INDIAN OIL CORPORATION LTD. Marketing Division, Head Office
Civil Work Specifications 2013 Volume - I
CONTENTS (Vol.- I) Sub Head No.
NAME OF SUB-HEAD
PAGE
1.0
GENERAL
04-06
2.0
EARTH WORK
07-39
3.0
MORTARS
40-54
4.0
CONCRETE WORK
55-81
5.0
REINFORCED CEMENT CONCRETE WORK
82-157
6.0
BRICK WORK
158-188
7.0
STONE WORK
189-223
8.0
MARBLE WORK
224-239
9.0
WOOD WORK AND PVC WORK
240-312
10.0
STEEL WORK
313-341
11.0
FLOORING
342-369
12.0
ROOFING
370-405
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1.0: GENERAL
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1.1
References
Page No 4
1.2
Rates
4
1.3
Interpretations
4
1.4
Floor and Levels
4
1.5
Special Structures
4
1.6
Foundations and Plinth
4-5
1.7
Measurements
5
1.8
Materials
5
1.9
Safety in Construction
5
1.10
Abbreviations
6
Clause No.
Brief Description
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0.0 GENERAL 1.1
Reference m entioned her ein s hall be appl icable t o al l s ections t o the ex tent t he c ontext per mits and ar e i ntended t o s upplement t he pr ovisions i n t he par ticular s ection. I n c ase of any discrepancy/ deviation, the provisions in the particular section shall take precedence.
1.2
The rates f or al l i tems of w ork unl ess c learly s pecified ot herwise s hall i nclude c ost of al l l abour, materials and other inputs involved in the execution of the items.
1.3
INTERPRETATIONS
1.3.1 Wherever any r eference i s m ade t o any I ndian S tandard, i t s hall be t aken as r eference t o t he latest edition with all amendments issued thereto. In the event of any variation between these specifications and the Indian Standard, the former shall take precedence over the latter. 1.3.2
IS : The standards, specification and code of practices issued by the Bureau of Indian Standards.
1.3.3 Best: The word ‘best’ when used shall mean that in the opinion of the Engineer-in-Charge, there is no superior material/ article and workmanship obtainable in the market and trade respectively. As far as possible the standard required shall be specified in preference to the word ‘best’. 1.4 FLOOR AND LEVELS 1.4.1 Building 1.4.1.1 Floor 1 is the lowest floor above the ground level in the building unless otherwise specified in a particular case. The floors above floor 1 shall be numbered in sequence as floor 2, floor 3 and so on. The number shall increase upwards. 1.4.1.2 Floor level: For floor 1, top level of finished floor shall be t he floor level and f or all other floors above floor 1, top level of the structural slabs shall be the floor level. 1.4.1.3 Plinth level: Floor 1 level or 1.2 m above the ground level whichever is lower shall be the plinth level. 1.5
Special Structures
1.5.1 For structures like ret aining w alls, w ing w alls, c himneys, o ver he ad reservoirs/ tanks an d ot her elevated structures, where elevations/ heights above a defined datum level have not been specified and identification of floors cannot be done as in case of building. Level, at 1.2 m above the ground level shall be the floor 1 level as well as plinth level. Level at a height of 3.5 m above floor 1 level will be r eckoned as floor 2 level and level at a height of 3.5 m above the floor 2 level will be floor 3 level and so on, where the t otal hei ght abo ve floor 1 l evel i s not a w hole num ber multiple o f 3. 5 metre. T op m ost f loor level s hall be t he next i n sequence t o the floor level below e ven i f t he difference in height between the two upper most floor levels is less than 3.5 metres 1.6 FOUNDATION AND PLINTH The work in foundation and plinth shall include: (a) For buildings: All works upto 1.2 metre above ground level or upto floor 1 level whichever is lower: (b) For abutments, piers and well steining: all works upto 1.2 m above the bed level: (c) F or r etaining wall, wing w alls, c ompound walls, chimneys, over he ad r eservoirs/ tanks an d other elevated structures: All works upto 1.2 metre above the ground level: (d) F or res ervoirs/ t anks ( other t han ov erhead res ervoirs/ t anks): A ll works u pto 1. 2 m etre abov e the ground level:
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(e) For basements: All works upto 1.2 m above ground level or upto floor 1 level whichever is lower. Note: Specific provision shall be made in the estimate for such situations where the foundation level is more than 3 (three) metre depth from the plinth for all types of structures mentioned above. 1.7 MEASUREMENTS 1.7.1 In booking di mensions, t he order s hall be c onsistent and i n t he sequence of l ength, w idth and height or depth or thickness. 1.7.2 Rounding off : Rounding off w here required shall be do ne in acc ordance with IS: 2-1960. The number of significant places rounded in the rounded off value should be as specified. 1.8 MATERIALS 1.8.1 Samples of all materials to be used on t he work shall b e got ap proved by the contractor from the Engineer-in-Charge well in time. The approved samples duly authenticated and sealed shall be kept in the custody of the Engineer-in-Charge till the completion of the work. All materials to be provided by the contractor shall be brand new and as per the samples approved by the Engineer-in-Charge. 1.8.2 Materials o btained by the c ontractor f rom the s ources appr oved by the Corporation shall be subjected t o t he M andatory t ests. Where s uch m aterials do no t conform t o t he re levant specifications, the matter shall be taken up by the Engineer-in-Charge for appropriate action against the defaulters. In all such cases, necessary documents in original and proof of payment relating to the procurement of materials shall be made available by the contractor to the Engineer-in-Charge. 1.8.3 Samples, whether submitted for approval to govern bulk supplies or required for testing before use and also the sample of materials bearing ‘Standard mark,’ if required for testing, shall be provided free of cost by the contractor. All other incidental expenditure to be incurred for testing of samples e.g. packaging, sealing transportation, loading, unloading etc. except testing charges shall be borne by the contractor. 1.8.4 The materials, supplied by the Department shall be deemed to be complying with the specifications. 1.8.5 Materials stored at s ite, de pending u pon t he i ndividual c haracteristics, s hall be p rotected f rom atmospheric effects due to rain, sun, wind and moisture to avoid deterioration. 1.8.6 Materials l ike timber, pai nts et c. shall be stored i n such a w ay t hat t here may not be an y p ossibility of f ire hazards. I nflammable m aterials and ex plosives s hall be s tored i n accordance w ith t he relevant rules and regulations or as approved by Engineer-in-Charge in writing so as to ensure desired safety during storage. 1.8.7 The unit weight of materials unless otherwise specified shall be reckoned as given in IS: 1911-1967. 1.9
SAFETY IN CONSTRUCTION
1.9.1 The contractor shall employ only such methods of construction, tools and plant as are appropriate for the type of work or as approved by Engineer-in-Charge in writing. 1.9.2 The contractor shall t ake al l pr ecautions and m easures t o ens ure s afety of w orks and w orkman and s hall b e f ully r esponsible f or the s ame. S afety pe rtaining to c onstruction w orks such as excavation, centering and shuttering, t renching, bl asting, dem olition, el ectric c onnections, s caffolds, ladders, working platforms, gangway, mixing of bituminous materials, electric and gas welding, use of hoisting and construction machinery shall be governed by IOCL safety code, relevant safety codes and the direction of Engineer-in-Charge
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1.10 ABBREVIATIONS The f ollowing abb reviations w herever t hey a ppear in t he s pecifications, s hall have the meaning or implication hereby assigned to them: Mm Cm M Km Mm2/sqmm Cm2/sqcm Dm2/sqdm M2/sqm Cm3/ cubic cm Dm3/ cubic dm M3/cum Ml Kl Gm Kg Q T Fps system °C Fig Re/Rs No Dia AC CI GC GP GI PVC RCC SW SWG
Millimetre Centimetre Metre Kilometre Square Milimetre Square centimetre Square decimetre Square metre Cubic centimetre Cubic decimetre Cubic metre Millilitre Kilolitre Gram Kilogram Quintal Tonne Foot pound second system Degree Celsius temperature Figure Rupee/ Rupees Number Diameter Asbestos cement Cast Iron Galvanised corrugated Galvanised plain Galvanised iron Polyvenyl chloride Reinforced cement concrete Stone ware Standard wire Gauge
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2.0: Earth Work
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CONTENTS
Cla us e No.
Brief Des cription
Page No .
List of Bureau of Indian Standard Codes
09
2.0
Definitions
10
2.1
Classification of Soils
10
2.2
Antiquities and Useful Materials
11
2.3
Protections
11
2.4
Site Clearance
11
2.5
Setting out and Making profiles
12
2.6
Blasting
12
2.7
Excavation in All kinds of soils
14
2.8
Excavation in Ordinary/ Hard rock
15
2.9
Earth work by mechanical means
16
2.10
Filling
18
2.11
Measurements
18
2.12
Rates
19
2.13
Surface Excavation
19
2.14
Rough Excavation and Filling
20
2.15
Excavation over Area (All kinds of Soil)
20
2.16
Excavation over Area (Ordinary/Hard rock)
20
2.17
Excavation in Trenches for Foundations and Drains (All kinds of Soil)
20
2.18
Excavation in Trenches for Foundation and Drains (Ordinary/ Hard rock)
21
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2.19
Excavation in Trenches for Pipes, Cables etc. and Refilling
21
2.20
Planking and Strutting
22
2.21
Excavation in Water, Mud or Foul position
23
2.22
Earth work for major works
24
2.23
Filling in Trenches, Plinth, under Floor etc.
25
2.24
Sand Filling in Plinth
25
2.25
Surface Dressing
26
2.26
Jungle Clearance
26
2.27
Felling Trees
27
2.28
Anti Termite Treatment
27
Fig. 2.1
The Design for Temporary Site Bench Mark
33
Fig. 2.2
Close and Open Planking and Strutting
34
Fig. 2.3 (i to viii)
Anti-Termite Construction Stage 1 to 8
35
Fig. 2.4
Anti-Termite Construction - Final Recommendations
39
LIST OF BUREAU OF INDIAN STANDARD CODES S . No. 1 2 3
I.S . N o. IS 632 IS 1200 (Pt 1) IS 1200 (Pt-27)
4 5 6 7 8 9 10 11
IS 4081 IS 4988 (Part IV) IS 6313 (pt-II) IS 6313(pt.-III) IS 6940 IS 8944 IS 8963 IS 12138
S ubje ct Gamma - BHC (Lindane) emulsifiable concentrates Method of measurement of earth work Method of measurement of earth work (by Mechanical Appliances ) Safety code for Blasting and related drilling operation Excavators Anti Termite measures in buildings (pre -constructional) Anti Termite Measures in Buildings for existing buildings Methods of test for pesticides and their formulations Chlorpyrifos emulsifiable concentrates Chlorpyrifos - Technical specifications Earth moving Equipments
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2.0 EARTH WORK 2.0 DEFINITIONS Deadmen or Tell Tales: Mounds of earth left undisturbed in pits dug out for borrowing earth Burjis: Short pillars of br ick/ s tone having t op s urface f inished with c ement pl aster f or m arking et c. Formation or Profile: Final shape of the ground after excavation or filling up. Foul c ondition: Filthy an d unh ygienic c onditions w here ph ysical movements are h ampered s uch as s oil mixed with sewage or night soil. Lead : All distances s hall b e m easured ov er t he s hortest practical r oute and no t nec essarily t he rou te actually t aken. R oute o ther t han s hortest pr actical r oute m ay be c onsidered i n c ases of unav oidable circumstances and approved by Engineer-in-charge along with reasons in writing. Carriage by manual labour shall be reckoned in units of 50 metres or part thereof. Carriage by animal and m echanical t ransport shall be reckoned i n one km. unit. D istances of 0.5 km. or more shall be taken as 1 km. and distance of less than 0.5 km. shall be ignored. However, when the total lead is less than 0.5 km., it will not be ignored but paid for separately in successive stages of 50 metres subject to the condition that the rate worked on this basis does not exceed the rate for initial lead of 1 km. by mechanical/animal transport. Lift: The v ertical distance for r emoval with ref erence to t he ground le vel. The excavation up to 1 .5 metres dept h below t he ground l evel and depos iting t he ex cavated m aterials upt o 1. 5 m etres above t he ground level are included in the rate of earth work. Lifts inherent in the lead due to ground slope shall not be paid for. Safety rules: Safety rules as laid down by the statutory authority and as provided in General Conditions of Contract shall be followed. 2.1 CLASSIFICATION OF SOILS 2.1.0 The earthwork s hall be c lassified under the f ollowing categories and m easured s eparately f or each category: (a) All kind of soils: Generally any strata, such as sand, gravel, loam, clay, mud, black cotton moorum, shingle, river or nallah bed boulders, siding of roads, paths etc. and hard core, macadam surface of any description (water bound, grouted tarmac etc.), lime concrete mud concrete and their mixtures which for excavation yields to application of picks, showels, jumper, sacrifiers, ripper and other manual digging implements. (b) Ordinary rock: Generally any rock which can be excavated by splitting with crow bars or picks and does not require blasting, wedging or similar means for excavation such as lime stone, sand stone, hard laterite, hard conglomerate and un-reinforced cement concrete below ground level. If required l ight blasting may be resorted to for loosening t he materials but this will not i n an y way entitle the material to be classified as ‘Hard rock’. (c) Hard rock: Generally any rock or boulder for the excavation of which blasting is required such as quartzite, granite, basalt, reinforced cement concrete (reinforcement to be cut through but not separated from concrete) below ground level and the like.
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(d) Hard rock (blasting prohibited): Hard rock requiring blasting as described under (c) but where the blasting is prohibited for any reason and excavation has to be carried out by chiselling, wedging, use of rock hammers and cutters or any other agreed method. 2.2 ANTIQUITIES AND USEFUL MATERIALS 2.2.1 Any finds of a rchaeological interest such a s relics of a ntiquity, coins, fossils o r other articles o f value shall be delivered to the Engineer-in-Charge and shall be the property of the Government. 2.2.2 Any material obt ained from t he ex cavation w hich i n t he opi nion o f t he E ngineer-in-Charge i s u seful shall b e s tacked separately i n regular s tacks as d irected b y t he Engineer-in-Charge a nd s hall be t he property of the Corporation. 2.3 PROTECTIONS 2.3.1 Excavation where directed by the Engineer-in-Charge s hall be s ecurely barri caded and pro vided with proper caution signs, conspicuously displayed during the day and properly illuminated with red lights a nd/or writte n us ing fluore s ce nt re fle ctive pa int a s dire cte d by e ngine e r in cha rge during the night to avoid accident. 2.3.2 The C ontractor shall t ake adequate pr otective m easures t o see that t he ex cavation o perations d o not damage the adjoining structures or dislocate the services. Water supply pipes, sluice va lve chambers, s ewerage pi pes, m anholes, dr ainage pipes and c hambers, c ommunication c ables, pow er supply c ables e tc. m et within th e course of excavation shall be p roperly su pported a nd a dequately protected, so that these services remain functional. However, if any service is damaged during excavation shall be restored in reasonable time. 2.3.3 Excavation s hall not be c arried out below the foundation level of the adjacent buildings until underpinning, s horing et c. i s done as per t he di rections of t he E ngineer-in-Charge f or w hich pay ment shall be made separately. 2.3.4 Any damages done by the contractor to any existing work shall be made good by him at his own cost. E xisting dr ains pi pes, c ulverts, ov er he ad w ires, w ater s upply l ines and s imilar s ervices encountered d uring t he course of ex ecution shall be prot ected against d amage by t he c ontractor. T he contractor shall not store material or otherwise occupy any part of the site in manner likely to hinder the operations of such services. 2.4 SITE CLEARANCE 2.4.1 Before the earth work is started, the area coming under cutting and filling shall be cleared of shrubs, rank vegetation, grass, brushwood, trees and saplings of girth up to 30cm measured at a height of one metre ab ove gr ound level an d rubbish removed up t o a distance of 50 metres out side the periphery of t he ar ea u nder c learance. T he ro ots o f t rees and saplings s hall be r emoved t o a d epth o f 60cm bel ow ground l evel or 30 c m bel ow f ormation l evel or 15 c m bel ow s ub grade l evel, w hichever i s lower, and the holes or hollows filled up with the earth, rammed and levelled. 2.4.2 The trees of girth above 30 cm measured at a height of one metre above ground shall be cut only after permission of the Engineer-in-Charge is obtained in writing. T he roots of trees shall a lso be removed a s s pecified i n 2.4.1. p ayment f or c utting s uch t rees a nd r emoving t he r oots shall be m ade separately. 2.4.3 Existing s tructures an d s ervices s uch a s ol d bu ildings, c ulverts, fencing, w ater s upply pipe l ines, sewers, power cables, communication cables, drainage pipes etc. within or adjacent to the area if required to b e diverted/removed, s hall b e diverted/dismantled as p er directions of t he Engineer-inCharge and payment for such diversion/dismantling works shall be made separately.
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2.4.4 In case of archaeological m onuments w ithin or adjacent to the area, t he contractor shall provide necessary f encing all-round such monuments as per the di rections o f t he E ngineer-in-Charge and pr otect the same properly during execution of works. Payment for providing fencing shall be made separately. 2.4.5 Lead of 50 m mentioned in the ‘Schedule Of Quantities’ is the average lead for the disposal of excavated ea rth within the site of work. T he actual lead for the lead for the disposal of ea rth m ay be more or less than the 50 m for which no cost adjustment shall be made in the rates. 2.4.6 Disposal of Earth shall be di sposed off at the specified location or a s d ecided b y the Engineer-inCharge. The contractor has to take written permission about place of disposal of earth before the earth is disposed off, from Engineer-in-Charge. 2.5 SETTING OUT AND MAKING PROFILES 2.5.1 A masonry pillar to serve as a bench mark will be erected at a suitable point in the area, which is visible from the largest area. This bench mark shall be constructed as per Fig. 2.1 and connected with the standard bench mark as approved by the Engineer-in-Charge. Necessary profiles with strings stretched on pegs, bamboos or ‘ Burjis’ s hall be m ade t o i ndicate t he c orrect formation l evels bef ore t he work i s s tarted. The c ontractor s hall s upply l abour and material f or c onstructing be nch mark, s etting o ut and m aking pr ofiles an d c onnecting b ench m ark with t he s tandard bench m ark at hi s ow n c ost. T he pegs, b amboos or ‘ Burjis’ and t he b ench m ark s hall be m aintained b y t he contractor at hi s o wn cost during the excavation to check the profiles. 2.5.2 The ground levels shall be taken at 5 to 15 metres intervals (as directed by the Engineer-inCharge) in uni formly sloping g round and at closer intervals w here local m ounds, pi ts or undulations are met w ith. T he ground l evels s hall be r ecorded i n f ield book s and pl otted on pl ans. T he pl ans s hall be drawn to a scale of 5 metres to one cm or any other suitable scale decided by the Engineer-in-Charge. North di rection l ine and pos ition o f bench mark shall i nvariable be shown on the pl ans. These pl ans s hall be signed b y the c ontractor an d the E ngineer-in-Charge or their au thorized rep resentatives before t he earth work is started. The labour required for taking levels shall be s upplied by the contractor at his own cost. 2.6 BLASTING 2.6.0 Where hard rock is met with and bl asting operations are considered necessary, the contractor shall obtain the approval of the Engineer-in-Charge in writing for resorting to blasting operation. Note: In ordinary rock blasting operations shall not be generally adopted. However, the contractor may res ort t o bl asting w ith t he perm ission of t he E ngineer-in-charge, but not hing ex tra s hall be pai d f or such blasting operations. The contractor shall obtain license from the competent authority for undertaking blasting work as well as for obt aining and storing t he ex plosive as pe r t he E xplosive A ct, 1884 as am ended up to dat e and the Explosive R ules, 1983. The c ontractor s hall purchase t he explosives fuses, detonators, et c. o nly from a licensed dealer. The contractor shall be responsible for the safe transportation, storage and custody as per explosive rules and proper accounting of the explosive materials. Fuses and detonators shall be stored separately and away from the explosives. The Engineer-in-Charge or his authorized representative shall have the right to check the contractor’s store and account of explosives. The contractor shall provide necessary facilities for this. The c ontractor s hall be r esponsible f or any dam age ar ising out of ac cident t o w orkmen, publ ic or property due to storage, transportation and use of explosive during blasting operation. 2.6.1 Blasting operations shall be c arried out under the supervision of a res ponsible authorized agent of the contractor (referred subsequently as agent only), during specified hours as approved in writing by
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the E ngineer-in-Charge. The age nt s hall be c onversant w ith t he r ules o f bl asting. I n case o f bl asting w ith dynamite or any other high explosive, the position of all the bore holes to be drilled shall be marked in circles w ith white pai nt. These s hall be i nspected b y t he contractor’s agent . B ore hol es s hall be o f a size that t he c artridge c an eas ily pas s do wn. After t he d rilling operat ion, t he age nt s hall i nspect t he hol es t o ensure t hat dri lling has been done onl y at t he m arked l ocations and no ex tra hol e has been drilled. The agent shall t hen prepare the necessary c harge separately for each bore hole. T he bore holes s hall b e thoroughly c leaned be fore a c artridge i s i nserted. O nly c ylindrical w ooden t amping rods shall be us ed for tamping. Met al rods or rods hav ing poi nted ends s hall nev er be us ed for tamping. O ne c artridge s hall be placed i n t he bore hol e and gently pressed but not ram med dow n. O ther c artridges s hall t hen be added as may be required to make up the necessary charge for the bore hole. The top most cartridge shall be connected to the detonator which shall in turn be connected to the safety fuses of required length. All fuses s hall b e c ut t o t he l ength r equired bef ore b eing i nserted i nto t he hol es. J oints i n f uses s hall b e avoided. Where joints are unavoidable a semi-circular nitch shall be cut in one piece of fuse about 2 cm deep from t he end and t he en d of oth er piece inserted into th e nitc h. T he two pi eces sh all th en be wrapped together with string. All joints exposed to dampness shall be wrapped with rubber tape. The maximum of eight bore holes s hall be l oaded and f ired at one oc casion. T he charges shall b e fired successively and not simultaneously. Immediately before firing, warning shall be given and the agent shall see that a ll p ersons have retired to a p lace of safety. The safety fuses of the charged holes shall be ignited in the presence of the agent, who shall see that all the fuses are properly ignited. Careful count shall be kept by the agent and others of each blast as it explodes. In case all the charged bore holes have exploded, the ag ent shall inspect the site soon after the blast b ut in case of misfire the agent shall inspect the site after half an hour and mark red crosses (X) over the holes which have not ex ploded. D uring t his i nterval of hal f an hour, nobody s hall appr oach t he m isfired hol es. N o driller shall work near such bore until either of the following operations have been done by the agent for the misfired boreholes. (a) The contractor’s agent shall very carefully (when the tamping is of damp clay) extract the tamping with a wooden scraper and withdraw the fuse, primer and detonator. After this a fresh detonator, primer and fuse shall be placed in the misfired holes and fired, or (b) The holes shall be cleaned for 30 cm of tamping and its direction ascertained by placing a stick in the hole. Another hole shall then be drilled 15 cm away and parallel to it. This hole shall be charged and fired. The misfired holes shall also explode along with the new one. Before leaving the site of work, the agent of one s hift shall inform the another agent relieving him for the next shift, of any case of misfire and each such location shall be jointly inspected and the action to be taken in the matter shall be explained to the relieving agent. The Engineer-in-Charge shall al so be i nformed by t he agent o f al l c ases o f misfires, their c auses an d steps taken in that connection. 2.6.2 General Precautions For t he s afety of per sons red f lags s hall be prom inently di splayed around t he area w here bl asting operations are t o be c arried out . A ll t he w orkers at s ite, ex cept t hose w ho a ctually i gnite t he f use, s hall withdraw to a s afe d istance o f a t least 20 0 m etres from the b lasting s ite. Audio w arning by b lowing whistle shall be given before igniting the fuse. Blasting work shall b e d one u nder c areful supervision and t rained p ersonnel shall be em ployed. Blasting shall not be done w ith i n 200 metres o f an existing structure, unl ess s pecifically per mitted b y t he Engineer-in-Charge in writing.
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All p rocedures a nd s afety p recautions f or t he u se of explosives drilling and l oading of explosives drilling and loading of explosives before and after shot firing and disposal of explosives shall be taken by the contractor as detailed in IS 4081, safety code for blasting and related drilling operation. 2.6.3 Precautions against Misfire The safety fuse shall be cut in an ob lique d irection with a knife. All saw dust shall b e cleared from inside of the detonator. T his c an be done by bl owing down t he detonator and t apping t he open end. No tools shall be inserted into the detonator for this purpose. If there is water present or if the bore hole is damp, the junction of the fuse and detonator shall be made water tight by means of tough grease or any other suitable material. The det onator s hall be i nserted i nto t he c artridge s o t hat about one third of t he c opper t ube i s l eft exposed out side the e xplosive. The safety fuse just abov e the det onator s hall be securely t ied in pos ition in the cartridge. Water proof fuse only shall be used in the damp bore hole or when water is present in the bore hole. If a m isfire has been f ound t o be due t o def ective f use, det onator or dy namite, t he ent ire consignment from which the fuse detonator or dynamite was taken s hall be got inspected by the Engineer-in-Charge or hi s aut horized r epresentative b efore r esuming th e blas ting or r eturning the consignment. 2.7 EXCAVATION IN ALL KINDS OF SOILS 2.7.1 All ex cavation operat ions m anually or by m echanical m eans s hall i nclude ex cavation an d ‘ getting out’ t he ex cavated m aterials. I n c ase of ex cavation f or t renches, bas ements, w ater t anks et c. ‘ getting out’ shall include throwing the excavated materials at a distance of at least one metre or half the depth of excavation, whichever i s m ore, clear off t he edge of ex cavation. In a ll o ther c ases ‘getting ou t’ s hall include de positing the ex cavated m aterials a s s pecified. T he s ubsequent d isposal o f the ex cavated material shall be either stated as a separate item or included with the items of excavation stating lead. 2.7.2 During the excavation the natural drainage of the area shall be maintained. Excavation shall be done from top to bottom. Undermining or undercutting shall not be done. 2.7.3 In firm soils, the sides of the trenches shall be kept vertical upto a depth of 2 metres from the bottom. F or g reater d epths, t he excavation p rofiles s hall be w idened b y al lowing s teps of 50 c ms on either s ide a fter ev ery 2 m etres from the bo ttom. A lternatively, the ex cavation c an be do ne s o as to give s lope of 1: 4 (1 h orizontal : 4 vertical). W here the s oil is s oft, loose o r slushy, the w idth of steps shall be suitably increased or sides sloped or t he s oil s hored up as directed by the Engineer-inCharge. It s hall be the res ponsibility of the contractor to tak e c omplete instructions in writing f rom the E ngineer-in-Charge regarding t he stepping , s loping or s horing t o be d one f or e xcavation deep er than 2 metres. 2.7.4 The excavation s hall be done true to levels, slope, shape and pat tern indicated by the Engineer-inCharge. Only the excavation shown on the drawings with additional allowances for centering and shuttering or as required by the Engineer-in-Charge shall be measured and recorded for payment. 2.7.5 In case of excavation for foundation in trenches or over areas, the bed of excavation shall be to the correct l evel or s lope and c onsolidated by w atering and ramming. I f t he e xcavation f or f oundation i s done t o a dep th great er t han t hat s hown in t he dra wings or as requi red by t he E ngineer-in-Charge, t he excess dept h shall be made good b y t he contractor at hi s ow n cost with t he c oncrete o f the mix u sed for levelling/ b ed c oncrete f or f oundations. Soft/defective spots at the bed of t he f oundations s hall be d ug out and filled with concrete (to be paid separately) as directed by the Engineer-in-Charge.
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2.7.6 While carrying out the excavation for drain work care shall b e taken to cut the side and bot tom to the r equired s hape, s lope and gradient. T he s urface s hall t hen be p roperly dressed. I f t he excavation i s done t o a dept h grea ter t han t hat s hown on t he dr awing or as req uired by t he E ngineer-in-Charge, t he excess dept h s hall be made good by the contractor at his o wn cost with s tiff clay puddle at places where the drains are required to be pitched and with ordinary earth, properly watered and rammed, where the drains are n ot r equired to be pitched. In case the d rain is r equired is to b e pitched, the b ack filling with clay p uddle, i f requ ired, s hall be done simultaneously a s t he p itching work p roceeds. T he bri ck pi tched storm water drains should be avoided as far as possible in filled-up areas and loose soils. 2.7.7 In all other cases where t he ex cavation is taken dee per b y t he contractor, it shall be br ought to the required l evel by t he c ontractor at hi s ow n c ost by f illing i n with ear th dul y watered, c onsolidated an d rammed. 2.7.8 In case the excavation is done wider than that shown on the drawings or as required by the Engineer-in-Charge, additional filling wherever required on the account shall be done by the contractor at his own cost. 2.7.9 The excavation shall be done manually or b y mechanical means as directed b y Engineer-in-charge considering feasibility, ur gency of work, availability of l abour /mechanical eq uipments and ot her f actors involved. C ontractor s hall ens ure every s afety measures f or t he w orkers. Neither any deduction w ill be made nor any extra payment will be made on this account. 2.8 EXCAVATION IN ORDINARY/HARD ROCK 2.8.1 All excavation op erations s hall include ex cavation an d ‘ getting out’ t he ex cavated m atter. I n c ase of excavation for trenches, basements, water tanks etc. ‘getting out’ shall include throwing the excavated materials at a distance of at least one metre or half the depth of excavation, whichever is more, clear off the edge or excavation. In all other cases ‘getting out’ shall include depositing the excavated materials as specified. The subsequent disposal of the excavated material shall be ei ther stated as a s eparate item or included with the item of excavation stating lead. 2.8.2 During the excavation, the natural drainage of the area shall be m aintained. E xcavation shall be done from top to bottom. Undermining or under cutting shall not be done. 2.8.3 Where hard rock is met with and bl asting operations are considered necessary, the contractor shall obtain t he approval of the Engineer-in-Charge i n w riting f or r esorting t o t he bl asting o perations. B lasting operations shall be done as specified in Para 2.6 and chiselling shall be done to obtain correct levels, slopes, s hape and pattern of ex cavation as per t he draw ings or a s requi red by t he Engineer-in-Charge and nothing extra shall be payable for chiselling. 2.8.4 Where blasting operations are prohibited or are not practicable, excavation in hard rock shall be done by chiselling. 2.8.5 In o rdinary rock e xcavation shall be c arried out by c rowbars, pick ax es or pneum atic drills an d blasting op eration s hall n ot be gene rally adop ted. Where bl asting ope rations are not pro hibited a nd i t i s practicable to resort to blasting for excavation in ordinary rock, contractor may do so with the permission of the Engineer-in-Charge in writing but nothing extra shall be paid for this blasting. Blasting shall be done as specified in Para 2.6. 2.8.6 If the excavation for foundations or drains is done to a depth greater than that s hown in the drawings o r as req uired by the E ngineer-in-Charge. T he ex cess dep th s hall be m ade good by the contractor at hi s o wn c ost w ith the c oncrete of t he mix us ed f or levelling/ be d c oncrete f or f oundations. Soft/ defective spots at t he bed of fo undations s hall b e dug out and fi lled with c oncrete (t o be p aid separately) as directed by the Engineer-in-Charge.
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2.8.7 In all other cases where t he ex cavation i s taken deeper by the contractor, it shall be br ought to the required l evel b y th e c ontractor at his own c ost by fil ling w ith earth d uly w atered, consolidated and rammed. 2.8.8 In case the excavation is done wider than that shown on the drawings or as required by the Engineer-in-Charge, f illing w herever required on t his ac count s hall be do ne by t he c ontractor at hi s own cost. 2.8.9 Only the excavation s hown on the dr awings or as required b y the E ngineer-in-Charge s hall be measured and rec orded f or pay ment ex cept i n c ase of hard ro ck, where b lasting o perations ha ve bee n resorted t o, e xcavation s hall be measured t o th e act ual l evels, pr ovided t he E ngineer-in-Charge i s satisfied that the contractor has not gone deeper than what was unavoidable. 2.8.10 The e xcavation s hall be d one m anually or by m echanical m eans as des ired by E ngineer-inCharge considering feasibility, urgency of work, availability of labour /mechanical equipments and other factors i nvolved C ontractor s hall en sure e very s afety m easures f or t he workers. Neither an y de duction will be made nor any extra payment will be made on this account. 2.9 EARTH WORK BY MECHANICAL MEANS Earth w ork b y m echanical means i nvolves c areful pl anning keeping i n v iew s ite conditions i .e. t ype o f soil, nature of excavation, distances through which excavated soil is to be transported and working space av ailable for em ploying these m achines. T he ea rth m oving equ ipment s hould be ac cordingly selected. The earth moving equipment consists of excavating and transporting equipment. Excavating equipments may be further classified as excavators and tractor based equipments. 2.9.1 Excavators Excavators generally used at site are as follows: (i) Dipper-shovel : It is used for excavating against a face or bank consisting of open-top bucket or dipper with a bottom opening door, fixed to an arm or dipper stick which slides and pivots on the jib of the crane. It is suitable for excavating all clay chalk and friable materials and for handling rock and stone. However, it is not suitable for surface excavation for which a skimmer is used. (ii) Backhoe : It is similar to face shovel except that the dipper stick pivots on the end of the jib and the dipper or bucket works towards the chassis and normally has no bottom door but is emptied by swinging away from the chassis to invert the bucket. It may be designed to carry both a front -mounted bucket loading mechanism and a rear mounted backhoe. It is mainly used to excavate trenches and occasionally used for the excavation of open areas such as small basements. In t he bac khoe mode t he buc ket l ifts, s wings and di scharges materials while t he under carriage i s stationary. W hen us ed i n t he ‘ loader’ m ode, the machine l oads or ex cavated t hrough f orward motion of the machine, and lifts, transports and discharges materials. (iii) Skimmer : This arrangement is similar to the face shovel except that in this case the bucket slides on rollers directly along the jib and thus has a more restricted movement. It is used for surface excavation and levelling in conjunction with transport to haul away the excavated material. (iv) Dragline : It is usually fitted with a long slender boom or jib and the bucket, which in operation faces towards the machine and has no door, is supported by cable only as on a crane. It works from the side of the excavation at normal ground level and is used for excavating large open excavations such as basements when the depth is beyond the limit of the boom of a backhoe. It is commonly used for open cast mining operations.
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(v) Clamshell : It consists of two hinged half-buckets or jaws pivoted to a frame which is suspended by cable from a long jib of an excavation. The grab is used for deep excavations of limited area on all types of soil except rock. Crane and Grab is a variant of this type of equipment. 2.9.2 Tractor-based Equipment It i s a se lf-propelled crawler or wheeled machine used to exert a pus h or pull force through mounted eq uipment. I t i s d esigned ei ther as a ttachments t o no rmal t racked o r w heeled t ractors o r as machines i n w hich t he ear th m oving at tachments and t he t ractor ar e designed as a s ingle i ntegrated unit. A tractor, which is hydraulically operated, can be rigged as : (i) Loaders : It is used for loading, light dozing, scraping and grabbing operations, lifting and transporting the materials (loose earth, rubble, sand, gravel aggregate etc) at various sites through forward motion of the machine. (ii) Tractor Shovel : This consists of a tipping bucket at the front attached by strong pivoted arms or booms to the frame of the machine. It is used for stripping top soil, excavating against a face, bulldozing and for loading spoil or loose materials. It is similar to crawler dipper-shovel. (iii) Trench D igger : It operates on the same principle as a backhoe excavator except that the bucket is controlled by hydraulic rams instead of cables and pulleys. (iv) Scraper : Scrapers provide unique capability to excavate, load, haul and dump materials. Scrapers are available in various capacities by a number of manufacturers with options such as self - loading with elevators, twin engines or push-pull capability. They are cost effective where the haul distance is too long for bulldozers, yet too short for trucks. This distance typically ranges from 120 m to 1200 m; however, the economics should be evaluated for each project. Scraper has an ope n bo wl with a c utting ed ge po sitioned bet ween t he a xles, w hich cuts, loads, transports, di scharges and s preads t hrough f orward m otion of t he machine. Loadi ng t hrough forward m otion of the machine c an be as sisted by a pow ered m echanism (elevator) f ixed t o t he scraper bowl. (v) Bulldozer and Angle-dozer : The most common equipment used for clearing and levelling activities is a bulldozer. The terms bulldozer is used to define a tractor mounted with a dozing blade. The b ulldozer consists o f a r ectangular st eel b lade with r enewable cutting e dge s et at right angles ( capable o f o nly tilting b ut no t ang ling) to the d irection o f travel a nd attached by s teel arms to the side frames of a crawler tractor. It m ay be used for excavating natural soil or for moving loose soil or debris, which is pushed forward as the tractor forces it ahead. (vi) Angledozer is capable of both tilting and angling 2.9.3 Transporting Equipment This implies horizontal movement primarily but it can involve some vertical movement too. (i) Dumpers : These are self-propelled wheeled machines, having an open body. It is designed for the transport of excavated materials and consists of a shallow tipping hopper or skip mounted on a wheeled chassis, such as, power barrow, dumper, multi-skip dumpers, high discharge dumpers, dump truck, etc. These can be rear dump, side dump or bottom dump. (ii) Vibratory Roller : It is a single Drum Vibratory Roller for compaction of embankments, etc. The smooth drum version is for compaction of granular and mixed soil. The sheepsfoot Roller consists of a hallow cylindrical steel drum or drums on which projecting feet are mounted. These
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feet penetrate into the fill as a rol ler moves forward and c ause compaction. T he geometry of the foot may be sheep, club pyramid, cone or cylinder foot. Such rollers are employed for compaction (densification) of cohesive and semi-cohesive soils. 2.10 FILLING 2.10.1 The earth used for filling shall be f ree from all roots, grass, shrubs, r ank vegetation, brushwood, tress, sapling and rubbish. 2.10.2 Filling with excavated earth shall be done in regular horizontal layers each not exceeding 20 cm in depth. All lu mps an d cl ods ex ceeding 8 cm i n a ny dir ection sh all b e br oken. E ach l ayer sh all be watered and consolidated with s teel r ammer or ½ t onne roller. Where specified, ev ery t hird and top must layer s hall a lso be consolidated w ith power roller of minimum 8 tonnes. W herever depth of filling exceeds 1.5 metre vibratory power roller shall be used to consolidate the filing unless otherwise directed by Engineer-in-charge. The top and sides of filling shall be n eatly dressed. The contractor shall make good all subsidence and shrinkage i n ear th fillings, e mbankments, t raverses e tc. dur ing ex ecution and till t he completion of work unless otherwise specified. 2.11 MEASUREMENTS 2.11.1 The length and breadth of excavation or filling shall be measured with a s teel tape correct to the nearest c m. T he dept h of c utting or hei ght of f illing s hall be m easured, c orrect t o 5 m m, by recording levels bef ore t he start of the w ork and af ter t he c ompletion of the w ork. T he c ubical c ontents s hall be worked out to the nearest two places of decimal in cubic metres. 2.11.1.1 In case of open footings up to the depth of 1.5 metres, all-round excavation of 30 cm. beyond the o uter di mension of f ooting shall b e m easured for payment t o m ake al lowances f or centering a nd shuttering. A ny additional excavation beyond t his l imit s hall be at t he ri sk and c ost of the c ontractor and shall not be measured for payment. 2.11.1.2 In case of open footings/Rafts at a depth of more than 1.5 metre, all-round excavation of 75 cm shall be m easured f or pa yment to m ake al lowance f or c entering and s huttering. A dditional ex cavation beyond this limit shall be at the risk and cost of the contractor and shall not be measured for payment. 2.11.2 In case the ground is fairly uniform and where the site is not required to be l evelled, the Engineer-in-Charge m ay permit t he measurements of dept h of c utting or height of f illing w ith s teel t ape, correct t o t he near est cm. In case o f bor row pi ts, di agonal r idges, c ross ridges o r dead -men, the position of which s hall b e f ixed by t he E ngineer-in-Charge, shall be l eft by t he c ontractor t o p ermit accurate measurements bei ng t aken w ith s teel t ape on the c ompletion of t he w ork D eduction of s uch ri dges an d dead men shall be made from the measurements unless the same are required to be removed later on and t he e arth s o r emoved i s ut ilized i n t he w ork. I n t he l atter c ase not hing ex tra w ill be paid f or t heir removal as subsequent operation. 2.11.3 Where ordinary rock and hard rock is mixed. The measurement of the excavation shall be made as specified i n 2. 11.1 and 2.11.2 T he t wo k inds of r ock s hall be s tacked s eparately and m easured i n stacks. T he net quant ity of t he two k inds of rocks s hall be ar rived at by appl ying deduc tion of 50% to allow for voids in stacks. If the sum of net quantity of two kinds of rocks exceeds the total quantity of the excavated material, then the quantity for each type of rock shall be worked out from the total quantity in the ratio of net quan tities in stack m easurements o f the two types o f rocks. If in the op inion of t he Engineering-in-charge stacking is not feasible, the quantity of ordinary and hard rock shall be worked out by means of cross-sectional measurements. 2.11.4 Where soil, ordi nary roc k and har d roc k are m ixed, t he measurements f or t he ent ire ex cavation shall be made as s pecified i n 2. 11.1 and 2. 11.2 E xcavated m aterials c omprising ha rd rock and ordinary rock shall be stacked separately, measured, and each reduced by 50% to allow for voids to arrive at the
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quantity payable under hard rock and ordinary rock. The difference between the entire excavation and the sum of t he quantities payable und er ha rd rock and or dinary roc k shall be pa id for as ex cavation in ordinary soil or hard soil as the case may be. 2.11.5 Where it is not possible or convenient to m easure the depth of cutting by recording levels as specified i n 2. 11.1 quantity of excavation s hall b e worked out from f illing. The ac tual measurements of the fill shall be calculated by taking levels of the original ground before start of the work after site clearance and after compaction of the fill as specified and the quantity of earth work so computed shall be reduced by 10% in case of consolidated fills and by 5% in case the consolidation is done by heavy mechanical m achinery t o arrive at t he net quant ity of ex cavation for pa yment. N o s uch d eduction s hall, however, be made in case of consolidation by heavy mechanical machinery at optimum moisture content, or when the consolidated filling is in confined situations such as under floors. 2.11.6. Recording Measurements for Earth Levelling Work 2.11.6.1 Level B ooks: In case of levelling operations and earthwork, measurements are required to be recorded in level bo oks in add ition to M easurement B ooks. T he Lev el B ooks s hould be nu mbered, accounted for and handled like Measurement Books. 2.11.6.2 Preparatory Works: Before starting the earth work, following steps should be taken : (1) Original ground levels should be recorded in the Level Book in the presence of the contractor or his authorized representative, and should be signed by him and the site engineer who records the levels. (2) Plans showing initial levels, location of bench marks and reduced levels, should be prepared and s igned b y bot h t he parties and at tached t o t he agreement bef ore c ommencement of t he work. 2.11.6.3 Final Levels (1) On completion of work, the levels should again be recorded in the Level Book and the contractor’s signatures obtained. (2) T he f ormation l evels as per f inal ex ecution of the w ork s hould be c ompared w ith t he proposed formation levels and the work got rectified within permissible tolerance. 2.12 RATES 2.12.1 Rates for Earthwork shall include the following: (a) Excavation and depositing excavated material as specified. (b) Handing of antiquities and useful material as specified on 2.2. (c) Protection as specified in 2.3. (d) Site clearance as specified in 2.4. (e) Setting out and making profiles as specified in 2.5. (f) Forming (or leaving) dead - men or ‘Tell Tales’ in borrow pits and their removal after measurements. (g) Bailing out or pumping of rain water from excavations. (h) Initial lead of 50 m and lift of 1.5 m. (i) Blasting operations for hard rock as specified in 2.6. 2.12.2 No deduction shall be m ade from the rate if in the opinion of the Engineer- in-charge, operations specified in 2.12.1 (b) to (h) are not required to be carried out on any account whatsoever. 2.13 SURFACE EXCAVATION 2.13.1 Excavations exceeding 1.5 m in width and 10 sqm. on pl an but not exceeding 30 cm. in depth in all types of soils and rocks shall be described as surface excavation and shall be done as specified in 2.7 and 2.8.
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2.13.1 Measurements The length and breadth shall be m easured w ith a s teel t ape c orrect to t he nearest cm. and t he area worked out to the nearest two places of decimal in square metres. 2.13.3 Rate shall be as specified in 2.12. 2.14. ROUGH EXCAVATION AND FILLING 2.14.1 Excavation for ea rth from borrow pits, cutting hill side slopes etc. shall be described a s rough excavation and shall be done as specified in 2.7, 2.8 and 2.9. 2.14.2 Wherever filling is to b e done, the earth from e xcavation shall b e directly u sed for filling a nd n o payment f or doubl e hand ling of ear th s hall be adm issible. F illing of ex cavated ear th shall be done as specified i n 2 .10. In case o f hill side cu tting, w here th e excavated m aterials is th rown d own t he hill slopes, payment for filling excavated earth shall not be admissible. 2.14.3 Measurements shall be as specified in 2.11. 2.14.4 Rates shall be as specified in 2.12. 2.15 EXCAVATION OVER AREA (ALL KINDS OF SOIL) 2.15.1 This shall comprise: (a) Excavation exceeding 1.5 m in width and 10 sqm on plan and exceeding 30 cm in depth. (b) Excavation for basements, water tanks etc. (c) Excavation in trenches exceeding 1.5 m in width and 10 sqm on plan. 2.15.2 Excavation shall be done as specified in 2.7. 2.15.3 Measurements shall be as specified in 2.11. 2.15.4 Rates shall be as specified in 2.12. 2.16 EXCAVATION OVER AREA (ORDINARY/ HARD ROCK) 2.16.1 This shall comprise: (a) Excavation exceeding 1.5 m in width and 10 sqm on plan and exceeding 30 cm in depth. (b) Excavation for basements, water tanks etc. (c) Excavation in trenches exceeding 1.5 m in width and 10 sqm on plan. 2.16.2 Excavation shall be done as specified in 2.8 and 2.9. 2.16.3 Measurements shall be done as specified in 2.11. 2.16.4 Rates shall be as specified in 2.12. 2.17 EXCAVATION IN TRENCHES FOR FOUNDATIONS AND DRAINS (ALL KINDS OF SOIL) 2.17.1 This shall comprise excavation not exceeding 1.5 m in width or 10 sqm on plan and to any depth in trenches (excluding trenches for pipes, cables, conduits etc.) 2.17.2 Excavation shall be done as specified in 2.7. 2.17.3 Measurements shall be as specified in 2.11. 2.17.4 Rates shall be as specified in 2.12.
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2.18 EXCAVATION IN TRENCHES FOR FOUNDATION AND DRAINS (ORDINARY/ HARD ROCK) 2.18.1 This shall comprise excavation not exceeding 1.5m in width or 10 sqm. On plan and to any depth in trenches (excluding trenches for pipes, cables, conduits etc.) 2.18.2 Excavation shall be done as specified in 2.8. and 2.9. 2.18.3 Measurements shall be as specified in 2.11. 2.18.4 Rates shall be as specified in 2.12. 2.19 EXCAVATION IN TRENCHES FOR PIPES, CABLES ETC. AND REFILLING 2.19.1 This shall comprise excavation not exceeding 1.5 mts in width or 10 sqm in plan and to any depth t renches for pi pes. C ables et c. and r eturning the ex cavated material t o f ill the t renches a fter pi pes, cables etc. are laid and their joints tested and passed and disposal of surplus excavated material upto 50 m lead. 2.19.2 Width of Trench (a) Upto one metre depth the authorized width of trench for excavation shall be arrived at by adding 25 cm t o t he ex ternal di ameter o f pi pe (not s ocket/ collar) cable, conduit et c. Where a pi pe is l aid on c oncrete bed/ c ushioning l ayer, t he aut horized w idth s hall be the ex ternal di ameter of pi pe (not socket/ collar) plus 25 cm or the width of concrete bed/ cushioning layer whichever is more. (b) For depths exceeding one metre, an allowance of 5 cm per metre of depth for each side of the trench shall be added to the authorized width (that is external diameter of pipe plus 25 cm) for excavation. This allowance shall apply to the entire depth of the trench. In firm soils the sides of the trenches shall be kept vertical upto depth of 2 metres from the bottom. For depths greater than 2 metres, the excavation profiles shall be widened by allowing steps of 50 cm on either side after every two metres from bottom. (c) Where m ore t han one pi pe, c able, c onduit et c, are l aid, t he di ameter s hall be r eckoned as t he horizontal distance from outside to outside of the outermost pipes, cable, conduit etc. (d) Where the soil is soft, loose or slushy, width of trench shall be suitably increased or side sloped or the soil shored up as directed by the Engineer-in-Charge. It shall be the responsibility of the contractor to take complete instructions in writing from the Engineer-in-Charge regarding increase in the width of trench. Sloping or shoring to be done for excavation in soft, loose or slushy soils. 2.19.3 Excavation : Shall be done as specified in 2.7, 2.8 and 2.9. 2.19.4 Refilling Filling in t renches s hall be c ommenced soon after the joints of pipes, cables, conduits etc. have been tested and passed. The space all-round the pipes, cables conduits etc. shall be cleared of all debris, brick bats etc. Where the trenches are excavated in hard/ soft soil, the filling shall be done with earth on the side and top of pipes in layers not exceeding 20 cm in depth. Each layer shall be watered, rammed and consolidated. A ll c lods an d l umps of earth ex ceeding 8 c m i n a ny di rection shall be broken or rem oved before t he e xcavated eart h i s us ed f or f illing. I n case of ex cavation trenches i n ordinary/ hard roc k, t he filling upt o a dept h o f 30c m above the crown of pi pe, cable, c onduits e tc. shall be done w ith fine material like earth, m oorum or pu lverized/ decomposed ro ck ac cording t o t he av ailability at s ite. T he rem aining filling s hall be do ne w ith boulders of s ize not ex ceeding 15c m m ixed w ith f ine m aterial l ike decomposed rock, moorum or earth as available to fill up the voids, watered, rammed and consolidated in layers not exceeding 30 cm. E xcavated m aterial c ontaining d eleterious m aterial, s alt pe ter ear th et c. s hall no t be used f or f illing. Ramming s hall b e d one with i ron r ammers where f easible and with b lunt ends of crow bars w here rammers c annot be u sed. S pecial care shall be taken to ens ure that no da mage is caused t o the pipes, Cables, Conduits etc. laid in the trenches.
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2.19.5 Measurements 2.19.5.1 Trenches f or pi pes, c ables, conduits et c. shall b e m easured in running metre correct t o the nearest cm in stages of 1.5 m depth and described separately as under: (a) Pipes, cables, conduits, etc. not exceeding 80 mm dia. (b) Pipes, cables, conduits etc. exceeding 80 mm dia but not exceeding 300mm dia. (c) Pipes, cables, conduits etc. exceeding 300 mm dia. 2.19.5.2 Where two or more categories o f each work are involved due to different classification of soil within t he s ame s tage of trench dept h or w here t he s oil i s s oft l oose or s lushy requi ring i ncrease i n t he width of trench or sloping sides or shoring, trenches for pipes, cables, conduits, etc. shall be measured in cubic m etres as s pecified i n 2. 10. E xtra ex cavation, i f any , on ac count of c ollar/ s ocket of pi pes s hall neither be measured nor paid for separately. 2.19.6 Rates The rate shall b e as specified in 2 .12 an d shall also include the cost of refilling a nd all other operations described above. 2.20 PLANKING AND STRUTTING 2.20.1 When the depth o f trench in soft/loose soil exceeds 2 m etres, stepping, sloping and/ or pl anking and strutting of sides shall be done. In case of loose and slushy soils, the depths at which these precautions are t o be t aken, s hall b e det ermined b y t he E ngineer-in-Charge ac cording t o t he nature of soil. Planking and s trutting s hall be ‘close’ or ‘open’ de pending on the n ature o f s oil and the dep th o f trench. T he t ype of pl anking and s trutting shall be determined by the E ngineer-in-Charge. I t s hall be t he responsibility o f the c ontractor to take al l nec essary s teps to pr event t he s ides of trenches f rom c ollapse. Engineer-in-Charge should take guidance from IS: 3764 for designing the shoring and strutting arrangements and specifying the profile of excavation. 2.20.2 Close Planking and Strutting Close pl anking and s trutting s hall be done by completely c overing the s ides of t he trench genera lly with short upright, members called ‘poling boards’. These shall be 250x38 mm in section or as directed by the Engineer-in-Charge. The boards shall generally be placed in position vertically in pairs. One boards on either side of cutting. These shall be kept apar t by horizontal wallings of s trong wood at a maximum spacing of 1. 2 metres cross strutted with b allies, or a s di rected by Engineer-in-Charge. T he l ength and diameter of the ba llies s trut shall depend upon the width of the trench. Typical sketch of close timbering is given in Fig. 2.2. Where the soil is very soft and l oose, the boards shall be pl aced horizontally against the sides of the excavation and s upported by v ertical ‘ wallings’ which s hall be s trutted to similar timber pi eces on t he opposite f ace of t he trench. The lowest boards supporting t he s ides shall be taken in t he ground for a minimum depth of 75 mm. No portion of the vertical side of the trench shall remain exposed. The withdrawal of the timber members shall be done very carefully to prevent collapse of the trench. It s hall be s tarted at one end and proceeded s ystematically t o the other end. C oncrete or m asonry s hall not be dam aged while re moving t he planks. No claim s hall be e ntertained f or any timber w hich cannot be w ithdrawn a nd i s l ost or buri ed, unl ess requ ired by t he E ngineer-in-Charge t o be l eft perm anently i n position. 2.20.3 Open Planking and Strutting In case of open planking and strutting, the entire surface of the side of the trench is not required to be covered. The vertical boards 250 mm wide & 38 mm thick, shall be spaced sufficiency apart to leave unsupported s trips of 50 cm a verage w idth. T he detailed a rrangement, si zes of th e ti mber a nd t he distance apart shall be subject to the approval of the Engineer-in-Charge. In all other respect,
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specifications for close pl anking and s trutting s hall a pply t o open pl anking and strutting. Typical sketch of open planking and strutting is given in fig. 2.2. 2.20.4 Measurements The dimensions shall be measured c orrect to the nearest c m and t he area of t he face s upported shall be worked out in square metres correct to two places of decimal. 2.20.4.1 Works shall be grouped according to the following: (a) Depth not exceeding 1.5 m. (b) Depth exceeding 1.5m in stages of 1.5 m. 2.20.4.2 Planking and strutting to the following shall be measured separately: (a) Trenches. (b) Areas- The description shall include use and waste of raking shores. (c) Shafts, walls, cesspits, manholes and the like (d) Where tightly driven close but jointed sheeting is necessary as in case of running sheeting is necessary as in case of running sand the item shall be measured separately and packing of cavities behind sheeting with suitable materials included with the item. (e) Planking and strutting required to be left permanently in position shall be measured separately. 2.20.5 Rates Rates s hall i nclude us e and w aste of al l necessary t imber w ork as mentioned abov e i ncluding f ixing and subsequent removal. 2.21 EXCAVATION IN WATER. MUD OR FOUL POSITION 2.21.1 All water that may accumulate in excavations during the progress of the work from springs, tidal or river seepage, broken water mains or drains (not due to the negligence of the contractor), and seepage from subsoil aquifer shall be bailed, pumped out or otherwise removed. The contractor shall take adequate measures for bailing and/or pumping out water from excavations and/or pumping out water f rom ex cavations a nd c onstruct di version channels, bunds , s umps, c offer dam s et c. as m ay be required. P umping shall be done di rectly fr om th e f oundation trenches o r fro m a s ump out s ide t he excavation in s uch a m anner as to pr eclude the p ossibility o f m ovement o f w ater through an y fresh concrete or m asonry and washing away parts of c oncrete or mortar. During laying of c oncrete or masonry a nd for a period of at l east 2 4 hours t hereafter, pumping s hall b e done f rom a suitable sump separated from concrete or masonry by effective means. Capacity and number of pumps, l ocation at w hich t he pumps are t o be installed, pumping hours et c. shall be decided from time to time in consultation with the Engineer-in-Charge. Pumping shall be d one in such a way a s not to cause damage to the work or a djoining property by subsidence etc. D isposal of w ater sh all no t cause inconvenience or nu isance in the ar ea or cause damage to the property and structure nearby. To prevent slipping of sides, planking and strutting may also be done with the approval of the Engineer-in-Charge. 2.21.2 Classification The earth work for various classification of soil shall be categorised as under: (a) Work in or under water and/or liquid mud: Excavation, where water is met with from any of the sources specified in 2.21.1 shall fall in this category. Steady water level in the trial pits before the commencement of bailing or pumping operations shall be the sub-soil water level in that area. (b) Work in or under foul position: Excavation, where sewage, sewage gases or foul conditions are met with from any source, shall fall in this category. Decision of the Engineer-in-Charge whether the work is in foul position or not shall be final.
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2.21.3 Measurements 2.21.3.1 The unit, namely, metre depth shall be the depth measured from the level of foul position/ subsoil water l evel an d upt o t he centre of gra vity of t he c ross s ectional area o f ex cavation actually d one i n the conditions c lassified i n 2.21.2. M etre depth s hall be rec koned c orrect t o 0.1 m , 0. 05 m or m ore s hall be taken as 0.1 m and less than 0.05 m ignored. The extra percentage rate is applicable in respect of each item but t he measurements s hall be l imited onl y t o the quant ities o f ear th w ork a ctually ex ecuted i n t he conditions classified in 2.21.2. 2.21.3.2 In case earth work in or under foul position is also in or under water and/or liquid mud, extra payment shall be admissible only for the earth work actually executed in or under foul position. 2.21.3.3 Pumping or bailing out water met within excavations from the s ources s pecified in 2.21.1 where envisaged and specifically ordered in writing by the Engineer-in-Charge shall be measured s eparately and paid. Quantity of water shall be recorded in kilolitres correct to two places of decimal. This payment shall be i n a ddition t o t he p ayment u nder respective i tems of ea rthwork a nd shall b e a dmissible o nly when pumping or bailing out water has been specifically ordered by the Engineer-in-Charge in writing. 2.21.3.4 Planking and strutting or any other protection work done with the approval of the Engineer-inCharge t o k eep t he t renches dry and/ or t o s ave t he f oundations agai nst da mage by c orrosion of ri se i n water levels shall be measured and paid for separately. 2.21.3.5 Bailing or pumping out water, accumulated in excavation, due to rains is included under respective items of earthwork and is not to be paid separately. 2.21.4 Rates The r ates f or r espective i tems des cribed ab ove s hall i nclude c ost of al l t he operations as m ay be applicable. 2.22 EARTH WORK FOR MAJOR WORKS 2.22.1 Excavation shall be undertaken t o t he w idth of t he Basement/Retaining w all f ooting i ncluding necessary margins for construction oper ation as per drawing or d irected ot herwise. Where t he nat ure o f soil or the depth of the trench a nd season of the year, do not per mit vertical sides, the contractor at h is own e xpense shall p ut up t he necessary s horing, s trutting a nd pl anking or c ut s lopes w ith or w ithout steps, to a safer a ngle or b oth with du e r egard to the safety of personnel a nd w orks an d t o t he satisfaction of t he E ngineer. M easurement of pl an area of ex cavation f or p ayment s hall be per mitted only. 2.22.2 All the major excavation shall be carried out by mechanical excavator. No extra payment shall be made for that. 2.22.3 The c ontractor s hall m ake a t h is o wn c ost all ne cessary ar rangements for m aintaining w ater level, in the area where works are under execution low enough so as not to cause any harm to the work shall be considered as i nclusive o f pu mping out or ba iling o ut w ater, if re quired, for which n o ex tra payment s hall be m ade. T his will i nclude water coming f rom any s ource, s uch as rains, ac cumulated rain w ater, floods, leakages from s ewer and w ater m ains, s ubsoil w ater table be ing hi gh or d ue t o any other c ause w hatsoever. The contractor s hall make ne cessary pr ovision of pu mping, dr edging bailing out w ater c oming from al l abov e sources and ex cavation and other works shall be k ept f ree of water by providing suitable system approved by the Engineer-in-charge. Sub-soil w ater t able at work s ite i s r eported t o be about appr ox. 6. 5 m. be low t he gener al gr ound level as observed in the month of April. The water level is likely to rise up to 1 to 2 m. during rainy season. I n order t o av oid pos sibility of basement floor of m ain bui lding bei ng get ting upl ifted/damaged due t o w ater p ressure, t he c ontractor s hall lower t he grou nd w ater t able bel ow t he pr oposed f oundation level by boring tube wells all around the proposed building using well point sinking method or any suitable method as approved by Engineer-in-charge. Sub soil water table shall be maintained at least 50 cm. below t he P.C.C. l evel d uring l aying of P .C.C. water proof ing t reatment, l aying of bas ement raf t and beams including filling of earth/sand under the basement floor. The water table shall not be allowed to rise
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above base of raft level until completion of outer retaining walls including water proofing of vertical surface of walls and back filling along the walls upto ground level and until the structure attains such height to counter bal ance t he upl ift pressure. H owever, t he c ontractor s hould i nspect t he s ite a nd m ake his ow n assessment about sub-soil water level likely to be encountered at the time of execution and quote his rates accordingly. Rate of all items are inclusive of pumping out or bailing out water, if required. Nothing extra on this account whatsoever shall be paid to him. The sequence of construction shall be got approved by the Engineer-in-charge. 2.22.4 The contractor shall take all ne cessary measures for the safety of traffic during construction a nd provide, e rect a nd m aintain s uch b arricades i ncluding s igns, m arkings, f lags, l ights a nd f lagman, a s necessary at either end of the excavation/embankment and at such intermediate points as directed by the Engineer-in-charge f or t he proper i dentification of c onstruction area. He shall b e res ponsible f or all damages and accidents caused due to negligence on his part. 2.22.5 The contractor s hall pro vide s uitable ba rricading w ith s uitably p ainted s ingle row of G .I. S heets about 3’- 0” wide (90 cms.) nailed or bolted with wooden poles spaced 2 to 3 metre apart and each pole 1.6 m to 2 m long 8 cm. to 10 cm. dia. The poles will be embedded in mobile iron pedestal rings suitably framed for giving stable support as per direction of the Engineer-in-charge. All management (including watch a nd ward) of b arricades s hall b e t he f ull r esponsibility of t he c ontractor. T he b arricades shall b e removed on ly a fter completion o f the work or part of the w ork. T he c ontractor’s r ate shall include al l above items of work and nothing extra shall be paid to the contractor over and above his quoted rates. 2.23 FILLING IN TRENCHES, PLINTH, UNDER FLOOR ETC. 2.23.1 Earth Normally ex cavated earth f rom s ame area s hall be used for f illing. E arth used f or f illing shall be f ree from s hrubs, ran k, v egetation, gras s, brus hwood, s tone s hingle and bo ulders (l arger t han 75m m i n an y direction), or ganic o r a ny ot her f oreign m atter. E arth c ontaining del eterious materials, s alt pet er ear th etc. shall not be us ed for filling. All clods and l umps of earth exceeding 8 cm in any direction shall be broken or removed before the earth is used for filling. 2.23.2 Filling The s pace a round t he f oundations and dr ains i n t renches shall be c leared of al l debris, brick bat s etc. T he filling s hall be done in layers not exceeding 20 c m in depth. E ach layer s hall be w atered, rammed and consolidated. Ramming shall be done with iron rammers where possible and with blunt end of crow bars where rammers cannot be used. Special c are shall be t aken to ensure that no damage is caused to the pipes, drains, m asonry or concrete in the trenches. In c ase of filling u nder floor, the finished level of filling shall be kept to the slope intended to be given to the floor. 2.23.3 Measurements 2.23.3.1 Filling Side of Foundations: The c ubical c ontents of bed concrete levelling course and masonry/ c oncrete i n foundations upt o t he gr ound l evel s hall be worked out and t he same deduc ted from the c ubical contents of e arthwork i n ex cavation f or foundations al ready m easured under t he res pective item of earth work to arrive at the quantity for filling sides of foundation. The quantity shall be calculated correct to two places of decimal. 2.23.3.2 Filling in Plinth and under Floors: Depth of filling s hall be the c onsolidated depth. T he dimensions of f illing shall be on t he basis of p re-measurement c orrect to the ne arest cm an d c ubical content worked out in cubic metres correct to two places of decimal. 2.23.4 Rates The rates include cost of all the operations described above. 2.24 SAND FILLING IN PLINTH 2.24.1 Sand Sand shall be c lean and free from dust organic and foreign matter and its grading shall be w ithin the limits of grading zone IV or V specified in Section 3 ‘Mortars’.
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2.24.2 Filling Sand filling s hall be done i n a manner similar to ear th filling i n pl inth specified in 2. 23.3.2. e xcept that consolidation s hall b e do ne by f looding w ith water. T he s urface of t he c onsolidated sand filling s hall be dressed t o t he r equired level or s lope and s hall not be c overed till t he Engineer-in-Charge has i nspected and approved the sand filling. 2.24.3 Measurements The length, breadth and depth of consolidated sand shall be measured with steel tape correct to the nearest cm and cubical contents worked out in cubic metres correct to two places of decimal. 2.24.4 Rates The rates include the cost of material and labour involved in all the operations described above. 2.25 SURFACE DRESSING. 2.25.1 Surface dressing shall include cutting and filling upto a depth of 15 cm and clearing of shrubs, rank vegetation, grass, brushwood, trees and saplings of girth upto 30 cm measured at a height of one metre abov e t he gr ound l evel and r emoval o f rubbish and ot her ex cavated material upt o a di stance o f 50 metres out side t he per iphery o f the a rea und er surface d ressing. H igh por tions o f the ground shall be c ut down a nd h ollows d epression f illed upto t he required l evel w ith t he e xcavated e arth s o a s t o gi ve an even, neat and tidy look. 2.25.2 Measurements Length and br eadth o f t he d ressed gr ound s hall be m easured c orrect t o the n earest cm and t he ar ea worked out in square metres correct to two places of decimal. 2.25.3 Rates The rates shall include cost of labour involved in all the operations described above. 2.26 JUNGLE CLEARANCE 2.26.0 Jungle clearance s hall comprise upr ooting o f rank v egetation, gr ass, br ushwood, shrubs, stumps, trees and saplings of girth upto 30 cm measured at a hei ght of one metre above the ground level. Where only clearance of grass is involved it shall be measured and paid for separately. 2.26.1 Uprooting of Vegetations The roots of trees and saplings shall be removed to a dep th of 60 cm below ground level or 30 cm below formation level o r 1 5 c m be low s ub-grade l evel, w hichever i s l ower. A ll h oles or hollows formed due to removal of roots shall be filled up with earth rammed and levelled. Trees, shrubs, poles, fences, signs, monuments, pi pe l ines, c able etc., w ithin o r adj acent t o t he area w hich are not required t o be disturbed du ring jungle clearance s hall be properly pr otected by the c ontractor a t his ow n c ost and nothing extra shall be payable. 2.26.2 Stacking and Disposal All us eful materials obt ained from c learing and g rubbing oper ation shall be s tacked i n the manner as directed b y t he E ngineer-in-Charge. Trunks and b ranches o f trees shall be c leared of l imbs and tops a nd stacked n eatly a t p laces indicated by t he E ngineer-in-Charge. The materials shall be the property of the Government. A ll uns erviceable materials w hich i n t he opi nion o f the E ngineer-in-Charge c annot be us ed or auctioned shall be removed up to a distance of 50 m outside the periphery of the area under clearance. It shall be e nsured by t he c ontractor t hat unserviceable materials are di sposed off i n s uch a manner t hat there is no likelihood of getting mixed up with the materials meant for construction. 2.26.3 Clearance of Grass Clearing and grubbing operation involving only the clearance of grass shall be measured and paid for separately and shall include removal of rubbish upto a distance of 50 m outside the periphery of the area under clearance.
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2.26.4 Measurements The length and breadth shall be measured c orrect to t he nearest c m and area w orked out i n s quare metres correct to two places of decimal. 2.26.5 Rates The rate includes cost of all the operation described above. Note: Jungle clearance and c learance of grass ar e not payable s eparately f or t he e arth w ork specified in 2.13 to 2.19. 2.27 FELLING TREES 2.27.1 Felling While c learing jungle, gr owth trees ab ove 30 c m gi rth ( measured at a hei ght of on e m etre above ground level) to be c ut, s hall be a pproved by the E ngineer-in-Charge an d then m arked at site. F elling trees shall include taking out roots upto 60 c m below ground l evel or 30 c m below formation level or 1 5 cm below sub-grade level, whichever is lower. All excavation bel ow general ground l evel arising out of the removal of t rees, s tumps etc. s hall be filled w ith s uitable material in 20 cm layers and c ompacted thoroughly s o t hat the s urfaces a t these points conform to the surrounding area. The trunks and branches of trees shall be cleared of limbs and tops and cut into suitable pieces as directed by the Engineer-in-Charge. 2.27.2 Stacking and Disposal Wood, br anches, t wigs o f t rees and o ther u seful material shall b e t he property of t he Government. The s erviceable m aterials s hall be s tacked i n t he manner as di rected by t he E ngineer-in-Charge upt o a lead of 50m. All u nserviceable m aterial, w hich i n t he opi nion of Engineer-in-Charge c annot be us ed or auc tioned shall be re moved f rom t he area and di sposed of f a s per t he di rections o f t he E ngineer-in-Charge. C are shall be taken to see that unsuitable waste materials are disposed off in such a manner that there is no likelihood of these getting mixed up with the materials meant for construction. 2.27.3 Measurements Cutting of tr ees ab ove 3 0 cm in gir th (measured at a height of o ne m etre a bove level) shall b e measured in numbers according to the sizes given below: (a) Beyond 30 cm girth, upto and including 60cm girth. (b) Beyond 60 cm girth, upto and including 120 cm girth. (c) Beyond 120 cm girth, upto and including 240 cm girth. (d) Above 240 cm girth. 2.27.4 Rate The rat e i ncludes t he c ost i nvolved i n a ll t he operations de scribed abo ve. T he c ontract unit rat e f or cutting trees above 30 cm in girth shall include removal of stumps as well. 2.28 ANTI-TERMITE TREATMENT 2.28.0 Sub-terranean t ermites ar e r esponsible f or m ost of t he t ermite da mage i n bui ldings. T ypically, they form nests or colonies underground. In the soil near ground level in a stump or other suitable piece of timber i n a conical o r d ome s haped m ound. T he t ermites f ind access t o the s uper-structure of th e building ei ther t hrough t he t imber bur ied i n the gr ound or by m eans of mud s helter t ubes c onstructed over unprotected foundations. Termite control in existing as well as new building structures is very important as the damage likely to be c aused by t he t ermites t o w ooden m embers of bui lding a nd ot her ho usehold art icle l ike f urniture, clothing, stationery etc. is considerable. Anti-termite treatment can be either during the time of
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construction i .e. pr e-constructional chemical treatment or af ter t he bui lding has been c onstructed i .e. treatment for existing building. Prevention of t he t ermite from re aching t he s uper-structure of the building an d i ts contents c an be achieved by creating a c hemical b arrier between t he ground, f rom w here t he t ermites c ome and o ther contents of the building w hich m ay form food for the termites. T his is ac hieved by treating the s oil beneath the building and around the foundation with a suitable insecticide. 2.28.1 Materials 2.28.1.0 Chemicals: Any one of the following c hemicals in w ater emulsion t o ac hieve the per centage concentration specified against each chemical shall be used: (i) Chlorphriphos emulsifiable concentrate of 20% (ii) Lindane emulsifiable concentrate of 20% Anti-termite t reatment c hemical is av ailable i n concentrated f orm in t he market and c oncentration i s indicated o n t he s ealed containers. T o achieve t he specified p ercentage of c oncentration, Chemical should be diluted with water in required quantity before it is used. Graduated containers s hall be us ed for dilution o f c hemical w ith w ater i n t he r equired pr oportion t o a chieve t he de sired pe rcentage o f concentration. F or ex ample, t o di lute chemical o f 20 % concentration. 19 par ts of water s hall be adde d to one part of chemical for achieving 1% concentration. Engineer-in-Charge s hall procure t he c hemical of r equired c oncentration in s ealed original c ontainers directly from the reputed and authorized dealers, chemical shall be kept in the custody of the EngineerinCharge or hi s a uthorized repres entatives a nd i ssued f or u se to m eet t he day’s requi rements. Empty containers af ter w ashing and c oncentrated c hemical l eft unus ed at t he end of t he day ’s w ork s hall be returned to the Engineer-in-Charge or his authorized representative. 2.28.1.1 Measurements: Concentrated chemical in sealed containers shall be measured in litres. Chemicals of different types and concentration shall be measured separately. 2.28.1.2 Rate: The Rate for the concentrated chemical shall include the cost of material, containers and all the operations involved in transportation and delivery at the place specified. 2.28.2 Safety Precautions Chemical used for anti-termite treatment are insecticides with a persistent action and are highly poisonous. This chemical can have an adverse effect upon health when absorbed through the skin, inhaled as vapours or spray mists or swallowed. The c ontainers hav ing em ulsifiable concentrates shall be clearly l abelled and kept securely c losed i n stores so that children or pet cannot get at them. Storage an d mixing of concentrates shall not be don e near an y f ire s ource o r flame. P ersons us ing these c hemical shall be w arned t hat abs orption t hough s kin is t he m ost likely source of a ccidental p oisoning. P articular care s hall b e taken t o pr event s kin c ontact with c oncentrates and pr olonged exposure t o dilute emulsion shall al so be avoided. A fter handling the concentrates or dilute emulsion. Workers shall wash themselves with soap and water and wear clean clothing, especially before eating. In the event of severe contamination, clothing shall be removed at once and t he s kin w ashed w ith s oap and w ater. If c hemical has s plashed into t he ey es, t hey s hall be flushed with plenty of soap and water and immediate medical attention shall be sought. Care should be taken in the application of chemicals to see that they are not allowed to contaminate wells or springs which serve as source of drinking water. 2.28.3 Anti-Termite Treatment: Constructional Measures The c onstruction m easures s pecified bel ow s hould be adopt ed f or prot ection agai nst s ubterranean termites or iginating bot h internally f rom w ithin the plinth and ex ternally from t he ar ea s urrounding t he building.
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(i) E arth f ree f rom roots, dea d l eaves, or other organic m atter s hall b e pl aced a nd compacted i n successive horizontal l ayers of l oose m aterial not more t han 200 m m t hick. D ry brick s hall be inserted a t last 50 m m in b rick m asonry for pr oviding apr on floor ar ound the per iphery. [See Fig. 2.3(i)] (ii)
Brick on ed ge m asonry in c ement m ortar shall be l aid on t he pl inth wall. Dry brick shall b e placed on the inner side of plinth wall for getting anticipated offset space for coarse sand and on the other side for installing anti-termite masonry groove. In the case of intermediate walls, dry bricks are placed on either side of the brick on edge masonry for getting offset space for coarse sand layer. [See Fig. 2.3(ii)]
(iii) The dry brick for the anti-termite groove shall be taken out and dense cement concrete 1:3:6 (1 cement : 3 sand : 6 coarse aggregate by volume) sub-floor carpet shall be laid casting the antitermite gr oove in position. In case of internal partition walls, the cement concrete sub-floor shall be laid on either side over the dry bricks to sufficient extent for getting staggered vertical joints over the joint of plinth wall and earth filling. [See Fig. 2.3(iii)] (iv) Superstructure m asonry s hall b e r aised over t he dense cement c oncrete s ub f loor carpet a nd over-head jobs completed. [See Fig. 2.3)(iv)] (v) The dry brick for coarse sand layer shall be removed and graded sand (of size 3 to 5 mm) layer at least 100 mm thick shall be compacted ov er the ear th filling and under neath the par tially l aid dense cement concrete sub-floor carpet [See Fig. 2.3)(v)] (vi) D ense c ement c oncrete ( 1:3:6 m ix.) sub-floor at least 75 m m thick shall be laid o ver the sand filling. Necessary finish may be provided to the cement concrete sub-floor carpet. [See Fig. 2.3)(vi)] (vii) D ry b rick provided f or apron f loor shall be taken out a nd 600 m m wide formation of earth i n 1:30 slope shall be made. Over the formation, 75 mm thick lime concrete 1:3:6 (1 lime:3 sand: 6 coarse aggregate, by volume) shall be laid. [See Fig. 2.3)(vii)] (viii) Over the 75 mm thick like concrete bed at least 25 mm thick cement concrete topping 1:2:4 (1 cement: 2 sand: 4 fine aggregate, by volume) shall be laid and 12 mm thick cement plaster shall be applied on foundation and plinth. [See Fig. 2.3)(viii)] The f inal r ecommendations i ncorporating t he c onstructional det ails gi ven abov e ( i t o v iii) ar e shown in Fig. 2.4. 2.28.4 Anti Termite Treatment : Treatment for Existing Building: Post Construction Treatment 2.28.4.1 Material (i) Che mica ls : Any one of the following chemicals conforming to relevant Indian Standards in water emulsion may be used for soil treatment in order to protect a building from termite attack. Chemical with Percent
Relevant Indian Standards
Chlorpyrifos
20EC
IS 8944
Concentration by weight (Active ingredient) 1.0
Lindane
20EC
IS 632
1.0
These c hemicals ar e available i n concentrated f orm i n t he market and c oncentration i s i ndicated on the sealed containers. To achieve the specified percentage of concentration, chemicals should be di luted with w ater i n r equired quant ity bef ore i t i s u sed. G raduated containers shall be used for di lution of chemicals w ith water in t he r equired pr oportion t o achieve the desired percentage of c oncentration. F or ex ample, t o di lute c hemical of 20 % c oncentration, 19 p arts of water s hall be adde d t o one part of c hemical f or achieving 1% c oncentration. O il or k erosene based s olution of c hlorpyrifos 20 EC or Li ndane 20 E C, 1.0 perc ent (by weight) c oncentration i s useful for treatment of wood. Engineer-in-charge shall procure the chemical of required
29 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
concentration in s ealed original c ontainers directly f rom the reputed and authorized representative. C hemical shall be kept i n the custody o f t he E ngineer-in-charge or hi s aut horized representatives and issued for use to meet the day’s requirements. Empty containers after washing a nd c oncentrated c hemical l eft unused at the end o f t he day’s w ork shall be r eturned to the Engineer-in-charge or his authorized representative. (ii) Me a s ure me nts : Concentrated chemical in sealed containers shall be measured in litres. Chemicals of different types and concentration shall be measured separately. (iii) Ra te : The rat e f or t he c oncentrated c hemical shall i nclude t he c ost of m aterial, c ontainers and all the operations involved in transportation and delivery at the place specified. (iv) S a fe ty P re ca utions : Chemical used for antitermite treatment are insecticides with a persistent action and are highly poisonous. This chemical can have an adverse effect upon health when absorbed through the skin, inhaled as vapours or spray mists or swallowed. The c ontainers h aving emulsifiable c oncentrates s hall be c learly l abeled an d kept s ecurely c losed i n stores so that children or pet cannot g et at them. Storage an d mixing of concentrates shall not be done near any fire source or flame. Persons carrying out chemical soil treatments should familiarize themselves and exercise due care when handling the chemicals whether in concentrated or in diluted form. After hand ling t he concentrates or di lute em ulsion, worker shall w ash t hemselves with s oap an d water a nd wear c lean c lothing es pecially b efore ea ting a nd s moking. I n t he e vent of s evere contamination, c lothing s hall be removed at onc e and the s kin washed with soap and w ater. I f chemical has splashed into the eyes, they shall be flushed with plenty of soap and water and immediate medical attention shall be sought. The use of chemical shall b e avoided w here there is any r isk of wells or other water s upplies becoming contaminated. 2.28.4.2 Treatment (i) O nce t he t ermites have an i ngress i nto t he building, t hey keep o n m ultiplying a nd d estroy t he wooden and cellulosic materials, and as such it becomes essential to take measures for protection against termites. Anti termite measures described below are necessary for the eradication an d control of termites in existing building. T o facilitate p roper penetrations of chemical i n t o t he surface t o be t reated, hand oper ated pres sure pump shall be us ed. T o ha ve proper check for uniform p enetration o f c hemical, g raduated c ontainers s hall be used. P roper check should be k ept so t hat t he specified quantity of c hemical i s us ed f or t he r equired area during the operation. Chemical treatment for the eradication and control of sub-terranean termites i n ex isting building s hall be done as per I S 6313 (P art III). Treatment s hall be got done only f rom t he appr oved s pecialized agenc ies u sing t he c hemical pr ocured di rectly by t he Engineer-in-Charge from reputed and authorized dealers. (ii) Treatment along outside of foundations: The soil i n contact w ith t he external wall of t he building shall b e tr eated with ch emical e mulsion at th e r ate of 7.5 litr es per s quare metre of vertical surface of the sub-structure to a depth of 300 mm. To facilitate this treatment, a shallow channel s hall be ex cavated al ong and c lose t o t he w all f ace. T he c hemical em ulsion s hall be directed t owards t he wall at 1. 75 l itres pe r ru nning m etre o f t he c hannel. R odding with 1 2 m m diameter mild steel rods at 150 m m apart shall be d one in the channel. I f necessary, for uniform dispersal of t he c hemical to 300 m m depth f rom t he ground l evel. T he balance c hemical of 0. 5 litre per running metre shall then be used to treat the bac kfill earth as it is returned to the channel directing the spray towards the wall surface. If there i s a concrete or masonry apr on around t he bui lding, appr oximately 12 mm d iameter hol es shall be drilled as close as possible to the plinth wall about 300 mm apart, deep enough to reach the soil below and the chemical emulsion pumped into these holes to soak the soil below at the rate of 2.25 litres per linear metre.
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In s oils w hich do not allow perc olation of chemicals t o des ired depth, t he uniform di sposal of t he chemical t o a dept h of 3 00 m m s hall be obt ained by s uitably modifying t he m ode of treatment depending on site condition. In c ase of RCC f oundations t he s oil (bac kfill) i n c ontact w ith t he column s ides and pl inth be ams along with external perimeter of the building shall be treated with chemical emulsion at the rate of 7.5 l itres/sqm. of t he v ertical s urface of t he s tructure. T o f acilitate t his t reatment, t renches s hall be e xcavated equal t o the w idth o f the shovel ex posing the sides of t he column and pl inth bea ms upto a depth of 300 mm or upto the bottom of the plinth beams, if this level is less than 300 mm. The chemical em ulsion shall be s prayed on t he bac kfill earth as i t is returned i nto t he t rench directing the spray against the concrete surface of the beam or column as the case may be. (iii) Treatment of Soil under Floors : The poi nts w here t he termites a re l ikely t o seek ent ry t hrough the floor are the cracks at the following locations: (a) At the junction of the floor and walls as result of shrinkage of the concrete; (b) On the floor surface owing to construction defects; (c) At construction joints in a concrete floor, cracks in sections; and (d) Expansion joints in the floor. Chemical treatment shall be provided in the plinth area of ground floor of the structure, wherever such cracks are noticed by drilling 12 mm holes at the junction of floor and walls al ong the cracks on t he floor and along the c onstruction and expansion joints at the i nterval of 300 m m to reach the s oil below. C hemical em ulsion s hall b e sq uirted i nto t hese holes u sing a h and op erated pressure pump to soak the soil below un til refusal or upto a m aximum of on e litre per hol e. T he holes s hall then be sealed properly with cement m ortar 1:2 ( 1 c ement: 2 coarse s and) f inished t o match t he ex isting f loors. T he c ement m ortar appl ied s hall be c ured f or at l east 10 day s as per instruction of Engineer-in-charge. (iv) Treatment of Voids in Masonry : The m ovement of t ermites t hrough t he m asonry w all m ay be arrested b y dr illing hol es i n masonry wall a t plinth level and s quirting chemical e mulsions i nto the holes to soak the masonry. The holes shall be drilled at an angle of 45 degree from both sides of the plinth wall at 300 mm i ntervals and emulsion squirted t hrough these holes t o soak the masonry us ing a ha nd ope rated pum p. T his treatment s hall a lso b e extended t o internal w alls having f oundations i n t he s oil. H oles shall a lso b e drilled at w all c orners and where door and window frames are embedded in the masonry or floor at ground. Emulsion shall be s quirted through the holes till refusal or to a maximum of one litre per hole. Care shall be taken to seal the holes after the treatment. (v) Treatment at Points of Contact of Wood Work : The w ood work which h as al ready b een damaged beyond repai rs by term ites s hall be replaced. The new t imber shall be dipped or liberally brushed at least twice with chemical i n oil or k erosene. All existing wood work in t he building which i s in c ontact with th e flo or o r w alls an d w hich is i nfested by te rmites, s hall be treated by spraying at the p oints o f contacts w ith the adjoining masonry w ith the chemical emulsion by dr illing 6 m m hol es at a downward angle of about 45 degr ee at j unction of w ood work and m asonry and s quirting c hemical e mulsion i nto t hese hol es t ill ref usal or t o a m aximum of half a litre per hole. The treated holes shall then be sealed. Infested w ood w ork in chaukhats, s helves, joints, pu rlins et c., i n c ontact with t he floor or the walls shall be p rovided w ith pr otective treatment by dri lling ho les o f abo ut 3 m m d iameter w ith a downward s lant t o the core of t he w ood w ork on the i nconspicuous s urface of t he frame. These holes should b e at least 150 mm centre to centre and should c over in entire f rame work. Chemicals s hall be liberally infused in these holes. If the w ood is not protected by paint or varnish t wo c oats of t he chemicals s hall be gi ven on al l t he s urfaces and c revices adj oining t he masonry.
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2.28.4.3 Measurements : All dimensions shall be measured correct to a cm. The measurements shall be made of the surface actually provided with anti termite treatment. Measurements shall be done separately f or treatment o f f oundations, s oils und er floors, v oids i n masonry and wood work as det ailed below: (i) Tre a tme nt a long outs ide of founda tions : The m easurements s hall be m ade i n running m etres taking length along the plinth of the building. (ii) Tre a tme nt of s oil unde r floors : The m easurements shall be made i n s quare metres, i nside c lear dimensions of rooms, verandah etc. shall be taken. (iii) Tre a tme nt of voids in ma s onry : The measurements shall be made in running metres along the plinth of the building. (iv) Tre a tme nt of wood work : The measurements shall be made in running metres for chowkhats, joints, purlins, beams etc. 2.28.4.4 Rates The rate shall include the cost of labour and all other inputs (except concentrated chemical) involved in all the operations described above including drilling, refilling and making good the holes. 2.28.4.5 Treatment of Electrical Fixtures If infestation in electrical fixture (like switch boxes in the wall) is noticed, covers of the switch boxes shall b e re moved a nd i nside of such b oxes shall b e t reated l iberally with 5 per cent M alathion d usting powder. The covers of the switch boxes shall be refixed after dusting.
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THE DESIGN FOR TEMPORARY SITE BENCH MARK Sub Head : Earthwork Clause : 2.5.1 75 x 75 x 6 mm M.S. PLATE EMBEDED.. IN CONCRETE & WELDED TO M.S. ROD
25 mm M.S. HEMISPHERICAL BALL WELDED TO PLATE
340 150
20 MM S LIT FOR DRAINAGE
100
25 mm M.S. ROD WELDED TO PLATE
CEMENT CONCRETE 1:2:4
BRICK WORK IN CEMENT MORTAR 1:4
350
LEVEL
GROUND 150 150
CEMENT CONCRETE 1:5:10
150 850 X - SECTIONAL ELEVATION
25
25
560 850
150
340
PLAN DRAWING NOT TO SCALE ALL DIMENSIONS ARE IN M.M.
Fig. 2.1 : Design for Temporary Site Bench Mark .
