Annexure A

Tender for Super-Structure (Hasdeo Bridge)
SECTION -VIII
TECHNICAL SPECIFICATIONS
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BRIDGE WORK
SPECIFICATION FOR SUPER-STRUCTURE OF BRIDGE (Steel

girders)
1.0 Books of reference
For the guidance of the bidder, list of the reference books, codes and
manuals are given herewith. The list is only indicative. Additional documents
as per the requirement of the works and as directed by the Engineer are to
be referred. Bidders are required to adhere to the latest instructions, updated
versions and revised editions of the documents.
Railway/IRS books of reference:

i. IRS Rules Specifying the Loads for Design of Super-Structure
and Sub-Structure for Bridges (Bridge Rules)
ii. Indian Railways Standard Code of Practice for the Design of
Steel or Wrought Iron Bridges Carrying Rail, Road or Pedestrian
Traffic (Steel Bridge Code)
iii. IRS Code of Practice for Metal Arc Welding in Structural Steel
Bridges Carrying Rail, Rail-cum-Road or Pedestrian Traffic
(Welded Bridge Code)
iv. IRS Specification for Fabrication and Erection of Steel Girder
Bridges and Locomotive Turn-Tables: Fabrication Specification
(B1)
v. IRS Code of Practice for Plain, Reinforced & Prestressed
Concrete for General Bridge Construction (Concrete Bridge
Code)
vi. Indian Railways Schedule of dimensions for Broad Gauge. -2005
vii. Indian Railways Bridge Manual, 1998.
viii. Indian Railways P. Way Manual. 2004
ix. Indian Railways Works Manual. 2000
x. M-3: Class I, II, III and IV steel forgings, blooms for forging and
billets for rerolling
xi. M-28: Classification, Testing and approval of metal-arc welding
electrodes for use on Indian Railways.
xii. M-39: Classification, testing and approval of submerged arc
welding wire flux combination
xiii. M-41: Corrosion resistance steel
xiv. M-42: High strength low alloy structural steel with enhanced
corrosion resistance
xv. M-43: High strength low alloy structural steel rivet bars with
enhance corrosion resistance.
xvi. P-31: Zinc chromate red oxide primer
xvii. M&C/PCN/102/96: Epoxy zinc phosphate primer
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xviii. M&C/PCN/103/86: Epoxy micaceous iron oxide

xix. M&C/PCN/109/88: Polyurethane red oxide
xx. M&C/PCN/110/88: Polyurethane aluminum
xxi. M&C/PCN/111/88: High build epoxy paint
xxii. RDSO/M&C/Specification: Classification, testing and approval of
CO2 welding filler wires for use on Indian Railways
Indian Roads Congress codes and specifications:

i. IRC-21: Standard specifications and Code of practice for Road
Bridges- Sections –III- Cement concrete (Plain & reinforced)
ii. IRC-24: Standard specifications and Code of Practice for Road
Bridge –Section –V- Steel Road Bridges.
iii. IRC- 83: Bearings for bridges.
iv. IRC-87: Design and erection of false work for road bridges
Indian Standards Codes & Specifications:

1) IS: 2062 –2011 Steel for general structural purposes.(new code
includes the provisions of IS:1077 & IS: 8500)
2) IS: 1786- High strength deformed steel bars & wires for concrete
reinforcement.
3) IS: 1148- Hot rolled rivet bars (up to 40mm dia) for structural
purposes.
4) IS: 1149- High tensile steel rivet bars for structural purposes.
5) IS: 1929 – Hot forged steel rivets for hot closing (12 to 36mm dia)
6) IS: 2004 Carbon steel forgings for general engineering purposes.
7) IS: 57 – Red lead for paints and other purposes.
8) IS: 75 – Linseed oil, raw and refined.
9) IS: 77 – Linseed oil, boiled for paints.
10) IS: 102 Ready mixed paints, brushing, red lead, non-settling, priming.
11) IS: 123 – Ready mixed paints, brushing, finishing, semi-gloss, for
general purposes to Indian Colours etc.
12) IS: 2339- Aluminum paints for general purposes, in dual container.
13) IS: 280- Mild steel wire for general engineering purposes.
14) IS: 456- Plain and reinforced concrete.
15) IS: 883 – Design of structural timber in buildings.
16) IS: 814- Covered electrodes for manual metal arc welding.
17) IS: 1182- Radiographic examination of butt joints in steep plates.
18) IS: 2595- Radiographic testing.
19) IS: 383- Coarse and fine aggregates from natural sources for
concrete.
20)IS: 2386 (all 8 parts) – Tests for aggregates for concrete.
21)IS: 3025 (all 49 parts) – Methods of sampling and test for water and
waste water.
22)IS: 1791 – Batch type concrete mixers.
23) IS: 4634- Methods of testing performance of batch type concrete
mixers.
24) IS: 6925- Methods of test for determination of water-soluble
chlorides in concrete admixtures.
25) IS: 9103 – Admixtures for concrete.
26) IS: 516 – Method of test for strength of concrete.
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27) IS: 4031 (all 15 parts) - Physical tests for hydraulic cement.
28) IS: 5513- Vicat apparatus.
29)IS: 10080- Vibration machine for casting standard cement mortar
cubes.
30)IS: 10262- Concrete mix design.
31) IS: 1343 – Prestressed concrete.
32) IS: 875 (all 5 parts) – design loads (other than earthquakes) for
buildings and structures.
33) IS: 2720 (all 41 parts)- Method of tests for soils.
34) IS: 800 General constructions in steel.
35) IS: 786- Conversion factors and conversion tables.
36) IS: 1024 – Welding in bridges and structures subject to dynamic
loading.
37) IS: 1261 - Seam welding in mild steel.
38)IS: 1367 (all 20 parts) - threaded steel fasteners.
39)IS: 6639- Hexagonal bolts for steel structures.
40) IS: 104 – Ready mixed paint, brushing, zinc chrome, priming.
41) IS: 2074- Ready mixed paint, air drying, red oxide-zinc chrome,
priming.
42) IS: 1852- Rolling and cutting tolerances for hot rolled steel products.
43)IS: 1270- Metric steel tape measure.
44)IS: 9595- Metal Arc Welding.
45) IS: 487- Brush, paint and varnish.
46) IS: 1030 – Carbon steel castings for general engineering purposes.
47) IS: 3400 (all 22 parts) - Methods of tests for vulcanized rubbers.
48) IS: 1915- Steel bridge code
49) IS: 1893- Earthquake resistant design of structures.
50) IS: 3502- Steel Chequered plates.
51)IS: 3085- Method of test for permeability of cement mortar and
concrete.
52)IS: 7320 – Concrete slump test apparatus.
53) IS: 5515- Compaction factor apparatus.
54) IS: 6586- Metal spraying for protection of iron steel.
55) IS: 5666- Etch primer.
56)IS: 3955- Design and construction of well foundations.
57)SP 6, 7, 16, 21, 22, 23, 24, 34, 36, 52, 60.
58)IS: 2911- Design and construction of pile foundation.
59)IS; 7205- Safety code for erection of structural steel work.
60)IS: 8629- Protection of iron and steel structures form atmospheric
corrosion.
61)IS: 5624- Foundation bolts.
62)IS: 7215- Tolerances for fabrication of steel structures.
63)IS: 8112- 43 Grade OPC.
64) IS: 4326- Earthquake resistant design and construction of buildings.
65) IS: 13920- Ductile detailing of reinforced concrete structures
subjected to seismic forces.
66) IS: 34 – White lead for paints.
67) IS: 887 – Animal tallow.
68)IS: 816- Metal arc welding for general construction in mild steel.
69)IS: 819- Resistance spot welding for light assemblies in mild steel
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70)IS: 1024 – Welding in bridges and structures subject to dynamic

loading.
71)IS: 1261- Seam welding in mild steel.
72)IS: 1323- Oxy-acetylene welding for structural work in mild steel.
73)IS: 4081- Safety code for blasting and related drilling operations.
74)IS: 3764- Safety code for excavation work.
75)IS: 7293- Safety code for working with construction machinery.
76)IS: 817- Training and testing of metal arc welders.
77) IS: 1200 (all relevant parts)- Method of measurement of building
and civil engineering works.
78) IS: 2132- Thin walled tube sampling of soils
79) IS 2131- Standard penetration test for soils.
Miscellaneous:
i. UIC-772R: Bearings of rail bridges.

ii. BS-5400 (all parts)
iii. BS-1449, 3484, 1134, 5296
iv. ASTM/AASHTO
Note: The books of reference shall also include further references

mentioned in above-mentioned books of references. All the
books, references and codes shall be of latest edition with up to
date correction slips.
1.1. G E N E R A L:
The girders shall be steel girders as per approved drawings.
Steel of approved grade and quality conforming to IS: 2062- 2011

(latest amendments and with all correction slips), is proposed to be
used for all components for all spans as per approved drawings.
The steel shall comply in all respects with the requirements of approved
drawings and relevant codes and specifications and shall be procured from
approved manufacturers only. It may be noted that quality of steel used for
fabrication shall be rigidly followed. Steel sections to be supplied by the
manufacturers shall be ultrasonically tested as per codal provisions at the
manufacturer’s premises before dispatch. The Contractor on receipt of
supply in his factory premises/fabrication workshop shall carryout random
USFD testing as per standards laid down in various codes or as per Quality
Assurance Plan and verify them with the list received from manufacturers.
Only tested steel shall be used for fabrication. All rolled sections shall bear
cast mark and shall be of such length as to avoid butt welded joints in
components of truss. Such rolled sections shall be within rolling tolerances
stipulated as per IS: 1852 and shall be free from defects.
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(i) Only weld able steel conforming to IS: 2062 of approved grade and
quality as per IRS B1 (latest revision with update correction slips)
shall be used for fabrication.
(ii) No Re-rolled Steel should be used.
(iii) Steel should be procured only from reputed steel manufacturers like
SAIL, RINL, TISCO or JINDAL. The source of steel should be got
approved by the Engineer / Employer.
(iv) In support of purchase, copy of vouchers are to be submitted.
The tenderer(s) shall supply information in the tender regarding

source/manufacturers from where procurement of steel is proposed by
him/them. However, the usage of type and grade of steel may vary during
the execution of the work depending upon the design requirement and
market availability. No claim shall be entertained from the Contractor on
this account and payment shall be as per relevant items in the schedule of
items, quantities and rates.
Steel for rivets shall conform to IS:1148 for M.S and IS:1149 for H.T.S.
Welding consumables for Manual Metal Arc Welding (MMAW) shall conform
to IRS-M- 28, wire and flux combination for submerged arc welding to IRS
M-3 and filler wires for CO2 welding to RDSO/M&C/Specification issued
vide letter No. M&C/W/111/24 dated 1.1.1994/7.2.1994.
All welding consumables (electrodes, wire, flux etc.) shall be procured only
from the manufacturers approved by RDSO subject to final approval by
Engineer.
All materials for the work shall pass tests and/or analysis prescribed by the
relevant IS specifications or such other equivalent specifications.
For all materials including rivets and bolts, the Contractor shall furnish
copies of test certificates from the manufacturers including proof sheets, mill
sheets etc. showing that the materials have been tested in accordance with
the requirements of various specifications and codal provisions.
If any further testing of materials is required by Engineer in respect of these

