MAHSR-P-4(X) & P-4(Y) Part 2 - Technical Specifications PDF

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) Section VI. Works Requirements...

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) Section VI. Works Requirements VI-2. Specifications (Technical Specifications) Table of Contents 1. FABRICATION OF STRUCTURAL STEELWORK FOR BRIDGES....................... 4 1.1 Scope of Specifications..................................................................................................... 4 1.2 Applicable Standards........................................................................................................ 4 1.3 Fabrication-Workshop and Yard....................................................................................... 9 1.4 Submittals....................................................................................................................... 10 Method Statement........................................................................................................... 10 Resources Report............................................................................................................ 11 Fabrication and Inspection Record.................................................................................. 11 1.5 Additional Tests.............................................................................................................. 12 1.6 Measurements................................................................................................................. 12 1.7 Contractor’s Painting and Welding Engineers / Supervisors............................................ 12 Painting Engineers / Supervisors..................................................................................... 12 Welding Engineers / Supervisors..................................................................................... 12 International Experts for Welding and Quality Management........................................... 13 2. STRUCTURAL STEEL WORK.................................................................................. 14 2.1 Materials......................................................................................................................... 14 General........................................................................................................................... 14 Steel................................................................................................................................ 15 Welding material/consumables........................................................................................ 16 Bolts, nuts, washers (high strength and ordinary) and studs............................................. 17 Paints.............................................................................................................................. 17 Inspection and testing of material.................................................................................... 17 2.2 Handling and Storage...................................................................................................... 17 2.3 Fabrication...................................................................................................................... 18 General........................................................................................................................... 18 Independent Examining Body (IEB)............................................................................... 19 Shop drawings................................................................................................................ 20 Test-fabrication (Using Partial Mock-Ups)...................................................................... 20 Page 1 of 88 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) 2.4 Method of Fabrication..................................................................................................... 20 General........................................................................................................................... 20 Straightening and bending of materials............................................................................ 21 Cutting of materials......................................................................................................... 21 Drilling of holes.............................................................................................................. 22 Welding.......................................................................................................................... 23 Welding procedure.......................................................................................................... 23 Inspection and Testing of fabrication works.................................................................... 31 Repair of fabrication defects........................................................................................... 