MOST 3rd Revision

Ministry of Surface Transport
(Roads Wing)
SPECIFICATIONS
FOR ROAD
AND BRIDGE
WORKS
(Third Revision)
Published by
Indian Roads Congress

New Delhi 1997
<<
Ministry of Surface Transport
(Roads Wing)
SPEd FICATIONS
FOR ROAD
AND BRIDGE
WORKS
(Third Revision)
LIBRARY & DOCUMENTATION CENTRE

LARSEN & TOUBRO LTD.
EGG CONSTRUCTION GROUP
P.B. No. 979
MOUNT PC~NAMALLEEROAD
MANi~riKKAM,CHENNAI-600 089
Rec’E r~’
Acc. No. - ...
Published by the Indian Roads

Congress on behalf of the Govt.
of India, Ministry of Surface
Transport (Roads Wing)
Copies can be hadfrom
the Secretary, indian Roads Congress,
Jamnagai House, Shahjahan Road,
New DelJzi.119 Oil
NEW DELHI-lgg7 Prk~eRs. 400/-

Plus packing & postage charges
<<
First Published April, 1973
Reprinted November, 1975
First Revision May, 1978
Reprinted September, 1981
Reprinted October, 1983
Reprinted April, 1986
Second Revision February, 1988
Reprinted August, 1988
Reprinted April, 1990
Reprinted June, 1992
Reprinted February, 1993
Reprinted July, 1993
Third Revision April, 1995
Reprinted January, 1997 (Incorporates Corrigendum
NoJ &2andCol. 12&l5ofp.662)
Reprinted January, 1998
Reprinted January, 1999
Reprinted May, 1999
Repri ntccl February, 2000
(The Rights of Publication and Translation are rese,ved)
Printed at M/s Dec Kay Printers, New Delhi-hO 015

1000 Copies
<<
PREFACETO THE THIRD REVISION
“Specifications for Road and Bridge Works” first published in 1973

has already undergone two revisions in the past. With the advent of the
externally aided projects based on international contract documents and
modernisationofHighway Construction, it became necessary to revise the
Specifications to be consistent with equipment based construction tech-
niques. Many of these revised specifications were included in the bidding
documents of individual projects. The specifications have now been
completely revised incorporating all the changes required to take into
account the latest construction practices and the suggestions received from
various users. A few additional chapters on topics not covered earlier
have also been added.
Revision of these specifications could be carried out in a short time

only due to the concerted efforts of officers of the Roads Wing and the
consultants whowere intimately connected with this work. I wish to record
my appreciation of the efforts put in by all concerned.
As with all specifications, the Third Revision of the Specifications

wilt also no doubt need furtherupdating in course of time. Feed back and
suggestions (or improvement would be welcome from all users of the
document.
New Delhi M. V. SASTRY

November, 1994. Director General ( Road Development)
<<
CONTENTS
SECTION SECTION CLAUSE CLAUSE TITLE PAGE

NO. TITLE NO. NO.
100 GENERAL 101 IN1RODUCTION 3

102 DEFINITIONS 3
103 MATERIALS AND TEST STANDARDS 6
104 SIEVE DESIGNATIONS 6
105 SCOPE OF WORK 7
106 CONSTRUCTION EQUIPMENT 8
107 CONTRACT DRAWINGS 9
108 SITE INFORMA11ON 9
109 SET11NG OUT 10
110 PUBLICUTILITIES 11
111 PRECAUTIONS FOR SAFEGUARDING 13
THE ENVIRONMENT
112 ARRANGEMENT FOR TRAFFIC 14
DURING CONSTRUCTION
113 GENERAL RULES FOR THE 17
MEASUREMENT OF WORKS FOR
PAYMENT
114 SCOPEOFRATHS FOR 19
DIFFERENT ITEMS OF WORK
115 METHODOLOGY ANDSEQUENCE OF 21
WORK
116 CRUSHED STONE A~GGREGAThS 21
117 APPROVAL OF MATERIALS 21
118 SUPPLYOFQUARRYSAMPLES 21
119 USE OFSURFACES BY 22
CONSTRUCTION TRAFFIC
120 SITE OFFICE FOR ENGiNEER AND 22
OTHER SUPERVISORY STAFF
121 FIELD LABORATORY 26
122 SFTE RESIDENTIAL 30
ACCOMMODATION FOR
ENGINEER AND OTHER
SUPERVISORY STAFF
123 PROVIDING AND MAINTAINING 32
WIRELESS COMMUNICATION
SYSTEM
124 PROVIDING AND MAINTAINING 33
VEHIQ..ES FOR THE ENGINEER
125 SUPPLY OF COLOUR RECORD 35
PHOTOGRAPHS AND ALBUMS
126 SUPPLY OF VIDEO CASSETIES 36
<<
11 Contents

NO. TITLE NO. NO.
200 SITE 201 CLEARING AND GRUBBING 41

CLEARANCE 202 DISMAN1UNG CULVERTS. 44
BRIDGES AND OTHER
STRUCFURESIPAVEMENTS
300 EARTHWORK~ 301 EXCAVATION FOR ROADWAY AND 49

EROSION DRAINS
CONTROL AND 302 BLASTING OPERATIONS 57
DRAINAGE 303 PRESPLITI1NG ROCK EXCAVATION 61
SLOPES
304 EXCAVATION FOR STRUCTURES 63
305 EMBANKMENT CONSTRUCTION 67
306 SOIL EROSION AND 83
SEDIMENTATION CONTROL
307 TURFING WITH SODS 85
308 SEEDING AND MULCHING 87
309 SURFACE/SUB-SURFACE DRAINS 90
310 PREPARATION AND SURFACE 94
TREATh(ENTOF FORMATION
311 WORKS TO BE KEPT FREE OF WATER 95
312 WATER COURSES ATCULVERTS 95
313 CONSTRUCTiON OF ROCKFILL 96
EMBANKMENT
101
400 SUB-BASES, 401 GRANULAR SUB-BASE
BASES (NON- 402 LIME TREATED SOIL FOR IMPROVED 105
BITUMINOUS) SUB-GRADE/SUB-BASE
AND 403 CEMENT TREATED SOIL SUB- 109
SHOULDERS BASE/BASE
404 WATER BOUND I ACADAM 112
SUB-BASE/BASE
405 CRUSHED CEMENT CONCRETE 121
SUB-BASE/BASE
406 WET MIX MACADAM SUB-BASE! 123
BASE
407 SHOULDERS, ISLANDS AND MEDIAN 128
408 CEMENT CONCRETE KERB AND 130
KERB WITH CHANNEL
409 FOO11~ATHSAND SEPARATORS 132
410 CRUStIER-RUN MACADAM BASE 133
500 BASES AND 501 PREPARATION OF SURFACE 139

SURFACE 502 PRIME COATOVER GRANULAR BASE 145
COURSES 503 TACK COAT 148
(BITUMINOUS) 504 BITUMINOUS MACADAM 149
505 BITUMINOUS PENETRATION 157
MACADAM
506 BUILT-UP SPRAY GROUT 160
<<
Contents ill

NO. TITLE NO. NO.
507 DENSE BITUMINOUS MACADAM 163

508 SURFACE DRESSING 170
509 OPEN GRADED PREMIX CARPET 177
510 MIX SEALSURFACING 185
511 SEMI-DENSE BITUMINOUS 186
CONCRETE
512 BITUMINOUS CONCRETE 189
513 SEAL COAT 192
514 SUPPLY OF MINERAL AGGREGATES 194
FOR PAVEMENTCOURSES
515 BITUMEN MASTIC 197
516 SLURRY SEAL 202
517 RECYCLING OF BiTUMINOUS 204
PAVEMENT
600 CONCRETE 601 DRYLEANCEMENTCONCRETE 211

PAVEMENT SUB-BASE
602 CEMENT CONCRETE PAVEMENT 220
603 ROLLED CEMENT CONCRETE BASE 247
700 GEOSYNTHETICS 701 GEOSYNTHETICS IN ROAD AND 255

BRIDQE WORKS
702 GEOTEXTILES IN SUB-SURFACE 257
DRAINS
703 REINFORCED EARTH 259
704 GEOSYNTIIETICS FOR HIGHWAY 263
PAVEMENTS
705 PROTECTION WORKS WITH 266
GEOSYNTHETICS
800 TRAFFIC SIGNS, 801 TRAFFIC SIGNS 273

MARKINGS & 802 OVERHEAD SIGNS 278
OTHER ROAD 803 ROAD MARKINGS 282
APPURTENANCES 804 I-IECTOMETREJIULOMETRE STONES 288
805 ROAD DELINEATORS 289
806 BOUNDARY STONES 289
807 FENCING 289
808 TUBULAR STEEL RAILING 290
809 CONCRETE CRASH BARRIER 291
810 METAL BEAM CRASH BARRIER 292
811 ROAD ‘TRAFFIC SIGNALS 295
900 QUALITY 901 GENERAL 299

CONTROL 902 CONTROL OF ALIGNMENT LEVEL 301
FOR ROAD AND SURFACE REGULARITY
WORKS 903 QUALITY CONTROL TESTS DURING 305
CONSTRUCtiON
<<
iv Contents

NO. TITLE NO. NO.
1000 MATERIALS 1001. GENERAL 323

FOR 1002. SOURCES OF MATERiAL 323
STRUCTURES 1003. BRICKS 323
1004. STONES 323
1005. CAST iRON 324
1006. CEMENT 324
1007. COARSE AGGREGATES 325
1008. SANtVFINE AGGREGATES 326
1009. STEEL 326
1010. WATER 329
1011. TIMBER 330
1012. CONCRETE ADMLXTURES 330
1013. REINFORCED CONCRETE PIPES 331
1014. STORAGE OF MATERIALS 331
1015. TESTS AND STANDARD OF 334
ACcEPTANCE
1100 PILE 1101. DESCRIP’IlON 339

FOUNDATIONS 1102. SUIT-SURFACE INVESTIGATION 339
1103. TYPE OF PILES 340
1104. MATERIALS 340
1105. TEST PILES 341
1106. PRECAST CONCRETE PILES 341
1107. CAST.!N.SITU CONCRETE PILES 344
1108. STEEL PILES 347
1109. TIMBERPILES 348
1110. DRIVING EQUIPMENT 348
1111. DRIVING 349
1112. RAKER (INCLINED) PILES 352
1113. P1LETESTS 353
1114. PILECAP 353
1115. IMPORTANT CONSIDERATIONS, 354
INSPECTION/PP..ECAU11ONS
FOR DIFFERENT TYPES OF PILES
1116. TOLERANCES 356
1117. TESTS AND STANDARDS OF 357
ACCEPTANCE
Ills. MEASUREMENTS FOR PAYMENT 357
1119. RATE 358
1200. WELL 1201. DESCRIPTION 361

FOUNDATIONS 1202. GENERAL 361
1203, SElliNG OUT AND PREPARATIONS 362
FOR SINKING
1204. CUlliNG EDGE 364
1205. WELL CURB 364
1206. WELL STEIN ING 365
1207. WELL SINKING 366
<<
Contents V

NO. TITLE NO. NO.
1208 BO11’OM PLUG 375

1209. SANDFILLING 376
.
1210. TOPPLUG 376
1211. WELLCAP 376
1211 TOLERANCES . 377
1213, TESTS AND STANDARDS 377
OF ACCEPTANCE
1214. MEASUREMENT FOR PAYMENT 377
1215. RATE 377
1300 BRICK 1301. DESCRIPTION 381

MASONRY 1302. MATERIALS 381
1303. PERSONNEL 381
1304. CEMENT MORTAR 381
1305. SOAKING OF BRICKS 382
1306, JOINTS 382
1307, LAYING 382
130& JOINTING OLD AND NEW WORK 383
1309, CURING 383
1310. SCAFFOLDING 384
1311. EQUIPMENT 384
1312. FINISHING OF SURFACES 384
13 13. ARC}IITEC11JRAL COPING FOR 386
WING/RETURNiPARAPET WALL
1314. ACCEPTANCE OF WORK 386
1315. MEASUREMENTS FOR PAYMENT 386
1316. RATE 387
1400 STONE 1401. DESCRIPTION 391

MASONRY 1402. MATERIALS 391
1403. PERSONNEL 391
1404, TYPE OFMASONRY 391
1405. CONSTRUCTION OPERATIONS 391
1406. ARCHITECTURAL COPING FOR 397
WING/RETURN/PARAPET WALLS
1407, TESTS AND STANDARD 397
OF ACCEPTANCE
1409. RATE 398
1500 FORMWORK 1501, DESCRIPTION 401

1502. MATERIALS 401
1503. DESIGN OF FORMWORKE 401
1504. WORKMANSHIP 402
1505. FORMED SURFACE AND FINISH 403
1506. PRECAUTIONS 404
1507. PREPARATION OF FORMWORK 404
BEFORE CONCRETING
<<
‘Ti (.on ten Is

NO. TITLE NO. NO.
1508. REMOVAL OF FORMWORK 405

1509. RE-USE OFFORMWORK 406
1510. SPECIALISED FORMWORK 406
1511. TESTS AND STANDARDS 407
OF ACCEPTANCE
1513. RATE 407
1600 STEEL REINFOR- 1601. DESCRIPTION 411

CEMENT 1602. GENERAL 411
(UNTENSIONED) 1603. PROTECTION OF REINFORCEMENT 411
l6O~ BENDING OF REiNFORCEMENT 411
1605. PLACING OF REINFORCEMENT 412
1606. BAR SPLICES 413
1607. TESTING AND ACCEPTANCE 415
1609. RATE 415
1700 STRUCTURAL 1701. DESCRIPTION 419

CONCRETE 1702. MATERIALS 419
1703. GRADES OF CONCRETE 419
1704. NOPORTIONING OF CONCRETE 42!
1705. ADMIXTURES 424
1706. SIZE OF COARSE AGGREGATE 424
1707. EQUIPMENT 425
1708. MIXING CONCRETE 426
1709. TRANSPORTING, PLACING AND 427
COMPACTION OF CONCRETE
1710. CONSTRUCTION JOINTS 428
1711. CONCRETING UNDER WATER 428
1712. ADVERSE WEAThER CONDITIONS 430
1713. PROTECTION AN!) CURING 431
1714. FINISHING 432
17 16. TESTS AND STANDARDS OF 433
ACCEPTANCE
1718. RATE 435
1800 PRESTRESSINC 1801. DESCRIPTION 439

1802. MATERIALS 439
1803. TESTING OF PRESTRESSING 441
STEEL AND ANCHORAGES
1805. SUPERVISION 445
1806. TENSIONING EQUIPMENT 445
1807. POST.TENSIONING 446
<<
(‘on t~’n S vii
SECTiON SECTION CLAUSE
CLAUSE TITLE PAGE
NO. T1TLE NO. NO.
1808. GROUTING OF PRESTRESSEI) 447

TENDONS
1809. PRE-TENSIONING 447
1810. SAFETY PRECAUTIONS
DURING TENSIONING 450
1811, TRANSPORTATION ANI) 451
STORAGE OF UNITS
OF ACCEPTANCE
1815. RATE 452
1900 STRUCTURAL 1901. DESCRIPTION 455

STEEL 1902. GENERAL 455
1903. MATERIALS 455
1904. FABRICATION 458
1905. ERECrION 471
1906. PAINTING 481
OF ACCEPTA ICE
1908. MEASUREMENFS FOR PAYMENT 488
1909. RATE 489
2000 BEARINGS 2001. DESCRIPTION 493

2002. GENERAL 493
2003. STEEL BEARINGS 493
2004. SPECIAL BEARINGS 498
2005. ELASTOMERIC BEARINGS 500
2006. POT BEARINGS 513
2007. INSPECTION AND TESTING 519
ACCEPTANCE
2010. RATE 519
2100 OPEN 2101. DESCRIPTION 523

FOUNDATIONS 2102. MATERIALS 523
2103. GENERAL 523
ACCEPTANCE
2106, TOLERANCES 526
2107. MEASUREMENTS FOR PAYMENT 52.6
2108. RATE 526
2200. SUB-STRUCTURE 2201. DESCRIPTION 529

2202. MATERIALS 529
<<
U Contents

NO. TITLE NO. NO.
2203. GENERAL 529

2204. PIERS AND ABUTMENTS 529
2205. PIER CAP AND ABUTMENT CAP 530
2206. DIRT/BALLAST WALL, 531
RETURN WALL & WING WALL
2.207. TESTS AND STANDARDS OF 531
ACCEPTANCE
2208. TOLERANCES IN CONCRETE 531
ELEMENTS
2210. RATE 532
2300 CONCRETE 2301. DESCRIPTION 535

SUPER- 2302. MATERIALS 535
STRUCTURE 2303 GENERAL 535
2304. REINFORCED CONCRETE 535
CONSTRUCTION
2305. PRESTRF.SSED CONCRETE 536
CONSTRUCTION
2:306. TOLERANCES 538
ACCEPTANCE
2309, RATE 539
2400 SURFACE AND 2401. GENERAL 543

‘,UB ~URFA( F 2402 PR! 1 IMINARY INVISTIGA I tON ~41
GEOTECEJNICAL 2403. DETAILED EXPLORATION 546
EXPLORATION 2404, EXPLORATION FOR BRIDGE 547
FOUNDATIONS RESTiNG
ON ROCK
2405. BORING 550
2406. RECORDS OF BORINGS 550
AND TRIAL PITS
2407. METHODS OF SAMPLING 551
2408. PROCEDURE FOR 552
TAKiNG SAMPLES
2409. PROTECTION, HANDLING 554
AND LABELLING OF SAMPLES
2410. TESTS FOR EXPLORATION 555
OF SHALLOW FOUNDATIONS
OF BRIDGES
2411. TESTS FOR EXPLORATION 555
FOR DEEP FOUNDATIONS OF
£1RIDGES
<<
CEontents 5 ix
SECTION SECTION CLAUSE CLAUSE TITLE PACE

NO. TITLE NO. NO.
2412. TESTING OF MATERIAL FOR 556

GUIDE BIJND AND HIGH
EMBANKMENT AND
ITS FOUNDATIONS.
2414. RATE 559
2500 RIVER TRAINING 2501. DESCRIPTION 563

WORK AND 2502. GUIDE BUND 563
PROTECTION 2503. APRON 564
WORK 2504 PITCHING/REVEThIENT 566
ON SLOPES
2505 RUBBLE STONE/CEMENT 569
CONCRETE BLOCK
FLOORING OVER CEMENT
CONCRETE BEDDING
2506. DRY RUBBLE FLOORING 570
2507. CURTAIN WALL AND 570
FLEXIBLE APRON
ACCEPTANCE
2510. RATE 571
2600 EXPANSION 2601. DESCRIPTION 575

JOINTS 2602. GENERAL 575
2603. REQUIREMENTS 576
2604. STEEL PLATE SLIDING 577
EXPANSICdtJOINTS
2605. FILLER JOINTS 578
2606. ELASTOMERIC SLAB 578
SEAL EXPANSION JOiNT
26p7. STRIP SEAL EXPANSION JOINT 583
ACCEPTANCE
2610. RATE 587
2700 WEARING 2701. DESCRIPTION 591

COAT AND 2702. WEARING COAT 591
APPURTENANCES 2703, RAILINGS 592
2704. APPROACH SLAB 593
2705. DRAINAGE SPOUTS 594
2706. WEEP HOLE 595
ACCEPTANCE
2708. MEASUREMENTSFOR PAYMENT 595
2709. RATE 595
<<
x CEontents

NO. TITLE NO. NO.
2800 REPAIR OF 2801. DES~R1PTION 599

STRUCTuRES 2802. GENERAL 599
2803, SEALING OF CRACKS 599
BY INJECTION OF EPOXY RESIN
2804. EPOXY MORTAR FOR 606
REPLACEMENT OF SPALLED
CONCRETE
2805. EPOXY BONDING OF NEW 609
CONCRETE TO OLD CONCRETE
2806. CEMENT GROUTING 609
2807. GUNITING/SHOTCRETE 612
2808. REPLACEMENT/RECTIFICATiON 614
OP BEARINGS
2809. DISMANTLING OF CONCRETE 615
WEARING COAT
2811). EXTERNAL PRESTRESSING 616
2811. TESTS ANDSTANDARDS OF 617
ACCEPTANCE
2813. RATE 618
2.900 PIPE 2901. SCOPE 621

CU1.,VEST S. 2902. MATERIALS 621
2903. EXCAVATION FOR PIPE 621
2904. BEDDING FOR PIPE 622
2905. LAYING OF PIPE 622
2906. JOINTING 623
2907. BACKFILLING 623
2908. HEADWALLS ANI) OTHER 624
ANCILLARY WORKS
2909. OPENING TO TRAFFiC 624
2911. RATE 624
3000 MAINTENANCE 3001. GENERAL 627

OF ROA [) 3002. RESTORATION OFRAIN.CUTS 627
3003. MAINTENANCE OF EARTHF.N 628
SHOULDERS
3004. BITUMINOUS WORK IN 629
CONNECTiON WITH
MAINTENANCE AND REPAIRS
3005. MAINTENAINING OF CEMENT 631
CONCRETE ROAD
<<
xi
SECTiON SECTION C1.,AIJSE (ELAL SE TITLF, PAGE
NO. HIITLE NO. NC).
A PPFEN DEC ‘ES
APPENDIX I. LIST OF I.R,C, PUBI.ICATIONS 637

RIIIRRID1OIN IIIFSPFUIKAI1ONS
CODES& STANDARDS
APPENDIX 1,15 OF INDIAN AND FOREIGN 640

SIANDARDSRIZIRRFDTOI\
1’IlESPFCEIFICATIONS
~\PEI.ENDI\
3. Ni F.’flRlI) OF SIEVING FOR 647
VQI 1 SOlES IODFIIRMINI nil
DEGREE OFPCELVERISATION
APPENDIX 4. GEIDEI.JNES ON SELECTION 648

OFT BE GRADE OF BFTIJMEN
APPENDIX 5. ANTI STRIPPING AGENTS USFEI) FOR 6 0

BITUMINOUS MATFERIALS AND MiXES
APPENDIX 1 (X)i-1 IE)RAF’F DOCUMENT ON ISC 9077-1979 CODE 655

01 PRA( 1 ICI FOR CORROSION PRO EEC lION
OF STEEL REINFORCEMENT ZN RB AND
RCC (EONSTRUCTION (REVISED)
APPENDIX 1 2oO/I~ HISTOR N’ GE SINKING Oi~\\rI.:I .1. 666

P00/I 2 P1 ANOI WEll NOS 661
200/LI 111:1 & SPIEL IN )~rEIINOS. 662
APPI EN~DIX 500/I INFORM ATION 1’O BE SEPPLTEI) TO Ti] F 663

MANt I k( 111(1 RI, UI PROPRII 1 NRN
SYSTIJ.MS
A PP1EE\ iTX I 700/I SPECIEICAJ’I( IN FOR CONSTRUCTiON JOINTS 665

1700/TI PF.R.MF.ABIL1TY TES’I 667
APPENDIX 1800/I ‘EFESTS ON’ SIIEA’I’IIING DCEC1’S 668

18(X)/tI PRESTRESSING REPORT 674
1800/Ill SPFECIFICA11ONS FOR GROUTING OF POST- 675
TENSIONED CABLES TN PRESTRESSED
CONCRETE
I 8(X)/IT GROUTING RECORD 681
<<
General
100
General
<<
General Section 100
101.. INTRODUCTION
These Specifications shall apply to all such road and bridge works
as are required to be excctltecl under the Contract or otherwise directed
by the F:~ngineer-in-Charge(hereinafter referred to is the Fngineer). in
every case, the work shall be carried out to the satisfaction of the
Engineer and conform to the location, lines.., dimensions., grades and cross-
sections shown on the drawings or as indicated by the Engineer. Tic
quality of materials, processing of materials as may be needed at the
,site,saiient features of the construction work and quality of finished
work shall comply with the requirements set forth in succeeding sec-
tions. Where the drawings and Specifications describe a portion of he.
work in only general terms, and not in complete detail, it shall be:
understood that only the best general practice is to prevail, materiab and
workmanship of the best quality are to be employed and instructions
of the Engineer are to be fully complied with,
A lisl of Indian Roads Congress Specifications and Recommended
Codes of Practice which have been made use of in the preparation
of these Specifications is given at Appendix-i. The latest e,dition of all
Specifications/Standards till 30 (thirty) days before the final dale of
submission of the tender, shall be adopted.
102. DEFINITiONS
The words like Contract, Contractor, Engineer (synonymous with
Eng.’neer-in-charge), Drawings, Employer, Government, Works’ and \Vcrk
Si to used in these. Specifications shall he considereti to have the meaning
as understood Ironi the definitions of these terms given in the Genera
Conditions of Contract,
The following abbreviations shall have the meaning as seI
be low E
ASS I ITO American Association of State highway and ‘I”ran~Ei~’!.~t.oioo
i’)IticiaE;
45151 American Society for Testing and Materials
PS British Standard published by the British Startddrls Institut’ior
Cml c~ur~~j~ Bearing Ratio
PlC Indian Roads Congress
IS IncIi~aStandard published by he Bureau of Indian SL’indari
The various elements in the cross-section of a road re.ferrHi

these Specifications are shown in the cross-sections in Figs. 0’ ~. ‘~
100-2,
‘l
<<
General
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5
Section 100 General
Treated shoulders shown in the cross-section shall be of two typesE-

(I) “Hanf’~ shoulders which have select gravel/moorsam, any other conip~scsed
granular layer or bricks.
“Paved” :shouiders which have a hiruminou, surfacing over granular layers.
103. MATERIALS AND TEST STANDARDS

The relevant standards for materials, as well .as the tesling
procedures, have been indicated at appropriate places in the Spec ifi-
eations. A list of these slandards with their full title and the year of
publication applicable is included at Appendix-2.
104. SIEVE DESIGNATIONS
Thesieve designations referred to in the Specifications correspond
to those specified by Bureau of Tndian Standards in IS: 460. Tahie
IOU-I gives the list of the commonly used IS sieves.
TABLE 100-1. DESIGNATION OF TEST SIEVES
iS Designation conforming to IS: 464)
u iron) (in micron)
* 125’ 850
106
* 710
* 90 600
75
~ 500
* 63 425
53 355
300
* 45
375 * 250
212
* ‘31.5
26.5 * 180
1St)
“ 224
19.0 * 125
106
~ 16..’O
13.2 ~ 90
75
11:2
9_So * 63
53
* 8.00
6.70 * 45
<< 6
General Section 100
* 5.60
4.75
* 400
3,35
* 2.80
2.36
2.00
1.70
* 1,40
Its
* 1.00 _______________
Noses 1. ~‘ are the principal sizes stated in 1SO~565 and are preferred.
2. Sieve sizes given in BS:410 & ASTM -E 11 are same as in 15:460
3. Only sieves with square openings shall be used.
105. SCOPE OF WORK

105]. The work to be carried out under the Contract shall consist
of the. various items as generally described in the Tender Documents
as well as in the Bill of Quantities furnished in the Tender Documents.
105.2. The works to be performed shall also include all general
works preparatory to the construction of roads, bridges.., canal crossings,
drainage and all other related works, The works shall include work of
any kind necessary for the due and satisfactory construction, completion
and maintenance of the works to the intent and meaning of the drawings
and these Specifications and further drawings and orders that may he
issued by the Engineer from time to time. The scope of work shall include
compliance by the Contractor with all General Conditions of Contract,
whether specifically mentioned or not in the various clauses of these
Specifications, all materials, apparatus, plant, equipment, tools, fuel,
water, strutting, timbering, transport, offices.,.stores, workshop, staff,labour
and the provision of proper and sufficient protective works, diversions,
temporary fencing, and lighting. It shall also include: safety of workers,
first-aid equipment, suitable accommodation for the staff and workmen
with adequate sanitary arrangements, the effecting and maintenance of
all insurances, the payment of all wages, salaries, fees, royalties, duties
or other charges arising out of the erection of works and the regular
clearance of rubbish, reinstatement and clearing-up of the site as may
be required on completion of works, safety of the public and protection
of the works and adjoining land.
<< 7
Section 100 General
105.3. The Contractor shall ensure that all actions are taken to build
in quality assurance in the planning and execution of works. The quality
assurance shall cover all stages of work such as setting out, selection
of materials, selection of construction methods, selection of equipment
and plant, deployment of personnel and supervisory staff, quality control
testing, etc. The work of building in quality assurance shall be
deemed to he covered in the scope of the work.
105.4. The Contractor shall furnish, at least 15 days in advanc.e, his
programme of commencement of item of work, the method of working
he intends to adopt for various items of work such as site clearance,
construction for embankment, sub-base, base, surfacing, culverts, bridges,
retaining walls, well-sinking, cast-in-situ piling, construction of cast-in-
situ prestressed concrete simply supported girders, cantilever construction
of prestressed concrete superstructure, and such other items for which
the Eagineer demands the submission of the method of working. He shall
provide information regarding the details of the method of working
and equipment he proposes to employ and satisfy the Engineer about
the adequacy and safety of the same. The sole responsibility for the
safety and adequacy of the methods adopted by the Contractor will,
however, rest on the Contractor, irrespective of any approval given by
the Engineer.
i06. CONSTRUCTION EQUIPMENT
In addition to the general conditions indicated in the Contract Docu-
ments, the following conditions regarding use of equipment in works
shall be satisfied:
(a) The Contractor shall he required to give a trial run of the equipment for establishing
their capability to achieve the laid clown 5peciflc.atior~and tolerances to the
satisfaction of the Engineer before commencement o~the work;
~h) All equipmcnt provided shall be of proven efficiency and shall he operated
and maintained at all times in a manner acceptable to the Engineer;
(c) All the plant/equipment to be deployed on the works shall be got approved
from the Engineer for ensuring their fitness and efficiency before commence
rnent of work;
(4) Any material or equipment not meeting the approval of the Engineer shall be
removed from the site forthwith;
(e) No equipment will be removed from site without permission of the Engineer;
and
(1) The Contractor shall also make available the equipment for site quality control
work as directed by the Engineer~
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General Section 100
107. CONTRACT DRAWINGS

107.1. The Contract Drawings provided for tendering purposes shall
be as contained in the Tender Documents and shall be used as a reference
only. The Contractor should visualise the nature and type of work con-
templated and to ensure that the rates and prices quoted by him in the
Bill of Quantities have due consideration of the qualitative and quan-
titative variations, as may be found at the site and complexities of work
involved during actual execution/construction.
107.2. The tendered rates/prices for the work shall be deemed
to include the cost of preparation, supply and delivery of all necessary
drawings, prints, tracings and negatives which the Contractor is required
to provide in accordance with the Contract,
107.3. Two copies of drawings, on the basis of which actual
execution of the work is to proceed, shall be furnished free. of cost
to the Contractor by the Engineer progressively according to the
work programme submitted by the Contractor and accepted by the En-
girteer. Drawings for any particular activity shall be issued to the
Contractor at least 30 days in advance of the scheduled date of the start
of the activity.
107,4. Examination and for approval by the Engineer of any drawings
or other documents submitted by the Contractor shall not relieve the Con-
tractor of his responsibilities or liabilities under the ~ontracL
108, SITE INFORMATION
108.1.. The information about the site of work and site conditions
in the Tender Documents is given in good faith for guidance only hut
the Contractor shall satisfy himself regarding all aspects of site conditions.
108.2. The location of the works and the general site particulars
are as generally shown on the Site plan/Index plan enclosed with the
Tender Documents.
108.3. Whereas the right-of-way to the bridge sites/road works shall
he provided to the Contractor by the Engineer, the Contractor shall
have to make his own arrangement for the land required by him for site
offices, labour camps, stores, etc.
108.4. The quarry charts enclosed with the Tender Documents
indicate the location of quarries and other sources from which naturally
occurring materials are available, for guidance of the Contractor. The
leads indicated in the said charts are only approximate. It is assumed
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Section tOO General
that the. Contractor has inspected the quarries, borrow areas etc , hefore
quoting his rates for the work to assess the availability of con,stnict ion
materials in required quantity and quality.
109. SETTING OUT
1091. The Contractor shall establish working Bench Marks tied
wtth the Reference Bench Mark in the area soon after taking possession
of the site, The Reference Bench Mark for the area shall he as indicated
tn the Contract Documents and the values of the same shall he obtained
hy the Contractor from the Engineer. The working Bench Marks shall
be at the rate of four per km and also at or near all drainage structures,
over.hndges and underpasses. The working Bench Marks/levels should
he got approved from the Engineer. Checks must he made on these
Bench Marks once every month and adjustments, ii any, got agreed ec it
the Engineer and recorded. An up-to-date record of all Bench Marks
including approved adjustments, if any, shall he maintained by the
Contn.ictor and also a copy supplied to the Engineer for his record
1092. The lines and levels of formation, side slopes., drainage works,
earriageways and shoulders shall he care lully set out and frequently
checked, care being taken to ensure that correct gradients and cross-
sections are ohtained everywhere.
109.3. In order to facilitate the setting out of the works, the centre
line of the carriageway or highway rntist be accurately c ieiblished by
the Contractor and approved by the Engineer. It must theit he accurately
referenced in a manner satisfactory to the Engineer, every 50 in intervals
in plain and rolling terrains and 20 in intervals in Ii illy terra in and
in all curve poinis as directed by the Engineer, with marker pegs and
chainage hoards set in or near the fence line, and a schedule of reference
dimensions shall be prepared and supplied by the Contractor to the
Engineer. These markers shall he maintained until the works rea.ch
finished formation level and are accepted by the Engineer
109A. On construction reaching the formation level stage, the centre
line shall again he set out by the Contractor and when approved by the
iEngineer, shall be accurately referenced in a manner satisfactory to
the Engineer hy marker pegs set at the outer limits of the formation,
109.5. No reference peg or marker shall he moved or withdrawn
without the approval of the Engineer and no earthwork or structural work
shall be commenced until the centre line has been referenced,
199,6. The Contractor will 6e the sole responsible party for safe-
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General Sieetion 100
guarding all survey monuments, bench marks, beacons, etc. The Engineer
wtll provide the Contractor with the data necessary for setting out
of the centre line, All dimensions and levels shown on the drawings or
mentioned in documents forming part of or issued under the Contract
shall he verified by the Contractor on ihe site and he shall immediately
inform the Engineer of any apparent errors or discrepancies in such
dimensions or levels The Contractor shall, in connection with the staking
c.iut of the centre line, survey the terrain along the road and shall subniit
to the Engineer for his approval, a profile along the road centre line
and cross-sections at intervals as required by the Engineer.
109.7. After obtaining approval of the Engineer, work on earthwork
can commence and the profile and cross-sections shall form the basis
for measurements and payment. The Contractor shall he responsible for
ensuring that all the basic traverse points are in place at the
comniencement of the contract and if any are missing, or appear to have
been disturbed, the Contractor shall make arrangements to re-establish
these points. A “Survey File” containing the necessary data will he
made available for this purpose. If in the opinion of the Engineer, design
modifications of the centre line or grade are advisable, the Engineer
will issoe detailed instructions to the Contractor and the Contractor shall
perform the modifications in the field, as required, and modify the groand
levels on the cross-sections accordingly as many times as required. There
will he no separate payment for any survey work performed by the
Contractor. The cost of these services shall he considered as being
included in the cost of the items of work in the Bill of Quantities.
109,8. The work of setting out shall be deemed to be a part of
general works preparatory to the execution of work and no separate
payment shall he made for the same.
109.9. Precision automatic levels, having a standard deviation of
±2mni per kin, and fitted with micrometer attachment shall he used
for all double run levelling work. Setting out of the road alignment
and measurement of angles shall be done by using Iheodolite with
traversing target, having an accuracy of one second. Measurement of
distances shall be done preferably using precision instruments like
Distomat.
110. PUBLIC UTILITIES
110.1. Drawings scheduling the affected services like water pipes,
sewers, oilpipelines, cables, gas ducts etc. owned by various authorities
including Public Undertakings and Local Authorities included in the
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SCL iUfl I General
(~iiti ~mentsshall be verified by the Contractor for the accuracy

~‘t Doe
of uie information prior to the commencement of any work.
110.2. Notwithstanding the fact that the information on affected
services may not be exhaustive, the final position of these services
within the works shall be supposed to have been indicated based on the
information furnished by different bodies and to the extent the bodies
are familiar with the final proposals. The intermediate stages of the works
are, however, unknown at the design stage, these being dictated by the
Contractor’s methods of working. Accordingly, the Contractor’s pro-
gramme must take into account the period of notice and duration of
diversionary works of each body as given on the Drawings and the
Contractor must also allow for any effect of these services aad altera-
tions upon the Works and for arranging regular nieetings with the various
hodies at the commencement of the Contract and throughout the period
of the Works. in order to maintain the required co-ordination. During
the period of the Works, the Contractor shall have no objection if the
public utility bodies vary their decisions in the execution of their proposals
in terms of programme and construction, provided that, in the opiniou
of the Engineer, the Contractor has received reasonable notice thereoF
before the relevant alterations are put in hand.
110.3. No clearance or alterations to the utility shall be carried out
unless specially orde.red by the Engineer.
110.4, An~ services affected by the Works must be temporarily
supported by the Contractor who must also take all measures reasonahly
required by the various bodies to proteci their services and propert)
during the progress of the Works,
110.5. The Contractor may be required to carry out certain works
tor and on behalf of the various bodies and he shall also provide,
with the prior approval of the Engineer, such assistance to the various
bodies as may be authorised by the Engineer,
liM. The work of temporarily supporting and protecting the public
utility services during cxecuiion of the Works shall be deemed to be
part of the Contract and no extra payment shall be made for the same.
110.7. The Contractor may he required to carry out the removal
or shifting of certain servieesfutilities on specific orders from the Engineer
for which payment shall be made to him, Such works shall be taken
up by the Contractor only after obtaining clearance from the Engineer
and ensuring adequate safety measures.
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General Section 100
111. PRECAUTIONS FOR SAFEGUARDING THE

ENViRONMENT
111.!. General
The Contractor shall take all precautions for safeguarding the en-
vironment during the course of the construction of the works. He
shall abide by all laws, rules and regulations in force governing pollution
and environmental protection that are applicable in the area where the
works are situated.
111.2. Borrowpits For Embankment Construction
Borrowpits shall not be dug in the right-of-way of the road. The
stipulations in Clause 305.2.2. shall govern.
111.3. Quarry Operations
The Contractor shall obtain materials from quarries only after the
consent of the Forest Department or other concerned authorities is
obtained. The quarry operations shall be undertaken within the purview
of the rules and regulations in force.
111.4. Control of Soil Erosion, Sedimentation and Water Pollution
The Contractor shall carry out the works in such a manner that soil
er.osion is fully controlled, and sedimentation and pollution of natural
water course,s, ponds, tanks and reservoirs is avoided. The stipulations
in Clause 306 shall govern.
111.5. Pollution from Hot-Mix Plants and Batching Plants
Bituminous hot-mix planis and concrete batching plants shall be
located sufficiently away from habitation, agricultural operations or
industrial establishments. The Contractor shall take every precaution
t.o reduce the levels of noise, vibration, dust and emissions from his
plant and shall he fully responsible for any claims for damages caused
to the owners of property, fields and residences in the vicinity.
111.6. Substances Hazardous to Health
The Contractor shall not use or generate any materials in the works
which are hazardous to the health of persons, animals or vegetation.
Where it is necessary to use some substances which can cause injury
to the health of workers, the Contractor shall provide protective clothing
or appliances to his workers.
111.7. Use of Nuclear Gauges
Nuclear gauges shall be used only where permitted by the Engineer.
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Section ItS) General
The (.‘ontraetc.ir shall provide the Engineer with a copy of the regulations
govern ir~g the. safe use of nuclear gauges he intends to employ arid
shall abide by such regulations,
111,8, The Contractor must take all reasonable steps to minimise
dust nuisanc.e during the construction of the works.
111.9. All existing highways and roads used by vehicle of the
Con uaeti.:ir or any of his sub-contractors or suppliers of materials or plant,
and similarly any new roads which are part ot ihe works and which
are being u sed by traffic, shall be kept clean and clear of all dust/mud
or other exiraneous materials dropped by the said vehicles or their tyres.
Sinularly, all dust/mud or other extraneous materials from the works
spreading on these highways shall he immediately cleared by the
Contractor.
111.10. Clearance shall be effected immediately by manual sweeping
and removal of debris, or, if so directed by the Engineer, by mechanical
sw~.e ping and clearing equipment, and all dust, mud an ‘1 other debris
shEll I he removed entirely from the road surface. Addi donally, if so
directed by the Engineer, the road surface shall he hosed or watered
using suitable equipment.
111.11. Any structural damage caused to the existing roads by
the Contractor’s (EonstrlliL:i on rqaipnlent shall be made geo.:t without
any extra cost.
ill. 12. Compliance with the foregoing wilt not relieve the Contractor
of any responsibility for complying with the requirenients of any Highway
Authority in respect of the roads used by hi in,
112. ARRAN(WMENT FOR TRAFFIC
DURING CONSTRUCTION
112.1. General
The Contractor shall at all times carry out work on the highway
in a manner creating least interference to the flow of traffic while
consistent with the satisfactory execution of the same. For all works
involving improvements to the existing highway, the Contractor shall,
in accordance with the directives of the Engineer, provide and maintain,
during execution of the work, a passage for traffic either along a part
of the existing carriageway under improvement, or along a temporar)
diversion constructed close to the highway. The Contractor shall take
prior approval of the Engineer regarding traffic arrnn~!ementsduring
construction
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General Section 100
112.2. Passage of Traffic along a part of the Existiug Car-

riageway under Improvement
For widening/strengthening existing carriageway where part width
of the existing carriageway is proposed to be. used for passage of traffic,
treated shoulders shall be provided on the side on which work is not
in progress. The treatment to the shoulder shall consist of providing
atleast 150 mni thick granular base course covered with bituminous
surface dressing in a width of atleast 1.5 m and the surf.ace shall
he. n dintamed throughout the period during which traffic uses the same
to the satisfaction of the Engineer. The continuous length in which
such work shall he carried out, would he limited normally tt.500 m
a.t a place. However, where work is allowed by the Engineer in longer
stretches passing place...s atie.ast 20 m long with additional paved width
of 2.5 m shall be. provided at every 0.5 km interval.
In case of widening existing two-lane to four-lane, the additional
two lanes would he constructed first and the traffic diverted to it and
only thereafter the required treatment to the existing carriageway would
ht. carried out, However, in case where on the request of the Contractor,
work on existing two-lane carriageway is allowed hy the Engine.e.r
with traffic using part of the cx isting carriageway, stipulations as in
para ahove shall 01)131 y.
After obtaining permission of the Engineer, the treated shoulder
shall be. dismnr.ntled, the debris disposed of and the area cleared as
per the direction of the Engineer.
112.3, Passage of Traffic along a Temporary Diversion
in stretches where. it is not possible to pass the traffic on part
width of the carriageway, a temporary diversion shall be constructe.d
with 7 mu carriageway and 2..5 m.. earthen shoulders on each side (total
width of roadway 12 m) with the following provision for road crust
in the 7 in widthE
(I) 200 miii (compacted) granular subbase;
(ii) 225 mm (compacted) granular base course; and
CoamlMix Seat Surracing.
ciii) Premix carpet with Seal
The alignment and longitudinal section of diversion including
junctions and temporary cross drainage provision shall he as approved
by the Engineer.
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Section 100 Genera]
112.4. Traffic Safety and Control

The Contractor shall take all necessary measures for the safety
of traffic during construction and provide, erect and maintain such bar-
ricades, including signs, markings, flags, lights and flagmen as may
he required by the Engineer for the information and protection of
traffic approaching or passing through the section of the highway
under improvement. Before taking up any construction, an agreed
phased programme for the diversion of traffic on the highway shall
be drawn up in consultation with the Engineer.
The barricades erected on either side of the carriageway/portion of
the carriageway closed to traffic, shall be of strong design to resist
violation, and painted with alternate black and white stripes. Red lanterns
or warning lights of similar type shall he mounted on the harricades
at night and kept lit throughout from sunset to sunrise.
At the points where traffic is to deviate from its normal path (whether
on temporary diversion or part width of the carriageway) the channel
for traffic shall be clearly marked with the aid of pavement markings,
painted drums or a similar device to the directions of the Engineer.
At night, the passage shall be delineated with lanterns or other suitable
light source.
One-way traffic operation shall be established whenever the traffic
is to be passed over part of the carriageway inadequate for two-lane
traffic, This shall be done with the help of temporary traftic signals
or fiagmen kept positioned on opposite sides during all hours, For
regulation of traffic, the flagmen shall be equipped with red and grec.n
flags and lanterns/lights.
On both sides, suitable regulatory/warning signs as approved by the
Engineer shall be installed for the guidance of road users. On each
approach, at least two signs shall be put up, one close to the point
where transition of carriageway begins and the other 120 m away. The
signs shall be of approved design and of reflectory type, if so directed
by the Engineer.
112$, Maintenance of Diversions and Traffic Control Devices
Signs, lights, barriers and other traffic control devices, as well as
the riding surface of diversions shall be maintained in a satisfactory
condition till such time they are required as directed by the Engineer.
The temporary travelled way shall be kept free of dust by frequent
applications of water, if necessary.
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General Section 100
112.6. Measurements for Payment and Rate

All arrangements for traffic during construction including provision
of temporary cross drainage structures, if required, and treated shoulder
as described in Clause 112.2 including their maintenance, dismantling
and clearing debris, where necessary, shall be considered as incidental
to the works and shall be the Contractor*s responsibility.
The construction of temporary diversion including temporary cross
drainage structures as described in Clause 112,3, shall be measured
in linear metre and the unit contract rate shall be inclusive of full com-
pensat~on for construction (including supply of material, labour, tools
etc.), maintenance, final dismantling, and disposal.
113, GENERAL RULES FOR THE MEASUREMENT OF
WORKS FOR PAYMENT
113.1. General
All measurements shall be made in the metric system. Different items
of work shall be measured in accordance with the procedures set forth
in the relevant sections read in conjunction with the General Conditions
of Contract. The same shall not, however, apply in the case of lumpsuri
contracts.
All measurements and computations, unless otherwise indicated, shall
be carried nearest to the following limits:
(I) length and breadth 10 nun
(iii height, depth or thickness of
earthwork, subgrade, sub-bases,
bases, surfacing and structural members 5 mm
(ia) areas 001 sq. rn.
(iv) cubic contents aoi cu. m.
In recording dimensions of work, the sequence of length, width and
height or depth or thickness shall be followed.
113.2. Measurement of Lead for Materials
Where lead is specified in the Contract for construction materials,
the same shall be measured as described hereunder:
Lead shall be measured over the shortest practicable route and
not the one actually taken and the decision of the Engineer in this regard
shall be taken as final. Distances upto and including 100 m shall be
measured in units of 50 m, exceeding 100 m but not exceeding 1 km
in units of 100 m and exceeding 1 km in units of 500 m, the half
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Section 1 00 General
and greater than half of the unit shall be reckoned as one and less than
half of the unit ignored. In this regard, the source of the material shall
be divided into suitable blocks and for each block, the distance from
the centre of the block to the centre of placing pertaining to that block
shall be taken as the lead distance.
113.3. Measurement of Pavement Thickness for Payment on
Volume Basis
The finished thickness of sub-base, base and bituminous courses to
he paid on volume basis shall be computed in the following manner:
Levels shall be taken before and after construction, at grid of points
10 m centre to centre longitudinally in straight reaches but 5 m at curves.
Nornìally, on two-lane roads, the levels shall be taken at four positions
transversely, at 0,75 and 2.75 m from either edge of the carriageway;
and on single lane roads, these shall be. taken at two positions
transversely, being at L25 in from either edge of the carriageway. For
multilane roads, levels shall be taken at two positions transversely
for e.ach lane at locations specified by the Engineer.
S. uitahlc references for the transverse grid lines should be left
in the form of embedded bricks on either ends or by other means so
that it is possible to locate the grid points for level measurements
alier each successive course is laid.
For pavement courses laid only over widening portions, atle.ast one
lire of levels shLill he taken on each strip of widening, or more depending
on the width .~fwidening a.s decided by the Engineer.
Notwithstanding the above, th.e measurements may he taken a.t closer
mtervals also, if SO desired by the Engineer, the need for which may
arise particularly in the case of estimation of the volume of the material
br profile. corrective cours.e (levelling course). The. average thickness
of the pavement course. in any area shall he the arithmetic mean of the
difference. of levels before and after constfliclion at all the grid points
falling in that area, provided that the thickness of finished work shall
he. limited to those shown on the drawings or approved by the Engineer
in writing.
As supplement to level measurements, the Engineer shall have the
option to take cores/make holes to check the depth of construction. The
holes made and the portions cut for taking cores shall be made good
by the Contractor by laying fresh mix/material including compacting as
required at no extra cost immediately after the measurements are recorded.
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General Section 100
113.4.Checking of Pavement Thickness for Payment Oil Area

Basis
Where payment for any bituminous course in Section 500 is allowed
to be made on area basis, the Engineer may have its thickness checked
with the help of a suitable penetration gauge at regular intervals or
other means as he may decide.
113.5. Measurement of Bituminous Courses for Payment on
Weight Basis
Plantmixed bituminous materials for pavement courses where des~
ignated to be paid on weight basis shall be weighed on accurate scales
approved by the Engineer. Approved scales shall me~in scales that
are of size, capacity, kind and type suitable for the weighing to he done,
and these shall be properly and adequately installed and maintained. Prior
to the use. of the scales and as frequently thereafter as the Engineer
may deem necessary to ensure accuracy, the scales shall be checked
and approved by the Engireer, or the Engineer may direct the Contractor
to have the scales checked by other competent agency at the cost
of the Contractor.
Location of the scales shall he as designated by the Pngineer. Trucks
used for hauling the material to he weighed shall be weighed empty
daily at such times as the Engineer directs, and each truck shall bear
a plainly leg ible identification mark.
For materials specified to be measured by weight, the Engineer will
have the option to make measurements of the finished work by volume
in accordance with Clause 113.3 and such volumes shall he converted
into weight for payment purposes. The factor for conversion from volume
measurement to weight measurement shall be computed from the..
representative density of the compacted material at site deterniined
at locations approved by the Engineer.
114. SCOPE OF RATES FOR DIFFERENT
ITEMS OF WORK
114.1.. For item rate contracts, the contract unit rates for different
items of work shall be payment in full for completing the work to the
requirements of the Specifications including full compensation for all the
operations detailed in the relevant sections of these Specifications under
“Rates”. In the absence of any directions to the contrary, the rates are
to be considered as the full inclusive rate fir finished work covering
all labour., materials, wastage, temporary work, plant, equipment, over-
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Section 100 General
hew] charges and profit as well as the general liabilities, obligations,
insurance and risks arising out of General Conditions of Contract,
114,2. The item rates quoted by the Contractor shall, unless otherwise
specified, also include compliance with/supply of the following
(i) General works such as setting out, clearance of site before setting out and clearance
of works after completion;
(ii) A detailed programme for the construction and completion of the work(using CPM!
PERT techniques) giving, in addition to construction activities, detailed netwo:rk
activities for the submission and approval of materials, procurement of critical
materials and equipment, fabrication of special products/equipment and their tn~
stallation and testing, and for all activities of the Employer that are likely to affect
the progress of work, etc., including updating of all such activities on the basis
of the decisions taken at the periodic site review meetings or as dirceted
by the Engineer;
(ii) Samples of various materials proposed to Ft used on the Work for conducting
tests thereon a.s required as per the provision:s of the Contract;
(iv) Design of mixes as per the relevant Clauses of th.e Specifications giving proportions
of ingredients, sources of aggregates and binder along with accompanying trial
mites as per the relevant Clautes of these Specifications to he submitted to the.
Engineer for his approval before use on the Works;
~v) Detailed design calculations and drawings for all Temporary Works (such as form..
work, staging, centering; specislised constructional handling and launchins,’
equipment and the like);
(vi) Detailed drawings for temptatcs, support and end anchorage, details for ~‘ restressing
e:ahle profiles, bar bending and cutting schedules for reinforcement, matrrial lists
(or fabrication of stnsctssral steel, mc;
(sir) Mill test reports for all mild and high tensile steel and. cast steel as per the relevant
provisions of the Specifications;
(sitti Testing of various finished items and materials including bitumen, cement,
concrete, bearings as required under these Specifications and furnishing test
reçxsrtsfeertifieates;
(is) Inspection Reports irs respect of fo nnwork, staging, reinforcement and other
items of work as per the relevant Specifications;
(a) Any other data which may he required. as per these .Speeiiieasions or
the Conditions of Contract or any other annexures/sehedules forming part of the
(.‘ontract;
(xi) Any other item of work which is not specifically provided in the Bill of Quantities
hut which is necessary for complying with she provisions of she Contract;
(,sii) All tesnporary works, formwork and false work;
(xiii) listahlishing and running a laboratory with facilities for testing for various items
of works as specified in Section 9~)and other relevant Clauses, where there
is no separate item in the Bill of Quantities for establishing and ntnning a
laboratory;
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General Section 100
(xiv) Cost of in~buihprovisions for Quality Asaurance;

(xv) Cost of safeguarding the environment; and
(xvi) (ost of providing “aa-boitt drawings” in original and two sets of prints.
114.3, Portions of road works beyond the Limits and/or any other
work may be got constructed by the Employer directly through
other agencies. Accordingly, other agencies employed by the Employer
may be working in the vicinity of the Works being executed by the
Contractor. The Contractor shall liaise with such agencie.s and adjust
his construction programme br the completion of work accordingly and
no claim or compensation due to any reason whatsoevcr will be
entertained on this account. The Employer will he indemnified by the.
Contractor for any claims from other agencies on this’ account.
115, METHODOLOGY AND SEQUENCE OF WORK
Prior to start of the construction activities at site, the Contractor
shall, within 30 days after the date of the Letter of Acceptance, submit
io the. Engineer for approval, the detailed construction methodology
including tnechanica.l equipment proposed to be used, sequence of vari~
ous activities and schedule from start to end of lhe. project. Programme
relating to pavement and shoulder construction shall be. an integrated
EtCEl.ivity to he done~ sii~~ultancouslyin a coordinated manner, The
nielho.dology and the sequence. shall he.so planned as to provide
proper safety, drainage and free flow of traffic..
116. CRUSHED STONE AGGREGATES
\Vhere, the terms crushed gravel/shingle, crushed stone, broken stone
or stone aggregate appear in any part of the Tender Documents or
Drawings issued for work, they refer to crushed gravel/crushed
shm pIe/crushed stone aggregate obtained from. .integrated crushing
plant having appropriate primary crusher, secondary crusher and
vibratory screen.
117. APPROVAL OF MATERIALS
Approval of all sources of material for work shall be obtained in
writing from the Engineer before their tise on the project.
118. SUPPLY OF QUARRY SAMPLES
Raw and processed samples of the mineral aggregates from the
approved quarry shall be submitted by the Contractor at no extra cost.
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Section 100 General
119. USE OF SURFACES i.Y CONSTRUCTION TRAFFIC
119,1. Ordinarily, no construction traffic shall be allowed on
pavement under construction unless authorised by the Engineer, Even in
that case the load and intensity of construction traffic should be so
regulated that no damage is caused to the subgrade or pavement layers
already constructed. Where necessary, service roads shall be constructed
for this purpose and the same shall be considered as incidental to
the work,
119.2. The wheels or tracks of plant moving over the various
pavement courses shall be kept free of deleterious materials,
119.3. Bituminous base course shall be kept clean and uncontami-
nated as long as the same remains uncovered by a wearing course or
sEurface treatment. The only traffic permitted access to the base course
shall be that engaged in laying and compacting the wearing course or
that engaged on such surface treatment where the base~course is
to be blinded and br surface dressed. Should the base course or tack
coat on the base course become contaminated, the Contractor shall make
good by clearing it to the satisfaction of the F.~~ngineer,
and if this is
impracticable, by removing the layer and replacing it to Specification
without any extra cost.
120. SITE OFFICE FOR ENGINEER AND OTHER
SUPERVISORY STAFF
120.1. Scope
The work covers the construction and provision of furnished site
office. acéommodation for the supervisory staff of Engineer and main-
taining the same.
120.2. Description
The Contractors hail arrange to provide fully furnished office
accommodation constructed as shown in drawings. Work includes
providing electric supply, all electrical items like lights, fans and complete
wiring, providing water supply including all pipes, flttings, tanks, tube
well, pumps, valves etc. complete,. septic tank, sewer lines., drains,
fencing, internal surfaced roads etc. complete as shown on the drawings.
The. Contractor shall provide the office accommodation within 4 months
from the date of the commencement of work or 3 months from the.
date of providing the land .and the working drawings for the construction
of office accommodation, whichever is later. List of furniture to he
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General Section 100
provided and maintained for Engineer’s site office shall be as in Table

I O&-2.
Table IOO~2. LIST OF FURNITURE TO BE PROVIDED AND MAINTAINED
FOR ENGINEER’S SITE OFFICE
SNo. item SpecifIcations Nos. Reqd.*
01 Executive table Make - Godrej Model

(for the Engineer) No, T-I08 or equivalent
02. Executive chair Make-Godrej Model

(for the Engineer~ No, PCH-701 or equivalent
03. Table 11or Site Make-Godrej Model No.

Engineer, Aecountant T-104 or equivalent.
and Head Clerk)
04, Ordinary chair Type Make-Godrej Model No.

I(For the Engineer, CHR-6 or equivalent.
Accountant, Read
Clerk and visitors)
05. Table (for all Make~OodrejModel No

other staff) T-i0l or equivalent
06. Ordinary ehair~Type Make-Codrej Model

II (for all other No. CITR-6 or equivalent
staff and visitors)
137. Stool Make-Godrej Model No.

ST-2 or equivalent.
OS Steel Almirah Make-Oodrej Model

1980mm a 915mm a No.1 Storewel plain
485mm or equivalent
09. Steel Atmirtth ilako’Godrej Model Minor

1270mm a 765 rum a p1 ant or ccitt iv alent
440 mm
11). Racks 5 Tie.r Made of slotted

1800 mm a 900 mm x angles and MS. Sheets
355 mm of Godrej make
Il. Typewriter Electronic—Bilingual

(English & Rindi)
Network make or equivalent.
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Section 100 General
0
S.No. Item Specifications Nos. Reqd.
12. Steel Cash Chest Make-Cktdrej Storewel

of size 1.5 x 1.5 or equivalent
@50 mm s 450 mm)
(approx.)
13. Air Coolers The coolers shall have 24”

(60cm) size fan with suitable
pump and shall be of either
GEC, Khaitan or Cool
Home make or equivalent
1 4. Room Heaters The heaters shall be of

2(100 W capactty - Bajaj
make or equivalent
5. Ceiling Pans Ceiling fans shall be of

1400 mm sue approved make and colour
16. CEompu cr with PC 486 with hard disc capacity

printer 230 MB, Maths eoprocessor,
Two disc drives of 5.25” (132 mm)
and 3.5’ (88 mm), 14” (350 mm)
size colour VGA monitor letter-
quality dotmatnEx pritster of 132
columns and 101 Key board
7. Phoroc:opier Make RICOH Model FT 4065 or

equivalent
Numbers to be decided by the Engineer as çxrr requirements of the Project.
120.3. Ownership
The sile office with all services, furniture anti fittings shall he the
property of the Employer. The land for the site office shall he provided
by the Engineer and the location shall he as indicated in the Drawings.
120.4, Maintenance
The Contractor shall arrange to maintain the site office until the
issue. of Taking over Certificate for the complete work, Maintenance
includes the day to day upkeep of the building and the surroundings,
attending to repairs to various parts of the building, furniture, fittings,
office equipment and the connected services as and when necessary.,.
including the periodic white/colour washing of building and painting of
wood work, steel work, replacing the broken window/door/ventilator
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General Section 100
glasses, furniture and other hardware and maintaining necessary watch
and ward during day and nighL
The Contractor shall arrange to provide uninterrupted supply of
electricity and water for the office building. In case of failure of main
power/water supply, alternate source shall be available for providing
uninterrupted supply. All sources, tappings and connected equipment and
fittings, piping, tanks, wiring and all accessories of the main alternate
power/water supply, for the site office accommodation shall be the
property of the Employer.
1.29.5. Measurements for Payment
The measurement for construction and provision of site office shall
be in square metres of the plinth area of the office accommodation
and the payment shall be made after the completion and handing over
of the buildings with connected services fully furnished including office.,
equipment for occupation.
if the Contractor fails to hand over the furnished office accommo-
da.tion within the period stipulated under Clause 1202, an amount
oURs. 15,000 per month or part thereof shall be debited to the Contractor’s
account for the period of delay.
The. measurement for maintenance of F..~ngin~r’ssite office ac—
commodation shall be on maintenance months and shall be niade on
completion of satisfactory maintenance every month,
if at any stage, the Contractor fails to carry out the required
maintenance satisfactorily, an amount of Rs. 5000 per month or part
thereof shall be debited to the Contractor’s account. In addition, the
month/months during which the Contractor fails to carry out the
required maintenance satisfactorily shall not be measured for payment.
If the Contract works are not completed within the stipulated period
or within the granted extended time of completion, maintenance of site
office accommodation in accordance with Clause 120.4 shall be carried
out by the Contractor at his own cost and as such no payment shall
he made for thc same. In case of any failure by the Contractor to do
so, an amount of Rs, 15,000 per month or part thereof shall be debited
to the Contractor’s account.
1.20,6. Rate
l’he Contract unit rate f.or constructing and providing Ihe site office
accommodation shall include the expenses of all the operations involved
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Section 100 General
in construction of the building including all services, fittings, fixtures,

furniture, fencing, internal surfaced roads, as mentioned under Clause
120.2.
The Contract unit rate for maintenance shall include expenses
towards all items of works detailed in Clause 120.4 including power
and water charges for supply from the mains and for providing
uninterrupted supply of power and water from alternate sources in case
of failure of main supply.
121, FIELD LABORATORY
121.1. Scope
The work covers the provision and niaintenance of an adequately
equipped field lab.mtory as required for site control on the quality of
materials and the works..
121,2. Description
The Contructor shall arrange to provide fully furnished and adequately
equipped field laboratory constructed as shown in drawings. The fold
laboratory shall preferably be located adjacent to the site office of the
Engineer and provided with amenities like water supply, electric. supply
etc. as for the site office of the Engineer in Clause 120.2.
The floor space requirement for the feld laboratory shaU he. as
indicated in the drawing It shall include office space for the Materials
.,
Engineers, one from the Contractor’s side and another from the Engineer’s
side and a store for the storage of samples. The remaining space shall
be provided for the. installation of equipment, laboratory tables and
cupboards, working space for carrying out various laboratory tests,
besides a. wash basin, toilet facility and a curing tank fOr the curing
of samples, around 4m x 2m x im in size and a fume chamber. The,
furnishing in each of two offices of the Materials Engineers shall he
as provided for the Site Engineer in Table 100-2.. Wooden/concrete work-
ing table with a working platform area of about Tm x TOm shall he
provide.d against the wails’, also providing wooden cupboards above and
below the working tables to store accessories such as sample moulds
etc. Atleast 4 racks of slotted angles and! MS. sheets as at SINo. ID
of Table 100-2 and atleast 6 stools for laboratory test operators as
at Sl,No 7 of Table 100-2 shall also be provided.
121.3. Laboratory Equipment
The. following items of laboratory equipment shall he provided
in the field laboratory..
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General Section 100
121.3.1. General
(I) Oven - Electrically operated,
thermostatically controlled, range
opto 200°C sensitivity 1°C 1 No.
(ii) Platform balance 300 kg capacity 1 No.
(iii) Balance 20 kg capacity-self indicating type 1 No.
(iv) Electronic Balance 5 kg capacity accuracy 0.5 gm 2 Nos.
(v) Water bath-electrically operated and 1 No.

thennostatically controlled with adjustable
shelves, sensitivity 1°C
(vi) Thennometers: 4 Nos.

Mercury-in-glass thermometer range
0° LO 250°c
Mercury-in-steel thermometer with 30 cm
stem, range upto 300°C
(vii) Kerosene or gas stove or electric hot plate 1 Nn,
(viii) Glasswares, spatulas, wire gauzes, As required

steel scales, measuring tape, casseroles,
karahis, enamelled trays of assorted sizes,
pessle.mortar, porcelain dishes, gunny bags,
plastic bags, chemicals, digging tools like
pickaxes, shovels etc.
(it) Set of IS sieves with lid and pan:

450 mm diameter: 1 set
63 mm, 53 mm, 37.5 mm, 26.5 mm, 13.2 mm, 93 mm,
6.7 mm and 4.75 nun size
200 mm diameter: 2 sets
2.36 sum, 2.0 mm, 1.18 mm, 6(1) micron, 425 micron,
300 micron, 150 micron, and 75 micron
(4 Water testing kit i set
(xi) Hrst aid box 1 set
121,3,2. For soils and aggregates

(i) Riffle Box I No.
(ii,) Auerhcrg Limits (liquid and plan ic

limits) determination apparatus 1 set
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Sechost 100 General
(iii) C~ompaetion Tess Equipment both 2.5 kg and 4.5 kg
rammers (1..ight and Heavy compactive efforts) I set
(iv) Dry Bulk D.nsisy Test apparatus (sand pouring

cylinder, tray, can etc.) complete I set
(v) Speedy Moisture Meter complete with chemicals I set
(vi) Post ~hole Auger with extensions 1 set
(vii) Core cutter apparatus 10 cm dia, 10/IS cm

height, complete with dolly, rammer etc. I set
(viti) Aggregate Impact Value Test apparatus/Los

Angeles Abrasion Test apparatus I set
)is) Flake ess and Elongation Test Gatiges I set
(x) Standard measures of 30, 15 and 3 litres

capacity alongwith standard tar ping rod 1 set
lsi) California Bearing Ratio test apparatus 1 set
(tii) l.;scoifined compression test apparatus I set

121.3,3. For bitumen and bituminous mixes
(i) F’cnetronseter with standard needles I set
(ii) Riffle box small size 1 No.
(iii) Centrifuge type bitumen extractor, hand

operated, complete wish I set
petroh/cosssmereial henzene
(iv) Marshall stability te.st apparatus, complete I set

witis all accessories
(v) l.:ic,ld density bottle aiongwith cutting tray,

chisel, hamnscr and standard sand 2 Nos.
(vi) 3 rn straight edge I No.
(vii) Camber hoard I No.
(viii) Core cuttistg machine witls 10 an dia diansond I set

cutting edge
(is) Vacuum pump and El specific gravity bottles I set
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General Section 100
121.3.4, For cement and cement concrete

(i) Vicat apparatus for testing setting times I set
(ii) Slump testing apparatsts 4 mets
(iii) Compression and Fleitttral strength testing
machine of 200 ton.ne capacity with additional
dial for flettssral testing 1 No.
(is) Needle Vibrator 2 Nos,
(v) Air Meter 1 No,
(vi) Vihrating hammer for vibrating dry mix as
for Dry Least Cement concrete stab-base I No.
r.~rote .~ The items and their numbers listed shove in this Clause shall be decided by
she Engineer as per reqstirements of the Project and modified accordingly.
121,4, Ownership
if provided as a separate payable item in the Bill of Quantities,
the field lab. ratory building and equipment shall be the property of the.
Employers and the land for laboratory will he provided by the Employer.
121.5. Maintenance
if çtrovide.d for as a separate payable item in the Bill of Qttanti ties,
the Contractor. shall .t.rrange. to maintain the field laboratory ~n a
saltsfac.tory rnanne.r until the. issue of Taking Over Certificate for the
coniplete. work, Maintenance includes all activities described itt Clause
120,4,
121.6. Measurements for Payment
If provide..d a..s’a separate payable item in the Bill of Quantities,
the. measurement for payment for the constrtsction of the field laboratory
shall be on square metres of plinth area.
‘l’he sttpplv of testing equipment, the erection, maintenance and.
running the. sante shall he on a lump sum basis.
121.7. Rate
If provide.d in the Bill of Quantities as a separate payable item,
thd~ contract unit rate for constructing and providing the field laboratory
shall include, expenses of all operations involved in construction of
the httilding including all services, fittings, fixtures, furniture and fencing
as mentioned in Clause 121.2,
The Contract unit rate for maintenance shall include expenses
towards’ all items of works and equipment in Clauses. .121.2 and 121.3
including power and water charges for supply from the mains and for
providing uninterrupted supply of power and water from alternate
sources in case of failure of main supply.
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Section 100 General
The. Contract lumpsum rate for the supply, erection, maintenance
and running of testing equipment s,hall include cost of supply, installation
and running including all consumables like chemicals and reagents.
122. SITE RESIDENTIAL ACCOMMODATION FOR
ENGINEER AND OTHER SUPERVISORY STAFF
122.1. Scope
The work covers the provision and maintenance of unfurnished
sile residential accommodation for the Engineer and other supervisory
staff.
The Contractor shall arrange to provide residential accommodation
constructed as shown in the drawings,
Work includes providing electric supply, all electrical items like
wiring, switches, all fittings, lights, fans, etc. complete; providing water
supply and sanitation including all pipes, littings, tanks, tube well, pumps,
valves etc. complete; septic tank, sewer lines, drains, fencing, internal
roads etc.., complete as shown in the drawings.
122.2. Ownership
The. site residential accommodation with all services and fittings
etc., shall he the property of the Employer. The land for the residential
acconi modat ion shall be provided by the Engineer and the location shall
be as indicated by the Engineer. The Contractor shall provide the
residential accotnmodation within 4 months from the date of commence~
me.nt of the. work or 3 months from the date of providing land and
the working drawings for the construction of residential accommo~
dation, whichever is later.
122.3. Maintenance
The Contractor shall arrange to maintain the supervisory staff
residential accommodation until the issue of Taking Over Certificat.e fbr
the complete work.
Maintenance includes attending to repairs to various parts of the
building, fittings etc. and the connected services as and when necessary,
including the annual white/colour washing of the building and periodic
painting of wood and steel work; replacing the broken window/door,
ventilator glasses and other hardware; and maintenance of internal roads.
The Contractor shall arrange to provide uninterrupted supply of
electricity and water for the buildings. In case of failure of main water
or power supply, suitable alternate arrangement shall be made for
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General Section 100
providmg uninterrupted supply. All sources/tappings and connected

enuipment and flttings, piping, tanks, wiring and all other accessories
of the. main and alternate power/water supply for the residential
accommodation shall be the property of the Employer.
122,4, Measurement for Payment
The measurement for construction of the residential accommodation
shalt be on square metres of piinth area of the accommodation. The
payment shall be made after the residential accommodation, complete
with all services, fencing etc., is constructed and handed over for
occupation. If the Contractor fails to complete and hand over the complete
residential accommodation within the period stipulated under Clause
122.2, an amount of Rs. 50,000 per month or part thereof shall be. debited
to the Contractor’s account for the peiiod of delay.
The measurement for mnaintenance of supervisory staff residential
accommodation shall be in maintenance months and shall be made on
completion of satisfactory maintenance every month. If at any stage
the Contractor fails to carry out the required maintenance satisfactorily,
an a.mount of R.s, 25,000 per month or part thereof shall he debited
tc.~ the Contractor’s account. In addition, the month/months during
winch the tontractor fails to carry out the required maintenance
satisfactorily shall not be measured for payment.
If the Contract works are not comnpleted within the stipulated period
or within the granted extended time of completion, maintenance of re.si-
den ti~daccommodation in accordance with Clause 122.3 shall be carried
out by the C.ontractor at his own cost and as such no payment shall
he. made. for the same. in case of any failure by the Contractor to do
so, an amount of Rs, 60,000 per month or part thereof shall be debited
122.5. Rate
The Contract unit rate for constructing and providing residential
accommodation for the Engineer and other supervisory staff shall in-
elude cost of all the. operations involved in construction of buildings
and connected services and fittings, fencing etc. complete.
The Contract unit rate for maintenance shall include the expenses
for all items of work detailed in Clause 122.3 including provision
of uninterrupted supply of power and water.
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Section 100 General
123. PROVIDING AND MAINTAINING WIRELESS
COMMUNICATION SYSTEM
123.1. Scope
The work covers the provision and maintenance of wireless coin
munieation systems with necessary mobile/base trans-receivers and other
accessories,
123.2, Supply
The Contractor shall arrange to supply, install and commission the
eimplete wireless systeni of approved quality suitable for a range of upto
65 km. The system shall consist of the foltowingE
(a) Mobile ‘t’rans.~receiversuitable for mounting on 4 wheelers with Microphone st...
sembly, Mobile Antenna with Oable and External Speaker assembly (3 \V audio
output) with all necessary fittings and accessories - IC sets.
(h) Base Trans-receivers with Microphone assembly suitable Antenna, csternat
speaker tush (3 SY audio output) with all necessary fittings a.r,.d accessories - 3
sets,
(c) to Not,
I-land held radio sets ..
The Contractor shall provide the complete wireless system within

12 months from the date of commencement of work or 8 months from
the ttate. on which frequency is allotted to him by the Coy L Department,
whichever is later. FTc shall submit a guarantee for replacement of any
d,e.feclive. trans-receiver/trans-receivers during the hurrency of the. con----
tract.
123.3. Approval
The Contractor shall. arrange to obtain all necessary statutory
approvals From various Government bodies for operating the system,. He
shall also fulfil the requirements laid down hy various Government
Departments and obtain the frequency to operate the wireless system.
123.4. Maintenance
The Contractor shall arrange to maintain the entire wireless system
including the mobile and base trans—receivers and all accessories until
the issue of the Taking Over Certificate for the complete work, He
shall replace any Trans-receiver or accessory which goes out of order,
at his own cost and provide all necessary spares and attend to all repairs
necessary for keeping the complete system in satisfactory working
condition, On issue of the Taking Over Certificate after obtaining
clearance from the Engineer, the Contractor shall dismantle the complete
wireless system and hand over to the Engineer.
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General Section 100
1233. Measurements for Payment
The measurement for supply and installation of wire:iecs system shall
be on lumpsum basis for the complete system as described in the
preceding pans.
If the Contractor fails to commission and hand over the complete
wireless system in the stipulated time, an amount of Rs, 10000 per month
or part thereof shall be debited to the Contractor’s account.!
The measurement for maintenance of the wireless system shall be
on maintenance months and shall be made on completion of satisfactory
maintenance every month. If the Contractor fails to carry out the required
maintenance as directed by the Engineer at any stage of work, an amount
of Rs, 5000 ~er month or part thereof shall be debited to the Contractor.
In addition, the month/months during which the Contractor fells to
carry out the required maintenance shall not be measured for payment!
if the Contract Works are not completed within the stipulated period
or within granted extended time of completion, the maintenance of
wireless system in accordance with Clause 1214 shall be carried out
by the Contractor at his own cost and as such, no payment shall be
made for the same. In case of any failure by the Contractor to do
so, an amount of Rs. 8000 per month or part thereof shall be debited
1216. Rates
The Contract unit rate for the supply and installation of wireless
system shall cover all the expenses towards the supply oF all necessary
items and expenses towards obtaining statutory approvak and operating
trequency erection omm is’aoning ‘~nd h mud~n° o~ U it inn c or
replacement of the trans~receiverftrans-receivcrs (which arc frmund defec~
the) during the currency of the Contract md all other incidentals,
The Contract unit rate for the maintenance of wireless system shall
be payment in full for carrying out periodic servicing and checking
of the system!!, replacement of components, attending to all necessary
repair, payment of taxes, if any, and other inddentals to keep the complete
system in satisfactory working condition.
124. PROVIDING AND ML% INTAI:NENG VEHICLES FOR
THE ENGINEER
124.1. Scope
The work covers prnvtd~ngand maintaining of hard top ~es~cnger
3:1
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Section 100 (ieneral
cars and br hard top leeps for use by the Engineer as described under
the Bill of Quantities,
124,2, Description
The passenger cars shall be petrol or diesel driven and may he Am.
hassador or equivalent having cylinder capacity of minimum 1400 cc
The hard top jeeps shall be 4 \V Drive either petrol or diesel driven
and may be Maruti Gypsy Model MG 410, Mahindra & Mahindra leep
Model MM 540/MM~440or equivalent. The number of vehicles to h1’
pm idc.d by the Contractor shall be decided hy the Engineer at vanno
limes, out of the total provision in the B ill of Quantities and md tEnted
in writing.
The Contractor shall provide within one month from the due of
order by the Engineer, vehicles as indicated above, l’he vehicless hal I
he provided and maintained unhl issue of the Taking Over (‘ertifitEatL
fix the complete Work. Initially, new vehicles shall he provided, in
case of vehicles of Indian make. a velt ide shall be replaced with a
new xrc’hiclt~after a maxim tim run of 75,001 km or two years whiche ci
is earlier, in case ot vehuEles of lbreign make approved b~’the Engineer
the vehicle shall be replaced with a new vehicle after a maximum run
uI 1,00,0110 km er three Lears u~hicheveris earlier. All necessary taxes
for operating the vehie ic’ shall he hilly prod anti all necessary papers
,shal be pros ided as reru red hy prevailing Motor Vehicles Act tvi th
iEomprrhensivc in~urance :ov er for the vehicles. The vehicles shall he
provided da> and night a’i required by the Engineer The Contractor
shall also makE’ as ailEd~lc. ~lnvrrs hEEivmne valid licence at such tunes and
or such duration as I nstruER d by the Engineer.
124.3. Ma i ritena mit
The vehicles shall hi’ “Pain tainet:l in a smooth rurning condoinn \l I
expenses required ha kec ping the vehicles in smooth runnine tEui](lltil)fl
such as fus’l, luhrieati.eu oil and oi her consumables, necessarx ~ o tee
antI maintena.rtt’e, dri,ers, rep:.iirs and rei:dacenient etc. are to IL’ ni
hy the Coiitraetor. In the evcx I of any x’r’hiele being off the reid
br main lenan ?s’ or on acEe 01 tnt of breakdown the Contractor shall pro V di
substitute vehicic(s) immediately, If the Contractor at any time tah s
provide vehicle(s) or substitute vehic Ic(s) as specified above, an anion i’~t
of Es. 500 per day dir part thereef for each vehicle (that the Contra trir
failed to pro~’~tie) shall he del’ i ted U the Contractor’s account. Also the
numher of days for which the sehicle(s’l were not prov iderl shalt
not he mel tided for pay me nt.
<< .34
Ocncrat Secuon (Xi)
If the Contract Works are not completed within the stipulated penod
or within the granted extended lime of completion, provision and maui
tcnance of vehicles in accordance with Clause 124.,! through 124 4 shall
be carried oot by the Contractor at his own cost and no payment shall
he made for the same. In case of any failure by the Contractor to
do so an amount of R s, 700 per clay or part thereof per vehicle sft ill
he debited to the Contractor’s account.
124.4. Withdrawal of Vehicles
the Contractor shall withdraw particular cc hide/vehicles fbr the
non-use by the Engineer if so directed by the Engineer. In such ca~e’~
the instructions for non-use of vehicle shall be given in writing 15 c1a~
in advance and the withdrawal of vehicles shall not be for a period H
le.ss than 1,5 days continuously at a time.
The payment for providing and maintaining vehicles shall b1
vehicle clay basis for actual number of clays the vehicles were prn’;
ri satisfiictory working order, No payment shall be male for the ~:~e
of withdrawal as per Claus..: IN ~1irrespective of the fact wlte:hc
~rehiclewas available or not
124,6. Rates
lhe Contract unit ratc tor providing and maintaining vehicle”:
Engineer shall include all expenses towards providing and eel’I!ng lLhL,
vehicles in smooth running condition including taxes dc rn “ni’ ‘i
I ri the. preceding paras.
125. SUPP[.X OF COLOUR RECORD PF1OTOG RAPIIS
AND ALBUMS
125.1. Scope
The work covers the s ippl of photographs, negat i e~ ani I all in
~. ‘~
to serve a.s a permanent re c orit of various stages/1”acet c’; I he c~‘~r

~
neecled br an authentic dricu men tat ion as approved b~ h a r’ ng I

125,2. Description
The Contractor shall arrange to take colour photograph sacv
stages/facets of the worl: including interesting and no’ H (cat ‘res
of the work’ as desired h) the Engineer. The. photograph.’;; shalt he
acceptable quality and they shall he tal•:en by a professior ally ci rrrrpe .en’
photographer with caineri having the facility ro reeori I te U t ‘1 “
<<
Section 1(X) General
photographs taken in the prints and negative. The Contractor shall supply
two colour prints of each of the photographs taken to the standard
postcard size mounted in albums of acceptable quality. Also the negative
in 35 mm size shall be supplied for each photograph. Each photograph
in the album shall be suitably captioned.
Supply of two copies of colour record photographs mounted in
the albums and the negative thereof shall be measured in number
of record photographs supplied.
Supply of additional prints of cokiur record photographs shall be
measured in number of additional prints supplied.
125.4. Rate
The rate for the supply of record photographs shall include the cost
of taking the photographs. developing and obtaining colour prints
cost of album, mounting of photographs and captioning the same etc.
The rate for additional colour prints shall similarly include all ensis
incurred..
The photographs and materials including negatives shall form a part
of the records of the Department and the prints o..f the same cannot
he supplied to anybedv else or published without the written permission
of the [)epartment
126. SUPPLY OF VIDEO CASSETTES
126.1. i)escription
The work conskts of taking video films of important activities of
the work as directed by the Engineer during, the currency of the proiect
and editing them to a vidpo film of playing time not less than 60 minutes
‘md upto 180 minutes as directed by the Engineer. It shall contain
naiTation of thene tivities in English by a competent narrator. The
edition of the video 1dm and the script for narration shall be as approved
by the Engineer. The video cassettes shall be of acceptable quality
and the film shaL he capable of producing: colour pictures.
126.2. Measu renients for Payment
The nlea’anement shall be by number of sets of edited master
cassettes each with four copies thereof.
.
<< 36
General Section 11)0
126.3. Rates
The contract unit rate shall include all expenses for making video
films with the help of a professionally competent photographer, editing,
narration and supplying the final edited master cassette aiongwiih
tour copies thereof..
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Site Clearance
200
Site Clearance
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Site Clearance Section 200
201. CLEARING AND GRUBBING
201.1. Scope
This work shill consist of cutting,,, removing and disposing of all
materials such as Lrees, hushes, shrubs, stumps, roots, grass, weeds, top
organic soil not exceeding 150 mm in thickness, nibbish etc., which in
the opinion of the Engineer are unsudable for incorporation in the
works, fnmi 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 excava-
tion, backlilling of pits resulting from uprooting of trees and stumps to
required compaction, handling, ‘salvaging, and disposal of cleared
materials, Ck.arin,g and grubbing shall be performed in advance of
earthwork operations and in accordance with the requirements of these
Specifications.
20L2. Preservatkni of Property/Amenities
Roadside trees, shrubs, any other plants, pole lines, fences, signs,
monuments, buildings, pipelines., .sewer~and all highway facilities within
or adjacent to the highway’’~.vhichare not to be disturbed shall be protected
from injury or damage. The Contractor shall provide and install at
his own expense, suitable safeguzuds approved by the Engineer for
this purpose.
During clearing and grubbing, the Contractor shall take all adequate
precautions against soil erosion, water pollution, etc., and where required,
undertake additional works to that effect vide Clause 306. Before start
of operations, the Contiactor 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 as stipulated in Clause 306.3.
2013, Methods, Tools and Equipments
Only such methods, tools and equipment as are 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, All trees, stumps, etc., falling within excavation and
fill lines shall be cut. to such depth below ground level that in no ease
these fall within 500 mm of the subgrade. Also, all vegetation such as
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Section 200 Site Clearance
roots, indeNgrowth, grass and other deleteriotis matter unsuitable for
incorporation in the embankment/subgrade shall be removed between
fill lines to the satisfaction of the Engineer. On areas beyond these
limitiE, trees and stumps required to be removed as directed by the
Engineer shall be cut down to I m below ground level so that these
do not present an unsightly appearance.
All branches of trces extending above the roadway shall he
trimmed as directed by the Engineer.
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.
Antli ills 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.
201.4. Disposal of Materials
All materials arising from clearing and grubbing operations shall
he the property of Government and shall he disposed of by the Contractor
a.s hereinal’ter provided or directed by the F...ngineer.
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 neatly stacked as directed by the Engineer.
Stacking of stumps, boulders, stones etc., shall he done at specified. .spots
with all lifts and upto a lead of 1000 m.
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 by the Engineer. Care shall he taken
to see that unsuitable waste materials are disposed of in such a manner
that there is no likelihood of lhese getting mixed up with the materials
meant for embankment, subgrade and road construction.
20 1,5. Measurements for Payment
Clearing and grubbing for road embankment, drains and cross-
drainage structures shall be measured on area basis in terms of hectares.
Clearing and grubbing of borrow areas shall be deemed to he a part
of works preparatory to embankment construction and shall be deemed
to have bee.n included in the rates quoted for the embankment construction
item and no separate payment shall he made for the same. Cutting of
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Site Clearance Section 20()
trees upto 300 mm in girth including removal of stumps and roots, and
trimming of branches of tmes extending above the roadway shall be
considered incidental to the clearing and grubbing operations. Removal
of stumps left over after trees have been cut by any other agency
shall also be considered incidental to the clearing and grubbing
operations.
Cutting, including removal of stumps and roots of trees of girth
above 300 mm and hackfilling to required compaction shall he measured
in ten-os of number according to the sizes given below:-
i) Above 3(X) mm to 6()0 mm
ii) Above 6(X) mm to 900 mm
fl) Above 9(X) mm to 1800 mm
iv) Above 1800 mm
For this purpose, the girth shall be measured at a height of 1 metre

above ground or at the top of the stump ii the height of the stump
is less than one metre from the ground.
201.6. Rates
201.6.1, The Contract unit rates for the various items of clearing
and grubbing shall be payment in full for carrying out the required
operations including full compensation for all labour, materials, tools,
equipment and incidentals necessary to complete the work, These ~vi11
also include removal of stumps of trees less than 300 mm in girth as
well as stumps left over after cutting of trees carried out by another
ag:ncy, excavation and back-filling to required density, where necessary,
and handling, salvaging, piling and disposing of the cleared materials
with all lifts and upto a lead of 1000 m.
201.6.2. The Contract unit rate for cutting (including removal of
stumps and roots) of trees of girth above 300 mni shall include
excavation and hackfilling to required compaction, handling, salvaging,
piling and disposing of the cleared materials with all lifts and upto
a lead of 1000 m.
201.6.3. Where a Contract does not include separate items of clearing
and grubbing, the sa.me shall be considered incidental to the earthwork
items and the Contract unit prices for the same shall be considered as
including clearing and grubbing operations.
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21)2. DISMANTLING CULVERTS, BRIDGES AND

OTHER STRUCTURES/PAVEMENTS
21)2.1. Scope
This work shall consist of removing, as hereinafter set forth, existing
culverts, bridges, pavements, kerbs and other structures like guard~rails.,
fences, utility services., manholes, catch basins, inlets, etc.~~)which are
in place but interfere with the new construction or are not suitable to
remain in place..~,and of salvaging and disposing of the resulting materials
and back filling the resulting trenches and pits.
Existing culverts, bridges, pavements and other structures which
are within the highway and which are designated for removal, shall
be removed upto the limits and extent specified in the drawings or as
indicated by the Engineer.
Dismantling and removal operations shall he carried out with such
equipment and in such a manner as to leave undisturbed, adjacent
pavement, structures aud any other work to be left in place.
All operations necessary for the removal of any existing structurc
which might endanger new construction shall be completed pnor w.
the start of new work.
20L2. Dismantling Culverts and Bridges
The structures shall be d~srnantled carefully and the resuh my
materials so removed as not to cause any damage to the serviceable’
materials to he salvaged, the part of the structure to be retained and
any other properties or structures nearby.
Unless otherwise specified, the superstnicture portion of eulvcrts/
bridges shall he entirely removed and other parts removed below
the ground level or as necessary depending upon the interference, they
cause to the new construction. Removal of overlying or adjacent material,
if required in connection with the. dismanding of the structures,.~shall
be incidental to this item.
Where existing culvert.sfbridges are to be extended or otherwise
incorporated in the new work, only such part or parts of the existing
structure shall he removed as are necessary and directed by the Engineer
to provide a proper connection to the new work. The connecting edges
shall be. cut, chipped and trimmed to the required lines and grades without
weakening, or damaging any part of the structure to be retained, Due
care should he taken to ensure that reinforcing bars which are to he
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Site Clearance Section 200
left in place so as to project into the new work as dowels or ties
are not injured during removal of concrete,
Pipe culverts shall he carefully removed in such a manner as to avoid
damage to the pipes.
Steel structures shall, Unless otherwise provided, be carefully dis-
mantled in such a manner as to avoid damage to members thereof. If
specified in the drawings or directed by the Engineer that the
structure is to be removed in a condition suitable for re-erection, all
rnemhers shall be match-marked by the Contractor with white lead paint
before dismantling; end pins, nuts loose plates, etc., shall be similarly
marke.d to indicate their proper location; all pins, pin holes an.d machined
surfaces shall be painted with a mixture of white lead and tallow and
all loose parts shall be securely wired to adjacent members or packed
in boxes,
Timber structures shall he removed in such a manner as’ to avoid
damage to such timber or lumber as is designated by the. Engineer to
be salvaged.
202.3. Dismantling Pavements and Other Structures
In removing pavements, kerhs, gutters. and other structures like
guard-rail’;, f~.nces,manholes, catch basins, inlets, etc., where portions
of the c~istingconstruction are to be leSt in the finished work, the
same ‘thall be removed to an existing joint or cut and chipped to
a true line, with a face perpendicular to the surface of the existing
structure, Sufficient removal shall be made to provide for proper grades
and connections with the new work as directed by the Engineer
AU concrete pavements, base courses in carriageway and shoulders
desoEnate.d for removal shall he broken to pieces whose volume shall
i.acE.
not scce.d 0 02 cu. m, ~mci stockpiled at designate.d locations if
‘.‘
the material is to he used later or otherwise arranged for disposal as

directed (see Clause 202,5)
202.4. Back-filling
Holes anti depre ‘eons LEaused by dismantlin,g operations shall he
hackfilled with ~ ,‘OE other approved materials and compacted to
required density as dire~ted by the Engineer.
292.5. Disposal of Materials
All materials obi unto by disin totlu .. ‘ di h th n ot
Governnitnt lJnless oth twi o s; II s imE~,
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value shall he placed in neat stacks of like materials within the righ o
cThway, as directed by the Engineer with all lifLs and upto a lead of
1000
Pipe t: ulverls that are removed shall he cleaned and neatly piled
on the nght•~of~way at points’ designated by the Engineer ss ith all lifts
and lead upto 1000 in.
Struc tura.i steel removed from old structures shall, unless otherwise
spec’i bed or directed, he stored in a neat and presentable manner on
blocks in locations suitable for loading. Structures or portions thereof
which are specified in the Contract for re~erectionshall he stored in
separate ~i1e~,
‘Timber or lurn her from old structures which is desig naled by the
E: ng ineer as rnateri a Is to he salvaged shall have all nails and bolts rem ove. il
theret’roin and shall be stored in neat piles in locations suitalElle for
loading.
Al I ma teria.ls obtained from dismantling operati 015 which, ut the
in miii of the En ~ineer, cannot he tised or auctioned sl all be disposed
ip
i
of as cI ireeted hy the f.i.ngineer with all lifts and upto a lead of 10011
nEt

The work of ilisniantling structures shall be paid for ut units indicated
‘I miw hy ok inc iu easiu’ernents before a nil after. as applicable’
ot Osinarililig t’rtck/sinnc masonry!
sonorole (1iliiri rid reinforced) cci in
tot Disinani irrg fte~Ste and cernci ii
concreie pas’ ririent en. in
jut nsrnarrwnt.~sleet siruciiire~ ionrie
(iv) tE)irrnarrikinii i rnher srmcru ret cii in
(v) t)isrnarittirig nlrxrs tonrit rails,
kerb.s, guilL rs Mid iitriciig irrear ft
(vi) t.Jiitiiy sen ices Nor
202.7. Rates
The Contract i nit rates for the various i teins of disinanti ing shall
paid in hill for carrying out the required operations including hill
a ipen sation for all labour, materials, tools, ec~tupnlen
t, safeguards and
neidentals necessary to complete the work. These will also include cx
.‘avation and back lilling where necessary to the required compac Lion
anti for handling, salvaging, piling and disposing of the cli.smantlta:l
materials within all lifts and upto a lead of 1000 rn,
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Earthwork, Erosion Control and
Drainage
300
Earthwork, Erosion
Control and Drainage
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Earthwork, Erosion Control Section 300
and Drainage
301. EXCAVATION FOR ROADWAY AND DRAiNS
301.1. 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 these Speci~
fications 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.
301,2. Classification of Excavated Material
301.2.1. Classification All materials involved in excavation shall
he classified by the F...~gineerin the following manner:
(a) Soil
This shalt comprise topsoil, turf, sand, silt, loam, clay, mud, peat, black cotton
soil, soft shale or loose moomna, a mixture of these and similar material which
yields to the ordinary application of pick, spade and/or shovel, rake or oth,e.r
ordinary digging implement. Removal of gravel or any other nodular material
having dimension in any one direction not ‘exceeding 75 mm occurring in such
strata shall be deemed to be covered under this category.
(It) Oniinaxy Rock (not reqttiring blast.ing)This shall include:
(i) rock types such as laterites, shales and conglomerates, varieties of limestone
and sandstone etc.,, which may be quarried or split with crow bara, also
including any rock which in dry slate may be hard, requiring blasting hut
which, when wet, becomes soft and manageable by means other than
blasting;
(ii) macadam surfaces such as water bound and bitumen/tar bound; soling
of 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 dirt. ension in any one directionbetween
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 storw masonry in cement mortar below
ground level; and
(iv) boulders which do not require. biaating 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.
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Sect ion 300 Earthwork, Erosion Control and Drainage
(c) Hard Rock (reqsüring blasting)

This shall comprise:
(i) any rock or cement concrete for the excavation of which the usc of
mechanical plant and/or blasting is required;
(ii) reinforced cement concrete (reinforcement cut through hut not separated
from the concrete) below ground level; and
(iii) lxsulders requiring blasting.
(il) Hard Rock (blasting prohibited)
I-lard rock requiring blasting as describest under (c) but where blasting is prohibited
for any reason and eacavation has to be carried out by chiselling, wedging or
any other agreed method,
(c) Marshy Soil
This shall include soils like soft clays and pears eacavated below the original
ground level of marshes and swamps and soils excavated from other areas
requiring continuous pumpi g or bailing out of water,
301,2.2. Authority for classification The classification of exca-

vation shall he 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.
301.3. Construction Operations
301.31. Seding out After the site has be.e.n cleared as per Clause
201., the. limits of excavation shall he set out hue to lines, curves, slopes,
grades and sections as shown on the drawings or a.s directed by the
Engineer., The Contractor shall provide all labour, survey instrtiments
and materials such as strings, pegs., nails, bamboos, stones, lime,, r.orl.ar,
concrete, etc.., required in connection with the setting otit of work,s and
the e.,sl.ablishment of bench marks. The Contractor shall be responsible
for the maintenance, of bench tnarks and other marks and stakes as” long
.as in t.he. opinion of the Engineer, they are required for the work.
301,3.2. Stripping and storing topsoil W’’hen so directed by the.
Enginte., the topsoil existing over the siles of excavation shall be stripped
to spe.cified depths constituting Horizon “A” and stockpile.d at designated
locations for re-use in covering embankment slopes, cut slopes, berrns
and olher disturbed areas where re-vegetation is desired. Prior to stripping
the topsoil, all trees, shrubs etc. shall be removed along with their roots,
with approval of the Engineer.
301,3.3. Excavation General All excavations shall he carrie.d
-
out in conformity with the directions laid here’.-in~underand in a manner
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Earthwork, Erosion Control and Drainage Section 300
approved by the Engineer, The work shall be so done that the suitable
materials available from. excavation are satisfactorily utilized as decided
upon beforehand.
While planning or executing excavations, the Contractor shall take
all adequate precautions against soil erosion, water pollution etc. as per
Clause 306, and take appropriate drainage measures to keep the site
free of water in accordance with Clause 3li.
The excavations shall conform to the lines, grades, side slopes and
levels shown on the drawings or as directed by the Engineer. The
Contractor shall not excavate outside the limits of excavation. Subject
to the pennitted 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.
All debris and lose 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 of the
Engineer and the resulting cavities filled with suitable material and
thoroughly compacted in an approved manner..
After excavatior, the sides of excav.ated area shall be trimmed and
the area contoured to minimise erosion and ponding, allowing for natural
drainage to t4ke. place. If trees were removed, new trees shall be planted,
as directed by the Engineer. The cost of planting new trees shall
he deemed to be incidental to the work.
301.3.4, Methods, tools and equipment Only such methods, tools
and. equipment as approved by the Engineer shall be adopted/used in
the work.. If so desired by the Engineer, th..e Contractor shall demonstrate
the efficacy of the. type of equipment to be used before the commencement
of work.
301.3.5. Rock excavation 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 un~
suitable materials are encountered at the fonnation 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 protrude.s above
the specified levels. Rocks and large boulders which are likely to cause
<< 51
Section 300 Earthwork, Erosion Control and Drainage
differential settlement and also local drainage problems should he
removed to the extent of 500 mm below the formation level in full
formation width including drains and cut through the side drains.
Where excavation is done to levels lower than those specified, the
excess excavation shall be made good as per Clauses 3013 3 and 301.6
to the satisfaction of the Engineer.
Slopes in rock cutting shall be finished to uniform lines correspond~
ing to slope lines shown on the drawings or as directed by the Engineer.
Notwithstanding the foregoing, all lose pieces of rock on excavaled
slope surface which move when pierced by a crowbar shall be removed,
Where blasting is to be resorted to, the same shall he carried out
to Clause 302 and all precautions indicated therein observed.
Where presplitting is prescribed to he done for the establishment
of a specified slope in rock excavation, the same shall be carried oUt
to (:latise 303.
3411.3.6. Marsh excavation The excavation of soils from marshes/
swamps shall be carned out as per the programme approved by the
Engineer.
Excavation of marshes shall begin at one end and prot~eedin one
Jirecnun aLEross tIlL’ entire marsh immediately ahead of backhlling. The
method and sequence of excavatin and hackfilling shall he such as to
ensure, to the extent practicable, the complete removal or displacement
of aM muck from within the lateral limits called for on the drawings
or as staked by tlie Eonineer, antI to the botton of the marsh. I’i rm s uppo rt
or levels indicated,
301 J,7, Excavation of road shou lders~verge/medianfor widening
of pavement or providing treated shou lder.s:ln work’s involving
widening of es isting pavements or providing treated shoulders, unless
ot.herwise spel,Eihed the shoulder/s crgc/mcdian shall he renioved to their
full width and to levels shown on drawings or as intlicated by the
Engineer. While doing so, care shall he taken to see that no portion
of the existing pavement designated br retention is loosened or disttirbed,
II’ the existing pavement gets d isttirhed or loosened, it shall he dis mantletl
anrl cut to a regular shape with sides vertical and the. di sttirhed/l oosenetl
portion removed completely and relaid as directed by the Engineer, at
the cost of the Contractor.
301.18. Excavation for surface/sub-surface drains Where the
Contract provides for construction of surface/sub-surface drains to Clause
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:309, excavation for these shall be carried out in proper sequence with
other works as approved by the Engineer.
301.3.9. Slides If slips, slides, over-breaks or subsidence occur
in cuttings during the process of construction, they shall be removed
at the cost of the Contractor as ordered by the Engineer. Adequate
precautions shall be taken to ensure that during construction, the slopes
are not rendered unstable or give rise to recurrent slides after construction.
if finished slopes slide into the roadway subsequently, such slides shall
he ri~mnovedand oaid for at the Contract rate for the class of excavation
involved, provided the. slide.s tire not due to any negligence on the part
of’ the Contractor. The classification of the debris ‘material from the
slips, slides etc. shall conform to its condition at the time of removal
and payment made accordingly regardless of its cOndition earlier.
301.3,10. Dewatering If water is met with in the excavations
due. to springs, seepage, rain., or other causes, it shall he removed
by suitable diversions, pumping or bailing out and the excavation
ke.pt dry whene.ver so required or directed by the. Engineer. Care shall
he taken to ci istEharge the. thai ned water into suitable outlets as ‘not
to cause damage to the works, crops or any other property. Due
to any negligence on the part of the Contractor, if’ any such damage.
is caused, it shall he the. sole responsibility of the Contractor to
re.pair/restore. to the. origtnal condition at his own cost or compensate
(Or the damage.
301.3.11 Disposal of excavated materials All the excavated
-
materials shall be the property cf the Employer. The. material obtained

from the excavation of roadway, shoulders, verges. drains’, cross~
drainage svorks etc.., shall be used for filling up of (i) roatiway emhank~
me.nt, (ii) the. existing pits in the right~of~’wayand (iii) for landscaping
of the road as directed by the Engineer, including levelling and spreadin,g
with all lifts and lead upto 10(X) in and no extra payment shall be
made for the same.
All hard niaterials, such as hard moortim, rubble, etc., not intended
for use as above, shall be stacked neatly on ~peeified land as directe.d
by the Engineer svith all lifts anti lead upto 1000 m.
Unsuitable antI surplus material not intended for use within th.e lead
sçieciiied above .sh.al.l also, if necessary, he transported with all lifLs anti
lead beyond initia.i 1000 m, disposed of or tised as directed by the
Engineer.
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Section 300 Earthwork, Erosion Control and l)rainagc
301,3,12. Backfllling Backfilling of masonry fconcrete/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 thmst on any part of the structure and/or not to cause
differential sett.lement. 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.
301.4, Plying of Construction Traffic
Construction traffic shall not use the cut formation and finished
subgrade without the prior permission of the Engineer. Any damage
arising out of such use shall he made good by the Contractor at his own
expense.
301.5. Preservation of Property
The Contractor shall undertake all reasonable precautions for the
protection and preservation of any or all existing roadside trees, drains,
sewers or. other sub~surface drains, pipes, conduits and any other
structures under or above ground, which may be affected by construction
operations and which, in the opinion of the Engineer, shall be continued
in use without any change. Safety measures taken by the Contractor
in this respect, shall be got approved from the Engineer. However,
if any of these objects is damaged by reason of the Contractor’s
negligence, it shall be replaced or restored to the original condition
at his expense. if the Contractor fails to do so, within the required
time as directed by the Engineer or if, in the opinion of the F ngineer,
the actions initiated by thO Contractor to replacefrestore the damaged
objects are not satisfactory, the Engineer shall arrange the replacement!
restoration directly through any other agency at the risk and cost of
the Contractor after issuing, a prior notice to the effect.
301.6. Preparation of Cut Formation
The cut lormation, which serves as a subgrade, shall be prepare.d
to receive th( sub-base/base course as directed by the Engineer.
Where the material in the suhgracle (that is within 500 mm from
the lowest level of the pavement) has a density less than specified in
Table 300.2, the same shall he loosened to a depth of 500 mm and
e am pacted in layers in accord antEe with the requirenients of CIa use 305
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Earthwork, Erosion Control an,d Drainage Section 300
Any unsuitable material encountered in the subgrade level shall be
removed as directed by the Engineer and replaced with suitable
material compacted in accordance with Clause 305.
in rocky formations, the surface irregularities shall be corrected
and the levels brought up to the specified elevation with granular base
niaterial as’ directed by t.he Engineer, laid and compacted in accordance
with the respective Specifications for these materials, The unsuitable
material shall be disposed of in accordance with Clause 301 .3.11. After
satisfying t.he density requirements, the cut formation shall be prepared
to receive the subbase/base course in accordance with Clauses 310 and
311 to receive the sub-base/base course.
391,7. Finishing Operations
Finishing operations shall include the work of properly shaping and
dressing all excavated surfaces,
When completed, no point on the slopes shall vary from the
de.signated slopes by more than 150 mm measured at right angles to the.
slope., except where excavation is in rock (hard or soft) where no
point shall vary more than 300 mm from the designated slope.. In
no case sEhail any portion of the slope encroach on the roadway.
The finished cut formation shall satisfy the surface tolerances
described in Clause 902.
Where directed, th..e topsoil removed earlier and conserved
(Clauses :301,3,2 and 3053.3) shall be spread over cut slopes, where
feasible, herm.s and other disturbed areas,.. Slopes may be roughened and
moistened slightly, pri.or to the application of topsoil, in order to Provide
satisfactory bond. The depth of topsoil shall be sufficient to sustain plant
growth, the usual thickness being from. 75 mm. to 100 mm.
301,8. Measurements for Payment
Excavation for roadway shall be measured by taking cross-
sections at suitable intervals in the original position before the work
starts and after iLs completion and computing the volumes in cu. m,
by the. method of average end areas for each class of material
encountered, Where it is not feasible to compute volumes by this method
because of erratic location of isolated deposits, the volumes shall he
computed by other accepted methods.
At the option of the Engineer, the Contractor shalt teave. depth
indicators during excavations of such shape and size and in such
.55
<<
positions as direCted so as to indicate the origina] ground level as
accurately as possible. The Contractor shall see that these remain
intact till the final measurements are taken.
For rock excavation, the overburden shall be removed first so that
necessary cross-sections could be taken for measurement. Where cross
sectional measurements could not be taken due to irregular configuration
or where the rock is admixed with other classes of materials, the
volumes shall he computed on the basis of stacks of excavated rubble
after making 35 per cent deduction therefrom, When volumes are
calculated in this manner for excavated material other than rock,
deduction made will be to the extent of 16 per cent of stacked volilimes.
Works involved in the preparation of cut formation shall be measured
in units indicated below
(i) Loosening and recompacdng the ... as. m.
loosened material at subgrade
ii) Loosening and removal of unsuitable as. m.
material and replacing with a
suitable material and compacting
to required density
(iii) Preparing rocky subgrade ...sq. m.
(iv) Stripping including storing and ... cu. m.
reapplication of topsoil
(v) Disposal of surplus material ... cu. m.
heyood initial I 000 ns lead
301.9. Rates
301,91. The Contract unit rates for the items of roadway and drain
excavation shall he payment in full for carrying out the operations
required for the individual items including full compensation for
(i) selling out;
(ii) transporting the excavated materials and depositing the same on sites of
embankment,, spoil banks or stacking as directed within att lifts and lead upto
t000 m or as otherwise specified;
(in) trimming bottoms antI slopes of excavation;
(iv) dewatering;
~v) keeping the work free of water as per clause 3tl; and
(vi) all labour, materials, tools, equipment, safety measures, testing and incidentats nec~
cssary to complete the work to Specifications.
Provided, however, where presplitting is prescribed to achieve a
<< 56
~pecifledslope in rock excavation, the same shall be paid for vide Clause
3015.
3019.2. The Contract unit rate for loosening and recompacting
the loosened materials at subgrade shall include full compensation for
ioosenmg to the specified depth, including breaking clods, spreading in
layers, watering where necessary and compacting to the requirements.
301.93. Clauses 301.9.1 and 305.8 shall apply as regards Contract
unit. rate for item of removal of unsuitable material and replacement
with suitable material respectively.
301.9.4. The Contract unit rate for item of preparing rocky suhgrade
as per Clause 301.6 shall be full compensation for providing, laying and
compacting granular base material for correcting surface irregularities
including all materials, labour and incidentals necessary to complete
the work and all leads and lifts.
301.93. The Contract unit rate for the items of stripping and storing
topsoil and of reapplication of topsoil shall include full compensation
for all the necessary operations including all lifts, hut leads upto 1000
m
301,9.6. The Contract unit rate for disposal of surplus earth from
roadway and drain excavation shall be full compensation for all labour,
equipment, tools and incidentals necessary on account of the additional
haul or transportation involved beyond the initial lead of 1000 m.
302. BLASTING OPERATIONS
302.1. General
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.
The Contractor may adopt any method or methods of blasting
cons’istent with the safety and job requirements. Prior to starting any phase
of the operation the Contractor shall provide information describing
pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the.
designs and specifications of the Explosives Department concerned and
located at the~approved site. No unauthorized person shall be admitted.
<< 57
Sec ion .300 Earthwork, Erosion Ccmtrol and Drainage
into the magazine which when not in use shall be kept securely
locked, No matches or inflammable material shall be allowed in the
magazine. The magazine shall have an effective lighlning conductor
The following shall be hung in the lobby of the magazine:
(a) A copy of the relevant niles regarding safe storage hot.h itt English and in the
language with which the workers coneented are familiar.
(0) A statement of up••to~datestock sn the maga~inc
(c) A certificate showing the lass slate of testing of the lightning conductor.
(to A notice that smok irtg is strictly proh hued.
All explosives shall be stored in a secure manner in cotnpliance with

all laws and ordinances, and all such storage places shall he clearly
marked. Where no local laws or ordinances apply, storage shall he
provided to the satisfaction of the Engineer anti in general not closer
than 3PP in from the road or from any building or camping area or
place of human occupancy. In addition to these, the Contractor shall
al so observe the following instructions and any itt Iher additional
instructions s~’hich may he given by the En e, ineer and shall be responsible
for damage to property and tiny aecidetit which may occur to workrtien
or the public on account of any operations connected with the storage,
itandlitig or use of explosives ard blasting, The Engineer shall frequently
check the Contractor’s compliance with these precautions.
302,2. Materials, Tools and Equipment
All the materials, tools and equipment used for blasting operations
shall be of approved type. The, Engineer may specify the type of
explosives to be allowed in special cases The fuse to be used in wet
locations shall he. sufficiently water-resistant as to he unaffected when
immersed in water for 30 minutes. The Tate of burning of the fuse
shall be ttniibrm and definitely known to permit such a length being
.
cut as will permit sti fficient time to the firer to reach safety before
explosion takes place. Ce,tonators shall he capable of giving effective
blasting of the explosives. The blasting po~vder,explosives, detonators,
fuses, etc., shall be fresh and not damaged due t.o dampness, moisture
or any other cause, They shall be inspected before use and damaged
articles shall be discarded totally a.i~dremoved from the site imrn cr1 iately.
3023. Personnel
The blasting operation shall remain in the charge of competent and
c ‘iperienced supervisor and workmen who are thoroughly acquainted ivi th
the details of hartdl ing explosives and blasting Operations,
<< 58
302,4.. Blasting Operations

Th..e blasting shall be carried out during fixed hours of the day
preferably during the mid-day luncheon hour or at the close of the
work as ordered in writing by the Engineer. The hours shall be made
known to the people in the vicinity. All the charges shall be. prepared
by the man in charge only,
The Contractor shall notify each public utility company having struc-
ture.s in proximity to the site of the work of his intention to use
explosEives. Such notice shall be given sufficiently in advance to enable
the companie.s to take such steps as they may deem necessary to protect
their property from injury. In advance of any blasting work within
50 m of any railway track or structures, the Contractor shall notify
the. concerned Railway Authority of the location, dale., time. and
approximate duration of such blasting operations.
Red danger flags shall be displayed prominently in all directions.
during, the blasting operations. The flags shall be planted 200 m from
the blasting site in all dire,ctions. People, except those who actually light
the fuse, shall he prohibited from entering this area, and ill persons
including workmen shall he excluded from the flagged area at least
10 minutes be.fore the firing, a warning siren being sounded lot the.
purpose,
The charge hoic.s shall be drilled to required depths and at suitable
places. Blasting should be as light as possible consistent with t.horough
breakage of the material necessary for economic loading and hauling.
Any method of blasting which leads to overshooting shall be discon-
tinued.
When blasting is done with powder, the fuse cut to the required length
shall he inserted into the hole and the. powder dropped in. The powder
shall be. gently tamped with copper rods with rounded ends. The explo.sivc.
POwder shall then be covered with tamping material which shall be
tarnped lightly but firmly.
When blasting is done with dynamite and other hig.h explosives, dy-
namite cartridges shall be prepared by inserting the square cut end of
a fuse. mb the de.ton ator and finishing it with nippers at tine opc.tn entl,
line. dc.tonatnr gently pushed into the primer leaving 1/3rd of the coppe.r
tube expose.d outside. The paper of the cartridge shall then he clc.se.d
up anti securely bound with wire or twine. Th..e primer shall be. housr.d.
into the explosive.. Boreholes shall be of such size that the cartridge
can easily g.n down. The. holes shall be cleared of all debris and
<< 59
Scetiort 300 Earthwork, Erosion Control and Drainage
esplosmve inserted. The space of about 200 mmn above the charge shall
then be gently filled with dry clay, pressed home and the rest of the
tamping fOrmed of any convenient material gently packed with a wooden
rammer,
At a time, not more than 10 such charges will be. prepared and
iircd. The man in charge shall blow a siren in a recognised manner
for cautioning the people. All the people. shall then he required to move.
to safe dIstances. The charges shall be lighied by the man~in-chargeonly,
The man-in-charge shall count the number of explosions. He shall satisfy
hint selF that all the charges have been exploded before allowing the
workmen 1.0 go hack to the work site,
Alter blasting operations, the Contractor shall compact the loose re-
Si LI ttal
material below suhgrade a.nd replace the material removeti
below stmbgrade with suitable materiaL
302.5. Misfire
In cast’ of misfire, the following procedure shall he observedE
.Suiiieietit tune shall he alloaed to account for the delayed blast, The man—in—
~bsrge shall inspect all the charges and dctenttine the missed c:harge
l~ii~II it is rho hlastin
1.; powder charge, it shall he completely flooded with water
ness Fr ~le shall he drilled at about ~i5tl trios from the old hole and fired. This
should lrlasr the ,‘ld charge. Should I I trot hIatt the old charge, the procedure
shall ho repeated till the old charge is hlr.tstect
11 i lit 5451’ ol ehirges of geltynire, dynamite, etc., the man-itt—charge shall gently
rr’nrs’ve the tamping and the primer with the detortator A frssh detonator and
u mrr shall then he used to blast the charge. Altsrnattvely, the hole may hre
I eared of 10(1 mm of tarrrprng and the drreetisrrr Llten ascertained by p1wittg
a strel. itt the hole. Anorlrer hole rrr.rs their he drilled t 50mm away ,snd parallel
or it ibis hole shtall then he ettarged and fired when thte to isfired hole shoe Id
explede.at the same time. ‘fire man-rn-c barge shall at ortec report to the
our r,setor’ s office artd the Fnrtineer all eases of misfire, the ccrrrse of the sarrrs
and ahat steps were taken in ronrreetron therewith.
If a at t sloe has been fOund to he due to defective detonator or
ilyrnatlirle, the whole quantity in the box from which defective article
‘was taken must be sent to the authority directed by the Engineer fur
inspect ion 10 ascertain whether all the remaining materials in the box
are also defective,
302.6. Account
A cLu’eful and day to day account of the explosive shall he maintained
lr~y the Con I racior in an approved register and manner which shall he
ripe a to inspect ion by the Engineer at all times.
<<
60
“‘303. PRESPLITTING ROCK EXCAVATION SLOPES
303.1. General
Presplitting is defined as the establishment of a specified excavation
slope in rock by the controlled use of explosives and blasting
accessories in properly aligned and spaced drill holes.
The presplitting technique shall be used for forming rock excavation
slopes at locations shown on the plans or as otherwise decided by the
Engineer,
Prior to starting drilling operations for presplitting, the Contractor
sha.I I furnish the Engineer a plan outlining the position of all drill holes,
i:iepth of drilli rig, type of explosives to be used, loading pattern and
seque rtce of Firing. The drilling and blasting plan is. for record purposes
only and will not absolve the Contractor of his responsibility for using
proper drilling and blasting procedures. Controlled blasting shall begin
with a short test section of a length approved by the Engin.eer The.
test sEectiorr shall he presplit, production drilled and blasted and suflTrc. ient
mate. naI excavated svia’i. reby the Engineer can deier.mn me, if the Contrac -
tor’ s methods have produced a.n acceptable slope.

All overburden soil and weathered. rock along the top of the
r,.~..xeavatinn for a distance of about 5 to 15 rn beyond the. drillirrg limits, -
or to the iEm.d of the excavation, as decided by Engineer shall be removed

belor.e drilling the prespliwng holes, Particular care and attention sEhaII
he di recEted to the beginning and end of excavations to ensure complete.
removal of all overburden sod and we.athere.d rock and to expose I resEh
rock to an elevation equal to the bottom of the adjacent lift of the.
lwesplittimtg holes being drilled,
S lope. holes for presplitting shall he drilled along the lin.e of the
planned slope within the specified tolerances, The drill holes shall
be not less than 60 mm nor more. than 75 mm in diameter, Drilling
opera.uotts shall be controlled by the use of proper equipment arldl
tech muque to ensure. that no hole shall deviate from the plane of the
plan neil slope by more. than 300 mm nor shall any hole deviate from
being parallel to an adjacent hole by more than two~third of the.
planned horizontal spacing between holes.
The length of presplit holes for any individual lift shall not excee.d
9 ni.
61
<<
Srction 300 Eanhwork, Erosion Control and Drainage
The spacing of presplit holes shall not exceed 900 mm on centres

and shall be adj usted to result in a uniform shear face between holes -
Auxiliary drill holes along the presplit line, not loaded or stemmed,
may be ordered by the Engineer. Except for spacing, auxiliary drill holes
shall conform to the provisions for presplit holes.
The line of production holes shall be placed inside the presplit
lines in such a manner as to avoid damage to the presplit face.
If necessary, to reduce shatter and overbreak of the presplit surface,
the first line of the production holes shall be drilled parallel to
the slope line at the top of the cut and at each bench level thereafter,
Any blasting technique, which results in damage to the presplit
surface, shall be immediately discontinued,
No portion of any production hole shall be drilled within 2.5 ni
of a pm’esplit plane except as approved by the Engineer. The bottom
of the production holes shall not be lower than the bottotu of the presplit
holes,
A u’taximum offset of 600 mm will he permitted for a construction
workiog bench at the bottom of each lift for use in drilling the next
IO\5dr presplitting pattern. The dlrilling operations shall be adjusted to
corn perrsate for drift of previous levels and for the offset at the start
of new levels to maintain the specified slope plane.
‘rhe maximum diameter of explosives used in presplit holes shall
not be greater than one-half the diameter of the presplit hole,
Only standard cartridge explosives prepared and packaged by explosive
otaoufacturing firms shall be used in presplit holes, These shall he fired
as roconimcndccl by the manufacturer, Ammonium nitrate composition
blasting agents will not be permitted in presplitting operations.
Stemming may be required to achieve a satisfactory presplit face.
Stemming material shall be dry free-running material all of which passes
II mm sieve and 90 per cent of which is retained on 2.80 mm sieve,
Stemnmned presplit holes shall be completely filled to the collar,
All charges in each presplitting pattern shall be detonated simul—
tarteously,
303.3. Tolerances
The presplit face shall not deviate more than 300 mm from the plane
passing through adjacent drill holes, except where the character of the
<< 62
rock is such that, as determined by the Engineer, irregularities are

unavoidable, When completed, the average plane of the slopes shall
confbrnt to the slopes indicated on the plans and no point on the
cumpleted slopes shall vary from the designated slopes by more than
300 mm. These tolerances shall be measured perpendicular to the plane
of the slope. En no case shall any portion of the slope encroach on
the side drains.
As long as equally satisfactory presplit slopes are obtained, then
either the. slope face may be presplit before drilling for production
blasting or presplitting the slope face and production blasting may
he done. at the same time, provided that the presplitting drill holes
are fired with zero delay and the production holes are delayed starting
ai the row of holes farthest from the slope and progressing in steps
to the row of holes nearest the presplit line, which row shall he delayed
at least 50 milliseconds, In either case the presplitting holes shall
exteod either to the end of the excavation or for a distance of not
less than IS m beyond the limn its of the production holes to be detonated,
The area of prespli tting to be paid for will be mneasured as sq uare
nietres of acceptable presplit slope surface.
303.5. Rates
The Contract unit rate for presplitting ~vork shall be payntteot 0
full for carrying out the required operations for obtaining acceptable
presplit slope surfaces, The qttantity of rock excavated through the
product on/presplit holes shall be paid for as pen’ Clause 301,9,1.
304. EXCAVATION FOR STRUCTURES
304.1. Scope
Excavatiumn for structures shall consist of the removal of n-iaterial
for the constrtic tiun of fotmdations for bridges, c nI verts, retaining walls,
headwalls, cutoff walls, pipe culverts and other similar structures, in
accordance with the requirements of these Specifications and the lines
and dimnensions shown on the drawings or as indicated by the Engineer.
The work shall include construction of the necessary cofferdams and cribs
and their suhseqtnent remnoval; all necessary sheeting, shoring, bracing,
draining and pumping; the removal of all logs, stumps, gnihs and other
deleterious niatler and obstructions, necessary for placing the foundations;
trimmning bottoms of excavations; hackfilling and clearing up the site
and the disposal of all surplus material.
<< 61
304.2. Classification or Excavation
All materials involved in excavation shall be classified in accordance
with Clause 301.2.
304,3.1. Setting out A.fter the site has been cleared according
to Clause 201, the limits of excavation shall be set out true to lines,
curves and slopes to Clause 301.3.1.
304.3.2, Excavation Excavation shall be taken to the width of
t,he. lowest step of the footing and the sides shall be left plunib where
the nature of soil allows it. Where the nature of soil or the depth of
the trench and season of the year do not perat.it vertical sides, the
Contractor at his own expense shall put up necessary shoring,
strutting and planking or cut slopes to a safer angle or both with due
regard to the safety of personnel aqd works and to the satisfaction of
the Engineer.
The depth to which the excavation is to be carried out shall be as
shown on the drawings, unless the type of material encountered is such
a.s to require changes, in which ease the depth shall be as ordere.d
by the Engineer. Propping shall be -undertaken when any foundation
or stresse.d zone from an adjoining structure is within a line ol 1 vertica,l
to 2. horizontal from the. bottom of the excavation,
Where. blasting is to he resorted to, the same shall he carried out
in accordance with Clause 302 and all precautions indicated therein
ohserved, Where. blastitig is likely to endanger adjoining foundations
or other structures, necessary precautions such as controlled blasting,
providing rubber mat cover to prevent flying of debris etc, shall he.
taken to prevent any damage.
304.3.3. Dewatéring and protection Normally, open foundations
shall he laid dry. Where water is met with in excavation due to stream
flow, seepa.ge, springs, rain or other reasons, the Contractor shall take
adequate measures such as hailing, pumping, constructing diversion
channels, drainage channels, bunds, depression of water level by welh
point system, cofferdarns and other necessary’ works to keep the
loundation trenches dry when so required and to protect the green
concrete/masonry against damage by erosion or sudden rising of ~iaLer
level. The methods to be adopted in this regard and other details
thereof shall be left to the choice of the Contractor but subject to
approval of the Engineer. Approval of the Engineer shall, however, not
64
<<
dii: cii nijr;:tiE.ior o[ i,hc respt.r fl ,:irhiirii’y For
tie or
Lire. reduircEd. t.hflsr shall Lie LEa rr
dc ILLnIE’d arid (‘ii rsti’’iictid MiLl Ii.: inalEle EE’L’ ;
is neces’cEa”y l:’nr facilitatinu, construction tc.i ha carried
of the cofh::rrdarn’~ shall he suirEh as
for thi corOnictieri sni:i irirspr’;.” toni and
el i(’i.iLn’i~riny equ.rpincno. ccc.., nude
it dcterminedbeLirchrindt th:.u the.’ l’aiiriidatio ns ~uEisitoit

i.’~ friand that the peri:Erihieon too
the hmndat.iori iE.oncriEtesl’iEill hr
In case of floycine ‘aater or .uEteslan sprines, the
‘c’ siuppe’.F or redi.iiEiE’Li as Far as possible’ Eli the Lint’: of
iii: iEViIiEEi’EE.tir,
any i.iLiridation eneir’rs~iri’‘iFoill F’cdrine
iii f’rri.E’EEttide t.h~’.E’ [Eii.ii;:’:iFiititY
IEEPF 1..FiiE: T’lt’i’~’~.niiiEi’ii‘Ed
eonerc.rte. No phlaipiliii shall be permitted derin,i:r
‘Ed EEiI]rr rL’F(’ or for a,nv ju~riodolaF least 24 hon rs thereafc.r.,
;s ii. is i,loiic: fire i’i’’i ri’~~tiit’tiih’
st.iniip separated fruni tI’te IE:’lencr.:t.’.:’
IF a watertlh.lht watt ‘.ir odier simdar rrlcatris.
AL the discretion oF the Contractor, cerrtent i.çroutmng or other
piire%’ell nicrthods may he used to prevent or reduce seepEipe L:ind
to ][l’rotirc i the exiEEal’atic’lil area.
‘rh.. ContractiErr shall t~.tki:rall precautions in diverting channels Lind
in dischareine; the drainei:i wati:~ras FlOt to cause damage to the sr i:rks.,
crops or arty other property.
.304.3.4. Preparation of toundahon The bouorn of the bEiundatirirl
IiI I hi.:r Fe. i.’elled blEith longitudinally art ii transversely or s tepperl L.ts
iliri:LctciEi by the hngini:~er. Be..lore looting is laid, the surface shalt be
si htly watered amid ramined., in the event ot excavation having been
cc per th ~.trithat shown on the draw ings or as otherwise ordcrei:l
by the Engineer, the extra depth shall he made tip with concrete
or nr asonry of the fotmn dation at the cost of the Contractor as per Clause
2104. i. Orrhnary lilling shall not he used for the purpose to hring the
fortndat inn to level.
\\rhctrt rock or other hard strata is encountered, it shall he freed
<< 65
Section 3t~.t Earthwork, Erosion Control and Drainage.
of all soft and loose material., cleaned and cut to a firm surface either
level and stepped as directed by the Engineer, All seams shall be cleaned
out and filled with cement mortar or grout to the satisfaction of the
Engineer. In the case of excavation in rock, annular space around footing
shall be filled with lean concrete (1:3:6 nominal mix) upto the top level
of rock.
If the depth of fill required is more than I .5m above the top of
the footing, filling upto 1.5m above top of footing shall be done with
lean concrete (1:3:6 nominal mix) followed by boulders grouted with
cement.
When foundation piles are used, the excavation of each pit shall
be substantially completed before beginning pile-driving operations
therein. After pile driving operations in a given pit are completed, all
loose and displaced materials therein shall be removed to the elevation
of the bottom of the footings.
304.3.5. Slips and slip-outs : If there are any slips or slip-outs in
the excavation, these shall be removed by the Contractor at his own
cost.
3Q4.3.6. Public safety : Near towns, villages and all frequented
places, trenches and foundation pits shall be securely fenced,
provided with proper caution signs and marked with red lights at night
to avoid accidents. Tha Contractor shall take adequate protective
measures to see that the excavation operations do not affect or damage
adjoining structures. For safety precautions, guidance may be taken
from IS : 3764.
304.3.7. Backfilling : Backfilling shall be done with approved
material after concrete or masonry is fully set and carried Out in such
a way as not to cause undue thrust on any part of the structure. All
space between foundation masonry or concrete and the sides of excavation
shall be refilled to the original surface in.. layers not exceeding 150
mm compacted thickness. The compaction shall be done with the help
of suitable equipment such as mechanical tamper, rammer, plate vibrator
etc., after necessary watering, so as to achieve a density not less than
the field density before excavation.
304.3.8. Disposal of surplus excavated materials: Clause 301.3.11
shalL apply. -

Excavation for structures shall be measured in cu. m. for each class
66
<<
of material encountered, limited to the dimensions shown on the drawings

or as directed by the Engineer. Excavation over increased width, cutting
of slopes, shoring, shuttering and planking shall be deemed as conven-
ience for the Contractor in executing the work and shall not be measured
and paid for separately.
Preparation of rock foundation shall be measured iti square metres.
Foundation sealing, dewatering, including pumping shall be deemed
to be incidental to the work unless separate provision is made for in
the ContracL In the latter case, payment shall be on lumpsum basis as
provided in the Bill of Quantities.
304.5. Rates
304,5.1. The Contract unit rate for the items of excavation for
structures shall be payment in full for carrying out the required
operations including full compensation for
(i) setting out;
(ii) construction of necessary cofferdams, cribs, sheeting, shoring and bracing and their
subsequent removal;
(iii) removal ofalt togs, stumps, grubs and other deleterious matter and obstructions,
for placing the foundations including trimming of bottoms of excavations;
(iv) fotmdation sealing, dewatering including pimping when no separate provision for
it is made in the Contract;
(v) backfilling, clearing up the site and disposal of all surplus material within all lifts
and leads upto 1000 m or as otherwise specified; and
(vi) alt labour, materials, tools, equipment, safety measures, diversion of traffic and
incidentals necessary to complete the work to Specification.
304.5.2. The Contract unit rate for preparation of rock foundation
shall be fufl compensation for cutting, trimming and cleaning the
foundation surface and filling/sealing of all seams with cement grout
or mortar including all materials, labour and incidentals required for
completing the work.
304.5.3. The Contract unit rate for transporting material from the
excavation for structures shall be full compensation for all labour, equip-
ment, tools and incidentals necessary on account of the additional
haul or transportation involved beyond the initial lead of 1000 m.
305. EMBANKMENT CONSTRUCTION
305.1. General
305.1.1. Description : These Specifications shall apply to the
construction of embankments including subgrades, earthen shoulders and
67
<<
Sect ion 300 Earthwork, Erosion Control and Drainage
miscellaneous hack fills with approved material obtained from roadway
and drain excavation, borrow pits or other sources. All embarikment.s,
suhgrades, earthen shoulders and miscellaneous hackfills shall he con-
structed 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.
305.2. Materials and General Requirements
305.21. Physical requirements:
305,21.!. The materials used in emhankments, subgrades, earthen
•;houlders and miscellaneous backfills shall he soil, moorum, gravel, a
nttxture of these or any other material approved by the Engineer. Such
materials shall be free of logs, stumps, roots, rubbish or any other
Lngredient likely to deteriorate or affect the stability of the embankment!
subg rade.
The following types of material shall be considered unsuitable for
embankment:
(a) Materials from swamps, marshes and bogs;
(h) Peat, log, stump and pedshable material; any soil that classifies as 01., 01,
Oti or Pt in accordance with IS 1498;
Cc Materials susceptible to spontaneous combustion;
Cd Materials in a frozen conditioss;
Clay having liquid limit eacceding 70 and plasticity index exceeding 45 and
(11 Materials wills salts resulting in leaching in thc embankment.
305.2.1.2, Expansive clay exhibiting marked swell and shrinkage

properties (“free swelling index” exceeding 50 per cent when tested as
per IS’: 2720 Part 40) shall not be used as a fill material. Where
-
an expansive clay with acceptable “free swelling index” value is used

as a till material, suhgrade and top 5(X) mm portion of the embankment
just below subgrade shall be non-expansive in nature.
305.2.1.3. Any fill material with a soluble sulphate content exceeding
1.9 grams of sulphate (expressed as SOS) per litre when tested in
accordance with 55 : 1377 Test 10, but using a 2:1 water-soil ratio
shall not be deposited within 500 mm or other distance described in
the Contract, of concrete, cement bound materials or other cementitious
materials forming part of the Permanent Works.
Materials with a total sulphate content (expressed as SO3) exceeding
0.5 per cent by mass, when tested in accordance with BS : 1377 Test
<< 68
]~5~ Fxosion Control and Drainage Section 3(X)
shall not be deposited within 500 mm, or other distances described

itt the~Contract, of metallic items forming part of the Permanent Works,
305,2.1,4. The size of the coarse material in the mixture of earth
ill c~id nan ft ttol exceed 75 mm when he int; placed in the embank tnert
i
and. 50 rnni when placed in the suhgrade. However, the Engineer may
hi discretion Permit the use of maieriai coarser than this also if he
:‘Eltts [tedthat the same will not present any difficulty as regards the
I a:.: EE tit Itt of fill material and its compactton to the requirements of
: ~pecifi,caiions, ‘the maximum particle siie shall not he more than
‘c ~ ii nil
i I I he compacted layer thickness.
305. 2,1.5. OrcI manly, ortly the materials sEatisfying the density
‘c ~i ttten U; g iv ert mn Table 3(X)—i shall be employed for the construct]on
te e nit bank men t and the subgrade.
id liL 300 I. IE)ENSt1’Y REQI,IRESIFNTS’ OF KMBASKME%T ANt)
SUBGRADE MATERIALS
si[ SYsirk Maxinsum I aborsstory dry ssntt weight wEt eti

tested as per IS: 2T20 (Part S~
‘‘.‘i]:”’,]K.srH nts tip to 3 metres Net tess th:sts 15.2 kNCcti m,

flit si.ibjec.tirit to
Itoso li it g.
ii.. e’,cei’dirsr, Net less than 16.0 kN/cti, en.

srntsanksiettts
is lit s tihtec’t to
t
eli irmndatiort
md eari.hcn Not tess tts3n t7.5 kS/eu. en.