and other items, it shall be arranged for by the Contractor at a reputed
laboratory/National test house as approved by Engineer. For this, nothing
extra shall be payable and accepted rates in the schedule of items,
quantities and rates shall be deemed to include this.
Even satisfactory outcome of such tests or analysis shall in no way limit,

dilute or interfere with the absolute right of the Engineer to reject the whole
or part of such materials supplied, which in the judgment of the inspecting
authority does not comply with the conditions of the contract. The decision of
the Engineer in this regard shall be final, binding and conclusive for all
purposes.
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1.2. The contractor shall procure the approved latest drawings from RDSO
and based on these approved drawing, contractor shall prepare a
detailed fabrication drawings incorporating latest circulars/guidelines
and get it proof checked from IIT/NIT and submit it to Engineer or
RDSO for its approval.
1.3. The contractor should prepare Quality Assurance Plan (QAP) based on
RDSO guidelines for fabrication of girders and get the same approved from
the RDSO before proceeding with the work. Girders should be got
fabricated by a firm who has full fledge fabrication workshop and
should have valid certification of RDSO for fabrication of girders. Any
another procedure will require approval of Engineer.
.
2.0 ASSEMBLING/ ERRECTION OF STEEL GIRDERS
Fabrication and Workmanship
2.1 General
Fabrication, Workmanship shall generally comply with current IRS

specification No.B1-2001 with latest correction/amendments thereof
unless otherwise specified in special conditions of this contract or as
specially directed by the Engineer in writing.
The fabrication of the girders and its accessories shall be carried out by
the Contractor in his factory premises or in a well-established fabrication
workshop to be set up by the Contractor at bridge site or any other
location as approved by the Engineer. In either case, the fabrication
workshop should have valid approval certificate from RDSO. The
workshop staff shall have requisite experience, proven skill and
experience in the technique of fabricating bridge girder (OWG & PG)
components. Accuracy of fabrication shall be realized through controlled
high precision jigs, fixtures and templates, which shall be inspected and
passed by RDSO or any other inspection agency as nominated by
Engineer. The fabrication shall be preceded by Quality Assurance Plans to
be submitted and and its approval from RDSO by the Contractor and
every activity shall be documented therein. The Quality Assurance Plans
shall clearly indicate how individual processes such as cutting of raw steel,
marking, drilling, assembly, riveting/welding, painting, handling etc shall be
monitored for quality. The quality parameters for monitoring shall be
identified along with monitoring frequency and quality records to be
maintained. The officials responsible for monitoring these identified quality
parameters shall also be specified in these quality plans. The Contractor
shall get these quality plans approved from RDSO before start of
fabrication work. The Engineer shall be empowered to check the
manufacturing process from time to time to ensure that the work is
executed as per approved quality plans. The quality records shall be
submitted to Engineer for record, after completion of fabrication work.
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The work of fabrication in Contractor’s fabrication shop will at all times be

open for inspection by Engineer or any other agency as nominated by
Engineer. Before dispatch of fabricated steel work from the shops the
same will be inspected in the Contractor’s fabrication workshop by
Engineer and/or any other authority/agency nominated by Engineer who
will thereafter issue inspection certificate.
Any defects noticed during inspection in the execution of work shall be

rectified or member component will be replaced by the Contractor at his
own cost. The decision of Engineer and/or the nominated agency for
inspection as to the existence of the defect, the manner in which the
defective work has to be rectified or replaced, shall be final and
conclusive.
In the fabrication of girder, necessary arrangement and provision shall be

kept for inspection facilities underneath the girder and also for carriage of
service cables, pipe lines etc as per approved plans.
2.2 Fabrication Drawings:
The Contractor shall prepare detailed fabrication/shop drawings on the

basis of approved latest drawing procured from RDSO alongwith latest
circular /guidelines contractor shall get it proof checked from IIT/NIT
and submit it to Engineer or RDSO for its approval. No separate
payment shall be made for this and accepted rates shall be deemed
to include this aspect The fabrication drawings shall be submitted by the
contractor to Engineer in triplicate, one copy of which will be returned after
scrutiny and approval. The fabrication drawings shall indicate member
sizes prior and after cutting, machining to obtain correct length and shape,
tolerance provisions, welding sequence, type and size of welding etc No
work of fabrication will be started without approval of fabrication drawings.
For Engineer’s use and record, the Contractor shall supply free of charge,
four sets of prints on strong paper and one set of neatly executed tracings
of all approved detailed drawings and fabrication drawings, soon after
communication of approval, for use at site.
2.3 Maintenance of records by fabricators

The records of fabrication shall be maintained in the registers as per the
formats given in Appendix I of B-1 Specification. For ready reference,
extract of the same has been given in the end of this specification as well.
2.4 Tolerances in Fabrication

Fabrication tolerance for girders shall be as stipulated in Appendix II of
IRS-B1-2001 (with latest revision). Permissible deviation for driven rivets
shall be as stipulated in Appendix-IV of IRS-B1-2001 (with latest revision).
2.5 Testing of the Materials
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In addition to the test certificate obtained from the steel

producers/suppliers/dealers, for conformity sake, all
materials/consumables, i.e. steel, rivets, welding electrodes, paints, etc
shall be got tested from the NABL approved labs/recognized labs. Proper
record of all such test results shall be maintained. A copy of the same be
given to client/IRCON as well. Test result of the supplier and that of the
lab should match with each other. In case of major difference, mater has
to be investigated. Decision of the IRCON shall be final in that regard.
Rolled steel shall also be ultrasonically tested by the reputed firm. Only
ultrasonically tested steel shall be used for fabrication work. Record of
ultrasonically tested steel shall be maintained separately.
All the testing work shall be done in accordance to the provisions of the
relevant codes.
Regarding radiographic testing/x-ray testing of the welded joints, matter

shall be finalized in consultation with the inspecting authority, i.e. RDSO.
Agreed to procedures shall be followed. Necessary arrangement for that
has to be got done by the tenderer at their own cost.
All testing work shall be got done by the contractor at their own cost.
Nothing extra shall be paid. Tenderers should quote their rate
accordingly.
2.6 Fabrication / Manufacture
The whole work shall be representative of the highest class of workmanship. The
greatest accuracy shall be observed in the design, manufacture and erection of
every part of the work to ensure that all parts will fit accurately together on
erection. For manufacture of the components of all spans to be made strictly
interchangeable as specified in ‘interchangeability’ criteria given in this
specification on the subsequent pages, approved set of same jigs and assembly
fixtures shall be used. The tolerances in manufacture shall be in accordance with
as shown in Appendix III of IRS B-1-2001 Specification. For ready reference, the
same are also produced in the end of this technical specification (Quality control
portion of this specification).
The Contractor shall state which of the following alternative methods of

manufacture he/she intends to adopt.
a). The whole of work to be erected complete and pieces marked to place.
b). All spans to be made strictly as per the interchangeable criteria described
subsequently of this technical specification
The Contractor shall maintain a master steel tape of approved make for which
he/she has obtained a certificate of accuracy from any National Test House or
Government recognized institutions, competent to do so.
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2.7 Templates
The templates through out the work shall be of steel. The template shall be
used for marking of cutting material and as well as profile machining for girders
of railway loading. Templates shall be used for marking of drilling holes in steel
structures other than girder of railway loadings. In case where actual materials
from a bridge have been used as templates for drilling similar pieces the
Inspecting Officer will decide whether they are fit to be used as part of the
finished structure.
The contractor shall supply and provide templates at his own cost. No separate
payment shall be made for this and accepted rates shall be deemed to
include this aspect. The templates used for the work shall be of steel and of
tested quality.
2.7.1 Template Shop
(i) Fully covered template shop consisting of uninterrupted steel or concrete floor
as approved having true and correct level covering adequate area shall be
provided by the contractor.
(ii) Camber layout shall be drawn to full scale from end of girder to half span. This
camber layout once approved shall be used for fabrication of master gusset
profiles and end profile of each member. It shall be used for working out the
actual lengths of each member and checked to conform to the calculated length.
(iii) Master gussets at every panel joint of top chord, bottom chord and middle web
panel shall be marked accurately on camber layout drawn on template floor.
(iv) All precautions shall be taken while drawing camber layout for correct setting
of angle of intersection of chord and web member and great accuracy shall be
ensured while transferring the same on master gusset. While marking centre
point of field rivet holes on master gusset, if there is symmetry of holes on
vertical axis, marking shall be made only on half the master gusset across
vertical axis, and holes drilled by inscribing each hole. Subsequently remaining
half portion shall be drilled through gusset using the same half portion master
gusset. This will help realize symmetry of holes in gusset and fairing of field
rivet hole during girder assembly.
Camber layout and fabrication of Master gusset at every panel joint requires
highly skilled and trained staff experienced in accurate fabrication of large
girders, drilling jigs and fixtures. At least one jig shall be required for each
component. Each jig shall be numbered and a record kept in register for
identification.
2.8 Flattening and Straightening
All steel materials, plates, bars and structurals shall have straight edges, flat
surfaces and be free from twist. If necessary, they shall be cold straightened or
flattened by pressure before being worked or assembled unless they are
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required to be of curvilinear form. Pressure applied for straightening or flattening

shall be such as it would not injure the material and adjacent surfaces or
edges shall be in close contact or at uniform distance throughout. Flattening
and straightening under hot condition shall not be carried out unless authorized
and approved by the Inspecting Officer.
2.9 Planning and Shearing
Except where otherwise indicated, cutting of all plates and sections shall be
affected by shearing or sawing. All edges shall be clean, reasonably square and
true. Wherever possible the edges shall be cut in a shearing machine, which will
take the whole length of the plate in one cut.
As per direction of the engineer, if required, the cut edges shall be ground
afterwards. Planing or machining of the edges or surface shall be carried out
when so specified in the contract drawings or where specifically ordered by the
Engineer. Where machining is specified, the plates or all sections shall be cut in
the first instance to such a size so as to permit not less than 3mm of metal being
removed from each sheared edge or end, in the case of plates or sections of
12mm or less in thickness and not less than 6mm of metal being removed in the
case of plates and sections exceeding 12mm in thickness. The butting ends of
all booms and struts where spliced shall be faced in an end milling machine after
members have been completely fabricated. In the case of compression members
the face shall be machined so that the faces are at right angle to the axis of the
members and the joint when made, will be in close contact throughout. At the
discretion of the Inspecting Officer, a tolerance of 0.4mm may be permitted at
isolated places on the butting line.
All marking and checking of master gussets, camber layout, etc shall preferably
be at the mean temperature of the fabrication zone.
2.10 Flame cutting
Flame cutting by mechanically controlled torch/torches shall be accepted both in