32 2.5 Check-assembly.............................................................................................................. 33 2.6 Painting at fabrication shop............................................................................................. 35 General........................................................................................................................... 35 Painting Specification..................................................................................................... 35 Surface preparation for painting work............................................................................. 35 Painting Procedure.......................................................................................................... 35 Hot-dip galvanizing........................................................................................................ 36 Inspection and Testing for painting................................................................................. 36 Repair of painting defects............................................................................................... 36 2.7 Quality management....................................................................................................... 37 General........................................................................................................................... 37 Subsidiary plans of WQMP............................................................................................. 37 Non-conformity and its rectification................................................................................ 38 2.8 Packing, loading, Transportation or shipping, Unloading and Stacking........................... 38 2.9 Measurement for Payment............................................................................................... 38 3. Bearings......................................................................................................................... 40 3.1 Elastomeric bearings for steel superstructure................................................................... 40 General........................................................................................................................... 40 Procurement.................................................................................................................... 40 Manufacturing and Workmanship................................................................................... 42 Acceptance of Bearings................................................................................................... 48 Certification and marking................................................................................................ 48 Transportation and Storage............................................................................................. 48 Check-assembly and delivery of bearings........................................................................ 48 Measurement for Payment of Bearings............................................................................ 49 3.2 Metallic bearing for Steel Superstructure......................................................................... 49 Page 2 of 88 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........................................................................................................................... 49 Procurement and Fabrication/manufacturer..................................................................... 49 Manufacturing and Workmanship................................................................................... 50 Acceptance of Bearings................................................................................................... 52 Certification and marking................................................................................................ 52 Transportation and Storage............................................................................................. 52 Check-assembly and delivery of bearings........................................................................ 52 Measurement for Payment of Bearings............................................................................ 52 Appendix-1 Dimensional Tolerance of Fabricated Steel Structure Elements............ 53 Appendix-2 Test of Welder for Fillet Welding............................................................ 56 Appendix-3 Test of welder for Stud Welding.............................................................. 59 Appendix-4 Hot-Dip Galvanizing................................................................................ 61 Appendix-5 Sample Format of Method Statement..................................................... 63 Appendix-6 Sample Work Control Sheets................................................................... 66 Appendix-7 Test-fabrication (Mock-ups).................................................................... 