Design, Engineering, Supply, Construction & Annexure-I

Commissioning of New Rock Phosphate Silo-D RFQ.No.252002220345,

Dated 14.06.2021
IFFCO,Paradeep Rev.0

ANNEXURE-I

DESIGN, ENGINEERING, SUPPLY, ERECTION,

CONSTRUCTION, COMMISSIONING

OF

NEW ROCK PHOSPHATE SILO-D

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Dated 14.06.2021
IFFCO,Paradeep Rev.0

CONTENTS

Sl. No. Title Page No.

1 Introduction 3
2 Site Data 4
3 Design Requirements 5
4 General Scope of the Project 6
5 Applicable Codes & Standards 11
6 Technical Specification for Civil Jobs 24
7 Technical Specification for Steel Structural Jobs 48
8 Technical Specification for Painting Jobs 58
9 Technical Specification for Conveying System 64
10 Technical Specification for Electrical & Instrumentation jobs 75
11 IFFCO scope for the Project 91
12 Inspection & Testing 92
13 Rejection of Equipments 93
14 Delivery Period 94
15 Progress Report 94
16 Dispatch ,Unloading & Storage of Material 95
17 Mechanical Completion, Commissioning & Acceptance 95
18 Guarantee 97
19 Documentation 99
20 Preferred Vendor List 101
21 Spares 104
22 General Terms & Conditions 105
23 Payment Terms 108
24 Price schedule 109
25 Safety requirements 111
26 Termination of Contracts 120

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1. INTRODUCTION :

IFFCO, Paradeep unit is a large phosphatic fertilizer complex located at Paradeep,

Odisha. The major raw materials required are sulphur, phosphate rock and ammonia
which are imported. Annual requirement of the complex is 7.7 lakh tonnes of sulphur, 35
lakh tonnes of phosphate rock and 4.5 lakh tonnes of ammonia.

Phosphate rock is generally imported from Jordan, morocco, Peru, Egypt and Vietnam
while sulphur and ammonia are imported from Gulf countries. The complex has a jetty
at Paradeep Port with two grab unloaders having capacity of 1500 tonnes per hour each
and one screw unloader with capacity 1800 tonnes per hour. Presently Paradeep Unit
has six silos for storage of solid raw materials which receives materials from the jetty
through 5.5 km long cross country conveying system.

Sl. Description Capacity

1 Rock Phosphate Storage Silo-A 75000 MT

2 Rock Phosphate Storage Silo-B 75000 MT

3 Rock Phosphate Storage Silo-C 100000 MT

4 Sulphur Storage Silo-A 60000 MT

5 Sulphur Storage Silo-B 48000 MT

6 Urea-Potash Storage Silo 80000 MT

To enhance the storage facility for Rock Phosphate an additional Silo is required with all
ancillary systems.

Therefore IFFCO Paradeep intends to engage a competent & experienced vendor for
design, engineering, supply, construction & commissioning of a new Rock Phosphate
Storage Silo on LSTK basis within a minimum time period.

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2. SITE DATA

Metrological data
Dry Bulb Temperature (Max ) 41 °C
Dry Bulb Temperature (Min) 8 °C
Wet Bulb Temperature 7.5-30 °C
Plant location
Paradeep, Jagatsignhpur District, Orissa state, India
20 0, 15’ 56.44’’ N
86 0 , 14’ 34.62’’ E
Altitude above sea level 6.0 m (Average)
Atmospheric pressure 762 mm Hg
Mean annual rainfall 1800 mm (Average)
Relative humidity
Average 75.0 %
Minimum 50.0 %
Maximum 90.0%
Wind velocity (Max.) 260 Km/h
Wind direction (wind rose attached) Mainly SW ↔ NE
Super cyclone prone area
Earth quake zone
Indian seismic zone No. III
Modified Mercalli scale,1931 VII
Soil Condition Site Geotechnical Report is to be
referred. Will be provided shortly
Fugitive dust in surrounding

3. DESIGN REQUIREMENTS
3.1. Construction of storage Silo & Conveying system

Proposed Rock Phosphate Silo-D shall be designed by a combination of RCC & Steel
structural sections. Suitable type of pilings shall be considered for all RCC foundations
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depending upon the geo technical study carried out to confirm the soil strata. Gable
end wall, retaining wall, underground conveyor gantry shall be made up of RCC. Silo
roof structure, unloading & transfer conveyor gantry, transfer tower, maintenance
tower, and all structural supports for conveying system shall be considered to be made
from steel structural.

3.2. Silo Operation:

Rock phosphate is unloaded into the storage silo through a conveyor having travelling
tripper arrangement with two way discharge. The tripper discharges at different
locations along the length of the Silo and rock phosphate is stored in form of heaps.
There is an underground reclaiming conveyor for shifting of material from silo to plant
for further operation. The reclaiming conveyor is fed through opening of gates located
at silo floor. The materials unloaded in the form of heap just above these gates for
feeding to the underground conveyor against gravity through these gates Earth moving
equipment is used further to move the materials near the discharge gates.

3.3. Proposed Hook up points

For transfer & unloading of Rock phosphate into the proposed Rock Phosphate Silo-D,
existing Transfer Point-12 (TP 12) may be used. At TP 12 existing conveyor R-10A is
feeding to unloading Tripper conveyor R-14 for unloading into Rock Silo-C. Proposed
transfer conveyor R-10B may be fed from existing R-10A conveyor by installing a
suitable diverter gate. Further conveyor R-10B will fed to proposed unloading tripper
conveyor R-15 at proposed TP 13.Rock phosphate will be reclaimed from Rock Silo-D
through underground reclaiming conveyor 103-D & transfer conveyor 104-B which will
in turn fed to existing transfer conveyor 104-A. Proposed layout plan is enclosed for
better understanding of the vendor.

4. GENERAL SCOPE OF THE PROJECT

The scope of work of this enquiry shall comprise of design, engineering, supply,
erection/construction, testing & commissioning of the following for successful completion of
the job.

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i) 100000 MT capacity Rock Phosphate storage Silo-D.

ii) Conveyor galleries.
iii) Conveying system for material intake from existing cross country conveying
system & discharge to Silo through travelling tripper conveyor, underground
reclaiming conveyor & transfer conveyor for Rock Phosphate feeding to existing
conveying system.
iv) Electrification, Automation (Heap sensing arrangement), illumination, lightening
protection, earthling etc.
v) For any additional work not covered in the scope bidders but required for the
complete commissioning of the whole system, vendor may quote unit rates for
items.

4.1 Design & Engineering

New Rock phosphate Silo –D along with all ancillary systems shall be constructed as per
the proposed layout plan enclosed.

Vendor has to arrange a site survey & detail technical discussion with IFFCO team for
better understanding of the complete scope before bidding.

Design & detail engineering of complete storage shed, transfer tower, maintenance tower,
transfer & underground reclaiming conveying system, travelling tripper shall be in
vendor’s scope. Before going for detail engineering vendor has to submit the basic
engineering documents for review & approval of IFFCO.

All the design calculations & drawings for civil, structural, conveying system shall be
vetted by M/s PDIL, New Delhi at the cost of LSTK contract.

Design criteria shall be similar to the existing Rock Silo-C.

4.2. Civil

Design specification, supply of material & execution procedure for relevant civil &
structural job shall be guided by the “Detail Specification for Civil & Structural
Works” attached as Annexure-II.

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4.1.1 Earthwork

All type of earthwork like excavation of earth for foundations, footings, columns, plinth
beams, walls, machine/equipment foundations, isolated pits, pavements, trenches for
pipelines/cables, drains , removal & disposal of extra earth material from site, providing
Mechanically Stabilised Mix (MSM) layer of suitable grade at required location and
supply & filling of sweet sand as per requirement shall be considered.

4.2.2 Piling

A geo technical survey is being carried out to know the existing soil strata at designated
location for the proposed Rock Silo-D. Pile type & detail design shall be done as per the
soil data received from the study. No. of piles, Pile diameter, Pile length shall be
designed considering all the load data (dead load & dynamic load). Pile type may be
Bored cast in situ or Driven cast in situ depending on load data & soil data. The designed
data of pile shall be verified by executing test piles at the desired locations before
execution of piling job.

4.2.3 RCC Works

This consist of the following

i) Pile cap & pedestal for columns of silo, conveyor trestle, transfer tower,
maintenance tower.
ii) Retaining wall & Gable end wall.
iii) Encasing/Embedding of steel column depending upon design.
iv) Underground Reclaiming Conveyor gallery.
v) Pent House (Exit point of underground reclaiming conveyor)
vi) Flooring of Silo inside area & plinth area, transfer tower &
maintenance tower area.

4.2.4 Roofing
Supply & installation of high impact PVC corrugated sheets of Palruf make over storage
shed, monitor area, transfer & maintenance tower and conveyor gantry made up of steel
structure. Wind Ties made up of GI flat of suitable size shall also be considered.

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Supply & application of suitable waterproofing material over roof of Pent House and any
other RCC roof exposed to atmosphere shall also to be considered.

4.2.5 Structural Steel Works

Supply, fabrication & painting of super structure of silo like Columns, Portals, Tie girders,
Rafters Tripper girder, walkways, monitor columns, monitor roofs & bracings ,purlins,
conveyor support, bracing system, rails/square solid bars for travelling tripper etc.

4.2.6 Protective Coating

All concrete and structural steel works shall be provided with protective coating as
specified in the bid. The painting system should conform to the stipulations of ISO
12944‐1998 for C‐5M environment or condition & more than 15 years durability. It is
required that the system should be valid for 10 years guarantee period. The painting shall
be carried out by agency approved by the paint manufacturers strictly in compliance with
the specifications under joint supervision of the applicator & manufacturer’s
representatives. ES 2001, attached with the bid may be referred in this regard

4.2.7 Material requirement

The supply of all materials for completion of the project shall be in contractor scope,
broadly as follows

4.2.7.1 Cement

i) Substructure: Super Sulphated cement confirming to IS 6909 shall be

used for Pile, Pile cap, pedestal & other underground works only.
ii) Superstructure works: OPC (53 grade) confirming to IS 12269.

4.2.7.2 Sand: The material should confirm to the specification enclosed in the bid.
However, only river sand shall be used by the contractor.

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4.2.7.3 Water: To be supplied by owner free of cost. However IFFCO will provide the
same at one point. Further distribution during construction shall be in the scope of
contractor

4.2.7.4 Aggregate: As per design specification.

4.2.7.5 Concrete: Only controlled concrete of M35 grade & above as specified shall be
used confirming to IS 456, except for the paving, filler walls which shall be of
grade M‐25

4.2.7.6 Reinforcement Only Fe 500 D reinforcement bars confirming to IS 1786 shall

be used

4.2.7.7 Structural steel: Structural steel materials shall conform to IS 2062 with a
minimum yield strength of 36000 psi, and designed in accordance with IS.

4.3 Mechanical Works

Supply, erection, commissioning & load trial of following conveying systems shall be in the
vendor’s scope.

i) Material Discharge facilities from existing R-10A conveyor to new R-10B conveyor.
ii) New R-10B Conveyor
iii) New R-15 Unloading Conveyor along with Travelling Tripper
iv) New Underground Reclaiming Conveyor 103D
v) Pneumatic/ Motorised Gate along with hopper for feeding to Underground
Reclaiming Conveyor.
vi) New Transfer Conveyor 104B.

Following Components of conveying system is to included but not limited for smooth &
trouble free operation of the complete conveying system.

i) Motorised Diverter Gate with Discharge Facilities

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ii) Discharge Hoppers/Chutes

iii) Conveyor Belt
iv) Drive Unit (Gear box, Motor, etc.)
v) Coupling
vi) Drive Pulley, Tail Pulley, Bend Pulley
vii) VGTU (Vertical Gravity Take up Unit) / HGTU (Horizontal Gravity Take up Unit)
viii) Carrying Idlers
ix) Return Idlers
x) Self-Aligning Idler
xi) Idler support brackets
xii) Cable Reeling Drum for Travelling Tripper
xiii) Walkways, Ladders & Maintenance Platforms.

4.4 Electrical / Instrumentation Works

Supply, installation & commissioning of all electrical items shall be in scope of the
vendor, majority comprising of the following.
i) New MCC for all electrical equipment
ii) Tripper Control Panel
iii) CRD control panel
iv) Ultrasonic Heap Sensing arrangements.
v) Belt weighing system including Load Cell for reclaimed material.
vi) Scoop Coupling Control panel
vii) Power, control , CRD cable
viii) Raychem make Heat shrinkable end termination kits for HV Cables.
ix) Cable Termination material for LV cables.
x) Cable Tray & Tray support system
xi) Conveyor safety switches (Pull Cord switch, Zero speed switch, Belt sway switch
etc.)
xii) Local Control station

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xiii) Illumination system in conveyor galleries, storage shed, maintenance tower,

transfer towers & staircases.
xiv) Electromagnet with Control Panel
xv) Lightening protection
xvi) Earthing
xvii) Welding receptacle

Only incoming supply to MCC shall be in the scope of IFFCO.

5. APPLICABLE STANDARDS
Following is a general listing of Codes and Standards to be used in the design &
engineering for construction of Rock Phosphate Silo-D with all ancillary systems. Specific
applicable codes and standards will be identified in System Design Descriptions /
Technical Specifications as appropriate. The latest editions/ revision of following codes
and standards along with addendums/ amendments, if any, shall be followed:

5.01 Earthwork

a) IS-1498 : Classification and identification of soils for

General Engineering purposes.
b) IS-3764 : Safety Code for excavation work.
c) IS-7293 : Safety Code for working with construction
machinery.
d) IS-4081 : Safety Code for blasting and related drilling
operation
f) IS-9759 : Guidelines for Dewatering during construction.
g) Indian Explosives Rule 2008.

5.02 Concrete

a) IS-269 : Ordinary and low heat Portland cement.

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b) IS-383 : Course and fine aggregate from natural sources

for concrete.
c) IS-432 : Mild Steel and medium tensile steel bars and
hard drawn steel wire for concrete reinforcement.
d) IS-455 : Portland Slag Cement.
e) IS-456 : Code of Practice for Plain and reinforced
concrete.
f) IS-460 : Test Sieves (all parts).
g) IS-516 : Methods of test for strength of concrete.
h) IS-1199 : Methods of sampling and analysis of concrete.
i) IS-1566 : Hard drawn steel wire fabric for concrete
Reinforcement.
j) IS-1786 : High strength deformed steel bars and wires for
concrete reinforcement.
k) IS 1489 : Part 1: Specification for Portland pozzolana
cement Part 1 Fly ash based
l) IS-1834 : Hot applied sealing compounds for joints in
concrete.
m) IS-2386 : Methods of test for aggregates for concrete (all
parts).
n) IS-2502 : Code of practice for bending and fixing of bars for
concrete reinforcement.
o) IS-3370 : Code of practice for concrete structures for
storage of liquids (all parts).
p) IS-3414 : Code of practice for design and installation of
joints in buildings.
q) IS-4948 : Welded steel wire fabrics for general use.
r) IS-7320 : Concrete slump test apparatus.
s) IS-7861 : Code of practice for extreme weather concreting
(all parts).
t) IS-8041 : Rapid Hardening Portland Cement.
u) IS-8112 : High strength ordinary Portland Cement.
v) IS-12269 : High strength ordinary Portland Cement.
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w) IS-10262 : Recommended guidelines for concrete mix

design.

5.03 Foundations

a) IS-1904 : Code of practice for structural safety of buildings:

Shallow foundations.
b) IS-2950 : Code of practice for design and construction of
raft foundations.
c) IS-2974 : Code of practice for design and construction of
Machine foundations (all parts).
d) IS 2911 : Code of practice for Design and Construction of
Pile Foundation.
5.04 Loading

a) IS-875 : Code of practice for design loads for buildings

and structures.
b) IRS : Bridge Rules of Government of India, Ministry of
Railways (Railway Board).
5.05 Masonry

a) IS-712 : Building limes.

b) IS-1077 : Common Burnt Clay Building Bricks.
c) IS-1127 : Recommendations for dimensions and
workmanship of natural building stones for
masonry work.
d) IS-1528 : Methods of sampling and physical tests for
refractory materials.
e) IS-1597 : Code of practice for construction of stone
masonry (all parts).
f) IS-2212 : Code of practice for brickwork.
g) IS-2116 : Sand for masonry mortars

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h) IS-2185 : Concrete masonry units.

(all parts - Hollow and Solid concrete blocks).
i) IS-2250 : Code of practice for preparation and use of
masonry mortars.
j) IS-2572 : Code of practice for construction of hollow
concrete block masonry.
k) IS-2691 : Burnt clay facing bricks.
l) IS-3414 : Code of practice for design and installation of
joints in buildings.
m) IS-3495 : Methods of tests of burnt clay building bricks.
n) IS-4441 : Code of practice for use of Silicate type chemical
resistant mortars.
o) IS-4860 : Acid Resistant Bricks.
p) IS 13757 : Specification for burnt clay fly ash building bricks

5.06 Doors, Windows & Ventilators

a) IS-399 : Classification of commercial timbers and their

zonal distribution.
b) IS-883 : Code of practice for design of structural timber in
building.
c) IS-1038 : Steel doors, windows and ventilators.
d) IS-1081 : Code of practice for fixing and glazing of metal
(steel and aluminium) doors, windows and
ventilators.
e) IS-1361 : Steel windows for industrial buildings.
f) IS-2835 : Transparent sheet glass for glazing and framing
purposes.
g) IS-1948 : Aluminium doors windows and ventilators.
h) IS-1949 : Aluminium windows for industrial building.
i) IS-3103 : Code of practice for Industrial ventilation.

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j) IS-3548 : Code of practice for glazing in buildings.

k) IS-3614 : Fire check doors.
l) IS-4351 : Steel door frames.
m) IS-6248 : Metal rolling shutters and rolling grills.

5.07 Roof & Flooring

a) IS-2204 : Code of practice for construction of reinforced

concrete shell roof.

b) IS-3201 : Criteria for the design and construction of precast

concrete trusses.

c) IS-2210 : Criteria for Design of R.C. shell structures and

folded plates.
d) IS-809 : Rubber flooring materials for general purposes.
e) IS-1195 : Bitumen mastic for flooring.
f) IS-1196 : Code of practice for laying bitumen mastic
flooring.
g) IS-1198 : Code of practice for laying, fixing and
maintenance of linoleum floors.
h) IS-1237 : Cement concrete flooring tiles.
i) IS-1443 : Code of practice for laying and finishing of
cement concrete flooring tiles.
j) IS-2114 : Code of practice for laying in situ terrazzo floor
finish.
k) IS-2571 : Code of practice for laying in situ cement
concrete flooring.
l) IS-5491 : Code of practice for laying in situ granolithic
concrete floor topping.
m) IS-5766 : Code of practice for laying burnt clay brick
flooring.
n) IS-1197 : Code of practice for laying of rubber floors.
o) IS-2441 : Code of practice for fixing ceiling coverings.
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5.08 Waterproofing

a) IS-1322 : Bitumen felts for waterproofing and damp

proofing.
b) IS-1346 : Code of practice for waterproofing of roofs with
bitumen felts.
c) IS-1609 : Code of practice for laying damp proof treatment
using bituminous felts.
d) IS-3036 : Code of practice for laying lime concrete for a
waterproofed roof finish.
e) IS-3037 : Bitumen mastic for use in waterproofing of roofs.
f) IS-3067 : Code of practice for general design, details and
preparatory work for damp proofing and water
proofing of buildings.
g) IS-3384 : Bitumen primer for use in water proofing and
damp proofing.
h) IS-4365 : Code of practice for application of bitumen mastic
for waterproofing of roofs.

5.09 Membrane Waterproofing

a) ASTMD-1076 : Solid Content

b) ASTMD-1475 : Specific Gravity
c) ASTMD-412 : Elongation
d) ASTMD-2240 : Hardness
e) ASTMD-822 : Water vapour transmission resistance

5.10 Soil Engineering

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a) IS-1498 : Classification and identification of soils for general

Engineering purposes.
b) IS-1892 : Code of practice for sub-surface investigation for
foundations.
c) IS-2131 : Method for standard penetration test for soils.
d) IS-2720 : Methods of test for soils (all parts).
e) IS-10379 : Field Control of Moisture and compaction of soils
for embankment and subgrade.

5.11 Water Supply, Drainage & Sewerage

a) IS-404 : Lead pipes.

b) IS-458 : Concrete pipes.
c) IS-651 : Salt glazed stoneware pipes and fittings.
d) IS-771 : Glazed fire-clay sanitary appliances (all parts).
e) IS-774 : Flushing cisterns for water closets and urinals
other than plastic cisterns.
f) IS-783 : Code of practice for laying of concrete pipes.
g) IS-1172 : Code of basic requirements for water supply,
drainage and sanitation.
h) IS-1626 : Asbestos cement building pipes, gutters and
fittings (all parts).
i) IS-1742 : Code of practice for building drainage.
j) IS-2064 : Code of practice for selection, installation and
maintenance of sanitary appliances.
k) IS-2065 : Code of practice for water supply in buildings.
l) IS-2470 : Code of practice for installation of septic tanks (all
parts).
m) IS-3114 : Code of practice for laying of Cast Iron pipes.
n) IS-4127 : Code of practice for laying of glazed stoneware
pipes.

