VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT – BLACK OIL TERMINAL

Doc No: 254625-300-SP-CIV-011 Rev: A Page 1 of 13

SPECIFICATION
FOR
DOORS & WINDOWS

Mott MacDonald Consultants (India) Pvt. Ltd. Hindustan Petroleum Corporation Ltd
Kothari House, CTS No. 185 Visakha Dispatch Station
Off Andheri - Kurla Road VR-ATP Area, Naval Base Post
Andheri (East) Visakhapatnam - 530 014
Mumbai 400 059 Andhra Pradesh

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List of Content Page Nos

1 Scope 5

2 Applicable Codes 5

3 Steel Door Windows and Ventilators 5

3.1 General 5
3.2 M.S.Windows and Ventilators 5
3.3 Procedure for Fixing Door, Windows and Ventilators 6
3.4 Tolerance 6
3.5 Hardware 6
3.6 Finish 7

4 Aluminium Doors, Windows and Ventilators 7

4.1 General 7
4.2 Material 7
4.2.1 Aluminium Alloy Extruded Sections 7
4.2.2 Glass panes 8
4.2.3 Screws, Fasteners 8
4.3 Standard sizes, tolerances and designation 8
4.3.1 Size 8
4.3.2 Tolerances 8
4.3.3 Designation 8
4.4 Sectional dimensions and weights 8
4.5 Fabrication 8
4.5.1 Frames 8
4.5.2 Shutters 9
4.5.3 Doors, Windows and Ventilators 9
4.6 Finishing 9
4.7 Handling, Storage 9
4.8 Installation 9
4.9 Hardware 9
4.10 Drawings/ Documents 11

5 Metal Rolling Shutters 11

5.1 General 11
5.2 Materials 11
5.2.1 Cold Rolled Steel Strips 11

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5.2.2 GI Sections 11
5.2.3 Steel Pipe 11
5.2.4 Cast Iron Castings 11
5.2.5 Springs 11
5.3 Fabrication 12
5.3.1 Curtain 12
5.3.2 Lock Plate 12
5.3.3 Guide Channels 12
5.3.4 Bracket Plate 13
5.3.5 Roller 13
5.3.6 Hood Covers 13

6 PVC Doors 13

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1 Scope
This Specification defines the requirements regarding material, sizes, construction, workmanship,
finishes and installation for doors, windows, ventilators and rolling shutters.

2 Applicable Codes
The following Indian Standards and Codes including all amendments and revisions shall be
considered as part of this specification.

IS:1038: 1983 : Specification for Steel Doors, Windows and Ventilators

IS:1081:1960 : Code of Practice for Fixing and Glazing of Metal Doors, Windows and
Ventilators.
IS:1361:1978 : Specification for Steel Windows for Industrial Buildings
IS:4351:2003 : Specifications for Steel Door Frames
IS:7452:1990 : Specification for Hot Rolled Steel Section for Doors, Windows and
Ventilators
IS:733:1983 : Wrought Aluminium and Aluminium Alloy Bars, Rods and Sections for
General Engineering Purposes.
IS:1948:1961 : Aluminium Doors, Windows and Ventilators
IS:1949:1961 : Aluminium Windows for Industrial Buildings
IS:4218:1967 : Specification for Screw Threads
IS:6248:1979 : Specification for Metal Rolling Shutters & Rolling Grills

3 Steel Door Windows and Ventilators

3.1 General
Steel Doors, Windows and Ventilators shall conform to IS: 1038, IS: 1361, IS: 1081 and IS: 4351
and shall be as per drawing issued by the Engineer. The Contractor shall submit for the
MMCI/HPCL Engineer-In-Charge’s approval the shop drawing covering all dimensions, details
of fabrication, construction and installation.

After approval of shop drawing, the Contractor shall submit one or more samples of the
fabricated item of each for the Engineer’s approval before mass fabrication. MMCI/HPCL
Engineer-In-Charge’s comments if any shall be incorporated during mass fabrication.

3.2 M.S.Windows and Ventilators

Sashes shall be square and flat. Sashes shall be constructed of sections which have been cut to
the required length, mitred and welded at corners. All the corners shall be through right angles
and welds shall be neatly cleaned off. Tee sections for glazing shall be tennoned and riveted into
the frames and where they intersect, the vertical tee shall be broached and the horizontal tee
threaded through it, and the intersection closed by hydraulic pressure.