71 Appendix-8 Painting Specification for Steel Truss Bridge......................................... 81 Appendix-9 Bearing Test Samples..................................... Error! Bookmark not defined. Appendix-10 Preheating Temperature (TP)for Welding (Sample calculation)............ 86 Appendix-11 Contents of subsidiary of WQMP (but not limited to the below)........... 87 Page 3 of 88 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) These technical specifications shall apply to the works which shall include fabrication of structural steelwork for superstructure, along with all materials, labour, supervision, management, tools, equipment, services and incidentals necessary for the fabrication, and procurement and supply of bearings, Check-assembly, corrosion protection, packing, loading, transportation or shipping of fabricated materials and bearings to the bridge-sites/site-delivery-yards of Interfacing Contractors, unloading, stacking , and handing over of the same to the respective Interfacing Contractors, for MAHSR steel bridge works, all complete in accordance with the provisions of the Contract. In case specifications have not been provided for any works, the Contractor shall follow the good practices suited for the purpose after obtaining approval of the Engineer. Fabrication work shall include fabrication of steel truss members and accessories along with all the related activities, but not limited to procurement of steel material, connection material, corrosion protection materials, bearings, accessory materials etc., and all required operations like cutting, milling, machining and welding of the structural steel to fabricate steel members of required shape and size as per the Drawings, along with conducting Test-fabrication and Check-assembly of the steel structure with bearings, and then the required painting of the steel work. Precedence of codes (the latest revisions) shall be in the following order, unless otherwise explicitly mentioned in the Bidding Documents: IRS JIS IRC IS Other International Codes. The codes listed hereunder are indicative, and not exhaustive: IRS - Indian Railway Standards: Specification for Fabrication and Erection of Steel Girder Bridge and Locomotive Turn-Tables (Fabrication Specification): SERIAL NO. B1-2001. M: 28 Indian Railways Standard Specification for Classification, Testing and Acceptable Criteria of Manual Metal Arc Welding Electrodes and Gas Welding Rode. M: 39 Classification, Testing and Approval of Submerged Arc Welding Wire-Flux Combinations for Use on Indian Railways. M: 46 Indian Railway Standard Specification for Classification, Testing and Acceptable Criteria of Filler Wires for MIG/MAG Welding – with and without gas shielding. Deleted Page 4 of 88 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) Deleted JIS - Japanese Industrial Standards JIS B 0403(1995): Castings−System of dimensional tolerances and machining allowances (CT13,14,15 means grade). JIS B 0405: General Tolerances−Part 1: Tolerances For Linear And Angular Dimensions Without Individual Tolerance Indications. JIS B 1178: Foundation bolts. JIS B 1180: Hexagon Head Bolt and Hexagon Head Screw. JIS B 1181: Hexagon Nuts and Hexagon Thin Nuts. JIS B 1186: Sets of High Strength Hexagon Bolt, Hexagon Nut and Plain Washers for Friction Grip Joints. JIS B 1198: Headed Stud. JIS B 0601: Surface Roughness. JIS G 3101: Rolled steels for general structure JIS G 3106: Rolled Steels for Welded Structure. JIS G 3131: Hot-rolled Mild Steel Plates, Sheet and Strip. JIS G 3191: Dimensions, Mass and Permissible Variations of Hot Rolled Steel Bars and Bar in Coil. JIS G 3192: Dimensions, Mass and Permissible Variations of Hot Rolled Steel Sections. JIS G 3193: Dimensions, Mass And Permissible Variations Of Hot Rolled Steel Plates, Sheets And Strips. JIS G 3194: Dimensions, Mass and Permissible Variations of Hot Rolled Flat Steel. JIS G 3452: Carbon Steel Pipes for Ordinary Piping. JIS G 4304: Hot-rolled stainless steel plate, sheet and strip. JIS G 5101: Carbon Steel Casting. JIS G 5102: Steel Casting for welding structure. JIS G 5111: High Tensile Strength Carbon Steel Casting and Low Alloy Steel Casting for Structural Purpose. JIS G 5501: Grey Iron Casting. JIS H 8641: Zinc Hot Dip Galvanizing. JIS H 8617: Electroplated coatings of nickel and chromium. JIS K 6254: Rubber, Vulcanized Or Thermoplastic-Determination Of Stress-Strain Properties. JIS K 6386: Rubber Material for Vibration Isolators. Deleted JIS Z 2305: Non-Destructive Testing—Qualification and Certification of NDT Personnel. Page 5 of 88 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) JIS Z 3060: Method for Ultrasonic Testing for Welds of Ferritic Steel. JIS Z 3104: Method Of Inspection And Acceptance Levels For Resistance Spot Welds. JIS Z 3118: Method for Measurement of Amount of Hydrogen Evolved from Steel Welds. JIS Z 3121: Methods of Tensile Test for Butt Welded Joints. JIS Z 3122: Methods of Bend Test for Butt Welded Joints. JIS Z 3211: Covered Electrode for Mild Steel, High