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o) IS-12251 : Code of practice for Drainage of Building

Basement.
p) IS-1536 : Centrifugally cast (spun) iron pressure pipes for
water, gas and sewage.
q) IS-1537 : Vertically cast iron pressure pipe for water, gas
and sewage.
r) IS-3486 : Cast iron spigot and socket drain pipes.
s) IS-5329 : Code of practice for sanitary pipe work above
ground for buildings.
t) IS-3076 : Low density polyethylene pipes for potable water
supplies.
u) IS-1538 : Cast iron fittings for pressure pipes for water, gas
and sewage.
v) IS-1230 : Cast iron rainwater pipes and fittings.
w) IS-1729 : Sand cast iron spigot and socket soil, waste and
ventilating pipes, fittings and accessories.
x) IS-784 : Pre-stressed concrete pipes.
y) IS-1726 : Cast iron manhole covers and frames.
z) IS-5961 : Cast iron grating for drainage purposes.
aa) IS-5219 : "P" and "S" traps.
[Part-I]
bb) IS-772 : General requirements for enamelled cast iron
sanitary appliances.
cc) IS-775 : Cast iron brackets and supports for wash basins
and sinks.
dd) IS-777 : Glazed earthenware wall tiles.
ee) IS-2548 : Plastic water closet seats and covers (all parts).
ff) IS-2527 : Code of practice for fixing rainwater gutters and
down pipes for roof drainage.

5.12 Paving & Road Works

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a) IS-73 : Paving bitumen

b) IS-702 : Industrial Bitumen
c) IS-1201 : Method of testing tar and bituminous materials.
d) Practice followed by Indian Road Congress (all parts).

5.13 Earthquake Resistant Design

a) IS-1893 : Criteria for earthquake resistant design of

structures.
b) IS-4326 : Code of practice for earthquake resistant design
and construction of buildings.

5.14 Structural Steelwork

a) IS-800 : Code of practice for general construction in steel.

b) IS-802 : Code of practice for use of structural steel in
Overhead Transmission Line.
Part-I: Load and permissible stresses.
Part-II: Fabrication, Galvanising, Inspection and
Packing.
c) IS-806 : Code of practice for use of steel tubes in general
building construction.
d) IS-808 : Rolled steel beams, channels and angle sections.
e) IS-813 : Scheme of symbols for welding.
f) IS-814 : Covered electrodes for manual metal arc welding
of carbon and carbon manganese steel.
g) IS-816 : Code of practice for use of metal arc welding for
general construction in mild steel.
h) IS-817 : Code of practice for training and testing of metal
arc welders.

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i) IS-818 : Code of practice for safety and health

requirements in electric and gas welding and
cutting operation.
j) IS-819 : Code of practice for Resistance spot welding for
light assemblies in Mild Steel.
k) IS-919 : Recommendations for limits and fits for
Engineering.
l) IS-1024 : Code of practice for use of welding in Bridges and
Structures subjected to Dynamic loading.
m) IS-1161 : Steel tubes for structural purposes.
n) IS-1182 : Recommended practice for Radiographic
Examination of Fusion Welded Butt joints in steel
plates.
o) IS-1239 : Mild steel tubes, tubulars and other wrought steel
fittings (all parts).
p) IS-1363 : Black hexagonal bolts, nuts and locknuts (dia. 6
to 39 mm) and black hexagon screws (dia.6 to 24
mm). [All parts]
q) IS-1364 : Precision and semi-precision hexagon bolts,
screws, nuts and locknuts (dia. range 6 to 39
mm). [all parts]
r) IS-1365 : Slotted counter sunk head screws (dia range 1.6
to 20 mm).
s) IS-1367 : Technical supply conditions for threaded steel
fasteners.
t) IS-1443 : Code of practice for laying and finishing of
cement concrete flooring tiles.
u) IS-1608 : Method for tensile testing of steel products.
v) IS-1730 : Dimensions for steel plate, sheet and strip for
structural and general Engineering purpose.
w) IS-1731 : Dimensions for steel flats for structural and
general Engineering purposes.
x) IS-1852 : Rolling and cutting tolerances for hot rolled steel
products.
y) IS-1977 : Structural steel (Ordinary quality)
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z) IS-2016 : Plain Washers

aa) IS-2062 : Steel for General structural purposes.
bb) IS-2074 : Ready mixed paint, air drying, red oxide
zinc-chrome, priming.
cc) IS-2633 : Methods of testing uniformity of coating of zinc
coated articles.
dd) IS-3613 : Acceptance tests for wire-flux combinations for
submerged-arc welding of structural steels.
ee) IS-3664 : Code of practice for Ultrasonic Pulse echo testing
by contact and immersions methods.
ff) IS-3757 : High strength structural bolts.
gg) IS-4000 : High strength bolts in steel structures.
hh) IS-4759 : Hot dip zinc coatings on structural steel and other
allied products.
ii) IS-5334 : Code of practice for Magnetic Particle Flaw
detection of welds.
jj) IS-7215 : Tolerances for fabrication of steel structures.
kk) IS-7280 : Base-wire electrodes for sub-merged arc welding
of structural steels.
ll) IS-7318 : Approval test for welders when welding
[Part-I] procedure approval is not required.
mm) IS-8500 : Structural steel – micro-alloyed (medium and high
strength qualities).
nn) IS-9595 : Recommendation for metal arc welding of carbon
and carbon manganese steels.
oo) AWS D.1.1 : Structural Welding Code.

5.15 Painting

a) IS-348 : Specification for French polish.

b) IS-427 : Specification for Distemper, dry colour as
required.
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c) IS-428 : Specification for Distemper, oil emulsion, colour

as required.
d) IS-1477 : Code of practice for painting of ferrous metal
[I & II] in buildings.
e) IS-2338 : Code of practice for finishing of wood and
[I & II] wood based materials.
f) IS-2339 : Specification for Aluminum Paints for general
purposes in dual containers.
g) IS-2395 : Code of practice for painting concrete, masonry
and plaster surface.
h) IS-2932 : Specification for enamel, synthetic, exterior - a)
undercoating, b) finishing.
i) IS-2933 : Specification for enamel, exterior - a)
undercoating, b) finishing.
j) IS-5410 : Specification for cement paint.
k) IS 7155 : Code of recommended practice for conveyor
safety
5.16 Conveying System

a) IS 4240 : Glossary of conveyors terms and definitions.

b) IS 14188 : Conveyor system-Maintenance facilities (Design
Parameters.
c) IS 6687 : Code of practice for Selection, Storage,
Installation & Maintenance of Conveyor belting.
d) IS 11592 : Code of practice for Selection & Design of belt
conveyors.
e) IS 15427 : Conveyor belting for Elastomeric & Steel cord
construction for General Material Handling.
f) IS 8531 : Specification for Pulleys for Belt Conveyor.
g) IS 4776 : Specification for troughed Belt Conveyors.
h) IS 7155 : Code of recommended practice for conveyor
safety.

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i) IS 7403 : Code of Practice for selection of standard Worm

& Helical Gearboxes.
j) IS 8598 : Specification for Idlers & Idler Sets for Belt
Conveyors.

5.17 Electrical System

a) IS 12615 : Codes for energy Efficient Induction Motors
b) IS 13947 : Low Voltage Switchgear and Control Gear
c) IS 10118 : Code of practice for selection, installation and
maintenance of switchgear and control gear.
d) IS 900 : Code of Practice for Installation and Maintenance
of Induction Motors.
e) IS 3043 : Code of practice for Earthing.
f) IS 7098
(Part I): XLPE insulated PVC Part-I sheathed cables for
working voltages upto and including 1100V.
g) IS 1554
(Part I) :PVC insulated (heavy duty) electric cables: For
working voltages up to and including 1100V.
g) IS 5133 : Boxes for Electrical Enclosures.
h) IS 10877 : Termination Kits
i) IS 4794 : Pushbutton switches
j) IS 2309 Code of practice for the protection of buildings
and allied structures against lightning.
k) IS 8686 : Static protective Relays
l) IS 6665 : Code of practice for Industrial Lighting
m) IS 4160 : Interlocking Switch Socket Outlet
n) IS 3938 : Specification of Electric Wire Rope Hoist
o) IS 3156 : Voltage Transformers
p) IS 2705 : Current Transformers
q) IS 9224 : Specification for Low voltage Fuses
r) IS 5216 : Recommendations on safety Procedures &
practices in Electrical work

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6. TECHNICAL SCOPE & SPECIFICATION FOR CIVIL JOBS

6.1 Earthwork
6.1.1 Excavation
6.1.1.1 Excavation shall be carried out in soil of any nature and consistency, in the
presence of water or in the dry, met on the site to the lines, levels and
contours shown on the detailed drawings and Contractor shall remove all
excavated materials to soil heaps on site or transport for use in filling on the
site or stack them for reuse as directed by the Owner / Consultant.
6.1.1.2 Surface dressing shall be carried out on the entire area occupied by the
buildings including plinth protection as directed without any extra cost. The
depth of excavation shown on the drawings are the depths after surface
dressing.
6.1.1.3 The site around all buildings and structures to a width of 3 metres beyond
the edge of plinth protection, ramps, steps, etc., shall be dressed and sloped
away from the buildings.
6.1.1.4 Black cotton soil, and other expansive or unsuitable soil excavated shall not
be used for filling in foundations, and plinths of buildings or in other
structures including manholes, septic tanks etc., and shall be disposed of
within the plant area, as directed, by the Engineer In-charge.
6.1.1.5 In case of trenches exceeding 2.0 metres depth or where soil is soft or
slushy, the sides of trenches shall be protected by timbering and shoring.
The Tenderer shall be responsible to take all necessary steps to prevent the
sides of trenches from caving in or collapsing. The extent and type of
timbering and shoring shall be as directed by the Owner/Consultant.
6.1.1.6 Where the excavation is to be carried out below the foundation level of
adjacent structure, the precautions to be taken such as under pinning,
shoring and strutting etc., shall be determined by Owner/Consultant. No
excavation shall be done unless such precautionary measures are carried
out as per directions of Owner/Consultant.

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6.1.1.7 Specification for Earth work shall also apply to excavation in rock in general.
The excavation in rock shall be done such that extra excavation beyond the
required width and depth as shown in drawings is not made. If the
excavation done in depth greater than required / ordered. The Contractor
shall fill the extra excavation with concrete of mix 1:5:10 as the foundation
concrete at his own cost.
6.1.1.8 The Contractor shall make all necessary arrangements for
dewatering/defiling as required to carry out proper excavation work by
bailing or pumping out water, which may accumulate in the excavation pit
from any cause / source whatsoever.
6.1.1.9 Contractor shall provide suitable draining arrangements at his own cost to
prevent surface water entering the foundation pits from any source.

6.1.10 The Contractor is forbidden to commence the construction of structures or to

carry out concreting before Owner/Consultant has inspected, accepted and
permitted the excavation bottom.

6.1.11 Excavation in disintegrated rock means rock or boulders including brickbats

which may be quarried or split with crow bars. This will also include laterite
and hard conglomerate.

6.1.12 Excavations in hard rock - meant excavation made in hard rock to be done
manually, or by blasting using only explosives and / or pneumatic hammers.
In case of blasting, control blasting should be adopted depending on site
conditions. For using explosives, Contractor shall follow all provisions of
Indian Explosive Act/Rules 1983, corrected/ revised up to date.

6.1.13 In case of hard rock excavation to be carried out using explosive the
Contractor shall obtain the written approval in advance.

6.1.2 Filling

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6.1.2.1 Back filling of excavations in trenches, foundations and elsewhere shall

consist of one of the following materials approved by Owner / Consultant.
i) Soil
ii) Sand
iii) Moorum
iv) Hard core
v) Stone / Gravel
All back filling materials shall be approved by the Owner /Consultant.

6.1.2.2 Soil filling - Soil material shall be free from rubbish, roots, hard lumps and
any other foreign organic material. Filling shall be done in regular horizontal
layers each not exceeding 20 cm. Depth.

6.1.2.3 Back filling around completed foundations, structures, trenches and in plinth
shall be done to the lines and levels shown on the drawings.

6.1.2.4 Back filling around pipes in the trench shall be done after hydro testing is
done.

6.1.2.5 Back filling around liquid retaining structures shall be done only after leakage
testing is completed and approval of Owner / Consultant is obtained.

6.1.2.6 Sand used for filling under foundation concrete, around foundation and in
plinth etc., shall be fine / course, strong, clean, free from dust, organic and
deleterious matter. The sand filling under foundation shall be rammed with
Mechanical compactor. Sand material shall be approved by Owner /
Consultant.

6.1.2.7 Moorum for filling, where ordered, shall be obtained from approved pits and
quarries which contain siliceous material and natural mixture of clay. Moorum

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shall not contain any admixture of ordinary earth. Size of Moorum shall vary
from dust to 10 mm.

6.1.2.8 Hard-core shall be of broken stone of 90 mm to 10 mm size suitable for

providing a dense and compact sub grade. Stone shall be sound, free from
flakes, dust and other impurities. Hard core filling shall be spread and
levelled in layers of 15 cm. thick, watered and well compacted with ramming
or with mechanical/hand compact including hand packing wherever required.

6.2 Plain & Reinforced Concrete Work

This specification deals with cement concrete, plain or reinforced, for general use, and
covers the requirements for concrete materials, their storage, grading mix design,
strength and quality requirements, pouring at all levels, reinforcements, protection, curing,
form work, finishing, painting, admixtures, inserts and other miscellaneous works.

6.2.1 Materials
6.2.1.1 Cement: Any of the following cements may be used as required.
IS: 269 Ordinary Portland Cement, 33 Grade.
IS - 455Portland Slag Cement.

IS - 6909 Specifications for Super Sulphate cement.

IS - 8041 Rapid Hardening Portland Cement.

IS - 8112 43 Grade Ordinary Portland cement.

IS - 12330 Sulphate Resistant Ordinary Portland cement.

IS - 12269 53 Grade Ordinary Portland cement.

6.2.1.2 Water: Water used for mixing and curing concrete and mortar shall conform
to the requirements as laid down in clause 4.3 of IS: 456. Sea-water shall
not be used for concrete work.

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6.2.1.3 Aggregates : Coarse and fine aggregates for cement concrete plain and
reinforced shall conform to the requirements of IS : 383 and / or IS : 515.
Before using, the aggregates shall be tested as per IS: 2386.

6.2.1.4 Coarse aggregate: Coarse aggregate for all cement concrete work shall be
broken or crushed hard stone, black trap stone obtained from approved
quarries or gravel.

6.2.1.5 Sand: Fine aggregate for concrete work shall be coarse sand from
approved sources. Grading of coarse sand shall be within grading zones I, II
or III laid down in IS: 383, table-4. If required the aggregates (both fine and
coarse) shall have to be thoroughly washed and graded as per direction of
Owner / Consultant.

6.2.2 Mixing
Design mix Concrete from batching plant set up by contractor will only be
allowed for RCC as well as PCC work. Hand mixing will not be allowed in
any circumstances.

6.2.3 Water Cement Ratio

Once a mix, including its water-cement ratio, has been determined and
specified for use by the Owner / Consultant, that water cement ratio shall
be maintained.

6.2.4 Laying
Concreting shall be commenced only after the Owner /Consultant has
inspected and passed the sub-base / base or the centering, shuttering and
reinforcement. Concrete in slab, beams, columns, footings etc., shall be laid
gently in layers not exceeding 15 cm and shall be properly consolidated by
means of approved mechanical vibrators.

6.2.5 Curing
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i) After the concrete has begun to harden, it shall be protected with moist
gunny bags, sand or any other material approved by the Owner
/Consultant against quick drying. After 24 hours of laying concrete, the
surface shall be cured by flooding with water or by covering with wet
absorbent materials for 7 days as per the direction of Owner /
Consultant.
ii) Approved curing compounds may be used in lieu of moist curing with
the permission of the Owner /Consultant. Such compounds shall be
applied to all exposed surfaces of the concrete as soon as possible
after the concrete has set. No extra payment shall be made for the
same.

6.2.6 Grades of Concrete

6.2.6.1 Grades of Cement concrete shall be as given below:

Grade Specified Characteristic compressive strength at 28 days

(N / mm2)

1. M - 7.5 07.5 ( 75 Kg / cm2 )

2. 10.0 ( 100 Kg / cm2 )

M - 10
3 15.0 ( 150 Kg / cm2 )
M - 15
4. 20.0 ( 200 Kg / cm2 )
M - 20
5. 25.0 ( 250 Kg / cm2 )
M - 25
6. 30.0 ( 300 Kg / cm2 )
M – 30
7 35.0 ( 350 Kg / cm2 )
M - 35

6.2.6.2 Grades lower than M-15 shall not be used in reinforced concrete.

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6.2.6.3 M-7.5 grades of concrete may be used for lean concrete bases and simple
foundation for masonry walls.

6.2.6.4 A sieve analysis test of aggregates shall be carried out as and when the
source of supply is charge without extra charge notwithstanding the
mandatory test required to be carried out as per CPWD Specification.

6.2.6.5 All test in support of mix design shall be maintained as a part of records of
the contract. Test cubes for mix design shall be prepared by the Contractor
under his own arrangements and at his costs, but under the supervision of
the Owner / Consultant.

6.2.7 Design Mix Concrete

6.2.7.1 Design mix shall only be allowed for all concrete works where it is
contemplated to be used by installing weigh batch mixing plant as per IS-
4925. At the time of tendering, the Tenderer, after taking into account the type
of aggregates, plant and method of laying he intends to use, shall allow in his
tender for the design mix i.e., aggregate/cement and water/cement ratios
which he consider will achieve the strength requirements specified, and
workability for concrete, to be properly furnished.
6.2.7.2 Soon after the Tenderer gets L.O.I. to commence the work, he shall carry out
preliminary tests for design mix on trial mixes proposed by him in design of
mix to satisfy the Owner/ Consultant that the characteristic strength specified
in clause 3.6.1 is obtained. Prior to this, the Contractor has to get design mix
done as per IS : 10262 through Government approved / reputed institute and
the Contractor shall arrange the same at his own cost. The concrete mix to be
actually used shall be approved by the Owner / Consultant.

6.2.7.3 Notwithstanding the above, the following shall be the maximum combined
weight of coarse and fine aggregate per 50 Kg of cement.

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Sl. Grade of Maximum weight of the fine and coarse aggregate

No. Concrete together per 50 kg of cement (for nominal mix only).

1. M - 10 480 kg.

2. M - 15 350 kg.

3. M - 20 250 kg.

6.2.7.4 The workability of concrete produced shall be adequate, so that the concrete
can be properly placed and compacted. The slump shall be as follows, when
vibrators are used.

Sl. No. Type of Concreting Slump

1. Mass concrete in R.C.C. foundations and 10 to 25 mm

retaining walls.
2. Beams, slabs and columns simply reinforced. 25 to 40 mm

3. Thin RCC sections or sections with congested 40 to 50 mm

reinforcement.

6.2.7.5 The minimum consumption of the cement irrespective of design mix shall not
be less than the following:
Grade of
SL. No. Minimum consumption of Cement.
Concrete.

1. M - 7.5 ( 1 : 4 : 8 ) 170 Kg / C.um.

2. M - 10 ( 1 : 3 : 6 ) 220 Kg / C.um.

3. M - 15 300 Kg / C.um.

4. M - 20 350 Kg / C.um.

5. M -25 380 Kg / C.um.

M -30 400 Kg / C.um.

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6.

6.2.8 Testing of Concrete

6.2.8.1 Testing of concrete, sampling and acceptance criteria shall be in accordance

with Clauses 14 and 15 of IS: 456.

6.2.8.2 A slump test shall be taken at each mixer at least once in every fifty batches
mixed. Any batch for which a slump test is being made shall not be
transferred to the place of laying until the slump test has been completed. Any
batch which gives a slump in excess of that described at the time of
preliminary tests shall be rejected and removed from the site.

6.2.8.3 At least six cubes shall be taken for every 30 Cu.m. metres of concrete or part
thereof deposited in the work on any day. Three cubes shall be tested for 28
days strength.

6.2.8.4 If a test for particular work does not meet the specified requirements, the
Owner / Consultant in his absolute discretion may accept the work at a
correspondingly reduced rate provided the average strength at 28 days is not
less than 85% of the specified strength.

6.2.8.5 If the results are poorer than 85% of the specified strength, the Owner /
Consultant may order further testing of any kind as may be deemed
necessary in his opinion, including load tests. The load tests shall be carried
on the portion of the structure involving concrete represented by the
unsatisfactory works test and such other adjoining elements of a building as
the Owner / Consultant may decide.

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If the results of the load tests are not satisfactory, the Contractor shall at his
own cost undertake remedial measures including dismantling and
reconstruction according to the directions and to the satisfaction of the Owner
/ Consultant. If the load test is successful, the Owner/ Consultant may
exercise his judgement before accepting or rejecting the work and shall still
have the power to apply a reduction in rate as herein stated before, in case
the work in question is accepted.

