A - ROAD WORKS

BASIC APPROACH AND GENERAL CONDITIONS FOR THE PREPARATION OF

STANDARD DATA BOOK
The basic approach for the preparation of Standard Data Book for Road works is indicated as under:
1. Description of Items:
The description of items is given briefly and linked with the relevant clause of the MORT&H
specifications for Roads and Bridge works (Fourth Revision), which may be referred for detailed
description provision and interpretation.
2.

Mechanical Means:
Due to mechanization of construction works, rate analyses for various items have been prepared
using mechanical means. However, manual means have also been provided for certain cases,
where access may be inaccessible for machines or quantum of work may not be large enough to
justify the use of machines.

3.

Overhead Charges:

3.1 The overhead charges provided in the analysis for road works is 10(Ten) percent which shall
include the following elements:
i)

Site accommodation, setting up plant, access road, water supply, electricity and general
site arrangements.

ii)

Office furniture equipment and communication.

iii)

Expenditure on
a) Corporate Office of contractor.
b) Site supervision.
c) Documentation and as built drawings.

iv)

Mobilisation/de-mobilisation of resources.

v)

Labour camps with minimum amenities and transportation to work sites.

vi)

Light vehicles for site supervision including administrative and managerial requirements.

vii)

Laboratory equipments and quality control including field and laboratory testing.

viii)

Minor T&P and survey instruments and setting our works, including verification of line,
dimension, trial pits and bore holes, where required.
1

4.

ix)

Watch and ward.

x)

Traffic Management during construction.

xi)

Expenditure on safeguarding environment.

xii)

Sundries.

xiii)

Financing expenditure.

xiv)

Sales/Turn over tax.

xv)

Work insurance/compensation.

Contractors Profit:
Contractors profit is also been taken uniformly as 10 percent, over the cost of items including
overhead charges.

5.

Basic Inputs:
The rates for material and labour adopted in the S.O.R. are as per the current market rate and
Labour Department, Government of Meghalaya.

6.

7.

Plants and Equipments:

6.1

A dozer is proposed for excavation where cutting and filling for the roadway is within
100m. For longer leads, a combination of hydraulic excavator and tipper is proposed.

6.2

Keeping in view the job and managerial factors and the age factor of machines, the output
of plant and equipment is taken approximately 70 percent of the rated capacity given by
the manufacturer under ideal conditions.

6.3

It has been assumed that a water tanker would make one trip per hour on an average.
Water charges have not been included for items where the requirement is very nominal. It
is assumed that the same would be covered under sundries.

6.4

Output of plant/equipment is considered for the compacted quantities.

6.5

The usage charges for machine include ownership charges, cost of repair and maintenance
including replacement of tyres and running and operating charges which include crew, fuel
and lubricants.

Materials:
2

8.

9.

7.1

Quantities of material given in the rate analysis are approximate for the purpose of
estimating and include normal wastages. Actual consumption would have to be based on
mix design.

7.2

The rates for material should include basic cost at locations of stone crusher, loading,
unloading, cost of carriage and stacking at plant sites as the case may be.

7.3

The alternative proposal for crushing own aggregate by installing crusher should be
compared with procurement of crushed aggregates from the market and proposal found
economical may be adopted.

7.4

The specification of materials shall be governed by section 1000 of MORT&H

specifications for Road and Bridge Works. (Fourth Revision).

Labour:
8.1

The wages for skilled, semi-skilled and unskilled labour, adopted in the S.O.R. have been
taken as per the latest Government Circular issued from Labour Department. However, the
rates for Head Mason, Carpenter, Welder, Blacksmith, Driller, Painter, etc., have been
adopted as per the actual current labour rates prevailing in the construction industry.

8.2

One mate has been provided for 25 labourers.

Carriage of Materials:
9.1

9.2

10

The Unit for vehicle for carriage has been taken as under:
a.

In hours where lead is defined including time required for loading and unloading.

b.

In tonne - Km. where lead is variable. The loading and unloading for such cases
have been provided separately.

Where the quantity of material to be transported is small such as dismantled materials and
the same are required to be loaded manually, provision of tractor-trolley has been made
instead of tipper.

General:
3

10.1

The clause numbers refer to MORT&H specifications for Road and Bridge works. (Fourth
Revision).

10.2

Assumptions made have been indicated in respective chapter in the form of notes where
required.

10.3

Sundries to cater for unforeseen contingency and miscellaneous items have been added in
the overhead charges.

10.4

Arrangement for traffic during construction shall be as per Clause 112 of MORT&H
specifications for Road and Bridge works. (Fourth Revision).

10.5

The supply of materials will be taken either at the location of mixing plant or at the work
site as the case may be.

10.6

Contractor will make his own arrangement for borrowing of earth. However,
compensation for earth taken from private land has been included in the rate analysis for
construction of embankment with borrowed earth.

10.7

The requirement of machinery have been worked out assuming effective working periods
of six hours per shift of 8 hours.

10.8

The cost of earthwork in urban roads will be comparatively higher due to following
reasons:
a)

There is mixed traffic on urban roads like slow moving hand and animal driven
carts, rickshaws, cycles, two/three wheeler apart from the usual vehicular traffic
resulting into traffic jams. This causes loss of working time, which may be in the
range of 10 - 15 percent.

b)

There is considerable disruption of traffic adversely affecting the efficiency of the

working parties including machines due to congestion caused by pedestrian traffic,
local road side vendors, parking of vehicles by the road side, encroachments by the
shopkeepers and local shops who make use of the berms of the road in front of
these shops and unauthorized conversion of road berms into mini local market. The
output of manpower and machines is substantially reduced due to factors
mentioned above.

c)

Cost of living in urban areas is comparatively more resulting into higher wages.

d)

At times, work is executed during night time due to heavy traffic during day time.
This involves extra expenditure by way of making arrangement for lighting and
special transport of working parties due to odd hour.

In the light of above, the authorities engaged in preparing the cost estimates may exercise
their judgment and cater for the additional cost to the extent of 2 to 3 percent, keeping in view the
4

severity of factors mentioned above. Support details for extra cost based on actual site conditions in
specific cases will have to be given in justification.
10.9

Credit for Dismantled material.

The dismantled material should be examined and a realistic assessment made for the credit
for such materials, which can be utilized for works or auctioned.

10.10 In the rate analysis of stone items, the quantities of sub-items involved in that analysis like
excavation for foundation, concrete, painting, lettering, etc., have been given. The rates for
such items may be taken from relevant chapters where the same have already been
analyzed.
10.11 The source of material and samples are required to be approved by the Engineer before
start of any work.
10.12 The rates of items include cost of testing of soil, materials and works.
10.13 The use of surface by construction vehicles shall be governed by Clause 119 of MORT&H
specifications. (Fourth Revision).
10.14 The contractor shall arrange to provide and maintain an adequate equipped field laboratory
as per Clause 121.
10.15 Quality control of works shall be governed by Section 900 of MORT&H specifications.
10.16 The various activities of works shall also be documented by photographs and video
cassettes as per Clauses 125 & 126 of MORT&H specifications.
10.17 The classifications of soil shall be as per Clause 301.2 of MORT&H specification.
10.18 The earth excavated from foundation has been considered to be backfilled and balance
utilized locally for road work except in the case of marshy soil.
10.19 The rate analysis for removal of unsuitable soil does not provide for replacement by
suitable soil which will have to be paid separately.
10.20 Item for hilly terrain have been analyzed separately.
10.21 The hire charges rate for machinery and equipments are applicable as present usage rate.
Suitable escalation may be added for subsequent years depending upon the market
situation.
10.22 10 percent extra cement may be provided for concreting under water, where required.
10.23 Grade of cement may be adopted as per mix design.
10.24 Quantities of cement in various grades of cement concrete have been taken as per IRC 212000 and IC 18-2000.
5

10.25 The rate for road delineators, boundary pillars and metal beam crash barriers have been
analyzed in Chapter 8.
10.26 The coarse and fine aggregates shall conform to IS:383.
10.27 Certain equipment like road rollers, are required to be available at site for complete period
of the shift though from the consideration of their output, they may be required only for 3
to 4 hours. This is necessitated to match with the output of other associated machines like
HMP, Pavers, etc,. In such cases, the hire charges or road rollers have been multiplied with
a factor of 0.65 to account for the idle period.
10.28 For pricing of RCC slab culvert, the items given in respective chapters in bridges section
may be referred.
10.29 Wherever electric generator has not been provided to run a plant or equipment, it is
assumed that it is fitted with a diesel engine.
10.30 Some of the firms in the field of construction chemicals have evolved new brands of
chemical for water proofing, sealing of cracks, cementing compounds, etc,. the market can
be explored to meet such requirements.
10.31 Some of the major steel producing firms have evolved thermo-mechanically treated steel
which has enhanced strength, better corrosion resistance, ductility, weld ability and high
temperature thermal resistance. Enquiries from these firms can be made on technical
specification and use of such products considered in works based on performance in works
where these have already been used.
10.32 Provision of Fly ash has been made in embankment construction, Sub-base construction
and Cement Concrete Pavement.
10.33 The Standard Data Book is for department use only. It cannot be produced in Court of
Law as reference/authority and thus it is Privilege Document.
10.34 In case it is decided to include the following items and their maintenance in the BOQ, the
scope and specifications should be worked out and defined in the detailed manner in the
tender document to avoid any dispute during execution.
MORT&H Clause Item.
120

Site Office and furniture for Engineer and his Staff.

122

Site residential accommodation for Engineer and other supervisory staff.

124

Providing and maintaining vehicle for the Engineer.

B - BRIDGE WORKS
6

BASIC APPROACH AND GENERAL CONDITIONS FOR THE PREPARATION OF

STANDARD DATA BOOK
The basic approach for the preparation of Standard Data Book for Bridge works is indicated as under:
Description of Items:
The description of items is given briefly and linked with the relevant Clause of the Ministrys
specifications for Road and Bridge Works (Fourth Revision), which may be referred for detailed
description, provisions and interpretation.
Overhead Charges:
The overhead charges include the following elements:
1)

Site accommodation, setting up plant, access road, water supply, electricity and general
site arrangements.

2)

Office furniture equipment and communications.

3)

Expenditure on

4)

a) Corporate office of contractor.

b) Site supervision.
c) Documentation and as built drawings.
Mobilisation/de-mobilisation of resources.

5)

Labour camps with minimum amenities and transportation to work sites.

6)

Light vehicles for site supervision including administrative and managerial requirements.

7)

Laboratory equipment and quality control including field and laboratory testing.

8)

Minor T&P and survey instruments and setting out works, including verification of line
dimensions, trial pits and bore holes, where required.

9)

Watch and ward.

10)

Traffic Management during construction.

11)

Expenditure on safeguarding environment.

12)

Sundries.

13)

Financing expenditure.

14)

Sales/Turn over tax.

15)

Work insurance/compensation.
7

For the purpose of calculation of overhead charges, the projects or categorized into three basic
types depending upon width of carriageway, length of the bridge and the present cost.
Category 1: Major Bridge including State of the Art Bridges and Minor Bridges 25%
Category 2: Minor Bridge included in the Road Packages

20%

Category 3: Rehabilitation of Bridges

30%

For the bridge having more than two lanes, equivalent length and cost can be adjusted
accordingly.
Contractors Profit:
Contractors profit is also been taken uniformly as 10 percent, over the cost of items including overhead
charges.
Basic Inputs:
The rates for material and labour adopted in the S.O.R. are as per the current market rate and Labour
Department, Government of Meghalaya.
Plants and Equipments:
The usage hire charges of machinery/equipment have been worked out based upon the present cost of
equipment, repairs, POL and operational charges. These charges are applicable for the current base year.
For subsequent years, these are required to be escalated depending upon the market situation.
In the analysis of rates, for any items of work, capacity of equipment with corresponding output has been
indicated which is most common in use for estimation purpose. Seeing the volume of job, different
capacity equipment with corresponding output can be provided for preparing estimate.
Materials:
The rates of materials should include basic cost at crushing units, cost of carriage including loading and
unloading and stacking of material at site of work and shall be determined through market enquiries.
Labour:
1. The wages for skilled, semi-skilled and unskilled labour, adopted in the S.O.R. have been taken as
per the latest Government Circular issued from Labour Department. However, the rates for Head
Mason, Carpenter, Welder, Blacksmith, Driller, Painter, etc., have been adopted as per the actual
current labour rates prevailing in the construction industry.
2. One mate has been provided for 25 labourers.
Carriage of Materials:
The Unit for vehicle for carriage has been taken as under:
a.

In hours where lead is defined including time required for loading and unloading.
8

b.
In tonne-Km. where lead is variable. The loading and unloading for such cases have been
provided separately.
General:
(i)

(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)

Bridge bearings and expansion joints are readymade items commercially produced by
specialized firms and in certain cases using imported technology and parts. The rates of these
items are to be obtained directly from different manufacturers approved by the Ministry and
shall be adopted after comparison.
Normal methods of curing has been covered in the schedule.
The testing of material and finished items of work is covered under overhead charges.
Traffic arrangements during construction are covered under overhead charges. Provision of
temporary division, where required shall be governed by Clause 112.3.
In the items for well foundation, provision for nominal island/temporary protection, deep
island/cofferdams with wooden ballies and sheet piles has been made.
For some of the items, certain size/specifications have been assumed. If sizes/specifications
other than the same are adopted, corresponding modifications may be made in the input of
analysis.
The items do not cover all components of bridge projects for all situations. There may be
specialized items for specific cases, which need to be analysed keeping in view the basic
approach.
In case bridge construction works are to be done on wide and deep water channel in major
rivers, etc., provision of floating barrages, etc., for taking the construction materials and
equipments beside water shall also be made separately.
Analysis for sinking of wells covers diameters from 6m to 12m and twin D Type of size 12m x
6m. For other shapes like rectangular or any other size, the rates of sinking may worked out on
prorata basis.
The lift for casting of concrete in well seining may be 2 to 2.5m restricting the free fall of
concrete to 1.5m and concreting layer to 450mm.

The Standard Data Book is for Department use only. It cannot be produced in Court of Law as
reference/authority and this is a privilege document.

CHAPTER 1
1. CARRIAGE OF MATERIALS
1.1 Preamble :
9

1.1.1

The provision of tipper has been made in hours where lead is known like disposal of the materials
upto 1 KM. In case where lead is variable like carriage of hot mix from plants or earth from
borrow areas, provision has been made in terms of tonne-kilometer (t-km), which can be adopted
as per actual conditions.

1.1.2

The cost of carriage will vary depending upon the riding surface of the road. Provision has
accordingly been made considering surface roads, unsurfaced graveled roads and katcha tracks.

1.1.3

The analysis for loading and unloading of Stone Boulders, stone aggregates, sand, kankar,
moorum, etc., has been done for manual means, as per site conditions.

1.1.4

Analysis of rate for loading and unloading have been done for manual means for adoption as per
actual situations.

CHAPTER-1 : CARRIAGE OF MATERIALS

Sl
No

Reference
to
MoRT&H
Specificat
ions

Rate
Item
No.

Descriptions

10

Unit

In
figure
s
(`)

In words

1.1

Loading and unloading of

stone boulders / stone
aggregates / sand / kanker /
moorum.
Placing tipper at loading point,
loading with front end loader,
dumping, turning for return trip,
excluding time for haulage and
return trip)
Loading and Unloading of
Boulders by Manual Means
Loading and Unloading of
Cement or Steel by Manual
Means and stacking.
Cost of Haulage Excluding
Loading and Unloading

1.2
1.3

1.4
(i)

Surfaced Road

(ii)

Un-surfaced Gravelled Road

(iii)

Kutcha Track and Track in river

bed / nallah bed etc...

cum

153.00

Rupees One Hundred

and Fifty Three only

cum

169.00

Rupees One Hundred

and Sixty Nine Only

tonn
e

234.00

Rupees Two Hundred

and Thirty Four only

tonn
e-km
tonn
e-km
tonn
e-km

CHAPTER 2
2.
2.1.1

SITE CLEARANCE

Preamble :
11

7.00

Rupees Seven only

8.00

Rupees Eight only

16.00

Rupees Sixteen only

Unless otherwise stated, the rates include sorting and disposal of unserviceable material and
stacking of serviceable material with all lifts and upto a lead of 1000 m.
2.1.2

Clearing and Grubbing :

This work shall consist of cutting, removing, and disposing of all materials such as trees, bushes,
shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150 mm in thickness, rubbish,
etc., which in the opinion of the Engineer are unsuitable for incorporation in the works, from the
area of road land containing road embankment, drains, cross-drainage structures and such other
areas as may be specified on the drawings or by the Engineer. It shall include necessary
excavation, backfilling of pits resulting from uprooting of trees and stumps to required
compaction, handling, salvaging and disposal of cleared materials. Clearing and grubbing shall be
performed in advance of earthwork operations and in accordance with the requirements of
MoRT&H Specifications.

2.1.3

2.1.4

Preservation of Property/Amenities :
(i)

Roadside trees, shrubs, any other plants, poles lines, fences, signs, monuments, buildings,
pipelines, sewers and all highway facilities within or adjacent to the Highway which are
not to be disturbed shall be protected from injury or damage. The Contractor shall provide
and install at his own expense, suitable safeguards approved by the Engineer for this
purpose.

(ii)

During clearing and grubbing, the Contractor take all adequate precautions against soil
erosion, sedimentation, water pollution, etc., The Contractor shall submit to the Engineer
for approval, his work plan including the procedure to be followed for disposal of waste
materials, etc., and the schedules for carrying out temporary and permanent erosion
control works.

Methods, Tools and Equipments :

(i)

Only such methods, tools and equipment as approved by the Engineer and which will not
affect the property to be preserved shall be adopted for the Work. If the area has thick
vegetation/roots/trees, a crawler or pneumatic tyred dozer of adequate capacity may be
used for clearance purposes. The dozer shall have ripper attachments for removal of tree
stumps.

(ii)

All trees, stumps, etc,. falling within excavation and fill lines shall be cut to such depth
below ground level that in no case these fall within 500 mm of the sub-grade. Also, all
vegetation such as roots, under-growth, grass and other deleterious matter unsuitable for
incorporation in the embankment/sub-grade shall be removed between fill lines to the
satisfaction of the Engineer. On areas beyond these limits, trees and stumps required to be
12

removed as directed by the Engineer shall be cut down to 1 m below ground level so that
these do not present an unsightly appearance.

2.1.5

(iii)

All branches of trees extending above the roadway shall be trimmed as directed by the
Engineer.

(iv)

All excavations below the general ground level arising out of the removal of trees, stumps,
etc., shall be filled with suitable material and compacted thoroughly so as to make the
surface at these points conform to the surrounding area.

(v)

Ant-hills both above and below the ground, as are liable to collapse and obstruct free
subsoil water flow shall be removed and their workings, which may extend to several
metres, shall be suitably treated.

Disposal of materials
(i)

All materials arising from clearing and grubbing operations shall be the property of
Government and shall be disposed of by the Contractor and hereinafter provided or
directed by the Engineer.

(ii)

Trunks, branches and stumps of trees shall be cleaned of limbs and roots and stacked. Also
boulders, stones and other materials usable in road construction shall be nearly stacked as
directed by the Engineer. Stacking of stumps, boulders, stones etc., shall be done at
specified spots with all lifts and upto a lead of 1000m.

(iii)

All products of clearing and grubbing which, in the opinion of the Engineer, cannot be
used or auctioned shall be cleared away from the roadside in a manner as directed the
Engineer. Care shall be taken to see that unsuitable waste materials are disposed of in such
a manner that there is no likelihood of these getting mixed up with the materials meant for
embankment, sub-grade and road construction.

(iv)

Dismantling of utilities like water pipe lines, electric and telephone lines, should be done
under the supervision of concerned departments and prior information to the users should
be disseminated.

(v)

In certain items of dismantling, like, pipe culverts, utilities, etc., excavation in earth and
dismantling of masonry works is not included in this analysis for which suitable notes
have been inserted. These items are required to be priced separately based on actual
quantities at site and nature of work.

(vi)

The dismantled materials should be examined and a realistic assessment and provision
made after due process for the credit for such materials, which can be utilised for works or
auctioned.
13

(vii)

In case where lead for disposal is more than 1000m, extra cost of carriage is required to be
added based on tonne-kilometerage.

(viii)

All minor T&P items required for dismantling are already included in overhead charges.

(ix)

For dismantling of utility services like water pipe lines, electric and telephone lines, prior
intimation should be given to users.

CHAPTER-2 : SITE CLEARANCE

Sl
No

Reference
to
MoRT&H
Specificat
ions

Rate
Item
No.

Descriptions

14

Unit

In
figure
s
(`)

In words

2.1

201

(i)
(ii)
(iii)

(iv)

2.2

2.3

201

Cutting of Trees, including

Cutting of Trunks, Branches
and
Removal.
Cutting of trees, including
cutting of trunks, branches and
removal
of
stumps,
roots,
stacking of serviceable material
with all lifts and up to a lead of
1000 metres and earth filling in
the depression/pit.
Girth from 300 mm to 600
mm
Girth from 600 mm to 900
mm
Girth from 900 mm to 1800
mm
Girth above 1800 mm

(i

Clearing Grass and Removal

of
Rubbish
Clearing grass and removal of
rubbish upto a distance of 50
metres outside the periphery of
the area.
Clearing and Grubbing Road
Land.
Clearing
and
grubbing
road
land
including
up-rooting
rank
vegetation,
grass,
bushes,
shrubs, saplings and trees girth
up to 300 mm, removal of
stumps of trees cut earlier and
disposal
of
unserviceable
materials
and
stacking
of
serviceable material to be used
or auctioned up to a lead of
1000 metres including removal
and disposal of top organic soil
not exceeding 150 mm in
thickness.
By Manual Means:-

In area of light jungle

In area of thorny jungle

201

each

234.00

each

531.00

each

865.00

each

1496.0
0

hectar
e

9959.0
0

hectar
e

31043.
00

hectar
e

42168.
00

Rupees Two Hundred

and Thirty Four only
Rupees Five Hundred
and Thirty One only
Rupees Eight
Hundred and Sixty
Five only
Rupees One
Thousand Four
Hundred and Ninety
Six only
Rupees Nine
Thousand Nine
Hundred and Fifty
Nine only

15

Rupees Thirty One

Thousand and Forty
Three Only
Rupees Forty Two
Thousand One
Hundred and Sixty

Eight only'
(ii)

2.4

By Mechanical Means

In area of light jungle

hectar
e

43272.
00

In area of thorny jungle

hectar
e

52524.
00

cum

411.00

cum

451.00

cum

922.00

cum

827.00

cum

1256.0
0

cum

331.00

202

Rupees Forty Three

Thousand Two
Hundred Seventy Two
Only
Rupees Fifty Two
Thousand Five
Hundred Twenty Four
Only

Dismantling of Structures.
Dismantling
of
existing
structures like culverts, bridges,
retaining
walls
and
other
structure
comprising
of
masonry,
cement
concrete,
wood work, steel work, including
T&P and scaffolding wherever
necessary,
sorting
the
dismantled material, disposal of
unserviceable
material
and
stacking
the
serviceable
material with all lifts and lead of
1000 metres.
Lime /Cement Concrete
(i)
I
A

B
C

II
A

By Manual Means
Lime Concrete, cement
concrete grade M-10 and
below
Cement Concrete Grade M15 & M-20
Prestressed / Reinforced
cement concrete grade M-20
& above
By Mechanical Means for
items No. 202( b) & ( c)
Cement Concrete Grade M15 & M-20
Prestressed / Reinforced
cement concrete grade M-20
& above

Rupees Four Hundred

and Eleven only
Rupes Four Hundred
and Fifty One only
Rupees Nine Hundred
and Twenty Two only

Rupees Eight
Hundred and Twenty
Seven only
Rupees One
Thousand Two
Hundred and Fifty
Six Only

Dismantling Brick / Tile work

(ii)
A

In lime mortar

16

Rupees Three
Hundred and Thirty
One Only

In cement mortar

cum

371.00

In mud mortar

cum

315.00

cum

308.00

Rubble stone masonry in

lime mortar

cum

347.00

Rubble stone masonry in

cement mortar.

cum

371.00

Rubble Stone Masonry in

mud mortar.

cum

331.00

cum

323.00

cum

315.00

cum

331.00

cum

636.00

Dry brick pitching or brick

soling

Rupees Three
Hundred and
Seventy One Only
Rupees Three
Hundred and Fifteen
Only
Rupees Three
Hundred and Eight
Only

Dismantling Stone Masonry

(iii)
A

(iv)

(v)

Dry rubble masonry

Dismantling stone pitching/

dry stone spalls.
Dismantling boulders laid in
wire
crates
including
opening
of
crates
and
stacking
dismantled
materials.
Wood work wrought framed
and fixed in frames of
trusses upto a height of 5 m
above plinth level
Steel work in all types of
sections upto a height of 5
m
above
plinth
level
excluding cutting of rivet.

Including dismembering

tonne

1285.0
0

Excluding dismembering.

tonne

969.00

Extra over item No( V ) A

and( V ) B for cutting rivets.
Scraping of bricks
dismantled from brick work
including stacking.

tonne

10.00

(vi)

17

Rupees Three
Hundred and Forty
Seven Only
Rupees Three
Hundred and
Seventy One Only
Rupees Three
Hundred and Thirty
One Only
Rupees Three
Hundred and Twenty
Three Only
Rupees Three
Hundred and Fifteen
Only
Rupees Three
Hundred and Thirty
One Only

Rupees Six Hundred

and Thirty Six Only

Rupees One
Thousand Two
Hundred and Eighty
Five Only
Rupees Nine Hundred
and Sixty Nine Only
Rupees Ten Only

In lime/Cement mortar

In mud mortar

697.00

249.00

(vii)

Scraping of Stone from

dismantled stone masonry

In cement and lime mortar

cum

281.00

In Mud mortar

cum

59.00

sqm

12.00

(viii)

(ix)

2.5

1000
numbe
rs
1000
numbe
rs

Scarping plaster in lime or

cement mortar from brick/
stone masonry
Removing all type of hume
pipes and stacking within a
lead
of
1000
metres
including
earthwork
and
dismantling
of
masonry
works.

Up to 600 mm dia

metre

103.00

Above 600 mm to 900 mm

dia

metre

141.00

Above 900 mm

metre

240.00

202

Rupees Six Hundred

and Ninety Seven
Only
Rupees Two Hundred
and Forty Nine Only

Rupees Two Hundred

and Eighty One Only
Rupees Fifty Nine
Only
Rupees Twelve Only

Rupees One Hundred

and Three Only
Rupees One Hundred
and Forty One Only
Rupees Two Hundred
and Forty Only

Dismantling
of
Flexible
Pavements
Dismantling
of
flexible
pavements and disposal of
dismantled materials up to a
lead of 1000 metres, stacking
serviceable and unserviceable
materials separately.
By Manual Means

I
A

Bituminous courses

cum

742.00

Granular courses

cum

584.00

II

Rupees Seven
Hundred and Forty
Two Only
Rupees Five Hundred
and Eighty Four Only

By Mechanical Means
A

Bituminous course

cum

18

527.00

Rupees Five Hundred

and Twenty Seven
Only

2.6

2.7

2.8

2.9

2.1
0

202

202

Dismantling
of
Cement
Concrete
Pavement.
Dismantling of cement concrete
pavement by mechanical means
using pneumatic tools, breaking
to pieces not exceeding 0.02
cum in volume and stock piling
at designated locations and
disposal of dismantled materials
up to a lead of 1000 metres,
stacking
serviceable
and
unserviceable
materials
separately.
Dismantling Guard Rails:

202

Dismantling guard rails by

manual means and disposal of
dismantled material with all lifts
and up to a lead of 1000
metres, stacking serviceable
materials and unserviceable
materials separately.
Dismantling Kerb Stone:
Dismantling kerb stone by
manual means and disposal of
dismantled material with all lifts
and up to a lead of 1000 metre.
Dismantling
Kerb
Stone
channel.
Dismantling kerb stone channel
by manual means and disposal
of dismantled material with all
lifts and up to a lead of 1000
metre.
Dismantling
Kilometre
Stone:
Dismantling of kilometre stone
including cutting of earth,
foundation and disposal of
dismantled material with all lifts
and lead upto 1000 m and back
filling of pit.

202

202

5th KM stone

cum

1833.0
0

Rupees One
Thousand Eight
Hundred and Thirty
Three Only

metre

88.00

Rupees Eighty Eight

Only

metre

27.00

Rupees Twenty Seven

Only

metre

40.00

Rupees Forty Only

each

385.00

Ordinary KM Stone

each

216.00

Hectometre Stone

each

43.00

19

Rupees Three
Hundred Eighty Five
Only
Rupees Two Hundred
Sixteen Only
Rupees Forty Three
Only

.11

2.1
2

2.1
3

2.1
4

202

202

202

202

Dismantling
of
Fencing:
Dismantling of barbed wire
fencing/ wire mesh fencing
including
posts,
foundation
concrete, back filling of pit by
manual
means
including
disposal of dismantled material
with all lifts and up to a lead of
1000
metres,
stacking
serviceable
material
and
unserviceable
material
separately.
Dismantling of CI Water Pipe
Line:
Dismantling of CI water pipe line
600 mm dia including disposal
with all lifts and lead upto 1000
metres
and
stacking
of
serviceable
material
and
unserviceable
material
separately under supervision of
concerned department.
Removal of Cement Concrete
Pipe
of
SewerGutter:
Removal of cement concrete
pipe of sewer gutter 1500 mm
dia under the supervision of
concerned department including
disposal with all lifts and up to a
lead of 1000 metres and
stacking of serviceable and
unserviceable
material
separately but excluding earth
excavation and dismantling of
masonry works.
Removal of Telephone /
Electric
Poles
andLines:
Removal of telephone / Electric
poles including excavation and
dismantling
of
foundation
concrete and lines under the
supervision
of
concerned
department, disposal with all
lifts and up to a lead of 1000
metres
and
stacking
the
Serviceable and unserviceable
material separately.

metre

40.00

Rupees Forty Only

metre

139.00

Rupees One Hundred

and Thirty Nine Only

metre

184.00

Rupees One Hundred

and Eighty Four Only

each

162.00

Rupees One Hundred

and Sixty Two Only

CHAPTER 3
3. EARTHWORK, EROSION CONTROL AND DRAINAGE
20

3.1 EXCAVATION FOR ROADWAY AND DRAINS

3.1.1

Scope :
This work shall consist of excavation, removal and satisfactory disposal of all materials necessary
for the construction of roadway, side drains and waterways in accordance with requirements of
MoRT&H Specifications and the lines, grades and cross-sections shown in the drawings or as
indicated by the Engineer. It shall include the hauling and stacking of or hauling to sites of
embankment and subgrade construction, suitable cut materials as required, as also the disposal of
unsuitable cut materials in specified manner, trimming and finishing of the road to specified
dimensions or as directed by the Engineer.

3.1.2

Authority for Classification :

The classification of excavation shall be decided by the Engineer and his decision shall be final
and binding on the Contractor. Merely the use of explosives in excavation will not be considered
as a reason for higher classification unless blasting is clearly necessary in the opinion of the
Engineer.
3.1.3

Construction Operation :
After the site has been cleared, the limits of excavation shall be set out true to lines, curves,
slopes, grades and sections as shown on the drawings or as directed by the Engineer. The
Contractor shall not excavate outside the limits of excavation. Subject to the permitted tolerances,
any excess depth/ width excavated beyond the specified levels/ dimensions on the drawings shall
be made good at the cost of the Contractor with suitable material of characteristics similar to that
removed and compacted to the requirements of Clause 305.

3.1.4

Excavation General :
(i) All excavations shall be carried out in conformity with the directions laid here-in-under
and in a manner approved by the Engineer. The work shall be executed in such a manner
so that the suitable materials available from excavation are satisfactorily utilised as
decided upon beforehand.
(ii) The Contractor shall provide all labour, survey instruments and materials such as strings,
pegs, nails, bamboos, stones, lime, mortar, concrete etc., required in connection with the
setting out of works and the establishment of Bench Marks. The Contractor shall be
responsible for the maintenance of Bench Marks and other marks and stakes as long as in
the opinion of the Engineer, they are required for the work.
(iii)

While planning or executing excavations, the Contractor shall take all adequate
precautions against soil erosion, sedimentation, water pollution etc., and take appropriate
drainage measures to keep the site free from water logging etc.

(iv)All debris and loose material on the slopes of cuttings shall be removed. No backfilling
shall be allowed to obtain required slopes excepting that when boulders or soft materials
are encountered in cut slopes, these shall be excavated to approved depth on instructions
21

of the Engineer and the resulting cavities filled with suitable material and thoroughly
compacted in an approved manner.
(v) After excavation, the sides of excavated area shall be trimmed and the area contoured to
minimize erosion and ponding, allowing for natural drainage to take place. If trees were
removed, new trees shall be planted, as directed by the Engineer. The cost of planting new
trees shall be deemed to be incidental to the work.
3.1.5

3.1.6

Rock excavation :
(i)

Rock, when encountered in road excavation, shall be removed upto the formation level or
as otherwise indicated on the drawings. Where, however, unstable shales or other
unsuitable materials are encountered at the formation level, these shall be excavated to the
extent of 500 mm below the formation level or as otherwise specified. In all cases, the
excavation operations shall be so carried out that at no point on cut formation the rock
protrudes above the specified levels. Rocks and large boulders which are likely to cause
differential settlement and also local drainage problems should be removed to the extent of
500 mm below the formation level in full formation width including drains and cut
through the side drains.

(ii)

Slopes in rock cutting shall be finished to uniform lines corresponding to slope lines
shown on the drawings or as directed by the Engineer. Notwithstanding the foregoing, all
loose pieces of rock on excavated slope surface which move when pierced by a crowbar
shall be removed.

Excavation of road shoulders/median for widening of pavement or providing treated

shoulders :
In works involving widening of existing pavements or providing treated shoulders, unless
otherwise specified, the shoulder/verge/median shall be removed to their full width and to levels
shown on drawings or as indicated by the Engineer. While doing so, care shall be taken to see that
no portion of the existing pavement designated for retention is loosened or disturbed. If the
existing pavement gets disturbed or loosened, it shall be dismantled and cut to a regular shape
with sides vertical and the disturbed/loosened portion removed completely and re-laid as directed
by the Engineer, at the cost of the Contractor.

3.1.7

Excavation for surface/sub-surface drains :

Where the Contract provides for construction of surface/sub-surface drains to Clause 309,
excavation for these shall be carried out in proper sequence with other works as approved by the
Engineer.

3.1.8

Classification of Excavated Material :

All materials involved in excavation shall be classified by the Engineer in the following manner:
(A) Soil
22

This shall comprise topsoil, turf, sand, silt, loam, clay, mud, peat, black cotton soil, soft shale
or loose moorum, a mixture of these and similar material which yields to the ordinary
application of pick, spade and/or shovel, rake or other ordinary digging implement. Removal
of gravel or any other nodular material having dimensions in any one direction not exceeding
75 mm occurring in such strata shall be deemed to be covered under this category.
(B) Ordinary Rock (not requiring blasting)
(i)

Rock types such as laterites, shales and conglomerates, varieties of limestone and
sandstone etc., which may be quarried or split with crow bars, also including any rock
which in dry state may be hard, requiring blasting but which, when wet, becomes soft and
manageable by means other than blasting;

(ii)

Macadam surfaces such as water bound and bitumen/tar bound; soling or roads, paths etc,
and hard core; compact moorum or stabilised soil requiring grafting tool or pick or both
and shovel, closely applied; gravel and cobble stone having maximum dimension in any
one direction between 75 and 300 mm;

(iii)

Lime concrete, stone masonry in lime mortar and brick work in lime/cement mortar below
ground level, reinforced cement concrete which may be broken up with crow bars or picks
and stone masonry in cement mortar below ground level; and

(iv)

Boulders which do not require blasting having maximum dimension in any direction of
more than 300 mm, found lying loose on the surface or embedded in river bed, soil, talus,
slope wash and terrace material of dissimilar origin.

(C) Hard Rock (requiring blasting)

(i)

Any rock or cement concrete for the excavation of which the use of mechanical plant
and/or blasting is required.

(ii)

Reinforced cement concrete (reinforcement cut through but not separated from the
concrete) below ground level; and

(iii)

Boulders requiring blasting.

(D) Hard Rock (blasting prohibited)

Hard rock requiring blasting as described under (c) but where blasting is prohibited for any
reason and excavation has to be carried out by chiseling, wedging or any other agreed method.

(E) Marshy Soil

This shall include soils like soft clays and peats excavated below the original ground level of
marshes and swamps and soils excavated from other areas requiring continuous pumping or
bailing out of water.
23

i)

3.1.9

Disposal of excavated materials :

All the excavated materials shall be the property of the Employer. The material obtained from the
excavation of roadway, shoulders, verges, drains, cross-drainage works etc., shall be used for filling up of
(i) roadway embankment, (ii) the existing pits in the right-of-way and (iii) for landscaping of the road as
directed by the Engineer, including leveling and spreading with all lifts and lead upto 1000 m and no
extra payment shall be made for the same.
(ii)

All hard materials, such as hard moorum, rubble, etc., not intended for use as above shall
be stacked neatly on specified land as directed by the Engineer with all lifts and lead upto
1000m.

(iii)

Unsuitable and surplus material not intended for use within the lead specified above shall
also, if necessary, be transported with all lifts and lead beyond initial 1000 m, disposed of
or used as directed by the Engineer.

3.1.10 Backfilling :
Backfilling of masonry/concrete/hume pipe drain excavation shall be done with approved material
after concrete/masonry/hume pipe is fully set and carried out in such a way as not to cause undue
thrust on any part of the structure and/or not to cause differential settlement. All space between
the drain walls and the side of the excavation shall be refilled to the original surface making due
allowance for settlement, in layers generally not exceeding 150 mm compacted thickness to the
required density, using suitable compaction equipment such as mechanical tamper, rammer, or
plate compactor as directed by the Engineer.
3.1.11 Blasting Operations:
(i)

Blasting shall be carried out in a manner that completes the excavation to the lines
indicated in drawings, with the least disturbance to adjacent material. It shall be done only
with the written permission of the Engineer. All the statutory laws, regulations, rules, etc.,
pertaining to the acquisition, transport, storage, handling and use of explosives shall be
strictly followed.

(ii)

The Contractor may adopt any method or methods of blasting consistent with the safety
and job requirement. Prior to starting any phase of the operation the Contractor shall
provide information describing pertinent blasting procedures, dimensions and notes.

(iii)

The replacement of unsuitable soil by suitable soil shall be included separately in the
estimate. The rate analyses for removal of unsuitable soil does not provide for replacement
by suitable soil.

(iv)

The possibility of using the blasted rock fragments for backfilling behind structures of
backfilling of foundation pits or filling in medians/ separators or use in service road shall
be examined before proposing disposal of excavated rock.

(v)

In case of hill roads, the cut earth can be pushed down the valley in case there is no
objection. In that case, cost of disposal is not required to be provided.
24

(vi)

For inhabited areas, controlled blasting with limited charges of explosives has been
provided. This involves smaller drill holes and additional requirement of electric
detonators. Provision has accordingly been made.

(vii)

Earth excavated from drains can be used in roadway berms. Hence, carriage for disposal
of same is not provided.

CHAPTER-3 : EARTH WORK, EROSION CONTROL AND DRAINAGE

Sl
No
3.1

Reference
to
MoRT&H
Specificat
ions
301

Rate
Item
No.

Descriptions

Unit

In
figure
s (`)

Excavation in Soil by Manual

Means.
Excavation for roadway in soil
using manual means including
loading in truck for carrying of cut
earth to embankment site with all

cum

156.00

25

In words
Rupees One Hundred
and Fifty Six Only

lifts and lead upto1000 metres.

3.2

3.3

3.4

3.5

301

301

301

301

Excavation in ordinary rock by

manual
means:
Excavation in ordinary rock using
manual means including loading
in a truck and carrying of
excavated
material
to
embankment site with in all lifts
and leads upto 1000 metres
Excavation in Soil with Dozer
with lead upto 100 metres:
Excavation for road way in soil by
mechanical
means
including
cutting and pushing the earth to
site of embankment upto a
distance of 100 metres (average
lead
50
metres),
including
trimming bottom and side slopes
in accordance with requirements
of lines, grades and cross
sections.
Excavation in Ordinary Rock
with Dozer with lead upto 100
metres:
Excavation
for
roadway
in
ordinary rock by deploying a
dozer, 80 HP including cutting and
pushing the cut earth to site of
embankment upto a distance of
100 metres ( average lead 50
metres ), trimming bottom and
side slopes in accordance with the
requirements of lines, grades and
cross sections.
Excavation
in
Hard
Rock
(requiring blasting)
with
disposal upto 1000 metres:
Excavation for roadway in hard
rock (requiring blasting)
by
drilling, blasting and breaking,
trimming of bottom and side
slopes
in
accordance
with
requirements of lines, grades and
cross
sections,
loading
and
disposal of cut road with in all lifts
and leads upto 1000 metres.

26

cum

197.00

Rupees One Hundred

and Ninety Seven
Only

cum

140.00

Rupees One Hundred

and Forty Only

cum

235.00

Rupees Two Hundred

and Thirty Five only

cum

412.00

Rupees Four Hundred

and Twelve Only

3.6

3.7

3.8

3.9

301

Excavation
in
Soil
using
Hydraulic Excavator CK 90 and
Tippers with disposal upto
1000 metres:
Excavation for roadwork in
soil with hydraulic excavator of
0.9 cum bucket capacity including
cutting and loading in tippers,
trimming bottom and side slopes,
in accordance with requirements
of lines, grades and cross
sections, and transporting to the
embankment location within all
lifts and lead upto 1000 metres.
Excavation in Ordinary Rock
using Hydraulic Excavator CK90 and Tippers with disposal
upto
1000
metres:
Excavation
for
roadway
in
ordinary rock with hydraulic
excavator of 0.9 cum bucket
capacity including cutting and
loading in tippers, transporting to
embankment site within all lifts
and lead upto 1000 m, trimming
bottom and side slopes in
accordance with requirements of
lines, grades and cross sections.
Excavation
in
Hard
Rock
(blasting
prohibited):
Excavation for roadway in hard
rock (blasting prohibited)
with
rock breakers including breaking
rock, loading in tippers and
disposal within all lifts and lead
upto 1000 metres, trimming
bottom and side slopes in
accordance with requirements of
lines, grades and cross sections.