tensile Strength Steel and Low Temperature Service Steel. JIS Z 3312: Solid Wires for MAG and MIG Welding of Mild Steel, High Strength Steel and Low Temperature Service Steel. JIS Z 3313: Flux Cored Wires for Gas Shielded and Self-Shielded Metal Arc Welding, High Strength Steel and Low Temperature Service Steel. JIS Z 3351: Solid Wires for Submerged Arc welding of Carbon Steel and Low Alloy Steel. JIS Z 3801: Standard Qualification Procedure for Manual Welding Technique. JIS Z 3841: Standard Qualification Procedure for Semi-Automatic Welding Technique. JIS Z 9003: Single Sampling Inspection Plans having Desired Operation Characteristics by Variables (Standard Deviation Known). IRC (Indian Roads Congress) and MORTH IRC:83(Part II): Standard Specifications and Code of Practice for Road Bridges (First Revision) – Jan 2015 MORTH Specifications for Road and Bridge Works 5th Revision 2013 IS - Indian Standards IS: 210: Grey Iron Casting. IS: 808: Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle Sections. IS: 813: Scheme of Symbols for Welding. IS: 814: Covered Electrodes for Manual Metal Arc Welding of Carbon and Carbon Manganese Steel-Specification. IS: 817: Code of Practice for Training and Testing of Metal Arc Welders. IS: 1030: Carbon Steel Casting for General Engineering Purpose. IS: 1161: Steel Tubes for Structural Purpose. IS: 1173: Hot Rolled and Slit Steel Tee Bars. IS: 1182: Recommended Practice for Radiographic Examination of Fusion Welded Butt Joints in Steel Plates. IS: 1269: Legal Metrology – Material measures of length, part 2. IS: 1239: Steel Tubes, Tubulars and Other Wrought Steel Fittings- Specification. Page 6 of 88 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) IS: 1363-1: Hexagon Head Bolts, Screws and Nuts of Product Grade “C”, prat 1: Hexagon Head Bolts (size range M5 to M64). IS: 1363-3: Hexagon Head Bolts, Screws and Nuts of Product Grade “C”, prat 1: Hexagon Nuts (size range M5 to M64). IS: 1364: Hexagon Head Bolts, Screws and Nuts of Product Grades A and B. IS: 1367-3: Technical Supply Condition for Treated Steel Fastener. IS: 1395: Low and Medium Alloy Steel Covered Electrode for Manual Metal Welding. IS: 1477 Part-1: Code for Practice for Painting of Ferrous Metal in Buildings. IS: 1730: Dimensions for Steel Plates, Sheets, Strips and Flats for General Engineering Purpose. IS: 1852: Rolling and cutting tolerance for hot rolled steel products. IS: 1875: Carbon Steel Billets, Blooms, Slabs and Bars for Forgings – Specification. IS: 2062: Hot Rolled Medium and High Tensile Structural Steel - Specification (Seventh Revision). IS: 2629: Recommended Practice for Hot-Dip Galvanizing of Iron and Steel. IS: 3502: Steel Chequered Plates. IS: 3601: Steel Tubes for Mechanical and General Engineering Purpose. IS: 3658: Code of Practice for Liquid Penetrant Flaw Detection. IS: 3703: Recommended Practice for Magnetic Particle Flaw Detection. IS: 3757: High Strength Structural Bolts. IS: 4000: Code of Practice for High Strength Bolts in Steel Structures. IS 4260: Recommended Practice For Ultrasonic Testing Of Butt Welds In Ferritic Steel. IS: 4899: Ferric and Martensitic Steel Casting for Use at Low Temperature. IS: 4923: Hollow Steel Sections for Structural Use. IS: 6586: Recommended Practice for Metal Spraying for Protection of Iron Steel. IS: 6623: High Strength Structural Nuts. IS: 6639: Hexagon Bolts for Steel Structure. IS: 6649: Hardened and Tempered Washers for High Strength Structural Bolts and Nuts. IS: 6745: Method for Determination of Mass of Zinc Coating on Zinc Coated Iron and Steel Articles. IS: 7280: Bare Wire Electrode for Submerged Arc Welding of Structural Steel. IS: 7283: Hot-Rolled Bars for The Production of Bright Bars and Machined Parts for Engineering Applications- Specification. IS: 7307-1: Approval Test for Welding Procedures, part 1: Fusion Welding of Steel. IS/ISO: 7452: Hot-Rolled Structural Steel Plates Tolerances on Dimensions and Page 7 of 88 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) Shape. IS: 9595: Metal-Arc Welding of Carbon and Carbon Manganese Steels – Recommendations. IS: 12778: Hot Rolled Parallel Flange Steel Section for Beams, Columns and Bearing Piles. IS: 12779: Rolling and Cutting Tolerances for Hot Rolled Parallel beam and column section. IS: 13805: General Standard for Qualification and Certification of NDT Personnel. IS: 14589: Zinc Priming Paint, Epoxy Based, Two-Pack –Specification. IS: 15911: Structural Steel (Ordinary Quality). IS: 16003: Specified and Qualification of Welding Procedures for Metallic Materials-General Rules. Other International Codes.  