‘ii lie t.i/i’er5e (ls,sckfil
H (1 0’ it t’:.iltle is net applicable for lightweight fill sssateciat e.g cinder, ft~ash
‘[he Ertc sneer etemy relax these rel:Iutrclments at his disc retton taking into account
I
its exists Lilsi lit

5 stE materials for cssitsrnsctton sand other relevant itsce~srs.
i
is he used in tat:mgraste slsststld also satisfy design dEeR at diii

1.115 ILtOLt wetg,ht apptt cable as ~ Tatsle 300’Z,
.305,2,2 General requirements

395,23,1, The tnaterials for embankment shall he obtained froni ap-
“ratieliEl source.’; vs ith preference given to materials becoming available
it nearby road way excavation or any other excavation under the satne
It ir;Etet.
69
<<
- as--- - -.

The work shall be so planned and executed that the best available
materials are saved for the subgrade and the embankment portion just
below the subgrade.
305.2,2.2. Borrow materials Where the materials are to be
obtained from designated borrow areas, the location, size and shape of
these areas shall be as indicated by the Engineer and the same shall
not be opened without his written permission. Where specific borrow
areas are not designated by the Employer/the Engineer, arrangement for
locating the source of supply of material for embankment and subgrade
as well as compliance to environmental requirements in respect of
excavation and borrow areas as stipulated, from time to time by the
Ministry of Environment and Forests, Government of India and the local
bodies, as applicable, shall be the sole responsibility of the Contractor.
Borrowpits along the road shall be discouraged. If permitted by the
Engineer, these shall not be dug continuously. Ridges of not less than
8 m width should be left at intervals not exceeding 300 m. Small drains
shall be cut through the ridges to facilitate drainage. The depth of
the pits shall be so regulated that their bottom does not cut an imaginary
line having a slope of 1 vertical to 4 horizontal projected from the
edge of the final section of the bank, the maximum depth in any case
being limited to 1.5 m. Also, no pit shall be dug within the offset width
from the toe of the embankment required as per the consideration of
stability with a minimum width of 10 m.
Haulage of material to embankments or other areas of fill shall
proceed only when sufficient spreading and compaction plant is operating
at the place of deposition.
No excavated acceptable material other than surplus to requirements
of the Contract shall be removed from the site. Should the Contractor
be permitted to remove acceptable material from the site to suit his
operational procedure, then he shall make good any consequent deficit
of material arising therefrom.
Where the excavation reveals a combination of acceptable and un-
acceptable materials, the Contractor shall, unless otherwise agreed by
the Engineer, carry out the excavation in such a manner that the
acceptable materials are excavated separately for use in the permanent
works without contamination by the unacccptable materials. The
acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the
<< 70
Earthwork, E~sionControl and l)rainage Section 300
stability of excavation or fills by the methods of stockpiling materials,
use of plants or siting of temporary buildings or structures.
The Contractor shall obtain representative samples from each of the
identified borrow areas and have these tested at the site laboratory
following a testing programme approved by the Engineer. It shall be
ensured that the subgrade material when compacted to the density
requirements as in Table 300-2 shall yield the design CBR value of
the subgrade.
TABLE 300-2. COMPACTION REQUIREMENTS FOR EMBANKMENT
AND SUIGRADE
Type of work! material R~iativecompaction as percentage

of max. laboratory dry density as
per IS: 2720 (Part 8).
1, Subgrade and earthen shoulders Not less than 97
2. Embankment Not less than 95
3. Ex pansive Clays
a) Subgrade and 500 mm Not allowed
portion just below
the subgrade
b) Remaining portion Not less than 90
of embankment
The Contractor shall at least 7 working days before commencement
of compaction submit the following to the Engineer for approval:
(i) The values of maximum thy density and optimum moisture content obtained
in accordance with IS: 2720 (Part 7) or (Part 8), as the case may be, appropriate
for each of the fill materials he intends to~use
(ii) A graph of density plotted against moisture content from which each of the
values in (I) above of maximum dry density and optimum moisture content were
determined.
(iii) The Dry density-moisture content .CBR relationships for light, intermediate and
heavy compactive efforts (light corresponding to IS: 2720 (Part 7), heavy
corresponding to IS: 2720 (Part 8) and intermediate in-between the two) for
each of the fill materials he intends to use in the subgrade.
Once the above information has been approved by the Engineer,

it shall form the basis for compaction.
305.3.1. Setting out : After the site has been cleared to Clause
201, the work shall be set out to Clause 301.3.1. The limits of
embankment/subgrade shall be marked by fixing batter pegs on both
sides at regular intervals as guides before commencing the earthwork.
The embankmenl/subgrade shall be built sufficiently wider than the
<< 71
Sec kit 300 Earthwork, Erqsion Control and Drainage
ilesign dimensnan so that surplus material may be trimmed, ensuring
chat the remaining material is to the desired density and in position
speci fled and conforms to the specified side slopes.
305.3,2. Dewatering lithe foundation of the embankment is in
an urea with stagnant water and in the op in ion of the i...ngineer it
is Feasible to remove it, the same shall he removed by bailing out or
p1: m pin oi~ di reetci I by the En gineer and the area of the embankment
II nil at ion hull be k:ept dry. Care shall be taken to d ~scharge the
ic.att”r so niL 10 cause daniac 10 the works, crops or any
ci’ property. [)i ie 0 any negligence on the part of the Contractor,
nucEh iI1ifl1aL~E’ LEalised, it shall be the sole responsih~Iityol the
?“~
1 IC’ re]pair/I”estore U to e.rkEEinal condition or compensate

LiL1flW~c ii, his own COSt.
LI’Ii,” LEmi:mnkrnent B5 10 be eIE)nsL.rueted under water, Clause
.0115 ,.:t .3. Sir ~ pmg and storing topsoil In localities where 010.”.I.
‘ ‘ ‘~.‘,I IELHe eI’l]LIE’llkalcIlnent materials are net conducive to plant growth.
1
the bng:ne.ei”, chc Lopsoil from all areas of

[ii ‘In all ...e’eas to be covered by ernhankntent leundaLion
I”’ ..;irIl{’P
15~...I IrL, ..r]:’lc’I.Eiiielt depths not exr:Eecd~ng i50 mm and .stored
III .“~1...r’..:sp1ler’; ‘1 ‘csr.Eeecllllll 2 i’ti for covering enthankrnent

~L’lhi’It I’’Iitt
‘..iIt IE’rther I:E1i1’ltul’lEncLl ~li’e.1Et1r;‘‘~h~rrct re~vef1et.ittieIn iS
‘~,lI:r(rL:’’~. and
be c.nn,Erce.ssarlis LralfilEEkc.d either bIEIIL1rL1
hen iii, i stol::Ekpile. StoehpillEls shall not he suicharged or
eI’El multiple hanr.ilinft,L.!, shall be kept to a minimum.
.1~115.3.4. Cr.im~wetingi~rourirlso pporting embankment/subgradeE

‘.~l,.D,..’,”;’ nEce~sEtr”’. thcr e’riginal grourul :;hall be levelled tiEl Facilitate
hr~~~i IdyLl” of cmhanl’anent sLE1uEiI’iI::ld, tnned with waler’
.irr~lthen LEI:inipacted by rollIng ~ a~.te’ ~:ti:hieve:‘ninirnum dry densitl,
spvcn ut Table 1001..
l]llr~,,E’,.o:r,:1, ~ltere (he dilferenee between the suhc;rade level (top of the
‘.~vibrradeOil which pi.tvement rests t and ground level is less, than U.S
round dc.ie.s not have 97 per cent relative compaction
It rlEi,”i pr..~cI
1.~ic’ li.iosened ri ihLJpLIE1‘Ar’,’it level
density
0.5asrn given
below intheTable 30O~2,the
subgrade ground
level, wateretEl
all ii LEcU It piaEted mu I ayers in aciEEordance witl’t Clauses 305,3.5 and 3053.6
i
I ‘El riot less than 97 per cent of’ dry dens,ity as given in Talle 300—2.
“A’ lucre. so directed by the Engineer, any unsuitable material occurring
7,
<<
h.Lrth’l’~IITk , E.,r1”lS’ik,T’I I:EOil trot and l)rainage Secliorl .itx:
,in the ent haru k n’ue n t foundation shall he removed and replaced by
approve il irtaterials lairl in layers to the required degree of compaction.
n’tban k.rtie n t or’ sEubgrade work shall not proceed until the fouttdttt~
tons fur ‘sin bank men lJsuhg rrtde have he.eit inspected by tltc Engineer
‘er ‘Lau.i sl:LIIE liEtry i:nttd itiOn and approved.
undati on tre attnent specified for crnhankments especially high
Fri
re’ittny on suspect foundations as revealed by horchole

sha ll’h’e LEarned out iru a rrtanne.r and to the depth as desinsd by
the entElund t:tn ~, hich ait emhankmnent is to he huilt
at’ cr1 IfI~’..’ .Erts.Fte.I tel types ía.) to (I.) in Clause 3052.1, at least 500
inasi be rerrioved and replaced by aceclE’Lthlc
~atEbrinkntentconstruction comnlencrt,s,
~pr eri,r.ling material itt layers and bringing to apprn.
1iritittr moisture content
‘‘.‘h,,.’: enil.tattkment tori subgrade material “rhail be spread
teirierat thic’Lness nut ‘~.Etxceeding 200 rout cnittpa~.Er...d
Hi Eli.. ~‘ i’’. ‘c ihe .Eotire t’r’trlth tO’ i::attl:tattkntent hy mecl’taruurEal incas.’,;,
smiler ,,trti eantpacted as’ per Clause 305J.fa The
have lty’..lrauiic control suitable. ion
sattt~,Esc’asto achieve the speed le t.~l’:.:tpc
i.e er’~~. “Thahl itctt be placed until the Layer
. .j~~’q e,t,..tL.’~, Ftu... h’sLtt Lhr’lrt’ugitl5’ compacted to dir:’ s
.5 ..‘t’tI” tI ttt L,.’F”ie 1001 curl cot approved by the Engineer. built
ted tsr ‘.hail lttE litttsl,ed p.rallel 10 the final cruss~s’t:’.,EELirt!t
ii’ “ . i~I Ku,
Er .51. \ir.ti.t.tI.Jt:L.’ crtttl,etE,i, of the rttal.eriai shall he checked Ert
Ito
to tEontrttcnce.t’neot of compaction; if fr:’aud tsr
‘‘iL .0 cc rr”:’’H l,,ttets, the satttiEr .‘rltall h’e made good. Wltere water’
is’ Os .,trlLlrEri in sttch rEr.lrtstrutEtLons, water shall he. sprinkled
‘t,tti.:er f;ttcd ‘.t’it.h sprinkler capable of applying
‘F, ‘:n lv “.‘r’Ltlt a sun crollahie rate of flow’ to variable widths’ of sunia:e
an, fleer’.:Iin,e,. The water shall he added unifbn’nly arid
: ml:’, eti use, I hy hiading, disc inc or harrowing until a uotf’onn
“,:‘..IJt’tE
H s.c eut ‘ d.tlE,tained tltrottghottt. the depth of’ the la’,,”er.
‘.
U titt’ P”tdttvrl;.I I r.Iehi”~’et’ed tO tlte roatElbed is too wet, it shall he t,,LnietEl,

‘tflt antI it‘ire’,t tire to the en it, till the moisture content is acceptable
I [‘aLEtrt:t’rt.
.Sl’tneiri eirt:Eutrtslances tu’ise, where. owing to wet w’eather,
hIts’ n”ot’rtt,rtt LEontertt eEtnno~be reduced to the required am’.iuot by the
i’;tOc.:riurC’~ t..ttittpctet ittn’w tEnEk shall he suspended.
73
<<
Moisture content of each layer of soil shall be checked in accordance
with IS: 2720 (Part 2), and unless otherwise mentioned, shall be so
adjusted, making due allowance for evaporation losses, that at the time
of compaction it is in the range of 1 per cent above to 2 per cent below
the optimum moisture content determined in accordance with IS :2720
(Part 7) or IS:2720 (Part 8) as the case may be. Expansive clays shall,
however, be compacted at moisture content corresponding to the specified
dry density, but on the wet side of the optimum moisture content obtained
from the laboratory compaction curve.
After adding the required amount of water, the soil shall be processed
by means of graders, harrows, rotary mixers or as otherwise approved
by the Engineer until the layer is uniformly wet.
Clods or hard lumps of earth shall be broken to have a maximum
size of 75 mm when being placed in the embankment and a maximum
size of 50 mm when being placed in the subgrade.
305.3.5.3. Embankment and other areas of fill shall, unless otherwise
required in the Contract or permitted by the Engineer, be constructed
evenly over their full width and their fullest possible extent and the
Contractor shall control and direct construction plant and other vehicular
traffic uniformly over them. Damage by construction plant and other
vehicular traffic shall be made good by the Contractor with material
having the same characteristics and strength as the material had before
it was damaged.
Embankments and other areas of unsupported fills shall not be con-
structed with steeper side slopes, or to greater widths than those shown
in the Contract, except to permit adequate compaction at the edges
before trimming back, or to obtain the final profile following any
settlement of the fill and the underlying material.
Whenever fill is to be deposited against the face of a natural slope,
or sloping earthworks face including embankments, cuttings, other fills
and excavations steeper than I vertical on 4 horizontal, such faces
shall be benched as per Clause 305.4.1 immediately before placing the
subsequent fill.
All permaneni faces of side slopes of embankments and other areas
of fill formed shall, subsequent to any trimming operations, be reworked
and sealed to the satisfaction of the Engineer by tracking a tracked
vehicle, considered suitable by the Engineer, on the slope or any other
method approved by the Engineer.
<< 74
305.3.6. Compaction : Only the compaction equipment approved by
the Engineer shall be employed to compact the different material types
encountered during construction. Smooth wheeled, vibratory, pneumatic
tyred, sheepsfoot or pad foot rollers, etc. of suitable size and capacity
as approved by the Engineer shall t~used for the different types and
grades of materials required to be compacted either individually or
in suitable combinations.
The compaction shall be done with the help of vibratory roller of
80 to 100 kN static weight with plain or pad foot drum or heavy pneumatic
tyred roller of adequate capacity capable of achieving required com-
paction.
The Contractor shall demonstrate the efficacy of the equipment he
intends to use by carrying out compaction trials. The procedure to be
adopted for these site trials shall first be submitted to the Engineer
for approval.
Earthmoving plant shall not be accepted as compaction equipment
nor shall the use of a lighter category of plant to provide any preliminary
compaction to assist the use of heavier plant be taken into account.
Each layer of the material shall be thoroughly compacted to the
densities specified in Table 300-2. Subsequent layers shall be placed only
after the finished layer has been tested according to Clause 903.2.2 and
accepted by the Engineer, The Engineer may permit measurement of
field dry density bya nuclear moisture/density gauge used in accordance
with agreed procedure and the gauge is calibrated to provide results
identical to that obtained from tests in accordance with IS: 2720 (Part
28). A record of the same shall be maintained by the Contractor.
When density measurements reveal any soft areas in the embank~
mentjsubgrade/earthen shoulders, further compaction shall be carried
out as directed by the Engineer. If inspite of that the specified compaction
is not achieved, the material in the soft areas shall be removed and
replaced by approved material, compacted to the density requirements
and satisfaction of the Engineer.
305.3.7. Drainage : The surface of the embankrnent/subgrade at
all times during construction shall be maintained at such a cross fall
(not flatter than that required for effective drainage of an earthen surface)
as will shed water and prevent ponding.
305.3,8. Repairing of damages caused by rain/spillage of water:
The soil in the affected portion shall be removed in such areas as
<< 75
directed by the Engineer before next layer is laid and refilled in
layers and compacted using appropriate mechanical means such as small
vibratory roller, plate compactor or power rammer to achieve the
required density in accordance with Clause 305.16. If the cut is not
sufficiently wide for use of required mechanical means for compaction,
the same shall be widened suitably to permit their use for proper
compaction. Tests shall be carried out as directed by the Engineer to
ascertain the density requirements of the repaired area. The work of
repairing the damages including widening of the cut, if any, shall be
earned out by the Contractor at his own cost, including the arranging
of machinery/equipment for the purpose.
305.3,9. Finishing operations Finishing operations shall include
the work of shaping and dressing the shoulders/verge/roadbed and
side slopes to conform to the alignment, levels, cross-sections and
dimensions shown on the drawings or as directed by the Engineer
\ubject to the surface tolerance described in Clause 902. Both the
upper and lower ends of the side slopes shall be rounded off to
4tnprove appearance and tb merge the embankment with the adjacent
terra in.
The topsoil, removed and conserved earlier (Clause 301.3.2 and
) shall be spread over the fill slopes as per directions of the
Engineer to facilitate the growth of vegetation. Slopes shall be roughened
and niotstened slightly prior to the application of the topsoil in order
La provide satisfactory bond. The depth of the topsoil shall be sufficient
a sustain plant growth, the usual thickness being from 75 mm to 150
unrn
Where directed, the slopes shall be turfed with sods in accordance
i~iih Clause 307. if seeding and mulching of slopes is prescribed, this
shall he done to the requirement of Claus’e 308.
When earthwork operations have been substantially completed, the
road area shall be cleared of all debris, and ugly scars in the construction
area responsible for objectionable appearance eliminated.
305.4. Construction of Embankment and Subgrade under
Special Conditions
305.4] Earthwork for widening existing road embankmenu
When art existing embankment and/or subgrade is to be widened
and its slopes are steeper than 1 vertical on 4 horizontal, continuous
horizontal benches, each at least 300 mm wide, shall be cut into the
76
<<
old slope for easuring adequate bond with the fresh embankment/subgrade
material to be added. The material obtained from cutting of benches
could be utilized in the widening of the embankmeni/subgrade. However,
when the existing slope against which the fresh material is to be placed
is flatter than 1~vertical on 4 horizontal,the slope surface may only be
ploughed or scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit
the use of conventional rollers, compaction shall be carried out with
the help of small vibratory rollers/plate compactor~’powerrammers or
arty other appropriate equipment approved by the Engineer. End dumping
of material from trucks for widening operations shall be avoided except
in difficult circumstances when the extra width is too narrow to permit
the movement of any other types of hauling equipment.
305.4.2. Earthwork for embankment and subgrade to be placed
against sloping ground Where an embankment/subgrade is to be
placed against sloping ground, the latter shalt be appropriately benched
or ploughed/scarified as required in Clause 305.4,1 before placing the
embankrnent/subgrade material. Extra earthwork involved in benching or
dtie to ploughing/scarifying etc. shall be considered incidental to the work.
For wet conditions, benches with slightly inward fall and subsoil
drains at the lowest point shall be provided as per the drawings,
before the till is placed against sloping ground.
Where the Contract requires construction of transverse subsurface
drain at the cut~llllinterface, work on the same shall be carried out to
Claose 309 in proper sequence with the embankment and suhgrade work
as approved by the Engineer.
305.4.3. Earthwork over existing road surface Where the
embankment is to be placed over an existing road surface, the work shall
he earned out as indicated below
(ii If the existing road surface is of granular or bituminous type and lies within
1 in of the new subgradc level, the same shatl be scarified to a stepth of 50 mm
or more if specified, so as to provide ample bond between the old and new material
ensuring that at least SOt) mm portion below the top of new suhgracle level
is compactesl to the desired density.
(ii) If the existing road surface is of cement concrete type and lies within I m
of the new subgrade level the same shall be removed completely.
(iii) If she level difference between the existing road surface and the new formation
level is snore than tm, the existing surface shall be petmitted to stay in place
without any modification.
<< 77
Section 3(X) Earthwork, Erosion Control and Drainage
305.4.4. Embankment and subgrade around structures To
avoid interference with the construction of abutments, wing walls or
return walls of culvert/bridge structures, the Contractor shall, at points
to be determined by the Engineer suspend work on embankment forming
approaches to such structures, until such time as the construction of the
latter is sufficiently advanced to permit the completion of approaches
without the risk of damage to the structure.
Unless directed otherwise, the filling around culverts, bridges and
other structures upto a distance of twice the height of the road from
the back of the abutment shall be carried out independent of the work
on the main embankment. The fill material shall not be placed against
any abutment or wing wall, unless permission has been given by the
Engineer but in any case not until the concrete or masonry has been
in position for 14 days. The embankment and subgrade shall be brought
up simultaneously in equal layers on each side of the structure to
avoid displacement and unequal pressure. The sequence of work in this
regard shall be got approved from the Engineer.
The material used for backfill shall not be an organic soil or highly
plastic clay having plaiticity index and liquid limit more than 20 and
40 respectively when tested according to 15:2720 (Part 5). Filling behind
abutments and wing walls for all structures shall conform to the general
guidelines given in Appendix 6 of IRC:78 (Standard Specifications and
Code of Practice for Road Bridges-Section VII) in respect of the type
of material, the extent of backfill, its laying and compaction etc. Thc
fill tnaterial shall be deposited in horizontal layers in loose thickness
and compacted thoroughly to the requirements of Table 300-2.
Where the provision of any filter medium is specified behind the
abutment, the same shall be laid in layers simultaneously with the laying
of fill material. The material used for filter shall conform to the
requirements for filter medium spelt out in Clause 2502/309.3.2 (B) unless
otherwise specified in the Contract.
Where it may be impracticable to use conventional rollers, the com-
paction shall be carried out by appropriate mechanical means such as
small vibratory roller, plate compactor or power rammer. Care shall be
taken to see that the compaction equipment does not hit or come too
close to any structural member so as to cause any damage to them
or excessive pressure against the structure.
305.4.5. Construction of’ embankment over ground incapable
of supporting construction equipment Where embankment is to
78
<<
be constructed across ground which will not support the weight of
repeated heavy loads of construction equipment, the first layer of the
fill may be constructed by placing successive loads of material in a
uniformly distributed layer of a minimum thickness required to support
the construction equipment as permitted by the Engineer. The Contractor,
if so desired by him, may also use suitable geosynthetic material to
increase the bearing capacity of the foundation. This exception to normal
procedure will not be permitted where, in the opinion of the Engineer,
the embankments could be constructed in the approved manner over
such ground by the use-cf lighter or modified equipment after proper
ditching and drainage have been provided. Where this exception is
permitted, the selection of the material and the construction procedure
to obtain an acceptable layer shall be the responsibility of the Contractor.
The cost of providing suitable traffic conditions for construction
equipment over any area of the Contract will be the responsibility of
the Contractor and no extra payment will be made to him. The remainder
of the embankment shall be constructed as specified in Clause 305.3.
305.4.6. Embankment construction under water : Where filling
or backfilling is to be placed under water, only acceptable granular
material or rock shall be used unless otherwise approved by the
Engineer. Acceptable granular material shall consist of graded, hard
durable particles with maximum particle size not exceeding 75 mm. The
material should be non-plastic having uniformity coefficient of not less
than 10. The material placed in open water shall be deposited by end
tipping without compaction.
305.4,7. Earthwork for high embankment : In the case
of high embankments, the Contractor shall normally use the material
from the specified borrow area. In case he desires to use different
material for his own convenience, he shall have to carry out neces~ary
soil investigations and redesign the high embankment at his own cost.
The Contractor shall then furnish the soil test data arid design of high
embankment for approval of thb Engineer, who reserves the right to
accept or reject it.
If necessary, stage construction of fills and any controlled rates
of filling shall be carried out in accordance with the Contract including
installation of instruments and its monitoring.
Where required, the Contractor shall surcharge embankments or other
areas of fill with approved material for the periods specified in the
Contract. If settlement of surcharged fill results in any surcharging
79
<<
Sec.t ion 300 Ear hwnrk, Erosion Control and Drainage
ntaterial, which is unacceptable for use in the fill being surcharged, lying
below formation level, the ContracEtor shall remove the unacceptable
material and dispose it as per direction of the Engineer. I-Ic shall
then bring the resultant level up to formation level with acceptable
material,
305,4.8. Settlement period \Vhere settlement period is specified
iii the Contract, tI-c embankment shall remain in place for the required
sLttIeFrlit.nt period before excavating for abutment, wingwall, retaining
wall, footings, etc., or driving foundation piles. The duration of the
required settlement period at each location shall be as provided for
in the Contract or as directed by the Engineer.
305.5. Plying of’ Traffic
Consiructien and other vehicular traffic shall not use the prepared
surLice of the embankment and/or subgrade without the prior permission
of the Engineer. Any damage arising out of such use shall, however,
he made good by the Contractor at his own expense as directed by the
Engineer.
34)5,6. Surface Finish and Quality Control of Work
The surface finish of comaruction of subgrade shall conform to the
u reiuents of Clause 902 Control on the quality of materials and
weeks shall be exercised in accordance with Clau~e903
305.7, Subgrade Strength
305.7.1. It shall be ensured prior to actual execution that the borrow
are:i material to be used in the subgrade satisfies the requirements of
design CBR.
305.7.2. Suhgrade shall be compacted and finished to the design
strength consistent with other physical requirements. The acwal
laboratory CI3R values of constructed subgrade shall he determined on
undisturbeci samples cut out from the compacted subgrade in CBR mould
fitted with cutting shoe or on remoulded samples, compacted to the
field density at the field moisture content.
Earth emhanknienllsubgrade construction shall be measured sepa-
rately by taking cross sections at intervals in the original position
before the work starts and after its completion and computing the volumes
of earthwork in cubic metres by the method of average end areas.
<< 80
The measurement of fill material from borrow areas shall be the dif-
ference between the net quantities of compacted fill and the net
quantities of suitable material brought from roadway and drainage
excavation. For this purpose, it shall be assumed that one cu,m. of
suitable material brought to site from road and drainage excavation
forms one cu.m. of cbmpacted fill and all buiking or shrinkage shall
be ignored. —
Construction of embankment under water shall be measured in
Cu,m.
Construction of high embankment with specified material and in
specified manner shall be measured in cu.m.
Stripping including storing and reapplication of topsoil shall be meas-
ured in cu.m.
Work involving Loosening and recompacting of ground supporting
embankment/subgrade shall be measured in cu. m.
Removal of unsuitable material at embankmentisubgrade foundation
and replacement with suitable material shall be measured in cu.m.
Scarifying existing granular/bituminous road surface shall be meas-
ured in square metres.
Dismantling and removal of existing cement concrete pavement
shall be measured vide Clause 202.6,
Filter medium and backfill material behind abutments, wing walls
and other retaining structures shall be measured as finished work in
position in cu.m.
305.9. Rates
305.9.1. The Contract unit rates for the items of embankment ~nd
subgrade construction shall be payment in full for carrying out the
required operations including full compensation for
(1) Cost of arrangement of land as a source of supply of material of required
quantity for construction unless provided otherwise in the Contract;
(ii) Setting Out;
(iii) Compacting ground supporting embankment/subgrade except where removal and

replacement of unsuitable material or loosening and recompacling is involved;
(iv) Scarifying or cutting continuous horizontal benches 300mm wide on side slopes
of existing embankment and subgrade as applicable;
(v) Cost of watering or drying of material in borrow . areas andlor embankment and
subgTade during construction as required;
81
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(vi) Spreading in layers, bringing to appropriate moisture content and compacting
to Specification requirements;
(vii) Shaping and dressing top and slopes of the embankment and subgrade including
rounding of corners;
(viii) Restricted working at sites o.f structures
(ix) Working on narrow width of embankment and subgrade;
(x) Excavation in all$oils from borrow pits/designated borrow areas including clearing
and grubbing and transporting the material to embankment and subgrade sire
with all lifts and leads unless otherwise provided for in the Contract;
(xi) All labour, materials, tools, equipnent and incidentals necessary to complete the
work to the Specifications;
(xii) Dewatering; and
(xiii) Keeping the embankment/completed formation free of water as per Clause 311.
305.9.2. In case the Contract unit rate specified is not inclusive of

all leads, the unit rate for transporting material beyond the initial lead,
as specified in the Contract for construction of embankment and subgrade
shall be inclusive of full compensation for all labour, equipment, tools
and incidentals necessary on account of the additional haul or trans-
pertation involved beyond the specified initial lead.
305.9.3. Clause 301.9.5 shall apply as regards Contract unit rates
for items of stripping and storing top soil and of reapplication of topsoil.
305.9.4. Clause 301.9.2 shall apply as regards Contract unit rate for
the item of loosening and recompacting the embankmenl/subgrade
foundation.
305.9.5. Clauses 301.9.1 and 305.8 shall apply as regards Contract
rates for items of removal of unsuitable material and replacement with
suitable material respectively.
305.9.6. The Contract unit rate for sÔarifying existing granular/bi-
tuminous road surface shall be payment in full for carrying out the
required operations including full compensation for all labour, materials,
tools, equipment and incidentals necessary to complete the work.
This will also comprise of handling, salvaging, stacking and disposing
of the dismantled materials within all lifts and upto a lead of 1000 m
or as otherwise specified.
305.9.7. Clause 202.7 shall apply as regards Contract unit rate for
dismantling and removal of existing cement concrete pavement.
305.9.8. The Contract unit rate for providing and laying filter
material behind abutments shall be payment in full for carrying out
82
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Earthwork, Erosion Control nd Drainagc Section. 300
the required operations including all materials, labour, tools, equipment
and incidentals to complete the work to Specifications.
305.9.9. Clause 305A..6 shall apply as regards Contract unit rate for
construction of embankment under water.
305.9.10. Clause 305.4.7 shall apply as regards Contract unit rate
for construction of high embankment. It shall include cost of instru-
mentation, its monitoring and settlement period, where specified in the
Contract or directed by the Engineer.
306. SOIL EROSION AND SEDIMENTATION CONTROL
3061. Description
This work shall consist of measures as shown on plans or as
directed by the Engineer to conirol soil erosion, sedimentation and water
pollution, through use of berms, dikes, sediment basins, fibre mats,
mulches, grasses, slope drains, and other devices.
306.2. Materials
All materials shall meet commercial grade standards and shall be
approved by the Engineer before being used in the work.
3063. Construction Operations
Prior to the start of the relevant construction, the Contractor shall
submit to the Engineer for approval his schedules for carrying out
temporary and permanent emsion/sedimentation control works as are
applicable for the items of clearing and grubbing, roadway and drainage
excavation, embankipent/subgrade constructio~i,bridges and other struc-
tures across water courses, pavement courses and shoulders. He shall also
submit for approval his proposed method of erosion/sedimentation control
on service road and borrowpits and his plan for disposal of waste
materials. Work shall not be started until the erosion/sedimentation control
schedules and methods of operations for the applicable construction have
been approved by the Engineer.
The surface area of erodible earth material exposed by clearing and
grubbing, excavation, borrow and fill operations shall be limited to the
extent practicable. The Contractor may be directed to provide immediate
permanent or temporary erosion and sedimentation control measures
to prevent soil erosion and sedimentation that will adversely affect
construction operations, damage adjacent propeEties, or cause contami-
nation of nearby streamS or ether water cotu~es, lakes, reservoirs
etc. Such work may involve the construction of temporary berms, dikes,
83
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sediment basins, slope drains and use of temporary mulches, fabrics,
mats, seeding, or other control devices or methods as necessary to control
erosion and sedimentation. Cut and fill slopes shall be seeded and turfed
as required on the plans.
The Contractor shall be required to incorporate all permanent erosion
and sedimentation control features into the project at the earliest
practicable time as outlined in his accepted schedule to minimize the
need for temporary erosion and sedimentation control measures.
Temporary erosion/sedimentation and pollution control measures will
be used to control the phenomenon of erosion,sedimentation and pollution
that may develop during normal construction practices, but may neither
be foreseen during design stage nor associated with permanent control
features on the Project.
Where erosion or sedimentation is likely to be a problem, clearing
and grubbing operations should be so scheduled and performed that
grading operations and permanent erosion or sedimentation control
features can follow immediately thereafter if the project conditions permit;
otherwise temporary erosion or sedimentation control measures may be
required between successive construction stages. Under no conditions
shall a large surface area of erodible earth material be exposed at one
time by clearing and grubbing or excavation without prior approval
of the Engineer.
The Engineer may limit the area of excavation, borrow and em-
bankment operations in progress, commensurate with the Contractor’s
capability and progress in keeping the finish grading, mulching, seeding
and other such permanent erosion, sedimentation and pollution control
measures, in accordance with the accepted schedule, Should seasonal
limitations make such coordination unrealistic; temporary erosion/sedi-
mentation control measures shall be taken immediately to the extent
feasible and justifkd.
in the event temporary erosion, sedimentation and pollution control
measures become necessary due to the Contractor’s negligence, care-
lessness or failure to install permanent controls as a part of ~thework
as scheduled or ordered by the Engineer, these shall be carried out at
the Contractor’s own expense. Temporary erosion, sedimentation and
pollution control work required, which is not attributed to the Contrac-
tor’s negligence, carelessness or failure to install permanent controls, will
be performed as ordered by the Engineer.
<< 84
Temporary erosion, sedimentation and pollution control may include
construction work outside the right-of-way where such work is necessary
as a result of road construction such as borrow pit operations,
service roads and equipment storage sites.
The temporary erosion,sedimentation and pollution control features
installed by the Contractor shall be acceptably maintained by him till
these are needed, unless otherwise agreed by the Engineer.
The soil erosion, sedimentation and pollution control works will be
measured in terms of units specified in the Bill of Quantities for the
respective items.
306.5. Rates
The Contract unit rate for different items of soil erosion, sedimen-
tation and pollution control works shall be payment in full for carrying
out all required operations including full compensation for all laboui,
tools, equipment and incidentals to complete the works to the Specifi-
cations.
307. TURFING WITH SODS
307.1. Scope
This work shall consist of furnishing and laying of the live sod of
perennial turf forming grass on embankment slopes, verges (earthen
shoulders) or other locatiOns shown on the drawings or as directed by
the Engineer. Unless otherwise specifled, the work shall be taken up
as soon as possible following construction of the embankment, provided
the season is favourable for establishment of the sod.
307.2. Materials
The sod shall consist of dense, well-rooted growth of permanent and
desirable grasses, indigenous to the locality where it is to be used, and
shall be practically free from weeds or other undesirable matter. At the
time the sod is cut, the grass on the sod shall have a length of
approximately 50 mm and the sod shall have been freed of debris.
Thickness of the sod shall be as uniform as possible, with some 50-
80 mm or so of soil covering the grass roots depending on the
nature of the sod, so that practically all the dense root system of the
grasses is retained in the sod strip. The sods shall be cut in rectangular
strips of uniform width, not less than about 250 mm x 300 mm in size
but not so large that it is inconvenient to handle and transport these
<< 85
Section 3(X) Earthwork, Erosion Control and Drainage
without damage. During wet weather, the sod shall be allowed to dry
sufficiently to prevent rearing during handling and during dry weather
shall be watered before lifting to ensure its vitality and prevent the
droppmg of the soil in handling.
307.3, Construction Operations
307.3,1. Preparation of the earth bed : The area to be sodded
shall have been previously constructed to the required slope and
cross section. Soil on the area shall be loosened, freed of all stones
larger than 50 mm size, sticks, stumps and any undesirable foreign
matter, and brought to a reasonably fine granular texture to a depth
of not less than 25 mm for receiving the sod.
Where required, topsoil shall be spread over the slopes. Prior to
placing the topsoil, the slopes shalt be scarified to a depth which, after
settlement, will provide the required nominal depth shown on the plans.
Spreading shall not be done when the ground is excessively wet.
Following soil preparation and top soiLing, where required, fertilizer
and ground limestone when specified shalt be spread uniformly at the
rate indicated on the plans. After spreading, the materials are incorporated
in the soil by discing or other means to the depths shown on the plans.
307.3.2. Placing the sods : The prepared sod bed shall be moistened
to the loosened depth, if not already sufficiently moist, and the sod
shall be placed thereon within approximately 24 hours after the same
had been cut. Each sod strip shall be laid edge to edge and such that
the joints caused by abutting ends are staggered. Every strip, after it
is snugly placed against the strips already in position, shall be lightly
tamped with suitable wooden or metal tampers so as to eliminate
air pockets and to press it into the underlying soil.
On side slopes steeper than 2 (horizontal) to I (vertical), the laying
of sods shall be started from bottom upwards. At points where water
may flow over a sodded area, the upper edges of the sod strips shall,
be turned into the soil below the adjacent area and a layer of earth placed
over this followed by its thorough compaction.
307.33. Staking the sods: Where the side slope is 2 (horizontal)
to 1 (vertical) or steeper and the distance along the slope is more than
2 m, the sods shall be staked with pegs or~nails spaced approximately
500 to 1000 mm along the longitudinal axis of the sod strips, Stakes
shall be driven approximately plumb through the sods to be almost
flush with them.
<< 86
Earthwork, Erosion Control andOrainage Section 300
307.3.4. Top dressing: After the sods have been laid in position,
the surface shall be cleaned of loose sod, excess soil and other foreign
material. Thereafter, a thin layer of topsoil shall be scattered over the
surface of top dressing and the area thoroughly moistened by sprinkling
with water.
307.3.5. Wateri~igand maintenance : The sods shall be watered
by the Contractor for a period of at least four weeks after laying.
Watering shall be so done as to avoid erosion and prevent damage
to sodded areas by wheels of water tanks.
The Contractor shall erect necessary warning signs and barriers,
repair or replace sodded areas failing to show uniform growth of
grass or damaged by his operations and shall otherwise maintain
the sod at his cost until final acceptance.
Turfing with sods shall be measured as finished work in square
metres.
307.5. Rate
The Contract unit rate for turfing with sods shall mean payment in
full for carrying out all the required operations explained above including
compensation for
(i) furnishing all the materials to be incorporated in the Works with all leads and
lifts; and
(ii) all labour, tools, equipments and incidentals to complete the work in accordance
with these Specificaüons.
The Contract unit rate for application of topsoil shall be as per
Clause 301.9.5.
308. SEEDING AND MULCHING
308.1. Scope
This shall consist of preparing slopes, placing topsoil, furnishing
alL seeds, commercial or organic fertilizers and mulching materials,
providing jute netting and placing and incorporating the same on
embankment slopes or other locations designated by the Engineer
or shown in the Contract documents.
308.2. Materials
A. Seeds: The seeds shall be of approved quality and type suitable for the soil
on which these are to be applied, and shall have acceptable purity and germination
to requirements set down by the Engineer.
<< 87
Fertilizer shall consist of standard commercial materials and conform to the grade
specified. Organic manure shall be fully puirefied organic maser such as cow
dung.
Mulching materials shall consist of straw, hay, wood shavings or sawdust,
and shall be delivered dry. They shall be reasonably free of weed seed and such
foreign materials as may detract from their effectiveness as a mulch or be
injurious so the plant growth.
B. Topsoil: Topsoil shall not be obtained from an area known to have noxious weeds
growing in it. If treated with herbicides or sterilents, it shall be got tested
by appropriate ~griculturalauthority to determine the residual in the soil. Topsoil
shall not contain less than 2 per cent and more than 12 per cent organic matLer.
C. BltumLrtous Emulsion: A suitable grade of bituminous cutback or emulsion
used as a tie down for mulch shall be as described in the Contract doarment
or as desired by the Engineer. Emulsified bitumen shall not contain any solvent
or diluting agent toxic to plant life.
D. Netting: Jute netting shall be undyed jute yam woven into a uniform open weave
with approximate 2.5 cm square openings.
Geonetting shall he made of uniformly extruded rectangular mesh having mesh
opening of 2 cm x 2 cm. The colour may be black or green. It shall weigh
not less than 3.8 kg per 1000 sq. m.
308.3. Seeding Operations

308.3.1. Seed-bed preparation : The area to be seeded shall be
brought to the required slope and cross-section by filling, reshaping
eroded areas and refinishing slopes, medians etc. Topsoil shall be evenLy
spread over the specified areas to the depth shown on the plans,
unless otherwise approved by the Engineer. The seed-bed preparation
shall consist of eliminating all live plants by suitable means using
agricultural implements. All stones 150 mm in smallest dimension and
larger shall be removed. The soil shall be excavated on the contour to
a depth of 100 mm. All clods larger than 25 mm in diameter shall
be crushed and packed. Where necessary, water shall then be applied.
All topsoil shall be compacted unless otherwise specified or approved
by the Engineer. Compaction shall be by slope compactor, cleated tractor
or similar equipment approved by the Engineer. Equipment shall be so
designed and constructed as to produce a uniform rough textured
surface ready for seeding and mulching and which will bond the topsoil
to the underlying material. The entire area shall be covered by a
minimum of 4 passes or 2 round trips of the roller or approved
equipment.
308.3,2. Fertilizer application : Fertilizer to the required quantities
shall be spread and thoroughly incorporated into the soil surface as a
part of the seed-bed preparation.
<< 88
308.3.3. Planting of seeds : All seeds shall be planted uniformly

at the approved rate. Immediately after sowing, the area shall be raked,
dragged or otherwise treated so as to cover the seeds to a depth of
6 mm.
The operation of seed sowing shall not be performed when the
ground is muddy or when the soil or weather conditions would otherwise
prevent proper soil preparation and subsequent operations.
308.3.4. Soil moisture and watering requirements: Soil-moisture
shall exist throughout the zone from 25 mm to at least 125 mm below
the surface at the time of planting.
Watering of the seeded areas shall be carried out as determined by
the Engineer.
308.4. Mulching, Applying Bituminous Emulsion and Jute
Netting! Geonetting
Within 24 hours of seeding, mulching material mixed with organic
manure shall be placed so as to form a continuous, unbroken cover
of approximate uniform thickness of 25 mm using an acceptable
mechanical blower. Mulching material shall be held in place and made
resistant to being -blown away by suitable means approved by the
Engineer. When called for in the Contract documents, mulch material
shall be anchored in place with bituminous emulsion applied at the
rate of 2300 litres per hectare. Any mulch disturbed or displaced
following application shall be removed, reseeded and remulched as
specified. Jute netting/Geonetting shall be unrolled and placed parallel
to the flow of water immediately following the bringing, ta’—finished
grade, the area specified on the plans or the placing of seed and fertilizer.
Where more than one strip is required to cover the given areas, they
shall overlap a minimum of 100 mm. Jute netting/ Geonetting shall
be held in place by approved wire staples, pins, spikes or wooden
stakes driven vertically into the soil.
308.5. Maintenance
The Contractor shall maintain all seeded and mulched areas
until final acceptance. Maintenance shall inciud~ protection of
traffic by approved warning signs or barricades ax~d repairing any
areas damaged following the seeding and mulching operations.
If mulched areas become damaged, the area shall be reshaped and
then seeded and mulched again as originally spe~ified.
<< 89
308.6. Measurements for payment
Seeding and mulching shall be measured as finished work in square
metxes.
308.7. Rate
The Contract unit rate for seeding and mulching shall be payment
in full for carrying out all the required operations including full
compensation for all materials, labour, tools and incidentals.
309. SURFACE/SUB-SURFACE DRAINS
309.1. Scope
This work shall consist of constructing surface and/or sub-surface
drains in accordance with the requirements of these Specifications
and to the lines, grades, dimensions and other particulars shown on
the drawings or as directed by the Engineer. Schedule of work shall
be so arranged that the drains are completed in proper sequence with
road works to ensure that no excavation of the completed road works
is necessary subsequently or any damage is caused to these works due
to lack of drainage.
309.2. Surface Drains
Surface drains shall be excavated to the specified lines, grades,
levels and dimensions to the requirements of Clause 301. The excavated
material shall be removed from the area adjoining the drains and if
found suitable, utilised in embankment/subgrade construction. All unsuit-
able material shall be disposed of as directed.
The excavated bed and sides of the drains shall be dressed to bring
these in close conformity with the specified dimensions, levels and slopes.
Where so indicated, drains shall be lined or turfed with suitable
materials in accordance with details shown on the drawings.
All works on drain construction shall be planned and executed in
proper sequence with other works as approved by the Engineer, with a
view to ensuring adequate drainage for the area and minimising erosion/
sedimentation.
3093. Sub-surface Dralns
309.3.1. Scope : Sub-surface drains shall be of close-jointed perfo-
rated pipes, open-jointed unperforated pipes, surrounded by granular
material laid in a trench or aggregate drains to drain the pavement courses.
Sub-surface drains designed using Geosynthetics and approved by the
Engineer can also be used.
<< 90
309.3.2. Materials
A. PIpe Perforated pipes br the drains may be ofmetatlasbestos cement/
cement concretelPVC, and unperforated pipes of vitrified claylccment concrete/
asbestos cement. The type, size and grade of the pipe to be used shall be
as specified in the Contract. In an case, however, shall the internal diameter
of the pipe be less than 100 mm. Holes for perforated pipes shall be on one
half of the circumference only and conform to the spacing indicated on the
drawings. Size of the holes shall not ordinarily be greater than half of ~
size of the material surrounding the pipe, subject to being minimum 3 mm and
maximum 6 mm. l)~~ stands for the size of the sieve that allows 85 per cent
of the material to pass through it.
R, Backfill materIal Backfill material shall consist of sound, tough, hard, durable
particles of free draining sand-gravel material or crushed stone and shall be free
of organic material, clay balls or other deleterious matter Unless the Contract
specifies any particular gradings for the backfill material or requires these to
be designed on inverted filter criteria for filtration and permeability to the approval
of the Engineer, the backfill material shall be provided on the following lines:
(i) Where the soil met with in the trench is of fine grained type (e.g.. silt,clay
or a mixture *hereot),the backfill material shall conform to Class I grading
set out in-Table 300-3.
(ii) Where the soil met with in the trench is of coarse silt to medium sand
or sandy type, the backfill material shall correspond to Class 11 grading
of Table 300-3.
(iii) Where soil met with in the trench is gravelly sand, the backfill material
shall correspond to Class III grading of Table 300-3.
Thickness of backfill material arouna the pipe shall be as shown
on the drawings subject to being at least 150 mm airound in all cases.
Geosynthetics for use with subsurface drain shall conform to the re-
quirements as per Section 700.
Table 300-3. GRADING REQUIREMENTS FOR FILTER MATERIAL
Par cent passIng by weIght
SIeve DesignatIon Class I Class H Class III
53mm — —. 100
45 mm — — 97.100
26.5mm — 100 —
22,4 mm — 95-100 58-100

11.2 mm 100 48-100 20-60
5.6 mm 92-100 28-54 4-32
2.8 mm 83-100 20-35 0-10
1,4 mm 59-96 — 0-5
710 micron 35-80 6-18 —
355 micron 14-40 2-9 —
l80micron 3-15 — —
90 micron 0-5 0-4 0-3
<< 91
309.3.3. Trench excavation: Trench for sub-surface drain shall

be excavated to the specified lines, grades and dimensions shown in the
drawings provided that width of trench at pipe level shall not be less
than 450 mm. The excavation shall begin at the outlet end of the drain
and proceed towards the upper end. Where unsuitable material is met
with at the trench bed, the same shall be removed to such depth
as directed by the Engineer and backfilied with approved material which
shall be thoroughly compacted to the specified degree.
309.3.4. Laying of pipe and backi’illing Laying of pipe in the
trench shall be started at the outlet end and proceed towards the upper
end, true to the lines and grades specified. Unless otherwise provided,
longitudinal gradient of the pipe shall not be less than 1 in 100.
Before placing the pipe, backfill material of the required grading(s)
shall be laid for full width of the trench bed ana compacted to a
minimum thickness of 150 mm or as shown on the drawings. The
pipe shall then be embedded flrmly on the bed.
Perforated pipes, unless otherwise specified, shall be placed with
their perforations down to minimise clogging. The pipe Sections shall
be joined securely with appropriate coupling fittings or bands.
Non-perforated pipes shall be laid with joints as close as possible
with the open joints wrapped with suitable pervious material (like double
layer of hessian, suitable Geosynthetics or some other material ~f
not less than 150 mm width) to permit entry of water but prevent fines
entering the pipes. In the case of non-perforated pipes with bell end,
the bell shall face upgrade.
Upgrade end sections of the pipe installation shall be tightly closed
by means of concrete plugs or plugs fabricated from the same material
as the pipe and securely held in place to prevent’ entry of soil materials.
After the pipe installation has been completed and approved,
backfill material of the required grading(s) (see Clause 309.3.2B) shall
be placed over the pipe to the required level in horizontal layers
not exceding 150 mm in thickness and thoroughly compacted. The
minimum thickness of material above the top of the pipe shall be 300
mm.
Unless otherwise provided, sub-surface drains not located below the
road pavement shall be sealed at the top by means of 150 mm thick
layer of compacted clay so as to prevent percolation of surface water.
<< 92
309.3.5. Use of geosynthetic in bying of pipe and backfilling
After excavating the trench for subsurface drain, the filter fabric shall
be placed, the pipe installed and the trench backfilled with permeable
mate’rial according to dimensions and details shown on the plans.
Surfaces to receive filter fabric prior to placing shall be free of loose
or extraneous material and sharp objects that may damage the filter
fabric ~duringinstallation. Adjacent rolls of the fabric shall be overlapped
a minimum of 450 mm. The preceding roll shall overlap the following
roll in the direction the material is being spread.
Damage to the fabric resulting from Contractor’s vehicles, equipment
or operations shall be replaced or repaired by the Contractor at
his expense.
309.3.6. Drain outlet The outlet for a sub-drain shall not be under
water or plugged with debris but should be a free outlet discharging
into a stream, culvert or open ditch. The bottom of the pipe shall be
kept above high water in the ditch and the end protected with a grate
or screen. For a length of 500 mm from the outlet end, the trench for
pipe shall not be provided with granular material but backfilled with
excavated soil and thoroughly compacted so as to stop water directly
percolating from the backfill material around the pipe. The pipe in
this section shall not have any perforations.
309.3.7. Aggregate drains : Aggregate drains shall be placed
within the verge/shoulders after completion of the pavement. Depth,
thickness and spacing of the aggregate drains shall be as shown on the
plan.
Trenches for aggregate drains shall be excavated to a minimum
width of 300 mm and to the depth shown on the plans or ordered by
the Engineer. The bottom of the trench shall be sloped to drain and shall
be free from loose particles of soil. The trench shall be excavated so
as to expose clearly the granular pavement courses to be drained.
Aggregate for the drains shall ~e durable gravel, stone or slag and
shall be free from vegetable matter and other deleterious substances.
The grading requirements are given at Table 300-4. Type B grading
may be used only where the drain is designed to intercept surface
water [lowingto the pipe and is likely to get slowly blocked. Type A
grading allows a much wider range.
93
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Section 300 Earthwork, Erosion Control an4 Drainage
TABLE 300.4. GRADING REQUIREMENTS FOR AGGREGATE DRAINS
Sieve Size Per cent passing by weight
TypeA TypeB
63mm — 100
37.5 mm 100 85-100
19mm — 0-20
9.5 rum 45-100 0-5
3.35 mm 25-80 —
600 micron 8-45 —
150 micron 0-10 —
75 micron 0-5 —

Measurement for surface and sub-surface drains shall be per
running metre length of the drain. Disposal of surplus material beyond
1000 m shall be measured in cu. m.
309.5. Rates
The Contract unit rates for surface and subsurface drains shall be
payment in full for all items such as excavation, dressing the sides and
bottom; providing lining, turfing, pitching, masonry, concrete and plas-
tering; providing, laying and jointing pipes; providing, laying and
compacting backfill and bed of granular material; providing, fixing
and painting of cover etc. including full compensation for all materials,
labour, tools, equipment and other incidentals to complete the work
as shown on drawings with all leads and lifts except for removal of
unsuitable material for which the lead shall be 1000 m. Provision of
inlets, gratings, sumps, outlet pipes, bedding, disbursers etc. wherever
required shall be incidental to construction of drain. The Contract
unit rate for disposal of surplus and unsuitable material beyond the
initial 1000 m lead shall be in accordance with Clause 304.5.3.
310. PREPARATION AND SURFACE TREATMENT OF
FORMATION
Preparation and surface treatment of the formation, that is top of
the subgrade, shall be carried out only after completion of any specified
subgrade drainage and unless otherwise agreed by the Engineer,
immediately prior to laying the sub-base or the road base where no
sub-base is required. The sequence of operations shall be as follows:
(a) All surfaces below carriageway, laybyes, footways and hard shoulders shall,
after reinstatement of any soft areas to the required Specifications be well cleaned
and freed of mud and slurry.
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(b) The surface shall be compacted by 4 passes of a smooth wheeled roller of 80
to 100 kN weight after spraying requisite amount of waler, if required, before
the commencement of rolling.
(c) The formation shall, wherever necessary, be regulated and trimmed to the re-
quirements of Clause 505.3.9 with motor grader.
(d) The trimmed formation shall be rolled by one pass of smooth wheeled roller
of 80 to 100 kN weight after spraying requisite amount of water, if required,
before the commencement of rolling.
Where the completed formation is not immediately covered with sub-
base or road base material, its moisture content shall be maintained
to prevent cracking in the formation by suitable measures as approved
by the Engineer. The entire work of surface treatment of formation shall
be deemed as incidental to the work of sub-base/base course to be
provided on the subgrade and as such no extra payment shall be made
for the same.
311. WORKS TO BE KEPT FREE OF WATER
311.1. The Contractor shall arrange for the rapid dispersal of water
collected/accumulated on the earthwork or completed formation during
construction or on the existing roadway or which enters the earthwork
or any other item of work from any source, and where practicable, the
water shall be discharged into the permanent outfall of the drainage
system. The arrangements shall be made in respect of all earthwork
including excavation for pipe trenches, foundations or cuttings.
311.2. The~Contractor shall provide, where necessary, temporary
water courses, ditches, drains, pumping or other means for maintaining
the earthwork free from water. Such provisions shall include carrying
out the work of forming the cut sections and embankments in such
manner that their surfaces have at all times a sufficient minimum
crossfall and, where practicable, a sufficient longitudinal gradient to
enable them to shed water ,and prevent ponding.
The works involved in keeping the earthwork or any other item
of works free of water shall be deemed as incidental to the respective
item of work and as such no separate payment shall be made for
the s~me.
312. WATER COURSES AT CUL’TERTS
312.1, Excavation carried out in the diversion, enlargement,
deepening or straightening water courses at culverts, where necessary,
shall include the operations such as clearing, grubbing, removal of
vegetation, trimming of slopes, grading of beds, disposal of excavated
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Section 300 Earthwork, ErosionControl and Drainage
materials, pumping, timbering etc. necessary for dealing with the flow
of water.
3 12.2. The beds and sloping sides of water courses shall, where
shown on the Drawings, be protected against the action of water by
rubble paving to form a flat or curved surface as indicated. The
protection shall consist of large smooth faced stones or of blocks of
precast concrete. Stones for rubble paving shall be roughly dressed
square. No stone shall be less than 255 mm in depth nor less than
0.02 cu. m. in volume and no rounded boulders shall be used. After
completion of construction of culverts, temporary diversion of water-
course, if any, shall be closed and water course restored for flow through
the culvert as per the direction of the Engineer.
The work for water courses at culverts as stated above shall be
measured in terms of units specified in the Bill of Quantities for respective
items. The temporary diversion of channel to facilitate construction of
culverts, its closure and restoration to original water course shall be
considered incidental to the work of construction of cülverts and no
extra payment shall be made for the same.
312.4. Rates
The Contract unit rates for di:fferent items for water courses at
culverts shall be payment in full for carrying out all j~equiredoperations
including full compensation for all cost of materials, laboUr, tools,
equipment and other incidentals to complete the work to the Specification,
313. CONSTRUCTION OF ROCKFILL EMBANKMENT
313.1, Scope -
In normal circumstances, the embankment should not be constructed

with rockfill material. However, where specifically permitted by the En-
gineer because of imperative economic or technical reasons, construction
of rockfill embankments shall be in accordance with th~lines, grades
and cross-sections as shown in drawings or as directed by the Engineer.
Rockfill shall not be used at least for a depth of 500 mm below
the formation level. There sho~ildbe a minimum of 500 mm thick earthen
cushion over the rocklill.
313.2. Material
The size of rock pieces used in rockfihl embankments shall be
such that they can be deposited in layers so as to suit the conditions
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evaluated in the field compaction trials or as directed by the Engineer.

The rockfill shall consist of hard, durable and inert~aterial,preferably
maximum size not exceeding 300 mm and per cent finer than 125 mm
not exceeding 10 per cent.
Argillaceous rocks (clay, shales etc.), unburnt colliery stock and chalk
shall not be used in rockfill.
The rock fragments and blinding material required for filling the
voids shall also satisfy the above requirements.
313.3. Spreading and Compaction
The material shall be tipped, spread and levelled in layers extending
to the full width of embankment by a suitable dozer. Fragments
of rock shall then be spread on the top of layer to the required extent
and layer compacted by minimum of 5 passes of vibratory roller
having Static weight 8-10 tonnes. The compacted thickness of each
layer shall not exceed 500 mm. After compaction of each layer, the
surface voids shall be filled with broken fragments. Next layer, where
required, shall be placed in the same manner, above the earlier compacted
layer.
The top layer of rockfill, on which normal earth fill will rest shall
be thoroughly blinded with suitable granular material to seal its surface.
Measurement shall be made by taking cross-sections at intervals in
the original position before the work starts and after its completion
and computing the volume in cu. m. by the method of average end
areas.
313.5. Rate
The Contract unit rate shall be paid in full for carrying out all
the above operations including cost of rockfill, broken fragments and
blinding material and shall provide full compensation for all items as
per Clause 305.9.1 and 305.9.2.
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Sub-Bases, Bases (Non-Bituminous) and
Shoulders
400
Sub-Bases, Bases (Non-
Bituminous) and Shoulders
<<
Sub-Bases, Bases (Non-Bituminous) and Shoulders Section 400
401. GRANULAR SUB-BASE

401.1. Scope
This work shall consist of laying and compacting well-graded material
on prepared subgrade in accordance with the requirements of these Speci-
fications. 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.
401.2. Materials
401.2.1. 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
400-1.
While the gradings in Table 400-1 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 400-2. The grading to be adopted for a project shall be
as specified in the Contract.
401.2,2. 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 Ill). 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 Ill 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.
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Section 400 Sub-Bases, Bases (Non-Bituminous) and Shoulders
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 H G rading HI
75.0mm 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
0.015 mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20
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 Gm ding 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
Nate The material passing 425 micron (0.425 mm) sieve for all the three gradings
when tested according to IS 2720 (Pail 5) shafi have liquid limit and plasticity
index not more than 25 and 6 per cent respectively.
401.3. Strength of sub-base
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.
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.
401.4.1. 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
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extraneous matter, lightly sprinkled with water if necessary and rolled

with two passes of 80 -100 kN smooth wheeled roller.
401.4.2, Spreading and compacting 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 adjustment and for maintaining the
required slope and grade during the operation or other means as approved
by the Engineer.
When the sub-base material consists of combination of materials men-
tioned in Clause 401.2.1, mixing shall be done mechanically by the mix-
in-place method.
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.
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 surMce or other means approved by the Engineer so that, at the time
of compaction, it is from I per cent above to 2 per cent below the
optimtim moisture content corresponding to 15:2720 (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.
Immediately thereafter, rolling shall start. If the thickness of the com-
pacted 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 porthns having unidirectional crossfall and super-.
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elevation and shall commence at the edges and progress towards
the centre for portions having crossfall on both sides.
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 became apparent, corrected by removing or adding fresh material.
The speed of the roller shall not exceed 5 km per hour.
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 he made good
to the full thickness of layer and re-compacted.
401.5. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements
of Clause 902.
Control on the quality of materials and works shall be exercised
by the~Engineer in accordance with Section 900.
401.6. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be
maintained in accordance with Clause 112.
Granular sub-base shall be measured as finished work in position
in cubic metres.
The protection of edges of granular sub-base extended over the full
formation as shown in the drawing shall be considered incidental to
the work of providing granular sub-base and as such no extra payment
shall be made for the same.
401.8. Rate
The Contract unit rate for granular sub-base shall be payment in
full for carrying out the required operations including full compensation
for
(i) making arrangements for traffic to Clause 112 except for initial treatment to verges,
shoulders and construction of diversions;
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(ii) furnishing all materials to be incorporated in the work including all royalties, fees,
rents where necessary and all leads and lifts;
(iii) all labour, tools, equipment and incidentals to complete the work to the Speci.
fications;
(iv) carrying out the work in part widths of road where directed; and
(v) carrying out the required tests for quality control.
402. LIME TREATED SOIL FOR IMPROVED

SUB-GRADFJSUB-BASE
402.1. Scope
This work shall consist of laying and compacting an improved sub-
grade/lower sub-base of soil treated with lime on prepared sub-grade in
accordance with the requirements of these Specifications and in confor-
mity with the lines, grades and cross-sections shown on the drawings
or as directed by the Engineer. Lime treatment is generally effective
for soils which contain a relatively high percentage of clay and silty
clay.
402.2. Materials
402.2.1. Soil : Except when otherwise specified, the soil used for
stabilisation shall be the local clayey soil having a plasticity index greater
than 8.
402.2.2. Lime Lime for lime-soil stabilisation work shall be com-
mercial dry lime slaked at site or pre-slaked lime delivered to the site
in suitable packing. Unless otherwise permitted by the Engineer, the
lime shall have purity of not less than 70 per cent by weight of Quick-
lime (CaO) when tested in accordance with IS :1514, Lime shall be
properly stored to avoid prolonged exposure to the atmosphere and
consequent carbonation which would reduce its binding properties.
402.2.3. Quantity of lime in stabilised mix Quantity of lime to
be added as percentage by weight of the dry soil shall be as specified
in the Contract, The quantity of lime used shall be related to its calcium
oxide content which shall be speãified. Where the lime of different
calcium oxide content is to be used, its quantity shall be suitably adjusted
to the approval of the Engineer so that equivalent calcium oxide is
incorporated in the wotk, The mix design shall be done to arrive at
the appropriate quantity of lime to be added, having due regard to the
purity of lime, the type of soil, the moisture-density relationship, and
the design CBRiUnconflned Compressive Strength (UCS) value specified
in the Contract. The laboratory CBR/UCS value shall be at least 1.5
times thc minimum field value of CBR/UCS stipulated in the Contract.
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402.2.4. Water : The water to be used for lime stabilisation shall
be clean and free from injurious substances. Potable water shall
be preferred.
402.3.1. Weather limitations : Lime-soil stahilisation shall not be
done when the air temperature in the shade is less than 100 C.
402.3.2. Degree of pulverisation: For lime stabilisation, the soil
before addition of stabiliser, shall be pulverised using agricultural im-
plements like disc harrows and rotavators to the extent that it passes
the requirements set out in Table 400-3 when tested in accordance
with the method described in Appendix 3.
TABLE 400-3. SOIL PULVERISATION REQUIREMENTS FOR LIME
STABILISATION
IS Sieve designation Minimum per cent by weight
passing the IS Sieve
26.5 mm 100
5.6 mm 80
40233. Equipment for construction: Stabilised soil sub-bases
shall be constructed by mix-in-place method of construction or as
otherwise approved by the Engineer. 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 pulverising and mixing the
soil with additive and water to specified degree to the full thickness
of the layer being processed, and of achieving the desired degree of
mixing and uniformity of the stabilised material. If so desired by the
Engineer, trial runs with the equipment shall be carried out to establish
its suitability for work.
The thickness of any layer to be stabilised shall be not less than
100 mm when compacted. The maximum thickness shall be 200 mm,
provided the plant used is accepted by the Engineer.
402.3.4. Mix-in-place method of construction:. Before deploying
the equipment, the soil after it is made free of undesirable vegetation
or other deleterious matter shall be spread uniformly on the prepared
subgrade in a quantity sufficient to achieve the desired compacted
thickness of the stabilised layer. Where single-pass equipment is to be
employed, the soil shall be lightly rolled at the discretion of the Engineer.
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The equipment used shall either be of single-pass or multiple pass

type. The mixers shall be equipped with an appropriate device for
controlling the depth of processing and the mixing blades shall be
maintained or reset periodically so that the correct depth of mixing
is obtained at all times.
With single-pass equipment the forward speed of the machine shall
be so selected in relation to the rotor speed that the required degree
of mixing, pulverisation and depth of processing is obtained. In multiple-
pass processing, the prepared subgrade shall be pulverised to the required
depth with successive passes of the equipment and the moisture content
adjusted to be within prescribed limits mentioned hereinafter. The
blending or stabilising material shall then be spread uniformly and mixing
continued with successive passes until the required depth and uniformity
of processing have been obtained.
The mixing equipment shall be so set that it cuts slightly into the
edge of the adjoining lane processed previously so as to ensure that
all the material forming a layer has been properly processed for the
full width.
402.3.5. Construction with manual means: Where manual mixing
is permitted, the soil from borrow areas shall first be freed of all
vegetation and other deleterious matter and placed on the prepared
subgrade. The soil shall then be pulverised by means of crow-bars,
pick axes or other means approved by the Engineer.
Water in requisite quantities may be sprinkled on the soil for aiding
pulverisation. On the pulverised soil, the blending material(s) in requisite
quantities shall be spread uniformly and mixed thoroughly by working
with spades or other similar implements till the whole mass is uniform.
After adjusting the moisture content to be within the limits mentioned
later, the mixed material shall be levelled up to the required thickness
so that it is ready to be rolled.
402.3.6. Addition of lime: Lime may be mixed with the prepared
material either in slurry form or dry state at the option of the Contractor
with the approval of the Engineer.
Dry lime shall be prevented from blowing by adding water to the
limc or other suitable means selected by the Contractor, with the
approval of the Engineer.
The tops of windrowed material may be flattened or slightly trenched
to receive the lime. The distance to which lime may be spread upon
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the prepared material ahead of the mixing operation shall be determined
by the Engineer.
No traffic other than the mixing equipment shall be allowed to pass
over the spread lime until after completion of mixing.
Mixing or remixing operations, regardless of equipment used, shall
continue until the material is free of any white streaks or pockets of
lime and the mixture is uniform,
Non-uniformity of colour reaction, when the treated material is tested
with the standard phcnolphthalein alcohol indicator, will be considered
e~’idenceof inadequate mixing,
402.3.7. Moisture content for compaction: The moisture content
at compaction checked vide IS :2720 (Part 2) shall neither be less than
the optimum moisture content corresponding to IS: 2720 (Part 8) nor
more than 2 per cent above it.
402.3.8. RoIling: Immediately after spreading, grading and levelling
of the mixed material, compaction shall be carried Out with approved
equipment preceded by a few passes of lighter rollers if necessary.
Rolling shall commence at edges and progress towards the centre,
except at superelevated portions where it shall commence at the inner
edge and progress towards outer edge. During rolling the surface shall
be frequently checked for grade and crossfall (camber) and any
irregularities corrected by loosening the material and rebioving/
adding fresh material. Compaction shall continue until the density
achieved is at least 98 per cent of the maximum dry density for the
material determined in accordance with IS: 2720 (Part 8).
Care shall be taken to see that the compaction of lime stabilised
material is completed within three hours of its mixing or such shorter
period as may be found necessary in dry weather.
During rolling it shall be ensured that roller does not bear directly
on hardened or partially hardened treated material previously laid other
than what may be necessary for achieving the specified compaction
at the joint. The final surface shall be well closed, free from movement
under compaction planes, ridges, cracks or loose material. All loose
or segregated or otherwise defective areas shall be made good to the
full thickness of the layer and recompacted.
402.3.9. Curing: The sub-base course shall be suitably cured for
a minimum period of 7 days after which subsequent pavement courses
shall he laid to prevent the surface from drying out and becoming
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friable. No traffic of any kind shall ply over the completed sub-base
unless pepnitted by the Engineer.
of Clause 902.
by the Engineer in accordance with Section 900.
402.5. Strength
When lime is used for improving the subgrade, the soil-lime mix
shall be tested for its CBR value. When lime stabilised soil is used
in a sub-base, it shall be tested for unconfined compressive strength
(UCS) at 7 days. In case of variation from the design CBR/UCS, in situ
value being lower, the pavement design shall be reviewed based on the
actua.l CBR/UCS values. The extra pavement thickness needed on
account of lower CBR/UCS value shall be constructed by the Contractor
at his own cost.
402.6. Arrangements of Traffic
402.7, Measurements for Payment
Stabilised soil sub-base shall be measured as finished work in position
in cubic metres.
402.8. Rates
The Contract unit rate for lime stabilised soil sub-base shall be
payment in full for carrying out the required operations including full
compensation for all components listed in Clause 401.8 (i) to (v).
403. CEMENT TREATED SOIL SUB-BASE/BASE
403.1. Scope
This work shall consist of laying and compacting a sub-base/base
course of soil treated with cement on prepared subgrade/sub-base, in ac-
cordance with the requirements of these Specifications and in conformity
with the lines, grades and cross-sections shown on the drawings or as
403.2. Materials
403.2.1. Material to be stabilised: The material used for cement
<< 109
treatment shall be soil including sand and gravel, laterite, ,kankar, brick
aggregate, crushed rock or slag or any combination of these. For use
in a sub-base course, the material shall have a grading shown in Table
400-4; it shall have a uniformity coefficient not less than 5, capable of
producing a well closed surface finish, For use in a base course, the
material shall be sufficiently well graded to ensure a well-closed surface
finish and have a grading within the range given in Table 400-4. If
the material passing 425 micron sieve is plastic, it shall have a liquid
limit not greater than 45 per cent and a plasticity index not grater than
20 per cent determined in accordance with IS:2720 (Part 5). The physical
requirements for the material to be treated with cement for use in a
base course shall be same as for Grading I Granular Sub-base, Clause
401.2.2.
403.2.2. Cement: Cement for cement stabilisation shalt comply with
the requirements of IS: 269, 455 or 1489.
Table 400-4. GRADING LIMITS OF MATERIAL FOR STABILISATION
WITH CEMENT
IS Slave size Percentage by mass passing

Sub-base Base
FIner than: Within the range:
53.0mm 100 100
37.5 mm 95 95-100
19.0 mm 45 45-100
9.5 mm 35 35-100
4.75 mm 25 25-100
600 micron X 8-65
300 micron 5 5-40
75 micron 0 0-10
403.2.3. Lime: If needed for pre-treatment of highly clayey soils,

Clause 402.2.2. shall apply.
403.2.4. Quantity of cement in stabilised mix: The quantity of
cement to be added as per cent by weight of the dry soil shall be
specified in the Contract. Also if lime is used as pretreatment for
highly clayey soils, the quantity as per cent by weight of dry soil shall
be specified in the Contract. The mix design shall be done on the basis
of 7-day unconfined compressive strength (UCS) anWor durability test
under 12 cycles of wet-dry conditions. The laboratory strength values
shall be at least 1.5 times the minimum field UCS value stipulated in
the Contract.
<< 110
403.2.5. Water: The water to be used for cement stabilisation shall

be clean and free from injurious substances. Potable water shall
be preferred.
403.3.1. Weather limitations : Stabilisation shall not be done when
the air temperature in the shade is less than 10°C.
403.3.2. Degree of pulverisation : For stabilisation, the soil before
addition of stabilizer, shall be pulverised, where necessar~,to the extent
that it passes the requirements as set out in Table 400-5 when tested
in accordance with the method described in Appendix 3.
TABLE’ 400.5. SOIL PULVERISATION REQUIREMENTS FOR CEMENT
STABILISATION
IS Sieve designation Minimum per cent
by weight passing the IS sieve
26.5 mm 100
5.6 mm 80
403.3.3. Clauses 402.3.3 to 402.3,5 shall apply as regards spreading

and mixing the stabiliser except that cement or lime plus cement as
the case may be, shall be used as the stabilising material.
403.3,4. Moisture content for compaction: The moisture content
at compaction checked vide IS: 2720 (Part 2) shall not be less than
the optimum moisture content corresponding to IS: 2720 (Part 8) nor
more than 2 per cent above it.
403.3.5. Rolling: Clause 402.3.8 shall apply except that care shall
be taken to see that the compaction of cement stabilised material is
completed within two hours of its mixing or such shorter period as may
be found necessary in dry weather.
403.3.6. Curing : The sub-base/base course shall be suitably cured
for 7 days. Subsequent pavement course shall be laid soon after to prevent
the surface from drying out and becoming friable. No traffic of any
kind shall ply over the completed sub-base unless permitted by the
Engineer.
403.4. Surface Finish and Quality Control of Works
of Clause 902.
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403.5. Strength
Cement treated soil sub-base /base shall be tested for the unconfined
compressive strength (UCS) value at 7 days, actually obtained in situ.
In case of variation from the design UCS, in situ value being on lower
side, prior to proceeding with laying of base/surface cotfrse on it,
the pavement design shall be reviewed for actual UCS value. The extra
pavement thickness needed on account of lower UCS shall be constructed
by the Contractor at his own cost.
403.7~ Measurements for Payment
Stabilised soil sub-base! base shall be measured as finished work
in position in cubic metres.
403.8. Rates
The Contract unit rate for cement treated soil sub-base/base with
pretreatment with lime if required shall be payment in full for carrying
out the required operations including full compensation for all com-
ponents listed in Clause 401.8 (i) to (v).
404. WATER BOUND MACADAM SUB-BASFJBASE
404.1. Scope
404.1.1. This work shall consist of clean, crushed aggregates me-
chanically 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 these Specifications
and in close conformity with the lines, grades, cross-sections and thickness
as per approved plans or as directed by the Engineer.
404.1.2. It is, however, not desirable to lay water bound macadam
on an existing thin black topped surface without providing adequate
drainage faciljty for water that would get accumulated at the interface
of existing bituminous surface and water bound macadam.
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404.2. Materials
40&2.I. 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 least two fractured
faces. The aggregates shall conform to the physical requirements set
forth in Table 400-6. 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).
404.2.2. 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.
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
Flakiness and IS:2386 30 per cent (Max)
Elongation (Part-i)
Indices (Tetal)
***
* Aggregate may satisfy requirements of either of the two tests.
Aggregates like brick metal, kankar, laterite etc. which gel softened in presence of waler
shall be tested for Impact value under wet conditions in accordance with IS: 5640.
~ The requirement of flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.
404.2.3. Crushed slag : Crushed slag shall be made from air-

cooled blast furnace slag. It shall be of angular shape, reasonably uniform
in quality and density and generally free from thin, elongated and
soft pieces, dirt or other deleterious materials. The weight of crushed
slag shall not he less than ii.2 kN per l11~and the percentage of ~lossy
<< 113
material shall not be more than 20. It should also comply with the
following requirements:
(i) Chemical stability To comply with requirements of
appendix of BS 1047
(ii) Sulphur content Maximum 2 per cent
(iii) Water absorption Maximum 10 per cent
404.2.4. Overburnt (Jhama) brick aggregates : Jhama brick
aggregates shall be made from overburnt bricks or brick bats and be
free from dust and other objectionable and deleterious materials.
404.2.5. Grading requirement of coarse aggregates The
coarse aggregates shall conform to one of the Gradings given in
Table 400-7 as specified, provided, however, the use of Grading No.1
shall be restricted to sub-base courses only.
TABLE 400-7. GRADING REQUIREMENTS OF COARSE AGGREGATES
Grading Size Range IS Sieve Per cent by
No. Designatktn weight passing
1. 90 mm to 45 mm 125 mm 100
90 rum 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5
2. 63 mm to 45 mm 90 mm 100
63 mm 90-100
53 mm 25.75
45 mm 0-15
22.4 mm 0-5
3. 53 mm to 224 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 I shall be 100 mm while for
layer with other Gradings i.e. 2 & 3, ii shall be 75 mm.
404.2.6. Screenings: 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.
<< 114
Sub-B ases, Bases (Non-Bituminous) and Shoulders Section 400
Screenings shall conform to the grading set forth in Table 400-8.

The consolidated details of quantity of screenings required for various
grades of stone aggregates are given in Table 400-9. The table also gives
the quantities of materials (loose) required for 10 m2 for sub-base/base
compacted thickness of 100f75 mm.
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 400-8. GRADING FOR SCREENINGS
Grading Size of IS Sieve Designation Per cent by weight

Classifi- Screenings passing the IS Sieve
cation
A 13.2 mm 13.2 mm 100

11.2 mm 95-100
5.6 mm 15-35
180 micron 0-10
B 11.2 mm 11.2 mm 100
5.6 mm 90-100
180 micron 15-35
TABLE 400.9. APPROXIMATE QUANTITIES OF COARSE AGGREGATES AND

SCREENINGS REQUIRED FOR I00t75 MM COMMCTEDTHICK.
NESS OF WATER ROUND MACADAM (WBM) SUB-BASFIBASE
COURSE FOR 10W AREA
Screenings
Classlfl. Size Compacted Loose Stone Screening Crushable Type such
catIon Range thickness Qty. as Mooruni or Gravel
Grading For. WBM Grading Loose
ClassI.. Sub-base! Cfassi- Qty.
ficalion base course ticatlon
& Size (Loose & Size
quantity)
Grading I 90 mm to 100 mm 1.21 to Type A 0.27 to Not 030 to
45 mm 1.43 mt 13.2 mm 0.30 m1 uniform 0.32 rn1
Grading 2 63 mm to 75 mm 0.91 to Type A 0,12 so -do- 0.22 to

45 mm 1.07 m5 13.2 mm 0.15 rn3 0.24 &
-do- -do- -do- -do- Type B 0.20 to -do- -do-

11.2 mar 0.22 sn’
Grading 3 53 mm to 75 mm -do- -do- 0.18 to -do- -do-

22.4 mm 0.21 mt
<< 115
404.2.7. Binding material : Binding material to be used for watcr

bound macadam as a filler material meant for preventing ravelling,
shall comprise of a suitable material approved by the Engineer having
a Plasticity lndex(PI) value of less than 6 as determined in accordance
with IS: 2720 (Part-5).
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 of water bound macadam will be
OA)6-0.09 m3/lOm2 and 0.08-0.lOmVlOm2 for 100 mm compacted thick-
ness.
The above mentioned quantities should be taken as a guide only,
for estimation of quantities for construction etc.
Application of binding materials may not be necessary when
the screenings used are of crushable type such as moorum or
gravel.
404.3.1. Preparation of base: The surface of the subgrade/
sub-base/base to receive the water bound macadam course shall be
prepared to the specified lines and crossfall (camber) and made free of
dust and other extraneous material. Any ruts or soft yielding places shall
be corrected in, an approved manner and rolled until firm surface is
obtained if necessary by sprinkling water. Any sub-base/base/surface
irregularities, where predominant, shall be made good by providing
appropriate type of profile corrective course (levelling course) to Clause
501 of these Specifications.
As far as possible, laying water bound macadam course over an
existing thick bituminous layer may be avoided since it will cause
problems of internal drainage of the pavement at the interface of two
courses. It is desirable to completely pick out the existing thin
bituminous wearing course where water bound macadam is proposed to
be laid over it. However, where the intensity of rain is low and
the interface drainage facility is efficient, water bound macadam can
be laid over the existing thin bituminous surface by cutting 50 mm x
50 mm furrows at an angle of 45 degrees to the centre line of the
pavement at one metre intervals in the existing road. The directions and
depth of furrows shall be such that they provide adequate bondage and
also serve to drain water to the existing granular base course beneath
the existing thin bituminous surface.
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404.3.2. Inverted choke : If water bound macadam is to be laid

directly over the subgrade, without any other intervening pavement
course, a 25 mm course of screenings (Grading B) or coarse sand
shall be spread on the prepared subgrade before application of the
aggregates is taken up. in case of a fine sand or silty or claycy subgrade,
it is advisable to lay 100 mm insulating layer of screening or coarse
sand on top of fine grainS soil, the gradation of which will depend
upon whether it is intended to act as a drainage layer as well. As a
preferred alternative to inverted choke, appropriate geosynthetics per-
forming functions of separation and drainage may be used over the
prepared subgrade as directed by the Engineer. Section 700 shall be
applicable for use of geosynthetics.
404.3.3, Spreading coarse aggregates : The coarse aggregates shall
be spread uniformly and eventy upon the prepared subgrade/sub-base/
base to proper profile by using templates placed across the road about
6 in apart, in such quantities that the thicknóss of each compacted
layer is not more than 1(X) mm for Grading I and 75 mm for Grading
2 and 3, as specified in Clause 404.2.5. Wherever possible, approved
mechanical devices such as aggregate spreader shall be used to
spread the aggregates uniformly so as to minimise the need for
manual rectification afterwards. Aggregates placed at locations which
are inaccessible to the spreading equipment, may be spread in one or
more layers by any approved means so as to achieve the specified results.
The spreading shall be done from stockpiles along the side of the
roadway or directly from vehicles, No segregation of large or fine
aggregates shall be allowed and the coarse aggregate as spread shall
be of uniform gradation with no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with
templates and all high or low spots remedied by removing or adding
aggregates as may be required. The surface shall be checked frequently
with a straight edge while spreading and rolling so as to ensure a finished
surface as per approved drawings.
The coarse aggregates shall not normally be spread more than 3
days in advance of the subsequent construction operations.
404.3.4, Rolling: Immediately following the spreading of the coarse
aggregate, rolling shall be started with three wheeled power rollers
of 80 to 100 kN capacity or tandem or vibratory rollers of 80 to 100
kN static weight. The type of roller to be used shall be approved by
the Engineer based on trial run.
<< 117
Except on superelevated portions where the rolling shall proceed

from inner edge to the outer, rolling shall begin from the edges
gradually progressing towards the centre. First the edge/edges shall be
compacted with roller running forward arid backward. The roller shall
then move inward parallel to the centre line of the road, in successive
passes uniformly lapping preceding tracks by at least one half width,
Rolling shall be discontinued when the aggregates are partially com-
pacted with sufficient void space in them to permit application of
screenings. However, where screenings are not to be applied, as in the
case of crushed aggregates like brick metal, laterite and kankar,
compaction shall be continued until the aggregates are thoroughly
keyed. During rolling, slight sprinkling of water may be done, if
necessary. Rolling shall not be done when the subgrade is soft or
yielding or when it causes a wave-like motion in the subgrade or sub-
base course.
The rotted surface shall be checked transversely and longitudinally,
with templates and any irregularities corrected by loosening the surface,
adding or removing necessary amount of aggregates and re-rolling
until the entire surface conforms to desired crossfail (camber) and grade.
in no case shall the use of screenings be permitted to make up
depressions.
Material which gets crushed excessively during compaction or
becomes segregated shall be removed and replaced with suitable
aggregates.
It shall be ensured that shoulders are built up simultaneously along
with water bound macadam courses as per Clause 407.4.1.
404.3.5. Application of screenings: After the coarse aggregate
has been rolled to Clause 404.3.4, screenings to completely fill the
interstices shall be applied gradually over the surface. These shall not
be damp or wet at the time of application. Dry rolling shall be done
while the screenings are being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregate. The screenings
shall not be dumped in piles but be spread uniformly in successive thin
layers either by the spreading motions of hand shovels or by mechanical
spreaders, or directly from tipper with suitable grit spreading arrange-
ment. Tipper operating for spreading the screenings shall be so driven
as not to disturb the coarse aggregate.
The screenings shall be applied at a slow and uniform rate (in three
or more applications) so as to ensure filling of all voids. This shall be
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accompanied by dry rolling and brooming with mechanical brooms, hand-

brooms or both. In no case shall the screenings be applied so fast and
thick as to form cakes or ridges on the surface in such a manner as
would prevent filling of voids or prevent the direct bearing of the roller
on the coarse aggregate. These operations shall continue until no more
screenings can be forced into the voids of the coarse aggregate.
The spreading, rolling, and brooming of screenings shall be carried
out in only such lengths of the road which could be completed within
one day’s operation.
404.3.6. Sprinkling of water and grouting : After the screenings
have been applied, the surface shall be copiously sprinkled with water,
swept and rolled. Hand brooms shall be used to sweep the wet
screenings into voids and to distribute them evenly. The sprinkling,
sweeping and rolling operation shall be continued, with additional
screenings applied as necessary until the coarse aggregate has been
thorougl.ly keyed, well-bonded and firmly set in its full depth and a
grout has been formed of screenings. Care shall be taken to see that
the base or subgrade does not get damaged due to the addition
of excessive quantities of water during construction.
In case of lime treated soil sub-base, construction of water bound
macadam on top of it can cause excessive water to flow down to the
lime treated sub-base before it has picked up enough strength (is still
“green”) and thus cause damage to the sub-base layer. The laying of
water bound macadam layer in such cases shall be done after the sub-
base attains adequate strength, as directed by the Engineer.
40&3.7. Application of binding material: After the application
of screenings in accordance with Clauses 404.3.5 and 404.3.6. the binding
material where it is required to be used (Clause 404.2.7) shall
be applied successively in two or more thin layers at a slow and
uniform rate. After each application, the surface shall be copiously
sprinkled with water, the resulting slurry swept in with hand brooms,
or mechanical brooms to fill the voids properly, and rolled during
which water shall be applied to the wheels of the rollers if necessary
to wash down the binding material sticking to them. These operations
shall continue until the resulting slurry after filling of voids, forms a
wave ahead of the wheels of the moving roller.
404.3.8. Setting and drying: After the final compaction of water
bound macadam course, the pavement shall be allowed to dry overnight.
Next morning hungry spots shall be filled with screenings or binding
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material as directed, lightly sprinkled with water if necessary and rolled.

No traffic shall be allowed on the road until the macadam has set. The
Engineer shall have the discretion to stop hauling traffic from using
the completed water bound macadam course, if in his opinion it would
cause excessive damage to the surface.
The compacted water bound macadam course should be allowed
to completely dry and set before the next pavement course is laid over
it.
404.4.1. The surface finish of construction shall conform to thc
requirements of Clause 902.
404.4.2. Control on the quality of materials and works shall be
exercised by the Engineer in accordance with Section 900.
404.4.3. The water bound macadam work shall not be carried out
~shenthe atmospheric temperature is less than 0°Cin the shade.
404.4.4. Reconstruction of defective macadam: The finished surface
of water bound macadam shall conform to the tolerance of surface
regularity as prescribed in Clause 902. However, where the surface ir-
regularity of the course exceeds the tolerances or where the course is
otherwise defective due to subgrade soil mixing with the aggregates,
the course to its full thickness shall be scarified over the affected area,
reshaped with added material or removed and replaced with fresh
material as applicable and recompac ted. En no case shall depressions be
filled up with screenings or binding material.
404.5. Arrangement for Traffic
During the period of construction, the arrangement of traffic shall
be done as per Clause 112.
404.6. Measurements for payment
Water bound macadam shall be measured as finished work in
position in cubic metres.
404.7. Rate
The Contract unit rate for water bound macadam sub-base/base
course shall be payable in full for carrying out the required operations
including full compensation for all components listed in Clause 401.S
(i) to (v) including arrangement of water used in the work as approved
by the Engineer.
<< 120
SubBases, Bases (Nonilituminous) and Shoulders Section 400
405, CRUSHED CEMENT CONCRETE SUB-BASE/BASE

405.1. Scope
This work shall consist of breaking and crushing the damaged
cement concrete slabs and recomp~tingthe same as sub-base/base
course in one or more layers. Where specified, it shall also include
treating the surface of the top layer with a penetration coat of bitumen,
The work shall be performed on such widths and lengths as may be
specified, in accordance with the requirements of these Specifications
and in con formity with the lines, grades and cross-sections shown
on the drawings or as otherwise directed by the Engineer.
405.2. Materials
405.2.1. Coarse aggregate : Coarse aggregate for this work shall
be hrokcn cement concrete slabs crushed to a size not exceeding 75 mm
and as far as possible, conforming to one of the gradings given in Table
4(X)-?.
405.2.2. Key aggregate : Key aggregate for the penetration coat
shall consist of crushed stone, crushed gravel, shingle or other stones.
it shall be clean, strong, durable, of fairly cubical shape and free of
disintegrated pieces, organic or other deleterious matter and adherent
coatings. The aggregate shall be hydrophobic and of tow porosity.
The aggregate shall be of 11.2 mm size defined as 100 per cent
passing through 13.2 mm sieve and retained on 5.6 mm sieve and shall
satisfy the physical requirements set forth in Table 500-3.
405.2.3. Binder: Binder for the penetration coat for the top layer
shall be bitumen of a suitable grade, as directed by the Engineer and
satisfying the requirements of IS: 73,217 or 454, as applicable or any
approved cutback or emulsion, satisfying the requirements of IS:8887.
405.3.1. General: Crushed cement concrete sub-base/base course
may be constructed in one or two layers, depending upon the thickness
of the concrete slabs dismantled and crushed. The thickness of each
layer shall, however, not exceed 100 mm in case of sub-base and 75
mm in case of base course.
The course shall be constructed as water bound macadam to Clause
404, using crushed cement concrete as coarse aggregate except that no
screenings or binding material need be applied. Where specified,
<< 12t
the top layer shall be treated with a penetration coat of binder described
in Clause 4053.2.
405.3.2. Application of penetration coat over the top layer:
Before the application of the penetralion coat, the surface shall be cleaned
of dust, dirt and other foreign matter, using mechanical broom or any
other equipment specified by the Engineer. Dust removed in the process
shall be blown off with the help of compressed air.
The binder shall be heated to the temperature appropriate to the
grade of bitumen used and sprayed on the dry surface in a uniform manner
a~the rate of 25 kg per 10 m2 area in terms of the residual bitumen
with the help of either self-propelled or towed bitumen pressure
sprayer with self-heating arrangement and spray nozzle capable of
spraying bitumen at specified rates and temperatures so as to provide
a uniform, unbroken spread of bitumen. Excessive deposits of binder
caused by stopping or starting of the sprayer or through leakage or
any other reason shall be suitably corrected.
Immediately after the application of binder, the key aggregates,
in a clean and dry state shall be spread uniformly on the surface at
the rate of 0,13 m3 per 10 m2 area, preferably by means of a mechanical
gritter, capable of spreading aggregate uniformly at specified rates
or otherwise manually with the approval of the Engineer, so as
to cover the surface completely. Immediately after the application of the
key aggregates, the entire surface shall be rolled to Clause 506.3.8.
of Clause 902.
Control on the quality of material and works shall be exercised by
the Engineer in accordance with Section 900.
done as per Clause 112.
Breaking the existing cement concrete pavement slabs, crushing and
recompacting the slab material as sub-base/base course shall be measured
as a single item in terms of the volume of sub-base/base laid in position
in cubic metres.
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Penetration coat shall be measured as finished work in square

metres.
405.7. Rates
405.7.!. The Contract unit rate for crushed cement concrete sub-
base/base course shalL be payment in full for carrying out the
required operations including full compensation for:
(0 making arrangements for traffic to Clause 112 except for initial treatment to
verges/shoulders and construction of diversions;
(ii) breaking the cement csiricrete slabs, crushing, sieving and recompacting the
slab material as suh-base)base course;
(iii) all labour, tools, equipment and incidentals to complete the work to the
Specifications; and
(iv) carrying out the work in part widths of road where directed.
405.7.2. The Contract unit rate for penetration coat shalt be payment
in full for carrying out the required operations including full
compensation for all components listed in Clause 504.8.
406. WET MIX MACADAM SUB-BASE/BASE
406.1. Scope
This work shalt 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 these Specifications. The material shall be laid in one or more layers
as necessary to lines, grades and cross-sections shown on the approved
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.
406.2. Materials
406.2.!. Aggregates
406.2.1.!. Physical requirements: Coarse aggregates shall be
,rushed 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 shalt
have at least two fractured faces. The aggregates shall conform
to the physical requirements set forth in Table 400-10 below.
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-

TABLE 400-10. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
WET MIX MACADAM FOR SUB-BASE/BASE COURSES
- Test TestMethod Requirements -
*Los Angii IS: 2386 (Part-4) 40per cent (Max,)

Abrasion value
or
*Aggregate IS: 2386 (Part-4) 30 per cent (Max.)
tmpact value or15:5640
2. Combined Flakiness and IS: 2386 (Part-I) 30 per cent (Max.)”’
Elongation indices (Total)
** 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.
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).
406.2.1.2. Grading requirements : The aggregates shall conform to
the grading given in Table 400-11.
TABLE 400-Il. GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX
MACADAM
tS Sieve Designation Percent by weight passing the IS sieve
53.00 iiiiii 100
45.00 mm 95-100
2650 mm —
22.40 mm 60-80
lt.20 mm 40-60
4.75 mm 25-40
236 mm 15-30
600.00 micron 8-22
75.00 micron - 0-8
Materials finer than 425 micron shall have Plasticity Index (P1) not
exceeding 6.
The final gradation approved within these limits shall be wefl 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.
406.3.1. Preparation of base: Clause 404.3.1. shall apply.
406.3,2. Provision of lateral confinement ofaggregates : While con-
structing wet mix macadam, arrangement shall be made for the lateral
<< 124
confinement of wet mix. This shall be done by laying materials in

adjoining shoulders along with that of wet mix macadam layer and
following the sequence of operations described in Clause 407.4.1.
406.3.3. Preparatk)n of mix : Wet Mix Macadam shall be prepared
in an approved mixing plant of suitable capacity having provision
for controlled addition of water and forced/positive mixing arrangement
like pugmill or pan type mixer of concrete batching plant, For small
quantity of wet mix work, the Engineer may permit the mixing to
he done in concrete mixers.
Optimum moisture for mixing shall be determined in accordance
with IS:2720 (Part-8) after replacing the aggregate fraction retained
on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size, While
adding water, due allowance should be made for evaporation losses.
However, at the time of compaction, water in the wet mix should not
vary from the optimum value by more than agreed limits. The mixed
material shotild be uniformly wet and no segregation should
be permitted.
406.3.4. Spreading of mix Immediately after mixing, the
aggregates shall be spread uniformly and evenly upon the prepared
subgrade/sub- base/base in required quantities. In no case should these
be dumped in heaps directly on the area where these are to be laid nor
shall their hauling over a partly completed stretch be permitted.
The mix may be spread either by a paver finisher or motor
grader. For portions where mechanical means cannot be used, manual
means as approved by the Engineer shall be used. The motor grader
shall be capable of spreading the material uniformly all over the surface.
Its blade shall have hydraulic control suitable for initial adjustments
and maintaining the same so as to achieve the specified slope and grade.
The paver finisher shall be self-propelled, having the foliowing
features
(i) Loading hoppers and suitable distribution mechanism
(ii) The screed shall have tamping and vibrating arrangement for initial compaction
to the layer as it is spread without ruuing or otherwise marring the surface
profile.
(iii) ‘I’he paver shall be equipped with necessaly control mechanism so as to
ensure that the finished surface is free from surface blemishes.
The surface of the aggregate shall be carefully checked with templates
and all high or low spots remedied by removing or adding aggregate
as may be required. The layer may be tested by depth blocks during
125
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Section 400 Sub-B ases, Bases (Non-Bituminous) and Shoulders
construction. No segregation of larger and fine particles should be

allowed, The aggregates as spread should be of uniform gradation with
no pockets of fine materials.
406.3.5. Compaction: After the mix has been laid to the required
thickness, grade and crossfatl/eamber the same shall be uniformly com-
pacted, to the full depth with suitable roller. If the thickness of single
compacted layer does not exceed 100 mm, a smooth wheel roller of 80
10 100 kN weight may he used. For a compacted single layer upto 200
mm, the compaction shall be done with the help of vibratory roller
of minimum static weight of 80 to 1(X) kN or equivalent capacity roller.
The speed of the roller shall not exceed 5 km/h.
In portions having unidirectional cross fall/superelevation, rolling
shall commence from the lower edge and progress gradually towards
the upper edge. Thereafter, roller should progress parallel to the centre
line of the road, uniformly over-lapping each preceding track by at
least one third width until the entire surface has been rolled. Alternate
trips of the roller shall be terminated in stops at least I m away from
any preceding stop.
In portions in camber, rolling should begin at the edge with the
roller running forward and backward until the edges have been firmly
compacted. The roller shall then progress gradually towards the centre
parallel to the centre line of the road uniformly overlapping each of
the preceding track by at least one-third width until the entire surface
has been rolled.
Any displacement occurring as a result of reversing of the direction
of a roller or from any other cause shall be corrected at once as specified
and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller,
the mixture shall be thoroughly compacted with mechanical tampers
or a plate compactor. Skin patching of an area without scarifying
the surface to permit proper bonding of the added material shall not
be permitted.
Rolling should not be done when the subgrade is soft or yielding
or when it causes a wave-like motion in the sub-base/base course or
subgrade. If irregularities develop Øuring rolling which exceed 12 mm
when tested with a 3 metre straight edge, the surface should be loosened
and prenlixed material added or removed as required before roiling again
so as to achieve a uniform surface conforming to the desired grade and
<< 126
Sub-B ases, Bases (Non-Bituminous) and Shoulders Section 40()
crossfall. In no case should the use of unmixed material be permitted
to make up the depressions.
Rolling shall be continued till the density achieved is at least
98 per cent of the maximum dry density for the material as determined
by the method outlined in IS: 2720 (Part—8)
After completion, the surface of any finished layer shall be well-
closed, free from movement under compaction equipment or any
conlpaetion planes, ridges, cracks and loose material. All loose,segregated
or otherwise defective areas shall be made good to the full thickness
of the layer and recompaeted.
406.3.6. Setting and drying: After final compaction of wet mix mac-
adam course, the road shall be allowed to dry for 24 hours.
406.4. Opening to Traffic
Preferably no vehicular traffic of any kind should be allowed on
the finished wet mix macadam surface till it has dried and the wearing
course laid.
406.5.!. Surface evenness : The surface finish of construction shall
conform to the requirements of Clause 902.
406.5.2. Quality control : Control on the quality of materials
and works shall be exercised by the Engineer in accordance with Section
900.
406.6. Rectification of Surface Irregularity
Where the surface irregularity of the wet mix macadam course
exceeds the permissible tolerances or where the course is otherwise
defective due to subgrade soil getting mixed with the aggregates, the
ftill thickness of the layer shall be scarified over the affected area, re-
shaped with added premixed material or removed and replaced with
fresh premixed material as applicable and recompaeted in accordance
with Clause 406.3. The area treated in the aforesaid manner shall not
be less than 5 m long and 2 m wide. In no case shall depressions
be filled up with unmixed and ungraded material or fines.
<< 127
Wet mix macadam shall be measured as finished work in position
in cubic metres.
406.9. Rates
The Contract unit rate for wet mix macadam shall be payment in
full for carrying out the required operations including lull
compensation for all components listed in Clause 4018.
407. SHOULDERS, ISLANDS AND MEDIAN
407.1. Scope
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 these Specifications and in conformity with
the lines, grades and cross-sections shown on the drawings or as directed
by the Engineer.
407.2. Materials
Shoulder on either side of the road may be of selected earth/
granular material/ paved conforthing to the requirements of Clause
305/401 and the median may be of selected earth conforming to the
Median/Traffic islands shall he 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.
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 briclçi’stone block edgings as shown in the drawings. The bricks
shall conform to Clause 1003 of these Specifications. Stone blocks
shall conform to Clause 1004 of these Specifications and shall be of
size 225 mm x 110 mm x 75 mm.
407.3. Size or Shoulders/Median/Islands
Shoulder (earthen/hard/paved)/median/traffic island dimensions shall
be as shown on ihe drawings or as directed by the Engineer.
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407,4. Construction Operations

407.4.1. Shoulder: The sequence of operations shall be such that
the construction of paved shoulder is done in layers each matching
the thickness of adjoining pavement layer, Only after a layer of pavement
and corresponding layers in paved and earth shoulder portion have been
laid and compacted, the construction of next layer of pavement and
shoulder shall be taken up.
Where the materials in adjacent layers are different, these shall
be laid together and the pavement layer shall be compacted first. The
corresponding layer in paved shoulder portion shall be compacted
thereafter, which shall be followed by compaction of earth shoulder layer.
The adjacent layers having same material shall be laid and compacted
together.
In all cases where paved shoulders have to be provided along
side of existing carriageway, the existing shoulders shall be excavaled
in full width and to the required depth as per Clause 301.3.7. Under
no circumstances, box cutting shall be done for construction of shoulders.
Compaction requirement of earthen shoulder shall be as per Table
300-2, In the case of bituminous courses, work on shoulder (earthenJ
hardJpaved), shall start~only after the pavement course has been laid
and compacted.
During all stages of shoulder (earthen/hard/paved) construction, the
required crossfall shall be maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material
shall be placed directly on the shoulder. Any spilled material dragged
on to the pavement surface shall be immediately removed, without
damage to the pavement, and the area so affected thoroughly cleaned.
407.4.2, Median and Islands : 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.
<< 129
Section 4(X) Sub—Bases, Bases (Non-Bituminous) and Shoulders
407,4.3, Bricklstone block edging: The bricks/stone blocks shall

be laid on edge, with the length parallel to the transverse direction of
the road, They shall be laid on a bed of 25 mm sand, set carefully,
rolled into position by a light roller and made flush with the finished
level of the pavement.
of Clause 902. Control on the quality of materials and works shall be
Shoulder (earthen/hard/paved), island and median construction shall
be measured as finished work in position as below:
(i) For excavation in cu. m.
(ii) For earthwork!granular fill in Cu. m,
(iii) For sub-base, base, surfacing courser in units as for respective items.
(iv) For kerb in running metres.
(v) For surfing and tilelslab finish in sqm.
(vi) For brick/stone btock edging in sqm.
407.7. Rate
The Contract unit rate for shoulder (hard/paved/earthen with brick
or stone block edging), island and median construction shall be payment
in full for carrying out the required operations including full compen-
sation for all components listed in Clause 401.8 (1) to (v) as applicable.
The rate for brick/stone block edging shall include the cost of sand
cushion.
408. CEMENT CONCRETE KERB AND KERB WITH
CHANNEL
408.1. Scope
This work shall consist of constructing cement concrete kerbs and
kerbs with channel in the central median and/or along the footpaths
or separators in conformity with the lines, levels and dimensions as
specified in the drawings.
408.2. Materials
Kerbs and kerb with channel shall be provided in cement concrete
of Grade M20 in accordance with Section 1700 of these Specifications.
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Sub-Bases, Bases (Non-Bituminous) and Shoukiers Section 400
408.3. Type of Construction
These shall be cast-in-situ construction with suitable kerb casting
machine in all situations except at locations where continuous casting with
equipment is not practicable. In those situations, precastconcrete blocks shall
be used.
408.4. Equipment
A continuous kerb casting equipment ofadequate capacity and controls,
capable of laying the kerbs in required cross-sections and producing a
well-compacted mass of concrete free of voids and honeycombs, shall be
used.
408.5.1. Kerb shall be laid on firm foundation of minimum 150 mm
thicknessof cement concrete of M1O grade cast in-situ or on extended width
of pavement. The foundation shall have a projection of 50 mm beyond the
kerb stone. Before laying the foundation of lean concrete, the base shall be
levelled and slightly watered to make it damp.
408.5.2. In the median portions in the straight reaches, the kerb shall be
cast in contintiotis lengths. In the portions where footpath is provided and/or
the slope of the carriageway is towards median (as in case of superelevated
portions), there shall be sufficient gap/recess left in the kerb to facilitate
drainage openings.
408.53. After laying the keibs and just prior to hardening of the
concrete, saw cut grooves shall be provided at 5 m intervals or as specified
by the Engineer.
408.5.4. Kerbs on the drainage ends such as along the footpath or the
median in superelevated portions, shall be cast with monolithic concrete
channels as indicated in drawings. The slope of the channel towards drainage
pipes shall be ensured for efficient drainageof the road surface.
408.5.5. Vertical and horizontal tolerances with respect to true line and
level shall be ±6mm.
Cement concrete kerb/kerb with channel shall be measured in linear
metre for the complete item of work.
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Foundation of kerb, where separately provided shall be measured
in linear metre for complete item of work.
408.7. Rates
The Contract unit rates for cement concrete kerb/kerb with channel
and foundation for kerb shall be payment in full compensation for
furnishing all materials, labour, tools, equipment for construction and
other incidental cost necessary to complete the work.
409. FOOTPATHS AND SEPARATORS
409.1. Scope
The work shall consist of cctistructing 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.
409.2. Materials -
The footpaths and separators shall be constructed with any of the

follçwing types
(a) Cast-in-situ cesnent concrete of Grade M20 as per Section 1700 of the Specifi-
cations.
(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.

409.3.1. Drainage pipes below the footpath originating from the
kerbs shall be first laid in the required slope and connected to the
drains/sumps/storm water drain/drainage chutes as per provisions of
the drawings, or as specified.
409.3.2. Portion on back side of kerbs shall be filled and compacted
with granular sub-base material as per Clause 401 of the Specifleations
in specified thickness.
409.33. The base shall be prepared and finished to the required
lines, levels and dimensions as indicated in the drawings with the
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following
(a) Minimum 150 mm thick,compacted granular sub-base materialas per Clause 401 of
the Specifications.
(b) Minimum 25 mm thick cement concrete of Grade M 15.
Over the prepared base, precast concrete blocks/tiles/naturalstone slabs

and/or east-in-situ slab shall be set/laid as described in Clauses 409.3.4 and
409
4093.4. Precast cement concrete blocks/tiles/natural stone slab:
The blocks/tiles/slabs shall be set on a layer ofaverage 12 mm thick cement-
sand mortar(l:3) laid on prepared base in such a way that there is no rocking.
The gaps between the blocks/tiles/slabs shall not be more than 12 mm and
shall he filled with cement-sand mortar (1:3).
409.3.5. Cast-in-situ cement concrete: The minimum thicknessof the
cement concrete shall be 25 mm and it shall he cast on the prepared base in
panels of specified size in a staggered manner. Construction joints shall be
provided as per Section 1700 of the Specifications.
Footpaths and separators shall be measured in sqmetrè between inside
of kerbs,
409.5. Rates
Contractunit rates shall he inclusive of full compensation of all labour,
materials, tools,equipment and incidentals toconstruction of footpaths. Cost
of providing pipes and arrangement for their discharge into appropriate
drainage channels shall be incidental to the construction of footpaths.
410. CRUSHER-RUN MACADAM BASE
410.1. Scope
This work shall consist of furnishing, placing and compacting crushed
stone aggregate sub-base and base courses constructed in accordance with the
requirements set forth in this Specification and in conformity with the lines,
grades, thicknesses and cross-sections shown on the plans or as directed by
the Engine r.
410.2. Materials
The material to be used for the work shall be crushed rock, Ifcrushed
gravel/shingle is used, not less than 90 percentby weightof the gravel/shingle
pieces retained on 4.75 mm sieve shall have at least two fractured faces. It
shall be free from any organic matter and other deleterious substances and
shall be of such nature that it can be compacted readily under watering and
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rolling to form a firm, stable base. The aggregate shall conform to the grading
and quality requirements shown in Tables 400-12 and 400-13.
At the option ofthe Contractor, thegrading for either 53 mm maximum
size or 37.5 mm maximum size shall be used, except that once a grading is
selected, it shall not be changed without the Engineer’s approval.
TABLE 400.12. AGGREGATE GRADING REQUIREMENTS
Sieve size Per cent passing by weight
53mm max. size 37.5mm max. size
63 mm 100
45 mm 87-lOG tOO
22~4 mm 5O~85 90-tOO
5.6 mm 25-45 35-55
710 micron 10-25 10-30
90 micron 2-9 2-9
TABLE 400-13. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR
CRUSHER-RUN MACADAM BASE
Test_-~ Test Method Requirements
4Los Angeles IS :2386 40 maximum
Abrasion value (Part-4)
or
*Aggregate IS :2386 30rnaxirnum
Impact value (Part.4) or
IS : 5640
2. Combined
Flakiness and IS :2386 30maximum***
Elongation Indices (Total) (Pan-i)
3. **W~t~.
absorption IS: 2386 2per cent
(Part-3) Maximum
4, liquid Limit of IS : 2720 Not more than

material passing 425 micron (Part-5) 25
5. Plasticity Index IS :2720 Not more than

ofmaterial passing 425 micron (Part-5) 6

~ If the water absorption is more than 2 per cent, soundness test shall be carried
out as per IS:2386 (Part-5).
~ To determine this combined proportion, the flaky stone from a representative
sample should first be separated out. Flakiness index is weight of flaky stone
separated out from the remaining (non-flaky) stone metal, Elongation index is
weight of elongated particles divided by total non-flaky partides. The value of
flakiness ~rsdexand elongation index so found are added up.
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410.3.1. Preparation or subgrade: Any ruts, deformations or soft
yielding places which occur in the sub-base or subgrade shall be
corrected and compacted to the required density before the aggregate
base course is placed thereon.
410.3.2, Spreading, watering, mixing and compaction: The ag-
gregate shall be uniformly deposited on the approved subgrade by means
of the hauling vehicle with or without spreading devices. Aggregate will
be distributed over the surface to the depth specified on the plans or
as directed by the Engineer.
After the base course material has been deposited, it shall be
thoroughly blade-mixed to full depth of the layer by alternately blading
the entire layer to the centre and back to the edges of the road. It
shall then be spread and finished to the required cross-section by means
of a motor grader.
Water shall be applied prior to and during all blading and
processing operations to moisten the material sufficiently to prevent
segregation of the fine and coarse particles. Water shall be applied
in sufficient amounts during construction to assist in compaction.
Alternatively, mixing of the crusher run material and water may be
done in a mixing plant as per Clause 406.3.3.
Compaction shall commence immediately after the spreading op-
eration. If the thickness of single compacted layer does not exceed 100
mm, a smooth wheel roller of 80 tolOO kN weight may be used. For
a compacted single layer upto 200 mm the compaction shall be done
with the help of vibratory roller of minimum static weight of 80 to 100
kN or equivalent capacity roller. The speed of the roller shall not
exceed 5 km/h. Each layer of material shall be compacted to riot less
than 98 per cent of the maximum density as determined by IS: 2720
(Part.8).
of Clause 902.
<< 135
Crusher-run macadam base shall be measured as finished work in
position in cubic metres.
410.7. Rate
The Contract unit rate for crusher run macadam base shall be
payment in full for carrying out the required operations including
full compensation for items as in Clause 401.8 (i) to (v).
<< 136
Base and Surface Courses (Bituminous)
500
Base and Surface Courses
(Bituminous)
<<
Base and Surface Courses (Bituminous) Section 500

501, PREPARATION OF SURFACE
501.1. Scope
This work shall consist of preparing an existing granular or black-
topped surface to specified lines, grades and cross-sections in advance
of laying a bituminous course. The work shall be performed on such
widths and lengths ~s shown in applicable drawing and consist of
scarifying and re-laying the granular base course and/or scarifying the
existing surface, filling of potholes, sealing of cracks and/or application
of a profile corrective course (levelling course) as necessary.
501,2. Materials
501.2.1. For scarifying and re-laying the granular surface
The materials used shall be coarse aggregates salvaged from scarification
of the existing granular base course supplemented by fresh coarse
aggregates and screenings so that aggregates and screenings thus
supplemented correspond to Clause 404: Water Bound Macadam or
Clause 406: Wet Mix Macadam, as the case may be.
501.2.2. For patching potholes and seating cracks: For patching
potholes, approved material having same specification as that of
profile corrective course shall be used. For sealing small cracks
finer than 3 mm, a fog seal conforming to Section 3000 shall be applied
while larger cracks wider than 3 mm shall be treated with an emulsion
slurry seal, conforming to Clause 516.
501.2.3. For profile corrective course: Aprofile corrective course
(levelling course) is essentially a pavement base material course for cor-
recting the existing pavement profile which has either lost its shape
or has to be given a new shape to meet the requirement of specified
lines, grades and cross-sections.
It shall be differentiated from the strengthening course or other
type of structural pavement course needed for upgrading as a remedial
measure against inherently deficient and/or distressed pavement. It is
meant to remove the irregularity in the existing road profile only.
501.2.4. Profile corrective course and its application: The type
of material for profile corrective course shall be as shown on the
drawing. If it is to be laid as part of the overlay/strengthening course,
the profile corrective course material shall be of the same specification
as that of the overlay/strengthening course. However, if provided as a
<< 139
Section 500 Base and Surface Courses (Bituminous)
separate layer, it may be of the same specification as the layer over which
it is to be laid or intermediate between underlying and overlying layers,
as shown on the Drawing.
(i) Wherever isolated high spots projecting over the pavement surface do exist, the
same shalt be cut by milling machine or any other approved method, to minimise
the profile corrective course requirensenL If, in the proceas,the bottom layer gets
disturbed, the local area shall be cut and filled with profile corrective course
mate ral
(ii) Where the maximum profile corrective course thickness works out to be not more
than 40 mm, it shall be done as an integral part of the overlay course. In other
cases, the profile corrective course shall be provided as a separate layer a5pting
such construction procedures and using such equipment as may be appropriate
to the specified type of material and thickness of the course to be provided.

501.3.1. Preparing existing granular surface : Where the
existing surface is granular, all loose and disintegrated materials shall
be removed and the surface lightly watered if the profile corrective
course to be provided as a separate layer is also granular. If,
however, over the existing granular surface, a profile corrective course
of bituminous material is to be laid, the existing granular surface shall
be primed as per Clause 502.
501.3.2. Scarifying existing bituminous surface Where necessary,
the existing bituminous layer in the specified width shall be removed
with care without causing undue disturbance to the underlying layer
by suitable method approved by the Engineer. After removing it, all loose
and disintegrated materials of underlying layer which might have been
disturbed in the process of removal shall, before laying of the
overlay course, be reset properly by spreading/hand packing of aggregates
and compacting with suitable roller/heavy hand rammers/approved
mechanical tampei~so that the level of the top surface of such scarified
area shall be even and properly graded with respect to adjoining surface.~.
Where applicable, the granular surface, after removal of the existing
bituminous layer, shalt be primed as per Clause 502 to receive a
bituminous profile corrective course. Reusable materials shall be stacked
as directed by the Engineer with all lift and lead of 1000 m.
501.3.3. Patching of potholes and sealing of cracks : Before pro-
viding profile corrective course on the existing pavement, potholes, if
any, shall be drained of water, cut to regular shape with sides vertical
upto the affected depth and slightly beyond the limits of affected area
and dried. All loose and disintegrated materials fror~it shall be removed.
The potholes shall then be filled with material as per Clause No.
<< 140
501.2.2 in layers not exceeding 75 mm after painting the sides and

bottom with a thin layer of hot straight-run bitumen/emulsion and
each layer shall be compacted with approved mechanical tampers!
small vibratory roller and the top layer shall be flush with the existing
bituminous surface. All loose and/or surplus materials on the surface
after making good the potholes, shall be removed.
The cracks in the old pavement surface shall be sealed with a fog
seal if cracks are small (less than 3 mm width); fog seal shall consist
of a spray of a bituminous cutback or a slow-setting bitumen emulsion
diluted with an equal amount of water, the rate of spray being 0.5
to 1.0 litre /sq.m depending upon the texture and dryness of the existing
bituminous surface. The spray is allowed to set to a firm condition and
traffic is allowed only thereafter so as to ensure that the material is
not picked up by traffic. For large cracks, the sealing shall be done
with emulsion slurry seal as per Clause 516 of these Specifications.
501.3.4. Laying the profile corrective course
501.3.4.1. After preparing the granular surface as in Clauses 501.3.1
and 501 .3.2, the profile corrective course with material as per Clause
501,2.3/501.2.4 shall be laid and compacted to the requirement of
particular Specification clause. Where a bituminous profile corredtive
course is to be laid over a primed granular surface, a tack coat
conforming to Clause 503 shall be applied prior to laying profile
corrective course.
501.3.4.2. An existing bituminous surface shall be prepared as per
Clause 501.3.3. and after applying a tack coat conforming to Clause
503, the bituminous profile corrective course shall be laid and
compacted to the requirement of particular Specjfication clause.
501,3.5. In specific situation of short sags or depressions in the
pavement, it may become necessary to provide corrective course in the
form of flat wedges, Normally, layers in maximum thickness at any
point more than’ 100 mm shall not be provided. In placing multiple
lifts, the lift of shortest length (at the lowest portion of the sag!
depression) should be provided first, with successive lifts extending
over and fully covering underneath layer, precluding development
of a series of joints on the top surfaces, as illustrated in Fig.500- 1.
For camber correction or correction of superelevation of the
existing carriageway, method as shown in the illustrative Fig. 500-2 shall
be adopted depending on the profile of the existing carriageway.
141
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LIFTS — EXISTING LAYER
(A) C~tRECT METHOD
EXISTING LAYER
— 2~
— 3-
(B) INCORRECT METHOD
Note Profile corrective course matenat so ne rn accordance with the tilt Inicieness
Fig. 500-LMethods for providing corrective course for short sags and depressions
<< 142
C
& a
B°
E41 ~
C
CO
0 td)
2
— a
—
—
Ha
a
a a
a
U Cl
a
0
C)
C)
a
0 U
Fig. 500-2. Correction of Camber or Super-Elevation
143
Section 500 Base and Surface Courses (13 ituminous)
501.3.6. Covering the profile corrective course: Work of

Profile Corrective Course shall be so planned that it shall be covered
by the designed base/wearing course at the earliest, before opening to
regular traffic.
Relevant provisions of Section 900 shall be exercised by the Engineer.
During the construction operations, arrangement of traffic shall be
done to Clause 112.
501,6.1. The work of filling potholes shall be considered incidental
10 the construction of Profile Corrective Course/bituminous course for
which the existing pavement surface is prepared.
The work of filling cracks by applying fog seal or emulsion slurry
seal shall be measured in square metres, and paid separately.
501.6.2. Scarifying existing bituminous surface shaU be measured
in squ~remetre.
501.6.3. Profile Corrective Course shall be measured as volunie com-
pacted in position in cubic metres or in tonnage as specified in the
contract, The volume shall be worked out by plotting the exact profile
of Profile Corrective Course as built up at site and superimposed on
the existing pavement profile.
501.7. Rates
501.7.1. Contract unit rate for scarifying of existing bituminous
surface including repairing/resetting disturbed underlying layer and also
removing and stacking reusable/unusable materials shall include cost of
all labour, supply of mater’als needed for repair/resetting, hire charges
of tools and plant and transportation of scarified materials with ‘all lifts
and upto a lead of 1000 m.
501.7.2. The contract unit rate for Profile Correctiye Course shall
be payment in full for carrying out the required operations including
full compensMion for:
(i) Making arrangements for traffic to tlause 112;
(ii) Providing all materials to be incorporated in she work including any royalties,
fees, rents (where applicable) and all leads and lins, unless the contract
specifically excludes any item of msteriai required for the work or provides
for separate payment in accordance with Clause 514;
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(iii) Preparation of the exposed surface/existing surface including filling of pot holes,
all cleaning operations and application of tack coat;
(iv) All labour, tools, equipment and incidentals necessary to complete the work
to the Specifications; and
(v) Carrying out the work in part widths of road where directed by the Engineer.
501.7.3. The contract unit rate for sealing cracks by applying fog
seal shall be inclusive of providing all materials and tools arid plant
and carrying out the work. The contract unit rate for sealing cracks
by providing emulsion slurry seal shall be as set forth in Clause 516.9.
502. PRIME COAT OVER GRANULAR BASE
502.1., Scope
This work shall consist of application of single coat of low
viscosity liquid bituminous material to an absorbent granular surface
preparatory to any superimposed bitUminous treatment or construction.
502.2. Materials
502,2.1. 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) Surfaces 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.
502.2.2, The different ranges of viscosity requirements ‘for the

primers to be used for the different types of surfaces to be primed,
as classified in 502.2.1, are given in Table 500-1.
TABLE 500-I. VISCOSITY REQUIREMENT AND QUANTITY OF
BITUMINOUS PRIMER
Type of surface Kinematic Viscosity Quan tity per
of Primer at 60~C 10 sq.m.
(Centistokes) ( kg)
Low porosity 30-60 6 to 9
Medium porosity 70.140 9 to 12
High porosity 250-500 12 to 15
502.2.3. The bituminous primer shall be Medium Curing Cutback
(MC) produced by fluxing, in an approved manner, bitumen of 80/100
penetration grade with kerosene. The cutback shall be free from water
and shall not show any signs of separation prior to use. Slow setting
Cationic emulsion as per IS: 8887 may also be used, but the particular
grade to be used for the work shall be got approved by the Engineer.
<< 145
Sampling and testing of bituminous primer shall be as per IS:2 17.
IS:454 and IS:8887.
502.3. Weather and Seasonal Limitations
The bituminous primer shall not be applied on a wet surface or
during dust storm or when the weather is foggy, rainy or windy. The
prime coat for surface treatment should not be applied when the
temperature in the shade is less than 10°C.
502.4. Construction
502.4,1. Equipment: The primer distributor shall be pneumatic
tyred self-propelled pressure distributor equipped for spraying the material
uniformly at the specified rates and temperatures. Spraying by manual
methods may be allowed for small areas at the discretion of the Engineer.
Power broom and/or blowers may be supplemented by hand brooms
51)2.4.2. Preparation of road surface: The surface to be primed
shall be swept clean, free from dust and shall be dry. It shall be shaped
to the specified grades and section. It shall also be free from ruts, any
other irregularities and segregated materials. Minor depressions and
potholes may be ignored until the surface is primed, after which they
shall be patched with a suitable premix material prior to the surface
treatment.
502.43. Application of bituminous primer: The bituminous primer
shall be sprayed/distributed uniformly over the dry surface, prepared as
per Clause 502A.2 using self-propelled sprayer equipped with self-heating
arrangement, suitable pump, adequate capacity compressor and spraying
bar with nozzles having constant volume or pressure system capable of
supplying primer at specified rates and temperature so as to provide a
uniformly unbroken spread of primer. If the surface to be primed is so
dry or dusty as to cause freckling of bituminous material, it shall be
lightly and uniformly sprinkled with water immediately prior to priming;
however, the bituminous material shall not be applied till such time as
no surface water is visible. The primer shall be applied at the rate as
specified in Table 500-1.
Temperature of application of a primer need only be high enough
to permit the primer to be effectively sprayed through the jets of the
spray bar and to cover the granular base surface uniformly in the desired
quantity.
<< 146
Base and Surface Courses (Bifliminous) Section 500
The desirable range of temperatures at the time of application of

MC-30, MC-70 and MC-250 grades shall be 30 to 55°C; 50 to 800C
and 75 to 100°Crespectively. For a bituminous emulsion primer, the
range of spraying temperature may be 20 to 60°C.
Following the application of bituminous material, the surface shall
be allowed to cure for at least 24 hours or for any other period so as
to allow penetration into the base course and aeration of volatiles from
the primer material. If it is not absorbed within 24 hours after application,
sand shall be spread over the surface to blot the excess primer. Care
shall be taken to prevent over-priming; any pools of excess primer left
on any part of the surface shall be swept out over the adjacent surface
before spreading sand.
The primer coat shall be applied only on the topmost water bound
macadam or any granular layer, over which the bituminous base
course/wearing course is to be laid.
502.4.4. Curing of primer and opening to traffic: It shall always
be ensured that while opening to any kind of traffic, the primed surface
is fully cured and is not sticky to avoid being picked up by traffic.
Normally, the primed surface shall be allowed to cure for not less
than 24 hours and during this period no traffic of any kind shall be
permitted.
592.4.5. Laying of bituminous course over primed surface: Bi-
tuminous base course or wearing course shall be laid over the primed
water bound macadam, wet mix macadam or any other granular base
course, in the usual manner as per relevant Specification for the same
including the requirement of tack coat as per Clause 503.
502.5. Quality Control of Work
Control on the quality of materials and work shall be exercised by
502,6. Arrangement for Traffic
During the Construction operations, arrangement of traffic shall be
Prime coat shall be measur~din terms of surface area of application
in square metres.
<< 147
502.8. Rate
The contract unit rate for prime coat shall be payment in full for
carrying out the required operations including full compensation for all
components listed in Clause 401.8 (i) to (v) and as applicable
to the work specified in these Specifications.
503. TACK COAT
503.1. Scope
This work shall consist of application of a single coat of low viscosity
liquid bituminous material to an existing road surface preparatory to
another bituminous construction over it.
503.2, Materials
Binder: The binder used for tack coat shall b~a bituminous emulsion
or cutback as specified in the Contract.
503.3. Construction Operation
503.3.1. Preparation of base: The surface on which the tack coat
is to be applied shall be cleaned of dust and any extraneous material
before the application of the binder, by using a mechanical broom
or any other approved equipment/method as specified by the Engineer.
503.3.2. Application of binder: Binder may be heated to the
temperature appropriate to the grade of cutback used and approved by
the Engineer and sprayed on the base at the rate specified in Table
500-2. The normal range of spraying temperature for a bituminous
emulsion shall be 20°C-60°Cand for a cutback 50°C-80°Cif RC-70/
MC-70 grade is used. It shall be the responsibility of the Contractor
to carefully handle the inflammable bituminous cutback material so as
to safeguard against any fire mishap. The binder shall be applied
uniformly with the aid of either self-propelled or towed bitumen pressure
sprayer with self-heating arrangement and spraying bar with nozzles
having constant volume or pressure system, capable of spraying bitumen
at specified rates and temperature so as to provide a uniformly unbroken
spread of bitumen. Work should be planned so that no more than the
necessary tack coat for the day’s operation is placed on the surface. After
application and prior to succeeding construction allow the tack coat to
cure, without being disturbed, until the water/cutter has completely
evaporated, as determined by the Engineer.
<< 148
TABLE 500.2. RATE OF APPLICATION OF TACK COAT

Type Surface Quantity of liquid
bituminous mater1i~in
kg per 10 sq. m. area
i) Normal bituminous surfaces 2.0 to 2.5
ii) Dry and hungry bituminous 2.5 to 3.0
surfaces
iii) Granular surfaces treated with 2.5 to 3.0
primer
iv) Non bituminous surfaces
a) Granular base (not primed) 3.5 to 4.0
b) Cement concrete pavement 3.0 to 3.5
Note : There is no need to apply a tack coat on a freshly laid bituminous course if the
subsequent bituminous course is overlaid the same day without opening it to traffic.

