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DELHI JAL BOARD, OFFICE OF THE EX.ENGINEER(NE)II

R-POCKET : DILSHAD GARDEN : DELHI-95.NIT NO. 46( 2007- 08)

Sealed tenders for the following works on percentage rate basis are hereby invited in two parts on the prescribed format from the registered contractors of Delhi Jal Board and appropriate category with CPWD, DDA, NDMC, Who must have executed three similar nature works each of value not less than 40% of estimated cost or two similar nature works each of value not less than 50% of estimated cost or one similar nature work of value not less than 80% of estimated cost (rounded off to nearest Rs. 10.00 lacs) in the last seven years only. The NIT/tender documents are available on the web site www.delhijalboard.nic.in & www.delhigovt.nic.in/tender. The interested bidders can also down load the Tender document and have to follow general conditions and guidelines along with various circulars issued by DJB time to time. Annexure ‘A’, Annexure ‘B’ and other information along with eligibility criteria for tendering are also available on web site. Rate quoted shall hold good for 90 days from the date of opening of tender, any further information/clarification may be sought from the office of under signed. Last Date of receiving of Complete Tender Format (A+B) ----- 02.04.08 3.00 PMDate of Opening of Annexure-(A) EARNEST MONEY ------ 02.04.08 3.05 PMDate of Opening of Annexure-B (TENDER) ------ 02.04.08 3.30 PMIf due to one or other reason, the office is closed on any of the above dates, the sale & opening of tenders will be on the next working day

Item No.

Name of Work Amount Put to Tender

Earnest Money

Tender Fee

Completion Period

1. Replacement of 450mm dia W/Line main road Brahmpuri, NE-II C.I OPTION D.I OPTION

3822640.003567682.00

76500.0071500.00

800.00800.00

4 Months

2. P/L/J water supply distribution net work in Shiv Vihar Phase-II in Karawal Nagar C.I.OPTION D.I.OPTION

2712535.002763221.00

54500.0055500.00

800.00800.00 3 Months

sd/- (ER. D.K.SHRIVASTWA) EX.ENGINEER (NE)-II

NO.DJB/EE(NE)II/NIT/07-08/ Dated_____________Copy to:

1. EO to Member drainage/Water/Chief Engineer (east)/SE(NE)/ADOV(W)2. Director(F&A)/A.C.A/Accountant(NE).3. Jr.Acctt.(NE)II/All ZE(NE)II/DM/Notice Board/Cashier(NE)II4. Head Clerk(NE)II with the instruction to ensure the wide publicity amongst the contractors and transmitted on DJB Web site.5. Delhi Jal Board Contractor Welfare Association(Regd) Villa 36, Block B.A Paschimi Shalimar Bagh, Delhi-88.6. PRO.(W)for published in the newspapers However NIT transmitted on the website vide unique No. 7. Office copy & M/file

EX.ENGINEER (NE) II

Other information along with eligibility criteria for tendering

The condition of contract (subjected to change or modification from time to time) are available on the DJB Web site which will be applicable for all the works and may be down loaded for the information of the bidders and the same need not to attach with the tender. However, these shall form a part of contract documents and shall be attached at the time of entering into contract with the successful tenderer. The same can be had against payment of Rs.150/- from the office of the undersigned. Further, the deduction of Tax will be made as per D- VAT as applicable. For each item the tender should be in separate envelope. More than one item in one envelope is not entertained. Any further information/clarification may be sought from the office of under signed.

Contract documents other than the above consisting of application form (Annexure-A), tender Form (Annexure-B), Bill of quantity, Special & particulars conditions and specification of each & every work along with the Press Notification shall be available on the Web site and the same shall be down loaded by the respective bidders. Tenders of only those tenderers/contractors will accepted who have downloaded annexure A & B original form website of DJB and no photocopies will be accepted. For the contractors/tenderers, who are not equipped with the down loading of system the above documents can be had manually from the office of the undersigned. The lowest tenderer will be responsible to collect the work order for this and separate correspondence will be made. The delay in execution of work due to not collecting the work order will be on the part of the contractor. The Tenderer/ Contractor shall put the tender fee (non refundable) and Earnest money in the shape of Demand Draft/CDR/drawn on scheduled bank in favor of Delhi Jal Board, Payable at Delhi along with application form (Annexure-A), The eligibility criteria for the contractors to be submitted in the envelop marked EARNEST MONEY (Part-A):

i) Photocopy of Registration in appropriate class of DJB. ii) Photocopy of Valid Registration Certificate under D-VAT. iii) Affidavit/Undertaking in respect of having not black listed/debarred in D.J.B. as well as in

any govt. deptt., iv) Performance certificates of similar type of works issued from the concerned EEs.

v) All documents (Self attested, stamped and legible) submitted must be properly paged and number of pages must be mentioned in the appropriate place in Annexure-A.

Pay order No., date, Amount & Name of issuing Bank should be mentioned on Application for issue of tender and Tender/Financial bid consisting of tender form (Annexure-B) in separate sealed cover marked (TENDER) (Part-B). Both the envelopes shall then be put in another sealed cover. Name of work, NIT No. , Item No. , name of the participating Firm , etc. should be mentioned on all the Envelopes including Annexure - A & Annexure - B. Part-A and Part-B shall be opened as specified as above in the presence of the bidder who may like to attend. The envelope mark TENDER Part –B, however, will be opened for those, who fulfill the criteria required/ if found in order under Bid Part - A otherwise the same shall be returned unopened to the tenderer.

The envelope marked EARNEST MONEY (PART-A) shall be opened first of all for examinations on the date of receipt of tender. Part-B of the tender shall be kept sealed under the safe custody of Executive Engineer. The tender financial bid (Part-B) shall be opened on specified date only of those contractors who fulfil the criteria required under Bid Part-A if found in order

fulfilling the requirements otherwise the same (Part-B of the tender) shall be returned to the tenderer unopened.

The contractors/tenderers are requested to go through the NIT/Tender documents properly/correctly before tendering and should carefully fill in all the required details in the tender forms. If the contractor fails to submit the above, the envelope (Part-A) will be rejected/cancelled as per condition mentioned above and no correspondence will be entertained. The capability/financial status, genuineness of the firm shall be checked by Engineer-in-charge before opening of Envelop-B (TENDER).

The Contractor participating in this NIT will quote the rates only for one option i.e. either for C.I. Pipe or D.I. Pipe. The lowest tendered cost with any of option shall be considered as the lowest evaluated tendered cost.

(ANNEXURE-A)

APPLICATION FORM

To,The Executive Engineer (NE)-II,DJB

Subject:-Tender for the work of

1. Replacement of 450mm dia W/Line main road Brahmpuri, NE-II {OPTION-1 :- C.I. PIPES} or {OPTION-2 :- D.I. PIPES 2. P/L/J water supply distribution net work in Shiv Vihar Phase-II in Karawal Nagar

{OPTION-1 :- C.I. PIPES} or {OPTION-2 :- D.I. PIPES

Press notification/N.I.T. No. -- 46 Item No. 01 or 02

Sir,

01 *I/We am/are registered with the DJB as Class (category)……..contractor/contractors eligible to tender upto Rs.________.Our registration No. is_________. It is further certified that the said registration is valid as on date_____________.01 *I/We am/are not registered with DJB. (In the case of manufacturer detail of manufacturing license/registration with State Industry Department is attached at page___________)

I/We am/are registered contractors with______________________. Particulars of the authority, Class and tendered amount/limit upto which I/We am/are eligible to tender are furnished below:

Name of department/authority

Class/category Tendering Limit

It is certified (confirmed) that this registration/these registration is/are valid as on date and we shall inform the department ourselves as soon as our registration expires or is cancelled/revoked.

The Particulars of the work done are furnished/enclosed as per the eligibility criteria set out in the Press Notification. The tender fee (Non-refundable) & earnest Money is also enclosed in the envelope marked EARNEST MONEY (PART-A)

I/We certify that we have gone through the General Conditions 1to 45, Clauses of contract Sl.No. 1 to 45, Instructions to bidders Sl.No.1 to 11, DJB safety codes Sl.No.1 to 16,

Model rules for protection of Health & sanitary arrangements for workers employed in or by Delhi Jal Board or its contractor Sl.No.1 to 12, Contractors Labour regulations 1 to 18. We further confirm of having full knowledge that the above conditions are to form a part of the contract agreement executed with the successful contractor.

I/We request, the permission may be granted to me/us to participate in the tender:

Encl: a) Tender Fee Rs._______in the shape of ___________

b) EMD Rs.________in the shape of ______________

c) Documents in support of fulfilling the eligibility criteria, registration etc. placed from page no.______to______.

Yours faithfully,

( Contractor )

Name Telephone No. Address

Note:- (*Strike out inapplicable portion) Strike out irrelevant name of works, options and item numbers.

( ANNEXURE – B)

DELHI JAL BOARD : GOVT. OF NCT OF DELHITENDER FORM

PERCENTAGE/ITEM RATE TENDER

TENDER FEE RS. 800.00

TO BE FILLED IN BY THE CONTRACTOR, TENDER DOWNLOADED FROM THE WEB SITE OR COLLECTED MAUALLY.

1. Replacement of 450mm dia W/Line main road Brahmpuri, NE-II {OPTION-1 :- C.I. PIPES} or {OPTION-2 :- D.I. PIPES 2. P/L/J water supply distribution net work in Shiv Vihar Phase-II in Karawal Nagar

{OPTION-1 :- C.I. PIPES} or {OPTION-2 :- D.I. PIPES

Press notification/N.I.T. No. -- 46 Item No. 01 or 02

a) To be submitted by___________________________________________(date & time)b) To be opened in the presence of tenderer who may be like to attend_____at (time)

1. Issued to/downloaded by________________________________(Contractor)2. Signature_____________________________

TENDER

I/We have read and examined the press notification/Notice Inviting Tender, specifications of the works as applicable, General conditions. The Instructions to the bidder Sl.No.1to 11, General conditions of contract Sl.No.1 to 45, Clauses of contract Sl.No.1 to 45, DJB safety code Sl. No.1 to 16, Model Rules for the protection of Health & sanitary arrangements for workers employed in or by Delhi Jal Board or its contractors Sl.No.1 to 12, Contractors Labour regulations Sl.No.1 to 18 and others relevant specifications given in I.S. codes, CPWD specification 1966 to 2002 alongwith other documents of the work.

I/We hereby tender for the execution of the work specified by Delhi Jal Board within the specified time and schedule of quantities in accordance in all respects with specifications, design, drawings and instructions in writing referred to the General Conditions/Clauses of contract etc. as given in the aforesaid Para.

We agree to keep the tender rate open for 90 days from the date of its submission and not to make any modification in its terms & conditions.

We are aware that the conditional tender is liable for rejection. Delhi Jal Board has a right to reject any tender or all the tenders without assigning any reasons.

A sum of Rs.________ has been submitted with the tender in the required form as Earnest Money. If I/we fails to commence the work within specified period, I/We agree that the Delhi Jal Board or designated office shall without prejudice to any other right or remedy, be at liberty to forfeit the Earnest Money absolutely otherwise the said earnest money shall be retained by him/DJB towards security deposit to execute all the works referred to in the tender documents upon the terms & conditions contained or referred to therein and to carry out such deviations as may be ordered.

I/We hereby declared that I/We shall treat the tender documents and other records connected with the works as secret/confidential documents and shall not communicate information/derive there from to any person other

than a person to whom I/We am/are authorize to communicate the same or use the information in any manner prejudicial to the safety of the Govt.

I/We agree that should I/We fails to commence the work specified as above an equal amount to the amount of earnest money mentioned in the form of invitation of tender and performance guarantee shall be absolutely forfeited to the DJB and the same may be at the opinion of the competent authority on behalf of DJB be recovered without prejudice to any other right or remedy available in the law out of the deposit in so far as the same may extend in terms of the said bond and in the event of deficiency out of any other money due to me/us under the said contract or otherwise.

I/We confirm that I/We are duly authorized to sign the tender documents.

I/We are aware and agree to the terms & conditions as mentioned in the aforesaid para, that will form the contract documents to be placed in the contract agreement to be signed by the DJB and the successful tenderer.

I/we hereby tender for the execution of work @ _________________% above/below (in figure) @ ____________________________________@ above/below (in words) on the bill of quantity.

Signature of the contractor

***Tender Fee unless otherwise specifically specifiedWork costing upto 1 lac Rs. 250/-Work costing more than 1lac upto 50 lacs Rs. 800/-Work costing more than 50 lacs upto 2 crores Rs. 1500/-Work costing above 2 crores Rs. 2500/-

Note:- (*Strike out inapplicable portion) Strike out irrelevant name of works, options and item numbers.

Name of Work : Replacement of 450mm dia W/Line main road Brahmpuri, NE-II

Bill of Quantity D.I. option Item No.1  Description Quantity Rate Unit Amount1 Demolishing cement concrete including

disposal of material within 50 meters lead.1:3:6 or richer mix 271.68 242.10 cum 65773.72

2 Cutting of bituminous road and taking out soling, matte ling, including sorting, screening and stacking and cost of barricading and watch and ward complete. 181.12 141.00 cum 25537.92

3 Earth work in excavation over areas (exceeding 30 cm in depth. 1.5 m in width as well as 10 sqm on plan) including disposal of excavated earth, lead up to 50 m and lift up to 1.5m; disposal earth to be leveled and neatly dressed. All kinds of soil. 905.92 91.50 cum 82864.23

4 Filling available excavated earth (excluding rock) in trenches, plinth, sides of foundations etc. in layers not exceeding 20cm in depth: consolidating each deposited layer by ramming and watering, lead up to 50 m and lift upto 1.5 m 679.21 30.25 cum 20546.10

5 Providing and laying S&S centrifugally cast (spun) iron pipes (Class LA) conforming to IS - 1536.       0.00

a) 100 mm dia pipe 10.00 488.90 metre 4889.00b) 200 mm dia pipe 5.00 1047.95 metre 5239.75c) 250 mm dia pipe 5.00 1412.20 meter 7061.006 Providing and laying S&S Centrifugally

cast (spun)/Ductile Iron pipes conforming to IS - 8329       0.00100 mm dia pipe K-7 20.00 491.90 Meter 9838.00200 mm dia pipe K-7 5.00 1021.15 Meter 5105.75250 mm dia pipeK-7 10.00 1358.25 Meter 13582.50450mm dia Ductile Iron Class K-7 pipes 948.00 3020.20 Meter 2863149.60

7 Providing and laying D.I specials of Class K - 12 suitable for push -on jointing as per IS : 9523       0.00

  Upto 600 mm dia 12.42 7724.80 Quintal 95942.018 Providing and laying D.I specials of Class K       999990.00

- 12 suitable for mechanical jointing as per IS : 9523

  Upto 600 mm dia 6.45 7992.55 Quintal 51551.949. Cutting of DI/MS Pipes & specials etc. by

gas plant. 28417.00 1.10 cm 31258.7010 Providing push-on-joints to Centrifugally

(Spun) cast iron pipes or Ductile Iron Pipes including testing of joints and including the cost of rubber gasket

a) 100 mm dia pipe 4.00 30.75 Each 123.00b) 200 mm dia pipe 9.00 73.70 Each 663.30c) 250 mm dia pipe 16.00 85.70 Each 1371.20d) 450 mm dia pipe 192.00 264.75 Each 50832.00e) 600mm dia pipe 1.00 365.55 Each 365.5511 Providing and fixing 1.6 m high corrugated

G I Sheet barricading with safeda ballies of 100mm dia 2.0 metre high placed at 2.5 m c/c.CGI sheets fixed with nails of required length and dia. to safeda ballies including excavating holes of size 0.30x0.30x0.40 meters getting out the excavated soil including consolidating by ramming, watering etc. disposal of surplus earth as directed within lead of 50.0 meters lift 1.5 meter and painting with bright red and white paint vertical strips 0.30 m wide alternately as directed by the Engineer in charge. 1523.20 12.80 sqm 19494.40

12 Labour for cutting CI pipe with steel saw       0.00a) 100 mm dia pipe 4.00 21.75 Each 87.00b) 200 mm dia pipe 4.00 54.60 Each 218.40c) 250 mm dia pipe 4.00 67.65 Each 270.60d) 450 mm dia pipe 2.00 121.10 Each 242.2013 Hiring pump sets for pumping out water @

3636.80 ltr. Per hour capacity including cost of operating staff and supply of lubricating oil. (Shift of 8 hrs. each) 15.00 222.20

EachShift 3333.00

14 Providing and laying S&S CI special such as tees, bends, collars, tapers and caps etc. (Heavy class)       0.00

  Upto 300 mm dia 2.24 1865.40 Quintal 4178.4915 Providing and fixing CI sluice valves (with

cap) complete with bolts, nuts, rubber insertions etc. (the tail pieces if required will be paid separately)       0.00

a) 200 mm diameter, Class I 1.00 5217.15 Each 5217.15250 mm diameter, Class I 2.00 7559.95 Each 15119.90

16 Providing C.I, S/V with hand wheel 39552.00 Each 79104.00

conforming to IS:14846/2000 with latest amendments of class PN-1, bearing ISI mark tested to pressure of 1:5m MPA (gauge) for body and 1.00 RNMPA (Gauge) for seat inside screws non-rising sterm of stainless steel as per IS-6603/72 wedge nuts of high tensile brass body seat rings and wedge facing ring shall be leaded tin bronze bonnet gasket shall be of compressed fibre board backseat arrangement spun gear box arrangement, gear ratio 1:4, Flanged to be machined and drilled to IS:1538/76, material of body and other part of sluice valve shall be as per IS code a) 450mm dia. 2 N0S

17 Fixing in position CI SV & providing flanged joints two nos i/c bolts, nuts ,3mm thick two washers for each bolts, rubber insertion complete with testing of joints 450mm dia 2 nos 1633.00 Each 3266.00

18 Supplying pig lead at site of work 0.53 3781.15 Quintal 2004.0019 Providing lead caulked joints to spun iron

or CI pipes and specials including testing of joints but excluding the cost of pig lead       0.00

a) 100 mm dia pipe 4.00 58.80 Each 235.20b) 200 mm dia pipe 4.00 116.90 Each 467.60c) 250 mm dia pipe 4.00 146.00 Each 584.0020 Shifting of water connectin from old C.I.

water main line to next C.I. water main i/c boring in the next C.I. main , providing and fixing brass ferrule of 6 mm diameter (wt. not less than 150 grams) and one meter G.I. Pipe of 15 mm dia. nominal bore with up to date refilling and disconnecting the existing connection from old water main i/c plugging the bore hole and depositing all serviceable as well as unserviceable material obtained during disconnection the bore complete in all respect as directed by Engr.-in-charge.. 15.00 176.15 Each 2642.25

21 Providing and fixing GI pipes complete with GI fittings including trenching and refilling etc (external work).

15 mm nominal bore30.00 54.25 Each 1627.50

22 Providing and fixing G.I Union in G.I pipe 30.00     0.00

including cutting and threading the pipe and making long screws etc. complete (new work)

a) 15 mm nominal bore. 15.00 51.90 Each 778.5023 Providing, laying and jointing glazed

stoneware pipe grade 'A' with stiff mixture of cement mortar in the proportion of 1:1 (1 cement : 1 fine sand) including testing of joints etc. complete.       0.00

a) 150 mm dia. 60.00 111.60 metre 6696.0024. Providing and laying cement concrete

1:5 :10 (1 cement : 5 coarse sand : 10 graded stone aggregate 40 mm nominal size) all-round S.W pipes including bed concrete as per standard design:       0.00

a) 150 mm dia. 60.00 233.35 metre 14001.0025 Providing and laying in position cement

concrete of specific grade excluding the cost of centering and shuttering- All works upto plinth level        

a) 1:2:4 (1 cement: 2coarse sand: 4 graded stone aggregate 20 mm normal size).. 6.00 1843.00 cum 11058.00

26 Brick work with bricks of class designation 75 in foundation and plinth in: Cement mortar 1:6 (1cement: 6 coarse sand) 6.00 1384.50 cum 8307.00

27 Constructing masonry chamber, inside with 75 class designation brick work in cement mortar 1:5 (1 cement: 5 find sand) for sluice valve, with CI surface box 100mm, top diameter, 160 mm bottom diameter and 180 mm deep (inside) with chain lid and RCC top slab 1:2:4 mix (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement mortar !:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement complete as per standard design.With F.P.S brick       0.00

a) 90x90x100 3.00 3741.90 Each 11225.70b) 120x120x100 1.00 5176.95 Each 5176.9528 Carriage of material by mechanical

transport including loading unloading & stacking Lime, moorum, building rubbish up to 5 Km 600.00 42.09 cum 25254.00

29 P/F Brass feruel 50 mm dia N/Bore i/c 10.00 816.00 Each 8160.00

borring & tapping the main i/c bailing out water excaviting treches & required size up to 3m depth.

30 Providing and fixing GI pipes complete with GI fittings including trenching and refilling etc (external work). 50 mm nominal bore 20.00 161.90 Meter 3238.00

                 Total   3567682.36      Say   3567682.00

EE(NE)II

Name of Work : Replacement of 450mm dia W/Line main road Brahmpuri, NE-II

Bill of Quantity C.I. option Item No.1  Description Quantity Rate Unit Amount1 Demolishing cement concrete including disposal

of material within 50 meters lead.1:3:6 or richer mix 271.68 242.10 cum 65773.72

2 Cutting of bituminous road and taking out soling, matte ling, including sorting, screening and stacking and cost of barricading and watch and ward complete. 181.12 141.00 cum 25537.92

4 Earth work in excavation over areas (exceeding 30 cm in depth. 1.5 m in width as well as 10 sqm on plan) including disposal of excavated earth, lead up to 50 m and lift up to 1.5m; disposal earth to be leveled and neatly dressed. All kinds of soil. 905.92 91.50 cum 82864.23

5 Filling available excavated earth (excluding rock) in trenches, plinth, sides of foundations etc. in layers not exceeding 20cm in depth: consolidating each deposited layer by ramming and watering, lead up to 50 m and lift upto 1.5 m 679.21 30.25 cum 20546.10

6 Providing and laying S&S centrifugally cast (spun) iron pipes (Class LA) conforming to IS - 1536.       0.00

a) 100 mm dia pipe 20.00 488.90 metre 9778.00b) 200 mm dia pipe 5.00 1047.95 metre 5239.75c) 250 mm dia pipe 10.00 1412.20 meter 14122.00d) 450 mm dia pipe 948.00 3376.85 meter 3201254.807 Providing push-on-joints to Centrifugally

(Spun) cast iron pipes or Ductile Iron Pipes including testing of joints and including the cost of rubber gasket       0.00

a) 100 mm dia pipe 4.00 30.75 Each 123.00b) 450 mm dia pipe 172.00 287.00 Each 49364.00

8 Providing and fixing 1.6 m high corrugated G I Sheet barricading with safeda ballies of 100mm dia 2.0 metre high placed at 2.5 m c/c.CGI sheets fixed with nails of required length and dia. to safeda ballies including excavating holes of size 0.30x0.30x0.40 meters getting out the excavated soil including consolidating by ramming, watering etc. disposal of surplus earth as directed within lead of 50.0 meters lift 1.5 meter and painting with bright red and white paint vertical strips 0.30 m wide alternately as directed by the Engineer in charge.