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3.3 Procedure for Fixing Door, Windows and Ventilators

Doors, Windows and Ventilators shall not be built in at the time the walls are constructed but
shall be subsequently fixed into prepared openings, in accordance with IS:1081. Holes for fixing
lugs are to be left or cut, and the doors and windows fixed after all the rough masonry and plaster
work has been finished. The frames of units shall be set in the opening by using wooden wedges
at the jambs, sill and head, and shall be plumbed in position. The lugs shall then be grouted into
their holes with concrete (1:2:4) / Masonry wall.

When RCC members (beam or column) form the sides of the opening, rawl plugs shall be fixed
in RCC and frames fixed to the members by 63 mm (2 ½”) x No. 10 galvanised wood screws.

In the case of steel work openings a mild steel or hard wood fillet shall be provided around the
frame to facilitate erection. The height of the unfinished opening shall depend on whether a
threshold is required or not. While fixing the door, care shall be taken to see that at least 6 mm
space is left between door and finished floor.

3.4 Tolerance
The sizes of doors, windows and ventilators shall not vary by more than + 1.5 mm than the size
specified on drawings.

3.5 Hardware
Necessary hardware for steel doors and windows shall be compatible with the basic material and
shall be provided along with the doors, windows and ventilators. Minimum hardware to be
provided shall be as per following table.

TABLE

STEEL DOOR AND WINDOWS

(MINIMUM HARDWARE)

FITTINGS DOORS WINDOWS VENTILATORS

SINGLE DOUBLE SINGLE DOUBLE TOP HUNG

SHUTTER SHUTTER SHUTTER SHUTTER SHUTTER

HINGES (HEAVY) 100 MM 3 6 - - -

HINGES (HEAVY) 75 MM - - 2 4 2
WIDE

ALDROP (300 MM) 1 1 - - -

PUSH AND PULL TYPE 2 2 - - -

HANDLE (100 MM)

CONCEALED TOWER 1 3 - - -
BOLTS (300 MM)

BUTT HINGES 75 MM - - - - 2
(HEAVY)

TWO POINT NOSE HANDLE - - 1 2 1

WITH STRIKING PLATE

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PEG STAY (300 MM) - - 1 2 1

PULLEY AND CORD-EYE - - - - -

KNOBS

SPRING CATCH AND - - - - -

CATCH PLATE

NOTES
1. All the fittings shall be in M.S. unless otherwise specified.
2. Single leaf door shutters and ventilator shutters of more than 0.80 m width shall be provided with
one extra hinge.
3. Where height of window shutter and door leaf exceeds 1.2 m and 2.15 m respectively one extra
hinge shall be provided for every additional height of 0.5 m or part thereof and length of top bolt
shall be increased by the height of the shutter/leaf above 2.15 m from floor level.
4. In double leaf shutters of doors, two tower bolts shall be fixed to the first shutter top and bottom
and one to the closing shutter at the top.
5. All hardware shall conform to the applicable Indian Standard.

3.6 Finish
After the fabrication of units all the steel surfaces shall be thoroughly cleaned free of rust, mill-
scale, dirt, oil, etc. and two coats of red oxide zinc chromate primer shall be applied. Two coats
of approved synthetic enamel paint shall be applied after installation of the door, window or
ventilator.

4 Aluminium Doors, Windows and Ventilators

4.1 General
Aluminium Doors, Windows and ventilators shall conform to IS:733, IS:1948, IS:1949, and
IS:1081 shall be as per drawings issued by the Engineer. The contractor shall submit for
MMCI/HPCL Engineer-In-Charge’s approval the shop drawings covering all dimension details
of fabrication, construction and installation. After approval of shop drawings the contractor shall
submit one or more samples of the fabricated item of each type for the MMCI/HPCL Engineer-
In-Charge’s approval before mass fabrication.

4.2 Material
4.2.1 Aluminium Alloy Extruded Sections
Aluminium alloy used in the manufacture of doors, windows and ventilators shall conform to IS
designation HE 9-WP of IS:733. The sectional properties of extruded sections shall be as given in
IS:733 or as manufactured by approved manufacturer such as Indal/Hindalco or equivalent. The
section shall be uniform in appearance, free from die lines and handling marks.

