Volume-IIID Technical Specification of Pipe Works
Volume-IIID Technical Specification of Pipe Works
Pipe Works
Item 2: Rising Main - Supply, lowering, laying, jointing, testing & commissioning of
necessary D. I. K-9 grade rising main, as per site condition with instruction of
Engineer-in-charge, including refilling, bedding, specials, valves, valve chamber,
thrust blocks & crossings as per tender specifications.
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d) 1For PE-100 pipes the BIS license shall be furnished by those who have no valid BIS
at present.
e) Up to 110 mm dia. pipes only push fit joints shall be used for joining of pipes. these
fittings shall carry the necessary international approvals for leak proof jointing. The
following quantity per Km. and part thereof the pipe shall be supplied free of cost
along with the pipe as per the following
Table-1
Size coupler Threaded Bend Tee Flag joint
adopter
63 mm dia. 2 2 2 3 nil
75 mm dia. 3 3 2 3 2
90 mm dia. 5 5 2 3 2
110 mm dia. 7 7 2 3 2
160 mm dia. 8 8 2 3 2
200 mm dia. 9 9 2 3 2
250 mm dia. 10 10 2 3 2
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2.1 General
The bidder shall have to arrange demonstration of the installation and testing of pipe
by manufacturer including fixing all specials and valves properly at least up to 10 %
of total quantity to be supplied by them at any place of the site of work under the bid.
The bidder shall have to arrange for random testing of pipes brought on site, in
CIPET in the presence of client representative and on satisfactorily report from the
CIPET the payment of pipes will be made.
2.2 Welding
HDPE pipes are joined by BUTT Fusion welding method with the help of electric heat
(Mirror) and hydraulically operated welding jack.
2.2.1 Precautions:
Since critical parameters for sound welding joint are temperature and pressure,
welding methods should insure proper temperature and pressure by using proper
equipments. The welding area has to be protected from adverse weather condition
like rain water, moisture, rough wind, dust and low ambient temperature (less than 50
C. Primary inspection of pipes should be done for ensuring defect free pipe before
starting welding.
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Proper Teflon cloth covering should be provided on mirror surface to avoid sticking of
melted HDPE material on plate surface.
After attaining the welding temperature of 200 c. on mirror surface the pipe ends are
simultaneously brought in contact with the heating surfaces of mirror. This is done by
using hydraulically operated welding jack. Initial contact pressure is applied which is
maintained till the uniform ring of molten bead is achieved. Then the contact
pressure is reduced until proper fusion takes place.
After proper fusion, the welding mirror is removed carefully without damaging the
head. The time of removal of the minor or should be as short as possible. After
removal of mirror, pipe ends are brought immediately to contact with each other
under initial welding pressure which is gradually increased to final welding pressure.
This pressure depends on the total welding surface of pipe.
The final welding pressure is maintained to be applied till the joint is cooled down to
ambient temperature naturally. Artificial cooling such as wrapping with wet cloth,
spraying of water etc. are not allowed.
2.3.1 Trench:
Since the welding of pipe is done outside of trench, the width of trench should be
kept as minimum as possible, Normally pipe O.D. plus 300 mm width should be
sufficient for laying. The depth of trench will be as per the requirement of client
depending on level survey (L.S) Here in our case the earth cover of average 1.2 mtr.
on top of pipe is to be provided. Hence the depth of trench will be pipe O.D. plus 1.2
mtr.
The trench should be made as straight as possible. Wherever necessary, trench can
be made with smooth curve but not below allowed bending radius of HDPE pipe,
which is 25 times of O.D.
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The bottom of trench should be properly dressed and made free from any sharp
objects.
2.3.2 Laying & Back Filling:
Laying of pipe lengths to be done carefully from one end without giving any impact on
pipe and As per I S. After laying of pipe, trench should backfilled with the layers of
good earth of dug soil as available. extra soil will be embedded on trench which will
be compacted by curing with water.
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2.7.5 Sampling
a) Lot - All fittings of the same size, same thickness, same length and fabricated in a
single consignment, shall be grouped together to constitute a lot.
b) The conformity of the lot to the requirements of this specification shall be ascertained
for each lot separately. The number of fittings to be sampled from each lot shall
depend on the size of the lot and shall be in accordance with col 1 and 2 of Table 1.
c) These fittings shall be selected from the lot at random. In order to ensure the
randomness of selection, procedures given in IS : 4905- .1968t may be followed.
d) Number of Tests and Criteria for Conformity
e) Each fitting so selected shall be examined for requirements given in 4 and 5. Any
fitting failing in one or more of these requirements shall be considered as defective.
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2.7.6 MARKING
All fittings shall be clearly and indelibly marked at a prominent place visible even after
the installation of the fittings with the following information:
a) The manufacturer’s name or identification mark, and
b) The size of the fitting and the appropriate class ( working pressure ) of IS :
4984-1972* to which the pressure rating of the fitting corresponds.