1523.20 12.80 sqm 19494.409 Labour for cutting CI pipe with steel saw       0.00a) 100 mm dia pipe 4.00 21.75 Each 87.00b) 200 mm dia pipe 4.00 54.60 Each 218.40c) 250 mm dia pipe 4.00 67.65 Each 270.60d) 450 mm dia pipe 10.00 121.10 Each 1211.0010 Hiring pump sets for pumping out water @

3636.80 ltr. Per hour capacity including cost of operating staff and supply of lubricating oil. (Shift of 8 hrs. each) 15.00 222.20

EachShift 3333.00

11 Providing and laying S&S CI special such as tees, bends, collars, tapers and caps etc. (Heavy class)       0.00

  Upto 300 mm dia 8.22 1865.40 Quintal 15333.58above 300 mm dia 26.21 2018.70 Quintal 52910.12

12 Providing and laying flanged CI standard specials such as tees, bends, collars, tapers, caps etc, suitable for flanged jointing as per IS : 1538       0.00

  Upto 300 mm dia 3.06 3033.05 Quintal 9281.13above 300 mm dia 5.30 3568.55 Quintal 18913.31

13 Providing and fixing CI sluice valves (with cap) complete with bolts, nuts, rubber insertions etc. (the tail pieces if required will be paid separately)       0.00

a) 200 mm diameter, Class I 1.00 5217.15 Each 5217.15250 mm diameter, Class I 2.00 7559.95 Each 15119.90

14 Providing C.I, S/V with hand wheel conforming to IS:14846/2000 with latest amendments of class PN-1, bearing ISI mark tested to pressure of 1:5m MPA (gauge) for body and 1.00 RNMPA (Gauge) for seat inside screws non-rising sterm of stainless steel as per IS-6603/72 wedge nuts of high tensile brass body seat rings and wedge facing ring shall be leaded tin bronze bonnet gasket shall be of

2 N0S

39552.00 Each 79104.00

compressed fibre board backseat arrangement spun gear box arrangement, gear ratio 1:4, Flanged to be machined and drilled to IS:1538/76, material of body and other part of sluice valve shall be as per IS code a) 450mm dia.

15 Fixing in position CI SV & providing flanged joints two nos i/c bolts, nuts ,3mm thick two washers for each bolts, rubber insertion complete with testing of joints 450mm dia 2 nos 1633.00 Each 3266.00

16 Supplying pig lead at site of work 4.29 3781.15 Quintal 16221.1317 Providing lead caulked joints to spun iron or CI

pipes and specials including testing of joints but excluding the cost of pig lead       0.00

a) 100 mm dia pipe 8.00 58.80 Each 470.40b) 200 mm dia pipe 6.00 116.90 Each 701.40c) 250 mm dia pipe 20.00 146.00 Each 2920.00d) 450 mm dia pipe 19.00 265.50 Each 5044.50e) 600 mm dia pipe 2.00 377.90 Each 755.8018 Shifting of water connectin from old C.I. water

main line to next C.I. water main i/c boring in the next C.I. main , providing and fixing brass ferrule of 6 mm diameter (wt. not less than 150 grams) and one meter G.I. Pipe of 15 mm dia. nominal bore with up to date refilling and disconnecting the existing connection from old water main i/c plugging the bore hole and depositing all serviceable as well as unserviceable material obtained during disconnection the bore complete in all respect as directed by Engr.-in-charge.. 15.00 176.15 Each 2642.25

19 Providing and fixing GI pipes complete with GI fittings including trenching and refilling etc (external work).

15 mm nominal bore30.00 54.25 Each 1627.50

20 Providing and fixing G.I Union in G.I pipe including cutting and threading the pipe and making long screws etc. complete (new work) 30.00     0.00

a) 15 mm nominal bore. 15.00 51.90 Each 778.5021 Providing, laying and jointing glazed

stoneware pipe grade 'A' with stiff mixture of cement mortar in the proportion of 1:1 (1 cement : 1 fine sand) including testing of joints etc. complete.       0.00

a) 150 mm dia. 60.00 111.60 metre 6696.00

22. Providing and laying cement concrete 1:5 :10 (1 cement : 5 coarse sand : 10 graded stone aggregate 40 mm nominal size) all-round S.W pipes including bed concrete as per standard design:       0.00

a) 150 mm dia. 60.00 233.35 metre 14001.0023 Providing and laying in position cement

concrete of specific grade excluding the cost of centering and shuttering- All works upto plinth level        

a) 1:2:4 (1 cement: 2coarse sand: 4 graded stone aggregate 20 mm normal size).. 6.00 1843.00 cum 11058.00

24 Brick work with bricks of class designation 75 in foundation and plinth in: Cement mortar 1:6 (1cement: 6 coarse sand) 6.00 1384.50 cum 8307.00

25 Constructing masonry chamber, inside with 75 class designation brick work in cement mortar 1:5 (1 cement: 5 find sand) for sluice valve, with CI surface box 100mm, top diameter, 160 mm bottom diameter and 180 mm deep (inside) with chain lid and RCC top slab 1:2:4 mix (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement mortar !:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement complete as per standard design.With F.P.S brick

      0.00a) 90x90x100 3.00 3741.90 Each 11225.70b) 120x120x100 1.00 5176.95 Each 5176.9526 Carriage of material by mechanical transport

including loading unloading & stacking Lime, moorum, building rubbish up to 5 Km 600.00 42.09 cum 25254.00

27 P/F Brass feruel 50 mm dia N/Bore i/c borring & tapping the main i/c bailing out water excaviting treches & required size up to 3m depth. 10.00 816.00 Each 8160.00

28 Providing and fixing GI pipes complete with GI fittings including trenching and refilling etc (external work). 50 mm nominal bore

20.00 161.90 Meter 3238.00                 Total   3822640.24      Say   3822640.00

EE(NE)II

Name of Work :- P/L/J water supply distribution net work in Shiv Vihar Phase-II

in Karawal Nagar.

Item No.2BILL OF QUANTITY (C I OPTION)

S.No. Description of Item Quantity Rate Unit Amount

1 Demolishing Cement Concrete including disposal of material within 50 m lead.

a) 1:3:6 or richer mix 52.44 242.10 cum 12695.722. Demolishing dry brick pitching in floors,

drains etc. including stacking serviceable material and disposal of unserviceable material within 50 mtr. Lead.

89.70 131.10 cum 11759.67

3. Cutting bituminous road including taking out soling and metal ling stone including strutting, screening and cost of barricading and watch and ward complete. 117.00 141.00 cum 16497.00

4. Demolishing brick work i/c staking serviceable material and disposal of unserviceable materials within 50mtr. Lead in cement mortar.

3.10 204.25 633.17

5. Earth work in excavation over areas (exceeding 30cm in depth 1.5mm in width as well as 10 sqm on plan) including disposal of excavated earth, lead up to 50m and lift up to 1.5m disposed earth to be leveled and neatly dressed. All kinds of soil

25.20 91.50 cum 2305.80

6. Excavating trenches of required width for pipes, cables, etc. including excavation for sockets, and dressing of sides, ramming of bottoms, depth upto 1.5 m including getting out the soil as required in layers not exceeding 20 cm in depth and including consolidating each deposited layer by ramming watering etc and disposing of surplus excavated soil as directed by engineering in charge within a lead of 50 m, All Kinds of Soil

a) Pipes, cables etc exceeding 80 mm dia but not exceeding 300 mm dia

3565.00 95.55 M 340635.75

7. Labour for cutting CI pipe with steel saw

a) 100 mm dia CI pipe 20nos 21.75 Each 435.00

b) 150 mm dia CI pipe 8nos 40.95 Each 327.60

c) 250mm dia CI pipe 4nos 67.65 Each 270.60

8. Providing and laying S & S Centrifugally Cast ( Spun ) Iron Pipes Class LA conforming to IS:1536

a) 100 mm dia 2905.00 488.90 M 1420254.50

b) 150mm dia 430.00 718.00 M 308761.50

c) 200 mm dia 50.00 1047.95 M 52397.50

d) 250mm dia 180.00 1412.20 254196.00

9. Providing and fixing 1.6 m high corrugated G I Sheet barricading with safeda ballies of 100mm dia 2.0 metre high placed at 2.5 m c/c.CGI sheets fixed with nails of required length and dia. to safeda ballies including excavating holes of size 0.30x0.30x0.40 meters getting out the excavated soil including consolidating by ramming, watering etc. disposal of surplus earth as directed within lead of 50.0 meters lift 1.5 meter and painting with bright red and white paint vertical strips 0.30 m wide alternately as directed by the Engineer in charge. 1426 12.80 sqm 18252.80

10. Providing and laying S&S CI special such as tees, bends, collars, tapers and caps etc. (Heavy class)

      0.00  Upto 300 mm dia 33.45 1865.40 Quintal 62397.63

11. Providing and laying flanged CI standard specials such as tees, bends, collars, tapers, caps etc, suitable for flanged jointing as per IS : 1538Upto 300 mm dia 5.62 3,033.05 Quintal 17045.74

12. Providing lead caulked joints to spun iron or CI pipes and specials including testing of joints but excluding the cost of pig lead       0.00

a) 100 mm dia pipe 222nos 58.80 Each 13053.60b) 150 mm dia pipe 47nos 88.20 Each 4145.40c) 250 mm dia pipe 27nos 146.00 Each 3942.00

13. Supplying pig lead at site of work8.13 3781.15 Quintal 30740.75

14. Providing and fixing C.I. Sluice valves ( with cap ) complete with bolts, nuts, rubber insertions etc. ( the tail pieces if required will be paid separately ). ISI Marked IS:14846

a) 100 mm diameter, class -1 10nos. 2,085.20 Each

20852.00

b) 150 mm diameter, class -1 3nos. 3095.70 Each 9179.10

c) 250mm dia 1no. 7559.95 Each 7559.95

15. Constructing masonry chamber, inside with 75 class designation brick work in cement mortar 1:5 (1 cement: 5 find sand) for sluice valve, with CI surface box 100mm, top diameter, 160 mm bottom diameter and 180 mm deep (inside) with chain lid and RCC top slab 1:2:4 mix (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement mortar !:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement complete as per standard design.With F.P.S brick       0.0090x90x100 13nos. 3741.90 Each 48644.70120X120X100 1no. 5176.95 5176.95

16. Dasinfecling CI water mains by flusing with water containing bleaching powder at 0.5 gms / leter of water and cleaning the same with fresh wter operation to be repeated 3 times including getting the sample of water from the disinfected main tested in the municipal labotary.

a) 100 mm dia 2905 263.15 100m 7644.50

b) 150 mm dia 430.00 402.30 100m 1729.89

c) 200 mm dia 50.00 545.45 100m 272.72

d) 250 mm dia 180.00 697.55 100m 1255.59

16 Providing push on joint to centrifugally (spun) cast iron pipes or ductile iron pipes including testing of joints and including the cost of rubber gasket.

a) 100 mm dia 600nos 30.75 Each 18450.00

b) 150mm dia 85nos 46.90 Each 3986.50

c) 250mm dia 60nos. 85.70 Each 5142.00

17. Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering all work upto plinth level1:2:4 (1 cement : 2 coarse sand : 4

graded stone aggregate 20mm nominal size) 2.52 1843.00 Cum 4607.50

18. Brick work with F.P.S. bricks of class designation 75 in foundation and plinth in cement mortar 1:6 (1cement : 6 coarse )

3.10 1,384.50 cum 4291.95

19. Carriage of material by mechanical transport including loading unloading and stackingLime moorum, building rubbish etc. lead up to 5 KM

50.00 42.09 Cum 2104.50

20. Hiring pump sets for pumping out water @ 3636.80 ltr per hour capacity. Hiring charges including cost of services of operating staff and supply of lubricating oil.(shift of 8hrs. each)

4nos. 222.20 EachShift

888.80

Total 27,12,534.38

Say Rs. 27,12,535/-

EX.ENGINEER(NE)II

Name of Work :- P/L/J water supply distribution net work in Shiv Vihar Phase-II in Karawal Nagar. Item No.2

Abstract of cost (D I OPTION)

S.No. Description of Item Quantity Rate Unit Amount1 Demolishing Cement Concrete including

disposal of material within 50 m lead.

a) 1:3:6 or richer mix 52.44 242.10 cum 12695.722. Demolishing dry brick pitching in floors,

drains etc. including stacking serviceable material and disposal of unserviceable material within 50 mtr. Lead.

89.70 131.10 cum 11759.67

3. Cutting bituminous road including taking out soling and metal ling stone including strutting, screening and cost of barricading and watch and ward complete. 117.00 141.00 cum 16497.00

4. Demolishing brick work i/c staking serviceable material and disposal of unserviceable materials within 50mtr. Lead in cement mortar.

3.10

204.25 cum

633.17

5. Earth work in excavation over areas (exceeding 30cm in depth 1.5mm in width as well as 10 sqm on plan) including disposal of excavated earth, lead up to 50m and lift up to 1.5m disposed earth to be leveled and neatly dressed. All kinds of soil

25.20 91.50 cum 2305.80

6. Excavating trenches of required width for pipes, cables, etc. including excavation for sockets, and dressing of sides, ramming of bottoms, depth upto 1.5 m including getting out the soil as required in layers not exceeding 20 cm in depth and including consolidating each deposited layer by ramming watering etc and disposing of surplus excavated soil as directed by engineering in charge within a lead of 50 m, All Kinds of Soil

a) Pipes, cables etc exceeding 80 mm dia but not exceeding 300 mm dia

3565.00 95.55 M 340635.75

7. Providing and fixing 1.6 m high corrugated G I Sheet barricading with safeda bellies of 100mm dia 2.0 meter high placed at 2.5 m c/c.CGI sheets fixed with nails of required length and dia. to safeda bellies including excavating holes of size 0.30x0.30x0.40 meters getting out the excavated soil including consolidating by ramming, watering etc. disposal of surplus earth as directed within lead of 50.0 meters lift 1.5 meter and painting with bright

1426.00 12.80 sqm 18252.80

red and white paint vertical strips 0.30 m wide alternately as directed by the Engineer in charge.

8. Providing & laying S&S centrifugally cast (spun)/ductile iron pipes confirming to IS: 8329

a) 100mm dia ductile iron K-7 pipe 2905.00 491.90 M 1428969.50

b) 150mm dia ductile iron K-7 pipe 430.00 707.40 M 304182.00c) 200 mm dia K-7 Pipe 50.00 1021.15 m 51057.50d) 250 mm dia K-7 pipe 180.00 1358.25 m 244485.009. Providing & Laying DI specials of

class K-12 suitable for push-on jointing as per IS :9523Upto 600 mm dia 20.04 7724.80 Qtl. 154804.99

10. Providing & Laying DI specials of class K-12 suitable for mechanical jointing as per IS :9523Upto 600 mm dia 2.50 7992.55 Qtl. 19981.39

11. Cutting of DI /MS Pipes & specials etc. by gas plant

2433.50 1.10 cm 2676.85

13. Providing lead caulked joints to spun iron or CI pipes and specials including testing of joints but excluding the cost of pig lead    

a) 250 mm dia pipe

2nos. 146.00 Each 292.0014. Supplying pig lead at site of work

0.12 3781.15 Qtl.

453.7315. Hiring pump sets for pumping out water @

3636.80 ltr per hour capacity. Hiring charges including cost of services of operating staff and supply of lubricating oil.(shift of 8hrs. each)

4nos. 222.20 EachShift

888.80

16. Providing and fixing C.I. Sluice valves ( with cap ) complete with bolts, nuts, rubber insertions etc. ( the tail pieces if required will be paid separately ). ISI Marked IS:14846

a) 100 mm diameter, class -1 10nos. 2,085.20 Each

20852.00

b) 150 mm diameter, class -1 3nos. 3059.70 Each 9179.10

c) 250mm dia diameter, class -1 1no. 7559.95 Each 7559.95

17. Constructing masonry chamber, inside with 75 class designation brick work in cement mortar 1:5 (1 cement: 5 find sand) for sluice valve, with CI surface    

box 100mm, top diameter, 160 mm bottom diameter and 180 mm deep (inside) with chain lid and RCC top slab 1:2:4 mix (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) necessary excavation foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) and inside plastering with cement mortar !:3 (1 cement : 3 coarse sand) 12 mm thick finished with a floating coat of neat cement complete as per standard design.With F.P.S brick90x90x100cm 13nos. 3741.90 Each 48644.70120x120x100cm 1no. 5176.95 Each 5176.95

18. Disinfecting CI water mains by flusing with water containing bleaching powder at 0.5 gms / leter of water and cleaning the same with fresh wter operation to be repeated 3 times including getting the sample of water from the disinfected main tested in the municipal labotary.

a) 100 mm dia 2905.00 263.15 100m 7644.50

b) 150 mm dia 430.00 402.30 100m 1729.89

c) 200 mm dia 50.00 595.45 100m 272.72

d) 250 mm dia 180.00 697.55 100m 1255.59

19 Providing push on joint to centrifugally (spun) cast iron pipes or ductile iron pipes including testing of joints and including the cost of rubber gasket.

a) 100 mm dia 838nos. 30.75 Each 25768.50

b) 150mm dia 132nos. 46.90 Each 6190.80

c) 250mm dia 86nos. 85.70 Each 7370.20

20. Providing and laying in position cement concrete of specified grade excluding the cost of centring and shuttering all work upto plinth level1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 20mm nominal size) 2.50 1843.00 Cum 4607.50

21. Brick work with F.P.S. bricks of class designation 75 in foundation and plinth in cement mortar 1:6 (1cement : 6 coarse ) 3.10 1,384.50 cum 4291.95

22. Carriage of material by mechanical transport including loading unloading and stacking

Lime moorum, building rubbish etc. lead up to 5 KM

50.00 42.09 Cum 2104.50

Total 27,63,220.52

Say Rs. 27,63,221/-

EX.ENGINEER(NE)II

SPECIFICAITON FOR PIPES & LAYING

1.1 SCOPEThis specification covers the general requirements for manufacture, supply, linings, coatings, laying, jointing, testing and commissioning of welded steel pipeline (either plate welded or spiral

welded) above / below ground including appurtenances and associated civil works required for the same.

1.2 MATERIALS1.2.1 a) Steel Plates - The steel plates used for manufacture of plate welded pipes, specials fittings and

stiffeners shall be of mild steel conforming to IS:2062, grade Fe 410. The procedure for cutting plates to sizes rolling of plates post bending, tack welding, internal and external welding, facing should be such that it results in pipes of required diameter and thickness conforming to IS:3589.b) All spiral welded pipes shall be manufactured as per IS:5504. The general requirements relating to supply of spiral welded pipes shall confirm IS:1387 and the process of manufacture shall be such that it results in pipes conforming to IS:5504 or equivalent International Standard.

1.2.2 Welding Consumables - such as electrodes, filler rods and wires shall conform to IS:814, IS:3613, IS:7280 and IS:6419, 816.

1.2.3 Cement - The cement used for lining shall be the Portland Cement conforming to IS:269 / IS:8041 / IS:1489 / IS:8112. The minimum cement content shall be 330 kg/m3 with 43 Grade of cement.

1.2.4 Sand for lining shall conform to IS:2116 as per clause A-3.1 of IS:3589-20011.2.5 Water - The water used in preparation of concrete mix shall be clear, colorless and free from

injurious quantities of organic matter, alkali, salt or other impurities that might reduce strength durability or other desirable qualities of mortar. It shall conform to IS:456.

1.2.6 Before fabrication of pipes and specials / fittings is commenced, the copies of the mill sheets and the manufacturer’s test certificates for plates and other materials required for the fabrication, shall be submitted by the Contractor to the Employer or his Representative for his approval and record.

1.2.7 When requested by the Employer or his Representative, the Contractor shall supply free of charge to the Employer, for testing suitable samples of the materials to be used / used in the works. The cost of such tests shall be borne by the Contractor and shall be included by him in his rates / bid amount. No reimbursement of testing charges shall be made to the contractor on this account.

1.3 INSPECTION1.3.1 All works and materials under the specification will be inspected during all phase of manufacture

and testing and such inspection shall not relieve the Contractor of his responsibility to furnish materials and performed work in accordance with this specification.

1.3.2 The Contractor shall notify the Employer or his Representative in advance of the production of materials and fabrication thereof, in the order that the Employer may arrange for mill and shop inspection. The contractor will arrange for, at his own cost, the inspection of material in DJB Officers.

1.3.3 That Employer or his Representative may reject any or all materials or work that do not meet with any of the requirements of this specification. The Contractor shall rectify or replace such rejected materials / performed work at his own cost, to the satisfaction of the Employer or this Representative.

1.3.4 The Employer or his Representative shall have free access to those parts of all plants or any other premises and sites that are concerned with the furnishing of materials or the performance of work under this specification.

1.3.5 The Contractor shall furnish to the Employer’s representative reasonable facilities and space without charge for inspection, testing and obtaining of any information he desires in respect of the quality of materials used and the progress and manner of the work.

1.3.6 The Contractor shall provide 2 (two) sets of accurate ‘Go’ and ‘No-Go’ ring gauges to measure the diameter of pipes, specials and fittings, gauges to measure plate thickness of pipes & specials for the use of the Employer or his Representative at no extra cost.

1.4 MANUFACTURE OF M.S. PIPE1.4.1 General

All pipes and specials shall be manufactured out of new mild steel plates/steel strips/coils, which shall be free from any cracks, surface flaws, laminations, excessive piting or any other defects. The

pipes shall be mill manufactured of either plate welded or spiral welded variety with longitudinal or spiral welds confirming to respective standards from a mill which can establish with authenticity having supplied similar pipes in the last 3 years which shall be truly cylindrical, and straight in axis. The method of manufacture shall be as per clause 6.3 of IS:3589. The ends shall be accurately cut and prepared for welding. No site-fabricated pipes are allowed. The external circumference of the pipe pieces, which are to be fixed adjacent to flange adopter with fixed outer diameter shall not deviate from theoretical by more than 1 mm. The pipe shall be rolled several times, if necessary, as pipe pieces should be truly cylindrical. The external longitudinal/spiral welding of the pipe shall be ground smooth flush with surface to the satisfaction of the Employer or his Representative. Nothing extra cost shall be charged by the Contractor for grinding work. The M.S. plate sheets / striper coil for fabrication of pipes shall be purchased only from manufacturers like SAIL, TISCO, ESSAR, JINDAL & ISPAT Industries Ltd. The purchase from dealers / stockists /distributor etc. shall not be permitted under any circumstances. The contractor if being the manufacturer of pipes, the M.S. Plates/Sheet/Striper coil shall be purchased by him/them from the above named manufacturers only. The vouchers in support of purchase of MS plates/sheet/striper coil shall be submitted to the dept./DJB. In case, the Contractor purchases the pipes from the manufacturer, the manufacture fabricating the pipe for Contractor shall have to purchase the MS Plate/Sheet/Stripper Coil from above named manufacturer only. The proof of purchase MS Plate/Sheet/Striper Coil from the above named manufacturers shall be submitted to DJB.Minor repair by welding or otherwise shall be permitted at the discretion of the Employer or his Representative but such repairs shall be done only after obtaining the permission of the Employer or his Representative. Any pipe or part thereof which develops injurious defects during shop welding or other operations, shall be rejected.

