1.0 SCOPE:
The work covered under this specification consist of providing and fixing block flush door shutter in accordance with the specification and drawings.
2.0 APPLICABLE CODES & SPECIFICATIONS:
The relevant I.S. specifications, standards and codes given below are made a part of this specification. All standards, specifications, code of practices referred to herein shall be the latest edition including all applicable amendments, revisions and additional publications.
List of Indian Standards No. I.S. No. I.S. Particulars
1. I.S. 204 (Part – I) Specification for tower bolts (ferrous metal) 2. I.S. 204 (Part – II) Specification for tower bolt (non ferrous metal) 3. I.S. 208 Specification for door handles
4. I.S. 723 Specification for steel countersunk head wire nails.
5. I.S. 848 Specification for synthetic resign adhesives for plywood.
6. I.S. 1200
(Part – XXI) Method of measurement of building and civil engineering works. (Wood work and joinery) 7. I.S. 1341 Specification for steel butt hinges.
8. I.S. 1659 Specification for block boards. 9. I.S. 1708
(Part-1 to 18) Method of testing of small clear specimens of timber. 10. I.S. 1734
(Part-1 to 20) Method of test for plywood. 11. I.S. 2202
(Part-I &II) Specification for wooden flush door shutters. (Solid core type). 12. I.S. 2209
(Part – I) Specification for mortice lock of timber. 13. I.S. 3564 Specification for door closers.
14. I.S. 4992 Specification for door handles for mortice lock. 15. I.S. 6760 Specification for slotted counter sunk head wood
screws.
3.0 BLOCK BOARD FLUSH DOOR SHUTTER:
Flush door shutter shall have a solid core and may be of the decorative or non- decorative type conforming to I.S. 2202.
The thickness and type of shutter shall be as specified in item of schedule of quantities.
Width and height of shutter shall be as shown in the drawings or as directed by the Engineer-Incharge. All four edges of shutter shall be square.
The shutter shall be free from twist or wrap in it’s plane. The moisture content in timbers used in the manufacture of flush door shutters shall be not more than 12 percent when tested according to I.S. 1708.
The core of flush door shall be a block board having wooden strips held in a frame constructed of stiles and rails. Each stile and rail shall be a single piece without any joint. The width of the stiles and rails shall not be less than 75 mm and not more than 100 mm. The width of each wooden strip shall not exceed 25 mm. Stiles, rails and wooden strips forming the core of a shutter shall be of equal and uniform thickness. Wooden strips shall be parallel to the stiles.
End joints of the pieces of wooden strips of small lengths shall be staggered. In a shutter, stiles and rails shall be of one species of timber. Wooden strips shall also be one species only but it may or may not be the same species as that of the stiles and rails.
The face panel shall be formed by gluing by the hot-press process on both faces of the core either plywood or cross-bands and face veneers. The thickness of the cross bands as such or in the plywood shall be between 1.0 mm and 3.0 mm. The thickness of the face veneers as such or in the plywood shall between 0.5 mm and 1.5 mm for commercial veneer and between 0.5 and 1.0 mm for decorative veneers. The direction of the veneer adjacent to the core shall be at right angles to the direction of the wooden strips. Finished faces shall be sanded to smooth even texture.
Lipping where specified, shall be provided internally on all edges of the shutters. Lipping shall be done with battens of first class teakwood or as specified. Joints shall not be permitted in lippipng.
The shutters shall be single leaf or double leaves as shown in the drawings or as directed by the Engineer-In-charge. In case of double leaves shutters the meeting at stiles shall be rebated by one third the thickness of the shutter. The rebating shall be either splayed or square type.
Wherever specified the opening for glazing of size as shown in drawing or as directed shall be made in the shutter for vision panel and or louver. Opening for glazing shall be lipped internally with teakwood batten of specified size.
Tolerance on width and height shall be (+) 3 mm and on thickness it shall be (+) 1.2 mm. The thickness of the door shutter shall be uniform through out with a permissible variation of not more than 0.8 mm when measured at any two points. Adhesive used for bonding various components like core, core frame, lipping, cross bands, face veneers, plywood etc. of flush door shutters and for bonding plywood shall be phenol formaldehyde synthetic resin conforming to I.S. 848.
Samples of flush door shutters shall be subjected to following tests in accordance with I.S. 2202 (Part – I & II):
End immersion test. Knife test.
Glue adhesion test.
All the sample shutters when tested shall satisfy the requirements of the tests as laid down in I.S. 2202 (Part – I & II) if the number of samples found unsatisfactory or a test is two or more the entire lot shall be considered unsatisfactory.
Fittings shall be provided to the contractor free of cost by the Department as decided by Engineer-In-charge. Screws for fixing these fittings shall be provided by the contractor and nothing extra shall be paid for the same.