301

301

301

cum

74.00

Rupees Seventy Four

Only

cum

110.00

Rupees One Hundred

and Ten Only

Mechanised

cum

703.00

Manual Method

cum

1097.0
0

Excavation
in
Hard
Rock
(controlled blasting)
with
disposal upto 1000 metres:
Excavation for roadway in hard
rock with controlled blasting by
drilling, blasting and breaking,
trimming of bottom and side
slopes
in
accordance
with
requirements of lines, grades and
cross
sections,
loading
and
disposal of cut road with in all lifts
and leads upto 1000 metres.

cum

507.00

27

Rupees Seven
Hundred Three Only
Rupees One
Thousand Ninety
Seven Only

Rupees Five Hundred

Seven Only

3.1
0

3.1
1

3.1
2

3.1
3

301

Excavation in Marshy Soil:

Excavation for roadway in marshy
soil with hydraulic excavator 0.9
cum bucket capacity including
cutting and loading in tippers and
disposal with in all lifts and lead
upto 1000 metres, trimming of
bottom and side slopes in
accordance with requirements of
lines, grades and cross sections.
Removal of Unserviceable Soil
with
Disposal
upto
1000
metres:
Removal of unserviceable soil
including excavation, loading and
disposal upto 1000 metres lead
but excluding replacement by
suitable soil which shall be paid
separately as per Clause 305.
Pre-splitting
of
Rock
Excavation
Slopes:
Carrying out excavation in hard
rock to achieve a specified slope
of the rock face by controlled use
of
explosives
and
blasting
accessories in properly aligned
and spaced drill holes, collection
of the excavated rock by a 80 HP
dozer, loading in tipper by a front
end loader and disposing of the
material with all lifts and lead
upto 1000 metres, all as specified
in Clause No. 303
Excavation for Structures:

301

303

304

(i)
A
B
(ii)
A

Earth work in excavation of

foundation of structures as per
drawing
and
technical
specification, including setting
out, construction of shoring and
bracing, removal of stumps and
other deleterious matter, dressing
of sides and bottom, backfilling
the excavation earth to the extent
required
and
utilising
the
remaining earth locally for road
work.
Ordinary soil
Manual Means (Depth upto 3
m)
Mechanical
Means
(Depth
upto 3 m)
Ordinary rock (not requiring
blasting)
Manual Means (Depth upto 3
m)

28

cum

80.00

Rupees Eighty Only

cum

74.00

Rupees Seventy Four

Only

sqm

156.00

Rupees One Hundred

and Fifty Six Only

cum

159.00

cum

57.00

cum

199.00

Rupees One Hundred

and Fifty Nine Only
Rupees Fifty Seven
Only
Rupees One Hundred
and Ninety Nine Only

B
(iii)
A
(iv)
A
(v)
A
B
3.1
4

3.1
5

3.1
6

3.1
7

305.4.3

305.4.3

305

305

Mechanical Means
Hard
rock
blasting )

77.00

cum

435.00

Rupees Four Hundred

and Thirty Five Only

cum

1013.0
0

Rupees One
Thousand and
Thirteen Only

cum

611.00

cum

214.00

sqm

29.00

Rupees Twenty Nine

Only

sqm

7.00

Rupees Seven Only

cum

540.00

Rupees Five Hundred

Forty Only

cum

183.00

Rupees One Hundred

and Eighty Three
Only

requiring

Manual Means
Hard
rock
prohibited )

Rupees Seventy
Seven Only

cum

blasting

Mechanical Means
Marshy soil
Manual means ( upto 3 m
depth)
Mechanical Means
Scarifying Existing Granular
Surface to a Depth of 50 mm
by
Manual
Means:
Scarifying the existing granular
road surface to a depth of 50 mm
and disposal of scarified material
within all lifts and leads upto 1000
metres.
Scarifying existing bituminous
surface to a depth of 50 mm
by
mechanical
means:
Scarifying the existing bituminous
road surface to a depth of 50 mm
and disposal of scarified material
with in all lifts and lead upto 1000
metres.
Construction of embankment
with Material Obtained from
Borrow
Pits:
Construction of embankment with
approved material obtained from
borrow pits with all lifts and leads,
transporting to site, spreading,
grading to required slope and
compacting to meet requirement
of Table 300-2
Construction of Embankment
with material deposited from
Roadway
Cutting:
Construction of embankment with
approved materials deposited at
site from roadway cutting and
excavation
from
drain
and
foundation of other structures
graded and compacted to meet
requirement of Table 300-2

29

Rupees Six Hundred

and Eleven Only
Rupees Two Hundred
and Fourteen Only

3.1
8

3.1
9

305

305.3.4
Case
-I

Case
-II
3.2
0

305

3.2
1

3.2
2

307

Construction of Subgrade and

Earthen
Shoulders:
Construction of subgrade and
earthen shoulders with approved
material obtained from borrow
pits with all lifts & leads,
transporting to site, spreading,
grading to required slope and
compacted to meet requirement
of Table 300-2
Compacting Original Ground
Compacting original ground
supporting
subgrade:
Loosening of the ground upto a
level of 500 mm below the
subgrade level, watered, graded
and compacted in layers to meet
requirement of Table 300-2 for
subgrade construction.
Compacting original ground
supporting embankment
Stripping and Storing Top Soil:
Stripping, storing of top soil by
road side at 15 m internal and reapplication
on
embankment
slopes, cut slopes and other areas
in localities where the available
embankment material is not
conducive to plant growth
Stripping, storing and relaying top soil from borrow
areas in agriculture fields:
Stripping of top soil from borrow
areas located in agriculture fields,
storing at a suitable place,
spreading and re-laying after
taking the borrow earth to
maintain
fertility
of
the
agricultural field, finishing it to the
required levels and satisfaction of
the farmer.
Turfing with Sods:
Furnishing and laying of the live
sods of perennial turf forming
grass on embankment slope,
verges or other locations shown
on the drawing or as directed by
the engineer including preparation
of ground, fetching of sods and
watering

30

Rupees Five Hundred

and Sixty Five only

cum

565.00

cum

88.00

Rupees Eighty Eight

Only

cum

59.00

Rupees Fifty Nine

Only

cum

141.00

cum

84.00

Rupees Eighty Four

Only

sqm

81.00

Rupees Eighty One

Only

Rupees One Hundred

and Forty One Only

3.2
3

3.2
4

3.2
5

3.2
6

309

Surface Drains in Soil:

Construction of unlined surface

drains of average cross sectional
area 0.40 sqm in soil to specified
lines,
grades,
levels
and
dimensions to the requirement of
clause 301 and 309. Excavated
material
to
be
used
in
embankment within a lead of50
metres (average lead 25 metres)
Mechanical means

Manual Means

Surface Drains in Ordinary

Rock:
Construction of unlined surface
drain of average cross sectional
area 0.4 sqm in ordinary rock to
specified lines, grades, levels and
dimensions as per approved
design and to the requirement of
Clause 301 to 309. Excavated
material
to
be
used
in
embankment at site.
Mechanical Means

Manual Means

309

309

309

Sub
Surface
Drains
with
Perforated
Pipe:
Construction of subsurface drain
with perforated pipe of 100 mm
internal
diameter
of
metal/
asbestos
cement/
cement
concrete/PVC,
closely
jointed,
perforations ranging from 3 mm to
6 mm depending upon size of
material surrounding the pipe,
with 150 mm bedding below the
pipe and 300 mm cushion above
the
pipe,
cross
section
of
excavation 450 x 550 mm.
Excavated material to be utilised
in roadway at site
Aggregate
SubSurface
Drains:
Construction of aggregate sub
surface drain 300 mm x 450 mm
with aggregates conforming to
Table 300-4, excavated material
to be utilised in roadway

31

metr
e
metr
e

metr
e
metr
e

90.00

Rupees Ninety Only

40.00

Rupees Forty Only

182.00
60.00

Rupees One Hundred

and Eighty Two Only
Rupees Sixty Only

metr
e

374.00

Rupees Three
Hundred and Seventy
Four Only

Metr
e

118.00

Rupees One Hundred

and Eighteen Only

3.2
7

3.2
8

3.2
9

310

313

301

3.3
0

3.3
1

Preparation
and
Surface
Treatment
of
formation:
Preparation and surface treatment
of formation by removing mud
and slurry, watering to the extent
needed to maintain the desired
moisture content, trimming to the
required line, grade, profile and
rolling with 8-10 tonne smooth
wheeled roller, complete as per
clause 310.
Construction
of
Rock
fill
Embankment:
Construction
of
rock
fill
embankment with broken hard
rock fragments of size not
exceeding 300 mm laid in layers
not exceeding 500 mm thick
including filling of surface voids
with stone spalls, blinding top
layer with granular material, rolled
with vibratory road roller, all
complete as per clause 313
A

301

EARTHWORK ON HILL ROAD

Excavation in Hilly Area in Soil
by Mechanical Means:
Excavation in soil in hilly area
by mechanical means including
cutting and trimming of side
slopes and disposing of excavated
earth with all lifts and lead upto
1000 metres.
Excavation in Hilly Area in Soil
by
Manual
Means:
Excavation in soil in hilly area by
manual means including cutting
and trimming of side slopes and
disposing of excavated earth with
all lifts and lead upto 1000 metres
Excavation in Hilly Area in
Ordinary Rock by Mechanical
Means not Requiring Blasting:
Excavation in hilly area in ordinary
rock not requiring blasting by
mechanical
means
including
cutting and trimming of slopes
and disposal of cut material with
all lift and lead upto 1000 metres

32

Sqm

4.00

Rupees Four Only

Cum

103.00

Rupees One Hundred

Three Only

Cum

181.00

Rupees One Eighty

One Only

Cum

191.00

Rupees One Hundred

and Ninety One Only

Cum

260.00

Rupees Two Hundred

and Sixty Only

3.3
2

3.3
3

301

301

Excavation in Hilly Areas in

Hard Rock Requiring Blasting:
Excavation in hilly areas in
hard rock requiring blasting, by
mechanical
means
including
trimming of slopes and disposal of
cut material with all lifts and lead
upto 1000 metres.
Excavation in Hilly Areas in
Hard Rock with controlled
Blasting:
Excavation in hilly areas in
hard rock with controlled blasting,
by drilling, blasting and breaking
trimming of bottom and side
slopes
in
accordance
with
requirement of lines, grades and
crossection and disposal of cut
road within all lifts and lead upto
1000 metres.

33

cum

341.00

Rupees Three
Hundred and Forty
One Only

cum

424.00

Rupees Four Hundred

Twenty Four Only

CHAPTER 4
4. SUB-BASES, BASES ( NON-BITUMINOUS) AND SHOULDERS
4.1 Preamble:
4.1.1

Quantities of materials provided are approximate and are meant for the purpose of estimating
only. Actual quantities shall be as per mix design.

4.1.2

For construction of sub-base, two alternatives as under have been provided:

a. Mix in place method
b. Plant mix method

4.1.3 While providing for the rate of materials, detailed local enquiries have been made and prevailing
market rates ascertained from concerned suppliers in the area keeping in view the location of
crushing plants and lead involved.
4.2. GRANULAR SUB-BASE
4.2.1

Scope :
This work shall consist of laying and compacting well-graded material on prepared subgrade in
accordance with the requirements of MoRT&H specifications. The material shall be laid in one or
more layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as
necessary according to lines, grades and cross-sections shown on the drawings or as directed by
the Engineer.

4.2.2

Materials :
(i)

The material to be used for the work shall be natural sand, moorum, gravel, crushed stone
or combination thereof depending upon the grading required. Materials like crushed slag,
crushed concrete, brick metal and kankar may be allowed only with the specific approval
of the Engineer. The material shall be free from organic or other deleterious constituents
and conform to one of the three gradings given in Table. 4.1.
Table 4.1. (Table 400-1) Grading for Close-Graded Granular Sub-base Materials
IS Sieve
Per cent by weight Passing the IS sieve
Designation
Grading I
Grading II
Grading III
75.0 mm
100
53.0 mm
80-100
100
26.5 mm
55-90
70-100
100
9.50 mm
35-65
50-80
65-95
4.75 mm
25-55
40-65
50-80
2.36 mm
20-40
30-50
40-65
0.425 mm
10-25
15-25
20-35
0.075 mm
3-10
3-10
3-10
CBR Value (Minimum)
30
25
20
34

(iii)

While the gradings in Table 4.1 are in respect of close-graded granular sub-base materials,
one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the corresponding
gradings for the coarse-graded materials for each of the three maximum particle sizes are
given at Table 4.2 The grading to be adopted for a project shall be as specified in the
Contract.
Table. 4.2 (Table 400-2) Grading for Coarse Graded Granular Sub-base Materials
IS Sieve
Per cent by weight passing the IS sieve
Designation
Grading I
Grading II
Grading III
75.0 mm
100
53.0 mm
100
26.5 mm
55-75
50-80
100
9.50 mm
4.75 mm
10-30
15-35
25-45
2.36 mm
0.425 mm
0.075 mm
<10
<10
<10
CBR Value (Minimum)
30
25
20
Note: The material passing 425 micron (0.425 mm) sieve for all the three gradings when
tested according to IS : 2720 (Part 5) shall have liquid limit and plasticity index not more than
25 and 6 per cent respectively

4.2.3

Physical requirements :
The material shall have a 10 per cent fines value of 50 kN or more (for sample in soaked
condition) when tested in compliance with BS:812 (Part 111). The water absorption value of the
coarse aggregate shall be determined as per IS: 2386 (Part 3). If this value is greater than 2 per
cent, the soundness test shall be carried out on the material delivered to site as per IS: 383. For
Grading II and III materials, the CBR shall be determined at the density and moisture content
likely to be developed in equilibrium conditions which shall be taken as being the density relating
to a uniform air voids content of 5 per cent.

4.2.4

4.2.5

Strength of sub-base :
(i)

It shall be ensured prior to actual execution that the material to be used in the sub-base
satisfies the requirements of CBR and other physical requirements when compacted and
finished.

(ii)

When directed by the Engineer, this shall be verified by performing CBR tests in the
laboratory as required on specimens remoulded at field dry density and moisture content
and any other tests for the quality of materials, as may be necessary.

Preparation of subgrade :
Immediately prior to the laying of sub-base, the subgrade already finished to Clause 301 or 305 as
applicable shall be prepared by removing all vegetation and other extraneous matter, lightly
35

sprinkled with water if necessary and rolled with two passes of 80 100 kN smooth wheeled
roller.
4.2.6

Spreading and compacting :

(i)

The sub-base material of grading specified in the Contract shall be spread on the prepared
subgrade with the help of a motor grader of adequate capacity, its blade having hydraulic
controls suitable for initial adjustments and for maintaining the required slope and grade
during the operation or other means as approved by the Engineer.

(ii)

When the sub-base material consists of combination of materials mentioned in Clause

401.2.1, mixing shall be done mechanically by the mix-in-place method.

(iii)

Manual mixing shall be permitted only where the width of laying is not adequate for
mechanical operations, as in small-sized jobs. The equipment used for mix-in-place
construction shall be a rotavator or similar approved equipment capable of mixing the
material to the desired degree. If so desired by the Engineer, trial runs with the equipment
shall be carried out to establish its suitability for the work.

(iv)

Moisture content of the loose material shall be checked in accordance with IS:2720 (Part
2) and suitably adjusted by sprinkling additional water from a truck mounted or trailer
mounted water tank and suitable for applying water uniformly and at controlled quantities
to variable widths of surface or other means approved by the Engineer so that, at the time
of compaction, it is from 1 per cent above to 2 per cent below the optimum moisture
content corresponding to IS:2720 (Part 8). While adding water, due allowance shall be
made for evaporation losses. After water has been added, the material shall be processed
by mechanical or other approved means like disc harrows, rotavators until the layer is
uniformly wet.

(v)

Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not
exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a
compacted single layer upto 225 mm the compaction shall be done with the help of a
vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot-drum
or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum
tyre pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required
compaction. Rolling shall commence at the lower edge and proceed towards the upper
edge longitudinally for portions having unidirectional crossfall and super elevation and
shall commence at the edges and progress towards the centre for portions having crossfall
on both sides.

(vi)

Each pass of the roller shall uniformly overlap not less than one-third of the track made in
the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and
any high spots or depressions, which become apparent, corrected by removing or adding
fresh material. The speed of the roller shall not exceed 5 km per hour.
36

(vii)

Rolling shall be continued till the density achieved is at least 98 per cent of the maximum
dry density for the material determined as per IS:2720 (Part 8). The surface of any layer of
material on completion of compaction shall be well closed, free from movement under
compaction equipment and from compaction planes, ridges, cracks or loose material. All
loose, segregated or otherwise defective areas shall be made good to the full thickness of
layer and re-compacted.
4.3. WATER BOUND MACADAM SUB-BASE/BASE

4.3.1

4.3.2

Scope :
(i)

This work shall consist of clean, crushed aggregates mechanically interlocked by rolling
and bonding together with screening, binding material where necessary and water laid on a
properly prepared subgrade/ sub-base/ base or existing pavement, as the case may be and
finished in accordance with the requirements of MoRT&H Specifications and in close
conformity with the lines, grades, cross-sections and thickness as per approved plans or as
directed by the Engineer.

(ii)

It is, however, not desirable to lay water bound macadam on an existing thin black topped
surface without providing adequate drainage facility for water that would get accumulated
at the interface of existing bituminous surface and water bound macadam.

Coarse aggregates :
Coarse aggregates shall be either crushed or broken stone, crushed slag, overburnt (Jhama) brick
aggregates or any other naturally occurring aggregates such as kankar and laterite of suitable
quality. Materials other than crushed or broken stone and crushed slag shall be used in sub-base
courses only. If crushed gravel/ shingle is used, not less than 90 per cent by weight of the gravel/
shingle pieces retained on 4.75 mm sieve shall have at lease two fractured faces. The aggregates
shall conform to the physical requirements set forth in Table. 4.3. The type and size range of the
aggregate shall be specified in the Contract or shall be as specified by the Engineer. If the water
absorption value of the coarse aggregate is greater than 2 per cent, the soundness test shall be
carried out on the material delivered to site as per IS: 2386 (Part 5).

4.3.3

Crushed or broken stone :

The crushed or broken stone shall be hard, durable and free from excess flat, elongated, soft and
disintegrated particles, dirt and other deleterious material.

37

Table 4.3 (Table 400-6) Physical requirements of Coarse Aggregates

for Water Bound Macadam For Sub-Base/Base Courses.
Test
Test Method
Requirements
1.
* Los Angeles
IS: 2386
40 per cent (Max)
Abrasion value
(Part-4)
Or
* Aggregate
IS: 2386
30 per cent (Max)
Impact value
(Part-4) or
IS:5640**
2.

Combined
IS:2386
30 per cent (Max)
Flakiness and
(Part-1)
Elongation
Indices (Total)
***
Aggregate may satisfy requirements of either of the two tests.

** Aggregates like brick metal, kankar, laterite etc. which get softened in presence of water
shall be tested for Impact value under wet conditions in accordance with IS:5640.
*** The requirements of flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.
Grading requirement of coarse aggregates :
The coarse aggregates shall conform to one of the Gradings given in Table. 4.4 as specified,
provided, however, the use of Grading No.1 shall be restricted to sub-base courses only.

Table No. 4.4 (Table 400-7) Grading Requirements of Coarse Aggregates

Grading Size Range
IS Sieve
Per cent by
No.
Designation weight passing
38

1.

90 mm to 45 mm

125 mm
90 mm
63 mm
45 mm
22.4 mm

100
90-100
25-60
0-15
0-5

2.

63 mm to 45 mm

90 mm
63 mm
53 mm
45 mm
22.4 mm

100
90-100
25-75
0-15
0-5

3.

53 mm to 22.4 mm

63 mm
100
53 mm
95-100
45 mm
65-90
22.4 mm
0-10
11.2 mm
0-5
Note : The compacted thickness for a layer with Grading 1 shall be 100 mm while for layer
other Gradings i.e. 2 & 3, it shall be 75 mm.

4.3.5

with

Screenings :
(i)

Screenings to fill voids in the coarse aggregate shall generally consist of the same material
as the coarse aggregate. However, where permitted, predominantly non-plastic material
such as moorum or gravel (other than rounded river borne material) may be used for this
purpose provided liquid limit and plasticity index of such material are below 20 and 6
respectively and fraction passing 75 micron sieve does not exceed 10 per cent.

(ii)

Screenings shall conform to the gradings set forth in Table. 4.5. The consolidated details
of quantity of screenings required for various grades of stone aggregates are given in
Table. 4.6. The table also gives the quantities of materials (loose) required for 10 m 2 for
sub-base/ base compacted thickness of 100/75 mm.

(iii)

The use of screenings shall be omitted in the case of soft aggregates such as brick metal,
kankar, laterites, etc. as they are likely to get crushed to a certain extent under rollers.

Table 4.5 (Table 400-8) Grading for Screenings

Grading
Classificatio

Size of
Screenings

IS Sieve
Designation
39

Per cent by weight

passing the IS Sieve

n
A

13.2 mm

13.2 mm
11.2 mm
5.6 mm
180 micron

100
95-100
15-35
0-10

11.2 mm

11.2 mm
5.6 mm
180 micron

100
90-100
15-35

Table. 4.6 (Table 400-9) Approximate Quantities of Coarse Aggregates and Screenings
Required for 100/75 mm Compacted Thickness of Water Bound Macadam (WBM)
Sub-Base/ Base Course for 10m2 Area.

Compacte
d
thickness

Classifica
- tion

Size
Range

Grading
1

90 mm
to 45
mm

100 mm

1.21 to
1.43 m3

Grading
2

63 mm
to 45
mm

75 mm

0.91 to
1.07 m3

Type A
0.12 to
13.2 mm 0.15 m3

-do-

0.22 to
0.24
m3

-do-

-do-

-do-

Type B
0.20 to
11.2 mm 0.22 m3

-do-

-do-

53 mm
to 22.4
mm

75 mm

-do-

-do-

-do-

-doGrading
3

Loose
Qty.

Screenings
Stone Screening
Crushable Type
such as Moorum or
Gravel
Grading For WBM Grading
Loose
Classifi- Sub-base/ Classifica Qty.
cation & base
tion &
Size
course
Size
(Loose
quantity)
Type A
0.27 to
Not
0.30 to
3
13.2 mm 0.30 m
uniform
0.32
m3

-do-

0.18 to
0.21 m3

Binding material :
(i)

Binding material to be used for water bound macadam as a filler material meant for
preventing raveling, shall comprise of a suitable material approved by the Engineer having
40

a Plasticity Index (PI) value of less than 6 as determined in accordance with IS: 2720
(Part-5).
(ii)

The quantity of binding material where it is to be used, will depend on the type of
screenings. Generally, the quantity required for 75 mm compacted thickness or water
bound macadam will be 0.06-0.09 m3 /10m2 and 0.08-0.10m3/10m2 for 100 mm compacted
thickness.

(iii)

The above mentioned quantities should be taken as a guide only, for estimation of
quantities for constructions etc.

(iv)

Application of binding materials may not be necessary when the screenings used are of
crushable type such as moorum or gravel.
4.4. WET MIX MACADAM SUB-BASE/BASE

4.4.1

4.4.2

Scope:
(i)

Wet Mix Macadam Sub-base/Base : This work shall consist of laying and compacting
clean, crushed, graded aggregate and granular material, premixed with water, to a dense
mass on a prepared subgrade/sub-base/base or existing pavement as the case may be in
accordance with the requirements of MoRT&H Specifications. The material shall be laid
in one or more layers as necessary to lines, grades and cross-sections shown on the
approved drawings or as directed by the Engineer.

(ii)

The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75
mm. When vibrating or other approved types of compacting equipment are used, the
compacted depth of a single layer of the sub-base course may be increased to 200 mm
upon approval of the Engineer.

Physical requirements :
(i)

Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used, not less than
90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at
least two fractured faces. The aggregates shall conform to the physical requirement set
forth in Table. 4.7 below.

Table 4.7 (Table 400-10) Physical Requirements of Coarse Aggregates for Wet Mix
Macadam for Sub- Base/Base Courses
Test
1.

* Los Angeles

Test Method
IS: 2386 (Part-4)
41

Requirements
40 per cent (Max.)

Abrasion value
Or
* Aggregate
Impact value
2.

Combined Flakiness and

Elongation Indices (Total)

IS: 2386 (Part-4)

or IS:5640

30 per cent (Max.)

IS:2386 (Part-1)

30 per cent
(Max)**

*Aggregate may satisfy requirements of either of the two tests.

** To determine this combined proportion, the flaky stone from a representative sample should
first be separated out. Flakiness index is weight of flaky stone metal divided by weight of
stone sample. Only the elongated particles be separated out from the remaining (non-flaky)
stone metal. Elongation index is weight of elongated particles divided by total non-flaky
particles. The value of flakiness index and elongation index so found are added up.
(ii)
4.4.3

If the water absorption value of the coarse aggregate is greater than 2 per cent, the
soundness test shall be carried out in the material delivered to site as per IS:2386
(Part-5).
Grading requirements :
The aggregates shall conform to the grading given in Table. 4.8

Table 4.8 (Table 400-11) Grading requirements of Aggregates for Wet Mix Macadam
IS Sieve Designation Per cent by weight passing the IS sieve
53.00 mm
100
45.00 mm
95-100
26.50 mm
22.40 mm
60-80
11.20 mm
40-60
4.75 mm
25-40
2.36 mm
15-30
600.00 micron
8-22
75.00 micron
0-8
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well graded from coarse to fine and shall
not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa.
4.5 SHOULDERS, ISLANDS AND MEDIAN
4.5.1

Scope :

42

The work shall consist of constructing shoulder (hard/paved/earthen with brick or stone block
edging) on either side of the pavement, median in the road dividing the carriageway into separate
lanes and islands for channelising the traffic at junctions in accordance with the requirements of
MoRT&H Specifications and in conformity with the lines, grades and cross-sections shown on the
drawings or as directed by the Engineer.
4.5.2

4.5.3

Materials :
(i)

Shoulder on either side of the road may be of selected earth/granular material/ paved
conforming to the requirements of Clause 305/401 and the median may be of selected
earth conforming to the requirements of Clause 305.

(ii)

Median/ Traffic islands shall be raised and kerbed at the perimeter and the enclosed area
filled with earth and suitably covered with grass turf/ shrubs as per Clause 307 and/or
paved as per Clause 409.3.4 or 409.3.5.

(iii)

Paved shoulders shall consist of sub-base, base and surfacing courses, as shown in the
drawings and materials for the same shall conform to relevant Specifications of the
corresponding items. Where paved or hard shoulders are not provided, the pavement shall
be provided with brick/stone edgings as shown in the drawings. The bricks shall conform
to Clause 1003 of MoRT&H Specifications. Stone blocks shall conform to Clause 1004 of
MoRT&H Specifications and shall be of size 225 mm x 110 mm x 75 mm.

Size of Shoulders/Median/Islands :
Shoulder (earthen/hard/paved)/median/traffic island dimensions shall be as shown on the
drawings or as directed by the Engineer.
4.6 MEDIAN AND ISLANDS

4.6.1

Scope :
Median and Islands shall be constructed in a manner similar to shoulder up to the road level.
Thereafter the median and islands, if raised, shall be raised at least 300 mm by using kerb stones
of approved material and dimensions and suitably finished and painted as directed by the
Engineer. If not raised, the median and islands shall be differentiated from the shoulder/pavement
as the case may be, as directed by the Engineer. The confined area of the median and islands shall
be filled with local earth or granular material or any other approved material and compacted by
plate compactor/power rammer. The confined area after filling with earth shall be turfed with
grass or planted with shrubs and in case of granular fill it can be finished with tiles/slabs as
directed by the Engineer.
4.7. FOOTPATHS AND SEPARATORS

4.7.1

Scope :
43

The work shall consist of construction footpaths and/or separators at locations as specified in the
drawings or as directed by the Engineer. The lines, levels and dimensions shall be as per the
drawings. The scope of the work shall include provision of all drainage arrangements as shown in
the drawings or as directed.
4.7.2

Materials :
The footpaths and separators shall be constructed with any of the following types :
(a) Cast-in-situ cement concrete of Grade M20 as per Section 1700 of the Specifications.
(b) Precast cement concrete blocks/tiles of Grade M20 as per Section 1700 of the Specifications.
The minimum thickness of the cement concrete block/tile shall be 25 mm and minimum size
shall be 300 mm x 300 mm.
(c) Natural stone slab cut and dressed from stone of good and sound quality, uniform in texture,
free from defects and at least equal to a sample submitted by the Contractor and approved by
the Engineer. The minimum thickness of the natural stone slab shall be 25 mm and minimum
size shall be 300 mm x 300 mm.

Sl
No

CHAPTER-4 : SUB-BASES, BASES ( NON- BITUMINOUS) AND SHOULDERS

Reference
Rate
to
Item
In
MoRT&H
Description
Unit
No.
figure
In words
Specificat
s (`)
ions

44

4.1

401
A

Granular Sub-base with Close

Graded Material (Table:- 4001)
By
Plant
Mix
Method:
Construction of granular sub-base
by
providing
close
graded
Material, mixing in a mechanical
mix plant at OMC, carriage of
mixed Material to work site,
spreading in uniform layers with
motor grader on prepared surface
and compacting with vibratory
power roller to achieve the desired
density, complete as per Clause
401

(i)

For Grading- I Material

cum

3096.0
0

(ii)

For Grading- II Material

cum

3146.0
0

(iii)

For Grading-III Material

cum

3028.0
0

By Mix in Place Method:

Rupees Three
Thousand and Ninety
Six Only
Rupees Three
Thousand One
Hundred and Forty
Six Only
Rupees Three
Thousand and Twenty
Eight Only

Construction of granular sub-base

by
providing
close
graded
material, spreading in uniform
layers with motor grader on
prepared surface, mixing by mix in
place method with rotavator at
OMC,
and
compacting
with
vibratory roller to achieve the
desired density, complete as per
Clause 401

4.2

401

(i)

For Grading- I Material

cum

2193.0
0

(ii)

For Grading- II Material

cum

2242.0
0

(iii)

For Grading-III Material

cum

2125.0
0

Granular Sub-Base with Coarse

Graded Material ( Table:- 4002) :
Construction of granular sub-base
by
providing
coarse
graded
material, spreading in uniform
layers with motor grader on
prepared surface, mixing by mix in

45

Rupees Two
Thousand One
Hundred and Ninety
Three Only
Rupees Two
Thousand Two
Hundred and Forty
Two Only
Rupees Two
Thousand One
Hundred Twenty Five
Only

place method with rotavator at

OMC,
and
compacting
with
vibratory roller to achieve the
desired density, complete as per
Clause 401

4.3

4.4

4.5

(i)

For Grading- I Material

cum

2172.0
0

(ii)

For Grading- II Material

cum

2292.0
0

(iii)

For Grading-III Material

cum

1760.0
0

402

402

403

Rupees Two
Thousand One
Hundred and Seventy
Two Only
Rupees Two
Thousand Two
Hundred and Ninety
Two Only
Rupees One
Thousand Seven
Hundred Sixty Only

Lime
Stabilisation
for
Improving
Subgrade:
Laying and spreading available soil
in the subgrade on a prepared
surface, pulverising, mixing the
spread soil in place with rotavator
with 3 % slaked lime having
minimum content of 70% of CaO,
grading with motor grader and
compacting with the road roller at
OMC to the desired density to form
a layer of improved sub grade
A

By Mechanical Means

cum

508.00

By Manual Means

cum

459.00

cum

646.00

cum

994.00

Lime Treated Soil for SubBase:

Providing, laying and spreading
soil on a prepared sub grade,
pulverising, mixing the spread soil
in place with rotavator with 3
percent slaked lime with minimum
content of 70 percent of CaO,
grading with motor grader and
compacting with the road roller at
OMC to achieve at least 98
percent of the max dry density to
form a layer of sub- base.
Cement Treated Soil Sub Base/
Base:
Providing, laying and spreading
soil on a prepared sub grade,
pulverising, adding the designed
quantity of cement to the spread
soil,
mixing
in
place
with
rotavator, grading with the motor
grader and compacting with the
road roller at OMC to achieve the
desired unconfined compressive
strength and to form a layer of

46

Rupees Five Hundred

and Eight Only
Rupees Four Hundred
and Fifty Nine Only

Rupees Six Hundred

and Forty Six Only

Rupees Nine Hundred

and Ninety Four Only

sub-base/base.

4.6

403

Cement Treated Crushed Rock

or combination as per Clause
403.2 and Table 400.4 in Subbase/
Base:
Providing,
laying
and
spreading
Material on a prepared sub grade,
adding the designed quantity of
cement to the spread Material, mixing
in place with rotavator, grading with
the motor grader and compacting with
the road roller at OMC to achieve the
desired
unconfined
compressive
strength and to form a layer of subbase/base.

(i)

(ii)
4.7

4.8

4.9

404.3.1

404.3.2

404

Rupees Two
Thousand Eight
Hundred and Ninety
Three Only
Rupees Two
Thousand Three
Hundred and Seventy
Seven Only

For Sub-Base course

cum

2893.0
0

For Base course

cum

2377.0
0

sqm

3.00

Rupees Three Only

sqm

6.00

Rupees Six Only

cum

1431.0
0

Making 50 mm x 50 mm
Furrows: Making 50 mm x 50
mm furrows, 25mm deep, 45 to
the center line of the road and at
one metre interval in the existing
thin bituminous wearing coarse
including sweeping and disposal of
excavated material within 1000
metres lead
i. 25mm deep furrow cutting
ii. 50mm deep furrow cutting
Inverted-Choke:
Construction of inverted choke by
providing, laying, spreading and
compacting screening B type/
coarse sand of specified grade in
uniform layer on a prepared
surface with motor grader and
compacting with power roller etc
Water Bound Macadam

47

Rupees One
Thousand Four
Hundred and Thirty
One only

A
(i)

(ii)

(iii)
B
(i)

(ii)
(iii)

4.1
0

406

Providing, laying, spreading and

compacting stone aggregates of
specific sizes to water bound
macadam specification including
spreading in uniform thickness,
hand
packing,
rolling
with
vibratory roller 8-10 tonnes in
stages to proper grade and
camber, applying and brooming
requisite
type
of
screening/
binding Materials to fill up the
interstices of coarse aggregate,
watering and compacting to the
required density.
By Manual Means
Grading- I
90mm to 45mm
@1.21 cum per 10sqm for
compacted thickness of 100
mm
Grading-II 63 mm to 45mm@
0.91 cum per 10 sqm for
compacted thickness of 75 mm
Grading-III 53 mm to 22.4
mm@ 0.91 cum per 10 sqm for
compacted thickness of 75 mm
By Mechanical Means:
Grading- I
90mm to 45mm
@1.21 cum per 10sqm for
compacted thickness of 100
mm
Grading-II 63 mm to 45mm@
0.91 cum per 10 sqm for
compacted thickness of 75 mm
Grading-III 53 mm to 22.4
mm@ 0.91 cum per 10 sqm for
compacted thickness of 75 mm

cum

2605.0
0

cum

2694.0
0

cum

3035.0
0

cum

2518.0
0

cum

2606.0
0

cum

2948.0
0

cum

3329.0
0

Rupees Two
Thousand Six
Hundred and Five
Only
Rupees Two
Thousand Six
Hundred and Ninety
Four Only
Rupees Three
Thousand and Thirty
Five Only
Rupees Two
Thousand Five
Hundred and
Eighteen Only
Rupees Two
Thousand Six
Hundred and Six Only
Rupees Two
Thousand Nine
Hundred and Forty
Eight Only

Wet Mix Macadam

Providing, laying, spreading and
compacting
graded
stone
aggregate to wet mix macadam
specification including premixing
the Material with water at OMC in
mechanical mix plant carriage of
mixed Material by tipper to site,
laying in uniform layers with paver
in sub- base / base course on well
prepared surface and compacting
with vibratory roller to achieve the
desired density.

48

Rupees Three
Thousand Three
Hundred and Twenty
Nine Only

4.1
1

4.1
2

409

Suggestiv
e

Footpaths and Separators:

Construction of footpath/separator
by providing a 150 mm compacted
granular sub base as per Clause
401 and 25 mm thick cement
concrete grade M15, over laid with
precast concrete tiles in cement
mortar 1:3 including provision of
all drainage arrangements but
excluding kerb channel.
Lime, Fly ash stabalised soil
sub-base:
Construction of Sub-base using
lime - fly ash admixture with
granular soil, free from organic
matter/ deleterious material or
clayey silts and low plasticity clays
having PI between 5 and 20 and
liquid limit less than 25 and
commercial dry lime, slaked at site
or pre-slaked with CaO content not
less than 50 percent, fly ash to
conform to gradation as per
Clause 4.3 of IRC: 88-1984, lime +
fly ash content ranging between
10 to 30 percent the minimum unconfined compressive strength
and CBR value after 28 days
curing and 4 days soaking to be
7.5kg/sq, cm and 25 percent
respectively, all as specified in
IRC: 88-1984.

sqm

1800.0
0

Rupees One
Thousand and Eight
Hundred Only

cum

690.00

Rupees Six Hundred

and Ninety Only

CHAPTER 5
5. BASE AND SURFACE COURSES (BITUMINOUS)
5.1 GENERAL REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS
5.1.1

Scope:

49

5.1.2

(i)

Bituminous pavement courses shall be made using the materials described in the following
Specifications.

(ii)

The use of machinery and equipment mentioned in various Clauses of MoRT&H

Specifications is mandatory. Details of the machinery and equipment are available in the
Manual for Construction and Supervision of Bituminous Works. Equipment mandatory for
any particular project shall be in accordance with the Contract Specification for that
project.

Binder :
The binder shall be an appropriate type of bituminous material complying with the relevant Indian
Standard (IS), as defined in the appropriate Clauses of MoRT&H Specifications, or as otherwise
specified herein. The choice of binder shall be stipulated in the Contract or by the Engineer.
Where penetration grades of bitumen are specified, they are referred to by a single-figure
designation in accordance with IS:73. Thus bitumen Grade 35 refers to a bitumen in the
penetration range 30 to 40. Where Modified Binder is specified, the Clause 521 of MoRT&H
Specifications shall apply.

5.1.3

5.1.4

Coarse Aggregates :
(i)

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material
retained on the 2.36 mm sieve. They shall be clean, hard, durable, of cubical shape, free
from dust and soft or friable matter, organic or other deleterious matter.

(ii)

The aggregates shall satisfy the physical requirements set forth in the individual relevant
clause for the material in question.

Fine Aggregates :
Fine aggregates shall consist of crushed or naturally occurring material, or a combination of the
two, passing 2.36 mm sieve and retained on the 75 micron sieve. They shall be clean, hard,
durable, dry and free from dust, and soft or friable matter, organic or other deleterious matter.

5.1.5

Source of material :
The source of all materials to be used on the project must be tested to the satisfaction of and be
expressly approved by the Engineer. The Engineer may from time to time withdraw approval of a
specific source, or attach conditions to the existing approval. Any change in aggregate source for
bituminous mixes, will require a new mix design, and laying trials, where the mix is based on a
job mix design. Stockpiles from different sources, approved or otherwise, shall be kept separate,
such that there is no contamination between one material and another. Each source submitted for
approval shall contain sufficient material for at least 5 days work.
5.2 PRIME COAT OVER GRANULAR BASE

5.2.1

Scope:
This work shall consist of the application of a single coat of low viscosity liquid bituminous
material to a porous granular surface preparatory to the superimposition of bituminous treatment
or mix.
50

5.2.2

Primer :
The choice of a bituminous primer shall depend upon the porosity characteristics of the surface to
be primed as classified in IRC:16. These are :
i) Surface of low porosity; such as wet mix macadam and water bound macadam.
ii) Surfaces of medium porosity; such as cement stabilized soil base.
iii) Surfaces of high porosity; such as a gravel base.

5.2.3

Primer Viscosity :
The type and viscosity of the primer shall comply with the requirements of IS 8887, as sampled
and tested for bituminous primer in accordance with these standards. Guidance on viscosity and
rate of spray is given in Table 5.1.
Table 5.1. (Table 500-1) Viscosity Requirement and Quality of Liquid Bituminous Primer
Type of surface

5.2.4

Kinematic Viscosity
of Primer at 60oC

Low porosity

30 60

Quantity of Liquid
Bituminous Material
per 10 Sq.m (kg)
6 to 9

Medium porosity

70 140

9 to 12

High porosity

250 500

12 to 15

Choice of primer :
The primer shall be bitumen emulsion, complying with IS 8887 of a type and grade as specified in
the Contract or as directed by the Engineer. The use of medium curing cutback as per IS 217 shall
be restricted only for sites at sub-zero temperature or for emergency applications as directed by
the Engineer.

5.3 TACK COAT

5.3.1

Scope :
This work shall consist of the application of a single coat of low viscosity liquid bituminous
material to an existing bituminous road surface preparatory to the superimposition of a bituminous
mix, when specified in the Contract or as instructed by the Engineer.

5.3.2

Binder :
The binder used for tack coat shall be bitumen emulsion complying with IS 8887 of a type and
grade as specified in the Contract or as directed by the Engineer. The use of cutback bitumen as
per IS 217 shall be restricted only for sites at sub-zero temperature or for emergency applications
as directed by the Engineer.
51

5.3.3

Application of tack coat :

(i)

The application of tack coat shall be at the rate specified in the Contract, and shall be
applied uniformly. If rate of application of Tack Coat is not specified in the contract then it
shall be at the rate specified in Table 5.2 below. The normal range of spraying temperature
for a bituminous emulsion shall be 20oC to 70oC and for a cutback, 50oC to 80oC if RC70/MC-70 is used. Where a geo-synthetic is proposed for use, the provisions of Clauses
703.3.2 and 703.4.4 shall apply. The method of application of the tack coat will depend on
the type of equipment to be used, size of nozzles, pressure at the spray bar, and speed of
forward movement. The Contractor shall demonstrate at a spraying trial, that the
equipment and method to be used is capable of producing a uniform spray, within the
tolerances specified.

(ii)

Where the material to receive an overlay is a freshly laid bituminous layer, that has not
been subjected to traffic, or contaminated by dust, a tack coat is not mandatory where the
overlay is completed within two days.
Table 5.2(Table 500-2) Rate of Application of Tack Coat
Type of surface

Quantity of liquid bituminous material

Kg per sq.m. area
0.20 to 0.25

i)

Normal bituminous surfaces

ii)

Dry and hungry bituminous surfaces

0.25 to 0.30

iii
)

Granular surfaces treated with primer

0.25 to 0.30

Non bituminous surfaces

a) Granular base (not primed)
b) Cement concrete pavement

0.35 to 0.40
0.30 to 0.35

iv)

5.4 BITUMINOUS MACADAM

5.4.1

Scope :
This work shall consist of construction in a single course having 50mm to 100mm thickness or in
multiple courses of compacted crushed aggregates premixed with a bituminous binder on a
previously prepared base to the requirements of MoRT&H Specifications. Bituminous macadam
is more open graded than the dense graded bituminous materials described in Clauses 507, 508
and 509 of MoRT&H, Hand Book of Specification for Roads & Bridge Work.