1.4.3 FABRICATION SPECIFICAITON1.4.3.1 The Contractor shall get the fabrication work done in a duly valid licensed factory of his own or

that from an approved nominated manufacturer. This factory meant for fabrication of pipes, specials etc. shall have arrangements for testing all sorts of matierals as per requirements of IS codes, etc. & machining as well as lining by centrifugal process, out-coating etc. for completing the work under the present contract within the contract period, the factory shall be equipped with adequate number of various equipments and plants such as :

¡ Plate bending machines for rolling of pipe drums¡ Machinery/equipments for manufacture of spiral welded pipes¡ Automatic welding machines (suitable for circumferential as well as longitudinal welding)¡ Facility to carry out ultra sonic testing of welds seam & body¡ X-ray fluoroscopy of the weld seam¡ Radiography of weld in pipe ends¡ Radiography of joints of junctions of spirally weld and scalp-end weld.¡ Extensive manual ultra sonic testing of weld seam & body¡ Such other equipments necessary to check welding as per IS Codes requirements.¡ Hydrostatic Testing Machines for carrying out tests as per relevant IS Codes.¡ Travelling gantry or crane of capacity of 5 tons or above with lifting arrangements.¡ Mobile cranes for loading/unloading of plates, pipes etc.¡ Lathe for machining of the flange rings, plates etc.¡ Equipment for sand blasting and applying paint by spray gun¡ Equipment for cold pressing of plates upto 25 mm thick¡ Bending machine of adequate capacity for manufacturing ring girders and other necessary equipments.¡ Equipments for centrifugal mortar lining in factory to new pipes experienced technical staff.¡ Equipment for mixing of concrete and mortar by weigh batching process.

¡ Equipment for fiber glass coating as per IS:10221 to the MS Pipes to be laid below ground level and epoxy coatings as per specifications for pipes to be laid above ground.¡ Arrangements for curing to centrifugally applied mortar lining in shade¡ Equipments/arrangements for testing of pipe shells and physical tests as per clause of respective IS Codes¡ Sand blasting equipments for cleaning the pipes no near white for internal linings & external coatings.¡ Trained personals for the above jobs so that all the works could be completed within the stipulated period¡ Any other equipment required for manufacture/testing of material any pipes even though not mentioned.

The factory shall have adequate area and shall also have stacking yard for the stacking of plates, structural, fabricated pipes and scrap etc. At the time of submitting the bid, the Contractor shall submit lists of equipments available with him for this work and balance, which shall be arranged / purchased by the bidder on receipt of Letter of Intent and also list of trained personal along with experience in the job and their qualifications etc.

The Bidder shall furnish with his bid details of the factory where he intends to get the fabrications done, such as its location and the equipment, plant and other facilitates available in the factory for the manufacture of M.S. Pipes and specials etc. required under this contract.For spirally welded pipes, the hot rolled coil after decoiling shall be cut, straightened, trimmed on both sides, for cutting of mill edges and to have constant width. the trimmed stripped edges shall be beveled by planning tools and cleaned on both sides by brushes for achieving good welding. The strap subsequently shall be pressed through drive roll and pre-bending roll where edges are bend slightly to eliminate the peaking effect in the region of weld seam. In the pipe forming device the strip shall be formed to pipe with high dimensional accuracy by three rolled bending devices and outer roller cage.The strip edge running together along with the formed pipe shall be welded in side at the lowest point by submerged arc welding process. This shall be followed by outside SAW welding at phase of 1800. This welding process shall be fully, automatic.Each pipe shall then be hydrostatically tested in the plant/mill and subjected to ultrasonic and radiographic testing of weld seam and body of the pipe.

1.44 Cutting Plates to Size1.44.1 The plates shall be indented / purchased by the Contractor in such length as to have minimum

wastage and so as to make the pipe as far as possible with on longitudinal joint. For pipes 600 mm dia and above the MS plate procured should have a minimum width of 1.8m.Before cutting, all the edges of the plates shall be cleaned by brushing / grinding on both the side as per requirement of IS Codes.After the plates are cut, the edges shall be made smooth and even by polishing with an electrical or pneumatic grinder to remove all inequalities. Care shall be taken to see that the cut edges of the plate are perfectly straight. Jigs to be used for this purpose shall depend upon the types of cutting machine used. The plates cut to the required shape shall be checked for correctness before they are rolled into pipe drums. If any corrections are required, the Contractor shall do the same buy re-cutting, if necessary. If any plate is found to be warped or to have corrugations, the defects shall be removed by putting the plate into a roller press, and not extra payment for this rectification work shall be made. The laminated or heavily corroded plate shall not be used in the manufacturing of the pipe.

1.4.4.2 Rolling of PlatesThe plates cut to the exact size shall be put into a rolling machine to form a pipe of the required diameter. The Contractor shall adjust the rolling machine so as to give a uniform curvature to the pipe throughout its circumference. The curvature obtained shall be checked by the Contractor’s

foreman during the process of rolling operation shall be repeated. Heating of plates to obtain the desired curvature shall not be permitted.

1.4.4.3 Tacking the DrumsThe rolled drums shall be kept on an assembly platform for tracking, care shall be taken to ensure that the tacked drums have their end faces at right angles to the axies of the pipe. While tacking the drum, a gap of 2mm to 4mm shall be maintained, where hand welding is permitted. However, where the welding is to be done on automatic welding machine, there is no need of maintaining such a gap depending on the penetration through complete thickness of the welding required to achieve this objective, clamp spiders, tightening rings and or any other approved gadgets shall be used. Each such drum, before being taken to the assembly platform, shall be numbered on the inside with oil paint, stating the plate thickness as well.

1.4.4.4 Assembly of Drums into PipesThe tacked drums shall then be transported to an assembly platform where they shall be tack welded together to form suitable pipe-lengths. Plate shall be bent in the maximum possible width to reduce the number of circumferential joints.The longitudinal joints shall be staggered at 30 degree. The drums when tacked together shall have no circumferential gap when the welding is done on automatic welding machine. But when hand welding is adopted gap of 2mm to 4mm shall be maintained to obtain a good but welded joint.The assembly shall be truly cylindrical and without any kinks. The faces shall be at right angles to the axis of the cylinder. A suitable arrangement for testing the corectness of the faces shall be provided by the Contractor at the assembly platforms.Standard Specification for WeldingAll components of a standard shell, either straight or bent etc. shall be welded, wherever possible by use of automatic arc welding machine by submerged Arc welded process with alternating current. Hand welding shall not be permitted except for sealing runs and such other minor works at the discretion of the Employer or his Representative. The strength of the joint shall be atleast equal to that of the parent material.The Contractor shall use electrodes either of Advani-Orlecon (over code-S), D&H (Medio) make (SFA 5.1 AWS E-6013) or other equivalent approved make and the size depending on the thickness of plate and the type of joint as approved by the Engineer-in-charge. The Contractor shall also use standard current and arc voltage required for the machine in use with such modifications as may be found necessary after experimental welding. For this purpose, samples of welded joints shall be prepared and tested in the presence of the Employer or his representative. The values once determined shall be maintained throughout the work and if any modifications are to be made, a written permission of the Employer or his Representative shall be obtained. In the case of thin sheets electric arc welding may not give satisfactory results and gas welding shall be resorted to. Gas welding shall be subjected to the same specifications and tests as those for electric welds. Welding shall be carried out inside as well as outside.All the shop and field welding shall conform to the requirements of IS:823 and IS:4353, IS:816, IS:3600 (part I).All longitudinal and circumferential joints shall be welded as per respective IS Codes. End preparation for such welding shall conform to IS:2825.

1.4.5.5 All circumferential welds involving plates of unequal thickness shall be so kept that the inside surfaces of plates match to provide stream lined joints without alternation in the internal diameter. As far as practicable welding of dissimilar thickness of shells shall be carried out in the shops.

1.4.5.6 The welding shall be of the best workmanship free from flaws, burns, etc. and the electrodes at the desired temperatures and dry. In order to maintain a good standard in welding, welders shall be tested by the Contractor before they are entrusted with the job. Qualification standard for welding procedures welders and welding operation shall conform to the requirements of IS:7307 and IS:7310. Periodical tests as regards their competence and efficiency shall also be taken at intervals of about 6 months and those found inefficient shall be removed from the job. Only those who pass

the test shall be posted on the job. If an incompetent welder has already welded some pipes all welding done by him previously shall be fully checked by X-ray in addition to the regular X-ray inspections. The defects if any shall be set right to the satisfaction of the Employer or his Representative. All such check tests and rectification of defects shall be entirely at the cost of Contractor. No pipe or steel sections shall be erected unless the work of the welder concerned has been proved to be satisfactory. Site welds shall be done by specially selected welders.

1.4.5.7 A record shall be maintained showing the names of welders and operators who have worked on each individual joint. Hand-welding if necessary shall preferably be carried out by a pair of welders so that by observing proper sequence distortion can be avoided. A joint entrusted to a particular individual or a pair shall be as far as possible completed by them in all respects including sealing run. No helper or other unauthorized person shall be permitted to do any welding whatsoever.

1.4.5.8 The welded joint after welding should not become brittle or sensitive to blows and there should be no loss of toughness due to welding or heat treatment. The material after welding and heat treatment is to be toughs than the base metal and is to retain its original ductility. No allowance will be made for thinning or weld and the weld should at no point be less than the nominal thickness of plate. Final welding of closure gaps should be carried out within a temperature range of average air temperature +/-80C as per Clause 6.3 of IS:5822.

1.4.5.9 Upon receipt of the order and prior to the start of fabrication, the Contractor shall submit to the Employer or his Representative for his approval the “welding procedure method statement’, he intends to use in the workshop. Similarly, prior to the start of the field welding, procedure for the field welding must be submitted to Employer or his Representative for HIS approval. Manual welding shall be adopted only when machine welding is not possible

1.5 Radiography of Welded Joints1.5.1 Soon after welding, each longitudinally/spiral and circumferential welded (minimum length as

specified in the code) length of the weld at random for each pipe shall be radiographed to deter welding defects except in habitated areas as per requirements of IS:4853 and as directed by the Employer or his Representative. However in such inhabited area ultrasonic testing with graph shall be done in lieu of radiography test. This sampling will be at random to ensure 100% coverage of junctions of longitudinal, spiral and circumferential joints. If the results of such radiography fail to conform to the requirements, the Contractor shall carry out at his expense 100% radiography test for the pertinent pipe as directed and fully satisfying the Employer or his Representative. The permissible percentage breakdown of radiography shall be as per IS Codes/Employer’s instructions. Also the welded joints shall be tested as per clause 6.2, 6.2.1 and 6.2.2 of IS : 5822

1.5.2 For mild steel pipes manufactured in factory/workshop fabricated from MS plate, 15% of the welded joints shall be subjected to ultrasonic test. All cross or T joints shall be radiographically tested. In case of field joints, 15% of the number of joints and T joints at random shall be put to Ultrasonic and radiography test respectively. Thrice the number of field joints shall be put to radiography test. Even after such radiography test, if any of the joint fails, the radiography of the 100% of the joints shall be carried out. All these testing shall be done by the Contractor at his own risk and cost. In inhabited areas ultrasonic testing with graph shall be done in lieu of radiographic tests.

1.5.3 The weld ripples or weld surface irregularities and slag etc., on both inside and outside shall be removed by any suitable mechanical process to a degree such that resulting radiographic contact due to any remaining irregularities cannot mark or be confused with that of objectionable defect. The radiograph shall be made in strict accordance with the latest requirements and as per the latest and most efficient technique either with X-ray or gamma ray equipment. The safety requirements during radiography shall be in accordance with IS : 2598.

1.5.4 The Photographs are to be marked in such a way that the corresponding portion of the welded seam can be readily identified. All radiographs will be reviewed by the Employer or his Representative to identify the defect and determine those which must be removed. Defects that are

not acceptable shall be removed by chipping, machining or flame gouging to sound metal and the resulting cavities shall be welded. After rectification, the joint is to be radiographed again to prove the quality of the repair. The radiographs will be judged as acceptable by the Employer or his Representative based on the latest standards prescribed by the relevant Indian Standards specification.

1.5.5 All X-ray shall be made with equipment and by personnel furnished by the Contractor. The films shall be developed within 24 hours of exposure and be readily accessible at all times for inspection by the Employer or his Representative. The Contractor shall provide for the use of the Employer or his Representative suitable X-ray viewing equipment X-ray films shall be properly maintained by the Contractor for handing over finally to the department on completion of the Contract. All films shall be identified by the No. and chart prepared indicating location of the joint each X-ray photo represents. In the event of additional radiographic inspections required of any work associated with the pipe erection, such inspection shall be performed by the Radiographer at the discretion of the Employer or his Representative at no extra cost to the Employer.

1.6 RADIOGRAPHIC INSPECTION1.6.1 General

a) The Contractor shall certify that the welding of pipes has been done only by qualified welders with approved quality of Electrodes and electric current (Voltage and amperage). The Contractor shall also make available to the Employer or his Representative a certified copy of the qualification tests of each Representative a certihed copy or the qualification tests or each welder and welding operator. The Employer or his Representative shall have the right at any time to call for and witness tests welding procedure or of the ability of any welder and welding operator.

b) Radiographic Inspection of welded jointsc) All welded joints to be radiographed shall be examined in accordance with IS: 2595Code of Practice for Radiographic Testing IS: 4853Recommended Practice for Radiographic Inspection of Fusion Welded Butt joints in

Steel Pipes. IS: 1182Recommended Practices for Radiographic Examination of Fusion Welded Butt-Joints

in steel plates. IS : 2598 Safety Code for Industrial Radiographic Practice. The reinforcement on each side of

all butt welded joints shall not exceed 1.5mmd) A complete set of radiographs and records as described in IS: 2595 Clause 14, for each job shall

be retained by the Contractor and kept on file for a period of at least one year. After one year all such records shall be handed over to the Employer or his Representative at no extra cost.

e) Final acceptance of radiographs shall be based on the ability to see the prescribed penetrameter image and the specified hole.

f) Sections of welds that are shown by radiography to have any of the following types of imperfections shall be judged unacceptable and shall be repaired by the Contractor at his won cost.

g) Any type of crack, or zone of incomplete fusion or penetration, any elongated slag inclusion which has length greater than 6mm any group of slag inclusion in line that have a aggregate length greater than thickness in a length of 12 times thickness, except when the distance between the successive imperfections exceeds 6L where L is the length of the longest imperfection in the group, rounded indications in excess of that specified by the acceptance standards given earlier.

1.7 TOLERANCE1.7.1 Tolerance for pipes in respect of diameter and straightness shall be in accordance with IS: 3589

however negative tolerance in pipe wall thickness is not permissible. 1.7.2 The shell in the completed work shall be almost fully round. The difference between maximum

and minimum inside diameters at any cross section shall not exceed 1% of the nominal diameter of the cross section under consideration subject to a maximum of 5 mm.

1.7.3 Machined parts shall be within the limits specified by IS 3589-2001.

1.7.4 Straight pipes shall have their faces perpendicular to the axis of the section with a maxinraim deviation of 2 mm on either side of the plane.

1.7.5 For the shell thickness, following tolerances are acceptable: (+) 10% and no negative Tolerance on pipes wall thickness. Permissible tolerance for specials for diameter arm length and angular deviation shall be in accordance with IS 3589 - 2001.

1.8 SHOP TESTING1.8.1 After fabrication, but before application of lining and protective coatings all pipes and specials

shall be subjected to a shop hydraulic test as per clause 10 of IS : 3589. Standard lengths of pipes shall be directly subjected to test and non-standard pipe and elbows can be tested as standard pipe before being cut to size.

1.8.2 The test pressure shall ensure that the plate material is stressed to 60% of the specified minimum yield stress as per Clause 10.1 of IS: 3589.

1.8.3 Each pipe shall be filled with water and the pressure slowly and uniformly increased by the manufacturer at his own cost until the required test pressure is reached.

1.8.4 The pipe to be tested shall be given a serial no. which shall be painted on its inside together with details such as pipe No. shell thickness, diameter, length etc. It shall be entered in the register to be maintained by the Contractor. A copy of results of the tests shall be sent every week on Mondays and another copy shall be sent along with the lot sent to the site for laying. The pipe shall also be given a certification mark as per clause 18.1, (a) IS Code: 3589 - 2001.

1.8.5 Prior to testing, the pipe shall be inspected thoroughly and all the apparent defects in welding such as porosity etc. shall be repaired by gouge and re-welding.

1.8.6 In case of use of spirally welded and plate welded pipes conforming to IS:5504 all types of required tests shall be carried out as are given in the respective Clauses of the said IS Codes for spirally and plate welded pipes. Test reports of all such tests shall be made available to the Employer along with the running bills.

1.8.7 The hydraulic test shall be carried out under cover at the fabrication shop- in the presence of and to the satisfaction of the Employer or his Representative or the inspection agency appointed by the Employer.

1.8.8 For indicating the pressure inside the pipe an accurate pressure gauge of approved make duly tested and calibrated for the accuracy of readings shall be mounted on one of the closures which close the pipe ends.

1.8.9 Nothing extra shall be paid for testing and for P/F of gauges & for filling the pipe with water and other equipments.

1.8.10 The pressures shall be applied gradually by approved means and shall be maintained for atleast I minutes or till the inspection -of all welded joints and pipes is done during which time the pipe shall be hammered throughout its length with sharp blows, by means of a I Kg hand hammer.

1.8.11 The pipe shall withstand the test without showing any signs of weakness, leakage, oozing or sweating. If any leak or sweating is observed in the welded joints, the same shall be repaired by gouging and re-welding after dewatering the pipe. The repaired pipe shall be re-tested to conform the specified pressure.

1.8.12 If any leak or sweating is observed in factory/mill made pipe shell, the pipe under test shall be rejected temporarily. The Contractor shall stack such rejected pipes separately in his yard. The Employer or his Representative, shall inspect the same and after taking cuts if necessary, shall determine the nature of repairs to be carried out there on and shall then decide as to how and where they shall be used. No payment shall be made for handling or carrying out repairs.

1.8.13 The Employer or his Representative shall be supplied with two copies of the results of all the tests carried out for which nothing shall be paid.

1.9 TESTING OF SITE WELDED JOINTS 1.9.1 The welded joints shall be tested for Tensile test and bend test in accordance with procedure laid

down in IS No.3600 method of testing fusion welded joints and weld metals in steel.

1.9.2 Test pieces shall be taken by the contractor from the welded joints at the position on fabricated pipes pointed out by the Employer or his Representative.

1.9.3 The sample so taken shall then be cut to the exact shape and dimensions and machined and handed over to the Employer or his Representative for testing. All the work upto and including machining and arranging for test shall be done by the Contractors at his own cost.

1.10 SUBMISSION OF WEEKLY PROGRESS REPORT1.10 The Contractor shall submit to the Employer or his Representative a Weekly progress report on

Mondays, wherein all the details of the work carried out in the factory shall be fully recorded. Similarly, works being done in the various units in the factory shall be separately mentioned. The Contractor shall maintain a register of all the finished materials giving dates of carrying out important operations such as :-• Total length of pipe to be supplied of each diameter (material wise).• Quantity already supplied.• Balance length of each diameter to be supplied.• Total No. of specials of each category to be manufactured.• No. of specials of each category manufactured & supplied.• Balance specials of each diameter to be manufactured and supplied.• Length of each diameter tested.• Balance of each diameter to be tested etc.• No. of fittings of each category required.• No. of fittings of each category to be arranged.• No. of gap pieces of each diameter shown in L-section of each line.• No. of gap pieces arranged / supplied.• No. of Manholes with covers arranged.• Approved no. of expansion joints of each diameter supplied.• No. of expansion joints of each diameter supplied.• Program for supplying the balance Materials, which may not have been mentioned but may be

required for completion of entire work.1.11 TRANSPORTING OF PIPE & SPECIALS ETC.1.11.1 All pipes and specials fabricated in the factory and temporarily stacked in the Contractor’s yard of

factory shall be transported to the site of laying after shop testing & cleaning them internally. The loading in the factory shall be carried out by means of either a crane, gantry or with shear legs, so as not to cause any damage to the finished material. Similarly, while unloading and stacking, great care shall be taken to ensure that the material is not damaged or dented. The equipments to be used for unloading will be different in different situations and in each case the one approved by the employer or his Representative shall be adopted. The material stacked at site shall be jointly inspected by the Employer or his Representative and Contractor and defect or damage notice shall be repaired to the satisfaction of the Employer or his Representative before payment is admitted/released.

1.11.2 Props of approved designs shall be fixed to the pipes during transit to avoid undue sagging and consequent distortion. After the pipes are carefully stacked, props may be removed and re-used for subsequent operations. The stacking ground, both in the Contractor’s yard and at the site of laying shall be leveled and shall be selected in such a way as not to get waterlogged during monsoon. If this cannot be done, the pipes shall be supported on sleepers to avoid contact with wet earth and subsequent rusting. In order to prevent sagging during transit, savings of steel plates can be utilized by cutting to the required length and tacking the same to the pipe ends, in place of props, if approved by the Employer or his Representative.

1.11.3 As explained in earlier paragraphs, materials such as pipes & tapers etc. may be transported to the site of laying as soon as the material is finished in all respects with the permission of the Employer or his Representative to avoid congestion in the Contractor’s yard. However, materials such as expansion joints, manholes with covers composite bends, “T branches and other complicated

materials etc. shall be stacked in the Contractor’s yard under his security arrangements until they are required for laying (and jointing) in the field. In view of this, the work of fabrication of such materials shall be properly synchronized as far as possible with the laying operations.

1.11.4 Fabricated materials such as man-hole covers to be provided & fixed in each section between the sluice valves and an other required places and as desired by the Employer and his Representative, appurtenances such as S.V.’s P.R.V’s, air valves etc. bolts, nuts, distance pieces, flanges, saddles, collars bypass arrangements etc. shall all be transported to the site of laying from the fabrication shop according to the needs of the laying/operations only. As regards access roads, the Contractor shall note that access road may lead upto some points on the alignment. Therefore, the Contractor shall have to make his own arrangement for connecting approaches to transport the pipes and other equipments & specials etc. across country to the actual site of laying at his own cost. Whatever may be the mode of transport he uses it shall be incumbent on the Contractor to carry and stack the pipes, specials and fitting along the alignment as close as possible to the site of laying.