6.2.9 Proportioning
Mixes of cement concrete shall be as ordered. Where the concrete is
specified by grade, it shall be prepared by mixing cement, sand and coarse
aggregate by weight as per mix design. In case the concrete is specified as
volumetric mix, then dry volume batching shall be done, making proper
allowances for dampness in aggregate and bulking in sand. Equivalent
volume batching for concrete specified by grade may however be allowed by
the Owner / Consultant at his discretion.

6.2.10 Precast Concrete

The specifications for precast concrete will be similar as for the cast-in-situ
concrete. All precast work shall be carried out in a yard made for the
purpose. This yard shall be dry, properly levelled and having a hard and
even surface. If the ground is to be used as a soft former of the units, shall
be paved with concrete or masonry and provided with a layer of plaster ( 1:2
proportion ) with smooth neat cement finish or a layer of M.S. sheeting. The
casting shall be over suitable vibrating tables or by using form vibrators as
per directions of Owner / Consultant. The yard, lifting equipment, curing
tank, finished material storage space etc, shall be designed such that the
units are not lifted from the mould before 7 (seven) days of curing and can be
removed for erection after 28 (Twenty Eight) days of curing. The moulds
shall preferably be of steel or of timber lined with G.I. sheet metal. The yard
shall preferably be fenced. Lifting hooks, wherever necessary or as directed

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by Owner/Consultant shall be embedded in correct position of the units to

facilitate erection, even though they may not be so on the drawings and shall
be burnt off and finished after erection. Precast concrete units, when ready
shall be transported to site by suitable means approved by
Owner/Consultant. Care shall be taken to ensure that no damage occurs
during transportation. All adjustments, levelling and plumbing shall be done
as per the instructions of the Owner /Consultant. The Contractor shall
render all help with instruments, materials and staff to the Owner /
Consultant for checking the proper erection of the precast units. After
erection and alignment the joints shall be filled with grout or concrete as
directed by Owner / Consultant. If shuttering has to be used for supporting
the precast unit they shall not be removed until the joint has attained
sufficient strength and in no case before 14 (fourteen) days. The joint
between precast roof planks shall be pointed with 1:2 (1 cement: 2 sand)
mortar where called for in the drawings.

6.2.11 Protection of Concrete

All concrete shall be protected from damaged by rain or by workmen,
equipment, overload or any other causes. All edges, corners and projections
of concrete members likely to be damaged, shall be protected by means of
wooden cover fillets.

6.2.12 Construction Joints

Construction joints shall be made only where shown on the drawings or as
approved by the Owner / Consultant. The procedure given in Clause 12.4 of
IS: 456 shall be followed for general guidance.

6.2.13 Separation joints

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Separation joint shall be obtained by using an approved alkathene sheet

struck on the surface against which concrete shall be placed. Adequate care
should be taken to cause no damage to the sheet.

6.2.14 Damp Proof Course

Damp proof course shall consist of cement concrete or R.C.C. of specified
proportions and thickness. Surface of brick or stone masonry shall be levelled
and prepared before laying the cement concrete.

6.2.15 Sampling of Concrete

Sampling and strength Test of concrete. Acceptance criteria and Inspection
and Testing of Structure: These shall be as per the requirements laid down in
clause Nos. 14, 15 and 16 of IS: 456.

6.3 Steel Reinforcement

6.3.1 Steel reinforcement shall comprise:

i) Cold twisted bars conforming to IS: 1786.
ii) Hard drawn steel wire fabric confirming to IS:432,Part-I
iii) Cold twisted bars confirming to IS:1786
iv) TMT bars

6.3.2 All joints in reinforcement shall be lapped adequately to develop the full
strength of the reinforcement, unless reinforcement are as per provision of IS:
456 as per instruction of Owner /Consultant.
Following procedure shall be followed for welding of Tor steel reinforcement
bars:
i) Welding of Tor steel reinforcement bars shall be taken up only after
specific approval by Owner / Consultant.
ii) Lap welding with longitudinal beads shall only be adopted.

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iii) Thickness of weld bead should be 0.2 x diameter of bar and the length
of the longitudinal bead required shall be 10 x diameter of bar, however,
the maximum length of continuous bead shall be limited to 5 x diameter
of bar with intermediate gap. When welding is done on both sides bead
length shall be 5 x diameter of bar on each side.
iv) Stripper at closer spacing shall be provided in the lap welded joints as
directed by Owner / Consultant.

6.3.3 M.S. round bars shall be hooked at ends as specified. Ribbed Tor-steel shall
be bent at right angles at ends as indicated or directed.

6.4. Form Work

6.4.1 The shuttering or form work shall conform to the shape, lines and dimension
as shown on the drawings and be so constructed as to remain sufficiently
rigid during placing and compacting of the concrete and shall be sufficiently
tight to prevent loss of liquid from the concrete. The surface that becomes
exposed on the removal of forms shall be examined by Owner / Consultant
or his authorised representative before any defects are made good. Work
that has sagged or bulged out or contains honey combing, shall be rejected.
All shuttering shall be plywood or steel shuttering.

6.4.2 The vendor shall be responsible for sufficiency and adequacy of all form
work. Centering and form work shall be approved by the Owner/Consultant,
before placing of reinforcement and concreting.

6.4.3 Stripping Time

Form shall not be struck until the concrete has reached a strength at least
twice the stress to which the concrete may be subjected at the time of
removal of form work. The strength referred to shall be that of concrete using
the same cement and aggregates, with the same proportions and cured

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under conditions of temperature and moisture similar to those existing on the

work. Where possible, the form work shall be left longer as it would assist the
curing.

Note: In normal circumstances and where Ordinary Portland Cement is used

forms may generally be removed after the expiry of the following
periods:

SL. NO. I T E M S PERIOD

1. Walls, columns and vertical faces of 24 to 48 hours as may be

all structural members. decided by the
Owner / Consultant.

2. Slabs ( props left under ) 3 days.

3. Beam soffits ( Props left under ) 7 days.

4.
Removal of props under slab
i). Spanning up to 4.5 m
7 days.
ii). Spanning over 4.5 m
7 days.
5. Removal of props under beams and
arches.
i). Spanning up to 6.0 m 14 days.
ii). Spanning over 6.0 m 21 days.

For other types of cements, the striping time recommended for ordinary
Portland Cement may be suitably modified.

6.5 Brick Work

6.5.1 Bricks

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All bricks shall conform to class 75 as designated in CPWD Specifications unless

specified otherwise. Flyash bricks may be used with approval of specification & test
reports.

6.5.2 Mortar
6.5.3 Cement and water shall conform to the requirements laid down for cement
concrete work.

6.5.4 Sand for masonry mortar shall be coarse sand conforming to IS: 2116.
Maximum quantities of clay, fine dust shall not be more than 5% by weight.
Organic impurities shall not exceed the limits laid down in IS: 2116.

6.5.5 Mixing of mortar shall be done a mechanical mixer. When quantity involved is
small, hand mixing may be permitted by the Owner / Consultant. Any mortar
remaining unused for more than 30 minutes after mixing shall be rejected.

6.5.6 Brick Masonry

Brick work shall be built in English bond, unless otherwise specified. The
thickness of joints shall be 10 mm ± 3 mm. Thickness of joints shall be kept
uniform. In case of foundations and manholes etc. joints up to 15 mm may be
accepted.

6.5.7 Half Brick Masonry

All courses shall be laid with stretchers. Reinforcement comprising 2 Nos.
6.0 mm dia. M.S. bars shall be provided over the top of the first course and
thereafter at every third course.

6.5.8 Laying
All iron fixtures, pie spouts, hold fasts of doors and windows, which are
required to be built into the wall shall be embedded in cement concrete
blocks 1: 2: 4 (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm

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nominal size) 150 mm x 100 mm x 100 mm size unless otherwise indicated

in the item.

6.5.9 Curing
Brick work shall be protected from rain by suitable covering when the mortar
is green. Masonry work shall be kept constantly moist on all faces for a
minimum period of seven days.

6.5.10 Cement Concrete Block

Cement concrete block shall be machined made in the proportion of such
that mix. shall not be leaner than one cement to twelve combined aggregates
(by volume) but having minimum strength of M-7.5. Combined aggregate
shall be graded as near as possible to IS: 383. The fineness modules of
combined aggregate shall be between 3.6 and 4. The concrete block shall be
properly cured as per IS: 456. The surface of concrete block shall have even
face without any honey-comb and free from cracks.

6.5.10.1 Mortar
Cement and water shall confirm to the requirements laid down for cement
concrete work.

6.5.10.2 Sand for concrete block masonry mortars shall be coarse sand generally
conforming to IS: 2116. Maximum quantities of clay, fine dust, shall not be
more than 5% by weight. Organic impurities shall not exceed the limits laid
down in IS: 2116.

6.5.10.3 Mix of mortar for building concrete block shall be as specified in the item of
work.

6.5.10.4 Mixing of the mortar shall be done in a mechanical mixer. When quantity
involved is small hand mixing may be permitted by Owner / Consultant. Any

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mortar remaining unused for more than 30 minutes after mixing shall be
rejected.

6.5.11 Concrete Block Masonry

The thickness of joints shall be 10 mm ± 3 mm. Thickness of joints shall be
kept uniform. In case of foundation and manholes etc., joints up to 15 mm
may be accepted.

6.5.12 Half Concrete Block

All courses shall be laid with stretchers. Reinforcement comprising 2 Nos. 6
mm dia. M.S. bars shall be provided over the top of the first course and
thereafter at every fourth course.

6.5.13 Laying

All iron fixture, pipes spouts, hold fasts of doors and windows which are
required to be built into the wall shall be embedded in cement concrete blocks
1: 2: 4 mix ( 1 cement: 2 coarse sand : 4 graded stone aggregate 20 mm
nominal size ) 150 mm x 100 mm x 100 mm size unless otherwise indicated
in the item.

6.5.14 Curing
Concrete block masonry shall be protected from rain by suitable covering
when mortar is green. Masonry work shall be kept constantly moist on all
faces for minimum period of seven days.

6.6 FLOORING & PAVING

6.6.1 Sub base of Floor

6.6.1.1 The area to be paved shall be divided into suitable panels. Form work shall
be provided. The boarding / battens shall be fixed in position with their toe at

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proper level, giving slope where required. Alternatively base concrete may be
deposited in the whole area at a stretch.

6.6.1.2 Before placing the base concrete the sub-base shall be properly wetted and
rammed. The concrete of the specified mix shall then be deposited between
the forms where provided, thoroughly tamped and the surface finished level
with the top edge of the forms. The surface of base concrete shall be spread
uniformly. The surface shall be finished rough to provide adequate bond for
the topping. Two or three hours after concrete has been laid the surface shall
be brushed with wire brush to remove any scum or latinate and swept clean
so that coarse aggregate is exposed.

6.6.2 Cement Concrete Floor Finish

6.6.2.1 The surface of base concrete shall be thoroughly cleaned by scrubbing with
coir or steel wire brush. Before laying the topping, the surface shall be
soaked with water at least for 12 hours and surplus water mopped up
immediately before the topping is laid.
6.6.2.2 The forms shall be fixed over the base concrete dividing into suitable panels.
Where glass dividing strips are provided, thickness of glass dividing strips
shall be 4 mm or as indicated. Before placing the concrete topping, neat
cement slurry at the rate of 2 Kg/Sq.m. shall be then thoroughly brushed
into the base concrete just ahead of the finish. The topping shall then be laid,
thoroughly compacted by using screed board/plate vibrator. The surface
floated with a wooden float to a fair and even surface shall be left for some
time till moisture disappears from it. Junctions with skirting / dado on wall
surfaces shall be rounded off using cement mortar 1:2. Curing shall be
carried out for a minimum of 7 days.

6.7 Plastering
6.7.1 Sand for plastering shall be 50% fine sand and 50% coarse sand from
approved sources.

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6.7.2 Preparation of surface shall be done as per CPWD Specifications.

6.7.3 Cement mortar shall be of the mix as indicated in the items and shall be
mixed as specified in the CPWD Specifications.
6.7.4 Joints in walls etc., shall be raked to a depth of 12 mm, brushed clean with
wire brushes dusted and thoroughly washed before starting the plaster work.
6.7.5 The surface shall be thoroughly washed with water cleaned and kept wet to
saturation point before plastering is commenced.
6.7.6 Cement mortar as indicated, shall be firmly applied to the masonry walls in a
uniform layer to the thickness specified and will be pressed into the joints. On
concrete surfaces rendering shall be dashed to the roughened surface to
ensure adequate bond. The surface shall be finished even and smooth.
Hectoring wherever required shall be done as per directions of Owner /
Consultant. Nothing extra shall be paid on this account.
6.7.7 All plaster work shall be cured for at least 7 days.
6.7.8 Integral water proofing compound shall be mixed with cement in the
proportion recommended by the manufacturer. Care shall be taken to ensure
that the water proofing material gets well and integrally mixed with cement.
All other operations are the same as for general plaster work.
6.7.9 For sand face plaster, undercoat of cement plaster 1:4 (1 cement: 4 sand) of
thickness not less than 12 mm shall be applied similar to one coat plaster
work. Before the under coat hardens the surface shall be scared to provide
for the top coat. The top coat also of cement mortar 1:4 shall be applied to a
thickness not less than 8 mm and brought to an even surface with a wooden
float. The surface shall then be tapped gently with a wooden float lined with
cork to retain a coarse surface texture, care being taken that the tapping is
even and uniform.

6.8 WHITE & COLOUR WASHING AND CEMENT PAINTING

6.8.1 White Washing

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6.8.1.1 Where white wash is indicated, 3 coats of white wash shall be applied. The
surface shall present a smooth and uniform finish.

6.8.1.2 White wash shall be prepared from lime slaked at site and mixed and stirred
with 5 litres of water for 1 Kg. of unslaked lime to make a thin cream. The
cream shall be screened through a clean, coarse cloth and suitable adhesive
such as DDL or equivalent as per manufacturer specification shall be added.
About 1.3 Kg of sodium chloride in hot water shall also be added for every 10
Kg. Of lime for making the coat hard and rule resistant. Indigo shall also be
mixed @ 3 gm/Kg of lime. Each coat shall be allowed to dry before next coat
is applied. When dry the wash should show no sign of cracking, one coat
consists of application with brushes in horizontal stroke followed by vertical
stroke.

6.8.2 Colour Washing

6.8.2.1 Where colour wash is indicated one coat of white wash and two coats of
colour of tints approved by the Owner / Consultant shall be applied. Dados
and skirting shall not be white washed, colour washed or distempered or
painted.

6.8.2.2 Only colour stainer of approved brand not affected by lime. Shall be added to
colour wash. Indigo (Neel) shall, however, not be added in colour wash.

6.8.2.3 The colour wash shall be applied as described for white wash. After the
surface has been prepared the first primary coat shall be of white wash.
Minimum two coats of colour wash shall then be applied. The entire surface
shall present a smooth and uniform finish of even tint or shade.

6.8.3 Distempering
6.8.3.1 Where distempering is required, two coats of distemper oil emulsion or dry
distemper over a priming coat as specified in the item shall be applied. Each

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coat of distemper shall be approved by the Owner /Consultant before next

coat is applied.
6.8.3.2 Distemper oil emulsion shall be as per IS: 248 of approved brand and
manufacture. The distemper shall be diluted with water or a prescribed
thinner in the proportion of 4 parts of paste by weight to one part of cold
water or in the proportion specified by the manufacturer, which shall be
invariably followed.

6.8.3.2 The surface to be distempered shall be cleaned of dust, dirt, chalking and
other foreign matter. All cracks, holes and surface defects shall be repaired
with gypsum to give a smooth surface, and papared and wiped clean. The
surface shall then be rubbed down again with sand paper and made smooth.
The surface thus prepared shall be given a coat of alkali resistant priming
paint conforming to IS: 109, or any other primer as specified by the
manufacturer and allowed to dry at least for 48 hours.

6.8.3.3 Dry distemper shall be of approved make and shade conforming to IS : 427
and shall be prepared as per manufacturer’s specification. The surface to be
distempered shall be cleaned of dust, dirt, chalking and other foreign matter.
All cracks, holes and surface defects shall be repaired with gypsum to give a
smooth surface, and papered and wiped clean. The surface shall then be
rubbed down again with sand paper and made smooth. The surface thus
prepared shall be given a coat of alkali resistant, priming paint conforming to
IS: 109, or any other primer as specified by the manufacturer and allowed to
dry at least for 48 hours.

6.8.3.4 After the primer coat has dried for at least 48 hours, the surface shall be
lightly sand papered to make it smooth for receiving the distemper, taking
care not to rub cut the priming coat and then dusted off. Prepared distemper
shall then be applied with brushes in horizontal strokes followed immediately
by vertical ones which together constitute one coat.

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6.8.3.5 Subsequent coats shall be applied in the same way, with time intervals of at
least 24 hours between consecutive coats.

6.8.3.6 A uniform finished surface without patches, brush marks, or distemper drops
shall be obtained.

6.8.4 Cement Painting

6.8.4.1 Cement paint shall comply with IS: 5410 specification for cement paint of
colour as required.

6.8.4.2 Where shown on drawings for external surfaces of sand faced plaster, or any
other surface, two coats of cement paint shall be applied of tint and shade as
approved by the Owner / Consultant.

6.8.4.3 On external plastered surfaces, sand faced or plain plastered and concrete
surfaces, cement paint shall be vigorously scrubbed on to work the paint into
the voids and provide a continuous paint film free from pin holes and other
openings. Curing shall be done between the coats and for at least 2 days
following the final coat.

6.9 PROTECTIVE COATING AND LINING SYSTEM

6.9.1 Application of Brick Layers

For laying of bricks on horizontal surface, a bedding mortar of 5 mm thick K-
based silicate cement must be laid in parallel strip of maximum 1.0 m width.
Bricks must be laid down leaving space of about 5 mm. This has to be
followed by 5 mm wide K-based silicate cement jointing for full depth of brick
and to be finished by 20 mm deep pointing with phenolic based cement. For
vertical surface lining, it is preferable to apply the mortar by trowel on back

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side of brick. Setting of lining takes place in approximately 1 - 7 days and

during this time it is necessary to keep the bricks undisturbed.

6.9.2 Acid Proof Brick Lining: 65 mm thick acid resisting bricks may be used if
required.

6.9.3 Waterproofing of RCC Tunnel for Conveyor 103-D:

In RCC works, the waterproofing of Tunnel is very important as no leakage
or seepage of water from ground or rocks is permitted for operation as well
as design point of view. Penetration of water in RCC works causes porosity &
due to shrinkage in concrete cracks develop in concrete & corrosion of steel
occurs which affects structural safety, durability & stability. For underground
tunnel care shall be taken for water proofing treatment from positive side of
wall / base of UG tunnel as per applicable codes & standards mentioned in
clause no.5 of this document. Any expansion joint / construction joint is
provided during construction in U/G tunnel, proper treatment as per sound
engineering practices shall be adopted during construction stage.

6.10 PVC PALRUF SHEETING & CLADDING

Complete supply & application of “PALRUF” make high impact corrugated
sheet, along with suitable dimension close fitting adjustable Ridges & Corner
Flashings shall be considered for the roofs & sides of storage shed, monitor
area, conveyor galleries, Maintenance towers, Transfer towers .

Detail specification for supply & application of PALRUF sheets shall be as

follows
6.10.1 All high Impact corrugated sheet shall be suitable for installation on roof of
the Rock Phosphate storage shed at an inclined angle as per design of the
silo roof.

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6.10.2 High Impact PVC sheet should have chemical resistance to corrosive
chemical environment like acids, alkalis, fluorine gas, SO3 gas, SO2 gas,
rock phosphate dust, sulphur dust etc.
6.10.3 High Impact PVC sheet should have resistance to high humid coastal
environment.
6.10.4 High Impact PVC sheet should be able to sustain the wind load of 110
kg/cm2.
6.10.5 High Impact PVC sheet should have low thermal insulation property.
6.10.6 High Impact PVC sheet should have UV resistance for at least 10 years.
6.10.7 High Impact PVC sheet should be Fire retardant and meets the highest
standards.
6.10.8 Material shall be supplied in Beige Color.
6.10.9 10 years warranty on the product & relevant certificate from the OEM shall
be obtained & submitted to IFFCO
6.10.10 The fixing screws (SS 410) & washers (SS 304) shall be supplied along with
washer (EPDM rubber moulded).
6.10.11 MOC of fixing screw with washer shall be SS410 of Hilti make. For any other
make screws, except Hilti make, prior approval have to be taken from
IFFCO.
6.10.12 IFFCO shall check the MOC of supplied screws by Alloy Analyser & the
rejected materials will be replaced by the vendor free of cost within stipulated
time frame.

