Portus Venture INDEX TO TECHNICAL SPECIFICATION

SR. No ITEM Doc.no

1 Anti-Termite Treatment Specifications PV/TECSPEC/CIVIL/01

2 Concrete Specifications PV/TECSPEC/CIVIL/02

3 Rebar Specifications PV/TECSPEC/CIVIL/03

4 Formwork System Specifications PV/TECSPEC/CIVIL/04

5 WP Membrane Specifications PV/TECSPEC/CIVIL/05

6 Masonry Works Specifications PV/TECSPEC/CIVIL/06

7 Plaster Specifications PV/TECSPEC/CIVIL/07

8 Structural Steel Specifications PV/TECSPEC/CIVIL/08

9 Crystalline Waterproofing Specifications PV/TECSPEC/CIVIL/09

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Table of Contents

Contents

1. SCOPE ........................................................................................................................................................ 2
2. LIST OF STANDARDS .................................................................................................................................. 2
3. TERMINOLOGY .......................................................................................................................................... 2
1. MATERIALS ................................................................................................................................................ 3
Chemicals ........................................................................................................................................3
2. SUBMITTALS .............................................................................................................................................. 3
3. WORKMANSHIP ......................................................................................................................................... 3
3.1 Treatment for the building without basement ........................................................................3
Treatment to top surface of plinth filling .........................................................................................3
Treatment at junction of wall and floor ...........................................................................................4
Treatment of soil along external perimeter......................................................................................4
Treatment of soil surrounding pipes and conduits ............................................................................4
Treatment for expansion joints ........................................................................................................4
3.2 Treatment for building with basement ...................................................................................4
Treatment to soil below raft ............................................................................................................4
Treatment to soil along the retaining wall .......................................................................................4
Treatment to soil along the external perimeter of the building .........................................................4
Treatment of soil surrounding waste pipes and conduits ..................................................................4
3.3 Essential requirements ...........................................................................................................5
4. QUALITY MANAGEMENT ........................................................................................................................... 5
5. SAFETY CONSIDERATION AND REQUIREMENTS ........................................................................................ 5
6. ENVIRONMENTAL CONSIDERATIONS AND REQUIREMENTS ..................................................................... 5
10. . COMPLETION AND DELIVERY .................................................................................................................. 6
11. METHOD OF MEASUREMENT & RATE ....................................................................................................... 6
12. ANNEXURES ............................................................................................................................................... 6

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1. SCOPE
1.1 The anti termite treatment mentioned below is to create a continuous chemical barrier zone below
and around the building which is under construction and / or which has already come up-to plinth
level.

2. LIST OF STANDARDS
2.1 Work shall be carried out as per latest version of Indian Standards and Code of Practices. List given
hereunder is not to be considered as conclusive and is for reference and guidance only. Any
discrepancies /conflict noticed shall be directed to the Owner /Owner’s Authorized Representative
for his direction/approval. However as a general rule more stringent specification shall take
precedence.

1 IS 4015 (Part-I & II) Guide for handling cases of pesticide poisoning
2 IS 6313 (Part-I) Code of practice for Anti- termite measures in buildings
constructional measures

3 IS 6313 (Part – II) Code of practice for anti-termite measures in Building

(pre constructional chemical treatment)

3. TERMINOLOGY
The following terms and abbreviations shall have the specific meanings as described hereunder. For
terms that are not described herein, the definitions as stated in the applicable Indian Standard
Specifications shall apply.
Plinth: a plinth is the base or platform upon which a column, pedestal, statue,
monument or structure rests.
Basement: Are one or more floors of a building that are either completely or partially below
the ground floor.
Retaining Wall: is built in order to hold back earth which would otherwise move downwards. Their
purpose is to stabilize slopes and provide useful areas at different elevations.

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1. MATERIALS
Chemicals

Chemical Relevant Indian Standard Concentration by weight, percent

Imidacloprid CIB Approved 0.075

Spraying Equipment
A pressure pump shall be used to carry out spraying operations to facilitate uniform
spraying and penetration of chemical into the earth. The chemicals, concentration and dosage
for horizontal and vertical surfaces are based on the IS code of practice for Anti- termite
measures in Buildings. IS 6313 (Part-II).

2. SUBMITTALS

2.1 Contractor shall submit for approval of the Owner /Owner’s Authorized Representative all details of
Material / Product which conforms to the specification laid down in documents.
Submittals shall include
□ Product data sheet
□ Manufacturers certificates
□ Test report of laboratories
□ Alternative product if any with tabulation for confirmation that alternatives proposed
meets / exceeds specification.
2.2 The contractor shall submit the Schedule of work to be carried out.

3. WORKMANSHIP

The principle of the treatment is to create a continuous chemical barrier below and around the
building so as to deny entry to the subterranean termites into the buildings. Treatment is designed
depending on the type of building and is described below.

3.1 Treatment for the building without basement

The treatment will commence after the foundation and the plinth wall construction is completed. The
treatment is carried out in the following stages.

Treatment to top surface of plinth filling

After the soil filling is completed in the plinth area and before the dry rubble packing or sub-grade is laid,
the entire surface of the filled soil and the top surface of plinth wall/ beam shall be treated with

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the chemical emulsion at 5 liters per sq.m. Light roding may be carried out in the soil surface to
facilitate absorption of the emulsion.

Treatment at junction of wall and floor

Roding if necessary to facilitate soaking , shall be carried out along the junction of wall and soil filling
at 15 cm intervals down up to 30 cm. Emulsion shall be sprayed along the wall junction at 1 liter per
linear meter so that it mixes thoroughly with the broken-up soil. The disturbed earth is then tamped
back in place.

Treatment of soil along external perimeter

The soil around the external perimeter of the building up to a depth of 30 cm shall be treated at 2.5
liters per linear meter of the plinth wall. Roding may be carried out to facilitate this treatment.

Treatment of soil surrounding pipes and conduits

When waste pipes and conduits enter the soil inside the area of the foundation, the soil surrounding
the point of entry must be loosened around each such pipe, waste or conduit for a distance of 15 cm
and up to a depth of 7.5cm and loosened soil shall be treated with chemical emulsion.

Treatment for expansion joints

The soil beneath these joints should receive special attention .The treatment should be
supplemented by treating through the expansion joints after the sub-grade has been laid at the rate
of 2 liters per linear meter.

3.2 Treatment for building with basement

The treatment starts when the excavation is complete and before laying soling and pcc. The
treatment is carried out in following stages.

Treatment to soil below raft

Before laying the rubble soling and pcc the compacted & leveled soil shall be treated at 5 liter
/sq.m.

Treatment to soil along the retaining wall

The soil coming in contact with the retaining wall shall be treated at 5 liter per sq.m. The treatment
shall follow the backfilling as backfilling is done in stages of 20 cms but not to exceed a depth of 1
meter. Roding may be carried out to facilitate the treatment.

Treatment to soil along the external perimeter of the building

The soil around the external perimeter of the building up to a depth of 30 cm shall be treated 2.25
liters per linear meter. Roding may be carried out to facilitate this treatment.

Treatment of soil surrounding waste pipes and conduits

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When waste pipes and conduits enter the soil inside the area of the foundation, the soil
surrounding the point of entry must be loosened around each such pipe, waste or conduit for a
distance of 15 cm and up to a depth of 7.5 cm and loosened soil shall be treated with chemical
emulsion.

3.3 Essential requirements

The removal of trees, stumps, logs or roots from a building site reduce the hazards from the
subterranean termites. The Contractor shall be responsible for keeping the area of treatment free
from all debris.
The Contractor shall not be allowed to carry out treatment when it is raining or when the soil is
saturated with sub-soil water. The chemical shall be applied to soil when the soil is dry and absorbent
.Immediate steps shall be taken by the Civil Contractor to cover the treated layer by laying soiling
/PCC etc.
The Contractor shall ensure that once formed, treated soil barriers zone must not be disturbed. In
case treated soil is disturbed, immediate steps shall be taken to restore the continuity and
completeness of barrier system at no additional cost to the Owner.
All the extra soil-filling for flower-Bed, Terrace Garden, Mud Fusca etc. coming above ground level of
the building must be treated. Sub-terranean termites may develop colonies in such fillings when
conditions are favorable

4. QUALITY MANAGEMENT
4.1 The contractor shall provide experienced supervision and work force to ensure that workmanship
is of specified quality.
4.2 Work shall not be subjected to harmful, dangerous, damaging or deleterious exposures while it is
in progress or on completion during contract period.
4.3 Contractor to undertake quality assurance by documenting a comprehensive Quality Assurance
Plan.

5. SAFETY CONSIDERATION AND REQUIREMENTS

8.1 The Contractor shall ensure that no infants and aged or any person having breathing problem or
sensitive to chemicals are present at the site at the time of treatment. The Contractor shall also
ensure that no human being or pets touch the treated surface.
8.2 The concentrates are oil solutions and present a fire hazard owing to the use of petroleum
solvents. Flames, sparks, etc. should not be allowed while mixing.

6. ENVIRONMENTAL CONSIDERATIONS AND REQUIREMENTS

8.3 Workers should wear clean clothing and should wash thoroughly with soap water, especially
before eating and smoking. If chemicals splash into the eyes, they shall be flushed with plenty

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of soap, water and immediate medical attention should be sought.

8.4 Care should be taken in the application of chemicals to see that they are not allowed to
contaminate wells or springs which serve as sources of drinking water.

10. . COMPLETION AND DELIVERY

Work related to anti termite treatment shall not be deemed as complete till such time all the following
condition is fulfilled:
 The contractor shall submit an undertaking in writing for a free service guarantee for 10
years from the date of completion of the treatment.

11. METHOD OF MEASUREMENT & RATE

Measurement
Measurement for payment in case of preconstruction treatment as detailed above shall be for
actual carpet area covered by building at ground level in plan in sqm.

Rate
The rate shall include the cost of all materials and labor involved in all the operations
described above including making holes and refilling and making good the same.

Free Service Guarantee

The contractor shall note that termite proofing work is subject to a free service guarantee
from the date of completion of the treatment. The contractor shall give an undertaking in
writing to the effect that during the guarantee period any infestation of subterranean termites
will be eradicated and necessary treatment carried out to prevent re-infestation, free of cost
to the Owner. The guarantee shall allow a minimum period of
- 10 (ten) years for pre-constructional treatment.

12. ANNEXURES

NIL.

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Contents
1. Scope ............................................................................................................................................. 2
2. Standards and codes ..................................................................................................................... 2
3. Terminology, definitions and abbreviations .................................................................................. 4

4. Materials........................................................................................................................................ 4
5. Submittals and Certifications required .......................................................................................... 7
6. Workmanship ................................................................................................................................ 8
7. Quality Management ................................................................................................................... 13
8. Safety considerations .................................................................................................................. 14
9. Environmental considerations ..................................................................................................... 14
10. Method of measurement ........................................................................................................ 14
11. Annexes ................................................................................................................................... 15
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Technical Specification: Concrete

1. Scope
This specification applies to all concretes including Plain Cement Concrete, Reinforced Cement
Concrete and Pre-stressed Concrete. It covers all concrete made for the projects of Godrej
properties Ltd. and shall include concrete manufactured at site or procured through RMC plants

2. Standards and codes

Work shall be carried out to Indian Standards and Code of Practices. In absence of relevant
Indian Standards, the latest revisions of International Standards shall be followed. List given
hereunder is not to be considered as conclusive and is for reference and guidance only. Any
discrepancies /conflict noticed shall be brought to the attention of the Owner / Owner’s
Authorized Representative for his direction/approval. However as a general rule more stringent
specification shall take precedence.

1 IS 269 Specification for Ordinary and low heat, Portland cement

2 IS 8112 Specification for 43 grade ordinary Portland cement

3 IS 12269 Specification for 53 grade ordinary Portland cement

4 IS 383 Specification for Coarse and fine aggregates from natural

sources for concrete
5 IS 456 Code of practice for plain and reinforced concrete

6 IS 460 Specification for test sieves

i) Wire cloth test sieve

ii) Perforated plate test sieve

iii) Method of examination of test sieves

7 IS 515 Specification for natural and manufactured aggregates from

natural sources for concrete.

8 IS 516 Method of test for strength of concrete

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9 IS 1199 Method of Sampling and analysis of concrete

10 IS 1791 Batch type concrete mixers

11 IS 2386 Method of test for aggregate for concrete

i) Particle size and shape

ii) Estimation of deleterious materials and organic impurities

iii) Specific gravity, density, voids, absorption and bulking.

12 IS 2505 General requirements for concrete vibrators

13 IS 2645 Specification for Integral cement water proofing compound

14 IS 3025 Methods of Sampling and test (Physical and Chemical for water
)
15 IS 4926 Specification for ready mixed concrete

16 IS 7861 Code of practice for extreme weather concreting

i) Recommended practice for hot weather concreting

ii) Recommended practice for cold weather concreting

17 IS 9103 Specifications for admixture for concrete

18 IS 10262 Recommendations for concrete mix proportioning

19 IS 12118 (Part I) Specification for two parts polysulphide based sealant :

general requirements

20 SP 23 Handbook on concrete mix

21 SP 24 Explanatory handbook on Indian Standards code for plain and

reinforced concrete (IS 456)

22 SP 27 Handbook of method of measurement of building works

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3. Terminology, definitions and abbreviations

The following terms and abbreviations shall have the specific meanings as described hereunder.
For terms that are not described herein, the definitions as stated in the applicable Indian
Standard Specifications shall apply.
3.1 Cement: In the most general sense of the word, cement is a binder, a substance that sets and hardens
independently, and can bind other materials together. The term cement shall include all types of
cement such as Ordinary Portland Cement Grade 33,43,& 53, Portland Pozollana cement, Blast
Furnace slag cement, Rapid Hardening cement.
3.2 Sand is a naturally occurring granular material composed of finely divided rock and mineral particles.
The composition of sand is highly variable, depending on thAe local rock sources and conditions. All
granular material of size less than 4.75 mm and more than 75 microns shall be classified as sand. The
terms sand and Fine Aggregate shall be used as synonyms.
3.3 Coarse Aggregate is the component of a composite material that resists compressive stress and
provides bulk to the composite material. For efficient filling, aggregate should be much smaller than
the finished item, but have a wide variety of sizes. All such materials having particle size greater than
4.75 mm shall be classified as coarse aggregates.
3.4 GGBS stands for Ground Granulated blast furnace slag
3.5 Water is a chemical substance with the chemical formula H2O. A water molecule contains one oxygen
and two hydrogen atoms connected by covalent bonds.
3.6 PH Value: pH is a measure of the acidity or basicity of an aqueous solution. Pure water is said to be
neutral, with a pH close to 7.0 at 25 degree Celsius.
3.7 Reinforcement: is a common steel bar, and is commonly used as a tensioning device
in concrete structures holding the concrete in compression. It is usually formed from carbon steel, and
is given ridges for better mechanical anchoring into the concrete
3.8 RMC: refers to ‘Ready Mixed Concrete’ procured through commercial Ready mix concrete plants. The
term RMC may be used for both the plant as well as concrete from such plants.
3.9 Admixture: are special chemicals used to modify one or more characteristic of concrete in its fresh or
hardened state.
3.10Supplementary cementitious materials: are added as part replacement of cement to enhance specific
properties of concrete; also known as mineral admixtures or additives.

4. Materials
4.1 Cement:
The type of cement to be used in concrete shall be as per the approved Concrete Mix Design.
Generally, the following types of cement may be used:
4.1.1 Ordinary Portland cement of grade 53 or 43
4.1.2 Portland Pozzolana Cement
4.1.3 Portland Blast Furnace Slag Cement
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Cement shall be received in bags of 50 kg or loose in bulkers and each batch shall be
accompanied with a test certificate of the factory. In case cement has been stored for over 3
months or for any reasons the stored cement shows signs of deterioration or contamination, it
shall be tested as per the direction of Engineer, and will be used in the works only if found
suitable.
4.2 Coarse aggregate:
4.2.1 Coarse aggregate shall be obtained from natural sources such as stone, gravel, etc crushed or
uncrushed or a combination thereof from approved quarries. Aggregate shall be hard, strong,
dense, durable, and clean and free from veins and adherent coatings. It shall be free from soft,
feeble, thin, elongated or laminated pieces and shall be roughly cubical in shape. It shall consist of
coarse material, most of which is retained on 4.75 mm IS sieve and shall contain only as much fine
material as is permitted in IS 383 for various sizes and grading.
4.2.2 Coarse aggregate shall conform to all requirements laid down in IS: 383
4.2.3 The maximum size of coarse aggregate should not be greater than one fourth of the minimum
thickness of the member and it should be restricted to 5 mm less than the minimum clear
distance between the main bars or 5 mm less than the minimum cover to the reinforcement.
4.2.4 Source of aggregate shall be from an approved location. Each source of aggregate shall be
approved by Owner / Owner’s Authorized Representative on the basis of tests conducted on
samples of aggregates from the source at an approved testing laboratory. In case available
aggregates do not meet certain requirements of IS 383 or any other specification, required
processing shall be carried out by the contractor to make the aggregates conform to IS: 383.
4.2.5 Coarse aggregate shall have a specific gravity of 2.6 (Saturated surface dry basis). Aggregate
below this specific gravity shall not be used without the special permission of the Engineer.
4.2.6 Once a specific source of supply of coarse aggregate is approved, the source shall not be changed
without the prior approval of the Engineer.

4.3 Fine aggregate

4.3.1 Natural sand deposited by stream or glacial agencies as a result of disintegration of rock shall be
used as fine aggregate. Fine aggregate shall pass through 4.75 mm sieve in total. Crushed sand
may be used or added to natural sand in approved proportions to achieve the required grading.
The fine aggregate shall conform to following standards.
4.3.2 IS 383 Specification for coarse and fine aggregates from natural sources for use in concrete.
4.3.3 IS 2116 Specification for sand for masonry mortars and grouts.
4.3.4 Sea sand shall not be used unless specifically approved by the Engineer in writing. If approved, the
required treatment to the sea sand to make it conform to the requirements of relevant Indian
Standard shall be done at the contractor’s cost.
4.3.5 Sand shall be hard, durable, chemically inert, clean and free from adherent coatings and organic
matter and shall conform to the requirements laid down in IS: 383.
4.3.6 If the fine aggregate containing more than allowable percentage of silt and / or deleterious
materials, it shall be thoroughly washed at site with clean fresh washed so as to bring the silt
content/ deleterious material’s content within allowable limits.
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4.3.7 Grading of fine aggregate shall conform to IS and shall fall within limits of one of the grading
zones given in IS 383. Fine aggregate falling in grading zone IV shall not be used in concrete.

4.4 Water
4.4.1 Water used for mixing and curing shall be clean, reasonably clear and free from
objectionable quantities of silt, oils, alkalis, acids, salts, sugar so as not to weaken mortar, or
concrete or cause efflorescence or attack the steel in RCC while curing. It shall be free of
elements, which significantly affects the hydration reaction or otherwise interferes with
hardening of concrete during curing or those elements which produce objectionable stains or
deposits.
4.4.2 Potable water is generally satisfactory but it shall be tested prior to use in the works.
4.4.3 Water used for mixing and curing shall satisfy the requirements of IS: 456.
4.4.4 Water shall be tested in accordance with IS 3025.
4.4.5 The PH value of water shall not be less than 6 nor more than 9.
4.4.6 The source of water shall be tested and got approved in writing from the Engineer prior to use in
the works.
4.4.7 Use of sea water shall not be permitted for any purpose related to making concrete.

4.5 Admixture
4.5.1 Admixtures shall be permitted to be used to modify the properties of concrete for single, or a
combination of purposes. This shall be used for specific purpose and the type and dosage of
admixture shall be as per the approved mix design of concrete.
4.5.2 Admixture shall comply with the requirements of IS: 9103.
4.5.3 Admixtures shall be free from chlorides and sulphates or any other material which may cause
problems to the concrete in the due course of time.
4.5.4 Admixtures are manufactured and sold by various companies under brand names. The contractor
proposing to use any one of them shall submit to the Engineer the technical literature with its
chemical composition, purpose of use and method recommended by the manufacturer.
4.5.5 The contractor’s proposal shall accompany the following with his request to use admixture.
4.5.6 The trade name of the admixture, its source and the manufacturer’s recommended method of
use.
4.5.7 Typical dosage rates and the possible detrimental effects of under and over-dosage.
4.5.8 Whether the admixture contains chloride in any free form or any other chemical present as an
active ingredient which is a likely cause of corrosion of reinforcement or deterioration of
concrete.
4.5.9 The average expected air content of freshly mixed concrete containing an admixture which causes
air to be entrained when used at the manufacturer’s recommended rate of dosage.
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4.6 Delivery and Storage of materials

4.6.1 Cement shall be received at site in bags of 50 kg as packed confirming to the relevant IS, bearing
the manufacturer’s name or his registered trade mark, grade of cement, type of cement. Each
batch shall be accompanied with the test certificate of the factory. Damp or torn bags shall be
rejected.
4.6.2 Cement shall be stored in dry and water proof shed so as to prevent deterioration due to
moisture, dampness. Bags shall be stacked on rigid water-proof platforms about 15 to 20 cm clear
above the floors, bags shall be stacked at least 45 cm clear or away from the surrounding walls
and in rows of two bags leaving in a space of at least 60 cm between two consecutive rows. A
maximum high stack of 10 bags is generally permitted. Stacks shall be so arranged that the first
batches are used first, (FIFO) and that they permit easy access for inspection and handling.
4.6.3 Different types of cement shall be stacked and stored separately.
4.6.4 Loose cement received shall be stored in Silos. Silos shall be equipped to receive cement by
pump. Silos shall be water tight and damp proof to keep the cement fresh.
4.6.5 Coarse Aggregates and Fine Aggregates shall be stored in such a way that it does not get mixed
with mud, dust, grass, vegetables and other foreign matter. Each type and grading of aggregate
shall be stored separately making sure that various grades of aggregates and sand do not get
mixed during storage and handling. The best way is to have a hard surface platform made out of
concrete, bricks or planks. The arrangement made for storage of aggregates should be to the
approval / satisfaction of the Engineer.
4.6.6 Water storage tanks shall be such as to prevent any deleterious materials getting mixed with it.
4.6.7 Admixtures shall not be exposed to direct sun light and shall be used within their stipulated shelf
life. Admixtures shall be stored separately and away from other liquids like diesel, grease and oil
to prevent errors in issue of admixtures to the site.
4.6.8 Storage of all supplementary cementitious materials like fly ash, ggbs and micro silica shall be
given the same importance as cement. Supplier’s instructions shall be adhered to for storage of
these materials where applicable.

5. Submittals and Certifications required

The contractor shall maintain a comprehensive record of the concrete works as per the approved
ITP. All records shall be in hard copy, signed by the Quality manager, unless electronic records
are permitted by the Engineer.
The following documents shall be submitted to the Engineer for approval and record:
5.1 Concrete mix design calculations and trial results
5.2 Pour plan for all major pours
5.3 Manufacturer’s Test Certificates for all materials brought to site
5.4 Records of tests on fresh and hardened concrete
5.5 Pour card for every concrete pour
5.6 Batch sheet for every batch / Transit mixer [for RMC supply]
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5.7 Post pour inspection record

5.8 Detailed methodology for carrying out repairs for any defect
5.9 Record for correction / repairs carried out

If required by the Engineer, contractor shall maintain and submit photographs indicating
compliance to various requirements of this specification and ITP.

6. Workmanship
6.1 Mix Design:
6.1.1 All concrete except that used in PCC and having grade more than or equal to M: 20 shall be made
as per approved mix design.
6.1.2 The contractor or the RMC supplier, as the case may be, shall submit the mix design document for
review and approval of the Engineer. The mix design shall be carried out by methods laid down by
Indian or International standard. In case the contractor / RMC supplier proposes to use his own
method of mix design, the step-by step method and various charts /tables used for the mixed
design shall be submitted along with the mix design document.
6.1.3 Unless otherwise permitted by the Engineer, the maximum content of fly ash /ggbs in the
concrete mix shall be limited to 35% by weight of total cementitious material. Content of micro
silica shall similarly be limited to 10% of total cementitious material.
6.1.4 Special characteristics of the concrete for specific situations like large pours [thermal properties],
long transportation distance [open time] etc. shall be identified, established and demonstrated
during the design mix approval process.
6.1.5 On review of the mix design document, trail mixes shall be carried out to validate the design mix.
The mix design shall be approved by the Engineer based on the tests conducted on the trial mixes.
6.1.6 Approval of the mix design by the Engineer shall not relieve the contractor / RMC supplier of their
responsibility to comply with the technical requirements.
6.1.7 In case of any major change in the constituent of the mix or required properties of concrete or
construction method, a new concrete mix shall be designed and got approved as per the
procedure detailed above.
6.1.8 Any modification in the mix, except for daily adjustment arising out of moisture content of the
aggregates, shall require the written approval of the Engineer.
6.1.9 Any concrete produced / delivered without the approval of the mix shall be liable to be rejected.

6.2 Concrete Equipment:

6.2.1 All equipment like the batching plant / concrete mixer, transit mixer, concrete pump or other
placement equipment, vibrators, screeds and finishing tools shall be maintained in good working
condition.
6.2.2 Equipment for batching concrete shall be capable of weigh batching. Volume batching shall not be
allowed for any concrete except PCC or small isolated pours of less than 0.5 cum.
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6.2.3 Needle vibrators shall conform to the requirements as laid down in IS: 2502 , screed vibrators to
IS: 2506 and form vibrators to IS: 4656. The vibrators shall be maintained so as to fulfil the
performance requirements laid down in the applicable I.S.
6.2.4 All equipments used for mixing, transporting and placing of concrete shall be maintained in clean
condition. All pans, buckets, hoppers, chutes, pipe lines and other equipments shall be thoroughly
cleaned after each period of placement.
6.2.5 All measuring devices shall be periodically calibrated and the calibration record maintained at all
time. The Engineer may disallow the use of any equipment if it’s effective is in doubt or if it has
not been calibrated.

6.3 Pour Plan

6.3.1 Before any concrete is placed, the entire placing programme, consisting of equipment layout,
proposed procedures, sequence of poring, method of compaction and finishing, rate of pouring
etc. shall be submitted to Engineer for approval. Concrete production capacity shall be of such as
to ensure a practically continuous flow of concrete during depositing without segregation of
materials, considering the size of the job and placement location.
6.3.2 For pours / placement of repetitious nature, a standard pour plan shall be got approved from the
Engineer.
6.4 Pre-pour approval
6.4.1 A pour card shall be documented to record approval of every concrete pour. Any concrete placed
without written pour card approval of the Engineer shall be liable to be rejected.
6.4.2 The format of the pour card shall be as approved by the Engineer. The contractor’s site Engineer
and contractors Quality control Engineer shall inspect the work and record their observations
before seeking the pour card approval of the Engineer.

6.5 Workmen Skills

6.5.1 The following tasks with regard to concrete works require specific skills and the contractor shall
arrange skilled and trained workmen for carrying out these tasks:
a. Concrete batching and mixing
b. Transportation using transit mixers
c. Concrete pumping
d. Concrete compaction using vibrators
e. Concrete finishing
6.5.2 The workmen deployed on the tasks specified in 5.5 above shall be provided periodical training
and the names of trained and certified workmen shall be furnished to the Engineer for approval.
6.5.3 At all times during concreting operation, the workmen carrying out these tasks shall be rehabilitee
identifiable through their ID card or badges.
6.5.4 If the Engineer is of the opinion that any workmen engaged for a task specified in 5.5 above is not
competent to carry out the same, he shall have the authority to order withdrawal of such
workmen from the concreting operations.
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6.5.5 Detailed information and guidelines, preferably in graphic format, dealing with the correct
method of carrying out the tasks shall be available and prominently displayed at the work place.