33 | Page HO Civil Specifications Volume - I
CLOSE AND OPEN PLANKING AND STRUTTING Sub Head : Earthwork Clause : 2.20.2 and 2.20.3
WALING 100 x 100 POLING 250 x 38
BOARD
POLING BOARD 250 X 38 RAKE
2000 STRUTS 2000 MAX 1200 MAX 300
BLOCKING
PLANKING & STRUTTING FOR SHALLOW-WIDE EXCAVATION
CLOSE PLANKING & S TRUTTING W ITH VERTICAL POLING BOARD
WALING 100 X 100
WALING 100 X 100 POLING BOARD 250 X 38 2000 2000 STRUTS
OPEN PLANKING & STRUTTING
POLING BOARD 250 X 38
CLOSE PLANKING & STRUTTING WITH LONGITUDINAL POLING BOARD
DRAWING NOT TO SCALE ALL DIMENSIONS ARE IN M.M.
Fig. 2.2 : Close & Open Planking & Strutting
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ANTI-TERMITE CONSTRUCTION STAGE -1 Sub Head : Earthwork Clause : 2.28.3(i)
EARTH FILLING 50
GL
100
DRY BRICK FOR APRON FLOOR
Drawing not t o S cale All dimensions in millimetres
Fig. 2.3(i) : Anti-Termite Construction – Stage 1
ANTI-TERMITE CONSTRUCTION STAGE -2 Sub Head : Earthwork Clause : 2.28.3(ii) BRICK ON EDGE IN CEMENT MORTAR DRY BRICK
DRY BRICK FOR ANTI-TERMITE GROOVE
100
GL
100 mm OFFSET PROVIDED ON THE INNER SIDE OF OUTER WALL FOR SAND LAYER
Drawing not to S cale All dimensions in millimetres
Fig. 2.3(ii) : Anti-Termite Construction – Stage 2 35 | Page HO Civil Specificfations Volume - I
ANTI-TERMITE CONSTRUCTION STAGE -3 Sub Head : Earthwork Clause : 2.28.3(iii) DENSE CEMENT CONCRETE (1:3:6) SUBFLOOR CARPET LAID CASTING ANT-TERMITE GROOVE IN POSITION DRY BRICK
12 mm THICK CEMENT PLASTER 75 75
100
68
A
100
GL 100 DETAIL AT A
Drawing not to S cale All dimensions in millimetres
Fig. 2.3(iii) : Anti-Termite Construction – Stage 3
ANTI-TERMITE CONSTRUCTION STAGE -4 Sub Head : Earthwork Clause : 2.28.3(iv) SUPERSTRUCTURE WALL
50
GL
Drawing not t o S cale All dimensions in millimetres
Fig. 2.3(iv) : Anti-Termite Construction – Stage 4 36 | Page HO Civil Specificfations Volume - I
ANTI-TERMITE CONSTRUCTION STAGE -5 Sub Head : Earthwork Clause : 2.28.3(v)
DRY BRICKS TAKEN OUT AND 100 mm THICK SAND LAYER LAID AND COMPACTED
GL
Drawing not to S cale
Fig. 2.3(v) : Anti-Termite Construction – Stage 5
ANTI-TERMITE CONSTRUCTION STAGE -6 Sub Head : Earthwork Clause : 2.28.3(vi) SKIRTING FLOOR FINISH
COMPLETED 75 m m THICK DENSE CEMENT CONCRETE SUBFLOOR
GL
Drawing not to S cale
Fig. 2.3(vi) : Anti-Termite Construction – Stage 6 37 | Page HO Civil Specificfations Volume - I
ANTI-TERMITE CONSTRUCTION STAGE -7 Sub Head : Earthwork Clause : 2.28.3 (vii)
50 600
25 GL
100 50 DRY BRICK TAKEN OUT AND LIME CONCRETE BED (1:3:6) LAID FOR APRON FLOOR
Drawing not t o S cale All dimensions in millimetres
Fig. 2.3(vii) : Anti-Termite Construction – Stage 7
ANTI-TERMITE CONSTRUCTION STAGE -8 Sub Head : Earthwork Clause : 2.28.3(viii)
12 mm T HICK CEMENT PLASTER
25 mm THICK CEMENT CONCRETE (1:2:4) TOPPING
GL
Drawing not t o S cale
Fig. 2.3(viii) : Anti-Termite Construction – Stage 8
38 | Page HO Civil Specificfations Volume - I
ANTI-TERMITE CONSTRUCTION FINAL RECOMMENDATIONS Sub Head : Earthwork Clause : 2.28.3(viii)(a)
SUPERSTRUCTURE FLOOR FINISH
75 mm THICK CEMENT CONCRETE SUBFLOOR
SAND FILLING
BRICK ON EDGE 75 100 12 mm T HICK CEMENT PLASTER 50
600 25
100
GL
EARTH FILLING
50 LIME CONCRETE APRON CEMENT CONCRETE TOPPING
Drawing not t o S cale All dimensions in millimetres
Fig. 2.4 : Anti-Termite Construction – Final Recommendations
39 | Page HO Civil Specifications Volume - I
3.0: Mortars
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CONTENTS Cla us e No.
Brie f De s cription
P a ge No.
List of Bureau of Indian Standard Codes
42
3.0
General
43
3.1
Materials
43
3.2
Preparation of Mortars & its Grade
48
Appendix A
Test for Organic Impurities
50
Appendix B
Test for Particle size (Sieve Analysis)
51
Appendix C
Test for Silt Content
52
Appendix D
Bulking of Fine Aggregates/ Sand (Field Methods)
53
Appendix F
Criteria for Selection of Masonry Mortars
54
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LIST OF BUREAU OF INDIAN STANDARD CODES
S. No.
I.S. No.
1 2
IS 269 IS 383
3 4 5 6 7 8 9 10 11 12
IS 455 IS 460 (Part I) IS 650 IS 12269 IS 1344 IS 1489 IS 1542 IS 1727 IS 2116 IS 2250
13
IS 2386 (Pt-I)
14
IS 2386 (Pt-II)
15
IS 2386 (Pt-III)
16 17 18
IS 3025 IS 3466 IS 3812 (Part I)
19
IS 3812 (Part II)
20
IS 4031 (Part I) to (Part XIII) IS 4032 IS 8041 IS 8042 IS 8043 IS 8112 IS 11652 IS 11653 IS 12174
21 22 23 24 25 26 27 28
Subje ct
Specification for 33 grade ordinary Portland cement Specification for coarse and fine aggregate from natural source for concrete. Specification for Portland slag cement. Specification for test sieves: wire cloth test sieves. Specification for standard sand for testing of cement Specification for 53 grade ordinary Portland cement Specification for calcined clay Pozzolana. Specification for Portland pozzolana cement Specification for sand for plaster Methods of Test for Pozzolanic materials Specification for sand for masonry mortar. Code of practice for preparation and use of masonry Mortar. Method of test for aggregate for concrete (Particle size and shape) -Do- Estimation of deleterious materials and organic impurities. -Do- Specific gravity, density, voids, absorption and bulking. Method of sampling and test for water Specification for masonry cement. Specification for fly ash for use as pozzolana in cement mortar and concrete Specification for fly ash for use as admixture in cement mortar and concrete Method of Physical test for hydraulic cement Method of chemical analysis of Hydraulic cement. Rapid hardening Portland cement. Specification for white cement Hydrophobic Portland cement Specification for 43 grade ordinary Portland cement Woven HDPE sacks for packing cement Woven polypropylene sacks for packing cement Jute synthetic union bags for packing cement
42 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
3.0 MORTARS 3.0 GENERAL Desirable properties of mortars for use in masonry are: (a) Workability (b) Water retentivity (c) Rate of stiffing (d) Strength (e) Resistance to rain penetration (f) Durability 3.1 MATERIALS 3.1.1 Water 3.1.1.1 Water used for mixing and c uring shall b e clean and f ree from injurious quantities of alkalies, acids, oils, salts, sugar, organic materials, vegetable growth or other substance that may be deleterious to bricks, stone, concrete or steel. potable water is generally considered satisfactory for mixing. The Ph value of water shall be not less than 6. 3.1.1.2 Water found satisfactory for mixing is also suitable for curing. However, water used for curing shall not produce any objectionable stain or unsightly deposit on the surface. 3.1.1.3 Sea water shall not be used for mixing or curing 3.1.1.4 Water from each source shall be tested before the commencement of the work. 3.1.2 Cement 3.1.2.1 The cement used shall be any of the following grade and the type selected should be appropriate for the intended use. (a) 33 grade ordinary Portland cement conforming to IS 269. (b) 43 grade ordinary Portland cement conforming to IS 8112. (c) 53 grade ordinary Portland cement conforming to IS 12269. (d) Rapid hardening Portland cement conforming to IS 8041. (e) Portland slag cement conforming to IS 455. (f) Portland Pozzolana cement (flyash based) conforming to IS 1489 (Part 1). (g) Portland Pozzolona cement (calcined clay based) conforming to IS 1489 (part 2). (h) Hydrophobic cement conforming to IS 8043 (i) Low heat Portland cement conforming to IS 12600. (j) Sulphate resisting Portland cement conforming to IS 12330 (k) White cement conforming to IS 8042 Different types of cement shall not be mixed together. In case more than one type of cement is used in any work, a record shall be kept showing the location and the types of cement used. 3.1.2.2 Caution in Use of Cement Grade 53 in Construction: Because o f the faster h ydration pr ocess, the c oncrete rel eases hea t of hy dration at a much f aster rate initially and r elease of heat is the higher in case of Grade. 53. The heat of hydration being higher, the chances of micro-cracking of concrete is much greater. Thus, during initial setting period of concrete, the higher heat of hydration can lead to damaging micro-cracking within the concrete which may not be visible at surface. This cracking is different from shrinkage cracks which occurs due to faster drying of concrete in windy conditions.
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The situation can be worse w hen we t end t o i ncrease the quant ity of t he cement in t he concrete with a be lief tha t such inc reases a re better fo r both s trength and du rability of c oncrete. T hus, it is v ery essential t o be forewarned t hat hi gher gr ade c ement specially gr ade 53 s hould be us ed onl y where s uch use i s w arranted for making hi gher s trength concrete and al so w here good Q uality A ssurance measures are in pl ace, b y w hich pr oper p recaution ar e taken t o relieve t he hi gher heat o f h ydration through chilling of aggr egates o r b y proper curing o f c oncrete. There ar e instances w here hi gher gr ade cement i s bei ng used ev en f or l ow s trength c oncrete, as , m ortar o r ev en f or pl astering. T his c an l ead t o unnec essary cracking of concrete/ surfaces. Another i ssue t o be cautioned against i s t he t endency of t he manufacturers to p roject G rade 53 cement as s tronger c ement, w hereas G rade 33 or 43 ar e enough t o pr oduce t he c oncrete of des ired characteristic strength. The scenario of method of production of cement by various manufacturers should al so be k ept i n m ind w hile ordering v arious grades of c ement. T he ability t o produc e c ements of particular f ineness get f ixed by t he m achinery i nstalled by t he m anufacturers, and t hus t he ability t o produce other various grades of cement by a particular manufacturer also gets limited. Whereas tendency t oday i s t o supply t he consumer what h e orders f or b y t he manufacturers b y s imply stamping such grades on the bags. Thus, it is often observed that cement bags marked as grade 33 or 43 may really be containing cements of much higher grade. 3.1.2.3 Compressive Strength : Compressive s trength re quirement of eac h t ype of c ement f or v arious grades when tested in accordance with IS 4031 (part 6) shall be as under: Strength in N/mm2 not less than for
Sample Age at testing
Gr. 33
Gr.43
Gr. 53
72 + 1 hr
16
23
27
168 + 2 hrs
22
33
37
672 + 4 hrs
33
43
53
3.1.2.4 Setting Time: Setting time of cement of any type of any grade when tested by Vicat apparatus method described in IS 4031 shall conform to the following requirement: (a) Initial setting time: Not less than 30 minutes (b) Final setting time: Not more than 600 minutes 3.1.2.5 Supply : The c ement s hall be packed in jute s acking bags c onforming to IS 2580, double hessian b ituminized (CRI t ype) or w oven HDPE c onforming t o I S 11652. Woven polypropylene conforming to I S 116 53, j ute s ynthetic uni on c onforming t o I S: 12174, or any ot her approved c omposite bags, bearing the manufacturer’s name or his registered trade mark if any, with grade batch no. and type of cement, with date of manufacturing of batch of cement. Every consignment of cement must have identification marks on packages indicating date of manufacturing grade and type of cement batch no. etc. Cement brought to works shall not be more than 6 weeks old from the date of manufacture. Effective precautionary measures shall be taken to eliminate dust-nuisance during loading or transferring cement. 3.1.2.6 Stacking and Storage : Cement in bags shall be stored a nd stacked in a s hed w hich is d ry, leak proof and as moisture-proof as possible. Flooring of the shed shall consists of the two layers of dry bricks laid on well consolidated earth to avoid contact of cement bags with the floor. For e xtra safety during monsoon, o r w hen cement i s expected t o be s tored f or an u nusually l ong period, each s tack shall b e c ompletely e nclosed by a water proofing m embrane, s uch as polyethylene, which shall cover the top of the stack. Care shall be taken to see that the water proofing membrane is not damaged at any time during use.
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3.1.3 Fine Aggregate 3.1.3.1 Aggregate most of which passes through 4.75 mm IS sieve is known as fine aggregate. Fine aggregate s hall c onsist of nat ural s and, crushed s tone s and, c rushed gra vel s and s tone d ust or m arble dust, fly ash and broken brick (Burnt clay). I t shall be h ard, durable, c hemically inert, clean a nd free from adher ent c oatings, o rganic matter et c. and s hall not contain an y appreciable a mount o f clay balls o r pellets and harmful impurities e.g. iron pyrites, alkalies, salts, coal, mica, shale or similar laminated materials in such fo rm or in s uch quan tities a s to c ause c orrosion of m etal or a ffect adv ersely the hardening, t he s trength, t he durabi lity or t he ap pearance of m ortar, pl aster o r c oncrete. T he sum of t he percentages o f al l deleterious material shall not ex ceed 5% . F ine aggr egate must be c hecked for o rganic impurities such as decayed vegetation humps, coal dust etc. in accordance with the procedure prescribed in Appendix ‘A’ of Chapter 3. 3.1.3.2 Silt Content : The maximum quantity of silt in sand as determined by the method prescribed in Appendix ‘C’ of Chapter 3 shall not exceed 8%. Fine aggregate containing more than allowable percentage of silt shall be washed as many times as directed by E ngineer-in-charge s o as t o br ing t he silt c ontent w ithin a llowable l imits f or w hich not hing extra shall be paid. 3.1.3.3 Grading : On the basis of particle size, fine aggregate is graded in to four zones. The grading when determined i n accordance w ith t he p rocedure p rescribed i n A ppendix ‘ B’ of C hapter 3 s hall be within t he l imits given i n Table 3.1 b elow. Where the g rading f alls o utside t he limits of any pa rticular grading z one o f s ieves, other t han 60 0 m icron I S sieve, b y a t otal a mount n ot e xceeding 5 pe r c ent, i t shall be regarded as falling within that grading zone. TABLE 3.1 Fine Aggregates (Clause 3.1.3 ) IS S ie ve
Gra ding Zone I
P e rce nta ge pa s s ing for Gra ding Zone II Gra ding Zone III
Gra ding Zone IV
10 mm
100
100
100
100
4.75 mm
90-100
90-100
90-100
95-100
2.36 mm
60-95
75-100
85-100
95-100
1.18 mm
30-70
55-90
75-100
90-100
600 microns
15-34
35-59
60-79
80-100
300 microns
5-20
8-30
12-40
15-50
150 microns
0-10
0-10
0-10
0-15
Note 1: Note 2: Note 3: Note 4:
For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 per cent. This does not affect the 5 per cent allowance permitted in 3.1.3.4 (e) (1) applying to other sieves. Allowance of 5% permitted in 3.1.3.4 (e) (1) can be split up, for example it could be 1% on each of three sieves and 2% on another or 4% on one sieve and 1% on another. Fine aggregate conforming to Grading Zone IV shall not be used in reinforced cement concrete unless tests have been made to ascertain the suitability of proposed mix proportions. Sand r equiring us e f or mortar f or plaster w ork shall conform t o I S 15 42 and f or masonry work shall conform to IS 2116.
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3.1.3.4 Type and grading of fine aggregate to be used shall be s pecified. It shall be c oarse sand, fine sand, s tone dus t o r m arble dust, fly a sh and s urkhi. U se o f s ea s and s hall no t be a llowed, un less otherwise specified. (a) Coarse sand shall be either river sand or pit sand or a combination of the two. Badarpur sand available in Delhi generally falls in category of pit sand. It shall be clean, sharp, angular, gritty to touch and composed of hard siliceous material. Its grading shall fall within the limits of grading zone I, II, III of Table 3.1. Grading of sand shall conform to IS 2116 for use in Masonry work. (b) Fine sand shall be either river sand or pit sand or a combination of the two. Its grading shall fall within the limits of Grading zone IV of Table 3.1. As a guideline, fine sand conforming to grading Zone IV can be generally obtained in Delhi by mixing one part of Badarpur sand and two parts of Jamuna Sand (by volume). Grading of sand shall conform to IS 1542 for use in plaster work. (c) S tone dus t s hall be o btained by c rushing har d s tones or gravel. I ts grading s hall f all w ithin t he limits of grading Zone, I, II, or III of Table 3.1. (d) Mar ble dus t shall be o btained by c rushing marble. I ts g rading s hall fall w ithin the l imits o f Grading Zone IV of Table 3.1. Grading of Marble dust for use in Mortar shall be as per following table. Grading of Marble Dust IS S ie ve 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron
P e rce nta ge P a s s ing 100 95-100 95-100 90-100 80-100 15- 50 0- 15
(e) S a nd for Ma s onry Morta r a nd for P la s te r- Sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of any of these. Sand shall be hard durable, clean and free from adherent coating and organic matter and shall not contain the amount of clay, silt and fine dust more than specified as under. Deleterious M aterial: Sand shall not contain any harmful i mpurities s uch a s i ron, py rites, al kalis, s alts, coal or ot her orga nic i mpurities, m ica, s hale or s imilar l aminated m aterials, soft f ragments, s ea s hale i n such f orm or i n such quantities as to af fect adversely t he hardening, s trength or d urability of the mortar. The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand / Marble dust shall not exceed the following limits: (1)
(2)
Clay, fine silt and fine dust when Not more than 5% by mass determined i n ac cordance w ithin IS 2386 (Part I I). In natural sand o r crushed gravel sand & crushed stone sand Colour of t he l iquid s hall be l ighter t han Organic impurities when determined in that indicated by t he s tandard s pecified i n accordance with IS 2386 (Part II) IS 2386 (Part II).
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Grading of sand for use in masonry mortar shall be conforming to IS 2116 (Table 3.2 below). Grading of sand for use in plaster shall be conforming to IS 1542 (Table 3.2 below): TABLE 3.2 Grading of Sand for use in Masonry Mortar and Plaster Gra ding of s a nd for us e in ma s onry morta r IS S ie ve De s igna tion
10 mm 4.75 mm 2.36 mm
Gra ding of s a nd for us e in pla s te r
Pe rce nta ge pa s s ing by I S S ie ve De s igna tion ma s s
100 100 90 to 100
10 mm 4.75 mm 2.36 mm
Gra ding of s a nd for us e in ma s onry morta r IS S ie ve De s igna tion
1.18 mm 600 micron 300 micron 150 micron
Pe rce nta ge pa s s ing by ma s s
100 95 to 100 95 to 100
Gra ding of s a nd for us e in pla s te r
P e rce nta ge pa s s ing by ma s s
70 to 100 40 to 100 5 to 70 0 to 15
IS S ie ve De s igna tion
1.18 mm 600 micron 300 micron 150 micron
P e rce nta ge pa s s ing by ma s s
90 to 100 80 to 100 20 to 65 0 to 50
Note: For c rushed s tone s ands, the p ermissible limit on 15 0 m icron IS S ieve i s increased to 20 %, t his does not affect the 5% allowance as per IS 2386 (Part 1). 3.1.3.5 Bulking: Fine aggregate, w hen dry or s aturated, has al most t he same V olume but dam pness causes increase in volume. In case fine aggregate is damp at the time of proportioning the ingredients for mortar or concrete, its quan tity shall be increased suitably to allow for bulkage, which shall be determined by the method prescribed in Appendix ‘D’ of Chapter 3.0 T able 3.3 g ives the relation between moisture content and percentage of bulking for guidance only. TABLE 3.3 Mois ture conte nt % a ge
Bulking % a ge (by volume )
2 3
15 20
4
25
5
30
3.1.3.6 Stacking: Fine a ggregate s hall be s o s tacked as to pr event dus t and foreign m atter ge tting mixed up w ith i t as far as practically p ossible. Mar ble dus t i n d ry c ondition shall be c ollected i n bags and properly s taked so a s not t o form l umps, suitable a rrangements shall be made to pr otect i t from moisture similar to those adopted for stacking of cement bags. 3.1.3.7 Measurements: As the fine aggregate bulks to a substantial extent when partially wet, measurements shall be taken when the stacks are dry or appropriate allowance made for bulking. 3.1.4 Broken Brick (Burnt Clay) Fine Aggregate 3.1.4.1 Broken Brick (Burnt Clay) Fine Aggregate, also known as Surkhi, shall be m ade by grinding well burnt ( but n ot u nder or o ver b urnt) br oken br icks as specified in I S 3068-1986. I t s hall n ot contain any harmful impurities, such as iron pyrites, salts, coal, mica, shale or similar laminated or other materials in such f orm of quantity as t o adv ersely affect hardening, s trength, durability o r appearance of the m ortar. The m aximum quantities of c lay, f ine s ilt, fine dust and organic impurities i n Surkhi (all taken together) shall not exceed five per cent by weight. The particle size grading of Surkhi for use in lime mortars shall be within the limits specified in Table 3.4.
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TABLE 3.4 IS S ie ve De s igna tion
P e rce nta ge pa s s ing (by wt)
4.75 mm 2.36 mm 1.18 mm 600 microns 300 microns 150 microns
100 90-100 70-100 40-100 5-70 0-15
3.1.4.2 Stacking: Surkhi shall be stacked on a hard surface or platform so as to prevent the admixture of clay, dust, vegetation and other foreign matter. It shall be also protected form rain and dampness and kept under adequate coverings. 3.1.4.3 Measurements: Surkhi shall be measured in regular stacks in cubic metres. Alternatively it may be measured by weight when supplied in bags. 3.2 PREPARATION OF MORTARS AND ITS GRADE 3.2.0 Grade of Masonry Mortar The grade of masonry mortar will be defined by its compressive strength in N/mm 2 at the age of 28 days as determined by the standard procedure detailed in IS 2250. 3.2.0.1 For proportioning the ingredients by volume, the conversion of weight into volume shall be made on the following basis: (a) (b) (c) (d)
Burnt Clay Pozzolana Coarse Sand (dry) Fine sand (dry) Fly Ash
860 Kg/cum 1280 kg/cum 1600 kg/ cum 590 kg/ cum
For details of grades and criteria for selection of Masonry mortars see Appendix ‘F’ of chapter-3. 3.2.1 Cement Mortar 3.2.1.1 This shall be pre pared by m ixing cement an d sand with or w ithout the a ddition of Pozzolana in specified proportions as per Appendix ‘F’. 3.2.1.2 Proportioning: Proportioning on w eight bas is s hall be pr eferred t aking i nto ac count s pecific gravity of sand and moisture content . Boxes of suitable size shall be prepared to facilitate proportioning on weight bas is. C ement ba g w eighting 50 k g s hall be t aken as 0. 035 c ubic m etre. O ther i ngredients i n specified proportion shall be measured using boxes of size 40 x 35 x 25 cm. Sand shall be measured on the basis of its dry volume in the case of volumetric proportioning. 3.2.1.3 Mixing 3.2.1.3.1 The mixing of mortar shall be done i n mechanical mixers operated manually or by power as decided by Engineer-in-Charge. The Engineer-in-Charge may, however, permit hand mixing at his discretion t aking i nto a ccount t he nat ure, magnitude and l ocation o f t he work and pr acticability of t he us e of mechanical mixers or where item involving small quantities are to be done or if in his opinion the use of mechanical mixer i s not f easible. In cases, where m echanical m ixers are not t o be used, T he contractor shall take permission of the Engineer-in-Charge in writing before the commencement of the work.
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(a) Me cha nica l Mixing: Cement and sand in the specified proportions shall be mixed dry thoroughly in a mixer. Water shall then be added gradually and wet mixing continued for at least three minutes. only the required quantity of water shall be added which will produce mortar of workable consistency but not stiff paste. Only the quantity of mortar, which can be used within 30 minutes of its mixing shall be prepared at a time. Mixer shall be cleaned with water each time before suspending the work. (b) Ha nd Mixing: The measured quantity of sand shall be levelled on a clean masonry platform and cement bags emptied on top. The cement and sand shall be thoroughly mixed dry by being turned over and over, backwards and forwards, several times till the mixture is of a uniform colour. The quantity of dry mix which can be used within 30 minutes shall then be mixed in a masonry trough with just sufficient quantity of water to bring the mortar to a stiff paste of necessary working consistency. 3.2.1.4 Precautions: mortar shall be u sed as soon as possible after mixing and before it beg ins to set, and in any case within half hour, after the water is added to the dry mixture.
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APPENDIX ‘A’
TEST FOR ORGANIC IMPURITIES (Clause 3.1.3.1)
The aggr egate must al so be checked for or ganic i mpurities s uch as dec ayed v egetation hum us, coal dust etc. What is called the colour test is reliable indicator of the presence of harmful organic matter in aggregate, except in the area where there are deposits of lignite. Fill a 350 m l cl ear gl ass m edicine bo ttle up to 7 0 m l mark with a 3% so lution o f cau stic soda or sodium hy droxide. T he sand i s nex t added gr adually until the v olume m easured by t he s andy l ayer i s 125 ml. The v olume is then made upto 200 ml by addition of more of solution. The bottle is then stoppered and shaken vigorously and allowed to stand for 24 hours. At the end of this period, the colour of t he l iquid w ill i ndicate w hether the sand c ontains a da ngerous am ount o f matter. A c olourless l iquid indicates a c lean s and f ree f rom organic m atter. A s traw c oloured solution i ndicates some or ganic matter but no t enough to be s eriously ob jectionable. D arker c olour means that the s and c ontains injurious amounts and should not be used unless it is washed, and a retest shows that it is satisfactory. Add 2.5 ml of two per cent solution of tannic acid in 10 per c ent alcohol, to 97.5 ml of three per c ent sodium hydroxide solution. Place in a 350 ml bottle, fix the stopper, shake vigorously and allow to stand for 24 hours before comparison with the solution above the sand. Note: A three per cent solution of caustic soda is made by dissolving 3 g of sodium hydroxide in 100 ml of water, preferably distilled. T he solution should be kept in a glass of bottle tightly closed with a rubber stopper. Handling sodium hydroxide with moist hands may result in serious burns. Care should be taken not to spill the solution for it is highly injurious to clothing, leather, and other materials.
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APPENDIX ‘B’
TEST FOR PARTICLE SIZE (SIEVE ANALYSIS) (Clause 3.1.3.3)
Apparatus: Perforated plate sieves of designation 10 mm, 4.75 mm and fine mesh sieve of designation 2.36 mm, 1.18 mm, 600 micron, 300 micron and 150 micron should be used. The balance or scale shall be such that it is readable and accurate to 0.1 per cent of the weight of the test sample. Sample: The w eight of s ample av ailable s hall no t b e l ess t han t he weight gi ven i n t he t able be low. T he sample of s ieving s hall b e pr epared f rom t he larger sample e ither b y quartering or by m eans of a s ample divider. TABLE SHOWING MINIMUM WEIGHTS FOR SAMPLING Maximum size present in Minimum weight of sample for substantial proportions (mm) sieving (Kg) 10 0.5 4.75 0.2 2.36 0.1 Test Procedure: The s ample s hall be bro ught t o an ai r-dry c ondition bef ore w eighing and s ieving. T his may be achieved either by drying at room temperature or by heating at a temperature of 100 degree to 110 degr ee c entigrade. The ai r d ry s ample s hall be w eighed and sieved successively o n t he appr opriate sieves starting with the largest. Care shall be taken to ensure that the sieves are clean before use. Each s ieve shall be s haken s eparately ov er a c lean tray u ntil no t more than a trace pa sses, but i n any c ase for a period of not less than two m inutes. T he s haking s hall be done with a v aried m otion, backwards a nd f orwards, left t o ri ght, c ircular c lockwise an d a nti-clockwise, and w ith f requent j arring, s o that t he m aterial i s k ept moving ov er t he s ieve s urface i n f requently c hanging di rections. M aterials s hall not be forced through the s ieve by hand pressure, but on sieves coarser than 20 mm, placing of particles is per mitted, Lu mps o f fine material, i f p resent may be broken by ge ntle pressure w ith fingers agai nst the side of the sieve. Light brushing of under side of the sieve with a s oft brush m ay be us ed to clear the sieve openings. Light bru shing with a fine camel hai r brush m ay be us ed on the 15 0 micron IS sie ve to pr event segregation o f p owder and b linding o f apertures. S tiff o r worn ou t brushes shall not be us ed for this purpose a nd pressure s hall not be a pplied to t he sur face o f th e sie ve t o forc e pa rticles thr ough t he mesh. On completion of sieving the material retained on each sieve, together with any material cleaned from the mesh, shall be weighed. Reporting of Results: The results shall be calculated and reported as: (a) T he c umulative p ercentage by weight of t he total sa mple passing e ach of the sie ves, t o th e nearest whole number: or (b) The per centage b y w eight o f the t otal s ample pas sing one s ieve and retained on the nex t smaller sieve, to the nearest 0.1 percent.
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APPENDIX ‘C’
TEST FOR SILT CONTENT (Clause 3.1.3.2)
The sand shall not contain more than 8% of silt as determined by field test with measuring cylinder. The method of determining silt contents by field test is given below: A s ample of s and t o be t ested s hall be p laced w ithout drying i n a 200 ml measuring c ylinder. T he volume of the sample shall be such that it fills the cylinder upto 100 ml mark Clean water shall be added upto 150 ml mark. Dissolve a l ittle salt in the water in the proportion one tea s poon t o half a l itre. T he m ixture s hall be shaken v igorously, t he l ast f ew s hakes b eing s idewise direction to level off the sand and the contents allowed to settle for three hours. The height of the silt visible as settled layer above the sand shall be expressed as a percentage of the height of s and below. T he sand containing more than the above al lowable percentage of silt, shall be washed so as to bring the silt contents within allowable limits.
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APPENDIX ‘D’
BULKING OF FINE AGGREGATES/SAND (FIELD METHODS) (Clause 3.1.3.5)
Two methods are suggested for determining the bulking of sand/fine aggregate. The procedure may be suitably v aried, i f nec essary. B oth depend on t he f act t hat t he v olume of i nundated s and/fine aggregate is the same if the sand/fine aggregate were dry. Method -1: Put sufficient quantity of sand loosely into a container until it is about two-third full. Level off the to p of t he sa nd and pus h a s teel r ule v ertically do wn th rough the s and at th e middle to bo ttom, measure the height. Suppose this is ‘X’ cm. Empty the s and ou t of the c ontainer i nto a nother c ontainer w here no ne of i t is lost. H alf fill the first container with water. Put back about half the sand and rod it with a steel rod, about 6 mm in diameter, so that its v olume is reduced to a m inimum. T hen add the remainder and lev el the top s urface of the inundated sand. Measure its depth at the middle with the steel rule. Suppose this is ‘Y’ cm. The per centage of bul king of t he s and due t o moisture s hall b e c alculated f rom t he f ormula: Percentage bulking = (X/Y -1) X 100 Method-2: In a 250 ml measuring cylinder, pour the damp sand, consolidate it by staking until it reached the 200 ml mark. Then fill the cylinder with the water and stir the sand well (the water shall be sufficient to submerge the sa nd c ompletely). It w ill be seen that the s and surface i s now below its original level. S uppose the surface i s a t t he mark o f Yml, the pe rcentage o f bulking o f sand due to moisture shall be c alculated from the formula. Percentage bulking= (200/Y - 1) x 100
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APPENDIX ‘F’
CRITERIA FOR SELECTION OF MASONRY MORTARS (Clauses 3.2.0, 3.2.0.1, 3.2.1.1)
(a) T he s election of masonry m ortars from dur ability c onsideration will ha ve t o c over bot h t he l oading a nd exposure condition of the masonry. The masonry mortar shall generally be as specified below in (b) to (g). (b) In case of masonry exposed frequent to rain and where there is further protection by way of plastering or rendering or other finishes, the grade of mortar shall not be less than 0.7 MM but shall preferably be of grade MM2. Where no protection is provided, the grade of mortar for external wall shall not be less than MM2. (c) In case of load bearing internal walls, the grade of mortar shall preferably be MM 0.702 or more for high durability but in no case less than MM 0.5. (d) I n t he c ase of m asonry w ork i n foundations l aid bel ow dam p proof c ourse, t he grade of m ortar for use in masonry shall be as specified below. (i) Where soil has little moisture, masonry mortar of grade not less than MM 0.7 shall be used. (ii) Where s oil is v ery damp, masonry mortar of grade preferably MM 2 or more shall be used. But in no case shall the grade of mortar be less than MM 2. (e) For masonry in building subject to vibration of machinery, the grade of mortar shall not be less than MM 3. (f) For parapets, where the height is greater than thrice the thickness, the grade of masonry mortar shall not be less than MM3. In case of low parapets the grade of mortar shall be the same as used in the wall masonry. (g) The grade of mortar for bedding joints in masonry with large concrete blocks shall not be less than MM 3. (h) The compressive strength shall be determined in accordance with the procedure given in IS 2250. (i) While mixing the p ozzolanic m aterial l ike f ly ash i n mortars Ordinary Portland cement only s hall be use. Grade of Masonry Mortar (IS 2250 )
S l. No.
Gra de
1 2
MM 0.7
(Clause 3.2.0)
Compre s s ive s tre ngth a t 2 28 da ys in N/mm
0.7 to 1.5
Ce me nt
1 1
P ozzola na (Fly As h)
--0.4*
S a nd
8 10
3 MM 1.5 1.5 to 2.0 1 --7 4 1 0.4* 8.75 5 MM 3 3.0 to 5.0 1 ---6 6 1** 0.21 4.2 7 1 0.4* 7.5 8 MM 5 5.0 to 7.5 1 ---5 9 1 0.4 6.25 10 1 0.4 5 11 MM 7.5 7.5 & above 1 ---4 12 1** 0.2* 2.1 13 1 --3 14 1 0.4 3.75 * Note :Pozzolana of minimum lime reactivity of 4 N/MM2 ** This ratio by volume correspondence approximately to cement Pozzolana ratio of 0.8:0.2 by weight. In this case, only ordinary Portland cement is to be used (see IS 269). Specifications for ordinary rapid hardening and low heat Portland Cement (Third revision). Note : Compressive strength shall be determined in accordance with the Appendix -A-IS 2550. .
.
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4.0: Concrete Work
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CONTENTS Cla us e No.
Brie f De s cription
P a ge No.
List of Mandatory Tests
57
List of Bureau of Indian Standard Codes
58
4.1 4.1.1 4.1.2
Material Coarse Aggregate Chemical Admixtures
59 59 61
4.2 4.2.1 4.2.2 4.2.3
Cement Concrete Grades of Cement Concrete Workability of Concrete Concrete Mix Proportioning
62 62 64 65
4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9
Batching Mixing Placing Compaction Construction Joints Concreting under Special Conditions
65 67 69 69 69 69
4.2.10 4.2.11 4.2.12 4.2.13 4.2.14 4.2.15 4.2.16
Curing Testing of Concrete Form Work Finishes Durability of Concrete Measurements Rate
70 71 71 71 71 74 76
4.3
Cement Fly Ash Concrete – DELETED
76
4.4 4.4.1
Damp Proof Course Cement Concrete Layer
77 77
4.4.2 4.4.3 4.4.4 4.4.5 4.4.6
Curing Application of Hot Bitumen Water Proofing Materials Measurements Rate
77 77 77 77 77
Appendix A
Determination of Particle Size
78
Appendix B
Test for Surface Moisture
78
Appendix C
Determination of Ten Per cent Fine Value
79
Appendix D
Slump Test
81
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LIST OF MANDATORY TESTS Ma te ria l
1
Cla us e
Fie ld/ La bora tory
Te s t
2
3
4
Te s t Min. qty of proce dure M a te ria l for Ca rrying out 5
Fre que ncy of Te s ting te s t
6
7
Stone aggregate
Concrete
4.1.2.3 Particle size
Field/ Lab
Appendix ‘A’
45 cum
For every 45 cum or part thereof for RCC Work only. For rest of items as decided by Engineer-incharge
4.1.2.5
(a) Estimation of organic impurities (b) Surface moisture (c) Determination of 10% fine value
Field/ Lab
IS 2386Part II
10 cum
Field/ Lab
IS 2386
10 cum
For every 40 cum or part thereof -do-
Field/ Lab
IS 2386
10 cum
-do-
(d) Specific gravity
Field/ Lab
IS 2386
10 cum
-do-
(e) Bulk density
Field/ Lab
IS 2386
10 cum
-do-
(f) Aggregate crusing Field/ Lab strength
IS 2386
10 cum
-do-
(g) Aggregate impact value
Field/ Lab
IS 2386
10 cum
-do-
Slump test
Field
Appendix ‘D’
10 cum
As per Site Engineer
4.2.2
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LIST OF BUREAU OF INDIAN STANDARDS CODES S . No.
I. S . No.
S ubje ct
1.
IS 383
Specification for coarse and fine aggregate from natural sources for concrete.
2.
IS 456
Plain and reinforced concrete - Code of practice
3.
IS 516
Method of test for strength of concrete
4.
IS 1199
Method of sampling and analysis of concrete
5.
IS 1200 (Part II)
Method of measurement of building and civil engineering work (concrete work)
6.
IS 1322
Specification for bitumen felt for water proofing and damp proofing.
7.
IS 1791
General requirements for batch type conrete mixers
8.
IS 2386
Method of test for aggregates for concrete (a) Part I - Particle size and shape (b) Part II - Estimation of deleterious materials and organic impurities (c) Part III - Specific gravity, density, voids absorption and bulking. (d) Part IV - Mechanical properties. (e) Part V - Soundness
9.
IS 2505
General requirements for concrete vibrators - immersion type.
10.
IS 2506
General requirements for concrete vibrators vibrators
11.
IS 2645
Specification for integral water proofing compounds for cement mortar and concrete
12.
IS 3068
Specification for broken brick (burnt clay) coarse aggregate for use in concrete.
13.
IS 3812
Specification for fly ash for use as Pozzolana and admixture in cement mortar and concrete.
14.
IS 4656
Specification for form vibrators for concrete.
15.
IS 7861 (Part-I)
Code of practice for extreme weather concreting (Part-I) recommended practice for hot weather concreting.
16.
IS 7861 (Part-II)
Code of practice for extreme weather concreting (Part-II) recommended.
17.
IS 9103
Specification for concrete admixtures.
- screed board concrete
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4.0 CONCRETE WORK 4.1. MATERIAL Water, c ement, fine aggregate or sand and Surkhi, shall be as specified in Chapter 3.0 Mortar. 4.1.1 Coarse Aggregate 4.1.1.1 General: Aggregate most of which is retained on 4. 75 mm IS Sieve and c ontains only as much fine m aterial as is per mitted in IS 383 for v arious sizes and gr ading is k nown as c oarse aggr egate. Coarse agg regate s hall be s pecified as stone agg regate, g ravel or br ick aggregate and it s hall be obtained from approved/ authorized sources. (a) S tone Aggre ga te : It shall consist of naturally occurring (uncrushed, crushed or broken) stones. It shall be hard, strong, dense, durable and clean. It shall be free from veins, adherent coating, injurious amounts of disintegrated pieces, alkali, vegetable matter and other deleterious substances. It shall be roughly cubical in shape. Flaky and elongated pieces shall be avoided. It shall conform to IS 383 unless otherwise specified. (b) Gra ve l: It shall consist of naturally occurring (uncrushed, crushed or broken) river bed shingle or pit gravel. It shall be sound, hard and clean. It shall be free from flat particles of shale or similar laminated material, powdered clay, silt, loam, adherent coating, alkali, vegetable matter and other deleterious substances. Pit gravel shall be washed if it contains soil materials adhering to it. These shall conform to IS 383 unless otherwise specified. (c) Brick Aggre ga te : Brick aggregate shall be obtained by breaking well burnt or over burnt dense brick/ brick bats. They shall be homogeneous in texture, roughly cubical in shape and clean. They shall be free from unburnt clay particles. Soluble salt, silt, adherent coating of soil, vegetable matter and other deleterious substances. Such aggregate should not contain more than one percent of sulphates and should not absorb more than 10% of their own mass of water, when used in cement concrete. It shall conform to IS 3068 unless otherwise specified. (d) Light weight aggregate such as sintered fly ash aggregate may also be used provided the Engineer-in-Charge is satisfied with the data on the proportion of concrete made with them. 4.1.1.2 Deleterious Material: Coarse aggregate s hall not c ontain any d eleterious m aterial, s uch a s pyrites, c oal, l ignite, mica, shale o r s imilar l aminated material, clay, al kali, s oft fragments, sea shells an d organic impurities in such quantity as to affect the strength or durability of the concrete. Coarse aggregate to be used for reinforced cement concrete. Coarse aggregate to be used for reinforced cement concrete shall not contain an y m aterial l iable t o at tack the steel reinforcement. A ggregates which are c hemically rea ctive w ith al kalies of c ement shall not be used. T he m aximum quant ity of del eterious material shall not b e more t han fi ve p ercent o f t he w eight of c oarse aggregate w hen d etermined in accordance with IS 2386. 4.1.1.3 Size and Grading (i) S tone a ggre ga te a nd gra ve l: It s hall be ei ther g raded or single s ized as s pecified. N ominal s ize and grading shall be as under:(a) Nominal sizes of graded stone aggregate or gravel shall be 40, 20, 16, or 12.5 mm as specified. For any one of the nominal sizes, the proportion of other sizes as determined by the method prescribed in Appendix ‘A’ of Chapter 4 shall be in accordance with Table 4.1.
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TABLE 4.1 Graded Stone Aggregate or Gravel
IS S ie ve De s igna tion
40 mm
P e rce nta ge pa s s ing (by we ight) for nomina l s ize of 20 mm 16 mm 12.5 mm
80 mm 100 63 mm 40 mm 95 to 100 100 30 to 70 95 to 100 100 100 20 mm 16 mm 90 to 100 12.5 mm 90 to 100 10 mm 10 to 35 25 to 55 30 to 70 40 to 85 4.75 mm 0 to 5 0 to 10 0 to 10 0 to 10 (b) Nominal sizes of single sized stone aggregate or gravel shall be 63, 40, 20, 16, 12.5 or 10 mm as specified. For any one of the nominal size, the proportion of other sizes as determined by the method prescribed in Appendix ‘A’ of Chapter 4 shall be in accordance with Table 4.2. TABLE 4.2 Single Sized (Ungraded) Stone Aggregate or Gravel
IS S ie ve De s igna tion
63 mm
P e rce nta ge pa s s ing (by we ight) for nomina l s ize of 40 mm 20 mm 16 mm 12.5 mm
10 mm
80 mm 100 63 mm 85-100 100 40 mm 0-30 85-100 100 20 mm 0- 5 0-20 85-100 100 16 mm 85-100 100 12.5 mm 85-100 100 10 mm 0-5 0-5 0-20 0-30 0-45 85-100 4.75 mm 0-5 0-5 0-10 0-20 2.36 mm 0-5 (c) When stone aggregate or gravel brought to site is single sized (ungraded), it shall be mixed with single sized aggregate of different sizes in the proportion to be determined by field tests to obtain graded aggregate of specified nominal size. For the required nominal size, the proportion of other sizes in mixed aggregate as determined by method prescribed in Appendix ‘A’ of Chapter 4 shall be in accordance with Table 4.1. Recommended proportions by volume for mixing of different sizes of single size (ungraded) aggregate to obtain the required nominal size of graded aggregate are given in Table 4.3. TABLE 4.3 Single Sized (Ungraded) Stone Aggregate or Gravel
Ce me nt concre te
(1)
1:6:12 1:6:12 1:5:10
Nomina l s ize of gra de d a ggre ga te re quire d (2)
63 40 63
50 mm
9 7.5
(3)
P a rts of s ingle s ize a ggre ga te of s ize 40 mm 20 mm 12.5 mm
9 -
(4)
(5)
3 3 2.5
-
(6)
10 mm
-
(7)
.
60 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
(1)
(2)
(3)
(4)
(5)
(6)
(7)
2.5 1:5:10 40 7.5 1:4:8 63 6 2 1:4:8 40 6 2 1:3:6 63 4.5 1.5 1:3:6 40 4.5 1.5 1:3:6 20 4.5 1.5 1:2:4 40 2.5 1 1.5 1:2:4 20 3 1 1:2:4 12.5 3 1 1: 11/2 :3 20 0 0 2 1 (i) The proportions indicated in Table 4.3 above are by volume when considered necessary, these proportions may be varied marginally by Engineer-in-Charge af ter making sieve analysis of aggregate brought to site for obtaining required graded aggregate. No a djustments i n rat e s hall b e m ade f or a ny variation i n t he pr oportions so o rdered by t he Engineer-in-Charge. I f single s ize coarse agg regate ar e no t premixed at site to obtain the graded coarse aggregate requ ired for the m ix, the volume of s ingle s ize aggr egates r equired f or t he m ix s hall be s uitably i ncreased t o account for reduction in total volume at the site of mixing. (ii) Brick Aggre ga te : Nominal size of brick aggregate shall be 40 mm and its grading shall be as specified in Table 4.4 when tested for sieve analysis for the method prescribed in Appendix ‘A’ of Chapter 4.0. TABLE 4.4 Brick Aggregate IS S ie ve De s igna tion 75 mm 37.5 mm 20.0 mm 4.75 mm
P e rce nta ge pa s s ing (by we ight) 100 95-100 45-100 0.50
4.1.1.4 Stacking: Aggregate shall be s tacked o n a ha rd, d ry and l evel p atch of g round. When s tack piling, the aggregate shall not form pyramids resulting in segregation of different sized materials. It shall be stacked separately ac cording t o no minal s ize o f coarse aggr egates. S tacking s hall be done i n regular stacks, of height not exceeding 100 cm. 4.1.1.5 Testing: Coarse aggregate shall be tested for the followings (as per IS 2386) (a) Determination of particle size and shape (Appendix ‘A’ of Chapter 4) (b) Estimation of organic impurities (as per IS 2386 - Part II) (c) Surface moisture (Appendix ‘B’ of Chapter 4) (d) Determination of 10% fine value (Appendix ‘C’ of Chapter 4) 4.1.1.6 Measurements: The aggregates shall be m easured in s tacks and p aid for af ter m aking a deduction o f 7 .5% o f t he gr oss measurements o f stacks i n respect o f aggr egates o f no minal s ize 40 mm and abo ve. N o dedu ction from the gros s m easurements o f the stacks is to be m ade in res pect o f aggregate of nominal size below 40 mm. 4.1.2 Chemical Admixtures When re quired, a dmixtures of a pproved q uality s hall b e m ixed w ith co ncrete, as sp ecified. T he admixtures shall conform to IS 9103 and as specified in Chapter 5 - R.C.C.
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4.1.2.1 Admixtures may be any one of the following classes for use in concrete:(a) Water Reducing Admixtures (b) Retarding Admixtures (c) Accelerating Admixtures. (d) Water Reducing and Retarding Admixtures. (e) Water Reducing and Accelerating Admixtures. (f) Permeability Reducing (water proofing) Admixtures. 4.1.2.2 Liquid Admixtures: Admixtures i ntroduced i nto t he c oncrete as l iquids gener ally f all i nto t he following categories. (a) Air Entraining. (b) Water Reducing. (c) Water Reducing Retarders. (d) Retarders. (e) Water Reducing Accelerators. (f) Accelerators. 4.1.2.3 Dosage of these admixtures may vary according to manufacturers specification. 4.1.2.4 Two or more admixtures may not be compatible in the same solution. It is therefore mandatory that when two admixtures manufactured by the same manufacturers is being used simultaneously, the manufacturer s hall c ertify the ir c ompatibility. In c ase the two o r m ore adm ixtures a re produces by different manufacturers, then, before their use in concrete, test shall be performed by the manufacturer to establish t heir compatibility, al l s uch t est re ports shall b e f urnished t o t he Engineer-in-Charge for hi s approval before their use in concrete. 4.1.2.5 Some admixture may be in the form of powder, particle or hi gh concentration liquids which may require mixing with w ater pr ior to dos ing. U nder these conditions w ater i n solution s hall be considered as part of total water content in the batch in order to maintain the water-cement ratio. 4.1.2.6 Admixture m anufacturer’s rec ommendation s hall be c arefully f ollowed s o as t o ens ure c omplete solution of the product or to prepare a standard solution of uniform strength for easier use. 4.1.2.7 Certain ad mixtures may c ontain significant amounts o f finely di vided i nsoluble materials o r ac tive ingredients which may or may not be readily soluble. It is essential for such admixtures that precautions be taken to ensure that these constituents be kept in a state o f un iform s uspension be fore actual batching. When rel atively small a mounts of po wered adm ixtures are to be u sed di rectly, these s hall b e pre-blended with cement. 4.1.2.8 Admixtures are sold under various trade names and may be in the form of liquids or powders. The proprietary name and th e n et q uantity of content shall be c learly i ndicated i n e ach pa ckage o r container of admixtures. The a dmixtures s hall b e uniform within e ach batch a nd u niform between all batches. 4.1.2.9 No admixtures shall be accepted for use in concrete unless these are tested in accordance with IS 9103 and the test results are approved by the Engineer-in-Charge. 4.2. CEMENT CONCRETE 4.2.1 Grades of Cement Concrete The concrete shall be in grade designated as under:
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TABLE 4.5 Grades of Concrete Group
Grade Designation
(1) ( Ordinary Concrete
2) M10 10 M15 15 M20 20 M25 25 M30 30 M35 35 M40 40 M45 45 M50 50 M55 55 M60 60 M65 65 M70 70 M75 75 M80 80
Standard Concrete
High Strength Concrete
Specified characteristic compressive strength of 150 mm Cube at 28 Days in N/mm2 (3)
Notes : 1. In the designation of conc rete mix M refers to the mix and the number to the spec ified compressive strength of 150 mm size cube at 28 days, expressed in N/mm2. 2. For concrete of compressive strength greater than M55, design parameters given in the standard may not be applic able and the v alues may be obtai ned from specialized li teratures and experimental results. 4.2.1.1 The characteristic strength is defi ned a s the streng th of material b elow wh ich not more than 5 percent of the test results are expected to fall. TABLE 4.6 Minimum Cement Content, Maximum Water-Cement Ratio and Minimum Grade of Concrete for Different Exposures with Normal Weight Aggregates of 20 mm Nominal; Maximum Size (Clause 4.2.1.1) Sl. No.
Exposure
(1) (2) (i) Mild (ii) Mo derate (iii) Sev ere (iv) Very Severe (v) Ext reme
Plain Concrete
Reinforced Concrete
Minimum Cement Content kg/m3
Maximum Free Water Cement Ratio
Minimum Grade of Concrete
Minimum Cement Content kg/m3
(3) 220 240 250 260 280
(4) 0.60 0.60 0.50 0.45 0.40
(5) M15 M20 M20 M25
(6) 300 300 320 340 360
63
Maximum Free WaterCement Ratio (7) 0.55 0.50 0.45 0.45 0.40
Minimum Grade of Concrete
(8) M20 M25 M30 M35 M40
Notes: 1. Cement c ontent presc ribed in this Table is i rrespective of the grades of c ement. The addi tions such a s fly or ground g ranulated blast furnace sl ag may b e tak en into account in the conc rete composition with respe ct to the c ement c ontent and water-cement ratio, if the s uitability is established and as long as the maximum amounts taken into account do not exceed the limit of pozzolona and slag specified in IS 1489 (Part 1) and IS 455 respectively. 2. Minimum grade for plain concrete under mild exposure condition is not specified. 3. The abo ve minimum c ement conte nt and ma ximum water ce ment rat io app ly only to 20 mm nominal maximum size aggregate. For other sizes of aggregate, these should be changed as per Table 6 of IS 456. The minimum grade of concrete for plain and reinforced concrete shall be as per Table 4.6. 4.2.1.2 Concrete o f grades lo wer than thos e given in Table 4.6 may be used for l foundation for masonry walls or temporary reinforced concrete construction.
ean conc rete,
4.2.2 Workability of Concrete 4.2.2.1 The concrete mix proportion chosen should be such that the concrete is of adequate workability for the placing c onditions of the co ncrete and c an properly be compacted with the means a vailable. Suggested ranges of workability of concrete measured in accordance with IS 1199 are given below: Placing Conditions
Degree of Workability
(1) Blinding conc rete: s hallow Very low sections: P avements using pavers Mass con crete: Li ghtly Low 25-75 reinforced sections in s labs, beams, wall, columns, : floors
Slump (mm)
(2)
(3) See 4.2.2.2
Hand placed pa vements: cana l lining; Strip footing Heavily re inforced se ctions in Medium 50-100 slabs, beams, walls, columns: Slip for m work: Pumped Medium 75-100 concrete Trench fill High
100-150
Tremie concrete
See 4.2.2.3
Note:-
Very High
For mo st o f the p lacing con ditions, internal vibrators (needle vibrators) are s uitable. The diameter of the needle shall be determined based on the density and spacing of reinforcement bars and thickness of sections. For tremie concrete, vibrators are not required to be used (see also 4.2.7)
4.2.2.2 In the ‘very low’ category of workability where strict control is necessary, for example, pavement quality con crete, measurement of workab ility be determination of c ompacting factor will b e more appropriate than slump ( see IS 1199) and a value of compacting factor of 0.75 to 0.80 is suggested. 4.2.2.3 In the ‘very high’ category of workability, measurement of workability by determination of flow will be appropriate (see IS 9103).
64 | Page HO Civil Specifications Volume - I
4.2.3 Concrete Mix Proportioning 4.2.3.1 The determination of the p roportion of cement, aggregate and water to attain the required strength shall be made as follows: (a) By designing the concrete mix: su ch c oncrete shall be ca lled ‘Design mix concrete’, for detai ls reference may be made to RCC Chapter. (b) By adopting nominal concrete mix: such concrete shall be called ‘Nominal mix concrete’. Design mix concrete is preferred to nomina l mi x. If design mix concrete cannot be use d for any reason on the work for grades of M20 or lower, nomi nal mix es ma y be used with the permis sion of Engineer-in-Charge, which, however, is likely to involve a higher cement content. 4.2.3.2 Nominal Mix Concrete: Nominal Mix Concrete may be u sed for concrete of M20 or lower. The proportions of materials for nominal mix concrete shall be in accordance with Table 4.7. The c ement c ontent of t he mix specified in Tab le 4.7 for any nominal mix sha ll be pro portionately increased if the quantity of water in the mix has to be increased to overcome the difficulty or placement and compaction, so that the water cement ratio as specified is not exceeded. TABLE 4.7 Proportions for Nominal Mix Concrete (Clause 4.2.3.2) Grade of Concrete
(1) M5 800 M7.5 625 M10 480 M15 330 M20 250 Note : Note : -
Total Quantity of Dry Aggregates by Mass per 50 kg of cement, to be taken as the Sum of the Individual Masses of Fine and Coarse Aggregates, Kg. Max (2)
Proportion of Fine Aggregate to Coarse Aggregate (by Mass)
(3) Generally 1:2 but subject to an upper limit of 1: 1 ½ and a lower limit of 1:2 ½
Quantity of Water per 50 kg of Cement, max Ltr.
(4) 60 45 34 32 30
The proportion o f the fine to coa rse aggregate should be adjusted f rom upper limit progressively as the grading of f ine aggregate bec omes finer and the ma ximum size o f coarse aggregate becomes larger. Graded coarse aggregate shall be used. Quantity of water requi red from dur ability point of view ma y be less tha n the value given above.
Example For an average grading of fine aggregate (that is, Zone II of Table 4 of IS 383), the proportions shall be 1:1 ½ , 1:2 and 1:2 ½ for maximum size of aggregates 10 mm, 20 mm and 40 mm respectively. 4.2.4 Batching To a void confusi on an d error in batching, consideration shou ld be given to u sing the smalle st practical nu mber of d ifferent concrete mixed o n any site or i n an y one plant. In batching concrete, the quantity of both cement and aggregate shall be determined by mass; admixture, if solid, by mass: liquid 65 | Page HO Civil Specifications Volume - I
admixture may however be m easured in volume or m ass: w ater sh all be w eighed or m easured b y volume in a calibrated tank (see also IS 4925). Ready-mixed c oncrete s upplied b y ready-mixed c oncrete pl ant shall be p referred. For l arge and medium project sites the concrete shall be sourced from ready-mixed c oncrete pl ants or f rom on s ite or of f s ite batching and mixing plants (see IS 4926). 4.2.4.1 Except w here it can be s hown to the satisfaction of the E ngineer-in-Charge that s upply of properly g raded ag gregate of uniform q uality can be m aintained o ver a p eriod of work, t he grading aggregate s hould be controlled b y obt aining t he coarse aggr egate i n di fferent s izes and bl ending them in the right proportions when required, the different sizes being stocked in separate stock-piles. T he material s hould be s tock-piled f or s everal hours preferably a d ay before us e. T he grading of c oarse and fine aggregate should be checked as frequently as possible, the frequency for a given job being determined by the Engineer-in-Charge to ensure that the specified grading is maintained. 4.2.4.2 The accuracy of the measuring equipment shall be within + 2 percent of the quantity of cement being measured and within + 3 percent of the quantity of aggregate, admixtures and water being measured. 4.2.4.3 Proportion/Type and grading of aggregates shall be made by trial in such a w ay so as to obtain densest possible concrete. All ingredients of the concrete should be used by mass only. 4.2.4.4 Volume batching m ay be al lowed o nly where w eigh-batching i s n ot pr acticable and p rovided accurate used in concrete have earlier been established. Allowance for bilking shall be made in accordance w ith I S 2386 ( Part 3) . T he m ass v olume r elationship s hould be c hecked a s f requently as necessary, the frequency for the given job being determined by Engineer-in-Charge to ensure that the specified grading is maintained. 4.2.4.5 It is important to maintain the water cement ratio constant at its correct value. To this end, determination of m oisture contents i n b oth fine a nd coarse ag gregates shall b e m ade a s frequently as possible, the frequency f or a given j ob be ing det ermined by the E ngineer-in-Charge a ccording t o weather conditions. T he a mount of t he adde d w ater s hall be adj usted to c ompensate f or any observed variations i n the m oisture contents. F or t he determination of m oisture c ontent in t he aggregates, I S 2386 (Part 3 ) m ay be referred to. To allow for t he v ariation in m ass for aggregate du e to v ariations in their moisture c ontent, suitable adj ustments in t he m asses of aggregates s hall be m ade. I n t he absence of exact data, o nly in t he c ase of n ominal m ixes, the amount o f s urface water may be es timated from t he values given in Table 4.8. TABLE 4.8 Surface Water Carried by Aggregate (Clause 4.2.4.5)
S l No.
Aggre ga te
(1)
(i) (ii) (iii) (iv) 1)
(2)
Very wet sand Moderately wet sand Moist sand 1) Moist gravel or crushed rock
Approxima te Qua ntity of S urfa ce Wa te r 3 P e rce nt by l/m ma s s (3) (4)
7.5 5.0 2.5 1.25-2.5
120 80 40 20-40
Coarser the aggregate, less the water it will carry.
.
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4.2.4.6 No substitutions in materials used on the w ork or alteration in t he es tablished proportions, except as permitted in 4.2.4.4 and 4. 2.4.5 shall be m ade without additional tests to show that the quality and strength of concrete are satisfactory. 4.2.5 Mixing Concrete s hall be m ixed in m echanical batch type c oncrete mixers c onforming t o I S 1791 having t wo blades an d fitt ed w ith p ower l oader (li fting h opper type ). H alf ba g m ixers an d m ixers without lifti ng hoppers s hall not be used f or mixing c oncrete. I n e xceptional c ircumstances, s uch as m echanical br eak down of m ixer, w ork i n remote areas or p ower b reakdown and w hen t he quantity of concrete w ork i s very small, ha nd m ixing m ay be d one w ith t he s pecific p rior p ermission of t he E ngineer-in-Charge i n writing subject to a dding 10% extra cement. When hand mixing is per mitted, it shall be carried out o n a water tight pl atform a nd care s hall be ta ken t o ensure th at mixing i s continued u ntil th e concrete i s uniform in colour and consistency. Before mixing the brick aggregate shall be well soaked with water for a minimum period of two hours and stone aggregate or gravel shall be washed with water to remove, dirt, dust and ot her f oreign materials. For guidance, t he m ixing t ime m ay be 1 1/2 to 2 m inutes, f or hydrophobic cement it may be taken as 21/2 to 3 minutes. 4.2.5.1 Power Loader: Mixer will be fitted with a power loader complying with the following requirements. (a) The hopper shall be of adequate capacity to receive and discharge the maximum nominal batch of unmixed materials without spillage under normal operating conditions on a level site. Note: In such a c ase the v olume of the m aximum nom inal batc h of m ixed m aterial is 50% greater than the nominal mixed batch capacity. (b) The minimum inside width of the feeding edge of the hopper shall be as specified below in Table 4.9. TABLE 4.9 Nomina l s ize of mixe r (T, NT or R). litre
T = Tilting;
Minimum ins ide width of hoppe r fe e ding e dge
140 200 280 375 500 1000 NT = Non-tilting; R = Reverse
1.0 1.1 1.2 1.4 1.5 2.0
(c) The design of the loader shall be such that it allows the loading hopper to be elevated to such a height that the centre line of the chute plate of the hopper when in discharge position, is at an angle of not less than 50º to the horizontal. A mechanical device to aid discharge of the contents as quickly as possible from the hopper to the drum may also be provided. Even when a mechanical device is provided, it is recommended that the angle of centre line of the chute plate of the hopper when in discharge position, should be as larger as practicable, preferably not less than 40º to horizontal. (d) When the means of raising and lowering the loading hopper includes flexible wire ropes winding on to a drum or drums, the method of fastening the wire to rope to the drums shall be such as to avoid, as far as possible any tendency to cut the strands of the ropes and the fastening should preferably be positioned clear of the barrel of the drum for example, outside the drums flange. When the loading hopper is lowered to its normal loading position, these should be at least one and a half drums of rope on the drum. .
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(e) Clutch bra ke and hydraulic control le ver shall be designe d s o a s to prevent d isplacement by liberation or by accidental contact with any person. (f) The cl utch and brake control arrangements shall als o be so de signed that the operator ca n control the falling speed of the loader. (g) Safety device shall be provided to secure the hopper in raised position when not in use. 4.2.5.2 Mixing Efficiency: The mixer sha ll be tested under norma l working conditions in accordance with the method specified in IS 46 43 with a view to check its ab ility to mix the ingredients t o obtain concrete ha ving uniformity with in the prescribed lim its. T he uniformity of mixed c oncrete sha ll be evaluated by finding the percentage variation in quantity (mass in water) of cement, fine aggregate and coarse aggregate in a freshly mixed batch of concrete. The percentage v ariation between the quantiti es of c ement, fine aggregate and coarse aggregates (as found by weighing in water) in the two halves of a batch and a verage of the two halv e of the batch shall not be more than the following limits: Cement Fine Coarse
aggregate aggregate
8% 6% 5%
4.2.5.3 Machine Mixing: The mixer drum shall be flushed clean with water. Measured quantity of coarse aggregate shall be p laced fi rst in the hopper. Thi s shall b e foll owed with measured quantity of fine aggregate and then cement. In case fine ag gregate is damp, half the required quanti ty of coarse aggregate shal l be placed in the hopper, foll owed by fine aggregate and ce ment. Fina lly the balance quantity of coarse aggregate shall be fed in the hoppe r, & then the dr y mate rials are slipped into th e drum by raising the hopper. The dry material shall be mixed for atleast four turns of the drum. While the drum is rotating, water shall be added gradually to achieve the water c ement ratio as specified or a s required by the Engineer-in-Charge. After addin g water, the mix ing shall be c ontinued until concrete of uniform colour, uni formly distributed materia l and consistency is obt ained. Mixing shall be done for atleast two minute s after adding water. If there is segregation after unloading from the mixer, th e concrete should be remixed. The drum shall be e mptied before r echarging. When the mixer is closed down for t he day or at any time exceeding 20 minutes, the drum shall be flushed cleaned with water. 4.2.5.4 Hand Mixing: When hand mixing has been specifically permitted in ex ceptional circumstances by the Engineer-in-Charge i n wr iting, subject t o add ing 10% e xtra c ement, i t shall be carr ied out on a smooth, clean a nd water tight pl atform of su itable siz e. Measured q uantity of sand shall b e s pread evenly on th e platform a nd the cement shall be dumped on the sand and di stributed evenly. Sand and cement shall be mix ed i ntimately with spade until mixture is of even c olour throughout. Meas ured quantity of coarse aggregate shall be s pread on top of cement sand mix ture and mixi ng done by showlling a nd turning till the coarse aggregate gets evenly distributed the cement sand mixture. Three quarters of the total quantity of water requ ired shall be ad ded in a hollow made in the middle of the mixed pile and the material is t urned towards the middle of pile with spade. The whole mixture is turned slowly o ver and again and the re maining quantity of wa ter is added gradual ly. The mixi ng shall be continued until c oncrete of uniform colour and cons istency is obta ined. The mixin g pl atform shall be washed and cleaned at the end of the day. 4.2.5.5 Transportation and Handling : Concrete shall be transported fr om the mix er to the place of laying as rapidly a s p ossible by methods whic h will pre vent the segregation or loss of any of the ingredients and maintaining the required workability. 68| Page
HO Civil Specifications Volume-I
During hot or c old weather, c oncrete shall be t ransported in deep c ontainers, ot her s uitable m ethods to reduce the loss of water by evaporation in hot weather and h eat l oss in cold weather m ay al so be adopted. 4.2.6 Placing The c oncrete s hall b e deposited as n early as p racticable i n its f inal p osition to av oid rehandling. It shall be laid gently (not thrown) and shall be thoroughly vibrated and compacted before setting commences a nd s hould n ot be s ubsequently di sturbed. M ethod of p lacing s hall be such as t o preclude segregation. C are shall be t aken t o avoid di splacement of reinforcement or movement of f orm w ork and damage due t o rains. A s a gener al gui dance, t he maximum free f all of c oncrete m ay be t aken as 1. 5 metre. 4.2.7 Compaction Concrete s hall be tho roughly c ompacted and ful ly w orked a round em bedded fixtures and into corners of t he f orm w ork. C ompaction s hall b e d one by m echanical v ibrator of a ppropriate t ype t ill a dense c oncrete is obtained. The m echanical vibrators shall c onform to I S 250 5, IS 2506, IS 2514 and IS 4656. To prevent segregation, over vibration shall be avoided. Compaction s hall b e c ompleted be fore the initial setting s tarts. F or the items w here m echanical vibrators a re not t o be u sed, t he c ontractor s hall t ake pe rmission of t he E ngineer-in-Charge i n w riting before t he s tart of t he w ork. A fter c ompaction t he t op s urface shall be f inished ev en a nd s mooth w ith wooden trowel before the concrete begins to set. 4.2.8 Construction Joints Concreting shall be carried out continuously upto construction joints. The position and arrangement of construction j oints shall be a s s hown i n t he structural d rawings o r a s di rected b y t he E ngineer-inCharge. N umber of su ch joint s sh all b e k ept m inimum. J oints s hall b e ke pt as st raight as p ossible. Construction joints should comply with IS 11817. 4.2.8.1 When the work has to be resumed on a surface which has hardened, such surface shall be roughened. It shall then be swept clean and thoroughly wetted. For vertical joints, neat cement slurry, of workable consistency by using 2 kgs of cement per sqm shall be applied on the surface before it is dry. For horizontal joints, the s urface shall be c overed with a layer o f mortar about 10 -15 mm thick c omposed of c ement and sand i n the s ame ratio a s the cement and sand in concrete m ix. T his l ayer of cement slurry of mortar shall be freshly mixed and applied immediately before placing of the concrete. 4.2.8.2 Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface w ith w ire o r br istle bru shes, c are be ing tak en t o av oid di slodgement o f pa rticles of c oarse aggregate. T he surface shall be thoroughly wetted and all free w ater removed. The s urface s hall t hen be coated w ith neat c ement s lurry @ 2 k gs of c ement pe r sqm. On t his s urface, a l ayer of c oncrete n ot exceeding 150 mm i n thickness shall first be pl aced and s hall be well r ammed agai nst ol d work particular at tention be ing paid t o corners a nd c lose s pots; work, thereafter, shall proc eed i n t he norm al way. 4.2.9 Concreting under Special Conditions 4.2.9.1 Work in Extreme Weather Conditions: During hot and cold weather, the concreting shall be done as per t he procedure set ou t i n I S 7861 ( Part-I)-1975 and I S 7861 (Part I I)-1981 respectively. Concreting shall n ot be done when t he t emperature f alls below 4.5ºC. I n cold w eather, t he concrete placed s hall be protected against frost. D uring hot w eather, it shall be ensured that the temperature of wet concrete does not exceed 38ºC.
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4.2.9.2 Under Water Concreting: Concrete s hall not be dep osited und er water i f i t i s p racticable to dewater the area and place concrete in the regular manner. When it is necessary to deposit concrete under water, the methods, equipment, m aterials a nd p roportions of the m ix t o be u sed shall be submitted to and approved by the Engineer-in-Charge before the work is started. Under-water c oncrete s hould hav e a s lump rec ommended i n 4. 2.2. T he w ater-cement r atio s hall not exceed 0. 6 an d m ay nee d t o be s maller, dependi ng on t he g rade of c oncrete or t he t ype of c hemical attack. For aggregates of 40 mm maximum particle size, the cement content shall be atleast 350 kg/m3 of concrete. 4.2.9.3 Concrete in Sea Water: Concrete in sea-water or exposed directly along the sea-coast shall be at least M20 Grade in the case of plain concrete and M30 in case of reinforced concrete. The use of slag or Pozzolana cement is advantageous under such conditions. (i) Special attention shall be given to the design of the mix to obtain the densest possible concrete: slag, broken brick, soft lime stone, soft sandstone, or other porous or weak aggregates shall not be used. (ii) As far as possible, preference shall be given to precast members unreinforced, well-cured and hardened, without sharp corners, and having trowel-smooth finished surfaces free from crazing, cracks or other defect; plastering should be avoided. (iii) No construction joints shall be allowed within 600 mm below low water-level or within 60 mm of the upper and lower planes of wave action. Where unusually severe conditions or abrasion are anticipated, such parts of the work shall be protected by bituminous or silico-fluoride coatings or stone facing bedded with bitumen. (iv) In reinforced concrete structures, care shall be taken to protect the reinforcement from exposure to saline atmosphere during storage, fabrication and use. It may be achieved by treating the surface of reinforcement with cement wash or by suitable methods. 4.2.10 Curing Curing is the process of preventing loss of moisture from the concrete. The following methods shall be employed for effecting curing. 4.2.10.1 Moist Curing : Exposed s urfaces o f c oncrete s hall be k ept c ontinuously in a dam p or w et condition by pondi ng or b y c overing w ith a l ayer of s acking, c anvas, H essian or s imilar m aterials and kept c onstantly w et f or at l east 7 d ays f rom t he da te of pl acing concrete i n case of o rdinary P ortland cement an d at l east 1 0 d ays w here mineral a dmixtures or blended c ements a re used. T he p eriod o f curing shall not be less than 10 days for concrete exposed to dry and hot weather conditions. In the case of concrete w here m ineral ad mixtures or b lended c ements ar e u sed, it is r ecommended that abo ve minimum periods may be extended to 14 days. 4.2.10.2 Membrane Curing : Approved curing compounds may be used in lieu of moist curing with the permission of t he Engineer-in-Charge. Such c ompound s hall be applied t o al l e xposed s urfaces of t he concrete as soon as possible after the concrete has set. Impermeable membrane such as polythene sheet covering the c oncrete surface may al so be u sed to p rovide effective ba rrier a gainst the evaporation. 4.2.10.3 Freshly laid concrete shall be protected from rain by suitable covering.
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4.2.10.4 Over the foundation concrete, the masonry work may be started after 48 hours of its compaction but the curing of exposed surfaces of cement concrete shall be continued along with the masonry work for at eas t 7 day s. A nd w here cement c oncrete i s us ed as bas e c oncrete f or f looring, t he flooring may be commenced before the curing period of base concrete is over but the curing of base concrete shall be continued along with top layer of flooring for a minimum period of 7 days. 4.2.11 Testing of Concrete Testing of concrete shall be done as described in chapter of R.C.C. 4.2.12 Form Work Form w ork shall be as s pecified i n R .C.C. c hapter and s hall b e p aid f or s eparately unl ess o therwise specified. 4.2.13 Finishes Plastering and special f inishes o ther t han t hose, obtained t hrough form work shall be s pecified and paid for separately unless otherwise specified. 4.2.14 Durability of Concrete A d urable concrete i s o ne t hat pe rforms satisfactorily i n t he w orking e nvironment d uring i ts anticipated exposure conditions during s ervice. T he m aterials and mix proportions s hall be such a s t o maintain its intergrity and, if applicable, to protect reinforcement from corrosion. The factors influencing durability include: (a) The environment; (b) The cover to embedded steel; (c) The type and quality of constituent materials; (d) The cement content and water/ cement ratio of the concrete; (e) Workmanship, to obtain full compaction and efficient curing; and (f) The shape and size of the member. 4.2.14.1 Requirements for Durability 4.2.14.1.1 Ge ne ra l Environme nt : The general environment to which the concrete will be exposed during its working life i s classified i nto f ive l evels of s everity, t hat i s, mild, moderate, s evere, v ery severe and extreme as described in Table 4.9. TABLE 4.9 Environmental Exposure Conditions S l. N o (1) (i)
Environme nt (2) Mild
(ii)
Moderate
(iii)
Severe
Expos ure Conditions (3) Concrete surfaces protected against weather or aggressive conditions, except those situated in coastal area. Concrete surfaces sheltered from severe rain or freezing whilst wet Concrete exposed to condensation and rain Concrete continuously under water Concrete i n c ontact or b uried un der no n-aggressive s oil/ gr ound water Concrete surfaces sheltered from saturated salt air in coastal area Concrete surfaces exposed to severe rain, alternate wetting and drying or occasional freezing whilst wet or severe condensation. Concrete completely immersed in sea water. Concrete exposed to coastal environment.
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(1) (iv)
(2) Very severe
(v)
Extreme
Note:
(3) Concrete surface exposed to sea water spray, corrosive fumes or severe freezing conditions whilst wet. Concrete i n c ontact w ith or bur ied unde r aggr essive s ub-soil/ gr ound water. Surface of members in tidal zone. Members in direct contact with liquid/ solid aggressive chemicals.
For the purpose of determining exposure conditions, all places within a distance of 10 kms. of coastal line, sea front would be treated as coastal area.
4.2.14.1.2 Fre e zing a nd Tha wing : Where freezing and thawing ac tions u nder w et c onditions e xist, enhanced du rability c an be obt ained by t he us e o f s uitable ai r ent raining adm ixtures. W hen c oncrete lower t han grade M 50 i s used under t hese c onditions, t he mean t otal ai r content by volume of the fresh concrete at the time of delivery into the construction should be: Nomina l Ma ximum Size Aggre ga te (mm) 20 40
Entra ine d Air Pe rce nta ge 5+1 4+1
4.2.14.1.3 Expos ure to S ulpha te Atta ck : For the very high sulphate concentration in Class 5 c onditions given in Table 4.11, some form of lining such as polyethylene or polychloroprene sheet: or surface coating based on a sphalt, c hlorinated rub ber, epo xy; or pol yurethane m aterials s hould also be us ed t o prevent access by the sulphate solution. 4.2.14.1.4 Chloride s in Concre te : The total amount of chlorides content (as CI) in the concrete at the time of placing shall be as under : S I. No.
Type of Us e of Concre te
(1) (i)
(2) Concrete containing metal and steam cured at elevated t emperature an d pr e-stressed c oncrete Reinforced concrete or plain concrete containing embedded metal Concrete not containing embedded metal or any material requiring protection from chloride
(ii) (iii)
Ma ximum T ota l A cid S oluble Chloride 3 Conte nt expre s s e d as kg/ m of Concre te
(3) 0.4
0.6 3.0
4.2.14.1.5 S ulpha te s in Concre te : The total water-soluble sulphate content of the concrete mix, expressed as S O3 should not ex ceed 4 per c ent by mass of the c ement in t he mix. The sulphate content should be calculated as the total from the various constituents of the mix. The 4 per cent limit does not apply to concrete made with super sulphate cement complying with IS 6909.
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TABLE 4.11 Requirements for Concrete Exposed to Sulphate Attack (Clause 4.2.14.1.3) Sl No.
Class
Concentration of s ulphates, Expresed as SO3 Concrete.
In Ground Water S O 3 in 2:1 ( Wa te r: (g/l) Soil E xtract) ( g /l)
In Soil Total S O 3 (%) (1) (i)
(2) 1
(ii)
2
(iii)
3
(4) Less than 1.0
(3) Traces ( 3(e) (5) If 3 (c) is more than 3(f) (6) If any test value exceeds 3(f) (7) If 3 (c) > 3(d) but < 3(f) (8) If 3 (c) < 3(d) and > 3(e) (9) If 3(c) < 3(e)
Compressive strength kg/cm2 in 28 days 315 265 210
. Cube No
i.e. 70% of 3( d) i.e. 130% of 3(d) Value of 3(c) s hall be c ompressive strength of sample EE may order further investigation 3(f) for It should be restricted to computation of strength Strength i s i n or der and concrete a ccepted at full rates. Concrete may be accepted at r educed rates in accordance with para 5.4.13.2 Work represented by this s ample s hall be rejected and ac tion t aken as pr escribed i n clause 5.4.10.4
.
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APPENDIX D
LIST OF EQUIPMENTS FOR SITE LABORATORY AT GRASS ROOT PROJECTS I. Aggregate Testing
1.
2. 3.
ITEMS Aggregate Testing
1.
STANDARD SIEVES (INDIAN STANDARD) (a) Set of coarse sieves 30 cm dia (GI sheet frames) with aperture size. (40 mm, 25 mm, 20 mm, 16 mm, 17.5 mm, 0 mm, 4.75 mm all with lid and pan) (a-1) Motorised sieve shaker for the above sieves (b) Set of fine sieves 20 cm dia of brass with aperture size (4.75 mm, 2.36 mm, 1.18 mm, 600 mic, 300 mic, 150 mic, 75 mic all with lid and Pan) (b-1) Motorised sieve shaker for the above sieves. Flakiness & Elongation index screen Riffle sample divider slot width 25mm
4. 5.
1 Los Angeles abrasion Testing Machine Bulk Density and voids of Aggregates cylindrical metal measures with capacity (3 ltr, 10 ltr, 15 ltr or 20 ltr) 6. Density basket of galvanized wire height 20 cm 7. Pycrometer 1000 ml capacity with Brass 8. Hot - Air Blower (Hair Dryer) 9. Aggregate impact value apparatus with automatic blow counter 10. Hot - plate 1000 to 2000 wells with regulator cum switch 11. Drying pans (Frying pans) 12. China clay dishes with dia 10 cm & 15 cm 13. Watch glasses for above 10 cm & 15 cm II. Concrete Testing 1. 2. 3. 4. 5. 6 7. 8. 9. 10. 11. 12. 13.
Sieve Brushes Concrete cube moulds 15x15x15cm Ultrasonic Test Equipment Pruning Rods 2 Kg weight length 40 cm and ramming face 25 mm 2 Extra Bottom plates for 15 cm cube mould Standard Vibration Table for gauging the cubes Compression Testing Machine with Electricity cum manually operated tamping unit with pressure guage preferable 30 cm dia, 0-150 tonne in 1 tonne divisions. Sensitivity 0.5 tonne. 1 Air content measuring apparatus Slump test Apparatus complete Pocket concrete pernetrometer 0 to 50kg/ sq.cm Baby Mixer Machine G.I. Tray approx 1mx1m with sides 10 cm high for hand mixing of concrete Concrete temperature measuring thermometer with Brass protection sheath 0100 degree centigrade
QUANTITY 1 set
1 No. 1 set
1 No. 1 No. 1 No. 1 No. 1 No. each 1 No. 1 No. 1 No. 1 Nos. 2 Nos. 2 Nos./each 2 Nos./each 2 Nos. 50 Nos. 1 No. 4 Nos. 6 Nos. 2 Nos. 1 No. 1 No. 3 Nos. 1 No. 1 No. 2 Nos. 2 Nos.
.
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III. Cement Testing 1. Mortar Cube Moulds 7.07x7.07x7.07 cm 2. Standard sand Grade I,II,III 3. Mortar Cube vibrator 4. Vicate needle apparatus Computer 5. Blaine’s Apparatus IV. Weighing Equipment 1. 2. 3. 4. 5. 6.
10 Nos. 50 kgs./each 1 No. 1 No. 1 No.
Physical Balance Capacity 200 gms with weight pony Dial type spring balance preferable with zero correction knob capacity 100 kgs reading to ½ kg. Counter scale capacity 1 kg and 10 kg Weighing platform capacity 100 kg Iron Weight of 5 kg, 2 kg, 1 kg, 500 gm, 200 gm, 100 gm Brass Weight of 50 gm, 20 gm, 10 gm, 5 gm, 2 gm, 1 gm
V. Water Measuring
5 litres, 2 litres, 1 litre, ½ litre
1 No. 2 Nos. 1 No./ each 1 No. 2 No./each 2 No./each 5 Nos./each
VI. Glass and Plastic Ware 1. 2. 3. 4.
Measuring cylinder TPX or Poly propylene capacity 100 ml, 500 ml, 250 ml, 100 ml Pyrex, corning or Borosil beakers with cover capacity 500 ml, 200 ml, 50 ml Wash Bottles capacity 500 ml Thermometers 1-100 degree centigrades/ max. and Min/ Dry and wet with table
2 Nos./each 2 Nos./each 2 Nos./each 1 No.
VII. Laboratory Tools 1. 2. 3. 4. 5. 6. 7. 8.
Set of box spanner ratchet Hammer 1lb Rubber Hammer Hacksaw with 6 blades Measuring tape 2 mtr Depth gauge 20cm Steel Foot Plate Vernier Calliper
2 Nos. 2 Nos. 2 Nos. 1 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos.
VIII. Miscellaneous Items 1. 2. 3. 4. 5. 6.
Trowels made from saw blade, 3 mm thick 16x10cm wooden handle Showels & Spade Steel plates 5 mm thick 75x75 cm Plastic or G.I. Buckets 15 ltr, 10 ltr, 5 ltr Wheel Barrow Floor Brushes, hair dusters, scrappers, wire brush, paint brushes, shutter steel plat oil, kerosene with stove etc.
6 Nos. 6 Nos./each 2 Nos. 2 Nos. 3 Nos. 3 Nos.
.
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ANNEXURE - A (Clause 5.9.3) SAMPLING OF CONCRETE After the truck mixer has re-mixed its delivery on site, allow at least the first one-third of a m3 of concrete to be discharged prior to taking any samples. Take at least 4 incremental samples from the remainder of the load avoiding sampling the last cubic metre of concrete. Thoroughly re-mix this composite sample either on a mixing tray or in the sampling bucket and proceed with the required testing. ANNEXURE - B (Clauses 5.9.4.2 & 5.9.4.3) CONCRETE MIX INFORMATION TO BE SUPPLIED BY THE PURCHASER RMC :
………………………………………………………………………………..
Contractor :
………………………………………………………………………….
Site : …………………………………………………………………………………. MIX CODE Grade (N/mm2) (Characteristic strength) Minimum C ement C ontent ( kg./m3) Mineral Additives (Pulverized f uel as h/Slag/Others) (kg/m3) Maximum Free water Cement Ratio Nominal Maximum Aggregate size Cement Type and Grade (if preferred) Target workability (Slump) (mm) Target workability at site Maximum Temperature of Concrete at the time of placing Class of sulphate Resistance (if applicable ) Exposure condition (if applicable) Class of finish (if applicable) Mix Application Method of Placing Any other requirements (early strength workability retention, permeability testing, chloride content restriction, maximum cement content, etc. ) Concrete Testing (Frequency) Material’s Testing (any non-routine requirements) Alternatives to be offered: Yes/No Method of Curing to be used by contractor Quantity (m3) . Note : Additional proforma for further information may be used, such as for specific test rates to be achieved
for concrete or raw materials, exact method statements of the contractors proposed site practice.
138 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
ANNEXURE - C (Clauses 5.9.6.2 and 5.9.6.3) CALIBRATION AND WEIGHING EQUIPMENT ACCURACY C-1. The following limits shall apply to all ready-mixed concrete plants : (a) The ac curacy, s ensitivity and ar rangement o f the w eighing dev ices s hall be such as to enabl e t he materials to be batched within the following tolerances : (1) Cement, mineral : Within + 2 percent of the quantity of the constituent Admixtures being measured. (2) Aggregate, chemical : admixtures and water
Within + 3 percent of the quantity of the constituent being measured.
(b) Analogue scales shall have scale increments not exceeding 5 kg. for cement and mineral admixtures, 25 kg. for aggregate and 2 kg. for water. (c) P reset c ontrols shall b e calibrated i n i ncrements not ex ceeding 5 kg. f or cement and mineral admixtures, 10 kg. for aggregate and 2 kg. for water. (d) F or c ontinuous mixer plants c alibration s hall be in inc rements no t exceeding 10 kg./m3 for cement and mineral admixtures, 25 kg./m3 for aggregates and 10 l/m3 for water. (e) Digital readous shall have a scale increments not exceeding 2 kg. for cement and mineral admixtures, 10 kg. for aggregate and 10 for water. (f) At the time of installation, or reconditional the accuracy of the indicated mass at any point on the scale shall be within 0.25 percent of the full scale reading. (g) Any other t ime during the masonry operation t he ac curacy shall be w ithin 0. 50 percent of t he f ull scale reading. (h) Chemical Admixture dispensers shall have scale increment for exceeding. Ra nge r of sca le in kg/l 0.1 - 0.5 0.5 - 1.0 1.0 - 10.0 more than 10.0
S ca le incre me nt in Kg/l 0.01 0.02 0.2 0.4(i)
All weighing and measuring equipment shall be tested and calibrated over its full working range at the following intervals : (1) Mechanical /knife edge systems : At least once every two month (2) Electrical /load cell systems
:
At least once every three months
Adequate and identified facilities shall be provided for the application of the test loads. (j) I n t he c ase of b atch weighing systems t esting and c alibration shall b e b ased o n t he a pplication test loads to the weigh hoppers. (k) Checks o n continuous w eigh systems shall b e b ased on comparison of p reset q uantities w ith those actually produced.
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(l) To achieve the required accuracy of calibration, a minimum of 500 kg. of stamped weights are required, except that for low capacity scale an acceptable limit on the total mass of calibration weight would be 20 percent of the scale capacity. (m) When calibration of weighing equipment is carried out all personnel involved should be competent and fully trained, the procedures should be fully documented, and special attention should be paid to the health and safety aspects of the procedure.
ANNEXURE - D
DELIVERY TICKET INFORMATION (Clause 5.9.6.5)
D-1 The f ollowing i nformation shall be i ncluded in t he delivery ticket t o accompany t he l oad t o t he purchaser : (a) Name or number of the ready-mixed concrete depot (b) Serial number of the ticket (c) Date (d) Truck number (e) Name of the Purchaser (f) Name and location of site (g) Grade or mix description of the concrete (h) Specified target workability (i) Minimum cement content (if specified) (j) Type of cement and grade (if specified) (k) Maximum free water-cement ratio (if specified) (l) Nominal maximum size of aggregate (m) Generic Type or name of any chemical and mineral admixtures included. (n) Quantity of concrete in m 3 (o) Time of loading (p) Signature of the plant operator (q) A statement w arning the pur chaser o f the p recautions needed to be t aken w hen working w ith cement and wet concrete. D-2 On site the following information will be added. : (a) Time of arrival on site. (b) Time when discharge was completed. (c) Any water/admixture added by the supplier to meet the specified workability. (d) A ny ex tra w ater /admixture added at the request o f the pur chaser o f the concrete, or hi s representative, and his signature. (e) Pouring location. (f) Signature of the purchaser or his representative conforming discharge of the load.