the case of mild steel and high tensile steelwork. Provided the edge as given by
the torch is reasonably clean and straight, plates may be cut to shape and beams
and other sections cut to length with a gas-cutting torch, preferably oxyacetylene
gas should be used. All flame cut edges shall be ground to obtain reasonably
clean square and true edges. Draglines produced by flame cut should be
removed. Unless machining has been specifically provided for, special care is to
be taken to ensure that ends of all plates and members are reasonably in close
contact and the faces are at right angles to the axis of the members and joints,
when made, are also reasonably in close contact. Use of multi-head flame cutting
machine having multiple oxy acetylene torches is desirable for higher productivity
and reducing the distortion due to cutting operation. Plasma-arc cutting method
can also be employed. This process offers less heat input causing less distortion.
2.11 Drilling and Sub-punching
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All holes shall be drilled but the Contractor may, if he/she so prefers sub-punch
them to a diameter 6mm less than that of finished holes, e.g. a punched hole
which is to be drilled out to 25mm in diameter shall not exceed 19mm in diameter
at the die end. When the rivet holes are to be sub-punched, they shall be marked
with a centre punch and made with a nipple punch or preferably, shall be
punched in a machine in which the position of the hole is automatically regulated.
The punching shall be so accurate that when the work has been put together
before drilling, a gauge 1.5mm less in diameter than the size of the punched
holes can be passed easily through all the holes. Holes for countersunk heads
of rivets, bolts or screws shall be drilled to the correct profile so as to keep the
heads flush with the surface Holes for countersunk heads of rivets, bolts or
screws shall be drilled to the correct profile so as to keep the heads flush with the
surface. No sub-punching shall be allowed in the main truss members of open-
web girders. Holes for turned bolts should be 1mm under drilled in shop and
should be reamed at site to suit the diameter of turned bolt.
Where the number of thicknesses to be rivetted exceeds three or the total

thickness is 90mm or more, the rivet holes, unless they have been drilled
through steel-bushed jigs, shall be drilled out in place 3mm all round, after
assembling. In such cases the work shall be thoroughly bolted together.
The steel bushes shall be case hardened by an approved process and checked
for diameter after the heat-treatment. The bores of bushes shall initially have a
tolerance of -0mm, 0.1mm. The tolerance shall be checked from time to time
and when the bores exceed a tolerance of, -0mm, +0.4mm, the bushes shall be
rejected. For this purpose, go and no-go gauges are to be used. Tolerances for
checking jigs from master plates shall be +0mm -0.13mm.
The work shall be taken apart after drilling and all burrs left by the drill and the
sharp edges of all the rivet holes completely removed.
2.12 Parts in Contact
All steel work intended to be riveted or bolted together shall be in contact over
the whole surface.
Drifts as shown in Fig. No.-1 may be used for drawing light members into position
but their use on heavy members should be restricted to securing them in their
correct positions. In no case, shall drifting be allowed to such an extent that holes
are distorted
Drifting to enlarge unfaired holes is prohibited. The holes that will have to be
enlarged to admit rivets should be reamed provided the Engineer permits such
reaming after satisfying himself about the extent of inaccuracy and the effect of
reaming on the soundness of the structure. The Purchaser retains the right to
reject all steel work if the holes are not properly matched.
2.13 Making of Joints
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Cleaning of permanent contact surfaces: Surfaces which will have permanent

contact shall be removed of paints and mill scale down to bare metal, clean and
dried and immediately a coating of red lead to IS: 102 shall be applied. Care shall
be taken to see that all burrs are removed and no surface defects exist before the
parts are assembled. Bolting and drifting: Only barrel drifts as per Fig. No.-1 shall
be used in erection. They may be used for drawing light members into position;
but their use on heavy members shall be restricted to securing them in their
correct position. Any apparent error in shop work, which prevents the assembling
and fitting up of the parts by the proper use of these drifts, shall be investigated
immediately. As all work is rigidly inspected in the manufacturers work before
dispatch, these difficulties should not arise and the cause should be first be
sought in the use of incorrect components or the transposition of a correct part. It
is usually important that parts should be correctly handled. Should error still
persist, the matter shall be immediately reported to the Engineer who will
decide what action is to be taken. No reaming shall be undertaken without the
written authority of the Engineer, except for the under drilled holes meant for
turned bolts. If approved, the Contractor shall supply, at his/her own expense,
any special rivets that maybe required. Copies of all correspondence relative to
the recourse to reaming and the use of over-size rivets shall invariably be sent by
the Engineer for information to the inspectorate concerned.
Joints shall normally be made by filling not less than 50% of the holes with
service bolts and barrel drifts in the ratio of four to one. The service bolts are to
be fully tightened up as soon as the joint is assembled.
Special methods of erection other than described in Appendix III of IRS B-1-2001
Specification: In cases where the joints have to withstand stresses arising from
special method of erection, provision is to be made to take the whole stress that
will or may occur. Cylindrical drifts and turned bolts shall be used to withstand
such stresses and no reliance is to be placed on the service bolts for this
purpose. Up to maximum of 40% of the holes of each member of the joint are to
be filled with drifts and balance of strength required is to be attained with turn
bolts. The Engineer will intimate the position and number of the drifts and bolts.
The condition of “Making of Joints” of this technical Specification must be
observed and the bolt fully tightened up as soon as the joint is made.
Where the manufacturing of girders has been done in accordance with

“Interchangeability” of this specification relating to steel girder bridges, the
erection shall be done in accordance with Appendix III of IRS B-1-2001
Specification. However, if the Contractor desires to adopt any other method of
erection, he/she shall submit the scheme and obtain the approval of the
Engineer. It shall be ensured that when in position, the girder has the camber as
per drawing.
In the event of an emergency arising such as the staging is in danger of being

carried away by floods before the riveting can be completed, the joints shall be
made secure by filling 40% of the holes with cylindrical drifts and equal
number with service bolts fully tightened.
2.14 Rivets and Riveting

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The dimensions on the drawings referred to the diameters of the rivet holes and
their finished rivets. The rivet holes shall be 1.5 mm greater than the diameter of
the rivet bars used. The rivets shall be made to IS: 1929. The shanks of the
undriven rivets shall be made of a length sufficient to fill the holes thoroughly and
form the head. The clearance i.e. the difference in diameter between the rivets
measured under head before being heated and the rivet hole shall not be less
than 0.75mm. Before rivetting is commenced, all works shall be properly bolted
so that the sections rivetted are in close contact throughout. Rivets shall
completely fill the holes and shall be machine driven by means of pressure or
percussion rivetters of approved design.
All rivets shall be properly heated to straw heat for the full length of the shank,
firmly backed and closed. The head of the rivet, particularly in long rivets, shall be
heated more than the point and in no case shall the point be heated, more than
the head. Sparking or burnt rivets shall not be used. Where it is impossible
to back up by normal method of holding up, ‘double gunning’ may be resorted
to. Alternatively pneumatic holding device may be used.
Gauges for rivet dimensions and contours shall be provided by the Contractor for
the use of the Inspecting Officer.
Rivets when driven shall completely fill the holes, have the heads concentric with
the shanks and shall be in full contact with the surface. Driven rivets when struck
sharply on the head with the 110-gm. rivet testing hammer, shall be free from
movement or vibration.
While rivetting built-up members, full care should be exercised to ensure that
the set of holes for field rivets in each flange of the built-up member, is aligned
dead-square in relation to that in the other flange and not ‘aborrated’. Use of
assembly fixtures shall be made to ensure this.
All loose and burnt rivets and rivets with cracks, badly formed, eccentric or
deficient heads shall be cut out and replaced. Permissible deviation of driven
rivets shall be as per Appendix IV of IRS B-1-2001 Specification. For ready
reference, the same has been produced in the “Quality Control” part of this
technical specification. Rivets shall also be cut out when required for the
examination of the work. Actual method of cutting out shall be approved by the
Engineer. Recupping and caulking shall in no circumstances be resorted to.
Riveting shall not be started until such time as the Engineer has personally
satisfied himself that the alignment of the girders is correct, the verticals plumb
laterally, the camber according to that shown on the camber diagram with
camber jacks screwed tight, all the joints and cover plates well up, service bolts
tight and field rivet holes coinciding. Special care should be taken that service
bolts are frequently re-tightened as the riveting proceeds.
All field rivets shall be tested as directed by the Engineer. Where practicable all
rivetting shall be done by pneumatic or hydraulic rivetting machine. The working
pressure to be employed when using pneumatic or hydraulic tools shall be
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approved by the Engineer. Hand rivetting shall only be done when sanctioned by
the Engineer. In such cases, means shall be adopted to ensure the rivets being
used in their entire -only to give the correct form of head. When all the rivets of
joints have been finally passed, they shall be painted as under. One coat of ready
mixed zinc chrome primer to IS: 104 followed by one coat of ready mixed paint
red oxide zinc chrome primer to IS: 2074.
Finishing coat as per painting schedule given under “Oiling, Painting and
Metallising” of this technical specification. For further details on the rivetting,
“Indian Railways Bridge Manual” can be referred to.
2.15 Field rivets, Bolts, Nuts and Service Accessories
Fabricators shall arrange rivets, bolts, nuts, drifts and service accessories, etc.
for all those works required as a part of shop fabrication. For field erection and
assembly work, it shall be the responsibility of launching/ erection contractor to
arrange such type of fittings.
2.16 Smithed Work
All joggles shall be performed by pressure. Craned sections or knees can be

formed by forging or by gas cutting and welding by any approved electric arc
process. Any bending, forging, cutting or welding shall be carried out in such a
manner as not to impair the strength in the metal. Forging shall be annealed as
indicated in the drawing.
If drop forging through dies is resorted to, excessive forging in one operation
shall be avoided. Where necessary, a series of intermediate stage dies shall be
manufactured and used.
2.17 Welding
Welding of the bridge girders shall be done under strict supervision of the
engineer. Approved procedures shall be followed. A brief of the same are given
herewith:
2.17.1 Drawings and Procedure Sheets
The symbols for welding used on the fabrication drawings and procedure sheets
shall be in accordance with IS: 813. If other symbols are used, a complete
explanation of their meaning shall be given.
The fabrication drawings and/or welding procedure sheets prepared for direction
of the welding organisation shall include the following information:
a) Specification of the parent metal, and electrodes and/or wire-flux

combinations.
b) Locations, sizes, actual lengths and details, i.e. form of joint, angle
between fusion faces, gap between parts, etc., of all welds.
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c) Whether welds are to be made in shop or field.

