emgf ms.pdf

Emaar MGF Land Ltd (North)

MS 01

WORK METHOD STATEMENT CONCRETE WORKS

0 0.1 21/03/08 QC Manager CEO (N)

Rev Issue Date Prepared Approved

MS 01 Emaar MGF Land Limited Concrete Works

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the activities for the construction of general reinforced concrete structures on site. More detailed / task specific method statements for the construction of specialized reinforced concrete structures may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose

The purpose of this work method statement is to ensure that;

• The concrete work done is according to standards and its procedures.

This is a draft document under continual improvement.


Issue 0.1

2.0 Construction Procedure

2.1 Setting Out

Setting out for the reinforced concrete structures will be carried out by the survey team on the completed and accepted formation.

All setting out will be based on the information contained on the most recent released approved construction drawings.

The setting out will be carried out from temporary and permanent benchmarks / Control points.

2.2 Blinding Concrete

Generally blinding concrete shall be 100mm thick unless specified otherwise.

Timber formwork cut to size may be erected and pinned to retain the blinding concrete and control the level. Large area pours may be carried out in sections or removable steel pins used to control the level of the concrete.

Blinding concrete shall be placed either by direct discharge via the truck chute or pumped. It will be placed and screwed to required level.

2.3 Reinforced Concrete Construction

The construction sequences for reinforced concrete structures shall be determined for each structure by Contractor and approved by Client. Pour sequences and construction joint layout shall be submitted separately as required.

2.3.1 Formwork

Reference: EMGF-MS-009

Formwork shall be constructed and erected in accordance with the work drawings issued for the structure.

Formwork shall be constructed to the exact sizes, shapes, lines and dimensions shown on the drawings and as required to obtain accurate alignment, location, grades, level and plumb of the finished structures.

Formwork shall be deemed to include all formers for openings, recesses, keyways, mouldings, chamfers, etc.

Chamfers (25mm) shall be installed at all exposed external corners.

The form panel (plywood) used shall be of an approved grade to achieve the required finishes.

Shutter release oil compatible with the concrete shall be used to aid striking of formwork and the preservation of the plywood surface finish. The shutter release agent shall be applied to the surface prior to erection.

All formwork shall be firmly propped and supported to prevent movement during and after concrete placement.



Issue 0.1

Striking of formwork shall be undertaken in a controlled manner as not to damage the concrete surface. Sequence of striking and striking times may be indicated on the temporary works drawings or as indicated in the following table.

T S

Ver , bea 1

Sof refi ) 3 days

Sof to beams (Props to be r 7 days

Pro

1. Spanni .5 m

2. Spanni

7 day

14 da

Pro

1. Spanning up to 6 m

2. S

14 da s

21 da

2.3.2 Reinforceme

Refe

ll be received and controlled in accordance einforcement Supply (MS-003).

IS: 1786 - 1985.

proved by Client. All cut and bent

visually inspected for cracks.

s and where necessary steel chairs or supports

strength grout. Heavy duty spacer pads or bars and steel chairs shall also be made on site to support the larger reinforcing steel mats.

ype of Formwork tripping Time

tical formwork to columns, wallsms 6 - 24 h

fit formwork to slabs (Props to bexed after removal of formwork

fit formworkefixed after removal of formwork)

ps to slabs:

ng up to 4

ng over 4.5 m

s

ys

ps to beams & arches:

panning over 6 m

y

ys

nt

rence: EMGF-MS-003

All reinforcement delivered to site shawith Method Statement for R

Each delivery shall be accompanied by the delivery docket, mill certificate and manufacturer’s certificate.

Samples shall be taken from each rebar delivery (from each bar size) and sent for testing for compliance with

Reinforcement steel shall be cut and bent on site in accordance with the bending schedules generated by Contractor and apreinforcement steel shall be tagged indicating size, shape code, structure and bar mark.

Dimension of bent steel shall be randomly checked by the site engineer and bends shall be

Reinforcement steel shall be fixed in position using binding wire (16 / 20 guage) and supported using concrete spacer blockto ensure sufficient is achieved.

Spacer blocks of the required size, shape, and texture will be manufactured on site using grade 40 concrete or high



Issue 0.1

2.3.3

fixed and supported on the shutters or by the

of concrete. Bolt

not to be subjected to welding.

2.3.4

it to Client

y batching plants and delivered to site in concrete agitator

aily basis.

rs in advance of the pour, then confirmed on the

creting a pre-pour inspection shall be carried out to check cleanliness,

e used to place concrete

ii. Using a static or truck mounted concrete pump.

Concrete shall bis not exerted on the shutters and that cold joint do not form.

Testing to c in site or approved

using electric or motor

ibrators shall be available in the event of a breakdown.

Cast In Items

All cast in items shall be supplied and fixed either during the fixing of the reinforcement steel or attached to the shutters prior or after erection.

Cast in items shall be securelyreinforcement steel.

Any openings in cast in items shall be taped over to prevent ingress threads will also be covered.

Hold down bolts are

Hold down bolts to be install using predrilled surface mounted template.

Concreting

Contractor shall get the mix design done from an approved lab and submfor approval.

Concrete shall be supplied btrucks / or pumped through direct pipe. Correction for moist aggregates shall be applied on a d

Batching by volume is not allowed.

Batching plant and/or weigh batchers shall be calibrated as per pre-approved frequency.

Concrete shall be pre-ordered 24 houday of the pour with the delivery time, quantity and grade.

Prior to conreinforcement steel, formwork, false work, cast in items and dimensions.

Following methods or a combination of methods may bdepending on access, volume of pour, conditions at the time and the structure being poured.

i. Direct discharge from the truck. (Maximum permissible free fall of concrete is 1.5m).

e placed in a controlled manner and rate to ensure that undue pressure

be onducted on concrete in Contractor Lab situatedexternal lab as per standards.

Once placed, concrete shall be consolidated / compacted driven vibratory pokers of a size comparable to the pour (either 40, 60 or 75 mm) and the amount of access. Spare vVibrators shall not be used to displace the concrete horizontally.



Issue 0.1

Exposed concrete surfaces shall be finished using equipment suitable to produce the required finish.

2.3.5

f rain must always be considered when preparing for concrete pours. by the Contractor’s Project Engineer. If continuous heavy

e concrete pour.

ffect the pour.

concrete trucks is maintained at

to the

andle the incoming volume of

with tarpaulins (or similar) to protect the surface.

2.3.6

edure IS: 7861 (Part I) –

mal concrete.

ding 32oC, the exposed areas shall be covered by tarpaulins, or

Wet Weather Working

The possibility oA forecast is to be obtainedrain is forecast, consideration must be given to delaying the pour until the weather pattern improves.

Tarpaulins, plastic and/ or hessian must be available in quantities to be able to cover the entire area of th

Additional water pumps or vacuum cleaners should be available to assist in keeping the water level at a level so as not to a

Wet weather gear must be available for all personnel working in the pour.

Plant must be available to ensure that access for the all times, especially on the ramps into excavations.

In the event of rain occurring during a pour the live faces of the layers of concrete shall be kept as close as possible to minimize the exposed horizontal concrete rain. Where possible the pour rate shall be slowed, particularly considering the life of the concrete should increase due to the moisture in the air. Always free water in forms shall be blown to the edge of the pours and removed.

In an extreme case were the base of the pour is inundated because either the dewatering pumps fail or the sump pumps can not hwater, the pour will continue. The concrete must be discharge behind the lower face at all times and never into water. The concrete is then vibrated forward, displacing the water.

As soon as practical and no later than when the pour achieves initial set it will be covered

Hot Weather Working

During hot weather, concreting shall be done as per proc1975.

The maximum temperature of fresh concrete is limited by the specification to 32oC for nor

Where weather conditions will result in surface temperatures of the reinforcement and soffit materials exceeshaded. Additionally if required the outside of the formwork can be cooled by wetting with cold water and the reinforcement and blinding can be kept damp using fine mist sprays. Where water is used, it must be ensured that the free water is removed from the blinding prior to covering with concrete. Where water is to be used, it needs to be used prior to materials getting too hot otherwise increased humidity may occur.



Issue 0.1

The concrete mixed temperature at discharge from the concrete agitator truck shall not exceed 32oC. The Lab technician shall check and record the concrete temperature

cold joints to develop. Where exposed faces of concrete are left for a

enerally

g fine mist sprays. Where mist sprays are used, free

2.3.7

ure IS: 7861 (Part II) –

2.3.8 Concrete Inspection and Curing

efects if e initial setting of concrete.

lended cement

spraying shall continue at regular intervals to avoid the

ocouples shall be monitored on a regular

each time a slump test is taken. If the concrete temperature exceeds 32oC at the point of placement, it shall be rejected. During the pour, concrete placement temperatures are to be regularly reported back to the Concrete Batch Plant even if the temperature is below 32oC.

The live faces of the layers of concrete shall be kept as close as possible to minimize the potential forperiod, the face must be rejuvenated prior to continuing dispatch of concrete.

Careful consideration must be made to the drying effects of hot weather and its likely effect on causing excessive cracking in the finished concrete surface. Gthough the high humidity often present in tropical areas will mean this is not an issue unless strong wind is present.

Should moisture loss be an issue, consideration shall be made to keeping intermediate layers of concrete moist usinwater is not permitted to be formed on the surface handover.

Hot Weather Working

During hot weather, concreting shall be done as per proced1981.

Concrete shall not be done when temperature falls below 4.5 degree Celcius.

Post

Post concreting inspection shall be done for dimension of formwork and dany remedial measures will be taken befor

Curing shall be done for at least 7 days from the date of placing concrete when OPC is used and at least 10 days when mineral admixture (like fly ash) or bis used. In dry and hot weather conditions the above duration shall be increased to 10 and 14 days respectively.

Curing shall be carried out by thoroughly wetting the concrete surface then covering with wet hessian. Water concrete surface becoming dry. For raft areas & slabs pond curing shall be followed.

Where necessary to protect the finish to the concrete surface the wet hessian will be supported off the surface of the concrete.

Where necessary (thick concrete slabs) thermocouples shall be installed (by attaching to the rebar) prior to concreting. The thermbasis during curing to ensure there is no temperature differential within the concrete.



Issue 0.1

3.0 Formats

S No. Number Description 1 EMGF-QA-001A Witness Point Notification 2 EMGF-ITP-001A Testing Frequency 3 EMGF-ITP-001B Pour Card 4 EMGF-ITP-001C Post Pour Inspection 5 EMGF-ITP-001D Compressive Strength of Concrete 6 EMGF-ITP-001E Sieve Analysis – Coarse Aggregates 7 EMGF-ITP-001F Sieve Analysis – Fine Aggregates 8 EMGF-ITP-001G Bar Bending Schedule



Issue 0.1

4.0 Storage and Handling

• All bent reinforcement steel shall be tied in bundles for easy lifting. • Reinforcement steel bundles shall be lifted using suitable slings. • Individual bars shall be manually lifted carried and lowered correctly by the workers. • Spacer blocks shall be stored under cover on timbers. • Spacer blocks shall be carried in boxes or sacks. • Timber and plywood should be delivered in packs. • Timber and plywood shall be off loaded and stacked by crane or forklift. • Shutter release oils retarder shall be stored in containers.


EMGF-ITP-001 A

S. No. Description Test Test Method Minimum Frequency Specified ValueGradation IS: 2386 Part - 1 One test per 50 m3 As requiredAggregate Crushing Value Aggregate Impact Value

IS: 2386 Part - 4 Once for each source of supply subsequently on monthly basis.

Less than 45 %

Soundness IS: 2386 Part - 5 Once for each source. 12 % when tested with Sodium sulphate and 18 % when tested with magnesium.

Deleterious Materias IS: 2386 Part - 2 Once for each source. Max. 5 %Specific gravity IS: 2386 Part - 3 Once for each source. As requiredWater Absorption IS: 2386 Part - 3 Once for each source. Max. 2 %Flakiness Index IS: 2386 Part - 1 Once for each source. Max.35 %Alkali Aggregate reactivity IS: 2386 Part - 7 Once for each source. Should be InnocuousFine Particals in free state Once for each source. Should be less than 1 %Gradation IS: 2386 Part - 1 One test per 50 m3 As requiredSilt Content IS: 2386 Part - 2 One test per 50 m3 Less Than 8 %Moisture Content IS:2720 Part - 2 Regularly As requiredDeleterious Materias IS: 2386 Part - 2 As required Max. 5%Freshness of cement Per lot Not older than 3 months when in useAge w.r.t date of receiving Per lot Not older than 3 months when in useTest Certificates from manufacturer accordence to IS 8112

Per lot Certificate Should be available with each & every lot from manufacturer.

Physical Testing Limits as per related IS.Fineness by dry sieving IS:4031-1 Per lot Supported by MTC/As required Limits as per related IS.Soundness IS:4031-3 Per lot Supported by MTC/As required Limits as per related IS.Consistency Test IS:4031-4 Per lot Supported by MTC/As required Limits as per related IS.Intial and Final setting time IS:4031-5 Per lot Supported by MTC/As required Limits as per related IS.

Compressive strength IS:4031-6 Per lot Supported by MTC/As required Limits as per related IS.Chemical TestingLoss of ignition, Percentage by mass

IS 4032 : 1985 Per lot Supported by MTC/As required Limits as per related IS.

Magnesia (MgO),Percent by mass


Sulphuric anhydride (SO3),Percentage by mass


Insoluble material percent by mass


QUALITY CONTROL TESTS AND THEIR MINIMUM FREQUENCY

Coarse Aggregate for Concrete

1

3 Cement

2 Fine Aggregate for Concrete

1 Rev. 0.2

EMGF-ITP-001 A

S. No. Description Test Test Method Minimum Frequency Specified Value


Volume of 0.02 Normal Naoh required IS:3025 part 22 to neutralize 100 ml of water using phenolpththalein as indicator

IS:3025 Part:22 Once for Each source. 5 mg/l

Volume of .02 normal H2so5 required to neutralized the 100 ml of water,Using mixed indicator

IS:3025 Part:23 Once for Each source. 25 mg/l

Organic IS:3025Part 16 Once for Each source. 200 mg/lInorganic- IS 3025 Part 18 Once for Each source. 3000 mg/lSulphates IS 3025 Part 24 Once for Each source. 400 mg/lChlorides IS3025(Part-32) Once for Each source. 500 mg/lSuspended matter IS3025 (Part 1) Once for Each source. 2000 mg/lPH value Once for Each source. Not less than 6

5 Admixture MTC/Third Party IS:9103:1999 Per lot As per IS:9103:1999Free from pitting,Loose Rust,Mill Scale, Oil, Grease, Paint, or any material which impair the bond

Visual Each Supply Material should be free from these defects

Physical TestingWt. per mts (kg) IS:1786-1985 As Required As per limits of IS 1786 or 11390.2 % Proof Stress N/mm2 IS:1786-1985 As Required As per limits of IS 1786 or 1139

Tensile Strength N/mm2 IS:1786-1985 As Required As per limits of IS 1786 or 1139Elongation % IS:1786-1985 As Required As per limits of IS 1786 or 1139Bend Test IS:1786-1985 As Required As per limits of IS 1786 or 1139Re-Bend test IS:1786-1985 As Required As per limits of IS 1786 or 1139Chemical TestingCarbon % IS:1786-1985 As Required As per limits of IS 1786 or 1139Sulphur % IS:1786-1985 As Required As per limits of IS 1786 or 1139Phosphorous % IS:1786-1985 As Required As per limits of IS 1786 or 1139Sulphur & Phosphorous % IS:1786-1985 As Required As per limits of IS 1786 or 1139

4 Water

6 Steel

Total solids

2 Rev. 0.2

EMGF-ITP-001 A



Slump Test IS:1199-1959 Batching plant site intially when work starts. Subsequently sampling may done from alternate dumpers.

As required

Temperature Daily Not less than 5 degree C, & not more than 32 degree C.

Stregth of concreteSample for 7 days IS : 516 - 1959 One sample for each pour Only for relationship between 7 days

and 28 days stregthSample for 28 days testing

IS : 516 - 1959 One sample for 1-5 m3 As required

Two sample for 6-15 m3 Three Samples for16-30 m3

Four Samples for31-50 m3

5 1 and above four plus oneadditional samplefor -each additional50 m3 or part thereof

8 Mortars Compressive strength IS:2250 one sample for every 2 cubic meter of mortar, minimum 3-samples for a day work

As per IS:2250

Concrete 7

3 Rev. 0.2

EMGF-ITP-001 B

BUILDING REF.: LOCATION: POUR No.:

DATE:

GRID: GRADE OF CONCRETE / SOURCE:

S No Yes No Remarks

1 Drawing status "Good for Construction"

2 Excavation / Slab level

3 Formwork level / line / verticality / position

4 Starter bar/lap location / level

5 Rebar dimension (dia, length), shape, number

6 Rebars securely tightened/bound by tie wires

7

8 Gap for vibrators

9 BBS checked, marked off and attached

10 Forms made from approved materials

11

12 Cleanliness

13 Release oil application

14 Blockouts / openings

15 Form Tightness/Sealing

16 Staging for labor access

17 Waterstop

18 Embedded items position/level/dimension

19 Cover to rebar

20 Molding strip position/dimension

21 Concrete finish level mark

22 Construction joint preparation / make wet

23 Form ties/separators/shoring supports

24 Concrete pump & pipes condition

25 Hopper / Chutes

26 Vibrator-nos., condition

27 Sleeve/sunny hose position and clearance

28

2930

/ /Contractor Engineer / /EMGF Site Engineer

During Concrete Check1 Approved mix design used

2 Slump checked complies with

34

Post Concrete Check1 Approval of striking the formwork is given2 Surfaces free from seggregation, cracks or any deformity3 Concrete Surfaces is in line and level as per drawing4

This Lot CONFORMS* / DOES NOT CONFORM# to the Contract requirements *delete one # Nonconformance Report No.: __________ .

Prepared by : (Contractor Engineer)Date

Approved by : (EMGF Site Engineer)Date

Approved by : (EMGF Construction Manager)Date

Formwork alignment/verticality/plumbness

No.and condition of scoops, floats, rakes, finishing screeds, etc.

Lighting arrangementMaterials for curing (e.g. curing mat / compound)

Name

Cube sampling done

Name

Curing arrangements are sufficient

Rebar surface free from rust, mortar, grease, oil, dirt, etc.

POUR APPROVAL GIVEN

EMAAR MGF LAND LTD

Description

Name

Temperature checked

Concrete Pour Card

REQUEST FOR INSPECTION

EMGF-ITP-001 D

: EMAAR - MGF

Location / Source : Date of Casting :

Location : Casted By :

Structure : Date of Testing :

Grade of Concrete : Concrete Quantity :

WPN No. : Ref. No. :

Length Width Height Individual Average

1

2

3

4

5

6

7

8

9

10

11

12

Remarks :

Contractor EMAAR - MGF

Represenative Represenative

EMAAR MGF LAND LIMITED

Name of ProjectName of Client Name of Contractor

COMPRESSIVE STRENGTH OF CONCRETE(As Per IS: 516)

OBSERVATIONS

SignatureFailure

Load KN

Size mmCompressive Strength

N/mm2S.

No.

Iden.

Mark

Volume

(cc)

Weight

(gm)

Density

(gm/cc)

Date of

TestAge Days

EMGF-ITP-001 E

Name of Project

Name of Client : EMAAR - MGF

Location/ Source :……………… Date of Sampling :………………

Location :……………… Sampled By :………………

Material :……………… Date of Testing :………………

Type of Agg. :………………

WPN No. :……………… Ref. No. :………………

Sieve Size (mm) Weight Retained

(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

63.00 mm

40.00 mm

20.00 mm

16.00 mm

12.50 mm

10.00 mm

4.75 mm

2.36 mm

Pan

Remarks :



OBSERVATIONS


:

SIEVE ANALYSIS OF COARSE AGGREGATE FOR CONCRETE (As Per IS: 2386 Part - 1)

EMGF-ITP-001 F

Name of Project

Name of Client : EMAAR - MGF




Type of Agg. :………………

WPN No. :……………… Ref. No. :………………


(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

10.00 mm

4.75 mm

2.36 mm

1.18 mm

600 mic.

300 mic.

150 mic.

Pan

Finess Modulus

Remarks :



Material Passing 75 micron

OBSERVATIONS


:

SIEVE ANALYSIS OF FINE AGGREAGTE FOR CONCRETE (As Per IS: 2386 Part - 1)

EMGF-ITP-001G

PROJECT NAME : DATE SCHEDULED :

PART of JOB / LOCATION : SCHEDULE No.

DRAWING Ref . : DATE REQUIRED ONSITE :

S # Shape of Bar Bar Mark

Dia of Bar

No of Bars

No of Member

Total No of Bars

Cut Length (Mts)

Bar Dia in mm :Total Length in Metres 'Dia Wise' :

Total Weight in MT :Grand Total in MT :

Name :

Date :

Signature :

dd-mm-yyyy

0

PREPARED

dd-mm-yyyy

VERIFIED


Bar Bending Schedule

Description / Item Remarks


MS 02

WORK METHOD STATEMENT CONCRETE SUPPLY

0 0.1 21/03/08 QC Manager CEO (N)


MS 02 Emaar MGF Land Limited Concrete Supply

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the activities for the construction of general reinforced concrete structures on site. More detailed / task specific method statements for the construction of specialized reinforced concrete structures may be developed as additional sections to this method statement as the need is identified.



Issue 0.1

2.0 Procedure

2.1 Approval of Concrete Mix Design

For all the grades of concrete, the Contractor shall get the design mix approved by the client before commencing the work. If the Contractor opts for RMC, its QC engineer/ material engineer should visit the plant and should check the following aspects:

• Batching records • Material storage conditions

The material engineer should check and get satisfied with the adequacy of the plant to carry out the testing of the material required for the concrete raw material (i.e. tests related to cement, sand, aggregates etc.)

The QC engineer / material engineer should visit the plant randomly during the course of the work.

2.2 Ordering Concrete

The order for the concrete i.e. quantity, grade of the concrete, time and place of concrete should be confirmed by the site supervisor /foreman one day advance to the site engineer.

Site engineer should confirm the quantity and grade as per drawings and specifications and then summarize and forward the concrete order. Any changes in the pour programme should be conveyed to the Client.

2.3 Sampling and testing of the concrete

- The supervisor / foreman should check the pre pour preparations as per EMGF-MS-001 - Concrete works.

- On the arrival of concrete truck the supervisor should check the delivery docket and confirm the concrete order for its grade and quantity.

- Before pouring the concrete the slump test should be carried out as per frequency determined in the ITP.

- Delivery notes for each batch of concrete shall be maintained by the respective site engineer using approved format.

- A set of concrete cubes should be cast as per the predetermined frequency with the proper identification marking. The supervisor / foreman should ensure that the cubes cast should be kept in water for curing. The Lab manager shall conduct slump tests and prepare the required number of cubes and cylinders.

- The results of laboratory testing and a monthly report shall be submitted to the Client. - Generally the cubes are tested for 7th and 28th day’s crushing strength and should be witnessed by client. The testing requirements should be in line with the relevant IS codes and the specifications of the project. Notification of Inspection shall be issued to client 24hrs prior to lab test. The slump test results and cube register should be maintained.



Issue 0.1

3.0 Conformance Criteria

The test method of material should be as per the following IS codes:- 1 Sieve Analysis of Coarse Aggregate for Concrete IS: 2386 Part-1 2 Sieve Analysis of Fine Aggregate for Concrete IS: 2386 Part-1 3 Blending of Aggregate for Concrete IS: 456-2000 4 Specific Gravity and Water Absorption for Aggregate IS: 2386 Part-3 5 Aggregate Impact Value IS: 2386 Part-4 6 Aggregate Crushing value test IS: 2386 Part-4 7 Flakiness and Elongation Index Combined IS: 2386 Part-1 8 Compressive Strength of Concrete IS: 516



MS 03

WORK METHOD STATEMENT REINFORCEMENT

0 0.1 21/03/08 QC Manager CEO (N)


MS 03 Emaar MGF Land Limited Reinforcement

Issue 0.1

1.0 Introduction

1.1 Scope

This method statement describes the cutting and bending of reinforcement for Mohali Integrated Township Project. This method statement shall be read in conjunction to the method statement EMGF-MS-001-Concrete Works.



Issue 0.1

2.0 Procedure

2.1 General

The limits of this procedure are to cover the works in the reinforcement fabrication yard and the delivery of the reinforcement to the work area. Reinforcement will be installed in accordance with EMGF-MS-001–Concrete Works.

2.2 Delivery of Reinforcement

All reinforcement shall be procured from sources approved by Client. The reinforcement will be delivered to the on-site fabrication yard and stored clear of the ground to prevent damage and accumulation of dirt and excessive rust. A delivery docket and mill certificates shall be supplied with every delivery of reinforcement to the on-site fabrication yard and the certificates shall be verified by the Materials Engineer to ensure they comply with the specification and the information on the tags attached to the bundles. No delivery will be accepted without these documents. Prior to fabrication of reinforcement, samples shall be taken from each batch of each size of each delivery and tested for compliance in accordance with IS1786. Only reinforcement bars with their ends painted green can be used for fabrication. The quality documentation (including delivery docket, mill certificates and sample test certificates) shall be collated for all reinforcement used in the project.

2.3 Cutting and Bending Reinforcement – General Requirements

Reinforcement is to be cut and bent in accordance with IS 2502, unless otherwise noted and shall only be cut or bent as shown in the reinforcing schedules that are supplied by the schedulers, or as otherwise approved for use. Reinforcement shall be bent on bar bending machines and should be to the specified dimensions and within the allowable tolerances, complying with IS 2502. Bars shall not be cut by oxy-acetylene torch unless approved by the Client. Reinforcement is not to be bent or straightened in a way that will injure or fracture the material. All bars are to bent cold, unless the Client gives approval to bend otherwise. Heating of reinforcement for bending should only be done when the Client approves the operation. Procedures shall be formulated for this operation. When significant numbers of bars are to be bent alike, the first bar is to be checked before others are bent. Where it is necessary to reshape steel previously bent, the Client’s approval should be obtained, and each bar should be inspected for signs of fracture. Any reinforcement which, in the opinion of the Materials Engineer by physical & visual inspection, unfit for use, shall not be used. All reinforcement shall be free from loose mill scales, loose rust, and coats of paints, oil and mud.



Issue 0.1

2.4 Cutting and Bending Reinforcement – Procedure

Contractor shall prepare a Bar Bending Schedule and submit to Client for approval.

The reinforcement scheduler shall produce the schedules from the ‘Good for Construction’ drawings and shall ensure bar size, shape codes and dimensions are correct. This shall be re-checked at each new revision of ‘For Construction’ drawings.

Prior to fabricating reinforcement, a ‘Bar Bending Schedule’ form EMGF-ITP-001G shall be completed by the Contractor’s Engineer. The relevant schedule of instruction shall be attached to the form and given to the Reinforcement Shop Supervisor for action.

Following completion of fabrication, the Reinforcement Shop Supervisor shall attach bundle tags to all bundles. The following information is recorded on the bundle tag.

o Shape of bar o Bar Diameter o Cut Length o No of Member o Total Length o Location code / Building Gridline (e.g. A / 1-2)

Batches of cut lengths shall be transferred, together with their tags, to the bending area. Bars shall bent to the dimensions on the schedule. The main bending machine is manually fed. The dimensions are controlled manually by the operator. The correct pin must be selected by the operator to match the bar size.

After bending, bars are bundled, tagged and stored in a lay down area adjacent to the onsite fabrication yard until delivery to the construction site is required. The size of bundles shall be planned based on weight and location of use.

2.5 Binding of Reinforcement

• Contractor shall ensure that samples were taken from each rebar delivery (from each bar size) and sent for testing for compliance with IS: 1786 – 1985.

• Client’s representative shall ensure that steel has been tested. • Lap lengths shall be as mentioned on GFC drawing. • Joggling of steel is not allowed. • Laps shall be staggered as per relevant BIS code. • While casting slab, proper steps shall be taken to ensure that the column

reinforcement stays straight. • Reinforcement steel shall be fixed in position using binding wire (16 / 20 gauge). • Reinforcement steel shall be supported using concrete spacer blocks and where

necessary steel chairs or supports to ensure sufficient is achieved. • Dimension of bent steel shall be checked by the Contractor and verified by Client

randomly and bends shall be visually inspected for cracks. • Welding of reinforcement is not allowed. In special cases, Client’s approval is

required. Structural Engineer shall be consulted while permitting welding.



Issue 0.1

2.6 Testing of Steel

Following tests shall be conducted by the Contractor.

Free from pitting, Loose Rust, Mill Scale, Oil, Grease, Paint, or any material which impair the bond

Visual Each Supply

Physical Testing Wt. per mts (kg) IS:1786-1985 0.2 % Proof Stress N/mm2

IS:1786-1985

Tensile Strength N/mm2

IS:1786-1985

Elongation % IS:1786-1985 Bend Test IS:1786-1985 Re-Bend test IS:1786-1985

As per IS 1786

Chemical Testing Carbon % IS:1786-1985 Sulphur % IS:1786-1985 Phosphorous % IS:1786-1985

Steel

Sulphur & Phosphorous %

IS:1786-1985

As per IS 1786



MS 04

WORK METHOD STATEMENT CONCRETE WORKS

0 0.1 21/03/08 QC Manager CEO (N)



Issue 0.1

1.0 Introduction

1.1 Scope

The method statement outlines the procedure to execute soil stabilization by spreading dry lime on the original ground.

Soil stabilization occurs when lime is added to a reactive soil to generate long-term strength gain through a pozzolanic reaction.

Benefits of soil stabilization include:

• Substantial increases in resilient modulus values.

• Very substantial improvements in shear strength.

• Continued strength gain with time, even after periods of environmental or load damage.

• Long-term durability over decades of service even under severe environmental conditions.



Issue 0.1


2.1 Setting Out

Survey level pegs will be installed for the first layer of subgrade.



2.2 Testing

• IS: 1514-1059 or IS: 712-1964 Lime shall be tested to determine its chemical properties at rate of one test per 5 tonnes.

• IS: 2720 (Part II)-1973 at rate of one test per 250 m2 Moisture content prior to compaction to be determined.

• IS: 2720 (Part XXVIII) every 500 m2 Dry density of compacted layer should be tested.

• IS: 2720 (Part XVI)-1 079 CBR Test of mixed material to be carried out every 3000m3.

2.3 Trial Patch

A trial patch of l00 m shall be tested jointly with Client to demonstrate the methodology and to confirm the amount of lime to be mixed with the soil.

2.4 Placing of Lime on Suitable Fill

• Upon surface preparation, suitable embankment / subgrade materials will be laid in 250mm layers.

• Dry lime will be added onto the fill area by the using a truck mounted mechanical spreader.

• The surface with lime will be scarified with a power rotavator which is attached to a 4 wheel drive tractor. Mix to be tested for lime content.

• Moisture is added accordingly with the tractor mounted vacuum water tank.

• Level pegs will be installed to enable the grader to level the ground again for compaction.

• A 13T ton vibratory roller will be used to achieve the compaction of not less than 95% for embankment and 97% for subgrade in accordance with IS:2720 (Part VIII).

• Mini roller (2T capacity) will be used to compact edges and behind structures.



Issue 0.1

• The moisture content at compaction shall neither be less nor be more than 2% ofthe optimum moisture content.

• Field density & CBR tests will be carried out jointly with the Client.

2.5 Placing of Lime in the Rain

• During light rains, lime spreading, mixing, and compaction can continue normal operation.

• The lime treated layer is largely impervious to moisture and it sheds rainwater similar to a paved road, so we will be able to work on the layer shortly after a heavy rain



MS 05

WORK METHOD STATEMENT BRICKWORK

0 0.1 21/03/08 QC Manager CEO (N)


MS 05 Emaar MGF Land Limited Brickwork

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of work required for carrying out brickwork on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The brickwork done is according to standards and its procedures.



Issue 0.1

2.0 Procedure

2.1 General

• ‘Good for Construction’ drawings shall be available.

• Construction material (cement, sand, water and bricks) should be from approved source.

2.2 Construction Material

• Bricks shall conform to IS 1077: 1991.

• Mortars for masonry shall be prepared in accordance with IS-2250:1981.

• Sand shall conform to IS 2116: 1980.

• Water used for mortar shall be potable (clean and free from deleterious material). Reference to IS 456:2000 may be made for limits of deleterious material.

• Mild steel reinforcement shall conform to IS 432: 1982.

2.3 Preparatory Works

• Bricks shall be saturated by soaking for at least 1 hour.

• The surface on which the brickwork has to rest shall be free from dirt / deleterious material.

• Pour water on the surface to clean and saturate.

• Concrete surface shall be hacked for proper key / bonding.

• Reference level shall be marked on columns, walls.

• Bricks with flaws shall not be used.

2.4 Construction

Reference: IS 2212: 1991 Brickwork – Code of Practice

• A mortar layer of specified thickness shall be placed above concrete surface as a base course of the bricks.

• Contractor shall get the layout and levels verified from the Client.

• Mortar mix (cement: sand) shall be as per GFC drawing.

• Mixing shall be done using a site concrete mixer.

• Batching shall be done using pre-fabricated wooden boxes.

• Bucket of known volume shall be used to measure water.

• A systematic bond shall be maintained.

• Bricks shall be placed with ‘frog’ on top.



Issue 0.1

• Mortar thickness shall be 8-12mm thick. Further the thickness of the bed joints shall such that four courses and three joints taken consecutively shall measure equal to four times the actual thickness of the brick plus 3 cm.

• No part of a wall, during its construction shall rise more than 1.0m above the general construction level, to avoid unequal settlement and improper joints.

• Height of lift shall be limited to 1.5m in any one day.

• The walls shall be taken up truly in plumb of true to the required batter where specified. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. Vertical joints in alternate course shall come directly over the other. Care shall be taken to keep the brickwork within the following permissible tolerances:

Deviation from vertical within a storey shall not exceed 6mm per 3m height.

Deviation from position shown on plan of any brickwork shall not exceed 10 mm.

• Damp proof course shall be consist of flexible material like tar or bitumen, or of a layer of dense concrete – as mentioned in GFC drawing.

• All conduits, concealed items shall be placed as per drawing.

• In case of thick walls (2 brick thick and more), the joint shall be grouted at every course in addition to bedding and flushing with mortar.

• As far as possible services should be planned with the help of vertical chases. Horizontal chases should be avoided. The depth of vertical chases and horizontal chases shall not exceed one third and one sixth of the thickness of masonry respectively. Vertical chases should not be closer than 2m in any stretch of a wall. These shall be kept away from bearings of beams and lintels. No chase shall be permitted in half brick load bearing walls.

2.5 Half Brick Masonry

• For half-brick partitions to be keyed into main walls, indents shall be left in the latter.

• The walls shall be reinforced with 2 No. 6 mm diameter mild steel round reinforcing bars laid and embedded in mortar at every third course. Such reinforcements shall be embedded in concrete columns or masonry walls at ends by length of 300mm (12").

2.6 Fixing of Frames

• Holdfast of adequate size and sufficient strength shall be either embedded in brickwork or later chases filled up with concrete.

• Iron holdfasts shall be coated with bitumen to avoid corrosion.

• Woodwork faces in contact with brickwork shall be coated with preservatives to avoid attack from insects and termites.



Issue 0.1

• Fixing of steel door and windows shall be done in accordance with IS 1081: 1960.

• Fixing of timber door and windows shall be done in accordance with IS 4913: 1968.

2.7 Curing

All brickwork shall be cured with water by keeping it moist for 7 days for proper development of strength.



Issue 0.1

3.0 Formats

EMGF-ITP-005 A - Frequency of Testing EMGF-ITP-005 B - Brickwork Inspection Card


EMGF-ITP-005 A

Emaar MGF Land Limited

Frequency of Testing Burnt Clay Bricks

Sampling Criteria - IS: 5454 -1978

S. No. Test Description BIS Code Frequency Acceptance Criteria

1 Dimensions IS 1077 - 1992 upto 10,000 – 20 bricks 10,001 – 35,000 – 40 bricks 35,001 – 50,000 – 60 bricks

Tolerance given in IS 1077-1992

2 Crushing Strength IS: 3495 Part - 1 Tender Spec or Min 75 kg/cm2

3 Water absorption IS 3495 Part - 2 Less than 15 %

4 Efflorescence IS: 3495 Part - 3

upto 10,000 – 5 bricks 10,001 – 35,000 – 10 bricks 35,001 – 50,000 – 15 bricks

Slight

5 Physical Appearance IS 1077 - 1992 Each Lot As per IS 1077-1992

Brickwork Inspection

Card EMGF – ITP – 005B

Project: Date:

Contractor:

Location / Grid: Wall Thickness:

Installation Inspection Check Satisfactory S No. Description Yes/No Remarks

Brickwork Drawings Approved - Proceed Further Materials: 1 Are tested and approved materials being used? 2 Sufficient material for the shift available? Preparatory Works: 3 Is surface clean? 4 Are bricks soaked? 5 Are reference levels marked? 6 Surface hacked for key / bonding? Mixing: 7 Mix ratio 8 Wooden boxes for measuring? 9 Mixer being used for mixing? Construction: 10 Levels and layout. 11 Damp proof course. 12 MS bars being grouted for half brick wall. 13 Conduits / concealed items. 14 Mortar being consumed within half an hour? Post Construction Inspection 15 Joints as per drawing and specifications? 16 Deviation from vertical within limits? 17 Mortar thickness 18 Height of lift / day <= 1.5m 19 Provision for door / window fixing 20 Curing Remarks:

Prepared by:

Verified by:

EMGF-ITP- 05 C

Name of Project Date of Sampling

Location Sampled By

Source Date of Testing

Name of Contractor Location of Testing

Length Width Height

(4520 - 4680) (2160 - 2240) (1360 - 1440) > 75 kg/cm2 <15% Slight

Remarks :

Contractor Emaar MGF

Emaar MGF Land Limited

Compressive

Strength

(kg/cm2)

Water

Absorption

(%)S. No.

Brick

Mark

Efflorescence

Dimensions (mm)

Remarks

TESTING OF BURNT CLAY BRICKS


MS 06

WORK METHOD STATEMENT PLASTER

0 0.1 21/03/08 QC Manager CEO (N)


MS 06 Emaar MGF Land Limited Plaster

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of work required for carrying out plaster finishes to walls, columns, ceilings and similar surfaces on backgrounds normally met with, such as brick, stone or concrete (plain or reinforced) on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The plaster done is according to standards and its procedures.



Issue 0.1

2.0 Procedure

2.1 General

• Thickness of plaster shall be as mentioned on GFC drawing. In the absence of any such specifications, following two clauses may be referred to.

• The external plaster shall be minimum 20 mm and shall be applied in two coats. Rendering coat shall be 12mm and finishing coat 8mm.

• The internal plaster unless specified otherwise shall be average of 15 mm thick on walls and minimum 6 mm thick for the ceiling. The interior plaster shall be applied in one coat only.

• The mix for plaster unless otherwise specified, shall be one part cement and four parts sand, to walls and one part cement, 3 parts sand to ceiling.

• Construction material (cement, sand) should be from approved source.


• Plastering operations shall not be started until all necessary fixing, such as door and window frames, mantelpieces are completed and all pipes and conduits to be embedded in the wall or plaster are installed.

• A preliminary inspection shall be made to ensure that the surfaces are in a suitable condition for plastering, particularly as regards their plainness and dryness. If dubbing out is necessary, it should be done in advance, so that an adequate time interval may be permitted before the application of the first undercoat. Plastering operations shall be so scheduled as to allow sufficient interval between undercoats and finishing coats.

2.3 Construction

• The material used in the preparation of plastering mixes shall be weighed and used in prescribed ratio. With prior approval from Emaar-MGF, material may be measured by volume using gauge boxes.

• For external plaster, the plastering operations may be started from the top floor and carried downwards. For internal plaster, the plastering operations may be started wherever the building frame and cladding work are ready and the temporary supports of the ceiling resting on the wall or the floor have been removed.

• Mixing may be done using a mixer. The mixer shall run at least 5 min after placing all the ingredients in the drum. In special cases Emaar-MGF may allow manual mixing. ‘Manual mixing’ shall be carried out on a clean, water-tight platform. During mixing, the mortar shall be heed back and forth for 10 to 15 ruin after the water is added.



Issue 0.1

• Cement plasters shall be used within half an hour after the addition of water. Any mortar or plaster which is partially set shall be rejected and removed forthwith from the site.

• The surfaces to be plastered shall first be prepared as described in 2.2.

2.4 Preparation of Background

a) Cleanliness - The loose layer of dust on masonry shall be removed either by watering or by brushing as required. A freshly cast concrete surface is often covered by laitance and this shall be removed. A concrete surface may also often be contaminated by the soap which is formed with calcium hydroxide and the oils in the moulds. The contaminated layer shall be removed by brush. Special care shall be taken in repairing for rendering an old plaster coat. Old layers of the plaster coat shall be completely removed and made good. Crumbled and frost-damaged parts shall be cut out and patched. Any trace of algae or mass formation shall be removed. If the background contains soluble salts, particularly sulphates, the application of the plaster shall be done only after the efflorescence of the salts is complete, and the efflorescence is thoroughly removed from the surface.

b) Roughness — Any smooth surface may be roughened by wire brushing, if it is not hard; or by hacking or bush-hammering if it is hard. Alternatively, to obtain a rough surface, a mortar (1 cement: 1.5 to 3 coarse sand by volume) prepared to a wet consistency may be forcibly dashed or to the surface (spatter dash treatment) by suitable means on to a hard surface like concrete. After roughening the surface, care shall be taken to moisten the surface sufficiently before plastering, as otherwise the surface may tend to absorb considerable amount of water from the plaster.

c) In addition to general roughness in the masonry, the joints shall also be raked to a depth of about 10mm for providing key to the plaster. On a soft smooth surface after hacking a thin coat of cement slurry (1: 1:: cement : fine sand) may be applied. In special cases wire netting, etc, may be fixed to improve further the key to the plaster.

d) Any unevenness must be leveled before the plaster is applied. projections shall not exceed 6 mm and local depression 12 mm.

e) Discontinuity in backgrounds caused by different material, for instance changing from concrete to brickwork, from clay brickwork to lightweight concrete block work or even changing from one type of brick to another shall be dealt with special care. The best treatment may be to separate the two portions by a neat cut through the plaster at the junction. The junction may be masked, if so desired, by fixing a cover strip to one side. Where grooves are not called for, the joint between concrete and masonry in filling, chasing for conduits, pipes, boxes etc. shall be covered by 24 gauge expanded galvanized metal strips, 300 mm wide installed before plastering.

f) Concrete surfaces shall have sufficient roughness to provide proper adhesion. The surface shall be uniformly wetted (not saturated) to provide correct suction.