6.10.13 Size of sheets to be fixing as per the site requirement, no excess over
lapping should be allowed or the cutting of sheets to bring as site
requirement not allowed.
6.10.14 Utmost safety has to be adhered during installation of the PALRUF sheeting
job. Cat Ladder or Roof Ladder should be made use of while laying sheets or
working on the roof, to ensure safety to the workmen. Further, life line and
safety belts shall be used while working on the roof. Cat ladders shall cover
at least three spans between purling and cross pieces shall not project at the

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edges of the purlin. Walking or working directly on the sheets may cause
cracks and sheet failure, leading to serious accidents which shall be strictly
adhered to. It shall be the responsibility of party to follow all safety norms and
all safety equipment required for carrying out the work and will be the full
responsibility of the party.
6.10.15 The Contractor shall deploy skilled and well trained workforce / labours with
supervisor(s) who have sufficient experience in sheeting work. They have to
obtain necessary height pass before undergoing a technical training
regarding for fixing of AC sheets. Only certified and qualified persons having
height pass will be allowed for Gate Entry. Hence, any violation in fixing of
sheets thereafter shall be levied on penalty as per direction of IFFCO.

7. TECHNICAL SPECIFICATIONS FOR STEEL STRUCTURES

This section covers the technical requirements for design, engineering,

supply, fabrication, blasting, painting and erection of all structural steel, rolled
sections, built up sections, plates, gratings, hand railings, toe guards & any
other miscellaneous steel required for the construction of proposed Rock
phosphate Silo-D along with all ancillary systems.

7.2 Specification & Design requirements

It is not the intent to specify completely herein all details of supply, erection
of ‘structural steel work’. However, the materials and services shall conform
in all respects to the relevant latest IS standards and be capable of
performing in continuous commercial operation in a manner acceptable to
the IFFCO.

7.2.1 Specifications and design drawings for structural-steel structures consisting

of plans, elevations, sections and details which define completely the
structure(s) requirements including, but not limited to, dimensions,
elevations, member sizes/weights, extent of fireproofing, location of
fixed/removable handrails, stairs, ladders, equipment framing/floor cut-outs,

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type(s) of flooring, hoist/crane, equipment support connection, member

forces/reactions/moments and column anchor bolts to permit a structural
steel fabricator to design, detail and prepare shop drawings, supply and
fabricate the structural steel structures.

7.2.2 Dead, live, wind, earthquake, thermal & other relevant load calculations shall
be considered for design of steel structural.

7.2.3 Detailed design calculations for each item with design assumptions if any,
design parameters, loads/forces and references to section of the
Code/Standard on which the designs are based shall be submitted for review
of client or vetting by client’s appointed consultancy/design organisation .

7.2.4 Structural steel materials shall conform to IS 2062 with a minimum yield
strength of 36000 psi, and designed in accordance with IS.

7.2.5 Minimum section sizes shall be considered as follows for designing of

structural members
i) ISA 65X65X8 mm
ii) ISMB 125X65X8 mm
iii) ISMC 125X65X8 mm

7.2.6 Where required, for safety, structural steel support columns shall be fire
proofed. The fire retardant coating/insulation shall be suitable for one hour
rating.

7.2.7 The structure shall be designed/detailed to assist in maintaining the structure

throughout its life. Any areas that may give rise to moisture or dirt traps shall
be eliminated, if possible. Structural form and details shall be selected to
ensure that all surfaces are readily acceptable for future painting etc.

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7.2.8 Design drawings for each structural building are required. The design
drawings shall consist of plans, elevations, erections and details which define
completely the building designs, forces and member sizes/weights to permit
a structural steel fabricator to calculate design stresses and detail, supply
and fabricate the building structural steel requirements.

7.2.9 In general all connections should be of bolted type to facilitate

erection/maintenance of equipment, piping etc.

7.2.10 Except in specific locations to be determined by owner, all platforms

should be of galvanized MS grating. The grating planks should have hot dip
galvanization coating of thickness 100 microns minimum. Grating should
be fixed with supporting structural beam by using necessary G.I. clamp/ clip.
7.2.11 For design of steel structures 1 mm corrosion margin should be kept.

7.2.12 The steel section sizes shall be as mentioned in design specification. The
bolts to be used for connection should be of class 4.6 or 8.8.
Manufacturers test certificate shall be submitted to the OWNER, when
asked for. For bolted joints, shanks and threaded bolts should be used
and it should be ensured that to achieve adequate shearing and bearing
values, the threaded length do not encroach the thickness of
connected members of dimension beyond the following limit:

1.5 mm for connected members of thickness below 12 mm

2.5 mm for connected members of thickness 12 mm and above

Nuts, lockouts, washers should be as per relevant standards.

7.3 Fabrication

7.3.1 Fabrication of steel structure shall be carried out in conformity with the best
modern practices and with due regard to speed with economy in fabrication
and erection and shall conform to IS: 800. All members shall be so fabricated
as to assemble the members accurately on site and erect them in correct
positions. Before despatch to site the components shall be assembled at

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shop and any defect found shall be rectified. All members shall be free from
kind, twist, buckle, bend, open joints etc., and shall be rectified before
erecting in position. Failure in this respect will subject the defective members
to rejection.

7.3.2 Fabrication and erection drawings shall be prepared by the Contractor on the
basis of design drawings to be issued to the Contractor in stages. These
drawings shall be prepared by the Contractor or by an agency approved by
the Owner / Consultant.

7.3.3 Fabrication drawings shall be thoroughly checked, stamped “checked” and

signed by the Contractor’s own responsible Engineer irrespective of the fact
that such drawings are prepared by the Contractor or an approved agency,
to ensure accuracy and correctness of the drawings. Unchecked or unsigned
drawing shall not be submitted to Owner/ Consultant for approval.

7.3.4 Fabrication drawings duly checked by the Contractor shall be submitted to

the Owner / Consultant for checking and approval within 30 days from receipt
of design drawings.

7.3.5 The approval accorded by Owner / Consultant on fabrication drawings shall

not relieve the Contractor of the responsibility of fabricating and erecting safe
and technically sound steel structures as per design drawings.

7.3.6 Fabrication drawings shall be drawn to a suitable scale large enough to

convey the information clearly and shall include the followings:

i) Reference to design drawing number (along with revision number) based

on which fabrication drawing has been prepared.
ii) Structural layout plans, elevations and sections with distinct erections
and sections with distinct erection marking of all members.
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iii) Framing plans, member sizes, orientations.

iv) Fabrication detail of each and every member.
v) Details of Shop / Field joints, connections and splices.
vi) Location, type and size of welds and bolts.
vii) Shape and size of edge preparation for welding.
viii) Bill of material including bolts for connections.

7.3.7 The Contractor shall however ensure accuracy of the following and shall be
solely responsible for the same.
i) Provision for erection and erection clearance.
ii) Marking of members.
iii) Cut length of members.
iv) Matching of joints and holes.
v) Provision kept in the members for other inter connected members.
vi) Bill of Materials.

7.3.8 Connections, splices and other details not shown on the design drawings
shall
be suitably designed and shown on the fabrication drawings based on good
Engineering practice, developing full strength of member.

7.3.9 Contractor shall incorporate all the revisions in his fabrication drawings
resulting from revision in design drawings if needed during the course of
execution of work at no extra cost.

7.3.10 Contractor shall supply three (3) prints of each fabrication drawing submitted
for checking to Owner /Consultant. After approval of fabrication drawings,
Contractor shall supply six (6) prints and soft copies of each approved
fabrication drawing to Owner / Consultant. The rates quoted by the
Contractor shall include the same.

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7.3.11 Every portion work shall have its erection mark or number stencilled on the
member for guidance in erection and bear all necessary marks of erections
as directed by the Owner / Consultant.

7.3.12 No part of the work is to be oiled, painted (except contact surfaces ) packed,
bundled, crated or despatched until it has been finally inspected and
approved by the Owner / Consultant or his authorised representative. The
whole steel work before being despatched from the Contractor’s shop shall be
dry and after being thoroughly cleaned from dust, mills scale, rust etc., and
shall be given two coats of primer and one coat of final paint as per painting
specification attached in this enquiry. Unless otherwise specified, all surfaces
inaccessible after welding shall be given two coats of primer and two coats of
paints as per painting specification attached in this enquiry.

7.3.13 The Owner / Consultant or his authorised representative shall have free
access at all reasonable time to all places where the work is being carried
out, and shall be provided by the Contractor at his own expenses all
necessary facilities for inspection during fabrication and erection. The Owner /
Consultant or his authorised representative shall be at liberty to reject the
work in whole or in part if the workmanship or materials do not conform to the
terms of the specifications mentioned herein. The Contractor shall remove,
replace or alter any part of the work as ordered by the Owner / Consultant or
his authorised representative.

7.4 WELDING

7.4.1 Welding shall be adopted in most of the cases for fabrication of steel
structure. Welding work shall be carried out as shown in relevant drawings as
per IS-816 or as required and approved by the Owner /Consultant. Welding
of joints shall be so arranged that the resulting tensile and compressive
stresses produced by each part of weld tend to balance each other.

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7.4.2 The step back method of welding shall be adopted for continuous runs.
Members which offer greater resistance to compression shall be welded first.
The work shall be securely held in position by means of tack weld, clamps or
jig before commencing of welding work so as to prevent relative movement
due to distortion or other cause. All welds with blow holes, slag-intrusion and
other defects must be removed from each run before another run is super
imposed and also from the final run. Any defects in the work shall be rectified
by the Contractor at his own expense. Bends, twists or distortion caused in
any member due to faulty workmanship and method adopted during welding or
in transit will be rejected and will have to be replaced / rectified by the
Contractor at his own expense. According to the size of electrodes used, the
Contractor is expected to adjust the current rating in the welding machine.

7.4.3 The Owner /Consultant reserves the right to have test done at any time for any
welding and the cost of the test shall be borne by the Contractor.

7.4.4 Wherever continuous plates are used in built up member such as girders,
columns, etc., the continuity of such plates shall be first ensured by full
strength butt joints before welding such plates with the main member to form
part of the built up member.

7.4.5 All connection / joints made in shop shall wherever possible be welded
connections and connections / joints made at site shall be bolted connections
/site welded connections. Continuous welding shall be done for all box
members even if it is not required from design point of view.

7.4.6 Electrodes used for welding shall comply with IS: 814 or IS: 815 or any
specification provided to the Contractor from time to time. No electrodes
remaining in open containers for more than 72 hours shall be used.

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7.4.7 No welder shall be employed to carry out welding in any position except those
who are fully qualified to weld in that position as per IS: 7318, Part-1
Qualifying tests for metal arc welders. Welders employed shall be required
both before commencing work and at intervals during the progress of work to
make test pieces as laid down in IS: 817 and IS: 7318, Part-1 for the purpose
of grading of welders and according to the said grading, welders will be
employed on jobs. Welders are to be got approved by Owner / Consultant
before engaging on work.

7.5 Erection & Setting of Steel Structure

The erection of steel work shall be in accordance IS: 800 and IS: 816.

7.5.1 The Contractor shall be responsible for the suitability, safety and capabilities of
all plant and equipment used for erection.

7.5.2 Prior to starting erection of fabricated structure, defects if any, shall be

rectified. The Contractor shall give to the Owner / Consultant not less than 24
hours’ notice of his intention to set out or give levels for any part of works, in
order that arrangements may be made for checking. The Contractor shall
provide all necessary arrangements and assistance which the Owner /
Consultant may require for checking the setting out.

7.5.3 The Contractor shall erect the structural steel members in position to
dimension and level, as in relevant drawings and shall take care to see that
component parts are not interchanged. Girders, stanchions etc., must rest
fairly on their beds and will not be taken as erected until completely plumbed,
aligned levelled, bolted or welded and strengthened, in every respect. The
camber, if any, is to be maintained as shown in relevant drawings.

7.5.4 Particular care should be taken to ensure free expansion and contraction
wherever provided in the relevant design / drawings or so directed on site.

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7.5.5 While erecting, the holes in different component parts of structure should be
made concentric with the use of drifts before any service bolts are fitted. No
drifting shall be allowed except for bringing together several parts forming a
member but the drifts must not be driven with such force as to disturb or
damage the metal above the holes. Hammering of bolts to make holes
concentric shall in no case be allowed. No nuts should be allowed to become
loose and no unfilled bolt holes are to be left in any part of the structure unless
otherwise specified in the relevant drawings. Welding should be adopted
wherever specified in the drawings. Wooden rams or mallets shall be used in
forcing members to position, in order to protect metal from injury or shocks.
Chipped edges shall be finished off smooth and all concave surface rounded
off.

7.5.6 All erection tools and plants viz. Derricks, Cranes etc., will have to be provided
by the Contractor as required in the erection work. All erection devices must
be removed after the work is over in such a way that no damage is done to the
erected structures. Any damage, in this respect must be rectified by the
Contractor at his own cost.

7.5.7 The maximum tolerance for line and level of the steel work shall be ± 3.0 mm
on any part of the structure. The structure shall not be out of plumb more than
3.5 mm on each 10.0 m. section of height and not more than 7.0 mm per 30.0
m section. These tolerances shall apply to all parts of the structure unless
mentioned in the drawings issued for erection purposes.

7.6 Match Marking & Stamping

i) All materials shall be match marked to facilitate erection.

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ii) All pieces shall be stamped on at least two sides with erection marks
as per fabrication drawings to facilitate identification on receipt and
assembly.

7.7 Transport to Site

All parts pertaining to one assembly shall be transported in the same lot. All
materials shall be transported in sequence of erection. Fabricated materials
transported not in sequence of erection shall not be paid until erection reaches
that stage.

7.8 Miscellaneous Steel structure

This section covers the design, engineering, supply, fabrication & erection of
miscellaneous steel structures like working platforms, walkways, support
structures for various equipment & hoists etc.

The Design drawings shall consist of plans, elevations, sections and details
which define completely the platforms/attachments including, but not limited to,
dimensions loads/forces, member sizes/weights, handrail, ladders, stairs, type
of flooring, brackets to permit a structural steel fabricator for detailing and
preparation of shop drawings, supply and fabricate the steel requirements for
the platforms/attachments.

7.8.1 All flooring for working platforms, walkways shall be covered with standard GI
grating. Bearing Bar thickness and depth shall be suitable for its intended
service and loads with acceptable deflection. The minimum size for frame bars /
bearing bar shall be 32 mm x 6 mm. and cross bar shall be 8 mm square
twisted. Pitch for bearing bar & cross bar shall be 35 mm & 75 mm respectively.
Grating shall be supplied galvanised. Thickness of Zinc coating as per IS 4759.

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7.8.2 Minimum clear width of stairs should be 1000 mm and maximum slope of stair
should not exceed 41 degree. Treads should be minimum 250 mm and made
of MS galvanized grating with suitable antiskid nosing.Stairs shall be in
accordance with IS.

7.8.3 Ladders may be provided to platforms which do not require frequent access by
the operating personnel as per OSHAS guideline (1910.27). Safety cages
should be provided as per safety norms.

7.8.4 Handrails shall be provided around the edge of platforms, stairs and places
where there is a difference in adjacent levels greater than 0.5m.Handrails
around platforms shall be of the two rail type with the top rail set 1100 mm
above finished floor level. Dismountable handrails, shall be provided around the
perimeter of hoist walls. Loading for handrail design shall be in accordance with
IS 4912.Spacing of handrail standards shall be commensurate with the design
loadings quoted above. Corner stanchions shall be located within 300mm of the
corner. MOC of Handrails pipes, Kick flats shall be ASTM A240 TP 304 .Kick
flats shall be not less than 100mm high above finished floor level. Thickness of
kick flats/toe guards shall be 4 mm. Kick flats shall be provided along all open
edges of platforms, walkways, landings and floors except at access points to
stairs and ladders.

8.0 TECHNICAL SPECIFICATIONS FOR PAINTING

This section comprises of complete supply, surface preparation and application
of recommended painting materials on the surface of Structural steel work,
conveyor gallery, support structures of equipment, platforms, walkways
doors/window frames, road barriers, chutes, stair case, cable tray support,
piping etc.

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8.1 Scope
8.1.1 The contractor shall arrange procurement, receipt, storage in his own safe
custody along with handling and transportation of all materials to be used for
painting work in a safe manner.

8.1.2 The contractor shall arrange at his own cost & maintain against weather, light
and fireproof storage facility for storage of all painting materials.

8.1.3 All required consumable paint material, shall be provided by the contractor.
Painting-brushes, wire-brushes, cotton waste, emery papers, abrasives for blast
cleaning purpose of required size, etc. shall also be provided by the contractor.
The contractor has to submit the challan of the paint manufacturer along with
manufacturer test certificates duly signed by the paint manufacturer for each lot
of paint purchased from the manufacturer/trader.

8.1.4 Contractor shall make their own arrangement for preparation of scaffolding /
shuttering, Platforms etc, for safe and satisfactory completion of job. Above three
meter safety net must be used for painting jobs, Rigid steel cup lock type
scaffolding along with ladder & hand railing shall be use for scaffolding. MS cup
lock scaffolding pipes is in the scope of contractor.

8.1.5 It is the responsibility of the contractor to train the paint application crew through
the experts/certified trainer (NACE Level) of respective paint manufacturers i.e.
how to apply their supplied paints throughout the contract period including
surface preparation. The trained manpower has to be certified by the paint
manufacturers & the expenses of training have to be bear by the contractors.

8.1.6 The contractor shall not alter any of the specifications except as directed in
writing by the Owner, but the owner shall have full right to alter, amend,
add/omit/vary any of the specifications and the contractor shall carry out such
variations

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8.1.7 All empty paint drums, caps. used brushes & other debris shall be collected on
daily basis and shall be placed on a designated area jointly identified by the
owner & contractor.

8.1.8 On periodical basis, in every two months all the collected drums shall be taken
from IFFCO plant.

8.1.9 The out gate pass of the empty drums shall be submitted along with the RA bill/
Final bill. No RA Bill and Final Bill will be accepted until unless empty paint drums
taken out from the IFFCO against the work Order.

8.2.0 All relevant safety gadgets/equipment like pressure gauges in air compressor &
blasting hopper, dead-man handle for safety of blaster etc. required for blasting &
painting job as per standard shall be maintained by the contractor at designated
area for painting job. Apart from the above all PPE like safety Helmets, Goggles,
Shoes, Hand Gloves, nose masks, required for the application crew shall be in
the scope of contractor.

8.2 Surface Preparation

8.2.1 Blast Cleaning (S-1 System)

Blast-cleaning of SA 2½ quality as per Swedish standard SIS-05-59-00-1967/ ISO-

8501-1:1988 or I.S. specification IS-1477- 1971(Part-1) will be carried out by
approved appliances, abrasives and techniques to obtain efficient and expeditious
work. Abrasive to be utilized for blast cleaning shall be 16/32 mesh size. No
damage shall occur to the item to be blast-cleaned as well as the surroundings.

8.2.2 Power Tool Cleaning

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For the removal of loosely adhering mill scale, paint and dust Power wire brushes,
needle guns grinders and disc sanders are generally used. Care should be taken,
particularly when using power wire brushes,

Not to polish the metal surface. It should be to ST-3 grade of Swedish Standard or
ISO: 8501:1988. Power tool cleaning shall be done as per the site condition and
Instruction of IFFCO.

8.3 Paint Specifications

Marine quality paints of the following specifications manufactured by reputed

manufacturer and which have been tried and approved by us shall only be used.
Manufacturer's test certificates for product quality shall be produced for all the
materials used by the contractor as and when asked by IFFCO. The contractor
shall supply and use following make of paint, “Jotun”

Final DFT of complete paint should be 400 microns

8.3.1 Epoxy Primer

Two component epoxy primer coating

Color & Gloss : Grey

Volume Solids : At least 75 ± 2%.
Mixing ratio : 3:1 by volume
Thinner : Jotun Thinner No.17
D.F.T. : 200 microns
Application method : Airless Spray

BRAND NAME: Brand Name: Penguard Pro GF (Jotun)

8.3.2 Epoxy Intermediate Coat

Two component epoxy barrier coating.

Color : Red

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Volume Solid : At least 75 ± 2%.

Mixing ratio : 3:1 by volume
Thinner : Jotun Thinner No.17
D.F.T. (microns) : 150 microns
Application method : Airless Spray

BRAND NAME: Penguard pro (Jotun)

8.3.3 Finish Coat

A two pack glossy Finish paint (Colour shade shall be specified by IFFCO
according to the area to be painted)

Volume Solid : At least 63 ± 2%.

Mixing : 10:1 by volume
Thinner : Jotun thinner No.10 / Jotun thinner No. 26
D.F.T. : 50 microns
Application method : Airless Spray / Brush (recommended by paint Manufacturer)

BRAND NAME: Hardtop XP (Jotun)

Note: 1) Party should submit NORSOK M 501 Certificate.

2) Coating inspection report shall be review by NACE level II certified painting
inspector.

8.4 Application

8.4.1 The interval between surface preparation and application of first coat of primer shall
be as short as practicable and in no case more than 4 hrs. Fertilizer/dust
accumulated must be completely removed prior to application of primer/paint.

