Indian Oil Corporation Limited Tender

"Fixing cladding with new/ old aluminium/ GI sheets, plain or corrugated. The job includes cutting, bending and grooving to proper s hape and size, providing minimum 50mm overlaps on both longitudinal and circumferential joints including end termination/cap and securing the overlaps alternately by POP rivets and self-tapping screws at every 150mm c/c, and securing additionally with metalic bands at a maximum spacing of 300mm c/c at any height and location with all labour, materials etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. (Payment of above shall be made on the area of the finished surface). Note: 1. Screw, required for metal jacket securement shall be SS /Cadmium plated steel self tapping , type A No.8 Dia*12mm long to BS 4176 complete with Neoprene washers under the head. Rivets required for metal jacket securement shall be the expanding aluminium ""POP"" blind eye type/SS, 9.5mm long* 5mm dia. 2. For additional securement of cladding, Band, SS 12mm (Min.) wide *24SWG thick is to be used for pipings and Band, SS 20mm wide *24SWG thick is to be used for equpiments. 3.For ensuring perfect water proofing, all the cladding joints shall be sealed with approved elastomeric metal sealant. 4. For insulations with vapour barrier, cladding shall not be applied until the vapour barrier has completely dried and solvents have dissipated. Self tapping screws/ rivets shall not be used to secure aluminium cladding as they may puncture the vapour barrier."

New / old aluminium / GI plain / corrugated sheets issue by the owner free of cost.

Aluminum sheet - Plain - 22 SWG as per ASTM B209 Alloy 3003 H16 or IS-737 Designation 31000, Condition H3 - to be arranged by contractor

Aluminium sheet - Corrugated - 22 SWG as per IS-737, Designation 31500/51300, Condition H4 - to be arranged by contractor

Providing and fixing single/ multiple layer of machine stitched LRB mineral wool mattresses conforming to IS:8183/ASTM C 592, Class-II, faced on one side with 20mm galvanised 22 SWG wire mesh, suitable for temperature up to 550 Deg C, in required thickness over the pipings and technological equipments like columns, vessels, ducts, horton spheres, storage tanks etc., including cleaning of the surface with wire brush, fixing the insulation mattresses in position and securing the same properly etc. all complete with tools, tackles, materials such as lacing, binding, stitching wire, labour etc. complete in accordance with the specifications laid down in the contract, latest IS standards and as per the directions of Engineer-in-Charge; but excluding the cost of scaffolding. "Note: 1. Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's test certificate in support of characteristics of insulation materials i.e. 'K' value, density etc. 2. The joints of fibrous insulation material shall be tightly butted and laced together with 1mm dia galvanised lacing wire. 3. Insulation thickness more than 75mm shall be in multi layers. 4. Each layer of the piping insulation shall be secured firmly in place with atleast 3 loops of 24SWG thick x 12mm wide SS bands, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. 5. Shells of equipments shall be secured by 24SWG thick x 20mm wide SS bands at every 225mm c/c 6.The item includes disposal of the debris to the directed place within 2km lead as per the direction of Engineer-in-Charge. "

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness- 25mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness - 50mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness - 75mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness- 100 mm

Providing and filling loose mineral wool with wire net, if required, and packing it properly in equipments etc complete with all labour and materials as per the direction of Engineer-in-Charge.

Tying, wrapping of ceramic fibre ropes for hot insulation of pipes, valves, flanges, tubes, instruments, gauge glasses etc. including taking out worn out insulation, if necessary, complete with all labour and materials except cost of scaffolding: Ceramic fibre ropes to be issued free of charge from the owner's stores. (Payment shall be made on the basis of length of the rope wrapped).

Rope size more than 19mm upto 25mm

Providing, tying and wrapping ceramic fibre braided rope (1260 Deg C Grade) made from ceramic fibre and braided with SS 304 wire (An additional wire is provided at center for reinforcement) for hot insulation of pipes ,valves, flanges, tubes, instruments, gauge glasses etc. including taking out worn out insulation, if necessary etc. complete with all labour and materials but excluding the cost of scaffolding. (Payment shall be made on the basis of length of the rope wrapped).