HDPE fittings conforming to specific requirements as prescribed in the relevant parts
of the standard may also be marked with the ISI Certification Mark
NOTE - The use of the ISI Certification Mark is governed by the provisions of the
Indian Standards Institution (Certification Marks) Act and the Ruler and Regulations
made there under. The ISI mark on products covered by an Indian Standard conveys
the assurance that they have been produced to comply with the requirements of that
standard under a well-defined system of inspection, testing and quality control which
is devised and supervised by ISI and operated by the producer. ISI markers products
are also continuously checked by 1% for conformity to that standard as a further
safeguard. Details of conditions under which a license for the use of.
The ISI Certification Mark may be granted to manufacturers or processors, may be
Obtained from the Indian Standards Institution.
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4.1 General:
Most old C.I pipes are cast vertically but this type has been largely superseded by
spun iron manufactured up to a dia. of 900 mm. The cast iron pipe has good lasting
qualities and there are many example of cast iron mains in this country which
continue to give satisfactory service after a century of use.
C.I flanged pipe and fittings are usually cast in the larger diameters. Smaller sizes
have loose flanges screwed on the end of double spigot-spun pipes.
The method of C.I pipe production used universally today is to form the pipes by
springing or centrifugal action. Compared with vertically casting in sand moulds, the
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spun process results in faster production, longer pipes with vastly improved metal
qualities, a smoother inner surface and reduced thickness and consequent light
weight.
Centrifugally cast spun iron pipes are available in diameters from 50 mm to 900 mm
inclusive and are covered with protective coatings.
Pipes are supplied in 3.7 m and 5.5 m lengths and a variety of joints is available
including spigot-and socket and flanged joints.
The centrifugally cast ductile iron pipes, recently developed, along with ductile iron
fittings are made from a material produced by treating molten iron of suitable
composition with magnesium. It possesses properties of high mechanical strength
without losing the resistance to corrosion and good casting qualities inherent in grey
iron. The pipes are suitable for hydraulic working pressure up to 40 kg/cm2
dependent on diameter, being subjected at works to a hydrostatic proof test pressure
of 1 times the recommended maximum working pressure. They can resist impact
Several type of joints, such as rubber gas-kets known as “Tyton joint and Electrolytic
Joint” mechanical joint known as :Sewer Gland Joint” and conventional joint known
as “Lead Joint” are used. IS: 3114-1965 should be followed for laying of cast iron
pipes.
Joints are classified into the following three categories depending upon their capacity
for movement:
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Rigid joints are those which admit no movement at all and copies flanged, welded
and turned and bored joint. Flanged joints require
Perfect alignment and close fitting are frequently used where a longitudinal trust must
be taken, such as at the valves and meters. Welded joints produced a continuous
line of pipes with the advantage that interior and exterior coatings can be made
properly and are not subsequently disrupted by movement of the joint.
The semi-rigid joint is represented by the spigot and socket with caulked lead joint.
Lead wool may be used in wet conditions. Lead –covered yarn instead of ordinary
jute Yarn is of great use in repair work, since the leaded yarn caulked into place will
keep back water under very slow pressure while the joint is being made. Proprietary
jointing compounds may also be used. The socketed end of the the pipe should be
used. The socketed end of the pipe should be kept against the flow of water and the
spigot end of the pipe should be kept against the flow of water and the spigot end of
the other pipe is inserted into this socket. A twisted spun yarn is filled into this gap
and it is adjusted by the yarning tool and is then caulked well. A rope is then placed
at the outer end of the socket and is made tight fit by applying wet clay, leaving two
holes on the top, one for escape of the entrapped air inside. The rope is taken out
and molten lead is poured into the annular space by means of a funnel. The clay is
then removed and the lead is caulked with a caulking tool.
Flexible joints are used where rigidity is undesirable such as with filling of granular
medium and where two sections cannot be welded. They comprise mainly
mechanical and rubber ring joint or tyton joints which permit some degree of
deflection at each joint and are, therefore, able to stand vibration and movement. In
tyton jointing special type of spigot and socketed end. The gasket is inserted into the
socket in the groove, the spigot end being lubricated with grease and slipped into the
socket by means of a jack used on the other end.
The working condition of absence of light, the presence of water and relatively cool
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uniform temperature are all conducive to the preservation of rubber and consequently
this type of joint is confidently expected to last as long as the pipes. Hence rubber
jointing is to be preferred to lead jointing and this therefore, obviates the necessity of
the import of this metal. In the flanged joints, the flanged ends are brought together in
alignment, rubber packing being inserted in between and bolted.
(iii) Sum of the maximum sustained operating pressure or the maximum pipeline
static pressure and the maximum calculated surge pressure
Subject to a maximum equal to the works test pressure for any pipes and fittings
incorporated in the pipe line.
The field test pressure should wherever possible be not less than two-thirds of the
works test pressure appropriate to the class of pipe expect in the case of spun iron
pipes and should be applied and maintained for at least 4 hours
Where the field test pressure is less than two-thirds the works test pressure the
period of test should be increased to at least 24 hours. The test pressure shall be
gradually raised at the rate of nearly 1 kg/cm2/min.