6.6 Batching and Mixing

6.6.1 The Engineer or his representative shall be allowed access to the control room of the batching
plant to witness the batch settings.
6.6.2 Prior to starting production of concrete, the moisture content of aggregates shall be measured
and suitable adjustment carried out in the mix proportions. Calculations showing such
adjustments shall be approved by the Engineer.
6.6.3 Moisture adjustment shall be carried out more frequently during rainy season, or if the stack of
aggregates exhibit widely varying moisture content at the surface and inside. Under no
circumstances shall the water/admixture content of the mix be adjusted based on visual
observation of the consistency of concrete.
6.6.4 All accessories shall be kept in first class working condition and so maintained throughout the
construction. Mixing shall be continued till materials are uniformly distributed and a uniform
colour of the entire mass is obtained and each individual particle of the coarse aggregate shows a
Complete coating of mortar containing its proportionate amount of cement.
6.6.5 Mixers, which have been out of use more than 30 minutes, shall be thoroughly cleaned before
putting in a new batch. The mixing plant shall be thoroughly cleaned before changing from one
type of cement to another.
6.6.6 Sampling of concrete for the purpose of workability test shall be done from a location to be
mutually agreed between the contractor /RMC supplier and the Engineer.

6.7 Transportation
6.7.1 All means of conveyance shall be adopted to deliver concrete of the required consistency and
plasticity without segregation or loss of slump whatever method of transportation is employed.
6.7.2 Concrete that has lost workability by the time it reaches the placement point shall be rejected.
Tempering of the concrete in the transit mixer by addition of water or cement slurry or admixture
shall not be permitted.
6.7.3 Placement: No concrete shall be placed in any part of the structure until the approval of the
Engineer has been obtained in writing.If concreting is not started within 24 hours of the approval
being given, it shall have to be obtained again from the Engineer-in-charge.
6.7.4 The open time of concrete shall be established and approved during the process of mix design.
Concrete shall be placed in the forms within such approved open time from leaving the mixer, and
once compacted, the concrete shall not be disturbed.
6.7.5 Concrete shall, in all cases, be deposited as nearly as practicable directly in its final position and
shall not be rehandled or caused to flow in a manner which will cause segregation, loss of
materials, displacement of reinforcement, shuttering or embedded inserts or impair its strength.
6.7.6 For locations where direct placement is not possible, and in narrow forms, contractor shall
provide suitable prop and Elephant Trunks to confine the movement of concrete. Special care
shall be taken when concrete is dropped from a height, especially if reinforcement is in the way,
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particularly in columns and thin walls. Except when otherwise approved by Engineer-in-Charge,
concrete shall be placed in the shuttering by shovels or other approved implements and shall not
be dropped from a height more than 1.5 m or handle in a manner which will cause segregation.
6.7.7 Concrete may be conveyed and placed by mechanically operated equipment e.g. pumps or
pneumatic placers. In such cases, the slump shall be held to the minimum necessary for conveying
concrete by this method.
6.7.8 When pumping is adopted, before pumping of concrete is started, the pipelines shall be
lubricated with one or two batches of mortar composed of one part cement and two parts sand.
The concrete mix shall be specially designed to suit pumping. Care shall be taken to avoid
stoppages in work once pumping has started.
6.7.9 When pneumatic placer is used, the manufacturer’s advice on layout of pipeline shall be followed
to avoid blockages and excessive wear. Restraint shall be provided at the discharge box to cater
for the reaction at the end. Manufacturer’s advice shall be followed regarding concrete quality
and all other related matters when pumping/ pneumatic placing equipments are used.
6.7.10 Concrete shall be placed in successive horizontal layers of uniform thickness ranging from 30 cm.
to 90 cm. as per the approved pour plan. These shall be placed as rapidly as practicable to prevent
the formation of cold joints or planes of weakness between each succeeding layers within the
pour. The thickness of each layer shall be such that it can be deposited before the previous layer
has stiffened.
6.7.11 Placement of concrete shall normally be carried out when the ambient temperature is more than
10 degree Celsius and less than 40 degree Celsius. Provisions of IS: 7861 part 1 shall be followed
when placing concrete under hot weather and IS: 7861 part 2 when placing concrete under cold
weather conditions.
6.8 Compaction
6.8.1 Concrete shall be compacted during placing, with approved vibrating equipment, until the
concrete has been consolidated to the maximum practicable density, is free of pockets of coarse
aggregate and fits tightly against all form surfaces, reinforcement and embedded fixtures.
Particular care shall be taken to ensure that all concrete placed against the form faces and into
corners of forms or against hardened concrete at joints is free from voids or cavities. The use of
vibrators shall be consistent with the concrete mix and caution is to be exercised not to over
vibrate the concrete to the point of segregation.
6.8.2 Immersion vibrators shall be inserted vertically at points not more than 450 mm. apart and
withdrawn when air bubbles cease to come to the surface. Immersion vibrators shall be
withdrawn very slowly.
6.8.3 In no case shall immersion vibrators be used to transport concrete inside the forms. Particular
attention shall be paid to vibration at the top of lift, e.g. in a column or wall.
6.8.4 The immersion vibrator shall penetrate the layer being placed and also penetrate the layer below
while the under layer is still plastic to ensure good bond and homogeneity between the two layers
and prevent the formation of cold joints.
6.8.5 Care shall be taken to prevent contact of immersion vibrators against reinforcement steel.
Immersion vibrators shall not be allowed to come in contact with reinforcement steel after start
of initial set. They shall also not be allowed to come in contact with forms or finished surfaces.
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6.8.6 When form vibrators are proposed to be used, the design of forms, spacing and type of vibrators
and their operating sequence shall be submitted for approval of the Engineer. If required, a mock
up shall be made to validate the process of form vibration.
6.8.7 Large flat elements of small thickness shall be compacted with screed vibrators.

6.9 Finishing
6.9.1 The type of finish for formed concrete surfaces shall be as follows, unless otherwise specified by
the Engineer.
6.9.2 For surfaces against which backfill or concrete is to be placed, no treatment is required except
repair of defective areas.
6.9.3 For surfaces below grade, which will receive waterproofing treatment, the concrete shall be free
of surface irregularities which would interfere with proper application of the water-proofing
materials which is specified for use.
6.9.4 Unless specified, surfaces which will be exposed when the structure is in service shall receive no
special finish, except repair of damaged or defective concrete, removal of fins and abrupt
irregularities, filling of holes left by form ties and rods and clean up of loose or adhering debris.
6.9.5 Surfaces which will be exposed to the weather and which would normally be levelled shall be
sloped for drainage. Unless the drawing specify a horizontal surface or shows the slope required,
the tops of narrow surfaces such as staircase treads, walls, curbs and parapets shall be sloped
across the width approx. as 1 in 30. Broader surfaces such as walkways, roads, parking areas and
platforms shall be sloped about 1 in 50.

6.10Curing
6.10.1 All concrete shall be cured by keeping it continuously damp for the period of time required for
complete hydration and hardening to take place.
6.10.2 Preference shall be given to the use of continuous sprays or ponded water, continuously
saturated covering of sacking, canvas, hessian or other absorbent materials. Special care shall be
taken of edges and corners of slabs to ensure the coverage of such places by curing water.
6.10.3 Extra precautions shall be exercised in curing concrete during extremes of cold and hot weather.
The quality of curing water shall be the same as that used for mixing concrete.
6.10.4 Concrete made with OPC shall be continuously cured for a minimum of 7 days and that made with
fly ash or ggbs shall be cured for a minimum of 10 days. Curing shall be un-interrupted and shall
also continue through the night.
6.10.5 The curing of horizontal surfaces exposed to the drying winds shall begin immediately the
concrete has hardened
6.10.6 Water shall be applied to formed surfaces immediately upon removal of forms. Surface coating
type curing compound shall be used only on special permission of Engineer. Curing compounds
shall be liquid type and pigmented.
6.10.7 No curing compound shall be used on surface where bonding with subsequent layer of concrete,
water proof membrane or paint is specified, unless the efficacy of bond between concrete cured
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with curing compound and the subsequent layer / membrane is established to the satisfaction of
the Engineer.
6.10.8 Such compounds shall be applied to all exposed surfaces of the concrete as soon as possible after
the concrete has set or the forms are removed. Before application of the curing compound, it
shall be ensured that the concrete is in saturated surface dry condition.

6.11Construction Joints: The position and orientation of construction joints shall be as shown on the
drawings by the design engineer. In the absence of such information, the location of construction
joints shall be got approved from the Engineer.
6.11.1 The construction joints shall conform to the requirements stipulated in IS: 11817.
6.11.2 Construction joints shall be placed at accessible locations to permit cleaning out of laitance,
cement slurry and unsound concrete, in order to create rough/uneven surface. It is recommended
to clean out laitance and cement slurry by using wire brush on the surface of joint immediately
after initial setting of concrete and to clean at the same immediately thereafter. The prepared
surface should be in a clean saturated surface dry condition when fresh concrete is placed,
against it.
6.11.3 Where high shear resistance is required at a construction joint, suitable shear keys should be
provided.
6.11.4 If stopping of concreting becomes unavoidable anywhere, a properly formed construction joint
shall be made where the work is stopped. Joints shall be either vertical or horizontal, unless
shown otherwise in drawing. Vertical joints in walls shall be kept to a minimum. Vertical joints
shall be formed against a stop board, horizontal joints shall be level and wherever possible,
arranged, so that the joint lines coincide with the architectural features of the finished work.

7. Quality Management
7.1 The contractor shall put in place a comprehensive Quality management plan to ensure that the work
is carried out as per specifications and compliance to all requirements are established and
demonstrated through comprehensive documentation. The contractor shall engage a qualified Quality
Manager to implement the quality plan.
7.2 Unless annexed to these specifications the contractor shall submit an inspection and test plan [ITP] for
the approval of the Engineer. The ITP shall cover tests on incoming materials, supervision of the
process and test on the completed work.
7.3 The ITP shall lay down the characteristics to be tested/inspected, frequency of tests, acceptance
criteria and the manner of documenting the results. Any test, compliance to which is mandatory for
further progress of the next stage of work shall be identified as a ‘Hold point’.
7.4 In the absence of an approved ITP, provisions of IS: 456 and any other Indian Standard referred there
in shall apply with regard to acceptance criteria and tolerances.
7.5 In case of any dispute about the interpretation of the test results or inspection of the concrete, the
decision of Engineer shall be final.
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8. Safety considerations
8.1 Apart from general safety and health hazards like working at heights, falling objects etc., the
contractor shall assess the hazards associated with concrete works and shall take specific action to
mitigate against the same. Some of the hazards associate with rebar works are listed for general
guidance below.
a. Bursting of pipelines during pump concrete
b. Uncontrolled movement of end hose of the concrete pump
c. Inhalation of fine particles of cement, fly ash and micro silica
d. Hazard associated with the use of needle vibrator
All workmen shall be made aware of the specific hazards that they face while working with concrete
and shall be provided with specific personal protective equipment to protect them.

9. Environmental considerations
9.1 Apart from general environmental impact of construction activities, the contractor shall assess the
environmental impact associated with concrete works and shall take specific action to mitigate against
the same.
9.2 As a general guide, the following safety hazards are identified as associated with concrete
construction
9.3 Discharge of wash water from batching plant and transit mixers
9.4 Noise pollution due to operation of vibrators
9.5 Particulate pollution due to dust in the aggregates, cement, fly ash and micro silica.
9.6 Completion and delivery: Work related to concrete construction shall not be deemed as complete till
such time all the following conditions are fulfilled:
9.7 All concrete in various parts of the structure is shown to have complied with the compressive strength
requirement at 28 days.
9.8 There are no defects in the concrete or all defects are repaired to the satisfaction of the Engineer.
9.9 All quality tests and inspection records are furnished to the Engineer.

10. Method of measurement

10.1 Concrete as actually done shall be measured for payment, subject to the following tolerances. Any
work done extra over the specified dimensions shall not be measured for payment.
10.2Linear dimensions shall be measured in full centimetres except for the thickness of slab which shall be
measured to the nearest half centimetre.
10.3Areas shall be worked out to the nearest 0.01 sqm.
10.4Cubic contents shall be worked out to the nearest 0.001 cum.
10.5 The concrete shall be measured for its length, breadth and height/ depth limiting dimensions to those
specified on drawings or as directed by the Engineer-in-Charge
10.6 No deductions shall be made for the following :
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a. Ends of dissimilar materials e.g. joists, beams, posts, girders, rafters, purlins, trusses, corbels,
steps etc. Up to 500 sq cm. in cross section.
b. Opening up to 0.1 sqm. (1000 sq cm)
c. Volume occupied by reinforcement.
d. Volume occupied by pipes, conduits, sheathing etc. not exceeding 25 sq cm. each in cross
sectional area.
e. Nothing extra shall be paid for leaving and finishing such cavities and holes.
10.7 Rates: The unit rate for concrete shall include the cost of all materials, labour, tools and plant required
for mixing, placing in position, vibrating and compacting, finishing as per directions of the Engineer,
hacking of concrete surfaces if required, hydro test of water retaining structures,curing and all other
incidental expenses for producing concrete of specified strength to complete the structure or its
components as shown on the drawings and according to these specifications.
10.8 All expenses likely to be incurred by the contractor in transporting materials to the site of works, the
expenses incurred in improving the quality of materials to acceptable levels (such as screening,
washing, etc.) and expenses incurred in proper storage of materials as directed by the Engineer,
expense incurred in testing, supervision, Quality, Safety and Environment management, repairs etc.
are to be included in the unit rate.

11.Annexes
NIL
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Contents
1. Scope ..................................................................................................................................................... 2
2. IS Standards ..................................................................................................................................... 2
3. Terminology .................................................................................................................................... 3
4. Materials ......................................................................................................................................... 3
5. Workmanship .................................................................................................................................. 4
6. Quality Management ...................................................................................................................... 7
7. Submittal & Certification Required ................................................................................................. 8
8. Safety Management ........................................................................................................................ 8
9. Environment Management ............................................................................................................. 8
10. Completion & Delivery ................................................................................................................ 8
11. Method of Measurement ............................................................................................................ 8
12. Annexures: NIL........................................................................................................................... 9
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TECHNICAL SPECIFICATIONS: REBAR

1. Scope
This specification applies to all reinforcement work provide in R.C.C. and Pre-stressed concrete
construction. It covers reinforcement work carried out with all grades of reinforcement steel and
applies to all projects of Godrej properties Ltd. It does not cover the work associated with
provision of high tensile steel bars, wires or strands used in pre-stressed concrete.

2. IS Standards
Work shall be carried out as per latest version of Indian Standards and Code of Practices. List
given hereunder is not to be considered as conclusive and is for reference and guidance only.
Any discrepancies /conflict noticed shall be directed to the Owner /Owner’s Authorized
Representative for his direction/approval. However as a general rule more stringent
specification shall take precedence.

1. IS 226 Specification for steel standard quality

2. IS 228 Methods for chemical analysis of steels

3. IS 280 Specification for mild steel wire for general engineering purpose.

4. IS 432 Specification for mild steel and medium tensile steel burn and hard drawn
steel wires for concrete requirement.
Part 1 Mild steel and Medium tensile steel bars.

Part 2 Hard drawn steel wire.

5. IS 456 Code of practice for construction and design of reinforced concrete.

6. IS 816 Code of practice for use of metal arc welding for general construction in mild
steel
7. IS 961 Specification for structural steel : high tensile steel bars

8. IS 1566 Hard drawn steel wire fabric for concrete reinforcement.

9. IS 1599 Method of Bend test

10. IS 1642 General requirements for fire protection.

11. IS 1785 Cold drawn stress relieved wire (part I)

12. IS 1786 Specification for high strength deformed steel bars and wires for concrete
reinforcement.
13. IS 2751 Code of practice for welding of MS bars.
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14. IS 2502 Code of practice for bending and fixing of bars for concrete reinforcement.

15. IS 4082 Recommendation on stacking and storage of construction materials at site

16. IS 5525 Recommendation for detailing of reinforcement in RCC work.

17. IS 9417 Recommendation for welding cold worked steel bars for reinforced concrete
construction
18 IS 13920 Ductile detailing of RC structures subjected to Seismic Forces

3. Terminology
The following terms and abbreviations shall have the specific meanings as described hereunder.
For terms that are not described herein, the definitions as stated in the applicable Indian
Standard Specifications shall apply.

3.1 Reinforcement: is a common steel bar, and is commonly used as a tensioning device
in concrete structures holding the concrete in compression. It is usually formed from carbon
steel, and is given ridges for better mechanical anchoring into the concrete
3.2 Rust: is a general term for a series of iron oxides. In general usage, the term is applied to red
oxides, formed by the reaction of iron and oxygen in the presence of water or air moisture.
3.3 Splicing: Connection of two or more pieces of linear material.
3.4 Shop Drawing: is a drawing or set of drawings produced by the contractor, supplier,
manufacturer, subcontractor, or fabricator. Shop drawings are typically required for pre-
fabricated components.
3.5 Binding wire: is a steel annealed wire used to tie the rebar together at their points of
intersection with each other.
3.6 Cover block: Is a block of approved material and appropriate size used to position the rebar
such as to result in the required distance between the rebar and concrete surface [cover]
3.7 Coupler: Is a special mechanical splicing device used to connect two pieces of rebar placed
end to end. Couplers are used in place of laps

4. Materials
4.1. Rebar: Unless otherwise specified in drawings, the steel bars shall be of “High strength
deformed steel bars and wires” conforming to the IS 1786 (latest revision), in the following
strength grades:
a. Fe 415, Fe 415D;
b. Fe 550, Fe 550D; and
c. Fe 600

Where “Fe” stands for specified minimum 0.2% proof / yield stress in N/mm2 and
“D” stands for same specified minimum 0.2% proof / yield stress but with enhanced
specified minimum percentage elongation.
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4.2. Binding Wire: The wires used for tying rebar together shall be 16 or 18 gauge, annealed
mild steel wires conforming to IS: 280 (latest revision). If specified in the BOQ the binding
wires may be PVC coated.
4.3. Cover Blocks: Cover blocks shall be of non-corrosive material such as mortar / concrete
blocks and plastic but not wooden or broken bricks or stone. Designed custom made PVC
cover spacers shall be permitted to be used in the Works.
4.4. Mechanical couplers: The Taper/ parallel Treaded Mechanical Splicing system should
conform to Type – II Mechanical Splice as classified under ACI-318 OF 2005, ( Defined as; A
full mechanical Splice shall develop in tension or compression, as required at least 1.25fy of
the bar and shall develop the specified tensile strength of the spliced bar)
Mechanical properties of the couplers shall be as under:

a. Tensile Strength - > or = to the actual strength of the bar.

b. Compression Strength - > or = to the actual strength of the bar.
c. Mode of failure – In rebar (outside coupler area)
d. Ductility: > 20% elongation at ultimate load.

4.5. The Physical Dimensions (these are indicative & may vary from manufacturer to
manufacturer)of the couplers shall be as under:

OUTER DIA COUPLER LENGTH BAR ENGAGEMENT

S.N. REBAR SIZE mm
mm mm mm
1 16 22 56 22

2 20 27 71 29

3 25 35 85 35

4 28 38 91 38

5 32 44 96 40

5. Workmanship
5.1. Storage: Reinforcement bars received at site shall be stored clear of the ground with the
use of timber sleeper, concrete sleeper or any other means. Each diameter of bars shall be
stacked separately. In the event of the rebar having to be stored through the rainy season,
adequate protection shall be provided by way of coating of cement slurry and covering by
tarpaulin sheets.

5.2. Bar Bending Schedule: Unless provided by the Engineer, the contractor shall generate a bar
bending schedule showing the shape, size, cut lengths and other details of each bar type.
The bar bending schedule shall be submitted for the approval of the Engineer.
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5.3. Cutting: All reinforcement shall be cut cold, unless otherwise permitted by the Engineer.
The cutting lengths of bars to be cut shall be calculated so as to result in the cut/bent bar of
correct dimensions facilitating the bars to achieve the desired cover when placed in the
forms. The ends of the bars shall be cut square and sharp edges, if any, shall be ground.

5.4. Bending:
5.4.1. All bars shall be accurately bent according to the sizes and shapes shown on the
detailed working drawing / bar bending schedules. They shall be bent gradually by
machine or other approved means. Reinforcing bars shall not be straightened and re-
bent in a manner that will injure the materials.
5.4.2. Bars containing cracks or splits shall be rejected. They shall be bent cold, except bars of
over 25 mm. in diameter which may be bent hot if specifically approved by the
Engineer.
5.4.3. Bars that depend for their strength on cold working shall not be bent hot. Bars bent
hot shall not be heated beyond cherry red colour (not exceeding 6450C) and after
bending shall be allowed to cool slowly without quenching.
5.4.4. Bars incorrectly bent shall be used only after straightening and re-bending such as not
to injure the material. No reinforcement bar shall be bent when in position in the work
without approval, whether or not it is partially embedded in hardened concrete. Bars
having kinks or bends other than those required by design shall not be used Placing &
Tying
5.4.5. Where reinforcement bars are bent aside at construction joints and afterwards bent
back into their original position, care should be taken to ensure that at no time the
radius of the bend is less than 4 bar diameters for plain mild steel or 6 bar diameters
for deformed bars. Care shall also be taken when bending back bars to ensure that the
concrete around the bar is not damaged.

5.5. Placing & fixing:

5.5.1. Reinforcement shall be accurately fixed by any approved means maintained in the
correct position as shown in the drawings by the use of blocks, spacers and chairs as
per I.S. 2502 to prevent displacement during placing and compaction of concrete.
5.5.2. At the time concrete is placed, reinforcement shall be free from mud, oil, or other non-
metallic coatings that decrease bond. Except for pre-stressing steel, steel
reinforcement with rust, mill scale, or a combination of both shall be considered
satisfactory, provided the minimum dimensions (including height of deformations) and
weight of a hand-wire-brushed test specimen comply with applicable specifications
5.5.3. Bars intended to be in contact at crossing point shall be securely bound together at all
such points with number 16 gauge annealed soft iron wire.
5.5.4. The vertical distances required between successive layers of bars in beams or similar
members shall be maintained by the provision of spacer bars at such intervals that the
main bars do not perceptibly sag between adjacent spacer bars.
5.5.5. Welding of crossing bars shall not be permitted for assembly of reinforcement unless
authorized by the engineer.
5.5.6. Groups of parallel reinforcing bars bundled in contact to act as a unit shall be limited to
four in any one bundle. Bundled bars shall be enclosed within stirrups or ties.
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5.5.7. It should be ensured that the ends of the binding wire are turned inwards and do not
project into the cover region.
5.5.8. Reinforcement rods which are likely to remain exposed for a period of more than 3
months shall be adequately protected against corrosion by painting them with a coat
of cement wash.
5.5.9. Unless otherwise specified, reinforcement shall be placed within the following
tolerances:
5.5.10. Tolerance in spacing

For effective depth, 200 mm or less + /- 10 mm

For effective depth, more than 200 mm + /- 15 mm

5.6. Cover
5.6.1. Nominal cover is the design depth of concrete cover to all steel reinforcements,
including links. It is the dimension used in design and indicated in the drawings. It shall
be not less than the diameter of the bar.
5.6.2. The amount of cover to reinforcement shall be as shown on the drawings. In the
absence of this information on the drawings, cover shall be provided as per guidelines
of IS 456.
5.6.3. The actual cover provided shall be not less than the cover shown on the drawing nor
shall it exceed the nominal cover by 5mm.
5.6.4. The correct cover shall be maintained by cement mortar cover blocks or other
approved cover blocks. When precast concrete blocks are used to provide the cover,
their strength shall be equal to or more than the strength of concrete in the member.
5.6.5. The strength and spacing of cover blocks in slabs should be adequate to sustain the
load of the reinforcement cage and other construction loads imposed on it.
5.6.6. Cover blocks shall be properly tied to the reinforcement in such a manner that they
cannot be displaced from their position during erection of reinforcement, formwork
and during concrete placement.

5.7. Lapping of rebar:

Laps shall be strictly as per the drawing or as directed by the Engineer For general guidance,
the following principles shall be followed.
5.7.1. Splices shall be provided as far as possible away from sections of maximum stress and
be staggered & as per details indicated in the drawings.
5.7.2. Not more than half of the total bars shall be lapped at any section.
5.7.3. Where more than one half of the bars are lapped at a section or where splices are
made at points of maximum stress, special precautions shall be taken, such as
increasing the length of lap and/or using spirals or closely spaced stirrups around
the length of the splice.
5.7.4. Lap splices shall not be used for bars larger than 36 mm diameter: For larger
diameters, bars may be welded. In cases where welding is not practical, lapping of
bars larger than 36 mm diameter may be permitted and additional spirals should be
provided around the lapped bars.
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5.7.5. When splicing of welded wire fabric is to be carried out, lap splices of wires shall be
made so that the overlap measured between the extreme cross wires shall be not less
than the spacing of cross wires plus 100 mm.

5.8. Welded joints and mechanical Connections (couplers)

5.8.1. Welded joints or mechanical connections in reinforcement may be used but in all cases
of important connections, tests shall be made to prove that the joints are of the full
strength of the connected bars.
5.8.2. Welding of reinforcement shall be done in accordance IS 9417. (Recommendation for
welding cold worked steel bars for RCC). Welded joints shall preferably be located at
points where steel will not be subject to more than 75 percent of the maximum
permissible stresses and welds so staggered that, at any one section, not more than 33
percent of the rods are welded.

6. Quality Management
The contractor shall put in place a comprehensive Quality management plan to ensure that
the work is carried out as per specifications and compliance to all requirements are
established and demonstrated through comprehensive documentation. The contractor shall
engage a qualified Quality Manager to implement the quality plan. Till such time a Quality
Management Plan and ITP is approved, the following provisions shall apply.
6.1. The rebar shall be procured only from pre-approved manufacturers. Rebar shall not be
procured from secondary manufacturers / re-rollers unless approved in writing by the
Engineer.
6.2. Contractor shall procure and provide reinforcing steel bars conforming to IS specified and
shall comply with all physical, chemical and mechanical tests. Bars without “ISI’ /
identification marking shall not be brought to site.
6.3. Any rebar brought to site shall not be used in the works unless its characteristics are tested
and found complying with the requirements of the applicable specifications. Till such time
the rebar is not permitted to be used in work, it shall be separately stored and identified to
preclude its use.
6.4. Unless specified agreed in the approved ITP, at least one sample shall be drawn from every
50 MT of rebar received at site of each diameter.
6.5. Cover to rebar shall be ensured by providing adequate numbers of cover blocks and chairs.
At the time of approval of the pour card, integrity of the cover blocks and their spacing shall
be inspected to ensure that they have not been displaced during installation of formwork.
6.6. The position of the rebar shall be inspected after placing concrete in the forms to ascertain
that the rebar are not damaged or displace from their original position and the desired
cover has been achieved.
6.7. Any rebar that has been installed in the works but is likely to exposed for a prolonged
period before concreting takes place shall be protected by application of a coat of water
cement grout.
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7. Submittal & Certification Required

7.1. The contractor shall maintain a comprehensive record of the concrete works as per the
approved ITP. All records shall be in hard copy, signed by the Quality manager, unless
electronic records are permitted by the Engineer.
7.2. The following documents shall be submitted to the Engineer for approval and record:
a. Manufacturers Test Certificate for every batch / lot of rebar brought to the site
b. Test certificate from an Independent Third Party Lab as applicable
c. Bar Bending Schedule for different pours
d. Test certificate regarding strength of coupler joint [if applicable]

8. Safety Management
Apart from general safety and health hazards like working at heights, falling objects etc., the
contractor shall assess the hazards associated with concrete works and shall take specific
action to mitigate against the same. Some of the hazards associate with rebar works are
listed for general guidance below.
a. Touching of hot objects
b. Flying sparks, metal chips or pieces
c. Piercing by falling or tripping on sharp objects

9. Environment Management
Apart from general environmental impact of construction activities, the contractor shall assess
the environmental impact associated with rebar works and shall take specific action to mitigate
against the same. Some of the environmental aspects associate with rebar works are listed for
general guidance below.