1.12 PROCEDURE FOR RECEIVING STEEL PIPES1.12.1 General

To ensure that the work of erecting pipes is not held up at any stage and place, the Contractor shall maintain an adequate stock of standard specials, flange rings, expansion joints, manhole covers, etc. and short lengths of pipelines, etc. at site in his field stores, in consultation with the Employer or his Representative. Wherever possible, the Contractor shall arrange one full month’s requirement of pipes, specials, etc. stacked along arrange one full month’s requirement of pipes, specials, etc. stacked along the alignment in such a way that no obstruction is caused to the traffic, residents, or for repairs to other utilities.

1.12.2 Stacking of Pipes, Etc. and InspectionThe Contractor shall keep in each section a responsible representative of his own to take delivery of the pipes, specials and appurtenances etc. transported from the fabrication stockyard or received from any other work site to the site of laying and to stack along the route on timber skids Padding shall be provided between coated pipes and timber skids to avoid damage to the coating. Suitable gaps in the pipes stacked shall be left at intervals to permit access from one side to the other. The pipes specials, appurtenances so received on site shall be jointly inspected and defects recorded, if any, such as protrusions, grooves, dents, notches, damage to the internal coating etc., shall be pointed out immediately to the Employer or his Representative at the site and in the acknowledgement challans. Such defects shall be rectified or repaired to the satisfaction of the Employer or his Representative entirely at the Contractor’s risk and cost. Contractor should also note that watch and ward of all materials is of the Contractor and if some thing is lost from the site and is paid, its cost shall be recovered from the Contractor.

1.l2.3 Handling of Pipes, Special Appurtenances Etc.It is essential to avoid damage to the pipes, fittings and specials, etc. or their coatings & lining at all stages during handling. The pipes and specials shall be handled in such a manner as not to distort their circularity or cause any damage to their surface treatment. Pipes shall not be thrown down from the trucks nor shall they be dragged or rolled along hard surfaces. Slings of canvas or equally non-abrasive materials of suitable width of special attachment shaped to fit the pipe ends shall be used to lift and lower the pipes to prevent damage to the coatings provided.Great care shall be taken in handling the pipe right from the first operation of manufacture until they are laid and jointed. The Contractor will provide temporary props in order to prevent any sagging of the pipes while they are stacked in their yard and while transporting to the site of delivery, i.e. laying. The props shall be retained until the pipes are laid if at any time these props are found to be dislodged or disturbed, the Contractor shall immediately reinstate them in such a way that the true shape of the pipe shell or specials is maintained to the satisfaction of the Employer or his Representative. No defective or damaged pipe or special shall be allowed to be

used in the work without rectification to the coating shall be repaired by the Contractor at his own cost to the to the original shape and to the satisfaction of the Employer or his Representative.

1.12.4 DentsWhenever any dent, i.e. a significant alteration of the curvature of the pipe shell is noticed, the depth of the dent shall be measured between the lowest point of the dent and the pipe shell curvature line. All dents exceeding 2 percent of the outer diameter of the pipe shall be removed by cutting out a cylindrical portion of the pipe and replacing the same by an undamaged piece of the pipe. The Employer or his Representative may permit insert of patching if the diameter of the patch is less than 25% of the nominal diameter of the pipe. Repairs by hammering with or without heating shall not be permitted. Any damage to the coating shall also be carefully examined and rectified fully by the Contractor at his own cost as per Clause 5.2.3.1 of IS : 5822.

1.12.5 Marking1.12.5.1 The component parts of the pipes shall be carefully marked as per IS Codes for identification in the

field in such a way that these could be located on the field.1.12.5.2 The marking operation shall be conducted with full size rulers and templates.1.12.5.3 The plates used for fabrication of pipes shall be laid out in such a way that when the shells are

completed one set of original identification markings for the material will be plainly visible. In case these markings are unavoidably cut out, they shall be accurately transferred by the Contractor to a location where these markings will be visible on the completed work.

1.12.5.4 Two copies of these details shall be furnished to the owner free of cost. 1.12.5.5 No separate payment will be made for these markings and the rates quoted shall be deemed to

include the cost of such markings.1.13 LAYING OF PIPELINE1.13.1 General

After having carried out excavation of trenches as is explained in these specifications else where the loose materials from the sides or the edges of the trench shall be prevented from falling inside the trench. Properly designed bedding as per site conditions for resting of the pipes shell then be provided before starting with the laying. The excavation of trenches for laying of M.S. pipe shall be as per clause 4.2.1 of IS:5822. Design of bedding with respect to installation condition shall be submitted by the Contractor for approval by the Employer.

1.13.1.2 When welding is to be carried out with pipes in the trench additional excavation of not more that 600 mm in depth and 900mm in length shall be provided all round the pipe at the position of the joint for facilitating in the welding.

1.13.1.3 Unless specified otherwise, the M.S. pipeline shall be buried with minimum cover of 1.0 meter above socket top and as approved by the Employer. No material shall be erected unless it has been previously passed by the employer or his Representative.

1.13.1.4 Where pipes are to be laid to curves, the deflection at each joint shall not exceed one degree. For sharper curves specifically made bends shall be provided.

1.13.2 Laying Programme1.13.2.1 The Contractor shall submit a detailed bar chart for procuring and laying of the pipelines, which

shall be subject to the Employer’s approval. In preparing this bar chart, the Contractor shall plan his activities such that the laying of pipes shall closely follow the procurement schedule and no pipes shall remain stacked at site for a period more than one month or as decided by the Employer. The Contractor shall also submit procurement schedule of pipes, specials and fittings.

1.13.2.2 Together with the bar chart he shall also submit a methodology describing how he will carry out this work within the contractual period and the required recourses in terms of construction equipments and other facilities that shall be utilized to complete the works.

1.13.2.3 Before commencing the work of pipe laying, the Contractor shall study the plan of the pipeline for the section concerned. He shall also study the details of laying i.e. underground or above ground. The under ground pipeline shall be laid on properly designed bedding and approved by the Employer or his Representative. The difference in depth due to uneven excavations by the

Contractor shall be made up by sand cushioning / C.C. (M-10) as per direction of Employer. For laying of pipe below ground, the Contractor shall also follow specifications/instruction as are given in these specifications for Excavation and Barricading etc. However, no pipelines shall cross beneath the bed of nallahs/drains. The width for the pipe line bridge shall be such as to accommodate the pipes and facilities.

1.13.2.4 All M.S. pipe laying, welding and testing etc. shall be as per Clause contained in IS:5822 and to the satisfaction of the Employer or his representative.

1.13.2.5 Erection of pipes/fabricated shells shall be carried out by the Contractor who shall equip himself at his own cost, with all necessary tools, machinery, equipments, generators, testing equipments, test plates and piping etc. and labour required for the purpose. The pipeline shall be constructed in lengths with a separate full time gang working on each length/section.

1.13.3 Handling of pipes and specialsCoated pipes and specials that are to be stored/kept on supports shall bear on the uncoated ends only. If bearing of coating is employed the supports shall be not less than 20 cm (8 inches) wide and so arranged to prevent damage to the coating. During handling of the pipes and fittings, coating shall be protected not less than 20 cm wide and placing strips of heavy belting or other approved sheet materials not less than 20 cm wide under all ropes or fastening.

1.13.4 Sand Bedding (Wherever Required)Where site situations require necessity of Sand beddings, the sand bedding of minimum 300 mm thickness shall be provided below pipe, prior to laying the pipe in trenches. It shall be completed with a light hand rammer. Any reduction in thickness due to composition shall be made up by adding sand during ramming. For the purpose of the bedding under this item only screened fine sand or grain size not larger than 2mm shall be used. The sand shall be clean, uncoated and free form clay lumps, injurious amounts of dust, soft particles, organic matter, loam or other deleterious substances. Nothing extra shall be paid for sand bedding or any other type of bedding for resting the pipes in trenches.If the sand supplied is unclean it shall be washed. In no case shall sand containing more than 3.5% by dry volume or 5% by wet volume of clay, loam or silt be accepted. Tests specified for determining silt in sand and organic impurities as described in IS:383 shall apply. Sieved and washed sand shall be stored on the works in such a manner as to prevent intrusion of any foreign matter, including coarser particles of sand or any clay or metal or chips. Tests as indicated above shall be performed if called for by the Employer or his Representative at the expense of the Contractor. During the work of providing sand bedding and laying the pipeline over it, loose material from the sides or edges of the trench shall prevented from falling inside the trench, by providing shoring and taking other measures. Also where necessary, trench shall be kept dry by pumping out seepage leakage waters continuously at no extra cost to the Employer.

1.13.5 Lowering and JointingBefore pipes are lowered, the trenches shall be examined as per Clause 4.2 & 4.2.1 of IS:5822. Also pipe handling and inspection snail be done as per Clause 5.1 to 5.2.5. Pipe laying below ground shall be as per Clauses 8.11 to 8.1.2.1 and pipe laying above ground shall be as per Clause 8.3.1 of IS:5822.At places where shoring timbering is provided the pipe shall be lowered into the trenches by removing only one or two struts at a time. It shall be seen that no part of the shoring is disturbed or damaged and, if necessary, additional temporary struts may be fixed during the lowering operations. In case of laying of pipe is not damaged in any way during the lowering operations. In case of laying of pipes and other situations also it shall also be necessary to see that the coating of pipe is not damaged in any way during the lowering and assembling. After the pipe is lowered into the trench, it shall be laid in correct line and level by using the leveling instruments, sight rails, theodolite etc. Care shall be taken to see that the longitudinal joints of two consecutive pipes at

each circumferential joints are staggered by 30 as mentioned in Clause 8.1.2 of IS:5822. While assembling the pipes, the ends shall have to be brought close enough to leave a uniform gap not exceeding 3mm. If necessary a marginal cut may be taken to ensure a close fit of pipe faces. For this purpose, only experienced cutters who can make uniform and straight cuts, shall be permitted to cut the faces of the pipes. No extra payment shall be made for such marginal cutting. There shall be no lateral displacement between the pipe faces to be joined. If necessary, spiders from inside and tightening rings from outside shall be used to bring the two ends in perfect contact and alignment. It may also be necessary to use jacks for this purpose. In no case shall hammering or longitudinal slitting be permitted. When the pipe is properly assembled and checked for correct line and level, it shall be firmly supported on wooden beams and wedges and tack welded. Some portion of the trench may be refilled at this stage so as to prevent the pipeline from losing its/alignment. The tack welded circumferential joints shall then be welded fully. Only experienced welders, who will be tested from time to time shall be permitted to carry out the welding work.On Completion of the pipe jointing and external protection against rusting the trench and the welding pits shall be cleaned filled and compacted in 150mm layers as per direction of the Employer.

1.13.6 Precautions against FloatationWhen the pipeline laid underground in a long narrow cutting gets submerged in water collected in the trench of cutting, it is subjected to an uplift pressure due to buoyancy and is likely to float if completely or partly empty. In the design of pipelines, provision is to be made to safeguard against floatation, providing sufficient overburden or by providing sufficient dead weight by means of blocks etc. Factor of safety for calculation for check against floating shall be taken as 1.2.In the case of works extending over one or more monsoon seasons, however, special care and precautions shall be necessary during the progress of work on this account. The Contractor shall close down pipe laying operations well in time for the monsoon. The work of providing blocks, refilling the earth to the required level, compacting the same, etc. shall always be done as soon as the pipeline in the cutting has been laid. The Contractor shall see that the water shall not be allowed to accumulate in open trenches. Where work is in an incomplete stage, precautionary work, such as blank-flanging in the open ends of the pipeline and filling the pipeline with water etc. shall be taken up as directed by the Employer or his Representative.Such works shall be to the Contractor’s account and no separate payment shall be made for the same. The Contractor’s rate for pipe laying shall be deemed to include such precautionary measures against floatation.Protection of the pipeline against floatation shall be suitably designed by the contractor his own cost.

1.13.7 Refilling of trenchesOn completion of the pipe laying operations in any section, for a length of about 100m and while further work is still in progress, refilling of trenches shall be started by the Contractor with a view of restricting the length of open trenches. Pipe laying shall closely follow the progress of Trench Excavation and the Contractor shall not permit unreasonably excessive length of trench excavation to remain open while awaiting testing to the pipeline. If the Employer or his Representative consider that the Contractor is not complying with any of the foregoing requirements, he may prohibit further trench excavation until he is satisfied with the progress of laying and testing of pipes and refilling of trenches. Only soft earth and moorum of good quality free from stones larger than 75mm in size and free from boulders, roots, vegetation etc. shall be utilized after the lumps are broken for filling in around the pipes for atleast 30 cm all around for pipes less than 1200mm diameter and d/4 for pipes greater than 1200 diameter. Filling shall be done in layers not exceeding 150mm and compacted to 95 percent of the maximum dry density as per as pert VII of IS:2720. The excavated material nearest to the trench shall be used first. Care shall be taken during backfilling, not to injure or disturb the pipes, joints or coating. Filling shall be carried out

simultaneously on both sides of the pipes so that unequal pressure does not occur. Walking or working on the completed pipeline unless the trench has been filled to height of atleast 30cm over the top of the pipe except as may be necessary for tamping etc. during backfilling work.The remaining portion of the trench may be filled in with a mixture of hard and soft material free from boulders and clods of earth larger than 150mm in size if sufficient quantity of good earth and moorum are not available, filling shall be done in layers not exceeding 150mm in thickness accompanied by adequate watering, ramming etc. so as to be compacted 95% of the maximum dry density as per part VII of IS:2720. Water contents of the soil shall be as near the optimum moisture content as possible. The trench shall be refilled so as to build up to the original ground level, keeping due allowance for subsequent settlement likey to take place.To prevent buckling of pipe, pipes shall be strutted from inside while the work of refilling is in progress, for which no separate payment shall be made separately.Strutting shall be done by means of strong spiders having atleast 6 arms, which shall be sufficiently stiff to resist all deformation of pipes. Spiders shall be provided at a maximum interval of 2 meters Strutting shall be done in such a way that inside lining is not damaged.Removal of all surplus will be the responsibility of contractor and the same has to be removed immediately after completion of backfilling, leveling and dressing etc. failing which it shall be removed at contractor’s cost.If suitable material for refilling is not available from excavation the Contractor shall bring good earth, moorum of approved quality as directed by the Employer. Nothing extra shall be paid for bringing earth from outside for filing upto final ground level shown in the approved L- section.No mechanical plant other than approved compacting equipment shall run over or operate within the trench until backfilling has reached its final compacted level or the approval of the Employer or his Representative has been obtained.Subsidence in filling in : If any subsidence take place either in the filling of the trenches or near about it during the maintenance period of 12 months from the date of completion of the Contract, the Contractor shall make good the same at his own cost or the Employer may without notice to the Contractor, make good the same in any way and with any material that he may think proper, at the expense of the Contractor. The Employer or his Representative may also, if he anticipates occurrence of any subsidence, employ persons to give his timely notice of the necessity of making good the same, and the expenses on this account shall be charged to the Contractor.

1.13.8 Welding1.13.8.1 Unless specified other wise all M.S. pipes and specials shall have butt welded joint. Where if

shown on drawings, flanged joints or collar sleeve collar. Collar sleeve joints shall be provided.1.13.8.2 The welding of pipes in the field should comply with IS:816. Electrodes for welding should

comply with IS:814. The welded joints shall be tested in accordance with IS:3600 (Part-I) and other relevant Codes. One test speciman taken from atleast one field joint out of 10 shall be subjected to test as per Clause 6.2, 6.2.1, 6.2.2 and 6.3 of IS:5822 i.e. the Contractor shall carry out all test for welding as are described under Clause 6 of IS:5822.

1.13.8.3 Except for routine welding of joints, no other work shall be done in the absence of Contractor’s engineer, either during the day-time or at night.

1.13.8.4 Chipping shall not be kept in arrears for more than 15 joints.1.13.8.5 Design for saddle pieces shall first be got approved from the Employer and then the saddle piece

shall be fixed in position as per approved drawings after checking bolts holes, by means of templates. Entire responsibility for proper design/shape for the saddles shall be of the Contractor.

1.13.9 Preparation of Pipe FacesPreparation of pipe faces for welding shall be done as per Clause 5.2.5 of IS:5822

1.13.10 Temperature

1.13.10.1 All works such as fixing flanges, base plates etc. in true alignment, and in correct position and tack-welding pipes shall be done at the mean temperature to be checked by contractor from metrological office.

1.13.10.2 For ascertaining the temperature, the Contractor shall provide, mercury cups and fix them to the pipe shell from outside and shall also provide thermometers of the required type and range. No extra payment shall be made for all this.

1.13.11 Fixing Expansion JointsExpansion joints shall be designed to allow /or thermal induced movement of pipelines laid above/below ground. Details regarding temperature data shall be collected by the Contractor from the metrological department at his own cost for designing the expansion joints.The bidder shall design the expansion joints as per Clause 8.3.2 of IS:5822 and provide at his own cost after approval from the Employer. The Contractor shall also submit detailed installation and fabrication drawings so as to carry out the work. Also the Contractor shall submit methodology and sequence of Installation of the expansion joints.Expansion joints shall be welded on to pipelines at locations indicated on Drawings to be supplied by Contractor with the bid document. Expansion joints shall be fabricated true to shape and sizes as shown in the approved drawings. All contact surfaces shall be properly machined and finished smooth to ensure smooth working of the joints. The steel bolts and nuts to be used in the manufacturing shall be of approved manufacturer. The joints shall be assembled without undue hammering or forcing in, to avoid damage to any part thereof. The packing material to be used in the expansion joints shall be asbestos synthetic rubber or any other suitable material and rubber ring as approved by the Employer. It shall be capable of withstanding the test pressure and shall have high compressibility and properties to withstand deterioration by abrasion or water action. For dispatch to the site, the expansion joints shall be assembled with steel ring without other packing using bolts and nuts only in a locked position. The machined surfaces shall be greased before assembly. All the remaining bolts, nuts and washers and the packing material including rubber rings shall be supplied by the Contractor at the site of laying along with expansion joining. If any expansion joint gets damaged during transportation, it shall be replaced by the Contractor at his own cost.If any defects are noticed after its erection at site the Contractor shall carryout necessary repair either at site or at their works as directed by the Employer. All expenses in this connection including its removal, transporting and re-fixing shall be borne by the Contractor. The responsibility as regards the defects noticed shall be determined by the Employer and his decision shall be final and binding on the Contractor.Hydrostatic pressure test shall be conducted in accordance with IS:5822 or equivalent international standards for the water tightness of expansion joints. The expansion joints shall prove the sound and watertight at the time of testing. Any leakage shall be stopped by normal tightening of bolts on the gland.

1.13.12 Saddle SupportsUnless otherwise specified pipeline shall be underground. However in certain reaches it shall be on R.C.C. or steel saddle supports spaced at suitable intervals. The ‘material and construction of R.C.C. / Steel structures such as saddles, anchor blocks, crossings etc. associated with the work of pipeline shall conform with the relevant I.S. Codes, good engineering practice and as directed by the Employer, or his Representative. The pipes to be laid at saddle supports shall be erected at mean temperature. Saddle supports shall either be sliding type or fixed type. In case of sliding support, the pipe shall be allowed to slide freely over the plate embedded in the saddle. Alternatively to achieve fixity, the pipe shall be anchored by providing suitable anchor bases with steel clamps. The rate for laying the pipe on saddle support shall be included in laying, aligning, welding provision of rigging screws with screw eyes etc.In such areas subjected to floods the contractor shall lay pipes on pillars having unsettleable strong footings and the invert of the pipe shall preferably be kept about 0.3 meter above HFL subject to

approval of Flood control department or any other concerned authority. Nothing extra shall be payable or recoverable on account of change in the proposed invert levels or location of the pipeline, if any.The Contractor shall adopt these specifications for other pipes also when the ground levels are low.Below the pipes, the Contractor shall provide necessary bedding/ saddle supports at his own cost required as per structural designs, which shall be got approved from the Employer or his Representative.

1.14 Erection of ShellsThe erection of shells shall be true to position, lines and grade or as modified by the Employer or his Representative. The Contractor shall provide at his own cost necessary saddles, pads etc. and all necessary instruments and other materials and labour required for proper erection and welding of shells in position and for the Employer or his Representative for checking the correctness of all the erection works.

1.14.2 The best of welders as selected from the their work in the Contractor’s workshop shall be selected for in-situ welding of the shells. The relevant provision under welding such as qualification standard for welding, procedures, tests on welder’s work and removal of defects etc. shall also apply in in-situ welding.

1.15 General Sequence of OperationsPipe laying shall generally start from the fixity points on either side, the expansion joint. If required for pipeline above ground being provided last. Fixing points are at all anchor blocks. Where such blocks are not required for long lengths, fixity shall be achieved by fixing the pipeline to the special type of R.C.C. or steel saddles as per site conditions. The distance between successive ‘fixity points shall not exceed 300m. While designing the transmission/ piping system the Contractor shall also fix positions of fixity points and location of Expansion Joints on the basis of temperature variations which occur in Delhi in the range of about 30 - 400C i.e. the temperatures at the time of Installation/Welding of joints and the maximum/ minimum temperature. The Contractor is also advised to check the outside temperature difference which generally prevails in Delhi from metrological/ weather department since ultimately responsibility shall be of the Contractor.

1.15.2 Anchor blocks shall be constructed before commencing the pipe laying work in any section as per IS:5330. The construction of the thrust/anchor blocks shall be carried out in 3 stages: in the first stage the lower part upto 150mm below the invert of the pipeline including concrete chairs to support it, shall be constructed in the second stage the pipeline on this part of the block shall be laid; and lastly, the remaining block around and over the pipeline with clamps shall be constructed.

1.15.3 The fixity saddles and ordinary saddles if the pipeline is above ground shall be cast atleast 3 weeks before the pipeline is laid on them. After all saddles between successive fixity points have been cast, a line plan showing the actual position thereof shall be prepared, after taking and measuring distances. In case of any errors in casting the pedestals, corrections shall be applied. The pipe laying work shall then start from the fixity points and shall proceed towards the expansion joints. The method of jointing the pipes and erecting them on previously cast R.C.C. saddles shall be determined by the Contractor and got approved from the Employer.

1.15.4 The pipe strakes shall be assembled in position on the saddles either by the cranes, portable gantries, shear legs or any other equipment approved by the Employer’s representative. Normally, not more than two pipes shall be aligned, tacked and kept in position on temporary supports. The Contractor shall not proceed with further work, until the circumferential joints of these pipes are fully welded. During assembly, the pipeline shall be supported on wooden sleepers and wedges, with the free end to the pipeline held in position by slings to avoid deflection due to temperature variations during the day time while full welding including the external gouging and sealing runs shall be done at proper temperature as per codes requirements and best Engineering practice. The Contractor shall maintain the continuity of the work by adding two more pipes on the second day in a similar manner, after full welding of the previous joints is completed. While this new work is

being done, the Contractor shall proceed with the work of providing permanent supports for the pipeline assembled and welded previously.