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TYPICAL SET UP OF STEEL WALL FORM WORK Sub Head : R.C.C. (Form Work) Clause : 5.2.3.6
Fig. 5.1A : Single Sided Wall Form (Adjustable)
CLIP
All Members are of Steel
Fig. 5.1B : Double Sided Wall Form Fig. 5.1 : Typical Set Up of Steel Wall Form Work
141 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
WALL FORM Sub H ead : R .C.C. ( Form W ork) Clause : 5.2.3.6
CLIPS
All Members are of Steel
Fig. 5.2 : Adjustable Curved Wall Form (Double Sided)
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TYPICAL FIXING DETAILS OF WALL TIES Sub Head : R.C.C. (Form Work) Clause : 5.2.3.6.
CO IL T IE LENGTH 75 LONG BOLT
PLASTIC
CONES
WASHER
37.5 30
SOLDIER
37.5 30
COIL PENETRATION
WALL THICKNESS
47.5
47.5
Fig. 5.3A : Wall Tie for Two Sided Shuttering All Members are of Steel WALL TUBES WALL TIE
CHANNEL SOULDIER 2.5 M LONG WALL FORM PANELS A - ASSEMBLY CLIP B - BRIDGE CLIP S - SINGLE CLIP
CHANNEL SOULDIER
D
C
C 1ST POUR
100 STARTER
WALLING TUBE
2ND POUR
3RD & SUBSEQUENT POUR
ELEVATION
Fig. 5.3B : Position of Wall Ties & Walling Tubes (Shuttering for 1st Pour should be properly Strutted by Rakers)
Drawing not to scale All dimensions are in MM
Fig. 5.3 : Typical Fixing Details of Wall Ties 143 | Page HO Civil Specifications Volume - I
175
50 LAP
E
500 500
C G
250
1000
E
50 LA P
C=175 D=1125 E=1250 F=1375 G=2500
175
C
TYPICAL STANDARD UNITS OF FORM WORK (CENTRING & SHUTTERING)
Sub Head : R.C.C. (Form Work) Clause : 5.2.3
A HF
LEDGER TUBE
1000
200
400
1000
200
DETAILS AT A
DETAILS OF H FRAME UNIT
200
1000
B
D
800
1000
KNOCK TO DROP
ADJ. STIRRUP HEAD D
75
C
75
DROP HEAD
3M
All Members are of Steel All dimensions are in MM Drawing not to scale
2M
2.4 M
1.2M
E - VERTICALS (IN DIFFERENT HEIGHTS)
Fig. 5.4 : Typical Standard Units of Form Work 144 | Page HO Civil Specifications Volume - I
TYPICAL COMPONENTS OF FORM WORK Sub Head : R.C.C. (Form Work) Clause : 5.2.3.2
ANGLE TRANSOME
DIAGONAL
TUBULAR TRANSOM/ LEDGER/HANDRAIL
B
A HOP-UP BRACKET
C ADJUSTABLE BASE
ANGLE TIE
E
D SCAFFOLD BOARD
F
FIXED BASE PLATE
H
G CLIP LOCK
SPIGOT LOCK
I
COLLAR-GRIP
J
K
Fig. 5.5 : Typical Components of Form Work
145 | Page HO Civil Specifications Volume - I
TYPICAL ARRANGEMENT OF COLUMN FORM WORK Sub Head : R.C.C. (Form Work) Clause : 5.2.3.2
CORNER ANGLE BRACKET
Fig. 5.6A : Four Sides Adjustable Column Form
CORNER ANGLE BRACKET EXTERNAL CORNER ANGLE
Fig. 5.6B : Two Sides Adjustable Column Form
SINGLE CLIP
TUBE
THROUGH TIE/WIRE TIE
Fig. 5.6C : Column Form with Adjustable Shuttering Wall Form Type Panels All Members are of Steel
Fig. 5.6 : Typical Arrangement of Column Form Work
146 | Page HO Civil Specifications Volume - I
TYPICAL COLUMN SHUTTERING
Sub Head : R.C.C. (Form Work) Clause : 5.2.3.2
All Members are of Steel
Fig. 5.7 : Typical Column Shuttering
147 | Page HO Civil Specifications Volume - I
TYPICAL DETAIL OF BEAM HEAD AND STIFFNER
Sub Head : R.C.C. (Form Work) Clause : 5.2.3.3
BEAM HEAD
A
BEAM HEAD
C
BEAM HEAD PROP ASSEMBLY OF BEAM HEAD OVER PROP B
STIFFNER
VARYING WIDTH 38 MM
10 MM
STIFFNER
FLOOR FORMS (OUT OF 14 GAUGE M.S. SHEET) (ADJUSTER FLOOR FORMS AVAILABLE IN VARIOUS SIZES
PLAN OF FLOOR (SLAB) FORMS
D
E
All Members are of Steel
Fig. 5.8 : Typical Detail of Beam Head and Stiffner
148 | Page HO Civil Specifications Volume - I
TYPICAL DETAILS OF MULTI STAGE SHUTTERING Sub Head : R.C.C. (Form Work) Clause : 5.2.3.4
STEEL CENTRING
BEAM HEAD
SHUTTERING
SUSPENDED FLOOR/SLAB TO BE CAST
PROPS./ VERTICALS
HEIGHT < 3.5 M
HEIGHT< 3.5 M
All Members are of Steel
Fig. 5.9A : Suspended Floor – Multi Stage Shuttering (Vertical Section)
TRANSOM VERTICALS
DIAGONALS
Fig. 5.9B Fig. 5.9 : Typical Details of Multi-State Shuttering 149 | Page HO Civil Specifications Volume - I
DETAILS OF EXPANSION JOINTS (IN VARIOUS LOCATIONS)
Sub Head: R.C.C. Clause : 5.4.5
5 Cm
10 MM WIDE JOINTS
GROOVE AT R.C.C. -MASONRY JUNCTION
Fig. 5.10 : Expansion Joints in Long Sun Shade
R.C.C. COPING
CRAFT PAPER OR BITUMEN PAINTING BRICK TILE
BITUMEN PAINTING LIME TERRACING/MUD PHUSKA
BITUMEN FILLER CEILING P LASTER R.C.C. BEAM
R.C.C. SLAB METAL CRADLE A.C. SHEET
RAWL PLUG & SC REWS WITH OVAL SHAPED SLOT & WASHER RAWL PLUG & SCREWS
Fig. 5.11 : Details of Raised Type Expansion Joint at Roof
150 | Page HO Civil Specifications Volume - I
EXPANSION JOINTS (CONTD.) Sub Head : R.C.C. Clause : 5.4.5 R.C.C. PRECAST TILE 25 MM THICK TO MATCH THE FLOOR FINISH & LAID OVER A COAT OF HOT BITUMEN 12 MM GAP FILLED WITH JOINT FILLER
R.C.C. SLAB METAL CRADLE FILLED UP WITH BITUMEN FILLER (ABOVE) PLASTER R.C.C. BEAM A.C. SHEET RAWL PLUG & SCREWS
RAWL PLUGS & SCREWS WITH OVAL SHAPED SLOT & WASHER
Fig. 5.12 : Typical Details of Expansion Joint at Floor R.C.C. COPING 75 MM THICK C.C. GOLA
BITUMEN FILLER METAL CRADLE 25 MM G AP
THROATING BITUMEN PAINTING BRICK TILES MUD PHUSKA/LIME CONC. R.C.C. SLAB GROOVE BEARING PLASTER WITH A THICK COAT OF LIME WASH OR KRAFT PAPER
Fig. 5.13 : Typical Details of Expansion Joint at Wall & Beam Junction
MASONRY TO BE CONSTRUCTED AFTER PLACING CANTILEVER SLAB C.C. GOLA
BRICK WALL PLASTER R.C.C. CANTILEVER SLAB EMBEDDED IN MASONRY AT ONE END, FREE AT THE OTHER END FLOOR FINISH
SKIRTING
MUD PHUSKA
PLASTER
BITUMEN FILLER METAL CRADLE R.C.C. BEAM 25 MM GAP
R.C.C. SLAB
Fig. 5.14 : Typical Details of Expansion Joint at Roof & Floor Junction
151 | Page HO Civil Specifications Volume - I
EXPANSION JOINTS (CONTD.) Sub Head : R.C.C. Clause : 5.4.5 A. TWIN BEAM WITH TWIN COLUMNS Twin B eams
A
Twin columns 150 Copper cradle for beam External face
A
PLAN
Twin columns
Twin B eams
300
Mud fuska laid to slope
Flooring R.C.C. Slab
R.C.C. Slab
R.C.C. Beam Plaster
12 mm open joint in floor staggered from expansion joint filled with bitumen
D Gap 25
D
Gap 12
25
SECTION A – A ON ROOF
SECTION A – A ON FLOOR
Fig. 5.15 : Twin Beam with Twin Columns B. SLAB & T-BEAM CONSTRUCTION OF LONG LENGTH (T-Beam changed into rectangular beam to provide intermediate expansion joint) 6 mm expansion joint filled with bitumen filler
Flooring R.C.C. Slab
Bitumen felt
Unfilled gap R.C.C. Rectangular Beam
12 mm expansion joint filled with bitumen filler or impregnated f ibre board
T-Beam
Fig. 5.16 : Slab & T-Beam Construction of Long Length C. LONG VERANDAH SLAB A
D. LONG WATER-RESERVOIR SLAB A
12000-13000
A
A
12000-13000
12
12 KEY PLAN
PLAN
Butt joint in floor & slab Flooring R.C.C. Slab Ceiling plaster
Bitumen felt PART SEC. A–A
A B C D E F
Fig. 5.17 : Long Verandah Slab
Hot bitumen painting @ 1.7 k.g/sqm. Bitumen filler Rawl plugs & 50 mm screws @ 300 mm c/c Asbestos sheet 150 mm wide or P.V.C. sheet Rawl plugs & screws with oval shaped slot & washers @ 300 mm c/c Copper cradle
SECTION A – A
Earth filling R.C.C. Slab Plaster 6 mm
Fig. 5.18 : Long Water Reservoir Slab
Drawing not to scale All dimensions are in mm
152 | Page HO Civil Specifications Volume - I
EXPANSION JOINTS (CONTD.) Sub Head : R.C.C. Clause : 5.4.5 RAWL PLUG & SCREW WITH OVAL SHAPED SLOT & WASHER
200 MM ASBESTOS CEMENT FLAT SHEET OR ALUMINIUM PLATE OR SIMILAR MATERIAL RAWL PLUG & SCREW
12 MM GAP
R.C.C. COLUMN INSIDE PLASTER
25 MM GAP
Fig. 5.19 : Typical Details of Expansion Joint Covering on Outer Face of Columns (Plan) STEEL OR ALUMINIUM ANGLE FIXED WITH RAWL PLUG & 50 MM SCREW @ 300 MM C/C 12 MM GAP
BRICK WORK PLASTER
25 MM G AP
R.C.C. COLUMN
Fig. 5.20 : Typical Details of Expansion Joints at Corner Column JOINT FILLER
EXPANDEX BOARD SEALING COMPOUND COLUMN
Fig. 5.21 : Typical Details of Expansion Joint at Isolated Twin Columns REINFORCEMENT
P.V.C. W ATER STOP/BAR
JOINT FILLER DISCONTINUTY IN BOTH CONCRETE & STEEL
Fig. 5.22 : Expansion Joint Subjected to Water Pressure (For water Tanks) 153 | Page HO Civil Specifications Volume - I
EXPANSION JOINTS (CONTD.) Sub Head : R.C.C. Clause : 5.4.5
FLOORING/MUD PHUSKA WITH TILES
BUTT JOINT IN THE FLOOR STAGGERED FROM EXPANSION JOINTS
50 TO 100 UNFILLED GAP AT TOP C R.C.C. SLAB R.C.C. BEAM
BED PLATE
GROOVE
B
GROOVE
A
B
B. INTERMEDIATE WALL WITH FLOOR BEAM
A. END WALL WITH ROOF/ SUSPENDED FLOOR SLAB FLOORING/MUD PHUSKA WITH TILES
BITUMEN FELT 25 TO 40 U NFILLED 300 GAP AT TOP
FLOORING
C R.C.C. SLAB CEILING PLASTER B
GROOVE
GROOVE
A
B
D. INTERMEDIATE WALL WITH FLOOR SLAB
C. END WALL WITH ROOF/ SUSPENDED FLOOR SLAB
MUD PHUSKA COVERED WITH TILES LAID TO SLOPE BRICK LAID WITH VERTICAL JOINT IN MORTAR
C
A
B
SEALING COMPOUND
JOINT FILLER
GROOVE WALL
WALL
PLASTER METAL SHEET
E. INTERMEDIATE WALL WITH ROOF SLAB
25 MM GAP FLAT ASBESTOS CEMENT SHEET OR ANY OTHER EQUALLY S UITABLE MATERIAL 150 MM WIDE
F. EXPANSION JOINT USING JOINT FILLER AND SEALING COMPOUND A B C
12 MM EXPANSION JOINTS FILLED WITH BITUMEN FILLER OR IMPREGNATED FIBRE BOARD 6 MM CEMENT PLASTER 1:3 (1C : 3F. SAND) FINISHED WITH A FLOATING COAT OF NEAT CEMENT AND A THICK COAT OF LIME WASH OR LAID WITH KRAFT PAPER HOT BITUMEN PAINTING @ 1.7 K.G./SQM. IN CASE OF ROOF SLAB/BEAM
C
HOT BITUMEN PAINTING @ 1.7 KG./SQM. BELOW BRICK WALL ONLY ON SUSPENDED FLOOR BEAM/SLAB
Drawing not to scale All dimensions are in mm
Fig. 5.23 : Expansion Joint (Contd.)
154 | Page HO Civil Specifications Volume - I
SEISMIC SEPARATION JOINTS Sub Head : R.C.C. Clause : 5.4.5 SHEET METAL FLASHING
PRE-CAST SLAB/TILES
BITUMEN
RUBBERISED PAD
RECTANGULAR BAR
FLOORING
FLAT BAR SET IN FORMS
R.C.C. SLAB CEILING PLASTER
MASTIC
GAP
GAP
RAWL PLUG WITH OVAL SHAPED SLOT
RAWL PLUG & SCREW
A.C. SHEET
Fig. 5.24: Seismic Separation at Floor Level R.C.C. COPING BITUMEN PAINTING
THROATING C.C. GOLA
LIME TERRACING/MUD FUSKA BRICK TILES
R.C.C. SLAB CEILING PLASTER FILLED UP WITH BITUMEN FILLER METAL CRADLE R.C.C. BEAM GAP
GAP RAWL PLUG & SCREWS
RAWL PLUG WITH OVAL SHAPED SLOT A.C. SHEET
Fig. 5.25 : Seismic Separation Joints Detail at Roof
155 | Page HO Civil Specifications Volume - I
CONSTRUCTION JOINTS Sub Head : R.C.C. Clause : 5.4.4
A. PROHIBITED JOINT IN SLAB (Clause - 5.4.4.3)
E. JOINT IN BEAM OR SLAB
C.C. FLOORING R.C.C. BASE/LEAN CON B. JOINT IN SLAB (STOP BOARD SLOTTED TO TAKE HORIZONTAL REINFORCEMENT)
C. STOP – BOARD
F. JOINT IN FLOORING FOR WATER RESERVOIRS
PLAN G. JOINT IN MONOLITHIC R.C.C. SLAB AND BEAM CONST.
R.C.C. SLAB SECONDARY BEAM D. KEYED JOINTS IN WALLS (WITH STOP-BOARD FITTED WITH 25 X 25 CHAMFER PIECE AND SLOTTED TO TAKE HORIZONTAL BARS) 1
MAIN BEAM H. SECTION A-A
REPRESENTS FIRST PLACING OF CONCRETE
2. REPRESENTS SUBSEQUENT PLACING OF CONCRETE
Drawing not to scale All dimensions are in mm
Fig. 5.26 : Construction Joints
156 | Page HO Civil Specifications Volume - I
ENCASING ROLLED STEEL SECTION Sub Head : R.C.C. Clause : 5.5.2
50
LAP NOT LESS THAN 100
EXPANDED METAL OF UNGALVANIZED WIRE MESH
R.S. JOIST
Fig. 5.27 : Steel Column 5 DIA WIRE HANGER AT 1200 C/C
R.C.C. SLAB
EXPANDED METAL OR UNGALVANIZED WIRE MESH
R.S. JOIST
25 25
Fig. 5.28 : Steel Beam with Slab Normally Cement Concrete 1 : 2 : 4 (1 Cement : 2 Coarse Sand : 4 Graded Stone Aggregate 12.5 Nominal Size) shall be used. Drawing not to scale All dimensions are in mm
157 | Page HO Civil Specifications Volume - I
6.0: Brick Work
158 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
CONTENTS Cla us e No.
P a ge No. 160
Brie f De s cription List of Mandatory Tests List of Bureau of Indian Standard Codes
161
6.0
Terminology
162
6.1
Bricks/ Brick Tiles/ Brick Bats/
164
6.2
Brick Work
169
6.3
Brick Work in Arches
174
6.4
Half Brick Work
176
6.5
Brick Tile Work
176
6.6
Honey Comb Brick Work
176
6.7
Joining Old Brick Work with New Brick Work
176
6.8
Moulding and Cornices
177
6.9
Brick Work under Water and Foul Conditions
178
6.10
Exposed Brick Work - DELETED
178
6.11
Cavity Wall - DELETED
178
6.12
Gypsum Partition Panels
179
6.13
Brick Edging
179
Appendix A
Test for Dimensional Tolerance
180
Appendix B
Test for Compressive Strength
181
Appendix C
Test for Water Absorption
182
Appendix D
Test for Efflorescence
183
Fig. 6.1
Brick Work
184
Fig. 6.2
Brick Pillars
185
Fig. 6.3 & 6.4
Brick Bonds
186
Fig. 6.5
Brick Work in Arches.
188 .
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LIST OF MANDATORY TESTS S l. No.
Ma te ria
Cla us e
(i)
Bricks/ Brick Tiles
6.1.3, 6.1.4, 6.1.5
(ii)
Sewer Bricks
6.1.4
(iii)
Burnt clay perforated building bricks
6.1.5
Te st
Testing of Bricks/Brick Tiles for dimensions, Compressive strength, Water absorption and efflorescence Dimensions, Compressive strength, Water absorption and Efflorescence --do--
Fie ld/ la bora tory Te s t
Te s P roce dure
Laboratory
Appendix A, B, C & D of Chapter 6
Laboratory
Appendix A, B, C & D of Chapter 6
-- do --
-- do--
Minimum Q ty. of ma te ria l for ca rrying out te s t As per Table 6.3 and 6.4
As per Table 6.3 and 6.4
-- do--
.
160 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LIST OF BUREAU OF INDIAN STANDARDS CODES
S . No. 1. 2. 3. 4. 5. 6.
IS . No. IS 712 IS 1077 IS 1200 (Part 3) IS 2212 IS 2222 IS 2849
7. 8. 9. 10. 11. 12. 13.
IS 3495 IS 3812 IS 4139 IS 4885 IS 5454 IS 12894 IS 13757
S ubje ct Specification for building limes. Common burnt clay building bricks. Method of measurements of brick works Code of practice for brick work. (1st Revision) Specification for burnt clay perforated building bricks. Specification for non load bearing gypsum partition blocks, (Solid and hollow types) Method of test for burnt clay building bricks. Specification for fly ash for use as pozzolana and admixture. Specification of calcium silicate bricks Specification for sewer brick Methods of sampling of clay building bricks. Pulverized fuel ash lime bricks specification, Specification of burnt clay fly ash bricks.
.
161 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
6.0 BRICK WORK 6.0. TERMINOLOGY Bond The ar rangement o f t he b ricks in successive c ourses to t ie t he br ick w ork t ogether bot h l ongitudinally and t ransversely. T he arr angement i s usually d esigned to en sure that no v ertical joint of one course is exactly over the one in the next course above or below it, and there is greatest possible amount of lap. Bed Joint Horizontal joint in brick work or masonry. Closer Any p ortion of a brick u sed i n constructing a w all, to close up the bond n ext to t he e nd brick of a course (See Fig. 6.3). Coping or Weathering The cover applied o ver or the geometrical form g iven to a p art o f structure to enable it to shed r ain water. Corbel A cantilever projecting from the face of a wall to form a bearing (see Fig. 6.1D) Cornice Horizontal or ornamental feature projecting from the face of a wall (see Fig. 6.1D) Course A layer of bricks including bed mortar. Cross joint A joint other than a bed joint normal to the wall face. Efflorescence A po wdery i ncrustment o f s alts l eft by e vaporation. T his m ay b e v isible o n the s urface o r m ay b e below surface. In the latter case, this is termed as crypto Efflorescence. Header A brick laid with its length across the wall. Indenting The leaving recesses into which future work can be bonded. Jamb The part of the wall at the side of an opening. Joint A junction of bricks. Jointing The operation of finishing joints as the masonry work proceeds. Pier A t hickened s ection f orming i ntegral pa rt of t he w all pl aced at i ntervals al ong t he wall p rimarily t o increase the s tiffness of the w all or to c arry a v ertical c oncentrated load. T he thickness of a pi er is the over a ll thickness i ncluding the thickness of the w all, or w hen b onded into on e leaf of a c avity w all the thickness obtained by treating this leaf as an independent wall (see Fig. (6.1A, 6.1B)).
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Pillar Pillar m eans a d etached masonry s upport. T his c an be rec tangular, c ircular, el liptical et c. I n c ase of rectangular pillar, the breadth shall not exceed three times the thickness and thickness itself shall not exceed more than thrice the length of brick (See Fig. 6.1C). Quoin An external corner in brick work, the term may also denote the brick used to form the quoin. Scaffolding A temporary erection of timber or steel work used in the construction, alteration, demolition or repairs of a bui lding t o support or to at tend of t he hoisting or l owering of w orkmen, t heir t ools a nd m aterials. Scaffoldings ar e of t wo t ypes, nam ely s ingle and doubl e s caffoldings. S ingle s caffolding c onsists of a row of v erticals c onnected t o w all b y h orizontal s upported o n a nd t ied to t he s tructure. D ouble scaffolding c onsists of t wo r ows of v erticals s ecured or l eashed t ogether w ith hor izontal and di agonal bracings forming essentially a structure independent of the building. It may also connect to the structure at convenient points for the sake of better stability. Sill
A brick work forming the lower boundary of door or window opening (see Fig. 6.1D).
Spandrel The space between the haunches and the road decking of an arch. Strecher A brick laid with its length in the direction of the wall. String course A hor izontal c ourse pr ojecting from a wall u sually i ntroduced at ev ery floor l evel or w indows o r bel ow parapet f or i mparting arc hitectural appe arance t o t he s tructure and al so k eeping of f t he rai n w ater. (s ee Fig. 6.1D). Templet A pattern of sheet metal used as a guide for setting out specific section and shape. Toothing Bricks left projecting in alternate courses to bond with future work. Wall joint A joint parallel to the wall face.
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6.1 BRICKS/BRICK TILES/BRICK BATS Bricks used in the masonry may be of the following type. (a) The Common Burnt Clay Bricks shall conform to IS:1077 and s hall be hand moulded or machine moulded. They shall be free from nodules of free lime, visible cracks, flaws warpage and organic matter, have a frog 100 mm in length 40 mm in width and 10 mm to 20 mm deep on one of its flat sides. Bricks made by extrusion process and brick tiles may not be provided with frogs. Each brick shall be marked (in the frog where provided) with the manufacturer’s identification mark or initials. Sand: Deleterious materials, such a s c lay an d s ilt i n the sand shall pr eferably b e l ess t han 5% . Lime: Lime shall conform to class ‘C’ hydrated lime of IS 712. Additives: Any suitable additive considered not detrimental to the durability of bricks may be used. (b) Calcium Silicate Bricks: The bricks shall conform to IS 4139. The Calcium silicate bricks shall be sound, compact and uniform in shape. Bricks shall be free from visible cracks, warpage, organic matter, large pebbles and nodules of free lime. Bricks shall be solid and with or without frog. The bricks shall be made of finely grounded sand siliceous rock and lime. In addition limited quantity of fly ash conforming to IS 3812 may be used in the mix. These bricks are also known as Fly Ash Sand Lime bricks in the construction industry. (c) Tile Brick: The bricks of 4 cm height shall be moulded without frogs. Where modular tiles are not freely available in the market, the tile bricks of F.P.S. thickness 44 mm (1-3/4") shall be used unless otherwise specified. (d) Brick Bats: Brick bats shall be obtained from well burnt bricks.
6.1.1 Dimensions The brick may be modular or non-modular. Sizes for both types of bricks/tiles shall be as per Table 6.1. W hile use of m odular bri cks/tiles i s recommended, non -modular (FPS) bricks/tiles c an al so be us ed where so s pecified. N on-modular br icks/tiles of s izes other than t he s izes m entioned i n Table 6 .1 m ay also be used where specified. TABLE 6.1 Type of Bricks / Tile s
Nomina l Size mm
Actua l S ize mm
Modular Bricks
200 × 100 × 100 mm
190 × 90 × 90 mm
Modular tile bricks
200 × 100 × 40 mm
190 × 90 × 40 mm
Non-modular tile bricks
229 × 114 × 44 mm
225 × 111 × 44 mm
Non-modular bricks
229 × 114 × 70 mm
225 × 111 × 70 mm
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6.1.2 Classification Bricks/Brick tiles shall be classified on the basis of their minimum compressive strength as given below : TABLE 6.2 Ave ra ge compre s s ive stre ngth Not le s s tha n Le s s tha n N/mm2 (kgf/cm2) N/mm2 (Kgf/cm2) 12.5 (125) 12.5 (125) 15.0 150 10 (100) 10 (100) 12.5 125 (75) 10 100 7.5 (75) 7.5 5 (50) 5 (50) 7.5 75 3.5 (35) 3.5 (35) 5.0 50 The bricks shall have smooth rectangular faces with sharp corner and shall be uniform in colour and emit clear ringing sound when struck. (Note: Upper l imits s pecified i n T able 6. 2 ar e f or calculating the av erage c ompressive s trength i n accordance with Appendix B of Chapter 6). Cla s s De s igna tion
6.1.3 Sampling and Tests Samples of bricks shall be subjected to the following tests : (a) Dimensional tolerance. (b) Water absorption. (c) Efflorescence. (d) Compressive strength. 6.1.3.1 Sampling: For carrying out compressive strength, water absorption, efflorescence and dimensional tests, t he s amples of br icks s hall be taken at r andom ac cording to t he size o f l ot as gi ven i n Table 6 .3 be low. T he s ample thus taken s hall be stored in a d ry place u ntil tests ar e m ade. F or the purpose of sampling, the following definition shall apply. (a) Lot: A collection of bricks of same class and size, manufactured under relatively similar conditions of production. For the purpose of sampling a lot shall contain a maximum, of 50,000 bricks. In case a consignment has bricks more than 50,000 of the same classification and size and manufactured under relatively similar conditions of production, it shall be divided into lots of 50,000 bricks or part thereof. (b) S a mple : A c ollection o f bricks selected for ins pection and/or tes ting from a lot to reac h the decision regarding the acceptance or rejection of the lot. (c) De fe ctive : A brick failing to meet one or more of the specified requirements. 6.1.3.2 The samples shall be taken as below: (i) Sampling from a Stack: When it is necessary to take a sample from a stack, the stack shall be divided into a number of real or imaginary sections and the required number of bricks drawn from each section. For this purpose bricks in the upper layers of the stack shall be removed to enable units to be sampled from places within the stack. Note: For other methods of sampling i.e. sampling in motion and sampling from lorries or trucks, IS :5454 may be referred. Scale of sampling and criteria for conformity for visual and dimensional characteristics:— Visual characteristics: The br icks s hall be s elected and i nspected f or as certaining t heir conformity to the requirements of the relevant specification.
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The number of bricks to be selected from a lot shall depend on the size of lot and shall be in accordance of C ol. 1 and 2 of T able 6. 3 f or v isual c haracteristics i n al l cases and di mensional characteristics if specified for individual bricks. (ii) Visual Characteristics: All the bricks selected above in accordance with Col. 1 and 2 of Table 6.3 s hall be examined f or v isual c haracteristics. I f t he num ber of d efective br icks f ound i n t he sample is less than or equal to the corresponding number as specified in Col. 3 of Table 6.3 the lot shall be considered as satisfying the requirements of visual characteristics, otherwise the lot shall be deemed as not having met the visual requirements. (iii) Dimensional Characteristics: The number of bricks to be selected for inspecting the dimensions and tolerance shall be in accordance with Col. 1 and 4 of Table 6.3. These bricks will be divided into groups of 20 bricks at random and each of the group of 20 bricks thus formed will be tested for all the dimensions and tolerances. A lot shall be considered having found meeting the requirements of dimensions and tolerance if none of the groups of bricks inspected fails to meet the specified requirements. TABLE 6.3 Scale of Sampling and Permissible Number of Defectives for Visual and Dimensional Characteristics No. of bricks in the lot
(1) 10001—35000
For cha ra cte ris tics s pe cifie d for individua l b rick No. of P e rmis s ible no.of defe ctive bricks to be s e le cte d in the sa mple (2) (3) 20 1
35001—50000
32
For dime ns iona l cha ra cte ris tics for group of 20 bricks No. of bricks to be s e le cte d (4) 40
2
60
Note: In case the lot contains 10000 or less bricks the sampling shall be as per decision of the Engineer-in-Charge. (iv) Scale of Sampling and Criteria for Physical Characteristics: The lot which has been found satisfactory in respect of visual and dimensional requirements shall be next tested for physical characteristics like compressive strength, water absorption, efflorescence as specified in relevant material specification. The bricks for this purpose shall be taken at random from those already selected above. The number of bricks to be selected for each of these characteristics shall be in accordance with relevant columns of Table 6.4. TABLE 6.4 Scale of Sampling for Physical Characteristics Lot s ize (1) 10001—35000 35001—50000
S a mple size for compre s P e rmis s ible No. s ive stre ngth, wa te r of d e fe ctive s a bs orption and efflore s ce nce for e fflore s ce nce (2) (3) 5 0 10 1
S a mple S ize (4) 10 20
Wa rpa ge
P e rmis s ible No of defe cts (5) 0 1
Note: In case the lot contains 10000 or less bricks, the sampling shall be as per decision of Engineer-in-Charge.
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(v) A lot s hall be considered ha ving s atisfied the requirements of phy sical characteristics i f the condition stipulated here in are all satisfied. (a) From the test results for compressive strength, the average shall be calculated and shall satisfy the requirements specified in relevant material specification. Note: In case any of the test results for compressive strength exceeds the upper limit for the class of bricks, the same shall be limited to the upper limit of the class for the purpose of averaging. (b) Wherever specified in the material specification, the compressive strength of any individual bricks tested in the sample shall not fall below the minimum average compressive strength specified for the corresponding class of brick by more than 20 per cent. (c) From the test results for water absorption, the average for the bricks in the sample shall be calculated and shall satisfy the relevant requirements specification in material specification. (d) The number of b ricks failing t o satisfy t he re quirements o f t he ef florescence s pecified i n t he relevant specification should not be more than the permissible no. of defectives given in Col. 3 of Table 6.4. 6.1.3.3 Dimensional Tolerances: The dimensions of, modular bricks when tested as described above as per procedure described in Appendix A of Chapter 6 shall be within the following limits per 20 bricks or locally available size as approved by Engineer-in-charge. (a) For modular size Length 7320 t o 3 880 m m ( 3800 ± 80 m m) Width 1760 to 1840 mm (1800 ± 40 mm) Height 17 60 t o 1 840 m m ( 1800 ± 40 m m) for 90 mm hi gh br icks 760 to 840 mm (800 ± 40 mm) for 40 mm high bricks (b) For non modular bricks Length 4520 t o 4 680 m m ( 4600 ± 80 m m) Width 2240 to 2160 mm (2200 ± 40 cm) Height 14 40 t o 1 360 m m ( 1400 ± 40 m m) for 70 mm hi gh br icks 640 to 560 mm (600 ± 40 mm) for 30 mm high bricks Brick Tiles 760 to 840 mm (800 ± 40 mm) for 40 mm high brick tiles In case of n on-modular bricks, % a ge tolerance will be ± 2% for g roup of 2 0 nu mbers of class 10 bricks, and ± 4% for other class of bricks. 6.1.3.4 Compressive Strength: The bri cks, w hen tested i n ac cordance w ith t he procedure l aid dow n in Appendix B of C hapter 6 s hall hav e a m inimum av erage c ompressive s trength f or v arious c lasses as given in T able 6. 2. T he c ompressive strength of a ny i ndividual bri ck t ested shall not f all be low t he m in. average c ompressive strength s pecified f or t he c orresponding c lass of brick by m ore t han 20%. I n c ase compressive strength of any individual brick tested exceeds the upper limit specified in Table 6.2 for the corresponding class of bricks, the same shall be limited to upper limit of the class as specified in Table 6.2 for the purpose of calculating the average compressive strength. 6.1.3.5 Water Absorption: The average water absorption of bricks when tested in accordance with the procedure laid down in Appendix C of Chapter 6 shall be not more than 20% by weight. 6.1.3.6 Efflorescence: The rating of efflorescence of bricks when tested in accordance with the procedure laid down in Appendix D of Chapter 6 shall be not more than moderate. 6.1.4 Sewer Bricks 6.1.4.1 Sewer bricks are intended for the lining of walls, roofs and floors of sewers used for ordinary sanitary (domestic) sewage. The general practice in the country is also to utilize common building bricks
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in the construction of sewers which is not satisfactory. However, these sewer bricks may not be suitable for sewers dealing with industrial effluent (sewage) for which the use of acid resistant bricks in accordance with IS 4860 may be considered. Sewer bricks shall conform to IS 4885. 6.1.4.2 Dimensions and Tolerances Dimensions: The standard sizes of the sewer bricks shall be as follows:
Le ngth Width He ight mm mm mm 190 90 90 190 90 40 For sewers of special shapes, such as the oval sewers, the bricks may have to be suitable tapered to conform to the radii of curvature of the arches and barrels and sides of sewers. Tolerance: The permissible tolerance on the dimensions specified in 6.1.4.2 shall be as follows : Dime ns ions
Tota l tole ra nce for 20 bricks mm mm 190 + 80 90 + 40 40 + 40 6.1.4.3 Compressive Strength: The average compressive strength obtained on a sample of sewer bricks when tested in accordance with the procedure laid down in IS 3495 (Part I) shall be not less than 17.5 N/mm2 (175 kgf/cm2 approximately) and the individual strength of any brick shall be not less than 16 N/mm2 (160 kgf/cm2 approximately). 6.1.4.4 Water Absorption: The a verage value of water a bsorption for five bricks after 24 h cold water immersion test w hen tested in ac cordance with IS 3 495 (Part 2) s hall not ex ceed 10 per c ent of the average dry weight of the brick and the absorption for any individual brick shall not exceed 12 per cent. 6.1.4.5 Efflorescence: When the bricks are tested in accordance with the method laid down in IS 3495 (Part 3), the rating of efflorescence shall not be more than ‘slight’. 6.1.5 Burnt Clay Perforated Building Bricks 6.1.5.1 General Quality: The bricks shall be made of suitable clay and shall be thoroughly burnt at the maturing temperature of clay. T hey shall be free f rom c racks, flaws and nodules of f ree l ime. They s hall have re ctangular face w ith s harp straight e dge at right ang le. T hey s hall be of uni form c olour and texture. These bricks generally should conform to IS 2222. 6.1.5.2 Dimensions and Tolerances: The s tandard size o f burnt c lay perforated bricks s hall be as follows: Le ngth (L) mm
Width (W) mm
He ight (H) mm
Modular
190
90
90
Non Modular
230
110
70
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The permissible tolerances on the dimensions shall be as follows:
Dime ns ion mm
Tole ra nce mm +4 +7
70, 90 110, 190
230 + 10 Note: The tolerances specified above shall apply to measurements on individual bricks. 6.1.5.3 Perforations: The area of perforation shall be between 30% and 45% of the total area of the corresponding face of the bricks. The pe rforation s hall b e uni formly di stributed over the surface. In t he c ase of rectangular perforations, the larger dimension shall be parallel to the longer side of the brick. The shorter side of the perforation shall be less than 20 mm in c ase of rectangular perforations and less than 25 mm diameter in case of circular perforations. The area of each perforation shall not exceed 500 mm2. The thickness of any shell shall not be less then 15 mm and that of any web not less than 10 mm. 6.1.5.4 Compressive Strength: The bri cks w hen t ested in a ccordance w ith the procedure laid dow n in IS 3495 (Parts 1 to 4) shall have a minimum average compressive strength of 7 N/ mm2 on net area. The c ompressive strength of any i ndividual brick t ested shall not f all bel ow t he minimum compressive strength specified f or the corresponding c lass of bri cks. The lot s hall t hen be c hecked f or next lower class of brick. 6.1.5.5 Water Absorption: The bricks when tested in accordance with the procedure laid down in IS 3495 (parts 1 to 4): after immersion in cold water for 24 hours water absorption shall not be more than 20 percent by weight. 6.1.5.6 Efflorescence: The bri cks when t ested i n accordance w ith t he proc edure l aid do wn i n I S 349 5 (Parts 1 to 4) shall have a rating of efflorescence not more than ‘slight’. 6.1.5.7 Warpage: The bricks when tested in accordance with the procedure laid down in IS 3495 (parts 1 to 4) the average warpage shall not exceed 3%. 6.2 BRICK WORK 6.2.1 Classification The brick work shall be classified according to the class designation of bricks used. 6.2.2 Mortar The m ortar for the bri ck w ork s hall be as s pecified, an d c onform to accepted s tandards. Li me s hall not be used where reinforcement is provided in brick work. 6.2.3 Soaking of Bricks Bricks s hall be s oaked in w ater be fore us e for a period for the w ater to just pe netrate the w hole depth of t he bri cks. Alternatively bri cks m ay be ade quately s oaked i n s tacks by prof usely s praying w ith clean water at regular intervals for a period not less than six hours. The bricks required for masonry work .
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using mud mortar shall not be s oaked. When the bricks are s oaked they shall be re moved from the tank sufficiently ear ly s o that a t the t ime o f laying they are s kin-dry. S uch s oaked b ricks shall be stacked on a clean place where they are not again spoiled by dirt earth etc. Note I: The period of soaking may be easily found at site by a field test in which the bricks are soaked i n w ater for different per iods a nd then br oken t o find the ex tent of w ater p enetration. The least period that corresponds to complete soaking will be the one to be allowed for in construction work. Note II : If the bricks are soaked for the required time in water that is frequently changed the soluble salt in the bricks will be leached out, and subsequently efflorescence will be reduced. 6.2.4 Laying 6.2.4.1 Bricks shall be laid in English Bond (Fig. 6.2, 6.3, 6.4) unless otherwise specified. For brick work in half brick w all, b ricks s hall b e l aid i n stretcher b ond. H alf or c ut bricks shall not b e used e xcept as closer where necessary t o c omplete t he bo nd. Closers i n s uch cases, s hall be cut t o t he r equired s ize and used near the ends of the wall. Header bond shall be used preferably in all courses in curved plan for ensuring better alignment. Note: Header bond s hall also be us ed in foundation footings un less thickness of w alls ( width of footing) m akes t he us e of headers i mpracticable. W here t hickness of f ooting i s uni form f or a num ber of courses, the top course of footing shall be headers. 6.2.4.2 All loose materials, dirt and set lumps of mortar which may be lying over the surface on which brick work is to be freshly started, shall be removed with a wire brush and s urface wetted. Bricks shall be laid on a full bed of mortar, w hen laying, eac h brick shall, b e p roperly bedd ed and s et in position by gently pressing with the handle of a trowel. Its inside face shall be buttered with mortar before the next brick is laid and pressed against it. Joints shall be fully filled and packed with mortar such that no hollow space are left inside the joints. 6.2.4.3 The walls shall be taken up truly in plumb or true to the required batter where specified. All courses shall be l aid t ruly horizontal and al l vertical j oints s hall b e t ruly vertical. Vertical j oints i n t he alternate c ourse s hall c ome di rectly one ov er the ot her. Q uoin, J ambs and ot her angl es s hall be properly plumbed as the work proceeds. Care shall be taken to keep the perpends properly aligned within following maximum permissible tolerances : (a) Deviation from vertical within a storey shall not exceed 6 mm per 3 m height. (b) Deviation in verticality in total height of any wall of building more than one storey in height shall not exceed 12.5 mm. (c) Deviation from position shown on plan of any brick work shall not exceed 12.5 mm. (d) R elative di splacement bet ween l oad be aring wall i n a djacent st oreys i ntended t o be vertical alignments shall not exceed 6 mm. (e) A set of tools comprising of wooden straight edge, masonic spirit levels, square, 1 metre rule line and plumb shall be kept on the site of work for every 3 masons for proper check during the progress of work. 6.2.4.4 All quoins shall be accurately constructed and the height of brick courses shall be kept uniform. This w ill be ch ecked using gr aduated w ooden straight edge or sto rey rod indicating hei ght of ea ch course i ncluding t hickness o f joints. T he position of damp proof co urse, w indow si lls, b ottom of lintels, top of the wall etc. along the height of the wall shall be m arked on the graduated straight edge or storey rod. A cute and obt use q uoins s hall be bonded, w here pr acticable i n t he s ame w ay as s quare quoi ns. Obtuse quoi ns shall be formed with squint showing t hree quar ters br ick on on e face and quarter br ick on the other.
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6.2.4.5 The brick work shall be built in uniform layers. No part of the wall during its construction shall rise more than one metre above the general construction level. Parts of wall left at different levels shall be raked back at an angle of 45 degrees or less with the horizontal. Toothing shall not be permitted as an alternative to raking back. For half brick partition to be keyed into main walls, indents shall be left in the main walls. 6.2.4.6 All pipe fittings a nd specials, spouts, h old fasts an d other fixtures which are re quired to be bu ilt into t he w alls s hall b e e mbedded, as specified, i n t heir c orrect po sition as t he work p roceeds unless otherwise directed by the Engineer-in-Charge. 6.2.4.7 Top courses of all plinths, parapets, steps and top of walls below floor and roof slabs shall be laid with brick on ed ge, u nless s pecified ot herwise. B rick on ed ge laid i n the t op courses at corner of w alls shall be p roperly r adiated and keyed i nto pos ition t o form c ut (maru) c orners as shown i n Fig 6. 4. Where bricks cannot be cut to the required shape to form cut (maru) corners, cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 gr aded stone aggregate 20 m m nom inal size) equal to thickness of course shall be provided in lieu of cut bricks. 6.2.4.8 Bricks shall be laid with frog (where provided) up. However, when top course is exposed, bricks shall b e laid with frog d own. F or the br icks to b e laid with frog d own, the frog shall b e filled with mortar before placing the brick in position. 6.2.4.9 In case of walls one brick thick and under, one face shall be kept even and in proper plane, while the other face may be slightly rou gh. In case of walls more than o ne brick thick, both the faces shall b e kept even and in proper plane. 6.2.4.10 To facilitate taking s ervice lines later without ex cessive c utting of completed w ork, sleeves (to be paid separately) shall be provided, where specified, while raising the brick work. Such sleeves in external walls shall be sloped down outward so as to avoid passage of water inside. 6.2.4.11 Top of the b rickwork in c oping a nd sills in external w alls s hall b e slightly tilted. Where b rick coping a nd s ills are proj ecting be yond t he f ace of t he w all, dri p c ourse/throating (t o be pai d separately) shall be provided where indicated. 6.2.4.12 Care shall be taken during construction that edges of jambs, sills and projections are not damaged in case of rain. New built work shall be covered with gunny bags or tarpaulin so as to prevent the mortar f rom be ing w ashed a way. D amage, if any, s hall be made g ood to the satisfaction of th e Engineer-in-Charge. 6.2.4.13 Vertical reinforcement in the form of bars (MS or high strength deformed bars or thermo mechanically treated bar s a s per di rection o f E ngineer-in-Charge)), c onsidered nec essary at the c orners and j unction of w alls and j amb openi ng doors, windows et c. s hall be enc ased w ith c ement mortar not leaner t han 1:4 (1 c ement : 4 c oarse s and), o r cement concrete mix as s pecified. The reinforcement shall be s uitably tied, pr operly em bedded in the foundation and at roof l evel. The dia. of bars shall not be less than 8 m m and c oncrete grade shall be m inimum 1:3:6 (1 cement : 3 c oarse sand : 6 g raded stone aggregate 20 mm nominal size). 6.2.4.14 In retaining walls and t he like, where water is likely to accumulate, weep holes, 50 t o 75 mm square s hall be provided at 2 m v ertically and horizontally u nless otherwise specified. The l owest weep hole shall be at about 30 cm above the ground level. All weep hol es shall be surrounded by loose stones and shall have sufficient fall to drain out the water quickly. Note : Work of providing loose stone will be payable extra.
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6.2.4.15 Work of cutting chases, wherever required to be made in the walls for housing G.I. pipe, CI pipe or any other fixtures shall be carried out in various locations as per guidelines given below : (a) Cutting of chases in one brick thick and above load bearing walls. (i) As far as possible s ervices s hould be pl anned with the hel p of vertical c hases. H orizontal chases should be avoided. (ii) T he depths of vertical c hases and hori zontal chases shall not exceed one-third a nd o ne-sixth of the thickness of the masonry respectively. (iii) W hen na rrow stretches o f masonry ( or short length o f walls) s uch as be tween door s and windows, cannot be avoided they should not be pierced with openings for soil pipes or waste pipes or timber joints, etc. Where there is a possibility of load concentration such narrow lengths of walls s hall b e checked f or stresses an d hi gh s trength bricks i n mortar or c oncrete walls provided, if required. (iv) H orizontal c hases w hen u navoidable should be located in the upper or lower one-third of height of storey and not more than three chases should be permitted in any stretch of a wall. No c ontinuous hor izontal chase s hall ex ceed o ne m etre in leng th. W here unav oidable, stresses in the affected area should be checked and kept within the permissible limits. (v) Vertical chases should not be closer than 2 m in any stretch of a wall. These shall be kept away from bear ings o f be ams and l intels. If unav oidable, s tresses i n t he a ffected ar ea should be checked and kept within permissible limits. (vi) Masonry directly above a recess, if wider than 30 cm horizontal dimension) should be supported o n lintel. Holes in m asonry m ay be pr ovided u pto 30 c m w idth and 30 c m height without any lintel. In the case of circular holes in the masonry, no lintel need be provided for holes upto 40 cm in diameter. (b) Cutting of chases in half brick load bearing walls. No chase shall be permitted in half brick load bearing walls and as such no recessed conduits and concealed pipes shall be provided with half brick thick load bearing walls. (c) Cutting of chases in half brick non-load bearing wall : Services should be pl anned with the hel p o f v ertical chases. H orizontal c hase should be p rovided only when unavoidable. 6.2.5 Joints The t hickness of al l t ypes of j oints i ncluding bri ck w all j oints and c ross j oints s hall be s uch t hat f our course and three joints taken consecutively shall measure as follows: (i) I n c ase of m odular b ricks c onforming t o I S 1077 s pecification f or c ommon burnt c lay bui ldings bricks, equal to 39 cm. (ii) In case of non-modular bricks, it shall be equal to 31 cm. Note : Specified t hickness of j oints s hall b e of 1 c m. D eviation f rom t he specified t hickness of al l joints shall not exceed one-fifth of specified thickness. 6.2.5.1 Finishing of Joints: The face of brick work may be f inished flush or by pointing. In flush finishing either the face joints of the mortar shall be worked out while still green t o give a finished surface flush with the face of the brick work or the joints shall be s quarely raked out to a d epth of 1 cm while the mortar is still green for subsequently plastering. The faces of brick work shall be cleaned with wire brush so as to remove any splashes of mortar during the course of raising the brick work. In pointing, the joints shall be squarely raked out to a depth of 1.5 cm while the mortar is still green and raked joints shall be brushed to remove dust and loose particles and well wetted, and shall be later refilled with mortar to give ruled finish. Some such finishes are ‘flush’, ‘weathered’, ruled, etc. 6.2.6 Curing The brick work shall be c onstantly kept moist on al l faces for a m inimum period of seven days. Brick work done during the day shall be suitably marked indicating the date on which the work is done so as to keep a watch on the curing period.
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6.2.7 Scaffolding Scaffolding s hall be s trong to w ithstand al l de ad, live a nd i mpact l oads w hich are l ikely to come on them. Scaffolding shall be provided to allow easy approach to every part of the work. 6.2.7.1 Single Scaffolding: Where plastering, p ointing or a ny ot her f inishing has been i ndicated f or brick work, single scaffolding may be provided, unless otherwise specified. In single scaffolding, one end of the put-logs/pole shall rest in the hole provided in the header course of brick masonry. Not more than one header for each put-log/pole shall be l eft out. Such holes shall not be allowed in the case of pillars, brick work l ess t han o ne m etre i n l ength bet ween t he op enings o r ne ar t he s kew ba cks of a rches or immediately under or ne ar t he s tructural m ember s upported by t he w alls. T he hol es f or put logs/poles shall be made good with brick work and wall finishing as specified. 6.2.7.2 Double Scaffolding: Where the brick work or tile work is to be exposed and not to be finished with plastering etc. double scaffolding having two independent supports, clear of the work, shall be provided. 6.2.8 Measurements 6.2.8.1 Brick work shall be measured in cubic metres unless otherwise specified. Any extra work over the specified dimensions shall be ignored. Dimensions shall be measured correct to the nearest 0.01 m i.e. 1 cm. Areas shall be calculated to the nearest 0.01 sq mtrs and the cubic contents shall be worked out to the nearest 0.01 cubic metres. 6.2.8.2 Brick work shall be measured separately in the following stages: (a) From foundation to floor one level (Plinth level) (b) Plinth (floor one) level to floor two level (c) Between two specified floor levels above floor two level Note : (i) Brick work in parapet walls, mumty, lift machine room and water tanks constructed on the roof up to 1.2 m height a bove roof s hall be m easured together w ith the corresponding w ork of t he f loor next below. 6.2.8.3 No deductions or additions shall be done and no extra payment made for the following : Note : Where m inimum area is de fined f or deduction of an o pening, v oid or both, s uch ar eas s hall refer only to opening or void within the space measured. (a) E nds of di ssimilar materials (t hat i s, j oists, bea ms, l intels, pos ts, gi rders, raf ters, purl ins, t russes, corbels, steps, etc.); up to 0.1 m2 in section; (b) Opening up to 0.1 m2 in area (see Note); (c) W all plates, be d p lates, a nd bea ring of s labs, Chajjas and t he like, where t hickness does not exceed 10 cm and bearing does not extend over the full thickness of wall; (d) Cement concrete blocks as for hold fasts and holding down bolts; (e) Iron fixtures, such a s wall ties, pipes upto 3 00 m m diameter and ho ld fasts for doors and windows; and (f) Chases of section not exceeding 50 cm in girth. (g) Bearing portion of drip course, bearing of moulding and cornice. Note : In calculating area of an openi ng, any separate lintel or s ills shall be i ncluded with the size of the opening but end portions of lintel shall be excluded. Extra width of rebated reveals, if any, shall also be excluded. 6.2.8.4 Walls half bri ck thic k and less shall each be measured separately in square metres stating thickness.
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6.2.8.5 Walls be yond ha lf brick t hickness s hall be m easured i n m ultiples of hal f brick w hich s hall be deemed t o be i nclusive o f m ortar j oints. F or t he s izes of br icks s pecified i n 6. 1.1, hal f br ick t hickness shall mean 100 mm for modular and 115 mm for non-modular bricks. Where fractions of half brick occur due to architectural or other reasons, measurement shall be as follows : (a) upto 1/4th brick-actual measurements and (b) exceeding 1/4 brick-full half bricks. 6.2.8.6 String courses, p rojecting pilasters, aprons, sills and ot her projections shall be f ully described and measured separately in running metres stating dimensions of each projection. 6.2.8.7 Square or rectangular pillars shall be measured separately in cubic metres in multiple of half brick. 6.2.8.8 Circular pillars shall be measured separately in cubic metres as per actual dimensions. 6.2.8.9 Brick work curved on plan shall be measured like the brick work in straight walls and shall include al l cutting a nd w astage of bricks, t apered v ertical j oints a nd u se of ex tra mortar, i f a ny. Brick work curved on plan to a mean radius not exceeding six metres shall be m easured separately and extra shall be pa yable over the r ates for brick work in straight walls. N othing extra shall be payable if the mean radius of the brick work curved in plan exceeds six metres. 6.2.8.10 Tapered w alls s hall be m easured n et as walls and ex tra p ayment shall be al lowed f or m aking tapered surface for brick work in walls. 6.2.8.11 Brick work with brick tiles shall be measured and paid for separately. 6.2.9 Rate The r ate s hall i nclude t he cost of materials and labour r equired f or al l t he op erations des cribed a bove except t he v ertical r einforcement and i ts enc asement i n c ement m ortar or cement c oncrete. T he r ate shall also include the following : (a) Raking out joints or finishing joints flush as the work proceeds; (b) Preparing tops of existing walls and the like for raising further new brick work. (c) Rough cutting and waste for forming gables, splays at eaves and the like. (d) Leaving holes for pipes upto 150 mm dia. and encasing hold fasts etc. (e) Rough cutting and waste for brick work curved in plan a nd for ba cking to stone or o ther types o f facing. (f) Embedding in ends of beams, joists, slabs, lintels, sills, trusses etc. (g) Bedding wall plates, lintels, sills, roof tiles, corrugated sheets, etc. in or on walls if not covered in respective items and (h) Leaving chases of section not exceeding 50 cm in girth or 350 sq cm in cross-section. (i) Brick on edge courses, cut brick corners, splays reveals, cavity walls, brick works curved on plan to a mean radius exceeding six metres. 6.3 BRICK WORK IN ARCHES (FIG. 6.5) 6.3.0 The detailed specifications for brick work mentioned in 6.2 shall a pply, in so far as these are applicable. Arch work shall include masonry for both gauged as well as plain arches. In gauged arches, cut or moulded bricks shall be used. In plain arches, uncut bricks shall be used. Brick for ming sk ew-backs sha ll be dr essed or cu t so as to gi ve pr oper ra dial be aring t o the e nd voussiors. D efects i n dressing of bricks s hall not be c overed by extravagant use of mortar, nor s hall the use of chips or bats etc. be permitted.
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The bricks of the spandrel wall at their junctions with the extrudes of the arch shall be cut to fit the curvature of the arch. 6.3.1 Circular Arches These s hall b e e ither ( a) plain ar ches, and s hall be bu ilt in ha lf brick c oncentric rings w ith br eak joints, or (b) gauged arches built with bricks cut or moulded to proper shape. The arch work shall be carried up f rom both ends s imultaneously and k eyed i n t he c entre. The bricks s hall be f lush w ith mortar and well pressed into their positions so as to squeeze out a part of their mortar and leave the joints thin and c ompact. A ll joints s hall be full of mortar and thickness of joints s hall not be less than 5 m m n or more than 15 mm. After t he arch i s c ompleted, t he haunches s hall be l oaded by f illing up t he s pandrels upt o t he crown level of the arch. Care shall be taken to load the haunches on two sides of the spandrels. When the arch face is to be pointed (and not plastered), the face bricks shall be cut to proper shape or moulded, so as to have the joints not more than 5 mm thick. These shall be laid with radial joints to the full depth of the arch. The voussoirs shall break joints to the full depth of the arch. 6.3.2 Flat Arches These shall be gauged arches of brick cut or moulded to proper shape. The extrados shall be kept horizontal and the intrados shall b e g iven slight camber of 1 in 1 00 of the span. The centre o f the arch from w hich joi nts shall r adiate, sh all be d etermined b y th e p oint of th e in ter-section of t he two lines drawn from the ends of the arch at the springing level and at 60° to horizontal. In flat arches, bricks shall be l aid with radial joints to the full depth of arch and v oussoirs breaking joints with each ot her. The arch work shall be carried up from both ends simultaneously a nd keyed in the centre. The thickness of the joints shall not exceed 5 mm. Flat arches may be used for the sake of appearance but for purpose of carrying loads of the wall above, these shall be used in conjunction with relieving arches, lintels placed below. 6.3.3 Centring and Shuttering The c entring and s huttering f or t he arch shall be got approved by t he E ngineer-in-Charge before the arch work is started. It s hall be strong e nough to b ear the d ead load of the ar ch a nd the live loads that are likely to come upon it during construction, without any appreciable deflections. The shuttering shall be t ightened w ith hard wood wedged or s and boxes, so that t he s ame c ould be eased w ithout j erks bei ng t ransmitted t o t he arch. The s equence of eas ing the s huttering s hall be g ot approved f rom t he E ngineer-in-Charge. The s huttering s hall be s truck w ithin 48 hou rs of t he c ompletion of the arch but not before 24 hours. This shall be do ne after the spandrel has been filled in and t he arch loaded. 6.3.4 Measurements The length o f th e ar ch shall be measured as t he mean of th e e xtrados and i ntrados o f th e a rch correct to a cm. The thickness of the arch shall be measured in multiples of the half brick. The breadth in the direction of the thickness of wall shall be measured as specified. The cubical contents shall be calculated in cubic metre, correct to two places of decimal. For arches exceeding 6 m in spans extra payment shall be made on the actual area of the soffit for additional cost of centring including all strutting, bolting, wedging, easing, striking and its removal. 6.3.5 Rate The rate is inclusive of the cost of the materials and labour required for all the operations described above.
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6.4 HALF BRICK WORK Brick work in half brick walls shall be done in the same manner as described above in 6.2.4 except that the bricks shall be laid in stretcher bond. When the half brick work is to be reinforced, 2 Nos. M.S. bars of 6 mm dia., s hall be embedded i n every third course as gi ven i n the item (the di a of bar s shall not exceed 8 mm). These shall be s ecurely a nchored at their end where t he par titions end. The free ends of the reinforcement shall be keyed into the m ortar of the main brick work to which the half brick work is joined. Lime mortar shall not be us ed. O ver l aps i n reinforcement, i f an y s hall not be less than 30 cm. The m ortar i nterposed bet ween t he reinforcement bars and t he brick s hall not be l ess t han 5 m m. The mortar covering in the direction of joints shall not be less than 15 mm. 6.4.1 Measurements The length and height of the wall shall be measured correct to a cm. The area shall be calculated in sq.m. where h alf brick wall is joined to the m ain w alls o f o ne brick or greater thickness and measurements for half brick wall shall be taken for its clear length from the face of the thicker wall. 6.4.2 Rate The rate includes the cost of the materials and labour involved in all the operations described above except reinforcement which is to be paid for separately. 6.5 BRICK TILE WORK 6.5.0 The work shall be done in the same manner as described in 6.2.4 except that brick tile shall be used instead of bricks. The measurement and rate shall be same as specified under 6.2. 6.6 HONEY COMB BRICK WORK The honey comb br ick w ork s hall be done w ith s pecified c lass o f br ick, l aid i n s pecified mortar. A ll joints and edges shall be struck flush to give an even surface. The thickness of the brick honeycomb work shall be half-brick only, unless otherwise specified. Openings shall be equal and alternate with half brick laid with a bearing of 2 cm on either side. 6.6.1 Measurements The length and height shall be measured c orrect to a c m. A rea s hall be c alculated in s quare m etres correct to two places of decimal. Honeycomb openings shall not be deducted. 6.6.2 Rate The rate includes the cost of materials and labour involved in all the operations described above. 6.7 JOINING OLD BRICK WORK WITH NEW BRICK WORK 6.7.1 In case the height of the bricks of old as well as new work is same, the old work shall be toothed to the full width of the new wall and to the depth of a quarter of brick in alternate courses. In case the height of the bricks is unequal, then the h eight of each course of new work shall be made equal to the height of the old work by adjusting thickness of horizontal mortar joints in the new wall. Where necessary, adjustment shall be made equal to thickness of old wall by adjusting the thickness of vertical joints. 6.7.2 For joining new cross wall to old main walls, a number of rectangular recesses of width equal to the thickness of cross wall, three courses in height and half a brick in depth shall be cut in the main
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walls. A space of the three courses shall be left between two consecutive recesses. The new cross wall shall be bonded into the recesses to avoid any settlement. 6.7.3 Joining of old brick work with the new brick work shall be done in such a way that there shall not be any hump or projection at the joint. 6.7.4 Measurement The height and thickness of vertical face in contact with new work shall be measured to the nearest 0.01 m and the area shall be calculated to the nearest 0.01 sqm. 6.7.5 Rate The rate includes the cost of labour and material involved in all the operations described above. 6.8 MOULDING AND CORNICES 6.8.0 The s pecifications described under 6.2 shall apply in so far these are applicable. Mouldings and cornices shall be made with br icks as s pecified for brick work. The bricks shall be cut and dressed to the required shape as shown in the architectural drawings. 6.8.1 Cornices s hall not ordinarily project b y m ore than 15 c m to 20 c m and this projection s hall be obtained b y proj ecting e ach bri ck course b y m ore t han one f ourth o f t he l ength. F or c ornices proj ecting more t han 20 c m and r equiring more than quar ter br icks projection, metal cramps shall be u sed and pai d for separately. 6.8.2 Corbelling shall be b rought roughly to shape by pl astering with the specified m ortar. When the mortar is still green, the mouldings shall be finished straight and true with the help of metal templates. 6.8.3 Curing and Protection The m ouldings and c ornices shall b e c ured f or a t l east s even d ays. T hese s hall b e pr otected f rom the effects of sun and rain by suitable covering and also from damage during the execution of the work. 6.8.4 Measurements For t he pur pose of measurements, t he s ectional p eriphery of m ouldings a nd c ornices (e xcluding t he portion in c ontact w ith w all) shall be measured i n centimetres and l ength i n metres (fig. bel ow). The gi rth and length shall be measured correct to a cm. No deduction shall be made from the masonry of wall for the bearing of the moulding and cornices.
Note : 1 The sectional periphery curve ABCDEF. 2. Length FA shall not be measured.
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6.8.5 Rate The rate includes the cost of materials and labour involved in all the operations described above. 6.9 BRICK WORK UNDER WATER OR FOUL CONDITIONS Brick Work under following conditions : (i) Work in or under w ater/or l iquid mud; (ii) Work in or under foul positions Shall be measured s eparately f or payment of extra rate over and above t he quantity measured and paid under para 6.2.8. 6.10 EXPOSED BRICK WORK - DELETED
6.11 CAVITY WALL - DELETED
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6.12
GYPSUM PARTITION PANELS
6.12.1 The material shall conform to IS:2849. 6.12.2 Dimensions As per the item nomenclature. 6.12.3 Laying (i) Panels are stored in a dry place and water should not come in contact with panels during or after construction. If the panels get wet, they should be dried before use. (ii) The floor should be perfectly level before laying the first course. All panels must be properly aligned t o t he pl umb. S uccessive l ayer of p anels m ust be al ternatively s taggered s o t hat v ertical joints are not in the same line. (iii) The recommended quantity of Gypsum Bonding Plaster must be used for joints and filling the grooves made for conduits, pipelines, etc. Excess Bonding Plaster must be scooped and removed, so that the joints and the places where the grooves are filled in are flush and even. (iv) The walls should be dry and sanding done properly especially at joints before the primer is applied so that the surface is even and joints will not be visible after painting. Avoid chasing with chisel and hammer. Use electrical saw or grooving tools for conduiting etc. (v) The recommended span of walls is maximum 6 meters and maximum height is 4.5 meters. (vi) Gypsum panel can easily be cut with coarse tooth hand saw, electric jigsaw, etc. The panels can be cut, sawn, drilled, milled or dowelled on the job. For concealed piping and conduit, the depth of groove should not exceed 50 mm. Hammer and chisel techniques to form chases must be avoided. (vii) Sanding: This application is to make the surface level without undulations. To make the gypsum wall surface level (in particular at joints, where there is excess bonding plaster), do sanding with sand paper at joints and other places, wherever you find uneven surface, otherwise joints will be visible after painting. It is important to sand all joints uniformly. (viii) Primer Application: The purpose of t he primer i s to gi ve a better adhesion t o t he pai nt and al so to reduce consumption of paint on the wall. Water thinable primers shall be used only. 6.12.4 Measurements The length and height shall be measured c orrect to a c m. A rea s hall be c alculated in s quare m eters correct to t wo pl ace of decimal. No deduction s hall be m ade f or ducts, opening m ade f rom the standard size of panel. 6.12.5 Rate The rate shall include the cost of materials and labour involved in all the operations described above. 6.13 BRICK EDGING 6.13.1 The edging shall be of bricks of class specified in the item. The specifications of bricks shall be as described in 6.1. Trenches of required depth and width shall first be made along the edge of the plinth protection to receive the bricks for edging. The bed of trenches shall be compacted to a firm and even surface. T he brick s hall be laid true to line in c ement m ortar 1 :4 ( 1 c ement: 4 fine s and) w ith length parallel and butting the plinth protection. The top face of the brick edging shall be in one level to conform to the finished le vel of th e pli nth pr otection adjacent to the ed ging. A fter t he co ncreting is do ne, no portion of t he brick e dging s hall pr oject a bove the a djacent concrete surface. Cement m ortar s hall conform to the specification described in chapter 3.0. 6.13.2 Measurements The brick edging shall be measured in running metere correct a cm. 6.13.3 Rate Rate shall include the cost of materials and labour involved in all operations.
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APPENDIX A
TEST FOR DIMENSIONAL TOLERANCE A -1. Sampling As per para 6.1.3.1 and 6.1.3.2.
(Clause 6.1.3.3)
A -2. Procedure All t he bl isters, l oose p articles of c lay a nd small p rojections shall b e r emoved f rom t he surface of bricks. E ach specimen of 20 bricks shall then be arranged upon a level surface successively as indicated in Fig. A, B and C of para A -4 below in contact with each other and in straight line. The overall length of the assembled bricks (20 Nos) shall be measured with a steel tape sufficiently long to measure the whole row at one stretch. A-3. Tolerance The actual dimensions of bricks when tested as described in A-2 shall be within the following limits per 20 bricks. Modular Bricks Length 3720 to 3880 mm (3800 ± 80 mm) Width 1760 to 1840 mm (1800 ± 40 mm) Height 1760 to 1840 mm (1800 ± 40 mm) for 90 mm high brick 760 to 840 mm (800 ± 40 mm) for 40 mm high brick Non-Modular Bricks For class 10 Length (4520 to 4680) mm (4600 ± 80 mm) Width (2240 to 2160) mm (2200 ± 40 mm) Height (1440 to 1360) mm (1400 ± 40 mm) for 70 mm high bricks (640 to 560) mm (600 ± 40 mm) for 30 mm high bricks For other classes Length (4320 to 4680) mm Width (2130 to 2310) mm Height (1340 to 1460) mm for 70 mm high bricks (840 to 920) mm for 44 mm high bricks A-4. Criteria for Conformity A lot s hall be c onsidered conforming to the r equirements o f d imensions and tolerances if a ll the groups of bricks are tested to meet the specified requirements. 1 to 2 CM
'A' Measurement of Length
4 CM 10 CM
'B' Measurement of Width 'C' Measurement of Height
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APPENDIX B
TEST FOR COMPRESSIVE STRENGTH (Clause 6.1.3.4)
B-1. Specimen Five whole bricks shall b e taken from the samples as specimens for this test. Length and w idth of each specimen shall be measured correct to 1 mm. B-2. Apparatus The app aratus consists o f compression testing machine, t he c ompression pl ate o f w hich s hall hav e a ball seating in the form of portion of a s phere the centre of which shall coincide with the centre of the plate. B-3. Procedure (a) P re -conditioning: The specimen shall be immersed in the water for 24 hours at 25º to 29ºC. Any surplus moisture shall be allowed to drain at room temperature. The frog of the bricks should be filled flush with mortar 1:3 (1 cement : 3 clean coarse sand of grade 3 mm and down) and shall be kept under damp jute bags for 24 hours, after that these shall be immersed in clean water for three days. After removal from water, the bricks shall be wiped out of any traces of moisture. (b) Actua l Te s ting: Specimen shall be placed with flat faces horizontal and mortar filled face upward between three 3 ply plywood sheets each of thickness 3 mm and carefully centred between plates of the testing machine. Plaster of Paris can also be used in place of plywood sheets to ensure a uniform surface. Load s hall be appl ied c arefully ax ially at uni form rate o f 14 N/mm2 per minute till the f ailure of t he specimen occurs. B-4. Reporting the Test Results The compressive strength of each specimen shall be calculated in N/mm2 as under : Maximum load at failure (in N) Compressive Strength = ———————————————— Area of Specimen (in sq mm) In case the c ompressive s trength of any individual brick tested exceeds the upper l imit of the average compressive s trength s pecified f or t he corresponding class of brick, t he s ame s hall be limited t o the u pper l imit of t he c lass s pecified i n 6. 1.2 f or t he p urpose of c alculating t he av erage c ompressive strength. C ompressive s trength of al l the i ndividual bricks c omprising t he s ample s hall be av eraged and reported. B-5. Criteria for Conformity A lot shall be considered having satisfied the requirements of average compressive strength if the average c ompressive s trength s pecified i n 6. 1.2 f or t he c orresponding c lass of bri ck t ested i s n ot bel ow the minimum average compressive strength specified for the corresponding class of bricks by more than 20 per cent.
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APPENDIX C
TEST FOR WATER ABSORPTION (Clause 6.1.3.5)
C-1. No. of Specimen Five whole bricks shall be taken from samples as specimen for this test. C-2. Apparatus A balance required for this test shall be sensitive to weigh 0.1 percent of the weight of the specimen. C-3. Procedure (a) P re -conditioning: The specimen shall be allowed to dry in a ventilated oven at a 110°C to 115°C till it attains a substantially constant weight. If the specimen is known to be relatively dry, this would be accomplished in 48 hours, if the specimen is wet, several additional hours may be required to attain a constant weight. It shall be allowed to cool at room temperature. In a ventilated room, properly separated bricks will require four hours for cooling, unless electric fan passes air over them continuously in which case two hours may suffice. The cooled specimen shall be weigh (W 1) a warm specimen shall not be used for this purpose. (b) Actua l Te s ting : Specimen shall be completely dried before immersion in the water. It shall be kept in clean water at a temperature of 27°C ± 2°C for 24 hours. Specimen shall be wiped out of the traces of water with a damp cloth after removing from the water and then shall be weighed within three minutes after removing from water (W 2). C-4. Reporting the Test Results The w ater ab sorption of each s pecimen shall be calculated as f ollows an d t he av erage of f ive t ests shall be reported. Water Absorption =
⎛W − W ⎞ 2
W
1
1
×100
C-5. Criteria for Conformity A lot shall be considered having satisfied the requirements of water absorption if the average water absorption is not more than 20% by weight.
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APPENDIX D
TEST FOR EFFLORESCENCE (Clause 6.1.3.6)
D-1. No. of Specimen Five whole bricks shall be taken as specimen for this test. D-2. Apparatus Apparatus required for this test shall be a shallow flat bottom dish containing distilled water. D-3. Procedure (actual testing) The brick shall be placed vertically in the dish with 2.5 cm immersed in the water. The room shall be warm (18ºC to 30º C) and w ell v entilated. The br icks should not be removed u ntil it abs orbs whole water. When the whole water is absorbed and the brick appears to be dry, place a similar quantity of water in that dish and allow it to evaporate as before. The brick shall be examined after the second evaporation. D-4. Reporting the Test Results The rating t o efflorescence i n a scending order shall b e re ported as ‘NIL’, ‘ SLIGHT’, ‘MODERATE’, ‘HEAVY’ or ‘SERIOUS’ in accordance with the following : (a) NIL: When there is no perceptible deposit of efflorescence. (b) S LIGHT: When not more than 10 per cent of the area of the brick is covered with a thin deposit of salts. (c) MODERATE: When t here is heavier deposit and co vering u pto 50% of th e a rea of the br ick surface but unaccompanied by powdering or flaking of the surface. (d) HEAVY: When there is a heav y depo sit of salts covering 50% or m ore of the brick surface bu t unaccompanied by powdering or flaking of the surface. (e) S ERIOUS : When there i s heavy deposit of s alts, accompanied pow dering and /or f laking of t he surface and tending to increase in the repeated wetting of the specimen. D-5. Criteria for Conformity A lot be considered having satisfied the requirements of efflorescence if for 4 out of the specimen of 5 bricks, the rating of efflorescence is not beyond “Moderate”.
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BRICK WORK Sub H ead : B rick W ork Clause : 6.0 & 6.2.8
OVERSAILING COURSE
COPING
MUD PHUSKA TILES SLAB
CORNICE
CORBLES
STRING COURSE
WINDOW SILL
A. PIER (1)
B. PIER (2)
FLOORING
C. PILLARS
DPC
D. TYPICAL SECTION OF BRICK WALL
THE BREADTH SHALL NOT EXCEED THREE TIMES THE THICKNESS AND THICKNESS ITSELF SHALL NOT EXCEED MORE THAN THREE BRICKS Drawing not to scale
Fig. 6.1 : Brick Work
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BRICK PILLARS Sub Head : Brick Work Clause : 6.2.4.1 EVEN COURSES
ODD COURSES 100 1 X 1½ BRICK
200
1 X 2 BRICK
150
200
150
100
1 X 2 ½ BRICK
200
100
200
100
50 100
200
100
150
50 100
300
200
100
1 ½ X 2 BRICK
100 50
2 X 2 BRICK
150
100
300
100
150
1 ½ X 1 ½ BRICK
400
100 50
200
Drawing not to scale All dimensions are in mm
Fig. 6.2 : English Bond
185 | Page HO Civil Specifications Volume - I
BRICK BONDS Sub Head : Brick Work Clause : 6.2.4.1 EVEN COURSES
100
200
50
ODD COURSES
100
1 BRICK WALL
100
200
200
Q UEEN CLOSER
1½ BRICK WALL 100
100
200
200
200
200
200
2 BRICK WALL Drawing not to scale All dimensions are in mm
Fig. 6.3 : English Bond
186 | Page HO Civil Specifications Volume - I
BRICK BONDS (Contd.) Sub Head : Brick Work Clause : 6.2.4.1 EVEN COURSES
ODD COURSES
200
100
200
Q UEEN CLOSER
1 BRICK WALL
100
200
300
100
200
200
100
1½
RICK B
ALL W
200
400
100
100
2 BRICK WALL
200
70 70 60 200
300
300
200
50 80 150
20
70 60 70
40 70 60 70
60 70 70
CUT BRICK CORNER (MARUCONA) Drawing not to scale All dimensions are in mm
Fig. 6.4 : English Bond
187 | Page HO Civil Specifications Volume - I
BRICK WORK IN ARCHES Sub Head : Brick Work Clause : 6.3 SPANDREL
KEY
EXTRADOS OR BACK SPRINGING POINT
FACE JOINTS NOT MORE T HAN 5 M M THICK
SOFFIT OR INTRADOS
JOINTS VAR YING FROM 5 T O 15 MM THICK ABUTMENT.
SPAN
PIER
PLAIN OR ROUGH
GAUGED CIRCULAR ARCH
SPAN SPAN
NE BRICK THICK
1 ½ BRICK THICK FLAT GAUGED ARCH
Drawing not to scale
Fig. 6.5 : Brick Work in Arches
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7.0: Stone Work
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CONTENTS Cla us e No.
Brie f De s cription
P a ge No.
List of Mandatory Tests
192
List of Bureau of Indian Standard Codes
193
7.0
Terminology
194
7.1
Random Rubble Stone Masonry
196
7.2
Coursed Rubble Masonry - First Sort
201
7.3
Coursed Rubble Masonry - Second Sort
202
7.4
Plain Ashlar Masonry
202
7.5
Punched Ashlar (Ordinary) Masonry
205
7.6
Moulded, Sunk, Carved Ashlar Masonry
205
7.7
Stone Veneering Work
206
7.8
Stone Chajja
208
7.9
Shelves, Coping, Plain, Cornices, String Courses etc.
209
7.10
Stone Jali
209
7.11
Dry Stone Cladding
210
7.12
Structural Steel Frame Work for Dry Stone Cladding
211
7.13
Adjustable Stainless Steel Cramps
212
Fig. 7.1
Stone Work
213
Fig. 7.2 to 7.7
Terminology
214
Fig. 7.8
Random Rubble Masonry
215
Fig. 7.9
Rubble Stone Masonry - Coursed
216
.
190 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
Fig. 7.10
Ashlar Stone Masonry
217
Fig. 7.11
Ashlar Stone Masonry (with Brick Backing)
218
Fig. 7.12
Moulded, Sunk, Carved - Stone Work
219
Fig. 7.13
Stone Work in Arches & Chajjas
220
Fig. 7.14, 7.15
Stone Veneering
221
Fig. 7.16
General Arrangement of Cramps
223
.
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LIST OF MANDATORY TESTS Material
Clause Test
Requirement
Field/ laboratory Test
Test Procedure
Stone
7.1.1 7.4 7.8 7.9
Not more than 2.5% by mass for sand stone and as specified in IS 1123 for other stones.
Laboratory
IS 1124
(ii) Transverse Not less than strength 7 N/mm2 (70 Kgf/cm2) for sand stone and as specified in IS 1123 for other stones. (iii) Resistance Not greater to wear than 2 mm on the average and 2.5 mm for any individual specimen for sand stone and as specified in IS 1123 for other stones. (iv) Durability Shall not develop signs of spalling, disintegration or cracks for sand stone and as specified in IS 1123 for other stones.
Laboratory
IS 1121 Part II
-do-
100 sqm/20 cum or part thereof or change of source as per direction of Engineerin- Charge -do-
Laboratory
IS 1706
-do-
-do-
Laboratory
IS 1126
-do-
-do-
(i) Water absorption
Minimum Qty. of material for carrying out test 50 sqm. for slabs and 10 cum in stone masonry
Frequency of Testing
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LIST OF BUREAU OF INDIAN STANDARD CODES S. No.
IS Code No.
Subject
1.
IS 737
Specifications for wrought aluminium and aluminium alloy, steel and strip for general engineering purpose.
2.
IS 1121 - (Pt. I)
Methods of determination of properties and strengths of natural building stones (Part-I compressive strength).
3.
IS 1122
Methods for determination of specific gravity of natural building stone
4.
IS 1123
Methods of identification of natural building stones.
5.
IS 1124
Methods of test of determination of water absorption, apparent, specific gravity and porposity of natural building stones.
6.
IS 1125
Methods of test of determination of weathering of natural building stone
7.
IS 1126
Methods of test for determination of durability of natural building stone
8.
IS 1128
Specification for Lime stone (Slab & Tiles).
9.
IS 1129
Recommendations for dressing of natural building stones.
10.
IS 1200 (Pt. IV)
Methods of measurements of building and Civil engineering works stone Masonry.
11.
IS 1197 (Pt. I)
Code of practice for construction of rubble stone masonry
12.
IS 1597 (Pt. II)
Code of practice for construction of ashlar stone masonry
13.
IS 1805
Glossary of terms relating to stones, quarrying and dressing
14.
IS 3620
Specification for latrite stone block for masonry
15.
IS 3622
Sand stone (Slab & Tiles)
16.
IS 4104 (Pt. I)
Code of practice for external facings and veneers (Part I-Stone facing).
17.
IS 4101 (Part II)
Code of practice for external facing and veneers: (Part II-Cement Concrete facing).
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7.0 STONE WORK 7.0 TERMINOLOGY Ashlar Stone masonry using dressed square stone blocks of given dimensions having faces perpendicular to each other and laid in courses. Bed Joint The joint where one stone presses on another for example, a hor izontal joint in a w all or radiating joint between the voussoirs or arch (See Fig. 7.1 and 7.13) Block (a) Hollow (Ope n a nd C los e d C a vity) Block: A c oncrete m asonry unit w ith any one of t he ex ternal dimension gr eater t han t he c orresponding d imension of a br ick and having o ne or more l arge holes or cavities w hich e ither pas s through the b lock (o pen c avity) o r do ef fectively pas s th rough the b lock (closed cavity) a nd having t he solid m aterial b etween 5 0% and 7 5% of t he t otal v olume of t he bl ock calculated from the overall dimensions. (b) Solid Block: A concrete masonry unit with external dimensions greater than corresponding dimension of a brick and having solid material not less than 75% of the total volume of the block calculated from over all dimension. Bond An interlocking arrangement of structural units in a wall to ensure stability. Bond Stone (through Stone) Selected long stone used to hold a wall together transversely (See Fig. 7.8). Corbel Stone b onded w ell into the w all with part of it projecting o ut of the face of wall to form a bearing surfaces. Cornice A horizontal moulded projection which crowns or finishes either a wall, any horizontal division of wall, or any architectural feature (See Fig. 7.1C). Cramp A s mall piece of metal o r the hardest or to ughtest st one pr ocurable, s unk in mortices a nd fixed across joints as addi tional ties. The ends o f metal cramps a re bent at right an gles and s tone cramps ar e dovetailed (See Fig. 7.1B). Course A layer of stones in wall including the bed mortar. Dowels Dowels a re s mall sections of metal, s tone or pebbl es b edded with m ortar in c orresponding m ortice in bed or side joint or adjacent stones (See Fig. 7.1A). Jamb The part of the wall at the side of an opening.
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Joggle A k ey b etween the s tones b y providing a gr oove i n on e s tone t o t ake a c orresponding c oncealed projection in the edges on the other stone (See Fig. 7.1B). Natural Bed The planes of stratification that occurs in a sedimentary rocks. Parapet A solid or pierced guard wall for flat stone terrace or balcony (or a bridge) or a c urb wall at the lower part of a pitched roof which is exposed to atmosphere on face back and top (See Fig. 7.1C). Quoin A qu oin is the external an gle of wall or bu ilding. The term is also app lied to stone specially selected and neatly dressed for forming such angle. Random Random or irregular size and shapes. Reveal The part of the jamb between the frame and the arris. Rubble Masonry Masonry bu ilt of s tones ei ther i rregular i n s hapes a s quarri ed or s quared an d onl y ham mer dre ssed and having comparatively thick joints. As far as possible, stones for rubble masonry shall be angular. Skewback Sloping surface against which the springing of an arch rests. Spandrel Space between the haunches below the decking level. String Course A horizontal band, plain or moulded, usually projecting slightly from the face of wall (See Fig. 7.1C). Surfacing or Dressing of Stones The stones are dressed to have different surfaces as indicated below. Template or Bed Block A block of stone or concrete bedded on a wall to distribute the pressure from a concentrated load. Self Faced Surfaces Surfaces of stone slabs used for roofing, flooring, lintels etc. as obtained from quarry. Squared Back Surface Means the surface shall be dressed back at right angles to the face of the stone. Chisel Drafted Margin The dressing done with a drafting chisel in narrow strips of width generally 2 to 5 cm. Chisel drafted margin shall be punch dressed. Hammer Dressed Surface A h ammer dressed s tone s hall ha ve n o s harp an d i rregular c orners and s hall ha ve a c omparatively even s urface s o as t o fi t well in m asonry. Hammer d ressed stone is also kn own a s h ammer f aced, quarry faced and rustic faced. The bushing from the general wall face shall not be more than 40 mm on exposed face and 10 mm on faces to be plastered (Fig. 7.2).
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Rock Faced Surface A rock faced stone shall have a minimum of 25 mm wide chisel drafted margin at the four edges, all the edges being in the same plane (Fig. 7.3). Rough Tooled Surface A rough tooled s urface shall ha ve a s eries of bands, made by means of a pl ane c hisel 4 to 5 cm wide, m ore or l ess p arallel t o t ool m arks al l over t he s urface. These m arks m ay be ei ther horizontal, vertical or at an angle of 45° as directed (Fig. 7.4). The edges and corners s hall be square and true. The depth or gap bet ween t he s urface and s traight edg e, hel d agai nst t he s urface s hall not be m ore t han 3 mm (Rough tooled stones are used where fairly regular plane faces are required for masonry work). Punched Dressed Surface A r ough s urface i s f urther dre ssed b y m eans o f p unch c hisel t o s how s eries of pa rallel ri dges. T he depth of gap between the surface and a straight edge held against the surface shall not exceed 3 mm (Fig. 7.5). Punched dressed stones are used where even surfaces are required. Close Picked Surface A punched s tone i s further dressed b y m eans of point c hisel so as to obt ain a finer surface, ridges o r chisel m arks left over being very tiny. The depth of gap bet ween the surface and a s traight edge k ept over the surface shall not exceed 1.5 mm (Fig. 7.6). Fine Tooled Surface Close picked s urface i s f urther dressed so t hat all t he projections are removed a nd f airly s mooth surface is obtained. The surfaces shall have 3 to 4 lines per centimetre width depending on the degree of hardness of stone and degree of fineness r equired (Fig. 7.7). This type of dr essing is commonly adopted for ashlar work. Polished Surface Surfaces having a hi gh gl oss f inish. P olishing o f s tones s hall be done by r ubbing t hem w ith s uitable abrasive, wetting the surface where necessary with water. Alternatively polishing of stones shall be done by holding them firmly on t he t op of revolving t able to w hich some abrasive m aterial like sand or carborundum is fed. The final polishing shall be performed by rubber or felt, using oxide of lime (called by trade name as putty powder) as a polishing medium. Moulded Cut to profile of a moulding with punched dressed surfaces, unless otherwise specified. 7.1 RANDOM RUBBLE STONE MASONRY 7.1.0 Material 7.1.1 Stone The s tone s hall be o f t he t ype specified s uch a s g ranite, t rap, l imestone, sand s tone, qu artzite, et c. and shall be obtained from the quarries, approved by the Engineer-in-Charge. Stone shall be hard, sound, durable and free from weathering decay and defects like cavities, cracks, flaws, sand holes, injurious v eins, pa tches of l oose or s oft m aterials a nd ot her s imilar def ects t hat m ay adversely af fect i ts strength and appearance. As far as possible stones shall be of uniform colour, quality or texture. Generally stone shall not contain crypst crystalline silica or chart, mica and other deleterious materials like iron-oxide organic impurities etc. Stones with round surface shall not be used. The compressive strength of common types of stones shall be as per Table 7.1 and the percentage of water a bsorption sh all g enerally n ot ex ceed 5% for sto nes oth er t han s pecified in T able 7. 1. F or laterite this percentage is 12%.