Rope size -12mm

Rope size -25mm

Supply and fixing in position of 25mm thick ceramic fibre rope braided with SS 304 wire (An additional wire is provided at center for reinforcement) of approved make suitable upto 1425 Deg C for insulation of instrument impulse piping including cleaning and removal of dust, rust, grease etc. from the piping surface, wrapping the ceramic fibre rope around the piping so as to cover the piping completely without leaving any gap. The item also includes provision of waterproofing over the ceramic fibre rope as per the following: A 3mm wet thickness layer of Insulkote or equivalent shall be applied over the ceramic rope. When the coating is still wet, a 7mil thick glass cloth (suitable for temperature up to 500 Deg C) is to be wrapped over the Insulkote with proper overlap. After 12 hours, a second layer of Insulkote or equivalent coating of wet thickness 3mm is to be applied over the glass fibre cloth. The final dry thickness of the water proofing shall not be less than 2.5mm. The item includes carrying out all the jobs as per the direction of the Engineer-in-Charge including all material, tools, tackles and labour etc. complete. (The payment shall be made per metre length of instrument impulse piping covered with insulation).

Providing all necessary materials and carrying out cold insulation works with Polyurethane foam (PUF) as per the following specifications on pipings and equipments like columns, vessels, exchagers, ducts etc., at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding: 1) A coat of approved bituminous paint (IS:158/69) shall be applied on the metal surface after through cleaning. 2) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on the painted surface for fixing Polyurathene foam (PUF) blocks and preformed pipe section of density 36 kg/cum conforming to ASTM C591, Type II, Grade-2 without gaps in between the required size and shape, tightening them by tying each layer with bands. 3).Each layer of the PUF insulation for pipes shall be secured firmly in place with atleast 3 loops of 24SWG thick x 20mm wide Aluminum bands, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. However, spacing of bands shall not exceed 225mm. 4). PUF Insulation for Shells of equipments shall be secured by 24SWG thick x 20mm wide Aluminum bands at every 225mm c/c. 5) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on each layer, surface and joint of PUF insulation and sections. 6) Encircle the last layer of PUF Insulation with wire netting of 24 SWG x 20mm GI. Stitching of wire net to be done with 22 SWG GI wire and 24SWG thick x 20mm wide aluminum band @ 225mm c/c to be provided over wire net for securement. 7) For vapour barrier, a 3.0 mm (wet) thick coating of bitumen emulsion or vapour seal mastic shall be applied to the surface of the insulation as soon as possible. Whilst this coat is still wet, glass cloth (7 mil thick and suitable for temperature up to 550 Deg C) shall be laid over the surface and embedded in the mastic. Care shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of air are trapped beneath the surface. At junctions in the glass cloth the overlap shall not be less than 75 mm. A second 3 mm thick coat of bitumen emulsion or vapour seal mastic shall be applied after approximately twelve hours. When dry this coating shall be a minimum of 1.5 mm thick. The total dry film thickness of vapour seal shall not be less than 2.5 mm with a tolerance of -0% to +50%. During this drying time the insulation shall be protected from the weather by “Alkathene” film, tarpaulin or similar materials approved by the Engineer-in- Charge. Vapour barrier shall be protected by cladding with aluminium sheets. Aluminium cladding (to be paid under separate item) shall not be applied until the vapour barrier has completely dried and its solvents have dissipated. Note: a. Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's test certificate in support of characteristics of insulation materials i.e. 'K' value, density etc. b.The item includes disposal of the debris to the directed place within 2km lead as per the direction of Engineer-in-Charge.