1.16 SPECIALS - FABRICATION1.16.1 Generals

Specials, such as tees, Y-pieces, bends (single or composite), tapers, tees, blank flanges and gap pieces, collars, expansion joints, man-hole covers etc. shall necessarily be in steel and shall be manufactured as per IS : 7322 standards and applicable codes and tested in the same manner as the pipes. Small branches, single piece bends etc. may be fabricated at the site. Care shall be taken to ensure that the fabricated fittings have at least the same strength as the pipeline to which they are to be joined and tested.

1.16.2 Bends1.16.2.1 Bends shall be fabricated taking into account the vertical and horizontal angles for each case. 1.16.2.2 The bends shall have welded joints and the upstream and downstream ends of each bend shall have

a straight piece of variable lengths as required at site.1.16.2.3 Bends shall be designed with deflection angle of maximum 10 deg between segments.1.16.2.4 When the point of intersection of horizontal angle coincides with that of a vertical angle, or when

these points can be made to coincide, a single combined or compound bend shall be used, designed to accommodate both the angles. The combined bend should have a pipe angle equal to the developed angle, arrived at from appropriate formula.

1.16.2.5 All joints in bends and other specials shall be thermally stress relieved as per Technical requirements / IS codes.

1.16.2.6 Details of thrust collars anchor bolts, holding down straps, saddle plates shall be furnished by the Contractor which will have to be got together with full specifications.

1.16.3 Deleted.1.16.4 Closing or Make Up Sections

Closing or makeup sections shall be fabricated by the Contractor to permit field adjustments in pipeline length to compensate for shrinkage in field welded joints, differences between actual and theoretical lengths and discrepancies in measurements. The Contractor shall initially plan the positions of closing gaps and submit proper drawings showing the materials / specials, which he shall be providing for closing of each gap at his own cost.

1.16.5 Heads/ClousersTwo types of closures/ heads are used in pipelines depends on their locations viz.:a) Closures for manhole covers andb) Blank flanges either of flat plate design of dished hemispherical closures. These shall be

properly designed and provided by the contractor at his own cost depending on locations where to be used.

1.16.6 Walkways, Stairs, Ladders, Handrails etc.Walkways, stairs, rungs, ladders, handrails etc. if required shall be manufactured and by the contractor and / or as directed by the Employer or his representative. They shall conform to well-established design and construction for each accessory concerned.

1.16.7 FlangesFlanges shall comply with IS: 7322. The nominal pressure rating shall be at least equal to the highest pressure rating of pipes or fittings to which they are attached.Flanges shall be properly designed and provided at the end of pipes of special where sluice valves, blank flanges, tapers and other flanged specials have to be introduced. The Flanges received from the manufactures will have necessary bolt holes drilled to IS: 1538 (part VI) The contractor shall assemble the flanges in the exact position by marginal cutting, if necessary, so as to get the desired position of the sluice valves and other specials and fittings etc. either vertical or horizontal and shall then fully weld the flanges from both sides in such a manner that no part of the welding protrudes beyond the flanges and if the Employer or his representative orders that such protrusions shall be removed, the contractor shall file or chip them off. If required and when ordered by the

employer or his representative, the contractor shall provide and weld gusset stiffeners, as directed on site. The drilling pattern shall be matching with the drilling pattern of flanges of valves and other fittings.

1.16.8 Blank FlangesBlank flanges of suitable thickness shall be provided at all ends left unattended for the temporary closure of work and also for commissioning a section of the pipeline or for testing the pipeline laid. For temporary closures, non-pressure blank flanges consisting of mild steel plates, tack welded at the pipe ends may be used. For pipes subjected to pressure, the blank flanges or domes suitably designed as per site requirements shall be provided.

1.16.9 Stiffener RingsThe Contractor shall provide stiffener rings wherever required. The Contractor shall weld the same to the pipes with one circumferential run on each side.All fillet welds shall have a throat thickness of not less than 0.7 times the width of welding.

1.17 LININGS AND COATINGS OF PIPELINES1.17.1 Preamble

The Contractor shall select scheme for lining and coating of pipes on the basis of soil & water reports and his own supporting investigations such as soil resistivity and other supplementary data or as directed by engineer-in-charge.Acceptable linings are :Cement mortar (shop applied, confirming to Annex - A - IS:3589 : 2001Cement mortar (in-situ) Conforming to 15:11906Liquid - Epoxy system conforming to Annex - B- IS : 3589 : 2001Fusion bonded Epoxy system conforming to Annex - C- IS 3589 : 2001Acceptable coatings are:Cement mortar confirming to Annex - A - IS:3589 : 2001Liquid - Epoxy system conforming to Annex - B- IS : 3589 : 2001Fusion bonded Epoxy system conforming to Annex -C-IS 3589 : 2001Tape coating system conforming to Annex - D- IS : 3589 : 2001 and IS:10221The Coating system should be recommended by a competent corrosion engineer.

1.17.2 Cement Mortar Lining for Internal Surface of Pipepline1.17.2.1 Scope

These specifications cover the requirements of providing materials and application of cement mortar lining at works applied by a centrifugal spinning process as per IS codes. The waterway of the M.S. pipes & fittings shall be completely covered with specified mortar. The mortar lining shall be completely free from cavities or visible air bubbles and pinholes and shall be thoroughly compacted throughout. The consistency of mortar and time and speed of centrifuging of the pipe shall be so adjusted that the segregation of the sand and cement is not there. The mix used to cement mortar lining shall be 1:2 (1 cement : 2 sand) as per Clause 2.4 of IS:11906. The work shall be started only after thorough cleaning of the pipes and sand blasting to near white and obtaining the written approval of the Employer or his representative in this respect. Before starting the cement lining work, the Contractor shall also ensure that all related works required are completed by him.

1.17.2.2 Applicable Codes and SpecificationThe following specifications, standards and codes in addition to those listed earlier to this specification are made a part of this specification. All standards, to this specification are made a part of this specification. All standards, specifications, codes of practices referred to herein shall be the latest edition including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to here in, this specification shall govern.IS:11906:1986 Recommendations for Cement Mortar Linings for CI Mild Steel

and Ductile Iron pipes & fittings.

IS:8112 43 grade ordinary portland cement.IS:3696 Safety Code for scaffolds and ladders (Part 1 & 2)IS:460 - 1985 Test SievesIS:2386 (Part 2) Methods of test for aggregates for concrete part 2 Estimation of

deleterious material and organic impurities from natural sources.IS:383 Coarse and fine aggregateIS: 456 Code of practice for plain and reinforced concreteIS: 516 Methods of test for strength of material

1.17.2.3 GeneralEmployer or his Representative shall have the right to inspect the sources of materials, the operation of procurement and storage of materials, Cement mortar batching and mixing equipment and the quality control system. Such an inspection shall be arranged and the Employer or his Representative and approval obtained prior to starting of lining work.

1.17.2.4 Method of ApplicationAll lining work shall be done by machine in factory as is described in Clause 1.17.2.1 of these specifications. However, for joints In Situ smooth lining shall be acceptable.

1.17.2.5 WorkmanshipAll works shall be performed in a thorough and workmanlike manner by trained personnel with previous experience under the supervision of experienced men skilled in the application of centrifugally applied cement lining as mentioned earlier. While submitting the bid, the Contractor shall give the names of such persons or the specialized agencies he will be deploying. The Bidder shall also clearly indicate the methodology he will be adopting for lining in straight reaches, at bends, (Horizontal & vertical) at compound bends, at tee positions and for other specials / fittings etc.

1.17.2.6 Programme of Lining and Plant and EquipmentThe list of plants and equipment proposed by the Contractor for carrying out the cement mortar lining application shall be furnished by the Contractor along with the Bid. The Contractor shall also furnish complete details of similar work executed by him in the near past and also the additional equipments he proposes to acquire and programme of completion if the work is allotted to him.

1.17.3 Materials of Construction1.17.3.1 Cement

Cement required for mortar lining shall be “Portland Cement conforming to IS: 8112- grade 43 cement.

1.l7.3.2 AdmixtureTo improve workability, density and strength of the mortar, admixtures as approved by the Employer or his Representative may be used by the Contractor at his own cost. No admixtures shall be used that would have a deleterious effect on water flowing in the pipe, which is required for drinking purposes. Bidder should indicate in his bid the details of admixture he proposes to use

117.3.3 Sanda) The quality of sand used shall be as per Clause 2, Para 2.2.1 and Table I under the above Clauses of IS: 11906.b) Organic impurities - “Test for Organic Impurities in Sand for Concrete / Cement mortar for linings shall be checked as per IS:2386 (Part - 2)

1.17.3.4 WaterWater used for mixing the mortar shall meet the requirement of IS: 456

1.17.4 Design Of Lining1.17.4.1 General

a) Composition of mortar for the lining shall be of cement, sand and water mixed to such a consistency as to produce a dense and homogenous lining that will adhere firmly to the pipe surface.

b) The contractor shall provide cement mortar lining in such a way that the lining surface shall be able to deliver a guaranteed “C” value of 140 as is provided in the “Manual on Water Supply for New Pipes”.

1.17.4.2 ProportionDry proportions of cement and sand shall be I part of cement to 2 parts of sand by weight as mentioned in Clause 2.4 of IS: 11906 and in Annexure A-6.1 of IS: 3589-2001. The works strength of the mortar as stated in Annexure - A-7.3 of IS: 3589-2001 should be not less than 31 N/mm2 after 28 days of curing.

17.4.3 Thickness of LiningMinimum lining thickness for pipes shall be as per IS: 3589 (Table-8) with no negative tolerance. However positive tolerances as per Clause 7.2 of IS: 11906 shall be acceptable. Bore diameters shall be maintained as given in Table - 1 of IS : 3589-2001

1.17.5 METHODS OF CONSTRUCTION1.17.5.1 Access Openings

Only such openings indicated by the Contractor and approved by Employer or his Representative shall be provided in the pipelines. After lining is completed, closure pieces will be welded to the pipes. Mortar lining of closure pieces and adjacent area shall be done by the Contractor and included in the overall bid amount for cement mortar linings.

1.17.5.2 Preparation of Pipe SurfaceThe interior surface of pipe to be lined shall be cleaned to remove all rust, chemical or other deposits, loose mill scale and deteriorated remains of old materials, oil, grease, and all accumulations of water, dirt and debris. Also the cleaning of the surface shall be carried out by the use of suitable chemicals and by mechanical means i.e. by sand blasting to near white, with the approval of Employer or his Representative. The extent of cleaning shall be to the satisfaction of the Employer or his Representative. After sand blasting, the sand remaining inside the pipeline shall be cleaned by use of a power-drive cleaner, incorporating revolving brushes on rotating arms. After this cleaning pipe shall be flushed with potable water and all standing water removed. Immediately prior to application of cement mortar lining by centrifugal spinning or by centrifuged sprinkler or by combination of both, all foreign material shall be removed. This includes sand and loose mortar that might have accumulated since the work of preparation of surfaces was last completed.

1.17.5.3 Lining ProcedureThe lining mortar shall be placed centrifugally. The mortar must be densely packed and shall adhere to the pipe wherever applied. The lining of specials shall be as per Clause 4.1 of IS: 11906 and hand rendering of specials shall be as per Clause 11.1.1 of the above code.

1.17.5.4 Surface FinishThe surface of cement mortar lining shall be uniformly & perfect smooth and shall be free from voids. The lining shall not have flaky area It shall not be crumbly and shall not have waves or grooves and shall be conform to Clause 10.1 and 10.2 of IS: 11906 Pipe shall not be dispatched until 21 days have elapsed since the date of lining.

1.17.5.5 Examining ProcedureIn the stretch of pipe that has been lined, the thickness of lining shall be in measured at both ends of the pipe, in at least, one section perpendicular to the pipe axis.

1.17.5.6 Keeping Circulatory - During LiningDuring the processes to lining the inside surface or the M5 Pipes, the Contractor shall ensure that roundness of the pipes is maintained. The Contractor at the time of submitting the bid shall explain fully as to how he will maintain the circularity inside the M.S. pipe and the equipments/tools available with him for this purpose.

1.17.5.7 Hand Application of Mortar Lininga) Hand placed mortar shall have a uniform and smooth surface with smooth transitions to adjacent centrifugally placed linings.

b) Cement mortar lining of bends, specials, areas closely adjacent to valves and other such places where centrifugal placing may not be practical shall be performed by hand. The Employer or his Representative may order the correction for any defect by hand application.c) Cement mortar for hand work shall be of the same materials as the mortar for machine placed lining.d) The areas to be lined shall be thoroughly cleaned as specified earlier and, if necessary, shall be moistened with water / cement grout immediately prior to placing the hand-applied mortar.e) Steel finishing towels shall be used for the hand application of cement mortar, except at bends the outer edge of hand trowelled areas may be brushed in order to reduce the abutting offset.f) All hand finishing work in a section of the pipeline shall be completed within 24 hours after completion of the machine application of mortar lining to that section. If necessary, application of mortar lining by machine shall be delayed or stopped to assure compliance with this schedule.

1.17.5.8 Special Requirements at Laterals and Service ConnectionsLateral and connections to the pipe that is being lined shall not be left obstructed by the lining operations. Before the lining is placed, the openings in the pipeline leading to air valves, blow offs, manholes and appurtenances, as well as to laterals and connections that transmit pressure to carry water from the pipeline, shall be temporarily covered or plugged with suitable devices. These shall be removed later without damaging the Cement mortar.

1.l7.5.9 CuringCuring shall commence immediately after completion of the mortar lining and hand finishing of a section of pipeline. This shall, however, not be later than 8-hours after mixing of mortar. The lining shall be kept continuously in moist condition for a period of 14 days. During the operation of lining, finishing and curing, exterior surface of the pipe exposed to sunlight shall be sprinkled enough water to keep the pipe cool. Open ends of pipes shall be suitably closed so as to maintain a moist atmosphere and prevent draught. Curing of mortar lining and simultaneously cooling of the pipeline externally shall be continued even beyond the period of 14 days as directed by the Employer or his Representative. In the opinion of Employer or his Representative, if the water for curing as per the specification may not be available. Employer or his Representative shall order the Contractor to use chemical curing which shall be carried out as per the manufacturers specifications. No extra payment will be made on this account. If the contractor desired so, use of approved curing compound will be permitted.

1.17.5.10 Tests of Cement Mortar used for LiningAs per clause A-7-3 of IS: 3589 : 2001, the mortar test cylinders shall obtain a minimum compressive strength of 18 MPa in 7 days and 31 MPa in 28 days. Pipe made with mortar lining that does not meet the strength requirements set forth herein shall be subject to rejection.

1.17.6 INSPECTION1.17.6.1 Responsibility of Engineer and Contractor

The entire procedure of applying cement mortar lining shall be subject in continuous inspection by the Employer or his Representative but such inspection will not relieve the Contractor of his responsibility to furnish material and perform work in accordance with this specification. All cement mortar linings not applied in accordance with this specification shall be subject to rejection by the Employer. Lining so rejected shall be removed and replaced by the Contractor at his own expense.A manual visual inspection of the lined pipe shall be by means of CCTV to determine the quality of the lining and to identify defective areas in linings for repair. The contractor shall procure/hire suitable equipment required for this purpose at his, own cost.

117.6.2 Defective LiningDefects in lining including but not restricted to sand pockets such as voids, over sanded areas, blisters, cracked and dummy areas, and thin spots shall be removed, and the area shall be repaired by hand application to the full required thickness of the mortar lining. Defective ares

encompassing the full diameter of the pipe shall be replaced by machine whenever practical. Defective lining rejected after initial set shall be replaced or repaired by the most practical method as determined by the Employer or his Representative and as per IS:11906.

1.17.6.3 GuaranteeIf on examination the Employer or his Representative finds in the cement mortar lining work within defect liability period after final completion and acceptance of the Contract work evidence of defective materials or workmanship as defined in this specification, then the Contractor shall perform the remedial work at his own expense in a manner acceptable to the Employer.The inside coating shall also not contain any constituent soluble in drinking water or any ingredient, which could impart any taste or whatsoever to potable water after sterilization and suitable washing of the mains.

1.18 CLEANING, EPOXY PAINTING/ COATING OF M.S. PIPES AND SPECIALS1.l8.1 General

The fabricated pipes and specials wherever laid above ground shall be provided out coating of the following specifications. The bidders can also suggest any other coating with this literature provided it is of better standards.

1.18.2 Surface CleaningAll the surfaces of steel pipes and specials to be painted shall be blast cleaned to Sa 2½ Swedish Standard SIS 055900 (equivalent to IS:1477-Part-1, Class-B i.e. near white) to remove all rust, mill ‘scale etc. Earlier to sand blasting oil and grease shall be removed by applying a suitable metal cleaning solution (quality, make and properties of the cleaning solution to be clarified by the Bidder at the time of submission of the bid) and wiping the clean rags. Also the bidder shall remove all foreign matter, which cannot be removed even by blasting to the satisfaction of the Employer.

1.18.3 Priming CoatThe blast-cleaned surface shall then be provided immediately a priming coat of following specifications in the fabrication shop. “One Coat of Zinc Anode 304 inorganic Silicate coating by airless spray (not by brush) to achieve a dry film thickness of 75 to 80 microns”.Each lot of paint i.e. primer supplied shall also be accompanied with the certified copies of the results of the test carried out by the manufacturer. If any sample of primer and/or paint is not conforming to the specifications, the entire consignment to which the sample may pertain shall be rejected. Only those primers and painting materials that have been approved by the Employer/owner in writing shall be used for this work. Therefore, the Bidder shall also clarify the following in respect of primer and the paint in his bid,i. Baseii. Catalystiii. Shadeiv. Characteristicsv. Pod lifevi. Mixing rationvii. Viscosityviii.Drying time.

1.18.4 Intermediate CoatThis shall be applied at fabrication shop and shall be of the following specifications, “Apply one coat of high build Micaceous iron oxide coating by airless spray to achieve a dry film thickness of 100 microns” - MAKE - Asian, Shalimar, Berger, Godlac Nerolac and Jenson & Nicholson.

1.18.4.1 The bidder shall also clarify the following in respect of paint to be used as intermediate coat(i) Shade(ii) Characteristics

(iii) Shell life(iv) Drying time(v) Finish(vi) Colour(vii) Toxicity

1.18.4.2 In addition to above the Bidder should also enclose with the bid results of the tests of the manufacturer in respect of the following :(i) Stripping test(ii) Flexibility and adhesion of 96 hours of drying(iii) Protection against corrosion under conditions of condensation(iv) Impact test(v) Resistance to heat(vi) Flash point(vii) weigh per 10 liters

1.18.4.3 Paint shall be applied only to dry, freshly cleaned surfaces, free from dust, rust, scales, grease or other substances which might affect the adhesion or the durability of the coating. In no case the paint shall be applied during rainy or misty weather.

1.18.4.4 All paints shall be applied by skilled workmen in a workmanship manner and the average coverage shall be equal to that recommended for first class work by the manufacturer on M.S. Steel pipes.

1.18.4.5 The primer coat and the intermediate coat shall be uniform in thickness and free from floods, runs, sags, drips or bare spots. Any bares pots noticed shall be recoated with an additional application of the primer and the intermediate coat.

1.18.4.6 Application of the paint under very strong sun or in the early morning in winter shall be avoided. All paintings shall be done at mean temperature recommended by the manufacturers. If during inspection any portion is found rusted, the same shall be removed by emery paper and recoated to the original specifications. When one coat is applied, the date of application of this coat should be written on either end of the section. Before application of the paint, it shall properly stirred so as to get a good mix.

1.18.4.7 The painting shall be done by cross brushing i.e. one coat shall be given vertically and another coat horizontality so as to get required uniform thickness and to avoid sagging.

1.18.5 Finish Coat1.18.5.1 This coat shall be given at erection site and shall be of the following specifications. “Apply one

coat of Catalyzed Epoxy Resin suitably pigmented of 75 microns dry film thickness” - Make : Asian, Shalimar, Berger, Godlac Nerolac and Jenson & Nicholson.

1.18.5.2 Total film thickness of all the coats shall be 250 microns.1.18.5.3 Over the finishing coat a coat of POLYURETHENE EPOXY FINISH shall also be applied of 30 -

micron thickness. (For reference BS:5493 Standard by consulted) Make : Asian, Shalimar, Berger, Godlac, Nerolac and Jenson & Necholson.

1.18.5.4 No coating shall be applied closer than 100 mm from ends of pipes and specials and this coating shall be done after field welding. The exposed steel surfaces shall be protected by rust preventive applications, which shall not interfere with the field welding.

1.18.5.5 Machined finished surfaces shall be effectively coated with white lead to prevent rust during loading / unloading and transport of pipes and specials from the fabrication shop to the site of erection to preserve the shop applied paint in the best practical condition.

1.18.5.6 After erection of the M.S. Pipeline on site above ground, all rust, damaged area and site weld portion of the pipelines shall be cleaned to near white and shall be painted with one coat of primer and two coats of paints as explained earlier. Over the two paints coats a coat of 30-micron thickness POLYURETHENE EPOXY FINISH shall also be provided. All paintings shall be done on clean dry surfaces so that there is proper adhesion of different coats with each other.

1.18.5.7 Thickness of each layer of paint shall be measured using elcometer or other standard measuring devices to be provided by the Bidder at his own cost. If the thickness is found to be less than the

specified, the outer surface of the pipe shall be re-surfaced to bring the same to the original specified thickness.

1.18.5.8 The bidder shall also check adhesion properties of the paints applied and submit necessary reports as asked by the Employer or his representative.

1.18.5.9 If, at any time during inspections, it is found that the procedure of applying paint is not as per standards laid down, all such painting work shall be rejected and rectified by the Bidder at his own cost as per direction of the Employer or his representative.

1.18.6 COVERING CAPACITY1.18.6.1 Covering capacity of the paint shall be checked and it shall be compared with that given by the

manufacturer.1.18.6.2 The contractor while submitting the bid shall also clarify the following :-

(a) In case the bidder wants to make changes in the painting systems, the Contractor should indicate the type of paint, its life span against start of rusting. However, the system and properties of the paint proposed should match with International Standards for non-rusting & longer life span.(b) The Contractor shall also submit along with the bid, the methodology to be adopted by him for painting of pipes above ground level. He shall also specify life span of the epoxy paint to be used by him.

1.18.7 Epoxy Inner LiningWherever permitted, the inner lining of food grade Polyurethene (P.U.) epoxy will be done after achieving cleaning as per clause 2.18.2. The thickness of various coats shall be as under :-* Primer : 150 - 170 micron* Intermediate coat : 150 - 170 micron* Sealing Coat : 150 - 170 micron

The total thickness shall not be less than 450 micron.1.19 EXTERNAL COATING OF M.S. PIPES LAID BELOW GROUND

Fiber Reinforced Coaltar Enamel Coating1.19.1 General

(i) Unless otherwise specified or stated on the drawings the M.S. Pipelines to be laid underground shall be shop approved external coating with Fiber Reinforced / Coal Tar Enamal in a shop / Factory.(ii) Fiber Reinforced Coal Tar Enamel shall be in accordance with IS 10221 - 1982.(iii) Shop applied - Hot applied Coal Tar Enamel Coating complete with inner and outer reinforcing wraps.(iv) Field Applied - Cold applied self adhesive PVC backed tape for field joints.(v) Sampling and testing of materials and coating shall be in accordance with IS 10221 / AWWAC203.