ISO - International Organization for Standardization: ISO 812: Rubber, vulcanized or Thermoplastic-determination of low temperature brittleness. ISO 815-1: Rubber, vulcanized or Thermoplastic-Determination of compression set at ambient, elevated temperatures. ISO 1106-1: Recommended practice for radiographic examination of fusion welded joints. Part 1: Fusion welded butt joints in steel plates up to 50 mm thick. ISO 1431-1: Rubber, vulcanized or Thermoplastic-Resistance to ozone cracking- Part 1 static and dynamic strain testing. ISO 1817: Rubber, vulcanized or thermoplastic-Determination of the effect of liquids. ISO 2400: Welds in Steel-Reference block for the calibration of equipment for ultrasonic examination. ISO 2409: Paints and varnishes – Cross cut test. ISO 2768-1: General Tolerances part 1: Tolerance for Linear and Angular Dimensions without Individual Tolerance Indications. ISO 3400: Method of test for vulcanized Rubber-Determination of tensile stress-strain properties. ISO 3690: Welding and allied processes -- Determination of hydrogen content in arc weld metal. ISO 4287: Geometrical Product Specifications (GPS)-Surface Texture: Profile Method-Terms, Definitions and Surface Texture Parameters. ISO 6272-1: Paints and varnishes -- Rapid-deformation (impact resistance) tests -- Part 1: Falling-weight test, large-area indenter. ISO 6272-2: Paints and varnishes -- Rapid-deformation (impact resistance) tests -- Part 2: Falling-weight test, small-area indenter. Page 8 of 88 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) ISO 6506-1: Metallic materials-Brinell hardness test-test method. ISO 6158: Metallic Coating-Electroplated Coatings of Chromium for Engineering Purpose. ISO 7270-1: Rubber-Analysis by pyrolytic gas-chromatographic methods Part 1: Identification of polymers (single polymers and polymer blends). ISO 7452: Hot-Rolled Structural Steel Plates – Tolerance on Dimensions and Shape. ISO 7743: Rubber, vulcanized or Thermoplastic-Determination of compression stress-strain properties. ISO 7619-1: Rubber, vulcanized or Thermoplastic-Determination of indentation hardness. ISO 9001: Quality Management Systems – Requirements. ISO 9712: Non-Destructive Testing – Qualification and Certification of NDT Personnel. ISO 9924-1: Rubber and rubber products- Determination of the composition of vulcanizates and uncured compounds by thermogravimetry -- Part 1: Butadiene, ethylene-propylene copolymer and terpolymer, isobutene-isoprene, isoprene and styrene-butadiene rubbers. ISO 13000-1:2005: Plastics – Polytetrafluoroethylene (PTFE) semi-finished products. ISO 15184: Paints and varnishes -- Determination of film hardness by pencil test.  European Norms (EN), American and British Standards (BS): BS EN ISO 13918: Welding-Studs and Ceramic Ferrules for Arc Stud Welding. EN 14399-3: High-strength structural bolting assemblies for preloading Part 3: System HR – Hexagon bolt and nut assemblies. EN 14399-6: High-strength structural bolting assemblies for preloading Part 6: Plain chamfered washers. EN 14399-10: High-strength structural bolting assemblies for preloading Part- 10: System HRC – Bolt and nut assemblies with calibrated preload. ASTM D471: Standard Test Method for Rubber Property-Effect of Liquids. The Contractor shall carry out the fabrication in the existing factory premises or in a dedicated fabrication-workshop set up for the purpose on any other location in accordance with the Contract (with all the necessary plant and equipment, workforce and establishment to maintain required quality standards), as approved by the Engineer. The Contractor shall also ensure the availability of adequate yard area and proper environment (free from rain, wind, direct sun light and dust) for conducting activities including but not limiting to storage and handling, templating, fabrication, painting, etc. However, activities such as storage for large size steel material (such as steel plates) and Page 9 of 88 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) fabricated material, Test-fabrication and Check-assembly may be conducted in open space. The Contractor shall also have a suitable storage yard for storage of the fabricated steel structural members and other materials till delivery of the same to the MAHSR construction contractors. This yard shall have proper facilities such as drainage and lighting including access for cranes, trailers and other heavy equipment. The Contractor shall submit following statements and records for approval of the Engineer. Any other statement/record not herein mentioned but demanded by the Engineer, shall also be submitted in the required format as desired. Method Statement Prior to commencement of any works, the Contractor shall prepare and submit to the Engineer for approval the Method Statements detailing the execution of the works involved, including information regarding calculations and shop drawings, references and information as may be relevant, and satisfying all the requirements under the Contract, as needed and demanded by the Engineer, including but not limited to the following. A typical Method Statement format is given at Appendix-5 for reference. Working organization Working period Main materials including but not limited to their procurement, testing, handling, storage, quality control, and disposal etc. (structural steel, connection material (bolts, nuts, welding consumables), corrosion-protection, bearings etc.) Structural steel fabrication (Test-fabrication with mock-up for the Engineers approval, steel material procurement, NC marking/cutting/drilling, member assembly/welding, straightening, drilling, painting etc.), and other issues influencing fabrication (girder’s length, curve, inclination and camber). Check-assembly (work-site preparation including providing suitable platform with stable foundation and any lighting, assembly and dismantling schedule and sequence, handling of components, temporary staging design and drawings, plant and machinery employed including their stand-by arrangement and upkeep, ensuring the required design camber after assembly and its recording stage wise, and necessary match marking before dismantling, quality control, inspection and acceptance, reporting formats and schedule) and any other relevant information. Storage for delivery of the fabricated steel structural members and other materials including but not limited to proper marking, grouping, labelling etc. of the fabricated steel structural members. Machinery (type, numbers, capacity, their location, mobilization and de-mobilization schedule of the equipment, measuring devices and their accuracy etc.) Quality control planning (acceptance criteria, quality control items, methods and position of quality control, document style of quality control records, records of construction, etc. along with appropriate testing methods). Page 10 of 88 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) Packing, loading and transportation or shipping of fabricated materials and bearings to the bridge site/site-delivery-yard of Interfacing Contractors including unloading and stacking. Any other detail that may be considered necessary and/or required by the Engineer or the Contractor. Resources Report The Contractor shall submit to the Engineer for approval, detailed list of employed manpower (along with their trade classification) and of all serviceable major items of plant and equipment deployed during the report period, and such reports and returns as mentioned in detail under the Contract and as required by the Engineer to ensure efficient and timely execution of the Works. Fabrication and Inspection Record The Contractor shall submit or report the following data to the Engineer. Two copies of such record shall be made and out of which one copy duly signed by the Contractor and its site engineer, shall be submitted to the Engineer. Wherever required, the data being submitted shall be subject to the approval of the Engineer prior to the commencement of relevant works. In this regard, the Engineer’s decision shall be final: Manufacturers test report (steel materials, bolts, nuts, washers and welding consumables). Schedule for documentation (relevant calculation, shop and/or working drawings, plan and/or procedures). Records of test results as and when tests conducted and as required by the Engineer. Structural steel fabrication record: Approval of fabrication-workshop Test-fabrication Material procurement and inspection Radiographic or PAUT testing on welding Ultrasonic testing on welding DPT (Dye-penetration test) Components inspection Check-assembly Paint material inspection (quality of paint, certifications, quantity of paint materials purchased along with expiry date etc.) Painting inspection (surface preparation, amount of use, management report of painting, dry film thickness and others if necessary) Hot-dip galvanizing inspection (if any) Assembly matching code drawing Acceptance inspection for purchasing or outsourcing All Quality Control (QC) records, Others Welding Procedure Qualification Record (WPQR) Page 11 of 88 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) Work control sheet for fabrication record of each work (drilling, welding, Check- assembly, painting). Refer Appendix-6 for samples. Inspection (at fabrication-workshops, at bridge site/site-delivery-yards of Interfacing Contractors) Employer reserves the right to conduct any additional tests as deemed necessary during the course of execution of works, over and above those specified in the Contract. Some of these tests may be carried out at relevant laboratories in Japan and any other country. The expenses for these additional tests shall be borne by the Employer. All measurements shall be made in the Metric System. Different items of work shall be measured in accordance with the procedures set forth in the relevant sections read in conjunction with the General and Particular Conditions of the Contract, General and Technical Specifications and from limits shown on the Drawings. All measurements and computations unless otherwise indicated, shall be carried nearest to the following limits. Length, Breadth, Height, Depth or Thickness: – 1 mm. Area - 0.001 Sq. meter. Cubic contents - 0.0001 Cu. meter. Weight – 0.001 MT or 1 Kg. In recording dimensions of work, the sequence of length, breadth and