8.4.2 Preparation of paint mixture, time gap between successive coating, period between
paint mixing and application of paint should be strictly as per recommendation of
paint manufacturers.
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8.4.3 Coating Inspection report shall be reviewed by NACE Level – 2 certified painting
inspector.

8.5 PAINTING SYSTEM

8.5.1 SYSTEM S1: Blast cleaning SA 2½ quality + 1 coat of epoxy primer + 1 coat of
epoxy MIO + 1 coats of epoxy finish paint (Color shade shall be specified by IFFCO
at the time of painting according to the area to be painted)

8.5.2 SYSTEM S2: Surface Preparation to power tool cleaning + Water washing followed
by solvent swab + 1 coat of surface tolerant aluminum pigmented epoxy primer + 1
coat of HB modified epoxy + 1 coats of finish paint (Color shade shall be specified
by IFFCO at the time of painting according to the area to be painted).

8.5.3 Painting will be carried out according to painting systems given above. The paints
used for above painting system should be of same as specified by manufacturer.
8.5.4 Inspection

Stage wise inspection shall be carried out as required by the specifications.

The following work in progress inspection shall be carried out by IFFCO.

SL STAGE INSPECTION

Prior to
1 1. Material 2. Dilution 3. Surface Preparation
Painting

During 1. Number of Coats 2. Drying Time 3. DFT measurement

2
Painting of each coat

After
1. DFT measurement 2. Finish Colour 3. Appearance 4.
3 completion
Identification mark
of Painting

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8.5.5 Guarantee
Guarantee of minimum 10 Year shall be provided on painting by successful Vendor.
Mode of guarantee shall be discussed & mutually agreed at the time of technical
discussion.

8.5.6 Reference Standards for Painting

IS: 1477 Part 1 : Code of practice for painting of ferrous metal in buildings
Pre-treatment.
IS: 1477 Part 2 : Code of practice of painting of ferrous metal in buildings
painting.
IS: 2379 : Color code for pipe lines color for ready mixed paints.
IS: 5 : Color for ready mixed paint

9.0 TECHNICAL SCOPE & SPECIFICATION FOR CONVEYING SYSTEM

This specification together with all relevant annexures cover the requirements for
detailed design, engineering, manufacture, supply, packing, forwarding,
transportation to site, unloading & storage at site, erection, testing, final painting &
commissioning & load trial of new conveying systems along with suitable Dust
Extraction /suppression systems required for the smooth & trouble free operation of
new Rock phosphate Silo-D. Apart from the above suitable modifications /
arrangements required for receipt of rock phosphate from existing cross country
conveying system R-10A at TP 12 and discharge of material to existing transfer
conveyor 104 A shall be in the scope of successful bidder.

9.1 Scope of Conveying System

The supply-cum-erection of new conveying system along with all components as
per relevant standard & code, modification in existing system for facilitation of
smooth operation of new Silo shall include but not limited to the following.

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Sl. Items Description Qty.

1 SS Discharge Chute Suitable Discharge facility from existing 1 Set
with diverter gate Conveyor R10 A
2 Conveyor R-10B New Transfer conveyor 1 Set
3 Conveyor R-15 New Storing Conveyor with Travelling 1 Set
Tripper
4 Conveyor 103-D New Underground Reclaiming 1 Set
Conveyor with hoppers & Manual Gates
for receipt of material from storage area
by gravity.
5 Conveyor 104-B New Transfer Conveyor 1 Set
6 SS Discharge chute Suitable modification for discharge of 1 Set
material from 104-B to 104-A
7 Dust Extraction All Transfer Tower & Tripper Discharge As per
/Suppression System Requirement

9.1.1 Cleaning & removal of existing facilities if any, at proposed location, shall be done
by IFFCO. However cleaning of any debris left out, levelling of land, cutting of
existing plantations and construction of any temporary roads to facilitate the
erection activities shall be considered in the vendor’s scope.

9.1.2 Modification work, wherever required, for installation /erection of new/proposed

equipment shall be in vendor scope.

9.1.3 Supply of commissioning spare parts. List to be submitted to IFFCO.

9.1.4 Supply of 2 years operation/maintenance spare parts.

9.1.5 All electrical, Instrumentation, structural supports, civil foundations including

grouting shall be considered in vendor’s scope.

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9.1.6 The bidders are advised to visit the proposed location at IFFCO, Paradeep to
access the exact requirements, conditions of existing system to hook up &
discharge and the site layout before bidding.
After visiting the site & accessing the actual requirement, the bidders shall prepare
a comprehensive list of items / equipment needed for supply, modifications required
in the existing facilities and furnish such list along with the offer.
However the supply & installation of the equipment shall not be limited to the above
only and the vendor has to provide all the equipment/ items required for satisfactory
& smooth commissioning of the system (with designed load condition) within their
quoted price.

9.2 Proposed Modifications

As per proposed layout enclosed in this tender document, following modifications
may be required for transfer of materials to new storage shed, reclaiming & transfer
of the same to Phosphoric Acid plant through existing conveying facilities.
i) As per existing layout of Cross country conveying system, Conveyor R-10A
is the last feed conveyor which feeds to the storing conveyor R-14 in Rock
Phosphate Silo-C. Hence to receipt the materials for storage in new Rock
Phosphate Silo-D, suitable modification is required in the existing discharge
facilities of conveyor R-10A (at TP 12) which shall further discharge the
material to new transfer conveyor R-10B.The conveyor R-10B shall be
terminated to the proposed new TP 13 to the North side of TP 12.

ii) Similarly existing 104-A conveyor is the endmost conveyor which receives
materials from Rock Silo-C through underground reclaiming conveyor 103-
C.To transfer the materials from new Rock Silo-D to PAP, discharge of
material shall be done to existing conveyor 104-A through new reclaiming
conveyor 103-D & new transfer conveyor 104-B.For the above arrangement,
modification may be required at existing TP-1A.

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Optional: Study for extension of existing Transfer Conveyor 104A to North

direction to have a single transfer conveyor for receipt of material from
Reclaiming Conveyor 103-D (Rock Silo-D) as well as from Reclaiming
Conveyor R-103C.

However Bidder is free to design a better & trouble free conveying system against
the proposed scheme to avoid any major modification if any.

9.3 Detailed Scope of Equipment

The Belt Conveying System shall be comprising of, but not limited to the followings,
i) Conveyor Belt
ii) Drive Unit comprising of Motor, Gearboxes, input & output couplings, motor
& coupling guards wherever required.
iii) All Pulleys & Pulley Guards.
iv) Bearing & Plummer blocks.
v) Belt Take-up Units.
vi) Troughing / Carrying Idlers, Return Idlers, Self-Aligning Carrying & Return
Idlers, Transition Idlers, Impact Idlers etc.
vii) External & Internal Belt Cleaners
viii) Deck Plates
ix) SS 304 Discharge Chutes (Min.6 mm thickness)
x) Cable Reeling Drums for travelling tripper
xi) Belt safety switches
xii) All Electrical & Instrumentation Items
xiii) All supporting steel structures / frames for supporting new/modified
equipment.
xiv) All fasteners.
xv) Any left out material addition to above required for smooth, safe & trouble
free operation of conveying system.

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9.4 Detail Specification for Mechanical Components

Detailed specifications of conveyor equipment are mentioned below. However,
details mentioned below, shall in no way relieve the contractor of his responsibility
for providing equipment capable of meeting the required performance. Vendor has
to provide data sheet of all proposed items along with the technical offer for review
& preparation of TQCS (Technical Quote Comparison Statement)

9.4.1 Conveyor Belt

The belt shall be manufactured as per IS-1891. The belt construction will be of
nylon/ nylon carcass having a thickness of 8 mm ±10%. Rating of the belt will be
1250/4. The Cover grade shall be M 24 but abrasion loss should be less than 120
mm3 when measured as per DIN 53516. Thickness of the top cover and bottom
cover shall be 4 mm and 2 mm respectively. All belting shall be free of longitudinal
and transverse buckling, wavy cord or any other unevenness that cause localized
points of flexing when belt is in service. Width tolerances shall not exceed 1%. All
plies shall be mildew inhibited. Belting with repaired carcass, blow-ups shall not be
acceptable. Unless otherwise specified, belt splices shall be field vulcanized and
the belt shall include sufficient length for the splice. Test Certificates of the belt
establishing conformance of the belt with IS-1891 (latest edition) and DIN 53516
shall be submitted by the contractor.

9.4.2 Drive Unit

Service factor for all mechanical power transmission equipment shall be 1.5 (min)
times of the absorbed power. However, service factor for fluid couplings shall be 2.0
times the installed power. All the components in drive unit shall be designed for
continuous duty i.e. 24 hrs/ day.

9.4.2.1Fluid Coupling
Scoop type fluid coupling with actuator shall be supplied by the contractor. The fluid
coupling shall be flame proof. It must be fitted with double oil seal at the output
shaft. The coupling as well as its individual components shall be dynamically

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balanced. The coupling shall be tested for pressure tightness against leakage and
at least 125% of the rated speed.

9.4.2.2 Gear Box

The reduction gear box used shall be helical gear type completely enclosed having
splash lubrication. The gear box shall be rated for 24 hours continuous working
having a minimum service factor of 1.5 on installed motor. The temperature rise
shall not exceed 50oC. Gear Box shall be designed as per BIS, DIN or AGMA
specifications. The gear box shall be supported on roller bearing of ample capacity.
The gear box housing shall be split type so as to have easy maintenance without
disturbing the assembly. Gear Box shall be provided with breather vent, oil level
indicator, dip stick, inspection cover and dowel holes. Suitable oil level indicator
shall be provided. Gear box shall be provided with heavy duty lugs (minimum two)
for handling by hoist. The gear box shall be tested in accordance with the accepted
standard.

9.4.2.3 Pin Bush Coupling

The high speed coupling between the fluid coupling and the gear box shall be pin
bush coupling.

9.4.2.4 Gear Coupling

Low speed coupling between the gear box and head pulley shall be Gear Coupling.

9.4.2.5 Drive base frame

It shall be constructed from built-up plates, dully machined to provide a leveled
surface and stress relieved, if required.

9.5 Pulley and Shaft

i) All pulleys and shafts are to be designed for worst conveyor loading
conditions and should be standardized as far as practically possible.

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ii) Pulleys shall be of welded construction, continuous rim and two end disc
type. Pulley hub arrangement to be of ring feeder type for easy removal of
shaft (for all pulleys).
iii) Pulleys shall be statically balanced and concentric about the shafts. The out
of roundness shall not exceed 0.5 mm for pulley diameter upto 400 mm and
1.0 mm for pulley diameter above 400 mm.
iv) Drive pulley shall have 20 mm thick rubber lagging with Herringbone groove.
v) Rubber lined/ lagging of all the pulleys should be hot vulcanized.
vi) Tail pulley, snub pulley, bend pulley and take up pulley shall have 12mm
thick smooth neoprene lagging with Duero meter hardness of 60 to 70 shore
“A” scale.
vii) Pulley faces shall be at least 200 mm greater than the belt width.
viii) Head and Tail pulley shall be flat faced.
ix) Shaft deflection shall be limited to 0.066% of bearing centers. All shafts shall
be provided with accurately machined key seats.
x) Shaft ends shall be flush with bearing edge, unless the extension is required
for mounting components.
xi) Minimum shaft diameter shall be 100 mm for all conveyor pulleys. Shaft
diameter calculation shall be submitted to IFFCO for their review before
manufacturing.
xii) The pulley rim thickness shall not be less than 10 mm.

9.6 Bearing and Plummer blocks:

i) All bearing shall be normally double spherical type, ball or roller and shall
have a minimum life rating of 30,000 hours under the total loads imposed.
ii) All Plummer block shall be fully self-aligning with one fixed end and one
expansion type for each shaft assembly. They shall include enclosures caps
where non drive shafts terminate at bearings. Grease seals shall be triple
labyrinth type to effectively exclude micron size dust, dirt and girt. Grease
fittings shall be buttoned type.
iii) Plummer block shall be two half with (i.e. of split type) with end covers.

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9.7 Belt Tensioning Device (Take-up Unit)

In case of vertical gravity take-up concrete counter weights consisting of cage and
guide channel shall be provided. The amount of travel for take-ups shall be based
on belt manufacturer’s recommendations but shall not be less than 4.0 % of pulley
centre distance.

9.8 Idlers
i) All conveyor idlers, carrying and return shall be constructed of constructed of
ERW tubes as per IS: 9295, GR-YST-210, having a minimum shell thickness of
4.85 mm (after machining) for roll diameter up to 139.7 mm. Shell thickness
shall be minimum 5.4 mm (after machining) for roll diameter above 139.7 mm.
ii) For all idlers material for the shaft shall be 40 C8 Black bar confirming to
IS: 1570.
iii) Tube diameter shall be 152.4 mm (min) and the shaft diameter shall be 30 mm
(min) for carrying idlers.
iv) The carrying idlers shall be 3 roll 45o Garland type. The carrying idlers to be
provided at 1000 mm (max) pitch.
v) Transition carrying idlers shall be 3 roll 35o, 25o, 10o garland type to help
carrying side of belt to flatten out before it goes to the terminal pulley at Head
end and tail end.
vi) Return idlers shall be of 2 roll garland type at 10o and the diameter of the tube
and idler shaft shall be 139.7 mm (min) and 30 mm (min) respectively. Return
idlers to be provided @ 3000 mm (max) pitch.
vii) The impact idlers shall be 3 roll 45o Garland type and the idler shaft diameter
shall be 35 mm (min). Impact idlers to be provided @ 500 mm (max) pitch.
viii) For lubrication, idlers shall be grease packed and sealed for life.
ix) All idler bearings shall be sealed and lubricated for L-10 life equal to 60,000hrs.
Make of idler bearing shall be SKF or FAG only. Bearing for idler having shaft
dia of 30 mm shall of series 6306 and for idlers having shaft dia. of 35 mm shall
be of 6307 series.

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x) Idlers are provided with double labyrinth sealing, back seal, weather seal and
dust seal cap and internal construction as per standard.
xi) Idlers shall be provided with two coats of Red Oxide primer paints and one coat
of polyurethane finish paint to protect from corrosion at sea shore area.
xii) Idlers shall be heavy duty in construction suitable for handling the rock
phosphate handling @ 3000TPH.

9.9 Discharge Chute

All the chutes shall be made from Stainless steel plate (SS 304 grade) of minimum
6 mm thick.

9.10 Scrapper
The conveyor shall be provided with:
i) External Scrapper: Spring loaded external scrapper shall be provided at the
discharge of the tripper. The scrapper shall be provided with PU blades with
stainless steel carrier tubes.
ii) Internal scrapper: Self adjusting V-plough internal scrapper with PU blades
shall be installed to protect the take up and tail pulley from material build up.
iii) Rotary Scraper: A rotary type scrapper shall be installed at the head pulley of
the conveyor.

9.11 Skirt Board

Skirt board shall be provided up to minimum length of 4 meters from the point of
material inlet in the conveyor. Top cover and side cover of the skirt board shall be
constructed of SS 304 plate of minimum 3.15 mm thickness. The gap between side
covers and the belt shall be sealed with soft rubber.

9.12 Deck Plate

Deck plate shall be provided from the point of loading of the conveyor till conveyor’s
entry in the silo. Deck plate shall be constructed of SS 304 and shall be of thickness
3 mm.

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9.13 Travelling Tripper

Travelling tripper with two way discharge chute shall be provided. The tripper shall
be provided with cross over platforms, maintenance platform and walkways.
Suitable hold down pulley shall be provided over concave curve of the belt. The
tripper wheel shall be double flanged with parallel tread running on anti-friction
bearing. The minimum hardness of the wheel shall be 350 BHN. Material of the
wheel shall be forged steel/ cast steel. The tripper shall run on rails (minimum 105
lbs/ yard). Traveling tripper shall be equipped with manual rail clamps, rail cleaners
and jacking pad. Tripper shall be equipped with electro thruster breaks which shall
be applied automatically once the motor is stopped and shall release on start of the
motor. The brake shall be designed to stop the tripper without slippage over the
rails even in wet conditions and at the accidental cut of conveyor belt during running
with high load. Power supply shall be fed to Tripper Control panel to be mounted on
Tripper platform through centre feed cable reeling drum.

MOC of Cable Reeling Drum, Enclosures of Slip Ring Assembly, CRD Control
panel, Tripper control panel shall be SS-304 as the atmosphere is very corrosive in
nature.

Telescopic chute with radar type heap sensor in both the chutes of tripper shall be
considered to minimise the generation of dust during unloading of rock phosphate
from the unloading conveyor through travelling tripper. There should be automatic
retraction of both telescopic chute when the chute closures to the heap from a pre-
set distance. For heap level control in the Silo, installation of Radar Level
Transmitters ( preferable Make – VEGA, Model – Vegapuls69 ) besides both the
discharge chutes on either side of Tripper is to be included in scope of supply. In
addition to the Radar Level transmitters, a Level Controller with local display should
be mounted besides the Tripper Control Panel along with an electrically operated
Hooter. The Controller shall detect high level on the basis of signal received from
the Radar Transmitters and energise the Hooter to alert the Tripper Operator.

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9.14 Technological Structure

Conveyor support structure including short post, stringers, tripper’s rail supporting
member, tripper structure, walkway, tail pulley base frame and drive unit base frame
etc. shall be adequately designed considering the load at various points in the
conveying system. While designing the structure, Seismic load shall be taken as per
IS: 1893 and wind load as per IS: 875 (260 KM/Hr). Support structure for the
Conveyor shall be standard steel sections conforming to IS 2062: 2004. Corrosion
allowance of 1.5 mm to be considered while determining the thickness of the
support structure. Painting on the support structure shall be done by the contractor
as per specifications mentioned in this document. Minimum thickness of all the fillet
weld joints shall be 6 mm.

9.15 Fasteners
All bolt, nut and screw shall be provided with metric screw threads to IS-1362. The
pitch of the threads shall generally be coarse series. All the bolts and nuts shall be
provided with spring washers. Fasteners for fixing the drive unit and all the pulleys
shall confirm to ASTM A 193/194 Gr. B8. All the other fasteners to be used in the
technological structure shall confirm to IS-1367 (part-III). For connecting idlers and
conveyor stringer fasteners used shall be of HT grade with lock nut arrangement.

9.16 Safety Guards

Safety guards shall be provided for all the rotating equipment. Guard shall
completely enclose moving parts so that physical contact with the moving parts
cannot be made with the Guard in place. Guards shall be constructed of steel wire
net casing/ anti-static aluminium plate. Design and construction of guard shall
permit easy removal.

9.17 Vibrating Pan Feeders

Vibrating Pan Feeders may be considered at the bottom of feed hoppers above
Reclaiming Conveyor No.103-D for smooth discharge of rock phosphate from

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storage shed through gravity. Feed-hoppers should have suitable

electric/pneumatic knocking system to disengage the stuck rock.

10. TECHNICAL SPECIFICATION FOR ELECTRICAL & INSTRUMENTATION

This specification covers the basic philosophy for design, engineering, supply and
installation of electrical equipment for the new Rock Phosphate Silo & its ancillary
system.

10.1 Scope
Electrical system shall be comprising of, but not limited to following, for smooth,
safe & trouble free operation of the complete Silo.

i) LV Switchboards for power supply to LV Motors, Power Sockets,

Illumination
ii) Tripper Control Panel, CRD Control Panel, Scoop Coupling Control Panel
iii) Power, Control, Signal & CRD cable.
iv) GI Angle cable tray
v) Cable tray support system
vi) Conveyor safety Switches (ZSS,BSS,PCS)
vii) Hooter / Siren
viii) Radar type Heap Sensor
ix) LED light fixtures
x) FRP junction Boxes for illumination circuits
xi) Earthing System
xii) Lightening Protection System
xiii) Interlocked type three phase Welding Socket Outlets.
xiv) Interlocked type single phase Power Socket Outlets.

10.2 Construction power for the project is made available by IFFCO. Contractor shall
make its own provision for connecting two nos. feeders from the nearby substation
at 415 volts & it is to be connected to Main Power distribution Board of contractor

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having duly approved specifications/Drawing. The power shall be distributed by

Contractor to meet all construction needs including site office for Contractor and the
Owner.

10.3 Design of the system shall take account of the climatic conditions as mentioned in
the site data and the Project environment is chemical, marine and dusty.

10.4 Battery limits

For HV Motors for R-15 conveyor vendors have to use existing 6.6 KV motor
feeders installed at Utility substation situated at a distance of 800 meter
approximately. Vendor has to consider supply & laying of cable from feeder to
equipment.

Power supply to Tripper Control panel, Scoop coupling control panel & Radiator for
R-15 conveyor, motorised diverter gate at TP 12, LSDB for illumination in R-10B &
R-15 conveyor galleries, power & welding socket outlets in conveyor galleries shall
be considered from Utility substation. Approx. distance of 750 meter shall be
considered for quote purpose

Power supply to reclaiming conveyor 103-D, Magnetic separator control panel,

conveyor 104-B, Power & Welding socket outlets in conveyor galleries shall be
considered from Old CHP substation. Approx. distance of 250 meter shall be
considered for quote purpose.