In the case of spun iron pipes, the hydrostatic test pressure after installation is to be
adopted instead of the works hydrostatic test pressure which is 35kg/cm2 uniformly
for all classes of pipe.
If pressure measurements are not made at the lowest pont of the section, an
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allowance should be made for the static head between the lowest point and the point
of measurement to ensure that the maximum pressure is not exceeded at the lowest
point. If a drop in pressure occurs, the quantity of water added in order to re-establish
the test pressure should be carefully measured. This should not pipeline per day for
each 30m head of pressure applied.
The allowable leakage during the maintenance stage of pipes carefully laid and well
tested during construction however. Should not exceed
qL =
Where,
D=diameter in mm:and
This figure is applicable to spigot and socket CI pipes and AC pressure pipes , thice
this figure may be taken for steel and prestressed concrete pipes.
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5.2 Inspection
This clause is applicable in general to all items / materials supplied by the contractor.
Inspection of items / materials shall be carried out at factory site by Inspecting
agency. The inspection call should be given 7 days in advance. Inspection shall be
carried out normally within one weeks time and on receipt of such intimation the
inspecting agency will inspect the materials as per the specification and on satisfying
itself, will mark the inspection marks on all pipes and issued inspection note to the
supplier and concerned consignee.
For inspection purpose the manufacturer has to go in for stenciling for identifying size
and class for proper segregation. The stock of offered material shall be in a
manageable batch with adequate space like spreading the pieces etc. to permit
proper inspection and inspection authority to be present during stamping so as to
ensure that only actually cleared material is stenciled. Manufacturer should not load
material after sunset to avoid inadvertent dispatch of wrong material.
Inspection note shall be issued by the inspection agency to supplier as well as
consignee. Materials with inspection mark will be dispatched to stores stipulated in
supply order and on receipt at stores, verification will be carried out by concerned
Engineer as regards quantity and quality. Here quality means physical soundness of
materials as precaution against breakage during transit. The supplier has to submit
the test certificate as well as detailed test results carried out by inspection authority to
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the consignee along with the dispatch documents of materials. The material shall be
considered as received only on receipt given by the concerned Engineer after
verifying and satisfying the above requirements.
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The contractor shall provide all necessary jointing materials such as nuts bolts,
rubber packing, white zinc, jute, lead wool etc. All tools and instruments, which are to
be required for installation of sluice valve shall be provided by the contractor. All
jointing materials shall be got approved from the engineer-in-charge before use. The
nuts and bolts shall conform to the relevant IS. The rubber packing shall conform all
specifications as narrated in respective IS.
6.3.2 Installation
The sluice valve shall be lowered in to the trench carefully, so that no part is
damaged during lowering operation. If necessary tailpieces shall be fitted with sluice
valve first outside the trench and then lowered in to the trench. The rubber packing
shall be three ply and of approved thickness. The packing shall be of full diameter of
the flange with necessary holes and the sluice valve bore. It shall be even at both the
inner and outer edges. The flange faces thoroughly greased. If flange faces are not
free, the contractor shall use thin fibers of lead wool. After placing the packing, nuts
and bolts shall be inserted and tightened to make the joint. The valve shall be tightly
closed when being installed to prevent any foreign materials from getting in between
the working parts of the valve. Each flange bolt shall be tightened a little at a time
taking care to tighten diametrically opposite bolts alternatively. The sluice valve shall
be installed in such a way that its Spindle shall remain in truly vertical position. The
other end of tailpiece shall be fitted with pipes so that continuous lines can work.
Extra excavation required for facility of lowering and fixing sluice valve shall not be
paid.
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Second Class bricks of Standard size shall be brought by the Contractor & shall get
approval before use in the work from the Engineer-in-charge. Brick Masonry wall in
CM1:6 & thickness of wall 23cm. Inside plaster 20mm thick inside plaster in C:M1:3.
20 mm dia. MS bar steps shall be provided and fixed in wall at 30 cm c/c for
facilitating access into the chamber. First step should be at a depth of 0.5 m from top
and last step should be 0.5 m above bottom.
Chamber shall be covered with 150 mm thick RCC 1:2:4 pre cast or cast in situ slab
in four parts with key hole to insert key for operation.
Reinforcement for the cover slab shall be provided considering heavy traffic load.
Curing of concrete, BB masonry, RCC etc. shall be done using chemical or water for
14 days.
12 mm dia. MS bar handles minimum two nos. shall be provided to each piece of
slab during the time of casting of slab.
All the above items shall be carried out in workman like manner as per prevalent
sound engineering practice and instruction of Engineer-in-charge.
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SAIL or Punjab Rolling Mill or any other Approved make or ISI marked. This includes
cuttings, bending, binding, placing, with all Equipments and labour required for the
work as directed by the Engineer-in charge and all operations covered within the
intent and purpose of the Specification.