Control on the quality of materials and works shall be exercised by
503,5. Arrangements for Traffic
be done to Clause 112.
503.6. Measurement for Payment
Tack coat shall be measured in terms of surface area of application
in square metres.
503.7. Rate
The contract unit rate for tack coat shall be payment in full for
components listed in Clause 401.8 (i) to (v) as applicable to the work
specified in these Specificatiot~s.
504. BITUMINOUS MACADAM
504.1, Scope
The work shall consist of construction, in a single course, of
compacted crushed aggregates premixed with a bituminous binder,
to serve as base/binder course, laid immediately after mixing, on a base
prepared previously in accordance with the requirement of these
Specifications and in conformity with the lines, grades and cross-sections
shown on the drawing or as directed by the Engineer.
504.2. Materials
504.2.1. Bitumen: The bitumen shall be paving bitumen of suitable
149
<<
Section 400 Sub-Bases, Bases (Non-Bituminous) and S~ou~ders
penetration grade (30/40 to 80/100) as per IS:73. The actual grade of bitumen
to be used shall be decided by the Engineer appropriate to the region, traffic,
rainfall and other environmental conditions, Guidelines on selection of the
grade of bitumen are given in Appendix-4.
504.2.2. Aggregates
504.2.2.1. The aggregates shall consist of crushed stone, crushed
gravel/shingleor other stones. They shall be clean, strong, durable, of fairly
cubical shape and free from disintegrated pieces, organic or other deleterious
matter and adherent coating. If crushed shingle/gravel 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 preferably be
hydrophobic and of low porosity. If hydrophilic aggregates are to be used,
thebitumen shall preferably be treated with anti~strippingagents of approved
quality in suitable dose as per Appendix-5. The aggregates shall satisfy the
physical requirements set forth in Table 500.3.
TABLE 500.3. PHYSICAL REQUIREMENTS OF AGGREGATES FOR
IUTUMINOUS MACADAM
S,No, Test Test Method Requirement
5 IS:2386(Part..4) 40per cent Maximum
1. Los Angeles Abrasion Value
2. Aggregate Impact Value5 IS:2386 ~Part-4) 30 per cent Maximum
3. Flakiness and Elongation55 IS:238$(Part-1) 30 per cent Maximum
Indices (Total)
4. Coating and Stripping of AASI ITO T 182 Minimum retained
Bitumen Aggregate Mixtures coating 95 percent
5. Soundness IS:23 86 (Part-5)
(i) Loss with Sodium 12 per cent Maximum
Sulphate 5 cycles
(ii) Loss with Magnesium IS per cent Maximum
Sulphate 5 cycles
6 Waterabsorptian - IS:2386(Patt-3) ZpercentMaximum
* Aggregates may satisfy requIrements 01 eitfler at 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
separated out from the remaining (non-flaky) stone metal. Ebngaflon index is
weight of elongated particles divided by total non-flaky particles. The value of
Note: If crushed slag is used, Clause 404.2.3. shall apply.
504.2.2.2. The aggregate for bituminous macadam shall conform to one
of the two gradings in Table 500-4, depending on the compacted thickness;
the actual grading shall be as specified in the Contract.
504.2.3. Proportioning of materials: The bitumen content for pre-
mixing shall be 3 to 3.5 per cent by weight of the total mix except when
otherwise directed by the Engineer.
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TABLE 500~2.RATE OF APPLICATION OF TACK COAT

Type Surface Quantity ef liquId
bItuminous material In
kg per 10 sq. m. area
i) Normal bitsaninous surfaces 2.0 to 2.5
ii) Dry and hungry bituminous 2.5 to 3.0
surfaces
iii) Granular surfaces treated with 2.5 to 3.0
primer
iv) Non bituminous surfaces
a) Granular base (not primed) 3.5 to 4,0
b) Cement concrete pavement 3.0 to 3.5
Note There is no need to apply a tack coat on a freshly laid bituminous course if the
subsequent bituminous course is overlaid the same day without opening it to traffic.

503.6. Measurement for Payment
Tack coat shall be measured in terms of surface area of application
in square metres.
503.7, Rate
The contract unit rate for tack coat shall be payment in full for
components listed in Clause 401.8 (i) to (v) as applicable to the work
specified in these Specifications.
504. BITUMINOUS MACADAM
504.1. Scope
The work shall consist of construction, in a single course, of
compacted crushed aggregates premixed with a bituminous binder,
to serve as base/binder course, laid immediately after mixing, on a base
prepared previously in accordance with the requirement of these
Specifications and in conformity with the lines, grades and cross-sections
shown on the thawing or as directed by the Engineer.
504.2. Materials
504.2.1. Bitumen: The bitumen shall be paving bitumen of suitable
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TABLE 500.4. AGGREGATE GRADING FOR BITUMINOUS MACADAM
IS Sieve DesIgnation Per cent by weight passing the sieve
Grading I GradIng 2
45.0 mm 100 —
26.5 mm 75.100 100

22.4 mm ‘ 60-95 75.100
11.2 mm 30.55 50-85
5.6 mm 15-35 20-40
2.8 mm 5.20 5-20
90.0 micron 0-5 0-5
The maximum compacted thickness of a layer shall be 100 mm.

The quantities of aggregates to be used shall be sufficient to yield
the specified thickness after compaction.
504.2.4. Variatioii in proportioning of material: The Contractor
shall have the responsibility for ensuring proper proportioning of materials
and producing a uniform mix. A variation in binder content ±0.3 per
cent by weight of total mix shall, however, be permissible for individual
specimens taken for quality control tests vide Section 900,
504.3.1. Weather and seasonal limitations : The work of laying
shall not be taken up during rainy or foggy weather or when the base
course is damp or wet, or during dust storm or when the atmospheric
temperature in shade is 10°Cor less.
504.3.2. Preparation of the base: The base on which bituminous
macadam is to be laid shall be prepared, shaped and conditioned to
the specified lines, grades and cross-sections in accordance with Clause
501, and a priming coat where needed shall be applied in accordance
with Clause 502 as directed by the Engineer.
504.3.3. Tack coat: A tack coat as per Clause 503 shall be applied
over the base.
504,3.4. Preparation and transport of mix: Bituminous macadam
mix shall be prepared in a hot mix plant of adequate capacity and capable
of yielding a mix of proper and uniform quality with thoroughly coated
aggregates.
Hot mix plant shall be of suitable capacity preferably of batch mix
type. Total system for crushing of stone aggregates and feeding of
aggregate fractions in required proportions to achieve the desired
mix, deployed by the Contractor must be capable of meeting the overall
151
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Specification requirements under stringent quality control. The plant shall
have the following essential features:
A-General
(a) The plant shall have coordinated set or essential units capable of producing
sxsifonn mix as per the job mix formula.
(b) cold aggregate feed system with minimum 4 bins having belt conveyor arrange-
ment for initial proportioning of aggregates from each bin in the required quantities.
In order to have free flow of fines from the bin, it is advisable to have
vibrator fitted on bin to intenninently shake it,
(c) Belt convryers below each bin shoold have variable speed drive motors. There
should be electronic load sensor on the main conveyer for measuring the flow
of aggregates.
(d) Dryer unit with burner capable of heating the aggregate to the required temperature.
without any visible unbumt fuel or carbon residue on the aggregate and reducing
the moisture content of the aggregate to the seecified minimum.
(e) The plant shall be fitted with suitable type of thermometric instruments at
appropriate places so as to indicate or record/register the temperature of heated
aggregate, bitumen and mix.
(f) Bitumen supply unit capable of heating, measuring/metering and spraying of
bitumen at specified temperature with automatic synchronisation of bitumen
and aggregate feed in the required proportion.
(g) A filler system suitable to receive bagged or bulk supply of filler material
and its incorporation to the mix in the correct quantity wherever required.
(h) A suitable built-in dust control system for the dryer to contain/recycle permissible
fines into the mix. It should be capable of preventing the exhaust of fine dust
into atmosphere for environmental control wherever so specified by the Engineer.
(i) The plant should have centralised control panel/cabin capable of presetting,
controlling/synchronising all operations starting from feeding of cold aggregates
to the discharge of the hot mix to ensure proper quality of mix. It should have
indicators for any malfunctioning in the operation.
(j) Every hot mix plant should be equipped with siren or horn so that the operator
may use the same before starting the plant every time in the interest of safety
of staff.
B - For Batch Type Plant
(i) Gradation control unit having minimum four deck vibratory screens for accurate
sizing of hot aggregate and storing them in separate bins. This unit should be
fully covered to reduce the maintenance cost and for better environmental
condition.
(ii) Proper arrangement for accurate weighing of each size of hot aggregate from
the control’ panel before mixing.
(iii) Paddle mixer unit shall be capable of prodlicing a homogeneous mix withuniform
coating of all particles of the mineral aggregate with binder.
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C - For Continuous Type Plant

(i) Gradation control unit having vibratory screens for accurate sizing of hot
aggregate and storing them in separate bins. This unit should be fully covered
to reduce the maintenance cost and for better environmental condition.
(ii) There should be appropriate arrangement for regulating and volumetric control
of the flow of hot aggregate from each bin to achieve the required proportioning.
(iii) Paddle mixer unit shall be capable of producing a homogeneous mix with
uniform coating of all particles of the mineral aggregate with binder.
D . For Drum MIx Plant
(i) It is a prerequisite that only properly screened and graded materials are
fed to the bins. If required, a vibratory screening unit shall be installed at the
plans site to ensure the same.
A primary 4-deck vibratory screening unit shall be installed before the multiple
bin cold feed system for screening the aggregates and grading sbe same.
(ii) Belt conveyers below each bin should have variable speed drive motors. There
should be electronic load sensor on the main conveyer for measuring the flow
of aggregate.
(iii) There should be arrangement to measure moisture content of the aggregate(s) so
that moisture correction may be applied for working out requirements of binder
and filler.
The temperature of binder at the time of mixing shall be in the
range of 15&C to 163°C and that of the aggregate in the range
of 155°C 163°C.provided that the difference in temperature between
-
the binder and aggregate at no time exceeds 14°C.

Mixing shall be thorough to ensure that a homogeneous mixture is
obtained in which all particles of the aggregates are coated uniformly,
and the discharge temperature of mix shall be between 130°C to 160°
C.
The mixture shall be trinsported from the mixing plant to the point
of use in suitable tipper vehicles. The vehicles employed for transport
shall be clean and be covered in transit if so directed by the Engineer.
Any tipper causing excessive segregation of materials by its spring
suspension or other contributing factors or that which shows undue
delay shall be removed from the work until such conditions are corrected.
504.3.5. Spreading: The mix transferred from the tipper at site to
the paver shall be spread immediately by means of self-propelled
me~hanicalpaver with suitable screeds capable of spreading, tamping,
and finishing the mix true to the specified lines, grades and cross-
sections. The paver finisher shall have the following essential features:
(a) Loading hoppers and suitable distributing mechanism.
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(b) All drives having hydrostatic drive/control.
(c) The machine shall have a hydraulically extendable screed for appropriate width
requirement.
(d) The screed shall have tamping and vibrating arrangement for initial compaction
so the layer as it is spread without rutting or otherwise marring the surface.
It shall have adjustable amplitude and variable frequency.
(e) The paver shall be equipped with necessary control mechanism so as to ensure
that the finished surface is free from surface blemishes.
(I) The paver shall be fitted with an electronic sensing device for automatic levelling
and profile control within the specified tolerances,
(g) The screed shall have the intemat heating arrangement.
(h) The paver shall be capable of laying either 2.5 to 4.0 m width or 4.0 to 7.0
m width as stipulated in the Contract.
(i) l’he paver shall be so designed as so eliminate skidding/slippage of the tyres
during operation.
However, in restricted locations and in narrow widths where the
available plant cannot be operated in the opinion of the Engineer, he
may permit manual laying of the mix.
The temperature of the mix at the time of laying shall be in the
range of 120°Cto 160°C. In multi-layer construction, the longitudinal
joint in one layer shall offset that in the layer below by about 150
mm, However, the joint in the top-most layer shall be at the lane line
of the pavement.
Longitudinal joints and edges shall be constructed true to the
delineating line parallel to the centre line of the road. All joints shall
be cut vertical to the full thickness of the previously laid mix and the
surface painted with hot bitumen before placing fresh material.
Longitudinal and transverse joints shall be offset by at least 250 mm
from those in the loWer courses and the joint on the topmost layer
shall not be allowed to fall within the wheel path. All transveme joints
shall be cut vertically to the full thickness of the previously laid mix
with asphalt cutter/pavement breaker and surface painted with hot
bitumen before placing fresh material. Longitudinal joints shall be
preferably hot joints. Cold longitudinal joints shall be properly heated
with joint heater to attain a suitable temperature of about 80°Cbefore
laying of adjacent material.
504.3.6. Compaction: After the spreading of mix, rolling shall be
done by 80 to 100 kN rollers or other approved equipment. Rolling
shall start as soon as possible after the material has been spread deploying
a sct of rollers as the rolling is to be completed in limited time frame.
‘54
<<
The roller shall move at a speed not more than 5 km/h. Rolling
shall be done with care to avoid unduly rougheniitg of the pavement
surface.
Rolling of the longitudinal joints shall be done immediately
behind thr paving operation. After this, the rolling shall commence at
the edges and progress towards the centre longitudinally except that
on ~uperelevated and uni-directional cambered portions, it shall
progress from the lower to the upper edge parallel to the centre line
of the pavement.
The initial or break.down rolling shall be done with 80 100 kN
-
static weight smooth wheel roller (3 wheels or tandem), as soon as it

is possible to roll the mix without cracking the surface or having the
mix pick up on the roller wheels, The second or intermediate rolling
shall follow the break-down rolling with vibratory roller of 80 to 100
kN static weight or pneumatic tyred roller of 150 to 250 kN weight,
with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely
as possible to the paver and be done while the paving mix is still at
a temperature that will result in maximum density. The final rolling shall
be done while material is still workable enough for removal of roller
marks, with 60 80 kN tandem roller. During the final rolling, vibratory
-
system shall be switched ofL The joints and edges shall be rolled with
a 80 to 100 kN static roller.
When the roller has passed over the whole area once, any high
spots or depressions which become apparent shall be corrected by
removing or adding mix material. The rolling shall then be continued
till the entire surface has been rolled to 95 per cent of the average
laboratory density (obtained from Marshall specimens compacted as
defined in Table 500-10), there is no crushing of aggregates and all
roller marks have been eliminated. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the
preceding pass. The roller wheel shall be kept damp if necessary to
avoid bituminous material from sticking to the wheels and being picked
up. In no case shall fuel, lubricating oil be used for this purpose, nor
excessive water poured on the wheels.
Rolling operations shall be completed in every, respect before the
temperature of the mix falls below 100°C.
Roller(s) shall not stand on newly laid material while there is a
risk that surface will be deformed thereby. The edges along and
transverse of the bituminous macadam laid and compacted earlier shall
155
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— I-

be cut to their full depth so as to expose fresh surface which shall
be painted with a thin surface coat of appropriate binder before the
new mix is placed against it.
504.4. Surface Finbh and Quality Control of Work
of Clause 902, Control on the quality of materials and works shall be
504.5. The bituminous macadam shall be covered with either the
next pavement course or wearing course, as the case may be, without
any delay. If there is to be any delay, the course shall be covered by
a seal coat to the requirement of Clause 513 before allowing any traffic
over it. The seal coat in such cases shall be considered incidental to
the work and shall not be paid for separately.
504.6. Arrangements of Traffic
done to Clause 112.
The work shall be measured as finished work in cubic metres or
by weight in metric t9nnes as provided in the Contract.
504.8. Rate
The contract unit rate for the work shalt be payment in full for
carrying out the required operations including full compensation for:
(I) Making arrangements for traffic to Clause 112 exceçx for initial treatment to verge,
shoulders and construction of diversions;
(ii) Preparation of base except for laying of profile corrective course but including
filling of potholes;
(iii) Providing all materials to be incorporated in the work including arrangement
for stock yards, all royalties, fees, rents where necessary and all leads and lifts;
(iv) All labour, tools, equipment, plant including installation of hot mix plant, power
supply units and all machineries, incidental to complete the work to the Speci-
fications;
(v) Carrying out the work in pan widths of the road where directed;
(vi) Carrying out all tests for control of quality; and
(vii) The rate shall cover the provision.of bitumen at 3.25 per cent of weight of
total mix, with the provision that the variation of quantity of bitumen will be
asseased and the payment adjusted as per the rate of bitumen quoted.
<< 156
The roller shall move at a speed not more than 5 km/h. Rolling
shall be done with care to avoid unduly roughenir~gof the pavement
surface.
Rolling of the longitudinal joints shall be done immediately
behind thr paving operation. After this, the rolling shall commence at
the edges and progress towards the centre longitudinally except that
on ~uperelevated and uni-directional cambered portions, it shall
progress from the lower to the upper edge parallel to the centre line
of the pavement.
The initial or break-down rolling shall be done with 80 100 kN
-
static weight smooth wheel roller (3 wheels or tandem), as soon as it

is possible to roll the mix without cracking the surface or having the
mix pick up on the roller wheels. The second or intermediate rolling
shall follow the break-down rolling with vibratory roller of 80 to 100
kM static weight or pneumatic tyred roller of 150 to 250 kM weight,
with minimum 7 wheels and minimum tyre pressure of 0.7 MPa as closely
as possible to the paver and be done while the paving mix is still at
a temperature that will result in maximum density. The final rolling shall
be done while material is still workable enough for removal of roller
marks, with 60 80 kN tandem roller. During the final rolling, vibratory
-
system shall be switched off. The joints and edges shall be rolled with
a 80 to 100 kN static roller.
removing or adding mix material. The rolling shall then be continued
till the entire surface has been rolled to 95 per cent of the average
laboratory density ~obtainedfrom Marshall specimens compacted as
defined in Table 500-10), there is no crushing of aggregates and all
roller marks have been eliminated. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the
preceding pass. The roller wheel shall be kept damp if necessary to
avoid bituminous material from sticking to the wheels and being picked
up. In no case shall fuel, lubricating oil be used for this purpose, nor
excessive water poured on the wheels.
Rolling operations shall be completed in every, respect before the
temperature of the mix falls below 100°C,
Roller(s) shall not stand on newly laid material while there is a
risk that surface will be deformed thereby. The edges along and
transverse of the bituminous macadam laid and compacted earlier shall
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Base and Surface Cours’es (Bituminous) Section 500
505. BITUMINOUS PENETRATION MACADAM

505.1. Scope
The work shall consist of construction of one or more layers of
compacted crushed coarse aggregatts with alternate applications of
bituminous binder and key aggregates in accordance with the require-
ments of these Specifications to serve as base,thinder course and in
conformity with the lines, grades arid cross-sections shown on the
drawings or as directed by the Engineer. Thickness of an individual
course shall not exceed 75 mm.
505.2. Materials
505.2.1. Bitumen: The binder shall be paving bitumen of suitable
penetration grade within the range of S-35 to 8-90 or A-35 to A-
90 (30/40 to 80/I 00) as per Indian Standards Specifications for “Paving
Bitumen” IS ;73, or apprcWed cutbacks satisfying the requirements of
IS 73, 217 or 454. The actual grade of bitumen or cut backs to be
used shall be decided by the Engineer, appropriate to the region,
traffic, rainfall and other environmental conditions. Guidance in this
regard may be obtained from Appendix-4.
505.2.2. Aggregates
505.2.2.1. The aggregates shall satisfy the physical requirements set
forth in Clause 504.2.2.1 and Table 500-3.
505.2.2.2. The coarse and key aggregates shall conform to the
grading given in Table 500-5.
505.2.3. Quantities of materials: The quantities of materials used
for this work shall be as specified in Table 500-6.
505.3.1. Weather and seasonal limitations: Clause No. 504.3.1
shall apply.
505.3.2. Preparation of the base: The ‘base on which the
Penetration macadam course is to be laid shall be prepared, shaped and
conditioned to the specified lines, grades and sections to Clause 501
or as directed by the Engineer. A priming coat where needed shall be
applied over the base in accordance with Clause 502 or as directed
by the Engineer. A tack coat as per Clause 503 shall be applied.
<< 157
Section 500 ~iase and Surface Courses (Bituminous)
TABLE 500.5. GRADING REQUIREMENTS OF COARSE AGGREGATES AND KEY

AGGREGATES FOR BITUMINOUS PENETRATION MACADAM
Per cent by weight passing the Steve
For 50 mm compacted for 75 mm compacted
‘ thickness thickness
IS Steve Coarse Key Coarse Key
Design. Aggregate Aggregate Aggregate Aggregate
atlon
63 mm —~ — 100 —
53 mm — —~ — —
45 mm 100 — 58-82 —
26.5 mm 37-72 — — 100

22.4 mm — 100 5-27 50-75
132 mm 2-20 50-75 — —
11.2 mm — — , — 5-25
5.6mm — 5-25 — —
2.8 mm 0-5 0-5 0-5 0-5

TABLE 500.6. QUANTITIFS OF MATERIALS REQUIRED FOR 10 sq.m.OF ROAD
SURFACE FOR BITUMINOUS PENETRATION MACADAM BASFJ
BINDER COURSE
Compacted Binder
thickness
‘ Straight Coarse Key
run bitumen Aggregate Aggregate
50 mm 50 kg 0.60 cu.m. 0.15 en. m.
75 mm 68 kg 0.90 cu.m. 0.18 cc. m.
505.3.3.. Spreading and compacting coarse aggregates: The
coarse aggregate in a dry and clean form shall be spread uniformly and
evenly at the rate specified in Table 500-6 preferably with the help
of a self-propelled or tipper tail mounted aggregate spreader capable
of spreading aggregate uniformly at the specified rates over the required
widths. The surface of the layer shall be carefully checked with
camber templates and all high and low spots remedied by removing or
adding aggregates as may be required. The spreading shall be carried
no further in advance of the rolling and penetrating operations than
can be completed in one average day’s work. Segregated aggregates or
aggregates mixed with earth or other foreign substances shall be removed
and replaced with graded aggregates.
505.3.4. Compaction: After the spreading of coarse aggregates,
dry rolling shall be done by 80 100 kN smooth-wheeled steel roller.
-
Rolling shall start as soon as possible after the material has been
spread. The rolling shall commence at the edges, parallel to the centre
line of the road and progress towards the centre longitudinally except
<< 158
on superelevated and uni-directional cambered portions, where it shall

progress from the lower to the upper edge after the edges have been
rolled. For superelevated portions, the overlapping should be approxi-
mately one-third of the width of the rear wheel on each trip.
After initial dry rolling, the surface shall be checked with a crown
template and a 3 metre straight-edge. The surface shall not vary more
than 10 mm from the template or straight-edge. All surface irregularities
exceeding the above lirnit shall be corrected by removing or adding
aggregates as required.
The rolling shall be done until the compacted coarse aggregate
has firm surface true to the cross section shown on the plans and that
it has a texture that will allow free and uniform penetration of the
bituminous material.
505,3.5. Application of bituminous material: After the coarse
aggregate has been rolled and checked, the bituminous binder shall be
applied at specified temperatures as directed by the Engineer. The
rate of application shall be as specified in Table 500-6.
At the time of applying the binder, the aggregates shall be surface
dry for full depth of the layer.
The bituminous material shall preferably be applied by a pressure
distributor uniformly over the surface at the specified rate. Over small
areas, where the use of a spray bar is impracticable, the bituminous
material shall be applied by the nozzle attachment. Only when permitted,
pouring pots may be used according tc~the directions of the Engineer.
505.3.6. Application of key aggregates: Immediately after the first
penetration of bitumen, the key aggregates in a clean and dry state
shall be spread uniformly over the surface by means of an approved
mechanical spreader or by approved manual methods at the rate
specified in Table 500-6.
If necessary, the surface shall be broomed to ensure uniform
application of the key aggregates. The entire surface shall then be
rolled with a 80 100 kN smooth steel wheel roller (along with
-
vibratory roller if available) to the Specifications conforming to Clause

505.3.4.
505.4. Surface Finish and Quality Control
of Clause 902.
<< 159
Controls on the quality of materials and works shall be exercised
505.5. The Penetration Macadam shall be provided with final sur-
facing (binderlwearing course) without any delay. If there is to be
any delay, the course shall be covered by a seal coat to the requirements
of Clause 513 before allowing any traffic over it. The seal coat in
such cases shall be considered incidental to the work and shall not be
paid for separately.
During the period of construction, arrangements for traffic shall be
done to Clause 112.
Penetration Macadam Base/Binder Course shall be measured as
finished work in square metres.
505.8. Rate
The contract unit rate for Penetration Macadam Course shall be
full compensation for all components ~isted in Clause 504.8 (i) to
(vi).
506. BUILT-UP SPRAY GROUT
506.1. Scope
This work shall consist of a two-layer composite construction of com-
pacted crushed coarse aggregates with application of bituminous binder
after each layer and key aggregates bn top for the second layer, ih
accordance with the requirements of these Specifications to serve as
a base course and in conformity with the tines, grades and cross-sections
shown on the drawings or as directed by the Engineer. Thickness of
the course shall be 75 rum.
Built-up spray grout shall be used in a single course in a pavement
structure.
506,2. Materials
506.2.1. Bitumen: Clause 504.2.1 shall apply.
506.2.2. Aggregates: The coarse aggregate shall conform to Clause
504.2.2.1.
The aggregate shall satisfy the physical requirements set out in Table
<< 160
500-3. The coarse and key aggregates for built-up spray grout shall
conform to the grading given in Table 500-7.
TABLE 500-7. GRADING REQUIREMENTS OF COARSE AND KEY GGREGATES
FOR BUILT-UP SPRAY GROUT
Per cent by weight passing the Sieve
IS Sieve
Designation Coarse Aggregate Key Aggregate
53.0 mm tOO —
26.5 mm 40-75 —
22.4 mm — lOt)
13.2 mm 0-20 40-75
5.6 mm — 0-20
2.8 mm 0-5 0-5
506.3.1. Weather and seasonal limitations: Clause 504.3,1 shall
apply.
506.3.2. Preparation of base: The base on which the b.uilt-up
spray grout course is to be laid shall be prepared, shaped and conditioned
to the specified lines, grades and cross-sections in accordance with
Clause 501. A priming coat where needed shall be applied in accordance
with Clause 502 with suitable primer as directed by the Engineer.
506.3.3. Jack coat: A tack coat over the base shall be applied as
per Clause 503.
506.3.4. Spreading and rolling coarse aggregates for the first
layer: Immediately after the application of tack coat, the coarse
aggregates in a dry and clean form shall be spread uniformly and
evenly preferably by mechanical means at the rate of 0.5 cu.m. per
10 sq.rr. area. The surface of the layer shall be carefully checked
with ten3plates and all high and low spots remedied by removing or
adding aggregates as may be required.
Immediately after spreading of the aggregates, the entire surface
shall be rolled with a 80 100 kN smooth-wheeled roller. Rolling
-
shall commence at the edges and progress towards the centre except
in superelevated and uni-directional 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.
After initial rolling, the surface shall be checked transversely and
longitudinally with templates and any irregularities corrected by loosening
161
<<
Scction 5(X) Base and Surface Courses (Bituminous)
the surface, adding or removing necessary amounts of aggregate,

followed by rolling.
Rolling shall be stopped before voids in the aggregate layer are closed
to such an extent as to prevent free and uniform penetration of the binder.
506.3-5. Application of binder first spray: The binder shall
-
1* heated to the temperature appropriate to grade of bitumen approved

by the Engineer and sprayed on aggregate layer at the rate of 15 kg/
10 sq. m. (in terms of straight-run bitumen) in a uniform manner with
the help of mechanical sprayers capable of spraying bitumen uniformly
at specified rates and temperatures. Excessive deposits of binder caused
by stopping or starting of the sprayers or through leakage or any
other reason shall be corrected promptly.
506.3.6. Spreading and rolling of coarse aggregate for the
second layer: Immediately after the first application of the binder,
the second layer of coarse aggregates shall be spread and rolled to Clause
506.3.4.
506.3.7. Application of’ binder-second spray: The second
aggregate layer shall then be given a binder spray at the rate of 15 kg!
10 sq. m. (in terms of straight-run bitumen) to Clause 506.3.5.
506.3.8. Application of key aggregate: Immediately after
second application of the binder, key aggregates in a clean and dry
state shall he spread uniformly and evenly, preferably by mechanical
means at the rate of 0.13 cu.m./10 sq. m. so as to cover the surface
completely. If necessary, ‘the surface shall be broomed to ensure uniform
application of the key aggregates. The entire surface shall then be rolled
with a 80-100 kN smooth-wheeled roller to Clause 506.3.4. While
rolling is in progress, additional key aggregates, where required, shall
be spread by hand. Rolling shall continue until the entire course is
thoroughly compacted and the key aggregates are firmly in position.
of Clause 902.
506.5. The built-up-spray-grout shall be provided with final surfacing
without any delay. If there is to be any delay, the course shall be
covered by a seal coat to the requirement of Clause 513 before
162
<<
Base and Surface Courses (Bituminous) Section 5(X)
allowing any traffic over it, The seal coat in such cases shall be
considered incidental to the work and shall not be paid for
separately.
During the period of construction, atrangement of traffic shall be
done to Clause 112.
Built-up spray grout shall be measured as finished work in square
metres.
506.8. Rate
The câutract unit rate for built-up spray grout shall be payment in
full for cañying out the required operations including full compensation
for all components listed in Clause 504.8 (i) to (vi).
597. DENSE BITUMINOUS MACADAM
507.1. Scope
This work shall consist of construction in a single course of 50
to 100 mm thick base/binder course to the following Specifications on
a previously prepared base.
507.2. Materials
507.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration
Grade S 65 or A 65 (60/70) as per Indian Standard Specifications for
“Paving Bitumen” IS: 73. In case of non- availability of bitumen of
this grade, S 90 (80/100) grade bitumen may be used with the approval
of the Engineer. Guidance to selection of the grade of bitumen may
he taken from Appendix-4.
507.2,2. Coarse aggregates : The coarse aggregates shall consist
of crushed stone, crushed gravel/shingle or other stones. They shall be
clean, strong, durable, of fairly cubical shape and free from disintegrated
pieces, organic or other deleterious matter and adherent coating. The
aggregates shall preferably be hydrophobic and of low porosity. If
hydrophilic aggregates are to be used, the bitumen shall be treated with
antistripping agents of approved quality in suitable doses. The aggregates
shall satisfy the physical requirements set forth in Table 500-8.
If crushed gravel/shingle is used, not less than 90 per cent by weight
ol the gravel/shingle pieces retained on 4.75 mm sieve shall have at
least two fractured faces. The portion of the total aggregate passing
<< 163
4.75 mm sieve 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 425 micron sieve shall
not exceed 4.
TABLE 500.5. PHYSICAL REQITIREMENTS OF AGGREGATES FOR DENSE
UtTUMINOUS MACADAM
S.No, Test Tess Method Requirement
I [AssAngetes Abrasion Valuet 15~2386~Part’4) 40 per cent maximum
2. Aggregate Impact valuet IS:2386(Pars-4) 30perceat Maximum
tt 15:2386 (Pan-i) 30 per cent Maximum
3. Flakiness and Elongauon
Indices (‘l’oial)
4 (‘oaring and Stripping of AASItTO T 182 Minimum retained
Bitumen Aggregate Mixtures coating 95 per cent
5, Scsindness IS:2386(Pan-5)
(i) Inst with Sodium S cycles 12 per cent Maximum
Sulphate
(ii) l,o.ss with Magncsium 5 cycles 18 per cent Maximum
Sulphate
5. Water ahsoption 15:2386 (l5art-3) 2 per cent Maximum
* Aggregates 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
separated out from the remaining (non-flaky) stone metal Elongation index is
weight of elongated parlicles divided by total non-flaky particles. The value of
507.2.3. Fine aggregates: Fine aggregates shall be the Fraction pass-
irtg 2.36 mm sieve and retained on 75 micron sieve, consisting of crusher-run
screening, gravel, sand or a mixture of both. These shall he clean, hard,
durable, ttncoated, dry and free from any injurious, soft or flaky pieces and
organic or other deleterious suhstances.
507.2.4. Filler: Filler shall consisl of finely divided mineral matter
such as rxk dust, hydraled lime or cement as approved by the Engineer.
The filler shall be graded within the following limits
tS Sieve Per cent passing by weight
601) micron 100
3(X) micron 95-1(X)
75 micron 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 lithe. When the coarse aggtregate is gravel,
164
<<
2 per cent by mass of total aggregate of portland cement or hydrated

lime shall be added and the percentage of fine aggregate reduced
accordingly. Cement or hydrated lime is not required when the gravel
is limestone.
507.2.5. Aggregate gradation : The combined coarse and fine ag-
gregates and filler (when used) shall produce a mixture to conform to
the grading set forth in Table 500-9.
TABLE 500-9. AGGREGATE GRADATION FOR DENSE
BITUMINOUS MACADAM
Sieve Designation Percentage passing the sieve by weight
37.5 mm 100
26.5 mm 90-100
13.2 mm 56-80
4,75 mm 29-59
2.36 mm 19-45
300 micron 5-17
75 micron 1-7
The aggregate mix, as used in work, shall not vaty from the low limit on one
sieve to the high limit on the adjacent sieve but shall be well graded.
507.3. Mix Design

507.3.!. Requirement of mix: Apart from conformity with grading
and quality requirements of individual ingredients, the mix shall meet
the requirements set out in Table 500-10.
TABLE 500-10. REQUIREMENTS OF DENSE BITUMINOUS MACADAM MIX
S.No. Description Requirements
1. Marshall stability (ASTM Designaiion-D-l559) 820 kg (1800 Ib)
determined an Marshall specimens compacted minimum
by 75 conipaction blows on each end
2. Marshall flow (mm) 2-4
3. Per cent Air voids 3-5
4. Minimum voids in m.intral aggregates (VMA) 10 per cent - 12 per cent
5. Per cent voids in mineral aggregates
filled by bitumen (VFB) 65-75
6. Binder content per cent by weight of total mix Not less than 4.0 per cent
507.3.2. Binder content: The binder content shall be so fixed as
to achieve the requirements of the mix set out in Table 500-10. Marshall
method for arriving at the binder content shall be adopted, replacing the
aggregates retained on 26.5 mm sieve by the aggregates passing 265
mm sieve and retained on 22.4 mm sieve.
<< 165
507.3.3. Job mix formula : The Coffiractor shall intimate to the
Engineer in writing, atleast 20 days before the start of the work, the
job mix formula proposed to be used by him for the work and shall
give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materiaLs expressed as follows where each is applicahle~:
(a) Binder, as percentage by weight of to4al mix;
(b) Coarse aggregatelFine aggregate/Mineral filler as percentage by weight
of total aggregate including mineral filler~
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 50010 as obtained by the Contractor;
(v) Test results of physical charaãeristics of aggregates to be used;
(vi) Mixing temperature and compacting temperature.
While working out the job mix formula, the Contractor shall ensure
that it is based on a correct and truly representative sample of the
materials that will actually be used in the work and that the mix and
its different ingredients satisfy the physical and strength requirements
of these Specifications.
Approval of the job mix formula shall be based on independent
testing by the Engineer for which samples of all ingredients of
the mix shall be furnished by the Contractor as required by the
former.
The approved job mix formula shall remain effective unless and
until modified by the Engineer. Should a change in the source of
materials be proposed, a new job mix formula shall be established
and got approved from the Engineer before actually using the
materials.
507.3,4. Permissible variation from job mix formula: It shall
be the responsibility of the Contractor to produce a uniform mix
conforming to the approved job mix formula subject to the
permissible variations of the individual percentages of the various
ingredients in the actual mix from the job mix formula to be used within
the limits as specified in Table 500-Il. These variations are intended
to apply to individual specimens taken for quality control tests vide
Section 900.
<< 166
TABLE 500.11. PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA

S.~4o, Description
0f Ingredients Permissible variation
by weight of total
mix-in per cent
Aggregate passing 13.2 men sieve and larger sieves ±8
2. Aggregate passing 112mm sieve and 5.6 mm sieve 7
3. Aggregate passing 2.80 mm sieve and 1.40 mm sieve 6
4. Aggregate passing 710 micron seive and 355 micron sieve ±S
5. Aggregate passing 180 micron sieve ±4
7. Binder ±0.3
8, Mixing temperature ±10°C
507.4.1. Weather and seasonal limitations: Clause 504.31. shall
apply.
507.4.2. Preparation of base: The base on which Dense Bituminous
Macadam is to be laid shall be prepared, shaped and conditioned to the
specified lines, grades and cross sections in accordance with Clause 501
or as directed by the Engineer. The surface shall be thoroughly swept
clean free from dust and foreign matter using mechanical broom and
dust removed or blown off by compressed air. In portions where
mechanical means cannot reach, other approved method shall be used.
A priming coat where needed, shall be applied in accordance with Clause
502 or as directed by the Engineer.
507.4.3. Tack coat: A tack coat over the base shall be applied as
per Clause 503.
507.4.4. Preparation of mix: Clause 504.3.4 shall apply.
.507,4.5, Spreading: The mix transported from the hot mix plant
to the site shall be spread by means of a self-propelled paver with
suitable screeds capable of spreading, tarnping and finishing the mix
to specified grade, lines and cross-section. Paver Finisher shall have
the essential features as spelt out in Clause 504.3.5. However, in
restricted locations and in narrow widths where the available equipment
cannot be operated in the opinion of the Engineer, he may permit
manual laying of the mix. Similarly for smaller jobs, mechanical paver
may be used with the approval of the Engineer.
The temperature of mix at the time of laying shall be in the range
of 120°-160°C.
Mixes wit’h a temperature of less than 120°Cshall not be put into
paver spreader. Longitudinal joints and edges shall be constructed
<<
167
true to the delineating lines parallel to the centre line of the road.
Longitudinal and transverse joints shall be offset by at least 250 mm
from those in the lower courses and the joint on the top most layer
shall not be allowed to fall within the wheel path. All lransverse joints
shall be cut vertically to the full thickness of the previously laid mix
with asphalt cutter and the surface painted with hot bitumen before
placing fresh material. Longitudinal joints shall be preferably hot joints.
Cold longitudinal joints shall he properly heated with joint heater to
attain a suitable temperature of about 80°Cbefore laying of adjacent
material. -
507.4.6. Rolling : After spreading the mix by paver, it shall be thor-

oughly compacted by rolling with a set of rollers moving at a speed
not more than 5 km/h, immediately following close to the paver.
Generally the initial or breakdown rolling shall he done with 80-100
kN static weight smooth-wheeled roller. The intermediate rolling shall
be done with 80 -100 kM static weight vibratory roller or with a
pneumatic tyred roller of 150-250 kM weight having a tyre pressure of
at least 0.7 MPa. The finish rolling shall be done with 60 8OkN weight
smooth wheeled tandem roller. All the compaction operations, i.e.,
breakdown roiling and intermediate rolling can be accomplished by using
vibratory tandem roller of 80-100 kN static weight. During initial
breakdown rolling and finish rolling, no vibratory compaction shall be
resorted to. The exact pattern of rolling shall be established after
trial compaction as approved by the Engineer. Any displacement occurring
as a result of reversing of the direction of a roller or from any other
cause shall be corrected at once as specified and/or removed and made
good. The rollers shall not be permitted to stand on pavement which
has not been fully compacted and where temperature is still more than
70°C.Necessary precautions shall be taken to prevent dropping of
oil, grease, petrol or other foreign matter on the pavement either when
the rollers are operating or standing.
The wheels of roller shall be kept moist to prevent the mix from
adhering to them. But in no case shall fuel/lubricating oil be used
for this purpose nor excessive water poured on the wheels, Rolling
shall commence longitudinally from edges and proceed towards the
centre, except that on superelevated and unidirectional cambered
portions, it shall progress from the lower to upper edge parallel to
the centre line of the pavement. The roller shall proceed on the fresh
material with rear or fixed wheel leading so as to minimise the
<< 168
pushing of the mix and each pass of the roller shall overlap the
preceding one by half the width of the rear wheel.
Rolling shall be continued till the density achieved is at least 98
per cent of that of laboratory Marshall specimen (compacted as defined
in Table 500-10) and all roller marks are eliminated. Skin patching of
an area that has been rolled, will not be permitted. Rolling operations
shall be completed in all respects before the termperature of the mix
f~.illsbelow 100°C.
Traffic may be allowed after completion of the final rolling when
the mix has cooled down to the surrounding temperature. The Dense
Bituminous Macadam shall be provided with an appropriate wearing
course as early as possible prior to regular opening to normal traffic and!
or impending rain.
of Clause 902.
During the period of construction, arrangements for the traffic shall
be done to Clause 112,
507.8. Measurements for P~~~ne~t
Dense Bituminous Macadam shall be measured as finished work
in cubic metres or tonnes as directed by the Engineer.
507.9. Rate
The contract unit rate for Dense Bituminous Macadam shall be
full compensation for all components listed in Clause 504.8 (i) to
(vi). The rate shall cover the provision of bitumen in the mix at 4,5
per cent of the weight of the total mix, with the provision that the
variation of quantity of bitun~nwill be assessed and the payment adjusted
as per the rate of bitumen quoted.
<< 169
508. SURFACE DRESSING

508.1. Single and Two-Coat Surface Dressing using Bitumen
508.1.1. Description: This 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 base prepared previously,
followed by a cover of stone chippings properly rolled to form a
wearing course to the requirements of these Specifications.
508.1.2. Materials
508.1.2.1. Binder : The binder shall be straight-run bitumen of
a suitable grade appropriate to the region, traffic, rainfall and other
environmental conditions as directed by the Engineer and conforming
to IS: 73. Guidance in this regard may be obtained from Appe,idix4.
508.1.2.2. Stone chippings : The stone chippings shall
conform to Clause 504.2.2.1. The Stone Polishing Value as measured
by BS 812 (Part 114), shall not he less than 55. The stone chippings
shall also conform to the quality requirements of Table 500-3
except that water absorption shall be restricted to a maximum of I
per cent. The size of stone chippings shall be in accordance with Table
500-12.
508.1.2.3. Quantities of materials: The quantities of materials used
tbr this wofk shall be as specified in Table 500-13.
TABLE 500-12. SIZE REQUIREMENTS OF STONE CHIPPINGS FOR SURFACE
DRESSING USING BITUMEN
S. Type of construction Normal size or Specifications
No. stone chipplngs
1. Single coat surface dressing 13.2 mm 100 per cent passing through 22.4mm
or the first coat of two-coat sieve & retained on 11.2 mm sieve.,
surface dressing
2. Second coat of two-coat 11.2 mm 100 per cent passing through 13.2 mm
surface dressing (also used sieve and retained on 5.6 mm sieve,
as a renewal coat)
TABLE 500-13. QUANTiTIES OF MATERIALS REQUIRED FOR 10 sq. ns.OF
ROAD SURFACE FOR SURFACE DRESSING USING BITUME~
S.No. Type or construction Binder Stone
chlppings
1. Single coat surface dressing or the first coat
of the two—coat surface dressing 18.0 kg 015 cu.m.
2. Second coat of the two-coat surface dressing
(also used as a renewal coat) 10.0 kg 0.10 cu.m.
<< 70
508,1.3. Construction operations
508.1.3.1. Weather and seasonal limitations: Clause 504.3.1
shall apply.
508.1.3.2. Preparation of base : The base on which the surface
dressing is to be laid shall be prepared, shaped and conditioned to
the specified lines, grade and cross-section in accordance with Clause
501 and as directed by the Engineer. Priming coat, where needed, shall
be provided as per Clause 502 and as directed by the Engineer. Where
the existing surface shows signs of fatting up, this shall be rectified.
The bituminous primed surface to be dressed shall be thoroughly cleaned
either by using a mechanical broom or any other approved equipment/
method as specified by the Engineer.
Dust removed in the process shall be blown off with the help of
compressed air.
508.1.3.3. Application of binder: Bitumen shall be heated to
l50~-.163°Cand sprayed on the dry surface in a uniform manner with
the help of self-propelled mechanical sprayers having self-heating
arrangement and bitumen pressure pump and spraying bar with nozzles
having constant volume or pressure system capable of spraying
bitumen uniformly at the rates specified in Table 500-13 and above
mentioned temperature. Excessive deposits of binder caused by stopping
or starting of the sprayer or through leakages or any other reason shall
he corrected by blotting with sand before the stone chippings are
spread.
508.1.3.4. Application of stone chippings: Immediately after
the application of binder, stone chippings in a dry and clean state shall
he spread uniformly on the surface by means of a self-propelled or
towed mechanical grit spreader capable of spraying uniformly at rates
specified in Table 500-13 so as to cover the surface completely. If
necessary, The surface shall be broomed to ensure uniform spread of
chippings.
508.1.3,5. RoIling: Immediately after the application of the cover
material, the entire surface shall be rolled with a 80-100 kN smooth
wheeled steel roller, 80-100 kN static weight vibratory roller, or other
approved equipment. Rolling shall commence at the edges and progress
towards the centre except in superelevated and uni-directional
cambered portions where it shall proceed from the lower edge to the
higher edge. Each pass of the roller shalt uniformly overlap not less
<< 171
than one-third of the track made in the preceding pass. While rolling
is in progress, additional chippings shall be spread by hand in
necessary quantities required to make up irregularities. Rolling shall
continue until all aggregate particles are firmly embedded in the
binder and present a uniform closed surface.
508.1.3.6. Application of second coat of surface dressing
Where surface dressing in two coats is specified, the second coat shall
he applied immediately after laying of the first coat. The construction
operations for the second coat shall be the same as described in
Clauses 508.1.3.3 to 508.1.3.5.
508.1.4. Opening to traffic : Traffic shall not be permitted to run
on any newly surface dressed area until the following day. in special
circumstances, however, the Engineer may open the road to traffic
immediately after rolling, but in such cases traffic speed shall be limited
to 16 km per hour till the following clay.
508.1.5. Surface finish and quality control of work: The surface
finish of construction shall conform to the requirements of Clause 902.
508.1.6. Arrangements for traffic : During the period of
construction, arrangement of traffic shall be done as per Clause 112.
508.1.7. Measurements for payment: Each coat of surface dressing
shall be measured as finished work in square metres.
508.1.8. Rates: The contract unit rate for each coat of surface
dressing shall be payment in full for carrying out the required
operations including full compensation for all components listed it
Clause 504.8 (i) to (vi).
508.2. Two—Coat Surface Dressing Using Cationic Bitumen
Emulsion
508.2.!, Scope
508.2.1.1. This work shall consist of two-coat surface dressing, each
coat consisting of a layer of cationic bitumen emulsion binder sprayed
on a base prepared previously, followed by a cover of stone aggregate,
properly roiled to form a wearing course to the requirements of these
Specifications.
508.2.1.2. It shall, however, not be applicable to a single coat
surface dressing using cationic bitumen emulsion.
<< 172
508.2.2. Material
508.2.2.1. Binder: The binder shall be a Cationic type bitumen
emulsion of Rapid Setting ~RS)grade complying with 1.5. 8887 and
having bitumen content 60 per cent minimum by weight.
508.2.2.2. Aggregate
(A)~General Requtrements: Clause 508.1.2.2. shall apply except the size requirement
which shall be as given in Table 500-14. Wet aggregates can be used for surface
dressing with Cationic bitumen emulsions and when aggregates are dusty, they
should be cleaned by washing or by sprinkling water copiously. If the road
surface is thy, a light sprinkling with waler shall be done.
(B) Size: The aggregates shalt conform to the size given in Table 500-14,
TABLE 500.14. REQUIREMENTS OF STONE dIPPINGS FOR SURFACE
DRESSING USING BITUMEN EMULSION
I. .For first coat-13.2 mm size Passing 22.4 mm sieve and retained on 11.2 mm sieve.
2. I’or second coat-6.7 mm size Passing 9.5 mm sieve and retained on 2.36 mm sieve.
(C) QuantIties of Materials: The quantities of materials used for this work shalt
be as given in Table 500-15.
TABLE 50045. REQUIREMENTS OF MATERIALS USING BITUMEN
EMULSION
MaterIal For 10 sq. m. area For FIrst Coat For Second Coat
Cationic Bitumen Emulsion 12 to 14 kg 16 to 18 kg
Aggregates 0.10 so 0.12 cu.m, 0.06 to 0.08 cu.m.
508.2.3. Construction operations

508.2.3.!. Weather limitations: Cationic bitumen emulsions should
not normally be stored below 0°C. However, surface dressing with
Cationic bitumen emulsion should be carried out only when the
atmospheric temperature is above 10°C.The work can be carried out
when the base is damp. All standing water in depressions shall, however,
be removed.
508.2.3.2. Preparation of base: The existing base on which surface
dressing is to be laid shall be prepared, shaped and corrected to a
uniform grade and camber in accordance with Clause 501.
The surface shall be cleaned to remove all loose particles, dust and
loreign matter. It is preferable to spray water on the surface to settle
the loose dust and also to expose clean surface of aggregates in the
case of granular base courses.
508.2.33. Preparation of binder: Before opening, the Cationic bi-
tumen emulsion drums should be rolled at slow speed, to and fro,
<< 173
for a distance of about 10 metres, 5 to 6 times to mix the contents

properly.
508.2.3.4. First Coat
(A) Application of Binder: Cationic bitumen emulsion binder can be applied on
wet road surface. If the road surface is dry, light sprinkling with water shall
he done. Cationic bitumen emulsion shall be sprayed uniformly on the prepared
base by mechanical sprayers. In exceptional cases spraying from a spraying
can may he resorted to at directed by the Engineer. The spraying can should
have 6 mm diameter holes spaced 30 mm apart to prevent clogging. An emulsion
tank of 30 litres capacity pressurized by compressed air from a hand pump and
a 12 mm flexible pipe with a spray nozzle is a simple and efficient arrangement
for spraying.
(B) Application of aggregate: Immediately after spraying of Cationic emulsion,
aggregate of 13.2 rum size shall be spread uniformly and evenly by mechanical
means to cover the surface completely and evenly. Any oversize aggregate,
if seen, shall be removed.
(C) Rolling : Immediately after the application of cover material, the surface
shall be rolled with 80-100 kN roller preferably by smooth wheeled tandem type.
The rolling shall begin at the edge and proceed towards the centre, parallel so
the centre line except in superelevated and unidirectional -.ambered porsionr
where it shall proceed from the lower edge to the higher edge. While rolling,
aggregates shall be added or removed so as to ensure a unifonnly covered
surface. Each-pass of roller shall uniformly overlap not less than one third
ol the track made in the preceding pass. Rolling shall continue for just enough
time to embed the aggregates in the binder and present a uniform closed
surface. Excessive rolling, resulting in crushing of aggregates shall be avoided.
508.2.3.5. Second coat

(A) ‘rune interval : ‘The second coat of surface dressing shall be applied on the
same day as the Isrst coat but at least not earlier than one hour after finishing
the rolling of the first coat.
(B) Application of emulsion: Traffic shall not be allowed on the first coat before
the appi ication of second coat. If the aggregates of the first coat appear to
be loose and unbonded - in few spots, the same shall not be disturbed.
‘[he Caliortic bitumen emulsion for secoqd coat shall be sprayed by mechanical
sprayer or in exceptional cases by using pouring can with the approval of the
Engineer, taking care not to disturb the first layer while walking over it.
(C) Application of aggregate: Immediately after the application of emulsion, 6.7
mm size aggregates shall be spread uniformly by mechanical means to cover
the whole surface evenly.
(II) Rolling: Rolling shall start soon after spreading the aggregates and all
operations carried out as per Clause 508.2.3.4 (C) to achieve a uniform closed
surface.
(E) Finishing: After one pass of the roller, depressions shall be filled with
6.7 mm size aggregate. If excess of aggregate is found in isolated spots, the
bigger size aggregates shall be removed to give a uniform surface. Finish
rolling on the next day helps to give a firm surface.
<< 174
508.2.4. Opening to traffic: The road may be opened to traffic 4

hours after completing rolling of the second coat, but preferably the
next day alter 24 hours.
Where the road width is single lane, traffic can be allowed at slow
speed of not more than 10 km per hour making sure to add aggregates
and emulsion wherever the surface has been picked up by traffic.
508.2.5. Surface finish and quality control of work : The
surface finish of construction shall conform to the requirements of Clause
902,
508.2.6. Arrangements for traffic : During the period of
construction, arrangement of traffic shall be done to Clause i 12.
508.2.7. Measurements for payment : Two coats of surface
dressing shall be measured as a fmished work in square metres,
508.2.8. Rate: The contract unit rate for two coats of surface
operations including full compensation for all components listed in
508.3. Surface Dressing with Precoated Aggregate using
Bitumen
508.3.1. Scope
508.3.1.1. The work shall consist of application of either a single
coat or two coats of surface dressing over a previously prepared base,
each coat consisting of application of bituminous binder sprayed on a
base previously prepared followed by a cover of precoated materials
properly rolled to form a wearing course to the requirements of these
Specifications.
508.3.1.2. This Specification may be adopted in lieu of the con-
ventional surface dressing to Clause 508.1, in situations where better
adhesion is required between the aggregates and binder during construc-
tion and later in service. The technique is basically the same as
conventional surface dressing except that a small quantity of binder is
used for precoating the aggregates. However,., it is quite different from
premix construction.
175
<<
508.3.2. Materials
508.3.2.1. Bind~r:The binder shall be straight run bitumen of
a suitable grade appropriate to the region, traffic and other environmental
conditions and as directed by the Engineer and conforming to
IS:73.
508.3.2,2. Aggregates : The aggregaS shall conform to Clause
504.2.2. They shall conforni to the quality requirements of Table 5(X)-
3 except that the water absorption shall be restricted to maximum of
I per cent. The Stone Polishing Value as measured by BS 812 (Part-
114) shall not be less than 55.
The size of the aggregates shall be .in accordance with Table
500-12.
508.3.2.3. Quantities of materials: The quantities of materials used
for this work shall be as specified in Tables 500-12 and 500-13.
508.3.2.4. Precoating: The aggregates shall be precoated with 0.75
to 1.00 per cent of their weight with binder and shall not be precoated
simultaneously with the surface dressing operation. The precoated ag-
grcgates shall be allowed to cure for at least one week so that they become
non-sticky to facilitate easy spreading like normal uncoated aggregates.
The aggregates, free of dust or fine parlicles shall be preheated to
160°Cfor pr~coatingand then mixed with bitumen binder (0.75 to
1.00 per cent hy weight of aggreg~fte) heated to its application
temperature. The aggregates and binder shall be thoroughly mixed in
a mixer of approved type till the aggregates are uniformly coated.
508.3.3.1 Weather and seasonal limitations: Clause 504.3.1
shall apply.
508.3.3.2. Preparation of base: Clause 508.1.3.2 shall apply.
508.3.3.3. Application of binder: After deducfing the binder quantity
consumed in precoating aggrega~e~[or:.‘first coat in terms of para
508.3.2.4 from the quantities spn:sfiecl in Table 500-13, remaining
binder of first coat shall be heated to 150°-165°Cand sprayed on the
clean and dry surface in a uniform manner preferably with the help of
mechanical sprayers having self-heating arrangement, bitumen, pressure
pump anti spray nozzle bar capable of spraying bitumen uniformly at
tha4xates and temperatures specified above. Excessive deposits of binder
caused by stoppage or starting of sprayer or through leakage or any
other reason shall be corrected before stone chip~ingsare spread.
<< 176
508.3.3.4. Application of aggregates : Immediately after the

application of binder, aggregates in a dry and clean state shall be spread
uniformly on the surface preferably by means of a mechanical griLLer
capable of spreading uniformly at the rates specified in Table 500-14
so as to cover the surface completely. If necessary, the surface shall
be broomed mechanically or manually to ensure uniform spread of
aggregates.
508.3.3.5. RoIling: Clause 508.1.3.5 shall apply.
508.3.3.6. Application of second coat of surface dressing : The
second coat of surface dressing, where specified, shall be applied
immediately after the first coat or soon after, depending upon the
conditions at site and type of binder used. The construction operations
for the second coat shall be the same as described in Clause 508.3.3.3.
to 508.3.3.5. except that the rate of application of aggregates and binder
for secànd coat shall be as specified in Table 500-13 after deducting
binder consumed for precoating the aggregates required for second coat
vide Clause 508.3.2.4.
508.3.4. Opening to traffic : Clause 508.1.4. shall apply.
finish of construction shall conform to the requirements of Clause 902.
508.3.6. Arrangements for traffic : During the period of construc-
tion, arrangement of traffic shall be done to Clause 112,
508.3.7. Measurements for payment: Each coat of surface dressing
.shall be measured as finished work in square metres.
508.3.8. Rates: The contract unit rate for each coat of surface
operations including full compensation for all components listed in
509. OPEN-GRADED PREMIX CARPET
509.1. Open-graded Premix Carpet using Bitumen
509.1.1. Scope : This work shall Consist of laying and compacting
an open-graded carpet of 20 mm thickness in a single course composed
of suitable small-sized aggregates prem’txed with a bituminous binder
on a previously prepared base, in accordance with the requirements
of these Specifications, to serve as a wearing course.
<< 177
509.1.2. Materials
509.1.2.1. Binder: The binder shall be bitumen of a suitable grade
appropriate to the region, traffic, rainfall ançl other environmental con-
ditions, as directed by the Engineer and satisfying the requirements
of IS 73, 217, 454 or other approved cuthack as applicable. Guidance
in this regard may be taken from Appendix 4. -
509.1.2.2. Aggregates: The coarse aggregates shall conform to

Clause 504.2.2.l.The Stone Polishing Value as measured by BS:812-
(Part 114) shall not be less than 55.
The aggregates shall satisfy the quality requirements set forth in
Table 500-3 except that the water absorption shall be limited to a
maximum of I per cent.
509.1.2.3. Proportioning of materials: The materials shall be
proportioned as per quantities given in Table 500-16.
2 OF ROAD
TABLE 500.16. QUANTITIES OF MATERIAlS REQUIRED FOR 10 m
SURFACE FOR 20 mm THICK OPEN-GRADED PREMIX CARPET
USING BITUMEN
Aggregates for Carpet
(a) Stone chippinga-13.2 mm size; passing 22.4 mm 0.18m5
steve and retained on 11.2 mm sieve
(b) Stone chippings-I1.2mm size passing 13.2 mm 0.09s&
sieve and retained on 5.6 mm sieve
Total 0.27&
Binder for Prembdng (quantities in terms of straight run bitumen)
(a) For 018 m5 of 13.2 mm size stone chippmgs 9.5 kg
at 52 kg per m’
(b) For 0.09 m3 of 11.2 mm size stone chippings 5.1 kg
at 56 kg per m3
Total 14.6 kg.
509.13. Construction operations

509.13.1. Weather and seasonal limitations: Clause 504.3.1 shall
apply.
509.1.3.2. Preparation of base: The underlying base on which
the bituminous carpet is to be laid shall be prepared, shaped and
conditioned to the specified lines, grade and cross-section in accordance
with Clause 501. A prime coat where needed shall be applied in
accordance with Clause 502 as directed by the Engineer.
178
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509.1,3.3. Tack coat : A tack coat complying with Clause 503, shall
be applied over the base preparatory to laying of the carpet.
509.1.3.4. Preparation of premix: Hot mix plant of appropriate
capacity and type shall be used for the preparation of mix material.
The hot mix plant shall have separate dryer arrangement for heating
aggregates and pugmill for mixing aggregates and binder.
The temperature of binder at the time of mixing shall be in the
range of 150°C to 163°C and that of the aggregates in the range of
1550 C to 163°C provided that the difference in temperature between
the binder and aggregates at no time exceeds 14°C. Mixing shall be
thorough to ensure that a homogeneous mixture is obtained in which all
particles of the aggregates are coated uniformly and the discharge
temperature of mix shall be between 130°C and 160°C.
The mix shall be immediately transported from the mixer to the
point of use in suitable vehicles or wheel barrows. The vehicles
employed for transport shall be clean and the mix being transported
covered in transit if so directed by the Engineer.
509.13.5. Spreading and rolling: The mixed material shall be
spread by suitable means. As soon as sufficient length of bituminous
material has been laid, rolling shall commence with 80-100 kN rollers,
preferably of smooth wheel tandem type, or other approved equipment.
Rolling shall begin at the edge and progress toward the centre
longitudinally, except that on the superelevated and uni-directional
cambered portions, it shall progress from the lower to upper edge
parallel to the centre line of the pavement.
removing or adding premixed materials. Rolling shall then be continued
until the entire surface has been rolled to compaction and all the roller
marks eliminated. In each pass of th~roller, preceding track shall be
overlapped uniformly by at least 1/3 width. The roller wheels shall be
kept damp to prevent the premix from adhering to the wheels and being
picked up. In no case shall fuel/lubricating oil be used for this purpose.
Excess use of water for this purpose shall be avoided.
Rollers shall not stand on newly laid material while there is a risk
that it will be deformed thereby. Rolling operations shall be completed
in every respect before the temperature of the mix falls below l000C,
<< 179
The edges along and transverse of the carpet lai,d and compacted
earlier shall be cut to their full depth so as to expose fresh surface which
shall be painted with a thin surface coat of appropriate binder before
the new mix is placed against it.
509.1.3.6. Seal coat: A seal coat conforming to Clause 513 shall
be applied to the surface immediately after laying the carpet.
509.1.4. Opening to traffic: No traffic shall be allowed on the road
tilt the seal coat has been laid. After the seal coat is laid, the road
shall be opened to traffi~according to Clause 513.4.
finish of construction shall conform to the requirements of Clause
902. Control on the quality of materials and works shall be exercised
509.1.6. Arrangements for traffic: During the period of construc-
lion, arrangement of traffic shall be done to Clause 112.
509.1.7. Measurements for payment: Open graded premix carpet
shall be measured as finished work in square metres.
509.1.8. Rate: The contract unit rate for open-graded premix carpet
shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 504.8.
509.2. 20mm Thick Premix Carpet using Cationic Bitumen Emul..
sion
.509.2.1. Scope: This work shall consist of laying and compacting
an olen graded premix carpet of 20mm thickness with Cationic bitumen
emulsion placed on a previously prepared base in accordance with the
requirements of these Specifications to serve as a wearing course.
509.2.2. Materials
509,2.2.1. Binder: The binder shall be Cationic bitumen emulsion
of Medium Setting (MS) grade complying with IS: 8887 and having
bitumen content 60 per cent minimum by weight. For liquid seal coat
MS grade can be used, but it is preferable to use Rapid Setting (RS)
grade of Cationic bitumen emulsion. However, for premix seal coat Stow
Setting (SS) grade Cationic bitumen emulsion shall be used.
509.2.22. Coarse aggregates : C!ause 509.1.2.2. shall apply. Ag-
gregates should be cleaned by washing or by spriniding water copiously.
The coarse aggregates shall satisfy the quality requirements set forth
<< 180
in Table 500-3, except that the water absorption value shall be limited
to a maximum of I per cent. Stripping value is not to be considered
unless directed by the Engineer. Water absorption up to 2 per cent may
be permitted in exceptional cases only.
509.2.2.3. Fine aggreg~tes~Fine aggregates for seal coat shall
be crushed stone chips or coarse sand, clean, uncoated and free from
clay, dust and other deleterious matter.
509.2.3. Quantities of materials required: The materials shall
be proportioned as per quantities given in Tables 500-17 and 500-18.
TABLE 500.17. QUANTITIES OF AGGREGATES FOR 10 nsa AREA
(A) Prembi Carpet
(a) Coarse aggregate 13.2 mm size; passing
Is 22.4 mm sieve and retained on IS 11.2 mm sieve 0.18 m’
(b) Coarse aggregate 11.2 mm size; passing
Is 13.2 mm sieve and retained on IS 5.6 mm sieve 0.09 in’
(B) For Seal Coat:
(a) Liquid seal coat:~
Crushed fine aggregates 6.7 mm size; passing IS 9.5 mm 3
sieve and retained on Is 2.36 mm sieve 0.06 m
(b) Premix seal coat:
Coarse sand or stone grit passing 2.36 mm
sieve and retained on 180 micron sieve 0.06 rn~
TABLE 500.18. QUANTITIES OF BINDER
(A) For Tack Coat For 10m2 area

(i) Normal bituminous surfaces 2.0 to 2.5 kg
(ii) Dry and hungry bituminous surface 2.5 to 3.0 kg
(iii) Granular surfaces treated with primer 2.5 to 3.0 kg
(iv) Non bituminous surfaces:
(a) Granular base (not primed) 3.5 to 4.0 kg
(b) Cement concrete surface 2.5 to 4.0 kg
(B) For Premix Carpet: 20 to 23 kg
(C) For Seal Coat:
(a) for liquid seal coat 12 to 14 kg
(b) for premix seal coat 10 to 12 kg
509.2.3,1. Aggregates
509.2.4.1. Weather limitations: Cationic bitumen emulsions shall
181
<<
Section500 Base and Surface Courses (Bituminous)
not normally be stored below 0°C.However, premix carpet work
with Cationic emulsion shall be carried out only when the atmospheric
temperature is above 10°C.
509.2.4.2. Preparation of base: The underlying base on which
the premix carpet is to be laid shall be prepared, shaped and conditioned
to the specified lines, grades and cross-sections in accordance with Clause
501. The cleaned surface can be finally washed with water, if it is readily
available.
509.2.4.3. Preparation of binder: Clause 508.2.3.3 shall apply.
509.2.4.4. Tack coat: Clause 508.2,3.4 (A) shall apply. Tack coat
shall be applied not earlier than 10 minutes before spreading the
premix. On water bound macadam surface, water shall be sprayed to
make the surface damp before applying tack coat.
509.2.4.5. Preparation of premix: Premixing of Cationic bitumen
emulsion and aggregates can be done in a suitable mixer such as cold
mixing plant as per IS~5435 (Revised) or concrete mixer or by shovels
in exceptional cases with the approval of the Engineer. However, for
large works, continuous mixing operation can be done either in batch
or continuous mixer units suitable for. emulsion mixes.
When using concrete mixer for preparing the premix, 0.135 cu.m.
(0.09 cu.m. of 13.2 mm size and 0.045 cu.m. of 11.2 mm size) of
aggregates per batch may be used as this quantity will cover 5 sq.m.
of road surface with 20 mm average thickness.
The aggregates required for one batch should be kept ready near
the mixer. The aggregates shall be cleaned free from dust and dirt, if
any, by dipping or washing or copiously sprinkling water.
First the coarse aggregates of 13.2 mm size shall be charged into
the mixer followed by 5 to 6.5 kg of Cationic bitumen emulsion and
then 11,2 mm size aggregates are added, followed by 5 to 6.5 kg of
Cationic bitumen emulsion. After the materials have been mixed
thoroughly, the mix shall be immediately transported to the laying
site in suitable vehicles. Too much mixing shall be avoided as it may
result in decoaiing of aggregates.
Because of ease of mixing, Cationic bitumen emulsion and
aggregates can be mixed manually by shovels when mechanical mixer
is not available or when the work is too small, with the approval of
the Engineer. 0.06 cu. m. of aggregates can be conveniently mixed
in one heap, with appropriate quantity of emulsion. It is preferable to
<< 182
make the aggregates damp before mixing as it reduces the effort

required for mixing and also helps to get better coating of aggregates.
The 13.2 mm size aggregates and emulsion are mixed first and then the
11.2 mm size aggregates and remaining quantity of emulsion are added
and mixed. Too much mixing shall be avoided as it will result in decoaiing
of aggregates.
509.2.4.6. Spreading of mix: The premixed caiionic bitumen emul.
sion and aggregates shall be spread within 10 minutes of applying the
tack coat. The mix is easily workable for about 20 minutes after mixing
and hence all levelling, raking, etc., should be completed within this time
for easy workability.
The mix should be spread uniformly to the desired thickness,
grades and crossfall (camber) making due allowance for extra quantity
required to fill up depressions, if any. The crossfall should be
checked by means of camber boards and inequalities evened out. Too
much use of blades or rakes should be avoided.
509.2.4,7. Rolling: The rolling shall start immediately after laying
the premix. Smooth wheeled tandem roller of 80.100 kN shall be used
preferably, though three wheeled steel roller of equivalent capacity
can also be used. While rolling, wheels of roller should be clean and
kept moist to prevent the premix from adhering to the wheels and being
picked up. In no case shall fuel/lubricating oil be used for this purpose.
Excessive use of water for this purpose shall also be avoided.
Rolling shall commence at the edges and progress towards the
centre longitudinally except in case of superelevated and uni-directional
cambered sections where rolling shall be done from lower edge towards
the higher edge parallel to the centre line of the road.
After one pass of roller over the whole area, depressions or
uncovered spots should be corrected by adding premix material. Rolling
shall be continued until the entire surface has been rolled to compaction
and all the roller marks eliminated. In each pass of the roller, preceding
track shall be overlapped uniformly by at least 1/3 width, Roller(s) shall
not stand on newly laid material while there is a risk that it will be
deformed thereby. At joints, the edges along the transverse of the carpet
laid and compacted earlier shall be cut to their full depth so as
to expose fresh surface which shall be painted with a thin surface
coat of binder before the new mix is placed against it.
509.2.4.8. Seal coat: A seal coat, liquid or premix type, shall be
applied 4 to 6 hours after laying the premix carpet.
<< 183
Liquid seal coat: Quantities of the materials required are given

in Tables 500-17 and 500-18.
For application of binder Clause 508.2.3.4 (A) shall apply.
Immediately after spraying emulsion, stone chips in a clean state
shall be spread uniformly, preferably by means of a mechanical gritter,
otherwise manually so as to cover the surface completely. Start rolling
with 60-80 kN roller soon after spreading the chips. The rolling
operation shall be as indicated in 509.2.4.7 as far as applicable.
Premix seal coat: The quantities of aggregate and binder to be
used shall be as given in Tables 500-17 and 500-18. Grit or sand used
for premix seal coat should be made thoroughly wet with wat~rbefore
mixing with emulsion of slow setting grade.
The mixing, spreading and rolling etc. shall be carried out as per
Clauses 509.2.4.5 to 509.2.4.7 except for the quantities and materials
which shall be for premix seal coat. Rolling shall be continued till the
premi~material completely seals the voids in the premix carpet and
smooth uniform surface is obtained.
509.2.5. Opening to traffic : Traffic should not be allowed over
the premix surface with or without seal coat, for 6 to 8 hours after
rolling. In case of single lane roads, traffic may be allowed at slow
speed not exceeding 10 km per hour. If any premix material gets picked
tip by vehicle tyres, the spot shall be filled up by new mix. It is
preferable to open the road to traffic the next day after 24 hours.
509.2.6. Surface finish and quality control : The surface finish
of construction shall conform to the requirements of Clause 902.
The control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 900,
509.2.7. Arrangements for traffic : During the period of construc-
tion, arrangement of traffic shall be done to Clause 112.
509.2.8. Measurements for payment : The premix carpet and seal
coat shall be measured as finished work in square metres.
509.2.9. Rates : The contract unit rate for premix carpet arid seal
coat shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 504.8
(i) to (vi).
<< 184
510. MIX SEAL SURFACING

510,1. Scope
510.1.1. This work shall consist of laying and compacting mix seal
surfacing in a single course composed of suitable aggregates premixed
with a bituminous binder on a previously prepared base, in accordance
with the requirements of these Specifications, to serve as a wearing
course.
510.1.2. Mix seal surfacing shall be of Type A or Type B as specified.
510.2. Materials
510.2.1. Binder: Clause 509.1.2.1 shall apply.
510.2.2. Coarse aggregates: Clause 509.1.2.2 shall apply.
510.2.3. Fine aggregates: The fine aggregates shall consist of crusher
run screening, natural gravel/sand or a mixture of both. These shall
be clean, hard, durable, uncoated, dry and free from injurious, soft
or flaky pieces and organic or deleterious substances.
510,2.4. Aggregates gradation: The coarse and fine aggregates shall
be so graded or combined as to conform to the grading set forth in Table
500-19.
TABLE 500.19. AGGREGATES GRADATION FOR MIX SEAL SURFACING
IS Sieve Per cent by weight p asslng the steve
Designation
For Type A Mtx For Type B Mix
Seal Surfacing Seal Surfacing
13.2 mm — 100
11.2 mm 100 88.100
5.6 mm 52-88 31-52
2.8 mm 14-38 5-25
90 micron 0.5 0.5
510.2.5. Proportioning of materials : The total quantity of

aggregates used for Type A or B mix seal surfacing shall be 0.27 cubic
metre per 10 square metres 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 metres area for Type A and Type B surfacing
respectively.
Clause 509.1.3.1 through 509.1.3.5 shall apply.
<< 185

the mix has cooled down to the surrounding temperature.
of Clause 902.
done to Clause 112.
Mix seal surfacing, Type A or 13 shall be measured as finished
work in square metres.
510.8. Rate
The contract unit rate for mix seal surfacing, Type A or B shall
full compensation for all components listed in Clause 504.8 (i) to (vi),
511. SEMI-DENSE BITUMINOUS CONCRETE
511.1. Scope
This work shalt consist of construction in a single course of semi-
dense bituminous concrete binder/wearing course on a previously
prepared bituminous base to the requirements of the Specifications.
511.2. Materials
511.2.1. Binder: Clause 504.2.1 shalt apply
511,2.2. Coarse aggregates: Clause 504.2.2 shall apply. The Stone
Polishing Value as measured by BS 812 (Part—114) shall not be
less than 55. The aggregates shall satisfy the physical requirements
as given in Table 500-3 except that the maximum value of water
absorption shall be I per cent. However, water absorption upto a
maximum of 2 per cent may be permitted in exceptional cases only.
51 1.2.3. Fine aggregates: Clause 507.2.3 shalt apply
511.2.4. Filler: Clause 507.2.4 shall apply.
511.2.5. Aggregates gradation: The mineral aggregates including
<< 186
filler shall be so graded or combined as to conform to the grading set

forth in Table 500-20.
TABLE 500.20. AGGREGATES GRADATION FOR SEMI-i)ENSE B11’UMINOUS
CONCRETE
IS Sieve Per cent by weight passing the IS sieve
Designation
Grading_1 Grading_2 Grading_3
22.4 mm .— 100 100
13.2 mm 100 85-100 79-100
11.2 mm 88-100 70-92 68-90
5,6 mm 42-64 42-64 33.55
2.8 mm 22-38 22-38 22-38
710 micron 11-24 11-24 6-22
355 micron 7-18 7-18 4-14
180 micron 5-13 5-13 2-9
90 micron 3-9 3-9 0-5
Note: Grading 1 shall be adopted for 25 mm compacted thickness and Grading 2/3 for
higher thicknesses.
511.3. Mix Design

511.3.1. Requirements of mix: Semi-dense bituminous concrete mix
shall he properly designed so as to satisfy the criteria laid down in Table
500-21.
TABLE 500-21. REQUIREMENTS OF SEMI-DENSE
BITUMINOUS CONCRETE MIX
1. Marshall Stability (ASTM Designation:
D 1559) determined on Marshall specimens
compacted with 75 compaction blows on each end 820 kg (1800 lIss) Minimum
3. Per cent air voids in mix 3-5
4. Per cent air voids irs mineral aggregate 13.15
(VMA) (Minimum) (for 13.2 mm max size)
11-13
(for 22.4 mm max size)
5. Per centage voidt in mineral
aggregates filled with bitumen (VFB) 65-75
6. Binder content, per cent by weight of mix Not less than 4.0 per cent
Notet : 1. Higher stability values consistent with other requirements should be achieved
as far as possible.
2. At bus stops, parking areas and roundabouts near minimum flow value should
be adopted.
3. Attempt should be to have well graded aggregates and the per cent voids in
the mix closer t.o the lower limit.
<< 187
to achieve the requirements of the mix set forth in Table 500-
2!. Marshall Method for arriving at the binder content shall be adopted.
511.3.3. Job mix formula: Clause 507.3.3 shall apply.
511.3.4. Permissible variation from job mix formula: The Con-
tractor shall have the responsibility ‘of ensuring proper proportioning
of materials in accordance with the approved job mix formula
and producing a uniform mix. The permissible variations of the individual
percentages of the various ingredients in the ac.tual mix from the job
mix formula may be within the limits as specified in Table 500-22.
These variations are intended to apply to individual specimens taken for
quality control tests vide Section 900.
TA BLE 500-22. PERMISSIBLE VARIATIONS FROM JOB MiX FORMULA
S,No. Description of ingredient PennSslble jariatlon by
weight ci total mix In
percentage
I. Aggregate passing 13,2 mm sieve and larger sieves ±8

2. Aggregate passing 11.2 mm sieve and 5.6.mm sieve ±7
3. Aggregate passing 2.8 nun sieve and 1.40 mm sieve ±6
4. Aggregate passing 710 micron sieve and 355 micron sieve ±5
7. Bitumen ±0.3
8. Mixing Temperature ± 10°C

apply.
511.4,2. Preparation of base : The base on which semi-dense bi-
tuminous concrete is to be laid.shall be prepared, shaped and conditioned
to the specified lines, grades and cross-sections in accordance with
Clause 501 or as directed by the Engineer.
511.4.3. Tack coat : A tack coat as per Clause 503 shall be applied
on the base.
511.4.4. Preparation of mix: Clause 507.4.4 shall apply.
511.4.5. Spreading of mix: Clause 507.4.5 shall apply.
511.4.6. Itolling: Clause 507.4,6 shall apply.
511.5. opening to Traffic
the mix has cooled down to the surrounding temperature.
<< 188

of Clause 902.
done to Clause 112.
Semi-dense bituminous concrete shall be measured as finished
work in cubic metres or tonnes as directed by the Engineer.
511.9. Rate
The contract unit rate for semi-dense bituminous concrete shall be
payment in full for carrying out the required operations including full
compensation for aH components listed in Clause 504.8 (i) to (vi).
The rate shall cover the provision of bitumen in the mix at 4.5 per cent
of the weight of the total mix, with the provision that the variation
of quantity of bitumen will be assessed and the payment adjusted as
per the rate of bitumen coated.
512. BITUMINOUS CONCRETE
512.1. Scope
This work shall consist of constructing in a single layer, bituminous
concrete (asptialtic concrete) of thickness 25 100 mm on previously
-
prepared bituminous course to the requirements of these Specifications.

512,2. Materials
512.2.1. Bitumen: Clause 507.2.1 shall apply.
512.2.2. Coarse aggregates : Clause 507.2.2 shall apply. The
Stone polishing Value as measured by BS : 812 (Part 114) shall not
~e les~thai 55. The aggregates shall satisfy the physical requirements
as given i~ Table 50~-8except that the maximum value for the
water absorption should be I per cent
512.2.3. Fine aggregates : Clause 507.2.3 shall apply.
512.2.4. Filler : Clause 507.2.4 shall apply.
512.2.5. Aggregates gradation : The mineral aggregates, including
<< 189
thineral filler shall be so graded or combined as to conform to the
grading set forth in Table 500-23.
TABLE 500-23. AGGREGATES GRADATiON FOR BITUMINOUS CONCRETE
15 Sieve Designation Per cent passing the sieve by weight
26.5 mm 100
19 mm 90-100
9.5 mm 56-80
4.75 mm 35-65
2.36 mm 23-49
300 micron 5-19
75 micron 2-8
512.3. Mix Design

512.3.1. Requirement of mix: Apart from conformity with the
grading and quality requirements of in~1ividualingredients, the mix shall
meet the requirements set forth in Table 500-24.
TABLE 500.24. REQUIREMENTS OF BITUMiNOUS CONCRETE MIX
S,No. Description Requirements
L Marshall stability (ASTM Designation: 820 kg (1800 Ib)
D-1559) determined on Marshall specimens Minimum
compacted by 75 compaction blowt on each end
3. Per cent air voids in mix ‘ 3-5
4. Per cent voids in mineral aggregate (VMA) Minimum 11-13 per cent
5. Per cent voids in mineral aggregates
filled by bitumen (VFB) 65-75
6. Binder content, per cent by weight of total mix Minimum 4,5
7. Water Sensitivity (ASTM D1075) Loss of Mm. 75 per cent
stability on immersion in water at 60°C retained strength
8. Swell Test (Asphalt Instt, MS-2, No, 2) 1.5 per cent Max,
to achieve the requirements of the mix set forth in Table 500-24.
Marshall method for arriving at the binder content shall be adopted.
512.3.3. Job mix formula: Clause 507.3.3 shall apply except that
the requirement of Bituminous Concrete mix shall be as per Table 500-
24.
512.3.4. Permissible variations from the job mix formula:
The Contractor shall have the responsibility of ensuring proper propor-
tioning of materials in accordance with the approved job mix formula
and producing a uniform mix. The permissible variations of individual
<< 190
percentages of various ingredients in the actual mix from the job mix
formula may be within the limits as specified in Table 5O0~l1. These
variations are intended to apply to individual specimens taken for quality
control tests vide Section 900.
apply.
512.4.2. Preparation of base: The base on which bituminous
concrete is to be laid shall be prepared, shaped and conditioned to the
specified levels, grade and crossfall (camber) in accordance with Clause
501 or as directed by the Engineer.
The surface shall be thoroughly swept clean free from dust and
foreign matter using mechanical broom and dust removed by mechanical
means or blown off by compressed air. In portions where mechanical
means cannot reach, other approved method shall be used.
512.4.3. Tack coat: A tack coat complying with Clause 503 shall
be applied over the base.
512.4.4. Preparation of mix: Clause 5074.4 shalt apply.
512.4.5. Spreading: Clause 507.4.5 shall apply.
512,4.6. Rolling: Clause 5074.6 shall apply.
Traffic may be allowed immediately after completion of the final
rolling when the mix has cooled down to the surrounding temperature.
The surface finish of construction shall conform to the
Control on the quality of materials and works shalt be exercised by
512,7. Arrangements for Traffic
done to Clause 112.
Bituminous concrete shall be measured as finished work in cubic
metres or tonnes as provided in the Contract.
<< 191
.__#--- .-. -. .- -

512.9. Rate
The contract unit rate for bituminous concrete shall be payment
in full for carrying out the required operations including full
compensation for all components listed in Clause 504.8 (i) to (vi).
The rate shall cover the provision of bitumen in the mix at 5.0 per
cent of the weight of the total mix with the provision that variation
of quantity of bitumen wilt be assessed and the payment adjusted as
per the rate of bitumen quoted.
513. SEAL COAT
513.1. Scope
513.1.1. This work shall consist of application of a seal coat for
sealing the voids in a bituminous surface laid to the specified levels,
grade and cross fall (camber).
513.1.2. Seal coat shall be of either of the two types as specified
below:
(A) Liquid seal coat comprising of an application of a layer of bituminous
binder followed by a cover of stone chippings.
(B) Prernixed seal coat comprising of a thin application of fine aggregates
premixed with bituminous binder.
513.2. Materials
513.2.1. Binder: Clause 509.i.2.1 shalt apply.
The quantity of bitumen shall be 9.8 kg and 6.8 kg per 10 square
metres area for Type (A) and Type (B) seal coat respectively.
513.2.2. Stone chippings for type (A) seal coat : The stone
chippings shall consist of angular fragments of clean, hard, tough and
durable rock of uniform quality throughout. They should be free of
elongated or flaky pieces, soft or disintegrated stone, organic or
other deleterious matter. Stone chippings shalt be of 6.7 mm size
defined as 100 per cent passing through 112 mm sieve and
retained on 2.36 mm sieve. The quantity used for ‘spreading shall
be 0.09 cubic metre per 10 square metres area. The chippings
shall satisfy the quality requirements spelt out in Table 500-3
except that the upper limit for water absorption value shall be 1 per
cent.
513.2.3. Aggregates 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.
<< 192
The aggregate shall pass 2.36 mm sieve and be retained on 180

micron sieve. The quantity used for premining shall be 0.06 cubic metre
per 10 square metre area.
513.3.1. Preparation of base: The seal coat shall be applied
immediately after the laying of bituminous course which is required to
be sealed. Before application of seal coat materials, the surface
shall be cleaned free of any dust or other extraneous matter.
513.3.2. Construction of type (A) seal coat: The binder shall be
heated in boilers of suitable design, to the temperature appropriate to
the grade of bitumen approved by the Engineer, and the seal coat applied
in accordance with the construction operations described in Clauses
508.1.3.3 through 508.1.3.5.
513.3.3. Construction of type (B) seal coat: Mixer of appropriate
capacity and type shall be used for preparation of mix material. The
plant shall have separate dryer arrangement for heating aggregate and
pugmill for mixing aggregate and binder.
The binder shall be heated in boilers of suitable design, to the
temperature appropriate to the grade of bitumen approved by the
Engineer. Also the aggregates shall be dry and suitably heated to a
temperature directed by the Engineer before the same are placed in the
mixer. Mixing of binder with aggregates to the specified proportions
shall be continued till the latter are thoroughly coated with the
former.
The mix shall be immediately transported from the mixing plant
to the point of use and spread uniformly on the bituminous surface to
be sealed.
As soon as sufficient length has been covered with the premixed
material, the surface shall be rolled with 80-100 kN smooth-wheeled
roller. Rolling shall be continued till the premixed material completely
seals the voids in the bituminous course and a smooth uniform surface
is obtained.
In the case of type (B) seal coat, traffic may be allowed soon
after final rolling when the premixed material has cooled down to the
surrounding temperature. However, as regards type (A) seal coat, Clause
508.1.4 shall apply.
<< 193
of Clause 902.
done to Clause 112.
Seal coat, Type (A) or (B) shall be measured as finished work in
square metres.
513.8. Rate
The contract unit rate for seal coat, Type (A) or (B) shall be
full compensation for all components listed in Clause 504.8 (i) to (vi).
514. SUPPLY OF MINERAL AGGREGATES FOR
PAVEMENT COURSES
514.!. Scope
These Specifications shall apply to works where it is intended
only to collect, transport and stack the mineral aggregates and
mineral filler for use in pavement courses. The actual work of laying
the courses shall, however, be governed by the Specifications for the
same, given elsewhere in these Specifications. The size and quantities
of the aggregates to be supplied shall be so selected by the Engineer
that the grading requirements set forth in these Specifications for the
courses for which the supply is intended are satisfied.
All the materials shall be procured from approved sources and shall
conform to the physical requirements, specified in the respective
Specifications for the individual items given elsewhere in these
Specifications.
514.2. Sizes of Mineral Aggregates
The mineral aggregates shall be designated by their standard sizes
in the Contract and shall conform to the requirements set forth in Table
500-25.
<< 194
TABLE 500-25. SIZE REQUIREMENTS FOR MINERAL AGGREGATES

Coarse Aggregate
S.No. Standard size Designation of sieve Designation of
of aggregates through which the sieve on which
aggregates shall the aggregates
wholly pass shall wholly be
retained
(i) 75 mm 106 mm 63 mm
(ii) 63mm 90mm 53mm
(iii) 45 mm 53 mm 26.5 mm
(iv) 26.5 mm 45 mm 22.4 mm
(v) 22.4 mm 26.5 mm 13.2 mm
(Vi) 13.2 mm 22.4 mm 11.2 mm
(vii) 11.2 mm 13.2 mm 6.7 mm
(viii) 6.7 mm 11.2 mm 2.8 mm
514.3. Stacking
1. Coarse Aggregates
Only the aggregates satisfying the Specification requirements shall
be conveyed to the roadside and stacked. Each size of aggregate shall
be stacked separately. Likewise, materials obtained from different quarry
sources shall be stacked separately.
2. Fine Aggregates : As given in relevant Specifications.
The aggregates shall be stacked entirely clear of the roadway on
even ground, or platform prepared in advance for the purpose by the
Contractor at his own cost and in a manner that permits of correct and
ready measurement. Materials shall not be stacked in locations liable
to inundation or floods.
The dimensions of the stacks and their location shall be as approved
by the Engineer. Where the material is improperly stacked, the Engineer
shall have the right to order complete re-stacking of the materials to
specifications at the cost of the Contractor. -
Mineral filler shall be supplied in dry state in bags or other suitable

containers approved by the Engineer and shall be protected from
weather dampness, etc., so as to prevent deterioration in quality.
514.4. Quality Conlrol of Materials
The Engineer shall exercise control over the quality of the materials
<< 195
so as to ascertain their conformity with the Specification requirements,

by carrying out tests for the specified properties.
Testing shall be to the following frequencies and the Engineer shall
have the right to modify these according to the needs.
3 of material.
Coarse and fine One test for each specified property per 50 m
aggregates
Mineral filler : One test for each specified property for every five tonnes,
subject to a minimum of one test for each consignman.
Materials not conforming to the Specification requirements shall not
be brought to the work site.
Coarse and fine aggregates supplied at site of works shall be paid
for in cubic metres. The actual volume of the aggregates to be paid
for shall be computed after deducting the specified percentages from
the volume computed by stack measurements in Table 500-26.
TABLE 500.26. PER CENT REDUCTION IN VOLUME OF AGGREGATES
S.No. Standard size Percentage reduction In volume
of aggregates computed by stack meamrensents
to arrive at the volume to be paid for
1. 75 mm and 63 mm 123
2. 45 mm and 26.5 mm 10.0
3. 22.4 mm, 13.2 mm, 11.2 mm and 6.7 mm 5.0
4. Fine aggregate 5.0
Unless otherwise directed, measurements shall not be taken until suf-

ficient materials for use on the road have been collected and stacked.
Immediately after measurement, the stacks shall be marked by white
wash or other means as directed by the Engineer.
Mineral filler as delivered at site of works shall be measured in
tonnes.
514.6. Rates
The contract unit rates for different sizes of coarse aggregates, fine
aggregates and mineral filler shall be payment in full for collecting,
conveying and stacking or storing• at site of works including full
compensation for
(i) all royalties, fees, rents where necessary;
(ii) all leads and lips; and
(iii) all labour, tooIs..equipi~entsand incidentals to complete the work to the Speci.
fications.
<< 196
515. BITUMEN MASTIC

515.1. Scope
515.1.1. This work shall consist of constructing a single layer of
25 mm to 50 mm thick Bitumen Mastic wearing course for road
pavements and bridge decks. The bitumen mastic shall be laid over
a Dense Bituminous Macadam base in case of road pavements and
over a Cement Concrete base in bridge decks.
515.1.2. The Bitumen Mastic is an intimate homogeneous mixture
of selected well-graded aggregates 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
515.2. Materials
515.2. 1. Bitumen: The binder shall be straight-run bitumen of
a suitable grade satisfying the requirements of IS:73 or industrial bitumen
as per IS:702. It shall be paving bitumen of Grade S 35 (30/40 penetration
grade) or any other appropriate grade as directed by the Engineer. The
requirements of physical properties of bitumen are as given in Table
500-27.
TABLE 500.27. REQUIREMENTS OF PHYSICAL PROPERTIES OF BITUMEN
S.No. Characteristic Requirement Method of tests
1. Penetration at 25°C (in 1/100 cm) 20 to 40 IS; 1203
2. Softening point (Ring and Ball Method) 50°C to 90°C IS; 1205
3. Ductility at 27°C(Minimum) 10 cm 15: 1208
4. Loss on heating (Maximum) 3 per cent IS: 1212
5. Solubility in CS
2 (Minimum) 99 per cent IS; 1216
515.2.2. Coarse aggregates: The coarse aggregates shall consist of
hard, durable crushed stones, which shall be clean, strong, free of
disintegrated pieces, organic and other deleterious matter and adherent
coatings. They shall be hydrophobic and of low porosity and shall satisfy
the physical requirements given in Table 500-3 except that the maximum
value of water absorption shall be 1 per cent.
The percentage and grading of the coarse aggregates to be
incorporated in the bitumen mastic depending upon the thickness of the
finished course shall be as in Table 500-28.
<< 197
TABLE 500.28. GRADING AND PERCENTAGE OF COARSE AGCREGATES

S.No. Type of work Thickness Percentage Grading of Coarse
of Finished of Coarse Aggregates
Course (mm) Aggregates
Passing Percen-
ts. Sieve tage
1. Wearing course (a) 2.5-40 (a) 30-40 19 mm 100
for pavement 13.2 mm 88-96
& bridge deck (b) 41.50 (b) 40-50 2.36 mm 0-5
515.2.3. Fine aggregates: The fine aggregates shall be the fraction
passing 2.36 mm and retained on 75 micron sieve consisting of crusher
run screening, natural sand or a mixture of both. These shall be
clean, hard, durable, uncoated, dry and free from any injurious soft
or flaky pieces and organic or deleterious substances.
515.2.4. Filler: The filler shall be limestone powder passing
75 micron sieve and shall have a calcium carbonate content of not
less than 80 per cent by weight when determined in accordance with
IS: 1195.
The grading of the fine aggregates inclusive of filler shall be as
given in Table 500-29.
TABLE 500-29. GRADING OF FINE AGGREGATES (INCLUSIVE OF FILLER)
S.No. IS. Sieve IS. Seive Percentage
Passing Retained by Weight
1 2.36 mm 600 micron 0.25
2 600 micron 212 micron 5-35
3 212 micron 75 micron 10-20
4 75 micron — 30-50
Bitumen Binder 14-17
515.3. Mix Design

515.3.1. Hardness number : The bitumen mastic shall have a
hardness number of 60 to 80 at 25°Cwithout coarse aggregates and 10
to 20 at 25°C after adding coarse aggregates. The hardness number
shall be determined in accordance with the method specified in IS: 1195.
to achieve the requirements of the mix set forth in Clause 5 15.3.1. and
shall be in the range of 14 to 17 per cent by weight of total mix as
indicated in Table 500-29.
515.3.3. Job mix formula: The Contractor shall intimate the
<< 198
Base ar.u .~urfaceCourses (Bituminous) Section 500
Engineer in writing at least 20 days before the start of the work, the
job mix formula proposed to be used by him for the work, indicating
the source and location of all materials, proportions of all materials such
as binder and aggregates, single definite percentage passing each sieve
for the mixed aggregates and results of the tests recommended
in various Tables and Clauses of this Specification.
apply.
515.4.2. Preparation of the base: The base on which bitumen mastic
is to be laid shall be prepared, shaped and conditioned to the specified
levels, grade and crossfall (camber) in accordance with Clause 501 or
as directed by the Engineer. In case of a cement concrete base, the
surface shall be thoroughly swept and scraped clean and free of dust
and other deleterious matter. Under no circumstances shall bitumen
mastic be spread on a base containing a binder which will soften under
high application temperatures. if any such spots or area are there,
the same shall be cut out and repaired before the bitumen mastic is
laid.
515.4.3. Tack coat : A tack coat as per Clause 503 shall be applied
on the base or as directed by— the Engineer:
515.4.4. Preparation of bitumen mastic : Preparation of bitumen
mastic consists of two stages. The first stage shall be mixing of filler
and fine aggregates and then heating the mixture to a temperature of
170°Cto 200°C~ Required quantity of bitumen shall be heated to 170°C
to 180°C and added to the heated aggregate. They shall be mixed and
cooked in an approved type of mechanically agitated mastic cooker for
some time till the materials are thoroughly mixed. Initially the filler
alone is to be heated in the cooker for an hour and then h~iJfthe quantity
of binder is added. After heating and mixing for some time, the tine
aggregates and the balance of binder are to be added and further cooked
for about one hour. The second stage is incorporation of coarse
aggregates and cooking the mixture for a total period of 3 hours. During
cooking and mixing, care shall be taken to ensure that the contents
in the cooker are at no time heated to a temperature exceeding
200°C.
In case where the material is not required for immediate use it shall
be cast into blocks with filler, fine aggregates and binder, weighing
about 25 kg each. These blocks when required to be used, have to
<< 199
Section 500 Base and Surface Courses (B iturninous)
be reheated in the mechanically agitated cooker to a temperature
of not less than 170°Cand not more than 200°C,thoroughly incorporated
with the requisite quantity of coarse aggregates and mixed continuously
for not less than an hour. Mixing shall be continued until laying
operations are completed so as to maintain the coarse aggregates in
suspension. At no stage during the process of mixing shall the temperature
exceed 200°C.
The bitumen mastic blocks (without coarse aggregates) shall show
on analysis a composition within the limits as given in Table 500-30.
TABLE 500.30. COMPOSITION OF BITUMEN MASTIC -BLOCKS WITHOUT
COARSE AGGREGATES
I.SSieve IS. Sieve Percentage by weight
.
Passing Retained
Minimum Maximum
236 mm 600 micron 0 22
600 micron 212 micron 4 30
212 micron 75 micron 8 18
75 micron — 25 45
Bitumen Content 14 17
The mix shall be transported to the laying site in a towed mixer

transporter having arrangement for stirring and keeping the mix hot
during transportation.
515.4.5. Spreading: The bitumen mastic shall be deposited directly
on the prepared base immediately in front of the spreader where it
is spread uniformly by means of wooden floats to the required thickness.
The mix shall be laid in one metre width cOntained between angle iron
of sizes suitable to retain the required thickness. The temperature of the
mix at the time of laying shall be around 170°C.In case blowing takes
place while laying the bitumen mastic, the bubbles shall be punctured
while it is hot and the surface treated well.
5 15.4.6. Joints: It shall be ensured that all construction joints are
properly and truly made. These joints shall be made by warming
existing bitumen mastic by the application of excess quantity of the
bitumen mastic mix which afterwards shall be trimmed off to make
it flush with the surfaces on either side.
515.4.7. Surface finish: The bitumen mastic surface can be slippery
after floating; in order to provide resistance to skidding, the bitumen
mastic after spreading, while still hot, and in plastic condition shall
be covered with a layer of stone aggregates of 9.5 mm size (passing
<< 200
13.2 mm sieve and retained on 6.7 mm sieve). Hard stone chips of

approved quality precoated with bitumen at the rate of two per cent
of S-65 to S-90 penetration grades at 25°Cat the rate of 0.005 cu.m.
per 10 sq.m. shall be rolled or otherwise pressed into the surface of the
mastic layer when the temperature of bitumen mastic is between 80°C
and 100°C.
The traffic may be allowed after completion of the work when the
bitumen mastic has cooled down to the surrounding temperature.
515.6 Quality Control of Work
The type and grade of bitumen; the quality, grade and percentage
of coarse and fine aggregates and tiller; the temperature control for
heating the materials/mix, laying, floating and compacting, hardness
number of the bitumen mastic, etc., should be strictly followed as
indicated in the various Clauses of this Specification or as directed by
the Engineer.
The quality control tests for coarse and fine aggregates shall be
exercised by the Engineer in accordance with Section 900. For mineral
filler, one test for each property for every 5 tonnes, subject to a minimum
of one test for each consignment shall be carried out.
The surface of the bitumen mastic tested with a straight edge
3.0 m long, placed parallel to the centre line of the carriageway shall
have no depression greater than 4 mm. The same limit shall also apply
in case of transverse profile when tested with a camber template.
done to Clause 112.
Bitumen mastic shall be measured as finished work in square
metres or by weight in metric tonnes as provided in the Contract.
515.9. Rate
The contract unit rate for bitumen mastic shall he payment in
for all components listed under Clause 504.8 (i) to (vi).
<< 201
516. SLURRY SEAL
516.1. Scope -
This work shall consist of mixing emulsified bitumen, well-graded

fine aggregates (with mineral filler) and water, spreading the mixture
and rolling on a pavement surfacing as a surface treatment. -
516.2. Materials
The materials for slurry seal immediately prior to mixing shall
conform to the following requirements:
516.2.1. Emulsified bitumen : The emulsified bitumen shall
be a Cationic rapid setting type as approved by the Engineer, conforming
to the requirements as per IS: 8887. It shall be capable of producing
a slurry as would develop early resistance to traffic and rain and is
sufficiently stable to permit mixing with the specified aggregates,
without breaking during the mixing and laying processes. If approved
by the Engineer, a slow setting emulsion may be used.
516.2.2. Water: Water shall be of such quality that the bitumen will
not separate from the emulsion before the slurry seal is in place of work.
516.2.3. Aggregates: The aggregates shall be crushed igneous
rock, limestone or slag and may be blended, if required, with clean, sharp,
naturally occurring sand free from silt, clay or other tine material to
produce a grading as given in Table 500-31. It shall meet the requirements
of the film stripping test (-IS: 6241) and suitable amount and type of
anti-stripping agent added, as may be i~eeded.
TABLE 500-31. AGGREGATES GRADING FOR SLURRY SEAL
Sieve size Percentage by mass passing
Finished thickness of sealing
3mm 1.5mm
4.75 mm 100 —
3.35 mm 80-100 100

2.36 mm 75-100 95-100
1.18 mm 55-90 70-95
600 micron 35-70 55-75
300 micron 20-45 30-50
150 micron 10-25 10-30
75 micron 5-15 5-15
<< 202
516.3. Proportioning
The mixed material shall consist of aggregates, water and emulsified!
bitumen (about 180-250 litres per tonne of dry aggregates) and where
necessary, Portland cement as an additive. The proportion of the additive
(portland cement) shall not normally exceed 2 per cent by weight of
dry aggregates. The precise proportion of each constituent should be
selected by laboratory tests and trials.
516.4. Mixing
The various constituents shall be weighed in the needed proportions
and mixed in a mechanical mixer so that all particles of the aggregates
are uniformly coated and the slurry is of such consistency as can
be satisfactorily laid. It shall be a semi-fluid, homogeneous mass with
no emulsion run-off.
516.5. Site Preparation
The pavement surface shall be suitably prepared by removing any
loose material, dust and vegetation after patching up any potholes, de-
pressions etc. All manhole covers, inspection covers and gully gratings
should be masked.
516.6. Laying
If required, a tack coat shall be applied. The rate of spread of tack
coat shall depend on the surface to be treated: for bituminous surfaces,
at the rate of 0.15 to 0.30 litreWsq.m. and for concrete surfaces at
the rate of 0.4 to 0.6 litres/sq.m. Spreading shall be carried out by
mechanical means. Spreading shall not be undertaken when the ground
temperature falls below 4°Cor wher the surface contains standing water.
The slurry shall be spread at a rate such that the cover of aggregates
(dry mass equivalent ) is 4-6 kg! sq.m. for 3 mm thick work and 2-
4 kg/sq.m. for 1.5 mm thick work.
The slurry shall be rolled by a pneumatic tyred roller having an in-
dividual wheel load between 7.5 and 15.0 kN making at least six
passes or as may be directed by the Engineer. Rolling shall commence
as soon as the slurry has set sufficiently to ensure that rutting or
excessive movement will not occur. Adequate steps shall be taken to
avoid damage by traffic until such time that the mixture has cured
sufficiently so that the slurry seal will not adhere to and be picked
up by the tyres of vehicles.
<< 203

of Clause 902. Control on the quality of materials and works shall be
Slurry seal shall be measured as finished work in square metres.
516.9. Rate
The contract unit rate for slurry seal shall be payment in full for
components listed in Clause 504.8 (1) to (vi).
517. RECYCLING OF BITUMINOUS PAVEMENT
517.1. Scope
This Specification covers the recycling of existing bituminous pave-
ment materials towards upgrading an old bituminous pavement which
has served its first-intended purpose. The work shall be performed on
such widths and lengths as may be directed by the Engineer and may
consist of pavement removal, stockpiling of materials from the old
pavement, addition of new bitumen and untreated aggregates in the
requisite proportions, mixing, spreading and compaction of the blended
materials.
517.2. Materials
517.2.1. Materials for recycled pavement: The recycled materials
shall be a blend of reclaimed and new materials proportioned to achieve
a paving mixture with specified engineering properties. The reclaimed
materials shall be tested and evaluated to find the optimum blend
meeting the mix requirements. Such testing and evaluation shall be
carried out on representative samples obtained by the random sampling
technique.
5 17.2.2. Extraction : ASTM Designation D-2172 shall be adopted
to quantitatively separate aggregates and bitumen from any representative
sample of reclaimed bitumen pavement.
517.2.3. Aggregates evaluation : Mechanical sieve analysis
(IS: 2386, Part 1) shall be performed on the aggregates portion of the
reclaimed bituminous pavement sample to determine the gradation.
Any deficiencies shall be made up by suitably blending the needed
sieve fractions of new and/or reclaimed aggregates with reclaimed
<< 204
bituminous pavement aggregates.

517.2.4. Evaluation of bitumen: Based on the relative weights
of extracted aggregates and bitumen in the reclaimed bituminous
pavement, the bitumen content shall be determined at 60°C to estimate
the required amount and grade of bitumen to be used in the recycled
mix design.
517.2.5. New bitumen: In order to increase the bitumen content to
meet the recycled mix design requirements and also to blend with the
aged bitumen in the reclaimed portion of the mixture to yield a bitumen
content meeting the design specifications, new low-viscosity bitumen
shall be added.
The new bitumen used for this purpose are penetration grades
80/100, 120/150 or 200/300 i.e. viscosity grades AC-JO, AC-5, AC-
2.5 (AR-4000, AR-2000, AR-bOO), as approved by the Engineer.
517.2.6. Recycling agents: These are organic materials with
chemical and physical characteristics selected to restore aged asphalt
to desired specification of viscosity of combined aged asphalt and
recycling agent.
517.2.7. Untreated aggregates: If necessary, fresh untreated aggre-
gates shall be added to the reclaimed bitumen pavement to produce a
mix with the desired gradation. Reclaimed aggregates materials, if any,
or any aggregates normally used for the desired bituminous mix or both
may be used for this purpose.
517.2.8. Combined aggregates: The blend of reclaimed and new
aggregates shall meet specified gradation criteria as approved by the En-
gineer. The blend of aggregates shall be checked for quality
requirements, including resistance to stripping as per Table 500-3.
517.3. Mix Design
The gradation requirement and bitumen, content in the final mix
shall conform to Clause 504, 507 or 512, depending upon whether the
final desired bituminous material is bituminous macadam, dense bitumi-
nous macadam or bituminous concrete respectively. The mix design shall
be done as per the Marshall method, the requirements conforming to
the values as set out in the above Clauses.
517.4. Reclaiming Old Pavement Materials
The removal of pavement materials to the required depth shall be
<< 205
accomplished either at ambient temperature (cold process)or at an

elevated temperature (hot process), as approved by the Engineer.
517.4.1. Cold process of removal: In the cold process, the ripping
and crushing operations shall be carried out using scarifiers, grid
rollers, or rippers or by any other means as directed by the Engineer.
The removed materials shall be loaded and hauled for crushing to the
size as directed by the Engineer. Alternatively, cold milling or planing
machines can be used to reclaim asphalt pavement to controlled depths.
After the asphalt treated layers are removed, any remaining aggregate
materials that are to be incorporated in the recycled hot mix shall be
scarified and removed. When the pavement material removal is com-
pleted, any drainage deficiencies shall be corrected. After that, the
base/sub-base as the case may be shall be cut, graded and compacted
to proper grade, cross-section and profile.
517.4.2. Hot process of removal: In this process, the road surface
shall be heated, usually by LPG or any other suitable means as approved
by the Engineer, before scarification. A travelling plant shall be used
and a milling drum that follows the planer, removes the heated soft
bituminous layer. The depth, width and speed of travel shall be adjusted
to suit specific ~requirementsas directed by the Engineer.
517.4.3. Stockpiling: In the cold process, the reclaimed asphalt
pavement material shall be stockpiled with the height of stockpiles
not exceeding 3 m. The reclaimed untreated aggregates base/sub-base
material shall be stockpiled in the same manner as new aggregates. The
number and location of stockpiles shall be carefully planned for
efficient operation of the hot-mix plant.
517.5. Mixing and Laying
517.5.!. Preparation of in ix: The mixing of recycled aggregates,
~~ew aggregates and bitumen shall be done in a hot mix plant of
suitable capacity which shall be either batch type or drum-mix type,
capable of meeting the overall Specification requirements under
stringent quality control.
The Plant shall have the features as given in Clause 504.3.4.
The temperature of binder at the time of mixing shall be
150-163 °Cand that of aggregate in the range of 155-163 °C. Provided
also that at no time shall the difference in temperature between the
aggregates and binder exceed 14 °C. The temperature of both the
aggregates and the bitumen at the time of mixing shall be in accordance
<< 206
with the job mix formula and strictly controlled. All overheated and
carbonized mixture, shall be rejected.
.Mixing shall be thorough to ensure that a homogeneous mixture is
obtained in which all particles of the mineral aggregates are coated uni-
formly.
Any tipper causing excessive segregation of materials by its spring
suspension or other contributing factors or that showing undue delays
shall be removed from the work until such conditions are corrected.
517.5.2. Spreading: The mix transported from the hot mix plant to
the site shall be spread by means of a self-propelled mechanical paver
with suitable screeds capable of spreading, tamping and finishing the mix
to specified grade, lines and cross—section. Paver Finisher shall have the
essential features as spelt out in Clause 504.3.5. However, in restricted
locations and in narrow width where the available equipment cannot
be operated in the opinion of the Engineer, he may permit manual laying
of the mix.
Mixes with a temperature of less than 120 °Cshall not be put into
paver spreader.
Longitudinal joints and edges shall be constructed true to the centre
line of the road. Longitudinal and transverse joints shall be offset by
at least 250 mm from those in the lower courses and the joints on
the top most layer shall not be allowed to fall within the wheel path.
All transverse joints shall be cut vertically to the full thickness
of the previously laid mix with pneumatic cutter and the surface painted
with hot bitumen before placing fresh material. Longitudinal joints
shall be preferably hot joints. Cold longitudinal joints shall be properly
heated with joint heater to attain a suitable temperature of about 80 °C
before laying of any adjacent material.
517.5.3. Compaction: Clause 507.4.6 shall apply.
517.5.4. Opening to traffic: Traffic may be allowed after completion
of the final rolling when the mix has cooled down to the surrounding
temperature.
of Clause 902.
<< 207

During the period of construction, arrangement for the traffic shall
The recycled pavement work shall be measured in cubic metres or
tonnes of finished work as provided by the Contract.
517.9. Rate
The contract unit rate for recycled pavement shall be payment in
for
(I) Making arrangements for traffic to Clause I 12,.
(ii) Providing all materials to be incorporated in the work, including all royalties.
fees, rents where necessary and all leads and hiss;
(iii) All labour, tools, equipment, plant and incidentals to complete the work
to the Specification;
(iv) Cariying out the work in part width of the road where directed~and
(v) Carrying our tests to control the quality of the ‘work.
<< 208
Concrete Pavement
600
Concrete Pavement
<<
Concrete Pavement Section 600
601. DRY LEAN CEMENT CONCRETE

SUB-BASE
601.1. Scope
601.1.1. The work shall consist of construction of dry lean ‘concrete
subbase for cement concrete pavement in accordance with the require-
ments 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.
601.1.2, 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.
601.2. Materials
601.2.1. Source of 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 pro-
poses 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.
601.2.2. Cement: Any of the following types of cement may be used
with prior approval of the Engineer:
(i) Ordinary Portland Cement IS 269
(ii) Portland Slag Cement IS : 455
(iii) Portland Po~zolanaCement IS 1489
If the subgrade is found to consist of. soluble suiphates in a

concentration more than 0.5 per cent, cement used shall be sulphate
resistant and shall conform to IS: 6909.
Cement to be used may preferably be obtained in bulk form. It shall
be stored in accordance with stipulations contained in Clause 1014 and
shall be subjected to acceptance test prior to its immediate use.
601.2.~. Aggregates:
601.2.3.1. Aggregates for lean concrete shall be natural material com-
plying with IS: 383. The aggregates shall not be alkali reactive.~Thélimits
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Section 600~ Concrete Pavement
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.
601.2.3.2. Coarse aggregate: 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
the coarse aggregate shall be 25 mm. The coarse aggregate shall comply
with Clause 602.2.4.2.
601.2.3.3. Fine aggregate: 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 shill 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.
601.2.3.4. The coarse and fine aggregates may be obtained in either
of the following manner:
(i) In separate nominal sizes of coarse and fine aggregates and mixed Logether
intimately before use,
(ii) Separately as 25 rem 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.
The material after blending shall conform to the grading as indicated
in Table 600-I.
TABLE 600.1. AGGREGATE GRADATION FOR DRY LEAN CONCRETE
Sieve Designation Percentage passIng the

sieve by welghh ~
26.50 mm 100
19.00 mm 80-100
9.50 mm 55.75
4.75 mm 35-60
600.00 micron 1045
75.00 micron 0-8
601.2.4. 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.
601.2.5. Storage of materials: All materials shall be stored in
accordance with the provisions of Clause 1014 of these Specifications and
‘1,,
<<
other relevant IS Specifications. All efforts must be made to store the
materials in proper places so as to prevent their deterioration or contami-
nation by foreign matter and to ensure their satisfactory quality and
fitness for use in the work. The storage place must also permit easy
inspection, removal and stor~t~ of materials. All such materials even
though stored in approved godo’~.ns must be subjected to acceptance test
immediately prior to their use. The requirement of storage yard specified
in Clause 602.2.9 shall also be applicable.
601.3. Proportioning of Materials for the Mix
601.3.1. The mix shall be proportioned with a maximum aggregate
cement ratio of 15 : 1. The w~aercontent shall be adjusted to the
optimum as per Clause 601.3.2 for facilitating compaction by rolling. The
strength and density requirements of concrete shall be determined in
accordance with Clause 601.6 by making trial mixes,
601.3.2. Moisture content: The right amount of water for the lean
concrete in the main work shall be decided so as to ensure full compaction
under rolling and shall be assessed at the time of rolling the trial length.
Too much water will cause the lean concr~t~iobe heaving up before
the wheels and picked up on the wheels of the roller and too little will
lead to inadequate compaction, a low rn-situ strength and an open-textured
surface.
The optimum water content shall be determined and demonstrated
by rolling during trial length construction and the optimum moisture
content and degree of compaction shall be got approved from the
Engineer. While laying in the main work, the lean concrete shall have a
moisture content between the optimum and optimum +2 per cent, keeping
in view the effectiveness of compaction achieved and to compensate for
evaporation losses.
6~I1.3.3.Cement content: The minimum cement content in the
lean concrete shall not be less than 150 kg/cu.ni. of concrete. If thi’~
minimum cement content is not sufficient to produce concrete of tht
specified strength, it shall be increased as necessary without additional
cost compensation to the Contractor.
601,3.4. Concrete strength: The average compressive strength of
each consecutive group of 5 cubes made in accordance with Clause
903.5.1.1 shall not be less than 10 MPa at 7 days. In addition, the
minimum compressive strength of any individual cube shall not be less
than 7.5 MPa at 7 days. The design mix complying with the above Clauses
<< 213
Section 600 Concrete Pavement
shall be got approved from the Engineer and demonstrated in the trial
length construction.
601.4. Subgrade
The subgrade shall conform to the grades and cross sections shown
on the drawings and shall be uniformly compacted to the design strength
in accordance with these Specifications and Specification stipulated in
the Contract. The lean concrete subbase shall not be laid on a subgrade
softened by rain after its final preparation; surface trenches and soft
spots, if any, must be properly back-filled and compacted to avoid any
weak or soft spot. As far as possible, the construction traffic shall be
avoided on the prepared subgrade. A day before placing of the sub-base,
the subgrade surface shall be given a fine spray of water and rolled with
one or two passes of a smooth wheeled roller after a lapse of 2-3 hours
in order to stabilise loose surface. If Engineer feels it necessary, another
fine spray of water may be applied just before placing sub-base.
6013. Construction
601.5.1. General: The pace and programme of the lean concrete sub-
base construction shall be matching suitably with the programme of
consi~ruction of the cement concrete pavement Over it. The sub-base
shall be overlaid with cement concrete pavement only after 7 days after
sub-base construction.
601.5.2. Batching and mixing: The batching plant shall be capable
of proportioning the materials by weight, each type of material being
weighed separately in accordance with Clause 602.9.3.2. The cement
from the bulk stock shall be weighed separately from the aggregates. The
capacity of batching and mixing plant shall be at least 25 per cent higher
than the proposed capacity for the laying arrangements. The batching
and mixing shall be carried out preferably in a forced action central
batching and mixing plant having necessary automatic controls to ensure
accurate proportioning and mixing. Other types of mixers shall be per-
mitted subject to demonstration of their satisfactory performance during
the trial length. The type and capacity of the plant shall be got approved
by the Engineer before commencement of the trial length. The weighing
balances shall be calibrated by weighing the aggregates, cement, water
and admixtures physically either by weighing with large weighing ma-
chine or in a weigh bridge. The accuracy of weighing scales of the
batching plant shall be within ±2 per cent in the case of aggregates
and ±1per cent in the case of cement and water.
<< 214
The design features of Batching Plant should be such that the

shifting operations of the plant will not take very long time when they
are to be shifted from place to place with the progress of the work.
601.5.3. Transporting: Plant mix lean concrete shall be discharged
immediately from the mixer, transported directly to the point where it is
to be laid and protected from the weather by covering the tippers!
dumpers with tarpaulin during transit. The concrete shall be transported
by tipping trucks, sufficient in number to ensure a continuous supply
of material to feed the laying equipment to work at a uniform speed and
in an uninterrupted manner. The lead of the batching plant to paving
site shall be such that the travel time available from mixing to paving
as specified in Clause 60 1.5.5.2 will be adhered to.
601.5.4. Placing: Lean concrete shall be laid/placed by a paver with
electronic sensor. The equipment shall be capable of laying the material
in one layer in an even manner without segregation, so that after
compaction the total thickness is as specified. The paving machine shall
have high amplitude tamping bars to give good initial compaction to the
sub-base.
The laying of the two-lane road subbase may be done either in full
width or lane by lane. Preferably the lean cdncrete shall be placed and
compacted across the full width of the road, by constructing it
in one go or in two lanes running forward simultaneously.
Transverse and longitudinal construction joints shall be staggered by
500-1000 mm and 200-400 mm respectively from the corresponding
joints in the overlaying concrete slabs.
601.5.5. Compaction
601.5.5.1. The compaction shall be carried out immediately after the
material is laid and levelled. In order to ensure thorough compaction
which is essential, rolling shall be continued on the full width till there
is no further visible movement under the roller and the surface is closed.
The minimum dry density obtained shall be 97 per cent of that achieved
during the trial length construction vide Clause 601.7. The densities
achieved at the edges i.e 0.5 m from the edge shall not be less than 95
per cent of that achieved during the trial construction vide Clause 601.7.
601.5.5.2. The spreading, compacting and finishing of the lean
concrete shall be carried out as rapidly as possible and the operation
shall be so arranged as to ensure that the time between the mixing
of the first batch of concrete in any transverse section of the layer and
<< 215
the final finishing of the same shall not exceed 90 minutes when the
concrete temperature is above 25 and below 30 degree Celsius and
120 minutes if less than 25 degree Celsius. This period may be reviewed
by the Engineer in the light of the results of the trial run but in no case
shall it exceed 2 hours. Work shall not proceed When the temperature
of the concrete exceeds 30 degree Celsius. If necessary, chilled water
or addition of ice may be resorted to for bringing down the temperature.
It is desirable to stop concreting when the ambient temperature is above
35°C. After compaction has been completed, roller shall not stand on the
compacted surface for the duration of the curing period except during
commencement of next day’s work near the location where work was
terminated the previous day.
601.5.5.3. Double drum smooth-wheeled vibratory rollers of mini-
mum 80 to 100 kN static weight are considered to be suitable for rolling
dry lean concrete. In case any other roller is proposed, the same shall be
got approved from the Engineer, after demonstrating its performance,
The number of passes required to obtain maximum compaction depends
on the thickness ‘of the lean concrete, the compactibility of the mix, and
the weight and type of the roller etc., and the same as well as the total
requirement of rollers for the job shall be determined during trial run
by measuring the in-situ density and the scale of the work to be
undertaken.
601.5.5.4. In addition to the number of passes required for compaction
there shall be a preliminary pass without vibration to bed the lean concrete
down and again a final pass without vibration to remove roller marks
and to smoothen the surface.
Special care and attention shall be exercised during compaction near
joints, kerbs, channels, side forms and around gullies and manholes.
In case adequate compaction is not achieved by the roller at these points,
use of plate vibrator shall be made, if so directed by the Engineer.
601.5.5.5. The final lean concrete surface on completion of compac-
tion and immediately before overlaying, shall be well closed, free from
movement under roller and free from ridg~s,low spots, cracks, loose
material, pot holes, ruts or other defects. The final surface shall be
inspected immediately on completion and all loose, segregated or defec-
tive areas shall be corrected by using fresh lean concrete material
laid and compacted as per Specification. For repairing honeycombed
surface, concrete with aggregates of size 10 mm and below shall be
spread and compacted. It is necessary to check the level of the rolled
<< 216
surface for compliance. Any level/thickness deficiency should be cor-

rected after applying concrete with aggregates of size 10 mm and below
after roughening the surface. Similarly the surface regularity also should
be checked with 3m straight edge. The deficiency should be made
up with concrete with aggregates of size 10 mm and below.
601.5.5.6. Segregation of concrete in the dumpers shall be controlled
by premixing each fraction of the aggregates before loading in the bin of
the batching plant, by moving the dumper back and forth while
discharging the mix on it and other means. Even paving operation shall
be such that the mix does not segregate.
601,5.6. Joints: Contraction and longitudinal joints shall be provided
as per the drawing.
At longitudinal or transverse construction joints, unless vertical forms
are used, the edge of compacted material shall be cut back to a vertical
face where the correct thickness of the properly compacted material has
been obtained.
601.5.7. Curing: As soon as the lean concrete surface is compacted,
curing shall commence. One of the following two methods shall be
adopted:
(a) The initial curing shaH be done by spraying with liquid curing compound. The
curing compound shall be white pigmented or transparent type with water retention
indea of 90 per cent when tested in accordance with BS 7542. Curing compound
shall be sprayed immediately after rolling is complete. As soon as the curing
compound has loss its tackiness, the surface shall be covered with wet hessian for
three days.
(b) Curing shall be done by covering the surface by gunny bagslhessian, which
shall be kept continuously moist for 7 days by sprinkling waler.
601.6. Trial Mixes
The Contractor shall make trial mixes of dry lean concrete with
moisture contents like 5.0, 5.5, 6.0, 6.5 and 7.0 per cent using cement
content specified and the specified aggregate grading but without
violating the requirement of aggregate-cement ratio specified in Clause
601.3.1. Optimum moisture and density shall be established by preparing
cubes with varying moisture contents. Compaction of the mix shall be
done in three layers with vibratory hammer fitted with a square or
rectangular foot as described in Clause 903.5.1.1. After establishing the
optimum moisture, a set of six cubes shall be cast at that moisture for the
determination of compressive strength on the 3rd and the seventh day.
Trial mixes shall be repeated if the strength is not satisfactory either by
<< 217
increasing cement content or using higher grade of cement. After the

mix design is approved, the Contractor shall construct a trial Section in
accordance with Clause 601.7.
If during the construction of the trial length, the optimum moisture
content determined as above is found to be unsatisfactory, the Contrac-
tor may make suitable changes in the moisture content to achieve a
satisfactory mix, The cube specimens prepared with the changed mois-
ture content should satisfy the strength requirement. Before production
of the mix, natural moisture content of the aggregate should be
determined on a clay-to-day basis so that the moisture content could be
adjusted. The mix finally designed should neither stick to the rollers nor
become too dry resulting in ravelling of surface.
601.7. Trial Length
601.7.1. The trial length shall be constructed at least 14 days in
advance of the proposed date of commencement of work. At least 30 days
prior to the construction of the trial length, the Contractor shall submit
for the Engineer’s approval a “Method Statement” giving detailed descrip-
tion of the proposed materials, plar~t,equipment, mix proportion, and
procedure for batching, mixing, laying, compaction and other construc-
tion procedures. The Engineer shall also approve the location and
length of trial construction which shall be a minimum of 60 m length and
for full width of the pavement. The trial length shall contain the construc-
tion of at least one transverse construction joint involving hardened
concrete and freshly laid sub-base. The construction of trial length will
be repeated till the Contractor proves his ability to satisfactorily construct
the subbase.
601.7.2. In order to determine and demonstrate the optimum mois-
ture content which results in the maximum dry density of the mix
compacted by the rolling equipment and the minimum cement content
that is necessary to achieve the strength stipulated in the drawing, trial
mixes shall be prepared as per Clause 601.6.
60 1.7.3. After the construction of the trial length, the in-situ density
of the freshly laid material shall be determined by sand replacement
method with 20 cm dia density cone. Three density holes shall be made
at locations equally spaced along a diagonal that bisects the trial length;
average of these densities shall be determined. These main density
holes shall not be made in the strip 50 cm irom the edges. The average
density obtained from the three samples collected shall be the reference
density and is considered as 100 per cent. The field density of regular
218
<<
work will be compared with this reference density in accordance with
Clauses 601.5.5.1 and 903.5.1.2. A few cores may be cut as per the
instructions of the Engineer to check segregation or any other deficiency.
601.7.4. The hardened concrete shall be cut over 3 m width and
reversed to inspect the bottom surface for any segregation taking place.
The trial length shall be constructed after making necessary changes in
the gradation of the mix to eliminate segregation of the mix, The lower
surface shall not have honey-combing and the aggregates shall not be held
loosely at the edges.
601.7.5. The trial length shall be outside the main works. The main
work shall not start until the trial length has been approved by the
Engineer. After approval has been given, the materials, mix proportions,
moisture content, mixing, laying, compaction plant and construction
procedures shall not be changed without the approval of the Engineer.
601.8. Tolerances for Surface Regularity, Level, Thickness,
Density and Strength
The tolerances for surface regularity, level, thickness, density and
strength shall conform to the requirements given in Clause 903.5. Control
of quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.
601.9. Traffic
No heavy commercial vehicles like trucks and buses shall be permit-
ted on the lean concrete sub-base after its construction. Light vehicles if
unavoidable may, however, be allowed after 7 days of its construction
with prior approval of the Engineer.
601.10. Measurement~for Payment
The unit of measurement for dry lean concrete pavement shall be the
cubic metre of concrete placed, based on the net plan areas for the
specified thickness shown on the drawings or as directed by the
Engineer.
601,11. Rate
The Contract unit rate payable for dry lean concrete sub-base shall
full compensation forall labour, materials and equipment, mixing, trans-
port, placing, compacting, finishing, curing, testing and incidentals to
complete the work as per Specifications, all royalties, fees, storage and
rents where necessary and all leads and lifts.
<< 219
602. CEMENT CONCRETE PAVEMENT
602.1. Scope
602.1.1. The work shall Consist of construction of unreinforced, dowel
jointed, plain 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. 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.
602.1.2. The design parameters, viz., thickness of pavement slab,
grade of concrete, joint details etc. shall be as stipulated in the drawings.
602.2. Materials
602.2.1. 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 Engi-
neer for the same shall be obtained at least 45 days before the scheduled
commencement of the work. If the Contractor later proposes to obtain
materials from a different source, he shall notify the Engineer for his
approval, at least 45 days belore such materials are to be used with
relevant test data.
602.2.2. Cement : 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.
(i) Ordinary Portland Cement, 33 Grade, IS 269.
(ii) Ordinary Portland Cement, 43 Grade IS 8112.
(iii) Ordinary Portland Cement, 53 Grade, IS 12269.
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.
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 pieces of paper bags and dispose them of suitably. No paper
pieces shall enter the concrete mix. Bulk cement shall be stored in
<< 220
accordance with Clause 1014. The cement shall be subjected to

acceptance test just prior to its use.
602.23. Admixtures : Admixtures conforming to !S: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 25 mm nominal size aggregate.
602.2.4. Aggregates
602.2.4.1. 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.
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.
602.2.4.2. Coarse aggregate: 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 25 mm 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.
Dumping and stacking of aggregates shall be done in an afiproved
manner. In case the Engineer considers that the aggregates are not free
<< 221
from dirt, the same may be washed and drained for at least 72 hours
before batching as directed by the Engineer.
602.2.4.3. Fine aggregate: 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
Clay lumps 4.0 per cent
Coal and lignite 1.0 per cent
Material passing IS Sieve No. 75 micron 4.0 per cent
be clean and free from injurious amount of oil, salt, acid, vegetable
the requirements stipulated in IS: 456,
602.2.6. 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 stiall conform to Grade S 240 and tie bars to
Grade S 415 of l.S.
602.2.7. Premoulded joint filler: Joint tiller 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
ke 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.
602.2.8. 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).
accordance with the provisionsof Clause 1014 of the Specifications and
other relevant IS Specifications. All efforts must be made to store the
materials in proper places so as to prevent their deterioration or
<< 222
contamination by foreign matter and to ensure their satisfactory quality

and fitness for the work. The platform where aggregates are stock piled
shall be levelled with 15 cm of watered, mixed and compacted granular
sub-base material. The area shall have slope and drain to drain off rain
water. The storage space must also permit easy inspection, removal
and storage of the materials. Aggregates of differentsizes shall be stored
in partitioned stack-yards. All such materials even though stored in
approved godowns must be subjected to acceptance test as per Clause
903 of these Specifications immediately prior to their use.
602.3. Proportioning of Concrete
602.3.1. After approval by the Engineer of all the materials to be
used in the concrete, the Contractor shall submit the mix design based on
weighed proportions of all ingredients for the approval of the Engineer.
The mix design shall be submitted at least 30 days prior to the paving
of trial length and the design shall be based on laboratory trial mixes
using the approved materials and methods as per IS:10262 (Recom-
mended Guidelines for Mix Design) or on the basis of any other rational
method agreed to by the Engineer. Guidance in this regard can also be
obtained from IS:SP:23 Handbook on Concrete Mixes. The target mean
strength for the design mix shall be determined as indicated in Clause
903.5.2. The mix design shall be based on the flexural strength of
concrete.
602.3.2. Cement content: The cement content shall not be less
than 350 kg per cu.m.of concrete. If this minimum cement content is not
sufficient to produce in the field, concrete of the strength specified
in the ddiwings/design, it shall be increased as necessary without
additional compensation under the Contract. The cement content shall,
however, not exceed 425 kg per cu.m. of concrete.
602.3.3. Concrete strength
602.3.3.1. While designing the mix in the laboratory, correlation
between flexural and compressive strengths of concrete shall be estab-
lished on the basis of at least thirty tests on samples. However, quality
control in the field shall be exercised on the basis of flexural strength.
It may, however, be ensured that the materials and mix proportions
remain substantially unaltered during the daily concrete production.
The water content shall be the minimum required to provide the agreed
workability for full compaction of the concrete to the required density as
determined by the trial mixes or other means approved by the Engineer
and the maximum free water cement ratio shall be 0.50.
<< 223
602.3.3.2. The ratio between the 7 and 28 day strengths shall be

established for the mix to be used in the slab in advance, by testing pairs
of beams and cubes at each stage on at least six batches of trial mix.
The average strength of the 7 day cured specimens shall be divided by
the average strength of the 28 day specimens for each batch, and the
ratio ‘R’ shall be determined. The ratio ~R’shall be expressed to three
decimal places.
If during the construction of the trial length or during normal
working, the average value of any four consecutive 7 day test results falls
below the required 7 day strength as derived from the value of ‘R’,
then the cement content of the concrete shall, without extra payment, be
increased by 5 per cent by weight or by an amount agreed by the
Engineer. The increased cement content shall be maintained at least until
the four corresponding 28 day strengths have been assessed for its
conformity with the requirements as per Clause 602.3.1. Whenever the
cement content is increased, the concrete mix shall be adjusted to maintain
the required workability.
602.3.4. Workability
602.3.4.1. The workability of the concrete at the point of placing
shall be adequate for the concrete to be fully compacted and finished
without undue flow. The optimum workability for the mix to suit the
paving plant being used shall be determined by the Contractor and
approved by the Engineer. The control of workability in the field shall
be exercised by the slump test as per IS :1199.
602.3.4.2. The workability requirement at the Batching Plant and
paving site shall be established by slump tests carried during trial paving.
These requirements shall be established from season to season and also
when the lead from Batching plant site to the paving site changes. The
workability shall be established for the type of paving equipment avail-
able. A slump value in the range of 30 ±15 mm is reasonable for paving
works but this may be modified depending upon the site requirement and
got approved by the Engineer. These tests shall be carried out on every
truck/dumper at Plant site and paving site initially when the work
commences but subsequently the frequency can be reduced to alternate
trucks or as per the instructions of the Engineer.
602.3.5. Design mix
602.3.5.1. The Contractor shall carry out laboratory trials of design
mixes with the materials from the approved sources to be used. Trial
224
<<
mixes shall be made in presence of the Engineer or his representative and
the design mix shall be subject to the approval of the Engineer. They
shall be repeated if necessary until the proportions that will produce a
concrete which complies in all respects with this Specification, and
conforms to the requirement of the design/drawings have been deter-
mined.
602.3.5.2. The proportions determined as a result of the laboratory
trial mixes may be adjusted if necessary during the construction of the
trial length. Thereafter, neither the materials nor the mix proportions
shall be varied in any way except with the written approval of the
Engineer.
602.3.5.3. Any change in the source of materials or mix propó~tions
proposed by the Contractor during the course of work shall be assessed by
making laboratory trial mixes and the construction of a further trial
length unless approval is given by the Engineer for minor adjustments
like compensation for moisture content in aggregates or minor fluctua-
tions in the grading of aggregate.
602.4. Sub-base
The cement concrete pavement shall be laid over the sub-base
constructed in accordance with the relevant drawings andSpeèifica-
lions contained in Clause 601. If the sub-base is found damaged at
some places or it has cracks wider than 10 mm it shall be t~epairedwith
fine cement concrete or bituminous concrete before laying separation
layer Pnor to laying of concrete it shall be ensured that the separation
membrane as per Clause 602.5 is placed in position and the same is clean
of dirt or other extraneous materials and free from any daniage.
602.5. Separation Membrane
A separation membrane shall be used between the concrete stab and
the subbase Separation membrane shall be impermáble plastic sheeting
125 microns thick laid flat without creases Before placing the separation
membrane, the sub-base shall be swept clean Of ~ll the extti~neóus
materials using air compressor. Wherever overlap of plastic sheets is
necessary, the same shall be at least 300 mm and an~damaged sheeting
shall be replaced at the Contractor’s expense. The separation membrane
may be nailed to the lower layer with concrete nails.
602.6. Joints
602 6 1 The location and type of Joints shall be as shown in the
drawing. Joints shall be constructed depending upon thèfr Thnctlonàl
‘
<< 225
requirement as detailed in the following paragraphs.The location of the

joints should be transferred accurately at the site and mechanical saw
cutting of joints done as per stipulated dimensions. It should be ensured
that the full required depth of cut is made from edge to edge of the
pavement. Transverse and longitudinal joints in the pavement and sub-
base shall be staggered so that they are not coincident vertically and
are at least I m and 0.3 m apart respectively. Sawing of joints shall be
carried out with diamond studded blades soon after the concrete has
hardened to take the load of the sawing machine and personnel without
damaging the texture of the pavement. Sawing operation could start
as early as 6-8 hours depending upon the season.
602,6.2. Transverse joints
602.6.2.1. Transverse joints shall be contraction and expansion joints
constructed at the spacing described in the Drawings. Transverse joints
shall b~straight within the following tólerailces along the intended line
of joints which is the straight line transverse to the longitudinal axis of
the carriageway at the position proposed by the Contractor and agreed to
by the Engineer, except at road junctions or roundabouts where the
position shall be as described in the drawings:
(i) Deviations of the filler board in the case of expansion joints from the intended line
of the joint shall not be greater than ±10mm.
(ii) The best fit straight line through the joint grooves as constructed shall he
not more than 25 mm from the intended line of the 3oInL
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 miii
(iv) Transv~rsejoints on each tide of the longitudinal joint shall be in line with each
other and of the same type and width, Transverse joints shall have a sealing
groove which shall be sealed in compliance with Clause 602.11.
602.6.2.2. Contraction joints: Contraction joints shall consist of

a mechanical sawn Joint groove 3 to 5 mm wide and 1/4 to 1/3 depth
of the stab ±5 mm or as stipulated in the drawings and dowel bars
complying with Clause 602 65 and as detailed in the drawings
The conti~action:~::jointsshall be cut as soon as the concrete has
undergone initial hardening and is hard enough to take the load of joint
sawing machine without causing damage to the slab.
602.6.2.3. E~ :i~iói~ joints: The expansion joints shall consist of a
joint filler board complying with Clause 602.2.7 and dowel bars comply-
ir~gwith Cl~use,6O~$.5,; and as detailed in the drawings. The filler board
sha~lbe positioi~edvcrtieally with the prefabricated joint assemblies along
<< 226
the line of the joint within the tolerances given in Clause 602,6.2. l~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.
602.63. Transverse construction joint: Transverse construction
joints shall be placed whenever concreting is completed after a day’s work
or is suspended for more than 30 minutes. These joints shall be provided
at the regular location of contraction joints using dowel bars. The joint
shall be made butt type. At all construction joints, steel bulk heads shall
be used to retain the concrete while the surface is finished. The surface
of the concrete laid subsequently shall conform to the grade and cross
sections of the previously laid pavement. When positioning of bulk heaW
stop-end is not possible, concreting to an additional 1 or 2 m length may
be carried out to enable the movement of joint cutting machine so that
joint grooves may be formed and the extra 1 or 2 rn length is cut out
and removed subsequently after concrete has hardened.
602.6.4. Longitudinal joint
602.6.4.1. The longitudinal joints shall be saw cut as per details of
the joints shown in the drawing. The groove may be cut after the final set
of the concrete. Joints should be sawn to at least 1/3 the depth of the slab
±5 mm as indicated in the drawing.
602.6.4.2. Tie bars shall be provided at the longitudtnai joints as
per dimensions and spacing shown in the drawing and in accordance with
Clause 602.6.6.
602.6.5. Dowel bars
602.6.5.1. 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. The dowel bar shall be supported on
cradles/dowel chairs in pie-fabricated joint assemblies positioned prior
to the construction of the slabs or mechanically inserted with vibration
into the plastic concrete by a method which ensures correct placement
of the bars besides full re-compaction of the concrete around the dowel
bars.
<< 227
602.6.5.2. Unless shown otherwise on the drawings, dowel bars

shall, be positioned at mid depth of the slab within a tolerance of ±20
mm, and centered equally about intended lines of the joint within a
tolerance of ±25 mm. Tey 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.
(i) For bars supported on cradles prior to the laying of the slab:
(a) All bars in ajount shall be within ±3mm per 300mm length of bar
(b) 2/3rd of the bars shall be within ±2 mm per 300 mm length of bar
(c) No bar shall differ in alignment from an adjoining bar by more than 3
mm per 300 mm length of bar in either the horizontal or vertical plane
(d) Cradles supporting dowel bar shall not extend across the line of joint i.e. no
steel bar of the cradle assembly shaH be continuous across the joint.
(ii) For all bars inseried after laying of the slab:
(a) Twice the tolerance for alignment as indicated in (I) above
602.6.5.3. Dowel bars, supported on cradles in assemblies, when

subject to a load of 110 N applied at either end and in either the vertical
or horizontal direction (upwards and downwards and both directions
horizontally) shall conform to be within the following limits:
(i) Two-thirds of the number of bars of any assembly tested shall not deflect more
than 2 mm per 300 mm length of bar
(ii) The remainder of the bars in that assembly shall not deflect more than 3 mm
per 300 mm length of bar.
602.6.5.4. The assembly of dowel bars and supporting cradles,

including the joint filler board in the case of expansion joints, shall
have the following degree of rigidity when fixed in position:-
(i) For expansion joints, the deflection of the top edge of the fillet board shall be not
greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
face of the joint filler board and disuibuted over a length of 600mm by means
of a bar or timber packing, at mid depth and midway bet wean individual fixings,
or 300 mm from either end of any length of filler board, if a continuous fixing
is used. The residual deflection after removal of the load shall be not more than
3 mm.
(ii) The joint assembly fixings to sub-base shall not fail under the l.3kN load applied
for testing the rigidity of the assembly but shall fail’be~orethe load reaches 2.6
kN.
(iii) The fixings for contraction joint shall not fail under 1.3 kN load and shall fail
before the load readies 2~6kN when applied over a length of 600 mm means
of a bar or limber packing placed as near to the level of the line of fixings as
practicable.
<< 228
(iv) Fixings shall be deemed to fail when there is displacement of the assemblies by
more than 3 mm with any foms of fixing, under the test load. The displacement
shall be measured at the nearest part of the assembly to the centre of the bar or
timber packing.
602.6.5.5. Dowel bars shall be covered by a thin plastic sheath for at
least two-thirds of the length from one end for dowel bars in contraction
joinLs or half the length plus 50 mm for expansion joints. The sheath
shall be tough, durable and of an average thickness not greater than 1.25
mm. The sheathed bar shall comply with the following pull-out tests:
(i) Four bars shall be taken at random from stock and without any special preparation
shall be covered by sheaths as required in this Clause. The ends of the dowel
bars which have been sheathed shall be cast centrally into concrete specimens
150 x 150 a 600 mm, made of the same mix proportions to be used in the
pavement, but with a maximum nominal aggregate size of 20 mm and cured in
accordance with IS: 516. At 7 days a tensile load shall be applied to achieve a
movement of the bar of at least 0,25 trim. The average bond stress to achieve
this movement shall not be greater than 014 MPa.
602.6.5.6. For expansion joints, a closely fitting cap 100 mm long
consisting of waterproofed cardboard or an approved synthetic material
like PVC or (31 pipe shall be placed over the sheathed end of each
dowel bar. An expansion space at least equal in length to the thickness
of the joint filler board shall be formed between the end of the cap and
the end of the dowel bar by using compressible sponge. To block the
entry of cement slurry between dowel and cap it may be taped.
602.6.6. Tie bars
602.6.6.1. 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.
602.6.6.2. Tie bars projecting across the longitudinal joint shall be
protected from corrosion for 75mm on each side of the 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.
602.6.6.3. Tie bars in longitudinal joints shall be made up into rigid
assemblies with adequate supports and fixings to remain firmly in
position during the construction of the slab. Alternatively, tie bars at
longitudinal joints may be mechanically or manually inserted into the
plastic concrete from above by vibration using a method which ensures
correct placement of the bars and recompaction of the concrete around the
tie bars.
<< 229
Section 600 Cemcrete Pavement
602.6.6.4. Tie bars shall be positioned to remain within the middle
third of the slab depth as indicated in the drawings and approximately
parallel to the surface and approximately perpendicular to the line of the
joint, with the centre of each baron the intended line of the joints within
a tolerance of ±50mm, and with a minimum cover of 30 mm below the
joint groove.
602.7. Weather and Seasonal Limitations
602.7.1. Concreting during monsoon months: When concrete is
being placed during monsoon months and when it may be expected
to rain, sufficient supply of tarpaulin or other water proof cloth shall be
provided along the line of the work, Any time when it rains, all freshly
laid concrete which had not been covered for curing purposes shall be
adequately protected. Any concrete damaged by rain snail be removed
and replaced. If the damage is limited to texture, it shall be retextured in
accordance with the directives of the Engineer.
602.7.2. Concreting in hot weather: No concreting shall be done
when the concrete temperature is above 30 degree Centigrade. Besides,
in adverse conditions like high temperature, low relative humidity,
excessive wind velocity, imminence of rains etc., if so desired by the
Engineer, tents on mobile trusses may be provided over the freshly laid
concrete for a minimum period of 3 hours as directed by the Engineer.
The temperature of the concrete mix on reaching the paving site shall
not be more than 30°C. To bring down the temperature, if necessary,
chilled water or ice flakes should be made use of.
No concreting shall be done when the concrete temperature is
below 5 degree Centigrade and the temperature is descending.
602.8. Side Forms, Rails and Guidewires
602.8.1. Side forms and rails: All side forms shall be of mild steel
of depth equal to the thickness of pavement or slightly less to accommo~
date the surface regularity of the sub-base. The forms can be placed on
series of steel packing plates or shims to take care of irregularity of sub-
base. They shall be sufficiently robust and rigid to support the weight
and pressure caused by a paving equipment. Sideforms for use with
wheeled paving machines shall incorporate metal rails firmly fixed at a
constant height below the top of the forms. The forms and rails shall
be firmly secured in position by not less than 3 stakes/pins per each 3
m length so as to prevent movement in any direction. Forms and rails shall
be straight within a tolerance of 3 mm in 3 m and when in place shall
<< 230
not settle in excess of 1.5 mm in 3 m while paving is being done.