height or depth or thickness shall be followed. Painting Engineers / Supervisors Prior to carrying out painting works, the Contractor shall appoint appropriate number of Painting engineers / supervisors for supervising the painting work, with at least ten years of experiences of painting work out of which 5 years in painting of Steel Bridges Structure in the fabrication workshop. Welding Engineers / Supervisors Prior to carrying out welding works, the Contractor shall appoint appropriate number of Welding engineers / supervisors for supervising the welding work with minimum ten years’ experience of welding work, management work and welding design work. Qualification of Welding engineer / supervisors shall be in accordance with following: Plan and design of welding work (including equipment and support system etc.). Procurement management of welding consumables. Management of execution of welding and its quality control. Management of Safety, Health and Environment (SHE) for welding. The credentials of the Welding Engineers / supervisors shall be examined and accepted by the International Expert for Welding and Quality Management (refer definition in Sub- Clause 1.7.3). Page 12 of 88 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) International Experts for Welding and Quality Management. The Contractor shall engage International Experts for Welding and Quality Management, on fulltime basis, in order to ensure technical accuracy, sound technical practice and compliance to the Quality Management System approved by the Engineer in order to achieve International Quality in the fabrication of steel truss members. Qualification of the International Experts shall be in accordance with following: 1. They shall have minimum experience of 10 years as a supervisor or quality assurance engineer or quality control engineer in the field of fabrication. This experience must include experience in at least 1 (one) International High-Speed Rail project or Japanese High- Speed Rail project for the fabrication of steel trusses or plate girders or steel arches for the superstructures of High-Speed Rail bridges. 2. Preferably, they shall have a sound knowledge of Japanese codes as well as international codes and standards regarding the fabrication of steel structures, such as the Japan Welding Engineering Society Standard, Japanese Industrial Standards (JIS) or American Welding Society D1.1. 3. They shall be an International Welding Engineer (IWE)/International Welding Technologist (IWT) certified by the International Institute of Welding (IIW), or a Senior Welding Engineer (SWE)/Welding Engineer (WE)/Associate Welding Engineer (AWE) certified by The Japan Welding Engineering Society (JWES 8103:2008). Page 13 of 88 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 section, Rolled steel bar 7452, IS:12778, IS:12779, IS: 3194, JIS G 3106 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. Page 14 of 88 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) Prior to procurement of materials, the Contractor shall submit list and detail of suppliers or manufactures to the Engineer for approval. This detail shall include but not limited to capacity, location, lead time for delivery and credentials of suppliers or manufacturers. However, the same does not absolve the Contractor of the overall responsibility for the timely completion of the work. Steel The Contractor shall procure steel material only from primary manufacturers approved by the Engineer. However, only certain isolated sections of structural steel, not being rolled by primary approved manufacturers, can be procured from the authorized re-rollers of primary approved manufacturers or authorized licensee of BIS having traceability system and who use billets produced by primary approved manufacturers. Traceability shall be ensured by the Contractor and submitted to the Engineer for approval. It may be noted that quality of steel used for fabrication shall be the essence of the contract and shall be rigidly followed. All the steel plates and rolled sections used in the fabrication must have Manufacturer’s Certificates clearly indicating specifications to which they conform. The Contractor shall ensure that the steel materials received at fabrication-workshop are colour coded to identify its grade. The steel plates having thickness more than 25mm shall have STRA value more than 25%, as per EN 10164. The Contractor shall conduct short transverse tensile test as per EN 10164 for each production batch of the steel plate procured. Steel plate to be welded shall conform to provisions of IS 2062, however for E450, Charpy impact value shall be 47J or more at the test temperature of (-)5 degrees- C as specified in JIS G 3106. Applicable member thickness and corresponding steel grade shall conform to Table 2.2 of these technical specifications. Table 2.2: Applicable Member Thickness and corresponding steel grade Member Thickness t(mm) IS Steel Grade JIS Steel Grade 9≦t≦16 B0 A 16