perpendicular to the member axis.
Location, preparation of surface and concreting of construction joints shall
conform to the additional specifications given in Appendix 1700/1.
1711. CONCRETING UNDER WATER
When it is necessary to deposit concrete under water, the methods, equipment,
materials and proportions of mix to be used shall be got approved from the Engineer
before any work is started. Concrete shall contain 10 per cent more cement than that
required for the same mix placed in the dry.
Concrete shall not be placed in water having a temperature below 5 degrees
Celsius. The temperature of the concrete, when deposited, shall not be less than 16
degrees Celsius, nor more than 40 degrees Celsius.
Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if
practicable, and in any case to reduce the flow of water to less than 3 metres per minute
through the space into which concrete is to be deposited. Coffer dams or forms in still
water shall be sufficiently tight to prevent loss of mortar through the joints in the walls.
Pumping shall not be done while concrete is being placed, or until 24 hours thereafter. To
minimise the formation of laitance, great care shall be exercised not to disturb the
concrete as far as possible while it is being deposited.
All under water concreting shall be carried out by tremie method only, using
tremie of appropriate diameter. The number and spacing of the tremies should be worked
out to ensure proper concreting. The tremie concreting when started should continue
without interruption for the full height of the member being concreted. The concrete
production and placement equipment should be sufficient to enable the underwater
concrete to be completed uninterrupted within the stipulated time. Necessary stand-by
equipment should be available for emergency situation.
The top section of the tremie shall have a hopper large enough to hold one full
batch of the mix or the entire contents of the transporting bucket as the case may be. The
tremie pipe shall not be less than 200 mm in diameter and shall be large enough to allow
a free flow of concrete and strong enough to withstand the external pressure of the water
in which it is suspended, even if a partial vacuum develops inside the pipe. Preferably,
flanged steel pipe of adequate strength for the job shall be used. A separate lifting device
shall be provided for each tremie pipe with its hopper at the upper end. Unless the lower
end of the pipe is equipped with an approved automatic check value, the upper end of the
pipe shall be plugged with a wadding of gunny sacking or other approved material before
delivering the concrete to the tremie pipe through the hopper, so that when the concrete is
forced down from the hopper to the pipe, it will force the plug (and along with it any
water in the pipe) down the pipe and out of the bottom end, thus establishing a
continuous stream of concrete. It will be necessary to raise slowly the tremie in order to
allow a uniform flow of concrete, but it shall not be emptied so that water is not allowed
to enter above the concrete in the pipe. At all times after placing of concrete is started and
until all the required quantity has been placed, the lower end of the tremie pipe shall be
kept below the surface of the plastic concrete. This will cause the concrete to build up
from instead of flowing out over the surface and thus avoid formation of layers of
laitance. If the charge in the tremie is lost while depositing, the tremie shall be raised
above the concrete surface and unless sealed by a check valve, it shall be replugged at the
top end, as at the beginning, before refilling for depositing further concrete.
1712. ADVERSE WEATHER CONDITIONS
1712.1. Cold Weather Concreting
Where concrete is to be deposited at or near freezing temperature, precautions
shall be taken to ensure that at the time of placing, it has a temperature of not less than 5
degrees Celsius and that the temperature of the concrete shall be maintained above 4
degrees Celsius until it has thoroughly hardened. When necessary, concrete ingredients
shall be heated before mixing but cement shall not be heated artificially other than by the
heat transmitted to it from other ingredients of the concrete. Stock-piled aggregate may
be heated by the use of dry heat or steam. Aggregates shall not be heated directly by gas
or on sheet metal over fire. In general, the temperature of aggregates or water shall not
exceed 65 degrees Celsius. Salt or other chemicals shall not be used for the prevention of
freezing. No frozen material or materials containing ice shall be used. All concrete
damaged by frost shall be removed. It is recommended that concrete exposed to freezing
weather shall have entrained air and the water content of the mix shall not exceed 30
litres per 50 kg of cement.
1712.2. Hot Weather Conditions
When depositing concrete in very hot weather, precautions shall be taken so that
the temperature of wet concrete does not exceed 40 degrees Celsius while placing. This
shall be achieved by stacking aggregate under the shade and keeping them moist, using
cold water, reducing the time between mixing and placing to the minimum, cooling
formwork by sprinkling water, starting curing before concrete dries out and restricting
concreting as far as possible to early mornings and late evenings. When ice is used to
cool mixing water, it will be considered a part of the water in design mix. Under no
circumstances shall the mixing operation be considered complete until all ice in the
mixing drum has melted.
The Contractor will be required to state his methodology for the Engineers
approval when temperatures of concrete are likely to exceed 40 degrees Celsius during
the work.
1713.
wind b)
c)
d)
e)
f)
Vibration and impact which may disrupt the concrete and interfere with its
bond to the reinforcement
Where members are of considerable size and length, with high cement content,
accelerated curing methods may be applied, as approved by the Engineer.
1713.1. Water Curing
surface which requires further finishing to be applied. All construction joints shall be
moist, cured and no curing compound will be permitted in locations where concrete
surface are required to be bonded together.
Curing compounds shall be continuously agitated during use. All concrete cured
by this method shall receive two applications of the curing compound. The first coat shall
be applied immediately after acceptance of concrete finish. If the surface is dry, the
concrete shall be saturated with water and curing compound applied as soon as the
surface film of water disappears. The second application shall be made after the first
application has set. Placement in more than two coats may be required to prevent
streaking.
1714.
FINISHING
Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut
inside the concrete member to a depth of at least 50 mm below the surface of the concrete
and the resulting holes filled with cement mortar. All fins caused by form joints, all
cavities produced by the removal of form ties other holes and depressions, honeycomb
sports, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated
with water, and carefully pointed and rendered true with mortar of cement and fine
aggregate mixed in the proportions used in the grade of concrete that is being finished
and of as dry a consistency as is possible to use. Considerable pressure shall be applied in
filling and pointing to ensure thorough filling in all voids. Surfaces which have been
pointed shall be kept moist for a period of twenty four hours. Special pre-packaged
proprietary mortars shall be used where appropriate or where specified in the drawing.
All construction and expansion joints in the completed work shall be left carefully
tooled and free from any mortar and concrete. Expansion joint filler shall be left exposed
for its full length with clean and true edges.
Immediately on removal of forms, the concrete work shall be examined by the
Engineer before any defects are made good.
a)
b)
TOLERANCES
TABLE 1700-8.
Quality of concrete in work, m
15
6 15
16 30
31 50
51 and above
No. of samples
1
2
3
4
4 plus one additional sample
3
for each additional 50 m or
part thereof
(ii)
(iii)
(iv)
After the passage of the above period, the specimen is taken out and
split in the middle by compression applied on two round bars on
opposite sides above and below.
(v)
1716.6. If the concrete is not able to meet any of the standards of acceptance as
prescribed, the effect of such deficiency on the structure shall be investigated by the
Contractor as directed by the Engineer. The Engineer may accept the concrete as substandard work. Any additional work required by the Engineer for such acceptance shall
be carried out by the Contractor at his cost. In case the concrete is not found to be
acceptable after investigation, the Contractor shall remove the rejected concrete
forthwith.
1717. MEASUREMENTS FOR PAYMENT
Structural concrete shall be measured in cubic meters. In reinforced or prestressed
concrete, the volume occupied by reinforcement or prestressing cables and sheathing
shall not be deducted. The slab shall be measured as running continuously through and
the beam as the portion below the slab.