Forms shall be cleaned and oiled immediately before each use. The
forms shall be bedded on a continuous bed of low moisture content lean
cement mortar or concrete and set to the line and levels shown on the
drawings within tolerances ±~ 10 mm and ±3 mm respectively. The
bedding shall not extend under the slab and there shall be no vertical
step between adjacent forms of more than 3 mm. The forms shall be
got inspected from the Engineer for his approval before 12 hours on
the day before the construction of the slab and shall not be removed until
at least 12 hours afterwards.
602.8.2. At all times sufficient forms shall be used and set to the
required alignment for at least 200 m length of pavement immediately in
advance of the paving operations, or the anticipated length of pavement
to be laid within the next 24 hrs whichever is more.
602.83. Use of guidewires
602.8.3.1. Where slip form paving is proposed, a guidewire shall be
provided along both sides of the slab. Each guidewire shall be at a
constant height above and parallel to the required edges of the slab as
described in the contract/drawing within a vertical tolerance of ±3mm.
Additionally, one of the wires shall be kept at a constant horizontal
distance from the required edge of the pavement as indicated in the
contract/drawing within a lateral tolerance of ±10 mm.
602.8.3.2. The guidewires shall be supported on stakes not more than
8 m apart by connectors capable of fine horizontal and vertical adjust..
ment. The guidewire shall be tensioned on the stakes so that a 500 gram
weight shall produce a deflection of not more than 20 mm when
suspended at the mid point between any pair of stakes. The ends of the
guidewires shall be anchored to fixing point or winch and not on the
stakes.
602.8.3.3. The stakes shall be positioned and the connectors
maintained at their correct height and alignment from 12 hours on the day
before concreting takes place until 12 hours after finishing of the
concrete. The guidewire shall be erected and tensioned on the
connectors at any section for at least 2 hours before concreting that
section.
602.8.3.4. The Contractor shall submit to the Engineer for his
approval of line and level, the stakes and connectors which are ready for
use in the length of road to be constructed by 12 hours on the working
231
<<
day before the day of construction of slab. Any deficiencies noted by the
Engineer shall be rectified by the Contractor who shall then re-apply for
approval of the affected stakes. Work shall not proceed until the Engineer
has given his approval. It shall be ensured that the stakes and guidewires
are not affected by the construction equipment when concreting is in
progress.
602.9. Construction
602.9.1. General: A systems approach may be adopted for construc-
tion of the pavement, and the Method Statement for carrying out the
work, detailing all the activities including indication of time-cycle,
equipment, personnel etc., shall be got approved from the Engineer
before the commencement of the work. The above shall include the type,
capacity and make of the batching and mixing plant besides the hauling
arrangement and paving equipment. The capacity of paving equipment,
batching plant as well as all the ancillary equipment shall be adequate
for a paving rate of atleast 300 m in one day.
602.9.2. Batching and mixing: Batching and mixing of the concrete
shall be done at a central batching and mixing plant with automatic
controls, located at a suitable place which takes into account sufficient
space for stockpiling of cement, aggregates and stationary water tanks.
This shall be, however, situtated at an approved distance, duly
considering the properties of the mix and the transporting arrangements
available with the Contractor.
602.9.3. Equipment for proportioning of materials and paving
602.9.3.1. Proportioning of materials shall be done in the batching
plant by weight, each type of material being weighed separately. The
cement from the bulk stock may be weighed separately from the
aggregates and water shall be measured by volume. Wherever properly
graded aggregate of uniform quality cannot be maintained as envisaged
in the mix design, the grading of aggregates shall be controlled by
appropriate blending techniques. The capacity of batching and mixing
plant shall be at least 25 per cent higher than the proposed capacity of
the laying/paving equipment.’
602.9.3.2. Batching plant and equipment:
(1) General- The batching plant shall include minimum four bins,
weighing hoppers, and scales for the fine aggregate and for each
size of coarse aggregate. If cement is used in bulk, a separate
scale for cement shall be included. The weighing hoppers shall
<< 232
oncrete Pavement Section 600
be properly sealed and vented to preclude dust during operation.

Approved safety devices shall be provided and maintained for
the protection of all personnel engaged in plant operation,
inspection and testing. The batch plant shall be equipped with a
suitable non-resettable batch counter which will correctly indi-
cate the number of batches proportioned.
(2) Bins and hoppers- Bins with minimum number of four adequate
separate compartments shall be provided in the batching plant.
(3) Automatic weighing devices-Batching plant shall be equipped
to proportion aggregates and bulk cement by means of automatic
weighing devices using load cells.
(4) Mixers- Mixers shall be pan type, reversible type or any other
mixer capable of combining the aggregates, cement, and water
into a thoroughly mixed and uniform mass within the specific
mixing period, and of discharging the mixture, without segrega-
tion. Each stationary mixer shall be equipped with an approved
timing device which will automatically lock the discharge lever
when the drum has been charged and release it at the end
of the mixing period. The device shall be equipped with a bell
or other suitable warning device adjusted to give a clearly
audible signal each time the lock is released. In case of failure
of the timing device, the mixer may be used for the balance of
the day while it is being repaired, provided that each batch is
mixed 90 seconds or as per the manufacturer’s recommendation.
The mixer shall be equipped with a suitable non-resettable batch
counter which shall correctly indicate the number of batches
mixed.
The mixers shall be cleaned at suitable intervals. The pickup
and throw-over blades in the drum or drums shall be repaired or
replaced when they are worn down 20 mm or more. The Con-
tractor shall (1) have available at thejob site a copy of the
manufacturer’s design, showing dimensions and arrangements of
blades in reference to original height and depth, or (2) provide
permanent marks on blade to show points of 20 mm wear from
new conditions. Drilled holes of 5 mm diameter near each end
and at midpoint of each blade are recommended. Batching
Plant shall be calibrated in the beginning and thereafter at
suitable interval not exceeding I month.
<< 233
(5) Control cabin An air-conditioned centralised control cabin
-
shall be provided for automatic operation of the equipment.

602.9.33. Paving equipment : The concrete shall be placed with
an approved fixed form or slip from paver with independent units designed
to (i) spread,(ii) consolidate, screed and float-finish, (iii) texture and cure
the freshly placed concrete in one complete pass of the machine in such
a manner that a minimum of hand finishing will be necessary and so as
to provide a dense and homogeneous pavement in conformity with the
plans and Specifications.The paver shall be equipped with electronic
controls to control/sensor line and grade from either or both sides of the
machine,
Vibrators shall operate at a frequency of 8300 to 9600 impulses per
minute under load at a maximum spacing of 60 cm. The variable
vibration setting shall be provided in the machine.
602.9.3.4. Concrete saw : The Contractor shall provide adequate
number of concrete saws with sufficient number of diamond-edge saw
blades. The saw machine shall be either electric or petrol/diesel driven
type. A water tank with flexible hoses and pump shall be made available
in this activity on priority basis. The Contractor shall have at least one
standby saw in good working condition. The concreting work shall not
commence if the saws are not in working condition.
602.9.4. Hauling and placing of concrete
602.9.4.1. Freshly mixed concrete from the central batching and
mixing plant shall be transported to the paver site by means of
trucks/tippers of sufficient capacity and approved design in sufficient
numbers to ensure a constant supply of concrete. Covers shall be used
for protection of concrete against the weather. The trucks/tippers shall
be capable of maintaining the mixed concrete in a homogeneous state
and discharging the same without segregation and loss of cement slurry.
The feeding to the paver is to be regulated in such a way that the paving
is done in an uninterrupted manner with a uniform speed throughout the
days work.
602.9.4.2. Placing of concrete
Concrete mixed in central mixing plant shall be transported to the
Site without delay and the concrete which, in the opinion of the Engineer,
has been mixed too long before laying will be rejected and shall be
removed from the site. The total time taken from the addition of the water
to, the mix, until the completion of the surface finishing and texturing
<< 23.4
shall not exceed 120 minutes when concrete temperature is less than 25°C
and 90 minutes when the concrete temperature is between 25°Cto 30°C.
Truck~ltippersdelivering concrete shall not run on plastic sheeting nor
shall they run on completed slabs until after 28 days of placing the
concrete. The Paver shall be capable of paving the carriageway as shown
in the drawings, in a single pass and lift.
602.9.4.3. Where fixed form payers are to be used, forms shall be
fixed in advance as per Clause 602.8. of the Specifications. Before any
paving is done, the site shall be shown to the Engineer, in order to verify
the arrangement for paving besides placing of dowels, tie-bars etc., as per
the relevant Clauses of this Specification. The mixing and placing of
concrete shall progress only at such a rate as to permit proper finishing,
protecting and curing of the pavement.
602.9.4.4. En all cases, the temperature of the concrete shall be
measured at the point of discharge from the delivery vehicle.
602.9.4.5. The addition of water to the surface of the concrete to
facilitate the finishing operations will not be permitted except with the
approval of the Engineer when it shall be applied as a mist by means
of approved equipment.
602.9.4.6. If considered necessary by the Engineer, the paving
machines shall be provided with approved covers to protect the surface of
the slab under construction from direct sunlight and rain or hot wind.
602.9.4.7. While the concrete is still plastic, its surface shall be brush
textured in compliance with Clause 602.9.8 and the surface and edges
of the slab cured by the application of a sprayed liquid curing membrane
in compliance with Clause 602.9.9. After the surface texturing, but before
the curing compound is applied, the concrete slab shall be marked with
the chainage at every 100 m interval.
602.9.4.8. As soon as the side forms are removed, edges of the slabs
shall be corrected wherever irregularities have occurred by using fine
concrete composed of one part of cement to 3 parts of fine chips and
fine aggregate under the supervision of the Engineer.
602.9.4.9. If the requirement of Clause 902.4. for surface regularity
fails to be achieved on two consecutive working days, then normal
working shall cease until the cause of the excessive irregularity has been
identified and remedied.
602.9.5, Construction by fixed form paver
602.9.5.1. The fixed form paving train shall consist of separate
<< 235
powered machines which spread, compact and finish the concrete in’ a
continuous operation.
602.9.5.2. The concrete shall be discharged without segregation into
a hopper spreader which is equipped with means for controlling its rate
of deposition on to the subbase. The spreader shall be operated to strike
off concrete uptq a level requiring a small amount of cutting down by
the distributor of the spreader. The distributor of spreader shall strike off
the concrete to the surcharge adequate to ensure that the vibratory
compactor thoroughly compacts the layer. If necessary, poker vibrators
shall be used adjacent to the side forms and edges of the previously
constructed slab. The vibratory compactor shall be set to strike off the
surface slightly high so that it is cut down to the required level by the
oscillating beam. The machine shall be capable of being rapidly adjusted
for changes in average and differential surcharge necessitated by changes
in slab thickness or cross fall, The final finisher shall be able to finish
the surface to the required level and smoothness as specified, care being
taken to avoid bringing up of excessive mortar to the surface by over-
working.
602.9.6. Construction by slip form paver
602.9.6.1. The slip form paving train shall consist of power machine
which spreads, compacts and finishes the concrete in a continuous
operation. The slip form paving machine shall compact the concrete by
internal vibration and shape it between the side forms with either a
conforming plate or by vibrating and oscillating finishing beams. The
concrete shall be deposited without segregation in front of slip form paver
across the whole width and to a height which at all times is in excess of
the required surcharge. The deposited concrete shall be struck off to
the necessary average and differential surcharge by means of the strike
off plate or a screw auger device extending across the whole width of
the slab. The equipment for striking-olf the concrete shall be capable
of being rapidly adjusted far changes of the average and differential
surcharge necessitated b’ change in slab thickness or crossfall.
602.9.6.2. The level of the conforming plate and finishing beams shall
be controlled automatically from the guide wires installed as per Clause
602.8 by sensors attached at the four corners of the slip form paving
machine. The alignment of the paver shall be controlled automatically
from the guide wire by at least one set of sensors attached to the paver.
The alignment and level of ancillary machines for finishing, texturing
and curing of the concrete shall be automatically controlled relative
<< 236
to the guide wire or to the surface and edge of the slab.

602.9.6.3. Slip-form paving machines shall have vibrators of variable
output, with a maximum energy output of not less than 2.5 KW per metre
width of slab per 300 mm depth of slab for a la~ ~ngspeed upto 1.5 m
per minute or pro-rata for higher speeds. The machines shall be of
sufficient mass to provide adequate reaction during spreading and
paving operations on the traction units to maintain forward movements
during the placing of concrete in all situations.
602.9.6.4. If the edges of the slip formed slab slump to the extent
that the surface of the top edge of the slab does not comply with the
requirements of Clause 602.14, then special measures approved by the
Engineer shall be taken to support the edges to the required levels and
work shall be stopped until such time as the Contractor can demonstrate
his ability to slip form the edges to the required levels.
602.9.7. Construction by hand-guided method: Areas in which
hand-guided methods of construction become indispensable shall be
got approved by the Engineer in writing in advance. Such work may
be permitted only in restricted areas in small lengths. Work shall be
carried out by skilled personnel as per methods approved by the
Engineer. The acceptance criteria regarding level, thickness, surface
regularity, texture, finish, strength of concrete and all other quality
control measures shall be the same as in the case of machine laid work.
602.9,8. Surface texture
602.9.8.1. 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.
602.9.8.2. The brushed surface texture shall be applied evenly across
the slab in one direction by the use of a wire brush not less than 450
mm wide but longer brushes are preferred. The brush shall be made of
32 gauge tape wires grouped together in tufts spaced at 10 mm centres.
The tufts shall contain an average of 14 wires and initially be 100 mm
long. The brush shall have two rows of tufts. The rows shall be 20 mm
apart and the tufts in one row shall be opposite the centre of the gap
between tufts in the. other row. The brush shall be replaced when the
shortest tuft wears down to 90 mm long.
602.9.8.3. The texture depth shall be determined by the Sand Patch
Test as described in Clause 602.12. This test Shall be performed at least
<< 237
once for each day’s paving and wherever the Engineer considers it
necessary at times after construction as under:
Five individual measurements of the texture depth shall be taken
at least 2 m apart anywhere along a diagonal line across a lane width
between points 50 m apart along the pavement. No measurement shall
be taken within 300 mm of the longitudinal edges of a concrete slab
constructed in one pass.
602.9.8.4. Texture depths shall not be less than the minimum re-
quired when measurements are taken as given in Table 600-2 nor greater
than a maximum average of 1.25 mm.
TABLE 600.2. Texture Depth
Number of Required
Time of Test Measurements Texture Depth (mm)
Specified Tolerance
Value
I Between 24 hours and 7 days after An average of 1.00 ±025

the constn., of the slab or until 5 measurements
ilie stab is first used by vehicles.
2. Not later than 6 weekt before the An average of 1.00 ÷0.25
road is opened to public 5 measurements -035
traffic. ,
602.9.8.5. After the application of the brushed texture, the surface of

the slab shall have a uniform appearance.
602.9.8.6. Where the texture depth requirements are found to be
deficient, the Contractor shall make good the texture across the full lane
width over length directed by the Engineer, by retexturing the hardened
concrete surface in an approved manner.
602.9.9. Curing
602.9.9.1. Immediately after the surface texturing, the surface and
sides of the slab shall be cured by the application of approved resin- based
aluminised reflective curing compound which hardens into an impervi-
ous film or membrane with the help of a mechanical sprayer.
Curing compounds shall contain sufficient flake aluminium in finely
divided dispersion to produce a complete coverage of the sprayed surface
with a metallic finish. The compound shall become stable and impervi-
otis to evaporation of water from the surface of the concrete within 60
rninutes of application a~dshall be of approved type. The curing com-
pot~~ds stall have a water relention efficiency index of 90 per cent in ac-
cordaiv’e with BS Specification No. 7542.
<< 238
602.9.9.2. The curing compound shall not react chemically with the
concrete and the film or membrane shall not crack, peel or disintegrate
within three weeks after application. Immediately prior to use, the curing
compound shall be thoroughly agitated in its containers. The rate of
spread shall be in accordance with the manufacturer’s instructions checked
during the construction of the trial length and subsequently whenever
required by the Engineer. The mechanical sprayer shall incorporate an
efficient mechanical device for continuous agitation and mixing of the
compound during spraying.
602.9.9.3. In addition to spraying of curing compound, the fresh
concrete surface shall be protected for at least 3 hours by covering the
finished concrete pavement with tents as described in Clause 602.7.2,
during adverse weather conditions as directed by the Engineer. After
three hours, the pavement shall be covered by moist hessian and the same
shall then be kept damp for a minimum period of 14 days after which
time the hessian may be removed. The hessian shall be kept continuously
moist. All damaged/tom hessian shall be removed and replaced by new
hessian on a regular basis.
602.9.9.4. The Contractor shall be liable at his expense to replace
any concrete damaged as a result of incomplete curing or cracked on a
line other than that of a joint.
602.10. Trial Length
602.10.1. The trial length shall be constructed at least one month in
advance of the proposed start of concrete paving work. At least one
month prior to the construction of the trial length, the Contractor shall
submit for the Engineer’s approval a detailed method statement giving
description of the proposed materials, plant, equipment and construction
methods. All the major equipments like paving train, batching plant,
tippers etc., proposed in the construction are to be approved by the
Engineer before their procurement. No trials of new materials, plant,
equipment or construction methods, nor any development of them shall
be permitted either during the construction of trial length or in any
subsequent paving work, unless they form part of further, approved
trials. These trial lengths shall be constructed away from the carriage-
way but with at least a subbase layer below it.
602.10.2. The Contractor shall demonstrate the materials, plant,
equipment and methods of construction that are proposed for concrete
paving, by first constructing a trial length of slab, at least 60 m but not
more than 300 m long for mechanised construction and at least 30 m long
<< 239
for hand guided methods. If the first trial is unsatisfactory, the Contractor
shall have to demonstrate his capability to satisfactorily construct the
pavement in subsequent trials.
602.10.3 The trial length shall be constructed in two parts over a
period comprising at least part of two separate working days, with a
minimum of 30 m constructed each day for mechanised construction and
a minimum of 15 m on each day for hand guided construction. The trial
length shall be constructed at a similar rate (speed, around lm/hr) to that
which is proposed for the main work.
602.10.4. Transverse joints and longitudinal joints of each type that
are proposed for dowel-jointed unreinforced concrete slabs in the main
work shall be constructed and assessed in the trial length. If in the trial
length the construction of expansion joint and longitudinal joint is not
demonstrated, the first 2 expansion joints and at least the first 150 m
of longitudinal construction joint for mechanised paving in the main
work, shall be considered as the trial length for these joints.
602.10.5. The trial length shall comply with the Specification in all
respects, with the following additions and exceptions:
602.10.5.1. Surface levels and regularity
(i) In checking for compliance with Clause 903.5 the levels shall be taken at intervals
at the locations specified in this Clause along any line or lines parallel to the
longitudinal centre line of the trial length.
(ii) The maximum number ofpermitted irregularities of pavement surface shall comply
with the requireçsents of Clause 902.4. Shorier trial lengths shall be assessed pro.
rats based on values for a 300 m length.
602.10.5.2. Joints
(iii) Alignment, of dowel bars shall be inspected as described in Clause 602.10.7 in any
two consecutive transverse joints. If the position or alignment of the dowel bars
at one of these joints does not comply with Clause 602.6.5, ii that joint remains
the only one that does not comply after the next 3 consecutive joints of the same
type have been inspected, then the method of placing dowels shall be deemed
to be satisfactory. In order to check sufficient joints for dowel bar alignment
without extending the trial length unduly, the Contractor may, by agreement with
the Engineer, construct joints at more frequent joint intervals than the normal
spacing required in the Contract.
(iv) If there are deficiencies in the first expansion joint that is constructed as a trial, the
next expansion joint shall be a trial joint. Should this also be deficient, further tziai
expansion joints shall be made as pars of the trial length which shall not form part
of the permanent works, unless agreed by the Engineer.
<< 240
602.10.53. Density
(v) Density shall be assessed as described in Clause 602.3.3, from a! least 3 cores
drilled from each part of the trial length.
602.10.5.4. Position of tie bars

(vi) Compliance with Clause 602,6,6 for the position and alignment of tie bars
shall be checked by drilling additional cores from the slab unless they can
be determined from cores taken for density.
602.10.6. Approval and acceptance

602.10.6.1 Approval of the materials, plant, equipment and construc-
tion methods shall be given when a trial length complies with the
Specification. The Contractor shall not proceed with normal working
until the trial length has been approved and any earlier defective trial
lengths have fren removed, unless that can be remedied to the satisfac-
tion of the Engineer, If the Engineer does not notify the Contractor of any
deficiencies in any trial length within 10 days after the completion of that
trial length, the Contractor may assume that the trial length, and the
materials, plant, equipment and construction methods adopted are accept-
able.
602.10.6.2. When approval has been given, the materials, plant,
equipment and construction methods shall not thereafter be changed,
except for normal adjustments and maintenance of plant, without the
approval of the Engineer. Any changes in materials, plant, equipment, and
construction methods shall entitle the Engineer to require ,the Contractor
to lay a further trial length as described in this Clause to demonstrate that
the changes will not adversely affect the permanent works.
602.10.6.3. Trial lengths which do not comply with the Specification,
with the exception of areas which are deficient only in surface texture and
which can be remedied in accordance with Clau~e602.9.8.6 shall be
removed immediately upon notification of deficiencies ~y the Engineer
and the Contractor shall construct a further trial length.
602.10.7. Inspection of dowel bars
602.10.7.1. Compliance with Clause 602.6.5. for the position and
alignment of dowel bars at construction and expansion joints shall be
checked by measurements relative to the side forms or guide wires.
602.10.7.2. When the slab has been constructed, the position and
alignment of dowel bars and any filler board shalT be measured after
carefully exposing them in the plastic concrete across the whole width of
the slab. When the joint is an expansion joint, the top of the filler board
241
<<
shall first be exposed sufficiently in the plastic concrete to permit

measurement of any lateral or vertical displacement of the board. During
the course of normal working, these measurements shall be carried out
in the pavement section at the end of day’s work by extending slab length
by 2 m. Alter sawing the transverse joint groove, the extended 2 m
slab shall be removed carefully soon after concrete has set to expose
dowels over half the length. These dowels can be tested for tolerances.
64)2.10.7.3. If the position and alignment of the bars in a single
joint in the slab is unsatisfactory then the next two joints shall be
inspected. If only one joint of the three is defective, the rate Of checking
shall be increased to one joint per day until the Engineer is satisfied that
compliance is being achieved. In the event of non-compliance in two
or more successive joints, the Contractor shall revert to the construction
of fresh trial lengths and make any necessary alteration to concrete
mix, paving plant or methods until the dowel bar position and alignment
are satisfactory.
602.10.7.4. After the dowel bars have been examined, the remainder
of the concrete shall be removed over a width of 500 mm on each side
of the line of the joint and reinstated to the satisfaction of the Engineer.
The dowels shall be inserted on both sides of the 1 m wide slab by drilling
holes and grouting with epoxy mortar. Plastic sheath as per Clause
602.6.5.5 ‘shall be provided on dowels on one of the joints. The joint
groove shall be widened and sealed as per Clause 602.11.
602.11. Preparation and Sealing of Joint Grooves
602.11.1, General
All transverse joints in surface slabs shall be sealed using sealants
~.lescrihedin Clause 602.2.8. Joints shall not be sealed before 14 days
after construction.
602.11.2. Preparation of joint grooves for sealing
602.11.2.1. Joint grooves usually are not constructed to provide the
minimum width specified in the drawings when saw cut joints are
adopted. They shall be widened subsequently by sawing before sealing.
iicpth/w idth gauges shall be used to control the dimension of the
groove.
602.11.2.2. If rough arrises develop when grooves are made, they
shall be ground to provide a chamfer approximately 5 mm wide. If the
groove is at an angle upto 10 degree from the perpendicular to the
surface, the overhanging edge of the sealing groove shall be sawn
<< 242
or ground perpendicular. If spalling occurs or the angle of the former is

greater than 10 degrees, the joint sealing groove shalt be sawn wider
and perpendicular to the surface to encompass the defects upto a maxi-
mum widl.h, including any chamfer, of 35 mm for transverse joints and
20 mm for longitudinal joints. If the spalling cannot be so eliminated then
the arrises shalt be repaired by an approved thin bonded arris repair
using cementitious materials.
602.11.2.3. All grooves shall be cleaned of any dirt or loose material
by air blasting with filtered, oil-free compressed air. If need arises the
Engineer may instruct cleaning by pressurised water jets, Depending
upon the requirement of the sealant manufacturer, the sides of the grooves
may have to be sand blasted to increase the bondage between sealant and
concrete.
602.11.2.4. The groove shall be cleaned and dried at the time of
priming and sealing.
602.11.2.5. Before seating the temporary seal provided for btocking
the ingress of dirt, soil etc., shall be removed. A highly compressible heat
resistant paper-backed debonding strip as per drawing shall be inserted
in the groove to serve the purpose of breaking the bond between
sealant and the bottom of the groove and to plug the joint groove so
that the sealant may not leak through the cracks. ‘The width of debonding
strip shalt be more than the joint groove width so that it is held tightly
in the groove. In the case of longitudinal joints, heat resistant tapes may
he inserted to block the leakage through bottom of the joint.
602.11.3. Sealing with sealanis
602.11.3.1. When sealants are applied, an appropriate primer shall
also be used if recommended by the manufacturer and it shall be
applied in accordance with their recommendation. The sealant shall be
applied within the minimum and maximum drying times of the primer
recommended by the manufacturer. Priming and sealing with applied
sealants shall not be carried out when the naturally occurring
temperature in the joint groove to be sealed is below 7°C.
602.11.3.2. If hot applied sealant is used it shall be heated and
applied from a thermostatically controlled, indirectly heated preferably
with oil jacketed melter and pourer having recirculating pump and
extruder. For large road projects, sealant shall be applied with extruder
having flexible hose and nozzle. The sealant shall not be heated to a
temperature higher than the safe heating temperature and not for a period
<< 243
longer than the safe heating period, as specified by the manufacturer. The
dispenser shall he cleaned out at the end of each day in accordance with
the manufacturer’s recommendations and reheated m4terial shall not be
used.
602.11.3.3. Cold applied sealants with chemical formulation like
polysulphide may be used. These shall be mixed and applied within the
time limit specified by the manufacturer. If primers are recommended
they shall be appLied neatly with an appropriate brush. The Movement
Accommodation Factor (MAF) shall be more than 10 per cent.
602.11.3.4. The sealants applied at contraction phase of the slabs
would result in bulging of the sealant over and above the slab. Therefore,
the Contractor in consultation with the Engineer, shall establish the right
temperature and time for applying the sealant. Thermometer shall be
hung on a pole in the site for facilitating control during the sealing
operation.
602.11.3.5. Sealant shall be applied, slightly to a lower level than
the slab with a tolerance of 5 ±2 mm.
602.11.3.6. During sealing operation, it shall be seen that no air
bubbles are introduced in the sealant either by vapours or by the
sealing process.
602.11.4. Testing of applied sea lants: Manufacturer’s certificate
shall be produced by the Contractor for establishing that the sealant is not
more than six months old and stating that the sealant complies with the
relevant standard as in Clause 602.2.8. The samples shall meet the
requirement of AASHTO M 282 for hot applied sealant or BS 5212: (Part-
2) for cold applied sealant.
602.12. Measurement of Texture Depth Sand Patch Method -
602.12.!. The following apparatus shall be used:

(i) A cylindrical container of 25 ml internal capacity
(ii) A nat wooden disc 64 mm diameter with a hard rubber disc, 1.5 mm thick, stuck
to one face, the reverae face being provided with a handle
(iii) Dry natural sand with a rounded particle shape passing a 300 micmn 15 sieve and
nctained on a 150 micron 15 sieve.
602.12.2. Method: The surface to be measured shall be dried, any

extraneous mortar and loose material removed and the surface swept
clean using a wire brush both at right angles and parallel to the
carriageway. The cylindrical container shall be filled with the sand,
tapping the base 3 times on the surface to ensure compaction, and
<< 244
striking off the sand level with the top of the cylinder. The sand shall
be poured into a heap on the surface to be treated. The sand shall be
spread over the surface, working the disc with its face kept flat in a
circular motion so that the sand is spread into a circular patch with the
surface depressions filled with sand to the level of peaks.
602.12.3. The diameter of the patch shall be measured to the nearest
5 mm. The texture depth of concrete surface shall be calculated from
3l000/(DxD) mm where D is the diameter of the patch in mm.
No vehicular traffic shall be allowed to run on the finished surface
of a concrete pavement within a period of 28 days of its construction
and until the joints are permanently sealed. The road may be opened to
regular traffic after completion of the curing period of 2~ days and after
scaling of joints is completed including the construction of shoulder,
with the written permission of the Engineer.
602.14. Tolerances for Surface Regularity, Level, Thickness
and Strength
The tolerances for surface regularity, level, thickness and strength
shall conform to the requirements given in Clause 903.5. Control of
quality of materials and works shall be exercised by the Engineer in
602.15.1. Cement Concrete pavement shall be measured as a fin-
ished work in square metres with specified thickness. The volume to be
paid for will be calculated on the basis of thickness and plans shown on
the project drawings and adjusted for the deficiency in thickness. No
additional payment shall be made for extra thickness of the slab. The full
payment will be made to this item after 28 days strength of the concrete
is found to be satisfactory.
The unit for measurement for concrete pavement shall be the cubic
metre of concrete placed, based on the net plan areas for the specified
thickness shown on the Drawings or directed by the Engineer. The rate
shall include all provisions of this Specification and shall include the
provision of all materials including polythene film, concrete, stock piling,
mixing, transport, placing, compacting, finishing, curing together with all
formwork, and including testing and submission of test certificates and
records. No deduction shall be made in measurement for openings
provided that the area of each is less than 0.5 sq. m. The unit rate
<< 245
Section &00 Concrete Pavement
as entered in the Bill of Quantities shall also include the full costs
of contraction, expansion, construction, and longitudinal joints, It shall
also incLude joint filler, keys, caulking rod, deboñding strip, sealant
primer, joint sealant, dowel bar and tie rod.
602.15.2, Pavement thickness
All precautions and care shall he taken to construct pavement
having uniform thickness as called for on the plans.
Thickness of the cement concrete pavement shall be calculated on the
basis of level data of the cement concrete pavement and the underlying
sub-base taken on a grid of 5 m x 3.5 m or 6.25 m x 3.5 m, the former
measurement being in longitudinal direction.
A day’s work is considered as a ~lot’ for calculating the average
thickness of the slab. In calculating the average thickness, individual
measurements which are in excess of the specified thickness by more than
10 mm shall be considered as the specified thickness plus 10 mm.
Individual areas deficient by more than 25 mm shall be verified by
the Engineer by ordering core cutting and if in his opinion the deficient
areas warrant removal, they shall be removed and replaced with concrete
of the thickness shown on the plans.
When the average thickness for the lot is deficient by the extent
shown in Table 600.3, the Contract unit price will be adjusted as per this
TabLe,
TAIILE 600.3. PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNFSS
Deficiency in the average Per cent of Contract

thickness of day’s work unit price payable
Upto5mm 100
6.10mm 87
11-15mm 81
16.20mm 75
21-25mm 70
In the stretch where deficiency of average thickness is more than

25 mm, the section whose thickness is deficient by 26 mm or more is
identified with the help of cores. Such slabs shall be removed and
reconstructed at the cost of the Contractor. During such rectification
work, care shall be taken to replace full slab and to the full depth.
<< 246
Concrete Pavement Seaion 600
602.16. Rate
The Contract unit rate for the construction of the cement concrete
shall be payment in fuLl for carrying out the operations required for
the different items of the work as per these Specifications including
full compensation for all labour, tools, plant, equipments, testing and
incidentals to complete the work as per Specifications, providing all
materials to be incorporated in the work including all royalties, fees,
storage, rents where necessary and all leads and lifts.
603. ROLLED CEMENT CONCRETE BASE
603.1. Scope
603.1.1. The work shall consist of construction of rolled concrete
base course 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,
material and Labour and performing all operations in connection with
the work, as approved by the Engineer.
603.1.2. 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.
603.2. Materials
603.2.1. Source of 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.
‘t~03.2.2.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 soltible 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
<< 247
preferably be obtained in bulk form. It shall be stored in accordance with

stipulations contained in Clause 1014 and shaLl be subjected to acceptance
test prior to its immediate use.
603.2.3. Aggregates
603.2.3.1. 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.
603.2.3.2. Coarse aggregate : Coarse aggregates shall consist ol’
stone or crushed gravel and shall be devoid of pieces of disintegrated
stone, soft, flaky, elongated, very angular or splintery pieces. The maxi-
mum size of the coarse aggregate shall be 25 mm. The coarse aggregate
shall comply with the Clause 602.2.4.2.
603.2.3.3. Fine aggregate : 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.
603.2.3.4. The coarse and fine aggregates may be obtained in either
of the following manner:-
(1) In separate nominal sizes of coarse and fine aggregates and mixed together
intimately before use.
(ii) Separately as 25 mm nominal single size, 12.5 mm nominal size graded aggregate
and fine aggregate of crushed stone dust or sand or a combination of these two.
The material after blending shall conform to the grading as indicated

in Table 600-4 below:
TABLE 600.4. AGGREGATE GRADATION FOR DRY LEAN CONCRETE
Sieve Designation Percentage Passing the

sieve by weight
37.5 mm 100
19.0 mm 80.100
9.5 mm 55-80
4.75 mm 35-60
600 micron 10-35
75 micron 0-8
<< 248
be clean and free from injurious amount of oil, salt, acid, vegetable
the requirements stipulated in IS: 456.
accordance with the provisions of Clause 1014 of these Specifications,
and other relevant IS Specifications. All efforts must be made to store
the materials in proper places so as to prevent their deterioration or
contamination by foreign matter and to ensure their satisfactory quality
and fitness for the work. The storage place must also permit easy
inspection, removal and storage of materials. All such materials even
though stored in approved godowns must be subjected to acceptance test
immediately prior to their use. The requirement of storage yard specified
in £lause 602.2.9 shall be applicable.
603.3, Proportioning of Materials for the Mix
603.3.1. The mix shall be proportioned with a maximum aggregate:
cement ratio of 15.1. After the approval of all the materials to be used
in the concrete, the Contractor shall submit the mix design based on
weighed proportion of all ingredients for the approval of the Engineer.
The mix design shall be submitted at least 30 days prior to the paving
of trial length and design shall be done based on the laboratory trials
using approved materials and methods. The water content shall be
adjusted to the optimum as per Clause 603.3.2. for facilitating compac-
tion by rolling. The target mean strength for the design mix as well as
acceptance Speciflcation of concrete shall be in accordance with Clause
903.5.2. The mix design shall be based on the flexural strength of
concrete.
603.3.2. Moisture content: The right amount of water for the rolled
concrete in the main work shall be decided for ensuring full compaction
under rolLing and shall be assessed at the time of rolling the trial length.
Too much water will cause the concrete to be picked up on the
wheels of the roller and too little will lead to inadequate compaction, a
low in-situ strength and an open textured surface. The optimum water
content shall be determined in accordance with Clause 603.7. and
demonstrated by rolling during trial length construction; and the optimum
moisture content and degree of compaction shall be got approved by
the Engineer. While laying, in the main work, the rolled concrete shall
have a moisture content between the optimum and optimum + 2 per cent,
<< 249
keeping in view the effectiveness of compaction achieved and to compen-

sate for evaporation losses.
603.3.3. Cement content: The minimum cement content in the
rolled concrete shall not be less than 150 kg/cuff. of concrete. If this
mininium cement content is not suflicient to produce concrete of the
specified strength, it shall be increased as necessary without additional
compensation under the Contract.
603.3.4. Concrete strength: The flexural strength as specified shall
be the governing criteria for approval of the mix, While designing the mix
in the laboratory, correlation between flexura! and compressive strengths
of concrete shall be established on the basis of tests on samples for use
at a later date to verify the in situ flexural strength of rolled concrete
through testing of cores.
At least a batch of two beam and cube specimens, one each for 3 day
and 7 day strength testing shall be cast for every 100 cum or part thereof
of concrete placed during construction. On each day’s work not Less than
four beams and four cubes shall be made.
A ratio between the 3 and 7 day strengths shall be established for
the mix to be used. This will help in assessing the fall in strength,
if any in advance so that corrective action can be taken for the future
work.
603.4. Subgrade
The subgrade shall conform to the grades and cross sections shown
on the drawings and shall be uniformly compacted to the design strength
in accordance with these Specifications and the Specification stipulated
in the Contract. The rolled concrete base shall not be laid on a subgrade
softened by rain after its final preparation; any surface trenches, soft spots
etc., must be properly back-filled and compacted to avoid any weak or
soft spot. As far as possible, the construction traffic shall be avoided on
the prepared subgrade. A day before placing of the sub-base, the subgrade
surface shall be given a fine spray of water and rolled with one or two
passes of a smooth wheeled roller after a lapse of 2-3 hours in order to
stabilise the loose surface. If the Engineer feels it necessary, another
fine spray of water may be applied just before placing the base course.
603.5. Construction
Clause 601.5 shaLl apply.
<< 250
603.6. Trial Mix
Using the specified cement content arid proportioned aggregates, the
Contractor shall make trial mixes at water contents ranging from 5 per
cent to 7 per cent by weight of dry materials at 0.5 per cent intervals
using an aggregate /cement ratio of not greater than 15.0. Optimum
moisture and density shall be established by preparing cubes with varying
moisture contents. The compaction of mould shall be done in three layers
as explained in Clause 903.5.2.1. The optimum moisture content deter-
mined normally gives an indication about the moisture content which
after minor adjustment may provide satisfactory mix which could be
rolled.
After determining the moisture content from the above trial mix, a set
of six beams and cubes shall be prepared for testing them on 3rd and 7th
day. if the flexural strength achieved is lower than the desired strength,
the above trial shall be repeated after increasing the cement content and
adjusting the mix appropriately.
During the construction of trial length as per Clause 603.7 minor
modifications may have to be carried Out to the moisture content of
the mix, But such modified mix shall have to satisfy the flexural strength
requirement. Flexural strength to be achieved shall be the governing
criteria for the design .of mix.
603.7. Trial Length
Clause 601.7 shall apply.
603.8. Traffic
No heavy commercial vehicles like trucks and buses shall be permit-
ted on the rolled concrete base after its construction. Light vehicles may
be, however, allowed after 7 days of its construction with prior approval
of the Engineer.
603.9. Tolerances for Surface ReguIarity~ Level, Thickness
and Strength
The tolerances for surface regularity, level, thickness and strength
shall conform to the requirements given in Clause 903.5. Control of
quality of materials and works shall be exercised by the Engineer in
The unit of measurement for concrete and rolled concrete pavement
shall be the cubic metre of concrete placed, based on the net plan areas
<< 251
for the specified thickness shown on the drawings as directed by the

Engineer.
603.11. Rate
The Contract unit rate payable for rolled cement concrete for base
course shall be payment in full for carrying out the required operations
including full compensation for all Labour, materials and equipment,
mixing, transport, placing, compacting, finishing, curing, testing and
incidentals to complete the work as per Specifications, all royalties, fees,
storage and rents where necessary and all leads and lifts.
<< 252
Geosynthetics
700
Geosynthetics
<<
Geosynthetics Section 700
701. GEOSYNTHETICS IN ROAD AND BRIDGE WORKS
701.1 Scope
This specification covers the various applications of Geosynthetic ma-
terials in road and bridge works including supplying and laying as per
special provisions.
“Geosynthetic is a general classification for all synthetic materials
used in geotechnical engineering application. It includes geotextiles,
geogrids, geonets, geomembranes and geocomposites.
(1) Geotextile : Any permeable textile natural or Synthetic, used with fotmdation, soil,
rock, earth, or any other geoteclasical engineering related material. In the present
chapter, ii is related to synthetic material only.
(ii) Geogrid: A deformed or non-deformed grid of polymeric material used primarily
for reinforcement purposes with foundation, soil, suck, earth, or any other geotech-
nical engineering related material.
(iii) Geonets : These are net made of polymeric material used for drainage of
foundation, soil, rock, earth or any other geotechnical engineering related material.
(iv) Geomembrane : An essentially impermeable membrane of polymeric material
used with foundation, soil, rock, earth or any other geotechnical engineering related
material, to control fluid migration.’
(v) Geocomposite A manufactured material using geotextiles. geognds, geonets ancil
or geomembrane in laminated or composite form.”
701.2 Material Testing and Acceptance

Unless otherwise stated, these Geosynthetic materials shall conform to
the requirements as under:
701.2.1. Geotextile : Geotextile shall be made of polyethylene or
polypropylene or polyester or similar fibres, either woven or nonwoven in
variety, through machine made process of heatbonding or needle punching
or weaving techniques. These fabrics are required to pass water through
but retain the soil particles, which require specific cross-plane permeabil-
ity or permittivity and apparant opening size or equivalent opening size or
095. The above two requirements alongwith the requirement of strength
and durability denote general characteristics of geotextiles to be used.
The type of geotextile to be used in a particuLar application shall be
decided on the basis of design.
701.2.2. Geogrid : Geogrid shall be made from integralLy jointed,
mono or bi-directionally orientated or stretched meshes made from poly-
ethylene or polypropylene or polyester or similar polymer, with high
255
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Section 700 Geosynthetics
secant modulus, in square, rectangular, hexagonal or oval mesh form.

Their junction strength shall be high with high creep resistance, and
dimensional stability. Their open structure shall permit effective interlock-
ing with soil, aggregates, rock etc., they shall be used as a tensile member
or reinforcement. Characteristics strength of such Geogrids vanes from 40
kN/m to 200 kN/m peak strength at a maximum elongation of 15 per cent
in the direction of the length of the roll.
701.2.3. Geonet : Geonet shall be made from a single extruded
unoriented process from polyethylene or polypropylene or similar
polymer. It shall have square or rectangular net shape aperture when used
for protective works like gabions and mattresses. While in polygonal
aperture it shall be used as a separator. It shall not be used as soil
reinforcement due to its high creep characteristics, neither as a slope
reinforcement or soil retaining wall or asphaltic reinforcement. Geonets
used in protective works for highway structures shall be atleast 650 gm/
sq.m. in unit weight. It shall be black in colour, available in roll form in
suitable width.
701.2.4. Geomembrane : Geomembrane shall be made from PVC or
polyethelene sheets of atleast 0.8 mm thickness, duly protected from ultra-
violet exposure with 2.5 per cent carbon black, in black colour, supplied
in roll form with 3 m or above width. The joints of these sheets shall be
heatbonded or seamed for effective permeation cut off, at site using
standard equipment as part of the laying process. While fixing on to a
slope, they shall not be punctured or stappled to impair their use.
701.2.5. Geocomposite : (leocomposites shall be made from combi-
nation of geonets, geogrids or geomembranes of above description using
heat bonded, seamed stitched or wrap techniques. Their principal use shall
be to regulate drainage in cross-plane or in-plane directions. Minimum
unit weight of such material shall conform to the special provisions or as
per Contract drawing.
701.2.6. Testing and acceptance : Geosynthetics shall be tested in
accordance with tests prescribed by BIS. In absence of IS Codes, tests
prescribed either by ASTM or British Standards or International Standards
Organisation, shall be conducted.
701.3 Application Areas
Some of the application areas for geotextiles and related materials and
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their functions are given below in table 700-1.

Table 700-1. ApplIcations and Functions of Geosynthetics
5. No. Application Area Geosynthetlcs Functions for

~ Involved Performance
I. Embankments on soft soils GT, GO KS

2. Retaining walls GO, GT R
3. Drainage and Filtration GT F, S
4. Drainage-prefab, composite GC, ON D, F, 5, B
5. ErosionControlriprap CIT ‘ F,S
6. Sediment control-silt fence GT B, It, S
7. Asphalt overlay GT, GC B, R, 5
Note GT = geotextile S = separation
GG = geogrid R = reinforcement
GC = geocomposite F = filtration
ON = geonet D = drainage
B = barrier
702. GEOTEXTILES IN SUB-SURFACE DRAINS

702.1. Scope
The work covers the use of geotextiles in subsurface drains, such as
fin drains or narrow. filter drains. The fin drain shall mean a planar
geocomposite structure designed to perform the same function as a narrow
filter drain. The work shall be carried out as per design drawings.
702.2. Materials
702.2.1. The geotextile fabric shall be a woven or non-woven fabric
consisting of long-chain polymeric filaments or yarns such as polypro-
pylene, polyethylene or polyester or any combination thereof, formed into
a stable network such that the filaments or yarns retain their relative
position to each other.
702.2.2. The geosynthetic material of which the drain is made shall
be treated with carbon black so that they are protected from the deleterious
effects of short term exposure to ultraviolet light, and shall be resistant to
degradation by acid, alkalis, common chemicals, bacteria, fungi and
moulds occurring in soils and highway construction materials. In case of
exposure to ultraviolet light, the Engineer may require evidence that the
geosynthetic material still complies with the requirements of this Clause.
Where necessary, the side intended for entry of water and direction of in-
plane flow shall be identified.
702.2.3. The geotextile shall
(a) Sustain a load of not less than 10 kN/m at break and have a minimum failure strain
257
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of 10 per cent when determined in accordance with BS:6906 (Part 1) or shall have
a grab tensile strength more than 0.4 kN/m and grab elongation corresponding to
this limit in accordance with ASTM D 4632.
(b) The Apparent opening size, shall satisfy the following
(i) Soil with 50 per cent or less particles by weight passing IS sieve 75 microns,
apparent opening size less than 0.6 mm.
(ii) Soil more than 50 per cent particles by weight passing IS sieve 75 microns,
apparent opening size less than 0.927 mm.
The test should be as per TF 25 # 6
(c) allow water to flow through it at right angles to its principal plane, in either
direction at a rate of not less than 10 litres/m2/sec. under a constant head of water
of 100 mm, determined in accordance with BS:6906 (Part 3) or ASTM D 4491 or
as stated in the design drawing. The flow rate determined in the test shall be
corrected to that applicable to a temperature of 15°Cusing published data on
variation in viscosity of water with temperawre.
(d) have a minimum puncture resistance of 200 N when determined in accordance with
BS:6906 (Part 4) or ASTM D 4833.
(e) have a minimum tear resistance of ISO N when determined in accordance with
ASTM Standard D 4533.
702.2.4. The composite drain shall have a flow rate through each face
of the drain of more than 75 per cent of the value specified in sub-Clause
702.2.3 (c), determined by direct measurement of the cOmposite drain
using BS:6906 (Part 3). The composite drain shall have values of long-
term in-plane flow rates as stated in the design drawing.
702.3. InstaHation
702.3.1. The installation of fin drains shall be as per the design
drawings. Where fin drains are assembled on site, the assembly area shall
be clean and dry and free of any wind-borne pollutants. No geotextile or
core material shall be exposed to daylight (or any source of ultraviolet
radiation) for a period exceeding a cumulative total of 50 hours. Whei~e
fin drains are laid in trench, the bottom of the trench shall be free of
irregularities and shall be brought to the required level. Rock and other
hard protrusions shall be removed and any excess cut in the trench bottom
filled and compacted back to the required grade with suitable excavated
or imported material as directed by the Engineer. Fin drains shall be
capable of being jointed longitudinally or laterally into pipe~systeinsor
chambers for inflow and outflow purposes. Joints parallel to the direction
of flow and any exposed edged shall be protected from the ingress of soil
by a geotextile wrapping with a minimum overlap of 150 mm or other
measures as agreed by the Engineer.
702.4. Narrow filter drains consisting of a porous or perforated pipe
<< 258
Gcosynthetics Section 700
laid in a narrow trench surrounded by a layer of geotext.ile filter shall have
the same properties of geotextile as specified in Clause 702.2. The spicing
of lengths of geotextile and minimum overlap shall be as per the design
drawing or as approved by the Engineer. Such drains shall be installed as
per the design drawing to Clauses 702.3 and 309.3.5.
Measurement for fin drain/narrow filter drains shall be per running
metre length of the drain. Disposal of surplus material beyond 1000 m
shall be measured in cu.m.
702.6, Rates
The Contract unit rates for subsurface drains shall be payment in full
for all items such as excavation, dressing the sides and bottom, providing
geotextile composites, laying and jointing pipes etc. including full
compensation for all materials, labour, tools, equipment incidental to
complete the work as shown on drawings with all leads and lifts except
for removal of unsuitable material for which the lead shall be 1000 m.
Provision of inlets, outlet pipes, bedding etc., wherever required shall be
incidental to construction of drain. The Contract unit for disposal of
surplus and unsuitable material beyond the initial 1000 m lead shall be in
accordance with Clause 301.3.11.
703. REINFORCED EARTH
703.1. Scope
The work covers the construction of reinforced earth structures,
together with the construction of earthwork in layers, assembly and
erection of reinforcing elements and placement of facing panels and all
associated components.
703.2. Reinforcing Element
703.2.1. The reinforcing element shall be of Oeotextile, aluminium
alloy strip, copper strip, carbon steel strip, mats of metal or synthetic
grids, or any other proprietary material which may be approved by the
Engineer and indicated on the drawings.
703.2.2. Geotextile The material shall conform to Clause 701.2.6.
703.2.3. Aluminium ahoy strip shall comply with BS:1470 quality
5454 in the H 24 condition.
703.2.4. Copper strip shall comply with BS:2870 quality C 101 or C
102 in the 1f2 H condition and shall have 0.2 per cent proof stress of not
less than 180 N/mm2.
<< 259
703.2.5. Carbon steel strip which shall be galvanized shall comply

with BS:l449 (Part 1), either quality KHR 34/20 P or quality 50/35 P,
each having a silicon content of not less than 0.25 per cent and not more
than 0.40 per cent. The fabricated element shall be galvanized in
accordance with BS:729, and the average zinc coating weight for any
individual test area shall not be less than 1000 gm/sq.m.
703.2.6. Stainless steel strip shall comply with BS:1449 (Part 2)
quality 316 S 31 or 3/6 S 33 except~thatthe material shall be cold rolled
to provide a 0.2 per cent proof stress of not less than 400 N/sq. mm and
the tensile strength shall not be less than 540 N/sq. m.
703.2.7, All metallic components buried in soil shall be of electrolyti-
cally compatible materials.
703.2.8. Geogrids : The supply of geogrids shall carry a certification
of BIS or ISO 9002 for all works. While the reinforcing element for wall
or slope portion shall be with mono oriented Geogrid, the reinforcement
for the foundation of a reinforced earth wall or slope shall be with bi-
directionally oriented Geogrid. For mono oriented Geogrid, the character-
istic design tensile strength at a strain not exceeding 10 per cent in 100
years shall be at least 40 kM/rn when measured as per GR1:GG3. The
strengt~.for bi-directionafly oriented Geogrid in the longitudinal direction
shall be at least 40 kN/m at a maximum elongation of 15 per cent. The
Geogrid shall be inert to all naturally occurring chemicals, minerals and
salts found in soil.
703.3. Earth Fill
The fill material for reinforced earth structures shall have an angle of
interface friction between the compacted fill and the reinforcing element
of not less than 25°C,measured in accordance with IS : 13326 (Part 1).
The soil should be predominantly coarse grained; not more than 10 per
cent of the particles shall pass 75 micron sieve. The soil should have
properties such that the salts in the soil should not react chemically or
electrically with the reinforcing elements in an adverse manner.
703.4. Facia Material
703.4.1. The facing shall comprise of one of following
(1) Reinforced concrete (Cast in situ or precast) stabs
(ii) Plain cement concrete form fill hollow block (Precast)
(iii) Masonry constn1ction, Rubble facia
(iv) Other proprietary and patented proven system
<< 260
The facing shall be sufficiently flexible to withstand any deformation
of the fill.
703.4.2. Facia unit joint filler should be durable, resistant to the effect
of air pollution and water/saline water.
703.4.3. Bedding material shall consist of either cement mortar or a
durable gasket seating such as resin bonded cork strip.
703.4.4. Connection between the facia and the reinforcing
element shall be by using polyethylene strips/rods, fibre glass dowels or
any other material shown in the drawing. Any other material used shall be
tested to provide 100 per cent joint strength as of parent element in
continuity.
Overlapping in principal reinforcement or in the joint shall
ensure load transfer through joints, perpendicular to the direction of
laying.
703.5. Construction Details
703.5.1. The plan area of the reinforced earth structure shall be
excavated to provide a nominally level base which may be stepped at the
back as required to receive the horizontal reinforcing element grid.
The depth of the foundation below the finished ground level at the
foot of the slope or wall shall not be less than 1000 mm.
Additional strip footing, trough guide made of concrete or anchor key
pad shall be provided at founding level to receive the facia or the bottom
most reinforcement connection. This shall have adequate soil cover
against erosion and scour in particular cases.
703.5.2. Orientation : The reinforcing elements shall be placed at
right angles to the face of the wall, with greater cross sectional dimension
in the horizontal plane. The placement of the elements including their
vertical/horizontal spacing and length shall be as in the drawing.
703.5.3. Facing batter: It may be necessary to set facing unit at an
additional batter than as provided in the drawing as there is a tendency for
initially positioned units of facia to lean outward as the fill material is
placed and compacted. Care and caution shall be taken to rectify this
phenomenon.
703.5.4. Drainage : Drainage shall be provided as per drawing given
in detail. The retained fill shall have a suitably designed drainage bay to
allow free draining of the reinforced fill.
<< 261
Section 700 Geosynthe tics
703.5$, Laying and compacting : The reinforcing elements shall

be laid free from all kinks, damage and displacement during
deposition, speading, levelling and compaction of the fill. The programme
of filling shall be such that no construction plant runs directly on the
reinforcement.
All construction plant having a mass exceeding 1000 Kg shall be kept
at least 1 .5 m away from the face of slope or wall. In this area (upto 1.5
m from the face of slope or wall), following compaction plant shall be
used
(I) Vibratory roller having a weight per metre width of roll not exceeding 13(X) kg.
with total weight not exceeding 10,000 kg.
(ii) Vibratory plate compactor of maximum weight 1000 kg.
(iii) Vibro tamper having a weight not exceeding 75 kg.
Compaction by any other method like using dozer or back blade

compaction by dozer or excavator bucket shall be permitted with due
approval from the Engineer after ascertaining the level of compaction so
achieved.
During construction of reinforced fill, the retained material beyond
the reinforcement at the rear or the structure shall be maintained at the
same level as reinforced fill,
The compacted layer shall not be more than 200 ram, to achieve
compaction of 95 per cent of maximum laboratory density where
measured as per IS : 2720 (Part 8). Temporary formwork shall be used to
support the construction as per specified details given in the drawing. The
forms, scaffolding and props shall be sufficient in numbers to allow taking
up of a sectoral construction schedule specified in the design.
Measurement for reinforcing elements shall be in linear metre for
anchor strips or in sq.m. for geogrid/geotextile etc.
The measurement for facia shall be in sq. metres. The measurement
for foundation for facia and capping beam shall be in linear metres.
Measurement for compacted earthfill shall be in cubic metres for
compacted soil.
703.7. Rates
Rate shall include cost of labour, plant hire, material storage and
handling expenses, for completing the works.
Rate for providing reinforcing elements shall include material cost, all
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transportation costs and storage of the same as per special provisions. The
rate shall also include cost of laying of the reinforcing elements including
all overlaps, jointing or stitching, heat bonding or extension.
Rate for facia fixing shall include cost of joints, all necessary
temporary formwork, scaffolding and all lifts and leads, if any, as shown
in the drawing, unless otherwise specified to the treated separately along
with foundation or slope/wall kerb at the top of slope or wall. Rate for bed
block and capping beam shall include all items of excavation, concrete,
reinforcing steel, formwork, labour and equipment.
Rate for soil fill shall include compaction as desired in requisite layers
through mechanical means, cost of hire or labour for plant operations,
dressing and levelling slopes, including special measures for edge
reinforcements as shown in the drawing.
704. GEOSYNTHETICS FOR HIGHWAY PAVEMENTS
704.1. Scope
This work shall consist of laying geosynthetic materials over existing
biuturninous surface, including preparation of surface and joining,
stitching or overlapping of geosynthetic fabric etc., as part of highway
pavement strengthening in layers as shown on drawings.
704.2. Paving Fabrics
704.2.1. Description : This work shall consist of furnishing and
placing as asphalt/bitumen overlay textile (paving fabric) beneath a
pavement overlay or between pavement layers to provide a water resistant
membrane and crack retarding layer.
704.3. Material Requirements
704.3.1. Paving rabric: The paving fabric will be a nonwoven heat
set material consisting of at least 85 per cent by weight polyolefins,
polyesters or polyarnides. The paving fabric shall be resistant to chemical
attack, rot and mildew and shall have no tears or defects which will
adversely alter its physical properties. The fabric shall be specifically
designed for pavement applications and be heat bonded only on one side
to reduce bleed-through of tack coat during installation. The fabric shall
meet the physical requirements of Table 704-2. Heavy duty paving fabrics
should be used in areas experiencing unusually high impact forces or
heavy loads such as airport runways and taxiways:
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Table 704.2. PhysIcal Requirements.Pavlng Fabrics
Tensile Strength 36.3 ASTM D 4632

Elongation 50 ASTM D 4632
Asphalt Retention 10 Texas DOT 3099
Melting Point 150 ASTM D 276
Surface Texture I-lest bonded on Visual Inspection
one side only
Notes
1. Certification of conformance from paving fabric manufacturer may be required.
2. All numerical values represent minimum average roll values (average of test
results from any sampled roll in a lot shall meet or exceed the minimum values) in
weaker principal direction, Lot shall be sampled according to ASTM D 4354,
“Practice for Sampling of Geosynthetics for Testing”.
3. Conformance of paving fabrics to specification property requirements shall be
determined as per ASTM 1) 4759, “Practice for Determining the Specification
Conformance of Geosynthetics”.
704.3.2. Tack Coat: The tack coat used to impregnate the fabric and
bond the fabric to the pavement shall be a paving grade Bitumen of 80-
100 penetration. A cationic or anionic emulsion may be used as approved
by the engineer. The use of cutbacks or emulsions which contain solvents
shall not be used.
704.4. Construction and Installation Requirements
704.4.1. Shipment and storage’: The paving fabric shall be kept dry
and wrapped such that it is protected from the elements during shipping
and storage. At no time shall the paving fabric be exposed to ultraviolet
light for a period exceeding fourteen days. Paving fabric rolls shall be
stored in a manner which protects them from the elements. If stored
outdoors, they shall be elevated and protected with a waterproof cover~.
The paving fabric shall be labeled as per ASTM D 4873, “Guide for
identification, storage, and handling of geotextiles”.
704.4.2. Weather limitations: Minimum air and pavement tempera-
ture shall be at least 10°Cand rising for placement of bitumen and shall
be at least 15°C and rising for placement bitumen emulsion. Neither
bitumen tack coat nor paving fabric shall be placed when weather
conditions, in the opinion of the engineer, are not suitable.
<< 264
704.43. Surface preparation : The pavement surface shall be
thoroughly cleaned of all dirt, water, and oil to the satisfaction of the
engineer. Cracks 3 mm wide or greater shall be cleaned and filled with
suitable bituminous material or by a method approved by the engineer.
Crack filling material shall be allowed to cure prior to paving fabric
placement. Potholes and other pavement distress shall be repaired. Repairs
shall be performed as directed by the engineer.
704.4.4. Tack coat application : The tack coat shall be spread by
means of a calibrated distributor spray bar. Hand spraying and brush
application may be used ir~!ocatiOns of fabric overlap. Every effort shall
be made to keep hand spraying to a minimum. The tack coat shall be
applied, uniformly to the prepared dry pavement surface at the rate of 1
kg/sq.m. or as recommended by the paving fabric manufacturer and
approved by the engineer. When using emulsions, the application rate
must be increased as directed by the engineer to offset the water content
of the emulsion. Within street intersections, on steep grades, or in other
zones where vehicle speed changes are common place, the normal
application rate shall be reduced by a~out20 per cent as directed by the
engineer. The tack coat application rate must be sufficient to saturate the
fabric and to bond the fabric to the existing pavement surface.
The temperature of the tack coat shall be sufficiently high to permit
a uniform spray pattern. For bitumen, the minimum temperature shall be
140°C.To avoid damage to the fabric, distributor tank temperatures shalt
not exceed 160°C.For bitumen emulsions, the distributor tank tempera-
tures shall be maintained between 55°Cand 70°C.
The target width of tack coat application shall be equal to the paving
fabric width plus 150 mm. The tack coat shall be applied only as far in
advance of paving fabric installation as is appropriate to ensure a tacky
surface at the time of paving fabric placement. Traffic shall not be allowed
on the tack coat. Excess tack coat shall be cleaned from the pavement.
704.4.5. Paving fabric placement : The paving fabric shall be placed
onto the tack coat using mechanical or manual laydown equipment
capable of providing a smooth installation with a minimum amount of
wrinkling or folding. The paving fabric shall be placed prior to the tack
coat cooling and losing tackiness. Paving fabric shall not be installed in
areas where the overlay asphalt tapers to a thickness of less than 40 mm.
Excess paving fabric which extends beyond the edge of existing pavement
or areas of tack coat application shall be trimmed and removed. When
bitumen emulsions are used, the emulsion shalt be allowed to cure
<< 265
properly such that essentially no water moisture remains prior to placing

the paving fabric. Wrinkles or folds in excess of 25 mm shall be slit and
laid flat. All transverse joints and slit folds or wrinkLes shall be shingle.
lapped in the direction of the paving operation, Brooming and/or
pneumatic rolling will be required to maximize paving fabric, contact with
the pavement surface. Additional hand-placed tack coat may be required
at laps and repairs as detcrm~n~d by the engineer to satisfy bitumen
retention of the lapped paving fabric. Alt areas with paving fabrics placed
will be ~pavedthe same day. No traffic except necessary construction
equipment will be allowed to drive on the paving fabric.
Turning of the paver and other vehicles shall be done gradually and
kept to a minimum to avoid movement and damage to the paving fabric.
Abrupt starts and stops shall also be avoided. Damaged fabric shall be
removed and replaced with the same type of fabric. Overlaps shall be
shingled-lapped in the direction of paving. Additional tack coat shall be
placed between the overlap to satisfy saturation requirements of the fabric.
Overlap shall be sufficient to ensure full closure of the joint but not exceed
150 mm.
704.4.6. Overlay placement: Bituminous overlay construction shall
closely follow fabric placement. All areas in which paving fabric has been
placed will be paved during the same day. Excess tack coat which bleeds
through the paving fabric shall be removed. Excess tack coat can be
removed by broadcasting hot mix or sand on the paving fabric.
705. PROTECTION WORKS WITH GEOSYNTHETICS
705.1. Scope
This work shall consist of laying boulder Gabions/Mattresses in wraps
of Geosynthetics in the form of bolsters, on slopes of embankments or in
apron. Gabions or Mattresses are also used for stone spurs. Geotextiles are
used for prevention of migration of fine soil particles.
705.2. Gabions/Mattresses with Geogrids and Geonets
Mattresses constructed with Geogrids or Geonets shall be used for
thickness of 300 mm or above as shown in the drawings. While adopting
a particular size for gabions or mattresses width of the roll of geogrid/
geonet may be kept in view to minimise wastage of the geosynthetic in
cutting off pieces. The mesh opening may very depending on functional
requirement but shalt have aperture between 35 mm and tOO mm. The
266
<<
c;eosynthetics Section 700
mesh/net shall have following characteristics

Aperture Rectangular, square or oval shaped (and not in diamond, round or.
polygonal shape).
Colour BLack
Mechanical : 1~akstrength ia~iless than 10 kN/m at maximum elongation of
Properties 15 per cent. Notmore than 5 per cent elongation at half peak load.
Stands/Fabric Integral joints with junction strength of 100 per cent of plain
Form strands as measured by GRI-003 standards. Material shall have
ISO 9002 ce~1ification.
Life : Aileast B years in case of continuous exposure and 5 years for
burned ~plications (drflned as capable of retaining atleast75 per
cent of its original strength after the life span awed.
7053. Construction
705,3.1. Assembly: Gabion and mattress boxes shall be assembled in
situ, on a level surface. After fabrication is done in situ they shall be
correctly filled in layers in dense packed state.
The bottom, sides and end panels shall be erected after removal of all
kinks, kept in an upright position to form rectangular boxes by joining the
sides with connectors of 40 mm x 6 mm size, or by ring staples. The top
corners shall be tie tensioned from sides to keep it erect for filling. For
gabions of 600 mm or more height, suitable cross internal ties shall be
placed in layers of 300 mm connecting opposite sides in lateral braces tied
with polymer braids of ultra-violet stabilised variety so as to ensure
protection against bulging of the gabions during filling with stones.
705.3.2. Construction and installation : The filling of the gabion/
mattress shalt be done by hand in layers so as to minimise viods and
achieve specified density. The stones in contact with the surface of the
geogrids/geonets shall be placed in such a way that their sharp edges are
kept turned inside so that they do not damage the material of the geogrids/
geonets. The opposite panels of the boxes shall be firmly secured with
lateral ties to withstand the design forces. The bottom of the gabion mesh
shall be secured in a key type excavation for preventing slide. The space
between the gabion and earthen sides shall be filled with sand and the
filling compacted, In most of the cases design shall be supplemented with
a Layer of geotextile under the gabion/mattress to prevent migration of
fines.
705.3.3. Laying boulder apron in crates : Mattresses of minimum
height 300 mm shalt be used. The typical size of a single continuous unit
shall be I m x 5 m size with baffles at 1 m centres. The size of boulders
shall be at least 100 mm or double the size of the aperture whichever is
267
<<
larger. The density of boulder filling shall be as stated in the drawing and
the specific gravity of stones not less than 2.65. Methodology of laying
boulders shall be as peg Clause 2503.3. Gabions if placed in the apron
shall be of size 1 m x 5 m in plan with height at least 600 mm, with baffles
in 1 m centres.
Gabions or mattresses made with polymer geogrids/geonets shall
always be laid in situ and shall not be performed, filled and transported
to be dropped in deep waters. Where depth of water is low or dry bed is
available, the boxes shall be filled in situ. In streams or water body having
running boulders in the bed, the gsbions/mattresses shall be armoured with
placement of loose large boulders alongside the gabion wall to protect
against impact hit of stray boulders.
Stakes or keying shall always be provided in the founding recess,
where the gabion be located, especially in case the ground is assessed to
be sloping or yielding type.
705,3.4. Groynes or spurs with crates : Groynes or spurs of gravity
retaining variety shall be constructed using geogrid/geonet gabions placed
in a stable configuration one over the other to form a well. They shall be
filled in situ on a shallow depth of water or dry bed with firm founding
and level strata. The provision of a layer of geotextile/geocomposite shall
be made while placing the structure if resting over a bed of fine soil to
prevent passage of fines and sinking.
705.3.5. Measurements for payment : The fabric of geotextile/
geocomposite shall be measured in sq. metres,, of plan area of actual use
(as per drawing).
The connecting rods or polymer braids shall be measured in metres.
Ring staples shall be measured in number provided per linear metre.
The boulder fill shall be measured in cubic metres.
The excavation for keying of gabions in the ground trenches shall be
measured in cubic metres.
The backfilling in side trenches shall be deemed part of the
excavation work.
705.3.6. Rate : The cost of Geosynthetic material for fabrication of
(iabions(Mattresses shall be all inclusive of supply, transportation and
storage.
The contract rate per cubic metre of crate fill shall Consist of cost of
boulders and their transportation.
<< 268
The contract rate for excavation and backfilling of trenches, seating

trench upto 15 cm (included in rate), shall include cost of labour, tools and
plant for completion of the work.
The cost of making a crate shall include preparation of box of
geogrid/geonet, tensioning and staking arrangements, tying, internal
crossbraids, etc., for foi’ming of the crates in an engineered manner arid
filling the crate by laying boulders. The east shall include transportation
of material from store to site.
Wherever composite system using Geosynthetics with natural mater-
rial like stone revetrnent etc. shall be used, the provision of measurement
and rate as per Clauses 2509 and 2510 are applicable.
<< ztt
Traffic Signs, Markings and
Other Road Appurtenances
800
Traffic Signs, Markings
and Other Road
Appurtenances
<<
Traffic Signs, Markings and Section 800
Other Road Appurtenances
801. TRAFFIC SIGNS
801.1. General
801.1.1. 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. In
the absence of any details or for any missing details, the signs shall be
provided as directed by the Engineer,
801.1.2. The signs shall be either reflectorised or non-refiectorised as
shown on the drawings or as directed by the Engineer. When they are
of reflectorised type, they shall be of retro-reflectorised type and made
of encapsulated lens type reflective sheeting vide Clause 801.3, fixed
over aluminium sheeting as per these Specifications.
801.1.3. In general, cautionary and mandatory signs shall be fabri-
cated 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.
801.2. Materials
The various materials and fabrication of the traffic signs shall
conform to the following requirements:
801.2.1, Concrete : Concrete shall be of the grade shown on the
Contract drawings or otherwise as directed by the Engineer.
801.2.2, Reinforcing steel : Reinforcing steel shall conform to
the requirement of IS:l786 unless otherwise shown on the drawing.
801.23. Bolts, nuts, washers: High strength bolts shall conform to
IS : 1367 whereas precision bolts, nuts, etc., shah conform to IS: 1364.
801.2.4. Plates and supports: Plates and support sections for the
sign posts shall conform to IS: 226 and IS: 2062 or any ot!~errelevant
IS Specifications.
80 1.2.5. Aluminium: 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.
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Section 800 Traffic Signs and Appurtenances
801.2.6. 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.
801.2.7. In respect of sign sizes not covered by IRC:67, the structural
details (thickness, etc.) shall be as per the approved drawings.
801.3. Traffic Signs Having Retro-reflective Sheeting
801.3.1. General requirements: 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 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.
801.3.2. 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 surfacer 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 800-1.
TABLE KOO-1. ACCEPTABLE MiNIMUM COEFFICIENT OF RETRO.
REFLECTION FOR HIGH INTENSITY GRADE SHEETING
(CANDELAS PER LUX PER SQUARE METRE)
Observation Entrance White Yellow Orange Green/ Blue
angle Angle Red •
(in degrees) (In degrees)
0.2 -4 250 170 100 45 20

0.2 ÷30 150 100 60 25 11
0.5 -4 95 62 30 15 7.5
0.5 +30 65 45 25 10 5,0
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Traffic Signs and Appurtenances Section 800
When totally wet, the sheeting shall not show less than 90 per cent
of the values of retro-reflectance indicated in Table 800.-I. At the end
of 7 years, the sheeting shall retain at least 75 per cent of its original
retro-reftectance.
801.3.3. Engineering grade sheeting: This sheeting shall be of
enclosed lens type consisting of microscOpic lens elements embedded
beneath the surface of a smooth, flexible, transparent, water-proof plastic,
resulting in a non-exposed lens optical reflecting system. The retro-
reflective surface after cleaning with soap and water and in dry condition
shall have the minimum coefficient of retro-reflection (determined in
accordance with ASTM Standard: E-810) as indicated in Table 800-2.
TABLE 800-2. ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-
REFLECTION FOR ENGINEERING GRADE SHEETING
(CANDELAS PER LUX PER SQUARE METRE)
Observation Entrance White Yellow Orange Green Red Blue

angle In angle In
degree degree
0.2 -4 70 50 25 9.0 14.5 4.0

O~2 +30 31) 22 7.0 3.5 6.0 1.7
0.5 .4 30 25 13.5 4.5 7.5 2.0
0.5 ÷30 15 13 4.0 2.2 3.0 0.8
When totally wet, the sheeting shall not show less than 90 per cent
of the values, of retro-reflection indicated in Table 800-2. At the end
of 5 years, the sheeting shall retain at least 50 per cent of its original
retro-reflectance.
801.3.4. Messages/borders: The messages (legends, letters, numerals
etc.) and borders shall either be screen-printed or of cut-outs. Screen
printing shall be processed and finished with materials and in a manner
specified by the sheeting manufacturer. Cut-outs shall be of materials as
specified by the sheeting manufacturer and shall be bonded with the
sheeting in the manner specified by the manufacturer.
801.3.S. For screen-printed transparent coloured areas on white sheet-
ing, the co-efficient’ of retro-reflection shall not be less than 50 per cent
of the values of corresponding colour in Tables 800-I and 800-2, as
applicable.
801.3.6. Cut-out messages and borders, wherever used, shall be made
out of retro-reflective sheeting (as per Clause 801.3.2 or 801.3.3 as appli-
cable), except those in black which shall be of non-reflective sheeting.
<< 275
801.3,7. Colour: Unless otherwise specified, the general colour
scheme shall be as stipulated in IS : 5 “Colour for Ready Mixed Paints”,
viz.
Blue - IS Colour No. 166: French Blue
Red - IS Colour No. 537: Signal Red
Green - IS Colour No. 284: India Green
Orange - IS Colour No. 591: Deep Orange.
The Colours shall be durable and uniform in acceptable hue when
viewed in day light or under normal headlights at night.
801.3.8. Adhesives : The sheeting shall either have a pressure-
sensitive adhesive of the aggressive-tack type requiring no heat, solvent
or other preparation for adhesion to a smooth clean surface, or a tack free
adhesive activated by heat, applied in a heat-vacuum applicator, in
a manner recommended by the sheeting manufacturer. The adhesive shall
be protected by an easily removable liner (removable by peeling Without
soaking in water or other solvent) and shall be suitable for the type of
material of the base plate used for the sign. The adhesive shall form a
durable bond to smooth, corrosion and weather resistant surface of the
base plate such that it shall not be possible to remove the sheeting from
the sign base in one piece by use of sharp instrument. In case of
pressure-sensitive adhesive sheeting, the sheeting shall be applied in
accordance with the manufacturer’s Specifications, Sheeting with adhe-
sives requiring use of solvents or other preparation for adhesive shall
be applied strictly in accordance with the manufacturer’s instructions.
801.3.9. Refurbishment: Where existing signs are specified for
refurbishment, the sheeting shall have a semi-rigid aluminium backing
pre-coated with aggressive-tack type pressure sensitive adhesive. The
adhesive shall be suitable for the type of material used for the sign and
should thoroughly bond with that material.
801,3.10. Fabrication
801.3.10.1. Surface to be reflectorised shall be effectively prepared
to receive the retro-refleetive sheeting. The aluminium sheeting shall
be de-greased either by acid or hot alkaline etching and all scale/dust
removed to obtain a smooth plain surface before the application of retro-
reflective sheeting. If the surface is rough, approved surface primer may
be used. After cleaning, metal shall not be handled, except by suitable
de~’ice or clean canvas gloves, between all cleaning and preparation
<< ~276
operation and application of reflective sheeting/primer. There shall be
no opportunity for metal to come in contact with grease, oil or other
contaminants prior to the application of retro-reflective sheeting.
801.3.10.2. Complete sheets of the material shall be used on the
signs except where it is unavoidable; at splices, sheeting with pressure
sensitive adhesives shall be overlappednot less than 5 mm. Sheeting with
heat-activated adhesives may be spliced with an overlap not less than 5
mm or butted with a gap not exceeding 0.75 mm. Where screen printing
with transparent colours is proposed, only butt jointing shall be used.
The material shall cover the sign surface evenly and shall be free from
twists, cracks and folds. Cut-outs to produce legends and borders shall be
bonded with the sheeting in the manner sjecified by the manufacturer.
801.3.11. Warranty and durability The Contractor shall obtain
from the manufacturer a seven-year warranty for satisfactory field
performance including stipulated retro-reflectance of the retro-reflective
sheeting of high intensity grade and a five year warranty for the adhesive
sheeting of engineering grade and submit the same to the Engineer. In
addition, a seven year and a five year warranty for satisfactory in-field
performance of the fmished sign with retro-reflective sheeting of high
intensity grade and engineering grade respectively, inclusive of the screen
printed or cut out Ieuer~legendsand their bonding to the retro.-reflective
sheeting shall be obtained from the Contractor/supplier and passed on
to the Engineer. The Contractor/supplier shall also furnish a certification
that the signs and materials supplied against the assigned work meets all
the stipulated requirements and carry the stipulated warranty.
Processed and applied in accordance with recommended procedures,
the reflective material shall be weather resistant and, following cleaning,
shall show no appreciable discolouration, cracking, blistering or dimen.
sional change and shall not have less than 50 per cent of the specified
minimum reflective intensity values (Tables 800-I and 800-2) when
subjected to accelerated weathering for 1000 hours, using type E or Eli
Wëatherometer (AASI3TO Designation M 268).
801.4. Installation
801.4.1. 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 galvanised iron (0.1). Post-
<< 277
end(s) shall be firmly fixed to the ground by means of properly designed

foundation. The work of foundation shall conform to relevant Specifica-
tions as specified,
801.4.2. All components of signs and supports, other than the
reflective portion and 0.1. posts shall be thoroughly descaled, 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.
801.4.3. The signs shall be fixed to the posts by welding in the case
of steel posts and by bolts and washers suitable size in the case
of reinforced concrete or 0.1. posts. After the nuts have been tightened,
the tails of the bolts shall be furred over with a hammer to prevent
removal.
The measurement of standard cautionary, mandatory and informa-
tion signs shall be in numbers of different types of signs supplied and
fixed, while~for direction and place identification signs, these shall be
measured by area in square metres,
801.6. Rate
The Contract unit rate shall be payment in full for the cost of
making the road sign, including all materials, installing it at the site and
incidentals to complete the work in accordance with the Specifications.
802. OVERHEAD SIGNS’
802,1. General
802.1.1. Overhead signs may be used in lieu of, or as an adjunct
to, ground signs where the situation so warrants for proper information
and guidance of the road user.The following conditions may be considered
while deciding about the provision of overhead signs:
(1) Traffic vohame at or near capacity
(2) Complex interchange design
(3) Three or more lanes in each direction
(4) Restricted sight distance
(5) Closely spaced interchanges
(6) Multi-Sic exits
(7) Large percentage of commercial vehicles
(8) High speed traffic
<< 278
(9) Consistency of sign message location through a series of interchanges

(10) Insufficient space for ground mounted signs
(11) Background of street lighting
(12) Distances of important places enroute highways at suitable intervals,
802.1.2. From safety and aesthetic standpoints, overhead signs shall

be mounted on overhead bridge structures wherever possible. Where
these are required to be provided at some other locations, the support
system should be properly designed based on sound engineering prin-
ciples, to safely sustain the dead load, live load and wind load on the
completed sign system. For this purpose, the overhead signs shall be
designed to withstand a wind loading of 150 kg/rn2 normal to the face of
the sign and 30 kg/rn2 transverse to the face of the sign. In addition to
the dead load of the structure, walkway loading of 250 kg concentrated
live load shall also be considered for the design of the overhead sign
structure.
802.2. Height
Overhead signs shall provide a vertical clearance of not less than 5.5
m over the entire width of the pavement and shoulders except where a
lesser vertical clearance is used for the design of other structures. The
vertical clearance to overhead sign structures or supports need not be
greater than 300 mm in excess of the minimum design clearance of
other structures.
802.3. Lateral Clearance
802.3.1. The minimum clearance outside the usable roadway shoul-
der for expressway signs mounted at the road side or for overhead sign
supports either to the right or left side of the roadway shall be 1.80 m.
This minimum clearance of 1.80 m shall also apply outside of an
unmountable kerb. Where practicable, a sign should not be less than 3 m
from the edge of the nearest traffic lane. Large guide signs should be
farther removed preferably 9 m or more from the nearest traffic lane,
unless otherwise specified. Lesser clearances, but not generally less than
1.80 m, may be used on connecting roadways or ramps at inter-changes.
802.3.2. Where a median is 3.6 m or less in width, considerLzion
should be given to spanning over both roadways without a central
support. Where overhead sign supports cannot be placed at a safe
distance away from the line of traffic or in an otherwise protected site,
they should either be so designed as to minimise the impact forces or
protect motorists adequately by a physical barrier or guard rail of suitable
design.
<< 279
802.4. Number of Signs at an Overhead Installation
In no case should there be more than three signs displayed at any one
Location, including regulatory or warning signs, either on the overhead
structure or on its support.
802.5. Materials for Overhead Sign and Support Structures
802.5.1. Aluminium alloy or galvanized steel to be used as truss
design supports shall conform to relevant IS. These shall be of sectiçns
and type as per structural design requirements as shown on the plans.
802.5.2. After steel trusses have been fabricated and all required
holes punched or drilled on both the horizontal truss units and the vertical
and support units, they shall be galvanized in accordance with IS
Specifications.
802.5.3. Where aluminium sheets are used for road signs, they shall
be of smooth, hard and corrosion resistant aluminium alloy conforming
to IS 736- Material Designation 24345 or 1900. Tbe thickness of sheet
shall be related to the size of the sign with minimum thickness of sheet
as 1.5 mm.
802.5,4. High strength bolts shall conform to IS: 1367 whereas
precision bolts, nuts etc. shall conform to IS: 1364.
802.5.5. Plates and support sections for sign posts shall conform to
IS: 226 and IS: 2062,
802.5.6. The overhead signs shall be reflectorised with high intensity
retro-reflective sheeting preferably of encapsulated lens type.
802.6. Size, Locations, etc. of Signs
802.6.1. The size of the signs, letters and their placement shall be
as specified in the Contract drawings and Specifications.
802.6.2. In the absence of details or for any missing details in
the Contract documents, the signs shall be provided as directed by
the Engineer.
802.7. Installation
802.7.1. The supporting structure and signs shall be fabricated and
erected as per details given in the plans.
802.7.2. Sign posts, their foundations and sign mountings shall be
so constructed as to hold signs in a proper and permanent position
to adequately resist swaying in the wind or displacement by vandalism.
<< 280
802.7.3. The work of construction of foundation for sign supports
including excavation and backfill, forms, steel reinforcement, concrete
and its placement shall conform to the relevant Specifications given
in these Specifications.
802.7.4. The structures shall be erected with the specified camber and
in such a manner as to prevent excessive stresses, injury and defacement.
802.7.5. Brackets shall be provided for mounting signs of the type
to be supported by the structure. For better visibility, they shall be
adjustable to permit mounting the sign faces at any angle between a
truly vertical position and three degree from vertical. This angle shall
be obtained by rotating the front lower edge of the sign forward. All
brackets shall be of a length equal to the heights of the signs being
supported.
802.7.6. Before erecting support structures, the bottom of each base
plate shall be protected with an approved material which will adequately
prevent any harmful reaction between the plate and the concrete.
802.7.7. The end supports shall be plumbed by the use of levelling
nuts and the space between the foundation and base plate shall be
completely filled with an anti-shrink grout.
802.7.8. Anchor bolts for sign supports shall be set to proper
locations and elevation with templates and carefully checked after
construction of the sign foundation and before the concrete has set.
802.7.9. Al! nuts on aluminium trusses, except those used on the
flanges, shall be tightened only until they are snug. This includes the nuts
on the anchor bolts. A thread lubricant shall be used with each aluminium
nut.
802.7.10. All nuts on galvanized steel trusses, with the exception of
high strength bolt connections, shall be tightened only to a snug condition.
802.7.11. Field welding sh~1lnot be permitted.
802.7.12. After installation of signs is complete, the sign shall be
inspected by the Engineer. If specular reflection is apparent on any sign,
its positioning shall be adjusted by the Contractor to eliminate or
minimize this condition.
802.8.!. Aluminium or steel overhead sign structure will be measured
for payment by the specific unit (each) complete in place or for each
<< 281
component of the overhead sign structure as indicated in the Bill of

Quantities and the detailed drawing(s).
802.8.2. Flat sheet aluminium signs with retro-reflective sheeting
thereon shall be measured for payment by the square metre for each
thickness, cqmplete in place.
802.9. Rate
802.9.1. The structural steel part of the overhead sign shall be
measured in tonnes while the sign hoard shall be measured in sq. in. Other
items like excavation for foundation and concrete in foundation to be
measured and paid in Cu. m. separately. The Contract unit rate for
overhead sign structure shall be payment in full compensation for
furnishing all labour, materials, tools, equipment, excavation, fabrication
and installation and all other incidental costs necessary to complete
the work to the Specifications.
802.9.2. The Contract unit rate for aluminium sheet signs shall
include the cost of making the sign including all materials and fixing the
same in position and all other incidental costs necessary to complete the
work to the Specifications.
803. ROAD MARKINGS
803.1. General
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.
803.2. Materials
Road markings shall be of ordinary road marking paint, hot applied
thermoplastic compound, or reflectorisedpaint as specified in the item and
the material shall meet the requirements as specified below.
803.3. Ordinary Road Marking Paint
803.3.1. Ordinary paint used for road marking shall conform to Grade
I as per IS: 164.
803.3.2. The road marking shall preferably be laid with appropriate
road marking machinery.
803.3.3. Laying thickness of road marking paint shall be as specified
by the Engineer.
<< 282
803.4. Hot Applied Thermoplastic Road Marking
803.4.1. General
(i) The work under this section consists of marking traffic stripes using a thennopi attic
compound meeting the requirements specified herein.
(ii) The thermoplastic compound shall be screeded/extnided 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 ~hatlproduce an adherent pavement marking of specified
thickness and width and capable of resisting deformation by traffic.
(iii) 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
(iv) 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.
893.4.2. Thermoplastic Material,

803.4.2.1. General : The thermoplastic material shall be homo-
geneously composed of aggregate, pigment, resins and glass reflectorizing
beads,
803.4.2.2. 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 800-3.
TABLE 800.3. PROPORTIONS OF CONSTITUENTS OP MARKING MATERIAL
(Percentage by weight)
Component White Yellow
Binder 18.0 mm. 1811 mm.

Glass Beads 30-40 30-40
Titanium Dioxide 10.0 miii. —
Calcium Carbonate and

Inert Fillers 42.0 max. See
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 this Specification
are met.
(ii) Propertles The properties of thermoplastic material, when tested in accordance
with ASTM D36i’BS.3262.(Part I), shall be as below:
(a) Luminance
White : Daylight luminance at 45 degrees-65 per cent miii, as per AASHTO
M 249
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Yellow : Daylight luminance at 45 degrees-45 per cent mm. as per AASHTO

M 249
(b) Drying tIme : When applied at a temperature specified by the manufacturer
and so the required thickness, the material shall set to bear traffic in not
more than 15 minutes.
(c) Skid resistance : not less than 45 as per BS 6044.
(d) Cracking resistance at low temperature: The material shall show no cracks
on application to concrete blocks.
(e) Softening point: 102.5 ±9.5 C as pet ASTM D 36.
(f) Flow resistance: Not more than 25 per cent as per AASIITO M 249.
(g) Yellowness Index (for white thermoplastic paint): not more than 0.12 as
per AASHTO M 249
(iii) Storage life : The material shall meet the requirements of these Specifications for
a period of one year. The themsoplastic material must also melt uniformly with
no evidence of skins or unmelted particles for the one year storage period. Any
material not meeting the above requirements shall be replaced by the manufac~
turer/ supplier/Contraiior,
(Iv) Reflectorlsation : Shall be achieved by incorporation of beads, the grading and
other properties of the beads shall be as specified ~un
Clause 803.4.3.
(v) Marking : Each container of the thermoplastic material shall be clearly and
indelibly marked with the following information:
1. The name, trade mark or oilier means of identification of manufacturer
2. Batch number
3. Date of manufacture
4. Colour (white or yellow)
S. Maximum application temperature and maximum safe heating temperature.
(vi) Sampling and testIng: The thermoplastic material shall be sampled and tested in
accordance with the appropriate ASTM/BS method. The Contractor shall furnish
to the Employer a copy of certified test reports from the manufacturers of the
thermoplastic material showing results of all tests specified herein and shall
certify that the material meets all requirements of this Specification.
803.4.3. Reflectorising glass beads

803.4.3.1. General : This Specification covers two types of glass
beads to be used for the production of reflectorised pavement markings.
Type 1 beads are those which are a constituent of the basic
thermoplastic compound vide Table 800-3 and Type 2 beads are those
which are to be sprayed on the surface vide Clause 803.6.3.
803.4.3.2. The glass beads shall be transparent, colourless and free
from milkiness, dark particles and excessive air inclusions.
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These shall conform to the requirements spelt out in Clause

803.4.3.3.
803.4.3.3. Specific requirements
A. Gradation: The glass beads shall meet the gradation require-
ments for the two types as given in Table 800-4.
TABLE 800.4. GRADATION REQUIREMENTS FOR GLASS BEADS
Per can t retaIned

Sieve size
Type 1 Type 2
1.18mm Oto3 -
850 micron 5 to 20 Oto5

600 -do- - 5to20
425 -do- 65 to 95 -
300 -do- - 30 to 75
180 -do- 0 to 10 10 to 30
below 180 micron - 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 re-
fractive 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 striping. They shall pass the free
flow-test.
803.4.3.4. Test methods: The specific requirements shall be tested
with the following methods:
(i) Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass
dish. Place the dish in a 250mm inside diameter desiccator which is filled within
25 mm of the top of a desiccator plate with sulphuric acid water solution
specific gravity L10). Cover the desiccator and let it stand for 4 hours at 2Oto 29
degree C. Remove sample from desiccator, transfer beads to a pan and inspect
for lumps or clusters, Then pour beads into a clean, dry glass funnel having a 100
mm stem and 6 mm orifice. If necessary, initiate flow by lightly tapping the
funnel. The glass spheres shall be essentially free of lumps and clusters and shall
flow freely through the funnel.
(ii) The requirements of gradation, roundness and refractive index of glass beads and
the amount of glass beads in the compound shall be tested as per BS 6088 and BS
3262 (Part I).
(iii) The Contractor shall furnish to the Employer a copy of certified test reports from
the manufacturer of glass beads obtained from a reputed laboratory showing
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results of all tests specified herein and shall certify that the material meets
all requirements of this Specification. Flowever, if so required, these tests may
be carried out as directed by the Engineer.
803.4.4. Application properties of thermoplastic material

803.4.4.1. The thermoplastic material shall readily get screeded/
extruded a1 temperatures specified by the manufxturers for respective
method of application to produce a line of specified thickness which
shall be continuous and uniform in shape having clear and sharp edges.
803.4.4.2. The material upon heating to application temperatures,
shall not exude fumes, which are toxic, obnoxious or injurious to
persons or property.
803.4.5. Preparation:
~i) ‘The material shall be melted in accordance with the manufacturer’s instructions in
a heater fitted with a mechanical stirrer to give a smooth consistency to the
thermoplastic material to avoid local overheating. The temperature of the mass
shall be within the range specified by the manufacturer, and shall on no account
be allowed to exceed the maximum temperature stated by the manufacturer. The
molten material should be used as expeditiously as possible and for thermoplastic
material which has natural binders or is otherwise sensitive to prolonged healing,
the material thall not be maintained t:n a molten condition for more than 4 hours.
(ii) After transfer to the laying equipment, the material shall be maintained within
the temperature range specified by the manufacturer for achieving the desired
consistency for laying.
803.4.6. Properties of finished road marking
(a) ‘I’he stripe shall not be slippery when wet.
(b) The marking shall not lift from the pavement in freezing weather.
(c) After application and proper drying, the stripe shall show no appreciable
deformation or discolouration under traffic and under road temperatures upto
60~C.
(d) The marking shall not deteriorate by contact with sodium chloride, calcium chloride
or oil drippings from traffic.
(e) l’he stripe or marking shalt maintain its original dimensions and position, Cold
ductility of the material shall be such as to permit normal movement with the road
surface without chopping or cracking.
(I) ‘I’he colour of yellow marking shall conform to IS Colour No. 356 as given in lS:
164.
803.5. Reflectorised Paint

Reflectorised paint, if used, shall conform to the Specification by the
manufacturers and approved by the Engineer. Reflectorising glass beads
for reflectorising paints where used shall conform to the requirement of
Clause 803.4.3.
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803.6. Application
803.6.1. Marking shall be done by machine. For locations where
painting cannot be done by machine, approved manual methods shall be
used with prior approval of the Engineer. The Contractor shall maintain
control over traffic while painting operations are in progress so as to
cause minimum inconvenience to traffic compatible with protecting the
workmen.
803.6.2. The thermoplastic material shall be applied hot either
by screeding or extrusion process. After transfer to the laying apparatus,
the material shall be laid at a temperature within the range specified by
the manufacturer for the particular method of laying being used. The
paint shall he applied using a screed or extrusion machine.
803.6.3. The pavement temperature shall not be less than 10°C
during application. All surfaces to be marked shall be thoroughly cleaned
of all dust, dirt, grease, oil and all other foreign matter before
application of the paint.
The material, when formed into traffic stripes, must be readily renew-
able by placing an overlay of new material directly over an old line of
compatible material. Such new material shall so bond itself to the old line
that no splitting or separation takes place.
Thermoplastic paint shall be applied in intermittent or continuous
lines of uniform thickness of at least 2.5 mm unless specified otherwise.
Where arrows or letters are to be provided, thermoplastic compound may
be hand~sprayed. In addition to the beads included in the material, a
further quatnity of glass beads of Type 2, conforming to the above
noted Specification shall be sprayed uniformly into a mono-layer on to
the hot paint line in quick succession of the paint spraying operation. The
glass beads shall be applied at the rate of 250 grams per square metre area.
803.6.4. The minimum thickness specified is exclusive of surface
applied glass beads, The method of thickness measurement shall be in
accordance with Appendices B and C of BS 3262 (Part 3).
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803.6.5. The finished lines shall be free from ruggedness on sides and
ends and be parallel to the general alignment of the carriageway. The
upper surface of the lines shall be level, uniform and free from streaks.
803.7. Measurements fof Payment
803.7.1. The painted markings shall be measured in sq. metres of
actual area marked (excluding the gaps, if any).
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803.7.2. In respect of markings like directional arrows and lettering,
etc., the measurement shall be by numbers.
803.8. Rate
The Contract unit rate for road markings shall be payment in full
compensation for furnishing all labour, materials, tools, equipment,
including all incidental costs necessary for carrying out the work at the
site conforming to these Specifications complete as per the approved
drawing(s) or as directed by the Engineer and all other incidental costs
necessary to complete the work to these Specifications.
804. HECTOMETRE/KILOMETRE STONES
804.1. General
The ‘work covers the supply, painting, lettering and fixing of distance
measurement stones and shall include:
(i) Flectometre stones
(ii) Kilometre stones
(iii) 5th Kilometre stones
804.2. The dimengions of the stones and the size, colour, arrange~
ment of letters and script shall be as per IRC : 26 “Type Designs for
200 Metre Stones” and 1RC: 8 “Type Designs for Highway Kilometre
Stones”.
804.3. The hectometre/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.
The measurement will be in numbers of 200 metre, kilometre and
5th kilometre stones fixed at site.
804.5. Rate
The Contract unit rate for hectometre/kilometre/5th kilometre stones
shall be payment in full compensation for furnishing all labour, materials,
tools, equipment and making the stones, painting and lettering and fixing
at site and all other incidental costs necessary to complete the work to
these Specifications.
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805. ROAD DELINEATORS
805.1. General
The work covers supplying and fixing roadway indicators, hazard
markers and object markers.
805.2. 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.
The measurement shall be made in numbers of delineators fixed
at site.
805.4. Rate
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 these Specifications.
806. BOUNDARY STONES
806.1. General
The work comprises of supplying and fixing boundary stonr~as per
designs and Specifications given in IRC: 25 “Type Designs fo Bdtrndary
Stones” and at locations indicated. iii the drawings or~asdirec~&i
by the
Engineer.
806.2. Measi~rernentsfor Payment
The measurement shall be made in numbers of bouridary,stones fixed
at site.
806.3. Rate
The Contract unit rate for boundary stones shall be paymënt 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 these Specifications.
807. FENCING
807.1. General
The work comprises of fixing Mild Steel (M.S.) pusts and providing
barbed wire fencing including necess~rystays and entry gates as shown
in the drawing (s) and as directed by the Engineer.
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807.2. 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 these ‘Specifications.
807.3. The barbed wire shall be of galvanised iron and shall conform
to IS:278.
807.4, Entry gate(s) shall be made of M.S. rods or other metal as per
the design shown in the drawing(s).
The measurement shall be in running metre of fencing including the
entry gates.
807.6, Rate
The Contract unit rate for fencing shall be payment in full com-
pensation for furnishing all labour, materials, tools, equipment for
fabrication and fixing at site and all other incidental costs necessary to
complete the work to these Specifications.
808. TUBULAR STEEL RAILING
808.1. General
The work shall consist of supplying, fixing and erecting tubular steel
railings as shown on the drawings and as directed by the Engineer.
808.2. The railings shall be of tubular steel in conformance to
IS:1239. The fabrication and painting except for the final coat shall be
completed before despatch to the site. Prior to the painting, all surfaces
shall be grit blasted to the satisfaction of the Engineer and pickled. The
priming coat of paint shall be applied as soon as the steel has dried.
808.3. The posts shall be vertical and of the type as shown in the
drawing with a tolerance not exceeding 6mm in a length of 3 m. The
railing shall be erected true to line and grade.
The railing shall be measured in linear metre from end to end along
the face of the railing, including end and intermediate posts, with
no deductions for gaps as shown on the drawings.
808.5. Rate
The Contract unit rate for Tubular Steel Railing shall be payment
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in full compensation for furnishing all labour; materials, tools, equipment
and plant required for fabrication, connection, oiling, painting, temporary
erection, inspection, test and final erection at site and all other
incidental costs necessary to complete the work to these Specifications.
809. CONCRETE CRASH BARRIER
809.1, General
809.1.1. This work shall consist of construction, provision and
installation of concrete crash barrier at the edges of the road and median
at locations and of dimensions as shown on the drawings or as directed
by the Engineer.
809.1.2. Concrete 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.
809.2. Materials
809.2.1. All materials shall conform to Section lOGO-Materials for
Structures as applicable, and relevant Clauses in Section 1600 shall govern
the steel reinforcement. The concrete barriers shall be constructed either
by the “cast-in-place with fixed forms” method or the “extrusion or slip
form” method or a combination thereof at the Contractor’s option with
the approval of the Engineer. Where “extrusion or slip form” method is
adopted, full details of the method and literature shall be furnished.
809.2.2. Concrete barriers shall be constructed with M ‘20 grade
concrete and with High Yield Strength deformed reinforcement conform-
ing to IRC: 21.
809.23. An expansion joint with pre-moulded asphalt filler board
shall be provided at the junction of crash bather on structure and crash
barrier on the fill. The crash barrier on the fill shall be constructed in
pieces of length not exceeding 20 m, with pre-moulded asphth filler
board joints.
809.3.1. The location of crash barrier shall be strictly adhered to
as shown on the drawing and as directed by the Engineer. Concrete
crash bathers shall present a smooth, uniform appearance in their
final position, conforming to the horizontal and vertical lines shown on
the plans or .as ordered by the Engineer and shall be free o1f lumps, sags
or other irregularities. The top and exposed faces of the bathers shall
conform to the specified tolerances, as defined in Clause R()9.4, when
t~stedwith 3 m straight edge, laid on the surface.
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809.3.2. When concrete barriers are to be constructed on recently

completed bridges, the height of the barriers shall be adjusted to
compensate for the camber and dead load deflection of the superstruc-
ture. The amount of adjustment shall be determined by the Engineer and
shall be ordered before the concrete is placed. Such barriers shall be
placed after form work has been released and as long after the
superstructure construction as possible without hampering the progress of
the work.
809.3.3. Backfilling to the concrete barriers shall be compacted in
layers to the compaction of the surrounding earthwork.
809.4. Tolerance The overall horizontal alignment of rails shall not
depart from the road alignment by more than ±30 mm, nor deviate in
any two successive lengths from straight by more than 6 mm and the
fices shall not vary more than 12 mm from the edge ot~a3 rn straight
edge. Rarriers shall be at the specified height as shown in the plans
above the edge of the nearest adjacent carriageway or shoulder, within
a tolerance of ±30 mm.
All barriers will be measured by linear metres of completed and
accepted length in place, corresponding end to end along the face of
concrete barriers including approach and departure ends.
809.6. Rate
The Contract unit rate shall include full compensation for furnishing
all labour, materials, tools, equipment and incidental costs necessary for
doing all the work involved in constructing the concrete barrier complete
in place in all respects as per these Specifications.
810. METAL BEAM CRASH BARRIER
810.1. General
810.1.1. 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.
810.1.2. Metal beam crash barrier shall generally be located on ap-
proaches to bridge structures, at locations where the embankment height
is more than 3 metres and at horizontal curves.
810.2. Materials
810.2.1. Metal beam rail shall be corrugated sheet steel beams of
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292
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.
810.2.2. Steel beam elements and terminal sections shall be
galvanised (zinc coated, O.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 galvanizing
shall be done after fabrication.
810.2.3. Concrete for bedding and anchor assembly shall conform to
Section 1700 of these Specifications.
810.3.!. The line and grade of railing shall be true to that shown on
the plans. The railing shall be carefully adjusted prior to fixing in place,
to ensure proper matching at abutting joints and correct alignment and
camber throughout their length. Holes for field connections shall be drilled
with the railing in place in the structure at proper grade and alignment.
810.3,2. Unless otherwise specified on the drawing, railing steel
posts shall be given one shop coat of paint (primer) and three coats of
paint on structural steel after erection, if the sections are not galvanised.
Any part of assembly below ground shall be painted with three coats of
red lead paint.
810.3,3. Splices and end connections shall be of the type and
designs specified or shown on the plans and shall be of such strength as
to develop full design strength of the rail elements.
810,4. Installation of Posts
810.4.1. Holes shall be dug or drilled to the depth indicated on the
plans or posts may be driven by approved methods and equipment,
provided these are erected in proper position and are free trom distortion
and burring or any other damage.
810.4.2. All post holes that are dug or drilled shall be of such size
as will permit proper setting of the posts and allow sufficient room
for backfilling and tapping.
810.4.3. Holes shall be backfilled with selected earth or stable
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materials in layers not exceeding 100 mm thickness and each layer shall
be thoroughly tamped and rammed. When backfihling and tamping are
completed, the posts or anchors~shall be held securely in place.
810.4,4. Post holes that are drilled in rock and holes for anchor
posts shall be backfilled with concrete.
810.4.5. Posts for metal beam guardrails on bridges shall be bolted to
the structure as detailed on the plans. The anchor bolts shall be set to
proper location and elevation with templates and carefully checked.
810.5. Erection
810.5.1. All guardrail anchors shall be set and attachments made
and placed as indicated on the plans or as directed by the Engineer.
810.5.2. All bolts or clips used for fastening the guardrail or fittings
to the posts shall be drawn up tightly. Each bolt shall have sufficient
length to extend atleast 6 mm through and beyond the full nut, except
where such extensions might interfere with or endanger traffic in which
case the bolts shall be cul off flush with the nut.
810.5.3. All railings shall be erected, drawn and adjusted so that
the longitudinal tension will be uniform throughout the entire length of
the rail.
810.6. Tolerance
The posts shall be vertical with a tolerance not exceeding 6 mm in
a length of 3 metre. The railing barrier shall be erected true to line and
grade.
810.?. Measurements for Payment
810.7.1. Metal beam railing barriers will be measured by linear
metre of completed length as per plans and accepted in place. Terminalsf
anchors of various types shall be paid for by numbers.
810.7.2. No measurement for payment shall be made for projections
or anchors beyond the end posts except as noted above, Furnishing and
placing anchor bolts and/or devices for guard rail posts on bridges
shall be considered incidental to the construction and the costs thereof
shall be included in the price for other items of construction.
810.7.3. No measurement for payment will be made for excavation
or backlilhing performed in connection with this construction.
810.8. Rate
The Contract unit rate shall include full compensation for furnishing
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of labour, materials, tools, equipments and incidental costs necessary for
doing all the work involved in constructing the metal beam railing barrier
complete in place in all respects as per these Specifications.
811. ROAD TRAFFIC SIGNALS
811.1. General
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.
811.2. The tralfic 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.
811.3. Materials
The various materials and fabrication thereof shall conform to
the following:
8113.1. Signal foundation: The signal foundations shall be con-
structed as per Specifications given in Clause 13 of IRC: 93 or as
shown in the drawings.
811.3.2. Constructional requirements: The constructional require-
ments for post, signal head assembly, signal head, optical system, lamp
and holder, visor, post, supports for overhead mounted signals,
equipment housing, locks, inter-connecting cables, earthing, mains termi-
nation, controller electrical components, etc., shall 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.
8113.3. 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.
811.4. Tests
Tests shall be carried out on all components of traffic signal
including tests on complete system for its performance as per relevant
Clauses of IRC : 93 and IS: 7537.
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811.5. Maintenance of Traffic Signals

It shall be the responsibility of the Contractor to provide for
maintenance of the signal section system throughout the warranty
period for at least five (5) years after installation and as per Clause 18
of IRC : 93.
The measurement for traffic signalisation system shall be by unit for
complete work as specified and as per drawing for complete road junction.
811.7. Rate
The Contract unit rate for the traffic signalisation system as a whole
shall be payment in full compensation for furnishing all labour, materials,
toots, equipment for preparing, supplying, fixing at site, testing and
maintenance throughout ~warrantyperiod and all other incidental costs
necessary to complete and maintain the work to these Specifications.
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Quality Control for
Road Works
900
Quality Control for
Road Works
<<
Quality Control for Road Works Section 900
901. GENERAL
901.1. All materials to be used, all methods adopted and all works
performed shall be strictly in accordance with the requirements of these
Specifications. The Contractor shall set up a field laboratory at locations
approvedby the Engineer and equip the same with adequate equipment and
personnel in order to carry out all required tests and Quality Control work
as per Specifications and/or as directed by the Engineer. The internal layout
of the laboratory shall be asper Clause 121 and/or asdirected by the Engineer.
The list of equipment and the facilities to be provided shall be got approved
from the Engineer in advance.
901.2. The Contractor’s laboratory should be manned by a qualified
Materials Engineer/Civil Engineer assisted by experienced technicians, and
the set-up should be got approved by the Engineer.
901.3. The Contractor shall carry out quality control tests on the
materials and work to the frequency stipulated in subsequent paragraphs.
In the absence of clear indications about method and or frequency of tests
for any item, the instructions of the Engineer shall be followed.
901.4. For satisfyinghimselfaboutthe quality ofthe materials and work,
quality control tests will also be conducted by the Engineer (by himself,by
his Quality Control Units or by any other agencies deemed fit by him),
generally to the frequency set forth herein under. Additional tests may also
be conducted where,in the opinion of the Engineer,need forsuch tests exists.
901.5. The Contractor shall provide necessary co-operation and
assistance in obtaining the samples for tests and carrying out the field tests
as requiredby the Engineer from time to time. This may include provision
of labour, attendants, assistance in packing and despatching and any other
assistance considered necessary in connection with the tests.
901.6. For the work of embankment, subgrade an&pavement, construc-
tion ofsubsequent layerofsame or othermaterial over thefinished layer shall
be done after obtaiiiing permission from the Engineer. Similar permission
from the Engineer shall be obtained in respect of all other items of works
prior to proceeding with the next stage of construction.
901.7. The Contractor shall carry out modifications in the procedure of
work, if found necessary, as directed by the Engineer during inspection,
Works falling short of quality shall be rectified/redone by the Contractor at
his own cost, and defective work shall also be removedfrom the site ofworks
by the Contractor at his own cost.
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Section 900 Quality Control for Road Works
901.8. The cost of laboratory building including services, essential

supplies like water, electricity, sanitary services and their maintenance
and cost of all equipment, tools, materials, labour and incidentals to perform
tests and other operations of quality control according to the Specification
requirements shall be deemed to be incidental to the work and no extra
payment shall be made for the same. If, however, there is a separate item
in the Bill of Quantities for setting up of a laboratory and installing testing
equipment, such work shall be paid for separately.
901.9: For testing of samples of soils/soil mixes, granular materials, and
mixes, bituminous materials and mixes, aggregates, cores etc., samples in
the required quantity and form shall be supplied to the Engineer by the
Contractor at his own cost.
901.10. For cement, bitumen, mild steel, and similar other materials
where essential tests are to be carried out at the manufacturer’s plants or
atlaboratories other than the site laboratory, the cost of samples, sampling,
testing and furnishing of test certificates shall be borne by the Contractor.
He shall also furnish the test certificates to the Engineer.
901.11. For testing of cement concrete at site during construction,
arrangements for supply of samples, sampling, testing and supply of test
results shall be made by ttte Contractor as per the frequency and number of
tests specified in the Handbook of Quality Control for Construction of
Roads and Runways (IRC: SP: 11) and relevant IS Codes or relevant clauses
of these Specifications, the cost of which shall be borne by the Contractor.
901.12, The method of sampling and testing of materials shall be as
required by the “Handbook ofQuality Control for Construction of Roads and
Runways” (IRC SP: 11), and these MOST Specifitations. Where they are
contradicting, the provision in these Specifications shall be followed.
Where they are silent, sound engineering practices shall be adopted. The
sampling and testing procedure to be used shall be aS approved by the
Engineer and his decision shall be final and binding on the Contractor.
901.13. The materials for embankment construction shall be got
approved from the Engineer. The responsibility for arranging and obtaining
the land for borrowing or exploitation in any other way shall rest with the
Contractor who shall ensure smooth and uninterrupted supply ofmaterials
in the required quantity during the construction period.
Similarly, the supply of aggregates for.construction of mad pavement
shall be from quarries approved by the Engineer. Responsibility for
arranging uniterrupted supply of materials from the source shall be that of the
Contractor.
300
<<
901.14. Defective Materials

All materials which the Engineer/his representative has determined
as not conforming to the requirements of the Contract shall be rejected
whether in place or not; they shall be removed immediately from the site as
directed. Materials, which have been subsequently corrected, shall not be
used in the work unless approval is accorded in writing by the Engineer.
Upon failure of the Contractor to comply with any order of the Engineer/his
representative, given under this Clause, theEngineer/his representative shall
have authority to cause the removal of rejected material and to deduct the
removal cost thereof from any payments due to the Contractor,
901.15. Imported Materials
At the time of submission of tenders, the Contractor shall furnish a
list of materials/finished products manufactured, produced or fabricated
outside India which he proposes to use in the work. The Contractor shall not
be entitled to extension of time for acts or events occurring outside India
and it shall be the Contractor’sresponsibility to make timely delivery to
the job site of all such materials obtained from outside India.
The materials imported from outside India shall conform to the relevant
Specifications of the Contract. In case where materials!finished products
are not covered by the Specifications in the Contract, the details of
Specifications proposed to be followed and the testing procedure as well as
laboratories! establishments where tests are to be carried out shall be
specifically brought out and agreed to in the Contract.
The Contractor shall furnish to the Engineer a certificate of compliance
ofthe tests carried out. Inaddition, certified mill test reports clearly identified
to the lot ofmaterials shall be furnished at the Contractor’s cost.
902. CONTROL OF ALIGNMENT, LEVEL AND SURFACE
REGULARITY
9011. General
All works performed shall conform to the lines, grades, cross sections
and dimensions shown on the drawings or as directed by the Engineer,
subject to the permitted tolerances described herein-after.
902.2. Horizontal Alignment
Horizontal alignments shallbe reckoned with respect to the centre line
of the carriagewayas shown on the drawings. The edges of the carriageway
asconstructed shall be correct within a tolerance of±10 mm therefrom. The
<< 301
corresponding tolerance for edges of the roadway and lower layers of

pavement shall be ±25 mm.
902.3. Surface Levels
The levels of the subgrade and different pavement courses as
constructed, shall not vary from those calculated with reference to the
longitudinal and cross-profile of the road shown on the drawings or as
directed by the Engineer beyond the tolerances mentioned in Table 900-i.
TABLE 900.1. TOLERANCES IN SURFACE LEVELS
I. Subgrade +20mm
-25 mm
2. Sub-base + 10mm
(a) Flexible pavement - 20mm
(b) Concrete pavement +6 mm
IDry lean concrete or Rolled concretel - 10mm
3. Base-course for flexible pavement

(a) Bituminous course +6 mm
- 6mm
(1,) Other than bituminous + 10mm

(i) Machine laid .10mm
+ l5rnxn
(ii) Manually laid - 15mm
4. Wearing course for flexible pavement

(a) Machine laid +6mm
-6mm
(I,) Manually laid + 10mm
- 10mm
5. Cement concrete pavement +5 mm

-6mm ~
~ Thit may not ex,,ceed -8mm at 0. 30cm from the edges.