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4.2.2 Glass panes

Glass panes shall be clear float glass / Obscure glass panes with 6 mm thick. Glass panes shall
also be free from flaws, specks or bubbles. All panes shall have properly squared corners and
straight edges. The sizes of glass panes for use shall be in accordance with Table I of IS:1948.

4.2.3 Screws, Fasteners

Screws and fasteners shall be of aluminium alloy or brass oxidised. Screw thread of machine
screws used in the manufacture of aluminium doors, windows and ventilators shall conform to
the requirement of IS:4218. Other threads shall be permissible if agreed to between the
purchaser (MMCI) and vendor (Contractor).

4.3 Standard sizes, tolerances and designation

4.3.1 Size
Overall dimension of windows, doors, ventilators, shall be derived from masonry opening minus
an allowance of 1.25 cm clearance on all sides for the purpose of fitting. However, type and
overall sizes shall be in accordance with IS:1948.

4.3.2 Tolerances
The sizes for doors, windows or ventilator frames shall not vary by more than ± 1.5 mm from
overall size as specified in drawing.

4.3.3 Designation
Doors, windows and ventilators shall be designated by symbol denoting their width, type and
height in succession as per IS : 1948.

4.4 Sectional dimensions and weights

Sectional dimensions and weights per unit length of the section shall conform to design drawing.
However, uses of specific sections for specified units as per manufacturers’ standard may be used
with prior approval of MMCI/HPCL Engineer-In-Charge.

4.5 Fabrication
4.5.1 Frames
Frames shall be square and flat, the corners of the frame being fabricated to a true right angle.
Both the fixed and opening frames shall be constructed of sections which have been cut to length,
mitred and screwed at the corners.

4.5.1.1 Sub Frames

Sub frame where recommended, shall match the main frame section. The corners of the sub
frame shall be at right angle. All sides of the sub frame adjacent to the masonry/concrete shall
be properly sealed to avoid any water entry inside.

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4.5.2 Shutters
All hinges, pivots, etc. shall be provided and fabricated in accordance with provisions given in
IS:1948. However, reference standards and drawings are also to be read in conjunction with the
IS Code.
4.5.3 Doors, Windows and Ventilators
The outer fixed frame shall be of section AL-FX8. The shutter frame shall be of either hollow
sections AL-HFX5 and AL-HFX6 or of solid sections AL-FX5 and AL-FX6. All other
attachments and accessories shall be provided in accordance with IS:1948. Alternatively,
selection of sections from Indal/ Hindalco or equivalent manufacturer’s specification duly
approved by MMCI/HPCL Engineer-In-Charge is also recommended.
4.6 Finishing
The aluminium sections to be used shall be properly buffed, cleaned by using mild acids and
water. Then the same shall be anodised to have average anodic film thickness of 25 microns.

To prevent damage to metal surfaces, a protective tape shall be applied after manufacturing and
same shall be removed at site only after completion of rough trades.

4.7 Handling, Storage

The extruded section or the fabricated windows/doors shall be protected against abrasions, water
stains and any other damages caused by acids or alkaline chemicals.

Cold metal shall preferably be placed in a dry storage area avoiding contact between it and other
metals. Use of wood face shelving racks is recommended. It shall also be kept away from
caustics, nitrates, phosphates, acids and cement.

4.8 Installation
The fabricated and assembled windows or door units (without glazing) shall be fixed in masonry
opening properly plastered and finished. Straightness and diagonal dimensions of the opening
shall not have tolerance more than ± 2 mm.

Aluminium screws or bolts are to be used with teak wood block on the back of the sections to
avoid dents and other mechanical damages during tightening of screws/bolts. All gaps between
the aluminium section and the masonry surface must be sealed with gun grade polymer based
sealant viz., silicone compound, polysulphide compound.

Cement mortar grout or cement mortar finishing of gaps after installation of aluminium units
shall strictly be restricted to protect the surface treatments given to the aluminium like anodising,
precoating etc.

All glass panes shall be fixed only after major activities are over in the area.