Issue 0.1

g) If a chemical retarder has been applied to the formwork, a roughened surface may be formed by wire-brushing and all the resulting dust and loose particles cleaned off, and care shall be taken that none of the retarders is left on the concrete or on other surfaces, as it may interfere with the set of the plaster or with other building operations.

2.5 Application of Undercoats

The Rendering or First Coat a) The rendering coat shall be 10 to 15 mm thick and carried to the full length of the

wall or to natural breaking points like doors or windows. Before the rendering coat hardens, it shall be roughened to provide mechanical key for the second coat.

b) Masonry walls on which plaster is to be applied directly, shall be properly set and cured with the joints raked to a depth of at least 10 mm. Before applying the rendering coat, the surface shall be cleaned and damped evenly to control suction, an essential treatment for securing first class work. The rendering coat shall be toweled hard and tight, forcing it into surface depressions to obtain a permanent bond.

c) On smooth concrete walls, the surface shall be roughened and the rendering coat shall be dashed on to ensure adequate bond. The dashing of the rendering coat shall be done using a strong whipping motion at right angles to the face of the wall, or it may be applied with a plaster-machine or cement-gun. In either case, the plaster shall be projected on to the surface with considerable force.

The Floating or Second Coat a) Before starting to apply the second coat, the surface of the rendering coat shall be

damped evenly. The second coat shall be approximately 3 to 8 mm thick. It shall be brought to a true, even surface and then roughened to provide bond for the finishing coat. Each under coat shall be damp-cured for at least two days.

2.6 Trueness of Plaster

The finished plaster surface shall not show any deviation more than 4 mm when checked with a straight edge of 2 m length placed against the surface.

2.7 Curing

Each coat shall be kept damp continuously till the next coat is applied or for a maximum period of 7 days. Moistening shall commence as soon as the plaster has hardened sufficiently and is not susceptible to injury. The water shall be applied by using a fine fog-spray. Soaking of wall shall be avoided and only as much water as can be readily absorbed shall be used. Excessive evaporation on the sunny or windward sides of buildings in hot dry weather, may be prevented by hanging matting or gunny bags on the outside of the plaster and keeping them wet.



Issue 0.1

After the completion of the finishing coat, the plaster shall be kept wet for at least seven days, and shall be protected during that period from extremes of temperature and weather.

2.8 References

IS 1661 : 1972 Code of Practice for Application of Cement and Cement-lime Plaster Finishes

IS 2250 : 1981 Code of Practice for Preparation and Use of Masonry Mortars


EMGF-ITP-06 A

Project: Date:

Location: From:

Drawing Ref.: To:

Description of work

Sub.Cont. EMGF

Deficiencies:

Remedial actions:

Post-Construction Checks

No Waviness is present in surfaces after finishing

Plaster finish, line and thickness is checked periodically with Plumb, Straight edge etc. while construction

1

Undercoat, if any is damp cured for atleast two days

Construction Operations

2

Chicken wire mesh being used for RCC and masonry joints.

Cement and Sand tested and approved


Inspection Sheet for Plaster Works

S.No.Check Satisfactory

Yes/No Inspection/Descriptions

Pre-Construction Checks

Remarks

3

Masonry / Surface to be plastered is cured properly at least 6 hours before the plastering

Thickness of the plaster coats are maintained at all points as per technical specification

Mortar Cube are casted minimum 3 nos. per day work

The finished plaster surface is within deviation of 4 mm when checked with straight edge of 2 m length

Ensure that Surfaces which are going to be plastered have completed their own curing period

All the debris laying on the floor top/adjoinning structure or machinery are cleaned properly

Plaster thickness is as per required specifications

All flooring, kitchen platform, doors, windows & switch plates are covered

Contractor's Representative

Name :

Date :

Emaar MGF Representative

Signature :

Sufficient tools / equipmetns for plastering works available on site

Efflorescence, Crumbled and frost-damaged parts, contaminated layers and laitance are completely removed from the suface to plastered

All the constituents of plaster mix are properly weighed and properly mixed in ratio mentioned in specifications

Proper hacking of R.C.C./ Smooth surface is done.

Mix for plaster is consumed within 30minutes after preparation

For external plaster, the plastering operations starts from top floor and carried downwards

Curing is done for atleast 7- days with proper arrangments available at the site

All necessary fixing (Door, Window frames, mantelpieces etc.) are completed and all pipes and conduits to be embedded in the wall or plaster are installed.


MS 07

WORK METHOD STATEMENT ROADWORKS

0 0.2 01/07/08 QC Manager CEO (N)

0 0.1 24/03/08 QC Manager CEO (N)


MS 07 Emaar MGF Land Limited Roadworks

Issue 0.2

1.0 Introduction

1.1 Scope

This work method statement describes the activities for the construction of roads on site. More detailed / task specific method statements for the construction of roads may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The road work done is according to standards and its procedures.



Issue 0.2


2.1 Setting Out

Setting out for the roadworks shall be carried out by the survey team on the completed and accepted formation.



The Contractor shall provide all labour, survey instruments and materials such as strings, pegs, nails, bamboos, stones, lime, mortar, concrete, etc., required in connection with the setting out of works and the establishment of bench marks. The Contractor shall be responsible for the maintenance of bench marks and other marks and stakes as long as in the opinion of the EMGF Engineer, they are required for the work.

2.2 Clearing and Grubbing

Clearing and grubbing shall be performed less than one month in advance of earthwork operations and in accordance with the requirements of tender specifications.

All vegetation such as roots, under-growth, grass and other deleterious matter unsuitable for incorporation in the embankment/subgrade shall be removed to the satisfaction of the EMGF Engineer.

2.3 Earthworks

The contractor shall notify the EMGF Engineer before starting excavation and before the ground is disturbed, to enable him to take existing levels for the purpose of measurements. The ground levels shall be taken at 5 to 15 meters intervals in uniformly sloping ground and at closer distance where local mounts, pits or undulations are met with ,as directed by the Engineer-in-charge. The ground level shall be recorded in field’s books and plotted on the plans, which shall be signed by the Contractor and the EMGF Engineer, before the earth work is actually started. The labour required for taking levels, shall be supplied by the contractor at his own cost.

The excavations shall conform to the lines, grades, side slopes and levels shown on the drawings or as directed by the EMGF Engineer. The Contractor shall not excavate outside the limits of excavation. Subject to the permitted tolerances, any excess depth/width excavated beyond the specified levels/dimensions on the drawings shall be made good at the cost of the Contractor with suitable material of characteristics similar to that removed and compacted to the requirements.



Issue 0.2

All debris and loose material on the slopes of cuttings shall be removed. No backfilling shall be allowed to obtain required slopes excepting that when boulders or soft materials are encountered in cut slopes, these shall be excavated to approved depth on instructions of the Engineer and the resulting cavities filled with suitable material and thoroughly compacted in an approved manner.

Where the material in the subgrade (that is within 500 mm from the lowest level of the pavement) has a density less than specified in Table A, the same shall be loosened to a depth of 500mm and compacted.

Materials & General Requirements

The materials which are considered unsuitable for embankments/Subgrade as per Clause 305.2.1.1 in MORT&H should not be used for the construction work.

Density Requirements of Embankment & Subgrade Materials

Sr. No. Type of Work M.D.D. as per IS: 2720 (Part-8)

1 Embankment up to 3 mts ht. Not less than 15.2 KN/Cu.m.

2 Embankment exceeding 3 mts ht Not less than 16.0 KN/Cu.m.

3 Subgrade & Earthen shoulders/Backfill Not less than 17.5 KN/Cu.m.

The materials to be used for subgrade works must satisfy the min. requirement of design CBR value of 7 % at 97 % of the M.D.D as per BOQ.

Table A: Compaction Requirements for Embankment and Subgrade ----------------------------------------------------------------------------------------------------------------- Type of work/material Relative compaction as percentage

of max. Laboratory dry density as per IS: 2720 (Part8)

-----------------------------------------------------------------------------------------------------------------

1. Subgrade and earthen shoulders Not less than 97 2. Embankment Not less than 95

The embankment and subgrade material shall be spread in layers of uniform thickness not exceeding 200 mm compacted thickness over the entire width of embankment by mechanical means, finished by a motor grader and compacted.

Successive layers shall not be placed until the layer under construction has been thoroughly compacted to the specified requirements and got approved by the EMGF Engineer. Each compacted layer shall be finished parallel to the final cross-section of the embankment.



Issue 0.2

Moisture content of the material shall be checked at the site of placement prior to commencement of compaction; if found to be out of agreed limits, the same shall be made good. Where water is required to be added in such constructions, water shall be sprinkled from a water tanker fitted with sprinkler capable of applying water uniformly with a controllable rate of flow to variable widths of surface but without any flooding. The water shall be added uniformly and thoroughly mixed in soil by blading, discing or harrowing until a uniform moisture content is obtained throughout the depth of the layer.

Moisture content of each layer of soil shall be checked in accordance with IS: 2720 (Part 2), and unless otherwise mentioned, shall be so adjusted, making due allowance for evaporation losses, that at the time of compaction it is in the range of 1 per cent above to 2 per cent below the optimum moisture content determined in accordance with IS: 2720 (Part 8).

Compaction: Only the compaction equipment approved by the Engineer shall be employed to compact the different material types encountered during construction. Smooth wheeled, vibratory, pneumatic tyred, sheep-foot or pad-foot rollers, etc. of suitable size and capacity as approved by the Engineer shall be used for the different types and grades of materials required to be compacted either individually or in suitable combinations.

The compaction shall be done with the help of vibratory roller of 80 to 100 kN static weight with plain or pad foot drum or heavy pneumatic tyred roller of adequate capacity capable of achieving required compaction.

2.4 Granular Sub Base

2.4.1 Preparation of Subgrade

Immediately prior to the laying of sub-base, the subgrade already finished as applicable shall be prepared by removing all vegetation and other extraneous matter, lightly sprinkled with water if necessary and rolled with two passes of 80-100 kN smooth wheeled roller.

2.4.2 Spreading and Compacting

The sub-base material of grading specified in the Contract shall be spread on the prepared subgrade with the help of a motor grader of adequate capacity, its blade having hydraulic controls suitable for initial adjustment and for maintaining the required slope and grade during the operation.



Issue 0.2

Moisture content of the loose material shall be checked in accordance with IS : 2720 (Part 2) and suitably by sprinkling additional water from a truck mounted or trailer mounted water tank and suitable for applying water uniformly and at controlled quantities to variable widths of surface or other means approved by the Engineer so that, at the time of compaction, it is from 1 percent above to 2 percent below the optimum moisture content corresponding to IS : 2720 (Part 8). While adding water, due allowance shall be made for evaporation losses. After water has been added, the material shall be processed by mechanical or other approved means like disc harrows, rotavators until the layer is uniformly wet.

For a compacted single layer upto 225 mm the compaction shall be done with the help of a vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required compaction. Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for portions having unidirectional crossfall and super elevation and shall commence at the edges and progress towards the centre for portions having crossfall on both sides.

Each pass of the roller shall uniformly overlap not less than one third of the track made in the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots or depressions, which become apparent, corrected by removing or adding fresh material. The speed of the roller shall not exceed 5 km per hour.

Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density for the material determined as per IS: 2720 (Part 8).

2.5 Wet Mix Macadam

2.5.1 Preparation of base:

Clause 2.4.1 shall apply.

2.5.2 Spreading of mix

The aggregates shall be spread uniformly and evenly upon the prepared subgrade /sub-base /base in required quantities. In no case should these be dumped in heaps directly on the area where these are to be laid nor shall their hauling over a partly completed stretch be permitted.

The mix may be spread either by a paver finisher or motor grader.



Issue 0.2

2.5.3 Compaction

After the mix has been laid to the required thickness, grade and crossfall/camber the same shall be uniformly compacted, to the full depth with suitable roller. For a compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent capacity roller. The speed of the roller shall not exceed 5 km/h.

In portions having unidirectional cross fall/superelevation, rolling shall commence from the lower edge and progress gradually towards the upper edge. Thereafter, roller should progress parallel to the centre line of the road, uniformly over-lapping each preceding track by at least one third width until the entire surface has been rolled. Alternate trips of the roller shall be terminated in stops at least 1 m away from any preceding stop.

Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry density for the material as determined by the method outlined in IS : 2720 (Part-8).

2.6 Rectification of Surface Irregularity

Where the surface irregularity of the wet mix macadam course exceeds the permissible tolerances or where the course is otherwise defective due to subgrade soil getting mixed with the aggregates, the full thickness of the layer shall be scarified over the affected area, reshaped with added premixed material or removed and replaced with fresh premixed material as applicable and recompacted. The area treated in the aforesaid manner shall not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and ungraded material or fines.

2.7 Base and Surface Courses (Bituminous)

2.7.1 Preparation of road surface

The surface to be primed shall be swept clean, free from dust, all loose material shall be removed and the surface lightly watered (Damp Surface). It shall be shaped to the specified grades and section. It shall also be free from ruts, any other irregularities and segregated materials. Minor depressions and potholes may be ignored until the surface is primed, after which they shall be patched with a suitable premix material prior to the surface treatment.

2.7.2 Application of bituminous primer

The bituminous primer shall be sprayed/distributed uniformly over the dry surface using self-propelled sprayer equipped with self-heating arrangement, suitable pump, adequate capacity compressor and spraying bar with nozzles having constant volume



Issue 0.2

or pressure system capable of supplying primer at specified rates and temperatures so as to provide a uniformly unbroken spread of primer. If the surface to be primed is dry or dusty as to cause freckling of bituminous material, it shall be lightly and uniformly sprinkled with water (Damp Surface) immediately prior to priming; however, the bituminous material shall not be applied till such time as no surface water is visible.

The desirable range of temperatures at the time application of MC-30, MC-70 and MC-250 grades shall be 30 to 550 C; 50 to 80 0 C and 75 to 100 0 C respectively. For a bituminous emulsion primer, the range of spraying temperature may be 20 to 60 0 C.

2.7.3 Bituminous Macadam

Binder: The binder shall be penetration bitumen of a suitable grade as specified in the contract & satisfying the requirements of IS: 73.

Aggregates: The aggregate shall conform to clause no. 504.2.2 except that the water absorption shall be limited to a maximum of one percent. The polished stone value, as measured by the test in BS: 812(part-114).

Proportioning of materials: Mix design, done in the Contractor’s laboratory jointly with EMGF Engineer or conducted by an approved third party, shall be submitted by the Contractor to EMGF Engineer for approval. The mix shall be produced in a calibrated batch type Asphalt Hot Mix Plant of an appropriate capacity. The temperature of Mix produced from plant shall be in range of 140 0C to 1600C. In no case the temperature of mix from plant shall not be more than 1650C. In such an eventuality, the mix should be rejected for use in permanent works. The temp of bitumen should be in the range of 1500C to 1650C at the time of mixing. The material should be tested in accordance with respective ITP or MORT&H specifications.

Spreading: The mix produced in the asphalt plant shall be transported in tippers to the site & unloaded in paver shall be spread immediately by means of self-propelled paver with suitable screeds capable of spreading, tamping, and finishing the mix true to the specified lines, grades and cross-sections.

The temperature of the mix at the time of laying shall be in the range of 120 0C to 160 0C.

Compaction: After the spreading of mix, rolling shall be done by 80 to 100 KN rollers or other approved equipment. Rolling shall start as soon as possible after the material has been spread deploying a set of rollers as the rolling is to be completed in limited time frame.

The roller shall move at a speed not more than 5 km/h. Rolling shall be done with care to avoid unduly roughening of the pavement surface. Rolling shall be continued until the specified density is achieved.

A trial patch of at least 100 sq mts. should be made to establish the number of passes i.e. no. of vibratory passes at low & high frequency, no. of plain passes, no. of passes



Issue 0.2

by PTR at a specified amplitude & frequency of vibration. After preparing the trial patch, the densities of the stretch should be checked & if found ok then the sequence of rolling shall be frozen & if found not ok then adjust the sequence of rolling or no. of passes.

2.7.4 Tack Coat

The normal range of spraying temperature for a bituminous emulsion shall be 200C - 600C and for a cutback 50 0 C – 80 0C if RC-70/MC-70 grade is used. It shall be the responsibility of the Contractor to carefully handle the inflammable bituminous cutback material so as to safeguard against any fire mishap. The binder shall be applied uniformly with the aid of either self-propelled or towed bitumen pressure sprayer with self–heating arrangement and spraying bar with nozzles having constant volume or pressure system, capable of spraying bitumen at specified rates and temperature so as to provide a uniformly unbroken spread of bitumen. Work should be planned so that no more than the necessary tack coat for the day’s operation is placed on the surface.

Weather & Seasonal Limitations

Laying shall be suspended while free-standing water is present on the surface to be covered, or during rain, fog and dust storms. After rain the bituminous surface, prime or tack coat, shall be blown off with a high pressure air jet to remove excess moisture, or the surface left to dry before laying shall start. Laying of bituminous mixtures shall not be carried out when the air temperature at the surface on which it is to be laid is below 100 c or when the wind speed at any temperature exceeds 40 km/h at 2 meters height unless specifically approved by EMGF.

2.7.5 Open Graded Premix Carpet

Binder: The binder shall be penetration bitumen of a suitable grade as specified in the contract & satisfying the requirements of IS: 73.

Aggregates: The aggregate shall conform to clause no. 504.2.2 except that the water absorption shall be limited to a maximum of one percent. The polished stone value, as measured by the test in BS: 812(part-114).

Quantity of Aggregates & Bitumen: Quantities of materials shall be calculated as per Table 500-23 of MORT&H specifications.

Proportioning of materials: Mix design, done in the Contractor’s laboratory jointly with EMGF Engineer or conducted by an approved third party, shall be submitted by the Contractor to EMGF Engineer for approval. The mix shall be produced in a calibrated batch type Asphalt Hot Mix Plant of an appropriate capacity. The temperature of Mix produced from plant shall be in range of 140 0C to 1600C. In no case the temperature of mix from plant shall not be more than 1650C. In such an eventuality, the mix should be rejected for use in permanent works. The temp of



Issue 0.2

bitumen should be in the range of 1500C to 1650C at the time of mixing. The material should be tested in accordance with respective ITP or MORT&H specifications.

Spreading: The mix produced in the asphalt plant shall be transported in tippers to the site & unloaded in paver shall be spread immediately by means of self-propelled paver with suitable screeds capable of spreading, tamping, and finishing the mix true to the specified lines, grades and cross-sections.

The temperature of the mix at the time of laying shall be in the range of 120 0C to 160 0C.

Compaction: After the spreading of mix, rolling shall be done by 80 to 100 KN rollers or other approved equipment. Rolling shall start as soon as possible after the material has been spread deploying a set of rollers as the rolling is to be completed in limited time frame.

The roller shall move at a speed not more than 5 km/h. Rolling shall be done with care to avoid unduly roughening of the pavement surface. Rolling shall be continued until the specified density is achieved.

A trial patch of at least 100 sq mts. should be made to establish the number of passes i.e. no. of vibratory passes at low & high frequency, no. of plain passes, no. of passes by PTR at a specified amplitude & frequency of vibration. After preparing the trial patch, the densities of the stretch should be checked & if found ok then the sequence of rolling shall be frozen & if found not ok then adjust the sequence of rolling or no. of passes.

2.7.6 Tack Coat

Tack coat, Weather & Seasonal Limitations shall be applied as per 2.7.4 in the construction practices.

2.7.7 Surface Dressing

This work shall consist of application of one coat or two coats of surface dressing wherever applicable, each coat consisting of a layer of bituminous binder sprayed on a previously prepared base, followed by a cover of bituminous binder sprayed on a previously prepared base, followed by a cover of stone chips rolled in to form a wearing course to the requirements of these specifications.

Materials

Binder

The binder shall have a kinematic viscosity lying in the range of 1*104 to 7*105 centistokes at the expected range of road surface temperatures at the construction site during the period of laying. The binder may be a pving bitumen as per IS: 73 or Bitumen Emulsion as per IS: 8887 or as specified in BOQ.

Aggregates

The chips shall confirm to the requirements of Clause 504.2.2., of MORT&H except that their water absorption shall be restricted to a maximum of 1 percent and they



Issue 0.2

shall have a polished stone value as measured by BS 812 (Part-114), of not less than 60. The chips shall be single sized, clean, hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other deleterious matter and confirming to one of the gradings given in Table 500-21 for nominal size 10 mm.

Rates of spread for Binder & Chippings

The stone aggregate with a uniform rate of 0.008cum/sqm, as per table 500-20. The rate of spray of binder shall be 0.9 kg/sqm as per MORT & H specs 510.2.3 with all lifts and leads complete as per MoRT&H specifications Clause 510 and as directed by the EMGF.

For emulsion, these rates of spread are for the residual bitumen and appropriate adjustment must be made to determine the total quantity.

Refer to manual for construction & supervision of bituminous works for the procedure of determining the rates of spread of binder and chips.

Anti-stripping agent

Where the proposed aggregate fails to pass the stripping test then an approved adhesion agent may be added to the binder in accordance with the manufacturer’s instructions. The effectiveness of the proposed anti-stripping agent must be demonstrated by the contractor, before approval by the EMGF.

Pre-Coated Chips

As an alternative to the use of an adhesion agent the chips may be pre-coated before they are spread except when the sprayed binder film is a bitumen emulsion. Pre-coating the chips may be carried out in accordance with 510.2.5 as per MORT&H specifications.

Construction Practices & Weather and Seasonal Applications shall be as per MORT&H Clause No. 510.



Issue 0.2

3.0 Formats

S No. Number Description 1 EMGF-QA-001A Witness Point Notification 2 EMGF-ITP-007A Testing Frequency 3 EMGF-ITP-007B Field Testing – Subgrade / Embankment 4 EMGF-ITP-007C Field Testing – GSB / WMM 5 EMGF-ITP-007D Field Testing – Bituminous Courses 6 EMGF-ITP-007E Gradation 7 EMGF-ITP-007F CBR 8 EMGF-ITP-007G Field Density – Core Cutter 9 EMGF-ITP-007H Field Density – Sand Replacement

10 EMGF-ITP-007I Atterberg Limits 11 EMGF-ITP-007J Flakiness and Elongation 12 EMGF-ITP-007K Proctor Test 13 EMGF-ITP-007L Moisture Content 14 EMGF-ITP-007M Aggregate Impact Value 15 EMGF-ITP-007N Crushing Value 16 EMGF-ITP-007P Rate of Spread of Binder – Prime and Tack 17 EMGF-ITP-007Q Binder Content by Extraction Test 18 EMGF-ITP-007R Stripping Value 19 EMGF-ITP-007S Marshall Stability 20 EMGF-ITP-007T Field Density of Bituminous Course


EMGF-ITP-007 A

Project: Mohali Hills

S. No. Description Test Test Method Minimum Frequency Specified ValueDensity Test IS: 2720 Part - 8 As Required As RequiredField Density Test IS: 2720

Part - 28/291 Test/1000sqm Not less than 95% for Emb. and

Not less than 97% for SubgradeSand Content IS: 2720 Part - 4 2 Test/3000 cum As RequiredAtterberg Limits IS: 2720 Part - 5 2 Test/3000 cum LL- Not more than 70

PI - Not more than 45 Density Test IS: 2720 Part - 8 2 Test/3000 cum SG - Not less than 17.5KN/cum

Emb - Not less than 15.2 KN/cumDeleterious Content Test IS: 2720 Part - 27 As Required As RequiredMoisture Content Test IS: 2720 Part - 2 1 Test/250 cum As RequiredCBR Test IS: 2720 Part - 16 1 Test/3000 cum As Required

1 test/1000sqm Min. 95% of MDD for Emb.1 test/500 sqm Min. 97% of MDD for Subgrade

Field moisture content IS: 2720 Part - 2 As Required Between +1% above to -2% below OMC

Gradation IS: 2720 Part - 4 1 test/200cum As RequiredAtterberg Limits IS: 2720 Part - 5 1 test/200cum LL- Not more than 25 and

PI - Not more than 6 Deleterious Constituent IS: 2720 Part - 27 1 test/250cum As RequiredCBR Test IS: 2720 Part - 16 Per Source As RequiredMoisture Content Test IS: 2720 Part - 2 1 test/250 Cum As RequiredDensity Test IS: 2720 Part - 8 Per Source As RequiredField Density Test IS: 2720 Part - 28 1 test/500 sqm Min. 98% of MDDField moisture content IS: 2720 Part - 2 1 test/250 cum Between +1% above to -2% below OMC

Aggregate Impact Value IS: 2386 Part - 4 1 test/200cum Max. 30 %Grading of Aggregates IS: 2386 Part - 1 1 test/100cum As RequiredFlakiness & Elongation Index Combined

IS: 2386 Part - 1 1 test/200cum Max. 30 %

Plasticity Index IS: 2720 Part - 5 1 test/100cum Max. 6%Density Test IS: 2720 Part - 27 Per Source As RequiredField Density Test IS: 2720 Part - 28 1 test/500 sqm Min. 98% of MDDField moisture content IS: 2720 Part - 2 1 test/250 cum Between +1% above to -2% below OMC

QUALITY CONTROL TESTS FOR ROADWORKS AND THEIR MINIMUM FREQUENCY

1 OGL

2

4

GRANNULAR SUB BASE

3

WET MIX MACADAM

IS: 2720 Part - 28/29

Field Density Test

Embankment, Subgrade and Earthen Shoulder

EMGF-ITP-007 A




Quality of Binder IS:73, IS:217and IS:8887

One samples per lot As Required

Binder temperature forappLCIation

At regular close intervals As Required

Rate of spread of Binder IRC: SP 11- Appendix 5

One test per 500 sqm and not less than two tests per day

As Required



Aggregate Impact Value/Los Angeles Abrasion value

IS: 2386 Part - 4 One test per 50 Cum of aggregate Max. 30 %

Flakiness and Elongation Index Combined


Stripping value of aggregates

IS: 6241 Initially one set of 3 representative specimens for each source of supply.

Min. retained coating 95%

Water sensitivity of mix AASHTO T 283 Initially one set of 3 representative specimens for each source of supply. Subsequently when warranted by changes in the quality of aggregates

Min. 80%

Grading of aggregates IS: 2386 Part - 1 Two tests per day per plant both on the individual constituents and mixed aggregates from the dryer

As Required

Water absorption of aggregates

IS: 2386 Part - 3 Initially one set of 3 representative specimens for each source of supply. Subsequently when warranted by changes in the quality of aggregates

Max. 2%

Soundness (Magnesium and Sodium Sulphate)

IS: 2386 Part - 5 Initially, one determination by each method for each source of supply, then as warranted by change in the quality of the aggregates.

Max. 18% and 12% with Sodium Sulphate and Magnesium Sulphate respectively

Percentage of fractured faces

When gravel is used, one test per 50 Cum of aggregate

As Required

PRIME COAT/TACK COAT

BITUMINOUS MACADAM

5

6

EMGF-ITP-007 A




Binder content and aggregate grading

ASTM D 2172 Periodic, subject to minimum of two tests per day per plant

As Required

Control of temperature of binder and aggregate for mixing and of the mix at the time of laying and rolling


Rate of spread of mixed material

Regular control through checks of layer thickness

As Required

Density of compacted layer ASTM D 2726 One test per 250 Sqm of area Min. 95% of Marshall Specimen



Aggregate Impact Value/Los Angeles Abrasion value


Flakiness & Elongation Index Combined


Stripping value of aggregates

IS: 6241 Initially one set of 3 representative specimens for each source of supply.

Min. retained coating 95%

Soundness (Magnesium and Sodium Sulphate

IS: 2386 Part - 5 Initially, one determination by each method for each source of supply, then as warranted by change in the quality of the aggregates.

Max. 18% and 12% with Sodium Sulphate and Magnesium Sulphate respectively

Water absorption ofaggregates

IS: 2386 Part - 3 Initially one set of 3 representative specimens for each source of supply. Subsequently when warranted by changes in the quality of aggregates

Max. 2%

Sand equivalent test IS: 2720 Part - 37 As Required Not less than 50%Plasticity Index IS: 2720 Part - 5 As Required Max. 4%Polished Stone value BS: 812 Part -114 As Required Min. 55%Percentage of fracturedfaces

When gravel is used, one test per 50 Cum of aggregate

As Required

Mix grading IS: 2386 Part - 1 One set of test on individual constituents and mixed aggregate from the dryer for each 400 tonnes of mix subject to a minimum of two tests per Plant per day

As Required

6

BITUMINOUS CONCRETE

7

BITUMINOUS MACADAM

EMGF-ITP-007 A




Stability of Mix ASTM D 2172 For each 400 tonnes of mix produced, a set of 3 Marshall specimens to be prepared and tested for stability, flow value, density and void content subject to a minimum of two sets being tested per plant per day.

Min. stability 9.0 KN at 60oc

Water sensitivity of mix (Retained Tensile Strength)

AASHTO T 283 Initially one set of 3 representative specimens for each source of supply. Subsequently when warranted by changes in the quality of aggregates

Min. 80%

Swell test on the mix Asphalt Institute, MS-2

As Required As Required

Control of temperature of binder in boiler, aggregate in the dryer and mix at the time of laying and rolling


Control of binder content and grading of the mix

ASTM D 2172 One test for each 400 tonnes of mix subject to a minimum of two tests per day per plant

As Required

Rate of spread of mixed material

Regular control through checks on the weight of mixed material and layer thickness

As Required

Density of compactedlayer

ASTM D 2726 One test per 250 Sqm area Min. 98% of Marshall Specimen

BITUMINOUS CONCRETE

7

EMGF-ITP-007 B

Sector : Chainage: From to

Road No. : Contractor

Work : Subgrade / Embankment

S. No. Item Contractor Date Emaar-MGF Date

1 NGL / EGL Recorded

2 Clearing and Grubbing

3 Material

3.1 Material tested as per ITP

3.2 Material from approved source

4 Compaction

4.1 Moisture Content (OMC)

4.2 Equipment approved

4.3 Test for Field Density

5 Material



6 Compaction




7 Material



8 Compaction




9 Line and Level

9.1 Finished levels checked & recorded

9.2 Undulations, if any, made good

Quality Standards have been met during construction.


EMGF - Name and Signature

Field Checklist for Earthworks

Layer 1

Layer 2

Layer 3

EMGF-ITP-007 B - Field Checklist - Earthworks R1

EMGF-ITP-007 C

Sector : Chainage: From to

Road No. : Contractor

Work Granular Layer

S. No. Item Contractor Date Emaar-MGF Date

1 Subgrade Top level recorded

2 Latest GFC available

3 Material

3.1 Material is from approved source


4 Compaction




5 Line and Level

5.1 Finished levels checked

5.2 Undulations checked

5.3 GSB Top level recorded

6 Material

6.1 Material is from approved source


7 Compaction




8 Line and Level

8.1 Finished levels checked

8.2 Undulations checked

Quality Standards have been met during construction.

Date of Completion:


EMGF - Name and Signature

Field Checklist for GSB/WMM

GSB

WMM

EMGF-ITP-007 C - Field Checklist - GSB WMM R1

EMGF-ITP-007 E / 1

Name of Project : Mohali Hills

Name of Client : EMAAR - MGF Name of Contractor:




WPN No. :……………… Ref. No. :………………

Sieve Size

(mm)

Weight Retained

(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Remarks

100.00 mm

75.00 mm

40.00 mm

25.00 mm

19.00 mm

10.00 mm

4.75 mm

2.00 mm

600 mic.

425 mic.

150 mic.

75 mic.

Pan

Remarks :



OBSERVATIONS


GRAIN SIZE ANALYSIS FOR SOIL(As Per IS: 2720 Part - 4)

EMGF-ITP-007 E / 2





Material : GSB Date of Testing :………………

WPN No. :……………… Ref. No. :………………


(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

75.00 mm 100

53.00 mm 80 - 100

26.50 mm 55 - 90

9.50 mm 35 - 65

4.75 mm 25 - 55

2.36 mm 20 - 40

425 mic. 10 - 25

75 mic. 3 - 10

Pan

Remarks :



OBSERVATIONS


SIEVE ANALYSIS FOR GRANULAR SUB-BASE(As Per IS: 2720 Part - 4)

EMGF-ITP-007 E / 3






WPN No. :……………… Ref. No. :………………


(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

53.00 mm 100

45.00 mm 95 -100

22.40 mm 60 - 80

11.20 mm 40 - 60

4.75 mm 25 - 40

2.36 mm 15 - 30

600 mic. 8 - 22

75 mic. 0 - 8

Pan

Remarks :



OBSERVATIONS


SIEVE ANALYSIS FOR WET MIX MACADAM(As Per IS: 2386 Part - 1)

EMGF-ITP-007 E / 4






Type of Grading :………………

WPN No. :……………… Ref. No. :………………


(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

26.50 mm 100

19.00 mm 90 - 100

13.20 mm 56 - 100

4.75 mm 16 - 36

2.36 mm 4 - 19

300 mic. 2 - 10

75 mic. 0 - 8

Pan

Remarks :



OBSERVATIONS


SIEVE ANALYSIS FOR BITUMINOUS MACADAM(As Per IS: 2386 Part - 1)

EMGF-ITP-007 E / 5






Type of Grading :………………

WPN No. :……………… Ref. No. :………………


(gms)

Percent Weight

Retained

Cumulative Percent

Weight Retained

Percent

Passing

Specification

Limits

26.50 mm

19.00 mm

13.20 mm

9.50 mm

4.75 mm

2.36 mm

600 mic.

300 mic.

150 mic.

75 mic.

Pan

Remarks :



OBSERVATIONS


SIEVE ANALYSIS FOR BITUMINOUS CONCRETE(As Per IS: 2386 Part - 1)

EMGF-ITP-007 F

: EMAAR - MGF Name of Contractor:

Location / Source :……………… Date of Soaking :………………

Location :……………… Date of Testing :………………

Material :……………… Soaking Period :………………

Static / Dynamic :……………… MDD (gm/cc) :………………

Volume of Mould, V :……………… OMC (%) :………………

WPN No. :……………… Ref. No. :………………

Re

ad

ing

s

Lo

ad

Lo

ad

kg

/cm

2

CB

R%

Re

ad

ing

s

Lo

ad

Lo

ad

kg

/cm

2

CB

R%

Re

ad

ing

s

Lo

ad

Lo

ad

kg

/cm

2

CB

R%

0.0

0.5

1.0

1.5

2.0

2.5

3.0

4.0

5.0

7.5

10.0

12.5

CBR Value (%) = ……………..

Remarks:



CALIFORNIA BEARING RATIO TEST


Name of Project

Name of Client

: Mohali Hills

(As Per IS: 2720 Part - 16)

OBSERVATIONS

Before Soaking After SoakingDescription

Mould No.

Av

era

ge

%

Wt. of Water w1 = w2 - w3 gms

Water Content % = w1/w x 1000

Dry Density gm/cc

Pe

ne

tra

tio

n

(mm

)

Mould No. Mould No.

LOAD TEST

Wt. of Dry soil w = w3 - w1 gms

Wt. of Oven dry soil + Container = w3 gms

Mould No.

Wt. of Mould + Wet Soil = W1 gms

Wt. of Mould = W2 gms

Wet of Wet Soil W3 = (W1 - W2) gms

Bulk Density of Soil = (W3 / V) gm/cc

Container No.

Weight of Container = w1 gms

Wt. of wet soil + Container = w2 gms

EMGF-ITP-007 G



Location / Source :……………... Date of Testing :……………...

Location :……………... M.D.D. (gm/cc) :……………...

Material :……………... O.M.C. (%) :……………...

Type of Layer :……………... Layer No. :……………...

WPN No. :……………… Ref. No. :………………

Description 1 2 3 4 5 6

Chainage

Weight of Core Cutter

+ Wet Soil (Ws), gms

Weight of Core Cutter (Wc),

gms

Weight of Wet Soil (Ws-Wc),

gms

Volume of Core Cutter (Vc)

in cm3

Bulk Density of Soil

Yb = (Ws-Wc)/Vc in gms/cm3

Container No.

Weight of Container with lid

(W1) in gms

Weight of Container + Wet

Soil with lid (W2) in gms

Weight of Container and Dry

Soil with lid (W3) in gms

Water Content

W=(W2-W3/W3-W1)x100,gms

Moisture content by RMM

Reading

Corrected value

Dry Density Yd = Yb /

(100+w) x 100, gm/cc

Degree of compaction %

Yd / MDD x100, gm/cc

Remarks:



OBSERVATIONS

FIELD DENSITY BY CORE CUTTER METHOD(As Per IS: 2720 Part - 29)


EMGF-ITP-007 H



Location/ Source :……………… Date of Testing :………………

Location :……………… Bulk Density of Sand (Y) gm/cc :………………

Material :……………… :………………

Type of Layer :……………… OMC (%) :………………

Layer No. :………………

WPN No. :……………… Ref. No. :………………

1 2 3 4 5 6

Reading

Corrected value

Remarks :



Wt. of Water w1 =w2 – w3 gms

Moisture Contents % = w1/w x 100

MDD (gm/cc)

Weight of Container = w1 gms

Wt. of Wet Material + Container, w2 gms

Wt. of Dry Material + Container, w3 gms

Wt. of Dry Material w= w3 - w1, gms

Wt. of Wet Material from Hole ,W6 gms

Volume of Hole, V = W6/Y

Bulk Density (gm/cc)

Container No.


Description

Chainage

OBSERVATIONS

Dry Density, gm/cc


FIELD DENSITY TEST BY SAND REPLACEMENT METHOD(As Per IS: 2720 Part - 28)

Moisture content by

RMM

Wt. of Cylinder + Sand before Pouring, W1 gms

Wt. of Cylinder + Sand after Pouring, W2 gms

Wt. of sand in Hole + Cone, W3 = W1-W2 gms

Wt. of sand in Cone, W4 gms

Wt. of sand in Hole, W5 = W3 - W4 gms

EMGF-ITP-007 I






WPN No. :……………… Ref. No. :………………

1 2 1 2

Liquid Limit (%) =

Plastic Limit (%) =

Plasticity Index (%) =

Remarks:



ATTERBERG LIMITS BY CONE PENETRATION APPARATUS(As Per IS: 2720 Part - 5)

Description

OBSERVATIONS

Weight of Container + Oven dry soil, W3 gms

Plastic LimitLiquid Limit

Weight of Container, W1 gms

No. of drops / Penetration (D)

Container No.

Water Content, Wn = (W4 / W5) x 100 %

Liquid Limit (%) = Wn / (0.65 + 0.0175D)

Average Limit (%)


Weight of Water , W4 = (W2 - W3) gms

Weight of Oven dry soil, W5 = (W3 - W1) gms

Weight of Container + Wet soil, W2 gms

EMGF-ITP-007 J



Location / Source :……………… Date of Sampling :………………



WPN No. :……………… Ref. No. :………………

Passing

Through

IS Sieve

(mm)

Retained

on

IS Sieve

(mm)

Weight of

Aggregate

Taken in Each

Fraction

A (gm)

Weight of

Aggregate in Each

Fraction Passing

Thicness Gauge

B (gm)

Weight of Non

Flaky

Aggregate taken

in Each Fraction

C (gm)

Weight of

Aggregate in Each

Fraction Retained

on Length Gauge

D (gm)

63.0 mm 50.0 mm

50.0 mm 40.0 mm

40.0 mm 31.5 mm

31.5 mm 25.0 mm

25.0 mm 20.0 mm

20.0 mm 16.0 mm

16.0 mm 10.0 mm

10.0 mm 6.30 mm

Remarks :




FLAKINESS INDEX AND ELONGATION INDEX(As Per IS: 2386 Part - 1)

Total Weight (gm)

OBSERVATIONS

Combined Flakiness and

Elongation Index = FI + EI

Flakiness Index

FI = B / A x 100 (%)

Elongation Index

EI = D / C x 100 (%)

EMGF-ITP-007 K



Location / Source :……………… Mould No. :………………

Location :……………… Weight of Moulds, gms :………………

Material :……………… Date of Sampling :………………

Date of Testing :……………… Sampled By :………………

WPN No. :……………… Ref. No. :………………

1 2 3 4 5 6

Remarks :



Weight of Soil, gms

Volume of Mould, gms

Wet Density of Soil, gms/cc

Weight of Container + Wet soil, gms

Container No.

Weight of Container , gms


Description

Weight of Soil+ Mould, gms

MODIFIED PROCTOR TEST (As Per IS: 2720 Part - 8)

OBSERVATIONS

Weight of Container + Oven dry soil, gms

Dry Density of Soil in gm/cc

Weight of Water , gms

Weight of Oven dry soil, gms

Moisture Content in %

EMGF-ITP-007 L

Name of Project





WPN No. :……………… Ref. No. :………………

Remarks :



Weight of Container + Oven dry soil, W3 gms

Weight of Water , W4 = (W2 - W3) gms

Weight of Oven dry soil, W5 = (W3 -W1) gms

Moisture Content w =( W4 / W5) x 100 in %


Description

MOISTURE CONTENT(As Per IS: 2720 Part - 2)

OBSERVATIONS

Sample - 1 Sample - 2 Sample - 3

Weight of Container , W1 gms

Weight of Container + Wet soil, W2 gms

Container No.

: Mohali Hills

EMGF-ITP-007 M






WPN No. :……………… Ref. No. :………………

Remarks :



Test No.1 Test No.2Description


AGGREGATE IMPACT VALUE TEST(As Per IS: 2386 Part - 4)

OBSERVATIONS

W4 = W1 - (W2 + W3), (If W4 > 1 gm, discard the test and carry out

fresh test), W4 gms

Aggregate Impact Value, AIV = W2 / W1 x 100 %

Average (%)

Weight of Aggregate Passing 12.5 mm and Retained on 10 mm

Sieve, W1 gms

Weight of Aggregate Passing 2.36 mm Sieve, W2 gms

Weight of Aggregate Retained on 2.36 mm sieve, W3 gms

EMGF-ITP-007 N






WPN No. :……………… Ref. No. :………………

Test No.1 Test No.2 Test No.3 Test No.4

Remarks:



Description

Percent Fines, Y = W2 / W1x 100

Load Required for 10 Percent Fines

= 14F/(Y + 4) KN

Weight of Fines Passing 2.36 mm Sieve, W2

gms

Weight of SSD Aggregate in air, W1 gms

Total Load Applied, F (KN)

(As Per IS: 2386 Part - 4)

OBSERVATIONS


TEN PERCENT FINES VALUE

EMGF-ITP-007 P




:……………… Description of Sample :………………

Bed Width :……………… Type of Material :………………

Area (Sq.m) :………………

:……………… Ref. No. :………………

Test No. Location

of

Tray

Tray

No.

Weight of

Empty

Tray,

W1 kgs

Weight of

Tray with

Sample,

W2 kgs

Weight of

Sample

collected,

W =

(W2 - W1)

kgs

Area of

Tray,

(D) sq.m.

