Index for Handbook

1. Introduction to Project

2. Scope

3. Safety

3.1. Safety working near IR track

3.2. Safety while working at night

3.3. Safety working with machinery

3.4. Measure to be taken in case of accident

3.5. Measures to be taken in case of damage to railway track

4. Earthwork

4.1. C&G

4.2. Cutting

4.3. Filling

4.3.1. Borrow area operation

4.3.2. Field embankment trial

4.3.3. Do’s & Don’t

4.4. Subgrade

4.5. Blanketing

4.6. Check List before start of work

4.7. Frequency of tests

4.8. Tolerances

5. Structures

5.1. Specifications

5.1.1. Cement

5.1.2. Fine aggregate

5.1.3. Coarse aggregate

5.1.4. Rebar

5.1.5. Prestressing wire

5.1.6. Transit mixer

6. Penalties & Awards

7. Clauses for RPFI

Construction of double track main line of 626 Km length.

Construction of RUB, FOB, MB, IMB, RFO, ROB, PS.

Construction of 20 Junction/Crossing stations.

Construction of buildings in Junction/Crossing stations and construction of sanitation, Electrical Distribution movement facility within the Station area.

Dismantling and relaying of existing factory siding.

Dismantling of Abandoned structure as mentioned in attachment 8 of Volume 2.

Construction of Safety wall as mentioned in Attachment 11 of Volume 2.

Removal of existing power Utilities as mentioned in Attachment 6 of Volume 2.

Removal and protection of existing Utilities as mentioned in Attachment 9 of Volume 2.

Construction of Retaining wall between DFC Embankment and existing Gas/Oil Pipelines as mentioned in Attachment 12 of Volume 2.

CONSTRUCTION MACHINERY 1 General 32.1.1 Construction machineries may include dumpers and dump trucks, lift trucks and telescopic handlers, transit mixers, batching & mixing plants, crushers, concrete pumps, piling rigs, vibro hammers, rail welding equipments, mobile elevating work platforms, cranes, tipper lorries, lorry loaders, skip wagons, 360° excavators, 180° backhoe loaders, crawler tractors, scrapers, graders, loading shovels, trenchers, side booms, pavers, planers, chippers, road rollers, locomotives, tankers and bowsers, trailers, hydraulic and mechanical breakers etc. 2 Safe Worthiness Certificate 2.1 Each construction equipment shall be in sound mechanical working condition and certified by either competent person under Factories Act or carry manufacturers’ warranty in case of brand new equipments or authorized persons / firms approved by Engineer before induction to any site.

2.2 Every such certificate shall have the date of purchase, main overhauling undertaken in the past, any accident to the equipment, visual examination details, critical components safety check, list of safety devises and its working condition, manufacturer’s maintenance checklist, past projects wherein the equipments were used etc as its minimum content. 3 Reverse Horns 32.3.1 All Vehicles shall be fitted with audible reverse alarms and maintained in good working condition. Reversing shall be done only when there is adequate rear view visibility or under the directions of a banksman. 4 General Operating Procedures 4.1 Drivers entering site shall be instructed to follow the safe system of work adopted on site. These shall be verbal instructions or, preferably, written instructions showing the relevant site rules, the site layout, delivery areas, speed limits, etc.

4.2 No passengers shall be carried, unless specific seating has been provided in accordance with the manufacturers recommendations.

4.3 Working on gradients beyond any equipments capability shall not be allowed.

4.4 Prevention of dumper and dump truck accidents should be managed by providing for adequate lateral clearances, wheel stops at a sufficient distance from the edges of excavations, spoil heaps, pits, markers, etc.

4.5 The manufacturer’s recommended bucket size shall not be exceeded in excavators.

4.6 If excavators operating on a gradient which cannot be avoided, it shall be ensured that the working cycle is slowed down, that the bucket is not extended too far in the downhill direction, and that travel is undertaken with extreme caution. A large excavator shall never be permitted to travel in a confined area, or around people, without a banksman to guide the driver, who should have the excavator attachment close in to the machine, with the bucket just clear of the ground. On wheeled excavators, it is essential that the tyres are in good condition and correctly inflated. If stabilizing devices are fitted, they should be employed when the machine is excavating. 4.7 When the front shovel of the 1800 backhoe loaders is being employed, the backhoe attachment shall be in its “travel” position, with the safety locking device in place.

4.8 When operating the backhoe in poor ground conditions, the stabilisers tend to sink into the surface of the ground, reducing stability. Therefore frequent checks shall be made for the stability of the machine. The loading shovel should always be lowered to the ground to stabilise the machine when the backhoe is employed.

4.9 The netting operation of the skip wagons should be carried out prior to lifting the skip to reduce the risks of working on the rear platform

32.4.10 If a tractor dozer is employed on clearing scrub or felling trees, it shall be provided with adequate driver protection.

32.4.11 When two or more scrapers are working on the same job, a minimum distance of at least 25m shall be kept between them.

4.12 In case of hydraulic breakers, hydraulic rams and hoses shall be in good working condition

4.13 While excavating care shall be taken against falling boulders, caving-in, etc., to avoid damage to men, equipment and materials. This precaution is all the more important while working close to existing railway tracks/ roads.