25mm thick with PUF blocks on any surface

50mm thick with PUF blocks on any surface

100mm thick with PUF blocks on any surface

Cleaning the surface thoroughly, providing all materials such as calcium silicate slabs/ curved segments/bevelled legs, wire mesh (3/4" x 24 swg), binding wires, aluminium bands, weather proofing compound and tying wire etc. and carrying out insulation works as per the following specifications on pipelines at any height including the cost of all materials, tools, tackles, labour etc. complete as per direction of the Engineer-in-Charge but excluding the cost of scaffolding. a) The surface shall be cleaned thoroughly using wire brush etc. and wiping it clean so that the surface is dry, free from dust, rust, grease and scales. b) Calcium silicate insulation in the form of half round pipe sections/curved segments/bevelled legs shall be fixed on the clean surface. For insulation thickness upto 75mm, only half round pipe sections shall be used for pipes of diameter upto 300mm. For diameters more than 300mm curved segments/ bevelled legs shall be used. c) Each layer of the insulation material shall be secured firmly in place with atleast 3 loops of 18 SWG SS binding wires, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. For long lasting securement, 20mm wide alluminium band of 24 SWG shall be provided at a pitch of max. 450mm. The wire should be tightened by twisting and the ends of wire to be pressed on to the insulation material. d) Any unavoidable installation gaps shall be filled up with clacium silicate powder paste. e) For single layer of insulation, circumferential joints shall be staggered. f) Insulation of flanges, valves and bends etc. shall be done using preformed insulation as far as practicable. g) For bends, pipe-coverings shall be cut as per the bend radius at site. Any unavoidable gaps shall be sealed by calcium silicate powder paste. Chicken wire-mesh shall be used as additional securement for insulation over bends, in place of aluminium bands. h) Expansion joints of 25mm shall be provided at suitable intervals as per the following guidelines:- Temp. (Deg. C.) Spacing Interval (mtr) Upto 300 5.0 From 300 up to 400 4.0 Above 400 2.7 i) Expansion joints shall be tightly packed with fibrous insulation. j) Applying 3mm thick Shalicoat / Insulcoat or equivalent weather proofing compound over the insulated surface. k) Approved protective finish like cement-sand plaster / sheet metal clading shall be provided over the insulated surface for which payment shall be made under a separate item. Note: 1. Contractor has to make his own arrangement for procurement and storage of all the material. 2. The item includes disposal of the debris to the directed place within 3 km. lead as per the direction of the Engineer-in-Charge. 3. The measurements shall be done as per the IS 14164: 1994.

Thickness of insulation - 25mm

Thickness of insulation - 50mm

Thickness of insulation - 75mm

Providing and fixing Insulation of Valves with ceramic fibre pad, Grade 1260 Deg C, Density 128 KG/M3 conforming to IS-15402-03/ASTM C-892, Type-III, Grade-8 on pipelines including securing with suitable cladding materials etc.at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. Ceramic blanket shall be encased in oil and water resistant silica cloth for Temperature Resistance upto 900 deg.C. and stitched with SS wire at the edges using 7-10 stitches per 25mm. The prefabricated pads shall be tailor-made to the size of Valve and Flange and manufactured at the factory with suitable SS hooks for lifting. Cladding, if required to be done shall be paid in separate item.

3" size - 25 mm thick pad

3" size - 50 mm thick pad

Providing & Fixing Insulation of equipments with prefabricated rockwool panels including providing 0.5mm thick SS Sheet cladding, rockwool boards/slabs having a density of 100 kg/m3, one side faced with 0.1mm SS foil for insulation thicknesses as stated below including providing 22g x 1/2" SS wire netting on all sides of the equipment at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in- Charge but excluding the cost of scaffolding. Note: 1.Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's certificate in support of characteristics of insulation materials i.e. 'K' value, density etc 2.The item includes disposal of the debris to the directed place within 2km. lead as per the direction of Engineer-in-Charge. 3.The measurements shall be done as per the IS 14164:1994

50mm thick

Providing & fixing 0.1mm thick Aluminium Foil over the technological equipments like columns, vessels, ducts, horton spheres and pipelines etc all complete with tools & tackles, materials such as lacing, binding, labour etc complete in accordance with the specification laid down in the contract and in latest IS standard as per directions of Engineer-in-Charge/ drawings issued. Overlap of the foils shall not be less than 50mm on any side and the foil should be bound securedly using binding wire of 24 SWG at pitch not more than 450 c/c. Contractor has to make arrangement of all materials required. Measurement shall be done on the finished surface. Note: 1.Contractor has to make his own arrangement for procurement and storage of all materials. 2.The item includes disposal of debris to the directed place within 2 Km lead as per direction of Engineer-in-Charge.