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Item No 3 - Effluent Disposal pipe: Design, supply, lowering, laying, jointing, testing &
commissioning of RCC NP2 Test Pressure, 0.7 Kg /Sq.m pipeline for effluent disposal,
as per design, beyond 500m, including refilling, encasing, provision of manholes at
every 30m, bedding & crossings as per tender specifications.
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3.1 Location:
Manholes shall be constructed at places approved by the Employer’s Representative.
In case manholes are to be laid along the river, they should be made of RCC or Brick
Manhole with appropriate jacketing arrangement or the top of brick manhole shall be
raised to a safe height above the highest flood level of river / drain as directed by
E.I.C.
3.2 Materials:
Manhole cover with frame of required size and weight shall be procured by the
contractor as per approval
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3.3 Excavation:
The excavation for construction of manhole including dismantling of all types of roads
surface guarding, barricading, lightening the trenches, dewatering if required,
removing and replacing, shifting of telephone/electric cables, pipe line etc. and all
other safety provisions like shoring and strutting etc. till refilling of trenches and
completion of manhole construction, stacking of excavated stuff within the specified
lead, back filling of selected excavated earth, watering and consolidation etc.
complete shall be carried out as per relevant specification of Excavation.
Before starting concrete the bed of foundation trenches shall be cleared of all loose
materials, leveled, watered and rammed as directed
a) Mixing:
The concrete shall be mixed in a mechanical mixer at the site of work. Hand mixing
may however be allowed for smaller quality of work if approved by the Engineer-in-
charge. When hand mixing is permitted by the Engineer-in-charge in case of
breakdown of machineries and in the interest of the work, it shall be carried out on a
water tight platform and shall be taken to ensure that mixing is continued until the
mass is uniform in colour and consistency. However, in such cases 10% more
cement than otherwise required shall have to be used without any extra cost. The
mixing in mechanical mixer shall be done for a period of 1.5 to 2 minutes. The
quantity of water shall be just sufficient to produce a dense concrete of required
workability for the purpose
c) Compacting:
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The concrete shall be rammed rapidly with heavy iron rammers to get the required
compaction and to allow all the interstices to be filled with mortar.
d) Curing:
After the final set, concrete shall be kept continuously wet, if required by ponding for
a period of not less than 7 days from the date of placement.
3.5 Reinforcement:
All the reinforcement bars shall be accurately placed in exact position shown on
the drawings and shall be securely held in position during placing of concrete by
annealed No.1 binding wire not less than 1 mm is size and by using stay block
ornately chair spacers, metal hangers, supporting wires or other approved devices it
sufficiently close intervals. Bars shall not be allowed to bag between supports nor
displaced during concrete of any other operation of the work. Reinforcement after
being placed in position shall be maintained in a clean condition until completely
embedded in concrete. Special care shall be exercised to prevent any displacement
of reinforcement in concrete already placed. To prevent reinforcement from
corrosion, concrete cover shall be provided as indicated on drawings.
Bars shall be bend cold to specified shape and dimensions or as directed, attain
proper radius of bends; Bars shall not be bent or straightened in a manner that will
injure the materials. Bars bend during transport of handling shall be straightened
before being used on the work. Unless otherwise specified for mild steel a `U' type
hook at the end of each bar shall invariably be provided to main reinforcement.
In case which are not round and in case of deformed bars, the diameter shall be
taken as the diameter of circle having an equivalent effective area. The cold twisted
steel bars shall be used or without hooks at the ends. Deformed bars without hooks
shall however, comply with relevant anchorage requirements.
Bars crossing each other where required shall be secured by binding wores
(annealed) of size not less than 1 mm in such a manner that they do not slip over
each other at the time of fixing and concreting.
As far as possible bars of full length shall be used. In case this not possible
overlapping of bars shall be done as directed. The overlaps shall be staggered for
different bars and located at points along the span where shear not bending moment
is maximum.
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When permitted or specified on the drawings joints of reinforcement bars shall butt
welded so as to transmit their full stresses. Welded joints shall preferably located at
points when 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
20 percent of the rods are welded. It shall be ensured that no viods are left in welding
and when welding is done in two or three stages, previous surface shall be cleaned
properly. Ends of the bars shall be cleaned of all loose scale, rust, grease, paint and
other foreign matter before welding. Only competent welders shall be employed on
the work.
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Gauge boxes for sand shall be of such dimensions that one bag containing 50 kg. of
cement forms one unit. The sand shall be free from clay, shale, loam, alkali and
organic matter and shall be of sound, hard, clean and durable particles. Sand shall
be as approved by the Employer’s Representative. If required by the Employer’s
Representative Sand shall be thoroughly washed till it is free of any contamination.
For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
conditions. Water shall then be added and mixing continued to give a uniform mix of
required consistency. Cement mortar shall be used within 25 minutes of mixing.
Mortar left unused in the specified period shall be rejected.
The Contractor shall arrange for tests on mortar samples if so required by Employer’s
Representative. Re tempering of mortar shall not be permitted.