d) Welding procedure, like welding sequence, pre-heating, post heating etc.
e) Details of testing and inspection requirements.
2.17.2 Butt Welds
Forms and details: All details of butt-welded joints shall be in accordance with
IS: 9595 and IS: 4353 as applicable.
Unsealed butt welds of single V, U, J and bevel types and incomplete
penetration butt welds shall not be used. Sketches of different types of butt weld
are given in Fig. No.-2 of the “SKETCHES” part of this specification.
Intermittent butt welds shall not be used.
Sealing or backing
Single V, U, J bevel or square butt welds shall generally be completed by
depositing a sealing run of weld metal on the back of the joints.
Where it is not practicable to deposit a run of weld metal on the back of the
joint, then single V, bevel or square butt welds, welded from one side only,
may be permitted, provided that another steel part of the structure or a special
steel backing strip is in contact with the back of the joint and the edges of the
steel parts of the joint are prepared as specified in IS: 9595 or IS: 4353,
whichever is applicable, to ensure complete fusion of the parts to be joined.
In all full penetration butt welds which are to be welded from both sides, the
back of the first run shall be gauged out by suitable means to clean sound
metal, before welding is started on the gauged out side (see Fig. 3 of the
“SKETCHES” part of this specification).
2.17.4 Butt welding parts of unequal cross-section
In butt welding steel parts in line with each other which are intended to
withstand dynamic forces, and which are of unequal width, or where the
difference in thickness of the parts exceeds 25% of the thickness of the thinner
part or 3 mm whichever is greater, the dimensions of the wider or thicker parts
shall be reduced at the butt joints to those of the smaller part, the slope being
not steeper than 1 in 5 (see Fig. 4 of the “SKETCHES” part of this specification).
Where the difference in thickness of the parts does not exceed 25% of the
thickness of the thinner part or 3 mm whichever is greater, the transition of
thickness shall be accomplished by sloping weld faces (see Fig. 5 of the
“SKETCHES” part of this specification) by chamfering the thicker part or by
combination of the two methods (see Fig. 6 of the “SKETCHES” part of this
specification), at an angle not steeper than 1 in 5.
Where the reduction of the dimensions of the thicker part is impracticable,

and/or where structures are not designed to withstand dynamic forces, the weld
metal shall be built up at the junction with the thicker part to dimension at-least
25% greater than those of the thinner part, or alternatively, to the dimensions of
the thicker member (see Fig. 7 of the “SKETCHES” part of this specification).
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2.17.5 Butt welded T joints
Butt weld in T joint shall be reinforced by welding as shown in Fig. 8 of the

“SKETCHES” part of this specification. Flange to web connection will also fall
under this category.
2.17.6 Ends of butt welds
The ends of butt joint shall be welded so as to provide the full throat thickness.
This shall be done, in all cases of parent metal more than 20 mm thick and
preferably in other cases also, by extending the ends of the butt welds past the
edges of the parts joined by the use of run-on and run-off plates with a similar
joint preparation and of reasonable thickness not less than the thickness of
the part joined and of the length not less than 40 mm (see Fig. 9 of the
“SKETCHES” part of this specification) If run on and run off plates are
removed after completion of the welds, the ends of the weld shall be finished
smooth and flush with the edges of the abutting parts. Run on and run off plates
are to be removed after completion of welds by abrasive cut off or by hacksaw
blade .To avoid thermal stress as well as heat affected zone, Oxy-acetylene
cut should not be permitted. If the parent metal is not more than 20 mm thick,
the ends of the butt welds may be chipped or cut back to sound metal and
then filled up with welds having a width not less than one and half time the ‘V’
opening and having the same reinforcement as adopted for the faces of the butt
weld (see Fig. 10 of the “SKETCHES” part of this specification).
2.17.7 Reinforcement of butt welds
Sufficient convexity not exceeding 3 mm, shall be provided as reinforcement to

ensure full cross sectional area at the joint. Where a flush surface is required, the
butt welds shall be first built up as specified above and then dressed flush.
2.17.8 Fillet Welds: Types of fillet welds
Normal fillet weld - A normal fillet weld is one in which the depth of penetration
beyond the root is less than 2.4 mm (see Fig. 11 of the “SKETCHES” part of this
specification).
Deep penetration fillet weld: A deep penetration fillet weld is one in which the
depth of penetration beyond the root is 2.4 mm or more (see Fig. 11 of the
“SKETCHES” part of this specification). It shall be used only by agreement
between purchaser and contractor, and tests shall be agreed between purchaser
and contractor to verify that the requisite route penetration is being obtained.
Table-1 Minimum size of first run of a fillet weld
Thickness of thicker Minimum

part size
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6 mm up to and including 5 mm.

20 mm
Over 20 mm up to and 6 mm.

including 32 mm
Over 32 mm up to and 8 mm.

including 50 mm
Table-2 Minimum size of a fillet weld
Thickness of thicker part Minimum

size
Upto and including 6 mm 3 mm
Over 6 mm upto and 4 mm
including 12 mm
including 18 mm
including 36 mm

including 56 mm
including 150 mm
Over 150 mm 16 mm
Notes:
i- When the minimum size of the first run of fillet weld and /or
minimum size of the fillet weld as given in Table-1 and Table-2 is
greater than the thickness of the thinner part, the minimum size
of the weld shall be equal to the thickness of the thinner part. The
thicker part shall be adequately pre-heated to prevent cracking of
the weld.
ii- Where the thicker part is more than 50 mm in case of steel to IS:
2062 special precautions like pre-heating as per IS: 9595 shall
be taken to ensure weld soundness.
2.17.9 Angle between fusion faces:
Fillet weld shall not be used for connecting parts, whose fusion faces form
an angle of more than 1200 or less than 600, unless such welds are
demonstrated by practical tests to develop the required strength.
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2.17.10 Intermittent fillet welds:
Intermittent fillet welds may be used in structures not subjected to dynamic loading,
to transfer calculated stress across a joint when the strength required is less than that
developed by a continuous fillet weld of the smallest allowable size for the thickness of
the parts joined.
Load carrying intermittent fillet welds shall not be used in members subjected to
dynamic loading, except for connecting intermediate stiffeners to webs of beams and
girders, subject to the provisions of “intermediate stiffeners” contained in this 23.5
specification.
Intermittent fillet welds shall not be used where they would result in the formation of
rust pockets.
Chain intermittent welding is to be preferred to stagger intermittent welding.
The distance along an edge of a part between effective lengths of consecutive

intermittent fillet welds, whether the welds are in line or staggered on alternate sides of
the edge, shall not exceed 12 times the thickness of the thinner part and shall in no
case exceed 150 mm. This requirement shall not be taken into account in complying
with the requirements of clauses 6.4 and 6.8 of IRS Steel Bridge Code.
In a line of intermittent fillet welds, there shall be a weld at both ends of the parts
connected. For staggered welds, this shall apply to both sides.
In built up members in whose parts are connected by intermittent filled welds,

continuous longitudinal fillet welds shall be used at the end for a length not less
than the width of the part concerned.
2.17.11 Fillet welds applied to the edge of a plate or section:
Where a fillet weld is applied to the square edge of a part, the specified size of the
weld shall generally be at-least 1.5 mm less than the edge thickness, in order to
avoid melting down of the outer corner, (see Fig. 14 of “SKETCHES” part of this
specification).
Where a fillet welds is applied to the rounded toe of a rolled section, the specified
size of the weld shall generally not exceed 3/4 of the thickness of the section at
the toe (see Fig. 14 of “SKETCHES” part of this specification).
Where a fillet weld equal in size to the thickness of the section at the toe of a rolled
section or at the square edge of a plate is required from design considerations and
is specially designated in the drawing, the toe or edge shall be specially built up
with weld metal in such a manner as to ensure full throat thickness, full fusion area
and no injury to the parent metal (see Fig. 15 & 16 of “SKETCHES” part of this
specification).
2.17.12 End Fillet:
When end fillets are used alone, each fillet shall be returned as a side fillet for a
minimum length equal to twice the size of the weld, and this returned length shall
be disregarded in calculating the strength of the joint.
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2.17.13 Fillet welds in slots or holes:
1.0 When welding inside a slot or a hole, in a plate or other part, in order to join the
same to an underlying part, fillet welding may be used along the wall or walls of the
slot or the hole, but the later shall not be filled with weld metal or partially filled in
such a manner as to form a direct weld metal connection between opposite wall.
The dimensions of the slot or hole shall comply with the following limits in terms of
the thickness of the steel part in which the slot or hole is formed.
2.0 The width or diameter to be not less than three times the thickness or 25 mm
whichever is greater.
3.0 Corners at the enclosed ends of slots to be rounded with a radius not less than
1.5 times the thickness or 12 mm whichever is greater.
4.0 The distance between the edge of the part and edge of the slot or hole or
between adjacent slots and/ or holes not to be less than twice the thickness when
measured along the direction of stress and five times the thickness when measured
normal to the direction of stress.26.8 End Returns:
Fillet welds terminating at the ends or sides of parts or members shall be returned
continuously around the corner for a distance of not less than twice the size of the
weld. This provision shall apply particularly to side and end fillet welds joining
brackets, beam seating and similar attachments at the tension side of such
connections.
2.18 Preparation of Joint Faces:
Preparation of joint faces shall be done as per IS: 9595.
2.18.1 Fusion faces:
The preparation of fusion faces, angle of preparation root radius and root face shall
be as specified in IS: 9595 and IS: 4353. Where the gap between the root faces of
a butt joint is excessive, the gap shall not be bridged since this procedure often
leads to cracking. The fusion faces of the joint shall be built-up with weld metal to
give the appropriate gap before the weld proper is commenced.
The preparation of fusion faces, angle of bevel, root radius and root face shall be
such that the limits of accuracy required by the appropriate application standard
can be achieved. When however, no appropriate application standard exists and
this standard is itself to be used, it is recommended that, for manual welding, the
tolerances on limits of gap and root face should be ±1 mm on the specified
dimensions for material up to and including 12 mm thick and ±2 mm for material
over 12 mm thick. The tolerance on the included angle between the fusion faces of
a V preparation is recommended to be ±5 degree and for U and J preparations +
10 degree. For an automatic process, closer limits are necessary and particular
requirements depend on the characteristics of the process.
It shall be ensured, if necessary, by suitable non-destructive tests that the fusion

faces and adjacent surfaces shall be free from cracks, notches or other

irregularities which might be the cause of defects or would interfere with the
deposition of the weld.
Fusion faces and the surrounding surfaces shall be free from heavy scale,
moisture, oil, paint or any other substance which might affect the quality of the weld
or impede the progress of welding. Certain proprietary protective coatings are
specially formulated with the intention that they should not interfere with welding.
The use of such coatings is not excluded by the requirements of this clause but
shall be demonstrated by means of specimen welds that the coating complies with
the above requirements.
2.18.2 Assembly for Welding:
Parts to be welded shall be assembled such that the joints are easily accessible
and visible to the operator.
Jigs and manipulators shall be used, where practicable, so that the welding can be
carried out in the most suitable position. Jigs shall maintain the alignment with the
minimum restraint so as to reduce the possibility of locked in-stress.
2.18.3 Sequence of welding and weld pass for composite girders, shear connectors etc:
For fabrication of welded composite girders, channel shear connectors shall be
welded on top flange plate prior to assembly of I-section. This facilitates correction
of any distortion of flange plate developed during the welding of channel shear
connectors.
In making a typical I-section four fillet welds are to be made. The welding sequence
to be followed is indicated by number 1 to 4 as shown in the Fig. No.-23.
Whenever a square butt weld in a 10 or 12mm thick plate is required to be made,