Providing and fixing 0.1mm thick SS-304 foil over the SS or AS pipelines or equipments prior to application of the LRB mattress/ ceramic fibre mattress for insulation as per direction of Engineer- in-Charge. Overlap of the foils shall not be less than 50mm on any side and the foil should be bound securedly using SS-304 binding wire of 24 SWG at pitch not more than 450 c/c and the lap joints shall be interposed with barrium chromate primer. The item includes the cost of all materials, labour, tools and tackles, consumables etc. complete. Measurement shall be made on the area of the finished surface.

Providing Vapour barrier over Insulations on piping and technological equipments like columns, vessels, ducts, horton spheres etc all complete with all tools & tackles, materials including lacing, binding, labour etc complete as per the direction of Engineer-In-Charge and as per the following to prevent ingress of moisture : i) Applying Ist coat of vapour seal mastic like Shalikote T-12, Llyod Mastic, Bitumen Emulsion or equivalent material with a wet thickness of 3mm over the insulation material. ii) Fixing 7 mil thick Glass Cloth suitable for temperature up to 550 Deg C over the mastic coating while the mastic is still wet. Minimim 75mm overlap shall be provided at all the edges and joints of the glass cloth. iii) Applying 2nd coat of Vapour seal mastic like Shalikote T-12, Llyod Mastic, bitumen emulsion or equivalent material with a wet thickness of 3mm over the glass cloth. The second layer of the mastic coating shall be applied after 12 hours of application of the Ist Coat and glass cloth. The total thickness of the vapour barrier shall not be less than 2.5mm when dry. Vapour barrier shall be protected by cladding material. Cladding (to be paid under separate item) shall not be applied until the vapour barrier has completely dried. Only Bands shall be used for securing the cladding over vapour barrier (Screws/ rivets shall not be used to prevent rupture of vapour barrier). Measurement shall be done on the finished surface as per relevant IS codes. Note- Contractor has to make his own arrangement for procurement and storage of all materials.

STEEL SCAFFLODING (MATERIALS IN CONTRACTOR'S SCOPE) The job includes supply of all scaffolding materials, transportation to work site, erection of scaffolding at site as per ISMS (IndianOil Safety Management System) Standard-1007 on Scaffold Safety with safest and reliable design. Scaffolding design should consider the worst load combination expected during its service period. The supporting structure should be sufficient in strength, stability, and rigidity; The safety of personnel associated with the erection, alteration, and dismantling of the scaffold; the safety of persons using the scaffold; and the safety of persons in the vicinity of the scaffold to be considered mandatorily. Standard Tags for "Fit for Use" in Green Color and "Not Fit for Use" in Red Color to be fitted on scaffolding as per ISMS Standard-1007. Note: 1. For measurement in SQM: 2 (length + width) X height area covered by the scaffolding is to be taken. 2. Scaffolding measurement to be done by breaking the height into parts as per height slab mentioned below and adopting respective rates against mentioned height slabs.

Upto 6 M

Above 6 m upto 10 m

Above 10 m upto 20 m

Intermediate plate form

PF, EDLI and ESI charges on employer contribution limited to sum of (1.87% of total executed value under Civil SOR-2023 items i.e., It.No.10 to 340) and (1.99% of total executed value under Mech. SOR-2024 items i.e., It.No.350 to 390). This is an Reimburseable Amount, which shall be certified based on submission of necessary documentary proof.

Part-B: Shutdown Insulation Jobs (40%)

Taking out old worn out damaged insulation materials of any thickness including wool, mattress, pre-formed sections or any other insulating materials including cladding of aluminium or GI sheet from any height and location etc. complete and transporting and stacking the serviceable materials to owner's storage point and damaged materials within 2.00 km lead inside Refinery .The job also includes cleaning the site, transporting the materials to directed place at any height, complete with all labour and materials etc. as per specification and direction of Engineer-In-Charge but excluding the cost of scaffolding. (Payment shall be made on the previously finished surface area).