All brickwork shall be in plumb and square/ circular unless otherwise shown on
drawing and true to dimensions shown. Vertical joints in alternate courses shall come
directly one over the other and be in line. Horizontal courses shall be leveled. The
thickness of brick courses shall be kept uniform. For walls of thickness greater than
230 mm both faces shall be kept in vertical planes unless otherwise specified. All
interconnected brickwork shall be carried out at nearly one level (so that there is
uniform distribution of pressure on the supporting structure) and no portion of the
work shall be left more than one course lower than the adjacent work. Where this is
not possible, the work shall be raked back according to bond (and not saw toothed)
at an angle not exceeding 45 degrees. But in no case the level difference between
adjoining walls shall exceed 1.25 M. Workmanship shall conform to IS: 2212.
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Brick shall be so laid that all joints are well filled with mortar. The thickness of joints
shall not be less than 6 mm and not more than 10 mm. The face joints shall be raked
to a minimum depth of 12 mm by raking tools daily during the progress of work when
the mortar is still green, so as to provide a proper key for the plastering to be done.
When plastering is not required to be done, the joints shall be uniform in thickness
and be struck flush and finished at the time of laying. The face of brickwork shall be
cleaned daily and all mortar droppings removed. The surface of each course shall be
thoroughly cleaned of all dirt before another course is laid on top. If mortar in the
lower courses has begun to set, the joints shall be raked out to a depth of 12 mm
before another course is laid.
Curing of plaster shall be started as soon as the applied plaster has hardened
enough so as not to be damaged. Curing shall be done by continuously applying
water in a fine spray and shall be carried out for at least 7 days.
Plastering with water proofing shall be done on inner face of brick masonry in cement
mortar (1:3) and 20 mm thick unless otherwise specified, as per IS only and cement
should be used SRC for inside plastering.
20 mm thick plastering in C.M. 1:3 shall be done on the outer face of brick masonry
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Plastering work inside of M H Chamber shall be carried out in two layers using SRC
grade cement, Water Proof, to the inner face, the first layer being 14 mm thick and
the second layer being 6 mm thick by using water proof compound as per I S
standard. The first layer shall be dashed against the prepared surface with a trowel to
obtain an even surface. The second layer shall then be applied and finished leaving
an even and uniform surface, trowel finished unless otherwise approved by the
Employer’s Representative.
3.12 Scaffolding:
For brick work in M.H., single scaffolding shall be permitted. In such cases, the inner
end of the horizontal scaffolding pole shall rest in a hole provided only in the header
course for the purpose. Only one header for each pole shall be left out. Such holes
for scaffolding shall, however, not are allowed in pillars/columns less than one meter
in width, or immediately near the skew backs of arches. The holes left in masonry
works for scaffolding purpose shall be filled and made good before plastering.
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The steps as per detail specification shall be fixed in the fashion narrated in drawing.
Cast iron steps shall be as per IS: 5455-1969. The steps shall be of grey cast iron of
grade 15 as per IS: 210. The steps shall be clean, well cast and they shall be free
from air and sand holes, cold shuts and wrappings. The portion of the step which
projects from the wall of the manhole shall have a raised checkered design to provide
an adequate non-slip grip. C.I. steps shall weigh not less than 5.30 kg each and shall
be of 165 mm x 385 mm overall dimensions. These steps shall be coated with a
black bituminous composition. The coating shall be smooth and tenacious. It shall not
flow when exposed to a temperature of 63°C and shall not be brittle as to chip of at
temperature of 0 °C.
Where the depth of invert of manhole exceeds 800 mm, steps of approved pattern
shall be fixed in the brickwork at the interval of 300 mm vertically and staggered at
380 mm horizontally centre to centre. Providing and fixing safety chain wherever
necessary as per the stipulations in the type design etc complete.
3.15 75 mm all round vata in C.M. 1:3 shall be provided at bottom of outer periphery of
masonry work over foundation concrete as per drawing.
4.2 Jointing:
Jointing of RCC pipes shall be done with SRC cement only and as per the
requirements of following specifications and as per the relevant IS. The type of joints
shall be as below. After jointing, extraneous material, if any, shall be removed from
the inside of the pipe and the newly made joints shall be thoroughly cured. In case,
rubber-sealing rings are used for jointing, these shall conform to IS 5382 and shall be
of such type as mentioned in IS-458:2003.
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case should it exceed the hydrostatic test pressure as specified in IS:458 (Latest
Edition).
Notes:
i) If any damage is caused to the pipeline during the execution of work or while
cleaning/testing the pipeline as specified. Contractor shall be held responsible for
the same and shall replace the damaged pipeline and retest the same at his own
cost to the full satisfaction of Engineer.
ii) Water for testing of pipeline shall be arranged by Contractor at his own cost.
ii) Pipes shall be brought on site proportionate to the required progress for Thirty days
only.
5.0 EXCAVATION :
Excavation for Sewer Collecting System and sewer manholes including all
safety provision using site rails and removing and spreading the excavated
stuffs directed with lead upto 90 M.