5.4.2

Bitumen :
The bitumen shall be paving bitumen of Penetration Grade complying with Indian Standard
Specifications for Paving Bitumen IS:73, and of the penetration indicated in Table 5.4.

5.4.3

Coarse Aggregate :
52

5.4.4

(i)

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material
retained on the 2.36 mm sieve. They shall be clean, hard, durable, of cubical shape, free
from dust and soft or friable matter, organic or other deleterious matter.

(ii)

The aggregates shall satisfy the physical requirements set forth in Table 5.3.

Fine aggregates :
Fine aggregates shall consist of crushed or naturally occurring material, or a combination of the
two, passing 2.36 mm sieve and retained on 75 micron sieve. They shall be clean, hard, durable,
dry and free from dust, and soft or friable matter, organic or other deleterious matter.
Table 5.3 (Table 500-3) Physical Requirements for Coarse Aggregates for Bituminous
Macadam
Property
Cleanliness
Particle shape

Test
Specification
1
Grain size analysis
Max 5% passing 0.075 mm sieve
Flakiness and Elongation Index
Max 30 %
2
(Combined)
Strength*
Los Angeles Abrasion Value3
Max 40 %
3
Aggregate Impact Value
Max 30 %
4
Durability
Soundness
Max 12 %
Sodium Sulphate
Max 18 %
Magnesium Sulphate
Water Absorption Water absorption5
Max 2 %
Stripping
Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures6
95%
7
Water Sensitivity
Retained Tensile Strength
Min 80 %
Notes : 1. IS: 2386 Part 1
4. IS: 2386 Part 5
2. IS: 2386 Part 1
5. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4*
6. IS: 6241
7. The water sensitivity test is only to be carried out if the minimum retained coating in the
stripping test is less than 95%.
* Aggregate may satisfy requirements of either of these two tests.

Table 5.4 (Table 500-4) Composition of Bituminous Macadam

Mix designation
Nominal aggregate size
Layer thickness
IS Sieve (mm)

Grading 1
Grading 2
40 mm
19 mm
80 100 mm
50 75 mm
Cumulative % by weight of total aggregate passing
53

45
100
37.5
90-100
26.5
75-100
100
19
90-100
13.2
35-61
56-88
4.75
13-22
16-36
2.36
4-19
4-19
0.3
2-10
2-10
0.075
0-8
0-8
Bitumen content, % by
3.1 3.4
3.3 3.5
weight of total mixture
Bitumen grade
35 to 90
35 to 90
Notes : 1. Appropriate bitumen contents for conditions in cooler areas of India may be up to 0.5
% higher subject to the approval of the Engineer.
Table 5.5( Table 500-5) Manufacturing and Rolling Temperatures
Bitumen
Penetratio
n

Bitumen
Mixing (oC)

Aggregate
Mixing (oC)

Mixed
Material (oC)

Rolling
(oC)

Laying
(oC)

35

160 -170

160 175

170 Maximum

100 Minimum 130 Minimum

65

150 165

150 170

165 Maximum

90 Minimum

125 Minimum

90

140 - 160

140 165

155 Maximum

80 Minimum

115 Minimum

5.5 BUILT-UP SPRAY GROUT

5.5.1

5.5.2

Scope :
(i)

This work shall consist of a two-layer composite construction of compacted crushed

coarse aggregates with application of bituminous binder after each layer, and with key
aggregates placed on top of the second layer, in accordance with the requirements of
MoRT&H Specifications, to serve as a base course and in conformity with the lines,
grades and cross-sections shown on the drawings or as directed by the Engineer. The
thickness of the course shall be 75 mm.

(ii)

Built-up spray grout shall be used in a single course in a pavement structure.

Bitumen :
Clause 504.2.1. shall apply. Where permitted by the Engineer, an appropriate grade of emulsion
complying with IS 8887 may be used.
54

5.5.3

Aggregates :
(i)

The coarse aggregate shall conform to Clause 504.2.2. of MoRT&H Specifications.

(ii)

The aggregate shall satisfy the physical requirements set out in Table 5.3. The coarse and
key aggregates for built-up spray grout shall conform to the grading given in Table 5.6.

Table 5.6(Table 500-7) Grading Requirements for Coarse and Key Aggregates for Built-up Spray
Grout.
IS Sieve
Designation (mm)
53.0
26.5
22.4
13.2
5.6
2.8

Cumulative per cent by weight of total aggregate passing

Coarse Aggregate
Key Aggregate
100
40 75
100
0 20
40 75
0 20
05
05

5.6 DENSE GRADED BITUMINOUS MACADAM

This clause specified the construction of Dense Graded Bituminous Macadam, (DBM), for use
mainly, but not exclusively, in base/binder and profile corrective courses. DBM is also intended
for use as road base material. This work shall consist of construction in a single or multiple layers
of DBM on a previously prepared base or sub-base. The thickness of a single layer shall be 50mm
to 100mm.
5.6.1

Bitumen :
The bitumen shall be paving bitumen of Penetration Grade complying with Indian Standard
Specifications for Paving Bitumen IS: 73, and of the penetration indicated in Table 5.9 for
dense bitumen macadam, or this bitumen as modified by one of the methods specified in Clause
521, or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade
of bitumen is given in The Manual for Construction and Supervision of Bituminous Works.

5.6.2

Coarse Aggregates :
(i)

5.6.3

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material
retained on the 2.36 mm sieve. They shall be clean, hard, durable, of cubical shape, free
from dust and soft or friable matter, organic or other deleterious substances. The
aggregates shall satisfy the physical requirements specified in Table 5.7, for dense
bituminous macadam.

Fine Aggregates :
(i)

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a

combination of the two, passing the 2.36mm sieve and retained on the 75 micron sieve.
55

(ii)
(iii)

They shall be clean, hard, durable, dry and free from dust, and soft or friable matter,
organic or other deleterious matter.
The fine aggregate shall have a sand equivalent value of not less than 50 when tested in
accordance with the requirement of IS:2720 (Part 37).
The Plasticity Index of the fraction passing the 0.425 mm sieve shall not exceed 4, when
tested in accordance with IS: 2720 (Part 5).

Table 5.7 (Table 500-8) Physical Requirements for Coarse Aggregate for Dense Graded Bituminous
Macadam
Property
Cleanliness(dust)
Particle shape
Strength*
Durability
Water Absorption
Stripping
Water Sensitivity**

Test
Grain size analysis1
Flakiness and Elongation Index
(Combined)2
Los Angeles Abrasion Value3
Aggregate Impact Value4
Soundness5
Sodium Sulphate
Magnesium Sulphate
Water absorption6
Coating and Stripping of Bitumen
Aggregate Mixtures7

Specification
Max 5% passing 0.075 mm sieve
Max 30 %

Retained Tensile Strength8

Min 80 %

Max 35 %
Max 27 %
Max 12 %
Max 18 %
Max 2 %
Minimum retained coating
95%

Notes : 1. IS: 2386 Part 1

5. IS: 2386 Part 5
2. IS: 2386 Part 1
6. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4*
7. IS: 6241
4. IS: 2386 Part 4*
8. AASHTO T283**
* Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the
stripping test is less than 95%.
5.6.4

Filler :
(i)

Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or
cement approved by the Engineer.

(ii)

The filler shall be graded within the limits indicated in Table 5.8.

Table 5.8(Table 500-9) Grading Requirements for Mineral Filler

IS Sieve (mm)
0.6

Cumulative per cent passing by weight of total aggregate

100
56

(iii)

5.6.5

0.3
95 100
0.075
85 100
The filler shall be free from organic impurities and have a Plasticity Index not greater than
4. The Plasticity Index requirement shall not apply if filler is cement or lime. When the
coarse aggregate is gravel, 2 per cent by weight of total aggregate, shall be Portland
cement or hydrated lime and the percentage of fine aggregate reduced accordingly.
Cement or hydrated lime is not required when the limestone aggregate is used. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table 5.7, then 2
per cent by total weight of aggregate, of hydrated lime shall be added without additional
cost.

Aggregate Grading and Binder Content :

When tested in accordance with IS:2386 Part 1 (wet sieving method), the combined grading of the
coarse and fine aggregates and added filler for the particular mixture shall fall within the limits
shown in Table 5.9.

5.6.6

Requirement for the mixture :

Apart from conformity with the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 5.10

Table 5.9 (Table 500-10) Composition of Dense Graded Bituminous Macadam Pavement Layers
Grading
1
2
Nominal aggregate size
40 mm
25 mm
Layer Thickness
80 100 mm
50 75 mm
IS Sieve1 (mm)
Cumulative % by weight of total aggregate passing
45
100
37.5
95 100
100
26.5
63 93
90 100
19
71 95
13.2
55 75
56 80
9.5
4.75
38 - 54
38 54
2.36
28 42
28 42
1.18
0.6
0.3
7 21
7 21
0.15
0.075
28
28
Bitumen content % by
Min 4.0
Min 4.5
mass of total mix2
Bitumen grade (pen)
65 or 90
65 or 90
Notes: 1. The combined aggregate grading shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve.
2. Determined by the Marshall method.
Table 5.10( Table 500-11) Requirements for Dense Graded Bituminous Macadam
Minimum stability (kN at 60oC)

9.0
57

Minimum flow (mm)

Maximum flow (mm)
Compaction level (Number of blows)

2
4
75 blows on each of the
two faces of the specimen
Per cent air voids
36
Per cent voids in mineral aggregate (VMA) See Table 5.11 below
Per cent voids filled with bitumen (VFB)
65 75
The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in
Table 5.11.
Table 5.11( Table 500-12) Minimum per cent Voids in Mineral Aggregate (VMA)
Nominal Maximum
Particle Size1 (mm)

Minimum VMA, Per cent

Related to
Design Air Voids, Per cent2
3.0
4.0
5.0
9.5
14.0
15.0
16.0
12.5
13.0
14.0
15.0
19.0
12.0
13.0
14.0
25.0
11.0
12.0
13.0
37.5
10.0
11.0
12.0
Notes: 1. The nominal maximum particle size is one size larger than the first sieve to retain more
than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values
between those listed.

5.6.7

Job Mix Formula :

The permissible variations of the individual percentages of the various ingredients in the actual
mix from the job mix formula to be used shall be within the limits as specified in Table 5.12
below. These variations are intended to apply to individual specimens taken for quality control
tests in accordance with Section 900.

Table 5.12(Table 500-13) Permissible Variations from the Job Mix Formula
Description

Permissible variation
Base/binder course
Wearing course
8%
7%
7%
6%

Aggregate passing 19 mm sieve or larger

Aggregate passing 13.2mm, 9.5mm
58

Aggregate passing 4.75mm

Aggregate passing 2.36mm,1.18mm,0.6mm
Aggregate passing 0.3mm, 0.15mm
Aggregate passing 0.075mm
Binder content
Mixing temperature

6%
5%
4%
2%
0.3%
10oC

5%
4%
3%
1.5%
0.3%
10oC

5.7 SEMI-DENSE BITUMINOUS CONCRETE (SDBC)

5.7.1

5.7.2

5.7.3

Scope :
This clause specified the construction of Semi Dense Bituminous Concrete, for use in
wearing/binder and profile corrective courses. This work shall consist of construction in a single
or multiple layers of semi dense bituminous concrete on a previously prepared bituminous bound
surface. A single layer shall be 25mm to 100mm in thickness.
Bitumen :
The bitumen shall be paving bitumen of Penetration grade complying with Indian Standard
Specification for Paving Bitumen, IS:73 and of the penetration indicated in Table 5.14, for semi
dense bituminous concrete, or this bitumen as modified by one of the methods specified in Clause
521, or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade
of bitumen is given in the Manual for Construction and Supervision of Bituminous Works.
Coarse Aggregates :
The coarse aggregates shall be generally as specified in Clause 507.2.2, except that the aggregates
shall satisfy the physical requirements of Table 5.13.
Table 5.13(Table 500-14) Physical Requirements for Coarse Aggregate for Semi Dense
Bituminous Concrete Pavement Layers
Property
Cleanliness(dust)
Particle shape
Strength*
Polishing
Durability
Water Absorption
Stripping
Water Sensitivity**

Test
Grain size analysis1
Flakiness and Elongation Index
(Combined)2
Los Angeles Abrasion Value3
Aggregate Impact Value4
Polished Stone Value5
Soundness6
Sodium Sulphate
Magnesium Sulphate
Water absorption7
Coating and Stripping of Bitumen
Aggregate Mixtures9

Specification
Max 5% passing 0.075 mm sieve
Max 30 %

Retained Tensile Strength8

Min 80 %

Max 35 %
Max 27 %
Min 55
Max 12 %
Max 18 %
Max 2 %
Minimum retained coating
95%

Notes : 1. IS: 2386 Part 1

6. IS: 2386 Part 5
2. IS: 2386 Part 1
7. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4*
8. AASHTO T283**
4. IS: 2386 Part 4*
9. IS: 6241
59

5. BS: 812 Part 114

* Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the
stripping test is less than 95%.
The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in Table
5.11.
5.7.4

Fine aggregates :
The fine aggregates shall be all as specified in Clause 507.2.3.

5.7.5

Filler :
Filler shall be generally as specified in Clause 507.2.4. Where the aggregates fail to meet
the requirements of the water sensitivity test in Table 5.13 then 2 per cent by total weight of
aggregate, of hydrated lime shall be added without additional cost.

5.7.6

Aggregate grading and binder content :

When tested in accordance with IS:2386 Part 1 (Wet sieving method), the combined
grading of the coarse and fine aggregates and added filler shall fall within the limits shown in
Table 5.14 for gradings 1 or 2 as specified in the Contract.

5.7.7

Requirements for the mixture :

Apart from conformity with the grading and quality requirements for individual
ingredients the mixture shall meet the requirements set out in Table 5.15.

5.7.8

Binder content :
The binder content shall be optimised to achieve the requirements of the mixture set out in
Table 5.15 and the traffic volume as specified in the Contract. The Marshall method for
determining the optimum binder content shall be adopted as described in the Asphalt Institute
Manual MS-2, replacing the aggregates retained on the 26.5mm sieve and retained on the 22.4mm
sieve, where approved by the Engineer.

Table 5.14 (Table 500-15) Composition of Semi Dense Bituminous Concrete Pavement
Layers
Grading
1
2
Nominal aggregate size
13 mm
10 mm
Layer Thickness
35 40 mm
25 30 mm
1
IS Sieve (mm)
Cumulative % by weight of total aggregate passing
45
60

37.5
26.5
19
100
13.2
90 100
100
9.5
70 - 90
90 100
4.75
35 - 51
35 51
2.36
24 39
24 39
1.18
15 - 30
15 30
0.6
0.3
9 19
9 19
0.15
0.075
38
38
Bitumen content % by
Min 4.5
Min 5.0
mass of total mix2
Bitumen grade
65*
65*
(penetration)
Notes: 1. The combined aggregate grading shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve.
2. Determined by the Marshall method.
3. Only in exceptional circumstances, 80/100 penetration grade may be used, as approved by
the Engineer.
Table 5.15 ( Table 500-16) Requirements for Semi Dense Bituminous Pavement Layers
Minimum stability (kN at 60oC)
Minimum flow (mm)
Maximum flow (mm)
Compaction level (Number of blows)
Per cent air voids
Per cent voids in mineral aggregate (VMA)
Per cent voids filled with bitumen (VFB)
5.7.9

8.2
2
4
75 blows on each of the
two faces of the specimen
35
See Table 5.11
65 78

Job Mix Formula :

The procedure for formulating the job mix formula shall be generally as specified in Clause
507.3.3 and the results of tests enumerated in Table 5.15 as obtained by the Contractor.

5.8 BITUMINOUS CONCRETE

5.8.1

Scope :
This clause specifies the construction of Bituminous Concrete, for use in wearing and profile
corrective courses. This work shall consist of construction in a single or multiple layers of
61

bituminous concrete on a previously prepared bituminous bound surface. A single layer shall be
25mm to 100mm in thickness.
5.8.2

Bitumen :
The bitumen shall be paving bitumen of Penetration grade complying with Indian Standard
Specification for Paving Bitumen IS:73 and of the penetration indicated in Table 5.17, for
bituminous concrete, or this bitumen as modified by one of the methods specified in Clause 521,
or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade of
bitumen is given in The Manual for Construction and Supervision of Bituminous Works.

5.8.3

Coarse Aggregates :
The coarse aggregates shall be generally as specified in Clause 507.2.2, except that the aggregate
shall satisfy the physical requirement of Table 5.16.

5.8.4

Fine Aggregate :
The fine aggregate shall be all as specified in Clause 507.2.3.
5.8.5

Filler :

Filler shall be generally as specified in Clause 507.2.4. Where the aggregate fail to meet the
requirements of the water sensitivity test in Table 5.16 then 2 per cent by total weight of
aggregate, of hydrated lime shall be added without additional cost.
5.8.6

Aggregate grading and binder content :

When tested in accordance with IS:2386 Part 1 (Wet grading method), the combined grading of
the course and fine aggregates and added filler shall fall within the limits shown in Table 5.17 for
gradings 1 or 2 as specified in the Contract.

5.8.7

Requirements for the mixture :

Apart from conformity with the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 5.11.

5.8.8

Binder content :
The binder content shall be optimised to achieve the requirements of the mixture set out in Table
5.18 and the traffic volume as specified in the Contract. The Marshall method for determining the
optimum binder content shall be adopted as described in the Asphalt Institute Manual MS-2,
replacing the aggregates retained on the 26.5mm sieve and retained on the 22.4mm sieve, where
approved by the Engineer.

5.8.9

Job Mix Formula :

The procedure for formulating the job mix formula shall be generally as specified in Clause
507.3.3 and the results of tests enumerated in Table 5.18 as obtained by the Contractors.

62

Table 5.16 (Table 500-17) Physical Requirements for Coarse Aggregate for Bituminous
Concrete Pavement Layers.
Property
Cleanliness(dust)
Particle shape
Strength*
Polishing
Durability
Water Absorption
Stripping
Water Sensitivity**

Test
Grain size analysis1
Flakiness and Elongation Index
Los Angeles Abrasion Value3
Aggregate Impact Value4
Polished Stone Value5
Soundness6
Sodium Sulphate
Magnesium Sulphate
Water absorption7
Coating and Stripping of Bitumen
Aggregate Mixtures9

Specification
Max 5% passing 0.075 mm sieve
Max 30 % (Combined)2
Max 30 %
Max 24 %
Min 55

Retained Tensile Strength8

Min 80 %

Max 12 %
Max 18 %
Max 2 %
Minimum retained coating
95%

Notes : 1. IS: 2386 Part 1

6. IS: 2386 Part 5
2. IS: 2386 Part 1
7. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4*
8. AASHTO T283**
4. IS: 2386 Part 4*
9. IS: 6241
5. BS: 812 Part 114
* Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the
stripping test is less than 95%.

Table 5.17(Table 500-18) Composition of Bituminous Concrete Pavement Layers

Grading
1
2
Nominal aggregate size
19 mm
13 mm
63

Layer Thickness
50 65 mm
30 45 mm
1
IS Sieve (mm)
Cumulative % by weight of total aggregate passing
45
37.5
26.5
100
19
79 - 100
100
13.2
59 79
79 100
9.5
52 - 72
70 88
4.75
35 - 55
53 71
2.36
28 44
42 58
1.18
20 - 34
34 48
0.6
15 - 27
26 38
0.3
10 20
18 28
0.15
5 - 13
12 20
0.075
28
4 10
Bitumen content % by
5.0 6.0
5.0 7.0
mass of total mix2
Bitumen grade
65
65
(penetration)
Notes: 1. The combined aggregate grading shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve.
2. Determined by the Marshall method.
Table 5.18 (Table 500-19) Requirements for Bituminous Pavement Layers
Minimum stability (kN at 60oC)
Minimum flow (mm)
Maximum flow (mm)
Compaction level (Number of blows)
Per cent air voids
Per cent voids in mineral aggregate (VMA)
Per cent voids filled with bitumen (VFB)
Loss of stability on immersion in water at
60oC (ASTM D 1075)

9.0
2
4
75 blows on each of the
two faces of the specimen
36
See Table 5.11
65 75
Min. 75 per cent
retained strength

5.9 SURFACE DRESSING

5.9.1 Scope :
The work shall consist of the application of one coat or two coats of surface dressing, each coat
consisting of a layer of bituminous binder sprayed on a previously prepared base, followed by a
cover of stone chips rolled in to form a wearing course to the requirements of MoRT&H
64

Specifications. For information on the Design of Surface Dressing refer to the Manual for
Construction and Supervision of Bituminous Works.
5.9.2

Binder :
The binder shall have a kinematic viscosity lying in the range 1x10 4 to 7x105 centistokes at the
expected range of road surface temperatures at the construction site during the period of laying.
The type of binder to be used will be stated in the Contract documents and shall comply with one
of the following:
Paving Bitumen
IS: 73
Bitumen Emulsion
IS: 8887

5.9.3

Aggregates :
The chips shall conform to the requirements of Clause 504.2.2., except that their water absorption
shall be restricted to a maximum of 1 per cent and they shall have a Polished Stone value, as
measured by the method given in BS812 (Part 114), of not less than 60. The chips shall be single
sized, clean, hard, durable, of cubical shape, free from dust and soft or friable matter, organic or
other deleterious matter and conforming to one of the gradings given in Table 5.19 below.
Table 5.19(Table 500-21) Grading Requirements for Chips for Surface Dressing
IS Sieve
Designation
mm
26.5
19.0
13.2
9.5
6.3
4.75
3.35
2.36
0.60
0.075
Minimum 65%
by weight of
aggregate

5.9.4

Cumulative per cent by weight of total aggregate passing

for the following nominal sizes (mm)
19
13
10
6
100
85-100
100
0-40
85-100
100
0-7
0-40
85-100
100
0-7
0-35
85-100
0-10
0-35
0-2
0-2
0-2
0-10
0-2
0 1.5
0 1.5
0 1.5
0 1.5
Passing 19
Passing
Passing 9.5
Passing
mm, retained
13.2mm,
mm,
6.3mm,
13.2mm
retained
retained 6.3
retained
9.5 mm
mm
3.35 mm

Rates of spread of binder and chips :

For the purpose of pricing the Bill of Quantities the rates of spread given in Table 5.20 shall be
priced.
Table 5.20 (Table 500-20) Nominal Rates of Spread for Binder and Chippings1
65

Nominal Chipping Size

Mm

Binder (penetration grade

Chips
bitumen)
Cum/m2
2
kg/m
19
1.2
0.015
13
1.0
0.010
10
0.9
0.008
6
0.75
0.004
Notes: 1.These rates of spread are for pricing purposes see Clause 510.2.3 and Clause 510.8.
2. For emulsion, these rates of spread are for the residual bitumen and appropriate
adjustment must be made to determine the total quantity.
3. Refer to Manual for Construction and Supervision of Bituminous Works for the
procedure of determining the rates of spread of binder and chips.
5.9.5

Application of binder :
The equipment and general procedures shall all be in accordance with the Manual for
Construction and Supervision of Bituminous Works. The application temperature for the grade of
binder used shall be as given in Table 5.21 and the rate of spray as given in 510.2.3.
Table 5.21 (Table 500-22) Spraying Temperatures for Binders
Binder grades
Whirling spray jets
Slot jets
o
o
Min C
Max C
MinoC
MaxoC
Penetration Grades
400/500
160
170
140
150
280/320
165
175
150
160
180/200
170
190
155
165
80/100
180
200
165
175

5.10

OPEN-GRADED PREMIX SURFACING

5.10.1 Scope :
This work shall consist of the preparation, laying and compaction of an open-graded premix
surfacing material of 20mm thickness composed of small-sized aggregate premixed with a
66

bituminous binder on a previously prepared base, in accordance with the requirements of

MoRT&H Specifications, to serve as a wearing course.
5.10.2 Binder :
The binder shall be a penetration bitumen of a suitable grade as specified in the Contract, or as
directed by the Engineer, and satisfying the requirements of IS: 73.
5.10.3 Aggregate :
The aggregate shall conform to Clause 504.2.2 except that the water absorption shall be limited to
a maximum of 1 per cent. The Polished Stone Value, as measured by the test in BS 812-(Part 114),
shall not be less than 55.
5.10.4 Proportioning of materials :
The materials shall be proportioned in accordance with Table 5.22.
Table 5.22 (Table 500-23) Quantities of Materials Required for 10m2 of Road Surface for
20mm Thick Open-Graded Premix Surfacing using Penetration Bitumen or Cutback.
Aggregates
(a)

Nominal Stone size 13.2 mm (passing 22.4 mm

sieve and retained on 11.2 mm sieve)
(b)
Nominal Stone size 11.2 mm (passing 13.2 mm
sieve and retained on 5.6 mm sieve)
Total
Binder (Quantities in terms of straight run bitumen)
For 0.18 m3 of 13.2 mm nominal size stone at 52
kg bitumen per m3
For 0.09 m3 of 11.2 mm nominal size stone at
56 kg bitumen per m3
Total

5.11

0.18m3
0.09 m3
0.27 m3
9.5 kg
5.1 kg
14.6 kg

OPEN GRADED PREMIX SURFACING USING CATIONIC

BITUMEN EMULSION

5.11.1 Scope :
67

This work shall consist of the preparation, laying and compaction of an open graded premix
surfacing of 20mm thickness composed of small-sized aggregate premixed with a cationic
bitumen emulsion on a previously prepared surface, in accordance with the requirements of
MoRT&H Specifications, to serve as a wearing course.
5.11.2 Binder :
The binder for Premix wearing course shall be cationic bitumen emulsion of Medium Setting
(MS) grade complying with I.S.8887 and having a bitumen content 65 per cent minimum by
weight. For liquid seal coat RS grade of Cationic bitumen emulsion shall be used. Where
expressly specified in the Contract MS grade emulsion shall be used or otherwise directed by the
Engineer. Slow Setting (SS) grade Cationic bitumen Emulsion shall be used for premix seal coat.
5.11.3 Aggregate :
The requirements of Clause 511.1.2.2 shall apply.
5.11.4 Proportioning of materials :
The materials shall be proportional as quantities given in Tables 5.23 and 5.24.
Table 5.23(Table 500-24) Quantities of Aggregate for 10m2 Area
(A)
(a)
(b)
(B)

Premix Carpet
Coarse aggregate nominal 13.2 mm size; passing IS
22.4mm sieve and retained on IS 11.2 mm sieve
Coarse aggregate nominal 11.2 mm size; passing IS
13.2mm sieve and retained on IS 5.6 mm sieve
For Seal Coat
Refer to Clause 513.

0.18m3
0.09 m3

Table 5.24 (Table 500-25) Quantities of Emulsion Binder

For 10m2 area
20 to 23 kg

(A) For Premix Carpet :

(B) For Seal Coat
(a For liquid seal coat
)
( For premix seal coat
b
)

5.12

12 to 14 kg
10 to 12 kg

CLOSE-GRADED PREMIX SURFACING/MIXED SEAL SURFACING

68

5.12.1 Scope :
(i)

This work shall consist of the preparation, laying and compaction of a close-graded
premix surfacing material of 20 mm thickness composed of graded aggregates premixed
with a bituminous binder on a previously prepared surface, in accordance with the
requirements of MoRT&H Specifications, to serve as a wearing course.

(ii)

Close graded premix surfacing shall be of Type A or Type B as specified in the Contract
documents.

5.12.2 Binder :
The provisions of Clause 511.1.2.1 shall apply.
5.12.3 Coarse aggregates :
The provisions of Clause 511.1.2.2 shall apply.
5.12.4 Fine aggregates:
The fine aggregates shall consist of crushed rock quarry sands, gravel/ sand or a mixture of both.
These shall be clean, hard, durable, un-coated, mineral particles, dry and free from injurious, soft
or flaky particles and organic or deleterious substances.
5.12.5 Aggregate gradation:
The coarse and fine aggregates shall be so graded or combined as to confirm to one or the other
gradings shown in Table 5.25 below as specified in the Contract.
Table 5.25 (Table 500-26) Aggregate Gradation
IS Sieve
Designation
(mm)
13.2 mm
11.2 mm
5.6 mm
2.8 mm
0.090 mm

Cumulative per cent by weight of

total aggregate passing
Type A
Type B
100
100
88 100
52 88
31 52
14 38
5 25
0-5
05

5.12.6 Proportioning of materials:

The total quantity of aggregates used for Type A or B close-graded premix surfacing shall be 0.27
cubic metre per 10 square metre area. The quantity of binder used for premixing in terms of
straight-run bitumen shall be 22.0 kg and 19.0 kg per 10 square metre area for Type A and Type B
surfacing respectively.

5.13 SEAL COAT

5.13.1 Scope :
69

(i)

This work shall consist of the application of a seal coat for sealing the voids in a
bituminous surface laid to the specified levels, grade and cross fall (camber).

(ii)

Seal coat shall be of either of the two types specified below :-

(A) Liquid seal coat comprising of an application of a layer of bituminous binder followed by a
cover of stone chips.
(B) Premixed seal coat comprising of a thin application of fine aggregate premixed with
bituminous binder.
5.13.2 Binder :
(i)

The requirements of Clauses 511.1.2.1 and 511.2.2.1 shall apply.

(ii)

The quantity of bitumen per 10 square metres, shall be 9.8 kg for Type A, and 6.8 kg for
Type B seal coat. Where bituminous emulsion is used as a binder the quantities for Type A
and Type B seal coats shall be 15 kg and 10.5 kg respectively.

5.13.3 Stone Chips for Type A seal coat :

The stone chips shall consist of angular fragments of clean, hard, tough and durable rock of
uniform quality throughout. They should be free of soft or disintegrated stone, organic or other
deleterious matter. Stone chips shall be of 6.7 mm size defined as 100 % passing through 11.2mm
sieve and retained on 2.36 mm sieve. The quantity used for spreading shall be 0.09 cubic metre
per 10 square metre area. The chips shall satisfy the quality requirements in Table 5.3 except that
the upper limit for water absorption value shall be 1 per cent.
5.13.4 Aggregate for Type B seal coat :
The aggregates shall be sand or grit and shall consist of clean, hard, durable, uncoated dry
particles and shall be free from dust, soft or flaky/ elongated material, organic matter or other
deleterious substances. The aggregate shall pass 2.36 mm sieve and be retained on 180 micron
sieve. The quantity used for premixing shall be 0.06 cubic metres per 10 square metres area.
5.13.5 Construction of Type A seal coat :
(i)

Bitumen shall be heated to 150oC-163oC and sprayed at the rate specified on the dry
surface in a uniform manner with a self-propelled mechanical sprayer as described in the
Manual for Construction and Supervision of Bituminous Works.

(ii)

Immediately after the application of binder, stone chips, which shall be clean and dry, shall
be spread uniformly at the rate specified on the surface preferably by means of a selfpropelled or towed mechanical grit spreader so as to cover the surface completely. If
necessary, the surface shall be brushed to ensure uniform spread of chips.

70

(iii)

Immediately after the application of the cover material, the entire surface shall be rolled
with a 8 10 tonne smooth wheeled steel roller, 8 10 tonne static weight vibratory roller,
or other equipment approved by the Engineer after laying trials if required.
Rolling shall commence at the edges and progress towards the centre except in superelevated and unidirectional cambered portions where it shall proceed from the lower edge
to the higher edge. Each pass of the roller shall uniformly overlap not less than one-third
of the track made in the preceding pass. While rolling is in progress, additional chips shall
be spread by hand in necessary quantities required to make up irregularities. Rolling shall
continue until all aggregate particulars are firmly embedded in the binder and present a
uniform closed surface.

5.13.6 Construction of Type B seal coat :

(i)

A mixer of appropriate capacity and type approved by the Engineer shall be used for
preparation of the mixed material. The plant shall have separate dryer arrangements for
heating aggregate.

(ii)

The binder shall be heated in boilers of suitable design, approved by the Engineer to the
temperature appropriate to the grade of bitumen or as directed by the Engineer. The
aggregates shall be dry and suitably heated to a temperature between 150 oC and 165oC or
as directed by the Engineer before these components are placed in the mixer. Mixing of
binder with aggregates to the specified proportions shall be continued until the latter are
thoroughly coated with the former.

(iii)

The mix shall be immediately transported from the mixing plant to the point of use and
spread uniformly on the bituminous surface to the sealed.

(iv)

As soon as a sufficient length has been covered with the premixed material, the surface
shall be rolled with an 8 10 tonne smooth-wheeled roller. Rolling shall be continued
until the premixed material completely seals the voids in the bituminous course and a
smooth uniform surface is obtained.

5.14 MASTIC ASPHALT

71

5.14.1 Scope :
(i)

This work shall consist of constructing of a single layer of mastic asphalt wearing course
for road pavements and bridge decks.

(ii)

Mastic asphalt is an intimate homogeneous mixture of selected well-graded aggregates,

filler and bitumen in such proportions as to yield a plastic and voidless mass, which when
applied hot can be trowelled and floated to form a very dense impermeable surfacing.

5.14.2 Binder:
Subject to the approval of the Engineer, the binder shall be a paving grade bitumen meeting the
requirements given in Table 5.26.
5.14.3 Coarse Aggregate:
(i)

The coarse aggregate shall consist of crushed stone, crushed gravel/ shingle or other
stones. They shall be clean, hard, durable, of fairly cubical shape, uncoated and free from
soft, organic or other deleterious substances. They shall satisfy the physical requirements
given in Table 5.3.

(ii)

The percentage and grading of the coarse aggregate to be incorporated in the mastic
asphalt depending upon the thickness of the finished course shall be as specified in Table
5.27 below.

Table 5.26(Table 500-29) Requirements for Physical Properties of Binder

Property
Test method Requirement
o
Penetration at 25 C
IS 1203
15 5*
Softening point, oC
IS 1205
65 10
o
Loss on heating for 5h at 163 C, % by mass Max.
IS 1212
2.0
Solubility in tricholoethylene, % by mass
Min.
IS 1216
95
Ash (mineral matter), % by mass
Max.
IS 1217
1.0
*In cold climatic regions (temperature 10oC), a softer penetration grade of 30/40 may be used.

Table 5.27 (Table 500-30) Grade and Thickness of Mastic Asphalt paving, and
Grading of Coarse Aggregate
72

Application

Thickness
range(mm)

Nominal size
of coarse
aggregate(mm)
13
13

Roads and carriageways

25 - 50
Heavily stressed areas i.e
40 - 50
junctions and Toll Plazas
Nominal size of coarse aggregate
IS Sieve (mm)
19
13.2
2.36

Coarse aggregate
content, % by
mass of total mix
40 10
45 10

13 mm
Cumulative % passing by weight
100
88 96
05

5.14.4 Fine Aggregate :

The fine aggregate shall be the fraction passing the 2.36 mm and retained on the 0.075 mm sieve
consisting of crusher run screening, natural sand or a mixture of both. These shall be clean, hard,
durable, uncoated, dry and free from soft or flaky pieces and organic or other deleterious
substances.
5.14.5 Filler :
(i)

The filler shall be limestone powder passing the 0.075 mm sieve and shall have a calcium
carbonate content of not less than 80 percent by weight when determined in accordance
with IS: 1514.

(ii)

The grading of the fine aggregate inclusive of filler shall be as given in Table 5.28 below.
Table 5.28(Table 500-31) Grading of Fine Aggregate (Inclusive of Filler)

IS Sieve (mm)
Passing 2.36 mm but retained on 0.600 mm
Passing 0.600 mm but retained on 0.212 mm
Passing 0.212 mm but retained on 0.075 mm
Passing 0.075

Percentage by weight of aggregate

0 - 25
10 30
10 30
30 - 55

5.15 SLURRY SEAL

5.15.1 Scope :
73

Slurry seal are mixtures of fine aggregate, Portland cement filler, bitumen emulsion and additional
water. When freshly mixed, they have a thick consistency and can be spread to a thickness of 1.5
5 mm. They may be used to seal cracks, arrest fretting and fill voids and minor depressions, to
provide a more even riding surface or a base for further treatment; they may also be used on top of
a single coat surface dressing.
5.15.2 Emulsified bitumen :
The emulsified bitumen shall be a cationic rapid setting type as approved by the Engineer,
conforming to the requirements of IS:8887. Where special mobile mixing machines are available,
Class A4* rapid setting or Class K3* road emulsions to BS 434: Part 1 should be used to obtain
very early resistance to traffic and rain. Generally, emulsion for slurry seal should be capable of
producing a slurry that will develop early resistance to traffic and rain and is sufficiently stable to
permit mixing with the specified aggregate, without breaking during the mixing and laying
processes. If approved by the Engineer, a slow setting emulsion may be used. Guidance on
selection of an appropriate grade of emulsion is given in the Manual for Construction and
Supervision of Bituminous Works.
5.15.3 Water :
(i)

Water shall be of such quality that the bitumen will not separate from the emulsion before
the slurry seal is in place.

(ii)

The pH of the water must lie in the range 4 to 7, and if the total dissolved solids in the
water amount to more than 500ppm, the Engineer may reject it, or order the Contractor to
conduct a trial emulsion mix to demonstrate that it does not cause early separation.

5.15.4 Aggregate :
The aggregate shall be crushed rock, or slag and may be blended, if required, with clean, sharp,
naturally occurring sand free from soft pieces and organic and other deleterious substances to
produce a grading as given in Table 5.29. The aggregates shall meet the requirements of the film
stripping test (IS:6241), and a suitable amount and type of anti-stripping agent added, as may be
needed (details given in Appendix 5).
5.15.5 Additives :
It is usual to use ordinary Portland cement, hydrated lime or other additives to control consistency,
mix segregation and setting rate. The proportion of the additive should not normally exceed 2
percent by weight of dry aggregates.
Table 5.29(Table 500-33) Aggregate Grading, Binder Content and Approximate Coverage
Rate
Sieve Size (mm)

Percentage by mass passing finished

thickness of sealing
74

9.5
4.75
3.35
2.36
1.18
0.600
0.300
0.150
0.075
Quantity or residual binder,
percentage by mass of
aggregate
Approximate coverage
rate(kg/m2)

5 mm
100
90-100
65-90
45-70
30-50
18-30
10-21
5-15
7.5 13.5

3 mm
100
80-100
75-100
55-90
35-70
20-45
10-25
5-15
10 - 16

1.5 mm
100
95-100
70-95
55-75
30-50
10-30
5-15
12 - 20

8 - 15

4-6

2-4

5.16 FOG SPRAY

5.16.1 Scope :Fog spray is a very light application of low viscosity bitumen emulsion for purposes of
sealing cracks less than 3mm wide or incipient fretting or disintegration in an existing bituminous
surfacing, and to help reduce loosening of chips by traffic on newly finished surface dressing.
5.16.2 Material :
(i)

The bitumen emulsion shall be as specified in the Contract or as instructed by the

Engineer. The emulsion shall be
SS-1h* (SS-1 can be used if the former is not available) complying with the requirements
of ASTM D-977, or;
CSS-1h* (CSS-1 can be used if the former is not available) complying with the
requirements of ASTM D-2397.

(ii)

Before use these emulsions shall be diluted, 1 part emulsion to 1 part water. Alternatively,
Class A 1-40* or K1-40* emulsions complying with the requirements of BS434:Part
1:1984 may be used. These emulsions have a lower viscosity than the above ASTM
grades, they are rapid setting and they do not require to be diluted. Because of their low
viscosity they should be used as soon as possible after delivery. If this is not possible, the
drums should be very thoroughly rolled before use.

5.16.3 Weather and Seasonal Limitations :

75

Spraying shall not take place when the temperature is below 10 oC, nor in windy or dusty
conditions, nor when it is raining or the surface to be sprayed is wet (a damp surface is acceptable
but refer to Clause 518.4.2).
5.17 MODIFIED BINDER
5.17.1 Scope :
Modified binders comprise a base binder, to which is added either natural rubber, crumb rubber or
a polymer. The purpose is to achieve a high performance binder with improved properties,
particularly at extremes of temperature.
5.17.2 Base Binder :
The base binder into which the modifier is incorporated shall conform to IS: 73. The choice of
grade shall be such that it is compatible with the modifier and, when mixed shall have the
properties described in Clause 521.3.
5.17.3 Modifier :
The modifier shall be a natural rubber, crumb rubber or any other polymer which is compatible
with the base binder and which allows the properties given in Clause 521.3 to be achieved. For
further details, IRC:SP:53-1999 may be referred to. The modifier, in the required quantity shall be
blended at the refinery or at the site plant capable of producing modified binder.
5.17.4 Modifier Proportions :
The quantity of modifier to be added shall be determined by tests on the base binder and the
modified binder and the properties desired. A reference may be made to the Manual for
Construction and Supervision of Bituminous Works for indicative dosage of different types of
modifiers. The properties of the modified binder shall be as given in Table 5.30 and 5.31.
according to the requirements of the Contract.