4.0 MODE OF MEASUREMENT:
Length and width of the shutter shall be measured to the nearest centimeter in closed position covering the rebates of the frames but excluding the gap between the shutters and the frame. Over laps of two shutters will not be measured.
All work shall be measured net as fixed and area calculated in square metre to nearest two places of decimal.
No deduction shall be made for providing openings for vision panel/ louvers.
Rate quoted for the items shall cover all the specifications described above and for the complete work as per item of work including all labour and materials.
The work of providing vision/ louver opening and making rebates in double shutter doors shall be measured and paid for under relevant item of schedule of quantities.
5.0 TEAK WOOD PANELLED SHUTTERS:
Teak wood door shutter shall generally conform to standard laid in I.S. 1002 or the latest revision for requirements of materials, construction workmanship and shall be of specified thickness and of 1st class C.P. teak wood or as specified of approved design with stiles, top, bottom and lock rail generally as per drawing. Wherever shown, each panel shall be in a single width piece, but when two or more pieces have to be used and are permitted, all of them shall be of equal width and shall be jointed with a tongue and groove joint with chamfered edges glued together and reinforced with metal dowels.
6.0 TEAK WOOD GLAZED SHUTTERS:
The specifications for teak wood panelled shutter shall generally apply to glazed shutters for frame, stiles etc.
The sash and beading required for glazing shall be of the best teak wood and shall be fixed as per the design shown in relevant drawing. Any mouldings, carvings shown shall be worked out from the teak wood member of bigger size.
7.0 GLAZING:
Glazing shall be generally with 4 mm. thick plain sheet glass/bajra glass unless otherwise mentioned in the schedule of quantities. The detailed specifications for glazing given hereafter shall be followed generally.
8.0 MISCELLANEOUS:
Wherever mentioned in the Schedule of quantities, vision panels, venetians, plastic laminates, push plates etc. shall be provided in all doors.
The vision panels shall be of size mentioned in the drawing and shall be provided with teak wood lipping alround the glass. The glass shall be 4 mm. thick or as specified of best quality (M/s. Triveni, I.A.G., Shree Vallabh or equivalent approved), free from defects.
Teak wood venetians or louvers shall generally conform to relevant specifications of timber. Necessary grooves and rebate in frames shall be provided as per drawing. Formica or approved equivalent plastic laminate of required design, required shade and colour shall be provided and fixed on flush door to the required size on any side of the shutter as shown in drawing. It shall be fixed with Fevicol or any other approved adhesive. Fixing shall be done in such a way that there shall not be any air gap, warpage or undulations on the surface. Finished surface of formica shall be cleaned with wax polish.
The shutters shall be painted on commercial facing side with two coats of synthetic/flat oil paint of approved shade and make over an approved coat of primer. The decorative veneer side of the shutter shall be wax or French polished with two or more coats so as to render a satisfactory surface.
The flush doors shall be single leaf or double leaf type as mentioned in the schedule of quantities. In case of double leaf shutters, the meeting of the stiles shall be rebated 20 mm. and shall be either splayed or square type and the T.W. lipping around the meeting shall not be less than 35 mm. deep. The meeting stiles shall be in single piece.
Sufficient care shall be taken to prevent any damage and loss of shape during handling, transporting, stacking, fixing etc. The door shutters shall be handled with utmost care to prevent any surface damage, warping etc.
9.0 MODE OF MEASUREMENT:
The work covered under the respective items in schedule and the above specifications shall be measured as follows:
The cubic contents for wood work shall be measured for the finished size, limiting to those shown in the drawings or ordered by the Engineer-in-charge. The cross sectional dimensions shall be measured equivalent to nearest enclosing rectangle (least rectangle/square) for wrought and planed sizes. The cubical content shall be worked out correct up to three places of decimals of a cubic metre. The frames embedded below finished floor shall not be measured.
The square meter areas for shutters shall be measured for the exposed surfaces of shutter between frames from inside or outside whichever is more. The linear dimensions shall be measured upto two places of decimals of a metre. The area for payment shall be worked out correct upto two places of decimals of a square metre. The rate for shutters shall include:
i) Cost of supply assembly and erecting in position.
ii) Cost of polishing, painting, supplying wood preservative, screws, nails, hold fasts etc.
iii) Cost of labour for making adjustments in frames, if required, shutters and also for fixing required fittings and fixtures.
iv) In case of flush doors, the rate for individual item mentioned in the schedule of quantities shall include cost of shutters, labour for provision of glass for vision panel, plastic laminate sheet push plate, teak wood louvers etc., transporting charges and labour for fixing of fixtures and fastenings except fixing of door closers and painting and polishing as specified.
SPECIFICATIONS FOR