Project for the Construction of Mumbai-Ahmedabad High Speed Rail Bidding Documents - Part 2

Package No. MAHSR-P-4(X) and P-4(Y) Section VI-2. Works Requirements (Technical Specifications)

Bolts, nuts, washers (high strength and ordinary) and studs

Bolts, nuts, washers and studs shall conform to the relevant reference standards listed in
Table 2.1 of these technical specifications and the Drawings.
Paints
Paint materials and other accessories shall conform to relevant standards listed in Table
2.1 of this Technical Standard.
Paints only from manufacturer approved by the Engineer shall be used. The Contractor
shall furnish to the Engineer, the date of manufacture of paint as certified by the
manufacturer with the necessary container marking and test certificate for paint
conforming to relevant code.
Inspection and testing of material
The Contractor shall submit to the Engineer copies of test certificates including steel,
bolts, paints etc., from the manufacturers including proof sheets, mill sheets etc.
showing that the materials have been tested in accordance with the requirements of
various specifications and relevant provisions.
All materials for the work shall pass tests and/or analysis prescribed by the relevant
reference standards listed in Sub-Clause 2.1.1 and elsewhere, in these technical
specifications. If the test results do not conform to above mentioned applicable
references, then the lot of material shall be rejected and got removed from the
Contractor’s fabrication-workshop.
Additional tests as instructed by the Engineer shall conform to Sub-Clause 1.5 of these
technical specifications. Even satisfactory outcome of such tests or analysis shall in no
way limit, dilute or interfere with the absolute right of the Engineer to reject the whole
or part of such materials supplied by the Contractor, which in the judgment of the
Engineer does not comply with the conditions of the Contract.
Paint material:
The tests for density (Weight per litre), consistency test, scratch test, flexibility
and adhesive test, shall be carried out in the field.
The Engineer reserves the right to get the paint re-tested at the Contractor’s
expenses as considered necessary, before giving approval, if the test results do not
conform to these technical specifications.
Steel tape: The Contractor shall use steel tape conforming to IS: 1269-Part-2 duly
tested and issued with certificate of accuracy by an accredited National testing house
for templating, fabrication of drilling jig etc.

The storage and handling/delivery plan as part of the overall Method Statement, shall
be proposed by the Contractor for the approval of the Engineer.
The Contractor shall have a suitable storage yard for storing the procured structural steel,
fabricated steel structural members and all other materials. The yard shall have proper
facilities such as drainage and lighting including access for cranes, trailers and other
heavy equipment.

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Project for the Construction of Mumbai-Ahmedabad High Speed Rail Bidding Documents - Part 2
Package No. MAHSR-P-4(X) and P-4(Y) Section VI-2. Works Requirements (Technical Specifications)

General
Materials shall conform to the Drawings and shall be in accordance with the standards
given in Table 2.1 below, unless otherwise specified in these technical specifications.
However, in case of non-availability of type and grade of any material, the Contractor can
propose alternate options, conforming to these technical specifications, for approval of the
Engineer. Any alternative option shall be of equivalent or of higher specification to that
indicated in the Drawings. No claim shall be entertained from the Contractor on this
account and payment shall be as per relevant items in the schedule of items, quantities and
rates.
Table 2.1: Reference Standards
Referred Standard
NO. Item/Description Indian Standard Japanese and Other
Industrial Standard
IS:808, IS:1730, IS:1852, JIS B 0601, JIS G 3101, JIS
Steel plate, Steel sections, IS:1161, IS:1173, IS:2062, G 3131, JIS G 3191, JIS G
1 Rolled steel, Rolled steel IS:3601, IS:4923, IS/ISO 3192, JIS G 3193, JIS G
3194, JIS G 3106
section, Rolled steel bar 7452, IS:12778, IS:12779, IS:
1875, IS: 7283.

2 High strength bolts, nuts and IS:3757, IS:4000, IS:6623, JIS B 1186
washers IS:6649
IS:1363-1, IS:1363-3, JIS B 1180, JIS B 1181
3 Ordinary bolts, nuts and
washers IS:1364, IS:1367-3, IS:6639

4 Cracks and defects-Flaw

IS: 3658, IS: 3703
detection
IS:814, IS:1395, IS:4353, JIS Z 3211, JIS Z 3312, JIS
5 Electrode, wire and flux IS:7280, IRS M:28, IRS Z 3313, JIS Z 3351, flux
M:39, IRS M:46, IS:9595 suitable for wire.