the sequence to be adopted is shown in Fig. No.-23.
2.18.4 Welding in solid web girders:
Flange Plates: Each flange shall, as far as possible, particularly in dynamically

loaded structures, consist of a single section rather than of two or more sections
super- imposed. The single section may comprise a series of sections laid end to
end and effectively welded at their junctions.
If the use of curtailed flange plates cannot be avoided the end of the plate shall be
tapered in plane to a rounded end and welded continuously round the end.
In dynamically loaded structures, flange plates laid end to end shall be joined by
butt welds, and welded cover plates shall not be used. Joints in flange plates shall
be butt welded and dressed flush before assembling.
Where the flange consists of more than one section, the butt joints shall be staggered.
Welded cover plates, where used in structures not subjected to dynamic loading,
shall have enough welds on either side to develop the load 5% more than that of
the element spliced.
The flange plate, welded directly to the web plate, shall not be more than 50 mm
thick when steel conforms to IS: 2062.
Web Plates : Splices in the webs of plate girders and rolled sections used, as
beams shall be made by butt welds dressed flush on all faces, in the case of
dynamically loaded structures. In the case of structures not subjected to dynamic
loading, splice plates may be used independently and not to reinforce a butt-welded
splice.
Intermediate stiffeners:
Where intermediate stiffeners are connected to the web by intermittent fillet welds
placed in pairs, one weld on either side of the stiffeners, the effective length of each
weld shall be not less than four times the thickness of the stiffeners.
Where staggered intermittent fillet welds are used, the effective length of each weld
shall be not less than 10 times the thickness of the stiffener.
Fillet welds placed on one side only of the stiffener shall not be used.
Intermediate stiffeners carrying cross bracings or diaphragms shall not be

connected to the web by intermittent fillet welds.
Intermediate stiffeners shall be located away from web splices.
2.19 Safety Precautions
Provisions of IS: 818, IS: 1179 and IS: 3016 shall generally apply for safety and
health requirements during welding operations.
2.20 Approval and Testing of Welding Procedures
Welding procedure test shall be carried out in accordance with IS: 7307(Part-I) to
demonstrate, by means of a specimen weld of adequate length on a steel
representative of that to be used, so as to confirm that satisfactory weld is
achievable with the welding procedure to be used for fabrication.
Provisions of IS: 9595 and IS: 4353, shall generally be followed, as applicable, for
welding procedure, details of workmanship, correction of weld faults, peening,
painting, etc. In case any of the provisions contained therein contravene the
provisions made on this code, the latter shall be followed.
In addition to the provisions of IS: 4353 the Inspector may, where deemed
necessary, require a sample joint having the same cross-section as the joint to be
used in construction and a length of at least 300 mm to be welded with the wire,
flux current, arc voltage and speed of travel that are proposed to be used and a
macroetched cross section of the welded joint prepared as a demonstration that the
specified requirements will be met, when the welding current, arc voltage and
speed of travel are established by a test made in accordance with requirements of
this clause, they shall be kept within the following limits of variations.

Welding current ±10%

Arc Voltage ± 7%
Speed of travel ±15%.
2.21 Approval and Testing of Welders
The welders shall be trained in accordance with IS: 817. The welders shall be
subjected to appropriate qualifying tests specified in IS: 7310 (Pt-I).
2.22 Welding Processes and Procedures:

Welding work shall be given to a contractor who does produce satisfactory
evidence of his ability to handle the work in a competent manner. The contractor
shall also prove the ability of the operator/Welders employed by him to produce
welds of the required strength. The contractor shall employ a competent welding
supervisor to ensure that quality of materials and the standard of workmanship
comply with the requirements laid down in this code.
The sizes and length of welds shall not be less than those specified in the drawings
nor shall they be substantially in excess of the requirements without prior approval
of the Engineer. The location of welds shall not be changed without prior approval
of the Engineer. Welds shall preferably be made in flat position.
In case of welds in structures subjected to dynamic loading, adequate means of

identification, either by identification stamp or other records shall be provided to
enable each weld to be traced to the welding operator by whom it was made.
During the entire welding of cooling cycle, the joints shall not be subjected to any
external forces or shocks.
Freedom of movement of one member of a joint shall be allowed wherever

possible. No butt joint shall be welded without allowing one component, freedom of
movement of the order of 1.5 mm.In making welds under conditions of severe
external shrinkage restraint, the welding shall be carried out with electrodes having
type 6 covering as per IRS:M-28 Specification. In case of welding using direct
current, earthing on the work piece to be welded shall be connected carefully at
more than one location with a view to avoid “Arc Blow” during welding.
All welds should be done by submerged arc welding process either fully automatic
or semi-automatic. Carbon-di–oxide (CO2) welding or manual metal arc welding
may be done only for welds of very short runs or of minor importance or where
access of the locations of weld does not permit automatic or semi-automatic
welding.
Neither the depth of fusion nor the maximum width in the cross section of weld
metal deposited in each weld pass shall exceed the width of the face of the weld
pass.
All welds should be done by submerged-arc welding process either fully automatic
or semi-automatic. Carbon di oxide welding or manual metal-arc welding may be
done only for welds of very short runs or of minor importance or where access of
the locations of weld do not permit automatic or semi-automatic welding.

Except for special types of edge preparation, such as single and double ‘U’ single
and double ‘J’ the fusion edges of all the plates which are to be joined by welding
may be prepared by using mechanically controlled automatic flame cutting
equipment and then ground to a smooth finish. Special edge preparation should be
made by machining or gouging.
The welding procedure shall be such as to avoid distortion and minimise residual
shrinkage stresses. Properly designed jigs should be used for assembly. The
welding techniques and sequence, quality, size of electrodes, voltage and current
required shall be as prescribed by manufacturers of the material and welding
equipment. The Contractor should submit full details of welding procedure in
proforma given at Appendix V of IRS B-1-2001 specification, copy of which is
available in “Maintenance of Records” of this specification.
Site welding should not be undertaken except in special circumstances with the
approval of the Engineer. Site welding should be confined to connections having
low stresses, secondary members, bracings etc.
Manual metal arc welding may be done taking adequate precautions as per IS:
9595 and under strict supervision.
2.23 Sequence of Welding
The sequence of welding shall be such that when possible the members, which
offer the greatest resistance to compression, are welded first.
The welding in the thinnest element of a section (usually the web in case of beams)
shall be done prior to the welding of the thicker elements (usually the flanges in
case of beams).
In making butt welded joints in rolled shapes, the sequence and procedure of
welding shall take into account unequal amount of expansion or contraction in
elements being welded.
Splices in each component part of a solid web girder or built-up member shall be
made before such component part is welded to other component part of the
member.
2.24 Position of Welding:
For fabrication of steel bridge girders the following positions of welding shall be
adopted.
I) Flat and horizontal position for Submerged Arc Welding (SAW) and
II) Horizontal or horizontal-vertical position for welding done using manual

metal Arc welding (MMAW) or CO2 welding.
All butt welds by the submerged arc process shall be made in the flat position. Fillet
welds may be made in either flat or horizontal-vertical position. The size of the
single pass fillet welds made in the horizontal-vertical position shall not exceed 8
mm.
2.25 Tack Welds:

Tack welds shall be not less than the throat thickness or leg length of the root run
to be used in the joint. The length of the tack weld shall not be less than four times
the thickness of the thicker part or 50 mm whichever is the smaller
Where a tack weld is incorporated in a welded joint, the shape, size and quality
shall be suitable for incorporation in the finished weld and it shall be free from all
cracks and other welding defects. Tack welds, which are prone to cracking, shall be
cut out and rewelded.
Tack welds shall not be made at extreme ends of joints.
2.26 Inter-run Cleaning:
Each run of weld bead shall be thoroughly cleaned to remove particles of slag,
spatters, etc. before the subsequent bead is super-imposed during multi-pass
welding. Similarly, each layer of weld should be thoroughly cleaned of slag,
spatters, etc, before depositing subsequent layers of weld with particular
reference to thorough cleaning of toes of the welds. Visible defects, such as
cracks, cavities and other deposition faults, if any, shall be removed to sound
metal before depositing subsequent run or layer of weld.
2.27 Stray arcing on Work:
Stray arcing shall be avoided as this can leave local hard spots or cracking which
are to be removed by mechanical means and be checked by inspection depending
upon the application.
2.28 Inspection and Testing of Welded Joints:
The inspection of bridge girders shall be done by RDSO. The Inspector designated
by the purchaser shall ascertain that fabrication by welding is performed in
accordance with the requirements of this code. Inspection of welds shall also be
carried out in accordance with this Code. For the provisions, which are not
incorporated in this Code, IS: 822 “Code of procedure for inspection of welds” shall
be followed.
He shall be furnished with complete detailed drawings showing the size, length,
type and location of all welds, which are required to be made. He shall be notified
in advance of the start of any welding operations. He shall have free access to the
work being done at all reasonable times by the contractor and facilities shall be
provided so that during the course of welding he may be able to inspect any layer
of weld metal. He shall be at liberty to reject any material that does not conform to
the provisions of this code and to require any defective welds to be removed and
re-welded.
2.29 Inspection prior to welding:
2.29.1 Parent metal:

All plates and sections shall be inspected in the contractor’s works before
fabrication. Verification of the quality of parent metal shall be carried out by
reference to the relevant test certificate. The Inspector may, at his discretion, ask
for spot checks to be made on the chemical composition and physical properties of
the material. Freedom from harmful defects such as cracks, surface flaws,
laminations, and rough, jagged or imperfect edges shall be verified by visual
examination of the material prior to welding. Dimensions of parts shall be checked
by measurement.
2.29.2 Edge preparation and set-up of parts:
Edge preparation shall conform to the relevant drawings and meet the
requirements of this code.
After the parts are assembled in position for welding, the Inspector shall check for
incorrect root gap, improper edge preparation and other features that might affect
the quality of the welded joint.
2.29.3 Verification of operator’s qualification:
Welding shall be permitted to be performed only by welders and welding operators