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TABLE 7.1
Type of stone Granite Basalt Lime stone (Slab & Tiles) Sand stone (Slab & Tiles) Marble Quartzite Laterite (Block)
Ma ximum Wa te r Abs orption P e rce nta ge by we ight 0.5 0.5 0.15 2.5 0.40 0.40 12
Minimum Compre s s ive S tre ngth kg./s q.cm. 1000 400 200 300 500 800 35
Note 1: Test for compressive strength shall be carried out as laid down in IS 1121 (Part I). Note 2: Test for water absorption shall be carried out as laid down in IS 1124. 7.1.2 Size of Stones Normally s tones us ed should be s mall en ough to be lifted an d pl aced b y h and. Unless otherwise indicated, the length of stones for stone masonry shall not exceed three times the height and the breadth on base shall not be greater than three-fourth of the thickness of wall, or not less than 150 mm. The height of stone for rubble masonry may be upto 300 mm. The selection and grading of stones for rubble m asonry is largely done at s ite and t he smaller s tones are used in the hearting of wall. 7.1.3 Random R ubble M asonry s hall be unc oursed or b rought t o courses as specified (Fig. 7.8 and 7. 9). Uncoursed rand om rubble m asonry shall be c onstructed with stones of s izes as ref erred to i n p ara 7 .0 and s hapes pi cked up ra ndom from the s tones br ought from t he ap proved q uarry. Stones having s harp corners or round surfaces shall, however, not be used. 7.1.4 Random r ubble m asonry br ought t o t he c ourse i s s imilar t o unc oursed r andom r ubble m asonry except th at th e co urses are r oughly le velled at in tervals varying fr om 3 00 m m to 900 m m in h eight according to the size of stones used. 7.1.5 Dressing Each s tone s hall b e hammer d ressed o n the face, the sides an d the b eds. H ammer d ressing s hall enable t he s tones t o be l aid c lose t o neighbouring s tones s uch t hat t he bushing i n t he f ace s hall not project more than 40 mm on the exposed face. (i) Face stone: At least 25% stones shall be headers tailing into the work at least 2/3rd the thickness of wall in super structure masonry. Such stones shall not be less than 200 sq. cm in cross sections. (ii) Hearting Stones: The hearting or interior filling of a wall face shall consist of rubble stones not less than 150 mm in any direction, carefully laid, hammered down with a wooden mallet into position and solidly bedded in mortar. The hearting should be laid nearly level with facing and backing. (iii) Quoin Stone: Quoin stone shall be less than 0.03 cum in volume. (iv) Jamb stones: The jambs shall not be made with stones specified for quoins except that the stones which w ere required t o be p rovided a t 1 metre c entre t o c entre on bot h the exposed faces shall here be provided only on the jamb and the length shall be equal to the thickness of the wall for wall u pto 60 cm and a l ine of head ers s hall be provided fo r w alls thicker than 60 c m as specified for bond.
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7.1.5 (A) Courses The masonry s hall be c arried out i n regular c ourses of hei ght not exceeding 50 c m and masonry on any da y w ill n ot be ra ised m ore t han 60 c m i n height w hen us ing m ortars ha ving c ompressive s trength less than 20 kg./sq. cm at 28 days and 100 cm when using mortars exceeding this strength. 7.1.5 (B) Thickness of Joints The joint thickness shall not exceed 30 mm at any point on the face. Chips of the stone and spalls shall be wedged i nto s eating bed of f ace s tones t o av oid ex cessive bed t hickness. No pi nning s hall b e allowed to avoid excessive joint thickness. 7.1.6 Mortar The mortar used for joining shall be as specified. 7.1.7 Laying Stone s hall be l aid on t heir nat ural bed and s hall be s olidly bedded f ull i n mortar w ith c lose j oints, chips of stone spalls be wedged into the work wherever necessary. No dry work or hollow spaces shall be allowed and ev ery stone whether large or small shall be carefully selected t o fit snugly the interstices between t he l arge s tones. M asonry s hall be built b reaking j oints i n a ll t he t hree directions. Bond stone and he aders s hall be pro perly laid i nto t he w ork a nd s hall be m arked by t he c ontractor w ith w hite lead paint. The bond stones shall be provided as specified in para 7.1.8. The masonry work in wall shall be carried up true to plumb or to specified batter. Random r ubble m asonry shall b e brought t o t he l evel c ourses at plinth, w indow s ills, lintel and roof levels. Le velling shall be do ne w ith c oncrete c omprising of on e p art of the m ortar as u sed for m asonry and two parts of graded stone aggregate of 20 mm nominal size. The masonry in structure shall be carried uniformly. Where the masonry of one part is to be delayed, the work shall be raked back at an angle not steeper than 45°. 7.1.7 (A) Raking out joints All the joints on the faces to be pointed or plastered shall be racked out with racking tool to a depth of 20mm while the mortar is still green. 7.1.8 Bond Stones Though bo nd s tones s hall be pr ovided i n w alls up to 60 0 m m thickness, a s et of t wo or m ore b ond stones overlapping each other by at least 150 m m shall be prov ided in a l ine from face to back. I n case of highly absorbent types of stones (porous lime stone and s and stone etc.) the bond s tone shall extend about two-third i nto t he wall, as through stones in such walls a set of two or more bond stones overlapping each other by at least 150 mm shall be provided. Each bond stone or a set of bond stones shall be p rovided for every 0.5 m 2 of the wall surface and s hall be p rovided at 1.5 m to 1.8 m apart clear in every course. In c ase of hi ghly a bsorbent t ypes of s tones (porous l ime stone a nd s and s tone et c.) single pi ece bond stones m ay give rise to da mpness. For all thicknesses of such w alls a set of two o r m ore bond stones ov erlapping each other by at least 15 cm shall be provided. Length of eac h s uch bond stone shall not be less than two-third of the thickness of the wall.
.
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Where bond stones of suitable lengths are not available pre-cast cement concrete block of 1:3:6 mix (1 cement : 3 coarse sand: 6 graded stone aggregate 20 mm nominal size) of cross section not less than 225 square centimetres and length equal to the thickness. At least one bond s tone or a s et of bond s tones shall be pr ovided at 1.5 m to 1.8 m apart clear in every course. (Bond stones shall be marked suitably with paint as directed by the Engineer-in-Charge). 7.1.9 Quoin and Jamb Stones The quoin and jamb stones shall be of selected stones neatly dressed with hammer or chisel to form the required angle. Quoin stones shall not be less than 0.01 cum in volume. Height of quoins and jamb stones shall not be less than 15 cm. Quoins shall be laid header and stretcher alternatively. 7.1.10 Joints Stones shall b e so laid that all joints are f ully pa cked with mortar an d chips. Face joints shall not be more than 20 mm thick. The joints shall be struck flush and finished at the time of laying when plastering or pointing is not to be done. For the surfaces to be plastered or pointed, the joints shall be raked to a minimum depth of 20 mm when the mortar is still green. 7.1.11 Scaffolding Single s caffolding having o ne s et of vertical s upport shall be allowed. The s upports s hall be s ound and strong, t ied together by horizontal pieces, over which t he s caffolding planks s hall be f ixed. T he inner end of th e h orizontal s caffolding member m ay rest i n a h ole pr ovided i n the m asonry. Such holes, however, shall not be allowed in pillars under one metre in width or near the skew back of arches. The holes left in masonry work for supporting scaffolding shall be filled and made good with cement concrete 1 : 3 : 6 (1 cement : 3 coarse sand : 6 stone aggregate 20 mm nominal size). 7.1.12 Curing Masonry work in cement or composite mortar shall be kept constantly moist on all faces for a minimum period of seven days. In c ase of masonry with fat lime m ortar curing s hall c ommence two days after laying of masonry and shall continue for at least seven days thereafter. 7.1.13 Protection Green work shall be protected from rain by suitable c overing. T he work shall also b e suitably protected from damage, mortar dropping and rain during construction. 7.1.14 Measurements 7.1.14.1 The length, height and t hickness shall be measured correct to a c m. The thickness of wall shall be measured at joints e xcluding the bus hing. O nly s pecified di mensions shall be al lowed; an ything ex tra shall be ignored. The quantity shall be calculated in cubic metre nearest to two places of decimal. 7.1.14.2 The work under the following categories shall be measured separately. (i) From foundation to plinth level (level one) : (a) work in or under water and or liquid mud, (b) work in or under foul positions. (i) Above plinth level and upto floor five level. (ii) Above floor five level to every floor/floors or part thereof. (iv) S tone masonry i n parapet s hall be measured t ogether w ith t he c orresponding i tem i n the w all o f the storey next below. 7.1.14.3 No deduction shall be made nor extra payment made for the following : (i) E nds o f d issimilar materials ( that i s j oists, beams, l intels, p osts, g irders, r afters p urlins, tr usses, corbels, steps etc.) upto 0.1 sqm in section.
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(ii) Openings each upto 0.1 sqm in area. In calculating the area of openings, any separate lintels or sills shall be included along with the size of opening but the end por tions of the lintels shall be excluded and the extra width of rebated reveals, if any, shall also be excluded. (iii) W all pl ates and bed pl ates, and bear ing of c hajjas and t he l ike, w here the t hickness does not exceed 1 0 c m and t he be aring d oes n ot ex tend over t he f ull t hickness of t he wall. Note: The bearing of floor and roof shall be deducted from wall masonry. (iv) D rain hol es and r ecesses f or c ement c oncrete bl ocks t o em bed hol d f asts f or door s, w indows etc. (v) B uilding i n masonry, i ron fixture, pi pes upt o 300 m m dia, hol d fasts o f door s and w indows et c. (vi) Forming chases in masonry each upto section of 350 sq cm. Masonry (excluding fixing brick work) in chimney breasts with smoke of air flues not exceeding 20 sq dm (0. 20 s q m ) i n s ectional area s hall be m easured as s olid and no ex tra payment s hall be m ade f or pargetting and c oring such f lues. Where f lues exceed 20 s q dm (0.20 s q m ) sectional are a, de duction shall be made for the same and pargetting and coring flues shall be measured in running metres stating size of flues and paid for separately. Aperture for fire place shall not be deducted and no extra payment made for splaying of jambs and throating. 7.1.14.5 Apertures f or fire places s hall not be deducted and extra l abour shall not be measured f or splaying of jambs, throating and making arch to support the opening. 7.1.14.6 Square or Rectangular Pillars: These s hall be measured as w alls, but ex tra pa yment s hall be allowed for stone work in square or rectangular pillars over the rate for stone work in walls. Rectangular pillar s hall m ean a de tached m asonry s upport r ectangular in s ection, s uch that its br eadth does n ot exceed two and a half times the thickness. 7.1.14.7 Circular Pillars (Columns): These shall be measured as per actual dimensions, but extra payment s hall be a llowed for s tone w ork in c ircular p illars ov er the r ate for s tone w ork in w alls. T he diameter as well as length shall be measured correct to a cm. 7.1.14.8 Tapered walls shall be measured net, as per actual dimensions and paid for as other walls. 7.1.14.9 Curved Masonry: Stone masonry curved on plan to a mean radius exceeding 6 metres shall be measured and i ncluded with g eneral s tone work. Stone work c ircular o n pl an t o a mean ra dius n ot exceeding 6 m etres s hall be m easured s eparately a nd shall include all cuttings and waste and templates. It shall be measured as the mean length of the wall. 7.1.15 Rate The rate shall include the cost of materials and labour required for all the operations described above and shall include the following : (a) Raking out joints for plastering or poi nting done as a s eparate item, or finishing flush as the work proceeds. (b) Preparing tops and sides of existing walls for raising and extending. (c) R ough c utting and w aste f or f orming gables c ores, s kew bac ks o r s pandrels of arc hes, splays at eaves and all rough cutting in the body of walling unless otherwise specified. (d) Bond stones or cement concrete bond blocks. (e) Leading and making holes for pipes etc. (f) B edding and poi nting w all pl ates, lintels, s ills etc. in or on walls, bedding roof t iles and corrugated sheets in or on walls. (g) Building in ends of joists, beams, lintels etc.
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7.2 COURSED RUBBLE MASONRY - FIRST SORT (FIG. 7.9) 7.2.1 Stone: Shall be as specified in 7.1.1. 7.2.2 Size of Stone: Shall be as specified in 7.1.2. 7.2.3 Dressing Face stones shall be hammer dressed on all beds, and joints so as to give them approximately rectangular bl ock s hape. T hese s hall be s quared on al l j oints and beds . T he bed j oint s hall be r ough chisel dressed for at least 80 mm back from the face, and side joints for at least 40 mm such that no portion of t he d ressed s urface i s m ore t han 6 mm fro m a straight e dge pla ced on i t T he re maining unexposed portion of the stone shall not project beyond the surface of bed and side joint. The bushing on the face shall not project more than 40 mm as an exposed face and 10 mm on a face to be plastered. The hammer dressed stone shall also have a rough tooling for minimum width of 25 mm along the four edges of the face of the stone, when stone work is exposed. 7.2.4 Mortar The mortar for jointing shall be as specified. 7.2.5 Laying All stones shall be wetted before use. The walls shall be carried up truly plumb or to specified batter. All courses shall be laid truly ho rizontal and al l v ertical j oints shall be truly v ertical. The he ight of ea ch course shall not be less than 15 cm nor more than 30 cm. Face stones shall be laid alternate headers and stretchers. No pinning shall be allowed on the face. No face stone shall be less in breadth than its height and at least one third of the stones shall tail into the work for length not less than twice their height. The hearting or the interior filling of the wall shall consist of stones carefully laid on their proper beds in mortar; chips and spalls of stone being used where necessary to avoid thick beds of joints of mortar and at the same time ensuring that no hollow spaces are left anywhere in the masonry. The chips shall not be used bel ow t he he arting s tone t o bri ng t hese up to t he l evel of f ace s tones. T he us e of c hips s hall be restricted t o t he f illing of i nterstices between t he adjacent stones i n hearting and these shall not exceed 10% of the quantity of stone masonry. The masonry i n a structure s hall be carried up uni formly but where br eaks a re unavoidable, the joints shall be raked back at angle not steeper than 45°. Toothing shall not be allowed. 7.2.6 Bond Stones Shall be as specified in 7.1.8 except that a bond stone or a set of bond stones shall be inserted 1.5 to 1.8 metres apart, in every course. 7.2.7 Quoins The quoins shall be of the same height as the course in which these occur. These shall be at least 450 m m l ong and shall b e l aid stretchers a nd hea ders al ternatively. T hese shall be l aid s quare o n t he beds, which shall be rough-chisel dressed to a depth of at least 100 mm. I n case of exposed work, these stones shall have a m inimum of 25 m m wide chisel drafts at four edges, all the edges being in the same plane. 7.2.8 Joints All bed joints shall be horizontal and al l side joints v ertical. All joints shall be fully packed with mortar, face joints shall not be more than one cm thick. When plastering or pointing is not required to be done, the joints shall be struck flush and finished at the time of laying. Otherwise, joints shall be raked to a minimum depth of 20 mm by raking tool during the progress of work, when the mortar is still green.
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7.2.9 Curing, Scaffolding, Measurements and Rates. Shall be as specified under 7.1. 7.3 COURSED RUBBLE MASONRY - SECOND SORT (FIG. 7.9) 7.3.1 Stone : Shall be as specified in 7.1.1. 7.3.2 Size of Stone : Shall be as specified in 7.1.2. 7.3.3 Dressing: Shall b e as s pecified in 7.2.3 e xcept that no por tion of dr essed surface of joints s hall show a d epth of g ap more than 10 mm from a st raight edge placed on it an d use of chips shall not exceed 15 per cent of the quantity of stone masonry. 7.3.4 Mortar The mortar for jointing shall be as specified. 7.3.5 Laying: Shall be as specified in 7.2.5 except that the use of chips shall not exceed 15% of the quantity of stone masonry and s tone, in each course need not be of the same height bu t not more than two stones shall be used in the height of a course. 7.3.6 Bond Stone, Quoins: Shall be as specified in 7.2.6 and 7.2.7 respectively. 7.3.7 Joints All bed joints shall be horizontal and all side vertical. All joints shall be fully packed with mortar, face joints shall not be more than 20 mm thick. When plastering or pointing is not required to be done, the joints shall be struck flush and finished at the time o f laying. O therwise, the joints s hall be r aked to a m inimum dep th o f 20 mm b y r aking tool during progress of work, where the mortar is still green. 7.3.8 Curing, Scaffolding, Measurement and Rates. Shall be as specified under 7.1. 7.4 PLAIN ASHLAR MASONRY (FIG. 7.10) 7.4.1(A) Stone shall be of t he type specified. It s hall b e h ard, s ound, d urable a nd to ugh, f ree fr om cracks, decay and weathering and defects like cavities, cracks, flaws, sand holes, veins, patches of soft or loose m aterials et c. bef ore s tarting t he w ork, t he c ontractor s hall get t he s tones appr oved by Engineer-in-Charge. 7.4.1(B) Kota Stone for Vineering Kota stone s hall be of s elected quality, har d, s ound, dense & ho mogeneous i n t exture f ree f rom cracks, dec ay, weathering an d f laws. T hey shall be m achine cut t o re quisite s ize and t hickness. They shall be of c olour i ndicated i n t he draw ings or as i nstructed by t he Engineer-in-Charge. T he s tone s hall have t he t op ( exposed) f ace pol ished bef ore bei ng br ought t o s ite unl ess otherwise s pecified. B efore starting t he w ork, t he contractor shall get t he samples of k ota stone a pproved f rom t he Engineer-inCharge. Dressing : Every stone shall be cut to the required size and shape and fine machine dressed to the full depth so that a straight edge laid along the side of stone shall be in full contact with it. The thickness of the slab after it is dressed shall be 20, 25, 30 or 40 mm as specified in the item. Tolerance of ± 2 mm shall be allowed for the thickness. 7.4.1(C) Red Sand Stone & White Sand Stone Ashlar Masonry The stone sh all be r ed or white as s pecified in t he de scription of i tem. T he st one sh all be hard, sound, tough, free from cracks, decay & weathering. In case of red sand stone, white patches or streaks .
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shall not be allowed. However scattered spots upto 10 mm diameter will be permitted. Before starting the work the contractor shall get samples of stone approved by the Engineer-in-Charge. 7.4.2 Size of Stone Normally s tones used should b e s mall e nough t o be l ifted and placed b y h and. T he l ength of t he stone s hall n ot e xceed t hree times the height a nd t he b readth o n base shall no t be greater t han three fourth of the thickness of wall nor less than 15 cm. The height of stone may be upto 30 cm. 7.4.3 Dressing Every stone s hall be c ut to the required size and shape c hisel dressed on all beds and joints so as to be free from w aviness and to gi ve truly v ertical and ho rizontal joints. I n ex posed masonry, t he faces t hat are to remain exposed in the final position and the adjoining faces to a depth of 6 mm shall be the fine chisel dressed so that when checked with 60 cm straight edge, no point varies from it by more than 1 mm. The top and bottom faces that are to form the bed joints shall be chisel dressed so that variation from 60 cm straight edge at no point exceeds 3 mm. Faces which are to form the vertical joints should be chisel dr essed s o t hat v ariation at any poi nt w ith 60 c m s traight edge do es not ex ceed 6 m m. A ny vertical fac e that is to c ome again st bac king o f m asonry shall be dre ssed s uch that v ariation f rom straight edge do es no t ex ceed 10 m m. All a ngles and edges that are to r emain ex posed in the final position shall be true, square and free from chippings. A s ample of dres sed s tone s hall be prepare d for approv al of Engineer-in-Charge. I t s hall be k ept at the worksite as a sample after being approved. 7.4.4 Mortar The mortar for jointing shall be as specified. 7.4.5 Laying All stones s hall be wetted b efore placing i n p osition. T hese shall b e f loated o n m ortar a nd b edded properly in position with wooden mallets without the use of chips or under pinning of any sort. The walls and pillars shall be carried up t ruly plumb or battered as s hown i n drawings. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. In c ase of as hlar w ork w ithout backing of bri ck work or c oursed rubble m asonry, f ace s tone s hall be laid h eaders a nd s tretchers al ternately u nless otherwise directed. T he headers s hall b e a rranged t o come as nearly as possible i n t he m iddle of s tretchers above a nd b elow. S tone s hall be laid i n regular courses of not less than 30 cm in height and all the courses shall be of same height, unless otherwise specified. For ashlar f acing w ith b acking of b rick work or coursed ru bble m asonry ( See F ig. 7 .11) f ace stone shall be l aid in al ternate c ourses of h eaders and stretchers u nless ot herwise directed. F ace s tone an d bond stone course shall be maintained throughout. All connected masonry in a structure shall be carried up nearly at one uniform level throughout, but where breaks are avoidable, the joint shall be made in good long steps so as to prevent cracks developing between new and old work. Bond stone provided in the masonry s hall be payable i n t he i tem of Ashlar masonry. Neither any de duction will be made f rom the brick masonry for embedding t he bond stone in the backing nor an y extra payment shall be made for any extra labour involved in making holes in brick masonry backing. When nec essary, j ib c rane o r o ther mechanical app liances shall be us ed to hoist the heavy pieces o f stones a nd place t hese i nto c orrect po sitions, c are b eing t aken t hat t he corners of t he stone a re no t damaged. S tone shall be covered with gunny bags, before tying c hain or rope is passed over it, and it shall be handled carefully. No piece which has been damaged shall be used in work.
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7.4.6 Bond Stones : Shall be as specified in 7.1.8. 7.4.7 Joints All joints shall be full of mortar. These shall be not more than 6 mm thick. Face joints shall be uniform throughout and a u niform recess of 20 m m depth from face shall b e left with the help o f the steel p late during the progress of work. 7.4.8 Pointing All exposed j oints s hall be poi nted with m ortar as s pecified. The pointing when f inished shall be s unk from stone face by 5 m m or as specified. The depth of mortar in pointing work shall not be less than 15 mm. 7.4.9 Curing Masonry w ork in cement or composite mortar shall be kept constantly moist on all faces for a minimum p eriod of s even da ys. I n case of m asonry w ith f at l ime m ortar, c uring s hall c ommence t wo days after laying of masonry and shall continue for at least seven days thereafter. 7.4.10 Protections Green work shall be protected from rain by suitable c overing. T he work shall also b e suitably protected from damage, mortar dropping and rain during construction. 7.4.11 Scaffolding Double scaffolding having two sets of vertical supports shall be provided. The supports shall be sound and strong, tied together with horizontal pieces over which scaffolding planks shall be fixed. 7.4.12 Measurements The finished w ork shall be measured c orrect to a c entimetre i n respect o f length, br eadth and hei ght. The cubical contents shall be calculated in cubic metre nearest to two places of decimal. 7.4.12.1 No deduction nor any extra payment shall be made for the following : (i) E nds o f di ssimilar materials (that i s joists, bea ms, pos ts, gi rders, rafters, pur lins, t russes, corbels, steps etc.) upto 0.1 sqm in section. (ii) Openings upto 0.1 sqm in area. In calculating the area of opening, any separate lintels or sills shall be included alongwith the size of the opening but the end portion of the lintels shall be excluded and extra width of rebated reveals, if any, shall also be excluded. (iii) Wall plates and bed plates and bearing of chajja and the like, where the thickness does not exceed 10 cm and the bearing does not extend over the full thickness of the wall. Note : The bearing of floor and roof slabs shall be deducted from wall masonry. (iv) Drainage holes and recesses left for cement concrete blocks to embed hold-fasts for doors and windows, building in the masonry iron fixture and pipes upto 300 mm diameter. (v) Stone walling in chimney breasts, chimney stacks, smoke or air flues not exceeding 0.20 sqm in sectional area shall be measured as solid and no extra measurement shall be made for pargetting and coring such flues. Where flues exceed 0.20 sqm in sectional area, deduction shall be made for the same and pargetting and coring flues paid for separately. 7.4.12.2 Square, Rectangular or Circular Pillars: Shall be m easured a nd paid f or as walls, bu t ex tra payment shall be allowed for such pillars and columns over the rate for stone work in walls. Rectangular pillars shall mean a detached masonry support, rectangular in section, such that its breadth shall not exceed two and half times the thickness. 7.4.12.3 Curved Stone Work: Stone work curved on a plan to a mean radius exceeding six metres shall be measured net and included with general stone work. Stone work circular on a plan to a mean radius not exceeding six metres shall be measured separately and extra payment shall be allowed and shall include all cutting and waste and templates. It shall be measured as the mean length of wall.
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7.4.13 Rate The r ate s hall i nclude the c ost of materials and l abour re quired for al l t he o perations d escribed above. Stone facing or wall lining upto and not exceeding 8 cm thickness shall be paid for under “Stone work for wall l ining et c. (Veneer w ork)”. The stone work o f thickness ex ceeding 8 c m s hall be pai d under relevant items of work. 7.5 PUNCHED ASHLAR (ORDINARY) MASONRY (FIG. 7.10) 7.5.1 Stone: Shall be a s specified in 7. 4.1. In c ase of red o r white s and stone, stone s hall b e red o r white as specified in the item. I n red sand stone, white patches or streaks shall not be allowed. However, scattered spots upto 10 mm diameter will be permitted. 7.5.2 Size of Stone : Shall be as specified in 7.4.2. 7.5.3 D ressing: Shall be as specified in 7.4.3 except that the faces exposed in view shall have a f ine dressed chisel draft 2.5 cm wide all round the edges and s hall be ro ugh tooled between the drafts, such that the dressed surface shall not be more than 3 mm from a straight edge placed over it. 7.5.4 Other Details The s pecifications f or m ortars, l aying a nd f ixing, bond stone, j oints, pointing, curing, p rotections, scaffolding, measurements and rates shall be same as specified in 7.4. 7.6 MOULDED, SUNK, CARVED ASHLAR MASONRY (FIG. 7.12) 7.6.1 Stone : Shall be as specified in 7.4.1. 7.6.2 Dressing Every stone shall be cut to the required size and shape and chisel dressed on all beds and joints so as to be f ree f rom a ny w aviness a nd t o gi ve p erfectly v ertical, h orizontal, r adial o r c ircular j oints w ith adjoining stones as the case may be. The dressed surface shall not be more than 3 mm from a straight edge p laced on i t. T he face s hall be g auged, cut, c hamfered, g rooved, rebated s unk o r pl ain m oulded and fine tooled as shown in t he working drawings. The joints 6 mm from the face shall also be fine tooled so that straight edge laid along it is in contact with every point. It shall be finest surface which can be given to a stone with the chisel and without rubbing. In case of sunk or moulded masonry, the corner stone shall be dressed at true right angles or true to the shape as specified. The corners being straight and vertical. For arch (See Fig. 7.13), dome or circular work (See Fig. 7.12) the stone shall be dres sed to require wedge shape so that joints shall be truly radial. 7.6.3 Sample The f ull s ize layout of t he m oulding etc. shall be p repared on platform f rom which s heet t emplates shall b e cut an d the stone dressed to templates to a uniform an d fine finish. All visible an gles a nd edg e shall be t rue s quare and free f rom c hippings. A s ample of dressed s tone s hall be pre pared f or approval and it shall be kept as sample after being approved by Engineer-in-Charge. In case of ashlar m oulded and c arved columns a full size m odel of the required m oulding, carving etc. shall be prepared in plaster of paris and kept at s ite of work as sample work after being approved b y the Engineer-in-Charge. The stones shall be moulded and carved in accordance with the approved model to a uniform and fine finish. 7.6.4 Other Details: Shall be as specified in 7.4.4., 7.4.5 and 7.4.7 to 7.4.11. 7.6.5 Centering and Shuttering Centering and shuttering required for arch dome or circular m oulded work shall be constructed as directed by the Engineer-in-Charge.
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7.6.6 Measurements The d imensions o f the c ircumscribing r ectangles o f the dr essed s tone us ed in the w ork s hall be measured c orrect to a cm and cubical contents shall be calculated in cubic metres, nearest to two places of decimal. 7.6.6.1 In case of sunk or moulded work the measurements for the work shall be taken course by course. The plain stone used in conjunction with sunk or moulded stone shall be measured and paid for under the relevant item of stone work. 7.6.6.2 Sunk or m oulded work in rectangular, square a nd c ircular pi llars, m oulded cornices a nd s tring courses s hall be measured und er s tone w ork s unk or m oulded bu t ex tra payment shall b e al lowed ov er the general w ork i n eac h c ase. N o s uch ex tra pay ment s hall be al lowed f or m oulded s tring and pl inth courses. 7.6.6.3 In case of arch d ome or circular m oulded work for arches exceeding six m etres in clear span extra payment for additional cost of centering shall be made on the actual area of soffit including strutting, bolting, wedging, easing, striping and removal. 7.6.7 Rate The rate includes t he cost of al l m aterials and l abour i nvolved i n al l the operations des cribed above, including centering and shuttering for arch, dome or circular moulded work. 7.7 STONE VENEERING WORK (FIG. 7.14, 7.15 & 7.16) Stone l ining upt o 8 c m s hall be t reated as v eneering w ork and l ining of greater t hickness as pl ain Ashlar Masonry. 7.7.1 Stone : Shall be as specified in 7.4.1. The s tone shall b e g ang s aw c ut i nto s labs of r equired t hickness al ong t he pl anes parallel t o t he natural bed of stone. 7.7.2 Dressing: Shall be as specified in 7.4.3 except that dressing at the back shall not be done, so as to ensure b etter g rip w ith t he hearting or b acking. The dr essed s labs s hall b e of t he t hickness a s specified, with permissible tolerance of ± 2 mm. 7.7.3 Mortar Mortar for fixing shall be as specified. 7.7.4 Laying The stone shall be wetted before laying. They shall then be fixed with mortar in position without the use of chips or underpinning of any sort. 7.7.4.1 Where so desired, the adjoining stones shall be secured to each other by means of copper pins 75 mm long and 6 mm diameter or as specified. 7.7.4.2 Further the stones shall be secured to the backing by means of cramps. T he material for cramps shall hav e hi gh resistance to corrosion under c onditions o f dampness and aga inst the chemical a ction o f mortar or concrete in which cramps are usually embedded. Cramps shall be of 25 mm x 6 mm and 30 cm long in case of backing of stone masonry walls and brick masonry walls thicker than 230 mm. In case of backing with brick masonry walls 230 mm or less thick or RCC members, cramps shall be of 25 x 6 mm and length as per requirement made out of stainless steel or any other metal specified in para 7.7.4.6. Generally the outer length of cramp in half brick work backing shall be 115 mm and in one brick work backing it shall be 150 mm. Typical shape and details of cramps for such backing are indicated in Fig. 7.15 for general guidance. This can be modified as directed by the Engineer-in-Charge, if so required at site. Cramps shall be spaced not more than 60 cm apart horizontally.
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Alternatively the stone may be s ecured to the backing by means of stone dowels 10 x 5 x 2.5 cm as per s hape i ndicated i n F ig. 7. 14 and t he adj oining s tone s ecured t o eac h ot her by m eans of s tainless steel cramps or copper p ins of the s pecified s ize. M inimum o ne c ramp/stone d owel shall b e used t o secure one slab to the backing. 7.7.4.3 Cramps may be attached to its sides (see Fig. 7.16A, 7.16B) or top and bottom (see Fig. 7.16C to F) o r s ides, t op and b ottom (s ee F ig. 7. 16G & H). T he minimum number of c ramps r equired f or f ixing facing unit to the wall are illustrated in F ig. 7.16. T he actual num ber of cramps and their s ections, however, shall be as per requirements of design to carry the loads. 7.7.4.4 Where cramps a re u sed to hold the unit in position only, the facings shall be provided with a continuous support on which t he stones rest at t he g round l evel and ot her s torey l evels, t he support being i n the form of p rojection from o r rec ess in to the c oncrete floor s lab, or a be am between the columns o r a m etal a ngle at tached t o t he f loor s lab o r b eams. T hese supports s hall pr eferably be at vertical i ntervals not more than 3. 5 m apar t and al so ov er t he heads o f al l openi ngs. S uch supports s hall also be provided where there is transition from thin facings below to thick facings above. 7.7.4.5 Alternatively cramps may be used to hold the units in position and in addition to support the units thus transferring the weight of the units to the backing. Such cramp should be properly designed as per IS 4101 (Part 1). 7.7.4.6 The cramps shall be of copper alloyed with zinc or nickel or of stainless steel of grade 304. 7.7.4.7 The pins, cramps and dowels shall be l aid in cement mortar 1:2 (1 cement : 2 f ine sand) and their samples got approved by the Engineer-in-Charge and kept at site. 7.7.4.8 The walls shall be carried up truly plumb. All courses shall be l aid truly horizontal and all vertical joints t ruly vertical. T he stone s hall break j oints o n t he f ace f or at l east h alf t he height of t he course, unless otherwise shown in the dr awings. T he stone shall be laid in regular courses not less than 20 cm height and all the stones shall be of the same height unless otherwise specified. No stone shall be less in length than one and a half times its height unless otherwise specified. 7.7.4.9 As far as possible the backing shall be c arried up s imultaneously with the face work. In case of reinforced cement c oncrete bac king, the lining s hall b e s ecured to the b acking after i t has s et an d g ot cured. The cramps shall be fixed in concrete at the required positions, while laying. 7.7.5 Joints The joints shall be d one with cement mortar 1: 3 ( 1 cement : 3 c oarse sand). All joints shall be f ull of mortar. S pecial c are s hall be t aken t o s ee t hat t he groundings f or v eneer work are f ull of m ortar. I f an y hollow groundings are detected by taping the face stones, these shall be taken out and relaid. The thickness of joints shall be as small as possible, not exceeding 5 m m. For a close butt jointed facing the thickness shall not exceed 1.5 mm. The face joints shall be uniform throughout. Where j oint f iller or c ompound is to be used, the j oints shall be r aked out to a depth of at least 25 mm after t he m ortar i n t he j oints has s et s ufficiently and t he f iller or c ompound applied. T he j oints m ay b e subsequently finished with a m ortar suited t o the appearance of the w ork. It is p referable to u se joint sealing c ompounds w here the facings ar e ex posed to heavy r ainfall and w inds an d their selections would depend upon local experience and availability of joint sealing compounds. In their absence only masonry mortars 1:3 (1 cement : 3 coarse sand) which are proved to be successful from local exposure conditions shall be used. 7.7.6 Other Details Specifications for pointing, curing, protections and scaffolding shall be specified under 7.4.
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7.7.7 Measurements The l ength a nd breadth of t he f inished w ork shall be measured i n metre correct t o cm. The a rea should be calculated in sq. metre correct to two places of decimal. The veneering w ork curved on plan s hall be m easured as pl ain work, but ex tra p ayment s hall be allowed for radii not exceeding six metres on external face. For radius beyond six metres the work shall be measured as plain work only, even the face may have to be dressed to curve. 7.7.8 Rate The r ate i ncludes t he c ost of m aterials and l abour i nvolved i n al l t he oper ations des cribed abov e, except for the c ost o f pr oviding and fixing p ins, dow els an d m etal c ramps and ledges and s upports, which shall be paid for separately unless otherwise stipulated in the item of work. 7.8 STONE CHAJJA (FIG. 7.13) 7.8.1 Stone slabs shall be hard, sound and durable. These shall be chisel dressed on all faces which are exposed t o v iew and rou gh dres sed at ot her s urface. A ngles s hall be t rue a nd edge l ines s traight. T he finished thickness shall be as stipulated with permissible tolerance of ± 2 mm. The length of stone slabs in chajja shall not be less than 60 cm unless otherwise specified. 7.8.2 In case of sloping chajja the stone shall be sloped as specified. It shall have minimum bearing of 20 cm measured horizontally on the wall and the bearing shall also be similarly sloped. Each slab shall have a hole in the centre of the bearing area through which the anchoring M.S. holding down bolt shall pass. The holding do wn bol ts shall be 12 mm di ameter and shall be bent at right angles at its lowest en d and buried horizontally for at least 7 cm in a joint 30 cm below the bearing surface. Each holding down bolt shall be secured at top by suitable washer and nut. The Chajjas shall be provided with cove supports, where cove is in brick masonry, it shall project out from the wall as under. 45 cm wide Chajjas, cove projection 15 cm, depth of cove 3 courses. 60 cm wide Chajjas, cove projection 20 cm, depth of cove 4 courses. 75 cm wide Chajjas, cove projection 25 cm, depth of cove 5 courses. 90 cm wide Chajjas, cove projection 30 cm, depth of cove 6 courses. 7.8.3 In case of horizontal Chajjas, the stone shall be fixed horizontally with a slight outer slope of about 1 cm. It s hall have m inimum b earing o f 1 5 c m on the w all. H olding dow n bo lts s hall be p rovided, on ly where so specified. 7.8.4 Pointing The j oints s hall be poi nted w ith 1: 2 c ement m ortar (1 c ement : 2 s tone dus t) w ith an adm ixture of pigment to match the stone shade, and properly cured. 7.8.5 Other Details Specifications for curing, protections and scaffolding shall be as specified under 7.4. 7.8.6 Measurements The length and breadth of the finished work shall be measured correct to a cm. The area of Chajjas projecting beyond the wall shall be calculated in sq m correct to two places of decimal. In case of sloping Chajjas, the sloping breadth shall be measured correct to a cm and the area of Chajjas projecting beyond the wall shall be calculated in sq m correct to two places of decimal. 7.8.7 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. Anchoring the coves shall be deemed to be included in the rate.
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7.9 SHELVES, COPING, PLAIN, CORNICES, STRING COURSES ETC. 7.9.1 Stone Stone shall be of uniform colour and texture and of the kind as stipulated. 7.9.2 Dressing The exposed faces and sides of shelves shall be chisel dressed such that the dressed surface shall not be m ore t han 3 m m f rom a s traight edge pl aced o n i t. A ll v isible angl es and edges s hall be f ree f rom chippings. The surfaces to be burried in the masonry shall be rough dressed. 7.9.3 Laying These shall be l aid in m ortar of specified m ix and f ixed as shown in drawing or as directed by the Engineer-in-Charge. 7.9.4 Other Details Specifications for pointing, curing, protections and scaffolding shall be as specified under 7.4. 7.9.5 Measurements 7.9.5.1 Shelves: The length and breadt h s hall be measured i nclusive of be arings correct of a cm. T he thickness shall be as specified with permissible tolerance of ± 2 mm. The area shall be calculated in sqm correct to two places of decimal. 7.9.5.2 Copings: The dimensions of t he c ircumscribing r ectangles of t he dressed stones a s u sed i n work s hall be measured correct to a cm. The cubical contents shall be calculated correct to two places of decimal in cum. 7.9.5.3 Plain Cornices, String Courses and Plinth Courses: The l ength, br eadth and dept h of t he stone i ncluding b earing s hall b e m easured c orrect t o a c m. T he c ubical c ontents s hall b e c alculated correct to two places of decimal in cu. m. 7.9.5.4 No deduction shall be m ade from the masonry of wall for the bearing of stone shelves, cornices, string courses. 7.9.6 Rate The r ate s hall i nclude t he c ost of al l m aterials a nd l abour required i n all t he o perations d escribed above. 7.10 STONE JALI 7.10.1 Stone shall be as specified in 7.4.1. 7.10.2 Dressing and Fixing The stone shall be cut into slabs of required thickness so as to make jali of the specified thickness. The jali shall be cut as per pattern shown on the drawings. All exposed faces shall be fine tooled to a uniform a nd s mooth finish. F ixing s hall be done w ith the ad joining w ork in gr ooves, r ebates e tc., as shown in the drawing or as directed by the Engineer-in-Charge. A tolerance of + 2 mm shall be allowed in the specified thickness of the jali. 7.10.3 Stone jalis s hall be fixed in gr ooves/rebates e tc. to ad joining S tone w ork/Brick work/RCC as shown i n t he d rawing or as directed b y E ngineer-in-Charge. N ecessary s ample for the s ame shall be g ot approved from the Engineer-in-charge before execution. The breakage of stone jail during fixing shall be the responsibilities of the contractor and replacement shall be provided at his risk and cost.
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7.10.4 Measurements The length and breadth of the stone forming the jali including its borders shall be measured correct to a cm and the area shall be calculated in square metres nearest to two places of decimal. 7.10.5 Rate It i ncludes t he c ost of l abour and m aterials required f or al l t he operations described abov e. I t al so includes the cost of making grooves or rebates in the adjoining work for fixing jali. 7.11 DRY STONE CLADDING 7.11.1 Material Stone s hall b e of the type a s specified in t he item. It shall be hard, sound durable and tough free from cracks, decay and weathering and defects like cavities cracks, flaws, holes, veins, patches of soft or loose materials etc. Thickness of stone shall be as specified Stone shall be cut with the gang saw to the required size and shape on all beds and joints so as to free from any waviness and to give truly vertical horizontal surface as required. The exposed face and sides of s tones f orming j oints s hall b e such that the straight edge l aid along the face of t he s tone i s i n contact with every point on it. All the visible angle and edges shall be square and free from chipping. The dressed stone shall be of the thickness specified with permissible tolerance of + 2 mm. Before starting t he work, t he c ontractor s hall get the samples of s tone approved by E ngineer-Incharge. Approved sample shall be kept in custody of Engineer-in-Charge and stones supplied and used on the work shall conform to sample with regard to soundness, colour, veining and general texture. The stone shall be cut b y gang s aw i nto slabs of r equired t hickness along t he p laces par allel t o t he natural bed. When necessary double scaffolding for fixing the stone at grea ter he ights, jib crane or other mechanical appl iances s hall be us ed t o hoi st the heavy pi eces of s tone and pl aced t hem i nto c orrect positions. Care shall have to be taken that corners of the stone are not damaged. Stone shall be covered with gunny bags before tying chain or rope is passed over and it shall be handled carefully. No pieces which has been damaged shall be used that work 7.11.2 Stacking and Storing Stone slabs are thin a nd britt le a nd should n ever be s tacked fl at a cross timber s upports. They should t herefore, be stacked o n edge o n t imber or l ike r unners. Packing pi eces i nserted b etween t he slabs may be ro pe or t imber. S labs shall be w ell covered with plastic sheeting to protect them from any possible staining. 7.11.3 Scaffolding As specified in 7.4.11. 7.11.4 Fixing The size & s hape of the c ramps shall be a s per dr awing and as pe r di rections o f E ngineer-in-charge. The s amples o f steel cramps should be ap proved i n adv ance before s tarting the s tone c ladding w ork. The cramp shall be attached to top and bottom of the stone. The cramps shall have inbuilt adjustment for vertical and hor izontal alignment. The cramps used to hold support and t ransfer the l oad of stone unit to the supporting structured steel shall be designed by the manufacturer an d approval of the same shall be obtained from the Engineer-in-Charge. The m inimum num ber of clamps re quired s hall be as per requi rement of des ign t o c arry t he l oad o f individual s tone s labs. The c ramps shall be s paced not more t han 60 c m ho rizontally and v ertically al ong the stone side for insertion of pins / bolt attached with the steel cramps. Adequate cutting in stone shall be made with precision instrument to hold the cramps pins at the joints.
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Stone s hall be s ecured w ith c lamps w ith hi gh qu ality w orkmanship. The w alls shall b e c arried up truly p lumb. A ll the c ourses s hall be laid truly horizontal an d a ll the v ertical joints truly v ertical. T he sequence of execution for cladding work shall be approved by the Engineer-in-Charge. Jointing: Joints horizontal and vertical shall be filled with weather sealant of make as approved by Engineer-in-charge w ith t he hel p o f pouring gun for filling the sealant. B efore f illing the joint with sealant, masking t ape ar e r equired t o be f ixed o n stones s urface on both edges of j oints o f t he s tones, s o t hat sealant m ay not spoil the surface of the stone. W hen all the joints are filled and s ealant has dried, the masking tape may be removed. Protection: Work s hall b e p rotected f rom rain b y suitable covering. The w ork shall al so be suitably protected from damage and rain during construction. Measurement: The length and breadth s hall be m easured c orrect t o a cm. T he area s hall be calculated in square m etre c orrect t o two places of decimal. Any o pening of area 0.01 s qm. o r less shall n ot be deducted. Rate: The rate i ncludes t he cost of m aterials and l abour i nvolved i n a ll operations described above including c ost of support s caffolding s taging, sealant, pouring guns but ex cluding the cost of s teel cramps drilling holes / making recesses in stones which shall be paid for separately. 7.12 STRUCTURAL STEEL FRAME WORK FOR DRY STONE CLADDING Specification f or structural f rame w ork f or d ry s tone cladding a re s ame specifications as f or steel work in built up sections (welded or bolted). 7.12.1 Fixing of Frame The pr operly des igned s tructural f rame f or w ithstanding t he w eight of s tone slab are f ixed/supported on wall surface with the help of M.S. brackets/lugs of angle iron/flat etc. which is welded at each junctions of m ember of f rame and al so e mbedded in c ement concrete bl ock 1: 2:4 (1 cement: 2 c oarse sand: 4 graded stone aggregate 20 mm nominal size) of size 300 x 230 x 300 mm. The concrete block can be made by cutting the hole of size as mentioned in brick wall and filling th e hole with cement concrete including provision of necessary centring/shuttering for holding of concrete. The frame can also b e supported o n RCC surface w ith t he help of a pproved e xpansion hold f astener by drilling t he holes in RCC surface. Steel c ramps a re ei ther w elded o r bol ted t o t he frame (by making nec essary holes i n frame w ork) for holding of stone. 7.12.2 Measurement The m ode of measurement s hall b e t he s ame, a s specified f or s teel work i n bui lt up section except that t he w eight of welding m aterial s hall not be added i n w eight of m embers f or pay ment and not hing extra s hall be pai d f or making holes for t emporary fastening of m embers during erection before welding, which also includes cost of cement concrete block, centring and shuttering and making holes in walls, but excluding the cost of expansion fastener, steel clamps which shall be paid for separately. 7.12.3 Rate The r ate s hall inc lude th e cos t of all la bour and material in volved in all t he o peration d escribed above. 7.13 ADJUSTABLE STAINLESS STEEL CRAMPS The cramps shall be stainless steel of make approved by the Engineer-in-charge. 7.13.1 The weight of the stainless steel clamp (including weight of nut and washer) shall not be less than 260 gms. 7.13.2 Necessary holes at suitable locations are to be done on steel frame work for dry stone cladding to be fixed.
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7.13.3 Necessary recessed are required to be done in stone slab which is required to be supported by clamps. 7.13.4 The one end of steel clamp is fixed on frame with nut and bolt and other end is inserted into recesses/hole for fixing the dry cladding stone on frame. 7.13.5 The rate includes cost of materials and other operations mentioned as above.
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STONE WORK Sub Head : Stone Work Clause : 7.0
COPING PARAPET CORNICE
DOWEL
A
STRING COURSE BED JOINT DOWEL JOINT
BED JOINT COPING METAL CRAMP
PARAPET
JOGGLE JOINT WINDOW SILL
JOGGLE
C B
CORNICE
SECTION OF ASHLAR WITH BRICK BACKING JOGGLE JOINT
Drawing not to scale
Fig. 7.1 : Stone Work
213 | Page HO Civil Specifications Volume - I
STONE WORK (Terminology) Sub Head : Stone Work Clause : 7.0
D
C
A
B
Fig. 7.3 : Rock Faced Stone Surface
Fig. 7.2 : Hammer Dressed Stone Surface
Fig. 7 .5 : Punched Stone Face Surface (Chisel drafted)
Fig. 7.4 : Rough Tooled Stone Surface
Fig. 7.6 : Closed Picked Stone Surface
Fig. 7.7 : Fine Tooled Stone Surface Drawing not to scale
214 | Page HO Civil Specifications Volume - I
RANDOM RUBBLE MASONRY Sub Head : Stone Work Clause : 7.1 Exposed face bushing not more than 40
Plastered f ace bushing not more than 10
Bond or through stone one per 0.5 sqm of wall surface
Chips not to exceed 20% of t he quantity of stone masonry SECTION
ELEVATION
ELEVATION
Drawing not to scale All dimensions are in mm
Face Joints not more than 25
Fig. 7.8 : Random Rubble Masonry 215 | Page HO Civil Specifications Volume - I
RUBBLE STONE MASONRY - COURSED Sub Head : Stone Work Clause : 7.2 & 7.3 FIRST SO RT
SECOND SO RT
Face Joints to be not more than 10
ELEVATION
ELEVATION
Plaster S urface Bushing not more than 10
Chips not to E xceed 15% of the Quantity of S tone Masonry Bond or Through Stone 1500 t o 1800 Apart (Clear)
Quoin S tone 450 Long Min.
ODD COURSE
Exposed f ace Bushing to be not more t han 40
Chips not to E xceed 10% of t he Q uantity of S tone Masonry
EVEN COURSE Drawing not to Scale All dimensions are in mm
Face Joints to be not more than 20
Quoin S tone 450 Long Min.
ODD COURSE
Bond or Through S tones 1500 t o 1800 Apart (Clear)
EVEN COURSE
Fig. 7.9 : Rubble Stone Masonry – Coursed
216 | Page HO Civil Specifications Volume - I
ASHLAR STONE MASONRY Sub Head : Stone Work Clause : 7.4 & 7.5 PUNCHED (ORDINARY)
PLAIN
Face Joints to be not more than 5 m m thick
ELEVATION
ELEVATION
Bond or Through S tone 1500 to 1800 Apart Clear
ODD COURSE
EVEN COURSE
Bond or Through Stone 1500 t o 1800 Apart Clear
ODD COURSE
EVEN COURSE
Drawing not to scale All dimensions are in mm
Fig. 7.10 : Ashlar Stone Masonry
217 | Page HO Civil Specifications Volume - I
ASHLAR STONE MASONRY (WITH BRICK BACKING)
Sub Head : Stone Work Clause : 7.4.5
Brick Backing
200
300
Face Stone
ELEVATION
SECTION
100
Mortar
EVEN COURSE
200
200
ODD COURSE Drawing not to scale All dimensions are in mm
Fig. 7.11 : Ashlar Stone Masonry (with Brick Backing)
218 | Page HO Civil Specifications Volume - I
MOULDED, SUNK, CARVED – STONE WORK Sub Head : Stone Work Clause : 7.6
DOME
COLUMN Finial Stone Work in Ashlar S pecially Moulded & Carved
Exposed Faces and S ide Joints 6 mm f rom Face shall be F ine Tooled
Stone Work in Dome
Plain Ashlar Stone Work in Column
Stone Work in Ashlar P lain, Moulded & Carved Column
Sunk or Moulded Stone Work in Circular P illars (Columns)
ELEVATION OF DOME WITH FINIAL
ELEVATION O F A COLUMN Backing Plain Ashlar
B
Sunk L
SECTIONAL PLAN OF A W ALL WITH A PROJECTION Plain Ashlar Moulded P linth Course
Moulded
Sunk Work B
H L
B
SECTION O F A WALL
Sunk
SECTIONAL PLAN OF A PO RCH PILLAR
Note : Sunk or Moulded Stone Work shown Shaded, to be measured as l x b x h
Drawing not to scale
Fig. 7.12 : Moulded, Sunk, Carved – Stone Work 219 | Page HO Civil Specifications Volume - I
STONE WORK IN ARCHES & CHAJJAS Sub Head : Stone Work Clause : 7.6 & 7.8
Spandrel
Extradose
Decking
Crown
Springing Skewback Intradose Bed Joints
Span
CIRCULAR ARCH
300
Stone Chajja
Anchoring bolt 12 mm
Triangular M.S. Washer 70
Span
Bed Joints 600
FLAT ARCH Drawing not to scale All dimensions are in mm
200
220 | Page HO Civil Specifications Volume - I
Brick Work Plaster
CHAJJA
Fig. 7.13 : Stone Work in Arches & Chajjas
Cove depth & Courses
STONE VENEERING Sub Head : S tone W ork Clause : 7.7 & 7.7.4.2 Gun Metal Cramp 300mm Long Not more than 600 Apart
Brick Backing B
A V
G
Stone Veneer 50 mm Thick
R
Copper Pin
SECTIONAL PLAN Gun M Cramp
C
SECTIONAL PLAN
etal
Stone Dowel
Face Joints to be not more than 15 mm Thick
Gun M etal Cramp SECTIONAL ELEVATION AT 'R.S.'
SECTIONAL ELEVATION AT 'P.Q.'
Stone Dowel
Brick Backing Gun M Cramp
Brick Backing
etal 200
Stone Veneer 50 Thick
Mortar 10 mm Thick
SECTIONAL AT 'X.Y'
Stone Veneer 50 thick
ENLARGED DETAILS AT 'B'
6 mm - 75 Lon g Copper Pin 2 6 2
2 5
3
75
Stone Veneer
PART SECTIONAL PLAN AT 'C'
PART SEC TIONAL PL AN A T ' A' Stone Veneer
2
3
26
103
62 Gun M etal Cramp
6 1.5
PART SECTIONAL ELEVATION AT 'C'
PART SECTIONAL ELEVATION AT 'A'
25
6
25
25 25
300 LONG GUN METAL CRAMP
Drawing not to scale All dimensions are in mm
6
165 LONG GUN METAL CRAMP
25
25
25
STONE DOWEL
GENERAL FIXING ARRANGEMENT
Fig. 7.14 : Stone Veneering
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STONE VENEERING
(Typical Fixing Arrangement) Sub Head : Stone Work Clause : 7.7.4.2 & 7.7.4.6
25 50
30
25 L PLAN
PLAN
6
6 mm S quare Gun Metal Pin
L = 115 MM for Half Brick Backing L = 150 MM for Full Brick Backing
20
6
20
ELEVATION
70
V = Variable as per Site Requirement Based on Thickness of Veneer Use
24
20 6 20
20
Brick Wall
25
V 6
FRONT ELEVATION
SIDE ELEVATION
Fig. 7.15A : Cramp for Brick Backing
Fig. 7.15B : Cramp for R.C.C. Work Backing
70
Non Corrosive Dash Fastener with Washer including B olt of Min. S ize 55 x 7 m m
R.C.C. Wall Stone Veneering
8 98
Mortar as S pecified Face Joints not to be more t han 5 m m
Mortar 10 m m Thick 80 mm or as S pecified SECTION
FRONT ELEVATION
Fig. 7.15C :Typical Details of Cramps for R.C.C. Backing Drawing not to scale All dimensions are in mm
Fig. 7.15 : Stone Veneering (Typical Fixing Arrangement) 222 | Page HO Civil Specifications Volume - I
GENERAL ARRANGEMENT OF CRAMPS Sub Head : Stone Work Clause : 7.7.4.3
A
D
G
B
C
E
F
H
Note : Cramps arrangement is shown above for veneerings with longer sides vertical. For veneerings having the longer sides horizontal, cramps would be arranged to suit the altered positions.
Drawing not to scale
Fig. 7.16 : General Arrangement of Cramps
223 | Page HO Civil Specifications Volume - I
8.0: Marble Work
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CONTENTS Cla us e No.
Brie f De s cription List of Mandatory Tests
P a ge 226
List of Bureau of Indian Standard Codes
227
8.0
General
228
8.1
Classification
228
8.2
Sizes and Tolerances
229
8.3
Physical Properties
229
8.4
Sampling
230
8.5
Marble Work - Table Rubbed and Polished (Plain Work)
230
8.6
Wall Lining / Veneer Work
233
8.7
Marble Stone Flooring and Marble Stone in Risers of Steps and Skirting
235
Fig. 8.1
Marble Stone Veneering (General Fixing Arrangement)
236
Fig. 8.2
Marble Stone Veneering (Typical Fixing Arrangement)
237
Fig. 8.3
General Arrangement of Cramps
238
Fig. 8.4
Marble Slab Urinal Partition
239
.
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LIST OF MANDATORY TESTS
Ma te ria l Cla us e
Marble
Granite
Te s t
8.3 (i) Moisture (Table 8.2) Absorption (ii) Hardness Test (iii) Specific Gravity (i) Moisture (ii) Specific Gravity
Fie ld/ Te s t La bora tory Proce dure Te s t Laboratory -do-do-do-do-
Minimum Qunatity Fre que ncy of te s ting o f ma te ria l/ work for ca rrying out th e te s t IS 1124 100 Sq.m. 100 sqm. or part thereof. Mho’s Scale -do-doIS 1122 -do-doIS 1124 -do-doIS 1122 -do-do-
.
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LIST OF BUREAU OF INDIAN STANDARDS CODES
S . No.
IS . No.
1.
IS 1122
2.
IS 1124
3. 4. 5. 6.
IS 1130 IS 4101 (Part 1) IS 3316 IS 14223 (Part 1)
S ubje ct Method of test for determination of true specific gravity of natural building stones. Method of test for determination of water absorption, apparent specific gravity and porosity of natural building stones. Marble (blocks, slabs and tiles). Code of practice for external facing and veneers: Stone facing. Specifications for structural granite Polished Building Stones (Part-1) Granite
.
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8.0 MARBLE WORK 8.0 GENERAL Marble s hall be har d, s ound, dens e and hom ogeneous i n t exture w ith crystalline texture as f ar as possible. It shall generally be uniform in colour and free from stains, cracks, decay and weathering. 8.0.1 Marbles are m etamorphic rocks capable of taking polish, formed from the re-crystallization of lim e stones o r dol omitic l ime s tones an d ar e di stinguished f rom l ime s tone by even v isibly c rystalined n ature and no flaggy stratification. Note : Marble is a product of nature hence it is difficult to guarantee uniformity of colour, veining or other characteristics that may be represented in any sample submitted. A sample will indicate only an average of colour, veining and other general texture and specified finish. 8.1 CLASSIFICATION The marble blocks, slabs and tiles shall be classified broadly in the following two categories: 8.1.1 White Marble Ra j Na ga r (pla in white ) Ma rble : It shall be plain white marble with coarse grains predominantly showing mica particles giving reflection in light. 8.1.2 Coloured Marble (i) Plain Black Marble Black marble sawn along veins locally known as ‘Peta Pasu sawing’ available at Bhainslana. (ii) Black Zebra Marble/ Cuddapa Balck (a) Bha ins la na Bla ck Ze bra Ma rble : Black m arble hav ing gr ey or w hite veins av ailable at Bhainslana. (b) Kis ha nga rh B la ck Ze bra Ma rble : Black m arble with g rey a nd/or w hite vei ns a vailable at Kishangarh. (c) Abu Bla ck Ze bra Ma rble : Black marble having white patches and streaks available at Abu. (d) Na rna ul Bla ck Ze bra Ma rble s : Black marble with thin white veins available at Narnaul. (e) Cudappa Black Marbles: Black Marble from Cuddapa (iii) Green Marble (a) Ba roda Gre e n Ma rble : Dark green marble with flowery pattern available at Baroda. (b) Abu G re e n Ma rble : Light green marble with green and/or brown streaks on white ground available at Ambaji. (c) Fa lna Gre e n Ma rble : Green marble with prominent yellowish pattern available at Falna. (d) Bundi G re e n Ma rble : Green m arble w ith pi nkish shades av ailable at U mar, ( Bundi). (iv)Grey Marble (a) Kuma ri Gre y Ma rble : Grey marble having light blue shades available at Makrana. (b) Bundi G re y Ma rble : Grey M arble with pink or green or black streaks av ailable at U mar (Bundi). (v) Brown Marble (a) Bar Brown Marble/Brown Marble with light and dark brown shades available at Bar. (b) Narnaul Brown Marble Brown marble having teak wood shades available at Narnaul. 8.1.3 Granite Stone It shall be of any colour and size as directed by Engineer-in-Charge. Granite shall be plain machine cut and mirror polished. The stone shall be smooth and of even surface without holes or pits. .
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8.2 SIZES AND TOLERANCES The size of marble blocks, slabs and tiles shall be as mentioned in Table 8.1. TABLE 8.1 Sizes of Marble Blocks, Slabs and Tiles
1. 2. 3.
Le ngth 30 to 250 70 to 250 10 to 60
Blocks Slabs Tiles
Width 30 to 100 30 to 100 10 to 60
Thickne s s 30 to 90 2 to 15 0.8 to 2.4
(1) All dimensions are in centimetre. (2) The length and width, of the blocks shall be in multiple of 30 cm. (3) Length and width of slab shall be in multiple of 10 cm. and thickness in multiple of 1 cm. (4) Tiles shall be square cut and linear dimensions in multiple of 10 cm. (5) Only slabs and tiles shall be machine cut and factory made. (6) For 8 mm thick tiles, special precautions will be required for fixing them like using special adhesive as per manufacturer’s specifications. Such tiles are not suitable for outside veneering work exposed to rains/sun if used in large areas in continuous stretches. For tiles of thickness 20 mm and above cramps may be provided if approved by Engineer-in-Charge. Tolerance The following tolerances shall be allowed in the dimension of blocks, slabs and tiles: Tolerance Blocks (a) Length + 2 per cent (b) Width + 2 per cent (c) Thickness + 2 per cent S la bs (a) Length + 2 per cent (b) Width + 2 per cent (c) Thickness + 3 per cent Tile s (a) Linear dimension + 3 per cent (b) Thickness + 1 per cent The s izes ot her than those mentioned abov e may be pr ovided as di rected b y the E ngineer-in-Charge and nothing extra shall be payble on this account. 8.3 PHYSICAL PROPERTIES 8.3.1 The physical properties of marble for blocks, slabs and tiles and method of tests are mentioned in Table 8.2. TABLE 8.2 Physical Properties of Marble & Granite Marble
Granite
Cha ra cte ris tic
Ma rble Re quire me nts
Me thod o f te s t
Gra nite Re quire me nt
(1) Moisture absorption after 24 hrs immersion in cold water (2) Hardness (3) Specific Gravity
Max. 0.4%
IS 1124
Max. 0.50% by weight
Min. 3 Min. 2.5
Mhos scale IS 1122
__
Min. 2.6
Me thod of te s t
IS 1124
__
IS 1122
.
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8.3.2 Approval of Sample Before s tarting t he w ork, t he c ontractor s hall get s amples of m arble appr oved by t he E ngineer-inCharge. A pproved samples sh all be ke pt in the cus tody of the E ngineer-in-Charge a nd th e marble supplied and us ed on t he w ork s hall c onform t o s amples w ith regard t o s oundness, c olour, v eining a nd general texture. 8.4 SAMPLING In an y c onsignment al l t he bl ocks/slabs/tiles of t he s ame g roup, s ize a nd finish s hall b e g rouped together t o constitute a l ot. S ample shall be s elected and t ested separately for eac h lot f or d etermining its conformity or otherwise to the re quirements of t he s pecification. T he nu mber of blocks/slabs/tiles to be selected for the samples shall depend upon t he size of the lot and s hall be in accordance with the Table 8.3. TABLE 8.3 Sample Size and Criteria for Conformity Numbe r of Blocks s la bs /Tile s in the lo t (1) Up to 50
Numbe r of blocks s la bs / T ile s to be s e le cte d in s a mple (2) As per site Engineer
50 to 200
Pe rmis s ible numbe r of de fe ctive s
S ub s a mple S i z e in no.
(3) 0
(4) 2
5
0
2
201 to 500
8
0
3
501 to 1000
20
1
4
Note: The blocks/slabs/tiles in the sample shall be taken at random and in order to ensure to randomness of selection, random tables may be used. Explanation 1 : All the blocks/slabs/tiles, selected in the sample, shall be examined for dimensions workmanship and general requirements. Any block/slab/tile fa iling in any o ne o r m ore of t he a bove re quirements shall be c onsidered a s defective. A l ot shall b e considered as c onforming t o t hese requirements i f t he number of defectives obtained is not more than permissible no. of defectives given in Col. 3 of table 8.3 Explanation 2 : The lot having been found satisfactory with respect to dimensions, workmanship and general requirement shall be tested for physical properties of the marble. For this purpose a sub sample of the s ize g iven i n Col. 4 of T able 8. 3 shall b e s elected a t ra ndom. T hese bl ocks/slabs/tiles i n t he s ub sample shall be tested for moisture absorption, hardness and specified gravity. The lot shall be considered having satisfied the requirements of the physical properties if none of the blocks/slabs/tiles tested for the requirements fails in any of these tests. 8.5 MARBLE WORK - TABLE RUBBED AND POLISHED (PLAIN WORK) Marble work in steps, jambs, columns and other plain work shall be as specified below: Joints in staircase treads, kitchen platforms shall be permitted only at curvature or when width/length is more than 0 .6/2 m trs. respectively. N umber of joints in eac h d irection s hall no t be m ore than o ne number for every 2 mtrs. length beyond the initial 2.00 m length. Additional joints due to curvature or for providing fixture shall be provide judiciously as given in sketch ‘A’ below.
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3.8 m 0.6 m
0.6m
1m
1.0m
0.9 m 0.6 m (I) T READ/STEPS IN STAIR CASE
(II) TYPICAL KITCHEN PLATFORM INDICATING LOCATION OF JOINT IN MARBLE TOP
SKETCH (A) 8.5.1 Dressing, Cutting and Rubbing Every m arble s tone s hall b e gang saw/machine cut to the required s ize a nd s hape, c hisel d ressed machine f inished on al l beds and j oints, s o as t o be f ree f rom any w aviness and t o gi ve truly v ertical, horizontal, radial or circular joints as r equired. The exposed faces and sides of stones forming joints upto 6mm. from the face shall be fine tooled machine cut such that a straight e dge laid along the face of the stone is in c ontact w ith ev ery po int on it. A ll w indow s ills, tread o f s teps, c ounters v anities m oulding edges etc. shall be machine cut & polished to give high gloss mirror finish as per direction of Engineerin-Charge. T hese s urfaces shall t hen b e rubbed smooth. All v isible a ngles a nd e dges s hall b e t rue, square and free from chipping. Beyond the depth of 6 mm from face, the joints shall be dressed with a slight splay so that the thickness of joint increases, in an i nverted V shape as shown in Fig. b elow. The surfaces of the stones coming in contact with backing need not be chisel dressed. EXTERNAL FACE 1.5 mm 6 mm
INVERTED V-SHAPE JOINT A s ample of dressed and rubbed s tone shall be prepared for approval and i t shall be kept on worksite after being approved by the Engineer-in Charge. 8.5.2 Mortar The mortar used for jointing shall be as specified. 8.5.3 Laying All marble stones s hall b e wetted b efore p lacing i n p osition. T hese shall t hen be f loated o n m ortar and bedded properly in p osition with wooden m allets without the use of chips or under pinning of an y sort. The walls and pillars shall be carried up truly in plumb or battered as shown in the drawings. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. In case of work without backing of br ick work or c oursed rubb le masonry, face stone shall be laid in headers and s tretchers al ternatively unl ess ot herwise di rected. T he header s s hall be arrang ed t o c ome
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as near ly as pos sible in t he middle o f stretchers abov e and bel ow. S tone s hall be l aid i n regular courses of not less than 15 cm in height and all courses shall be of the same height unless otherwise specified. For w ork f acing w ith backing of brick w ork or c oursed rubble m asonry, f ace s tone s hall be l aid i n alternate courses of header and stretchers unless otherwise directed. Face stone and bond stone courses shall have break joint on t he face of atleast half the height of the standard course and the bond shall be c arefully m aintained through ou t. A ll t he c onnected m asonry in a structure s hall b e c arried u p nearly at on e u niform l evel t hroughout b ut w here breaks ar e u navoidable t he j oints s hall be m ade i n good long steps so as to prevent cracks developing between new and old work. When necessary jib crane or other mechanical appliances shall be used to hoist the heavy pieces of stones a nd place these i n to correct p ositions, care being taken that the corners of t he stone are not damaged. Stone shall be covered with gunny bags, before putting chain or rope is passed over it, and it shall b e h andled c arefully. N o pi ece w hich h as been d amaged s hall b e u sed i n w ork. T he m atching of grains shall be carried out as directed by the Engineer-in-Charge. 8.5.4 Bond Stone Bond or through stones running right through the thickness of walls, shall be provided in walls upto 60 cm thick and i n case of wall above 60 c m thickness a s et of two or m ore bond s tones ov erlapping each other by atleast 15 cm shall be provided in a line from face to back. At least one bond stone or a set of bond stones shall be provided for every 0.5 sqm of the wall surface. All bond stones shall be marked suitably as directed by the Engineer-in-Charge. 8.5.5 Joints The depth of joints 6 mm from the face shall be uniform and as fine as possible but shall be not more than 1.5 mm thick on t he ex posed face. Beyond t he depth of 6 m m from f ace, the t hickness of j oints shall increase in an inverted V shape so as to give good mortar bond between two stones. The inverted portion of the joints shall be filled with bedding mortar and the face 6 mm portion with pointing mortar. 8.5.6 Curing The work shall be kept constantly moist on all faces for a period of atleast seven days. 8.5.7 Finishing After the marble work is cured, it shall be rubbed with carborandum stone of different grades no. 60, 120 and 320 i n s uccession or w ith electrical rubbing m achines rubbed w ith c arborandum i tems 0 to 6 nos.in succession, so a s to give a pl ane true and h ighly smooth surface. It shall then be cleaned with a solution of oxalic acid, washed and finished clean. 8.5.8 Protection Green w ork s hall be prot ected from ra in by s uitable c overings. T he w ork shall a lso be s uitably protected from damage during construction. 8.5.9 Scaffolding Double s caffolding hav ing two sets o f v ertical supports s hall be pr ovided w here nec essary. The supports s hall be s ound and s trong, t ied t ogether by hori zontal pi eces ov er which t he s caffolding plank shall be fixed. 8.5.10 Tolerances As per para 8.2 Note: The a bove Para 8 .5. al so app lies t o t he A shlar m asonry ref erred i n C hapter No. 7. 0 - Stone Work.
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8.5.11 Measurements For plain work: Measurements shall be taken correct to a cm in length and breadth and correct to 0.5 cm in thickness. 8.5.11.1 In the case of radially dressed or circular stone used in the work, the dimensions of the circumscribing rectangle of t he dres sed s tone, s hall be m easured c orrect t o a c entimetre and t hickness, correct to 0.5 cm. The cubical contents shall be calculated in cubic decimetre nearest to two places of decimal. 8.5.11.2 The marble work in arches and dom es shall be m easured a s for plain work, but extra shall b e allowed for such work over the rate for plain work. 8.5.11.3 Sunk or moulded work in marble shall be measured by volume as per plain marble work or work in arches or domes as the case may be on the basis of circumscribed rectangular block of the finished work but extra s hall be paid f or s uch work over t he r ate f or plain w ork for w ork i n ar ches and do mes. For the purpose of extra payment, volume of every stone sunk or moulded shall be considered. 8.5.12 Rate The rate includes the cost o f m aterials and labour required for all the operations i/c cutting of recesses in wall cutting moulding corners edge rounding finishing & polishing as specified. 8.5.13 Use of Finished Marble Slabs and Tiles In case such finished tiles are used, these shall be measured and paid for separately. 8.6 WALL LINING/VENEER WORK 8.6.1 Unless a nd ot herwise s pecified in the no menclature of the item, the m arble slabs u sed for w all lining/veneer work shall be gang s aw c ut (polished & m achine c ut) and c onform t o di mensions gi ven i n Table 8.1 above. Back shall not be polished/ cut in order to ensure a good grip with the hearting of backing. The cut slabs s hall be o f the thickness as s pecified w ith a tolerance p ermissible under par a 8 .2 ab ove. T he tolerance in wall lining when straight edge of 3 m length is placed should not be more than 2 mm. 8.6.2 Laying The stone shall be wetted before laying. They shall then be fixed with mortar in position without the use of chips or u nder pi nning of any s ort. Care s hall be taken to m atch the grains of v eneer w ork as directed b y th e E ngineer-in-Charge. F or purpose of m atching t he g rains, t he m arble slabs s hall b e selected j udiciously hav ing uni form pattern of v eins/streaks. P referably t he slabs s hall be t hose got o ut of the same block from the quarry. The area to be veneered shall be reproduced on the ground and the marble slabs l aid i n p osition a nd a rranged i n t he m anner t o gi ve t he de sired m atching of g rains. A ny adjustment needed f or achieving t he b est results s hall be then c arried out by repl acing or i nterchanging the particular slabs. Special care shall be t aken to ac hieve t he continuity o f gr ains bet ween t he t wo slabs one a bove t he other along t he h orizontal j oints. This shall t hen b e g ot a pproved b y t he Engineer-inCharge and eac h marble s labs num bered pr operly and the same nu mber shall be marked on a s eparate drawing as w ell as on t he s urface t o be ac tually veneered, s o as t o ens ure t he fixing of t he particular slabs in the correct location. For the facing of the columns also the same procedure as mentioned above shall be followed. 8.6.2.1 Where so desired, the adjoining stones shall be secured to each other by means of copper pins 75 mm long and 6 mm diameter or as specified.
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8.6.2.2 The stones shall be secured to the ba cking by means of cramps. The material for cramps shall have h igh r esistance to c orrosion under c onditions o f dam pness and a gainst the c hemical a ction o f mortar or concrete in which cramps are usually embedded. Cramps shall be of 25 × 6 mm and 3 0 cm long in case of backing of stone masonry walls and brick masonry walls t hicker than 230 mm. In c ase o f bac king with b rick masonry walls 230 mm o r less thick or RCC members cramps shall be of 25 × 6 mm and length as per requirement made out of gun metal or any ot her m etal s pecified in para 8 .6.2.6. G enerally t he out er l ength of c ramp i n hal f bri ck w ork bac king shall be 115 mm and in one brick work backing it shall be 150 mm. Typical shape & details of cramps for such backing are as indicated in Fig. 8.2 for general guidance. This can be modified as directed by the Engineer-in-Charge if so, required at site. Cramps shall be spaced not more 60 cm apart horizontally. Alternatively the stone may be secured to the backing by means of stone dowels 10 x 5 x 2.5 cm as per shape indicated in Fig. 8.1. 8.6.2.3 The adjoining stones shall be secured to each other by means of gun metal cramps or copper pins of the specified size. Cramps may be attached to its sides (see Fig. 8.3A, 8.3B) or top and bottom (See Fig. 8. 3C, D, E, F) or sides, top and bottom (see Fig. 8. 3G, 8.3H). The general a rrangement of cramps required for fixing facing unit to the wall are illustrated in Fig 8.3. The actual number of cramps and their sections, however, shall be as per requirements of design to carry the loads. 8.6.2.4 Where cramps a re u sed to h old the unit in position onl y, the facings shall be provided with a continuous support on which t he stones rest at t he g round l evel and ot her s torey l evels, t he support being i n the form of p rojection from o r rec ess in to the c oncrete floor s lab, or a beam betw een the columns o r a m etal a ngle at tached t o t he f loor s lab o r b eams. T hese supports s hall pr eferably be at vertical i ntervals not more than 3. 5 m apar t and al so ov er t he heads o f al l openi ngs. S uch supports s hall also be provided where there is transition from thin facing below to thick facings above. 8.6.2.5 Alternatively cramps may be used to hold the units in position and in addition to support the units thus transferring the weight of the units to the backing. Such cramps should be properly designed as per IS 4101 (Part 1). 8.6.2.6 The cramps may be of copper alloyed with zinc, tin, nickel, lead or stainless steel. 8.6.2.7 The pins, cramps and dowels shall be laid in cement mortar their samples got approved by the Engineer-in-Charge and kept at site.
1:2 (1 cement : 2 fine sand) and
8.6.3 Joints All joints s hall be f ull of m ortar. S pecial c are s hall be taken t o s ee t hat groundings for v eneer w ork are full o f mortar. If any h ollow gr oundings a re det ected b y t apping t he face s tones, these shall be t aken out a nd r elaid. The t hickness of t he f ace j oints s hall be uniform, straight a nd as f ine a s p ossible, n ot more than 1.5 m m and in the face joint, the top 6 mm d epth shall be filled with m ortar specified for the pointing. 8.6.4 Mortar The mortar used for jointing slabs shall be as specified. 8.6.5 Curing, Finishing, Protection and Scaffolding It shall be as specified under 8.5.6, 8.5.7, 8.5.8 and
8.5.9.
8.6.6 Measurements The length an d b readth shall be measured c orrect to a c m. In case of radially dr essed or c ircular slabs us ed i n t he work, the di mensions of t he circumscribing rectangles o f the d ressed s tone us ed in the work, shall be measured & paid for. The area shall be calculated in sqm nearest to two places of decimal.
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Marble w ork in lining u pto 4 c m thickness s hall b e pa id by ar ea un der v eneer w ork an d lining o f greater thickness paid by volume under plain marble work. 8.6.7 Rate The r ate i ncludes t he c ost of m aterials and l abour r equired f or al l t he oper ations des cribed abov e except for the cost of providing and fixing of dowel a nd cramps which shall be paid for separately, unless otherwise stipulated in the item of work. When factory made finished slabs and tiles are used, no further finishing as mentioned in para 8.5.7 shall be required nor anything extra shall be payable. 8.7 MARBLE STONE FLOORING AND MARBLE STONE IN RISERS OF STEPS AND SKIRTING Refer to relevant clause in subhead 11.0 of flooring of Specifications. 8.7.0 Marble Slab Urinal Partitions The partitions shall be of marble slab embedded in the wall. The size and shape of the marbles slab shall be as per direction of Engineer-in-Charge. The finished thickness shall be 18 mm. The specifications for marble/granite stone work, in general, shall be as specified. The marble granite stone shall be cut into slabs of required thickness and shall be one piece. (Fig. 8.4). 8.7.1 Finishing The partition of t he slab to b e e mbedded in t he masonry shall b e ro ugh dressed. Dressing an d rubbing of the ex posed portion of the slab s hall be as des cribed. T he dres sed slab s hall be of the thickness as specified with a tolerance of + 1.5mm. The s lab shall be got app roved from the E ngineer-inCharge before fixing. 8.7.2 Fixing shall b e a s specified except that the r ecess shall b e 7.5 cm wide. Fixing shall b e d one by cutting c hase with chase c utter/fine tools i n a recess of 7.5 cm X 7. 5 cm filled with c ement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 6mm nominal size). Fixing can also be done by epoxy grout in a chase of 2.0 X 7.5 cm as per direction of Engineer-in-Charge. 8.7.3 Measurement shall be as per para 8.6.6. 8.7.4 Rate shall include the cost of labour and materials involved in all the operations described above i ncluding t he l eaving/cutting of rec ess i n t he wall, m oulding, c urves, ed ge roun ding, f inishing an d polishing as specified.
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MARBLE STONE VENEERING Sub Head : Marble Work Clause : 8.6.2.2 Gun Metal Cramp 600mm Long Not more than 600 Apart
Brick Backing B
A V
G
Stone Veneer 50 mm Thick
C
R
Copper Pin SECTIONAL PLAN
SECTIONAL PLAN Gun Metal Cramp
Stone Dowel
Face Joints to be not more than 15 mm Thick
Gun Metal Cramp ENLARGED DETAILS AT 'R.S.'
SECTIONAL ELEVATION AT 'P.Q.'
Stone Dowel
Brick Backing
Brick Backing
Gun Metal Cramp
Mortar 10 mm Thick
200
Stone Veneer 50 Thick
SECTION AT 'X.Y'
Stone Veneer 50 thick
ENLARGED DETAILS AT 'B'
6 mm - 75 Long Copper Pin 2 6 2
2 5
3
75
Stone Veneer
PART SECTIONAL PLAN AT 'C'
PART SECTIONAL PLAN AT 'A' Stone Veneer
2
3
26
103
62 Gun M etal Cramp
5 1.5
PART SECTIONAL ELEVATION AT 'C'
PART SECTIONAL ELEVATION AT 'A'
250
25
100 15
6
25
115
25 25
6
50
25
25
25
50 300 LONG GUN METAL CRAMP
165 LONG GUN METAL CRAMP
STONE DOWEL
Drawing not to scale All dimensions are in mm
Fig. 8.1 : Marble Stone Veneering (General Fixing Arrangement)
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MARBLE STONE VENEERING (Typical Fixing Arrangement) Sub Head : Marble Work Clause : 8.6.2.2 25 50
30
25 L PLAN
PLAN
6 20
20 6 20
24
V = Variable as per Site Requirement Based on Thickness of Veneer Use
6 mm S quare Gun Metal Pin
L = 115 MM for Half Brick Backing L = 150 MM for Full Brick Backing
20
6
20
ELEVATION
70
Brick Wall
25
V 6
FRONT ELEVATION
SIDE ELEVATION
Fig. 8.2A : Cramp for Brick Backing
Fig. 8.2B : Cramp for R.C.C. Work Backing
70
Non Corrosive Dash Fastener with Washer including B olt of Min. S ize 55 x 7 m m
R.C.C. Wall
EQ
EQ
8 98
Stone Veneering
Mortar as S pecified Face Joints not to be more t han 1.5 mm
Mortar 10 m m Thick 80 mm or as S pecified SECTION
FRONT ELEVATION
Fig. 8.2C :Typical Details of Cramps for R.C.C. Backing
Drawing not to scale All dimensions in mm
Fig. 8.2 : Marble Stone Veneering (Typical Fixing Arrangement)
237 | Page HO Civil Specifications Volume - I
GENERAL ARRANGEMENTS OF CRAMPS Sub Head : Marble Work Clause : 8.6.2.3
A
D
G
B
C
E
F
H
Note : Cramps arrangement is shown above for veneerings with longer sides vertical. For veneerings having the longer sides horizontal cramps would be arranged to suit the altered positions.
Drawing not to Scale
Fig. 8.3 : General Arrangements of Cramps
238 | Page HO Civil Specifications Volume - I
MARBLE SLAB URINAL PARTITION Sub Head : Marble Work Clause : 8.7
Shape as per requirement
450 above Ground Level or upto Ground Level as Directed
75
Drawing not to scale All dimensions are in mm
Fig. 8.4 : Marble Slab Urinal Partition
239 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
9.0: Wood Work
240 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
CONTENTS Cla us e No.
List of Mandatory Tests
Brie f De s cription
P a ge No. 244
List of Bureau of Indian Standard Codes
245
9.0
Terminology
247
9.1
Timber
248
9.2
Panelling Material
251
9.3
Door, Window and Ventilator Frames
257
9.4
False Ceiling and Partition Frames
258
9.5
Trusses
258
9.6
Panelled Glazed or Panelled and Glazed Shutters
259
9.7
Flush Door Shutters
264
9.8
Wire Gauze Fly Proof Shutters
266
9.9
Wall Lining
267
9.10
Shelves
268
9.11
Trellis (Jaffri) Work
268
9.12
Pelmets
268
9.13
Hold Fasts
269
9.14
Expanded Metal, Hard Drawn Steel Wire Fabric and Wire Gauze in Wooden Frames
269
9.15
Fittings
269
9.16
Laminated Veneer Lumber (LVL) - DELETED
278
9.17
Partitions
279
9.18
UPVC Door Frames - DELETED
279
9.19
PVC Door Shutters - DELETED
279
9.20
PVC Door Frame
279
9.21
30mm Thick Panel PVC Door Shutter
280
.
241 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
9.22
Fibre Glass Reinforced Plastic (FRP) Door Frames - DELETED
280
9.23
Fibre Glass Reinforced Plastic (FRP) Shutters - DELETED
281
9.24
Solid PVC Foam Profile Doors - DELETED
281
9.25
Solid PVC Foam Shutters - DELETED
281
9.26
Factory Made Fibre Glass Reinforced Plastic Chajja - DELETED
281
9.27
Wall Panelling
281
Appendix A
Permissible Defects for Various Grade of Timbers
282
Appendix B
Different Climatic Zones for Moisture Content of Timber
283
Appendix C
Moisture Content of Timber
284
Appendix D
Physical and Mechanical Properties of Plywood
285
Appendix E
Physical and Mechanical Properties of FPT or Graded Particle Board.
285
Appendix F
Test for Flush Door Shutters
286
Appendix G
Test for Mortice Locks
288
Appendix H
Schedule of Fitting for Doors and Windows
289
Appendix I
Method of Test for Edge Straightness and Squareness of Plywood
290
Appendix J
Method of Test for Edge Straightness and Squareness of Coir Veneer Board - DELETED
Appendix K
Method for Test of Coir Veneer Board for Determination of Glue Shear Strength - DELETED
Fig. 9.1
Joints in Timber
291
Fig. 9.2
Terminology Timber Door, Window and Ventilator Components
292
Fig. 9.3
Wooden Flush Door Shutters
293
Fig. 9.4
Hold Fast
294
Fig. 9.5 to 9.6
Hinges
295
Fig. 9.7
Sliding Door Bolts
297
Fig. 9.8
Barrel Tower Bolts
298
Fig. 9.9
Pull Bolt Locks
299
.
242 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
Fig. 9.10
Mortice Lock & Latch
300
Fig. 9.11
Mortice Night Latch
301
Fig. 9.12
Handles for Doors & Windows
302
Fig. 9.13
Floor Door Stopper - Cast Type
304
Fig. 9.14
Window Stay & Hooks & Eyes
304
Fig. 9.15
Hasps & Staples
305
Fig. 9.16
LVL Shutter
306
Fig. 9.17
Partitions
307
Fig. 9.18
UPVC Door Frame - DELETED
307
Fig. 9.19
24 mm Thick PVC Door Shutters - DELETED
307
Fig. 9.20
30 mm Thick PVC Door Shutters - DELETED
307
Fig. 9.21
PVC Door Frame
308
Fig. 9.22
30 mm Thick Panel PVC Door Shutter
309
Fig. 9.23
FRP Door Frame
Fig. 9.24 Fig.9.24 B Fig. 9.25
Typical Sketch of FRP Door Shutter Sketch Illustrating Dimensions of shutter Solid PVC Foam Profile Shutter
Fig. 9.26
Solid PVC Foam Shutter (28 mm Thick) - DELETED
Fig. 9.27
FRP Chajja - DELETED
Fig. 9.28
Wall Panelling
310 311
312
.
243 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LIST OF MANDATORY TESTS
Ma te ria l
Cla us e
Te s t
Fie ld/ La bora tory Te s t
1 Timber
2 9.1.6
3 Moisture content
Flush door
9.7.10
End immersion Test knife test Adhesion Test
Mortice Locks
9.15.13
Testing spring
of
Te s t Min. Fre que ncy P roce dure Qua ntity of of Te s ting Ma te ria l for ca rrying out the te s t 4 5 6 7 Field (by Appendix ‘C’ 1 cum Every one moisture meter) cum or part laboratory test thereof. as required by Engineer-inCharge Laboratory IS 2202 26 shutters As per Appendix ‘F’ sampling and testing specified in clause 9.7.11 Laboratory IS 220950 Nos 100 or part Appendix ‘G’ thereof.
.
244 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
9.0 WOOD WORK AND P.V.C. WORK 9.0 TERMINOLOGY Ballies : Thin round poles usually without bark. Beam : A s tructural timber generally l ong in pr oportion t o i ts width and thickness and us ed for supporting load primarily by its internal resistance to bending. Block B oard : A B oard h aving a c ore made up of s trips of w ood, ea ch no t ex ceeding 25 mm in w idth, laid s eparately or gl ued or otherwise joined to f orm a slab w hich is glued between two o r more outer veneers with the direction of the grain of the core blocks running at right angles to that of the adjacent outer veneers. Core : The inner layers of a composite wood product. Cross B and : A general term i ndicating a t ransverse l ayer of veneer or v eneers i n composite w ood products. Decorative Veneers : Veneers having attractive appearance due to figure, colour, grain, lusture, etc. Hard W ood : A c onventional t erm used t o denote the w ood obtained f rom broad-leaved t rees. It has no relationship t o t he phy sical pr operties of har dness or s trength. O n ac count of t he c onfusion t his w ord might cause, its use is discouraged. Freeze Rail : Horizontal member, m ortised or ot herwise s ecured t o t he s tiles of a door , provided j ust below the freeze panel usually provided for decorative purposes in the uppermost portion of the door. Joint : A prepared connection for joining adjacent pieces of wood, veneer, etc. Dovetail Joint : A joint at the corner of two pieces in such a way that the notches made to one are fitted exactly i nto proj ections of c orresponding size and shape m ade i n the ot her. T here are v arious k inds of dovetail j oints f or i nstance, l apped dovetail j oint, w edge shaped dovetail j oint, et c. j oined i n a w ay which will resist withdrawal except in the direction in which it was assembled (Fig. 9.1C). Mitred J oint : A joint, b etween two m embers at an angle w hich bi sects t he j oining angle usually t he joining faces are cut at 45° to form a right angle (Fig. 9.1B). Mortise and Tenon Jo int : A j oint i n w hich t he reduc ed e nd (tenon) of one member f its i nto t he corresponding slot (mortise) in another member (Fig. 9.1D). Tongue a nd G roove J oint : A joint in w hich a tongue is provided on edge of one m ember to fit into a corresponding groove on the other (Fig. 9.1A). Knot : Base of a branch or limb embedded in the tree which becomes visible when it is cut. Diameter of a Knot : The m aximum distance b etween t wo p oints f arthest apart on t he pe riphery of a round knot, on the f ace where it becomes visible. In t he c ase of a spike o r splay k not, t he m aximum width of the knot visible on the face on which it appears shall be taken as its diameter. Muntin : Small hor izontal or v ertical d ividing bar s w ithin bas ic framework o f a w indow, or door subdividing and supporting the glass panes or panels of doors.