1718. RATE
The contract unit rate for structural concrete shall cover costs of all materials,
labour, tools, plant and equipment required for mixing, transporting and placing in
position, vibrating and compaction, finishing and curing as per this section or as directed
by the Engineer, including all incidental expenses, sampling and testing, quality
assurance and supervision. Unless mentioned separately as an item in the Contract, the
contract unit rate for concrete shall also include the cost of providing, fixing and
removing formwork required for concrete work as per Section 1500.
Where concrete is found to be acceptable as sub-standard work, the Contractor
shall pay a discount over contract unit rate, as decided by the Engineer. For deficiency in
compressive strength of concrete when accepted by the Engineer, the reduction in rate
may be applied as under:
Design Strength Observed Strength
Per cent reduction = ----------------------------------------------------------- X 100
Design Strength
1901. DESCRIPTION
This work shall include furnishing, fabricating, transporting, erecting and painting
structural steel, rivet steel, cast steel, steel forgings, cast iron and other incidental metal
construction of the kind, size and quantity in conformity with the drawings and these
specifications or as desired by the Engineer.
1902. GENERAL
General requirements relating to the supply of material shall conform to the
specifications of IS : 1387, for the purpose of which the supplier shall be the Contractor
and the purchaser shall be the Engineer.
Finished rolled material shall be free from cracks, flaws, injurious seams, laps,
blisters, ragged and imperfect edges and other defects. It shall have a smooth and uniform
finish, and shall be straightened in the mill before shipment. They shall also be free from
loose mill scale, rust, pits or other defects affecting its strength and durability.
The acceptance of any material on inspection at the mill i.e. rolling, mills,
foundry or fabricating plant where material for the work is manufactured, shall not be a
bar to its subsequent rejection, if found defective.
Unless specified otherwise, high tensile steel rivet conforming to IS : 1149 shall
be used for members of high tensile steel conforming to IS : 961 and shall not be used for
mild steel members.
Unless specified otherwise, bolted connection of structural joints using high
tensile friction grip bolts shall comply with requirements of IS : 4000.
Cast iron shall be used in any portion of the bridge structure, except where it is
subject to direct compression.
1903. MATERIALS
1903.1. All materials shall conform to Section 1000. Special requirements are
given below:
Mild steel for bolts and nuts shall conform to IS : 226 but have a minimum tensile
strength of 44 kg/sq. mm. and minimum percentage elongation of 14. High tensile steel
for bolts and nuts shall conform to IS : 961 but with a minimum tensile strength of 58
kg/sq. mm. High strength friction grip bolts shall be permitted for use only on satisfactory
evidence of performance to the requirements (not covered by these specifications)
specified by the Engineer or included in the special provisions.
For cast steel, the yield stress shall be determined and shall not be less than 50 per
cent of the minimum tensile strength.
Plain washers shall be of steel. Tapered or other specially shaped washers shall be
of steel, or malleable cast iron.
Parallel barrel drift shall have a tensile strength not less than 55 kg/sq. mm. with
elongation of not less than 20 per cent measured on a gauge length of 4So (So = cross
section area).
1903.2. Materials for castings and forgings, fasteners and welding consumables
shall be as under:
1903.2.1. Castings and Forgings: Steel castings and forgings shall comply with
the requirements of the following Indian Standards, as appropriate:
IS : 1030
IS : 1875
IS : 2004
IS : 2644
IS : 4367
1093.2.2. Fasteners: Bolts, nuts, washers and rivets shall comply with the
following or relevant IS Standards as appropriate:
IS : 1929
IS : 2155
IS : 1363
IS : 1364
IS : 1367
IS : 3640
IS : 3757
IS : 6623
IS : 6639
IS : 5624
Foundation bolts
IS : 7002
IS : 5369
IS : 5370
IS : 5372
IS : 5374
IS : 6610
IS : 6649
IS : 814
(Part 2)
IS : 1278
IS : 1395
Low and medium alloy Steel covered electrodes for manual Metal
Arc Welding
IS : 3613
IS : 7280
Bare wire electrodes for gas shield arc welding of structural steel
IS : 6419
Welding rods and bare electrodes for gas shielded arc welding of
structural steel
IS : 6560
1903.3 In aggressive environment, corrosion resistant steel can be used. These are
low-alloyed steels containing a total of 1 per cent 2 per cent alloys, in particular,
copper, chromium, nickel and phosphorous.
1093.3. Paints
All material for paints and enamels shall conform to the requirements specified on
the drawings or other special provisions laid down by the Engineer.
The type of paints which can be used shall be as follows:
a) Ordinary i.e. paints based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy
b) Chemical Resistant-one pack type (ready for use) and two pack type (mixed
before use).
c) Vinyl
d) Chlorinated rubber
e) Bituminous
f) Epoxy
g) Polyurethane
h) Zinc rich
Unless otherwise specified, paints shall conform to he relevant IS specifications.
The paints which have been tested for the following qualities as per specifications given
in the relevant IS codes only shall be used:
-
Drying time
Consistency
1904.
FABRICATION
1904.1. General
All work shall be in accordance with the drawings and as per these specifications
with care being taken that all parts of an assembly fit accurately together. All members
shall carry mark number and item number and, if required, serial number.
Unless specifically required under the contract, corresponding parts need not be
interchangeable, but the parts shall be match marked as required under Clause 1904.7.
Templates, jigs and other appliances used for ensuring the accuracy of the work
shall be of mild steel; where specially required, these shall be bushed with hard steel.
All measurements shall be made by means of steel tape or other device properly
calibrated. Where bridge materials have been used as templates for drilling, these shall be
inspected and passed by the Engineer before they are used in then finished structure.
All structural steel members and parts shall have straight edges and blunt
surfaces. If necessary, they shall be straightened or flattened by pressure unless they are
required to be of curvilinear forms. They shall also be free from twist. Pressure applied
for straightening or flattening shall be such as would not injure the materials.
Hammering shall not be permitted. Adjacent surfaces or edges shall be in close contact
or at uniform distance throughout.
The Contractor shall submit his programme of work to the Engineer for his
approval at least 15 days before the commencement of fabrication. This programme shall
include the proposed system of identification and erection marks together with complete
details of fabrication and welding procedures.
The Contractor shall prepare shop drawings for fabricating any member and
obtain approval of the Engineer before the start of work. Complete information regarding
the location, type, size and extent of all welds shall be clearly shown on the shop
drawings. These drawings shall distinguish between shop and field welds.
1904.2. Preparation of Edges and Ends
All structural steel parts, where required, shall be sheared, cropped, sawn or flame
cut and ground accurately to the required dimension and shape.
End/edge planing and cutting shall be done by any one of the following
prescribed methods or left as rolled:
a)
b)
c)
If ends of stiffeners are required to be fitted, they shall be ground, so that the
maximum gap over 60 per cent of the contact area does not exceed 0.25 mm.
Where flame cutting or shearing is used, at least one of the following
requirements shall be satisfied.
a)
b)
c)
d)
e)
f)
Wherever specified by the Engineer, the flame cut edges shall be ground or
machined over and above the requirement (a) to (f).
Where machining for edge preparation in butt joint is specified, the ends shall be
machined after the members have been fabricated.
Outside edges of plate and section which are prone to corrosion shall be smoothed
by grinding or filing.
In the case of high tensile steel at least 6 mm of the material from the flame cut
edge shall be removed by machining.
Longitudinal edges of all plates and cover plates in plate girders and built-up
members shall be machined except in the following cases:
a)
Rolled edges of single universal plates or flats may not be
machined. b)
Covers to single flange plates may be left unmachined.
c)
Machine flame cutting instead of machining is acceptable for edges of
single plates in compression and for edges of single plates, 25 mm or less
thick, in tension.
d)
Edges of single shaped plates over 25 mm thick not capable of being
machined by ordinary method may be machine flame cut and the end
surface ground.
e)
Edges of universal plates or flats of the same nominal width used in tiers
may be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12mm thick and over shall be machined and
those less than 12 mm thick may be sheared and ground.