Taking out old worn out damaged cladding of any thickness (plain or corrugated; GI or Aluminium sheet) from any height and location and transporting and stacking the serviceable materials to owner's storage point and damaged materials to the directed place within refinery premises within 2.00 km lead. The job also includes cleaning the site, transporting the materials to directed place, complete with all labor and materials etc.as per direction of Engineer-in-Charge but excluding the cost of scaffolding. (Payment shall be made on the previously finished surface area).

"Fixing cladding with new/ old aluminium/ GI sheets, plain or corrugated. The job includes cutting, bending and grooving to proper s hape and size, providing minimum 50mm overlaps on both longitudinal and circumferential joints including end termination/cap and securing the overlaps alternately by POP rivets and self-tapping screws at every 150mm c/c, and securing additionally with metalic bands at a maximum spacing of 300mm c/c at any height and location with all labour, materials etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. (Payment of above shall be made on the area of the finished surface). Note: 1. Screw, required for metal jacket securement shall be SS /Cadmium plated steel self tapping , type A No.8 Dia*12mm long to BS 4176 complete with Neoprene washers under the head. Rivets required for metal jacket securement shall be the expanding aluminium ""POP"" blind eye type/SS, 9.5mm long* 5mm dia. 2. For additional securement of cladding, Band, SS 12mm (Min.) wide *24SWG thick is to be used for pipings and Band, SS 20mm wide *24SWG thick is to be used for equpiments. 3.For ensuring perfect water proofing, all the cladding joints shall be sealed with approved elastomeric metal sealant. 4. For insulations with vapour barrier, cladding shall not be applied until the vapour barrier has completely dried and solvents have dissipated. Self tapping screws/ rivets shall not be used to secure aluminium cladding as they may puncture the vapour barrier."

New / old aluminium / GI plain / corrugated sheets issue by the owner free of cost.

Aluminum sheet - Plain - 22 SWG as per ASTM B209 Alloy 3003 H16 or IS-737 Designation 31000, Condition H3 - to be arranged by contractor

Aluminium sheet - Corrugated - 22 SWG as per IS-737, Designation 31500/51300, Condition H4 - to be arranged by contractor

Providing and fixing single/ multiple layer of machine stitched LRB mineral wool mattresses conforming to IS:8183/ASTM C 592, Class-II, faced on one side with 20mm galvanised 22 SWG wire mesh, suitable for temperature up to 550 Deg C, in required thickness over the pipings and technological equipments like columns, vessels, ducts, horton spheres, storage tanks etc., including cleaning of the surface with wire brush, fixing the insulation mattresses in position and securing the same properly etc. all complete with tools, tackles, materials such as lacing, binding, stitching wire, labour etc. complete in accordance with the specifications laid down in the contract, latest IS standards and as per the directions of Engineer-in-Charge; but excluding the cost of scaffolding. "Note: 1. Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's test certificate in support of characteristics of insulation materials i.e. 'K' value, density etc. 2. The joints of fibrous insulation material shall be tightly butted and laced together with 1mm dia galvanised lacing wire. 3. Insulation thickness more than 75mm shall be in multi layers. 4. Each layer of the piping insulation shall be secured firmly in place with atleast 3 loops of 24SWG thick x 12mm wide SS bands, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. 5. Shells of equipments shall be secured by 24SWG thick x 20mm wide SS bands at every 225mm c/c 6.The item includes disposal of the debris to the directed place within 2km lead as per the direction of Engineer-in-Charge. "

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness- 25mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness - 50mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness - 75mm

LRB Mattress of density 150 Kg/cum - Water repellent Grade -Thickness- 100 mm

Providing and filling loose mineral wool with wire net, if required, and packing it properly in equipments etc complete with all labour and materials as per the direction of Engineer-in-Charge.

Tying, wrapping of ceramic fibre ropes for hot insulation of pipes, valves, flanges, tubes, instruments, gauge glasses etc. including taking out worn out insulation, if necessary, complete with all labour and materials except cost of scaffolding: Ceramic fibre ropes to be issued free of charge from the owner's stores. (Payment shall be made on the basis of length of the rope wrapped).