Rate of

Spread

= W/D,

kg/sq.m.

Average

Rate of

Spread

kg/sq.m.

Specif-

ication

Limits

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Remarks:



OBSERVATIONS


WPN No.

Location

RATE OF SPREAD OF BINDER FOR PRIME COAT/TACK COAT (As Per IRC: SP 11 - Appendix 5)

Description of Sample: Ref No:

Location/Chainage Sampling Date:

Sampled By: Testing Date:

a.

b.

c.

d

e.

f.

g.

h

I.

Sieve Size

26.5 100 100

19.0 90 100

13.2 56 88

4.75 16 36

2.36 4 19

0.300 2 10

0.075 0 8

0.00 0.00

Conducted By : Checked By:

Contractor's Representative EMGF RepresentativeJMF - Job Mix Formula

EMGF-ITP-007 Q1

321

Total

Pan

Total Wt. Of Agg After Test (e+c)-b,gm

Wt. Of Bitumen (a-f), gm

Cumulative Wt.

Reatained (g)

Filler / Binder Ratio

Wt. Reatained (g)

% Bitumen by Wt. Of Mix

Wt. Of Mix (gm)

Wt. Of Filter before Test (gm)

Wt. Of Filter After Test (gm)

Wt. Of Aggregate After Test (gm)

Wt. of Fines

Cum Retained (%) Passing %

Spec./JMF LimitsS No TEST Sample 1 AverageSample 2

MORT&H Limits

(3.3-3.5)+0.3

0.6 to 1.2

JMF

4

EMAARMGF LAND LIMITED

MOHALI INTEGRATED TOWNSHIP PROJECT

Tested By:

CONTRACTOR

BITUMEN EXTRACTION/SIEVE ANALYSIS FOR BITUMINOUS MACADAM-GRADING 2 AS PER MORT&H

CLAUSE NO. 504

0

20

40

60

80

100

0.01 0.10 1.00 10.00 100.00SIEVE IN SIZE

PE

RC

EN

TA

GE

PA

SS

ING




a.

b.

c.

d

e.

f.

g.

h

I.

Sieve Size

11.2 100 100

5.6 0 0

0.00 0.00





Tested By:

CONTRACTOR

EMGF-ITP-007 Q2

MORT&H Limits

0.6 to 1.2

JMF

4

AverageSample 2 Spec./JMF LimitsS No TEST Sample 1


Wt. Of Mix (gm)




Wt. of Fines

Total

Pan



Cumulative Wt.

Reatained (g)


Wt. Reatained (g)


21

BITUMEN EXTRACTION/SIEVE ANALYSIS FOR OPEN GRADED PREMIX CARPET(Type B) AS PER

MORT&H CALUSE NO. 511

3

0

20

40

60

80

100

0.01 0.10 1.00 10.00 100.00SIEVE IN SIZE

PE

RC

EN

TA

GE

PA

SS

ING




a.

b.

c.

d

e.

f.

g.

h

I.

Sieve Size

2.36 100 100

0.18 0 0

0.00 0.00



321

Total

Pan



Cumulative Wt.

Reatained (g)


Wt. Reatained (g)


Wt. Of Mix (gm)




Wt. of Fines


Spec./JMF LimitsS No TEST Sample 1 AverageSample 2

MORT&H Limits

0.6 to 1.2

JMF

4



Tested By:

CONTRACTOR

BITUMEN EXTRACTION/SIEVE ANALYSIS FOR SEAL COAT IMMEDIATELY AFTER LAYING THE SURFACING AS PER MORT&H CLAUSE NO.

513

EMGF-ITP-007 Q3

0

20

40

60

80

100

0.01 0.10 1.00 10.00 100.00SIEVE IN SIZE

PE

RC

EN

TA

GE

PA

SS

ING

EMGF-ITP-007R



Location / Source :……………… Weight of Aggregate :………………

Location :……………… Date of Sampling :………………

Material :……………… Sampled By :………………

Grade of Bitumen ::……………… Date of Testing :………………

Binder Content :………………

WPN No. :……………… Ref. No. :………………

Remarks :



Time of Placing in Water Bath

Temperature of Water Bath, oC

Time of Visual Inspection

Retained Coating Area (%)


Description

STRIPPING VALUE OF AGGREGATE(As Per IS: 6241)

OBSERVATIONS

Sample - 1 Sample - 2 Sample - 3

Temperature of Aggregate Before

Mixing, oC

Temp of Bitumen Before Mixing, oC

Type of Mixing

EMGF-ITP-007 S




Location :……………… Date of Testing :………………

Material :……………… Proving Ring Factor :………………

WPN No. :……………… Ref. No. :………………

1 2 3 4 5 6

Remarks :



Flow, mm

Stability, Proving Ring Reading

Stability, kg

Volume Correction Factor

Corrected Stability, kg


OBSERVATIONS

Mould No.Description Average

MARSHALL STABILITY FOR BITUMINOUS WORKS(As Per ASTM: D2726)

Bulk Density = W1 / V (gm/cc)

Weight of Specimen in Air, W1 gms

Weight of Specimen in Water, W2 gms

Weight of SSD Specimen in Air, W3 gms

Bulk Volume , V = (W3 -W2) cc

EMGF-ITP-007 T




Location :……………… Marshall Density (gm/cc) :………………

Material :……………… Type of Layer :………………

WPN No. :……………… Ref. No. :………………

1 2 3 4 5 6

Remarks :




Description

Chainage

OBSERVATIONS


FIELD DENSITY TEST FOR BITUMINOUS WORKS(As Per ASTM: D2726)

Weight of Specimen in Air, W1 gms

Weight of Specimen in Water, W2 gms

Weight of SSD Specimen in Air, W3 gms

Bulk Volume , V = (W3 -W2) cc

Bulk Density = W1 / V (gm/cc)

Test Core No.

Thickness (mm)


MS 08

WORK METHOD STATEMENT CONCRETE REPAIR

0 0.1 25/03/08 QC Manager CEO (N)


MS 08 Emaar MGF Land Limited Concrete Repair

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the repair to reinforced concrete structures on site. More detailed / task specific method statements for the construction of specialized reinforced concrete structures may be developed as additional sections to this method statement as the need is identified.

1.2 Reference

IS 13935: 1993 – Repair and Seismic Strengthening of Buildings



Issue 0.1

2.0 Procedure

2.1 Definition

Minor Defect: such as pin holes and minor grout / mortar loss, honeycomb with no exposure of reinforcement or embedded items.

Major Defect: such as significant voids, honeycomb, damage, delamination or spalling usually with exposure of reinforcement or embedded items.

Cracks: classed as per IS 13935: minor and medium (from 0.5mm to 5mm); major (5mm and above).

2.2 Products and Admixture

Concrete repairs shall be conducted using products approved by Client, or similar, such as those listed below

2.3 Repair

2.3.1 General

• All repairs shall be conducted according to manufacturer’s work instructions of the selected product.

• Before undertaking the repair, the Contractor shall inform the Client using WPN format (EMGF-QA-001A), indicating the type of defect and proposed procedure for repair.

• The surface shall be sound with laitance removed to ensure a good mechanical key.

• Surface to be repaired shall be so cleaned that it is free from dust, oil and other deleterious material.



Issue 0.1

• Reinforcement and cast-in-items, if exposed, shall be cleaned and if necessary, suitably coated.

• The finished and final colour of repaired area shall be as similar as possible to the surrounding concrete.

2.3.2 Minor Repair

Minor defects shall be repaired as follows: • Identify the area to be repaired. • Surface shall be cleaned. • Laitance shall be removed to obtain sound surface. • Repair surface shall be coated with acrylic based bonding agent. • All ingredients shall be weighed and packed in polyethylene bags. • Repair to be conducted as per manufacturer’s instructions after approval from

EMGF. • Area to be cured with curing compound.

2.3.3 Major Repair

Major defects shall be repaired as follows:

• Identify the area to be repaired. • Surface shall be cleaned. • Laitance shall be removed to obtain sound surface. • Reinforcement and exposed concrete shall be cleaned using compressed air. • Required formwork shall be fabricated. • Exposed concrete shall be dampened, then primed using Nitobond EP or

similar product. • Fill the repair area with structural grade polymer modified reinstatement

mortar (eg Rendroc S2). • Apply curing compound.

2.3.4 Cracks

• A V grove shall be cut along the crack. • 12mm dia holes shall be drilled every 300mm along the crack. • Clean the holes with air compressor. • Fix nozzles and inject low viscosity epoxy grout as per manufacturer’s

instructions.

For cracks in retaining walls, waterproofing requirements shall be considered in conjunction with this document.


EMGF-ITP-008 A

Project: Date:

Location: From Grid:

Drawing Ref.: To Grid:

Sub.Cont. EMGF

Deficiencies:

Remedial actions:

Sufficient tools / equipmetns for grouting, plastering works and finshings are available on site

Efflorescence, Crumbled and frost-damaged parts, contaminated layers and laitance are completely removed from the suface to be water proofed from both sides

Before application of tapecrete, plastering of outer surface is done with cement mortar of specified ratio mixed with approved admixture as per manufacturer's specifications.

Three coats of tapecrete each mixed with grey cement are applied on prepared surfaces as per their priscribed rate in BOQ/Technical Specification

A coat of neat cement slurry is applied on plastered surface before application of tapecrete

Representative of approved waterproofing agency is present on worksite

Sealing of all corners, joints, junction of pipes and masonry etc. with Epoxy putty is complete in all respects


Name :

Date :


Signature :


Outside Application

Inside Application

Cement plasters done for protection on the both side treatments are in line and free from deviations

Surfaces are cleaned with air compressor on both of the sides

Two coats of acrylic based water proofing chemical mixed with neat cement slurry coating as per manufacturers specifications are provided in required thickness and mix ratio

Curing is done as recommended by the manufecturer or water proofing agency

Cracks & honeycombing, if any in the foundation wall or between the wall and raft are repaired as per concrete repair method statement

All corners, joints, junction of pipes and masonry etc. are sealed properly


Inspection Checklist for Basement Waterproofing


Yes/No Inspection/DescriptionsRemarks


For injection grouting from inside, GI nozzles are placed in minimum required depth in walls and fixed at the centre to centre distance mentioned in technical Spec./BOQCement slurries of required viscositites under pressure by pump using acrylic based water proofing chemical mixed with neat cement slurry are injected properly

1

Layers of protective plaster of required thickness and mix ratio is applied over treated surface

2

Nozzles are sealed propely after the injection operation with suitable compound recommended by manufecturer

Waterproofing compounds, Cement and Sand is tested and approved


3

Emaar MGF Land Ltd

MS 09

WORK METHOD STATEMENT FORMWORK

0 0.1 25/03/08 QC Manager CEO (N)


MS 09 Emaar MGF Land Limited Formwork

Issue 0.1

1.0 Introduction

1.1 Scope

This method statement describes the work of Formwork as required by the drawing & specifications.

This document shall be read in conjunction with EMGF-MS-001.



Issue 0.1


2.1 General Requirements

Description: Formwork shall include all temporary or permanent forms required for forming the concrete of the shape, dimensions and surface finish as directed by the Engineer, together with all props, staging, centering, scaffolding and temporary construction required for their support.

Materials: Materials and components used for formwork shall be examined for damage or excessive deterioration before use/re-use and shall be used only if found suitable after necessary repairs. All staging and scaffolding work shall be constructed with MS pipes / Structural steel sections. The metal used for forms shall be of such thickness that the forms remain true to shape. All bolts should be countersunk.

2.2 Design of Formwork

Contractor shall furnish the design and drawing of formwork for approval to the client. The design shall facilitate proper and safe access to all parts of formwork for inspection. It shall ensure that the forms can be conveniently removed without disturbing the concrete.

2.3 Workmanship

• The formwork shall be robust and strong and the joints shall be leak-proof.

• The number of joints in the formwork shall be kept to a minimum by using large size panels. The design shall provide for proper “soldiers” to facilitate alignment.

• All joints shall be leak proof and must be properly sealed. Use of PVC JOINT sealing tapes, foam rubber or PVC T-section is essential to prevent leakage of grout.

• As far as practicable, clamps shall be used to hold the forms together. Where use of nails is unavoidable minimum number of nails shall be used and these shall be left projecting so that they can be withdrawn easily.

• Opening for fixtures and other fittings shall be provided in the shuttering as directed by the Engineer.

• Shuttering for walls, sloping members and thin sections of considerable height shall be provided with temporary openings to permit inspection and cleaning out before placing of concrete.

• The formwork shall be so made as to produce a finished concrete true to shape, line and levels and dimensions.

• Where metal forms are used, all bolts and rivets shall be countersunk and well ground to provide a smooth, plane surface. Where timber is used it shall be well seasoned, free from loose knots, projecting nails & splits



Issue 0.1

• To increase life of formwork where plywood is used all cuts I holes on the ply will be coated with approved primer.

• Forms shall be made sufficiently rigid by the use of ties and bracings to prevent any displacement or sagging between supports. They shall be strong enough to withstand all pressure, ramming and vibration during and after placing the concrete. Screw jacks or hard wood wedges where required shall be provided to make up any settlement in the formwork either before or during the placing of concrete.

• Suitable camber shall be provided to horizontal members of structure, specially in long spans to counteract the effects of deflection. The formwork shall be so fixed as to provide for such camber.

• The formwork shall be coated with an approved release agent that will effectively prevent sticking and will not stain the concrete surface. Lubricating (machine oils) shall be prohibited for use as coating.

2.4 Formed Surface & Finish

The formwork shall be lined with material approved by the Client so as to provided a smooth finish of uniform texture and appearance. This material shall leave no stain on the concrete and so fixed to its backing as not to impart any blemishes. It shall be of the same type. Internal ties and embedded metal parts shall be carefully detailed and their use shall be subject to the approval of the Engineer.

2.5 Preparation of Formwork before Concreting

The inside surfaces of forms shall be coated with a release agent supplied by approved manufacturer to prevent adhesion of concrete to the formwork. Release agents shall be applied strictly in accordance with the manufacturer’s instructions and shall not be allowed to come into contact with any reinforcement.

Before re-use of forms, the following actions shall be taken care of:

• Contact surfaces of the forms shall be cleaned carefully and dried before applying a release agent.

• Form surface shall be evenly and thinly coated with release agent.

• Release agent shall not come in direct contact with reinforcement or hardened concrete.

2.6 Removal of Formwork

The formwork shall be so removed as not to cause any damage to concrete. Centering shall be gradually uniformly lowered in such a manner as to permit the concrete to take stresses due to its own weight uniformly and gradually to avoid any shock or vibration. Where not specifically approved, the time of removal of formwork (when ordinary



Issue 0.1

Portland Cement is used without any admixtures at an ambient temperatures exceeding 15 degrees Celsius) shall be as under

Re-use of Formwork

Ty Str

Verticbea 16

Soffitrefi ) 3 days

Sof to beams (Props to be ref ork) 7 days

Pro

1. Spanni

2. Spanni

7 days

14 da

Props

1. Spanning up to 6 m

2. Spa

14 day

21 da

The form panel (plywood) used shall be of an approved grade to achieve the required finishes.

2.7

W tled, its individual components shall be examined for damage and damaged pieces shall be removed for rectification. Such

2.8

Deviation from specified dimension of cross-section of columns & beams: -6mm/+l2

iii. .02 times the width of the footing in the direction of deviation

pe of Formwork ipping Time

al formwork to columns, walls, ms - 24 h

formwork to slabs (Props to be xed after removal of formwork

fit formworkixed after removal of formw

ps to slabs:

ng up to 4.5 m

ng over 4.5 m

ys

to beams & arches:

nning over 6 m

s

ys

hen formwork is disman

examination shall always be carried out before being used again. Before re-use all components shall be cleaned of deposits of soil, concrete or other unwanted materials. Threaded parts shall be oiled after cleaning. All bent steel props shall be straightened before re-use. The condition of the timber components, plywood and steel shuttering plates shall be examined closely for distortion and defects before re-use.

Standards of Acceptance

i. mm.

ii. Deviation from dimension of footings: In plan: -12mm / +50mm. Eccentricity: 0but not more than 50mm.

iv. Thickness: +/- 0.05 times the specified thickness.



Issue 0.1

3.0 Formats

Formwork Checklist – EMGF-ITP-009A


Formwork Check List EMGF – ITP – 009A

Project: Date:

Contractor: Total Area:

Location / Grid: Structure:

Installation Inspection Check Satisfactory S No. Description Yes/No Remarks

Formwork Drawings Approved - Proceed Further Materials: 1 Are the correct form materials being used? 2 Is the form face appropriate to the finish required? Formwork Frames: 3 Are they to dimension and within tolerance? 4 Are they accurate to line, level and plumb? Bracing/Props: 5 Are supported elements wedged and nailed? 6 Is the bracing firmly connected? Fixing: 7 Is the nailing/screwing adequate? 8 Are all ties, clamps and bolts tight? 9 Are wedges tight and nailed? Cleanliness: 10 Are the form faces cleaned? 11 Is any damage correctly repaired? 12 Is the correct release agent in use? 13 Is it being correctly applied? 14 Has all debris been removed from within the form? Water tightness: 15 Are all joints properly sealed and cramped? 16 Are the construction joints sealed? Concrete/Concreting: 17 Are forms maintaining line, level, plumb, shape, etc during Stripping: 18 Do the procedures enable stripping without damage to form 19 Are the provisions consistent with the re-use times required? 20 Has the crane the necessary slings, etc to move the forms 21 Is the storage area for the formwork organised? Safety: 22 Are there adequate guardrails, handrails, walkways, signs, Prepared by:

Verified by:

Emaar MGF Land Ltd

MS 10

WORK METHOD STATEMENT ANTI TERMITE TREATMENT

0 0.1 27/03/08 QC Manager CEO (N)


MS 10 Emaar MGF Land Limited Anti Termite Treatment

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes covers the chemical treatment of soils for the protection of buildings from attack by subterranean termites. It includes reference to the chemicals to be used, lays down minimum rates of application for usage, and outlines procedures to be followed while the building is under construction on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The pre-construction anti-termite treatment done is according to standards and its procedures.



Issue 0.1

2.0 Procedure

2.1 General

Chemical toxic to subterranean termites may be used effectively to check termite infestation in the soil. The following chemicals conforming to relevant Indian Standard in water emulsion are effective when applied uniformly over the area to be treated.

2.2 Mound Treatment

If termite mounds are found within the plinth area of the buildings these should be destroyed by means of insecticides in the form of water suspension or emulsion which should be poured into the mounds at several places after breaking open the earthen structure and making holes with crow-bars. The quantity to be used will depend upon the size of the mound. For a mound volume of about 1 m3, 4 litres of an emulsion in water of one percent Chlorpyrifos 20 EC or Lindane 20 EC may be used.

2.3 Soil Treatment

a. The chemical emulsions described below shall be applied uniformly at the prescribed rate in all the stages of the treatment. A suitable hand operated compressed air sprayer or watering can should be used to facilitate uniform disposal of the chemical emulsion. On large jobs, a power sprayer shall be used.

b. In the event of water logging of foundation, the water shall be pumped out and the chemical emulsion applied when the soil is absorbent.

c. Barrier shall be complete and continuous under the whole of the structure to be protected. All foundations shall be fully surrounded by and in close contact with the barrier or treated soil. Each part of the area treated shall receive the prescribed dosage of chemical.

d. Soil treatment should start when foundation trenches and pits are ready to take mass concrete in foundations. Laying of mass concrete should start when the chemical emulsion has been absorbed by the soil and the surface is quite dry. Treatment should not be carried out when it is raining or when the soil is wet with rain or sub-soil water. The foregoing requirements apply also in the case of treatment to the filled earth surface within the plinth area before laying the sub-grade for the floor.

e. Once formed, treated soil barriers shall not be disturbed. If, by chance, treated soil barriers are disturbed, immediate steps shall be taken to restore the continuity and completeness of the barrier system.

2.4 Treatment for Masonry Foundations and Basements

The bottom surface and the sides (up to a height of about 300 mm) of the excavations made from masonry foundations and basements shall be treated with the chemical at the rate of 5.0 l/m2 surface area.

After the masonry foundations and the retaining wall of the basements come up, the backfill in immediate contact with the foundation structure shall be treated at the rate of



Issue 0.1

7.5 l/m2 of the vertical surface of the sub-structure for each side. If water is used for ramming the earth fill, the chemical treatment shall be carried out after the ramming operation is done by rodding the earth at 150 mm centres close to parallel to the wall surface and spraying the chemical emulsion at the above dosage. After the treatment, the soil should be tamped in place. The earth is usually returned in layers and the treatment shall be carried out in similar stages. The chemical emulsion shall be directed towards the masonry surfaces so that the earth in contact with these surfaces is well treated with the chemical.

2.5 Treatment for RCC Foundations and Basement

The treatment shall start at a depth of 500 mm below the ground level except when such ground level is raised or lowered by filling or cutting after the foundations have been cast. In such cases, the depth of 500 mm shall be determined from the new soil level resulting from the filling or cutting mentioned above, and soil in immediate contact with the vertical surfaces of RCC foundations shall be treated at the rate of 7.5 l/m2.

2.6 Treatment of Top Surface of Plinth Filling

The top surface of the consolidated earth within plinth walls shall be treated with chemical emulsion at the rate of 5 1/rn2 of the surface before the sand bed or sub-grade is laid. If the filled earth has been well rammed and the surface does not allow the emulsion to seep through, holes up to 50 to 75 mm deep at 150 mm centres both ways may be made with 12 mm diameter mild steel rod on the surface to facilitate saturation of the soil with the chemical emulsion.

2.7 Treatment at Junction of the Wall and the Floor

Special care shall be taken to establish continuity of the vertical chemical barrier on inner wall surface from ground level up to the level of the filled earth surface. To achieve this, a small channel 30 mm x 30 mm shall be made at all the junctions of wall and columns with the floor (before laying the sub-grade) the rod holes made in the channel up to the ground level 150 mm apart and the iron rod moved backward and forward to break up the earth and chemical emulsion poured along the wall at the rate of 7.5 l/m2 of vertical wall or column surface so as to soak the soil right to the bottom. The soil should be tamped back into place after the operation.

2.8 Treatment of Soil along External Perimeter of Building

After the building is complete, the earth along the external perimeter of the building should be rodded at intervals of 150 mm and to a depth of 300 mm. The rods should be moved backward and forward parallel to the wall to break up the earth and chemical emulsion poured along the wall at the rate of 7.5 l/m2 of vertical surfaces. After the treatment, the earth should be tamped back into place.

2.9 Treatment of Walls Retaining Soil above Floor Level

Retaining walls like the basement walls or outer walls above the floor level retaining soil need to be protected by providing chemical barrier by treatment of retained soil in the immediate vicinity of the wall, so as to prevent entry of termites through the voids in masonry, cracks and crevices, etc above the floor level. The soil retained by the walls shall be treated at the rate of 7.5 l/m2 of the vertical surface so as to affect a



Issue 0.1

continuous outer chemical barrier, in continuation with that of the one formed under 3.4.

2.10 Treatment of Soil Surrounding Pipes, Wastes and Conduits

When pipes, wastes and conduits enter the soil inside the area of the foundations, soil surrounding the point of entry shall be loosened around each such pipe, waste or conduit for a distance of 150 mm and to a depth of 75 mm before treatment is commenced. When they enter the soil external to the foundations, they shall be similarly treated at a distance of over 300 mm unless they stand clear of the walls of the building by about 75 mm.

2.11 Treatment for Expansion Joints

The soil beneath expansion joints should receive special attention when the treatment under 2.7 is carried out. This treatment should be supplemented by treating through the expansion joint after the sub-grade has been laid, at the rate of 2 litres per linear metre.


EMGF-ITP-010 A

Project: Date:

Location: From:

Drawing Ref.: To:

Description of work:

Contractor EMGF

1

2

Deficiencies:

Remedial actions:

In case of earth filling/plinth filling, holes are made in mentioned depth

and spacings

Signature :

5 Post-

Construction

Checks

No Anti termite barrier is disturbed, if disturbed it is maintaned again,

No water is poured on the sprayed antitermite barrier

Name :

Date :

Concrete is not poured on the surface till chemical get absorbed

properly in soil/surface

Continuity of the vertical chemical barrier on inner wall surface from

ground level up to the level of the filled earth surface is maintaineed

properly

Contractor's Representative Emaar MGF Representative

Remarks

4

3

Rate of spray is maintained as mentioned in method statement

Representative of Approved Agency for Antitermite is present on site

Spraying apparatus available on site is in working condition

Chemical is mixed in proper ratio as mentioned in method statement

Surface for Antitermite treatment is completley cleaned and compacted

Surface/soil for Antitermite treatment is completley dry and absorbent

Construction

Operations

Materials From Approved Source

Pre-Construction

Checks

Proper Safety precautions are taken on site


Inspection Sheet for Anti Termite Treatment

S.No.

Check Satisfactory


Emaar MGF Land Ltd

MS 11

WORK METHOD STATEMENT EARTHWORKS

MS 11 Emaar MGF Land Limited Earthworks

Issue 0.1

1. Introduction

This method statement describes the resources, procedures and tests to be adopted for entire completion of earthwork activities for the Mohali Integrated Township project to the requirements of the Contract Technical specifications & Drawings.

The work scope associated with this method statement includes:

• Permission for Excavation;

• Excavation of footings for non-piled structures;

• Trenches;

• Embankment/Sub-grade improvement including excavation, replacement and compaction beneath roads, footings;

• Suitability of Material for the Work;

• Stockpiling or removal of spoil material.

• Backfill around completed footings and structures;

• Backfilling in Trenches;

• Compaction



Issue 0.1

2. PROCEDURE

2.1 Permit to Excavate

At least 24 hours prior to the commencement of any excavation works for a given location within the boundary fence, the Permit to Excavate application form shall be completed and submitted by the subcontractor to EMGF representative. EMGF shall complete, endorse and return the permit providing comprehensive information about existing underground services or other hazards in the area in question. If services are identified in the permit then the site engineer shall instruct the survey team to set out the position and line of all services prior to commencement of excavation.

The Construction Manager shall register and retain the original endorsed permits in the site files. In addition, the site superintendent shall inform all personnel associated with the excavation with the hazards listed in the permit.

On completion of excavation work covered by the permit, the contractor shall immediately inform the Construction Manager. The Construction Manager shall then sign off the permit to indicate completion of work and then return the permit to the Customer.

2.2 Initial Record Survey

Prior to commencement of earthworks, initial record survey shall be completed to measure and record the levels of the existing surface at not more than 10 meter and record in the Field Level Book in the presence of EMGF Representative. Also the position and levels of all existing utilities and structures that are visible at the surface and within the site boundary or works area shall be recorded. A plot (including data log) of the survey shall be submitted to the EMGF for information.

2.3 Excavation

2.3.1 Structures

1 Contractor shall employ sufficient Excavators/JCB, Tippers and Manpower for the commencement of work on site as per schedule & targets set by EMGF to achieve.

2 Layout of Proposed location shall be done at site based upon Northing -Easting coordinates and as per relevant Drawings and as per guidance of the Construction Manager/Project Manager.

3 Mass excavations shall generally be benched to a minimum width of 600 mm at intervals of 1.5 to 2 metres depth. Deep excavations (> 6 metres) may require design calculations to prove stability for soil type and slope/bench arrangement or as specified in relevant Drawings.

4 Cuttings shall have slopes as shown on the Drawings. These may be revised by the EMGF Representative on the basis of site inspection and investigation during the excavation.



Issue 0.1

5 All excavated material will be spoiled in the same location unless alternative measures are required / requested by the client. Spoil for temporary excavations may be stockpiled in windrows not more than 2.5m high provided the maximum slope shall not exceed more than 1:2 (v:h). Appropriate measures shall be adopted to ensure that this surplus material does not become contaminated prior to hand-over.

6 Any unsuitable material should be removed from site to offsite locations. Surplus or rejected excavated material not required for filling is to be transported off the Site to an approved dump site provided by the EMGF. The Contractor is to take all precautions to prevent any spillage or soiling of the public roads during the removal operation, and is to pay all dues in connection therewith.

7 Suitable access shall be maintained to or from excavations and trenches for various trades and equipment deliveries.

8 In general, bailer slopes in loose sand shall be 1 in 1, whilst batters in cohesive materials (clayey soils) may be up to 1 in 2 slopes. In addition, the suitability of all minor slopes shall be subject to visual inspection by competent personnel. Other considerations, such as ground water and vibration, may require the use of flatter slopes.

9 Cut faces shall be cleaned of loose or unstable material progressively as the unstable excavation proceeds.

10 Haul roads with suitable surfacing shall be established and maintained for both access to the excavation and access to the temporary stockpile.

11 Width of excavation around structures/work site shall be sufficiently more than the actual dimensions to allow sufficient space for formwork constructions and adequate work area.

2.3.2 Trenches

1 Contractor shall employ sufficient Excavators/JCB, Tippers and Manpower for the commencement of work on site as per schedule & targets set by EMGF to achieve.

2 Trench cutting requires the sides of excavation to be cut and braced if required by EMGF.

3 In the absence of such guidelines, trenches up to 1.2 meters in depth may be cut with near vertical sides without shoring. Deeper trenches will require suitable benching and batter slopes.

4 Excavated material will be stockpiled or removed from site as required.

5 The minimum width of trenches shall be kept at the bottom, as per recommendations of relevant BIS codes.

6 The trench shall be excavated to the exact gradient as specified so that no making of the sub grade by backfilling is required and the concrete bed, where required may be prepared with greater ease giving a uniform & continuous bearing and support for the pipe.



Issue 0.1

7 When the bottom of the trench at the specified gradient is found unstable or includes ashes & cinders, all types of refuse, vegetable, or other organic material, they shall be removed to the satisfaction of the Construction Manager/Project Manager. Before laying the concrete bed, where necessary the specified gradient by backfilling with an approved material in uncompacted layers of 80 mm. The layer shall then compacted by tamping or ramming or any other mechanical means as directed by Construction Manager/Project Manager.

8 The bottom of the trench shall be trimmed off to present a plain surface and all irregularities shall be levelled.

9 Trenches should be backfilled with the suitable excavated soil or as guided by the EMGF representatives in layers as per the trench zones defined by the relevant BIS codes or as per Drawings /GFC Technical specifications.

10 Compaction shall be done in layers of using suitable machinery as determined by the width of the trench.

11 Care shall be taken not to drop heavy volumes of fill on top of services. Power rammers shall not be used within 300mm of any part of any underground service.

12 Each fill layer shall uniformly compact to minimum percentages of Standard Proctor Density as specified in ITP 11.

13 Trenches may be filled by hand shovel or backhoes / excavators in layers using site fill material or imported material once approval to proceed has been granted.

14 Where a pipeline is supported on concrete, the Contractor must not place the overlay material until the concrete has obtained its initial set. Backfill must not be placed within 24 hours of placing the concrete, or longer where specified by the Design Drawings.

15 Filling around pipes and conduits shall be brought up uniformly on each side of the pipe.

16 Proper care shall be taken in backfilling to avoid damage or displacement of services.

2.4 Dewatering

1 Depending on the depth and size of excavation, ground water level and permeability of the

soil, contractor shall propose the dewatering system to locally reduce groundwater influx.

2 Contractor shall be ready with a contingency plan to remove surface water from excavated area in case of rain.

2.5 Backfilling

1 Backfill operations shall only proceed after an inspection has been completed, and approval has been given.

2 Filling around structures shall be carried out in such a manner as to avoid uneven loading of the structure and only at such time as any works have achieved adequate strength to accept



Issue 0.1

the loading. In the absence of guidelines, Contractor shall start backfilling after demonstrating that 85 per cent of the design strength of the concrete has been achieved.

3 Selected backfill shall be placed adjacent to structures in uniform thickness. The selected backfill shall consist of a granular material having grain size maximum dimension not exceeding 50mm and all properties as per technical specification.

4 The selected backfill shall be placed in layers, with a maximum uncompacted placement in thickness of 300mm. It should be done as per trench zones defined in the relevant standards.

5 Compaction shall start at the wall and proceed away from it.

6 In the case of framed structures, embankments at both ends of the structure framed shall be brought up simultaneously; the difference between the levels of the Structures embankments at the respective member shall not exceed 500mm.

7 Excavators and tip trucks shall be used for loading and hauling fill from stockpiles where required. Generally dozers and graders shall be used to spread and trim site won and imported fill layers to required levels.

8 Compaction will be carried out using appropriate vibratory or static compaction equipments. For confined operations, excavators and plate compactors shall be used for placing and compacting layers of fill material.

9 Following the excavation of soft spots beneath structural formations, holes shall be filled with suitable material and compacted.

2.6 Material

1 The materials used for the embankments shall be soil , morum, gravel, or a mixture of these or any other material approved by the EMGF representative . Such material shall be free from logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or affect the stability of the embankment.

2 For Embankment up to 3.0 meters height (not subjected to extensive flooding) the Modified Proctor Density shall not be less than 15.2 kN/cum. For more than 3.0 meters height, maximum lab density shall not be less than 16.0 kN/cum.

3 In case of Sub grade and backfilling, Modified Proctor Density shall not be less than 17.5 kN/ cum.

4 CBR value for the soil used as sub grade material should be as per drawing requirements/ Technical Specification.

5 The size of the coarse material in the mixture of earth shall ordinarily not exceed 75mm when being placed in embankment and 50mm in sub grade.

6 Material with following properties shall NOT be used either for embankment or subgrade. The materials from swamps, marshes, bogs, Peat, log, stump & perishable material, Materials



Issue 0.1

susceptible to spontaneous combustion, Material in a frozen condition, Clay having liquid limit exceeding 70 and plasticity index 45, Materials with salt resulting in leaching in embankment, Expansive clay exhibiting marked swell and shrinkage properties.

7 Soil for backfilling around structures and trenches shall have a LL and PI not exceeding 40 and 20 respectively.



Issue 0.1

3. Compaction of Earthwork

The Compaction of the earthwork is dependent on type of machinery, depth of earthwork, moisture content of soil, type of soil & many other circumstances. Hence proper selection of equipment shall be made to achieve the desired compaction required as per relevant technical specifications, BIS codes, or contract technical specifications.

For construction of road works it should be Min. 95 % for the embankment constructions & 97 % for the sub grade works & for Backfilling in the trenches it should be Min. 95 % of Modified Proctor Density test as per IS : 2720 (Part-VIII).

For structural works, degree of compaction achieved shall be 95% of the Modified Proctor Density.



Issue 0.1

4. Identification System

The establishment of a simple but effective identification system is required for each compacted layer of each section, segment area or lot of the works that is subject to compliance testing. This identification system may be a combination of grid, coordinate or chainage references in combination with alpha-numeric code. MDD (Maximum Dry Density) and in-situ density test reports associated with each lot tested shall reference the respective identification system. In addition, a contract drawing shall be marked up showing the test area on plan and, where required, showing the datum level (or zone) below final formation.



MS 12

WORK METHOD STATEMENT DRAINAGE WORKS – RCC PIPES

0 0.1 27/05/08 QC Manager CEO (N)


MS 12 Emaar MGF Land Limited Drainage Works

Issue 0.1

1.0 Introduction

This method statement describes the work of Drainage system using RCC Pipes as required by the drawing & specifications to be adopted for Projects under EMGF (N).



Issue 0.1

2.0 Procedure

2.1 Pre – Construction

(i) Ensure that construction material has been tested as per the relevant ITP.

(ii) Pipes shall be inspected for any damage during transport / handling. No repair shall be undertaken at site.

(iii) Survey for final set out as per drawing.

(iv) The existing ground level is to be determined and recorded in Field Book. Contractor’s representative shall get the Field Book signed from EMGF Representative.

(v) Set out the drain.

(vi) The final excavation level is to be determined using latest GFC Drawing.

2.2 Excavation

(i) After all the pre-excavation works are completed, the execution of excavation work shall be carried out to the line and level shown on the drawings. Excavation shall be done in such a manner that the excavated faces may not assume unstable slopes, and any adjacent foundations shall not be disturbed. In cases where water seepage occurs, causing interference with the work, such conditions shall be rectified by proper methods such as gravitational drainage or pumping.

(ii) The width of trench at the bottom shall be such to provide at least 150mm clearance on both sides of the pipeline (d+300mm).

(iii) Bed of the trench shall be trimmed and leveled to permit even bedding of pipeline. The bed shall be free from any extraneous material which may damage the pipe.

2.3 Laying of Pipe

(i) Joints shall be laid on PCC (1:4:8) cradle.

(ii) Drainage lines shall be laid to the gradient & profiles given in latest GFC Drawing.

(iii) Laying shall preferably be done upgrade of slope.

(iv) The annular space between socket and spigot shall be filled with cement mortar (1:2).

(v) Haunching of joints shall be done as per GFC Drawing. In the absence of specifications width shall be outer diameter plus 300mm. Haunching shall extend 150mm on either side of the joint.

(vi) No drains shall be laid in the middle of the road unless otherwise specifically shown in the drawing.

(vii) When the pipe line is under a road way a minimum cover of 1.0m is recommended for adoption. Bedding shall be in monolithic layer of PCC or RCC (1:4:8). Bedding type should be decided on site conditions.



Issue 0.1

2.4 Testing and Backfilling

(i) Pressure test shall be conducted to ensure there is no leakage. Format EMGF ITP 012 A shall be duly filled and signed by EMGF representative.

(ii) Backfilling shall be done with suitable material in layers not exceeding 200mm. The compaction shall be done with the help of suitable equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve at least 95% proctor density w.r.t field density before excavation. To the extent available, selected spoils from excavated materials shall be used as backfill. Fill material shall be free from clods, salts, sulphates, organic or other foreign material. All clods of earth shall be broken or removed.

2.5 Chamber

(i) All chambers and other such works as specified shall be constructed in first class designation 75 FPS brick in cement mortar 1:4 mix (1 cement: 4 coarse sand) or as specified in the schedule of quantities. Chambers shall be supported on base of cement concrete of such thickness and mix as given shown on the GFC drawings.

(ii) The chamber shall be connected to the nearest main storm water drain by RCC pipe of specified size as given in drawings and as per site requirement. The chamber shall be built at the location fixed by EMGF Representative.

(iii) The wall of chamber shall be plastered with 12mm thick cement plaster 1:3 (1 cement: 3 course sand) finished smooth and cured for at least 7 days.

2.6 Formats

(i) EMGF - ITP 012 A – Inspection Check List (ii) EMGF - ITP 012 B – Material Inspection and Test Plan


EMGF-ITP-012 A

Project: Mohali Hills - Infrastructure Date:

Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

Straightness test

Leakage test

6

7

Deficiencies:

Remedial actions:

Encasing as per specification and GFC drawing

Permit to BackfillStretch may be Backfilled

MTC Available/Outside Testing Done

Drainage line is straight & according to design levels as per drawings

Haunching as per Specification

Curing of Encasing & Haunching

levels & Alignment checked before excavation

Excavation Done As per Drawing

Bottom level of trench checked before laying

Signature :

Plaster with good finishing and proper thickness as per drawing


Name :

Date :


Remarks

8

3

4

5 Testing

Backfilling

Manholes / Chamber

Cover fitted properly and as per specifications

Proper Curing is done

Backfill done in layers as per Trench Zone and compacted as per specificati

Quality of materials checked as per specification

Brickwork & Cement Concrete work according to dimension and as per specification, GFC Drawing

Check SatisfactoryYes/No

Test Register Maintained

Inspection/Descriptions



Inspection Sheet for Drainage System

S.No.


Laying Operations

Inside of drainage free from obstructions through out its entire length

Rubber Ring Properly fixed

Trench excvated as per specifications

Specified Compaction of excavated bottom and its design levels

Pipe laid with sockets leading uphill and rested on well compacted surface

EMGF-ITP-012 B

BIS Reference: IS 458

upto 50 51 to 100 101 to 300 301 to 500

501 and

above upto 50 51 to 100 101 to 300 301 to 500

501 and

above

1 Testing of concrete during casting

2 Hydrostatic Test 2 3 5 7 10 0 0 0 0 0

3 Three Edge Bearing Test 2 3 5 7 10 0 0 0 0 0

4 Permeability Test 2 3 5 7 10 0 0 0 0 0

5 Dimensional Requirement 8 13 20 32 50 0 1 2 3 5

6 Finish 8 13 20 32 50 0 1 2 3 5

7 Straightness 8 13 20 32 50 0 1 2 3 5

8 Ultimate Load Test 0 0 0 0 0

Lot: In any consignment, all the pipes of same class, same size and belonging to the same mix of concrete shall be grouped together to constitute a lot.

These pipes shall be selected at random. In order to ensure the randomness of selection, procedures given in IS 4905 may be followed.

Tests with S No. 2, 3, 4 and 7 shall be carried out in accordance to IS 3597 and S .No. 5 and 6 in accordance to IS 458.

As per IS 516

As mutually agreed by Purchaser & Manufacturer

Test

Inspection and Test Plan

ITP - 12B Precast Concrete Pipes

S. No.

Number of Samples for Lot Size Permissible Number of Defectives

EMGF-ITP-012 C

Project: Location / Road No.

Contractor: From Manhole: To Manhole:

Sector: From Node: To Node:

Contractor EMGF

1

3

4

5

Comments, if any:

Note: All the faulty joints are to be embedded with 150 mm thick concrete 1 : 2 : 4, 300 mm in length & the section retested.

Sign:

EMGF Representative

Name:

Designation:

Date:

2hrs minimum

No. of Joints Leaked

All the faulty joints are repaired as per Method Statement

The pipeline is again tested & found OK

c) Total Hrs. Test Head Maintained

2

Date:

Sign:

Name:

Designation


RemarksObservation

EMAAR MGF LAND LIMITEDInspection Sheet for Hydraulic Test for RCC Pipes

S.No. Inspection/Descriptions

Check Satisfactory

Yes/No

a) Start Time :

b) End Time:

Head of Water Maintained During the Test 1.5 m Minimum


MS 13

WORK METHOD STATEMENT SEWERAGE WORKS – SW PIPIES

0 0.2 27/06/08 QC Manager CEO (N)

0 0.1 27/05/08 QC Manager CEO (N)


MS 13 Emaar MGF Land Limited Sewerage Works – SW Pipes

Issue 0.2


1.0 Introduction

This method statement describes the work of Sewerage system as required by the drawing & specifications to be adopted for Projects under EMGF (N).

Without restricting to the generality of the foregoing system shall include Sewerage pipeline excavation, bedding of pipes, manholes, drop connections and other allied works including underground trenches.


Issue 0.2


2.0 Procedure

2.1 Pre – Construction Activities


(ii) Pipes shall be inspected for any damage during transport / handling. No repair shall be undertaken at site.

(iii) Each pipe shall be rung with a wooden hammer or mallet and those that do not ring true and clear shall be rejected. Sound pipes shall be carefully stacked to prevent damage.