The ends of plates and sections forming the main components of plate girders or
of built-up member shall be machined, machine flame cut, sawn or hand flame cut and
ground.
Where ends of stiffeners are required to be fitted, they shall be machined,
machine flame cut, sawn, sheared and ground, or hand flame cut and ground.
The ends of lacing bar shall be rounded unless otherwise required .
Other edges and ends of mild steel parts may be sheared and any burrs at edges
shall be removed.
1904.3. Preparation of Holes
1904.3.1. Drilling and punching: Holes for rivets, black bolts, high strength
bolts and countersunk bolts/rivets (excluding close tolerance and turn fitted bolts) shall be
either punched or drilled. The diameter of holes shall be 1.5 mm larger for bolts/rivets
less than 25 mm dia and 2.0 mm for more than or equal to 25 mm.
All holes shall be drilled except for secondary members such as, floor plate, hand
rails etc. Members which do not carry the main load can be punched subject to the
thickness of member not exceeding 12 mm for material conforming to IS : 226.
Holes through more than one thickness of material or when any of the main
material thickness exceeds 20 mm for steel conforming to IS : 961, IS : 8500 shall either
be sub-drilled or sub-punched to a diameter of 3 mm less than the required size and then
reamed to the required size. The reaming of material more than one thickness shall be
done after assembly.
Where several plates or sections form a compound member, they shall, where
practicable, be firmly connected together by clamps or tacking bolts, and the holes be
drilled through the group in one operation. Alternatively, and in case of repetition work,
the plates and sections may be drilled separately from jigs and templates. Jigs and
templates shall be checked at least once after every 25 operations. All burrs shall be
removed.
In case of repetition of spans, the erection of every span shall not be insisted
upon, except where close tolerance or turned bolts are used, provided that methods are
adopted to ensure strict interchangeability. In such cases, one span in ten or any number
less than ten of each type shall be erected from pieces selected at random by the Engineer
and should there be any failure of the pieces to fit, all similar spans shall be erected
complete. In the event of spans being proved completely interchangeable, all
corresponding parts shall carry the same mark so that sorting of the materials at site is
facilitated.
1904.3.2. Block drilling: Where the number of plates to be riveted exceeds three
or the total thickness is 90 mm or more, the rivet holes, unless they have been drilled
through steel bushed jigs, shall be drilled out in place 3 mm all round after assembling. In
such cases, the work shall be thoroughly bolted together.
1904.3.3. Size of holes : The sizes of holes in millimetres are given in Table
1900-1 below:
TABLE 1900-1 : DIAMETER OF HOLES FOR RIVETS
Nominal dia of Rivets (mm)
12
14
16
18
20
22
24
27
30
33
1904.3.4. Close tolerance bolts and barrel bolts: Holes for close tolerance and
turn fitted bolts. The diameter of the holes shall be equal to the nominal diameter of the
bolt shank minus 0.15 mm to 0.0 mm.
The members to be connected with close tolerance or turn fitted bolts shall be
firmly held together by service bolts or clamped and drilled through all thicknesses in
one operation and subsequently reamed to required size within specified limit of
accuracy as specified in IS : 919 tolerance grade H8.
The holes not drilled through all thicknesses at one operation shall be drilled
smaller size and reamed after assembly.
1904.3.5. Holes for high strength friction grip bolts: All holes shall be drilled
after removal of burrs. Where the number of plies in the grip does not exceed three, the
diameters of holes shall be 1.6 mm larger than those of bolts and for more than three plies
in grip, the diameters of hole in outer plies shall be as above and dia of holes in inner
plies shall be not be less than 1.6 mm and not more than 3.2 mm larger than those in
bolts, unless otherwise specified by the Engineer.
1904.3.6. Removal of burrs: The work shall be taken apart after drilling and all
burrs left by drilling and the sharp edges of all rivet holes completely removed.
1904.4. Rivet and Riveting
The diameter of rivets shown on the drawings shall be the size before heating.
Each rivet shall be of sufficient length to form a head of the standard dimensions as given
in IS handbook on Steel Sections, Part I. It shall be free from burrs on the underside of
the head.
When countersunk heads are required, the heads shall fill the countersunk. The
included angle of the head shall be as follows:
a)
b)
90 degrees
120 degrees
The tolerance on the diameter of rivets shall be in accordance with IS : 1148 and
IS : 1149 for mild steel rivets and high tensile steel rivets respectively and unless
otherwise specified, the tolerance shall be minus tolerance.
Rivets shall be driven when hot so as to fill the hole as completely as possible and
shall be of sufficient length to form a head of standard dimension. When counter-sunk
head is required, the head shall fill the counter-sunk hole. Projection after counter-sinking
shall be ground off wherever necessary.
Rivets shall be heated uniformly to a light cherry red colour between 650
degrees Celsius to 700 degrees Celsius for hydraulic riveting and orange colour for
pneumatic riveting of mild steel rivets and shall be red hot from head to the point when
inserted and shall be upset in its entire length so as to fill the hole as completely as
possible when hot. Rivets, after being heated and before being inserted in the hole shall
be made free from scale by striking the hot rivet on a hard surface.
Wherever possible, the rivets shall be machine driven, preferably by direct acting
riveters. The driving pressure shall be maintained on the rivets for a short time after the
upsetting is completed. High tensile steel rivets shall be heated upto 110 degrees Celsius.
Any rivet whose point is heated more than prescribed, shall not be driven.
Where flush surface is required, any projecting metal shall be chipped or ground
off.
Before riveting is commenced, all work shall be properly bolted up so that the
various sections and plates are in close contact throughout. Drifts shall only be used for
drawing the work into position and shall not be used to such an extent as to distort the
holes. Drifts of a larger size than the nominal diameter of the hole shall not be used. The
riveting shall be done by hydraulic or pneumatic machine unless otherwise specified by
the Engineer.
Driven rivets, when struck sharply on the head by a quarter pound rivet testing
hammer, shall be free from movement and vibrations. Assembled riveted joint surfaces,
including those adjacent to the rivet heads, shall be free from scale, dirt, lose scale, burrs,
other foreign materials and defects that prevent solid seating of parts.
All loose or burnt rivets with cracked or badly formed defective heads or with
heads which are unduly eccentric with the shanks, shall be removed and replaced. In
removing rivets, the head shall be sheared off and the rivet punched out so as not to injure
the adjacent metal and, if necessary, they shall be drilled out. Recupping or recaulking
shall not be permitted. The parts not completely riveted in the shop shall be secured by
bolts to prevent damage during transport and handling.
1904.5. Bolts, Nuts and Washers
1904.5.1. Black bolts (black all over): Black bolts are forged bolts in which the
shanks, heads and nuts do not receive any further treatment except cutting of screw
threads. They shall be true to shape and size and shall have the standard dimensions as
shown on the drawings.
1904.5.2. Close tolerance bolts: Close tolerance bolts shall be faced under the
head and turned on the shank.
1904.5.3. Turned barrel bolts: The diameter of the screwed portion of turned
barrel bolts shall be 1.5 mm smaller than the diameter of the barrel unless otherwise
specified by the Engineer. The diameter of the bolts as given on the drawing shall be the
nominal diameter of the barrel. The length of the barrel shall be such that it bears fully on
all the parts connected. The threaded portion of each bolt shall project through the nut by
at least one thread. Faces of heads and nuts bearing on steelwork shall be machined.