Provided, however, that the negative tolerance for wearing course
shall not be permitted in conjunction with the positive tolerance forbase
course, if the thickness of the former is therebyreduced by more than 6 mm
for flexible pavements and 5 mm for concrete pavements.
For checking compliance with the above requirement for subgrade, sub-
base and base courses, measurements of the surface levels shall be taken on
a grid of points placed at 6.25 m longitudinally and 3.5 m transversely.For
any 10 consecutive measurements taken longitudinally or transversly, not
more than one measurement shall be permitted to exceed the tolerance as
above, this one measurement being not in excess of 5 mm above the
302
<<
permitted tolerance.
For checking the compliance with the above requirement for
bituminous wearing courses and concrete pavements, measurements of the
surface levels shall be taken on a grid of point~spaced at 6.25 m along the
length and at 0.5 m from the edges and atthe ceèure of the pavement. In any
length of pavement, compliance shall be deemed to be met for the final road
surface, only if the tolerance given above is satisfied for any point on the
surface.
902.4. Surface Regularity of Pavemer’ Courses
The longitudinal profile shall be checked with a 3 metre long straight
edge/moving straight-edge as desired by the Engineer at the middle of each
traffic lane along a line parallel to the centre line of the road.
The maximum permitted number of surface irregularities shall be as per
Table 900-2.
TABLE 900.2. MAXIMUM PERMIITEI) NUMBER OF SURFACE
IRREGULARITIES
Surfaces of Surfaces of laybys, service

carriageways areas and all bitumInous base
and paved courses
shoulders ~
1rre~’isrity 4mm 7mm 4mm 7mm
Length(m) 300 75 300 75 300 75 300 75
National Highways/
Expressways’ 20 9 2 1 40 18 4 2
Roads of lower
category’ 40 18 4 2 60 27 6 3
‘Category of each section of road as described in the Contract

The maxirnurn allowable difference between the road surface and
underside of a 3 m straight-edge whenplacedparallelwith, or at right angles
to the centre line of the road at points decided by the Engineer shall be:
for pavement si1tface (bituminous and cement concrete) 3 mm
forbituminous base courses 6 mm
for granular sub-base/base courses 8 mm
for sub-bases under concrete pavements 10 mm
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I - -

902.5. Rectification
Where the surface regularity of subgrade and the various pavement
courses fall outside the specified tolerances, the Contractor shall be liable
to rectify these in the manner described below and to the satisfacion of
the Engineer.
(I) Subgradet Where the surface is high, it shall be trimmed and suitably compacted.
Wherethe same is low, the deficiency shall be corrected by scarifying the lower layer
and adding fresh material and recompacsing to the required density÷The degree of
compaction and the type of material to be used shall conform to the requirements
of Clause 305.
(ii) Granular Sub-base: Same as at (i)above, except that the degree of compaction and
the type ofmaterial to be used shall conform to the requirements of Clause 401.
(iii) Lime/Cement Stabilized Soil Subbase: For lime/cement treated materials where
the surface is high, the same shall be suitably trimmed while taking care that the
material below is notdisturbed due to this operation. However, where the surface
is low, the same shall be corrected as described herein below.
For cement treated material • when the time elapsed between detection of irregularity
and the time of mixing of the material is less than 2 hours, the surface shall be
scarified to a depth of 50 mm supplemented with freshly mixed materials as
necessary and recompacted to the relevant specification. When this time is more
than 2 hours, the full depth of the layer shall be removed from the pavement and
replaced with fresh material toSpecification This shall alan apply to lime treated
material except that the time criterion shall be 3 hours instead of 2 hours.
(lv) Water Bound Macadam/Wet MIx Macadam Sub.baseiBase: Where the surface
is high or low, the top 75 mm shall be scarified, reshaped with added material as
necessary and recompacted to Clause 404. This shall also apply to wet mix macadam
to Clause 406.
(v) Bituminous Constructions: Forbituminous constructionother than wearing course,
where the surface is low, thedeficiency shall be corrected by adding fyesh material
over a suitable tack coat if needed and recompacting to specifications. Where the
surface ishigh, the full depth of the layer shall be removed and replaced with fresh
material and compacted to specifications.
For wearing course, where the surface is high or low, the full depth of the layer shall
be removed and replaced with fresh material and compacted to specifications. In all
cases where the removal and replacementof a bituminous layer is involved, the area
treated shall not be less than 5 m in length and not less thari 35 m in width
(vi) Dry Lean Concrete Sub.base/Rolled Cement Concrete: The defective length of
the course shall be removed to full depth and replaced with material conforming to
Clauses 601 or 603, as applicable. ‘the area treated shall be at least 3m long, not less
than I lane wide and extend tothe full depth. Beforerelaying the course, the disturbed
subgrade or layer below shall be corrected by levelling, watering and compacting.
(vll) Cement concrete pavement: The defective areas having surface irregularity
exceeding 3 mm but not greater than 6 mm may be. rectified by bump cutting or
scrabbling or grinding using approved equipment. When required by the Engineer
areas which have been reduced in level by the above operation(s) shall be retextured
<< 304
Quality Contml for Road Works Section 900
in an approved manner either by cutting groove~( 5 mm deep) or roughening the

surface by hacking the surface. If high areas in excess 6mm or low areas in excess
of 3 mm occur, exceeding the permitted numbers and ifthe Contractor carusot rectify,
the slab shall be demolished and reconstructed at the Contractor’s expense and
innocasethearearemoved shalibe less than thefullwidthofthe lane in ~iiich the
irregularity occurs and full length of the slab
If deemed necessary by the Engineer, any section of the slab which deviates from
the specified levels asd tolerances shall be demolished and reconstructed ax the
Contractor’s expense,
903, QUALITY CONTROL TESTS DURING CONSTRUCTION

903.1, General
The materials supplied and the works carried Out by the Contractor
shall conform to the specifications prescribed in the preceding Clauses.
For ensuring the requisite quality of construction, the materials and
works shall be subjected to quality control tests, as described hereinafter.
The testing frequencies set forth are the desirable minimum and the
Engineer shall have the full authority to carry out additional tests as
frequently as he may deem necessary, to satisfy himself that the materials
and works comply with the appropriate specifications. However, the
number of tests recommended in Tables 900-3 and 900-4 may be reduced
at the discretion of the Engineer if it is felt that consistency in the quality
of materials can still be maintained with the reduced number of tests.
Test procedures for the various quality control tests are indicated in
the respective Sections of these Specifications or for certain tests within this
Section. Where no specific testing procedure is mentioned, the tests shall be
carried out as per the prevalent accepted engineering practice to the
directions of the Engineer.
903.2. Tests on Earthwork for Embankment, Subgrade Construc-
tion and Cut Formation
903.2.1, Borrow material Grid the borrow area at 25 m c/c (or
closer, if the variability is high) to full depth ofproposed working. These. pits
should be logged and plotted for proper identification of suitable sources of
material. The following tests on representative samples shall be carried out:
(a) Sand Content [IS: 2720 (Part-4)J: 2 tests per 3000 cubic metres of soil.
(b) Plasticity Test uS: 2720 (Part’5)J: Each type to be tested,2tests per3000 cub. metres
of soil.
(c) Density Test [IS:2720 (Part S)l: Each soil type to be tested, 2 tests per 3000 cubic
metres of soil.
(d) Deleterious Content Test [IS:2720 (Part—27)): As and when required by the
Engineer.
<< 305
(e) Moisture Content Test (IS :2720 (Pa*2)l: One test for every 250 cubic metres of
soil.
(I) CBR Teston materials to be incorporated In the sub~radeon soaked/unsoaked
samples uS : 2720 (Part.16)]: one CBR test for every 3000 cu. m. atleast or closer
as and when required by the Engineer.
903.2.2. Compaction Control: Control shall be exercisedon each layer

by taking at least one measurement ofdensity for each 1000 square metres
ofcompacted area, or closeras required to yield the minimum number of test
results for evaluating a day’s work on statistical basis. The determination
of density shall be in accordance with IS: 2720 (Part-28). Test locations shall
be chosen only through random sampling techniques. Control shall not be
based on the result of any one test but on the mean value of a set of
5-10 density determinations. The number oftests in one set of measurements
shall be 6 (if non-destructive tests are carried out, the number of tests shall
be doubled) as long as it is felt that sufficient control over borrow material
and the method of compaction is being exercised. Ifconsiderable variations
are observed between individual density results, the minimum number of
tests in one set of measurement shall be increased to 10. The acceptance
criteria shall be subject to the condition that themean density is not less than
the specified density plus:
[11.65 —
1.65 1 times the standard deviation.
[ (No. of samples)°~j
However, for earthwork in shoulders (earthen) and in the subgrade,
at leastone density measuz~ementshall be taken for every 500 square metres
for the compacted area provided further that the number oftests in each set
ofmeasurements shall be atleast 10. In other respects, the control shall be
similar to that described earlier.
903.2,3. Cut formation : Tests for the density requirements of cut
formation shall be carried out in accordance with Clause 903.2.2.
903.3. Tests on Sub-bases and Bases (excluding bitumen bound
bases)
The tests and their frequencies for the different types ofbases and sub-
bases shall be as given in Table900-3. The evaluation of density results and
acceptance criteria for compaction control shall be on lines similar to those
set out in Clause 903.2.2.
903.3.1. Acceptance criteria: The acceptance criteriafor tests on the
strength of cement/lime stabilised soil and distribution of stabiliser content
shall be subject to the condition that the mean value is not less than the
<< 306
specified value plus:
1.65
1.65 — I times the standard deviation.
(No. of samples)°~j
TABLE 900.3. CONTROL TESTS AM) THEIR MINIMUM FREQUENCY FOR SUB.
BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)
SI. Type of Test Frequency (mm.)

No. Construction
I Granular 3
(i) Gradation One test per 200 m
One test per 200 m’
(ii) Atterberg limits One test per 250m2
(iii) Moisture content
prior to compaction
One test per 500 m2
(iv) Density of
compacted layer
As required
(v) Deleterious
constituents
As required
(vi) C.B.R.
One test for each
2. Lime/Cement (i) Quality of Iime/ consignment subject
Stabilised cement
to a minimum of one test
Soil Sub-base per 5 sonnes
(ii) Lime/Cement Regularly, through

content procedural checks
(iii) Degree of Periodically as

puiverisation considered necessarj
(iv) CBR or Unconfined As required

Compressive Strength
testona setof3
specimens
(v) Moisture content prior One test per 250 sq. m.

to compaction
(vi) Density of compacted One test per 500 in2
layer
(vii) Deleterious constituents As required
3. Water Bound (i) Aggregate Impact One test per 200 in1 of
Macadam Value aggregate
(ii) Grading One test per 100 m2
(iii) Flakiness Index One test per 200m’ of
and Elongation aggregate
Index
(iv) Atterberg limits One test per 25 in5 of
of binding material binding material
<< 307
Section 900 Quality Control far Road Works
SI. Type of Test Frequency (miss.)

No. Construction
(v) Auerberglimitsof Onelesiper

portion of aggregate 100 cubic metre
passing 425 micron of aggregate
sieve
4. Wet Mix Macadam (1) Aggregate impact One test per 200m’
Value of aggregate
(ii) Grading One testper 100 m’

of aggregate 3
(iii) Flakiness and One test per 200 m
of aggregate
Elongation Index One test per 100 m3
(iv) Atterberg limits of
of aggregate
portion of aggregate
passing 425 micron
sieve One test per 500 m2.
(v) Dthsity of compacted
layer,
903,4. Tests on Bituminous Constructions

903.4.!. The tests and their minimum frequencies for the differenttypes
of bituminous works shall be as given in Table 900-4.
903.4.2. Acceptance criteria : The acceptance criteria for tests on
density and Marshall stability shall be subject to the condition that the mean
value is not less than the specified value plus:
r1.65 --
1.65 1
times the standard deviation.
(No. of samples)°~j
TABLE 900-4. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR
BITUMINOUS WORKS
S. Type of Construction Test Frequency (minimum)

No.
I. Prime Coat/Tack Coat (i) Quality of binder Two samples per lot to be
subjected toall or some tests
as directed by theEngineer
(ii) Binder temperature At regular close intervals
for application
(iii) Rate of spread of Two tests per day
Binder
2. Seal Coat/Surface (I) Quality of binder Two samples per lot Dress-
Dressing ingto be subjected to all or
308
<<
S. Type ofConstruction Test Frequency (Minimum)

No.
some tests as directed by

the Engineer
5 of
(ii) Aggregate Impact One test per 50 m
aggregate
Value *
-do-
(iii) Flakiness Index
and Elongation Index
Initially one set of 3
(iv) Stripping value of
representative specimens
aggregates for each source of supply.
Subsequently when war-
ranted by changes ‘in the
quality of aggregates
-do-
(v) Watcrabsorptionof
aggregates
One testper25m’oI aggre-
(vi) Grading of aggregates
gate
As required
(vii) Stone polishing value At regular close intervals
(viii) Temperatureof
binder as application
One test per 500m2 of
(jx) Rate of spread of
work
materials
3. Open-graded Premix (i) Quality of binder Two samples per lot to be
Carpet/Mix-Seal subjected to all or some
Surfacing tealsas directed by Engineer
(ii) Aggregate Impact One test perSO m’ of
Value aggregate
(iii) flakiness Index and -do-
Elongation Index of
aggregates
(iv) Stripping value Same as mentioned under
Serial No.2
(v) Water absosplion of Sameas mentioned under
aggregates Serial No.2 -
(vi) Grading ofaggregates One test per 25 m5 of aggre-
gates
(vii) Stone polishing value As required
(viii) Temperature of At regular close intervals
binder at application
(ix) Binder content Two tests perday
(x) Rate of spread of Regular control through
mixed material checks on materials and
layer thickness
Bituminous Macadam (I) Quality of binder Two samples per lot to be

subjectedto all or some tests
as directed by the Engineer
<< 309
S. Type of Construction Test Frespsency (Minimum)

No.
3 of
(ii) Aggregate Impact One test per 50 m
aggregate
Value -do--
(iii) Flakiness index and
Elongation index of
aggregates Same as mentioned under
(iv) Stripping value
Serial No. 2
(v) Grading of aggregates teats per day per plant
both on the individuai con-
stituents and mixed aggre-
gates from the dryer
Same as in Serial No. 2
(vi) Water absorption of
aggregates
Periodic, subject to mini-
(vii) Binder content mum oftwo tests per day per
plant
At regular close intervals
(viii) Control oftemperature
ofbinder and aggregate
for mixing and ofthe
mix at the time of
laying and rolling Regular control through
(ix) Rate of spread of
checks of layerthickness
mixed material
5. Bituminous (i) Quality ofbinder Two samples per lot to be
Penetration Macadarn/ subjectedto all orsome tests
Built-up Spray-Grout as directed by the Engineer.
(ii) Aggregate Impact Value One test per ZOOm’ of
aggregate
(iii) Flakiness Index and —do-
Elongation Index
(iv) Stripping value Same as mentioned under
Serial No 2
(v) Water absorption of Sameas in Serial No.2
aggregates
(vi) Aggregate grading Onetestper lOOm’ ofaggre-
gate
(vii) Temperature of binder At regular close intervals
at application
(viii) Rateofipreadof One test per 500 m’ of area
binder
6. Dense Bituminous (i) Quality ofbinder Two samples per lot to be

Macadam/Semi Dense subjected to all or some
Bituminous Concrete! tests as directed by the
Bituminous Concrete Engineer
(ii) Aggregate Impact Value One testper 50 m’ of
aggregate
310
<<
S. Type of Construction Test Frequency (Minimum)
No,
(iii) Flakiness Index and —do-

Elongation Index of
aggregates
(iv) Stripping Value As in Serial No.2
(v) Water absorption of As in Serial No. 2
aggregates
(vi) Sand equivalent test As required
(vii) Stone Polishing Value As required, for Semi Dense
Bituminous Concrete/Bitu-
minous Concrete
(viii) Mix grading One set of tests on individ-
ual constituents and mixed
aggregate from the dryer for
each 400 tonnes of mix
subject to a minimum of
two tests per plant per day
(ix) Stability ofMix For each 400 tonnes ofmix
peoduced,asetof 3 Marshall
specimens to be prepared
andtessed forstability, flow
value, density and void
content subject to a mini-
mum oftwo sets beingtested
per plant per day
(a) Water sensitivity of As required for Bituminous
mix (i~etentionof Concrete
Marshall Stability)
(xi) Swell tell on the mix -do.
(xli) Control of temperature At regular close intervals
of binder in boiler,
aggregate in the dryer
and mix at the time of
laying and rolling
(xiii) Control ofbinder One test for each 400
content and gradation tonnes of mix subject to a
in the mix minimum of two tests per
day perplant
(xiv) Rate of spread of Regular control and
mixed material through checks on the
weight of mixed material
and layer thickness
(xv) Density of compacted One test per 250 m~area
layer
<< 311
903.5. Quality Control Tests for Concrete Road Construction

903.5.1. Dry lean concrete sub-base:
903.5.1.1. Sampling and testing of cubes: Samples of dry lean
concrete for making cubes shall be laken from the uncompacted material
from different locations immediately before compaction at the rate of 3
samples for each 1000 sq. m. or part thereof laid each day. The sampling
of mix shall be done from the paving site.
Test cubes of 150mm size shall be made immediately from each mix
sample.
Cubes shall be made in accordance with the methods described in 15:516
except that the cubes shall be compacted by means of a vibratory hammer
with the motilds placed on a level and rigid base. The vibrating hammer shall
be electric or pneumatic type fitted with a square or rectangular foot having
an area ofbetween 7500 to 14000 sq.mm. The compaction shall be uniformly
applied for 60 ±5 seconds with a downward force ofbetween 300 Nand 400
N on to each of the three layers of the lean concrete material placed into the
mould. The surface of each compacted layer shall be scarifiedbefore the
next layer is added to give key for the next layer. The final layer shall be
finished flush with the top of the cube mould.
The dry lean concrete cubes shall be cured in accordance with IS:5 16.
903.5.1.2. In-situ density: The dry density of the laid material shall be
determined from three density holes at locations equally spaced along a
diagonal that bisects each 2000 square metre or part thereof laid each day
and shall comply with the requirements as per Clause601.5.5.1. This rate of
testing may be increased at the discretion of the Engineer in case ofdoubt or
to determine the extent of defective area in the event of non-compliance.
Density holes at random may be made to check the density at edges.
903.5.13. Thickness: The average thickness of the subbase layer as
computed by the level data ofsub-base and subgrade or lower sub-base shall
be as per the thickness specified in the contract drawings. The thickness at
any single location shall not be 10mm less than the specified thickness. Such
areas shall be correctedas stated in Clause 601.5.5.5. Areas which cannot be
repaired should be replaced over full width. The extent of deficient area
should be decided based on cores.
903.5.1.4. Frequency of quality control tests: The frequency of
quality control tests for levels, alignment and materials shall be as in Table
900-6.
<< 312
903.5.2. Pavement concrete

903.5.2.1. Samplingand testing ofbeam and cube specimens: Atleast
two beam and two cube specimens, oneeach for7 day and 28 day strength
testing shall be cast for ever 150 cu.m (or part thereof) of concrete placed
during construction. On each day’s work, not less than three pairs of beams
and cubes shall be made for each type ofmix from the concrete delivered to
the paving plant. Each pair shall be from a differentdelivery ofconcrete and
tested at a place to he designated by the Engineer in accordance with the
testing procedure as outlined in Clause 602.3.3. Groups of four consecutive
results from single specimens tested at28 days shall be used for assessing
the strength for compliance with the strength requirements. The specimens
shall be transported in an approved manner to prevent sudden impact
causing fractures or damage to the specimen.The flexural strength testresults
shall prevail over compressive strength tests for compliance.
A quality control chart indicating the strength values of individual
specimens shall be maintained for continuous quality assurance. Where
the requirements are not met with, or where the quality of the concrete
or its compaction is suspect, the actual strength of the concrete in the slab
shall be ascertained by carrying Out tests on cores cut from the hardened
concrete at such locations. The cores shall be cut at the rate of 2 cores for
every 150 cu. m. of concrete. The results of crushingstrength tests on these
cores shall not be less than 0.8 times the corresponding crushing strength of
cubes, where the height to diameter ratio of the core is twO. Where height to
diameter ratio is varied, then the necessary corrections shall be made in
calculating the crushing strength of cubes in the following manner.
The crushing strengths of cylinders with height to diameter ratios
between 1 and 2 may be corrected to correspond to a standard cylinder of
height to diameter ratio of 2 by multiplying with the correction factor
obtained from the following equation:
f= 0.lln+0.78
where f = correction factor and
n = height to diameter ratio
The correctedtest results shall be analysed forconformity with the speci-
fication requirements for cube samples. Wherethe core tests are satisfactory,
they shall have precedence for assessing concrete quality over the results of
moulded specimens. The diameter of cores shall not be less than 150 mm.
If, however, the tests on cores also confirm that the concrete is not
satisfying the strength requirements, then the concrete corresponding to
<< 313
the area from which the cores were cut should be replaced,i.e., atleast over
an area extending between two transverse joints where the defects could be
isolated or over larger areas, if necessary, as assessed by additional cores
and their test results. The equivalent flexural strength at 28 days shall be
estimated in accordance with Clause 602.3.3.2,
In order to ensure that the specified minimum strength at 28 days is
attained in 99 per cent of all test beams, the mix shall be proportioned
to give an average strength at28 days exceeding the specified strength by
2.33 times the standard deviation calculated first from the flexural strengths
of test beams made from the trial mix and subsequently from the accumu-
lating result of flexural strengths of job control test beams.
The standard deviation shall be re-calculated from the test results
obtained after any change in the source or quality of materials and the
mix shall be adjusted as necessary to comply with the requirements.
An individual 28 day test strength below thespecified strength shall not
be evidence for condemnation of the concrete concerned ifthe average 28
day strength of this beam plus the preceding 5 and succeeding 4 beams
exceeds the specified strength by 2.33 times the standard deviation and
provided that there is no other evidence that the concrete mix concerned is
substandard.
Beams shalibemade each dayin pairs at intervals, each pairbeing from
a different batch of concrete. At the start of the work, and until such time
as the Engineer may order a reduction in the number of beams required, at
least six pairs of beams and cubes shall be made each day, one of each pair
for testing at 28 days for determination of ifle minimum permissible
flexural strength and the other for testing at an early age for the Engineer
to assess the quality ofthe mix. When the firstthirty numberof28-day results
are available, and for so long as the Engineer is satisfied with the quality
of the mix, he may reduce the number of beams and cubes required.
During the course ~f construction, when the source of any material
is to be changed, or if there is any variation in the quality of the materials
furnished,additional tests and necessary adjustments in the mix shall be made
as required to obtaIn the specified strength.
The flexural strengths obtained on beams testedbefore28 days shall be
used in conjunction with a correlation between them and th~28 day flexural
strengths to detect any deterioration in the quality of the concrete being
produced. Any such deterioration shall be remedied without awaiting the
28 day strengths but the earlier strengths shailnot constitute sole evidence
<< 314
Quality Control for Read Works Section 900
of non-compliance of the concrete from which they were taken.

Concrete shall not comply with the Specification when more than one
test beam in a batch has a 28 day strength less than the specified strength and
the average 28 day flex ural strength of the batch of beams is less than the
specified strength plus 2.33 times the standard deviation of the batch.
Should the c~ncretefail to pass the Specification for strength as
described above, the Contractor may, all at his own expense, elect to cut
cores from the suspect concrete as the Engineer shall direct. From the
relation between cube strength and flexural strength, the core strength shall
be converted to flexural strength.
The equivalent flexural strength at 28 days shall be the estimated
insitu strength multiplied by 100 and divided by the age-strength relation
obtained from Table 900-5.
Any concrete that fails to meet the strength specification shall be
removed and replaced at Contractor’s expense.
TABLE 900.5. AGE- STREr’~GTHRELATION OF CONCRETE
(RELATED TO 100 PER (TENT AT 28 DAYS)
DAYS 0 2 4 6 8
0 . 41.0 60.0 71.0 77.5

10 81.5 85.0 87.5 90.0 92.0
20 94.0 96.0 97.5 98.5 100.0
30 101.0 102.0 103.5 1043 105.5
40 106.5 107.0 108.0 1093 110.0
50 110.5 111.0 112.0 1125 113.0
60 114.0 1143 115.0 115.5 116.0
70 116.5 117,0 1173 118.0 118.5
80 119.0 1193 1193 120.0 120.5
90 121,0 121.5 122.0 122.0 122.5
100 123.5 1233 123.5 124.0 124.5
110 125.0 125.0 1253 1253 126.0
120 126.0 1263 127.0 127.0 1273
130 127.5 128.0 128.5 1283 129.0
140 129.0 1293 1293 130.0 130.0
150 130.5 1303 131.0 131.0 131.5
160 131.5 1313 132.0 132.0 132.5
170 1323 132$ 133.0 133.0 1333
180 1333 134.0 134.0 1343 134.5
190 135.0 135.0 135.0 135.5 135,5
200 135.5 1353 136.0 136.0 136.5
<< 315
I-a-a----—.
210 136.5 136.5 137.0 137.0 137.0

220 137.0 1373 137.5 1373 138.0
230 138.0 138$ 138.5 138.5 138.5
240 139.0 139.0 139.0 139.5 139.5
250 139.5 140.0 140.0 140.0 140.0
260 140.5 1403 140.5 140.5 141.0
270 141.0 141.0 141.5 141$ 141.5
280 142.0 142.0 142.0 142.0 142.0
290 142.5 142.5 142.5 142.5 142.5
3(X) 143.0 143.0 143.0 !43.0 143.5
310 143.5 1433 144.0 144.0 144.0
320 144.0 144.5 144.5 144.5 144.5
330 144.5 145.0 145.0 145.0 145.0
340 145.0 1453 145.5 145.5 145.5
350 146.0 146.0 146.0 146.0 146.0
360 146.0 146.0 146.5 146.5 146.5
903.5.2.2. In-situ density The density of the compacted concrete

shall be such that the total air voids are not more than 3 per cent. The air
voids shall be derived from the difference between the theoretical
maximum dry density of the concrete calculated from the specific gravities
of the constituents ofthe concrete mix and the average value of three direct
density measurements made on cores at least 150mm diameter. Three cores
shall be taken from trial lengths and in first two km length of the pavement,
while the slab isbeing constructed during normal working. The proportions
of the mix and the vibratory effortimparted i.e the frequency and magnitude
of vibration shall be adjusted to achieve the maximum density.
All cores taken for density measurement in the trial section shall also
be checked for thickness. The same cores shall be made use of for determin-
ing in-situ strength. In case of doubt, ftdditional cores may be ordered by the
Engineer and taken at locations decided by him to check the density of
concrete slab or the position of doweljtie bars without any compensation
being paidfor the same.
In calculating the density, allowance shall be made for any steel in
cores.
Cores removed from the main carriageway shall be reinstated with com-
pacted concrete with mix proportions of 1 partof portland cement: 2 parts
of fine aggregate : 2 parts of 10 mm nominal size single sized coarse
aggregate by weight. Before filling the fine mix, the sides shall be hacked
and cleaned with water. Thereafter cement-sand slurry shall be applied to
the sides just prior to filling the concrete mix.
316
<<
903.5.23. Thickness: Thickness shall be controlled by taking levels as

indicated in Clause 902.3. Thickness of the slab at any point checked as
mentioned above shall be within a tolerance of -5 mm to + 25 mm of the
specified thickness as per Drawing. Thickness deficiency more than 5 mm
may be accepted and paid for ata reduced rate given in Clause 602,15.2. In
no case, however, thicknessdeficiency shall be more than 25 mm.
903.5.2.4. Summary of control tests : Table 900-6 gives a summary of
frequency of testing of pavement quality concrete.
TABLE 900.6 . FREQUENCY OF QUALITY CONTROL TESTS FOR
PAVING QUALITY CONCRETE
1. Levels, alIgnment and texture
(i) Level tolerance Clause 902.3

(ii) Widthof pavement and position of Clause 902.2.
paving edges
(iii) Pavement thickness Clauses 902.3 and 903,5.2.3
(iv) Alignment ofjoints, widths, To be checked c~tone Joint
depths of dowel grooves per 400 m length or a day’s
work whichever is more.
(v) Surface regularity both Once a day orone day’s
transversely and longitudinally work, without disturbing
the curing operation.
(vi) Alignment of dowel bars and To be checked in trial length
their accuracy~tiebars as per Clause 64)2.10.5.2
and once on every 2 km.
(vii) Texture depth Clause602.9,8
2. Quality of Materials and Concrete
Control tests for materials and concrete shall be as under:
Cement Physical and chemical IS: 269 Once for each source of
tests IS: 455 supply and occasionally
IS : 1489 when called for in case
IS : 8112 ~oftongiirnproper storage.
IS : 12269 B~sides,the Contractor also
will submit daily test data on
cement released by the
Manufactwer.
2. Coarse and (i) Gradation IS: 2386 One zest for every day’s
Fine (Pt 1) work of each fraction of
aggregates coarse aggregate and fine
aggregate. initially; may be
relaxed later at the discre-
tion of the engineer.
(ii) Deleterious IS: 2386 -do-
constituents (Pt. 2)
317
<<
(iii) Water absoiption IS:2386 Regularly as required

(Pt. 3) subjectto a minimum of one
zest a day for coarse aggre.
gale & two tests a day for
frne aggregate. This data
shall be used for correcting
the waterdemand ofthe mix
on daily basis.
3. Coarse (i) Los Angeles Abrasion IS:2 386 Once foreach source of
Aggregate value or Aggregate (Pt.4) supply and subsequently
Impact test on monthly basis.
(ii) Soundness lS:2386 Before approving the
(Pt5) aggregates and every month
subsequently
(iii) Alkali aggregate IS:2386 -do-
reactivity (Pt.7)
4. Water Chemical Tests lS:456 Once for approval of source
of supply, subsequently only
in case of doubt.
5. Concrete (i) Strength of lS:516 2cubes and2beams per
concrete 150 in’ or part thereof (one
forlday tnd other for 28 day
strength) or minimum 6
cubes and 6 beams per day’s
work whichever is more.
(ii) Core strength on IS:5l6 As per the requirement of
hardened concrete the Engtheer~ only in case of
doubt,
(iii) Workability of fresh IS:1199 One teat per each dumper
concrete.Slump Test load at both Batching plant
site and paving site initially
wheat work starts. Subte-
quendy sampling may be
done from alternate dumper.
(iv) Thickness determination From the level data of con~
crete pavement surface and
sub-base at grid points of 5/
6.25mx33m
(v) Thickness measurement 3 cores per trial
for trial length length.
(vi) Verification of level of String line or steel forms
string line in the case of shall be checked for level at
slip form paving and steel an interval of 5.0 m or
forms in the case of fixed 6.25 m. The level tolerance
form paving allowed shall be ±2~nm.
These shallbc got approved
1.2 hours before the corn-
meatcement of the concret~
ing activity.
<< 318
903.5.3. Rolled Concrete Base

903.5.3.1. Sampling and testingofbeamsand cubes: Clause9O3.5.2, 1
shall apply
903.5.3.2. Thickness Thickness shall be controlled by taking levels
as indicated in Clause 903.5.1.3.
903.5.3.3. In-situ density : The dry density of the laid material shall be
determined from three density holes at locations equally spaced along a
diagonal that bisects each 2000 square metre or part thereof laid each dayand
shall comply with the requirements as per Clause 601.5.5.1. This rate of
testing may be increased atthe discretion of the Engineer in case of doubt or
to determine the extent of defective area in the event of non compliance.
Density holes at random may be made to check the density atedges.
903.5.3.4. Summary of control tests : Table 900-6 gives the summary
of tests for levels, alignment and materials.
903.5.4. Summary of rate of sampling and testing:
(i) Strength 3 beams and 3 cubes for each 100 sq. in. or pan thereof laid each day.
(ii) Density 3 density holes for each 2000 sq.m. or past thereof laid each day.
(iii) Cores : Only when Engineer instructs. They shall not be cut on regular basis.
A, relation between flexural strength and compressive strength may be

developed by regression analysis using the available data. This may be
updated from time to time.
<< 319
Materials for Structures
1000
Materials for Structures
<<
Materials for Structures Section 1000
100L GENERAL
Materials to be used in the work shall conform to the
specifications mentioned on the drawings, the requirements laid down
in this section and specifications for relevant items of work covered
under these specifications.
If any material, not covered in these specifications, is required to
be used in the work, it shall conform to relevant Indian Standards,
if there are any, or to the requirements specified by the Engineer.
1002. SOURCES OF MATERIAL
The Contractor shall notify the~Engineer of his proposed sources
of materials prior to delivery. If it is found after trial that sources
of supply previously approved do not produce uniform and satisfactory
products, or if the product from any other source proves unacceptable
at any time, the Contractor shall furnish acceptable material from other
sources at his own expense.
1003. BRICKS
Burnt clay bricks shall conform to the requirements of IS:l077,
except that the minimum compressive strength when tested flat shall
not be less than 8.4 MPa for individual bricks and 10.5 MPa for average
of 5 specimens. They shall be free from. cracks and flaws and nodules
of free lime. The brick shall have smooth rectangular faces with
sharp corners and emit a clear ringing sound when struck. The size
may be according to local practice with a tolerance of ±~ per cent.
1004. STONES
Stones shall be of the type specified. It shall be hard, sound, free
from cracks, decay and weathering and shall be freshly quarried
from an approved quarry. Stone with round surface shall not be used.
The stones, when immersed in water for 24 hours, shall not absorb
water by more than 5 per cent of their dry weight when tested
in accordance with IS:1 124.
The length of stones shall not exceed 3 times its height nor
shall they be less than twice its height plus one joint. No Stone shall
be less in width than the height and width on the base shall not
be greater. than three-fourth of the thickness of the wall nor less than
150 mm.
323
<<
Section 1000 Materials for Stnictures
1005. CAST IRON
Cast iron shall conform to IS:210. The grade number of the
material shall not be less than 14,
1006. CEMENT
Cement to be used in the works shall be any of the following
types with the prior approval of the Engineer
a) Ordinary Portland Cement, 33 Grade, conforming to IS~269.
b) Rapid Hardening Portland Cement, confonning to IS:8041.
c) Ordinary Portland Cement, 43 Grade, conforming to lS:81 12.
d) Ordinary Portland Cement, 53 Grade, confonning to IS:12269.
e) Sulphate Resistant Portland Cerneni, confomting to lS:12330.
Cement conforming to IS:269 shall be used only after ensuring
that the minimum required design strength can be achieved without
exceeding the maximum permissible cement content of 540 kg/cu.m. of
concrete.
Cement conforming to IS:8112 and IS:12269 may be used provided
the minimum cement content mentioned elsewhere from durability
considerations is not reduced. From strength considerations, these cements
shall be used with a certain caution as high early strengths of cement
in the 1 to 28-day range can be achieved by finer grinding and higher
constituent ratio of C3S/C2S, where C3S is Tricalcium Silicate and C2S
is Dicalcium Silicate. In such cements, the further growth of strength
beyond say 4 weeks may be much lower than that traditionally expected.
Therefore, further strength tests shall be carried out for 56 and 90 days
to fine tune the mix design from strength considerations.
Cement conforming to IS: 12330 shall be used when sodium sulphate
and magnesium sulphate are present in large enough concentration to
be aggressive to concrete. The recommended threshold values as per
IS:456 are sulphate concentration in excess of 0.2 per cent in soil sub-
strata or 300 ppm (0.O3per cent) in ground water. Tests to confirm actual
values of sulphate concentration are essential when the structure is
located near the sea coast, chemical factories, agricultural land using
chemical fertilizers and sites where there are effluent discharges or where
soluble sulphate bearing ground water level is high. Cement conforming
to IS: 12330 shall be carefully selected from strength considerations to
ensure that the minimum required design strength can be achieved
without exceeding the maximum permissible cement content of 540 kg/
cu.m. of concrete.
<< 324
Materials for Stmctures Section 1000
Cement conforming to IS:8041 shall be used only for precast

concrete products after specific approval of the Engineer.
Total chloride content in cement shall in no case exceed 0.05 per
cent by mass of cement. Also, total sulphur content calculated as sulphuric
anhydride (SO3) shall in no case exceed 2.5 per cent and 3.0 per cent
when tn-calcium aluminate per cent by mass is upto 5 or greater than
5 respectively.
1007. COARSE AGGREGATES
For plain and reinforced cement concrete (PCC and RCC)
or prestressed concrete (PSC) works, coarse aggregate shall consist of
stone, crushed gravel, natural gravel or a suitable combination thereof
or other approved inert material. They shall not consist pieces of
disintegrated stones, soft, flaky, elongated particles, salt, alkali,
vegetable matter or other deleterious materials in such quantities
as to reduce the strength and durability of the concrete, or to attack
the steel reinforcement. Coarse aggregate having positive alkali-
silica reaction shall not be used. All coarse aggregates shall conform
to IS:383 and tests for conformity shall be carried out as per IS:2386,
Parts I to VIII.
The contractor shall submit for the approval of the Engineer, the
entire information indicated in Appendix A of IS:383.
Maximum nominal size of coarse aggregate for various structural
components in FCC, RCC or PSC, shall conform to Section 1700.
The maximum value for flakiness index for coarse aggregate shall
not exceed 35 per cent. The coarse aggregate shall satisfy the following
requirements of grading
TABLE 1000-1 REQUIREMENTS OF COARSE AGGREGATE
IS Sieve Size Per rent by Weight Passing the Steve
40mm 20mm 12.5mm
63mm 100 — —
40mm 95-100 100 —
20 mm 30.70 95.100 100

12.5mm — — 90-100
10 mm 10-35 25.55 40.85
4.75mm 0-5 0-10 0-10
<< 325
Section 1000 Materials for Structures
1008. SANDIFINE AGGREGATES

For masonry work, sand shall conform to the requirements of
IS:21 16.
For plain and reinforced cement concrete (FCC and RCC)
or prestressed concrete (PSC) works, fine aggregate shall consist of clean,
hard, strong and durable pieces of crushed stone, crushed gravel, or
a suitable combination of natural sand, crushed stone or gravel. They
shall not contain dust, lumps, soft or flaky, materials, mica or other
deleterious materials in such quantities as to reduce the strength and
durability of the concrete, or to attack the embedded steel. Motorised
sand washing machines should be used to remove impurities from sand,
Fine aggregate having positive alkali-silica reaction shall not be
used. All fine aggregates shall conform to IS:383 and tests for conformity
shall be carried out as per IS:2386, (Pans I to VIII). The Contractor
shall submit to the Engineer the entire information indicated in Appendix
A of lS:383. The fineness modulus of fine aggregate shall neither
be less than 2.0 nor greater than 3.5.
Sand/fine aggregate for structural cOncrete shall conform to the fol-
lowing grading requirements
TABLE 1000-2
IS Sieve Size Per cent by Weight Passing the Sieve
Zone Zone II Zone Ill
10mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18 mm 30.70 55-90 75-100
600 uderon 15-34 35.59 60.79
300 micron 5-20 8-30 12.40
150 micron 0-10 0-10 0-10
1009. STEEL
1009.1. Cast Steel
The use of cast steel shall be limited to bearings and other similar
parts. Steel for castings shall conform to Grade 280-520N of IS: 1030.
In case where subsequent welding is unavoidable in the relevant cast
steel components, the letter N at the end of the grade designation of
the steel casting shall be replaced by letter W. 0.3 per cent to 0.5 per
cent copper may be added to increase the corrosion resistance properties.
<< 326
Materials for Stmctures Section 1000
1009.2. Steel for Prestressing

The prestressing steel shall conform to either of the following
(a) Plain hard drawn seel wire conforming to IS:1785 (Part I) and 1S~1785(Part II).
(b) Cold drawn indented wire conforming to 1S:~O03
(c) High tensile steel bar conforming to lS:2090
(d) (Jncoated stress relieved strands conforming to 1S:600t
10093. Reinforcement I Untensioned Steel
For plain and reinforced cement concrete (FCC and RCC) or
prestressed concrete (PSC) works, the reinforcement / untensioned steel
as the case may be shall consist of the following grades of reinforcing
bars.
TABLE 1008-3
Grade liar Type conforming Characteristic Elastic
Designation to governing IS Strength i’y MPa Modulus GPa
Specification
S 240 lS:432 Part 1 240 200
Mild Steel Bar
S 415 IS:1786 High Yield 415 200
Strength Deformed
Bars (HYSD) ~
Other grades of bars conforming to IS:432 and IS: 1786 shall not
he permitted.
All steel shall be procured from original producers, no re-rolled steel
shall be incorporated in the worL
Only new steel shall be delivered to the site. Every bar shall be
inspected before assembling on the work and defective, brittle or burnt
bar Shall be discarded. Cracked ends of bars shall be discarded.
Fusion-bonded epoxy coated reinforcing bars shall meet the require-
ments of IS: 13620. Additional requirements for the use of such reinforce-
ment bars have been given below
(a) Patch up materials shall be procured in sealed containers with certi(icates from
the agency who has supplied the fusion bonded epoxy bars.
(b) PVC costed 0.1. binding wires of 180 shall catiy be used in conjtutction with
fusion bonded epoxy bars.
(c) (lairs for supporting the reinforcement shall also be of fusion bonded epoxy
coated bars.
(d) The cut ends and damaged ponictes shall be touched up with repair patch up
material.
<< 327
(e) The bars shall be cut by saw-cutting rather than flame cutting.
(I) While bending the bars, the pins of work benches shall be provided with PVC
or plastic sleeves.
(g) The coated steel shall not be directly exposed to sun rays or rains and shall
be protected with opaque polyethelene sheets or such other approved materials
(Ii) While concreting, the woTkmen or trolleys shall not directly move on coated bars
but can move on wooden planks placed on the bars.
When specified in the contract, protective coating prescribed by
CECRI shalt be provided in conformance to specifications given in
Appendix /000/!, The CECRI coating process shall be allowed to be
implemented at the site of works provided a representative of the Institute
is present throughout the duration of the coating process who shall certify
that the materials and worimanship are in accordance with prescribed
specifications developed by the Institute.
1009.4. Grey Iron Castings
Grey Iron castings to be used for bearings shall have the following
minimum properties
(i) Minimum ultimate tensile strength 370 MPa
(ii) Modulus of Elasticity 147000 Ml’s
(iii) Brinell Hardness 230 Ml’s
(iv) Shear Strength 370 Ml’s
(v) Compressive Strength 1370 Ml’s
The testing shall be as specified in IS:210.
1009.5. Steel Forgings
Forged steel pins shall comply with clause 3, 3A or 4 of IS: 1875
and steel forgings shall comply with clause 3, 3A or 4 of IS:2004. Raw
materials of the forging will be taken as per IS:1875 with minimum
reduction ratio of 1.8:1. Alter atively, if forging is made from ingot,
a minimum reduction ratio between the ingot and forging will be 4:1.
Forging shall be normalised.
1009.6. Structural Steel
Unless otherwise permitted herein, all structural steel shall before
fabrication comply with the requirements of the following Indian
Standards:
IS:226 Structural Steel (Standard Quality)
1S~961 Structural Steel (High Tensile)
IS:2062 Weldable Structural Steel
IS:8500 Weldable Structural Steel (medium & high strength qualities)
<< 328
IS 1148 : Hot rolled rivet bars (0110 40mm dia) for structural purposes
IS:1 149 High tensile rivet bars for structural purposes
IS: 1161 Steel tubes for structural purposes
IS:4923 : Ilollow Steel sections for structural use
lS:1 1587 : Structural weather resistant steel
IS:808 Specifications, for Rolled Steel Beam, Channel and Angle Sections
IS:1239 : Mild Steel Tubes
IS:1730 : Dimension for Steel Plate, sheet and strip for structural and general
engineering purposes
IS: 1731 : Dimension for Steel flats for structural andgeneral engineeringpurposes
IS: 1732 : Dimension for round and square steel bars for structural and general
engineering purposes
IS:1852 : Rolling and cutting tolerances for hot rolled steel products
The use of structural steel not covered by the above standards may
be permitted with the specific approval of the authority. Refer to Section
1900 for further details.
1009.7. Stalnless Steel
Stainless steel shall be austenitic chromium-nickel steel, possessing
rust, acid and heat resistant properties conforming to IS:6603 and IS:6911.
Mechanical properties/grade for such stainless steel shall be as specified
by the accepting authority, but in no case be inferior to mild steel.
Generally, stainless steel is available as per AISI grades. AISI 304 which
is equivalent to grade O4Crl8Ni 110 of IS:6911 satisfies the requirements
of mechanical properties of structural steel. Other grades of stainless steel
for specific purposes may be provided as per specific requirements. For
application in adverse/ corrosive environment, stainless steel shall
conform to AISI 316L or 02G17 Ni Mo2 of IS:6911.
1010. WATER
Water used for mixing and curing shall be clean and free from
injurious amounts of oils, acids, alkalis, salts, sugar, organic materials
or other substances that may be deleterious to concrete or steel. Potable
water is generally considered satisfactory for mixing concrete. Mixing
and curing with sea water shall not be permitted. As a guide, the following
concentrations represent the maximum permissible values
(a) To ncuüalise 200 ml sample of water, using phenolpthalein as an indicator, it
should not require more than 2 ml of 0.1 normal NsOH.
(b) To neutralise 200 ml sample of water, using methyl orange as art indicator, it
should not require more than 10 ml of 0.1 normal H~.
<< 329
-.-—-;-

(c) The permissible limits for solids shall be as follows when tested in accordance
with lS:3025
Permissible Limits (max)
Organic 200 mg/lit
Inorganic 3000 mg/lit
Sulphatcs (SO
4) 500 mg/lit
Chlorides (Cl) 500 mg/lit *
Suspended matter 2000 mg/lit
~ In case of structures of lengths 30m and below, the permissible limit of chlorides
may be increased upto 1000 mg/lit.
All samples of water (including potable water) shall be tested and suitable measures
taken where necessary to ensure conformity of the water so the requirements stated
berein.
(d) The pH value shall not be less than 6
1011. TIMBER
The timber used for structural purposes shall conform to IS:883,
1012. CONCRETE ADMIXTURES
1012.1. General
Admixtures are materials added to the concrete before or during
mixing with a view to modify one or more of the properties of concrete
in the plastic or hardened state.
Concrete admixtures are proprietary items of manufacture and shall
bc obtained only from established manufacturers with proven track record,
qttality assurance and full fledged laboratory facilities for the manufacture
and testing of concrete.
The contractor shall provide the following information concerning
each admixture after obtaining the same from the manufacturer
(a) Norsnal dosage and detrimental effects, if any, of under dosage and over dosage.
(b) The chemical names of the main ingredients in the admixtures.
(c) The chloride content, if any, expressed as a percentage by the weight of the
adsnixture.
(d) Values of dry material content, ash content and relative density of the admixture
which can be used for Uniformity Tests.
(e) Whether or not the admixture leads to the entertainment of air when used as per
the manufacturer’s recommended dosage, and if so to what extent.
(Q Where two’ or more admixturea are proposed to be used in any one mix,
confirmation as to their compatibility.
(g) There would be no increase in risk of corrosion of the reinforcement or other
embedments as a result of using the admixture.
<<
330
1012.2. Physical and Chemical Requirements
Admixtures shall conform to the requirements of IS:9103. In addition,
the following conditions shall be satisfied
(a) “Plasticisers” and “Super-Plasticisers” shall meet the requirements indicated for
“Water reducing Admixture”.
(h) Except where resistance to freezing and thawing and to disru11ive action of de.
icing salts is necessary, the air content of freshly mixed concrete in accordance
with the pressure method given in lS:1199 shall not be more than 2 per cent
higher than that of the corresponding control mix and in any case not more than
3 per cent of the test mix.
(c) The chloride content of the admixture shall not exceed 0.2 per cent when tested
in accordance with IS:6925. In addition, the maximum permissible limit of chloride
content of all the constituents as indicated in Section 1700 shall also be observed
(d) Uniformity tests on the admixtures are essential to compare qualitatively the com-
position of different samples taken from batch to batch or from the same batch
at different times.
The tests that shall be performed along with permissible variations in the same
are indicated below
- Dry Material Content to be within 3 per cent and 5 per cent of liquid and
solid admixtures respectively of the value stated by the manufacturer
- Ash content to be within 1 per cent of the value stated by the manufac-
turer.
Relative Density (for liquid admixtures) to be within 2 per cent of the value
stated by the manufacturer.
(e) All tests relating to the concretes admixtures shall be conducted periodically at
an independent laboratory and compared with the data given by the manufacturer
1013, REINFORCED CONCRETE PIPES
Reinforced concrete pipes for highway structures shall be of NP4
type conforming to the requirements of IS:458.
1014. STORAGE OF MATERIALS
1014.1. General
All materials may be stored at proper places so as to prevent their
deterioration or intrusion by foreign matter and to ensure their satisfactory
quality and fitness for the work. The storage space must also permit easy
inspection, removal and restorage of the materials. All such materials
even though stored in approved godawns/places, must be subjected to
acceptance test prior to their immediate use.
1014.2. Brick
Bricks shall not be dumped at site. They shall be stacked in regular
<<
tiers as they are unloaded, to minimise breakage and defacement. The

supply of bricks shall be available at site at any time. Bricks selected
for use in different situations shall be stacked separately.
1014.3. Aggregates
Aggregate stockpiles may be made on ground that is denuded of
vegetation, is hard and well drained. If necessary, the ground shall be
covered with 50 mm plank.
Coarse aggregates, unless otherwise agreed by the Engineer in
writing, shall be delivered to the site in separate sizes (2 sizes when
nominal size is 25 mm or less and 3 sizes when the nominal size is
32 mm or more). Aggregates placed directly on the ground shall not
be removed f~omthe stockpile within 30 cm of the ground until the
final cleaning up of the work, and then only the clean aggregate will
he petmitted to be used.
Jn the case of fine aggregates, these shall be deposited at the mixing
site not less than 8 hours before use and shall have been tested and
1014.4. Cement
Cement shall be transported, handled and stored on the site in such
a manner as to avoid deterioration or contamination. Cement shall be
stored above ground level in perfectly dry and water.tight sheds and shall
be stacked not more than eight bags high. Wherever bulk storage
containers are used their capacity should be sufficient to cater to the
requirement at site and should be cleaned at least once every 3 to 4
months.
Each consignment shall be stored separately so that it may be readily
identified and inspected and cement shall be used in the sequence in
which it is delivered at site. Any consignment or part of a consignment
of cement which had deteriorated in any way, during storage, shall not
be used in the works and shall be removed from the site by the Contractor
without charge to the Employer.
The Contractor shall prepare and maintain proper records on site in
respect of delivery, handling, storage and use of cement and these records
shall be available for inspection by the Engineer at all times.
The Contractor shall make a monthly return to the Engineer on the
date corresponding to the interim certificate date, showing the quantities
of cement received and issued during the month and in stock at the end
of the month.
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1014.5. Reinforcement /Untensioned Steel
The reinforcement bars, when delivered on the job, shall be stored
above the surface of the ground upon platforms, skids, or other supports,
and shall be protected from mechanical injury and from deterioration by
exposure.
1014.6. Prestressing Materials
All prestressing steel, sheathing, anchorages and sleeves or coupling
must be protected during transportation, handling and storage. The
prestressing steel, sheathing and other accessories must be stored under
cover from rain or thmp ground and protected from the ambient
atmosphere if it is likely to be aggressive. Storage at site must be kept
to the absolute minimum.
(a) Tendon: Wire, strand and bar from which tendons are to be fabricated shall be
stored about 300mm above the ground in a suitably covered and closed space
so as to avoid direct climatic influences and to protect them from splashes from
any other materials and from the cutting operation of an oxy-acetylene torch or
arc welding process in the vicinity. Under no circumstances, tendon material shall
be subjected td any welding operation or on site heat treatment or metallic coating
such as galvanising. Storage facilities and the procedures for transporting material
into or out of store, shall be such that the material does not become kinked or
notched. Wire or strand shall be stored in large diameter coils which enable the
tendons to be laid out straight. As a guide, foe wires above 5mm dia, coils of
about 2sn dia without breaks or joints shall be obtained from manufacturer and
stored. Protective wrapping for tendons shall be chemically neutral, All prestressing
steel must be provided with temporary protection during storage.
(5) Anchorage Components : The handling and storing procedures shall maintain
the anchorage components in a condition in which they can subsequently perform
their function to an adequate degree. Components shall be handled and stored
so that mechanical damage and detrimental corrosion are prevented. The corrosion
of the gripping and securing system shall be prevented. The use of correctly
formulated oils and greases or of other corrosion preventing material is recom-
mended where prolonged storage is required. Such protective material shall be
guaranteed by the producer to be non.aggressive and non-degrading.
Prestressing steel shall be stored in a closed store having single door

with double locking arrangements and no windows. Also the air inside
the store shall be kept dry as far as possible by using various means
to the satisfaction of the Engineer. Also instrument measuring the air
humidity shall be installed inside the store. This is with a view to
eliminating the possibility of initial rusting of prestressing steel during
storage. The prestressing steel shall be coated with water solvabletrease.
The prestressing steel should be absolutely clean and without any signs
of rust.
333
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All prestressing steel shall be stored at least 30 cm above ground
level and it shall be invariably wrapped by protective cover of tar paper
or polythene or any other approved material.
The Contractor should see that prestressing steel shall be used within
3 months of its manufacture. He should chalk out his programme in this
respect precisely, so as to avoid initial corrosion before placing in
position.
1014.7. later
Water shall be stored in containers/tanks covered at top and cleaned
at regular intervals in order to prevent intrusion by foreign matter or
growth of organic matter. Water from shallow, muddy or marshy surface
shall not be permitted. The intake pipe shall be enclosed to exclude silt,
mud, grass and other solid materials and there shall be a minimum depth
of 0.60 m of water below the intake at all times.
1015. TESTS AND STANDARD OF ACCEPTANCE
All materials, even though stored in an approved manner shall be
subjected to an acceptance test prior to their immediate use.
independent testing of cement for every consignment shall be done
by the Contractor at Site in the laboratory approved by the Engineer before
use. Any cement with lower quality than those shown in manufacturer’s
certificate shall be debarred from use. In case of imported cement, the
same series of tests shall be carried out before acceptance.
1015.1. Testing and Approval of Material
The Contractor shall furnish test certificates from the manufacturer/
supplier of materials along with each batch of material(s) delivered to
site.
The Contractor shall set up a field laboratory with necessary
equipment for testing of all materials, finished products used in the
construction as per requirements of conditions of contract and the relevant
specifications. The testing of all the materials shall be carried out by
the Engineer or his representative for which the Contractor shall make
all the necessary arrangements and bear the entire cost.
Tests which cannot be carried out in the field laboratory have to
be got done at the Contractor’s cost at any recognised laboratory / testing
establishments approved by the Engineer.
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1015.2. Sampling of Materials

Samples provided to the Engineer or his representative for their
retention are to be in labelled boxes suitable for storage.
Samples required for approval and testing must be supplied well in
advance by at least 48 hours or minimum period required for carrying
out relevant tests to allow for testing and approval. Delay to works arising
from the late submission of samples will not be acceptable as a reason
for delay in the completion of the works.
If materials are brought from abroad, the cost of sampling/testing
whether in India or abroad shall be borne by the Contractor.
1015.3. Rejection of Materials not Conforming to the Specifi-
cations
Any stack or batch of material(s) of which sample(s) does not
conform to the prescribed tests and quality shall be rejected by the
Engineer or his representative and such materials shall be removed from
site by the Contractor at his own cost. Such rejected materials shall not
be made .acceptable by any modifications.
1015,4. Testing and Approval of Plant and Equipment
All plants and equipment used for preparing, testing and production
of materials for incorporation into the permanent works shall be in
accordance with manufacturer’s specifications and shall be got approved
by the Engineer before use.
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Pile Foundations
1100
Pile Foundations
<<
Pile Foundations Section 1100
1101. DESCRIPTION
1101,.!. This work shall consist of construction of all types of piles
for structures in accordance with the details shown on the drawings
and conforming to the requirements of these specifications.
1101.2. The construction of pile foundations requires a careful choice
of the piling system depending upon sub-soil conditions and loading
characteristics and type of structure. The permissible limits of total and
differential settlements, unsupported length of pile under scour, impactl
entanglement of floating bodies and any other special requirements of
project are also equally important criteria for selection of the
piling system. The method of installing the piles, including details
of the equipment shall be submitted by the Contractor and got
approved from the Engineer.
.
1101.3. The work shall be done as per IS:291l except as modified

herein.
1102. SUB-SURFACE INVESTIGATION
1102.1. The complete sub-surface investigation of strata in which
pile foundations are proposed shall be carried out in advance and by
in-situ pile tests. For details of geotechnical sub-surface explorations
reference may be made to Section 2400, At least one bore-hole for
every foundation of the bridge shall be executed. Borings should be
carried upto sufficient depths so as to ascertain the nature of strata
arottnd the pile shaft and below the pile tip. However, depth of boring
shall not be less than
i) 1.5 times estimated length of pile in soil but not less than 15 m beyond the probable
length of pile
ii) 15 times diameter of pile in weak/jointed rock but minimum 15 m in such rock
iii) 4 times diameter of pile in sound, hard rock but min[mum 3 m in such rock
1102.2. The sub-surface investigation shall define adequately strati-
fication of sub-strata including the nature and type of strata, its variation
and extent and specific properties of the same. The investigation shall
be adequate for the purpose of selection of appropriate piling system
and for estimating design capacities for different diameters and length
of piles.
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Section 1100 Pile Foundations
1102.3. Pressure meter tests may be used in the case of rock, gravel
or soil for direct evaluation of strength and compressibility charac-
teristics. Though these tests are of specialised nature they are most
appropriate for difficult/uncertain sub-strata especially for important
projects,
1102.4. For piles socketed into rocks, it is necessary to determine
the uniaxial compressive strength of the rock and its quality.
The investigation shall also include location of ground water table
and other parameters including results of chemical tests showing sulphate
and chloride content and any other deleterious chemical content in soil
and/or ground water, likely to affect durability.
1103. TYPE OF PILES
The piles may be of reinforced concrete, prestressed concrete,
steel or timber. The piles may be of solid or hollow sections or steel
cased piles filled with concrete. Concrete piles may be driven cast-
in-situ or precast or bored cast-in-situ or precast piles. driven into
preformed bores. The shape of piles may be circular, square, hexagonal,
octagonal, “H” or “I” Section.
1104. MATERIALS
1104.1. The basic materials shall conform to the specifications for
materials given in Section 1000. The specifications for steel reinforce-
ment, structural concrete, prestressed concrete and structural steel
to be used in pile foundations shall be as given in the relevant sections.
1104.2. Concrete in Piles
Grade of concrete to be used in cast-in-situ piles shall not be less
than M 20 and the cement content shall not be less than 400 kg per
cubic meter of concrete. Grades of concrete for precast reinforced and
prestressed concrete piles shall not be less than M 25 and M 35
respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ
piles and 0.45 for precast piles.
The minimum slump of concrete for driven cast-in-situ piles shall
be 1,00 mm to 150 mm and that of bored cast-in-situ piles 150 mm
to 200 mm. The slump should not exceed 200 mm in any case.
Concrete mix should have homogeneous mixture with required
workability for the system of piling adopted. Suitable and approved
admixtures may be used in concrete mix where necessary.
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Where piles are exposed to actiân of harmful chemicals or severe

conditions of exposure due to presence of sulphate, chloride etc.
it may be preferable to opt for higher grades of concrete restricting
water cement ratio to 0.45. Special types of cement, such as sulphate
resistant cement may” be used where considered appropriate.
1105. TEST PILES
1105.1. Test piles which are shown on the drawings or specified
in the contract or installed by the Contractor on his own to determine
the lengths of piles to be furnished shall conform to the requirements
for piling as indicated in these specifications, if they are to be incorporated
in the completed structure.
Test piles that are to become a part of the completed structure
shall be installed with the same type of equipment that is pro-
posed to be used for piling in the actual structure.
Test piles which are not to be incorporated in the completed
structure shall be removed to at least 600 mm below the proposed
soffit level of pile cap and the remaining hole shall be backfilled
with earth or other suitable material.
The piles shall be load tested in accordance with provisions laid down
in this section.
1106. PRECAST\CONCRETE PILES
1106.1. General
Precast concrete piles shall be of the size and shape as shown in
the approved drawings. if a square section is employed, the corners
shall be chamfered at least 25 mm unless otherwise specified
on the drawings. The length of pile shall not normally exceed 25 metres.
However, where special equipments for handling and installation are
available to the satisfaction of the Engineer, longer length could
be permitted.
Piles shall be cast with a driving point and for hard driving, shall
be shod with a metal shoe approved by the Engineer.
1106.2. Stacking, Storing and Handling
Care shall be taken that at all stages of transporting, lifting and
handling, piles are not damaged or cracked. During transport and stacking
of piles, they shall be supported at the same points as those provided
for lifting purposes. If the piles are put down temporarily during handling,
they shall be placed on trestles or blocks located at the same points.
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Piles shall be stored at least 300 mm above tim level ground
which is not liable to ui ~ual subsidence or settlement under the weight
of the stack of piles. They shall be placed on timber supports which
are level and spaced so as to avoid bending. The supports shall be verti
cally one above the other. Spaces shall be left round the piles to
enable them to be lifted without difficulty. The order of stacking
shall be such that the older piles can be withdrawn without disturbing
newer piles. Separate stacks shall be provided for different lengths of
piles. Where piles are stacked in layers, the number of layers shall
not exceed three. Whanever curing is needed during storage,
arrangements shall be made to enable the piles to be watered. For
detailed precautions with regard to curing operations specifications
for structural concrete given in Section 1700 shall apply.
Before the operation of handling and driving the piles, the
minimum periods counted from the time of casting shall be allowed for
as indicated in Table 1100-1. Prestressed piles shall not be lifted or
handled until fully stressed.
TABLE 1100.1 TIME FOR CURING PRECAST PILES
Minimum periods from time of casting
Type of cement Strike side. End of Lift from Drive

used in casting shutters wet curing castIng (days)
the pile (hours) (days) bed (days)
. 28
Ordinary Portland 24 7 10
Rapid hardening Portland 12 7 * 7 10
1106,3. Lengthening of Piles

Where a pile is to have another length cast on it during driving,
the longitudinal reinforcement shall preferably be joined by full pene-
tration butt welding. The concrete at the top of the original pile shall
be cut down to expose not less than 200 mm of the bars to avoid spalling
of the concrete by heat. The added bars have to be held accurately and
rigidly in position during welding. Where facilities on site are insufficient
to make proper butt welding practicable, the joint may be made by
lapping. The reinforcement at the head of pile will need to be exposed
for full anchorage length or 600 mm whichever is greater and the new
bars over-lapped for this distance. Unless otherwise specified, the
extension of the pile shall be formed to the same cross-sectional profile
and wiLh concrete of at least the same strength as that specified for the
original pile. The stirrup spacing shall in no case be greater than
<< 342
150 mm. Not more than one extension shall be permitted. In case
more than one extension is permitted by the Engineer, only approved
mechanical couplers shall be used.
Driving shall not be resumed until
(i) The strength of the concrete in the extension is at least equal to the specified
characteristic strength of concrete in pile, and
(ii) The approval of the Engineer has been obtained.
1106.4. Removal of Surplus Length

Any length of pile surplus to that required for incorporation in the
structure shall be cut off neatly and removed. During the process
of cutting off, it shall be ensured that projecting reinforcement to
be anchored into the pile cap and the prestressing strands/wires
are not damaged. When stripping prestressed concrete piles, shock
release of tendons shall be avoided. Reference may also be made
to clause 7.7.1. of IS:2911 (Part I Section 3) in this connection.
1106.5. Risen Piles
Level reading should be taken on each pile after driving and
again after all the piles are driven. Piles which are found to have
risen due to ground heave or as a result of driving adjacent piles, shall
be re-driven to the original depth or resistance unless re-driving tests
on adjacent piles have shown this to be unnecessary.
1106.6, Manufacture
The pile should be cast in one continuous operation from end to
end of each pile. Manufacture of precast concrete piles shall conform
to the guidelines contained in clause Nos. 7.1,7.2 and 7.3 of IS:2911
(Part I, Section 3).
Pile shall be provided with suitable shoe for protecting the point
of the pile during driving in hard ground.
Piles shall not be moved from casting bed until the concrete has
hardened sufficiently.
Piles shall not be driven in less than 28 days after casting or unless
their strength at the time of driving is at least that specified for 28
days.
1106.7. Prestressed Concrete Piles
Additional specifications for precast prestressed concrete piles shall
conform to those contained in clause 8 of IS:2911 (Part I Section 3).
<<
343
1107. CAST-IN-SITU CONCRETE PILES

Cast-in-situ concrete piles may be either installed by making a
bore into the ground by removal of material or by driving a metal casing
with a shoe at the tip and displacing the material laterally. The
two types of piles are termed as “bored piles” and “driven piles”
respectively. Cast-in-situ concrete piles may be cast in metal shells
which may remain permanently in place. However, other types of
cast-in-situ concrete piles, plain or reinforced, cased or uncased, may
be used if in the opinion of the Engineer the soil conditions permit
their use and if their design and the methods of placing are satisfactory.
The metal casing shall be of sufficient thickness and strength to hold
its original form and show no harmful distortion after it and adjacent
casings have been driven and the driving core, ~f any, has been
withdrawn.
Cast-in-situ concrete driven piles shall be installed using a properly
designed detachable shoe at the bottom of the casing. Certain specific
requirements of cast-in-situ driven piles shall be as per Clauses 1110
and 1111.
Any liner or bore-hole which is improperly located or shows
partial collapse that would affect the load carrying capacity of the pile,
shall be rejected or repaired as directed by the Engineer at the
cost of the Contractor.
Wherever practicable, concrete should be placed in a clean dry
hole. Where concrete is placed in dry and there is casing pre-
sent, the top 3 m of the pile shall be compacted using internal vibrators.
The concrete should invariably be poured through a tremie with a
funnel so that the flow is directed and concrete can be deposited in
the hole without segregation.
Where the casing is withdrawn from cohesive soils for the
formation of cast-in-situ pile, the concreting should be done with
necessary precautions to minimise the softening of the soil by excess
water. Where mud flow conditions exist, the casing of cast-in-situ piles
shall not be allowed to be withdrawn.
Care shall be taken during concreting to prevent as far as
possible the segregation of the ingredients. The displacement or distortion
of reinforcement during concreting and also while extracting the tube
shall be avoided.
<< 344
If the concrete is placed inside precast concrete tubes or
consists of precast sections, these shall be free from cracks or other
damage before being installed.
The concrete shall be properly graded, shall be self-compacting
and shall not get mixed with soil, excess water, or other extra-
neous matter. Special care shall be taken in silty clays and other soils
with the tendency to squeeze into the newly deposited concrete and
cause necking. Sufficient head of green concrete shall be maintained
to prevent inflow of soil or water into the concrete.
The placing of concrete shall be a continuous process from the
toe level to the top of the pile. To prevent segregation, a tube or tremie
pipe as appropriate shall be used to place concrete in all piles.
To ensure compaction by hydraulic static heads, rate of placing
concrete in the pile shaft shall not be less than 6 m (length of pile)
per hour.
Bored cast-in-situ piles in soils which are stable, may often be
installed with only a small casing length at the top. A minimum of
2.0 m length of top of bore shall invariably be provided with casing
to ensure against loose soil falling into the bore. In cases in which
the side soil can fall into the hole, it is necessary to stabilise
the side of the bore hole with drilling mud, or a suitable steel
casing. The casing may be left in position permanently specially
in cases where~ the aggressive action of the ground water is to be
avoided, or in the cases of piles built in water or in cases where
significant length of piles coWd be exposed due to scour.
For bored cast-in-situ piles, casing/liner shall be driven open ended
with a pile driving hammer capable of achieving penetration of the liner
to the length shown on the drawing or as approved by the Engineer.
Materials inside the casing shall be removed progressively by air lift,
grab or percussion equipment or other approved means.
Where bored cast-in-situ piles are used in soils liable to flow, the
bottom of the casing shall be kept enough in advance of the boring
tool to prevent the entry of soil into the casing, thus preventing the
formation of cavities and settlements in the adjoining ground. The
water level in the casing should generally be maintained at the natural
ground water level for the same reasons. The joints of the casing
shall be made as tight as possible to minimise inflow of water or
leakage of slurry during concreting.
<< 345
Boring shall be carried out using rotary or percussion type

equipment. Unless otherwise approved by the Engineer, the diameter
of the bore-holes shall be not more than the inside diameter of the
liner.
Prior to the lowering of the reinforcement cage into the pile
shaft, the shalt shall be cleaned of all loose materials. Cover to
reinforcing steel shall be maintained by suitable spacers.
The diameter of the finished pile shall not be less than that specified
and a continuous record shall be kept by the Engineer as to the volume
of concrete placed in relation to the pile length cast.
Before concreting under water, the bottom of the hole shall be
cleaned of drilling mud and all soft or loose material very carefully.
in case a hole is bored with use of drilling mud, concreting should
not be taken up when the specific gravity of bouom slurry is more
than 1.2. The drilling mud should be maintained at 1.5m above the.
ground water level.
Concreting under water for cast-in-situ concrete piles may be done
either with the use of tremie method or by the use of an approved
method specially designed to permit under water placement of concrete.
General requirements and precautions for concreting under water
are as follows
(a) The concreting of a pile must be completed in one continuous operation. Also,
for bored holes, the finishing of the bore, cleaning of the bore, lowering of
reinforcement cage and concreting of pile for full height must be accomplished
in one continuous operation without any stoppage.
Q,) The concrete should be coherent, rich in cement with high slump and restricted
water cement ratio.
(c) The tremie pipe wilt have to be large enough with due regard to the size of
aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less
than 150 mm and for larger aggregate, larger diameter tremie pipes may be
necessary.
(11) The first charge of concrete should be placed with a sliding plug pushed down
the tube ahead of it to prevent mixing of water and concrete.
(e) The tremie pipe should always penetrate well into the concrete with an adequate
margin of safety against accidental withdrawal if the pipe is surged to discharge
the concrete.
(f) The pile should be concreted wholly by tremie and the method of depoaitinn should
not be changed part way up the pile to prevent the taitance from being entrapped
within the pile.
(g) All tremie tubes should be scn3pulously cleaned after use.
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The minimum embedment of cast-in-situ concrete piles into pile

cap shall be 150 mm. Any defective concrete at the head of the
completed pile shall be cut away and made good with new concrete.
The clear cover between the bottom reinforcement in pile cap from the
top of the pile shall be not less than 25 mm. The reinforcement in
the pile shall be exposed for full anchorage length to permit it to be
adequately bonded into the pile cap. Exposing such length shall be
done carefully to avoid damaging the rest of the pile, in cases where
the pile cap is to be laid on ground, a levelling course of M 15 nominal
mix concrete 100 mm thick shall be provided. Defective piles shall be
removed or left in place as judged convenient without affecting the
performance of adjacent piles or pile cap. Additional piles shall be
provided to replace the defective piles.
1108. STEEL PILES
Steel piles shall be “H” or “I” sections as shown on the drawings
and shall be of structural steel conforming to the specifications given
in Section 1000.
Steel piles shall be protected by suitable anti-corrosive paint-
ing as specified on the drawing. Piles shall be stored above the ground
using protective packing to minimise damage to surface coating. Each
pile shall be supplied preferably in one piece without splices.
At the option of the Contractor, steel piling consisting of structural
steel plates welded together may be substituted for the rolled sections
specified, provided that the depth, width and average thicknesses are
at least equal to those of the rolled sections, the steel plates conform
to specification given in Section 1000, the flanges are welded to
the web with continuous fillet welds on either side of the web, and
the welding conforms to Clause 1904.8 of these specifications.
The length of the steel pile may be built up in sections either
before or during driving operations. The sections shall be of identical
cross-section. Pile splices shall be made with full penetration butt
welds over the whole cross-section. Pile splices shall develop at least
the yield strength of pile.
The connections shall be made by butt-welding the entire cross-
section in accordance with the provisions in Clause 1904.8 of these
specifications. Care shall be taken to properly align the sections
connected so that the axis of the pile will be straight. The number
of welded connections in the length of pile shall be as few as possible.
<< 347
1109. TIMBER PILES
The Engineer shall stamp each pile on the butt with a stamp which
shall make an impression that is readily legible. Treated timber piles
will be inspected by the Engineer after treatment,
- Untreated timber may be used as test piles.
Untreated timber piles and treated timber piles shall be of approved
quality.
Treated timber piles shall be driven within 6 months after treat-
ment.
Timber piles shall be fumished with tip protection and shall be
protected by the use of steel straps as hereinafter specified. Tip protection
shall be suitable for use on timber piling of the size to be driven. Details
of tip protection shall be furnished to the Engineer for review and
approval before driving piles. Not less than 2 separate steel straps shall
be placed within 600 mm of the butt of each pile after the pile is square
cut, Not less than 2 separate steel straps shall be placed within 300 mm
of the tip of each pile. Additional intermediate steel straps shall be
placed at not more than 3 metres centre measured along the length of
the pile.
Timber piles which are to be capped shall be separately cut off
so that true bearing is obtained on every pile. Piles inaccurately
cut off shall be replaced. Splicing of timber piles shall not be permitted
except by written permission of the Engineer.
1110. DRIVING EQUIPMENT
Piles or their casings may be driven with any type of drop hammer,
diesel hammer or single-acting steam or compressed air hammer,
provided they penetrate to the prescribed depth or attain the designed
resistance without being damaged. The weight or power of the hammer
should be sufficient to ensure a penetration of at least 5 mm per blow,
unless rock has been reached. It is always preferable to employ the
heaviest hammer practicable and to limit the stroke, so as not to damage
the pile. The minimum weight of the haniiper shall be 2.5t. In the
case of precast concrete piles the mass of the hammer shall be not
less than 30 times the mass of 300 mm length of pile.
Steam or air hammers shall be furnished along with boiler or air
compressor of capacity at least equal to that specified by the manufacturer
of the hammers. The boiler or air compressor shall be equipped with
<< 348
an accurate pressure gauge at all times. The valve mechanism and
other parts of steam, air or diesel hammers shall be maintained in first
class condition so that the length of stroke and number of blows per
minute for which the hammer is designed, will be obtained. Inefficient
steam, air or diesel hammers shall be removed from the work.
1111. DRIVING
1111.1. General Procedure
Details of the equipment and the method proposed for driving the
piles shall be submitted with the tender for scrutiny and approval
of the Engineer. Piles shall be installed from firm ground or from
temporary supports or from fixed platform. The arrangement shall provide
sufficient rigidity to ensure accuracy of pile driving under all conditions
of tide, stream flow or hammer drop.
During driving the top of pile shall be protected by a suitable
helmet of substantial steel constru~tion. The helmet shall provide
uniform bearing across the top of the pile and shall hold the pile centrally
under the hammer. No pile shall be driven unless inspected and
Piles shall be driven from a fixed frame of sufficient rigidity to
ensure accuracy of driving within specified tolerances. Forces producing
undue bending or torsional stresses in piles shall not be applied during
driving. The force of the hammer shall be directed centrally and axially
during driving.
The stroke of a single acting or drop hammer shall be limited to
1.2 m unless otherwise permitted by the Engineer. A shorter stroke
may be necessary when there is danger of damaging the pile.
Piles shall not be bent or sprung into position but shall be effectively
guided and held on-line during the initial stages of driving. Attempts
to correct any tendency for the pile to run off-line by the application
of significant horizontal restraint will not be permitted. Shortly after the
commencement of driving and at regular intervals throughout the driving
operation, checks shall be made to ensure that the pile frame does not
exert any undue lateral force on the pile due to restraint within
the helmet.~
If the indications are that a pile will finish outside the specified
tolerances, driving operations on that pile will cease. The pile shall
be withdrawn, the hole filled and the pile re-driven at no extra cost.
349
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To avoid the possibility of premature “set-up” pile driving shall be
continuous in the later stages, without any deliberate stops. (Delays of
an hour or less may lead to significant “set-up” in piles i.e. resistance
to further driving increases after driving is stopped).
If any pile is damaged in any way during driving, it shall be
repaired or replaced as directed by the Engineer, at no extra cost.
If during driving, the head of a pile is damaged to the extent that
further driving is not possible, the head shall be cut off and driving
continued. The cost of cutting off shall be bome by the Contractor and
where, as a result of such cutting off the head, the pile is too short,
the Contractor, shall, at his own cost, supply and splice on sufficient
length of pile to restore the pile to its correct length.
Piles should be driven to the minimum acceptable penetration
shown on the drawings. This may require preboring and/or jetting as
indicated in these specifications with the full approval of the Engineer.
Piles shall be driven to nominal refusal or the required ultimate
dynamic capacity nominated on the drawings or until the top of the
pile is at the level required and specified on the drawing whichever
gives the lowest toe elevation. The Engineer’s decision in these matters
shall be final. Nominal refusal shall be taken as equivalent to 25 mm
total penetration for the final 20 blows using a hammer of driving
energy as specified and shall be used as the criterion for acceptance
for piles founded on rock. Severe driving which results in an average
set per blow less than 0.5 mm will not be permitted.
Where hard drilling is encountered because of dense strata or
obstructions located above the predetermined pile tip level, nominal
refusal shall not be considered to have been achieved unless the
Engineer is satisfied that the total number of blows, as the average driving
resistance specified for nominal refusal, indicates that further driving
will not advance the pile through dense strata or obstructions,
The pile shall be driven as accurately as possible to the vertical
or to specified batter. Straining the pile into position can damage it
and the driving equipment should be adjusted as much as possible
to follow the position of the pile. Any deviation from the proper
alignment shall be noted and promptly reported to the Engineer. If
the deviation is to such an extent that the resulting eccentricity cannot
be taken care of by strengthening the pile cap or pile ties, such a
pile shall, at the discretion of the Engineer, be replaced or supplemented
by an additional pile. Unless otherwise specified, the permissible
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positional deviation for piles shall be limited to those indicated in Clause

1116.
Care shall be taken not to damage the pile by over-driving. Any
sudden change in the rate of penetration which cannot be ascribed
to the nature of the ground shall be noted and its cause ascertained, if
possible, before driving is continued.
When employing a tube which is subsequently withdrawn for the
formation of cast-in-situ pile, consideration shall be given to the
possibility of doing harm to a pile recently formed by driving the
tube nearby before the concrete has sufficiently set. The danger of doing
harm is greater in compact soils than loose soils. No pile shall be
bored or driven within 3 in of a newly cast pile until at least 24 hours
after completion of its installation.
Driving piles in loose sand tends to compact the sand which in
turn increases the skin friction. Therefore, driving a number of friction
piles in a group shall proceed outward from the centre as otherwise
it will be difficult to drive the inner piles to the same depth as the others.
In the case of stiff clay also, the driving for a group of piles shall
proceed outward from the centre. However, in case of very soft soil,
the driving may proceed from outside to inside, so that the soil is
restrained from flowing out during driving operations.
If there is a major variation between the depth at which adjacent
foundation piles in a group meet refusal, a boring shall be made nearby
to ascertain the cause of this difference. If the boring shows that the
soil contains pockets of highly compressive material below the
level of the shorter pile, it will be necessary to enforce penetration
of all the piles to a level below the bottom of the zone which shows
such pockets.
1111.2. Preboring and Jetting
Driving of the piles may be assisted by preboring holes or by the
use of jets or both subject to the approval of the Engineer. These
may be used essentially to achieve the minimum penetration shown on
the drawings where such penetration is not reached under normal
conditions of driving indicated in Clause 1111.1.
The diameter of the hole shall not be greater than the diagonal
dimension of the pile less 100 mm.
The maximum depth of the preboring shall be such that the
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specified set (or less) is obtained when the toe of the pile is at
founding level. Preboring shall be as approved by the Engineer and
shall not extend below one metre above the founding level and the
pile shall be driven to at least one metre below the prebored hole. To
ensure that the pile is properly supported laterally in the hole, any
space remaining around the pile at the ground level after driving is
finished shall be backfilled with approved granular material.
When water jetting is used, at least two jets shall be attached to
the pile symmetrically when this type of technique is used. The volume
and pressure of water at the outlet nozzles shall be sufficient to freely
erode material adjacent to the toe of the pile. The maximum depth
of jetting shall be such that the specified set (or less) is obtained
when the toe of the pile is at founding level. Jetting shall cease as
directed by the Engineer and shall not proceed below one metre above
the founding level and the pile shall be driven at least one metre below
the pre..bored hole.
To avoid very hard driving and vibration in materials such as
sand, jetting of piles by means of water may be carried out only by
express permission of the Engineer and in such a manneras hot to impair
the bearing capacity of piles already in place, the stability of the
soil or the safety of any adjoining buildings. Details of the arrangement
for jetting shall be got approved from the Engineer in advance.
If, for jetting, large quantities of water are used, it may be necessary
to make provision for collection of water when it comes to the ground
surface, so that the stability of the piling plant is not endangered by
the softening of the ground.
Jetting shall be stopped before completing the driving which
shall always be finished by ordinary methods. Jetting shall be stopped
if there is any tendency for the pile tips to be drawn towards the
pile already driven owing to the disturbance to the ground.
1112. RAKER (INCLINED) PILES
The maximum rake to be permitted in piles shall not exceed the
following
I) I m S for large diameter cast-in-situ piles viz 0.75 m diameter and above
ii) I in 5 for smaller diameter casI-’m-situ piles
iii) I in 4 for precast driven piles
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Pile Foundations Secilon 1100
1113. PILE TESTS

1113.1. General
The bearing capacity of a single pile may be determined from test
loading a pile. The load test on a con~retepile may not be carried
out earlier than 28 days from the time of casting of the pile.
There shall be two categories of tests on piles, namely, initial tests
and routine tests. Initial tests should be carried out on test piles which
are not to be incorporated in the work, Routine tests shall be carried
Out as a check on working piles. The number of initial and routine
tests on piles shall be as determined by the Engineer depending
upon the number of foundations, span length, type of superstructure
and uncertainties of founding strata. In any case, the initial load tests
shall not be less than 2 in number, while the routine load tests shall
not be less than 2 per cent of the total number of piles in the structure
nor less than 2 in number.
The above stipulations hold good for both vertical as well as
lateral load tests on pile foundations.
However, both initial and routine tests may be suitably increased
for important structures or cases with large variation in the sub-
surface strata.
The methodology of carrying out load tests and of arriving at
sale load on piles shall conform to IS:2911 (Part IV).
In case of any doubt of workmanship or load carrying capacity of
working piles not subjected to routine tests, or when ordered. by the
Engineer, or when provided in the contract, load tests on working
piles may be supplemented by non-destructive testing. Such tests
may include “integrity Testing” of ~oncrete in the installed pile and
utitisation of “Pile Driving Analyser” which gives an indication of
pile capacity in end bearing and side friction.
1114. PILE CAP
Pile Caps shall be of reinforced concrete. A minimum offset of
150 mm shall be provided beyond the outer faces of the outer most
piles in the group. If the pile cap is in contact with earth at the bottom,
a levelling course of minimum 100 mm thickness of M 15 nominal mix
concrete shall be provided.
The attachment of the pile head to the cap shall be adequate for
the transmission of loads and forces. A portion of pile top may be
<< 353
stripped of concrete and the reinforcement anchored into the cap. Manual
chipping may be permitted after three days of pile casting, while
pneumatic tools for chipping shall not be used before seven days
after pile casting. The top of pile alter stripping shall project at least
150 mm into the pile cap. A layer of surface reinforcement may be
provided with a cover of 25 mm to retain the integrity of concrete below
the main cap reinforcement which is to be laid 25 mm above the pile
top.
Concreting of the pile cap shall be carried out in dry conditions.
The bottom of the pile cap shall be laid preferably as low as possible
taking account of the water level prevalent at the time of casting.
The top of concrete in a pile shall be brought above cut-off
level to permit removal of all laitance and weak concrete before pile
cap is laid. This will ensure good concrete at the cut-off level.
1115. IMPORTANT CONSIDERATIONS, INSPECTION/
PRECAUTIONS FOR DIFFERENT TYPES OF PILES
1115.1. Driven Cast-in-Situ Piles
1115.1.1, Specialist literature and the guidelines from the pile
construction industry shall be consulted regarding the method of instal-
lation, equipment and accessories for pile driving and recording
of data.
1115.1.2. During installation of piles the final “set” of penetration
of pile per blow of hammer shall be checked taking an average of
last 10 blows.
1115.1.3. The pile shoes which may be of either cast iron conical
type or mild steel flat type shall have double reams for proper seating
of the removable casing tube inside the space between the reams.
1115.1.4. Before commencement of pouring of concrete, it shall be
ensured that there is no ingress of water in the casing tube from
the bottom. Further adequate control during withdrawal of the casing
tube is essential so as to maintain sufficient head of concrete inside
the casing tube at all stages of withdrawal.
1115.1.5. Concrete in piles shall be cast upto a minimum height
of 600 mm above the designed ~toplevel of pile, which shall be stripped
off at the time of construction of pile cap.
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354
1115.2. Bored Cast-lu-Situ Piles

1115.2.1. While concreting uncased piles, voids in concrete
shall be avoided and sufficient head of concrete is to be maintained
to prevent inflow of soil or water into the concrete. It is also necessary
to take precautions during concreting to minimise the softening of the
soil by excess water. Uncased cast-in-situ piles shall not be allowed where
mudflow conditions exist.
1115.2.2. The drilling mud such as bentonite suspension shall be
maintained at a level sufficiently above the surrounding ground water
level to ensure the stability of the strata which is being penetrated
throughout the boring process until the pile has been concreted.
1115.2.3. Where bentonite suspension is used to maintain the
stability of the bore-hole, it is essential that the properties of
the material be carefully controlled at stages of mixing, supply to the
bore-hole and immediately before concrete is placed. It is usual to
limit
i) Tht~density of benton~tesuspension to 1.05 gjcc
ii) The marsh cone viscosity between 30 and 40
~i) The p11 value between 9.5 and 12
iv) The silt content less than I per cent
v) The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing con-

tamination of bentonite slurry for clay and silt.
1115.2.4. The bores shall be washed by bentonite flushing to ensure
clean bottom at two stages viz, after completion of boring and prior Io
concreting alter placing of reinforcement cage. Flushing of bentonite
shall be done continuously with fresh bentonite slurry till the consistency
of inflowing and out-flowing slurry is similar.
1115.2.5. Tremie of 150 mm to 200 mm diameter shall be used for
concreting. The tremie should have uniform and smooth cross-section
inside, and shall be withdrawn slowly ensuring adequate height
of concrete outside the tremie pipe at all stages of withdrawal.
Other recommendations for tremie concreting are
(i) The sides of the bose-hole have to be stable throughout.
(ii) The tremie shall be water-tight throughout its length and have a hopper attached
at its head by a water-tight connection
<<
355
(iii) The tremie pipe shalt be large enough in relation to the size of aggregates. For
20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm and
for larger size aggregate tremie pipe of larger diameter is required.
(iv) The tremie pipe shall be lowered to the bottom of the bore-hole, allowing water
or dotting mud to rise inside it before pouring concrete.
(v) The tremie pipe shall always be kept full of concrete and shall penetrate well
into the concrete in the bore-hole with adequate margin of safety against accidental
withdrawal if the pipe is surged to discharge the concrete.
1115.2.6. For very long or large diameter piles, use of retarding

plasticiser in concrete is desirable.
1115.2.7. For large diameter piles, it may be essential to conduct
non-destructive pile integrity tests to evaluate integrity of the pile.
1115.2.8. Where possible, it may be desirable to grout the base
of pile with cement slurry under suitable pressure after concrete in the
pile attains the desired strength. For this purpose, conduit pipes with
easily removable plugs at the bottom end should be placed in the bore
alongwith reinforcement cage before concreting.
1116. TOLERANCES
1116.1. Permissible Tolerances for Pile
i) Precast Concrete Piles
a) Variation in cross-sectional dimensions ±5 mm
h) Variation in length ±25 mm
c) Surface irregularities measured
with 3 m straight edge 5 mm
d) Row for length in mm Pile Length
in mm
1000
ii) Driven Piles
a) Variation in cross-sectional dimensions ÷50 mm, -10 mm
b) Variation from vertical or specified rake 1 in 50
c) Variation in the final position
of the head in plan 75 mm
d) Variation of level of top of piles : ±25 men
iii) Bored Piles
a) Variation in cross-sectional dimensions + 50 mm, -10 mm
b) Variation from vertical or specified rake I in 50
c) Variation in the final position : 50 men
of the head in plan
d) Variation of level of top of piles ±25 mm
<< 356
1116.2. Permissible Tolerances for Pile Caps

(a) Variation in dimensions : ÷50mm - 10 mm
(b) Misplacement from specified position in plan : 15 mm
(c) Surface irregularities measured
with 3 m straight edge 5 mm
(d) Variation of levels at the top : ±25 mm
1117. TESTS AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with these Specifica-
Lions and shall meet the prescribed criteria.
The work shall conform to these Specifications and shall meet the
prescribed standards of acceptance.
1118. MEASUREMENTS FOR PAYMENT
For supply of precast concrete, timber or steel piles of speci-
fied cross-section, the measurement shall be in metres of the length
of piles ordered in writing by the Engineer measured from the head
to the butt of the shoe or the tapered point. Reinforcement in precast
concrete piles shall not be measured for payment.
For cast-in-situ driven and bored concrete piles of specified cross-
section, the measurement shall be the length in metres of the accepted
pile that remains in the finished structure complete in place. Reinforce-
ment in cast-in-situ driven and bored concrete piles shall be measured
for payment as per Section 1600.
Routine and Initial Pile Load Tests shall not be measured for
payment.
For installation of the pile, i.e. by driving in the case of precast
concrete, timber, steel and cast-in.~situ driven piles, and by boring
in the case of cast-in-situ bored piles the measurement shall be
the length in metres that remains in the finished structure complete
in place, limited to that shown on drawings or ordered by the Engineer.
No distinction shall be made for penetration through hard strata or rock
and socketing into rock.
For steel 1iner~fcasingshown on the drawings to be permanently
left in place, the measurement shall be by weight in tonnes that remains
in the finished structure complete in place, limited to that shown on
drawings or ordered by the Engineer.
For the pile cap, the quantity of concrete shall be measured in
cubic metres as per Section 1700. While reinforcement in pile cap
<< 357
shall be measured in tonnes as per Section 1600,

1119. RATE
The contract unit rate for supplying precast concrete, timber or
steel piles shall include cost of all labour, materials, tools and equipment,
and other work involved in making or fabricating the pile complete
as shown on the drawing, and where required its loading, transport,
delivery to site unloading and stacking it at the place indicated by the
Engineer. The cost of reinforcement as per Seciton 1600 in precast
concrete piles shall be deemed to be included in the quoted rate for supply
of piles.
The contract unit rate for cast-in-situ driven and bored piles shall
include the cost of concrete and all other items as per Section 1700.
The contract unit rate shall also include costs of all labour, materials,
equipments and all other incidentals involved in conducting routine
and initial pile load tests including installation of piles for initial load
tests.
The contract unit rate for reinforcement in cast-in-situ driven and
bored piles shall be as per Section 1600.
The contract unit rate for installation of piles shall include full com-
pensation for furnishing all labour, materials, tools and equipment, and
incidentals for doing all the works involved in driving timber, precast
concrete and steel piles, driving or making bores for cast-in-situ
driven and bored concrete piles, cutting off pile heads, all complete in
place to the specified penetration of piles. Providing temporary
liner/casing and its withdrawal and placing reinforcement in position
shall also be deemed to be included in the rate for installation of piles
and no additional payment shall be made for the same.
The contract unit rate for permanent steel liners shall incude cost
of all labour, fabrication and placing the steel liner to the required depth
as shown on the drawings and as ordered by the Engineer.
The contract unit rate for concrete in pile cap shall cover all costs
of labour, materials, tools, plant and equipment, formwork and staging
including placing in position, sampling and testing and supervision, all
as per Section 1700. Reinforcement in the pile cap shall be paid for
separately as per Section 1600.
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Well Foundations
1200
Well Foundations
<<
Well Foundations Section 1200.
1201. DESCRIPTION
This work consists of construction of well foundation, taking it down
to the founding level through all kinds of ~ub-sLrata,plugging the
bottom, filling the inside of the well, plugging the top and providing
a well cap in accordance with the details shown on the drawing -and
as per these specifications, or as directed by the Engineer.
In case of well foundations of size larger than 12 m diameter,
-
supplemental construction specifications will be necessary.

1202. GENERAL
1202.1, Wells may have a circular, rectangular, or D-shape in plan
and may consist of one, two or more comprirtments in plan. The outer
wall of the well is known as -well stein~g which may be cellular.
The process of taking down the web • the founding level is
known as well sinking. Aftu reaching the fot~ndinglevel, the hollow
inside the well, (“dredge hole”) is plugged at the bottom by concrete
(“bottom plug”). The dredge hole is then filled with approved filling
upto the level indicated on the drawings and provided with a concrete
plug (“top plug”).
To facilitate sinking of well, steel cutting edge is fabricated and
connected to a concrete well curb of required shape. On top of the
well curb, adequate height of well steining is cast and the process
of sinking is carried out. After a portion of the well has been sunk,
another height of well staining is cast on top of the previous section
and further sinking carried out. This process is continued till the bottom
level of the well reaches the founding level.
At the top of the well steining, an adequately designed “well cap”
is laid which transmits the loads and forces from the sub-structure (piers
‘or abutments) to the foundations.
1202.2. At least one bore-hole must be available/carried out in ac-
cordance with these specifications at each well foundation location,
prior to commencement of work, The depth of bore-holes should extend
upto a depth equal to one and a half times the outer diameter/least
dimension of the well below the anticipated founding level. The results
of soil exploration should be presented in accordance with clause
7.4 of IRC:78. In case the well foundation is to rest on a rocky strata,
it may be necessary to undertake additional borings /probings prior to
commencement of work to ascertain the actual profile and the quality
361
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Section 1200 Well Foundations
of the rocky strata, at the level at which the well has to be seated,
etc.
12023, Blasting may have to be resorted to in order to facilitate
sinking through difficult strata, such as boulders and rocks etc. In case
blasting is anticipated, protective/strengthening measures specified in
clause 710.6 (IV) of IRC:78 shall be taken. The grade of concrete in
bottom 3 metres of steining shall not be leaner than M 20 or as shown
on the drawings.
1202.4, In case the bore hole data shows the presence of steeply
dipping rock, chiselling may have to be resorted to so as to obtain
proper seating of the fouodation. For this purpose, the well may require
to be, dewatered completely under high air pressure inside the well. This
process is known as pneumatic sinking. Pneumatic sinking may also have
to be resorted to in cases where obstacles such as tree trunks, large
sized boulders or hard strata etc. cannot be removed by open dredging.
The necessity of adop4ng pneumatic sinking shall be decided by the
EngineeP.
The curb and steining have to be specifically designed for speciai
loading* ~Thenpneumatic sinking is adopted.
1203, SETTING OUT AND PREPARATIONS FOR SINKING
120~1.Necessary reference points shall be fixed, away from the
zone of blow-ups or possible settlements resulting from well sinking
operations. Such reference points shall be connected to the perma-
nent theodolite stations with the base line on the banks. The centre
of the individual wells shall be marked with reference to these stations.
The distance, wherever practicable, shall be checked with the help of
accurate tapes and precision distomat.
Reference points shall also be fixed to mark X-X axis (usually
traffic direction) and Y-Y axis (normal to X-~Caxis) accurately.
A temporary bench mark shall also be established near the well
foundation, away from the zones of blow-ups or possible settlement.
The bench mark shall be checked regularly with respect to the
permanent bench mark established at the bridge site.
1203.2. For wells which are to be pitched in water, an earthen or
sand island shall be constructed. Sand islands are practicable for water
depths of about 5 metres under stable bed soil conditions. For greater
depths or in fast flowing rivers or for locations where soil is too weak
to sustain sand island, floating caissons may have to be adopted.
362
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Well Foundations Section 1200
The plan dimensions of sand islands shall be such as to have a
working space of at least 2 metres all around the steining. The dimension
of the sand islands shall however be not less than twice the dimension
in plan of the well or caisson. Sand islands shall be maintained to perform
their functions, until the well is sunk to a depth below the bed level
at least equal to the depth of water.
Sand island shall be protected against scour and the top level shall
be sufficiently above the prevailing water level to be decided by the
Engineer so that it is safe against wave action.
While sand islands are constructed at well location, floating caissons
are generally fabricated at or near the banks on dry land or dry docks.
floating caissons are towed into position in floating condition.
Floating caissons may be of steel, reinforced concrete or a com-
bination of the two. They should have at least 1.5 m free board
above water level and increased, if considered necessary, in case there
is a possibility of caissons sinking suddenly owing to reasons such as
scour likely to result from the lowering of caissons, effect of waves,
sinking in very soft strata etc.
Stability of floating caissons sh~flbe ensured against overturi~-
ing and capsizing while being towed and during sinking for the action
of water current, wave pressure, wind etc.
For floating caissons, a detailed method statement for fabrication,
floating and sinking of caissons shall be prepared and furnished to
the Engineer. Such statement shall include the total tonnage of steel
involved, fabrication and welding specifications, list of materials and
plant and a description of operations and manpower required for the
work. The caisson shall be tested for leakages before being towed to
site.
12033. Equipment
Equipment shall be deployed for construction of well foundation
as required and as directed by the Engineer. Generally, the following
equipments may be required for the work:
(a) Crane with grab buckets capacity 0.5 to 2.0 cern.
-
(b) Submersible pimps

(c) Air compressors, air locks and other accessories where pneumatic sinking of well
is anticipated.
(ci) Chisels of apprepriste sizes
363
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(e) Aqua-header for cutting rocky strata
(I) Diving helmets and accessories

(g) Equipment for concrete production, transportation planing and compaction.
1204. CUTTING EDGE
1204.1. The mild steel cutting edge shall be made from structural
steel sections, The cutting edge shall weigh not less than 40 kg per
metre length and be properly anchored into the well curb, as shown
in the drawing.
When there are two or more compartments in a well, the bottom
end of the cutting edge of the inner walls of such wells shall be kept
at about 300 mm above that of outer walls.
1204.2. The parts of cutting edge shall be erected on level firm
ground. Temporary supports shall be provided to facilitate erection and
maintaining the assembly in true shape. The fabrication may be carried
out in the shop or at site. Steel sections shall not be heated and forced
into shape. However, “V’t cuts may be made in the horizontal portion,
uniformly throughout the length, to facilitate cold bending. After
bending, such “V” cuts should be closed by welding. Joints in the lengths
of structural sections, unless otherwise specified shall be fillet welded
using single cover plate to ensure the requisite strength of the original
section,
12043. The cutting edge shall be laid about 300 mm above
prevalent water level.
1205. WELL CURB
1205.1. The well curb may be precast or cast-in-situ. Steel formwork for
well curb shall be fabricated strictly in conformity with the drawing.
The outer face of the curb shall be vertical, Steel reinforcements shall
be assembled as shown on the drawings. The bottom ends of vertical
bond rods of steining shall be fixed securely to thei cutting edge with
check nuts or by welds.
The formwork on outer face of curb may be removed within 24 hours
after concreting. The formwork ott inner face shall be removed after
72 hours.
1205.2. All concreting in the well curb shall be done in one
continuous operation.
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1206. WELL STEINING

1206.1. The dimensions, shape, concrete strength and reinforce-
ments of the well shall strictly conform to those shown on the drawings.
The fomtwork shall preferably be of M.S. sheets shaped and stiffened
suitably. In case timber forms are used, they shall be lined with plywood
or M.S. sheets.
1206.2. Steining built in the first lift above the well curb shall not
be more than 2 metres and in subsequent lifts it shall not exceed the
diameter of the well or the depth of well sunk below the adjoining
bed level at arty time. For stability, the first lift of steining shall be
cast only after sinking the curb at least partially for stability.
ConcNting of steining may be carried out in subsequent lifts of about
2 to 2.5 metres. Attempts should be made to minimise the number of
construction joints. The concreting layers shall be limited to about 450
mm restricting the free fall of concrete to not more than 1.5 m. Laitance
formed at the top surface of a lift shall be removed to expose coarse
aggregates before setting of concrete at the proposed construction
joint. As far as possible, construction joints shall not be kept at the
location of laps in the vertical steining bars.
1106.3. The steining of the well shall be built in one straight line
from bottom to top such that if the well is tilted, the next lift of
steining will be aligned in the direction of th~tilt. The work will be
checked carefully with the aid of straight edges of lengths approved
by the Engineer. Plumb bob or spirit level shall not be used for
alignment. After sinking of a stage is complete, damaged portions if any,
of steining at top of the previous stage shall be properly repaired
before constructing the next stage.
1206.4. The height of steining shall be calibrated by making at least
4 gauges (preferably in traffic direction and in a direction normal to traffic
direction) distributed equally on the outer periphery of the well each
in the form of a 100 mm wide strip painted on the well, with every
metre mark shown in black paint. The ,,~gaugesshall start with zero at
the bottom of the cutting edge. Marking of the gauges shall be done
carefully with a steel tape.
1206.5. After reaching the founding level, the well steining shall
be inspected to check for any damage or cracks. The Engineer will
direct and the Contractor shall execute the remedial measures before
acceptance of the well staining. In case the well cannot be~accepted
even with any remedial measures, then the well shall stand rejected.
<< 365
1207. WELL SINKING
1207.1. General
The well shall as far as possible be sunk true and vertical through
all types of strata.
Sinking or loading of the well with kentledge shall be commenced
only after the steining has been cured for at least 48 hours or as specified
in the drawings.
No well shall be permitted to be placed in a pre-dredged hole.
The well shall be sunk by excavating material uniformly from
inside the dredge hole. Use of water jetting, explosives and divers
may be adopted for sinking of wells through difficult strata with prior
approval of the Engineer.
Normally dewatering of well should not be permitted as a means
for sinking the well. It also shall never be resorted to if there is *any
danger of sand blowing under the well. Dewatering sl~ailhowever be
done when well is to be founded into rock. Pneumatic sinking may
have to be resorted to where obstacles such as tree trunks, large size
boulders, etc. are met at the bottom or when there is hard strata which
cannot be removed by open dredging, The necessity for pneumatic
sinking shall be decided by the Engineer.
Sinking history of well shall be maintained in the format given
in Appendix 1200/I.
1207,2, Use of Kentledge as Sinking Load
Kentledge shall be placed in an orderly and safe manner on the
loading platform and in such a way that it does not interfere with
the excavation of the material from inside the dredge hole and also does
not in any way damage the steining of the well.
Where tilts are present or there is a danger of well developing
a tilt, the position of the load shall be regulated in such a manner
as to provide greater sinking effort on the higher side of the well.
1207.3. Use of Water Jetting
Water jetting may be employed for well sinking wherever neces-
sary.
1207A, Use of Explosives
Mild explosive charges may be used as an aid for sinking of the
well only with prior permission of the Engineer. Blasting of any sort
<< 366
shall only be done in the presence of the Engineer and not before the
concrete in the steining has hardened sufficiently and is more than 7
days old. When likelihood of blasting is predicted in advance, protection
of the bottom portion of the well shall be done as per these specifications.
After blasting operations are completed, the well curb and steining should
be examined for any cracks and remedial measures taken.
If blasting has been used after the well has reached the design
foundation level, normally 24 hours shall be allowed to Lapse before
the bottom plug is laid.
The charges shall be exploded well below the cutting edge by
making a sump so as to avoid chances of any damage to the curb or
to the steining of the well. A minimum-sump of I metre depth should
be made before resorting to blasting. Use of large charges, 0.7 kg
or above, may not be allowed except under expert direction and with
the permission from the Engineer. Suitable pattern of charges may
be arranged with delay detonators to reduce the number of charges
fired at a time. The burden of the charge may be limited to 1 metre
and the spacing of holes may normally be kept as 0.5 to 0.6 metres.
All prevalent laws concerning handling, storing and using of ex-
plosives shall be ~strictlyfollowed.
All safety precautions shall be taken as per IS:4081 “Safety Code
for B lasting and related Drilling Operations”, to the extent applicable,
whenever blasting is resorted to.
There shoulçl be no equipment inside the well nor shall there be
any labour in the close vicinity of the well at the time of exploding
the charges.
If rock blasting is to be done for seating of the well, the
damage caused by flying debris should be minimised by covering
blasting holes by nibber mats before blasting.
1207.5, Use of Divers
Use of divers may be made both for sinking purpose like removal
of obstructions, rock blasting and for inspection. All safety precautions
shall be taken as per any acceptable safety code for sii~kingwith divers
or any statutory regulations in force.
Only persons trained for the diving operation shall be employed
and shall be certified to be fit for diving by an approved doctor.
They shall work under expert supervision. The diving and other
<<
367
equipments shall be of acceptable standard and certified to this effect
by an approved independent agency. It shall be well maintained for
safe use.
Arrangement for ample supply of low pressure clean cool air shall
be ensured through an armoured flexible hose pipe. Standby
compressor plant shall be provided in case of breakdown.
Separate high pressure connection for use of pneumatic tools
shall be made. Electric lights where provided shall be at 50 volts
(maximum). The raising of the diver from the bottom of wells shall
be controlled so that decompression rate conforms to the rate as laid
down in appropriate regulations.
1207.6. Use of Pneumatic Sinking
1207.6.1. General
The Engineer shall familiarise himself with particular reference to
caisson diseases and working of the medical air-lock. A doctor
competent to deal with cases of “Caisson Diseases” or other compli-
cations arising as a result of working under high pressure, shall be
stationed at the construction site when pneumatic sinking is under
progress.
The contractor shall provide complete facilities including the
issuing of orders to ensure strict enforcement of the requirements
outlined in these specifications.
Safety provisions as contained in IS:4138 and in these speci.
fications shall be strictly followed.
Pneumatic sinking shall be restricted to a depth of 30.0 m.
1207.6.2. Man-Locks and Shafts
Locks, reducers, and shaft used in connection with caissons shall
be of riveted construction throughout. The material used in their
manufacture shall be steel plate with thickness not less than 6 mm.
Shafts shall be subjected to hydrostatic or air pressure test of at
least 0.5 MPa, at which pressure they shall be tight. The pressure at
which testing has been done shall be clearly and visibly displayed.
Shafts shall be provided, with a safe, proper and suitable staircase
for its entire length including landing platforms which are not more than
6 metres apart. Where this is impracticable due to space constraint,
suitable ladders along with landing platforms shall be installed. These
<< 368
shall be kept clear and in good condition at all times and shall be
constructed, inspected and maintained to the entire satisfaction of the
Engineer.
A 1.0 m wide platform with 1.0 m high railing shall be provided
all round the caisson air locks.
Where 15 or more men are employed, caissons shall have two locks,
one of which shall be used as a man lock.
Locks shall be located so that the lowest part of the bottom door
shall not be less than 1 metre above high water level.
The supply of fresh air to the working chamber shall at all times
be sufficient to permit work to be done without any danger or excessive
discomfort. All air supply lines shall be supplied with check valves and
carried as near to the face as practicable.
A man-lock shall be used solely for the compression or de-
compression of persons, and not for the passage of plant and
material and shall be maintained in a reasonably clein and sufficiently
warm state. However, any hand tool or hand instruments used for
the purpose of the work may be carried into the man-lock.
Where it is not reasonably practicable to provide a separate man-
lock for use by persons only, the lock when it is in actual use for
compression or decompression of a person or persons shall not be put,
simultaneously, to any other use and shall be in a reasonably clean and
sufficiently warm stale.
1207.6.3. Valves
Exhaust valves shall be provided, having risers extending to the
upper part of the chamber. These shall be operated, whenever
necessary specially after a blast. Precautions shall be taken that men
are not allowed to resume work after a blast until the gas and smoke
are cleared.
1207.6.4. Medical supervision and certification
Every employee absent from work for 10 or more consecutive days
due to illness or any other disability shall be required to pass the regular
physical examination by the doctor before being permitted to return
to work.
After a person has been employed continuously in compressed air
for a period of 2 months, he shall be re-examined by the doctor and
<< 369
shall not be permitted to work until such re-examination has been made
and the report is satisfactory.
No person known to be addicted to the excessive use of
intoxicants shall be permitted to work in compressed air.
The doctor shall, at all times, keep a complete and full record of
examinations made by him, which shall contain dates of examinations, a
clear and full description of the person examined, his age and
physical condition at the time of examination and a statement as
to the period such a person has been engaged in such employment.
Records shall be kept at the place where the work is in progress
and shall be subject to inspection by authorised officers.
Every man lock shall always have a doctor or a responsible person
in attendance. In case the person in charge is not a doctor he must
have positive means of promptly communicating with and securing the
services of a competent doctor in case of emergency, Such arrangements
shall invariably be subject to the approval of the Engineer.
if the air pressure exceeds 0.2 MPa gauge or if 50 or more men
are employed, it is obligatory for the person in charge of medical
lock to be a doctor experienced in this type of work.
All cases of compressed-air illness shall be reported and copies of
all such reports shall be kept on file at the place of work.
1207.6.5. Lighting
All lighting in compressed air chambers shall be operated only by
electricity. Two independent electric lighting systems with independ-
ent sources of supply shall be used. These shall be so arranged that
the emergency source shall become automatically operative in case of
failure of the regularly used source.
The minimum intensity of light on any walkway ladder, stairway,
or lower working level shall be one-quarter (1/4) candlepower. In all
work places, the lighting shall always be such as to enable workmen
to see their way about clearly. All external parts of lighting fixtures and
electrical equipment lying within 2.5 metres above the floor shall be
constructed of non-combustible, non-absorbing insulating materials. If
metal is used it must be effectively earthed. Portable lamp shall have
non-combustible, non-absorbing insulating sockets, approved handles,
basket guards and approved cables. The use of worn or defective
portable and pendant conductors, shall be prohibited.
<< 21(1
1207.6.6. Safety against fire hazard
No oil, gasoline, or other combustible material shall be stored within
30 metres of any shaft, caisson, or tunnel opening. However, oil
may be stored in suitable tatiks in isolated fireproof buildings, provided
such buildings are not less than 15 metres from any shaft, caisson, or
tunnel opening or any building directly connected thereto.
Positive means shall be taken to prevent leaking flammable
liquids from flowing into areas specifically mentioned in the preceding
paragraph.
Where feasible, a fire hose connected to a suitable source of water
shall he provided at the top of every caisson. Where lire mains are
not accessible, a supply of water shall be stored in tanks near the
top of every caisson, provided fire pails or suitable pumps are kept
available. Approved fire extinguishers shall also be provided.
1207.6.7. Sanitation
Properly heated, lighted and ventilated dressing rooms shall be
provided for all employees engaged in compressed air work. Such rooms
shall contain lockers and benches and be open and accessible to men
during intermission between shifts. Adequate toilet accomodation of one
for every twenty five employees shall be provided.
Care shall be taken to keep all parts of the caissons and other
working compartments, including locker rooms, dry rooms, rest rooms,
and other equipment in a good sanitary condition and free from refuse,
decaying, ‘or other objectionable matter.
No nuisance shall be tolerated in the air chamber. Smoking shall
be strictly prohibited and all matches and smoking materials shall be
left out of the locker rooms.
A separate dry-room shall be provided where working clothes may
be dried within reasonable time.
1207.6.8. Protection against gases
In all cases where gas is expected including alluvium impregnated
with decayed vegetable matter the use of Davy Safety Lamp shall be
compulsory.
1207,6.9. Additional safety provisions
a) The weight of the pneumatic platform and that of steining and kentledge, if
any, shall be sufficient to resist the uplift from air inside, skin friction being
rtglected in this case. If, at any section the total weight acting downwanls is
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371
leas than the uplift pressure of air inside, additional kentledge shall be placed
on the well.
If it is not possible to make the well heavy enough during excavation, “blowing
down” may be used. The men should be withdrawn and air pressure reduced,
The well should then begin to move with small reduction in air psessure. “Blowing
down” should only be used when the ground is such that it will not heave
up inside the chamber when the pressure is reduced. When the well does not
move with the seduction in air pressure, kentledge should be added~,“Blowing
down” should be in short stages and the drop should not exceed, 03 metre at
any stage. To control sinking during blowing down, use of packings are
recomsnended.
b) The pneumatic sinking plant and other allied machinery shall not only be of proper
design and make, but also shall be worked by competent and well trained
personnel. Every part of the machinery and its fixtures shall be minutely
examined before installation and use. Availability ofappropriate spares, standbys,
safety of personnel as recommended in 15:4138 for working in compressed air
must be ensured at site. Codes far safety and for working in compressed air
and other labour laws and practices prevalent in the country, as specified to
provide safe, efficient and expeditious sinking shall be followed,
c) inflammable materials shall not be taken into air locks and smoking shall be
prohibited. Wherever gases are suspected to be issuing out of dredge hole, the
sante shall be analysed by trained personnel and necessary precautions adopted
to avoid hazard to life and equipment,
d) Where blasting is resorted to, it shall be carefully controlled and all precautions
regarding blasting shall be observed. Workers shall be allowed inside after
blasting only when a competent and qualified person has examined the chamber
and steining thoroughly and found the same to be safe,
1207.7. Precautions During Sinking

a) When the wells have to be sunk close to each other and clear distance between
them is not greater than the diameter of wells, sinking shall be taken up on all
wells and they shall be sunk altemately so that sinking of wells proceeds
uniformly. Simultaneous and even dredging shall be carried out in the wells in
such a manner that the difference in the levels of the sump and cutting edge
in the adjacent wells does not exceed half the clear gap between them. Plugging
of all the wells shall be done together.
b) During sinking of dumb-bell or double D-shaped wells, the excavation in both
the dredge holes should be carried out simultaneously and equally.
c) Bore chart shall be referred to constantly during sinking for taking adequate
care while piercing different types of strata. The type of soil as obtained
during the well sinking should be compared with bore chart s& as to
take prompt decisions.
d) Before seasonal floods all wells on which sinking is in progress shall be
sunk to sufficient depths below the designed scour level. Punher~theyshall
be temporarily filled and plugged so that they do not suffer any tilt or shift
during the floods.
e) All necessary precautions shall be taken against any possible damage to the
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Well Foundations Seclion 1200
foundations of existing structures in the vicinity of the wells, prior to commence-

mènt of dredging from inside the welL
f) The dredged material shall not be allowed to accumulate over the well. It shall
be dumped and spread, as far away as possible, and then continuously and
simultaneously removed, as directed by the Engineer. In case the river stream
flows along one edge of the well being sunk, the dredged material shall not
be dumped on the dry side of the bank but on the side on which the over
current flows.
g) Very deep rump shall not be made below the well curb, as it entails risk of
jumping (sudden sinking) of the well. The depth of rump shall be generally limited
to one-sixth of the outes diameter/least lateral dimension of the well in plan.
Normally, the depth of sump shall not exceed 3.0 metres below the level of the
cutting edge unless otherwise specifically permitted by the Engineer.
h) hi case a well sinks suddenly with a jerk, the steinjpg of the well shall be
examined to the satisfaction of the Engineer to see that no damage has occurred
to it,
i) In pneumatic sinking, the well shall not, at any time, be dropped to a depth
greater than 500 mm by the method of “blowing down”,
j) Dewatering shall be avoided if sand blows are expected. Any equipment and
men workmg inside the well shall be brought out of the well as soon as there
are any indications of a sand-blow.
k) Sand blowing in wells can often be minimised by keeping the level of water
inside the well higher than the water table and also by adding heavy kentledge.
I) In soft strata prone to settlement/creep, the constmction of the abutment wells
shall be taken up only after the approach embankment for a sufficient distance
near the abutment has been completed.
1207.8. Tilts and Shifts
The inclination of the well from the vertical is known as tilt and
the horizontal displacement of the centre of the well at the founding
level from its theoretical position is known as shift.
Unless otherwise specified, the tilt of any well shall not exceed 1
(horizontal) in 80 (vertical), and the shift at the Well base shall not
be more than 150 mm in any resultant direction.
Tilts and shifts shall be carefully checked and recorded in the format
vide Appendix 1200/11 regularly during sinking operations. For the purpose
of measuring the tilts along the two axes of the bridge, reduced level
of the marks painted on the surface of the steining of the well shall
be taken. For determination of shift, locations of the ends of the two
diameters shall be precisely measured along the two axes, with reference
to fixed reference points.
Whenever any tilt is noticed, adequate preventive measures like
placing eccentric kentledge, pulling, strutting, anchoring or dredging
<<
unevenly and depositing dredge material unequally, putting obstacles
below cutting edge. Water jetting etc., shall be adopted before any further
sinking. After correction, the dredged material shall be spread out
uniformly.
A pair of wells close to each other have a tendency to come
closer while sinking. Timber struts may be introduced in between the
steining of these wells to prevent tilting.
Tilts occurring in a well during sinking in dipping rocky strata can
be safeguarded by suitably supporting the curb.
In the event of a well developing tilt or shift beyond the
specified permissible values, the Contractor shall have to carry out, at
his own cost, suitable remedial measures to the satisfaction of the
Engineer, to bring the tilt and shift within permissible values, as far
as practicable.
If the resultant tilt and / or shift of any well exceeds the specified
permissible values, generally it should not exceed I in 50 and 300 mm
respectively. The well so sunk shall be regarded as not conforming to
specifications and a sub-standard work. The Engineer in his sole
discretion, may consider accepting such a well, provided
(1) Calculations for foundation pressures and steining stresses, accounting rot the
actual tilt and shift furnished by the Contractor show that the well is safe.
Any remedial measures required to bring the stresses within permissible values
(such as increase in the dimension of the well cap, provision of dummy weights
oct the well cap etc, shall be carried out by the Contractor without claiming
for any extra cost,
(ii) The Contractor shall agree to reduction in rates in accordance with Clause
1215(g).
In case the Engineer, in his discretion, rejects the well, the Contractor
shall dismantle the rejected well to the extent directed by the Engineer
and remove the debris. Further, the Contractor shall, at his own risk
and expense complete the bridge with modified span arrangement
acceptable to the Engineer.
1207,9. Seating of Wells
The well shall be uniformly seated at the founding strata. it
shall be ensured by test borings that the properties of the soil encountered
at the founding strata and upto a depth of one and a half times the
well diameter is identical to that adopted in the design. The procedure
for test borings shall satisfy the provisions of these specifications.
In case the soil encountered is inferior to that adopted in design,
<< 374
Well Foundations Se~tion1200
the well shall be re-designed’ by the Engineer adopting the soil

properties actually encountered and the founding level intimated to the
Contractor, who shall carry out the work.
In case of seating of wells in hard rocky strata, where the rock
profile is steeply sloping, pneumatic methods of sinking may be adopted
to seat the well evenly as directed by the Engineer. The decision of
adopting pneumatic sinking shall be taken by the Engineer. The cutting
edge may also be embedded for a suitable depth in the rocky strata,
as decided by the Engineer keeping in view the quality of rock. As
an additional measure of safety, the well shall be anchored to the rocky
strata by anchor bars provided in the steining of the well, as shown
on the drawing irrespective of the fact that tension develops or not
at the base of the well under design loads. After the well has been
evenly seated on good hard rock, arrangements shall be made
to facilitate proper inspection in dry and visible conditions before the
bottom plug is laid.
1208. BOrIOM PLUG
For bottom plug, the concrete mix shall be designed (in dry
condition) to attain the concrete strength as mentioned on the drawing
and shall contain 10 per cent more cement than that required for
the same mix placed dry, to cater for underwater concreting. However,
the total cement content shall not be less than 363 kg/cu.m. of concrete
with a slump in the range of 150 mm to 200 mm. Admixtures may
be added to the concrete to impart the required characteristics indicated
herein.
Concrete for the bottom plug shall be laid by trernie pipe method.
Tremie concrete when started shall be continued without interruption
for full concreting in the bottom plug. The concrete production equipment
and placement equipment should be sufficient to enable under water
concreting within stipulated time. Necessary standby equipment should
be available for emergency situation.
Before commencing plugging, all loose material from the bottom of
the well shall be removed.
Concreting shall be done in one continuous operation till the dredge
hole is filled upto the required height and thereafter sounding shall
be taken upto ensure that the concrete has been laid to the required
height.
<< 375
Least disturbance shall be caused to the water inside the well
while laying concrete in the bottom plug.
Concrete shall not be disturbed in any way for at least 14 days.
In order to check any rise in the level of the bottom plug
soundings should be taken at the close of concreting and once every
day for the subsequent 3 days.
The soundness of the bottom plug may be tested by dewatering the
well by 5 metres below the surrounding water level and checking the
rise of water. The rate of rise shall preferably be less than 10 cms
per hour. In case the rate is higher, suitable remedial measures as
directed by the Engineer, shall be taken by the Contractor at his
own cost.
1209. SAND FILLING
Sand filling shall commence after a period of 3 days of laying of
bottom plug. Also, the height of the bottom plug shall be veri-
fied before starting sand filling.
Sand shall be clean and free from earth, clay clods, roots,
boulders, shingles, etc. and shall be compacted as directed. Sand filling
shall be carried out upto the level shown on the drawing, or as directed
by the Engineer.
1210. TOP PLUG
After filling sand upto the required level a plug of concrete shall
be provided over it as shown on the drawing, or as directed by
the Engineer.
1211 WELL CAP
A reinforced cement concrete well cap will be provided over the
top of the steining in accordance with the drawing. Formwork will be
prepared conforming to the shape of well cap. Concreting shall be carried
out in dry condition. A properly designed false steining may be
provided where possible to ensure that the well cap is laid in dry
conditions.
The bottom of the well cap shall be laid preferably as low as
possible, taking account the water level prevalent at the time of casting.
Bond rods of steining shall be anchored into the well cap.
<< 376
1212. TOLERANCES
The permissible tilt and shift shall not exceed I (horizontal) in 80
(vertical) and the shift at the well base shall not be more than 150
mm in any resultant direction.
For the well steining and well cap the permissible tolerances
shall be as follows
a) Variation in dimension : ÷50mm - 10 mm
b) Misplacement from specified position in plan : 15 mm
c) Surface irregularities measured with 3 m straight edge: 5 mm
d) Variation of levels at the top : ±25mm

tions and shall inSt the prescribed criteria.
All quantities shall be measured from the drawing, or as ordered
by the Engineer, excepting those required to be provided by the
Contractor at his cost.
a) The cutting edge shall be measured in tonnes based on the net weight of metal
used in it, as per Section 1900.
b) The concrete in curb, well steining and well cap shall be measured in cubic
metres in each of the items as per Section 1700. The reinforcements shall be
measured in tonnea separately in each of the items, as per Section 1600.
c) The measurement for well sinking shall be made in twining metres for
different depths and in different types of strata (for example, predominantly sand/
clay soil, soft rock, hard rock, etc) as specified in the Contract. The depth
of sinking shall be measured from the level specified in the Contract. If no
level has been specified in the Contract, sinking shall be measured from she
low waler level or from the level at which the cutting edge was laid, whichever
is higher.
d) The qusntity of concrete in bottom and top plug shall be measured in cubic
metres as per Section 1700.
e) The quantity of sand filling shall be measured in cubic metres.
fl Pneumatic sinking, where required shall be paid as a separate item and

shall be measured in cubic metres of material to be excavated.
1215. RATE
a) The Contract unit rates ofcutting edge shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, samplinj and testing,
<< 377
I-. -

and, supervision, all as per respective Section of Stnsctural Steel Work
and as described in this section,
h) The Contract unit rates for concrete in curb, steining, bottom plug, top plug
and well cap, shall cover all costs of labour, material, tools, plant and
equipment, forthwork and staging including placing in position, sampling and
testing, and, supervision, all as per respective Section of Stnsctural Concrete
and as described in this section.
c) The Contract unit rates for reinforcement in curb, steining, and well cap, shall
cover all costs of labour, material, tools, plant and equipment, including bending
to shape, placing in position, sampling, testing and supervision, all as per
respective Section of Steel Reinforcement and as described in this section.
d) The Contract unit rates for sand filling shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, sampling, testing and
supervision, all as described in this section.
e) The Concrete unit rates for sinking shall cover the costs of labour, tools, and
equipment and plant and for all operations and other incidentals for sinking of
well including seating exceptingrprovisions of pneumatic sinking as described in
this Section. The unit rates shall specify the strata such as types of soil, rock,
etc. The rate shall cover all testing and supervision required for the work.
I) The Contract unit rate of material to be excavated by pneumatic sinking
shall cover all costs & labour, material, tools, plant and other equipment and
other incidentals and safety provisions and supervision required for pneumatic
sinking as per this Section.
g) Reduction in contract unit rates for sinking as a penalty, in’ pursuance of clause
1207,8.
If any well with tilt and/or shift exceeding beyond permissible values
is accepted by the Engineer, the Contractor shall give a ~reductionin
the rates as follows
S,Nu, Amount of tilt and/or shift Per eent deduetlors
on the rate(s) for
. sinkIng of whole
sidl
1. Tilt exceeding the specified permissib4e value but 5 per cent
equal to or within 1 in 60
2. Tilt exceeding 1 in 60 10 per cent
but equal to or within I in 50
3. ‘lilt exceeding I in 50 20 per cent
4. Shift exceeding the specified pennissible 2 per cent
value but equal to or within 200 mm
5. Shift exceeding 200 mm but equal 5 per cent
to or within 300 mm
6. Shift exceeding 300 mm 10 per cent
Penalties for excessive tilt and shift shall be deducted separately.
<< 378
Brick Masonry
1300
Brick Masonry
<<
Brick Masonry Secuon 1300
1301. DESCRIPTION
This work shall consist of construction of structures with bricks
jointed together by cement mortar in accordance with the details shown
on the drawings or as approved by the Engineer.
1302. MATERIALS
All materials to be used in the work shall conform to the
requirements laid down in Section 1000.
1303. PERSONNEL
Only trained personnel shall be employed for construction and’
supervision.
1304. CEMENT MORTAR
Cement and sand shall be mixed in specified proportions given in
the drawings. Cement shall be proportioned by weight, taking the unit
weight of cement as 1.44 tonne per cubic metre. Sand shall be pro-
portioned by volume taking into account due allowance for bulking.
All mortar shall be mixed with a ~ninimum quantity of water to
produce desired workability consistent with maximum density of mortar.
The mix shall be clean and free from injurious type of soil/acid/alkali!
organic matter or deleterious substances.
The mixing shall preferably be done in a mechanical mixer
operated manually or by power. Hand mixing can be resorted to as
long as uniform density of the mix and its strength are assured subject
to prior approval of the Engineer. Where permitted, specific
permission is to be given by the Engineer. Hand mixing operation shall
be carried out on a clean water-tight platform, where cement and
sand shall be first mixed dry in the required proportion by being turned
over and over, backwards and forwards several times till the mixture
is of uniform colour. Thereafter, minimum quantity of water shall be
added to bring the mortar to the consistency of a stiff paste. The mortar
shall be mixed for at least two minutes after addition of water.
Mortar shall be mixed only in such quantity as required for
immediate use. The mix which has developed initial set shall not be
used. Initial set of mortar with ordinary Portland Cement shall
normally be considered to have taken place in 30 minutes after mixing.
In case the mortar has stiffened during initial setting time because
of evaporation of water, the same can be re-tempered by adding water
381
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Section 1300 Brick Masonry
as frequently as needed to restore the requisite consistency, but this

re-tempering shall not be permitted after 30 minutes. Mortar unused
for more than 30 minutes shall be rejected and removed from site
of work.
1305. SOAKING OF BRICKS
All bricks shall be thoroughly soaked in a tank filled with water
for a minimum period of one hour prior to being laid. Soaked bricks
shall be removed &om the tank sufficiently in advance so that they
are skin dry at the time of actual laying. Such soaked bricks shall
be stacked on a clean place where they are not contaminated with
dirt, earth, etc.
1306. JOINTS
The thickness of joints shall not exceed 10mm, All joints on
exposed faces shall be tooled to give concave finish.
1307. LAYING
All brickwork shall be laid in an English bond, even and true to
line, in accordance with the drawing or as directed by the Engineer,
plumb and level and all joints accurately kept Half and cut bricks
shall not be used except when necessary to complete the bond.
Closer in such cases shall be cut to the required size and used
near the ends of the walls. The bricks used at the face and also at
all angles forming the junction of any two walls shall be selected whole
bricks of uniform size, with hue and rectangular faces.
All bricks shall be laid with frogs up on a full bed of mortar
except in the case of tile bricks. Each brick shall be properly bedded
and set in position by slightly pressing while laying, so that the mortar
gets’-into all their surface pores to ensure proper adhesion. All head
and side joints shall be completely filled by applying sufficient mortar
to brick already placed and on brick to be placed. All joints shall
be properly flushed and packed with mortar so that no hollow spaces
are left. No bats or cut bricks shall be used except to obtain dimensions
of the different courses for specified bonds or wherever a desired shape
so requires.
The brick work shall be built in uniform layers, and for this
purpose wooden straight edge with graduations indicating thickness
of each course including joint shall be used. Corners and other advanced
work shall be raked back. Brickwork shall be done true to plumb or
in specified batter. All courses shall be laid truly horizontal and
382
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Brick Masonry Section 1300
vertical joints shall be truly vertical. Vertical joints in alternate

courses shall come directly one over the other. During construction,
no part of work shall rise more than one metre above the general
construction level, to avoid unequal settlement and improper jointing.
Where this is not possible in the opinion of the Engineer, the works
shall be raked back according to the bond (and not toothed) at an angle
not steeper than 45 degrees with prior approval of the Engineer.
Toothing may also be permitted where future extension is contemplated.
Before laying bricks in foundation, the foundation slab shall be thor-
oughly hacked, swept clean an~wetted. A layer of mortar not less than
12 mm thick shall be spread on the surface Of the foundation slab
and the first course of bricks shall be laid.
1308. JOINTING OLD AND NEW WORK
Where fresh masonry is to join with masonry that is partially/entirely
set, the exposed jointing surface of the set masonry shall be cleaned,
roughened and wetted, so as to effect the best possible bond with the
new work. All loose bricks and mortar or other material shall be removed.
ln the case of vertical or inclined joints, it shall be further ensured
that proper bond between the old and new masonry is obtained
by interlocking the bricks. Any portion of the brickwork that has been
completed shall remain undisturbed until thoroughly set.
In case ‘of sharp corners specially in skew bridges, a flat cutback
of 100 mm shall be provided so as to have proper and bonded laying
of bricks;
1309. CURING
Green work shall be protected from rain by suitable covering and
shall be kept constantly moist on all faces for a minimum period of
seven days. Brick work carried out during the day shall be suitably
marked indicating the date on which the work is done so as to keep
a watch on the curing period. The top of the masonry work shall be
left flooded with water at the close of the day. Watering may be
done carefully so as not to disturb or wash out the green mortar.
During hot weather, all finished or partly completed work shall
be covered or wetted in such a manner as will prevent rapid drying
of the brickwork.
During the period of curing of brick work: it shall be suitably
protected from all damages. At the close of day’s work or for other
<< 383
period of cessation, watering and curing shall have to be maintained.
Should the mortar perish i.e. become dry, white or powdery through
neglect of curing, work shall be pulled down and rebuilt as directed
by the Engineer. If any stains appear during watering, the same shall
be removed from the face.
1310. SCAFFOLDING
The scaffolding shall be sound, strong and safe to withstand all
loads likely to come upon it. The holes which provide resting space
for horizontal members shall not be left in masonry under one metre
in width or immediately near the skew backs of arches. The holes left
in the masonry work for supporting the scaffolding shall be filled and
made good. Scaffolding shall be got approved by the Engineer. However,
the Contractor shall be responsible for its safety.
1311. EQUIPMENT
All tools and equipment used for mixing, transporting and laying
of mortar and bricks shall be clean and free from set mortar, dirt
or other injurious foreign substances.
1312. FINISHING OF SURFACES
1312.1. General
All brickwork shall be finished in a workmanlike manner with the
thickness of joints, manner of striking or tooling as described in thdse
above specifications.
The surfaces can be finished by “jointing” or “pointing” or by
“plastering” as given in the drawings.
For a surface which is to be subsequently plastered or pointed, the
joints shall be squarely raked out to a depth of 15 mm, while the mortar
is still green. The raked joints shall be well brushed to remove dust
and loose particles and the surface shall be thoroughly washed with
water, cleaned and wetted.
The mortar for finishing shall be prepared as per Clause 1304.
1312.2. Jointing
In jointing, the face of the mortar shall be worked out while
still green to give a finished surface flush with the face of the brick
work. The faces of brick work shall be cleaned to remove any splashes
of mortar during the course of raising the brick work.
384
<<
1312.3. Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by
volume of cement and sand or as shown on the drawing. The mortar
shall be filled and pressed into the raked joints before giving the
required finish. The pointing shall be ruled type for which it shall,
while still green, be ruled along the centre with half round tools of
such width as may be specified by the Engineer. The super flush mortar
shall then be taken off from the edges of the lines and the surface of
the masonry shall be cleaned of all mortar, The work shall conform
to IS:2212.
1312.4. Plastering
Plastering shall be done where shown on the drawing. Superficial
plastering may be done, if necessary, only in structures situated in fast
flowing rivers or in severely aggressive environment.
Plastering shall be started from tOp and worked down. All putlog
holes shall be properly filled in advance of the plastering while the
scaffolding is being taken down. Wooden screeds 75 mm wide and of
the thickness of the plaster shall be fixed vertically 2.5 to 4 metres
apart, to act as gauges and guides in applying the plaster. The mortar
shall be laid on the wall between the screeds using the plaster’s float
and pressing the mortar so that the raked joints are properly filled.
The plaster shall then be finished off with a wooden straight edge
reaching across the screeds. The straight edge shall be worked on the
screeds with a small upward and sideways motion 50 mm to 75 mm
at a time. Finally, the surface shall be finished off with a plasterer’s
wooden float. Metal floats shall not be used.
When recommencing the plastering beyond the work suspended
earlier, the edges of the old plaster shall be scrapped, cleaned and
wetted before plaster is applied to the adjacent areas.
No portion of the surface shall be left unfinished for patching up
at a later period.
The plaster shall be finished true to plumb surface and to the proper
degree of smoothness as directed by the Engineer.
The average thickness of plaster shall not be less than the
specified thickness. The minimum thickne~over~any portion of the
surface shall not be less than the specified thickness by more than
3mm.
<< 385
Any cracks which appear in the surface and all portions which
sound hollow when tapped, or are found to be soft or otherwise
defective, shall be cut in rectangular shape and re~doneas directed
by the Engineer.
1312.5. Curing of Finishes
Curing shall be commenced as soon as the mortar used
for finishing has hardened sufficiently not to be damaged during
curing. It shall be kept wet for a period of at least 7 days. During
this period, it shall be suitably protected from all damages.
1312.6. Scaffolding for Finishes
Stage scaffolding shall be provided for the work. This shall be
independent of the structure.
1313. ARCHITECTURAL COPING FOR WINGIRETURN/
PARAPET WALL
This work shall consist of providing an Architectural coping for
wing/return/parapet walls.
The material used shall be cement mortar 1:3 or as shown on the
drawings prepared in accordance with Clause 1304.
The cement mortar shall be laid evenly to an average thickness of
15 mm to the full width of the top of the wall and in continuation
a band of 15 mm thickness and 150 mm depth shall be made out of
the mortar along the top outer face of the walls.
1314. ACCEPTANCE OF WORK
All work shall be true to the lines and levels as indicated on
the drawing or as directed by the Engineer, subject to tolerances as
indicated in these specifications.
Mortar cubes shall be tested in accordance with !S:2250 for
compressive strength, consistency of mortar and its water retentivity.
The frequency of testing shall be one sample for every 2 cubic meties
of mortar, subject to a minimum 3 samples for a day’s work.
In case of plaster finish, the minimum surface thickness shall
not be less than the specified thickness by more than 3mm.
All brick work shall be measured in cubic metres. Any extra work
done by the Contractor over the specified dimensions shall be ignored.
386
<<
In arches, the length of areh shall be measured as the mean
length between the extrados and intrados.
The work of plastering and pointing shall be measured in square
metres of the surface treated.
Architectural coping shall be measured in linear metres.
1316. RATE
The contract unit rate for brick work shall include the cost of
all Labour, materials, tools and plant, scaffolding and other expenses
incidental to the satisfactory completion of the work, sampling, testing
and supervision as described in these specifications and as shown on
the drawings.
The contract unit rate for plastering shall include the cost of all
Labour, materials, tools and plant, scaffolding and all incidental
expenses, sampling and testing and supervision as described in these
specifications.
The contract unit rate for pointing shalt include erecting and
removal of scaffolding, all labour, materials, and equipment incidental
to complete the pointing, raking out joints, cleaning, wetting, filling with
mortar, trowelling; pointing and watering, sampling and testing and
supervision as described in these specifications.
The contract unit rate for architectural coping shall include cost
of all labour, materials, tools and plant, sampling and testing and
<< 387
Stone Masonry
1400
Stone Masonry
<<
Stone Masonry Section 1400
1401. DESCRIPTION
This work shall consist of the construction of structures with stones
jointed together by cement mortar in accordance with the details shown
on the drawings and these specifications or as approved by the Engineer.
1402. MATERIALS
All materials used in stone masonry shall conform to Section 1000
except cement mortar for stone masonry which shall conform to
Clause 1304.
1403. PERSONNEL
Only trained personnel shall be employed for construction and
supervision.
1404. TYPE OF MASONRY
The type of masonry used for structures shall be random masonry
(coursed or uncoursed) or coursed rubble masonry (First sort). However,
for bridge work generally, course rubble stone masonry shall be used.
The actual type of masonry used for different parts of structures shall
be specified on the drawings.
For facing work, ashlar masonry shall be used where indicated on
the llrawings.
1405. CONSTRUCTION OPERATIONS
1405.1. General Requirements
The dressing of stone shall be as specified for individual type
masonry work and it shall also conform to the general requirements
of 15:1597 and requirement for dressing of stone covered in 15:1129.
Other specific requirements are covered separately with respect to
particular types of rubble stone work.
1405.2. Laying
1405.2.1. The masonry work shall be laid to lines, levels, curves
and shapes as shown in the plan. The height in cach course shall be
kept same and every stone shall be fine tooled on all beds joints and
face full and true. The exposed faces shall be gauged out, grooved,
regulated and sunk or plain moulded as the case may be. The faces
of each stone between the draft be left rough as the stone comes from
quarry except where sacrificial layer is to be provided or plastering is
resorted to due to aggressive environment.
<< 391
Section 1400 Stone Masonry
1405.2.2. Stones shall be sufficiently wetted before laying to

prevent absorption of water from mortar.
Stratified stones must be laid on their natural beds. All bed joints
shall be normal to the pressure upon them.
Stones in the hearting shall be laid on their broadest face that gives
a better opportunity to fill the spaces between stones.
The courses of the masonry shall ordinarily be pre-determined.
They shall generally be of the same height. When there is to be variation
in the height of courses, the larger courses are to be placed at lower
levels, heights of courses decreasing gradually towards the top of the
wall. The practice of placing loose mortar on the course anti pouring
water on it to fill the gaps in stones is not acceptable. Mortar may
be fluid mixed thoroughly and then poured in the joints. No dry or
hollow space shall be left anywhere in the masonry and each stone
shall have all the embedded faces completely covered with mortar.
In tapered walls, the beds of the stones and the planes of course
should be at right angles to the batter. In case of bridge piers with batter
on both sides, the course shall be horizontal.
The bed which is to receive the stone shall be cleaned, wetted
and covered with a layer of fresh mortar. All stones shall be laid
full in mortar both in bed and vertical joints and settled carefully in
place with a wooden mallet immediately on placement and solidly
embedded in mortar before it has sel Clean chips and spalls shall be
wedged into the mortar joints and bed wherever necessary to avoid
thick beds or joints of mortar. When the foundation masonry is laid
directly on rock, the face stones of the first course shall be dressed
to fit into rock snugly when pressed down in the mortar bedding
over the rock. No dry or hollow space shall be left anywhere in the
masonry and each stone shall have all the embedded faces completely
covered with mortar, For masonry works over rock, a levelling course
of 100 mm thickness and in concrete M 15 shall be laid over rock
and then stone masonry work shall be laid without foundation concrete
block.
Face works and hearting shall be brought up evenly but the top of
each course shall not be levelled up by the use of flat chips.
For sham corners specially in skew bridges, through stones shall be
used in order to avoid spalling of corners.
In case any stone already set in mortar is disturbed or the joints
<< 392
Stone Masonry SecLion 1400
broken, it ~hallbe taken out without disturbing the adjoining stones

and joints. Dry mortar and stones thoroughly cleaned from the joints
and stones and the stones reset in fresh mortar. Attempt must never
be made to slide one stone on top of another, freshly laid.
Shaping and dressing shall be done before the stone is laid in
the work. No dressing and hammering, which will loosen the
masonry, will be allowed after it is once placed. All necessary chases
for joggles, dowels and clamps should be formed before hand.
Sufficient transverse bonds shall be provided by the use of bond
stone extending from the front to the back of the wall and in case
of thick wall from outside to the interior and vice versa. In the latter
case, bond stones shall overlap each other in their arrangement.
In case headers are not available, precast headers of M 15
concrete shall be used. Cast~in-situheaders are not permitted.
Stones shall break joint on the face for at least half the height of
the course and the bond shall be carefully maintained through~
out.
In band work at all angle junctions of waIls, the stones at each
alternate course shall be carried into each of the respective walls
so as to unite the work thoroughly.
The practice of building up thin faces tied with occasional
through stones and filling up the middle with small stuff or even dry
packing is not acceptable.
All quoins and the angles of the opening shall be made from
selected stones, carefully squared and bedded and arranged to bond
alternately long and short in both directions~
All vertical joints shall be truly vertical. Vertical joints shall be
staggered as far as possible. Distance between the nearer vertical
joints of upper layer and lower shall not be less than half the height
of the course.
Only rectangular shaped bond stones or headers shall be used.
Bond stones shall overlap each other by 150 mm or more.
All connected masonry in a structure shall be carried up nearly
at one uniform level throughout but when ,breaks are unavoidable the
masonry shall be raked in sufficiently long steps to facilitate
jointing of old and new work. The stepping of raking shall not be more
than 45 degrees with the horizontal.
<< 393
section 1400 Stone Masonry
14053. Random Masonry (Uncoursed and Coursed)