10. Completion & Delivery:

Work related to rebar construction shall not be deemed as complete till such time all the
following conditions are fulfilled:

10.1. There are no defects in the rebar work or defects have been rectified to the satisfaction
of the Engineer. Specifically, the cover required for the rebar should have been achieved as
per permissible tolerances, as seen after the completion of concrete pour.
10.2. The concrete of which rebar forms a part has been accepted by the Engineer, unless the
rebar is meant to be permanently protruding outside concrete
10.3. All quality documents, test certificates have been submitted

11. Method of Measurement

Reinforcement shall be measured as follows:

11.1. Lengths of different diameters of bars actually used including authorized overlaps shall be
measured nearest to a centimeter and their weight calculated.
11.2. If rebar is procured by the contractor, weight per metre given in table 3.8 shall be used.
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11.3. If rebar is supplied by the client free of cost on tonnage basis to the project site, per
metre weight for each diameter of the bar shall be fixed by the Engineer from actual
stocks of steel available at site or weight per meter given in table 3.8 shall be used.
11.4. Chairs and spacer bars shall not be measured and paid for. For reconciliation purpose it
will be taken into account, if steel is supplied free of cost by the Owner.
11.5. In case of welded coupled joints, measurement for payment shall be equivalent to the
length of overlap, as per design.
11.6. Quoted rates shall include, in addition to cost of material,
a. Cover blocks
b. Cutting, bending, placing and fixing in position.
c. Binding wire as approved.
d. Cleaning of bars
e. Decoiling of steel
f. Double handling if any.
g. All necessary scaffolding
11.7. In case rebar is supplied by the Owner free-of-cost, the quoted rate shall include, in
addition to 4a) to 4d) above, loading, Transportation & Unloading from Owner’s store to
work site and returning surplus material back to store.

12. Annexures: NIL

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Contents
1. Scope........................................................................................................................................................................ 2

2. List of Standards ............................................................................................................................................... 2

3. Terminology ............................................................................................................................................................. 3
4. Material............................................................................................................................................................ 4

5. Submittals ........................................................................................................................................................ 6

6. Workmanship .......................................................................................................................................................... 6

7 Quality Management............................................................................................................................................. 13

8 Safety Considerations and Requirements ............................................................................................................. 16

9 Environmental considerations ........................................................................................................................ 16

10 Completion and delivery ............................................................................................................................ 17

11 Measurements ........................................................................................................................................... 17

12 Annexures .................................................................................................................................................. 19
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TECHNICAL SPECIFICATIONS FOR FORMWORK SYSTEM

1. Scope
This specification applies to requirements for providing, fabricating and erecting of
Cast-in-situ formwork and all other supports to the concrete during its setting and
subsequent removal of forms and applies to all projects of Godrej properties Ltd

2. List of Standards
Work shall be carried out as per latest issues of Indian Standards and Codes of Practices.
The list of Indian Standards given hereunder is not to be considered as conclusive and
is for reference and guidance only. Any discrepancies/conflict noticed shall be directed
to the Owner/Owner’s Authorised Representative for his direction/approval. However
as a general rule the more stringent specification shall take precedence.

1. IS:6461-1972 Glossary of terms relating to cement concrete Part V -

(Part V) formwork for concrete
2. IS 456 Code of practice for construction and design of reinforced
concrete.
3. IS 2751 Code of practice for welding of M.S bars used for RCC
4. IS 4014 Code of practice for steel (Part 1 & 2) tubular scaffolding
5. IS 4082 Recommendation on stacking and storage of construction
materials
6. IS:4990:1993 Specifications for Plywood for concrete shuttering work
7. IS 303 Specification for plywood for general purpose.
8 IS:2750-1964 Specifications for Steel Scaffolding-Civil Structural
Specifications
9 IS 3696 Safety Code of scaffolds and ladders :
Part 1 Scaffolds
Part 2 Ladders
10 IS 8989 Safety code of erection of concrete formed structures
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11 IS:1200 (Part Method Of Measurement Of Building And Civil Engineering

V) - 1982 Works Part V Formwork
12 EN 755 - 9, System form work.
GB/T 6892-
2015, JGJ 386-

3. Terminology
3.1 Back form: Formwork to the top surface of a sloping slab
3.2 Bearer (Runner): Horizontal member supporting joists.
3.3 Bracings: The system of members, usually diagonal, which acts in compression or
tension and stiffens a frame against deformation.
3.4 Diagonal: Member transferring horizontal and wind loads through props.
3.5 False work (staging, centering): Temporary structure used to support a
permanent structure during erection and until it becomes self-supporting.
3.6 Formwork (Shuttering): is the term given to either temporary or
permanent molds into which concrete or similar materials are poured.
(Ref: Annexure Image no E,F & G)
3.7 Four way head: To support to I-section beams below slab or beam bottom.
3.8 Joist (Batten): Horizontal member supporting sheeting (slabs & beams).
3.9 Prop base: Seating for prop( Punching shear).
3.10 Prop cap: seating for bearer. Prop footing (Spreader): Member transferring all
loads on unyielding strata.
3.11 Prop: Vertical member supporting bearer (Axial load)
( Ref: Annexures Image no A )
3.12 Reinforcement: is a common steel bar, and is commonly used as a tensioning
device in concrete structures holding the concrete in compression. It is usually
formed from carbon steel, and is given ridges for better mechanical anchoring
into the concrete.
3.13 Riband: Horizontal member laid flat to resist horizontal pressure from formwork.
3.14 Scaffolding: is a temporary structure used to support people and material in the
construction or repair of buildings and other large structures. (Axial load)
( Ref: Annexures Image no B )
3.15 Sheeting (Sheathing): Supporting membrane in contact with the wet concrete.
3.16 Shikanja: To hold the two opposite formwork or to hold the two right angle
formwork.
3.17 Soldier: A vertical member, acting as a beam or cantilever, and used in
conjunction with form ties or struts to support and prevent movement of forms.
3.18 Starter (Kicker): Small height of wall or column cast along with the footing.
3.19 Stop-end (Bulkhead): Vertical formwork to form a construction joint in concrete.
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3.20 Striking (Stripping): Scientific dismantling and removing formwork (pre-

planned).
3.21 Strut: is a structural component designed to resist longitudinal compression.
Struts provide outwards-facing support in their lengthwise direction.
3.22 Stud: A vertical or horizontal stiffener to the back of the form sheeting.
3.23 Tie Bolt: Interconnecting two opposite formworks to resist hydrostatic loads.
3.24 Tripod: To keep prop in exact plumb & position
3.25 Wailing or Waling: Horizontal member resisting hydrostatic concrete load on
sheeting (vertical walls)
3.26 Wedge: Packing piece used for correct leveling & easy striking of formwork.
3.27 Yoke: a) For columns-Horizontal frame support encircling formwork.
b) For slip form-Vertical frame support straddling inner & outer formwork.

4. Material
4.1 Material used in form work shall be a combination of timber, plywood, steel props,
steel plates, or specially designed and manufactured moulds of plastic or reinforced
fiber glass or steel or aluminum alloy or a combination of these.
4.2 Use of timber shall be limited to beam bottoms and runners; it shall not be used for
soffit of slab, except in edge panels.
4.3 Use of material shall depend upon its location, type of finish specified and subject to
acceptability by the Owner/Owner’s Authorised Representative. Recommendations
are as under:
a. Steel Props:
Heavy duty, drop head and adjustable type or as per standard system to be
adopted.
b. Steel Plates
MS angles 45 x 45 x 4 mm thick frame work with minimum 16 gauge thick sheet.
c. Ply wood -
Marine ply - Plastic coated
- 12 mm thick with timber framing for sides of beam
- 18 mm thick with timber framing for beam bottom and wall panels.
- 12/18 mm thick for slab depending upon slab thickness and supporting
system.
d. Bracing
40 NB medium duty MS steel pipes with clamps.
NB (Nominal Bore) is pipe size specified with two non-dimensional numbers.
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e. Timber
I.Jungle wood timber in the form of planks and battens (runners), which are
strong, durable.
II.Teak wood /good quality jungle wood shall be used for special decorative
moulds. Moulds used in work shall be smooth planed or finished with
laminate.
III. Silver wood shall be used for bracing to raker props, walkway battens and
planks, beam bottom topi etc.

f. System foam work

I.High bearing capacity, good stability, The bearing capacity of most aluminium
formwork system can reach 60-80 kN/m2 .
II. Simple operation, with weight of 18–22 kg, each worker install 20–30 m2 per
day yet no need for lifting tower
III. Efficient construction, high project quality, aluminium formwork
system, early stripping formwork system, ensure that each layer of the
construction cycle control within 4–5 days. With finished smooth surface allows
without the need for extensive plastering.
IV. Standard, the precise-designed formwork system with little
measurement error, high accuracy, such as the main wall, column, beams,
stairs and balconies, cycle time can be approximately 300 times,
V. Environmental protection, high recycling value, full aluminium productive
process leads to no galvanization, reduce the pollution of our earth.

4.4 System /Form work designed with proposed material in use shall be able to retain
its shape, lines, and dimensions as shown in the approved drawings. It shall safely
carry the full load of concrete together with any live load and impact loads likely to
occur during concreting, especially when concrete pumps and large buckets with
crane are deployed.
4.5 Material used shall conform to appropriate Indian Standards. It shall be the solely
the Contractor’s responsibility to entirely achieve the standard expected and to the
satisfaction of the Owner/Owner’s Authorised Representative.
4.6 Standard rolled steel sections shall be used with due fabrication for standard special
moulds, unitized form work scaffolds, staging, etc.

4.7 System
Patented, proprietary designed, metal (steel, aluminum or fiber glass) form work
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best suited for type of work under taken, shall be used.

Supporting shall be done using metal props only. No timber props or ballies shall
be allowed. Wire nails conforming to appropriate Indian Standard specifications
only shall be used.

4.8 Bolts / Nuts /Clamps

Standard or tailor-made MS bolts, nuts, clamps shall be used. Use of these shall
not be harmful to concrete and shall be easily removable. If left in concrete, they
shall be inert to concrete in all respects. Prior approval shall be obtained from the
Owner/Owner’s Authorised Representative before use of tailor-made MS bolts.
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4.9 Form release Agents

These agents shall be of approved make such as BASF, Sika or equivalent.
Emulsion or oil or chemical agent being used shall not react with reinforced
concrete at any stage. Use of these agents shall not lead to any chemical reaction
which may be harmful to reinforced concrete for its durability & strength. These
shall not produce any stain, insoluble in water and shall not stick to concrete
surfaces which will reduce bonding of masonry to mortar or paint, etc.
The Form release agent following properties:
a. It shall allow for fast and easy striking of formwork.
b. It shall Easy to apply
c. It shall be extremely stable during placement and vibration of concrete.
d. It shall not stain or contaminate the finished concrete surface.
e. It shall protect steel forms from rusting.

5. Submittals
5.1 The contractor shall maintain a comprehensive record of the formwork material as
per the approved ITP. All records shall be in hard copy, signed by the Quality
manager, unless electronic records are permitted by the Engineer.
5.2 Submittals shall include
5.2.1 Product data sheet
5.2.2 Design & drawing of proposed formwork system
5.2.3 Manufacturers certificates for Plywood
5.2.4 Test report of laboratories for Plywood
5.2.5 Pre Pour Check list

6. Workmanship
6.1 Designing
The Contractor shall design, draw, prepare and submit method statement backed by
designed calculations, taking into account the points noted in clause 6 hereinbelow at
least six weeks prior to the start of any activity Or as per approved schedule. Required
drawing and sketches shall be enclosed along with statement for the proposed area to
be taken up for working. The statement shall give
Loads considered
6.1.1 Materials proposed
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6.1.2 Repetitions expected

6.1.3 Staging/supporting arrangement
6.1.4 Deployment of proprietary metal form work system.
6.1.5 Method of handling
It shall be the responsibility of the Contractor to get the design approved from
Owner/Owner’s Authorized Representative at least four weeks prior to start of
formwork. The approval of the Owner/Owner’s Authorized Representative shall not
however relieve the Contractor of the full responsibility for the design & construction of
formwork.

6.2 Experience
The Contractor shall provide
6.2.1 Site supervisors and foremen who shall be well qualified and have an experience
of at least 5(five) years on similar nature of form work.
6.2.2 Semi skilled/skilled labour shall have a minimum experience of 3(Three) years in
doing similar nature of form work.

6.3 Supervision
The Contractor shall be responsible to provide experienced foremen (with at least Five
years’ experience) in supporting/executing similar nature and magnitude of work and
the latter shall be able to read drawings and shall be capable of guiding and getting
work executed to desired quality.

6.4 Equipment
The Contractor shall provide all required tools, plants, equipment including their proper
maintenance during construction at site.

6.5 Proprietary metal formworks

The Contractor shall arrange to provide proprietary system metal formwork
applicable/adoptable to various areas of works. He shall be responsible to deploy the
required manpower and mechanism for handling, shifting, transporting placing in
position.
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6.6 Examination of strata

The Contractor shall examine and convince himself, prior to start of work, that the
strata is firm, rigid and safe to enable erection of scaffold. In the absence of suitable
strata, the same shall be improved by him prior to proceeding with the work. If this is
not possible due to site condition, method of erection and support etc. shall be
adequately detailed and got approved from the Owner/Owner’s Authorized
Representative prior to start of work. In any case the entire responsibility of the
proper functioning and safety of the formwork shall rest with the Contractor

6.7 Form work shall be used for following concrete finishes:

a. Textured or decorative finish
b. Fair-faced finish
c. Rough finish

6.8 The Contractor shall account for all material and labour etc. to achieve the above
finishes to the satisfaction of the Owner/Owner’s Authorised Representative.
a. Erection of form work may be from pre-moulded, pre-fabricated, pre-assembled
plates or forms reasonable enough to transport and erect at site to correct line
and level as set out at site.
b. Supports shall be firm and maintained in position by nails, cross bracings, tie
rods, locking bolts and nuts. It shall be rigid and stiff so as to retain its shape
during and after concreting.
c. Joints between adjacent shuttering plates shall be water-tight and no cement
slurry shall be allowed to slip through. This shall be achieved by providing foam
tapes between two plates. Joints of shuttering plates for the all slab soffits not to
be plastered subsequently shall be ground flush to achieve even and smooth
surface.
d. Pre-fabricated or site forms shall be assembled in such a way, so as to ensure de-
shuttering without any jerk to the green concrete. For this purpose, double
wedges shall be used. Wedges shall be nailed, with the nail heads reasonably left
out, allowing easy removal while de-shuttering.
e. Pre-fabricated or on-site fabricated forms shall be of sufficient thickness and
with the required supporting runners in either direction. Supporting runners
shall be standardized in size for easy replacement and universal use at site.
f. Props shall be of steel only. Their spacing and size shall be as per approved
design. Care shall be taken to ensure that all props are installed in plumb. The
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base of the props shall be a proper steel plate or timber plank, for equal
distribution of load.
g. In repeated use, panels shall be clearly marked for using at defined locations.
h. Successive lift shall be tightened with previous lift by fixing foamed strips at
joints to avoid slurry leakage.
i. Infill pieces and panels shall be well dressed, leveled and jointed with main
formwork so as to achieve smooth, even natural finish.
j. Props, soldiers, wailings, shores, bearers, clamps, wall & ties etc. shall be
provided at required spacing as per approved scheme.
k. Inserts and pockets shall be provided and fixed to correct line and level and with
sufficient rigidity to keep them in position while placing concrete and when
vibration is in progress.
l. Sloping, brackets, chhajjas, etc shall be well secured and firmly restrained.
m. Adequate access and working platforms shall be arranged with required safety to
avoid reinforcement displacement, damage to shuttering and easy movement of
concrete gang.
n. Props and scaffolds are to be erected to correct plumb, lines, and levels and with
required ties. Load carrying capacity of props shall be as per recommendations
of the manufacturer.
o. Props and scaffolds shall not be loaded beyond their permissible capacities as
allowed by manufacturer of props /scaffolds. No additional prop or support
beyond what is shown on the approved drawing/scheme shall be erected.
p. Heavy, medium and light duty props shall not be mixed up.
q. Beams and slabs shall have a camber of 4 mm per meter subject to a maximum
of 20mm or as directed by the Owner/Owner’s Authorised Representative.
r. All angles and corners shall be sharp and well defined. In places where concrete
edges are permanently exposed and require no further treatment, they shall be
chamfered in a triangle of 25x25mm.
s. Steel props shall be provided with adequate horizontal and cross – bracing as per
approved design/scheme using steel pipes and steel couplers.
t. At the design and erection stage, the following additional points shall be
considered and incorporated into the shutters.
u. Openings for cleaning prior to start of concreting.
v. Pouring points shall avoid high drops and provide easy access to vibrator
needles.
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6.9 Surfaces shall be treated with Form release Agents or emulsion as approved by the
Owner/Owner’s Authorised Representative prior to laying of reinforcement. The
following point shall be observed very carefully:
6.9.1 Joints of mould shall be water-tight. It is easy to check from bottom by
making sure that no light is visible.
6.9.2 Props shall be on solid base, be in plumb, in one straight line, and braced
horizontally and diagonally as per approved design / scheme.
6.9.3 Tie bars in beams, walls and columns shall be at the correct place and
fully tight.
6.9.4 All saw dust, dirt; shavings and any other unwanted materials shall be
cleaned and hosed out preferably using compressed air.
6.9.5 Provision shall be made for observing form work while concreting and
any other platform needed for movement of workers without any
disturbance to the reinforcement.

6.10 Opening/inserts
All required openings and pockets shall be provided as detailed in the drawing. The
Contractor shall provide for the required materials, labour for fixing and supporting
during concreting, in his quoted price. It is imperative that all openings and pockets
shall be de-shuttered with care and all corners of openings shall be preserved. All
openings/pockets shall be in a correct line and level. After concreting, the openings
shall be secured by proper covering against any accident and guard rail and warning
notice, if any, will be provided.
6.11 In case of multistory building, any upper floor shall be suitably supported on at
least one floor below the same or as approved by the Owner/Owner’s Authorized
Representative. The concreting of upper floor shall be done only after concrete in
lower floors has attained the desired strength.
6.12 If formwork to columns is erected to the full height, one side shall be left open
and built up in sections as concrete pouring proceeds. Windows shall be left for
pouring concrete from the sides to limit the drop of concrete to 1 (one) metre or as
directed by the Engineer.
6.13 For liquid retaining structures no sleeves for through bolts shall be used nor shall
through bolts be removed. Bolts, in this case, shall be cut at 25mm. depth from the
surface and the hole made good by sand and cement mortar of the same
proportions as the concrete just after striking the formwork.
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6.14 Removal of form work

6.14.1 Forms 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.
6.14.2 Under normal circumstances and where 53/43 grade O.P Cement is
used, forms shall be removed after expiry of the following periods:
a. Walls, columns and vertical face 24 to 48 hrs
b. Slabs (props left under) 3 days
c. Beam soffits (props left under) 7 days
d. Removal of props under slabs
Spanning upto 4.5 m 7 days
Spanning over 4.5 m 14 days
e. Removal of props under beams and arches
Spanning upto 6 m 14 days
Spanning over 6 m 21 days

6.14.3 For other cements, the stripping time shall be suitably modified in
consultation with the Owner/Owner’s Authorised Representative
/Owner/Owner’s Authorised Representative’s Authorized Representative.
6.14.4 Where the shape of elements is such that the form work has re-entrant
angles, the form work shall be removed as soon as possible after the
concrete has set, to avoid shrinkage or cracking that might occur due to
the restraint imposed.
6.14.5 For precast moulds, the stripping time shall be 24 hours. The mould may
be lifted and stored in the yard within 24 hours to 48 hours as approved
by the Owner/Owner’s Authorised Representative.
6.14.6 Invariably mortar curb is provided for curing of slabs by ponding water
Removal of side forms of peripheral beams damages the curbs. To
prevent this, removal of side forms at all such locations shall be done not
before 2 day of slab concreting.
6.14.7 Casting dates shall be written on all RC surfaces immediately after
stripping of formwork.

6.15 Maintenance of pockets / inserts

It shall be responsibility of the Contractor to protect, maintain and handover the
pockets &/or inserts to next Contractor / Owner/Owner’s Authorised Representative in
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finished Condition. No additional cost due to this shall be paid by the Owner/Owner’s
Authorised Representative.
6.15.1 On completion of concreting, inserts shall be cleaned and required treatment
such as oiling, greasing, covering with plastic/plywood boxes, painting, etc. shall
be carried out by the Contractor subject to approval of the Owner/Owner’s
Authorised Representative. Inserts and pockets shall be protected from any kind
of damage during the course of construction.
6.15.2 Opening and pockets shall be de-shuttered with due care not to damage edges,
falling of debris within pockets etc. Further, all openings and pockets shall be
preserved, secured against accident by covering, putting up guard rails, warning
notice etc. as approved by the Owner/Owner’s Authorised Representative.
Guarding and protecting pockets shall be the responsibility of the Contractor at no
extra cost to the Owner/Owner’s Authorised Representative.

6.16 Cleaning / stacking

6.16.1 All formwork after deshuttering shall be cleaned with a stiff wire brush to
remove dust, grout, concrete etc. and if required maintained/repaired prior to
being reused. Steel plates, props, frames, proprietary formwork system shall be
oiled, greased to protect against rusting, weathering etc.
6.16.2 Plywood and timber form shall also be applied with preservative agent if it is to
be kept for long time without use. It shall be adequately protected against heat,
rain etc.

6.17 Contractor shall be responsible for the

a. Design, construction, erection, maintenance and striking of form work
(proprietary or custom made)
b. Form work shall provide the following
 Desired Shape, size and finish to concrete within desired tolerances
 Rigidity and durability during placement of concrete
 Leak proof and water tight joints/junctions
 Easy removal without disturbing concrete
 Easy access for handling and placing concrete
 Adequate safety
c. Workers shall be equipped with required safety measures such as safety belts,
helmets and safety tackles.
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7 Quality Management
7.1 Checking prior to concreting
a. All props and struts are in plumb, at right spacing, properly tightened and locked.
b. Formwork is correctly aligned and leveled.
c. Stop ends are properly secured and sealed.
d. All ties are properly tightened.
e. All inserts, pockets etc are at desired levels and secured.
f. Joints are sealed so as to ensure no possibility of leakage of grouts
g. Reinforcement has proper covers and required spacers.
h. All forms are cleaned, free from rubbish, tie wires etc.
i. Proper access for concreting and compaction is available.
j. Required guard rails and toe guard are provided

7.2 The following gauges/templates shall be used by the contractor for ensuring
proper formwork. These gauges shall be made available for the Owner/Owner’s
authorized representative to check the formwork dimensions:
a. Cover vibrator gauge of 40mmX65mmX1200mm long.
b. Winged cover gauge for column cover for the full set of columns to be provided
and shall not be removed earlier than 4 hours before concreting commences.
c. Beam width gauge at the time of shuttering checking and before laying of
reinforcement for slab.
d. Wooden battens of various thicknesses for beam stopper to be placed at
construction joint locations.

7.3 Tolerances
7.3.1 Tolerance is a specified permissible variation from lines, grade or dimension given
in drawings. No tolerances specified for horizontal or vertical building lines or
footings shall be considered to permit encroachment beyond the legal boundaries.
Unless otherwise specified, the following tolerances will be permitted.

7.3.2 Tolerances for RCC buildings

a. Variation from the plum
I. In the lines and surfaces of columns, piers, walls and in arises 3 mm per 2.5 m
but not
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more than 10 mm.

II. For exposed corner columns and other conspicuous lines,
In any bay upto 5 height : 5 mm
In height 10 m or more : 10 mm

b. Variation from the level or from the grades indicated on the drawings
I. In soffits of slab, ceilings, beam and in arises
Upto 2.5 m span : 5 mm
Between 2.5 & 5m : 8 mm
Spans more than10 m : 10 mm
II. For exposed lintels, sills, parapets, horizontal grooves and other conspicuous
lines,
Upto 5 m span : 5 mm
More than 10 m span : 8 mm

c. Variation of the linear building lines from established position in plan and
related position of columns, walls and partitions.
I. In any bay up to 5 m maximum : 5mm
II. In 10 m or more : 10 mm

d. Variation in the sizes and locations of sleeves, openings in walls and floors 5mm
(except in the case of and for anchor bolts for which the tolerance shall be
1mm).
e. Variation in cross-sectional dimensions of columns and beams and in the
thickness of slabs and walls – 5 mm + 10 mm

f. Footings
I. Variation in dimension in plan
- 5 mm + 50 mm
II. Misplacement or eccentricity
2% of footing width in the direction of misplacement but not more than 50
mm
III. Reduction in thickness
5% of specified thickness subject to a maximum of 50mm
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g. Variation in steps
Riser Tread
I. In a flight of stairs 3 mm 5 mm
II. Consecutive steps 1.5 mm 3 mm

7.3.3 Tolerances in other concrete structures.

a. Variation of the constructed linear outline from established position in plan
I. In 5 m : 5 mm
II. In 10 m or more : 10 mm
b. Variations of dimensions to individual structure features from established
positions
I. In super structure : 25 mm
II. In buried construction : 50 mm
c. Variation from plumb, from specified batter or from curved surfaces of all
structures
I. Upto 2.5 m : 3 mm
II. 2.5 m to 5 m :8 mm
III. 5 m to 10 m or more :12 mm
IV. In buried construction : Twice the above

d. Variation in cross sectional dimensions of columns, beams, buttresses, piers and

similar members : (-) 5 mm (+) 10 mm

e. Variation in the thickness of slabs, walls, arch sections, and similar members
:(-) 5 mm (+) 10 mm

f. Footings for columns, piers, walls, buttresses and similar members.

I. Variation of dimensions in plan
(-) 10 mm (+) 50 mm
II. Misplacement or eccentricity
2% of footing width in the direction of misplacement but not more than 50
mm
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III. Reduction in thickness

5% of specified thickness subject to a maximum of 50mm

8 Safety Considerations and Requirements

Apart from general safety and health hazards like working at heights, falling objects etc.,
the contractor shall assess the hazards associated with Formwork and shall take specific
action to mitigate against the same. Some of the hazards associate with rebar works are
listed for general guidance below.
a. Fall from height
b. Heavy object movement
c. Slippage
d. Trip over materials
e. formwork or false work collapse
f. falling objects
g. slips and trips
h. noise
i. electrocution
j. Chemical hazard

All workmen shall be made aware of the specific hazards that they face while working with
formwork material and shall be provided with specific personal protective equipment to
protect them.

9 Environmental considerations
9.1 Apart from general environmental impact of construction activities, the contractor
shall assess the environmental impact associated with Formwork and shall take specific
action to mitigate against the same.
9.2 As a general guide, the following hazards are identified as associated with formwork.
a. Noise pollution due to operation
b. Formwork activity involves following type of waste :
I. Non-hazardous waste: like Scrap wood, Fixtures, Metal scraps, Electrical
wiring and components.
II. Hazardous waste like Used oil, solvents, sealers, thinners, Cleanup materials
(such as rags) contaminated with the items listed above Drums and
containers that once contained the items listed above.
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9.3 When wastes are produced at the site, the contractor or subcontractor who produces
the waste typically is responsible for ensuring its proper handling and disposal.

10 Completion and delivery

Work related to Formwork shall not be deemed as complete till such time all the following
conditions are fulfilled:
10.1 The Contractor achieves the finishes to the satisfaction of the Owner/Owner’s
Authorised Representative.
10.2 There are no defects in the finished surface or all defects are repaired to the
satisfaction of the Engineer.
10.3 All quality tests and inspection records are furnished to the Engineer.