who are qualified in accordance to the “Approval and Testing of Welders” contained
in this specification. The Contractor shall, if so required, prescribe the welding
procedure to be followed. Before any welding on the actual job is allowed under the
contract, the Inspector shall verify, in accordance with the provisions of IS: 9595
and IS: 4353 as applicable, that the procedure prescribed is satisfactory.
2.30 Inspection after Welding:
For visual inspection of defects, the weld surface shall be thoroughly cleaned of
oxide layers and adherent slag. If chipping hammer is used to remove slag, care
shall be taken to see that hammer marks do not obscure the evidence of fine
cracks. Brushing with a stiff wire-brush or grit blasting shall normally be followed.
Welding profile - The finished welds shall be visually inspected and shall conform to
the size and contour specified in the drawings (Acceptable and defective weld
profiles are illustrated in Fig. 17 to 21 of the “SKETCHES” part of this specification).
Conformity of fillet welds as to size and contour shall be determined by the use of
gauges as per Figure No.-22 of “SKETCHE” part of this specification. Concavity
and excessive convexity of fillet welds shall be marked for correction.
2.31 Acceptance levels for Quality of Welds:
Welds shall meet acceptance levels as per Table No.-3 of “QUALITY CONTROL”
part of this specification.
2.31.1 Dimensional check:
The weldment shall be inspected for dimensional accuracy (including warpage) and
shall be within the tolerances specified.
2.32 Non-destructive tests:
2.32.1 Radiographic tests:
Butt welds shall be examined by radiographic test, which will present satisfactory
evidence to the Inspector that welds are meeting the quality requirements. Other
welds may be examined by radiographic or any other non-destructive method,
which are equally effective. Welds shall also be examined by liquid penetrant flaw
detection method or by magnetic particle flaw detection method as per IS: 3658 and
IS: 3703.
2.33 Marking of Defective Welds:
The marking shall be positive and clear and in accordance with the method of
marking followed and understood by the Inspector and shop personnel involved in
making the repairs. Marking shall be permanent enough to be evident until the
repair is carried out and the inspection completed. After the repair has been done, it
shall be inspected again and properly marked to indicate whether the repair is
satisfactory or not.
2.34 Bolts, Nuts and Washers
Bolts, Nuts and Washers shall be in accordance with the following

specifications: Black hexagonal bolts to IS: 6639 and Nuts to IS: 1363.
Precision and turned bolts with nuts and hexagonal screws to IS:1364.
Plain washers to IS: 2016 and IS: 5369.
Spring washers - IS: 3063.
Taper washers - IS: 5372 and IS: 5374.
Manufacture, workmanship, Marking, Packing etc. for Bolts and Nuts shall comply
with the requirements of IS: 1367.
Where the head and nuts bear on timber, square washers having the length of
each side not less than three diameters of the bolt and the thickness not less than
one quarter of the diameter shall be provided. Steel, wrought iron or malleable cast
iron taper washers shall also be provided for al heads and nuts bearing on beveled
surfaces.
For black bolts a clearance (difference in diameter) of 1.5mm for all sizes of bolts
shall be allowed.
Where turned bolts are required they shall be carefully turned and shall be parallel
throughout the barrel. Holes for turned bolts should be 1mm under drilled in shop
and should be reamed at site to suit the diameter of the turned bolts.
The following limits of tolerances shall be permitted upon the diameter of the shank
of turned bolts and of the holes which they are to fit:

Limit of Shank of bolt Hole(mm)

tolerance (mm)
High 0.000 +0.125
Low - 0.125 0.000
The shank of each turned bolt shall be of such a length that it is in full contact with
the work, throughout, the screwed portion being made at least 1.5mm less in
diameter than the shank or to suit the next smaller size of screw thread. The shank
portion shall be joined to the threaded portion by a 450 chamfer within the thickness
of the washer. Washers with perfectly flat faces should be provided with all turned
bolts.
The washers under the nut shall have a hole of 1.5mm larger in diameter than the
shank of the bolt and shall have a thickness of not less than 6mm so that the nut,
when screwed up, shall not bear on the shoulder of the bolt.
2.35 Connecting Pins:
All connecting pins shall be finished accurately to gauge and parallel throughout,
straight and with smooth surface entirely free from flaws and of sufficient length
to ensure that all parts connected thereby shall have a full bearing on the pin. They
shall be turned to a smaller diameter at the end for the thread and driven to place
with a pilot nut, where necessary to preserve the thread.
2.36 Pin Holes:
Pinholes shall be bored smooth straight and true to gauge and at right angles to the
axis of the member. Boring shall only be done after the member has been rivetted
up and the diameter of the pin shall not be less than that of the hole by more than
0.5mm.
2.37 Bearing and Expansion gear
All steel bed and bearing plates or plates over saddle castings, shall be made
perfectly level and all rivet heads on their bearing surfaces shall countersunk and
dressed flush.
The saddles, knuckle-bearers and roller bed-plates shall be planed on all bearing
surfaces and elsewhere as indicated on the Contract Drawings and all bolt-holes
shall be drilled. The bottom edge of ribs should be machined and welded to the
bottom slabs after which the top edges of the ribs should be machined as a whole
and the top plate welded. Subsequently the top and bottom surfaces should be
machined to the specified tolerances as given in Appendix VI of B1 specification.
Generally in connection with the bearing gear all meeting surfaces including the
sides of the roller frames, shall be machined, all bolts except anchor bolts turned
and fitted, all washers faced, the rollers knuckles and pins polished to smooth
surface and the whole finished in the style of first class machined work.

Tolerances shall be as specified in Appendix VI of IRS B-1-2001 specification and

shall be shown on the drawings.
2.38 Erection in Contractor’s Works:
The work shall be temporarily erected complete at the Contractor’s Works for
inspection by the Inspecting Officer, with the exception of such rivetting as has to
be done at site, so that accuracy of fit and perfection of workmanship may be
assured. The work shall be put together with sufficient numbers of parallel drifts or
turned bolts or both to bring the pieces into place. When so erected all holes left to
be filled at site shall be so fair that a parallel gauge turned to a diameter 0.8mm
less than that of the hole, of a length equal to the depth of the hole, can be passed
through them without difficulty. No drift shall be used anywhere in the work larger in
any part than the hole in which it is to be driven. Holes for turned bolts, which have
been 1 mm-under drilled in shop, should be reamed at site by the erecting agency.
2.39 Interchangeability:
Every span is to be temporarily erected complete in Contractor’s works adopting

the method of giving camber and all parts as marked to their place, unless the
whole of the work is made completely interchangeable by the use of steel jigs and
hard steel bushes controlled by master gauges, in which case the first span must
be completely erected to test the accuracy of the templates. Further spans or part
span assemblies built from parts selected at random by the Inspecting Officer shall
be erected from time to time to check the accuracy of the work as the Inspecting
Officer may require. If the work is considered interchangeable by the Inspecting
Officer a simplified scheme of marking will be permitted, i.e. all pieces that are
identical shall bear one distinguishing mark irrespective of the span to which they
belong. Should the interchangeability not to the satisfaction of the Inspecting
Officer, the whole of the spans must be erected complete and all parts marked to
their place without additional charge. The tenderers must state in their tenders
whether they intend to adopt complete interchangeability or not. Under special
arrangement with the Purchaser, it shall be permissible for approved portions of the
work to be dispatched before complete erection of the first span, provided the
Contractor satisfies the Inspecting Officer that such portions of the work are strictly
interchangeable and will assemble correctly and accurately in the complete
structure.
2.40 Camber
In order to ensure that the fabrication and erection of main girders shall be such as
to eliminate secondary stresses in the loaded span, the nominal length (i.e. the
lengths which will give no camber) of member shall be increased or decreased by
the amount shown on the camber diagram supplied by the Purchaser. For setting of
the angles of intersection of the chords and web members and also for templating
the gusset, full size of panels with nominal lengths of the members, shall be used.
Similarly, the machining of all chords butts shall be to suit the nominal outline as
defined earlier.
The procedure for erecting the span at Contractor’s work shall be as specified. The
site rivetting holes shall be rivetted or bolted and drifted as specified in Appendix III
of IRS B-1-2001 specification.
When supported on blocks or stagings, the girders shall be erected to the

camber specified in the fabrication drawings according to which the girders have
been manufactured. A camber diagram indicating the relevant height of each
panel point when erected on blocks at the manufacturing works shall be supplied by
the Engineer. The cambering of the main girders along with pre–stressing, when all
panel points are supported on the blocks or stagings, shall be carried out in
accordance with Appendix ‘A’ of Steel Bridge Code. Special methods of erection
will require special erection drawings approved by the Engineer, which must not be
deviated from.
In the case where the girders are erected on yielding supports such as a service
span, due allowance shall be made for the anticipated yield when the camber
blocks are set out.
Frequent checks shall be made of the camber of girders during erection and care
taken to see that the camber as per drawing is obtained when the girder is
completely assembled. When span is supported on ends and intermediate supports
are removed the dead load camber shall be recorded and entered in bridge
register. This will provide the reference to compare the camber checked during
technical inspection.
2.41 Testing
The Inspecting Officer shall be empowered, at his/her discretion to make or have

made under the supervision, any of the tests specified in the specifications
mentioned herein in addition to such other tests as he/she may consider
necessary, at any time upto the completion of the contract and to such an extent
as he/she may think necessary to determine the quality of all materials used
therein. In doing so, he/she shall be at liberty under any reasonable procedure,
he/she may think fit to select, identify, have cut-off and take possession of test
pieces from the material either before, during or after its being worked up into the
finished product.
He shall also be empowered to call for a duly authenticated series of mechanical

tests to be obtained from the maker for these materials used in the work and to
accept the same in lieu of other tests to the extent he/she deems fit. The Contractor
shall supply the material required for the test pieces and shall also prepare the test
pieces necessary.
The test shall be carried out by the Contractor, for which Contractor shall provide all
facilities including supply of labour and plant. Inspecting officer may at his/her
discretion direct the Contractor to dispatch such tests pieces as he/she may require
to the National Test House or elsewhere as he/she may think fit for such testing
purposes.
2.42 Check on Tests made at Contractor’s work
The Inspecting Officer may at his/her discretion, check test results obtained at
Contractor’s work by independent tests at National Test House. The Inspecting
Officer shall at all times be empowered to examine and check the working of the
Contractor’s plant before and after using it. Should the Contractor’s plant be found,
in the Inspecting Officer’s opinion, unreliable, he/she is empowered to cancel any

tests already carried out in this contract and have these tests carried out at any
National Test House or elsewhere, as he/she may think fit.
2.43 Analysis
The Contractor shall supply authenticated copies of analysis of any materials used
in the contract when required to do so by the Inspecting Officer who shall be
empowered to accept them to the extent he/she thinks fit. In addition to the above
samples may, at the Inspecting Officer’s discretion be subjected to complete
analysis at the National Test House or elsewhere as the Inspecting Officer may
determine, the cost of the same to be borne by the Purchaser.
2.44 Inspection – general
The Inspecting Officer shall have free access to the works of the Contractor at all
reasonable times and shall be at liberty to inspect the process of manufacture at
any such time and to reject in whole or part, any work or material that does not
conform to the provisions of this Specification and may order the same to be
removed, replaced or altered at the expense of the Contractor. All gauges and
templates necessary to satisfy the Inspecting Officer of the complete
interchangeability of parts must be supplied by the Contractor free of cost.
3.0 Oiling, Painting, Metallising of Girders, Packing and Dispatching
No part of the work shall be painted or coated, packed or dispatched, until it has
been finally inspected and approved by the Inspecting Officer. Dry Film Thickness
shall be measured by Eclometer or any other approved method.
When so specified by the Purchaser, the whole of the work except machined
surfaces shall be given protective coating using one of the systems of painting or
metallising given herewith. Prior to the application of protective coating, the surface
of work shall be carefully prepared removing mill-scale, rust, etc. using wire
brushes, sand or grit blasting as stipulated and approved by the Purchaser.
Specifications for metallising and painting of bridge girders shall be as per IRS B1-
2001. No painting work will be permitted during the monsoon period.
3.1 Surface Preparation (for all types of Painting and Metallising)
Surface of all components /members of the superstructure shall be prepared as per