5.1 General
5.1.1 The excavation for trenches will generally, refers to open excavation for trenches in
true line and level and shall have the width and depth as shown in the drawings and
or as directed in wet / dry conditions for Sewer collecting System and sewer
manholes construction work.
5.1.2 The item includes Dewatering/Desludging of existing Soak pits with all safety
measures and precautionary measures for all lifts coming across the line passing
through Soak pits by using suitable capacity of sewage mud pumps and disposed off
all rubbish of all kind, bush, wood and trees shall be removed as directed by
Engineer-in-Charge.
5.1.3 The restoration of the public utilities , on alignment of the pipeline net work such as
telephone line, electric line , soak pit , septic tank , pipe line for soak pit & Septic
tank, gas line , etc shall have to be restored in original shape including replacement ,
repairing , with all material , and labor to the satisfaction of engineer in charge.
During the execution of water network pipe line, there will be various types of utility
services on the alignment which may be damaged. The contractor has to inform the
engineer in charge for all these utilities and take approval of the concerned Govt
Dept or its owner before damaging the same. During the execution it should not be
damaged. If in case it is required to remove these utilities to carry out the work
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5.5 Excavation:
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5.5.1 The excavation for the pipe trenches shall also include removal of all materials of
whatever nature and whether wet or dry condition necessary for laying of pipelines
exactly in accordance with alignment, levels grades and curves shown on the plans
or as directed by the Engineer-in-charge. Trenches shall be excavated to the exact
width and depth according to the size of pipe and the sides shall be left vertical as far
as possible or according to the angle of repose of various soils. Unless there is a
specific extra provision in the contract for shoring and strutting or for cutting side
slopes the contractor shall at his own cost do the necessary shoring and strutting or
cutting of slopes to the angle of repose or both approved by the Engineer-in-charge.
The contractor shall notify the Engineer before starting excavation to enable him to
take cross sectional levels for purpose of measurements before the ground is
disturbed. The bottom of the trenches shall be leveled both longitudinally and
transversely or slopped as directed by the Engineer. The contractor shall at his own
cost to remove such portions of boulders or rocks, as are rectified to make the
bottom of the trench level. No filling shall be allowed to bring the trench to level. If by
contractor’s mistake excavation is made deeper than shown on the plans and if
ordered by the Engineer the extra depth shall have to be made with selected
excavated stuff only with watering, ramming etc. as directed, by the Engineer and at
the cost of the contractor. Other hard excavation shall be cleared of all sorts including
loose materials and cut to firm surface, either level, stepped as directed by the
Engineer. The Engineer may order such changes in the dimensions and alignment of
pipe trench as may be deemed necessary to secure satisfactory cover over pipeline.
After each excavation is completed, the contractor shall notify the Engineer to that
effect and no laying of pipeline will be allowed to be laid until Engineer has approved
the depth and dimensions of trenches, level and measurements.
5.5.2 Excavation by the Use of Explosives
Unless otherwise stated herein, I.S. Specification “IS: 4081: Safety Code for Blasting
and related Drilling Operations” shall be followed. As far as possible all blasting shall
be completed prior to commencement of construction. At all stages of excavation,
precautions shall be taken to preserve the rock below and beyond the lines specified
for the excavation, in the soundest possible condition. The quantity and strength of
explosives used shall be such as will neither damage nor crack the rock outside the
limits of excavation. All precautions, as directed by Employer’s Representative, shall
be taken during the blasting operations and care shall be taken that no damage is
caused to adjoining buildings or structures as a result of blasting operations. In case
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exploded by drilling a fresh hole along the misfired hole (but not nearer than 600 mm
from it) and by exploding a new charge.
vi) A wooden tamping rod with a flat end shall be used to push cartridges home and
metal rod or hammer shall not be permitted. The charges shall be placed firmly into
place and not rammed or pounded. After a hole is filled to the required depth, the
balance of the hole shall be filled with stemming, which may consist of sand or stone
dust or similar inert material.
vii) Contractor shall preferably detonate the explosives electrically.
viii) The explosives shall be exploded by means of a primer, which shall be fired by
detonating a fuse instantaneous detonator (F.I.D) or other approved cables. The
detonators with F.I.D. shall be connected by special nippers.
ix) In dry weather and normal dry excavation, ordinary low explosive gunpowder may be
used. In damp rock, high explosive like gelatin with detonator and fuse wire may be
used. Underwater or for excavation in rock with substantial accumulated seepage
electric detonation shall be used.
x) Holes for charging explosives shall be drilled with pneumatic drills, the drilling pattern
being so planned that rock pieces after blasting will be suitable for handling without
secondary blasting.
xi) When excavation has almost reached the desired level, hand trimming shall have to
be done for dressing the surface to the desired level.