1904.5.4. High strength friction bolts and bolted connections: The general
requirement shall be as per relevant IS specifications mentioned in clause 5.3. of
(Fasteners) of IRC : 24. Unless otherwise specified by the Engineer, bolted connections
of structural joints using high tensile friction grip bolts shall comply with requirements in
IS : 4000.
1904.5.5. Washers: In all cases where the full bearing area of the bolt is to be
developed, the bolt shall be provided with a steel washer under the nut of sufficient
thickness to avoid any threaded portion of the bolt being within the thickness of the parts
bolted together and to prevent the nut when screwed up, from bearing on the bolt.
For close tolerance or turned barrel bolts, steel washers whose faces give a true
bearing shall be provided under the nut. The washer shall have a hole diameter not less
than 1.5 mm larger than the barrel and a thickness of not less than 6 mm so that the nut
when screwed up, will not bear on the shoulder of the bolt.
Taper washers with correct angle of taper shall be provided under all heads and
nuts bearing on bevelled surfaces.
Spring washers may be used under nuts to prevent slackening of the nuts when
excessive vibrations occur.
Where the heads or nuts bears on timber, square washers having a length of each
side not less than three times the diameter of bolts or round washers having a diameter of
3 times the diameter of bolts and with a thickness not less than one quarter of diameter
shall be provided.
1904.5.6. Studs: Ordinary studs may be used for holding parts together, the holes
in one of the parts being tapped to take the thread of the stud. Counter-sunk studs may be
used for making connections where the surfaces are required to be clear of all
obstruction, such as protruding heads of bolts or rivets, studs may also be welded on the
steel work in the position required.
1904.5.7. Service bolts: Service bolts shall have the same clearance as black
bolts and where it is required that there should be no movement prior to final riveting,
sufficient drifts or close tolerance bolts shall be used to locate the work.
1904.5.8. Tightening bolts: Bolted connection joints with black bolts and high
strength bolts shall be inspected for compliance of codal requirements.
The Engineer shall observe the installation and tightening of bolts to ensure that
correct tightening procedure is used and shall determine that all bolts are tightening.
Regardless of tightening method used, tightening of bolts in a should commence at the
most rigidly fixed or stiffest point and progress towards the free edges, both in initial
tightly screwed up shall be employed. All parts shall fit accurately and be in accordance
with drawing and specifications.
The steel work shall be temporarily assembled at place of fabrication.
Assembly shall be of full truss or girder, unless progressive truss or girder
assembly, full chord assembly, progressive chord assembly or special complete structure
assembly is specified by the Engineer.
The field connections of main members of trusses, arches, continuous beams,
spans, bends, plate girders and rigid frame assembled, aligned, accuracy of holes and
camber shall be checked by Engineer and then only reaming of sub-size holes to
specified size shall be taken up.
After the work has been passed by the Engineer and before it is dismantled, each
part shall be carefully marked for re-erection with distinguishing marks and stamped with
durable markings. Drawings showing these markings correctly shall be supplied to the
Engineer.
Unloading, handling and storage of steel work as per these specifications shall be
the responsibility of the Contractor. The cost of repairs or of rejected material, its
removal and the cost of transporting replacement material to the site shall be borne by the
Contractor.
Where close tolerance or turned barrel bolts are used for those cases where
interchangeability is not insisted upon, each span shall be erected and members of each
span marked distinctly.
1904.8. Welding
1904.8.1. All welding shall be done with the prior approval of the Engineer and
the workmanship shall conform to the specifications of IS : 823 or other relevant Indian
Standards as appropriate.
When material thickness is 20 mm or more, special precautions like preheating
shall be taken as laid down in IS : 823. Surfaces and edges to be welded shall be smooth,
uniform and free from fins, tears, cracks and other discontinuities. Surface shall also be
free from loose or thick scale, slag rust, moisture, oil and other foreign materials.
Surfaces within 50 mm of any weld location shall be free from any paint or other material
that may prevent proper welding or cause objectionable fumes during welding.
The general welding procedures including particulars of the preparation of fusion
faces for metal arc welding shall be carried out in accordance with IS : 9595.
The welding procedures for shop and site welds including edge preparation of
fusion faces shall be submitted in writing in accordance with Clause 22 of IS : 9595 for
the approval of the Engineer before commencing fabrication and shall also be as per
details shown on the drawings. Any deviation from above has to approved by Engineer.
Preparation of edges shall, wherever practicable, be done by machine methods.
Machine flame cut edges shall be substantially as smooth and regular as those
produced by edge planing and shall be left free of slag. Manual flame cutting shall be
permitted by the Engineer only where machine cutting is not practicable.
Electrodes to be used for metal arc welding shall comply with relevant IS
specifications mentioned in IRC : 24. Procedure test shall be carried out as per IS : 8613
to find out suitable wire-flux combination for welded joint.
Assembly of parts for welding shall be in accordance with provisions of IS : 9595.
The welded temporary attachment should be avoided as far as possible, otherwise
the method of making any temporary attachment shall be approved by the Engineer. Any
scars from temporary attachment shall be removed by cutting, chipping and surface shall
be finished smooth by grinding to the satisfaction of the Engineer.
Welding shall not be done when the air temperature is less than 10 degrees
Celsius. Welding shall not be done when the surfaces are moist, during periods of strong
winds or in snowy weather unless the work and the welding operators are adequately
protected.
1904.8.2. For welding of any particular type of joint, welders shall qualify to the
satisfaction of the Engineer in accordance with appropriate welders qualification as
prescribed in any of the Indian Standards IS : 817, IS : 1966, IS : 1393, IS :7307 (part I),
IS : 7310 (Part I) and IS : 7318 (part I) as relevant.
1904.8.3.In assembling and joining parts of a structure or of built-up members,
the procedure and sequence of welding shall be such as to avoid distortion and minimise
shrinkage stress.
All requirements regarding pre-heating of parent material and interpass
temperature shall be in accordance with provision of IS : 9595.
1904.8.4. Peening of weld shall be carried out wherever specified by the
Engineer:
a)
b)
prevent scaling or flaking of weld and base metal from over peening.
1904.8.5. Where the Engineer has specified the butt welds are to be ground flush,
the loss of parent metal shall not be greater than that allowed for minor surface defects.
The ends of butt joints shall be welded so as to provide full throat thickness. This may be
done by use of extension pieces, cross runs or other means approved by the Engineer.
Extension pieces shall be removed after the joint has cooled and the ends of the weld
shall be finished smooth and flush with the faces of the abutting parts.
The joints and welds listed below are prohibited type, which do not perform well
under cyclic loading.
a)
b)
c)
d)
e)
f)
1904.8.6. The run-on and run-off plate extension shall be used providing full
throat thickness at the end of butt welded joints. These plates shall comply with the
following requirements.
(i)
One pair of run-on and one pair of run-off plates from same thickness
and profile as the parent metal shall be attached to start and finish of all
butt welds preferably by clamps.
(ii)
1904.8.7. Welding of stud shear connectors: The stud shear connectors shall be
welded in accordance with the manufacturers instructions including preheating.
The stud and the surface to which studs are welded shall be free from scale,
moisture, rust and other foreign material. The stud base shall not be painted, galvanised
or cadmium plated prior to welding.
Welding shall not be carried out when temperature is below 10 degrees Celsius or
surface is wet or during periods of strong winds unless the work and the welder is
adequately protected.
The welds shall be visually free from cracks and shall be capable of developing at
least the nominal ultimate strength of studs.
The procedural trial for welding the stud shall be carried out when specified by
the Engineer.