6 Stud IS:2062 JIS B 1198, ISO 13918

7 Chequered plate IS:3502

8 Cast steel IS:1030, IS:4899

9 Carbon Steel Pipe IS:1161, IS:1239Part1 JIS G 3452

10 Handling and storage of steel IS 4082, IRS: B1-2001

and connection material
11 Painting As per Appendix-8

Note:
Priority shall be given for Indian Standards.

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Project for the Construction of Mumbai-Ahmedabad High Speed Rail Bidding Documents - Part 2
Package No. MAHSR-P-4(X) and P-4(Y) Section VI-2. Works Requirements (Technical Specifications)

Appendix-8 Painting Specification for Steel Truss Bridge

1. The painting shall be as per C-5 Painting system confirming to “Handbook for
Corrosion Protection of Steel Road Bridges 26th March 2014 (Japan Road
Association)”

2. All the constituent paint products shall be procured from one Integrated source only
and the paint source shall be approved by the Engineer.

3. Detailed procedure for sampling and testing of the paint components as per Japanese
Industrial standard JIS K 5659:2008 (Long durable paints for steel structures) shall
be arranged within the quoted rates in RDSO or IITs or any other NABL certified
laboratory as directed by the Engineer. The Top coat shall be confirming to class-1
in terms of clause 4 & 5 of JIS K 5659:2008.

4. Painting specification for different areas to be painted shall conform to tables below,

Table 1: External and Internal surface (except contact surface with concrete)
Process Type of painting Standard Target Coating
coverage DFT interval
by spray (μm) (20℃)
(g/m2)
Fabrication Surface Blast cleaning: ISO Sa
workshop preparation 21/2
~ 4 hours
1st coat Inorganic Zinc-rich Paint 600 75

2 days ~ 10
nd
2 coat/ Epoxy resin paint 160 - days
Mist coat
1 day ~ 10
rd
3 coat Epoxy resin paint 540 120 days

1 day ~ 10
th
4 coat Fluoro resin paint for 170 30 days
undercoat
1 day ~ 10
5th coat Fluoro resin paint for 140 25 days
topcoat
Table 2: Friction joint interface at high-tensile bolt Joint
Process Type of painting Standard Target Coating
coverage DFT interval
by spray (μm) (20℃)
(g/m2)
Fabrication Surface Blast cleaning: ISO Sa
workshop preparation 21/2 ~ 4 hours
st
1 coat Inorganic Zinc-rich Paint 600 75

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Project for the Construction of Mumbai-Ahmedabad High Speed Rail Bidding Documents - Part 2
Package No. MAHSR-P-4(X) and P-4(Y) Section VI-2. Works Requirements (Technical Specifications)

Table 3: Contact surface to concrete (Upper surface of Sacrificial Shuttering, Upper

surface of Cross Beam, Upper Surface of Stringer, except contacting area to
slab concrete of Bottom Chord Gusset Plate)
Process Type of painting Standard Target Coating
coverage DFT interval
by spray (μm) (20℃)
(g/m2)
Fabrication Surface Blast cleaning: ISO Sa
workshop preparation 21/2 ~ 4 hours
st
1 coat Inorganic Zinc-rich Paint 240 30

Table 4: Contact area with high-strength bolt and washer at splice plate
Process Type of painting Standard Target Coating
coverage DFT interval
by spray (μm) (20℃)
(g/m2)
Fabrication Surface Blast cleaning: ISO Sa
workshop preparation 21/2 ~ 4 hours
st
1 coat Inorganic Zinc-rich 600 75
Paint

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Project for the Construction of Mumbai-Ahmedabad High Speed Rail Bidding Documents - Part 2
Package No. MAHSR-P-4(X) and P-4(Y) Section VI-2. Works Requirements (Technical Specifications)
Table 4
Table 3
Table 1
Table 1

Table 2
Table 1Table 1
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