Table 5.30(Table 500-44) Requirements of Polymer Modified Binders (Elastomeric

Thermoplastics and Rubber Latex)
76

Designation

Grade and Requirements

PMB
PMB 70 PMB40
120
90 to 150 50 to 89 30 to 49

Penetration at 25oC, 0.1 mm,

100g, 5 sec.
Penetration at 4 oC, 0.1mm,
35
22
200g, 60 sec., Minimum*
Softening Point, (R&B), oC, Minimum
38
48
Fraass Breaking Point, oC, Maximum*
-24
-16
Ductility at 27 oC, cm, Minimum
75
50
o
Flash Point, COC, C, Minimum
220
220
Elastic Recovery of Half Thread in
70
60
o
Ductilometer at 15 C, % Minimum
(50)**
(40)**
Separation, Difference in Softening
4
4
o
Point, R&B, C, Maximum
Viscosity at 150oC, Poise
1-3
2-6
Test on Thin Film Oven Test Residue, TFOT (IS:9382-1979)
Penetration at 4oC, 0.1 mm, 200g,
18
15
60 sec., Minimum*
Loss in Weight, %, Maximum
1.0
1.0
Increase in Softening Point, oC,
7
6
Maximum
Reduction in Penetration at 25oC,
35
35
%, Maximum
Elastic Recovery of Half Thread in
60
40
o
Ductilometer at 15 C, % Minimum
(35)**
(30)**
* Relevant to snow bound cold climate areas
**Natural Rubber Modified Bitumen

Method of Test
IS:1203-1978

18

IS:1205-1978

59
-12
50
220
50
(30)**
4
4-8

IS:1205-1978
IS:9381-1978
IS:1208-1978
IS:1209-1978
ASTM
D5976-1996
ASTM
D5976-1996
IS:1206-1978

12

IS:1203-1978

1.0
5

IS:9382-1979
IS:1205-1978

35

IS:1203-1978

35
(25)**

ASTM
D5976-1996

Table 5.31(Table 500-46) Requirements of Polymer Modified Binders (Treated with Modified
Crumb Rubber)
77

Designation

Grade and Requirements

CRMB
120
50-70

Penetration at 25oC, 0.1 mm,

100g, 5 sec.
Softening Point, (R&B), oC,
50
Minimum
Elastic Recovery of Half Thread in
40
o
Ductilometer at 15 C, % Minimum
Test on Thin Film Oven Test Residue, (IS:9382-1979)
Reduction in Penetration at 25oC,
60
%, Maximum
Increase in Softening Point (R&B),
5
0
C, Maximum
Elastic Recovery of Residue of Half
25
Thread in Ductilometer at 15 oC, %
Minimum
CRMB Crumb Rubber Modified Bitumen

CRMB
70
50-60

Method of
Test

CRMB4
0
40-60

IS:1203-1978

55

60

IS:1205-1978

35

30

ASTM
D5976-1996

60

60

IS:1203-1978

IS:1205-1978

20

15

ASTM
D5976-1996

5.18 CRACK PREVENTION COURSES

5.18.1 Scope :
This clause covers the provision of Stress Absorbing Membrane (SAM) and Stress Absorbing
Membrane Interlayer (SAMI) as measures to inhibit the propagation of cracks. A SAM is an
elastomeric bitumen rubber membrane, which is laid over a cracked road surface, together with a
covering of aggregate chips, in order to extend the life of the pavement before major treatment is
carried out. SAM can be laid as a single coat or a double coat. A SAMI is a layer which is applied
to a cracked pavement surface but which is followed (within 12 months) by the application of an
overlay course. A SAMI may be a material similar to that used for a SAM. It may alternatively
consist of a bitumen impregnated geo-textile.
5.18.2 Binder :
Binder shall be a modified binder complying with the requirements of Clause 523, according to
the requirements of the Contract, except that paving grade bitumen of 80-100 penetration
complying with the requirements of IS:73 shall be used in the case of a bitumen impregnated geotextile.
5.18.3 Aggregate :
The requirements of Clause 510.2.2 apply except that the Polished Stone Value requirements does
not apply in the case of a SAMI. Where required by the contract, aggregate shall be pre-coated
using either of the techniques permitted by the Clause 510.2.5.

5.18.4 Rates of spread of binder and aggregate :

78

The rates of spread of binder and aggregate shall be according to one of the size alternatives in
Table 5.32, as specified by the Contract.
Table 5.32 (Table 500-47) Quantity of Materials Required for 10 Sq.m of Road Surface for
Stress Absorbing membrane
Sl.
No

Type and Width of

Crack

Specification of SAM
to be applied

1.

Hair cracks and map

cracks upto 3mm width
Map cracks or alligator
cracks 3mm to 6mm width
Map cracks or alligator
cracks 6mm to 9mm width

Single coat SAM or 2nd

coat of two coat SAM
Single coat SAM

2.
3.
4.
5.
6.
7.

Two coat SAM

1st coat
2nd coat
Two coat SAM
1st coat
2nd coat
Single coat SAM as
interlayer
Single coat SAM as
interlayer

Quantity Quantity of Chipping

of binder
Kg/10m2
8 10
0.10m3 of 5.6mm chips
10 -12

0.11m3 of 5.6mm chips

12 14

0.12m3 of 5.6mm and

11.2mm chips in 1:1 ratio
0.103 of 5.6mm chips

Cracks above 9mm width

and cracked area above
14 16
0.12m3 of 11.2mm chips
50%
8 - 10
0.103 of 5.6mm chips
All types of cracks with
8 - 10
0.10 m3 of 5.6mm chips
crack width below 6mm
All types of cracks with
10 - 12
0.10 m3 of 11.2mm chips
crack width above 6mm
Bitumen Impregnated
Geo-textile
Note 1: Binder quantities for bitumen impregnated geotextile shall be in the range 0.9 to 1.2 litres/
m2. Binder quantities outside this range are permitted according to the geotextile
manufacturers instructions and subject to the agreement of the Engineer.

CHAPTER-5 : BASES AND SURFACE COURSES (BITUMINOUS)

Sl

Reference

Item

Descriptions

79

Unit

Rate

No
5.1

to
MoRT&H
Specificat
ions
502

In
figure
s
(`)

No.
Prime coat
Providing and applying primer
coat with bitumen emulsion on
prepared surface of granular base
including clearing of road surface
and spraying primer at the rate of
0.60 kg/sqm using mechanical
means.
I. Low Porosity
II. Medium Porosity
III.High Porosity

5.2

503

(i)
(ii)
(iii)
(iv)
(v)
5.3

In words

504

(i)

(ii)

Tack coat.
Providing and applying tack coat
with bitumen emulsion using
emulsion pressure distributor at
the rate of 0.20 kg per sqm on the
prepared
bituminous/granular
surface cleaned with mechanical
broom.
Normal Bituminous surface @
0.25kg/sqm
Dry
and
Hungry
Bituminous
Surface @0.3kg/sqm
Granular surface treated with
primer @0.3kg/sqm
Non
bituminous
surface
@0.4kg/sqm
Cement
Concrete
base
@0.35kg/sqm
Bituminous Macadam
Providing and laying bituminous
macadam with 100-120 TPH hot
mix plant producing an average
output of 75 tonnes per hour using
crushed aggregates of specified
grading premixed with bituminous
binder, transported to site, laid
over a previously prepared surface
with paver finisher to the required
grade, level and alignment and
rolled as per Clauses 501.6 and
501.7 to achieve the desired
compaction
For Grading I ( 40 mm nominal
size )
For GradingII (19 mm nominal
size)

80

Rupees Fifty Nine

Only
Rupees Seventy
Seven only
Rupees Ninety Five
Only

sqm

59.00

sqm

77.00

sqm

95.00

sqm

17.00

Rupees Seventeen
Only

sqm

20.00

Rupees Twenty Only

sqm

20.00

Rupees Twenty Only

sqm

26.00

sqm

23.00

cum

9571.0
0

cum

9703.0
0

Rupees Twenty Six

Only
Rupees Twenty Three
Only

Rupees Nine
Thousand Five
Hundred and Seventy
One Only
Rupees Nine
Thousand Seven

Hundred and Three

Only
5.4

5.5

506

Built-Up-Spray Grout:

507

(i)
(ii)
5.6

508

Providing, laying and rolling of

built-up-spray grout layer over
prepared base consisting of a two
layer composite construction of
compacted
crushed
coarse
aggregates using motor grader for
aggregates.
key
stone
chips
spreader may be used with
application of bituminous binder
after each layer, and with key
aggregates placed on top of the
second layer to serve as a base
conforming to the line, grades and
cross-section
specified,
the
compacted layer thickness being
75 mm
Dense
Graded
Bituminous
Macadam:
Providing and laying dense graded
bituminous macadam with 100120
TPH
batch
type
HMP
producing an average output of 75
tonne per hour using crushed
aggregates of specified grading,
premixed with bituminous binder
@ 4.0 to 4.5 percent by weight of
total mix of mix and filler,
transporting the hot mix to work
site, laying with a hydrostatic
paver finisher with sensor control
to the required grade, level and
alignment, rolling with smooth
wheeled, vibratory and tandem
rollers to achieve the desired
compaction
as
per
MoRTH
specification Clause 507 complete
in all respects.
for Grading I ( 40 mm nominal
size )

sqm

445.00

cum

11059.
00

for GradingII(19 mm nominal

size)

cum

11060.
00

Semi
Concrete

Dense

Bituminous

81

Rupees Four Hundred

and Forty Five Only

Rupees Eleven
Thousand and Fifty
Nine Only
Rupees Eleven
Thousand and Sixty
Only

I
(i)

(ii)

II
(i)

(ii)

III
(i)
(ii)

5.7

509

Providing and laying semi dense

bituminous concrete with 100-120
TPH batch type HMP producing an
average output of 75 tonnes per
hour using crushed aggregates of
specified grading, premixed with
bituminous binder @ 4.5 to 5
percentof
mix
and
filler,
transporting the hot mix to work
site, laying with a hydrostatic
paver finisher with sensor control
to the required grade, level and
alignment, rolling with smooth
wheeled, vibratory and tandem
rollers to achieve the desired
compaction
as
per
MoRTH
specification
Clause
:
508
complete in all respects
Bitumen
For Grading I ( 13 mm nominal
size )
For GradingII (10 mm nominal
size)
Polymer Modified Bitumen
for Grading I ( 13 mm nominal
size )
for GradingII (10 mm nominal
size)
Crumb
rubber
Modified
Bitumen (CRMB-55)
for Grading I ( 13 mm nominal
size )
for GradingII (10 mm nominal
size)
Bituminous Concrete

82

cum

11904.
00

cum

12744.
00

cum

12933.
00

cum

13888.
00

cum

12055.
00

cum

12911.
00

Rupees Eleven
Thousand Nine
Hundred and Four
Only
Rupees Twelve
Thousand Seven
Hundred and Forty
Four Only
Rupees Twelve
Thousand Nine
Hundred and Thirty
Three Only
Rupees Thirteen
Thousand Eight
Hundred Eighty Eight
Only
Rupees Twelve
Thousand and Fifty
Five Only
Rupees Twelve
Thousand Nine
Hundred and Eleven
Only

I
(i)

(ii)

II
(i)

(ii)

III
(i)

(ii)

5.8

510

Providing and laying bituminous

concrete with 100-120 TPH batch
type hot mix plant producing an
average output of 75 tonnes per
hour using crushed aggregates of
specified grading, premixed with
bituminous binder @ 5.4 to 5.6
percent
of mix and filler,
transporting the hot mix to work
site, laying with a hydrostatic
paver finisher with sensor control
to the required grade, level and
alignment, rolling with smooth
wheeled, vibratory and tandem
rollers to achieve the desired
compaction
as
per
MORTH
specification
Clause
:
509
complete in all respects
.Bitumen
for Grading I ( 13 mm nominal
size )
for GradingII (10 mm nominal
size)

cum

13174.
00

cum

13184.
00

cum

14342.
00

cum

14351.
00

cum

13345.
00

cum

13355.
00

Rupees Thirteen
Thousand One
Hundred and
Seventy Four Only
Rupees Thirteen
Thousand One
Hundred and Eighty
Four Only

Polymer Modified Bitumen

for Grading I ( 13 mm nominal
size )
for GradingII (10 mm nominal
size)
.Crumb
rubber
Modified
Bitumen (CRMB-55)
for Grading I ( 13 mm nominal
size )
for GradingII (10 mm nominal
size)
Surface Dressing.
Providing and laying surface
dressing as wearing course in
single coat using crushed stone
aggregates of specified size on a
layer of bituminous binder laid on
prepared surface and rolling with
8-10 tonne smooth wheeled steel
roller

83

Rupees Fourteen
Thousand Three
Hundred and Forty
Two Only
Rupees Fourteen
Thousand Three
Hundred and Fifty
One Only
Rupees Thirteen
Thousand Three
Hundred and Forty
Five Only
Rupees Thirteen
Thousand Three
Hundred and Fifty
Five Only

Case
I
Case
II
5.9

511

Case
I
i
ii
iii
Case
II
5.1
0

512.00

19mm nominal chipping size

13mm nominal chipping size
Open - graded Premix Surfacing
Providing, laying and rolling of
open - graded premix surfacing of
20 mm thickness composed of
13.2 mm to 5.6 mm aggregates
either using penetration grade
bitumen or cut-back or emulsion to
required line, grade and level to
serve as wearing course on a
previously
prepared
base,
including mixing in a suitable
plant, laying and rolling with a
smooth wheeled roller 8-10 tonne
capacity, finished to required level
and grades.
Mechanical
method
using
penetration grade bitumen and
HMP of appropriate capacity not
less than 75 tonne/hour
Bitumen VG-10(80/100)
Polymer Modified Bitumen
Crumb rubber Modified Bitumen
(CRMB-55)
Open
-graded
premix
surfacing
using
cationic
bitumen emulsion
Close
Graded
Premix
Surfacing/Mixed Seal Surfacing
:
Mechanical means
using HMP of appropriate capacity
not less than 75 tonnes/hour.
Providing, laying and rolling of
close-graded
premix
surfacing
material of 20 mm thickness
composed of 11.2 mm to 0.09 mm
(Type-A) or 13.2 mm to 0.09 mm
(Type-B)
aggregates using
penetration grade bitumen to the
required line, grade and level to
serve as wearing course on a
previously
prepared
base,
including mixing in a suitable
plant, laying and rolling with a
Smooth wheeled roller 8-10 tonne
capacity, and finishing to required
level and grade.
Bitumen VG-10(80/100)
Type A

84

Rupees One Hundred

and Twenty Six Only
Rupees One Hundred
and Three Only

sqm

126.00

sqm

103.00

sqm

195.00

sqm

209.00

sqm

197.00

sqm

235.00

Rupees Two Hundred

and Thirty Five Only

sqm

250.00

Rupees Two Hundred

and Fifty Only

Rupees One Hundred

and Ninety Five Only
Rupees Two Hundred
and Nine Only
Rupees One Hundred
and Ninety Seven
Only

Type B
sqm
II

Polymer Modified Bitumen

Type A

Type B
III

Crumb
rubber
Bitumen(CRMB-55)
Type A

513
(i)

(ii)

5.1
2

5.1
3

515

516

Rupees Two Hundred

and Twenty Seven
Only
Rupees Two Hundred
and Seventy Two
Only

sqm

272.00

sqm

245.00

sqm

254.00

sqm

230.00

sqm

97.00

Rupees Ninety Seven

Only

sqm

73.00

Rupees Seventy
Three Only

sqm

1008.0
0

Rupees Two Hundred

and Forty Five Only

Modified

Type B
5.1
1

227.00

Seal Coat
Providing and laying seal coat
sealing the voids in a bituminous
surface laid to the specified levels,
grade and cross fall using Type A
and B seal coats
Providing and laying of premix
sand seal coat with HMP of
appropriate capacity not less than
75 tonne/ hours using crushed
stone chipping 6.7 mm size and
penetration bitumen of suitable
grade.
Mastic Asphalt
Providing and laying 25 mm thick
mastic asphalt wearing course
with
paving
grade
bitumen
meeting the requirements given in
Table 500-29, prepared by using
mastic cooker and laid to required
level and slope after cleaning the
surface,
including
providing
antiskid surface with bitumen
precoated fine-grained hard stone
chipping of 13.2 mm nominal size
at the rate of 0.005 cum per 10
sqm and at an approximate
spacing of 10 cm center to center
in both directions, pressed into
surface when the temperature of
surfaces is not less than 100 C,
protruding 1 mm to 4 mm over
mastic surface, all complete as per
Clause 515
Slurry Seal:
Providing and laying slurry seal
consisting of a mixture of fine
aggregates, portland cement filler,
bituminous emulsion and water on

85

Rupees Two Hundred

and Fifty Four Only
Rupees Two Hundred
and Thirty Only

Rupees One
Thousand and Eight
Only

i.

5.1
4

85.00

sqm

58.00

sqm

35.00

sqm

48.00

Rupees Forty Eight

Only

sqm

56.00

Rupees Fifty Six only

i. PMB-70

sqm

102.00

ii. CRMB-55

sqm

94.00

3 mm thickness

iii

1.5 mm thickness

518
(i)

Case
I

Rupees Eighty Five

Only
Rupees Fifty Eight
Only
Rupees Thirty Five
Only

sqm

ii.

(ii)
5.1
5

a road surface including cleaning

of surface, mixing of slurry seal in
a suitable mobile plant, laying and
compacting to provide even riding
surface.
5 mm thickness

Fog Spray
Providing
and
applying
low
viscosity bitumen emulsion for
sealing cracks less than 3 mm
wide or incipient fretting or
disintegration
in
an
existing
bituminous surfacing.
.In case it is decided by the
engineer to blind the fog spray,
the following may be added
Crack Prevention Courses
Stress Absorbing Membrane
(SAM) crack width less than 6
mm:
Providing and laying of a stress
absorbing membrane over a
cracked road surface, with crack
width below 6 mm after cleaning
with a mechanical broom, using
modified binder complying with
clause 521, sprayed at the rate of
9 kg per 10 sqm and spreading 5.6
mm crushed stone aggregates @
0.11 cum per 10 sqm with
hydraulic chip spreader, sweeping
the surface for uniform spread of
aggregates and surface finished to
conform to Clause 902.

Case
II

Stress Absorbing Membrane

(SAM) with crack width 6 mm
to 9 mm:
Providing and laying of a stress
absorbing membrane over a
cracked road surface, with crack
width 6 to 9 mm after cleaning
with a mechanical broom, using
modified binder complying with
Clause 521, sprayed at the rate of
11 kg per 10 sqm and spreading

86

Rupees One Hundred

and Two Only
Rupees Ninety Four
Only

11.2
mm
crushed
stone
aggregates @ 0.12 cum per 10
sqm, sweeping the surface for
uniform spread of aggregates and
surface finished to conform to
Clause 902.

Case
III

i. PMB-70

sqm

118.00

ii.CRMB-55

sqm

109.00

sqm

156.00

sqm

143.00

Rupees One Hundred

and Eighteen Only
Rupees One Hundred
and Nine Only

Stress Absorbing Membrane

(SAM) crack width above 9 mm
and cracked area above 50
percent:
Providing and laying a single coat
of a stress absorbing membrane
over a cracked road surface, with
crack width above 9 mm and
cracked area above 50 percent
after cleaning with a mechanical
broom, using modified binder
complying
with
clause
521,
sprayed at the rate of 15 kg per 10
sqm and spreading 11.2 mm
crushed stone aggregates @ 0.12
cum per 10 sqm, sweeping the
surface for uniform spread of
aggregates and surface finished to
conform to Clause 902.
i.PMB-70
ii.CRMB-55

87

Rupees One Hundred

and Fifty Six Only
Rupees One Hundred
and Forty Three Only

CHAPTER 6
6. CEMENT CONCRETE
6.1 DRY LEAN CEMENT CONCRETE SUB-BASE
6.1.1

6.1.2

Scope :
(i)

The work shall consist of construction of dry lean concrete sub-base for cement concrete
pavement in accordance with the requirements of these Specifications and in conformity
with the lines, grades and cross-sections shown on the drawings or as directed by the
Engineer. The work shall include furnishing of all plant and equipment, materials and
labour and performing all operations, in connection with the work, as approved by the
Engineer.

(ii)

The design parameters of dry lean concrete sub-base, viz., width, thickness, grade of
concrete, details of joints, if any, etc, shall be as stipulated in the Contract drawings.

Materials :
The Contractor shall indicate to the Engineer the source of all materials with relevant test data to
be used in the lean concrete work sufficiently in advance and the approval of the Engineer for the
same shall be obtained at least 45 days before the scheduled commencement of the work. If the
Contractor later proposed to obtain the materials from a different source, he shall notify the
Engineer for his approval at least 45 days before such materials are to be used.

6.1.3

Cement :
(i) Any of the following types of cement may be used with prior approval of the Engineer.
(a)

Ordinary Portland Cement

IS: 269

(b)

Portland Slag Cement

IS: 455

(c)

Portland Pozzolana Cement

IS: 1489

(ii) If the subgrade is found to consist of soluble sulphates in a concentration more than 0.5 per
cent, cement used shall be sulphate resistant and shall conform to IS:6909.
88

(iii)

Cement to be used may preferably be obtained in bulk form. It shall be stored in accordance
with stipulation contained in Clause 1014 and shall be subjected to acceptance test prior to its
immediate use.

6.1.4

Aggregates :
Aggregates for lean concrete shall be natural material complying with IS:383. The aggregates
shall not be alkali reactive. The limits of deleterious materials shall not exceed the requirements
set out in IS:383. In case the Engineer considers that the aggregates are not free from dirt, the
same may be washed and drained for at least 72 hours before batching, as directed by the
Engineer.

6.1.5

Coarse Aggregates :
Coarse aggregates shall consist of clean, hard, strong, dense, non-porous and durable pieces of
crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky,
elongated, very angular or splintery pieces. The maximum size of the coarse aggregate shall be 25
mm. The coarse aggregate shall comply with Clause 602.2.4.2.

6.1.6

Fine aggregates :
(i)

The fine aggregate shall consist of clean, natural sand or crushed stone sand or a
combination of the two and shall conform to IS:383. Fine aggregate shall be free from soft
particles, clay, shale, loam, cemented particles, mica, organic and other foreign matter. The
fine aggregate shall comply with Clause 602.2.4.3.

(ii)

The coarse and fine aggregates may be obtained in either of the following manner :

(a)

In separate nominal sizes of coarse and fine aggregates and mixed together intimately before use.

(b)

Separately as 25mm nominal single size, 12.5 mm nominal size graded aggregates and fine aggregate of
crushed stone dust or sand or a combination of these two.
(iv)

The material after blending shall conform to the grading as indicated in Table 6.1.

Table 6.1(Table 600-1) Aggregate Gradation for Dry Lean Concrete

Sieve Designation

Percentage passing the

sieve by weight
100
80-100
55-75
35-60
10-35
0-8

26.50 mm
19.00 mm
9.50 mm
4.75 mm
600.00 micron
75.00 micron
89

6.1.7

Water :
Water used for mixing and curing of concrete shall be clean and free from injurious amounts of
oil, salt, acid, vegetable matter or other substances harmful to the finished concrete. It shall meet
the requirements stipulated in IS: 456.

6.2 CEMENT CONCRETE PAVEMENT

6.2.1

6.2.2

Scope :
(i)

The work shall consist of construction of unreinforced, dowel jointed, plain cement
concrete pavement in accordance with the requirements of MoRT&H Specifications and in
conformity with the lines, grades and cross sections shown on the drawings. The work
shall include furnishing of all plant and equipment, materials and labour and performing
all operations in connection with the work, as approved by the Engineer.

(v)

The design parameters, viz., thickness of pavement slab, grade of concrete, joint details
etc. shall be as stipulated in the drawings.

Source of materials :
The Contractor shall indicate to the Engineer the source of all materials to be used in the concrete
work with relevant test data sufficiently in advance, and the approval of the Engineer for the same
shall be obtained as least 45 days before the scheduled commencement of the work. If the
Contractor later proposed to obtain materials from a different source, he shall notify the Engineer
for his approval, at least 45 days before such materials are to be used with relevant test data.

6.2.3

Cement :
(i)

Any of the following types of cement capable of achieving the design strength may be
used with prior approval of the Engineer, but the preference should be to use at least the 43
Grade or higher.

(a)

Ordinary Portland Cement, 33 Grade, IS: 269

(b)

Ordinary Portland Cement, 43 Grade, IS: 8112

(c)

Ordinary Portland Cement, 53 Grade, IS: 12269

(ii)

If the soil around has soluble salts like sulphates in excess of 0.5 per cent, the cement used
shall be sulphate resistant and shall conform to IS: 12330.

(iii)

Guidance may be taken from IS: SP: 23, Handbook for Concrete Mixes for ascertaining
the minimum 7 days strength of cement required to match with the design concrete
strength. Cement to be used may preferably be obtained in bulk form. If cement in paper
bags are proposed to be used, there shall be bag-splitters with the facility to separate
90

pieces of paper bags and dispose them of suitably. No paper pieces shall enter the concrete
mix. Bulk cement shall be stored in accordance with Clause 1014. The cement shall be
subjected to acceptance test just prior to its use.
6.2.4

Admixtures :
Admixtures conforming to IS:6925 and IS:9103 shall be permitted to improve workability of the
concrete or extension of setting time, on satisfactory evidence that they will not have any adverse
effect on the properties of concrete with respect to strength, volume change, durability and have
no deleterious effect on steel bars. The particulars of the admixture and the quantity to be used,
must be furnished to the Engineer in advance to obtain his approval before use. Satisfactory
performance of the admixtures should be proved both on the laboratory concrete trial mixes and in
trial paving works. If air entraining admixture is used, the total quantity of air in air-entrained
concrete as a percentage of the volume of the mix shall be 5 1.5 per cent for 25mm nominal size
aggregate.

6.2.5

6.2.6

6.2.7

Aggregates :
(i)

Aggregates for pavement concrete shall be natural material complying with IS: 383 but
with a Los Angeles Abrasion Test result not more than 35 per cent. The limits of
deleterious materials shall not exceed the requirements set out in IS: 383.

(ii)

The aggregates shall be free from chert, flint, chalcedony or other silica in a form that can
react with the alkalies in the cement. In addition, the total chlorides content expressed as
chloride ion content shall not exceed 0.06 per cent by weight and the total sulphate content
expressed as sulphuric anhydride (SO3) shall not exceed 0.25 per cent by weight.

Coarse aggregates :
(i)

Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable pieces
of crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone,
soft, flaky, elongated, very angular or splintery pieces. The maximum size of coarse
aggregate shall not exceed 25mm for pavement concrete. Continuously graded or gap
graded aggregates may be used, depending on the grading of the fine aggregate. No
aggregate which has water absorption more than 2 per cent shall be used in the concrete
mix. The aggregates shall be tested for soundness in accordance with IS: 2386 (Part-5).
After 5 cycles of testing the loss shall not be more than 12 per cent if sodium sulphate
solution is used or 18 per cent if magnesium sulphate solution is used.

(ii)

Dumping and stacking of aggregates shall be done in an approved manner. In case the
Engineer considers that the aggregates are not free from dirt, the same may be washed and
drained for at least 72 hours before batching as directed by the Engineer.

Fine aggregates :
The fine aggregate shall consist of clean natural sand or crushed stone sand or a combination of
the two and shall conform to IS: 383. Fine aggregate shall be free from soft particles, clay, shale,
loam, cemented particles, mica and organic and other foreign matter. The fine aggregate shall not
contain deleterious substances more than the following :
91

6.2.8

Clay lumps

4.0 per cent

Coal and lignite

1.0 per cent

Material passing IS Sieve No.75 micron

4.0 per cent

Water :
Water used for mixing and curing of concrete shall be clean and free from injurious amount of oil,
salt, acid, vegetable matter or other substances harmful to the finished concrete. It shall meet the
requirements stipulated in IS: 456.

6.2.9

Mild Steel bars for Dowels and Tie bars :

These shall conform to the requirements of IS: 432, IS: 1139 and IS: 1786 as relevant. The dowel
bars shall conform to Grade S 240 and tie bars to Grade S 415 of IS.

6.2.10 Premoulded joint filler :

Joint filler board for expansion joints which are proposed for use only at some abutting structures
like bridges and culverts shall be of 20-25 mm thickness within a tolerance of
1.5 mm and
of a firm compressible material and complying with the requirements of IS:1838, or BS
Specification Clause No.2630 or Specification for Highway Works, Vol.I Clause 1015. It shall be
25 mm less in depth than the thickness of the slab within a tolerance of 3 mm and provided to
the full width between the side forms. It shall be in suitable lengths which shall not be less than
one lane width. Holes to accommodate dowel bars shall be accurately bored or punched out to
give a sliding fit on the dowel bars.
6.2.11 Joint sealing compound :
The joint sealing compound shall be of hot poured, elastomeric type or cold polysulphide type
having flexibility, resistance to age hardening and durability. If the sealant is of hot poured type it
shall conform to AASHTO M282 and cold applied sealant shall be in accordance with BS 5212
(Part 2).
6.2.12 Expansion joints :
The expansion joints shall consist of a joint filler board complying with Clause 602.2.7 and dowel
bars complying with Clause 602.6.5 and as detailed in the drawings. The filler board shall be
positioned vertically with the prefabricated joint assemblies along the line of the joint within the
tolerances given in Clause 602.6.2.1 and at such depth below the surface as will not impede the
passage of the finishing straight edges or oscillating beams of the paving machines. The adjacent
slabs shall be completely separated from each other by providing joint filler board. Space around
the dowel bars, between the sub-base and the filler board shall be packed with a suitable
compressible material to block the flow of cement slurry.
92

6.2.13 Dowel Bars :

(i)

Dowel bars shall be mild steel rounds in accordance with Clause 602.2.6 with
details/dimensions as indicated in the drawing and free from oil, dirt, loose rust or scale.
They shall be straight, free of irregularities and burring restricting slippage in the concrete.
The sliding ends shall be sawn or cropped cleanly with no protrusions outside the normal
diameter of the bar.

(ii)

Unless shown otherwise on the drawings, dowel bars shall be positioned at mid depth of
the slab within a tolerance of 20mm, and centered equally about intended lines of the
joint within a tolerance of 25mm. They shall be aligned parallel to the finished surface
of the slab and to the centre line of the carriageway and to each other within tolerances
given hereunder, the compliance of which shall be checked as per Clause 602.10.7.

(iii)

Dowel bars shall be covered by a thin plastic sheath for at least two-thirds of the length
from end for dowel bars in contraction joints or half the length plus 50 mm for expansion
joints.

6.2.14 Tie bars :

(i)

Tie bars in longitudinal joints shall be deformed steel bars of strength 415 MPa complying
with IS:1786 and in accordance with the requirements given below. The bars shall be free
from oil, dirt, loose rust and scale.

(ii)

Tie bars projecting across the longitudinal joint shall be protected from corrosion for
75mm on each side of joint by a protective coating of bituminous paint with the approval
of the Engineer. The coating shall be dry when the tie bars are used.

6.2.15 Surface texture :

After the final regulation of the slab and before the application of the curing membrane, the
surface of concrete slab shall be brush-textured in a direction at right angles to the longitudinal
axis of the carriageway.
6.2.16 Texture depth :
Texture depths shall not be less than the minimum required when measurements are taken as
given in Table 6.2 nor greater than a maximum average of 1.25mm.
Table 6.2(Table 600-2) Texture Depth
Time of Test

1. Between 24 hours and 7 days

after the construction, of the
slab or until the slab is first
used by vehicles.
2. Not later than 6 weeks before
the road is opened to public

Number of
Measurement
An average of 5
measurements
An average of 5
measurements
93

Required Texture Depth

(mm)
Specified
Tolerance
Value
1.00
0.25

1.00

0.25
-0.35

traffic.

6.3
6.3.1

6.3.2

ROLLED CEMENT CONCRETE BASE :

Scope :
(i)

The work shall consist of construction of rolled concrete base course for cement concrete
pavement in accordance with the requirements of MoRT&H Specifications and in
conformity with the lines, grades and cross sections shown on the drawings or as directed
by the Engineer. The work shall include furnishing of all plant and equipment, material
and labour and performing all operations in connection with the work, as approved by the
Engineer.

(ii)

The design parameters of rolled cement concrete base course viz., width, thickness, grade
of concrete, details of joints, if any, etc. shall be as stipulated in the contract drawings.

Materials :
The Contractor shall indicate to the Engineer the source of all materials to be used in the lean
concrete work with relevant test data sufficiently in advance and the approval of the Engineer for
the same shall be obtained at least 60 days before the scheduled commencement of the work. If
the Contractor later proposes to obtain the materials from a different source, he shall notify the
Engineer for his approval at least 60 days before such materials are to be used.

6.3.3

Cement :
Any of the following types of cement may be used with prior approval of the Engineer.
(i)

Ordinary Portland Cement

IS: 269, 8112 or 12269

(ii)

Portland Slag Cement

IS: 455

(iii)

Portland Pozzolana Cement IS: 1489

If the subgrade is found to consist of soluble sulphates in a concentration more than 0.5 per cent,
cement used shall be sulphate resistant and shall conform to IS: 12230. Cement to be used may
preferably be obtained in bulk form. It shall be stored in accordance with stipulated contained in
Clause 1014 and shall be subjected to acceptance test prior to its immediate use.
6.3.4

Aggregates :
Aggregates for lean concrete shall be natural material complying with IS: 383. The aggregates
shall not be alkali reactive. The limits of deleterious materials shall not exceed the requirements
94

set out in IS: 383. In case the Engineer considers that the aggregates are not free from dirt, the
same may be washed and drained for at least 72 hours before batching as directed by the
Engineer.

6.3.5

Coarse aggregate :
Coarse aggregates shall consist of clean, hard, strong, dense, non-porous and durable pieces of
crushed stone or crushed gravel and shall be devoid of pieces of disintegrated stone, soft, flaky,
elongated, very angular or splintery pieces. The maximum size of the coarse aggregate shall be
25mm. The coarse aggregate shall comply with the Clause 602.2.4.2.

6.3.6

Fine aggregate :
(i)

The fine aggregate shall consist of clean natural sand or crushed stone sand or a
combination of the two and shall conform to IS: 383. Fine aggregate shall be free from
soft particles, clay, shale, loam, cemented particles, mica, organic and other foreign matter.
The fine aggregate shall comply with the Clause 602.2.4.3.

(ii)

The coarse and fine aggregates may be obtained in either of the following manner:-

(a)

In separate nominal sizes of coarse and fine aggregates and mixed together intimately
before use.

(b)

Separately as 25mm nominal single size, 12.5mm nominal size graded aggregate and fine
aggregate of crushed stone dust or sand or a combination of these two.

(iii)

The material after blending shall conform to the grading as indicated in Table 6.3 below:
Table 6.3(Table 600-4) Aggregate Gradation for Dry Lean Concrete
Sieve Designation

Percentage Passing the

sieve by weight
100
80 100
55 80
35 60
10 35
0-8

37.5 mm
19.0 mm
9.5 mm
4.75 mm
600 micron
75 micron

95

CHAPTER 6 : CEMENT CONCRETE PAVEMENTS

Sl
No
6.1

6.2

Reference
to
MoRT&H
Specificat
ions
601

602

Rate
Item
No.

Descriptions

Unit

In
figure
s
(`)

In words

Dry Lean Cement Concrete

Sub- base:
Construction of dry lean cement
concrete Sub- base over a
prepared sub-grade with coarse
and fine aggregate conforming to
IS: 383, the size of coarse
aggregate not exceeding 25 mm,
aggregate cement ratio not to
exceed
15:1,
aggregate
gradation after blending to be as
per Table 600-1, cement content
not to be less than 150 kg/ cum,
optimum moisture content to be
determined during trial length
construction, concrete strength
not to be less than 10 Mpa at 7
days, mixed in a batching plant,
transported to site, laid with a
paver with electronic sensor,
compacting with 8-10 tonne
vibratory roller, finishing and
curing.
Cement Concrete Pavement:
Construction of un-reinforced,
dowel jointed, plain cement
concrete
pavement
over
a
prepared sub base with 43 grade
cement @ 400 kg per cum,
coarse
and
fine
aggregate
conforming to IS 383, maximum
size of coarse aggregate not
exceeding 25 mm, mixed in a
batching and mixing plant as per
approved mix design, transported
to site, laid with a fixed form or
slip
form
paver,
spread,
compacted and finished in a
continuous operation including
provision
of
contraction,

96

cum

cum

4342.0
0

7931.0
0

Rupees Four
Thousand Three
Hundred and Forty
Two Only

Rupees Seven
Thousand Nine
Hundred and Thirty
One Only

expansion,
construction
and
longitudinal joints, joint filler,
separation membrane, sealant
primer, joint sealant, debonding
strip,
dowel
bar,
tie
rod,
admixtures as approved, curing
compound, finishing to lines and
grades as per drawing

6.3

603

Rolled
Base:

Cement

Concrete

Construction of rolled cement

concrete base course with coarse
and fine aggregate conforming to
IS:383, the size of coarse
aggregate not exceeding 25 mm
with
minimum,
aggregate
cement ratio15:1 and minimum
cement content of 200 kg/cum,
aggregate gradation to be as per
Table
600-4
after
blending,
mixing in batching plant at
optimum
moisture
content,
transporting to site, laying with a
paver with electronic sensor,
compacting with 8-10 tonnes
smooth wheeled vibratory roller
to achieve, the designed flexural
strength, finishing and curing.

97

cum

4483.0
0

Rupees Four
Thousand Four
Hundred and Eighty
Three Only

CHAPTER 7
7. PIPE CULVERTS
7.1

DESCRIPTION

7.1.1

Scope :

7.1.2

This work shall consist of furnishing and installing reinforced cement concrete pipes, of the type,
diameter and length required at the locations shown on the drawings or as ordered by the Engineer
and in accordance with the requirements of MoRT&H Specifications.
Materials :
(i)
(ii)

All materials used in the construction of pipe culverts shall conform to the requirements of
Section 1000 of MoRT&H Specifications.
Each consignment of cement concrete pipes shall be inspected, tested, if necessary, and
approved by the Engineer either at the place of manufacture or at the site before their
incorporation in the works.
7.2

7.2.1

EXCAVATION FOR PIPE

The foundation bed for pipe culverts shall be excavated true to the lines and grades shown on the
drawings or as directed by the Engineer. The pipes shall be placed in shallow excavation of the
natural ground or in open trenches cut in existing embankments, taken down to levels as shown on
the drawings. In case of high embankments where the height of fill is more than three times the
external diameter of the pipe, the embankment shall first be built to an elevation above the top of
the pipe equal to the external diameter of the pipe, and to width on each side of the pipe of not
less than five times the diameter of pipe, after which a trench shall be excavated and the pipe shall
be laid.
98

7.2.2

Where trenching is involved, its width on either side of the pipe shall be a minimum of 150 mm or
one-fourth of the diameter of the pipe whichever is more and shall not be more than one-third the
diameter of the pipe. The sides of the trench shall be as nearly vertical as possible.

7.2.3

The pipe shall be placed where the ground for the foundation is reasonably firm. Installation of
pipes under existing bridges or culverts shall be avoided as far as possible. When during
excavation the material encountered is soft, spongy or other unstable soil, and unless other special
provisions, such unsuitable material shall be removed to such depth, width and length as directed
by the Engineer. The excavation shall then be backfilled with approved granular material which
shall be properly shaped and thoroughly compacted upto the specified level.

7.2.4

Where bed-rock or boulder strata are encountered, excavation shall be taken down to at least 200
mm below the bottom level of the pipe with prior permission of the Engineer and all
rock/boulders in this area be removed and the space filled with approved earth, free from stone or
fragmented material, shaped to the requirements and thoroughly compacted to provide adequate
support for the pipe.
Trenches shall be kept free from water until the pipes are installed and the joints have hardened.

7.2.5

7.3 BEDDING FOR PIPE

7.3.1

7.4.1

The bedding surface shall provide a firm foundation of uniform density throughout the length of
the culvert, shall conform to the specified levels and grade, and shall be of one of the following
two types as specified on the drawings :
(i)
First Class bedding : Under first class bedding, the pipe shall be evenly bedded on a
continuous layer of well compacted approval granular material, shaped concentrically to
fit the lower part of the pipe exterior for at least ten per cent of its overall height or as
otherwise shown on the drawings. The bedding material shall be well graded sand or
another granular material passing 5.6 mm sieve suitably compacted/ rammed. The
compacted thickness of the bedding layer shall be as shown on the drawings and in no
case shall it be less than 75 mm.
(ii)
Concrete cradle bedding : When indicated on the drawings or directed by the Engineer, the
pipe shall be bedded in a cradle constructed of concrete having a mix not leaner than M 15
conforming to Section 1700. The shape and dimensions of the cradle shall be as indicated
on the drawings. The pipes shall be laid on the concrete bedding before the concrete has
set.
7.4 LAYING OF PIPE
No pipe shall be laid in position until the foundation has been approved by the Engineer. Where
two or more pipes are to be laid adjacent to each other, they shall be separated by a distance equal
to at least half the diameter of the pipe subject to a minimum of 450 mm.

99

7.4.2

The arrangement for lifting, loading and unloading concrete pipes from factory/yard and at site
shall be such that the pipes do not suffer any undue structural strain, any damage due to fall or
impact. The arrangement may be got approved by the Engineer.

7.4.3

Similarly, the arrangement for lowering the pipe in the bed shall be got approved by the Engineer.
It may be with tripod-pulley arrangement or simply by manual labour in a manner that the pipe is
placed in the proper position without damage.

7.4.4

The laying of pipes on the prepared foundation shall start from the outlet and proceed towards the
inlet and be completed to the specified lines and grades. In case of use of pipes with bell-mouth,
the belled end shall face upstream. The pipes shall be fitted and matched so that when laid in
work, they form a culvert with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed at the cost of the Contractor.

7.4.5

7.5

JOINTING

7.5.1

The pipes shall be jointed either by collar joint or by flush joint. In the former case, the collars
shall be of RCC 150 to 200 mm wide and having the same strength as the pipes to be joined.
Caulking space shall be between 13 and 20 mm according to the diameter of the pipe. Caulking
material shall be slightly wet mix of cement and sand in the ratio of 1:2 rammed with caulking
irons. Before caulking, the collar shall be so placed that its centre coincides with the joint and an
even annular space is left between the collar and the pipe.

7.5.2

Flush joint may be internal flush joint or external flush joint. In either case, the ends of the pipes
shall be specially shaped to form a self centering joint with a joining space 13 mm wide. The
jointing space shall be filled with cement mortar, 1cement to 2 sand, mixed sufficiently dry to
remain in position when forced with a trowel or rammer. Care shall be taken to fill all voids and
excess mortar shall be removed.

7.5.3

For joining pipe lines under light hydraulic pressure, the recess at the end of the pipe shall be
filled with jute braiding dipped in hot bitumen or other suitable approved compound. Pipes shall
be so jointed that the bitumen ring of one pipe shall set into the recess of the next pipe. The ring
shall be thoroughly compressed by jacking or by any other suitable method.

7.5.4

All joints shall be made with care so that their interior surface is smooth and consistent with the
interior surface of the pipes. After finishing, the joint shall be kept covered and damp for at least
four days.
7.6 BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid and the jointing material
has hardened. The backfill soil shall be clean, free from boulders, large roots, excessive amounts
of sods or other vegetable matter, and lumps and shall be approved by the Engineer. Backfilling
upto 300 mm above the top of the pipe shall be carefully done and the soil thoroughly rammed,
tamped or vibrated in layers not exceeding 150 mm, particular care being taken to thoroughly
consolidate the materials under the haunches of the pipe. Approved pneumatic or light mechanical
tamping equipment can be used.

7.6.1

100

7.6.2

Filling of the trench shall be carried out simultaneously on both sides of the pipe in such a manner
that unequal pressures do not occur.

7.6.3

In case of high embankment, after filling the trench upto the top of the pipe in the above said
manner, a loose fill of a depth equal to external diameter of the pipe shall be placed over the pipe
before further layers are added and compacted.