11 Measurements
Wherever it is not specifically stated in description of the item that form work shall be paid for
separately, the rate of R.C.C. item shall be deemed to include the cost of the form work.
11.1 Formwork shall be measured as the area (in square meters) of shuttering in contact
with the concrete.
11.2 It shall be measured to the nearest centimeter and the areas worked out corrected to
second decimal place.
11.3 No deductions shall be made for openings less than or equal to 0.4 sq m in size.
11.4 Formwork to secondary beams shall be measured up to sides of the main beams but no
deduction shall be made from the form work of the main beam.
11.5 No deduction shall be made from the formwork of column at intersection of the beam.
11.6 The quoted rate shall be applicable for all working conditions and heights, depths or
lifts specified in the BOQ. The rate shall include the cost of materials and labour for various
operations involved, such as, Splayed edges, notching, allowance for overlaps and
plastering at angles, battens, centering, shuttering, strutting, propping, bolting, nailing,
welding, casing, striking and removal.
11.7 Filling to form stop chamfered edges or splayed external angles not exceeding 75 mm
to footing and 25 mm to beams, columns and like. Temporary openings in the forms for
pouring concrete and removing rubbish.
11.8 Dressing with oil/approved emulsion/soap solution to prevent adhesion of concrete
with shuttering.
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11.9 Racking or cutting Fixing inserts and openings at the correct line and level and any
required stage to support the same at the directed height and place.
11.10 Platforms, if any, required to keep check on form while the concreting is in progress.
11.11 Filling and making joints water-tight to the satisfaction of the Owner/Owner’s
Authorized Representative or Owner/Owner’s Authorized Representative’s Authorized
Representative.
11.12 Cleaning the shuttering.
11.13 Inserts shall be measured by weight or enumerated as specified in the BOQ.
11.14 Any work damaged through premature or careless removal of form shall be removed
and reconstructed at the Contractor’s cost.
11.15 Holes for electrical conduits, hooks for fans and for plumbing shall be deemed to be
included in the price of items.
11.16 Precast units shall be measured as detailed in BOQ including Casting, lifting, curing and
stacking
11.17 Lifting and placing in position at various slab levels including required staging and
shuttering, and de shuttering for concreting.
11.18 If the specified type of finish is not obtained the Contractor shall only be paid 50% (fifty
percent) of the quoted rate for the defective area. The balance shall only be paid after
completion of the rectification and certification by the Owner/ Owner’s Authorized
Representative.
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12 Annexures
A. Adjustable Props

B. H-Frame Scaffolding
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C. Wedge lock System

D. Adjustable Telescopic Steel Spans

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E. Slab Shuttering

F. Slab Shuttering
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G. Wall , System, Column Formwork

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Contents
1. Scope ............................................................................................................................................................ 2
2. List of Standards ........................................................................................................................................... 2
3. Terminology .................................................................................................................................................. 2
4. Submittals and Certifications ........................................................................................................................ 3
5. Materials ....................................................................................................................................................... 3
6. Workmanship ............................................................................................................................................... 3
7. Quality Management .................................................................................................................................... 7
8. Safety Considerations and Requirements..................................................................................................... 7
9. Environmental considerations ...................................................................................................................... 8
10. Measurement ........................................................................................................................................... 8
11. Completion and delivery ................................................................................................................................. 9
12. Annexures ................................................................................................................................................. 9
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Technical Specifications for APP membrane Type Waterproofing

1. Scope
This specification applies to an installation and placing of APP membrane waterproofing sheets
for different structural components at different locations in the structure. This specification
does not cover any waterproofing technique other than APP Membrane. Also it doesn’t
comment on any manufacturing technique or specifications of the constituents used for the
manufacturing of APP Membrane sheets.

2. List of Standards
Work shall be carried out as per latest version of Indian Standards and Code of Practices. List
given hereunder is not to be considered as conclusive and is for reference and guidance only.
Any discrepancies /conflict noticed shall be directed to the Engineer for his direction/approval.
However as a general rule more stringent specification shall take precedence.

Sr. No Code No. Description

1 IS 702 Specification for industrial bitumen

2 IS 1203 Method of testing of tar and bituminous material

Specification for bitumen felts for waterproofing and damp
3 IS 1322
proofing
Code of practice for laying damp-proofing treatment using
4 IS 1609
bitumen felts.
PV/TECH
5 Technical Specification for Concrete works
SPEC/CIVIL/02
PV/TECH
6 Technical Specification for Formwork
SPEC/CIVIL/04

3. Terminology
The following terms and abbreviation shall have the specific meanings as described hereunder.
For terms that are not described herein, the definitions as stated in the applicable Indian
Standard Specifications shall apply.
1.1 APP Membrane: Membrane is the term used for the object with a negligible thickness or
small thickness. APP (Atactic Polypropylene) membrane is nothing but sheets of polymer /
bituminous material with an ability to resist the unnecessary passage of water.
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4. Materials
4.1 Primer: The bitumen primer shall conform to the requirements laid down in IS 3384.
4.2 APP Modified Membrane:
It is a polymeric water proofing membrane manufactured to high standards. It is five
layered APP modified polymeric membrane with centre core as 20 micron HMHDPE/100
micron HMHDPE (High Molecular High Density Polyethylene Film), is the heart of the
membrane and protects against water and moisture. The center core is sandwiched on
both sides by high quality polymeric mix with properties of high softening point, high heat
resistance and cold resistively to make it ideal for all water proofing treatment. The
polymeric mix is protected on both sides with 20 micron HMHDPE film. The membrane is
available in variable thickness and weights. Usual width is 1.0 m.
4.3 Bonding Material:
This shall consist of blown type bitumen conforming to IS 702 or residual bitumen 85/25
conforming to IS 73 heated to the correct working temperature of 180°C. The penetration
of the bitumen shall not be more than 40 when tested in accordance with IS 1203, unless
otherwise specified each coat of bonding material shall be of blown type bitumen of grade
85/25 heated to a working temperature of 180 degree C and applied @ 1.20 kg / sq.m of
the surface area.
4.4 Surface Finish:
Surface finish shall be with brick tiles of class designation 100 grouted with cement mortar
1:3 (1 cement : 3 fine sand ) with 2% integral water proofing compound by weight of
cement over a 12 mm thick layer of cement mortar 1:3 (1 cement: 3 fine sand) and finished
neat and Finish shall be measured and paid for separately.

5. Submittals and Certifications

The contractor shall maintain a comprehensive record of the installation and placing APP
membrane waterproofing as per the approved ITP. All records shall be in hard copy, signed by
the Quality manager, unless electronic records are permitted by the Engineer.
Submittals shall include the following documents:
5.1 Product data sheet
5.2 Manufacturers certificates
5.3 Test report of laboratories
5.4 Alternative product if any with tabulation for confirmation that alternatives proposed
meets / exceeds specification.
5.5 The contractor shall submit the Schedule of work to be carried out.

6. Workmanship
6.1 Preparation of Surface:
6.1.1 The surface to be treated shall have a minimum slope of 1 to 120. This grading shall
be carried out with cement concrete or cement plaster with coarse sand, as
desired, to the average thickness required and finished smooth. Such grading shall
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be paid for separately. Junctions between the roof and vertical faces of parapet
walls, chimneys etc. shall be chased by running triangular fillets 7.5 x 7.5 cm. size,
cement concrete. At the drain mouths, the fillets shall be suitably cut back and
rounded off for easy application of water proofing treatment and easy flow of
water. Cement concrete shall be 1:2:4 mix (1 Cement: 2 Coarse sand: 4 Graded
stone aggregate 20 mm Nominal size).
6.1.2 The provision of fillets shall be deemed to be covered by the item of water proofing
and shall not be measured or paid for separately. In existing roof where gola and
drip course are provided at the junction of roof and vertical face of parapet wall,
chimney stacks, etc. These shall be dressed suitably and finished smooth so as to
ensure an easy and gradual turning of the flashing.
6.1.3 Any dismantlement or forming and finishing smooth the junction for forming the
base of the flashing shall not be measured or paid for separately and shall be
deemed to form part of the preparation of the surface. While the grading of roof
surface is being done, it shall be ensured that the outlet drain pipe has been fixed
and mouth at the entrance have been eased and rounded off properly for easy flow
of water.
6.1.4 When any pipe passes through the roof to be treated, angular fillet of shape shall
be built around it for the water proofing treatment to be taken over it. These fillets
shall not be measured or paid for separately. For carrying over and tucking in the
water proofing felts into the parapet walls, chimneys stacks etc. a horizontal groove
6.5 cm. deep, 7.5 cm. wide section with its lower edge at not less than 15 cm.
above the graded roof surface shall be left on the inner face of the same; during
construction if possible. When such groove has not been left, the same shall be cut
out neatly and the base at rear of the groove shall be finished smooth with cement
plaster 1:4 (1 cement: 4 coarse sand). Such cutting of the groove and its finishing
smooth shall be part of the water proofing or paid for separately.
6.1.5 No deduction shall be made either for not making the groove or when the latter
has already been left in the masonry by the construction agency. Tucking in the
water proofing felt will be required where the parapet wall exceeds 45 cm. in the
height from the graded surface. Where the height is 45 cm or less, no groove will be
required as the water proofing treatment will be carried over the top of the parapet
wall to its full thickness. In the case of low dividing walls of height 30 cm. or less,
outlets therein shall be cut open for full height and the bottom and sides shall be
rendered smooth and corners rounded and such treatment shall not be measured
and paid for separately.
6.1.6 Where expansion joints are left in the slab the provision of dwarf walls and/or RCC
slabs for covering them and finishing the surface smooth shall be the responsibility
of the construction agency, which had laid the roof slab and will not be included in
the operation of water proofing.
6.1.7 The graded surface of the roof and concrete fillets and the faces of walls shall be
thoroughly cleaned with wire brush and all loose scales etc. removed. The surface
shall then be dusted off. Any crack in the roof shall be cut to V section, cleaned and
filled up flush with cement mortar slurry 1:4 (1 cement : 4 coarse sand) or blown
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type petroleum bitumen of IS grade 85/25, or approved quality conforming to IS

702. Such cleaning of the surface or treating the cracks shall not be paid for
separately.
6.2 Treatment:
The waterproofing treatment shall be of five or seven course as specified. In seven course
treatment, the first four courses shall be the same as for five course treatment. The fifth
course shall be a layer of APP modified polymeric membrane. The sixth course shall be a
coat of bonding material and the top most seventh course shall be of specified surface
finish.
6.3 Laying
6.3.1 First course shall be a coat of bitumen primer @ 0.40 kg per sq.mt followed by
subsequent course as per treatment required.
6.3.2 Drain outlets shall be given a four or six course treatment as specified for the roof in
the description of the item in the manner specified for the flat roof surface. Water
proofing treatment shall be carried into the drain pipe or outlets by at least 10 cm.
The water proofing treatment laid on the roof surface shall overlap the upper edge
of the water proofing treatment in the drain outlets by at least 10 cm.
6.3.3 The APP modified polymeric membrane shall be cut to the required length, brushed
clean of dusting material and laid out flat on the roof to eliminate curls and
subsequent stretching. The membrane shall normally be laid in length in the
direction of the slope and laying shall be commenced at the lowest level and worked
up to crest. The membrane shall not be laid in single piece of very long lengths as
they are likely to shrink; 6 to 8 m is suitable length. The roof surface shall be cleaned
and dry before starting the membrane treatment. Each length of membrane shall be
laid in position and rolled up for a distance of half its length. The hot bonding
material shall be poured on the roof across the full width of the rolled membrane as
the latter is steadily rolled out and pressed down. The pouring shall be so regulated
that the correct weight of bonding material per unit area is spread uniformly over
the surface. Excess bonding material that gets squeezed out at the ends shall be
leveled up as laying proceeds. When the first half of the strip of felt has been
bonded to the roof, the other half shall be rolled up and then unrolled on the hot
bonding material in the same way. Subsequent strips shall also be laid in the same
manner. Each strip shall overlap the preceding one by at least 7.5 cm. at the
longitudinal edges and 10 cm. at the ends. All overlaps shall be firmly bonded with a
blow lamp and leveling down unevenness. The fourth layer of bonding material in
the five course treatment shall be carried out in a similar manner after the flashing
has been completed.
6.3.4 In a seven course treatment the fifth layers of membrane shall be laid in the manner
already described, taking care that laps in the membrane are staggered from those
in the earlier layer. The sixth layer of bonding material shall be carried out after the
flashing is done.
6.3.5 High Parapet Walls, Chimney Stacks etc.:
Membrane shall be laid as flashing wherever junctions of vertical and horizontal
surfaces occur. Longitudinal laps shall be 10 cm. The lower layer of flashing
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membrane in a six course treatment shall overlap the roof water proofing by not less
than 20 cm. while the upper layer shall overlap the roofing felt by 10 cm. The
minimum overlap of the flashing membrane in five course treatment over the
roofing membrane shall be 10 cm. The flashing shall consist of the same five or
seven course treatment as for the roof except that the final course shall be replaced
by an application of 12 mm thick cement plaster 1:3 on the vertical and sloping faces
only, of the flashing. The overlap along the length of flashing shall stagger with those
in the second layer of flashing membrane (in a seven course treatment and with the
joints in the roof membrane). The upper edge of the finishing membrane shall be
well tucked into the flashing grooves in the parapet, chimney tacks etc. to a depth of
not less than 6.5 cm. Corresponding applications of bonding material shall also be
made. The flashing treatment shall be firmly held in place in the grooves with wood
edges at intervals and the grooves shall be filled up with cement mortar 1:4 (1
cement: 4 coarse sand) or cement concrete 1:2:4 (1 cement: 2 coarse sand : 4
graded stone aggregate 6 mm nominal size) and surface finished smooth with the
rest of the wall. The cement work shall be cured for 7 days. When dry, the exposed
plaster joints of grooves shall be painted with bitumen and two coats of bituminous
solution shall be applied on the vertical and sloping surface of flashing. After the top
flashing membrane layer has been fixed, the penultimate layer of bonding material
shall be applied over the roofing membrane and the horizontal overlaps and vertical
and sloping surfaces of the flashing at the specified rate.
6.3.6 Low Parapet Walls:
Where parapet walls are of height 45 cm. or less, membrane flashings shall be
provided in the same manner as for flashings in the case of high parapet walls
except that the upper edge shall be carried upto the full height of the wall and taken
right across the top of the parapet and down on the external vertical faces to a
minimum distance of 5 cm.
6.3.7 Low Dividing Walls:
Where low dividing walls or inverted beams are met with, the same shall be covered
with a four or six layer treatment as for the main roof, the latter bearing carried
down both sides of the wall and overlapping the roofing treatment as in the case of
flashing of high parapet walls. Drain outlets where formed in the low dividing walls,
shall be given water proofing treatment of the same number of courses as specified
for the flat roof surface. The bottom and sides shall be so treated that all overlaps
are in the direction of flow of drainage.
6.3.8 Expansion Joints:
Where the expansion joints are provided in the slabs, the joints and their cover slabs
shall be suitably treated with water proofing. A typical sketch of an expansion joint
with the RCC slabs on either side of the joint turned vertically up and dwarf walls by
not less than 7.5 cm. and are provided with throating on their underside along their
length. The water proofing treatment shall be taken up the sloping junction fillets
and the vertical faces of the walls to the underside of the cover slabs. The cover
slabs are given the water proofing treatment like the roofs slabs, after the cross
joints between adjacent cover slabs are first sealed with 15 cm width of roofing felt
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struck to them with bitumen. The water proofing treatment shall be carried own the
sides of the cover slabs to their full thickness. Care shall be taken to see that
overlaps if any in the roofing over the cover slabs stagger with the joints between
cover slabs. The formation of the expansion joints and provision of the cover slabs
shall be the responsibility of the construction agency. The formation of the junction
fillets and the water proofing treatment of the joint and cover slabs shall be carried
out by the water proofing agency. Nothing agency extra shall be paid for the sealing
of the cross joints in the cover slab with 15 cm. width of bitumen strips.
6.3.9 Pipes:
Where vertical pipe outlets are met with, 7.5 x 7.5 cm fillets of lime or cement
concrete of the type and section shall be provided and flashing of four or six course
treatment, same as for the roofing treatment shall be laid. The upper edge of the
flashing shall be laid sloping down forward and butted against the pipe and annular
depression so formed shall be filled with hot bitumen. A circular metal collar in the
shape of an inverted truncated cone shall be fixed on the pipe to throw off the rain
water clear of the flashing and this shall be paid for separately.

7. Quality Management
7.1 The contractor shall put in place a comprehensive Quality management plan to ensure
that the work is carried out as per specifications and compliance to all requirements are
established and demonstrated through comprehensive documentation. The contractor
shall engage a qualified Quality Manager to implement the quality plan.
7.2 The standardized Inspection and Test plans [ITP] shall be adopted for the purpose of
testing material and establishing documentary evidence of conformance to technical
requirements. If the contractor proposes to adopt his own ITP, the same shall be
submitted for the approval of the Engineer. Any dilution of the testing frequency,
acceptance criteria from the standardized ITP shall have to be supported by well-
articulated arguments.

8. Safety Considerations and Requirements

8.1 Apart from general safety and health hazards the contractor shall assess the hazards
associated with installation and placing of APP membrane waterproofing sheets and shall
take specific action to mitigate against the same. Some of the hazards associated with
installation and placing of APP membrane waterproofing sheets works are listed for
general guidance below.
a. Fire hazard during torch work
b. Skin burn while fixing bitumen sheets with torch
c. For Safety considerations during concrete works refer PV/TECH SPEC/CIVIL/02.
d. For Safety considerations during to Formwork refer PV/TECH SPEC/CIVIL/04.
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8.2 All workmen shall be made aware of the specific hazards that they face while doing
installation and placing of APP membrane waterproofing sheets and shall be provided with
specific personal protective equipment to protect them.

9. Environmental considerations
9.1 Apart from general environmental impact of construction activities, the contractor shall
assess the environmental impact associated with installation and placing of APP
membrane waterproofing sheets and shall take specific action to mitigate against the
same.
a. APP Membrane Waterproofing Works activity involves following type of waste :
i. Non-hazardous waste : like Scrap wood, Fixtures
ii. Hazardous waste : like used Waste pieces of APP Membrane sheets, Concrete
waste, oil, paint, solvents, sealers, thinners, Cleanup and materials contaminated
with the items listed above Drums and containers that once contained the items
listed above.
b. For Environmental considerations during concrete works refer PV/TECH
SPEC/CIVIL/02.
c. For Environmental considerations during Form works refer PV/TECH SPEC/CIVIL/04.
9.2 When wastes are produced at the site, the contractor or subcontractor who produces the
waste typically is responsible for ensuring its proper handling and disposal.

10.Measurement
10.1Measurement:
Length and breadth shall be measured correct to a cm. The area shall be calculated in
square meters correct to two places of decimal. Measurements shall be taken over the
entire exposed area of roofing and flashing treatment including flashing over low parapet
walls, low dividing walls and expansion joints and at pipe projections etc. Overlaps and
tucking into flashing grooves shall not be measured. Vertical and sloping surfaces of water
proofing treatment shall also be measured under the five or seven course treatment as
the case may be, irrespective of the fact that the final course is replaced by bitumen
primer. No deduction in measurements shall be made for either openings or recesses for
chimney stacks, roof lights and neither the like, for areas up to 0.4 sq.m nor anything shall
be paid for forming such openings. For areas exceeding 0.40 sq.m deduction will be made
in measurements for full opening and nothing extra shall be paid for forming such
openings.
10.2Rate:
The rate shall include the cost of all labour and materials involved in all the operations
described above. The top most layer shall be paid separately.
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11.Completion and delivery

Installation and placing of APP membrane waterproofing sheets shall not be deemed as
complete till such time all the following conditions are fulfilled:
11.1 There are no defects in the APP Membrane waterproofing work or defects have been
rectified to the satisfaction of the Engineer. Specifically, the distortion that may occur to
the membrane should have been eliminated up to permissible tolerances, before the
completion of relative activity.
11.2 All quality documents, test certificates have been submitted.

12.Annexures
NIL
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Table of Contents
1. Scope .......................................................................................................................................... 2
2. List Of Standards ........................................................................................................................ 2
3. Terminology ............................................................................................................................... 4
4. Materials .................................................................................................................................... 5
5. Submittals ................................................................................................................................ 14
6. Workmanship........................................................................................................................... 14
7. Quality Management............................................................................................................... 22
8. Safety Considerations And Requirements .............................................................................. 23
9. Environmental Considerations And Requirements ................................................................ 23
10. Completion And Delivery ..................................................................................................... 24
11. Method Of Measurement & Rate........................................................................................ 24
12. Annexures ............................................................................................................................ 28

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Specification for Masonry Work

1. Scope
The work covered under this specification consists of Masonry works including
following items for the projects of Godrej Properties Ltd.
 Concrete Block Masonry
o Solid Concrete Blocks
o Hollow Concrete Blocks
o Autoclave Aerated Concrete Blocks
o Hollow Light Weight Concrete Blocks
o Solid Light Weight Concrete Blocks
 Brick Masonry
o Clay Bricks
o Clay Fly Ash Bricks
o Fly Ash Lime Bricks
o Sand Lime(Calcium Silicate) Bricks
o Auto-Clave Bricks
 Stone Masonry
o Random Rubble Masonry
o Rubble Masonry-Coursed

2. List of Standards
The work shall be carried out as per latest versions of Indian Standards and Code of
practices. List given hereunder is not to be considered as complete and is for reference/
guidance only. Any discrepancies / conflicts noticed shall be directed to the Engineer for
his direction / approval.
However as a general rule the more stringent specification shall take precedence.
IS 269 Specification for ordinary and low heat Portland cement grade
33
IS 383 Specification for coarse and fine aggregates from natural sources
for concrete.
IS 456 Code of Practice for plain and reinforced concrete.
IS 1077 Common burnt clay building bricks.
IS 1121 Methods of determination of properties and strengths of natural
(Part I) building stones (Part-I compressive strength).
IS 1122 Methods for determination of specific gravity of natural building
stone
IS 1123 Methods of identification of natural building stones
IS 1124 Method of test for determination of water absorption, apparent
specific gravity and porosity of natural building stones

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IS 1125 Methods of test of determination of weathering of natural

building stone
IS 1126 Methods of test for determination of durability of natural
building stone
1127 Recommendations for dimensions and workmanship
Of natural building stones for masonry work.
IS 1128 Specification for Lime stone (Slab & Tiles).
IS 1129 Recommendations for dressing of natural building stones
IS 1197 Code of practice for construction of rubble stone masonry
(Pt. I)
IS 1200 Method of measurements of brick works
(Part 3)
IS 1200 Method of measurements of natural building stones
(Part 4)
IS 1597 Specification for Construction of Rubble Stone Masonry
(Part I)
IS: 1609 Code of Practice for laying Damp-proof treatment
Using bitumen felts.
IS 1805 Glossary of terms relating to stones, quarrying and dressing
IS 2185 Specification for concrete masonry units
Part - 1 Hollow and solid concrete blocks
Part -2 Hollow and solid light weight concrete blocks
Part - 3 Autoclave Cellular (Aerated) concrete blocks
IS: 2212 Code of Practice for Brickwork.
IS 2222 Specification for burnt clay perforated building bricks.
IS: 2250 Code of Practice for preparation and use of Masonry Mortar.
IS 2572 Code of Practice for construction of hollow concrete block
masonry.
IS 2849 Specification for non-load bearing gypsum partition blocks, (Solid
and hollow types)
IS 3495 Method of test for burnt clay building bricks.
IS 3812 Specification for fly ash for use as pozzolana and admixture.
IS 4139 Specification of calcium silicate bricks
IS 4885 Specification for sewer brick
IS 5454 Methods of sampling of clay building bricks.
IS-6041 Construction of autoclaved cellular concrete block masonry

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IS-6072 Specifications for autoclaved reinforced cellular concrete wall

slabs
IS-6073 Autoclaved Reinforced Cellular Concerted floor and roof slabs
IS-6441 Methods of test for autoclaved Cellular Concrete
products(Determination of unit weight or bulk Density &
Moisture ) Part 1,2,3,4,5,6 & 8
IS 8112 Specification for ordinary pozzolana cement grade 43.
IS 9103 Specifications for admixtures in concrete
IS 12269 Specification for 53 grade ordinary Portland cement
IS 12894 Pulverized fuel ash lime bricks specification
IS 13757 Specification of burnt clay fly ash bricks.

3. Terminology
The following terms and abbreviations shall have the specific meanings as described
hereunder. For terms that are not described herein, the definitions as stated in the
applicable Indian Standard Specifications shall apply.
3.1. Bond: The arrangement of the bricks in successive courses to tie the brick work
together both longitudinally and transversely. The arrangement is usually
designed to ensure that no vertical joint of one course is exactly over the one in
the next course above or below it, and there is greatest possible amount of lap.
3.2. Bed Joint: Horizontal joint in brick work or masonry.
3.3. Block: A concrete masonry unit, either hollow (open or closed cavity), or solid
(other than units used for bonding, such as a half block), any one of the external
dimension of which is greater than the corresponding dimension of a brick.
3.4. Bushing: It is the finished projection provided on the rock surface.
3.5. Cross Joint: joint other than a bed joint normal to the wall face
3.6. Closer: Any portion of a brick used in constructing a wall, to close up the bond
next to the end brick of a course
3.7. Coping or Weathering : The cover applied over or the geometrical form given to
a part of structure to enable it to shed rain water
3.8. Corbel: A cantilever projecting from the face of a wall to form a bearing
3.9. Cornice: Horizontal or ornamental feature projecting from the face of a wall
3.10. Course: A layer of bricks/blocks/stones including bed mortar
3.11. Efflorescence: A powdery incrustment of salts left by evaporation. This may be
visible on the surface or may be below surface. In the latter case, this is termed
as crypto Efflorescence.
3.12. Header: A brick laid with its length across the wall. Selected long stones used to
hold a wall together transversally.
3.13. Hearting: The infilling which forms the core of a rubble wall.
3.14. Jamb: The part of the wall at the side of an opening.

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3.15. Quoin: A quoin is the external angle of a wall or building. The term is also applied
to a stone specially selected and neatly dressed for forming such an angle.
3.16. Spandrel: The space between the haunches and the road decking of an arch.
3.17. Stretcher: A brick/stone/block laid with its length in the direction of the wall.
3.18. String course: horizontal course projecting from a wall usually introduced at
every floor level or windows or below parapet for imparting architectural
appearance to the structure and also keeping off the rain water.
3.19. Toothing: Bricks left projecting in alternate courses to bond with future work.