247 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
Particle Board : A bo ard m anufactured f rom pa rticles o f w ood o r ot her l ignocellulose m aterial, fo r example, f lakes, granules, s havings, slivers, s plinter aggl omerated, f ormed and pressed t ogether by use of an or ganic binder together with one or m ore of the agents, such as he at, pressure, m oisture and a catalyst. Particle : Distinct particle o r f raction of wood, or other l ignocellulose m aterial p roduced m echanically for use as t he a ggregate f or m aking a par ticle boa rd. T his m ay be i n t he f orm of f lake, granule, s having, splinter and sliver. Plywood : A board formed of three or more layers of veneers cemented or glued together, usually with the grain of adjacent veneers running at right angles to each other. Rebate : A recess along the edge of a piece of timber to receive another piece or a door, sash or a frame. Sapwood : The outer layers of the log, which in the growing tree contain living cells and feed material. The sapwood is usually lighter in colour, and is readily attacked by insects and fungi. Seasoning : A process involving the reduction of moisture content in timber under more or less controlled conditions towards or to an amount suitable for the purpose for which it is to be used. Seasoned T imber : Timber w hose moisture c ontent has bee n reduced t o the specified minimum, und er more or less controlled processes of drying. Structural Timber : Timber used in framing and load bearing structures or timber used or intended for use in buildings where strength is the primary consideration. First Class Wood Individual hard and sound knots shall not be more than 25 mm in diameter and the aggregate area of all the knots shall not exceed one per cent of the area of the piece. Second Class Wood Individual hard and sound knot shall not be m ore than 40 m m i n diameter and aggregate of all the knots shall not exceed one and hal f per cent of the area of the piece. Wood shall be gen erally free from sapwood, but traces of sapwood may be allowed. 9.1 TIMBER Timber is classified as under : (i) Teak wood (ii) Deodar wood (iii) N on-coniferous t imbers o ther t han teak (iv) Coniferous timber other than deodar. The t imber shall b e f ree from d ecay, f ungal growth, b oxed heart, pitch pockets o r s treaks on t he exposed edg es, splits and c racks. The t imber s hall be g raded as f irst g rade a nd s econd g rade on t he basis o f th e p ermissible defects in the ti mber a s given i n A ppendix ‘ A’ of Chapter 9.0. For b oth the grades, knots should be avoided over a specified limit. 9.1.1 Teak Wood (Tectona Grandis) It i s o f outstanding merit i n r etention of s hape and d urability. The hear t wood is one o f the m ost naturally durable woods of the world. It usually remains immune to white ant attack and insect attack for very long periods. It is, however, not always immune from fungus attack (rot). Taken as a whole, good quality teak is very durable, it is relatively easy to saw and work. It can be furnished to a fare surface and takes polish well. It is generally used for making furniture and all important timber construction.
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9.1.1.1 Superior Class Teak Wood such as Balarsha, Malabar and Dandeli : Individual hard and sound knot shall not be more than 12 mm in diameter and the aggregate area of all the knots shall not exceed one half per cent of the area of the piece. It shall be close grained. 9.1.2 Deodar Wood (Cedrus Deodars) It is the strongest of the Indian conifers. Its weight and strength is 20% per cent less than teak. It is easy to saw and works to a s mooth finish. It is not, however, a s uitable wood for polish or paint work as the oil in the wood and especially near knots, always seeps through such finishes and discolours them. It is us ed for hous e bu ilding, furniture and o ther c onstruction w ork. It is a lso s uitable for bea ms, floors, boards, posts, window frames and light furniture etc. 9.1.3 Sal Wood (Shoera Robusta) Sal is about 30 pe r cent heavier than teak, 50 pe r cent harder, and a bout 20 to 30 per c ent stronger. In shock resistance it is about 45 per cent above teak. Its heart wood is a naturally durable wood, and usually remains immune to attack by white ants and f ungi for a l ong pe riod, while its sapwood is very perishable and s hould not be us ed. W ell dried s al is n ot a really eas y w ood to s aw and w ork. It is a rough c onstructional w ood t han a c arpentary t imber. N o i ndividual hard and sound k not s hall ex ceed 25 mm in diameter and the aggregate area of all the knots shall not exceed 1% of the area of the piece. It c an be used f or a variety of pu rposes, such as for be ams, rafters, flooring, piles, bridging, t ool handles, picker arms and tent pegs, etc. 9.1.4 Kail Wood (Pinus Roxburghie) Kail Wood is not a very durable w ood. B ut it is eas y to s aw a nd work and usually v ery popular i n wokshops. It can be br ought to a f ine smooth surface, but is more suitable for paint and e namel finishes than for polish work. It is useful for joinery works, constructional work, light furniture and house fitments. 9.1.5 Other Species The other species of timber as given in Table 9.1 of chapter 9.0 can also be used for various activities of building construction. TABLE 9.1 Species of Timber Ava ila bility Tra de Ave ra ge Unit North Ea s t Ce ntra l We s t S outh S l. Bota nica l Na me Na me wt Kg/m 3 Zone Zone Zone Zone Zone No. Teak 640 — Y X X X 1. Tectone grandis linnf Khair 1010 X X X Y Y 2. Acacia Catechiu Willd Babul 785 X X X Y Z 3. Acacia Arabica Willd — X 4. Adina Cordifolia Roxb HK. f Haldu 675 X — — 545 X — Y Y — 5. Cedrus Deodara D Don Deodar 690 X X Y X 6. Magnifera Indica Linn Mango 575 X — — — — 7. Pinus Roxburghie Chir 515 X — — — — 8. Pinus Excelsa Wall Kail X X X — — 9. Shorea Robusta Gaertn. Sal (U.P.) 881 10. Terminalia Myrioecarpa — X — — — 610 Heurcket Muell Arg. Hollock 11. Lagerstroemia Lanceolata Benteak — Y X 675 — — Wall 515 Y Y Y Z Y 12. Gamelinc Arborea Ronb. Gamari 801 X X X Y X 13. Terminalia Bellirica Roxb. Bahora — X X Y Y 800 14. Pterocarpus Marsupium Bijasal Roxb Note : The Average unit wt. is at 12% moisture content.
249 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
NORTH ZONE
:
Jammu and Kashmir, Punjab, Himachal Pradesh, Delhi, Uttar Pradesh and Rajasthan. EAST ZONE : Assam, Manipur, Tripura, West Bengal, Bihar, Orissa, Sikkim, Andamans, North East Frontier Agency and Nagaland. CENTRAL ZONE : Madhya Pradesh, Vidharbha areas of Maharashtra State and the North East Part of Andhra Pradesh (Godavari delta area). WEST ZONE : Maharashtra State (Except Vidharbha areas), Gujarat and North West part of Karnataka. Tamil Nadu, Andhra Pradesh (except the Godawari Delta area) Kerala and karnataka (except north west port) SOUTH ZONE : Tamil Nadu, Andhra Pradesh (Except the Godawari delta area) Kerala and Karnataka (except North West part) The availability of timbers is categorised under three classes as indicated below: X - Most common, 1415 m3 (1000 tonnes) and more per year. Y - Common, 355 m3 (250 tonnes) to 1415 m3 (1000 tonnes) per year and Z - Less common, below 355 m3 (250 tonnes) per year. 9.1.6 Moisture Content Control on moisture content of timber is necessary to ensure its proper utility in various climatic conditions. F or s pecifying t he permissible l imit of moisture c ontent i n t he t imber t he c ountry has be en divided into four climatic zones as per Appendix B of Chapter 9. In each of the zones, maximum permissible l imit o f moisture content o f t imber for different u ses, w hen det ermined i n a ccordance with the procedure laid down in Appendix ‘C’ shall be as per Table 9.2 of Chapter 9. TABLE 9.2 Maximum Permissible Moisture Content of Timber S l.No.
1. 2. 3. 4.
Us e
Beams, Rafters & Posts Doors and windows (a) 50 mm and above thickness (b) Thinner than 50 mm Flooring strips Furniture & Cabinet making
Zone I 12 10 8 8 10
Ma x Mois ture Conte nt P e rce nt Zone Zone Zone II III IV 14 17 20 12 10 10 12
14 12 10 14
16 14 12 15
9.1.6.1 Tolerance on Moisture Content : Average Moisture content of all the samples from a lot shall be within + 3 per c ent and m oisture c ontent of individual samples within + 5 per c ent of m aximum permissible moisture content specified in T able 9 .2. T hese t olerance are t he ab solute values over t he percentage moisture content f or Sl. No. 1 & 2 of Table 9. 2. No tolerance on moisture c ontent is permitted for Sl. No. 3 & 4 of Table 9.2. 9.1.7 Seasoning of Timber The p rocess of drying t imber under c ontrolled c onditions i s c alled seasoning of t imber. T imber s hall be ei ther ai r seasoned or k iln seasoned and i n bot h cases moisture c ontent of the s easoned t imber s hall be a s specified i n Table 9. 2 o f C hapter 9 unl ess ot herwise s pecified, ai r seasoned t imber shall be us ed. Kiln seasoning of timber, where specified, shall be done as per IS 1141 in a plant approved by Engineerin-Charge.
.
250 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
9.1.8 Preservation of Timber Preservative t reatment does not i mprove b asic pr operties of t imber but g ives varying de gree of pr otection against deterioration due t o a ttacks b y f ungi, t ermites, b orers and m arine organisms. P reservative t reatment, where specified, shall be done using Oil type, Organic solvent type or Water-soluble type preservative. Oil type preservatives s hall be us ed i f t he t imber i s not r equired t o be p olished or painted. B efore pr eservative treatment, t he t imber s hall be s awn an d seasoned. All surfaces exposed af ter treat ment, e xcept due to planing, s hall be t horoughly brushed with t he pr eservation b efore j ointing. P reservative t reatment of t imber shall be done as per IS 401 in a plant approved by the Engineer-in-Charge. 9.2 PANELLING MATERIAL 9.2.1 Timber Timber panels shall be preferably made of timber of larger width. The minimum width and thickness of a panel shall be 150 mm and 15 mm respectively. When made from more than one piece, the pieces shall be joined with a continuous tongue and groove joint, glued together and reinforced with metal dowels. The gr ains of t imber pan els s hall r un al ong t he l onger di mensions of t he p anels. T he panel s shall b e designed such that no single panel exceeds 0.5 square metre in area. 9.2.2 Plywood /Plywood Boards 9.2.2.1 Plywood bo ards ar e f ormed b y gl uing a nd pressing t hree or m ore l ayers of v eneers w ith t he grains of adjacent v eneers running at right angl es to each other. The v eneers shall be either rotary cut or sliced and s hall be s ufficiently s mooth t o permit an ev en s pread of gl ue. F ace v eneers m ay be ei ther decorative on bot h s ides or one s ide commercial and t he ot her dec orative. P lywood s hall be of B WP grade or BWR grade as per IS 303. 9.2.2.2 Adhesive : Adhesive us ed for bonding B WP g rade o f ply wood boa rds s hall b e B WP t ype synthetic resins conforming to IS 848 . 9.2.2.3 The thickness of all veneers shall be uni form, within a t olerance of ± 5 per c ent. Corresponding veneers on either side of the centre one shall be of the same thickness and species. The requirements of thickness and core veneers shall be as follows: (a) I n 3 pl y bo ards upto 5 mm t hick. T he c ombined thickness of the face v eneers shall n ot ex ceed twice the thickness of centre ply. (b) In multiply boards, the thickness of any veneer shall not be m ore than thrice the thickness of any other veneer. (c) The sum of the thickness of the veneers in one direction shall approximate to the sum of the thickness of the veneers at right angle to them and shall not be greater than 1.5 times this sum except for 3 ply as specified in (a). 9.2.2.4 Thickness :Plywood b oards are a vailable in t hickness ra nging f rom 3 t o 25 mm. T olerance i n thickness shall be ± 10% for boards upto and including 5 mm; ± 7% for boards from 6 to 9 mm and ± 5% for boa rds above 9 m m thickness. T he boar ds shall be of un iform thickness and the surfaces of t he boards shall be sanded to a smooth finish. Number of plys in plywood boards shall be as per Table 9.3. TABLE 9. 3 Thickne s s in mm 3,4,5,6 5,6,8,9 9,12,15,16
No. of ply 3 5 7
Thickne s s in mm 12,15,16,19 19,22,25
No. of ply 9 11 (Above 11 Ply as ordered)
Note : Plywood of 9 mm thick of 5 or 7 ply may be used generally. .
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9.2.2.5 Moisture content of the plywood boards when tested in accordance with IS 1734 (Part 1) shall not be less than 5 per cent and not more than 15 per cent. 9.2.2.6 Testing : One sample for every 100 sqm or part thereof shall be taken and t esting done a s per IS 30 3. H owever, t esting m ay not be done i f t he t otal r equirement of pl ywood boards i s l ess t han 3 0 sqm. All the samples tested shall meet the requirements of physical and mechanical properties of plywood boards specified in Appendix D of Chapter 9. 9.2.3 Particle Boards 9.2.3.1 Particle boards shall be of medium density and manufactured from particles of agro waste, wood or lignocellulose i.e. material blended with adhesive and formed into solid panels under the influence of heat, moisture, pressure etc. The particle boards shall be flat pressed three layered or graded and of Grade-I as per Table 1 of IS 3087. Both surfaces of the boards shall be sanded to obtain a smooth finish and shall conform to IS 3087. 9.2.3.2 Adhesives : Adhesives used for bonding shall be BWP type synthetic resin conforming to IS 848. 9.2.3.3 Thickness and Tolerance : Thickness o f par ticle b oards shall be as s pecified. T olerance i n thickness shall be ± 5% for boards upto and including 25 mm thick and ± 2.5 per cent for boards above 25 mm thickness. Each board shall be of uniform thickness. 9.2.3.4 Testing : One sample for every 100 sqm or part thereof shall be taken and testing done as per IS 3087. However, testing may not be done if the total requirement of particle boards in a work is less than 30 sqm. All the samples tested shall meet the requirement of physical and mechanical properties of particle boards specified in Appendix E of Chapter 9.0. 9.2.4 Veneered Particle Boards 9.2.4.1 Veneered P article B oards with c ore of F PT-1 or graded board G rade-I part icle board (I S 308 7) with commercial or general purpose veneer (Type-1) or decorative veneers on both faces or with decorative veneer on one face and commercial /general purpose veneers on the other Type-2. Face veneers are bonded using adhesives under the influence of heat and pressure. 9.2.4.2 Adhesives : The adhesive used for bonding veneers shall be BWP or BWR type conforming to IS 848 for grade I veneered particle board. 9.2.4.3 Thickness & Tolerance : Veneered particle boards are available in various thickness 6, 10, 12, 20, 25, 30, 35, 40, 45 & 50 mm. Tolerance in thickness shall be ± 5%. 9.2.4.4 Testing : One sample for every 100 sqm or part thereof shall be taken and testing done as per IS 3097. H owever, testing may not be done i f t he t otal requirement o f v eneered par ticle boar ds in a work is less t han 30 s qm. A ll t he s amples t ested s hall meet t he requirements o f ph ysical and m echanical properties of veneered particle boards as under:
252 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
Physical and Mechanical properties of Veneered particle board 1. 2. 3. 4. 5.
Moisture Content Water Absorption (a) 2 hrs. soaking (b) 24 hrs. soaking Water Resistance
5-15%
Swelling in Water (a) General absorption for 2 hrs. immersion (b) Surface absorption for 2 hrs. Adhesion of plies
Not more than 25% Not more than 50% No sign of disintegration or delamination after 3 hrs. boiling in water. Not more than 7% Not more than 5% Knife test
9.2.4.5 Type of face veneers, t hickness of v eneered par ticle boards and adhesive used for bonding shall be as specified. Unless otherwise stated, exterior grade veneered particle boards with BWP type synthetic resin adhesive shall be used. 9.2.5 Non-Asbestos Fibre Boards 9.2.5.1 Fibre boards shall be of m edium den sity cement bo ard reinforced with wood fibre, pro duced b y fiberizing steamed wood under pressure, bl ended with adhe sive and wax a nd formed i nto solid pan els under controlled conditions of heat and pressure as per IS 14862. 9.2.5.2 Adhesives : The ad hesive used for bo nding s hall b e B WP t ype s ynthetic resin c onforming t o IS 848. 9.2.5.3 Thickness : Fibre boards are available in thickness 6, 9, 12, 15, 18, 22, 25, 30, 35 & 40 mm. The t olerance i n t hickness s hall be ± 0. 3 m m. T hickness of f ibre boards and adhes ive used f or bonding shall be a s s pecified. U nless o therwise s tated, ex terior g rade f ibre boards bonded w ith B WP type synthetic resin adhesive shall be used. 9.2.6 Float Glass, Frosted Glass Float glass used shall be as specified in sub-head 21.0 of this specifications. For p anel e xceeding 0 .5 sqm in area, the nom inal thickness o f the g lass to be used s hall be a s specified. 9.2.7 Wire Cloth (Wire Gauze) 9.2.7.1 Wire Cloth which shall generally conform to IS 1568 shall be regularly woven with equally spaced galvanised mild steel wires in both warp and weft directions. The wire cloth shall be properly selvedged by one or more wires in each edge. 9.2.7.2 Mesh : Average width of aperture and the nominal diameter of the wire shall be as under: Ave ra ge width of Ape rture Nomina l dia . of wire mm mm 1.40 0.63 1.18 0.56 1.00 0.50 9.2.7.3 Width of aperture and dia of wire cloth shall be as specified. Unless otherwise stated, wire cloth of 1.40 mm average aperture width woven with 0.63 mm nominal dia galvanised mild steel wire shall be used. .
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9.2.7.4 Fly-proof wire cloth (a perture 1.40 m m) is ge nerally provided in Kitchen a nd dining ar eas while wire cloth of smaller aperture is used in mosquito proof shutters. 9.2.8 Veneered Decorative Plywood Decorative pl ywood s hall be o f two g rades nam ely B WR and MR D ecorative P lywood shall be o f two types. Type I and type 2 and shall conform to IS 1328. 9.2.8.1 Requirement of Type-I Veneered decorative plywood shall be as under: (a) Open slits checks or open joints not more than 150 mm in length and 0.5 mm in width shall be permissible provided the same are rectified with a veneer insert bounded with synthetic resin adhesive, as the case may be and further provided that the insert matches with the surrounding veneer in colour as well as figure. (b) T he decorative veneered s urface shall be free from t orn grain, d ead k nots di scolourisation a nd sapwood. (c) The decorative veneered surface shall be selected for figure, texture, colour and grain etc. It shall be free from all manufacturing and wood defects except to the Engineer-in-charge permitted under para 9.2.8.1(a). All veneers shall be matched or mismatched to achieve a decorative effect in colour figure and grain. 9.2.8.2 Adhesive : The adhesive for bond ing v eneers s hall be M R and BWR t ype s ynthetic re sin adhesive conforming to IS 848 for MR and BWR grade veneered decorative plywood respectively. 9.2.8.3 Dimensions and Tolerances: 9.2.8.3.1 The dimensions of plywood boards shall be as follows: 2400 mm x 1200 mm 2100 mm x 900 mm 2100 mm x 1200 mm 1800 mm x 900 mm 1800 mm x 1200 mm 9.2.8.3.2 Thickne s s : The thickness of plywood board shall be 3 mm, 4 mm, 6 mm, 9 mm, 12 mm, 19 mm and 25 mm. Note: Any ot her dimensions (l ength, width and t hickness) as agreed t o b etween t he m anufacturer and the purchaser may also be used. 9.2.8.3.3 Tolerances: Tolerances on the nominal sizes of finished boards shall be as follows: Dime ns ion Length Width
Tole ra nce +6 mm -0 +3 mm -0 mm
Thickness: (i) Less than 6 mm (ii) 6 mm and above Edge straightness
+ 10 per cent + 5 per cent 2 mm per 1000 mm Or 0.2 per cent Squareness 2 mm per 1000 mm Or 0.2 per cent Note : Edge straightness and squareness shall be tested as per Appendix I. .
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9.2.9.3.2 Tolerances : Tolerances on the nominal sizes of finished boards shall be as given below : Dimension Tolerance Length + 6 mm -0 Width + 3 mm -0 Thickness 5 per cent Edge straightness 2 mm per 1000 mm or 0.2 per cent Squareness 2 mm per 1000 mm or 0.2 per cent Note : Edge straightness and squareness shall be tested as per IS 12823. 9.2.10 Coir Veneer Board for General Purposes : DELETED 9.2.11 Marine Plywood : DELETED 9.2.12 Fire Retardant Plywood : DELETED 9.2.13 Decorative Thermosetting Synthetic Resin Bonded Laminated Sheets 9.2.13.1 Scope : Decorative thermosetting synthetic resin bonded laminated sheets shall generally conform to IS 2046. This material is intended for interior use and is not intended for load bearing applications. 9.2.13.2 Terminology : For the purpose of this standard, the definition given under para 2 o f IS 1998 shall apply. 9.2.13.3 Types : The material shall be of two types namely:(a) Type 1 - Having only one side bearing decorative surface the other side being roughened or given an appropriate treatment to promote adhesion to the base. This type shall generally be used, unless specified otherwise. (b) Type 2 - Having both sid es be aring the dec orative surface, the tw o sid es m ay be dif ferent in colour or pattern or both. 9.2.13.4 Requirements (i) Appe a ra nce : The types of surface finish of decorative and reverse side, edge finish, colour and pattern shall be as agreed to between the purchaser and the supplier. The sheets shall be reasonably free from local deformation. Note : Since s heets m ay v ary s lightly in c olour and appearance, i t i s recommended t hat s heets for any one scheme may be matched. (ii) Fla tne s s : For nominal thickness 1.5 mm - when a sheet is tested for flatness in accordance with the method given in Appendix -C of IS 2046, the height above the flat surface at the edge of full manufactured and trimmed width shall nowhere exceed 150 mm. (iii) Tole ra nce t o nom ina l t hickne s s : The depar ture f rom nom inal t hickness of s heet at any po int, shall not exceed the value given below: Nominal Thickness Tolerance Upto 1.5 mm + 0.25 mm (iv) Straightness of edges of rectangular finished panels, resistance to dry heat, resistance to boiling water, resistance to staining, gross breaking strength, packing and marking, sampling and criteria for conformity etc. shall be as per IS 2046.
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9.3 DOOR, WINDOW AND VENTILATOR FRAMES 9.3.1 Timber for door, window and ventilators frames shall be as specified. Timber shall be sawn in the direction o f the g rains. A ll members o f a fra me s hall b e of th e sa me spe cies of ti mber a nd s hall b e straight w ithout a ny w arp or bow . F rames s hall hav e s mooth, w ell-planed (wrought) s urfaces ex cept t he surfaces touching the w alls, lintels, sill etc., which may be l eft clean sawn. Rebates, rounding or moulding s hall be done be fore t he members a re jointed into frames. The dep th o f t he r ebate for hous ing the shutters shall be 15 mm, and the width of the rebates shall be equal to the thickness of the shutters. A tol erance of ± 2 m m s hall be p ermitted i n th e spe cified f inished d imensions of t imber sections in frames. 9.3.2 Joints The Jamb pos ts shall be through tenoned in to t he mortise of the transoms to the full t hickness of the transoms and the thickness of the tenon shall be not less than 2.5 cm. The tenons shall closely fit into the m ortise without an y w edging or filling. The contact surface o f te non and m ortise b efore putting together sh all be gl ued w ith polyvinyl ac etate di spersion ba sed ad hesive conforming to IS 4835 or adhesive c onforming IS 851 and pinned w ith 10 mm dia h ard w ood dowels, o r bam boo p ins or s tar shaped m etal pins. T he joints s hall be a t right a ngles w hen c hecked from the inside s urfaces o f the respective m embers. T he j oints s hall be pres sed i n pos ition. E ach as sembled door f rame s hall be f itted with a temporary stretcher and a temporary diagonal brace on the rebated faces. 9.3.3 Fixing of Frames The frames shall be got approved by the Engineer-in-Charge before bei ng pai nted, oi led or otherwise t reated and bef ore f ixing i n p osition. T he s urface of t he f rames abutting m asonry or c oncrete and the portions of the frames embedded in floors shall be given a coating of coal tar. Frames shall be fixed t o t he a butting masonry or c oncrete with holdfasts or metallic f asteners a s s pecified. After f ixing, the j amb po sts of t he f rames s hall be pl ugged suitably and f inished neat . V ertical m embers of t he do or frames s hall be em bedded in the floor for the full thickness of the floor finish and s hall be s uitably strutted and w edged i n o rder to pr event warping dur ing c onstruction. A minimum o f three hol d f asts shall be fixed on each side of door and window frames one at centre point and other two at 30 cm from the top and bottom of the frames. In case of window and ventilator frames of less than 1 m in height two hold fasts shall be f ixed on eac h side at quarter p oint of the frames. Hold fasts and m etallic fasteners shall be measured and paid for separately. 9.3.4 Measurements Wood work wrought, framed and fixed shall be measured for finished dimension without any allowance for t he wastage or for di mensions be yond specified di mension. H owever, i n case o f members having m ouldings, r oundings or rebates and members of c ircular o r varying s ections, f inished dimensions shall be t aken as the sides of the smallest square or rectangle from which such a s ection can be cut. Length of each member shall be measured over all to the nearest cm so as to include projection for tenons. Width and thickness shall be measured to the nearest mm and the quantity shall be worked out in unit of upto three places of decimal. 9.3.5 Rate The rate shall include the cost of material and labour involved in all the operations described above except the hold fasts or metallic fasteners which will be paid for separately.
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9.4 FALSE CEILING AND PARTITION FRAMES This w ork shall b e d one as specified i n 9. 3 except t hat t he scantlings n eed n ot b e planed unless otherwise specified. 9.5 TRUSSES 9.5.0 The work shall be carried out as per detailed drawings and as directed by the Engineer-in-Charge specified timber s hall be u sed. S awing s hall b e truly s traight and s quare, and in the d irection o f the grains. T he s cantlings s hall be ac curately pl aned smooth t o the f ull di mensions and r ebate r oundings and m ouldings s hown in the dr awings, bef ore the same ar e f ramed. Patching or pl ugging of any k ind shall not be permitted. A tolerance of +3 mm and -2 mm shall be allowed in the finished cross sectional dimension. 9.5.1 Joints Joints shall be simple, neat and strong. All mortise and tenon joints, mitred joints, scarfs etc. shall fit in fully and accurately without wedging or fillings. The joints shall be as per detailed drawings. Holes of correct s izes s hall be dri lled bef ore i nserting s crews/bolts. D riving i n s crews with ham mer i s proh ibited. Holes for bolts s hall be of uniform diameter. T he s crews, b olts and n ails shall be di pped i n oil before using. The heads of nails and screws shall be sunk and puttied or dealt with as instructed by EngineerinCharge. T he ga uge and length of nails, scr ews and bolt s shall be ap proved by the E ngineer-inCharge before using on works. 9.5.2 Shaping Form and Cutting The wood sections, as specified or required, shall be straightened, cut square and to correct lengths. A fine accuracy shall be en sured in the fabrication of various member so that these can be assembled without b eing u nduly packed, strained o r f orced i nto p osition a nd when b uilt up, shall b e t rue t o s hape and free from twist, kinks, buckles or open joints. 9.5.3 Fabrication As per drawing, a full size truss diagram shall first be drawn on a l evelled platform. From this full size diagram, templates of all joints as for tenons, mortises, scarves etc. shall be made for use in the fabrication. T he t emplate shall be m ade t o c orrespond t o eac h m ember and pl ate hol es f or s crews a nd bolts s hall b e m arked accurately on t hem and dri lled. T he t emplates s hall be l aid on w ooden m embers and t he hol es for s crewing and bol ting marked on them. The ends o f t he w ooden members s hall al so be marked fo r cutting. T he base of columns and th e posi tion of anchor b olts shall b e ca refully se t ou t. Before f abrication of t he t russ i ndividual m embers s hall be as sembled t ogether t o ens ure c lose ab utting or lapping of the surfaces of the different members and fitted close together as per drawing. 9.5.4 Hoisting and Placing in Position The t russes s hall be h oisted a nd placed i n position carefully, w ithout any da mage t o i tself a nd other building w ork a nd i njury to w orkman. The t russes shall be s ecured t o w alls by m eans of holding down bolts or as directed by the Engineer-in-Charge. The necessary mechanical appliances such as lifting tackel, winch etc. for hoisting the truss shall be us ed. The trusses s hall be stayed temporarily till they are permanently s ecured i n pos ition and c onnected with eac h ot her b y means o f purlins. H olding do wn bol ts cleats used for purlins and bottom plates used for tie and rafter member shall be paid for separately. 9.5.5 Surface Treatment Wood work s hall not be painted, oiled or otherwise tr eated before it h as been a pproved by t he Engineer-in-Charge. All portions of timber built into or against or close to masonry or concrete or burried in ground shall be gi ven two coats of boi ling c oal tar. A ll junctions of rafters, purlins, b eams an d w all plates shall be painted with approved wood primer.
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9.5.6 Measurements Wood w ork s hall be m easured f or f inished dimensions. N o al lowance s hall b e m ade for di mensions supplied beyond t hose specified. Length of each piece shall be measured over al l near est to a cm, so as to i nclude pr ojections f or te nons, s carves or mitres. W idth and t hickness sh all b e measured to t he nearest mm. Cubical contents can be worked out in uni ts cubic meters upto 3 places of decimal in whole numbers. 9.5.7 Rate The r ate i ncludes the c ost of m aterials and l abour i nvolved i n a ll the oper ations des cribed abov e. Unless otherwise specified, iron fixtures such as bolts and nuts, M.S. steel plates, holding down bolts and staining, priming, painting or polishing of the work shall be paid for separately. 9.6 PANELLED GLAZED OR PANELLED AND GLAZED SHUTTERS (FIG. 9.2) 9.6.0 Panelled or gl azed s hutters f or doors, w indows, v entilators and c upboards s hall be c onstructed in the fo rm of ti mber fr ame w ork of st iles and r ails with p anel in serts of ti mber, p lywood, bl ock board, veneered p article boa rd, f ibre b oard w ire ga uze o r f loat g lass. T he s hutters m ay b e s ingle or multipanelled, as shown in the drawings or as directed by the Engineer-in-Charge. T imber f or f rame work, m aterial for panel ins erts and thi ckness of shu tters sh all be as specified. A ll members of th e shutters s hall be straight without any warp or bo w and shall have smooth w ell pl aned face at right angles to each other. Any warp or bow sh all n ot ex ceed 1 .5 mm f or d oor shutter a nd 1 mm f or window a nd v entilator shutters The right angl e f or t he s hutter s hall be c hecked b y m easuring t he diagonals and t he di fference between t he t wo di agonals s hould not b e m ore t han 3 m m. G enerally pa nelled gl azed or pane lled an d glazed shutter shall conform to IS 1003 (Pt. 1 & 2). 9.6.1 Frame Work 9.6.1.1 Timber for stiles and rails shall be of the same species and shall be sawn in the directions of grains. S awing s hall be truly s traight and square. The t imber s hall be pl aned s mooth and ac curate to t he required dimensions. The stiles and rails shall be joined to each other by plain or haunched mortise and tenon joints and the rails shall be inserted 25 mm short of the width of the stiles. The bottom rails shall have double tenon joints and for other rails single tenon joints shall be provided. The lock rails of door shutter shall have its centre line at a height of 800 mm from the bottom of the shutters unless otherwise specified. T he t hickness of e ach t enon shall b e approximately o ne-third t he f inished t hickness of t he members and the width of each tenon shall not exceed three times its thickness. 9.6.1.2 Gluing of Joints : The c ontact s urfaces o f t enon and m ortise s hall be t reated, bef ore put ting together, with bulk type synthetic res in adhe sive c onforming t o I S 851 suitable f or c onstruction in w ood or synthetic resin adhesive (Phenolic and aminoplastic) conforming to IS 848 or polyvinyl acetate dispersion b ased ad heshive c onforming t o I S 4 835 an d pi nned w ith 1 0 m m di a ha rdwood do wels or bamboopins o r s tar shaped m etal pi ns; after t he f rames a re put t ogether and pressed i n position by means of press. 9.6.1.3 Stiles and bottom rail shall be m ade out of one pi ece of timber only. Intermediate rail exceeding 200 mm in width may be of one or more pieces of timber. The width of each piece shall be not less than 75 m m. W here m ore t han one pi ece of timber i s used f or rails, they s hall be j oined w ith a c ontinuous tongued a nd grooved j oint gl ued to gether an d re inforced w ith metal d owels at r egular i ntervals not exceeding 200 mm. 9.6.1.4 Door Shutters 9.6.1.4.1 Finished dimensions and tolerances of components of door shutters has been given in Table 9.5 below.
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TABLE 9.7 Dimensions and Tolerances of Components of Window and Ventilator Shutters
De s cription of compone nts
Ve ntila tor S hutte rs
Window Shutte rs Width mm 80 ± 3
Thickne s s mm 25 ± 1 30 ± 1
Width mm 80 ± 3
Munting
60 ± 3
60 ± 3
Glazing bars
40 ± 1
25 ± 1 30 ± 1 25 ± 1 30 ± 1
Stiles and rails
40 ± 1
Thickne s s mm 20 ± 1 22.5 ± 1 25 ± 1 27.5 ± 1 30 ± 1 -do-do-
9.6.1.5.2 De s igna tion : Window a nd ventilator s hutters s hall b e d esignated by symbols d enoting t he width, type and height of window and ventilators in following manner. (a) Width : It shall be indicated by the number of modules in the width of opening (b) It shall be indicated by the following letters of alphabet: W-window, V- Ventilator , S-Single shutter, T-Double shutter (c) Height : It shall be indicted by the number of modules in the height of opening. Example : 10 W T 12 w ould mean a window shutter s uitable for a double s hutter w indow o f 1 0 modules width and 12 modules height. 12 V 6 w ould m ean v entilator s hutter s uitable for a v entilator of 12 m odules w idth and 6 m odules height. 9.6.1.5.3 S ize s : Sizes of window and v entilator shutters shall generally conform to the modular sizes specified in Tables 9.8 and 9.9 respectively. These sizes are derived after allowing the thickness of the frame and a margin of 5 mm all round based on 100 mm module. 9.6.1.5.4 Tolerances on the overall dimensions of window and ventilator shutter shall be + 3 mm. TABLE 9.8 Dimensions of Timber Window Shutters De s igna tion (1) 6 WS 12 10WT 12 12 WT 12 6 WS 13 10 WT 13 12 WT 13
Width mm (2) 500 460 560 500 460 560
He ight mm (3) 1100 1100 1100 1200 1200 1200
.
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TABLE 9.9 Dimensions of Timber Ventilator Shutters
De s igna tion (1) 6V6 10 V 6 12 V 6
Width mm (2) 500 900 1100
He ight mm (3) 500 500 500
9.6.2 Mounting and glazing bars where required shall be stubtenoned to the maximum depth which the size of the member would permit or to a depth of 25 mm whichever is less. Unless otherwise specified the finished dimensions of the components of frame work of shutters shall be as given in Table 9.7. The tolerance on width of styles and rail shall be ± 3 mm. The tolerance in thickness will be ± 1 mm. The thickness of all components of frame work shall be the same as the thickness of the shutter. Tolerance on over all dimensions of the shutter shall be ± 3 mm. 9.6.3 Rebating The s hutters s hall be s ingle-leaf or doubl e l eaved as s hown i n the dr awings or as di rected by t he Engineer-in-Charge. In c ase of doubl e leaved s hutters, t he m eeting of t he stiles s hall be rebated b y on ethird the thickness of the s hutter. The rebating s hall be either s played or s quare ty pe as s hown in Fig. 9.2. 9.6.4 Panelling The panel inserts shall be either framed into the grooves or housed in the rebate of stiles and rails. Timber, plywood, and pa rticle board pa nels as given in para 9. 2 of this sub head and s hall be f ixed only with gr ooves. The depth of the groove shall be 12 mm and its width shall accommodate the panel inserts such that the faces are closely fitted to the sides of the groove. Panel inserts shall be f ramed into the grooves of stiles and rails to the full depth of the groove leaving space of 1.5 mm. Width and depth of the rebate shall be equal to half the thickness of stiles and rails. Glass panels, asbestos panels wire gauze panels and panel inserts of cupboard shutters shall be housed in the rebates of stiles and rails. 9.6.4.1 Timber Panels : Timber panels shall be preferably made of timber of large width; the minimum w idth an d thi ckness of th e pa nel sh all b e 10 0 m m, an d 15 m m r espectively. W hen m ade from m ore t han o ne piece, t he pieces s hall be j ointed with a continuous t ongued and g rooved j oint glued together and reinforced with headless nails at regular intervals not exceeding 100 mm. Depth and thickness of such joint shall be equal to one-third of thickness of panel. The panels shall be designed suc h th at no s ingle pa nel e xceeds 0. 5 squ are m etre in a rea. T he gr ains of ti mber pa nels shall r un along t he longer dimensions of the panels. All panels shall be of the same species of timber unless otherwise specified. 9.6.4.2 Plywood Panels : Plywood boards used f or panel ling of s hutters s hall be BWP t ype or gr ade as specified in 9.2.2. Each panels shall be a single piece of thickness, 9 m m for two or more panel construction and 12 mm thickness for single panel construction unless otherwise specified. 9.6.4.3 Veneered Particle Board Panels : Veneered Particle board used for panelling of shutters shall be Exterior Grade bonded with BWP type synthetic resin adhesive as specified in 9.2.4.2. Each panel shall be a single piece of thickness 12 mm unless otherwise specified. 9.6.4.4 Fibre Board Panels : Fibre board used for panelling of shutters shall be E xterior Grade bonded with B WP t ype s ynthetic resin adhesive E ach f ibre board panel s hall be a s ingle pi ece unl ess ot herwise specified. .
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9.6.4.5 Wire Gauze Panels: Wire G auze us ed for panelling of s hutters shall be w oven w ith 0. 63 mm dia ga lvanised m ild s teel wire to form av erage aper ture s ize o f 1 .40 m m as s pecified in 9 .2.7. W ire gauze s hall be s ecurely housed i nto t he r ebates of s tiles and r ails by giving r ight angl es bend t urned back and fixed by means of suitable staples at intervals of 75 mm and over this wooden beading shall be fixed. The s pace bet ween the rebate and the beadi ng s hall be fixed with putty t o gi ve a neat finish. E ach wire gauz e pa nel s hall b e a single piece, a nd the panels s hall be s o de signed that no s ingle panels exceeds 0. 5 s qm in are a. However, c are s hall be t aken to pr event s agging of w ire ga uge, of pa nel b y providing and fixing 20 x 20 mm s quare or equivalent beading to the external fac e to the required patterns as decided by the Engineer-in-Charge. 9.6.4.6 Glass Panels : Glass pane lling ( Glazing) shall be d one as s pecified in 9 .2.6. G lazing in the shutters of door s, w indows and v entilators of bat h, W C and Lav atories s hall be pr ovided w ith f rosted glass t he w eight of which shall be not l ess t han 10 kg/sqm. F rosted glass panes s hall be f ixed w ith frosted face on the inside. G lass panels shall be fixed by providing a t hin layer of p utty conforming to IS 419 ap plied between glass pane and all along the length of the rebate and also between glass panes and wooden beading. 9.6.4.7 Putty can be prepared by mixing one part of white lead with three parts of finely powdered chalk and then add ing boiled linseed oil to the mixture to form a s tiff pa ste and ad ding varnish to the pa ste a t the rate of 1 l itre of varnish to 18 kg of paste. Fixing of glass panes without beading shall not be permitted. G lazing shall b e done after t he s hutters have be en p rimed and prepared f or pai nting, s o t hat wood may not draw oil out of putty. 9.6.4.8 Finish : Panels of shutters shall be flat and well sanded to a smooth and level surface. 9.6.5 Beading Beadings in panelled shutter shall be provided . Each length of beading shall be single piece. Joints at the c orners s hall b e mitred and ex posed edges s hall be rounded. B eading shall be f ixed with headless nails at 75 mm intervals. For external shutters, the beading shall be fixed on the outside face. 9.6.6 Machine/Factory made Shutters Machine m ade s hutters, where s pecified, s hall be procured f rom an ap proved factory. F or machine made s hutters, op erations l ike sawing, p lanning, making t ongue a nd t enons, c utting groov es, m ortises and rebates, drilling holes and pressing of joints shall be done by suitable machines. Machines made shutters shall be brought to the site fully assembled but without any priming coat. Panel inserts of sheet glass and wire gauze may, however, be fixed at site. 9.6.7 Fixing of Shutters For side hung shutters of height upto 1.2 m, each leaf shall be hung on two hinges at quarter points and for shutter of height more than 1.2 m, each leaf shall be hung on three hinges one at the centre and the other two at 200 mm from the top and bottom of the shutters. Top hung and bottom hung shutters shall be hung on two hinges fixed at quarter points of top rail or bottom rail. Centre hung shutter shall be suspended on a suitable pivot in the centre of the frame. Size and type of hinges and pivots shall be as specified. Flap of hinges shall be neatly counter sunk i nto t he recesses cut to the exact di mensions of flap. Screws f or fixing t he hi nges shall be screwed in with screw driver and not hammered in. Unless otherwise specified, shutters of height more than 1.2 mm shall be hung on butt hinges of size 100 mm and for all other shutters of lesser height butt hinges of size 75 mm shall be used. For shutter of more than 40 mm thickness butt hinges of size 125 × 90 × 4 mm shall be used. Continuous (piano) hinges shall be used for fixing cup-board shutters where specified. 9.6.8 Fittings Fittings shall be provided as p er schedule of f ittings d ecided b y E ngineer-in-Charge. A ppendix H gives f or g uidance t he s chedule of f ittings a nd s crews usually provided. C ost of p roviding a nd f ixing shutter shall i nclude c ost of hi nges and nec essary screws f or f ixing the same. All ot her fittings shall b e paid f or s eparately. T he f ittings s hall conform t o specifications l aid down i n 9 .15. Where t he f ittings ar e stipulated to be supplied by the department free of cost, screws for fixing these fittings shall be provided by contractor and nothing extra shall be paid for the same.
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9.6.9 Wooden Cleats and Blocks Wooden c leats and bl ocks shall be f ixed t o doors and w indows as di rected by Engineer-in-Charge, as p er si ze and sh ape a pproved b y hi m. T hese are i ncluded i n th e co st of pr oviding a nd f ixing t he shutters. 9.6.10 Measurements Framework and panelling shall be measured separately. 9.6.10.1 Framework of Shutters : The overall length and width of the framework of the shutters shall be measured n earest t o a c m in fi xed po sition ( overlaps not t o be measured in ca se o f do uble le aved shutters) and the area calculated in square metres correct to two places of decimal. No deduction shall be made to form panel openings or louvers. No extra payments shall be made for shape, joints and labour involved in all operations described above. 9.6.10.2 For panelling of each type or for glazed panel length and w idth of opening for panels inserts or glazed panels shall be measured correct to a c m before fixing the beading and the area shall be calculated to the nearest 0.01 sq.m. The portions of the panel inserts or glazed panel inside the grooves or rebates shall not be measured for payment. 9.6.11 Rate Rate i ncludes t he cost of materials and labour i nvolved i n al l the operations described above. The framework and panelling of each t ype or gl azed panels s hall be paid s eparately. T he rate f or framework includes the c ost o f butt hinges and nec essary s crews as specified i n 9 .6.7. H owever, e xtra shall be p aid for providing moulded beading where specified. Nothing extra shall be paid for plain beading as stated in 9.6.5. 9.7 FLUSH DOOR SHUTTERS (Fig. 9.3) 9.7.0 Flush door shutters shall have a solid core and may be of the decorative or non-decorative (Paintable type a s pe r IS 2 202 (Part I). Nominal thickness of shutters may b e 2 5, 3 0 o r 35 mm. Thickness and type of shutters shall be as specified. 9.7.1 Width and height of the shutters shall be as shown in the drawings or as indicated by the Engineer inCharge. All four edges of the shutters shall be square. The shutter shall be f ree from twist or warp in its plane. The moisture content in timbers used in the manufacture of flush door shutters shall be not more than 12 per cent when tested according to IS 1708. 9.7.2 Core The c ore o f the flush doo r s hutters s hall be a b lock boa rd ha ving w ooden s trips he ld in a frame constructed of stiles and rails. Each stile and rail shall be a single piece without any joint. The width of the stiles and rails including lipping, where provided shall not be less than 45 mm and not more than 75 mm. The w idth o f eac h wooden s trip s hall not e xceed 30 mm. Stiles, r ails and wooden s trips forming t he core of a shutter shall be of equal and uniform thickness. Wooden strips shall be parallel to the stiles. End joints of the pieces of wooden strips of small lengths shall be staggered. In a shutter, stiles and rails shall be of one species of timber. Wooden strips shall also be o f one species only but i t may or may not be of the same species as that of the stiles and rai ls. A ny species of timber may be us ed for core of flush door. However, any non-coniferous (Hard wood) timber shall be used for stiles, rails and lipping. 9.7.3 Face Panel The face panel shall be formed by gluing, by the hot-press process on both faces of the core, either plywood or cross-bands and face veneers. The thickness of the cross bands as such or in the plywood shall be bet ween 1. 0 mm and 3. 0 mm. The t hickness of the face veneers as such or in the plywood shall be between 0.5 mm and 1.5 mm for commercial veneers and between 0.4 mm and 1.0 mm for
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decorative veneers, provided that the combined thickness of both is not less than 2.2 mm. The direction of the veneers adjacent to the core shall be at right angles to the direction of the wooden strips. Finished faces shall be sanded to smooth even texture. Commercial face veneers shall conform to marine grade plywood and decorative face veneers shall conform to type I decorative plywood in IS 1328. 9.7.4 Lipping Lipping, w here s pecified, s hall be pr ovided i nternally on al l edges of t he s hutters. Li pping s hall be done with battens of first class hardwood or as specified of depth not less than 25 mm. For double leaved shutters, dept h of t he lipping at meeting of stiles shall be not l ess than 35 mm. Joints shall not be permitted in the lipping. 9.7.5 Rebating In the case of d ouble leaves shutters the meeting o f stiles shall b e rebated b y 8 m m to 10 m m. The rebating shall be either splayed or square type as shown in drawing where lipping is provided. The depth of lipping at the meeting of stiles shall not be less than 30 mm. 9.7.6 Opening for Glazing When required by the purchaser opening for glazing shall be provided and unless otherwise specified t he opening f or gl azing shall b e 2 50 m m i n height and 150 m m o r 2 00 m m i n width u nless directed ot herwise. T he bott om of th e op ening s hall b e at a h eight o f 1.4 m from t he b ottom of th e shutter. O pening f or gl azing s hall be l ipped i nternally w ith w ooden bat ten of w idth not l ess t han 25 mm. Opening for glazing shall be provided where specified or shown in the drawing. 9.7.7 Venetian Opening Where specified the height of t he v enetian opening shall b e 350 mm from t he b ottom of t he shutter. T he w idth of t he ope ning s hall be as d irected bu t shall provide fo r a cle ar s pace o f 75 mm between t he e dge of t he door and v enetian op ening b ut i n n o c ase t he op ening s hall ex tend be yond the s tiles o f the s hutter. T he top ed ge o f the op ening s hall b e lipped internally w ith w ooden ba ttens of w idth no t less than 25 mm. V enetian op ening sha ll be provided where specified o r s hown in t he drawing. 9.7.8 Tolerance Tolerance on w idth and h eight shall be + 3 mm and tolerance on nom inal thickness shall be ± 1.2 mm. T he t hickness of t he door s hutter s hall be u niform t hroughout w ith a permissible v ariation of not more than 0.8 mm when measured at any two points. 9.7.9 Adhesive Adhesive used for bonding various components of flush door shutters namely, core, core frame, lipping, c ross-bands, f ace v eneers, plywood e tc. and f or bonding plywood shall c onform t o BWP t ype, phenol formaldehyde synthetic resin adhesive conforming to IS 848. 9.7.10 Tests Samples of flush door shutters shall be subjected to the following tests: (a) End Immersion Test (b) Knife Test (c) Glue Adhesion Test One end of each sample shutter shall be t ested for End Immersion Test. Two specimens of 150 x 150 mm size shall be cut from the two corners at the other end of each sample shutter for carrying out Glue A dhesion T est. Knife T est s hall be d one on the remaining portion of each s ample shutter. T est shall be done as laid down in Appendix F of Chapter 9.
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9.7.11 Sample Size Shutters of dec orative and non -decorative t ype from eac h m anufacturer, i rrespective of t heir thickness, s hall be gr ouped s eparately and e ach group s hall c onstitute a l ot. T he num ber of s hutters (sample size) to be selected at random from each lot for testing shall be as specified in Table 9.10. If the total number of shutters of each type in a work (and not the lot) is less than twenty five, testing may be done at the discretion of t he E ngineer-in-Charge and i n such cases extra payment shall be m ade f or the sample shutter provided the sample does not fail in any of the test specified in 9.7.10. For knife t est, g lue ad hesive t est, s lamming t est, the end i mmersion t est, t he nu mber of shutters shall be as per col. 4 of Table 9.10. TABLE 9.10 Sample Size and Criteria for Conformity Lot S ize
S a mple S ize
(1) Upto 50 51 - 300 300 and above
(2) As per site Engineer 13 20
P e rmis s ible no. of de fe ctive (3) 0 1 1
S ub. S a mple s ize (4) 1 2 2
9.7.12 Criteria for Conformity All the sample shutters when tested shall satisfy the requirements of the tests laid down in Appendix F of Chapter 9. T he l ot shall be d eclared as conforming t o t he requirements when numbers of defective sample do es not ex ceed t he perm issible num ber gi ven i n c ol. 3 of T able 9. 10. I f t he num ber of s ample shutters f ound unsatisfactory fo r a t est is o ne, t wice th e n umber of samples ini tially t ested shall be selected and tested for the test. All sample shutters so tested shall satisfy the requirement of the test. If the num ber of s amples f ound uns atisfactory f or a t est i s t wo or m ore, t he e ntire l ot s hall be c onsidered unsatisfactory. 9.7.13 Fixing This shall be as specified in 9.6.7. 9.7.14 Measurements Length and width of the s hutters s hall be measured to the near est cm i n c losed pos ition c overing t he rebates of t he frames but excluding t he gap between t he s hutter and t he frame. Overlap of t wo s hutters shall not be measured. All work shall be measured net as fixed and area calculated in square metres to nearest two places of decimal. No deduction shall be made for providing venetian opening and opening for glazing. 9.7.15 Rates The rate i ncludes t he c ost of material a nd l abour i nvolved i n al l t he operations d escribed above. Extra rate shall be payable for providing rebates in double leaved shutters. Glazing when provided shall be measured & paid for separately as specified in 9.6.10.2. 9.8 WIRE GAUZE FLY PROOF SHUTTERS 9.8.0 Specified timber shall be us ed, and i t shall be sawn in the direction of the grains. Sawing shall be truly straight and square. T he tim ber s hall be planed s mooth and ac curate to the fu ll dim ensions, rebates, roundings and mouldings as shown in the drawings made, before assembly. Patching or plugging of any kind shall not be permitted except as provided.
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9.8.1 Stile and Rails The Specifications shall be a s des cribed under 9 .6.1.3. The stiles and r ails s hall be gi ven a rebate t o receive the wire gauze which shall form the panels. 9.8.2 Wire Gauze This shall be unless specified otherwise conform to para 9.2.7 and 9.6.4.5. The wire gauze shall be bent at right angles in the rebates of stiles and rails, turned back and fixed tight with blue tacks at about 75 m m c entres, f ixed alternately i n t he t wo f aces of t he r ebates. O ver t his, w ooden beading shall b e fixed with brads or small screws at about 75 mm centres. The space between the beading and rebates, where the wire gauze is bent, shall be neatly finished with putty, so that the end of the wire gauze may not be visible. 9.8.3 Fixing Fittings, Wooden cleats, blocks and Measurement shall be as specified under 9.6. 9.8.4 Rate This includes the cost of materials and labour involved in all the operations described above, and as specified under 9.6. 9.9 WALL LINING 9.9.0 Specified timber shall be u sed, and it shall be sawn in the direction of the grains. Sawing shall be truly straight and square. T he tim ber s hall be planed s mooth and ac curate to the fu ll dim ensions, rebates, roundings, and mouldings as shown in the drawings made, before assembly. Patchings or plugging of, any kind shall not be permitted except as provided. 9.9.1 Grounds Grounds s hall be pro vided w here s o s pecified. T hese s hall consist of f irst class hard w ood pl ugs or the class of wood used for fabricating the frames, of trapezoidal shape having base of 50 × 50 m m an d top 35 × 35 mm with depth of 5.0 cm and embedded in the wall with cement mortar 1:3 (1 cement : 3 fine sand) and batten of first class hard wood or as specified of size 50 × 25 mm or as specified, fixed over the plugs with 50 mm long wood screws. The plugs shall be spaced at 45 to 60 centimetres centre to centre, depending upon the nature of work. The battens shall be painted w ith priming coat, of approved wood primer before fixing. 9.9.2 Panelling 9.9.2.1 Material : This panelling shall be dec orative or non-decorative (Paintable) type as per design and t hickness specified by t he E ngineer-in-Charge, of 2nd class t eak w ood, FPT-1 or graded wood prelaminated particle board or as specified in item. 9.9.2.2 Ornamental Work : The ornamental wood work shall be painted on the back with priming coat of approved wood pri mer be fore f ixing t he s ame t o t he grounds w ith s crews, which s hall be s unk i nto t he wood work and their tops covered with putty. The ornamental work shall be made true and accurate to the dimensions shown in the working drawings. The fixing shall be done true to lines and levels. The planks for wall lining shall be tongued and grooved, unless otherwise specified. 9.9.2.3 Measurements : Length and breadth shall be measured correct to a cm. Wall panelling such as teakwood panelling and block panelling, plain lining, and plain skirting each shall be measured separately i n s quare m etre n earest t o t wo p laces o f de cimal. T he moulded w ork s hall be m easured in cm running metre i.e. in running metres stating the girth i n cm. The s ectional periphery (girth) of moulding ex cluding t he portion i n contact w ith wall shall be m easured in c m correct t o 5 mm and l ength in metre correct to a cm.
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The measurements for gr ound s hall be taken on the bas is o f cubical contents o f bat tens and pai d for separately, unless otherwise specified. Where onl y pl ugs are required t o be f ixed f or t he ornamental w ork, t he c ost f or t he s ame s hall be deemed to be included in the rate of ornamental work and no separate payment shall be made for plugs. 9.9.2.4 Rate : The rate includes the cost of materials and labour required for all the operation described above. 9.10 SHELVES 9.10.0 Shelves and v ertical part itions of c upboards shall be o f t imber planks fibre board, particle board, block board or veneered particle board as specified. Thickness and type of planks or boards shall be as specified. E ach s helf s hall be a s ingle pi ece a nd vertical pa rtitions b etween t wo consecutive s helves shall be w ithout any joint. E xposed edges of boards hav ing particle board c ore s hall be s ealed w ith 3 mm thick s ingle piece teak w ood s trips of w idth equal t o t he t hickness of board w ith headless pi ns. The arrangement of s helves a nd v ertical p artitions s hall be as per dra wings or a s di rected by t he Engineerin-Charge. 9.10.1 Fixing Planks for shelves shall be planed on all faces and ed ges. In case of boards they shall be sawn to the required size truly straight and square. Timber battens 25 x 40 mm unless otherwise specified shall be planed smooth and fixed inside the cupboard with wooden plugs and screws. Shelves shall be fixed to the battens and v ertical portions s hall be hel d i n po sition by f ixing t hem t o t he battens and s helves using screws. Teakwood strips for edge sealing of the boards shall be planed smooth and fixed with headless nails. Tolerance in width shall be ± 1.5 mm and in thickness 1 mm. 9.10.2 Measurements Length and width of shelves and vertical partitions shall be measured correct to a cm. separately for each type of board stating its thickness. Area shall be calculated correct to 0.01 sqm. 9.10.3 Rate It includes the cost of materials and labour required for all the operations described above. 9.11 TRELLIS (JAFFRI) WORK : DELETED 9.12 PELMETS 9.12.0 Planks and curtain rods of specified timber shall be us ed, and i t shall be sawn in the direction of the g rains. S awing s hall b e truly s traight and square. The timber s hall be pl aned smooth and ac curate to the f ull d imensions, r ebates, r oundings, and m ouldings as s hown i n t he dr awings m ade, bef ore assembly. Patching or plugging of any kind shall not be permitted. 9.12.1 Sides, front and top of the pelmets shall be of 12 mm planks or boards of specified quality and width unless otherwise stated. These shall project from the wall face by 15 cm or as specified, and shall be securely fixed to walls with wood screws by means of wooden plugs and 10 cm long 25 × 3 mm M.S. flat bent in the form of angle or by any other device approved by the Engineer-in-Charge. The pelmets shall be pr ovided w ith c urtain rods and br ackets or c urtain r ails w ith r ollers, stop e nds an d b rackets wooden, brass or chromium plated brass as specified. Intermediate wooden brackets shall be provided, if the front length of pelmet exceeds 1.5 metres. 9.12.2 Measurements The pelmets box shall be measured along the sides and front planking correct to a centimetre. 9.12.3 Rate The rat e i ncludes t he cost of s ides, f ront and t op p lanking c urtain rod s w ith brackets or c urtain rai ls with rollers labour and materials required for all the operations described above.
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9.13 HOLD FASTS 9.13.0 These shall be made from mild steel flat 40 × 5 mm size conforming to IS 7196 without any burns or dents. 5 cm l ength o f M. S. flat at one end s hall be bent at r ight angl e and one hol e 11 mm dia shall b e made in it f or fix ing to w ooden fra me w ith 1 0 m m dia nut b olt. The bol t he ad s hall b e su nk i nto t he wooden frame, 10 mm deep and plugged with wooden plug. At the other end 10 cm length of the hold fast flat shall be forked and bent of length as specified at right angle in opposite direction and embedded in cement concrete block of size 30 x 10 x 15 cm of mix 1:3:6 (1 cement : 3 c oarse sand : 6 grade d stone aggregate, 20 mm nominal size) or as specified (see Fig. 9.4). 9.13.1 Measurements Measurements for the hold fasts shall be in number. 9.13.2 Rate It includes the cost of labour and material involved in all the operations described above including fixing bolt and cement concrete blocks. 9.14 EXPANDED METAL, HARD DRAWN STEEL WIRE FABRIC AND WIRE GAUZE IN WOODEN FRAMES 9.14.0 Expanded m etal, hard drawn steel wire fabric or wire gauge or weld m esh as described in the item of work shall be fixed to the window frames on the outside or inside as per detailed drawings or as directed by the Engineer-in-Charge. These shall be free from rust and other defects. Expanded Metal This shall be in the form of rhombus with its opening diagonals 20 × 60 mm and strands 3.25 mm wide and 1.6 mm thick weighing 3.633 kg/m2 unless otherwise specified. Welded Steel Drawn Wire Fabric This shall c onform t o I S 4948 and shall ha ve r ectangular mesh of 7 5 × 25 m m s ize w ith w ires o f diameter not less than 5 mm longitudinally and 3.15 mm transversely. Its weight shall be not less than 7.75 kg/m2 unless otherwise specified. Wire-Gauze This shall be as per clause 9.2.7. 9.14.1 Fixing Expanded metal, hard drawn steel wire fabric and w ire gauze shall be c ut in one piece to the size of the frame (out to ou t). E xpanded m etal a nd hard d rawn s teel w ire fabric s hall be fixed on t o the f rame with staples, over which wooden beading 60 x 20 mm shall be fixed with wood screws. 9.14.2 Measurements The length and breadth shall be m easured c orrect to a c m, the area from outside to outside of beading shall be calculated in square metre nearest to two places of decimal. 9.14.3 Rate It includes the cost of labour and materials required for all the operations described above. 9.15 FITTINGS 9.15.0 Fitting shall be o f mild steel brass, aluminium or as specified. Some mild steel fittings m ay h ave components of c ast i ron. These s hall be w ell made, reasonably smooth, and free f rom sharp edges and corners, f laws and ot her def ects. S crew holes shall be counter s unk t o suit t he hea d of s pecified wood screws. These shall be of the following types according to the material used.
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(a) Mild S teel F ittings : These s hall be b right finish black stone enam elled or copper ox idised (black finish), nickel chromium plated or as specified. (b) Brass Fittings : These s hall be finished bri ght s atin f inish or n ickel chromium plated or copper oxidised or as specified. (c) Aluminium Fittings : These s hall b e ano dised to nat ural matt f inish or d yed ano dic coating not less than grade AC 10 of IS 1868. The fi ttings g enerally u sed for d ifferent type of d oors and windows a re in dicated i n Appendix H attached. The fittings to be actually provided in a particular work shall, however, be decided by the Engineer-in-Charge. Screws us ed f or f ittings s hall be o f t he s ame metal, and finish as t he fittings. H owever, c hromium plated brass screws or stainless steel screws shall be used for fixing aluminium fittings. These shall be of the size as indicated in respective figures. Fittings shall be f ixed i n proper pos ition as s hown in t he drawings or as di rected by the E ngineer-inCharge. These shall be truly v ertical or ho rizontal as the case may be. S crews shall be d riven ho me with screw driver and not ham mered i n. Recesses s hall be c ut to the ex act size and dept h f or t he c ounter sunking of hinges. 9.15.1 Butt Hinges (Fig. 9.5A) These shall be of the following types according to the material used. (a) Mild steel butt hinges (Medium). (b) Cast brass butt hinges light/ordinary or heavy. (c) Extruded aluminium alloy butt hinges. 9.15.1.1 Mild Steel (Medium) ( Fig. 9.5A) : These shall be m edium type manufactured from M.S. sheet. These shall be well made and shall be free from flaws and defects of all kinds. All hinges shall be cut clean and s quare and al l sharp edges an d c orners shall be rem oved. T hese shall gen erally c onform t o IS 1341. Hinge Pin : Hinge pin shall be made of mild steel wire. It shall fit inside the knuckles firmly and rivetted head shall be well formed so as not to allow any play or shake, and shall allow easy movement of the hinge, but shall not cause looseness. Knuckles : The number of k nuckles i n the hi nges of di fferent s izes shall be as per I S 1341. The s ize of knuckles s hall b e straight and at right an gle to the f lap. T he m ovement of t he hinges shall b e free a nd easy and working shall not have any play or shake. Screw Holes : The screw hol es s hall be c lean and c ounter s unk. T hese shall be s uitable f or c ounter sunk head w ood screws and o f t he s pecified size for d ifferent t ypes, and sizes of h inges. The size o f the holes shall be such that when it is counter s unk it shall be able t o accommodate t he full depth of counter sunk head of the wood screws. The nos. of screw holes shall as specified in IS 1341. 9.15.1.2 Cast Brass : These s hall be light/ordinary or heavy as s pecified. T hese shall be well made and shall be f ree f rom flaws and def ects of all k inds. These s hall be f inished bright or c hromium pl ated or oxidised or as specified. These shall generally conform to IS 205. Hinge Pin : Hinge pin shall be made of brass or of stainless steel. The hinge pins shall be firmly rivetted and shall be prop erly f inished. T he m ovement of t he hi nge pi n s hall be f ree, ea sy an d s quare and shall not have any play or shake. Knuckles : The num ber o f knuckles in eac h hi nge shall not be l ess than five. T he num ber o f knuckles i n case of sizes less than 40 mm shall be three. The sides of the knuckles shall be straight and at right angle to the flap. The movement of the hinge pin shall be free and easy and working shall not have any play or shake.
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Screw Holes : The s crew h oles s hall be c lean an d c ounter s unk and of t he specified size f or d ifferent types and size of hinges. The size of the holes shall be such that when it is counter sunk it shall be able to accommodate the full depth of counter sunk head of wood screw specified. 9.15.1.3 Extruded Aluminium Alloy : These s hall be manufactured from e xtruded s ections. These s hall be well made and free from flaws and defects of all kinds. These shall generally conform to IS 205. Hinge Pin : Hinge p in s hall be m ade of m ild s teel (galvanised or al uminium alloy). T he a luminium a lloy hinge pi n s hall be anodi sed. T he hi nge pi n s hall be f inally rivetted and s hall be pr operly f inished. T he movement of hinges shall be free easy and square and shall not have any play or shake. Knuckles : Number o f k nuckles i n each hi nge pin s hall no t b e l ess t han 5. T he n umber of k nuckles in case of sizes less than 40 mm be straight and at right angle to the flap. The movement of the hinge pin shall be free and easy and working shall not have any play or shake. Screw Holes : The s crew hol es s hall be s uitable f or c ounter s unk head wood s crews, and of specified sizes for different type of hinges. The size of the holes shall be such that when it is counter sunk it shall be able to accommodate the full depth of counter sunk head of wood screw specified. 9.15.2 Parliament Hinges (Fig. 9.5B) 9.15.2.1 These shall be of mild steel cast brass or as specified, and shall generally conform to IS 362. The s ize of parliament hi nges s hall b e t aken a s t he w idth between o pen f langes. M ild s teel parliament hinges sh all be c opper o xidised (thi ck fi nish) or a s spe cified. T he bra ss p arliament hinges s hall b e finished bright, chromium plated or oxidised or as specified. 9.15.2.2 The hinge pin shall be made of mild steel in the case of brass hinges. The hinge pin shall be mild s teel (g alvanised) i n the c ase of aluminium al loy hi nges. T he hi nge p in shall be f irmly ri vetted an d shall be pr operly f inished. T he m ovement o f t he h inges s hall be f ree, eas y and s quare, and s hall not have any play or shake. All s crew holes s hall be c lean and c ounter s unk to s uit the counter sunk head of w ood s crews specified. 9.15.3 Spring Hinges (Single or double acting) 9.15.3.1 These shall be single acting when the shutter is to open on one side only or double acting when the shutter opens on both sides. These shall be made of M.S. or brass as specified, and shall generally conform to IS 453. Hinges shall w ork smoothly and s hall hold t he d oor shutter t ruly vertical i n c losed p osition. E ach double-acting s pring hi nge shall w ithstand the following t ests w hich s hall be carried out a fter fixing i t to a swing door in the normal manner. (a) When the door is pushed through 90° and released 2000 times on each side in quick succession the hinge shall show no sign of damage or any appreciable deterioration of the components during or on completion of the test. (b) The door shall require a force of 2.0 ± 0.5 kg for 100 mm hinges and 3.0 ± 0.5 kg for 125 mm and 150 mm hinges at a distance of 45 cm from the hinge pin to move the door through 90º. The size of spring hinge shall be taken as the length of the plate. 9.15.3.2 These shall be of the following type: (a) Mild S te e l : The cylindrical casing shall be m ade either from M .S. sheet of 1.60 m m thickness, lap jointed and brazed, welded and rivetted, or from solid drawn tube of thickness not less than 1.60 m m; or fr om m ild s heet of 1. 60 m m thi ckness p ressed to fr om t he two c asing a nd t he distance piece. It shall be stove enamelled black or copper oxidized or as specified.
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(b) Ca s t Bra s s : The cylindrical casing shall be made either from brass sheet of 1.60 mm thickness, lap jointed and brazed, or from solid drawn brass tube of not less than 1.60 mm thickness. It shall be satin, bright nickle plated or copper oxidized or as specified. 9.15.4 Rising Hinges These s hall b e m ade of br ass, f inished b right or chromium plated o r ox idised or as s pecified. I ts shape and pat tern s hall be appr oved b y t he E ngineer-in-Charge. T he s ize of t he rising hi nge s hall be taken as the length of its plate. 9.15.5 Continuous Piano Hinges (Fig. 9.6B) 9.15.5.1 These shall be made from mild steel or aluminium alloy sheet, these shall generally conform to IS 3818. All screw holes shall be clean and counter sunk. Piano hinges shall be fixed in the entire length of the cup board shutters. Its size will be the width of the two flaps when open. 9.15.5.2 M.S. Piano Hinges : These shall be made from 1 mm or 0.80 mm thick M.S. sheets and shall be protected with anti-corrosive treatment, such as bright polished, chromium plated or oxidised finish. Hinge pin shall be of galvanised mild steel. It shall fit in the knuckle firmly so as not to allow any play or shake and shall allow easy movement of hinge, but shall not cause looseness. The sides of the knuckles shall be s traight and at right angles to the flap. The movement of the hinge shall be free and easy and working shall not have any play and shake. 9.15.5.3 Aluminium Piano Hinges : These shall b e made of a luminium alloy s heet and shall be anodised. The anodic coating shall not be less than the grade AC 15 of IS 1868. Hinge pin shall be made of aluminium alloy with anodic coating not less than the grade of AC-15 of IS 1868. The hinge pin shall fit in the knuckle firmly so as not to allow any play or shake and shall allow easy movement of hinge but shall not cause looseness. The sides of the knuckles shall be s traight and at right angles to the flap. The movement of the hinge shall be free and easy, and working shall not have any play and shake. 9.15.5.4 Sampling and Criteria for Conformity : It shall be same as specified in clause 9.15.1.4. 9.15.6 Tee Hinges (Fig. 9.6A) These shall be m ade from M.S. s heets and shall be either bright finished or s tove enamelled black or as s pecified. T hese s hall gene rally c onform to IS 206 ( Tee h inges s hall b e w ell m ade, free from burrs, f laws, an d de fects of a ny k ind. T he m ovement s hall be s quare, and t he w orking s hall b e free and eas y without an y play or shake. The hol e for the hinge shall be c entral to the bore and s hall be square. The hinge pin shall be firm and rivetted over, so that the heads are well formed. All screw holes shall be clear and counter sunk and shall be suitable for the counter sunk head of wood screws. 9.15.7 Sliding Door Bolts (Aldrops) (Fig. 9.7) 9.15.7.1 These shall be of m ild steel, cast b rass, aluminium o r a s s pecified, an d shall be capable of smooth sliding action. 9.15.7.2 M.S. Sliding Door Bolts : These shall be made of M.S. sheets and M.S. rods and shall generally conform t o IS 281. M .S. s liding door b olts s hall be c opper ox idised ( black f inish) or a s specified.
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9.15.7.3 Cast Brass Sliding Door Bolts : These shall be made from rolled brass and shall generally conform to IS 2681. The hasp shall be of cast brass and secured to the bolt as shown in Fig. 9.7. Alternatively, the hasp and the bolt may be cast in one piece. The fixing and staple bolts shall be c ast with 6 mm studs. B olts s hall be finished to shape and hav e threaded ends and pr ovided with robs washers an d nuts o f square or hex agon type. A ll c omponents s hall be finished s mooth an d pol ished be fore as sembly. Cast brass sliding bolts shall be finished bright or chromium plated or oxidised or as specified. 9.15.7.4 Aluminium Sliding Door Bolts : These s hall b e m ade of al uminium al loy a nd s hall genera lly conform t o I S 2 681. A luminium sliding door bolts s hall be a nodized. All s crew h oles s hall be counter sunk to suit the counter sunk head of screws of specified sizes. All edges and corners shall be finished smooth. In case of single leaf door, when iron socket plate or a brass or aluminium fixing bolts (or sliding door bolt) cannot be f ixed, hole of suitable size shall be dr illed in the door frame and an i ron or brass plate cut to shape shall be fixed at the face of the hole. The leading dimensions of the sliding door bolts are illustrated. 9.15.8 Tower Bolts (Fig. 9.8) 9.15.8.0 These shall generally conform to IS 2 04 ( Part. I) & IS 204 ( Part. II). Tower bolts shall be well made and shall be free from defects. The bolts shall be finished to the correct shape and shall have a smooth ac tion. A ll t ower bolts m ade w ith s heet of 1.2 m m t hickness and above s hall hav e c ounter s unk screw holes t o s uit c ounter s unk h ead of wood s crews. All s harp edges and c orners shall b e re moved and finished smooth. The height of knob of tower bolt when the door, window etc. is in closed position from the floor level shall be not more than 1.9 metre. 9.15.8.1 Tower bolts shall be of the following types: (a) A luminium bar rel t ower bol ts w ith bar rel and b olt of ex truded s ections of al uminium a lloy. T he knob shall be properly screwed to the bolt and rivetted at the back. (b) Brass tower bolts with cast brass barrel and rolled or cast brass bolt. or Brass tower bolts with barrel of extruded sections of brass and rolled or drawn brass bolt. The knobs of brass tower bolts shall be c ast and t he bolt fixed with knob, steel spring and bal l shall be provided between the bolt and the barrel. (c) Mild steel barrel tower bolts with mild steel barrel and mild steel bolt. or Mild steel tower bolts with mild steel barrel and cast iron bolts. The plates and straps after assembly shall be firmly rivetted or spot welded. The rivet head shall be properly formed and the rivet back shall be flush with the plate. These shall be made in one piece. 9.15.8.2 Unless otherwise specified bolt shall have finish as given below : (a) Mild steel tower bolts (Types 1 and 2) Bolts bright finished or plated as specified and barrel and socket stove enamelled black. (b) Brass tower bolts (type 3 to 5) Bolt and barrel polished or plated as specified. (c) Aluminium alloy tower bolts (type 6) Bolt and barrel anodized. The anodic film may be either transparent or dyed as specified. The quality of anodized finish shall not be less than grade AC-10 of IS 1868.
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9.15.9 M.S. Locking Bolt with Holes for Pad Locks 9.15.9.1 This shall conform to IS 7534. 9.15.9.2 This shall be of mild steel polished bright or c opper oxidised batch electrogalvanised or stove enamelled. In case of stove enamelled locking bolts, the bolt may be finished bright. 9.15.10 Pull Bolt Locks (Fig. 9.9) 9.15.10.1 These s hall be of M.S. c ast brass or aluminium a s specified. M .S. p ull bolt locks s hall be copper oxidized (black finish) or as specified. 9.15.10.2 Brass pull bolt locks shall be finished bright, chromium plated or oxidised as specified. Aluminium pull bolt locks shall be anodised and the anodic coating shall not be less than grade. A.C. 10 of IS 1868. T he bol t s hall be 10 mm i n diameter and t he fixing plate 3 m m thick. The stop bl ock s hall be screwed to the fixing plate by a small ball and spring over which the bolt shall slide. 9.15.10.3 The fixing plate shall have four holes for fixing it to the door leaf, two of which shall be square to receive 6 mm dia. bolts with round heads, the remaining two shall receive machine screwed with lock nuts. The receiving plate shall be of the same width and thickness as the fixing plate and shall have 3 counter sunk holes. Where t he bo lt s lides into w ooden m embers, l ike t he c howkhat, which ha ve a rebat e, t he rec eiving plate shall also be correspondingly shaped so as to fit into the rebate. The screws and bolts shall have the same f inish as the main bolt. The leading dimensions of pull bolt locks are given i n the drawing. The denominating s ize o f the pull bolt l ocks s hall be length of the fixing p late be tween guid es pl us the thickness of the guides. 9.15.11 Door Latch 9.15.11.1 This shall be o f mild steel, cast brass, or as specified and s hall be capable of smooth sliding action. In c ase, of mild steel latch, it s hall be copper oxidized ( black finish) or as specified and in case of brass, it shall be finished bright, chromium plated or oxidized or as specified. The size of door latch shall be taken as the length of the latch. 9.15.12 Indicating Bolt (Vacant/Engaged) These s hall be of cast brass f inished bright c hromium plated, or ox idized or as s pecified. The s hape and pattern shall be approved by the Engineer-in-Charge. 9.15.13 Mortice Lock and Latch (Fig. 9.10) 9.15.13.0 This should generally conform to IS 2209. 9.15.13.1 The size of the mortice lock shall be denoted by the length of the body towards the face and it shall be 65 mm, 75 mm and 100 mm as specified. The measured length shall not vary more than 3 mm from the length specified. 9.15.13.2 Non-interchangeable Keys : Testing of non-interchangeable keys shall be as per IS 2209. 9.15.13.3 The clear depth of the body shall not be more than 15 mm. The fore end shall be firmly fitted to the b ody s uitably by c ounter s unk head s crew. T he l atch b olt s hall b e of s pecified m aterial a nd of section not less than 12 x 16 mm for all sizes of locks. If made of two piece construction both parts shall be rivetted. Ordinary lever mechanism with not less than two levers shall be pro vided. False levers shall not be used. L ever shall be fitted w ith o ne s pring of p hosphor bro nze or s teel w ire a nd shall w ithstand the tests as provided in IS 2209.
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9.15.13.4 Locking bolts, spring and strike plate shall conform to IS 2209. 9.15.13.5 Handles : These shall conform to IS 4992. 9.15.13.6 Keys : Each lock shall be provided with two keys. 9.15.13.7 Sampling, Criteria for Conformity : It shall be the same as specified in clause 9.15.1.4. 9.15.13.8 Tests : The finally assembled locks shall be tested as prescribed in Appendix ‘G’ of Chapter 9. 9.15.14 Mortice Latch (with Locking Bolt) 9.15.14.1 These are generally used in doors of bath rooms, WC’s and private rooms. 9.15.14.2 Mortice latch shall, in respect of shape, design and mechanism of the latch and its components parts, generally conform to IS 5930. The material used for the different component parts of the latch shall comply with Tables 1 and 2 of IS 5930, unless otherwise specified. 9.15.14.3 The size of the latch shall be denoted by the length of the body towards the face and shall be 65 mm, 75 mm or 100 mm as specified. The depth of the body shall not be more than 15 mm. 9.15.14.4 The latch shall be of size 10 × 18 mm of shape as shown in Fig. 1 of IS 5930. The locking bolt shall be of section not less than 8 x 25 m m for all size of locks. The m echanism of the latch bolt, its spring, striking plate etc. shall be as described in IS 5930. 9.15.14.5 The handles provided shall conform to IS 4992. 9.15.14.6 Sampling, criteria for conformity shall be same as per clause 9.15.1.4. 9.15.15 Mortice Lock and Latch (Rebated) 9.15.15.1 These are slightly different from mortice lock described in 9.15.14 and are designed for use in double leaved doors. These should generally conform to IS 6607. 9.15.15.2 Handles, Keys, Sampling, Criteria for Conformity and Test : These s hall be s ame a s specified in clause 9.15.14. 9.15.16 Mortice Night Latch (Fig. 9.11) 9.15.16.1 This is a mortice lock having a single spring bolt withdrawn from the outside by using the key and f rom i nside by t urning t he k nob and with an arrangement w hereby t he lock can be prevented f rom being opened by its key from outside while the night latch is used from inside the room. 9.15.16.2 This should generally conform to IS 3847. 9.15.16.3 It shall be c ast or s heet brass, cast or s heet aluminium alloy or M ild steel as specified and of best quality of approved make. These shall be bright finished or copper oxidised (black) finish as specified. N ominal size of the latch s hall be denoted by the length of the face ov er the bod y in m illimetres. These shall have not less than two levers. False (Dummy) levers shall not be allowed. 9.15.16.4 Keys : Each latch s hall be provided w ith two k eys w hich s hould w ork smoothly and w ithout any appreciable friction in the lock.
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9.15.17 Cupboard or Wardrobe Lock This should gener ally c onform to IS 729. The s ize o f the c upboard l ock shall be 40, 50, 65 & 75 mm. This s hall be m ade o f cast b rass an d s hall be o f the bes t m ake o f a pproved qu ality. T hese s hall be finished bright or chromium plated or oxidised or as specified. The size of the lock shall be denoted by the length of the face across the body in mm. These locks shall be fitted with four, f ive or s ix levers as specified. False ( dummy) levers shall not be used. 9.15.18 Kicking Plates 9.15.18.1 This shall be of brass (finished bright or chromium plated or oxidised) bronze, stainless steel, aluminium or as s pecified. A luminium k icking pl ates s hall be a nodised and t he anodi c coating s hall n ot be less than grade AC-10 of IS 1868. It shall be m ade from a pl ate of minimum thickness 3.0 mm & 1.5 mm in ca se of st ainless ste el. S hape of the pl ate shall be as specified. This s hall ha ve be velled or straight edges and shall be f ixed by m eans of c ounter s unk or rounded screws of the s ame m aterial and finish as t hat o f the pl ate. The s hape and pat tern s hall be ac cording t o the d rawings and as appr oved b y the Engineer-in-Charge. 9.15.19 Door Handles (Doors and Windows) (Fig. 9.12) 9.15.19.1 These should generally conform to IS 208. The door handles shall be well made and free from defects. T hese s hall be f inished c orrect to s hape and d imensions. A ll edges and c orners s hall be removed a nd f inished s mooth s o as to facilitate ea sy h andling. C ast handle s hall be f ree from c asting defects. W here t he grip portion of the handl e i s joined w ith the bas e pi ece by m echanical m eans, the arrangement shall be such that the assembled handle shall have adequate strength comparable to that of integrally cast type handles. 9.15.19.2 Door handles shall be of the following types according to the material used: (a) Cast or Sheet Aluminium Alloy Handles : These shall be of aluminium of specified size, and of shape and pattern as app roved b y t he Engineer-in-Charge. T he size of t he h andle shall be det ermined by the inside grip of the handle. Door handles shall be of 100 mm size and window handles of 75 mm size unless, otherwise specified. These shall be fixed with 25 mm long wood screws of designation No. 6. Aluminium handles, shall be anodi zed and t he anodic coating shall not be less than grade AC 15 - IS 1868 as specified. The finish can be bright natural, matt or satin or dyed as specified. (b) Cast Brass Handles: These s hall be of c ast brass of specified s ize and of t he s hape and pattern as approved by the Engineer-in-Charge. The size of the handle shall be determined by t he inside grip of t he handle. D oor handl es s hall be of 100 m m s ize and w indow handl es of 75 m m s ize, unl ess ot herwise specified. These shall be fixed with 25 mm long wood screws of designation No 6. Brass handles shall be finished bright satin or nickel chromium plated or copper oxidised or as specified. (c) Mild Steel Handles : These shall b e of mild s teel s heet, pr essed i nto oval s ection. T he size of t he handles will be determined by the inside grip of the handle. Door handles shall be 10 mm size and window handles of 75 mm size unless otherwise specified. These shall be fixed with 25 mm long wood screws of des ignation N o. 6. , I ron handl es s hall b e c opper ox idised ( black finish) or s tove enam elled black or as specified. 9.15.20 Floor Door Stopper (Fig. 9.13) 9.15.20.1 The floor door stopper shall conform to IS 1823. This shall be made of cast brass of overall size as specified and s hall have rubber cushion. The shape and pat tern of stopper shall be appr oved by the E ngineer-in-Charge. I t s hall be of bras s f inished bri ght, c hromium pl ated or ox idised or as s pecified.
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The size of floor stopper shall be determined by the length of its plate. It shall be well made and shall have four counter sunk holes for fixing the door stoppers to the floor by means of wood screws. The body for housing of the door stopper shall be c ast in one pi ece and it shall be fixed to the cover plate by means of brass or m ild steel screws and cover pl ate shall be of casting o r of sheet m etal. The spring shall be fixed firmly to the pin. Tongue which would be p ressed w hile closing or opening of the door shall be c onnected t o t he l ower pa rt by m eans of c opper pi n. O n t he e xtreme e nd a r ubber pi ece s hall b e attached to absorb s hock. A ll parts of the do or s topper s hall b e of good w orkmanship and finish, burrs and sharp edges removed. It shall be free from surface and casting defects. Aluminium stopper shall be anodised and anodic film shall not be less than grade AC-10 of IS 1868. TABLE 9.18 Requirements for Rubber for Use in Floor Door Stoppers P a rticula rs Relative density Max. Hardness Ageing for 24 hours at 100o + 1oC
Re quire me nts Te s ting Proce dure 1.3 IS 3400 (Part IX) IS 3400 (Part 2) 60 + 5 (a) Change in initial hardness IS 3400 (Part II) (b) Shall not develop brittleness -do+ 5, - 0
9.15.21 Hanging Rubber Door Stopper 9.15.21.1 These s hall be of c ast brass, finished bright, c hromium plated or as s pecified. Aluminium stopper shall be anodi sed and t he anodic coating shall not be l ess than grade AC-10 of IS 1868. The size a nd p attern of t he door stopper s hall be a pproved b y t he Engineer-in-Charge. T he s ize s hall be determined by its length. 9.15.22 Universal Hydraulic Door Closer (Exposed Type) 9.15.22.1 These shall be made of cast iron/aluminium alloy/zinc alloy and of sh ape and pattern as approved by the Engineer-in-Charge. 9.15.22.2 These shall generally c onform to I S S pecifications for door closers (Hydraulically r egulated) I S 3564. 9.15.22.3 The door closers m ay be polished or p ainted and finished with lacquer to d esired c olour. Aluminium al loy do or closer shall be anodi zed and t he anodic coating shall not be l ess than gr ade AC 15 of IS 1868. All dents, burrs and sharp edges shall be removed from various components and they shall be pickled, scrubbed and ri nsed t o r emove grease, rus t, sca le or an y other for eign ele ments. A fter pickling, all the M.S. parts shall be given phosphating treatment in accordance with IS 3618. 9.15.22.4 The nominal size of door closers in relation to the weight and the width of the door size to which it is intended to be fitted shall be given in Table 9.19. TABLE 9.19 Type and Designation of Door Closers De s igna tion of clos e rs 1. 2. 3.