1.19.2 PrimerThe primer shall be coal - tar or synthetic base primer in accordance with IS : 10221 and shall be highly compatible with the coal tar enamel used.Coal tar primer shall consist of processed or coal tar pitch and refined coal tar oils only suitably blended to produce a liquid to be applied by spraying and that shall produce an effective bond between the metal and subsequent coating tar enamel as per Clause 4.1.1 of IS : 10221.The primer shall not contain Benzol or other toxic or highly volatile solvents. There shall be no added pigments and inert fillers and shall show no tendency to settle out in the container and shall have characteristics as specified in table I of above code. The coverage shall be uniform and shall result in a dry film thickness of minimum of 50 microns.

1.19.3 Coal Tar EnamelCoal Tar Enamel used for coating shall be of make : STP Eastern coating or equivalent confirming to IS:10221.

The enamel shall consist of specially processed tar pitch, blended with inert and non hygroscopic mineral fillers, properly graded, clear dust free and without asphalt to be applied at the manufacturer recommended temperature as mentioned in Clause 4.2.1, 4.2.2 of above code.The enamel should be impermeable to water and shall also be immune to attack of calcium, magnesium and other salts normally encountered in the route of the pipeline.

1.19.4 Inner WrapThe inner wrap or reinforcement to coal tar enamel shall be non-woven fiber glass tissue consisting of uniform porous mat of chemically resistant Boro-silicate glass. Glass fiber mono filaments making up the mat shall be bonded with suitable inert material like phenolic or urea type compatible with coal tar enamel. the fibrous glass mat is reinforced in the longitudinal direction with continuous filament glass yarn at 10 mm centers as per Clause 4.3.1 and table - 7 of above code.The glass fiber shall have characteristics in accordance with IS 10221 except of the following :Weight: 50g/m2 (Minimum)Thickness : 0.5mm (Minimum)

1.19.5 Outer WrapThe outer wrap shall non-woven fiberglass felt type in accordance with IS 7193. It shall have glass fiber tissue specified in Clause 4.3.1 saturated with plasticised coal tar enamel in accordance with IS 10221, 4.3.2.1 and table 10 of IS:10221. The outer wrap shall be of make : STP, Eastern Coating or equivalent confirming to IS-10221.The resultant outer wrap shall be uniform, flexible and have random pinhole to facilitate the release of hot gases and to allow sufficient bleed through of the enamel to achieve better adhesion of the outer wrap.The outer surface of outer wrap shall be lightly dusted with talc or other approved mineral powder sufficient to prevent sticking in the roll under conditions likely to be met in application at site.The inside surface shall receive minimum dusting necessary in order that the bond between the outer wrap and the enamel shall not be impaired.The physical characteristics of the outer wrap shall be in accordance in with IS 10221 / AWWA C203 except for the following :Nominal thickness 0.75mmWeight585g/m2 (Min) and 730g /m2 (Max)

1.19.6 Field Applied TapeGeneral Requirements of pipeline wrapping tapes shall be in accordance with IS 10221. Primer shall be suitable by brush or spray application and materially in accordance with tape manufacturer’s recommendation.Tape shall be PVC backed bituminous compund with excellent adhesion to itself and to steel pipe and highly conformable to values, flanges, etc and shall have the following minimum characteristics.Adhesion to steel : 2N/mmThickness of adhesive compound : 0.90mmThickness of PVC backing : 0.75mmTotal thickness : 1.65mmTape strength : 12.0 N/mmElongation : 260%Dielectric strength : 20,000 V / mm

1.19.7 Shop ApplicationPrior to coating, the external surfaces of pipe shall be thoroughly cleaned free from all loose mill scale, dirt, rust, scale corrosion products, grease, moisture and other foreign material and prepared for priming by one of the following methods :a. Blast cleaning of grade Sa 2 to whiten accordance with ISO 8501 (part I)

b.Chemical cleaning to include degreasing, acid picking and phosphates with intermediate washing as recommended by the primer / enamel manufacturer’s instructions.After surface preparation by shot blasting, before flash rusting can occur the pipe exterior shall be coated with primer spread at a controlled rate to the manufacturer’s recommendations and thereafter allowed to dry.The primer shall be applied to clear, dust-free and dry pipe and thereafter should kept free from moisture, dust or any other containment. The coating shall be uniform and free from runs, drips flooded in base areas, particularly in weld areas.When the pipe surface temperature is below 70 C or moisture is present on the pipe surface, the pipe shall be warmed for sufficient time to dry the pipe before priming.The enamel for coating shall be drawn from heating appliances recommended by manufacturer. The enamel temperature at the time of application shall be in accordance with manufacturer’s instructions. The maximum temperature in the boilers shall be limited to 2700 C. Enamel held at these temperature for above six hours or longer shall not be used.Enamel should not be applied to the primed pipe when the pipe metal temperature is below 70 C. there shall be two of coal tar enamel. Each coat of enamel shall have a minimum thickness of 2.4mm at any point with an overall thickness of minimum 5mm on the pipe body and shall be reinforced by a spiral inner wrap of fiber glass tissue pulled into the hot enamel in such a manner that the fiber glass tissue is embedded half way into the enamel without touching the steel surface or appears at the enamel surface.The coal tar impregnated outer wrap shall be simultaneously applied with the inner wrap. Both inner wrap outer wrap shall be overlapped by 25mm. the overlaps of the inner and outer wraps shall be staggered from each other by a minimum distance of 100mm. There should be a minimum of 0.8mm of enamel between pipe surface and the inner wrap.The completed coating shall be well bonded to the pipe metal, uniform smooth and free from holidays, laminations or other defects.The coating and wrapping shall be carefully trimmed off 150mm from the ends of each pipe.The pipes shall be finally dressed with latex emulsion in accordance with AWWA C203 / IS:10221.

1.19.8 Field ApplicationOn completion of welding and hydrostatic testing, the expressed section of pipe shall be thoroughly cleaned free from loose mill sacle, metal bans, weld spatter and any dirt, rust grease, moisture and any foreign matter.Adjoining area of shop coating near field joint of approximately 150mm shall be prepared by hand wire brushing where field applied tape will overlap.The primer shall be applied to joint area ensuring coverage is complete especially at welds.Tapes shall be wrapped inaccordance with manufactrurer’s instructions. Application rate and time for overlapping shall be in accordance with tape manufacturer’s recommendations.Tape shall be applied with a 50% overlap and even tensioning to ensure good confirmation with no wrinkles or air pokets. Wrapping shall start and finish to give a minimum 75mm overlap onto the adjoining shop coating.

1.19.9 Tests and Inspection Tests on primer and enamel shall be in accordance with IS 10221 / AWWA C203. Before coating, test results determing the characteristics of printer, enamel and fiberglass shall be submitted to the Employer for approval. Different tests on coal tar and enamel like high temperature test, deflection test, impact test and peel test shall comply with the requirements specified in IS 10221. All test certificates shall be submitted to the Employer.The completed coating shall be solid, free of wrinkles and pockets or tears and thoroughly bonded to pipe throughout and shall be inspected using a Holiday detector (Electrical Inspection).

The voltage of the Holiday Detector shall be set depending upon the coating thickness and manufacturer’s recommendations.The voltage of the Holiday Detector shall be recalibrated at the start of each day’s work and after every four hours of coating operation.Contractor should note that all the works connected with wrapping / outcoating shall be done as per IS:10221 and the bidder shall submit all test reports as are mentioned in IS:10221.

1.19.10 TolerancesPermissible tolerance for straight pipe and fittings shall be as per Clause 12.5 of IS:3589.Outside DiameterThe permissible tolerance for outside diameter shall be as per Clause 12.3 of IS:3589.

1.19.11 Handling of Pipes and SpecialsCoated pipe and specials that are to be stored on supports shall bear on the uncoated ends only. If bearing to coating is employed the supports shall not less than 20cm (8 inches) wide and so arranged to prevent damage to the coating.During handling of the pipes and fittings, coating shall be protected not less than 20cm wide and placing strips of heavy belting or other approved sheet materials not less than 20 cm wide under all ropes or fastening.

1.20 Laying General1.20.1 General

Since choice of route of a pipe line is governed by the economic consideration and other factors such as existence of underground & surface utilities the Contractor shall carry out field survey along pipeline routes. The Contractor shall then mark out any changes called for on a plan. The Contractor may then take ground levels of the strips width along the alignment if he feels. The Contractor shall also prepare L-sections show position of bends (Vertical and Horizontal). of valves, sluice valves, Zero Velocity Valves, Air chambers, Surge Tanks etc., and submit for approval from the Employer.Also on L-sections the Contractor shall show pipe inverts, depth of cuttings, cushion available over the pipe top, pillars tops if the pipe is on be laid above the ground, position of drains, nallahs, bridges, roads to be constructed by him for crossing of nallahs, roads to be crossed , rail tops railway bridges and all other obstructions to be crossed for laying of the pipeline.For areas, which require special permission from any other authority, separate drawings shall be prepared by the Contractor for getting permissions from the appropriate authority. Such permissions can be for road crossings, railway track crossing, road cuttings, cable shifting, Nallahs crossing and other utilities etc. Applications for such permission addressed to the utility authority shall be moved by the Contractor and pursued by him. Any delay for getting the permission shall be to the Contractor’s account. DWB shall help the Contractor to the extent of issuing an essential letter. amounts demanded by the utility Department for restoration of their utilities shall initially be paid by the Contractor after informing the employer and such amounts paid to the other departments shall be reimbursed by the DWB within 3 weeks to the Contractor as is clarified in the earlier chapter.

1.20.2 TransportationThe transportation of all materials to work site and stacking shall be done in such a manner as to cause minimum inconvenience to the traffic and other construction works, Pipes shall be protected during handling against impact, shock and free fall to avoid cracks and damage. Pipes shall be loaded for transportation in such a way that they are secure and no movement can take place on the vehicle during transit. The same care shall be taken if pipes are transferred from one vehicle to another. However, short the journey may be. The cement mortar lining of pipes which may get damaged during transportation is to be repaired otherwise it shall be rejected. the decision of rejection shall be taken by the Employer or his Representative. In order to avoid damage during transportation or due to other causes to the factory provided lining the contractor may carry out in-situ lining by creating all such conditions as are existing in the factory. Contractor should note

specifically that pipes with damaged lining and out coating shall not be accepted at all. Nothing extra shall be paid for in-situ lining and making of special arrangement at site and in the factory.

1.20.3 Unloading of PipesEach pipe consignment shall be inventoried and inspected with care upon arrival though the pipes have been inspected and loaded with care at the factory. Overall examination shall be made during unloading to ensure that the pipes have reached the laying site / destination in good condition. If there be any sign of rough treatment on the lining or out coatings each pipe shall be inspected for damage. Damaged pipes shall be rejected and not paid.While unloading, pipes shall not be thrown down from the trucks on ground or on the hard roads. Cranes or Mechanical equipment shall be used for unloading the pipe from the truck. In order to avoid damage to the pipes especially to the spigot end, pipes shall not be dragged along concrete and similar pavements with hard surfaces.

The pipe shall be laid on timber battons and secured with wooden wedges. The pipes shall be stacked with each tier at right angles to the preceding tier. Removal of pipes from tiers for laying etc. shall be done carefully with mobile cranes so that no damage occurs to the pipe or the lining or the coating provided.

1.20.4 Lowering of Pipes and FittingsThe pipes shall be lowered in to the trenches cautiously to prevent disturbances of the bed excavated in required grade and sides of the trench.Proper implements, tools and facilities satisfactory to the Authority shall be provided and used for the safe and convenient execution of the work. All pipes, fittings and other appurtenances shall be carefully lowered into the trench, piece by piece, by means of a derrick, mobile cranes ropes or other suitable tools or equipment in such a manner as to prevent damage to pipes materials and protective coatings and lining. Under no circumstances shall pipes and special etc. be dropped or dumped into the trench. Pipes lowered into trenches with the help of chain pulley blocks and tripod supports used for this purpose shall be regularly checked to prevent all risks of accidents.

1.20.5 Trail TrenchesThe Contractor shall also dig trial trenches at every 250 meter along the alignment so as to have full knowledge of the under ground soil characteristics of soil, water table and various utilities. Contractor shall also make local inquires regarding the existing services and water table etc. No claim for not having known the existence of any utility shall be entertained by the Department.

1.20.6 Site PreparationBefore start of excavation and pipe laying the Contractor shall carry on preliminary work of making the alignment onsite with wooden pegs, clearing and disposal of shrubs, grasses large and small bushes, trees hedges, fences gates, portion of old masonry boulders and debris etc. lying along route of the pipe alignment. Were trees have been felled, the resulting timber shall be stocked properly by the Contractor at the location shown by the Employer or his representative and handed over to the concerned authorities. Tree roots with in 0.5m from either side of the pipelines shall be completely removed before laying the pipes and such other things as mentioned earlier / elsewhere.If any difference or discrepancy is found between the DWB reports and the DWB Contractor nothing extra shall be paid. The contractor should, therefore, collect all the correct data himself before submitting his tenders. Ultimate responsibility for very thing (proper alignment, designs and execution) shall be of the Contractor.

1.20.7 Protection to Existing ServicesThe Contractor will provide at his own cost temporary supports, adequate protection and maintenance to all underground services and surface structures such as drains, sewers, water mains, electric and telephone cables, electric poles, telephone poles, telephone cable ducts, electric cable, ducts, gas lines or any other utility met with during excavation and pipe laying. Nothing extra shall be paid for the above and nor any extension of time shall be given for proper checking

or location of utilities and maintenance done by the Contractor. If shifting of any of the utility of cables, poles or gas line etc. is required or any permanent R.C.C.- support is required to be provided for any of the utility it shall be provided by the Contractor at his own cost.The pipeline shall be so laid as not to obstruct access to other services for inspection, repairs and replacement. When such utilities are met-with during excavation the concerned authorities shall be intimated / approached by the Contractor and arrangements to protect / support the utilities in consultation with them shall be taken. If any of the utility gets damaged by the Contractor or his workers or his sub-contractor, entire responsibility shall be of the Contractor and shall restore the utility to the original order / shape / specifications at his own cost without involving the employer.

1.20.8 Trench Excavation Width & DepthThe excavation shall be done to the required grade and formation. Special consideration shall be given to the trench depths so as to provide a minimum cover of not less than the following above the top of pipe socket.Pipe Dia Cover DepthM.S. Pipe (lined & Out) Coated 1.0 M (minimum)Increased depth of excavation may be required to avoid surface drains, road crossing, railway or other crossings. Incase of less cushion extra suitable designed protection over pipes be provided as per direction of Engineer-in-Charge.ID of Pipe in mm Maximum Top WidthUpto to 800 mm dia 2.0 mAbove 800 mm dia 3.0 mThe width of the trench at bottom between the face of excavation or sheeting (where required) shall be such as to provide 200mm clearance between the pipe and the trench sides. In case of excavation in rocky soil, the pipes shall be bedded on 300 mm of fine sand material for full width of the trench as per direction of Employer or his representative. Where pipes are bedded directly in good ordinary soil on the bottom of the trench an even fully compacted bed as indicated in fig.1A of the above code shall be provided. The Contractor shall also ensure that the soil has sufficient bearing capacity as not to settle with the load coming over it. In cases where subsoil water is met with, the trenches shall be kept dry by providing well point equipments and pipes laid on 300 mm thick bedding under the pipe in mix M:15. In cases where any damage can occur to the outer coating (Contractor to clarify while submitting the bid, the type of coating he proposed to provide at his own cost) to the outer coating already provided so as to prevent any damage to the pipe or earlier coating. In cases where the soil is weak or slushy pipes shall be supported by providing suitable footings or by straight piles with pile caps with pipe supporting structures as per site requirements.In case where the pipes have to face flood waters pipe bottom shall be kept as is explained in Clause 1.13.12. the pillars for supporting the pipes in such situation shall be constructed in M-15 concrete or R.C.C. or piling may have to be done for supporting the piping system. All such works for structural safety of the works shall be to the account of the Contractor who will also submit structural designs and drawings. the footing of the pillars shall be kept below the maximum scour depth as per code requirements / provision.In cases where the Contractor has done excavation deeper than the required the extra depth excavated shall be filled with graded compacted sand for full width of trench or with C.C. (M-10) as per direction of the Employer. Nothing extra shall be paid for excess excavation and for the laying of C.C.i.e M-10.In order that no inconvenience is caused to the public due to digging of trenches, the pipe laying below roads of width more than 25 meter or where the width of road is less and the intensity of traffic is more the work shall be done by the Contractor by trench less technology provided the conditions at site permit. All equipment for use for trenchless technology shall be arranged by the Contractor at his own cost.

1.20.9 Blasting

Blasting for Excavation in rocky areas is not permitted. If rock is met with at any place along the alignment of the pipeline, it shall be cut with chisels. Excavated rock shall be stacked as per directions of Employer or his Representative and as per C.P.W.D. specifications.

1.20.10 Braced & Sheeted TrenchesIn places where the soil has a tendency of side slipping the Contractor shall provide sheeting and Bracing at his own cost as per site requirement/good Engineering practice. the sheeting shall be done to the full depth as may be required. In case any accident occurs or there is any loss of life or damage to any property or existing works / services the responsibility shall be of the Contractor to make up the losses.

1.20.11 Surface MaterialThe excavated materials which in the opinion of the Employer’s representative are suitable for re-use in restoring the surface (roads or any other structure) shall be kept separate from the general excavated material as directed by the Employer’s representative.

1.20.12 Stacking Excavated MaterialAll excavated material shall be stacked in such a manner that it will not endanger the work or workmen and it will avoid obstructing footpaths, road and drive ways, hydrants under pressure, surface unobstructed and accessible during the construction work. Gutters shall be kept clear or other satisfactory provision made for street drainage, and natural water-courses shall not be obstructed.

1.20.13 Protection of Persons and Property etc.To protect persons from injury and to avoid damage to properties (Government or Private), the contractor shall take safety measures at this own cost for the progress of the construction work and until it is safe for traffic to use the roadways. All materials, pipes equipment and pipes which may serve as obstruction to traffic shall be enclosed by fences of barricades and shall be protected by illuminating proper lights when the visibility is poor. The rules and regulations of the local authorities regarding safety provisions shall be observed by the Contractor at his own cost. Any material which is not to be used at site shall be removed from the work site so that no inconvenience is caused.

1.20.14 Maintenance of Traffic & Closing of LanesThe work shall be carried, including closing of roads/street in such a manner, which will cause the least interruption to traffic. Where it is necessary for traffic to cross the open trenches, suitable bridges shall be provided. Suitable diversion signs indicating that a street is closed shall; be placed and necessary detour signs for the proper maintenance of traffic shall be provided at no cost of the employer.In areas subject to flooding the Contractor as such shall have to provide pillar / supporting structures for laying and jointing of the pipes with required saddles and other necessary requirements as per structural designs and also thrust blocks anchor blocks, expansion joints and in addition will have to cross a number of spurs and major and minor roads and nallahs etc. Along the alignment the pipes line will also have to cross a number of other major and minor roads also. The Contractor shall as such provide necessary structures and arrangements (bridges, culverts etc.) desired by the department incharge of the utilities to be crossed for laying the pipe lines. The Contractor may also assess himself the other obstructions to be crossed by him for laying the piping systems.The Contractor as such shall provide necessary arrangement (bridge, culverts, pillars etc), required as per designs and as per conditions on which the permissions have been given by the departments incharge of the utilities.The Contractor is therefore, advised to investigate himself all obstructions and structural provisions to be made by him at his own cost for which nothing extra shall be paid at a later date.The Contractor should also submit methodology for laying the pipelines across each obstruction and along each of the alignment with the bid. The Contractor shall submit calculations for maximum scour depth, soil testing / S.B.C. reports, designs for pillar foundation, thrust blocks /

anchor blocks, arrangements and detailed drawings for supporting the M.S. Pipes on the supporting pillars / structures.

1.21. Cleaning, Disinfectioning and Commissioning of the PipelinesUpon completion of a newly laid main, the main shall be initially flushed clean and then disinfected by the Contractor at his cost as directed by the Employer or his Representative.It is expected from the Contractor that he will lay only thoroughly cleaned pipes during the process of laying of pipes and shall not leave any tool or brick bats etc. in the line. Also when laying is not being done he will keep the open ends closed with temporary blank flanges so that nothing can enter the pipe.For final flushing and cleaning, the department will allow water from one of its mains for two fillings only for which, Contractor will be charged at a rate of Rs. 10/- per KL the time of flushing / cleaning. The sampling points for the turbidity and chlorine sampling shall be at the end points and at the interconnection point.The main shall be flushed prior to disinfect ion.

1.21.1 DisinfectionIn the case of mains of different diameters, water from the existing distribution system or other approved source of supply shall be made to flow at a constant measured rate into the newly laid pipeline. the wear shall receive a dose of chlorine also fed at a constant mesasured rate. the two rates shall be proportioned so that the concentration in the water entering the pipelines is maintained at not less than 300 mg/l. The chlorine shall be applied continuously and for a sufficent period to develop a solid column of ‘Slug’ of chlorinated water that will as it passes along the line expose all interior surfaces to a concentration of at least 300 mg/1 altleast 3 hours. As the chlorinated water flows past tees and other fittings and crosses related valves and hydrants shall be operated so as to disinfect the appurtenances. The bidder can also use continuous feed method of disinfection with chlorine as per IS 5822 with the prior approval of the employer.After the applicable retention period the heavily chlorinated water shall be flushed from the main until the chlorine concentration in the water leaving the mains is not higher than that generally prevailing in the system or less than 1 mg/1.After final flushing and before the water main is placed in service, a sample or samples of water shall be collected from the branches and at the end of the line and tested for bacteriological quality and shall show the absence of coliform organisms. If the initial disinfection fails to produce satisfactory samples, disinfection shall be repeated until satisfactory, samples are obtained before the main is placed in service. Testing of water samples shall be got done from the DWB laboratory for which the Contractor will have to deposit testing charges on rates prevailing at the time of testing.The Contractor is expected to carry out the disinfection work as a part of laying the pipes and his rates for laying the pipes should include the disinfection and other connected works till the mains are placed in service, unless otherwise specified.

1.21.2 Distance Indicators and MarkingsThe Contractors shall supply and fix indicators at all points of change of direction, at all valves and at every one Kilometer intervals along the buried pipeline. Indicators shall consist of 10 cm x 10 cm precast concrete post 1.25 meter long, set 0.75 meter into the ground and painted white above ground level. The description shall be written in blue at one face of the precast post.In case of the pipeline laid above ground details such as chainages, invert levels of pipe, appurtenance number, pedestal / saddle number etc. shall be suitably marked either on the pipeline or the supporting structure etc. in distinct colour. The bidder / Contractor shall include the cost of this in his rates for the other items. Nothing extra shall be paid on this account.