1405.3.1. Dressing : Stone shall be hammer dressed on the face,
the sides and beds to enable it to come in proximity with the
neighbouring stone. The bushing on the exposed face shall not be more
than 40 mm.
1405.32. insertion of chips : Chips and spalls of stone may be used
wherever necessary to avoid thick mortar beds or joints and it shall
be ensured that no hollow spaces are left anywhere in the masonry.
The chips shall not be used below hearting stones to bring these upto
the level of face stones. Use of chips shall be restricted to filling
of interstices between ‘the adjacent stones in hearting and they shall
not exceed 20 per cent of the quantity of stone masonry~.
1405.3.3. Hearting stones : The hearting or interior filling of the
wall face shall consist of rubble stones not less than 150 mm in any
direction, carefully laid, hammered down with a wooden mallet
into position and solidly bedded in mortar. The hearting should be
laid nearly level with facing and backing.
1405.3.4. Bond stones : Through bond stones shall be provided
in masonry upto 600 mm thickness and in case of masonry above
600 mm thickness, a set of two or more bond stones overlapping each
other at least by 150 mm shall be provided in a line from face to back.
in case of highly absorbent types of stones (porous limestone and
sandstones, etc.,) the bond stone shall extend only about two-third into
the wall, as through stones in such cases may give rise to penetration
of dampness and therefore, for all thicknesses of such masonry, a set’
of two or more bond stones overlapping each other by at least 150
mm shall be provided, One bond stone or a set of bond stones shall
be provided for every 0.50 sq. m. of the masonry surface.
1405.3.5. Quoin stone: Quoin stone i.e. stone specially selected and
neatly dressed for forming an external angle in masonry work, shall
not be less than 0.03 cubic metre in voltime.
1405.3.6. Plum stone : The plum stones are selected long stones
embedded vertically in the interior of the masonry to form a bond
between successive courses and shall be provided at about 900 mm
intervals.
1405.3.7. Laying: The masonry shall be laid with or without courses
as specified. The quoins shall be laid header and stretcher alternately.
Every stone shall be fitted to the adjacent stone so as to form neat
<< 394
and close joint. Face stone shall extend and bond well in the back.
These shall be arranged to break joints, as much as possible,
and to avoid long vertical lines of joints.
1405.3.8. Joints : The face joints shall not be more than 20 mm
thick, but shall be sufficiently thick to prevent stone-to-stone contact
and shall be completely filled with mortar.
1405.4. Square Rubble Coursed Rubble (First Sort)
-
1405.4.1. Dressing : Face stones shall be hammer dressed on all

beds and joints so as to give them rectangular shape. These shall
be square on all joints and beds. The bed joints shall be chisel drafted
for at least 80 mm back from the face and for at least 40 mm for
the side joints. No portion of the dressed surface shall show a depth
of gap more than 6 mm from the straight edge placed on it. The
remaining unexposed portion of the stone shall not project beyond the
surface of bed and side joints. The requirements regarding bushing
shall be the same as for random rubble masonry.
1405.4.2. Hearting stones : The hearting or interior filling of the
wall face shall consist of flat bedded stone carefully laid, on prepared
beds in mortar. The use of chips shall be restricted to the filling
of interstices between the adjacent stones in hearting and these shall
not exceed 1Q per cent of the quantity of masonry. While using chips
it shall be ensured that no hollow spaces are left anywhere in the
masonry.
1405.4.3. Bond stones : The requirements regarding through or
bond stone shall be the same as for random rubble masonry, but these,
shall be provided at 1.5 metre to 1.8 metre apart clear in every course.
1405.4.4. Quoin stone : The quoins shall be of the same height
of the course in which these occur and shall be formed of header stones
not less than 450mm in length. They shall be laid lengthwise alternately
along each face, square in their beds which shall be fairly dressed
to a depth of at least 100 mm.
1405.4.5. Face stone : Face stones shall tail into the work for
not less than their heights and at least one-third of the stones shall
tail into the work for a length not less than twice their height. These
shall be laid as headers and stretchers alternately.
1405.4.6, Laying: The stones shall be laid on horizontal courses
and all vertical joints should be truly vertical. The quoin stones should
be laid header and stretcher alternately and shall be laid square
<< 395
Section 14(X) Stone Masonry
on their beds, which shall be rough chisel dressed to a depth of at least

100 mm.
1405.4.7. Joints : The face joints shall not be more than 10 mm
thick, but shall be sufficiently thick to prevent stone-to-stone contact
and shall be completely filled with mortar.
1405,5. Ashlar Masonry (Plain Asbiar)
1405.5.1. Dressing : Every stone shall be cut to the required size
and shape, chisel dressed on all beds and joints so as to be fn~efrom
all bushing. Dressed surface shall not show a depth of gap of more
than 3 mm from straight edge placed on it. The exposed faces and
joints, 6 mm from the face shall be fine tooled so that a straight edge
can be laid along the face of the stone in contact with every point.
All visible angles and edges shall be true and square and free from
chippings. The corner stones (quoins) shall be dressed square and corner
shall be straight and vertical.
1405.5.2. Bond stones : Through bond stones ‘shall be provided
in masonry upto 600 mm thickness and in case of masonry above
600 mm thickness, a set of two or more bond stones overlapping each
other at least by 150 mm shall be provided in a line from face to back.
In case of highly absorbent types of stones (porous limestone and
sandstones, etc.,) the bond stone shall extend only about ,two-third into
the wall, as through stones in such cases may give rise to penetration
of dampness and, therefore, for all thicknesses of such masonry a
set of two or more bond stones overlapping each other by at least 150
mm shall be provided. One bond stone or a set of bond stones shall
be 1.5 metres to 1.8 metres apart clear in every course.
1405.5.3. Laying : The face Stone shall be laid header and stretcher
alternately, the header being arranged to come as nearly as possible
in the middle of stretchers above and below. Stones shall be laid
in regular courses not less than 300 mm in height and all courses of
the same height unless otherwise specified. No stone shall be less
in width than its height or less in length than twice its height, unless
otherwise specified.
1405.5.4. Joints : All joints shall be full of mortar. These shall not
be less than 3 mm thick. Face joints shall be uniform throughout, and
a uniform recess of 20 mm depth from face shall be left with the help
of a stone plate during the progress of work.
<< 396
1405.6L Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by
volume of cement and sand or as shown on the drawing. The mortar
shall be filled and pressed into the raked out joints before giving
the required finish. The pointing shall conform to Clause 1312.3 of
the specification. The work shall conform to 15:2212. The thickness
of joints shall not be less than 3 mm for Ashlar masonry. However,
the maximum thickness of joints in different works shall be as follows:
Random Rubble 20 mm
Coursed Rubble L5 mm
Ashlar Maonry 5 mm
l405.7. Curing
Curing shall conform to Clauses 1309 and 1312.5
1405.8. Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9. Weep Holes
Weep holes shall conform to Clause 2706.
1405.10. Jointing with Existing Structures
For Jointing with existing structures, the specifications given under
Clause 1308 shall apply.
1406. ARCHITECTURAL COPING FOR WING/RETURNI
PARAPET WALLS
Architectural coping for wing/return/parapet walls shall conform to
:lause 1311
1407, TESTS AND STANDARD OF ACCEPTANCE
All work shall be done to the lines and levels as indicated on
he drawing or as directed by the Engineer subject to tolerances as
pecified in these specifications.
Mortar cubes shall be taken in accordance with 15:2250 for
compressive strength, consistency of mortar and its water retentivity.
The frequency of testing shall be one sample for every two cubic
metres of mortar sul~jectto a minimum 3 samples for a thy’s work.
1408, MEASUREMItNTS FOR PAYMENT
Stone masonry shall be measured in cubic metres.
397
<<
Section 1400 Stone Masonry
In arches, the length of arch shall be measured as the mean
length between the extrados and intrados.
The work of pointing shall be measured in square metres.
Architectural coping shall be measured in linear metres.
1409. RATE
The contract unit rate for stone masonry shall include the cost
of all labour, materials, tools and plant, scaffolding, sampling and testing,
supervision and other expenses incidental to the satisfactory completion
of the work as described herein above.
The contract unit rate for pointing shall include erecting and
removal of scaffolding, all labour, materials and equipment incidental
to complete pointing, raking out joints, cleaning, wetting, filling with
mortar, trowelling, pointing and watering, sampling and testing and
The contract rate for architectural coping shall include the cost of
all labour, materials, tools and plant, sampling and testirg and supervision
as described in these specifications.
398
<<
Formwork
1500
Formwork
<<
Formwork Section 1500
1501. DESCRIPTION
Formwork shall include all temporary or permanent forms required
for forming the concrete of the shape, dimensions and surface finish
as shown on the drawing or as directed by the Engineer, together with
all props, staging, centering, scaffolding and temporary construction
required for their support. The design, erection and removal of formwork
shall conform to IRC:87 “Guidelines for Design and Erection of
Falsework for Road Bridges” and these specifications.
1502. MATERIALS
All materials shall comply with the requirements of IRC:87. Materials
and components used for formwork shall be examined for ~lamage or
excessive deterioration before use / re-use and shall be used only if
found suitable after necessary repairs. In case of timber formwork, the
inspection shall not only cover physical damages but also signs of attacks
by decay, rot or insect attack or the development of splits.
Forms shall be constructed with metal or timber. The metal used
for forms shall be of such thickness that the forms remain true to
shape. All bolts should be countersunk. The use of approved internal
steel ties or steel or plastic spacers shall be permitted. Structural
steel tubes used as support for forms shall have a minimum wall thickness
of 4 mm. Other materials conforming to the requirements of IRC:87
may also be used if approved by the Engineer.
1503. bESIGN OF FORMWORK
1503.1. The Contractor shall furnish the design and drawing of
complete forniwork (i.e. the forms as well as their supports) for approval
of the Engineer before any erection is taken up. If proprietary system
of formwork is used, the Contractor shall furnish detailed information
as per Appendix 1500/i to the Engineer for approval.
Notwithstanding any approval or review of drawing and design by
the Engineer, the Contractor shall be entirely responsible for the
adequacy and safety for formwork.
1503.2. The design of the formwork shall conform to provisions of
IRC:87. It shall ensure that the forms can be conveniently removed
without disturbing the concrete. The design shall facilitate proper
and safe access to all parts of formwork for inspection.
1503.3. In the case of prestressed concrete superstructure, careful
<< 401
Section 1500 Formwork
consideration shall be given to redistribution of loads on props due to
prestressing.
1504. WORKMANSHIP
1594,1. The formwork shall be robust and strong and the joints
shall be leak-proof.
Balli shall not be used as staging. Staging must have cross
bracings and diagonal bracings in both directions. Staging shall be
provided with an appropriately designed base plate resting on firm strata.
1504.2. The number of joints in the formwork shall be kept to a
minimum by using large size panels. The design shall provide for
proper “soldiers” to facilitate alignment. All joints shall be leak proof
and must be properly sealed. Use of PVC JOINT sealing tapes,
foam rubber or PVC T-section is essential to prevent leakage of
grout.
1504.3. As far as practicable, clamps shall be used to hold the
forms together. Where use of nails is unavoidable minimum number
of nails shall be used and these shall be left projecting so that they
can be withdrawn easily. Use of double headed nails shall be preferred.
1504.4. Use Qf ties shall be restricted, as far as practicable. Wherever
ties are used they shall be used with HDPE sheathing so that the ties
can easily be removed. No parts prone to corrosion shall be left
projecting or near the surface. The sheathing shall be grouted with
cement mortar of the same strength as that of the structure.
1594.5. Unless otherwise specified, or directed, chamfers or fillets
of sizes 25 mm x 25 mm shall be provided at all angles of the form work
to avoid sharp corners. The chamfers, bevelled edges and mould-
ings shall be made in the formwork itself, Opening for fixtures
and other fittings shall be provided in the shuuering as directed by the
Engineer.
1504.6. Shuttering for walls, sloping members and thin sections
of considerable height shall be provided with temporary openings to
permit inspection and cleaning out before placing of concrete.
1504.7. The formwork shall be constructed with precamber to the
sofflt to allow for deflection of the formwork. Pre-camber to allow
for deflection of formwork shall be in addition to that indiôated for the
perthanent structure in the drawings.
1504.8. Where centering trusses or launching trusses are adopted
<< 402
for casting of superstructure, the joints of the centering trusses, whether
welded, riveted or bolted should be thoroughly checked periodically.
Also, various members of the centering trusses should be periodically
examined for proper alignment and unintended deformation before
proceeding with the concreting. They shall also be periodically checked
for any deterioration in quality due to steel corrosion.
1504.9. The formwork shall be so made as to produce a finished
concrete true to shape, line and levels and dimensions as shown on
the drawings, subject to the tolerances specified in respective sections
of these specifications, or as directed by the Engineer.
1504.10. Where metal forms are used, all bolts and rivets
shall be countersunk and well ground to provide a smooth, plane surface.
Where timber is used it shall be well seasoned, free from loose knots,
projecting nails, splits or other defects that may mar the surface of
concrete.
1504.11. Forms shall be made sufficiently rigid by the use of ties
and bracings to prevent any displacement or sagging between supports.
They shall l~estrong enough to withstand all pressure, ramming and
vibration during and after placing the concrete. Screw jacks or hard
wood wedges where required shall be provided to make up any settlement
in the formwork either before or during the placing of concrete.
1504.12. The formwork shall take due account of the calculated
amount of positive or negative camber so as to ensure the correct
final shape of the structures, having regard to the deformation of
false work, scaffolding or propping and the instantaneous or deferred
deformation due to various causes affecting prestressed structures.
1504.13. Suitable camber shall be provided to horizontal members
of structure, specially in Ion~spans to counteract the effects of
deflection. The formwork shall be so fixed as to provide for such camber,
1504.14. The formwork shall be coated with an~approved release
agent that will effectively prevent sticking and will not stain the concrete
surface. Lubricating (machine oils) shall be prohibited for use as coating.
1505. FORMED SURFACE AND FINISH
The formwork shall be lined with material approved by the
Engineer so as to provide a smooth finish of uniform texture and
appearance. This material shall leave no stain on the concrete and
so fixed to its backing as not to impart any blemishes. It shall be
of the same type and obtained from only one source throughout
<< 403
for the construction of any one structure. The contractor shall make
good any ithperfections in the resulting finish as required by the
Engineer. Internal ties and embedded metal parts shall be carefully
-.
detailed and their use shall be subject to the approval of tfie Engineer.
1506. PRECAUTIONS
(i) Special measures in the design of formwork shall be taken to ensure that it
does not hinder the shrinkage of concrete, The sof fit of the fomiwork shall
be so designed as to ensure that the formworit does not restrain the shortening
and/or hogging of beams during prestressissg. The forms may be removed at
the earliest opportunity subject to the minimum time for removal of forms with
props retained in position.
(ii) Where necessary, forsnwork shall be so arranged that the soffit form, properly
supported on props only can be retained irs position for such period as may
be required by matu:ring conditions.
(iii) Any cut-outs or openings provided in any stmcturai member to facilitate erection
of formwork shall be closed with the same grade of concrete as the adjoining
structure immediately after removal of fomswork ensuring watertight joints.
(iv) Provision shall be made for safe access en, to and about the forrnwork at the
levels as required.
(v) Close watch shall be maintained to check for settlement of formwork during
concreting. Any settlement of fomswork during concreting shall ho promptly
rectified.
(vi) Water used for curing should not be allowed to stagnate near the base plates
supporting the staging and should be properly drained.
1507. PREPARATION OF FORMWORK BEFORE
CONCRETING
The inside surfaces of forms shall, except in the case of
permanent form work or where otherwise agreed to by the Engineer
be coated with a release agent supplied by approved manufacturer or
of an approved material to prevent adhesion of concrete to the formwork.
Release agents shall be applied strictly in accordance with the manu-
facturer’s instructions and shall not be allowed to come into contact
with any reinforcement or prestressing tendons and anchorages.
Different release agents shall not be used in formwork for exposed
concrete.
Before re-use of forms, the following actions shall be taken
(i) The contact surfaces of the forms shall be cleaned carefully and dried before
applying a release agent
(ii) It should be ensured that the release agent is appropriate to the surface to
be coated, The same type and make of release agent shall be used throughout
on similar fomswork materials and different types should not be mixed.
<< 404
(iii) The form surfaces shall be evenly and thinly coated with eleare ageuL The
vertical surface shall be treated before horizontal surface and any excess wiped
Out.
(iv) The release agent shall not come in contact with reinforcement or the
hardened concrete
All forms shall he thoroughly cleaned immediately before con~
creting.
The Contractor shall give the Engineer due notice before placing
any concrete in the forms to permit him to inspect and approve the
formwork, but such inspection shall not relieve the contractor of
his responsibility for safety of formwork, men, machinery, materials
and finish or tolerances of concrete.
1S08. REMOVAL OF FORMWORK
The scheme for removal of formwork (i.e. de-shuuering and de-
centering) shall be planned in advance and furnished to the Engineer
for scrutiny and approval. No formwork or any part thereof shall
be removed without prior approval of. the Engineer.
The formwork shall be so removed as not to cause any damage~
to concrete. Centering shall be gradually and uniformly lowered in
such a manner as to permit the concrete to take stresses due to its
own weight uniformly and gradually to avoid any shock or vibration.
Where not specifically approved, the time of removal of formwork
(when ordinary Portland Cement is used without any admixtures at an
ambient temperatures exceeding 10 degrees Celsius) shall be as
under
a) Walls, piers, abutments, 12 to 48 hours as may 1~e
colwnns and vertical faces decided by the Engineer
of structural members
b) Soffits of Slabs
(with props left under) 3 days
c) Props (left under slabs) : 14 days

d) Softit of Girders : 7 days
(with props left under)
e) Props (left under girders) 21 days
Where there are re-entrant angles in the concrete sections, the
formwork should be removed at these sections as soon as possible after
the concrete.has set, in order to avoid cracking due to shrinkage of
concrete.
<< 405
1509. RE-USE OF FORMWORK

When formwork is dismantled, its individual components shall be
examined for damage and damaged pieces shall be removed for rec—
tification. Such examination shall always be carried Out before
being used again. Before re-use all components shall be cleaned of
deposits of soil,, concrete o~ other unwanted materials. Threaded
parts shall be oiled after cleaning.
All bent steel props shall be straightened before re-use. The
maximum deviation from straightness is 1/600 of the length. The
maximum permissible axial loads in used props shall be suitably reduced
depending upon their condition. The condition of the timber components,
plywood and steel shuttering plates shall be examined closely for
distortion and defects before re-use.
1510. SPECIALISE1) FORMWORK
Specialised formwork may be required in the case of slipform work,
underwater concreting, segmental construction etc. Such specialised form-
work shall be designed and detailed by competent agencies and a set
of complete working drawings and installation instructions shall be
supplied to the Engineer. The site personnel shall be trained in
the erection and dismantling as well as operation of such specialised
formwork. In case proprietary equipment is used, the supplier shall
supply drawings, details, installation instructions, etc.~in the form of
manuals along with the formwork. Where specialised formwork is used,
close co-ordination with the design of permanent structure is necessary.
For slipform the rate of slipping the formwork shall be designed
for each individual case taking into account various parameters including
the grade of concrete, concrete strength, concrete temperature, ambient
temperature, concrete admixtures, etc. In the case of segmental construc-
tion, the concrete mix shall be normally designed for developing high
early strength so that the formwork is released as early as possible.
in order to verify the time and sequence of striking/removal of
specialised formwork, routine field tests for the consistency of concrete
and strength development are mandatory and shall be carried out
before adoption.
For specialised formwork, the form lining material may be either
plywood or steel sheet of appropriate thickness., Plywood is preferred
where superior quality of surface is desired, whereas steel sheeting is
normally used where large number of repetitions are involved.
406
<<

tions and shall meet the prescribed criteria.
Unless stated otherwise the rate for concrete in Plain Concrete or
Reinforced Concrete or Prestressed Concrete shall be deemed to include
all formwork required in accordance with this section and shalt not be
measured separately.
Where it is specifically stipulated in the Contract that the formwork
shall be paid for separately, measurement of formwork shall be taken
in square metres of the surface area of concrete which is in contact with
formwork.
1513. RATE
The unit rate of the Plain Concrete or Reinforced Concrete or
Prestressed Concrete as defined in respective sections shall be deemed
•to cover the costs of all formwork, including cost of all materials,
labour, tools and plant required for design, construction and removal
of formwork and supervision as described in this section including
properly supporting the members until the concrete is cured, set and
hardened as required.
Where the contract unit rate for formwork is specifically provided
as a separate item, it shall include the cost of all materials, labour,
tools and plant required for design, construction and removal of formwork
and supervision as~described in this Section including properly
supporting the members until the concrete is cured, set and hardened
as required.
407
<<
Steel Reinforcement (Untensioned)
16D0
Steel Reinforcement
(Untensioned)
<<
Steel Reinforcement (Untensioned) Section 1600
1601, DESCRIPTION
This work shall consist of furnishing and placing coated or
uncoated mild steel or high strength deformed reinforcement bars
(untensioned) of the shape and dimensions shown on the drawings and
conforming to these Specifications or as approved by the Engineer.
1602. GENERAL
Steel for reinforcement shall meet with the requirements of Section
1000.
Reinforcements may be either mild steel/medium tensile steel or high
strength deformed bars. They may be uncoated or coated with epoxy
or with approved protective coatings.
1603. PROTECTION OF REINFORCEMENT
Uncoated reinforcing steel shall be protected from rusting or
chloride contamination. Reinforcements shall be free from rust, mortar,
loose mill scale, grease, oil or paints. This may be ensured either by
using reinforcement fresh from the factory or thoroughly cleaning all
reinforcement ui remove rust using any suitable method such as sand
blasting, mechanical wire brushing, etc., as directed by the Engineer.
Reinforcements shall be stored on blocks, racks or platforms and above
the ground in a clean and dry condition and shall be suitably marked
to facilitate inspection and identification.
Portions of uncoated reinforcing steel and dowels projecting from
concrete, shall be protected within one week after initial placing
of concrete with a brush coat of neat cement mixed with water to
a consistency of thick paint. This coating shall be removed by lightly
tapping with a hammer or other tool not more than one week before
placing of the adjacent pour of concrete. Coated reinforcing steel shall
be protected against damage to the coating. If the coating on the bars
is damaged during transportation or handling and cannot be repaired,
the same shall be rejected.
1604. BENDING OF REINFORCEMENT
Bar bending schedule shall be furnished by the Contractor and got
approved by the Engineer before start of work.
Reinforcing steel shall conform to the dimensions and shapes
-
given in the approved Bar Bending Schedules.
411
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I~~s.—. -.~ .... .- -
Section 1600 Steel Reinforcement (Untensioned)
Bars shall be bent cold to the specified shape and dimensions or

as directed by the Engineer using a proper bar bender, operated by hand
or power to obtain the correct radii of bends and shape.
Bars shall not be bent or straightened in a manner that will damage
the parent material or the coating.
Bars bent during transport or handling shall be straightened before
being used on work and shall not be heated to facilitate straightening.
1605. PLACING OF REINFORCEMENT
a) The reinforcement cage should generally be fabricated in the yard at ground level
and then shifted and placed in position. The reinforcement shall he placed strictly
in accordance with the dr%wings and shall be assembled in position only
when the structure is otherwise ready for plac:ing of concrete. Prolonged time
gap between assembling of reinforcements and casting of concrete, which
may result in rust formation on the surface, shall not be permitted.
b) Reinforcement bars shall be placed accurately in position as shown on the
drawings. The bars, crossing one another shall be tied together at every
intersection with binding wire (annealed), conforming to lS:280 to make the
skeleton of she reinrorcement rigid such that the reinforcement does not get
displaced during placing of concrete, or any other operation, The diameter
of binding wire shall not be lesa than 1 mm.
c) liars shall he kept in position usually by the following methods:
(i) In caseof beam and slab construction, industrially produced polymer rover
blocks of thickness equal to the specified cover shall be placed between the
bars and formwork subject to satisfactory evidence that the polymer
composition is not hannful to concrete and reinforcement. Cover blocks
made of concrete may be permiued by the Engineer, provided they have
the same strength and specification as those of the member.
(ii) tn case of dowels Mr columns and walls, the vertical reinforcement shall
be kept in position by means of timber templates with slots cut in them
accurately, or with cover Socks tied to the reinforcement. Timber templates
shall be removed after the concreting has progressed upto a level just
below their location.
(iii) Layers of reinforeernents shall be separated by spacer bars at approximately
one metre intervals. The minimum diameter of spacer bars shall be 12 mm
or equal to maximum size of main reinfoscanent or maximum size of
coarse aggregate, whichever is greater. Horizontal reinforcement shall not
be allowed to sag between supports.
(iv) Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting
wiies etc, or other subsidiary reinforcement shall be provided to fix the
reinforcements firmly in its correct position.
(v) Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks
etc., as devices for positioning reinforcement shall noI~be permitted.
d) liars coated with epoxy or any other approved protective coating shall be
412
<<
placed on supports that do not damage the coating. Supports shall be installed
in a manner suchthat planes of weakness are not created in hardened concrete.
The coated reinforcing steel shall be held in place by use of plastic or plastic
coated binding wires especially manufactured for the purpose. Reference shall
be made to Section 1000 for other requirements.
e) Placing and fixing of reinforcement shall be inspected and approved by the
Engineer before concrete is deposited.
1606. BAR SPLICES
1606.1. Lapping
All reinforcement shall be furnished in full lengths as indicated on
the drawing. No splicing of bars, except where shown on the drawing,
will be permitted without approval of the Engineer. The lçngths of the
splice shall be as indicated on drawing or as approved by the Engineer.
Where practicable, overlapping bars shall not touch each other, and
shall be kept apart by 25 mm or 1 !/4 times the maximum size of coarse
aggregate, whichever is greater. If this is not feasible, overlapping bars
shall be bound with annealed steel binding wire, not less than 1 mm
diameter and twisted tight in such a manner as to maintain minimum
clear cover to the reinforcement from the concrete surface. Lapped
splices shall be staggered or located at points, along the span where
stresses are low.
1606.2. Welding
1606.2.1. Splicing by welding of reinforcement will be permitted
only if detailed on the drawing or approved by the Engineer. Weld
shall develop an ultimate strength equal to or greater than~thatof the
bars connected.
1606.2.2. While welding may be permitted for mild steel reinforcing
bars conforming to 15:432, welding of deformed bars conforming to
lS:i 786 shall in general be prohibited. Welding may be permitted in case
of bars of other than S 240 grade including special welding grade
of S 415 grade bars conforming to 15:1786, for which necessary chemical
analysis has been secured and the carbon equivalent (CE) calculated
from the chemical composition using the formula
Mn Cr+Mg+V Ni+Cu
CE= C+-j-+ ~ +
is 0.4 or less.
1606,2.3. The method of welding shall conform to 15:2751 and
15:9417 and to any ~upplernentalspecifications to the satisfaction of the
Engineer.
413
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Section 1600 Steel Reinforcement (Untensioned)
Welding may be carried out by metal arc welding process. Oxy-

acetelene welding shall not be permissible. Any othtr process may be
tised subject to the approval of the Engineer and necessary additional
requirements to ensure satisfactory joint performance. Precautions on
over heating, choice of electrode, selection of correct turrent in arc
welding etc., should be strictly observed.
All bars shall be butt welded except for smaller diameter bars
(diameter of less than 20 mm) which may be lap welded. Single-V or
Double-V butt joints may generally be used. For vertical bars single
bevel or double bevel joints may be used.
Welded joints shall be located well away from bends and not less
than twice the bar diameter away from a bend.
Generally, shop welding in controlled conditions is to be
preferred, where feasible. Site welding where necessary ‘shall, however,
be permitted when the facilities, equipment, process, consumables,
operators, welding procedure are adequate to produce and maintain
uniform quality at par with that attainable in shop Nelding to the
satisfaction of the Engineer.
Joint welding procedures which are to be ~employed shall
invariably be established by a procedure specification. All welders
and welding operators to be employed shall have to be qualified by
tests prescribed in IS:2751. inspection of welds shall conform to
IS:822 and destructive or non-destructive testing may be undertaken
when deemed necessary. Joints with weld defects detected by visual
inspection or dimensional check inspection shall not be accepted.
Suitable means shall be provided for holding the bars securely in
position during welding. It must be ensured that no voids are left
in welding. When welding is done in 2 or 3 stages, previous surface
shall be cleaned properly. Bars shall be cleaned of all loose scale, rust,
grease, paint ‘and other foreign matter before carl%ring out welding.
Only competent and experienced welders shall be employed on the
work with the approval of the Engineer. No welding shall be done on
coated bars.
M.S. electrodes used for welding shall conform to IS:8l4.
1606.2.4. Welded joints shall prefeiably be located at points where
steel will not be subject to more than 75 per cent of the maximum
permissible stresses and welds so staggered that at any one section,
not more than 20 per cent of the bars are welded.
<< 414
1606.2.5. Welded pieces of reinforcement shall be tested, Specimens
shall be taken from the site and the number and frequency of tests
shall be as directed by the Engineer.
1606.3. Mechanical Coupling of Bars
Bars may be joined with approved patented mechanical devices as
indicated on the drawing or as approved by the Engineer e.g. by special
grade steel sleeves swftgged on to bars in end to end contact or by
screwed couplers. In case such devices are permitted by the Engineer,
they shall develop at least 125 per cent of the characteristic strength
of the reinforcement bar.
1607, TESTING AND ACCEPTANCE
The material shall be tested in accordance with relevant IS speci-
fications and necessary test certificates shall be furnished. Additional
tests, if required, will be got carried out by the Contractor at his own
cost.
The fabrication, furnishing and placing of reinforcement shall be in
accordance with these specifications and shall be checked and accepted
by the Engineer.
Reinforcement shall be measured in length including hooks, if
any, separately for different diameters as actually used in work, excluding
overlaps. From the length so measured, the weight of reinforcement
shall be calculated in tonnes on the basis of IS: 1732. Wastage, overlaps,
couplings, welded joints, spacer bars, chairs, stays, hangers and
annealed steel wire or” other methods, for binding and placing shall
not be measured and cost of these items shall be deemed to be included
in the rates for reinforcement.
1609. RATE
The contract unit rate for coated/uncoated reinforcement shall cover
the cost of material, fabricating, transporting, storing, bending, placing,
binding and fixing in position as shown on the drawings as per these
specifications and as directed by the Engineer, including all labour,
equipment, supplies, incidentals, sampling, testing and supervision.
The unit rate for coated reinforcement shall be deemed to also
include cost of all material, labour, tools and plant, royalty, transpor-
tation and expertise required to carry out the work. The rate shall also
cover sampling, testing and supervision required for the work.
<< 415
Structural Concrete
1700
Structural Concrete
<<
Structural Concrete Section 1700
1701. DESCRW~ION
The work shall consist of furnishing and placing structural concrete
and incidental construction in accordance with these specifications and
in conformity with the lines, grades and dimensions, as shown on the
drawings Or as directed by the Engineer.
1702. MATERIALS
All materials shall conform to Section 1000 of these Specifications.
1703. GRADES OF CONCRETE
1703.1. The grades of concrete shall be designated by the charac-
teristic strength as given in Table 1700-I, where the characteristic strength
is defined as the strength of concrete below which not more than 5 per
cent of the test results are expected to fall.
TABLE 1700-1.
,Grade Designation Specified characteristic Compressive strength
of 150 mm tithes at 28 days, in MPa
M 15 15
M 20 20
M 25 25
M 30 30
M 35 35
M 40 40
M 45 45
M 50 50
M 55 55
1703.2. The lowest grades of concrete in bridges and corresponding

minimum cement contents and water-cement ratios shall be maintained
as indicated in Tables 1700-2 and 1700-3.
TABLE 1700-2 FOR BRIDGES WITH PRFSTRESSED CONCREFE OR THOSE
WITH INDIVIDUAL SPAN LENGTHS MORE THAN 30 M OR
THOSE THAT ARE BUILT WITH INNOVATIVE DESIGN/CON-
STRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO
Structural Member Mlii. cement content Max. water cement ratio
for all exposure
condlilom (kglcnin) Exposure conditions
Normal Severe
a) FCC members 360 0.45 0.45
b) RCC members 400 , 0.45 0.40
c) PSC members 400 0.40 0.40
419
<<
a .. ..d.-- ~
Section 1700 Stiucuiral Concrete
(B) MINIMUM STRENGTH OF CONCRETE

Member Conditions of Exposure
Moderate Severe
a) PCCniranbers M25~ M30
b) RcCmernbers M35 M40
c) PSCmembers , M35 M40
TABLE 1700-3. FOR BRUSGES OTHER THAN THOSE MENTIONED IN TABLE
1700~2AND FOR CULVERTS AND OTHER INCIDENTAL CON-
STRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO
Structural Member Mtn. cement content Max. water cement

(kg/cii,m) ratio
~ Exposure conditions Exposure conditions
~ Normal Severe Normal Severe
a) FCC members 250 310 0.50 0.45

b) RCC members 310 400 0.45 0.40
(B) MINIMUM STRENGTH OF CONCRETE
Member Conditions of Exposure
Moderate Severe
a) PCCmembers MiS M20
b) RCCmembers M20 M25
Notes Applicable to Tables 1700-2 and 1700-3

(I) The minimum cement content is based on 20 mm aggregate (nominal max. size),
For 40mm and larger size aggregates, it may be reduced suitably but the reduction
shall not be more than 10 per cent
(ii) For underwater concretinj, the cement content shall be increased by 10 per cent.
Cmii) 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
(iv) Moderate conditions of exposure shall mean other that those mentioned in (iii)
abovt
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.
1703.3. Concrete used in any component or structure shall be
specified by designation along with prescribed method of design of mix
i.e. “Design Mix” or “Nominal Mix”. For all items of concrete, only
“Design Mix” shall be used, except where “Nominal Mix” concrete is
permitted as per drawing or by the Engineey.”Nominal Mix” may be
420
<<
permitted only for minor bridges and culverts or other incidental
construction where strength requirements are upto M 20 only. “Nominal
Mix” may also be permitted for non-structural concrete or for scr~d
below open foundations.
1703.4. If the Contractor so elects, the Engineer may permit the use
of higher grade concrete than that specified on the drawing, in which
event the higher grade concrete shall meet the specifications applicable
thereto without additional compensation.
1704. PROPORTIONING OF CONCRETE
Prior to the start of construction, the Contractor shall design the mix
in case of “Design Mix Concrete” or propose no?ninal mix in case of
“Nominal Mix Concrete”, and submit to the Engineer for approval, the
proportions of materials, including admixtures to be used. Water-reducing
admixtures (including plasticisers or super-plasticisers) may be used at
the Contractor’s option, subject to the approval of the Engineer. Other
types of admixtures shall be prohibited, unless specifically permitted by
the Engineer.
1704.1. Requirements of Consistency
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 1700-4, or ~s directed by the Engineer. The slump
of concrete shall be checked as per IS:5 16.
TABLE 17004
TYPE SLUMP (mm)
I (a) Structures with exposed inclined’surface requiring low 25
slump concrete to allow proper compaction
(b) plain cement concrete 25
2. RCC structures with widely spaced reinforcements; e.g. solid 40 ‘ 50
columns, piers, abatments, footings, well steining
3. RCC struclures with fair degree of congestion of 50 - 75
reinforcement; e.g. pier and abutment caps, box culverts well
curb, well cap, walls with thickness greater than 300 mm
4. RCC and PSC structures with highly congested 75 ‘ 125
reinforcements e.g. deck slab girders, box girders,
walls with thickness less than 300 mm
5. Underwater concreting through tremie 100 200
e.g. bottom plug, cast-in-situ piling
<<
421.
Section 1700 Structural Concrete
1704.2. Requirements for Designed Mixes

1704.2.1. Target mean strength
The target mean strength of specimen shall exceed the specified char-
acteristic 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 1700-5
TABLE 1700.5.
Concrete Grade Current Margin Target Mean Strength
CMPa) (MPa)
M 15 10 ‘ 25
M 20 JO 30
N4 25 11 36
M 30 12 42
M 35 12 47
M 40 12 52
M 45 13 58
M 50 13 63
M 55 14 69
The initial current margin given in the Table 1700-5 shall be used
tifl sufficient data is available to determine the current margin as per
sub-clause (i) above,
1704.2.2. Trial mixes
The Contractor shall give notice to enable the Engineer to be present
at the making of trial mixes and preliminary testing of the cubes. The
Contractor shall prepare trial mixes, using samples of approved materials
typical of those he proposes to use in the works, for all grades to the
Engineer’s satisfaction prior to commencement of concreting. The initial
trial mixes shall generally be carried out in an established laboratory
approved by the Engineer. In exceptional cases, the Engineer may permit
the initial trial mixes to be prepared at the site laboratory of the
Contractor, if a full fledged concrete laboratory has been established well
before the start of construction, to his entire satisfaction. In all cases
complete testing of materials forming the constituents of proposed Design
Mix shall have been carried out prior to making trial mixes.
Sampling and testing procedures shall be in accordance with these
specifications.
422
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When the site laboratory is utilised for preparing initial mix design,
the concreting plant and means of transport employed to make the trial
mixes shall be similar to that proposed to be used in the works.
Test cubes shall be taken from trial mixes as follows. For each mix,
set of six cubes shall be made from each of three consecutive batches.
Three cubes from each set of six shall be tested at an age of 28 days
and three at an earlier age approved by the Engineer. The cubes shall
be made, cured, stored, transported and tested in accordance with these
specifications. The average strength of the nine cubes at 28 days shall
exceed the specified characteristic strength by the current margin minus
3.5 MPa.
1704.23. Control of strength .of design mixes
a) Adjustment to Mix Proportions
Adjustments to mix proportions arrived as in the trial mixes shall be made subject
to the Engineer’s approval, in order to minimise the variability of strength and
to maintain the target mean strength. Such adjustments tall not be taken to imply
any change in the current margin.
b) Change of Current Margin
When required by the Engineer, the Contractor shall recalculate the current margin
in accajdance with Clause 1704.2.1. The recalculated value shall be adopted as
directed by the Engineer, and is shall become the current margin for concrete
produced subsequently.
c) Additional Trial Mixes
During production, the Contractor shall carry out trial mixes and tests, if required
by the Engineer, before substantial changes are made in the material or in the
proportions of the materials to be used, except when adjustments to the mix
proportions are carried out in accordance with sub-clause Ca) above.
1704.3. Requirements of Nominal Mix Concrete
Requirements for nominal mix concrete unless otherwise specified,
shall be as detailed in Table 1700-6.
TABLE 1700-6. PROPORTIONS FOR NOMINAL MIX CONCRETE
Concrete Total Quantity of dry aggregate Proportion of fine to
Grade by mass per 50 kg of cement to be Coarse aggregate
taken as the sum of Individual (by mass)
masses of flue and coarse
aggregates (kg)
MIS 350 Generally 1:2, subject to
upper limit 1:1.5 and
lower limit of 1:2.5
M20 250 —do—--
<< 423
1704.4, Additional Requirements

Concrete shall meet with any other requirements as specified on the
drawing or as directed by the Engineer. Additional requirements shall
also consist of the following overall limits of deleterious substances in
concrete
a) The total chloride content of all constituents or concrete as a percentage of mass
of cement in mix shall be limited to values given below:
- Prestiessed Concrete : 0.1 per cent
- Reinforced concrete exposed to chlorides in service : 0,2 per cent
(e.g. structures located near sea coast)
- Other reinforced concrete construction : 0.3 per cent
b) The total sulphuric anhydride (SO,) content of all the constituents of concrete as
a peitentage of mass of cement in the mix shall be limited so 4 per cent
1704.5. Suitability of Proposed Mix Proportions
The Contractor shall submit the following information for the
Engineer’s approval
a) Nature and source of each material
6) Quantities of each material per cubic metre cYf fully compacted concrete
c) Either of the following
(i) appropriate existing data as evidence of satisfactory previous perfosmance
for the target mean strength, current margin, consistency and water/cement
1
ratio and any other additional requirement(s) as specific
(ii) full details of tests on trial mixes.
d) Statement giving the proposed mix proportions for nominal mix concrete.
Any change in the source of material or in the mix proportions shall’
be subject to the Engineer’s prior approval.
t705. ADMIXTURES
Use of admixtures such as superplasticisers for concrete may be made
with the approval of the Engineer.
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 manu-
facture, transportation and compaction of concrete proposed to be used
in the project.
1706. SiZE OF COARSE AGGREGATE
The size (maximum nominal) of coarse aggregates for concrete to
<< 424
be used in various components shall be given as Table 1700-7.
TABLE 1700-7.
Components Maximum Nominal Size of Coarse Aggregate
(mm)
I) RCC well curb 20
ii) RCCJPCC well steining 40
iii) Well cap or Pile Cap
Solid type piers and abutments 40
iv) RCC work in girders,slabs,
wearing coat, kerb, approach 20
slab, hollow piers and
abutments, pier/abutment
caps, piles
v) PSC work 20
vi) Any other item As specified by Engineer
Maximum nominal size of aggregates shall also be restricted to the

smaller of the following values
a) 10 mm less than the minimum lateral clear distance between main reinforcements
b) 10 mm less than the minimum clear cover to the reinforcements
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.
‘1707. EQUIPMENT
Unless specified otherwise, equipment for production, transportation
and compaction of concrete shall be as under
a) For Producsicm of Concrete
i) For overall bridge length of test than 200 metres - batch type concrete mixer
diesel or electric operated, with a minimum size of 200 litres, automatic water
measuring system and integral weigher (hydraulic/pneumatic type)
ii) For overall bridge length of 200 metres or more - concrete batching and
mixing plant fully automatic with minimum capacity of 15 cu.m.per hour.
All measuring devices of the equipment shall be maintained in a

clean and serviceable condition. Its accuracy shall be checked over the
range in use, when set up at each site and thereafter periodically as
The accuracy of the measuring devices shall fall within, the following
limits:
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Measurement of Cement ± 3 per cent of the quantity of cement in each batch
Measurement of Water ± 3 per cent of the quantity of water in each batch
Measurement of Aggregate ±3 per cent of she quantity of aggregate in each batch
Measurement of Admixture ± 5 per cent of the quantity of admixture in each batch
b) For Concrete Transportation
depending upon actual requirement
i) Concrete dumpers
minimum 2 scones capacity
ii) Powered hoists
minimum 0.5 tonne capacity
iii) asutes
iv) Buckets handled by cranes
v) Transit truck mixer
vi) Concrete pump
vji) Concrete distributor booms
viii) Belt conveyor
ix) Cranes with skips
x) Tremies
c) For Compaction of Concrete
size 25 mm to 70 mm
i) Internal vibrators
minimum 500 watts
ii) Form vibrators full width of carriageway
iii) Screed vibrasors (upto two lanes)
1708. MIXING CONCRETE

Concrete shall be mixed either in a concrete mixer or in a batching
and mixing plant, as per these specifications, Hand mixing shall not be
permitted. The mixer or the plant shall be at an approved location
considering the properties 9f tl~emixes and the transportation arrange-
ments available with the Contractor. The mixer or the plant shall be
Mixing shall be continued till materials are uniformly distributed and
a uniform colour of the entire mass is obtained, and each individual
particle of the coarse aggregate shows complete coating of mortar
containing its proportionate amount of cement. In no case shall mixing
be done for less than 2 minutes.
Mixers which have been out of use for more than 30 minutes shall
be thoroughly cleaned before putting in a new batch, Unless otherwise
agreed to by the Engineer, the first batch of concrete from the mixer
shall contain only two thirds of the normal quantity of coarse aggregate.
Mixing plant shall be thoroughly cleaned before changing from one type
of cement to another.
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426
1709. TRANSPORTING, PLACING AND COMPACTION OF
CONCRETE
The method of transporting and placing concrete shall be approved
by the Engineer. Concrete shall be transported and placed as near as
practicable to its final position, so that no contamination, segregation
or loss of its constituent materials takes place. Concrete shall not be freely
dropped into place from a height exceeding 1.5 metres.
When concrete is conveyed by chute, the plant shall be of such size
and design as to ensure practically continuous flow. Slope of the chute
shall be so adjusted that the concrete flows without the use of excessive
quantity of water and without any segregation of its ingredients. The
delivery end of the chute shall be as close as possible to the point of
deposit. The chute shall be thoroughly flushed with water before and
after each working period and the w~terused for this purpose shall be
discharged outside tbe formwork.
All formwork and reinforcement contained in it shall be cleaned and
made free from standing water, dust, snow or ice immediately before
placing of concrete.
No concrete shall be placed in any part of the structure until the
approval of the Engineer has been obtained.
If concreting is not started within 24 hours of the approval being
given, it shall have to be obtained again from the Engineer. Concreting
then shall proceed continuously over the area between the construction
joints. Fresh concrete shall not be placed against concrete which has been
in position for more than 30 minutes unless a proper construction joint
is formed.
Except where otherwise agreed to by the Engineer, concrete shall
be deposited in horizontal layers to a compacted depth of not more than
450 mm when internal vibrators are used and not exceeding 300 mm
in all other cases.
Concrete when deposited shall have a temperature of not less than
5 degrees Celsius, and not more than 40 degrees Celsius. It shall be
compacted in its final position within 30 minutes of its discharge from
the mixer, unless carried in properly designed agitators, operating
continuously, when this time shalt be within 1 hour of the addition of
cement to the mix and within 30 minutes of its discharge from the agitator.
It may be necessary to add retarding admixtures to concrete if trials show
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427
that the periods indicated above are unacceptable. In all such matters,
the Engineer’s decision shall be final.
Concrete shall be thoroughly compacted by vibration or other means
during placing and worked around the reinforcement, tendons or duct
formers, embedded fixtures and into corners of the formwork to produce
a dense homogeneous void-free mass having the required surface finish.
When vibrators are used, vibration shall be done continuously during the
placing of each batch of concrete until the expulsion of air has practically
ceased and in a manner that does not promote segregation. Over vibration
shall be avoided to minimise the risk of forming a weak surface layer.
When external vibrators are used, the design of formwork and disposition
of vibrator shall be such as to ensure efficient compaction and to avoid
surface blemishes. Vibrations shalt not be applied through reinforcement
and where vibrators of immersion type are used, contact with reinforce-
ment and all inserts like ducts etc., shall be avoided. The internal vibrators
shall be inserted in an orderly manner and the distance between insertions
should be about one and a half times the radius of the area visibly affected
by vibration. Additional vibrators in serviceable condition shall be kept
at site so that they can be used in the event of breakdowns.
Mechanical vibrators used shall comply with IS:2502, IS:2506,
JS:2514 and IS:4656.
1710. CONSTRUCTION JOINTS
Construction joints shall be avoided as far as possible and in no case
the locations of such joints shall be changed or increased from those
shown on the drawings, except with express approval of the Engineer.
The joints shalkbe provided in a direction perpendicular to the member
axis.
Location, preparation of surface and concreting of Construction
joints shall conform to the additional specifications given in Appendix
1700/!.
1711. CONCRETING UNDER WATER
When it is~necessary to deposit concrete under water, the methods,
equipment, materials and proportions of mix to be used shall be g~t
approved from the Engineer before any work is started. Concrete shall
contain 10 per cent more cement than that required for the same mix
placed in the dry.
Concrete shall not be placed in water having a temperature below
<< 428
5 degrees Celsius. The temperature of the concrete, when deposited,
shall not be less than 16 degrees Celsius, nor more than 40 degrees
Celsius.
Coffer dams or forms shall be sufficiently tight to ensure still water
conditions, if practicable, and in any case to reduce the flow of water
to less than 3 metres per minute through the space into which concrete
is to be deposite4. Coffer dams or forms in still water shall be sufficiently
tight to prevent loss of mortar through the joints in the walls. Pumping
shall not be done while concrete is being placed, or until 24 hours
thereafter. To minimise the formation of laltance, great care shall be
exercised not to disturb the concrete as far S possible while it is being
deposited.
All under water concreting shall be carried out by tremie method
only, using tremie of appropriate diameter. The number and spacing of
the tremies should be worked out to ensure proper concreting. The tremie
concreting when started should continue without interruption for the full
height of the member being concreted. Tht concrete production and
placement equipment should be sufficient to enable the underwater
concrete to be completed uninterrupted within the stipulated time.
Necessary stand-by equipment should be available for emergency situ-
ation.
The top section of the tremie shall have a hopper large enough to
hold one full batch of the mix or the entire contents of the transporting
bucket as the case may be. The tremie pipe shall not be less than 200
mm in diameter and shall be large enough to allow a free flow of concrete
and strong enough to withstand the external pressure of the water in which
it is suspended, even if a partial vacuum develops inside the pipe.
Preferably, flanged steel pipe of adequate strength~for the job shall be
used. A separate lifting device shall be provided for each tremie pipe
with its hopper at the upper end. Unless the lower end of the pipe is
equipped with an approved automatic check valve, the upper end of the
pipe shall be plugged with a wadding of gunny sacking or other approved
material before delivering the concrete to the tremie- pipe through the
hopper; so that when the concrete is forced down from the hopper to
the pipe, it will force the plug (and along with it any water in the pipe)
down the pipe and out of the bottom end, thus establishing a continuous
stream of concrete. It will be necessary to raise slowly the tremie in
order to allow a uniform flow of concrete, but it shall not be emptied
so that water is not allowed to enter above the concrete in the pipe.
At all times after placing of concrete is started and until all the requiycd
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quantity has been placed, the lower end of the tremie pipe shall be kept
below the surface of the plastic concrete. This will cause the concrete
to build up from below instead of flowing out over the surface and thus
avoid formation of layers of laitance. If the charge in the tremie is lost
while depositing, the tremie shall be raised above the concrete surface
and unless sealed by a check valve, it shall be replugged at the top end,
as at the beginning, before refilling for depositing further concrete.
1712. ADVERSE WEATHER CONDITIONS
1712.1. Cold Weather Concreting
Where concrete is to be deposited at or near freezing temperature,
precautions shall be takel) to ensure that at the time of placing, it has
a temperature of not less than 5 degrees Celsius and that the temperature
of the concrete shall be maintained above 4 degrees Celsius until it has
thoroughly hardened. When necessary, concrete ingredients shall be
heated before mixing but cement shall not be heated artificially other
than by the heat transmitted to it from other ingredients of the concrete.
Stock-piled aggregate may be heated by the use of thy heat or steam.
Aggregates shall not be heated directly by gas or on sheet metal over
fire. In general, the temperature of aggregates or water shall not exceed
65 degrees Celsius. Salt or other chemicals shall not be used for the
prevention of freezing. No frozen material or materials containing ice
shall be used. All concrete damaged by frost shall be removed, It is
recommended that concrete exposed to freezing weather shall have
entrained air and the water content of the mix shall not exceed 30 litres
per 50 kg of cement.
1712.2. Hot Weather Conditions
When depositing concrete in very hot weather, precautions shall be
taken so that the temperature of wet concrete does not exceed 40 degrees
Celsius while placing. This shall be achieved by stacking aggregate under
the shade and keeping them moist, using cold water, reducing the time
between mixing and placing to the minimum, cooling formwork by
sprinkling water, starting curing before concrete dries out and restricting
concreting as far as possible to early mornings and late evenings. When
ice is used to cool mixing water, it will be considered a part of the
water in design mix. Under no circumstances shall the mixing operation
be considered complete until all ice in the mixing drum has melted.
The Contractor will be required to state his methodology for the En-
gineer’s approval when temperatures of concrete are likely to exceed 40
degrees Celsius during the work.
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1713. PROTECTION AND CURING
Concreting operations shall not commence until adequate arrange-
ments for concrete curing have been made by the Contractor.
Curing and protection of concrete shall start immediately after com-
paction of the concrete to protect it from
a) Premature drying out particularly by solar radiation and wind
b) High internal thermal gradients
c) Leaching our by rain and flowing water
d) Rapid cooling during the first few days after placing
e) Low temperature or frost
0 Vibration and impact which may disrupt the concrete and interfere with its bond
to the reinforcement
Where members are of considerable size and length, with high cement
content, accelerated curing methods may be applied, as approved by the
Engineer.
1713.1. Water Curing
Water for turing shall be as specified in Section 1000.
Sea water shall not be used for curing. Sea water shall not come
into contact with concrete members unless it has attained adequate
strength.
Exposed surfaces of concrete shall be kept continuously in a damp
or wet condition by ponding or by covering with a layer of sacks, canvas,
Hessian or similar materials and shall be kept constantly wet for a period
of not less than 14 days from the date of placing of concrete.
1713.2. Steam Curing
Where steam curing is adopted, it shall be ensured that it is done
in a suitable enclosure to contain the live steam in order to minimise
moisture and heat losses. The initial application of the steam shall be
after about four hours of placement of concrete to allow the initial set
of the concrete to take place.
Where retarders are used, the waiting period before application of
the steam shall be increased to about six hours.
The steam shall be at 100 per cent relative humidity to prevent loss
of moisture and to provide excess moisture for proper hydration of the
cement. The application of steam shall not’be directly on the concrete
and the ambient air temperature shall increase at a rate not exceeding
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5 degrees Celsius per hour until a maximum temperature of 60 degrees
Celsius to 70 degrees Celsius is reached. The maximum temperature shall
be maintained until the concrete has reached the desired strength.
When steam curing is discontinued, the ambient air temperature shall
not drop at a rate exceeding 5 degrees Celsius per hour until a temperature
of about 10 degrees Celsius above the temperature of the air to which
the concrete Will be exposed, has been reached.
The concrete shall not be exposed to temperatures below freezing
for at least six days after curing.
1713.3, Curing Compounds
Curing compounds shall only be permitted in special circumstances
and will require specific approval of the Engineer. Curing compounds
shall not be used on any surface which requires further finishing to be
applied. All construction joints shall be moist, cure4 and no curing
compound will be permitted in locations where concrete surfaces are
required to be bonded together.
Curing compounds shall be continuously agitated during use. All con-
crete cured by this method shall receive two applications of the curing
compound. The first coat shall be applied immediately after acceptance
of concrete finish. If the surface is dry, the concrete shall be saturated
with waler and curing compound applied as soon as the surface film
of water disappears. The second application, shall be made after the first
application has set. Placement in more than two coats may be required
to prevent streaking.
1714. FINISHING
Immediately after the removal of forms, exposed bars or bolts, if
any, shall be cut inside the concrete member to a depth of ai least
50 mm below the surface of the concrete and the resulting holes filled
with cement mortar. All fins caused by form joints, all cavities produced
by the removal of form ties and all other holes and depressions,
honeycomb spots, broken edges or corners, and other defects, shall be
thoroughly cleaned, saturated with water, and carefully pointed and
rendered true with mortar of cement and fine aggregate mixed in the
proportions used in the grade of concrete that is being finished and of
as dry a consistency as is possible to use. Considerable pressure shall
be applied in filling and pointing to ensure thorough filling in all voids.
Surfaces which have been pointed shall be kept moist for a period of
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twenty four hours. Special prepackaged proprietary mortars shall be used

where appropriate or where specified in the thawing.
All construction and expansion joints in the completed work shall
he left carefully tooled and free from any mortar arid concrete. Expansion
joint filler shall be left exposed for its full length with clean and true
edges,
Immediately on removal of forms, the concrete work shall be
examined by the Engineer before any defects are made good.
a) The work that has sagged or contains honeycombing to an extent detrimental to
structural safety or architectural a~earassceshall be rejected.
b) Surface defect of a minor nature may be accepted. On acceptance of such work
by the Engineer, the same shall be rectified as directed by the Engineer.
1715. TOLERANCES
Tolerances for dimensions/shape of various components shall be as
indicated in these specifications or shown on the drawings or as directed
by the Engineer.
1716.1. Concrete shall conform to the surface finish and tolerance
as prescribed in these specifications for respective components.
1716.2, Random sampling and lot by lot of acceptance inspection
shall be made for the 28 days cube strength of concrete.
1716.2.1. Concrete under acceptance shall be notionally divided into
loLs for the purpose of sampling, before commencement of work. The
delimitation of lots shall be determined by the following
(i) No individual lot shall be more than 30 cu.m. in volume
(ii) At least one cube formthg an item of the sample representing the lot shall be
taken from concrete of the same grade and mix proportions cast on any day.
(iii) Different grades of mixes of concrete shall be divided into separate lots
(iv) Concrete of a lot shall be used in the same identifiable component of the bridge
1716,2.2. Sampling and testing

I. Concrete for making 3 test cubes shall be taken from a batch of concrete at point
of delivery into construction, according to procedure laid down in 15:1199.
2, A randorrt sampling procedure to ensure that each of the concrete batches forming
the lot under acceptance inspection has equal chance of being chosen for taking
cubes shall be adopted.
3. 150 mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with 15:516. The 28~daytest strength result
for each cube shall form an item of the sample.
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1716.2.3. Test specimen and sample strength Three test specimens
shall be made from each sample for testing at 28 days. Additional cubes
may he required for various purposes such as to determine the strength
of concrete at 7 days or for any other purpose.
The test strength of the sample shall be the average of the strength
of 3 cubes. The individual variation should not be more than ±15 per
cent of the average.
1716.2.4. Frequency : The minimum frequency of sampling of
concrete of each grade shall be in accordance with Table 1700-8
TABLE I7OO~8
Quantity of Concrete In work, m’ No. of samples
1-5 1
6~15 2
16-30 3
31-50 4
51 and above 4 plus one additional
5 or sample for each
part thereof
actditional 50 m
At least one sample shall be taken from each shift of work,
17 16.2.5. Acceptance criteria
Compressive Strength
When both the following conditions are met, the concrete complies
with the specified compressive strength
a) The mean strength determined from any group of fourconsecutive samples should
exceed the specified characteristic compressive strength.
b) Strength of any sample is not less than the specified characteristic compressive
strength minus 3 MPa.
The quantity of concrete represented by the test results include the
batches from which the first and last samples were taken, together with
all intervening batches.
Chloride and Sulphate Content
The total chloride and sulphuric anhydride (SO
3) content of all the
constituents of concrete as a percentage of mass of cement in the mix
shall not exceed the values given in this section of the specifications.
1716.3. Density of Fresh Concrete
Where minimum density of fresh concrete is specified, the mean of
any four consecutive samples shall not be less than the specified value
and any individual sample result shall not be less than 97.5 per cent
of the specified value,
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Structural Concreic Section 1700
1716,4. Density of Hardened Concrete

Where minimum density of hardened concrete is specified, the mean
of any four consecutive samples shall not be less than the specified value
and any individual sample result shall not be less than 97.5 per cent
of the specified value.
1716.5. Permeability Test
The concrete should pass the following test if it is properly compacted
and is not considered permeable.
(i) Prepare a cylindrical test specimen 150 mm dia and 160 mm Isigh
(ii) After 28 days of curing, the test specimcn is fitted in a machine such that thc
specimen can be placed in water under pressure upto 7 bars. A typical machine
is shown in Appen4Lz 1700/fl.
(iii) At first a pressure of one bar ir applied for 48 hours, followed by 3 bars for
24 hours and 7 bars for next 24 hours.
(iv) After the passage of the above period, the specimen is taken out and split in the
middle by compression applied on two round bars on opposite sides above and
below,
(v) The water penetration in the broken core is to be measured with a scale and the
depth of penetration assessed in mm (max. permissible limit 25 mm).
1716.6. If the concrete is not able to meet any of the standards of

acceptance as prescribed, the effect of such deficiency on the Structure
shall be investigated by the Contractor as directed by the Engineer. The
Engineer may accept the concrete as sub-standard work. Any additional
work required by the Engineer for such acceptance shall be carried out
by the Contractor at his cost. In case the concrete is not found to be
acceptabiL after investigation, the Contractor shall remove the rejected
concrete forthwith.
Structural concrete shall be measured in cubic metres. In reinforced
or prestressed concrete, the volume occupied by reinforcement or
prestressing cables and sheathing shall not be deducted. The slab shall
be measured as running continuously through and the beam as the portion
below the slab.
1718. RATE
The contract unit rate for structural concrete shall cover costs of all
materials, labour, tools, plant and equipment required for mixing, trans-
porting and placing in position, vibrating and compacting, finithing and
curing as per this Section or as directed by the Engineer, including all
<< 435
incidental expenses, sampling and testing, quality assurance and super-

vision. Unless mentioned separately as an item in the Contract, the
contract unit rate for concrete shall also include the cost of providing,
fixing and removing formwork required for concrete work as per Section
1500.
Where concrete is found to be acceptable as sub-standard work, the
Contractor shall pay a discount over the contract unit rate, as decided
by the Engineer. For deficiency in compressive strength of concrete when
accepted by the Engineer, the reduction in rate may be applied as under
Design Strength —Observed Strength

Per cent reductton = . x 100
Design Strength
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Prestressing
1800
Prestressing
<<
Prestressing Section 1800
1801. DESCRIFFION
Structural concrete containing prestressed steel reinforcement to in-
troduce precompression is termed as prestressed concrete.
The work shall be carried out in accordance with the drawing and
these specifications or as approved by the Engineer.
Concrete and untensioned steel for the construction of prestressed
concrete members shall conform to the requirements of sections 1700
and 1600 for Structural Concrete and Steel Reinforcement respectively
in so far as the requirements of these Sections apply and are not
specifically modified by requirements set forth herein.
1802. MATERIALS
~J8O2.1.All materials shall conform to Section 1000.
1802.2. Sheathing
L~
~4802.2,1.The sheathing ducts shall be of the spiral corrugated

type, Unless otherwise specified, the material shall be Cold Rolled
Cold Annealed (CRCA) Mild Steel conforming to !S:5 13 intended for
mechanical treatment and surface refining but not for quench hardening
or tempering.
The material shall normally be bright finished. However, where
specified, as in case of use in aggressive environment, galva..
aired or lead-cOated mild steel strips shall be used.
The thickness of sheathing shall be as shown on the drawing, but
shall not be less than 0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts
having internal diameter of 50 mm, 75 mm and 90 mm respectively.
For bigger diameter of ducts, thickness of sheathing shall be based
on recommendations of prestressing system supplier or as directed by
the Engineer.
The sheathing shall conform to the requirement as per tests
specified in Appendix 1800/!.
For major projects, the sheathing ducts should preferably be
manufactured at the project site utilising appropriate machines. With
an arrangement, long lengths of sheathing ducts may be used with
consequent reduction in the number of joints and couplers. Where
sheathing duct joints are unavoidable, such joints shall be made
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Section 1800 Prestressirg
slurry tight by the use of corrugated threaded sleeve couplers which
may be tightly screwed onto the outer side of the sheathing ducts.
The length of the coupler should not be less than 150 mm but
should be increased upto 200 mm wherever practicable. The joints
between the ends of the coupler and the duct shall be sealed with adhesive
seating tape to prevent penetration of cement slurry during concreting.
The couplers of adjacent ducts should be staggered wherever
practicable. As far as possible, couplers should not be located in
curved zones. The corrugated sleeve couplers are being conveniently
manufactured using the sheath making machine with the next higher
size of die set.
1802.2.2. The intemat area of the sheathing duct shall be in
accordance with the recommendations of the system manufacturer and
shall be about three times the area of the tendons. In case of 6T13,
t2Tt3 and t9Tl3 sizes of tendons comprising 12/13 mm dia strands,
the inner diameter of the sheathing shall not be less than 50 mm,
75 mm and 90 mm respectively or those shown in the drawing, which
ever is greater.
Where prestressing tendons are required to be threaded after
concreting the diameter of sheathing shall be about 5 mm larger than
that required as above.
1862,2.3. In severe environment, cables shall be threaded after con-
creting. In such cases a temporary tendon shall be inserted in the
sheathing or the sheathing shall be stiffened by other suitable method
rluring concreting.
1802.3. Anchorages
1802.3,1. Anchorages shall be procured from authorised manufac-
turers only. Anchorages shall conform to BS:4447. Test certificates
from a laboratory fully equipped to carry out the tests shall be
furnished to the Engineer. Such test certificates shall not be more than
i2 months old at the time of making the proposal for adoption of a
particular system for the project.
No damaged anchorages shall be used. Steel parts shall be
protected from corrosion at alt times. Threaded paris shall be protected
by greased wrappings and tapped holes shall be protected by suitable
plugs until used. The anchorage components shall be kept free from
mortar and loose rust and any othc”’ deleterious coating.
<< 440
1802.3.2. Swages of prestressing strand and button-heads of
prestressing wire, where provided shall develop a strength of at least 95
per cent of the specified breaking load of the strand or wire as the case
may be. Where swaging/button-heading is envisaged, the Contractor shall
furnish details of his methodology and obtain approval of the Engineer,
prior to his taking up the work.
1802.3.3. Untensioned Steel reinforcements, around anchorages shall
conform to the details of prestressing system and as shown on the
drawing.
1803. TESTING OF PRESTRESSING STEEL
AND ANCHORAGES
All materials specified for testing shall be fumished free of cost
and shall be delivered in time for tests to be made welt in advance
of anticipated time of use.
All wire, strand or bars to be shipped to the site shall be assigned
a lot number and tagged for identification purposes. Anchorage assemblies
to be shipped shall he like-wise identified;
All samples submitted shall be representative of the lot to he
furnished and in the ease of wire or strand, shalt be taken from the
same master roll, The Contractor shalt furnish samples of at least 5.0
in length selected from each tot for testing. Also, two anchorage
assemblies, complete with distribution plates of each size or types to
be used, shall he furnished alongwith short lengths of strands as required.
\/1804 WORKMANSHIP
1804,1. Cleaning
Tendons shall he free from loose rust, oil, grease, tar, paint, mud
or any other deleterious substance.
Cleaning of the steel may be carried out by immersion in suitable
solve!nt solutions, wire brushing or passing through a pressure box
containing carbonindum powder. Flowever, the tendons shalt not be
brought to a polished condition,
i804.2. Straightening
High tensile steel wire and strand shall be supplied in coils nf
sufficiently large diameter such that tendons shall retain their physical
properties and shall he straight as it unwinds fror the coil. Tendons
of any type that are damaged, kinked or bent shalt not be used,
<< 441
Section 1800 Prestressing
The packing of prestiessing wire/strand shall be removed only
just prior to making of cable for plaeemeni Suitable stands shall be
provided to facilitate uncoiling of wire~1strandswithout damage to
steel. Care shall be taken to avoid the possibility of steel coming
into,contact with the ground.
1804.3. Positioning
1804.3.1. Post-Tensioning
Prestressing tendons shall be accurately located and maintained
in position, both vertically and horizontally, as per drawings.
Tendons shall be so arranged that they have a smooth profile
without sudden bends or kinks.
The locationing of prestressed cables shall be such as to facili-
tate easy placement and vibration of concrete in between the tendons.
High capacity tendon shall be used to reduce the number of cables
thereby eliminating the necessity of grouping. The selected profiles
of the tendons shall be such that theic anchorages are not located in
the top deck surface. Where two or more rows of cables have to
be used, the cables shalt be vertically in line to enable easy flow
of concrete. The clear vertical and horizontal distances between any
two cables shall in no case be less than 100mm anywhere along the
length of the superstructure. .Where precast segments are used,
the clear distance shall be at least 150 mm.
Sheathing shall be placed in correct position and profile by
providing suitable ladders and spacers. Such ladders may be pro-
vided a. ~ntervalsof approximately 1.0 m. Sheathing shall be tied rigidly
with such ladders/spacer bars so that they do not get disturbed during
concreting.
The method of supporting and fixing shall be such that profile of
cables is not disturbed during vibrations, by pressure of wet concrete,
by workmen or by construction traffic.
Sheathing in which the permanent tendon will not be in place
during concreting shall have a temporary tendon inserted or shall be
stiffened by some other method to the approval of the Engineer.
The temporary tendon shall be pulled out before threading the
permanent tendon into place by a special threading machine or other
contrivance.
Where possible tendons shalt not be placed until immediately
<<
prior to stressing. Tendons shall be handled with care to avoid damage

or contaminatiqn, to either the tendon or the sheathing. Any tendons
damaged or contaminated shall be cleaned or replaced.
1804.3.2. Pre-Tensioning. Prestressing steel shall be accurately
located and maintained in position, both vertically and horizontally, as
per drawings.
1804.3.3. Each anchorage device shall be set square to the line of
action of the corresponding prestressing tendon and shall be positioned
securely to prevent movement during concreting.
The anchorage devices shall be c!eaned to the satisfaction of the
Engineer prior to the placing of concrete. After concreting, any mortar
or concrete which adheres to bearing or wedging surfaces, shall be
removed immediately.
1804.4. Cutting
Cutting and trimming of wires or strands shall be done by
suitable mechanical or Ilame cutters. When a flame cutter is used,
care shall he taken to ensure that the Ilame does not come in contact
with other stressed steel. The location of flame cutting of wire or
strand shall be kept beyond 75 mm of where the tendon will be gripped
by the anchorage or jacks.
In post-tensioning the ends of prestressing steel projecting beyond
the anchorages, shall be cut after the grout has set,
1804.5. Pnitection of Prestressing Steel
Prestressing steel shall be continuously protected against corro-
sion, until grouted. The corrosion protector shall have no deleterious
effect on the steel or concrete or, on the bond strength of steel
to concrete. (Jrouting shall conform to these specifications or as directed
by the Engineer.
In the case of external prestressing, steel shall be encased in suitable
polyethelene pipes before grouting.
1804.6. Sheathing
i’he joints of all sheathings shall he. water-tight. Special attention
shall be paid to the junction at the anchorage end, where the sheathing
must~tightly fit on the protruding trumpet end of anchorage and
thereafler sealed preferably with heat shrink tape, to make it water-
proof.
<< 443
The heat-shrink tape is supplied in the form of bandage rolls

which can be used for all diameters of sheathing ducts. The bandage
is coated on the underside with a heat sensitive adhesive so that after
heating the bandage material shrinks on the sheathing duct and
ensures fonnation of a leak-proof joint. The heating is effected by means
of a soft gas flame.
A sheath making machine should be positioned at the site of work
for large projects so that sheathing can be prepared as and when it
is required for construction.
The sheathing and all joints shall be water tight. Any temporary
opening in the sheathing shall be satisfactorily plugged and all joints
between sheathing and any other part of the piestressing system shall
be e.fiectively sealed to prevent entry of mortar, dust, water or other
deleterious matter. Sheathing shall be neatly fitted at joints without
internal projection or reduction of diameter.
Enlarged portions of the sheathing at couplings or anchorages
shall be of sufficient tength to provide for the extension of the tendons.
1804.7. Grout Vents
Groi~t vents of at least 20 mm diameter shall be provided at both
ends of the sheathing and at all valleys and crests along its length.
Additional vents with plugs shall also be prov’ded along the length
of sheathing such that the spacings of consecutive vents do not exceed
21) rn. Each of the grout vents shall be provided with a plug or
similar device capable of withstanding a pressure Of 1.0 MPa without
the loss of water, air pressure or grout.
1804.8 Anchorages
All bearing surflices of the anchorages shall be cleaned prior to con-
cretmg and tensioning.
Anchor cones, blocks and plates shall he securely positioned and
maintained during concreting such that the centre line of the duct
passes axially through the anchorage assembly.
The~ anchorages shall he recessed from the concrete surface by a
minimum cover of 11)1) mm.
After the prestressing operations are completed and prestressing
wires/strands are cuL, the surface shall he painted with two coats
of epoxy of suitable formulation having a dry film thickness of 80
444
<<
Prcstressing Section 1800
microns per coat and entire recess shall be filled with concrete or
non-shrink/pre-packaged mortar or epoxy concrete.
1804.9. Structural Concrete
Structural concrete shall conform to Section 1700. The formwomk
shall conform to Section 1500.
\/t8O5. SUPERVISION
Al! prestressing and grouting operations shall be undertaken by
trained personnel only. A representative of supplier of the prestressing
system shall be present during all tensioning and grouting operations
and shall ensure, monitor and certify their correctness.
~•fl. TENSIONING EQUiPMENT
All tensioning equipment shall be procured from authorised manu-
facturers only and be approved by the Engineer prior to use. Where
hydraulic jacks are used, they shall be power-driven unless otherwise ap-
proved by the Engineer. The tensioning equipment shalt satisfy the
following requirements
(i) The means of attachments of the prestressing steet to the jack or any other
tensioning apparatus shalt be safe and secure.
(ii) Where two or more wires/strands constitute a tendon, a single multipill stressing
jack shalt be used which is capable of tensioning simulsaneou sty atl the wi reel
strands of the tendon. Suitable facilities for handling and attaching the multi~
putt jack to the tendons shalt be provided.
(iii) The tensioning equipment shalt be such that it can apply controtted total force
gradually on the concrete without inducing dangerous tecondary stresses in steel,
anchorage or concrete; and
(iv) Means shalt be provided for direct measurement of the force by use of dynamo~
meters or pressure gauges fined in the hydraulic system itself to determine the
pressure in the jacks. Facilities shalt also be provided for the tinear measurement
of the extension of prestressing steel to the nearest mm and of any slip of the
gripping devices at trai~sfer.
All dynamo meters and pressure gauges including a master gauge
shall be calibrated by an approved laboratory immediately prior to use
and then at intervals not exceeding 3 months and the true force
determined from the calibration curve.
Pressure gauges shall be concentric scale type gauges accurate to
within two per cent of their full capacity. The minimum nominal
size of gauge shall be 100 mm. The gauge shall be so selected that when
the tendon is stressed to 75 per cent of its breaking load, the gauge
is reading between 50 per cent and 80 per cent of its full capacity.
<< 445
Section t800 Prestressing
Suitable safety devices shall be fitted to protect pressure gauges

against sudden release of pressure.
Provision shall be made for the attachment of the master gauge to
be used as a check whenever requested for by the Engineer.
POST-TENSiONING
Tensioning force shall be applied in gradual and steady steps and
carried out in such a manner that the applied tensions and elongations
can be nieasured at all times. The sequence of stressing, applied
tensions and elongations shall be in accordance with the approved
drawing or as directed by the Engineer.
It shall be ensured that in no case, the load is applied to the concrete
before it attains the strength specified on the drawing or as stipulated
by the preStressing system supplier, whichever is more.
After prestressing steel has been anchored, the force exerted by the
tensioning equipment shall be decreased gradually and steadily so
as to avoid shock to the prestressing steel or 2nchorage.
The tensioning force applied to any tendon shall be determined by
direct reading of the pressure gauges or dynamo-meters and by
comparison of the measured elongation with the calculated elonga-
tion. The calculated elongation shall be invariably adjusted with respect
to the modulus of elasticity of steel for the particular lot as given by
the manufacturer.
The difference between calculated and observed tension and
elongation during prestressing operations shall be regulated as follows:
a) tf the calculated elongation is reached before the specified gauge pressure

is obtained, continue tensioning titt attaining the specified gauge pressure, provided
the elongation does not exceed t .05 times the catculated elongation. If 1.05
times the catculated elongation is reached before the specified gauge pressure
it auaincd, stop stressing and inform the Engineer.
b) tf the catcutated elongation has not been reached at the specified gauge pressure,
continue tensioning by intervats âf 5 kg/sq. c.m. until the calculated elongation
is reached provided the gauge pressure does not exceed 1.05 times the
specified gauge pressure.
c) tf the otongation at 1.05 times the specified gauge pressure is less than 0.95
times the calculated elongation, the following measures must be taken, in
succession, to determine the cause of this lack of discrepancy
i) Check the correct functioning of the acit, pump and teada.
ii) Desension the cable. Slide it in its duct to check that it is not blocked by
<< 446
mortar which has entered through holes in the sheath. Retension the cable
if free.
iii) Re —establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.
If the required elongation is still not obtained, further finishing operations such
as cutting or sealing, should not be undertaken without the approsal of
the Engineer.
d) When stressing from one end only, the slip at the end remote from the jack
shall be accurately measured and an appropriate allowance made in the measured
extension at the jacking end.
A complete record of prestressing operations along with elongation

and jack pressure data shall be maintained in the format given in
Appendix /800/Ii. The number of stages of prestressing and grouting
shall be reduced to a minimum, preferably 2 in the case of simply
supported girders.
~ GROUTING OF PRESTRESSED TENDONS
Grouting shall conform to Appendix 1800/I!!. A record of grouting
operations shall be maintained in the format given in Appendix 1800/
IV.
1809. PRE-TENSIONJNG
1809,1. General
The planning and construction aspects of the tensioning bed,
tensioning bench, abutments at location of anchorage, steam curing
system, formwork of the concrete elements and arrangements for de-
moulding, lifting, stacking and transportation of the pre-tensioned
concrete elements are all specialised items and shall be entrusted to
engineers specifically experienced in this type of work.
1809.2. Stressing Bed for Pre-tensioning
The abutments and bed for pre-tensioning of tendons shall be
designed to withstand the total tensioning force.
A notice shall be displayed adjacent to the stressing bed showing
the maximum tensioning force permitted.
Where concrete elements are cast and prestressed individually, the
stressing bench or moulds shall be rigid enough to sustain the reaction
of the prestressing force without distortion.
In the long line method of prestressing, sufficient locator plates
should be distributed throughout the length of the bed to ensure that
<< 447
the wires are maintained in their proper position during concreting.

The moulds shall be free to slide in the direction of their length
and thus permit the transfer of the prestressing force to alt the concrete
elements along the whole line.
Sufficient space shall be left in between the ends of concrete elements
to permit access for cutting the strands/wires after transfer. Hold-
downs or deflectors shalt be used for holding or deflecting the tendons
in required position firmly. Deflectors which are in contact with the
tendon shall have a diameter not less than the tendon or 15 mm,
whichever is greater.
The tensioning force required to be applied as stated on the
drawings shalt be the force remaining in the strands/wires after all
strands/wires have been inchored to the abutments of the stressing
bed and after the anchorage slip has already taken place. The tensioning
force shall be determined by direct reading of the pressure gauges
or dynamo-meters and by the measured elongation after slip.
The Contractor shall submit method of tensioning the tendons
including the arrangement and layout of prestressing beds and all tendon
deflection points to the Engineer for approval before manufacture
commences.
l’he Contractor shall carry out trial stressing operations to establish
the frictional resistance offered by the hold-downs and the slip during
anchoring.
Where sheathing of pre-tensioned tendons is required to prevent
bond over a specified length, it shall consist of plastic tubing or other
material approved by the Engineer and shall be of a quality, diameter
and thickness such that bond shall be effectively prevented. The
tubing shall be fastened to the tendon in such a manner that cement
mortar cannot enter. The Engineer may order that the pull-in of the
tendon be measured during the transfer of prestress.
The Contractor shall also submit calculations showing that the hold-
downs have been designed and constructed to withstand concentrated
loads resulting from the application of the tensioning force.
1809.3, Tensioning Procedure
The tensioning of the wires and strands shall be done not too
much in advance of concreting.
The tensioning force shall be applied gradually and uniformly.
448
<<
In order to remove slack and to lift tendons off the bed floor, an
initial force approved by the Engineer shall be applied to the tendons.
Allowance shall be made for this force in calculating the required
elongation.
Tendons shall be marked for measurement of elongation after the
initial force has been applied. When required by the Engineer, tendons
shall be marked at both the jacking end and dead end of the stressing
bed and at couplers if used so that slip and draw-in may be measured.
Where deflected strands have been specified, the Engineer may
direct the elongation or strain gauge measurements be taken at various
positions along the tendon to determine the force in the tendon at those
positions.
1809,4. Transfer of Prestress
While the process of tensioning can be accomplished by means of
hydraulic jacks, some positive mechanical means shall be provided to
maintain the tension during the entire period between the tensioning
of the wires/strands and transfer of the prestressing force to the concrete
element.
Transfer of prestress shall not proceed until the Engineer has
approved the proposed method. Tendons and deflection devices shall
be released in such a pre-determined order that unacceptable tensile
stresses are not induced in the concrete.
Prior to transfer of the force to the units, all tendons shall be tested
for tightness and any loose tendon shall be reported to the Engineer
who will decide whether the ti1~itsaffected shall be rejected.
The Engineer may require that tendons be marked at each end
of any unit to allow measurement of the pull-in of the concrete.
Tendons shall be released gradually and preferably simultaneously.
Under no circumstances shall tendons be cut while under ten~on.
On completion of the transfer of prestress, the projecting lengths of
tendon shall be cut off flush with the end surface of the unit, unless
otherwise shown, by a method approved by the Engineer.
In no case shall the transfer of prestressing force to the concrete
elements take place before concrete attains the strength specified in the
drawings. To determine the specified strength, additional cube testing
shall be undertaken at the Contractor’s cost. In case steam curing is
employed, the cubes shall be pLaced in the same environment as the
<< t49
concrete elements to obtain an accurate assessment of concrete strength

at the time of transfer.
The sequence of transfer of prestressing force shall be done strictly
as indicated in the drawings and ensuring that eccentricities of the
prestressing force in the vertical and horizontal directions of the concrete
element is a minimum during the entire sequence.
The maximum slip of any tendon during transfer shall not exceed
3 mm at any end of the concrete element. In case this slip is exceeded,
the concrete element in question shalt be rejected.
1809.5. Protection of Ends
The exposed ends of the tendons and the concrete surfaces of the
ends of the units shall be wire brushed clean of alt rust, loose mortar,
grease and dirt.
The exposed ends of the tendons and concrete surface within 50 mm
of tendons shalt be then abraded to provide a clean sound surface.
An epoxy tar paint suitably formulated to give a dry film thickness
of 80 microns per coat shalt then be immediately applied over the ends
of the tendons unless otherwise directed.
A second coat of paint shalt be applied prior to the drying out
of the first coat.
ifl SAFETY PRECAUTIONS DURING TENSIONING
~dare shalt be taken during tensioning toensure the safety of all
persons in the vicinity.
Jacks shall be secured in such a manner that they will be held in
position, should they lose their grip on the tendons.
No person shall be allowed to stand behind the jacks or close to
the line of the tendons white tensioning is in progress.
The operations of the jacks and the measurement of the elongation
and associated operations shall be carried out in such a manner and
from such a position that the safety of all concerned is ensured.
A safety barrier shall be provided at both ends to prevent any tendon,
which might become loose from recoiling unchecked.
During actual tensioning operation, warning sign shall be displayed
at both ends of the tendon,
After prestressing, concrete shall neither be drilled nor any portion
<<
450
cut nor chipped away nor disturbed, without express approvat of

the Engineer.
No welding shall be permitted on or near tendons nor shall any
heat be applied to tendons. Any tendon which has been affected by
welding, weld spatter or heat shall be rejected.
ipt: TRANSPORTATION AND STORAGE OF UNITS
Precast girders shall be transported in an upright position. Points
of support and the direction of reactions with respect to the girder shall
approximately be the same during transportation, and storage as when
the girder is placed in final position.
When members are to be stacked, they shall be firmly supported
at such bearing positions as will ensure that the stresses induced th
them are always less than the permissible design stresses. Further,
inclined side supports shall be provided at the ends and along the length
of a precast girder to prevent lateral movements or instability.
Care shall be taken during storage, hoisting and handling of the
piecast units to prevent their cracking or being damaged. Units damaged
by improper storing or handling shall be replaced by the Contractor
at his expense.
N A~12. TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons
shalt be limited to the following
a) Variation 1mm the specified horizontal profite 5 mm
h) Variation 1mm the specified vertical pmfile 5 mm
c) Variation 1mm the specified position in member 5 mm
$13, TESTS AND STANDARDS OF ACCEPTANCE

~the materials shall be tested in accordance with these Specifica-
tions and shall meet the prescribed criteria,
\$4. MEASUREMENTS, FOR PAYMENT
Prestressed Concrete shall be measured in cubic metres. The
volume occupied by mild steel reinforcement /HYSD bars, high tensite
steel, sheathing and anchorages shall not be deducted.
High tensile (prestressing) steel shall be paid for separately and
its length shall be measured as actually !icorporated in the finished work.
451
<<
From the length so measured its weight shall be calculated in tonnes

on theoretical basis and paid for.
Anchorage devices, additional length of cables for attaching jack,
ducts or sheathing, grout, non-prestressed steel reinforcement fixed to the
anchorage devices, making of recesses and filling the same, protection
by painting with epoxy and furnishing samples for testing shall all
be deemed to be included in the item of high tensile steel and shall
not be measured separately.
RATE
The contract unit rate for cast-in-place prestressed concrete shall
cover the cost of all materials, labour, tools and plant required for
mixing, placing in position, vibrating and compacting, finishing as per
directions of the Engineer, curing and other incidental expenses for
producing concrete of specified strength to complete the structure or its
components as shown on the drawings and according to specifications.
The contract unit rate shall also include the cost of making, fixing
and removing of all centring and forms required for the work unless
otherwise specified in the Contract.
For precast prestressed concrete members, the rate in addition to
above shall also include the cost of all materials, labour, tools and plant
required to transport and place these members in their final position
as shown on the drawings and as directed by the Engineer.
The cdntract unit rate for high tensile steel shall cover the cost of
material, labour, tools and plant required for manufacturing, placing,
tensioning, anchoring and grouting the high tensile steel in the prestressed
concrete as shown on the drawings and as per specifications herein above
or as directed by the Engineer.
The cost of anchorage devices, additional length of cables for
attaching jack, ducts or sheathing, grout, non-prestressed steel reinforce-
ment fixed to the anchorage devices, making of recesses and filling the
s~me,protection by painting with epoxy and furnishing samples for testing
shall all be included in the unit rate: Rate shall also include payments
if any to be made to the supplier of the prestressing system who has
to monitor, ensure and certify the correctness of all operations.
<< 452
Structural Steel
1900
Structural Steel
<<
Structural Steel Section 1900
1901. DESCRIFFION
This work shall include furnishing, fabricating, transporting, erecting
and painting structural steel, rivet steel, cast steel, steet forgings, cast
iron and other incidental metal construction of the kind, size and quantity
in conformity with the drawings and these specifications or as desired
by the Engineer.
1902. GENERAL
General requirements relating to the supply of material shall conform
to the specifications of IS:1387, for the purpose of which the supplier
shall be the Contractor and the purchaser shall be the Engineer.
Finished rolled material shall be free from cracks, flaws, injurious
seams, laps, blisters, ragged and imperfect edges and other defects. It
shall have a smooth and uniform finish, and shall be straightened in
the mill before shipment. They shall also be free from loose mill scale,
rust, pits or other defects affecting its strength and durability.
The acceptance of any material on inspection at the mill i.e. rolling
mills, foundry or fabricating plant where material for the work is
manufactured, shall not be a bar to its subsequent rejection, if found
defective.
Unless specified otherwise, high tensile steel rivet conforming to
IS: 1149 shall be used for members of high tensile steel conforming
to 15:961 and shall not be used for mild steel members.
Unless specified otherwise, bolted connection of structural joints
using high tensile friction grip bolts shall comply with requirements
of 15:4000.
Cast iron shall not be used in any portion of the bridge structure,
except where it is subject to direct compression.
1903. MATERIALS
1903.1. All materials shall conform to Section 1000. Special require-
ments are given below
Mild steel for bolts and nuts shall conform to 15:226 but have a
minimum tensile strength of 44 kg/sq. mm. and minimum percentage
elongation of 14. High tensile steel for bolts and nuts shall conform
to IS:961 but with a minimum tensile strength of 58 kg/sq. mm. High
strength friction grip bolts shall be permitted for use only on satisfactory
455
<<
Section 1900 Structural Steel
evidence of performance to the requirements (not covered by these
specifications) specified by the Engineer or included in the special
provisions.
For cast steel, the yield stress shall be determined and shall not
be less than 50 per cent of the minimum tensile strength.
Plain washers shall be of steel. Tapered or other specially shaped
washers shall be of steel, or malleable cast iron.
Parallel barrel drifts shall have a tensile strength not less than
55 kg/sq.mm. with elongation of not less than 20 per cent measured on
a gauge length of 44So (So = cross sectional!! area).
1903.2. Materials for castings and forgings, fasteners and welding
consumables shall be as under
1903.2.1. Castings and Forgings : Steel castings and forgings shall
comply with the requirements of the following Indian Standards, as ap-
propriate
IS: 1030 Carbon Steel Castings for General Engineering purposes
IS:1875 Carbon Steel Billets, blooms, slabs, bars for forgings
IS:2004 Carbon Steel Forgings for General Engineering purposes
IS:2644 High Tensile Steel Casings
lS:4367 Alloy & tool steel forgings for general industrial use
1903,2.2. Fasteners : Bolts, nuts, washers and rivets shall comply
with the following or relevant IS Standards as appropriate
IS: 1929 Hot forged steel rivets for hot closing (12-36mm dia)
IS:2l55 Cold forged steel rivets for hot closing (6-16mm dia)
IS:1363 Hexagon head bolts, screw and nuts product grade C
IS:1364 Hexagon head bolts, screw & nuts product grade A & B
IS: 1367 Technical supply conditions for threaded steel fastener
(Parts 1 to 18)
IS:3640 Hexagon fit bolts
IS:3757 High tensile friction grip bolts
IS:6623 High strength structural nuts
IS:6639 Hexagon bolts for steel structure
IS:5624 Foundation bolts
456
<<
IS:7002 Prevailing torque type steel hexagon lock nuts
IS:5369 Plain washers and lock washers general requirements
-
IS:5370 Plain washers with outside dia = 3 X inside dia

IS:5372 Taper washers for channels (ISMC)
IS:5374 Taper Washers for I beams (ISMB)
ES:6610 Heavy washers for steeL structures
IS:6649 Hardened and tempered washers for high strength struc-
tural bolts and nuts
1903.2.3. Welding consumables
Welding consumables Shall comply with the following Indian Stand-
ards as appropriate
IS:814 Covered Electrodes for Metal Arc Welding of structural
(Part 1) steel for welding other than sheets
IS:8 14 For welding Sheets
(Pail 2)
IS: 1278 Filler rods and wires for gas welding
IS: 1395Low and medium alloy Steel covered electrodes for
manual Metal Arc Welding
IS:36l3 Acceptance Tests for wire flux combinations for sub-
merged arc welding of structural steel
IS:7280 Bare wire electrodes for gas shielded arc welding of
structural steel
15:6419 Welding rods and bare electrodes for gas shielded arc
welding of structural steel
IS:6560 Molybdenum and chromium-molybdenum low alloy steel
welding rods and bare electrodes for gas shielded arc
welding
1903.3. In aggressive environment, corrosion resistant steel can be
used. These are low-alloyed steels containing a total of 1 per cent 2 -
per cent alloys, in particular, copper, chromium, nickel and phosphorous.

1903.4. Paints
All materials for paints and enamels shall conform to the require-
metns specified on the drawings or other special provisions laid down
by the Engineer.
457
<<
The type of paints which can be used shall be as follows

a) Ordinary i.e. pants based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy
I,) Chanical Resistant - one pack type (ready for use) and two pack type (mixed
before use).
c) Vinyl
d) Chlorinaied rubber
e) Bituminous
1) Epoxy
g) Polyurethane
h) Zinc rich
Unless otherwise specified, paints shall conform to the relevant IS
specifications. The paints which have been tested for the following
qualities as per specifications given in the relevant IS codes only shall
be used
- Weight test (weight for 10 litre of paint, thoroughly mixed)
- Drying time
- Consistency
- Dry thickness and rate of consulnl*ion.
1904. FABRICATION
1904.1. General
All work shall be in accordance with the drawings and as per
these specifications with care being taken that all parts of an assem-
bly fit accurately together. All members shall carry mark number and
item number and, if required, serial number.
Unless specifically required under the contract, corresponding parts
need not be interchangeable, but the parts shall be match marked as
required under Clause 1904.7.
Templates, jigs and other appliances used for ensuring the accuracy
of the work shall be of mild steel; where specially required, these shall
be bushed with hard steel. All measurements shall be made by means
of steel tape or other device properly calibrated. Where bridge materials
have been used as templates for drilling, these shall be inspected and
passed by the Engineer before they are used in the finished structure.
All structural steel members and parts shall have straight edges and
blunt surfaces. If necessary, they shall be straightened or flattened by
<< 458
pressure unless they are required to be of curvilinear forms. They
shall also be free from twist. Pressure applied for straightening or
flattening shall be such as would not injure the materials. Hammering
shall not be permitted. Adjacent surfaces or edges shall be in close
contact or at uniform distance throughout.
The Contractor shall submit his programme of work to the Engineer
for his approval at least 15 days before the commencement of fabrication.
This programme shall include the proposed system of identification and
erection marks together with complete details of fabrication and welding
procedures.
The Contractor shall prepare shop drawings for fabricating any
member and obtain approval of the Engineer before the start of work.
Complete information regarding the location, type, size and extent of
all welds shall be clearly shown on the shop drawings. These drawings
shall distinguish between shop and field welds.
1904.2. Preparation of Edges and Ends
All structural steel-parts, where required, shall be sheared, cropped,
sawn or flame cut and ground accurately to the required dimension and
shape.
End/edge planing and cutting shall be done by any one of the
following prescribed methods or left as rolled
a) Shearing, cropping, sawing
1 machining, machine flame cutting.
b) Hand flame cutting with subsequent grinding to a smooth edge.
c) Sheared edges of plate not more than 16 mm thick with subsequent grinding
th smooth profile, which are for secondary use such as ssiffeners and gussets.
If ends of stiffeners are required to be fitted, they shall be ground,
so that the maximum gap over 60 per cent of the contact area does not
exceed 0.25 mm.
Where flame cutting or shearing is used, at least one of the
following requirements shall be satisfied.
a) The cut edge is not subjected to applied stress.
b) The edge is incorporated in weld.
c) The hantness of cut edge does not exceed 350 HV30.
d) The material is removed from edge to the extent of 2 mm or minimum necessary,
so that the hardness is less than 350 HV 30.
e) Edge is suitably heat treated by approved method to the satisfaction of the Engineer
and shown that cracks had not developed by dye penetrant or magnetic particle
test.
<< 459
f) Thickness of plate is less than 40 mm for machine flame cutting for snateriak
confomiing to l&226 and IS:2062, The requirement of hardness below 350 IN
30 of flame cur edges thould be specified by the Engineer.
Wherever specified by the Engineer, the flame cut edges shall be

ground or machined over and above the requirement (a) to (1).
Where machining for edge preparation in butt joint is specified, the
ends shall be machined after the members have been fabricated.
Outside edges of plate and section, which are prone to corrosion
shall be smoothed by grinding or filing.
In the case of high tensile steel at least 6 mm of the material from
the flame cut edge shall be removed by machining.
Longitudinal edges of all plates and cover plates in plate girders and
buiIt.~up members shall be machined except in the following cases
a) Rolled edges of single universal plates or flats may nor be machined.
b) Covers to single flange pktes may be left unmachined.
c) Machine flame cutting instead of machining is acceç~ablefor edges of single plates
in compression and for edges of single plates, 25 mm or less thick, in tension.
d) Edges of ~ingte shaped plates over 25 mm thick not capable of being machined
by ordinary method may be machine flame cut and the and surface ground.
e) Edges of universal plates or flats of the same nominal width used in tiers may
be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12 mm thick and over shall
be machined and those less than 12 mm thick may be sheared and
ground.
The ends of plates and sections forming the main components of
plate girders or of built~upmembers shall be machined, machine flame
cut, sawn or hand flame cut and ground.
Where ends of stiffeners are required to be fitted, they shall be
machined, machine flame cut, sawn, sbeared and ground, or hand flame
cut and ground.
The ends of lacing bar shall be rounded unless otherwise required.
Other edges and ends of mild steel parts may be sheared and any
burrs at edges shall be removed.
1904.3. Preparation of Boles
1904,3.1. Drilling and punching Holes for rivets, black bolts, high.
strength bolts and countersunk bolts/rivets (excluding close tolerance
and turn fined bolts) shall be either punched or drilled. The diameter
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of holes shall be 1.5 mm larger for bolts/rivets less than 25 mm dia

and 2.0 mm., for more than or equal to 25 mm.
All holes shall be drilled except for secondary members such as,
floor plate, hand rails etc. Members which do not carry the main load
can be punched subject to the thickness of member not exceeding
12 mm for material conforming to lS:226.
Holes through more than one thickness of material or when any of
the main material thickness exceeds 20 mm for steel conforming to
lS:2062 or 16 mm for steel conforming to IS:961, IS:8500, shall either
be sub-drilled or sub-punched to a diameter of 3 mm less than the
required size and then reamed to the required size. The reaming of
material more than one thickness shall be done after assembly.
Where several plates or sections form a compound member, they
shall, where practicable, be firmly connected together by clamps or
tacking bolts, and the holes be drilled through the group in one operation.
Alternatively, and in the case of repetition work, the plates and sections
may be drilled separately from jigs and templates. Jigs and templates
shall be checked at least once after every 25 operations. All burrs
shall be removed.
In the case of repetition of spans, the erection of every span shall
not be insisted upon, except where close tolerance or turned bolts
are used, provided that methods are adopted to ensure strict interchangea-
bility. In such cases, one span in ten or any number less than ten of
each type shall be erected from pieces selected at random by the
Engineer and should there be any failure of the pieces to fit, all similar
spans shall be erected complete. In the event of spans being proved
completely interchangeable, all corresponding parts shall carry the same
mark so that sorting of the materials at site is facilitated.
1904.3.2. Block drilling : Where the number of plates to be riveted
exceeds three or the total thickness is 90 mm or more, the rivet holes,
unless they have been drilled through steel bushed jigs, shall be drilled
out in place 3 mm all round after assembling. In such cases, the work
shall be thoroughly bolted together.
1904.3.3. Size of holes: The sizes of holes in millimetres are given
in Table 1900-i below:
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461
Sec lion 1900 Structural Steel
TABLE 1900-i DtAMVFER OF HOLES FOR RIVV1’S
Nozninaldia of Rivets (mm) ma of Holes (mm)
12 13.5
14 15.5
16 17.5
18 19.5
20 21.5
22 23.5
24 25.5
27 29.0
30 32.0
33 35.0
1904.3.4. Close tolerance bolts and barrel bolts : Holes for close.
tolerance and turn fitted bolts. The diameter of the holes shall be
equal to the nominal diameter of the bolt shank minus 0.15 mm to
0.0 mm.
The members to be connected with close tolerance or tum fitted
bolts shall be firmly held together by service bolts or clamped ‘and
drilled through all thicknesses in one operation and subsequently
reamed to required size within specified limit of accuracy as specified
in 15:919 tolerance grade H8.
The holes not drilled through all thicknesses at one operation
shall be drilled to smaller size and reamed after assembly.
1904.3.5, Holes for high strength friction grip bolts : All holes
shall be drilled after removal of burrs. Where the number of’’plies
in the grip does not exceed three, the diameters of holes shall be 1.6
mm larger than those of bolts and for more than three plies in grip,
the diameters of hole in outer plies shall be as above and dia of holes
in inner plies shall not be less than 1.6 mm and not more than
3.2 mm larger than those in bolts, unless otherwise specified by the
Engineer.
1904.3.6. Removal of burrs : The work shall be taken apart after
drilling and all burrs left by drilling and the sharp edges of all rivet
holes completely removed.
1904.4. Rivet and Riveting
The diameter of rivets shown on the drawings shall be the size
before heating. Each rivet shall be of sufficient length to form a head
of the standard dimensions as given in IS handbook on Steel Sections,
Part I. It shall be free from burrs on the underside of the head.
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When countersunk heads are required, the heads shall fill the
countersunk. The included angle of the head shall be as follows
a) For plates over 14 mm thickness 90 degrees
b) For plates upto and including 14 mm thickness 120 degrees
The tolerance on the diameter of rivets shall be in accordance with

IS: 1148 and IS: 1149 for mild steel rivets and high tensile steel rivets
respectively and unless otherwise specified, the tolerance shall be minus
tolerance.
Rivets shall be driven when hot so as to fill the hole as com-
pletely as possible and shall be of sufficient length to form a head of
-
standard dimension. When counter-sunk head is required, the head shall

fill the counter-sunk hole. Projection after counter-sinking shall be
ground off wherever necessary.
Rivets shall be heated uniformly to a “light cherry red” colour
between 650 degrees Celsius to 700 degrees Celsius for hydraulic riveting
and “orange colour” for pneumatic riveting of mild steel rivets and shall
be red hot from head to the point when inserted and shall be upset
in its entire length so as to fill the hole as completely as possible when
hot. Rivets, after being heated and before being inserted in the hole
shall be made free from scale by striking the hot rivet on a hard surface.
Wherever possible, the rivets shall be machine driven, preferably by
direct acting riveters. The driving pressure shall be maintained on
the rivets for a short time after the upsetting is completed. High tensile
steel rivets shall be heated upto 1100 degrees Celsius. Any rivet whose
point is heated more than prescribed, shall not be driven.
Where flush surface is required, any projecting metal shall be
chipped or ground off.
Before riveting is commenced, all work shall be properly bolte
up so that the various sections and plates are in close contact throughout.
Drifts shall only be used for drawing the work into position and shall
not be used to such an extent as to distort the holes. Drifts of a larger
size than the nominal diameter of the hole shall not be used. The riveting
shall be done by hydraulic or pneumatic machine unless otherwise
specified by the Engineer.
Driven rivets, when struck sharply on the head by a quarter pound
rivet testing hammer, shall be free from movement and vibrations.
Assembled riveted joint surfaces, including those adjacent to the rivet
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heads, shall be free from scale, dirt, loose scale, burrs, other foreign
materials and defects that would prevent solid seating of parts.
All loose or burnt rivets and rivets with cracked or badly formed
defective heads or with heads which are unduly eccentric with the shanks,
shall be removed and replaced. In removing rivets, the head shall be
sheared off and the rivet punched out SO as not to injure the adjacent
metal and, if necessary, they shall be drilled out. Recupping or
recaulking shall not be permitted. The parts not completely riveted
in the shop shall be secured by bolts to preventdamage during transport
and handling.
1904.5. Bolts, Nuts and Washers
1904.5.1. Black bolts (black all over) : Black bolts are forged bolts
in which the shanks, heads and nuts do not receive any further treatment
except cutting of screw threads. They shall be true to shape and size
and shall have the standard dimensions as shown on the drawings,
1904.5.2. Close tolerance bolts : Close tolerance bolts shall be faced
under the head and turned on the shank.
1904.5.3. Turned barrel bolts: The diameter of the screwed portion
of turned barrel bolts shall be 1.5 mm smaller than the diameter of
the barrel unless otherwise specified by the Engineer. The diameter of
the bolts as given on the drawing shall be the nominal diameter of
the barrel. The length of the barrel shall be such that it bears fully on
all the parts connected. The threaded portion of each bolt shall project
through the nut by at least one thread. Faces of heads and nuts bearing
on steel work shall be machined.
1904.5.4. High strength friction bolts and bolted connections: The
general requirement shall be as per relevant IS specifications mentioned
in clause 5.3 of (Fasteners) of IRC:24. Unless otherwise specified by
the Engineer, bolted connections of structural joints using high tensile
friction grip bolts shall comply with requirements mentioned in IS:4000.
1904.5.5. Washers : In all cases where the full bearing area of
the bolt is to be developed, the bolt shall be provided with a steel
washer under the nut of sufficient thickness to avoid any threaded portion
of the bolt being within the thickness of the parts bolted together and
to prevent the nut when screwed up, from bearing on the bolt.
For close tolerance or turned barrel bolts, steel washers whose faces
give a true bearing shall be provided under the nut. The washer shall
have a hole diameter not less than 1.5 mm larger than the barrel and
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a thickness of not less than 6 mm so that the nut when screwed up,
will not bear on the shoulder of the bolt.
Taper washers with correct angle of taper shall be provided under
all heads and nuts bearing on bevelled surfaces.
Spring washers may be used under nuts to prevent slackening of
the nuts when excessive vibrations occur.
Where the heads or nuts bear on timber, square washers having
a length of each side not less than three times the diameter of bolts
or round washers having a diameter of 3h/~ times the diameter of
bolts and with a thickness not less than one quarter of diameter shall
be provided.
1904.5.6. Studs : Ordinary studs may be used for holding parts
together, the holes in one of the parts being tapped to take the thread
of the stud. Counter-sunk studs may be used for making connections
where the surfaces are required to be clear of all obstruction, such
as protruding heads of bolts or rivets, studs may also be welded on the
steel work in the positions required.
1904.5.7. Service bolts: Service bolts shall have the same clearance
as black bolts and where it is required that there should be no movement
prior to final riveting, sufficient drifts or close tolerance bolts shall be
used to locate the work.
1904.5.8. Tightening bolts: Bolted connection joints with black bolts
and high strength bolts shall be inspected for compliance of codal
requirements.
The Engineer shall observe the installation and tightening of bolts
to ensure that correct tightening procedure is used and shall determine
• that all bolts are tightened. Regardless of tightening method used,
tightening of bolts in a joint should commence at the most rigidly fixed
or stiffest point and progress towards the free edges, both in initial
snugging and in final tightening.
The tightness of bolts in connection shall be checked by inspec-
tion wrench, which can be torque wrench, power wrench or calibrated
wrench.
Tightness of 10 per cent bolts, but not less than two bolts, selected
at random in each connection shall be checked by applying inspection
torque. If no nut or bolt head is turned by this application, connection
can be accepted as properly tightened, but if any nut or head has turned
all bolts shall be checked and, if necessary, re-tightened.
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1904.5.9. Drifts : The barrel shall be drawn or machined to the

required diameter for a length of not less than one diameter over
the combined thickness of the metal through which the drifts have to
pass. The diameter of the parallel barrel shall be equal to the
nominal diameter of the hole subject to a tolerance of +0 mm and -
0.125 mm. Both ends of the drift for a length equal to 11/2 times the
diameter of the parallel portion of the bar shall be turned down
with a taper to a diameter at the end equal to one-half that of parallel
portion.
1904.6. Pins and Pin Holes
1904.6.1. Pins : The pins shall be parallel throughout and
shall have a smooth surface free from flaws. They shall be of
sufficient length to ensure that all parts connected thereby shall
have a full bearing on them. Where the ends are threaded, they shall
be turned to a smaller diameter at the ends for the thread and shall be
provided with a pilot nut, where necessary, to ~protectthe thread when
being drawn t~ place.
Pins more than 175 mm in length or diameter shall be forged and
annealed. -
1904.6.2. Pin holes : Pin holes shall be bored true to gauge, smooth,
straight at right angles to the axis of the member and parallel with
each other, unless otherwise required. The tolerance in the length of
tension members from outside to outside of pin boles and of compression
members from inside to inside of pin holes shall be one millimetre.
In built-up members, the boring shall be done after the members have
been riveted or welded.
The specified diameter of the pin hole shall be its minimum diameter.
The resulting clearance between the pin and the hole shall not be less
than 0.5 mm and not more than 1.0 mm.
1904.7. Shop Erection and Match Marking
Before being dispatched, the steel work shall be temporarily
erected in the fabrication shop for inspection by the Engineer either
wholly or in such portion as the Engineer may require so that he may
be satisfied both in respect of the alignment and fit of all connections.
For this purpose, sufficient number of parallel drifts and service bolts
tightly screwed up shall be employed. All parts shall fit accurately
and be in accordance with drawings and specifications.
The steel work shall be temporarily assembled at place of fabrication.
<< 466
Assembly shall be of full truss or girder, unless progressive truss
or girder assembly, full chord assembly, progressive chord assembly
or special complete structure assembly is specified by the Engineer.
The field connections of main members of trusses, arches, continuous
beams, spans, bends, plate girders and rigid frame assembled, aligned,
accuracy of holes and camber shall be checked by Engineer and then
only reaming of sub-size holes to specified size shall be taken up.
After the work has been passed by the Engineer and before it is
dismantled, each part shall be carefully marked for re-erection with
distinguishing marks and stamped with durable markings. Drawings
showing these markings correctly shall be supplied to the Engineer.
Unloading, handling and storage ~f steel work as per these
specifications shall be the responsibility of the Contractor. The cost of
repairs or of rejected material, its removal and the cost of transporting
replacement material to the site shall be borne by the Contractor.
Where close tolerance or turned barrel bolts are used for those cases
where interchangeability is not insisted upon, each span shall be erected
and members of each span marked distinctly.
1904.8. Welding
1904.8.1. All welding shall be done with the prior approval of the
Engineer and the workmanship shall conform to the specifications of
IS:823 or other relevant Indian Standards as appropriate.
When material thickness is 20 mm or more, special precautions like
preheating shall be taken as laid down in IS:823. Surfaces and edges
to be welded shall be smooth, uniform and fret from fins, tears, cracks
and other discontinuities. Surface shall also be free from loose or thick
scale, slag rust, moisture, oil and other foreign materials. Surfaces within
50 mm of any weld location shall be free from any paint or other
material that may prevent proper welding or cause objectionable fumes
during welding.
The general welding procedures including particulars of the prepa-
ration of fusion faces for metal arc welding shall be carried out in
accordance with IS:9595.
The welding procedures for shop and site welds including edge
preparation of fusion faces shall be submitted in writing in accordance
with Clause 22 of IS :9595 for the approval of the Engineer before
commencing fabrication and shall also be as per details shown on the
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drawings. Any deviation from above has to be approved by Engineer.