Any rock excavation beyond an over break limit of 75 mm shall be filled up as
instructed by Employer’s Representative, with concrete of strength not less than
M10. Stopping in rock excavation shall be done by hand trimming.
xii) Contractor shall be responsible for any accident to workmen, public or Employer’s
property due to blasting operations. Contractor shall also be responsible for strict
observance of rules, laid by Inspector of explosives, or any other Authority duly
constituted under the State and / or Union Government as applicable at the place of
excavation.
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from the area of the excavation. The method used shall be such as not to render
unstable or unsafe the portion, which was originally sound and safe.
Any material not requiring removal in order to complete the permanent works, but
which, in the opinion of Employer’s Representative, is likely to become loose or
unstable later, shall also be promptly and satisfactorily removed.
5.8 Protection:
The trenches shall be strongly fenced and red light signal shall be kept at night and
arrangement of watchman to prevent accidents should be done. Sufficient care and
protective measure shall be taken to see that the excavation shall not affect or
damage the adjoining structure. The contractor shall be entirely responsible for any
injury to life and damage to the properties etc. Necessary protection work such as
guide ropes, crossing places, barricades, caution boards etc. shall be provided by the
contractor.
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At the joints of pipes, the trench shall be excavated to an additional depth of 15 cm.
and width of 30 cm. And length of 15 cm. beyond the edge of collar on both the sides
or as directed. The rate include for such extra excavation made at the joints. The
trenches shall be excavated perfectly in straight line. The bottom of the trench shall
be kept as per invert level or as directed. To maintain the proper slope the usual
method of site rails and boning rods shall be adopted. The contractor shall have to
provide and fix and maintain sight rails and boning rods without any extra cost.
If the contractor fails or makes delay to give hydraulic test of the pipe line laid in any
of the section, without any genuine reason, he shall be responsible to get any part of
the length trenches refill in such case (i.e. before testing) for safety of pedestrian
and/or vehicular traffic as found necessary by the engineer-in-charge without any
extra cost. If found necessary and directed by the Engineer-in-charge, the contractor
shall have to excavate the refilled trenches, during hydraulic test without any extra
cost.
At all road crossings, trenches shall be excavated only for half width of the road and
pipe shall be laid. The other half shall be excavated only after back filling over the
laid pipeline is done so as to make it suitable for the traffic. The contractor shall
provide diversion when the pipeline is to be laid along the road as required and shall
maintain the diversion or any part of it, without any extra cost. At all road crossings,
the pipe shall be laid below the crest of road.
The contractor shall break the road surface by chiseling to the exact width and length
as shown on the drawing or as directed by the Engineer-in-charge.
The excavated stuff shall be deposited in uniform layers to avoid mixing with other
kind of materials at non-objectionable place or as directed by the Engineer-in-charge.
Where the trenches are excavated in soil, the filling from the bottom of the trench to
the level of the center line of the pipe shall be done by hand compaction with
selected approved earth in layers not exceeding 8 cm; backfilling above the level of
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the center line of the pipes shall be done with selected earth by hand compaction, or
other approved means in layers not exceeding 15 cm. in case of excavation of
trenches in rock, the filling up to a level 30 cm above the top of the pipe shall be done
with fine materials such as earth, murrum, etc. The filling up to the level of the
centerline of the pipe shall be done by hand compaction in layers not exceeding 8 cm
whereas the filling above the centerline of the pipe shall be done by hand compaction
or approved means in layers not exceeding 15 cm. The filling from a level 30 cm
above the top of the pipe to the top of the trench shall be done by hand or other
approved mechanical methods with broken rock filling of size not exceeding 15 cm
mixed with fine material as available to fill up the voids.
Filling of the trenches shall be carried out simultaneously on both sides of the pipe to
avoid unequal pressure on the pipe.
7.0 BEDDING :
Providing bedding incl. ramming, watering, consolidating etc.
1.1 The sand/granular material to be use for bedding shall be free from salts, organic or
other foreign matter. All clods of sand shall be broken.
1.2 As soon as the work in trench has been completed and measured the site of trench
shall be cleared of all debris, brick bats, mortar dropping etc. sand filled with sand in
layers not exceeding 20 cms. Each layer shall be adequately watered, rammed and
consolidated before the succeeding layer is laid. The sand shall be rammed with
iron rammers where feasible and with the butt ends of crowbars, where rammer
cannot be used.
1.3 The finished level of bedding shall be kept to shape intended to be given to
excavation.
1.4 The consolidation may be done by hand rammers, where so specified. The extent of
consolidation required shall also be as specified.
1.5 The sand / granular material shall be allowed to be used in bedding the trenches.
Under no circumstances black cotton soil be used for bedding.The available
excavated earth should be compacted in such a manner that rocky surface shall not
be observed.