1.22 APPURTENANCES1.22.1 Butterfly Valves : Deleted1.22.2 Sluice Valves

Make : These shall be of IVC, Kirloskar, BSJ Sahoo, Shiv Durga, Upadhya.

1.22.2.1 Design RequirementSluice valves shall conform to IS:14846. The flanges shall be flat faced as per IS:1538 Part 4 and Part 6.Sluice Values should close with clockwise rotation of the hand-wheel. The direction of closing shall be marked on the hand wheel.Sluice Values shall be flanged (flat faced) and drilling shall conform to IS:1538 Part 4 and 6.

1.22.2.2 Features of ConstructionThe valves shall have non-rising spindle.Valve shall be with bushing arrangement for replacement of packing without leakage. Material for component parts shall be as per table I and manufacture as per clause 7 of the said code Paras 7.1 to 7.14.The valve shall be supplied with spur / worm / bevel / gear arrangement so that the valve can be operated with an effort not more than 7 kg on the hand - wheel.Valves shall be provided with renewable shoe and channel arrangement.

Body and wedge rings shall be provided.Collared drain plugs of gunmetal shall be provided for all valves.

1.22.2.3 Materials of ConstructionSr. Component Preferred Ref. To Gradeor No. Material IS No Designation

i Body, bonnet, dome, stool Grey cast iron 210 FG 200cover, wedge, stuffing box,gland, thrust plate and cap

ii Hand wheel Grey cast iron 210 FG 200 iii Stem Stainless Steel 6603 12 Cr 13 04

Cr 18 Ni 10 04 Cr 17 Ni 12 MO2

iv Wedge nut, shoe, channel Leaded tin bronze 318 LTB-2 v Body seat ring, wedge Leaded tin bronze 318 LTB-2

facing ring and bushes vi Bolts Carbon steel 1363 Class 4.6

(part 3) vii Nuts Carbon steel 1363 Class 4.0

(part 3) viii Gasket Rubber 638 Type B ix Gland packing Jute and hemp 5414 x Gear Spheroidal 1865 Gr 500/7

graphite iron xi Gear housing Grey cast iron 210 FG 200 xii Pinion & pinion shaft Wrought carbon 1570 C55 Min 75

steel (part 3) Valves above 200 mm shall be provided with Bye-pass arrangements. Valves with rating PN

1.6 shall be of SG iron.1.22.3 KINETIC AIR VALVE1.22.3.1 Design requirement

a)Kinetic Air Valves shall be as per IS:14845b)Kinetic Air Valves shall be double orifice typec)Kinetic Air Valves shall be provided with an isolating sluice valve fixed in lying position with meter gear arrangement

d)All flanges of Kinetic Air Values shall be flat faced in accordance with Is-1538 Part IV & VIe)The isolating sluice value of the Kinetic Air Valve shall conform to Is-14846

1.22.3.2 Feature of Constructiona)Kinetic Air Valve shall have kinetic feature for easy flow of airs and to avoid the timber ball get caught in high velocityb)One of the orifice of Kinetic Air Valve should have smaller size vulcanite rubber coated timber ball to rest on a bronze orifice nipple.c)Another orifice of the Kinetic Air Valve should have larger size vulcanite rubber ball to rest on neoprene-moulded seatd)Nominal size shall be cast on the body of the valve

1.22.3.3. Material of ConstructionBody : C.I. to IS-210 Gr. FG 200 - for PN 1.0 valve

SG Iron / MS for PN 1.6 rating valveCover & Cowl : C.I. to IS - 210 Gr. FG 200 - for PN 1.0 valve

SG Iron / MS for PN 1.6 rating valveBuoyant Balls : Vulcanite coated seasoned teakOrifice Nipple : Gun Metal to IS - 318 Gr. LTB - 2Large Orifice : Neoprene Rubber

1.22.3.4 Shop TestingAs per clause 12 IS 14845 approved makes IVC/Kirloskor/BSJ Shaoo, Shiv Durga,Upadhya

1.22.3.5 MakeIVC, KIRLOSKAR, BSJ Sahoo, Shiv Durga, UpadhyaThese shall be Glenn Field design as per figure H-20 of G & K catalogue dia 50 to 300 mm. The Contractor shall attach with his bed documents technical literature of P.R.V’s proposed to be used by him for approval. The Rating for P.R.V.’s shall be PN 1.0.

1.22.4 Scour Sluice ValvesThe contractor will provide Scour Valves with necessary arrangements upto the disposal points wherever there is difference of level at the lowest point upto the length of 50M. The location of S.V.’s is adjustable depending upon the availability of diffusal arrangements. Size of Scour valve shall be 300mm of the size of the water min.

1.22.4.1 Design RequirementsScour Sluice Valves shall conform to IS:780 or IS:14846, rating shall be PN 1.0.Valves shall be flanged (flat faced) and drilling shall conform to IS:1538 Parts 4 or 6.

1.22.4.2 Features of ConstructionThe Valves shall have non-rising spindleBody and wedge rings shall be providedValves shall be provided with hand -wheel

1.22.4.3 Materials of ConstructionBody : CI to IS 210 Gr. FG 200Wedge : CI to IS Gr. FG 200Spindle : Stainless Steel to IS 6603Seat Rings : Leaded tin Bronze to IS 318scour Sluice Valves shall be provided with locking arrangements for hand-wheel

1.22.4.4 Shop Testing WitnessingAs per Ch 10 IS 14846 open end testThe valves shall have Bureau of Indian Standards Certfication markMake : IVC, KIRLOSKAR, BSJ Sahoo, Shiv Durga, Upadhya

1.22.5 Air ValvesThe air valve shall be provided where there is change in elevation and distance between the two air valves should be less than 2 kms. Recommended Sizes of Av’s area as under :-Pipe Size Size of Air Valve

1000/1500 mm 100 mm/150mmThe work of fixing appurtenances i.e sluice valves, air valves , scour valves etc shall be carried our carefully so as not to damage them during handling, erection and fixing. The work shall be executed in a work manner like maner under the direction of a competent Foreman / Engineer of the Contractor Qualified. Rubber packing of 6mm thickness (4 ply with cloth insertion) and of approved by the employer or his representative shall be used.The jointing material such as nuts, bolts, washers, rubber packing etc, shall all be provided by the Contractor.Bolts, nuts, washers, to be used for joints shall conform ro IS:1364 (latest edition) and of make approved by the Employer or his representative.Throughout erection, the valves shall be supported properly on wooden sleepers and pre-cast concrete blocks of approved design etc and shall be concentrated immediately thereafter, as directed by the Employer’s Representative. Before the valves are actually fixed, they shall be cleaned and greased and it shall be seen that all parts are in perfect working condition. In the case of air valves, the Contractor shall take special care of the dexine joints and the ebonite and / or vulcanite balls until they are fixed in position. They shall be kept immersed in water in suitable containers.

1.22.6 Field Hydraulic TestAfter erection at site and after the concrete anchor blocks have been constructed and line completed the pipelines shall be subjected to a hydraulic test pressure of 10Kg/cm2 as is detailed earlier. The general procedure for testing the pipelines shall be as per Sub-Clause under Clause 11.0 of IS:5822.When the filed test pressure is less than 2/3 the works test pressures the period of test should be at least 24 hours. The test pressure shall be gradually raised at a rate of 0.1N /mm2 per minute.

If drop in pressure occurs the quantity of water added in order to reestablish the test pressure shall be carefully measured and the leakage allowed should only be to the limits specified in IS code for the pipe material adopted.

CONDITIONS AND SPECIFICATIONS FOR WATER LINES1. The contractor shall inform the Engineer-in-Charge in advance for the production of material and fabrication for the factory inspection.2. The contractor shall arrange and allow free access to the factory/plants, provide facilities for inspections and testing and shall provide information in respect of the character of material used, the progress and the manner of the work. The Engineer-in-Charge reserves his rights to reject any pipe/all pipes fittings that are considered not manufactured/fabricated in accordance with the procedure and specifications.3. The contractor shall provide two sets of accurate ring gauges for measurement of pipes and fittings at no extra cost.4. It shall be responsibility of the contractor to supply the pipes along the alignment as shown. (The alignment is subjected to change without any extra claims of the contractor as per the site requirement) by carting with suitable transport and place the same in sound conditions by providing supports so as to avoid any damage to the pipes and specials.5. No payment for the partially finished or partially fabricated pipes and fittings or for the rejected material on the receipt of the pipes. The payment of the specials and pipes shall be regulated as per the bill of quantity. The contractor shall submit proof of the weight if applicable, challan/gate-pass duly verified by AE/JE with the bills. Lower weight worked out on the basis of Dharam Kanta receipt and with the standard weight based on relevant I.S. code with specifications shall be considered for payment.6. The item of laying and jointing of pipes exclude the cost of welding of joints, cost of rubber rings but include placing the pipe in position and testing.7. The tenderer will retain modvit benefit, which shall not be passed on the Delhi Jal Board if permissible and applicable.8. The department has the right to get the material of C.I./M.S./H.S./ D.I./M.S. lined & coated pipe inspected by the officers of the department and also from the outside agency such as DGS&D, TCE/EIL/3rd party agency or otherwise in the field as well as in the manufacturing unit/factory/plant. The charges including transport facilities, to & fro fare charges and stay at outstation as applicable for the same shall be borne/provided by the contractor. The deficiency pointed out during inspection shall be rectified by the contractor without any extra cost.9. RUBBER GASKETSRubber gasket for use with the push on joints shall be ISI marked and conforming to IS:1280- 1989.10. CAST IRON SLUICE VALVESC.I.S./Valves with hand wheel or otherwise as specified shall be conforming to relevant I.S. code and shall bear ISI mark The valve shall be of make upadhyaya / SIR/ KVMC / VENUS / IVC / Kirloskar / Shiv Durga /or otherwise as specified in the tender documents.11. MARKINGMarking on pipes, the tolerances in diameter, shall be carried out as per procedure laid in IS:1536-1989 . in addition to above each pipe shall be marked in bold with ‘DELHI JAL BOARD’.12. LAYING & JOINTING(I) Each pipe shall be brushed and cleaned thoroughly before laying spigot and socket of the pipes and specials shall be cleaned and then placed carefully inside the trenches, over pillars or pushed inside the pipe culvert/box culvert. At the close of day, the ends shall be closed with wooden disc/purdi free of cost.(II) The lining and out coating of D.I./H.S.pipe and special etc. shall not be removed/dismantled at any cost. In case, the D.I./H.S. Pipe/special have to cut into pieces only small portion of lining/out coating shall be removed and the same shall be repaired thereafter by providing cement mortar lining and cut pasting at the welded joint of pipes specials.

(III) Rock is not likely to met during execution. In case the same is encountered the excavation shall be done by chieselling . blasting under no circumstances shall be done. A measurement of the rock cut shall be done in stacks after allowing deduction of voids by 50% . the payment shall be made on the basis of relevant DSR plus minus contractor’s enhancement.(IV) In some narrow streets work can be done during night only. Those the contractor shall pan the work in such a way that cutting, laying and filling shall be done during one night so that the work is complete before next morning.(V) The contractor may have to shift or rehandle the pipes, which have to be stacked else where due to non-availability of sufficient space or traffic congestion. Nothing extra shall b paid on this account.(VI) The water connection or sewer connection damaged during the execution shall be restored on the same day.(VII) As per clause 9.1 of IS:10221, a Cathodic Protection system conforming to IS:8062 ( Part II )- 1976 shall be provided in conjunction with appropriate and wrapping system as specified in IS:10221, where the soil resistivity is less than 5000 ohm-cm.13..The contractor shalla) provide necessary foundation & bedding, saddles & pillars etc. for the pipe line as per specifications/BOQ item.b)Provide & fix in position the necessary appurtenances viz.D.I. specials, Sluice Valves, Air Valves, NRV etc. of suitable size & specifications.c) Construct of anchorage block, supporting saddles/pillars for pipe line, thrust blocks, cross drainage work and chambers etc. for valves & specials as per direction of Engineer-incharge.d) Making suitable inter connection with existing water main as per directions of Engineer-in-charge.14. The contractor has to arrange for suitable tackle like cranes, recovery van, excavator, chain pully block, sleepers, ropes, generating sets, and electric welding set etc. for carrying out work as per direction of Engineer-in-charge at his own cost. No payment shall be made for witching of pipes and specials over bridges under roads/railway culverts/channels and nallas etc. irrespective of any length of pipes to be laid.15. RELAYING OF PIPE LINE:-The item of relaying mentioned in the bill of quantity shall include the operations of re-excavation dejointing removal of pipe and relaying and back filling the trenches as per direction of Engineer-in-Charge.16. PIPE BEDDING:-i) The bottom of the trench shall be suitably reounded to fit underside of the pipe, extra excavation will have to be done for socket/tapering portion of the PSC pipe so that the pipe is bedded on soil.ii) In case of loose soil, cement concrete bedding shall bprovided before laying of pipe line as directed by the Engineer-incharge and the payment will be made as per B.Q.iii) In case of rock cutting, Jamuna sand bedding not less than 15 cm. In thickness shall be provided before laying of pipeline as directed by Engineer-in-charge and shall be paid to the contractor.17. The work of diversion of road etc. including construction of diversion guide walls/bricks pavement bituminous road etc. will be done by the contractor in terms of contract. But its maintenance such as patches, filling of depressions, watering, consolidating, engaging night chowkidar, red lantern, barricading with ballies, providing fencing, providing red and white coloured caution boards with florescent paint lettering etc. required for smooth and safe plying of traffic shall be provided free of cost of the contractor. Excavated earth/malba and stone will have to be put on the refilling if required free of cost to facilitate smooth traffic. When barricading with G.I. sheet is done, same will be paid as per B.Q.18. TESTING OF JOINTS:-The different sections of the pipes laid will be tested hydraulically as directed by the Engineer-in-charge to a test pressure equal to one and a half time the working pressure. Necessary equipment such as generating sets, high-pressure pumps, test plates and dummy plates to be put on the test etc., pressure guage and water etc. required for hydraulic test shall be arranged by the contractor.a. During the course of testing, if any joint is found leaking, the contractor will repair the same free of cost.In case, fixing of step/plain collar is felt necessary, the same shall be supplied and fixed by the contractor and the payment shall be made as per B.O.Q.

19. TEST PROCEDURE :-Each section shall be properly sealed off preferably with special stop ends (test plates) and end secured by adequate anchors. The section under test shall be filled with water taking care tht all air is displaced from the pressure for a period in order to achieve condition as stable as possible for testing. More water shall be pumped into water main from calibreated container until the required test pressure is reached. The test pressure shall be maintained through out the test priod of 60 minutes by means of continuous pumping, using a pressure relieve valves. The excess water coming from pressure relief valve shall be returned to the calibrated container. The rate of loss of water from the container shall be determined at regular intervals. The accepted rate of loss of water for the pipeline shall not be more than 3 litre/mm dia meter/km/30m head.20. FINAL TESTING:-After all sections have been jointed together on completion of sectional testing, test on the complete pipeline should be carried out. This test should be carried out at a pressure not less than the working pressure of the pipeline, care being taken to ensure that the pressure at the lowest point in the pipeline does not exceed the maximum. During the test an inspection should be made of all work, which has not been subjected to sectional tests. Interconnection work shall be completed by taking up he job continuously working day & night.21. SPECIFICATIONS:-The work shall be carried out as per CPWD specification of 1996 –2002 with upto date corrections slips for works at Delhi unless otherwise specified. The following I.S.Code practice with upto date revision and other relevant I.S.Code shall be followed for laying water pipe lines:-I. Welded Steel I.S. 5822-1986II. P.S.C. Pipes I.S. 784- 1978III. C.I.Pipes I.S.1536-1989IV. M.S. Specials I.S.7322-1985V. H.S.Pipe I.S.1916-1989VI. C.I. Specials I.S.1538-1993VII. D.I.Pipes I.S.8329-2000VIII. D.I. Specials I.S.9523-2000

SPECIFICATION FOR C.I. PIPES AND C.I. SPECIALS/FITTINGS

1. SCOPEThis specification and scope of work covers the manufacturring, supply, testing and delivery of C.I. pipes and C.I. specials and pipe fittings. The tenderer shall supply pipes as per IS-1536: 1989 and specials as per IS: 1538-1993 required for curves, tees, branches, manholes, air valves, scour and sluice valves. Specials shall suit the C.I. pipes and air valves, scour valves and sluice valves etc. and conform to the details given in bill of quantity and else where in the tender documents. The dimensions of the fittings shall conform to IS: 1538:1993.2. C.I. PIPE2.1 C.I. pipe shall be manufactured and tested as per IS:1536-1989 and shall be ISI marked suitable for rubber gaskets ISI with each pipe joint known at tyton joint.2.2 The pipes shall be such that they could be cut, drilled or machined.2.3 In case of flanged pipes, the flanges shall be at right angles to the axis of the pipe and machined on face. The bolt holes shall be drilled as per stipulations given in the relevant BIS.3. C.I. SPECIALS/FITTINGS3.1 C.I. specials shall be manufactured as per IS:1538-1993 and shall be ISI marked.3.2 In case of flanged joints, the flanges shall be at right angles to the axis of the pipe and machined on the face.

3.3 The bolt hole circle shall be concentric with the bore and bolt holes shall be located off the centre lines as per IS:1538-1993. Fittings shall be tested as per IS:1538-1993.

CONDITIONS AND SPECIFICATIONS FOR DUCTILE IRON PIPELINE AND FITTINGS

1.1 Scope

This specification covers the requirement for manufacturing supplying, laying, joining, testing and commissioning of Ductile Iron pipeline and fittings including associated civil works required for the same.

1.2 Standards

The following standards, specifications and codes are part of this specification. In all cases, the latest revision of the codes including all applicable official amendments and revisions shall be referred to. In case discrepancy between this specification and those referred to herein, this specification shall govern.

IS:8329 Centrifugally Cast Ductile Iron pipes for water, gas and sewage

IS:9523 Ductile Iron pipes fittings for pressure pipes for water, gas and sewage

IS:12288 Code of practice for use and laying of Ductile Iron pipes.

IS:638 Sheet rubber jointing and rubber insertion jointing

IS:1500 Methods for Brinell hardness test for metallic material

IS:5382 Specification for rubber sealing rings for gas mains, water mains and sewers.

IS:3764 Excavation work-code of safety

IS:460 Test Sieves-Part-I

IS-8112 Specifications for 43 grade Ordinary Portland Cement

1.3 Manufacturing and Source for Supply of Ductile Iron Pipes and Fittings

1.3.1 General

a) The Ductile Iron pipes should confirm to IS:8329 and the pipe should be ISI marked & manufacturer should have valid BIS licence.

b) The D.I. pipes if procured from country other than India the manufacturer of pipes shall bear ISO certification mark .The manufacturer must have produced D.I. pipes for a minimum quantity of 40,000 MT per annum in any one year during the last three years. It shall be responsibility of Contractor to arrange testing of pipes including all incidentals at his own cost. The quoted rate shall be inclusive of all duties and levies and nothing extra shall be payable .No foreign exchange shall be payable for the pipes procured and imported from outside the country.

c) The bidder shall not deviate from the technical specification of pipe materials, fittings, pumps, motors and valves etc. Alternative offers will be out rightly rejected.

d) All tests specified either in this specification or in the relevant Indian standards specified above shall be performed by the supplier/contractor at his own cost and in presence of Engineer-In-Charge, if desired. For this, sufficient notice before testing of pipes and fittings shall be given to the Engineer-In-Charge.

1.3.2 Materials

(a) The Ductile Iron pipes shall be centrifugally cast (spun) Ductile Iron pipes confirming to the IS:8329. The pipes used will be with push on joints (rubber gasket joints). The class of pipes to be used shall be of the class K-9.

The pipes shall be coated with bitumen as per annexure 'C' of IS:9523 and shall have factory applied centrifugal cement mortar lining inside as per the provisions of appendix 'B' of the IS:8329.

The pipe shall be supplied in standard length of 5.50 and 6.00-meter length with suitably rounded or chamfered ends. Each pipe of the push on joint variety shall also be supplied with a rubber SBR gasket. The gasket shall confirm to IS:5382.

(b) The Ductile iron fittings shall be manufactured and tested in accordance with IS:9523. The fittings shall be provided with cement mortar lining inside and outside bitumen coating. The Ductile Iron Fittings shall be of Class K-12 ( K-14 for Tees ) suitable for either push-on jointing or flanged jointing as per the site requirement with PN10 flanges. The Ductile Iron Fittings shall be procured from the same manufacturer who will be supplying Ductile Iron Pipes. The fitting may be of the following type as per site requirement:

Flanged Socket Flanged spigot Double socket Bends (900, 450, 22½0, 11¼0) Double socket branch flanged tee Double socket taper All Flanged Tee All Flanged Taper Double Flanged Bends (900, 450, 22½0, 11¼0)

(c) The manufacturer of pipes shall preferably supply the Ductile Iron fittings. The rubber gaskets for jointing should preferably be manufactured by the manufacturer of pipes. In case they are not, it will be the responsibility of the manufacturer of pipes to have them manufactured from a suitable manufacturer under it's own supervision and have it tested at his/sub contractors premises as per the contract. The pipe manufacturer will however be responsible for the compatibility and quality of the gaskets.

(d) Alternative to the standard Ductile Iron Fittings, fabricated M.S. fittings with inside cement mortar lining may be used, if necessary. If required, the MS flanges can also be welded to the D.I pipes, as per the procedures laid down by the manufacturer of D.I. Pipes.

1.3.3 Dimensions and Tolerances

The internal diameter thickness and length of barrel, dimensions of pipes and fittings shall be as per the relevant tables of IS:8329/IS 9523 of different class of pipes and fittings.

1.4 Ductile Iron Pipes

1.4.1 Inspection and testingThe pipes will be subjected to following tests for acceptance:Visual and dimensional check as per clause 13 and 15 of IS 8329

Mechanical Test as per clause 10 of IS 8329 Hydrostatic test as per clause 11 of IS 8329 The test reports of the rubber gaskets shall be as per acceptance tests of the IS 5832 and will be in

accordance to clause 3.8.The Sampling shall be as per provisions of the IS 8329.

1.4.2 MarkingAll pipes will be marked as per clause 18 for IS 8329 and show below: Manufacturer name/stamp Nominal diameter Class reference A white ring line showing length of insertion at spigot end Delhi Jal Board

1.4.3 Packing and Transport:

The pipes should be preferably transported by road from the factory and stored as per the manufacturer specifications to protect damage.

1.5 Specials/Fittings for Ductile Iron Pipes

1.5.1 General

This section covers the general requirements for Ductile Iron (DI) fittings suitable for push-on-joints or flanged jointing to be used with Ductile Iron pipes with push-on-jointing and flanged system.

1.5.2 Supply:

All the DI fittings shall be supplied one rubber ring for each socket. The rubber ring shall conform to IS:5382 and as per socket profile of pipes. Flanged fittings shall be supplied with one rubber gasket per flange and the required number of nuts and bolts.