4.9 Hardware
Necessary hardware for aluminium doors and windows shall be compatible with the basic
material and shall be provided along with the doors, windows and ventilators. Minimum
hardware to be provided shall be as per following table

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TABLE

ALUMINIUM DOOR AND WINDOWS

(MINIMUM HARDWARE)

FITTINGS DOORS CASEMENT SLIDING VENTILATO

WINDOWS WINDOWS RS

Single Double Single Double

Shutter Shutter Shutter Shutter

MORTICE LOCK 1 1 - - - -
(7 LEVERS)

PUSH AND PULL TYPE - - - - - -

HANDLE (100 MM)

CONCEALED TOWER 1 3 - - - -
BOLTS (300 MM)

BUTT HINGES 75 MM 3 6 2 4 - -
(HEAVY)

TWO POINT NOSE - - 1 2 - -

HANDLE WITH
STRIKING PLATE

PEG STAY (300 MM) - - 1 2 - -

SPRING CATCH AND - - - - - -

CATCH PLATE

NOTES
1. All the fittings shall be anodised aluminium (finish compatible with original frame) type unless
otherwise specified.
2. Single leaf door shutters and ventilator shutters of more than 0.80 m width shall be provided
with one extra hinge.
3. Where height of window shutter and door leaf exceeds 1.2 m and 2.15 m respectively one extra
hinge shall be provided for every additional height of 0.5 m or part thereof and length of top bolt
shall be increased by the height of the shutter/leaf above 2.15 m from floor level.
4. In double leaf shutters of doors, two tower bolts shall be fixed to the first shutter at top and
bottom and one to the closing shutter at the top.
5. All hardware shall conform to the applicable Indian Standards.

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4.10 Drawings/ Documents

Prior to fabrication, Contractor shall submit 3 copies of shop drawing indicating details of all
members, sections and hardware for MMCI/HPCL Engineer-In-Charge’s approval. All
certificates against tests for anodising and other physical properties of material shall be produced
to the Engineer for acceptance.

5 Metal Rolling Shutters

5.1 General
5.1.1 Metal Rolling Shutters shall conform to IS:6248, and shall be as per drawings issued by the
Engineer. The Contractor shall submit for MMCI/HPCL Engineer-In-Charge’s approval, the
shop drawing covering all details of fabrication, construction and installation. After approval of
shop drawing the Contractor shall submit one sample for approval before mass fabrication.

5.1.2 Rolling shutters shall be pull & push type with ball bearings.

5.2 Materials
5.2.1 Cold Rolled Steel Strips
Cold Rolled Steel Strips used for rolling shutter lath sections shall conform to temper No. 5,
Dead soft quality of IS:4030.

5.2.2 GI Sections
GI Sheets and Plates used for manufacturing the guide channels, brackets and lock plate shall be
of hot rolled steel of thickness not less than 18 gauge conforming to IS:5986. These shall be free
from surface defects and the edges shall be cleanly sheared.
All components of rolling shutter to be hot dip galvanised with a zinc coating containing not less
than 97.5% pure zinc. The minimum weight of zinc coating to be 230 g/sq.m.. The coating shall
be free from flaking/peeling.

5.2.3 Steel Pipe

GI Pipes used for the suspension shaft of the roller shall be heavy duty pipe suitable for
mechanical purposes and shall conform to IS:1161.

5.2.4 Cast Iron Castings

Cast Iron Castings used for roller pulley wheels, U-clamps shall conform to Grade 15 of IS:210.
These shall be free of blow holes, surface defects such as cracks, burrs etc.

5.2.5 Springs
The springs used in the roller for counter balancing the rolling shutter shall be made either from
high tensile spring steel wire or flat spring steel strip.

The spring steel wire used or helical spring shall conform to Grade 2 of IS:4454.

Flat spring steel strip used for spiral spring shall be from 0.8 to 1.0 percent carbon steel strip
especially hardened and tempered.

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5.3 Fabrication
5.3.1 Curtain
This shall be built up from interlocking lath sections. The lath sections shall be from 18 gauge
section. The lath section shall be rolled so as to have interlocking curls at both edges and a deep
corrugation at the centre with a bridge depth of 16 mm to provide sufficient curtain stiffness for
resisting manual pressure and normal wind pressure.

Each lath section shall be continuous single piece without any welded joint. When interlocked,
the lath section shall have a distance of 75 mm between rolling centres. Each alternate lath
section shall be fitted with a malleable cast iron (conforming to IS:2108) or mild steel clips
securely riveted at either end, thus locking the lath section at both ends and preventing lateral
movement of the individual lath sections. The clips shall be so designed as to fit the contour of
the lath sections.