1904.9. Tolerances
Tolerances in dimensions of components of fabricated structural steel work shall
be specified on the drawings and shall be subject to the approval of the Engineer before
fabrication. Unless specified, all parts of an assembly shall fit together accurately within
tolerances specified in Table 1900-2.
A machined bearing surface, where specified by the Engineer, shall be machined
within a deviation of 0.25 mm for surfaces that can be inscribed within a square of side
0.5 m.
from
straightness
2 mm
3.5 mm
3 mm
+ 0 mm
- 3 mm
+ 3 mm
- 2 mm
i) In elevation
+ 5 mm
- 0 mm
ii) In plan
L/1000 subject to a maximum of 10 mm
5. Deviation of centre line of web from centre 3 mm
line of flanges in built-up members at
contact surfaces
6. Deviation from flatness of plate of webs of 0.005 d to a maximum of 2 mm where d is
built-up members in a length equal to depth of the member
the depth of the member
7.Tilt of flange of plate girders
a) At splices and stiffeners, at supports, at 0.005 b to a minimum of 2 mm where b is
the top flanges of plate girders and at width of the member
bearings
b) at other places
0.015 b to a maximum of 4 mm where b is
width of the member
8. Deviation from squareness of flange to L/1000, where L is nominal length of the
web of columns and box girders
diagonal
9.
Deviation from squareness of fixed base D/500, where D is the distance from the
plate (not machined) to axis of column. column axis to the point under consideration
1905. ERECTION
1905.1. General
The provisions of this item shall apply to erection of steel bridge superstructures
or main members of bridge superstructures, composed of steel, which span between
supports.
If the sub-structure and the superstructure are built under separate contracts, the
department will provide the substructure, constructed to correct lines, dimensions and
elevations properly finished and will establish the lines and the elevation required for
setting steel.
The Contractor shall erect the structural steel, remove the temporary construction,
and do all work required to complete the construction included in the contract in
accordance with the drawings and the specifications and to the entire satisfaction of the
Engineer.
1905.2. Organisation and Equipment
The Contractor shall submit erection plans prepared by the fabricator, showing a
method and procedure of erection, compatible with the details of fabrication.
A detailed scheme must be prepared showing stage-wise activities, with complete
drawings and working phase-wise instructions. This should be based on detailed stagewise calculation and take into account specifications and capacity of erection equipment
machinery, tools, tackles to be used and temporary working loads as per Codal
provisions.
The scheme should be based on site conditions e.g. hydrology, rainfall, flood
timings and intensity, soil and sub-soil conditions in the river bed and banks, maximum
water depth, temperature and climatic conditions and available working space, etc.
The scheme should indicate precisely the type of temporary fasteners to be used
as also the minimum percentage of permanent fasteners to be fitted during the stage
erection. The working drawings should give clearly the temporary jigs, fixtures, clamps,
spacer supports, etc.
Unless otherwise provided in the contract, the contractor shall supply and erect all
necessary falsework and staging and shall supply all labour, tools, erection plant and
other materials necessary to carry out the work complete in all respects.
The Contractor shall supply all rivets, bolts, washers, etc. required to complete
erection at site with an allowance for wastage, etc., of 12 per cent of the net number of
field rivets, bolts, washers required, or a minimum of five number of each item.
Service bolts and nuts, ordinary platters, washers and drifts for use in the erection
of work shall be supplied at 60 per cent (45 per cent bolts and 15 per cent drifts) of the
number of field rivets per span in each size (this includes wastage). A reduction in the
quantities of service bolts, etc., may however, be specified by the Engineer if more than
one span of each type is ordered.
Prior to actual commencement of erection all equipment, machinery, tools,
tackles, ropes, etc. need to be tested to ensure their efficient working. Frequent visual
inspection is essential in vulnerable areas to detect displacements, distress, drainages, etc.
Deflection and vibratory tests shall be conducted in respect of supporting
structures, launching truss as also the structure under erection and unusual observation
reviewed; looseness of fittings are to be noted.
For welded structures, welders qualifications and skill are to be checked as per
standard norms. Non-destructive tests of joints as per designers directives are to be
carried out.
Precision non-destructive testing instruments available in the market should be
used for noting various important parameters of the structures frequently and systematic
record is to be kept.
Safety requirements should conform to IS : 7205, IS : 7223 and IS : 7269 as
applicable and should be a consideration of safety, economy and rapidity.
Erection work should start with complete resources mobilised as per latest
approved drawings and after a thorough survey of foundations and other related structural
work. In case of work of magnitude, maximum mechanisation is to be adopted.
The structure should be divided into erectable modules as per the scheme. This
should be pre-assembled in a suitable yard/platform and its matching with members of
the adjacent module checked by trial assembly before erection.
The structure shall be set out to the required lines and levels. The stocks and
masses are to be carefully preserved. The steelwork should be erected, adjusted and
completed in the required position to the specified line and levels with sufficient drifts
and bolts. Packing materials are to available to maintain this condition. Organised
Quality Surveillance checks need to be exercised frequently.
Before starting work, the Contractor shall obtain necessary approval of the
Engineer as to the method adopted for erection, the number and character of tools and
plants. The approval of the Engineer shall not relieve the Contractor of his responsibility
for the safety of his method or equipment or from carrying out the work fully in
accordance with the drawing and specifications.
During the progress of work, the Contractor shall have a competent Engineer or
foreman in charge of the work, who shall be adequately experienced in steel erection and
acceptable to the Engineer.
1905.3. Handling and Storing of Materials
Suitable area for storage of structures and components shall be located near the
site of work. The access road should be free from water logging during the working
period and the storage area should be on levelled and firm ground.
The store should be provided with adequate handling equipments e.g. road mobile
crane, gantries, derricks, chain pulley blocks, winch of capacity as required. Stacking
area should be planned and have racks, stands sleeper, access tracks, etc., and properly
lighted.
Storage should be planned to suit erection work sequence and avoid damage or
distortion. Excessively rusted, bent or damaged steel shall be rejected. Methods of
storage and handling steel, whether fabricated or not shall be subject to the approval of
the Engineer.
Fabricated materials are to be stored with erection marks visible, such as not to
come contract with earth surface or water and should be accessible to handling
equipment.
Small fitting hand tools are to be kept in containers in covered stores.
All joint surface for bolted connections including bolts, nuts, washers shall be free
from scale, dirt, burrs, other foreign materials and defects that would prevent solid
seating of parts. The slope of surface of bolted parts in contact with bolt head and nut
shall not exceed 1 in 20, plane normal to bolt axis, otherwise suitable tapered washer
shall be used.
All fasteners shall have a washer under nut or bolt head whichever is turned in
tightening.
Any connection to be riveted or bolted shall be secured in close contact with
service bolts or with a sufficient number of permanent bolts before the rivets are driven
or before the connections are finally bolted. Joints shall normally be made by filling not
less than 50 per cent of holes with service bolts and barrel drifts in the ratio 4:1. The
service bolts are to be fully tightened up as soon as the joint is assembled. Connections to
be made by close tolerance or barrel bolts shall be completed as soon as practicable after
assembly.
Any connection to be site welded shall be securely held in position by approved
methods to ensure accurate alignment, camber and elevation before welding is
commenced.
The field riveting, welding, bolted and pin connection shall conform to the
requirements of Clause 1904 as appropriate.
The correction of minor misfits involving harmless amounts of reaming, cutting
and chipping will be considered a legitimate part of erection. However, any error in the
shop fabrication or deformation resulting from handling and transportation which
prevents proper assembling and fitting up of parts by moderate use of drifts or by a
moderate amount of reaming and slight chipping or cutting shall be reported immediately
to the Engineer and his approval of the method of correction obtained. The correction
shall be made in the presence of the Engineer.