CHAPTER 7 : PIPE CULVERTS

Sl
No
7.1

7.2

7.3

7.4

Reference
to MoRT&H
Specificatio
ns
408

2700

Rate
Item
No.

Descriptions

In
figures
(`)

In words

cum

5337.00

Rupees Five
Thousand Three
Hundred Thirty
Seven Only

cum

5420.00

Rupees Five
Thousand Four
Hundred Twenty Only

5636.00

Rupees Five
Thousand Six
Hundred and Thirty
Six Only

Unit

PCC 1:3:6 in Foundation:

Plain cement concrete 1:3:6
mix
with
crushed
stone
aggregate 40 mm nominal size
mechanically mixed, placed in
foundation and compacted by
vibration including curing for
14 days.
Plain cement concrete M15
mix with stone aggregates
20
mm
nominal
size
mechanically mixed and
vibrated in foundation upto
a depth of 1.50m below
ground level and 1 or 1.50
m above Ground Bed Level
Plain cement concrete M15
mix with aggregates 20
mm
nominal
size
mechanically mixed and
vibrated in superstructure
upto 4m above and 1.5m
from Bed Ground Level.
Reinforced
cement
concrete M20 mix with
stone aggregates 20mm
nominal size mechanically
mixed and vibrated for
reinforced concrete work in
slab
excluding
steel
reinforcement,
but
including
centering
and

101

cum

shuttering laid in position.

Cas
eI
7.5

using concrete Mixer

7.6

Using Concrete Mixer

1400/2200

7.8

1400/2200

7.1
0

7.1
1

Rupees Six Thousand

Three Hundred and
Fifty Three Only

cum

6574.00

Rupees Six Thousand

Five Hundred and
Seventy Four Only

MT

85062.0
0

Rupees Eighty Five

Thousand and Sixty
Two Only

cum

3738.00

Rupees Three
Thousand Seven
Hundred and Thirty
Eight Only

cum

188.00

Steel
reinforcement
for
R.C.C.
works
including
bending,
binding
and
placing in position.
HYSD

7.9

6353.00

RCC Grade M20

Cas
eI

7.7

cum

1300 & 2200

Coursed
Rubble
stone
masonry in cement sand
mortar 1:3 in foundation
unto a depth of 1.50m and
also 1.50m above ground
level/bed level
Extra for coursed rubble
stone
masonry
in
superstructure
upto
a
height of 4 metre or part
thereof above 1.50 m from
ground/bed level.
Random
Rubble masonry
(coursed) in cement sand
mortar 1:3 in foundation
unto a depth of 1.50m and
1.50m above.
Providing regular dry stone
masonry wall with hammer
dressed or blunt chisel
dressed stone, stone of
heavy section (size not less
than 25cm x 25cm x 30cm
long) with proper key stone
each not less than 25cm x
25cm x 75cm long in
foundation upto a depth of
1.50m and 1.50 above
ground/bed level.
Cement pointing 1:2 deep
variety (out or weather) on
Brick and tile work.

102

Rupees One Hundred

and Eighty Eight Only

3636.00

Rupees Three
Thousand Six
Hundred and Thirty
Six Only

cum

1908.00

Rupees One
Thousand Nine
Hundred and Eight
Only

sqm

77.00

cum

Rupees Seventy
Seven Only

7.1
2
7.1
3

1300 & 2200

7.1
4

2500.00

7.1
5

710.1.4 of
IRC : 78 &
2200

Cement plaster 12mm thick

in cement mortar 1:3.
Rubble
stone
laid
in
cement mortar 1:3 in floor

1400.00

Dry boulder
flooring

7.1
8

2900

2900

in

Providing and filling in

foundation trenches and at
the back of abutments,
wing walls etc. and below
pipe bed in layers not
exceeding 150mm thick
including
watering
and
compacting including all
lead
and
lift.
(a) Filter media behind
abutment wing and return
wall (Boulder filling).
Making
and
filling
expansion
joints,
with
bitumen filler (Bitumen 40
percent,
asbestos
5
percent and sand 55%)
12mm wide.
Laying Reinforced Cement
Concrete
Pipe
NP3
/
Prestressed Concrete Pipe
on First Class Bedding in
Single Row .

7.1
6

7.1
7

pitching

sqm

119.00

cum

3237.00

cum

1094.00

cum

979.00

Rm

17.00

1000 mm dia (Full Pipe)

metr
e

8072.00

1000 mm dia (Half Pipe)

metr
e

8850.00

Laying Reinforced Cement

Concrete
Pipe
NP4/prestrssed
concrete
pipe on first class bedding
in
single
row:
Laying
Reinforced
cement
concrete pipe NP4/prestrssed
concrete pipe for culverts on
first class bedding of granular
material in single row including
fixing collar with cement
mortar 1:2 but excluding
excavation, protection works,
backfilling,
concrete and
masonry works in head walls
and parapets .

103

Rupees One Hundred

and Nineteen Only
Rupees Three
Thousand Two
Hundred and Thirty
Seven Only
Rupees One
Thousand and Ninety
Four Only

Rupees Nine
Hundred and Seventy
Nine Only

Rupees Seventeen
Only

Rupees Eight
Thousand and
Seventy Two Only
Rupees Eight
Thousand Eight
Hundred and Fifty
Only

7.1
9

1000 mm dia (Full Pipe)

metr
e

10052.0
0

1000 mm dia (Half Pipe)

metr
e

10515.0
0

1200 mm dia (Full Pipe)

metr
e

12992.0
0

1200 mm dia (Half Pipe)

metr
e

14190.0
0

Laying Reinforced Cement

Concrete
Pipe
NP
4
/prestrssed concrete pipe
on first class bedding in
double
row
:
Laying
Reinforced
cement
concrete pipe NP4 /prestrssed
concrete pipe for culverts on
first class bedding of granular
material
in
double
row
including fixing collar with
cement
mortar
1:2
but
excluding
excavation,
protection works, backfilling,
concrete and masonry works
in head walls and parapets .
1000 mm dia (Full Pipe)

metr
e

20255.0
0

1000 mm dia (Half Pipe)

metr
e

21180.0
0

2900

Rupees Ten
Thousand and Fifty
Two Only
Rupees Ten
Thousand Five
Hundred and Fifteen
Only
Rupees Twelve
Thousand Nine
Hundred and Ninety
Two only
Rupees Fourteen
Thousand One
Hundred and Ninety
Only

Rupees Twenty
Thousand Two
Hundred and Fifty
Five Only
Rupees Twenty One
Thousand One
Hundred and Eighty
Only

CHAPTER 8
8. TRAFFIC SIGNS, MARKINGS AND OTHER ROAD APPURTENANCES
8.1
8.1.1

TRAFFIC SIGNS

Scope :
104

8.1.2

8.1.3

(i)

The colour, configuration, size and location of all traffic signs for highways other than
Expressways shall be in accordance with the Code of Practice for Road Signs, IRC: 67 or
as shown on the drawings. For Expressways, the size of the signs, letters and their
placement shall be as specified in the Contract drawings and relevant Specifications of
MoRT&H for Roads & Bridge Works. In the absence of any details or for any missing
details, the signs shall be provided as directed by the Engineer.

(ii)

The signs shall be either reflectorised or non-reflectorised as shown on the drawings or as

directed by the Engineer. When they are of reflectorised type, they shall be of retroreflectorised type and made of encapsulated lens type reflective sheeting vide Clause
801.3, fixed over aluminium sheeting as per MoRT&H Specifications.

(iii)

In general, cautionary and mandatory signs shall be fabricated through process of screen
printing. In regard to informatory signs with inscriptions, either the message could be
printed over the reflective sheeting, or cut letters of non-reflective black sheeting used for
the purpose which must be bonded well on the base sheeting as directed by the Engineer.

Materials :
(i)

Concrete shall be of the grade shown on the Contract drawings or otherwise as directed by
the Engineer.

(ii)

Reinforcing steel shall conform to the requirement of IS: 1786 unless otherwise shown on
the drawing.

(iii)

High strength bolts shall conform to IS: 1367 whereas precision bolts, nuts, etc., shall
conform to IS: 1364.

(iv)

Plates and support sections for the sign posts shall conform to IS: 226 and IS: 2062 or any
other relevant IS Specifications.

(v)

Aluminium sheets used for sign boards shall be of smooth, hard and corrosion resistant
aluminium alloy conforming to IS: 736-Material designation 24345 or 1900.

(vi)

Signs with a maximum side dimension not exceeding 600 mm shall not be less than 1.5
mm thick. All others shall be at least 2 mm thick. The thickness of the sheet shall be
related to the size of the sign and its support and shall be such that it does not bend or
deform under the prevailing wind and other loads.

(vii)

In respect of sign sizes not covered by IRC:67, the structural details (thickness, etc.) shall
be as per the approved drawings.

Traffic signs having retro-reflective sheeting :

The retro-reflective sheeting used on the sign shall consist of the white or coloured sheeting
having a smooth outer surface which has the property of retro-reflection over its entire surface. It
shall be weather-resistant and show colour fastness. It shall be new and unused and shall show no
105

evidence of cracking, scaling, pitting, blistering, edge lifting or curling and shall have negligible
shrinkage or expansion. A certificate of having tested the sheeting for these properties in an
unprotected outdoor exposure facing the sun for two years and its having passed these tests shall
be obtained from a reputed laboratory, by the manufacturer of the sheeting. The reflective sheeting
shall be either of Engineering Grade material with enclosed lens or of High Intensity Grade with
encapsulated lens. The type of the sheeting to be used would depend upon the type, functional
hierarchy and importance of the road.
8.1.4

High intensity grade sheeting :

This sheeting shall be of encapsulated lens type consisting of spherical glass lens, elements
adhered to a synthetic resin and encapsulated by a flexible, transparent water-proof plastic having
a smooth surface. The retro-reflective surface after cleaning with soap and water and in dry
condition shall have the minimum co-efficient of retro-reflection (determined in accordance with
ASTM Standard E : 810) as indicated in Table 8.1.
Table 8.1(Table 800-1) Acceptable Minimum Coefficient of Retro-reflection for High
Intensity Grade Sheeting (Candelas as per Lux per Square Metre)
Observation
Angle (in
degree)
0.2
0.2
0.5
0.5

Entrance
Angle (in
degree)
-4
+30
-4
+30

White

Yellow

Orange

Green/
Red

Blue

250
150
95
65

170
100
62
45

100
60
30
25

45
25
15
10

20
11
7.5
5.0

When totally wet, the sheeting shall not show less than 90 per cent of the values of retroreflectance indicated in Table 8.1. At the end of 7 years, the sheeting shall retain at least 75 per
cent of its original retro-reflectance.
8.1.5

Installation :
(i)

Sign posts, their foundations and sign mountings shall be so constructed as to hold these in
a proper and permanent position against the normal storm wind loads or displacement by
vandalism. Normally, signs with an area upto 0.9 sq.m shall be mounted on a single post,
and for greater area two or more supports shall be provided. Sign supports may be of mild
steel, reinforced concrete or galvanized iron (G.I). Post-end(s) shall be firmly fixed to the
ground by means of properly designed foundation. The work of foundation shall conform
to relevant Specifications as specified.

(ii)

All components of signs and supports, other than the reflective portion and G.I posts shall
be thoroughly de-scaled, cleaned, primed and painted with two coats of epoxy paint. Any
part of mild steel (M.S) post below ground shall be painted with three coats of red lead
paint.
106

(iii)

The signs shall be fixed to the posts by welding in the case of steel posts and by bolts and
washers of suitable size in the case of reinforced concrete or G.I. posts. After the nuts have
been tightened, the tails of the bolts shall be furred over with a hammer to prevent
removal.
8.2. ROAD MARKINGS

8.2.1

Scope:
The colour, width and layout of road markings shall be in accordance with the Code of Practice
for Road Markings with paints, IRC: 35, and as specified in the drawings or as directed by the
Engineer.

8.2.2

Materials :
Road markings shall be of ordinary road marking paint, hot applied thermoplastic compound, or
reflectorised paint as specified in the item and the material shall meet the requirement as specified
below.

8.2.3

Ordinary Road Marking Paint :

(i)

Ordinary paint used for road marking shall conform to Grade I as per IS: 164.

(ii)

The road marking shall preferably be laid with appropriate road marking machinery.
(iii)

8.2.4

8.2.5

Laying thickness of road marking paint shall be as specified by the Engineer.

Hot Applied Thermoplastic Road Marking :

(i)

The work under this section consists of marking traffic using a thermoplastic compound
meeting the requirements specified herein.

(ii)

The thermoplastic compound shall be screeded/extruded on to the pavement surface in a

molten state by suitable machine capable of controlled preparation and laying with surface
application of glass beads at a specific rate. Upon cooling to ambient pavement
temperature, it shall produce an adherent pavement marking of specified thickness and
width and capable of resisting deformation by traffic.

(c)

The colour of the compound shall be white or yellow (IS colour No.356) as specified in
the drawings or as directed by the Engineer.

(d)

Where the compound is to be applied to cement concrete pavement, a sealing primer as

recommended by the manufacturer, shall be applied to the pavement in advance of placing
of the stripes to ensure proper bonding of the compound. On new concrete surface any
laitance and/or curing compound shall be removed before the markings are applied.

Thermoplastic Material :
The thermoplastic material shall be homogeneously composed of aggregate, pigment, resins and
glass reflectorising beads.
107

8.2.6

Requirements :
(i)

Composition : The pigment, beads, and aggregate shall be uniformly dispersed in the
resin. The material shall be free from all skins, dirt and foreign objects and shall comply
with requirements indicated in Table 8.3.
Table 8.3 (Table 800-3) Proportions of Constituents of Marking Material
(Percentage by weight)
Component
White
Yellow
Binder
18.0 min.
18.0 min.
Glass Beads
30 40
30 40
Titanium Dioxide
10.0 min.
Calcium Carbonate and
42.0 max.
See
Inert Fillers
Yellow Pigments
Note

Note : Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the
manufacturer, provided all other requirements of MoRT&H Specification are met.
8.2.7 Reflectorising glass beads :

8.2.8

(i)

MoRT&H Specifications covers two types of glass beads to be used for the production of
reflectorised pavement markings.

(ii)

Type 1 beads are those which are a constituent of the basic thermoplastic compound vide
Table 8.3 and Type 2 beads are those which are to be sprayed on the surface vide Clause
803.6.3.

(iii)

The glass beads shall be transparent, colourless and free from milkiness, dark particles and
excessive air inclusions.

(iv)

These shall conform to the requirements spelt out in Clause 803.4.3.3.

Specific requirements :
(A) Gradation : The glass beads shall meet the gradation requirements for the two types as given
in Table 8.4
Table 8.4 (Table 800-4) Gradation Requirements for Glass Beads
Sieve size
1.18
850 micron
600 micron
425 micron

Per cent retained

Type 1
0 to 3
5 to 20
65 to 95
108

Type 2
0 to 5
5 to 20
-

300 micron
180 micron
Below 180 micron

0 to 10
-

30 to 75
10 to 30
0 to 15

(B) Roundness : The glass beads shall have a minimum of 70 per cent true spheres.
(C) Refractive Index : The glass beads shall have a minimum refractive index of 1.50.
(D) Free flowing properties : The glass beads shall be free of hard lumps and clusters and shall
dispense readily under any conditions suitable for paint stripping. They shall pass the free
flow-test.
8.3. HECTOMETRE/ KILOMETRE STONES
8.3.1

Scope:
(i)

The work covers the supply, painting, lettering and fixing of distance measurement stones
and shall include:

(a)

Hectometre stones

(b)

Kilometre stones

(c)

5th Kilometre stones

(ii)

The dimension of the stones and the size, colour, arrangement of letters and script shall be
as per IRC: 26 Type Designs for 200 Metre Stones and IRC: 8 Type Designs for
Highway Kilometre Stones.

(iii)

The hectometer/kilometre stones may be made of local stones, concrete or any other
material available locally and approved by the Engineer. The stones shall be bedded into
the ground with adequate foundations as indicated in the drawings or in the relevant I.R.C.
Specifications or as directed by the Engineer. The orientation and location of the stones
shall be as indicated in the drawings or in the relevant I.R.C. Specifications or as directed
by the Engineer.

8.4. ROAD DELINEATORS

8.4.1

8.4.2

Scope :
(i)
The work covers supplying and fixing roadway indicators, hazard markers and object
markers.
(ii)
The design, materials to be used and the location of the road delineators shall conform to
Recommended Practice for Road Delineators, IRC : 79, and to relevant drawings or as
otherwise directed by the Engineer.
Measurement for Payment :
The measurement shall be made in numbers of delineators fixed at site.

8.4.3

Rate :
109

The Contract unit rate for Road Delineators shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing, supplying and fixing at site and all other
incidental costs necessary to complete the work to MoRT&H Specifications.
8.5 BOUNDARY STONES
8.5.1

Scope :
The work comprises of supplying and fixing boundary stones as per designs and Specifications
given in IRC: 25 Type Designs for Boundary Stones and at locations indicated in the drawings
or as directed by the Engineer.

8.5.2

Measurements for Payment :

The measurement shall be made in numbers of boundary stones fixed at site.

8.5.3

Rate :
The Contract unit rate for boundary stones shall be payment in full compensation for furnishing
all labour, materials, tools, equipment for preparing, supplying and fixing and all other incidental
costs necessary to complete the work to MoRT&H Specifications.
8.6 FENCING

8.6.1

(iii)

Scope :
(i)

The work comprises of fixing Mild Steel (M.S) posts and providing barbed wire fencing
including necessary stays and entry gates as shown in the drawing(s) and as directed by
the Engineer.

(ii)

The M.S. posts shall conform to IS:226 and shall be of angle iron of size indicated in the
drawings. The angle iron shall be embedded in concrete to a sufficient depth below ground
as indicated in the drawings. The steel shall be fabricated and painted to conform to
Section 1900 of MoRT&H Specifications.

The barbed wire shall be of galvanised iron and shall conform to IS:278.
(iv)

8.6.2

Entry gate(s) shall be made of M.S. rods or other metal as per the design shown in the
drawing(s).

Measurement for Payment :

The measurement shall be in running metre of fencing including the entry gates.

8.6.3

Rate :
The Contract unit rate for fencing shall be payment in full compensation for furnishing all labour,
materials, tools, equipment for fabrication and fixing at site and all other incidental costs
necessary to complete the work to the Specifications.
8.7 METAL BEAM CRASH BARRIER

8.7.1

Scope :
110

8.7.2

(i)

This work shall consist of furnishing and erection of metal beam crash barrier of
dimensions and at locations as shown on the drawing(s) or as directed by the Engineer.

(ii)

Metal beam crash barrier shall generally be located on approaches to bridge structures, at
locations where the embankment height is more than 3 metres and at horizontal curves.

Materials :
(i)

Metal beam rail shall be corrugated sheet steel beams of the class, type, section and
thickness indicated on the plans. Railing posts shall be made of steel of the section, weight
and length as shown on the plans. All complete steel rail elements, terminal sections,
posts, bolts, nuts, hardware and other steel fittings shall be galvanised. All elements of the
railing shall be free from abrasions, rough or sharp edges and shall not be kinked, twisted
or bent.

(ii)

Steel beam elements and terminal sections shall be galvanised (zinc coated, 0.55 kg per
square metre, minimum single spot) unless otherwise specified. The galvanising on all
other steel parts shall conform to the relevant IS Specifications. All fittings (bolts, nuts,
washers) shall conform to the IS: 1367 and IS: 1364. All galvanising shall be done after
fabrication.
8.8 ROAD TRAFFIC SIGNALS

8.8.1

8.8.2

Scope :
(i)

The traffic signal, its configuration, size and location shall be in accordance with IRC: 93
and IS: 7537 and as shown in the drawings or as directed by the Engineer. Prior to
installation of signals, the Contractor shall submit to the Engineer, for approval, detailed
proposals showing the signal type, sizes, paint and structural details of the signal posts
including control system.

(ii)

The traffic signals shall have a complete electronic mechanism for controlling the
operation of traffic with an auxiliary manual controller. The time plan of signals shall be as
per drawing and shall be modified as directed by the Engineer.

Materials :
The various materials and fabrication thereof shall conform to the following:

8.8.3

Signal foundation :
The signal foundations shall be constructed as per Specifications given in Clause 13 of IRC : 93
or as shown in the drawings.

8.8.4

Constructional requirements :
The constructional requirements for post, signal head assembly, signal head, optical system, lamp
and holder, visor, post, supports for overhead mounted signals, equipment housing, locks, interconnecting cables, earthing, mains termination, controller electrical components, etc., shall
111

conform to IS: 7537 unless otherwise stated in IRC: 93. The post shall be painted and protected as
per Clause 3.7 of IS: 7537.
8.8.5

Optical requirements :
The shape of all signal lenses shall be circular and shall be of specified colour and size and as
shown in the drawing. Quality of lenses, arrangement of lenses, illuminations, visibility and
shielding of signals shall be as per relevant Clauses of IRC: 93 and IS: 7537.

CHAPTER-8: TRAFFIC SIGNS, MARKINGS & OTHER ROAD APPURTENANCES

Sl
No

Reference
to
MoRT&H
Specificat
ions

Rate
Item
No.

Descriptions

112

Unit

In
figure
s
(`)

In words

8.1

408

Cast in Situ Cement Concrete

M20
kerb
:
Construction of cement concrete
kerb with top and bottom width
115 and 165 mm respectively,
250 mm high in M 20 grade PCC
on M-10 grade foundation 150
mm thick, foundation having 50
mm projection beyond kerb stone,
kerb stone laid with kerb laying
machine, foundation concrete laid
manually, all complete as per
Clause 408
A

8.2

408

Using Concrete Mixer

Rm

386.00

Rupees Three
Hundred and Eighty
Six Only

Rm

703.00

Rupees Seven
Hundred and Three
only

Cast in Situ Cement Concrete

M 20 Kerb with Channel:
Construction of cement concrete
kerb with channel with top and
bottom width 115 and 165 mm
respectively, 250 mm high in M
20 grade PCC on M10 grade
foundation 150 mm thick, kerb
channel 300 mm wide, 50 mm
thick in PCC M20 grade, sloped
towards the kerb, kerb stone with
channel laid with kerb laying
machine, foundation concrete laid
manually, all complete as per
Clause 408.
A

8.3

801

(i)

(ii)

Using Concrete Mixer

Printing
new
letter
and
figures
of
any
shade:
Printing new letter and figures of
any shade with synthetic enamel
paint black or any other approved
colour to give an even shade.
Hindi
Matras commas and the like not
to be measured and paid for Half
letter shall be counted as half .

English and Roman.

113

cm
heig
ht
per
letter
cm
heig
ht
per
letter

1.00

Rupee One Only

0.60

Paisa Sixty Only

8.4

801

Retroreflectorised
Traffic
signs:
Providing and fixing of retroreflectorised
cautionary,
mandatory and informatory sign
as per IRC
:67 made
of
encapsulated lens type reflective
sheeting vide clause 801.3, fixed
over aluminium sheeting, 1.5 mm
thick supported on a mild steel
angle iron post 75 mm x 75 mm x
6 mm firmly fixed to the ground
by means of properly designed
foundation
with
M15
grade
cement concrete 45 cm x 45 cm x
60 cm, 60 cm below ground level
as per approved drawing
(i)

90 cm equilateral triangle

each

12372.
00

( ii )

60 cm equilateral triangle

each

7163.0
0

( iii )

60 cm circular

each

10573.
00

( iv )

80 mm x 60 mm rectangular

each

15862.
00

(v)

60 cm x 45 cm rectangular

each

10224.
00

(vi )

60 cm x 60 cm square

each

12640.
00

90 cm high octagon

each

21017.
00

( vii )

114

Rupees Twelve
Thousand Three
Hundred Seventy Two
Only
Rupees Seven
Thousand One
Hundred Sixty Three
Only
Rupees Ten Thousand
Five Hundred Seventy
Three Only
Rupees Fifteen
Thousand Eight
Hundred Sixty Two
Only
Rupees Ten Thousand
Two Hundred Twenty
Four Only
Rupees Twelve
Thousand Six
Hundred Forty Only
Rupees Twenty One
Thousand Seventeen
Only

8.5

801

Direction
and
Place
Identification signs upto 0.9
sqm size board:
Providing and erecting direction
and place identification retroreflectorised sign as per IRC:67
made of encapsulated lens type
reflective sheeting vide clause
801.3, fixed over aluminium
sheeting, 2 mm thick with area
not exceeding 0.9 sqm supported
on a mild steel single angle iron
post 75 x 75 x 6 mm firmly fixed
to the ground by means of
properly designed foundation with
M15 grade cement concrete 45 x
45 x 60 cm, 60 cm below ground
level as per approved drawing

8.6

8.7

8.8

801

803

803

sqm

25830.
00

Rupees Twenty Five

Thousand Eight
Hundred Thirty Only

sqm

26389.
00

Rupees Twenty Six

Thousand Three
Hundred Eighty Nine
Only

sqm

88.00

Rupees Eighty Eight

Only

sqm

82.00

Rupees Eighty Two

Only

Direction
and
Place
Identification signs with size
more than 0.9 sqm size board:
Providing and erecting direction
and place identification retroreflectorised sign asper IRC :67
made of encapsulated lens type
reflective sheeting vide clause
801.3, fixed over aluminium
sheeting, 2 mm thick with area
exceeding 0.9 sqm supported on
a mild steel angle iron post 75
mm x 75 mm x 6 mm, 2 Nos.
firmly fixed to the ground by
means of properly designed
foundation with M 15 grade
cement concrete45 cm x 45 cm x
60 cm, 60 cm below ground level
as per approved drawing
Painting Two Coats on New
Concrete
Surfaces:
Painting two coats after filling the
surface with synthetic enamel
paint in all shades on new
plastered concrete surfaces
Painting on Steel Surfaces:
Providing and applying two coats
of ready mix paint of approved
brand on steel surface after
through cleaning of surface to
give an even shade

115

8.9

803

Painting
Lines,
Dashes,
Arrows etc on Roads in Two
Coats
on
New
Work:
Painting lines, dashes, arrows etc
on roads in two coats on new
work with ready mixed road
marking paint conforming to
IS:164 on bituminous surface,
including cleaning the surface of
all dirt, dust and other foreign
matter, demarcation at site and
traffic control
(i)
(ii)

8.1
0

803

sqm

112.00

Up to 10 cm in width

sqm

96.00

Over 10 cm in width

sqm

72.00

Rupees Seventy Two

Only

Up to 10 cm in width

sqm

77.00

Rupees Seventy
Seven Only

sqm

2305.0
0

Rupees Two
Thousand Three
Hundred and Five
Only

4541.0
0

Rupees Four
Thousand Five

Painting
Lines,
Dashes,
Arrows etc on Roads in Two
Coats
on
Old
Work:
Painting lines, dashes, arrows etc
on roads in two coats on old work
with ready mixed road marking
paint confirming to IS: 164 on
bituminous
surface,
including
cleaning the surface of all dirt,
dust and other foreign matter,
demarcation at site and traffic
control
(i)
(ii)

8.1
1

8.1
2

Rupees One Hundred

and Twelve Only
Rupees Ninety Six
Only

Over 10 cm in width

Road
Marking
with
Hot
Applied
Thermoplastic
Compound with Reflectorising
Glass Beads on Bituminous
Surface
:
Providing and laying of hot
applied thermoplastic compound
2.5
mm
thick
including
reflectorising glass beads @ 250
gms per sqm area, thickness of
2.5 mm is exclusive of surface
applied glass beads as per
IRC:35 .The finished surface to be
level, uniform and free from
streaks and holes
Kilo Metre Stone:

804

(i)

Reinforced
cement
concrete
M15grade kilometre stone of
standard design as per IRC:81980, fixing in position including
painting and printing etc
5th kilometre stone (precast)

116

each

(ii)

(iii)
8.1
3

8.1
4

8.1
5

Ordinary
(Precast)

Kilometer

stone

Hectometer stone (Precast)

805

Road Delineators:

806

Supplying and installation of

delineators (road way indicators,
hazard markers, object markers),
80-100 cm high above ground
level, painted black and white in
15 cm wide stripes, fitted with 80
x 100 mm rectangular or 75 mm
dia circular reflectorised panels at
the top, buried or pressed into the
ground and confirming toIRC-79
and the drawings.
Boundary pillar:

807

Reinforced cement concrete M15

grade
boundary
pillars
of
standard design as per IRC:251967, fixed in position including
finishing
and
lettering
but
excluding painting.
G.I Barbed wire Fencing 1.2
metre
high:
Providing and fixing 1.2 metres
high GI barbed wire fencing with
1.8 m angle iron posts 40 mm x
40 mm x 6 mm placed every 3
metres center to center founded
in M15 grade cement concrete,
0.6 metre below ground level,
every 15th post, last but one end
post and corner post shall be
strutted on both sides and end
post on one side only and
provided with 9 horizontal lines
and 2 diagonals interwoven with
horizontal wires, fixed with GI
staples, turn buckles etc complete
as per Clause 807

117

Hundred and Forty

One only
Rupees Two
Thousand Six
Hundred and Forty
One Only
Rupees Seven
Hundred and Eighty
Eight Only

each

2641.0
0

each

788.00

each

2375.0
0

Rupees Two
Thousand Three
Hundred and Seventy
Five Only

each

606.00

Rupess Six Hundred

and Six Only

metr
e

376.00

Rupees Three
Hundred and Seventy
Six Only

8.1
6

8.1
7

807

G.I Barbed wire Fencing 1.8

metre
high:
Providing and fixing 1.8 metres
high GI barbed wire fencing with
2.4 m angle iron posts 50 mm x
50 mm x 6 mm placed every 3
metres center to center founded
in M15 grade cement concrete,
0.6 metre below ground level,
every 15th post, last but one end
post and corner post shall be
strutted on both sides and end
post on one side only and
provided with 12 horizontal lines
and 2 diagonals interwoven with
horizontal wires, fixed with GI
staples, turn buckles etc complete
as per Clause 807
Metal Beam Crash Barrier

810
A

Type - A, "W" : Metal Beam

Crash
Barrier:
Providing and erecting a "W"
metal
beam
crash
barrier
comprising of 3 mm thick
corrugated sheet metal beam rail,
70 cm above road/ground level,
fixed on ISMC series channel
vertical post, 150 x 75 x 5 mm
spaced 2 m centre to centre, 1.8
m high, 1.1 m below ground/road
level, all steel parts and fitments
to be galvanised by hot dip
process, all fittings to conform to
IS:1367 and IS:1364, metal beam
rail to be fixed on the vertical post
with a spacer of channel section
150 x 75 x 5 mm, 330 mm long
complete as per Clause 810

metr
e

643.00

Rupees Six Hundred

and Forty Three Only

metr
e

4850.0
0

Rupees Four
Thousand Eight
Hundred Fifty Only

CHAPTER 9
9. MAINTENANCE OF ROAD
9.1 DESCRIPTION
9.1.1

Scope :
118

The Specifications shall apply to all items of road maintenance works as required to be carried out
under the Contract or as directed by the Engineer. The works shall be carried out in conformity
with the relevant Specifications to the required level, grade and lines using approved materials,
the works shall be carried out using light duty machinery or manual means provided the quality of
the end product does not suffer. In execution of maintenance works, a reference is made to the
IRC publications: Manual for Maintenance of Roads and Code of Practice for Maintenance for
Bituminous Surfaces of Highways, IRC 82-1982 for guidance and compliance wherever
applicable. Wherever the Specification is not clear, good engineering practice shall be adopted in
the construction to the satisfaction of the Engineer.
9.2
9.2.1

RESTORATION OF RAIN CUTS

Scope :
The work shall consist of earthwork for restoration of rain cuts in the embankment and shoulders,
using suitable material, and compacting the same.

9.2.2

Materials :
The materials used for restoration of rain cuts shall consist of soil conforming to Clause 305.2.

9.2.3

Construction Operation :
(i)
(ii)

The area affected by rain cuts shall be cleared of all loose soil benched. The width of the
benches shall be at least 300 mm and they shall extend continuously for a sufficient
length. The height of the benches shall be in the range of 150-300 mm.
Fresh material shall be deposited in layers not exceeding 250 mm loose thickness and
compacted so as to match with the benching at a moisture content close to the optimum.
Compaction shall be carried out using suitable equipment such as plate compactors and
rammers or by suitable implements handled manually. The finished work shall conform to
alignment, levels and slopes as indicated in the drawing.
9.3 MAINTENANCE OF EARTHEN SHOULDER

9.3.1

Scope :
The work of maintenance of earthen shoulder shall include making up the irregularities/loss of
material on shoulder to the design level by adding fresh approved soil and compacting it with
appropriate equipments or to strip excess soil from the shoulder surface as per the requirement of
MoRT&H Specification.

9.3.2

Material :
The material to be added to the shoulder, if required, shall be a select soil conforming to Clause
305 of MoRT&H Specification.

9.3.3

Construction Procedure :
119

This work shall include:

(i)
Making up of the earthen shoulder by adding extra soil and compacting the same; and/or
(ii)
Stripping a layer of soil to achieve the required grade and level.
9.4 BITUMINOUS WORK IN CONNECTION WITH MAINTENANCE AND REPAIRS
9.4.1 General :
The scope and type of maintenance work to be carried out shall be in accordance with the
provisions of the Contract or as instructed by the Engineer.
9.4.2

Filling Pot-holes and Patch Repairs :

(i)

9.4.3

9.4.4

This work shall include repair of pot-holes and patching of all types of bituminous
pavement.
(ii)
The work shall include the removal of all failed material, in the pavement courses and, if
necessary, below the pavement, until the root cause of the failure is removed; the trimming
of the completed excavation to provide firm vertical faces; the replacement of material of
at least as high a standard as that which was originally specified for the pavement layer;
the painting of tack coat on to the sides and bases of excavations prior to placing of any
bituminous materials and the compaction, trimming and finishing of the surfaces of all
patches to form a smooth continuous surface, level with the surrounding road.
Crack Sealing :
Crack sealing shall consist of one or more of the following operations as instructed under
the Contract.
(i)
fog seal
(ii)
filling cracks with a binder, or a combination of crusher dust and a binder.
(iii)
by treating the crack sealing as a patch repair.
Crack filling :
Crack filling shall be carried out using a binder of a suitable viscosity, normally a slowcuring bitumen emulsion, as instructed by the Engineer. For wider cracks, in excess of an average
of 3mm in width the application of emulsion may be preceded by an application of crusher dust,
or other fine material acceptable to the Engineer.

CHAPTER-9 : MAINTENANCE OF ROADS

Sl
No

Reference
to
MoRT&H
Specificat
ions

Rate
Item
No.

Descriptions

120

Unit

In
figure
s
(`)

In words

9.1

9.2

9.3

9.4

9.5

9.6

3002

3003

3003

3004.2

3004.3.3

3004.4

Restoration of Rain Cuts:

Restoration of rain cuts with soil,
moorum, gravel or a mixture of
these,
clearing the loose soil,
benching for 300 mm width,
laying fresh material in layers not
exceeding
250
mm
and
compacting with plate compactor
or power rammers to restore the
original alignment,
levels and
slopes.
Maintenance
of
Earthen
Shoulder (filling with fresh
soil):

Rupees Two Hundred

and Fifty Only

Cum

250.00

Making up loss of material/

irregularities on shoulder to the
design level by adding fresh
approved soil and compacting it
with appropriate equipment.
Maintenance of Earth Shoulder
(stripping excess soil):

Sqm

41.00

Stripping excess soil from the

shoulder surface to achieve the
approved level and compacting
with plate compactor
Filling Pot- holes and Patch
Repairs with open - graded
Premix surfacing,
20mm:
Removal of all failed material,
trimming of completed excavation
to provide firm vertical faces,
cleaning of surface, painting of
tack coat on the sides and base of
excavation as per Clause 503,
back filling the pot holes with hot
bituminous material as per Clause
511, compacting, trimming and
finishing the surface to form a
smooth continuous surface, all as
per Clause 3004.2
Crack Filling:

sqm

110.00

Rupees One hundred

and Ten Only

sqm

200.00

Rupees Two Hundred

Only

Filling of crack using slow - curing

bitumen emulsion and applying
crusher dust in case crack are
wider than 3mm.
Dusting
Applying crusher dust to areas of
road where bleeding of excess
bitumen has occurred.

metr
e

4.00

Rupees Four Only

sqm

1.00

Rupee One Only

121

Rupees Forty One

Only

9.7

9.8

9.9

3000

3000

3000

Hill Side Drain Clearance:

Removal of earth from the
choked
hill
side
drain
and
disposing it on the valley side
manually
Land Slide Clearance in soil:
Clearance of land slides in soil and
ordinary rock by a bull-dozer D 80
A-12, 180 HP and disposal of the
same on the valley side
Land slide Clearance in Hard
Rock Requiring Blasting:
Clearing of land slide in hard rock
requiring blasting for 50 percent of
the boulders and disposal of the
same on the valley side.

metr
e

22.00

Rupees Twenty Two

Only

cum

71.00

Rupees Seventy One

Only

cum

137.00

Rupees One Hundred

Thirty Seven Only

cum

970.00

Rupees Nine Hundred

and Seventy Only

Additional Item
9.1
0

Providing
temporary
restoration work in the form of
a pallasiding with empty bags
fully filled up with approved
locally available sand moorum,
gravel etc. including stiching
the bags with jute strings of
required diameter and placing
the filled up sand cement bags
in proper slope to withstand
temporarily the road structure
from sliding (sand and cement
bag will be
supplied
by
contractor up to work site)
complete as directed

122

Chapter 10
10. FOUNDATIONS
10.1

Preamble:

10.1.1 Excavation for structure has been provided both by manual and mechanical means. The rate
relevant to a particular situation may be adopted.
10.1.2 The earth excavated from foundation has been proposed to be backfilled and balance quantity
utilised for road work locally except for marshy soil where disposal has been provided.
10.1.3 The rock foundations are required to be prepared which has been analysed.
10.1.4 In case of rocks, excavation has been considered upto a depth of 3 m only.
10.1.5 Embedment of foundation in soft and hard rocks has been provided as required by the
Specifications.
10.1.6 De-watering has been provided in excavation for foundation. In case de-watering is not required
for a particular site condition, the same may be omitted.
10.1.7 Mixing of cement concrete has been considered both by using concrete mixer and batching plant.
The rate can be adopted depending upon availability of equipment and as approved by the
Engineer.
10.1.8 Concrete batching plant is generally placed within one km of the bridge site. In case of longer
lead, transportation cost may be worked out based on tonne km.
10.1.9 The coarse and fine aggregate for cement concrete shall as per IS:383.
10.1.10 Description of items has been given very briefly. Relevant clauses of MoRT&H Specifications
may be referred for detailed specification.
10.1.11 The rate analysis for well foundation has been included for well diameter of 8.0 m. Well for twin
D type has also been included.
10.1.12 Steel reinforcement for cement concrete works are required to be provided separately. The rate
for the same has been analysed.
10.1.13 Appendix-4 of IRC:78-2000 may be referred regarding precautions to be taken during sinking of
wells.
10.1.14 In case of blasting during sinking of wells the inner face of the curb is required to be protected
with the steep plates of thickness not less than 10 mm upto top level of well curb. For height
above top of curb, the thickness of steel plate may be reduced to 6 m. This extra height of steel
lining should be limited to 3 m.
10.1.15 The concrete mix used in bottom plug shall have a minimum cement content of 330 kg/cum and
a slump of about 150 mm to permit easy flow of concrete through tremie to fill-up all cavities.
10.1.16 Necessary safety precautions shall be taken for excavation on open foundations for which
guidance may be taken from IS:3764.
10.1.17 A leveling course of 100 mm thickness in M 10(1:3:6) shall be provided before laying open
foundations.
123

10.1.18 In the case of open foundation, de-watering shall not be permitted from the time of placing of
concrete upto 24 hours after placement.
10.1.19 In case of open foundations in rock, the trenches around the footing shall be filled-up with
concrete of M 15 grade upto a level of 0.6 m for hard rock and 1.5 m for soft rock above the
foundation level. The portion above this may be filled by boulders grouted with cement.
10.1.20 When there are two or more compartments in a well, the lower edge of the cutting edge of the
middle stems of such wells shall be kept about 300 mm above that of outer stems to prevent
rocking.
10.1.21 The well curb shall be in RCC of mix not leaner than M 25 grade with minimum steel
reinforcement of 72 kg/cum excluding bond rods.
10.1.22 The top of the bottom plug shall be at least 300 mm above top of curb.
10.1.23 No de-watering shall be carried out within 7 days of casting of bottom plug.

124

CHAPTER-10 : FOUNDATIONS
Sl
No
10.
1

Referenc
e to
MoRT&H
Specificat
ions
304.0

Rate
Item
No.

Descriptions

Unit

In
figures
(`)

In words

Excavation for Structures:

Earth work in excavation of
foundation of structures as per
drawing
and
technical
specification, including setting
out, construction of shoring and
bracing, removal of stumps and
other
deleterious
matter,
dressing of sides and bottom
and backfilling with approved
material.
Ordinary soil

I
A

Manual Means

(i)

upto 3 m depth

cum

76.00

(ii)

3 m to 6 m depth

cum

98.00

(iii)

Above 6 m depth

cum

130.00

cum

77.00

Rupees Seventy
Seven Only
Rupees Eighty Eight
Only

Rupees Seventy Six

Only
Rupees Ninety Eight
Only
Rupees One Hundred
and Thirty Only

B
(i)

Mechanical Means
Depth upto 3 m

(ii)

Depth 3 m to 6 m

cum

88.00

(iii)

Depth above 6m

cum

105.00

II

Ordinary rock (not requiring

blasting)
Manual Means
Depth upto 3 m

cum

109.00

Mechanical Means

cum

101.00

cum

396.00

Rupees Three
Hundred and Ninety
Six Only

cum

707.00

Rupees Seven
Hundred and Seven
Only

A
(i)
B

Hard
rock
blasting )

III
A

A
V
(i)

Rupees One Hundred

and Nine Only
Rupees One Hundred
and One Only

requiring

Manual Means
Hard
rock
prohibited )

IV

Rupees One Hundred

and Five Only

blasting

Mechanical Means
Marshy soil
upto 3 m depth

125

10.
3

304.0

10.
4

Subanalysis
(Addl)

Manual means

cum

557.00

Mechanical Means

cum

123.00

cum

1297.00

cum

4228.00

cum

5185.00

cum

3591.00

cum

3011.00

Sand Filling in Foundation

Trenches as per Drawing &
Technical Specification
A

D
10.
5

1400.0

Cement
mortar1:2
(1cement :2 sand)
Cement
mortar1:4
(1cement :4 sand)
Cement
mortar1:6
(1cement :6 sand)
Stone
masonry
work
in
cement
mortar
1:3
in
foundation
complete
as
drawing
and
Technical
Specification.