4.14 All wood working machines shall be fitted with suitable guards and devices such as top guard, riving knife, push stick, guards for drive belts and chains, and emergency stop switch easily accessible by the operator.

Contractor shall arrange to provide necessary training to their supervisors and staff including lookout man / flagman etc. for safety requirements as per IRPWM for working near IR tracks. Such training can be arranged at ZEC / DTC or any other authorized institute of Indian Railways. Employer shall assist the Contractor in organizing such training and all the charges for such training shall be borne by the Contractor. The Contractor shall ensure that the safety norms are followed for working in the premises of IR and in the vicinity of running tracks and electrified territories (ii) Inform the Engineer / Employer about : (a) Name and address of the Contractor’s supplier / sub-contractor assigned to execute the work

(b) Name of the vehicle drivers / equipment operators identified for the work

(c) Location, duration and timings during which the SOD of IR is to be infringed (iii) Provide the Engineer / Employer with (a) copy of detailed planning of work including protection of IR track and safety measures proposed (duly consented by the Engineer and approved by the Employer)

(b) copy of the competency certificate of the Contractor’s Supervisor incharge of the work (to be issued by the Engineer) (iv) Demarcate the working area at site in consultation with the Engineer / Employer

(v) Barricade / temporary fencing along the stretch of the concentration of the work area along the IR track, as consented by the Engineer

(vi) Provide adequate watch and ward, flagmen, lighting etc. including signage boards

Measures during execution of Work (i) It shall be ensured that no workmen and staff is working on line / trackside unless proper ‘Permit to Work’ shall be issued for those lines by the Indian Railways and Engineer.

(ii) It shall be ensured that the moving dimensions of IR shall not be infringed. In case of track crossing, the work is required, the same shall not be carried out without permission from the Engineer and IR. Safety of all the existing fixed structures near the vicinity of the Site shall also be ensured.

(iii) No vehicles shall be plied within 6m of the centre of the IR track without the specific approval from Engineer / Employer. Individual vehicle / construction equipment shall not be left un-attended. No vehicle shall ply from sun-set to sunrise and during the period when the visibility is impaired, except in case of emergency and with the consent of the Engineer

(iv) Where the construction vehicles are required to ply along the existing running tracks of IR, the Contractor shall deploy the adequate patrolmen to prevent tendency of the vehicle drivers to come close to the tracks and infringe

(v) All the drivers of the road vehicles / machines plying near the running tracks of IR shall be provided with a red flag / red lamp so that in the event of any obstruction, they shall stop the incoming train,

(vi) It shall be ensured that the line of demarcation shall not be infringed by the road vehicles / construction equipment

(vii) It shall be ensured that only eligible and competent staff shall be employed for the work and they must wear identity card while working near running tracks of IR

(viii) For working during night, sufficient illumination shall be provided for the entire work area for safety of the workmen and public

(ix) Temporary Engineering signals as required shall be provided

(x) Existing engineering indicator boards shall be lit as per Permanent Way Manual (PWM) of Indian Railways.

(xi) Lookout man with red and green flags / hand signals and whistle shall be deployed wherever required.

(xii) No part of the stacked material shall infringe the moving dimensions of IR. Material shall be stacked to such a height that it does not lead to infringement of SOD in case of accidental toll off.

(xiii) Any temporary arrangement shall not infringe with the moving dimensions of IR.

(xiv) Where the work is planned to be done within 3.5m from the centre of the IR tracks, it shall require traffic block and all the necessary safety precautions shall be ensured as per the requirements of Para No. 806 and 807 of PWM of Indian Railways.

(xv) First aid kit shall be readily available at the site .

(xvi) In case any cable / utility is found while working, the Contractor shall inform the Engineer immediately. In case a large number of cables / utilities are found during excavation, the work shall be carried out in the presence of representative from the concerned owning agency of the utility / cable.

(xvii) It shall be ensured that the existing emergency sockets of IR are not damaged.

Clearing & Grubbing

Clearing & Grubbing should be performed at full formation width plus 1 m.The clearing and grubbing shall consist of cutting, removing, disposing and clearing the designated areas of all the obstructions like trees having girth 300mm or less, bushes, shrubs, roots, grass, weeds, snags, vegetation, loose and deleterious / organic material, pavement materials & signages / markers (if any), top organic soil not exceeding 150 mm in thickness, rubbish and objectionable material etc., which in the opinion of the Engineer are unsuitable for incorporation in the works and shall include grubbing stumps and roots and disposing of all material resulting from the clearing and / or grubbing from the Right of Way containing embankment, drains, structures etc. and such other areas as may be specified by the Engineer

Contractor shall be responsible for filling up of the all the existing dry / abandoned wells, low lying areas, local depressions, drains etc. within the Permanent Works area at no extra cost to the Employer

Holes / pots left after removal of vegetation, trees, roots, and stumps shall be backfilled with acceptable materials and compacted to the density prescribed for layers at the depths concerned below subgrade At end of Work the entire right of way areas shall be left with an orderly and neat appearance.

Do’s Don’t

Cutting

All excavations for the railway formation in cutting shall be performed as specified herein and in a manner consented by the Engineer, and the complete earthwork shall conform to the required alignment, levels, grades, and cross-sections