4. Materials
4.1 Cement
4.2.1 The type of cement to be used in concrete/mortar shall be as per the
approved Concrete Mix Design. Generally, the following types of cement
may be used:
 Ordinary Portland cement of grade 53 or 43
 Portland Pozzolana Cement
 Portland Blast Furnace Slag Cement
4.2.2 Cement shall be received in bags of 50 kg or loose in bulkers and each
batch shall be accompanied with a test certificate of the factory. In case
cement has been stored for over 3 months or for any reasons the stored
cement shows signs of deterioration or contamination, it shall be
tested as per the direction of the Engineer, and will be used in the works
only if found suitable
4.2 Coarse Aggregate
4.2.1 Coarse aggregate shall be obtained from natural sources such as stone,
gravel, etc. crushed or uncrushed or a combination thereof from
approved quarries. Aggregate shall be hard, strong, dense, durable, and
clean and free from veins and adherent coatings. It shall be free from
soft, feeble, thin, elongated or laminated pieces and shall be roughly
cubical in shape. It shall consist of coarse material, most of which is
retained on 4.75 mm IS sieve and shall contain only as much fine material
as is permitted in IS 383 for various sizes and grading.
4.2.2 Coarse aggregate shall conform to all requirements laid down in IS: 383
4.2.3 The maximum size of coarse aggregate should not be greater than one
fourth of the minimum thickness of the member and it should be
restricted to 5 mm less than the minimum clear distance between the
main bars or 5 mm less than the minimum cover to the reinforcement.
4.2.4 Source of aggregate shall be from an approved location. Each source of
aggregate shall be approved by Engineer on the basis of tests conducted
on samples of aggregates from the source at an approved testing
laboratory. In case available aggregates do not meet certain
requirements of IS 383 or any other specification, required processing

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shall be carried out by the contractor to make the aggregates conform to

IS: 383.
4.2.5 Coarse aggregate shall have a specific gravity of 2.6 (Saturated surface
dry basis). Aggregate below this specific gravity shall not be used without
the special permission of the Engineer.
4.2.6 Once a specific source of supply of coarse aggregate is approved, the
source shall not be changed without the prior approval of the Engineer.
4.3 Fine Aggregate
4.3.1 Natural sand deposited by stream or glacial agencies as a result of
disintegration of rock shall be used as fine aggregate. Fine aggregate shall
pass through 4.75 mm sieve in total. Crushed sand may be used or added
to natural sand in approved proportions to achieve the required grading.
The fine aggregate shall conform to following standards.
4.3.2 IS 383 Specification for coarse and fine aggregates from natural sources
for concrete.
4.3.3 IS 2116 Specification for sand for masonry mortars and grouts.
4.3.4 Sea sand shall not be used unless specifically approved by the Engineer in
writing. If approved, the required treatment to the sea sand to make it
conform to the requirements of relevant Indian Standard shall be done at
the contractor’s cost.
4.3.5 Sand shall be hard, durable, chemically inert, clean and free from
adherent coatings and organic matter and shall conform to the
requirements laid down in IS: 383.
4.3.6 If the fine aggregate containing more than allowable percentage of silt
and / or deleterious materials, it shall be thoroughly washed at site with
clean fresh washed so as to bring the silt content/ deleterious material’s
content within allowable limits.
4.3.7 Grading of fine aggregate shall conform to IS and shall fall within limits of
one of the grading zones given in IS 383. Fine aggregate falling in grading
zone IV shall not be used in concrete.
4.4 Water
4.4.1 Water used for mixing and curing shall be clean, reasonably clear and
free from objectionable quantities of silt, oils, alkalis, acids, salts, sugar
so as not to weaken mortar, or concrete or cause efflorescence or
attack the steel in RCC while curing. It shall be free of elements, which
significantly affects the hydration reaction or otherwise interferes with
hardening of concrete during curing or those elements which produce
objectionable stains or deposits.
4.4.2 Potable water is generally satisfactory but it shall be tested prior to use in
the works. Water used for mixing and curing shall satisfy the
requirements of IS: 456.
4.4.3 Water shall be tested in accordance with IS 3025. The PH value of water
shall not be less than 6 nor more than 9.

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4.4.4 The source of water shall be tested and got approved in writing from the
Engineer prior to use in the works.
4.4.5 Use of sea water shall not be permitted for any purpose related to
making concrete.
4.5 Concrete Blocks
4.5.1 Concrete blocks may be hollow (open ended for ease of laying conduits)
or solid and shall be referred to by its nominal dimension. The term
nominal dimension includes the thickness of the mortar joint. Actual
dimensions of the block shall be 10 mm short of the nominal dimensions.
4.5.2 Blocks shall be made in sizes and shapes to fit different construction
needs. It includes stretcher, corner, double corner or pier, jambs, header,
bull-nose, partition block and concreted floor units. Nominal dimensions
of concrete blocks shall be, Length – 400, 500, or 600 mm
Height – 200 or 100 mm
Width - 100, 150, 200, 250, or 300 mm
4.5.3 Maximum permissible variation shall be ± 5 mm in length and ±3 mm in
width and height of the block. Actual dimensions of block shall be 10 mm
short of nominal dimensions.
4.5.4 The average crushing strength shall be determined as per I.S 2185.For
load bearing wall density of hollow block shall be not less than 1500 kg
/mm3 and minimum average compressive strength of units shall be 3.5 to
7 N/mm2. For block density less than 1500 kg /mm3 but not less than
1000 kg /mm3 average compressive strength of units shall be 2.0 to5
N/mm2 .
4.5.5 For non-load bearing wall, hollow block density shall be not less than
1000kg / mm3 and minimum average compressive strength of units shall
be1.5 N/mm2.
4.5.6 Face shells and web dimensions shall not be less than the values given in
IS 2185 Part I – Table 1 “Minimum face shell and web thickness”.
4.5.7 Concrete shall be mixed in mechanical mixers. Blocks shall be moulded,
laid and compacted With automatic machines. No hand/manual
compaction shall be permitted unless approved by the Engineer in writing
for special blocks. Care shall be taken to see that the mix is placed in
layers and each layer thoroughly tamped until the whole mould is filled
up. Blocks shall be protected until they are sufficiently hardened to
permit handling without damage.
4.5.8 Blocks shall be cured in the curing yard by keeping them continuously
moist for at least 14 days.
4.5.9 Steam-cured blocks shall be preferred. Cured blocks shall be allowed to
dry for a period of 4 weeks before being used. The blocks shall be
allowed to complete their initial shrinkage before they are laid in the wall
4.5.10 All blocks shall be sound and free of cracks or other defects. Where faces
are exposed, they shall be free of chips, or other imperfections, and the

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overall dimensions of the blocks shall be in accordance with the tolerance

as specified.
4.5.11 Blocks shall be considered to be conforming to IS if requirements of the
conditions mentioned in clauses 11 & 12 of IS 2185 (Part I) are satisfied.
4.5.12 Autoclave Aerated Concrete Blocks: Autoclaved aerated concrete, or
AAC, is also known as Autoclaved Cellular concrete(ACC), is a light weight,
precast building material, made with fine aggregates, cement, and an
expansion agent that causes the fresh mixture to rise like bread dough. In
fact, this type of concrete contains 80% air. In the factory where it is made,
the material is molded and cut into precisely dimensioned units.
 Blocks are larger and lighter than traditional concrete masonry.
Compressive
Thickness Height Length Density
strength
100 mm 200 mm 600 mm 550-700 kg/m 3 30 - 50 kg/cm2
150 mm 200 mm 600 mm 550-700 kg/m 3 30 - 50 kg/cm2
200 mm 200 mm 600 mm 550-700 kg/m 3 30 - 50 kg/cm2

4.6 Bricks
4.6.1. Common Burnt Clay Bricks
Common Burnt Clay Bricks shall conform to IS:1077 and shall be hand
moulded or machine moulded. They shall be free from nodules of free
lime, visible cracks, flaws warpage and organic matter, have a frog 100
mm in length 40 mm in width and 10 mm to 20 mm deep on one of its
flat sides. Bricks made by extrusion process and brick tiles may not be
provided with frogs. Each brick shall be marked (in the frog where
provided) with the manufacturer’s identification mark or initials.
4.6.2. Fly ash bricks
a. Fly ash bricks (cement bonded) shall be locally made. Bricks shall
have smooth rectangular faces with sharp and square corners.
Bricks shall be hand or machine moulded and shall be made from
the admixture of suitable good quality of fly ash, sand and cement
as per the composition mentioned below :
FLY ASH: 50-60%
SAND: 32-40%
CEMENT : 8-12%
b. The fly ash bricks will be as per latest relevant IS code. The bricks
will be of dimension as per standard clay brick, suitable for
making 230mm thick full brick wall, 115mm thick half brick wall
and 75mm thick minor partition walls, as applicable, as per
drawing/specification/BOQ. A maximum tolerance of (+/-) 2mm
shall be allowed as the manufacturing tolerance. The bricks shall

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have frog of 100 mm in length 40 mm in width and 10 to 20 mm

deep of one of its flat sides.
c. The bricks when tested in accordance with the procedure laid
down in IS 3495 (part 2) : 1992 after immersion in cold water for
24 hrs., water absorption shall be within 13-15% by weight.
Similarly, the porosity of the fly ash bricks shall be within 12-20%.
The bricks shall have a minimum crushing strength of 50 Kg/CmSq.
4.6.3. Mechanized Autoclave Fly Ash Lime Brick:
These bricks shall be machine moulded and prepared in plant by
appropriate proportion of fly ash and lime. The autoclave fly ash bricks
shall conform to IS 12894. Visually, the bricks shall be sound, compact
and uniform shape, free from visible cracks, warpage and organic
matters. The brick shall be solid with or without frog, and of 100/80 mm
in length, 40 mm width and 10 to 20 mm deep one of its flat side as per IS
12894. The brick shall have smooth rectangular faces with sharp corners
and shall be uniform in shape and colour. Fly ash shall conform to IS 3812
and lime shall conform to class ‘C’ hydrated lime of IS 712.
4.6.4. Dimensions: The brick may be modular or non-modular. Sizes for both
types of bricks/tiles shall be as per following Table. While use of modular
bricks/tiles is recommended, non-modular (FPS) bricks/tiles can also be
used where so specified. Non-modular bricks/tiles of sizes other than the
sizes mentioned in Table below may also be used where specified.
Type of Bricks/ Tiles Nominal Size mm Actual Size mm
Modular Bricks 200 × 100 × 100 190 × 90 × 90 mm
mm
Modular tile bricks 200 × 100 × 40 mm 190 × 90 × 40 mm
Non-modular tile bricks 229 × 114 × 44 mm 225 × 111 × 44 mm
Non-modular bricks 229 x 114 × 70 mm 225 x 111 × 70 mm
4.6.5. Classification: Bricks/Brick tiles shall be classified on the basis of their
minimum compressive strength as given below :
Class Average compressive strength
Designation Not less than Less than
N/mm2 (kgf/cm2) N/mm2 (Kgf/cm2)
12.5 (125) 12.5 (125) 15 150
10 (100) 10 (100) 12.5 125
7.5 (75) 7.5 (75) 10 100
5 (50) 5 (50) 7.5 75
3.5 (35) 3.5 (35) 5 50
The bricks shall have smooth rectangular faces with sharp corner and
shall be uniform in colour and emit clear ringing sound when struck.

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4.7 Stone
4.7.1. The stone shall be of the type specified such as granite, trap, limestone,
sand stone, quartzite, etc. and shall be obtained from the quarries,
approved by the Engineer-in-Charge. Stone shall be hard, sound, durable
and free from weathering decay and defects like cavities, cracks, flaws,
sand holes, injurious veins, patches of loose or soft materials and other
similar defects that may adversely affect its strength and appearance. As
far as possible stones shall be of uniform colour, quality or texture.
Generally stone shall not contain crypst crystalline silica or chart, mica
and other deleterious materials like iron-oxide organic impurities etc.
4.7.2. Stones with round surface shall not be used.
4.7.3. The compressive strength of common types of stones shall be as per
following Table and the percentage of water absorption shall generally
not exceed 5% for stones other than specified in following Table For
laterite this percentage is 12%.
Type of stone Maximum Water Minimum
Absorption Compressive
Percentage by weight Strength kg./sq.cm

Granite 0.5 1000

Basalt 0.5 400
Lime stone(Slab & Tiles) 0.15 200
Sand stone (Slab & Tiles) 2.5 300
Marble 0.40 500
Quartzite 0.40 800
Laterite (Block) 12 35
.
Note 1: Test for compressive strength shall be carried out as laid down in
IS 1121 (Part I).
Note 2: Test for water absorption shall be carried out as laid down in IS
1124.
4.7.4. Size of Stones
a) Normally stones used should be small enough to be lifted and placed
by hand. Unless otherwise indicated, the length of stones for stone
masonry shall not exceed three times the height and the breadth on
base shall not be greater than three-fourth of the thickness of wall, or
not less than 150 mm. The height of stone for rubble masonry may be
upto 300 mm.
b) The selection and grading of stones for rubble masonry is largely done
at site and the smaller stones are used in the hearting of wall.
c) Random Rubble Masonry shall be uncoursed or brought to courses as
specified. Uncoursed random rubble masonry shall be constructed
with stones of sizes as referred above. and shapes picked up random

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from the stones brought from the approved quarry. Stones having
sharp corners or round surfaces shall, however, not be used.
d) Random rubble masonry brought to the course is similar to
uncoursed random rubble masonry except that the courses are
roughly levelled at intervals varying from 300 mm to 900 mm in
height according to the size of stones used.
4.7.5. Dressing: Each stone shall be hammer dressed on the face, the sides and
the beds. Hammer dressing shall enable the stones to be laid close to
neighbouring stones such that the bushing in the face shall not project
more than 40 mm on the exposed face.
4.8 Mortar
4.8.1 Mortar shall be prepared by mixing graded fine aggregate with cement
and approved non shrinking compound (as specified by engineer in
charge and as per instructions laid down by manufacturer) in the
proportion specified for respective items of work as detailed in the BOQ.
4.8.2 Mixing of mortar shall be done by mechanical mixers only. Hand mixing
may be permitted in specific cases with the written permission of the
Engineer.
4.8.3 Mortars shall be specified by proportion. Volumetric mixing shall be
based on dry volumes of each ingredient. For convenience, measurement
boxes shall correspond to volume of one cement bag i.e. 0.035 cum.
Boxes shall be of size 33.33 x 30 x 35 cm (L x B x D). These shall be marked
as mortar mixing boxes. Hand mixing or mechanical mixing shall be done
with the use of these boxes.
4.8.4 Cement mortar shall be prepared by mixing cement and sand in specified
proportions. Proportioning shall be carried out as detailed above. Sand
shall be suitably added to allow for bulking, if required. Bulking shall be
determined as laid down in IS 2386 Part III. Cement and sand added to
mixer shall be thoroughly mixed and water shall be added to it gradually.
After addition of water the mixer shall run for a minimum of 2 minutes.
The mortar so mixed, shall be consumed within 4 hours.
4.9 Damp Proof Course
4.9.1. It shall consist of a layer of concrete 40 mm thick in the ratio of 1:2:4
(1cement: 2 sand: 4 stone aggregate of 10 mm nominal size). The
concrete layer shall be provided with a water proofing treatment which
may either be a surface treatment or integral waterproofing compounds.
For surface treatment of concrete, hot bitumen at the rate of 1.7 kg/100
sqm may be used.
4.9.2. Alternatively Slate and Cuddappah stone slabs can also be used which
shall be of minimum 40 Mm thickness with exposed edges finely dressed,
true and square. These slabs be embedded in Cement mortar 1:3 with
non-shrinking compound additive as per manufacturers
recommendations.

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4.10 Admixture
4.10.1. Additives or admixtures may be added to the cement or concrete mix
conforming to the Indian Standard specifications IS 9103.
4.10.2. Admixtures shall be permitted to be used to modify the properties of
concrete for single, or a combination of purposes. This shall be used for
specific purpose and the type and dosage of admixture shall be as per the
approved mix design of concrete.
4.10.3. Admixtures shall be free from chlorides and sulphates or any other
material which may cause problems to the concrete in the due course of
time.
4.10.4. Admixtures are manufactured and sold by various companies under
brand names. The contractor proposing to use any one of them shall
submit to the Engineer the technical literature with its chemical
composition, purpose of use and method recommended by the
manufacturer.
4.10.5. The contractor’s proposal shall accompany the following with his request
to use admixture.
a) The trade name of the admixture, its source and the
manufacturer’s recommended method of use.
b) Typical dosage rates and the possible detrimental effects of under
and over-dosage. Whether the admixture contains chloride in any
free form or any other chemical present as an active ingredient
which is a likely cause of corrosion of reinforcement or
deterioration of concrete.
c) The average expected air content of freshly mixed concrete
containing an admixture which causes air to be entrained when
used at the manufacturer’s recommended rate of dosage.
4.11 Joint Fillers
04.11.1. Bituminous impregnated, pre-moulded joint filler board shall be of
approved quality, from approved manufacturer and shall conform to IS
1838 part I
4.12 Metal Reinforcement
04.12.1. Expanded metal used shall comply with IS 412
4.13 Bonding Agent
4.13.1. Bonding agent of approved make shall be used for application on RCC
surfaces having interface with block work.
4.14 Delivery & Storage of Material
4.14.1. Bricks: The Contractor to ensure the following:
a. Bricks shall be stacked in regular tiers as and when they are
unloaded to minimize breakage and defacement. These shall not
be dumped at site.

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b. Bricks stacks shall be placed close to the site of work so that least
effort is required to unload and transport the bricks again by
loading on pallets or in barrows. Building bricks shall be loaded or
unloaded a pair at a time unless palletized. Unloading of building
bricks or handling in any other way likely to damage the corners
or edges or other parts of bricks shall not be permitted.
c. Bricks shall be stacked on dry firm ground. For proper inspection
of quality and ease in counting the stacks shall be 50 bricks long,
10 bricks high and not more than 4 bricks in width, the bricks
being placed on edge, two at a time along the width of the stack.
Clear distance between adjacent stacks shall not be less than 0.8
m. Bricks of each truck load shall be put in one stack.
d. Bricks of different types, such as clay bricks, clay fly ash bricks, fly
ash lime bricks, sand lime (calcium silicate) bricks, auto-clave
bricks etc. shall be stacked separately. Bricks of different
classification and size consideration (such as, conventional and
modular) shall be stacked separately.
4.14.2. Concrete Blocks: The Contractor to ensure the following:
a. Blocks shall be unloaded one at a time and stacked in regular tiers
to minimize breakage and defacement. These shall not be
dumped at site. The height of the stack shall not be more than 1.2
m. The length of the stack shall not be more than 3.0 m, as far as
possible and the width shall be of two or three blocks.
b. Load, unload deliver, store all concrete blocks with due care, at
site so as to be free from damage, dirt, intrusion of foreign
materials etc. Normally blocks cured for 28 days only should be
received at site. In case blocks cured for less than 28 days are
received, these shall be stacked separately. All blocks should be
water cured for 10 to 14 days and air cured for another 15 days;
thus no blocks with less than 28 days curing shall be used in
building construction.
c. Blocks shall be placed close to the site of work so that least effort
is required for their transportation. The date of manufacture of
the blocks shall be suitably marked on the stacks of blocks
manufactured at factory or site.
d. All blocks shall be handled carefully from manufacture to laying
and properly stacked in position convenient for the work. They
shall be kept free from standing water and protected from rain,
mud and contamination by other materials.
e. Protect blocks from any extreme weather conditions.

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5. Submittals
The contractor shall maintain a comprehensive record of the block works as per
the approved ITP. All records shall be in hard copy, signed by the Quality
manager, unless electronic records are permitted by the Engineer.
5.1 Concrete Block Masonry /Brick Masonry
5.1.1. The following documents shall be submitted to the Engineer for approval
and record:
a. Manufacturer’s Test Certificates for concrete blocks /bricks
brought to site.
b. Records of tests performed on blocks/bricks.
c. Detailed methodology for carrying out repairs for any defect
d. Record for correction / repairs carried out
5.1.2. Prepare sample panels of approximately 1 m2 of faced blockwork
/brickwork including pointing, and obtain approval before proceeding
5.1.3. If required by the Engineer, contractor shall maintain and submit
photographs indicating compliance to various requirements of this
specification and ITP.
5.2 Stone Masonry: A sample wall, 10 m2. In area shall be built and approved by the
Engineer and all works shall match with this sample.

6. Workmanship
6.1 Concrete Block Masonry
6.1.1. Concrete blocks may not be wetted like brick masonry prior to use. In
total dry climate top & sides of block shall be moistened to avoid
absorption of water from mortar.
6.1.2. The window sill levels shall be properly ascertained by the Contractor
prior to commencement of blockwork. All surfaces on which blockwork is
to be built shall be cleaned of any foreign matter influencing the bond
between the surface and blockwork. The use of chipped or defaced
blocks will not be permitted in any facework. Concrete blockwork shall be
laid in English bond.(Fig. 1 as annexed). Height of block work constructed
in one day shall be restricted to 1.2 meter.
6.1.3. Cut blocks shall not be used. Special solid precast blocks at site shall be
cast well in advance to be used as spacers and to adjust breaking of
vertical joints. Blocks can be cut horizontally or vertically for use as
spacers and to adjust breaking of vertical joints at approval of Owner or
Owner’s representative.
6.1.4. All cross (vertical) joints shall be filled by well buttering the ends of the
block with mortar and then sliding it against its neighbour.
6.1.5. Cracks in block masonry are due to shrinkage or expansion of blocks
or due to load settlement, thermal expansion or changes in moisture
content in the structural members enclosing the block walls. The

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following measures are recommended to prevent formation of cracks. All

blocks shall be cleaned before placing and shall be moistened with water
for at least 3 hours before using by a method which will ensure that each
block is thoroughly and uniformly wetted. Expansion joints shall be
provided in walls exceeding 30 m in length. Reinforcement should be
provided in the bed joints in block work, one course above and one
course below windows and above doors in order to distribute the
shrinkage/ temperature stresses occurring at the corners of openings,
more uniformly throughout the walls.
6.1.6. In framed structures, erection of partition and panel walls should be
delayed to the extent feasible to take care of deformations due to
structural loads. Partition walls should be suitably reinforced in lower
courses to strengthen against excessive deflections of floor slabs and
should be separated from the ceiling by a layer of resilient material. Joint
shall be provided in the plaster or any other finish.
6.1.7. Where required, damp proof course layer shall be laid as specified
Exposed faces and corners of masonry damaged during construction shall
be removed and repaired in a manner acceptable to Engineer.
6.1.8. Blockwork of single block thickness shall be laid in stretcher bond, and
blockwork of double block thickness in alternate courses of headers and
stretchers. No broken blocks will be accepted except where necessary for
bonding. Alternate courses of load bearing block walling at intersection
shall be carried through the full thickness the adjoining wall. Course
heights shall not vary throughout the building and each course shall be
level and set out so that bed joints occur in line with sills, lintels and
other features. Hollow blocks shall be filled with specified grade concrete
indicated on the Drawings
6.1.9. At junctions of walls with concrete structure cast in, cut and pin or shot
fire ties to concrete at 320 mm centres vertically to project 250 mm into
blockwalls or as per indicated in the drawings. For blockwork built against
the face of concrete structure, cast in or out and pin ties to concrete at
900 mm centres horizontally, 320 mm centres vertically and staggered, to
project 75 mm into block walls or as per indicated in drawings. Pin up and
wedge blockwork to structural soffits, and fill solid with mortar.
6.1.10. Scaffolding:
Scaffolding independent of block work i.e. double legged scaffolding shall
be provided. It should be tied to block work or structure at suitable
intervals in both directions. Two rows of planks shall be provided all
around. Planks shall be at least 50 mm thick and well-tied to scaffolding.
Railing on the outside face shall be provided. While erecting scaffolding,
the following points must be noted and closely followed:
a. Minimum number of openings shall be provided in the horizontal
direction.

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b. Scaffolding must be sound and strong and easy to maintain and

erect.
c. Openings left in the block work must be closed before finishing
the plaster.
6.1.11. In case all the block work is not raised together, raking back shall be
carried out at an angle not steeper than 45 degrees. No blockwork shall
be carried up higher than 1.5m in one day. Joints in walling to be
plastered or rendered shall be raked out 10mm deep to form a key.
6.1.12. Two nos. of 8 mm diameter reinforcement steel shall be provided in
every 3rd layer as horizontal reinforcement. Vertical stiffener shall be
provided in form of either 2 nos. 12 mm diameter steel placed at every
4m OR 1 no. of 10 mm diameter steel at every 1.5 m & by grouting the
void in masonry block using cement sand mortar (1:1:2).
6.1.13. For installation of electrical (or any other service) conduit in the block
work, one side of the block work may be cut. The conduits shall be
installed in the hollow part of the block. Chasing of the front face of the
block shall not be permitted.
6.1.14. The date of construction of block work shall be written on wall by paint.
6.1.15. Workmen Skills: The following tasks with regard to concrete works
require specific skills and the contractor shall arrange skilled and trained
workmen for carrying out these tasks:
6.1.16. Mortar batching and mixing
6.1.17. Transportation using hoists
6.1.18. Blocks Laying
6.1.19. Blockwork finishing including pointing
6.1.20. The workmen deployed on the tasks specified above shall be provided
periodical training and the names of trained and certified workmen shall
be furnished to the Engineer for approval.
6.1.21. At all times during blockwork operation, the workmen carrying out these
tasks shall be rehabilitee identifiable through their ID card or badges.
6.1.22. If the Engineer is of the opinion that any workmen engaged for a task
specified above is not competent to carry out the same, he shall have the
authority to order withdrawal of such workmen from the blockwork
operations.
6.1.23. Detailed information and guidelines, preferably in graphic format, dealing
with the correct method of carrying out the tasks shall be available and
prominently displayed at the work place.
6.1.24. Finishing of Joints: Strike off joints not visible in the finished work as the
work proceeds. Fill joints in fair faced work as the work proceeds to
provide a smooth surface flush with the block face.
6.2 Brick Masonry
6.2.1. Bricks shall be soaked in water before use for a period for the water to
just penetrate the whole depth of the bricks. Alternatively bricks may be
adequately soaked in stacks by profusely spraying with clean water at

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regular intervals for a period not less than six hours. The bricks required
for masonry work using mud mortar shall not be soaked. When the bricks
are soaked they shall be removed from the tank sufficiently early so that
at the time of laying they are skin-dry. Such soaked bricks shall be stacked
on a clean place where they are not again spoiled by dirt earth etc.
6.2.2. The window sill levels shall be properly ascertained by the Contractor
prior to commencement of brickwork. All surfaces on which brickwork is
to be built shall be cleaned of any foreign matter influencing the bond
between the surface and brickwork. The use of chipped or defaced blocks
will not be permitted in any facework. Brickwork shall be laid in English
bond.(Fig. 1 as annexed). For brick work in half brick wall, bricks shall be
laid in stretcher bond. No part of the wall during its construction shall rise
more than 1.0 metre above the general construction level. Parts of wall
left at different levels shall be raked back at an angle of 45 degrees or less
with the horizontal. Toothing shall not be permitted as an alternative to
raking back. For half brick partition to be keyed into main walls, indents
shall be left in the main walls. Mortar joints shall be kept uniformly 10
mm thick.. Joints shall be raked 10 mm deep while mortar is green.
6.2.3. Broken bricks shall not be used. Cut bricks shall be used if necessary to
complete bond or as closers.
6.2.4. Bricks shall be laid with frogs upwards over full mortar beds. Bricks shall
be pressed into mortar and tapped into final position so as to embed fully
in mortar. Inside faces shall be buttered with mortar before the next
bricks is placed and pressed against it. Thus all joints between bricks shall
be fully filled with mortar. Brickworks two bricks thick or more shall have
both faces in true plane. Brickwork of lesser thickness shall have one
selected face in true plane.
6.2.5. Half or cut bricks shall not be used except as closer where necessary to
complete the bond. Closers in such cases, shall be cut to the required size
and used near the ends of the wall. Header bond shall be used preferably
in all courses in curved plan for ensuring better alignment.
6.2.6. Where required, damp proof course layer shall be laid as specified
Exposed faces and corners of masonry damaged during construction shall
be removed and repaired in a manner acceptable to Engineer.
6.2.7. All pipe fittings and specials, spouts, hold fasts and other fixtures which
are required to be built into the walls shall be embedded, as specified, in
their correct position as the work proceeds unless otherwise directed by
the Engineer-in-Charge.
6.2.8. Top courses of all plinths, parapets, steps and top of walls below floor
and roof slabs shall be laid with brick on edge, unless specified otherwise.
Brick on edge laid in the top courses at corner of walls shall be properly
radiated and keyed into position to form cut corners as shown in Fig 6.4.
Where bricks cannot be cut to the required shape to form cut corners,
cement concrete 1:2:4 (1 cement :2 coarse sand : 4 graded stone