(a)
10.
6

Cement
mortar1:3
(1cement :3 sand)

Rupees Five Hundred

and Fifty Seven Only
Rupees One Hundred
and Twenty Three
Only
Rupees One
Thousand Two
Hundred and Ninety
Seven Only
Rupees Four
Thousand Two
Hundred and Twenty
Eight Only
Rupees Five
Thousand One
Hundred Eighty Five
Only
Rupees Three
Thousand Five
Hundred and Ninety
One Only
Rupees Three
Thousand and Eleven
Only

1500,
1700 &
2100

Random Rubble Masonry

cum

3829.00

Rupees Three
Thousand Eight
Hundred and Twenty
Nine Only

Plain/Reinforced
cement
concrete in open foundation
complete as per drawing and
technical specifications.
A

PCC Grade M15

cum

6114.00

PCC Grade M20

cum

6906.00

RCC Grade M20

Case
I
E
Case
I
G
Case
I

Using concrete mixer

cum

Rupees Six Thousand

One Hundred and
Fourteen Only
Rupees Six Thousand
Nine Hundred and Six
Only

7137.00

Rupees Seven
Thousand One
Hundred and Thirty
Seven Only
Rupees Seven
Thousand Six
Hundred and Sixty
Six Only

RCC Grade M25

Using concrete Mixer

cum

7666.00

RCC Grade M30

Using Concrete Mixer

cum

7679.00

126

Rupees Seven
Thousand Six

Hundred and Seventy

Nine Only
10.
7

10.
8

1200
&1900

1200,
1500
&1700
A

Providing and laying cutting

edge of mild steel weighing
40 kg per metre for well
foundation complete as per
drawing
and
technical
specification.
Plain/Reinforced
cement
concrete, in well foundation
complete as per drawing and
technical specification
Well curb

MT

132414
00

(i)

RCC M20 Grade

cum

8235.00

(ii)

RCC M25 Grade

cum

8867.00

Well steining

Rupees One Lakh

Thirty Two Thousand
Four Hundred
Fourteen Only

Rupees Eight
Thousand Two
Hundred and Thirty
Five Only
Rupees Eight
Thousand Eight
Hundred and Sixty
Seven Only

Rupees Six Thousand

Four Hundred and
Sixty Eight Only
Rupees Seven
Thousand Three
Hundred and Six Only
Rupees Seven
Thousand Five
Hundred and Forty
Nine Only
Rupees Eight
Thousand One
Hundred and Twenty
Eight Only

(I)

PCC M15 Grade

cum

6468.00

(ii)

PCC M20 Grade

cum

7306.00

(iii)

RCC M20 Grade

cum

7549.00

(iv)

RCC M25 Grade

cum

8128.00

C
(i)

Bottom Plug
PCC Grade M20
cum

8306.00

Rupees Eight
Thousand Three
Hundred and Six Only

cum

5880.00

Rupees Five
Thousand Eight
Hundred and Eighty
Only

cum

7078.00

cum

7679.00

D
(i)
E
(i)
(ii)

Top plug
Grade M15 PCC
Well cap
RCC Grade M20
RCC Grade M30

127

Rupees Seven
Thousand and
Seventy Eight Only
Rupees Seven
Thousand Six

Hundred and Seventy

Nine Only
10.
9

section
1200

Sinking of 8 m external
diameter well
(other than
pneumatic method of sinking )
through all types of strata
namely sandy soil,
clayey
soil and rock as shown
against each case, complete
as per drawing and technical
specifications.
Depth
of
sinking is reckoned from bed
level.
A

Sandy soil

(i)

Depth below bed level upto

3.0 M

metr
e

10624.0
0

(ii)

Beyond 3m upto 10m depth

metr
e

13211.0
0

(iii)

Beyond 10m upto 20m

metr
e

17447.0
0

(iv)

Beyond 20m upto 30 m

metr
e

32726.0
0

metr
e

39271.0
0

metr
e

14437.0
0

metr
e

37630.0
0

metr
e

49697.0
0

metr
e

52182.0
0

(v)
B

Add
20%
of
cost
for
Kentledge
including
supports,
loading
arrangement and Labour .
Beyond 30m upto 40 m

Rupees Ten Thousand

Six Hundred and
Twenty Four Only
Rupees Thirteen
Thousand Two
Hundred and Eleven
Only
Rupees Seventeen
Thousand Four
Hundred and Forty
Seven Only
Rupees Thirty Two
Thousand Seven
Hundred and Twenty
Six Only
Rupees Thirty Nine
Thousand Two
Hundred and Seventy
One Only

Clayey soil ( 8m dia. Well )

(i)

(ii)
(iii)

Depth upto 3.0 M

Beyond 3m upto 10m depth

Beyond 10 m upto 20 m
(Add 5% for every additional
meter depth of sinking over
the rate of sinking for the
previous meter)
Add
5%
for
cost
of
dewatering on the cost if
required

128

Rupees Fourteen
Thousand Four
Hundred and Thirty
Seven Only
Rupees Thirty Seven
Thousand Six
Hundred and Thirty
Only
Rupees Forty Nine
Thousand Six
Hundred and Ninety
Seven Only
Rupees Fifty Two
Thousand One
Hundred and Eighty
Two Only

(iv)
a

C
(i)
D
(i)

10.
10

1207.0

Beyond
20m
m(including
Kentledge)

upto
25%

30
for

Add
5%
for
cost
of
dewatering on the cost if
required.

metr
e

116523.
00

metr
e

122350.
00

metr
e

20049.0
0

metr
e

34924.0
0

cum

1297.00

Rupees One Lakh

Sixteen Thousand
Five Hundred and
Twenty Three Only
Rupees One Lakh
Twenty Two Thousand
Three Hundred and
Fifty Only

Soft rock ( 8m dia well )

Depth in
upto 3m

soft

rock

strata

Hard rock ( 8m dia well )

Depth in hard rock strata
upto 3 m
Sand filling in wells complete
as per drawing and technical
specifications

Rupees Twenty
Thousand and Forty
Nine Only
Rupees Thirty Four
Thousand Nine
Hundred and Twenty
Four Only
Rupees One
Thousand Two
Hundred and Ninety
Seven Only

CHAPTER 11
11. SUB-STRUCTURE
11.1

DESCRIPTION

11.1.1 Scope :
The work shall cover furnishing and providing of masonry or reinforced concrete sub-structure in
accordance with the drawings and MoRT&H Specifications or as directed by the Engineer.
129

11.1.2 Materials :
Materials shall conform to Section 1000 of MoRT&H Specifications for Roads & Bridge Works
(Fourth Revision)
11.2 GENERAL
11.2.1 (i)

A method statement for construction indicating the following shall be submitted by the
Contractor for approval of the Engineer, well in advance of the commencement of substructure :

(a)

Sources of Materials

(b)

Design, erection and removal of formwork.

(c)

Production, transportation, laying and curing of concrete.

(d)

Personnel employed for execution and supervision.

(e)

Tests and sampling procedures

(f)

Any other point.

(ii)

Arrangements for execution under water wherever necessary, shall be included in method
statement.

(iii)

Dimensions, lines and levels shall be set out and checked with respect to permanent
reference lines and permanent bench mark.
11.3 PIERS AND ABUTMENTS

11.3.1 Masonry, formwork, concrete and reinforcement for piers and abutments shall conform to relevant
sections of MoRT&H Specifications. In case of concrete piers, the number of horizontal
construction joints shall be kept minimum. Construction joints shall be avoided in splash zones
unless specifically permitted by the Engineer and provided they are treated in accordance with
special provisions. No vertical construction joint shall be provided. The work shall conform
strictly to the drawings or as directed by the Engineer.
11.3.2 In case of tall piers and abutments, use of slipform shall be preferred. The design, erection and
raising of slipform shall be subject to special specifications which will be furnished by the
Contractor. The concrete shall also be subject to additional specification as necessary. All
specifications and arrangements shall be subject to the approval of the Engineer.
11.3.3 The surface of foundation/well cap/pile cap shall be scrapped with wire brush and all loose
materials removed. In case reinforcing bars projecting from foundations are coated with cement
slurry, the same shall be removed by tapping, hammering or wire brushing. Care shall be taken to
remove all loose materials around reinforcements. Just before commencing masonry or concrete
work, the surface shall be thoroughly wetted.
11.3.4 In case of solid (non-spill through type) abutments, weep holes as shown on the drawings or as
directed by the Engineer, shall be provided in conformity with Section 2706 of MoRT&H
Specifications.
130

11.3.5 The surface finish shall be smooth, except the earth face of abutments which shall be rough
finished.
11.3.6 In case of abutments likely to experience considerable movement on account of backfill of
approaches and settlement of foundations, the construction of the abutment shall be followed by
filling up of embankment in layers to the full height to allow for the anticipated movement during
construction period before casting of superstructure.
11.4

PIER CAP AND ABUTMENT CAP

11.4.1 Formwork, reinforcement and concrete shall conform to relevant sections of MoRT&H
Specifications.
11.4.2 The locations and levels of pier cap/abutment cap/pedestals and bolts for fixing bearings shall be
checked carefully to ensure alignment in accordance with the drawings of the bridge.
11.4.3 The surface of cap shall be finished smooth and shall have a slope for draining of water as shown
on the drawings or as directed by the Engineer. For short span slab bridges with continuous
support on pier caps, the surface shall be cast horizontally. The top surface of the pedestal on
which bearings are to be placed shall also be cast horizontally.
11.4.4 The surface on which elastomeric bearings are to be placed shall be wood float finished to a level
plane which shall not vary more than 1.5 mm from the straight edge placed in any direction across
the area. The surface on which other bearings (steel bearings, pot bearings) are to be placed shall
be cast about 25 mm below the bottom level of bearings and as indicated on the drawings.
11.5

DIRT/ BALLAST WALL, RETURN WALL AND WING WALL

11.5.1 Masonry, concrete and reinforcement shall conform to relevant sections of MoRT&H
Specifications.
11.5.2 In case of cantilever return walls, no construction joint shall generally be permitted. Wherever
feasible, the concreting in cantilever return walls shall be carried out in continuation of the ballast
wall.
11.5.3 For gravity type masonry and concrete return and wing wall, the surface of foundation shall be
prepared in the same manner as prescribed for construction of abutment. No horizontal
construction joint shall be provided. If shown on drawing or as directed by the Engineer, vertical
construction joint may be provided. Vertical expansion gap of 20 mm shall be provided in return
wall/ wing wall at every 10 metre intervals or as directed by the Engineer. Weep holes shall be
provided as prescribed for abutments or as shown in the drawings.
11.5.4 Formwork, reinforcement and concrete in dirt/ ballast wall shall conform to relevant sections of
MoRT&H Specifications.
11.5.5 The finish of the surface on the earth side shall be rough while the front face shall be smooth
finished.
11.5.6 Architectural coping for wing wall/ return wall in brick masonry shall conform to section 1300 of
MoRT&H Specifications.
131

11.6

TESTS AND STANDARDS OF ACCEPTANCE

11.6.1 The materials shall be tested in accordance with MoRT&H Specifications and shall meet the
prescribed criteria.
11.6.2 The work shall conform to MoRT&H Specifications and shall meet the prescribed standards of
acceptance.
11.7 TOLERANCES IN CONCRETE ELEMENTS
(a) Variation in cross-sectional dimensions

10mm, -5 mm

(b) Misplacement from specified position in plan

10 mm

(c) Variation of levels at the top

10mm

(d) Variations of reduced levels of bearing areas

5mm

(e) Variations from plumb over full height

10mm

All surfaces except bearing areas

5 mm

Bearing areas

3 mm

(f) Surface irregularities measured with 3 m straight edge

CHAPTER 11 : SUB-STRUCTURE
Sl
No
11.
1

Reference
to
MoRT&H
Specificat
ions
1400
&2200

Rate
Item
No.

Descriptions

Unit

Stone masonry work in

cement
mortar 1:3 for
substructure complete as
per drawing and Technical
Specifications.

132

In
figure
s
(`)

In words

A
11.
2

11.
3

11.
4

1500,
1700 &
2200

Random Rubble Masonry

cum

3966.0
0

Rupees Three
Thousand Nine
Hundred and Sixty
Six Only

Plain/Reinforced
cement
concrete in sub-structure
complete as per drawing
and
technical
specifications.
RCC Grade M30
(a)

Height upto 5m

cum

8162.0
0

(b)

Height 5m to 10m

cum

8392.0
0

( c)

Height above 10m

cum

8719.0
0

each

508.00

2706 &
2200

Providing weep holes in

Brick
masonry/Plain/Reinforced
concrete abutment,
wing
wall/return wall with 100
mm dia AC pipe, extending
through the full width of
the structure with slope of
1V :20H towards drawing
foce.
Complete
as
per
drawing
and
Technical
specifications.
Back
filling
behind
abutment, wing wall and
return wall complete as per
drawing
and
Technical
specification .

710.1.4 of
IRC:78
and 2200

Granular material

cum

1576.0
0

Sandy material

cum

2106.0
0

133

Rupees Eight
Thousand One
Hundred and Sixty
Two Only
Rupees Eight
Thousand Three
Hundred and Ninety
Two Only
Rupees Eight
Thousand Seven
Hundred and
Nineteen Only

Rupees Five Hundred

and Eight Only

Rupees One
Thousand Five
Hundred and Seventy
Six Only
Rupees Two
Thousand One
Hundred and Six Only

11.
5

11.
6

11.
7

11.
8

11.
9

710.1.4 of
IRC:78
and 2200

2000,
1000 &
2200

2000,
1000 &
2200

2000 &
2200

2000 &
2200

Providing and laying of

Filter media with granular
materials/stone
crushed
aggregates satisfying the
requirements laid down in
Clause 2504.2.2. of MoRTH
specifications
to
a
thickness of not less than
600 mm with smaller size
towards the soil and bigger
size towards the wall and
provided over the entire
surface behind abutment,
wing wall and return wall to
the full height compacted
to
a
firm
condition
complete as per drawing
and Technical Specification.
Supplying,
fitting and
fixing in position true to
line and level cast steel
rocker bearing conforming
to IRC: 83(Pt.-1) Section IX
and Clause 2003 of MoRTH
specifications
complete
including all accessories as
per drawing and Technical
Specifications.
Supplying,
fitting and
fixing in position true to
line and level forged steel
roller bearing conforming
to IRC: 83(Pt.-1) Section IX
and Clause 2003 of MoRTH
specifications
complete
including all accessories as
per drawing and Technical
Specifications.
Supplying,
fitting and
fixing in position true to
line and level sliding plate
bearing with PTFE surface
sliding on stainless steel
complete
including
all
accessories as per drawing
and Technical Specifications
and BS: 5400, Section 9.1
& 9.2 (for PTFE)
and
Clause 2004 of MoRTH
Specifications.
Supplying,
fitting and
fixing in position true to
line and level elastomeric
bearing conforming to IRC:
83 (Part-II) Section IX and
Clause 2005 of MoRTH
specifications
complete

134

cum

1068.0
0

Rupees One
Thousand and Sixty
Eight Only

tonne
capacity

725.00

Rupees Seven
Hundred and Twenty
Five Only

tonne
capacity

565.00

Rupees Five Hundred

and Sixty Five Only

tonne
capacity

338.00

Rupees Three
Hundred and Thirty
Eight Only

cubic
centimet
re

1.60

One Rupee and Sixty

Paise Only

including all accessories as

per drawing and Technical
Specifications.

CHAPTER 12
12. CONCRETE SUPERSTRUCTURE
12.1 DESCRIPTION
12.1.1 Scope :
The work shall cover furnishing and providing of concrete superstructure in accordance with the
drawings and as per MoRT&H Specifications for Roads & Bridge Works (Fourth Revision) or as
directed by the Engineer.
12.1.2 Materials :
Materials shall conform to Section 1000 of MoRT&H Specifications
12.2 GENERAL
12.2.1 (i)

A method statement for construction indicating the following shall be submitted by the
Contractor for approval of the Engineer, well in advance of the commencement of
superstructure :

(a)

Sources of Materials

(b)

Design, erection and removal of formwork.

(c)

Production, transportation, laying and curing of concrete.

(d)

Pre-stressing system, if applicable.

(e)

Personnel employed for execution and supervision.

(f)

Tests and sampling procedures

(g)

Equipment details

(h)

Any other point.

(iii)

Dimensions, lines and levels shall be set out and checked with respect to permanent
reference lines and permanent bench mark so that the final product is in accordance with
the drawings or as directed by the Engineer.
135

(iv)

(v)

The work shall conform to the following sections besides stipulations in this section with
regard to specific type of construction:
(a) Formwork

Section 1500

(b) Steel Reinforcement

Section 1600

(c) Structural Concrete

Section 1700

(d) Pre-stressing

Section 1800

Additionally, some of the common types of superstructure construction shall have features
as discussed in this Section.
12.3

REINFORCED CONCRETE CONSTRUCTION

12.3.1 Solid Slabs

(i)

Where adjacent span of slab has already been casted, the expansion joint and filler board
shall be placed abutting the already cast span which shall form the shutter on that side of
the new span to be casted. The whole of the slab shall be casted with reinforcement
embedded for the road kerb and railings. No other construction joint shall be allowed
except with the permission of the Engineer.

(ii)

Where wearing coat is required to be provided, after the deck slab has been casted, the
surface of the slab shall be finished rough, but true to lines and levels as shown on the
drawings, before the concrete has hardened. The areas of construction joints shall be
treated in the prescribed manner.

(iii)

The top of the slab shall be covered with clean moist sand as soon as the top surface has
hardened. Curing shall be carried out as per Section 1700 of MoRT&H Specifications.

(iv)

Where the slab is resting on bearings, the same shall be placed in position in accordance
with the drawings, before casting of deck slab.
12.4

RCC T-BEAM AND SLAB

12.4.1 Provision of construction joint shall conform to the drawings or as per directions of the Engineer.
No construction joint shall be provided between the bottom bulb and the web. If not indicated on
the drawing, construction joint may be provided at the junction of the web and the fillet between
the web and the deck slab with the permission of the Engineer.
12.4.2 The portions of deck slab near expansion joints shall be casted alongwith reinforcements and
embedments for expansion joints. For this purpose, the portion of deck slab near expansion joints
may be casted in a subsequent stage, if permitted by the Engineer.
12.4.3 The surface finish of the deck slab shall be finished rough but true to lines and levels as shown in
the drawings before the concrete has hardened. Care shall be taken for setting of bearings as
indicated in the drawings.
136

12.5 GRADES OF CONCRETE

12.5.1 The lowest grades of concrete in bridges and corresponding minimum cement contents and watercement ratios shall be maintained as indicated in Tables 12.1 and 12.2 below.

Table 12.1(Table 1700-2) Minimum Strength of Concrete

Member

Conditions of Exposure
Moderate
Severe
M 25
M 30
M 35
M 40
M 35
M 40

a) PCC members
b) RCC members
c) PSC members

Table 12.2(Table 1700-3)Minimum Strength of Concrete

Member

Conditions of Exposure
Moderate
Severe
M 15
M 20
M 20
M 25

a) PCC members
b) RCC members
Notes : Applicable to Tables 12.1 & 12.2
(i)

The minimum cement content is based on 20mm aggregate (nominal max. size). For 40mm and
larger size aggregate, it may be reduced suitably but the reduction shall not be more than 10 per
cent.
(ii)

(iii)
(iv)

For underwater concreting, the cement content shall be increased by 10 per cent.
Severe conditions of exposure shall mean alternate wetting and drying due to sea spray, alternate
wetting and drying combined with freezing and buried in soil having corrosive effect.
Moderate conditions of exposure shall mean other that those mentioned in (iii) above

The cement content shall be as low as possible but not less than the quantities specified above. In no
case shall it exceed 540 kg/cu.m. of concrete.
12.6 PROPORTIONING OF CONCRETE
Prior to the start of construction, the Contractor shall design the mix in case of Design Mix
Concrete or propose nominal mix in case of Nominal Mix Concrete, and submit to the
Engineer for approval, the proportions of materials, including admixture to be used. Waterreducing admixtures (including plasticisers or super-plasticisers) may be used at the Contractors
137

option, subject to the approval of the Engineer. Other types of admixtures shall be prohibited,
unless specifically permitted by the Engineer.
12.6.1 Requirements of Consistency :
(i)
(ii)

The mix shall have the consistency which will allow proper placement and consolidation
in the required position. Every attempt shall be made to obtain uniform consistency.
The optimum consistency for various types of structures shall be as indicated in Table
12.3, or as directed by the Engineer. The slump of concrete shall be checked as per IS:516.

Table 12.3. (Table 1700-4)

1
2
3
4
5

Type
(a) Structures with exposed inclined surface requiring low
slump concrete to allow proper compaction
(b) Plain cement concrete
RCC structures with widely spaced reinforcements; e.g. solid
columns, piers, abutments, footings, well steining
RCC structures with fair degree of congestion of reinforcement;
e.g. pier and abutment caps, box culverts well curb, well cap,
walls with thickness greater than 300mm
RCC and PSC structures with highly congested reinforcements
e.g. deck slab girders, box girders, walls with thickness less than
300mm
Underwater concreting through tremie e.g bottom plug, cast-insitu piling

Slump (mm)
25
25
40 50
50 75
75 125
100 - 200

12.6.2 Requirements for Designed Mixes :

12.6.3 Target mean Strength :
The target mean strength of specimen shall exceed the specified characteristic compressive
strength by at least the current margin.
(i)
The current margin for a concrete mix shall be determined by the Contractor and shall be
taken as 1.64 times the standard deviation of sample test results taken from at least 40
separate batches of concrete of nominally similar proportions produced at site by the same
plant under similar supervision, over a period exceeding 5 days, but not exceeding 6
months.
(ii)
Where there is insufficient data to satisfy the above, the current margin for the initial
design mix shall be taken as given in Table 12.4.
Concrete Grade
M 15
M 20

Table 12.4(Table 1700-5)

Current Margin
Target Mean Strength
(MPa)
(MPa)
10
25
10
30
138

M 25
M 30
M 35
M 40
M 45
M 50
M 55

11
12
12
12
13
13
14

36
42
47
52
58
63
69

The initial current margin given in Table 1700.4 shall be used till sufficient data is
available to determine the current margin as per sub-clause (i) above.
12. 7

ADMIXTURES

12.7.1 Use of admixtures such as super plasticisers for concrete may be made with the approval of the
Engineer.
12.7.2 As the selection of an appropriate concrete admixture is an integral part of the mix design, the
manufacturers shall recommend the use of any one of his products only after obtaining complete
knowledge of all the actual constituents of concrete as well as methodologies of manufacture,
transportation and compaction of concrete proposed to be used in the project.
12.8

SIZE OF COARSE AGGREGATE

12.8.1 The size (maximum nominal) of coarse aggregates for concrete to be used in various components
shall be given in Table 12.5.
Table 1700-7
Components
i)
ii)
iii)
iv)

v)
vi)

RCC well curb

RCC/PCC well steining
Well cap or Pile Cap
Solid type piers and abutments
RCC work in girders, slabs,
wearing coat, kerb, approach
slab, hollow piers and
abutments, pier/abutment
caps, piles
PSC work
Any other item

Maximum Nominal Size of Coarse Aggregate

(mm)
20
40
40
20

20
As specified by Engineer

12.8.2 Maximum nominal size of aggregates shall also be restricted to the smaller of the following
values :
a)
10mm less than the minimum lateral clear distance between main reinforcements
b)
10mm less than the minimum clear cover to the reinforcements
139

12.8.3 The proportions of the various individual size of aggregates shall be so adjusted that the grading
produces densest mix and the grading curve corresponds to the maximum nominal size adopted
for the concrete mix.

CHAPTER-12 : SUPER-STRUCTURE
Sl
No
12.
1

Reference
to
MoRT&H
Specificat
ions

Rate
Item
No.

1500,
1600 &
1700

A
Cas
eI
(i)

(ii)

B
Cas
eI
(i)

(ii)

C
Cas
e1
(i)

Description

Unit

In
figure
s (`)

In words

Furnishing
and
Placing
Reinforced/Prestressed
cement concrete in superstructure as per drawing and
Technical Specification.
RCC Grade M25
Using Concrete Mixer
For solid slab super-structure,
20-30 percent of (a+b+c)
For T-beam & slab,
percent of (a+b+c)

cum

9189.0
0

cum

9556.0
0

cum

9293.0
0

cum

9665.0
0

25-35

Rupees Nine
Thousand One
Hundred and Eighty
Nine Only
Rupees Nine
Thousand Five
Hundred and Fifty Six
Only

RCC Grade M 30
Using Concrete Mixer.
For solid slab super-structure,
20-30 percent of (a+b+c)
For T-beam & slab,
percent of (a+b+c)

25-35

Rupees Nine
Thousand Two
Hundred and Nine
Three Only
Rupees Nine
Thousand Six
Hundred and Sixty
Five Only

RCC Grade M35

Using concrete mixer.
For solid slab super-structure,
18-28 percent of (a+b+c)

140

cum

9321.0
0

Rupees Nine
Thousand Three
Hundred and Twenty

One Only
(ii)
(iii)

12.
2

12.
3

12.
4

12.
5

1600

2702

515 &
2702

2703,
1500,
1600 &
1700

For T-beam & slab,

percent of (a+b+c).

23-33

For box girder and balanced

cantilever, 38-58 percent of
cost of concrete.
Supplying, fitting and placing
HYSD bar reinforcement in
super-structure complete as
per drawing and Technical
Specifications .
Providing and laying Cement
concrete wearing coat M-30
grade including reinforcement
complete as per drawing and
Technical Specifications.

Rupees Nine
Thousand and Seven
Hundred Only
Rupees Eleven
Thousand Two
Hundred and Sixteen
Only

cum

9700.0
0

cum

11216.
00

MT

94117.
00

Rupees Ninety Four

Thousand One
Hundred and
Seventeen Only

cum

12995.
00

Rupees Twelve
Thousand Nine
Hundred and Ninety
Five Only

sqm

541.00

Rupees Five Hundred

and Forty One Only

metr
e

3900.0
0

Mastic Asphalt
Providing and laying 12 mm
thick mastic asphalt wearing
course on top of deck slab
excluding prime coat with paving
grade
bitumen
meeting
the
requirements given in Table 50029,
prepared by using mastic
cooker and laid to required level
and slope after cleaning the
surface,
including providing
antiskid surface with bitumen
precoated fine grained hard stone
chipping of 9.5 mm nominal size
at the rate of 0.005cum per 10
sqm and at an approximate
spacing of 10 cm center to center
in both directions, pressed into
surface when the temperature of
surfaces not less than 100 deg. C,
protruding 1 mm to 4 mm over
mastic surface, all complete as
per Clause 515.
Construction of RCC railing of
M30 Grade in-situ with 20 mm
nominal size aggregate, true
to line and grade, tolerance
of vertical RCC post not to
exceed 1 in 500, centre to
centre
spacing
between
vertical post not to exceed
2000 mm, leaving adequate
space between vertical post
for expansion,
complete as
per approved drawings and

141

Rupees Three
Thousand and Nine
Hundred Only

Technical Specifications.

12.
6

2705

Drainage Spouts complete as

per drawing and Technical
specification

12.
7

2700

12.
8

1500,
1600,
1700 &
2704

12.
9

2607

PCC
M15
Grade
leveling
course below approach slab
complete as per drawing and
Technical Specification
Reinforced cement concrete
approach
slab
including
reinforcement and formwork
complete as per drawing and
Technical Specification
Strip Seal Expansion Joint
Providing and laying of a strip seal
expansion
joint
catering
to
maximum horizontal movement
upto 70 mm, complete as per
approved drawings and standard
specifications to be installed by
the manufacturer/supplier or their
authorised
representative
ensuring
compliance
to
the
manufacturer's instructions for
installation.

Rupees Seven
Thousand Six
Hundred and Forty
Six Only
Rupees Five
Thousand Eight
Hundred and Eighty
One Only

each

7646.0
0

cum

5881.0
0

cum

12274.
00

Rupees Twelve
Thousand Two
Hundred and Seventy
Four Only

metr
e

15441.
00

Rupees Fifteen
Thousand Four
Hundred and Forty
One Only

CHAPTER 13
13. REPAIR OF STRUCTURES
13.1 DESCRIPTION
13.1.1 Scope :
(i)
(ii)

Repair of structures shall be carried out in accordance with the repair plans and MoRT&H
Specifications or as directed by the Engineer. Where repair work is not covered by
MoRT&H Specifications, special specification may be framed.
Implementation of repair schemes shall also conform to provisions of IRC:SP:40.
13.2 SEALING OF CRACKS BY INJECTION OF EPOXY RESIN
142

13.2.1 General :
(i)
The work of epoxy adhesive utilising the Structural Concrete Bonding Process shall
conform to MoRT&H Specifications.
(v)

The Contractor shall furnish detailed methodology of construction including sources of

supply of material, tools, equipment and appliances to be used on work, details of
personnel and supervision.

13.2.2 Personnel :
The Contractors personnel shall be qualified and experienced in epoxy injection process.
13.2.3 Material :
The material for injection shall be suitable two-component low viscosity epoxy resin, having the
required characteristics of bonding with concrete and resistance to moisture penetration. Epoxy
mortar or polysulphide resin may be used for sealing the surface.
The material for epoxy injection shall conform to the following:
(i)
The mixing ration of resin and hardener shall generally be between 1 to 1 and 2 to 1 by
volume subject to manufacturers recommendation.
(ii)
Neither the mixed epoxy adhesive nor their individual components shall contain solvents
and thinners.
(iii)
The components shall be free of lumps or foreign material. The viscosity of the individual
components shall not change more than 15 per cent when kept in closed containers at 25
degrees Celsius after two weeks.
(iv)

Consistency requirement.

Standard
Version
cps
(200-300)

Low Viscosity
Version
Cps
(100-190)

Viscosity of Mixed Adhesive

at 25 degree Celsius
(v) Pot Life of mixed adhesive
1 hour 15 minutes*
at 25 degree Celsius
(vi) Set time of mixed adhesive
3 6 hours
at 25 degree Celsius
*In the case of two component injection system where resin and hardener get mixed at point
of injection pot life at 25 degrees Celsius shall be not greater than 15 min 10 minutes.
13.3 CEMENT GROUTING
143

13.3.1 Material :
(i)

Grouting shall normally be performed with a mixture of neat Portland Cement and water.
Other additives and admixtures may be added to improve the impermeability, strength, etc.
on the approval of the Engineer. The size of the particles and the consistency of the grout
must be suited to the passageways it must follow. Neat grout will not flow freely into holes
smaller than about three times the largest cement particle. Except in large cavities where
thick mortar can be placed, the sand should all pass the 28-mesh sieve and have a large
portion passing the 50- and the 100- mesh sieves. The proportions of Ordinary Portland
Cement to sand will depend upon the size of the spaces to be filled and will vary from a
neat grout to about 1:1 mix. The amount of water to be added depends upon the
consistency required. Grouts with as little as 16 litres of water per bag of cement could be
handled and it should seldom be necessary to use more than 35 to 40 litres of water per
bag of cement.

(ii)

Where necessary and approved by the Engineer, admixtures to Portland Cement grout
mixtures may be added for delaying the setting time, increasing flow ability, minimising
segregation and shrinkage.

13.3.2 Preparation:
The surface shall be cleaned with wire brush and compressed air, 15mm dia and 150 to
200 mm deep holes along the length of the cracks at a spacing of 500 mm may be drilled
by wet drilling using rotary percussion drills nipples inserted in these holes.
13.3.3 Proportioning, Mixing and Equipment for Grouting :
(i)

The cement grout shall be mechanically mixed using a system of power-driven paddles of
high speed centrifugal pump. The grout pump to be used shall permit close control of
pressures to allow a flexible rate of injection with minimum clogging of valves and ports.
The most satisfactory equipment for injecting grout is a pump of the double-acting flexible
reciprocating type giving a steady flow. The grout pump shall be so placed as to reduce the
waste in cleaning lines. It is preferable to add 50 per cent or more of the mixing water into
the mixer before adding the dry ingredients and then the remaining water. A continuous
supply of grout is preferable to an intermittent one. Consistency of the grout may be
determined by trials starting with thin grout i.e. about 40 litres of water per bag of cement
and progressively decreasing the water content to about 15 litres per bag of cement.

(ii)

Where the mixer and pump are combined in one unit, the dry material shall be screened
before mixing. If the mixer and pump are in separate units, the grout shall pass through a
screen before it enters the pump.

13.3.4 Application :
(i)

Highest practical pressure within the limits 100-400 kPa should be used in order to force
the surplus water from the grout. As the pressure may be distributed hydraulically over
considerate areas, vigilance must be exercised to prevent damage or the needles waste of
144

(iii)

grout. Grouting is to be done by attaching a packer (consisting of expansible tube of

rubber) to the end of the grout supply pump through the holes and nipples.
(ii)

Pressure shall be steady to ensure a continuous flow of grout. Grouting shall not be
continued till the hole consumes mix at the rate of not less than 30 litres in 20 minutes or
until refusal at the grouting pressure of 400 kPa at any hole until refusal. Should the grout
escape from an adjacent nipple, it should be plugged of capped. Any seam, crack or joint
through which grout escapes shall be caulked with epoxy mortar as soon as thick grout
appears.

13.3.5 Cleaning of Equipment :

After completion of each grouting operation or temporary shutdown, it is advisable to force clear
water through the pump until the discharge line shows no colour, after which the pump covers
shall be removed and the valve chambers thoroughly cleaned.
13.3.6 Testing :
Percolation test done at the end of grouting operation shall give a value of less than 2 lugions.
Note:
For specialised treatment like polymer modified cementitious grout injection,
manufacturers literature and specification shall be followed.
13.4 GUNITING/SHOTCRETE
(i)

The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight of
cement, 300 parts by weight quartz sand, 35-50 parts by weight water and 2 parts by
weight approved quick setting compound. In general, dry mix shotcrete shall be used.
(ii)
Ordinary Portland cement conforming to IS:269 shall be used in guniting.
Sand for guniting, shall comply with the requirements stipulated in IS:383. In general, sand should
neither be too coarse to increase the rebound nor too fine to increase the slump. Sand should preferably
have a moisture content between 3 to 6 per cent.

The grading of sand shall lie within the limits given below :
IS Sieve
Designation
4.75 mm
2.36 mm
1.18 mm
600 microns
300 microns
150 microns

per cent Passing the sieve

95 100
65 90
45 75
30 50
10 22
28

145

(iv)

(v)

For thick sections it may be advantageous to incorporate coarse aggregate in the mix
provided adequate guniting equipment is available. Coarse aggregate, when used, shall
conform to grading given in Table I of IS: 9012. The percentage of coarse aggregate may
normally be kept as 20 to 40 per cent of the total aggregate and the mix shall be suitably
designed.
Water/cement ratio for guniting shall fall within the range 0.35 to 0.50 by mass, wet
enough to reduce the rebound. Drying shrinkage may be between 0.06 per cent to 0.10 per
cent. The quick setting compound shall be added at the nozzle with water just before
guniting.

13.4.1 Workmanship :
(i)

The cement and sand shall be batched and mixed and conveyed through a hose pipe with
the help of compressed air. A separate line shall bring the water under pressure. The
cement, sand and water mix shall be passed through and intimately mixed in a special
manifold and then projected at high velocity to the surface being repaired. The density of
gunite shall not be less than 2000 kg/cum. The strength of gunite shall not be less than 25
MPa. For effective guniting, the nozzle shall be kept 60 to 150 cm away from the surface,
preferably normal to that surface. While enclosing reinforcement bars during repairs the
nozzle shall be held closer at a slight angle and the mix shall be wetter than the normal.

(ii)

Test panels simulating actual field conditions shall be fabricated for conducting
preconstruction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS:9012 shall be followed.

(iii)

It should be ensured from tests that a strength of about 25 MPa at 28 days is available for
the mortar/concrete mix.

(iv)

The defective concrete shall be cut out to the full depth till sound concrete surface is
reached. Under no circumstances should the thickness of concrete to be removed be less
than clear cover to the main reinforcement. No square shoulders shall be left at the
perimeter of the cut-off portion and all edges shall be tapered. Thereafter, all loose and
foreign materials should be removed and the surface be sandblasted to make it rough to
receive shotcrete after applying a coat of bonding epoxy as per recommendations of the
manufacturer @ 1.0 kg per 1.5 sq.m of surface area.

(v)

The exposed reinforcement shall be thoroughly cleaned free of rust, scales etc. by wire
brushing. Wherever the reinforcements have been corroded, the same shall be removed
and replaced by additional reinforcement. Before application of gunite, a coat of neat
cement slurry should be applied on the surface of the reinforcement.

(vi)

Sufficient clearance shall be provided around the reinforcement to permit encasement with
sound gunite. Care shall be taken to avoid sand pockets behind the reinforcement.

(vii)

A thickness of 25 to 40 mm of gunite can normally be deposited in one operation. If, for

some reason, the total thickness is to be built up in successive operations, the previous
layer should be allowed to set but not become hard before the application of the
146

subsequent layer. It would always be necessary to apply guniting on a damp concrete

surface.
(viii)

(ix)

(x)

Where required, welded wire fabrics 5cm x 5cm x No.10 gauge shall be provided in the
first layer of guniting. The fabric shall be tied properly. In case the damage to the concrete
member is too deep, the specifications for guniting as well as requirement of placement of
wire mesh has to be decided as per field conditions.
The stipulations given in IS:9012 regarding application of gunite should be followed so as
to keep the rebound to the minimum. The quality of guniting and workmanship shall be
such that the percentage of rebound mentioned in IS:9012 can be adhered to. In no
circumstances shall the rebound material be re-used in the work.
It would be desirable that green gunite is moistened for at least 7 days. Guniting work
shall not be done during windy or rainy conditions.
13.5 DISMANTLING OF CONCRETE WEARING COAT

13.5.1 Commencement of Dismantling :

(i)
Before commencing dismantling, the nature and condition of concrete, the condition and
position of reinforcement should be ascertained. The Contractor shall familiarise himself
with the structural design and ensure that the overall stability of the bridge is not affected.
(ii)

The existing expansion joint assemblies shall be removed carefully along the entire width
of the carriageway. The deck slab for a width of 400 mm on either side should be removed
for placing of reinforcement, anchor rods, anchor bolts and other fixing assemblies for the
new expansion joints and pouring of fresh concrete. The gap between the girders over the
piers should be cleared of all debris. A temporary platform in the gap at the end of girders
shall be erected to collect the materials falling down during concreting and fixing of
expansion joints.

(iv)

The service lines, if any, shall be disconnected/diverted before the dismantling work starts.

13.5.2 Dismantling of concrete wearing coat shall be carried out using jack hammers or suitable manual
methods as approved by the Engineer. Care should be taken to avoid any damage to the existing
structure including reinforcement or pre-stressing anchorages for cables, if any, located in the
deck slab.

13.5.3 Precautions During Dismantling Work :

(i)
(ii)
(iii)

For general guidelines, reference may be made to Section 100.

Dismantling work shall not be carried out at night, or during storm or heavy rain. A
warning device shall be installed in the area to be used to warn the workers in case of
mishap/emergency.
Safety helmets conforming to IS:2925 shall be used by the workmen engaged in
dismantling work. The sheds and tool boxes should be located away from the work site.
Goggles preferably made up of celluloids and gas masks shall be worn at the time of
147

(v)

dismantling, especially where tools like jack hammers are deployed to protect eyes from
injuries from flying pieces, dirt, dust etc. Leather or rubber gloves shall be worn by the
workers during the demolition of RCC work. Screens made up of GI sheets shall be placed
wherever necessary to prevent the flying pieces from injuring the workers.
Water should be sprayed to reduce the dust while removing concrete wearing course with
jack hammer. No work shall be taken up under the span when dismantling work is in
progress.

CHAPTER-13: REPAIR AND REHABILITATION

Sl
No

Reference
to MoRT&H
Specificati
ons

Rate
Item
No.

Description

Unit

148

In
figures
(`)

In words

13.1

13.2

13.3

13.4

2809

Removal of existing cement

concrete wearing coat including
its disposal complete as per
technical specification without
causing any detrimental effect to
any part of the bridge structure
and
removal
of
dismantled
material with all lifts and lead
upto 1000m (Thickness 75 mm).
Guniting concrete surface with
cement mortar applied with
compressor
after
cleaning
surface and spraying with epoxy
complete
as
per
Technical
Specification.
Providing and inserting nipples
with approved fixing compound
after drilling holes for grouting as
per
Technical
Specifications
including
subsequent
cutting/removal and sealing of
the hole as necessary of nipples
after completion of grouting with
Cement/Epoxy.
Sealing of cracks/porous concrete
by injection process through
nipples/Grouting complete as per
Technical Specification.

2807

2800

2806

A
13.5

13.6

13.7

2803

Cement Grout.
Sealing of crack / porous concrete
with Epoxy Grout by injection
through nipples complete as per
Clause 2803.1.
ADDITIONAL ITEM
Painting including supply of paint
over steel work with anticorrosive paint two coats after
properly cleaning the surface by
steel brushes, gunny bags, emry
cloth etc. complete as directed.
Painting including supply of paint
over steel work in built up girders
with alluminium paints two coats
after properly cleaning and filing
the surface by steel brushes,
gunny bags, emry cloth etc.
complete as directed.

a) For unit 12 m clear span

149

278.00

Rupees Two Hundred

and Seventy Eight
Only

sqm

2372.00

Rupees Two
Thousand Three
Hundred and Seventy
Two Only

each

154.00

Rupees One Hundred

and Fifty Four Only

kg

122.00

kg

1810.00

sqm

106.00

each

26958.0
0

sqm

Rupees One Hundred

and Twenty Two Only
Rupees One
Thousand Eight
Hundred and Ten
Only

Rupees One Hundred

and Six Only

Rupees Twenty Six

Thousand Nine
Hundred and Fifty
Eight Only

b) For unit 18 m clear span

c) For unit 24 m clean span

d) For unit 30 m clean span

e) For unit 36.32 m clean span

f) For unit 60 m clean span

13.7

13.8
0

Painting including supply of paint

over steel work with alluminium
paint of approved quality for two
coats after properly cleaning the
surface by steel brushes, gunny
bags, emery cloth etc. etc.
complete as directed.
Painting including supply of paint
over wood work with synthetic
enamel paint of approved quality
two coats after properly cleaning
and filling the surface complete
as directed.