Preparation of edges shall, wherever practicable, be done by machine
methods.
Machine flame cut edges shall be substantially as smooth and
regular as those produced by edge planing and. shall be left free of
slag. Manual flame cutting shall be permitted by the Engineer only where
machine cutting is not practicable.
Electrodes to be used for metal arc welding shall comply with
relevant IS specifications mentioned in IRC:24. Procedure test shall be
carried out as per IS:8613 to find out suitable wire-flux combination
for welded joint.
Assembly of parts for welding shall be in accordance with provisions
of IS:9595.
The welded temporary attachment should be avoided as far as
possible, otherwise the method of making any temporary attachment shall
be approved by the Engineer. Any scars from temporary attachment shall
be removed by cutting, chipping and surface shall be finished smooth
by grinding to the satisfaction of the Engineer.
Welding shall not be done when the air temperature is less than
10 degrees Celsius. Welding shall not be done when the surfaces are
moist, during periods of strong winds or in snowy weather unless the
work and the welding operators are adequately protected.
1904.8.2. For welding of any particular type of joint, welders shall
qualify to the satisfaction of the Engineer in accordance with appropriate
welders qualification test as prescribed in any of the Indian Standards
IS:817, IS:1966, IS: 1393, IS:7307 (part I), IS:7310 (Part I) and IS:7318
(part I) as relevant.
1904.8.3. In assembling and joining parts of a structure or of built-
up members, the procedure and sequence of welding shall be such as
to avoid distortion and minimise shrinkage stress.
All requirements regarding pre-heating of parent material and
interpass temperature shall be in accordance with provision of IS:9595.
19048.4. Peening of weld shall be carried out wherever specified
by the Engineer
a) If specified, peening may be employed to be effective on each weld~1ayerexcept
first.
b) The peening should be carried out after weld has cooled by light blows from
<< 468
a power hammer using a round nose tool. Care shall be taken to prevent
scaling or flaking of weld and’ base metal from over peening.
1904.8.5. Where the Engineer has specified the butt welds are to
be ground flush, the loss of parent metal shall not be greater than
that allowed for minor surface defects. The ends of butt joints shall be
welded so as to provide full throat thickness. This may be done by use
of extension pieces, cross runs or other means approved by the Engineer.
Extension pieces shall be removed after the joint has cooled and the
ends of the weld shall be finished smooth and flush with the faces of
the abutting parts.
The joints and welds listed below are prohibited type, which do
not perform well under cyclic loading.
a) Butt joints not fully welded throughout their cross-section
b) Groove welds made from one side only without any backing grip
c) Inteimittent groove welds
d) Intermittent fillet welds
e) Bevel-grooves and J-grooves in butt joints for other than horizontal position.
f) Plug and slot welds
1904.8.6. The run-on and run-off plate extension shall be used
providing full throat thickness at the end of butt welded joints. These
plates shall comply with the following requirements.
(i) One pair of ~‘run-on”and one pair of “nm-off” plates prepared from same
thickness and profile as the parent metal shall be attached to start and finish
of all butt welds preferably by clamps.
(ii) When “nm-on” and “run-off’ plates shall be removed by flame cutting, it should
be rut at more than 3 mm from parent metal and remaining metal shall be
removed by grinding or by an~’ other method approved by the Engineer.
1904.8.7. Welding of stud shear connectors : The stud shear

connectors shall be welded in accordance with the manufacturer’s
instructions including preheating.
The stud and the surface to which studs are welded shall be free
from scale, moisture, rust and other foreign material. The stud base shall
not be painted, galvanised or cadmium plated prior to welding.
Welding shall not be carried out when temperature is below 10
degrees Celsius or surface is wet or during periods of strong winds unless
the work and the welder is adequately protected.
The welds shall be visually free from cracks and shall be capable
of developing at least the nominal ultimate strength of studs.
<< 469
The procedural trial for welding the stud shall be carried out when
specified by the Engineer.
1904.9. Tolerances
Tolerances in dimensions of components of fabricated structural steel
work shall be specified on the drawings and shall be subject to the
approval of the Engineer before fabrication. Unless specified, all parts
of an assembly shall fit together accurately within tolerances specified
in Table 1900-2.
A machined bearing surface, where specified by the Engineer,
shall be machined within a deviation of 0.25 mm for surfaces that can
be inscribed within a square of side 05 in.
TABLE 1900.2 FABRICATION TOLERANCES
A. INDIVIDUAL COMPONENTS
1. Length
a) Member with both ends finished for ±1 mm
contact bearing
b) Individual components of members with + 0 mm
end plate conneution - 2 mm
c) Other members
I) Upto and including 12 M ±2mm
ii) Over 12 M ±3.5mm
2. Width
Width of built-up girders ~3 mm
b) Deviation in the width of members +0 mm
required to be inserted in other members -3 mm
3. Depth
Deviation in the depths of solid +3 mm
web and open web girders -2 mm
4. Straightness
a) Deviation from streighiness of 1./3000 subject to a
columns maximsin of 15 mm
where L is length of
member
1) In elevation +5 rum
-0mm
ii) In plan 111000 subject to a
- maximum of 10 mm
5. Deviation of centre line of web from centre

line of flanges in built-up members at contart
surfaces - 3 mm
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6. Deviation from flatness of plate of webs of 0.005 d to a maximum

built-up members in a length equal to the of 2 mm where d is depth
depth of the member of the member
7. Tilt of flange of plate girders

a) At splices and stiffeners, at 0.005 b to a
supports, at the top flanges of minimum of 2 mm where b
plate girders and at bearings is width of the member
b) at other places 0.015 b to a

maximum of 4 mm where
b is width of the member
8, Deviation from squareness of 111000. where

flange to web of columns and L is nominal length
box girders of the diagonal
9. Deviation from squareness of D/500, where D is

fixed base plate (not machined) the distance from
to axis of column. This dimension the column axis to
shall be measured parallel to the the point under
longitudinal axis of the column at consideration on
points where the outer surfaces of the base plate
the column sections make contact
with the base plate

machined ends to axes of columns as defined in 9 above

machined ends to axes of beams as defined in 9
or girder above
12. Ends of members abutting at joints 1/600 of depth of

through cleats or end plates, member subject to
permissible deviation from a maximum of 1.5 mm
squareness of ends
1905. ERECTION
1905.1. General
The provisions of this item shall apply to erection of steel bridge
superstructures or main members of bridge superstructures, composed of
steel, which span between supports.
If the sub-structure and the superstructure are built under separate
contracts, the department will provide the substructure, constructed to
correct lines, dimensions and elevations properly finished and will
establish the lines and the elevation required for setting steel.
<< 471
The Contractor shall erect the structural steel, remove the tempo-
rary construction, and do all the work required to complete the
construction included in the contract in accordance with the drawings
and the specifications and to the entire satisfaction of the Engineer.
1905.2. Organisation and Equipment
The Contractor shall submit erection plans prepared by the fabricator,
showing a method and procedure of erection, compatible with the details
of fabrication.
A detailed scheme must be prepared showing stage-wise activities,
with complete drawings and working phase-wise instructions. This should
be based on detailed stage-wise calculation and take into account
specifications and capacity of erection equipment machinery, tools,
tackles to be used and temporary working loads as per Coclal provisions.
The scheme should be based on site conditions e.g. hydrology,
rainfall, flood timings and intensity, soil and sub-soil conditions in the
river bed and banks, maximum water depth, temperature and climatic
conditions and available working space, etc.
The scheme should indicate precisely the type of temporary fas-
teners to be used as also the minimum percentage of permanent fasteners
to be fitted during the stage erection. The working drawings should
give clearly the temporary jigs, fixtures, clamps, spacer supports, etc.
Unless otherwise provided in the contract, the contractor shall supply
and erect all necessary falsework and staging and shall supply all labour,
tools, erection plant and other materials necessary to carry out the work
complete in all respects.
The Contractor shall supply all rivets, bolts, nuts, washers, etc.
required to complete erection at site with an allowance for wastage,
etc., of 12 1/ per cent of the net number of field rivets, bolts, washers
required, or a minimum of five number of each item.
Service bolts ‘and nuts, ordinary platters, washers and drifts for use
in the erection of work shall be supplied at 60 per cent (45 per cern
-
bolts and 15 per cent drifts) of the number of field rivets per span
in each size (this includes wastage). A reduction in the quantities of
service bolts, etc., may however, be specified by the Engineer if more
than one span of each type is ordered.
Prior to actual commencement of erection all equipment, machinery,
tools, tackles, ropes, etc. need to be tested to ensure their efficient
472
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working. Frequent visual inspection is essential in vulnerable areas to
detect displacements, distress, drainages, etc.
Deflection and vibratory tests shall be conducted in respect of
supporting structures, launching truss as also the structure under erection
and unusual observations reviewed; looseness of fittings are to be noted.
For welded structures, welders’ qualificatons and skill are to be
checked as per standard norms. Non-destructive tests of joints as per
designer’s directives are to be carried out.
Precision non-destructive testing instruments available in the market
should be used for noting various important parameters of the structures
frequently and systematic record is to be kept.
Safety requirements should conform to IS:7205, IS :7273 and IS:7269
as applicable and should be a consideration of safety, economy and
rapidity.
Erection work should start with complete resources mobilised as
per latest approved drawings and after a thorough survey of
foundations and other related structural work. In case of work of
magnitude, maximum mechanisation is to be adopted.
The structure should be divided into erectable modules as per the
scheme. This should be pre-assembled in a suitable yard/platform and
its matching with members of the adjacent module checked by trial
assembly before erection.
The structure shall be set out to the required lines and levels. The
stocks and masses are to be carefully preserved. The steelwork should
be erected, adjusted and completed in the required position to the
specified line and levels with sufficient drifts and bolts. Packing materials
are to be available to maintain this condition. Organised “Quality
Surveillance” checks need to be exercised frequently.
Before starting work, the Contractor shall obtain necessary
approval of the Engineer as to the method adopted for erection, the
nnmber and character of tools and plants. The approval of the Engineer
shall not relieve the Contractor of his responsibility for the safety of
his method or equipment or from carrying out the work fully in
accordance with the drawings and specifications.
During the progress of work, the Contractor shall have a competent
Engineer or foreman in charge of the work, who shall be adequate-
ly experienced in steel erection and acceptable to the Engineer.
<< 473
1905.3. Handling and Storing of Materials

Suitable area for storage of structures and components shall be
located near the site of work. The access road should be free from
water logging during the working period and the storage area should be
on levelled and firm ground.
The store should be provided with adequate handling equipments
e.g road mobile crane, gantries, derricks, chain pulley blocks, winch
of capacity as required. Stacking area should be planned and have racks,
stands sleeper, access tracks, etc., and properly lighted.
Storage should be planned to suit erection work sequence and
avoid damage or distortion. Excessively rusted, bent or damaged steel
shall be rejected, Methods of storage and handling steel, whether
fabricated or not shall be subject to the approval of the Engineer.
Fabricated materials are to be stored with erection marks visible,
such as not to come into contact with earth surface or water and should
be accessible to handling equipment.
Small fitting hand tools are to be kept in containers in covered
stores.
All materials, consumables, including raw steel or fabricated material
shall be stored specification-wise and size-wise above the ground upon
platforms, skids or other supports. It shall be kept free from dirt and
other foreign matter and shall be protected as far as possible from
corrosion and distortion. The electrodes shall be stored specification-
wise and shall be kept in dry warm condition in properly designed
racks. The bolts, nuts, washers and other fasteners shall be stored on
racks above the ground with protective oil coating in gunny bags. The
paint shall be stored under cover in air-tight containers.
IS:7293 and IS:7969 dealing with handling of materials and
equipments for safe working should be followed. Safety nuts and bolts
as directed are to be used while working. The Contractor shall be held
responsible for loss or damage to any material paid for by the Department
while in his care or for any damage to such material resulting from his
work.
1905.4. Formwork
The formwork shall be properly designed, substantially built and
maintained for all anticipated loads. The Contractor, if required, shall
submit plans for approval to the Engineer. Approval of the plans, however,
shall not relieve the Contractor of his responsibility.
474
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1905.5, Straightening Bent Material

The straightening of plates, angles and other shapes shall be done
by methods not likely to produce fracture or any injury. The metal shall
not be heated unless permitted by the Engineer for special cases, when
the heating shall not be to a temperature higher than that producing
a dark “cherry red” colour, followed by as slow cooling as possible.
Following the straightening of a bend or buckle the surface shall be
carefully investigated for evidence of fracture. Sharp kinks and bends
may be the cause for rejection of material.
1905.6. Assembling Steel
The parts shall be accurately assembled as shown on the drawings
and match marks shall be followed. The material shall be careful-
ly handled so that no parts will be bent, broken or otherwise
damaged.
Hammering which will injure or distort the members shall not be
done. Bearing surface or surfaces to be in permanent contact shall
be cleaned, before the members are assembled. The truss spans shall
be erected on blocking, so placed as to give the proper camber. The
blocking shall be left in place until the tendon chord splices are
fully riveted and all other truss connections pinned and bolted. Rivets
in splices of butt joints of compression members and rivets in railings
shall not be driven until the span has been swung.
All joint surface for bolted connections including bolts, nuts,washers
shall be free from scale, dirt, burrs, other foreign materials and defects
that would prevent solid seating of parts. The slope of surface of bolted
parts in contact with bolt head and nut shall not exceed 1 in 20,
plane normal to bolt axis, otherwise suitable tapered washer shall be
used.
All fasteners shall have a washer under nut or bolt head
whichever is turned in tightening.
Any connection to be riveted or bolted shall be secured in close
contact with service bolts or with a sufficient number of permanent
bolts before the rivets are driven or before the connections are finally
bolted. Joints shall normally be made by filling not less than 50 per
cent of holes with service bolts and barrel drifts in the ratio 4:1. The
service bolts are to be fully tightened up as soon as the joint is
assembled. Connections to be made by close tolerance or barrel bolts
shall be completed as soon as practicable after assembly.
<< 475
Any connection to be site welded shall be securely held in

position by approved methods to ensure accurate alignment, camber and
elevation before welding is commenced.
The field riveting, welding, bolted and pin connection shall
conform to the requirements of Clause l9()4 as appropriate.
The correction of minor misfits involving harmless amounts of
reaming, cutting and chipping will be considered a legitimate part
of erection. However, any error in the shop fabrication or deformation
resulting from handling and transportation which prevents proper
assembling and fitting up of parts by moderate use of drifts o~by
a moderate amount of reaming and slight chipping or cutting shall be
reported immediately to the Engineer and his approval of the method
of correction obtained. The correction shall be made in the presence
of the Engineer.
1905.7. Field Inspection
1905,7.1. General
All materials, equipment and work of erection shall be subject to
the inspection of the Engineer who shall be provided with all facilities
~nc!udinglabour and tools required at all reasonable times. Any work
found defective is liable to be rejected.
1905.7.2. No protective treatment shall be applied to the work until
the appropriate inspection and testing has been carried out. The stage
inspection shall be carried out for all operations so as to ensure the
correctness of fabrication and good quality. Girder dimensions and
camber shall not he finally checked until all welding and heating
operations are completed and the member has cooled to a uniform
temperature.
1905.7.3, Testing of material : Structural steel shall be tested for
mechanical and chemical properties as per various IS codes as may
he applicable and shall conform to requirements specified in IS:226,
IS:2062, IS:1l587, IS:1977, IS:8500 and IS:961, etc.
Rivets, bolts, nuts, washers, welding consumables, steel forging,
casting and stainless steel shall be tested for mechanical and chemical
properties in the appropriate IS Code.
Rolling and cutting tolerance shall be as per lS:1852. The thick-
ness tolerance check measurements for the plate and rolled sections
shall be taken at not less than 15 mm from edge.~
<< 476
Laminations in plates shall be carried Out by ultra-sonic testing or

any other specified methods.
Steel work shall be inspected for surface defects and exposed
edge laminations during fabrication and blast cleaning. Significant edge
laminations found shall be reported to the Engineer for his decision.
Chipping, grinding, machining or ultrasonic testing shall be used to
determine depth of imperfection.
1905.7.4. Bolted connections : Bolts and bolted connection joints
with high strength friction grip bolts shall be inspected and tested,
according to IS:4000.
Rivets and riveted connection shall he inspected and tested for
compliance of coda! requirements.
The firmness of joint shall be checked by 0.2 mm filler gauge,
which shall not go inside under the rivet head by more than 3 mm. There
shall not be any gap between members to be riveted.
Driven rivets shall be checked. with rivet testing hammer. When
stnick sharply on head with rivet testing hammer, rivet shall be free
from movement and vibration.
All loose rivets and rivets with cracks, badly formed or deficient
heads or with heads which are eccentric with shanks, shall be cut out
and replaced.
The alignment of plates at all bolted splice joints and welded butt
joints shall be checked for compliance with coda! requirements.
Testing of flame cut and sheared edges is to be done, where the
hardness criteria given in the code are adopted. Hardness testing shall
be carried out on six ~pecimens.
1905.7.5. Welding and welding consumables : Welding procedure,
welded connection and testing shall be in compliance with cbdal
requirements.
All facilities necessary for stage inspection during welding and on
completion shall be provided to the Engineer or their inspect-
ing Authority by manufacturer.
Adequate means of identification either by identification mark or
other record shall be provided to enable each weld to be traced to
the welder(s) by whom it was carried out.
<< 477
Section 1900 Strucunal Steel
All metal arc welding shall be in compliance with IS:9595 provi-

sions.
The method of inspection shall be in accordance with IS:822 and
extent of inspection and testing shall be in accordance with the relevant
standards or in the absence of such a standard, as agreed with the
Engineer.
Procedure tests
The Destructive and Non-Destructive test of weld shall be carried
out according to IS:7307 (Part I).
Non-Destructive Testing of Welds
One or more of the following methods may be applied for
inspection or testing of weld
(i) Visual Inspection All welds shall be visually inspected, which should cover
all defects of weld such as size, porosity, crack an the weld or in the HAZ
(Heat Affected Zone) etc. Suitable magnifying glass may be used for visual
inspection. A weld shall be acceptable by visual inspection if it shows that
a) The weld has no cracks.
b) Through fusion exists between weld and base metal and between adjacent
layers of weld metal.
c) Weld profiles are in accordance with requisite clauses of IS:9595 or as agreed
with the Engineer
d) The weld shall be of full cross section, except for the ends of intermittent
fillet welds outside their effeclive length.
e) When weld is transverse to the primaay stress, undercut shalt not be more
than 025 mm deep in the part that is undercut and shall not be more than
0.5 mm deep when the weld is parallel to the primary stress in the part that
is undercut.
1) The fillet weld in any single continuous weld shall be permitted to under
nan the nominal fillet weld size specified by 1.6 mm without correction
provided that undersize ponion of the weld does not exceed 10 per cent
of the length of the weld. On the web.to..flange welds on girders, no under-
nan is permitted at the ends for a length equal to twice the width of the
flange.
g) The piping porosity in fillet welds shall not exceed one in each 100 mm
of weld length and the maximum diameter shall not exceed 2.4 mm, except
for fillet welds connecting ssiffeners to web where the sum of diameters of
piping porosity shall not exceed 9.5 mm in any 25 mm length of weld and
shall not exceed 19 mm in any 300 man length of weld.
h) The full penetration groove wetd in butt joints transv~rseto the direction
of computed tensile stress shall have no piping porosity. For all other groove
welds, the piping porosity ~haIi not exceed one in 100 mm of length and
the maximum diameter shall not exceed 2.4 mm.
<<
478
(ii) Magnetic Particle and Radiographic Inspection: Welds that are subject to radio-
graphic or magnetic particle testing in addition to visual inspection shall have
no crack.
Magnetic particle test shall be carried out for detection of crack and other
discontinuity in the weld according to IS:5334.
Radiographic test shall be carried out for detection of intemal flaws in the weld
such as crack, piping porosity inclusion, lack of fusion, incomplete penetration,
etc. This test mat be carried out as per 15:1182 and 15:4853.
Acceptance Criteria The weld shall be unacceptable if radiographic or magnetic
particle testing shows any of the type of discontintrities indicated in the code.
(iii) Ultrasonic Inspection : The Ultrasonic testing in addition to visual inspection shall
be carried out for detection of internal flaws in the weld such as cracks, piping
porosity inclusion, lack of fusion, incomplete penetration, etc. Acceptance criteria
shall be as per 15:4260 or any other relevant IS Specification and as agreed
to by the Engineer.
iv) Liquid Penetration Inspection The liquid penetrant teat shall be carried out for
detection of surface defect in the weld, as per 15:3658, in addition to visual
inspection.
The non-destnjctive testing of following welds be carried out using one of
the method or methods described at (ii),(iii) and (iv) above, as may be agreed
to by the Engineer.
a) All transverse butt welds in tension flange
b) 10 per cent of the length of longitudinal and transverse butt welds in tension
flanges.
c) 5 per cent of the length of longitudinal and transverse butt welds in
conspression flanges.
ci) All transverse butt welds in webs adjacent to tension flanges as specified
by the Engineer.
The particular length of welds in webs to be tested shall be
agreed with the Engineer, in case of (b) or (c).
Where specified by the Engineer, bearing stiffeners or bearing
diaphragms adjacent to welds, flange plates adjacent to web/flange welds,
plates at cruciform welds, plates in box girder construction adjacent to
corner welds or other details shall be ultrasonically tested after fabrication.
Any lamination, lamellar tearing or other defect found shall be
recorded and reported to Engineer for his decision.
Testing of Welding for Cast Steel The testing of weld for cast
steel shall be carried out as may be agreed to by the Engineer.
Stud Shear Connectors Stud shear connectors shall be subjected
to the following tests
<< 479
to the Engineer who will determine whether the component/member may
be accepted without rectification, with rectification or rejected.
1906. PAINTING
1906.1. General
Unless otherwise specified, all metal work shall be given approved
shop coats as well as field coats of painting. The item of work shall
include preparation of metal surfaces, application of protective covering
and drying of the paint coatings and supply of all tools, scaffolding,
labour and materials necessary.
Coatings shall be applied only to dry surfaces and the coated
surfaces shall not be exposed to rain or frost before they are dry. The
coatings shall be applied to all surfaces excluding shear connectors
and inner surfaces of fully sealed hollow sections. Care shall be
taken during coating of adjacent surfaces to build up primer on the shear~
connectors.
1906.1.1. Types of paints
(i) Ordinary Paints
These include paints based on drying oils, alkyd resin, modified alkyd
resin, phenolic varnish epoxy, etc.
Alkyd resin paints for the protection of steel structures are based
partly on natural oils and partly on synthetic resins. These paints shall
be used for steel structures in atmospheres which are not too aggressive.
Oil based paints can be used for steel structures in cases where
the surface preparation cannot be ideal. Ordinary painting can generally
be sub-divided into two groups:
a) Primary Coats
This shall be applied immediately after the surface preparation and
should have the properties of adhesion, corrosion inhibition and imper-
viousness to water and air.
b) Finishing Coats
These are applied over the primary coat and should have the
properties of durability, abrasion resistance, aesthetic appearance and
smooth finish.
<< 481
(ii) Chemical Resistant Paints

The more highly corrosion resistant paints can be divided into two
main groups
a) One pack paints (ready for use)
b) Two pack paints (mixed before use)
The two pack paints shall be mixed together immediately before

use since they are workable thereafter only for a restricted period
of time and dry up as a result of a reaction between their components
and yield hard tough films with resistance to abrasion.
(iii) Vinyl Paints
These are based on polyvinyl resins such as polyvinyl-chloride
(PVC) and polyvinyl-acetate, etc.
Certain types of vinyl resin paints yield thick, relatively soft and
rubber like coatings with good chemical resistance. They can be repainted
without difficulty.
(iv) Chlorinated Rubber Paints
These paints also have good chemical resistance. The main fields
of applications shall be in aggressive environments. In general,
chlorinated rubber paints do not have a high gloss.
(v) Bituminous Paints
As a paint vehicle, bituminous is inferior, but because of the
low price, this should be applied in greater thickness (upto several
millimetres) and may be suitable for some situations. A significant
advantage of bitumen paints is their impermeability to ingress of water.
However, bituminous paints do not withstand effectively detrimental
effects of oil.
(vi) Epoxy Paints
These resin paints have good adherence to a well prepared sub-
strata. They are mechanically strong and resistant to chemicals. A
disadvantage of epoxy resin paints is that it can rapidly become dull
when exposed to strong sunlight. These disadvantages do not, however,
greatly influence their protective power.
(vii) Polyurethane Paints
The chemical and mechanical behaviour of polyurethane paint
resembles those of epoxy paint very much. However, polyurethane paint
retains its gloss for a longer period. Because of the high price of
482
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polyurethane paint, a combination of the two viz., polyurethane and
epoxy paints may sometimes be used.
(viii) Zinc Rich Paints
Instead of introducing an inhibitive pigment into paint, metallic zinc
can be used and such paints can provide cathodic protection to steel,
1906.1.2. Surfaces which are inaccessible for cleaning and painting
after fabrication shall be painted as specified before being assembled for
riveting.
All rivets, bolts, nuts, washers etc., are to be thoroughly cleaned
and dipped into boiling linseed oil conforming to IS:77.
All machined surfaces are to be well coated with a mixture of white
lead conforming to IS:34 and Mutton Tallow conforming to IS:887.
For site paintings, the whole of the steel work shall be given the
second cover coat after final passing and after touching up the primer
and cover coats, if damaged in transit.
1906.1.3. Choice of painting system
The choice of suitable painting system is dependent on factors such
as:
- Available application methods viz, brush, roller or spray
- Durability in a specific environment
Availability of skilled manpower
Cost I benefit etc.
It is therefore necessary to consult various manufacturers of paint

and ascertain the above aspects while deciding on the appropriate choice
of painting system.
1906.1.4, Quality of paint The paints which have been tested for
the following qualities as per the specifications given in the relevant IS
codes should only be used
Weight Test (weight per 10 litre of paint thoroughly mixed)
- Drying time
Flexibility and Adhesion
Consistency
- Dry thickness and rate of consumption
1906.1.5. Unless otherwise specified, all painting and protective

coating work shall be done in accordance with IS:l477 (Part 1).
<< 483
1906.2. Surface Preparation
Steel surface to be painted either at the fabricating shop or at the
site of work shall be prepared in a thorough manner with a view to
ensuring complete removal of mill scale by one of the following
processes as agreed to between the fabricator and the Engineer:
a) Dsy or wet gi’t / Sand blasting
b) Pickling which should be restricted to single plates, ban and sections
c) F1an~ecleaning
Primary coat shall be applied as soon as practicable after cleaning

and in case of flame cleaning, primary coat shall be applied while
the metal is still warm.
All slag from welds shall be removed before painting. Surfaces
shall be maintained dry and free from dirt and oil. Work out of doors
in frosty or humid weather shall be avoided.
1906.3. Coatings
Prime coat to be used shall conform to the specification of primers
approved by the Engineer. Metal coatings shall be regarded as priming
coatings. Primer shall be applied to the blast cleaned surface before any
deterioration of the surface is visible. In any case, the surface shall
receive one coat of primer within 4 hours of abrasive blast cleaning.
All coats shall be compatible with each other. When metal coat-
ings are used, the undercoat shall be compatible with the metal
concerned. The undercoat and finishing coat shall preferably be from
the same manufacturer. Successive coats of paints shalt be of different
shades or colours and each shall be allowed to dry thoroughly before
the next is applied. Particular care shall be taken with the priming and
painting of edges, corners, welds and rivets. Typical guidelines for
epoxy based paints and the conventional panting system for bridge
girders as given below may be complied with
a) Epoxy Based Painting
i) Surface preparation Remove oil/grease by use of petroleum hydrocarbon
solution (IS:1745) and Grit blasting to near white metal surface.
ii) Paint system: 2 coats of epoxy zinc phosphate primer 60 micron Total
5 coats = 200 micron
b) Conventional Painting System for areas where corrosion is
not severe
<< 484
Priming Coat
One heavy coat or ready mixed paint, red lead primer conforming
to IS:102
or
One coat of ready mixed zinc chrome primer conforming to IS: 104
followed by one coat of ready mixed red oxide zinc chrome primer
conforming to IS:2074.
or
Two coats of zinc chromates red oxide primer conforming to IS:2074
Finishing Coats
Two cover coats of red oxide paint conforming to IS:123 or any
other approved paint shall be applied over the primer coat. One coat
shall be applied before the fabricated steel work leaves the shop. After
the steel work is erected at site, the second coat shall be given after
touching tip the primer and the cover coats if damaged in transit.
c) Conventional Painting System for areas where corrosion is
severe
Primh~gCoat
Two coats of ready mixed red lead primer conforming to IS:102
or
One coat of ready mixed zinc chrome primer conforming to IS: 104
followed by one coat of zinc chromate conforming oxide primer to
IS:2074.
Finishing Coats :
Two coats of aluminum paint conforming to IS:2339 shall be ap-
plied over the primer coat. One coat shall be applied before the
fabricated steel work leaves the shop. After the steel work is erected
at site, the second coat shall be given after touching up the primer and
the cover coats if damaged in transit.
1906.4. Painting in the Shop
All fabricated steel shall be painted in the shops after inspection
and acceptance with at least one priming coat, unless the exposed surfaces
are subsequently to be cleaned at site or are metal coated. No primer
shall be applied to galvanised surfaces.
<< 485
Shop contact surfaces, if specifically required to be painted, shall
be brought together while the paint is still wet.
Field contact surfaces and surfaces to be in contact with cement
shall be painted with primer only. No paint shall be applied within
50mm of designed location of field welds. Paint shall be completely dried
before loading and transporting to site.
Surface not in contact but inaccessible alter shop assembly shall
receive the fully specified protective treatment before assembly.
Where surfaces are to be welded, the steel shall not be painted
or metal coated within a suitable distance from any edges to be welded
if the specified paint or metal coating would be harmful to welders or
is expected to impair the quality of site welds.
Exposed machined surfaces shall be adequately protected.
1906.5. Painting at Site
Surfaces which will be inaccessible after site assembly shall receive
the full specified protective treatment before assembly.
Surfaces which will be in contact after site assembly shall receive
a coat of paint (in addition to any shop priming) and shall be brought
together while the paint is still wet.
Damaged or deteriorated paint surfaces shall be first made good
with the same type of coat as the shop coat.
Where steel has received a metal coating in the shop, this coat-
ing shall be completed on site so as to be continuous over any welds,
bolts and site rivets.
Specified protective treatment shall be completed after erection.
1906.6. Methods of Application
The methods of application of all paint coatings shall be in
accordance with the manufacturer’s written recommendation and shall
be as approved by the Engineer. Spray painting may be permitted
provided it will not cause inconvenience to the public and is appropriate
to the type of structure being coated. Areas hard to gain access to
for painting and areas shaded for spray application shall be coated
first by brushing.
Oil based red lead primers must be applied by brush only, taking
care to work into all corners and crevices.
The primer, intermediate and finishing coats shall all be applied so
<<
as to provide smooth coatings of uniform thickness. Wrinkled or blistered
coatings or coatings with pinholes, sags, lumps or other blemishes shall
not be accepted. Where the Engineer so directs, the coating shall be
removed by abrasive blast cleaning and replaced at the Contractor’s
expense.
1906.7. Guideline of Specifications for Protective Coating
System in Different Environments
Since the seriousness of the problem of corrosion depends upon
atmospheric conditions and these vary enormously, there is no single
protective system or method of application that is suitable for every
situation.
However, as a guide, broad recommendations are given in Table
1900-3 for various types of coatings in various environmental conditions
which should be complied with, Approximate life to first maintenance
is also indicated and can be used as a guide.
TABLE 1900.3: RECOMMENDATIONS FOR TYPES OF
PROTECTIVE COATINGS
System Environment
i) Wire brush to remove all loose rust Suitable for mild conditions where
and scale; 2 coats drying oil type appearance is of some importance and
primer, 1 under coat alkyd type where regular maintenance is intended,
paint; I finishing coat alkyd This system may deteriorate to a marked
type. Total dry film thickness extent if it is exposed to moderate
= 150 pin aggressive atmospheric conditions for
lengthy period
ii) Wire brush to remove all loose Similar to (i) but where appearance
rust and scale 2 coats drying oil is not very important provides longer life
type primer~2 under coats micaceous in mild condition. Will provide upto 5
iron oxide (MXO) pigmented years life to first maintenance in polluted
phenolic modified drying oil. Total inland environment
dry film thickness = 170 ~un
iii) Blast clean the surface; 2 coats Compared to (i), this would provide a
of quick drying primer~ longer life in mild conditions arid could
undercoat alkyd type paint; I be used in less mild situation e.g.
finishing coat alkyd type. inland polluted, where maintenance
Total dry film thickness: could easily be canied our at
130 - 150 pm regular intervals
iv) Blast clean the surface; 2 coats of Suitable for general structural steel
drying type oil primer, 1 undercoat work exposed to ordinary polluted
micaceous iron oxide pigmented drying inland environments where appearance
oil type paint. Total dry film is not of primary importance.
thickness : 165 - 190 ~tm
487
<<
v) Blast clean the surface; 2 coats of Suitable for structures in reasonably

metallic lead pigmented chlorinated aggressive conditions e.g. near the coast.
rubber primer, I undercoat of high Will provide long-term protection than
build chlorinated rubber. 1 finishing (iv) in non-coastal situations. Also
coat of chlorinated rubber. Total dry suitable for aggressive Interior situations
film thickness 200 pm such as industrial areas.
vi) Blast clean the surface; Suitable for sea water splash zones
350 - 450 pm thickness. or for conditions of occurrence of
coal tar epoxy. frequent salt sprays.
vii) Pickle; hot dip galvanised Suitable for steel work in reasonably
(Zinc). Total thickness : 85 pin mild conditions Life of 15-20 years
before first maintenance could be
expected in many siwations
viii) Grit blast, hot dip galvanised. Provides a longer life than (vii)
(Zinc). Total thickness = 140 pan because of thicker zinc coating
ix) Grit blast; I coat of sprayed zinc/ Expected to provide long term
aluminum followed by suitable sealer protection approx 15-20 years
Total thickness = 150 pro in aggressive atmosphere

The materials .shall be tested itt accordance with relevant IS speci-
fications and necessary test certificates shall be furnished. Additional
tests, if required, shall be got carried out by the Contractor at his own
cost.
The fabrication, furnishing, erecting, painting of structural steel work
shall be in accordance with these specifications and shall be checked
and accepted by the Engineer.
The measurements of this Item shall be in tonnes based on the net
weight of metal in the fabricated structure computed on the basis of
nominal weight of materials.
The weight of rolled and cast steel and cast iron shall be determined
from the dimensions shown on the drawings on the following basis
Rolled or cast steel : 7.84 x 1O~kg/cu. cm.
Cast Iron 7.21 x IO’ kg/cu. cm.
Weight of structural sections shall be nominal weight

Weight of castings shall be computed from the dimensions shown
on the drawings with an addition of 5 per cent for fillets and over-runs.
<< 488
Stnsctural Steel Section 1900
Weight of weld fillets and the weight of protective coatings shall

not be included.
Weight of rivet heads shall be computed by taking the weight of
100 snap heads as given in Table 1900-4.
When specially agreed upon, allowance for snap heads may be taken
as a flat percentage of the total weight. This percentage may be taken
as 3 per cent or modified by mutual ~greement.
TABLE 1900-4 WEIGHT OF RIVET HEADS
Din or Rivet as manufactured Weight of 100 snap heads
mm kg
12 1.3
14 2.1
16 3.4
18 4.45
20 6.1
22 8.1
24 10.5
27 15.0
30 20.5
33 27.2
The Contractor shall supply detailed calculation sheets for the weight
of the metal in the fabricated structure.
No additions shall be made for the weight of protective coating
or weld fillets.
Where computed weight forms the basis for payment, the weight
shall be calculated for exact cut sizes of members used in the structure,
deductions being made for all cuts, except for rivet holes. Additions
shall be made for the rivet heads as mentioned above.
When specially agreed upon, the basis for payment may be the
bridge weight complete, according to specifications included in special
provisions of the Contract.
1909. RATE
The contract unit rate for the completed structural steel work shall
include the cost of all materials, labour, tools, plant and equipment
required for fabrication, connections, oiling, painting, temporary erection,
inspection, tests and complete final erection as shown on the drawings
and as specified in these Specifications.
<< 489
Bearings
2000
Bearings
<<
Bearings Section 2000
2001. DESCRIPTION
This work shall consist of furnishing and fixing bearings in position
in accordance with the details shown on the drawings, to the requirements
of these specifications or as directed by the Engineer.
2002. GENERAL
i) Bearing plates, bars, rockers, assemblies andother expansion orfixed devices shall
be constructed in accordance with the details shown on the drawings.
ii) The beanngs may either be supplied directly to the Engineer by the manufacturer
to be installed by the Contractor or the Contractor is to supply and install she
bearings as part of the contract. In the former cue, the manufacturer shall be
associated with the installation of the bearings to the full satisfaction of the
Engineer, whereas in the latter case, the Contractor shall be solely responsible
for the satisfactory supply and installation of the bearing, Inthe detailed description
of the specification, a general reference shall be made to the Contractor or
manufacturer and the interpresarion shall be as per terms of contract.
iii) The Contractor shall exercise the utmost care in setting and fixing all bearings
in their correct positions and ensuring that uniformity is obtained on all bearing
surfaces.
iv) Bearings shall be handled with care and stored under cover.
v) When bearing assemblies or plates are shown on the drawings to be placed (not
embedded) directly on concrete, the concrete bearing area shall be constructed
slightly above grade (not exceeding 12 miss) and shall be finished by grinding.
vi) It shall be ensured that the bearings are set truly level and in exact position
as indicated on the drawings so as to have full and even bearing on the
seats. Thin mortar pads (not exceeding 12 miss) may even be made to meet
with this requirement.
vii) It shall be ensured that the bottoms of girders to be rtceived on the bearings
are plane at the locations of these bearings and care shall be taken thatthe bearings
are not displaced while placing the girders.
viii) MS. bearings sliding on M.S. Plates shalt not be permitted. For sliding plate
bearings stainless, steel surface sliding on stainless steel plate with mild steel matrix
shell be used. The other option shall be to provide PTFE surface sliding on
stainless steel.
ix) Some types of bearings which have been successfully used in various bridges
in India have been covered by these Specifications. For innovative types of
structures or in special cases, special types of bearings to suit the requirements
may have to be provided for which special specifications may be laid down by
the Engineer.
2003. STEEL BEARINGS
2003,1. Materials
The material for steel bearings shall conform to the requirements
493
<<
Section 2000 Bearings
of Section 1000. Some additional requirements for materials for steel

bearings are indicated below
a) Railway axles (R 19) are also acceptable as forged steel for rollers.
b) For the purpose of checking the soundness of cast steel components, castings
shall be ultrasonically examined following procedures as per 15:7666 with
acceptance standard as per IS:9565. The castings may also be checked by any
other accepted method of non..destnsctive testing as specified in 15 1030.
Quality level of castings shall be level 3 as per iS:9565.
The grease for bearings shall conform to the requirements of IS:503

(Grade 4).
a) All work shall conform strictly to the drawings and shall be in accordance with
the provisions of this section. Care shall he taken to ensure that all parts of an
assembly fit accurately together. The workmanship shall satisfy all relevant
provisions laid down in Section 1900.
b) Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing
plates shall be machined and all bolt holes shall be drilled. The whole bearings
shall be fitted and finished as required for good quality machined work to the
satisfaction of the Engineer. However, in case of bearings which are to be groused
or bedded on a suitable yielding material on any surface which is to be in
permanent contact with the grout or the yielding material may be left unmachined.
c) In prestressed concrete construction where launching of girders is employed,
in order to avoid slipping or jumping of rollers due to vibeation or jolts, adequate
measures may be taken to ensure that the roller assembly is not disturbed. It
is normal practice to provide rocker bearings on the launching end and place
Use beam on the rocker end slightly in advance of placing on the roller.
d) During concreting of girders, the bearings shall be held in position securely by
providing temporary connection between the top and bottom plates in case of
fixed bearings and between top plate, base plate and saddle plate in case of roIler~
cum-rocker bearing or by any other suitable arrangement which prevents the
relative displacement of the components.
e) In prestressed precast girders, where recesses are left on the underside of girders
to receive the anchor bolts, grout holes extending to the beam sides or to the
deck level shall be provided. The cement sand grout shall have a mix of 1:1.
2003.3. Workmanship
a) Fabrication shall be carried out by an organisation experienced and qualified to
undertake precision engineering of this type and be approved by the Engineer.
h) Workmanship shall be of good quality, neatly finished and of good appearance.
c) Castings shall be tnse to the forms and dimensions shown on the drawings and
shall be free from pouring faults, sponginess, cracks, blow holes and other defects
on position, affecting their appearance or strength. Warped or distorted castings
will not be accepted. Exposed surfaces shall be smooth and dense.
<< 494
d) All castings shall be cleaned by sand or shot blasting to remove sand or scale
and to present a clean uniform surface.
e) All irregularities, fins or risers shall be ground off flush with the adjacent surface.
Castings with visible cracks, blow holes or similar blemishes shall be rejected
if the imperfections are located in bearing surfaces or cannot be remedied to
the approval of the Engineer.
1) imperfections which are not located in bearing surfaces shall be cleaned out,
filled with weld metal of the appropriate composition and ground flush.
g) All surfaces of major components like top plates, saddle plates, base plates, rollers
of the bearings shall be machined all over for correct alignment, interchangeability,
proper fitting, etc.
2003.4, Tolerances
Tolerances for its individual components or of the assembled bearings
shall be as shown on the drawings or subject to the approval of the
Engineer.
Unless otherwise specified, the following tolerances shall be main-
tained
Diameter of Rollers, Knuckle Pins and Bores
Tolerances on diameter of rollers and all convex surfaces shall
conform to K7 of IS:919.
Tolerances on diameter of a]] concave surfaces shall conform to
D8 of IS:919.
Height of Bearings
Tolerances on height of any component casting shall not exceed
+0.5mm. No minus tolerance shall be allowed. The edges of all ribs
shall be parallel throughout their length.
Base Plate
Tolerance on length and width of the base plate shall not exceed
+1.0 mm, tolerance on the thickness of the plate shall not exceed
+0.5 mm. No minus tolerance shall be allowed. All rocking, rolling and
sliding surfaces shall have a machine smooth finish to 20 micron
maximum mean deviation as per IS:3073.
Castings
No minus tolerance shall be allowed in the thickness of any part
of the castings. The edges of all ribs shall be parallel through-
out their length.
<<
495
2003.5. Installation of Steel Bearings

2003.5.1. General
a) Bearings shall be placed in the positions as shown on the drawings with all
bearing surfaces in full contact and to the tolerances as specified.
b) Roller and rocker bearings shall be placed so that their axles of rotations are
horizontal and nomial to the direction of movement of the members they support.
Upper and lower bearing plates shall be set horizontal in both directions.
c) During installation the bearings shall be pre.set with respect to the bearing
axis to account for the movement due to the following
i) Temperature variation between the average temperature prevailing at the time
of installation and the mean design temperature.
ii) Shrinkage, creep and elastic shortening.
d) For bridges in gradient, the beanng plates shall be placed in a horizontal plane.
2003.5.2. Placing
a) On supporting stmctures, pockets shall be provided to receive anchor bolts;
one side of the pocket shall project beyond the bearing plate. The pocket shall
be filled with mortar of mix li and the concrete bearing area also shall be finished
level by a thin and stiff mortar pad of mix 1:1 (the thickness not exceeding
12 mm) just before placing of bearing assemblies or bottom plate on the concrete
seat.
b) in case of precast girders a recess of 6 mm shall be provided on the underside
with a level fsnish for housing the beating plate. A thin and stiff mortar pad
of mix 1:1 with thickness not exceeding 3 mm shall be provided over the
top plate before lowering the precast beam in position in order to ensure full
and even pressure on the plate surface.
c) It shall be ensured that while placing the girders, the bearings are in their exact
positions as indicated on the approved drawing and not displaced therefrom.
d) All concrete surfaces to be in contact with the mortar shall be thoroughly cleaned
and kept saturated with water for a period not less than 24 hours before placing
mortar and operations are to be carried out when the surface temperatures of
the exposed bearings are the minimum practical.
e) No ntortar that is more than 30 minutes old after completion of mixing, shall
be used.
f) After placing and finishing the mortar, the bearing shall be checked for position
and shims or other temporary supports removed and the mortar made good. If
the bearing has moved, it or the plate shall be lifted, the mortar removed and
the whole procedure repeated.
g) Exposed faces of the mortar shall be cured under damp Hessian for 7
days.
h) Placing of the bearing and mortar shall only be carried out in the presence of
the Engineer.
<<
2003.5,3. Checking, cleaning and lubrication : Before erection,

each bearing shall be uncrated, disassembled and checked. Any damaged
parts shall be made good for approval.
All bearings with sliding surfaces shall be cleaned and lightly
lubricated with an approved lubricant immediately before erection.
2003,5.4. Testing
i) The materials to be used in the bearings shall conform to the specifications
laid down in clause 2003.1.
ii) If inquired, a suitable number of complete bearings as specified by an accepting
authority shall be tested to 1.25 times the design load. Recovery should be 100
per ceent. Contact surfaces shall be examined by illumination source for any
defects, cracks, etc. Segmental rollers shall be tested for design movements.
iii) For large lots (consisting of 12 sets or more), a quality control report shall
be submitted as detailed below:
a) Unless otherwise agreed upon by the Engineer and the manufacturer,
the latter shall furnish a complete report on the process of quality control.
The Engineer may appoint an authorised inspection agency for inspection
purpose on his behalf. Such an inspection agency shall also submit reports
to the Engineer regarding various tests performed on the beating or certify
the acceptance of the beatings.
b) Test certificates of all raw materials shall be submitted. If manufacturer’s
test certificates are not available for the raw materials, the bearings menu.
facturer shall perform the necessary confirmatory tests as per relevant codes
of practice and shall furnish the test results.
c) A detailed quality control system induding stage by stage inspection,
starting from raw materials upto the finished bearing shall be submitted by
the bearing manufacturer.
d) The Engineer shall reserve the right to witness such inspection at manu~
facturer’s works with or without prior permission of the manufacturer, For
this, the beating manufacturer shall have in.plant testing facilities as far
as possible and practicable.
e) The bearing manufacturer shall maIntain a list of consumption of raw
material for a period of at least previous one year.
0 Test certificates of bearings manufactured during preceding one year shall

be made available at the manufacturer’s works.
g) In case the lot size of similar bearings exceeds 12 sets as per the direction
of the Engineer, one extra set of bearings for each 24 sets of beatings
or part thereof, shall be manufactured and the cost of such extra bearings
shall be borne by the user.
h) The Engineer shall select the extra bearing(s) at random and shall perform
various tests including destructive testing on it at his discretion, either at
the manufacturer’s works or at any other approved test laboratory, notwith.
standing the test reports submitted.
<< 497
i) In case there is a major discrepancy regarding material, the engineer shall

declare the whole lot of bearings as unacceptable.
j) In case minor defects in fabrication, like welding or machining, is found
in the test bearing before destructive testing and if the test hearing is found
to he acceptable after destructive testing, the minor defects in the test
bearings shall not he a bar to the acceptance of the entire lot.
k) The opinion of the Engineer in cases (i) and (3) above shall be binding on
the manufacturer.
2004. SPECIAL BEARINGS

2004.1. Spherical Bearing
This bearing only takes care of vertical load and horizontal force
due 10 sliding friction. The bearing will permit uniaxial translatory
movement along longitudinal axis of the bridge and rotation along all
axes.
The bearing shall consist of the following pacts
Bottom Plate
A bottom plate with concave surface is integrally cast on circular!
square plate. The bottom plate is connected to the sub-structure by
means of tight fitted anchor bolts, which are embedded in concrete.
The material of bottom plate shall be cast steel.
Pure unfilled quality dimpled PTFE of specified thickness shall be
provided on top of concave surface of bottom plate in order to allow
smooth rotation.
Saddle Plate
A saddle plate with square/circular/rectangular top and convex surface
at bottom shall be placed in the concave surface of bottom plate.
The radius of curvature of the convex bottom of the saddle plate shall
he slightly less than that of the concave top surface of the bottom plate
to enstire sufficient contact over a small area. Rotation along all axes
shall be permitted along the contact surface of the saddle plate and
we bottom plate. Pure unfilled quality dimpled PTFE sheet shall be
recessed to specified depth of recess over the top of saddle plate.
Suitable elastomeric seal shall be provided on the saddle plate to prevent
ingress of dirt and moisture. The material of saddle plate shall be cast
steel.
Top Plate
The top plate shall have stainless steel plate welded to its bottom
which shall slide over PTFE. The assembly shall be connected to
498
<<
the superstructure by tight fitted anchor bolts. Translatory movements

along longitudinal axis of bridge shall be accommodated at the PTFE/
Stainless steel sliding surface. The material of top plate shall be cast
steel.
Guide Plate
Guide Plates shall be welded to saddle plate so as to permit only
longitudinal movement. The material of guide plates should be cast
steel.
2004.2. Pin Bearing
Pin bearing shall ensure fixity by arresting translatory movement.
The pin bearing shall not take any vertical load, It will take care of
the longitudinal horizontal force of the entire superstructure unit as
well as transverse horizontal force developed at the fixed end.
A pin bearingshall consist of a short height structural built-up column
embedded in pier cap and the protruding length inside soffit of deck
shall have rocker plates on all four sides, which permit rotation.
Pin bearing shall resist horizontal force from any direction and will
permit rotation but will not bear any vertical load. The material of
pin bearing including rocker plates shall be high tensile steel conforming
to IS:961.
2004.3. In general the sliding spherical and pin bearing shall conform
to BS:5400, Parts 9.1 and 9.2 and all relevant clauses of this specification.
Bearings shall be guaranteed for design loads and movements. The term
bearing shall include the entire assembly covering all the accessories
required for operation, erection and dismantling for replacement. All
bearings shall be of replaceable type~ These bearings should be
based on their design to the specifications mentioned/international
specifications. The manufacturer should get their design approved from
appropriate authority and the manufacturer should be associated
with installation of bearings.
2004.4. Materials
All materials, particularly the following, shall be original, unused
or non-re-cycled conforming to relevant specifications
Cast Stcel~Mild Steel, Stainless Steel shalt conform to Clause 2003.1.
- Copolymer Poly Tr~r*Fluora Ethylene (FIFE) unfitted quality shall have required
properties as per BS:5400 and thickness shall be as specified.
Anchor Bolts shall be as per relevant IS specifications.
<< 499
2004.5. Seating of Pin Bearing
i) Backing plate with studs welded on the face opposite to the seating of manufacture
shill be delivered by the mannfacnner.
ii) This backing plate shall be aecurarety positioned on the reinforcement grid of
the pedestal and IevdletL
iii) Studs shalt be tack welded/tied so the reinforcement to keep the backing plate
inpruper location during casting.
iv) Depth of embecknent of the backing plate in the concrete shall be as per
relevant drawing.
v) The mund base of the pot (bottom) of the pin beating assembly shall be connected
to the backing pLates by anchor screws after concreting of tier cap/pedestal.
vi) In order so ensure’successful tranth~rof large horizontal forces so be resisted
by the Pin bearing, great care shall be taken in desaihng the reinforcement in
the sub.stnrcsurc and the super-structure adjacent to the studs in the backing plate.
2004.6. Acceptance Test on Spherical Bearings
1. ALl bearings shalt be checked for overall dimensions
2. All bearings shall be load tested to 1.25 limes design vertical load
3. A pair of bearings selected at random shall undergo testing in order to determine
coefficient of friction which shall be less than 01)5.
4. Two beatings selected at random shall be tested for pennissible meanon.
2004.7. Acceptance Test on Pin Bearings

1. All bearings shall be checked for overall dimensions.
2. ALl bearings shalt be load tested (if required, for design horizontal load only)
2005. ELASTOMERIC BEARINGS
The term “bearing” in this case refers to an elastomeric bearing
consisting of one or more internal layers of elastomer bonded to internal
steel laminates by the process of vulcanisation. The bearing shall cater
for translation and/or rotation of the superstructure by elastic deformation.
2005.1. Raw Material
Chloroprene (CR) only shall be used in the manufacture of bear-
ing.
Grades of raw elastomer of proven use in elastomeric bearings,
with low crystallization rates and adequate shelf life (e.g. Neoprene
WRT, Bayprene lit), Skyprene B-5 and Denka S-40V) shall be used.
No reclaimed rubber or vulcanized wastes or natural rubber shall
be used.
The raw elastomer content of the compound shall not be lower than
<< 500
60 per cent by its weight. The ash content shall not exceed 5 per cent.
(as per tests conducted in accordance with ASTM D-297, sub-section
10).
EPDM and other similar candidate elastomers for bridge bearing use
shall not be pennitted.
Properties
The elastomer shall comform to the properties specified in Table
2000.1
TABLE 200e.l. PROPERTIES OF ELASTOMER
Propcrtly UnIt Test Method, IS Value of the
spedftcatlcsa cbaracteristk
reference • spedfled
Physical Prupesties
1.1. Hardness IRHD IS:3400 60 + 5

(Past Ii)
12. Minimum Tensile Ml’s IS:3400 17
Strength (Pan I)
1.3. Minimum Elongation Per cent IS:3400 400
atbreak (Part!)
2. Max ~mwn Compression

Set Per cent IS:3400
(PartX)
duration temperature
(h) (deg C)
+Oto 100±1 35
242
3. Accelerated Agemg
IS:3400
(Pastry)
duration temperature
(h) (dcgC)
CR 70 l00~1
3.1 Max change in

Hardness IRHD +15
3.2. Max change in Percent .15
Tensile Strength
3.3. Max change in
Elongation Per cent -40
Shear modulus of the elastother bearing shall neither be less than

0.80 MPa nor greater than 1.20 MPa.
The adhesion strength of elastomer to steel plates determined
<< 501
according to IS:3400 (Part XIV) method A shall not be less than 7

kN/m.
For elastomeric bearings (CR) used in adverse climatic conditions
the following ozone resistance test shall be satisfied
The ozone resistance of elastomer shall be proved satisfactory when
assessed by test according to IS:3400 (Part XX). The strain, temperature,
duration and ozone concentration of the test shall be 20 per cent,
40 ~ I degree Celsius, 96 h and 50 pphm by volume respectively,
No cr~ickingdetected by visual observation at the end of the test
shall be considered satisfactory. No specific tests forassessment of low
temperature resistance may be deemed necessary.
NOTE : For use of elastomer in extreme cold climates, the Engineer
may specify special grade of low temperature resistant elastomer
in conformity with operating ambient temperature conditions. The sped.
fications of such special grade elastomer including the tests for low
temperature resistance shall be mutually agreed to by the Engineer and
the producer supplier and are outside the purview of these specifications.
Laminates of mild steel conforming to IS:226 shall only be per-
mitted to be used. Use of any other material like fibre glass or similar
fabric as laminates shall not be permitted.
The manufacturers of elastomeric bearings shall satisfy the Engineer
that they have in-house facilities for testing the elastomer for carrying
out the following tests in accordance with the relevant provisions of
ASTM D-297.
a) Identification of polymers to confirm the usage of
Chioroprene (Appendix X-2)
b) Ash content test to determine the percentage (sub-section 34)
c) Specific gravity test : (tub-section 15)
d) Polymer content test : (sub-section 10)
The Engineer shall invariably get the test (a) performed within his
presence or in the presence of his authorised representative to satisfy
the requirement. In case of any disputes regarding interpretation of results
the Engineer may carry out test as per ASTM S-3452-78 (Chromatography
test) at the manufacturer’s cost in a recognised test house.
The elastomer specimen to conduct the Lest shall be obtained from
the bearings selected at random for destructive test. Remaining part
of the test bearing shall be preserved by the Engineer for any Lest to
be done in future, if required.
502
<<
2005.2. Fabrication
Bearing with steel laminates shall be cast as a single unit in a mould
and vulcanised under heat and pressure.
Casting of elements in separate units and subsequent bonding
shall not be permitted, nor shall cutting from large size cast be permitted.
Bearings of similar size to be used in particular bridge project shall
be produced by identical process and in one lot as far as practicable.
Phased production may only be resorted to when the total number of
bearings is large enough.
The moulds used shall have standard surface finish adequate to
produce bearings free from any surface blemishes.
Steel plates for laminates shall be sand blasted, clean of all mill
scales and shall be free form all contaminants prior to bonding by
vulcanisation. Rusted plates with pitting shall not be used. All edges of
plates shall be rounded.
Spacers used in mould to ensure cover and location of laminates
shall be of maximum size and number practicable. Any hole at surface
or in edge cover shall be filled in subsequently.
Care shall be taken to ensure uniform vulcanising conditions and
homogeneity of elastomer through the surface and body of bearings.
The bearings shall be fabricated with the tolerances specified in
Table 2000-2.
TABLE ~.2 TOLERANCES
ITEMS TOLERANCES
Overall plan dimensions -0, + 6 mm
2. Total beaiing thickness -0, + 5 mm
3. Parallelism
a) Of top surface of bearing with
respect to the bottom surface as datum I in 200
b) Of one side surface with
respect to the other as datum 1 in 100
4& Thickness of individual internal ±20 per cent (max. of 2 mm)
layer of elastomer
b) Thickness of individual outer layer .0, + 1 mm
5a. Plan dimensions of laminates -3mrn,+0
b) Thickness of laminates ~l0 per cent
c) Parallelism of laminate with
respect to bearing base as datum 1 in 100
503
<<
Section 2000 Beatings
The vulcanising equipmen~ressshall be such that between the
plattens of press the pressure and temperature are uniform and capable
of being maintained at constant values as required for effecting a uniform
vulcanisation of the bearing.
The moulding dies utilised for manufacturing the bearings shall
be so set inside the platten of the press so that the pressure developed
during vulcanisation of the product is evenly distributed and the
thickness maintained at all places are within acceptable tolerance limits
taking into consideration the shrinkage allowance of valcanizate.
The raw compound which has been introduced inside the metal dies
for vulcanisation shall be accurately weighed each time and it must
be ensured that sufficient quantity has been put inside the die for proper
flow of material at every place so that a homogeneous and compact
bearing is produced without any sign of sponginess or deficiency of
material at any place.
Before any vulcanizate of any batch of production is used for
producing vulcanised bearings, test pieces in the form of stand-
ard slab and buttons shall be prepared in accordance with prescribed
standards and salient properties tested and recorded regularly against
each batch of j~oductionto monitor the quality of the products.
2005.3. Acceptance Specifications
The manufacturer shall have all the test facilities required for the
process and acceptance control tests installed at his plant to the complete
satisfaction of the Engineer. The test facilities and their operation shall
be open to inspection by the Engineer on demand.
All acceptance and process control tests shall be conducted at the
manufacturer’s plant. Cost of all materials, equipment and labour shall
be borne by the manufacturer unless otherwise specified or specially
agreed to between the manufacturer and Engineer.
Acceptance testing shall be commenced with the prior submittal of
testing programme by the manufacturer to the Engineer and after
obtaining his approval.
Any acceptance testing delayed beyond 180 days of production
shall require special approval of the Engineer and mOdified acceptance
specification, if deemed necessary by him.
All acceptance testing shall be conducted by the inspector with
aid of the personnel having adequate expertise and experience in rubber
<< 504
testing provided by the manufacturer, working under the supervision
of the Inspector and to his complete satisfaction.
Lot by lot inspection and acceptance shall be made.
2005.3.1. Acceptance lot : A lot under acceptance shall comprise
all bearings, including the pair of extra test bearings where applicable
of equal or near equal size produced under identical conditions of
manufacture to be supplied for a particular project.
The size and composition of acceptance lot shall be got approved
by the Engineer.
For the purpose of grading levels of acceptance, testing lots shall
be classified as follows
i) A lot size of 24 or larger number of bearings shall be defined as a large lot
ii) A lot size of less than 24 bearings shall be defined as a small tot
When the number of bearings of equal or near equal size for
a single bridge project is large and phased production and accept-
ance is permitted, the number of bearings supplied in any single phase
of supply shall comprise a lot under acceptance. When such phased
supply is made, each such lot shall be considered as a large lot
for the purpose of acceptance testing.
2005.3.2. Levels of acceptance inspection : The level of acceptance
testing shall generally be graded into the following two levels depending
on lot size
Level I acceptance testing
Level 2 acceptance testing
Acceptance testing Level 1 is a higher level inspection and shall
be applicable to large lots only, unless otherwise specified. This shall
involve manufacture of two extra bearings for each lot to be used as
test bearing and eventually consumed in destructive testing.
Acceptance testing Level 2 shall be applicable to small lots
only, (i.e. less than 24 lots) for which one extra bearing shall be
manufactured. Out of the lot one bearing shall be selecled at random
for carrying out material tests. This bearing shall be excluded from
the lot accepted.
Acceptance inspection level 1 may be specifiedat the sole discretion
of the engineer taking into account the special importance of bridge
project for small lots also under the purview of special acceptance
<< 505
inspection. The cost of extra bearings, in such cases shall be borne

by the user, while the cost of all other materials, equipment and testing
shall be borne by the manufacturer.
2005.3.3, Testing : Acceptance testing shalt comprise general in-
spection, test on specially moulded test pieces and test on complete
bearings or sections for measurement of various quality characteristics
detailed below
2005.3.3,1. Acceptance testing level I
General Inspection
All bearings of the lot shall be visually inspected for any defects in surface
finish, shape or any other discernible superficial defects.
2. All bearings of the lot shall be checked for tolerances specified in Table 2DO0~
2.
3. All bearings of the lot shall be subjected to axial load to correspond to ~m
(i.e. average compressive stress) = 15 MPa applied in steps and held constant
while visual examination is made to check for discernible defects like
a) Misalignment of reinforcing plates
b) Poor bond. at laminate/steel interface
c) Variation in thickness of elastomer layers
d) Any surface defects
e) Low stiffness
Deflection under loads between om=5 MPa and ~m=l 5 MPa shall
be measured and recorded for all bearings with sufficient accuracy (~
5 per cent), Variation in stiffness of any individual bearing from the
mean of the measured values for all such bearings of the lot shall not
be larger than 20 per cent (of the mean value).
Tests on specially moulded test pieces
1. Test pieces shall be moulded by the manufacturer with identical compound
and under identical vulcanising conditions as used in the manufacture of the
bearings of the acceptance, lot, The process shall be open to inspection by the
Engineer.
2. Test pieces offered for inspection shall be identified by suitable markings and
duly certified by the manufacturer.
3. The quality characteristics to be tested are listed below. The specification
references in parenthesis shall define the corresponding specification for test
piece, test method and criterion for acceptance.
Composition (see Note I below)

Hardness (Table 2000-1 1.1) ,
<< 506
Tensile strength (Table 2000-1 1.2) ,
Elongation at Break (Table 2000-1 1.3) ,
Compression Set (Table 2000-1 2) ,
Accelerated Ageing (Table 2000-1 3) ,
Adhesion Strength (Clause 2005.1)

Ozone Resistance (see Note 2 below)
Note I.
For acceptance testing the properties enumerated in Clause 2005.1
and specific gravity of elastomer of test pieces from test bearing shall
be compared with those for corresponding specially moulded test pieces
furnished by the manufacturer. The following variations shall be deemed
maximum acceptable
Specific Gravity ± 0.2
Ash Content ±0.5 per cent
Hardness (Table 2000-1 1.1) ,
Tensile strength (Table 2000-1 1.2) ,
Elongation at Break (Table 2000-1 1.3) ,
Compression Set (Table 2000-I 2) ,
Accelerated Ageing (Table 2000-1 3) ,
Adhesion Strength (Clause 2005.1)

Note 2.
Ozone resistance test can be waived by the Engineer for bearings
of CR when satisfactory results of ozone resistance tests on similar
grade of elastomer may be available from process control records or
development test data furnished by the manufacturer.
Where such process control data are not available or the
frequency of testing~not deemed adequate, ozone resistance test shall
be mandatory for acceptance of bearings of CR.
However, such tests may not be insisted for bearings not located
under adverse conditions of exposure and where the test on accel-
erated ageing could be considered as adequate.
Process and acceptance control tests for ozone resistance by an
independent testing agency shall be acceptable.
Tests on Complete Bearings or Sections
I. Two bearings thall be selected at random from the lot as test bearings. These
bearings shall be excluded from the lot accepted.
<< 507
2. The following tests shall be conducted on test bearings

Test for determination of shear modulus
Test for detennination of elastic modulus
Test for determination of shear modulus (short teim loading)
Test for determination of adhesion strength
Test for determination of ultimate compressive strength
The test specifications and acceptance criteria shall conform to those~
given in Appendix 2 of IRC:83 (Part II).
2005.3.3.2. Acceptance testing level 2
General Inspection. This shall conform to the provision in Clause
2005.3.3.1 in all respects.
Test on specially moulded test pieces. This shall conform to the
provisions in Clause 2005.3.3.1 in all respects.
Test on complete bearings. Test for determination of shear
modulus shall be conducted using two bearings of the lot selected at
random and conforming to relevant provisions of Clause 2005.3.3.1.
These bearings shall however be part of the lot accepted. The
remaining tests stipulated in aforesaid clause shall be carried out Ofl
all bearings selected at random which shall be excluded from the
lot accepted.
2005.3.4. Special acceptance inspection : Special acceptance
inspection may comprise the following
1. Acceptance testing by an independent external agency with separate or
supplemental test facilities provided by it.
2. Acceptance testing on test pieces prepared from the surface or body of the test
bearings instead of specially moulded test pieces.
3. Acceptance tests not covered by these specifications but according to the speci-
fications laid down by the Engineer.
Special acceptance inspection may be specified under the follow-
ing conditions
a) Special contract agreement
b) Unsatisfactory evidence of process or acceptance control
2005.3.5. Inspection certificate : A lot under inspection shall be
accepted by the Inspector and so certified, when no defect is found
with respect to any of the quality characteristics tested on samples
drawn from the lot according to specifications laid down in Clause
2005.3.3 covering general inspection tests on specially moulded test
pieces and on complete bearings.
<< 508
In case of any bearing with defect, the lot shall be rejected by

the Inspector and so certified.
In case any bearing is found to be defective with respect to
any quality characteristic, discerned by general inspection tests
specified in Clauses 2005.3.3.1 and 2005.3.3.2, tests on specially
moulded test pieces and complete bearings as applicable according to
Clauses 2005.3.3.1 and 2005.3.3.2 shall nevertheless be completed.
If the said lot, rejected by general inspection, satisfies the acceptance
criteria in respect of these other tests, the lot and individual
bearings found defective shall be àlearly identified in the inspection
certificate,
The manufacturer shall obtain from the inspector, authorised by
the Engineer, immediately on completion of his inspection, an inspection
certificate which shall include the details of a lot or lots accepted/rejected
by him and records of all test measurements.
2005.3,6. Quality control certificate: The manufacturer shall certify
for each lot of bearing under ac~eptance:
That an adequate system of continuous quality control was operat-
ed in his plant.
That the entire process remained in control during the production
of the lot of bearings under acceptance as verified from the quality
control records/charts which shall be open to inspection of Engineer/
Inspector on demand.
A certified copy of results of process control testing done on samples
of elastomer used in the production of the lot shall be appended and
shall include at least the following information
Composition of compound raw elastomer ahd ash content, the grade
-
of raw elastomer used (including name, source, age on shelf), test results
of hardness, tensile strength, elongation at break, compression set,
accelerated ageing, etc.
A higher level certification of the process quality control shall be
called for at the sole discretion of the Engineer in special cases e.g.
where adequate inspection of bearings similar to those comprising the
lot under inspection produced in the same plant is not available
with the Engineer or in case of any evidence of process or acceptance
control being deemed unsatisfactory. The higher level certification
shall comprise submittal of a complete quality control report as given
<< 509
in Appendix 3 of JRC:83 (Part II) supplementing the quality control

certificate,
2005.3.7 Acceptance The manufacturer shall furnish the following
to Engineer for the acceptance judgement
Quality control certificate as lain down in Clause 200516.
2. Inspection certificate as laid down in Clause 2O053.5~.
The manufacturer shall furnish any supplementary information on

the system of quality control and/or process and acceptance control
testing as may be deemed necessary by the Engineer.
In case of any evidence of process or acceptai~cecontrol testing
being deemed unsatisfactory by him, Engineer at his sole discretion
may call for a special acceptance of the lot according to specifications
laid down by him, without any prejudice to his right to reject the lot.
The entire cost of such supplementary inspection shall be borne by
the manufacturer.
The Engineer shall be the sole authority for accep~anccof a lot
on scrutiny of the certificates alongwith any supplementary evidence
and complete satisfaction therewith.
In case of rejection of a lot, the Engineer shall reserve the right.
to call for special acceptance inspection for the succeeding lots offered
for inspection, according to the specifications laid down by him. The
enhire cost of such tightened inspection shall be borne by the manu-
facturer.
2005.4. Cerification and Marking
Bearings shall be transported to bridge site after final acceptance
by Engineer and shall be accompanied by an authenticated copy of the
certificate to that effect.
An information card giving the following details for the bearings,
duly certified by the manufacturer shall also be appended
Name of manufacturer
Date of manufacture
Elastomer grade used
Bearing dimensions
Production batch no.
Acceptance lot no.
Date of testing
<< 510
Specific bridge location, if any

Explanation of markings used on the bearing
All bearings shall have suitable index markings identifying the in-
formation. The markings shall be made in indelible ink or flexible
paint and if practicable should be visible after installation. The
top of the bearing and direction of installation shall be indicated.
2005.5. Storage and l~andling
Each elastomeric bearing shall be clearly labelled or marked. The
bearing shall be wrapped in a cover. They shall be packed in timber
crates with suitable arrangement to prevent movement and to protect
corners and edges.
Care shall be taken to avoid mechanical damage, contamination
with oil, grease and dirt, undue exposure to sunlight and weather to the
bearings during transport and handling prior to and during installation.
2005.6. Installation
Installation of multiple bearings one behind the other on a
single line of support shall be of identical dimensions.
Bearings must be placed between true horizontal surfaces (maximum
tolerance 0.2 per cent perpendicular to the load) and at true plan position
of their control lines marked on receiving surfaces (maximum tolerance
± 3 mm).
Concrete surfaces shall be free from local irregularities (maximum
tolerance ±i mm in height).
Design shall be checked for the actual inclination in seating if larger
inaccuracies than those specified are permitted.
For cast-in-place concrete construction of superstructure, where bear-
ings are installed prior to its concreting, the forms around the bearings
shall be soft enough for easy removal. Forms shall also fit the bearings
snugly and prevent any leakage of mortar grout. Any mortar contami-
nating the bearings during concreting shall be completely removed
before setting.
For precast concrete or steel superstructure elements, fixing of
bearing to them may be done by application of epoxy resin adhesive
to interface, after specified surface preparation. The specifications for
adhesive material, workmanship and control shall be approved by the
Engineer. Care shall be taken to guard against faulty application and
consequent behaviour of the adhesive layer as a lubricant. The bonding
<< 511
by the adhesive shall be deemed effective only as a device for installation

and shall not be deemed to secure bearings against displacement for
the purpose of design.
As a measure of ample safety against accidental displacement, the
bearings shall be placed in a recess as shown in Fig. 9 of IRC:83 (Part
II).
2005.7. Seating of Elastomerk Bearings on a Non-Horizontal
Plane
Installation of elastomeric bearings on a Non-Horizontal Plane shall
be as follows
I) Elastorneric bearings shall be delivered with MS backing plate fastened to the
bearing from the manufacturer.
ii) Template of 6 mm M.S. plate and of size same as bearing holding base plate
with matching holes for the anchor screws shall be used. Anchors shall be fined
to the templates with the anchor screws but with MS washers in place of elastomer
washers. The above template assembly shall be fitted in the fomtwork at its
proper location and in a vertical plane.
iii) After casting of the pedestal and removal of the fonnwork, the template is to
be removed.
A. Installation with race plate and without template b-situ casting
I) The sub-assembly of elastomeric bearing wish the MS backing plate shall be fitted
to the embedded anchors with anchor screws and elastomeric washers replacing
the steel washer.
ii) A clearance is required between the stainless steel face of the eleazomenc beating
and that of the vertical face of the face plate with stainless steel top installed
on the projection below the soffit. This shalt be achieved by inserting removable
steel sheeting of thickness as per the drawing, during preparation of the formwork
before casting of the superstnremre.
iii) The face plate with stainless steel top and pack plate shall be assembled with
the anchors with elastomeric washers and anchor screws. The assembly shall
be fined in the formwork at its proper location and in a vertical plane. The
removable steel shims shall be removed at an appropriate time after the casting
of the super-strocture.
B, Installation with face plate and with template in-situ casting
i) Template of 6 mm MS plate and of size same as face pimp with stainless steel
top and matching holes for the anchor screws shall be used. Anchors shall be
fitted to the templates with the anchor screws but with MS washers in place
of elastoiner washers. Separate screws may be used in case of inconvenience
of in the length of original anchor screws. The above template assembly shall
be fitted in the fonnworic for the super-strocture at its proper location and in
a vertical plane.
ii) After removal of the superstructure fonnwosk, the template shall be removed.
<< 512
iii) The face plate with the required thickness of pack plate shall be loosely fitted
to the anchors embedded in the projection below the superstmcture, with elastomer
washers and anchor screws.
iv) The sub-assembly of elastomeric beating with the MS backing plate shall be
fined to the embedded anchors in the pedestal with anchor screws and elastomeric
washers replaang the steel washer this time.
v) The required clearance between thettainless steel face of the elastosneric bearing
and that of the vertical face plate installed on the projection below the soffit
shall be checked. After adjustment of the required working clearance the small
gap between the vertical face of the prcpection below the soffit and the back
of the face plate (with pack plates, if any) shall be grouted with epoxy grout.
2006. POT BEARINGS

2006.1. General
2006.1.1. Pot type bearings shall consist of a metal piston supported
by a disc or unreinforced elastomer confined within a metal cylinder
to take care of rotation. Horizontal movement, if required, shall’ with
a system of sealing rings be provided by sliding surfaces of PTFE pads
sliding against stainless steel mating surfaces. The pot bearings shall
consist of cast steel assemblies or fabricated structural steel assemblies.
2006,1.2. Provisions of IRC-83 (Part I) shall be applicable for all
metallic elements. Provisions of IRC:83 (Part II) shall be applicable
for all elastomer elements. When any items are not covered by IRC:83
(Parts I and II), the same shall be as per guidelines given hereunder
and BS:5400 (Sections 9.1 and 9.2), except that no natural rubber shall
be permitted. If there is any conflict between BS on the one hand
and IRC on the other, the provisions of IRC will be guiding.
2006.13. Combination bearings using any judicious combination and
sliding element shall be permitted. As for example :
Name Ru~atlon Sliding Generally for
Element Element
Pot Pot None Vertical Load
Elastomer Elastomer None* Horizontal Buffer
Pot PTFE Pot l9?E-SS~ Vertical Load and
Horizontal Load
Spherical Spherical PTFE.SS~ Vertical Load and
Knuckle PiPE Knuckle Horizontal Load
Elastoiner PTFE Elastomer FT?E-SS~ Transverse Guide
Elastomer SS~ Elastomer SS.SS’ Transverse Guide
Etastomer shall permit movement by shear
** Stainless Steel
513
<<
For special and innovative bridges, new combinations beyond what

is shown may be required. The same may be used g1~approval by
the Engineer.
200&2. Fabrication
i) The surface mating with the FIFE in the sliding pair shall be corrosion resistant
stainless steel, Normally, the stainless steel shall form the upper component.
The stainless steel shall overlap the PTFF after full movement on all sid~.If
stainless steel sheet is used, it should be bonded by continuous welding átong
the edges. Adhesive or any other bonding can be approved by the Engineer. The
surrace shall be prepared by thorough cleaning to remove grease, dust or any
other foreign substance.
ii) PiPE modular sheets of the sliding pair shall be located by confinement assisted
by bonding. Confined PTFE shall be recessed into the metal backing plate. The
shoulders of the recess shall be sharp and square to restrict the now of PTFE.
iii) The thickness of the PTFE shall not be less than 4.5 mm with projection above
the recess not exceeding 2.0 mm. When the piston is subjected to tilting, the
seal must slide along the wall and alter its shape according to the angle of tilt
At the same time, it must be sufficiently rigid to bridge the gap between
the piston and the wall of the pot. However, the percentage of plan area of
the lubrication cavities to the gross area shall not exceed 25 per cent. The
depth of the cavity shall not exceed 2.0 mm.
iv) The diameter to thickness ratio of the confined elastomer shall not exceed 15.
The surface of the confined elastomer shall be smooth.
v) A seal shall be provided to prevent extrusion ofthe confmed elastomer between
the piston and the pot wall, The seal should stay functional under the loads
and rotations acting on it. Additional seal shall be provided to prevent entry
of dust! into the pot. Sealing rings for .pot bearings shall be fabricated from
stainless steel. When the piston is subjected to tilting, the seal must slide along
the wall and alter its shape according to the angle of tilt. At the same time,
it must be sufficiently rigid to bridge the gap between the piston and the wall
of the pot,
vi) The hardness of the piston and pot wall at their contact region shall be
minimum 350 BHN to reduce wear. The surface finish of the pot base in
contact with the confined elastomer shall be very smooth.
vii) All bearings shall be installed with anchor and anchor screws or some
similar device such that while replacing, the bearings can be removed with
minimum lifting of the supersirueturt
viii) The extemal surfaces of the assemblies shall be completely cleaned by sand
blasting. After sand blasting, dust shall be removed from the sw’face using clean
and dry compressed air or a clean brush after which suitable coating shall be
applied.
ix) Pot bearings including all parts as shown on the drawings shall be fully shop
assembled at the manufacturer’s works to ensure proper fitting of all parts.
<< - 514
2006.3. Materials
a) Steel
i) Structural steel shall conform to 15:226 and 15:2062, as applicable.
ii) Cast steel shall conform to Cr 280-520W of 15:1030. 0,3 to 0.5 per cent
copper may be added to increase the corrosion resistance properties.
ii) Stainless steel shall conform to AlS1:304 or XO4CrISNiIO of 15:6911 for
ordinary applications. For applications with adverse/corrosive environment,
the stainless steel shall conform to AlSt:316L or O2Crl7Nil2Mo2 of
15:69 11.
b) PTFE
PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality. It shall
be free sintered. The mechanical properties of unfilled PiPE shall comply with
Grade A of BS:3784.
c) Elastomer
‘ftc confined elastonser inside pot will have the following properties
a) Hardness IRlID 1S3400 (Part II) 50 + 5
h) Mm tensile MPa TS:3400 (Part 1) 15.5
strength
c) Mm elongation at break,) shall be as per Table 2000-1
Max compression set and ) “Properties of Elastomer”
Accelerated ageing
For other details, refer to Clause 2005.1.
2006.4. Workmanship
2006.4.1. Welding
All welding shall conform to IS:9595 with electrodes of suitable grade
as per IS:814. Preheating and post weld stress relieving shall be done
as per TS:9595.
2006.4.2. Cast steel assemblies Cast steel for pot bearing
assemblies shall conform to requirements of relevant IS. Castings shall
he true to the forms and dimensions shown on the drawings, and
shall be free from pouring faults, sponginess, cracks, blow holes and
other defects affecting their appearance or their strength. Warped or
distorted castings shall not be accepted. Exposed surfaces shall t;e smooth
and dense.
All irregularities, fins or risers shall be ground off flush with the
adjacent surface. Castings with visible cracks., blow holes, or similar
blemishes shall be rejected if the imperfections are located on bearing
surfaces or cannot be remedied to the satisfaction of the Engineer.
<< 515
Imperfections which are not located on bearing surfaces shall be cleaned

Out, filled with weld metal of the appropriate composilion and ground
flush with adjacent surfaces.
2006.4.3. Structural steel assemblies: Defects arising from the
fabrication of the steel shall be inspected by the Engineer, who will
decide whether the materials may be repaired by the Contractor or
will be rejected. The cost of repairs or replacement shall be borne by
the Contractor.
All steel whether fabricated or not, shall be stored above the
ground on platforms, skids, or other supports, and adequately protected
against corrosion. Excessively rusted, bent or damaged steel shall be
rejected.
All plate.s shall be flat and rolled bars and shapes straight before
marking out or being worked Straightening shall be done by methods
.
which shall not damage the material. Sharp kinks and bends shalt be
the cause for rejection.
Steel may be flame cut to shape and length so that a regular surface,
free from excessive gouges and striations is obtained. Flame cutting by
hand shall be done only with the approval of the Engineer.
Exposed corners shalt be machined or ground.
2006.4.4. Tolerances
i) Plan dimensions : -o to +5 mm
ii) Overall height : -0 to +3 mm
iii) Height of elastomer : ±5 per cer~t
iv) Height of any steel component
a) Machined : .0 to + I mm
b) Unmachined Class 2 of lS:4897
v) Stainless steel sliding surface
a) Flatness : 0.0004L. where L = length in
direction of measurement
b) Surface Finish Ra 0.2.5 pm as per IS:3(Y73
2006.4.5. Painting
i) All non-working surfaces shall be coated with two coats of epoxy primer and
one or more coat each of epoxy intermediate and finish, total thickness ~g0.150
p.m or any other painting scheme as approved by the Engineer.
ii) Silicon grease shall be applied at the PTFEISS inierface after testing.
iii) Anchor sleeves shall be cement coated at the manufacturer’s works.
<< 516
2006.5. Test
2006.5,1. Raw materials Necessary test certificates for all
raw materials as in Clause 2006.3 above shall be furnished by
manufacturers. Reference may also be made to Clause 2005.1 for tests
on elastomers.
2006.5.2. Test on casting : Tests specified in IS:1030 shall
be performed. Castings shall be ultrasonically tested and
certificates submitted. Quality level of castings shall be level 3 as per
IS:9565.
2006,5.3. Test on welding All welding shall be tested by
Dye Penetration method. But welding shall be tested by Ultrasonic
method. Soundness of welding shall be certified by the manufacturer.
2006.5.4. Acceptance test on bearing
I) All bearings shall be checked for overall dimenuons.
ii) All bearings shall be load tested to Li times maximum design capacity
including seismic force. Bearing tested at higher loads cannot be used.
iii) A pair of bearings arlected at random will undergo testing in oidcr to detennine
the coefficient of friction “if. The coefficient of fricuon shall be ~ 0.05 at
the deMgn load.
iv) Two bearings selected at random shall be tested for pemthsible rotation.
2006.6. Installation of POT-cum-PTFE Bearings

2006.6.1. General
i) Care shall be taken during installation of the bearings to permit their correct
functioning in accordance with the design scheme.
ii) To prevent contamination, dismantling of the bearings at site shall not be
done.
iii) The load shall be transferred onto the bearings only when the bedding material
has developed sufficient strength. The props for the forrnwork shall only be
removed after lapse of appropriate time. In special cases, this can be ensured by
suitable devices like jacks, etc.
iv) Temporary damps and shims (introduced to maintain working clearance) shall
be removed at ass appropriate time, before the bearing is required to permit
movement.
v) Permitted installation tolerance of the bearing from plane of sliding shall be
maintained,
vi) Cement based non-shrink grout with air releasing additive and epoxy based grout,
whichever is specified shall be first tried at the site. For the proprietary grout
mixes, appropriate instructions from the manufacturer shall be followed specially
with regard to the following
<< 517
a) Preparauon~>r.oncretecleaning, roughening, pre.soaking, etc.

h) Fonzts->sturdiness, leak proofing, shape, hrader funnel vents, etc.
c) earing Base->cleaning, etc.
d) Plaeernent..>rnircing, consistency!, time period, finishing, etc.
e) Protection->curing, ambient temperature, etc.
2006.6.2. In-situ casting of superstructure
i) Pormwork around the bearing shall be carefully sealed to prevent leakage.
ii) Sliding plates shall be fully supported and care taken to prevent tilting, dis.
placement or distortion of the bearings under the weight of wet concrete.
iii) Bearings shall bc protected during concreting operation. Any snort ar
contaminating the bearing shall be completely removed before it sets.
2006.6,3. Seating of bearing
A. Using Template
i) Template with required rigidity and matching holes corresponding to the base
of the bearing shall he used.
ii) All the anchors shall be fitted to the tower face of the template using the
anchor screws but with steel washer replacing the elastomer washers,
Separate screws may be used in case of inconvenience in the length of the
original anchor screws.
iii) The. template assembly shall be located with regard to level and alignment.
It shall be ensured that the sop of the anchors lie in a horizontal plane at
the required elevation. ‘I’he anchors shall be tied/welded so reinforcements
to avoid displacement during concreting.
is) Concreting of she pedessallpier cap shall be done to a level leaving a gap
of 25~~51)rnnt below she template.
s) The template and steel washers shall be removed prior to placement
of she hearing assembly with temporary clamps. The bearing assembly
shall he Fitted to the anchors with the help of anchor screws and elastosncr
washers. Level at the bearing shalt be checked.
vi) The gap below the bearing assembly shall be grouted with cement based
grout. Reference may be made to Clause 2006.6.1 (vi).
B. Without Tempiale with Gap

i) Pockets commensurate with the sizes of the anchors shalt be kept in pedestals
during concreting of the same. The pedestal shall be cast approximately 25
mm shon of the required finished level.
ii) Anchors shall be fitted to the bearing bettom with elastomer washers and
anchor screws. The bearing assembly shalt be seated in the location on
steel chairs/packs. ‘flat anchors fitted below the bearing shall go into pockets
in the bed block. Level and alignment of the bearing shall he checked. it
shalt be ensured that the bearing sits in a horizontal plane.
518
<<
iii) The gap below the bearing assembly including anchor pockets shall be
grouted with cement based grouL Reference may be made so Clause 2006.6.1
(vi).
C. Without Template without Gap

Elongated pockets commensurate with the sizes of the anchors
shall be kept in pedestals during concreting of the same. The geometry
and location of the anchor pockets (with tapered funnel extension, if
required) shall be such that after placement of the bearing the pockets
can be successfully grouted. The pedestal shall be cast 5 mm 15 -
tnm short of the required finished level. The required level shall be
achieved by chipping before placement of the bearing. Careful control
shall be exercised to cast at the exact finished level or 1 mm -
3 mm down from the required finished level.

D. Seating of bearings shall be as per manufacturer’s instructions.
2007. INSPECTION AND TESTING
Where any patents are used, the manufacturer’s certificate with
test proofs shall be sttbmitted alongwith the design and got approved
by the Engineer before their itse in work.
The materials shall be tested in accordance with these specifica-
The work shall confonn to these specifications and shall meet the
Bearings shall be measured in numbers, according to their capaci-
ties and particular specifications given on the drawings.
The quantity of elastomeric bearings shall be measured in cubic
centimetres of finished dimensions.
2010. RATE
The contract unit rate of each type of bearing shall include the cost
of supplying and fixing the bearings in position complete as specified
on the drawings or as decided by the Engineer.
The rate shall also include the cost of samples and their testing when
desired by the Engineer.
In case of steel bearings the rate shall include the cost of all nuts,
519
<<
bolts, the cost of all tests prescribed in the specifications and shown on
the drawings.
Where the Department supplies the bearings, the rate for fixing them
shall include the cost of anchor bolts, their fixing, transport of bearings
from the place of supply to the site, handling and placing them in position
as per direction of the Engineer.
<< 520
Open Foundations
2100
Open Foundations
<<
Open Foundations Section 2100
2101. DESCRIPTION
The work shall cover furnishing and providing plain or reinforced
concrete Ibundation placed in open excavation, in accordance with the
drawings and these specifications or as directed by the Engineer.
2102. MATERIALS
Mate~rialsshall conform to Section 1000 of these Specifications.
2103. GENERAL
A method statement for construction indicating the following shall
he submitted by the Contractor for approval of the Engineer, well
in advance of the commencement of open foundation
i) Sources of Materials
ii) Design, erection and removal of forenwork
iii) Prodectior, sraesportation, laying and curing of concrete
iv) Persomtct employed for execution and supervision
v) Teats and sampliitg procedures
vi) Equipment details
vii) Any other point
Necessary arrangements for execution under water wherever

necessary, shall he included in method statement.
Dimensions, lines and levels shall be set out and checked with
respect to permanent reference lines and permanent bench mark.
2104. WORKMANSHIP
2104.1. Preparation of Foundations
Excavation for laying the foundation shall be carried out in accord-
ance with Section 300 of these specifications. The last 300 mm of
excavation shall be done just before laying of lean concrete below
foundation.
in the event of excavation having been made deeper than that
shown on the drawing or as ordered by the Engineer, the extra depth
shall be made up with MlS concrete in case of foundation resting
on soil and foundation grade concrete for foundations in rock, at the
cost of the Contractor and shall be considered as incidental work.
Special care shall be taken not to disturb the bearing surface. Open
fotindations shall be constructed in dry conditions and the Contractor
<< 523
Section 2100 Open Foundations
shall provide for adequate dewatering arrangements to the satisfaction
of the Engineer.
2104.2. Setting Out
The plan dimensions of the foundation shall be set out at the bottom
of foundation trench and checked with respect to original reference line
and axis. It shall be ensured that at no point the bearing surface is
higher than the founding level shown on the drawing or as directed
by the Engineer.
2104.3. Construction
Where the bearing surface is earth, a layer of M15 concrete
shall be provided below foundation concrete. The thickness of lean
concrete layer shall be 100 mm minimum unless otherwise specified.
No formwork is necessary for the lean concrete layer. For
foundation concrete work, side formwork shall be used. Formwork for
top of the foundation concrete shall also be provided, if its top has
slopes steeper than I (vertical) to 3 (horizontal). When concrete is laid
in slope without top formwork, the slump of the concrete shall be carefully
maintained to ensure that compaction is possible without slippage down
the slope of freshly placed concrete. In certain cases it may be necessary
to build the top formwork progressively as the concreting proceeds
up the slope. Reinforcement shall be laid as shown on the drawing.
Before laying of lean concrete layer, the earth surface shall be
cleaned of all loose material and wetted, Care shall be taken to avoid
muddy surface. If any portion of the surface has been spoiled by over-
wetting, the same shall be removed. Concrete M15 shall be laid to the
thickness as required. No construction joint shall be provided in the lean
concrete.
Before laying foundation concrete, the lean concrete or hard rock
surface shall be cleaned of all loose material and lightly moistened.
Foundation concrete of required dimensions and shape shall be laid
continuously upto the location of construction joint shown on the
drawing or as directed by the Engineer.
Formwork and concrete shall conform to Sections 1500 and 1700
respectively of these specifications. Furnishing and providing steel
reinforcement shall conform to Section 1600.
The concrete surface shall be finished smooth with a trowel. The
location of construction joint and its treatment shall be done as per
<< 524
Open Foundations Section 2100
requirements of Section 1700. Formwork shall be removed not earlier

than 24 hours after placing of concrete. Where formwork has been
provided for top surface, the same shall be removed as soon as concrete
has hardened. Curing of concrete shall be carried out by wetting
of formwork before removal. After its removal, curing shall be done
by laying not less than 10 cm of loose moistened sand, free from clod
or gravel and shall be kept continuously moist for a period of 7 days.
Dewatering, where necessary for laying of concrete, shall be
carried out adopting any one of the following procedures or any other
method approved by the Engineer:
i) A pit or trench deeper than the foundation level as necessary may be
dug beyond the foundation pit ckinng construction so that the water level is
kept below the foundation level.
ii) Water table is depressed by well point system or other methods.
iii) Use of steellconcrese caissons or sheet piling for creating an enclosure for the
foundations, which can subsequently be dawatered,
Before backfihling is commenced, loose sand laid on foundation shall

be removed and dispersed as directed by the Engineer.
All spaces excavated and not occupied by the foundation or other
permanent works shall be refilled with earth upto surface of surrounding
ground in accordance with Section 300. In case of excavation in rock,
the annular space around foundation shall be filled with Ml 5 concrete
upto the top of rock.
The protective works, where provided shall be completed before
the floods so that the foundation does not get undermined.
• The work shall conform to these Specifications and shall meet the
No point of the surface of the lean concrete in the case of foundation
on soil or the surface of hard rock in the case of foundation of hard
rock, shalt be higher than the founding level shown on the drawing
or as ordered by the Engineer. Levels of the surface shall be taken
at intervals of not more than 3 metres centre to centre, subject to a
minimum of nine levels on the surface.
<< 525
Section 2100 Open Foundations
2106. TOLERANCES
a) Variation in dimensions ÷50mm - 10 mm
b) Misplacement rrom specified position in plan 15 mm
c) Surface irregularities measured with 3 m straight edge 5 mm
ci) Variation of levcls at the top ±25mm
2107. MEASUREMENT FOR PAYMENT

Excavation in foundation shall be measured in accordance with
Section 300 based on the quantity ordered or as shown on the drawing.
Lean concrete shall be measured in cubic metres in accordance
with Section 1700, based on the quantity ordered or as shown on the
drawing.
Concrete in foundation shall be measured in cubic metres in
accordance with Section i700, based on the quantity ordered or as shown
on l.he drawing.
~einforcement steel shall be measured in tonnes in accordance with
Section 1600, based on the quantity ordered or as shown on the drawing.
2108. RATE
The contract unit rates for excavation in foundation, lean concrete
and concrete in foundation aftd reinforcement steel shall include all works
as given in respective sections of these specifications and cover all
incidental items for furnishing and providing open foundation as mentioned
in this Section,
<< 526
Sub-structure
2200
Sub-structure
<<
Sub- structure Section 2200.
2201. DESCRIPTION
The work shall cover furnishing and providing of masonry or
reinforced concrete sub-structure in accordance with the drawings and
as per these specifications or as directed by the Engineer.
2202. MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2203. GENERAL
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 sub-structure
1) Sources of Materials
ii) Design, erection and removal of fosmwork
iii) Production, transportation, laying and ewing of concrete
iv) Personnel employed for execution and supervision
v) Tests and sampling procedures
vi) Equipment details
vii) Any other point
Arrangements for execution under water wherever necessary, shall

be included in method statement.
Dimensions, lines and levels shall be set out and checked with
respect to permanent reference lines and permanent bench mark.
2204. PIERS AND ABUTMENTS
Masonry, formwork, concrete and reinforcement for piers and
abutments shall conform to relevant sections of these 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 con-
struction joint shall be provided. The work shall conform strictly to the
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 specifications as necessary. All
<< 529
Section 2200 Sub- Structure
specifications and arrangements shall be subject to the approval of the
Engineer.
The surface of foundation/well capflile 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.
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.
The surface finish shall be smooth, except the earth face of
abutments which shall be rough finished.
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.
2205. PIER CAP AND ABUTMENT CAP
Formwork, reinforcement and concrete shall conform to relevant
sections of these specifications.
The locations and levels of pier cap/abutment cap/pedestals and bolts
for fixing bearings shall be checked carefully to ensure alignment in ac-
cordance with the drawings of the bridge.
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 horizontal. The top surface
of the pedestal on which bearings are to be placed shall also be cast
horizontal.
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 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.
<< 530
Sub- structure Section 2200
2206. DIRT/ BALLAST WALL, RETURN WALL AND
WING WALL
Masonry, concrete and reinforcement shall conform to relevant
sections of these specifications.
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.
For gravity type masonry and concrete return and wing wall, the
st face of foundation shall be prepared in the same manner as prescribed
for construction of abutmeni No horizontal construction joint shall be
provided. If shown on drawing or 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 on the drawings.
Formwork, reinforcement and concrete in dirt/ballast wall shall
conform to relevant sections of these specifications.
The finish of the surface on the earth side shall be rough while the
front face shall be smooth finished.
Architectural coping for wing wall/return wall in brick masonry shall
conform to section 1300.
2207, TESTS AND STANDARDS OF ACCEPTANCE
The work shall conform to these specifications and shall meet the
2208. TOLERANCES IN CONCRETE ELEMENTS
(a) Variation in cross-sectiohal dimensions +10 mm, -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 ±5 snm
(e) Variations from plumb over fuil beigld : ±10mm
(0 Swface irregularities measured with 3 m atraigjn edge
All surfaces except bearing areas 5 mm
Bearing areas 3 mm
<< 531
Section 2200 Sub- Structure
Masonry in sub-structure shall be measured in cubic metres in
accordance with Section 1300 or 1400, based on the quantities ordered
or as shown on the drawing.
Concrete in sub-structure shall be measured in cubic metres in
accordance with Section 1700, based on the quantity ordered or as shown
on the drawing. No deduction shall be made for weep holes.
Steel in concrete of sub-structures shall be measured in tonnes, in
accordance with Section 1600, based on the quantity ordered or as shown
on the drawing.
Weep holes shall be measured as per Section 2700, based on the
quantity ordered or as shown on the drawings.
2210. RATE
The contract unit rates for masonry, concrete, reinforcement and
weep holes shall include all works as given in respective sections of
these specifications and cover all incidental items for furnishing and
providing substructure as mentioned in this Section.
<< 532
Concrete Superstructure
2300
Concrete Superstructure
<<
Concrete Superstructure Section 2300
2301. DESCRIPTION
The work shall cover furnishing and providing of concrete super-
structure in accordance with the drawings as per these specifications or
2302. MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2303. GENERAL
2303.1. A method statement for construction, indicating the follow-
ing, shall be submitted by the Contractor for approval of the Engineer,
well in advance of the commencement of the construction of superstruc-
ture
i) Sources of Materials
ii) Design, erection and removal of fonnwodc
iii) Production, transportation, laying and curing of concrete
iv) Prestressing sysiem, if applicable
v) Personnel employed for execution and supervision
vi) Testa and sampling procedure
vii) Equipment details
viii) Any other point
2303.2. 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.
2303.3. The work shall conform to the following sections besides
stipulations in this section with regard to specific type of construction:
i) Formwosk Section 1500
ii) Strel Reinforcement Section 1600
iii) Structural Concrete Section 1700
iv) Prestressing Section 1800
Additionally, some of the common types of superstructure construc-

tion shall have features as discussed in this Section.
2304. REINFORCED CONCRETE CONSTRUCTION
2304.1. Solid Slabs
Where adjacent span of slab has already been cast, the expansion
joint and filler board shall be placed abutting the already cast span which
535
<<
Section 2300 Concrete Superstructure
shall form the shutter on that side of the new span to be cast. The
whole of the slab shall be cast with reinforcement embedded for the
road kerb and railings. No other construction joint shall be allowed except
with the express permission of the Engineer.
Where wearing coat is required to be provided, after the deck
slab has been cast, 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.
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.
Where the slab is resting on bearings, the same shall be placed
in position in accordance with the drawings, before casting of deck slab.
2304.2. RCC 1-Beam and Slab
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 m~aybe provided at the junction of the web and the
fillet between the web and the deck slab with the permission of the
Engineer.
The portions of deck slab near expansion joints shall be cast
alongwith reinforcements and embedments for expansion joints. For this
purpose, the portion of deck slab near expansion joints may be cast
in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true
to lines and levels as shown on the drawings before the concrete
has hardened. Care shall be taken for setting of bearings as indicated
on the drawings.
2305. PRESTRESSED CONCRETE CONSTRUCTION
2305.1. PSC Girder and Composite RCC Slab
PSC Girder may be precast or cast-in-situ as mentioned on the
drawing or as directed by the Engineer. Girders may be post-tensioned
or pre-tensioned. Where precast construction is required to be adopted,
selection of casting yard and details of methodology and of equipment
for shifting an~J launching of girders shall be included in the method
statement.
<< 536
Cuncrete Superstructure Section 2300
In case of cast-in~~situ
construction, the sequence of construction in-
cluding side shifting of girders, if applicable, and placing on bearings
shall be in accordance with the drawings.
The PSC girder constituting the top flange, web and the bottom
flange shall be concreted in a single operation without any construction
joint.
The portions of deck slab near expansion joints shall be cast along-
with reinforcements and embedments for expansion joints. For this
The surface finish of the deck slab shall be finished rough but
true to lines and levels as shown on the drawings before the concrete
has hardened, Care shall be taken for setting of bearings as indicated
on the drawings.
2305.2. Box Girder
Box girders may be simply supported or continuous. Simply
supported box girders shall have minimum construction joints as
approved by! the Engineer. In the case of continuous box girders the
sequence of con~tructionand location of construction joints shall strictly
follow the drawings.
The box section shall be constructed with a maximum of one con-
struction joint located in the web below the fillet between the deck
slab and web. If permitted by the Engineer, one additional construction
joint may be permitted and this construction joint shall be! located
in the web above the fillet between the soffit slab and web.
The portions of deck slab near expansion joints shall be cast
alongwith reinfotcements and embedments for expansion joints. For this
The surface finish of the deck slab shall be finished rough but true
to lines and levels as shown on the drawings before the concrete
has hardened. Care shall be taken for setting of bearings as indicated
on the drawings.
2305.3. Cantilever Construction
Continuity~of untensioned reinforcement from one segment to the
next must be ensured by providing full lap length as necessary.
<< 537
Section 2300 Concrete Superstructure
The design of the superstructure shall take into account the following
aspects which form an integral part of the construction operations
a) Stability against overturning for each statical condition through which the
assembly passes, shall be checked.
b) Stresses at each preceding segment joint with the addition of evesy segment or
change of statical conditions shall be checked, The load of equipment as well
as construction live load shall be taken into accotmL
c) Precanibenng of the superstructure during construction shall be done in such a
manner that the finally constructed structure under permanent load attains the
final profile intended in the drawings.
2306. TOLERANCES
2306.1. Precast Concrete Superstructure
Variation in cross-sectional dimensions
a) upto and including 2m : ±5 mm
over 2m ±5 mm
b) Variation in length overall and length between shall not exceed ±10mm
bearings or ±0.1per cent of the
span length, whichever
is lesser
c) Permissible surface irregularities when measured
with a 3 m straight edge or template 5 mm
2306.2. Cast-in-Situ Superstructure
a) Variations ir~thickness of top and bottom slab -5 mm to +10 mm
for box girders, top and bottom flange for
T.girders or slabs
b) Variations in web thickness -5 mm to +10 mm
c) Variations in overall depth or width ±5 mm
d) Variation in length overall and length between shall not exceed +10mm
bearings Or ±0.1per can of the
span length, whichever
is lesser
e) Permissible surface irregularities when 5 mm
measured with a 3 m straight edge or template
2307, TESTS AND STANDARDS OF ACCEPTANCE

The work shall conform to these specifications and shall meet the
<< 538
Concrete Superstructure Section 2300

Concrete in superstructure shall be measured in accordance with
Section 1700, based on the quantity ordered or as shown on the
drawings.
Steel reinforcement (untensioned) in superstructure shall be measured
in accordance with Section 1600, based on the quantity ordered or as
shown on the drawings.
High tensile steel (prestressing) in superstructure shall be measured
in accordance with Section 1800, based on the quantity ordered or as
shown on the drawings.
2309. RATE
The contract unit rates for concrete, steel reinforcement (unten~
sioned) and high tensile steel (prestressing) shall include all works as
given in respective sections of these specifications and cover all incidental
items for furnishing and providing superstructure as mentioned in this
section.
<<
Surface and Sub-surface
Geotechnical Exploration
2400
Surface and Sub-surface
Geotechnical Exploration
<<
Surface and Sub-surface Section 2400
Geotechnical Exp’oration
2401. GENERAL
2401.1. The objective of sub-surface exploration is to determine
the suitability or otherwise of the soil or rock surrounding the foundation
and soil parameters and rock characteristics for the design of foundation
by in-situ testing or testing of sampIe~’corestaken out of exploration.
The sub-surface exploration shall be planned in such a way that different
types of soil upto the desired depth and their profile for the full proposed
length of the bridge can be recorded and other information such
as mechanical and physical properties like grain-size distribution, sen-
sitivity, any existence of deleterious material in soil or ground water,
etc., are determined alongwith soil parameters and rock characteristics.
The sub-surface exploration shall also throw light on porosity of rock
and subsidence due to mining, ground water level, artesian condition,
if any, likely sinking and driving effort, likely constructional diffi-
culties, etc.
2401,2, Field Investigation
Field investigations of sub-surface has. usually three phases
i) Reconnaissance
ii) Preliminary Explorations
iii) Detailed Explorations
2401.2.1. Reconnaissance includes a review of available topo-

graphic and geological information, aerial photographs and data from
previous investigations and site examinatiorr.
2401.2.2. Preliminary investigation shall include the study of
existing geological information, previous site reports, geological maps,
air photos, etc. and surface geological examination. For large and
important structures the information may be supplemented by geophysical
methods. In some cases where no previous sub-strata data are available,
exploratory geophysical investigation may need to be supplemented
by resorting to a few bore-holes. These will help to narrow down the
number of sites under consideration and also to locate the most desirable
location for detailed sub-surface investigation like bore or drill holes,
sounding probes, etc.
2401.2.3. The scope of detailed investigation for bridges may be
decided based on data obtained after preliminary investigation. Based on
data obtained after preliminary investigations, the bridge site, type of
543
<<
Section 2400 Surface and Sub-surface Geotechnical Exploration
structure with span arrangement and the location and type of foundations,
shall be tentatively decided. Thereafter, the scope of detailed inves-
tigation including the extent of exploration, number of bore-holes,
type of soundings, type of tests, number of tests, etc., shall be decided,
so that adequate data considered to be necessary for the detailed
design and execution, are obtained.
2401.2.4 The width of exploration One purpose of ‘detailed
exploration for high embankments is to ascertain the average shear
strength of each strata. The other purpose is to ascertain the
compressibility of the clayey strata. It is, therefore, necessary that
detailed and well illustrated description of the characteristics of
stratification should be prepared. After the general shape and trend of
the boundaries of the various soil deposits have been determined and
rough assessment of their strength has been made by sUb-surface
sounding, with or without sampling in exploratory boring, the location
of bore-hole(s) for undisturbed sampling shall be decided. At least
one representative undisturbed sample should be collected from each
strata, When the homogeneous strata is very thick, one representative
sample shall be collected for each 3 m thickness of the strata.
2401.3. Soil investigation for foundations shall contain a programme
for boring and retrieval of samples. The field work shall consist of
excavation, drilling of bore-holes for the purposes of collection of
undisturbed and disturbed samples, standard penetration tests, in-situ vane
tests, static and dynamic cone penetration tests, other field tests, as
specified by the Engineer and preparation of bore-logs. Collection and
preservation for testing of disturbed and undisturbed samples from bore-
holes, borrow pits, etc., as specified by the Engineer shall form a part
of the above. All in-situ tests shall be supplemented by laboratory
investigations. Relevant Indiab Standards such as 15:1498, IS:1888,
IS: 1892, 15:2131, IS:2132, IS:2720, 15:4434 and IS:4968 and Appendix
I of IRC:78, etc., shall be followed for guidance.
2401.4. The soundings by dynamic method shall be carried out
in bore-holes using a standard sampler as specified in IS:2131.
2402. PRELIMINARY INVESTIGATION
2402.1. Foundations
2402.1.1. Preliminary exploration shall be carried out to determine
the soil profile showing the boundaries between the different soil types
and between loose and dense parts in the same type of deposits.
<< 544
Surface and Sub-surface Geotachnical Exploration Section 2400
For guidance reference may be made t~LRC:75. For this purpose, as

a first step, a suitable type of sub-surface sounding (e.g. static or dynamic
cone penetration test) shall be carried out. As many soundings as
necessary should be made, until the penetration data is complete enough
to leave no doubt concerning the general shape and the trend of
boundaries of the various soil deposits. Exploratory drill holes should
then be made at one or two locations where average condition prevails
and near those few points where the penetration diagrams indicate
maximum deviations from the average.
2402.1.2. The exploration shall cover the ~ntirelength of the bridge
and also extend at either side for a distance about twice the depth
below bed of the last main foundations. If there is any necessity for
designing investigation for approaches particularly on soft soil or with
high embankment or there is a possibility of considering alternatives
between via~luctor earthen embankment, the extended length ançl
location of the borings beyond the proposed .iccation of abutment
should be determined and executed.
2402.1.3. The depth of exploration should be at least iV2 times
the minimum width of foundation below the proposed foundation level.
Where such investigation end in any unsuitable or questionable foundation
material the exploration shall be extended to a sufficient depth into
firm and stable soils or rock but not less than four times the minimum
depth of foundation below the earlier contemplated foundation level.
In case of good sound rock the stipulation of minimum depth ma~
be decreased based on difficulty to conduct core drilling and the
minimum depth may be resthcted to 3 metres.
2402.2. Guidebund and Embankment
The depth of exploration should include all strata likely to affect
stability of the embankment, guide bund and/or cause undesirable
settlement. In general, the requirement of settlement governs the depth
of exploration for high embankments in particular. However, borings
can be terminated at shallower depths when firm strata or bed rock
is encountered. Ordinarily, the boring shall be taken to a depth of at
least 1.5 times the height of embankment and guidebund. However,
where highly compressible strata are encountered, the boring may have
to be taken deeper. In order to ensure that farm strata is sufficiently
thick, the boring should extend 3 metre into the firm strata.
<< 545
Section 2400 Surface and Sub-surface t3coteclmical Exploration
2403. DETAILED EXPLORATION
2403.1. The exploration shall cover the entire length of the bridge
and also extend at either end for a distance of about twice the depth
below bed of the last main foundation to assess the effect of the approach
embankment on the end foundations. Generally the sub-surface inves-
tigations (preliminary and detailed) for bridges shall extend to a depth
below the anticipated foundation level equal to about one and a half
times the width of the foundation. However, where such investigations
end in any unsuitable or questionable foundation material, the exploration
shall be extended to a sufficient depth into firm and stable soils or to
rock.
2403.2. The type and extent of exploration shall be divided into
the following groups as per requirement of foundation design and
likely method of data collection
i Foundation requiring shallow depth of exploralion
i~) Foundation requiring large depth of exploration
iii) Fills behind abutments and protection wo~ts
24033. Location Boring

Where the data made available by detailed exploration indicates
appreciable variation or where variations in a particular foundation
are li~el’,to appreciably affect the construction (specially in case
of bridge foundations resting on rock), it will be necessary to resort
to additional bores/soundings to establish complete profile of the
underlying strata, The additional borings /soundings shall be decided
depending upon the extent of variation at a particular foundation
location and should cover the entire area of the particular foundation.
2403.4. Construction Stage Exploration
Whenever a change in the sub-soil strata/rock profile is encountered
during construction, explorations shall be resorted to establish the correct
data for further decisions.
2403.5. Logging of bore..holes by radio-active methods shall be done
for detailed investigations as specified in the contract or in spe-
cial provisions.
2403.6. For bridge works, the investigations shall be comprehen-
sive enough to, enable the designer to estimate or determine the fol-
lowing
i) the engineering properties of the soit/rodç
546
<<
Surface and Sub-surface Geotechnical Exploration Section 2400
ii) the l~cationand extent of soft layers and gas pockets, if any, under the hard
founding strata,
iii) the geological condition like type of rock, faults, fissures or sabsidence due to
mining, porosity etc.,
iv) the ground water level,
v) artesian conditions, if any,
vi) quality of water in contact with the foundation,
vii) the depth and extent of scour,
viii) suitable depth of foundation,
ix) the bearing capacity of the foundation,
a) probable settlement and probable differtstial settlement of the ‘foundations,
xi) likely sinking or driving effort, and
xii) likely coustmction difficulties.
2404. EXPLORATION FOR BRIDGE FOUNDATIONS REST-

ING ON ROCK
2404.1. Investigation and interpretation of data for rock is
a specialised work. To arrive at the characteristic strength of rock
mass, reliance shall be placed more on in-situ tests in comparison
to laboratory tests. An engineering geologist shall also be associated
in the exploration programme.
2404.2. Identification and classification of rock types for engineering
purposes may in general be limited to broad, basic geological classes
in accordance with accepted practice. Strength of parent rock alone
is of limited value because overall characteristics depend considerably
on character, spacing and distribution of discontinuities of the rock
mass, such as the joints, bedding planes, faults and weathered seams.
An important factor affecting the behaviour is the weathered zone at top.
24043. Basic Information Required from Explorations
i) Depth of rock strata and its variation ovdr the site,
ii) Whether isolated boulder or massive rock formation,
iii) Extent and character of weathered zone,
iv) Stmcnue of rock. including bedding planes, fauks, fissures, solution cavities etc.,
v) Properties of rock m si-strength, geological formation, etc.,
vi) Erodibilily of rock to the extent possible.
vii) Colour of water.
<< 547
Section 2400 Surface and,Sub-surface Geotechnical Exploration
2404.4. Exploration Programme
If preliminary investigations have revealed presence of rock
within levels where the foundation is to rest, it is essential to take up
detailed investigation to collect necessary information mentio~ied in
clause 2404.3. The exploratory bore-hole shall be drilled into the rock
to a depth of about 3 metres to distinguish a boulder from a continuous
rock formation.
2404.5. The extent of exploration shall be adequate enough to
give a complete picture of the rock profile both in depth and across
the channel width to assess the constructional difficulties in reach-
ing the foundation levels.
2404.6. The depth of boring in rock depends primarily on local
geology, credibility of the rock, extent of structural loads to be
transferred to foundation etc. Normally, it shall pass through the upper
weathered or otherwise weak zone, well into the sound rock. Minimum
depth of boring in sound rock shall be 3 metres.
2404.7. Detailed Investigation for Rock
2404.7.1. This covers sounding, boring and drilling. An adequate
investigation programme shall be planned to cover the whole area for
genera! characteristics and in particular the foundation location, to
obtain definite information regarding rock-depth and its variation over
the foundation area. The detailed programme of exploration will depend
on the type and depth of over-burden, the size and importance of
the structure, etc. To decide this, geophysical methods adopted
at the preliminary investigation stage will be helpful, this data being
supplemented by sounding, bore-holes and .drill holes.
2404.7.2. Drilling through rock is a very specialised work and every
care shall be taken to notice and record any small change during
drilling. The time required to drill through a certain depth, amount
of core recovery, physical condition, length of pieces of core~.joints,
colour of water residue, weathering and evidence of disturbance and
other effects shall be carefully noticed and entered in the drilling
log. For guidance, IS:5313 may be referred to. The data shall
be presented in accordance with 15:4464.
244)4.7.3. The cores shall be stored properly in accordance with
JS:4078.
<< 548
2404.7.4. The rock cores obtained shall be subjected to following

laboratory tests:
i) Visual identification for texture, stmctuie, composition, colour and grain size.
ii) Laboratory tests shall be done for specific gravity, porosity and moisture content.
2404.7.5. In-situ tests shall be made in accordance with IS:7292;
IS:73l7; and IS:7746. In addition, laboratory tests can also be made
on samples.
2404.7.6. Usc of in-situ tests for measuring strength and deforma-
tion characteristics shall be made. Use of bore-hole photography will
be desirable to evaluate the presence of faults, fissures or cavities,
etc..
2404.8. Special Cases
2404.8.1. Investigation for conglomerate : A drill hole shall be
made same as for rock. The samples collected shall be subjected to
suitable tests depending upon the material, special care shall be taken
to ascertain erodibility of the matrix. Where possible, specially for
shallow foundation, Plate Load Test shall be conducted.
2404.8.2, Investigation for laterites : The investigation shall be
generally similar to that required for cohesive soils, use of penetration
tests shall be preferred, if suitable correlation charts are available. This
may be static or dynamic penetration tests or vane shear tests. In the
case of hard laterite, recourse may have to be made to core drilling
as for soft rocks. For laterites at shallow depths, use of Plate Load
Test may be advantageous.
2404.9. Caution
2404.9.1. The interpretation of laboratory results on rock samples
depends upon the relationship of the specimens tested to the overall rock
characteristics, enumerated in Appendix 1 of IRC:78. For this purpose,
care shall be exercised in the choice of specimen size and its orientation
in relation to the joint pattern.
2404,9.2. In some cases, the foundation behaviour will be dominated
by a possible mode of failure involving movement along some joint
surface, fissures or weak layer within a generally strong rock system
and also by possible weathering. In-situ shear tests may be conducted
wherever feasible, as such tests are likely to give more representative
data than the shear tests conducted on core samples.
<< 549
Section 2400 Surface and Sub-surface Geotecimical Exploration
2404.10. Presentation or Data
The data shall be given in diagrammatic form in 3 sheets giving
the following details
Sheet 1: Plan showing the position of bore-holes clearly marked
so as to fix the position at a future date.
Sheet 2 : This shall contain the bore-log chart and test results of
the samples separately for each bore-hole/pit etc.
Sheet 3 : This shall contain pictorial representation of the bore-
log data to get an overall picture of the soil profile at the cross-
section of the river.
NOTE : For guidance, refer to lRC:78~.
2405. BORING
Boring shall be done by any of the following methods depending
on the soil type and types of samples required for the investigation:
i) Auger Boring
ii) Shell and Auger Boring
iii) Percussion Boring
iv) W.jh Boring
v) Rotary Boring
For preliminary and detailed sub-surface investigation only
rotary drills shall be used. The casing shall also be invariably provided
with diameters not less than 150 mm upto the level of rock, if any.
However, use of percussion or wash boring equipment shall be permitted
only to penetrate through bouldery or gravelly strata for progressing
the boring but not for the collection of samples. While conducting
detailed borings, the resistance to the speed of drilling i.e. rate of
penetration, core loss, etc., as already specified in Appendix 3 of IRC:78
shall be carefully recorded to evaluate the different types of strata
and to distinguish specially sand from sandstone, clay from shale, etc.
2406. RECORDS OF BORINGS AND TRIAL PiTS
2406.1. The field records for the preliminary and detaIled explo-
ration shall contain the date when the boring was made, the location
of the boring with reference to a permanent system of co-ordinates and
the elevation of the ground surface with respect to a permanent
bench mark. They shall include elevation at which the water table axtd
the upper boundary of each of the successive soil strata were encountered,
<< 550
the investigator’s classification of the layer on the basis of general

information obtained from field examination (refer to Appendix 2.1 of
IRC:75) and the value of the resistance obtained by means of Standard
Penetration Test. The type of tools used for borings shall be recorded.
If the tools were changed, the depth at which the change was made
and the reason thereof shall also be noted. Incomplete and abandoned
borings shall be described with no less care than successfully completed
drill holes. The notes shall contain everything of significance observed
on the job such as the elevation at which wash water was lost from
the hole.
2406.2. For all borings and. trial pits, necessary information as
detailed below shall be given. A site plan showing the disposition of
the bore holes shall also be attached
a) Agency
b) Location with reference map
c) Pit1Bor~-ho1enumber
d) Reduced level (RI.) of ground suiface or other reference point
e) Dates of starting and completion
0 Name of supervisor
g) Scales of p’ans and sections
It) Dimensions, methods of advancing exploration such as by hand tools, blasting.
boring, etc.
i) Generaldescriptionofatratametwith and RLs at which they are met
j) Position and ahitude of contaas, faults, strong joint, slidcen sides, etc.
k) Inflow of water, methods of controlling the water, required capacity of pumps
for dewatering
I) Thelevelatwhichthe sub-soil water is met with
m) Dip and strike of bedding and of cleavage.
n) Visual description of strata
o) Results of field tests e.g. SPT, in-situ vane shear test etc.
p) Any other information and remarks.
2406.3. Upon removal of sampling tube, the length of the ~imple
in the tube and the length between the top of the tube and the top
of the sample in the tube shall be measured and recorded.
2407. METHODS OF SAMPLING
There are two types of samples viz. (a) Disturbed sample (b)
<< 551
Undisturbed sample. The usual methods for sampling conforming to

IS:1892 and IS:2132 are given below
Nature of Ground Type of Sample Method of Sampling
Soil Disturbed Hand Samples
Auger San~ples
~ Shdl Samples
Undisturbed Hand Samples
Tube Samples
Rock Disturbed Wash Samples from
percussion or rotary drilling
Undisturbed Cores
2408. PROCEDURE FOR TAKING SAMPLES

2408i. For proper identification of sub-surface material, sample
should be recovered containing all the constituents of the materials in
their proper proportion. In clayey deposits such samples could be collected
by split spoon samplers. In the case of sandy deposits, sampling spoons
shall be fitted with suitable devices for retaining samples. All
data required for soil identification (Appendix 2.1 of IRC:75) should
be collected from the samples so extracted when undisturbed samples,
which are more desirable for collection of some of the data, are not
available. Penetration test should be carried out with the standard split-
spoon sampler or penetrometers if the soil is coarse grained. When it
is known in advance that the soil profile is fairly regular, preliminary
and detailed investigation may be combined. Tube samplers can be used
in place of split spoon samplers for collecting samples in clayey strata.
2408.2. Disturbed Soil Samples
2408.2.1. Disturbed samples of soil shall be obtained in the
course of excavation and boring. For procuring samples from below the
ground water level, where possible, special type of sampler shall be
used. Where Standard Penetration Test is conducted, representative
samples shall be obtained from the split spoon. While collecting
disturbed samples from borrow areas it shall be ensured that the samples
‘collected represent all types of borrow materials to be used in the
construction of embankment and sub-grade.
2408.2.2. The size of sample generally required shall be as given
in Table 2400-1.
<<
552
Surface and Sub-surfale Geotechnical Exploration Section 2400
TABLE 2400-1 SIZ~OF SOIL SAMPLE REQUIRED
S. No. PURPOSE OF SAMPLE SOIL TYPE WEIGW.1 OP SAMPLE
REQUIRED Kg
I. Soil identification, Cohesive soils 1
natural moisture Sands and
content tests, Gravels 3 ‘
mechanical analysis
and index properties,
• chemical tests
2, Compression testS Cohesive soils
and sand 12.5
3. Comprehensive Cohesive soils 25 - 50
examination of and sands
construction material Gravelly soil 50 - 100
and borrow area soil
including soil ‘
stabilisaticn
2408.2.3, While taking out disturbed soil samples, Standard Pene-

tration Test may also be conducted to find out the bearing capacity
of the sub-soils at specified levels.
2408.3. Undisturbed SoØ Samples
24083.1. The location of the bore-hole shall be as indicated
on the drawing or given by the Engineer.
The depth of the bore-hole shall be as indicated on the drawing
or shall be governed by the criteria given therein or as directed by the
Engineer.
24083,2. Samples shall be obtained in such a manner that their
moisture content and structure do not get altered. This may be ensured
by careful protection and packing and by use of correctly designed
sampler.
2408.3.3. Standard Penetration Test may have to be conducted in
each case to obtain additional data as directed by the Engineer. In soft
clay, in-situ vane shear test as per JS:4434 may have to be conducted.
Where all the three operations have to be carried out in one layer, the
sequence shall be undisturbed soil sampling followed by in-situ vane
shear test, followed by Standard Penetration Test.
2408.3.4. For compression test samples, a core of 40 mm diameter
and about 150 to 200 mm length may be sufficient, but for other
laboratory tests, a core of 100 mm diameter and 300 mm length
<< 553
shall be taken as far as possible, unless otherwise specified by the
Engineer.
2408.3.5. The upper few millimetres of both types of sample shall
be rejected as the soil at the bottom of the bore hole usually gets
disturbed by the boring tools.
2408.4. Rock Samples
2408,4.1. Disturbed samples: The sludge from percussion borings
or from rotary borings which have failed to yield a core, shall be
collected for a disturbed sample. It may be recovered from circulating
water by settlement in a trough.
2408.4.2. Undisturbed samples Block samples taken from the rock
formation shall be dressed to a size of about 90 x 75 x 50 mm.
For core samples - cores of rock shall be takth by means of
rotary drills fitted with a coring bit with core retainer, if warranted.
2408.4.3. In case of rock at shallow depths which can be
conveniently reached, test pits or trenches are the most depend-
able and valuable methods since they permit a direct examination
of the surface, the weathered zone and presence of any discontinuities.
It is also possible to take representative samples for tests. For guidance,
IS:4453 may be referred to.
2409. PROTECTION, HANDLING AND LABELLING OF
SAMPLES
2409.1. Care shall be taken in handling and labelling of samples
so that they are received in a fit state for examination and testing and
can be correctly identified as coming from a specified trial pit or
boring.
2409.2. The disturbed material in the upper end of the tube shall
be completely removed before applying wax for sealing. The length
and type of sample so removed should be recorded.
2409.3. The soil at the lower end of the tube shall be reamed
to a distance of about 20 mm. After cleaning, both ends shall be sealed
with wax applied in a way that will prevent wax from entering the sample.
Wax used for sealing should not be heated to more than a few degrees
above its melting temperature. The empty space in the samplers, if any,
should be filled with moist soil, saw dust, etc., and the ends covered
with tight fitting caps.
<< 554
2409.4. Labels giving the following information should be affixed

to the tubes
a) Tube number
b) Job designation
c) Sample location
d) Boring number
e) Sample number
f) Depth
g) Penetration
h) Gross recoveiy ratio
The tube and boring numbers should be marked in duplicate.
Duplicate markings of the boring number and sample number on
a sheet which will not be affected by moisture should be enclosed
inside the tube.
2410. TESTS FOR EXPLORATION OF SHALLOW
FOUNDATIONS OF BRIDGES
2410.1. Test pits or trenches are the most dependable and valuable
methods of exploration since they permit direct visual examination
and more reliably the type of soil and their stratification. This will also
allow in-situ tests like plate bearing tests, shear tests and uni-axial
jacking tests, etc.
2410.2. Tests shall be conducted on undisturbed samples, which
may be obtained from çpen pits. The use of Plate Load Test (as per
15:1888) is considered desirable to ascertain the safe bearing pressure
and settlement characteristics. A few exploratory bore holes or soundings
shall be made to safeguard against presence of weak strata underlying
the foundation. This shall extend to a depth of about P12 times the
proposed width of foundation.
The laboratory results shall correlate with in-situ tests like Plate
Load Tests and Penetration Test results.
2411, TESTS FOR EXPLORATION FOR DE1~PFOUNDA-
TIONS OF BRIDGES
2411.1. The tests to be conducted at various locations for properties
of soil, etc., are different for cohesive and cohensionless soils. These
are enumerated below and shall be carried out, wherever practicable,
according to soil type.
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555
• ••_&..•.—•— - .•
2411.1.1. Cohesionless soil

a) aassifkation tests, density, etc.
b) Field tests.
- Plate Load test as per IS:l88&
• Dynamic Penetration test as per IS:2l31 and Use of Dynamic Cone
penetration test as per 15:4968 (Part I or Pan 2) may be conducted where
considered appropriate
c) Laboratory tests : Sharing strength test - triaxial or box shear test - in case of
the possibility of rise of water table, the tests shall be done on sawrated samples.
2411.1.2. Cohesive soils -
a) Classification tests, density, etc.

b) Field tests
- Plate Load Test.
- Unconfined Compression Test as per 15:2720 (Part 10).
- Vane Shear Test as per 15:4434.
- Static Cone Penetration Test (15:4968 Part 3),
c) Laboratory tests : Shearing strength test - triaxial tests (15:2720 Part 9). Consoli-
dation Test (15:2720 Part 15)
Note : Where dewatering is expected, samples may be tested for
permeability (15:2720 Part 17.).
2411.2. The sub-surface exploration for bridge works can be divided
into 3 zones
i) between bed level and upto anticipated maximum scour depth (below H.F+L.)
ii) from the maximum scour depth to the foundation level.
iii) from foundation level to about P4 times the width of the foundation below it.
2411.3. The sub-soil water shall be tested for chemical properties
to ascertain the hazard of deterioration to foundations. Where dewatering
is expected to be required, permeability characteristics shall be deter-
mined.
2411.4. For the different zones categorised in pant 2411.2 the data
required, such as soil classification, particle size distribution, shearing
strength characteristics, method of sampling disturbed and undisturbed
samples, testing, including particle size distribution, shear strength, un-
confined compression test, shall be complied with.
2412. TESTING OF MATERIAL FOR GUIDE BUND AND
HiGH EMBANKMENT AND ITS FOUNDATIONS
2412.1. The soil properties for the embankment foundation shall
be as specified in particular specifications and shall be got verified
556
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prior to construction operation. In case the actual soil properties

do not match the particular specification, then embankment design shall
be revised.
2412.2. Field investigation for the embankment material should be
carried out to collect general information as indicated in IRC:75. For
details refer to Clause 305.
Field investigatior.s for sub-soil strata shall consist of taking minimum
two bore holes for each approach to a bridge along centre line of the
alignment at a distance of 50 m and 120 m behind the abutment positions
on both sides. The depth of bore holes below the ground level Enay
ordinarily be 2.5 times the maximum height of the embankment subject
to minimum depth of 20 m. Thin walled sampling tubes of 100 m~n
internal diameter and 450 mm minimum length conforming to IS:2132
shall be used for collecting undisturbed samples from bore-holes
at an interval of 2.5 to 3.5 m. Standard penetration test should be
conducted immediately after undisturbed sample is collected.
2412.3. In addition to the relevant identification tests, mentioned
in IRC:75, it shall be necessary to conduct some of the following
tests on the undisturbed samples collected from the sub-strata. The
choice of test is primarily determined by the type of soil, type of stability
analysis (vide Table 2400-2), availability of apparatus and cost of
investigation.
TABLE 2400.2 SHEAR STRENGTH TESTS FOR STABILITY ANALYSIS
S. Stage in LIfe Strength Shear Test Type of

No. of Embankment Parameters Analysis
1. (a) During construction Unconsolidated undrained Total

or immediate triaxial shear test on stress
post-construction undisthibed samples analysis
cuu, ~uU and on compacted
embankment material
1 (b) — do — S~ Unconlined compression — do —
test in laboratory or
vane shear test
I (c) During construction c~’ Consolidated undrained Effective
or immediate test with pore-pressure stress
post-construction measurement on as analysis
compacted soil samples of
embankment materials and on
undisturbed samples
2. Long term stability C~ — do — — do —
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Section 24(X) Surface and Sub-surface Geotechnical Exploration
2412.4. Laboratory Investigations of Embankment Material

2412.4,1. The following tests should be conducted on representative
samples of embankment material
S. NO. TEST TEST METHOI)
I) Gradation Test (Sieve Analysis) 15:2720 (Part 4)
ii) Aucrberg Limit Test IS:2720 (Part 5)
iii) Standard Proctor Test IS:2720 (Part 7)
iv) Natural Moisture Content 15:2720 (Part 2)
2412.4.2 In addition to the above, there is need for shear strength
tests on compacted samples of the fill material. For this purpose, the
relative compaction should be 95 per cent of the Standard Proctor
maximum dry density and moisture content, same as that likely to prevail
in the embankment during the period covered by the stability analysis
or to be used in the field during construction. Undrained test shall
be run on cohesive soils and sheer strength parameters should be
ascertained for the ranges of normal pressures which are likely to be
experienced in the field. In cases where effective stress analysis is
required to be done, pore-pressure measurements should also be made
during the undrained tests and effective strength and pore-pressure
parameters should be found out. For fill material of cohesionless soils,
a direct shear box test (!S:2720-Part 13) may be conducted to ascertain
shear strength of soil.
2412.4.3. The results of reconnaissance, field and laboratory
investigations for embankments shall be consolidated into a well-knit
report. The record of findings and recommendations, if any, may be pre-
sented in the form of written test, graphs, figures and tables, as
appropriate for different types of data and findings.
Information and data to be contained in the report should include
general location map, pertinent geological information on reconnaissance
observations, sub-soil profile (Fig. 2,1 of IRC:75), boring logs and
summary of sub-soil properties (Fig. 2.2 of IRC:75), graphs and tables
related to laboratory investigations, results of borrow area investigations
(Fig, 2.3 of IRC:75) and recommendations, if any.
The undisturbed samples shall be collected from each layer of
sub-soil unless the stratum is such that undisturbed samples cannot
be collected using ordinary sampler. Where indicated by the Engineer,
undisturbed samples shall be collected using piston sampler or core-
cutter or such special devices. In thick layers undisturbed samples shall
be collected at 3 m interval.
558
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In case of bridge and road structures, the work of boring and
trial pits shall be considered as incidental to the foundation works
and nothing extra shall be paid unless otherwise specified in the contract
In cases where it is specified to be paid separately, like contract for
soil investigation, the work shall be measured in running metres for
boring, in cubic meters for trial pits, in number of samples for collection
of disturbed and undisturbed samples and in number of tests for each
type of test.
2414. RATE
The contract unit rate shall include the cost of all labour, materials,
tools and plant an5 equipment required for doing the boring or making
pits as per these specifications, taking out and packing the samples,
sending and getting them tested in approved laboratories and making
available the test report as specified or directed by the Engineer inclusive
of all incidental costs to complete the work as per the specifications.
559
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River Training Work
and Protection Work
2500
River Training Work
and Protection Work
<<
River. Training Work Section 2500
and Protection work
2501 DESCRIPTION
River training and protection work shall include construction of guide
bunds, guide walls, bank protection, flooring and approach embankment
protection as required for ensuring safety of the bridge structure and
its approaches against damage by flood/flowing water. Construction
of various components shall conform to IRC:89 and these specifications
or as directed by the Engineer.
2502. GUIDE BUND
2502.1. This work shall consist of construction of embankment of
guide bund and provision of pitching/rivetment on slopes, apron, toe
protection, curtain walls etc. as indicated on the drawing in accordance
with these specitkations or as approved by the Engineer.
The provisions given hereunder are applicable only to guide bunds
for bridges across alluvial rivers. Guide bonds for bridges across
submontane rivers shall call for supplemental specifications.
2502.2. The alignment and layout of guide bund shall be as indicated
on the drawing or as approved by the Engineer. The construction of
embankment for guide band shall conform to provisions of SecLion 300
of these Specifications. Pitching, filter underneath pitching and turfing,
apron, toe protection, curtain walls, etc., shall be as per these specifi-
cations.
2502.3. Guide bands shall generally be made of locally available
materials from the river bed preferably cohesionless materials. Trial pits
shall be taken in borrow holes to examine suitability of soil for
construction and also to decide the types of earth moving machinery
to be arranged. The borrow pits should be sufficiently away from
the location of the launching apron. No borrow pits should be dug on
the river side of the guide bunds.
Construction of guide band shall be taken in hand alongwith the
construction of the bridge. Every effort shall be made to complete
the work of the guide bund in one working season. Where there is any
doubt about completion of the whole guide bund within one working
season, suitable measures shall be planned and executed for protection
of completed work. In such cases the construction of guide bund shall
be started from abutment towards upstream.
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Section 2500 River Training Work & Protection Woat
2502.4, Construction of apron and pitching of the guide bonds shall
generally confonu to clause 2503 and 2504 of these Specifications.
Sufficient, length of pit along the guide bond shall be ready within
one to two months of commencement of work so that the placing
of stones in the apron and in the slope pitching can be commenced.
As a guideline, earthwork should be completed within 80 per cent
of working season and about 70 per cern working season shall be
available for laying apron and pitching. No portion o the guide bond
should be left below HFL before the onset of monsoon.: Bottom of
apron pit shall be as low as permitted by sub-soil waler/lowest water
level. Sufficient labour and appropriate earth moving machinery and
trained staff shall be deployed in construction.
2502.5. The Contractor shall furnish his planning for approval of
the Engineer regarding transport of stones from the quarries to the
site of work inking into account the quantities of stone required to be
transported every day, train/truck, etc., deployed, available ferry or boats
and labour available for loading and unloading and fbr laying within the
time frame for construction of guide bond. Adequate reserve of stones
should be maintained for major works as decided by the Engineer.
Reserve stones shall be stacked far away from the main channel of
the river.
2502.6. Where the alignment of guide bond or the approach
embankment crosses a brunch channel of the river, the branch channel
may be either diverted to the main channel of the river with the help
of spurs, etc. or closed by a properly designed closing dyke or
closure bund before taking up construction of guide bond.
2503. APRON
2503.1. General
This work shall consist of laying boulders directly or in wire
crates on the bed of rivers for protection against scour
Where the required size of boulders are not available economically,
cement concrete blocks of equivalent weight shall be used. The grade
of concrete shall be M 15 nominal mix, (This holds good for pitching
on slopes and flooring also). Cement concrete blocks shall be preferred
where practicable.
The stones used in aprOn shall be sound, hard, durable and fairly
regular in shape. Stone subject to marked deterioration by water or
weather shall not be used.
564
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River Training Wait & Protection Work Section 2500
Quarry stones are preferable to round boulders as the latter roll off
easily. Angular stones fit into each other better and have good interlocking
characteristics.
Where the required size stones are not economically available,
cement concrete blo~ksin Ml 5 grade conforming to Section 1700 or
stones in wire crates in combination may be iLsed in place of isolated
stones of equivalent weighL Cement concrete blocks will be preferred,
wherever practicable.
25032. Laying Boulder Aproth
The size of stone should conform to clause 5,3,7,2 of IRC:89.
The size of stone shall be as large as possible. In no case any
fragment shall weigh less than 40 kg. The specific gravity of stones
shall be as high as possible and it shall not be less than 2.65.
To ensure regular and orderly disposition of the full intended
quantity of stone in the apron, template cross walls in dry
masonry shall be built about a metre thick and to the full height of the
specified thickness of the apron at intervals of 30 metres aft along the
length and width of the apron. Within these wails, the stone then shall
be hand packed.
The surface on which the apron is to be laid shall be levelled
and prepared for the length and width as shown on the drawings. In
case the surface on which apron is to be laid is below the low water
level, the ground level may be raised upto low water level by dumping
earth and the apron laid thereon. The quantity of stone required in
the apron shall be re-worked out by taking the toe of pitching at higher
level.
2503.3. Laying Wire Crates and Mattresses in the Apron
Wire crates shall be made from hot dipped galvanized mild steel
wi:re of diameter not less than 4 mm in annealed condition having tensile
strength of 300450 ItPa conforming to IS:280. The galvanizing
coating shall be heavy coating for soft condition conforming to 15:4826.
The mesh of the crate shall not be more than 150 mm,
Wire crates for shallow or accessible situations shall be 3 metre x
1.5 metre x 1.25 metre in size. Where these have to be deposited
and there is a chance of overturning, the crate shall be divided into ii
metre compartments by cross netting.
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ccc
Section 2.5(X) River Training Work & Proteaion Work
For deep or inaccessible situations, wire crates can be made

smaller subject to the approval of the Engineer.
Wire dates built in~-s’itu, shall not he larger than 7.5 metres x 3
metres x 0.6 metre, nor smaller than 2 metres x 1 metre x 0.3 metre
Sides of large crates shall be securely stayed at intervals of
not more than 1 .50 metres to prevent bulging.
The netting shall be made by fixing a row of spikes on a beam
at. a spacing equal to the mesh. The beam must be a little longer
than the width of netting required. The wire is to be cut to lengths
about three times the length of the net required. Each piece shall be
bent at the middle around one of tt~e.~spikesand the weaving commenced
IrVin one corner,
A double twist shall he given at each intersection. This twisting shall
he carefully done by means of a strong iron bar, five and half turns
being given to the bar at each splice.
The bottom and two ends of the crate or mattress shall he macIc
at one time. The. other two sides shall he made separately and shall
he secured tn the bottom and the ends by twisting adjacent wires together.
‘The top shall he made separately and shall be fixed in the same manner
as the sides after the. crates or mattress have been filled.
Wherever possible, crates shall be placed in position before
filling with boulders. The. crates shall be filled by carefully hand~packing
the boulders as. tightly as possible and not by merely throwing in
stones or boulders.
For laying of wire crates in aprons of bridges, two situations arise:
i) Where the crates arc to be bid in deep water and have to be dumped and then
joined together.
ti) Where depth of water is tow or dry bed is avaitabte, tn such cases, the crates
can be laid at site.
2504. PITCHING / REVETMENT ON SLOPES

2504.1. Description
This work shall consist of covering the slopes of guide hunds,
training works and road embaukments with stone, boulders, cement
concrete blocks or stones in wire crates over a layer of granular material
called filter. While river side slopes are given this protection against
river action, the rear slopes, not subjected to direct attack of the river,
<<
River Training Work & Protection Work Section 2500
may be. protected against ordinary wave splashing by 0.3M.6 metre thick
cover of clayey or silty earth and turfed.
2504.2. Pitching/Filter media
2504.2.1. Pitching : The pitching shall be provided as indicated in
the drawings. The thickness and the shape of stone pitching shall he
shown on the drawing.
The stone shall be sound, hard, durable and fairly regular in shape.
Quarry stone should be used. Round ho ulders shall not he. allowed. The
stone.s subje.ct to marked deterioration by water or weather shall not he
accepted.
Thes ize and weight of stone shall conform to clause 5.3.5.1 of
l.R,C:89. No stone, weighing les~sthan 40 kg shall, however, he used.
The s. izes of spalis ,sha,I I be a minimum of 25 mm and shall he suitable
to fill the. voids in the pitching.
Where. t.he required size stones are not economically available.,
cement concrete blocks in MIS grade conforming to Section 17(X) or
stone.s in.wire crates may be used in place of isolated stones of equivalent
weight. Cement concrete blocks will be preferred wherever practicable..
Use of geosynthetics has been dealt with in Section 700.
2504,2.2, Filter media : l’he material for the filter shall consist of
s.and, gravel, stone or coarse sand. To prevent escape of the embankment
material through the voids of the stone pitching / cement concrete blocks
as well as to allow free movement of water without creating any uplift
head on the pitching, one or more layers of graded materials, commonly
known as a filter medium, shall be provided underneath the pitching.
The gradation of the filter material shall satisfy the following re~
quircme.nts
Provision of a suitably designed filter is necessary under the slope
pitching to prevent the escape of underlying embanktnent material
through the. voids of stone pitching/cement concrete blocks when suh~
jected to the attack of flowing water and wave action, etc. In order
to achieve, this requiretnent, the filter may be provided in one or more
layers satisfying the following criteria
D 15 (Filter)
<5
D 85 (Base)
(Filter) < 20
D 15 (Base)
<< 567
Section 25(X) River Training Work & Protection Work
D 50 (Filter)
‘—<25
D 50 (Base)
Notes I. Fitter design may not be required if embankment coon us or cit or Ch
soits with liquid timit greater than 30, resistant to nsirrace erosion. to
this case, if a tayer of material is used as bedding for pitching, it shall
be welt graded and its It) 85 size shatt be at teast twice the nsaximum
void size in pitching.
2. tn the foregoing, 0 15 means the size of that sieve which attows 15 per
cent by weight of the fitter materiat to pass through it and simitar is
the meaning of t) 50 and 1. 85.
3. tf more than one fitter tayer is required, the same requirement as atxsve
shalt be fottowed for each tayer. The finer fitter shatt be considered as
tsase materiat for selection of coarser fitter.
4. The fitter shatt be cotnpacted to a fimi condition. The thickness of ntter
is generally of the order of 200 mm to 300 nun. Where titter is provided
in two tayers, thickness of each layer stsatt be 150 mm..