1905.7. Field Inspection
1905.7.1. General
All materials, equipment and work of erection shall be subject to the inspection
of the Engineer who shall be provided with all facilities including labour and tools
required at all reasonable times. Any work found defective is liable to be rejected .
1905.7.2. No protective treatment shall be applied to the work until the
appropriate inspection and testing has been carried out. The stage inspe ction shall be
carried out for all operations so as to ensure the correctness of fabrication and good
quality. Girder dimensions and camber shall not be finally checked until all welding and
heating operations are completed and the member has cooled to a uniform temperature.
1905.7.3. Testing of material: Structural steel shall be tested for mechanical and
chemical properties as per various IS codes as may be applicable and shall conform to
requirements specified in IS : 226, IS : 2062, IS : 11587, IS : 977, IS : 8500 and IS : 961,
etc.
Rivets, bolts, nuts, washers, welding consumables, steel forging, casting and
stainless steel shall be tested for mechanical and chemical properties in the appropriate
IS Code.
Rolling and cutting tolerance shall be as per IS : 1852. The thickness tolerance
check measurements for the plate and rolled sections shall be taken at not less than 15
mm from edge.
Laminations in plates shall be carried out by ultra-sonic testing or any other
specified methods.
Steel work shall be inspected for surface defects and exposed edge laminations
during fabrication and blast cleaning. Significant edge laminations found shall be
reported to the Engineer for his decision.
Chipping, grinding, machining or ultrasonic testing shall be used to determine
depth of imperfection.
1905.7.4. Bolted connections: Bolts and bolted connection joints with high
strength friction grip bolts shall be inspected and tested according to IS : 4000.
Rivets and riveted connection shall be inspected and tested for compliance of
codal requirements.
The firmness of joint shall be checked by 0.2 mm filler gauge, which shall not go
inside under the rivet head by more than 3 mm. There shall not be any gap between
members to be riveted.
Driven rivets shall be checked with rivet testing hammer. When struck sharply on
head with rivet testing hammer, rivet shall be free from movement and vibration.
All loose rivets and rivets with cracks, badly formed or deficient heads or with
heads which are eccentric with shanks, shall be cut out and replaced.
The alignment of plates at all bolted splice joints and welded butt joints shall be
checked for compliance with codal requirements.
Testing of flame cut and sheared edges is to be done, where the hardness criteria
given in the code are adopted. Hardness testing shall be carried out on six specimens.
1905.7.5. Welding and welding consumables: Welding procedure, welded
connection and testing shall be in compliance with codal requirements.
All facilities necessary for stage inspection during welding and on completion
shall be provided to the Engineer or their inspecting Authority by manufacturer.
Adequate means of identification either by identification mark or other record
shall be provided to enable each weld to be traced to the welder(s) by whom it was
carried out.
All metal arc welding shall be in compliance with IS : 9595 provisions.
The method of inspection shall be in accordance with IS : 822 and extent of
inspection and testing shall be in accordance with the relevant standards or in the absence
of such a standard, as agreed with the Engineer.
Procedure tests
The Destructive and Non-Destructive test of weld shall be carried out according
to IS : 7307 (Part I).
Non-Destructive Testing of Welds
One or more of the following methods may be applied for inspection or testing of
weld:
(i)
d) The weld shall be of full cross section, except for the ends of
intermittent fillet welds outside their effective length.
e) When weld is transverse to the primary stress, undercut shall not be
more than 0.25 mm deep in the part that is undercut and shall not be
more than 0.8 mm deep when the weld is parallel to the primary stress
in the part that is undercut.
f)
g) The piping porosity in fillet welds shall not exceed one in each 100
mm of weld length and the maximum diameter shall not exceed 2.4
mm, except for fillet welds connecting stiffeners to web where the sum
of diameters of piping porosity shall not exceed 9.5 mm in any 25 mm
length of weld and shall not exceed 19 mm in any 300 mm length of
weld.
h) The full penetration groove weld in butt joints transverse to the
direction of computed tensile stress shall have no piping porosity. For
all other groove welds, the piping porosity shall not exceed one in 100
mm of length and the maximum diameter shall not exceed 2.4 mm.
(ii)
(iii)
(iv)
b)
c)
d)
The particular length of welds in webs to be tested shall be agreed with the
Engineer, in case of (b) or (c).
Where specified by the Engineer, bearing stiffeners or bearing diaphragms
adjacent to welds, flange plates adjacent to web/flange welds, plates at cruciform welds,
plates in box girder construction adjacent to corner welds or other details shall be
ultrasonically tested after fabrication.
Any lamination, lamellar tearing or other defect found shall be recorded and
reported to Engineer for his decision.
Testing of Welding for Cast Steel: The testing of weld for cast steel shall be
carried out as may be agreed to by the Engineer.
Stud Shear Connectors: Stud shear connectors shall be subjected to the following
tests:
a)
b)
The studs whose welds have failed the tests given in (a) and (b) shall be replaced.
1905.7.6. Inspection requirement: The fabricated member/component made
out of rolled and built-up section shall be checked for compliance of the tolerances given
in Table 1900-2. Inspection of member/components for compliance with tolerances, and
the check for deviations shall be made over the full length.
During checking, the inspection requirement shall be placed in such a manner that
local surface irregularities do not influence the results.
For plate, out-of-plane deviation shall be checked at right angle to the surface
over the full area of plate.
The relative cross-girder or cross frame deviation shall be checked over the
middle third of length of the cross girder or frame between each pair of webs and for
cantilever at the end of member.
The web of rolled beam or channel section shall be checked for out-of-plane
deviation in longitudinal direction equal to the depth of the section.
During inspection, the component/member shall not have any load or external
restraint.
Inspection Stages: The inspection to be carried out for compliance of tolerances
shall include but not be limited to the following stages:
a)
b)
c)
For cross girders and frames, cantilevers in orthotropic decks and other
parts in which deviations have apparently increased on completion of site
assembly.
Where, on checking member/component for the deviations in respect of out-ofplane or out-of-straightness at right angles to the plate surface, and any other instances,
exceed tolerance, the maximum deviation shall be measured and recorded. The recorded
measurements shall be submitted to the Engineer who will determine whether the
component/member may be accepted without rectification, with rectification or rejected.
1906.
PAINTING
1906.1. General
Unless otherwise specified, all metal work shall be given approved shop coats as
well as field coats of painting. The item of work shall include preparation of metal
surfaces, application of protective covering and drying of the paint coatings and supply of
all tools, scaffolding, labour and materials necessary.
Coatings shall be applied only to dry surfaces and the coated surfaces shall not be
exposed to rain or frost before they are dry. The coatings shall be applied to all surfaces
excluding shear connectors and inner surfaces of fully sealed hollow sections. Care shall
be taken during coating of adjacent surfaces to build up primer on the shear connectors.
1906.1.1. Types of paints
(i)
Ordinary Paints
These include paints based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy, etc.
Alkyd resin paints for the protection of steel structures are based partly on natural
oils and partly on synthetic resins. These paints shall be used for steel structures in
atmospheres which are not too aggressive.
Oil based paints can be used for steel structures in cases where the surface
preparation cannot be ideal. Ordinary painting can generally be sub-divided into two
groups:
a)
Primary Coats
This shall be applied immediately after the surface preparation and should have
the properties of adhesion, corrosion inhibition and imperviousness to water and air.
b) Finishing Coats
These are applied over the primary coat and should have the properties of
durability, abrasion resistance, aesthetic appearance and smooth finish.