IFFCO will provide power supply to the LV Switchboard (415 V) to be supplied by

the vendor for all LT electrical equipment. Besides this everything will be in the
scope of the contractor.

10.5 System details:

Voltage 6.6 KV ± 10%, Unearthed

415 V ± 10%, solidly Earthed

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Frequency 50 Hz ± 5%

Combined Variation ±10%

Fault Level 300 MVA for 6.6 KV system

36 MVA for 415 V System

No. of Phases 3 Phase & N

Control Supply 110 V DC for ACB Feeders

110 V AC for DOL

Space heater 240 V± 10%, 50 Hz ± 5%,

10.6 General Construction Features

i) The electrical system and installation shall be designed as per latest practice to
provide maximum reliability, flexibility, safety to personnel and equipment and
ease of operation and maintenance.
ii) All equipment shall have adequate and standard ratings.
iii) All equipment shall have T5/T6 temperature class.
iv) All electrical equipment shall be enclosed in dust, damp, vermin and corrosion
proof enclosure. All outdoor equipment shall be flame proof and shall be suitable
for area classification mentioned in clause 2 i.e. “Site Date‟ and shall also be
provided with canopy as far as practicable. Special care shall be taken to ensure
that the parts to be opened for inspection and maintenance retain their dust
tightness even after repeated opening & closing.
v) All mating surface shall be properly machined. Neoprene gaskets shall be used
for dust proofing. The gasket shall be without any gap.
vi) Enclosure of sheet steel work shall not be less than 2.5 mm thick for all
equipment except MCC & control panels.
vii) Only non-hygroscopic materials shall be used for insulation. All insulation shall
be specially impregnated to withstand the ambient conditions.
viii) All live parts and bus bars shall be adequately protected to prevent inadvertent
or accidental contact.
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ix) All external hardware shall be of stainless steel up to 8mm dia. and those more
than 8mm dia. shall be of MS-cadmium plated or zinc passivated.

10.7 Motors
i) Motors shall be supplied as per the engineering standard for Induction motor
(IS: 325).
ii) The motor shall be energy efficient type having minimum efficiency class of
IE3 as per IS: 12615 – 2011.

iii) Duty cycle of the motor shall match with the driven machine requirement. The
margin between the installed power and absorbed power shall be as
recommended by the driven machine supplier but shall not be less than the
following:

Motor Rating % Margin on BHP of driven M/c

Up to 22 KW 125

22 KW to 55 KW 115

Above 55 KW 110

d) Motor shall be suitable for the following voltages:

i) Up to 150 KW: 415 V, 3- phase AC supply

ii) Above 150 KW: 6.6 KV, 3- phase AC supply

In case of motor rated for 6.6 KV, the terminal box shall be suitably designed for
proper termination of XLPE insulated cables through heat shrinkable end
termination kit. Identical terminal box shall be provided on both side of motor so
that HT cable can be terminated on either side of motor as per site requirement.

10.8 Tripper Control Panel, CRD control panel, Local control panel for Scooping
Coupling Actuator & Radiator and Control Panel for Safety Switches:

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i) All control panels shall be of single front having bottom cable entry. All
DOL feeder and SFU feeders shall be fixed type.
ii) Enclosure shall be of IP 65 & suitable as per Area Classification.
iii) Control Panel incoming feeder shall be provided with heavy duty switch
with proper protection system, current transformers, ammeter and
voltmeter with selector switches, LED indication lamps. Outgoing motor
feeders shall be provided with switch fuse unit, HRC fuse, CT, ammeter,
contactor, thermal overload relay etc.
iv) Minimum 1 number spare feeder for each type and rating of motor feeder
shall be provided in the panel.
v) In Tripper control panel there shall be interlocking between CRD motor &
Tripper travel motor such that tripper travel motor stops whenever CRD
cable is tight to prevent cable damage. Also tripper movement shall be
restricted at both end by 2 nos. of end limit switch to be provided at each
end.
vi) In scooping & radiator control panel there shall be an interlocking for
automatic scooping out of fluid coupling whenever the oil temperature in
circulating line is more than the specified designed limit.
vii) Tripper control panel shall be wired to a local control station suitable for
mounting on tripper car for controlling tripper movement while standing
outside of tripper trolley.
viii) The compartment modules shall be liberally designed for easy operation
and maintenance.
ix) Make, type & rating of all components of control panel shall be as per
make list attached.
x) GA, power & control schematic drawings of control panels shall be
submitted to IFFCO approval. Manufacturing clearance shall be given
only after approval of IFFCO.

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10.9 Local Control Station

i) For control of all motors, local control stations shall be provided near the
motors. The enclosure material of construction shall be FRP with IP-65
protection class suitable for area classification as mentioned in clause no. 2.
ii) Each LCS shall have provisions as indicated in specification sheet of LCS.
iii) TNC (Trip-Neutral-Close) type switch shall be mounted for closing/tripping of
VCB feeders for HT motors (6.6 KV). For LT motors (415 V) mushroom
head lockable type RED stop pushbutton with NC actuators & Flush head
type GREEN start pushbutton with NO actuators shall be mounted on LCS.
iv) The ammeter shall be flush mounting, moving iron spring controlled type, of
accuracy class 1.5 as per IS:1248, with square face of minimum size 72 mm
x 72 mm having scale range 0-240O.
v) The ammeter for motor shall be provided with uniform scale up to CT
primary current and compressed end scale up to the 6 times the C.T.
primary current. Adjustable red pointer shall be provided to indicate the full
load current of the motors. Zero adjusters shall be provided for operation
from the front of the meter. All ammeters shall be operated through 1 Amp.
CT secondary only. The CT ratio and full load current shall be as indicated
in specification sheet.
vi) Indication lamp shall be LED type having good illumination in all direction
with lumen output of minimum 200 milli Candella.
vii) All the components shall be mounted on a base plate inside the enclosure.
Necessary actuating system for control switches, non-yellowing acrylic/glass
cover for ammeter and indication lamps shall be provided on the front cover.
No wiring shall be carried out on the front cover.
viii) Each control station shall be provided with minimum 2 mm thick stainless
steel nameplates indicating the code number and description of the
equipment controlled by it. Similar labels shall be provided for all indication
lamps, push buttons, control switches. The nameplate and label shall be
fixed with screws only.

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ix) All LCS shall be of minimum two gland hole of 25 mm. dia.for control cable
entry & shall be supplied with required double compression stainless steel
cable glands.
x) All Local Control Stations shall have weather proof, dust & vermin proof IP-
65 enclosure and be suitable for outdoor installation. Spring loaded
transparent flapper shall be provided on LCS to protect the LCS from water,
dust & solution. A rain hood shall be offered as an additional protection.
Rain hood shall be of the same material as of the main enclosure. The
enclosure shall be suitable for mounting on wall or on steel structure. 4 Nos.
holes suitable for 12 mm bolts shall be provided outside the enclosure for
fixing the control stations.

10.10 Conveyor Safety Switches

i) Pull Chord Switch (IP 65 Protection): The pull cord switches shall be
installed on both sides of the conveyor at an interval of 25 meters with a
minimum of one for each conveyor for tripping the conveyor under
emergency. The switch shall be of heavy duty, suitable for 110 V AC control
supply. It shall be totally enclosed, dust & vermin proof in cast metal
enclosure with trip and reset levers shall be mounted along the walkway
side/s. The pull cord switch shall be operated through PVC coated stranded
steel wire rope running along the entire length on both side of each
conveyor. The trip lever shall have arrangement for fastening the pull cord by
securing through two opening in the lever head. In case of emergency
pulling of the rope shall trip the switch and stop the conveyor. When the
cause of emergency has been cleared the reset lever on the limit switch
shall be pressed to bring the trip lever to normal position. All pull chord
switches shall be grouped zone wise & connections done accordingly.
Indications as stated in this specification shall be taken on PLC/safety switch
control panel. Adequate length of pull cord rope shall be provided.

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Arrangement of Pull chord rope shall be such that it can be easily accessible
for operation.

ii) Belt Sway Switch (IP 65 Protection): The belt sway switch shall be suitable
for 110V AC, control supply. The switches shall be totally enclosed dust and
vermin proof in cast metal enclosure shall be installed as per this
specification. The limit switch lever arm shall be so connected that any
harmful deflection of belt from its design path shall actuate the lever and thus
trip the contacts inside the limit switch. Consequently the conveyor stops.
The lever mechanism shall be spring returned type and shall return to
normal position when the belt has been aligned. Indications as stated in this
specification shall be taken on Safety switch control panel. These shall be
mounted on both sides of conveyor at an interval of 50 meters or minimum
one pair for shorter length of conveyor.

iii) Zero speed switch (IP 65 Protection): The zero speed switches shall be
suitable for 110V AC/240 V AC control supply. The zero speed switches
shall be electronic type contact less, proximity switch comprising of sensing
element and relay unit having 2NO+2NC contact. The sensing element shall
be plastic moulded. Zero speed switches shall be mounted locally. 1 No.
Zero speed switch per conveyor and other equipment, as required, shall be
provided. In case speed falls down to abnormally low value, the switch
contact change over takes place and thus stops the equipment. Indications
as stated in this specification shall be taken on PLC/safety switch control
panel.

iv) Limit switches (IP 65 Protection): The switch shall be of heavy duty & shall
be totally enclosed dust and vermin proof in cast metal enclosure. The limit
switch type shall be selected to meet the specific requirement for different
position. There shall be 2NO+2NC contact wired up to terminal points for

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external connection. The lever mechanism shall be spring returned type and
shall return to normal position whenever the fault clears.

10.11 Interlocked type switch socket

i) Interlocked type SPN (single phase-neutral) switch sockets for temporary
lighting and portable tools shall be of 15 Amp, 240V, 1- phase, 3-pin design.
These shall be located to cover a radius of 30 meter & shall be fed from local
power distribution panel.
ii) Interlocked type TPN (three phase-neutral) switch sockets for welding outlet
in each conveyor shall be of 63 Amp, 415V, 3- phase, 4-pin design. These
shall be located at an interval of 100 meter and shall be fed from the local
power distribution panel.
iii) The switch socket shall be heavy duty industrial type. All the Plug & sockets
shall be of interlocked type & comply with the latest issue of IS: 4160
(Standards for Interlocking Switch Socket Outlet).Interlocking arrangements
shall be such that it is not possible to insert or withdraw the plug with the
switch in “ON‟ position. Interlocking shall be provided such that the contacts
cannot be energized when the plug & socket are separated. Switch socket
shall also conform to specification sheet attached.
iv) The enclosure for switch sockets and plugs shall be of cast aluminium alloy
LM-6 / FRP and shall be suitable for Area classification as specified in clause
no.2.
v) These shall have dust and hose proof construction conforming to IP 65 and
preferably with hinged cover, suitable for fixing on wall / structure. A rain
hood shall be offered as an additional protection. Rain hood shall be of the
same material as of the main enclosure. Suitable arrangement for looping of
cables from one switch socket to the other shall be provided. Necessary
terminals, cable glands and lugs for looping shall be provided. Also one no.
threaded plug for each switch socket shall be supplied loose.

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vi) All jointing surfaces shall be smoothly machines and of shall be of sufficient
width to prevent ingress of dust. Further the cover shall be provided with
continuous gaskets made of neoprene to prevent ingress of dust.
vii) The Air break switches shall be quick make, quick break rotary type and of
utilization category AC-23.Switches shall be hand operated from outside the
cover. The switch handle shall remain fixed to the front cover while removing
the front cover.
viii) The sockets shall be provided with link type HRC fuses. The fuses shall be
capable of withstanding a short circuit current of 50 KA and shall be delayed
action type. These shall be mounted on a shrouded base.
ix) The socket outlet shall be located in the lower part of the enclosure and shall
be provided with a threaded aluminium/FRP cover attached to the body with
SS chain, to protect the socket after extraction of the plug. Spring loaded
automatic shutter shall not be acceptable.
x) The plugs shall be so constructed that these can be easily fitted in to the
socket outlets and shall be provided with knurled knob arrangement for
screwing on the body of the socket so that it can be securely fixed on the top.
The plug base and cover shall be firmly secured to each other and shall be
sufficiently robust in construction to withstand normal usage. The plug and
socket contacts shall be self-aligning type with best electrical continuity.
xi) The plug shall be provided with cable entry suitable for receiving TRS flexible
heavy duty copper conductor cable of specified size. The arrangement shall
be such that the conductors are relieved from strain including twisting where
they are connected to the terminals and that the outer surface of the cable at
the place of entry is not damaged.
xii) The switch shall be provided with 2 nos. single compression type cast
aluminium cable glands one on either side or both on the top. The external
bolts and nuts shall be of stainless steel.

10.12 Junction Box

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15 A & 63 A dust proof & weather proof heavy duty FRP junction boxes suitable for
mounting on structure or wall, complete with mounting accessories, required
numbers of cable glands and terminals of suitable sizes shall be used for looping
the cables wherever required. All unused cable entries shall be sealed with
threaded plug which shall be fitted with endless neoprene rubber gasket.

10.13 Cable
i) All Power cables shall be considered as per IS 7098 & all control cables shall
be as per
ii) All cables in addition shall be fire resistant low smoke (FRLS) type.
iii) The cable sizes shall be selected in accordance with current rating based on
load Current, site ambient condition, method of laying and the no. of cables
to be laid together.
iv) Permissible voltage drops as specified below
 High voltage cables for general distribution - 1%
with max. Operating current
 Medium voltage cables for distribution with - 1%
maximum operating current
 Motor feeding cables referred to the full load current - 5%
 Motor feeding cables referred to the starting current - 10%
 Lighting cables
 Main lighting distribution board to lighting - 2.5%
Sub distribution board / junction box
 Lighting sub-distribution board / junction box - 2.5%
v) The minimum size of power cables shall be 16 sq. mm (Al) and 2.5 Sq. mm
(Cu).
vi) The control cables shall be 2.5 Sq. mm (Cu). However, wiring in the
panel/switch boards shall be by means of 1.5 sq. mm Cu cables except for
C.T. wiring which shall be 2.5 sq. mm. The voltage grade of cables for 6.6
kV system shall be 6.6kV (UE) /11 KV(E) & the voltage grade of cables for
415 V/220V system shall 1.1 kV.

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vii) Approximate length of power, control & lighting cable required for all
electrical equipment shall be finalised after joint survey & finalisation of
cable tray route layout drawing. However, for the estimation & bidding
purpose vendor may take the approximate distance mentioned in clause no.
10.1 with suitable margin. Accordingly contractor shall workout the actual
cable requirement.
viii) All HT & LT power and control cables from electrical field equipment to
switchgear & other control panel shall be supplied and laid by the contractor.
Terminations at switchgear end as well as at the equipment end shall be
done by contractor under supervision of owner’s representative. Termination
of HT motor at both ends includes supply of Raychem make heat shrinkable
end termination kits & for LT motors required size double compression SS
cable glands, lugs.
ix) All cables shall be used without any intermediate joints.
x) All cables shall have their Run Nos. marked close to their termination as well
as intermediate positions for proper identification.

10.14 Cable Tray & Support System

i) For laying & clamping of cables between LT & HT switchboard and electrical
field equipment, the contractor shall provide GI Angle type cable racks / trays
of suitable width with proper supporting arrangements. Thickness of the
material of the GI cable trays and its accessories shall be 6.0 mm. The rung
spacing shall be 300 mm.
ii) The cable trays shall be supplied with required quantity of GI cable tray
bends & T pieces. The corners of the cable trays shall have a smooth circular
radius. In case of multi-tier trays, the minimum gap between the two tiers and
between top tier and ceiling beam (bottom) shall be 300 mm.
iii) HV cables shall be installed on racks dedicated to that duty.
iv) 415 V power cables, lighting and small power cables and motor control cables
shall be installed on separate racks dedicated to that duty.

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v) Instrument cables shall be run on racks dedicated to that duty and have
physical separation of a minimum of 0.5 metre from all other cabling. These
racks may also be used for telephone, communication and Public Address (PA)
system cabling.
vi) Provision for 25 % extra space shall be kept in cable racks for future use.
vii) GI Cable trays shall be earthed at regular intervals not more than 25M apart.
viii) Fabrication & installation of proper cable support system along with the supply
& laying of required GI angle cable trays shall be in the scope of the vendor.
ix) For the cable trays and supports, supplied and installed by the contractor,
payment shall be made to the contractor on the basis of unit rates indicated by
the vendor in their billing schedule.

10.15 Illumination System

10.15.1 General Requirement

i) The scope of illumination shall cover design, calculations, lighting layout,
cabling etc. for the silo, conveyor gantries and transfer towers/buildings covered
in this package. The system shall include supply & installation of lighting sub
distribution boards, fixtures with lamps, mounting brackets for installation of light
fixtures & junction boxes, cables, cable trays etc. as required for the
completeness of the job.
ii) The power to lighting fixtures shall be provided from required numbers of
lighting sub-distribution board (LSDB) mounted at a convenient location at
operating height from ground / working floor. 415V, 3-phase & neutral incoming
supply shall be fed to the LSDB from the existing LDB. Each circuit shall have
maximum loading of 1000W.
iii) Cable looping facility shall be provided in the lighting fixture.
iv) Double compression SS cable glands, copper lugs or any consumable items
required for the completion of job shall be in the scope of vendor.
v) All fixtures in a row shall be fed from R, Y & B phase alternatively. There shall
be separate neutral for each phase.

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vi) Circuits controlling outdoor lighting and indoor lighting shall be separate.
Outdoor lighting shall be automatically controlled through astronomical timer
with provision for bypass manual control.
vii) Lighting layout drawings shall be submitted by party for approval.
viii) Light fixtures shall be installed at proper height for ease of maintenance.

10.15.2 Lighting Sub Distribution Board (LSDB)

i) Each LSDB shall have 1 No. incomer with 63A SFU and each outlets with 16 A
double pole MCB. All MCBs shall be of 10KA breaking capacity conforming to
IS: 8828.

ii) The enclosure for LSDB shall be made of high quality FRP and shall be suitable
for area mentioned in clause no. 2. Canopy for rain protection shall be
considered. The enclosure shall be suitable for mounting on wall or on steel
structure. 4 nos. holes suitable for 12mm bolts shall be provided outside the
enclosure for fixing the LSDB.
iii) The LSDB shall have all cable entries from the bottom only with heavy duty
double compression type SS cable glands suitable for 1.1 KV HRPVC-A-FRLS
PVC (ST2 type) outer sheathed cables. Incoming cable size shall be 3.5x50 sq.
mm armoured aluminium cable and outgoing cable size shall be 3x2.5 sq. mm.
armoured copper cable. Gland plate for cable glanding shall be of SS-304
detachable type.

iv) Three phase and neutral bus bar system of adequate size shall be provided to
which all outgoing and incoming MCBs shall be connected.

v) Individual earth terminals shall be provided for the earth conductor of the
outgoing cables beside the phase and neutral terminals.

vi) Suitable label inscription for the board and circuit nos. of all outgoing feeders
shall be provided. The label inscription of the board shall contain description and
code no. The circuit nos. of outgoing feeders shall be serially indicated as 1R,
1Y, 1B, 2R, 2Y, 2B……….

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vii) The board shall be complete with terminal block, cable glands, cable lugs and
other accessories as required.

10.15.3 Lighting Fixtures

i) All Light Fixtures shall be of LED type of suitable rating as per approved
illumination calculation.
ii) Lighting systems voltage throughout the area shall be 240 V single phase.
iii) For lighting fixtures, 3 core 2.5 sq. mm Cu armoured shall be used.
iv) Normally the load on one lighting Junction Box shall be limited to 1000W
approx.

10.16 Earthing

i) Complete earthing system design and installation shall be carried out as per IS:
3043.
ii) Common underground earthing grid shall be considered for the complete
system. The overall earth resistance (dry) shall be limited to 1 ohm.
iii) Earthing grid/ring shall comprise of buried GI earth strips and copper bonded
earth electrodes.
iv) For equipment earthing, minimum two numbers of electrodes shall be provided
around each section. However, all these earth electrodes shall be inter
connected. Tapping from existing nearest earthing grid shall be taken through
minimum of 2 Nos. 50 mm x 6 mm G.I. strip and fixed along the entire length of
all the conveyors to form local earth grid.
v) Inter-connecting pits having an earth bus in an enclosed brick chamber without
earth electrode shall be provided in the common underground earthing grid for
convenience of taking earth conductors inside the plants.
vi) All non-current carrying parts of various electrical equipment as well as cable
armouring, metal conduit, G.I. pipe, cable racks/trays, brackets, supporting
structure etc. shall be effectively earthed.
vii) All non-electrical equipment such as equipment base plate, steel structures,
pipelines, vessels, tanks etc. shall be effectively earthed.
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viii)
ix) As far as possible, the reinforcement rods inside concrete column shall be
connected to the earthing grid/ring to reduce the overall earth resistance.
x) Individual electrical equipment shall be earthed by GI strip/GI wire/Aluminium
cable. Earth buses shall be provided in plants for earthing groups of
electrical/non electrical equipment to earthing grid/rings.
xi) Size of earthing grid/ring and earth conductors of equipment for Sub-stations
shall be as per Clause.No.17.3.2 of IS: 3043. The fault current magnitude shall
be decided based on system fault level. The time duration shall be taken as 3
seconds for H.V. & 1 second for M.V.
xii) Size of earthing conductor for the electrical equipment in plants shall be as per
Clause.No.12.2.2 of IS: 3043.
xiii) All equipment shall have two external earth connections. For lighting fixtures,
earthing shall be provided through armouring of cables.
xiv) Earthing connection below ground shall be made by welding and connections to
the equipment shall normally be bolted type.
xv) The earth conductor shall be protected against mechanical damage and
corrosion particularly at the point of connection to earth, terminals of equipment
and accessories. Welded joints shall be protected by applying epoxy resin or
bituminous paint.