Rope size more than 19mm upto 25mm

Providing, tying and wrapping ceramic fibre braided rope (1260 Deg C Grade) made from ceramic fibre and braided with SS 304 wire (An additional wire is provided at center for reinforcement) for hot insulation of pipes ,valves, flanges, tubes, instruments, gauge glasses etc. including taking out worn out insulation, if necessary etc. complete with all labour and materials but excluding the cost of scaffolding. (Payment shall be made on the basis of length of the rope wrapped).

Rope size -12mm

Rope size -25mm

Supply and fixing in position of 25mm thick ceramic fibre rope braided with SS 304 wire (An additional wire is provided at center for reinforcement) of approved make suitable upto 1425 Deg C for insulation of instrument impulse piping including cleaning and removal of dust, rust, grease etc. from the piping surface, wrapping the ceramic fibre rope around the piping so as to cover the piping completely without leaving any gap. The item also includes provision of waterproofing over the ceramic fibre rope as per the following: A 3mm wet thickness layer of Insulkote or equivalent shall be applied over the ceramic rope. When the coating is still wet, a 7mil thick glass cloth (suitable for temperature up to 500 Deg C) is to be wrapped over the Insulkote with proper overlap. After 12 hours, a second layer of Insulkote or equivalent coating of wet thickness 3mm is to be applied over the glass fibre cloth. The final dry thickness of the water proofing shall not be less than 2.5mm. The item includes carrying out all the jobs as per the direction of the Engineer-in-Charge including all material, tools, tackles and labour etc. complete. (The payment shall be made per metre length of instrument impulse piping covered with insulation).

Providing all necessary materials and carrying out cold insulation works with Polyurethane foam (PUF) as per the following specifications on pipings and equipments like columns, vessels, exchagers, ducts etc., at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding: 1) A coat of approved bituminous paint (IS:158/69) shall be applied on the metal surface after through cleaning. 2) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on the painted surface for fixing Polyurathene foam (PUF) blocks and preformed pipe section of density 36 kg/cum conforming to ASTM C591, Type II, Grade-2 without gaps in between the required size and shape, tightening them by tying each layer with bands. 3).Each layer of the PUF insulation for pipes shall be secured firmly in place with atleast 3 loops of 24SWG thick x 20mm wide Aluminum bands, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. However, spacing of bands shall not exceed 225mm. 4). PUF Insulation for Shells of equipments shall be secured by 24SWG thick x 20mm wide Aluminum bands at every 225mm c/c. 5) A coat of hot bitumen of 85/25 grade conforming to IS:702 to be applied on each layer, surface and joint of PUF insulation and sections. 6) Encircle the last layer of PUF Insulation with wire netting of 24 SWG x 20mm GI. Stitching of wire net to be done with 22 SWG GI wire and 24SWG thick x 20mm wide aluminum band @ 225mm c/c to be provided over wire net for securement. 7) For vapour barrier, a 3.0 mm (wet) thick coating of bitumen emulsion or vapour seal mastic shall be applied to the surface of the insulation as soon as possible. Whilst this coat is still wet, glass cloth (7 mil thick and suitable for temperature up to 550 Deg C) shall be laid over the surface and embedded in the mastic. Care shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of air are trapped beneath the surface. At junctions in the glass cloth the overlap shall not be less than 75 mm. A second 3 mm thick coat of bitumen emulsion or vapour seal mastic shall be applied after approximately twelve hours. When dry this coating shall be a minimum of 1.5 mm thick. The total dry film thickness of vapour seal shall not be less than 2.5 mm with a tolerance of -0% to +50%. During this drying time the insulation shall be protected from the weather by “Alkathene” film, tarpaulin or similar materials approved by the Engineer-in- Charge. Vapour barrier shall be protected by cladding with aluminium sheets. Aluminium cladding (to be paid under separate item) shall not be applied until the vapour barrier has completely dried and its solvents have dissipated. Note: a. Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's test certificate in support of characteristics of insulation materials i.e. 'K' value, density etc. b.The item includes disposal of the debris to the directed place within 2km lead as per the direction of Engineer-in-Charge.