(ii)
The more highly corrosion resistant paints can be divided into two main groups:
a)
b)
The two pack paints shall be mixed together immediately before use since they
are workable thereafter only for a restricted period of time and dry up as a result of a
reaction between their components and yield hard tough films with resistance to abrasion.
(iii)
Vinyl Paints
These paints also have good chemical resistance. The main fields of applications
shall be in aggressive environments. In general, chlorinated rubber paints do not have a
high gloss.
(v)
Bituminous Paints
As a paint vehicle, bituminous is inferior, but because of the low price, this should
be applied in greater thickness (upto several millimetres) and may be suitable for some
situations. A significant advantage of bitumen paints is their impermeability to ingress of
water. However, bituminous paints do not withstand effectively detrimental effects of oil.
(vi)
Epoxy Paints
These resin paints have good adherence to a well prepared sub-strata. They are
mechanically strong and resistant to chemicals. A disadvantage of epoxy resin paints is
that it can rapidly become dull when exposed to strong sunlight. These disadvantages do
not, however, greatly influence their protective power.
(vii)
Polyurethane Paints
1906.1.5. Unless otherwise specified, all painting and protective coating work
shall be done in accordance with IS : 1477 (Part 1).
Primary coat shall be applied as soon as practicable after cleaning and in case of
flame cleaning, primary coat shall be applies while the metal is still warm.
All slag from welds shall be removed before painting. Surfaces shall be
maintained dry and free from dirt and oil. Work out of doors in frosty or humid weather
shall be avoided.
1906.3. Coatings
Prime coat to be used shall conform to the specification of primers approved by
the Engineer. Metal coatings shall be regarded as priming coatings. Primer shall be
applied to the blast cleaned surface before any deterioration of the surface is visible. In
any case, the surface shall receive one coat of primer within 4 hours of abrasive blast
cleaning.
All coats shall be compatible with each other. When metal coatings are used, the
undercoat shall be compatible with the metal concerned. The undercoat and finishing coat
shall preferably be from the same manufacturer. Successive coats of paints shall be of
different shades or colours and each shall be allowed to dry thoroughly before the next is
applied. Particular care shall be taken with the priming and painting of edges, corners,
welds and rivets. Typical guidelines for epoxy based paints and the conventional painting
system for bridge girders as given below may be complied with:
a) Epoxy Based Painting
i) Surface preparation: Remove oil/grease by use of petroleum
hydrocarbon solution (IS : 1745) and Grit blasting to near white metal
surface.
ii) Paint system: 2 coats of epoxy zinc phosphate primer = 60 micron;
Total 5 coats = 200 micron
The primer, intermediate and finishing coats shall all be applied so as to provide
smooth coatings of uniform thickness. Wrinkled or blistered coatings or coatings with
pinholes, sags, lumps or other blemishes shall not be accepted. Where the Engineer so
directs, the coating shall be removed by abrasive blast cleaning and replaced at the
Contractors expense.
1906.7. Guideline of Specifications for Protective Coating
System in Different Environments
Since the seriousness of the problem of corrosion depends upon atmospheric
condition and vary enormously, there is no single protective system or method of
application that is suitable for every situation.
However, as a guide, broad recommendations are given in Table 1900-3. for
various types of coatings in various environmental conditions which should be complied
with. Approximate life to first maintenance is also indicated and can be used as a guide.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
-3
2501. DESCRIPTION
River training and protection work shall include construction of guide bunds,
guide walls, bank protection, flooring and approach embankment protection as required
for ensuring safety of the bridge structure and its approaches against damage by
flood/flowing water. Construction of various components shall conform to IRC : 89 and
these specifications or as directed by the Engineer.
2502. GUIDE BUND
2502.1. This work shall consist of construction of embankment of guide bund
and provision of pitching/rivetment on slopes, apron, toe protection, curtain walls etc. as
indicated on the drawing in accordance with these specifications or as approved by the
Engineer.
The provisions given hereunder are applicable only to guide bunds for bridges
across alluvial rivers. Guide bunds for bridges across submontane rivers shall call for
supplemental specifications.
2502.2. The alignment and layout of guide bund shall be as indicated on the
drawing or as approved by the Engineer. The construction of embankment for guide bund
shall conform to provisions of Section 300 of these Specifications. Pitching, filter
underneath pitching and turfing, apron, toe protection, curtain walls, etc., shall be as per
these specifications.
2502.3. Guide bunds shall generally be made of locally available materials from
the river bed preferably cohesionless materials. Trial pits shall be taken in borrow holes
to examine suitability of soil for construction and also to decide the types of earth moving
machinery to be arranged. The borrow pits should be sufficiently away from the location
of the launching apron. No borrow pits should be dug on the river side of the guide
bunds.
Construction of guide bund shall be taken in hand alongwith the construction of
the bridge. Every effort shall be made to complete the work of the guide bund in one
working season. Where there is any doubt about completion of the whole guide bund
within one working season, suitable measures shall be planned and executed for
protection of completed work. In such cases the construction of guide bund shall be
started from abutment towards upstream.
2502.4. Construction of apron and pitching of the guide bunds shall generally
conform to clause 2503 and 2504 of these Specifications. Sufficient length of pit along
the guide bund shall be ready within one to two months of commencement of work so
that the placing of stones in the apron and in the slope pitching can be commenced. As a
guideline, earthwork should be completed within 80 per cent of working season and
about 70 per cent working season shall be available for laying apron laying apron and
pitching. No portion of guide bund should be left below HFL before the onset of
monsoon. Bottom of apron pit shall be as low as permitted by sub-soil water/lowest water
level. Sufficient labour and appropriate earth moving machinery and trained staff shall be
deployed in construction.
2502.5. The Contractor shall furnish his planning for approval of the Engineer
regarding transport of stones from the quarries to the site of work taking into account the
quantities of stone required to be transported every day, train/truck, etc., deployed,
available ferry or boats and labour available for loading and unloading and for laying
within the time frame for construction of guide bund. Adequate reserve of stones should
be maintained for major works as decided by the Engineer. Reserve stones shall be
stacked far away from the main channel of the river.
2502.6. Where the alignment of guide bund or the approach embankment crosses
a branch channel of the river, the branch channel may be either diverted to the main
channel of the river with the help of spurs, etc. or closed by a properly designed closing
dyke or closure bund taking up construction of guide bund.
2503. APRON
2503.1. General
This work shall consist of laying boulders directly or in wire crates on the bed of
rivers for protection against scour.
Where the required size of boulders are not available economically, cement
concrete blocks of equivalent weight shall be used. The grade of concrete shall be M15
nominal mix. (This holds good for pitching on the slopes and flooring also). Cement
concrete blocks shall be preferred where practicable.
The stones used in apron shall be sound, hard, durable and fairly regular in shape.
Stone subject to marked deterioration by water or weather shall not be used.
Quarry stones are preferable to round boulders as the latter roll off easily. Angular
stones fit into each other better and have good interlocking characteristics.
Where the required size stones are not economically available, cement concrete
blocks in M15 grade conforming to Section 1700 or stones in wire crates in combination
may be used in place of isolated stones of equivalent weight. Cement concrete blocks will
be preferred, wherever practicable.
2503.2. Laying Boulder Apron
The size of stone conform to clause 5.3.7.2. of IRC : 89.
The size of stone shall be as large as possible. In no case any fragment shall
weigh less than 40 kg. The specific gravity of stones shall be as high as possible and it
by twisting adjacent wires together. The top shall be made separately and shall be fixed
in the same manner as the sides after the crates or mattress have been filled.
Wherever possible, crates shall be placed in position before filling with boulders.
The crates shall be filled by carefully hand-packing the boulders as tightly as possible
and not by merely throwing in stones or boulders.