1.5.3 Lubricant for Ductile Iron Pipes and Specials:

1.5.4 General:

This section covers the requirements for lubricant for the assembly of Ductile Iron pipes and specials suitable for push-in rubber ring joints.

1.5.5 Specification:

The lubricant has to have the following characteristics:

must have a paste like consistency and be ready for use.

has to adhere to wet and dry surfaces of DI pipes and rubber rings

to be applied in hot and cold weather; ambient temperature O-50 0C, must be non toxic.

must be non toxic

must be water soluble

must not affect the properties of the drinking water carried in the pipes

must not have an objectionable odour

has to inhibit bacterial growth

must not be harmful to the skin

must have a shelf life not less than 2 years Acceptance tests.

They shall be conducted in line with the provisions of the IS 9523

1.5.6 Packing:

All the DI fittings shall be properly packed with jute cloth. Rubber rings shall be packed in polyethylene bags. Rubber rings in PE bags and nuts, bolts etc. shall be supplied in separate jute bags.

1.6 Specifications for laying and jointing of Pipe line system for Water Supply:

1.6.1 Preparatory Work:

The contractor will inspect the route along which the pipeline is proposed to be laid. He should observe/find out the existing underground utilities/construction and propose an alignment along which the pipeline is to be laid. He should make all efforts to keep the pipe as straight as possible with the help of ranging rods. Wherever there is need for deviation, it should be done with the use of necessary special or by deflection in pipe joints (limited to 75% of permissible deflection as per manufacturer). The alignment as proposed should be marked on ground with a line of white chalk and got approved from Engineer-in-Charge. The Contractor will than prepare an L-Section along this alignment showing the location of proposed pipe line. The L-section should be got approved from the Site Engineer/Engineer-In-Charge. The position of fittings, valves, should be shown on the plan.

1.6.2 Alignment and the L-Sections:

The alignments, L-section (depth of laying) and location of specials, valves and chambers may be changed at site in co-operation with and after approval of the Engineer-In-Charge. The minimum cover to the top of the pipe shall be 1 m.

1.6.3 Standards:

Except as otherwise specified in this technical specification, the Indian Standards and Codes of Practice in other latest version, National Building code, CPWD specifications and manual for water supply of GOI shall be adhered to for the supply, handling, laying, installation, and site testing of al material and works.

1.6.4 Tools and Equipment:

The contractor has to provide all the tools and equipment required for the timely, efficient and professional implementation of the work as specified in the various sections of the contract and as specified by the instructions of manufacturers of the pipes and other material to be handled under this contract. On demand he shall provide to the Engineer-In-Charge a detained list of tools and equipment available. If in the opinion of the Engineer-In-Charge the progress or the quality of the work cannot be guaranteed by the available quantity and type of tools and equipment, the contractor has to provide additional ones to the satisfaction of the Engineer-In-Charge. The Contractor will always have a leveling instrument on site.

1.6.5 Handling and Laying of pipes:

1.6.6 Transportation of pipes and specials & Storage:-

The Contractor has to transport the pipes and other materials from manufacturer to the site of laying as indicated by the Engineer-In-Charge. Pipes should be handled with care to avoid damage to the surface and the socket and spigot ends, deformation or bending. Pipes shall not be dragged along the ground or the loading bed of a vehicle. Pipes shall be transported on flat bed vehicles/trailers. The bed shall be smooth and free from any sharp objects. The pipes shall rests uniformly on the vehicle bed in their entire length during transportation. Pipes shall be loaded and un-loaded manually or by suitable mechanical means without causing any damage to the stacked pipes.

The transportation and handling of pipes shall be made as per IS 12288. Handling instructions of the manufacturers of the pipes shall be followed. All precautions set out shall be taken to prevent damage to he protective coating, damage of the jointing surfaces or the ends of the pipes.

Whatever method and means of transportation is used, it is essential that the pipes are carefully placed and firmly secured against uncontrolled movement during transportation to the satisfaction of Engineer-In-Charge.

Cranes or chain pulley block or other suitable handling and lifting equipment shall be used for loading and un-loading of heavy pipes. However, for pipes up to 400 mm nominal bore, skid timbers and ropes may be used. Where using crane hooks at sockets and spigot ends hooks shall be broad and protected by rubber or similar material, in order to avoid damage to pipe ends and lining. Damage to lining must be repaired before pipe laying according to the instructions of the pipe manufacturer. Pipes shall not be thrown directly on the ground.

When using mechanical handling equipment, it is necessary to employ sufficient personnel to carry out the operation efficiently with safety. The pipes should be lifted smoothly without any jerking motion and pipe movement should be controlled by the use of guide ropes in order to prevent damage caused by pipes bumping together or against surrounding objects.

Rolling or dragging pipes along the ground or over other pipes already stacked shall be avoided too.

The pipe should be given adequate support at all times. Pipe should be stored on a reasonably flat surface free from stones and sharp projections so that the pipe is supported through out its length. In storage, pipe racks should provide continuous support and sharp corners of metal racks should be avoided. Pipes should not be stacked in large piles for all pipes and especially under warm temperature conditions. Socket and Spigot pipes should be stacked in layer with sockets placed in alternate ends of the stack to avoid lop sided stacks.

Pipes should not be stored inside another pipe. On no account the pipes should be stored in stressed or bent condition or near the sources of heat. Pipes should not be stacked more that 1.5m high and pipes of different sizes and classes should be stacked separately. The ends of the pipes should be protected from abrasion.

The Contractor shall provide proper and adequate storage facilities to protect all the materials and equipments against damage from any cause whatsoever and in case of any such damage/theft, the Contractor shall be held responsible.

1.6.7 Pipe trench:

1.6.7.1 Trench excavation:

The trench excavation of pipeline shall be in accidence with IS 12288. Pipe trenches shall be excavated to the lines and levels shown on the drawings or as directed by the Engineer-In-Charge. The depth of the excavated trench shall be as given in the drawings or as directed by the Engineer-In-Charge. The width of the trench at bottom between the faces or sheeting shall be such as to provide 200 mm clearance on either side of the DI pipe.

The depth should be sufficient to provide cover not less than 1000 mm so that the pipeline for protection against traffic loads. It may be necessary to increase the depth of pipeline to avoid land drains or in the vicinity of roads, railways or other crossings. Care should be taken to avoid the spoil bank causing an accumulation of rainwater.

The bottom of the trench shall be trimmed and leveled to permit even bedding of the pipes. It should be free from all extraneous matter, which may damage the pipe or the pipe coating. Additional excavation shall be made at the joins of the pipes, so that the pipe is supported along its entire length.

All excavated material shall be stacked in such a distance from the trench edge that it will not endanger the work or workmen and it will avoid obstructing footpaths, roads and drive ways. Hydrants under pressure, surface boxes, fire or other utility controls shall be left unobstructed and accessible during the construction work. Gutters shall be kept clear or other satisfactory provisions made for street drainage, and natural watercourses shall not be obstructed.

To protect persons from injury and to avoid damage to property, adequate barricades, construction signs, torches, red lanterns and guards, as required, shall be placed and maintained during the progress of the work and until it is safe for traffic to use the roadways. All materials, piles equipment and pipes which may serve as obstruction to traffic shall be enclosed by fences or barricades and shall be protected by illuminating proper lights when the visibility is poor.

As far as possible, the pipe line shall be laid below existing services, like water and gas pipes, cables, cable ducts and rains but not below sewers, which are usually laid at greater depth. Where it is unavoidable, pipe line should be suitably protected. A minimum clearance of 150mm shall be provided between the pipe line and such other services.

Trees, shrubbery fences, poles, and all other property and surface structures shall be protected. Tree roots shall be cut within a distance of 50 cm from pipe joints in order to prevent roots from entering them. Temporary support, adequate protection and maintenance of all under ground and surface structures, drains, sewers and other obstructions encountered in the progress of the work shall be provided. The structures, which will be disturbed, shall be restored after completion of the work.

Where water forms or accumulates in any trench the Contractor shall maintain the trench free of water during pipe laying.

Wherever necessary to prevent caving, trench excavations in soils such as sand, gravel and sandy soil shall be adequately sheeted and braced. Where sheeting and bracing are used, the net trench width after sheeting shall not be less than that specified above. The sides of the excavation shall be adequately supported at all times and, except where described as permit under the Contract, shall be not battered.

The Engineer-In-Charge in co-operation with the Contractor shall decide about the sheeting/bracing of the trench according to the soil conditions in a particular stretch and taking into account the safety requirements of the Contractor's and Engineer's staff. Generally, safety measures against caving have to be provided for trenches with vertical walls if they are deeper than 2.0 m.

1.6.7.2 Trench excavation to commensurate with the laying progress:

The work of trench excavation should be commensurate with laying and jointing of the pipeline. It should not be dug in advance for a length greater than 500 m ahead of work of laying and jointing of pipeline unless otherwise defined by the Engineer-In-Charge. The contractor has to ensure the following:

Safety protections as mentioned above, have to be incorporated in the work process

Hindrances to the public have to be minimised

The trench must not eroded before the pipes are laid

The trench must not be filled with water when the pipes are laid

The trench must not be refilled before laying of the pipes.

The bed for the laying of the pipes has to be prepared according to the L-Section immediately before laying of the pipes.

1.6.7.3 Bedding of the pipes:

The trench bottom shall be even and smooth so as to provide a proper support for the pipe over its entire length, and shall be free from stones, lumps, roots and other hard objects that may injure the pipe or coating. Holes shall be dug in the trench bottom to accommodate sockets so as to ensure continuous contact between the trench and the entire pipe barrel between socket holes. The requirement of other type of bedding for certain/complete length of pipes may also be checked on the drawings issued for the same.

1.6.8 Laying and jointing of pipes:

1.6.8.1 General

The pipes will be cleaned in the whole length with special care of the spigot and sockets on the inside/outside to ensure that they are free from dirt and unwarranted projections. The whole of the pipes shall be placed in position singly and shall be laid true to profile and direction of slope indicated on longitudinal sections. The pipes shall be laid without deflection in a straight alignment between bends and between high and low points. Vertical and horizontal deflection between individual pipes needs the approval of the Engineer-In-Charge. In no case the deflection shall be more than 75% of those recommended by the manufacturer.

Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or any other objects that may have entered the interior of the pipes, particularly the spigot end and the socket including the groove for the rubber ring. The Contractor shall not leave a gap for fittings and shall lay line in a continuous stretch.

Pipes and the related specials shall be laid according to the instructions of the manufacturers and using the tools recommended by them.

Cutting of pipes shall be reduced to a minimum required to conform to the drawings. Cutting has to be made with suitable tools and according to the recommendations of the manufacturer. The spigot end has to be chamfered again at the same angle as the original chamfered end. Cutting shall be perpendicular to the center line of the pipe. If there is no mark for the insertion depth on the spigot end of the (cut) pipe it shall be marked again according to the instructions of the manufacturer.

Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or any other objects that may have entered the interior of the pipes, particularly the spigot end and the socket including the groove for the rubber ring. End caps are removed only just before laying and jointing.

All specials like bends, tees etc. and appurtenances like sluice or butterfly valves etc. shall be laid in synchronization with the pipes. The Contractor has to ensure that the specials and accessories are ready in time to be installed together with the pipes.

At the end of each working day and whenever work is interrupted for any period of time, the free ends of laid pipes shall be protected against the entry of dirt or other foreign matter by means of approved plugs or end caps.

When pipe laying is not in progress, the open ends of installed pipe shall be closed by approved means to prevent entrance of trench water and dirt into the line.

1.6.8.2 Laying and jointing of DI pipes

Pipes should be lowered into the trench with tackle suitable for the weight of pipes. For smaller sizes, up to 200 mm nominal bore, the pipe may be lowered by the use of ropes but for heavier pipes suitable mechanical equipment have to be used.

All construction debris should be cleared from the inside of the pipe either before or just after a joint is made. This is done by passing a pull-through in the pipe, or by hand, depending on the size of the pipe. All persons should vacate any section of trench into which the pipe is being lowered.

On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of the pipe being laid does not move into or out of the socket of the laid pipe during the jointing operations. As soon as the joint assembly has been completed, the pipe should be held firmly in position while the trench is back filled over the barrel of the pipe.

The designed anchorage shall be provided to resist the thrusts developed by internal pressure at bends, tees, etc.

Where a pipeline crosses a watercourse, the design and method of construction should take into account the characteristics of the watercourse to ascertain the nature of bed, scour levels, maximum velocities, high flood levels, seasonal variation, etc., which affect the design and laying of pipeline.

The assembly for the pipes shall be made as recommended by the pipe manufacturer and using the suitable tools.

The socket and spigot ends of the pipes shall be brushed and cleaned. The chamfered surface and the end of the spigot end have to be coated with a suitable lubricant recommended by the manufacturer o the pipes. Oil, petroleum bound oils, grease or other material, which may damage the rubber gasket, shall not be used as lubricant. The rubber gasket shall be inserted into the cleaned groove of the socket. It has to be checked for correct positioning.

The two pipes shall be aligned properly in the pipe trench and the spigot end shall be pushed axially into the socket either manually or with a suitable tool specially designed for the assembly of pipes and

as recommended by the manufacturer. The spigot has to be inserted up to the insertion mark on the pipe spigot. After insertion, the correct position of the socket has to be tested with a feeler blade.

Deflection of the pipes, if any shall be made only after they have fully been assembled. The deflection shall not exceed 75% of the values indicated by the pipe manufacturer.

For ease of laying, the pipes shall be laid with socket facing the direction in which the work is progressing. For pipes on slope, the socket should be laid with socket facing uphill.

1.6.9 Anchoring of the pipeline:

Thrust blocks shall be provided at each bend, tee, taper, end piece to prevent undue movements of the pipeline under pressure. They shall be constructed as per designs submitted and approved by Engineer-In-Charge, according to the highest pressure during operation or testing of the pipes, the safe bearing pressure of the surrounding soil and the friction coefficient of the soil.

1.6.10 Testing of Pipelines:

1.6.11.1 Sectional tests

After laying and jointing the pipeline shall be tested for tightness of barrels and joints, and stability of thrust blocks in sections approved by the Engineer-In-Charge. The length of the sections depends on the topographical conditions. Preferably the pipeline stretches to be tested shall be between two chambers (air valve, scour valve, bifurcation, other chamber ). At the beginning, the Contractor shall test stretches not exceeding 2 km. After successful organization and execution of tests the length may be extended to more than 2 km after approval of the Engineer-In-Charge.

The contractor himself shall arrange the water required for testing. The Contractor shall fill the pipe and compensate the leakage during testing. The Contractor shall provide and maintain all requisite facilities, instruments, etc. for the field-testing of the pipelines. The testing of the pipelines generally consists in three phases: preparation, pre-test/saturation and test, immediately following the pre-test. Generally, the following steps are required which shall be monitored and recorded in a test protocol if required:

Complete setting of the thrust blocks.

Partial backfilling and compaction to hold the pipes in position while leaving the joints exposed for leakage control

Opening of all intermediate valves (if any)

Fixing the end pieces for tests and after temporarily anchoring them against the soil (not against the preceding pipe stretch)

At the lower end with a precision pressure gauge and the connection to the pump for establishing the test pressure

At the higher end with a valve for air outlet

If the pressure gauge cannot be installed at the lowest point of the pipeline, an allowance in the test pressure to be read at the position of the gauge ha to be made accordingly

Slowly filling the pipe from the lowest point(s).

The water for this purpose shall be reasonably clear and free of solids and suspended matter.

Complete removal of air through air valves along the line.

Closing all air valves and scour valves.

Slowly rising the pressure to the test pressure while inspecting the thrust blocks and the temporary anchoring.

Keeping the pipeline under pressure for the duration of the pre-test/saturation of the lining by adding make-up water to maintain the pressure at the desired test level. Make up water to be arranged by Contractor himself at his own cost.

Start the test by maintaining the test pressure at the desired level by adding more make-up water; record the water added and the pressure in intervals of 15 minutes at the beginning and 30 minutes at the end of the test period.

Water used for testing should not be carelessly disposed off on land, which would ultimately find its way to trenches.

The testing conditions for the pipelines shall be as per the test pressures and condition laid out in IS 8329 for DI pipes.

The pipeline stretch will pass the test if the water added during the test period is not exceeding the admissible limits. No section of the pipework shall be accepted by the Engineer-In-Charge until all requirements of the test have been obtained.

On completion of a satisfactory test any temporary anchor blocks shall be broken out and stop ends removed. Backfilling of the pipeline shall be completed.

1.6.11.2 Leakage Test

The testing conditions for the pipelines are summarized as follows:

Maximum hydrostatic test pressure for DI K-9 pipes shall be 1.5 times working Pressure in the pipeline or 10 Kg./cm2, whichever is maximum.

The method of filling the pipeline with water shall be approved by the Engineer-In-Charge. The length under test shall be filled making certain that all the air is displaced through an air valve installed at the top of blank flange situated at the high end of the line. The length shall remain under constant moderate pressure 10 to 20 m of head of water, for a period of several hours until the pressure can be maintained without additional pumping.

The pressure shall then be slowly increased at a maximum rate of 10 m per minute to the full test pressure and pumping discontinued for a 3 hours or until the pressure has dropped by 10 m, whichever occurs earlier. The quantity of water pumped to restore the pressure shall be the measure of leakage from discontinuation of pumping until its resumption.

The pipe length shall pass the test if the leakage is not more than 1.00 litres per mm diameter per kilometer per 24 hours for each 100 m head of pressure applied and the full test pressure has been sustained for at least 3 hours.

If it is required to test a section of a pipeline with a free end, it is necessary to provide temporary support against the considerable end thrust developed by the application of the test pressure. The end support can be provide by inserting a wooden beam or similar strong material in a short trench excavated at right angle to the main trench and inserting suitable packing between the support and pipe end.

The pipeline stretch will pass the test if the water added during the test period is not exceeding the admissible limits. No section of the pipe work shall be accepted by the Engineer-In-Charge until all requirements of the test have been obtained.

On completion of a satisfactory test any temporary anchor blocks shall be broken out and stop ends removed. Backfilling for the pipeline shall be completed.

1.6.11.3 Failure to pass the test

All pipes or joints which are proved to be in any way defective shall be replaced or remade and re-tested as often as may be necessary until a satisfactory test shall have been obtained. Any work, which fails or is proved by test to the unsatisfactory in any way shall be redone by the Contractor. No payments shall be made against replacement or remade and retested pipeline.

1.6.11 Flushing and disinfecting of pipelines.

After testing and commissioning, the contractor shall flush the pipes with a velocity not less than 1 m/s or as approved by the Engineer-In-Charge. Disinfection of drinking after pipelines shall be done as directed by Engineer-In-Charge.

1.6.12 Backfilling of the pipe trench:

The backfilling of pipe trench should be done as approved by Engineer-In- Charge & as per the provision of IS: 12288.

1.7 Pillars for ductile iron pipesIn case of unstable subsoil or in case of ductile iron pipes laid above ground they shall be laid on pillars. Each pipe is supported at the plain end and behind the socket. One pillar shall support the socket end of one and the plain end of other pipe. The pillars shall be of Cement Concrete and shall be founded on solid soil, not subject to erosion by wind or water. The foundation of the pillars has to be calculated according to the soil conditions.The top of the pillar shall from two saddles for the pipe having the same readius as the pipe. The socket will be lying free between the two saddles. The pipes shall be laid on a coat of polyethylene of 2mm thickness, put on mortar. It has to be ensured that the spigot end of the pipe is supported by the saddle and does not unduly compress the rubber ring in the lower part. Each pipe is fixed by one adjustable galvanized steel spanner, fixed to the pillar with anchor bolts. In case of vertical deviations the pipes shall be protected against uplift by additional reinforced clamps of mid steel. In this case, the design of the pillar has to be made taking in account these uplift forces and design will be given by Contractor.

1.8 Thrust BlocksThe thrust blocks shall be of plain cement concrete on site. This should be as per design and drawing to be given by the contractor and approved by Engineer-In-Charge. The thrust blocks shall be cast directly against the undisturbed soil. If this is not possible, the backfilled soil at the contact surface shall be compacted well to full satisfaction of Engineer-In-Charge so that anchor block is not displaced during operation and testing.

1.9 Backfilling around chambers and thrust blocksAfter the completion o chambers and thrust blocks the space between the structure and the excavation shall be backfilled with compacted material. Such backfill shall be placed in layers of 15 cm measured before compaction, wetted, if necessary, to optimum moisture and compacted well as per instruction of Engineer-In-Charge.

1.10 Other Civil and Related Works1.11 Crossing of existing Distribution Pipes and connecting pipes The work shall be carried out as per the directions of Engineer-In-Charge.

1.12 Poles of electrical or telephone linesIn case of impossibility of deviation of pipeline, poles of electricity lines (33, 11, 0.4 KV), telephone lines or anchor cables of poles have to be relocated. These works have to be executed by the respective department or according to its instructions. In case o the respective department denies for relocating the utility services the same shall be carried out by the contractor. The amount shall be reimbursed from the provisional sum after certification from the Engineer-In-Charge. The Contractor has the full responsibility in case of destruction of lines or poles due to the attention of his staff. All cross for the reinstatement to the original status of the lines have to be borne by contractor.

1.13 Testing and Commissioning1.13.1 Commissioning

After successful sectional tests after pipe laying and other pre-commissioning tests after physical completion, the pipeline shall be commissioned by the Contractor. Dynamic commissioning shall be made in conjunction with or after the commissioning of the respective system.During testing/commissioning, the Contractor shall supply all material and labour to supervise, adjust, test, repair and do al things necessary to maintain the testing/commissioning. This shall include labour on a 24 hour-a-day basis during the test period and for such other period of continuous operation as the Engineer-In-Charge may consider necessary to establish the efficient operation of the cluster distribution system.If any test result shows noticeable variation from the specification requirements for the system the Contractor shall immediately take steps to rectify the deficiency without any extra cost.The Contractor shall test and commission the system for 7 days at a stretch, from the date of commissioning. On expiry o this period he system shall be taken over by the Engineer-In-Charge and a taking-over certificate shall be issued by the Engineer-In-Charge, provided all defects and/or deficiencies noticed are rectified to the satisfaction of the Engineer-In-Charge.Generally, the timing of most of the commissioning tests will depend on the availability of the respective pumps, the water and power availability at the pumping station ad the completion of the reservoir.Should the supply of water from the pumping station fail or should any other event beyond the Contractor's control interfere, the commissioning shall be during such a number of operational periods as the Engineer-In-Charges may consider equivalent. Any repairs of replacement require and during this period shall be done by the Contractor at his own cost.The Contractor shall allow for commissioning to be conducted at any time during the commissioning period without extra charges under the Contract. no leaks in pipes, joints, specials and valves all valves are properly installed and operational execution of the entire work including finishing according to the drawings and the

specifications submission of as built drawings

1.14 Other Services:Contractor shall take the necessary precautions avoid the damage to other services such as water supply lines, telephone cables, electrical cables, storm water drains etc. in case of any damages to any of the services, contractor shall be responsible for restoring the facilities in bare minimum time at his own cost.