25mm thick with PUF blocks on any surface

50mm thick with PUF blocks on any surface

100mm thick with PUF blocks on any surface

Cleaning the surface thoroughly, providing all materials such as calcium silicate slabs/ curved segments/bevelled legs, wire mesh (3/4" x 24 swg), binding wires, aluminium bands, weather proofing compound and tying wire etc. and carrying out insulation works as per the following specifications on pipelines at any height including the cost of all materials, tools, tackles, labour etc. complete as per direction of the Engineer-in-Charge but excluding the cost of scaffolding. a) The surface shall be cleaned thoroughly using wire brush etc. and wiping it clean so that the surface is dry, free from dust, rust, grease and scales. b) Calcium silicate insulation in the form of half round pipe sections/curved segments/bevelled legs shall be fixed on the clean surface. For insulation thickness upto 75mm, only half round pipe sections shall be used for pipes of diameter upto 300mm. For diameters more than 300mm curved segments/ bevelled legs shall be used. c) Each layer of the insulation material shall be secured firmly in place with atleast 3 loops of 18 SWG SS binding wires, one loop to be placed not more than 75mm from each end and atleast one loop shall be equally spaced betweeen two end loops. For long lasting securement, 20mm wide alluminium band of 24 SWG shall be provided at a pitch of max. 450mm. The wire should be tightened by twisting and the ends of wire to be pressed on to the insulation material. d) Any unavoidable installation gaps shall be filled up with clacium silicate powder paste. e) For single layer of insulation, circumferential joints shall be staggered. f) Insulation of flanges, valves and bends etc. shall be done using preformed insulation as far as practicable. g) For bends, pipe-coverings shall be cut as per the bend radius at site. Any unavoidable gaps shall be sealed by calcium silicate powder paste. Chicken wire-mesh shall be used as additional securement for insulation over bends, in place of aluminium bands. h) Expansion joints of 25mm shall be provided at suitable intervals as per the following guidelines:- Temp. (Deg. C.) Spacing Interval (mtr) Upto 300 5.0 From 300 up to 400 4.0 Above 400 2.7 i) Expansion joints shall be tightly packed with fibrous insulation. j) Applying 3mm thick Shalicoat / Insulcoat or equivalent weather proofing compound over the insulated surface. k) Approved protective finish like cement-sand plaster / sheet metal clading shall be provided over the insulated surface for which payment shall be made under a separate item. Note: 1. Contractor has to make his own arrangement for procurement and storage of all the material. 2. The item includes disposal of the debris to the directed place within 3 km. lead as per the direction of the Engineer-in-Charge. 3. The measurements shall be done as per the IS 14164: 1994.

Thickness of insulation - 25mm

Thickness of insulation - 50mm

Thickness of insulation - 75mm

Providing and fixing Insulation of Valves with ceramic fibre pad, Grade 1260 Deg C, Density 128 KG/M3 conforming to IS-15402-03/ASTM C-892, Type-III, Grade-8 on pipelines including securing with suitable cladding materials etc.at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in-Charge but excluding the cost of scaffolding. Ceramic blanket shall be encased in oil and water resistant silica cloth for Temperature Resistance upto 900 deg.C. and stitched with SS wire at the edges using 7-10 stitches per 25mm. The prefabricated pads shall be tailor-made to the size of Valve and Flange and manufactured at the factory with suitable SS hooks for lifting. Cladding, if required to be done shall be paid in separate item.

3" size - 25 mm thick pad

3" size - 50 mm thick pad

Providing & Fixing Insulation of equipments with prefabricated rockwool panels including providing 0.5mm thick SS Sheet cladding, rockwool boards/slabs having a density of 100 kg/m3, one side faced with 0.1mm SS foil for insulation thicknesses as stated below including providing 22g x 1/2" SS wire netting on all sides of the equipment at any height including the cost of all materials, tools and tackles, labour etc. complete as per direction of Engineer-in- Charge but excluding the cost of scaffolding. Note: 1.Contractor has to make his own arrangement for procurement and storage of all the materials and has to produce manufacturer's certificate in support of characteristics of insulation materials i.e. 'K' value, density etc 2.The item includes disposal of the debris to the directed place within 2km. lead as per the direction of Engineer-in-Charge. 3.The measurements shall be done as per the IS 14164:1994