5.3.2 Lock Plate

The Lock Plate provided at the bottom of the shutter, shall be composed of a GI Plate 3.15 mm
thick, reinforced with GI angle 35 x 35 x 5 mm at bottom of the plate or as specified in BOQ.
The lock plate shall be fitted with sliding bolts at either end to engage with suitable receiving
pockets at the bottom of the guide channel.
The sliding bolts shall be capable of being locked by means of padlocks both from outside and
inside. The lock plate shall also be provided with pulling handles, one handle for 2.5 m width and
2 handles for widths above 2.5 m. Pulling handles shall be fixed on both inside and outside faces
of the lock plate.

5.3.3 Guide Channels

These shall be of GI deep channel section of rolled, pressed or built up (fabricated) construction.
The thickness of the sheet used shall not be less than 3.15 mm. The depth of the guide should be
such that there is sufficient clearance between curtain and inner surface of guide.

The curtain shall project into the guide at least 40 mm for shutters upto 3.5 m width and 60 mm
for greater widths. There shall be a clearance of 10 mm between guide wall and the end clips of
the curtain.

Where the shutter is installed in heavy windy zones, special wind locking arrangements shall be
provided to prevent the curtain coming out of the guide. The clear gap on either side of the
curtain and inner faces of the guide channel shall be 5 mm. The depth and width of the guide
channel shall be as follows :

a) CLEAR WIDTH OF SHUTTER DEPTH OF GUIDE CHANNEL

(MINIMUM)
Upto 3.5 m 65 mm
3.5 m to 8 m 75 mm
8 m and above 100 mm

Width of Guide Channel shall be 25 mm for lath sections with bridge depth of about 12 mm and
32 mm for lath sections with bridge depth of 16 mm.

Fixing Cleats : Each guide shall have a minimum of 3 fixing cleats. The spacing of cleats shall
not exceed 0.75 m. Alternatively, the guide channels may also be provided with suitable dowels
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hooks or pins for embedding in the walls. The guide channel shall be attached to the wall plumb
and true.

5.3.4 Bracket Plate

This shall be fabricated out of GI Plate of 3.15 mm thick. Thicker plates may be used depending
upon the height of the shutter. Dimensions shall be as given in IS:6248.

The bracket plate may be square, circular or hexagonal with a U-shaped cast iron or mild steel
clamp riveted or welded to it at the centre. The bracket plate should have sufficient cross
sectional area to resist the shear arising out of the weight of the curtain, suspension shaft etc. and
shall be held rigidly by suitable foundation bolts.

5.3.5 Roller
The suspension shaft of the roller shall be made of steel pipe conforming to heavy duty of
IS:1161. The diameter shall be sufficient to limit deflection of shaft under the weight of the
rolling shutter. The deflection of the shaft shall not exceed 5 mm per metre width of the shutter.
Diameters of the steel pipe for various widths upto 6 m and height 5 m shall be as per IS:6248.
Sizing of pipe diameter for greater widths and heights shall be designed giving due consideration
for deflection limit mentioned above.
The pipes of the suspension shaft which are clamped to the brackets shall be fitted with rotatable
cast iron pulleys to which the curtain is attached. The pulleys and the pipe shaft shall be
connected by means of pretensioned helical springs to counterbalance the weight of the curtain
and to keep the shutter in equilibrium in any partly opened position.

5.3.6 Hood Covers

These shall be made of GI sheets not less than 20 gauge thick, and shall be hexagonal, square or
circular contour depending on the contour of the bracket plate. The hood cover shall be stiffened
with angle or flat stiffeners at top and bottom edges to retain shape. The hood cover shall be
fixed to the bracket plate by means of angle cleats. The hood cover shall also be supported all
along the top at suitable intervals to prevent sagging.

6 PVC Doors
Doors shall have robust frames and stiffeners all of plastic made out of UV-stabilised special
compounds / grades of PVC of approved make, reinforced with steel sections concealed inside
the cavity of PVC sections with EDPM weather sealing strips, along with fixed PVC sheets and
sliding / (brass) hinged openable PVC shutters with or without glazing at top. PVC doors shall
be obtained from reputed and approved manufacture.

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