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At Roads, Railway, public highways, at such other crossings as are shown in the
construction Drawings issued by the company the pipeline shall be installed in M.S.
casing pipes Conforming to the specifications given herein. The casing pipes shall be
installed in accordance with the details given in drawing And the casing, bushing and
insulators, etc., shall be installed on the carrier pipe as Detailed in drawings. Casing
pipe size shall be as per approved by appropriate authority to facilitate the insertion
of the sewerage pipe without disturbing the casing pipe and to provide adequate
drainage, Casing shall be installed with even Bearing throughout its length and shall
slope towards one end, as specified or desired by the engineer-in-charge. The ends
of the casing shall be sealed to outside of carrier pipe in accordance with the details
given in drawing. Before installation, holes for installing vent pipes shall be cut and
burrs if any shall be removed. The welding of both carrier pipe and casing pipe shall
be done in accordance with the welding specifications, given herein. Before installing
the casing Pipe, it should be cleaned of all internal obstructions and during
installation care Should be taken to keep the inside clean. The section of carrier pipe
to be placed in any casing shall be closed at each end, hydrostatically tested
preferably with dead weight tested for at least two hours. Only on successful
completion of this test, shall the carrier pipe section be inserted in the casing pipe.
The installation of casing may open cut as circumstances may permit or require as
directed by the engineer-in-charge. The installation of casing in bended section of the
carrier pipe shall be performed by meter bends of the casing pipe provided that the
length of each meter cut out of casing pipe shall be such as to provide a clearance of
at least 1-1/2" between the inside of the casing pipe and the outside of the coated
carrier pipe. Excavation for casing installation done if any shall be immediately
backfilled at the completion of the work with suitable solid matter and packed
thoroughly to prevent seepage of water into the excavation
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providing & fixing of required size of G.I/M.S pipe for railway premises as per
instruction of Railway authority & under supervision of Railway authority incl
Providing &supplying fixing of ISI make sluice valve of required size at both
side of railway boundary with construction of brick age pavement incl C;C;
1:3:6 encasing of pipe at both side Providing & fixing of M.S/Iron Manhole
frame with cover for valve chamber with locking arrangement etc. complete
with all material labour fabrication, hydraulic testing of pipe & valve etc
complete (45 mt Length). Note: The above rates are for 45 mt length for all
Road/Railway crossing, if crossing length is increased or decreased than
correction of Rs=(Rate of SOR)/45 per meter shall be + or - as per actual length.
At, and Road , Railway ,& canal crossings the work shall be performed to the
specifications Of local authorities or such public bodies as may be in charge (S) of
Roads, Railway and Canals to be crossed. In case, however the minimum
requirements of the governing agencies are less than Those set out in the drawing or
the specifications given herein, then the Requirements given in the drawings and the
specifications given for encased line Shall be followed. Whereas the casing pipe in
the case of encased line to be laid normal by boring, tunneling, engineer-in-charge
may at his discretion permit open-cuts to be made for the installation of casing
provided, however, that the TENDERER shall procure the necessary permit / license
for the same from competent authority. At locations wherein the open cut methods
are permitted, the TENDERER shall pass the carrier pipe through the casing located
in the trench after the approval of the engineer in charge in writing and care shall be
exercised to avoid damage to pipe coating and wrapping during this operation. The
TENDERER shall produce a certificate in writing from concerned authorities for its
satisfactory restoration and payment therefore. At all crossings the carrier pipe shall
be laid straight without bends so that if Necessary the pipe at a later date may be
replaced without cutting the casing. The Carried pipe shall extend at least 2 meters
beyond the end of casing pipe at either End. At Road crossings the TENDERER shall
eliminate unnecessary bending of pipe to Conform to the contour of ground by
gradually deepening the ditch at such Approaches as directed by the engineer – in -
charge. Where the installation of the Casing has been made by open cut
TENDERER shall install suitable
Temporary bridge Work ensuring the safety of the traffic aids and safeguards for
protection of the Public safety, or he shall provide suitable diversions as desired by
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the engineer in Charge. At all Roads, Railway pipeline crossings shall be bored with
horizontal boring machine. The method of carrying out a cased crossing by boring for
various crossings on this Pipeline route shall be jointly inspected by the
representative of the COMPANY and TENDERER for each category of work prior to
commencement of actual work. Pipeline under Road track and irrigation canal an
applicable portion of the right of way shall be encased in accordance with the
specification. This item of work shall include, necessary clearing and grading
required therefore, trenching to the depths and widths required, welding of casing
and carrier pipes, testing, lowering in, Installation of vent assembles, end seals,
insulator and all other fittings that may be Required, backfilling, clean up, complete
restoration to the original condition and Further strengthening and protective works
as may be required. The work shall be carried out in accordance with the drawings
and as directed by the engineer-in-Charge. For various operations mentioned above,
the specifications pertaining to these operations shall apply in addition to the
specifications given herein. The TENDERER shall be permitted to use William Sons
type Neoprene seals in place of concrete end seals for the crossings. The item shall
be procured by the TENDERER Himself as per the provisions under the appropriate
head of work in case TENDERER so desires. The representative of the COMPANY
may also be associated to determine the quality of the material and its delivery
schedule from the open market. However, the particular work defined under the
proper head shall not be delayed on account Of non availability of Neoprene end
seals. In such case, concrete seals may be provided. On both ends of pushing
concrete supports are to be provided as per direction of Engineer in charge.
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