10.17 Lightning Protection

i) Complete lightning protection system design and installation shall be carried out
as per IS: 2309.
ii) The number of down conductors shall be minimum two.
iii) Bare metallic structures shall not have any air termination rods at the top. The
earth connections shall be welded to the bottom of structure at 300mm above
floor level. However, tall metallic columns with insulation at top shall be
provided with air termination rods.

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iv) Separate earth electrodes shall be provided for each down conductor of
lightning protection. However, these shall be inter-connected with the other
electrodes in main grid.
v) Horizontal air termination conductor shall be cleated on the top of the parapet
wall of the structure at suitable intervals. The down conductor shall be cleated
with wall / structure at regular interval.
vi) Down conductor / Earth conductor size shall be considered/design as per
applicable standard.
vii) Equipment earthing conductor and lightning protection conductor shall be run
separately without touching each other at any point.

10.18 Mounting Structure for LCS/ Safety Switches/ Junction Boxes

Structures fabricated out of mild steel standard sections, i.e. channels, angels, flats
etc conforming to IS: 2062 shall be fixed on the conveyor structure at suitable
locations for mounting of LCS, safety switches, hooters and Junction Boxes, as per
mounting details of the respective items.

11. IFFCO’S SCOPE FOR THE PROJECT

i) IFFCO will remove any material lying at site & provide a clear space at the
proposed location for site execution by successful bidder. However any levelling
& compassion of soil, construction of temporary roads for movement of vehicles
of the contractor shall be considered in vendor’s scope.
ii) Water and electricity for execution of the job shall be provided by IFFCO on free
of cost basis from the convenient tapping points within plant battery limit and
contractor shall manage for bringing the same to utility points in safe manner.
iii) IFFCO will provide space for storage of material supplied by the vendor at a
pre-determined space mutually agreed upon by the vendor & IFFCO. However
unloading & storing of material at site shall be in vendor’s scope.

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12. INSPECTION AND TESTING

i) QAP of all the equipment / items to be supplied by the contractor shall be

submitted by them for IFFCO’s approval. No manufacturing clearance/ dispatch
clearance shall be given to the contractor without prior approval of the QAP.
Manufacturing, testing, inspection, supply and erection shall be done as per the
approved QAP.
ii) All components of the system shall be subjected to inspection and testing at
different stages of manufacture by IFFCO’s Inspection Engineers as per
relevant standards.
iii) The contractor, on demand from IFFCO Inspection Engineer, shall carryout
such tests in an appropriate manner in the presence of IFFCO Engineers free of
charge to owner.
iv) In all cases where tests are to be carried out, the contractor shall provide free of
charge such labour, materials, apparatus and instruments and supervisory staff,
as may reasonably be demanded, to carryout efficiently such tests of
equipment, material or workmanship in accordance with the contract.
v) If the equipment/ part of equipment are to be manufactured at any other
premises, the contractor shall obtain permission for the owner to inspect and
test the work.
vi) Contractor shall dispatch the equipment only after the inspection done at work /
waived-off by IFFCO.
vii) The contractor shall give at least 10 days clear notice to owner when the
different parts / complete equipment are ready for inspection. If the equipment /
parts are not provided for inspection on the appointed dates, the owner
reserves the right to recover all the expenses incurred on their inspector’s visit
from the contractor.
viii) IFFCO shall ensure that the inspection is carried out promptly after receiving
notice. In the event of waiver of inspection by owner, such inspection or test,

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shall be carried out internally by the contractor in inspector’s absence. The

contractor shall furnish such test / inspection reports for inspector’s perusal.
ix) No inspection, test or acceptance during the course of manufacture or at final
stages shall relieve the contractor from his responsibility for any failure to
conform to the contract specifications or for faulty design, material or
workmanship which may subsequently develop up to the guaranteed period.
x) The contractor shall furnish necessary test certificates, drawings and other
relevant data as may be required for inspector’s review. Such inspection by
IFFCO inspectors shall however not relieve the contractor of their responsibility
for the quality and workmanship guarantee of the equipment.

13. REJECTION OF EQUIPMENTS

i) For acceptance or rejection of equipment / part, inspection at IFFCO’s site shall

be final even when prior inspection has been carried out at contractor’s/ sub-
contractor’s work by IFFCO.
ii) If the equipment are as per contract specification or fail to perform specified
duties or otherwise not found satisfactory by the inspector, the owner shall be
entitled to reject the equipment / material or part thereof and ask for free
replacement within reasonable time, failing which the owner has all the powers
to obtain his requirements elsewhere at contractor’s risk and cost.
iii) In the event of such rejection the owner shall be entitled to the use of
equipment in a reasonable and proper manner for a time reasonably sufficient
to enable him to obtain replacement.
iv) Equipment rejected by owner shall be removed by contractor if installed and
taken back at his own cost within 15 days of notice.
v) In case of rejection of equipment, owner shall have the right to recover the
amount if any paid from any of his invoices pending with the owner or by any
other alternative method.

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vi) Nothing in these clauses shall be deemed to deprive the owner of his right or in
any way relieve the contractor of his obligation under the contract.

14. DELIVERY PERIOD

A kick off meeting along with site survey by the engineering team of the vendor
shall be scheduled within 15 days of acceptance of LOI/PO.

Following delivery schedule shall be considered for project completion.

i) Detailed Bar Chart : Vendor shall submit a detailed bar chart in MS Project up
to level 4 for complete design & engineering, supply, civil construction,
structural fabrication & painting, erection, installation of conveying system,
commissioning and load trial/GTR within 15 days from the date of Site visit &
kick off meeting.
ii) For Design & Engineering: 90 days from the date of Site visit & kick off
meeting.
iii) For Supply: Supply of all the items in contractor’s scope shall complete within
180 days months from the date of Site visit & kick off meeting.
iv) For Site Execution: 240 days / 8 months from the date of Site handover.
However vendor may planned parallel activities for Civil Construction, Structural
fabrication & painting job at site to minimise the complete execution period.
v) For Load test & Commissioning: 30 days from completion of mechanical
erection.

15. PROGRESS REPORT

Contractor shall submit regular progress report on monthly basis, in a format

mutually agreed with IFFCO. However, any indication in the progress report
showing slippage in time schedule shall not constitute waiver/ extension of
guaranteed completion period.

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16. DISPATCH, UNLOADING AND STORAGE OF MATERIAL AT SITE

i) All care shall be taken to ensure safe transport and protect the component parts
from such damages during transportation which may render them unsuitable for
use at site.
ii) Receipt & unloading practices will be as per prevailing rules & regulations at
IFFCO Paradeep site.
iii) Proper arrangement for Storage of Cement & Reinforcement items shall be
arranged by vendor at allocated site.
iv) All structural may be supplied in knocked-down condition but secured
completely and placed on wooden slabs to avoid direct contact with vehicle.
v) All other machinery parts including electrical and minor components shall be
supplied packed in wooden crates suitably and match-marked to ensure correct
assemble at site.
vi) The cargo shall be marked with the name of consignee, purchase order number
and other necessary information as indicated by the purchaser before dispatch.
vii) Loading, unloading and storage at site, safety and protection of various
components at site etc. shall be the sole responsibility of the contractor /
supplier. The contractor shall also arrange for the safe handling, storage,
protection and security of his goods at site. For this, IFFCO shall provide an
open space to the contractor which shall be developed by the contractor for
safe storage of supplied equipment.

17. MECHANICAL COMPLETION,COMMISSIONING AND ACCEPTANCE

17.1 Mechanical Completion: Mechanical completion shall be considered as achieved

when the system is mechanically complete along with the pre-commissioning
activities and is ready for feeding. This shall include but not limited to the following:
i) Installation as per FINAL PROPOSAL is complete in all respects in accordance
with the drawings, specifications including any approved changes there to and
in accordance with all applicable codes and laws.
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ii) The machinery, conveyors and all drives are aligned and run or cycled under
no-load conditions.
iii) Instruments are installed, inspected and simulation test done.
iv) The electrical system is installed and tested in accordance with applicable
codes and specifications. All wiring is checked for correct hook-up. Motor
rotation is checked and power system protective devices are set. Following test
should be specifically conducted before commissioning of the system
 Insulation Test.
 Continuity Test.
 Simulation Test.
 Earth Resistance Test.
 No Load & Load Run Test for motors
v) Painting is completed to the extent that the incomplete work does not prevent
plant start-up and commissioning.
vi) Successful completion of no-load test of all the equipment and the complete
system.
vii) Temporary construction facilities are removed to the extent necessary to permit
the plant start-up and commissioning.
viii) IFFCO shall inspect and certify that the contractor executed the job in
accordance with drawings and specifications.
ix) When the complete belt conveyors and related equipment have been fully
erected at site, CONTRACTOR shall request IFFCO for their agreement to start
the No-load Test Run. IFFCO shall, within 72 hours of receipt of such request,
issue his agreement or advise contractor in writing of any deficiencies noticed in
the equipment.
x) Omissions / Rectifications of minor items, if any, not affecting commissioning
shall not withhold MECHANICAL COMPLETION as long as the contractor
agrees to supply / rectify the same within the specified period. The decision of
the IFFCO is final in this regard.
17.2 Commissioning: After issue of Mechanical completion certificates by IFFCO,
CONTRACTOR & IFFCO shall mutually decide the date of Commissioning (feed

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in) of the equipment. From the date of Commissioning, the equipment shall be
gradually brought up to full load or any other load at the discretion of IFFCO, and
thereafter the equipment shall be run for a minimum period of 5 days. IFFCO shall
have the right to reduce this period where deemed necessary because of IFFCO’s
difficulties. During this period of 5 days of operation or the reduced period, the
system shall run at an average of 90% of rated capacity. If the CONTRACTOR is
not able to bring the load to 90% of the rated capacity as mentioned above within 2
(two) months, IFFCO shall, without prejudice to any of his rights under the
contract, has the right to take over the equipment and to proceed with
modifications / rectifications /additions as he considers necessary at
CONTRACTOR‟s cost and risk to achieve this sustained load run.

18. GUARANTEE
18.1 Performance Guarantee
i) Capacities: All the equipment and the complete System should be able to
achieve at least 100% of the specified design capacities at a particular period
and normally. However, a margin of 5% should be kept over the specified
design capacity while designing the equipment, for occasional over-loading.
ii) Power Consumption: In no case, the individual equipment shall consume
more than 10% of the specified power consumption. However, the complete
system shall not consume more than the specified guaranteed maximum
power consumption.
iii) Noise Pollution: The equipment shall be guaranteed against excessive noise
pollution. Noise should not exceed 85 dBA measured at a distance of 1.0
meters from the noise emitting source.
iv) The complete Handling system and its equipment including its all accessories
and auxiliaries shall be guaranteed for satisfactory operation while handling
the specified capacity continuously for 24 hours per day, 7 days per week and
330 days per year to ensure trouble free performance.
v) In case the equipment fails to show specified performance, the contractors
shall carryout modifications in design, provided materials and complete the

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equipment free of cost to the Purchaser and show load trial to achieve the
specified performance.
vi) In case, the contractor fails to achieve the specified performance even after
the modifications within one month time of the trial runs, the Purchaser
reserves the right to make alternative arrangements for modification /
rectifications at contractor’s cost & risk without any prejudice to any terms of
the contract.

18.2 Material & Workmanship Guarantee: Shall be valid for a period of 18 months from
the date of supply or 12 months from date of commissioning, whichever is earlier.

i) All components as well as the complete equipment shall be guaranteed

against defective design, bad workmanship and faulty material of
construction for complete guarantee period.
ii) In the event of notice of any such defects during guarantee period, the
contractor shall immediately arrange for replacement or rectification free of
cost to Purchaser failing which purchaser reserves the right to arrange
rectification or replacement at contractor’s cost.

18.3 Tolerance for accepting performance Guarantee

i) Throughput (capacity): The equipment/subassembly shall get automatically
rejected if it is unable to achieve even 95% of the design capacity. However,
any reduction in throughput from 100% of design capacity shall also be liable
for penalties. For every 1% reduction in capacity, a penalty of 1 % the total
contract value shall be deducted from the bills of the contractor, subject to
maximum 5 % of the contract value.
ii) Power Consumption: Contractor must specify the maximum guaranteed
power consumption at the rated (normal) capacity. Any increase in power
consumption, penalty @ 0.5% of the contract value for every 1% excess
consumption shall be deducted from the bills, subject to max. 5% of the
contract value. If the complete equipment consumes more than 10% of the

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power consumption than the specified power consumption, the equipment

shall be rejected.

19. DOCUMENTATION

19.1 With offer: Two stage bidding process will be applicable for this project.Bid
documents shall be submitted in two parts. Technical & Price bid will be submitted
in separate sealed envelope. Bidders, in their technical offer are required to furnish,
but not limited to, the following details/ documents:

i) Design basis with all the assumptions made by the bidder.

ii) Detailed list of items considered by the bidder in their scope for the
completion of the job.
iii) Specifications of materials of construction of parts / component as per
applicable standards and good industry practices.
iv) Conveyor layout, as envisaged by the bidder with tentative GA drawing for
the complete system as per scope defined in clause no.
v) Proposed Bar chart covering all the aspects of work involved.
vi) List of spares (commissioning & two year operations) considered by the
bidder in their scope of supply. Spare prices (two year operation spars) shall
be included for bid evaluation process. Spare prices shall be valid for a
minimum period of 5 Years.
vii) List of deviation by the bidder if any (only in the specified format).

19.2 After placement of order: After placement of order, bidder shall furnish a detailed
bar chart in MS Project up to level 4 and QAPs for the items to be supplied against
the order awarded. Drawings/ documents to be furnished during the course of
execution of this job are indicated below:

i) During detail design and engineering. Contractor shall furnish soft copies
of all the drawings/ documents through mail for IFFCO’s approval/ reference
as per approved QAP/ITP. List of documents/ drawings to be submitted by

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the contractor during the period of design and engineering is given as below.
However, an exhaustive list of all the drawings/ documents shall be prepared
by the contractor which shall be approved by IFFCO, after placement of
order.

 Detail Layout Drawings for Storage shed, Transfer towers,

Maintenance towers, transfer & reclaiming conveyors.
 Detail drawings of foundation along with design calculation.
 Detail drawings of Piles along with relevant load data.
 Bill of material (civil, mechanical & electrical).
 GA drawings of the conveying system with specification sheet
and load data.
 Power, capacity and shaft dia. calculation for the conveyor.
 GA drawing of the tripper with specification sheet & load data.
 Idler schedule and idler drawings.
 Pulley schedule and pulley drawings.
 GA drawing of the take up unit. Drawings of the inlet chutes
and tripper discharge chute.
 GA Drawings of drive base frame, pulley frames.
 GA Drawings of skirt board and deck plate.
 Details drawings of tripper including frame, CRD, Rail cleaners,
rail clamps, and scrapper.
 Detail drawings of short post, stringers, rails supporting
structure etc.
 GA, SLD & Control schematic drawing of Tripper control panel
& local control panel for fluid coupling oil cooler & Scooping
motor.
 GA SLD & control schematic of MCC.
 Lighting layout with detail illumination calculation.
 Cable tray layout.
 Grounding layout.
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 Layout drawings for lightening protection.

 Control schematic diagram of safety switches.

For all other bought out items, contractor shall furnish their GA drawings for
IFFCO’s approval.

ii) During Procurement stage:

 Unpriced purchase order copy for all bought out items.
 Soft copies of detail drawings for IFFCO’s review before start of
manufacturing.
 Soft copies of test certificates/ material test certificates/ inspection
reports before dispatch.

iii) During Project Execution: Monthly progress reports in format mutually

agreed with IFFCO.

iv) After completion of the job:

 Hard Copies: Four sets of all as-built drawings.

 Hard Copies: All GA drawings & specification sheets of all bought out
items
 Hard Copies: Four sets of Operation and maintenance manual of all
equipment.
 Soft copy of all the drawings & documents in Auto-Cad format in CDs
(two).
 Guarantee Certificates.

20. PREFERED VENDOR LIST:

Make of all the bought out items shall be as per the list given below.
Sl.No. Item Vendor’s Name
MECHANICAL

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1 Conveyor Belt i) MRF

ii) Hindustan Rubber (Silvasa)
2 Gear Box and Worm gear reducer i) Elecon
3 Flexible coupling (Fluid coupling i) Premium
and pin bush coupling) ii) Elecon
4 Gear Coupling i) Elecon
5 Pin bush Coupling i) Fenner India
6 Radiator for scoop Coupling i) Premium
7 Thruster Brake i) Electromag
8 Skirt Board i) Indiana Conveyor
9 Belt Cleaner i) Thejo Engineering
10 Pulleys i) FL Smith
ii) Rampur Engineering
11 Carrying & Return Idler (HPPE) i) Global Conveying system,
Goa
ii) Indiana Conveyor
iii) TRF Ltd.
12 Impact Idler i) Indiana Conveyor
ii) TRF Ltd.
13 Self-Aligning Idler i) Indiana Conveyor
ii) TRF Ltd.
14 Idler Frame i) Indiana Conveyor
ii) TRF Ltd.
15 External Belt cleaner i) Hosch
ii) Kaveri
16 Nuts, Bolts etc. i) GKW
ii) Precision Fasteners Ltd.
iii) Accurate metal Industries
17 EOT Crane i) REVA
ELECTRICAL

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1 Motor-HT BHEL
2 Motor-LT i) ABB
ii) BBL
iii) Crompton
iv) Siemens
3 MCC Panel i) L&T
ii) Interlec
4 LSDB i) Hensel
ii) Crabtree
iii) Cape Electric
iv) Obo
5 Cable i) Gloster
ii) KEC
iii) Cords Cable
iv) CCI
6 GI Cable tray i) Indiana
ii) Shruti Industries
iii) Pinax
7 LCS i) Sumip/Pushtron
8 Limit Switches and other safety i) Jayashree
devices ii) AG Systems
iii) BCH
9 LED Light Fixtures i) Philips
10 CRD i) Bengal Technocrat
ii) Electrozavod
11 Single Phase & Three phase Switch i) Hensel
Socket ii) Crabtree
12 Radar Type Heap Sensor i) Vega(Model- Vegapuls69)

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21. LIST OF SPARES: Bidder shall quote for following commissioning and two year
maintenance spare for the system.

Commissioning spares:

S.No Description Quantity (nos.)