150

each

40108.0
0

Rupees Forty
Thousand One
Hundred and Eight
Only

each

65751.0
0

Rupees Sixty Five

Thousand Seven
Hundred and Fifty
One Only

each

83285.0
0

Rupees Eighty Three

Thousand Two
Hundred and Eighty
Five Only

each

97531.0
0

Rupees Ninety Seven

Thousand Five
Hundred and Thirty
One Only

each

195609.
00

Rupees One Lakh

Ninety Five Thousand
Six Hundred and Nine
Only

sqm

106.00

Rupees One Hundred

and Six Only

sqm

101.00

Rupees One Hundred

One Only

APPENDIX I :LABOUR RATES

Labour
Sl.
N
o.

Rate

Description of Labour

Uni
t

In
Figures
(`)

Mate / Supervisor

day

450.00

Carpenter( Ist Class)

day

400.00

Mason (Ist Class)

day

400.00

Painter ( Ist Class)

day

400.00

Blacksmith (Ist Class)/ Welder/

Plumber/ Electrician

day

400.00

Driller

day

350.00

Mason (IInd Class)

day

350.00

Blaster (Stone cutter)

day

300.00

Chiseller (Head Mazdoor)

day

300.00

10

Mazdoor (Skilled)

day

170.00

11

Mazdoor (Semi -Skilled)

day

150.00

12

Mazdoor (Un-skilled)

day

130.00

151

In Words
Rupees Four
Hundred Fifty Only
Rupees Four
Hundred Only
Rupees Four
Hundred Only
Rupees Four
Hundred Only
Rupees Four
Hundred Only
Rupees Three
Hundred Fifty Only
Rupees Three
Hundred Fifty Only
Rupees Three
Hundred Only
Rupees Three
Hundred Only
Rupees One
Hundred Seventy
Only
Rupees One
Hundred Fifty Only
Rupees One
Hundred Thirty
Only

APPENDIX II: RATES OF STONE BOULDERS, STONE AGGREGATES, STONECHIPS,GRANULAR SUB-BASE MATERIAL , SAND, etc
Rate
Sl.
Uni
In
N
Description
t
Figure
o.
s (` )
In Words
Stone Boulder of size 150 mm and
Cu
1
650.00 Rupees Six Hundred
below at Crusher Plant
m
Fifty Only
2

Supply of quarried stone 150 - 200

mm size for Hand Broken at site

Cu
m

635.00

Rupees Six Hundred

Thirty Five Only

Boulder with minimum size of 300 mm

for Pitching at Site

Cu
m

600.00

Rupees Six Hundred

Only

Coarse sand at Mixing Plant(Coarse

sand)

Cu
m

800.00

Rupees Eight Hundred

Only

Coarse sand at Site(Fine sand river)

Cu
m

750.00

Rupees Seven
Hundred Fifty Only

Fine sand at Site (fine sand hill)

Cu
m

700.00

Rupees Seven
Hundred Only

Moorum at Site

Cu
m

200.00

Rupees Two Hundred

Only

Gravel/Quarry spall at Site

Cu
m

400.00

Rupees Four Hundred

Only

Granular Material or hard murrum for

GSB works at Site

Cu
m

400.00

Rupees Four Hundred

Only

12

Filter media/Filter Material as per Table

300-3 (MoRT&H Specification)

Cu
m

500.00

Rupees Five Hundred

Only

13

Close graded Granular sub-base

Material 53 mm to 9.5 mm

Cu
m

1200.0
0

14

Close graded Granular sub-base

Material 37.5 mm to 9.5 mm

Cu
m

1280.0
0

15

Close graded Granular sub-base

Material 26.5 mm to 9.5 mm

Cu
m

1310.0
0

16

Close graded Granular sub-base

Material 9.5 mm to 4.75 mm

Cu
m

1340.0
0

17

Close graded Granular sub-base

Material 9.5 mm to 2.36 mm

Cu
m

1350.0
0

Rupees One Thousand

Two Hundred Only
Rupees One Thousand
Two Hundred Eighty
Only
Rupees One Thousand
Three Hundred Ten
Only
Rupees One Thousand
Three Hundred Forty
Only
Rupees One Thousand
Three Hundred Fifty
Only

152

Close graded Granular sub-base

Material 4.75mm to 2.36 mm

Cu
m

1070.0
0

Rupees One Thousand

Seventy Only

Close graded Granular sub-base

Material 4.75mm to 75 micron mm
Stone crusher dust finer than 3mm
with not more than 10% passing 0.075
sieve.
Coarse graded Granular sub-base
Material 2.36 mm & below

Cu
m

970.00

Rupees Nine Hundred

Seventy Only

Cu
m

270.00

Rupees Two Hundred

Seventy Only

Cu
m

1000.0
0

22

Coarse graded Granular sub-base

Material 26.5 mm to 4.75 mm

Cu
m

1350.0
0

Rupees One Thousand

Only
Rupees One Thousand
Three Hundred Fifty
Only

23

Coarse graded Granular sub-base

Material 53 mm to 26 .5mm

Cu
m

1100.0
0

Rupees One Thousand

One Hundred Only

24

Aggregates below 5.6 mm

Cu
m

1200.0
0

25

Aggregates 22.4 mm to 2.36 mm

Cu
m

1420.0
0

Rupees One Thousand

Two Hundred Only
Rupees One Thousand
Four Hundred Twenty
Only

26

Aggregates 22.4 mm to 5.6 mm

Cu
m

1400.0
0

27

Aggregates 45 mm to 2.8 mm

Cu
m

1320.0
0

28

Aggregates 45 mm to 22.4 mm

Cu
m

1250.0
0

29

Aggregates 53 mm to 2.8 mm

Cu
m

1350.0
0

30

Aggregates 53 mm to 22.4 mm
(grade III)

Cu
m

1300.0
0

31

Aggregates 63 mm to 2.8 mm

Cu
m

1290.0
0

Rupees One Thousand

Three Hundred Only
Rupees One Thousand
Two Hundred Ninety
Only

32

Aggregates 63 mm to 45 mm(grade
II)

Cu
m

1200.0
0

Rupees One Thousand

Two Hundred Only

33

Aggregates 90 mm to 45 mm(grade I)

Cu
m

1000.0
0

34

Aggregates 10 mm to 5 mm

Cu
m

1690.0
0

35

Aggregates 11.2 mm to 0.09 mm

Cu
m

1680.0
0

Rupees One Thousand

Only
Rupees One Thousand
Six Hundred Ninety
Only
Rupees One Thousand
Six Hundred Eighty
Only

18
19
20
21

153

Rupees One Thousand

Four Hundred Only
Rupees One Thousand
Three Hundred
Twenty Only
Rupees One Thousand
Two Hundred Fifty
Only
Rupees One Thousand
Three Hundred Fifty
Only

36

Aggregates 13.2 mm to 0.09 mm

Cu
m

1650.0
0

Rupees One Thousand

Six Hundred Fifty Only

37

Aggregates 13.2 mm to 5.6 mm

Cu
m

1650.0
0

Rupees One Thousand

Six Hundred Fifty Only

38

Aggregates 13.2 mm to 10 mm

Cu
m

1650.0
0

Rupees One Thousand

Six Hundred Fifty Only

39

Aggregates 20 mm to 10 mm

Cu
m

1600.0
0

40

Aggregates 25 mm to 10 mm

Cu
m

1580.0
0

Rupees One Thousand

Six Hundred Only
Rupees One Thousand
Five Hundred Eighty
Only

41

Aggregates 19 mm to 6 mm

Cu
m

1600.0
0

42

Aggregates 37.5 mm to 19 mm

Cu
m

1150.0
0

Rupees One Thousand

Six Hundred Only
Rupees One Thousand
One Hundred Fifty
Only

43

Aggregates 37.5 mm to 25 mm

Cu
m

1100.0
0

Rupees One Thousand

One Hundred Only

44

Aggregates 6 mm nominal size

Cu
m

1650.0
0

45

Aggregates 10 mm nominal size

Cu
m

1620.0
0

Rupees One Thousand

Six Hundred Fifty Only
Rupees One Thousand
Six Hundred Twenty
Only

46

Aggregates 13.2/12.5 mm nominal

size

Cu
m

1600.0
0

Rupees One Thousand

Six Hundred Only

47

Aggregates 20 mm nominal size

Cu
m

1500.0
0

Rupees One Thousand

Five Hundred Only

48

Aggregates 25 mm nominal size

Cu
m

1400.0
0

Rupees One Thousand

Four Hundred Only

49

Aggregates 40 mm nominal size

Cu
m

1200.0
0

Rupees One Thousand

Two Hundred Only

154

APPENDIX III : HIRE CHARGES OF MACHINERIES

Sl.
No

Description of
Machineries
1.

2.

3.
4.
5.
6.
7.
8.
9.

Units of
Measureme
nts

Usage
Charge
(`/Hr)

Running
Charge
(`/Hr)

Total
Charge
without
Diesel
(`/Hr)

Total
Charge
with
Diesel
(`/Hr)

Air Compressor
170/250
Air Compressor with
Pneumatic chisel
attachment for
cutting hard clay

Capacity in
cfm/hour
3094

193.00

298.00

491.00

679.00

336.00

492.00

828.00

3821.00

Batching and Mixing

Plant
Batching and Mixing
Plant
Batch Type Cold
Mixing Plant
Bitumen Pressure
Distributor
Bitumen Boiler oil
fired
Bitumen Sprayer

3 Cum/hour

350.00

426.00

776.00

1199.00

15-20
Cum/hour
100-120 tph

747.00

739.00

1486.00

2332.00

1400.00

550.00

1950.00

2796.00

Sqm/hour

337.00

367.00

704.00

1033.00

1500
Capacity in ltr
4 tonnes

402.00

418.00

820.00

1290.00

399.00

360.00

759.00

1370.00

2850.00

6228.00

9707.00

1120.00

566.00

9078.00
(450/perso
n)
1686.00

20 Cum/hour

920.00

538.00

1458.00

1881.00

45 & 30
Cum/hour
1 Capacity in
cum
Cum/hour

56.00

299.00

355.00

590.00

10.00

83.00

93.00

93.00

150.00

306.00

456.00

550.00

Cum/hour

84.00

306.00

390.00

484.00

80 tonnes

873.00

618.00

1491.00

2713.00

Boat to carry at least

20 persons

10. Chain Excavator

Concrete paver
finisher with 40 HP
Motor
12. Concrete pump
11.

13. Concrete bucket

14. Concrete Mixer(A)
0.4/0.28 cum
15. Concrete Mixer (B) 1
cum
16. Crane

155

2062.00

17. Crane

35 tonnes

622.00

551.00

1173.00

1784.00

18. Crane

3 tonnes

114.00

331.00

445.00

680.00

19. Crane

F-15

622.00

761.00

1383.00

1994.00

20. Crane

5-tonne
capacity

350.00

331.00

681.00

916.00

21. Crane

10 tonne
capacity
15 tonne
capacity
20 tonne
capacity
40 tonne
capacity
0.75 cm

600.00

331.00

931.00

1166.00

900.00

331.00

1231.00

1701.00

1600.00

331.00

1931.00

2401.00

3000.00

331.00

3331.00

3942.00

900.00

331.00

1231.00

1466.00

175 cum per

hour

2800.00

500.00

3300.00

3864.00

75 cum per
hour

1250.00

500.00

1750.00

2314.00

Cum/hour

975.00

465.00

1440.00

2098.00

Cum/hour

1692.00

532.00

2224.00

3070.00

75
tonnes/hour
1750
Sqm/hour

1400.00

839.00

2239.00

8819.00

263.00

375.00

638.00

967.00

337.00

360.00

697.00

885.00

15.00

87.00

102.00

102.00

22. Crane
23. Crane
24.

Crane

25. Crane with grab 0.75

cum capacity
Cement concrete
26.
batch mix plant
(effective output)
Cement concrete
27.
batch mix plant @ 75
cum per hour
28.
Dozer D-50-A-15
29.

Dozer D-80-A-12

30. Drum Mix Plant for

cold mixes
31. Emulsion Pressure
Distributor
32.
33.

Emulsion Sprayer

4 tonnes

Epoxy injection gun

34. Front end loader 1

cum bucket capacity
35. Generator (a) 125
KVA
36.
Generator (b) 63 KVA

Cum/hour

311.00

483.00

794.00

1170.00

125-160 KVA

164.00

326.00

490.00

725.0

KVA

143.00

286.00

429.00

617.00

37.

50 Cum/hour

377.00

402.00

779.00

1625.00

KVA

92.00

326.00

418.00

653.00

KVA

159.00

361.00

520.00

708.00

38.
39.

GSB Plant
Generator 33 KVA
Generator 100 KVA

156

40.

Generator 250 KVA

41. Hotmix Plant 120

TPH capacity
42. Hotmix Plant 100
TPH capacity
43. Hotmix Plant 60 to
90 TPH capacity
44. Hotmix Plant 40 to
60 TPH capacity
45. Hot Mix Plant 20 to
40 TPH
46. Hydraulic Chip
Spreader
Hydraulic/Loader
47.
cum Excavator of 1
cum bucket
48. Integrated Stone
Crusher
49. Integrated Stone
Crusher

KVA

166.00

286.00

452.00

640.00

Cum/hour

2365.00

878.00

3243.00

14993.00

Cum/hour

1866.00

822.00

2688.00

13028.00

Cum/hour

1495.00

686.00

2181.00

11581.00

Cum/hour

970.00

615.00

1585.00

10985.00

Cum/hour

726.00

557.00

1283.00

8333.00

1500
Sqm/hour
Cum/hour

846.00

599.00

1445.00

1868.00

404. 00

492.00

896.00

1319.00

100 TPH

5590.00

588.00

6178.00

10314.00

200 TPH

2241.00

544.00

2785.00

4430.00

50.00

171.00

221.00

221.00

hour

105.00

146.00

251.00

298.00

80 Rm/hour

125.00

346.00

471.00

800.00

Cum/bucket

696.00

595.00

1291.00

1620.00

1 Capacity in
tone
1250
Sqm/hour
ED-30

56.00

249.00

305.00

399.00

230.00

323.00

553.00

882.00

298.00

323.00

621.00

997.00

Cum/hour

759.00

504.00

1263.00

1592.00

270 Sqm/hour

337.00

314.00

651.00

1074.00

Cum/hour

947.00

668.00

1615.00

1944.00

Cum/hour

1725.00

146.00

1871.00

2200.00

Cum/hour

274.00

668.00

942.00

1271.00

50. Jack for lifting 40

tonne lifting capacity
51.
52.
53.
54.

Joint Cutting M/C2-3

blades(For rigid
pavement)
Kerb casting machine
Loader cum Dozer
Mastic Cooker

55. Mechanical Broom

Hydraulic
56.
Mini Vibratory Roller
57. Motor grader 3.35
mtr blade
58. Mobile Slurry seal
equipment
Paver finisher
59.
Hydrostatic with
sensor 75 TPH
Paver finisher
60.
Hydrostatic with
sensor 100 TPH
61. Paver finisher
Mechanical 75 TPH

157

62. Paver finisher

Mechanical 100 TPH
63. Piling rig with
Bantonite pump
64. Pneumatic Road
Roller ST
65. Pneumatic Sinking
Plant
66. Pot Hole Repair
machine
Pre-stressing Jack
67.
with pump and
accessories
68.
Plate compactor
69.
70.

Rotavator
Ripper

71. Road Marking

Machine
72.
Soil Compactor

Cum/hour

629.00

668.00

1297.00

1626.00

3525.00

509.00

4034.00

6149.00

2 Cum/hour

485.00

482.00

967.00

1296.00

1.5-2
Cum/hour
4 Cum/hour

1344.00

629.00

1973.00

2584.00

358.00

460.00

818.00

1147.00

52.00

340.00

392.00

439.00

1012.00

508.00

1520.00

1943.00

25 Cum/hour

18.00

216.00

184.00

231.00

60 Cum/hour

11.00

208.00

234.00

281.00

10 m/hour

26.00

248.00

299.00

346.00

541.00

336.00

877.00

885.00

297.00

409.00

706.0

1082.00

3450.00

467.00

3917.00

4152.00

120.00

112.00

232.00

232.00

185

416

601.00

789.00

223 Rm/hour

73.
74. Smooth Wheeled
Roller 8 tonne
75. Snow blower
equipment 140 HP @
600 cum per hour
76. Steel Drum 300mm
diameter 1.2 mtr
height
77. Spot Mix Plant

70 Cum/hour

78. Tandem Road Roller

8-10 tonnes

246.00

470.00

716.00

951.00

10-12 tonnes

179.00

448.00

627.00

721.00

Cum/hour

446.00

432.00

878.00

1301.00

Cum/hour

437.00

432.00

869.00

1074.00

Capacity in
HP

162.00

422.00

584.00

866.00

83. Tractor with rotavator

173.00

670.00

843.00

1172.00

84. Tractor with ripper

180.00

588.00

768.00

1097.00

1350.00

433.00

1783.00

2206.00

79. Tipper Truck

80. Transit Mixer 4/4.5
cum
81. Transit Mixer 3.0
cum
82. Tractor

85. Truck trailer 30 tonne

capacity

6-10 tph

158

86. Tunnel Boring

Machine
87. Vibratory Roller 8-10
tonne
88. Water Tanker 6 KL

1250.00

500.00

1750.00

5886.00

Cum/hour

527.00

481.00

1008.00

1384.00

Capacity in KL

120.00

446.00

566.00

848.00

89. Wet Mix Plant 60 TPH

777.00

515.00

1292.00

8342.00

90. Wet Mix Plant 100

TPH
91. Wet Mix Plant 75 TPH

1750.00

701.00

2451.00

9501.00

1500.00

586.00

2086.00

9136.00

APPENDIX IV : RATES OF CONSTRUCTION MATERIALS

Sl.
No.

Description of Item

Unit

Rate
In
figure
s
(` )

AC pipe 100 mm dia

Alluminium Paint

metre

250.0
0

litre

300.0
0
159

In words
Rupees Two Hundred Fifty Only

Rupees Three Hundred Only

Barbed wire

kg

65.00

Rupees Sixty Five Only

Binding wire

Kg

80.00

Rupees Eighty Only

Brick

each

8.10

Credit for excavated rock

found suitable for use

cum

66.00

Rupees Sixty Six Only

Curing compound

liter

250.0
0

Rupees Two Hundred Fifty Only

each

1600.
00

Rupees One Thousand Six Hundred Only

cum

180.0
0

Rupees One Hundred Eighty Only

Road Delineators from ISI

certified firm as per the
standard drawing given in
IRC - 79
Earth Cost or
compensation for earth
taken from private land

Rupees Eight and Ten paise Only

10

Galvanised MS flat clamp

Nos

26.00

Rupees Twenty Six Only

11

GI bolt 10 mm Dia

Nos

39.00

Rupees Thirty Nine Only

12

Hot applied thermoplastic

compound

litre

525.0
0

Rupees Five Hundred Twenty Five Only

13

M.S. Clamps

Nos

60.00

Rupees Sixty Only

14

Nipples 12mm

Nos

30.00

Rupees Thirty Only

15

Nuts and bolts

Kg

130.0
0

Rupees One Hundred Thirty Only

16

Paint

litre

280.0
0

Rupees Two Hundred Eighty Only

17

Primer

Kg

120.0
0

Rupees One Hundred Twenty Only

18

Random Rubble Stone

cum

300.0
0

Rupees Three Hundred Only

19

Reflectorising glass beads

Kg

180.0
0

Rupees One Hundred Eighty Only

20

Sand bags (Cost of sand and

Empty cement bag)

Nos

5.00

160

Rupees Five Only

21

Scrap tyres of size 900 x 20

Nos

30.00

Rupees Thirty Only

22

Steel drum 300 mm dia 1.2

m high/empty bitumen drum

Nos

100.0
0

Rupees One Hundred Only

23

Unslaked lime

tonne

3600.
00

Rupees Three Thousand Six Hundred

Only

24

Water

KL

235.0
0

Rupees Two Hundred Thirty Five Only

25

Wire mesh 50mm x 50mm

size of 3mm wire

Kg

100.0
0

Rupees One Hundred Only

APPENDIX V : MARKET RATES OF ISI CLASS NP3 AND NP4 HUME PIPES
Sl
.
N
o.
1

ISI
Cla
ss

NP3

Intern
al
diame
ter
1.00m

Rate

Barrel
length

Barrel
thickn
ess

Unit

2.50m

100m
m

Runnin
gmetre

161

In
figures
(`)

In words

Rupees Seven
7560.00 Thousand Five
Hundred Sixty Only

Runnin
gmetre

Rupees Six Thousand

NP3 1.00m
1.25m
6338.00 Three Hundred
Thirty Eight Only
Rupees Seven
Runnin
115m
Thousand Two
NP4 1.00m
2.50m
g7231.00
m
Hundred Thirty One
metre
Only
Rupees Seven
Runnin
115m
Thousand Five
NP4 1.00m
1.25m
g7575.00
m
Hundred Seventy Five
metre
Only
Rupees Nine
Runnin
115m
Thousand Three
NP4 1.20m
2.50m
g9348.00
m
Hundred Forty Eight
metre
Only
Runnin
Rupees Ten Thousand
115m
NP4 1.20m
1.25m
g10238.00 Two Hundred Thirty
m
metre
Eight Only
The following materials will be issued by the Department from the SubDivisional godowns / Magazine, subject to availability in the P.W.D. Stores and
the recovery of cost will be made from the Contractor's bill at the rates shown
below. In case the materials are not available from the P.W.D. Godowns, the
same may be procured by the Contractor from the open market with the
approval of the Engineer.
Rupees Six Thousand
Four Hundred Only
Cement
per tonne
6400.00
100m
m

Cold twisted bars

(HYSD Bars)

Gelatin

Electric Detonators @ 1
detonator for 1/2
gelatin stick of 125 gms
each

100 Nos.

Bitumen (60-70 grade)

tonne

Bitumen (80-100
grade )

tonne

per tonne

kg

162

Rupees Fifty Eight

Thousand One
58120.00
Hundred Twenty
Only
Rupees Ninety Nine
99.60 and Sixty paise Only
Rupees One
Thousand Five
1573.00
Hundred Seventy
Three Only
Rupees Fifty Five
Thousand Six
55626.00
Hundred Twenty Six
Only
Rupees Fifty Four
Thousand Six
54636.00
Hundred Thirty Six
Only

Bitumen (modified
graded,CRMB-55)

tonne

Bitumen (PMB-55)

tonne

Mastic bitumen ( 30-40

grade)

tonne

Rupees Fifty Five

Thousand Seven
55713.00
Hundred Thirteen
Only
Rupees Sixty Two
62000.00 Thousand Only

54400.00

tonne
10

Bitumen Emulsion for

premix carpeting

53719.00
tonne

11

Bitumen Emulsion
(Rapid Setting)

12

Bitumen Emulsion
( Medium Setting)

13

Bitumen
emulsion( Slow Setting)

43318.00
tonne
48440.00
tonne
45471.00
tonne

14

Bitumen emulsion for

seal coat

53447.00

163

Rupees Fifty Four

Thousand Four
Hundred and Forty
Only
Rupees Fifty Three
Thousand Seven
Hundred Nineteen
Only
Rupees Forty Three
Thousand Three
Hundred Eighteen
Only
Rupees Forty Eight
Thousand Four
Hundred Forty Only
Rupees Forty Five
Thousand Four
Hundred Seventy
One Only
Rupees Fifty Three
Thousand Four
Hundred Forty Seven
Only

RECOMMENDED STANDARDS FOR HIGHWAYS

Road Width
The roadway width for single and two lane roads in plain and rolling terrain shall be as given in
the Table below:
TABLE I : ROADWAY WIDTH FOR SINGLE-LANE AND TWO-LANE ROAD IN PLAIN AND
ROLLING TERRAIN
Sl.No.

Road Classification

Road width (in metres)

1.

National Highways and State Highways (Single or two lanes)

12.00

2.

Major District Roads (Single or two lanes)

9.00

Other District Roads

3.

4.

i)Single lane

7.50

ii)Two lane

9.00

Village Roads (Single lane)

7.50

TABLE II: ROADWAY WIDTH FOR SINGLE-LANE AND TWO-LANE ROADS IN MOUNTAINOUS AND STEEP
TERRAIN

Sl.No.

Road Classification

Road width (in metres)

National Highways and State Highways

1.

i)Single lane

6.25

ii)Two lane

8.80

2.

Major District Roads and Other District Roads (Single lane)

4.75

3.

Village Roads (Single lane)

4.00

Note:
1. The roadway width given above are exclusive of parapets (usual width 0.6m) and side drains (usual
width 0.6m).These should be provided in addition to the shoulders as necessary.
2. The road way width of village road are on the basis of a single lane carriageway of 3m. If a higher
pavement width is adopted, the roadway width should be increased correspondingly.
3. In hard rock stretches, or unstable locations where excessive cutting might lead to slope failure, width
of road way should be reduced by 0.8m on two lane road and 0.4m in other cases. However, where
such stretches occur in continuous long length, reduced in roadway width should not be effected unless
requisite passing place are provided.
4. On roads which are subjected to heavy snowfall, where snow regular clearance is done over long
periods to keep the road open to traffic, roadway width may be increased by 1.5m for MDRs, ODRs
and VRs.
164

Passing places are not necessary on two lane National and State Highways having roadway width
in accordance with Table I above. But on single lane sections having narrower roadway, it may be
desirable to provide some passing places depending on actual needs. On other roads, these should be
provided in general at the rate of 2-3 per cent kilometer. Their exact location should be judiciously
determined taking into consideration the available extra width on curves and visibility.
Normally, the passing places/lay-byes should be 3.0 m wide and 30m long on the inside edge (i.e.
towards the carriageway side) and 20m long on the farther side.
WIDTH OF CARRIAGE WAY
The standard width of carriageway shall be as indicated in Table III below. Total width should be
determined in relation to the design traffic and capacity of the roadway.
TABLE III: WIDTH OF CARRIAGE WAY
Width of carriage way (in metres)
Single lane

Two lanes
without kerbs

Two lanes with

raised kerbs

Multi-lane
pavement width
per lane

3.75**

7.0

7.5

3.5

Notes: 1.**
On village roads, the carriageway width may be restricted to 3.0m normally.
Widths greater than 3.0m may however be adopted judiciously depending on the types and
intensity of traffic cost and related factor.
2.

Except on important trunk routes, an intermediate carriageway width of 5.5 metres may
also adopted instead of regular two lanes if the same is considered advantageous.

Where the carriageway width changes i.e. from single lane to two lanes to four lanes, transition
should be effected through a taper of 1 in 15 to 1 in 20.
PERMANENT CAMBER OR CROSS-FALL:
The Camber or cross-fall on straight sections of roads should be as recommended in the Table IV
below for various types of surfaces. For a given surface type, the steeper value may be adopted in areas
having high intensity of rainfall and the lower values where the intensity of rainfall is low.

TABLE IV : CAMBER/CROSSFALL VALUES FOR DIFFERENT ROAD SURFACE TYPES

165

Sl.N
o.

Surface type

Camber/Cross-fall

1.

High type Bituminous surfacing or

cement concrete

2.

Thin bituminous surfacing

3.

Water Bound Macadam, Gravel

4.

Earth

1.7 - 2.0 percent

(1 in 60 to 1 in 50)
2.0 - 2.5 percent
(1 in 50 to 1 in 40)
2.5 - 3.0 percent
(1 in 40 to 1 in 33)
3.0 - 4.0 percent
(1 in 33 to 1 in 25)

DESIGN TRAFFIC AND CAPACITY

The width of carriageway should be sufficient for the design traffic, i.e. traffic accepted on the
road in the design year. Design traffic will depend on the rate of growth of traffic, the design period,
importance of road in the system, nature of road side development, etc., for making capacity
computations under mixed traffic condition. The different types of vehicles should be converted to a
common unit known as Passenger Car Unit (PCU) by multiplying their number with relevant
equivalency factors. Tentative values of equivalency factors are given in Table V below. These are meant
for use in open section in plain terrains away from intersection. For more details in this respect, reference
may be made to IRC : 64-1976 Tentative Guidelines on Capacity of Roads in Rural Areas.
TABLE V : EQUIVALENCY FACTORS FOR DIFFERENT TYPES OF VEHICLES
Sl.N
o.

Vehicle type

Equivalency factor

1.

Passenger car, tempo, auto-rickshaw or agricultural

tractor

1.0

2.

Cycle, Motorcycle or scooter

0.5

3.

Truck, bus or Agricultural Tractor, Trailer Unit

3.0

4.

Cycle Rickshaw

1.5

5.

Horse-drawn vehicle

4.0

6.

Bullock cart

6-8

166

TABLE VI : MINIMUM TRANSITION LENGTH FOR DIFFERENT SPEEDS AND CURVE ROAD
Plain and rolling terrain

Mountainous and steep terrain

Design Speed (Km/h)

Curve
radius

Curve
radiu

Design speed (Km/p)

P(met
re)
100

80

65

50

40

35

50

Transition length - mts

45
60

40

30

25

20

Transition length (Km/h)

NA

70

14

NA

75

55

20

NA

NA

NA

NA

30

35

20

90

NA

74

45

35

25

NA

25

20

100

80

45

40

25

30

30

25

15

150

70

40

35

20

40

NA

25

20

15

170

NA

60

35

30

20

50

40

20

15

15

200

90

50

30

25

NR

55

40

20

15

15

240

75

40

25

20

70

30

15

15

15
NR

300

NA

60

35

20

20

80

NA

25

15

15

360

130

55

30

20

NR

90

55

25

15

15

400

115

45

25

NR

100

45

20

15

15

500

65

35

20

125

45

15

15

NR

600

80

35

20

150

35

15

700

70

30

NR

200

30

15

800

60

30

200

20

15

900

55

30

250

20

15

1000

50

NR

300

15

NR

1200

40

400

15

1500

35

500

NR

1800

30

2000

NR

NA - Not applicable.

NR - Transition not required.

The extra width of carriageway to be provided at horizontal curves on single and two-lane roads is
given in Table VII below. For multi-lane roads, the pavement widening may be calculated by adding half
the widening for two-lane roads to each lane.
TABLE VII : EXTRA WIDTH OF PAVEMENT AT HORIZONTAL CURVES
167

Radius of
curve
(m) Extra
width
(m)

Upto 20

21 to 40

41 to 60

61 to 100

101 to
300

Above
300

Two-lane

1.5

1.5

1.2

0.9

0.6

Nil

Singlelane

0.9

0.6

0.6

Nil

Nil

Nil

The widening should be effected by increasing the width at an approximately uniform rate along
the transition curve. The extra width should be continued over the full length of the circular curve. On
curve having no transition, widening should be achieved in the same way as the super-elevation i.e.
(two-third) being attained on the straight section before the start of the curve and (one-third) on the
curve.
The widening should be applied equally on both side of the carriageway, except that on hill roads
it will be preferable the entire widening is done on the inside. Similarly, the widening should be provided
only on the inside when the curve is plain circular and has no transition.
Recommended gradients for different classes of terrain are given in Table below:
TABLE VIII : GRADIENTS FOR ROADS IN DIFFERENT TERRAIN
Sl.N
o.

Terrain

1.

Plain or rolling

2.

Mountainous terrain,
steep terrain having
elevation more than
3,000m above the mean
seal level

3.

Steep terrain upto

3,000m height above
mean sea level

Ruling
gradient

Limiting
gradient

Exceptional
gradient

3.3 percent

5 percent

6.7 percent

(1 in 30)

(1 in 20)

(1 in 15)

5 percent

6 percent

7 percent

(1 in 20)

(1 in 16.7)

(1 in 14.3)

6 percent

7 percent

8 percent

(1 in 16.7)

(1 in 14.3)

(1 in 12.5)

Gradients upto the Ruling gradient may be used as a matter of course in design. However, in
special situations such as isolated over-bridges in flat country or roads carrying a large volume of slow
168

moving traffic it will be desirable to adopt a flatter gradient of 2% from the angle of aesthetic, traffic
operation and safety.
The limiting gradient are meant to be adopted only in difficult situations and for short lengths of
continuous grade steeper than the ruling gradient.
Exceptional gradients are meant to be adopted only in difficult situations and for short length not
exceeding 100m at a stretch in mountainous and steep terrain. Successive stretches of exceptional
gradient must be separated by a minimum length of 100m having gentler gradient (i.e. limiting gradient
or flatter gradient).
The rise in elevation over a 2 Km length shall not exceed 100m in mountainous terrain and 120m
in steep terrain.
VERTICAL CURVES
Vertical curves are introduced for smooth transition at grade changes. Convex vertical curves and known
as summit curves. Vertical concave curves are known as valley or sag curves. Both these should be designed as
square parabolas.
The length of the vertical curves is controlled by sight distance requirement but curves with greater length
are as aesthetically better.
Curves should be provided at all grade changes exceeding those indicated in the Table IX below. For
satisfactory appearance the minimum length should be as shown in the following Table.
TABLE IX : MINIMUM LENGTH OF VERTICAL CURVE
Design Speed

Max. grade change

Minimum length vertical

curves (in metres)

(Km)

(percent not requiring a vertical

curve)

Upto 35

1.5

15

40

1.2

20

50

1.0

30

65

0.8

40

80

0.6

50

100

0.5

60

WORKMANSHIP AND QUALITY CONTROL

CONCRETE
169

Measuring - The quantity of cement shall be determined by weight. Ordinary Portland Cement
shall be taken to weigh 1440 kg/m3, and rapid hardening Portland cement to weigh 1210 kg/m3. The
quantities of fine and coarse aggregates shall be determined either by volume or preferably by weight.
The proportions given in Table XII are based on the assumption that the aggregates are dry. If aggregates
are wet, due allowance shall be made for bulking in accordance with IS : 2386 m (Part III) - 1963 :
Methods of test for Aggregates for Concrete: Part III- Specific Gravity, Density, Voids, Absorption and
bulking.
Mixing - Concrete shall normally be mixed in mechanical mixer.
Mixing shall be continued until there is a uniform distribution of the materials and the mass is
uniform in colour and consistency, but in no case shall mixing be done for less than two minutes.
When hand mixing is permitted by the Engineer-in-Charge, it shall be carried out on a water-tight
platform and care shall be taken to ensure that mixing is continued until the mass is uniform in colour and
consistency.
Transporting : Concrete shall be handled from the place of mixing to the place of final deposit as rapidly
as practicable by methods which will prevent the segregation or loss of any of the ingredients. If
segregation does occur during transport, the concrete shall be re-mixed before being placed.
During hot or cold weather, concrete shall be transported in deep containers. The deep containers on
account of their lower ratio of surface area to mass, reduce the rate of loss of water by evaporation during
hot weather and loss of heat during cold weather.
PLACING AND COMPACTING:
GENERAL: The concrete shall be placed and compacted before setting commences and should not be
subsequently disturbed. Method of placing should be such as to preclude segregation.
.
CONSTRUCTION JOINTS:- Concreting shall be carried out continuously up to construction joints, the
position and arrangement of which shall be pre determined by the designer.
When the work has to be resumed on a surface which has hardened, such surface shall be roughened. It
shall then be swept, clean, thoroughly wetted and covered with a 13 mm layer of mortar composed of
cement and sand in the same ratio as the cement and sand in the concrete mix. This 13 mm layer of
mortar shall be freshly mixed and placed immediately before placing of the concrete.
When the concrete has not fully hardened, all laitance shall be removed by scrubbing the wet surface with
wire or bristle brushes, care being taken to avoid dislodgement of particles of aggregate. The surface shall
be thoroughly wetted and all free water removed. The surface shall then be coated with cement grout. The
first layer of concrete to be placed on this surface shall not exceed 150 mm in thickness, and shall be well
rammed against old work, particular attention being paid to corners and clot spots.
Concrete shall be thoroughly compacted during the operation of placing, and thoroughly around the
reinforcement, embedded fixtures and into corners of the form work.

170

MECHANICAL VIBRATION: The use of mechanical vibrators for compacting concrete is

recommended, provided that the reduced water content recommended is adopted. Over-vibration or
vibration of every wet mix is harmful and should be avoided.
GROUTING :
A series of round cages made of 50 mm mesh of 6 mm steel and extending over the full height to be
concreted shall be prepared and laid vertically over the area to be concreted so that the distance between
centre of the cages and also towards the face of the concrete shall not exceed one metre.
Stone aggregates of not less than 50 mm and not more than 200 mm size shall be deposited outside the
steel cages over the full area and height to be concreted with due care to prevent the displacement of the
cages. A stable 1:2 cement:sand grout with a water-cement ratio of not less than 0.6 and not more than 0.8
shall be prepared in a mechanical mixer and sent down under pressure (about 2 kg.cm ) through 38 to 50
diameter pipe terminating into steel cages, about 50 mm above the bottom of the concrete. As the
grouting proceeds, the pipe shall be raised gradually up to a height of not more than 600 mm above its
starting level, after which it may be withdrawn and placed into the next cage for further grouting by the
same procedure.
After grouting the whole area for a height of about 800 mm, the same operation shall be repeated. If
necessary, for the next layer of 600 mm and so on.
The amount of grout to be sent down shall be sufficient to fill all the voids of the stone which may be
either ascertained or safely assumed as 55 percent of the volume to be concreted.
To minimise the formation of laitance, great care shall be exercised to disturb the concrete as little as
possible while it is being deposited.

GRADE OF
CONCRETE

TABLE X : STRENGTH REQUIREMENTS OF CONCRETE

(Clause 5.2.1, 5.2.2, 5.2.2.1, and 5.2.3.)
(All Values in kg/cm)
COMPRESSIVE STRENGTH OF 15 - cm CUBES AT 28 DAYS AFTER
MIXING, CONDUCTIONED IN ACCORDANCE WITH IS : 516 -1959
Preliminary Test
Work Test
Min
Min

M 100

135

100

M 150

200

150

M 200

260

200

M 250

320

250

M 300

380

300

M 350

440

350

M 400

500

400

NOTE 1:
171

a)

b)

Preliminary Test -A test conducted in a laboratory on the trial mix* of concrete produced in the
laboratory with the object of :
1)

Designing a concrete mix before the actual concreting operational start

2)

Determining the adjustments required in the designed mix when there is a change in the materials
used during the execution of work, or

3)

Verifying the strength of concrete mix.

Work Test -A test conducted either in the field or in a laboratory on the specimen made on the works, out
of the concrete being used on the works.
TABLE XI : OPTIONAL WORKS TEST REQUIREMENTS OF CONCRETE

(Clause 5.2.2.1)
(All values in Kg/cm)
(All test conducted in accordance with IS: 516 -1959)
GRADE OF CONCRETE

COMPRESSIVE
STRENGTH ON 15 - cm
CUBES MIN AT 7 DAYS

MODULUS OF RUPTURE
BY
BEAMS TEST, MIN
At 72 - 2 hr
At 7 Day

M 100

70

12

17

M 150

100

15

21

M 200

135

17

24

M 250

170

19

27

M 300

200

21

30

M 350

235

23

32

M 400

270

25

34

NOTE - Notes 2 and 3 under Table 1 are also applicable to Table 11.

TABLE XII : CONCRETE MIX PROPORTIONS

(Clause 5.3.3.1., 5.3.3.2,. 5.3.3., 5.3.3.6 and 20.1.1)
172

Grade of
Concrete

Ordinary Concrete
Total quantity of
Dry Aggregates
by Volume per 50
Kg of Cement, to
be taken as the
sum of the
Individual
Volumes of Fine
and Coarse
Aggregates, Max

Proportion of
Fine Aggregate
to Coarse
Aggregate

Quantity of Water
per 50 Kg of
cement max

Litres
Litres
M 100

300

M 150

220

M 200

160

M 250

100

* NOTE 1:

NOTE 2 :

Generally 1:2 for

fine aggregates to
coarse aggregate
by volume but
subject to an upper
limit of 1:1 and a
lower limit of 1:3*

34
32
30
27

The proportions of the aggregates should be adjusted from upper limit to lower
progressively as the grading of the fine aggregates becomes finer and the maximum
size of coarse aggregate become larger. Example : For an average grading of fine
aggregate (i.e., Zone II of IS: 383 -1963) the proportions shall be 1:1 , 1:2 and 1:3 for
maximum size of aggregate 10 mm and 40 mm respectively.
It may be noted for general guidance that M 100, M 150, M 200, M 250 of ordinary
concrete correspond approximately to 1:3:6, 1:2:4, 1:1:3 and 1:1:2 nominal mixes of
concrete currently used in the country.

TABLE XIII : APPROXIMATE FOR AIR CONTENT

NOMINAL MAXIMUM SIZE

ENTRAPPED AIR, AS PERCENTAGE

OF VOLUME OF CONCRETE

OF AGGREGATE
mm
10

3.0

20

2.0

40

1.0

173

3.3 SELECTION OF WATER CONTENT AND FINE TWO TOTAL AGGREGATE RATIO
3.3.1: For the desired workability, the quality of mixing per unit volume of concrete and the ratio of fine
aggregate to total aggregate by absolute volume are to be estimated from Table V as applicable,
depending upon the nominal maximum size and type of aggregates.
TABLE XIV : APPROXIMATE SAND AND WATER CONTENTS PER CUBIC METRE
OF CONCRETE FOR GRADES UPTO M 35
NOMINAL MAXIMUM
SIZE OF AGGREGATE
mm
10

WATER CONTENT *PER

CUBIC
METRE OF CONCRETE
KG
280

SAND AS PERCENT OF
TOTAL AGGREGATE
BY ABSOLUTE
VOLUME.
40

20

186

35

40

165

30

* Water content corresponding to saturated surface dry aggregate.