For laying of wire crates in aprons of bridges, two situations arises:
2504.
i)
Where the crates are to be laid in deep water and have to be dumped and
then joined together.
ii)
Where depth of water is low or dry bed is available. In such cases, the
crates can be laid at site.
PITCHING/REVETMENT ON SLOPES
2504.1. Description
This work shall consist of covering the slopes of guide bunds, training works and
road embankments with stone, boulders, cement concrete blocks or stones in wire crates
over a layer of granular material called filter. While river side slopes are given this
protection against river action, the rear slopes, not subjected to direct attack of the river,
may be protected against ordinary wave splashing by 0.30.6 metre thick cover of clayey
or silty earth and turfed.
2504.2 Pitching/Filter media
2504.2.1. Pitching: The pitching shall be provided as indicated in the drawings.
The thickness and the shape of stone pitching shall be shown on the drawing.
The stone shall be sound, hard, durable and fairly regular in shape. Quarry stone
should be used. Round boulders shall not be allowed. The stones subject to marked
deterioration by water or weather shall not be accepted.
The size and weight of stone shall conform to clause 5.3.5.1 of IRC : 89. No
stone, weighing less than 40 kg shall, however, be used. The sizes of spalls shall be a
minimum of 25 mm and shall be suitable to fill the voids in the pitching.
Where the required size stones are not economically available, cement concrete
blocks in M15 grade conforming to Section 1700 or stones in wire crates may be used in
place of isolated stones of equivalent weight. Cement concrete blocks will be preferred
wherever practicable. Use of geosynthetics has been dealt with in Section 700.
2504.2.2. Filter media: The material for the filter shall consist of sand, gravel,
stone or coarse sand. To prevent escape of the embankment material through the voids of
the stone pitching/cement concrete blocks as well as to allow free movement of water
without creating any uplift head on the pitching, one or more layers of graded materials,
commonly known as a filter medium, shall be provided underneath the pitching.
The gradation of the filter material shall satisfy the following requirements:
Provision of a suitably designed filter is necessary under the slope pitching to
prevent the escape of underlaying embankment material through the voids of stone
pitching/cement concrete blocks when subjected to the attack of flowing water and wave
action, etc. In order to achieve this requirement, the filter may be provided in one or more
layers satisfying the following criteria:
D 15 (Filter)
<5
D 85 (Base)
4<
D 15 (Filter)
< 20
D 15 (Base)
D 50 (Filter)
< 25
D 50 (Base)
Notes : 1.
2.
In the foregoing, D 15 means the size of that sieve which allows 15 per
cent by weight of the filter material to pass through it and similar is the
meaning of D 50 and D 85.
3.
If more than one filter layer is required, the same requirement as above
shall be followed for each layer. The fine filter shall be considered as base
material for selection of coarser filter.
4.
2504.3
Construction Operations
Before laying the pitching, the sides of banks shall be trimmed to the required
slope and profiles put up by means of lines and pegs at intervals of 3 metres to ensure
regular straight work and a uniform slope throughout. Depressions shall be filled and
thoroughly compacted.
The filter granular material shall be laid over the prepared base and suitably
compacted to the thickness specified on the drawings.
The lowest course of pitching shall be started from the toe wall and built up in
courses upwards. The toe wall shall be in dry rubble masonry (uncoursed) conforming to
Clause 1405.3, in case of dry rubble pitching and shall be in nominal mix cement
concrete (M15) conforming to Clause 1704.3 in case of cement concrete block pitching.
The stone pitching shall commence in a trench below the toe of the slope. Stone
shall be placed by derrick or by hand to the required length, thickness and depth
conforming to the drawings. Stones shall be set normal to the slope, and placed so that
the largest dimension is perpendicular to the face of the slope, unless such dimension is
greater than the specified thickness of pitching.
The largest stones shall be placed in he bottom courses and for use as headers for
subsequent courses.
In hand placed pitching, the stone of flat stratified nature should be placed with
the principle bedding plane normal to the slope. The pattern of laying shall be such that
the joints are broken and voids are minimum by packing with spalls, wherever necessary,
and the top surface is as smooth as possible.
When full depth of pitching can be formed with a single stone, the stones shall be
laid breaking joints and all interstices between adjacent stones shall be filled in with
spalls of the proper size and wedged in with hammers to ensured tight packing.
When two or more layers of stones must be laid to obtain the design thickness of
pitching, dry masonry shall be used and stones shall be well bonded. To ensure regular
and orderly disposition of the full intended quantity of stone as shown, template cross
walls in dry masonry shall be built about a metre wide and to the full height of the
specified thickness at suitable intervals and all along the length and width of the pitching.
Within these walls the stones shall be hand packed as specified.
2404. Toe Protection
In conformity with clause 5.3.7. of IRC : 89, a toe wall shall be provided at the
junction of slope pitching and launching apron of a guide bund so as to protect the slope
pitching from falling even when the apron is not laid at low water level. The toe wall
shall be in dry rubble masonry (uncoursed) conforming to Clause 1405.3 in case of dry
rubble pitching or pitching/revetment with stones in wire crates and in nominal mix
cement concrete (M15) conforming to Clause 1704.3 in case cement concrete blocks
have been used in pitching. For protection of toes of bank slopes terminating either in
short aprons at bed levels or anchored in flooring/rocky bed, the provisions of clause
8.2.2. of IRC : 89 may be complied with. The relevant specifications of the protective
works for individual components will be followed.
2505. RUBBLE STONE/CEMENT CONCRETE BLOCK FLOORING OVER
CEMENT CONCRETE BEDDING
2505.1. This work shall consist of construction rubble stone/c.c. block flooring
laid over a cement (M15) bedding. The floor protection will comprise rigid flooring
stated above with curtain walls and flexible apron.
2505.2. Construction Operations
Excavations for laying the bedding and floor protection works shall be carried out
as per specifications under proper supervision. Before laying the foundation and
protection walls, the excavated trenches shall be thoroughly inspected by the Engineer -in
Charge to ensure that:
a)
There are no loose pockets and unfilled depressions left in the trench.
b)
The soil at the founding level is properly compacted to the true lines and
level so as to have an even bedding.
c)
Cement concrete nominal mix (grade M 15) of 300 mm thickness shall then be
laid in accordance with provisions given in Section 1700 except that the surface of the
concrete shall not be given a smooth finish. The paving work shall be embedded in green
concrete.
Flooring shall consist of 150 mm thick flat stone/cement concrete blocks
(Nominal mix Grade M 15 conforming to Section 1700). It shall be bedded on a layer of
cement mortar (1:3) prepared to Clause 1304. Spalls shall be used to fill in the voids. The
joints shall then be filled with cement mortar and finished neat. The stone shall break
joints and the joints shall not exceed 20 mm in thickness. Spacing of joints may be 20 m
or so. The top of flooring shall be kept to 300 mm below the lowest bed level.
2506.
This work shall consist of construction dry rubble flooring at cross drainage
works for relatively less important works.
The base for the flooring shall be prepared to the specified levels and slopes and
The materials shall be tested in accordance with these Specifications and shall
meet the prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed
standards of acceptance.
2509.
The protection works shall be measured as set forth below. If directed by the
Engineer for measurement, the materials may have to be stacked at site before laying and
nothing extra will be paid to the Contractor for this stacking.
The earth work in construction of embankment for guide bund shall be measured
in cubic metres unless otherwise specified.
The boulders/cement concrete blocks and wire crates in apron shall be measured
in cubic metres.
The filter and stone pitching shall be measured separately in cubic metres unless
otherwise specified.
Rubble stone/cement concrete blocks, flooring and cement concrete bedding shall