(iv) All defective pipes should be segregated, marked in a conspicuous manner and their use in the works prevented.

(v) Survey for final set out as per drawing.

2.2 Excavation

(i) After all the pre-excavation works are completed, the execution of excavation work shall be carried out to the line and level shown on the drawings. Excavation shall be done in such a manner that the excavated faces may not assume unstable slopes, and any adjacent foundations shall not be disturbed. In cases where water seepage occurs, causing interference with the work, such conditions shall be rectified by proper methods such as gravitational drainage or pumping.

(ii) Bed of the trench shall be trimmed and leveled to permit even bedding of pipeline. The bed shall be free from any extraneous material which may damage the pipe.

(iii) Width of trench bottom shall be as follows:

Diameter of Pipe (d) Average depth Width

All dia <= 1.2 m d + 300mm

All dia > 1.2 m d + 400mm

Not withstanding the above, width shall be at least 750mm for depth more than 900mm.

(iv) A concrete bed as per GFC Drawing shall be provided. In absence of clear specifications, concrete bed shall be 1:5:10 and 150mm thick.

2.3 Laying of Pipes

(i) Pipes shall be laid to the gradient & profiles given in latest GFC Drawing.

(ii) Under no circumstances shall pipes be dropped or dumped into trench.

(iii) The pipes shall be laid with sockets leading uphill and should rest on solid and even foundations for the full length of the barrel. Socket holes shall be formed in the


Issue 0.2


foundation sufficiently deep to allow the pipe jointer enough room to work right round the pipe and as short as practicable to admit the socket and allow the joint to be made.

2.4 Jointing

(i) Tarred gaskin shall first be wrapped round the spigot of each pipe and the spigot shall then be placed into the socket of the pipe previously laid, the pipe shall then be adjusted and fixed in its correct position and the gaskin caulked tightly home so as to fill not more than one quarter of the total length of the socket.

(ii) The remainder of the socket shall be filled with stiff mix of cement mortar 1:1 (1cement: 1 clear sharp washed sand). When the socket is filled, a fillet should be formed round the joint with a trowel forming an angle of 45 degrees with the barrel of the pipe. The mortar shall be beaten up and used after it has begun to set.

(iii) After the joint has been made any extraneous material shall be removed from inside of the joint with a suitable scraper or “Badger”. The newly made joints shall be protected until set from the sun, drying winds, rain or dust. Sacking or other materials, which can be kept damp, shall be used. The joints shall be exposed and space left all round the pipes for inspection by the Construction Manager. The inside of the sewer must be left absolutely clear in bore and free from cement mortar or other obstructions throughout its entire length, and shall efficiently drain and discharge.

(iv) Joint shall be cured for at least 7 days or till backfilling is done.

2.5 Encasing and Haunching

(i) Wherever the soil cushion on top of the pipe is less than 1200mm, stoneware pipes shall be encased as per latest GFC Drawing.

(ii) In the absence of clear specifications, width of encasing shall be ‘outer dia of pipe plus 400mm’. Cover on top shall be 150mm. Concrete shall be 1:5:10.

(iii) Where the soil cushion is greater than 1200mm, haunching shall be done throughout the length of the pipe as per latest GFC Drawing.

(iv) Curing shall be done for 7 days or till backfilling is done.

2.6 Testing

(i) All lengths of the sewer and drain shall be fully tested for water tightness by means of water pressure maintained for not less than 30 minutes. Testing shall be carried out from manhole. All pipes shall be subjected to a test pressure of at least 1.5 metre head of water. The test pressure shall, however, not exceed 1.5 metre head at any point. The pipes shall be plugged preferably with standard design rubber plugs on both ends. The upper end shall, however, be connected to a pipe for filling with water and getting the required head.


Issue 0.2


(ii) Sewer lines shall be tested for straightness by:

• Inserting a smooth ball 12mm less than the internal diameter of the pipe. In the absence of obstructions such as yarn or mortar projecting at the joints the ball should roll down the invert of the pipe and emerge at the lower end.

• Means of a mirror at one and a lamp at the other end. If the pipeline is

straight the full circle of light will be seen otherwise obstruction of deviation will be apparent.

(iii) Any joint found leaking / sweating shall be rectified or embedded in to 150mm thick concrete, 1:2:4, 300mm length and the section retested.

2.7 Manhole

(i) Manholes shall be constructed as per latest GFC drawing.

(ii) Levels shall be checked carefully.

(iii) Brick masonry shall be done in 1:4 mortar. PCC below brickwork to be 1:4:8.

(iv) Plastic encapsulated approved foot rest, orange in colour, shall be fixed in concrete 30x20x15 cm.

(v) Horizontal and vertical spacing between foot rest shall be 300mm. It shall protrude 100mm from wall.

(vi) Plaster, both internal and external, shall be 12mm thick with neat cement finish (1:4).

2.8 Backfilling

(i) All backfill material shall be free from cinders, ashes, slag, refuse, rubbish, vegetable or organic material, lumpy or frozen material, boulders, rock, stone or other material which in opinion of Authority, is unsuitable or deleterious, however materials containing stones up to 200 mm may be used in Zone C.

(ii) Backfilling shall be done with suitable material in layers not exceeding 300mm. The compaction shall be done with the help of suitable equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve at least 95% field density w.r.t proctor density. All the backfilling should be done as per trench zoning (A,B,C), In Trench zone A as defined in IS : 4127(1983), laying of Salt Glazed Stoneware pipes, the backfilling should be done in layers of 80 mm & then compacting the earth to the required field density of the Modified proctor density with ref to IS:2720(part-8). In trench zone B & C the soil should be compacted in thickness of 300 mm & compacted to the desired density.

(iii) Trench Zone Definition

• Zone A: From the bottom of the trench or from the top of the concrete, when concrete bedding is provided, to the level of centre line of the pipe.


Issue 0.2


• Zone B: From the level of the centre line of the pipe to the 300 mm above the top of the pipe.

• Zone C: From a level 300 mm above to the top of the pipe to the top of the trench.

2.9 Formats


EMGF-ITP-013 A


Location: From MH:

Drawing Ref.: To MH:

Sub.Cont. EMGF1

2

Straightness test

Hydraulic Test

7

8

Deficiencies, if any:

Remedial actions:

Testing

Permit to Backfill



Laying Operations

Specified Compaction of excavated bottom and its level

PCC Done - Thickness of concrete checked and appearance acceptable

Pipe laid with sockets leading uphill

No obstruction and cleanliness inside for entire length checked

Haunching as per Specification

5

Curing of Encasing & Haunching



Physical Checks


Inspection Sheet for Sewerage System

Trench excavated as per specifications

Check SatisfactoryYes/NoS.No. Inspection/Descriptions

Tarred gaskin wrapped around the spigot of pipe and the spigot placed into the socket of the previously laid pipe

Remainder of the socket filled with cement mortar 1:1, forming an angle of 45 degrees with the barrel of pipe

Free from rough texture

Damages on surfaces/Edges

Manufacturer Name Marking

Cross-section survey of OGL

Alignment of pipeline

Excavation as per Drawing

Cross-section survey of bottom level after excavation

Quality of materials checked as per specification

Manhole cover fitted properly and as per specifications

Brickwork according to dimension and as per specification, GFC Drawing

Plaster with good finishing and proper thickness as per drawing

Foot rest fixed in concrete as per drawing (spacing, material etc)

Contractor

Date :


Signature :

Backfill done in layers as per trench zone and compacted as per specification

Remarks

9

3

4

6

Encasing as per specification and GFC drawing

Name :

Curing is done

Backfilling

Manholes

Stretch may be backfilled

EMGF-ITP-013 B


upto 150151 to 1200

1201 to 10000 upto 150

151 to 1200

1201 to 10000

1 Acid Resistance 3 5 8 0 0 0

2 Alkali Resistance 3 5 8 0 0 0

3 Water Absorption 3 5 8

4 Crushing Strength 3 5 8 0 0 0

upto 150151 to

280281 to

500501 to 1200

1201 to 3200

3201 to 10000 upto 150

151 to 280

281 to 500

501 to 1200 1201 to 3200 3201 to 10000

5 Dimensional Requirement* 20 32 50 80 125 200 1-4 (4-5) 2-5 (6-7) 3-7 (8-9) 5-9 (12-13) 7-11 (18-19) 11-16 (26-27)

6 General Quality* 20 32 50 80 125 200 1-4 (4-5) 2-5 (6-7) 3-7 (8-9) 5-9 (12-13) 7-11 (18-19) 11-16 (26-27)

7 Hydraulic Test 0 0 0 0 0 0

S. No. Test

1 Field Dry Density

2 Hydraulic Test

Lot: All the pipes or fittings of the same type, size and manufactured under similar conditions of production, shall be grouped together to consitute a lot. These pipes shall be selected at random. In order to ensure the randomness of selection, procedures given in IS 4905 may be followed.Tests shall be carried out in accordance to IS 651.

* - "a-b (c-d)"The number of pipes or fittings in the first sample shall be first selected and subjected to inspection for general quality and dimensions. If in the first sample the number of defectives, that is, those failing either for general quality or dimensions, is less than or equal to the corresponding acceptance number (a), the lotshall be considered as conforming to the requirements of general quality and dimensions. If the number of defectives in the first sample is greater than or equal to the corresponding rejection number (b), the lot shall be considered as not conforming. If the number of defectives in the first sample lies between the corresponding (a) and (b), a second sample, shall be selected and subjected to inspection, if in the combined sample, the number of defectives is greater than or equal to the corresponding rejection number (d), the lot shall be considered as not conforming.

Every 200 sqm

Length between every two manholes.

Number of Samples for Lot Size

ITP - 13 B Salt Glazed Stoneware PipesInspection and Test Plan

mean+0.6range < limit

TestS. No.

5% of the Lot Size.

Permissible Number of Defectives

Frequency of Testing

EMGF-ITP-013 C

Project: Location / Road No.

Contractor: From Manhole: To Manhole:

Sector: From Node: To Node:

Contractor EMGF

1

3

4

5

Comments, if any:

Note: All the faulty joints are to be embedded with 150 mm thick concrete 1 : 2 : 4, 300 mm in length & the section retested.

a) Start Time :

b) End Time:

Head of Water Maintained During the Test 1.5 m Minimum

RemarksObservation

EMAAR MGF LAND LIMITEDInspection Sheet for Hydraulic Test for SW Pipes


Check Satisfactory

Yes/No

Name:

Designation


2

Date:

Sign:

30 mins minimum

No. of Joints Leaked

All the faulty joints are repaired as per Method Statement

The pipeline is again tested & found OK

c) Total Hrs. Test Head Maintained

Sign:

EMGF Representative

Name:

Designation:

Date:


MS 14

WORK METHOD STATEMENT WATER SUPPLY

0 0.1 27/05/08 QC Manager CEO (N)


MS 14 Emaar MGF Land Limited Water Supply

Issue 0.1

1.0 Introduction

This method statement describes the work of laying centrifugally cast (spun) ductile iron pressure pipes of diameters 80 mm and above as required by the drawing & specifications to be adopted for EMGF (N) Projects.

Ductile Iron Pipes and the fittings shall conform to IS: 8329-1977.



Issue 0.1

2.0 Procedure

2.1 Pre – Construction Activities


(ii) Material shall be inspected for any damage during transport / handling. No repair shall be undertaken at site.

(iii) Cranes shall be used for the off loading of the pipes more than 400 mm nominal bore & for smaller bore than 400mm skid timbers and rope shall be used.

(iv) The diameters and thickness of the standard pipes shall be as given in below table

Pipe diameter (mm) Pipe shell thickness (mm) Nominal Diameter Outside Diameter Pipes with flexible

joint and welded-on flanges

Pipes with cast-on flanges

80 98 6.0 7.0 100 118 6.1 7.2 150 170 6.3 7.8 200 222 6.4 8.4 250 274 6.8 9.0 300 326 7.2 9.6 350 378 7.7 10.2 400 429 8.1 10.8 450 480 8.6 11.4 500 532 9.0 12.0 600 635 9.9 13.2 700 738 10.8 14.4 800 842 11.7 15.6 900 945 12.6 16.8

1000 1048 13.5 18.0

(v) The tolerance on wall thickness, length, diameter and standard mass of pipes and fittings shall be accordance with IS: 8329 - 1990.

(vi) Survey for final set out as per drawing.

(vii) The existing ground level is to be determined and recorded in Field Book. Contractor’s representative shall get the Field Book signed from EMGF Representative.

2.2 Excavation

(i) The final excavation level is to be determined using latest GFC Drawing.

(ii) After all the pre-excavation works are completed, the execution of excavation work shall be carried out to the line and level shown on the drawings. Excavation shall be done in such a manner that the excavated faces may not assume unstable slopes, and any adjacent foundations shall not be disturbed. In cases where water seepage occurs, causing interference with the work, such conditions shall be rectified by proper methods such as gravitational drainage or pumping.



Issue 0.1

(iii) Sides of trench shall be dressed and bottoms shall be rammed before laying of pipes.

(iv) The width of trench at the bottom shall be such to provide at least 200mm clearance on both sides of the pipeline (d+400mm).

2.3 Laying of Pipe

(i) Supply lines shall be laid to the gradient & profiles given in latest GFC Drawing.

(ii) The cutting of pipe for inserting valves, fittings, etc, shall be done in a neat manner without damage to the pipe or lining so as to leave a smooth end at right angles to the axis of the pipe

(iii) Basic requirements of jointing procedures (like Cleanliness, correct location of all components, compliance of manufacturer’s instructions for jointing and centralization of spigot within socket) shall be fulfilled.

(iv) Only gaskets complying with IS: 12820, IS: 8329 & supplied by the pipe manufacturers for push on joints (with adequate specified lubricants with the help of adequate tools) shall be used. The quality of rubber gasket shall be of SBR grade for bulb 2 type and heel-5 type with IRHD hardness of 50+5, -4, & 80+/- 4 respectively.

(v) The internal surface of pipes and fittings except blank flanges, sockets and bell mouth shall be lined with cement mortar mix (1:3.5). Cement shall be ordinary Portland cement.

(vi) Proper care shall be taken to prevent the damage of protective coating and bruising or damage of the jointing surfaces



Issue 0.1

3.0 Hydraulic Testing

(i) Hydraulic test shall be conducted on pipeline to ensure quality work. Format EMGF ITP 014 A shall be duly filled and signed by EMGF representative.



Issue 0.1

4.0 Masonry Chambers

(i) Masonry chambers and other such works as specified shall be constructed in first class designation 75 FPS brick in cement mortar 1:5 mix (1 cement: 5 Fine sand) or as specified in the schedule of quantities. Chambers shall be supported on base of cement concrete of such thickness and mix as given shown on the GFC drawings.



Issue 0.1

5.0 Backfilling

(i) All backfill material shall be free from cinders, ashes, slag, refuse, rubbish, vegetable or organic material, lumpy or frozen material, boulders, rock, stone or other material which in opinion of Authority, is unsuitable or deleterious, however materials containing stones up to 200 mm may be used in Zone C.

(ii) Backfilling shall be done with suitable material in layers not exceeding 300mm. The compaction shall be done with the help of suitable equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve at least 95% field density w.r.t proctor density.

(iii) Sufficient notice (W.P.N.) shall be given to EMGF representative for inspection before proceeding for the different activities in work (like excavation of trenches, level checking, before testing, before backfilling and during backfilling).

Disinfection

(i) Mains intended for potable water shall be disinfected before commissioning for use.



Issue 0.1

6.0 Formats



EMGF-ITP-014 A


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF1

2

Leakage test, if necessary

7

8

Deficiencies, if any:

Remedial actions:

Quality of rubber gasket at site as per specifications

Hydraulic TestingTest Register Maintained

Name :

Backfilling

Flushing & Disinfection

Stretch may be backfilled

Backfill done in layers as per trench zone and compacted as per specification

Mains intended for potable water disinfected before commissioning for use

Backflow of chlorinated water occur in supply lines after the disinfection in the mains intended for potable water

Remarks

9

3

4

6

Cross-section survey of OGL

Contractor

Date :


Signature :

S.No. Inspection/DescriptionsCheck Satisfactory

Yes/No

Alignment of pipeline


Tarred gaskin wrapped round the spigot of pipe and the spigot placed into the socket of the previously laid pipe

Excavation Asper Drawing

Cross-section survey of bottom level after excavation

Free from rough texture

Damages on surfaces/Edges


Physical Checks


Inspection Sheet for Water Supply

Trench excavated as per specifications

5

Testing

Permit to Backfill


Laying Operations

Specified Compaction of excavated bottom and its level

Pipe laid with sockets leading uphill and rested on solid

Obstruction and Cleanliness inside for entire length

The internal surface of pipes and fittings except blank flanges, sockets and bell mouth shall be lined with cement mortar mix (1:3.5)

Compliance of manufacturer’s instructions for jointing and centralization of spigot within socket

Manufacturer Name Marking

EMGF-ITP-014 B

80-250 300-600 700-1000 1100-1400 1600-2000

1 Maximum Batch Size of pipes 200 100 60 40 30

2 Minimum tensile strength 420 MPa 420 MPa 420 MPa 420 Mpa 420 Mpa

3 % Minimum Elonagation at break 10 10 10 7 7

4 Brinell Hardness in HB 230 230 230 230 230

5 Hydostatic Test Should pass Should pass Should pass Should pass Should pass

External

Dia. D *

External

Dia. E *Length Ovality Wall Thickness

Flange

Thickness

1 80

2 100

3 125

4 150

5 200

6 250

7 300

8 350

9 400

10 450

11 500

12 600

13 700

14 750

14 800

15 900

16 1000

17 1100

18 1200

19 1400 +10, -5 +6,-6

20 1600

21 1800

22 2000

* Dimensional Details are mentioned in Detailed Drawings as per IS 8329

**The tolerance given Is subject to minimum thickness against Classes mentioned in IS 8329. No limit for the plus tolrance is specified

Minimum Requirements for diameter given

Nominal Diameters in mm (DN)Tolrances

Description/Tests

IS: 1608

IS: 1608

IS: 1500

IS: 8329

+ 7.5,-4

+ 4.5, -4.5

Sr. No.


Remain within

tolrance on

External

diameter

-(1.3+.001DN)**

Ref. Standards

ITP - 14 Ductile Iron Pipes

+/-(2+.05b)

Sampling criteria for various tests, unless specified in ITP shall be as laid down in IS 11606

The frequency of testing is related to the system of production and quality control used by the manufacturer for the Minimum tensile Strength test and

%minimum Elongation at Break

not exceed

2%

+12,-6 +6,-6

+100, -100

+5.5, -5.5

+5.5, -5.5

+5.5, -5.5 +8.5, -4

+4.5,-4.5

+5,-5

If test piece representing a batch size fails in the test in the first instance, two additional tests shall be made on test pieces selected from two other

pipes from the same batch. If both the test results satisfy the specified requirements, the batch shall be accepted. Should either of these additional

test pieces fail in the test, the batch shall be deemed as not complying with this standard

+4,-4

+ 5.5, -2.5

+6.5,-3.5

Sr. No.

not exceed

1%

+ 7.5,-4

Emaar MGF Land Ltd

MS 16

WORK METHOD STATEMENT ELECTRICAL WORKS FOR BUILDING

0 0.1 18/09/08 Electrical Manager

CEO (N)


S. No. Checklist Document No.

1

Conduit EMGF-ITP-16A

Cable Tray EMGF-ITP-16B

Wire EMGF-ITP-16G

Armoured Cable EMGF-ITP-16J

Unarmoured Cable EMGF-ITP-16K

2

Conduit EMGF-ITP-16C

Cable Tray EMGF-ITP-16D

Wire EMGF-ITP-16H

Cable (Armoured / Unarmoured) EMGF-ITP-16L

3

Conduit EMGF-ITP-16E

Cable Tray EMGF-ITP-16F

Wire EMGF-ITP-16I

Sample test

Test on Delivery of Material at Site

Installation Checklist

Checklists for Electrical Works

Doc NO. : EMGF-ITP-16A

Rev No. : 0.1

Date : 01.08.2008

Item Description:

I S Code Reference: Date of Receipt of Material

Spec Reference:

S.No Description Specified in

Spec/IS

Actual Remarks

1 Make

2 Colour

3 Internal diameter

4 External diameter

5 Thickness

6 Manufacture’s label

(Distance between two

labels to be specified)

MICROMETER GAUGE

Make : Sr. No. : Range :

VERNIER CALLIPER

Make : Sr.No. : Range :

If any other instrument is used. Detail to be mentioned.

Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date

Material Sample Inspection

CONDUIT

Doc NO. : EMGF-ITP-16B

Rev No. : 0.1

Date : 01.08.2008

Item Description:


Spec Reference:


Spec/IS

Actual Remarks

1 Make

2 Material

3 Protection

4 Internal height

5 Internal width

6 External height including

cover7 External width

8 Thickness

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date


CABLE TRAY

Doc NO. : EMGF-ITP-16C

Rev No. : 0.1

Date : 01.08.2008

Item Description:

Date of Receipt of Material:

Quantity:____________ Mtr Value: Rs____________________

Challan No. / Invoice No._________________________ dated_____________________

Test Certificate Sr. No.__________________________ dated_____________________


Spec Reference:


Spec/IS

Remarks

1 2 3

1 Visual Check for No

Damage

2 Storage

2-a Placed at Covered Location

2-b Distance from Wall more

than 6"

2-c Storage Over 3-4 Wooden

Sleeper / MS Channel

3 Make

4 Colour

5 Internal diameter

6 External diameter

7 Thickness

8 Manufacture’s label

(Distance between two

labels to be specified)

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date

Note: Satisfactory check in the above format does not absolve the contractor of his ultimate responsibility and obligation to deliver the

works as per contractual provisions.

Material Inspection After Delivery

CONDUIT

Actual

(3-4 Sample to be checked in a Lot)

Doc NO. : EMGF-ITP-16D

Rev No. : 0.1

Date : 01.08.2008

Item Description:






Spec Reference:


Spec/IS

Remarks

1 2 3

1 Visual Check for No

Damage

2 Storage

2-a Placed at Covered Location

2-b Distance from Wall more

than 6"

2-c Storage Over 3-4 Wooden

Sleeper / MS Channel

3 Make

4 Material

5 Protection

6 Internal height

7 Internal width

8 External height including

cover

9 External width

10 Thickness

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date

Note: Satisfactory check in the above format does not absolve the contractor of his ultimate responsibility and obligation to deliver the works

as per contractual provisions.


CABLE TRAY

Actual

(3-4 Sample to be checked in a Lot)

Doc NO. : EMGF-ITP-16E

Rev No. : 0.1

Date : 01.08.2008

Item Description:

IS:

Spec:

BOQ:

S.NoContractor

EngineerClient Engineer Remark

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Contractor Client

Signature

Name

Designation

Date

Location

Wooden screws used for fixing spacer bar having uniform and

required pitch

Spacer bar fixed securely to wall / structural member

Vise marks painted

Check the drawings used for installation are current & approved.

Threads painted

Saddles provided as per distance specified

Space bar provided

Drilled holes matching PVC sleeves

Comments/Remarks:

Line & level maintained

All extra holes closed

PVC bushes provided before wiring

Check nuts provided

All junction boxes covers fixed with both screws

PVC conduits & accessories joined with solvent

Note: Satisfactory check in the above format does not absolve the contractor of his ultimate responsibility and obligation to deliver

the works as per contractual provisions.

Drg Reference

Installation Check List for Conduit

Verified By (Yes / No)

Reference

Activities / Items to Inspect

Check all materials used have approved submittals.

Doc NO. : ITP-16F

Rev No. : 0.1

Date : 01.08.2008

Item Description:

IS:

Spec:

BOQ:

S.NoContractor


1

2

3

4

5

8

10

12

13

Contractor Client

Signature

Name

Designation

Date

Note: Satisfactory check in the above format does not absolve the contractor of his ultimate responsibility and obligation to

deliver the works as per contractual provisions.



Comments/Remarks:

Any cover screws missing

Covers fixed properly

Check supports as per distance specified


Uniform level maintained

All gaps/openings closed/sealed

Location Drg Reference

Installation Check List for CABLE TRAY


Reference

All gaskets in place

Junction boxes rigidly fixed to raceways

Doc NO. : EMGF-ITP-16G

Rev No. : 0.1

Date : 01.08.2008

Item Description:


Spec Reference:

S. No. Description Specified in

Spec/IS

Actual Remarks

1 Make

2 Size

3 Insulation Grade

4 Insulation Type

5 Insulation Thickness

6 Conductor Material

7 Nos of Wires

8 Dia of wire

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date


ELECTRICAL WIRE

Doc NO. :EMGF-ITP-16H

Rev No. : 0.1

Date : 01.08.2008

Item Description:





I S Code Reference:

Spec Reference:


Spec/IS

Remarks

1 2 3

1 Visual Check for No Damage

2 Placed at Covered Location

3 Make

4 Size

5 Insulation Grade

6 Insulation Type

7 Insulation Thickness

8 Conductor Material

9 Nos of Wires

10 Dia of wire

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor ClientSignat

ure

Name

Design

ation

Date




ELECTRICAL WIRE

Actual

Doc NO. : ITP-16I

Rev No. : 0.1

Date : 01.08.2008

Item Description:

IS:

Spec:

BOQ:

S.NoContractor


1

2

3

4

5

8

10

12

13

14

15

16

17

Contractor Client

Signature

Name

Designation

Date


Switches connected in phase

Switch boxes connected to earth

Third pin of socket earthed

Location

All gaskets in place

Joints in wires

Circuits of different systems segregated properly

Ferrules indicating device, ckt and DB details provided.

Ferrules identifying neutral & dedicated as per relevant circuits

provided.





Comments/Remarks:

Loop in at terminal or through connectors

I.R. Values Satisfactory

Crimping lugs provided

Drg Reference

Installation Check List for Wiring


Reference

Doc NO. : EMGF-ITP-16J

Rev No. : 0.1

Date : 01.08.2008

Item Description:


Spec Reference:


Spec/IS

Actual Remarks

1 Make

2 Size

3 Outer Seath

3-a Material (PVC/FLRS etc)

3-b Class / Temp Resistance

3-c Thickness

3-d Uniformity

4 Armoured

4-a Type (Single/double wire)

4-b Material (GI / Steel Strip)

4-c Strip Size: Width x Thickness

4-d Uniformity

5 Inner Seath



5-c Thickness

5-d Uniformity

6 Core

6-a Nos

6-b Insulation (PVC / FRLS)

6-c Insulation Class / Temp

Resistance


ELECTRICAL ARMOURED CABLE

Page 11 of 14

Doc NO. : EMGF-ITP-16J

Rev No. : 0.1

Date : 01.08.2008


ELECTRICAL ARMOURED CABLE

6-d Thickness of insulation

6-e Uniformity

6-f Colors

7 Conductor

7-a Material (Cu/ Al)

7-b Nos and Size of Strand in each

Conductor

7-c Insulation Class / Temp

Resistance8 Overall

8-a Diameter of Cable

8-b Weight Kg/Mtr

8-c Current Rating

8-d Voltage Rating

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date

Page 12 of 14

Doc NO. : EMGF-ITP-16K

Rev No. : 0.1

Date : 01.08.2008

Item Description: Date

I S Code Reference:

Spec Reference:


Spec/IS

Actual Remarks

1 Make

2 Size

3 Outer Seath



3-c Thickness

3-d Uniformity

4 Core

4-a Nos

4-b Insulation (PVC / FRLS)

4-c Insulation Class / Temp Resistance

4-d Thickness of insulation

4-e Uniformity

4-f Colors

5 Conductor

5-a Material (Cu/ Al)

5-b Nos and Size of Strand in each

Conductor5-c Insulation Class / Temp Resistance

6 Overall

6-a Diameter of Cable

6-b Weight Kg/Mtr

6-c Current Rating

6-d Voltage Rating

MICROMETER GAUGE


VERNIER CALLIPER



Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date


ELECTRICAL UNARMOURED CABLE

Page 13 of 14

Doc NO. :EMGF-ITP-16L

Rev No. :0.1

Date :01.08.2008

Item Description:

Make: (As per Approved Sample):





I S Code Reference:

Spec Reference:


Spec/IS

Remarks

1 2 3

1 Visual Check for No Damage

2 Storage Place

3 Sealing of Both end of cable

4 Continuity Test to ensure no

damage during transport

5 Sealing of Both end of cable

6 Matching with Approed sample

Comments/Remarks :

Contractor Client

Signature

Name

Designatio

n

Date

Note: Satisfactory check in the above format does not absolve the contractor of his ultimate responsibility

and obligation to deliver the works as per contractual provisions.


ELECTRICAL CABLE

Actual

(3-4 Sample to be checked

Page 14 of 14


MS 17

WORK METHOD STATEMENT PLUMBING WORKS FOR BUILDING

0 0.1 16/07/08 QC Manager CEO (N)


MS 17 Emaar MGF Land Limited Plumbing Works for Buildings

Issue 0.1

1.0 Introduction

This method statement describes the resources, procedures and tests to be adopted for entire completion of Plumbing Works for Buildings for the Mohali Integrated Township project to the requirements of the Contract Technical specifications & Drawings.


• Water Supply System

• Soil Waste and Vent Pipes

• Fire Fighting System



Issue 0.1

2.0 Procedure

2.1 Water Supply System

2.1.1 Chlorinated PVC Pipes (Internal & External)

Unloading, Inspection and Storage

• Ensure that material has been tested as per the relevant ITP. • Pipes shall be of make mentioned in the relevant BOQ. • Material shall be inspected for any damage during transport/handling. No repair shall be

undertaken at site. • All pipes for internal and external works shall be conforming to Specific Gravity ASTM

D 792 at 230C should be 1.55 as specified and Tensile Strength as per ASTM D 638 at 230C should be 55 N/mm2.

• All pipes shall be straight, smooth, and free from irregular bore, blow holes, cracks and other manufacturing defects.

• Pipes shall be supplied in lengths of 2, 3, 4 or 6 meters either plane or sliding/grooved socket.

• Each component of a piping system (tubing and fitting and manifold) shall bear a permanent marking of the manufacturer’s name or trade-mark and symbol of the organization. While tubing shall bear a permanent marking of its appropriate classification, ASTM & SDR number, temperature & pressure rating, words potable or initials NSF-PW. All the marking shall be within interval of 1.5 meters.

• CPVC pipe and fittings shall remain in original packaging until needed for installation at site. If pipe and fittings must be stored outdoors, cover them with an opaque tarp.

• CPVC pipes shall be stored and maintained properly. CPVC pipe, that has been stored outdoors and pipes that has faded in colour, shall not be used unless it has been covered properly.

Laying & Joining

• All pipes shall be fixed in accordance with layout and alignment shown on the drawings. Care shall be taken to avoid air pockets.

• When installing CPVC piping in cold weather, be sure to allow for movement caused by normal expansion and contraction.

• Use tools specifically designed for use with plastic pipe and fittings. • CPVC pipe shall be cut square to obtain the proper insertion depth and to provide the

maximum bonding area for solvent cementing. CPVC pipe shall be cut with a wheel-type plastic tubing cutter, ratchet-style cutter, fine-toothed hand saw (hack saw), or power saws. A miter box should be used when working with saws to ensure a square cut.

• Burrs, filings, shavings etc. caused by the cutting process shall be removed from the outside and inside of the pipe. Shavings and other debris will prevent proper contact of the joining surfaces and can lead to joint failure. Chamfering tools are available for this purpose.

• Any cuts, fractures, splits, or other damaged areas must be removed prior to joining. • Cut off at least 50 mm beyond any visible fracture.



Issue 0.1

• Dirt, debris, and moisture shall be wiped from the pipe end and fitting socket using a clean, dry rag. Moisture will slow the cure time and reduce joint strength. Components, that appear irregular or those do not fit properly, shall not be used.

• Dry fit of the pipe and fitting shall be checked prior to assembly. The pipe shall enter the fitting socket easily one-quarter to three-quarters of the way.

• Only CPVC Cement conforming to ASTM F493 shall be used. Pipes from ½” up to 2” pipes and fittings, single step medium bodied CPVC solvent cement should be used. For CPVC pipes and fittings upwards of 2”, a primer shall be used followed by heavy bodied solvent cement conforming to ASTM F493. The use of the wrong or inappropriate cement can result in failure.

• Only fresh solvent cement shall be used. Solvent cement that has exceeded its shelf life or that has become discoloured or jellied shall not be used.

• Avoid using solvent cement near sources of heat; do not smoke near solvent cements. Application instructions by manufacturer shall be followed carefully

• The two-step solvent includes the application of primer to the outside of the pipe and the interior fitting socket prior to applying the solvent cement. When using primer, it shall be applied to both the pipe and fittings using the appropriate size applicator. A dauber or paint brush approximately half the size of the pipe diameter is appropriate. A rag shall not be used as applicator.

• It shall be necessary to ensure the entire joining surfaces are wet. • Solvent cement shall be applied immediately after primer application while primed

surfaces are tacky. Cement application for one or two-step process shall include application of a heavy coat, even coat of cement to the outside pipe end, application a medium coat to the fitting socket. A second application of cement shall be applied to the pipe end if there was little or no interference when the dry fit was checked. Excess cement shall not be allowed to puddle in the pipe or fitting.

• After application of solvent cement, pipe shall be inserted immediately into the fitting while rotating the pipe one-quarter turn to help distribute cement. Properly align the fitting for installation at this time. Pipe shall bottom completely to the stop in the fitting. Assembly shall be hold for 10 to 15 seconds to ensure initial bonding. A continuous bead of cement shall be evident around the pipe and fitting junction. Cement in excess of the bead shall be wiped off with a rag.

• Assembled joints shall be allowed to set and cure properly prior to testing the system. Setting and curing times depends on type of cement used, pipe size, temperature, humidity, and tightness of fit.

• Cement manufacturer‘s recommendations of cure time shall be followed prior to pressure testing.

• Process of jointing the pipe shall not start without prior approval of EMGF representative.

• CPVC Pipes in shafts and other locations shall be supported by galvanized M.S. clamps of design approved by Project Manager. Pipes in wall chases shall be anchored by G.I. hooks. Pipes at ceiling level shall be supported on structural clamps fabricated from M.S. structure. Pipes in typical shafts shall be supported on slotted angles/channels as per standard drawings.

• Horizontal runs shall be supported with a distance of 900 mm and vertical runs shall be supported with a minimum distance of 1500 mm. Spacing of clamps, hooks etc. shall be as per good engineering practice approved by the Project Manager.



Issue 0.1

• Contractor shall provide adequate number of unions on pipes 50 mm and below to enable easy dismantling later when required. Unions shall be provided near each gunmetal valve, stop cock, or check valve and on straight runs as necessary at appropriate locations as required and/or directed by EMGF representative.

Testing

• All the pipes and fittings shall be tested as per ITP 017. • After laying and jointing, the pipes and fittings shall be inspected under working

condition of pressure and flow. The pipes and fittings after they are laid shall be tested to hydraulic pressure of 1.5 times the working pressure or 7.5 kg/sqcm which ever is more. The pipes shall be slowly and carefully charged with water allowing all air to escape and avoiding all shock or water hammer. The draw of taps and stop cocks shall then be closed and specified hydraulic pressure shall be applied gradually. Pressure gauge must be accurate and preferably should have been recalibrated before the test. The test pump having been stopped, the test pressure should be maintained without loss for at least two hours. The pipes and fittings shall be tested in sections as the work of laying proceeds, having the joints exposed for inspection during the testing. Any joint found leaking shall be redone and all leaking pipes removed and replaced without extra cost. Use of any compound or stop leak compound will not be permitted.

• In case of leaks the piping shall be redone in such portions & the test is repeated till satisfactory results are obtained.

• All the results and observation shall be filled and maintained in register and dully signed by the EMGF representative

Disinfection

• Before acceptance of the water-supply pipeline system the pipelines shall be rinsed in advance. The water flowing speed shall be at a minimum of 2 meters/second. While rinsing each of faucets shall be opened. The lowest point of the system shall be at the water outlet. Rinsing of pipelines will depend upon the water quality at the water outlet (it shall be same like inlet water).

• After the drinking-water-supply pipelines are rinsed they shall be disinfected with free chlorinous water which will be kept within them for over 24 hours.



Issue 0.1

2.1.2 Aqua Gold PVC Pipes (External & Internal)


• Ensure that material has been tested as per the relevant ITP. • Pipes shall be of make Supreme as mentioned BOQ. • Loading, transporting & unloading of Pipes shall be done with care. • Material shall be inspected for any damage during transport / handling. No repair shall be

undertaken at site. • All pipes shall be straight, smooth, and free from irregular bore, blow holes, cracks and

other manufacturer defects. • Each pipe shall be clearly and indelibly marked with the Trade mark/Manufacturer name,

nominal outside diameter, and batch/lot number. All the marking shall be within interval of 1.5 meters.

• All pipes shall confirm to ASTM D-1785. • All the fittings shall be of same material as of pipe. • Pipes for water supply systems are physically checked as given below.

Schedule 40 (Standard)

Schedule 80 (Heavy) Nominal

Bore Outside

Diameter (D) Wall

Thickness (t) Working Pressure

Wall Thickness (t)

Working Pressure

(mm) (mm) (mm) MPa psi (mm) MPa psi 12 21.34 + 0.10 2.77 + 0.51 4.14 600 3.73 + 0.51 5.86 850 20 26.67 + 0.10 2.87 + 0.51 3.31 480 3.91 + 0.51 4.76 690 25 33.40 + 0.13 3.38 + 0.51 3.10 450 4.55 + 0.53 4.34 630 32 42.16 + 0.13 3.56 + 0.51 2.55 370 4.85 +0.58 3.59 520 40 48.26 + 0.15 3.68 + 0.51 2.28 330 5.08 + 0.61 3.24 470 50 60.32 + 0.15 3.91 + 0.51 1.93 280 5.54 + 0.66 2.76 400 65 73.02 + 0.18 5.16 + 0.61 2.07 300 7.01 +0.84 2.9 420 80 88.90 + 0.2 5.49 + 0.66 1.79 260 7.62 + 0.91 2.55 370

100 114.3 + 0.23 6.02 + 0.71 1.52 220 8.56 + 1.02 2.21 320 150 168.28 + 0.28 7.11 + 0.86 1.24 180 10.97 + 1.32 1.93 280

• Pipes should be stored on a reasonably flat surface free from stones and sharp projections all along its length.

• Pipes should not be stacked in large piles especially under warm temperature conditions as the bottom pipes may be distorted, thus creating problems in jointing. Socket and spigot pipes should be stacked in layers with sockets placed at alternate ends of the stacks to avoid lopsided stacks. Stacks shall not be more than 1.5 m high. Avoid storing one pipe in another.

• Pipes of different sizes and classes should be stacked separately. On no account should pipes stored in a stressed or bent condition. In tropical conditions, pipes should be stored in shade. In wintry conditions or cold weather the impact strength of PVC is reduced making it brittle; therefore more care shall be exercised in handling of the pipes. If due to improper storage or handling, a pipe becomes kinked, the damaged portion should be cut out completely. Kinking is likely to occur in thin walled pipes.



Issue 0.1

Laying & Jointing • The required length of the pipe shall be cut perpendicular to the axis of the pipe length

with a metal cutting saw or an ordinary handsaw with small teeth. • Cutting shall not raise a burr or ridge on the cut end of the pipe. Failure to remove the

ridge will result in cement in the fitting or socket being scraped away from the jointing surfaces, leading to a dry joint with probability of joint failure. All burrs and ridges shall be removed with a de burring knife, file, or abrasive paper.

• Chamfering shall be provided approximately 2 mm wide, 100 to 150 chamfer on pipe ends.

• Both the inner and outer surfaces of the fitting shall be cleanly finished, smooth and free from grooving, blistering or other deleterious defects, when viewed without magnification. Each end of the fitting shall be free from chips and rough edges, and shall be square to the axis of the approximate line.

• Before applying cement, Pipe end shall be inserted into the socket of next pipe and its fittings and checked for interference about 4/3 to 2/3 of socket depth. The pipe and the socket shall be at their extreme tolerances & it shall be a snug fit. Another pipe end or the socket shall be selected if there is a loose fit. Insertion depth shall be marked with marker.

• Any dirt, moisture or grease shall be cleaned properly with clean dry rag and contacting surfaces shall be roughened with sand paper or emery cloth.

• Generous coatings of solvent cement shall be evenly applied on the inside of the fitting all around the circumference for the full length of insertion & on the outside of the pipe end up to the marked line.

• The pipe shall be pushed into the fitting socket & held for 1-2 minutes. • The surplus cement on the pipe surface shall be wiped out. • Solvent cement shall be cured before pressurizing the system. It shall be recommended to

cure for 12 hours after application of last coat of cement. • Process of jointing the pipe shall not start without prior approval of EMGF

representative. • In case of buried pipe in trenches, anticorrosive tapes of make as specified in BOQ shall

be provided as per manufacturers’ specification. It shall be 100mm wide and 4mm thick and lay before an initial coat of primer.

• All pipes shall be fixed in gradient towards the outfalls of drains. Pipes for internal works shall be in chase unless otherwise shown on drawings. Where required pipes may be run at ceiling level in suitable gradient and supported on structural clamps. Spacing for clamps for such pipes shall be 180cms for vertical and 120cms in horizontal.

Testing

• All the pipes and fittings shall be tested as per ITP 017 • UV Stabilization of the Pipe shall be ensured by Third party testing. • Water Test: The water test shall be performed before the connection of the appliances. It

shall be carried out in sections so as to limit the static head as required. The pipe system shall be filled with water and stabilized for at least 2 hours. After stabilizing, Pressure shall be applied to the rate of not exceeding 1.5 times the maximum rated pressure of the lowest rated component for at least 1 hour (but not more than 24 hour) at ambient



Issue 0.1

temperature. Test shall be found satisfactory when there will be no leakage in any part of the section, decrease in pressure during testing.

• Defects, if any revealed in the test shall be rectified and the procedure repeated until a satisfactory result is obtained


Disinfection

• Before acceptance of the water-supply pipeline system the pipelines shall be rinsed in

advance. The water flowing speed shall be at a minimum of 2 meters/second. While rinsing each of faucets shall be opened. The lowest point of the system shall be at the water outlet. Rinsing of pipelines will depend upon the water quality at the water outlet (it shall be same like inlet water).




Issue 0.1

2.1.3 PP-R Pipes for Water supply


• Ensure that material has been tested as per the relevant ITP. • The supplied pipes and fittings with the instructions and quality certificates should be

conformed to the design standards. • Material shall be inspected for any damage during transport/handling. No repair shall be

undertaken at site. • Loading, transporting & unloading of Pipes shall be done with care. • All pipes shall be straight, smooth, and free from irregular bore, blow holes, cracks and

other manufacturer defects. • Each pipe shall be clearly and indelibly marked with the Trade mark/Manufacturer name,

nominal outside diameter, and batch/lot number. All the marking shall be within interval of 1.5 meters. All the fittings shall be of same material as of pipe.