Ma s s of Width of the door Re ma rks the door (mm) (kg) Upto 35 Upto 700 For light doors such as double leaved and toilet doors. 36 to 60 701 to 850 Interior doors, such as of bed rooms, kitchen and store 61 to 80 851 to 1000 Main doors in a building, such as entrance doors
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9.15.23 Casement Brass Stays (Straight Peg Type) (Fig. 9.14) 9.15.23.1 These shall be m ade of mild steel, cast brass, aluminium (extruded section) or plastic (Polypropylene) a s s pecified. M ild s teel casement stays shall b e a copper o xidised ( black f inish) or a s specified. C ast br ass s tays s hall be f inished b right or c hromium pl ated o r as s pecified. A luminium s tays shall be anodi sed and the anodic coating shall not be less than grade AC-10 of IS 1868. Aluminium and M.S. stays shall be made from channel section. The stays shall not weigh less than that indicated below: 200 mm 250 mm 300 mm
0.24 kg each 0.28 kg each 0.33 kg each
9.15.23.2 The shape and pattern of the stays shall be app roved by the Engineer-in-Charge. The size of stays s hall be det ermined by i ts l ength as s hown i n t he pl ate. T he pl astic (Polypropylene) s tays s hall conform to IS 6318. 9.15.24 Quadrant Stays 300 mm These shall be made of cast brass and finished bright or chromium plated or as s pecified. T he shape and pattern shall be approved by the Engineer-in-Charge. It shall not weigh less than 0.20 kg each. 9.15.25 Hasp and Staple Safety Type (Fig. 9.15) 9.15.25.1 This shall be made of mild steel, cast brass or aluminium as specified. This shall generally conform to I S 363. M .S. Hasp and s taples s hall be f inished bl ack enam elled, or copper ox idised (bl ack finish) or as specified. B rass has p and staples s hall be finished br ight chromium plated o r o xidised o r a s specified. Aluminium ha sp and s taples s hall be an odized an d t he anod ic c oating s hall not be l ess t han grade AC 15 of IS 1868. 9.15.25.2 M.S. hasp and staples shall be m anufactured from M.S. sheet and brass hasp and staples by casting and A luminium hasp a nd staples s hall be m ade f rom dye s ection. The hi nge pi n w hich i n a ll cases shall be of mild steel, shall be firm and its rivetted heads well formed. The movement of hasp shall be free, easy and square and shall not have any play or shake. The hasp shall fit, in the staple correctly. The size shall be determined by the length of the bigger of the hasp. 9.15.25.3 The staple except in the case of cast one, shall be rivetted properly to its plate. The ends of the hi nge pi n f or t he s afety t ype has p s hall be rivetted and pr operly f inished. A ll s crew hol es s hall be clean and counter sunk to suit counter sunk wood screw. All edges and corners shall be rounded. 9.15.26 P.T.M.T (Polytetra Methyline Tetraphthalate) Fittings : DELETED 9.16 LAMINATED VENEER LUMBER (LVL) : DELETED
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9.17 PARTITIONS 9.17.1 Materials (i) Gypsum Board conforming to IS 2095 (Pt.-I) (ii) Non asbestos multi-purpose cement board conforming to IS 14862 (iii) Tapered edge calcium silicate board Tapered Edge Calcium Silicate Board are manufactured from Siliceous and Calcareous materials reinforced w ith fibres. The boards are made in a laminar process and then autoclaved to give a stable crystalline s tructure. I t i s l ightweight an d c an be fixed to e ither s ide o f timber, aluminum or lightweight galvanized metal sections. The partitions are non-load bearing and can easily be assembled at site. 9.17.2 Installation The G.I. frame and board partitions shall be fixed as per nomenclature of the item and directions of Engineer-in-Charge. (Fig. 9.17). 9.17.3 Jointing & Finishing Joints of th e b oards are finis hed w ith s pecially f ormulated J ointing co mpound a nd f ibre ta pe t o provide seamless finish. Board surface can be decorated with any type of paint, wall paper, wood veneer & hard laminates. Services should be incorporated before commencement of board fixing. 9.17.4 Fitting and Fixtures It is easy and simple to attach different fittings to wall panelling boards. Inclined nails can be fixed to the boards itself for light materials. For h eavier m aterials the fastening should be centered on internal stud work o r steel o r wood f rame b ehind t he b oards, f ixed before boarding. Services should b e incorporated before commencement of board fixing. 9.17.5 Tolerance Tolerance in dimensions shall be + 5 mm. 9.17.6 Measurements 9.17.6.1 Length and breadth of superficial area of the finished work shall be measured correct to a cm. Area shall be calculated in square meter correct to two places of decimal. No deduction will be made of openings o f a reas upt o 0 .40 s qm no r shall ex tra pa yment be made ei ther for an y ex tra material or labour involved in forming such openings. 9.17.6.2 For openi ngs exceeding 0. 40 sqm. in area, deduction i n measurements s hall be made but ex tra will be payable for any extra material or labour involved in making such openings. 9.17.7 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above including all scaffolding, staging etc. 9.18 UPVC DOOR SHUTTERS : DELETED 9.19 PVC DOOR SHUTTERS : DELETED 9.20 PVC DOOR FRAME : 9.20.0 Material Polyvinyl c hloride R esin s uspension gr ade i s t he b asic r aw m aterial f or f orming PVC c ompound.PVC resin t hen is mixed w ith c hemicals l ike C alcium, S tearate, H ydrocarbon Wax, T itanium D ioxide,Calcium Carbonate, A crylic pr ocessing a ids. F urther, add itives like impact modifiers, pi gments, epox y pl asticizer, UV stabilizer, lubricants, chemical blowing agent etc. are added. The purpose of adding the chemicals and
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9.21.6 Fittings Fittings shall be provided as per schedule of fittings decided by Engineer-in-Charge. In moisture prone areas M.S. fittings and screws should not be used. Hardware such as handles, tower bolt,stopper, buffer etc. hould be directly screwed (not pre-drilled) and fitted on the door. 9.21.7 Measurements Length and width of the shutters shall be measured to the nearest cm in closed position covering the rebates of the frames but excluding the gap between the shutter and the frame. Area is calculated to the nearest 0.01 sqm.. 9.21.8 Rate The specified rate include the cost of the door shutter and labour involved in fixing of the shutter. Fittings & fixtures on the door shutter except hinges & screws shall be paid extra as provided. 9.22 FIBRE GLASS REINFORCED PLASTIC (FRP) DOOR FRAMES : DELETED 9.23 FIBRE GLASS REINFORCED PLASTIC (F.R.P.) SHUTTERS :DELETED 9.24 SOLID PVC FOAM PROFILE DOORS :DELETED 9.25 SOLID PVC FOAM SHUTTERS : DELETED 9.26 FACTORY MADE FIBRE GLASS REINFORCED PLASTIC CHAJJA : DELETED 9.27 WALL PANELLING (Fig. 9.28) All specification same as per clauses 9.17.1 to 9.17.7.
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APPENDIX A
TABLE FOR PERMISSIBLE DEFECTS FOR VARIOUS GRADES OF TIMBERS (Clause 9.1)
S l. No. (1) (i) (ii)
(iii)
De fe cts (2) Cross-grain Sound knots and live knots
Dead and loose knots (plugged)
(iv)
Pitch pockets or streaks
(v)
Sapwood
(vi)
Pin holes
Firs t Gra de (3) Not steeper than 1 in 15 (i) Stiles and Rails
S e cond Gra de (4) Not steeper than 1 in 10 (i) Stiles and rails
(a) Short Exposed Face: Not more than 15 mm size and not more than 1 knot/metre (b) Long Exposed Face- Not more than 15 mm size and not m ore t han 1 k not/m. N o knot s hall oc cur within 20 mm of the edges
(a) S hort ex posed F ace - Not m ore than 15 mm size and not more than 3 knots per stile and 1 knot per rail (b) Long Exposed Face- Not more than 2 0 mm size and not more than 3 k nots per s tile and 1 k not per rail
(ii) Panels - Not more than 20 mm size and not more than 2 2 knots/m . No k not shall oc cur o n edge of any c omponent of a panel. (i) Stils and Rails - Not more than 10 mm size - centrally located and not more than 1 knot / m
(ii) P anels - Not m ore t han 20 m m s ize 2 and not more the 4 knot/m . No knots shall occur on edge of any component of a panel.
(ii) Panels - Not more than 15 mm size and not more than 2 2 knots/m . No k not s hall occur o n edges of any component of a panel. None
Total not exceeding 5 mm wide and 150 mm long per metre. (This restriction ap plies o nly t o super group species). Permitted provided they are not in cluster None
(i) Stiles and Rails - Not more than 10 mm size, c entrally l ocated a nd not more t han 3 knots per stile and 1 k not per rail. (ii) P anels - Not m ore t han 15 m m s ize 2 and not more than 4 knots/m . No knot s hall occur on edge of any component of a panel. Permissible except on e xposed edges provided t hat they a re c lean and filled u p with suitable putty or filler when pitch pockets or streaks are located on the exposed edge s o f the c ore, they shall be cut out and filled with piece of wood of similar s pecies with grain r unning in the same direction. The piece shall be well glued. Total not ex ceeding 10 m m w ide and 300 mm long per metre. (This r estriction applies only to super group species). Permitted.
Permitted provided they are not more than 10 mm in diameter and not more than one per metre and provided such worm holes are pl ugged w ith s imilar t imber in s uch a manner that the pluging merges with the surrounding area both as to colour and grain. Note : (i) Dead and loose knots are permitted only if they are suitably plugged. (ii) Knot shall not occur where hinges or locks are to be fixed.
(vii)
Worm holes
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APPENDIX B
DIFFERENT CLIMATIC ZONES FOR MOISTURE CONTENT OF TIMBER (Clause 9.1.6)
68°
72°AFGHANISTAN 76°
80°
84°
88°
92°
96°
36° 36°
INDIA SHOWING DIFFERENT C LIMATIC ZO NES FOR MOISTURE CONTENTS FOR SEASONED WOOD
Gilgit J AMMU AND KAS HMIR Srinagar Leh 32°
32°
HIMACHAL P RADES H P UNJ AB Shimla Chandigarh Dehradun HARYANA 28°
Delhi Bikaner RAJ AS THAN Jodhpur Barmer
24°
Gwalior
GUJ ARAT
I
Ahmedabad
20°
Diu Daman Dadra & N agar Haveli Bombay
BHUTAN
Agra
Jaipur
Indore
N
Silvasa
NAGALAND Kohima
Kanpur
D
MEGHALAYA Shilong MANIP UR Imphal B ANGL ADESH Aizwal
Patna
Bhopal Jabalpur MADHYA P RADES H Raipur
Bhagalpur Gaya BIHAR
I
Nagpur
A
Durgapur
ORIS S A
24°
MIZORAM
Calicutta
20°
Bhubaneshwar BAY OF B ENGAL
Pune Vishakhapatnam
Hyderabad
ARABIAN S EA 16°
28°
ARUNACHAL P RADES H Itanagar
16°
Bijapur Pananji (Goa, Daman & Diu) Goa
NOTE OF S HADING
Narcondam Ireland (India) Barren I reland (India)
Zone I 12°
TAMIL NADU
Zone I I
Madras
Bangalore
Zone III P ONDICHERRY
Port Blair
Zone IV
Kavaratti Madurai
I 72°
Note 1 : Note 2 : Note 3 : Note 4 :
8°
Trivandrum
8°
O C E A N
N D I A N 76°
80°
84°
88°
92°
Based upon Survey of India map with the permission of the Surveyor General of India. The territorial waters of India extend into the sea to a distance of twelve nautical miles measured from the appropriate base line. The boundary of Meghalaya shown on this map is as interpreted from the North-Eastern Area (Reorganisation) Act, 1971, but has yet to be verified. The administrative headquarters of Chandigarh, Haryana and Punjab are at Chandigarh.
.
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APPENDIX C
MOISTURE CONTENT OF TIMBER (Clause 9.1.6)
C-1 Moisture content of timber shall be checked for every 1 cum or part thereof by electrical moisture meters as per IS 287. C-2 Electrical moisture meters are of resistance type and shall be used when the moisture content is within a range of 8 to 25 per cent. When checking moisture content with electrical moisture meter, it shall be ensured that : (a) Timber is not hot or surface wet and the moisture gradient is not large due to wet cores. (b) Electrode probes are of adequate depth (not less than one-fifth the thickness of the timber). C-3 Sufficient number of reading at different positions are taken on each piece of timber to eliminate localised variations in surface moisture and species corrections are applied for the make of electrical resistance type moisture meter. C-4 If for any reason, w hatsoever, t he result o f e lectrical m oisture are no t to be re lied u pon the moisture content shall be checked by the oven drying method. C-5 For checking moisture content by oven drying method, a complete test cross section, 12 to 19 mm long in the direction of timber grain, free from all defects shall be cut from each piece of timber selected for test as follows : (a) I f w eighing c an be do ne i mmediately, t he t est section s hall be c ut from a poi nt at l east 45 cm from one end of the piece or from its centre. (b) In case cutting of test section from the piece is not permissible the moisture content in the whole section can also be determined by collecting a boring to a depth of half of the thickness of the piece by means of an auger, in a preweighed weighing bottle which should then be sealed properly. C-6 The test sections obtained above shall be weighed, immediately after cutting, on a balance the sensitivity of which is not less than 10 mg. They shall be dried in a ventilated, and preferably thermostatically controlled, oven at a temperature of 100°C to 105°C untill the weight is constant. The weight of the test section shall be deemed to have become constant if successive weighing at intervals of 2 to 5 hours do not differ from one another by more than 50 mg. The test weight shall be taken to be the oven dry weight of the test section. C-7 The percentage moisture content in the test section shall be calculated as follows : Moisture content (Per cent) = Where :
W1 - W O ——————— × 100 WO
W 1 = initial weight of t est s ection and W O = oven dry weight of test section C-8 When m oisture c ontent of t imber is c hecked by ov en drying m ethod, r esults of electrical m oisture meter shall be ignored. .
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APPENDIX D
PHYSICAL AND MECHANICAL PROPERTIES OF PLYWOOD (Clause 9.2.2.6)
D-1 Moisture content 5 to 15 per cent. D-2 Shear Strength Dry S ta te 135 110
Average Individual
Re s is ta nce to Mois ture 100 80
APPENDIX E
PHYSICAL AND MECHANICAL PROPERTIES OF FPT OR GRADED PARTICLE BOARD (Clauses 9.2.3.4 )
S l. N o.
P rope rtie s
(i) (ii)
Density variation, percent Water absorption, percent (a) 2 h soaking (b) 24 h soaking
(iii)
Linear expansion (swelling in water). 2 h soaking-percent (a) Length (b) Width Thickness, swelling, percent 2 h soaking Swelling in thickness due to surface absorption, percent
(iv) (v)
Fla t pre s s e d Thre e la ye r multi la ye r & gra de d Gra de - I Gra de -II ± 10 ± 10
Modulus of rupture, N/mm (a) Average (b) Minimum
(vii)
Modulus of elasticity, N/mm (a) Average (b) Minimum 2 Tensile strength perpendicular to surface, N/mm (a) Upto 20 mm thickness (b) Above 20 mm thickness
(ix) (x)
40 80
0.5 0.5 8 6
0.5 0.5 12 9
15 13
11 10
2500 2250
2000 1800
0.45 0.40
0.3 0.3
0.2 0.15
-
1250 850
1 250 700
2
(vi)
(viii)
10 20
2
Tensile strength perpendicular to surface, N/mm (a) After cyclic test 2) (b) Accelerated water resistance test Screw withdrawal strength, N (a) Face (b) Edge (for thickness >12mm)
2
1) Cyclic Tes t— Specimen are immersed in water at 27 ± 2°C for a period of 72 h, followed by drying in air at 27 ± 2°C for 24 H and then heating in dry air at 70°C for 72 h. Three such cycles are to be followed and then the specimens are tested for tensile strength perpendicular to surface. 2)
Acce le ra te d Wa te r Re s is ta nce Te s t— Specimen are immersed in water at 27 ± 2°C and water is brought to boiling and kept at boiling temperature for 2 h. Specimen are then cooled in water to 27 ± 2°C and then tested for tensile strength perpendicular to surface.
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APPENDIX F
TESTS FOR FLUSH DOOR SHUTTERS (Clause 9.7.1 to 9.7.10)
F-1. END IMMERSION TEST Door shutters shall be tested for resistance of their base to immersion in water as follows : The door shutter shall be immersed v ertically to a height of 30 cm in water at room temperature for 24 hours a nd then allowed t o d ry f or 24 hours at 27 ± 2 °C and relative humidity of 65 ± 5 p er cent. T he cycle shall be repeated eight times. There shall be no delamination at the end of the test.
25 cm
F-2. KNIFE TEST (i) Appa ra tus : The type of knife required to be used in the test is given in Fig. below. It may be made from a 250 x 25 mm file. The cutting edge should be kept chiselsharp. The test shall be carried out on a stout table to which a wooden batten is screwed against which the edge of test piece is placed.
Drawing not to scale
KNIFE FOR TESTING PLYWOOD FOR ADHESION OF PLIES (ii) P roce dure : The knife is inserted with its cutting edge parallel to the gr ain of the outer veneer and worked into, or if possible along a glue line and the veneer is prised upwards. A hard and dense specie of plywood requires considerable force to effect entry and to prise and veneer. In a soft timber the knife
.
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tends to follow an easy course through the wood and in this case it is essential that the knife be firmly guided along the glue line. The bond s hould just pass the requirement, it is judged by the relative amount of wood fibre left on the core veneer, a nd t he area pr ised of f. T he gr ading i s a ssessed chiefly o n t he a ppearance of t he b reak. The force needed to effect separation is also an accompanying requirement. The bond is ‘excellent’, when it is difficult to find the glue line and impossible to keep the tool within it for more than 6 mm without cutting adjacent wood. On prising upwards, the veneer usually breaks off over a width slightly greater than that of the tool. The bond is ‘poor’ when knife meets little opposition in the glue line and the prise results in the easy removal of al most al l t he v eneers f rom one s ide o f t he t est pi ece. T he s eparated v eneers a re us ually almost free from adherent fibre. (iii) Re porting of te s t re s ults : The results shall be reported as ‘pass standard’ ‘excellent’ or ‘poor’. F-3. GLUE ADHESION TEST Four s quare s ections, 150 x 150 m m s hall b e c ut from the c orners of the door. T hese four c orner sections as cut from the door shall be i mmersed in boiling water for 4 hou rs, then dried at 27 ± 2°C and relative humidity of 65 ± 5 per cent for 24 hours. At the end of the drying period, the samples shall be examined for delamination. In t he case of the glue l ines in the pl ywood, all the four exposed edges of t he plywood on both faces of a specimen shall be examined for delamination. A specimen s hall b e c onsidered t o have p assed t he t est i f no de lamination has oc cured i n t he g lue lines in the plywood and if no single delamination more than 50 mm in length and more than 3 mm in depth ha s occured i n the a ssembly gl ue lines b etween the plywood faces an d the stile a nd r ail. Delamination a t t he c orner s hall be m easured continuously around the corner. D elamination at a k not, knot hole, a pi tch pocket and worm hole or other p ermissible wood defects shall not be c onsidered i n assessing t he sample. A do or shall b e d eemed t o have p assed t his t est i f t hree of t he f our s pecimens tested pass the test.
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APPENDIX G
TEST FOR MORTICE LOCKS (Clause 9.15.13)
The finally assembled lock shall withstand the test given as below : The locking bolt shall be f irst locked in the forward position. A load of 40 kg. shall be appl ied without shock in the direction perpendicular to securing face as well as on both the locking faces of protruding bolt in turn. Then the load shall be applied by means of a fixed steel board 3 mm thick by rounded edge held in such a position that the centre line is approximately 3 mm from the fore end. A typical arrangement for the purpose of this test is shown in Fig. below : Beam 75 c m Long Approx Lock
Fixed Bearer
Fixed Block
Steel Bar 75 cm Long Approx.
Movable Weight 40 kg
Base
Fig. : Strength Test for Locking Bolt When the spindle with ha ndle is inserted into hol e i n the follower and t urned, the latch bolt shall draw smoothly into the lock body and shall be within one millimetre from the face of the fore end. When the latch bolt is pressed in to the lock body by pressure, the action shall be smooth and when fully pressed the latch bolt shall not project more than one millimetre from the face of the fore end. When a k ey is inserted in key hole from on e side o f the lock an d turned to withdraw the locking bolt the action shall be s mooth and w ithout impediment. When the direction of t urn is reversed to lock the locking bolt t hen also t he a ction shall be smooth and without i mpediment. In t he l ocked position t he locking bolt shall project 12 mm from the face of the fore end, although one millimetre free movement is permissible. I n the withdrawn pos ition t he l ocking bo lt s hall not p roject more than one millimetre from the face of the fore end. The locking bolt shall be worked by turning key in both the direction 6000 times. At the end of the test, the lock shall continue to work smoothly. The test shall be repeated with the key inserted from the other side of the lock. Note : The clearance for levers while in the operating condition shall not exceed 0.25 mm. When the key is turned to lock the locking bolt at the same time applying a reasonable pressure by finger on it, after completion of the key rotation the locking bolt shall be positively locked in the forward position. This test shall be repeated with the key inserted from the other side of the lock.
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APPENDIX H
SCHEDULE OF FITTING FOR DOORS AND WINDOWS (Clause 9.6.8)
S l. No
Na me o f Fittings
1 1.
S ingle leaf wire gua ze door s hutte rs
S ingle leaf wardrobe/ cupboard s hutters
S ingle le a f window s hutte rs pa ne lle d or gla ze d
Fan light/ clear s torey window s hutters
De s igna tion no. of wood s cre w
Length in m m of wood s cre ws IS 6760
Re marks
4 3
S ingle leaf door s hutters inter communicating pane lled or gla ze d 5 3
6 3
7 -
8 -
9 -
10 9
11 40
12
-
-
-
-
-
2
2
8
20
-
-
-
-
1
1
-
6
20
3 1
2 -
3 -
2 -
-
1 1 -
-
6 10 8 6 9
20 30 30 30 35
-
1
-
-
-
-
-
9
35
2 2
1 2
1 2
1
1 -
-
-
9 6
30 25
-
-
-
-
-
1
-
6
20
-
-
-
-
-
1
-
6
30
-
-
-
1
-
-
-
6
30
-
-
-
1
1
-
-
6
20
-
-
-
-
-
-
1
8
30
Double leaf doors s hutters pane lled or gla ze d
S ingle leaf door s hutters exte rnal pane lled or gla ze d
3 6
2
2 Butt Hinges 100 mm Butt Hinges 75 mm
3
Butt Hinges 50 mm
4 5 6 7 8
Piano Hinges Tower Bolt 250 mm Tower Bolt 150 mm Tower Bolt 100 mm Sliding door Bolt 300 mm 9 Sliding door Bolt 250 mm 10 Floor door stopper 11 Door handle with plate 100 mm 12 Window handle with plate 75 mm 13 Casement stay 300 mm 14 Helical door spring (Superior quality) 15 Cupboard /Wardrobe Lock 16 Fanlight Catch Notes :
For fixing wooden cleat
A : Door Sh utters 1. Door of room adjoining the verandah, corridor, lobby or hall, shall be considered as external door. 2. Where the height of the door leaf exceeds 2.15 metres above the floor level, one extra hinge shall be provided for every additional height of 0.50 metre, or part thereof and the length of top bolts shall be increased by the height of the leaf above 2.15 metres from floor level. 3. Single leaf door shutters of more than 0.80 m in width shall be provided with one extra hinge. 4. Fan light shutters of more than 0.80 metre width shall be provided with one extra hinge and extra quadrant stay. 5. In double leaf shutters of doors, two door bolts shall be fixed to the first shutter and one to the closing shutter at the top. 6. In case of single leaf inter communicating, panelled, glazed or panelled door shutter for bath and w.c. one tower bolts will be replaced by a bathroom latch. 7. For shutter exceeding 40 mm thickness, heavy type M.S. butt hinges of 125 x 90 x 4 mm shall be used. 8. In case of external door shutters, instead of sliding door ball mortice lock can be provided where specified. 9. Cupboard and wardrobe shutters will have ball catches where specified. 10. Finger plates shall be provided in case of bath and wc shutters in office buildings.
B : Wind ow Sh utters 11. In case of windows with double shutters, two tower bolts shall be fixed to the closing shutters and one tower bolt to the first shutter at the top. 12. In case of window shutters, hooks and eyes may be provided in lieu of casement stays where specified. 13. Where the height of window s hutter e xceeds 1.20 metres one extra hi nge shall be provided a nd l ength o f t op b olts shall b e i ncreased b y height of the leaf above 2.15 metres from the floor level. 14. Window shutter with steel frames shall be provided with s ix hinges i n case of double l eaf shutters a nd t hree h inges i n case of single l eaf shutters, irrespective of height and width of shutters. C : Fa nligh t an d Cleres tory Win dow or Ve n tilator 15. Centrally hung and bottom hung CS windows an d fan lights, will be provided with chain and hook bamboo pole with hook for opening ventilators shall be provided for each residence or for set of 4 rooms in case of office building. 16. Centrally hung clerestory windows or fan lights will have fan light pivots in lieu of hinges.
.
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APPENDIX I
METHOD OF TEST FOR EDGE STRAIGHTNESS AND SQUARENESS OF PLYWOOD (Clause No. 9.2.8.3)
I.1 PROCEDURE FOR EDGE STRAIGHTNESS I.1.1 The straightness of the edge an d ends of plywood shall be v erified against a s traight edge not less than the full length of the plywood. If the edge on the end of the plywood is convex, it shall be held against the straight edge i n such a w ay as to give approximately equal gap at each end. T he largest gap between the straight edge and the edge shall be measured to the nearest millimeter and recorded. I.2 PROCEDURE FOR SQUARENESS I.2.1 The squareness of plywood shall be c hecked with a 120 0 mm x 1200 mm square by applying one arm of the square to the plywood. The maximum width of the gap shall be recorded.
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JOINTS IN TIMBER Sub Head : Wood Work and PVC Work Clause : 9.0
A. TONGUE & GROOVE JOINT
C. DOVETAIL JOINT
Drawing not to Scale
B. MITRED JOINT
D. MORTISE & TENON JOINT
Fig. 9.1 : Joints in Timber
291 | Page HO Civil Specifications Volume - I
TERMINOLOGY TIMBER DOOR, WINDOW & VENTILATOR COMPONENTS Sub Head : Wood Work and PVC Work Clause : 9.6 A Width of Opening Head of Frame
Top Rail
DETAILS AT
A
Hold Fast Glazed Panel
8 to 10 mm
Door Frame Stile
T/3
Meeting Stile
T/3 T/3 45°
Lock Rail Wooden Panel
8 to 10 mm
Bottom Rail
Structural Floor Level
SPLAYED TYPE REBATE
Finished Floor Level
T/2
Metal Pin
T/2
GLAZED AND PANELLED DOOR
SQUARE T YPE REBATE
Head of Frame Glass Panel Transome Hold Fast Glass Panel Stile
Bottom Rail
TOP HUNG VENTILATOR
CENTRE HUNG VENTILATOR
BOTTOM HUNG VENTILATOR
WINDOWS AND VENTILATORS Drawing not to Scale All dimensions are in mm
Fig. 9.2 : Terminology Timber Door, Window & Ventilator Components 292 | Page HO Specifications Volume - I
WOODEN FLUSH DOORS SHUTTERS Sub Head : Wood Work and PVC Work Clause : 9.7 TOP RAIL Lipping Where Provided Stile
Cross Band
Face Veneer
BLOCK BOARD & PARTICLE BOARD CORE
PARTICLE BOARD CORE
Battens Battens
Equally Distributed Voids
Intermediate Rail Equally Distributed Voids
CELLULAR CORE
Drawing not to Scale
BLOCK BOARD CORE
HOLLOW CORE
Fig. 9.3 : Wooden Flush Doors Shutters
293 | Page HO Civil Specifications Volume - I
HOLD FAST Sub Head : Wood Work and PVC Work Clause : 9.13
40
20
100
100
Door Frame
Hold Fast
200 11 mm Hole
10 15
50
Wooden Plug
5
Enlarged Section of Bolt
Nut & Bolt 10 mm dia
C.C. Block
50
Drawing not to Scale All dimensions are in mm
Fig. 9.4 : Hold Fast
294 | Page HO Civil Specifications Volume - I
HINGES Sub Head : Wood Work and PVC Work Clause : 9.15.1 to 9.15.2 A
C
C D
D
B
Counter Sunk Holes
Uncranked C ranked
Knuckles
A. DIMENSION OF MEDIUM WT. MILD STEEL BUTT HINGES Size of Hinge
Length (A)
Breadth (B)
Thickness of Flap (C)
Dai of Hinge Pin (D)
No. of Knuckles
No. of Screw Holes
Holes for Screw No.
1
2
3
4
5
6
7
8
50 75 100
50 ± 0.5 75 ± 0.5 100 ± 0.5
37 ± 1 47 ± 1 58 ± 1
1.50 ± 0.06 1.70 ± 0.06 1.90 ± 0.06
3.15 ± 0.08 4.00 ± 0.08 5.60 ± 0.08
3 5 5
4 6 8
6 8 10
Min 7
A
C
D Min 7 B
Kunckle
R6
Min 7 C
Counter Sunk Hole
B. PARLIAMENT HINGES Drawing not to Scale All dimensions are in mm
Fig. 9.5 : Hinges
295 | Page HO Civil Specifications Volume - I
HINGES Sub Head : Wood Work and PVC Work Clause : 9.15.5, 9.15.6 A. T EE HINGES E D
X X
R
F
G B
X
C
A
DIMENSIONS Size 250 300
A
B
250 ±3 300 ±3
C
D
100 ±2 30 ±15 5.6 ±0.10 115 ±2 30 ±1.5 6.30 ±0.10
E
F
G
R
Screw Designation No.
No. of Holes in Strap
No. of Holes in Tee
2.24 ±0.10 2.26 ±0.10
45 ±2 50 ±2
40 ±1 50 ±1
8 ±1 8 ±1
9 9
5 5
3 3
Min 0.80 Max. 1.0 Thick
B. PIANO HINGES L2
L1
L1
B
L3 L1
L1
L1
2.5 mm φ Pin
1825 ± 5
DIMENSIONS Nominal
40 30
Size
Drawing not to Scale All dimensions are in mm
B 40 ± 1 30 ±1
L1 25 ± 2 75 ± 2
L2 25 ± 1 25 ± 1
L3 20 ± 1 15 ± 1
Fig. 9.6 : Hinges
296 | Page HO Civil Specifications Volume - I
SLIDING DOOR BOLTS Sub Head : Wood Work and PVC Work Clause : 9.15.7 3.15
2.15
2
250
20±1 8 mm sq hole for Carriage Bolt
6.0±5 Bolt 60± 2
45 ±1
10.0±5 HASP
17.5±5 φ
100±2
Back Plate
40±1
17.5±5φ
CLIP 25±1
12±1
3.15
Bore to be Countersunk 27±1
11±5
8±.5
17.5±5 φ
12 sq ±1
8 sq Hole for Carriage Bolt
55 ±1
12± 0.5φ 50±2
Washer 40±1
Hex or Sq Nut
STAPLE MILD STEEL
C.I. BOLT A M F B E
C CAST TYPE
DIMENSIONS Size
A
B
C
E
F
M
Screw Designation No.
250 300
250 ± 2 300 ± 2
100 ± 2 100 ± 2
45 ± 1 45 ± 1
55 ± 1 55 ± 1
15 ± 1 15 ± 1
16.0 ± 0.5 16.0 ± 0.5
9 9
Drawing not to Scale All dimensions are in mm
Fig. 9.7 : Sliding Door Bolts
297 | Page HO Civil Specifications Volume - I
BARREL TOWER BOLTS Sub Head : Wood Work and PVC Work Clause : 9.15.8
B A
Y
F
E
B G G Y
Screw Holes
C
SECTION YY
Spring and Ball
PRESSED
16
E+5 F
F
CAST OR EXTRUDED
DIMENSIONS Width of Barrel C When When D=10.0 D=12.00
Size
A
B
D
E
150
150+3 -1
170 + 3 -1
32+3 -1
38+3 -1
10 or 12 ± 0.5
25±1
200
200+3 -1
220+3 -1
32+3 -1
38+3 -1
10 or 12 ± 0.5
25±1
250
250+3 -1
270+3 -1
32+3 -1
38+3 -1 ±0
10 or 12 .5
25±1
Thickness of Metal of Barrel Sheet F G Brass or Aluminium Sheet Mild Zinc Alloy Alloy Steel or When When Brass D=10.0 D=12.0 2.0 1.60 2.40 1.25 mm +0.5 ±10.33 ±0.36 ±0.15 1 to 1:5 -0.2 more than 2.0 1.60 2.40 1 to 1.25 dia of +0.5 ± 0.33 ±0.36 ±0.15 bolt -0.2 2.0 +0.5 -0.2
1.60 ±0.33
2.40 ±0.36
1 to 1.25 ±0.15
Screw Designation No. 8
8
10
Drawing not to Scale All dimensions are in mm
Fig. 9.8 : Barrel Tower Bolts
298 | Page HO Civil Specifications Volume - I
PULL BOLT LOCKS Sub Head : Wood Work and PVC Work Clause : 9.15.10
Guide and 10 mm Plate 3 mm Thick 8 mm Round Head with Square Seal
6 mm Round Head Nut with Square Seat Door Frame
Shutter
Slide and Stop Block Iron Screw Open Position PLAN
ELEVATION 10 mm Dia bolt in Locking Position
Drawing not to Scale
Fig. 9.9 : Pull Bolt Locks
299 | Page HO Civil Specifications Volume - I
MORTICE LOCK & LATCH Sub Head : Wood Work and PVC Work Clause : 9.15.13 Locking Bolt Guide Pin
8
Lever Spring Fulorum Pin
1
4
7
5
+2 5.5 -0
100 ±1
12 Min 3 Optional
Latch Spring Pivot Pin
6 2
Lever Pivot Pin
1 Body
Locking Bolt Body Cover
Size of Lock ASSEMBLED WITHOUT BODY COVER
25
12
16 4 Latch Bolt Alternative Fixture for Face Plate
25 2 Case Plate
6 Lever
Locking Pin 25 Striking Plate 8 mm Square Hole for Connecting Rod
25 3 Face Plate Optional
7 Latch Spring
8 Follower
5 Locking Bolt
Key
Drawing not to Scale All dimensions are in mm
Fig. 9.10 : Mortice Lock & Latch 300 | Page HO Civil Specifications Volume - I
MORTICE NIGHT LATCH Sub Head : Wood Work and PVC Work Clause : 9.15.16 Nominal Size (L) Case Plate
Face Plate (Optional)
Body
Spring
Fore End Right Latch
Locking Bolt
Levers
Follower
1
1.25 min
2
6
7
3
100
4
5
ASSEMBLY WITHOUT BODY COVER
BODY
BODY COVER 3
Square Hole 2 Follower Square Hole 3 Latch Spring
5 Locking Lug
10 6 Latch Bolt 25 8
25
15 min
4 Lever
7 Locking Bolt
1 CASE PLATE
Drawing not to Scale All dimensions are in mm
Fig. 9.11 : Mortice Night Latch 301 | Page HO Civil Specifications Volume - I
HANDLES FOR DOORS AND WINDOWS Sub Head : Wood Work and PVC Work Clause : 9.15.19
F D
C
E
B X F
G
R3 3
C
A 1A
0.75
B
X
SECTION XX A
E F
H G
D B
Fig. 9.12.3 : Typical Door Handle (Type 3) F G
E
A 1B
Fig. 9.12.1 : Typical Door Handle (Type 1)
C
Fixing Arrangement
D
B
C
A
B
G
H G
Continuous Plate may be Provided where desired
F
F E
Note : M5 x 20 mm G.I. Countersunk machine screw or any other suitable fixing arrangement may be used
E
Fig. 9.12.2 : Typical Door Handle (Type 2)
Drawing not to Scale All dimensions are in mm
Fig. 9.12.4 : Typical Door Handle (Type 4)
Fig. 9.12 : Handles for Doors and Windows
302 | Page HO Civil Specifications Volume - I
TABLE 2 A DIMENSIONS OF DOOR HANDLES (Fig. 9.12.1 to 9.12.3) All dimensions in millimetres Type of Hea d
Re f to. Fig.
S ize s
A Min
B
C Min
D Min
E Min
F Min
G Min
H Min
I Scre w Holes * Min No. in Size De s igna tion of Ea ch Counte r-s unk He a d Lug Wood Scre w (s e e IS 6760-1972 #)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
9.12.1A
75 100 125 150
125 150 190 215
75 100 125 150
20 25 25 30
2.5 3.0 4.0 1.5
5 8 10 12
8 10 12 15
15 20 22 25
-
-
2 2 2 2
6 6 6 8
9.12.1B
75 100 125 150
85 110 140 165
75 100 125 150
20 25 25 30
2.5 3.0 3.0 4.0
5 5 7.5 7.5
8 10 12 15
15 20 22 25
-
-
2 2 2 2
6 6 6 8
2.
9.12.2
75 100 115 135
125 150 175 200
75 100 115 135
20 25 28 30
-
10 11 13 14
16 19 22 25
32 38 45 50
20 20 25 32
1.0 1.0 1.0 1.25
2 2 3 3
6 6 8 8
3.
9.12.3
1.25 1.25 1.60
1 2 2
6 6 6
1.
* #
75 100 75 20 5 14 16 8 90 125 90 25 6 16 20 10 100 150 100 28 7 18 25 12 More evenly spaced screw holes may be provided, if so required by the purchaser.
Specification for slotted countersunk head wood screws. TABLE 2 B DIMENSIONS OF DOOR HANDLES All dimensions in millimetres.
Type
Ref to Fig.
S ize s
A Min
B
C Min
D
E#
G Dia
No. in Each Lug
Scre w H oles ** No. in a S ize Des ignation of plate when Counter-s unk Hea d a continuous Wood Scre ws (s e e P late is us ed IS : 6760-1972 $ )
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
4
9.12.4
75
115
75
25
5 ± 0.5
10 ± 0.5
30 + 0 30 + 0 30 - 1
2
4
6
100
140
100
30
5 ± 0.5
10 ± 0.5
30 + 0 30 + 0 30 - 1
2
4
6
125
175
125
35
5 ± 0.5
12 ± 0.5
30 + 0 38 + 0 30 - 1
3
6
6
3
6
6
30 + 0 38 + 0 30 - 1 In case a continuous base plate is used, the thickness may be reduced to 3 mm. Hexagonal or round. More evenly placed screw holes may be provided, if so required by the purchaser. Specification for slotted countersunk head wood screws. 150
# ** $
200
150
35
5 ± 0.5
12 ± 0.5
.
303 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
FLOOR DOOR STOPPER - CAST TYPE Sub Head : Wood Work and PVC Work Clause : 9.15.20
12.5
B C
A
40 16
Spring
Rubber Piece 16
Cover Plate
45R
20 T1
5 Body or Housing 32
8 φ Pin
18
12.5
2
25
DIMENSION Thickness of Door Shutter
A
B
C
Casting T1
30
35.0 ± 0.5
140.0 ± 0.5
13
35
40.0 ± 0.5
140.0 ± 0.5
8
40
45.0 ± 0.5
150.0 ± 0.5
13
45
50.0 ± 0.5
150.0 ± 0.5
8
Drawing not to Scale All dimensions are in mm
Screw Designation No.
4.5 + 0.3 -0 4.5 ± 0.3 -0 4.5 + 0.3 -0 4.5 + 0.3 -0
No. of Holes for T1
9
4
9
4
9
4
9
4
Fig. 9.13 : Floor Door Stopper – Cast Type
WINDOW STAY Sub Head : Wood Work and PVC Work Clause : 9.15.23 80 mm to Web
73
30
22 75
65
65
300 Locking Bracket
75
18
8 mm dia Pin
Drawing not to Scale All dimensions are in mm
Fig. 9.14 : Window Stay 304 | Page HO Civil Specifications Volume - I
HASP & STAPLES Sub H ead : Wood Work a nd P VC Work Clause : 9.15.25
Install Thus
T
T for mild Steel Sheet T1for Cast or Extruded Section of Brass
F
K
A ¼B
D
½B
G
¼B
R
B
E
C
H
d D1
H f or Mild Steel Sheet H' f or C ast o r Extruded Section or Brass
HASP (Mild Steel or Brass)
Staple ( Mild S teel) D+18
T1 D+1.5
R
K
T2
STAPLE (Brass or Aluminium) MILD S TEEL
Size 90 115 150
A B 90±2 38±1.5 115±2 38±1.5 150±2 45±1.5
C 46±2 46±2 60±2
E F D 5.0± .5 35±1.5 5.0± .10 5.0± .10 5.0± .5 55±1.5 6.0± .5 65±1.5 6.30± .10
G 28±1.5 28±1.5 33±.5
H 8±.5 8±.5 10±.5
J 12±1 12±1 15±1
BRAS S CAS T OR EXTRUDED
Size 90 115 150
A 90±2 115±2 150±2
B 40±1.5 40±1.5 46±1.5
Drawing not to Scale All dimensions are in mm
C 42±1.5 42±1.5 48±1.5
K 8±1 8±1 14±1
R 8±.5 8±.5 9±.5
ThickNess
D 5±.25 5±.25 6±.25
E 6±.5 6±.5 7±.5
F 35±1 45±1 65±1
G 28±.5 28±.5 32±.5
H 10±.5 10±.5 11±.5
K 8±1 11±1 14±1
R 6.5±.5 6.5±.5 7.5±.5
T1 2±.25 2±.25 3±.25
T2 3±.25 3±.25 4±.25
Thickness of Sheet
Dia of Hinge Pin d
T 2± .10 2± .10 2.24± .10
Screw Holes No. on No. on Screw Hasp Staple Designation No.
4± .10 4± .10 5± .10
3 3 4
Dia of Hinge Pin d
Dia of Butt D1
No. on Hasp
3.15±.10 3.15±.10 4±.10
6±.2 6±.2 8±.2
3 3 4
4 4 4
8 8 10
Screw Holes No. on Screw Staple Designation No. 4 4 4
5 8 0
Fig. 9.15 : Hasp & Staples .
305 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LVL SHUTTER Sub Head : Wood Work and PVC Work Clause : 9.16.6
Top Rail
1/3 t
100 Stile 2/3t
12 mm thick Rubber Wood Lipping Alround 100 PANEL Center Line of Lock Rail
100
100 mm Long Hinges
Beading for fixing Panel
Lock Rail
t
Fig. 9.16A : Single Tenon Joint
150
25 mm PANEL
65 mm
850
Beading for Fixing Panel
200 mm 20 mm 65 mm
BOTTOM RAIL
200
25 mm
Fig. 9.16B : Double Tenon Joint
All Dimension are in mm
Fig. 9.16 : Typical Illustratino of Panelled LVL Door Shutter
0 to 10 mm
0 to 10 mm 1/3
1/2
1/3 1/3 A - S played Type
1/2 B - S quare Type
Fig. 9.16D : Meeting of Stiles for Double Leaved Door Shutters Fig. 9.16C : Common Methods of Joining Panel with Stiles and Rails with/ without Beading
Fig. 9.16 : LVL Shutter
306 | Page HO Civil Specifications Volume - I
PARTITIONS Sub H ead : Wood W ork a nd P VC Work Clause : 9.17.2
Ceiling Channel
Fillet
Board Fillet Metal Stud at 610 mm Centres
Stud at 610 mm c/c
Calcium Silicate Board
Skirting
Skirting Floor Channel
ELEVATION Floor and Ceiling Channel IS OMETRIC VIEW
WALL AND E ND DE TAIL
610 T-JUNCTION
CORNER DETAIL P LAN
DETAILS Board Board Fillets Floor/Ceiling Channel Stud Bracing Member Screws (C/S head)
8 / 10 / 12 mm Thick 60 / 100 mm 50 x 32 x 32 x 0.55 mm 48 x 50 x 48 x 0.55 mm 45 x 15 x 15 x 0.9 mm 25 & 35 mm long, self drilling with under head cutter
One layer board on each side of studs On each side of all studs and channels Top and bottom perimeter of the partition Vertically at 610 mm c/c At horizontal board joint on both side 12 mm from the edge & 40 mm from the corner of the board at 200 mm c/c
Fig. 9.17 : Partitions
307 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
PVC DOOR FRAME Sub Head : Wood Work and PVC Work Clause : 9.20.1 50 mm 5 mm 5 mm
C 150mm Long 'L' Shape Brakcet 15 mm x 15 mm sq. Tube 19 Gauge inserted into 19 x 19 mm M.S. Square Tube of 19 Guage
Top Rail
15 mm
47 mm
EDPM Rubber Gasket
Lock Rail
75 mm Long M.S. Screws fixed with PVC Fasteners for Fixing Frame to Wall
Section View of Solid PVC Choukhat 30 mm
D
40 mm Lock Rail (Upper) (Detail at 'H') Panel
100 mm
Hinge
75 mm Detail at 'F' PVC 'C' Channel 25 mm
100 mm
100 mm
DETAIL AT 'D' (Scale - 1:3)
B
A
30 mm 25 mm
ELEVATION (Scale - 1 : 25)
Bottom Rail
15 mm
Lock Rail (Lower) E
19 mm x 19 mm M.S. Square Tube
25 mm
Solid PVC Choukhat
5 mm
25 mm
47
50 mm
25 mm 5 mm PVC Panel
15 mm x 15 mm M.S. Square Tube Top Rail (Detail at -G) Gap insert below Top Rail
15 mm
Detail at 'G' PVC 'C' Channel
PVC Beading
PVC Beading 5 mm PVC Panel
Detail at 'H' PVC Bottom Rail
Gap insert below bottom Rail 100 mm
100 mm
Gap insert for Top
30 mm
Bottom Rail (Detail at - H) 15 mm x 15 mm M.S. Square Tube Gap insert for bottom Detail at 'E' (Scale - 1:3)
Detail at 'C' (Scale - 1 : 3) 19 mm M.S. 5 mm PVC Square Tube Beading 50 mm 75 mm
5 mm PVC Beading
19 mm M.S. Solid PVC Square Tube Choukhat 50 mm 75 mm
47 mm
Solid PVC Choukhat
40 mm
Hinge 5 mm PVC 'C' Channel (Detail at 'F') Detail at 'A' (Scale - 1 :3)
5 mm PVC Panel
5 mm PVC 'C' Channel (Detail at 'F')
40 mm Detail at 'B' (Scale - 1 :3)
Fig. 9.21 : PVC Door Frame 308 | Page HO Civil Specifications Volume - I
30 mm THICK PANEL PVC DOOR SHUTTER Sub Head : Wood Work and PVC Work Clause : 9.21.1(a)
Top Rail B
7 mm (5 mm + 2 mm PVC Beading)
75 mm
47 mm
B
150 mm Long 'L' Shape Bracket
Plain Solid PVC 19 mm x 19 mm M.S, Choukhat Square Tube 50 mm
40 mm
Stiles
5 mm Taper Plain
Hinge
5 mm PVC Sheet
PVC 'C' Channel
Beading
(Sectional View 'AA') 19 mm M.S. Square Tube
C
Hinge Lock Rail
C
Panel
A
PVC Choukhat Bottom Rail
ELEVATION
Gap insert for Top 15 mm x 15 mm M.S. Square Tube
75 mm Long Steel Screws
A
50 mm
47 mm
Tapper Lock Rail (Upper) 5 mm Both Side Prelam PVC Panel
Taper Plain Top Rail
7 mm (5+2) PVC Beading
7 mm (5mm + 2 mm) Lock Rail (Lower)
5 mm PVC Panel (Sectional View 'BB')
(Sectional View 'CC')
15 mm M.S. Square Tube
Fig. 9.22 : 30 mm Thick Panel PVC Door Shutter
309 | Page HO Civil Specifications Volume - I
SKETCH ILLUSTRATING DIMENSIONS OF SHUTTER Sub Head : Wood Work and PVC Work Clause : 9.23.1
45 mm
M H - 95 mm = Height of Shutter
3 mm
M H - 10 mm = Overall Height of Door Frame
M H = Modular Height of Door Opening
5 mm Clearance
Thickness of Door Frame - Rebate = 45 mm
Finished Floor Level 5 mm Clearance
M w - 100 mm = Width of Shutter M w - 10 mm = Overall Width of Door Frame Mw = Modular Width of Door Opening
40 mm
Structural Floor Level
Fig. 9.24B : Sketch Illustrating Dimensions of Shutter
310 | Page HO Civil Specifications Volume - I
SINGLE REBATE DOOR FRAME Sub Head : Wood Work and PVC Work Clause : 9.24.1
750 Fisher Screw
Door Frame (60 mm x 30 mm) 40 x 20 M.S. Pipe
2100
PVC Foam Profile Panel Door Beading Profile Door Frame (60 mm x 30 mm)
DETAIL - X
60 30
PVC Foam Profile
22
FRONT ELEVATION
30
8
30
X Typical Door Frame Detail (60 mm x 30 mm)
100
230
INSIDE
OUTSIDE 690 750 PLAN
Drawing not to scale Al dimensions are in mm
Fig. 9.25 : Solid PVC Foam Profile Frame
311 | Page HO Civil Specifications Volume - I
3 mm Thick HPL Sheet
WALL PANELLING Sub Head : Wood Work and PVC Work Clause : 9.27
Perimeter Channel
Perimeter Channel Calcium Silicate Board
Ceiling Section
Vertical M/F Ceiling Section
Calcium Silicate Board
Wall Skirting
FRAME & BOARDING ARRANGEMENT Fig. 9.28 : Wall Panelling
312 | Page HO Specifications Civil Volume - I
Perimeter Channel Fixed to the Soffit and floor ELEVATION
10.0: Steel Work
313 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
CONTENTS Cla us e No.
De s cription List of Mandatory Tests
P a ge No. 316
List of Bureau of Indian Standards Codes
317
10.0
Definitions/Terminology
318
10.1
Materials
318
10.2
Steel Work in Single Section Fixed Independently with Connecting Plate
320
10.3
Steel Work in Built up Section (Riveted and Bolted)
321
10.4
Steel Work in Built up Section (Welded)
325
10.5
Collapsible Steel Gates
326
10.6
M.S. Sheet Sliding Shutter - DELETED
327
10.7
M.S. Sheet Shutters - DELETED
327
10.8
Rolling Shutters
327
10.9
Rolling Grills -Shutters
329
10.10
Steel Doors, Windows, Ventilators & Composite Units - DELETED
329
10.11
T-Iron Doors, Windows & Ventilators Frames - DELETED
329
10.12
Pressed Steel Door Frames - DELETED
329
10.13
Tubular Hollow Section Trusses - DELETED
329
10.14
Fan Clamps
329
10.15
M.S. Hollow Rectangular Door Frames (I-Type Section) - DELETED
330
10.16
Factory Made Glazed Steel Doors, Windows and Ventilators - DELETED
330
10.17
Steel Work for Staircases, Chequred Plate, Grating, Ladder, Railings, Bracket and Gate etc.
330
10.18
Steel Work for Hand Rails
330
314 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
Appendix A
Mechanical Properties and Chemical Composition of Steel
331
Appendix B
Welding Process
334
Appendix C
Steel Tubes for Structural Purposes
335
Appendix D
Shapes, Weights and Designation of M S Rolled Steel Section
336
Fig. 10.1
Welds and Rivets
339
Fig. 10.2
Collapsible Steel Gate
340
Fig. 10.3
Typical M.S. Sheet Shutters - DELETED
-
Fig. 10.4, 10.5 & 10.6
Doors, Windows and Ventilators - DELETED
-
Fig. 10.7
Fixing Butt Hinges to T-Iron Frame - DELETED
-
Fig. 10.8
Pressed Steel Door & Window Frames - DELETED
Fig. 10.9
Fan Clamps
341
.
315 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LIST OF MANDATORY TESTS
Ma te ria l
1 Steel if arranged by the contractor Steel tubular pipes
Cla us e
Te s t
F ie ld/ la bora tory te s t
Te s t proce dure
2 10.1.1
3 Tensile strength (b) Bend test
4 Laboratory
5 IS 1599
10.13
(a) Tensile Test (b) Bend Test (c) Flattening Test
Laboratory
IS 1608
(a)
IS 2329 IS 2328
Min.quantity of ma te ria l for ca rrying out the te s t 6 50 tonne
Fre que ncy of te s ting
7 Every 50 tonne or part thereof. Every 20 tonne or Every 20 part thereof tonne or part thereof
.
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LIST OF BUREAU OF INDIAN STANDARDS CODES S l. No. 1 2 3 4 5 6 7.
Code No. IS 63 IS 198 IS 228 IS 277 IS 800 IS 806 IS 808
8. 9. 10
IS 812 IS 813 IS 814
11
IS 816
12 13
IS 817 IS 818
14 15 16 17
IS 822 IS 823 IS 1038 IS 1081
18 19 20
IS 1148 IS 1161 IS 1182
21 22
IS 1200- (Pt. VIII) IS 1363 Part I
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
IS 1363 Part II IS 1363 Part-III IS 1367 IS 1599 IS 1608 IS 1821 IS 1852 IS 1894 IS 1977 IS 2062 IS 2074 IS 4351 IS 4454 (Part I) IS 4711 IS 4736 IS 4923 IS 6248 IS 7452
S ubje ct Whiting for paints and putty Varnish gold size Structural steel (Standard quality) Specification for galvanized steel sheets (Plain and corrugated) Code of practice for use of structural steel in general in steel construction Code of practice for use of steel Tubes in general building construction Dimensions for Hot rolled steel beams, columns, channel and angle sections Glossary of terms relating to welding and cutting metals Scheme of symbols for welding Covered electrodes for manual metal arc welding of carbon and carbon manganese steel Code of practice for use of metal arc welding for general construction in mild steel Code of practice for training and testing of metal arc welders Code of practice for safety and healthy requirements in electric and gas welding and cutting operations Code of procedure for inspection of welds Manual for metal arc welding in mild steel Steel doors, windows and ventilators Code of practice for fixing and glazing of metal (Steel and aluminium) doors, windows and ventilators Hot rolled steel rivet bars (upto 40 mm diameters) for structural purposes Steel tubes for structural purposes Recommended practice for radiographic examination of fusion welded butt joints in steel plates Method of measurements of steel work and iron works Haxagon head bolts, screws, and nuts of product grade C (Hexagon Head bolt) Haxagon Head Bolts, screws and nuts of product Grade ‘C’ Haxagan Head Bolts, screws and Nuts of product grade ‘C’ Technical supply conditions for threaded steel fasteners Method for bend test Metallic materials - Tensile Testing at Ambient Temperature. Dimensions for clearance holes for bolts and screws Rolling and cutting tolerance for hot rolled steel products Method for tensile testing of steel tubes Structural steel (ordinary quality) Hot Rolled low, medium and high tensile structural steel Ready mixed paint, air drying redoxide zinc chrome priming Specification for steel door frames Steel wires for mechanical springs. Cold drawn unalloyed steel wire. Methods for sampling of steel pipes, tube and fittings. Hot - dip zinc coating on mild steel tubes Hollow Steel Sections for Structural Use - Specification Metal rolling shutters and rolling grills Specification for hot rolled steel sections for doors, windows and ventilators.
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10.0 STEEL WORK 10.0 DEFINITIONS/ TERMINOLOGY Bead A single run of weld metal deposited on surface. Butt Weld A weld in which the weld metal lies substantially within the extension of the planes arc the surfaces on the parts joined. Crater A depression left in weld metal where the a rc was broken or the flame was removed. End Crater A crater at the end of a weld or at the end of a joint. Fillet Weld A w eld of a pproximately trian gular cr oss-section join ing tw o s urfaces a pproximately at th e rig ht angles to each other in a lap joint, tee joint or corner joint. It is of two types: (1) Continuous (2) Intermittent. Fusion Welding Any welding process in which the weld is made between metals in a state of fusion without hammering or pressure. Non- fusion Welding A term appl ied t o t he dep osition, b y t he O xy-Acetylene process of f iller metal on parent metal w ithout fusion of the latter. Oxy-Ace tyle ne P re s s ure We lding Pressure welding in which any Oxy-Acetylene flame is used to make the surface to be united plastic. No filler metal is used. Run The metal deposited during one passage of the electrode or blow pipe in the making of a joint. Throat thickness See Fig. 10.1. Weld A union between two pieces of metal at faces rendered plastic or liquid by heat or pre ssure, or bot h, Filler metal may be used to effect the union. 10.1 MATERIALS Micro-Alloying Elements Elements s uch as ni obium, bo ron, v anadium and t itanium added singly o r i n c ombination t o ob tain higher strength to weight ratio and better toughness, formability and weldability as compared to unalloyed steel of similar strength level.
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Weldability A m etallic s ubstance i s c onsidered t o be w eldable by a gi ven pr ocess and for t he gi ven pur pose, when m etallic continuity to a stated degree can be obtained by welding using a s uitable procedure, s o that t he j oints c omply with t he requirements s pecified i n regard t o bot h t heir l ocal properties and t heir influence on the construction of which they form a part. Controlled Rolling A ho t r olling p rocess in w hich the temperature o f the s teel a nd its r eduction r atio ar e c ontrolled, particularly dur ing t he f inal r olling pas ses, i n or der t o ac hieve f ine gr ain m icro s tructure and opt imum mechanical properties. Normalizing Rolling A hot rolling process in which the final r olling passes are c arried out at a suitable higher temperature, followed by c ooling i n n atural ai r t o a t emperature bel ow t he t ransformation t emperature, i n order t o produce a structure, analogous to that obtained by a separate normalizing treatment of hot rolled product. 10.1.1 Steel 10.1.1.1 Supply of Material : General requirements relating to supply of structural steel shall conform to IS 8910. 10.1.1.2 Grades : There shall be ni ne grades of steel as given in Tables 10.1 and 10. 2. W hile placing the order the steel should be designated by ‘Designation’ (See Table 10.1 and 10.2). 10.1.1.3 Manufacture : The processes used in the steel making and further hot rolling into steel plates, strips, s ections, flats, b ars, et c., are left to t he discretion o f th e m anufacturer/supplier. If r equired, secondary r efining m ay follow steel m aking, a s a lso no rmalizing r olling/controlled ro lling du ring manufacturing of s ections or as per the agreement between the purc haser and the manufacturer/ supplier. 10.1.1.4 Freedom from Defects 10.1.1.4.1 All finished materials shall be well and cleanly rolled to the dimensions, sections and masses s pecified. T he f inished m aterial s hall be r easonably f ree f rom s urface f laws; laminations; rough/ jagged and imperfect edges and all other harmful defects. 10.1.1.4.2 Minor surface defects may be removed by the manufacturer/supplier by grinding provided the t hickness i s n ot r educed l ocally by m ore t han 4 pe rcent b elow t he m inimum s pecified t hickness. Reduction i n t hickness by gr inding gr eater t han 4 percent but not ex ceeding 7 per cent m ay be m ade subject to mutual agreement between the purchaser and manufacturer/supplier. 10.1.1.4.3 Subject to agreement with the purchaser, surface defects which cannot be dealt with as in 10.1.1.4.2 m ay be r epaired by c hipping or grinding f ollowed by welding a nd i nspection by a m utually agreed procedure such that : (a) After complete removal of the defects and before welding, the thickness of the item is not to be reduced by more than 20 percent at any place. (b) Welding is carried out by procedure APPROVED by competent authority with approved electrodes and the welding is ground smooth to the correct nominal thickness; and (c) S ubsequent to the finish grinding, the item may be req uired to be n ormalized or ot herwise heattreated at the purchaser’s discretion. 10.1.1.4.4 Welding as mentioned in 10.1.1.4.3 is not permissible for grade designation E 250 material.
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10.1.1.5 Chemical Composition : Ladle A nalysis t he l adle anal ysis of t he steel, w hen c arried out by the method specified i n t he r elevant part o f I S 2 28 or a ny other established i nstrumental / chemical method, shall be as given in Table 10.1. In case of dispute, the procedure given in IS 228 and its relevant parts shall be the referee method and where test methods are not specified shall be as agreed to between the purchaser and the manufacturer/supplier. 10.1.2 Rivets Rivets shall be made from rivet bars of mild steel as per IS 1148. 10.1.3 Bolts These are o f t wo t ypes namely t urned and fi tted bol ts and bl ack b olts. T urned & fi tted bolts a re turned t o e xact d iameter i n aut omatic l athe. F or t hese bol ts, w hether rea med or dri lled bolts, t he s ame unit s tresses ar e al lowed as for r ivets. In case of bl ack bol ts which ar e not finished to e xact sizes, a lower working s tress other t han f or t urned b olts is adopted. T hey shall c onform t o I S 136 7 - Technical supply conditions for threaded steel fasteners. 10.1.4 Electrodes The e lectrodes r equired f or m etal ar c w elding s hall be c overed e lectrodes and s hall c onform to IS 814. 10.2 STEEL WORK IN SINGLE SECTION FIXED INDEPENDENTLY WITH CONNECTING PLATE 10.2.0 The steel work in single s ection of R.S. joists, flats, T ees Angles fixed i ndependently with o r without connecting plate, is described in these clauses. 10.2.1 Fabrication The steel sections as specified shall be straightened and cut square to correct lengths and measured with a steel tape. The cut end s ex posed to v iew s hall be finished s mooth. N o two pi eces shall be w elded or otherwise jointed to make up the required length of member. All straightening and shaping to form, shall be done by pressure. Bending or cutting shall be carried out in such a manner as not to impair the strength of the metal. 10.2.2 Painting All surfaces which are to be painted, oiled or otherwise treated shall be dry and thoroughly cleaned to remove all loose scale and loose rust. Surfaces not in contact but inaccessible after shop assembly, shall receive the full specified protective treatment before assembly. This does not apply to the interior of sealed hollow sections. Part to be encased in concrete shall not be painted or oiled. A priming coat of approved steel primer such as Red Oxide/Zinc Chromate primer conforming to IS 2074 shall be applied before any member of steel structure are placed in position or taken out of workshop. 10.2.3 Erection Steel w ork s hall be h oisted a nd pl aced in p osition carefully w ithout any da mage to itself and other building work and injury to workmen. Where necessary mechanical appliances such as lifting tackle winch etc. shall be used. The suitability and capacity of all plant and equipment used for erection shall be upto the satisfaction of the Engineer-in-charge. 10.2.4 Measurements The w ork as f ixed in pl ace s hall be m easured i n ru nning m etres c orrect t o a m illimetre and w eights calculated on t he bas is of s tandard t ables c orrect t o t he neares t k ilogram. The s tandard w eight of s teel sections s hall c onform t o I S 808 w ith t olerance i n s izes as per I S 1852 . T olerance i n w eight i s g iven i n Table 10. 3. S teel s ections s hall be ac ceptable w ithin t olerance l imits. P ayment f or s teel s ections s hall be made as per actual weight within tolerances. Sections having weight on higher side than permissible
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tolerance, m ay be ac ceptable but pa yment s hall be m ade on t he b asis o f standard w eight o nly. S teel sections having weight variations lower side than permissible variation shall not be acceptable. Unless ot herwise s pecified, weight o f c leats, br ackets, pac king pi eces, bol ts, nu ts, w ashers, di stance pieces, separaters, diaphgram gussets (taking overall square dimension) fish plates, etc. shall be added to the w eight o f r espective items. In r iveted w ork al lowance is to be m ade f or w eight o f r ivet hea ds. Unless otherwise specified an addition of 2.5% of the weight of s tructure s hall be m ade for s hop and site rivet heads in riveted steel structures. No ded uction s hall b e m ade f or r ivet/ or b olt holes ( excluding h oles f or anc hor or hol ding do wn bo lts). Deduction in case of rivet or bolt hole shall however be made if its area exceeds 0.02 sqm. The weight of steel sheets, plates and strips shall be taken from relevant Indian standards based on 7.85 K g/m2 for e very m illimetre s heet t hickness. For rolled sections, s teel ro ds an d s teel s trips, w eight given in relevant Indian Standards shall be used. 10.2.5 Rate Rate includes the cost of labour and materials required for all the operations described above. 10.3 STEEL WORK IN BUILT UP SECTIONS (RIVETED AND BOLTED) The steel work in built up section (Riveted and bolted) such as trusses, framed work etc. is specified in this clause. 10.3.1 Laying Out A figure of the steel structure to be f abricated shall be dr awn on a l evel platform to full scale. This may be done in full or in parts, as shown on drawings or as directed by the Engineer-in-Charge. S teel tape shall be used for measurements. 10.3.2 Fabrication Fabrication s hall g enerally be done as specified i n I S 8 00. I n m ajor w orks or w here s o s pecified, shop dr awings gi ving c omplete information for t he f abrication of the c omponent par ts of t he s tructure including the location, t ype, size, length and details or rivets, bolts or welds, s hall be prepared in advance of the actual fabrication and approved by the Engineer-in-charge. The drawings shall indicate the shop and field rivets, bolts and welds. The steel members shall be distinctly marked or stenciled with paint with the identification marks as given in the shop drawings. Great accuracy shall be observed in the fab rication of v arious members, s o that th ese can be assembled without being unduly packed, strained or forced into position and when built up, shall be true and free from twist, kinks, buckles or open joints. Wooden or metal s heet t emplates shall be made to c orrespond t o eac h member, and pos ition o f rivet holes shall be marked accurately on t hem and hol es drilled. The templates shall t hen be l aid on the steel members, and holes for riveting and bolting marked on them. The ends of the steel members shall also be marked for cutting as per required dimensions. The base of steel columns and the positions of anchor bolts shall be carefully set out at the required location. 10.3.2.1 The steel section shall be s traight or to be straightened or flattened by pressure unless required to be of curvilinear form and shall free from twists. These shall be cut square either by shearing or sawing to correct length and measured by steel tape. No tow pieces shall be welded or joined to make up for the required length of member. 10.3.2.2 Making Holes : Holes t hrough m ore t han o ne t hickness of m aterials f or m embers, such as compound stanchion and girder flanges shall, where possible, be drilled after the members are
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assembled and tightly clamped or bolted together. Punching may be permitted before assembly, provided the holes are punched 3mm less in diameter than the required size and reamed after assembly to the full diameter. The thickness of material punched shall be not greater than 16 mm. Rivet Holes The diameter for rivets and black bolts holes shall be taken as the nominal diameter of a rivet/ black bolts plus 1.5 mm for rivets/ bolts of nominal diameter less than or equal to 25 mm” and 2.0 m m for rivets of nominal diameter exceeding 25 mm, unless specified otherwise. Holes for turned and fitted bolts shall be drilled or reamed large by 0.2 to 8 mm depending upon the dia. of bolts. Holes shall have their axis perpendicular to the surface bored through. The drilling or reaming shall be free f rom b urrs, an d t he hol es s hall b e c lean a nd ac curate. H oles f or r ivets a nd bolts shall n ot b e formed by gas cutting process. Holes for counter sunk bolts shall be made in such a m anner that their heads sit flush with the surface after fixing. 10.3.2.3 Assembly : Before making holes in individual members, for fabrication and steel work intended to be riveted or bolted together shall be assembled and clamped properly and tightly so as to ensure close abutting, or lapping of the surfaces of the different members. All stiffeners shall be fixed (or placed) tightly both at top and bottom without being drawn or caulked. The abutting joints shall be cut or dressed true and straight, and fitted close together. Web plates of girders, which have no cover flange plates, shall have their ends flush with the tops of angles un less ot herwise required. T he w eb plate w hen spliced, shall have c learance of n ot m ore than 5mm. The erection clearance of cleated ends of members connecting steel to steel shall preferably be not greater than 1.5 mm. The erection clearance at the ends of beams without web cleats shall not be more than 3 mm at each end but where for practical reasons, greater clearance is necessary, seating designed suitably shall be provided. Column splices and butt joints of struts and compression members re quiring c ontact for stress transmission shall be ac curately, machined and close but ted ov er t he whole s ection. In column caps and bases, the ends of shafts together w ith the attached gussets, an gles, channels etc. after r iveting together shall b e accurately m achined s o t hat t he pa rts c onnected, b utt a gainst e ach other over t he entire s urfaces o f c ontact. C onnecting angl es or channels shall be fabricated and pl aced i n pos ition w ith great accuracy so that they are not unduly reduced in thickness by machining. The ends of all bearing stiffeners shall be machined or grounded to fit tightly both at top and bottom. 10.3.2.4 Riveting : Rivets shall be used, where slip under load has to be avoided. P re limina rie s b e fore R ive tings :- Members to be riveted shall have all parts firmly placed and held together be fore a nd d uring riveting, an d s pecial care shall be taken i n t his respect for al l s ingle riveted connections. F or m ultiple r iveted c onnections, a s ervice bol t s hall be pr ovided i n ev ery t hird or f ourth hole. P roce s s of Rive ting The r iveting s hall be c arried out by us ing m achines of t he s teady pr essure type. H owever, w here such f acilities ar e not av ailable hand r iveting m ay be per mitted by t he E ngineer-in-charge. T he r ivets shall be heated red hot, care being t aken to c ontrol the t emperature of heating s o as not t o burn t he steel. R ivets o f di ameter l ess t han10mm may be driven c old. Rivets s hall be finished neat w ith heads full and of equal size. The heads shall be central on shanks and shall grip the assembled members firmly.
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All loose, burnt, or badly formed rivets with eccentric or def icient heads shall be c ut out and replaced. In cutting out rivets, care shall be t aken s o as not to i njure the assembled m embers. Caulking and recapping shall not be permitted. For t esting rivets, a ham mer w eighing approx. 0.25 kg s hall be u sed and both heads of t he rivet (Specially t he m achine h ead) s hall b e t apped. W hen s o t ested, t he ri vets s hall not gi ve a hol low sound and a jar where so specified, other tests shall be carried out to ensure the soundness of rivets. All rivets heads shall be painted with approved steel primer paint within a week of their fixing. 10.3.2.5 Bolting : The nominal length of the bolt shall be t he distance from the underside of the head to the further end of the shank. The nominal diameter of the bolt shall be the diameter at the shank above the s crewed t hreads. Bolts, nut s and washers s hall be t horoughly cleaned a nd di pped i n d ouble boiled linseed oil, before use. All bolts heads and nuts shall be hexagonal unless specified otherwise. The screwed threads s hall c onform t o I S 1363 and t he t hreaded s urface s hall not be tapered. The bol ts s hall be of s uch length as t o project at l east two c lear threads bey ond t he nut s w hen f ixed i n pos ition, and these shall fit in the holes without any shake. The nuts shall fit in the threaded ends of bolts properly. Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads and nuts of bolts a satisfactory bear ing. The t hreaded por tion of each bol t s hall pr oject through the nut at l east two thread. In a ll cases where the full bearing area of the bolt is to b e developed, the bolt shall be pro vided with a washer of sufficient thickness under the nuts to avoid any threaded portion of the bolt being within the thickness of the parts bolted together. Where there is a risk of the nuts being removed or becoming loose due to vibrations or reversal of stresses, these shall be secured from slackening by the use of lock nut, spring washers as directed by the Engineer-in-charge. 10.3.3 Erection 10.3.3.0 Steel members shall be hoisted and erected in position carefully, without any damage to itself, other structures and equipment and injury to workmen. The method of hoisting and erection proposed to be adopted by the c ontractor shall be got approved from t he E ngineer-in-charge in adv ance. T he contractor however shall be fully responsible for the work being carried out in a safe and proper manner without undul y s tressing t he v arious m embers an d pr oper equi pment s uch as der ricks, l ifting t ackles, winches, ropes etc. shall be used. 10.3.3.1 The work of erection m ay be done in suitable units as may be directed by the Engineer-incharge. Fabricated members shall be lifted at such points so as to avoid deformation or excessive stress in members. The s tructure or part o f it placed i n p osition s hall b e secured against over-turning or collapse by suitable means. During ex ecution, t he s teel members s hall be securely bol ted or ot herwise fastened when nec essary temporarily braced to provide for all loads including those due to erection equipments and its operation to be carried safely by structure during erection. The steel members shall be placed in proper position as per approved drawing, final riveting or permanent bolting shall be do ne only after proper alignment has been checked and confirmed. 10.3.3.2 Trusses shall be lifted only at nodes. The trusses above 10 m in span shall not be lifted by slinging at t wo m id poi nts o f r afters, which s hall be t emporary br aced b y a wooden member o f a suitable section. A fter the t russes ar e pl aced i n position, purlins and w ind bracings shall be f ixed a s soon as possible.
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The end of the truss which faces the prevailing winds shall be f ixed with holding down bolts, and the other end kept free to move. In case of trusses of spans upto 10m the free end of the truss shall be laid on lead sheet or steel plate as per design, and the holes for holding down bolts shall be made in the form of obl ong slots s o as t o per mit t he free movements o f the t russ end. For l arger spans t he truss s hall b e provided with proper bearing as per design. 10.3.3.3 Columns and stanchions shall be erected truly vertical with the necessary cross bracing etc. and t he base shall be properly f ixed with t he f oundation c oncrete by means of anc hor bol ts et c. as per drawing. 10.3.3.4 Anchor bolts to be placed in the concrete foundation should be held in position with a wooden template. A t the t ime of c oncreting a nchor b olt l ocations s hall be provided w ith s uitable t imber m ould or pipe sleeve to allow for adjustment which shall be removed after initial setting of concrete. The spaces left around an chor bolts s hall be linked t o a s topping c hannel i n t he concrete l eading t o t he s ide o f t he pedestal and o n the underside of t he base pl ate t o allow the s paces being grouted up after the base plate is fixed in the position along with the column footing. Grouting shall be of cement mortar 1:3 (1 cement: 3 coarse sand) or as specified. 10.3.3.5 Bedding of Column, Stanchions etc.:- Bedding shall not be carried out until the steel work has been finally l evelled, plumbed an d c onnected together. The s tanchion s hall be s upported o n s teel wedges and adjusted t o make t he c olumn pl umb. For m ultistoreyed buildings, t he be dding shall not b e done un til sufficient number of bottom lengths of stanchions have been properly lined, levelled and plumbed a nd sufficient f loor b eams ar e f ixed in p osition. T he b ase plates shall b e wedged clear of t he bases by M.S. wedges and adjusted where necessary to plumb the columns. The gaps under the base plate may be made upto 25 mm which shall be pressure grouted with cement grouts. With s mall c olumns, if p ermitted by t he Engineer-in-charge, t he c olumn b ase shall be f loated o n a thick c ement gr out on the c oncrete pe destal. T he anc hor bo lt ho les in the bas e p late m ay b e m ade about 10 to 15 mm larger than the bolts. In such cases suitable washers shall be provided. 10.3.4 Painting Before the members of the steel structure are placed in position or taken out of the workshop these shall be painted as specified in 10.2.2. 10.3.5 Measurements The w ork as f ixed i n position s hall b e m easured i n running m etres c orrect t o a millimetre and their weight calculated on the basis of standard tables correct to the nearest kilogram. The standard weight of steel sections shall conform to IS 808 w ith tolerance in sizes as per I S 1852. Tolerenace in w eight is g iven in T able 1 0.3. Steel sections s hall b e a cceptable within t olerance l imits. Payment for steel s ections shall be made as per ac tual weight within tolerances. S ections hav ing weight on hi gher s ide than permissible tolerance, may be a cceptable but payment shall be made on the basis of standard weight onl y. Steel s ections having w eight v ariations lower t han p ermissible v ariation s hall not be acceptable. Unless o therwise specified. Weight o f cleats, b rackets, pac king pi eces, bol ts nut s, w ashers, di stance pieces, separators diaphragm gussets (taking overall square dimensions) fish plates etc. shall be added to the weight of respective items. No deductions shall be made for skew cuts. In riveted work, allowance is to be m ade f or w eight of ri vet heads . U nless ot herwise s pecified and a ddition of 2. 5% of t he w eight o f structure shall b e m ade f or s hop a nd s ite ri vet heads i n ri veted s teel structures. N o d eduction s hall be made for rivet/ or bolt holes (excluding holes for anchor or holding down bolts). Deduction in case of rivet or bolt hole shall, however, be made if its area exceeds 0.02 m 2.
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The w eight o f s teel s heet and s trips s hall be taken f rom r elevant I ndian S tandards bas ed on 7. 85 kg/m 2 for ev ery millimetre sheet thickness. F or rolled sections, steel rods and s teel s trips, w eight gi ven i n relevant Indian Standards shall be used. 10.3.6 Rate The rate s hall i nclude t he cost o f all m aterials and l abour i nvolved i n all t he operation described above. 10.4 STEEL WORK IN BUILT UP SECTION (WELDED) 10.4.0 The steel work in built up s ections (welded) such as in trusses, form work etc. is specified in this clause. 10.4.1 Laying out It shall be as specified in 10.3.1. 10.4.2 Fabrication 10.4.2.1 Straightening, shaping to form, cutting and assembling, shall be as per 10.3.2 as far as applicable, except t hat t he words “ri veted or b olted” s hall b e re ad as “ welded” and holes shall o nly be used for the bolts used for temporary fastening as shown in drawings. 10.4.2.2 Welding : Welding shall generally be done by electric arc process as per IS 816 and IS 823. The electric a rc method is usually ad opted and is e conomical. Where el ectricity for public is not av ailable generators shall be arranged by the c ontractor at his ow n c ost u nless otherwise s pecified. G as welding shall onl y by resorted t o using ox yacetylene f lame with s pecific approval of the E ngineer-in-charge. G as welding s hall no t be permitted f or s tructural s teel w ork G as w elding r equired heating of t he members t o be welded along with the welding rod and is likely to create temperature stresses in the welded members. Precautions shall therefore be taken to avoid distortion of the members due to these temperature stresses. The work shall be done as shown in the shop drawings which should clearly indicate various details of the joint to be welded, type of welds, shop and site welds as well as the types of electrodes to be used. Symbol for welding on plans and shops drawings shall be according to IS 813. As far as possible every efforts shall be made to limit the welding that must be done after the structure i s erected so as t o avoid t he i mproper welding t hat i s likely t o be done due to h eights a nd difficult pos itions on s caffolding et c. apart f rom t he as pect of e conomy. T he maximum di a of el ectrodes for w elding w ork s hall b e as p er IS 814. Joint surfaces w hich a re to be w elded together shall be f ree from l oose m ill s cale, rust, paint, gr ease or other f oreign m atter, w hich ad versely af fect t he q uality o f weld and workmanship. 10.4.2.3 Precautions : All operation connected with welding and cutting equipment shall conform to the safety r equirements gi ven i n I S 8 18 f or safety requirements a nd H ealth provision i n Electric a nd gas welding and cutting operations. 10.4.2.4 Operation, Workmanship and process of Welding is described in Appendix B, 10.4.2.5 Inspection and testing of welds shall be as per IS 822. 10.4.2.6 Assembly : Before w elding i s c ommenced, t he members t o be w elded s hall first be brought together and firmly clamped or tack welded to be held in position. This temporary connection has to be strong enough to hold the parts accurately in place without any disturbance. Tack welds located in places where final welds will be made later shall conform to the final weld in quality and shall be cleaned off slag before final weld is made.
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10.4.2.7 Erection : The specification shall be as des cribed in 10. 3.3 ex cept that while er ecting a welded structure adequate m eans s hall be employed f or t emporary f astening the m embers t ogether and bracing the frame work until the joints are welded. Such means shall consists of applying of erection bolts, tack welding or ot her pos itive devices i mparting s ufficient s trength a nd stiffness t o res ist a ll t emporary l oads and l ateral forces i ncluding wind. O wing to t he s mall nu mber o f bol ts or dinarily employed for joints which are t o be welded, t he t emporary support of heavy gi rders c arrying columns s hall be s pecially at tended. Different m embers which shall be f illet welded, shall be brought i nto as c lose c ontact a s p ossible. T he gap due to faulty workmanship or incorrect fit if any shall not exceed. 1.5 mm if gap exceeds 1.5 mm or more occurs locally the size of fillet weld shall be increased at such position by an amount equal to the width of the gap. 10.4.2.8 Painting : Before the member of the steel structures are placed in position or t aken out of the workshop these shall be painted as specified in para 10.2.2. 10.4.3 Measurements The m ode of m easurements s hall be t he s ame a s specified i n 10.2.4 e xcept t hat w eight of welding material s hall not be add ed i n t he w eight of m embers f or pay ment and not hing ex tra s hall be pai d for making and filling holes for temporary fastening of members during erection before welding. 10.4.4 Rate The r ate shall i nclude t he c ost of all l abour a nd materials i nvolved i n al l t he operations described above. 10.5 COLLAPSIBLE STEEL GATES 10.5.0 These shall be of approved manufacture and shall be fabricated from the mild steel sections. 10.5.1 The gates shall consist of double or single collapsible gate depending on the size of the opening. These shall consist of vertical double channels each 20 x 10 x 2 mm. at 10 cm. centre to centre braced with flat iron diagonals 20 x 5 mm and top and bottom rails of T- iron 40 x 40 x 6 mm @ 3.5 kg/m with 40 mm di a. bal l beari ngs i n every f ourth d ouble channel, unl ess ot herwise s pecified. Wherever c ollapsible gate is not provided within the opening and f ixed a long the outer wall surface, T- iron at the top may be replaced by flat iron 40 x 10 mm. The c ollapsible gate shall be pr ovided w ith ne cessary bol ts and nuts, l ocking arr angement, s toppers and handl es. A ny s pecial f ittings like s pring, catches and l ocks, shall be so specified i n t he des cription o f item where so required. The gate shall open and close smoothly and easily. 10.5.2 Fixing T- iron rails shall be f ixed to the floor and t o the Lintel at top by means of anchor bolts embedded in cement c oncrete of f loor and l intel. T he anc hor bol ts s hall be pl aced appr oximately a t 45 c m c entres alternatively in the two flanges of the T- iron. The bottom runner (T- iron) shall be em bedded in the floor and p roper g roove shall be f ormed along t he r unner f or t he p urpose. T he collapsible s hutter shall b e fixed at sides by fixing the end double channel with T-iron rails and also by hold- fasts bolted to the end double channel and fixed in masonry of the side w alls on the other side. In c ase the collapsible s hutter is not required to reach the lintel, beam or slab level, a Tee-section suitably designed may be fixed at the top, em bedded in m asonry and provided w ith n ecessary c lamps an d roller arrangement a t t he top. A ll the adjoining w ork dam aged i n fixing o f gat e s hall be made good t o match t he existing w ork, w ithout a ny extra cost. 10.5.3 Painting All t he m embers of t he c ollapsible gat e i ncluding T -iron s hall be t horoughly c leaned of f rus t, s cales, dust etc. a nd g iven a pri ming coat o f appro ved steel primer conforming to IS 20 74 b efore fixing them in position.
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10.5.4 Measurements The height and breadth shall be measured correct to a cm. The height of the gate shall be measured as the l ength of the d ouble c hannels and br eadth f rom ou tside t o ou tside of t he en d f ixed do uble channels i n open p osition, of t he g ate. The area shall b e calculated i n s quare m etres, correct t o t wo places of decimal. 10.5.5 Rate The rate shall include the cost of materials and labour involved in all the operations described above. 10.6 M.S. SHEET SLIDING SHUTTER : DELETED 10.7 M.S. SHEET SHUTTERS : DELETED 10.8 ROLLING SHUTTERS 10.8.1 Rolling shutters shall conform to IS 6248. These s hall include necessary l ocking arrangement and handles e tc. T hese s hall be s uitable for fixing in the position as s pecified i.e. outside or inside on or below lintel o r b etween jambs of t he o pening. T he door shall b e either push a nd pull t ype or o perated with mechanical device supplied by the firm. Shutters upto 10 sq. metre shall be of push and pull type and s hutters w ith an area of ov er 10 s q. m etre s hall generally be provided w ith reduction gear operated by mechanical dev ice w ith chain or handl e, i f bear ings ar e s pecified for eac h o f oper ation, these shall be paid for separately. 10.8.1.1 Shutter : The shutter be built up of inter locking lath section formed from cold rolled steel strips. The t hickness of the s heets f rom which the l ath sections hav e been r olled shall be not l ess than 0. 90 mm for the s hutters upto 3. 5 m w idth. S hutters ab ove 9 metres w idth s hould be di vided in 2 p arts w ith provision of one middle fixed or movable guide channel or supported from the back side to resist wind pressure. T he lath s ection s hall be r olled s o a s to have interlocking c urls a t both edges an d a de ep corrugation a t th e ce ntre with a bridge de pth of n ot le ss th an 12 m m to provide s ufficient c urtain of stiffness for resisting manual pr essures and nor mal w ind pr essure. E ach l ath section shall be continuous single pi ece w ithout any welded j oint. W hen i nterlocked, t he l ath s ections shall hav e a di stance of 75 mm rolling centers. Each alternate lath section shall be fitted with malleable cast iron or mild steel clips securely riveted at either ends, thus l ocking i n the l ath section a t bot h ends pr eventing l ateral movement of the individual lath sections. The clips shall be so designed as to fit the contour of the lath sections. 10.8.1.2 Spring : The spring shall be of coiled type. The spring shall be m anufactured from high tensile spring steel wire or strips of adequate strength conforming to IS 4454- Part I . 10.8.1.3 Roller and Brackets : The suspension shaft of the roller shall be made of steel pipe conforming to h eavy d uty as p er IS 1 161. For s hutter u pto 6 m etre width and h eight not e xceeding 5 metre, steel pipes of 5 0 m m nom inal bore s hall be u sed. T he s haft s hall be s upported on m ild steel brackets of size 375 x 375 x 3.15 mm for s hutters upto a clear height of 3.5 metre. The size of mild steel brackets sh all be 50 0 x 50 0 x 10 m m for shutters of cle ar hei ght above 3.5 m an d upto 6. 5 m. The suspension shaft c lamped t o t he b rackets s hall be f itted with rotatable cast i ron p ulleys t o w hich t he shutter is a ttached. The pul leys and pi pe s haft shall connected b y means o f pr etensioned hel ical springs to c ounter balance the weight of t he s hutter a nd to k eep the s hutter in equilibrium in any p artly o pen position. 10.8.1.4 When the width of the opening is greater than 3.5 mtr. The cast iron pulleys shall be interconnected with a c age formed out of m ild steel flats of at least 32 x 6 mm and m ild steel dummy rings made of similar fl ats to di stribute the t orque uni formly. Self a ligning two ro w ball b earing with special cast iron casings shall be prov ided at the extreme pulley and c aging rings shall have a m inimum spacing of 15mm and at least 4 number flats running throughout length of roller shall be provided.
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10.8.1.5 In case of shutters of large opening with mechanical device for opening the shutter the roller shall be f itted with a pur ion wheel at one end w hich in contact with a w orm fitted to the bracket plate, caging and pulley with two ball bearing shall be provided. 10.8.1.6 Guide Channel : The w idth o f gu ide c hannel s hall be 25 m m the m inimum d epth o f gu ide channels shall be as follows: Cle a r width of shutte rs Upto 3.5 m 3.5 m upto 8 m 8 m and above
De pth of guide cha nne l 65 mm 75 mm 100 mm
10.8.1.7 The gap between the two legs of the guide channels shall be sufficient to allow the free movement of the shutter and at the same time close enough to prevent rattling of the shutter due to wind. 10.8.1.8 Each guide channel shall be provided with a minimum of three fixing cleats or supports for attachment to the wall or column by means of bolts or screws. The spacing of cleats shall not exceed 0.75 m . A lternatively, the guide channels m ay also be provided w ith suitable dowels, hooks or pins for embedding in the walls. 10.8.1.9 The guide channels shall be attached to the jambs, plumb and true either in the overlapping fashion or embedded in grooves, depending on the method of fixing. 10.8.1.10 Cover : Top cover shall be of mild steel sheets not less than 0.90 mm thick and s tiffened with angle or flat stiffeners at top and bottom edges to retain shape. 10.8.1.11 Lock plates with sliding bolts, handles and anchoring rods shall be as per IS 6248. 10.8.2 Fixing The arrangement for fixing in different situations in the opening shall be as per IS 6248. 10.8.2.1 Brackets shall be fixed on the lintel or under the lintel as specified with rawl. Plugs and screws bolts etc. The shaft along with the spring shall then be fixed on the brackets. 10.8.2.2 The lath portion (shutter) shall be laid on ground and the side guide channels shall be bound with ropes etc. The shutter shall then be placed in position and top fixed with pipe shaft with bolts and nuts. The side guide channels and cover frames shall then be fixed to the walls through the plate welded to the guides. These plates and bracket shall be fixed by means of steel screws bolts, and rawl plugs concealed i n pl aster to m ake their location i nvisible. F ixing shall be do ne a ccurately i n a w orkmen l ike manner that the operation of the shutter is easy and smooth. 10.8.3 Measurements Clear w idth and c lear h eight of t he openi ng f or rolling s hutter s hall be m easured c orrect t o a m m. The clear di stance b etween the two jambs of the op ening s hall be c lear width an d the c lear distance between the sill and the soffit (bottom of lintel) of the opening shall be the clear height. The area shall be calculated in square metres correct to two places of decimal. 10.8.4 Rate The rate s hall include t he c ost o f materials and l abour involved in al l the oper ations de scribed abo ve including c ost of t op c over and spring e xcept b all be aring and m echanical de vice of chain and c rank operation, which shall be paid for separately.