TABLE XV : CALCULATION OF THE QUANTITIES OF CEMENT
The following standard will be adopted for calculating the quantity of cement:
1

2
3

Cement concrete:1:1 : 3
1:2:4
1:3:6
1:4:8
Brick work Masonry 1:3
Mortar
Stone Masonry
1:3 Mortar with random rubble
masonry
1:3 Mortar Stone Masonry
1:4 Mortar
1:6 Mortar
Plastering 12 mm thick
1:2 Mortar
1:3 Mortar
1:4 Mortar
1:6 Mortar
Finishing on R.C.C. work
Finishing on Plain Concrete
Flush or rolled or cut or
weather pointing on brick with
mortar, 1:3

400 Kg
330 Kg
220 Kg
170 Kg
122.4

Per Cubic Metre of Concrete

Per Cubic Metre of Concrete
Per Cubic Metre of Concrete
Per Cubic Metre of Concrete
Per Cubic Metre of Concrete

168.50 Kg
153 Kg

Per Cubic Metre of Masonry

Per Cubic Metre of Masonry

90 Kg
50 Kg
Brick Work
11.5 Kg/m

Per Cubic Metre of Masonry

Per Cubic Metre of Masonry
Stone Work
15.30 Kg /m2

8.20 Kg /m2
6.20 Kg/m
4.35 Kg /m2
1:2:4
1:3:6

10.70 Kg /m
8.20 Kg /m
5.50 Kg /m
1.35 Kg /m
2.00 Kg/m

100 Sq.m

174

153 Kg

Raising and cut pointing on

brick work with mortar 1:3
Flush or ruled pointing in stone
work with mortar 1:3
Raised and cut pointing in stone
work with mortar 1:3

7
8

100 Sq.m

235 Kg

100 Sq.m

117 Kg

100 Sq.m

194Kg

If contractor misuses the quantity of cement in more than the above standards the cost will be
recovered from him at double the price specified in the recovery schedule.
Whenever the strength of concrete is specified in the tender, the variances of cement required to
obtain the design strength may be used even if it is at variance with the above standard, subject to the
approval by the Superintending Engineer-In-Charge in writing.
TABLE XVI : UTILISATION OF MATERIALS OF DIFFERENT ITEMS (TO BE ADOPTED FOR
DEDUCTION OF FOREST ROYALTY AND FOR CARRIAGE)
1

(a) Stone -1.00 Cum

Per Cu.m of C.C.

(b) Sand - 0.37 Cu.m

Per Cu.m of C.C.

(a) Stone -0.90 Cu.m

Per Cu.m of C.C.

(b) Sand - 0.45 Cu.m

Per Cu.m of C.C.

P.C.C

(a) Stone - 0.90 Cu.m

Per Cu.m of C.C.

& R.C.C M25

(b) Sand - 0.45 Cu.m

Per Cu.m of C.C.

P.C.C.M 15

(a) Stone - 0.85 Cu.m

Per Cu.m of C.C.

(b) Sand - 0.45 Cu.m

Per Cu.m of C.C.

P.C.C.M 15

(a) Stone - 0.85 Cu.m

Per Cu.m of C.C.

1:3:6 & 1:4:8

(b) Sand - 0.45 Cu.m

Per Cu.m of C.C.

Plastering 12 mm thick 1:3

Sand - 0.015 Cu.m

Per Sq.m

Pointing 1:2

Sand - 0.32 Cu.m

Per Sq.m

Coursed rubble Stone Masonry in

C.C 1:3

Stone -1.16 Cu.m

Per Cu.m of masonry

Sand - 0.32 Cu.m

Per Cu.m of masonry

Random rubble Masonry in C.C 1:3

Stone -1.16 Cu.m

Per. Cu.m of masonry

Sand - 0.35

Per. Cu.m of masonry

2
3
4
5

P.C.C.M. 25
P.C.C.M. 25

TABLE XVII : CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR SUB BASES AND
BASES (EXCLUDING BITUMEN BOUND BASES)
SI.

Type of Construction

Test

Frequency
175

No.
1

Granular sub-base

(i) Gradation

One test per 200 m

(ii) Atterberg limits

One test per 200 m

(iii) Moisture content prior to compaction One test per 250 m

3.

(iv) Density of compacted layer

One test per 500 m

(v) Deleterious constituents

As required

(vi) C.B.R.

As required

Lime/Cement Stabilised (i) Quality of lime / Cement

Soil Sub-base

One test for each

consignment subject of a
minimum of one test per 5
tonnes

(ii) Lime / Cement content

Regularly, through
procedural checks

(iii) Degree of Pulverisation

Periodically as considered
necessary

(iv) CBR or Unconfined Compressive

strength test on a set of 3 specimen

As required

(v) Moisture content prior to Compaction

One test per 250 sq.m

(vi) Density of compacted layer

One test per 500 m

(vii) Deleterious constituents

As required

Water Bound Macadam (i) Aggregate Impact Value

(ii) Grading

One test per 200 m of

aggregate
One test per 200 m of
aggregate

(iii)Flakiness Index and Elongation index One test per 200 m of

aggregate

176

(iv) Atterberg limits of binding material

(v) Atterberg limits of portion
of aggregate passing 425 micron sieve
4.

Wet mix Macadam

One test per 25 m2 of

binding material
One test per 100 cubic
metre of aggregate

(i)Aggregate impact value

One test per 200 m3 of

aggregate

(ii)Grading

One test per 100 m3 of

aggregate

(iii)Flakiness Index and Elongation Index One test per 200 m3 of

aggregate
(iv)Atterberg limits of portion of aggregate One test per 100 m3 of
passing 425 micron sieve
aggregate
(v)Density of compacted layer

One test per 500m2

903.4

Test on Bituminous Construction

903.4.1

The test and then minimum frequencies for the different types of bituminous works shall be as given
in Table XVIII.

903.4.2

Acceptance Criteria : The acceptance criteria for test on density and Marshall stability shall be
subjected to the condition that the mean value is not less than the specified value plus:

1.65 -

1.65

times the standard deviation

(No. of samples) 0.5

TABLE XVIII : CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR

BITUMINOUS WORK
Sl.
No
.
1.

2.

Type of
Construction
Prime coat / tack coat/
Fog Spray

Seal Coat/Surface
Dressing

Test

Frequency

(i) Quality of binder

Number of samples per lot to test as

per IS 73, IS:217 and IS:887 as
applicable

(ii) Binder temperature for

application
(iii) Rate of spread of
binder
(i) Quality of binder

At regular close

(ii) Aggregate impact

Value/Loss Angles
Abrasion Value

One test per 50 m3 of aggregate

177

One test per 500 m2 and not less than

two tests per day.
Same as mentioned under Serial No.1

(iii) Flakiness Index and

Elongation Index
(iv) Stripping value of
aggregates(Immersion
Tray Test)

(v) Water absorption of

aggregates
(vi) Water sensitivity of
mix.

- do Initially one set of 3 representative

specimens for each source of supply
subsequently when warranted by
changes in the equality of aggregates.
- do Initially one set of 3 representative
specimens for each source of supply
subsequently when warranted by
changes in the quality of aggregates.

(vii) Grading of aggregates

One test per 25m of aggregate

(viii) Soundness
Magnesium &
Sodium Sulphate)

Initially, one determination by each

method for each source of supply,
then as warranted by changes in the
quality of the aggregate.

(ix) Polished stone Value

As Required

(x) Temperature of
binder at application

At regular close interval

(xi) Rate of spread of

materials

One test per 500 m2 of work, and not

less than two tests per day.

(xii) Percentage of
fractural faces

When gravel is used, one test per 50

m of aggregate

SI.
No.

Type of
Construction

Test

Frequency

3.

Open - graded Premix

surfacing Closed Premix
Surfacing

(i) Quality of binder

(ii) Aggregate Impact Value /
Loss Angeles Abrasion
Value
(iii) Flakiness Index and
Elongation Index
(iv) Stripping value
(v) Water absorption of
aggregates
(vi) Water sensitivity of mix
(vii) Grading of aggregates
(viii) Soundness (Magnesium
and Sodium Sulphate )
(ix) Polished stone value
(x) Temperature of binder at
application
(xi) Binder content

Same as mentioned in Serial No.1

Same as mentioned under Serial
No.2

178

- do Same as Serial No. 2

Same as Serial No. 2
Same as Serial No. 2
Same as Serial No. 2
Same as mention in Serial No. 2
As Required
At regular close interval
One test per 500m3 and less than two

4.

Bituminous Macadam

(xii) Rate of spread of mixed

materials
(xiii) Percentage of fractured
faces
(i) Quality of binder
(ii) Aggregate Impact
Value/Loss Angeles
Abrasion Value
(iii) Flakiness Index and
Elongation Index
(iv) Stripping value
(v) Water sensitivity
(vi) Grading of aggregates

(vii) Water absorption of

aggregates
(viii) Soundness (Magnesium
and Sulphate)

5.

Bituminous
Penetration
Macadam/Built-up
Spray- Grout

test per day

Regulars control through checks on
materials and layer thickness
Same as Serial No. 2
Same as Serial No. 2
Same as mentioned in Serial No. 2

Same as mentioned in Serial No. 2

Same as Serial No. 2
- do Two tests per day per plant both on
the individual constituents
and mixed aggregates from the dryer
Same as Serial No. 2
Same as mention in Serial No. 2

(ix) Percentage of fractured

faces
(x) Binder content and
aggregate grading
(xi) Control of temperature of
binder and aggregate for
mixing and of the mix at
the time of laying and
rolling.
(xii) Rate of spread of mix
material
(xiii) Density of compacted
layer

Same as mention under Serial No. 2

(i) Quality of binder

Same as mentioned in Serial No. 1

(ii) Aggregate Impact

Value/Loss Angeles
Abrasion Value.
(iii) Flakiness Index and
Elongation Index
(iv) Stripping Value

One test per 200 m of Aggregate

(v) Water absorption of

aggregates

Same as mentioned in Serial No. 2

179

Periodic, subject of minimum of two

tests per day per plant
At regular close intervals

Regular control through checks of

layer thickness
One test per 250 m3 of area

-doSame as mentioned in Serial No. 2

(vi) Water sensitivity of mix

Dense Bituminous
Macadam/Semi
Dense
Bituminous Concrete/
Bituminous Concrete

Same as mentioned in Serial No. 2

(vii) Aggregate grading

One test per 100 m3 of aggregate

(viii) Soundness (Magnesium

and Sodium Sulphate)

Same as mentioned in Serial No. 2

(ix) Percentage of fractured

faces
(x) Temperature of binder at
application
(xi) Rate of spread of binder

Same as mentioned in Serial No. 2

(i) Quality of binder

(ii) Aggregate impact
Value/Los
Angeles Abrasion Value

Same as mentioned in Serial No. 1

Same as mentioned in Serial No. 2

(iii) Flakiness Index and

Elongation Index
(iv) Stripping Value
(v) Soundness (Magnesium
and Sodium Sulphate)
(vi) Water absorption of
aggregates
(vii) Sand equivalent test
(viii) Plasticity Index
(ix) Polished stone value

(x) Percentage of fractured

faces
(xi) Mix grading

(xii) Stability of Mix.

(xiii) Water sensitive of

mix(Retained Tensile
Strength)
(xiv) Swell test on the mix
180

At regular close intervals

Same as mentioned in Serial No. 2

-doSame as mentioned in Serial No. 2

Same as mentioned in Serial No. 2
Same as mentioned in Serial No. 2
As required
As required
As required, for Semi Dense
Bituminous Concrete/Bituminous
Concrete
Same as mentioned in Serial No. 2
One set of tests on individual
constituents and mixed aggregate
from the dryer for each 400 tonnes
of mix subject to a minimum of two
tests per plant per day.
For each 400 tonnes of mix
produced, a set of 3 Marshall
specimens to be prepared and tested
for stability, flow value density and
void content subject to a minimum
of two set being tested per plant per
day.
Same as mentioned in Serial No. 2

As required for the Bituminous

Concrete

Mastic Asphalt

(xv) Control of temperature of

binder in boiler, aggregate in
the dryer and mix at the time
of laying and rolling.
(xvi) Control of binder
content and gradation in the
mix.
(xvii) Rate of spread of mixed
material

At regular close interval

(xviii) Density of compacted

layer
(i) Quality of binder
(ii) Aggregate impact
Value/Los Angeles Abrasion
Value
(iii) Flakiness Index and
Elongation Index
(iv) Stripping Value
(v) Water sensitive of mix
(vi) Grading of aggregates

One test per 250 m

(vii) Water absorption of

aggregates
(viii) Soundness (Magnesium
and Sodium Sulphate)
(ix) Percentage of fractured
faces
(x) Binder content and
aggregate grading
(xi) Control of temperature of
binder and aggregate for
mixing and of the mix at the
time of laying and rolling
(xii) Rate of spread of mixed
material
(xiii) Hardness number

8.
9.

Slurry seal
Cold Mix

(i) Quality of binder

(i) Quality of binder
(ii) Aggregate Impact Value/
Los Angeles Abrasion Value
(iii) Flakiness Index and
Elongation Index
181

One test for each 400 tonnes of mix

subject to a minimum of two tests
per day per plant
Regular control and through checks
on the weight of mixed material and
layer thickness

Same as mentioned in Serial No. 1

Same as mentioned in Serial No. 2

- do - do - do Two tests per day per plant both on

the individual constituents and
mixed aggregates from the dryer
Same as mentioned in Serial No. 2
Same as mentioned in Serial No. 2
Same as mentioned in Serial No. 2
Periodic, subject to minimum of two
tests per day per plant
At regulars close interval

Regular control through checks of

layer thickness
One test for each 400 tonnes of mix
subject to a minimum of two test per
day.
Same as mentioned in Serial No. 1
Same as mentioned in Serial No. 1
Same as mentioned in Serial No. 2
-do-

(iv) Stripping Value

(v) Water sensitivity of mix
(vi) Grading of aggregates
(vii) Percentage minimum
coating
(ix) Soundness (Magnesium
& Sodium Sulphate)
(x) Percentage of fractured
faces
(xi) Binder content and
aggregate grading
(xii) Mix stability

10.

Modified Binder

(i)Softening Point
(ii) Penetration at 250C and
40C
(iii) Elastic Recovery

-do-doTwo tests per day per plant both on

the individual constituents and
mixed aggregates from the dryer.
Two tests per day per plant
Same as mentioned in Serial No. 2
When gravel is used, one test per
50m3 of aggregate
Periodic, subject to minimum of two
tests per day per plant
For each 400 tonnes of mix
produced, one set of 3 Marshall
specimens to be prepared and tested
for stability, flow
density and void content subject
to a minimum of two sets of tests per
plant per day.

Initially on submission thereafter

daily if site blended, weekly if preblended
-do-do-

(iv) Ductility

-do-

(v) Flash Point

-do-

(vi) Fraass Breaking

Initially on submission

(vii) Viscosity at 1500C

-do-

(viii) Thin film oven test,

penetration, softening point,
elastic recovery of residue,
loss on heating

-do-

182

PROCEDURE FOR CHECKING SURFACE REGULATING USING A STRAIGHT - EDGE

The procedure to be followed for checking the surface regularity, with a straight edge is as follows
:
(i)

The 3 metre straight edge may be made of steel of seasoned hard wood. When made of wood, it
may be 75 mm wide and 125 mm deep and its test face should preferably be shod with a metallic
plate. The edge should be perfectly straight and free from warps, rots or defects of any kind.

(ii)

Periodically, the straight edge should be checked for its trueness with a string or a metallic master
straight-edge. The straight-edge should be rectified/replaced as soon as the same has lost it
trueness.

(iii)

The depression under the straight edge are to be measured with a graduated wedge. The wedge
should preferably be metallic but may alternatively be of seasoned hard wood. These should be
graduated to read undulation upto 25 mm with a least count of at least 3 mm.

(iv)

For recordings undulation in the longitudinal profile the straight-edge is to be placed be sufficient
for a single lane pavement and along three lines for the two- lanes pavement. One additional line
may be covered for each additional line may be covered for each additional lane.

(v)

The straight -edge has limitations as regards the measurement of undulations at vertical curves.
Additional templates may be made for this purpose especially if the curves are sharp.

(vi)

The straight-edge may be placed at the starting point, wedge inserted between it and the test
surface where the gap is maximum and reading taken. The edge may then be slided forward by
about length, i.e., 1.5 m and the wedge reading repeated. This process should be continued. The
straightedge need not always be moved forward but may be moved backward and forward to
183

record maximum at allocation. Locations with undulation in excess of the specified magnitude
should be marked on the surface.
(vii)

A team of three persons consisting of two workmen and a supervisor and equipped with one
straight-edge and two graduated wedges would be required. The two workmen will operated the
straight-edge while the supervisor will take measurements with the wedge and do the marking on
the surface.

TABLE XIX : RECOMMENDED STANDARDS FOR SURFACE EVENNESS,

OF PAVEMENT CONSTRUCTIONS

Type of construction

Longitudinal profile 3 metre

straight-edge
Maximum
Maximum number of
permissibl undulation permitted
e
in any 300 metre
undulation
length, exceeding
, mm
mm
18

16

12

Cross Profile
Maximum
permissible
variation from
specified profile
under camber
template, mm
10
6

Earthen sub-grade

24

30

15

Stone Soiling/
Brick Soiling
Stabilised Soil

20

30

15

30

12

Water Bound
Macadam Oversize
metal
(40-90mmsize)
Water Bound
Macadam with
normal size

15

30

12

12

30

3
4

184

7
8
9
10

metal(20 - 50 mm
and 40-60 mm
size), penetration
macadam or BUSG
Surface dressing
(two coat) over
WBM (20-50 mm
or 40-63 mm size
metal),
penetration
macadam or BUSG
Open graded
premix carpet 2025 mm thick
Bituminous
Macadam
Asphaltic Concrete
Cement Concrete

12

20

10

30

10

20

10

10

NOTES:
1. *For surface dressing in all other cases the standard of surface evenness will be the same as for the surface
receiving the surface dressing.
2. These are for machines laid surface, if laid manually due to unavoidable reasons discretion of the
Engineer-in-Charge. However, this relaxation does not apply to the values of maximum undulation for
longitudinal profiles mentioned in column 3 of the table.
3. Surface evenness requirements in respect of both longitudinal and cross profiles should be simultaneously
satisfied.
Size

Area

(mm)

(cm)

Perimet
er

Weight
Kg/m

N/m

(cm)
6

0.283

1.89

0.222

2.18

0.503

2.51

0.395

3.87

10

0.785

3.14

0.617

6.05

12

1.131

3.77

0.888

8.71

16

2.011

5.03

1.579

15.48

18

2.645

5.65

1.997

19.59

20

3.143

6.28
185

2.467

24.2

22

3.801

6.91

2.985

29.27

25

.4.909

7.85

3.855

37.82

28

6.157

8.8

4.836

47.44

32

8.042

10.05

6.316

61.96

36

10.179

11.31

7.994

78.42

40

12.566

12.57

9.869

96.81

TABLE XX: ROLLED STEEL BEAMS

DIMENSIONS AND PROPERTIES
Designation

ISJB 150
ISJB 175
ISJB200
ISJB225
ISJB75
ISJB 100
ISGB 115
ISJB 150
ISJB 175
ISJB 200
ISJB226
ISJB275
ISJB 300
ISJB325
ISJB350
ISJB400
ISJB450

Weight Section Depth Width Thickness Thickness

Moment of inertia Radii of
per
al
of
of
of
of
Gyration
Metre
Area Section Flange Flange
Web
Ixx
rps
rxx cm4 ryy cm4
4
4
W
h
b
f
tw
cm
cm
Kg
a
mm
mm
mm
mm
cm
7.1
9.01
150
0
4.6
3
322.1
9.2
5.98
1.01
8.1
10.28
175
0
4.8
3.2
479.3
9.7
6.83
0.97
9.9
12.64
200
0
5
3.4
780.7
17.3
7.86
1.17
12.8
16.28
225
0
5
3.7
1308.1
40.5
8.97
1.58
6.1
7.71
75
0
5
3.7
72.7
10
3.07
1.14
8
10.21
100
0
6.4
4
16.8
12.7
4
1.12
11.9
15.12
125
75
6.5
4.4
406.8
43.4
5.19
1.69
14.2
18.08
150
0
6.8
4.8
688.2
55.2
6.17
1.75
16.7
21.3
175
9J
6.9
5.1
1096.2
79.6
7.17
1.93
19.8
25.27
200
100
7.3
5.4
1696.6
115.4
8.19
2.13
23.5
29.92
225
100
8.6
5.8
2501.9
112.7
9.15
1.94
27.9
35.53
250
125
8.2
6.1
3717.8
193.4
10.23
0.33
33
42.02.
275
140
8.8
6.4
5375.3
287
11.31
2.61
37.7
48.08
300
100
9.4
6.7
7332.9
376.2
12.35
2
43.1
.54.90
325
165
9.8
7
9874.6
510.8
13.14
3
49.5
63.01
300
165
11.4
7.4
13158.3 631.9
14.45
3.17
56.9
72.43
400
165
12.5
8
19306.3 716.4
16.33
3.15

186

ISJB 500

65.3

83.14

450

170

13.4

8.6

ISJB 550

75.0

95.90

500

180

14.1

9.2

ISJB 600

86.3

ISJB 100

99.5

ISJB 125

11.5

ISJB 150

13.0

109.9
7
126.6
9
14.60

500

190

15.0

27536.
1
38759
8.0

9.9

000

210

15.5

10.5

100

75

7.2

4.0

125

75

7.6

53161.
6
72867.
6

4.4

ISJB 175

14.9

16.60

150

00

7.6

4.8

ISJB 200

19.3

19.00

175

9J

8.6

5.5

ISJB 225

25.4

24.62

200

100

10.8

5.7

ISJB 250

31.2

32.33

225

110

11.8

6.5

ISJB 275

37.3

39.72

200

125

12.5

6.9

ISJB 300

44.2

47.55

300

140

12.4

7.5

257.5
449.0
726.4
1272.0
2235.4
3441.8

56.26

853.0

18.20

3 20

1003.
9

20.10

.34

21.99

3.48

23.98

3.79

1281.
9

4.20

1.67

5.20

1.62

40.8

6.18

1.66

43.7

7.19

1.86

52.6

8.32

7.19

85.0

9.31

2.34

150.0

10.39

2.65

218:3

12.37

2.84

1335.
1

334.5

ISI HANDBOOK FOR STRUCTURAL : STRUCTURAL STEEL SECTIONS

TABLE XXI : ROLLED STEEL BEAMSDIMENSIONS AND PROPERTIES
Moduli of Section Radius Radius Slope of
Zxx
Zyy of Root at Root Flange
r1
r2
D
mm
mm
degrees
cm
cm

h1

Connection Details
h2
hi
c

mm

mm

mm

mm

mm

g1
(min)
mm

Maximum
size of
flange Rivet
mm

Designatio
n

429

3.7

5.0

1.5

91.5

130.4

9.80

23.50

3.00

30

45

ISJB 150

54.8

3.9

5.0

1.5

91.5

155.0

10.0

23.40

3.10

30

45

ISJB 175

78.1

5.8

5.0

15

91.5

1755

10.25

28.38

3.20

30

45

ISJB 200

116.3

10.1

6.5

1.5

91.5

201.1

11.95

38.15

3.35

40

45

12

ISJB225

19.4

4.0

6.5

2.0

91.5

51.7

11 65

2315

3.35

30

ISJB75

33.6

5.1

7.0

3.0

91.5

73.0

13.50

23 00

3.50

30

50

ISJB 100

65.1

11.6

8.0

3.0

91.5

954

14.80

35 30

3 70

35

50

12

ISJB 115

91.8

13.8

9.5

3.0

91.5

1169

16.55

37.60

3.90

40

50

12

ISJB 150

125.3

17.7

9.5

3.0

91.5

141.6

16.70

42.45

4 05

50

50

12

ISJB 175

169.7

23.1

9.5

3.0

91.5

1657

17.15

47.30

4.20

55

50

16

ISJB 200

222.4

22.5

12.0

6.0

98.0

180.3

22.35

47.10

4.45

55

55

16

ISJB225

297.4

30.9

13.0

6.5

98.0

202.6

23.70

59 45

4.55

65

60

22

ISJB 250

392.4

41.0

14.0

7.0

98.0

223.7

25.65

66.80

4.70

80

60

22

ISJB275

15.0

75

98.0

245.1

27.45

71.65

4.85

90

60

22

ISJB300

488.9

50.2

187

607.7

61.9

16.0

80

98.0

266.5

29.25

79.00

5.00

100

65

25

ISJB325

751.9

76.6

16.0

8.0

98.0

288.3

30.85

78.80

5.20

100

65

25

ISJB 350

965.3

86.8

16.0.

8.0

3362

31

78.50

5.50

100

65

25

ISJB400

100.4

16.0

8.0

98.0
98.0

384.0

33.00

80.70

5.80

100

70

28

ISJB 450

430.2

43.90

85.40

6.10

100

70

32

ISJB 500

476.1

36.95

90.05

6.45

100

70

32

ISJB 550

520.0

39.90

99.75

6.75

100

75

12

ISJB 600

65.0

17.50

35.50

3.50

35

55

12

ISJB 100

89.2

17.90

35.30

3.70

35

55

12

ISJB 125

113.9

18.05

37.60

3.90

40

55

12

ISJB 150

134.5

20.25

42.25

4.25

50

55

16

ISJB 175

152.7

23.65

47.15

4.35

55

60

20

ISJB 200

173.3

25.85

51.75

4.75

60

60

22

ISJB 225

1223.8
1543.2
1933.2
2428.9
51.5
71.8
96.9
145.4
223.5

118.2
140.5
173.5
10.9
11.7
13.1
18.9
30.0

17.0
18.0
20.0
9.0
9.0
9.0
10.0
11.0

8.5
9.0
10.0
4.5

98.0
98.0
98.0
98.0
98.0

4.5
4.5
5.0
5.5

98.0
98.0
98.0
98.0

305.9

39.7

12.0

6.0

410.5

53.5

13.0

6.5

98.0

194.1

27.95

59.05

4.95

65

65

22

ISJB 250

573.6

64.8

14.0

98.0

241.5

29.25

66.25

5.25

80

65

22

ISJB 300

778.9

76.8

14.0

7.0
7.0

98.0

288.0

31.00

65.95

5.55

80

65

22

ISJB 350

98.0

334.4

32.08

65.55

5.95

80

70

22

ISJB 400

7.0

1022.9

88.9

14.0

1350.7

111.2

15.0

7.5

98.0

379.2

35.40

70.30

6.20

90

70

22

ISJB 450

1808.7

152.2

17.0

8.5

98.0

242.1

37.95

84.90

6.20

100

70

28

ISJB 500

h1

Connection Details
h2
h1
c

g1
(min)
mm

Maximum
size of
flange Rivet

Designatio
n

75

32

ISMB 550

Moduli of Section Radius Radius Slope of

Zxx
Zyy of Root at Root Flange
r1
r2
D
cm
cm
mm
mm
degrees
2359.8

193.0

18.0

9.0

3000.4

252.5

20.0

10.0

111.9

19.0

8.0

4.0

172.5

30.2

8.0

4.0

262.5

47.0

9.0

348.5

59.8

9.0

4.5
4.5

475.4

85.7

10.0

654.8

99.0

11.0

5.0
5.5

887.0

117.6

12.5

6.0

1171.3

138.8

13.0

6.5

1558.1

170.7

14.0

7.0

2091.0

239.0

15.0

7.5

2723.9

299.2

16.0

3540.0

376.2

17.0

3854.2
194.1

423.9
57.6

98
98
96
96
96
96
96
96
96
96
96
96

8.0

96

8.5

96

mm

mm

mm

mm

mm

467.5

41.25

89.40

7.10

100

509.7

45.15

99.00

00

25,32

ISMB 600

116.6

16.70

47.30

7.50 140,10
0
4.20
55

55

16

ISWB 150

139.5

17.75

59.60

4.40

65

55

22

ISWB 175

158.8

20.60

66.95

4.55

00

55

22

ISWB 200

181.4

21.80

71.80

4.70

00

55

22

ISWB 225

203.8

23.10

00.65

4.85 140,10
0
5.20 140,10
0
5.50 140,10
0
140,10
5.80
0
140,10
6.10
0

00

22,32

ISWB 250

250.1

24.95

00.30

295.5

27.25

96.00

340.5

29.75

95.70

384.0

33.00

95.40

431.0

34.50 120.45 6.45

473.4

38.30 119.75 6.75

514.2

42.90 119.40 7.10

18.0

9.0

96

507.9

8.0

4.0

94

112.0

46.05 119.10 7.40

19.0

188

72.30

4.30

140
140
140
140
00

00
00
65
70

22,32
22,32
22,32
22,32

ISWB 300
ISWB 350
ISWB 400
ISWB 450

70

32

ISWB 500

75

32

ISWB 550

00

32

ISWB 600

00

32

ISWB 600

55

22

ISHB 150

205.3

00.2

8.0

4.0

94

218.1

63.2

8.0

4.0

360.8

96.7

9.0

4.5

372.2

98.6

9.0

4.5

469.3

120.3

10.0

5.0

487.0

123.0

618.9

156.9

10.0

5.0

94
94
94
94
94

10.0

5.0

94

10.0

5.0

94

638.7

159.7

836.3

175.5

11.0

5.5

863.3

178.4

11.0

5.5

1094.8

196.1

12.0

6.0

1131.6

199.4

12.0

6.0

1404.2

218.3

14.0

7.0

4441.2

221.3

14.0

1742.7

238.8

15.0

1792.3

242.1

15.0

94
94
94
94
94

7.0

94

7.5

94

7.5

94

112.0

19.0

70.80

5.70

00

55

22

ISHB 150

112.0

19.0

69.10 7.40

00

55

22

ISHB 150

158.4

20.8

55

22,32

ISHB 200

55

22,32

ISHB 200

180.5

96.95 4.55 140,10

0
20.8 96.10 5.40 140,10
0
22.2 109.25 4.75 140

55

28

ISHB 225

180.5

22.2 108.20 5.80

140

55

32

ISHB 225

203.5

23.2 121.55 4.95

140

00

32

ISHB 250

203.5

23.2 120.60 5.90

140

00

32

ISBH 250

249.8

25.1 121.20 5.30

140

00

249.8

25.1 120.30 6.20

140

00

296.0

27.0 120.85 5.65

296.0

27.0 119.95 6.55

340.1

29.9 120.45 6.05

340.1

29.9 191.70 6.80

386.2

31.9 120.10 6.40

386.2

31.9 119.35 7.15

158.4

140
140
140
140
140
140

32

00
00

ISBH 300

32

ISBH 300

32

ISBH 350

32

ISBH350

65

32

65

32

65

32

65

32

ISBH 400
ISBH 400
ISBH 450
ISBH 450

TABLE XXII : SQUARE AND ROUND BARS

Diameter
of width

Weight
per

Perimete
r round

Sectional
square

Area
round

Perimete
r Square

Round

mm
5.0
5.5
6.0
7.0
8.0
9.0
10
11
12
14
16
18
20
22
25
28
32
36
40

Sq.Kg
0.20
0.24
0.28
0.38
0.50
0.64
0.78
0.95
1.13
1.54
2.01
2.54
3.14
3.80
4.91
6.15
8.04
10.17
12.56

Kg
0.15
0.19
0.22
0.30
0.39
0.50
0.62
0.75
0.89
1.21
1.58
2.00
2.47
2.94
3.95
4.82
6.31
7.99
9.86

cm2
0.25
0.30
0.36
0.49
0.64
0.81
1.00
1.21
1.44
1.96
2.56
3.24
4.00
4.84
6.25
7.84
10.24
12.96
16.00

cm2
0.20
0.24
0.28
0.38
0.50
0.64
0.79
0.95
1.13
1.54
2.01
2.54
3.14
3.80
4.91
6.16
8.04
10.18
12.57

cm2
2.0
2.2
2.4
2.8
3.2
3.6
4.0
4.4
4.8
5.6
6.4
7.2
8.0
8.0
10.0
12.2
12.8
14.4
16.0

Sq.cm2
1.57
1.77
1.88
2.20
2.51
2.83
3.14
34.46
3.77
4.40
5.03
5.65
6.28
6.91
7.85
8.80
10.05
11.31
12.57

189

45
50
56
63
71
80

15.90
19.62
24.62
31.16
39.47
50.24

12.49
15.41
19.34
24.47
31.08
39.36

20.25
25.00
31.36
39.69
50.41
64.00

15.9
19.64
24.63
31.17
39.49
50.27

18.0
20.0
22.4
25.2
28.4
32.0

TABLE XXIII : RIBBED TORSTEEL

Size
(mm)

Area
(sq.m)

W/t/Kg
(Metre)

Perimete
r
(cm)

6
8
10
12
14
16
18
20
22
25
28
32
36
40

0.283
0.503
0.785
1.131
1.539
2.011
2.545
3.142
3.801
4.909
6.157
8.042
10.179
12.566

0.222
0.395
0.617
0.888
1.208
1.578
2.000
3.466
2.98
3.854
4.83
6.313
7.99
9.864

1.89
2.51
3.14
3.77
4.4
5.03
5.65
6.28
6.91
7.85
8.8
10.05
11.31
12.57

Length
(per
tonne)
Metre
5410
2532
1631
1125
829
633
500
405
336
260
207
159
125
101

TABLE XXIV : WEIGHT OF BUILDING MATERIALS

Sl.N
o.
I

Materials

Weight in Kgs.

EARTH, SOILS, CLAY, ETC.

190

Per Remarks

14.14
15.71
17.59
19.78
22.31
25.13

1.

Earth alluvial

16CD

Cu.m

2.

Earth dry

1410-1850

Cu.m

3.

Earth Moist

1600-2000Cu.m

Cu.m

4.

Clay wet Compact

2080

Cu.m

5.

Clay moist Compact

1760

Cu.m

6.

Clay dry Compacts

1440

Cu.m

7.

Clay dry Lumps

1040

Cu.m

8.

Gravel Loose

1600

Cu.m

9.

Gravel Rammed

1920-2160

Cu.m

1460

Cu.m

10.

Single 3mm 38mm

11.

Sand Dry Clean

1540-1600

Cu.m

12.

Sand Dry River

1840

Cu.m

13.

Sand Dry Wet

1769-2000

Cu.m

14.

Peat Dry

580-640

Cu.m

15.

Sand Compact

800

Cu.m

16.

Sand wet Compact

360

Cu.m

II

BUILDING STONES
1.

Basalt

2600

Cu.m

2.

Gneiss

2400-2690

Cu.m

3.

Graphite

2690-2800

Cu.m

4.

Laterite

2080-2400

Cu.m

5.

Lime Stone

2400-2640

Cu.m

6.

Marble

7220

Cu.m

7.

Pumice

800-1220

Cu.m

8.

Quartzite

2640

Cu.m

9.

Sand stone

2240-2400

Cu.m

10.

Slate

2800

Cu.m

11.

Chalk

1600-1920

Cu.m

191

III BITUMINOUS
1.

Bituminous macadam

2282

Cu.m

2283

Cu.m

1600-1920

Cu.m

IV BRICKS

1.

Common Burnt Clay

bricks

2.

Engineering bricks

2160

Cu.m

3.

Bricks ballast

1200

Cu.m

4.

Bricks dust (Surkhi)

1000

Cu.m

1400

Cu.m

1050-1280

Cu.m

260

Cu.m

CEMENT
1.

Ordinary and Allumina

2.

Rapid hardening

VI PLAIN CEMENT CONCRETE

1.

Aerated

2.

Brick aggregate

1760-1260

Cu.m

3.

Stone ballast

2240-2720

Cu.m

VII REINFORCED CEMENT CONCRETE

1.

With 1% Steel

2310-2470

Cu.m

2.

With 2% Steel

2370-5530

Cu.m

3.

With 3% Steel

2560-2720

Cu.m

4.

Concrete with brick

aggregate and lime
mortar

1920

Cu.m

2080

Cu.m

1600-1840

Cu.m

1920

Cu.m

VIII MORTARS
1.

Cement

2.

Lime

IX MASONRY
1.

Brick masonry with

common burnt clay
192

bricks
2.

Brick masonry with T.

Moulder bricks

2400

Cu.m

3.

Stone masonry dry

rubble

2000

Cu.m

4.

Concrete with brick

lime, Sand stone,
Granites, etc,.

2240-2640

Cu.m

BRITISH AND METRIC EQUIVALENTS

LENGTH
1 inch
1 foot
1 yard
1 chain
1 chain
1 mile
1609.34 M
1 knot
39.37 inch
0.3937 inch
3.2808 feet
1.0936 yard
0.62137 mile
AREA
1
1
1
1
1
1
1
1
1
1
1

Sq. inch
Sq. foot
Sq. yard
acre
Sq. mile
Sq. cm
Sq. m
Sq. m
acre
hectare
Bigah

2.54 centimetre
30.48 centimetre
91.44 centimetres 0.944 metre
2011.68 centimetres
66 feet
5.280 feet, 80 chains, 1760 yards,
6,076.115 feet/hour
1 metre
1 centimetre
1 metre
1 metre
1 kilometre
0.00064516 Sq.m
929.03 Sq.cm 0.0929 Sq.m
0.83613 Sq.m
0.40468 hectare
259 hectare - 2.58999 Sq. Km.
0.155 Sq. inch
10.7639 Sq. ft.
1.196 Sq.yd.
4046.86 Sq.mts.
2.471 acres - 10.000 Sq.m
(132 x 132)Sq.ft
193

1 Sq. Km.
VOLUME

1 cu.in
1 cu. ft
1 cu. yd.
1 gallon
cu.in
1 cu.m
1 litre
1 cu.decimetre
1 cu.m
1 cu.m
WEIGHT
1
1
1
1
1
1
1
1
1

100 Hectare
-

16.387 cu centimeters
0.0283168 cu.m = 28.317 litres
0.76455 cu.m = 28.317 litres
3.785 litres = 0.1336 cu.ft. = 231.00

61023.74 cu.in
0.0353 cu.ft.
61.024 cu.inch
35.3148 cu.ft
1.30795 cu.yrd

grain
penny weight
dram
ounce
pound
milligram
gram
kg
tonne

0.0648 gm
1.5552 gm
1.772 gm
28.350 gm, 437.5 grains
453.59 gm, 7000 grains 0.45359 Kg
0.015 grain
0.0022046 lbs 15.432 grain
100 Kg, 220, 46 lbs 1968 cwt
0.9842 tons, 2,2046 lbs

TABLE XXV : USEFUL CONVERSION TABLE

Sl.N
o.

To convert

Into

Multiply by

1.

Metres

Feet

3.28084

0.3048

2.

Kilometre

Mile

0.6213

1.6093444

3.

Square Kilometre

Sq. miles

0.386101

2.58999

4.

Square metres

Sq. feet

10.7639

0.92903

5.

Cubic metres

Cu. feet

35.3147

0.028317

6.

Cubic metres

Gallon (IMP)

219.969

0.00464509

7.

Litre

Gallon

0.219976

4.5609

8.

Kilograms

Pounds

2.20462

0.453924

194

Quintal (100 Kg)

Maunds
(Avoir)

2.67923

0.373242

10.

Quintal (100 mkg)

Hundred
weight

1.96840

0.50802

11.

Tonnes (Metric ton)

Tons (British)

0.9842

1.01605

12.

Kilometre per hour

Miles per hour

0.62137

1.60934

13.

Kilometre per hour

Feet per sec.

0.91134

1.09728

14.

Kilogram per cu.m

Pound per
cu.ft.

0.0624

16.018

15.

Kilogram per litre

Pound per
cu.ft.

62.426

0.0160189

16.

Tonnes per sq. m

Tons per Sq.ft

0.09143

10.937

9.

INDIAN PRACTICAL CIVIL ENGINEERS HANDBOOK

METRIC UNITS
1 sq. kilometre (km2)

1,000,000 sq. metre = 100 hectares

(ha)
1
1
1
1
1

sq.
sq.
sq.
sq.
sq.

hectometer
decameter
m (m2)
decimeter (dm2)
cm (cm2)

=
=
=
=
=

10,000 sq. m = 100 ares = 1ha

100 sq. metres = 1 are
1 sq. metres = 100 sq. dm.
1/100 sq. metres = 100 sq. cm.
1/10,000 sq. metres = 100 sq. mm

CONVERSION FACTORS
1 Sq. inch

1 Sq. foot

=
=

1 Sq. yard =
=
=

6.45 sq. cm
=
645.16 sq.
929.03 sq. cms
0.093 sq. m

1 sq. mm =
mm 1 sq. cm
1 sq. dm
=
1 sq.m

0.00155 sq. inch

=
0.155 sq. ins.
15.50 sq. inch
=
10.76 sq. ft.

0.836 sq. mts

0.836 centare
4046 sq. mts

or

1 centare

1 sq. dm
1 hectare =
CUBIC MEASURES

BRITISH UNITS

=
0.01196 Sq. yards
2.471 acres

METRIC UNITS
195

1.196 sq. yards.

1728 Cu.ins=
Cu.cm
27 Cu.ft.
=
Cu.dm
1 Cu.in
1 Cu.m
=
Cu.ins
1 Cu.ft.
61.02Cu.ins
=
=

1 cu.ft

1000 Cu.mm

1 cu.yd

1000 Cu.mm`

16387 Cu.mm

1000 Cu.dm
1 cu.cm (cm3)

16.387 Cu.cm
=

1 cu.mts

Cm 4x0.024
in.4

in. 4x41.623
Cm.4

Cm 3x0.061
in.3

in. 3x16.387
Cm.3

Cm 2x0.155
in.2

in. 2x6.45
Cm.2

in x2.54
Cm

Cm x0.3937 =

in

0.061

1 cu.dm (dm3)

28,317 Cu.cm

2831.7 Cu.dm
0.028 Cu.m

=
0.035 Cu.ft.
35.315 Cu.ft.
1.308 Cu.yds.

=
=

ft. 4x0.0086

m.4

m. 4x115.862 =

ft.4

ft. 3x0.0283

m.3

m.3 x35.3147 =

ft.3

CONVERSION FACTORS
1/25 inch
1 inch
1 foot
1 yard
1 rod
1 furlong
1 mile

= 1mm
1mm
= 0.03937 inch
= 25.4 mm
1 cm
= 0.3937 or 2/5 inch
= 2.54 cm (exact)
1 dm
= 3.937 inches
= 30.48 cms
= 0.328 feet
= 0.3048 metres
1 metre
= 39.37 inches
= 0.9144 metres
= 3.281 ft.
= 91.44 cms
= 1.094 yds.
= 5.029 mts.
1 dkm
= 32.81 ft.
= 0.201 Km.
= 10.94 yds.
= 201.168 mts.
1 Hm
= 328 ft., 1 inch
= 1.609 Km.
1 km
= 32.80 ft. ,10 inch
= 1609 metres.
= 4.97 furlongs,1093.6 yards
= 5/8 or 0.621 mile

Metric Equipment in Millimetres of fractions of an inch:

196

Inch
mm
inch

/16

1.58
7
9

/16

/8

3.17
5
5

/8

/16

4.76
2
11

/16

/4

6.35
0

/16

7.93
7
13

/16

/8

9.52
5
7

/8

/16

11.11
2

12.70

15

/16

mm

14.2
9

15.8
7

17.4
6

19.0
5

20.6
4

22.2
2

23.81

inch

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.10

mm

0.25
4

0.50
8

0.76
2

1.01
6

1.27

1.52
4

1.778

2.03
2

2.28
6

2.540

197

25.40