1. Carrying idlers 2% of qty

2. Return idlers 2% of qty

3. Impact idlers 2% of qty

4. Self-Aligning Idlers 2% of qty

5. Fluid coupling seal kit One number for each type

6. Fusible Plug One number for each type

7. Oil seals for gear box One number for each type

8. Couplings NIL

9. Any other spare as considered by the bidder.

Two year Maintenance spare:

1. Carrying idlers 6% of total qty

6% of total qty
2. Return idlers

6% of total qty
3. Impact idlers

6% of total qty
4. Fluid coupling seal kit

5. Fusible plug 4 nos for each type

6. Oil seals for gear box 6 nos for each type

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7. Low speed coupling for conveyor 1 no for each type

8. Input and output coupling for travelling 1 no for each type

tripper

9. Self-Aligning Idlers 6% of total qty

As per OEM
10. Spares for CRD recommendation
As per OEM
11. Spares for Thruster Brake Assembly recommendation

12. Any other spare as considered by the bidder.

22. GENERAL TERMS AND CONDITIONS

i) Contractor shall arrange adequate “Working Team” to execute the work in
totality. The working should consist of technically competent Site-in-
charge with competent supervisors and sufficient number of skilled and
unskilled manpower.
ii) All the tool, tackles, hardware and consumables required for the
completion of job shall be arranged by contractor. Contractor shall
submit list of tools, tackles etc. which he will use to perform the work and
the same will be brought inside the plant site duly signed by Security In-
charge as per prevailing security rules at IFFCO. These tools etc. shall
not be removed from the site till the completion of job. A gate pass must
be obtained from IFFCO in order to remove the same from site. All the
tool, tackles, machinery, furniture brought by the contractor shall remove
within 30 days of expiry of the contract.
iii) All the tools, tackles, machinery etc. used by the contractor shall be in
healthy condition. IFFCO’s representative, at any instant can check the
soundness of the equipment either by reviewing their fitness certificates

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or by witness testing at site (to be arranged by the contractor at his own

cost in absence of the fitness certificate).
iv) Contractor must keep the record of inspections carried out during the
execution of the job. In case of site execution, contractor shall be
responsible for providing safe access to IFFCO’s inspector for carrying
out the inspection at any desired location / elevation.
v) The contractor to take suitable Insurance Cover Policy for his workmen to
cover the risk of accident/death and payment of compensation under the
“Workmen Compensation Act” at his cost. The contractor to submit
documentary proof in this regards to IFFCO.
vi) Contractor shall ensure to pay minimum wages for his own employees as
per the minimum wages fixed and notified by Govt. of Orissa / IFFCO
within next 07 (Seven) days for each passed month in presence of
IFFCO’s Engineer In charge.
vii) Contractor shall abide by all safety rules prevailing in IFFCO Paradeep
and act on the instructions of IFFCO, where it is necessary to operate a
“permit to work system”. Contractor should take safety work permit from
concerned plant’s Shift Engineer, before start of work and get it renewed
in each shift. While working at heights, safety belts shall necessarily be
used.
viii) Job Safety Analysis is to be carried out & a document is to be prepared
and the same has to be approved from by IFFCO safety officer in charge.
ix) Contractor shall observe all statutory and legal requirement issued by
central and state governments applicable to work as well as any local
regulations applicable to the site. IFFCO shall not be responsible for any
injury / accidents / Insurance Coverage of contractor's personnel, while
working at IFFCO site.
x) The contractor shall obtain the necessary clearances, Certificate of
compliance/ completion certificate with test results from statutory
authorities as required. The vendor shall furnish all necessary drawings
and test certificates as required by the Inspector.
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xi) Contractor shall not permit the entry to the site of any persons not directly
connected / concerned with the work. All employees of contractor shall
confirm to any rules of conduct etc. established by IFFCO. Failure to do
so will be sufficient cause for removal of such a person from the site.
xii) Contractor shall make his own arrangement for the residential
accommodation of his staff and supervisors and for their transportation, to
and from the site, to the place of stay. However in exigent circumstances,
IFFCO may consider to provide chargeable accommodation subject to
availability of space.
xiii) The contractor shall write / maintain logbook for job allocated and its
progress, obtain signature immediately on completion of job from the
respective engineer. The job wise material consumption is also to be
recorded in the log book.
xiv) The contractor shall arrange necessary Gate pass for his personnel along
with photographs for security requirement. Contractor should be in
possession of the gate pass while inside plant premises and produce the
same on demand by IFFCO authority.
xv) The contractor shall be responsible for the performance of his workmen
to the entire satisfaction of IFFCO.
xvi) The contractor shall mobilize sufficient skilled manpower for executing job
at parallel fronts.
xvii) Contractor shall arrange for issue of material from IFFCO‟s Store and for
returning material to store or disposing the scrap to IFFCO‟s scrap yard
on completion of the job.
xviii) All measurement sheets shall be submitted for verification by IFFCO
Engineer within 07 days from date of completion of job and all monthly
running bills completed with all relevant documents shall be submitted
within 10 days of each passing month.
xix) IFFCO shall provide the space for construction of working shed and for
storage of the material required for completing the system. It will be the

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responsibility of the contractor to ensure proper and safe storage of the

material and to maintain good housekeeping in their work area.
xx) Hydra, crane and other earth moving equipment required by the
contractor may be issued by IFFCO on chargeable basis, subject to their
availability and on advance intimation of minimum one day.
xxi) Subletting of the contract is not permitted. However, if it is required in the
interest of the project, prior approval of IFFCO shall be taken by the
contractor before engaging the subcontractor.
xxii) It is highly recommended that the bidder shall visit the site to see the
actual site conditions before submitting their offer.
xxiii) All equipment shall be provided with stainless steel nameplates
containing the relevant particulars along with the description and Code
Nos. of equipment.
xxiv) The contractor shall coordinate with IFFCO‟s other vendors involved in
the project and shall freely exchange all technical information required for
the purpose of this package.

23. PAYMENT TERMS

i) 10% advance against submission of following

 Acceptance of LOI/PO & WO
 Proforma Invoice
 Advance Bank Guarantee (ABG) of equivalent amount issued from
any Indian nationalized / scheduled bank in prescribed format valid up
to completion of Supplies plus 30 days claim period.
 Performance Bank Guarantee of 10% of total order value issued from
any Indian nationalized / scheduled bank in prescribed format valid till
the end of Warranty period plus 06 months claim period.
The payment shall be released within 30 days of the date of the receipt of invoice
with supporting document (ABG, PBG & Acceptance of LOI).

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ii) 70% of order along with applicable taxes and duties on pro rata basis after
receipt & acceptance of supplied material at site.
iii) 10% of order after mechanical completion & receipt of all As-Built drawings
and documents including operation & maintenance manual.
iv) 10% after commissioning of all equipment & GTR.

24. PRICE SCHEDULE

Bidder after thoroughly understanding the quantum of the job , specified
requirements and other terms & conditions of this project shall strictly quote as per
the price schedule mentioned below.

Sl. Item description Unit Qty. Rate Amount

A. Design & Engineering

1 Civil Lumpsum QUOTED QUOTED QUOTED

2 Structural Lumpsum QUOTED QUOTED QUOTED

3 Conveying System Lumpsum QUOTED QUOTED QUOTED

4 Electrical & Instrumentation Lumpsum QUOTED QUOTED QUOTED

B. Supply

1 Concrete Cubic QUOTED QUOTED QUOTED

Meter
2 Reinforcement & Embedment MT QUOTED QUOTED QUOTED

3 Miscellaneous Civil Items Lumpsum QUOTED QUOTED QUOTED

4 Steel Structure MT QUOTED QUOTED QUOTED

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5 Paint Litre QUOTED QUOTED QUOTED

6 Conveying System Lumpsum QUOTED QUOTED QUOTED

7 Electrical & Instrumentation Lumpsum QUOTED QUOTED QUOTED

C. Construction / Erection & Commissioning

1 Civil Construction of Storage Cubic QUOTED QUOTED QUOTED

Shed Meter
2 Civil Construction of Cubic QUOTED QUOTED QUOTED
Underground RCC Conveyor Meter
Gallery
3 Foundation & pedestals for Cubic QUOTED QUOTED QUOTED
Transfer points, Trestles & Meter
equipments.
4 Structural Fabrication MT QUOTED QUOTED QUOTED

5 Painting Sq. Meter QUOTED QUOTED QUOTED

6. Erection of all Mechanical Lumpsum QUOTED QUOTED QUOTED

Items
7 Erection of all Electrical Items Lumpsum QUOTED QUOTED QUOTED

8 Commissioning Lumpsum QUOTED QUOTED QUOTED

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25. SAFETY REQUIREMENTS

25.1 Compliance of Statutory Requirement

i) All requirements under the Factories Act 1948 and the rules framed there
under in the Orissa Factories Rules 1950, including all amendments thereto.
ii) All requirements of Employee Compensation Act & ESIS Act, including all
amendments thereto.
25.2 Qualification and Experience of Manpower to be deployed
i) Contractor shall deploy only experienced and qualified Engineers, Safety
Officer, Supervisors and Workmen.
ii) The Safety officer deployed by the contractor shall be qualified as per
statutory requirements.
iii) Contractor’s Skilled Workmen like Riggers, Scaffolders, Welders, Fitters,
Crane Operators, their specialized Equipment Operators like Welding
machine, Power Generators, etc. must have sufficient past experience and
skill on the relevant jobs. The Electricians to be deployed must have valid
qualification.

25.3 Training

i) Training in Fire & Safety is mandatory for all Contractors’ Supervisors &
workers and it will be conducted by IFFCO Fire & Safety Department.
ii) All contractors’ workmen must have to undergo Medical Examination, Height
Phobia Test and Safety training before they are issued gate passes by
Security Department of IFFCO Paradeep.
iii) Daily Tool Box talks must be conducted by the Safety Officer/Supervisor of
the contractor prior to starting of jobs at site. Attendance of workers with their
signatures in such Tool Box talks must be properly recorded in a register.
The register should also contain the name of the persons delivering Tool Box
talks with dates along with the bulletin of topics discussed.

25.4 Compliance to Work Permit System

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i) Contractor shall not carry out any work without valid Work Permit issued by
the authorised person of IFFCO at the project site as per Work Permit
System.
ii) Contractor shall comply with all the Hot Works/Cold Works/Vessel
Entry/Work at Height Permit conditions specified in the Permit.
iii) Display of Permit shall be done at Worksite for random checking by the plant
Officials & Fire & Safety Department.

25.5 Requirement of Supervision and Safety records

i) Contractor will not carry out any work without having Supervisor at site. If it is
required to work simultaneously in more than one location under the same
Contract, One Supervisor must be deployed at each of the locations. If a
Supervisor has to leave his Site for any reason, he must stop the Site
activities for that Period of Time.
ii) Contractor must provide at least one full time qualified Safety Officer at the
project site.
iii) Contractor to maintain safety register and records for tool box meeting etc.
iv) Contractor to carry out monthly check of PPEs.
v) Contractor to carry out weekly safety site inspection /audits, monthly safety
meetings and maintain records.
vi) Contractor to submit monthly safety report on first week of every month to
the Engineer-in-Charge and F&S Dept.
vii) Contractor must periodically check all the lifting machines, cranes, ropes &
lifting tackles at site and all the valid test certificates shall be submitted to
F&S Department of IFFCO.

25.6 Use of Personal Protective Equipment

i) The PPEs shall be of Standard quality and BIS approved. For such PPEs
where BIS is not available, the PPEs shall be of any international standard
like CE/EN/FM marked.

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ii) All Supervisors and Workmen of the Contractor shall enter plant premises
wearing Safety Shoes & Helmet, failing which entry will be denied. The
Contractor should provide basic PPEs to all Supervisors and Workmen.
iii) Minimum requirements for all jobs are –
 Safety Helmet (Industrial Safety Helmet), shall confirm to IS: 2925-
1984.
 Safety Shoes with steel toe, shall confirm to IS: 15298.
 Safety goggles
 Hand Gloves.
 Reflective jackets.

25.7 Specific requirements as per Job or activity

i) ISI approved Double Lanyard with scaffolding hooks full body safety harness
for working above Height of 1.8 Meter from the Ground Level. It shall confirm
to requirement made under IS: 3521-1983.
ii) Eye Protection Goggles.
iii) Welders Helmet and gloves.
iv) Face & Body protection for handling chemicals and hot works.
v) Hand Protection gloves for gas cutting, grinding, electrical works.
vi) Hearing protection for high noise areas or works.
vii) Respiratory protection/mask as per requirement of job and working condition.

25.8 Warning Signs and Barriers

The contractor shall arrange necessary material to secure the work site and to warn
the plant personnel or other workers of hazards. This shall include - Warning signs,
Barricades around excavations and welding and cutting jobs at height, including
illuminating warning signs.

25.9 Specific Job Requirements

25.9.1 Earth excavation

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i) All excavated pit & trenches shall be barricaded with tap and rigid pipelines.
ii) Pumping out of accumulated water from pit is to be done at regular intervals.
Run-away water shall be prevented from entering the excavated area, as
such water can cause erosion of soil and sudden collapse of earth.
iii) Excavated earth shall be stacked at least one meter away from cutting edge
to avoid collapse of trench and sliding of heaped earth into trench.
iv) All the safety precautions as stipulated in IS: 3764-1992- (Excavation work-
code of safety) shall be followed while excavation work.
v) Movement of heavy vehicles shall be restricted on loose soil.

25.9.2 Piling and Other Deep Foundations

The following precautionary measures shall be taken:

i) Piling machine operators shall have sufficient past experience and properly
trained.
ii) Prior to piling, all underground services shall be located and made safe.
iii) There shall be a firm level base for the crane. If necessary crane mats shall
be provided.
iv) The workers shall use necessary personal protective equipment.
v) All cranes, lifting appliances and lifting gear must have appropriate
certificates of testing and shall be of capacity required for the job. The test
date, due date and identification mark shall be mentioned on all cranes,
lifting appliances and lifting gears.
vi) Particular attention shall be provided to the risk of damage to lifting gear from
sharp edges.
vii) Relevant BIS Safety Code for piling and deep foundations shall be followed.

25.9.3 Work at Height

Proper Scaffolding is to be ensured as per following guidelines

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i) Only cup-lock type mild steel scaffolding shall be used by the contractor.
Scaffolding pipes shall be in good condition and preferably painted.
ii) Metal scaffolds shall confirm to IS: 2750-1964 in addition to IS:3696 (Part 1)
iii) Proper base plate supports must be provided in the scaffolding posts.
iv) Safe step ladder / monkey ladder with cage and hand rail shall be provided
to access scaffold platforms. The intermediate & final stage must be
provided with hand rails and toe guards on the working platforms.
v) Safety nets must be installed to catch workers and / or debris falling whilst
working on structural fabrications. The Safety nets shall confirm to
requirements made under IS: 11057- 1984.
vi) All members of metal scaffolding shall be checked periodically to screen out
defective /rusted members. All joints should be properly lubricated for easy
tightening.
vii) Clear access to scaffolds shall be maintained at all times. For prohibiting
entry of unauthorized persons in scaffolds area, barricades should be put up
and warning notices prominently displayed.
viii) It is essential to obtain stability certificate from the manufacturer about
safety and stability of metal scaffolds under likely worst combination of loads.
ix) While working at height using scaffolding, double lanyard full body harness
with scaffolding hooks must be worn.
x) All the scaffolds shall be initially and periodically certified by competent
scaffolding inspector and tagged appropriately. Only fit-to-use scaffolds shall
be in use.
xi) It shall be ensured that only trained & experienced workers are engaged in
scaffolding work.

25.9.4 Hot Work (Welding, Cutting & Grinding etc.)

Adherence to relevant codes and employment of qualified and tested welder are
two basic requirements for welding and gas cutting process. Hazards such as

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electricity, heat/flame, flammable gas etc. are present in this process. Hence
following precautions must be followed while carrying out these operations.

i) Hot work permit shall be obtained wherever applicable before

commencement of the work.
ii) All fire precautions as stipulated in IS: 3016 (code of practice for fire
precautions in welding and cutting operations) shall be followed while
welding/gas cutting.
iii) Welder helmet, welding gloves (18“long), Safety Shoes is minimum required
PPEs to be provided for welders.
iv) For cutting jobs face shield, gloves and safety shoes must be worn.
v) Fire extinguishers, sand buckets and water shall be provided when hot work
is in progress.
vi) Gas cylinders used for gas cutting shall
 Be of approved make.
 Be kept upright, and is kept away from hot work and care shall be
taken to prevent heating of gas cylinders.
 Be stored in trolley with chain arrangement.
 Gas cylinder valves shall always be checked and shall be closed when
not in use.
 Be stored in a well-ventilated area.
 Be fitted with safety caps when not in use.
 Not be lifted by nozzle and rolled.
 Flashback arrestor must be provided in Cutting torch, LPG Cylinder
and Oxygens cylinder.
vii) When working at a height, do not place cylinders directly beneath the working
area, as molten metal may fall onto the hoses, causing leaks and possibly
igniting the gasses.
viii) During electric arc welding process, very high ultra violet radiation is
generated. The welder and any person working in close proximity, in order to

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prevent permanent damage to the eyes must wear suitable eye protection.
When not in use, power supply to the holder and electrode shall be turned off.
ix) Hose shall be in good condition, and properly clamped.
x) Welding cable shall have proper insulation with minimum number of joints.
xi) All equipment shall be properly earthed, and cables properly insulated and
connected.
xii) RCCB shall be provided in every welding circuit.
xiii) Earthing shall be dedicated for each circuit.
xiv) All portable grinder must be double insulated type. Before use grinding wheel
must be checked for any crack, damage etc.
xv) Never adjust the work piece or work mounting device when the machine is
operating.
xvi) Grinding wheel must be properly guarded. Never operate the grinding
wheels at speed in excess of recommended speed.
xvii) On-bench grinders, adjust tool rest 1/16 to 1/8 inch from the wheel.
xviii) Radiography shall be carried out under hot work permit. Radiography
to be carried out in ‘NO WORKMEN ZONE’ and preferably during evening/
night. Based on the maximum allowable radiation, area shall be cordoned off.
Adequate warning signs on the outskirt of cordoned area shall be provided.
All required Personal Protective Equipment’s must be used.

25.9.5 Working with Machineries / Material Handling Equipment

Material handling is highly hazardous operation. Hence special attention by

contractor is required in this respect. Following precautions are essential:

i) Safe working space for all handling equipment shall be provided. Proper
material stockyard should be made and all material should be
stacked/arranged/kept in orderly manner with proper moving space for
handling machinery. Proper wooden sleepers should be provided below steel
plates and such other materials.

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ii) Proper warning boards/signs shall be provided when machineries like

cranes, hoists are being operated.
iii) Brakes, clutches of winches shall be checked on regular basis through third
party inspection agency. Chains, ropes, belts shall be inspected and
repaired/changed and test certificate to be submitted to IFFCO’s F&S
department.
iv) All moving parts of the material handling equipment must be provided with
suitable guards.
v) Lifting ropes should be inspected for kinking, loose wires, high strands,
corrosion, nicking, lubrication, and change in diameter /cross section.
vi) Flag Man should always accompany during heavy vehicle/ hydra/ crane
movement.
vii) All works involving the use of crane shall be properly planned in advance
and shall be ensured that crane is capable of lifting the load. Safe load
capacity should be clearly marked on jibs, winches, pulleys, slings and
ropes. All job cranes should have an automatic safe load indicator which
alerts the operator.
viii) The condition of the ground at the crane location should be satisfactory to
support the crane and the load.
ix) Load test of all cranes, lifting tools, tackles and lifting gear must be done by
competent person certified by Directorate of Factories and Boilers, Odisha.
The test date, due date and identification mark shall be mentioned on all
cranes, lifting appliances and lifting gears. The test certificate shall be
submitted to IFFCO’s Fire & Safety Department.
x) Crane operators and signallers must be trained and sufficiently experienced.
The crane operator must possess valid license to operate the crane.
xi) No person should be allowed to stand or work under lifted load and inside
the swing area.

25.10 Electrical Safety

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i) The contractor shall ensure that all electrical equipment used by his
personnel are properly earthed or grounded and fitted with a proper plug top.
Use of damaged/bare cables/conductors for any machine is strictly
prohibited. Cable shall be laid preferably in one piece length to avoid joints.
All cable must be properly insulated.
ii) Work permit and isolation of the electrical system before taking up the work
must be ensured.
iii) All circuits shall be provided with dedicated ELCB/RCCB. There shall also be
dedicated earthing for each equipment and effectiveness of earthing shall be
checked every time before commencing work/switching on the electrical
system.
iv) Any earthing wire not to be connected to the structure/pipelines.
v) IS: 5216-1982 “Recommendations on safety procedures and practices in
Electric Works" shall be referred for further safety measures.

25.11 Traffic Safety

i) Contractor’s driver must get themselves familiarized with factory roads and
traffic regulations on certain roads.
ii) All vehicles entering or leaving the factory must come to a complete halt at
the security gates, for checking by the security Office.
iii) All the vehicles including heavy machineries like hydra, crane etc. shall be
registered on Contractor Vehicle Pass Entry System of IFFCO Paradeep
Unit.
iv) The maximum speed limit for all the vehicles with in the company premises
is 20 KMPH.
v) Anyone driving a motor vehicle on company property must be in possession
of a valid driving license.
vi) Transportation of contract personnel not permitted by goods carrier like
Tractor Trolley, forklift, Dumper etc.
vii) Hydra shall not be allowed to move with load outside the project site.

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viii) Within the project site Hydra shall not carry any material more than 6 m
long.
ix) No crawler mounted vehicles shall be allowed to move on the in-plant roads.
If necessary slip plates shall be provided.

25.12 House Keeping

Contractor must ensure the highest standard of housekeeping in his areas of work
on a daily basis. Good Housekeeping will eliminate many unnecessary hazards
causing accidents.

25.13 Penalty System for Safety Violations

Any contractor violating the Factories act 1948 & Odisha Factory Rule 1950 shall
be issued Safety Offence notice and may be penalized with the approval of Unit
Head. Project In-charge or concerned engineers may inform to Fire & Safety
department about the penalty amount with Work order no. through email to penalize
the contractor.

26. TERMINATION OF CONTRACT

Following actions on part of contractor may call for termination of the contract.

i) If the contractor does not maintain adequate resources to execute job in time
/ start the work / expedite the job.
ii) If the defects pointed out are not rectified and in case of defects that are
likely to cause severe accident of machinery or human beings.
iii) If the contractor executes work in unsafe manner violating prevailing safety
rules applicable in IFFCO as per clause no. 25.
iv) Not complying with the statutory requirements applicable to such contractors.
v) In case of theft of IFFCO property.

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If contractor fails to comply all the clauses stated above, IFFCO reserves the right to
invite third agency to complete work solely at the risk and responsibility of the
contractor.

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