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10.9 ROLLING GRILLS - SHUTTERS 10.9.0 Rolling grill shutter is meant to provide visibility or ventilation or both, the degree of protection and safety is less as compared to a rolling shutter. The situations where a certain amount of ventilation combined with safety is required rolling shutter-cum-grill may be provided in which the rolling shutter may have a rol ling grill portion either at the top or a t the bottom or at both places. In addition, the rolling grill portion may also be provided in the middle of the shutter. The total height of the grill portion in all the segments o f r olling s hutter-cum-grill s hall no t ex ceed 1 .0 m and the he ight of the g rill portion in any individual segment shall not be more than 0.5 m. 10.9.1 Rolling gr ills shutters are similar in design, construction an d op eration to ro lling shutters and all the provisions of P ara 10 .8 s hall b e ap plicable to rolling grills shuters except in respect o f t he s hutter portion, and shall conform to IS 6248. 10.9.2 Shutters Rolling g rill shutter and the rolling g rill po rtion o f the rolling s hutter-cum-grill s hall be f abricated with 8 mm d iameter m ild s teel r ound bar s. S traight bars and bars bent to t he requ ired profile a re p laced alternatively and hel d i n p osition with 20 mm w ide and 5 mm thick mild steel flat links. S traight bar s shall be spaced not exceeding 150 mm centre to centre and the bars bent to required profile shall be placed symmetrically be tween two c onsecutive s traight bar s. U nless o therwise s pecified or d irected b y the Engineer-in-charge, bar s pl aced al ternatively with s traight bar s shall be bent t o form a c orrugated profile such that t he pitch of the corrugation is 100 to 120 mm and the depth of corrugation is 80 to 100 mm. all the bent bars shall have uniform profile. Straight bar along with the adjoining bent bars on it both sides shall be he ld in po sition b y passing the b ars through holes in the links. Each link shall ha ve three holes and the length of the links shall be such that the distance from the centre of the hol e to the nearest edge of the flat is not less than the diameter of the hole. The corner of the links shall be rounded. All links shall be of uniform size and s hape. T he s pacing of the links m easured along the straight bar s hall be the same as c entre to centre d istance between t wo consecutive c rests/ tr oughs of the b ars b ent t o t he required profile. Each bar and link shall be continuous single piece without any joint. 10.9.3 Measurement & Rate The m easurement and r ate s hall be as s pecified i n 10. 8.3 and 10. 8.4 respectively. I n case o f R olling Shutter-cum-Grill, where the area of the grill portion is half or less than half the area of opening, it shall be measured an d pai d as ro lling s hutter a nd w here t he area of gri ll po rtion i s m ore t han hal f t he a rea of opening, it shall be measured and paid as rolling grill. 10.10 to 10.13 ITEMS DELETED 10.14 FAN CLAMPS (Fig. 10.9) 10.14.1 The fan clamps shall be of the following types: (a) Fan clamp to be fixed during the laying of R.C.C. slab, shall be of type I, as shown in (Fig. 10.9) This s hall be made of 1 6 mm M.S. b ar bent to s hape with i ts e nds hooked. T he o verall height of the clamps shall be made to suit the depth of slab. (b) Fan clamps for beams shall be of type II as shown in (Fig. 10.9). It shall be similar to fan clamp, type I, except that its height shall be greater depending on the depth of the beam rib. (c) I n case low ceiling h eights, circular cast iron b ox for ceiling fan clamp shall be fixed d uring the laying of R .C.C. s lab a nd shall be as s hown i n (Fig. 10.9). T he size of c ast i ron box s hall be 140mm internal d ia with 73 m m hei ght, the t hickness of cast i ron ri m shall be 4. 5 mm bot tom and t op l id shall be of 1. 5 m m t hick M .S. s heet, w ith i ts t op surface hacked s o a s t o e nsure proper bon ding w ith t he c oncrete.The l ids shall be screwed i nto the cast i ron box by m eans of 3.3mm dia round head screws one each at the corners. The box can be of M.S. sheet, the thickness of side walls c an be reduc ed t o 3 m m without ef fecting i nner di a of t he box . T he fan clamp shall be made of 12mm dia M.S. bar bent to shape with its ends bent as per drawing.
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10.14.2 Fixing Holes f or in serting t he f an cla mps in t he positions sh own in t he drawing or as i nstructed b y th e Engineer-in-charge s hall b e m ade i n t he s huttering after the l atter has been fixed i n p osition. A fter s teel reinforcement is tied, fan c lamps s hall be fixed with their loops truly vertical and at the correct depth from the under-side of the slab or b eam. The hooked arms and t he loop shall be tied to the reinforcement, either directly or through cut pieces of M.S. bars with annealed steel wire 1.6 mm or 1.00 mm thick. The clamp s hall nei ther be di sturbed out of pos ition d uring c oncreting nor shall t hey be bent out of s hape when shuttering of slabs or beams is removed. The exposed portion of l oops of t he cl amps s hall be giv en t wo o r more c oats of p aint, inc luding priming coat, of approved steel primer as ordered by the Engineer-in-charge. 10.14.3 Measurements Clamps of type I and 3 shall be counted in numbers. Fan clamps type II, shall be counted and paid for under fan clamps type I, but they shall in addition be paid for their extra height as determined by the depth of the beam. 10.14.4 Rate The rat e per f an c lamps shall include t he c ost of l abour and materials i nvolved i n all t he operat ions described above. In the case of type I and 3 clamps, the rate shall apply irrespective of the thickness of the slabs. 10.15 to 10.16 ITEMS - DELETED 10.17 STEEL WORK WELDED IN BUILT-UP SECTIONS USING STRUCTURAL STEEL (A) In Stringers, Treads, Landing etc. of Stair cases including use of Chequred Plate wherever required (B) In Grating, Frames, Guard Bar, Ladder, Railings, Bracket, Gates and similar work. 10.17.1 General specifications for these items to be same as for steel work welded in built-up sections as m entioned in p ara 10.4 ex cept that steel used for fabrication of these items to be of type used f or structural use/purposes. 10.17.2 Steel members used for fabricating these items to be designed structurally to withstanding the all l oads t o be c arried o ut by t he m embers during er ection, f ixing a nd f unctional use i n designed l ife. Work to be executed as per structural drawings. 10.18 S TEEL WORK W ELDED I N BUILT-UP TUBULAR/ERW TUBULAR PIPES AND G.I. PIPES
SECTIONS
FOR
HAND
R AIL
USING
M.S.
10.18.1 General specifications to be same as for steel work welded in built-up section as mentioned in para 10.4. 10.18.2.1 Hot finished welded ( HFW) Hot finished seamless (HFS) a nd e lectric re sistance welded tube shall conform to IS 1161. 10.18.2.2 G.I. pipes used for Hand rail to be conforming to IS 1239-Part I for medium grade. GI pipes to be screwed and socketed type and of required nominal bore. 10.18.2.3 Galvanising of GI pipes shall conform to IS 4736. 10.18.2.4 All screwed tubes and socket of GI pipes shall have pipe threads conforming to the requirements of IS 554. 10.18.2.5 The fittings for GI pipes to be conforming to IS 1239 (Part-II). 10.8.3 Measurement of Hand Rail of M.S. Tubular/E.R.W Tubular Pipes The w ork a s f ixed i n place s hall b e m easured i n r unning m etres correct t o a c entimeter a nd t heir weights c alculated o n th e ba sis of st andard t ables c orrect t o t he n earest kilo gram o r ac tual w eight whichever is less unless otherwise specified.
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APPENDIX A MECHANICAL PROPERTIES AND CHEMICAL COMPOSITION OF STEEL TABLE 10.1 Chemical Composition (Clause 10.1.1) Grade Designation
Quality
1 E 165 (Fe 290) E 250 (Fe 410 W) E 250 (Fe 410 W) E 250 (Fe 410 W) E 300 (Fe 440) E 350 (Fe 490) E 410(Fe 540) E 450 (Fe 570 ) E 450 (Fe 590)
2 A B C D E
Ladle analysis, Percent, Max C 3 0.25 0.23 0.22 0.20 0.20 0.20 0.20 0.22 0.22
Mn. 4 1.25 1.50 1.50 1.50 1.30 1.50 1.60 1.60 1.80
S 5 0.045 0.045 0.045 0.040 0.045 0.045 0.045 0.045 0.045
P 6 0.045 0.045 0.045 0.040 0.045 0.045 0.045 0.045 0.045
Notes: 1. 2.
3. 4. 5. 6.
7. 8. 9. 10.
Carbon equivalent (CE) based on ladle analysis =
Si 7 0.40 0.40 0.40 0.45 0.45 0.45 0.45 0.45 Mn
Carbon Equivalent (CE), Max
Method of Dexodiation1
8 0.42 0.41 0.39 0.40 0.42 0.44 0.46 0.48
9 Semi-killed or killed Semi-killed or killed Killed Killed Semi-killed or killed Semi-killed or killed Semi-killed or killed Semi killed or killed Semi killed or killed
+
(Cr+Mo+ V)
+
(Ni + Cu)
C+6 5 15 When the steel is killed by aluminium alone, the total alu minium content shall not b e less than 0.02 per c ent. When t he steel is killed by si licon al one, t he s ilicon content shall no t be l ess than 0.10 per cent. When the s teel is silicon-aluminium killed, the silicon content s hall not b e less than 0.30 per cent and total aluminium content shall not be less than 0.01 per cent. Microalloying el ement like Nb, V, Ti and B shall be added singly or i n comb ination. Total microalloying element shall not be more than 0.25. New grades designati on system ba sed on yie ld stress ha s been adopted, simu ltaneously o ld designations have also been given in parentheses. Steel of qualities A, B and C are generally suitable for weldi ng process es. The wel dability increases from quality A to C. Copper may be presen t between 0 .20 to 0.35 per cent a s mutually a greed to between the purchaser and the man ufacturer. The copper b earing quality shall be designated with a suffix Cu, for e xample, E 250 Cu. In case of produ ct analysis the copper co ntent shall be betwee n 0.17 and 0.38 per cent. Nitrogen content of ste el shall not e xceed 0. 012 per ce nt whic h shall be ensured by the manufacturer by oc casional check analysis . For micro alloy ed ste el t his is to be reduced to 0.009 per cent. The steel, if required may be treated with rare earth element for better formability. Lower limits for carbon equivalent and closer limits for other elements may be mutually agreed to between the purchaser and the manufacturer. Incidental element-E lements not qu oted in Tab le 1 shall not be int entionally added t o stee l without the agreement of the purchaser, other than for the purpose of fi nishing the heat. All reasonable precautions s hall be taken to prevent the addi tion from scrap or other materi als used i n manufacture of such ele ments which affect the hardenability, mechanica l properties and applicability.
1. “To be supplied subject to the agreement between the purchaser and the manufacturer”. 331 | Page HO Civil Specifications Volume - I
TABLE 10.2 Mechanical Properties (Clause 10.1.1) Grade Designation
1 E 165 (Fe 290) E 250 (Fe 410 W) E 250 (Fe 410 W) E 250 (Fe 410 W) E 300 (Fe 440) E 350 (Fe 490) E 410 (Fe 540) E450 (Fe 570) E 450 (Fe 590) 1 2 3
Quality
Tensile strength Min. MPa
2 - 290
3
A 410
Yield stress, ReH Min. MPa
40
4
5 165
6
250 240
Percentage elongation at Guage length Lo 5.65 √SO Min.
Internal Bend Diameter Min.)
Charpy V-Notch Impact Energy Min. J
At 20oC
9 -
at Room Temp. 10 -
3t
2t
-
-
< 25
>25
7 23
8 2t
230
23
11 -
B
410
250 240
230
23
2t
3t
27 (See Note 3 )
C
410
250 240
230
23
2t
3t
27 (See Note 3 )
- 440
300 290
280
22
2t
3t
50
30
- 490
350 330
320
22
2t
3t
50
25
- 540
410 390
380
20
2t
3t
50
25
D 570
450 430
420
20
2t
3t
45
20
E 590
450 430
420
20
2t
3t
45
20
1 MPa= 1MN/m2= 0.102 kgf/mm2=144.4 psi Temperature of Charpy impact values will be subject to mutual agreement. The more stringent req uirements t han those given ab ove may b e a s agreed to between the purchaser and the manufacturer.
332 | Page HO Civil Specifications Volume - I
TABLE 10.3 (Clause 10.2.4 &10.3.5) Sl. No.
Steel Section
(i)
Beams and columns (RS joists)
(ii) (iii)
Channels Equal and unequal leg Angles (a) upto 3 mm thickness (b) Over 3 mm thickness Tee bars (a) Web thickness upto 3 mm (b) Web thickness above 3 mm Bulb angles Bars in straight length Upto and including 10 mm Over 10 mm and upto and including 16 mm Over 16 mm Bars in coils Flats Upto 3 mm thickness Over 3 mm thickness Plates Strips Consignment in straight length (i) upto 5 tons (ii) Above 5 tons Sheets
(iv) (v) (vi)
(vii) (viii) (ix) (x)
(xi)
Over in mm
Tolerance in weight per meter percentage Plus Side Minus Side (a) Beams < 200 mm (+) 4 (-) 1 (b) > 200 mm 2.5 2.5 2.5 2.5
Standard weight as per IS IS
808
IS 808
5 5
5 3
IS 808
5 2.5 2.5
5 2.5 2.5
IS 1173
7
IS 1732
7 55
IS 1252
3 3 Weight tolerance is not applicable 5 5 5 10
5 3 2.5 10
7 5
7 5
Thickness Upto and including in mm
-
1.25 mm
1.25mm 1.6 mm
1.60 4.00
Tolerance on calculated weight (Percent) +9
IS 1730 IS 1730 IS 1730
IS
1730
+8 +7
333 | Page HO Civil Specifications Volume - I
APPENDIX B WELDING PROCESS (Clause 10.4.2.4)
(a) The work shall be positioned for downward welding wherever possible. (b) Arc length voltage and amperage shall be suited to the thickness of material, type of groove and other circumstances of the work. The welding current and electrode sizes for different types of joints shall be as per IS 9595. (c) The sequence of welding shall be such as will avoid undue distortion and minimize residual shrinkage stresses. Recommendation of IS 9595 shall be followed. Process of Welding The electrode manipulation during welding shall be such as to ensure that: (1) The parent metal is in a fused stage when the filler metal makes contact with it. (2)
The weld metal does not overflow upon any unfused parent metal forming overlapping.
(3)
The parent metal is not under-cut along the weld toes.
(4)
The flowing metal floats, the slag, the oxides, and the gas bubbles to the surface behind the advancing po ol. I n c ase any of t hese requirements is unat tainable by manipulation, t he c urrent shall be adjusted or the electrode size changed. Each time the arc is started the electrode shall be moved in such a w ay that the fusion of base metal at t he s tarting poi nt i s as sured. A t the completion of a run t he m ovement of electrode shall be slowed down to fill the arc crater. After every interruption of the arc except at completion of a run, the arc shall be restarted ahead of the previous deposit and then move back to fill the crater or such alternative technique shall be us ed as will ens ure complete filling o f the crater, o r complete fusion bet ween the new and ol d de posit and t he bas e m etal at t he poi nt of j unction, and res ult i n c ontinuity of weld, Before welding operation is completed, all traces of slag shall be removed from the deposit, by chipping if ne cessary, and the de posit an d the a djoining base metal shall be wire brushed an d c leaned at all poi nts. T he req uirements s hall appl y not o nly to s uccessive l ayers, but also t o successive beads, and t o t he o ver l apping area w herever a j unction i s m ade o n starting a new electrode.
(5)
The welds shall be free from cracks, discontinuity in welding and other defects such as (i) under-size (ii) o ver-size, ( iii) under-cutting and ( iv) ov er-cutting i n t he c ase o f f illet w elds and defects (ii), (iii) & (iv) in the case of butt welds.
All d efective welds w hich shall b e c onsidered harmful t o t he structural s trength s hall be c ut out a nd rewelded. In c ase of w elded butt joints in steel of thickness upto 50m m the w eld joint shall be s ubjected to radiographic examination as described in IS 1182. All welds shall be cleaned of slag and other deposits after completion. Till the work is inspected and approved pa inting s hall n ot b e done. The s urface t o be painted s hall be cleaned of s patter, rust, loose scale, oil and dirt.
334 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
STEEL TUBES FOR STRUCTURAL PURPOSES
APPENDIX C
(Clause 10.13.1) Nominal Bore (mm) 15 21 20 26 25 33
Outside Diameter (mm) .3 .9 .7
32 42
.4
40 48
.3
50 60
.3
65 76
.1
80 88
.9
90 1
01.6
100 11
4.3
110 12
7.0
125 13
9.7
135 15
2.4
150 16
5.1
150 16
8.3
175 19
3.7
200 21
9.1
225 24 250 27 300 32 350 35
4.5 3 3.90 5.60
L means Light
M means Medium
Class H H M H L M H L M H L-1 M H L M H L M H L M H L M H L M H L M H L M H L M H L M H-1 H-2 L M H L M H H H H H
Wall Thickness (mm) 3.2 3.2 3.2 4.0 2.60 3.2 4.00 2.90 3.2 4.0 2.9 3.6 4.5 3.2 3.6 4.50 3.2 4.00 4.8 3.6 4.0 4.8 3.6 4.5 5.4 4.5 4.8 5.4 4.50 4.8 5.4 4.50 4.8 5.40 4.50 4.8 5.40 4.50 4.8 5.40 6.3 4.8 5.40 5.9 4.8 5.60 5.90 5.90 5.90 6.30 8.00
Weight (kg/m) 1.44 1.87 2.41 2.93 2.54 3.10 3.79 3.23 3.56 4.37 4.08 5.03 6.19 5.71 6.42 7.93 6.72 8.36 9.9 8.7 9.63 11.50 9.75 12.2 14.5 13.6 14.50 16.2 15.00 15.90 17.90 16.40 17.50 19.60 17.80 18.90 21.30 18.20 19.40 21.70 25.20 22.40 25.10 27.30 25.40 29.50 31.00 34.70 38.90 49.30 68.60
H means Heavy 335 | Page HO Civil Specifications Volume - I
APPENDIX D SHAPES, WEIGHTS AND DESIGNATION OF MS ROLLED STEEL SECTION Designation Wt kg/m
Situation of Use of Section
T2
1.036
T3 T6
1.14 0.839
F2 F3 F5 1.55
1.46 2.28
F4B
2.28
F7D
1.419
FX6 FZ7
2.52 1.90
FX8 FZ5 K11B 1.80
2.31 2.52
K12 B
2.30
Vertical and horiz ontal glazing bars for doors a nd shashes : windows, ventilators glazi ng bars for d oor side lights su b dividing bars for fixed length, sas h bars for do ors, windows and ventilators whee l steel al uminium or wood en beading is used for fixing glasses. Vertical glazing bar for FZ 7 frame Vertical and horiz ontal glazing bar for standard windows and ventilators. Inner frames for open-in windows. Outer frames for open-in windows. (a) Inner and middle frames in centre-hung ventilators (b) F5 i s some ti mes us ed as inner frames for open-out windows. A lso us ed a s inner fra me for bottom hung ventilators (c) F8 is a lso used as outer frame for botto m hung ventilators. Central mullion (meeting bar for shutters) for wi ndows and ventilators using F7D as inner frames, outer frames for openin windows i n rain y areas, subdividing bars for openable windows and top-hung ventilators. Inner and outer frames for windows and top hung v entilators, for inner fra mes for c entre-hung ventilators and outer frame s for door sidelights. Inner frame for doors Used a s outer frame f or indu strial sha shes. Also used f or outer frame for wooden doors Outer frames for doors Inner frames for doors (a) Vertical coupling mullion for standard windows (b) Can be use d as horizontal coupling bar when openable windows are to be coupled above fixed ones or between two fixed windows. (c) Can als o be used a s h orizontal coupling mullion where windows are not exposed to weather. Horizontal c oupling mulli on, also known as weather bar, Especially used when the coupled unit is exposed to rain.
336 | Page HO Civil Specifications Volume - I
APPENDIX D
SHAPES 9.5
9.5
3
8
9.5
1R
25 ± .4
1R
1R
1R
2R Max.
2R
19 ± .4
1R 2R Max.
3
22 ± .4 WEIGHT 1.14 Kg/m T3
WEIGHT 1.038 Kg/m T2
25 ± .4
1
3 32 ± .8
3 12 ± .4
2R max
WEIGHT 1. 46 Kg/m F2
2R
3
2R max
2R
2R
2
2 3
1R
2R max
2R
2R
3
22 ± .4
4
1R
1R 2R
4
7 2R
4
1 2R
1R
44 ± .8
2R
20 ± .4 1R 3
1R
2R max
2R
3
2
2.5 1
25 ± .4
13
13 ± .4
3
2R
2R
3
2R max.
7 2R max
1.5
1R 2R 1
3
1R
WEIGHT 0.839 K g/m T6 All dimensions in millimetres
3
2R Max.
22 ± .4
16 ± .4
2R
1R 22 ± .4
1R
8
1R
1R
1R
3
13 ± .4
3
20 ± .4
9.5
WEIGHT 1.55 kg/m F5
1R
2R 3
1
WEIGHT 2. 28 kg/m F3 All dimensions in millimetres 22 ± .4
22 ± .4
1R
2R
2 2R 1R
1R
14 1
2R 2R
.2
WEIGHT 1. 92 kg/m F8 All dimensions in millimetres
1
2R 2R max
3
13 ± .4
20 ± .8
2
2R
1R 13 ± .4
1R
3
1R
13 ± .4
1R
46 ± .8
2R max 2R
1
5
7
2R max
3 12
1
3
1R 2R max
20 ± .4
3 1R
2R
1R 2R max
8
5
19 ± .4
3
5
14 ± .4
1R
22 ± .4
20 ± .4
1.5
3
2R max
3
3
3
2R 2R
1R 1
3
WEIGHT 1.419 kg/m F7D All dimensions in millimetres
WEIGHT 2. 28 kg/m F4B
337 | Page HO Civil Specifications Volume- I
APPENDIX D
10
22 ± .4
3
33 ±.8
1 1R 1
15 ± .4
26 ± .4 1R
3
WEIGHT 1.90 kg/m FZ7 All dimensions in millimetres
1.2
3 3.5
2R
3
29 ± . 4
2R max.
2R 1R
2R max
1.2
1R 2R
2R max
2R max 1R
2R
1R
3
3
29 ± .4 2R
2R
2R
4
44 ± .8
1R
.5
1R
1.2
32 ±.4
1R
11 ± .4
3.5
10
SHAPES
WEIGHT 2.52 kg/m FX6
29 ± .4 1R
27 ± .4
13 3
2R
2R 1R
3 3.5
1
3 3.5
2R
5
1R
6
.5
.2
1R
2R max 1R
1
3
21 ± .8
2R max 2R
22 ± .4
2R
43 ± .8
44 ± .8
2R
2R max
29 ± .4
2R
2R
3
1.2
3.5
19
1R
5
3.5
29 ± .4
10
1 1R
3
15 ± .4
22 ± .4
1R
1
1.2
3
1R
2R max 1R
WEIGHT 2.52 kg/m FZ5 All dimensions in millimetres
WEIGHT 2. 31 kg/m FX8
2.5
3 3
6R
3R
2R max.
1R 2R max
9 2R
3
13
2R
1.2
2R
2R
50 ± .8
35 ± .8
3
3 2R 2R
12 2R
2R max WEIGHT 1. 80 kg/m K11B
3
2R
2R 3
15
3
23 ± .4
3
27 ± .8
3
2R max
1.2 2R
3
35 ± .8 WEIGHT 2.30 kg/m K12B
338 | Page HO Civil Specifications Volume - I
WELDS AND RIVETS Sub Head : Steel Work Clause : 10
B. BUTT W ELDS
A. BEAD W ELDS
Toe Weld Face Original S urface of Work Toe
Fusion Zone Root Fusion Zone
C. PLAIN BUTT JOINT
Convex
Concave
D. FILLET WELD
Mitre Z = Depth of Fusion X = Throat Thickness Y = Effective Throat Thickness Z
Z
Z
Lap
Corner
F. FUSION PENETRATION
E. F ILLET W ELDS 1.5D
Flat Sunk
Z
1.5D
1.5D
1.5D
1.6D
Counter Head
Round Sunk
Counter Head
Pan Head
2.5D
Bend Test
Flattening Test
0.7D Shank Tail
d = E ffective Diametre D = Normal Diametre
G. RIVETS Drawing not to Scale
Fig. 10.1 : Welds and Rivets 339 | Page HO Civil Specifications Volume - I
COLLAPSIBLE STEEL GATE Sub Head : Steel Work Clause : 10.5
20 x 10 x 2 Channel Iron 3.5 kg/m T-Iron 40 x 40 x 6
T Iron 40 x 40 x 6
38 Dia Ball B earing
Channel 20 x 10 x 2
Flat Iron Hanger Rivets Fixing with Hold Fast to Wall
Flat I ron 20 x 5 Locking Arrangement
Height
Handle
Lock Handle
Holding Hook
Pulley or 38 m m Ball Bearing
100 SECTION
Pulley or 38 mm Ball B earing
Opening
Channel
100
FRONT ELEVATION
FRONT ELEVATION
450
Rivets
450
Opening PLAN
PLAN
Drawing not to Scale All dimensions are in mm
Fig. 10.2 : Collapsible Steel Gate
CPWD SPECIFICATIONS 2009
340 | Page HO Civil Specifications Volume - I
FAN CLAMPS Sub Head : Steel Work Clause : 10.14
75
200
Top of Slab
200
25 Min 16
A
32
Distribution Reinforcement
16 17 Ceiling Finish
Tie Bar Main Reinforcement
50
Exposed Loop shall be Painted
100
16 mm φ 200
75
200
Top of Slab
R.C.C. Slab
R.C.C. Beam Rib
B
32 100 Min
Reinforcement Bar Ceiling Finish Exposed Loop shall be Painted
50
100
160 Top Lid 15 th.
Hole for Conduit Entry 1.5
36.5
C
76 73 36.5
180
Bottom Lid 1.5 Th.
ELEVATION
14
12
58.5
13
3.3 mm Dia Tapped Hole SECTION 5
140
CIRCULAR CAST IRON BOX 16
PLAN WITHOUT TOP AND BOTTOM LID
Drawing not to Scale All dimensions in millimetres
Fig. 10.9 : Fan Clamps
341 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
11.0: Flooring
342 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
CONTENTS Cla us e No.
De s cription List of Mandatory Tests
P a ge No. 345
List of Bureau of Indian Standards Codes
346
11.1
Brick on Edge Flooring
347
11.2
Cement Concrete Flooring
348
11.3
Cement Concrete Flooring with Metallic Hardner Topping
350
11.4
Cement Plaster in Risers of Steps, Skirting & Dado
351
11.5
Cement Concrete Pavement in Courtyard and Terrace, etc.
352
11.6
Terrazo (Marble Chips) Flooring laid in situ - DELETED
352
11.7
Terrazo (Marble Chips) Skirting in situ - DELETED
352
11.8
Wax Polishing
352
11.9
Crazy Marble Flooring - DELETED
353
11.10
Terrazo Tile Flooring
353
11.11
Terrazo Tiles in Risers of Steps, Skirting & Dado
355
11.12
Chequered Tile Flooring
356
11.13
Chequered Tiles in Stair Treads
357
11.14
Acid or Alkali Resistant Tiles - DELETED
358
11.15
Pressed Ceramic Tiles Flooring
358
11.16
Pressed Ceramic Tile Flooring (Vitrified Tile Flooring)
359
11.17
Fixing of Tile Flooring with Cement based High Polymer Modified Quick Set Adhesive (Water Based)
360
11.18
Pressed Ceramic Tiles in Skirting & Dado.
360
11.19
Marble Stone Flooring
361
11.20
Marble Stone in Risers of Steps and Skirting
363
11.21
Kota Stone Flooring
364
11.22
Kota Stone in Risers of Steps, Skirting & Dado
364
343 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
11.23
Red or White Fine Dressed Sand Stone Flooring
365
11.24
Red or White Fine Dressed and Rubbed Sand Stone Flooring
366
11.25
Wooden Flooring
366
11.26
Wood Block Flooring
366
Appendix A
Abrasion Test for Concrete Hardening Compounds
367
Appendix B
Test Requirements and Procedure for Testing Pre-Cast Cement Concrete/Terrazo Tiles
368
Fig. 11.1
Crazy Marble Flooring - DELETED
Fig. 11.2
Chequred Terrazo Tiles
369
344 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LIST OF MANDATORY TESTS
Ma te ria l
Cla us e
1. Terrazzo Tiles
2. 11.10.1 & 11.11.1
Pressed ceramic tiles (for floor & wall)
11.4,11.5 & 11.16
Te s t
F ie ld/ La bora tory Te s t
Te s t P roce dure
3. 1. Transverse strength 2. Water absorption 3. Abrasion Atest
4. Laboratory
5. I S: 1237
1. Dimensions and surface quality 2. Physical properties 3. Chemical properties
Laboratory
I S: 13630
Min. qua ntity of ma te ria l for ca rrying out the te s t 6. 5000 Nos. (no testing need be done if total number of tiles of all types of all sizes from all manufacturers used in a work is less than 5000 Nos)
3000 Nos.
Fre que ncy of te s ting
7. One test for every 10,000 Nos. or part thereof for each type and size from a single manufacturer. (One test to be done even if the number of terrazo tiles of any type and size from a single manufacturers is less than 5000 Nos. provided the total number of terrazo tiles of all types and sizes from all manufacturers used in a work exceed 5000 Nos. 3000 Nos. or part thereof
.
345 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
LIST OF BUREAU OF INDIAN STANDARDS CODES
S .No. 1. 2. 3. 4. 5. 6. 7.
IS No. IS 269 IS 401 IS 451 IS 455 IS 661 IS 702 IS 1124
8. 9. 10.
IS 1130 IS 1141 IS 1200-(Part XI )
11. 12.
IS 1237- Edition 2.3 IS 1322
13.
IS 1443
14.
IS 1489 (Part-I)
15.
IS 1489-(Part II)
16.
IS 1580
17. 18. 19. 20. 21. 22.
IS 2114 IS 2571 IS 3622 IS 3670 IS 4457 IS 5318
23. 24. 25. 26. 27. 28. 29. 30.
IS 5766 IS 8041 IS 8042 IS 8043 IS 8112 IS 12330 IS: 13630 (Part-1 to 15) IS 13712
31.
IS 15622
S ubje ct Specification f or 33 gr ade ordinary portland Cement Code of practice for preservation of timber Technical s upply c onditions for w ood s crews Specification for portland slag cement Code of pr actice f or t hermal insulation of c old s torages Specification for industrial bitumen Method of t est f or determination of w ater ab sortion, appare nt specific gravity and porosity of natural building stones Specification f or m arble ( blocks, s labs an d t iles) Code of practice for Seasoning of timber Method of m easurement o f B uilding and Civil E ngineering w ork (Part 11) paving, floor finishes, dado and skirting Specification for cement concrete flooring tiles Specification f or bitumen f elts f or w ater proofing and dampproofing Code of p ractice f or l aying a nd f inishing of c ement c oncrete flooring tiles Specification f or por tland poz zolana c ement (Part-I) flyash based Specification f or P ortland poz zolana c ement ( Part I I) c alcined clay based Specification f or bituminous c ompounds f or water proofing and caulking purpose Code of practice for laying in-situ terrazzo floor finish Code Code of practice for laying in-situ cement concrete flooring Specification for sand stone (Slab & Tiles) Code of pr actice f or c onstruction of t imber floors Acid and/or alkali Resistant tiles. Code of practice f or l aying of har d w ood parquet and w ood block floors Code of practice for laying of burnt clay brick floor Specification for rapid hardening portland c ement Specification for white portland cement Specification for hydrophobic portland cement Specification for 43 grade ordinary portland cement Specification for sulphate resisting portland cement. Methods of Testing of ceramic tiles Specification for ceramic tiles; definition, classification characteristic and marking Specification for pressed ceramic tile
346 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
11.0 FLOORING 11.1 BRICK ON EDGE FLOORING 11.1.1 Bricks Bricks of Specified class designations shall be used. These shall conform to the specifications described i n S ubhead 6. 0. B roken br icks s hall not be us ed i n flooring ex cept f or c losing t he l ine. T he bricks shall be laid on edge. 11.1.2 Mortar The m ortar used s hall be as specified (in case of dry bricks flooring fine sand shall be f illed in the joints). 11.1.3 Base Concrete 11.1.3.1 Flooring shall be laid on base concrete where so provided. The base concrete shall be provided with the s lope required for the flooring. F loors in v erandah, courtyard k itchens, ba ths s hall have s lope ranging from 1 : 36 t o 1 : 48 d epending upon l ocations as dec ided by t he E ngineer-in-Charge. Floors in water cl oset por tion sh all have slope of 1 : 30 or as decided by the Engineer-in-Charge to drain off washing water. Plinth masonry off-set shall be depressed so as to allow the base concrete to rest on it. 11.1.3.2 If the base is of lean cement concrete, the flooring shall commence within 48 hours of the laying of bas e, failing w hich, the s urface of bas e shall be roughened w ith s teel w ire brus hes w ithout disturbing the c oncrete. B efore l aying t he f looring t he b ase shall be w etted a nd smeared with a coat of c ement slurry at 2 kg of cement spread over an area of one sqm so as to get a good bond between sub-grade and flooring. 11.1.3.3 Where base concrete is not provided, the earth below shall be properly sloped, watered, rammed and consolidated. Before laying the flooring, it shall be moistened. 11.1.4 Soaking of Bricks Bricks r equired for flooring s hall be pe rfectly s oaked in s tacks be fore us e, by pr ofusely s praying clean water at regular intervals for a period of not less than six hours so as to keep them wet to the satisfaction of th e E ngineer-in-Charge. (In case the joints are to be filled with sand, the bricks need not be soaked). 11.1.5 Laying 11.1.5.1 The bricks shall be l aid on t he edge, diagonal herring bone bond, or other pattern as specified or directed by the Engineer-in-Charge. 11.1.5.2 Bricks shall be laid on e dge on 12 mm thick mortar of specified ratio bed and each brick shall be properly bedded and set home by gentle tapping with trowel handle or wooden mallet. Its inside face shall be buttered with mortar, before the next brick is laid and pressed against it. 11.1.5.3 On completion of a p ortion of flooring, the vertical joints shall be fully filled from the top with mortar. D uring laying, the s urface o f the flooring s hall b e frequently c hecked w ith a straight e dge o f length at least 2 m, so as to obtain a true plain surface with the required slope. 11.1.6 Joints Bricks s hall be so laid that all joints are f ull of mortar. The thickness o f joints shall not e xceed 1. 0 cm for brick work with bricks of any class designation. All face joints shall be raked to a minimum depth of 15 mm b y raking tool during the progre ss o f work when the mortar is still gr een so a s to provide prop er key for the plaster or pointing to be done. Where plastering or pointing is not required to be done, the joints shall be struck flush and finished at the time of laying. The face of brick work shall be cleaned on the same day on which brick work is done and all mortar droppings removed promptly.
347 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
11.1.7 Curing Brick work shall be protected from rain by suitable covering when the mortar is green. Brick work in cement m ortar, s hall be kept c onstantly m oist on al l f aces f or a m inimum period of s even day s. B rick work carried ou t shall be suitably marked indicating the date on w hich the work is done s o as to keep a watch on the curing period. 11.1.8 Measurements Length and breadth of the flooring shall be m easured correct to a c m and area shall be c alculated in square m etres c orrect t o t wo pl aces of dec imal. Lengt h and br eadth s hall be m easured bef ore l aying skirting, dado or wall plaster. No deduction shall be m ade nor extra paid for voids not exceeding 0.20 sqm. D eduction f or ends of di ssimilar m aterials or ot her art icles em bedded s hall not be m ade f or area s not exceeding 0.10 sqm. Brick flooring when l aid in diagonal her ring bone bond or ot her pat tern as specified or di rected b y t he Engineer-in-Charge shall be measured separately. 11.1.9 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above, i ncluding application of c ement s lurry on base c oncrete or R CC s lab and c leaning of base. B ase concrete shall be paid for separately. 11.1.10 Dry Brick Flooring All pr ovisions of para’s 11.1.1 t o 1 1.1.8 w ill b e applicable except t hat bricks n eed not be soaked. Bricks will be laid on a bed of 12 mm thick mud mortar laid to required slope. The joints shall be as thin as possible and not exceeding 5 mm which will be filled with fine sand. No curing is to be done. 11.1.10.1 Rate: The rate shall include the cost of all materials and labour involved in all the operations described above. 11.2 CEMENT CONCRETE FLOORING 11.2.1 Cement Concrete Cement concrete of specified mix grade shall be used and it shall generally conform to the specifications described under sub head 4.0 . 11.2.2 Base Concrete 11.2.2.1 Flooring shall be laid on base concrete where so provided. The base concrete shall be provided with t he s lopes required f or t he f looring. F looring i n v erandah, C ourtyard, k itchens & bat hs s hall hav e slope ranging from 1 : 48 t o 1 : 60 depending upon l ocation and as decided by the E ngineer-in-Charge. Floors i n w ater c loset portion s hall hav e s lope of 1:30 or as decided by t he Engineer-in-Charge t o drain off washing water. Further, necessary drop in flooring in bath, WC, kitchen near floor traps ranging from 6 mm to 10 mm will also be provided to avoid spread of water. Necessary margin to accommodate this drop shall be made in base concrete. Plinth masonry off set shall be depressed so as to allow the base concrete to rest on it. 11.2.2.2 The flooring shall be commenced pr eferably within 48 hour s of the laying of bas e concrete. The surface of the base shall be roughened with steel wire br ushes without di sturbing t he concrete. Immediately before laying the flooring, the base shall be wetted and a coat of cement slurry @ 2 kg of cement spread over an area of one sqm so as to get a good bond between the base and concrete floor. 11.2.2.3 If the cement concrete flooring is to be laid directly on the RCC slab, the top surface of RCC slab shall be cleaned and the laitance shall be removed and a coat of cement slurry @ 2 kg of cement spread over an area of one sqm so as to get a good bond between the base and concrete floor.
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11.2.3 Thickness The thickness of floor shall be as specified in the description of the item. 11.2.4 Laying 11.2.4.1 Panels : Flooring of specified thickness shall be laid in the pattern including the border as given in the d rawings o r as d irected b y t he E ngineer-in-Charge. The bo rder panel s s hall not e xceed 450 mm in width and the joints in the border shall be in line with panel joints. The panels shall be of uniform size and no dimension of a panel shall exceed 2 m and the area of a panel shall not be more than 2 sqm. The joints of borders at corners shall be mitred for provision of strips. 11.2.4.2 Laying of Flooring with Strips : Normally cement concrete flooring s hall be laid in on e operation us ing gl ass/aluminium/PVC/brass s trips/stainless s teel s trips o r an y ot her strips as r equired as per drawing or instructions of the Engineer-in-Charge, a t the junction of t wo panels. This m ethod ensures uniformity in colour of all the panels and straightness at the junction of the panels. 2 m m PVC strips s hall be fixed w ith their tops a t proper l evel, gi ving requi red slopes. Cost of pr oviding an d f ixing strips shall be included in the rate. Concreting : Cement c oncrete s hall be placed i n t he panel s an d be l evelled w ith t he hel p of s traight edge and t rowel and beat en with thapy or mason’s trowel. The bl ows shall be f airly heavy in the beginning but as c onsolidation t akes pl ace, l ight r apid s trokes shall be given. B eating s hall c ease as soon as the surface is found covered with a thin layer of cream of mortar. The evenness of the surface shall be t ested with straight edge. Surface of f looring be t rue t o requ ired s lopes. While l aying concrete, care shall be taken to see that the strips are not damaged/disturbed by the labourers. The tops of strips shall be visible clearly after finishing with cement slurry. Shuttering : The panels shall be bound ed by angle iron or f lats. The angle iron/flat shall have the same depth a s th e co ncrete fl ooring. T hese sh all b e fi xed i n po sition, w ith th eir top a t pro per lev el gi ving required s lopes. The surface of the angle iron or flats, to come in contact with concrete shall be smeared with s oap s olution or non-sticking oi l (Form oi l or raw l inseed oil) bef ore c oncreting. T he flooring s hall butt against the unplastered masonry wall. Concreting : The c oncreting shall be done i n t he manner des cribed under 11. 2.4.2. The angl e i ron/ flats used for shuttering, shall be removed on the next day of the laying of cement concrete. The ends thus exposed shall be repaired, if damaged with cement mortar 1 : 2 (1 cement : 2 coarse sand) and allowed to set fo r minimum p eriod of 24 h ours. T he alternate p anels s hall t hen be c leaned of d ust, mortar, droppings etc. and concrete laid. While laying concrete, care shall be taken to see that the edges of the previously laid panels are not damaged and fresh mortar is not splashed over them. The joints between the panels should come out as fine straight lines. 11.2.5 Finishing 11.2.5.1 The finishing of the surface shall follow immediately after the cessation of beating. The surface shall be left for some time, till moisture disappears from it or surplus water can be mopped up. Use of dry cement or c ement a nd s and mixture stiffening the concrete t o a bsorb excessive moisture shall not be permitted. Excessive trowelling shall be avoided. 11.2.5.2 Fresh cement shall be mixed with water to form a thick slurry and spreaded @ 2 kg of cement over an area of one sqm of flooring while the flooring concrete is still green. The cement slurry shall then be properly processed and finished smooth.
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11.2.5.3 The edges of sunk floors shall be finished an d rounded with cement m ortar 1:2 (1 cement : 2 coarse sand) and finished with a floating coat of neat cement. 11.2.5.4 The junctions of floor with wall plaster, dado or skirting shall be rounded off where so specified. 11.2.5.5 The m en engag ed on f inishing o perations shall be pro vided with raised wooden platform to sit on so as to prevent damage to new work. 11.2.6 Curing The curing shall be done for a minimum period of ten days. Curing shall not be commenced until the top layer has hardened. Covering with empty gunnies bag shall be avoided as the colour of the flooring is likely to be bleached due to the remanents of cement dust from the bags. 11.2.7 Precautions Flooring in lavatories and bath room shall be laid only after fixing of water closet and squatting pans and floor traps. Traps shall be plugged while laying the floors and opened after the floors are cured and cleaned. A ny dam age d one t o W .C.’s s quatting pa ns and f loor t raps duri ng the ex ecution of work s hall be made good. During cold weather, concreting shall not be done when the temperature falls below 4°C. The concrete pl aced s hall b e protected aga inst f rost by s uitable c overing. C oncrete dam aged by f rost s hall be r emoved a nd w ork r edone. D uring h ot w eather, pr ecautions s hall b e t aken to s ee that t he temperature of wet c oncrete does not ex ceed 38° C. No concreting s hall be l aid within half an hour of the closing t ime o f the da y, unl ess per mitted b y t he Engineer-in-Charge. T o f acilitate rounding of j unction of s kirting, d ado a nd f loor, t he s kirting/dado s hall be l aid al ong w ith t he b order or adjacent p anels of floor. 11.2.8 Measurement Length and breadth shall be measured before laying skirting, dado or wall plaster. No deduction shall be made nor extra paid for voids not exceeding 0.20 sqm. Deductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 sqm. The f looring d one e ither with strips (i n one operation) or without s trips (i n al ternate pa nels) s hall b e treated as same and measured together. 11.2.9 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above i ncluding appl ication o f c ement s lurry on R CC slab o r on bas e c oncrete i ncluding roughening and cleaning t he s urface but excluding t he c ost of s trips w hich s hall be paid s eparately under r elevant i tem. Nosing of steps where provided shall be paid for separately in running metre. Nothing extra shall be paid for laying the floor at different levels in the same room or courtyard and rounding off edges of sunk floors. In case the flooring is laid in alternate panels, nothing extra shall be paid towards the cost of shuttering used for this purpose. 11.3 CEMENT CONCRETE FLOORING WITH METALLIC HARDENER TOPPING 11.3.0 Wherever floors a re required to withstand heavy wear and t ear, use of floor hardener shall be avoided a s f ar a s possible by u sing richer m ixes of c oncrete, unless t he use of a m etallic hardner i s justified on the basis of cost. Where metallic hardener topping is used, it shall be 12 mm thick. 11.3.1 Metallic Hardening Compound The c ompound s hall b e o f approv ed qu ality c onsisting of uni formally grad ed i ron pa rticles, f ree f rom non-ferrous metal particles, oil, grease sand, soluble alkaline compounds. Where so directed by the Engineer-in-Charge it shall be tested as described in Appendix A.
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11.3.2 Base Concrete It shall be as specified in 11.2.2. 11.3.3 Under Layer Cement concrete f looring of s pecified t hickness and m ix (m entioned i n i tem for under l ayer) s hall be laid as under la yer (11.2.1 an d 11.2.4). T he top surf ace sh all be ro ughened w ith bru shes w hile the concrete is still green and the forms/strips shall be kept projecting up 12 mm over the concrete surface, to receive the metallic hardening compound topping. 11.3.4 Topping This shall consist of 12 mm thick layer of mix 1:2 (1 cement : 2 s tone aggregate 6 mm nominal size) by volume or as otherwise specified with which metallic hardening compound is mixed in the ratio of 1 : 4 (1 m etallic c oncrete har dener : 4 c ement) b y w eight. M etallic harde ner s hall be dry m ixed t horoughly with c ement on a c lean dry pac ca platform. This dry m ixture s hall be m ixed with s tone aggregate 6 mm nominal size or as otherwise specified in the ratio of 1 : 2 (1 cement : 2 stone aggregate) and well turned over. Just enough water shall then be added to this dry mix as required for floor concrete. The m ixture so obtained shall b e l aid i n 1 2 m m t hickness, on cement c oncrete f loor within 2 t o 4 hours of its laying. The topping shall be laid true to provide a uniform and even surface. It shall be firmly pressed into the bottom concrete so as to ha ve go od bond w ith it. After the initial set has started, the surface shall be finished smooth and true to slope with steel floats. The junction of f loor w ith wall pl aster, dado or s kirting and f inishing operations shall be dealt w ith as described in 11.2.5. The men engaged on finishing operations shall be provided with raised wooden platform to sit on, so as to prevent damage to new work. 11.3.5 The specifications for curing, precautions to be t aken, ‘Measurements’ and ‘ Rates’ shall be a s specified in 11.2. 11.4 CEMENT PLASTER IN RISERS OF STEPS, SKIRTING, DADO 11.4.0 Plaster at the bottom of wall not exceeding 30 cm in height above the floor shall be c lassified as skirting. It shall be flush with wall plaster or projecting out uniformly by 6 mm from the wall plaster, as specified. T he w ork s hall be pr eferably carried out s imultaneously w ith t he l aying of f loor. I t’s c orners and junctions with floor shall be finished neatly as specified. 11.4.1 Thickness The thickness of the plaster specified shall be measured exclusive of the thickness of key i.e. grooves or open j oints i n b rick w ork. The av erage thickness s hall not be l ess t han t he specified t hickness. The av erage thickness s hould be r egulated at t he t ime of pl astering b y k eeping s uitable t hickness of t he gaug es. E xtra thickness required in rounding of corners at junctions of wall shall be ignored. 11.4.2 Preparation of Wall Surface The joints shall be raked out to a depth of at least 15 mm in masonry walls. In case of concrete walls, the surfaces shall be roughened by hacking. The surface shall be cleaned thoroughly, washed with water and kept wet before skirting is commenced. 11.4.3 Application Skirting with specified mortar and to specifed thickness shall be laid immediately after the surface is prepared. It shall be laid along with the border or adjacent panels of floor. The joints in skirting shall be kept true and straight in c ontinuation of the line of joints in borders or adjacent panels. The skirting shall be finished smooth with top truly horizontal and joints truly vertical except where otherwise indicated.
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11.4.4 Finishing The finishing o f surface s hall be don e s imultaneously with t he bor ders or the adjacent panel s o f floor. The cement to be applied in the form of slurry for smooth finishing shall be at the rate of 2 kg of cement per litre of water applied over an area of 1 sqm. Where skirting is flush with plaster, a groove 10 mm wide and upto 5 mm deep shall be provided in plaster at the junction of skirting with plaster. 11.4.5 Curing Curing shall be commenced on the next day of plastering when the plaster has hardened sufficiently and shall be continued for a minimum period of 7 days. 11.4.6 Measurement Length and height shall be measured correct to a cm and its area shall be calculated in sqm correct to two pl aces of dec imals for a s pecified the thickness. Length s hall be m easured as the f inished l ength of skirting. Height shall be measured from the finished level of floor correct to 5 mm. 11.4.7 Rate Rate shall include the cost of all materials and labour involved in all the operations described above. 11.5 CEMENT CONCRETE PAVEMENT IN COURTYARD AND TERRACE ETC. 11.5.1 Specifications described in 11.2.1, 11.2.2.1, 11.2.3, 11.2.4, 11.2.6 and 11.2.7 shall hold good as far as applicable except that : (i) The panels shall be of uniform size and no dimension of a panel shall exceed 1.25 m and the area of panel should not exceed 1.25 sqm for the thickness of panels upto 50 mm. (ii) Concreting shall be done in alternate panels only and no glass/asbestos strips shall be provided. 11.5.2 Finishing The finishing of the surface shall follow immediately after the cessation of beating. The surface shall be left for some-time, till moisture disappears from it or surplus water can be mopped up. Use o f dr y c ement or c ement a nd s and m ix on the s urface t o s tiffen the c oncrete or to abs orb excessive m oisture s hall not b e p ermitted. E xcessive t rowelling s hall be a voided. W hen t he s urface becomes fa irly s tiff, it s hall be f inished rough w ith w ooden floats or w here s o specified chequered uniformly by pressing a piece of expanded metal of approved size. 11.5.3 Measurements Same as 11.2.8 except that the volume will be calculated in cum nearest to two decimal places. 11.5.4 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above ex cept t he bas e c oncrete bel ow flooring w hich s hall be pai d for s eparately. C hequering to pat tern shall be paid for separately unless otherwise specified. 11.6 MARBLE CHIPS FLOORING: DELETED 11.7 MARBLE CHIPS SKIRTING: DELETED 11.8 WAX POLISHING 11.8.1 Application, Polishing and Precautions Wax polish shall be of approved brand and manufacture and in sealed containers. It shall be applied in uniform layer to the dry surface of the floor/skirting.
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11.8.2 When the layer of the wax is stiffened and surface o f floor is saturated with the polish, po lishing shall be resorted with machine fitted with bobs (pad of rags) and shall be done until shades of all chips have appeared and glossy surface is obtained. 11.8.3 The fresh p olished floor surface shall be spreaded with dr y saw du st to a thickness of ab out 12 mm u niformly. A fter th e surplus w ax h as b een s oaked f rom th e flo or s urface t he s aw du st s hall be removed. 11.8.4 Measurements Length and breadth shall be measured correct to a cm and its area shall be calculated in sqm correct to two places of decimal. 11.8.5 Rates The r ate shall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. 11.9 CRAZY MARBLE FLOORING 11.10 TERRAZO TILE FLOORING 11.10.1 Terrazo Tiles Terrazo tiles shall gener ally c onform to I S 123 7-Edition 2. 3. R equirements an d methods o f t esting o f tiles ar e de scribed i n A ppendix B . Unless ot herwise s pecified, th e til es s hall b e su pplied w ith i nitial grinding and grouting of wearing layer. The size of tiles shall be as given in Table 11.2 or as shown in the drawings or as required by the Engineer-in-Charge. Half tiles f or use with t he f ull tiles shall be such as t o m ake t wo half tiles when joined together, match with the dimensions of one full tile. TABLE 11.2 Le ngth
Bre a dth
Thickne s s not
Nomina l
Nomina l
less tha n
200 mm 250 mm 300 mm
200 mm 250 mm 300 mm
20 mm 22 mm 25 mm
11.10.1.1 Tolerance : Tolerances on length and breadth shall be plus or minus one millimetre, and tolerance on thickness shall be plus 5 mm. The variation of dimensions in any one delivery of tiles shall not exceed 1 mm on length and breadth and 3 mm on thickness. 11.10.1.2 The t iles s hall be m anufactured in a factory under pressure process s ubjected t o hy draulic pressure o f not less than 140 k g per s quare c entimetre and s hall be giv en the initial g rinding w ith machine and grouting of the wearing layer before delivery to site. T he w earing layer s hall b e free from projections, depressions, cracks, holes, cavities and other blemishes. The edges of wearing layer may be rounded. 11.10.1.3 The proportion of cement to aggregate in the backing of tiles shall be not leaner than 1:3 by weight. Where colouring material is used in the wearing layer, it shall not exceed 10 per cent by weight of cement used in the mix. 11.10.1.4 The finished thickness of the upper layer shall not be l ess than 5 mm for size of marble chips ranging from the smallest upto 6 mm and also, not less than 5 mm for size of marble chips ranging from the smallest upto 12 mm, and not less than 6 mm for size of marble chips varying from the smallest upto 20 mm.
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11.10.2 Laying 11.10.2.1 Base concrete or RCC slab on which the tiles are to be laid shall be cleaned, wetted and mopped. The b edding f or t he t iles s hall be w ith c ement mortar o f s pecified proportion and i n c onformity with provisions in relevant para of chapter on ‘Mortar’. Cement mortar 1:4 (1 Cement : 4 c oarse s and) b edding shall b e used. A verage thickness of t he bedding mortar shall be 20 mm and the thickness at any place shall not be less than 10 mm. 11.10.2.2 Cement mortar bedding shall be spread, tamped and corrected to proper levels and allowed to harden for a day before the tiles are set. If cement mortar is laid in bedding the terrazo tiles, these shall be set immediately after laying the mortar. Over this bedding neat grey cement slurry of honey like consistency shall be spread at the rate of 4.4 kg of c ement per square metre over such an area as would accommodate about t wenty tiles. T iles s hall be washed c lean and s hall be f ixed in t his grout one after another, eac h tile being gent ly t apped with a wooden mallet till i t is properly b edded, and i n l evel with the adjoining tiles. The joints shall be k ept as thin as possible not exceeding 1 mm and i n straight lines or to suit the required pat tern. T he joints shall be p roperly c leaned before filling with cement g rout of matching colour. 11.10.2.3 The surface of the flooring during laying shall be f requently checked with a s traight edge of length at least 2 metre, so as to obtain a true surface with the required slope. 11.10.2.4 Where full tiles or half tiles can not be fixed, tiles shall be cut (sawn) from full tiles to the required size and their edges rubbed smooth to ensure a straight and true joint. 11.10.2.5 Tiles which are fixed in the floor adjoining the wall shall enter not less than 12 m m under t he plaster, s kirting o r d ado. T he j unction between w all pl aster a nd t ile w ork shall be f inished n eatly a nd without waviness. 11.10.2.6 After the tiles have been laid, surplus cement grout that may have come out of the joints shall be cleared off. 11.10.3 Curing, Wax Polishing and Finishing 11.10.3.1 The day after the tiles are l aid all joints shall be c leaned of the grey cement grout with a w ire brush or trowel t o a depth of 5 mm and all dust and loose mortar removed and cleaned. Joints shall then be grouted with grey or w hite cement mixed with or without pigment to match the shape of t he topping of the wearing l ayer of t he tiles. The same cement slurry s hall be applied to the entire surface of the tiles in a thin coat with a view to protect the surface from a brasive damage and f ill the pin ho les that may exist on the surface. 11.10.3.2 The floor shall then be kept wet for a minimum period of 7 days. The surface shall thereafter be gr ounded e venly with m achine fitt ed w ith c oarse gr ade grit b lock (N o. 60). W ater s hall be u sed profusely d uring gr inding. A fter grinding t he s urface s hall be t horoughly w ashed t o r emove a ll gr inding mud, cleaned and mopped. It shall then be covered with a thin coat of grey or white cement, mixed with or without pigment to match the colour of the topping of the wearing surface in order to fill any pin hole that appear. The s urface shall be again c ured. The second gr inding s hall then be c arried ou t w ith machine fitted with fine grade grit block (No. 120). 11.10.3.3 The final grinding with machine fitted with the finest grade grit blocks (No. 320) shall be carried out the day after the second grinding described in the preceding para or before handing over the floor, as ordered b y t he Engineer-in-Charge. Wax pol ish s hall be of approv ed brand and m anufacture and i n sealed containers. It shall be applied in uniform layer to the dry surface of the floor. When the layer of the
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wax is stiffened and surface of floor is saturated with the polish, polishing shall be resorted with machine fitted with bobs (pad of rags) and shall be done until shades of all chips have appeared and glossy surface is obtained. The fresh polished floor surface shall be spreaded with dry saw dust to a thickness of about 12 mm uniformly. After the surplus wax has been soaked from the floor surface the saw dust shall be removed. 11.10.3.4 For small areas or w here circumstances so require, hand grinding/polishing with hand grinder may be per mitted i n l ieu o f machine pol ishing a fter laying. F or hand pol ishing t he following carborundum stones, shall be used: 1st grinding
—
coarse grade stone (No. 60)
Second grinding
—
medium grade (No. 80)
Final grinding
—
fine grade (No. 120)
In all other respects, the process shall be similar as for machine polishing. 11.10.3.5 After the final polish, oxalic acid shall be dusted over the surface at the rate of 33 gm per square m etre s prinkled w ith w ater and r ubbed har d w ith a ‘namdah’ bl ock (pad of w oollen r ags). T he following day t he f loor s hall be wiped with a m oist r ag an d dr ied with a s oft c loth an d f inished c lean. Wax polishing to be done as given at 11.10.2.3 11.10.3.6 If any tile is disturbed or damaged, it shall be r efitted or replaced, properly jointed and polished. 11.10.4 Measurements 11.10.4.1 Terrazo tiles flooring with tiles manufactured from ordinary grey cement without pigment and coloured t errazo t ile f looring s hall be m easured s eparately ac cording t o par a 11. 6.5 T errazo t ile f looring shall be m easured as l aid i n s quare metre c orrect t o t wo p laces of de cimal. F or length an d breadth dimensions c orrect t o a cm before l aying s kirting, dado or w all pl aster shall be t aken. N o deduc tion shall be made nor extra paid for voids not exceeding 0.20 sqm. Deductions for ends of dissimilar materials or other articles em bedded shall not be m ade f or areas not ex ceeding 0. 10 s quare m etre. N othing ex tra shall be paid for use of cut tiles nor for laying the floor at different levels in the same room or courtyard. 11.10.4.2 Terrazo tile flooring laid in floor borders and similar band shall be measured under the item of terrazo tile flooring. Nothing extra shall be paid in respect of these and similar bands formed of half size or multiplies of half size standard tiles or other uncut tiles. 11.10.4.3 Treads of stairs a nd steps pa ved with tiles without nosing, s hall also be m easured und er flooring. Moulded nosing shall be paid in running metre except where otherwise stated, returned moulded ends and angl es t o m ouldings s hall be i ncluded i n t he des cription. E xtra s hall, how ever, be paid for such areas where the width of treads does not exceed 30 cm. 11.10.5 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. W here cement m ortar bed ding i s u sed i n p lace of l ime m ortar t he r ate w ill b e ad justed accordingly. 11.11 TERRAZO TILES IN RISERS OF STEPS, SKIRTING AND DADO 11.11.1 The terrazo tiles shall be as specified in 11.10.1, as far as applicable. The m inimum finished thickness of tiles shall, however, be 12 mm. The finished thickness of the upper layer shall be not less than 5 mm for size of marble chips from the smallest upto 12 mm and not less than 6 mm for size of chips varying from the s mallest upto 20 mm. Where the bigger sized chips are used the tiles shall be not less than 20 mm thick. The requirements of transverse strength tests specified in Appendix B, shall not apply when the tiles used are less than 20 mm thick.
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11.11.2 Preparation of Surface The specification for this shall be same as specified in 11.4.2. 11.11.3 Laying 12 mm thick plaster of cement mortar 1:3 (1 c ement : 3 c oarse sand) or m ix as specified, shall then be ap plied and allowed to ha rden. T he pl aster shall then b e roughened with wire brushes or by scratching di agonal l ines 2 mm deep at appr oximately 7. 5 c m centres bot h w ays. The bac k o f tiles s hall be buttered with a c oat of grey cement slurry and edges with grey or w hite cement slurry with or w ithout pigments to match the shade of tiles, and s et in the bedding mortar. These shall be t amped an d corrected t o proper pl anes and l ines. T he t iles s hall be s et i n t he requi red p attern and but t j ointed. T he joints shall be as fine as possible. Top of skirting or dado s hall be t ruly horizontal with projection from finish wall surface not more than tile thickness and joints truly vertical except where otherwise indicated. The risers of steps, skirting or dado shall rest on the top of the tread or flooring. Where full size tiles cannot be fixed, the tiles shall be cut (sawn) to the required size and their edges rubbed smooth. 11.11.4 Curing, Polishing and Finishing The specifications as in 11.10.3 shall hold good as far as applicable. Wax Polishing shall be done only with hand. 11.11.5 Measurements The thickness of the skirting shall be as stated. Le ngth shall be measured along the finished face of riser, skirting or dado correct to a cm. Height shall be measured from the finished level of tread or floor to the top (the underside of tread in the case of steps). This shall be m easured correct to 5 m m in case of risers and skirting (not exceeding 30 cm in height). In case of heights more than 30 cm, as in the case of d ado an d o n w alls, the h eight s hall be m easured c orrect to a c m and s uch w ork s hall be paid for separately. The area shall be calculated in square metre, correct to two places of decimal. Where the height of risers, skirting or dado does not admit of full size or other finished size tiles and the tiles are to be cut (sawn), nothing extra shall be paid for the same. 11.11.6 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. Nothing extra shall be payable for use of cut (sawn) tiles to suit the size of risers, skirting, portions of dado etc. 11.12 CHEQUERED TILE FLOORING 11.12.1 Chequered Tiles The tiles shall be of nominal sizes such as 20 × 20 cm, 25 × 25 cm and 30 × 30 cm or of standard sizes with eq ual sides. The size of tiles to be used shall be a s shown in dra wings or a s required by the Engineer-in-Charge. T he centre t o c entre di stance of c hequers s hall not be l ess t han 2. 5 c m and not more than 5 cm. The overall thickness of the tiles shall not be less than 30 mm. The grooves in the chequers shall be uniform and s traight. The depth of the grooves shall not be less than 3 mm. The chequered t iles shall be cement tiles, or terrazo tiles as specified in the description of the item. The thickness of the upper layer, measured from the top of the chequers shall not be less than 6 mm. The terrazo tiles shall be given the first grinding with machine before delivery to site. The t iles s hall c onform t o t he s pecifications for pl ain c ement c oncrete or t errazo t iles i n respect of method of manufacture and the mix of the backing and wearing layers.
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11.12.2 Laying, curing, Polishing and F inishing shall be as specified in 11.10.2 and 11. 10.3 e xcept that wax polishing will not be done and the polishing of the tiles and the chequer grooves, after laying, may be done by hand. Special care shall be t aken to pol ish t he grooves i n s uch a manner as t o get a uni form section and t hat their finish shall match with the finish of flat portion of the tiles. Cement concrete tiles normally d o n ot re quire po lishing but w here polishing is r equired t he s ame s hall be done as des cribed above. 11.12.3 Measurement and Rate: Shall be as specified in 11.10.4 and 11.10.5. 11.13 CHEQUERED TILES IN STAIR TREADS (FIG. 11.2) 11.13.1 Chequered Tiles The specifications for tiles shall be as specified in 11.12.1 except in the following respects : (1) The length of the tiles including nosing shall be as specified. (2) The nosing edge of the tile shall be rounded. (3) The minimum thickness of the tile shall be 30 mm. (4) The front portion of the tile for a minimum length of 75 mm from and including the nosing shall have grooves running parallel to the nosing and at centres not exceeding 25 mm. Beyond that the tiles shall have the normal chequer pattern. (5) The nosing shall also have the same wearing layer as the top. 11.13.2 Preparation of Surface and Laying 11.13.2.1 RCC or brick work in treads on which the tiles are to be laid shall be cleaned wetted an d mopped. The beddi ng for tiles s hall be with cement m ortar 1: 4 (1 cement : 4 coarse sand) or of specified mix. T he m inimum thickness of bedding m ortar at an y pl ace shall be 10 m m. B edding mortar shall be spread, t amped a nd c orrected t o pro per l evels. A fter l aying bedding m ortar, neat grey cement slurry of honey like consistency shall be spread over the mortar at the rate of 4.4 kg of cement per square metre over each t read. T iles shall b e washed cleaned a nd s hall b e f ixed i n t his gr out b utting one at another. Each tile being gently tapped with a wooden mallet till it is properly bedded, and is in level and line with the adjoining t iles. T he j oints s hall be k ept as t hin a s pos sible an d i n s traight lines. The surface s hall b e checked with a straight edge during laying to obtain a true surface. 11.13.2.2 The square end of the tile shall, as far as possible butt against the riser face of the concrete or brick tread and in any case shall be embedded under the side wall plaster, skirting or dado and under the riser tile or other finish to a depth of not less than 10 mm. 11.13.2.3 Where full size tiles cannot be f ixed, these shall be c ut (sawn) to the required size (along the groove of t he c hequers where t he c ut ed ge i s e xposed) a nd used. T he c ut i n t he c ase of em bedded edges w ill be n eat a nd true w hile t he cut i n t he case of exposed e dges shall i n addition b e r ubbed smooth to ensure a straight and true joints. 11.13.2.4 After the tiles have been laid surplus cement grout shall be cleaned off. 11.13.3 Curing, Polishing and Finishing The s pecifications s hall be as des cribed i n 11. 12.2 except t hat pol ishing of t he t reads nos ing an d chequered gro oves, af ter l aying, m ay be don e by h and i n t he s ame m anner as s pecified un der t errazo tile flooring. Special care shall be taken to polish the nosing and the grooves in such a manner as to get a uniform, section for the grooves and the nosing and their finish shall match with the finish of the flat portion of the tiles.
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11.13.4 Measurements Chequred tiles on stair treads shall be measured in square metre correct to two places of decimal. Length shall b e m easured correct t o a cm b efore laying skirting, d ado or w all pl aster. Width s hall be measured correct to a c m from the outer edge of the nosing, as laid, before providing the riser. In the case of the edge tiles of the landing and wide steps, width shall be measured upto the near edge of the chequered s tair t read t iles. D eductions f or ends of di ssimilar m aterials or o ther art icles em bedded shall not be made for areas not exceeding 0.10 square metre. 11.13.5 Rate The r ate s hall i nclude t he cost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. Nothing extra shall be payable for cutting the tiles to suit the size of treads and also for nosing. 11.14 ACID OR ALKALI RESISTANT TILES : DELETED 11.15 CERAMIC TILE FLOORING 11.15.1 Ceramic Tiles The tiles shall be of approved make and shall generally conform to IS 15622. They shall be flat, and true to s hape and f ree f rom b listers c razing, chips, welts, c rawling or ot her i mperfections det racting f rom their app earance. The tiles shall be t ested as pe r IS 13630. Classification an d C haracteristics of pr essed ceramic tiles shall be as per IS 13712. The tiles s hall be square o r rectangular of nominal size. T able 1,3,5, and 7 of IS 15622 give t he modular p referred s izes an d table 2, 4,6 an d 8 give the most c ommon no n modular s izes. T hickness shall be specified by the manufacturer. It includes the profiles on the visible face and on the rear side. Manufacturer/supplier and party s hall choose the w ork size o f t iles i n or der to al low a no minal joint w idth upto 2mm for unrectified floor tiles and upto 1mm for rectified floor tiles. The joint in case of spacer lug tile shall be as per s pacer. The tiles shall conform to table10 of IS 15 622 with water absorption 3 t o 6% (Group BII). The t op s urface of the tiles s hall be gl azed. Glaze s hall be e ither gl ossy or m att as s pecified. T he underside of the tiles shall not have glaze on m ore than 5% of the area i n order that the tile may adhere properly to the base. The edges of the tiles shall be pr eferably free from glaze. However, any glaze if unavoidable, shall be permissible on only upto 50 per cent of the surface area of the edges. 11.15.2 Coloured Tiles Only the glaze shall be coloured as specified. The sizes and specifications shall be the same as for the white glazed tiles. 11.15.3 Decorative Tiles The type and size of the decorative tiles shall be as follows : (i) Decorated white back ground tiles The size of these tiles shall be as per IS 15622. (ii) Decorated a nd h aving c oloured back-ground The sizes of the tiles shall be as per IS 15622. 11.15.4 Preparation of Surface and Laying 11.15.4.1 Base concrete or t he RCC slab on w hich the tiles are t o be l aid shall be c leaned, wetted and mopped. The bedding for the tile shall be with cement mortar 1:4 (1 cement : 4 coarse sand) or as specified. T he av erage thickness o f the bedd ing s hall be 20 m m or as s pecified while the thickness under any portion of the tiles shall not be less than 10 mm.
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11.15.4.2 Mortar shall be s pread, tamped and corrected to proper levels and al lowed to harden sufficiently to offer a f airly rigid cushion for the tiles to be s et and t o e nable the mason to place wooden plank across and squat on it. 11.15.4.3 Over this mortar bedding neat grey cement slurry of honey like consistency shall be spread at the rat e of 3.3 kg of ce ment per square m etre ove r an are a upto one square m etre. T iles sh all be soaked in w ater w ashed clean and shall be fixed i n this grout one after another, each tile gently being tapped with a wooden mallet till it is properly bedded and in level with the adjoining tiles. The joints shall be kept as thin as possible and in straight lines or to suit the required pattern. 11.15.4.4 The surface of the flooring during laying shall be frequently checked with a straight edge about 2 m long, so a s to o btain a t rue surface with the required slope. In bath, toilet W.C. kitchen a nd balcony/verandah flooring, s uitable t ile drop or as shown i n d rawing w ill b e g iven i n addi tion t o required slope to avoid spread of water. Further tile drop will also be provided near floor trap. 11.15.4.5 Where full size tiles cannot be fixed these shall be cut (sawn) to the required size, and their edge rubbed smooth to ensure straight and true joints. Tiles which are f ixed in the floor adjoining the wall shall enter not less than 10 mm under the plaster, skirting or dado. 11.15.4.6 After tiles have been laid surplus cement slurry shall be cleaned off. 11.15.5 Pointing and Finishing The joints shall be c leaned off the grey cement slurry with wire/coir brush or trowel to a depth of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush pointed with white cement added w ith pigment i f required t o match t he c olour of t iles. W here s pacer l ug t iles are provided, t he half the dept h of j oint s hall be f illed w ith pol ysulphide or as specified on t op w ith under f illing w ith c ement grout w ithout the l ugs re maining ex posed. T he f loor s hall t hen be k ept wet for 7 day s. After curing, t he surface s hall be w ashed and f inished clean. T he f inished f loor s hall not s ound hol low w hen t apped w ith a wooden mallet. 11.15.6 Measurements Length and breadth shall be measured correct to a cm before laying skirting, dado or wall plaster and the area ca lculated i n s quare m etre correct to t wo places of d ecimal. W here co ves ar e us ed a t th e junctions, the length and breadth shall be measured between the lower edges of the coves. No de duction s hall b e m ade n or ex tra p aid for v oids not e xceeding 0. 20 square m etre. D eductions for ends of dissimilar materials or other articles embedded shall not be made for areas not exceeding 0.10 square metre. 1.15.7 Rate The rate for flooring shall include the cost of all materials and l abour involved in all the operations described a bove, Nothing extra s hall be paid for t he us e of c ut ( sawn) tiles i n the work. R ate s hall include colour tiles. 11.16 VITRIFIED TILE FLOORING 11.16.1 Operations as de scribed i n 1 1.15.1 t o 11 .15.6 s hall be f ollowed ex cept t he t iles s hall c onform t o Table 12 of I S 1 5622 ( Tiles w ith water abs orption E ≤ 0.08 per c ent G roup BIa) and t he j oint t hickness i n flooring shall not be more than 1mm. 11.16.2 Rate The rate for flooring shall include the cost of all materials and labour involved in all the operations described above. Nothing extra shall be paid for the use of cut (sawn) tiles in the work.
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11.17 FIXING OF TILE FLOORING WITH CEMENT BASED HIGH POLYMER MODIFIED QUICK SET ADHESIVE (WATER BASED) 11.17.1 When tile flooring is to be laid over the existing flooring without dismantling old flooring it can be laid with a dhesive. T he ol d f looring s hall be t horoughly cleaned an d c hecked f or undu lations, if an y s hall be rectified with cement mortar 1:3 (1 cement: 3 coarse sand). Old cement concrete surface shall be hacked and cleaned off to have proper bond with the old surface. 11.17.2 High pol ymer m odified qui ck s et t ile adhes ive ( conforming t o I S 15477) shall be t horoughly mixed with water and a paste of zero slump s hall be prepared s o t hat i t can b e used with i n 1.5 t o 2 hours. It s hall b e s pread ove r a n ar ea not m ore than o ne sqm a t o ne ti me. Average thi ckness of adhesive s hall be 3 m m The a dhesive s o s preaded shall be c ombed us ing s uitable t rowel. T iles s hall be pressed f irmly i n to the position with slight twisting action checking i t s imultaneously t o ens ure go od contact gently being tapped with wooden mallet till it is properly backed with adjoining tiles. The tiles shall be fixed within 20 minutes of application of adhesive. The surplus adhesive from the joints, surface of the tiles shall be immediately cleaned. 11.17.3 The surface of the flooring shall be frequently checked during laying with straight edge of above 2m long so as to attain a true surface with required slope. 11.17.4 Where spacer lugs tiles are provided these shall be filled with grout with lugs remaining exposed. 11.17.5 Where f ull s ize tile c an not be f ixed t hese s hall be cut (s awn) t o t he required size and edges rubbed smooth to ensure straight and true joints. Tiles which are fixed in floor adjoining to wall shall enter not less than 10 mm under plaster, skirting or dado. 11.17.6 Finishing: para 11.15.5 shall apply. 11.17.7 Measurements: para 11.15.6 shall apply. 11.17.8 Rate Provisions of para 11.15.7 and 11.16.2 shall apply. 11.18 CERAMIC/VITRIFIED TILES IN SKIRTING AND DADO 11.18.1 The tiles s hall be o f appr oved make and s hall gener ally c onform to IS 15622. The t iles shall be pressed ceramic covered by a glaze thoroughly matured and fitted to the body. The tiles shall be sound, true to shape, flat and free from flaws and other manufacturing defects affecting their utility. The top surface of the tiles shall be glazed. The underside of the tiles shall not have glaze on more than 5% of the area in order that the tile may adhere properly to the base. The edges of the tiles shall be free from glaze, however, any glaze if unavoidable shall be permissible on only upto 50 per cent of the surface area of edges. The glaze shall be free from welts, chips, craze, specks, crawlings or other imperfections detracting from the a ppearance when viewed f rom a di stance of one m etre. T he gl aze s hall be e ither glossy or m att as specified. T he glaze shall be white in c olour ex cept i n t he c ase of c oloured tiles when c olours s hall b e specified by the Engineer-in-Charge. There may be more than one colour on a tile. 11.18.1 (a) Dimensions and Tolerances Glazed pressed c ramic tiles s hall be made s quare or rectangular in sizes T able 1, 3, 5 & 7 of IS 15622 give the modular sizes and table 2, 4, 6 & 8 of IS 15622 gives the sizes of non modular tiles. The tiles shall conform to IS 15622 for dimensional tolerance, physical and chemical properties. Half t iles f or us e as full t iles s hall ha ve dimensions which s hall be s uch as t o make t he hal f t iles when jointed t ogether ( with 1 m m j oint) m atch with dimensions of f ull t iles. T iles m ay be m anufactured i n s izes other than those specified. above. The thickness of the tiles shall be 5 mm or 6 mm or as specified.
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The dimensions of f ittings as sociated with th e g lazed til es namely c over base, r ound edge ti le, angles corner cups, ridge and legs, cronices and capping beads shall be of the shape and dimensions as required and the thickness of fittings shall be the same as the thickness of tiles given above. 11.18.2 Preparation of Surfaces The joints shall be raked out to a depth of at least 15 mm in masonry walls. In case o f c oncrete walls, t he s urface shall be hac ked and roughened with w ire br ushes. The surface shall be cleaned thoroughly, washed with water and kept wet before skirting is commenced. 11.18.3 Laying 12 m m t hick pl aster of cement m ortar 1: 3 (1 c ement : 3 c oarse s and) m ix of as s pecified s hall be applied and allowed to h arden. T he pl aster s hall be roughened with wire brushes or b y s cratching diagonal at closed intervals. The tiles should be soaked in w ater, washed c lean, and a coat of c ement slurry applied liberally at the back of tiles and set in the be dding mortar. The tiles shall be tamped an d corrected to pr oper plane and lines. The t iles shall be s et in the required pattern and j ointed. The joints shall be as fine as possible. Top of s kirting or dado s hall be truly horizontal and j oints t ruly v ertical ex cept w here otherwise indicated. O dd si ze/cut size of ti le shall b e adjusted at b ottom to take c are of slope of the fl ooring. Skirting and da do shall rest on t he top of the flooring. Where full size tiles cannot be f ixed these shall be cut (s awn) t o t he required s ize and t heir edges rubbed s mooth. S kirting / dado s hall not proj ect from t he finished “surface of wall” by more than the tile thickness, undulations if any shall be adjusted in wall. 11.18.4 Curing and Finishing The joints shall be c leaned off the grey cement grout with wire/coir brush or trowel to a depth of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush pointed with white cement added with pigments if required to match the colour of tiles. The work shall then be kept wet for 7 days. After cur ing, th e surface sha ll be washed and f inished clean. The f inished w ork s hall n ot s ound hollow when tapped with a wooden mallet. 11.18.5 Measurements Length shall be measured correct to a cm. Height shall be measured correct to a cm in the case of dado and 5 m m in the case of riser and skirting. The area s hall be c alculated in square metre, correct to two pl aces of dec imal. L ength and hei ght s hall be m easured al ong t he finished f ace of the s kirting o r dado including c urves where s pecials s uch as coves, i nternal and external angles and beads are us ed. Where cornices are used the area of dado shall be measured excluding the cornices. Nothing extra will be paid for cutting (sawn) the tiles to sizes. 11.18.6 Rates The rate s hall i nclude t he cost o f all material a nd l abour i nvolved i n all t he operations described above. The rat e s hall not i nclude c ost of c ornices w hich shall b e m easured and pai d f or i n ru nning meters separately. 11.19 MARBLE STONE FLOORING 11.19.1 Marble Stone It shall be as specified in sub head 8.0. 11.19.2 Dressing of Slabs Every stone shall be c ut to the required size and s hape, fine chisel dressed on al l sides to the full depth so that a straight edge laid along the side of the stone shall be fully in contact with it. The top surface s hall a lso b e f ine c hisel dr essed t o r emove a ll waviness. I n c ase machine c ut slabs are u sed, fine c hiesel dres sing of m achine c ut s urface ne ed not be done prov ided a s traight edge l aid any w here along t he m achine cut s urfaces i s i n contact with every point on it. T he sides and top s urface of slabs shall be m achine r ubbed o r t able r ubbed w ith c oarse s and b efore paving. A ll an gles and e dges o f t he marble slabs shall be true, square and free from chippings and the surface shall be true and plane.
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The t hickness of th e slabs shall be 1 8, 30 or 4 0 m m a s specified i n t he description of th e i tem. Tolerance of + 3% shall be allowed for the thickness. In respect of length and breadth of slabs a tolerance of + 2% shall be allowed. 11.19.3 Laying 11.19.3.1 Base concrete or the RCC slab on which the slabs are to be l aid shall be c leaned, wetted and mopped. The bedding for the slabs shall be with cement m ortar 1:4 (1 cement : 4 c oarse sand) o r a s given in the description of the item. 11.19.3.2 The average thickness of the bedding mortar under the slab shall be 20 mm and the thickness at any place under the slab shall be not less than 12 mm. 11.19.3.3 The slabs shall be laid in the following manner: Mortar of th e s pecified mix s hall b e sp read u nder th e ar ea of e ach sl ab, rou ghly to t he average thickness s pecified in the item. T he s lab s hall be w ashed clean bef ore laying. It s hall be laid on top, pressed, t apped with wooden m allet a nd br ought t o l evel with t he a djoining s labs. I t s hall be l ifted an d laid a side. The top surface of the mortar shall then be c orrected by adding fresh mortar at hollows. The mortar is al lowed to h arden a bi t an d c ement s lurry of ho ney like c onsistency shall be s pread ov er t he same at the rate of 4.4 kg of cement per sqm. The edges of the slab already paved shall be but tered with grey or white cement with or without admixture of pigment to match the shade of the marble slabs as given in the description of the item. The slab to be paved shall then be lowered gently back in position and tapped with wooden mallet till it is properly bedded in level with and close to the adjoining slabs with as fine a joint as possible. Subsequent s labs s hall b e l aid in t he same m anner. A fter e ach s lab h as b een l aid, surplus c ement o n the surface of the slabs shall be cleaned off. The flooring shall be cured for a minimum per iod of seven days. The surface of the flooring a s laid shall b e true to levels, an d, slopes a s instructed b y the Engineer-in-Charge. Joint thickness shall not be more than 1 mm. Due car e sh all b e tak en to m atch the g rains o f sl abs which s hall be s elected ju diciously ha ving uniform pattern of Veins/streaks or as directed by the Engineer-in-Charge. 11.19.3.4 The slabs shall be matched as shown in drawings or as instructed by the Engineer-in-Charge. 11.19.3.5 Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the plaster s kirting or d ado. The j unction bet ween w all plaster and f loor s hall be finished n eatly a nd w ithout waviness. 11.19.3.6 Marble slabs flooring shall also be laid in combination with other stones and/or in simple regular pattern/design as described in item of work and/or drawing. 11.19.4 Polishing and Finishing Slight unev enness a t the m eeting edges o f slabs s hall then be rem oved by f ine c hiselling and finished i n t he s ame m anner as specified i n 11.10.3 ex cept t hat hi gh g loss mirror f inish po lish shall be done. Cement slurry with or without pigments shall not be applied on the surface before each polishing. 11.19.5 Measurements Marble stone f looring with di fferent k ind of m arble s hall be m easured s eparately and in s quare m etre correct t o t wo p laces of decimal. Length a nd breadth s hall b e m easured c orrect t o a cm before l aying skirting, dado or wall plaster. No deduction shall be m ade nor extra paid for voids not exceeding 0.20 square metre. Deductions for ends of dissimilar materials or other articles embedded shall not be made
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for areas not exceeding 0.10 square m etre. Nothing extra shall be pai d for laying the floor at different levels in the same room. Steps and t reads of stairs paved with marble stone slabs shall also b e measured under t he i tem of M arble Stone f looring. E xtra shall, ho wever, be paid f or s uch are as where the width of treads does not exceed 30 cm. Nosing for treads shall be measured in running metre and paid for extra. The width of treads shall be measured from the outer edge of the nosing, as laid, before providing the riser. 11.19.6 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. However, extra shall be paid for making special type of pattern/design/flowers as per drawings. No deductions shall be made in rate even if flooring is done without any pattern/design. 11.20 MARBLE STONE IN RISERS OF STEPS AND SKIRTING 11.20.1 Marble Stone Slabs and Dressing of Slabs shall be as specified in 11.19.1 and 11.19.2 except that the thickness of slabs shall be 18 mm. A tolerance of + 3% mm shall be allowed, unless otherwise specified in the description of the item. 11.20.2 Preparation of Surface It s hall be a s s pecified i n 11. 18.2 w here n ecessary, t he w all s urface s hall be c ut uni formly t o t he requisite depth so that the skirting face shall have the projection from the finished face of wall as shown in drawings or as required by the Engineer-in-Charge. In no case the skirting should project by more than thickness of stone. 11.20.3 Laying The risers of steps and skirting shall be in grey or white cement admixed with or without pigment to match the shade of the stone, as specified in the description of the item, with the line of the slab at such a distance from the wall that the average width of the gap shall be 12 mm and at no place the width shall be less than 10 mm, if necessary, the slabs shall be held in position by temporary M.S. hooks fixed into the wall at suitable intervals. The skirting or riser face shall be checked for plane and plumb and corrected. The joints shall thus be l eft to harden then the rear of the skirting or riser slab s hall be packed with cement m ortar 1: 3 (1 cement : 3 c oarse s and) or other m ix as specified in the d escription of the item. The fixing hooks shall be removed after the mortar filling the gap has acquired sufficient strength. The joints s hall b e as fine as p ossible but n ot m ore than 1 m m. T he top line of s kirting an d risers shall be truly horizontal and joints truly vertical, except where otherwise indicated. The risers and skirting slab shall be matched as shown in drawings or as instructed by the EngineerinCharge. 11.20.4 Curing, Polishing and Finishing It sha ll be a s sp ecified i n 11. 19.4 as f ar as a pplicable, e xcept t hat c ement slu rry w ith o r without pigment shall not be applied on the surface and polishing shall be done only with hand. The face and top of skirting shall be polished. 11.20.5 Measurements Length shall be m easured along the finished face of riser or s kirting, correct to a c m. Height shall be measured from the finished l evel of tread or floor, to the top (the under side of tread, i n t he case of steps) correct to 0.5 cm. The areas shall be calculated in square metre correct to two places of decimal. Dado and lining of pillars etc. shall b e m easured as ‘Marble w ork i n w all lining. If the t hickness i s upto 25 mm or as “Marble Work” in Jambs, walls, columns and other plain work’ if the thickness is more.
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11.20.6 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all the o perations d escribed above. 11.21 KOTA STONE FLOORING 11.21.1 Kota Stone Slabs The s labs s hall be of s elected qual ity, har d, s ound, dens e and hom ogeneous i n t exture f ree from cracks, dec ay, w eathering and flaws. They s hall be hand or machine cut t o t he requisite t hickness. They shall be of the colour indicated in the drawings or as instructed by the Engineer-in-Charge. The s labs s hall hav e t he t op (ex posed) f ace pol ished bef ore bei ng br ought t o s ite, unl ess ot herwise specified. The slabs shall conform to the size required. Before starting the work the contractor shall get the samples of slabs approved by the Engineer-in-Charge. 11.21.2 Dressing Every s lab s hall be cut to t he required s ize and s hape and fine c hisel dr essed on the s ides to the full depth so that a straight edge laid along the side of the stone shall be in full contact with it. The sides (edges) s hall be t able rubbed w ith c oarse s and or machine rubbed bef ore paving. A ll angl es and edg es of the slabs shall be true, square and free from chippings and the surface shall be true and plane. The t hickness of t he slab af ter i t i s dr essed s hall b e 20, 2 5MM o r as specified i n t he description of the item. Tolerance of ±2 mm shall be allowed for the thickness. In respect of length and breadth of slabs Tolerance of ± 5 mm for hand cut slabs and ± 2 m m for m achine cut slabs shall be allowed. 11.21.3 Preparation of Surface and Laying The s pecification s hall be as des cribed i n 11. 19.3 except t hat t he edges of the s labs t o be jointed shall be buttered with gr ey c ement, w ith a dmixture of p igment to match t he s hade o f th e sla b. T he thickness of the joints should be minimum as possible. In any location, it shall not exceed 1 mm. 11.21.4 Polishing and Finishing The s pecifications s hall be as d escribed in 11.10.3 ex cept t hat ( a) f irst p olishing with coarse g rade carborundum stone shall not be done, (b) cement slurry with or without pigment shall not be applied on the surface before polishing. 11.21.5 Measurements and Rates These shall be as described in paras 11.19.5 and 11.19.6. 11.22 KOTA STONE IN RISERS OF STEPS, SKIRTING AND DADO 11.22.1 Kota Stone Slabs a nd D ressing s hall be as specified i n 11.21.1 a nd 11.21.2 except that the thickness of the slabs shall be 25 m m or as specified in the description of the item. The slabs may be o f uniform size if required. 11.22.2 Preparation of surface shall be as specified in 11.20.3. 11.22.3 Laying shall be as specified in 11.20.3 except that the joints of the slabs shall be set in grey cement mixed with pigment to match the shade of the slabs. 11.22.4 Curing, P olishing and F inishing shall be as specified in 11.10.3 except that first polishing with coarse grade carborundum stone shall not be done. 11.22.5 Measurements Length shall be m easured along the finished face of riser, skirting o r dado correct to a cm. Height shall be measured from the finished level of tread of floor to the top (the underside of tread in the case of
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steps). This shall be measured correct to a mm in the case of risers of steps and skirting and correct to a cm in the case of dado. The area shall be calculated in square metre correct to two places of decimal. Lining of pillars etc. shall also be measured under this item. 11.22.6 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. 11.23 RED OR WHITE FINE DRESSED SAND STONE FLOORING 11.23.1 Stone Slabs The slabs shall be red or white as specified in the description of the item. The stone slabs shall be hard, s ound, durable and t ough, f ree f rom cracks, de cay and w eathering. I n c ase of red sand stone, white pat ches or s treaks s hall not be al lowed. H owever, s cattered s pots upt o 10 m m di ameter w ill be permitted. B efore s tarting the w ork t he c ontractor s hall get s amples of s labs appr oved by t he E ngineerin-Charge. The s labs shall be hand o r machine cut to the requisite t hickness al ong pl anes pa rallel to t he nat ural bed of stone and should be of uniform size if required. 11.23.2 Dressing of Slabs Every slab shall be cut to the required size and shape and chisel dressed on all sides to a minimum depth of 20 mm. The top and the joints shall be fine tooled so that straight edge laid along the face is fully in contact with it. In case machine cut stones are used, chisel dressing and fine tooling of machine cut surface need not be don e pr ovided a s traight edg e l aid an ywhere al ong the machine cut s urface i s i n contact with every point on it. The thickness of the slabs after dressing shall be 40 m m or as specified in the description of item with a permissible tolerance of ± 2 mm. 11.23.3 Laying 11.23.3.1 Base concrete on w hich the slabs are to be l aid shall be c leaned, wetted and m opped. The bedding for the slabs s hall be w ith c ement m ortar 1:5 (1 c ement : 5 c oarse s and) or as given in the description of the item. 11.23.3.2 The average thickness of the bedding mortar under the slabs shall be 20 mm and t he thickness at any place under the slabs shall not be less than 12 mm. 11.23.3.3 The slab shall be laid in the following manner: Mortar o f s pecified m ix s hall be spreaded u nder e ach slab. T he slab s hall be washed c lean b efore laying. It shall then b e laid on top, pr essed and larried, s o that a ll h ollows unde rneath ge t filled and surplus mortar works up through the joints. The top s hall be tapped w ith a w ooden mallet and br ought t o level an d close t o t he adjoining s labs, w ith t hickness of j oint not exceeding 5 m m. S ubsequent s labs shall be laid in the same manner. After laying each slab surplus mortar on t he surface o f slabs shall be cleaned off and joints finished flush. 11.23.3.4 In case pointing with other mortar mix is specified, the joint shall be left raked out uniformly and to a depth of not less than 12 mm when the mortar is still green. The pointing shall be cured for a minimum period of 7 day s. The surface of the flooring as laid shall be true to levels and slopes as instructed by the Engineer-in-Charge. 11.23.3.5 Slabs which are fixed in the floor adjoining the wall shall enter not less than 12 mm under the plaster, s kirting or dado. The j unction between w all pl aster s kirting and f loor shall be f inished neatly and without waviness.