• All pipes and fittings shall confirm to DIN 16962 & DIN 8077 : 1999-70 • Pipes for water supply systems are physically checked as given below.

PN 10 PN 16 PN 20 Size

Wall Thickness

Internal Diameter

Wall Thickness

Internal Diameter

Wall Thickness

Internal Diameter

16 - - 2.3 11.4 2.7 10.6 20 1.9 16.2 2.8 14.4 3.4 13.2 25 2.8 19.4 3.5 18 4.2 16.6 32 3.0 26.0 4.5 23.0 5.4 21.2 40 3.7 32.6 5.6 28.8 6.7 26.6 50 4.6 40.8 6.9 36.2 8.4 33.2 63 5.8 51.4 8.7 45.6 10.5 42 75 6.9 61.2 10.4 54.2 12.5 50 90 8.2 73.6 12.5 65.0 15.0 60.0

110 10.0 90.0 15.2 79.6 18.4 73.2 • Pipes should be stored on a reasonably flat surface free from stones and sharp projections

all along its length. • Pipes should not be stacked in large piles especially under warm temperature conditions

as the bottom pipes may be distorted, thus creating problems in jointing. Stacks shall not be more than 1.5 m high. Avoid storing one pipe in another.

• Pipes of different sizes and classes should be stacked separately. On no account should pipes stored in a stressed or bent condition. In tropical conditions, pipes should be stored in shade. If due to improper storage or handling, a pipe becomes kinked, the damaged portion should be cut out completely. Kinking is likely to occur in thin walled pipes.



Issue 0.1

Laying and Jointing • The required length of the pipe shall be cut perpendicular to the axis of the pipe length

with a metal cutting saw or an ordinary handsaw with small teeth. • When PP-R Pipes are laid with other pipes in parallel, there should be a distance

minimum 100mm. • Cutting shall not raise a burr or ridge on the cut end of the pipe. All burrs and ridges shall

be removed with a de-burring knife, file, or abrasive paper. • Both the inner and outer surfaces of the fitting shall be cleanly finished, smooth and free

from grooving, blistering or other deleterious defects, when viewed without magnification. Each end of the fitting shall be free from chips and rough edges, and shall be square to the axis of the approximate line.

• Any dirt, moisture or grease shall be cleaned and dried properly with clean dry rag. • Insertion depth shall be marked with the help of suitable marker. • Material of external surface of the pipe and internal surface of the fittings shall be heated

on small welding machine (Poly-fusion Device) up to 260 0C to 280 0C. Temperature of welding machine shall be ensured before heating the jointing surfaces. While heating the pipes and fittings, slight pressure shall be applied from the both sides. There shall not be any twist or turn the pipe and fitting while pushing. When the welding heating time is reached, remove both pipe and fittings together, again without twisting or turning while pulling out of the welding adaptor. Almost immediately, push both pipe and fitting together until the depth is reached. Joints shall be adjusted for more than 5 degrees during this time.

• The heating duration should be conformed to the regulations stipulated by the manufacturer. In the course of melting or cooling the removal or turning of the pipe is prohibited.

• Process of jointing the pipe shall not start without prior approval of EMGF representative.

• In case of buried pipe in trenches, weather proof treatment like covering with bitumen faced hessian of make as specified in BOQ shall be provided as per manufacturers’ specification.

• In case of buried pipe, excavation and backfill shall strictly follow Method statement EMGF MS-011.

• All pipes shall be fixed in gradient towards the outfalls of drains. Pipes for internal works shall be in chase unless otherwise shown on GFC drawings. Where required pipes may be run at ceiling level in suitable gradient and supported on structural clamps. Spacing for clamps for such pipes shall be 1800 mm for vertical and 1200 mm in horizontal.

• Guide marks on pipe and fittings shall be referred to avoid misalignment.

Testing • All the pipes and fittings shall be tested as per ITP 017. • UV Stabilization of the Pipe shall be ensured by third party testing. • Water Test: The water test shall be performed before the connection of the appliances. It

shall be carried out in sections so as to limit the static head as required. The pipe system shall be filled with water and stabilized for at least 2 hours. After stabilizing, Pressure shall be applied at the rate of 1.5 times the maximum rated pressure of the lowest rated



Issue 0.1

component or two times the working pressure (which ever is more) for at least 1 hour (but not more than 24 hour) at ambient temperature. Test shall be found satisfactory when there will be no leakage in any part of the section and no decrease in pressure during testing.

• Defects, if any revealed in the test shall be rectified and the procedure repeated until satisfactory results are obtained


Disinfection






Issue 0.1

2.1.4 Galvanized Iron Pipes

Unloading, Inspection & Storage

• Ensure that construction material has been tested as per the relevant ITP. • Material shall be inspected for any damage during transport / handling. No repair shall be

undertaken at site. • Loading transporting & unloading of GI Pipes shall be done with care. Handling shall be

such as to avoid impact. Gradual unloading by inclined plane or by means of rope is recommended.

• The pipes and specials shall be inspected and defects noticed, if any, such as protrusions, grooves, dents, notches, etc, shall be rectified. Care shall be taken that the resulting wall thickness does not become less than the minimum specified. If the wall thickness becomes less than the minimum the damaged portion should be cut out as a cylinder and replaced by an undamaged piece of pipe. GI Pipes shall be of at least medium class.

• All dents exceeding 2 percent of the outer diameter of the pipe shall be removed. Dents shall be removed by cutting out a cylindrical portion of the pipe and replacing the same with an undamaged piece of the pipe

• Each pipe shall be clearly and indelibly marked with the Trade mark/ Manufacturer name, nominal outside diameter, and batch/lot number.

• Pipes are physically checked as per IS: 1239-1992.

S. No. Internal Diameter

Outside Diameter

Thickness Weight Per

meter

1 15 mm 21.8 mm 2.6 mm 1.21 Kg/m

2 20 mm 27.3 mm 2.6 mm 1.56 Kg/m

3 25 mm 34.2 mm 3.2 mm 2.41 Kg/m

4 32 mm 42.9 mm 3.2 mm 3.10 Kg/m

5 40 mm 48.8 mm 3.2 mm 3.56 Kg/m

6 50 mm 60.8 mm 3.6 mm 5.03 Kg/m

7 65 mm 76.6 mm 3.6 mm 6.42 Kg/m

8 80 mm 89.5 mm 4.0 mm 8.36 Kg/m

9 100 mm 115 mm 4.5 mm 12.2 Kg/m

10 150 mm 166.5 mm 4.8 mm 18.9 Kg/m

Tolerance -10.00% +7.50%

• All fittings shall be malleable iron galvanized fittings confirming to IS: 1879, having manufacturer mark stamped on it.



Issue 0.1

• Padding shall be provided between coated pipes and timber skids to avoid damage to the coating. Suitable gaps in the pipes stacked shall be left at intervals to permit access from one side to other.

Laying

• Layout of all the pipe lines and points shall be done as per approved drawings. • Length of different pipes required shall be worked out and cut accordingly. • Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in neat

manner. • The fixing shall be done in standard pattern holder bat clamps, keeping the pipes

minimum 15mm from the wall. • Pipes shall be laid in manner as to provide proper accessibility for repair and maintenance

works. • GI Pipes in shafts and other locations shall be supported by MS clamps of approved

design. Clamps shall be embedded in brickwork in cement mortar 1:3, and shall be spaced at regular interval in straight lengths.

• Chase cutting shall be done in walls where embedded pipeline is shown in Drawing. Pipes in wall chases shall be anchored by iron hooks.

• In case of pipes embedded in wall, pipes shall be painted with one coat anticorrosive bituminous paint of approved shade and quality.

• Pipe with necessary fittings shall be placed in position and fixed with plumbing nails or clamps.

• Contractor shall provide adequate number of unions on all pipes to enable dismantling later.

• In case of hot water or steam connection, insertion gasket shall be of suitable high temperature grade.

• Bolt hole diameter for flanges shall conform to the specification for CI Sluice valve of IS: 780.

• Underground GI Pipes shall be laid in Trenches as given below: Diameter of Pipe Width of Trench Depth of Trench 15mm to 50mm 30 cm 60cm 65mm to 100mm 45cm 75cm

• All Earthworks shall be done in accordance with Earthwork in trenches from Method

statement Ref. no. EMGF-MS-011

Jointing

• Joints for GI pipes shall be screwed joints. • The ends of the pipe shall be carefully threaded, with pipe dies & tapes in such a manner

as will not result in slackness of joints when the two pieces are screwed together. • The screw threads of pipes and fittings shall be protected from damage until they are

fitted.



Issue 0.1

• In jointing the pipes, the inside of the fitting and the screwed end of the pipes shall be oiled and rubbed over with white lead and a few threads of spun yarn wrapped around the screwed end of the pipe.

• The end shall then be screwed in the fitting with the pipe wrench. • Care shall be taken that all pipes & fittings are properly jointed.

Testing

• All the pipes and fittings shall be tested as per ITP 017. • All the openings shall be close before testing. Pipeline shall be filled with water slowly

and carefully allowing all air to escape. Then pressure shall be applied and fixed at 10 kg/cm2. Pressure shall be maintained for at least half an hour in undisturbed conditions. If the pressure drops, each and every joint shall be checked for leakage. Then pressure is released at the highest point to check that pipeline is clear through out its length.



Disinfection






Issue 0.1

2.2 Soil, Waste discharge, Ventilation and Rain Water System

2.2.1 uPVC Pipes


• Ensure that material has been tested as per the relevant ITP. • Pipes shall be of make Supreme or mentioned in the relevant BOQ. • Material shall be inspected for any damage during transport / handling. In case of

damage, no repair shall be undertaken at site. • All pipes shall be straight, smooth, and free from irregular bore, blow holes, cracks and

other manufacturer defects. • All pipes for soil and waste discharge systems shall be of Type-B while for rain water

pipes, waste pipes, bath wastes, overflow, kitchen equipment waste connections and condensate drainage (Ventilation pipes)in buildings shall be of Type-A both confirming to IS 13592.

• All the fittings shall be of uPVC material and confirm to IS 14735. • Each pipe shall be clearly and indelibly marked with the Trade mark / Manufacturer

name, nominal outside diameter, and batch/lot number. • In vents and rain pipes (Type-A), marking shall also include class of Pipe & pressure

ratings of pipe at intervals not more than 3 meters as specified in table given below,

S. No. Class of Pipe Colour of Marking Working Pressure kg/cm2

1 Class 1 Red 2.5 2 Class 2 Blue 4.0 3 Class 3 Green 6.0 4 Class 4 Brown 8.0 5 Class 5 Yellow 10.0 6 Class 6 Black 12.5

• Pipes shall be supplied in lengths of 2, 3, 4 or 6 meters either plane or sliding / grooved

socket. • Pipes for soil waste discharge systems are physically checked as given below,

Out side Diameter

Out side Dia. at any point

Wall thickness S Type-A

Wall thickness S Type-B

S. No.

Nominal Outside Diameter (DN) Min. Min. Min. Min. Min. Max.

Min. Max.

1 40 40.0 40.3 3.2 3.2 1.8 2.2 3.2 3.8 2 50 50.0 50. 3 3.2 3.2 1.8 2.2 3.2 3.8 3 63 63.0 63. 3 3.2 3.2 1.8 2.2 3.2 3.8 4 75 75.0 75. 3 3.2 3.2 1.8 2.2 3.2 3.8 5 90 90.0 90. 3 3.2 3.2 1.9 2.3 3.2 3.8



Issue 0.1

6 110 110.0 110.4 3.2 3.2 2.2 2.7 3.2 3.8 7 125 125.0 125.4 3.2 3.2 2.5 3.0 3.2 3.8 8 140 140.0 140.5 3.6 3.6 2.9 3.4 3.6 4.2 9 160 160.0 160.5 4.0 4.0 3.2 3.8 4.0 4.6

• In case of any discrepancy in dimensions, IS 4985 and IS 13592 shall be followed. • Pipes should be stored on a reasonably flat surface free from stones and sharp projections

all along its length. • Pipes should not be stacked in large piles especially under warm temperature conditions

as the bottom pipes may be distorted, thus creating problems in jointing. Socket and spigot pipes should be stacked in layers with sockets placed at alternate ends of the stacks to avoid lopsided stacks. Stacks shall not be more than 1.5 m high.

• Storing one pipe in another shall be avoided. • Pipes of different sizes and classes shall be stacked separately. On no account pipes shall

stored in a stressed or bent condition. In tropical conditions, pipes should be stored in shade. In wintry conditions or cold weather the impact strength of PVC is reduced making it brittle; therefore more care shall be exercised in handling of the pipes.

• In case of improper storage or handling, a pipe can be kinked; the damaged portion shall be cut out completely.

Laying & Jointing

• The required length of the pipe shall be cut perpendicular to the axis of the pipe length

with a metal cutting saw or an ordinary handsaw with small teeth. • Type of jointing for uPVC pipe will depends upon the purpose for which it will be used. • Cutting shall not raise a burr or ridge on the cut end of the pipe. Failure to remove the

ridge will result in cement in the fitting or socket being scraped away from the jointing surfaces, leading to a dry joint with probability of joint failure. All burrs and ridges shall be removed with a de burring knife, file, or abrasive paper.

• Chamfering shall be provided approximately 2 mm wide, 150 chamfer on pipe ends. • Both the inner and outer surfaces of the pipes and fittings shall be cleanly finished,

smooth and free from grooving, blistering or other deleterious defects, when viewed without magnification. Each end of the fitting shall be free from chips and rough edges, and shall be square to the axis of the approximate line.

• Before applying Solvent cement/Sealing rings, Pipe end shall be inserted into the socket of next pipe and its fittings shall be checked. The pipe and the socket shall be at their extreme tolerances. In such case, it shall be a snug fit. Another pipe end or the socket shall be selected if there is a loose fit. Insertion depth shall be marked with marker.

• Soil and waste system pipes shall be fixed with sealing rings made of elastomers as specified in IS 5382, having IRHD hardness 50 + 5. The sealing ring shall have no detrimental effect on the properties of the fitting and shall not cause the test assembly to fail. The width of the sealing ring shall be compatible with the groove in the socket. Rubber lubricant shall be applied on the pipe before fixing sealing ring.

• Generous coatings of solvent cement shall be evenly applied on the inside of the fitting all around the circumference for the full length of insertion & on the outside of the pipe end up to the marked line.

• The total length of the insertion socket (injection moulded socket) marked on the pipe shall be checked for depth for pipe end insertion into the fitting socket.



Issue 0.1

• The pipe shall be pushed into the fitting socket & held for 1-2 minutes. • The surplus cement on the pipe surface shall be wiped out. • Curing for cement joints shall be as per manufacturer’s recommendations. • The pipes and trap shall be set in cement concrete blocks (1:2:4 mix) firmly supported on

the structural floor. • All pipes shall be fixed in gradient towards the outfalls of drains. Pipes for internal works

shall be in chase unless otherwise shown on drawings. Where required pipes may be run at ceiling level in suitable gradient and supported on structural clamps. Spacing for clamps for pipes shall be 180cms for vertical and 120cms in horizontal.

• It shall be ensured that water carried out from building through pipes is not causing dampness in building area.

Testing

• All the pipes and fittings shall be tested as per ITP 017. • Water Test: The water test shall be performed before the connection of the appliances. It

shall be carried out in sections so as to limit the static head as required. The pipe shall be filled with water and not disturbed for 2 hours for stabilization. After that, pressure not exceeding 1.5 times the maximum rated pressure of lowest rated component at ambient temperature and system is inspected for blow holes and cracks. It shall be ensured that all the openings affected by the test shall be closed and supports shall be provided to the plugs used as stoppers.





Issue 0.1

2.2.2 Cast Iron Pipes


• Ensure that material has been tested as per the relevant ITP. • Material shall be inspected for any damage during transport / handling. No repair shall be

undertaken at site. • All pipes shall be straight, smooth, and free from irregular bore, blow holes, cracks and

other manufacturer defects. • Loading transporting & unloading of CI Pipes shall be done with care. Handling shall be


• While unloading, pipes shall not be thrown down from the trucks on hard roads. Unloading them on timber skids without a steadying rope and thus allowing the pipes to bump hard against one another shall not be allowed. In order to avoid damage to the pipes and specially to the spigot end, pipe shall not be dragged along concrete and similar pavements with hard surfaces

• Pipes are physically checked as per IS : 1729-1979.

Internal Diameter

Outside Diameter Thickness. Weight S. No.

mm mm mm kg/Pipe 1 50 60 5 11.41 2 75 85 5 16.52 3 100 110 5 21.67 4 150 160 5 31.92 Toler. +3.5 +3.5 -2 +10%

• The pipes and fittings shall be inspected for defects and be rung with a light hammer preferably while suspended to detect cracks. Smearing the outer side with chalk dust helps the location of cracks. If doubt persists further confirmation shall be obtained by pouring the kerosene inside the pipe at the suspected Spot; if a crack is present the kerosene seeps through and shows on the outer surface. If a pipe is mishandled either accidentally or due to carelessness during unloading or lowering operation it shall be thoroughly inspected before laying and shall be rejected if found unsuitable by the authority.

• The pipes shall be tested for pinholes by filling water after inserting the pipe end into the ground.


• Fittings shall be of required degree of curvature with or without access doors. • Pipes being taken to stock ground for storage and held pending for further distribution

shall be arranged into stacks. The first layer of pipes should be laid on a firm foundation consisting of solid timber set level on the ground. Subsequent layers should be placed according to the method of stacking adopted. Care shall be taken so that the pipes do not rest on their sockets. The height of any stack shall not exceed 2 m.



Issue 0.1

• Waste and vents pipes smaller than 65mm dia. shall be of medium class galvanized Iron and fittings instead of Cast Iron.

Laying & Jointing • Layout of all the pipe lines and fittings shall be as per GFC drawings. • Length of different pipes required shall be worked out and cut accordingly. • Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in neat

manner. • In case of buried pipe, excavation and backfill shall strictly follow Method statement

EMGF MS-011. • Pipes shall be laid in manner as to provide proper accessibility for repair and maintenance

works. • In case of buried pipes, all the sockets shall lead uphill and support on the solid

foundation for the full length, sufficient space shall be available for jointer to work. • Basic requirements of jointing procedures shall be fulfilled like Cleanliness, correct

location of all components, compliance of manufacturer’s instructions for jointing and centralization of spigot within socket.

• Spun yarn shall be soaked in cement paste and two turns of it are placed inside the joint caulked into the socket by means of suitable caulking tools, maintaining a depth of 25mm all around for lead.

• When the spun yarn has been caulked right, clay is placed in the shape of a ring over the socket to act as a guide for lead pouring.

• Refined pig lead shall confirm to IS 1729. • Lead shall be heated in a melting pot kept in easy reach of the joint to be poured so that

the molten metal will not be chilled in being carried from the melting pot to the joint and shall be brought to a proper temperature so that when stirred it will show a rapid change of colour. Before pouring, all scum shall be removed. Each joint shall be made with one continuous pour filling of the entire joint space with lead

• The lead shall then be solidly caulked with suitable tools by hammering the joint to make up for the shrinkage of the molten lead on cooling.

• The lead shall then be finally flushed with the face of the socket • The approximate depth & weight of pig lead for various diameter of CI pipes shall be as

given in table under:

PIPE SIZE (mm)

DEPTH OF LEAD JOINT (mm)

WT. OF LEAD PER JOINT (kg)

50 25 0.77 75 25 0.88 100 25 0.98 150 38 1.50

• All vertical pipes shall be fixed by M.S. clamps while branch pipes shall be connected to

the stack at the same angles as that of the fittings. • Horizontal pipes running along ceiling shall be fixed iron structural clamps of design

shown in the drawing.



Issue 0.1

• The clamping of pipe stack shall be done using MS holder bat clamps made of 40x3 mm MS flat. For this 100x100 mm pocket shall be cut in the wall. The clamp will fix in position and grouted with 1:2:4 cement concrete.

• Cast Iron waste pipes under sunken slab and in wall chases shall encase in cement concrete 1:2:4 mix( 1 cement; 2 coarse sand; 4 stone aggregate 12mm size) 75mm in bed and all-round over the pipe.

• Exposed surface of cast iron pipes shall be painted with two or more coats of synthetic enamel paint of approved quality, shade and colour code.

Testing

• All the pipes and fittings shall be tested as per ITP 017. • All lengths of the sewer and drain shall be fully tested for water tightness by means of

water pressure maintained for not less than 30 minutes. Testing shall be carried out from manhole to manhole. All pipes shall be subjected to a test pressure of at least 1.5 meter head of water. The test pressure shall, however, not exceed 1.5 meter head at any point. The pipes shall be plugged preferably with standard design rubber plugs on both ends. The upper end shall, however, be connected to a pipe for filling with water and getting the required head. Pipes shall be checked for any crack or leakage.


• Sewer lines shall be tested for straightness by: a) Inserting a smooth ball 12mm less than the internal diameter of the pipe. In the absence

of obstructions such as yarn or mortar projecting at the joints the ball should roll down the invert of the pipe and emerge at the lower end.

b) Means of a mirror at one and a lamp at the other end. If the pipeline will be straight the full circle of light will be seen otherwise obstruction of deviation will be apparent.

• Smoke Test (Alternate test): It shall start after completing the entire stacks. For this all the outlets shall be plugged and then smoke shall pass from bottom most point from the smoke machine (Smoke is produced by burning oily wastes/tar paper or similar material in a combustion chamber). It shall be conducted under a pressure of 25mm maintained for 10 minutes. All the joints shall be checked for leakage. Then the smoke is released at the highest point and checked whether full smoke is coming out or not. It also ensures that pipeline in not choked at any point.

• Any joint found leaking / sweating shall be rectified or embedded in to 150mm thick concrete, 1:2:4, 300mm length and the section retested.

• All the results and observation shall be filled and maintained in register and dully signed by the EMGF representative.



Issue 0.1

2.3 Fire Fighting Systems

2.3.1 Mild Steel Pipes


• Ensure that construction material has been tested as per the relevant ITP. • Material shall be inspected for any damage during transport / handling. No repair shall be

undertaken at site. • Loading transporting & unloading of MS Pipes shall be done with care. Handling shall be


• The pipes and specials shall be inspected and defects noticed, if any, such as protrusions, grooves, dents, notches, etc, shall be rectified. Care shall be taken that the resulting wall thickness does not become less than the minimum specified. If the wall thickness becomes less than the minimum the damaged portion should be cut out as a cylinder and replaced by an undamaged piece of pipe. MS Pipes shall be of heavy class.

• All dents exceeding 2 percent of the outer diameter of the pipe shall be removed. Dents shall be removed by cutting out a cylindrical portion of the pipe and replacing the same with an undamaged piece of the pipe.


• Pipes are physically checked as per IS: 1239-1992.

S. No. Internal Diameter

Outside Diameter

Thickness Weight Per

meter

1 15 mm 21.8 mm 3.2 mm 1.45 Kg/m

2 20 mm 27.3 mm 3.2 mm 1.88 Kg/m

3 25 mm 34.2 mm 4.0 mm 2.95 Kg/m

4 32 mm 42.9 mm 4.0 mm 3.82 Kg/m

5 40 mm 48.8 mm 4.0 mm 4.41 Kg/m

6 50 mm 60.8 mm 4.5 mm 6.26 Kg/m

7 65 mm 76.6 mm 4.5 mm 8.05 Kg/m

8 80 mm 89.5 mm 4.0 mm 8.36 Kg/m

9 100 mm 115 mm 4.8 mm 10.4 Kg/m

10 150 mm 166.5 mm 5.4 mm 21.9 Kg/m

• Suitable gaps in the pipes stacked shall be left at intervals to permit access from one side to other.



Issue 0.1

Laying

• Layout of all the pipe lines and points shall be done as per approved drawings. • Length of different pipes required shall be worked out and cut accordingly. • Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in neat

manner. • The fixing shall be done in standard pattern holder bat clamps, keeping the pipes

minimum 15mm from the wall. • Pipes shall be laid in manner as to provide proper accessibility for repair and maintenance

works. • MS Pipes in shafts and other locations shall be supported by MS clamps of approved

design. Clamps shall be embedded in brickwork in cement mortar 1:3, and shall be spaced at regular interval in straight lengths.

• Chase cutting shall be done in walls where embedded pipeline is shown in Drawing. Pipes in wall chases shall be anchored by iron hooks.

• In case of pipes embedded in wall, pipes shall be painted with one coat anticorrosive bituminous paint of approved shade and quality.

• Pipe with necessary fittings shall be placed in position and fixed with plumbing nails or clamps.

• Contractor shall provide adequate number of unions on all pipes to enable dismantling later.

• All Earthworks shall be done in accordance with Earthwork in trenches from Method statement Ref. no. EMGF-MS-011

Jointing

• Joints for MS pipes shall be screwed joints for diameter less than 50mm. • The ends of the pipe shall be carefully threaded confirming to the requirements of IS:554,

with pipe dies & tapes in such a manner as will not result in slackness of joints when the two pieces are screwed together.

• The screw threads of pipes and fittings shall be protected from damage untill they are fitted.

• In jointing the pipes, the inside of the fitting and the screwed end of the pipes shall be oiled and rubbed over with white lead and a few threads of spun yarn wrapped around the screwed end of the pipe.

• The end shall then be screwed in the fitting with the pipe wrench. • Care shall be taken that all pipes & fittings are properly jointed so as to make the joints. • Joints for MS pipes shall be welded joints for diameter greater than 50mm. • Joints between MS pipes & fittings shall be made with the pipes and fittings having “V”

groove & welded with electrical resistance welding in an approved manner, using 3.15 m welding electrodes.

• Walls shall be filled with cement concrete 1:3:6 (1 cement: 3 coarse sand: 6 graded stone aggregate 20 mm nominal size).



Issue 0.1

Testing

• All the pipes and fittings shall be tested as per ITP 017. • All the openings shall be close before testing. Pipeline shall be filled with water slowly

and carefully allowing all air to escape. Then pressure shall be applied and fixed at 14 kg/cm2. Pressure shall be maintained for at least half 120 minutes in undisturbed conditions. If the pressure drops, each and every joint shall be checked for leakage. Then pressure is released at the highest point to check that pipeline is clear through out its length.




EMGF-ITP-017 A

Project: Mohali Hills Date:

Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

4

6 Water Test

Deficiencies:

Remedial actions:

Post-Construction Checks7

8 DisinfectionRinsing of whole Sysetem is done before acceptance


After completion of work all the holes for pipes are closed

System is working properly without any restriction

Proper disinfection is done with chlorinous water


Setting Time and Proper curing conditions are maintained as per manufacturer recommendations

Pipes amd fittings are straight, smooth, proper colour, proper packagings and free from irregular bore, blow holes, cracks and other manufacturer defects

Both the inner and outer surfaces of the pipes and fittings cleanly finished, smooth, free from Dirt, debris, grooving and moisture and other deleterious defects before application of cement

Pipe cutting as per required length and perpendicular to the axis of the pipe length

Chases as per requirement


Name :

Date :

Signature :

5

Testing

3



Laying Operations

Clamps properly fixed in walls

Proper Horizontal and vertical Spacing of structural clamps/ supports available


Inspection Sheet for CPVC Pipes


Yes/No Remarks

Pipes, fittings and CPVC Solvent Cement(Medium & heavy Bodied) From Approved Source

Layout and alignment of pipes as per drawings

Diameter and thickness of pipes as per requirement

Proper marking on pipes as per MS-017


Physical Checks

All the walls holding the structural clamps and supports are made good after installation of the system

Proper tools available for cutting like a wheel-type plastic tubing cutter, ratchet-style cutter, fine-toothed hand saw (hack saw), or power saws etc.

One Step Cement coating applied evenly to make entire joining surfaces wet

Proper application of primer to the outside of the pipe and the interior fitting socket prior to applying the solvent cement for pipe greater than size 2", in case of heavy bodied cement

Second Cement coating applied evenly in case of dia. Greater than 2"

EMGF-ITP-017 B


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

6 Water Test

7

Deficiencies:

Remedial actions:

Generous coatings of solvent cement evenly applied on the inside of the fitting all around the circumference for the full length of insertion & on the outside of the pipe end up to the marked line

Setting Time and Proper curing is maintained as per manufacturer recommendations

Insertion depth properly marked on the pipes

All the Dents from pipes are removed


3

Rinsing & Disinfection

All the walls holding the structural clamps and supports are made good with cement mortar after installation of the system


Backfill done in layers and compacted as per specification

Rinsing of whole Sysetem is done before acceptance


Laying Operations






Physical Checks

Inspection Sheet for Aqua gold PVC Pipes

S.No.

Pipes, fittings and Solvent Cement From Approved Source

Check SatisfactoryYes/No Remarks

5

Testing



Name :

Date :

Signature :


Anticorrosive tape applied in case of Buried pipes

Pipes amd fittings are straight, smooth, proper colour, proper packagings and free from irregular bore, blow holes, cracks and other manufacturer defects

Both the inner and outer surfaces of the pipes and fittings are cleanly finished, smooth and other deleterious defects before application of cement

Pipe cutting is as per required length and perpendicular to the axis of the pipe length


Contractor's Representative Emaar MGF Representative

9

Contacting surfaces are roughened with sand paper/emery cloth

4 Pre-Construction Checks

Exacavation as per Drawing, incase of buried pipes

Backfilling

8After completion of work all the holes for pipes are closed


Proper tools are available for cutting like a wheel-type plastic tubing cutter, ratchet-style cutter, fine-toothed hand saw (hack saw), or power saws etc.

EMGF-ITP-017 C


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

6 Water Test

7

Deficiencies:

Remedial actions:

3 Physical Checks

Laying Operations



All the walls including the structural clamps and supports are made good after installation of the system


Inspection Sheet for PP-R Pipes


Pipes and fittings from Approved Source







Remarks

5

Testing





Name :

Date :

Signature :


Proper weather proof treatment like covering with bitumen faced hessian of make as specified in BOQ as per manufacturer recommendations is done in case of buried pipe in trenches,

Pipes amd fittings are straight, smooth, with proper packagings and free from irregular bore, blow holes, cracks and other manufacturer defects

Both the inner and outer surfaces of the pipes and fittings cleanly finished, smooth, free from Dirt, debris, grooving and moisture and other deleterious defects before application of cement




Rinsing of whole Sysetem is done before acceptance

Post-Construction Checks8

Rinsing & Disinfection9

4Exacavation as per Drawing, incase of buried pipes

Backfilling Backfill done in layers and compacted as per specification

Guide marks on pipe and fittings referred to avoid misalignment.

Minimum distance of 100mm maintaied from other pipes

Heating of External surface of pipe and internal surface of fittings is done on temperature 260 0 to 280 0


Heating durations maintained as per manufacturer recommendations

EMGF-ITP-017 D


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

Water Test

Smoke test

7

Deficiencies:

Remedial actions:

Physical Checks3Proper marking on pipes as per MS-017

Fittings & specials are as per specification

4



8 Post-Construction Checks

Minimum distance of 15mm of pipe from wall is maintained

Sufficient tools are available for preparation Screwed Joints in case of pipe less than dia 50mm

Joints for Dia. greater than 50mm made with the pipes and fittings having “V” groove & welded with electrical resistance welding in an approved manner



In case of pipes embedded in wall, pipes painted with one coat anticorrosive bituminous paint of approved shade and quality.



Inside of the fitting and the screwed end of the pipes oilling is done and rubbed over with white lead and a few threads of spun yarn wrapped around the screwed end of the pipe

Pipes amd fittings are straight, smooth, and free from irregular bore, blow holes, cracks and other manufacturer defects


Chamfering as per requirement

Both the inner and outer surfaces of the pipes and fittings cleanly finished, smooth and free from grooving, and other deleterious defects



Name :

Date :

Signature :


Remarks

5

6 Testing




Laying Operations

Proper Spacing of structural clamps/ supports available as per MS-017

Check Satisfactory


Inspection Sheet for G.I. / M.S. Pipes

S.No.

Pipes and fittings From Approved Source


Diameter and thickness of pipes as per Type and requirement



EMGF-ITP-017E


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

4

Water Test

Smoke test

Deficiencies:

Remedial actions:

3


Inspection Sheet for uPVC Pipes

S.No.

Pipes, fittings and Sealing Rings/Solvent Cement From Approved Source

Yes/No



Sealing Rings properly inserted/Cement coating applied evenly

Physical Checks


Laying Operations

Proper Spacing of structural clamps/ supports is available

Pipes and trap set in cement concrete blocks (1:2:4 mix) are firmly supported on the structural floor

Check Satisfactory


Remarks

5

6 Testing


All the outlets kept for external, connection should be in plumb with lower floor.

All the walls including the structural clamps and supports are made good after installation of the system

Fittings & specials are proper





Name :

Date :

Signature :


Procedure for curing of cements joints as per manufecturer reccomendations



Chamfering as per requirement





Layout and position of pipes and outlets as per DrawingPre-Construction Checks

EMGF-ITP-017 F


Location: From:

Drawing Ref.: To:

Sub.Cont. EMGF

1

2

Water Test

Smoke test

Straightness Test

7

Deficiencies:

Remedial actions:



Inspection Sheet for G.I. / M.S. Pipes

S.No.

Pipes , fittings and refined pig lead From Approved Source


3



Fittings & specials are as per specification

Physical Checks


Laying Operations

Proper Spacing of structural clamps/ supports available



Remarks

5

6 Testing




Name :

Date :

Signature :


Spun yarn soaked in cement paste caulked properly inside the joints maintaining a depth of 25mm all around for lead


Length of pipes required worked out and cut accordingly.

In case of buried pipes, all the sockets lead uphill and support on the solid foundation for the full length


Pipe is clean and location of all components is correct,


Minimum distance of 15mm of pipe from wall is maintained

All scum removed before pouring of lead,

Each joint made with one continuous pour filling of the entire joint space with lead

Approximate depth & weight of pig lead for various diameter of CI pipes as per MS - 017

Exposed surface of pipes painted with two or more coats of synthetic enamel paint of approved quality, shade and colour code



4 Pre-Construction Checks

Sufficient space available for jointer to work

Jointing and centralization of spigot within socket is compliaying with manufacturer’s instructions




EMGF-ITP-017 G


upto 1000

1001 to 3000

3001 to 10000

Above 10001

upto 1000

1001 to 3000

3001 to 10000

Above 10001

upto 1000

1001 to 3000

3001 to 10000

Above 10001

First 5 8 13 20 0 0 0 0 2 3 4 5

Second 5 8 13 20 1 1 1 3 2 4 5 7

First 13 20 0 0 2 2 2 3

Second 13 20 1 3 2 2 2 4

First 5 8 13 20 0 0 0 0 2 2 2 3

Second 5 8 13 20 1 1 1 3 2 2 2 4

First 5 8 0 0 2 2 2 2

Second 5 8 1 1 2 2 2 23

4

5

6

Lot: All the pipes or fittings of the same type, size and manufactured under similar conditions of production, shall be grouped together to consitute a lot. These pipes shall be selected at random. In order to ensure the randomness of selection, procedures given in IS 4905 may be followed.Tests shall be carried out in accordance to IS 13592

The number of pipes or fittings in the first sample shall be first selected and subjected to inspection for testing. If in first sample the number of defectives, that is, those failing either for Colour, Visual Appearance and Dimensional Requirements, is less than or equal to the corresponding acceptance number, the lot shall be considered as conforming to the requirements of general quality and dimensions. If the number of defectives in the first sample is greater than or equal to the corresponding rejection number, the lot shall be considered as not conforming. If the number of defectives in the first sample lies between the acceptance & rejection number, a second sample, shall be selected and subjected to inspection, if in the combined sample, the number of defectives is greater than or equal to the corresponding rejection number, the lot shall be considered as not conforming.

at least one sample from each size and typeproduced during the period or shall be subjected to tests once in six months.

Water tightness of joints

Vicat softening temperature

Effect of Sunlight

Resistance to H2SO4

Testing after completion of pipe system

0

1

0

1

2

Rejection number

3

3

1

Reversion, Stress Relief, Tensile and Axial Shrinkage Tests

For dia. < 110mm

For dia. > 110mm

Number of Samples for Lot Size Accceptance number

Colour, Visual Appearance and Dimensional Requirements

For dia. < 110mm

For dia. > 110mm

8

13

Test

Inspection and Test PlanITP - 17 uPVC Pipes

S. No.Sample

no.


MS 18

WORK METHOD STATEMENT ROAD FURNITURE

0 0.1 20/07/08 QC Manager CEO (N)


MS 18 Emaar MGF Land Limited Road Furniture

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the activities for the construction of road furniture works on site. More detailed task specific method statements for the construction / installation of road furniture may be developed as additional sections to this method statement as the need is identified.

The purpose of this work method statement is to give brief detail of following construction activities done in accordance to standards and specific procedures.

• Traffic Signs

• Road Markings

• Kerb Stone



Issue 0.1

2.0 Traffic Signs

Traffic signs shall be made as per Technical Specifications / Relevant Codes / BOQ / MORT&H Clause No. 801.

In the absence of any specifications, Retro-Reflective Sheeting type sign boards made of encapsulated reflective sheeting over aluminium sheeting 2.0 mm thick complete including vertical pipes/angels posts etc.

The colour, configuration, size & location of all traffic signs shall be in accordance with the code of practice for Road Signs, IRC: 67 or as shown on the drawings.

On delivery, the signs shall be packed with bubble packing plastic sheets and marked the contents on the packing.



Issue 0.1

2.1 Signs With Respect to the Carriageway

2.1.1 Signs shall be placed as per GFC Drawing.

2.1.2 Normally the signs shall be on the left hand side of the road. The signs may be placed on the left side of the carriageway repeated on the other side of the carriageway, if local conditions are such that the signs might not seen by the drivers. For more than 2 lane roads signs may be placed on both shoulders & median.

2.1.3 On kerbed road, the extreme edge of the sign adjacent to the road shall not be less than 60 cm away from the kerb line. On roads without kerb, the extreme edge of the sign adjacent to the highway shall be at the distance of 2 to 3 meters from the edge of the carriageway depending on the local conditions, but in no case shall any part of sign shall come in the way of vehicular traffic.

2.1.4 On kerbed roads, the bottom edge of the lowest sign shall not be less than 2 meters and not more than 2.5 meters above the kerb. On roads without kerb, the bottom edge of the lowest sign shall not be less than 2 meters and not more than 2.5 meters above the crown of the pavement.

2.1.5 To improve the visibility of sign on multi-lane carriageway, the minimum height of the lower edge of the sign should be kept as 3 meters above crown, the highest point of the carriageway.

2.1.6 The signs shall be so placed that these do not obstruct vehicular traffic on the carriageway and if placed on the shoulder / footpath / refuse island, obstruct pedestrians as little as possible.

2.1.7 The difference in level between the lower edge of the sign and the carriageway shall be as uniform as possible for signs of same class on the same route.

2.1.8 The overhead signs shall be mounted to ensure better visibility & effective in communicating the drivers. Overhead signs shall provide a vertical clearance of not less than 5.5 meters over the entire width of pavement & shoulders except where a lesser vertical clearance is used for the design of other structures.

2.2 Orientation of the Signs

2.2.1 The signs shall normally be placed at right angles to the line of travel of the approaching traffic. Signs relating to parking however, should be fixed at an angle (approximately) 15 degrees to the carriageway so as to give better visibility.

2.2.2 Where light reflection from the sign face is encountered to such an extent to the reduce legibility, the sign should be turn slightly away from the road.

2.2.3 On horizontal curves, the sign should not be fixed normal to the carriageway, but the angle of placement should be determined with regard to the course of approaching traffic.

2.2.4 Sign faces are normally vertical, but on gradients it may be desirable to tilt a sign forward or backward from the vertical to make it normal to the line of sight.



Issue 0.1

2.3 Materials For Signs

2.3.1 Concrete: Concrete shall be of M15 grade (Mix 1:2:4)

2.3.2 Reinforcing Steel: Reinforcing steel shall conform to the requirements of IS: 1786 unless otherwise specified.

2.3.3 Bolts, Nuts, Washers: High strength bolts shall conform to IS: 1367 whereas precision bolts shall conform to IS: 1364.

2.3.4 Plates & Supports: Plates & support sections for the signposts shall conform to IS: 226 and IS: 2062 or any other stated IS specifications.

2.3.5 Aluminium: Aluminium sheets used for sign shall be of smooth hard and corrosion resistant aluminium alloy conforming to IS: 736- Material Designation 24345 or 1900.

2.3.6 Plate thickness: Signs with a maximum side dimension not exceeding 600 mm shall be related to the size of sign and its support shall be such that it does not bend or deform under prevailing wind and other loads.

2.3.7 Retro reflective sheeting: The retro reflective sheeting used on the signs shall consists of the white or coloured sheeting having a smooth outer surface which has the property of retro reflection over its entire surface. It shall be weather resistant and colourfastness. It shall be new and unused and shall show no evidence of cracking, scaling, pitting, blistering,, edge lifting or curling and shall have negotiable shrinkage or expansion. The reflective sheeting shall be of high intensity grade with encapsulated lens as per clause no. 801.3.2 of MORT&H.

2.3.8 Adhesives: The sheeting shall either have a pressure sensitive adhesive of the aggressive tack type requiring no heat, solvent or other preparation for adhesion to a smooth cleaned surface, or a tack free adhesive activated by heat applied in a heat vacuum applicator in a manner recommended by sheeting manufacturer.

2.3.9 Fabrication: Surface to be reflectorised shall be effectively prepared to receive the retro-reflective sheeting. The aluminium sheeting shall be de-greased either by acid or hot alkaline etching, and all scale/ dust removed to obtain a smooth plain surface before the application of retro reflective sheeting. If the surface is rough, approved surface primer may be used. After cleaning metal shall not be handled, except by suitable device or clean canvas gloves. There shall be no opportunity for metal to come in contact with grease, oil or other contaminants prior to application of retro reflective sheeting. Complete sheets of the material shall be used on the signs except where it is unavoidable. Sheeting with heat activated adhesives may be spliced with an overlap not less than 5mm or butted with a gap not exceeding 0.75 mm. At splices sheeting with pressure sensitive adhesives shall be overlapped not less than 5 mm.

2.3.10 Message / Borders: The messages & borders shall either be screen-printed or of cut outs. Screen printing shall be processed and finished with materials as specified by the sheeting manufacturer. Cut outs shall be of materials as specified by sheeting manufacturer and shall be bonding with the sheeting in the manner specified by the



Issue 0.1

sheeting manufacturer. For screen printing transparent coloured areas on white sheeting, the co-efficient of retro reflection shall not be less than 50 % of the values of corresponding colours as given in Table 800-1 or 800-2 in MORT&H as applicable. Cut-out messages & borders, wherever used shall be made out of retro-reflective sheeting (as per clause 801.3.2 or 801.3.3 of MORT&H as applicable), except those in black which shall be of non-reflective sheeting.