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aggregate 20 mm nominal size) equal to thickness of course shall be

provided in lieu of cut bricks. In case of walls one brick thick and under,
one face shall be kept even and in proper plane, while the other face may
be slightly rough. In case of walls more than one brick thick, both the
faces shall be kept even and in proper plane. To facilitate taking service
lines later without excessive cutting of completed work, sleeves shall be
provided, where specified, while raising the brick work. Such sleeves in
external walls shall be sloped down outward so as to avoid passage of
water inside.
6.2.9. Top of the brickwork in coping and sills in external walls shall be slightly
tilted. Where brick coping and sills are projecting beyond the face of the
wall, drip course/throating shall be provided where indicated. New built
work shall be covered with gunny bags or tarpaulin so as to prevent the
mortar from being washed away. Damage, if any, shall be made good to
the satisfaction of the Engineer-in-Charge
6.2.10. Vertical reinforcement in the form of bars (MS or high strength deformed
bars or thermo mechanically treated bars as per direction of Engineer-in-
Charge)), considered necessary at the corners and junction of walls and
jamb opening doors, windows etc. shall be encased with cement mortar
not leaner than 1:4 (1 cement : 4 coarse sand), or cement concrete mix as
specified. The reinforcement shall be suitably tied, properly embedded in
the foundation and at roof level. The dia. of bars shall not be less than 8
mm and concrete grade shall be minimum 1:3:6 (1 cement: 3 coarse sand
: 6 graded stone aggregate 20 mm nominal size).
6.2.11. In retaining walls and the like, where water is likely to accumulate, weep
holes, 50 to 75 mm square shall be provided at 2 m vertically and
horizontally unless otherwise specified. The lowest weep hole shall be at
about 30 cm above the ground level. All weep holes shall be surrounded
by loose stones and shall have sufficient fall to drain out the water
quickly.
6.2.12. Work of cutting chases, wherever required to be made in the walls for
housing G.I. pipe, CI pipe or any other fixtures shall be carried out in
various locations as per guidelines given below :
a. Cutting of chases in one brick thick and above load bearing walls.
 As far as possible services should be planned with the help of
vertical chases. Horizontal chases should be avoided
 The depths of vertical chases and horizontal chases shall not
exceed one-third and one-sixth of the thickness of the masonry
respectively.
 When narrow stretches of masonry (or short length of walls) such
as between doors and windows, cannot be avoided they should
not be pierced with openings for soil pipes or waste pipes or
timber joints, etc. Where there is a possibility of load
concentration such narrow lengths of walls shall be checked for

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stresses and high strength bricks in mortar or concrete walls

provided, if required.
 Horizontal chases when unavoidable should be located in the
upper or lower one-third of height of storey and not more than
three chases should be permitted in any stretch of a wall. No
continuous horizontal chase shall exceed one metre in length.
Where unavoidable, stresses in the affected area should be
checked and kept within the permissible limits.
 Vertical chases should not be closer than 2 m in any stretch of a
wall. These shall be kept away from bearings of beams and lintels.
If unavoidable, stresses in the affected area should be checked
and kept within permissible limits.
 Masonry directly above a recess, if wider than 30 cm horizontal
dimension) should be supported on lintel. Holes in masonry may
be provided upto 30 cm width and 30 cm height without any
lintel. In the case of circular holes in the masonry, no lintel need
be provided for holes upto 40 cm in diameter.
b. Cutting of chases in half brick load bearing walls:
 No chase shall be permitted in half brick load bearing walls and as
such no recessed conduits and concealed pipes shall be provided
with half brick thick load bearing walls.
c. Cutting of chases in half brick non-load bearing wall :
 Services should be planned with the help of vertical chases.
Horizontal chase should be provided only when unavoidable
6.2.13. Finishing of Joints: The face of brick work may be finished flush or by
pointing. In flush finishing either the face joints of the mortar shall be
worked out while still green to give a finished surface flush with the face
of the brick work or the joints shall be squarely raked out to a depth of 1
cm while the mortar is still green for subsequently plastering. The faces
of brick work shall be cleaned with wire brush so as to remove any
splashes of mortar during the course of raising the brick work. In
pointing, the joints shall be squarely raked out to a depth of 1.5 cm while
the mortar is still green and raked joints shall be brushed to remove dust
and loose particles and well wetted, and shall be later refilled with
mortar to give ruled finish. Some such finishes are ‘flush’, ‘weathered’,
ruled, etc. The thickness of all types of joints including brick wall joints
and cross joints shall be such that four course and three joints taken
consecutively shall measure as follows:
 In case of modular bricks conforming to IS 1077 specification for
common burnt clay buildings bricks, equal to 39 cm.
 In case of non-modular bricks, it shall be equal to 31 cm
6.2.14. Curing: The brick work shall be constantly kept moist on all faces for a
minimum period of seven days. Brick work done during the day shall be

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suitably marked indicating the date on which the work is done so as to

keep a watch on the curing period
6.2.15. Scaffolding: Please refer scaffolding of Blockwork specified above.
6.2 Random Rubble Stone Masonry
6.2.1. For all works below ground level the masonry shall be random rubble
uncoursed with ordinary quarry dressed stones for the hearting and
selected quarry dressed stones for the facing.
6.2.2. For all works above ground level and in superstructure the masonry shall
be random rubble uncoursed, well bonded, faced with hammer dressed
stones with squared quoins at corners. The bushings on the face shall
not be more than 40 mm on an exposed face and on the face to be
plastered it shall not project by more than 12 mm nor shall it have
depressions more than 10 mm from the average wall surface.
6.2.3. Face stones shall extend back sufficiently and bond well with the
masonry. The depth of stone from the face of the wall inwards shall not
be less than the height or breadth at the face. Face stones or hearting
stones shall not be less than 150 mm in any direction.
6.2.4. Chips and spalls shall be used wherever necessary to avoid thick mortar
joints and to ensure that no hollow spaces are left in the masonry. The
use of chips and spalls in the hearting shall not exceed 20 percent of the
quantity of stone masonry. Spalls & chips shall not be used on the face of
the wall and below hearting stones to bring them to the level of face
stones.
6.2.5. The maximum thickness of joints shall not exceed 20 mm. All joints shall
be completely filled with mortar. When plastering or pointing is not
required to be done, the joints shall be struck flush and finished as the
work proceeds. Otherwise, the joints shall be raked to a minimum depth
of 20 mm by a raking tool during the progress of the work while the
mortar is still green.
6.2.6. Through or bond stones shall be provided in walls up to 600 mm thick
and in case of walls above 600 mm thickness, a set of two or more bond
stones overlapping each other by at least 150 mm shall be provided in a
line from face to back. In case of highly absorbent types of stones
(porous lime stone and sand stone, etc.) the bond stone shall extend
about two-thirds into the wall and a set of two or more bond stones
overlapping each other by at least 150 mm shall he provided. Each bond
stone or a set of bond stones shall be provided for every 0.5 sqm of wall
surface.
6.2.7. All stones shall be sufficiently wet before laying to prevent absorption of
water from the mortar. All connected walls in a structure shall be
normally raised uniformly and regularly. However if any part of the
masonry is required to be left behind, the wall shall be raked back (and
not saw toothed) at an angle not exceeding 45. Masonry work shall not
be raised by more than one metre per day.

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6.2.8. Stones shall be laid with its grains horizontal so that the load transmitted
is always perpendicular to the natural bed.
6.2.9. Green work shall be protected from rain by suitable covering. Masonry
work shall be kept constantly moist on all the faces for a minimum period
of seven days for proper curing of the joints.
6.2.10. Scaffolding
a. Single scaffolding having one set of vertical support shall be used and
the other end of the horizontal scaffolding member shall rest in a hole
provided in the masonry. The support shall be sound and strongly tied
together with horizontal pieces over which the scaffolding planks shall
be fixed.
b. The holes which provide resting space for horizontal members shall
not be left in pillars less than one metre in width. The holes left in the
masonry work for supporting the scaffolding shall be filled and made
good with concrete of M-15 before plastering /pointing.
c. The scaffolding shall be strong enough to withstand all loads likely to
come upon it and shall meet the requirements specified in IS 2750:
1964.
d. For pillars less than one metre in width or for first class masonry or for
building having more than two storeys, double scaffolding having
two sets of vertical support shall be provided.
6.3 Coursed Rubble Stone Masonry (First Sort)
6.3.1. All stones shall be wetted before use. All courses shall be laid truly horizontal
and shall be of the same height in any course. The height of course shall
not be less than 150 mm and not more than 300 mm. The width of stone
shall not be less than its height.
6.3.2. Face stones shall tail into the work for not less than their height and at
least 1/3rd the number of stones, shall tail into the work for a length not
less than twice their- height but not more than three-fourths the
thickness of the wall whichever is smaller. These should be laid as
headers and stretchers alternately to break joints by at least 75 mm.
6.3.3. The face stones shall be squared on all joints and beds; the bed joints
being hammer or chisel dressed true and square for at least 80 mm back
from the face and the side joints for at least 40 mm. The face of the
stone shall be hammer dressed so that the bushing shall not be more
than 40 mm on an exposed face and 10 mm on a face to be plastered. No
portion of the dressed surface shall show a depth of gap more than 6 mm
from a straight edge placed on it. The remaining unexposed portion of
the stone shall not project beyond the surface of bed and side joints.
6.3.4. No spalls or pinning shall be allowed on the face. All bed joints shall be
horizontal and side joints shall be vertical and no joints shall be more
than 10 mm in thickness. When plastering or pointing is not required to
be done, the joints shall be struck flush and finished as the work
proceeds. Otherwise, the joints shall be raked to a minimum depth of 20

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mm by a raking tool, during the progress of the work while the mortar is
still green.
6.3.5. Hearting shall consist of flat bedded stones carefully laid on their proper
beds and solidly bedded in mortar. The use of chips shall be restricted to
the filling of interstices between the adjacent stones, in hearting and
these shall not exceed 10 percent of the quantity of the stone masonry.
Care shall be taken so that no hollow spaces are left anywhere in the
masonry.
6.3.6. The through or bond stones shall be provided at 1.5 m to 1.8 m apart
clear in every course but staggered at alternate courses.
6.3.7. The quoins which shall be of the same height as the course, in which they
occur, shall not be less than 450 mm in any direction. Quoin stones shall
be laid as stretchers and headers alternately. They shall be laid square on
their beds, which shall he rough chisel dressed to a depth of at least 100
mm from the face. These stones shall have a minimum uniform chisel
draft of 25mm width at four edges, all the edges being in the same plane.
6.4 Coursed Rubble Stone Masonry (Second Sort)
6.4.1. Shall be same as of Coursed Rubble Masonry(first Sort) explained above
except that the use of chips shall not exceed 15% of the quantity of stone
masonry and stone, in each course need not be of the same height but
not more than two stones shall be used in the height of a course.

7. Quality Management
The contractor shall put in place a comprehensive Quality management plan to
ensure that the work is carried out as per specifications and compliance to all
requirements are established and demonstrated through comprehensive
documentation. The contractor shall engage a qualified Quality Manager to
implement the quality plan.
7.1. Unless annexed to these specifications the contractor shall submit an
inspection and test plan [ITP] for the approval of the Engineer. The ITP
shall cover tests on incoming materials, supervision of the process and
test on the completed work.
7.2. The ITP shall lay down the characteristics to be tested/inspected,
frequency of tests, acceptance criteria and the manner of documenting
the results. Any test, compliance to which is mandatory for further
progress of the next stage of work shall be identified as a ‘Hold point’.
7.3. In the absence of an approved ITP, provisions of IS: 2185 and any other
Indian Standard referred there in shall apply with regard to acceptance
criteria and tolerances.
As general guidelines, Care shall be taken to keep the perpends properly
aligned within following maximum permissible tolerances for brick work:
a. Deviation from vertical within a storey shall not exceed 6 mm per 3 m
height.

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b. Deviation in verticality in total height of any wall of building more

than one storey in height shall not exceed 12.5 mm.
c. Deviation from position shown on plan of any brick work shall not
exceed 12.5 mm.
d. Relative displacement between load bearing wall in adjacent storeys
intended to be vertical alignments shall not exceed 6 mm.
e. A set of tools comprising of wooden straight edge, masonic spirit
levels, square, 1 metre rule line and plumb shall be kept on the site of
work for every 3 masons for proper check during the progress of
work.

Block work Tolerances (mm)

Position on plan 15
Length 15
Height 10
Level of bed joints (in any 5 m) 10
Straightness (in any 5 m) 15
Verticality (in any 3 m) 15
7.4. In case of any dispute about the interpretation of the test results or
inspection of the block work, the decision of Engineer shall be final.

8. Safety Considerations and Requirements

Apart from general safety and health hazards like working at heights, falling objects etc.,
the contractor shall assess the hazards associated with block works and shall take
specific action to mitigate against the same.
8.1. As a general guide, the following safety hazards are identified as associated with
concrete construction
8.1.1. Falling hazards from heights
8.1.2. Scaffolding arrangement.
8.2. All workmen shall be made aware of the specific hazards that they face while
working with Masonry Works and shall be provided with specific personal
protective equipment to protect them.

9. Environmental Considerations and Requirements

Apart from general environmental impact of construction activities, the contractor shall
assess the environmental impact associated with Masonry works and shall take specific
action to mitigate against the same.
9.1. As a general guide, the following safety hazards are identified as associated with
masonry works
9.2. Particulate pollution due to dust in the aggregates, cement, fly ash.

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10. Completion and Delivery

Work related to Masonry construction shall not be deemed as complete till such time all
the following conditions are fulfilled:
All Masonry in various parts of the structure is shown to have complied with the
drawings and specifications.
There are no defects in the Masonry or all defects are repaired to the satisfaction of the
Engineer.
All quality tests and inspection records are furnished to the Engineer.

11. Method of Measurement & Rate

11.1. Method of measurements
11.1.1. Concrete Block Masonry: Hollow or solid cement concrete block work
shall be measured in square meters for every thickness of masonry
mentioned in BOQ. Any work done extra over the specified dimensions
shall not be measured for payment.
11.1.2. Brick Masonry:
a. Brick work shall be measured in cubic metres unless otherwise
specified. Any extra work over the specified dimensions shall be
ignored. Dimensions shall be measured correct to the nearest 0.01
m i.e. 1 cm. Areas shall be calculated to the nearest 0.01 sq mtrs
and the cubic contents shall be worked out to the nearest 0.01
cubic metres.
b. No deductions or additions shall be done and no extra payment
made for the following:
 Ends of dissimilar materials (that is, joists, beams, lintels,
posts, girders, rafters, purlins, trusses, corbels, steps, etc.); up
to 0.1 m2 in section;
 Opening up to 0.1 m2 in area (In calculating area of an
opening, any separate lintel or sills shall be included with the
size of the opening but end portions of lintel shall be
excluded. Extra width of rebated reveals, if any, shall also be
excluded);
 Wall plates, bed plates, and bearing of slabs, chajjas and the
like, where thickness does not exceed 10 cm and bearing does
not extend over the full thickness of wall;
 Cement concrete blocks as for hold fasts and holding down
bolts;
 Iron fixtures, such as wall ties, pipes up to 300 mm diameter
and hold fasts for doors and windows; and
 Chases of section not exceeding 50 cm in girth.
 Bearing portion of drip course, bearing of moulding and
cornice.

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c. Exposed brickwork using selected ordinary brick or face bricks for

the exposed face shall be measured in area as an extra over the
ordinary brickwork if so provided in the Schedule of Items. It shall
be measured by volume including the composite backing if so
provided in the Schedule.
d. Walls half brick thick and less shall each be measured separately in
square meters stating thickness.
e. String courses, projecting pilasters, aprons, sills and other
projections shall be fully described and measured separately in
running metres stating dimensions of each projection.
f. Square or rectangular pillars shall be measured separately in cubic
metres in multiple of half brick.
g. Circular pillars shall be measured separately in cubic metres as per
actual dimensions
h. Brick work curved on plan shall be measured like the brick work in
straight walls and shall include all cutting and wastage of bricks,
tapered vertical joints and use of extra mortar, if any. Brick work
curved on plan to a mean radius not exceeding six metres shall be
measured separately and extra shall be payable over the rates for
brick work in straight walls. Nothing extra shall be payable if the
mean radius of the brick work curved in plan exceeds six
metres.Tapered walls shall be measured net as walls and extra
payment shall be allowed for making tapered surface for brick
work in walls.
i. Brick work with brick tiles shall be measured and paid for
separately.
11.1.3. Stone Masonry:
a. Measurement shall be in cum correct to two places of decimal.
The quantities measured and paid for, shall be those as actually
executed after making necessary deductions for openings, lintels
etc.
b. No deductions or additions shall be done and no extra payment
made for the following:
 Ends of dissimilar materials (that is, joists, beams, lintels,
posts, girders, rafters, purlins, trusses, corbels, steps, etc.); up
to 0.1 m2 in section;
 Opening up to 0.1 m2 in area (In calculating area of an
opening, any separate lintel or sills shall be included with the
size of the opening but end portions of lintel shall be
excluded. Extra width of rebated reveals, if any, shall also be
excluded);
 Wall plates, bed plates, and bearing of slabs, chajjas and the
like, where thickness does not exceed 10 cm and bearing does
not extend over the full thickness of wall;

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 The bearing of floor and roof shall be deducted from wall

masonry.
 Drain holes and recesses for cement concrete blocks to embed
hold fasts for doors, windows etc.
 Building in masonry, iron fixture, pipes upto 300 mm dia, hold
fasts of doors and windows etc.
 Forming chases in masonry each upto section of 350 sq cm.
a. Masonry (excluding fixing brick work) in chimney breasts with
smoke of air flues not exceeding 20 sq dm (0.20 sq m) in sectional
area shall be measured as solid and no extra payment shall be
made for pargetting and coring such flues. Where flues exceed 20
sq dm (0.20 sq m) sectional area, deduction shall be made for the
same and pargetting and coring flues shall be measured in running
metres stating size of flues and paid for separately. Aperture for
fire place shall not be deducted and no extra payment made for
splaying of jambs and throating.
b. Apertures for fire places shall not be deducted and extra labour
shall not be measured for splaying of jambs, throating and making
arch to support the opening.
c. Square or Rectangular Pillars: These shall be measured as walls,
but extra payment shall be allowed for stone work in square or
rectangular pillars over the rate for stone work in walls.
Rectangular pillar shall mean a detached masonry support
rectangular in section, such that its breadth does not exceed two
and a half times the thickness.
d. Circular Pillars (Columns): These shall be measured as per actual
dimensions, but extra payment shall be allowed for stone work in
circular pillars over the rate for stone work in walls. The diameter
as well as length shall be measured correct to a cm.
e. Tapered walls shall be measured net, as per actual dimensions and
paid for as other walls.
f. Curved Masonry: Stone masonry curved on plan to a mean radius
exceeding 6 meters shall be measured and included with general
stone work. Stone work circular on plan to a mean radius not
exceeding 6 meters shall be measured separately and shall include
all cuttings and waste and templates. It shall be measured as the
mean length of the wall.
11.2. RATES
Providing safe working conditions at all work fronts at all times shall be the
responsibility of the Contractor. Adequate Personal Protective Equipment (PPE)
shall be provided to all workers & Visitors to the Site. The quoted rates shall be
deemed to include for all safety related expenses as required for the nature of
the work being executed unless otherwise covered specifically as a payable item
in the BOQ pertaining to safety items.
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Rates for items shall include followings –

11.2.1. Material and labour, for the completion of items as specified including
any centering, shuttering, curing etc. at all heights and levels
11.2.2. Raking out joints.
11.2.3. Preparing the tops and sides of masonry done earlier.
11.2.4. Forming and preparing expansion, contraction or construction joints as
detailed above or specified in the BOQ or drawings.
11.2.5. Providing weep holes, openings, etc. for outlets, embedding down take
pipes, etc. wherever necessary during construction, and finishing
exposed surfaces as per instruction of the Engineer.
11.2.6. Bond stones or cement concrete bond blocks
11.2.7. Rough cutting and waste for forming gables cores, skew backs or
spandrels of arches, splays at eaves and all rough cutting in the body of
walling unless otherwise specified.
11.2.8. Curing and protection as specified.

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12. Annexures

Figure 1 English Bond

Figure 2 : Random Rubble Masonry

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Figure 3 : Rubble Masonry - Coursed

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Table of Contents

Contents
1. SCOPE ...................................................................................................................................................... 2
2. LIST OF STANDARDS ................................................................................................................................. 2
3. TERMINOLOGY......................................................................................................................................... 3
4. MATERIALS .............................................................................................................................................. 3
5. SUBMITTALS AND CERTIFICATIONS ......................................................................................................... 4
6. WORKMANSHIP ....................................................................................................................................... 4
7. QUALITY MANAGEMENT ......................................................................................................................... 7
8. SAFETY CONSIDERATIONS AND REQUIREMENTS ..................................................................................... 8
9. ENVIRONMENTAL CONSIDERATIONS AND REQUIREMENTS.................................................................... 8
10. COMPLETION AND DELIVERY ............................................................................................................... 9
11. METHOD OF MEASUREMENT .................................................................................................................... 9
12. ANNEXURES ....................................................................................................................................... 10

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1. SCOPE
1.1 The Scope of Work covered under this specification will consist of following:
Plastering work to correct line, level and plumb within acceptable tolerances, preparing surfaces,
applying plaster, providing reinforcement such as beads (where applicable), chicken mesh,
scaffolding and curing for the prescribed period. Work may be in single coat or multiple coats as
specified under relevant items of BOQ.
1.2 Finish shall be as specified and approved by Owner / Owner’s Authorized Representative
1.3 Finishing of grooves, jams, sills, bands, motifs, etc. shall be part of the work.
1.4 Work shall include providing required material and labour at all locations with requisite lead and lift.
 Internal single coat cement sand mortar plaster minimum 12 mm thick.
 Internal to ducts double coat cement sand mortar plaster minimum 18 mm thick with approved
waterproofing compound.
 External double coat cement sand plaster minimum 20 mm thick with approved waterproofing
compound

2. LIST OF STANDARDS
2.1 STANDARD
Indian standards for this section shall be as listed below. In case any discrepancies or ambiguities
are noticed it shall be brought to the notice of the Owner / Owner’s Authorized Representative and
clarification/confirmation sought. The decision of the Owner/ Owner’s Authorized Representative
shall be final. However as a general rule the more stringent specifications shall be followed.

1. IS 383 Specification for coarse and fine aggregates from natural

sources for concrete.
2. IS 412 Specifications for expanded metal steel sheets for general
purposes.
3. IS 1489 Specification for Portland pozzolana cement.
4. IS 1542 Specifications for sand for plaster
5. IS 1661 Code of practice for application of cement and cement-
lime plaster finishes.
6. IS 2402 Code of practice for external rendered finishes.
7. IS 2645 Specifications for integral cement water proofing
compound.
8. IS 8112 Specification for 43 grade ordinary Portland Cement.
9. IS2386 Methods of test for aggregates of concrete

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3. TERMINOLOGY
The following terms and abbreviations shall have the specific meanings as described hereunder. For
terms that are not described herein, the definitions as stated in the applicable Indian Standard
Specifications shall apply.
3.1 PH Value: pH is a measure of the acidity or basicity of an aqueous solution. Pure water is said to be
neutral, with a pH close to 7.0 at 25 degree Celsius.
3.2 Mortar: Mortar is a workable paste used to bind construction blocks together and fill the gaps
between them. The blocks may be stone, brick, cinder blocks, etc. Mortar becomes hard when it
sets, resulting in a rigid aggregate structure. Modern mortars are typically made from a mixture of
sand, a binder such as cement and water.
3.3 Chicken Wire/ Mesh: Chicken Wire/ Mesh is a mesh made out of thin, flexible galvanized steel wire.
The chicken mesh is used as a matrix to hold cement or plaster.

4. MATERIALS
4.1 CEMENT
Cement shall be Ordinary Portland Cement conforming to IS and shall be of grade 43 or Portland
Pozzolana Cement approved by the Owner/Owner’s authorized representative. The cement shall be
received in bags of 50 kg and each batch shall be accompanied with a test certificate from the
factory. It shall be tested before use to ascertain its strength, setting time, etc. In case cement has
been stored for over 2 months or for any reasons the stored cement shows signs of deterioration or
contamination, it shall be tested as per the direction of the Owner/Owner’s Authorized
Representative prior to use in the works
4.2 WATER
Water used for mixing and curing shall be clean, reasonably clear and free from objectionable
quantities of silt, oils, alkalis, acids, salts etc so as not to weaken mortar. The water shall conform
to IS 456.
Water tested shall be in accordance with IS 3025. The contents of deleterious materials in water
shall not exceed the maximum values as given in IS 456 Table 1 “Permissible Limits for Solids (in
water)”.
4.3 COLOURED CEMENT
Colored cement may be either ready-mixed material or may be obtained by mixing pigments and
cement at site. The pigments to be mixed with cement shall conform to Appendix “A” of IS 2114
code of practice for laying in-situ Terrazzo Floor Finish.
4.4 SAND
Sand shall conform to IS 1542 specification for sand for plaster. For white or coloured renderings,
only quartz or silica sand shall be used. For textured finishes produced by treatment of freshly
applied final or finishing coat with a tool, coarser particles used shall be screened through 2.36 mm
IS sieve. For torn texture a slightly larger portion of material coarser than 4.75 mm IS sieve shall be
used.
4.5 INTEGRAL WATERPROOFING COMPOUND

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Integral water proofing compound shall conform to IS 2645 (specification for integral water proofing
compound).
4.6 FIBROUS MATERIAL
Certain natural fibers, such as flax, sisal, manila, jute hemp, and coconut fibers may be used in the
mortar. They shall be clean, dry and free from oil and other impurities.
4.7 EXPANDED METAL
Expanded metal used as background for rendering shall comply with requirements of IS 412.
4.8 GI OR POLYPROPYLENE CHICKEN MESH
Chicken mesh of 26 gauge with opening of 25 x 25 mm hot dipped galvanized shall be provided over
junctions of any two dissimilar materials about 150 mm wide as directed by the Owner / Owner’s
Authorized Representative.
4.9 BEADS
Zinc coated steel for exterior work shall be used. Nominal sizes to be provided are 5 mm bead with
60 mm minimum expanded metal wings. Gauge and size shall be as recommended by the approved
manufacturer.
4.10 BONDING AGENT
Chemical bonding adhesive of approved chemical admixture manufacturers shall be used over
concrete surface as per recommendations of manufacturer.
4.11 BINDER
Fiberglass fibers free of dirt, oil, grease, deleterious material or other impurities about 12 to 50 mm
long of approved manufacturer in proportion as recommended by manufacturer shall be used to
achieve dense mix as per instruction of the Owner / Owner’s Authorized Representative.