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11.23.3.6 The finished floor shall not sound hollow when tapped with wooden mallet. 11.23.4 Finishing In case of chisel dressed stone flooring slight unevenness, if any existing between the edges of slabs at joints shall then be removed by chiselling in a slant. 11.23.5 Measurements These shall be as specified in para 11.19.5. 11.23.6 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. Where poi nting i s to be done, this w ill be pai d ex tra unl ess specifically i ncluded i n t he des cription of the item. 11.24 RED OR WHITE FINE DRESSED AND RUBBED SAND STONE FLOORING 11.24.1 Stone Slabs shall be as specified in 11.23.1. 11.24.2 Dressing The s pecifications f or dressing t he t op surface an d t he sides s hall be a s d escribed i n 1 1.23.2. I n addition t he dre ssed t op and sides s hall b e t able r ubbed with c oarse grade carborundum s tone before paving, to obtain a perfectly true and smooth surface free from chisel marks. The thickness of the slabs after dr essing s hall be as s pecified w ith a p ermissible tolerance of ± 2 mm. 11.24.3 Laying The slabs shall be laid with 3 mm thick or 5 mm thick joints as specified in the description of the item. Where the joints are to be limited to 3 mm thickness, the slabs shall be laid a s specified in 1 1.19.3 except that the bedding mortar shall be as specified in 11.23.3 and sides of the slabs to be jointed shall be buttered with cement mortar 1:2 (1 cement : 2 stone dust) admixed with pigment to match the shade of the slab. Where the slabs are to be laid with 5 m m thick joints, the specifications for laying shall be as described in 11.23.3. 11.24.4 Finishing shall b e as s pecified in 1 1.23.4 e xcept t hat c hisel m arks a nd u nevenness s hall be removed by rubbing with coarse grade carborundum stone. 11.24.5 Measurement and Rate shall be as specified in 11.23.5 and 11.23.6. 11.25 WOODEN FLOORING : DELETED 11.26 WOOD BLOCK FLOORING : DELETED.
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APPENDIX A
ABRASION TEST FOR CONCRETE HARDENING COMPOUNDS (Clause 11.3.1)
A-1 Preparation of Sample 25 mm cylinder shall be prepared in ratio 1:2 mix (1 cement: 2 grades stone aggregate 6 mm nominal s ize by w eight) one each w ith and w ithout the admixture of c oncrete hardening c ompound. The concrete hardening c ompound s hall be us ed i n the proportion by w eight of cement as recommended by the firm. T he cylinder s hall b e placed inside a damp box for 2 4 hours a nd then cured in water for 27 days. After t hat, t hey s hall be s ubject t o abra sion t est on ‘ Dorry T ype Avery Abrasion T esting M achine, using Emery powder No 80 as the abrasing medium under the condition given in para A-2 below: A-2 Conditions of Test (a) Area of rubbing surface shall be same in both the cylinders. (b) Age of cylinder
28 days
(c) Duration of Test
60 minutes
(d) Total distance traverse During rubbing
About 2.4 km
(e) Pressure on rubbing surface
0.04 kg/cm2
A-3 Results of Tests The following observations shall be made in both the cases. (a) Composition of the Test specimen (b) Mean thickness rubbed away (c) Percentage loss in weight A-4 Remarks Percentage l oss i n weight in t he case o f c ylinders w ith c oncrete har dening compound, s hould not be more than 40% of the percentage loss in the case of cylinder without concrete hardening compound.
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APPENDIX B
TEST REQUIREMENTS AND PROCEDURE FOR “PRE-CAST CEMENT CONCRETE/ TERRAZO TILES”
TESTING
(Clause 11.10.1 & 11.11.1)
B-1 Sampling The tiles required o f c arrying out t est des cribed bel ow s hall be t aken b y ‘ random s ampling’. E ach t ile sample shall be marked to identify the consignement from which it was selected. Minimum quantity of tiles for carrying out the test and frequency of test shall be as specified in the list of Mandatory Test. The number of tiles selected for each mandatory test shall be as follows” (a) For conformity to requirements on shape and dimensions, wearing layer, and general quality - 12 tiles (b) For wet transverse strength test - 6 tiles (c) For resistance to wear test - 6 tiles (d) For water absorption test - 6 tiles Note: (1) The tests on the tiles shall not be carried out earlier than 28 days from the date of manufacture. (2) The tiles selected for (a) may as well after verification of requirements, be used for (b). B-2 Flatness of the Tiles Surface The tiles when tested according to procedure laid down in IS 1237 edition 2.3, the amount of concavity and convexity shall not exceed 1 mm. B-3 Perpendicularity When t ested i n accordance w ith t he p rocedure l aid do wn i n I S 1237 edition 2. 3, t he l ongest g ap between the arm of the square and edge of the tile shall not exceed 2 per cent of the length of edge. B-4 Straightness When tested as per IS 1237 edition 2.3, the gap between the thread and the plane of tile shall not exceed 1 percent of the length of edge. B-5 Water Absorption When tested the average water absorption shall not exceed 10 per cent. B-6 Wet Transverse Strength Test Six fu ll s ize tiles s hall be te sted for th e de termination o f w et t ransverse strength. When tes ted according to the procedure laid down in IS 1237 edition 2.3, the average w et transverse strength shall not be less than 3 N/mm2 (30 kgf/cm2) B-7 Resistance to Wear Test When tested according to IS 1237 edition 2.3, average wear shall not exceed 3.5 mm and the wear on any i ndividual s pecimen shall n ot ex ceed 4 mm, f or general purp ose t iles. And 2 mm and 2.5 m m of average wear on any individual specimen, respectively for heavy duty floor tiles.
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CHEQURED TERRAZO TILES
Sub Head : Flooring Clause : 11.13
5 Equal Spaces Wearing Layer of Marble Chips
3025 Depth of Grove 3 mm
6
Nosing
20
SIDE ELEVATION
200 NOMINAL
330
PLAN TILE FOR STAIR TREADS Drawing not to Scale All Dimensions are in mm
Fig. 11.2 : Chequered Terrazo Tiles
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12.0: Roofing
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CONTENTS Cla us e No.
Brie f De s cription List of Bureau of Indian Standards Codes
P a ge No. 373
12.0
Terminology
374
12.1
Corrugated Galvanised Steel Sheet Roofing
374
12.2
Ridges and Hips of Plain Galvanised Steel Sheets
377
12.3
Valley and Flashing of Plain Galvanised Steel Sheets
377
12.4
Gutters Made of Plain Galvanised Steel Sheets
378
12.5
KLIPPON Galvalume Precoated Metal sheet Roofing
379
12.6
Non-Asbestos High Impact Poly Propylene Reinforced Cement Semi-Corrugated Sheet Roofing - DELETED
380
12.7
Ridges and Hips of Non-Asbestos High Impact Poly Propylene Reinforced Cement - DELETED
380
12.8
Other Roofing Accessories of Non-Asbestos High Impact Poly Propylene Reinforced Cement - DELETED
380
12.9
Eaves and Valley Gutters of Non-Asbestos High Impact Poly Propylene Reinforced Cement - DELETED
380
12.10
Painting of Roof Slab with Hot Bitumen
380
12.11
Mud Phuska Terracing with Brick Tile Paving
381
12.12
Paving over Mumty Roofs with Bricks Tile
383
12.13
Cement Concrete Gola
384
12.14
Khurras
384
12.15
Red or White Sand Stone Roofing - DELETED
385
12.16
Wooden Ceiling - DELETED
385
12.17
Ceiling with Fibre Insulating Building Boards - DELETED
385
12.18
Particle Board/Multipurpose Cement Board Ceiling - DELETED
386
12.19
Plain/Semi Perforated Particle Board Tiles Ceiling - DELETED
386
12.20
Transluscent White Acrylic Plastic Sheet Ceiling - DELETED
386
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12.21
Plaster of Paris (Gypsum Anhydrous) Ceiling over Wooden Strips - DELETED
386
12.22
Rain Water Spouts
386
12.23
Cast Iron Rain Water Pipes
387
12.24
Cast Iron Accessories for Rain Water Pipes
389
12.25
Thermal Insulation for Roofing
390
12.26
Unplasticised Polyvinyl Chloride Pipes and Fittings
394
Appendix A
Galvanised Steel Sheets
396
Fig. 12.1
C.G.S. Sheets
398
Fig. 12.2
Galvanised Steel Sheet Gutter
399
Fig. 12.3
Wind Tie and Flashing
400
Fig. 12.4
Non-Asbestos Corrugated Sheet
401
Fig. 12.5
Non-Asbestos Cement Accessories
402
Fig. 12.6
Non-Asbestos Cement Gutters
403
Fig. 12.7
Cement Concrete Khurra-Gola
404
Fig. 12.8
Holder Bat Clamp
405
.
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LIST OF BUREAU OF INDIAN STANDARDS CODES
S l. No. 1. 2. 3 4. 5. 6.
BIS Code
S ubje ct
IS 73 IS 277 IS 651 IS 702 IS 1199 IS 1200 (PT.IX)
7.
IS 1200 (PTX)
8 9.
IS 1230 IS 1367 (PT -13)
10 11. 12. 13.
IS 2095 (PT-1) IS 2115 IS 2633 IS 2645
14.
IS 3007 (PT.1)
15.
IS 3007 (PT.2)
16.
IS 3087
17. 18.
IS 3144 IS 3346
19. 20. 21. 22
IS 3348 IS 3384 IS 4671 IS 5382
23.
IS 5688
24. 25.
IS 6598 IS 7193
26. 27.
IS 8183 IS 10192
28.
IS 13592
29. 30 31
IS 14753 IS 14 862 IS 14871
Specification for paving Bitumen Galvanised s teel s heets ( plain and c orrugated) Glazed stoneware pipes and fittings Specification for industrial bitumen Methods of sampling and analysis of concrete Method of m easurements of bui lding a nd c ivil e ngineering works: Part - 9 Roof covering ( including cladding) Method of m easurements of bui lding a nd c ivil e ngineering works: Part -10 ceiling and lining Cast iron rain water pipes and fitting Technical s upply c onditions f or t hreaded s teel f asteners pt .13 ho t d ip galvanized coating on threaded fasteners Gypsum pl aster boar ds ( Pt.1) pl ain G ypsum pl aster boar ds Code of practice for flat roof finish: mud phuska Method of testing uniformity of coating on zinc coated articles Specification for integral water proofing compounds for cement mortar and concrete Code of practice for laying of asbestos cement sheets: part- 1 corrugated sheets Code of pr actice f or l aying of as bestos c ement s heets par t- 2 s emicorrugated sheets Particle boards of wood and o ther l ignocellulogic m aterials ( medium density) for general purposes - specifications Methods of test for mineral wool thermal insulation materials Method of the determination of thermal conductivity of thermal insulation materials Specification for fibre insulation boards Specification f or bi tumen p rimer for w ater pr oofing and d amp pr oofing Expanded polystyrene for thermal insulation purposes Specification f or r ubber s ealing r ings f or gas m ains, w ater m ains and sewers Methods of t est of per formed b lock t ype an d p ipe c overing t ype t hermal insulations Cellular concrete for thermal insulation Specification f or gl ass f ibre bas e c oal tarpitch & bi tumen felts (Amendment I) Bonded mineral wool Specifications f or s ynthetic r esin b onded g lass f ibre (SRBGF) f or electrical purposes. Unplasticised po lyvinyl c hloride ( UPVC) pi pes f or s oil an d Waste discharge system for inside and outside building. Specifications f or pol ymethyl Methacrylate ( PMMA) ( Arylic) s heets Fibre cement flat sheets - specifications Specifications f or products in f ibre reinforced cement - Long c orrugated or Asymmetrical section sheets and fittings for roofing and cladding.
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12.0 ROOFING 12.0 TERMINOLOGY 12.0.1 Accessories Purpose m ade f ittings, s uch as apron flashing pi eces, ba rge boa rds, bottom glazing f lashing, corner piece (c orner f lashing), eaves f iller pi eces, ex pansion j oints, hi p c apping, h ip t ile or c ap, ri dge c apping, ridge finials, roof lights, ventilators, with which the roof is furnished. 12.0.2 Eaves The lower edge of the inclined roof. 12.0.3 Finial A decorative fitting used at the Junction of ridges and hips to form a water proof covering and at the top of conical, pyramidal, or dome roofs. 12.0.4 Flashing A s trip of i mpervious m aterial, usually m etal us ed t o ex clude w ater f rom the junction bet ween a roof covering and another part of the structure. 12.0.5 Gable Part of wall above the general eaves level at tie end of ridged or partially hipped roof. 12.0.6 Gutter Any form of roof water channel. 12.0.7 Hip The out er angle (m ore t han 180 degree) f ormed b y t he inclined ri dge bet ween t wo i ntersecting ro of slopes. 12.0.8 Pitch 12.0.8.1 The a ngle o f inclination with the h orizontal of the r afters or substructure surface o n which the roof coverings are laid. 12.0.8.2 In patent glazing, the angle at which the plane of a stretch of glazing is inclined to the horizontal. 12.0.9 Pitched Roof A roof the pitch of which is greater than 10 degree to the horizontal. 12.0.10 Ridge The horizontal inter-section at the apex of the two rising roof surfaces inclined in opposite directions. 12.0.11 Valley The re-entrant angle formed by the inter-section of two inclined roof surfaces. 12.0.12 Verge Free edge of a roof surface ending at a gable. 12.1 CORRUGATED GALVANISED STEEL SHEET ROOFING 12.1.1 C.G.S. Sheets These s hall be of t he t hickness s pecified i n t he de scription of t he i tem and s hall c onform t o I S 277. The s heets shall be of 275 grade of c oating ( See A ppendix-A) unl ess otherwise specified i n the description of item.
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The s heets s hall be free from c racks, s plit edges , twists, s urface flaws e tc. T hey s hall be c lean, bright and s mooth. The g alvanising shall be n on-injured a nd i n perfect c ondition. The sheets s hall n ot show signs of rust or w hite powdery deposits on t he surface. The corrugations shall be u niform in depth and pitch and parallel with the side. 12.1.2 Purlins Purlins o f the specified m aterial o r M .S. rolled sections of requisite s ize s hall be f ixed o ver the principal rafters. These shall not be spaced at more than the following distances. (Table 12.1) TABLE 12.1
Thickne s s of C.G.S . she e t Ma ximum spa cing of purlins 1.00 mm 2.00 metre 0.80 mm 1.80 metre 0.63 mm 1.60 metre The top surfaces of the pur lins shall be uniform and plane. They s hall be painted before fixing on top. Embedded portions of wooden purlins shall be coal tarred with two coats. 12.1.3 Slope Roof shall not be pitched at a flatter slope than 1 vertical to 5 horizontal. The normal pitch adopted shall usually be 1 vertical to 3 horizontal. 12.1.4 Laying and Fixing 12.1.4.1 The sheets shall be laid an d fixed in the m anner de scribed below, un less otherwise shown in the working drawings or directed by the Engineer-in-Charge. 12.1.4.2 The sheets shall be l aid on t he purlins to a true plane, with the lines of corrugations parallel or normal to the sides of the area to be covered unless otherwise required as in special shaped roofs. 12.1.4.3 The sheets shall be laid with a minimum lap of 15 cm at the ends and 2 ridges of corrugations at each side. The abov e m inimum end l ap o f 15 c m s hall appl y t o s lopes o f 1 v ertical t o 2 hor izontal a nd steeper s lopes. F or f latter s lopes t he m inimum permissible end l ap s hall be 20 c m. T he m inimum l ap of sheets with ridge, hi p and valley s hall be 20 cm measured at right angles to the line of t he ridge, hi p and valley res pectively. T hese s heets s hall be c ut t o s uit t he di mensions or s hapes of t he roof , ei ther al ong their length or their width or in a slant across their lines of corrugations at hips and valleys. They shall be cut carefully with a straight edge chisel to give a smooth and straight finish. 12.1.4.4 Lapping in C.G.S. sheets shall be painted with a coat of approved steel primer and two coats of painting with approved paint suitable for G.S. sheet, before the sheets are fixed in place. 12.1.4.5 Sheets shall not generally be f ixed into gables and p arapets. They shall be ben t up al ong their side edges close to the wall and t he junction shall be pr otected by suitable flashing or by a pr ojecting drip course, the later to cover the junction by at least 7.5 cm. 12.1.4.6 The laying operation shall include all scaffolding work involved. 12.1.4.7 Sheets shall be f ixed to the purlins or other roof members such as hip or v alley rafters etc. with galvanised J or L hook b olts an d nu ts, 8 m m di ameter, w ith bitumen an d G .I. limpet w ashers or w ith a limpet washer f illed w ith w hite l ead a s d irected b y t he Engineer-in-Charge. W hile J h ooks ar e u sed f or fixing s heets on angle i ron pu rlins, a nd L hooks a re us ed f or f ixing t he s heet t o R .S. j oists, t imber o r precast concrete purlins. The length of the hook bolt shall be varied to suit the particular requirements. .
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The b olts shall be sufficiently long so that after fixing they project above the top of the n uts by not less than 10 mm. The grip of J or L hook bolt on the side of the purlin shall not be less than 25 mm. There shall be a minimum of t hree hook bolts placed at the r idges of c orrugations i n each sheet on every purlin and their spacing shall not exceed 30 cm. Coach screws shall not be used for fixing sheets to purlins. 12.1.4.8 The galvanised coating on J or L ho oks, and bol ts shall be c ontinuous and f ree from defects such as blisters, flux stains, drops, excessive projections or other imperfections which would impair serviceability. The galvanised c oating should c onform to IS 1367 (Pt. XIII) T he m ass of c oating per square meter of the surface shall be as under: Mass and Equivalent Thickness of Coating
Minimum Ma s s (g/m 2 ) 375
Ave ra ge Thickne s s (µm) 54
Minimum Ma s s (g/m 2 ) 300
Individua l Thickne s s (µm) 43
12.1.4.9 Where slopes of roofs are less than 21.5 degrees (1 vertical to 2.5 horizontal) sheets shall b e joined t ogether at t he side l aps by gal vanised i ron bol ts and nu ts 25 × 6 mm s ize, eac h bol t provided with a bitumen and a G.I. limpet washer or a G.I. limpet washer filled with white lead. As the overlap at the sides extends t o t wo c orrugations, t hese bolts shall be placed zig-zag over t he t wo overlapping corrugations, s o that t he ends of the ov erlapping sheets s hall be draw n ti ghtly to eac h o ther. T he spacing of these s eam bolts shall not exceed 60 cm along each of the staggered rows. Holes for all bolts shall be drilled a nd n ot punched in t he ri dges of t he corrugations f rom t he underside, while t he s heets are on the ground. 12.1.5 Wind Tie Wind ties shall be of 40 x 6 mm flat iron section or of other size as specified. These shall be fixed at the eaves of the sheets. The fixing shall be done with the same hook bolts which secure the sheets to the purlins. The ties shall be paid for separately unless described in the item of roofing. 12.1.6 Finish The roof when completed shall be true to lines, and slopes and shall be leak proof. 12.1.7 Measurements 12.1.7.1 The length and breadth shall be measured correct to a cm. Area shall be worked out in sqm correct to two places of decimal. 12.1.7.2 The superficial area of roof covering shall be measured on the flat without allowance for laps and corr ugations. P ortion of roo f co vering o verlapping th e rid ge o r hip e tc. sh all be i ncluded in t he measurements of the roof. 12.1.7.3 Roof with curved sheets shall be m easured and pai d for separately. M easurements shall be taken on the flat and not girthed. 12.1.7.4 No deduction in measurement shall be made for opening upto 0.4 sqm and nothing extra shall be allowed f or forming such op enings. For any opening exceeding 0. 4 sqm in area, deduction in measurements f or t he f ull opening s hall be m ade and in s uch c ases t he labour i nvolved in m aking these openings s hall be pai d f or s eparately. C utting ac ross c orrugation s hall be m easured on t he f lat and no t girthed. No additions shall be made for laps cut through.
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12.1.8 Rate The rate shall include the cost of all the materials and labour involved in all the operations described above including a c oat of approved steel primer and two coats of approved steel paint on ov erlapping of C.G.S. s heets. This includes the c ost of roof sheets, galvanised iron J or L hooks, bolts and nuts, galvanised iron seam bolts and nuts, bituminous and galvanised iron limpet washers etc. 12.2 RIDGES AND HIPS OF PLAIN GALVANISED STEEL SHEETS 12.2.1 Ridges and Hips Ridges and hips of C.G.S. roof shall be covered with ridge and hip sections of plain G.S. sheet with a minimum lap of 20 c m on either side over the C.G.S. sheets. T he end laps of the ridges and hips and between ridges and hips shall also be not less than 20 c m. The ridges and hips shall be of 60 cm overall width plain G.S. sheet, 0.6 mm or 0.8 mm thick as given in the description of the item and shall be properly bent in shape. 12.2.2 Fixing 12.2.2.1 Ridges shall be f ixed to the purlins below with the same 8 m m dia G.I. hook bolts and nuts and bitumen and G.I. limpet washers which fix the sheets to the purlins. 12.2.2.2 Similarly, hips shall be fixed to the ro of m embers b elow such a s pu rlins, h ip an d valley rafters with the s ame 8 mm di a G .I. hook bolts an d nut s an d bi tumen a nd G .I. limpet w ashers w hich fix the sheets to those roof members. At least one of the fixing bolts shall pass through the end laps of ridges and hips, on either side. If this is not possible extra hook bolts shall be provided. 12.2.2.3 The end laps of ridges and hips shall be joined together with C.G.S sheet by galvanised iron seam bolts 25 x 6 m m size each with a b itumen and G .I. washer or white lead as directed by the Engineer-in-Charge. There shall be at least two such bolts in each end lap. 12.2.2.4 Surface of C.G.I. sheets of ridge and hip sections and the roofing sheets which overlap each other s hall be painted with a c oat of approved prim er and tw o c oats of approved paint s uitable for painting G.S. Sheets before they are fixed in place. 12.2.3 Finish The ed ges o f the ridges and h ips s hall be s traight from end to end and their s urfaces s hould b e plane and parallel to the general plane of the roof. The ridges and hips shall fit in squarely on the sheets. 12.2.4 Measurement The measurements shall be taken for the finished work in length along the centre line of ridge or hip, as the case may be, correct to a c m. The laps in ridges and hi ps and bet ween ridges and hi ps shall not be measured. 12.2.5 Rate The rate s hall i nclude t he c ost of al l labour and materials specified above, i ncluding painting, c ost of seam bolts and any extra G.I. hook bolts, nuts and washers, required. 12.3 VALLEY AND FLASHING OF PLAIN GALVANISED STEEL SHEETS 12.3.1 Valley and Flashing Valley shall be 90 cm wide overall plain G.S. sheet 1.6 mm thick or other size as specified in the item bent to shape a nd fixed. They shall lap with the C.G.S. sheets not less than 25 c m width on ot her side. The end laps of valley shall also be not less than 25 cm.
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Valley sheets shall be laid over 25 mm thick wooden boarding if so required. Flashing shall be of pla in G.S. sheet of 40 cm o verall w idth 1.25 mm thi ck or 1.0 0 m m thick as specified in the item bend to shape and fixed. They shall lap not less than 15 cm over the roofing sheets. The end laps between flashing pieces shall not be less than 25 cm. 12.3.2 Laying and Fixing Flashing a nd v alley sheets s hall be fixed to the r oof m embers below, s uch as purlins a nd v alley rafters with the same 8 mm dia G.I. hook bolts and nuts and bitumen and G.I. limpet washers which fix the sheets to those roof members. At least one of the fixing bolts shall pass through the end laps of the valley pieces on other side. If this is not possible extra hook bolts shall be provided. The free end of flashing shall be fixed at least 5 cm inside masonary with the mortar of mix 1: 3 (1 cement: 3 coarse sand). Refer Fig. 12.3. 12.3.3 Surface of G.S. sheets under overlaps shall be painted with a coat of approved primer and two coats of approved paint suitable for painting G.S. sheets. 12.3.4 Finish The edges of v alley and flashing s hould be s traight f rom end t o end. T he surfaces s hould be t rue and without bulges and depressions. 12.3.5 Measurements The length of the valleys and flashing shall be measured for the finished work correct to a cm. The laps along the length of the valley or flashing pieces, including the portion embedded in masonary, shall not be measured. 12.3.6 Rates The rate for valleys, shall be for all the labour and materials specified above, including painting, cost of seam bolts and the cost of requisite G.I. hook bolts, nuts and washers required over and above those needed for connecting the roof sheets to the roof members. The r ate for v alleys shall e xclude t he c ost of boarding underneath which shall be paid for separately. The rate for flashing shall be for all the labour and materials specified above, and shall include the cost of painting and mortar for fixing in wall. 12.4 GUTTERS MADE OF PLAIN GALVANISED STEEL SHEETS (FIG. 12.2) 12.4.1 Gutters Gutter shall be fabricated from plain G.S. Sheets of thickness as specified in the item. Eaves gut ters s hall be of the s hape an d s ection s pecified in t he des cription of t he i tem. T he o verall width of the sheet referred to therein shall mean the peripheral width of the gutter including the rounded edges. The longitudinal edges shall be turned back to the extent of 12 mm and beaten to form a rounded edge. The ends of the sheets at junctions of pieces shall be hooked into each other and beaten flush to avoid leakage. 12.4.2 Slope Gutter shall be laid with a minimum slope of 1 in 120. 12.4.3 Laying and Fixing 12.4.3.1 Gutter shall be supported on and f ixed to M.S. flat iron brackets bent to shape and f ixed to the requisite slope. The maximum spacing of brackets shall be 1.20 metres.
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12.4.3.2 Where these brackets are to be fixed to the sides of rafters, they shall be of 40 × 3 m m section bend to shape and fixed rigidly to the sides of rafters with 3 Nos. 10 mm dia bolts, nuts and washers. The b rackets s hall ov erlap t he rafter n ot l ess t han 30 cm and t he c onnecting b olts s hall be at 1 2 c m centres. 12.4.3.3 Where the brackets are t o be f ixed to the purlins, the brackets shall consist of 50 × 3 m m M.S. flat iron bent to shape with one end turned at right angle and fixed to the purlin face with 2 Nos. of 10 mm dia bol ts nut s and w ashers. The br acket w ill be stiffened by pr ovision o f 50 × 3 mm. M. S. flat w hose over hung portion bent to right angle shape with its longer leg connected to the bracket with 2 N os. 6 mm dia M.S. bolts, nuts and washers and its shorter leg fixed to face of purlin with 1 No. 10 mm dia, bolt, nut and w asher. The over hang of the vertical portion of the bracket from the face of the purlin shall n ot exceed 22.5 cm with this arrangement. The spacing of the brackets shall not exceed 1.20 metres. 12.4.3.4 The g utter shall be fixed to the bra ckets with 2 N os. G.I. bo lts an d nuts 6 m m dia, ea ch fitted with a pair of G .I. and bitumen w ashers. T he c onnecting bolts s hall be abov e the w ater line of the gutters. 12.4.3.5 For connection to down take pipes, a prop er drop end or f unnel shaped connecting piece shall be made out of G.S. sheet of the same thickness as the gutter and riverted to the gutter, the other end tailing into the s ocket of t he r ain-water p ipe. W herever n ecessary s top en ds, an gles e tc., s hould b e provided. 12.4.4 Finish The gutters when fixed shall be true to line and slope and shall be leakproof. 12.4.5 Measurements Measurements shall be taken for t he finished w ork al ong t he c entre l ine o f the top width o f t he gut ter connection t o a c m. T he ho oked l ap portion i n t he j unctions a nd gu tter l engths s hall not be measured. The number of brackets which are fixed to purlins with stiffener flats should be measured. 12.4.6 Rate The rate shall include the cost of all labour and materials specified above, including all specials such as angles, junctions, drop ends or funnel shaped connecting pieces, stop ends etc., flat iron brackets and bolts and nuts required for fixing the latter to the roof members. Brackets of 50 × 3 mm flats fixed to purlins with stiffener flats will be paid extra. 12.5 PRECOATED METAL ROOFING : TRACDEK KLIPPON or equivalent) type. 12.5.1 Material : Cold Rolled Steel Conforming to ASTM: A446 having yield stress of 275 MPa and Base metal thickness of 0.5 mm. 12.5.2 Finish : Steel surface shall have Hot Dip Metallic Coating - AZ i.e. Aluminium Zinc alloy comprising 55% aluminium, 43.5% Zinc and 1.5% Silicon as per ASTM-0 A792. Total mass of the coating mass on both sides shall be 150 gm /sq.m as det ermined b y t riple spot tests. S teel s hall hav e O rganic coating with Modified Polyester paint on continuous coil coating line. Thickness of coating on top side shall be 20 micron Silicon Modi fied P olyester ov er 5 micron E poxy primer and thickness o f coating on bac k side shall be 5 micron Polyester over 5 micron Epoxy primer. Total coated thickness shall be 0.58 mm. Approximate mass of completed roofing shall be 6.06 kg /sq.m
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Recommended span for wind loads as per IS: 875-1993 shall be as follows: a) b) c) d) e)
Single Span 1500 mm End Span 1200 mm Internal Span 2000 mm Overhang 200 mm Roofing sheets are available upto 12000 mm. But from transportation limitations it is recommended to use 6000mm long sheets. Overall width of sheet available is 460 mm.
12.5.3 : Laying of Sheets The sheets are to be fastened to roof purlins with fixing clips, which are concealed during fixing and do not require any fastening holes through the sheets. The fixing clip shown in the enclosed drawing/ illustration are to be used to fasten steel cladding. The clips for fastening sheets require only two fasteners per clip and provide an easy positive engagement in the ribs of the profile. The two fasteners are inserted only through the two punched holes. Four dimples are also provided in the clip but these are for auxiliary fasteners only. The fasteners used to fix clips shall be wafer head, selfdrilling, Zinc coated fasteners of size no 12-24x32mm. The clip has a short return l eg and l ong return l eg. The clip must be pos itioned w ith t he s hort l eg engaging over the male rib of the under lapping sheet. 12.5.4 : Flashing and Clapping The Flashing, Clapping and Trims shall be manufactured from the same material as the roof sheeting and in s tandard lengths of 2.5 metres. These a re t o be fixed w ith N o. 10 - 16 x 16 mm hot di pped Z inc coated self-tapping screws. The width shall be up to 1000 mm as per site requirements. 12.5.5: Measurements The measurement shall be taken for the finished work in superficial area on the flat in the plane of the roof/side measured i n s q.m w ithout al lowance for l aps and c orrugations and payment s hall be e ffected based on the rates quoted by Contractor. The laps between the sheets both at the ends and at the sides, shall not be measured. However, the overlaps o f t he sheets ov er v alley gut ters, ridge, hi p and flashing pi eces shall be i ncluded i n t he measurement. The rate s hall i nclude t he cost o f al l materials and l abour i nvolved i n al l the oper ations des cribed i n these specifications and as may be necessary for the work. The rate quoted shall also include providing any staging or any temporary structure required for the purpose of installing the roof. 12.5.6 : Rates The m easurement f or pr e-coated m etal r oofing s hall be done if it is t o be pai d separately as per Schedule of Rates. Otherwise, these measurements will be in built into the rate for canopy items. 12.6 TO 12.9: ITEMS DELETED 12.10 PAINTING OF ROOF SLAB WITH HOT BITUMEN 12.10.1 Preparing the Surface The s urface shall be painted only w hen it is thoroughly dry. T he s urface to be painted s hall be cleaned w ith wire brushes and c otton or gu nny c loth. A ll loose m aterials and scales s hall b e removed and the surface shall be further cleaned with a piece of cloth lightly soaked in kerosene oil.
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12.10.2 Painting with Bitumen 12.10.2.1 The contractor shall bring the bitumen to site in its original packing and shall open and use it in the pr esence of t he E ngineer-in-Charge o r hi s aut horised r epresentative. T he c ontainers s hall not be removed fro m th e site u ntil th e painting job is co mpleted an d the E ngineer-in-Charge h as sa tisfied himself regarding the quantity of bitumen actually used and has given his permission to remove the empty containers. 12.10.2.2 The surface prepared and treated shall be painted uniformly with bitumen of approved quality such a s re sidual t ype p etroleum bitumen of p enetration 8 0/100, hot c ut b ack b itumen or equivalent a s per s pecifications of t he manufacturer. T he c oat o f bi tumen s hall be continued 15 c m al ong t he v ertical surfaces joining the roof. In case of parapet walls it shall be continued upto the drip courses. 12.10.2.3 Residual type petroleum bitumen of penetration 80/100 shall be heated to a temperature of not less than 180 degree C and not more than 190 degree C and shall be applied on the roof surface at not less than 180 degree C. S imilarly, hot cut back bitumen shall be heated to a temperature of not less than 165 degree C and not more than 170 degree C and shall be a pplied on the surface at not less than 165 degree C. 12.10.2.4 Care shall be taken to see that no blank patches are left. The quantity of bitumen to be applied per 10 s quare metres of roof surface shall be 17 k g, unless otherwise stipulated in the description of the item. It shall be carefully regulated so that the application is uniform at the stipulated rate of 17 Kg. per 10 square metres. 12.10.3 Spreading Sand Immediately af ter p ainting, dr y, c lean s harp coarse s and at t he r ate of 60 cubic d ecimeter per 1 0 sqm. shall be evenly spread and levelled over the surface when the bitumen is still hot. 12.10.4 Measurements The s uperficial area of the s urface painted s hall b e measured in s quare m etres. N o deduction in measurements s hall be m ade f or unpainted areas o f r oof slab occupied by c himney s tacks, roof l ights etc. o f ar eas, eac h up to 4 0 s q. de cimetre. T he m easurements o f length and br eadth s hall be taken correct to a cm. 12.10.5 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. 12.11 MUD PHUSKA TERRACING WITH BRICK TILE PAVING 12.11.1 Mud Phuska For m ud phuska, selected soil w hich should be a go od quality earth s uitable for m aking bri cks n ot containing excessive c lay or s and, f ree f rom s tones, k ankar, v egetable m atter and other f oreign m atter, shall be collected and stacked at site. The soil shall not be c ollected f rom a locality infested w ith w hite ants. Before laying on the roof, the soil shall be made damp by adding water about 12 hours earlier. It shall be turned over with phawaras so as to break clods and to pulverise the same. Quantity of water to be added to the soil shall be carefully regulated so that the soil shall have optimum moisture content at the time of laying and compaction on the roof. The soil shall be laid on the roof to requisite thickness and slope, well compacted with wooden rammers and thappies, to obtain an e ven surface to correct slope. Average thickness of soil after compaction shall be as specified for the item. Note: A practical way of determining the moisture content of soil suitable for giving good compaction is that the soil should contain that much quantity of moisture, which when a handful of soil is moulded with hand to the shape of a ball, it shall just retain its form. If the soil on moulding cannot retain its shape of a ball, moisture content is inadequate. On the other hand, if the ball can be plastically deformed on pressing with hand, the moisture content is on the high side.
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12.11.2 Mud Plaster After laying the mud phuska, the surface shall be given a coat of mud plaster 25 mm thick and the plaster shall be allowed to dry and crack. The mud plaster s hall be pr epared fr om th e s ame soil as f or mud p huska. The dr y s oil s hall b e reduced to fine powder and mixed with water in a pit, adding fibrous reinforcing materials such as chopped straw (Bhusa) in proportion of 35 kg per cum of soil. The mixture shall be allowed to mature for a period of not l ess t han 7 day s. D uring t his per iod it s hall be w orked ov er w ith f eet and spades (Phawaras) at intervals so as to get pugged into a homogeneous mass free from lumps and clods. The mud mortar shall be puddled again very thoroughly just before use. The consistency of mud mortar shall be checked by taking it on a trowel and observing how it slides off the face of trowel. The mortar shall readily slide off the trowel and should not be so wet as to part on to large drops before falling. Alternatively slump test may be performed in accordance with IS 1199. The slump should be about 70 mm. 12.11.3 Gobri Leaping After t he m ud plaster has dr ied, t he s urface s hould be gi ven a coat of gobri l eaping so as t o completely fill a ny c rack t hat may hav e formed in the m ud p laster. M ortar for gobr i leaping s hall b e prepared by m ixing equal quant ities of f resh gobar and f inely s ieved c lay an d addi ng s ufficient w ater t o form a thin p aste. The qu antity of gobar used i n go bri l eaping s hall no t be less t han 0.03 cum per 1 00 sqm of plaster area. Five pe rcent of c ut b ack bitumen b y m ass of dry clay m ay be added to improve upon the water proofing qualities. 12.11.4 Laying of Bricks Tile After t he g obri l eaping h as d ried, b rick t iles s hall be l aid us ing t he m inimum am ount of pl ain m ud mortar (without b husa) a s b edding s o as t o o btain c orrect s lope a nd even s urface of t ile f loors. C are shall be exercised to see that mud mortar does not rise into the vertical joints of the tiles more than 12 mm. The brick tiles shall be ei ther flat tile bricks of class designation 100 o r machine moulded tile bricks of class designation 125 conforming to IS 2690 (Prt I) as per the nomenclature of the item. The tiles shall be laid such t hat the thickness of joints shall not be l ess than 6 mm and more than 12 mm in width. After the tiles are well s et and bedding mortar has dried, joints of the tiles shall be grouted with cement mortar of mix 1:3 (1 cement : 3 fine sand) such that all the joints of tiles are completely filled with mortar and the joints should be f inished neat. Cement us ed f or t he mortar s hall be m ixed w ith 2% of i ntegral water proofing compound which should conform to IS 2645. 12.11.5 Curing As soon as cement grouting obtains initial set, the surface of the brick tile floor shall be c overed with wet gun ny bag s, he ssian cloth or wet s and t o pre vent qui ck dry ing. After 8 -12 hours , t he brick t ile f loor shall be cured by frequent sprinkling of water on the surface for a period of 7 days. After curing has been done, the surface shall be swept clean. The tile surface as completed shall be even and true to slopes of 1 in 48 or as specified and should be leak proof. Note: When surplus earth of a suitable quality exists at the site of work, the contractor shall be allowed to use the same free of cost for laying the mud terracing, mud plaster and gobri leaping on the top. The Engineer-in-Charge shall be the final authority to decide whether the earth obtained from excavation is surplus to the requirements at site and is suitable for mud phuska work. 12.11.6 Measurements Length and br eadth s hall be m easured c orrect t o a c m. T he m easurements s hall be taken f or t he finished work, (mud phuska terracing of stipulated thickness with mud plaster, gobri leaping and tile paving and grouting) over the tiled surface, in superficial area.
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No dedu ctions i n m easurements s hall be m ade f or ei ther openi ngs or rec esses f or c himney sta cks, roof l ights or khurras, of area u pto 0. 40 sqm. N o extra s hall be p aid ei ther f or a ny e xtra materials or labour involved in forming such openings, recesses etc. For areas exceeding 0.40 sqm deductions will be made in the measurements for the full opening but extra shall be paid for any extra labour, materials etc. in forming such openings. For pl us or m inus dev iation f rom t he av erage t hickness s tipulated f or t he m ud phus ka i n t he i tem, payments will be adjusted in the r ate admissible to the contractor for the relevant schedule i tem provided that such deviations were authorised by the Engineer-in-Charge in writing. 12.11.7 Rate The r ate shall i nclude t he c ost of all m aterials a nd l abour involved i n all t he o perations d escribed above. 12.12 PAVING OVER MUMTY ROOFS WITH BRICKS TILE 12.12.0 The roofs shall be paved with bricks tile laid flat and grouted with cement mortar. 12.12.1 Bricks Tile These shall conform to the specifications detailed in subhead 6.0 of brick work 12.12.2 Cement Mortar The cement mortar s hall be of 1: 3 m ix ( 1 cement : 3 fine s and) unl ess ot herwise specified in the description of the item and shall conform to the specifications described in subhead 3.0 of Mortars. 12.12.3 Preparing the Surfaces The s urface s hall b e h acked, r oughened an d c leaned of al l d ust and ot her f oreign m atter. I t s hall then be wetted before applying the mortar. 12.12.4 Paving and Grouting Cement mortar shall be spread in 12 mm layer over the surface evenly to required slope. Brick tiles which had been soaked as in br ick work i n w ater for at least an hour before hand shall then be laid open jointed and flat on the m ortar and l ightly pressed, and s et to pl ane s urface t rue t o slopes et c. us ing a trowel and wooden straight edge. The brick tiles s hall be l aid with t heir joints not more t han 10 mm wide. They shall be laid with their longitudinal lines of joints truly parallel and horizontal and at right angles to the sloping edges of the roof. Transverse joints i n al ternate r ows s hould come di rectly i n l ine w ith one anot her. Transverse joints i n adjacent courses shall not have distance by less than 5 c m. As soon as the paving is done, the open joints shall be grouted with cement mortar 1:3 (1cement : 3 fine sand). Cement used for grouting mortar shall be m ixed w ith 2% (by uni t of c ement) w ater proofing c ompound c onforming t o I S 2645. C are s hall be taken to see that no joints are left unfilled or inadequately filled. The joints shall be finished flush with the brick surface. 12.12.5 Curing The t ile pav ing s hall be c ured f or at l east 7 day s during w hich period it s hall be s uitably protected from damage. 12.12.6 Measurements Length and br eadth s hall be measured c orrect t o a c m. Me asurements shall be taken for t he finished work in superficial area covered. No deduc tion i n m easurement s hall be m ade f or either openi ngs or r ecesses f or c himney s tacks, roof lights, or for khurras, for areas upto 0.40 sqm nor extra shall be paid for forming such openings. For similar a reas ex ceeding 0. 40 sqm deduc tion shall be made i n measurements for al l openi ngs but nothing extra shall be paid for forming such openings.
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12.12.7 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above. 12.13 CEMENT CONCRETE GOLA (FIG. 12.7) 12.13.1 Cement Concrete The specifications for concrete shall be the same as described in subhead 4.0 of concrete work. 12.13.2 Gola A chase of 75 mm wide a nd 75 mm d eep shall be cut in the p arapet wall just ab ove the junction of mud phuska or lime concrete with parapet wall and it shall be filled with cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 stone aggregate 10 mm and down gauge) the external face finish with a slope of 1 : 0 .75 a nd t he exposed s urface of t he g ola s hall be p lastered w ith c ement m ortar 1 : 3 (1 cement : 3 fine sand). Expansion joint at every 3.5 to 4.5 metres shall be provided and filled with bitumen filler. The bitumen filler shall be p repared by mixing bi tumen, cement and coarse sand in t he ratio of 80 : 1 : 0. 25 (80 k g of hot bitumen : 1 kg of cement and 0.25 cum of coarse sand). 12.13.3 Curing The finished surface shall be cured for at least 7 days. 12.13.4 Measurements The length of the finished gola shall be measured at its junction with the wall face correct to a cm. No deduction shall be made in measurements for gaps for water outlets. 12.13.5 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above including the cost of bitumen filler in expansion joint. The rate includes for all turnings and roundings at all the corners and risers. 12.14 KHURRAS (FIG. 12.7) 12.14.0 The khurras shall be constructed before the brick masonry work in parapet wall is taken up and it shall be of size 45 cm x 45 cm unless otherwise specified in the description of the item and shall be made of c ement concrete 1 :2:4 mix ( 1 cement : 2 c oarse s and : 4 graded s tone a ggregate 20 m m nominal size) or other mix as stipulated in the description of the item. 12.14.1 Laying 12.14.1.1 A PVC sheet of size 1 m x 1 m x 400 micron (alternatively, aluminium foil of 32 SWG) shall be laid under the khurra and then cement concrete shall be laid over it to average thickness of 50 mm with its top surface lower than the level of adjoining roof surface by not less than 50 mm. 12.14.1.2 The concrete shall be laid to a size greater than the stipulated size of the khurra in such a way that the adjoining terracing shall overlap the concrete on i ts three edges by not less than 7.5 cm. The concrete will slope uniformly from the edges to t he outlet, t he slope being as much as pos sible and in no case less than 20 mm cement concrete at the outlet. The concrete shall be c ontinued at the same slope through the width of the wall into the outlet opening to ensure a water tight joint. 12.14.1.3 The khurras and the sides of the outlet shall then be rendered with 12 mm coat of cement plaster 1:3 mix (1 c ement : 3 c oarse sand) or ot her mix as stipulated in the d escription of the item. This shall be done w hen the concrete is still green and s hall be finished. The sides of the khurras and sides of the outlet opening shall be well rounded. The size of the finished outlet opening shall be 10 cm wide and by 20 cm high or as directed by the Engineer-in-Charge.
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12.14.1.4 In cases where rain water is to be disposed off through rain water pipes, iron grating shall be provided at t he o utlet as a s afeguard against choking, i f s o di rected by t he E ngineer-in-Charge. I ron gratings, shall be of overall size 20 × 25 cm. with an outer frame of 15 × 3 m m M.S. flat to which 4 N os M.S. bars of 10 mm dia shall be welded in a vertical direction keeping equal clear spacing of 2.5 cm. or as directed by the Engineer in Charge. 12.14.2 Measurements Khurras shall be counted in numbers. 12.14.3 Rate The rate is for each c ompleted khurra of the s pecified size and is inclusive of the cost of al l materials and labour in forming the khurras and outlet opening as described above, except for iron gratings which shall be paid for separately. 12.15 RED OR WHITE SAND STONE ROOFING: DELETED 12.16 WOODEN CEILING : DELETED 12.17 FALSE CEILING & THERMAL INSULATION 12.17.1: Scope : This specification covers the scope of false ceiling for canopies and sales building. 12.17.2 : Material Cold R olled S teel -Confirming IS: 513 ha ving minimum yield s tress o f 240 MPa and minimum tensile stress of 300 MPa. Base metal thickness -for ceiling panels: 0.45 mm & for carriers 0.55 mm 12.17.3 : Coating Hot Dip Metallic coating: 120 gms/m2. Zinc coating (galvanising) as per IS:277. Coating mass: 120 gms/m2. (total of both sides) as determined by triple spot tests. Organic Coating: Organic coating with Modified Polyester paint on a continuous coil coating line. Top side: 15 micron Modified Polyester over 5 micron Epoxy primer Back side: 5 microns Alkyd backer coat. Total coated thickness: for ceiling panels 0.50mm for carriers 0.60mm Approximate mass of completed ceiling 4.95 kg/ m2. 12.17.4 : Span The r ecommended s pan f or wind loads shall be as per I S:875. I n gener al, t he s pas for c arriers and suspenders shall be 1200 mm c/c. 12.17.5 : Dimentions The overall height of the false ceiling shall be as per the structural drawings and instructions issued by IOC Divisional Engineers for various locations based on the site requirements etc. The false ceiling shall be strictly as per the approved shop drawings and any deviation will be accepted only with the prior approval of the IOC Divisional Engineer. For Ceiling Panels: 150-F or 200-F Flush panel: 150 mm or 200 mm wide x 17 mm deep with tongue and groove interlocking arrangement. For Carriers: 34.5 mm wide x 48 mm deep. However, this shall be checked for design wind loads and if found necessary, the depth can be increased to 75 mm. However, no extra shall be paid for. Length for ceiling Panels: Up to 6000 mm Length for Carriers: Up to 5000 mm
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12.17.6 : Fixing method The Ceiling panels shall be clipped onto carriers, which are suspended from steel trusses with the help of G .I. s uspension angl es o f size 25 x 25 x 0. 5 mm thick b y m eans o f r igid suspension. The suspension system shall be rigid and meant for exteriors. The longitudinal joints of two panels shall be but jointed with a special panel splice behind the joint. The carriers joint of two carriers shall be jointed by means of carriers splices maintaining a module of 150 mm. the spans shall not exceed as recommended and manufacturer’s recommendations for installation shall be followed. 12.17.7 : Appearance The f alse ceiling s hould be o f white c olour as per standard t echnical s pecification and s hould be erected w ith t he bot tom face t ruly at hor izontal pl ane. If t he canopy bottom c hord members a re pl aced inclined s uch as up ward s lope o f cantilever por tion ( if required as per ar chitectural requirement) t hen t he plane of false ceiling shall be parallel to bottom chord of truss and/ or as per architectural requirement. The false ceiling should also be provided to cover up any left over vertical portion on the front facia as directed by the site engineer. In such cases, The vertical surface of the false ceiling shall be flush with the back lit facia. Contractors are required to obtain the details of the facia first and it is preferable to carry out the false ceiling work after the front facia work is completed. 12.17.8 : Construction The CONTRACTOR shall carry out the work without any damages to the property and without causing disturbance to the normal working of the Retail Outlets. Also, CONTRACTOR should work during nights, if directed by IOC, to avoid disruption of sale at the Retail Outlets at no extra cost. The entire work should be well co-ordinated so that other contractors also can work simultaneously. All the necessary scaffolding tools etc. hav e to be a rranged b y t he contractors at t heir ow n cost. The r ates s hall be deem ed t o i nclude necessary scaffolding at site. 12.17.9 : Painting The pai nting on al l t he roofing / false ceiling shall be got done i n the manufacturing p rocess be fore brought t o s ite f or erection. Any s urface da mage/ c hipping et c. on t he out er e xposed s urfaces o f any components suffered during transit, handling, erection or any other cause has to be made good properly by the C ontractor at hi s o wn expenses and matching t he shade with ad jacent c omponents a s instructed b y IOC/ENGINEER. 12.18 PARTICLE BOARD /MULTIPURPOSE CEMENT BOARD CEILING: DELETED 12.18 PLAIN/SEMI PERFORATED PARTICLE BOARD TILES CEILING : DELETED 12.19 To 12.21 ITEMS DELETED 12.22 RAIN WATER SPOUTS 12.22.0 The sectional area of rain water spouts provided shall be generally at the rate of 1 square cm per 70 t o 80 s quare decimetre of roof area drained. H owever i n l ocations subject t o excessive and high intensities of rainfalls, the area of s pouts provided may be suitably i ncreased t o suit l ocal conditions. No spout shall be less than 80 mm in diameter. The spacing of spouts shall be arranged to suit the position of openings in the wall. 12.22.1 Stone Ware Spouts The spouts shall be 100 mm in diameters and 60 cm long. 12.22.1.1 The stone ware pipe shall be perfectly sound, free from fine cracks, imperfections of glazing etc. They must be straight cylindrical and of standard nominal diameter and length and depth of socket as given in IS 651. Full length of pipes shall be used on the work. They must be thoroughly salt glazed inside and outside shall generally conform to IS 651.
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12.22.1.2 Fixing : These shall be provided at the mouths of khurras and shall be f ixed in cement mortar 1:3 (1 c ement : 3 c oarse sand) w ith t he s ocket em bedded i n t he m asonry and t he spigot end projecting outside. The m asonry al round t he pipe a nd socket s hall be t horoughly wetted and t he h oles s hall be given a coat of cement mortar alround. The S.W. pipe shall then be i nserted and fixed with a surround of mortar. I n c ase t he hol e has bec ome m uch l arger t han t he s ize of t he pipe, c ement c oncrete 1: 2:4 (1 cement: 2 c oarse s and: 4 graded stone ag gregate 12.5 mm no minal size) shall be us ed to fill in the annular s pace. T he s pouts s hall s lope dow nward at t he rate of 1 i n 6. T he projection out side t he w all shall be uni form and not less than 40 cm. The entrance into the pipe shall be smoothly rounded to meet the internal bore of the pipe to facilitate easy flow. Care shall be taken to ensure that the vertical plane through the centre line of the spouts is at right an gles to the plane of the wall. Spouts in a row shall b e true to line. 12.22.1.3 Measurements : Spouts shall be measured in numbers. 12.22.1.4 Rate : The rate shall include the cost of all materials and l abour involved in all the operations described above including scaffolding. 12.23 CAST IRON RAIN WATER PIPES (FIG. 12.8) 12.23.1 Cast Iron Pipes Pipes shall c onform t o I S 12 30 a nd shall be perfectly, s mooth and cylindrical, their i nner and o uter surfaces be ing as nearly as pra cticable c oncentric. T hese s hall be sound an d of uniform c astings, f ree from l aps, pi n hol es or other i mperfections and s hall be neat ly finished and c arefully f itted bot h i nside and outside. The ends of pipes shall be reasonably square to their axes. 12.23.2 Dimensions C.I. rain w ater pipes shall be of the dia specified i n the description of the item and shall b e in full length of 1. 8 m etre i ncluding s ocket end s of t he pi pes, u nless s horter l engths are re quired at j unctions with fittings. The pipe lengths shall be in each case be with socket. The pipes shall be supplied without ears unless otherwise specifically mentioned. The pipes supplied shall be factory painted (with a tar base composition) both inside and outside which shall be smooth and tenacious. Every pipe shall ring clearly when struck all over with a light hand hammer. When shorter pipes are cut f rom f ull l engths t hey s hall be c ut w ith a hacksaw. T he s izes, w eights, s ockets and t olerances of pipes shall be as shown in Table 12.7. TABLE 12.7 Dimensions and Weight of C.I. Rain Water Pipes Nomina l s ize of pipe s (Inte rna l dia me te r in mm) 1. PIPE (a) External diameter in mm Tolerance in mm (b) Thickness in mm Tolerance in mm (c) Nominal weight of 1800 mm long pipe without ears in kg Tolerance in weight Tolerance in length in mm
50
75
100
125
150
53 ±3 3.00 ±1
79 ±3 3.00 ±1
104 ± 3.50 3.00 ±1
130 ± 3.50 3.00 ±1
156 ± 4.00 4.00 ±1
7.50 (-) 10% ± 13.00
11.00 (-) 10% ± 13.00
14.00 (-) 10% ± 13.00
20.00 (-) 10% ± 13.00
26.00 (-) 10% ± 13.00
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Nomina l s ize of pipe s (Inte rna l dia me te r in mm) 2. SOCKET (a) Internal diameter in mm Tolerance in mm (b) Thickness in mm Tolerance in mm (c) Internal depth in mm Tolerance in mm
50
75
100
63 ± 3.00 4.00 ± 1.00 60 ± 10
89 ± 3.00 4.00 ± 1.00 65 ± 10
114 ± 3.00 4.00 ± 1.00 65 ± 10
125
150
139 ± 3.00 4.00 ± 1.00 75 ± 10
167 ± 3.00 4.00 ± 1.00 75 ± 10
Note: 1. All dimensions are in mm. 2. P ipes weighing m ore tha n th e no minal weight m ay be a ccepted provided th ey c omply i n every other respect with the requirements of this standard. 3. The above table applies only to rain water pipes fixed on wall face. 4. For pipes and fittings which are to be embedded in masonry, specifications shall correspond with those of pipes for soil, waste, and vent pipes. For their weights, specifications under chapter 19.0 shall be referred to. 12.23.3 Fixing and Jointing 12.23.3.1 Pipes shall be ei ther fixed on f ace of wall or embedded in masonry, as required in the description of the item. 12.23.3.2 Plain pipes (without ears) shall be secured to the walls at all joints with M.S. holder bat clamps. The clamps shall be made from 1.6 mm thick galvanised M.S. sheet of 30 mm width, bent to the required shape and s ize so as to fit tightly on t he socket of the pipe, when tightened with screw bolts. It shall be f ormed out of two semi-circular pieces, hinged with 6 m m dia M.S. bolt on one s ide and provided with flanged ends on t he other side with hole to fit by the screw bolt and nut , 40 m m long. The clamp shall be p rovided with a hook made out of 27.5 cm long 10 mm diameter M.S. bar, rivetted to the ring at the centre of one semi circular piece. The details of the clamps are shown in Fig 12.8. The clamps shall be f ixed to the wall by embedding their hooks in cement concrete block 10 x 10 x 10 cm in 1:2:4 mix (1 cement : 2 c oarse sand : 4 gr aded stone aggregate 20 m m nominal size) for which necessary holes shall be made in the wall at proper places. The clamps shall be kept about 25 mm clear off finished face of wall, so as to facilitate cleaning and painting of pipes. Note : Where G .I. sheet clamps are n ot provided, M.S. sheet clamps of 3 m m thick and 20 m m wide shall be used for making the clamps. 12.23.3.3 The pipes shall be fixed perfectly vertical or to the lines as directed. The spigot of the upper pipe shall be pr operly fitted in the socket of the lower pipe such that there is a uni form annular space for filling with the jointing material. The annular space between the socket and the spigot shall be filled with a few tur ns of sp un yarn soaked in ne at ce ment s lurry. These s hall be pressed h ome b y means o f caulking tool. M ore skins of yarn shall be w rapped if necessary and shall be r ammed hom e. The joint shall then be filled with stiff cement mortar 1:2 (1 cement : 2 fine sand) well pressed with caulking tool and finished smooth at top at an angl e of 45 de gree sloping up. The joints shall be k ept wet for not less than 7 days by tying a piece of gunny bag, four fold, to the pipe and keeping it moist constantly. 12.23.3.4 Where pipes are to be embedded in masonry, these shall be fixed in masonry work as it proceeds. In s uch c ases c are shall be tak en to keep the pipes abs olutely v ertical or to the line as directed by t he E ngineer-in-Charge. The pipe s hall hav e a s urrounding of 12 m m m inimum t hickness of mortar at every portion of the external surface. The m ortar shall be of the s ame m ix as is used in the masonry. The joint shall be caulked with lead as soon as the next length of pipe is placed in position.
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The op en end (socket en d) of the pipe s hall be kept closed till the next length is fitted a nd jointed, t o prevent any brick bats or concrete or pieces of wood falling in and choking the pipe. The depth of lead from the lip of socket shall be 25 mm minimum. In case of 100 mm dia. 75 mm and 50 mm pipes, the quantity of lead required per joint shall be 1.00 kg, 0.66 kg and 0.50 kg respectively f or purpose of reckoning theoretical Consumption. In order t o ensure t hat r equired q uantity of l ead i s pou red i nto t he j oint a nd t o c ontrol w astage of lead, at the beginning, three or four samples shall be made and the quantum of lead per joint approved by the Engineer-in-Charge. The ac tual c onsumption of l ead s hould b e w ithin ± 5% of t he a pproved sample j ob s ubject t o t he provision that a variation of ± 20% shall be allowed over the theoretical quantity of lead due to dimensional tolerances allowed as per Indian Standards. This variation includes allowances of wastage also. 12.23.3.5 The spigot end shall butt the shoulder of the socket and leave no gap in between. The annular space between the socket and the spigot will be first well packed in with spun yarn leaving 25 mm from the lip o f t he socket for t he l ead. The joint s hall t hen be lead c aulked as des cribed i n det ail under jointing of S.C.I soil, waste and vent pipes. 12.24 CAST IRON ACCESSORIES FOR RAIN WATER PIPES (FIG. 12.8) 12.24.1 C.I. Fittings C.I. accessories s uch as bends of v arious deg rees, heads , of fsets of di fferent proj ections, bra nches and shoes shall conform to IS 1230. Bends shall be of the nearest standard degree as actually required at site. Heads shall be of the flat or corner t ype a s requi red. Offsets s hall be of t he projection as s tipulated i n t he des cription of t he item. Branches shall be single or double as described in the item and shall be of the nearest standard degree as actually required. Standard shoes shall be of overall vertical length, 180 mm for 75 mm dia., 205 mm for 100 m m dia and 2 75 mm f or 150 di a s ized pi pe f rom t op of s ocket t o l owest t ip of s hoe. S hoes of longer lengths if used shall be in lengths 300 mm, 375 mm, 450 mm, or 600 mm from top of socket to lowest tip of shoe of as actually required at site. 12.24.2 Dimensions The fittings shall be of the diameter specified in the description of the item. The thickness of the fittings and det ails of spigots and s ockets shall be s ame a s those of the corresponding size of straight pipes. The fittings shall be supplied without ears unless otherwise specifically mentioned i n t he i tem. The fittings s hall be f actory painted w ith a tar b asis c omposition b oth inside and ou tside which s hall be s mooth and t enacious. Every f ittings s hall ring c learly when s truck a ll over w ith a l ight hard ha mmer. T he f ittings s hall be of s tandard s ize and t heir i ndividual w eights s hall conform to the weights given in the Table 12.8. TABLE 12.8 Weight of C.I. Rain Water Pipe Fittings
S .No
De s cription
1 1. 2.
2 Bends (Plain) Offsets (Plain) (a) 55 mm projection (b) 75 mm projection
75 mm dia (we ight in kg) 3 3.20
100 mm dia (we ight in kg) 4 4.50
2.70 3.20
5.00 5.50
150 mm dia (we ight in kg) 5 9.10 8.20 9.10
Unit 6 Each Each Each
.
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1
3. 4. 5.
6. 7.
2 (c) 115 mm projection (d) 150 mm projection (e) 225 mm projection (f) 300 mm projection Branches (Plain) Single Double Standard shoes (Plain) Longer shoes (Plain) (a) 300 mm (b) 375 mm (c) 450 mm (d) 600 mm Heads Extras: (a) For ears cast on any fitting and short pipes (b) For inspection doors fitted on any fitting
3 4.10 4.50 5.00 6.00
4 5.90 6.40 7.30 8.60
5 9.50 10.40 11.80 12.70
6 Each Each Each Each
5.00 6.80 3.20
7.30 10.00 4.10
14.50 19.10 8.60
Each Each Each
3.20 4.10 5.50 7.30 6.40
5.00 5.50 6.40 8.60 6.80
11.30
Each Each Each Each Each
0.90
0.90
1.35
Each
1.80
1.80
2.25
Each
Note: 1. The above table applies only to rain water fittings which are part of pipe lines fixed on wall face. Permissible tolerance in weight of fittings shall be 5%. 2. For fittings to be used with pipe lines to be embedded in masonry, specifications shall correspond with those of pipe fittings for soil, waste and vent pipes. For their weights, specifications under S.C.I. soil, waste and vent pipes may be referred to. 12.24.3 Fixing and jointing shall be as specified in 12.23.3. 12.24.4 Measurements The f ittings s hall be m easured by num bers. W here l onger s hoes are us ed i n l ieu of s tandard s hoes specified in the description of the item, they shall be measured as standard shoes of 180 mm, 205 mm and 275 mm for 75 mm dia, 100 mm dia and 150 mm dia respectively in number and the extra lengths of the shoes shall be measured and paid for under the corresponding size of pipes. 12.24.5 Rate The rate shall include in the c ase of fittings fixed on the face of w all, the cost of all m aterials and labour i nvolved i n al l t he op erations d escribed above i ncluding j ointing b ut ex cluding t he supply and fixing t he M .S. hol der bat clamps i n w alls and t he anchoring c oncrete. U nless ot herwise s pecified i n t he description of t he item, the ra te s hall app ly fo r f ittings w ithout ac cess doo rs. I n the c ase of fittings forming part of a rain w ater pi pe line e mbedded in m asonry, t he r ate shall be for s upplying and embedding the fittings in masonry but shall not include for the jointing and lead caulking which shall b e paid for separately. 12.25 THERMAL INSULATION 12.25.1 With Cellular Concrete : 12.25.1.1 Types and Grades: Cellular concrete is a light weight concrete formed by producing gas or air b ubbles i n cement s lurry o r a cement s and s lurry. C ellular c oncrete s hall c onform t o I S 6 598 a nd shall be of following two types depending on the manner of manufacture.
.
390 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
(i) Type I: High pressure steam cured (auto-claved) materials in the form of precast blocks. (ii) Type II: Materials cured under natural conditions (that is under ambient pressure and temperature) by w ater. T he m aterial m ay be either cast i n s itu or m ay be i n the f orm of pre cast blocks. Grades - Each of t hese t wo t ypes of t he material s hall ha ve t hree gr ades, na mely: Grade A - Light weight cellular concrete; Grade B - Medium w eight c ellular c oncrete a nd; Grade C - Heavy weight cellular concrete. 12.25.1.2 Materials (a) Aggre ga te : A v ariety of s illicious f ines, s uch as ground quar ts s and s hale, f lyash a nd gr anulated slag may be used in the manufacture of cellular concrete. (b) Water and binder shall conform to para 3.1.1 and 3.1.2 of Specifications. (c) Ga s s ing Age nts : Organic foaming agents based on resin soap, glue, surface active agents, or fine aluminium powder, zinc, dust, calcium carbide, calcium by pocheride etc. may be used for gassing the concrete. 12.25.1.3 Dimensions : The di mensions o f t he type I and t ype I I p recast cellular concrete bl ock shall be either 50 or 60 cm in length, 20, 25 or 30 cm in width and 7.5, 10, 15, 25 or 40 cm in thickness. 12.25.1.3.1 Tole ra nce : A tolerance of ±3 percent shall be a llowed on width and height and ±1 percent on thickness. 12.25.1.4 Requirement for Cellular Concrete TABLE 12.9
S. No. 1. 2.
3.
4.
Cha ra cte ris tics
Gra de A Upto 320
Gra de B 321 to 400
Gra de C 400 to 500
Te s t re fe re nce
Density in IS 5688 kg/cum Crushing Strength in kg/sq. cm. (type I) 7.0 12.0 20.0 -do(type II) 2.5 4.5 8.0 Thermal conductivity in kw/cm deg c 0.7 0.85 1.0 IS 3346 at 50 deg. c mean temperature Capillary absorption not to exceed 20% in case of type I cellular concrete when tested as per Appendix A of IS 6598.
12.25.1.5 Sampling: In a consignment, cellular concrete of the same type and grade and manufactured approximately in the same period shall be grouped to form a lot. If it is in the form of blocks, a lot shall be made up of not more than 1000 blocks. If the material is in situ, not more than 10 t ons of materials shall constitute a lot. If the material is transported in lorries and received as such, the material in lorry (or vehicle load) & may conveniently be termed as lot. Each lot shall be tested for all the requirements separately. .
391 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
If the lot is made up o f precast blocks, the number of sample blocks to be tested shall be s elected at random as per the following Table 12.10. TABLE 12.10
Lot S ize Up to 100 101 to 300 301 to 500 501 to 1000
S a mple s ize (block to be sa mple d) (n) 5 8 13 20
P e rmis s ible No. of de fe ctive s (vis ua l and dime ns iona l re quire me nts ) (a ) 0 0 0 1
12.25.1.6 General : Cellular concrete if done with precast blocks shall be laid on terrace slab after thoroughly cleaning the s urface. T he blocks s hall be l aid o ver a layer of 1 2 mm average thick c ement mortar 1: 4 ( 1 c ement : 4 c oarse s and) and t he joints shall al so be filled properly with neat c ement s lurry. The joints shall be s taggered. Thickness of j oints shall be as m inimum as possible and not m ore than 5 mm. 12.25.1.7 Measurements : Length and breadth of the roofing insulation shall be m easured correct to a cm and the surface area worked out in square metre of the finished work. No deduction shall be made for openings of areas upto 40 square decimetre. No extra payment will be made f or any extra m aterial or l abour i nvolved i n forming s uch op enings. For op enings ex ceeding 4 0 square decimetre in area, deduction for the full opening will be made, but nothing extra will be paid for any extra material or labour involved in forming such openings. 12.25.1.8 Rate : The rate shall include the cost of all materials and labour required in providing cellular concrete. 12.25.2 With Resin Bonded Fibre Glass Wool (Bonded Mineral Wool) 12.25.2.1 Material: The material shall be mineral wool made from rock slag or gl ass processed from a molten s tate i nto f ibrous form and shall be bonded w ith a s uitable bi nder. B onded mineral w ool s hall conform to specifications of group I of IS 8183. 12.25.2.2 Dimensions: The bonded m ineral w ool shall be s upplied i n w idth of 50, 60, 75 and 100 cms, and length of 100, 120 and 140 cms and the thickness of the bonded mineral wool shall be 25, 40, 50, 65 or 75 mm. 12.25.2.3 Tolerances: For w idth and l ength, t he di mensional t olerances of t he bonded m ineral w ool slabs shall be -½%. F or nominal thickness in the range 25 to 75 mm the tolerance shall be -2 mm. A n excess, in all dimensions is permitted. 12.25.2.4 Requirements for Fibre Glass Wool TABLE 12.11 S. No. 1. 2.
Cha ra cte ris tics
Group I
Bulk density Recovery after compression
12 to 15 kg/cum not less than 90% of original thickness
Te s t Re fe re nce IS 3144 Annex. A of IS 8183
.
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S. No. 3. 4. 5. 6. 7.
Cha ra cte ris tics
Group I
Shot content max Moisture content and absorption Incombustibility Thermal conductivity deg. C at mean temperature 50 deg.C Sulphur content
Te s t Re fe re nce
500 micron - 5% 250 micron - 15% not more than 2%
IS 3144
Incombustible 0.49 mw/ cmoC
IS 3144 IS 3346
Not more than 0.6%
IS 3144
IS 3144
12.25.2.5 General : Bonded mineral wool insulation can be either laid over false ceiling or alternatively it can be fixed to the ceiling when the space above false ceiling is being used for carrying return air. In the first case the bonded mineral wool can either be fixed with suitable adhesive to the false ceiling board or else it can simply be rolled over the suspended false ceiling. In the second case when space above false ceiling is to be us ed for carrying return air 1.5" x 1.5" slotted an gle (3" length) shall be f ixed to the c eiling b y m eans of rawl plugs at 2’0" s pacing. Draw 14 gauge t ie wires from t he slots. Make a mat of mineral wool i nsulation bac ked w ith scrim c loth with a l ight coating of Plaster of Paris or pol ythene faced hessian and 2 4g x 1" wire mesh netting. The joints of wire netting should be butted and tightly laced down with G.I. wire. Stretch the mat tightly across the angles holding it in place by means of tie wires. 12.25.2.6 Measurements : Length and bre adth o f the roofing insulation shall be m easured correct to a cm and the surface area worked out in square metre of the finished work. No deduction shall be made for openings of areas upto 40 square decimetre. No extra payment will be made f or any extra m aterial or l abour i nvolved i n forming s uch op enings. For op enings ex ceeding 4 0 square decimetre in area, deduction for the full opening will b e m ade, b ut n o extra w ill be p aid for a ny extra material or labour involved in forming such openings. Boarding fixed t o c urved surf aces i n na rrow widths s hall be measured a nd p aid for separately. Circular cutting and waste shall be measured and paid for separately in running metres. 12.25.2.7 Rate : The rate shall include the cost of all materials and labour required i n providing bonded mineral wool. 12.25.3 With Expanded Polystyrene : 12.25.3.1 Material : Expanded polystyrene shall conform to IS 4671. It is of two types as given below: (a) Type N - Normal (b) Type SE - It shall be of self e xtinguishing type when tested in accordance with Appendix E of IS 4671. 12.25.3.2 Dimensions : The size of the finished boards shall be 1.0 × 0.5 m or as specified and having a thickness of 15, 20, 25, 40, 50, 60, 75 or 100 mm. 12.25.3.2.1 ±2 mm.
: The tolerances on l ength, width and t hickness of the finished board shall be
.
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12.25.4 With Exfoliated Vermiculite : 12.25.4.1 Material : Exfoliated vermiculite consists of vermiculite mineral which has been expanded many times of its or iginal vo lume aft er being s ubjected to high temperature ( 700 d egree C to 1 000 degree C). It is utilised as a thermal insulation material after mixing it with a cementitious material. 12.26 UNPLASTICISED POLYVINYL CHLORIDE PIPES AND FITTINGS 12.26.1 UPVC Pipes Pipes s hall c onform t o Type A pi pes of I S 13592. T he i nternal and ex ternal s urfaces of the pi pes shall be smooth and clean and free from groovings and other defects. The end shall be clearly cut and shall be s quare with the axis of the pipe. The end may be chamfered on the plain sides. S light shallow longitudinal gr ooves or i rregularities i n t he w all thickness shall be per missible provided t he w all t hickness remains within the permissible limit. 12.26.2 Colour of Pipe Surface colour of the pipes shall be dark shade of grey or as specified . 12.26.3 Marking Each p ipe s hall be c learly and i ndelibly m arked with t he f ollowing i nformations at i ntervals not m ore than 3 meter. (a) Manufacturer’s name or trade mark. (b) Nominal outside dia of pipe. (c) Type ‘A’ (d) Batch number. 12.27.4 Dimensions 12.26.4.1 Diameter and Wall Thickness: Mean out side diameter, out side di ameter at any po int an d wall thickness for type -A manufactured plain or with socket shall be as given in Table- 1 of IS 13592. UPVC r ain w ater pipes s hall b e of t he di a, s pecified i n t he description of t he i tem and s hall be i n nominal lengths o f 2 ,3,4 or 6 metres either p lain or w ith s liding/grooved socket u nless shorter l engths are required at junctions with fittings. Tolerances on specified length shall be + 10 mm and - 0 mm. 12.26.5 Fixing and Jointing Pipes s hall b e e ither f ixed on f ace of w all or em bedded in m asonry as r equired i n t he description of the item. Plain pipes shall be secured to the walls at all joints with PVC Pipes clips by means of 50 x 50 x 50 mm hard w ood pl ugs, s crewed w ith M. S. screws o f required l ength i /c c utting b rick w ork and fixing in cement mortar 1:4 (1 cement : 4 coarse sand ). The clips shall be kept about 25 mm clear off finished face of wall, so as t o facilitate cleaning of pipes. Pipes shall be fixed pe rfectly vertical or to the l ines a s di rected. The pipes s hall be fi tted to fi ttings with s eal ri ng c onforming to IS 5382 al lowing 1 0 m m ga p for t hermal expansion. 12.26.6 Installation in Wall/Concrete The w alls/concrete s lots s hould al low f or a s tress f ree i nstallation. P ipes an d f ittings t o be i nserted into the slots without a cement base have to be applied first with a thin coat of PVC solvent cement
394 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
followed by s prinkling of dry s and (medium s ize). Allow i t to dry. T he p rocess gi ves a s ound bas e f or cement fixation. This process is repeated while joining PVC material to CI/AC materials. 12.26.7 Fittings Fittings used shall be of the same make as that of the PVC pipes Injeciton moulded or fabricated by the manufacturer and s hall hav e a minimum wall t hickness o f 3.2 mm. The fittings shall be s upplied w ith grooved s ocketted ends with s quare groov es and provided with Rubber G asket c onforming t o I S 538 2. The pl ain en ds of the fittings s hould b e chamfered. The f ittings s hall b e joined w ith the he lp of R ubber lubricant. The details of fittings refer IS 13592. 12.26.8 Measurements The f ittings s hall be m easured by num bers. The pi pes shall be measured net w hen fixed correct t o a cm. excluding all fittings along its length. 12.26.9 Rate The r ate s hall i nclude t he c ost of all m aterials a nd l abour i nvolved i n all t he o perations d escribed above including j ointing but excluding the s upply and fixing of w all plugs and P VC clips w hich s hall be paid for separately. Note : These pipes shall be used only i n s haft or unexposed location t o a void d amage t o t hese pipes due to willful act.
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APPENDIX A
GALVANISED STEEL SHEETS (Clause 12.1.1)
A-1 Dimensions A-1.0 S izes of pl ain S heet: T he pl ain s heets s hall be s upplied i n any c ombination of the f ollowing lengths, widths and thickness. (a) Length : 2500 and 3000 mm (b) Width : 900 and 1000 mm (c) Thickness : 0.50, 0.63, 0.80, 1.00 mm A-1.1 In case o f sheets supplied in coil, the internal diameter o f coil shall b e 45 0, 510 and 610 mm and the mass of each coil shall not exceed 12 tonne. A-1.1.1 Coils weighing more than 12 tonnes may be supplied subject to mutual agreement between the contracting parites. A-1.2 Corrugated sheets. A1.2.1 Length- The length of the corrugated sheets shall be as follows: 2500, 3000 mm A-2 Zinc Coating The w eight of c oating r eferred t o i n t his s pecification s hall r epresent t he t otal weight of zinc bot h s ide inclusive. On any sample selected at random from the delivery, one set of three samples each 50 x 50 mm or 50 mm diameter shall be selected at random from one sheet for every 500 G.S. sheets, the coating for the different classes shall be within the limit specified in table below: TABLE I Mass of Coating (Total Both Sides)
Gra de of coa ting
Minimum a ve ra ge coa ting Triple spot te s t g/s qm 600 600 450 450 350 350 275 275 * minimum individual value obtained in triple spot test.
Minimum coa ting single s pot te s t g/s qm* 510 380 300 235
A-3 Mass The mass of sheets and c oils shall be c alculated as given in Table II on the basis of nominal dimensions and mass of zinc coating.
.
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TABLE II Calculation of Mass of Sheets or Coils
Type of ma te ria ls Order o f c a lcula tion Sheet
Mass of single sheet Total mass
Coil
Unit mass of coil Mass of single coil Total mass (kg)
Me thod o f c a lcula tion Nominal mass of single sheet plus mass of zinc coating Mass of single sheet (kg) x number of sheets Unit mass of sheet (kg/m2)x width (mm) x10 -3 Unit mass of coil (kg/m)x length (m) Total mass of each coil
Numbe r of Nume ra ls in re s ulta nt va lue Rounded off to 4 effective figures Rounded off to integral value of kg Rounded off to 3 effective figures
Integral number of kg
Note: (i) Nominal mass of single sheet shall be calculated by calculating the volume of the sheet and multiplying the same with density of sheet (density 7.85 g/ cubic cm) and rounding the same to 4 effectve figures. (ii) Mass of the coating shall be calculated by multiplying the surface area of single sheet with indicated inominal coating mass (g/square metre) as shown for triple spot test (Table I). (iii) For calculation of corrugated sheet mass, the width before corrugation shall be considered while calculating the area. A-4 Corrugations The depth and pitch of corrugation shall be as follows: De pth of Corruga tion P itch of Corruga tion (mm) (mm) A 17.5 75 B 12.5 75 The number of corrugations shall be 8,10, 11 or 13 per sheet. The overall width of the sheets before and after corrugation shall be as given in Table below. Gra de
TABLE III Details of Corrugations Numbe r of corruga tions (1) 8 10 11 13 8 10 11 13
Gra de
(2) A A A A B B B B
Nomina l ove ra ll width of she e t me a s ure d betwe e n crowns of outs ide corruga tions Be fore corruga tion Afte r corruga tion Mm mm (3) (4) 750 660 900 810 1000 910 1200 1110 750 680 900 830 1000 930 1200 1130
.
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C.G.S. SHEETS Sub Head : Roofing Clause : 12.1 8 mm dia G hook Bolt with Nut Limpet Washer Bitumen Washer
C.G.S. Sheet
Purlin
S IDE LAP
2000 for 1.00 mm Thick Sheet 1800 for 0.80 mm Thick Sheet 1600 for 0.63 mm Thick Sheet
Purlin Spacing
100
Purlin
Overhang
LAYING Drawing Not to Scale All Dimensions are in mm
Fig. 12.1 : C.G.S. Sheets
398 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
GALVANISED STEEL SHEET GUTTER Sub Head : Roofing Clause : 12.1
40 x 3 M.S. Flat Iron Bracket Hooked Joint
5 mm G.I. Bolt and Nut to Connect Gutter to Bracket
Slope < 1 in 120
Flow
A
CROS S S ECTION
Spacing > 1120
L-S ECTION C.G.S. Roofing Battens 25 x 50
Common Ra
20
DETAIL AT H 40 x 3 M.S. Flat Iron Bracket Spaced at not More than 1200 Centres G.I. Bolt and Nut 8 mm Dia with a Set o f Bi tumen and G.I. W asher o n Either Side
fter
Wall Plate
2 No s. 1 0 D ia B olts Nut & Washer
10 mm d ia M. S. B olt Nut and Washer
FIXING BRACKET TO RAFTE R
Principal Rafter Gutter Tie Beam
P LAN
50 x 3 M.S. Bracket Bent to Shape to Support Gutter
FIXING B RACKET T O P URLIN DES IGNATING S IZE A
50
Rivets at 35 c/c
50
G.I. Gutter
100
Funnel Shape Connection Piece 100 D ia A .C. R ain Water Pipe
S ECTION ACROS S GUTTER
Drawing Not to Scale All Dimensions are in mm
P LAN
S ECTION ALONG GUTTER
Fig. 12.2 : Galvanised Steel Sheet Gutter
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WIND TIE AND FLASHING Sub Head : Roofing Clause : 12.1.5 & 12.3
50 mm Inside Flashing G.S. 400 mm x 1.25 mm 50
Wind Tie M.S. Flat 40 x 6 mm
Drawing Not to Scale All Dimensions are in mm
Fig. 12.3 : Wind Tie and Flashing
400 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
NON-ASBESTOS CORRUGATED SHEET Sub Head : Roofing Clause : 12.5, 12.8 280
146
GI Hook Bolt GI Nut GI Flat Washer Bitumen Washer
Purlin SIDE LAP SEM I CORRUGATED SHEET
SIDE LAP
Side Lap
1750
C
C
1750
C
D
1600max
End Lap
D
D
Termediate Purlin Principal Rafter
Purlins
300 max 3000
FIXING SHEETS CHANNEL PURL IN
A
B
B
B
B
Purlin Position to Suit Overhang to Gutter
LAYING OF SHEETS
A B C D
Principal Cleat
Purlin
A
Uncut Sheet Top Left Hand Corner Cut Bottom Right Hand Corner Cut Top Left Hand Corner and Bottom Right Hand Corner Cut
1080
GI Hook Bolt GI Washer Bitumen Washer
Principal Rafter
150
END LAP AND FIXING SHEETS TO MS ANGLE PURLIN Sheeting L Type Hook Bolt
270
Use as Ventilator Curve
APRON PIECE
RSJ Purlin G.I Bolt G.I. Washer
200 Each
S TYPE LOUVER
1000
300 EAVE FILLER PIECE
Drawing Not to Scale All Dimensions are in mm
12.4 : Non-Asbestos Corrugated Sheet
401 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
NON-ASBESTOS CEMENT ACCESSORIES Sub Head : Roofing Clause : 12.8 Ridge Coach Screw
Crank Bolt M.S. Angle Purlin
TW Purlin
S ECTION S HOWING ALTERNATIVE FIXING ACCES S ORIES ONE P IECE P LAIN ANGULAR RIDGE This Portion of Inner Ring of Ridge to be Trimmed Off
R
eparation S uitably Pai nted o n
idges to Fit in Corrugations where Sheets Overlap
Outer Wing of R idge
Inner Wing of Ridge
J-Type Hook Bolt Sheets
This Portion of Outer Ring of Ridge to be Trimmed Off
FIXING O F S ERRATED ADJ US TABLE RIDGE 1.12 mm Outer Wing
Mushroom H ead Roofing Bolt with Bitumens G.I. Washer
Inner Wing Tin Painted Black
S ERRATED ADJ US TABLE RIDGE
J-Type Hook Bolt
Glass Glazing Tee
MS Angle Glazing Runner
UNS RP RATED ADJ US TABLE RIDGE Drawing Not to Scale All Dimensions are in mm
Fig. 12.5 : Non-Asbestos Cement Accessories
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NON-ASBESTOS CEMENT GUTTERS Sub Head : Roofing Clause : 12.9 A
A
D
C
B
B
VELLEY GUTTER Nominal Size 900X200X225 600X150X225 450X125X150 400X125X150
A 900 600 450 400
S
B 200 150 125 125
D
T
BOUNDARY WALL GUTTER OR EAVES GUTTER C 225 225 150 150
D 12.5 12.5 12.5 12.5
A
A
A
C
Nominal Size 500X150X250 450X150X300 300X150X225 275X125X175
A 500 450 300 275
C
B
S
K
B 150 150 150 125
C 250 300 225 175
HALF ROUND GUTTER Nominal Size 150 250 300
D 12.5 12.5 12.5 10.0
B
S
DROP END WITH SOCKET
FOR HALF ROUND GUTTER
Type of Gutter
290
310
C
DROP END WITH SPIGOT
Nominal Size 150
A 150
B 90
C 240
S 70
250
200
200
300
100
300
200
200
300
100
125
150
90
240
70
200
150
90
240
70
Ogee Gutter
190
T 9.5 9.5 9.5
K
K NOZZLE
A 150 250 300
290
K 105 110 105 110 115 105 110 115 105 110 105 110 115
D 90 100 90 100 150 90 100 150 90 100 90 100 150
215
230
S
S
For Boundary Wall & Valley Gutter
215
D
D
DROP END
NOZZLE
S 105 110 115
D 90 100 150
230
ANGLE FOR BOUNDARY WALL GUTTER
ANGLE FOR HALF ROUND GUTTER
Drawing Not to Scale All Dimensions are in mm
Fig. 12.6 : Non-Asbestos Cement Gutters
CPWD SPECIFICATIONS 2009
403 | Page HO Civil Specifications Volume - I
CEMENT CONCRETE KHURRA - GOLA Sub Head : Roofing Clause : 12.13 and 12.14
Wall
450 A B C D E P.V.C. Sheet 1000 x 1000 (400 Micron Thick)
F
12 mm Plaster
KHURRA
A B C D E
GOLA
A
Brick Tiles
B C D E
Mud Phuska/Lime Concrete Painting with Hot Bitumen 80/100 at 1.7 kg/sq.cm. R.C.C. Slab 6 mm Thick Ceiling Plaster Finished neat and Thick Coat of White Washing or Kraft Paper
F
P.V.C. Sheet 1000 x 1000 (400 Micron Thick)
Drawing Not to Scale All Dimensions are in mm
Fig. 12.7 : Cement Concrete Khurra - Gola
404 | P a g e H O C i v i l S p e c i f i c a t i o n s V o l u m e - I
HOLDER BAT CLAMP Sub Head : Roofing Clause : 12.23, 12.24 M.S. Holder Bat Clamp 1.6 Thick and 30 Wide Galvanised M.S. Clamp
C.I. Rain Water Pipe
Wall
Hook 275 Long and 10 dia of M.S. Bar Nut
Bolt Shoe Cement Concrete Block 1:2:4 (1 Cement : 2 C. Sand : 4 Stone Aggregate) 40 mm G.I. Bolt and Nut 100 Clearance 25
100
FRONT ELEVATION
6 mm Dia Pin 12 mm Plaster
SECTION PLAN
Cement Mortar
60
36
35
6 mm Dia G.I. Sheeting Bolt 25 Long
M.S. HOLDER BAT CLAMP FOR C.I. RAIN WATER PIPE
Cement Mortar 1:2 6 25 72
Bitumen Socket Spun Yarn
A.C. Rain Water Pipe
Wall
Screw Designation No. 18
ELEVATION 25 22 6 6 20
SECTION ELEVATION
Core Holes
16 Dia 10
150
M.S. Flat 3 mm thick 20 mm Wide
Wooden Block
72 132 DETAIL AT 'A'
30 5.5
Dia of Pipe 'R'
50 mm
80 mm
100 mm
30 mm
46 mm
58 mm
No te : The clamp shall be Galvanised throughout. SECTION PLAN
Drawing Not to Scale All Dimensions are in mm
Fig. 12.8 : Holder Bat Clamp
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