2.3.11 Colour: Colours shall be as specified in the GFC drawings. In absence of any reference from drawings, the general colour scheme shall be as stipulated in IS: 5 “Colour for ready mixed paints”. The colour shall be durable and uniform in acceptable hue when viewed in day light or under normal headlights at night.

2.4 Warranty & Durability

The contractor shall obtain from the manufacturer a seven-year warranty for satisfactory field performance including stipulated retro-reflectance of the retro-reflective sheeting of high intensity grade and submit the same to the EMGF. In addition, a seven year warranty for satisfactory in field performance of the finished sign with retro-reflective sheeting of high intensity grade, inclusive of the screen printed or cut-out letters/legends and their bonding to the retro-reflective sheeting shall be obtained from the contractor/supplier and passed on to EMGF. The contractor/supplier shall also furnish a certification that the signs and materials against the assigned work meet all the stipulated requirements and carry stipulated warranty.



Issue 0.1

2.5 Installation

2.5.1 Installation shall be done as per GFC Drawing.

2.5.2 Sign posts, their foundations and sign mountings shall be so constructed as to hold these in a proper and permanent position against the normal storm wind loads or displacement by vandalism. Normally, signs with an area up to 0.9 m2 shall be mounted on a single post, and for greater area two or more supports shall be provided. Sign supports may be mild steel, reinforced concrete or galvanized iron. Post-ends shall be firmly fixed to the ground by means of properly designed foundation. The work of foundation shall conform to relevant specifications as specified.

2.5.3 All components of signs and supports, other than the reflective portion and G.I. posts shall be thoroughly de-scaled, cleaned, primed & painted with two coats of epoxy paint. Any part of mild steel post below ground shall be painted with three coats of red lead paint.

2.5.4 The signs shall be fixed to the posts by welding in the case of steel posts and by bolts and washers of suitable size in the case of reinforced concrete or G.I. posts. After the nuts have been tightened, the tails of the bolts shall be furred over with a hammer to prevent removal.

2.5.5 The frames & support poles shall be packed with jute cloth to avoid scratches during transit.

• For overhead signs the erection shall be done first & than the sign boards shall be hoisted & bolted / welded in proper position.



Issue 0.1

3.0 Road Markings

This work is for the supply & application of marking paint to asphalt pavements. The marking paint must be supplied in various colours as indicated on the drawings & must be suitable for use on asphalt pavements to indicate the markings as detailed on the drawings. The marking paint shall be confirming with the ASTM D-36/BS-3262(Part-1) as per Drawings & Technical specifications / MORT&H Clause No. 803.

3.1 Materials

Paint shall be specifically formulated for use on asphalt pavements & shall comply with the requirements with ASTM D-36/BS-3262(Part-1), & shall be suitable for Retro-Reflective pavement marking. The paint shall be delivered at site in sealed containers bearing the name of the manufacturer and the type of paint. The viscosity of the paint shall be such that it can be applied without being thinned. The no-pick up time of the paint must not exceed 30 minutes.

3.1.1 Requirements

3.1.1.1 Composition: The pigment, beads, and aggregates shall be uniformly dispersed in the resin. The material shall be free from all skins, dirt and foreign objects and shall comply with requirements indicated in Table below:

Proportions of Constituents of Marking Material

Percentage by Weight

Sr. No. Component White Yellow

1 Binder 18.0 min. 18.0 min.

2 Glass Beads 30-40 30-40

3 Titanium Dioxide 10.0 min. -

4 Calcium Carbonate & Inert Fillers 42.0 max.

5 Yellow Pigments - See Note

Note: Amount of yellow pigment, calcium carbonate & inert fillers shall be at the option of the manufacturer, provided all other requirements of this specification are met.

3.1.1.2 Properties: The properties of Thermoplastic material, when tested in accordance with ASTM D-36/BS-3262(Part-1), shall be as below:

• Luminance:

o White: Daylight luminance at 45 degree - 65 % min. as per AASHTO M-249

o Yellow: Daylight luminance at 45 degree - 45 % min. as per AASHTO M-249

• Drying Time: When applied at a temperature specified by the manufacturer & to the required thickness, the material shall set to bear traffic in not more than 15 minutes.

• Skid Resistance: Not less than 45 as per ASTM D 36.



Issue 0.1

• Cracking Resistance at low temperature: The material shall show no cracks on application to concrete blocks.

• Softening Point: 102.50c +/-9.50c as per ASTM D-36.

• Flow Resistance: Not more than 25% as per AASHTO M 249.

• Yellowness Index: (For White Thermoplastic Paint): Not more than 0.12 as per AASHTO M 249.

3.1.1.3 Storage Life: The material shall meet the requirement of these specifications for a period of one year. The thermoplastic material must also melt uniformly with no evidence of skins or unmelted particles for the one year storage period. Any material not meeting the above requirements shall be replaced by the Manufacturer/Supplier/Contractor.

3.1.1.4 Reflectorisation: Shall be achieved by incorporation of beads, the grading and other properties of the beads shall be as specified in MORT&H Clause No. 803.4.3

3.1.1.5 Marking: Each container of the thermoplastic material shall be clearly and indelibly marked with the following information:

• The name trade mark or other means of identification of manufacturer

• Batch No, Date of Manufacturer, Colour (White or Yellow).

• Maximum application temperature and maximum safe heating temperature.

3.1.1.6 Sampling and Testing

The thermoplastic material shall be sampled & tested in accordance with the appropriate ASTM/BS method. The contractor shall furnish to the Employer a copy of certified test reports from the manufacturers of the thermoplastic material showing results of all tests specified herein and shall certify that the material meets all requirements of this specification.



Issue 0.1

3.1.2 Reflectorising Glass Beads

Grading Requirements of the Glass Beads are as specified in the Table shown below:

Sieve Size Type 1 (%Retained) Type 2 (%Retained)

1.18 mm 0-3 -

850 micron 5-20 0-5

600 micron - 5-20

425 micron 65-95 -

300 micron - 30-75

180 micron 0-10 10-30

Below 180 micron - 0-15

• Roundness: The glass beads shall have a minimum of 70 % true spheres.

• Refractive Index: The glass beads shall have a min refractive index of 150.

• Free Flowing Properties: The glass beads shall be free of hard lumps & clusters & shall dispense readily under any conditions suitable for paint stripping. They shall pass the free flow-test as specified in MORT&H Clause No. 803.4.3.4.

3.2 Application Properties of Thermoplastic Material

The thermoplastic material shall readily get screeded / extruded at temperatures specified by the manufacturer for respective method of application to produce a line of uniform thickness of at least 2.5 mm unless specified otherwise which shall be continuous & uniform in shape having clear & sharp edges. The minimum thickness specified is exclusive of surface applied glass beads. The method of measurement of thickness shall be in accordance with Appendices B & C of BS-3262(Part-3).

The material upon heating to application temperatures shall not exude fumes which are toxic, obnoxious or injurious to person or property.

3.3 Preparation

• The material shall be melted in accordance with the manufacturer’s recommendation in a heater fitted with a mechanical stirrer to give a smooth consistency to the thermoplastic material to avoid local overheating. The temp of the mass shall be within the range as specified by manufacturer, and shall on no account be allowed to exceed the max temp stated by the manufacturer. The molten material should be used as expeditiously as possible and for thermoplastic material which has natural binders or is otherwise sensitive to prolonged heating, the material shall not be maintained in a molten condition for more than 4 hours.



Issue 0.1

• After transfer to the laying equipment, the material shall be maintained within the temperature range specified by the manufacturer for achieving the desired consistency for laying.

3.4 Application

• The road marking shall be laid in one layer with appropriate road marking machine approved by the Engineer. Before the road marking machine is used on the permanent works, the satisfactory working of the machine shall be demonstrated on suitable site, which is not part of the permanent works. The rate of application shall be checked & adjusted as necessary before application on a large scale and thereafter daily.

• All surfaces to be marked shall be thoroughly cleaned of all dust, dirt, grease, oil & other foreign matter before application of the paint.

• There shall be control over traffic while painting operations are in progress so as to cause minimum inconvenience to traffic compatible with protecting the workmen.

• The thermoplastic shall be applied hot either by screeded/extruded process.

• After transfer to the laying apparatus, the material shall be laid at a temperature within the range specified by the manufacturer for the particular method of laying being used.

• The paint shall be applied using a hand pushed manual machine screed type or fully automatic extrusion type.

• The thermoplastic paint shall be applied in intermittent or continuous lines in uniform thickness of at least 2.5 mm exclusive of surface applied solid glass beads.

• Where arrows or letters are to be provided, thermoplastic compound may be hand sprayed.

• The finished lines shall be free from ruggedness on sides and ends and be parallel to the general alignment of the carriageway. The upper surface of the lines shall be level, uniform & free from streaks.

• In addition to beads included in the material, a further quantity of glass beads of type 2, conforming to the above noted specifications shall be sprayed uniformly into a mono-layer on to the hot-paint line in quick succession of the paint spraying operation. The glass beads shall be applied at the rate of 250 grams per m2 area unless specified otherwise.

3.5 Properties of Finished Road Marking

• The strip shall not be slippery when dry.

• The marking shall not be lift from the pavement in freezing weather.

• After application & proper drying, the strip shall not show appreciable deformation or discoloration under traffic and under a temp up to 600 c.



Issue 0.1

• The marking shall not deteriorate by contact with sodium chloride, calcium chloride or oil drippings from traffic.

• The strip & marking shall maintain its original dimensions & position. Cold ductility of the material shall be such as to permit normal movement with the road surface without chopping or cracking.

• The thickness of the road marking shall be determined as per BS: 3262 (Part-3).

• The relative density of road marking material shall be determined as per BS: 3262 (Part-3).

• Road Traffic marking shall be constructed to accuracy within the tolerance given below:

• Width of lines & other markings shall not deviate from the specified width by more than 5%.

• The position of lines, letters figures, arrows and other markings shall not deviate from true position specified by more than 20 mm.

• The alignment of any edge of a longitudinal line shall not deviate from the true alignment by more than 10 mm in 15 m.

• The length of segment of broken longitudinal line shall not deviate from specified length by more than 150 mm.

The work shall be carried out as per requirements of the Contract Technical specifications.

Weather and Seasonal Limitations:

• The pavement temperature shall not be less than 100C during application.



Issue 0.1

4.0 Kerb Stone

This work shall consist of providing and fixing of kerb stone in conformity in lines levels and dimensions as specified in the GFC drawings / BOQ /Technical specifications.

4.1 Materials

Kerb stones shall be of cement concrete of specified grade in accordance with the section 1700 of MORT&H. Shape of the kerb stones shall be as per GFC drawing.

Supplier shall submit samples and get them approved from EMGF.

4.2 Type of Construction

These shall be pre-cast as specified in the Technical Specifications with conformity in lines & levels as given in the drawings or as directed by EMGF representative.

Appropriate measures shall be taken to check the quality of concrete mix at the manufacturer’s lab & a certificate from manufacturer as well as third party to ensure the compressive strength of the kerbs. The precast kerbs should be as per required dimensions, shape as shown in the drawings with appropriate grooves.

4.3 Laying Operations

• Kerbs shall be laid on firm foundation or on extended width of pavement / or as shown in the GFC drawings.

• The foundation shall have a projection of at least 50 mm beyond the kerb stone (or as shown in GFC drawings).

• In the portions where footpath is provided and / or the slope of the carriageway is towards median as in case of superelevation, there shall be sufficient gap / recess left in the kerb to facilitate drainage openings.

• Vertical & Horizontal tolerance with respect to true line shall be +/- 6 mm per 200m.

• The slopes of the channel towards drainage pipes shall be ensured for efficient drainage of the road surface.

• The joints between the Kerbs shall be filled with cement mortar (ratios as given in technical specifications) providing appropriate curing to the joints. Joints shall be pointed as per EMGF representative’s directions.



MS 19

WORK METHOD STATEMENT TILING WORK

0 0.1 29/06/08 QC Manager CEO (N)


MS 19 Emaar MGF Land Limited Tiling Work

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of work required for carrying out flooring work (tiles – ceramic, vitrified, etc) on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose

Laying Stones / tiles as per the pattern approved in shop drawing to the required line and level over the evenly laid cement mortar with straight line joints and finished as per the specifications..



Issue 0.1

2.0 Procedure

2.1 General

• Ratio of cement to sand in mortar shall be as per GFC drawing. • Only sufficient quantity of cement mortar shall be prepared to consume within 30

minutes of mixing water. • Cement mortar shall be preferably prepared with manual mixer. • Decide the method of handrail fixing before stair case floor finish is taken up and

leave proper holes, inserts etc, for same. • Decide the type of nosing and its method of fixing, before staircase floor finish

work is taken up (preferably the nosing has to be rounded - the special name for this rounding is Bull nosing).

• Carry out survey on the constructed staircase, carry out rectification required, to ensure

o all treads are of equal width o both landings on either side of the flights are of equal width and / or as per

drawings. • Ensure the total riser height is equally divided between landings and accordingly

the individual riser height is fixed, thus ensuring all risers are of equal height (preferably not to exceed 150mm).

• Ensure the stair floor surface is not very smooth like the other floor surfaces, but a little more rough or provided with grooves so that sufficient grip for the foot is available for the person, while climbing or getting down.


• Mark the tile pattern on wall and floor as per drawing. • Carry out a dry mock up in one room for checking workmanship and other points. • Do check thickness of bed mortar that could be accommodated within proposed

flooring thickness. • Mark the level of finished floor in 2 to 3m intervals. • Roughen the surface by chipping or hacking to receive the base mortar and

cleaning. • Prepare the surface by:

o clearing all dirt and loose matter,

o chipping and clearing of plastering mortar droppings,

o chipping and clearing of unevenness in the concrete slab or base

• Complete all pipeline works to their final positions and levels. • Fix in position to line and level, all other inserts required.

2.3 Layout

• Tile joint lines of flooring and dado must continue through and through in a room unless a different pattern is designed by the Architect.



Issue 0.1

• Tile joints must be at right angles to the Entrance Door line in the room (unless otherwise specified as such, or a different pattern is envisaged)

• Plan the tile joints coinciding with the door jamb edges on both sides. • One tile joint to fall at right angle on the centre line of the door (this is preferable

and not a must). • First full tile to start from the door jamb line or from the threshold if it is there. • When there is a border of different colour, in the room layout, then it is better to

provide o one full tile between wall and the border first,

o second the border tile,

o then distribute the space with full tiles, pushing “more than half tiles” to the edges inside the border tiles.

• Cut tiles or Part tiles must be positioned in the wall ends of the room. • If, end tile sizes are less than half tile sizes, do not use such cut pieces. In stead,

omit one full tile and substitute the one plus part tile as two more than half size tile.

• For example - in one row if 8.3 tiles are required as per the dimension of the room, Instead of using 8 no full tiles and 2 no of 0.15 tiles in the ends, use 7 No. full tiles + 2 no of 0.65 tiles on either side. This will increase the aesthetic appearance better.

• When curved area or angular area is adjoining a true rectangle or square in the room layout, carry out tile joints from rectangle or square into the angular or curved area.

• Do not plan tile joints from curved area into the regular shape. • The door, window, ventilator top line and dado top line (or a tile joint line at that

level), must fall in same line, if dado is up to this level. (i.e. horizontally the same line should join the door top, window top, and the dado top).

• The tile joint line must not cut the window bottom line or any intermediate working platform top line. (i.e. the window bottom line and tile joint line must merge into each other and should not cut).

2.4 Construction

2.4.1 Flooring

• Prepare and lay base mortar to the required level. • Spread the polythene sheet on the clean floor, if specified. Over the sheet spread

the bed mortar for an area that could be completed within a session of say 2hours, and level the bed, gently tamp the mortar for consolidation (if, no polythene sheet, spread the mortar directly on clean floor).

• Then scratch the bed mortar top for tile grip. • Spread the cement slurry in honey like consistency for a row of tiles that could be

laid in next half hour. • Position the soaked tiles as per pattern and press down the tile, in a sequence to

get straight joints in both longitudinal and cross directions.



Issue 0.1

• Use tile spacers to ensure proper straight joints (if it is specified). • Gently tap and press each tile to ensure proper seating and to check air entrapped

in the tile escapes. • While pressing the tile down the slurry must rise in the sides and joints. If

required apply a little more slurry to ensure this. • There should be no hollow sound when the tile is stuck. • Check the level of flooring with the straight edge frequently to ensure the correct

level. • Complete the floor and ensure level is okay • After initial setting time, scrape the joint thoroughly, clean the floor and apply

pointing in the joints. • Cure for 7 days. • Thorough clean with mild hydrochloric acid and water.

2.4.2 Dado Works

• For the dado work, tiling must start from bottom, so that cut pieces could be left in the bottom.

• To do this, fix a full tile on the top of floor trap. Then, stretch the horizontal line on top of this tile to the door jamb. Usually, the floor at the door entry point will be the top most point in the room. So, if a full tile is placed on floor trap which is the lowest point, considering the Floor gradient in the toilet or bath room, then tiles will have cut sizes from door point to the floor trap.

• The size difference between tile near the door jamb and the full tile on the floor trap is the amount of gradient given on the floor. (This difference should not exceed 0.25 times the tiles width). Tiling done with this kind of cut sizes will add aesthetics to the dado work.

• When a window is intervening in the dado, the vertical tile joint line on either side of the window must coincide with window jambs. First fix these lines and then distribute other tiles on the sides of the window, with part tiles, if any, pushed near the walls.

• If sanitary/ water supply fittings are on the wall, the fitting position must come in a position of four tile corners.

• Alternately it can be in the centre of a full tile. (Care must be taken to drill the hole for such fittings properly and finish the tile. Use a diamond tipped drill for drilling holes in tiles. DO NOT PUNCH OR CHISEL a hole in the tiles)

• Fittings should preferably be not in any other position. To get such corner or centre position, if the height of the dado has to be increased, then it has to be done.(while increasing match the door window top line (as given in point above)

• Height of dado work in a day must be limited to 1m only. If more height is there continue the work next day.

• Make the wall wet and apply a layer of plaster (viz the base course of thickness as specified).



Issue 0.1

• It is expected that the base scratch coat of plaster to make up defects and unevenness is already applied, cured for required number of days so that a hard base is available for the tiles.

• Cover the back of the tile fully with cement slurry (honey like consistency) and press tile to the wall and gently tap with mallet.

• Check plumb of the tiles, vertical line of the joints, horizontal line of joints at frequent intervals and proceed to the top.

• After required number of layer of tiles, finish the top of tile with cement paste properly (top of dado) and complete touch up of wall above, if required. This touch up is to cover up the scratch made in the plaster.

• The jamb joints must be finished with tiles chamfered at the edges or using special shaped tiles.

• After initial set clean the tile joints and tiles properly. • Scrape the joint and finish the joint by pointing, with white cement paste (mixed

with pigment to match shade of tile). Procedure for pointing same as in flooring. • Clean the tiles and joints properly and cure for required number of days.

2.4.3 Stair Cases

• The tile joints on the treads must be parallel to the flight line unless the flight is in a curve.

• The tile joints in the treads should form a continuous straight line parallel to the flight line and at right angles to the nosing line.

• The joints in the riser and tread line must also be in one straight line unless specified as otherwise.

• In curved landings and straight flights the joint lines must go from flight to the landing.

• In curved flights the cross tile joints across the treads must be on the circumferential / peripheral lines of the curve. The longitudinal joints (along the treads) in the treads must be laid in the radial directions of the curve.

• The tiles must be laid on a dry mock up first, checked and then laid in position, particularly when the staircase is a curved one.

2.4.4 Laying Elevation Works or Veneer Works

• Complete all preparatory works for veneering (stated in 5.4 of chapter I general above).

• Mark the stone/ tile layout in any area nearby from which reference can be made of and then start the work.

• The work must start from bottom to top, in veneer work. • Height of veneer work in a day must be limited to 1m to 1.5m so that tiles laid in

position are not loaded unduly. If more height is there continue the work next day.

• Sort the tile and soak the same as stated in flooring. • Cover the back of the tile fully with slurry of thick paste (honey like consistency)

and press tile to the wall and gently tap with mallet.



Issue 0.1

• Check plumb, horizontal line of joint at frequent intervals and proceed to the top. • The jamb joints must be finished with tiles chamfered at the edges. • Finish the top of tile with cement paste properly and complete. • After initial set, clean the tile joints and tiles properly. Scrap the joint and finish

the joint with white cement (mixed with pigment to match shade of tile) by pointing.

2.4.5 Pointing

• Point the joints with white cement paste (mixed with color pigment or stainer to match the shade of tile). After scraping the joint press down the white cement paste of right consistency with pointed trowel/ rubber squeeze (neither too stiff nor too watery). Then scrape/ clean the excess paste on the tile edges and in level with tile top. If required, use the straight edge to cut straight line in pointing. Clean the floor thoroughly and leave for setting.

• Barricade the floor for next two days to ensure proper setting. Cure the floor for adequate number of days.

• Do clean the floor again and check the pointing and carry out any repair required. • Do a mild acid wash to clean thoroughly and apply recommended polish. • Protect to avoid any damage to the floor, till same is ready for handing over.

2.5 Quality Checks

• Tile sizes should be consistent within tolerances as per BIS Code. • Floor / Surfaces are even and levelled; levelled to proper falls in wet areas like

kitchen and toilets. • Tile joints are aligned and consistent with skirting and wall tiles. • Tiles should not butt tightly with each other. Joints size to be 1.5mm to 4mm or

as stated by Architect. • Chipping, cracks in tiles or mortar droppings should not be present. • Hollowness should not be detected in any place by tapping with any hard object

on the floor.

2.6 Tolerances

Glazed tiles: (as per I.S. 777- 1970) Dimensional tolerance in Length & breadth to be measured to an accuracy of 0.1mm. Average deviation can be + or - 0.8mm to the sizes specified. Thickness of tile is 4mm, 5mm, 6mm,or 7mm. The tolerance I thickness is +0.5mm or –0.5mm While measuring variation of individual dimension in length and breadth can be + or - 0.5mm from average value.

Ceramic Tiles: (as per code I.S.13755and 13754:1993) Group B II a and group B II b tiles

Dimensional tolerance in length and breadth measured as a percentage of average size of each tile


EMGF-ITP-019 A

Project: Date:

Location: From:

Drawing Ref.: To:

Description of work

Contractor EMGF

1

2

Deficiencies:

Remedial actions:

Signature :

Post-Construction

Checks

Proper Curing is done for the joints for atleast 7-days

Floor / Surfaces are even and levelled; levelled to proper falls in wet areas like

kitchen and toilets

7

Tiles joints are not butt tightly with each other, Joints are as stated in drawing


Name :

Date :


The type of nosing, junctions rebates, corners and its method of fixing is

decided, before staircase floor finish work is taken up

The tile joint line is not cutting window bottom line/any intermediate working

platform top line.



Level of finished floor and the tile pattern on wall and floor is marked as per

drawing at suitable interval

Bed Mortar is freshly perpared and laid in thickness as per

drawings/specifications

Surface for work is cleared of all dirt, loose matter and plastering mortar

droppings

Dimensional Tolrances are as per approved ITP

The floor area is cleaned properly.

Tile joints are aligned and consistent with skirting and wall tiles.

The surface is well roughned by chipping or hacking and properly cleaned to

receive the base mortar


Inspection Sheet for Tilling Works

S.No.

Check Satisfactory


All pipeline works/concealed works below floor are complete to their final

positions and levels

Joints are planned from regular shape (rectangular/square) to curved/Angular

area

Cut tiles or Part tiles are positioned in the wall ends of the room/ used

appropriately

Proper Tools for the works are availble on site

Tile joints are planned to fullfilling the requirements of the different pattern as

per Good For Cnstruction drawing

Back of the tile is fully covered with cement slurry (honey like consistency) and

pressed to the wall and gently tapped with mallet

Tile joints is at right angles to the Entrance Door line in the room

Pointing is done with white cement paste, of approved brand mixed with proper

shade, of right consistency with pointed trowel/ rubber squeeze .

Layout Planning3

Wall is made wet and a layer of plaster is applied to base scratched coat of

plaster to make up defects and unevenness, cured for required number of days

so that a hard base is available for the tiles.

The method of handrail fixing is decided before stair case floor finish is taken up

and proper holes, inserts etc, are left

Cement slurry is spread in honey like consistency for a row of tiles that could be

laid in next half hour

In case of Staircase, tile joints on the treads are parallel to the flight line unless

the flight is in a curve and at right angle to nosing line

In curved landings and straight flights the joint lines is going from flight to the

landing.

Levels checked with straight edge are okay

Pre-Construction

Checks

4

In sanitary/ water supply fittings are on the wall, the fitting position is coming in

a position of four tile corners.

Plumb of the tiles, vertical line of the joints, horizontal line of joints are checked

at frequent intervals and proceed to the top

Height of work in a day is limited to 1 meter

Pointing is done with white cement paste, of approved brand mixed with proper

shade, of right consistency with pointed trowel/ rubber squeeze .

Excess cement paste is cleaned on the tile edges and made in level with tile

top

Fixing Operation

Flooring

5

Tiles are properly tapped to ensure it is well seated and entrapped air is

removed, While pressing the tile down the slurry is rising in the sides and joints

Excess cement paste is cleaned on the tile edges and made in level with tile

top

Fixing Operation

Elevation works/

Dado works

6

Tiling is starting from bottom to top, all cut pieced are used in the bottom

In case of window intervening in work, the vertical tile joint line on either side of

the window is coinciding with window jambs

EMGF-ITP-019 B

BIS Reference IS 13753, IS13754, IS13711

Length &

BreadthThickness

Straightness

of SidesRectangularity Surface Quality

Water

absorption

by weight

Modoulous of

Rupture

Scratch

hardness

of surface

Abrasion

Resistance

Coefficient of linear

thermal expansion from

ambient temp. to 1000C

Resistance

to staining

Resistance to

household

chemicals

Resistance to

acids and

alkalis

+ / - 1.2% + / - 10% + / - 0.75% + / - 1%

+ / - 1% + / - 10% + / - 0.5% + / - 0.6%

+ / - 0.75% + / - 5% + / - 0.5% + / - 0.6%

+ / - 0.6% + / - 5% + / - 0.5% + / - 0.6%

+ / - 1.2% + / - 10% + / - 0.75% + / - 1%

+ / - 1% + / - 10% + / - 0.5% + / - 0.6%

+ / - 0.75% + / - 5% + / - 0.5% + / - 0.6%

+ / - 0.6% + / - 5% + / - 0.5% + / - 0.6%

+/ - 0.75

+/ - 0.5

+ 0.6 / - 0.3

+ / - 0.5%

+ / - 0.6%

+ / - 0.7%

+ / - 0.8%

30,40,50,60,70,

80,90,100, 1m2

5

10

7

103 5 1 5 5 5

30,40,50,60,70,

80,90,100, 1m3

5

10

7

103 5 1 5 5 5

Acceptance

number Ac1

1,1,2,2,2,3,4,4,

4%

0

0

0

00 0 0 0 0 0

Rejection

number Re1

3,4,5,5,6,7,8,9,

9%

2

2

2

22 2 2 2 2 2

Acceptance

is Ac2

3,4,5,6,7,8,9,10,5

%1 1

1

11 1 1 1 1 1

Rejection

number Re2

4,5,6,7,8,9,10,11,

>5%

2

2

2

22 2 2 2 2 2

1. All dimension tolrances are the permissimble Percentage of deviation from their respective work size of tile.

2. Dimensional test is only for tiles with individual facial areas a 4 cm2.

5. In Modulus of rupture test, number of sample size shall be 7 Only for tiles with lengths > 48 mm.

Minimum Class

B

Minimum Class

B

As mentioned

by

manufecturer

Max 9 x 10-6

K-1

Max 9 x 10-6

K-1

Max 9 x 10-6 K-1

Required

Required

Physical Properties

Minimum

Class 2

Minimum

Class 2

Minimum

Class 2

Chemical Properties

Max. 345

Max. 540

Minimum Class

B

Avg.15<12 mm

thk.

Avg.12>12mm

thk.

Min. 5 for

glazed; Min.

6 for

unglazed

Min. 5 for

glazed; Min.

6 for

unglazed

Min. 3 for

walls ; Min.

5 for floors

Avg. > 22 Min. 20

Avg. > 18 Min. 166<W.A.<10

individul 11

Average

Shall be 10 to

20%

10 samples each batch

+ / - 0.3 + / - 0.5%

Min.95 % of tiles

shall be free from

visible defects

that would

impair the

appearance of a

major area of tiles

Dimensional and Surface Quality


ITP - 19 Ceramic Tiles

Group B II a

Titles Specifications

3<W.A.<6

individul 6.6Required

S <90cm2

90cm2<S<90cm

2

Group B II b

Sample Size

Inspection

by attributes

if required 1

2

Group B III

S <90cm2

90cm2<S<90cm

2

190cm2<S<410cm

2

S>410cm2

190cm2<S<410cm

2

S>410cm2

size of side 1 < 12 cm

size of side 1 > 12 cm

tiles with spacer leg

< 250 cm2

250<S<500 cm3

500<S<1000 cm3

1000cm3<S

Initial number

3.For Surface quality test,at least for 1 m2 minimum number of sample shall be of 30 tiles. Whatever the number of tiles in 1 m2, the test sample should be to the nearest to 10 tiles as given above. Conformity to AOL 2.5% in accordance with IS 2500 (Part 1

& 2) is an acceptable alternative to the procedures in above table.

4. In Water absorption test, number of sample size shall be 5 only for tiles with individual facial areas > 0.04 m2. In the case of tiles weighing <50 g a sufficient number shall be taken so as to form 5 test specimens each weighing between 50 gm and 100 gm.

Second number

10 samples each batch

0

2

Initial

Sample

Intial +

Second

sample

EMGF-ITP-019 C

BIS Reference: IS 4457-1982

1 Dimension Tolerance of + 2.5% Random

2 Shade Random

3 Squareness

Gap between the inner edge of the square

and the adjacent side of the tile shall not

exceed 1mm per 100 mm Run

Random

4 Warpage As per manufacturers data Random

5 Compressive Stregth Random

6 Flexural Strength Random

7 Resistance to Acid Random

8 Abrasion Resistance Random

70 N/mm2 Min

20 N/mm2 Min


ITP - 19 Unglazed Vitreous Acid Resistance Tiles

S.No ActivitySampling

planFrequency

Loss in mass shall not exceed 1.5%

Average wear 2mm, Max, Wear on Individual specimen 2.5mm,

Max

Testing

Agency

5 samples upto a lot size of 8,

8 samples upto a lot size of 9 to 25,




50 samples upto a lot size of 501 above.

1 test up to lot size of 101 to 300 tiles

2 tests for lot size more than 300 tiles

External Test

house

Site

Laboratory.

Acceptance Criteria

Permissible number

of defectives uoto a

lot size of 50 is zero

and then upto 100

its 1, and upto 500

its 2 and above 500

its 3 numbers


MS 20

WORK METHOD STATEMENT STONE FIXING

0 0.1 20/07/08 QC Manager CEO (N)


MS 20 Emaar MGF Land Limited Stone Fixing

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of work required for carrying out stone fixing (natural stones) on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose

Laying stones as per the pattern approved in shop drawing to the required line and level over the evenly laid cement mortar with straight line joints and finished as per the specifications.



Issue 0.1

2.0 Procedure

2.1 General

• Ratio of cement to sand in mortar shall be as per GFC drawing. • Only sufficient quantity of cement mortar shall be prepared to consume within 30

minutes of mixing water. • Cement mortar shall be preferably prepared with manual mixer. • Decide the method of handrail fixing before stair case floor finish is taken up and

leave proper holes, inserts etc, for same. • Decide the type of nosing and its method of fixing, before staircase floor finish

work is taken up (preferably the nosing has to be rounded - the special name for this rounding is Bull nosing).

• Carry out survey on the constructed staircase, carry out rectification required, to ensure

o all treads are of equal width o both landings on either side of the flights are of equal width and / or as per

drawings. • Ensure the total riser height is equally divided between landings and accordingly

the individual riser height is fixed, thus ensuring all risers are of equal height (preferably not to exceed 150mm).

• Ensure the stair floor surface is not very smooth like the other floor surfaces, but a little more rough or provided with grooves so that sufficient grip for the foot is available for the person, while climbing or getting down.

2.2 Layout

• Tile joint lines of flooring and dado must continue through and through in a room unless a different pattern is designed by the Architect.

• Tile joints must be at right angles to the Entrance Door line in the room (unless otherwise specified as such, or a different pattern is envisaged)

• Plan the tile joints coinciding with the door jamb edges on both sides. • One tile joint to fall at right angle on the centre line of the door (this is preferable

and not a must). • First full tile to start from the door jamb line or from the threshold if it is there. • When there is a border of different colour, in the room layout, then it is better to

provide o one full tile between wall and the border first,

o second the border tile,

o then distribute the space with full tiles, pushing “more than half tiles” to the edges inside the border tiles.

• Cut tiles or Part tiles must be positioned in the wall ends of the room.



Issue 0.1

• When curved area or angular area is adjoining a true rectangle or square in the room layout, carry out tile joints from rectangle or square into the angular or curved area.

• Do not plan tile joints from curved area into the regular shape. • The door, window, ventilator top line and dado top line (or a tile joint line at that

level), must fall in same line, if dado is up to this level. (i.e. horizontally the same line should join the door top, window top, and the dado top).

• The tile joint line must not cut the window bottom line or any intermediate working platform top line. (i.e. the window bottom line and tile joint line must merge into each other and should not cut).


• Carry out a dry mock up in one room for checking workmanship and other points. • Mark the level of finished floor in 2 to 3m intervals. • Roughen the surface by chipping or hacking to receive the base mortar and

cleaning. • Prepare the surface by:

o clearing all dirt and loose matter,

o chipping and clearing of plastering mortar droppings,

o chipping and clearing of unevenness in the concrete slab or base

• Complete all pipeline works to their final positions and levels. • Fix in position to line and level, all other inserts required. • Do select stones to have uniform shade and stack selected stones separately so

that stones of one colour and shade are laid in one room. • Do check the thickness of stone / mortar could be accommodated within the given

thickness of flooring viz. between given datum level and top of PCC or slab level actually available.

• Do prepare the stone tile layout (shop drawing) for each room with actual dimensions as available at site and then only start the flooring work. This drawing must show stone sizes, thickness, panel arrangement, panel dividers, levels, joint width etc.

2.4 Construction

2.4.1 Flooring

• Do prepare required number of stones for a room, the individual stone to correct size as per the prepared layout (to correct length, breadth, and thickness, shape as per design after removing defective spots, undesired streak etc)

• Mark the level of finished floor in 2 to 3m intervals. • Mark the stone/ tile joint positions in the wall with paint if required. (If the

pattern is marked on floor itself, it may go off when bed mortar is spread on the floor).



Issue 0.1

• Spread the polythene sheet on the clean floor. Over the sheet spread, place the panel dividers in position as per pattern specified (setting the panel divider in cement mortar).

• For metallic panel dividers, the top level has to be 0.5mm to 1mm down the level of unpolished floor, so that after polishing the levels match. Otherwise grinding the metal to level will be difficult.

• In between the panel dividers, spread the bed mortar for an area that could be completed within a session of say 2 hours, and level the bed mortar, gently tamp the mortar for consolidation. (if polythene sheet is not specified, the same need not be done)

• Then scratch the bed mortar top for grip to individual stones. • Spread the cement slurry in honey like consistency for an area of stones that

could be laid in next half an hour.

NOTE on bed mortar and slurry:

1. For laying marble stones, use grey cement in bed mortar and use white cement slurry completely covering the grey cement mortar. Since marble is a soft variety of stone and will absorb grey colour of the cement, NO trace of grey cement must come in contact with marble, thereby spoiling the natural colour of the stone.

2. For other stones grey cement bed and slurry can be used. Jointing and pointing has to be with white cement mixed with coloring pigment to match shade of stone.

• Where separate colour border stones are to be fixed, lay the border stones first and then proceed with floor work.

• Position the stone/ tiles as per pattern and press down the stone/ tile, in a sequence to get straight joints in both longitudinal and cross directions.

• While pressing the stone/ tile down the slurry must rise in the sides and fill the bevelling, joints. If required apply a little more slurry before placing the stone, to ensure this.

• Gently tap each stone/ tile to ensure proper seating and to release air entrapped beneath the tile.

• There should be no hollow sound when the stone/ tiles are struck. • Use stone/ tile spacers to ensure proper straight joints (if it is specified). • Check the level of flooring with the straight edge frequently to ensure the correct

level (reference points are already made and available at 2m or 3m intervals and / or at convenient points reached by straight edge).

• Complete the floor and ensure level is okay. • After lapse of initial setting time, do point the joints with white cement paste

(mixed with colour pigment or stainer to match the shade of tile). After scraping the joints, press down the white cement paste of right consistency with pointed trowel (not too stiff nor too watery). Then scrape the excess paste on the stone/ tile edges and in level with stone/ tile top. Clean the floor thoroughly and leave for setting. (Ready mixed grouts are also available, and can be used)

• Barricade the floor for next two days to ensure proper setting. Cure the floor for adequate number of days and then start polishing.



Issue 0.1

2.4.2 Polishing the Floor

• Start polishing using polishing machine using rough, medium and smooth polishing stones in the same sequence of rough, medium, and smooth (rough polishing is also called rough cut). Remove the muck then and there.

• After rough polish, the floor has to be washed with clear water. Apply fresh white cement slurry over the entire floor and check the joints in particular. After a day’s gap, the second cut can be carried out.

• For any major shade difference or defects noticed in the stone panels, that particular stone / tile has to be replaced immediately.

• Carry out the medium polish. Again after the medium cut, wash the floor with clean water. Apply fresh white cement slurry over the entire floor and check the joints in particular.

• After a day or two, carry out the smooth polish. Again after the smooth polish, wash the floor with clean water. After this, the wax polish or mansion polish can be applied and allowed air dry. The floor is ready for use.

• Now the floor must be smooth and uniform in shade, to the desired level and as per pattern.

• Do spread the protection layer to avoid any damage to the floor till same is ready for handing over.

2.4.3 Precautions in Polishing

• Before starting, check the defects in the polishing machine, if any, like wobbling, looseness of carborundum stones, the flatness of grinding stone etc. Check electrical connections for safety while working in wet conditions.

• While polishing NO sand must be used to hasten the rough cut or other cuts. The harder grains in sand may scratch the stone surface and cause a permanent damage resulting in replacement of the stone.

• The machine must always run horizontal with out any wobbling. Wobbling machines produce uneven polishing.

• Muck should not be disposed off / allowed into the sanitary water supply fittings and fixtures.

2.4.4 Dado Works

• Mark the stone/ tile layout on the finished floor and then start the work. • The work must start from bottom to top, in dado. Bottom row to have cut stone

sizes and other rows full sizes. • To do this, fix the first stone/tile on top of floor trap of bath room / kitchen. Then

stretch the top line of this stone, horizontally to the door location. Usually the floor level at the bottom of door shutter will be the top most point in the room. Then fix another stone at this point cut to required size (this will not be full size since a gradient is given in floor).

• Then prepare stones/ tiles to suit sizes from door jamb to the floor trap. (working drawing or shop drawing is a must for this and must contain dimension of each stone /tile)



Issue 0.1

• Height of dado work in a day must be limited in such a way that stones laid in position are NOT loaded unduly. If more height is to be done, continue the work next day.

• Sort the stones / tile and soak the same as stated in flooring. • Cover the back of the stone/ tile fully with slurry of thick paste (honey like

consistency) and press stone/ tile to the wall and gently tap with mallet. • Check plumb, horizontal line of joint at frequent intervals and proceed to the top. • The jamb joints must be finished with stones/ tiles bevelled at the edges. • Finish the top of stone/ tile with cement paste properly and complete touch up in

the wall above if required. • After lapse of initial setting time, do point the joints with white cement paste

(mixed with colour pigment or stainer to match the shade of tile). After scraping the joints, press down the white cement paste of right consistency with pointed trowel (not too stiff nor too watery). Then scrape the excess paste on the stone/ tile edges and in level with stone/ tile top. Clean the floor thoroughly and leave for setting.

2.4.5 Stair Cases

• Mark the stone/ tile layout on the side wall of the staircase and then start the work.

• The work must start from top to bottom. • Sort the tread and riser stones / tile. Tread stones thickness same as floor, riser

stones thickness same as dado or skirting stones. • Holes for handrail fixing in tread stones, have to be drilled in the correct position. • Take up stone work on risers on first day and treads on next day. • Carry out the base scratch plaster for the risers as backing. When the backing is

wet, cover the back of the riser stone/ tile fully with cement slurry (honey like consistency) and press stone/ tile to the riser. Gently tap with mallet.

• Next day spread the bed mortar, place the tread stone over the bed mortar covering the stone with cement slurry.

• Check plumb, horizontal line of joint at frequent intervals and proceed from the top to bottom.

• Landings shall have laying procedure as in flooring. • After lapse of initial setting time, do point the joints with white cement paste

(mixed with colour pigment or stainer to match the shade of tile). After scraping the joints, press down the white cement paste of right consistency with pointed trowel (not too stiff, nor too watery). Then scrape the excess paste on the stone/ tile edges and in level with stone/ tile top. Clean the floor thoroughly and leave for setting.

2.4.6 Polishing Skirting & Dado and Staircase:

• Start polishing manually using rough, medium and smooth polishing stones in the same sequence of rough, medium, and smooth. Remove the muck then and there.



Issue 0.1

• After rough polish, the dado has to be washed with clear water. Apply fresh white cement slurry over the entire dado and check the joints in particular. After a day’s gap, the second cut can be carried out.

• For any major shade difference or defects noticed in the stone panels, that particular stone has to be replaced immediately.

• Carry out the medium polish. Again, after the medium cut, wash the dado with clear water. Apply fresh white cement slurry over the entire dado and check the joints in particular.

• After a day or two, carry out the smooth polish. Again after the smooth polish, wash the dado with clear water. After this, the wax polish or mansion polish can be applied and allowed air dry.

• The handrails have to be fixed in position before final polish is carried out. Ensure polishing is properly done around the balusters of handrails.

2.4.7 Laying Elevation Works or Veneer Works

• Veneer work is always with pre-polished stones only. • Mark the stone/ tile layout in an area nearby from which reference can be made of

and then start the work. • The work must start from bottom to top, in veneer work. • Height of veneer work in a day must be limited in such a way that stones laid in

position should not be loaded unduly. If more height is there continue the work next day.

• Where stones are to be fixed with metal cramps, prepare the notches, fix the cramps in position using adhesives (if specified).