following provisions before application of first coat of paint/primer or before
metalizing.
(i) The surface should be clean, dry and free from contaminants and it should be
rough enough to ensure adhesion of the paint film. However it should not be
so rough that the film cannot cover the surface peaks.
(ii) The cleaning of the surface shall be done initially with the use of emery paper,
wire brushes, scrapers etc. for spot cleaning to remove rust, scale etc.
Subsequently, sand blasting of the surface shall be done to remove rust, mill
scale along with some of the base metal. This will be achieved by high
velocity impact of abrasive material against the surface in accordance with the
provisions of IS:6586, which will also create a base for good adhesion. The
abrasive material once used for cleaning heavily contaminated surface should
not be reused even though re-screened. Washed salt free angular silica sand
of mesh size 12 to 30 with a minimum of 40% retained on a 20 mesh screen
shall be used for blasting. The material specifications and other requirements
shall be as provided in Indian Railways Bridge Manual, 1998 (with latest
revision).
(iii) All site rivets, bolts, nuts and washers shall be thoroughly cleaned and dipped
in boiled linseed oil. All machined surfaces are to be well coated with a mixture
of white lead conforming to IS:34 and Mutton tallow conforming to IS:887 as
per specifications before dispatch to site. Nothing extra shall be payable to
contractor on this account.
3.2 Metallising and Painting of Floor and Deck systems of the Bridge
(i) All the components in the floor and deck system in open web girders of this
Railway Bridge shall be metalized as per IRS specifications. Components to
be metalized in rail deck are cross girders, stringers, connecting gussets and
other components.
(ii) The sprayed coating shall be applied as soon as possible after surface
preparation.
(iii) The wire method shall be used for the purpose of metallising, the diameter of
the wire being 3mm or 5mm. Specified thickness of coating shall be applied in
multiple layers and in no case less than 2 passes of the metal spraying unit
shall be made over every part of the surface. The surface after spraying shall
be free from uncoated parts of lumps of loosely spattered metal.
(iv) The composition of the aluminium to be sprayed shall be in accordance with

BS:1475, material 1-B(99.5%) aluminium otherwise as per IS:739 and
IS:2590. However, the selection of metal for spraying, i.e. Zinc or Aluminium
shall be subject to final approval.
(v) At least one layer of the coating must be applied within four hours of blasting
and the surface must be completely coated to the specified thickness within 8
hours of blasting.
(vi) Minimum thickness of metal coating applied shall be 115 microns and average
thickness shall be 150 microns. The metal coating shall be checked for
thickness by approved magnetic thickness measuring gauge. At least one

reading for each sqm of area painted shall be taken. The calibration of the
gauge shall be checked against a standard of similar thickness within an
accuracy of 10 %.
(vii) For measurement of dry film thickness, following instruments may be used
by the contractor. Dry film thickness is to be measured as described in
Appendix-VII of IRS BI-2001.
(a) Electronic coating thickness gauge.
(b) Elcometer (magnetic thickness gauge) Dial type.
(c) Surface profile gauge.
(viii) Any oil, grease or other contamination should be removed by thorough

washing with a suitable thinner until no visible traces exist and the surfaces
should be allowed to dry thoroughly before application of paint. The coatings
may be applied by brush or spray. If sprayed, pressure type spray guns must
be used. One coat of wash primer to IS: 5666 shall be applied first. After 4
to 6 hours or the application of the wash primer, one coat of Zinc chrome
primer to IS: 104 with the additional provison that zinc chrome to be used in
the manufacture of primer shall conform to type 2 of IS:51 shall be applied.
(ix) The third coat shall be by Aluminium paint conforming to IS:2339. The girder
parts shall be dispatched to site after the third coat (i.e. first finishing coat or
cover coat).
(x) After assembling and launching at site, second finishing coat of Aluminium
paint conforming to IS:2339 shall be applied after touching up the primer and
first finishing coat.
3.3 Painting of other components of this bridge (other than those in floor and
deck systems)
Protective coatings by paintings as per following painting schedule may be applied

with the approval of the Engineer:
a) Primer coat: Two coats of ready mixed paint red lead primer to IS:102.
Or
One coat of ready mixed zinc chrome primer to IS:104 followed by one coat
of zinc chrome red oxide primer to IS:2074
b) Finishing Coat: Two coats of aluminium paint to IS:2339 shall be applied over
the primer coats. One coat shall be applied before the fabricated steel work
leaves the shop. After the steel work is erected at site, the second coat shall
be applied after touching up the primer and the finishing coat if damaged in
transit.
3.4 Miscellaneous
(i) Final dry film thickness in case of metallising shall be average 150 microns
and shall be measured before application of final finishing two coats.
(ii) Surface preparation shall not be done unless approved paints of sufficient
quantity (both primer and finishing) are available in stock.
(iii) Special care should be taken in preparing corners, junctions of members,

head and nuts of bolts, rivets, holes, areas less accessible, hidden pockets
etc. Surface preparation at such locations shall not be inferior to that attained
over the rest of the area.
(iv) Surface preparation shall not be carried out in the following conditions:
- In rainy season from June to September and from December to January.
- In extremely windy/misty/dust blowing conditions.
- At night
- In winter before 8 A.M.
- In summer between 11 and 15 hrs, in areas, which are likely to be
exposed to direct sunlight.
Engineer reserves the right to change the above timings.
Final dry film thickness in case of metallising as well epoxy painting shall be
average 150 microns and shall be measured before application of final finishing
coats.
Surface preparation shall not be done unless approved paints of sufficient quantity
(both primer and finishing) are available in stock.
Special care should be taken in preparing corners, junctions of members, head

and nuts of bolts, rivets, holes, areas less accessible, hidden pockets, etc. Surface
preparation at such locations shall not be inferior to that attained over the rest of the
area.
Surface preparation shall not be carried out in the following conditions:
B. In rainy season from June to September and from December to January.

C. In extremely windy/misty/dust blowing conditions
D. At night
E. In winter before 8 A.M.
F. In summer between 11 and 15 hours, in areas, which are likely to be
exposed to direct sunlight.
3.4.1 Inspection

Adhesion: The sprayed metal coating shall be subjected to an adhesion test using
the method described in IRS B1-2001if any part of the coating between the lines
breaks away from the base metal; it shall be deemed to have failed the test.
Articles that have been rejected shall have the defective sections blasted clean off
all sprayed material prior to re-spraying. Where the rejection has been solely due to
too thin a coating, sprayed metal of the same quality may be added provided that
the surface has been kept dry and is free from visible contamination.
3.5 Paints: Source & Quality:
Paint and other accessories including those for metallising for the work will be
supplied by the contractor. Paints manufactured by the following firms (or more)
may be used subject to their bearing in the approved list of RDSO and final
approval by Engineer-in-charge.
1.M/s. British/Burger paints

2.M/s. Johnson & Nicholson
3.M/s. Shalimar paints
4.M/s. I.C.I.
5.M/s. Nerolac.
The contractor shall furnish to IRCON, the date of manufacture of paint as certified
by the manufacturers with the necessary container marking and test certificate for
paint conforming to relevant IS code. In addition to this, he shall also submit the
necessary vouchers in respect of paint purchased by him.
IRCON reserves the right to get the paint tested at contractor’s expenses as
considered necessary by IRCON. If the test results do not conform to relevant IS
specifications fully, then the lot of paint shall be rejected and got removed from the
contractor(s) storage. If the paint has already been applied it shall be removed.
In addition to above, the following tests are required to be carried out in the field:
i.Weight per litre

ii.Consistency test
iii.Scratch test
iv.Flexibility and adhesive test
Note – IRCON reserves the right to reject the lot of paint even on the basis of field results.
3.5.1 Painting – General Instructions
Painting shall not be commenced till the surface preparation has been approved by
the Engineer or his representative or inspecting officer.
Sealed containers of paint of approved brand shall be used. The paint drums must
be rolled, turned upside down and shaken before opening. The paint must be

stirred well before use. Over stirring which results in invisible air bubbles etc., shall
be avoided.
Where brush painting is accepted, the paint must be applied by means of flat
brushes not more than 75mm in width having soft flexible bristles conforming to IS:
384.
Round and oval brushes of approved quality conforming to IS: 487 may also be
used as per the instructions of the Engineer or his representative or inspecting
officer.
All new bushes should be soaked in raw linseed oil conforming to IS: 77 for at least
24 hours before use.
A little blue paint shall be added, in the first coat of aluminium paint to distinguish it
from second coat. For paints of other colours for final and finishing two coats,
suitable pigment shall be used as per instruction of the Engineer, to distinguish the
first coat from the second coat.
The date of painting shall be marked with paint on the member.
3.6 Care During Painting
Paint should be mixed in small quantities sufficient to be consumed within one hour
in the case of red lead paint.
The applied coat of paint shall be uniform, and free from brush marks, sack marks,
blemishes, scratching, non-uniform thickness, holes, log marks, fuel staining,
cracking, scaling, and other defects.
Paint shall be applied only on dry and clean surface free from moisture or dust
(including scrapping dust).
Paint should be used within the prescribed shelf life from the date of manufacture.
Each coat of paint shall be left dry till it sufficiently hardens before the
subsequent coat is applied. Each coat of paint shall be inspected by the engineer or
inspecting officer and certified as satisfactory before applying subsequent coat.
The payment for complete painting of all components of girders including all
accessories, painting of contact surface etc. including all labour and material, is
included in the accepted rates for item in the schedule of items, rates and quantities
and nothing extra shall be paid.
3.7 Specification for Metallising with Sprayed Aluminium for Bridge Girders
3.7.1 Surface Preparation:
The surface shall be thoroughly cleaned and roughened by compressed air blasting
or centrifugal blasting with a suitable abrasive material in accordance with Clause 3
of IS: 6586. Immediately, before spraying it shall be free from grease, scale, rust,
moisture or other foreign matter. It shall be comparable in roughness with a

reference surface produced in accordance with appendix A of IS: 5905 and shall
provide an adequate key for the subsequently sprayed metal coating.
3.7.2 Metal Spraying
The metal spraying shall be carried out as soon as possible after surface
preparation but in any case within such period that the surface is still completely
clean, dry and without visible oxidation. If deterioration in the surface to be coated
is observed by comparison with a freshly prepared metal surface of similar quality
which has undergone the same preparation, the preparation treatment should be
repeated on the surface to be coated.
The wire method shall be used for the purpose of metallising the diameter of the
wire being 3mm or 5mm. Specified thickness of coating shall be applied in multiple
layers and in no case less than 2 passes of the metal spraying unit shall be made
over every part of the surface. At least one layer of the coating must be applied
within 4 hours of blasting and the surface must be completely coated to the
specified thickness within 8 hours of blasting.
i- Purity of Aluminium:
The chemical composition of aluminium to be sprayed shall be 99.5% aluminium
conforming to IS: 2590.
ii- Appearance of the coating:
The surface of the sprayed coating shall be of uniform texture and free from lumps,
coarse areas and loosely adherent particles.
iii- Thickness of the coating:
The nominal thickness of the coating shall be 150 µ (microns). The minimum local
thickness, determined in accordance with procedure given below, shall be not less
than 110 µ (microns).
3.7.3 Shop Painting:
Any oil, grease or other contamination should be removed by thorough washing

with a suitable thinner until no visible traces exist and the surfaces should be
allowed to dry thoroughly before application of paint. The coatings may be applied
by brush or spray. If sprayed, pressure type spray guns must be used. One coat
of wash primer to IS: 5666 shall be applied first. After 4 to 6 hours of the
application of the wash primer, one coat of Zinc chrome primer to IS: 104 with the
additional proviso that zinc chrome to be used in the manufacture of primer shall
conform to type 2 of IS: 51 shall be applied.
After hard drying of zinc chrome primer, one coat of Aluminium paint to IS: 2339
(brushing or spraying as required) shall be applied.
3.7.4 Site Painting:

After the steel work is erected at site a second cover coat of Aluminium paint
to IS:2339 (brushing or spraying as required) shall be applied after touching up the
primer and the cover coat given in the shop if damaged in transit.
3.7.5 Method for the Determination of Local Thickness
Equipment:
Any magnetic or electro-magnetic thickness meter that will measure local

thickness of a known standard with an accuracy of ± 10 percent.
Calibration of Instrument
Calibrate and check the meter on one of the following standards (as appropriate):
(I) (Applicable to magnetic and elecro-maganetic meters other than the pull-off
type) A soft brass shim, free from burrs, in contact with the grit-blasted surface of
the base metal prior to its being sprayed. The thickness of the' shim shall be
measured by micro meter and shall be approximately the same as the thickness of
the coating.
(ii) A sprayed metal coating of uniform known thickness approximately the same as
the thickness of the sprayed coating to be tested, applied to a base of similar
composition and thickness to the article being sprayed, grit-blasted in accordance
with Clause 1.
Procedure:
For each measurement of local thickness, make an appropriate number of

determinations, according to the type of instrument used. With instrument
measuring the average thickness over an area of not less than 0.645 cm 2, the
local thickness shall be the result of the one reading.
With instruments having one or more pointed or rounded probes, the local
thickness shall be the mean of three readings within a circle of 0.645 cm 2 area.
With meters having two such probes, each reading shall be the average of two
determinations with the probes reversed position.
3.7.6 Method of Test For Adhesion

Using a straight edge and hardened steel scriber which has been ground to a
sharp 30 degree point scribe two parallel lines at a distance apart equal to
approximately 10 times the average coating thickness. In scribing the two lines,
apply enough pressure on each occasion to cut through the coating to the base
metal in a single stroke.
3.7.7 Inspection:
Determination of Local Thickness

The minimum local thickness shall be determined by the method described above.
Adhesion
The sprayed metal coating shall be subjected to an adhesion test using the
method described above. If any part of the coating between the lines breaks away
from the base metal, it shall be deemed to have failed the test.
Articles, which have been rejected, shall have the defective sections blasted
clean of all sprayed metal prior to repaying. Where the rejection has been solely
due to too thin a coating, sprayed metal of the same quality may be added
provided that the surface has been kept dry and is free from visible contamination.
The erection rate is to include the supply of all site rivets, turned and black Bolts,
nuts, washers etc. required to complete erection at site as per relevant codes &
practices.
3.8 Name Plate
A neat casting bearing the name of the Contractor, the place and year of
manufacture, drawing number, the contract number and the standard of loading to
be specified by the Purchaser shall be bolted conspicuously on each span. The
drawing of the name plate shall be approved by the Engineer.
3.9 Erection Mark
Every portion of the work shall be distinctly stencilled with paint with letter size not
less than 10 mm for guidance in the erection in the field, and stamped with the
letters specified in the drawings. In the case of non-interchangeable work, the
system of marking shall be in accordance with the drawings prepared by the
tenderer and approved by the Purchaser.
3.10 Packing
All projecting plates or bars shall be kept in shape by timber or angle bars spiked or
bolted to them , and the ends of the chord lengths, end posts and plate girders at
their shipping joints shall be protected and stiffened so as to prevent damage or
distortion in transit as the Inspecting Officer may direct.
All threaded ends and machined surfaces are to be efficiently protected against
damage in transit. The parts shall be sent out in lengths convenient for transport. All
straight bars and plates except small pieces are to be sent out in convenient
bundles temporarily rivetted or bolted together or bound with wrought iron or
suitable wire as the Inspecting Officer may direct. All rivets, bolts, nuts, washers,
plates under 300 mm square and small articles generally are to be packed
separately for each span in cases each weighing, when full, not more than 350 kg,
or in strong petroleum casks, or in barrels approved by the Inspecting Officer. If not
entirely filled by the contents the space left shall be closely packed with wood
shaving or other suitable material. Bolts and rivets of different sizes shall be
separately packed in bags, each bag having a label indicating its contents. A list of
the contents shall be placed in the top of each case or cask. In the case of imported
material all cases shall be made of 32mm boards with ends nailed with 90mm wire
nails strengthened by battens and 38mmx 1.6mm (No. 16 BG) hoop -iron and made
thoroughly secure for transit to India. All casks shall be in sound condition, and if
not entirely filled by the contents the space left shall be closely packed with wood-
wool or other suitable material. The heads shall be firmly secured by means of
hoops in the usual way, and in addition each head shall be further secured by a
strong wooden batten and not less than two strips of 1.6mm (No.16 BG) hoop- iron
passing over the head and nailed to the staves on both sides. The hop-iron shall be
long enough to pass over two hoops on each side of the cask and be nailed in such
a manner that the hoops cannot slack back. Bolts and rivets of different sizes shall
be packed in a separate canvas bags, each bag having a label in dictating its
contents. End field holes to be bolted in case of members having split in plate and
channels.
3.11 Dispatch or Shipping marks
Each package, case or bundle is to have clearly stencilled on it in good oil paint the
address as stated in the order of contract, gross and net weight description of
contents and such marks as may be required by the Purchaser must be shown
against each item in the invoice. The Contractor is to provide necessary stencil
plates for marking. Every piece of bundle shall be marked and in the case of
material (shipped to India) all cases or casks shall be clearly cut or branded, not
merely painted, with their net and gross weights and with such shipping marks and
other particulars as the Inspecting Officer may direct and each bundle shall also
have a metal label securely attached with wire stamped with similar marks. The
marking shall be done with thick oil paint and in such a manner that it cannot be
washed off or obliterated.
3.12 Loading
All trucks or wagons are to be loaded to as near their full capacity as is consistent
with safe transport. While loading the material in wagon, truck or trailor, care should
be taken that heavier material is loaded first and lighter material is kept on top so
that lighter material is not damaged due to heavy weight. While transporting the
material by road, adequate safety precautions shall be taken as per extant
instructions.
The Contractor shall apply all dunnage and lashing required to hold the material
securely in position free of charge.
While handling any girder or girder component it shall be ensured no damage to

material takes place in the form of dent/cut mark etc. Wooden blocks, rubber pads
shall be used to avoid direct contact between materials to be handled and handling
equipment.
3.13 Tracings and Printings
Except in the case of standard spans fabricated without any modifications to the
standard drawings the Contractor shall supply free of charge, one set of neatly
executed tracing on linen. They shall be fully dimensioned and contain all erection
marks, notifications as to the colour the work has been printed, the name of the
Contractor and any alterations from the contract drawings, which may have been
made in executing the work. The drawings shall conform to standard sizes as given
in IS: 962 and shall not exceed AO size. The drawings shall not be folded but rolled
outwards on a roller, in addition to three sets of full size copies on strong paper
made by an approved process.
3.14 Rivets and Bolts lists
The Contractor shall also supply, without charge, three complete lists of the rivets,
bolts, service bolts, washers and drifts required for erecting the work at site,
showing the parts of the work to which the various rivets and bolts belong and
having each item marked so as to indicate the particular case in which it will be
found.

Annexure A

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Tender for Super-Structure (Hasdeo Bridge)

SPECIFICATION FOR SUPER-STRUCTURE OF BRIDGE (Steel

1.0 Books of reference

Railway/IRS books of reference:

xviii. M&C/PCN/103/86: Epoxy micaceous iron oxide

Indian Roads Congress codes and specifications:

Indian Standards Codes & Specifications:

70)IS: 1024 – Welding in bridges and structures subject to dynamic

i. UIC-772R: Bearings of rail bridges.

Note: The books of reference shall also include further references

The girders shall be steel girders as per approved drawings.

Steel of approved grade and quality conforming to IS: 2062- 2011

The tenderer(s) shall supply information in the tender regarding

If any further testing of materials is required by Engineer in respect of these

Even satisfactory outcome of such tests or analysis shall in no way limit,

Fabrication, Workmanship shall generally comply with current IRS

The work of fabrication in Contractor’s fabrication shop will at all times be

Any defects noticed during inspection in the execution of work shall be

In the fabrication of girder, necessary arrangement and provision shall be

2.2 Fabrication Drawings:

The Contractor shall prepare detailed fabrication/shop drawings on the

2.3 Maintenance of records by fabricators

2.4 Tolerances in Fabrication

2.5 Testing of the Materials

In addition to the test certificate obtained from the steel

Regarding radiographic testing/x-ray testing of the welded joints, matter

2.6 Fabrication / Manufacture

The Contractor shall state which of the following alternative methods of

2.7.1 Template Shop

2.8 Flattening and Straightening

required to be of curvilinear form. Pressure applied for straightening or flattening

2.9 Planning and Shearing

2.10 Flame cutting

Flame cutting by mechanically controlled torch/torches shall be accepted both in

2.11 Drilling and Sub-punching

Where the number of thicknesses to be rivetted exceeds three or the total

2.12 Parts in Contact

2.13 Making of Joints

Cleaning of permanent contact surfaces: Surfaces which will have permanent

Where the manufacturing of girders has been done in accordance with

In the event of an emergency arising such as the staging is in danger of being

2.14 Rivets and Riveting

2.15 Field rivets, Bolts, Nuts and Service Accessories

2.16 Smithed Work

All joggles shall be performed by pressure. Craned sections or knees can be

2.17.1 Drawings and Procedure Sheets

a) Specification of the parent metal, and electrodes and/or wire-flux

c) Whether welds are to be made in shop or field.

2.17.2 Butt Welds

2.17.4 Butt welding parts of unequal cross-section

Where the reduction of the dimensions of the thicker part is impracticable,

2.17.5 Butt welded T joints

Butt weld in T joint shall be reinforced by welding as shown in Fig. 8 of the

2.17.6 Ends of butt welds

2.17.7 Reinforcement of butt welds

Sufficient convexity not exceeding 3 mm, shall be provided as reinforcement to

2.17.8 Fillet Welds: Types of fillet welds

Table-1 Minimum size of first run of a fillet weld

Thickness of thicker Minimum

6 mm up to and including 5 mm.