5. SUBMITTALS AND CERTIFICATIONS

5.1 Within 15 days of award of work and in any case before commencement of major activities, the
contractor shall submit a safety plan to the Engineer/ Owner/ Owner’s Authorized Representative
for approval.
5.2 A format of the Quality Assurance Plan / Inspection and test plan which will be duly approved by the
Owner & will be strictly adhered to during the course of execution.
5.3 The Contractor shall submit product literature with samples for the approval of the Owner /Owner’s
Authorized Representative.
5.4 Samples of following products shall be submitted for approval. Samples shall be minimum 300 mm
long and 300 mm wide. Minimum 3 nos. of samples shall be submitted for each item.
1. GI corner beads (where applicable)
2. GI /polypropylene Chicken mesh
3. GI metal reinforcement

6. WORKMANSHIP
7.1 MORTAR

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7.1.1 Mortar shall be prepared by mixing fine graded aggregate with cement in the proportion
specified for respective items of work as detailed in the BOQ. Mixing of mortars shall be done
by mechanical mixers only. Hand mixing may be resorted to in specific cases only after obtaining
the written permission of the Owner / Owner’s Authorized Representative.
7.1.2 Mortar shall be specified by proportion only and not by strength. Volumetric mixing shall be
based on dry volumes of each ingredient. For convenience, measurement boxes shall
correspond to volume of one cement bag i.e. 0.035 cum. Boxes shall be of size 33.33 x 30 x 35
cm (L x B x D). These shall be marked as mortar mixing boxes by red paint. Hand or mechanical
mixing shall be done with the use of these boxes.
7.1.3 Sand shall be added to adjust for bulkage if required. Bulkage shall be determined as specified in
IS 2386 Part III. Cement and sand added to mixer shall be thoroughly mixed and thereafter
water shall be added to it gradually. After addition of water the mixer shall run for a minimum of
2 minutes. The mortar mixed shall be consumed within 4 hours of adding of water.

7.2 PREPARATION OF SURFACES

Preparation of surfaces
a) Surfaces to be plastered must be clean and free from dust, loose material, oil,
grease, mortar droppings, sticking of foreign matter, traces of moss, etc. It is very
important to ensure that there should not be any chance of the plaster getting
separated due to presence of materials harmful for bonding.
b) Raking out of joints ensures a good key between block work & plaster and is
expected to be carried out along with masonry. However, the quality of raking
shall be rechecked thoroughly prior to start of plastering work and if required the
joints shall be raked as instructed by the owner/ owner’s authorized
representative.
c) Raked Joints shall be grouted / pointed with square crushed aggregates.
d) Rust remover shall be applied to any metal surfaces which are in contact with
plaster.
e) Actual plastering shall be commenced only after completion of block masonry
works , electrical conduiting works and curing of electrical chasing works (if any)
and after obtaining the approval of the Owner / Owner’s Authorized
Representative. Plaster work should follow the steps mentioned below:
 Surface must be thoroughly cleaned, hacked and applied with approved
chemical adhesive over concrete surface to receive scratch coat.
 Plastered area must be provided with level dabs or spots for checking with
2-3 m straight edge. Thickness of plaster must not be less than the
thickness specified.
 Corner beads may be fixed at locations shown in drawing or as required by
the Owner / Owner’s Authorized Representative.

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 Plaster stops shall be fixed to correct line, level and plumb where plaster
terminates or abuts with other surfaces.
 Requisite concealed services must be completed and tested.
 No further cutting of masonry shall be permitted.
 Repairs carried out to masonry or concealing work must be cured and dry.
 Masonry surface must be sufficiently damp to prevent absorption of
moisture from plaster, while concrete surface can be pre-wetted and
surface dried before starting of plaster.
 Plaster dabs shall be checked for plumb and level by the Owner / Owner’s
Authorized Representative. Joints, concealing and repairing areas must be
covered with GI mesh as per the instruction of Owner / Owner’s Authorized
Representative.
Any unavoidable projections in masonry and concrete surfaces shall be chiseled back. Care shall be
taken that surrounding surfaces are not damaged and reinforcement is not exposed.

7.3 APPLICATION OF PLASTER

a) All concrete surfaces shall be applied with 5 mm thick skim coat mixed with approved bonding
agent as per the manufacturer’s recommendations. Surface of the skim coat shall be cured for 3
days.
b) The method of application of plaster is important. It is recommended that the mix be thrown on
the surface (rather than sticking with trowel) which improves the adhesion of plaster with
masonry surface.
c) 12-15 mm thick full depth coat material should be applied over skim / scratch coat with pressure
to ensure proper adhesion.
d) Plaster shall be leveled & made even using aluminum hollow section, 2-3 m long. There shall
not be more than 2 mm difference in level of the plastered surface when checked with 3 m
straight edge. It is important that enough pressing is done with trowel to achieve compact filling
of joints and that the area is fully compacted.
e) Corners, external or internal, shall be finished along with final coat.
f) Finishing of plaster may be carried out with wooden float (randhas) or trowel led smooth with
sheet metal trowels as specified. Care shall be taken to avoid excessive toweling and
overworking of the wooden float.
g) All corners, internal or external, shall be truly vertical or horizontal. These shall be finished with
a proper template to achieve best workmanship for rounding and chamfering as specified or
directed.
7.4 CUTTING PLASTER
Plaster shall be cut to correct horizontal or vertical line at the end of the day or if work is required to
be suspended for any reason.
7.5 PLASTER JOINTS
It is advisable to provide joints treated with groove or any other detail as suggested by the Owner /
Owner’s Authorized Representative at junctions with RC surfaces. These joints if not specified

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shall be treated with 150 mm wide reinforcing chicken mesh (approved by the Owner / Owner’s
Authorized Representative) fixed over joints by GI nails before the area is plastered.
7.6 CURING PLASTER
Date of carrying out plaster shall be painted on the surface in large visible letters to ensure
adequate curing. Plaster shall be cured for 14 days by wet curing. During this period plaster shall be
protected from exposure to extremes of temperature and weather.

7.7 WORKMANSHIP CONSIDERATIONS FOR SPECIFIC PLASTER TYPES

7.7.1 12 mm thick internal plaster

Single coat cement-sand plaster with cement-sand mix in proportion of 1:4 shall be carried out
over the entire area as detailed above. This shall be finished with wooden float to give the best
smooth surface possible.
7.7.2 18 to 25 mm ordinary cement sand plaster
This plaster shall be carried out in two coats. Maximum thickness of the undercoat shall be 12
mm and balance thickness shall form the second finishing coat. First coat shall be scarified to
provide adequate bond for the second coat.
7.7.3 Cement finished plaster
This shall be carried out in the same manner as above, for specified thickness in single or double
coat. Thereafter it shall be finished uniformly over the entire area with a paste of neat cement
when the plaster has just hardened and finished smooth with a steel trowel. It shall be worked
over again to achieve a smooth leveled surface. Quantity of cement applied shall be not less
than 1 kg/sqm.
7.7.4 External Cement Plaster
7.7.4.1 This shall generally be carried out on the outside face and exposed area of masonry work and
concrete work. It shall be of minimum 20 mm thickness and shall be in two coats. The coat shall
be CM 1:4 (1 cement: 4 sand) mixed with water-proofing compound 2% by weight of cement
and applied as usual and surface shall be scarified.
7.7.4.2 The second coat shall be applied after 7 to 10 days and shall be of CM 1:4 (1 cement: 4 sand).
Mortar shall be mixed with slightly coarse sand. Mix shall be worked over with 3 m gauge or
wooden float to achieve a uniform surface.

7. QUALITY MANAGEMENT
8.1 All materials used shall be tested as per standards and samples approved by Owner/Owner’s
Authorized Representative
8.2 GI corner beads shall be of approved quality.
8.3 Metal reinforcement used shall be as specified and conforming to applicable Indian Standard.

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8.4 Mockups
Prior to start of the work, the Contractor shall prepare mockups for each type of finish and
application required to verify samples submitted and to observe / test aesthetic effect, quality of
material and workmanship.
The Mockup shall:
a) Demonstrate the proposed range of aesthetic effect and workmanship.
b) Be of full size and thickness including joints, supporting system if any, using proposed
material.
c) Be submitted within 7 days from the advance notice given to the Owner /Owner’s
Authorized Representative
d) Be retained till ordered to be removed by the Owner /Owner’s authorized representative.

8. SAFETY CONSIDERATIONS AND REQUIREMENTS

9.1 Apart from general safety and health hazards like working at heights, falling objects etc., the
contractor shall assess the hazards associated with plastering works and shall take specific action to
mitigate against the same.
9.2 Scaffolding/ Ladders and other access mechanisms:
9.2.1 Scaffoldings should be rigid, allowing free and safe movement of workers on the platform and it
should be at sufficient distance or height from the working areas.
9.2.2 After erection of the scaffolding, approval shall be obtained from the Owner/Owner’s
Authorized Representative prior to commencement of plastering works
9.2.3 All ladders used shall be angled to minimize the risk of tipping over.
9.2.4 Access ladders should extend at least 1m above the working platform.
9.2.5 Ladders should be in good condition, free of debris, and free from defects. The ladders shall be
inspected regularly.
9.3 PPE
9.3.1 All workers should wear proper Personal Protective Equipment while carrying out the plastering
works.
9.3.2 PPE should include but not be limited to hard hats, safety glasses, hand gloves and work boots.

9. ENVIRONMENTAL CONSIDERATIONS AND REQUIREMENTS

10.1 Apart from general environmental impact of construction activities, the contractor shall assess
the environmental impact associated with plastering works and shall take specific action to mitigate
against the same.
10.2 Care should be taken to minimize particulate pollution due to dust in the sand, cement, and
other components.

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10. COMPLETION AND DELIVERY

Work related to concrete construction shall not be deemed as complete till such time all the
following conditions are fulfilled
11.1 All plaster has been cured properly and to the satisfaction of the Engineer
11.2 Unless indicated otherwise in writing by the Engineer, all chasing and chiseling work shall be
made good to the satisfaction of the Engineer.
11.3 There are no defects in the plaster or all defects are repaired to the satisfaction of the Engineer
11.4 All quality tests and inspection records are furnished to the Engineer.

11. METHOD OF MEASUREMENT

12.1 MEASUREMENT
12.1.1 Plaster work shall be measured in square meter to the second decimal place.
12.1.2 Thickness of plaster shall be the average depth of plaster as specified. But if extra thickness
occurs due to bad quality of bricks, stones or blocks or due to bad workmanship, the repairs
required to be carried out shall be at the cost of Contractor.
12.1.3 Grooves, bands in continuation of large areas or plaster areas shall be considered as part of the
plaster and not measured separately.
12.1.4 Isolated areas and width below 300 mm shall be specified and detailed separately in the BOQ
and measured in running meter.
12.1.5 Ceiling plaster, including ribbed beam slab shall be measured in square meters.
12.1.6 Beams and columns in continuation of masonry shall be measured in square meter.
12.1.7 Jambs, sills, coves, cornices, etc. shall be a part of plaster and no separate payment shall be
made towards these items.
12.1.8 Deductions
 No deduction for an opening in plaster shall be made for area less than 0.5 sq m.
 In case the area of an opening is between 0.5 sqm and 3.0 sqm, only 50% of the area shall be
deducted from each face.
 In case the widths of door or window frames are equal to masonry, full area of the opening shall
be deducted.
 In case of openings of area above 3 sqm each deduction shall be made for opening on each face
and jambs, soffits, sills shall be measured.
12.1.9 Plaster to ceiling and walls shall be measured separately if specified in the BOQ.

12.2 RATE

12.2.1 Description of item in the BOQ, unless otherwise stated, includes, wherever necessary,
conveyance and delivery handling, unloading, storing, fabrication, hoisting, all labour for
finishing to required shape and size, setting, fitting and fixing in position, straight cutting and
waste, return of packings, clearing off the work place on completion of works and other
incidental charges.

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12.2.2 Levels and heights shall be as indicated in the BOQ.

12.2.3 Preparation of surface shall be as approved by the Owner / Owner’s Authorized Representative
12.2.4 Trimming off the projections on masonry shall be included in the price.
12.2.5 Scaffolding and working platform shall be included in the price.
12.2.6 Materials as detailed and as required to complete item as specified shall be included in the
price.
12.2.7 Curing of plaster shall be included in the price.
12.2.8 Cleaning of adjacent areas, windows, door frames, etc. including masonry surface in exposed
masonry work, shall be included in the price.
12.2.9 Forming grooves for joints between beams/columns and masonry etc. shall be included in the
price. Any special treatment if detailed shall be measured separately and billed in BOQ.
12.2.10 Providing and fixing chicken mesh at junction of R.C.C., brick work, edges, corners, chiseled and
repaired brick work prior to plaster over concealed conduit, etc. shall be as directed by the
Owner / Owner’s Authorized Representative. It shall be considered as part of item and no
separate charge will be payable.

12. ANNEXURES
NIL

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Contents
1. Scope .......................................................................................................................................... 2
2. List of Standards ......................................................................................................................... 2
3. Terminology................................................................................................................................ 3
4. Materials .................................................................................................................................... 3
5. Submittals ......................................................................................................................................... 4
7. Workmanship - Fabrication ........................................................................................................ 5
6. Quality Management................................................................................................................ 13
7. Safety Management ................................................................................................................. 15
9. Environmental Management ................................................................................................... 15
10. Completion & Delivery.......................................................................................................... 16
11. Method of Measurement ..................................................................................................... 16
12. Annexures: Nil .................................................................................................................. 16
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Technical Specifications for Structural Steel Work

1. Scope
This specification applies to fabrication, erection and placing of structural steel in main
load bearing elements of a building. This does not cover fabrication and installation of
steel in sundry work such as railings, gratings, architectural features

2. List of Standards
All work shall be carried out as per the latest version of relevant Indian Standards. The
list of IS standards given hereunder is not to be considered as conclusive and is for
reference and guidance only. Any discrepancies /conflict noticed shall be directed to the
Engineer for his direction/approval. However as a general rule more stringent
specification shall take precedence

IS Code
S.N. Title
No.
Code of Practice for use of structural steel in general
1 IS: 800
building construction
Code of Practice for use of steel tubes in general building
2 IS 806
construction.

3 IS 808 Dimension for hot rolled steel sections.

4 IS 813 Scheme of symbols for welding

Covered electrodes for metal arc welding of (Part I & II)

5 IS 814
structural steel.
Code of practice for use of metal arc welding and general
6 IS 816
construction in mild steel.

7 IS 822 Code of Practice for inspection of welds.

8 IS 1161 Steel tubes for structural purposes.

Recommended practice for Radiographic examination of

9 IS 1182
fusion welded butt joints in steel plates
Rolling and cutting tolerances for hot rolled steel
10 IS 1852
products.

11 IS 2062 Hot Rolled Low, Medium and High Tensile Structural Steel

12 IS 2595 Code of practice for Radiographic testing.

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Code of practice for testing of fusion welded (Part-I)

13 IS 3600
joints and weld metal in steel

14 IS 4923 Hollow steel sections for structural use.

Code of practice for magnetic particle flaw detection of

15 IS 5334
welds.
Code of practice for use of metal arc welding in tubular
16 IS 6227
structure.

17 IS 7215 Tolerances for fabrication of steel structures.

Method of measurement in Building Civil Engineering

18 IS 12000
work.

3. Terminology
The following terms and abbreviations shall have the specific meanings as described
hereunder. For terms that are not described herein, the definitions as stated in the
applicable Indian Standard Specifications shall apply
3.1. Fabrication: as an industrial term refers to building a metal structure by cutting,
bending, joining and assembling of steel elements.
3.2. Shop Drawing: is a drawing or set of drawings produced by
the contractor, supplier, manufacturer, subcontractor, or fabricator. Shop drawings
are typically required for pre-fabricated components.
3.3. Joist: is one of the horizontal supporting members that run from wall to wall, wall
to beam, or beam to beam to support a ceiling, roof, or floor.
3.4. Camber: an upward curvature of a joist to compensate for load deflection due in
buildings.
3.5. Welding: a fabrication process that joins materials, usually metals by fusing them
at high temperature.

4. Materials
4.1. Structural Steel: Structural steel used in the works shall be either of the following
types : -
4.1.1. Mild steel conforming to IS 2062: 2006 - Hot Rolled Low, Medium and High
Tensile Structural Steel
4.1.2. All steel tubes shall be hot finished seamless steel tubes (HFS) or cold drawn
seamless (CDS) of the specified strength and as approved by the Engineer and
shall conform to IS: 1161.
4.2. Threaded Fasteners: All bolts and nuts shall be delivered as per technical conditions
specified in IS: 1367.
4.3. Black bolts, nuts and screws shall be In accordance with IS: 1363.
4.4. Wherever counter sunk screws are specified, they shall be precision grade, slotted,
counter sunk head, machine screws conforming to type ‘R’ of IS : 1364.
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4.5. Wherever high tensile special quality bolts and nuts are specified, they shall comply
with provision of IS: 3757 and IS: 800.
4.6. Coach screws shall be in accordance with IS: 1120 and wood screws shall conform
IS: 451.
4.7. All plain washers shall conform to requirements of IS: 2016.
4.8. Wherever spring washers for bolts, nuts and screws are specified, they shall be in
accordance with the provisions of IS: 3003.
4.9. Cast Iron: Cast iron shall conform to IS: 210. All cast iron goods shall be of best
quality and make and as approved by the Engineer.
4.10. Cast steel shall conform to IS: 1030. Unless specified otherwise, the steel shall be
grade 2 and shall cater for all tests specified in the said standard.
4.11. Rails for the cranes shall comply with the requirements of IRST-12-64 or IS: 3443
if so instructed by the Engineer. They shall be obtained from an approved
manufacturer.
4.12. Electrodes: Electrodes used for metal arc welding of mild steel shall be heavy
coated type electrodes conforming to IS: 814 (Part l & II) and shall be of best quality
approved by the Engineer.
4.13. Handling and Storage: Structural steel shall not be stored in mud and dirt and
proper drainage of the storage area shall be provided. Steel shall be protected from
damage or from being spoilt by adjacent construction operations.
4.14. Fabricated steel shall not be handled until the paint has thoroughly dried. Care
shall be taken to avoid paint abrasions and other damages. Steel work shall be
transported in the largest practical lengths and in such a way as not to overstress
the fabricated sections.
4.15. All pieces bent or otherwise damaged shall be replaced by the Contractor at his
own cost.
4.16. Storage of fabricated steel at the job site shall be the responsibility of the
Contractor. Material shall be stored at the Job site in a manner which does not
overload the existing or newly constructed structures. Materials shall be protected
against excessive deflection, corrosion or deterioration.
4.17. As far as practicable, stacking of fabricated steel shall be done in sequence of
erection, but heavy members shall not be stacked on top of the light ones.

5. Submittals
5.1. Prior to start of delivery of structural steel, the Contractor shall submit the
following to the Engineer for review.
5.1.1. Certified copies of mill test reports including chemical analysis and physical
properties as required by the applicable Indian Standards for each consignment
of steel.
5.1.2. Where such mill certificates are not available the Contractor shall employ an
approved testing laboratory to perform the required tests and chemical analysis
at his own cost.
5.2. Before commencement of any structural steel fabrication work, the Contractor shall
submit the following to the Engineer for his approval:
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5.2.1. Fabrication drawings including details of connections.

5.2.2. Assembly, erection and installation drawings and manuals indicating the
sequence of work, welding and bolting procedure to be used. Cambers for
trusses and large span girders shall be shown.
5.2.3. Painting details and Galvanising if specified by the owner in the drawing.
5.2.4. For composite construction the details and calculation of details and calculation
of false work and forms supporting the concrete work in steel structure shall be
submitted.
5.2.5. The drawings prepared by the Contractor and all subsequent revisions etc. shall
be at the cost of Contractor for which no separate payment will be made.

6. Workmanship - Fabrication
6.1. Shop Drawings:
6.1.1. The Contractor shall prepare required detailed shop drawings giving complete
information necessary for the fabrication of the structure. All information should be
clearly given and the drawings shall be in conformity with best modern practices. A
marking diagram allotting distinct identification marks to each separate piece of steel
work shall be prepared in sufficient detail to ensure convenient assembly and
erection. Symbols used for welding in the drawings shall be in accordance with IS:
813.
6.1.2. The Contractors shall prepare comprehensive details of material sheets for each shop
drawings giving therein all the items shown on the drawings together with their
weights, marks, numbers, cutting lengths etc. Three copies of all working drawing and
bill of material sheets shall be submitted to the Engineer for approval.
6.1.3. Fabrication shall not commence until the approval of the relevant drawings has been
obtained from the Engineer. While the shop drawings prepared by the Contractor
and approved by the Engineer are deemed to represent the correct interpretation of
the work to be done, the Contractor is not relieved of the responsibility for accuracy
of detailed dimensions shown thereon.
6.1.4. The Contractor shall not commence detailing unless design drawings are officially
released for preparation of shop drawings. The Contractor shall be responsible for
the correctness of all fabrication drawings. Fabrication drawings shall be revised by
the Contractor to reflect all revisions in design drawings as and when such revisions
are made by the Engineer.
6.1.5. No fabrication drawings will be accepted for OWNER’S approval unless checked and
approved by the Contractor's qualified structural engineer and accompanied by an
erection plan showing the location of all pieces detailed.
6.1.6. The Contractor shall ensure that connections are detailed to obtain ease in erection
of structures and in making field connections.
6.1.7. The shop drawings prepared by the Contractor and all subsequent revisions etc. shall
be at the cost of the Contractor for which no separate payment will be made.
6.1.8. Templates: All fabrication shall be carried out in accordance with IS: 800. Extensive
use of templates shall be made. The templates shall be steel bushed where
considered necessary by the Engineer.
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6.1.9. In case actual members are used as templates for similar pieces, it will be at the
discretion of the Engineer to decide whether such pieces are fit to be incorporated in
the finished structure.
6.1.10. The Contractor shall arrange for corresponding part of each unit manufactured
from the same drawings to be interchangeable as far as economic manufacturing
conditions permit, and shall advice the Engineer of the precise arrangement made in
this respect, but prior approval of a gas torch, but prior approval of the Owner or
Owner’s Authorized Representative, in writing, should be taken.
6.2. Cutting:
6.2.1. Gas Cutting shall normally be permitted for mild steel only. Gas cutting of high tensile
steel may be permitted provided special care is taken to leave sufficient metal to be
removed by machining so that metal hardened by flame is removed. Gas cutting shall
preferably be done by machine; Hand flame cutting may only be permitted subject to
the approval of the Owner or Owner’s Authorized Representative. Gas cut edges shall
be free of gouge. Any gouges that remain after cutting shall be removed by grinding.
6.2.2. Rolled sections shall be sawn or flame cut to length. Small plate pieces like gussets
may be sheathed or chopped to size. Sawing, shearing and chopping shall be clean
and free from any distortion. If necessary the edges shall be ground afterwards.
6.2.3. For tubular construction, cutting of the pipe and preparation of joint surface shall be
done in a neat manner for a good fit up. The ends of the tubes may be flattened or
otherwise framed for connections, provided that the methods adopted for such
flattening do not injure the material. The change of section shall be gradual.
6.3. Straightening: All materials shall be straight unless required to be of curvilinear form
and shall be free from twists. If necessary the materials shall be straightened and/or
flattened by pressure. Heating of rolled sections and plates for purpose of straightening
will not be permitted. Limited straightening may however be effected by local
application of heat with
6.4. Drilling
6.4.1. Holes shall preferable be done by drilling. Punching shall not be restored to unless
previously approved by the Owner or Owner’s Authorized Representative. In any
case, punching of holes in materials having a thickness in excess of the connector
diameter or in the materials thicker than 16mm shall not be permitted. Where
punching is permitted the holes shall be punched 3 mm less in diameter than the
required size and reamed after assembly to the full size.
6.4.2. Holes shall be drilled or punched at right angles to the surface of the member, not
more than 1.5 mm/2.0 mm (as the case may be depending upon whether the
connector diameter Is less than or more than 25 mm) larger than the connector
diameter. Holes shall not be formed or enlarged by burning or gas cutting. Holes shall
be clean-cut without torn or ragged edges. Outside burrs resulting from drilling
operations shall be removed.
6.4.3. Holes through more than one thickness of material of members such as compound
stanchions and girder flanges shall be drilled after the members are assembled and
tightly clamped or bolted together. They shall then be separated and burrs removed
if so directed by the Owner or Owner’s Authorized Representative.
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6.4.4. Steel member’s adjustment shall be provided with slotted holes as shown on the
drawings. Suitable templates shall be used for proper location of the holes.
6.5. Fabrication Tolerances: Cutting, punching, drilling, welding and fabrication tolerances
shall be generally as per relevant IS codes.
6.5.1. Unless otherwise shown on the drawings, the fabricating tolerances shall generally be
as follows:
a. Compression members shall not deviate from straightness by more than 1/
1000 of the axial length between points which are to be laterally supported.
b. A variation of 1 mm is permissible in the overall length of members with both
ends finished for contact bearing.
c. Members without ends finished for contact bearing which are to be framed
together in parts of the structure, may have a variation from the detailed length
not greater than 2mm for members 10 meters or less in length and not greater
than 3 mm for members over 10 meters In length.
6.6. Assembly:
6.6.1. All connections shall be either bolted or welded as shown on the drawings.
Contractor shall not redesign or alter any connection without prior approval of the
Engineer.
6.6.2. The component parts shall be assembled in such a manner that they are neither
twisted nor otherwise damaged and shall be prepared so that the specified camber if
any is provided. Drifting done during assembly shall not distort the metal or enlarge
the holes. Poor matching of holes shall be cause for rejection. However if permitted
by the Owner or Owner’s Authorized Representative holes that must be enlarged due
to mismatch, shall be reamed.
6.7. Bolting:
6.7.1. All steel work which is bolted together shall be in close contact over the whole
surface. Where two bolted surfaces are to be in permanent contact after assembly,
each shall be thoroughly scraped free of loose scales, dirt and burrs and a heavy coat
of red oxide, zinc chrome or other approved paint applied after cleaning and drying.
6.7.2. All bolts shall be provided with washers under the nut tapered on the inside of the
flanges of R.S. Joists and channels. Bolts and studs shall project not less than one full
thread through the nut after tightening. Unless otherwise specified, the ends of the
bolts shall be enlarged by hammering after erection to prevent the removal of nuts.
6.7.3. High strength bolts shall be used in bearing or friction as shown on the drawings.
6.7.4. High strength bolted joints shall be made without the use of erection bolts. Bolts shall
be of a length that will extend not less than 6 mm, or three times the pitch of the
thread whichever is higher, beyond the nuts. Bolts shall be entered into holes
without damaging the threads. Members shall be brought tightly together with
sufficient high-strength fitting up bolts which shall be retightened as all the bolts are
finally tightened. Bolt-heads shall be protected from damage during placing. Bolts
that have been completely tightened shall be marked for identification. Bolted parts
shall fit solidly together and shall not be separated by interposed compressible
materials. The contact surface in high strength bolted connections shall be free of oil,
paints, lacquer, loose scale or other coatings. The facing surfaces shall be machined
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flat. Final tightening of high strength bolts shall be by turn-of-nut method.