• Sort the stones / tile and soak the same as stated in flooring. • Cover the back of the stone/ tile fully with slurry of thick paste (honey like

consistency) and press stone/ tile to the wall and gently tap with mallet. • Check plumb, vertical and horizontal line of joint, at frequent intervals and

proceed to the top. • The jamb joints must be finished with stones/ tiles bevelled at the edges. • Finish the top of stone/ tile (when veneering ends in top) with cement paste

properly and complete. • After initial set, clean the stone/ tile joints and stones/ tiles properly. Scrap the

joint and finish the joint with white cement (mixed with pigment to match shade of tile) by pointing.

• Clean the tiles and joints properly and cure for required number of days.

2.5 Quality Checks

• Dimensions should be consistent within tolerances as per BIS Code. • Floor / Surfaces are even and levelled; levelled to proper falls in wet areas like

kitchen and toilets. • Chipping, cracks or mortar droppings should not be present. • Hollowness should not be detected in any place by tapping with any hard object

on the floor.



Issue 0.1

2.6 Protection

The floor finish once laid and finished completely, must be protected from any damage, before the same is put to use.

For natural stone floors the protection steps are:

• Cover the polished floors with a thin film of plaster of paris (3mm thick minimum) which can be easily wiped out later.

• When the floor is to be used by persons for other works like electrical lighting etc, the floor can be covered with dry hessian cloth or dry sacks craft paper polythene sheets rice husk

• Do not allow usage of tools and equipment over the floors, which are not having rubber wheels.

• Always keep the room under lock and key and permit usage only by authorised persons.

2.7 Tolerances

For marble: In blocks of the dimensional tolerance is + 2 % (length breadth and thickness)

In slabs of marble the tolerances are + 2 % in length and breadth, + or - 3 % in thickness.

For tiles the tolerance in length and breadth are + 4 % and nil in thickness as per IS code. However practically the thickness has to be ensured with the same 4 % tolerance limits.

For sand stones In thickness + or – 3mm for rough cut (length and breadth refer Point 1.2 above)

In thickness + or –3mm for machine cut

In length and breadth for machine cut + or –1mm 2.8 References

IS 1130-1969 Marble blocks, slabs and tiles

IS 3622-1977 Specification for sand stone slabs and tiles in flooring

IS 1129 - 1972 Dressing natural stones

IS 8348 - 1977 Stacking and packing of stone slabs for transportation

IS 4101-1967 Code of practice for external facing and veneers – part 1 stone facing


EMGF-ITP-020 A

Project: Date:

Location: From:

Drawing Ref.: To:

Description of work

Sub.Cont. EMGF

1

2

Deficiencies:

Remedial actions:

Polishing Operations7The handrails are fixed in position before final polish is carried out.

Polishing machine is ready to use with flat and properly fixed grinding stones

Rough polishing is done with proper rough polishing stone and white cment slurry is poured over it

Medium polishing is done with medium polishing stone and white cment slurry is poured over it

Smooth polishing is done with Smooth polishing stone

Fixing Operation

Flooring

5

Stones are properly tapped to ensure it is well seated and entrapped air is removed, While

pressing the tile down the slurry is rising in the sides and joints

Excess cement paste is cleaned on the tile edges and made in level with tile top

Fixing Operation

Elevation works/ Dado

works

6

In case of window intervening in work, the vertical joint line on either side of the window is

coinciding with window jambs

In sanitary/ water supply fittings are on the wall, the fitting position is coming in a position of four

tile corners.

Plumb of the stone, vertical line of the joints, horizontal line of joints are checked at frequent

intervals and proceed to the top

Pointing is done with white cement paste, of approved brand mixed with proper shade, of right

consistency with pointed trowel/ rubber squeeze .

Excess cement paste is cleaned on the tile edges and made in level with tile top

Stone fixing is starting from bottom to top, all cut pieced are used in the bottom

Layout Planning3

Wall is made wet and a layer of plaster is applied to base scratched coat of plaster to make up

defects and unevenness, cured for required number of days so that a hard base is available for

the tiles.

The method of handrail fixing is decided before stair case floor finish is taken up and proper

holes, inserts etc, are left

Cement slurry( as per relevent specifications) is spread in honey like consistency for a row of

stone that could be laid in next half hour

In case of Staircase,joints on the treads are parallel to the flight line unless the flight is in a curve

and at right angle to nosing line

In curved landings and straight flights the joint lines is going from flight to the landing.

Levels checked with straight edge are okay

Pre-Construction

Checks

4

Pointing is done with white cement paste, of approved brand mixed with proper shaded pigment,

of right consistency with pointed trowel/ rubber squeeze .

Protection layer is provided on the polished surface

Wax polish or mansion polish is applied and left for drying

Back of the stone is fully covered with cement slurry (honey like consistency) and pressed to the

wall and gently tapped with mallet

Tile joints is at right angles to the Entrance Door line in the room

Remarks

All pipeline works/concealed works below floor are complete to their final positions and levels

Joints are planned from regular shape (rectangular/square) to curved/Angular area

Cut stone or Part Stone are positioned in the wall ends of the room/ used appropriately

Proper Tools for the works are availble on site

Slab joints are planned to fullfilling the requirements of the different pattern as per Good For

Cnstruction drawing

The surface is well roughned by chipping or hacking and properly cleaned to receive the base

mortar


Inspection Sheet for Stone Fixing Works

S.No.

Check Satisfactory


Dimensional Tolrances are as per approved ITP

The floor area is cleaned properly

Joints are aligned and consistent with skirting and wall tiles.

Ensure polishing is properly done around the balusters of handrails.

Bed Mortar is freshly perpared and laid in thickness as per drawings/specifications

Surface for work is cleared of all dirt, loose matter and plastering mortar droppings

The type of nosing, junctions rebates, corners and its method of fixing is decided, before staircase

floor finish work is taken up

The joint line is not cutting window bottom line/any intermediate working platform top line.



Level of finished floor and the pattern on wall and floor is marked as per drawing at suitable

interval


Name :

Date :


Signature :

Post-Construction

Checks

Proper Curing is done for the joints as per manufecturer recommendations

Floor / Surfaces are even and levelled; levelled to proper falls in wet areas like kitchen and toilets7

Joints are not butt tightly with each other, Joints are as stated in drawing

EMGF-ITP-020 B

A. Sand Stone BIS Reference: IS 3622-1977a Source approval Once per source

b Dimension Check In machine cut the tolerance in length and breadth shall be + 1mm

c Thickness Permissible variation + 3mm

d Shade Acceptable by Client.

e Water Absorption <2.5% by weight f Transverse Strength >7.00 N/mm2

g Resistance to Wear Not greater than 2mm thk on the average and 2.5mm for any individual specimen

h Durability Shall not develop signs of spalling, disintegration or cracks.

B. Marble BIS Reference: IS 1130-1969a Source approval Once per source

b Dimension Check Blocks +2%, Slabs +2%, Tile +4%. Site Laboratory.

c Thickness Blocks +2%, Slabs +3%.

d Shade Acceptable by Client.

e Water absorption <0.4% by weight

f Mhos Scale Hardness Test >3.0

g Specific Gravity >2.5

C. Granite BIS Reference: IS 3316-1974a Dimension Check Length and breadth + 2mm

b Thickness Tolerance in thick + 1mm

c Shade Acceptable by Client.

d Water absorption <0.5% by weight

e Compressive strength >1000 kgf/sqm

f Specific Gravity >2.61). Permissible number of defectives upto a lot size of 500 is zero and above that its one2). Apart from BIS Refernce mentioned above, IS 1124, IS 1126 shall be used

Site Laboratory.

3 upto a lot size of 100 number,3 upto a lot size of 101 to 300 number,6 upto a lot size of 301 to 500numbers,6 upto a lot size of 501 to 1000 numbers

External Test house



External Test houseIS 1706


Site Laboratory.

Inspection and Test PlanITP - 20 Stone Fixing Works For Buildings

2 upto a lot size of 25,2 upto a lot size of 26 to 100,3 upto a lot size of 101 to 200,4 upto a lot size of 201 to 500,5 upto a lot size of 501 to 1000 num.

External Test house

3 upto a lot size of 25 numbers,5 upto a lot size of 26 to 100 number,8 upto a lot size of 101 to 200 number,13 upto a lot size of 201 to 500numbers,20 upto a lot size of 501 to 1000 numbers

Frequency Testing AgencyS.No Description Acceptance Criteria


MS 21

WORK METHOD STATEMENT PAINTING WORKS FOR BUILDING

MS 21 Emaar MGF Land Limited Painting Works for Buildings

Issue 0.1

1.0 Introduction

This method statement describes the supply of material, preparation of all type of surfaces, procedures of applications and tests to be adopted for entire completion of Painting Works for Buildings for EMGF (N) projects to the requirements of the Contract Technical specifications & Drawings.


• Oil Bound Distempering

• Cement Painting

• Acrylic Emulsion Painting

• White Washing ( including Color Washing)



Issue 0.1

2.0 PROCEDURE

2.1 Oil Bound Distempering

2.1.1 General Requirements

• All the materials, to be used in the work shall be as per IS:428 of approved brand/manufacturer, required shade and with relevant test certificates showing requisite properties.

• Material shall not be accepted on work if it has not been tested as per the relevant ITP. • All paints and paint constituents to be used for the work shall be delivered to the work

area in original sealed containers, bearing manufacturers labels, batch Number, date of manufacturing.

• Sufficient Brushes/rollers and empty tins, each of good quality and appropriate size shall be available before starting of work.

• The primer used shall be cement primer or distemper primer of same manufacturer as that of distemper.

• Constituent adhesives such as thinner, driers etc. shall be those recommended by the paint manufacturer.

• Drop cloth and polythene sheets of suitable size & quality shall be available so that other materials and surfaces can be protected.

• In case the work is required to be executed at higher elevations above the floor, the contractor shall arrange height pass for each and every person employed by him for this work for working at this elevation.

2.1.2 Preparation of surface before painting

• Before new work is distempered, the surface shall be thoroughly brushed free from mortar droppings and other foreign matter using sand paper, scrapers and wire brushes to receive the finish coat.

• Pitting / unevenness shall be made good with plaster of Paris mixed with the colour to be used. The surface shall then be rubbed down again with a fine grade sand paper and made smooth.

• Surface shall be dried for at least 48 hours. • In case of areas affected by fungus or algae, it shall be cleaned with wire-brush

thoroughly and wash with water. After drying one coat of Anti-fungal solution shall be applied and allowed to dry.

• A coat of distemper shall be applied over the patches and the patched surface shall be allowed to dry thoroughly.

2.1.3 Application of Paint

• Before application of oil bound distemper, a priming coat of distemper primer or cement primer shall be applied over the prepared surface as per manufacturer recommendations. No white washing coat shall be used as a priming coat for oil bound distemper.

• Primer coat shall be allowed to dry for 48 hours, before oil emulsion paint is applied. • Primer coat shall be preferably applied by brushing and not by spraying.



Issue 0.1

• If the wall surface plaster has not dried completely cement primer shall be applied before distempering the walls. But if distempering is done after the wall surface is dried completely, distemper primer shall be applied.

• Before opening the packing drum, it shall be rolled on the floor and after opening the drum; paints shall be stirred well so that no material / pigments remain settled at the bottom.

• Suitably the paint shall be checked as per requirement before opening. • The method of paint application and planning for work depending upon the area shall be

jointly discussed and decided with EMGF Representative. • For new work one coat of distemper diluted with thinner (water) shall be applied

in horizontal strokes. The first coat shall be followed by vertical strokes which constitute another coat with 15 cm double bristled distemper brush shall be used.

• Two or more coats of distemper shall be applied on primer coat to obtain even shade. • The final coat shall be done by using approved roller. • The paint dries by evaporation of the water content and as soon as the water has

evaporated the film gets hard and the next coat shall be applied. • The number of coats shall be as stipulated in the BOQ. • Paint thickness (DFT) shall be as per the Manufacturer’s specifications. In case the dry

film thickness of finish paint is observed less than the specified values, additional coat shall have to be applied free of charge.

• The surface on finishing shall present a flat velvety smooth finish. If necessary more coats shall be applied till the surface presents a uniform appearance.

2.1.4 Precautions

• Old brushes and rollers used with paints shall be completely dried of turpentine or oil paints by washing in warm soap water before using again.

• Brushes and rollers shall be quickly washed in water immediately after use and kept immersed in water during break periods to prevent the paint from hardening on the brush and roller.

• Splashes on floors etc. shall be cleaned out without delay as they will be difficult to remove after hardening.

• Washing of surfaces treated with emulsion paints shall not be done within 3 to 4 weeks of application.

• Equipment / structures adjacent to work area shall be suitably protected and care shall be taken to prevent intoxication of the surrounding area.



Issue 0.1

2.2 Cement Painting


• Cement paint, to be used in the work shall be as per IS:5410 of approved brand/manufacture, required shade and with relevant test certificates showing requisite properties as per BOQ/Technical Specification.

• Material shall not be accepted on work if it has not been tested as per the relevant ITP. • All paints and paint constituents to be used for the work shall be delivered to the work


• Sufficient brushes/rollers and empty tins, each of good quality and appropriate size shall be available before starting of work.

• Cement paints shall have proper storage (cool and dry place) and shall not be 6 months old in its original packing.




• The surface shall be cleaned of all dropping, dirt, dust, grease and other foreign matter by brushing and washing.

• Patches in plaster shall be repaired and a coat of waterproof cement paint shall be applied on patches after wetting the surface completely.

• The surface shall be cleaned thoroughly scrapping of all whitewash. While colour wash proof cements paint shall be applied on existing surfaces previously treated with wash and colour wash.

• In case of areas affected by fungus or algae, it shall be cleaned with wire-brush thoroughly and wash with water. After drying one coat of Anti-fungal solution shall be applied and allowed to dry.

• Whole surface shall be thoroughly wetted with clean water before the cement paint is applied. But at time of application it shall be moist not wet.


• Cement paint shall be prepared with proper two step formulation. In first step two parts of cement paint and one part of water shall be stirred thoroughly and allowed to stand undisturbed for 5 minutes. Care shall be taken while adding cement paint gradually to the water and not vice versa. In second step remaining one part of water shall be added to the mix and stirring it thoroughly until liquid of workable and uniform consistency will be obtained.

• In all cases the manufacturers instructions shall be followed meticulously. • The method of paint application and planning for work depending upon the area shall be

jointly discussed and decided with EMGF Representative.



Issue 0.1

• The lid of cement paint drums shall be kept tightly closed when not in use, as by exposure to atmosphere the cement paint rapidly becomes air set due to its hydrophobic qualities.

• Cement paint shall be used within an hour after mixing otherwise the mixture will thicken which affect the flow and finishing of the paint.

• The solution shall be stirred well periodically while application. • Cement paint shall not be applied when temperature is 8°C or below, or due to fall below

8°C within 24 hrs. • The solution should be applied on shady portions of the buildings so that direct heat of

sun shall be avoided on the surface. • The completed surface shall be cured after days work as per manufacturer

recommendations. • The second coat shall be applied after first coat is set at least for 24 hours. • Second coat shall dampen with clear water after 24 hours. • In special cases, a coat of cement primer shall be applied followed by two or more coats

of water proof cement paint.

2.2.4 Precautions

• Old brushes and rollers used with paints shall be completely dried of turpentine or oil paints by washing in warm soap water before using again.



• Water proof cement paint shall not be used on the surface treated already with white wash, distemper dry or oil bound varnishes, paints etc.



Issue 0.1

2.3 Acrylic Emulsion Paints


• All the materials, to be used in the work shall be as per IS: 5411 – 1969 of approved

brand/manufacture, required shade and with relevant test certificates showing requisite properties.

• Paints shall not be accepted on work if it has not been tested as per the relevant ITP. • All paints and paint constituents to be used for the work shall be delivered to the work


• Sufficient brushes/rollers and empty tins, each of good quality and appropriate size shall be available before starting of work.

• Constituent adhesives such as thinner, driers etc. shall be those recommended by the paint manufacturer.




• Before new work is started, the surface shall be thoroughly brushed free from mortar droppings and other foreign matter using sand paper, scrapers and wire brushes to receive the finish coat.

• Pitting in plaster shall be made good with plaster of paris mixed with the colour to be used. The surface shall then be rubbed down again with a fine grade sand paper and made smooth.

• A coat of paint shall be applied over the patches. The patched surface shall be allowed to dry thoroughly before the regular coat of acrylic emulsion paint is applied.

• No white washing coat shall be used as a priming coat.


• Before opening the packing drum, it shall be rolled on the floor and after opening the drum paints shall be stirred well so that no material/pigments remains settled at the bottom.

• Suitably the paint shall be checked as per requirement before opening. The choice of method of application i.e. by brush or roller will be decided by the EMGF Representative.

• The method of paint application depending upon the area shall be jointly discussed and decided with EMGF Representative

• The application of paint shall be as per manufacturer’s instructions & specifications. • The thinning of emulsion shall be done with water and not with turpentine. Thinning with

water will be particularly required for the undercoat which is applied on the absorbent surface. The quantity of water to be added shall be as per manufacturer’s instructions.

• The number of coats shall be as stipulated in the BOQ.



Issue 0.1

• Paint thickness (DFT) shall be as per the Manufacturer’s specifications. In case the dry film thickness of finish paint is observed less than the specified values, additional coat shall have to be applied free of charge.

• The paint dries by evaporation of the water content and as soon as the water has evaporated the film gets hard and the next coat shall be applied.

• The time of drying varies from one hour on absorbent surfaces to 2 to 3 hours on non-absorbent surfaces.

• The surface on finishing shall present a flat velvety smooth finish. If necessary more coats shall be applied till the surface presents a uniform appearance.

2.3.4 Precautions

• Old brushes and rollers used with emulsion paints shall be completely dried of turpentine or oil by washing in warm soap water before using again.


• In the preparation of walls for plastic emulsion painting, oil based putties/plasters shall be prohibited in filling cracks, holes etc.


• Washing of surfaces treated with emulsion paints shall not be done within 3 to 4 weeks of application.

• Equipment / structures adjacent to work area shall be suitably protected and care shall be taken to prevent intoxication of the surrounding area.



Issue 0.1

2.4 White Washing


• The wash shall be prepared from fresh stone lime (Narnaul/Satna or Dehradun quality). • Material shall not be accepted on work if it has not been tested as per the relevant ITP. • All constituents to be used for the work shall be delivered to the work area in original

sealed containers, bearing manufacturers labels, batch Number, date of manufacturing. • Water to be used for wash shall be free from water bodies or any type of impurities. • Sufficient Brushes/rollers and empty tins, each of good quality and appropriate size shall

be available before starting of work. • Drop cloth and polythene sheets of suitable size & quality shall be available so that other

materials and surfaces can be protected. • In case the work is required to be executed at higher elevations above the floor, the

contractor shall arrange height pass for each and every person employed by him for this work for working at this elevation.


• The surface shall be thoroughly brushed free from mortar droppings and other foreign matter using sand paper, scrapers and wire brushes to receive the finish coat.

• It shall be cleaned to remove all dirt and dust. • All loose scales shall be removed. • Old surfaces with smoke particles, grease spots shall be cleaned thoroughly. • Holes in the plaster as well as patches shall be filled with mortar. • In case of areas affected by fungus or algae, it shall be cleaned with wire-brush

thoroughly and wash with water. After drying one coat of Anti-fungal solution shall be applied and allowed to dry.

• Any unevenness shall be made good by applying putty made of plaster of paris mixed with water on the entire surface including filling up the undulations and then sand papering the same after it dry.

• Surface shall dry for at least 48 hours before white washing.


• Fat lime shall be prepared by mixing thoroughly with about 5 litres of water for 1 kg of un-slaked (powder) lime to make a thin cream. Thin cream shall still stand for a period of 24 hours. After that it shall be screened through a clean coarse cloth. 40 grams gum shall be mixed in hot water for ten litres of wash for better bonding.

• Indigo (neel) up to 3 gm per kg of lime dissolved in water shall be added and stirred properly.

• Ground white chalk shall be used for preparation of the wash. It shall be dissolved in sufficient quantity of warm water and thoroughly stirred to form thin slurry which shall then be screened through a clean coarse cloth. Two kg of gum and 0.4 kg of copper sulphate dissolved separately in hot water shall be added for every cum of the slurry which shall then be diluted with water to the consistency of milk also as to make a wash ready for use.

• The method of paint application and planning for work depending upon the area shall be jointly discussed and decided with EMGF Representative.



Issue 0.1

• White wash shall be done on ceiling prior to walls and applied vertically and horizontally with the ‘Moonj’ brushes.

• Each coat should be allowed to dry before next coat is applied. The brush marks shall not be visible after final coat.

• In case of color wash, it shall be applied after the first coat of white wash. Smooth and uniform finish on the surface shall be maintained.

• In color wash, the mineral colours not affected by lime, shall be added. Indigo shall however, not be added. No color wash shall be done until a sample of the color wash of the required tint or shade has been got approved from the EMGF Representative. The colour shall be of even tint or shade over the whole area.

• Three or more coats, shall then be applied on the entire surface till it represents a smooth and uniform finish.

• Shade of the color wash shall be prepared by adding approved pigments of approved shade.

• Do not use any primary coat as no primary coat is needed on surface. Two coats of white wash shall be applied before color wash of new shade on the old surface.

2.4.4 Precautions

• Doors, windows, floors, articles of furniture etc. and other parts of building shall be protected from splashes.

• Splashes on floors etc. shall be cleaned out without delay. • Old brushes shall be completely dried of turpentine or oil by washing in warm soap water

before using again. • Brushes and rollers shall be quickly washed in water immediately after use and kept

immersed in water during break periods to prevent the paint from hardening on the brush and roller.


EMGF-ITP-21 A


Location: From:

Drawing Ref.: To:

Description of work

Sub.Cont. EMGF

1

2

3

Deficiencies:

Remedial actions:

4

Mix proportion done as per specification .

Weather and temperature conditions are favourable for the work

Signature :


Sufficient Brushes/rollers and empty tins available on site

Surface for application is clean , dry, free from mortar droppings and other foreign matter

Suitable primer coat has been applied and dried properly

Sufficient Height pass available

Pitting/Evenness is made good with plaster of Paris mixed with the colour to be used.


Name :

Date :


Remarks

8

Coat of distemper applied over the patches and the patched surface shall be allowed to dry thoroughly.

No. of coats & colour shade are checked as per Specification

Required quantity of material for one hour work is mixed at a time.


Surface on finishing is presenting a flat velvety smooth finish.

Plastered surface is dried/ wet as per requirement of the paint material / Primer


Proper Curing is done as per manufecturer recommendations

After drying ,there are no brush marks or colour variations & surface presents a uniform appearance

Paint thickness (DFT) is as per required specifications

Proper line cutting is checked at corner if two colour shade applied

Oil Bound Distempering / Cement Painting / Acrylic Emulsion Painting / White Washing / Color Washing

Constituent adhesives such as thinner, driers etc. and additives are available recommended by the manufacturer.


Inspection Sheet for Painting Works



All flooring, kitchen platform, doors, windows & switch plates are covered



Cracks (if any) rectified

The floor area is cleaned properly.

No Waviness should be there in surfaces before applying first coat of paint.

First coat is dried for period specified by manufecturer & then start the second coat. This procedure maintained till final coat

EMGF-ITP-21 B

BIS Reference: IS 101 - 1964 Cl 13

1 Consistency Smooth uniform and suitable for brush application Random Each Lot

2 Drying Time : Hard Dry Not more than 8 hrs Random Each Lot

3 Finish Smooth and Glossy Random Each Lot

4 Wet Capacity Between -10 and +20% of the approved sample or the value declared by the manufacturer Random Each Lot

5 Salt & Spray Test Shall pass Random Each Lot

6 Colour Close match to the specified IS colour Random Each Lot

7 Residue on sieve, % by mass Max 0.3 Random Each Lot

8 Water Content, % by mass Max. 0.5 Random Each Lot

9 Flexibility and Adhesion Afetr 96 hrs air drying no visible damage or Detachment of film Random Each Lot

10 Stripping Test Scratches Free from Jagged edges Random Each Lot

11 Scratch hardness No visible scratch as to show the bare metal Random Each Lot

12 Protection against corrosion No signs of breakdown or corrosion Random Each Lot

13 Keeping Properties Not less than one year Random Each Lot

14 Fastness to light To pass the Test Random Each Lot

Manufacturer Lab

External Test house

Inspection and Test PlanITP - 21 Ready Mixed Paints and Enamels

S.No Activity Acceptance Criteria Sampling plan Frequency Testing Agency


MS 22

WORK METHOD STATEMENT ALUMINUM DOORS AND WINDOWS

0 0.1 25/07/08 QC Manager CEO (N)


MS 22

Emaar MGF Land Limited Aluminium Doors and Windows

Issue 0.1

1.0 Introduction

This method statement describes the fabrication, erection and fixing of doors and windows for Buildings for the EMGF (N) projects to the requirements of the Contract Technical specifications & Drawings.


• Aluminum Doors and Windows


MS 22


Issue 0.1

2.0 Procedure


• Aluminium doors and windows shall be fabricated from approved extruded sections and the manufacture & installation shall be carried out by an approved specialised agency.

• Unless otherwise specified the fabrication shall be done with heavy gauge extruded box sections.

• The sections free of scratches shall be of the sizes & details as shown on drawings. The details shown on the drawings indicate generally the sizes of the component parts and the general standards.

• All materials and details especially the weather-strip, gaskets and sealants shall be of approved high quality material capable of resisting the local climatic & environmental requirements.

2.2 Ordering

It is a must that a drawing showing elevation and cross section of the doors / windows is enclosed with the order.

In ordering aluminum doors and windows, do give details of

• Height and Breadth of structural opening • Extruded frame section details like

o size or dimension o weight per meter length

preferably with the manufacturer’s extrusion section number • Shutter styles, rails, and mullion member details like

o Size or dimension o weight per meter length

preferably with the manufacturer’s extrusion section number

• Details about fixed portion, openable portion of shutters, fan light • Shutter operation type like

o Side hung o Top hung o Central hung o Sliding shutters o Foldable type with method of folding

• Shutter fixing arrangement like o floor mounted hinges o butt hinges o non projected type of hinges o friction hinges o other arrangement

• Details of fixtures like handles, kick plates etc • Glazing details like

o Single glazing o Double glazing with vacuum seal in between o Glass thickness


MS 22


Issue 0.1

o Glass type like ◊ plain glass, ◊ sheet glass, ◊ plate glass ◊ wired glass ◊ heat resistant glass ◊ toughened glass ◊ reflective glass etc o Method of fixing glass

• Surface finish needed like o matt finish o scratch brush finish o glossy finish o anodizing o powder coating its color thickness in microns desired

• safety grill arrangements desired, if any, and details of same as stated in Steel / wooden windows

• Special arrangements needed for glass fixing like rubber gaskets, poly sulphide sealant jointing for gaps between masonry and door / windows etc

Note: Use I.S. Code designations of doors and windows as far as possible in the orders, drawings etc. In case I.S. Designations are NOT available, do give complete details.

2.3 Fabrication

• All jointing shall be of mechanical type. • The aluminum sections joints shall be designed to withstand a minimum wind load of

175 kg per sqm. • The design shall also ensure that the maximum deflection of any framing shall not

exceed L/175 of the span of the member. • All members shall be accurately machined and fitted to form hairline joints prior to

assembly. • The jointing accessories such as cleats, brackets, etc. shall be of such material as not

to cause any bimetallic action. • The design of the joint and accessories shall be such that the accessories are fully

concealed. • The fabrication shall be done in suitable sections to facilitate easy transportation,

handling and installation. • Adequate provision shall be made in the door and window members for anchoring to

supports and fixing of hardware and other fixtures as approved by the Client. • The fabricated frames shall be square and flat with corners in a true right angle.


Before starting on aluminum doors / windows fixing, check by visual inspection the following:


MS 22


Issue 0.1

• design and sections of door, window frame is as per architectural requirements for sizes, arrangement of fixed openable panels dimensions, diagonals.

• hinge positions, locking arrangement, tower bolts fastening arrangements etc are as per Architect’s drawings, and their operation.

• guard bars spacing and verticality, grill design, grill member sections for windows • hold fast / fixing clamps provisions • the door / window position in the structure is as per drawing

2.5 Installation

• Just prior to installation, the doors, windows, etc. shall be stacked on edge on level bearers and supported evenly.

• Unless otherwise shown window/door frames shall be fixed to openings with 20mm thick aluminum sub-frames. Width of sub-frame shall be exactly the same width as the frames.

• The sub-frames shall be pre-fixed to the masonry surrounds with approved fasteners. • The face of sub-frame shall be in true line, level and plumb. • The fixing hole positions shall be taken from the unit and marked on this chalk line at

the corresponding points. In case of masonry holes for fixing the lugs or holdfasts shall be cut 5 cm (or 2 in) square and 5 cm to 10 cm (or 2 in to 4 in) deep, unless it is possible to put slotted lugs into joints in brickwork. In the case of concrete or stone, fixing plugs are recommended to be embedded in the masonry during construction at the appropriate places.

• To ensure that all units are set at the appropriate heights in their openings, the datum line for the sill of the door, window or ventilator shall be taken from a fixed point on the wall or from finished floor or ceiling with the help of a level. The datum level for the sill of the door, window or ventilator unit shall be given by the builder to the fixer.

• Door, Window and Ventilator units shall be checked to ensure that they are square and working satisfactorily. The unit shall then be set in its opening by using wooden wedges at jambs, head and sill, and shall be plumbed to the line chalked round the reveal. A spirit level shall be used to ensure that the frame is square and true and free from any warp and twist. When adjusting to the correct line, the wedges shall be struck with the hammer, care being taken so as not to strike the frame. The wedges shall not be inserted so firmly as to distort the frames, and wherever possible, they shall be placed near the points where a glazing bar meets the frame.

• When the sub-frame is properly secured and all major internal and external finishing works are completed, the assembled doors/windows shall be placed in correct final position in the opening and fixed to the sub-frame by cadmium plated machine screws of required size and spacing suited to the purpose.

• Where aluminum comes into contact with masonry, concrete, plaster or some dissimilar metal, it shall be coated with an approved insulation lacquer or plastic tape to ensure that electro-chemical corrosion is avoided. Insulation material shall be trimmed off to a clean flush line on completion.

• After the doors/windows have been fixed in their correct assigned position, the open hollow sections abutting masonry/concrete shall be filled with cement grout (1 cement: 3 coarse sand) densely packed and finished neat. Packing grout shall be of the expanding type made by approved additive.


MS 22


Issue 0.1

• For fixing glasses, do measure individual panel size of each shutter and cut glass for each door / window separately, and mark each panel with easy identification marks.

• Do measure and prepare beading, glazing strips for individual panels separately. • Then fix the glass with beading using rubber beading, glazing clips, sealant etc. • All splatter and drips from wet cement and plaster during fixing of aluminum frames

should be removed immediately.

2.6 Fixing Composite Units

• In the case of composite windows and doors, the different units are to be assembled first. The assembled composite units shall be checked for line, level and plumb before final fixing is done. Units may have to be assembled in their final location if the situation so warrants.

• Where larger units are formed by coupling individual units altogether, the mullions and transomes shall be bedded in mastic to ensure weather tightness. Mastic shall be applied-liberally to the channels of the outside frame sections before assembly, and the two units being coupled shall be drawn together tight with clamps, the mastic being squeezed out and cut off neatly when the units shall be screwed together tight.

• Coupling screws vary in length for different types of coupling but manufacturers shall supply correct sizes and quantities, if coupling requirements are detailed when ordering.

2.7 Fittings and Hardware

• Any hardware, if fixed in position, shall be removed before fixing the unit in the surround and the moving part shall be secured with wire or string during erection and while the building work is being completed to prevent damage to the part.

• Hardware shall be fixed as late as possible preferably just before the final coat of paint is applied. It shall be fitted in a workmanlike manner, so that it may not work loose, and in such a way that screws and pins are not marked and mutilated by hammers and screw drivers.

• It shall be tested for correct operation. • When side hung casement are fitted with friction hinges, the hinges shall be adjusted

to the required tension by adjusting the nuts on top and bottom hinges equally. If one hinge is tighter than the other the casement may get twisted when opening or closing, and there is a consequent danger of breakage of the glass panes.

2.8 Glazing

• Before glazing, all opening parts shall be checked to see that they are closing correctly and are well bedded and not twisted in any way.

• The weight of glass in a side hung casement causes it to drop slightly on its hinges. Before glazing, therefore, the casement shall be set in a slightly high position in its frame. The glass shall also be set slightly out of square in the frame, that is, high and towards the outside (handle) jamb. This can be effected by using little springs of wood to wedge the glass at certain points (see Fig. 14).

• The frame shall be completely cleaned and bedding putty shall be placed in the rebate before glazing. Glass shall then be cushioned into this bedding putty properly and shall be fronted with front putty which shall stop 2 to 3 mm (or to in) from the sight


MS 22


Issue 0.1

line of the back rebate to enable the painting to be clone up to the sight line, to seal the edge of the putty to the glass.

• The back putty which has oozed out over the glazing rebate shall then be cut off square and smoothed down. This back putty is necessary as apart from preventing contact of the glass with the steel at any point; it will also prevent glass rattle and the ingress of moisture which may corrode the steel frame.

• Glass shall be secured by special spring glazing clips (see IS: 1038-1975 regarding number of clips) before applying the front putty.

• When glazing very large panes of glass, or when heavy wind pressure may be experienced or in any case where specially desired by the user, glazing bead may be used instead of front putty.

2.9 Tolerance

• Door window frames sizes +1.5mm or -1.5 mm.

2.10 Reference

• IS 1081 – Fixing and Glazing of Metal Doors, Windows and Ventilators • IS 1948 – Aluminum Doors and Windows


EMGF-ITP-022 A

Project: Date:

Location: From:

Drawing Ref.: To:

Description of work

Contractor EMGF

1

2

Deficiencies:

Remedial actions:

Proper Curing is done for concrete holding the lugsand holdfasts

Aluminum in contact with masonry, concrete, plaster or some dissimilar metal is coated with an approved insulation

Gap between frame & track is filled propely by sealant/material specified in BOQ

Glass is fixed propely with beading as per technical Specifications

All fittings and hardware is properly installed

All the internal & external plaster works are completed.




Inspection Sheet for Doors and Window Fixing Works



3

Frame is found ok in line & plumb and properly fixed in the wall/structural component

Frame structurally fixed in the wall/structural component as per requirement

Extra beading material is cleaned/ removed from the work place

5

Assembled doors/windows are correctly placed in final position in the opening and fixed to the frame by screws(as mentioned in BOQ) of required size

For fixing glasses, glass is cut as per size of individual panel of door / window separately and each panel is marked with easy identification marks.

Any defects & water leakage is checked and found by spraying water on the window.

4

Location and dimensions of Frame is as per drawing and size of panel


Name :

Date :


Signature :


Gauge,quality & coating of the aluminum section and glass is as per requirements

Preparation for method of fixing, like openings for hold fasts, coach screws, is done

Proper slots for lugs and holdfasts are available for fixing of frame

Frame is in right angle and diagonally ok

The sliding /openable operation movement of door/window is free or without any obstruction




MS 23

WORK METHOD STATEMENT FALSE CEILING FOR BUILDING

0 0.1 25/07/08 QC Manager CEO (N)


MS 23

Emaar MGF Land Limited False Ceiling

Issue 0.1

1.0 Introduction

This method statement describes the material specification, installation and finishing of gypsum boards false ceiling for Buildings for the EMGF(N) projects to the requirements of the Contract Technical specifications & Drawings.


• Gypsum boards false ceiling


MS 23


Issue 0.1

2.0 PROCEDURE


• Gypsum board and all accessories, suspension systems, finishing coats etc. shall be of approved brand.

• Gypsum board in thickness indicated, in 12.5mm thickness shall comply with ASTM C 840 for application system and support spacing indicated.

• All boards shall be sound, free from cracks, broken-edges and such other imperfections that would render them unfit for use.

• G.I. corner beads, edge trim and control joints complying with ASTM C 1047 shall be provided as per requirements and drawings.

• Materials for joint treatment shall comply with ASTM C 475, ASTM C 840 and recommendations of manufacturer or both gypsum board.

• Paper reinforcing tape shall be used as joint tape. • Gypsum board shall be provided of types indicated in maximum lengths available to

minimize end to end joints.


Before starting of False Ceiling work, check by visual inspection the following: • Bottom levels for fixing of false ceiling shall be marked properly. • Ducts, pipes and conduits shall be completed before commencement of the false ceiling

works. • Care shall be taken for the location of lighting, Air Conditioners and other utilities before

installation of ceiling. • Structure / Components supporting false sealing shall be checked for any defect like

cracks, water leakage, structural deformities etc. • Sufficient positions / locations shall be available for the hanger to connect or suspend.

2.3 Installation

• Hangers to be secured to structural support by connecting directly to structure where possible, otherwise to be connected to cast-in concrete inserts or other anchorage devices fasteners as required.

• Hangers shall not connect or suspend from steel framing from ducts, pipes or conduits. • All hangers and braces shall be at least 50mm clear of ducts, pipes and conduits. • Suspended steel framing components shall be installed in size and at spacing indicated

but not less than that required by referenced steel framing installation standard. • All boards and frame members shall be installed in level without any sagging. • Boards shall be jointed and finished so as to have a flush look which includes filling as

finishing the tapered and square edges of the boards with jointing compound and paper tape.

• Wire-tie or clip furring members to main runners and to other structural supports shall be as per indicated in drawing.

• Perimeter wall track or angle shall not touch where grid suspension system meets vertical surfaces, suspended from structure above.


MS 23


Issue 0.1

• There shall be mechanically joining of main beam and cross furring members to each other and butt-cut to fit into wall track. Wall track shall be free moving from vertical wall surfaces.

• Cross-bracing and additional framing shall be provided as indicated or required to resist wind uplift for exterior soffits

• The openings shall be sealed with compressible weather strip type edge seal to allow vertical movement.

• Sound attenuation blankets shall be installed where indicated, prior to gypsum board unless readily installed after board has been installed.

• Two coats of primer suitable for Gypsum board and three or more coats of oil bound distemper paint shall be applied (as per recommended practices of India Gypsum or equivalent) etc

2.4 Quality Checks

• Steel framing components for suspended ceilings shall be installed so that cross furring members or grid suspension members are level to within 3mm in 4m as measured both lengthwise on each member and transversely between parallel members.

• Gypsum board shall be properly jointed with the cross bracing without any gap visible from bottom.

• All the openings for the electrical wiring, cassette air conditioners etc. shall be sealed properly.


EMGF-ITP-023 A


Location: From:

Drawing Ref.: To:

Description of work:

Sub.Cont. EMGF

1

2

Deficiencies:

Remedial actions:


Cross-bracing and additional framing is provided as indicated/required to resist wind uplift for exterior soffits

Mechanically joining of main beam and cross furring members is done to each other and butt-cut is done to fit into wall track

All openings are sealed with compressible weather strip type edge seal

Minimum 50mm clear diastance is maintained of hangers and braces from the ducts, pipes and conduits

Remarks

Gypsum board are properly jointed with the cross bracing without any gap visible from bottom.




Cross furring members or grid suspension members are levelled within 3mm in 4M as measured both lengthwise on each member and transversely between parallel members.

All the openings for the electrical wiring, cassette air conditioners etc. are sealed properly.

Bottom levels for fixing of false ceiling is marked


Ducts, pipes and conduits are complete in all respects

4


Inspection Sheet for False Ceiling Works



3

Size and spacing of suspended steel framing components is maintained


All boards are sound, free from cracks, broken-edges and other imperfections

Sufficient positions/locations are available for the hangers to connect or suspend

Hangers is not connected or suspended from steel framing from ducts, pipes or conduits

Lighting Arrangements, Air Conditioners and other utilities are located properly

Sound attenuation blankets is installed where indicated

Required coats of primer, suitable for Gypsum, board and oil bound distemper paint shall be applied

Signature :

5


Name :

Date :

EMGF-ITP-23 B

BIS Reference: IS 2095(Part-1) :1996

S.No.

Width 0 -5 0 -8

Length 0 -6 0 -6

Thickness +/-6 +/-6

Transvrese directionLogitudinal direction

3 Water Absorption Test

Taper Width

Taper Depth

upto 500 501 to 10001001 to

30003001 & above upto 500 501 to 1000

1001 to 3000

3001 & above

1 5 8 13 20 0 0 1 1

2 2 3 5 8 0 0 0 0

3 2 3 5 8 0 0 0 0

1).In case of perforated base board, tolerance in thickness is 0 -162).The lot which has been found as conforming to the dimensional requirements shall then be subjected to transverse strength test and water absorption test

Inspection and Test PlanITP - 23 Gypsum Board

Limits shall subject to mutual agreement between pruchaser and manufecturer

Number of Samples for Lot Size

Gypsum wall Board Gypsum base Borard

Sampling and Criteria for conformity

Dimensional Requirement tolrances in mm

Transverse strength Test

Water Absorption Test

TestS. No.

180 for 9.5mm, 235 for 12.5mm

Dimensional requirements

Acceptance Number

1

2

Testing Requirements

Test Descriptions

Taper profile in mm450 to 65

0.8 to 2.0

Transverse Strength in Newton in terms of Min.breaking load for thickness mentioned in mm

140 for 9.5mm,180 for 12.5mm,220 for 15mm, 250 for 19mm, 300 for23mm, 380 for 25mm

360 for 9.5mm,500 for 12.5mm,650 for 15mm, 750 for 19mm, 850 for23mm, 1000 for 25mm

125 for 9.5mm, 165 for 12.5mm


MS 24

WORK METHOD STATEMENT AC SPLIT UNITS

0 0.1 11/09/08 Sr Manager MEP CEO (N)


EMGF-ITP-24 A

Item Description:



Quantity:____________ Nos Value: Rs____________________


Dealer Name/Code

S1 S2 S3

1 Visual Check for Physical Damage

2 Storage Place

3 Make

4 Color

5 Model

6 TR/BTU/Kcal

7 Indoor Unit Serial No.

8 Outdoor Unit Serial No.

9 Remote with Batteries

10 Catalogue/ Owners Manual

Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date


SPLIT AIR CONDITIONER UNIT

ActualS.No Description Specified in

Spec/IS(If

applicable)

Remarks

EMGF-ITP-024 B

Item Description:



Quantity:____________ Nos Value: Rs____________________


Dealer Name/Code


Spec/IS(If

applicable)

Remarks

1 Visual Check for Physical Damage

2 Storage Place

3 Make

4 Color

5 Model

6 TR/BTU/kCal

7 Indoor Unit Serial No.

8 Outdoor Unit Serial No.

9 Remote with Batteries

10 Catalogue/ Owners Manual

Comments/Remarks :

Contractor Client

Signature

Name

Designation

Date


SPLIT AIR CONDITIONER UNIT

Actual


MS 26



WORK METHOD STATEMENT

INSTALLATION OF AHU & FCU

MS 26 Emaar MGF Land Limited Installation of AHU & FCU

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of installation of AHU (Air Handling Unit) and FCU (Fan Coil Unit) on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The installation of AHU and FCU is according to standards and its procedures.