50mm thick

Providing & fixing 0.1mm thick Aluminium Foil over the technological equipments like columns, vessels, ducts, horton spheres and pipelines etc all complete with tools & tackles, materials such as lacing, binding, labour etc complete in accordance with the specification laid down in the contract and in latest IS standard as per directions of Engineer-in-Charge/ drawings issued. Overlap of the foils shall not be less than 50mm on any side and the foil should be bound securedly using binding wire of 24 SWG at pitch not more than 450 c/c. Contractor has to make arrangement of all materials required. Measurement shall be done on the finished surface. Note: 1.Contractor has to make his own arrangement for procurement and storage of all materials. 2.The item includes disposal of debris to the directed place within 2 Km lead as per direction of Engineer-in-Charge.

Providing and fixing 0.1mm thick SS-304 foil over the SS or AS pipelines or equipments prior to application of the LRB mattress/ ceramic fibre mattress for insulation as per direction of Engineer- in-Charge. Overlap of the foils shall not be less than 50mm on any side and the foil should be bound securedly using SS-304 binding wire of 24 SWG at pitch not more than 450 c/c and the lap joints shall be interposed with barrium chromate primer. The item includes the cost of all materials, labour, tools and tackles, consumables etc. complete. Measurement shall be made on the area of the finished surface.

Providing Vapour barrier over Insulations on piping and technological equipments like columns, vessels, ducts, horton spheres etc all complete with all tools & tackles, materials including lacing, binding, labour etc complete as per the direction of Engineer-In-Charge and as per the following to prevent ingress of moisture : i) Applying Ist coat of vapour seal mastic like Shalikote T-12, Llyod Mastic, Bitumen Emulsion or equivalent material with a wet thickness of 3mm over the insulation material. ii) Fixing 7 mil thick Glass Cloth suitable for temperature up to 550 Deg C over the mastic coating while the mastic is still wet. Minimim 75mm overlap shall be provided at all the edges and joints of the glass cloth. iii) Applying 2nd coat of Vapour seal mastic like Shalikote T-12, Llyod Mastic, bitumen emulsion or equivalent material with a wet thickness of 3mm over the glass cloth. The second layer of the mastic coating shall be applied after 12 hours of application of the Ist Coat and glass cloth. The total thickness of the vapour barrier shall not be less than 2.5mm when dry. Vapour barrier shall be protected by cladding material. Cladding (to be paid under separate item) shall not be applied until the vapour barrier has completely dried. Only Bands shall be used for securing the cladding over vapour barrier (Screws/ rivets shall not be used to prevent rupture of vapour barrier). Measurement shall be done on the finished surface as per relevant IS codes. Note- Contractor has to make his own arrangement for procurement and storage of all materials.

STEEL SCAFFLODING (MATERIALS IN CONTRACTOR'S SCOPE) The job includes supply of all scaffolding materials, transportation to work site, erection of scaffolding at site as per ISMS (IndianOil Safety Management System) Standard-1007 on Scaffold Safety with safest and reliable design. Scaffolding design should consider the worst load combination expected during its service period. The supporting structure should be sufficient in strength, stability, and rigidity; The safety of personnel associated with the erection, alteration, and dismantling of the scaffold; the safety of persons using the scaffold; and the safety of persons in the vicinity of the scaffold to be considered mandatorily. Standard Tags for "Fit for Use" in Green Color and "Not Fit for Use" in Red Color to be fitted on scaffolding as per ISMS Standard-1007. Note: 1. For measurement in SQM: 2 (length + width) X height area covered by the scaffolding is to be taken. 2. Scaffolding measurement to be done by breaking the height into parts as per height slab mentioned below and adopting respective rates against mentioned height slabs.

Upto 6 M

Above 6 m upto 10 m

Above 10 m upto 20 m

Intermediate plate form

PF, EDLI and ESI charges on employer contribution limited to sum of (1.87% of total executed value under Civil SOR-2023 items i.e., It.No.10 to 340) and (1.99% of total executed value under Mech. SOR-2024 items i.e., It.No.350 to 390). This is an Reimburseable Amount, which shall be certified based on submission of necessary documentary proof.