Retightening shall not be permitted. Whenever the Contractor intends to use other
means of tightening he shall obtain prior approval of the Owner or Owner’s
Authorized Representative.
6.7.5. In case of high strength friction grip bolts, hardened washers shall be used under the
nuts or the bolt heads, whichever are turned to tighten the bolts.
6.7.6. Anchor bolts shall be set by use of templates secured firmly in place to permit true
positioning of the bearing plates and assemblies. When in drawings anchor bolts are
shown to be installed in sleeves, the sleeves shall be completely filled with grout.
6.8. Welding:
6.8.1. Welding shall be done in accordance with IS:816. Welding procedures shall be based
on the specific analysis of any given heat of steel (based on the certified mill test
reports) and shall be subject to the review of the Engineer. These procedures shall
call for one or all of the following
a. Proper bead shape.
b. Minimized penetration to prevent dilution of the weld metal with the alloy
elements.
c. Preheating, controlled inter pass temperature and controlled heat input.
6.8.2.
6.8.3. Welding shall be performed only by qualified and tested welders specifically trained
and experienced for the type of job required to execute the welding work to the
complete satisfaction of the Owner or Owner’s Authorized Representative. However
periodical testing of welders shall be done as per IS 817, IS 7310 (Part I) and IS 738
(Part I).
6.8.4. Use of standard weld symbols as adopted by IS: 813 is mandatory. Pre-qualified joints
which are detailed, prepared and welded in accordance with the requirement of IS:
816 shall be invariably used.
6.8.5. Structural welding shall not commence until joint elements are bolted or tacked in
intimate contact and adjusted to dimensions shown with allowance for any weld
shrinkage that is expected. Welding sequence shall be planned and controlled to
avoid undue stress Increase or undue distortions in restrained members. Heavy
sections and those having a high degree of restraint shall be welded with low
hydrogen type electrodes.
6.8.6. If copper wire spacers are used between two surfaces to be welded to reduce
transverse stresses in the weld, care shall be taken that it does not mix with the weld
metal.
6.8.7. Concave bead shape shall be avoided. Ratio of weld width to weld depth shall
preferably vary from a minimum of 1 to 1, to a maximum of 1.4 to 1.
a. Width-of-weld
b. ——————— = 1 to 1.4
c. Depth of fusion
6.8.8. Field welding shall not be permitted unless shown on the drawings.
6.8.9. Subsequent to fabrication, the overlapping or contacting surfaces, or other closed
sections (such as tubular, box section) which are inaccessible to painting shall be seal
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welded. When the end of the tube is not automatically sealed by virtue of its
connection by welding to another member the end shall be properly and completely
sealed. Before sealing, the inside of the tube shall be made dry and free from loose
scale.
6.8.10. Order of assembly of the tubular sections shall consist of welding the tensile
member to the main member first. Compression members shall be cut back to
overlap the tensile member and then welded to both of these members.
6.8.11. No welding shall be done when the surface of the member is wet nor during
periods of high wind. No welding shall be done on base metal at a temperature below
5oC. Base metal shall be preheated to the temperature as per relevant IS codes.
6.8.12. Each layer of multiple layer welds except root and surface runs may be
moderately peened with light blows from blunt tool. Due care should be taken to
prevent scaling or flaking of weld and base metal from over peening.
6.8.13. Electrodes other than low-hydrogen electrodes shall not be permitted for
thicknesses of 32 mm and above.
6.9. Shop assembly:
6.9.1. Steel work shall be temporarily shop erected completely or partially as directed by
the Owner or Owner’s Authorized Representatives so that the accuracy of fit may be
checked before dispatch. Due notice shall be given to the Owner or Owner’s
Authorized Representative so that the accuracy of fit may be checked before
dispatch. Due notice shall be given to the Owner or Owner’s Authorized
Representative when the work is ready for inspection and the assembly shall not be
dismantled until it has been inspected and approved by the Owner or Owner’s
Authorized Representative.
6.9.2. The parts shall be assembled with a sufficient number of parallel drifts to bring and
keep the components in place. In the case of parts drilled or punched through steel
jigs resulting in similar parts being interchangeable for portion of the steel work,
trial assembly shall be carried out to the extent required by IS : 1915.
6.9.3. All erection marks shall be die-stamped and also distinctly stencilled in paint. The
marking shall be as per the marking diagram approved by the Owner or Owner’s
Authorized Representative.

6.10. Erection:
6.10.1. As far as possible, the Contractor shall deliver the fabricated steel work to the site
in the same sequence as that which he wishes to follow for the erection. Dispatch
should be scheduled to avoid cluttering up of the site. The bolts required for
erection shall be bagged according to size prior to dispatch.
6.10.2. All structural work shall be erected in accordance with IS : 800/IS : 806 and as per
the approved erection drawings. The Contractor shall be responsible for setting out
the works. The suitability and capacity of all plant and equipment used for erection
shall be to the Satisfaction of the Engineer. These equipments shall be regularly
serviced and maintained. Occupational safety practices shall be strictly adhered to
and shall be to the satisfaction of the Owner or Owner’s Authorized Representative.
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6.10.3. Individual pieces shall be plumbed, levelled and aligned. Drift pins may be used only
to bring together the several parts. They shall not be used in such manner as to
distort or damage the metal. Temporary bracing, guy line and staging shall be
provided to ensure proper alignment and to adequately protect all people’s
property and to withstand all loadings to which the structure may be subjected
during erection.
6.10.4. Attachment of such temporary steel work to the permanent steel work shall only
be done with the approval of the Owner or Owner’s Authorized Representative.
Temporary steel work shall remain in position until the structure is stable and self-
supporting and permanently bolted or welded to the satisfaction of the Owner or
Owner’s Authorized Representative. After removal of temporary steel work, the
permanent structure shall be made good to the complete satisfaction of the Owner
or Owner’s Authorized Representative.
6.10.5. No permanent bolting or welding shall be done until proper alignment has been
obtained. Erection of the parts with any moderate amount of reaming, chipping
or cutting shall be immediately reported to the Owner or Owner’s Authorized
Representative. The steel work shall be rejected unless corrective action is
approved by the Owner or Owner’s Authorized Representative.
6.10.6. No erection shall be permitted more than 2 storeys above a complete bolted
and/or welded floor or above a decked surface.
6.10.7. Placement of joists shall not start until the supporting work is secured. Temporary
bracing, connections and anchors shall be provided to ensure lateral stability during
erection. Bracing to steel joists shall be installed immediately after joist erection,
before any construction loads are applied. Horizontal or vertical bracing shall be
provided in accordance with the drawing or type / span of the joists. Alternatively
ends of the bracing lines shall be anchored at node point that is laterally
restrained either by wall or by elevational bracing.

6.11. Erection Tolerances:

Columns
1.1 Deviation of column axes at
foundation top level with respect to true axes
In longitudinal direction ± 5 mm
In lateral direction ± 5 mm
1.2 Deviation in the level of bearing ± 5 mm
surface of columns at foundation top with
respect to true level
1.3 Out of plumb (verticality) of column
axis from true vertical axis, as measured at
column top :
For columns up to and including 15 meters in ± 1/1000 of column height in
height mm or ±15mm whichever is less
For columns exceeding 15 meters in height ± 1/1000 of column height in
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mm or ± 20 mm whichever is
less
1.4 Deviation in straightness in ± 1/1000 of column height
longitudinal and transverse planes of column in:mm or ± 10 mm whichever is
at any point along the height less
1.5 Difference in erected position of ± 10 mm
adjacent pairs of columns along length or
across width of building prior to connecting
trusses/beams with respect to true distance
1.6 Deviation in any bearing or seating ± 5 mm
level with respect to true level
1.7 Deviation in differences in bearing ± 10 mm
levels of a member on adjacent pair of
columns both across and along the building
2.0 Trusses And Beams
2.1 Shift at the center of span of top ± 1/250 of height of truss in mm
chord member with respect to the vertical or ± 15 mm whichever is less
plane passing through the center of bottom
chord
2.2 Lateral shift of top chord of truss at ± 1/1500 of span of truss in mm
the center of span from the vertical plane or ± 15 mm whichever is less
passing through the center of supports of the
truss
2.3 Lateral shift in location of truss from ± 10 mm
its true vertical position
2.4 Lateral shift in location of purlin true ± 5 mm
position
2.5 Deviation in difference of bearing i) ±20 mm for trusses
levels of trusses or beams from the true
difference
ii) For beams with:
Depth < 1800mm ±6mm
Depth > 1800mm ±10 mm
2.6 Deviation in sag in chords and 1/1500 of length in mm or 10mm
diagonals of truss between node points whichever is smaller
2.7 Deviation in sweep of trusses, beams 1/1000 of span in mm subject to a
etc. in the horizontal plane maximum of 10 mm
3.0 Crane Girders & Rails
3.1 Shift in the center line of crane rail ± 5 mm
with respect to center line of web of crane
girder
3.2 Shift in plan of alignment of crane rail ± 5 mm
with respect to true axis of crane rail at any
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point
3.3 Difference in alignment of crane rail ± 1 mm
in plan measured between any two points 2
meters apart along rail
3.4 Deviation in crane track with respect
to track gauge
For track gauges upto and including 15 ± 5 mm
meters
For track gauges more than 15 meters ± [5 + 0.25 (S-15)] where S in
meters is true gauge
3.5 Deviation in the crane rail level at any 1/1200 of the gauge distance or ±
point from true level 10mm whichever is less
3.6 Difference in the crane rail actual ± 2 mm
levels between any two points 2 meters
apart along the rail length
3.7 Difference in levels between crane
track rails at
Supports of crane girders ± 15 mm
Mid span of crane girders ± 20 mm
3.8 Relative shift of crane rail surfaces at 2 mm subject to grinding of
a joint in plan and elevation surfaces for smooth transition
3.9 Relative shift in the location of crane 1/1000 of track gauge S in mm
stops (end buffers) along the crane tracks subject to maximum of 20 mm
with track gauge S in mm

4.0 Chimneys And Towers

4.1 Out of plumb (verticality) from the 1/1000 of the height of the
true vertical axis chimney or tower in mm
5.0 Bunkers

5.1 Deviation in length of bunker from ± 1/1000 of length in mm

true length
5.2 Deviation in width of bunker from ± 1/1000 of width in mm
true width
Deviation in height of bunker from true ± 1/500 of height in mm
height
Deviation in diagonal length in any ± 1/500 of diagonal length in mm
horizontal cross section from the true
diagonal length
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6.12. Field Modifications: Correction to accommodate minor misfits in steel structure by

moderate use of drift pins and reaming will be permitted. Errors that cannot be
corrected by these measures and require modifications, must be reported
immediately to the Owner or Owner’s Authorized Representative along with
Contractor’s proposed solution.

6.13. Grouting under base plates:

6.13.1. Grouting under base plates shall be done after erection of the structural steel
unless otherwise approved by the Owner or Owner’s Authorized Representative. All
bearing plates, bearing assemblies and masonry plates shall be set level and to the
elevations shown on plans. These shall be shimmed with approved means and
grouted to assure full bearing on the supporting substrata regardless of the
tolerances otherwise permitted.
6.13.2. The grout to be used in superstructure stanchion bases shall be cement mortar
1 : 2 (1 cement : 2 coarse sand), mixed with non-shrink admixture and shall have a
28 days’ compressive strength of at least 30MPa. Surfaces which are to receive the
grout shall be thoroughly cleaned immediately prior to the grouting operation. The
grout shall be carefully worked under the base plates and shall completely fill the
space under the base plates. Air pockets in the grout packing shall be avoided.
6.13.3. After the grout has had its initial set, the grout shall be cut back flush with the base
plate and the surplus grout shall be removed. Before leaving the site, the Contractor
shall retighten the nuts of all anchor bolts.

6.14. Cleaning and paint touch up: After erection, exposed surfaces of field connections,
unpainted areas adjacent to tie connections and damaged area of the shop coat
shall be cleaned to the same standards required as the shop coat. These shall then
be painted with the same paint used in the shop coat.
6.15. Inserts and Embedments: Various steel inserts and embedments are required under
the Contract to be fabricated, positioned and secured firmly into place inside the
formwork prior to concrete being poured. There are also requirements of jointing,
threading, bolting and welding inserts and embedments of structural steel elements
in order to establish structural continuity and connection. Great care shall be
exercised by the Contractor in executing all aspects of the work related to inserts
and embedments, including tolerances, so that the final assembly of the concrete
elements can meet satisfactorily the continuity and contiguity requirements
intended in the structure.

7. Quality Management
The contractor shall put in place a comprehensive Quality management plan to ensure
that the work is carried out as per specifications and compliance to all requirements are
established and demonstrated through comprehensive documentation. The contractor
shall engage a qualified Quality Manager to implement the quality plan. Till such time a
Quality Management Plan and ITP is approved, the following provisions shall apply
7.1 The Contractor shall give due notice to the Engineer in advance of the materials
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or workmanship getting ready for inspection.

7.1.1 All rejected material shall be promptly removed from the shop and replaced with
new material for the Engineer’s approval/inspection.
7.1.2 The fact that certain material has been accepted at the Contractor’s shop shall
not invalidate final rejection at site by the Engineer if it fails to be in proper
condition or has fabrication inaccuracies which prevent proper assembly.
7.1.3 No materials shall be painted or dispatched to site without inspection and
approval by the Engineer unless such inspection is waived in writing by the
Engineer.
7.1.4 Shop inspection by the Engineer or submission of test certificates and
acceptance thereof by the Engineer shall not relieve the Contractor from the
responsibility of furnishing material conforming to the requirements of these
specifications, nor shall it invalidate any claim which the Engineer may make
because of defective or unsatisfactory material and/or workmanship.
7.1.5 The Contractor shall provide all the testing and inspection services and facilities
for shop work except where otherwise specified.
7.1.6 For fabrication work carried out in the field the same standard of supervision
and quality control shall be maintained as in shop fabricated work. Inspection
and testing shall be conducted in a manner satisfactory to the Engineer.
7.1.7 Qualified welders shall only be deployed for the work and welder’s qualification
tests shall be performed.
7.1.8 If mill test reports are not available for any steel materials the same shall be got
tested by the Contractor to the Engineer’s satisfaction to demonstrate
conformity with the relevant specification.
7.1.9 All fillet welds shall be tested either by Die penetration test of Magnetic particle
test.
7.1.10 If heat treatment is performed, the completed weld shall be examined after heat
treatment. All defects shall be repaired and retested.
7.1.11 All full strength butt welds shall be radiographed in accordance with the
recommended practice from radiographic testing as per relevant IS codes.
7.1.12 In event of failure of any member to satisfy inspection or test requirement, the
Contractor shall notify the same to the Engineer. The Contractor shall obtain
permission from the Engineer before commencing any repairing work. The
quality control procedures to be followed are to ensure that satisfactory repairs
are carried out subject to approval of the Engineer
7.1.13 The Contractor shall maintain records of all inspection and testing which shall be
made available to the Owner or Owner’s Authorized Representative as and when
demanded.
7.2 Tolerances: The dimensional and weight tolerances for rolled shapes shall be in
accordance with I.S. 1852 for indigenous steel and equivalent applicable codes for
imported steel. The tolerance for fabrication of structural steel shall be as per IS
7215.
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7.3 End milling: Where compression joints are specified to be designed for bearing, the
bearing surfaces shall be milled true and square to ensure proper bearing and
alignment.

8. Safety Management
Apart from general safety and health hazards like working at heights, falling objects etc.,
the contractor shall assess the hazards associated with concrete works and shall take
specific action to mitigate against the same. This shall be achieved by development of a
Safety management manual. The manual shall be built around a Hazard Identification
Risk Analysis and Control matrix [HIRAC] and control measures based on the same.
Some of the hazards associate with steel works is listed for general guidance below:
8.1 All hazards associated with working with Electricity / electrical equipment
8.2 All hazards working with industrial gasses & related fire hazards
8.3 Flying sparks, metal chips or pieces
8.4 Till such time a Safety manual / HIRAC is developed and control measures
implemented, the following provisions shall apply.
8.5 Contractor shall maintain first aid facilities at site. All workmen must wear Helmets,
Safety belts, shoes etc. All required precautions including medical check-up shall be
taken for working at heights.
8.6 All critical industrial injuries shall be reported promptly to Engineer and a copy of
contractor’s report covering each personal injury requiring the attention of a
physician shall be furnished to Engineer.
8.7 The contractor shall provide, and maintain barricades, guards, guard rails, temporary
bridges and walkways, watchmen, night illuminations and danger signals illuminated
from sunset to sunrise, and all other necessary appliances and safeguards to protect
the work, life property, equipment and materials. Barricades shall be of substantial
construction and shall be painted such as to increase their visibility at night.
8.8 Notwithstanding any stipulations by Engineer, the contractor shall be solely
responsible for initiating maintaining and supervising all safety precautions and
programs in connection with the work, and shall comply with all laws, ordinances,
codes, rules, regulations and lawful orders of any public authority having jurisdiction
for the safety of persons or property or to protect them from damages, injury or loss
during the entire contract period including non-working hours.
8.9 The contractor shall perform any and all operations and shall furnish any materials
and equipment necessary during an emergency endangering life or property without
waiting for Engineer’s instructions and, in all such cases, shall notify, the ENGINEER
of the emergency as soon as practicable.

9. Environmental Management
Apart from general environmental impact of construction activities, the contractor shall
assess the environmental impact associated with rebar works and shall take specific
action to mitigate against the same. Some of the environmental aspects associate with
rebar works are listed for general guidance below.
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10. Completion & Delivery

Work related to rebar construction shall not be deemed to be complete till such time all
the following conditions are fulfilled:
10.1 There are no defects in the fabricated elements or all defects have been rectified
to the satisfaction of the Engineer.
10.2 All structural elements are erected and to the permissible tolerance and touch
up paint is applied at all required locations.
10.3 Any cladding that is supported by the steel work is installed
10.4 All quality documents / test certificates are compiled and submitted.

11. Method of Measurement

11.1 For purposes of payment, the weight of the actual completed structures shall be
calculated from the approved drawings for different items of work. The Contractor
shall submit to the Engineer relevant material list containing weight of each item.
11.2 No allowances will be permitted for bolts, nuts, washers, studs, screws etc.,
galvanizing, welding or for rolling margins. One tonne for the purpose of payment
shall mean One Metric Tonne i.e. 1000 Kgs.
11.3 The weight of members made out of standard rolled section such as beams,
channels, angles etc. shall be based on standard IS: 808 without deducting for
holes, notches, bevels, cuts etc. Where a component consists of a cut joist or
channel, the full weight of the rolled section shall be considered only if more than
half the section is used. Otherwise, only half the section unit weight shall be
considered for calculation of the weight of the components.
11.4 The weight of any built-up members shall be based on the weight of each
component.
11.5 Providing safe working conditions at all work fronts at all times shall be the
responsibility of the Contractor. Adequate Personal Protective Equipment (PPE)
shall be provided to all workers & Visitors to the Site. The quoted rates shall be
deemed to include for all safety related expenses as required for the nature of the
work being executed unless otherwise covered specifically as a payable item in the
BOQ pertaining to safety items.
11.6 The payment for the inserts and embedment shall be based on the weight of the
fabricated piece at the same rate as that applicable to structural steel. The said
rate shall be deemed to include supply of materials (including rounds/bars), labour
and all works related to steel inserts and embedment indicated in this
specification.

12. Annexures: Nil

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Table of Contents
1. Scope ........................................................................................................................................................ 2
2. List of Standards ....................................................................................................................................... 2
3. Terminology.............................................................................................................................................. 2
4. Materials................................................................................................................................................... 2
5. Submittals and Certifications .................................................................................................................... 3
6. Workmanship ........................................................................................................................................... 3
7. Quality Management ................................................................................................................................ 5
8. Safety Considerations and Requirements ................................................................................................. 5
9. Environmental considerations .................................................................................................................. 6
10. Completion & Delivery.............................................................................................................................. 6
11. Method of Measurement: ........................................................................................................................ 6
12. Annexure .................................................................................................................................................. 7
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Technical Specification: Crystalline Waterproofing Works

1. Scope
This specification applies to waterproofing work by the method of Crystallization provided
in construction. It covers waterproofing work carried out at any location in the structure
and applies to all projects of Godrej properties Ltd. It does not cover the work associated
with provision of other water proofing techniques. For the other techniques the separate
specifications which are provided, can be referred. In case of any conflict between the
provision of this document and technical recommendations or/ specifications of
manufacturer of the Crystalline water proofing compound, the later shall prevail.

2. List of Standards
Sr. No Code No. Description

1 PV/TECH SPEC/CIVIL/02 Technical Specification for Concrete works

2 PV/TECH SPEC/CIVIL/03 Technical Specification for Rebar works

3 PV/TECH SPEC/CIVIL/04 Technical Specification for Formwork

3. Terminology
3.1 Crystallization: It is a catalytic reaction between the sealant and the water which forms
crystals inside the pores of the member on which it has been applied.
3.2 Pores: These are the air pockets present in the concrete member formed during the
process of hydration.
3.3 Capillary: It’s a phenomenon associated with surface tension and resulting in the
elevation or depression of liquids in pores.

4. Materials
Crystalline Waterproofing compound: This is a prepackaged, gray-colored chemical that,
when mixed with water and other approved materials and applied, penetrates into concrete
and concrete unit masonry and reacts chemically with the byproducts of cement hydration
in the presence of water to develop crystalline growth within substrate capillaries to
produce an impervious, dense, waterproof substrate. Names of some of the manufacturers
of Crystalline compound and their products are listed below.
 American PERMAQUIK Inc.; Super 200.
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 Conproco Corporation; Conpro Super Seal.

 Euclid Tamms; HEY'DI K-11.
 Krypton Group of Companies (The); Krystol T1 & T2 Waterproofing System.
 Vandex USA LLC; Vandex Super/Super White.
 Xypex Chemical Corporation; Xypex.
 Penetron Inc. USA
Since these chemicals are manufactured and supplied by the vendors as per their own R&D
efforts, no generic specifications are available for the material. It is recommended that the
type and brand of the chemical proposed to be used should be approved by the Engineer.
To obtain the approval, datasheet from the manufacturer may be provided and mock trials
conducted to validate the efficacy of the material and workmanship proposed.

5. Submittals and Certifications

5.1.1 The contractor shall put in place a comprehensive Quality management plan to
ensure that the work is carried out as per specifications and compliance to all
requirements are established and demonstrated through comprehensive
documentation. The contractor shall engage a qualified Quality Manager to
implement the quality plan. The standardized Inspection and Test plans [ITP] shall be
adopted for the purpose of testing material and establishing documentary evidence
of conformance to technical requirements.
5.1.2 If the contractor proposes to adopt his own ITP, the same shall be submitted for the
approval of the Engineer. Any dilution of the testing frequency, acceptance criteria
from the standardized ITP shall have to be supported by well-articulated arguments.
5.1.3 To preclude any possibility of inadvertent dilution of the water proofing chemical or
it’s mixing with other material; the unique number of each container of the
Crystalline waterproofing compound brought to site shall be recorded.
5.1.4 The empty containers shall be handed over to Godrej and shall not be removed
from the site. The consumption of water proofing compound per unit area shall be
assessed on the basis of the overall consumption of the compound brought to site.

6. Workmanship
6.1 Floor Area:-
6.1.1 The bottom of the foundation shall be leveled both longitudinally and
transversally or stepped as directed by the Engineer.
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6.1.2 Before the PCC is laid, the surface shall be slightly watered and rammed. When
rock or other hard strata is encountered, it shall be freed of all loose and soft
materials, cleaned and cut to a firm surface either level, stepped, or serrated as
directed by the Engineer.
6.1.3 All seams in the bed rock shall be cleaned out and filled with PCC M10 or grout
to the satisfaction of the Engineer.
6.1.4 PCC of M10 concrete minimum thickness 100mm shall be laid over the above
compacted finished surface.
6.1.5 A layer of cement slurry admixed with approved waterproofing compound (in
the proportion recommended by manufacturer) shall be spread evenly over the
PCC layer and finished smooth.
6.1.6 The surface applied with the water proofing compound shall be cured properly
for a period of 1 to 2 days.
6.1.7 Providing and applying Chemical Crystallization Based waterproofing treatment
(from approved manufacturers) over the P.C.C. as a slurry application in 2 coats
to a total dosage rate of minimum 1.5 to 1.6 Kg. Per Sqm. or as per
manufacturers’ specification.
6.1.8 The above chemical application is protected by a coat of cement, sand mortar in
the proportion 1:4 admixed with approved waterproofing compound and
specialized acrylic based shrinkage compensating plasticizing admixture in the
proportion recommended by the manufacturer. The thickness of the treatment
shall be average 40mm.
6.1.9 The layers of sand cement mortar to be spread by grouting process. The surface
prepared to be cured properly for a minimum period of 1 to 2 days.
6.1.10 The tying of the reinforcement bars with proper cover blocks is to be undertaken
after the above layer is cured.

6.2 Wall Area:

6.2.1 The external face of the retaining wall shall be thoroughly cleaned and all
concrete projections chipped. Protruding binding wires, wooden pieces, etc. shall
be totally removed. The bolt holes, pipe sleeves, puddle flanges etc. shall be
plugged properly using micro concrete admixed with approved chemical water
proofing compound in the proportion recommended by the manufacturer.
6.2.2 Over the cleaned external surface of the retaining wall, Chemical Crystallization
Based waterproofing compound (from approved manufacturers) should be
applied in 2 coats at a total dosage rate of minimum 1.5 / 1.6 Kg. per Sqm. or as
per manufacturers’ specification.
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6.2.3 The applied waterproofing compound should be water cured for a minimum
period of 3 days before back filling.
6.2.4 All construction joints and honey combed areas in the external surface of the
retaining wall shall be chased open and treated with two coats of Crystalline
slurry application or Crystalline plugging materials.
6.2.5 All back filling work to be done only after seven days of completing the water
proofing treatment. Only murum / soft soil free from rocks / boulders should be
used for back filling near the wall, taking adequate care to avoid damage to
water proofing treatment.

7. Quality Management
7.1 The contractor shall put in place a comprehensive Quality management plan to
ensure that the work is carried out as per specifications and compliance to all
requirements are established and demonstrated through comprehensive
documentation. The contractor shall engage a qualified Quality Manager to
implement the quality plan.
7.2 The standardized Inspection and Test plans [ITP] shall be adopted for the purpose of
testing material and establishing documentary evidence of conformance to technical
requirements. If the contractor proposes to adopt his own ITP, the same shall be
submitted for the approval of the Engineer. Any dilution of the testing frequency,
acceptance criteria from the standardized ITP shall have to be supported by well-
articulated arguments.

8. Safety Considerations and Requirements

8.1 Apart from general safety and health hazards, the contractor shall assess the hazards
associated with Crystalline Waterproofing Works and shall take specific action to
mitigate against the same. Some of the hazards associate with works is listed for general
guidance below.
a. For Safety considerations related to concrete works during Crystalline
waterproofing refer GPL/TECH SPEC/CIVIL/02
b. For Safety considerations during to Rebar works GPL/TECH SPEC/CIVIL/03.
c. For Safety considerations during Form works refer GPL/TECH SPEC/CIVIL/04.
8.2 All workmen shall be made aware of the specific hazards that they face during
Crystalline waterproofing works and shall be provided with specific personal protective
equipment to protect them.
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9. Environmental considerations
9.1 Apart from general environmental impact of construction activities, the contractor
shall assess the environmental impact associated with crystalline waterproofing
works and shall take specific action to mitigate against the same.
9.2 As a general guide, the following hazards are identified as associated with Crystalline
waterproofing works.
9.2.1 Noise pollution due to operation
9.2.2 Crystalline Waterproofing Works activity involves following type of waste :
a. Non-hazardous waste: like Scrap wood, Fixtures
b. Hazardous waste like used Concrete waste, oil, paint, solvents, sealers,
thinners, Cleanup and materials contaminated with the items listed
above Drums and containers that once contained the items listed above.
9.3 When wastes are produced at the site, the contractor or subcontractor who
produces the waste typically is responsible for ensuring its proper handling and
disposal.

10. Completion & Delivery:

Work related to Crystalline waterproofing construction shall not be deemed as complete
till such time all the following conditions are fulfilled:
a. There are no defects in the waterproofing work or defects have been rectified to the
satisfaction of the Engineer. Specifically, the no of coats showing the required
uniformity of the waterproofing slurry should have been achieved as per permissible
tolerances.
b. All quality documents, test certificates have been submitted.

11. Method of Measurement:

The work of waterproofing using crystalline compound shall be measured and paid in
sq.m of the surface area of concrete over which the compound is applied. No deduction
shall be made for any opening such as tie rod, sleeve etc.. No extra payment shall be
made for repairing minor surface irregularities, minor honeycombs or filling tie rod holes.
The quoted rate shall be deemed to include:
a. Cost of Crystalline waterproofing compound including its wastage
b. Cost of mockup / validation trials
c. Cost of sampling and testing of compound through approved third party test agency
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d. Cost of all temporary arrangement required for application of the compound

e. Cost of surface preparation, all types of chemical treatment / application towards
surface preparation, and curing of the treated concrete as per manufacturer’s
recommendations.

12. Annexure
NIL