Issue 0.1

2.0 Procedure

2.1 General

• ‘Good for Construction’ drawings shall be available. • Construction material and make of (AHU & FCU) should be from approved

source.

2.2 Construction Type (AHU & FCU)

• The air handling units shall be double skin construction, draw-thru type comprising of various sections, filter section, coil section and fan section, mixing box, (wherever the return air and fresh air are ducted).

• The fan coil units shall be vertical type for floor mounting, horizontal type for ceiling-suspension. Floor-mounted vertical units shall have vertical top discharge; and horizontal units mounted within ceiling space shall have horizontal discharge and shall be ductable. All units shall be complete with chilled water coil, one or more centrifugal fans and motor, cleanable & washable metallic filters, double-wall insulated condensate drain pan.

2.3 Capacity (AHU)

• The air handling capacities, maximum motor horse power and static pressure shall be as shown on GFC Drawings and in Schedule of Quantities. However, contractor shall verify the capacity after carrying out heat load calculation on the basis of latest information on lighting, equipment & occupancy collected from Project Manager. All heat loads shall be submitted to consultant for their review.

2.4 Capacity (FCU)

• The air moving and coil capacities shall be as shown on GFC Drawings and indicated in Schedule of Quantities or based on heat load calculations. Minimum 8 mm external static pressure shall be delivered by all fan coil units.

2.5 Construction & Installation of AHU

2.5.1 Casing

• The housing/casing of the air handling unit shall be of double skin construction. • The Frame work shall be of extruded aluminium section having Thermal break. • All the frame shall be assembled using pressure die cast aluminium or steel joints

to make a sturdy, strong & self supporting frame work for various sections 25 mm thick double skin panel shall be made of 0.6 mm pre-painted GSS / pre-plastified GSS on outside and 0.6 mm galvanised sheet inside with polyurethane foam insulation having density of 38 kg/m3, injected in between.

• These panels shall be screwed on to the frame work with soft rubber gasket fixed in built-in groove of aluminium frame in between to make the joints air tight.



Issue 0.1

• Frame work of each section shall be jointed together with soft rubber gasket in between to make the joints air tight. Suitable air tight access doors/panels with

• Nylon hinges and locks shall be provided for access to various sections for maintenance.

• The entire housing shall be mounted on rolled formed GSS channel frame work having pressure die cast aluminium jointers.

• Drain pan shall be constructed of 18 G stainless steel with necessary slope to facilitate fast removal of condensate.

• Necessary arrangement shall be provided to slide the coil in the drain pan.

2.5.2 Damper

• Dampers shall be opposed blade type. • Blades shall be made of double skinned aerofoil aluminium sections with

integral gasket and assembled within a rigid extruded aluminium alloy frame. • All linkages and supporting spindles shall be made of aluminium or nylon,

turning in teflon bushes. • Manual dampers shall be provided with a bakelite knob for locking the damper

blades in position. • Linkages shall be extended wherever specified for motorised operation. Damper

frames shall be sectionalised to minimise blade warping. • Air leakage through dampers when in the closed position shall not exceed 1.5%

of the maximum design air volume flow rate at the maximum design air total pressure.

2.5.3 Motor and Drive

• Fan motors shall be energy efficient and shall be 415±10% volts, 50 cycles, three phase, totally enclosed fan-cooled class F, with IP-55 protection. Motors shall be especially designed for quiet operation and motor speed shall not exceed 1440 rpm. Drive to fan shall be provided through belt-drive arrangement. Belts shall be of the oil-resistant type.

2.5.4 Fan

• Fans shall be centrifugal, forward inclined blades. Fan casing shall be made of galvanised steel sheet.

• Fan wheels shall be made of galvanised steel. • Fan shaft shall be grounded C40 carbon steel and supported in self-aligning

plummer block operating less than 75% of first critical speed, grease lubricated bearings.

• Pulleys shall be individually tested and precision balanced dynamically. • Motors shall be mounted inside the AHU casing on slide rails for easy belt

tensioning, and be totally enclosed, fan cooled, to be class `F’ insulation. Motors shall drive heavy duty V-belt, constant pitch, drive selected at 110% of motor horsepower.



Issue 0.1

• Both fan and motors assemblies shall be mounted on a deep section aluminium alloy or galvanised steel (depending on size) base frame and housed with AHU.

• Isolation shall be provided from the unit casing by combination spring and rubber anti vibration mounts and flame retardant, waterproof and fireproof neoprene impregnated flexible connection on the fan discharge.

2.5.5 Cooling Coils

• Chilled water coils shall have 12.5 to 15 mm dia tubes minimum 0.4 mm thick with sine wave aluminium fins firmly bonded to copper tubes assembled in zinc coated steel frame.

• Face and surface areas shall be such as to ensure rated capacity from each unit and such that the air velocity across the coil shall not exceed 150 meters per minute.

• The coil shall be pitched in the unit casing for proper drainage. • The coil shall have copper header with chilled water supply & return connections

protruding out of AHU casing by minimum 150 mm and fitted with dielectric coupling for connection with MS pipes.

• Each coil shall be factory-tested at 21 kg per sq. m air pressure under water.

• Tube shall be hydraulically / mechanically expanded for minimum thermal contact resistance with fins. Fin spacing shall be 4 - 5 fins per cm.

• Water pressure drop in coil shall not exceed 10 PSIG. • All public area AHU’s shall be provided with minimum 6 Row Cooling Coil.

All TFA AHU’s shall be provided with minimum 6-8 row cooling coil. • Reheat coil may be provided if indicated in Schedule of Quantities.

2.5.6 Filters

• Each unit shall be provided with a factory assembled filter section containing washable synthetic type air filters having anodised aluminium frame.

• The filter shall have minimum 90% efficiency down to 10 microns . • The media shall be supported with HDP mesh on one side and aluminium

mesh on other side. • Filter banks shall be easily accessible and designed for easy withdrawal and

renewal of filter cells. • Filter framework shall be fully sealed and constructed from aluminium alloy.

2.5.7 Accessories

• Each air handling unit shall be provided with manual air vent at high point in the cooling coil and drain plug in the bottom of the coil.

• In addition, the following accessories may be required at air handling units, their detailed specifications are given in individual sections, & quantities separately identified in schedule of Quantities.



Issue 0.1

a. Insulated butterfly valves, balancing valves, `Y’ strainer, union & condensate drain piping with ‘U’ trap upto sump or floor drain in air handling unit room, as described in section “Piping”.

b. Thermometers in the thermometer wells & pressure gauge (with ball valve & GI fitting) within gauge ports in chilled water supply and return lines.

c. In case AHU is located at a distance from AHU control panel then local isolation shall be provided along with pad locking arrangement to isolate the power supply to the motor. The access panel shall be provided with positive interlocking as a safety.

2.5.8 Isolators

• Vibration isolators shall be provided with all air handling units. Vibration isolators shall be cushy foot mounting type or rubber pads as per manufacturer recommendation.

2.5.9 Fresh Air Intakes

• Extruded aluminium construction duly anodized (20 microns and above) fresh air louvers with bird screen and dampers shall be provided in the clear openings in masonry walls of the air handling unit rooms having at least one external wall. Louvers, damper, pre-filters, ducts and fresh air fan with speed regulator shall be provided as shown on Drawings and in Schedule of Quantities. Fresh air dampers shall be of the interlocking, opposed-blade louver type. Blades shall be made of extruded aluminium construction and shall be rattle-free. Dampers shall be similar to those specified in “Air Distribution”. Fresh air fans and fresh air intakes shall be as per the requirements of Schedule of Quantities.

2.5.10 Painting

• Shop coats of paint that have become marred during shipment or erection shall be cleaned off with mineral spirits, wire brushed and spot primed over the affected areas, then coated with paint to match the finish over the adjoining shop painted surface.

2.5.11 Performance Data

• Air handling unit shall be selected for the lowest operating noise level of the equipment. Fan performance rating and power consumption data, with operating points clearly indicated shall be submitted and verified at the time of testing and commissioning of the installation.

2.5.12 Testing

• Cooling capacity of various air handling unit models be computed from the measurements of air flow and dry and wet bulb temperatures of air entering and leaving the coil. Flow measurements shall be by an anemometer and temperature measurements by accurately calibrated mercury-in-glass thermometers. Also, cooling capacity shall be verified by measuring the flow rate and temperature difference at inlet & outlet of AHU. Computed results shall



Issue 0.1

conform to the specified capacities and quoted ratings. Power consumption shall be computed from measurements of incoming voltage and input current.



Issue 0.1

2.6 Construction & Installation of FCU

2.6.1 Cabinets

• Cabinets for floor mounted FCU shall be constructed of 18 gauge die-formed cold-rolled galvanized sheet steel, bonderized and painted with approved shade of powder coating finish. The cabinets shall be of sufficient size to enclose all piping and control valves, and shall have access doors to piping and controls. Access panels shall have positive locking fasteners for easy removal. Horizontal furred-in type units mounted within ceiling space shall be provided with a cabinet housing, the coil and fan section with provision to mount filters within the fan section.

2.6.2 Interior Chassis

• The interior chassis shall be constructed of not less than 16 gauge cold rolled galvanized sheet steel bonderized and painted with approved shade of powder coating finish. All ceiling suspended vertical fan coil units shall be securely mounted from the building structure with top panel set dead level in both directions. In case of ceiling suspended horizontal units fan deck and cooling coil shall be easily removable from FCU without lowering down of the FCU or disturbing the other installation.

2.6.3 Drain Pan

• Drain pan shall be fabricated from 18 gauge cold rolled stainless steel steel with all corners welded, and an additional inner bottom panel of 18 gauge stainless steel shall be provided to prevent damage to, and floatation of the bottom panel insulation. The pan shall be insulated with not less than 15 mm thick expanded polystyrene or 8 mm thick expanded polyethylene insulation sandwiched between top and bottom panels to effectively prevent condensation. The pan shall be of sufficient size to catch all drip page of condensation from any part of the unit. In all cases pan shall be large enough to cover cooling coil supply and return water headers, bends control valves, strainers and entire copper piping.

2.6.4 Cooling / Heating Coil

• All cooling / heating coils shall be standard three-row staggered seamless copper tube with aluminium sine wave fins. The coil shall be fitted with dielectric coupling for connection with MS pipes. Tubes shall be minimum 10 mm OD and wall thickness shall be minimum 0.5 mm. Fin spacing shall be 10 to 12 fins per inch. All bends and joints shall be enclosed within insulated end sections of the base unit for protection against sweating. Tubes shall be mechanically / hydraulically expanded for minimum thermal contact resistance with fins. Air vent shall be provided in headers at a level higher than coils. The cooling coil shall be easily removable from back side of FCU without disturbing the other Installations. All coils shall be factory tested at 21 KG per sq. cm (300



Issue 0.1

psig) air pressure while submerged in water. The coil shall be selected for maximum face velocity of 330 feet per minute.

2.6.5 Fans

• Fans shall be centrifugal forward curve double inlet ductable, direct driven by a shaded-pole motor.

2.6.6 Motor

• Motor shall be 220 ± 6% volts, 50 cycles single phase, energy efficient, six pole, shaded pole type, speed not exceeding 1000 rpm at maximum airflow. Motors shall have three speed windings and shall be factory wired to a terminal block mounted within the fan section. Motors shall have extended shaft on both sides. All motors shall be provided with ball bearings.

2.6.7 Installation

• Ceiling suspended horizontal units and units mounted within the ceiling space shall be hung through rubber-in-shear vibration isolator suspenders.

2.6.8 Accessories

• All fan coil units shall be equipped with copper piping connections, dielectric union and manual air vent at the cooling coil outlet header. In addition, the following accessories may be required at fan coil units; their detailed Specifications are given in individual sections and quantities separately identified in Schedule of Quantities.

a. Imported fan coil units as specified in Schedule of Quantities shall be suitable

for accommodating ball valve at outlet / inlet and globe valve within the tray.

b. Ball valve, globe valve, two way valve with copper piping and brass fitting shall be done at site.

c. Adjustable discharge air grille as shown on Drawings and in Schedule of

Quantities.

2.6.9 Painting

• Shop coats of paints that have become marred during shipment or erection shall

be cleaned off with mineral spirits, wire brushed and spot primed over the affected areas, then coated with enamel paint to match the finish over the adjoining shop painted surfaces.

2.6.10 Performance Data

• Fan coil units shall be selected for the lowest operating noise level having

standard sound level rating of NC 30 at low speed and NC 35 at medium/high speed. Fan performance rating and power consumption data, with operating



Issue 0.1

points clearly indicated, shall be submitted by the Tenderer and verified at the time of testing and commissioning of the installation.

2.6.11 Testing

• Cooling capacity of various fan coil unit models shall be computed from the

measurements of air flow and dry and wet bulb temperatures of air entering and leaving the coil. Flow measurements shall be by anemometer and temperature measurements by accurately calibrated mercury-in-glass thermometers. Computed ratings shall conform to the specified capacities and quoted ratings. Power consumption shall be computed from measurements of incoming voltage and input current.

2.7 Air Handling Unit (Data to be filled by supplier / Contractor)

General a. Manufacturer b. Type of unit (Double/Single skin) (draw-thru/blow thru) c. Material and thickness of casing (inner/outer) d. Material and thickness of drain pan. e. Material and thickness of sandwiched insulation for drain pan f. Type of flexible connection g. Type of vibration isolator Fan Section. a. Manufacturer. b. Type of fan d. Material and thickness of fan wheel blades e. Material and thickness of housing. f. Confirm statically and dynamically balanced g. Type of bearings. h. Fan RPM i. Efficiency



Issue 0.1

Motors a. Manufacturer b. Type c. Electrical characteristics (±10% voltage variation) d. Motor speed (RPM) e. Motor Efficiency f. Class of Insulation Cooling Coil. a Manufacturer b Material of tubes c Material of fins d No of fins/inch e Test pressure. Air Filters a. Manufacturer b. Type of filters c. Filter medium d. Pressure drop across filters (mm. of water) / Clean & Dirty e. Efficiency



Issue 0.1

2.8 Air Handling Units (Operating Data)

AHU NO. --------------------------------------------------------------------------------------------------------------------- AIR QTY (CFM) --------------------------------------------------------------------------------------------------------------------- SP (MM) --------------------------------------------------------------------------------------------------------------------- COIL FACE AREA (SFT) --------------------------------------------------------------------------------------------------------------------- COIL FACE VEL (FPM) --------------------------------------------------------------------------------------------------------------------- FILTER FACE VEL (FPM) --------------------------------------------------------------------------------------------------------------------- FAN OUTLET VEL (FPM) --------------------------------------------------------------------------------------------------------------------- NO. OF ROWS --------------------------------------------------------------------------------------------------------------------- FAN MOTOR (HP) --------------------------------------------------------------------------------------------------------------------- OVERALL DIMENSIONS LxWxH (METRES) --------------------------------------------------------------------------------------------------------------------- OPERATING WEIGHT ---------------------------------------------------------------------------------------------------------------------



Issue 0.1

2.9 Fan Coil Units (Data to be filled by Supplier / Contractor)

Capacity (TR) 1 1.5 2 3 a. Manufacturer b. Model Type c. Actual Capacity (TR) at HI Speed. MED Speed LO speed. d. Actual Air Quantity (CFM) at HI Speed. MED Speed LO speed. e. Coil face area (ft2)

f. Unit size: L mm W mm H mm g. Material/Gage i. Casing ii. Blowers iii. Drain pan with sandwich insulation. iv. Copper Tubes dia & wall thickness v. Fins/inch h. Rows of cooling coil j. Type of filter l. Motor make m. Motor H P/RPM n. Electrical characteristics. (230 ± 6% volts) o. Material of flexible connection p. Type of vibration isolators

2.10 Controls



Issue 0.1

3/2 Way Valve AHU’s FCU’s a. Make of valve b. Model c. Type (Modulating/Diverting) d. Modulating Motor make e. Model f. Control signal g. Voltage of motor h. Transformer provided j. Valve linkage make and model. Thermostat for Fan Coil Unit a. Make / Type b. Model

Cooling/heating or cooling only d. Range e. Differential f. Fan Speeds g. Sub base provided h. Electrical characteristics Additional Controls make and model of following controls/instruments. a. Pressure gauge b. Thermometer c. Electronic thermometer d. Temperature indicator



Issue 0.1

3.0 Formats

EMGF-ITP-026 A & A1 - AIR HANDLING EQUIPMENT TEST REPORT

EMGF-ITP-026 B - COOLING / HEATING TEST REPORT (AHU) EMGF-ITP-026 C - FAN COIL TEST REPORT


EMGF-ITP-026 A

AIR HANDLING EQUIPMENT TEST REPORT PROJECT_____________________________________ SYSTEM / UNIT________________________ LOCATION___________________________________________________________________________________

UNIT DATA MOTOR DATA

Make/Model No. Make / Frame

Type/Size H.P / RPM

Serial Number Volts/Phase/cycles

Arr./Class F.L amps.

Discharge Pully Diam/Bore

Pully diam/Bore Pully /Distance.

No. Belts/make/size

No.Filters/type.size (Pre.)

No.Filters/type/size (secondary)

TEST DATA

DESIGN ACTUAL TEST DATA DESIGN ACTUAL

Total Cfm Discharge S.P

Total S.P

Fan RPM Cooling Coil S.P

Motor Volts. T1 T

2 T

2 T

3 T

3 T

1

Filters S.P

Outside air cfm

Return air cfm

REMARKS TEST DATE______________________________________ READINGS BY _________________________

EMGF-ITP-026 A

EMGF-ITP-026 A1- AIR HANDLING EQUIPMENT TEST REPORT AIR SYSTEMS

I. Air Handlers Performance • The TAB procedure shall establish the right selection and performance of the AHUs with the

following results :

a. Air-IN DB and WB temperature. b. Air-OUT DB and WB temperature. c. Dew point air leaving. d. Sensible heat flow. e. Latent heat flow. f. Sensible heat factor. g. Fan air volume. h. Fan air outlet velocity. i. Fan static pressure. j. Fan power consumption. k. Fan speed.

EMGF-ITP-026 B

COOLING / HEATING TEST REPORT (AHU) PROJECT ____________________________________________________________________________________ COIL DATA COIL NO. COIL NO. COIL NO. COIL NO.

System Number

Location

Coil Type

No. Rows Fins/In

Manufacturer

Model Number

Face Area, Sq.Ft.

TEST DATA

DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL

Air Qty. CFM

Air Vel. FPM

Press. Drop In.

Out. Air DB/WB

Ret. Air DB/WB

Ent. Air DB/WB

Lvg. Air DB/WB

Air AT

Water flow. GPM

Press. Drop PSI

Ent. Water Temp

Lvg .Water Temp

Water AT

Exp.Valve / Refrig

Refrig. Suction Pr.

Refrig. Suct. Temp

Inlet Steam press.

Remarks: Readings by: Date:

EMGF-ITP-026 C

FAN COIL TEST REPORT

PROJECT___________________________________________________________ DATE__________________ LOCATION____________________________________________________________________________________ MANUFACTURER______________________________________________________________________________

TEMPERATURE DEG. F AREA SERVED

FCU MAKE CAPACITY TR GRILLE ROOM

REMARKS

Contractor Name: Client Name:

Signature: Signature:

Date: Date:


MS 27

WORK METHOD STATEMENT DUCT FABRICATION AND LAYING



MS 27 Emaar MGF Land Limited Duct Fabrication and Laying

Issue 0.1

1.0 Introduction

1.1 Scope

This work method statement describes the method and sequence of work required for fabricating and installing duct work on site. More detailed / task specific method statements may be developed as additional sections to this method statement as the need is identified.

1.2 Purpose


• The Ducting Fabrication, Installation and Testing work done is according to standards and its procedures.



Issue 0.1

2.0 Procedure

2.1 General

• ‘Good for Construction’ drawings shall be available.

• Construction material (G.I sheets Galvanizing shall be Class VIII – light coating of zinc, nominal 120gm/sq.m surface area and Lock Forming Quality prime material along with mill test certificates, anchor fastener, gasket, Volume control dampers, Grill, Diffusers, Fire Dampers) should be from approved source.

2.2 Construction Material

• Galvanized steel sheet (Plain & Corrugated) shall conform to IS : 277 - 1992

• Metal air ducts in accordance with IS : 655 - 1963 (Reaffirmed 1991).

• Air conditioning (Safety Code) with IS : 659 – 1964 (Reaffirmed 1991).


All ducts shall be fabricated from galvanized steel / aluminum of the following thickness, as indicated as below:

24 Gauge – 0.63mm

22 Gauge – 0.8 mm

20 Gauge – 1.0 mm

18 Gauge – 1.25 mm

• For Ducts with external SP up to 250 Pa

Pressure 250 Pa Rectangular Ducts G. S. Duct Section Length 1.2 m (4 ft) Maximum Duct Size

Gauge

Joint Type Bracing Spacing

1–750 mm 26 C & SS Nil 751 – 1000

mm 26 4 Bolt Transverse Duct Connector-

E (TDC) with built in sealant Nil

1001 – 1200 mm

24 4 Bolt TDC –E Nil

1201 – 1500 mm

24 4 Bolt TDC-H Nil

1501 – 1800 mm

22 4 Bolt TDC-H Nil

1801 – 2100 mm

20 4 Bolt TDC-J Nil

2101 – 2700 mm

18 4 Bolt TDC-J Nil



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• For Ducts with External SP up to 500 Pa

External Pressure 500 Pa Rectangular

Ducts G. S. Duct Section Length 1.2 m (4 ft)

Maximum Duct Size

Gauge

Joint Type Bracing Spacing

1–600 mm 26 C & SS Nil 601-750 mm 26 4 Bolt Transverse Duct Connector-E

(TDC) with built in sealant Nil

751-1000 mm 24 4 Bolt TDC-E Nil 1001-1200

mm 22 4 Bolt TDC-H Nil

1201-1300 mm

20 4 Bolt TDC-J Nil

1301-1500 mm

18 4 Bolt TDC-J Nil

1501-1800 mm

18 4 Bolt TDC-J Nil

1801-2100 mm

18 4 Bolt TDC-J Nil

2101-2250 mm

18 4 Bolt TDC-J Nil

2251-2400 mm

18 4 Bolt TDC-J Nil

2401-2700 mm

18 4 Bolt TDC-J 600

'C'-cleat; 'S'-S cleat; 'SS'-Standing S cleat; 'AI' -Angle Iron in mm

*Distance of reinforcement/bracing from each joint. Bracing material to be same as of material used for joining of duct sections.

FOR ALUMINUM DUCTS MATERIAL SHALL BE ONE COMMERCIAL GAUGE HIGHER WITH 22 G AS MINIMUM

2.4 Fabrication Standards & Equipment

All duct construction and installation shall be in accordance with SMACNA standards. In addition ducts shall be factory fabricated utilizing the following machines to provide the requisite quality of ducts.

• A coil (Sheet metal in Roll Form) line to facilitate location of longitudinal seams at corners/folded edges only, for required duct rigidity and leakage free characteristics. No longitudinal seams permitted along any face side of the duct.

• All ducts, transformation pieces and fittings to be made on CNC profile cutter for requisite accuracy of dimensions, location and dimensions of notches at the folding lines.

• All edges to be machine treated using lock formers, flangers and rollers for turning up edges.



Issue 0.1

2.5 Duct Construction

All ducts shall be fabricated and installed in workmanlike manner, conforming to relevant SMACNA codes.

• Ducts so identified on the Drawings shall be acoustically lined and insulated from outside.

• Duct dimensions shown on drawings, are overall sheet metal dimensions inclusive of the acoustic lining where required and indicated in Schedule of quantities.

• The fabricated duct dimensions should be as per approved drawings and care should be taken to ensure that all connecting sections are dimensionally matched to avoid any gaps.

• Ducts shall be straight and smooth on the inside with longitudinal seams shall be airtight and at corners only which shall be either Pittsburgh or snap button as per SMACNA practice, to ensure air tightness.

• All ducts up to 75cms width within conditioned spaces shall have slip and drive (C & S/SS) joints. The internal ends of slip joints shall be in the direction of airflow.

• Care should be taken to ensure that S/SS Cleats are mounted on the longer side of the duct and Cleats on the shorter side.

• Ducts and accessories within ceiling spaces, visible from air-conditioned areas shall be provided with two coats of mat black finish paint.

• Changes in dimensions and shape of ducts shall be gradual (between 1:4 and 1:7). • Air-turns (vanes) shall be installed in all bends and duct collars designed to permit the

air to make the turn without appreciable turbulence. • Ducts shall be fabricated as per details shown on Drawings. • All ducts shall be rigid and shall be adequately supported and braced where required

with standing seams, tees, or angles, of ample size to keep the ducts true to shape and to prevent buckling, vibration or breathing.

• All sheet metal connection, partitions and plenums, required to confine the flow of air to and through the filters and fans, shall be constructed of 18 gauge GSS / 16gauge aluminum, thoroughly stiffened with 25mm x 25mm x 3mm galvanized steel angle braces and fitted with all necessary inspection doors as required, to give access to all parts of the apparatus.

• Access doors shall be not less than 45cm x 45cm in size. • Plenums shall be shop/factory fabricated panel type and assembled at site. • Fixing of galvanized angle flanges on duct pieces shall be with rivets heads inside i.e.

towards GS sheet and riveting shall be done from outside. • Self adhesive Neoprene rubber / UV resistant PVC foam lining 5mm nominal

thickness instead of felt shall be used between duct flanges and between duct supports in all ducting installation.

2.6 Installation Practice

All ducts shall be installed generally as per tender drawings, and in strict accordance with approved shop drawings to be prepared by the Contractor:

• The Contractor shall provide and neatly erect all sheet metal work as may be required to carry out the intent of these Specifications and Drawings.

• The work shall meet with the approval of Owner’s site representative in all its parts and details

• All necessary allowances and provisions shall be made by the Contractor for beams, pipes, or other obstructions in the building, whether or not the same are shown on the drawings. Where necessary to avoid beams or other structural work, plumbing or



Issue 0.1

other pipes, and conduits, the ducts shall be transformed, divided or curved to one side (the required area being maintained) all as per the site requirements.

• If a duct cannot be run as shown on the drawings, the contractor shall install the duct between the required points by any path available in accordance with other services and as per approval of owner’s site representative.

• All ductwork shall be independently supported from building construction. • All horizontal ducts shall be rigidly and securely supported, in an approved manner,

with trapeze hangers formed of galvanized steel rods and galvanized steel angle/channel or a pair of brackets, connected by galvanized steel rod under ducts.

• The spacing between supports should be not greater than 2.0 meter. • All vertical ductwork shall be supported by structural members on each floor slab. • Duct supports may be through galvanized steel insert plates left in slab at the time of

slab casting. • Galvanized steel cleat with a hole for passing the hanger rods shall be welded to the

plates. Trapeze hanger formed of galvanized steel rods shall be hung through these cleats.

• Wherever use of metal insert plates is not feasible, duct support shall be through dash/anchor fastener driven into the concrete slab by electrically operated gun.

• Hanger rods shall then hang through the cleats or fully threaded galvanized rods can be screwed into the anchor fasteners.

• Ducting over furred ceiling shall be supported from the slab above or from beams after obtaining approval of Owner’s site representative. In no case shall any duct be supported from false ceiling hangers or be permitted to rest on false ceiling. All metal work in dead or furred down spaces shall be erected in time to occasion no delay to other contractor’s work in the building.

• Where ducts pass through brick or masonry openings, it shall be provided with 25mm thick TF quality expanded polystyrene around the duct and totally covered with fire barrier mortar for complete sealing.

• All ducts shall be totally free from vibration under all conditions of operation. Whenever ductwork is connected to fans, air handling units or blower coil units that may cause vibration in the ducts, ducts shall be provided with a flexible connection, located at the unit discharge.

• Flexible connections shall be constructed of fire retarding flexible heavy canvas sleeve at least 10cm long securely bonded and bolted on both sides.

• Sleeve shall be made smooth and the connecting ductwork rigidly held by independent supports on both sides of the flexible connection.

• The flexible connection shall be suitable for pressure at the point of installation. • Duct shall not rest on false ceiling and shall be in level from bottom. Taper pieces

shall taper from top.

2.7 The Preparatory Work

To conduct the above test, following preparatory works are required to be carried out including the availability of approved for construction shop drawings and submittals:

• All outside air intake return air and exhaust air dampers are in proper position. • All system volume dampers and fire dampers are in full open position. • All access doors are installed & are air tight. • Grilles are installed & dampers are fully open. • Provision and accessibility of usage of TAB instruments for traverse measurements

are available. • All windows, doors are in close position.



Issue 0.1

• Duct system are of proper construction and are equipped with turning vanes and joints are sealedHoldfast of adequate size and sufficient strength shall be either embedded in brickwork or later chases filled up with concrete.

• Iron holdfasts shall be coated with bitumen to avoid corrosion. • Woodwork faces in contact with brickwork shall be coated with preservatives to

avoid attack from insects and termites.

2.8 Dampers

• Dampers: All duct dampers shall be opposed blade louver dampers of robust 16 G GSS construction and tight fitting. The design, method of handling and control shall be suitable for the location and service required.

• Dampers shall be provided with suitable links levers and quadrants as required for their proper operation. Control or setting device shall be made robust, easily operable and accessible through suitable access door in the duct. Every damper shall have an indicating device clearly showing the damper position at all times.

• Dampers shall be placed in ducts at every branch supply or return air duct connection, whether or not indicated on the Drawings, for the proper volume control and balancing of the air distribution system.

2.9 Fire & Smoke Dampers

• All supply and return air ducts crossing fire rated walls, and floor crossings shall be provided with Motor operated Fire & smoke damper of at least 90 minutes rating as per UL555/1995 tested by CBRI. These shall be of multi-leaf type and provided with Spring Return electrical actuator having its own thermal trip for ambient air temperature outside the duct and air temperature inside the duct. Actuator shall have Form fit type of mounting, metal enclosure and guaranteed long life span. The damper shall shut automatically in case of power failure.

• Fire damper blades and outer frames shall be of 16G galvanized steel construction fitted with 18 gage extended sleeves on both sides. The damper blade shall be pivoted on both ends using chrome plated spindles in self lubricated bronze bushes. Stop seals shall be provided on top and bottom of the damper housing made of 16G galvanized sheet steel. For preventing smoke leakage metallic compression seals will be provided.

• The electric actuator shall be energized either upon receiving a signal from smoke detector. The fire damper shall also close upon sensing temperature rise in supply air ducts thru the electronic temperature sensor.

• Each damper shall be provided with its own control panel, mounted on the wall within the AHU room and suitable for 240 VAC supply. This control panel shall be suitable for spring return actuator and shall have at least the following features:

• Potential free contacts for AHU fan ON/ Off and remote alarm

indication. • Accept signal from external smoke / fire detection system for

tripping the electrical actuator. • Test and reset facility. • Indicating lights / contacts to indicate the following status: • Power Supply On • Alarm • Damper open and close position.



Issue 0.1

• Actuators shall be mounted on the sleeve by the damper supplier in his shop and shall furnish test certificate for satisfactory operation of each Motor Operated Damper in conjunction with its control panel. Control panel shall be wall mounted type and located in AHU room or nearest electrical room.

• It shall be HVAC Contractor’s responsibility to co-ordinate with the Fire Alarm System Contractor for correctly hooking up the Motor Operated Damper to Fire Detection / Fire Management System. All necessary materials for hooking up shall be supplied and installed by HVAC Contractor under close co-ordination with the fire protection system contractor.

• HVAC Contractor shall demonstrate the testing of all Dampers and its control panel after necessary hook up with the fire protection / fire management system is carried out by energising all the smoke detectors with the help of smoke.

• HVAC Contractor shall provide Fire retardant cables (FRLS) for satisfactory operation and control of the Damper.

• HVAC Contractor shall strictly follow the instructions of the Damper Supplier or avail his services at site before carrying out testing at site. Installation of damper shall be as per manufacturer recommendation or as per Project Manager Instructions. Damper shall be provided with GI sleeves extending on either side of wall up to 3 inches to 6 inches. The damper shall be supported with structural wall by providing 32 mm x 32 mm angle frame on all sides of sleeve. Damper shall be supported with structure using a fastener. Installation details in form of sketch shall be submitted prior to execution and gotten approved from Project Manager/Consultant.

• Fire/smoke damper shall be provided with factory fitted sleeves; however, access doors shall be provided in the ducts in accordance with the manufacturer’s recommendations. The location of actuator shall not foul with the fire rated wall. However, damper shall be placed on the fire rated wall.

• The Contractor shall also furnish to the Owner, the necessary additional spare actuators and temperature sensor ( a minimum of 5% of the total number installed) at the time of commissioning of the installation.

• Filling-up the annular gap between wall and duct / smoke damper with fibreglass and applying fire sealant.

2.10 Fire Dampers

• Wherever required, fire damper shall be provided with approved fire damper of at least 1½ hour fire rating as per UL555/1995 tested by CBRI. This shall be curtain type fire damper.

• Fire damper blades shall be one piece folded high strength 16 gage galvanised steel construction. In normal position, these blades shall be gathered and stacked at the frame head providing maximum air passage and preventing passing air currents from creating noise or chatter. The blades shall be held in position through fusible link of temp 70o C.

• In case of fire, the intrinsic energy of the folded blades shall be utilized to close the opening. The thrust of the suddenly released tension shall instantly drive the blades down and keep it down without the use of springs, weights or other devices subject to failure.

• Fire damper sleeves and access doors shall be provided within the duct in accordance with the manufacturer’s recommendation.

• The contractor shall also furnish to the Owner, the necessary additional fusible links (spares), as recommended by the manufacturer, at the time of commissioning of the installation.

• Filling-up the annular gap between wall and duct / fire damper with fibreglass and applying fire sealant.



Issue 0.1

2.11 Supply and Return Air Registers

Supply & return air registers shall be of either steel or aluminium sections as specified in schedule of quantities. Steel construction registers shall have primer Coat finish whereas extruded aluminium registers shall be either Anodised or Powder Coated. These registers shall have individually adjustable louvers both horizontal and vertical. Supply air registers shall be provided with key operated opposed blade extruded aluminium volume control damper anodised in matt black shade.

The registers shall be suitable for fixing arrangement having concealed screws as approved by Architect. Linear continuous supply cum return air register shall be extruded aluminium construction with fixed horizontal bars at 15 Deg. inclination & flange on both sides only (none on top & bottom). The thickness of the fixed bar louvers shall be minimum 5.5 mm in front and 3.8 mm in rear with rounded edges. Flanges on the two sides shall be 20 mm/30 mm wide as approved by Architect. The grilles shall be suitable for concealed fixing. Volume control dampers of extruded aluminium anodised in black colour shall be provided in supply air duct collars. For fan coil units horizontal fixed bar grilles as described above shall be provided with flanges on four sides, and the core shall be & suitable for clip fixing, permitting its removal without disturbing the flanges.

• All registers shall be selected in consultation with the Architect. Different spaces

shall require horizontal or vertical face bars, and different width of margin frames. These shall be procured only after obtaining written approval from Architect for each type of register.

• All registers shall have a soft continuous rubber/foam gasket between the periphery of the register and the surface on which it has to be mounted. The effective area of the registers for air flow shall not be less than 66 percent of gross face area.

• Registers specified with individually adjustable bars shall have adjustable pattern as each grille bar shall be pivot able to provide pattern with 0 to +45 degree horizontal arc and up to 30 degree deflection downwards. Bars shall hold deflection settings under all conditions of velocity and pressure.

• Bar longer than 45 cm shall be reinforced by set-back vertical members of approved thickness.

• All volume control dampers shall be anodised aluminium in mat black shade. • In case of continuous grille/diffuser, dummy grille shall be blanked-off using GI sheet

duly painted black.

2.12 Supply and Return Air Diffusers

Supply and return air diffusers shall be as shown on the Drawings and indicated in Schedule of Quantities. Mild steel diffusers/dampers shall be factory coated with rust-resistant primer. Aluminium diffusers shall be powder coated & made from extruded aluminium section.

• Rectangular Diffusers shall be steel / extruded aluminium construction, square & rectangular diffusers with flush fixed pattern for different spaces as per schedule of quantities These shall be selected in consultation with the Architect. These shall be procured only after obtaining written approval from Architect for each type of diffuser.



Issue 0.1

• Supply air diffusers shall be equipped with fixed air distribution grids, removable key-operated volume control dampers, and anti-smudge rings as required in specific applications, and as per requirements of schedule of quantities. All extruded aluminium diffusers shall be provided with removable central core and concealed key operation for volume control damper.

• Linear Diffuser shall be extruded aluminium construction with removable core, one or two way blow type. Supply air diffusers shall be provided with volume control/ balancing dampers within the supply air collar. Diffusers for different spaces shall be selected in consultation with the Architect, and provided as per requirements of schedule of quantities. All diffusers shall have volume control dampers of extruded aluminium construction anodised in mat black shade.

• Slot Diffuser shall be extruded aluminium construction multislot type with air pattern controller provided in each slot. Supply air diffusers shall be provided with Hit & Miss volume control dampers in each slot of the supply air diffusers. Diffusers for different spaces shall be selected in consultation with the Architect and provided as per requirement of Schedule of Quantities.

2.13 Measurements for Ducting

Unless otherwise specified, measurements for ducting for the project shall be on the basis of centre-line measurements described herewith :

• Duct Work shall be measured on the basis of external surface area of ducts. Duct measurements shall be taken before application of the insulation. The external surface area shall be calculated by measuring the perimeter comprising overall width and depth, including the corner joints, in the centre of each duct section, multiplying with the overall length from flange face to flange face of each duct section and adding up areas of all duct sections. Plenums shall also be measured in similar manner. For tapered rectangular ducts, the average width and depth shall be considered for perimeter, whereas for tapered circular ducts, the diameter of the section midway between large and small diameter shall be adopted, the length of tapered duct section shall be the centre line distance between the flanges of the duct section.

For special pieces like bends, tees, reducers, branches and collars, mode of measurement shall be identical to that described above using the length along the centre line.

The quoted unit rate for external surface of ducts shall include all wastage allowances, flanges and gaskets for joints, nuts and bolts, hangers and angles with double nuts for supports, rubber strip 3 mm thick between duct and support, vibration isolator suspension where specified or required, inspection chamber / access panel, splitter damper with quadrant and lever for position indication, turning vanes, straightening vanes, and all other accessories required to complete the duct installation as per the Specifications. These accessories shall NOT be separately measured nor paid for.

• Special Items for Air Distribution shall be measured by the cross-section area perpendicular to air flow, as identified herewith :



Issue 0.1

o Grilles and registers - width multiplied by height, excluding flanges. Volume control dampers shall form part of the unit rate for registers and shall not be separately accounted.

o Diffusers - cross section area for air flow at discharge area, excluding flanges. Volume control dampers shall form part of unit rate for supply air diffusers and shall not be separately accounted.

o Linear diffusers - shall be measured by cross-sectional areas and shall exclude flanges for mounting of linear diffusers. The supply air plenum for linear diffusers shall be measured with ducting as described earlier.

o Fire / Smoke dampers - shall be measured by their cross sectional area perpendicular to the direction of air flow. Quoted rates shall include the necessary collars and flanges for mounting, inspection pieces with access door, electrical actuators and panel. No special allowance shall be payable for extension of cross section outside the air stream.

o Control panel for Fire/Smoke dampers shall be measured by numbers which shall include FRLS cable for interconnection of control panel, actuator & AHU panel. No additional payment on account of FRLS cable shall be made.

o Flexible connection - shall be measured by their cross sectional area perpendicular to the direction of air flow. Quoted rates shall include the necessary mounting arrangement, flanges, nuts and bolts and treated-for-fire requisite length of canvas cloth.

o Kitchen Hoods - shall be measured by their cross sectional area at the capture point of fumes, parallel to the surface of kitchen equipment. Quoted rates shall include the grease filters, provision for hood light, suspension arrangement for the hood, profile to direct the air to ventilation ducts and provision for removable drip tray.

2.14 Testing and Balancing

After the installation of the entire air distribution system is completed in all respects, all ducts shall be tested for air leaks by visual inspection.

The entire air distribution system shall be balanced using an anemometer. Measured air quantities at fan discharge, at various outlets and return air shall be identical to or less/excess than 5 percent in excess of those specified and quoted. Branch duct adjustments shall be permanently marked after air balancing is completed so that these can be restored to their correct position if disturbed at any time. Complete air balance report shall be submitted for scrutiny and approval, and four copies of the approved balance report shall be provided with completion documents.

FORMATS

EMGF-ITP-027 A - Material Inspection Card EMGF-ITP-027 B - Rectangular Duct Traverse Report

EMGF-ITP-027 C - Grilles and Diffusers Test Report


EMGF-ITP-027 A

Material Inspection Card Project

Location Date

Contractor

GALVANIZED STEEL SHEETS CARD a. Make b. Thickness/Gage c. Class of Galvanising GRILLES / DIFFUSERS / DAMPERS Make, material and gauge of the following :

Description Make Material Gauge a. Fire / smoke damper, rating, make of damper motor

b. Motorized damper

c. Grilles/Diffuser

d. Slot Diffuser

e. Duct Damper

f. FA Damper

g. Access Panel.

Remarks: Checked by:

Date:

EMGF-ITP-027 B

RECTANGULAR DUCT TRAVERSE REPORT

PROJECT______________________________SYSTEM______________________________________ LOCATION / ZONE_____________________ACTUAL AIR TEMP. ________________DUCT S.P_________

DUCT SIZE___________SQ.FT.________

REQUIRED FPM____________CFM__________

ACTUAL FPM____________CFM_________

POSITION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1

2

3

4

5

6

7

8

9

10

11

12

13

Velocity Subtotals

REMARKS. TEST DATE___________________________________ READINGS BY _________________________________

EMGF-ITP-027 C

GRILLES AND DIFFUSERS TEST REPORT.

PROJECT_______________________________________ SYSTEM __________________________________ OUTLET MANUFACTURER____________________________TEST APPARATUS___________________ AREA

OUT LET

DESIGN

PRLIMINA

RY

FINAL

SERVED NO. TYPE

SIZE

CFM

VEL VELOR CFM

VEL.OR CFM

VEL CFM

REMARKS. TEST DATE______________________ READINGS BY _________________________

emgf ms.pdf

Documents

blinding concrete

concrete surface

concrete placement

construction sequences

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timber formwork

construction procedure