Before laying the. pitching, the side.s of banks shall he trimmed to
the required slope and profiles put up by means of line and pegs at
intervals of 3 metres to ensure regular straight work and a uniform.. slope
throughout. Depressions shall be’ filled and thoroughly compacted.
The. filte.r granular material shall he laid over the prepared base and
suitably compacted to the thickness .specified on the drawings.
The lowest course of pitching shall he started from the toe wall
antI built up in courses upwards. The toe wail shall he in dry mhhle.
masonry (uncoursed) confonning to ‘Clause 1405.3, in case of dry rubble
pitching and shall be in nominal mix cement concrete (M 15) conforming
to Clause. 1704.3. in case. of cement concrete block pitching.
The stone pitching shall commence in a trench below the toe of
the slope. Stone shall he placed by derrick or by hand to the required
length, thickness and depth conforming to the drawings. Stones shall
he set normal to the. slope, and placed so that the largest dimension
is: perpendicular to the face of the slope, unless such dimension is
i.,,reater than the specified thickness of pitching.
The largest stones shall be placed in th,e bottom courses and for
use as: headers for subsequent courses.
in ha.nd placed pitching, the stone of flat stratified nature should
he placed with the principal bedding plane normal to the slope. The
pattern of laying shall be such that the joints are broken and voids
<< 568
River Tfaining Work & Protection Work Section 2500
are minimum by packing with spalls, wherever necessary, and the top
surface is as smooth as possible.
When full depth of pitching can be formed with a single stone,
the stones shall be laid breaking joints and all interstices ‘between
adjncent stones shall be filled in with spalis of the proper size and
wedged in with hammers to ensure tight packing..
When two or more layers of stones must be laid to obtain the
design thickness of pitching, dry masonry shall be use.d and stone.s
shall he well bonded. To ensure regular and orderly disposition
.
of the full intended quantity of stone as shown, template cross walls

in dry masonry shall be built about a metre wide and. to the full
he.ight of the specified thickness at suitable intervals’ and all along
the length and width of. the pitching. Within these walls the stones:
shall he hand packed us specified.
2504.4. Toe Protection
in conformity with clause 5.3.7. of IRC:89, a toe wall shall he
provided at the junction of slope pitching and launching apron of a guide
hund so as to protect the slope pitching from falling even when the
apron is not laid at low water level. The toe wall shall he in dry rubble
masonry (uncoursed) conforming to Clause 1405.3 in case of dry rubble
pitching or pitching! revetment with stones in wire crates and in nominal
mix cement concrete (M 15) conforming ‘to Clause 1704.3 in case ce.n’tent
concrete blocks have been used in pitching. For protection of toes of
hank slopes terminating either in short aprons at bed levels or anchored
in flooring / rocky bed, the provisions of clause 8.2.2 of 1RC:89 may
he complied with, The relevant specifications of the protective works
br individual components will be followed.
2505. RUBBLE STONE/CEMENT C ONCRETE BLOCK
FLOORING OVER CEMENT CONCRETE BEDDING
2505,1. This work shall consist of constructing ntbble stone / c.c.
block flooring laid over a cement concrete (M 15) bedding. The floor
protection will comprise rigid flooring stated above with curtain walls
.and flex ible apron.
Excavations ‘for laying the bedding and floor protection works shall
he carried out as per specifications un.der proper supervision. BefOre
laying the foundation and protection walls, the excavated trenches shall
he. t.horoug,hly inspected by the Engineer’in..Charge to ensure that
<< 569
.Sc.ct’iot’s 250t) River Training Work & Protection Worrk
a)i’he.re are no too.se t~cketsand unfitted depressions teft in the stench.

h) The soit at the founding tevct is property compacted to tnie tines and level so
as to have an even bedding..
c) Att concrete and oiher ete.rnents are taid in dry bed.
Cement concrete nominal mix (grade M ‘15) of 300 mm thickness

shall then be laid in accordance with provisions given in Section 1700
c~.xeeptthat the surface of the concrete. shall not be given a smooth
finish, ‘The p.aving work shall he embedded in green concrete.
1”lcioring shall consist of 150 nim thick flat stone/cement concrete
blocks (Nominal’ mix Grade. M 15 conforming to Section 1700). it shall
he bedded on a layer of ceme.nt mortar (1:3) prepared to Clause I 3&4.
Spalls shall be used to fill in the voids. The joints shall then be. filled
with cement mortar and finished neat. The stone shall hre..ak joints
and the joints shall not excee.d 20 mm in thickness. Spacing of joints
may he 20 m or so. The top of flooring shall be kept to 3.00 mm below
the. lowest bed level.
2506, I)RY RUBBLE FLOORING
This work shall consist of constructing dry rubble flooring at cross
drainage works for relatively less important works.
The. base for the flooring shall be prepared to the specified levels’
and slopes and compacted suitably with hand rammers or other ;neans
to have an even bedding.
The thickness ol’ flooring shall be made with one stone only. The
stones shall then be laid closely on the prepared base in one or more
layers as specified and the bond used shall be. as specified by the Engineer.
2507, CURTAIN WALL AND FLEXIBLE APRON
2507.1. Curtain Wall
The. rigid flooring shall be enclosed by curtain walls (tied to the.
wing walls) with a minimum depth below floor level of 2 in on upstream
side and 2.5 m on downstrea.m side.. The curtain wall ‘will be in cement
concrete. M 15/stone masonry in cement mortar 1:3. The rigid flooring
shall he continued over the top width of curtain wall.
2507.2. Flexible Apron
Flexible. apron 1 m thick comprising lose stone boulders (weighing
not less than 40 kg) shall be. provided beyond curtain walls for a minimum
distance of 3 m on upstream side. and 6 m on downstream side. The
<<
570
River Training Work &. Protection Work Section 2500
work of floor protection shall be simultaneously completed alongwith the
work on bridge, foundations.
‘the materials shall. he tested in accordance with. these Specifications
and shall mee.t the prescribedl criteria.
“the work shall conform to these Specificatkns and shall meet the
p~’e.serihed standards of acceptance.
The protection works’ shall he measured as’ se.t forth be.!o’w. if
directed by the. Engineer for me.asure.n’tent, the materials may have to
best.ack.e.d at site before laying and nothing extra will he paid to
the Contractor for this stacking.
The earth work in construction of embankment for guide hued shall
‘he measured in cubic me.tre.s unless otherwise specified.
The boulders/cement concrete blocks and wire crates in a.pron shall
be measured in cubic metres.
The filter arid stone pitching shall be measured separately in cuhie
n’ie.u’e.s unless’ otherwise specified.
Rubble stone/ee.me.nt concrete blocks, flooring and cement con.
crete bedding shall be mea.stired in cubic metres for each class of material.
Preparation of base for laying the f.ooring shall be deemed incidental
to the work,
For laying apron, e.xcavation upto an average depth of 150 mm shall
he deemed to he included in the main item and shall not be measured
separately unless otherwise specified, Excavation more t.han 150 mm
shall he measured in cubic metres as given in Clause 304.
2510. RATE
The. contract unit rate for the construction of embankment for
guide bund shall cover the cost of all materials including transportation,
laying, compacting, all labour, toEs, equipment, sampling and testing,
supervision and all incidentals necessary for completing the work
according to these specifications.
The contract unit rate for one cubic metre of finished work of apron
shall include the cost of all material, labour, tools and plant fo~completing
the work according to above specifications. Fxeavation upto an average
depth of 150 mum shall also be deemed to be included in the rate. its
.571
<<
Section 2500 River Training Work & Protection Work
dressing of the bed, Excavation beyond this depth shall be paid for
separately unless otherwise specified.
The contract unit rate for one ctibic metre of filter or sto.e/cement
concrete block pitching on slopes shall include the cost of preparing
the b:ases, putting to the profiles, laying and compacting the filter
and s.tone pitching of dry rubble/cement concrete block rivetment for
embankment slopes to the specified thickness, lines, curves, slopes and
ieve.is and all labour and materials as well as tools and ‘plant required
for the work,
The contract unit rate for rubble stone/cement concrete b~ock
flooring shall include the cost of all material, labour and tools and plant
for completing the work as per these specifications.
<<
Expansion Joints
2600 ‘
Expansion Joints
<<
Expansion Joints Section 2690
260!. DESCRIPTiON
This work shall consist of fabrication and placing of expansion
mints as indicated on the drawing and conforming to these speci~
fica.tions or as directed by the Engineer.
2602. GENERAL
a) The expansion ~omu shalt be designed and duty got approved try the Engineer.
It ehalI cater for expected movement and rotation of the ssmcture at the
~ and provide smooth riding surface, It shatt atso be easy for inspection,
snaintcnance and replacement.
h) hxpans~ossjoints shalt be robust, durabte, water~might and reptaceable. Site
fabricated expansion joints shall be prohibited. ‘Expansion joints shatt be obtained
by the Engineer either directly or through the Contractor from approved
manufacturers and beof proven type.
c) For bridges with prestreesed concrete superstructure, with individual span length
snore than 2.0 m or built with innovative designfeonstruceion etastomeric e spansion
joints of slab seat or strip seat type shatt be provided..
Foe slab type of bridges of spans less than tO metres continuous surfacing
may tat provided across the expansion gaps, suppo:rted on a 20 mm thick plate
placed and fised at the level of the deck stab,
c) For brid,gcs other than ttsose ntentioned in (c) abeve with spares atseve 1
an alternative specification of stiding steet plate joint or filled joints with copper
plates may at so he adopted if approveat by the Engineer, apan ‘1mm elastosneric
expansion joint of stab seal or strip seat type.
1) Vctticular traffic shatt not he allowed over expansion joints after its constmc.tion
for such period as may be detemsirsed by the Engineer.
iø Proprietary type deck joints offered by the Contractor in tieu of th’e type speciliect
shall cossepty irs alt respects with the manufacturer’s specifications and meet
the required range of movements and rotations and be fit for the purpose of
ensur.ing satisfactory long tersrs performance its the bridge.
Where alternative type proprietary deck joints are proposed hy the
Contractor, the following information shall be provided.
i) Name and location of itse proposed manufacturer.
ii) Dimensions and general details of mite joint including material tpeci fication.s,
ltotding down belt or anchorage details and instáttation procedures.’
iii) [ividence’ .of satisfactory perfomsanm under similar envirormsenmal conditions of
similar joints being produced by the manufacturer.
.Any acceptance of alternative types will be at the sole discretion

of the Engineer,
Such deck joints shall be installed in accordance with the manu~
575
<<
Section 2600 Expansion Joints
facturer’s recommendations and to the general requirements of this Speci-

flcation.
No expansion joint shall be provided only for the width of the
carriageway. It shall follow the profile including the kerb and the
footway and facia., if provided. The type of expansion joint for the latter
may he made different from that used for the carriageway expansion joint.
2603. REQUIREMENTS
2603.!. The requirement criterion will be separately applicable for
the expansion joint proper and the transition zone of attachment to the
deck,
2603.2. There are two types of performance requirements for the cx.
pansion joint proper viz, from the necessity of the bridge and from the
road users e.g. man, animal and vehicle.
2603.3, Performance Requirement with Respect to Bridges
The expansion joint shall
a) Withstand the imposesi toad inclusling the impact load frotn live toami anti other
sources.
h) Allow expansion and contraction movement due to temperatstre, creep, shrinkage,
preatretting and structural deformations.
c) Permit relative rotation in elevation and plan due to the causes as noted akove,
d) Be waterproof. Bridge deck expansion joint seals play a critical role in preventing
the degradation of the stmctsaral components of the bridge system. Without
effective joint seals, water passes through the bridge deck and works harmfully
to corrode steel components and cause deterioration of the concrete. Rain water
gathers various corroding additives from the atmosphere and also from the
carriageway.
e) Ensure seating. In case bridge deck joints are not seafed, apart from tots of
waterproofing, grit and other forms of road debria may enter the joint Debris,
when ‘unpacted with the joint can seriously restrict the moventent instead of
facilitating the same, In the case of proprietary joint.s being accepted for
adoption,’ the sealing shall be as specified by them,
I) Ensure long life by being resistant to corrosion
1
g) Be easy so install,
h) Be easy to maintain. Replaceability of expantion joint shall be one of the basic
criteria for selection of type of expansion joint,
i) Be resistant to the materialt likely to collect/spill over the deck in its normal
service.
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<<
2603.4. Performance Requirement with Respect to User
a) Provide smooth continuity at the top of the deck for riding comfort,
5) Be of skid resistant surface,
c) Be non-damaging to the rubber tyre,
d) Make minimusn noise during vehicular crosaing,
e) Ensure that animal paws and hooves should not gee entangled where bridges are
used by animal drawn traffic,
t) Permit passing of bullock cart steel tyre for bridges where bullock carts ply,
g) Look good aesthetically.
2603.5. Performance Requirement for Transition Zone
It is the zone of connection of joint a.ssernbly and the adjoining deck.
a) Permit transfer of generated forces without distress, i.e,, without getting uprooted.
The puwoae will not be served if the bonding is with the wearing coat only.
Anchorage must he provided with the deck atnicwral element,
b) Ensure that surface in the transition zone stays undisturbed during long term
service,
2604. STEEL PLATE SLIDING EXPANSION JOINTS
a) In this type of buried joint, the wearing coat shall be made continuous over the
joint. The other altemative shall be to keep a gap in the wearing coat which
is filled up with a seal and filler, to be provided in extremely hot areas,
b) Materials for steel plates shall conform to Section 1900. The exposed metallic
components ~hall be galvanised or coated with approved anti-corrosive painL The
thickness shall be 20 mm or so for obtaining satiafactory perfonnance.
c) Plates shall be placed to the line, grade and expansion gap shewrs on the drawings
with any adjustment required for temperature, particular care being taken ~ith
the top of the plates.
d) Plates shall be firmly held in place during concreting by methods approved by
the Engineer.
e) Any temporary bolts or other fixings which prevent relative movement of the
adjacent pasts of the joint shall be removed as soon as the concrete has set
sufficiently so hold the expansion plates in their correct positions. In any case,
temporary bolts or other fittings shall be removed within 6 hours of placing
concrete unless otherwise directed by the Engineer.
Q Care shall be taken to prevent damage to expansion joint plates or its coating.
g) if any damage occurs, the plates and coatings shall he restored by the Contractor
to the satisfaction of the Engineer.
h) Plates shall be free ofoil, nan, loose paint or other similar material before coating.
<< 577
Section 26(X) Expansion Joints
2605, FILLER JOINTS

a) The components of this type of joint shall be at least 2 rem thick corrugated
copper plate placed slightly below the wearing coat, 20 mm thick compressible
fibre board to protect she edges, 20 mm thick pre-moulded joins filler filling the
gap upto the top level of the wearing coat, sealed with a joint sealing compound.
h) The material used for filling expansion joins shall be bitumen impregnated felt.
elastotner or any other suitable material, as specified on the drawings.! impregnated
felt shall conform to the requirements of iS~1838, and shall be got approved
front the Engineer. The joint filler shall consist of large pieces and assembly of
small pieces to make up the required size shall be avoided,
c) Expansion joins mttteriais shall be handled with care and stored under cover
by the Contractor to prevent damage.
d) Any damage occurring after delivery shall be made good to the satisfaction of
the Engineer and at the expente of the Contractor.
e) Joint gaps shall be constructed as shown on the drawings. Surfaces of ~oinr
grooves shall be thoroughly cleaned with a wire brush to remove all loose
materials and dirt and debris, then washed or jetted out..
f) Pte.mnoulded expansion joint filler shalt not be placed in position until immediately
prior to the placing of the abtrtting material. If the two adjacent surfaces of
the joint are to be placed at different times, this type of joint filler shall not
be placed until the second face is about so be placed.
g) Sealants shall b. installed in accordance with the manufacturer’s recommen-
dastons and all appropriate requirements for joins face priming.
h~i Sealants shall be finished approximately 3 runt below the upp.r surfaces of the
!joint.
i) Joint materials spilt or splashed oito finished surfaces of the bridge during joint
filling operations shall be removed and the surfaces made good so the Engineers
approval.
No joins shall be sealed until inspected by the Engineer and approval is given
to proceed wish the work,
2606. ELASTOMERIC SLAB SEAL EXPANSION JOINT
2606.1. MateriaLs
a) Steel inserts shall conform to IS ~226.Use of any other materials like fibre-glass
or similar material shall not he permitted.
b) Elastomer for elastosnerie slab unit (11513) shall conform to clause 915.1 of
IRC:83 (Part Ii), compounded to give hardness IRIID 60 ~5, subject to the
following additional stipulations
i) Chloroprene (CR) only shall be used in the manufacture of elastomeric ex-
pansion joints. No reclaimed/natural rubber or vulcsnised wastes shall be
used.
ii) The chloroprene material ttsed in the manufacture of elassomeric (expansion
joints) shall be Neoprene WRT, Rayprene 110, Skyprene 85 or Derrka 5-
40V.
<< 578
Expansion Jotnts Section 2600
iii) Chioroprene content of the compound shall tsot be lower than 6111 per cent
by weighs. The ash content shall not exceed 5 pr cent (as per tests cortducsed
in accordance with ASTM D.297 fin (1) and (ii) above.
iv) EPDM, and other similar candidate etastoroers for etpansion joints shall
not be permitted.
c) Elastomeric plugs.
d) Spacer hers, marked with centre to centre distance of fixing holes.
e) Fixing bolts and nuts ntade of stainless steel.
11) Anchor bars comprising hooked anchor stiffenert welded !with lower steel inserts
and sinusoidal anchor bars welded with horizontal leg of the edge steel inserts!,
‘i’he elaborate anchoring arrangements of steel inserts shall be pennanently welded]
tied witlt the steel reinforcetnenL
2606.2. Fabricatkyn
a) Steel inserts shall be grit blasted and provided with epoxy paint.
b) Edges of reinforcing steel sections shall be rounded,
c) Expansion joints shalt be fully moulded to the required size in one single
vulcanising operation including the encasing layers! ~t integral and homogeneous
part
st) Tolerances of fabrication shall be at follows
i) Plan dimension .> ±5 mm
ii) Total height -> ±3 mm
2606.3. Supply and Handling

i) The Contractor shall supply all steel-reinforced elastomeric expa:os!iort joints
including bolts, nuts, sealant, plugs and all other accessories for the effective
installation of the joints including angled jointing sections for kerbs.
ii) Expansion joins material shall be handled wish care and stored under cover by
the Consractor to prevent damage. Any damage occurring after delivery shall
be made good at site expense of the Contractor so the satisfaction of the Iin!gineer.
2606.4.1, Expansion joints shall be installed as per approved
drawhtg. Steel inserts, spacer bars, concreting of pockets, fixing of
eiaslonie,r slab unit and presetting!, etc., shall be done as per the following:
a) Steel inserts
i) Deck casting shall be done leaving pockets or recess For steel inserts
and anchors of the expansion joint as per drawing.
ii) Steel insetis shall be towered as the appropriate locasion inside !the pocket.
iii) The sop of the inseti shall be flush with the finished level of wearing course
maintaining the camber,
iv) Spacer bars, duly set appropriately to the month of installation!~!shalthe
fisted under proper supervision.
<< 579
v) Anchor rods shall be tied/welded with the existing deck main reinforcement,
mainsaining level and alignment
vi) Welding between anchor rods and deck reinforcement is preferable.

If welding is not possible, strong steel sie wires shall be used for fastening,
under proper supervision.
b) Spacer Bar
i) Spacer bars shalt be used to ensure proper positioning of bolts and also
levelling of the steel inserts during fixing of the same with the deck
reinforeemens and catting second stage concreting in the pocket thereafter,
ii) The 2nd stage concreting operation shall preferably he started within
24 hours of firing the steel inserts. In such cases, spacer bars should
be removed just after concreting is finished. If there is a substantial time
lag between fixing of inserts and concreting, then any one of the following
methods shall be adopted, depending on the support condition
a) For simply supported bridge resting on simple elastomeric bearings,
(with no dowel pins), insert shall be placed in position with spacer
bars at every altemasejoinis. Such joints shall be called restrained
joints hereafter. in other words, mserts shall not he fixed simnulsa-
rseously at swo ends of one span. If the above condition is satisfied,
interts with spacer bars shall he kept in position for a substantially
longer period at such restrained joints. Spacer bars shall he removed
after concreting of such restrained joints and inserts placed in position
with spacer hems at the other unrestrained joints thereafter.
h) For bridges resting on other than elassomeric bearings (including
hearings with dowel pins at one end), after placing and aligning
the inserts and securing the same, the spacer bars shall he removed,
Concreting shall be done with great care so that inserts are not
dislocated or distorted.
iii) While removing the spacer bar after concreting, one must take care so see
that the concrete is not datnaged during withdrawal of spacer bar. If the
spacer bar happens to be snugly fisted, it shall not be pulled by any means;
it shall he gas cut in two pieces and then removed.
c) Concreting of Pocket
i) Concreting of pocket shall be done with greas care using proper mix
conforming so grade similar to that of the deck casting besides ensuring
efficient bonding besween deck and steel insert. Also proper r.are shalt be
given for ensuring efficient bonding with the already cast concrete.
ii) Needle vibrasors shall be used. Care shall be saken so thas the position of
steel insert is not disturbed during vibration.
iii) Spacer bar shall he resnoved within an appropriate time before the joint
is required to pennis nsovenaent
d) Fixing of Elastosnerie Slab Unit (ESIJ)
i) Special jig shall be used to preset the ESU during installation.
ii) ESU (mounted on the jig, if preses) shall be lowered to position.
<<
580
iii) The line and level on the ESU should he adjusted.
iv) ESU shall be removed and coated with special adhesive
v) ESU shalt he placed in position again, ensuring waterproof joining at
required faees.
vi) ESU shall he tightened with stainless steel nuts and lock washers in
position. Tightened nuts shall be locked with lock washers,
vi) Special sealant shall be poured inside the plug holes.
vii) The etastotneric plugs shall be pressed in position after applying adhesive
on the appropriate surface.
viii) ESU shall he fined in position after completion of wearing course. While
completing this part of the wearing course, adequate care shall be taken to
ensure a waterproof joining with she already existing wearing course.
e) [‘re-Setting
i) The main purpose of presetting of the steel insens as the time nf its
installation is to ensure as closely as possible the condition that in the
long nsn as the mean average annusl temperature, the ESU remains at
its nominal stare.
ü) Major factors responsible for changing the longitudinal length of the
bridge superstructure are indicated below
a) Temperasure variation from annual mean,
b) Changes due to shrinkage of concrete~
c) Changes due to elastic shortening and creep of the prestressed bridge
superstrucsure.
d) Deformation of superstructure and substructure, if any.
Resultant changes in expansion gap due to first factor can occur in both
directions from any pre-selected mean position whereas changes due to
creep and shrinkage are unidirectional such that the expansion
gap continuously increases with passage of time,
The steel insert unit of expansion joint can be fixed in any

month of the year, As stated earlier, the expansion gap betwen bridge
superstructure may vary from time to time; hence the initial fixing
distance between fixing points will obviously depend on the month
of installation of steel insert. The c/c distance between stainless steel
fixing of bolts as indicated in the drawing can be taken as only
nominal. The same shall be modified by presetting depending on
i) The difference hesween the mean temperature of she month of fixing of
steel insert and the annual average temperasure.
ii) The elapsed period besween the casting and/or prestresaing and fixing of
steel insert for calculating the remnant creep and shrinkage.
<< 581
Section 261X1 Expansion Joints
2606.4.2. Special requirements for installation

i) [‘nor to csnistnction of bridge deck area adjacent to the joint, the supplier
shall provide detailed working drawings showing the location of all bolts, recesses
and holes necessary for the installation of the joint. Reinforcing bars in
.supenstntcsume shall be amended as required to ensure that there will be no
interference in the installation of she joint.
ii) All bearing surfaces and recesses which are in contact with the joint assembly
shall he checkesl with a straight edge to ensure flatness of profile.
ins) No boles shall he sIn lIed for firing bolts within 7 days of concreting Holes for
the bolts shall he drilled to the size and depth shown on the drawitigs
iv) 5ecttons of the jointing making she completed joint shall follow a straight
line.
s) ‘l’he. fi sing, hulLs shall not lxi placed in a position sntil at least 4 weeks after
stressing is completed in pose-tensioned box or beam and slab stmctures.
Prior to placing sections of joinsing, contact surfaces shall he cleaned to remove
all grease, tar, paint, oil, mud or any other foreign material that may affcos
adhesion of the sealant.
ci) Sealsnt shall only he applied to dry contact surfaces. Sufficient sealant shall he
applied to the contact surfaces so cause extrusion of sealant when the jointing
is fised in position.
vii) Final scaling of the finished expansion joint shall be completed
immediately after completion of installation All exposed ends, joints between
units and other areas of possible leakage shalt be tilled with sealant. All voids
between she sides of she jointing and concrete or plates shall he filled with
sealant.
sin) Bolt cavities shall he cleaned and plugged wish neoprene cavity plugs Prior
to placing the plugs sufficient sealant shall he placed in the cavities to cause
extrusion of the sealant by the plugs.
ix) All escess sealant shall be removed from the jointing and adjacent areas.
2606.5. Acceptance Test

2606.5.1, As per clause 918,7 of IRC-83 (Part II), necessary quality
control certification by the manufacturer in regard to properties of
Elastomer and steel will be furnished.
For severe environmefit, ozone resistance test as per clause 915.2.3
of IRC:83 (Part El), shall be carried out for elastomer,
The properties of the elastomer shall conform to Table I of clause
915.2 of IRC:83 (Part II). The acceptance testing for elastomer material
shall conform to clause 91&4,l,2 of IRC:83 (Part II) with additional
criteria as stated in Clause 2005.
<< 582
2606.5.2. The fabricated expansion joint shall he subjected to

the frsflowing accepiance tests
i) Routine test.. Each expansion joint shall be tested for at least 100 cycles for
a teas movesnent which shall be 10 per cent more than the design expansion)
contradion mowesnent.
ii) In addition to routine test, one out of every 20 expansion joints shall he subjected
to the teat movement for 40(X) cycles.
The. lot shalt be rejected if the elastomer material shows signs of fatigue or
pesananent set or distress in the teat. The test piece shall not be used in the
bridge.
iii) The type test for abrasion resistance shall be carried out for one joint out of
every 20 not. as per 15:34(X) (Part 3) and the standard deviation shall be within
20 per cent
NJ3. The manufacturer shall preferably have in-house testing
facility. Otherwise, the testing shall be got done by him at his expen e.
at any testing establishment selected by the Engineer. A manufacttjrer
who cannot carry out the acceptance test shall not be entitled to supply
elastomeric slab seal joint...
2607. STRIP SEAL EXPANSION JOINT
26071. Components
Strip seal expansion joint shall comprise the following items
a) Edge beams This special claw leg profiled member shall be of extruded roiled
steel section combining good weldability with notch toughness.
b) Strip seal This shall be of dhloroprene with high tear strength, insensitive
to oil, gasoline, and ozone. It shall have high resistance to aging. This component,
provided to ensure water tightness, shalt have bulbous shape of the pan of the
seal which is inserted into the groove, provided in the edge beam, The seal shotsld
be vulc.anised in single operation for minimum full length of joint..
c) Rigid Anchorage - This shall be welded to the edge beam at staggered distance,.
toops - This shall be made of weldable steel connecting the rigid
ct) Anchor
anchorage with deck reinforcement.
2607,2. Material
a) Edge beams of this special section are at present being directly imported
in India. The steel shall conform to steel grade Rst 37-2 of German Standard
or eqtaivalenL
h) Chloroprene of strip seal shalt conform to clause 915.1 of D.C:83 (Past Ii). The
propertiea of chtoroprene ahait conform to Table 26OO~i.
c) Anchosage steel shall conform to 15:2062,
d) Anchor loop shall confonn to 15:2062,
583
<<
TABLE 2600-1. STRIP SEAL ELEMENT SPECIFICATION
Sealing element is made of chloropmne and must be a extruded
section. The working movement range of the sealing element shall bc
at least 80 mm with a maximum of 100 mm at right angles to the joint
and ±40mm parallel to the joint .
PROPERTY SPECIFIED VALUE
Hardness 63 ±5 Shore A
Tensile Strength Mm Ii MPa
Elongation at fracture Mm 350 per cent
Tear Propagation Strength
Longitudinal Mm 10 N/rnnt
Transverse Mm 10 N/mm
Shock Elasticity Mm 25 per cent
3
Abrasion Mm 220 mm
Residual Costpressive Strain
Max 28 per cent
(22 hT7O deg C /30 per cent strain)
Ageing in hot air
(14 day s/TO deg C)
Max ÷5Shore A
Change in hardness Max -20 per cent
Change in tensile strength
Max -20 per cent
Change in elongation at fracture
Ageittg in ozone
No cntcks
(24 h/5~phxttt25deg C/20 per cent strain)
Swelling behaviour in Oil
(116 h/25 per cern C) ASTM Oil no.
Max 5 per cent
Volume Change Max 10 Shore A
(hange in hardness
ASTM Oil no.3 Max 25 per cent
Volunte Change
Max 20 Shore A
Change in hardness
Mm -35 deg C
Cold Hardening Poirtt
2607.3. Fabrication (Pre-installation)
a) Rolled steel profiles for edge beams shall be long enough so cater for a 2-lane
carriageway. These shall be cut to size of actssal requirements by means of a
mitre box saw~Alignment of the cut-to-size steel profiles shall then be made in
accordance with the actual bridge cross~sectionon work tables. For this purpose,
the contour of bridge cross-section shall be sketched onto these tables. After
the steel profiles are aligned, they will be chucked to the tables by means of
screw clamps and tacked by arc welding.
h) Anchor plates shall be cut to the required size by gas cutting. These shall
be welded to the edge beams.
c) Anchor loops shall be bent to the required shape and welded to anchor plates!!
d) The finally assembled joints shall then be clamped and transported to the work
site.
584
<<
2607.4. Handling and Storage
a) For transportation and storage, auxiliary brackets shall be provided to hold the
joint assembly together.
h) ‘the
Bridgemanufacturer
Contractor allshall supply ofeither
stripdirectly to incltading
the Ergmeer
sealantsor and
to the
the materials seal joints all
other accessories for the effective installation of the jointing.
c) Expansion joint, material shall be handled with care. It shall be stored under
cover on suitable lumber padding by the Contractor to prevent damage. Any
damage occurring after delivery shall be made good at the Bridge Contractors
expense to the satisfaction of the Engineer.
26073.1. The width of the gap to cater for movement due to thermal
effect, prestress, shrinkage and creep, superstructure deformations (if
any) and sub-structure deformations (if any) shall he determined and
intimated to the manufacturer. Depending upon the temperature at wttich
the joint is likely to be installed, the gap dimension shall be preset.
26073.2. Taking the width of gap for movement of the joint into
account, the dimensions of the recess in the decking shall be established
in accordance with the drawings or design data of the manufacturer.
The surfaces of the recess shall he thoroughly cleaned and all dirt
and debris removed. The exposed reinforcement shall be suitably
adjusted to permit unobstructed lowering of the joint into the recess.
2607,5.3. The recess shall be shuttered in such a way that
dimensions in the joint drawing are maintained, The formwork shall
he tight.
2607,5.4, Immediately prior to placing the joint, the presetting shall
be inspected. Should the actual temperature of the structure be different
from the temperature provided for presetting, correction of the presetling
shall be done. After adjustment, the brackets shall be tightened again.
2607.5.5. The joint shall be lowered in a pre-determined position.
Following placement of the joint in the prepared recess, the joint
shall be levelled and finally aligned and the anchor loops on one side
of the joint welded to the exposed reinforcement bars of the structure.
Upon completion, the same procedure shall be followed for the other
side of the joint. With the expansion joint finally held at both sides,
the auxiliary brackets shall be released, allowing the joint to take up
the movement of the structure.
2607,5.6. High quality concrete shall then be filled into the recess.
The packing concrete must feature low shrinkage and have the same
<< 585
slrengl.h as that of the superstrnctnre, hut in any case not less than M
35 grade. (kxxl compaction and earefttl curing of concrete is particularly
irnportanl.. After the cnncrete has cured, the movable installation brackets
slill in place shall be removed.
2.607,5,7, Rolled up neoprene strip seal shall he cut into the required
length and inserted between the edge beams by using a crow bar pttshing
the bulb of the seal into the steel grooves of the edge beams. A landing
to a bead shall he formed in the thickened end of the edges of the
seal which would force the thickened end against the steel beam due
to wedge effect when the strip seal is buttoned in place.
26073.8. As soon as the concrete in the recess has become inttially
sel., a sturdy ramp shall be placed over the joint to protect the exp..sed
steel beams and neoprene seals from site traffic. Expansion joint shall
not he expose.d to traffic loading before the carriageway surfacing, is
placed.
26073.9. The carriageway surfacing shall he finished flush with the
top of the steel sections. The actual junction of the surfacing/wearing
coat with the steel edge section shall be formed by a wedge shaped
joint with a sealing compound. The horizontal leg of the edge beam shall
he cleaned beforehand. It is particularly important to ensure thorough
and careful compaction of the surfacing in order to prevent any
pretnature depression forming in it,
Acceptance Test
i) All steel elements shall be finished with corrosion protection system.
ii) For neoprene seal, the acceptance test shall conform to the requirements stipulated
srs Table 2600-1. It shall also be stretch tested, If a manufac.tnrer ia to supply
this type ofjoint, they will have to produce a test certificate accordingly conducted
in a recognised laboratory in India or abroad.
iii) In view of the imporlaasce of the built up edge beams, special investigation
of fatigue at.rengtla of this section wish anchorages to withstand 2 x 10’ load
change cyclea without showing signs of damage, will be required. The supplier
shall have to produce a test certificate in this regard, conducted in a
recognised laboratory, in India or abroad.
iv) The manufacturer shall produce test certificates indicating that anchorage system
had beers seated in a recognised laboratory to detennine optimum configura-
Sn of anchorage assembty under dynamic loading.
s) ‘l’he manufacturer shall satisfy the Engineer that water tightness test for
the type of joint has been carried out in a recognired laboratory so check the
water tightness under a water pressure of 4 bars.
vi) As strip seal type ofjoint is specialisal in nature, generally of the proprietary
<< 586
Expansion joLrtt.’~ Section 2600
ty ~ the manufacturer shall he rrei uired to produce cvidcncr ‘

1:”f stir tact’“ry
perfonnance of this type of joint
2608. TES1’S AND STANDARDS OF ACCEPTAN(.’F
The tnaterials shall be. tested in accordance web these spL,:cit’ira..
i ionsand shall meet the prescribed criteria.
The work shall conform to these spec ifications and shall meet the
2609. MEASUREM ENTS FOR PAYMENT
The. expansion joinl. shall be measured in rtinning metres. l::’ctr
iii led joints., the rate per running metre shall include the. cost of .sea Ian
br the depth provided in this drawing.
2610. RATE
‘t’he. contract unit rate shall include the cost of all material, lahous’,
equipment and other incidental charges for fixing the joints complete
in all respects as per these specifications in the case of Bridge. Contractor
supplyin~~, the expansion joint. If the. manufacturer supplies the expansion
joint dtreclly to the Engineer, the cost of installatton, handling and fixing,
shall he borne by the Bridge Contractor.
<<
587
Wearing Coat and Appurtenances
2700
Wearing Coat and
Appurtenances
<<
Wearing Coat and Appurtenances Section 2700
2701. DESCRIPTION
l’his work shall include wearing coat and bridge appurtenances’.
such as railing, approach slab, drainage spouts, weep holes in
conformity with details shown on the drawing and these peciftca-
tions or as approved by the Engineer.
2702. WEARING COAT
2702.1. Bituminous Wearing Coat
Specifications for bituminous concrete/bitumen mastic in wearing
coat shall conform to Section 500 except for the special require.-
mnents as stated hereinafter.
.2702.1.1. Principles of bituminous wearing coat shall ‘comprise.
the. following
i) A layer of mastic asphalt, 6 mm thick after applying a prime coat over the
top of the deck before the wearing coat is laid. The prime coat and the layer
of mastic asphalt shalt be laid as per Clauses 503 and 515 respectively.
ii) 50 mm thick asrthaltic concrete wearing coat in two layers of 25 rum each as
per Clause 512.
in cas.e of high rainfall intensity areas, the thickness of mastic as’phall
layer mnay be increased to i2 mm,
2702.1.2. For high traffic density, an alternative specification
br ‘wearing course comprising 40 mm bituminous concre..te.. ov’eri.aid
with ‘2.5 mm thick bitumen mastic layer can he adopted. The work shall
be done in conformity with Section 500.
270 2. Cement Concrete Wearing Coat
Cement concrete wearing coat may be provided in case of isolated
hri.dg.e construction or bridges ‘located in remote. areas. It shall not he
laid monolithic witll the deck.
The. l.hickness of wearing coat shall be 75 mm. The minim’tum grade
of concrete shall he M 30 with water cement ratio as 0.4.
Curing of wearing coat earlier than what is generally required
may be resorted to, so as to avoid formation of shrinkage cracks in hot
weather,
All carriageway and fo..tpath surfaces shall have non-skid charac-
teristics.
<< 591
Section 2700 Wearing Coat & Appurtenances
The cross slope in the deck shall be. kept as 2.5 per cent for
decks, level in longitudinal profile.
2702.3. For providing cross camber no variation in thickness of
wearing coat shall be permitted.
2703. RAILINGS
2703.1. General
a) Bridge railing includes the portion of the structure erected on and above
the kerb for the protection of pedestrians and traffic.
h) Railings shall not be cortstnicted until the centering falsewonlc for the
span has been released and the span is self-supporting. For concrete with steel
re:inforcenient, specifications of the items ofcontrolled concrete and reinforcement
mentioned under relevant sections of this specifications shall be applicable.
c) The type of railing shall be carefully erected true to line and grade. Posts shall
be vertical with a tolerance not to exceed 6 mm in 3 metres. The pockets left
for posts shall be filled up with non-shrinkable mortar
d) The type of railing to be constructed shall ‘be as shown on the drawings..
e) Care shall be exercised in assembling expansion joints in the tailings to ensure
that they function properly.
0 The bridge railings shall be amenable to quick repairs.
g) Railing materials, particularly metal railings, shall be handled and stored with
care, so that the material and parts are kept clean and free from damage.
Railing materials shall be stored above the ground on plstfonns, skids, or
other supports and kept free from grease, dirt and other contaminants.
Any material which is lost, stolen or damaged after delivery

shall be replaced or repaired by the Contractor. Methods of repair
shall not damage the material or protective coating.
2703.2. Metal Railings
Materials, fabrication, transportation, erection and painting for bridge
railings shall conform to the requirements of section 1900.
All complete steel rail elements, pipe terminal sections, posts, bolts,
nuts, hardware and other steel fittings shall be galvanised or painted
with an approved paint.
If galvanised, all elements of the railing shall be free from abrasions,
rough or sharp edges, and shall not be kinked, twisted or bent. If
straightening is necessary, it shall be done by methods approved by
the Engineer.
Damaged galvanised surfaces, edges of holes and ends of steel
railing cut after galvanising shall be cleaned and re-galvanised.
<< 592
Wearing Cost & Appurtenances Section 2700
The railing shall be carefully adjusted prior to fixing in place to

ensure proper matching at abutting joints and correct alignment and
camber throughout their length. Holes for field connections shall be
drilled with the railing in place in the structure at proper grade and
alignment.
Unless otherwise specified on the drawings, meta.l railing shall be
given on..e shop coat of paint and three coats of paint after erection
if sections are not galva.nised.
Railings shall not follow any irregularity in the alignment of the
deck, When shown on the drawings, the rail elements shall be curved
before erection.
2703.3. Cast-in-Situ Concrete Railings
The portion of the railing or parapet which is to he cast in
place. shall be constructed in accordance with the requirements for
Stntctural Concrete in Section 1700. The reinforcement shall conform
to Section 1600.
Forms shall either be of single width hoards or shall be. lined
with suitable material duly approved by the Engineer. Form joints in
plane surfaces will not be permitted.
All mouldings, panel work and bevel strips shall be constructed
according to the details shown on the drawings.... All corners in the
finished work shall be true, sharp and clean-cut and shall be free from
cracks, spalls or other defects. Casting of posts shall be done in single
pour,
2703.4.. Precast Concrete Railings
Precast members for railings shall be of reinforced cement
concrete and shall conform to the specifications given in See-
lions 1600 and 1700. The maximum size of the aggregate shall be
limited to 12 mm and the concrete grade shall be M 30. The precast
members shall be removed from the moulds as soon as practicable
and shall be kept damp for a period of at least 10 days. During this
period they shall be protected from sun and wind. Any precast member
that becomes chipped, marred or cracked before or during the’ process
of placing shall be rejected, Special care shall be taken to watch the
surface of the cast-in-situ portion of the deck.
2704. APPROACH SLAB
Reinforced concrete approach slab covering the entire width of the
<< 593
roadway shall he. provide..d as per details given on the drawings
or as approved by the Engineer. Minimum length of approach
slab shall be 3.5 m and minimum thickness 300 mm,
The cement concrete and reinforcement shall conform to Sections
1700 and 1600 respectively. The base for the approach slab shall he
as shown on l.he. drawings’ or as’ directed hy the Engineer.
2705.. DRAINAGE’ SPOUTS
27’05, I. ‘this work shall consist of furnishing and fixing in position
of drainage spouts a.~ddrainage pipes for bridge decks.
l)s am tv& don g km ~‘ ludt n il cIt ftt tson shall lx n suet ci by
.suUicicnt number of drainage fixtures embedded in the deck slab, The
spout’s shall he of’ not Ie.s.s than 100 mm in diameter and shall he of
corrosive resistant material such as galvanise.d steel with suitable. clean-
out fi,x owes. The spacing of drainage spouts shall not exceed 10 m.
“the. discharge from drainage s-pout shall he kept away from the deck
structure, In case. of viaduco in urban areas, the drainage spouts should
be connected with suitably located pipelines to clis’charge the surface
run -off to drains provided at ground level.
2705.2. Fabrication
The. drainage assemh]y shall be fabricated 1.0 the dimensions shown
on the drawings; all rn ater’i ~Js shall he corrosio’n resistant; stee
components shall he. of mild stee’ conforming to IS:’226, The drairtage.
asse.mhly shall be. seam ‘welded for u’ate.r tightness and then hofidip
galvanised.
2705.3. Placement
The galvanised assembly shall be given two coats of bituminous
painting’ befOre placenient. ‘The whole assembly shall he placed in true
position, lines’ and. levels as shown in the drawing ‘wit.h.oece.s.sary
cut-out i.n the shuttering for deck slab and held in place Firmly.
Where the reinforcements of the deck are required to be
cut, equivalent.
reinforcements shall be placed at the corners of the assembly.
2705.4. Finishing
Aflersetling of the deck slab concrete, the shrinkage cr.acks
around the. .asscmhly shall he totally sealed with polysulphide sealant
or bituminous sealant as pe.r IS: 1834 and the excess sealant trimmed
to receive the wearing coat. After the wearing coat is completed, similar
<<
594
.1] 1115. c(’11d1 & Appurtenances Section l7tX)
‘.;eriftnt shall he firtishecl to cover at leasl 50 mm on the wearing

cc’ut surface all round the drainage assembly.
2706. WEEP HOLE
Weep holes shall he provided in solid plain concrcte(retnli.irced
ct’s’lc’rciL’, hrick/slnne masonry, ahutmenl, wing wall and return walls w~
u on lhe ci rawing or directed by the Engineer to drive moisture
the l’uck filling. Weep holes shall he provided with 100 mm d
C’ pipe or 51 rt,tctttres in plo in/reinforced concrete, or brick mason rv. I
iti slone masonry, weep holes shall be 80 mm wide, 15(1 turn
Ii ph or’ circular with I 50mm diameter. Weep holes shall extend through
full w ith of concrete/masonry wtth slope of about 1 verlical’ 211
lit tt’tttiiil towards the draining’ face The spacing of weep holes shall
aenerall~he Ira in either direction or as showrt tn the drawing ss jIb
Ii, t u est at about I 50 mm above the low w ater level or a rotsn d
level ss h iche.~cr is higher or as directed by the Engineer.
2707, i’ESTS ANt) Si’ANDARDS OF ACCEPTAN(’F:
TIre materia.ls shall be tested in accordance with these Spec it’rca-
arid shall meet the prescrihed criteria,
‘l’he work shall c’onforn’i to these Specification.s and shall meet die
prcsc ri bed standards of acceptance.
270$. MEASUREMENTS FOR PAYMENT
‘l”he tneasurcment for payment for wearing coat, railings and
approach slab shall be made as given below
Cement concrete wearing coat shall he measured in cubic met rr.s Asphalt Ic
concrete wearing coat shalt be measured in square metres.
.1 Railings shalt he measured in running metres.
Approach stab and its base shalt be enc’asurrd separately in cubic metres.
is I Orain rye spouts shall he measured in numbers,
Weep holes in conc:reseThric:k masonry structure shall he measured in rs.trriFs.:ss
For structures in stone masonry, weep holes shall be deezi’md to be included
En the itrm of stone masonry wortc and shalt not be measured separately.
2709. RATE
The contract tinit rate for wearing coat shall include the cost of all
labour, material, tools and plant and other cost necessary for completion
of the work as per these Specifications.
‘I’he contract unit rate of railings shall include the cost of all labour,
<<
595
material, tools and plant required for completing the work as per these
Specifications..
‘the contract unit rate for approach slab shall include the cost ol’
all labour, tnate.rial, tools and plant required for completing the work
as per these Specifications. The rate for base shall include cost of
all labour, material, tools and plant required, including preparation of
surface and consolidation complete in all respects.
‘the contract unit rate for each drainage spout. shall include the cosl
of all labour, material, tools and plant required for completing
the,: work as per these Specifications. It shall also include the cost of
providing flow drain pipes with all fixtures upto the point of ground drains’
wherever sho’wn on the drawings.
The contract unit rate for weep hole shall include the cost of
all labour, material, tools and plant required for completing the work
as per these Specifications.
<< 596
Repair ofStructures
2800
Repair of Structures
<<
Repair of Structures Section 2800
2801. DESCRIPTiON
Repair of structures shall be carried out in accordance with the repair
plans and these specifications or as directed by the Engineer. Where
repair work is not covered by these specifications, special specifica~
tion may he framed.
Implementation of repair schenes shall also conform to provisions
of IRC:SP:40.
2802. GENERAL
2802.1, Environmental Aspect
Care shall be taken to ensure suitable mitigation measures against
noise and dust, pollution and damages to the environs whether temporary
or permanent and shall be taken as incidental to work.
2802,2. Phasing
The sequence of work shall be in accordance w’ith the drawings or
as directed by the F.~~ngineer.
2802.3. Traffic Management
Traffic management, signage, signalling arrangement, barricading,
and lighting arrangement shall be in accordance with Section 100 and
with t.hese specifications and shall be considered as incidentals to work.
2802.4. Safety Precautions
Adequate precautions shall be taken for safety .of personnel, road
users and existing services, which, during execution, shall be considered
as incidentals to work.
Persons working should wear safety helmets and rubber gloves.
2802,5, Dismantling’ and Removal of Material
t)is.mantling of any bridge component and removal of materials
shall conform to Section 200 and this section and as shown on the
2803. SEALING OF CRACKS BY INJECTION
OF EPOXY RESIN
2803,1. General
The work of epoxy adhesive utilising the Structural Concrete Bonding
Process shall conform to these specifications.
599
<<
Section 2800 Repair of Structures
2803.2. The Contractor shall furnish detailed methodology of con-
stntction including sotirces of supply of material, tools, equipment and
appliances to be used on work, details of personnel and supervi-
sion.
2803.3. Personnel
The Contractor’s personnel shall be qualified and experienced in
epoxy injection process.
2803.4. 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 poly.s’ulphide resin may he used for sealing the surface.
The material for epoxy injection shall conform to the following
I) The mixing ratio of resin and hardener shall generally be between I to I and
2 to I by volume subject to manuracturer’s recommendation.
ii) Neither the mixed epoxy adhesives nor their individual components shall contain
solvents and thinners,
iii) The components shatl be free of lumps or foreign material, The viscosity of the
individual components shall not change more than ±15per cent when kept in
closed containers at 2.5 degrees ~etsius after two weeks.
iv) Consistency requiremeni
Standard Low Viscosity
VersIon Version
cpa cpa
Viscosity of Mixed Adhesive
at 25 degrees Celsius (200-300) (t0O-t90)
v) Pot Life of mixed adhesive 1 hour ±15minutes ‘
at 25 degrees Celsius
Si) Set time of miscrl adhesive 3 6 hours
at 25 degrees Celsius
*ln the case of two component injection system where resin and hardener get mixed
at point of injection pot life at 25 degrees Celsius shaH be not greater than 15 rain ~lO
minutes.
2803.5. Equipment for injection

The equipment shall be portable, positive displacement type pur ~
with interlock to provide positive ratio control of exact propori ons
of ihe two components at nozzle. The pumps shall be generally electr:.’aliy
powered and shall provide in-line metering and mixing. The tolerance.
on mix ratio shall be 5 per cent by volume, The injection equipment
600
<<
Repair of Stnictures Section 2800
shall have automatic pressure control capable of discharging mixed
adhesive at any pre.set pressure within the prescribed limits and shall
be additionally equipped with a manual pressure control.
The injection equipment shall be equipped with sensors on both
the components A and B reservoirs, that will automatically stop the
machine when only one component is being pumped to the mixing head.
if considered appropriate, suitable compressed air operated epoxy in-
jection gun can be used with prior approval of the Engineer for manual
injection of mix when resin and hardener had been mixed in a separ.ate
unit,
2803.6. Preparation
Surfaces adjacent to cracks or other areas of application shall be
cleaned of dirt., dust, grease, ‘oil .efflorescence or other foreign matle.r
by brushingJwater jetting/sand blasting. Actds and corrosives shall not
be permitted for cleaning.
Entry ports shall he provided along the crack at intervals of not more
than the thickness of concrete at the location.
Surface seal material shall he applied to the face of the crack between
the entry ports, For through cracks, surface seal shall be applied to both
faces,
Before proceeding with the inject.ion, the surface seal material must
gain adequate strength with respect to concrete strength of the member!
injection pressure.
2803.7. Epoxy Injection
Injection of epoxy adhesive shall begin at lowest entry por and
continue until there is an appearance of epoxy adhesive ~at the next
entry pOrt adjacent to the entry port being pumped.
When epoxy adhesive travel is indicated by appearance at the next
acUacent port, injection shall be discontinued on the entry port being
pumped a.nd entry port shall be sealed. Thereafter, epoxy injection shall
he. transferred to next adjacent port where epoxy adhesive has appeared.
Epoxy adhesive injection shall be performed continuously until cracks
are completely filled.
If port to port travel of epoxy adhesive is not indicated, the work
shall immediately be stopped. In case the volume of the injected tnate,rial
<< 601
Section 28(X) Repair of Structures
exceeds 2 litres for a particular entry port, the work shall be stopped
and the specifications may be reviewed.
2803.8. Precautions for Application
a) t.Jntess otherwise. specified, components A and B, i.e., resin and hardener, shall
be at a temperature between tO degrees Celsius and 35 degrees Celsius at the
time of mixing.
is) Temperautre ot structural nsemhee during epoxy injection shall he between
10 degrees C.elsics and 35 degree.s Celsius unless otherwise specified.
c.) Inssnediately prior to use, each cotnponent shslt he thoroughly mixed with a
clean paddle. The paddle shall be of a type that does not induce air into the
material, Separate dean paddle must he used for each component
d) Any heating of the adhesive components shall he. done by application of instirect
heat in case the work is to he done in cold climate,
c) Just before use, the two components shall be thoroughly mixed in. the ratios
specified by the manufacturer, The length of mixing time shall he in strict
accordance with manufacturer’s recommendations, When mixed, all ad.i.csives
with different coloured components shall have a uniform colour without streaks.
~fl The use of sulvents and thinners will not he permitted except for cleaning
of equipment.
2803.9. Testing
2803.91, Mateilal Testing’. Prior to approval of the material, the
following tests shall be carried out at site or in an authorised laboratory
for each batch of resin and hardener and each combination thereof at
the. co:st of the Contractor.
i) Viscosity test for resin and hardener and the mix - three specimens each.
ti) Pot life test - thre.e specimens each.
iii) Bond test - three specimens each.
is) Shear test - six specimens each, 3 after 24 hours and the other three aftet 72
hours of curing
Suhsc.quent~testsshall be. carried out as directed by the Engineer.

a) Pot t,ife Tests
i) 500 gm of resin formulation shall be prepared by thoroughly raising the
resin and hardener/accelerator/catalyst component in proposed proportion
in a I kg capacity hernispheral porcelain bowl by means of a spatula or
any other agitating device and nose down the time and the ambient
temperature.
ii) With a clean dry 25 mm size painter’s brush, the resin formulation shall
be applied on a clean dry surface such as cement concrete over iS-
20 cm length, starting immediately after mixing the fonnulation and
repeating operation every five minutes. When it becomes just difficult
to spread the resin property with the hmsh, the time is notett The
602
<<
Ret:tais’ csf Structures Section 2800
time elapsed since corrspletion csf tnixing of resin fomtulation is taken as
its pot life,
iii) One pot life test shalt he performed on commencement of work and the
sattte shalt be repeated even’ four hostrs..
iv) In case the material fails to satisfy the Pot life test it shall not lx. used
for injectton.
Wttese the resin and hardener get mixed at point of injection, the pot life is r.oi
irrtportant and no teats may be required.
Ls,t Bond Test
.A standard ISO snm diameter and 300 mm long concrete cylinder shalt he east
in 2. pieces by providing a separating media at an axis of 45 degrees Celsius
to tlse longer axis of the cylinder (refer to Fig. 2.800/1).
‘I’hree sets of such split cylinders shall he prepared in advance, Two pieces of
each set shall be joined wir.h epexy rnorear at four p. mrs to give a clear gap
of shout 0.2 mnns, which will be injected with epoxy resin at site, After epoxy
has been cured, load test is esrried out on the cylinder which shall not he test
than Sf) per cent of the cube strength of the concrete mix and the failure shalt
not take place at she ,joint injected with epoxy resin,
~e) Sttear Tests
Two steel plates, minimssm 3mm thick, shall be bonded with epoxy at site using
the same resin mix as used/proposed to he used for injection. The assembly shalt
he kept in mechanical clamp till epoxy is cured, A total of six specimens shall
be prepared for each hatch of materials. Three test specimens shalt then he
subjected to a shear force along the axis after 24 hours and the minimunt shear
strength before failure shalt nut be less than 1 MPa, (refer Fig. 2800/2).
The. remaining test specimens shall be similarly tested after 72 hours

of curing. The shear strength before f’ailure shall not be less than 2.,5
MPa,
2803.9,2, Core test : If directed by the Engineer, core tests shall
be. con.ducted for the acceptance of the work. The selection of the
location of cores shall be made under the direction of the Engineer
in such a way that damage in critical/stressed areas .of the structure
is avoided, The procedure for the test shall be as under.
The. Contractor shall ohtain 5 cm diameter initial core samples in
the first 50 linear metres, Thereafter, frequency of core sampling
shall he as specified or as agreed by the Engineer.
The depth of the core shall generally be less than 20 cm.
l’ests and Acceptance Criteria shall be as follows
s) Penetration/Visual Examination - a minimum of 90 per cent of the crack shall
be full of epoxy adhesive,
603
<<
Section 2800 , Repair of Structures
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604
b) Bond Strength : Concrete failure before adhesive failure or 40 MPa with no failure
of either co~xcreLeor adhesive
If the cores taken in first 50 m length pass tests as specified above,

epoxy adhesive injection work at area represented by cores will be
accepted.
If cores fail either by lack of penetration or bond strength, work
shall not proceed further until the areas represented by the cores are re~
injected and retested for acceptance.
Filling of Field Control Testing Core Holes
This procedure consists of using two~component bonding agent
applied to surfaces of cored holes followed by application of Non-
Shrink cement grout mix placed by hand trowel, thoroughly rodded
and tamped in place, and finished to match finish and texture of existing
concrete to the satisfaction of the Engineer. Materials and procedures
for filling testing core holes shall be submitted to and approved by the
Engineer before proceeding with core testing work.
2803.9.3. Test br injection equipment At all times during the
course of the work the Contractor shall keep complete and accurate
records and make available to the Engineer of the pressure and ratio
tests specified above so that the efficacy and accuracy of the injection
equipment is verified.
In addition, the Engineer at any time without prior intimation of the
Contractor may request the Contractor to conduct the tests specified
below, in the presence of the Engineer.
a) Pres~areTest
The mixing head of the injection equipment shall be disconnected and the two
adhesive component delivery lines shall be attached to the pressure check device,
which shall consist of two independent vatved nozzles capable of sensing the
pressure. The cheek device shall be closed and equipment operated until the
gauge pressure in each tine reads 5 MPa, The. pumps shall be stopped and
the gauge pressure shall not drop below 4 MPa within 2 minutes.
The preasure test shall be run for each injection unit at the beginning and
after break of every shift.
b) Ratio Test
The mixing head of the injection equipment shall be disconnected and the two
adhesive components shall be pumped simultaneously through the ratio check
device, which shall consist of two independent valved nozzles. There shall
be a pressure gauge capable of controlling back pressure by opening or closing
valved nozzles capable of sensing the back pressure behind each valve. The
discharge pressure shall be adjusted to read 5 bar for both adhesive components,
<< 605
which shall be simultaneously discharged into separate calibrated containers
during the same time period and the amounts discharged into the calibrated
containers simultaneously during the same period shall be compared to de-
termine that the volume/discharge conforms to themanufacturer’s recommended
ra.tio for applicable material.
2804. EPOXY MORTAR FOR REPLACEMENT OF

SPALLED CONCRETE
2804.1. Material
2804.1.1. Formulation
The epoxy resins for use in the mortar shall be obtained from a
reputed manufacturer and the mortar shall be prepared in conform-
i ty with the manufacturer’s recommendations.
They shalt generally conform to the following:
Pot Life : 90 minutes at 25 degrees Celsius
60 minutes at 30 degrees Celsius
45 minutes at 35 degrees Celsius
Bond Strength : 12 MPa
Tensile Strength : 16 MPa
The Contractor shall carry out tests on the samples made out or
requirements indicated above.
The sand content in the mortar shall be in accordance with the
desired consistency.
2804.2. Proportioning and Mixing
The resin and hardener shall be mixed before adding the dry
filler. The mixed ready to use mortar should not contain lumps of
unwetted filler and should be uniform in colour. For a total weight
øf 1 kg or less, hand mixing will be sufficient. For quantities in excess
of 1 kg, the component shall be mixed for 3 minutes with a slow speed
400-600 rpm - electric drill with a Jiffy mixer, The stirrer shall be
moved up and down and along the sides until an even streak free colour
is obtained. Whipping in an excessive amount of air shall be avoided.
If no power is available, a flat putty knife may be used to reach
into the corners of the can and hand mixing done for at least 5 minutes.
2804.3. Surface Preparation
Surface upon which epoxy is to be placed shall be free of rust,
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606
grease, oil, paint, asphalt, loose material, unsound concrete, dust or any
other deleterious material.
Since cured epoxy does not provide adequate bond with any
material, all overlay, whether epoxy or cement based, shall be done
within pot life of the base epoxy layer.
2804.4. Contaminants, such as oil, grease, tar, asphalt, paint, wax,
curing compounds or surface impregnants like linseed oil or silicons,
including laitance and weak or loose concrete shall be removed. When
bonding to asphalt, the surface should be roughened so that clean
aggregate is exposed. Epoxy bonding agents shall not be applied when
ii rains, or in standing water. The surface must be dry.
Two general methods of surface preparation shall be followed

a) Mechanical that includes grinding, grit blasting, water blasting and scarification.
b) Chemical that includes acid etching with 15 per cent by weight of hydrochloric
solution, followed by repeated flushing with high pressure stream of water.
2804.5. Application
Epoxy primer coat shall be applied with the help of stiff nylon
bristle brushes or hard rubber rollers or spray gun depending upon
the nature of surface and extent of work area. As far as possible,
the coating shall be uniformly thick.
Before the primer coat is fully cured, epoxy mortar shall be
applied by means of !rowels and floats. The interval between the
application of primer coat 3nd epoxy mortar shall be approximate-
ly 15/30 minutes depending upon the ambient temperature.
Seat Coat shall be applied after 24 hours curing, after mild
roughening of the surface of the mortar,
2804.6. Coverage
The coverage of resin mix would depend on the system of resin
used. However, as a general guideline the coverage area shall be as
under
a) Primer Coat. One kg of resin-hardener mix covers an area of 3-6 square metres
per coal depending on the fmish of the concrete.
b) Epoxy Mortar. One square metre of surface requires approximately 20-
24 kg of epoxy mortar when laid to a thicknest of 10mm.
c) Seal Coal. 4 to 6 square metres per kg of mix depending on the temperanire
of application.
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607
2804.7. Cleaning and Maintenance of Equipment
Tools and equipment are best cleaned immediately after use since
the removal of cured resin is difficult and time consuming. The bulk
of resin shall be removed using a scraper and remainder washed
away completely using solvents such as toluene, xylene or acetone.
Equipments used for epoxy shall always be cleaned before it hardens.
Solvents used for this purpose may be Acetone (flammable), Methyl Ethyl
Kethone (flammable), Methyl Chloride (non-flammable). Cured epoxies
may be removed using Methylene Chloride.
2804.8. Testing
Epoxy used for making mortar shall conform to all requirements
and testing procedures as laid down in Clause 2803.9.
2804.9. Handling Precautions
Epoxy resins can cause irritation of skin in sensitive persons if in~
correctly handled. The resin and hardener should not be allowed to come
into direct contact with skin. The most effective protection is achieved
by wearing rubber or polythene gloves.
2804.10. Personnel and Environment ,Safety
Any skin contact with epOxy materials, solvents and epoxy strippers
should be avoided. Epoxy resins and particularly epoxy hardeners (B
component) may cause a rash on the skin. The official toxicity
classification on the container labels may be looked for before starting
work.
Rubber gloves, with a cloth liner, and protective clothing shall be
worn. Bather creams are recommended but are not substitutes for
protective clothing. Eyes shall be protected where splashing could occur
while spraying or mixing. Good ventilation shall be ensured and
inhalation of vapours avoided. If materials are sprayed, a respirator
shall be used.
If skin contact occurs, it shall be immediately washed with a cleaner,
followed by soap and water. Should eye contact occur, it shall be flushed
immediately with plenty of water for 15 minutes and a doctor called
for.
If contact occurs with the clothing, it shall be immediately changed
to prevent further skin contact, and if the contact occurs with components
A or B, the clothing shall be thrown away. Hardened epoxy is not harmful
but will break the clothing.
<< 608
All emptied, used buckets, rags and containers shall be removed

from site. These shall be stored in waste disposal bags and suitably
disposed.
2805. EPOXY BONDING OF NEW CONCRETE TO
OLD CONCRETE
2805.1. Epoxy resin used for bonding shall be obtained from a
reputed manufacturer. The pot life of such bonding epoxy shall not
be less than 60-90 minutes at normal temperature.
2805.2. The entire surface of the existing concrete member should
be thoroughly cleaned by wire brush and then with compressed air to
remove dust and loose particles from the surface. Any crack or spalling
of concrete shalt be sealed by epoxy injection/epoxy mortar/grouting
as decided by the Engineer. A coating of suitable epoxy resin at the
rate of 0.8 kg/sq.m. (minimum) should then be applied on the surface
of the existing cOncrete members. Fresh concrete shall then be placed
within the pot life of the resin system.
2805.3. Testing
2805.3.1. Epoxy used for bonding work Shall satisfy the criteria
mentioned in Clause 28019.
2805.3.2. Two concrete cubes 150 mm size cast as per approved
design mix shall be placed, as shown in Fig. 2800/3 at a distance
of 150 mm from each other. Epoxy resin system suggested for bonding
new to old concrete shall be applied on the opposite faces of the cubes.
Fresh cement concrete cube of grade as per approved design mix
shall be cast with water cement ratio of 0.4 or less in the manner
shown in Fig. 2800/3. The assembly shall be cured in water for 28
days and steel spacer removed thereafter.
The cube assembly shall .be subjected to compression load after 28
days of curing, thereby subjecting the bond to shearing load. Failure
must not occur at this joint.
2806. CEMENT GROUTING
2806.1. Material
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
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Section 2800 Repair ofStrucuires
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610
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. Orouts
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.
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~andshrinkage.
2806.2. Preparation
The surface shall be cleaned with wire brush and compressed air.
15 mm din and 150 to 200 mm deep hoLes along the length of
the cracks at a spacing of 500 mm may be drifted by wet drilling using
rotary percussion drills and nipples. inserted in these boles.
2806.3. Proportioning, MixIng, and Equipment for Grouting
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 cemenL
Where the mixer and pump are combined in one unit1 the dry
material shall be screened before mixing. if the mixer and pump are
in separate uwis, the grout shall pass through a screen before it enters
the pump.
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611
2806.4. Application
Highest practical pressure within the limits 100-400 kPa should be
used in order to force the surplus water from the grout. As thb pressure
may be distributed hydraulically over considerable areas, vigilance must
be exercised to prevent damage or, the needless waste of grout. Orouting
is ~o be done by attaching a pscker (consisting of expansible tube
of rubber) to the end of the grout supply pump through the holes and
nipples.
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 iefhsaL Should the grout escape
from an adjacent nipple,it should be plugged or capped. Any seam,
crack or joint through which grout escapes shall be caulked with epoxy
ffiortar as soon as thick grout appears.
2806.& Cleaning o~Equipment
After completion of each grouting operation or temporary shutdown,
it is advisable to force dear water through the pump until the discharge
line shows no colour, aflCr which the pump covers shall be removed
and the valve chambers thoroughly cleaned.
2S06.6~Testing
Percolation test done at the end of grouting operation shall give a
value of less than 2 lugions.
NOTE: For specialised trea~ntentlike polymer modified cemenu*iour grom injection.
manufactumr’s htemune and specification shall be followed.
2807. GUNIT1NG/SHOTCRETE
2807.1. 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.
2807.2. Ordinary Poilland cement conforming to IS:269 shaft be used
in guniting.
28073. Sand for guniting shall comply with the requirements stipu-
lated in IS:383. In general, sand should neither be zoo 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.
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612
Repair of Stmctures Scc~ion2800
The grading of sand shall lie within the limits given below
IS Sieve per cent Passing the sieve
Designation
4.75mm 95. 100
2.36mm 65.90
1,18mm 45.75
600 microns 30 - 50
300 microns 10 - 22
150 microns 2 8
2807.4. 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.
2807.5. 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.
2807.6. Workrnansh~p
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/cu.m. The strength
of gunite shall not be less than 25 MPa. For effective guniting, the
nozzle shall be kept 60 to l50~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.
2807.7. 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 lS:90l2 shall be followed.
2807.8. It should be ensured from tests that a strength of about
25 MPa at 28 days is available for the mortar/concrete mix.
2807.9. The defective concrete shall be cut out to the full depth
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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 sand~
blasted to make it rough to receive shotcrete after applying a coat
of bonding epoxy as per recommendation of the manufacturer @ 1.0
kg per 1.5 sq.m. of surface area.
2807.10. 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 near
cement slurry should be applied on the surface of the reinforcement.
2807.11. Sufficient clearance shall be provided around the rein-
forcement to permit encasement with sound gunite. Care shall be taken
to avoid sand pockets behind the reinforcement.
2807.12. 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 applicati&n of the
subsequent layer. It would always be necessary to apply guniting on
a damp concrete surface.
2807.13. Where required, welded wire fabrics Scm x 5 cm 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.
2807.14. 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.
2807.15. It would be desirsble that green gunite is moistened for
at least 7 days. Guniting work shall not be done during windy or rainy
conditions.
2808. REPLACEMENT/RECTIFICATION OF BEARINGS
2808.1. The replacement/rectification of bearings shall be carried
out in accordance .with approved repair plan or as approved by the Engi-
neer.
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2808.2. Lifting of superstructure spans may be carried out by jacking

up from below or by lifting the span from top. Where jacks are
employed, their location/number and size shall be selected in such
a manner so that there are no undue stresses created in the structure.
Jacks may be placed on piers/pier caps or specially erected trestles
in accordance with the approved methodology for lifting of superstruc.
ture. All jacks shall be operated from one control panel by a single
control lever. The system will have provision for manual over ride
to control the loads of any particular jack. The jacks should be
so synchronised that differential lift between individual jacks shall
not exceed 1 mm
2808.3. Necessary repair/replacement of bearings shall be carried
out as indicated in the repair plan or as directed by the Engineer. Care
shall be taken to plan the execution of repair in the shortest possible
period.
2808.4. Precautions during Lifting of Girders for Rectification of
Bearings
Walkie talkies system .or similar audio arrangements should be
available for communicating instructions regarding lifting, stopping,
starting etc. The operator shall have a clear view of the jacks and
the lifting of each girder controlled by reading the dial gauges.
2809. DISMANTLING OF CONCRETE WEARING COAT
2809.1. Commencement of Dismantling
i) Before commencing dismantling, the nature and condition of concrete, the
condition and position of reinforcement should be ascestained. 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
iii) The service lines, if any, shall be disconnected/ diverted before the dismantling
work starts.
2809.2. 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 prestressing anchorages for cables,
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Section 2800 Rcpair of Structures
if any, located in the deck slab.
2809,3. Precautions During Dismantling Work
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 mishaplemergency.
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 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.
2810. EXTERNAL PRESTRESSING
2810.1. Various components constituting the system of external
prestressing are as follows
H.T. Strands/Wires, HDPE Sheathing, Deviator Blocks, Anchor
Plates, Anchorages and grouting material.
2810.2. Material
H,T. Strands / Wires
H.T.Strands wires shall conform to Section 1000.
HDPE Sheathing
HDPE Sheathing shall conform to IS:4984 suitable for a working
pressure of 6 bars. Its density shall be 955 kg/cum, shore hardness
D63, yield stress 24 MPa and ultimate tensile strength 35 MPa.
Deviator Blocks
As necessitated by the profile of the external cable, suitable stranW
wire deviator block fabricated from M.S.Sections shall be provided. The
deviator block shall be given a coat of suitable paint (preferably epoxy
based) after sand blasting.
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Anchorages
Depending upon the prestressing force, suitable anchorages and
wedges shall be used conforming to relevant codes and section 1800.
28103, Workmanship
a) Stressing of cables shalt be earned out as per instructions given in the drawing,
and conforming to Section 1800.
b) Care should be taken to avoid any damage to the existing sisucture, by way of
stress concentration or’any other reason during fixing of the deviator blocks and
after stressing of cable. The deviator blocks shall be so fixed as not to allow any
movement due to prestressing forces. Radius of corvature of the surface of the
deviator block interfacing with the cable shall be minimum one metre.
c) The anchorages shall be sealed with suitable epoxy mortar system after the
stressing of cables, A minimum cover of 50mm shall be provided for the anchor
plates and anchorages.
d) Suitable grouting inlet points and vent points shall be provided by way of HDPE
‘1” vent connections to the sheathing.
e) Grouting of cables shall be carried out as per provisions made in Section 1800.
2810.4. It shall be ensured that no part of the existing structure

is damaged/distressed due to the external prestressing.
The behaviour of the girder shall be monitored by measurement of
deflection so that only required amount of external presiressing is
imparted to the girder. Care shall be taken to avoid excess prestressing
and impairment to the girders.
prescribed standards of accepthnce.
2812, MEASUREMENTS FOR PAYMENT
a) Measurement for sealing of cracks and injection shalt be made by weighs
of epoxy consumed in kg for epoxy grouting. For provision of nipples required
for grouting, the payment shalt be for number of nipples inserted.
b) Measurement for sealing of cracks and injection shall be made by weight
of cement consumed in kg for cement grouting.
c) Measurement for application of epoxy mortar for specified thickness shalt be
per square metre of surface area of application.
d) Measurement for bonding of old and new concrete by epoxy mortar shall
be measured in square metre surface area of interface.
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e) Measurement for guniting/shoicreting, shall be per square metre of surface area
of application.
f) Payment for replacemenUrectification of bearings shall be for each number of
bearing assembl~replaced/rectified.
g) Dismantling of wearing coat shall be measured in square metre of area of
wearing course dismantled.
h) Provision of external prestressing shall be measured in tonnes of FIT. ste&
strand/wire measured from anchorage to anchorage before stressing.
2813. RATE
The contract unit rate for sealing of cracks and injection of cement
grout shall include cost of all materials, labour, toots and plant, placing
in position, testing, curing and other incidental expenses for the
satisfactory completion of the work as per these specifications.
The contract unit rate for application of epoxy mortar for
specified thickness shall include cost of all materials, labour, tools and
plant, placing in position, testing and other incidental expenses including
surface preparation for the satisfactQry completion of the work as per
these specifications and as shown on the drawings.
The contract unit rate for gunitinglshotcreting shall include cost
of all materials, labour, tools and plant, placing in position, testing,
curing, surface preparation and other incidental expenses including
the provision of nipples for the satisfactory completion of the work as
per these specifications.
The contract unit rate for replacement/rectification of bearings shall
include cost of all materials, labour, tools and plant, placing in position,
site welding/riveting/bolt connections, operation of jacks and other
incidental expenses for the satisfactory completion of the work as per
these specifications and as shown on the drawings.
The contract unit rate for dismantling of wearing coat shall include
cost of all jirnterials, labour, tools and plant, traffic management,
signages, safety precautions and other incidental expenses including
removal of existing expansion joints for the satisfactory completion of
the work as per these specifications.
The contract unit rate for external prest.ressing shall include cost
of all materials, labour, tools and plant, temporary works, testing, curing
and other incidental expenses including the careful monitoring of the
deflection of girders being externally prestressed for the satisfactory
completion of the work as per these specifications and as shown on
the drawings.
<< 618
Pipe Culverts
2900
Pipe Culverts
<<
Pipe Culverts Section 2900.
2901. SCOPE
This work shall consist of furnishing and installing reinforced cement
concrete pipes, of the type, diameter and length required at the locations
shownon the drawings or as ordered by the Engineer and in accordance with
the requirements of these Specifications,
2902. MATERIALS
All materials used in the construction of pipe culverts shall conform to
the requirements of Section 1000.
Each consignment ofcement concrete pipes shall be inspected, tested,
ifnecessary, and approved by the Engineer either at the place ofmanufacture
or at the site before their incorporation in the works.
2903. 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 enibankments, 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.
Where trenching is involved, its width on either side of the pipe shall
be a minimum of 150mm orone~fourthofthediameterbf the ~ipe 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.
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
construction methods are called for on the drawings or in special
provisions, such unsuitable material shall be removed to such depth, width
and length as directed by the Engineer. The excavation shall then be
backlilled with approved granular material which shall be properly shaped
and thoroughly compacted upto the specified level.
Where bed-rock or boulder strata are encountered, excavation shall be
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621
Section 2900 Pipe Culverts
taken down to atleast 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.
2904. BEDDING FOR PIPE
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 approved granular material, shaped
concentrically to fit the lower part ofthe pipe exterior for atleast ten per cent of i t.s
overall heightor 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 ~ yer 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 t~,the
Engineer, the pipe shall be bedded in a cradle constructed of concrete having a mix
not leaner than M 15 confomiing to Section 1700, The shape and dimensions of the -
cradle shall be as indicated on the drawings. The pipes thafi be laid on the conere~e
bedding before the conérete has set,
2905. 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 adistance equal to at least half the diameter
of the pipe subject to a minimum of 450 mm.
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.
Similarly, the arrangement for lowering the pipe in the bed shall be
got approved by the Engineer. Tt, 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.
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 belied end shall face
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Pipe Culverts Section 2900
upstream. The pipes shall be fitted and matched so that when laid in work,
they form aculvert with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed
at the cost of the Contractor.
290t JOINTING
The pipes shall bejointed either by collarjoint or by flushjoint. In the
former case, the collars shall be of RCC 150 to 200 mm wide and having the
same strength as the pipesto be jointed. Caulking space shall be between 13
and 20 mm according to the diameter of the pipe. Caulking material shall be
slightly wet mix ofcement 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 thejointand an even annularspace is leftbetween the collarand the pipe.
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
jointwith ajointing space 13 mm wide. The jointing space shall be filled with
cement mortar, 1 cement 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.
For jointing 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 ofthe next pipe. The ring shall be
thoroughly compressed by jacking or by any other suitable method.
All joints shall be made with care so that their interior surface is
smooth andconsistent with the interior surface of the pipes. After finishing,
the joint shall be kept covered and damp for at least four days.
- 2907. BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid
and thejointing 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 vthrated in layers not exceeding 150 mm,
particular care being taken to thordughly consolidate the materials under the
haunches of the pipe. Approved pneumatic or light mechanical tamping
equipment can be used.
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623
Section 2900 Pipe Culverts
Filling of the trench shall be carried out simultaneously on both sides
of the pipein such a manner that unequal pressures do not occur.
In caseofhigh emba*rnent, 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.
2908. HEADWALLS AND OTHER ANCILLARY WORKS
Headwalls, wing walls, aprons and other ancillary works shall be
constructed in accordance with the details shown on the drawings or as
directed by the Engineer. Masonry for the walls shall conform to Section
1300, 1400 or 1700 as applicable. Aprons shalt conform to Section 2500.
2909. OPENING TO TRAFFIC
No traffic shall be permitted to cross the pipe line unless height of
filling above the top of the pipe line is atleast 600 mm.
R.C.C. pipe culverts shall be measured along their centre between the
inlet and outlet ends in linear metres.
Selected granular material and cement concrete for pipe bedding shall
be measured as laid in cubic metres. Ancillary works like headwalls, etc.,
shall be measured as provided for under the respective Sections.
2911. RATE
The Contract unit rate for the pipes shall include the cost of pipes
including loading, unloading, hauling, handling, storing, laying in position
and jointing complete and all incidental costs to complete the work as per
these Specifications.
Ancillary works such as excavation including backfiiling, concrete
arid masonry shall be paid for separately, as provided under the respective
Clauses.
<<
624
Maintenance of Road
3000
Maintenance of Road
<<
Maintenance of Road Section 3000
3001. GENERAL
The Specificationsshall apply to all itemsofroad 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 therelevant Specifications
to the required level, grade and lines using approvM 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, areference is made tothe 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 appli-
cable. Wherever the Specification is not clear, good engineering practice
shall be adopted in the construction to the satisfaction of the Engineer.
3002. RESTORATION OF RAIN CUTS
3002.1. Scope
The work shall consist of earthwork for restoration of rain cuts in the
embankment and shoulders, using suitable material, and compacting the
same.
3002,2. Materials
The material used for restoration of rain cuts shall consist of soil
conforming to Clause 305.2.
3002.3. Construction Operation
The area affected by rain cuts shall be cleared of all loose soil and
benched. The width of the benches shall be at least 300 mm and they shall
extend continuouslyfora sufficient length. Theheight of thebenches shall be
in the range of 150-300 mm.
Fresh material shall be deposited in layers notexceeding 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 platecompactors andrammers or by suitable implements
handled manually. The finished work shall conform to aligmnent, levels and
slopes as indicated in the drawing.
The earthwork foi~restoration of rain cuts shalt be measured in cubic
metres.
<< 627
Section 3000 Maintenance of Road
3002.5. Rate
The Contract rate for the item of earthwork for restoration of rain cuts
shall be payment in full for carrying out the required operation including
full compensation for:
(i) Supply ofmaterial including all leads and lifu and the costof arrangement of land;
(ii) Setling out;
(iii) Removal ofloose material from the cain cuts;
(iv) Benching ofold earthwork; and
(v) Compacting after adding required quantity of water.
3003. MAINTENANCE OF EARTHEN SHOULDER

3003.1. Scope
The work of maintenance ofearthen shouldershall 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 this
Specification.
3003.2. Material -
The material to be added to the shoulder, ifrequired, shall be a select soil

conforming to Clause 305.
3003.3. Construction Procedure
This work shall involve:
(i) Making up ofthe earthen thoulderby adding extra soil and compacting rhesame; andl
or,
(ii) Stripping a layer of soil to achieve the required grade and level.
Wherever extra earth is required to be added, the earthen shoulder

shall be stripped and loosened to receive fresh soil. The deficiency of
thickness shall be made up in layers of loose thickness not exceeding 250
mm. Water shall be added, if required, to attain the optimum amount and the
layercompacted by 80 to lOOkN smooth wheelroller, vibratory roller, hand
roller, plate vibrator or hand rammer to obtain atleast 94 per cent of the
maximum dry density in accordance with IS: 2720 (Part 8). The finished
surface shall have the specified cross. slope and line in accordance with the
drawing.The side slopes shall be trimmed to therequired slope with the help
of grader or manual methods using hand tools.
Wherever the earth is required to be excavated from the shoulder, this
shall be done either using equipment like grader or by inanual means using
<< 628
hand tools. The resulting surface shall be uniform and have a field density
of atleast 94 per Cent of maximum density obtained in accorthnce with
IS : 2720 (Part 8). If the surface is not uniformly compacted, it shall be
excavated to a depth of 150 mm and the soil mixed with water if required
and compacted at a moisture content close to the optimum to achieve 94 per
cent of maximum density as stated above.
3003,4. Measurements for Payment
Maintenance of earthen shouldershall be measured in sq. metres.
3003.5. Rate
The Contract unit rate for maintenance of earthen shoulder shall be
payment in full compensation for:
(i) furnishing earth required formaking up of shoulders including all leads and lifts,cost
of land and compaction;
(ii) excavation of earth as required and disposal of the earth at the location approved; and
(iii) all tools, equipments and incidentals to complete the work in accordance with the
above Specification.
3004. BiTUMINOUS WORK IN CONNECTION WITH
MAINTENANCE AND REPAIRS
3004.1. Filling Pot-holes and Patch Repairs
3004.1.!. Scope : This work shall include repair of pot-holes and
patching of all types of bituminous surfaces with a bituminous mix either
produced atplant site or atthe site itself with manual method of mixing and
placed at site in the pot holes or in patches after trimming the pot-hole or
depression to proper shape and depth, side painting with tack coat and
compacting the layer to the levels specified in the drawing.
3004.1.2. Materials The materials used for the pot-hole and patch
repair of bituminous surface shall be as per the Contract and shall be of the
same type as used for the existing bituminous surface. Amix superior to the
one on existing surface can also be considered appropriate for repair work.
An emulsified bitumen mix compatiblewith the existing layerShall also be
considered appropriate.
The grading ofaggregates and bitumen content of the mix used for such
patch repair shall be in accordance with Clause 501.
3004.13. Preparation ofthe area for pot-hole and patch repair Each
pot-hole and patch repair area shall be inspected and all loose material
removed. The area shall be cut/trimmed either with jack hammer or hand
tools like chisels, pick-axes etc., such that the area is in the shape of a
<< 629
I - I ~
rectangle or square. The edges shall be cut vertically uptothe level where the
lowerlayer is stable without any loose material, The area shall be thoroughly
cleaned with compressed air or any appropriate method approved by the
Engineer to remove all dust and loS particles. The area shall be tacked or
primed with cutback or emulsion depending upon whether the lower layer
is bituminous or granular in nature. The sides, however, are to be painted
with hot tack coat material using a brush. The primecoal and tack coat shall
conform to Clauses 502 and 503 of these Specifications, respectively.
3004.1.4. Backfilling operation : The mix to be filled shall be either
ahot mix or a cold storable mix (using bituminous emulsion). Mixing shall
be done in a plant of suitable capacity. It shall be placed in thicknesses not
more than 100 mm (loose). It shall be compacted in layers with roller/plate
compactor/hand roller/ rammer. While placing the final layer, the mix shall
be spread slightly proud of the surface so that after rolling, the surface shall
be flush with the adjoining surface. If the area is large, the spreading and
levelling shall be done using hand shovel and wooden straight edge. During
the processof compaction with roller or other means, the surface level shall
be checked using a 3 m straight edge.
3004.1.5. Measurements for payment: Filling of pot-holes and patch
repair shall be measured in sq.m.
3004.1.6. Rate: The Contractunit rate for filling of pot-holes and patch
repair shall be in full compensation for
(i) fumi thing all materials required;
(ii) works involved in trimming, tacking, priming with cutback or emulsion;
(iii) all labour, tools, equipments and incidentals to complete the work inaccordancewith
the Specifications.
3004.2. Sealing of Cracks with Fog Seal

3004.2.1. Scope: Fog seal shall consist of an application of emulsified
bitumen, withoul any aggregate cover for sealing fine hair-cracks like
shrinkage cracks and alligator cracks or rejuvenating oxidised bituminous
surfaces. Areas having cracks with less than 3 mm width shall be considered
for this treatment.
3004.2.2. Material : Bituminous emulsion for Fog Seal shall be of a
slow setting type.
3004.2.3. Application : The area to be applied with fog seal shall be
thoroughly cleaned with compressed air, scrubbers, etc. The cracksshall be
cleaned with pressure airjet to remove all dirt, dust, etc. The fog seal shall
be applied at the rate of 0.5-1.0 litre/sq.m. using equipment like a pressure
<< 630
tank, flexible hose and spraying bar or lance. Traffic shall be allowed on the
surface after the seal has set to a non-tacky and firm condition so that if is
not picked up by the traffic.
3004.2.4. Measurements for payment: The fog seal work shall be
measured in sq.metres.
3004.2.5. Rate : The Contract unit rate for application of fog seal shall
be in full compensation for:
(i) supplying of fog seal material and all the operations for applying it; and
(ii) all the labour, tools,equipments and incidentals to complete the work in accordance
with this Specification.
3004.3. Slurry Seals

Clause 516 shall apply, with the modification that simple implements
and tools amenable to manual methods shall be used.
3004.4. Premix Carpetfor Renewal of Surface
The work shall consist of laying a 20 mm thick open-graded premix
carpet for renewal of surface. The stipulations contained in Clause 509 shall
govern as regards scope and materials. A tack coat shall be applied
conforming to Clause 503, but manual methods or use of relatively small
capacity equipment shallbe permitted. The premix shall be prepared in hot-
mix plants of suitable capacity or small portable mixers, approved by the
Engineer. Rolling shall be done as per Clause 509.1.3.5. A seal coat
conforming to Clause 513 shall be applied after laying the carpet.
The work shall be measured in sq.rnetres and the Contract unit rate shall
cover supply of all materials, labour and equipment and carrying out the
work to Specifications.
3004.5. Surface Dressing for Maintenance Work
The work shall be done in conformity with Clause 508, except that the
use of small and portable equipment shall be permitted.
3005. MAINTENANCE OF CEMENT CONCRETE ROAD
3005.1. Repair of Joint (hooves with Epoxy Mortar or Epoxy
Concrete
3005,1.1. Scope : The work shall consist of repair of spalled joint
grooves of contraction joints, longitudinal joints and expansion joints in
a concrete pavement using epoxy mortar or epoxy concrete.
3005.1.2. Materials: The type/grade of epoxy compatible with the
coefficient of thermal expansion of concrete shall be used with either
<< 631
processed fine aggregate or fine stone chips to produce a dry mix forrepairing
spalled or damaged edges.
3005.1.3. Repairing Procedure: Spalled or broken edges shall be
shaped neatly with a vertical cut with chisels into the shape of rectangle.
Small pneumatic chisels also may be used, provided the cutting depth can
be controlled. The depth of the cut shall be the minimum to effect repair.
After shaping the spalled area, it shall be cleaned and primed. The epoxy
mortar/concrete is then applied using hand tools like trowels, straight edges,
brushes etc. The repaired edge shall be in line with the joint groove and shall
be flush with the concrete slabs. During the repair work, any damagenoticed
to the joint sealant shall be made good by raking Out the affected portion
and resealiag.
3005.1,4. Traffic: Although the epoxy mixes set in 2-3 hours time, it is
desirable to divert the traffic for 12 hours or as per the recommendation ofthe
manufacturers.
3005,1.5. Measurements for payment: Repair of joint grooves shall
be measured in linear metres.
3005.1.6. Rate: The Contractunit rate for repair of joint grooves with
epoxy mortar or epoxy concrete shall be in full compensation for~
(i) supply and application of epoxy primer, epoxy mortar or epoxy
concrete;
(ii) all tools, equipment and incidentals to complete the work in accor-
dance with the above Specification.
3005.2. Repair InvolvingRemoval of OldJoint Sealant and Sealing
with Fresh Sealant in Cement Concrete Pavements
3005.2.1. Scope: The repair of sealant of contraction, longitudinal or
expansion joints shall include removal of the existing sealant and resealing
the joint with fresh sealant material.
3005,2,2. Material: Sealant material to be replaced shall be either hot
poured rubberised bitumen or polysulphide type of sealant as per Clause
602.2.8. As per the recommendation of the manufacturer, appropriate type of
primer also shall be applied.
3005.2,3. Repairing procedure: The existing sealant shall be raked out
with the help of a metal raker such that most of the sealant is removed.
Subsequently, the sealant stuck to the sides of the grooves shall be removed
thoroughly either by using saw cutting machine so that grooves may be
widened by one mm or by sand blasting. In no case the old sealant shall be
<< 632
present during resealing operation, If joint grooves are found inadequate in

depth, they shall be deepened as directed by the Engineer.
Before commencing the sealing operation, compressed air shall be used
to clean the joint grooves to clean the joint groove. A heat resistant, paper
backed compressible debonding strip or tape should be inserted in accor-
dance with the requirement of Clause 602.11.2. Sealant may be poured
either using hand held pourer or using mechanised sealing machines.
Sealants should not be heated directly but in double jacketed machine. All
precautions and arrangements shall be taken not to spill the sealant on the
concrete pavement. The sealant may be poured to a depth of 5 ±2 mm
from the pavement surface.
3005,2,4. Measurements for payment: Repair ofjoint sealant shall be
measured in linear metres.
3005.2.5. Rate: Contract unit rate for repair~of joint sealant shall be in
full compensation for~
(i) removal of old sealant, regrooving or sand blasting the sealinggroove and placing of
debondmg strip or tape.
(ii) all tools, equipments and incidentals to compkte the work in accordance with the
above Specification.
<< 633
Appendices
Appendices
<<
Appendices
Appendsxl
LIST OF IRC PUBLICATIONS REFERRED TO IN THE
SPECIFICATIONS, CODES & STANDARDS
NumbeT Designation TItle
IRC : 21965 Route MaskqSigns forNanonal Highways (FiratRevision)

IRC : 5-1985 Standard Specifications & Code of Practice for Road Bridges, Section
1-General Feawres ofDesign (Sixth Revisiou)
[RC :6-1966 Standard Specifications &Codeof Practice forRoad Bridges, Section
H-Loads and Stresses (Third Reviston)
IRC : 8-1980 Type Designs for Highway Kilometre Stones (Second Revision)
IRC 10-1961 Recommended Practice for Borrowpiis for Road F.mbankments
ConstnKted by Manual Operation
LRC : 14-1977 RecommendedPractice for2an Thick Bitumen and TarCarpets (Third
Revision)
IRC : 16-1989 Tentative Specification for Printing of Base Course with Bituminous
Primers
IRC : 17-1965 Tentative Specification for Single Coat BituminoqsSurface Dressing
IRC : 18-1985 Design Criteria for Prestiessed Concrete Road Bridges (Post-
Tensioned Concrete) (Second Revision)
IRC : 19-1977 Standard Specifications and Code of Practice for Water Bound Mac-
adam (Second Revision)
IRC : 20-1966 Recommended Practice for Bituminous Penetration Macadam (Full
Gan~)
IRC : 21-1987 Standard Specifications and Code ofPractice forRoad Bridges, Section
HI-Cement Concrete (PLain and Reinforcec~(First Revision)
[RC : 22-1986 StandardSpecifications and CodeofPractice for Road Bridges, Section
VI- Composite Construction for Road Bridges (First Revision)
1RC : 23-1966 Tentative Specification for Two Coat Bituminous Surface Dressing
IRC : 24-1967 Standard Specifications and CodeofPracticeforRoad Bridges, Section
V-Steel Road Bridges
IRC : 25-1967 Type Designs for Boundary Stones
[RC :26-1967 Type Designs for 200-metre Stones
mc : 27-1967 Tentative Specification for Bituminous Macadam (Base & Binder
Course)
IRC : 29-1968 Tentative Specification for 4 cm Asphaltic Concrete Surface Course
IRC :30-1968 Standard Letters and Numerals of Different Heights for Use on
Highway Signs
<< 637
Appendices
Number Designation Title
IRC : 35-1970 Code ofPractice for Road Markings (withPaints)

IRC :36-1970 Recommended Practice for the Construction ofEarth Embankments
for Road Works
IRC : 37-1984 Guidelines forthe Design ofFlexible Pavements (FirstRevision)
IRC : 40-1970 Standard Specifications andCode of Practice forRoad Bridges, Section
1V-(Brick, Stone and Block Masonry)
IRC : 45-1972 Recommendations for Estimating the Resistance of Soil below the
Maximum Scour Level in the Design ofWell Foundations of Bridges.
IRC : 47-1972 Tentative Specification for Built-up Spray Grout
IRC 48-1972 Tentative Specification for Bituminous Surface Dressing using Pre-
coated Aggregates
IRC : 49-1973 Recommended Practice for the Pulverixation ofBlack Cotton Soils for
Lime &abilisation
1RC : 50-1970 Recommended Design Criteria for the Use ofCement Modified Soil
in Road Construction
IRC :51-1973 Re~ommendedDesIgnCritcriaforthe LJseof Sol’ LimeMixesin Road
Construction
IRC : 56-1974 Recommended Practice for Treatment of Embankment Slopes for Ero-
sion Control
IRC : 63-1976 Tentative Guidelines for the Use of Law Grade Aggregates and Soil
Aggregate Mixtures in Road Pavement Construction
IRC :67-1977 Codeof Practice for Road Signs
IRC 72-1978 Recommended Practice for Use and Upkeep ofEquipment, Tools and
Appliances for Bituminous Pavement Construction
IRC : 75-1979 Guidelines for the Design of High Embankments
IRC : 78-1983 StandardSpecifications and CodeofPractice forRoad Bridges, Section
VII -Eoundation ofSubstructure (First Revision)
IRC : 79-1981 RecommendedPractice for Road Delineators
IRC : 82-1982 Code of Practice for Maintenance of Bituminous Surfaceof Highways
IRC : 83-1982 Standard Specifications and Code ofPractice for Road Bridges, Section
IX-Bearings, Part I: Metallic Bearings
IRC : 83-1987 Standard Specification andCode ofPractice for Road Bridges, Section
LX, Bearings,Part IhElattomeric Boarings
IRC : 87-1981 Guidelines for the Design & Erection of False Work forRoad Bridges
1RC : 89-1985 Guidelines for Design and Construction of River Training and Control
Works for Road Bridges
IRC : 90-1985 Guidelines for Selectiçm, Operation and Maintenance of Bituminous
Hot Mix Plant
IRC : 93-1985 Guidelines on Design amid Installation of Road Traffic Signals
638
<<
Appendices
IRC :94-1986 Specifications for Dense Bituminous Macadam

IRC:SP:1l-1977 Handbook ofQuality Control for Coesuuction.ofRoads and Runways
(First Revision)
IRC : SP :31-1986 New Traffic Signs
Miniatty of Shipping & Transport (Roads Wing) Handbook on goad
Construction Machinery(1985)
IRC : Special IRC Highway Research Board, State ofthe Art: Granular and Bound
Report 11, 1992 Bases and Sub-Bases
<< 639
Appendices
Appendix 2
LIST OF INDIAN AND FOREIGN STANDARDS REFERRED
TO IN THE SPECIFICATIONS
(A) INDIAN STANDARDS
IS : 5-1978 Colour for ready mixed paints and enamels

IS : 73-1992 Paving bitumen
IS : 164-1981 Ready mixed paints, brushing, for road masking, to Indian Standard
Colour No. 356 Golden yellow, white and black
IS : 210-1978 Grey iron castings
IS : 215-1961 Road tar
IS : 217-1988 CUtbaCkbitumen
IS : 226-1975 Structural steel (standard quality)
IS 269-1989 33 grade ordinary portland cement (fourth revision)
IS : 278-1978 Galvanized steel barbed wire for fencing
IS : 280-1978 Mild steel wire for general engineering purposes
IS : 334-1982 Glossary of terms relating to bitumen and tar
IS : 383-1970 Coarse and fine aggregates from natural sources for concrete
IS : 432-1982 Mild steel and medium tensile steel bars andhard-drawn steel wire for
concrete reinforcement
(Part I) Mild steel and medium tensile steel bars
(Part 11) Hard-drawn steel wire
IS : 443-1975 Methods of sampling and test for rubber hoses
IS = 454-1961 Digboi typecutback bitumen
IS : 455-1989 Portland stag cement (fourth revision)
IS : 456-1978 Code of practice for plain and reinforced concrete (third revision)
IS : 458-1988 Concrete pipes (with and without reinforcement)
IS : 460-1985 Test sieves
IS : 508-1973 Specification grease graphited (second revision)
IS : 516-1959 Methods oftest for strength of concrete
IS : 702-1988 Industrial bitumen (second revision)
IS ~:736 -1986 Wrought aluminium and aluminium alloys, plate~for general engineer-
i:ng purposes
IS : 814-1974 Covered electrodes for metal arc welding of miki steel
640
<<
Appendices
IS : 823-1964 Code ofprocedure for manual metal arc weldtug ofmild steel
IS : 961-1975 Stnmctural steel (High tensile)
IS : 1002-1956 Multipurpose grease No. 1, No.2and No.3
IS : 1030-1974 Steel castings for general engineering purposes
IS :1077-1976 Common burnt day building brides
IS :1124-1974 Method oftest for water *bsosptiovs ci natural building stones
IS :1129-1972 Dressing ofnatural building stones
IS :1139-1966 Hot rolled mild steel and medium tensile sleet deformed bars for
concrete reinforcement
IS : 1148-1973 Rivet bars for structural purposes
IS :1149-1973 High tensile rivet ban for structural purposes
IS :1195-1968 Procedure for resting for hardness number of bitumen mastic
IS: 1199-1959 Method of sampling and analysis of concrete
IS : 1201 to indian standard methods for resting tar and bituminous materials
1220- 1978
iS : 1239-1979 Mild steel tubes (fourth revision)
(Part I)
IS : 1239-1979 Mild steel tubular and other wrought steel pipe fittings (second revi-
(Part II) sion)
IS : 1364-1967 Precision and semi-precision hesagon boks,sctnwa,nutsandlocknsts
(diameter range 6 to S9tnm) (first revision)
IS : 1367-1984 Technical supply conditions for threaded steel farmers
IS : 1387-1967 General requirements for the supply of metallurgical materials
IS : 1398-1960 Packing paper, waterproof, bitumen-laminated
15: 1442-1964 Covered electrodes for metal arc welding ofhigh tensile structural steel
1St: 1448 Method of tests for petroleum and its products
IS : 1477 Code of practice for finishing of it-on and steeWferious metal in
buildings : painting and allied finishes
(Pan I)-1971 Operationsand workmanship
IS : 1489-1991 Portland-pozzolana cement
IS : 1498-1970 Qassification and identification of soils for general engineering
purposes
IS : 1514-1959 Methods of sampling and test forquick lime and hydrated lime
IS : 1732-1971 Dimensions for round and square steel bars for structural and general
engineering pwposes
IS :1785 Plain hard-drawn steel wire for pretuessed concrete
(Part I)-1966 Cold-twisted steel bars for concrete reinforcement
641
<<
Appendices
IS : 1786-1985 High ttrength deformed steelbars andwires for concrete reinforcement

IS : 1838 Prefonned fillerforexpansion jointin concretepavement and structures
(non extntding and resilient type)
(Part 1)- 1983 Bitumen impregnated fibre (first revision)
IS : 1888-1982 Method of load tests on soils
IS :2004-1978 Carbon steel forgingfor general engineering purposes
15 :2062-1980 Stnicturai steel (fusion welding quality)
IS :2116-1980 Sand for masonry mortars
IS 2131-1981 Methods for standard penetration test for soils
IS :2250-1965 Code of practice for preparation and use of masonry mortars
15 :2386-1963 Methods of test for aggregates for concrete
(Paul) Particle size and shape
(Part 2) Estimation of deleterious materials and organic impurities
(Part 3) Specific gravity, density, voids, absorption and bullring
(Part 4) Mechanical properties
(Part 5) Soundness
(Past 6) Measuriig mortar making properties of fine aggregates
(Part 7) Alkali - Aggregate reactivity
(Part 8) Petrographic examination
IS : 2720 Methods of test for soils
(Part 2)4973 Determination of water content
(Part 3)-I980 Detennination ofspecific gravity
Section 1 Pine grained soils
Section Il Medium and coarse grained soils
(Past 4)-1985 Grain size analysis
(Part 5)-1985 Determination ofliquid and plastic limits
(Part 7)4980 Determination of moisture content/dry density relation using light
compaction
(Pan 8)-I983 Determination of water content-dry density relation using heavy
compaction
(Part 10)-1973 Determination ofunconfined compressive strength
(Part 13)-1985 Direct shear test
(Part I4)-l983 Determination of density index (relativedensity)ofcobesionless soils
(Part 16)-1987 Laboratory determination of CBR
(Part 27)-1977 De~rminationof total soluble suliihates
<<
642
Appendices
(Part 28)-1974 Determination ofdry density of soils in-place by the sand replacement
method
(Part 29)-1975 Determination ofdiy density of soils in-place by core cutter method
(Part 37)- 1976 Determination of sand equivalent values of soils and fine aggregates
(Part 40)- 1977 Determination of free swell index of soils
IS :3117-1965 Specification for bitumen emulsion for roads (cationic type)
IS : 3466-1967 Masonry cement
iS : 3764-1992 Code of safesy for excavation work
IS : 4138-1977 Safety code for working in compressed air
ES : 4332 Method oftest for stabilized s#iLs
(Part 1)4967 Method ofsampling andpreparation of stabilized soils for testing
(Part 3)4967 Test for detemnnarion of moisture content-dry density relation for
stabilized soil mixtures
(Part 4)4968 Wetting and dryingand,freezing and thawingtestsforcosnpactedsoil-
cement mixtures
(Part 5)-I 970 Detemiination ofunconfsned compressive strength of stabilized soil
(Part 7)4973 Determination of cement content of cement stabilized soils
(Part 8)-1969 Determination oflime content of lime stabilized soils
IS 4434-1978 Code of practice for in-situ vane shear test for soils
IS 4826 Hotdipped galvaniaed coatingon sound scaled wires
IS :5317-1969 Specification for bitumen mastic for bridge decking and roads
IS : 5435 (Revised) General requirements for old asphaltmacadam mixing plant
IS : 5640-1970 Method for determining the aggregate impact value of soft coarse
aggregate
IS :6006-1970 IJncoaxed stress relieved strands for prestrcs~cdconcrete
IS :6241-1971 Method often for determination of stripping value ofroad aggregates
IS :6909-1991 Supersulpbated cement
IS :6925-1973 Methods of test for determination of waxer soluble chlorides in
concrete admixtures
IS : 7537-1974 Road traffic signals
IS :8041-1978 Rapid hardening portland cement
IS :8112-1989 43 grade ordinary portland cement
ES : 8887-1978 Specification for bitumen emulsion for roads (cationic type)
IS :9103-1979 Admixtures for concrete
IS : 10262-1982 Guidelines for concrete mix design
643
<<
Appendices
Number DesIgnation TItle
iS: 12269-1987 Specification for 53 grade ordinary poilland cement

IS: 12330-1988 Specification for sulphate resisting pon~heidcement
IS : 13321 Glossary of terms for geosynthesics pats 1: lenna used in materials and
(Part 1)-1992 propetties
IS: 13325-1992 Determination of tensile properties of extruded polymer geogrids
using the wide strip-test method
iS : 13326 Evaluation of interface friction between geo-synthetics and soil-
(Part l)-l992 method of test part 1: Modified threct shear technique
IS: SP23-1982 Handbook on concrete mixes (based on indian standards)
(B) FOREIGN STANDARDS
ASTM :D-36 Thennoplastie material
ASTM : D-395 Compression set of vulcanized rubber
ASTM :D-412 Tension testing of vulcanized tubber
ASTM : D-429 Adhesion of vulcanized rubber to metal
ASTM : D-573 Accelerated aging of vulcanized robber by the oven method
ASTM : D-624 Tear resistance of vulcanized rubber
ASTM : D-664 Test method for neutralisation numberfor potentiomerric titration
ASTM : D-797 Young’s modulus in flexure of elastomer at normal and subnormal
temperature
ASTM 1075 Effect of water on cohesion of compacted bituminous mixtures
ASThI D-1149 Accelerated ozone cracking of vulcanized rubber
ASTM D-1559 Test for resistance to plastic flow of bituminous mixtures using
Marshall apparatus
ASThI D-2172 Extraction, quantitative of bitumen from bituminous paving mixtures
ASTM D-2240 indentation hardness of rubber and plastic by means of a Durometer
ASTM D-3625 Test method for effect of water on bitumen coated aggregate using
boiling water,
ASTM : D-4533 Test method for trapezoid tearing strength ofgeolextiles.
ASTM : fl-li Specification for wire cloth sieves for testing purposes -
ASTM:E-S10 Test method for coefficientofretro-reflectión or retro-reflection sheet-
ing.
AASFETO: DM283 Coarse aggregate for highway and aixport construction
AASHTO: DM 294-70 Fine aggregate for bituminous paving mixtures
AASHTO : DM 288-82 Geotextiles used for subsurface drainage pu~oses
AASI-ITO : DM 17-77 Mineral filler for bituminous paving mixtures
AASHTO: DR 5-80 Selection and use ofemulsified asphaits
<< 644
Appendices
AASHTO: DM 81-75 Cut-back asphalt (rapid-curing type)

AASHTO : Dlv! 82-75 Cut-back asphalt (medium~curingtype)
AASHTO: DM 140-80 Emulsified asphalt
AASHTO: DM 7-10 Materials for embankments and subgrades
AASHTO : DM147-65 Materials for aggregate and soil-aggregate
(1980) sub-base, base and surface courses
AASIITO : OM 216-68 Lime for soil stabilisation
AASHTO : DM 249-79 White andyeliow reflectivethermoplasticstripingmaterials(solid form)
AASHTO : DM 268-77 Weatherometer
AASHTO: DM282.80 Joint sealants,hot poured, elastometic type. (or ASTM : D3406) for
portlandcement concrete pavements
BS ~‘~10-1969 Test sieves
BS 729-1971 Hot dip galvanized coatings on iron and steel articles
ES 812-1975 Testing aggregates
Part 2- Methods for determination of physical properties
Part 3 - Methods for determination ofmechanical properties
Part lii - Method for determination often per cent fines value (TFV)
Part 114- MethOd for detennination of’ the polished-stone value
BS : 1047.1952 Air-cooled blastfumace slag coarse aggregate for concrete
BS 1154-1970 Vulcanized natural rubber compounds
BS : 1377-1975 Methods of rest for soils for civil engineering pur~p~scs
ES : 1447-1973 Mastic asphah (limestone fine aggregates) for roads and footways
BS : 1449-1956 Steel plate, sheet and strip
Part 1-1972 Carbon steel plate, sheet and strip
Part 2-1967 Stainless and heat resisting plate, sheet and strip
BS : 1470-1972 Wrought alinninimn and aluminium alloys for general engineering
purposes - plate, sheet and strip
IS :2630 Preformedjoint filler
BS : 2870 Rolled copper and copper alloys : sheet, strip and foil
BS : 3262 Hot-applied thermoplastic road marking materials
Part-i Specification for constituent materials and mi,uus’es
Part-2 Specification for mad performance
Part-3 Specification for application of material to road surface
BS : 5212 Cold poured joint sealants for concrete pavements
Part 2-1975
<< 645
Appendices
BS : 6044 Specification for pavement marking paints

B.S : 6088 Specificationforsolid glassbeadaforuse with roadmaikingcompounds
and for other industrial uses
ES : 6906 Methods of teatfor geotextiles
Past I Determination of the tensile properties using a wide width strip
Part 2 Determination of the apparent pore size distribution by dry sieving
Pail 3 Determination of waterfiow normalto theplane ofthegeotearile under
a constant head
Part 4 Determination ofthe puncture resistance (CBR puncture teat)
Part 7 Determination of in-plane waterfiow
ES : 7542 Method at test for curing compound forconcrete
CR111 and ICC, Bituminous Road Construction Hand Book
New Delhi
The asphalt han&took, manual
Asphalt institute
series No.4 (MS-4) 1989 edition
GRI-GGI Geogrid rib tensile strength
GRI-GG2 Geogrid junction strength
GRU3G3 Tensile creep testing ofGeogrids
(GRI denotes standards for test prepared by Geosynthetic Research Institute at Drexel
University Philaddphia, USA)
<< 646
Appendices
Appendix 3
(Clause 4023.2 and 403.3.2)
METHOD OF SIEVING FOR WET SOILS TO
DETERMINETHE DEGREE OF PULVERISATION

I. A sample of pulverised soil approximately 1kg in weight should be taken and weighed(W
1).
2.. It should be spread on the sieve and shaken gently, care being taken to break the lumps of
soils as little as possible. Weight of soil retained on the sieve should be recorded (Wi).
Lumps offiner soils in the retained material should be broken until all the individual
particulars finer than the aperture size of the sieve are separated.
3. The soil should again be placed on the sieve and shaken until sieving is complete. The
retained material should be weighed (W,).
4. WeIght of roil by per cent passing the sieve can than he calculated from the expression:
(W1—W2)x 100
(W1-W,)
<< 647
Appendices
Appendix 4
GUIDELINES ON SELECTiON OF THE GRADE OF BITUMEN
(Source Bituminous Road Construction Handbook, Indian OilCotporation and Central Road
Research Institute)
A For bituminous premix carpet, choice is governed by climatic conditions and intensity of
traffic.
(I) Grade 30/40 for areas where difference between maxtrnutn and minimum
airnospheric temperatures is less than 25 C and traffic intensity is greater than 150(1
commercialvehicles per day. For traffic intensityteas than 1500 commercial vehicles
per day, Grade 50/60 is preferred.
(ii) Where the difference between maximum and minimum atmospheric temperature
ismorethan25~Cand trafficintensity is greaterthanl500conmrercial vehicles per
day, Grade 50/60 maybe used. For traffic intensity of less than 1500 commercial
vehiclesperday,Grade 8OflOOmay beused. Forroads withvery heavy traffic greater
than 4500 commercial vehicles per clay, such asmetropolitan city roads, Grade
30/40 is preferred.
(iii) Grade 80/100 may be used in high altitude and snow-bound regions, irrespective of
traffic intensity cotlaideration.
B For bituminous macadam and penetration macadam as also built-up spray grout, Grade
30/40 (for hot climates) and 60/70 or 801100 for other climates are suggested.
C For a dense-graded bituminous concrete, a more viscous grade like 60170 can withstand
stresses of heavier wheel loads better than a less viscous grade of 80/100. Similarly
pavingbitumen grade 60/70 isrnore advantageous for roadswith largenumberofrepetitions
ofwheel loads like expressways, urban roads, factoryroads etc. High stability requirement
cannot be meteffectively by less viscous bitumen.
D A more viscous grade of bitumen is advantageous inreducing stripping ofbitumen film
from aggregates in the presence of water.~
E With rounded river shingles,amore viscous grade ofbitumen compensates tosomeextent
for poor mechanical interlock. A comparison of penetration grades andviscosity grades
(AC-23to AC-40)ofasphalt cement and AR grades (basedonRolling Thin Film Oven Test
residue) is shown below.
648
<<
Appendices
tt~
AR.
100
AR.
SO
AC. LU
C,
2000
0 t
>4 10 ;c. 2.5
~1ooo
Coniparision of per~etration grades and viscosity

grades of bitumert
649
<<
Appendices
Appendix 5
ANTI-STRIPPING AGENTS USED FOR BITUMINOUS

MATERIALSAND MIXES
I. Scope
1.1. Anti-stripping agents are used for bituminous materials and mixes to ensure adhesion
between aggregates (hydrophilic in nature) and bitumen, even under submergence in water.
Prior approval of the Engineer shall be taken in respect of both qualitative and quantitative
use of a particular product.
2. MaterIals
2.1. The anti-stripping agents shall be fatty acid amines having a long hydrocarbon
chain.
2.2. PhysIcal and Chemical Requirements : The anri.stripping agents shall conform to
the physical and chemical requirements as detailed in Table AS-I.
2.3, Storage and Handling : Anti-stripping agents shall be properly stored in closed
containers made of steel or aluminium. Containers made of zinc, copper, polythene PVC and
most types ofrubber are not suitable for use. A~most of the anti-stripping agents cause irritation
when in contact with human skin and are also irritating to the eyes, protective gloves for
hands and goggles forthe eyes shall be used while handlingthem, specially in caseof liquid anti-
stripping agents.
3. Use in Sprayed Work
3.1. AdditIve Dosage: The dosage shall be determined depending on the nature
(stripping value) of the aggregate and the size of aggregate. While the recommended minimum
dose of anti-stripping agent for sprayed work is given in Table A5-2, the actual dosage shall be
determined in the laboratory as directed by the Engineer.
3.2. MixIng Procedure During Construction: The anti-stripping agent supplied in
liquid, solid or concentrate form shall be thoroughly mixedwith liquid bituminous material or
with straight rim bitumen. Whenused with straight run bitumen, the correct dose of anristripping
agent shall be mixed in a hot bitumen tank boiler.
The two constituents shall be agitatedtill the anti-stripping agent is thoroughly mixed. The
doseofanti-stripping agenishall suitably be increased ifthe binderis to remain in bitumen boiler
tots longerperiod.
4. Use in Premix Work
4.1. Additive Dosage: The dosage shall be determined depending on the nature
(stripping value) ofthe aggregate and the percent voids in the mix~Whilethe recommended
minimum doses fordifferent types of bituminous premix materials in terms of voids content are
given in Table A5-3, the actual dosage shall be determined irs the laboratory as directed by the
Engineer.
650
<<
Appendices
TABLE A5.1,SPECIFICATION FOR ANTISTRIPPING COMPOUND
S~No. Test Method - Litelt
1. Appearance Visual Liquid/Solid
2. Odour Smelling Agreeable
3. Specific gravity 27’C IS: 1202-1978 0.860-1.03
4. Pour point ‘C Maximum IS: 1448 42
5. Flash point (COC~ IS 1448 150

Minimum
6. Water Content per cent Vol. IS: 1448 1.0

Maximum
7. Solubility in diesel As given at Complete

oil (HDOorLDO) in end of
theraiioof298at Appendix
50’C
8. Total base value mg ASTM 1)664 200

KOHIg minimum
9. Nitrogen content per cent Elemental 7,0

Wt. minimum Analyser
10. Strippingvalue with IS : 6241 No stripping

bitumen containing As given at
lpercentWLantiatripping theendof
compound at 40’ C Appendix
24 hours
11. Under water coating - do - Complete

test Coating
12. Thermal stability at - do - Should not

163’C 5 hours lose its efficacy
13. Boiling water lest percent ASTM D 3625 95

minimum coating
14. Retained Marshall As given at 75

Stability per cent minimum the end of
appendix
<< 651
Appendices
TABLE A5.2. TENTATIVE RECOMMENDED MINIMUM DOSE OF

ANTISTRIPPING AGENT FOR SPRAYED WORK
Aggregate Dose ofantlatripping agent In per cent by

stripping weight of bitumen
value
Surface Penetration Surface Liquid
dressing Macadam! Dressing seal
with Built up with coat
precoated spray grout uncoated
aggregate aggregate
0-25 0,5 0.6 0.7 08
25-50 0.6 0.7 0.8 1.0
50-100 0.75 1.0 1.0 1.0
4.2. Mixing Procedure During Construction : The required dose of the anti-stripping
agent shall be poured into th~hot bitumen tank and allowed 15 to 30 minutes of circulation
or stirred to ensure a homogeneous mix. It is necessary to use a stable antismripping agent or
increase the dose according to expected degradation. Alternatively, the correct dose shalibe
injected intothe bitumen line by means ofa pump. The agent isfed into the bitumen first before
it is sprayed on the aggregate in the mix; thus, no separate mixing time for mixing the agent
with bitumen is required. In rolled asphalt and bitumen mastic surfacing works, precoated
chippings are pressed intothe hard surfacewhile the mix isstill hot to makethe newly laid surface
skid resistant. These chippings shall be precoated with bitumen treated with antistripping
compound. -
TABLE AS-3. TENTATIVE RECOMMENDED MINIMUM DOSE OF
ANTISTRIPPING COMPOUND IN BITUMEN PREMIX WORKS
Stripping Dose of antistripping agent in per cent by weight of bitumen

value ol
aggregate Voids content VoIds content Voids content
3-5 percent 5.10 per cent 10-15 per cent
0-25 0.3 0.4 0.5
25.50 0.4 0.5 0.6
50-100 0.6 0.8 1.0
<< 652
— .. .. —.———.—. . .. .
Appendices
Annexw’e to the Appendix S
TESTING PROCEDURE FOR SOLUBILITY OF

ANTISTRIPPING AGENT IN DIESEL OIL
Procedure: 98m1 ofdiesel oil (HDO orLDO) and2m1 ofantistrij~ingagent shall betaken
inameasuringcylinderwith stopper. The cylinder along withita contents shall be keptin water
bath,maintained as5O°+l°Cforhalfanhour.Issball then betalcenout fromwaterbath and shaken
vigorously for 10 minutes, The ssopper shall be removed and the cylinderkeç* in waterbath for
half an hour and examined for separation ur settlemenL
Reporting ofresults: An antistripping agent is repoited to be completely soluble in diesel
oil ifno separation or settlement is observed for half an hour.
TESTING STRIPPING VALUE OF AGGREGATES USING BITUMEN WITH
VARYING PERCENTAGES OF AWI’ISTRIPPING AGENT.
Procedure: Coarse aggregate passing 19mmsieve and retained on 13.2 mm sieve shall
be washed and dried in an oven for 24 hours at 110°C. Such dried 200 gms ofcoarse aggregates
shall be heated at 149°Cand then mixed with 801100 penetration gradebitumen5percentby
weight of coarse aggregate heated upso 163°C. The mixture shall be mixed thoroughly for
uniform coating of aggregates by bitumen. The mix shall then be transferred to a 500ml beaker
and allowed to cool to room temperature. Distilled water shall be added inthebeaker,which shall
be placed in a water bathmaintained at40°~ 1°Cfor24 hours. The percentagedegree of stripping
shall be assessed visually. The test shall also be conducted with water containing 1 per cent
Sodium Chloride, as a precautionary measure to eliminate water contamination. The test is
repeated using bitumen containing upto one per cent ofantisiripping agentin stages of0.25 per
cent.
TESTING EFFICACY OF ANTISTRIPPING AGENT TO COAT AGGREGATES
WITH BITUMEN IN PRESENCEOF WATER
Procedure: The antistrippingageteshailbe added in percentcontents of 00,0,25,0.50.,
035, l.O0and 1.25 to cutbackbitumen MC3(4partsofbiuunen&WlOOand 1 part of kerosene
oil). The blends shall be used for testing their abilityto coat the road aggregates under water,
(a) 100gm of cleananddry stonedussconforsning to followinggradation shall betaken:
Steve Size per cent passing
236mm 100
1.18mm 80
600mic. 75
300mic. 45
3~’4of its volume with distilled water at 40°C. The
The bottle shall be Filled to
bitumen-antistripping agent blend shall be added in the bottle at the rate of 7.5 per cent by
weight of stone dust. The stopper shall be replaced and the bottle shall be vigorously shaken
for two minutes.The water shall be then drained off and the stone dust shall be transferred to a
piece of paper and examined visually forsatisfying complete coating. The minimusn per cent
content of antistripping agent at which the stone dust sample is thoroughly coated shall be
recorded. The test shall be repeated at 60°Cin water as well as 1 per cent solution of Sodium
Chloride in water for both the testing temperatures.
653
<<
Appendices
(b) The under water coating test shall further be conducted with coarse aggregate,
passing 19 mm sieve and retained on 13.2 mm sieve. In this case the per cent
content of she cuthack-antistripping agesn blendshall be kept at 5 per cent by weight
of coarse aggregate. In order to take care of contamination in water, the test shall
also be carried out in the I per cent Sodium Chloride in water.
The minimum per cent contentof antistripping agent atwhich stone dust/coarse aggregate
is thoroughly coated as per (a) and
~i) shall be taken as the dose of antistripping agent.
TESTING FOR THERMAL STABILITY OF ANTISTRIPPING AGENT
Procedure: Blends of antistripping agent and bitumen of 80/100 grade shall be prepared
with 0.00,0.25,0.50, 0.75 and 1.00 per cent consents of antistmipping agent and kept in oven at
163°Cfor five hours. After the heat exposure, she blend samples are fluxed with kerosene oil
so obtain the consistency of MC 3 and tested for under water coating test
Reporting of test results: An antistripping agent ahall be deemed to be beat resistant if the
dose requirement before and after beat exposure remains unchanged.
QUANTITATIVE EVALUATION OF RETAINEDMARSHALL STABILITY
VALUES AFTER IMMERSION IN WATER
Procedure: For quantitative evaluation, the tests shall be carried out as stipulated in
ASTM D1075 (Effect ofWater on Cohesion ofcompactedBisuminous Mixtures). Thegradasion
of aggregates shall be such as to give sufficient voids in the compacted bituminous mix to bring
out the effects of stripping. The gradation of aggregates shall be as under:
Steve Size per cent Passing
19.00mm . 100
13.20 mm 75-100
9.50mm 60-80
4.75mm 35-55
2.36mm 20-35
600 mic 10-22
300 mic 6-16
lSOmic 4-12
75 mic 2-8
The Marshall test specimens shall be prepared using Sper centbitumen of80/100 grade by
weight of aggregates blended with varying percentages of anristripping agents from 0 to I per
ient in steps of 0.25 per cent The test samples shall give a void content of about 6’per cent. At
least 8 standard Marshall specimens for each of the varying antistripping agent percentages shall
be prepared. Bath set of 8 test specimens shall be sorted out in two groups of4 each so that the
average specific gravity of the specimen in group I shall be essentially the same as in group IL
Group-I shall be tested for Marshall Stability in the usual procedure ASTM D1559. Group-Il
specimens shall be immersed in water for 24 hours at 60°C ±1°C.and then shall be teased
immediately for Marshall stability as per ASTM D 1559.
CalculatIon: The numerical index of resistance of bituminous mixtures to the detrimental
effect of water shall be expressed as the index of retained stability: -
Average Marshall Stability ofGroup-Il

x 100 per cent
Average Marshall Stability of Group-i
RequIrement for acceptance: A minimum of 75 per cent of resaiised Marshall strength
shall be required for acceptance.
654
<<
Appendices
Appendix 1000-1
DRAFT DOCUMENT ON IS : 9077-1979 CODE OF PRACTICE
FOR CORROSION PROTECTION OF STEEL REINFORCEMENT
IN RB AND RCC CONSTRUCTION (REVISED)
FOREWORD
This Indian Standard has been revised taking into consideration the experience gained
over the years, developments thote have taken place subsequently and also considering the
need for evolving suitable acceptance tests for quality control. In this regard, the electrochernical
tests developed at the Central Electrochemical Research Institute, Karaikudi, and also the tens
specified in ASTMA775(A775 M-90 for powder epoxy coating have been considered.
This revised standard supersedes earlier standard namely 15:9077-1979. While revising
this standard, is was decided so cover the various test procedures required to ensure the quality
of individual product as well as the finished products. Is was also decided that this standard
should include very stringent test procedures particularly for finished products so that these
procedures can be used to evaluate not only the corrosion resistance of a particular finished
product covered by this standard but also any other finished product such as galvanising,
powder epoxy etc.
1. SCOPE;
1.1. This standard (revised) specifies the recommended practice for surface preparation,
surface pretreatment and anti-corrosive treatment based on inhibited and sealed cement slurry as
an in-situ process forcorrosion protection ofmild steel reinforcesnent/ IIYSD bars in conventional
reinforced concrete structures and conventional reinforced brickwork, constructions This
practice is alto applicable for non-prestressing steels (mild steel reinforcement/HYSI) bart) used
in prestressedConcrete ssmcture.
1.2. This standard applies only for in-situ corrosion pmtecsicn of rn:ild steel reinforcement)
HYSD bars after all bending and shaping operations are completed. However, this does not
preclude the possibility of using this practice as a factory process.
2. ANT1CORROSIVE TREATMENT PROCFSS SEQUENCES
The anticorrosive treatment should necessarily include the following sequential steps~
(a) Surface preparation (dc-rusting)
Since presence of oil, grease, dirt, heavy scale and rust will adversely affecttheperformance
of any anticorrosive treatment, it is essential to adopt suitable surface preparation technique,
Surfacepreparation can be either by acid pickling or by sand blasting.
(b) Surface pretreatment
Surface preparation should be immediately followed by a surface treatment step to
ensure temporary protection during the time lag between the dc-rusting and finish coating.
Thispretreatsnent should not adversely affect either tbe adhesion ofthe finish coat or corrosion
performance.
(c) Inhibited Cement Slurry coating
A minimum of2 coats should be applied to ensurefull coverage.
(d) Sealing treatment
Sealing treatment should make the coating harder and less permeable.
655
<<
Appendices
A typical flow diagram is shown in Fig. 1000/1.

3. PROCEDURE FOR SURFACE PREPARATION
3.1. Sand Blasting
Sand blasting of the steel surface to SAE 2 1/2 standards can be done
3.2. De-rusting by Pickling
The pickling weld should be preferably based on hydrochloric acid and should include an
efficient inhibitor so prevent base metal attack.
A typical dc-mating solution should have the following characteristics:
(a) inhibitor efficiency should not be less than 97 per cent.
(b) weighs loss of a polished standard mild steel reinforcerrsesst / HYSD bars
specimen when dipped in the solution for 10 minutes shouldnot be more than 2 g per
sq. metre.
(c) Specific gravity when tested using a standard specific gravitybottle should be around
1.12.
4. PROCEDURE FOR SURFACE PRE-TREATMENT
De:in.sted surface should be immediately converted by using phosphating treatment. It
should be ensured by a suitable rinsing process that no residual acid is remaissing on the
surface atthe time ofpisosphating. A typical phosphating composition ofbnsahable consistency
should have the following characteristics:
(a) Coating weighs when tested as per test procedure A given hereunder should be around
4.5 gsns./sq.m.
(b) Density ofthe product should be in the range of 1.22 to 1.4 kg/litre.
(c) Presence of fungicide shall be tested by dissolving the jelly in deionized water, the
resulting solution shall be yellow incolour.
(d) Presence of phospisasingchesnical in jelly shall be ensured with ammonia molybdate
test
(e) pH of the composition when tested in a standard specific gravity bottle should be
asound 2.5 0.1
(I) Nail scratch test should clearly leave a mark on the specimen. This indicates the
existence ofthe coating.
5. PROCEDURE FOR INHIBITED CEMENT SLURRY COATING
5.1. A typical inhibitor admixture used should have the following characteristics:-
(i) It should in liquid form ready for mixing with the ordinary portland cement
(ii) Specific gravity when tested using a standard specificgravity bottle should be 1.04
+0.02
(iii) pH when tested using a pH meter should be 12.75 ~0.25
(iv) Tolerable limit for chloride in inhibitor - admixture when tested using anodic polari-
sation technique (as per test procedure H) should be 300 ±25 ppm
5.2. OrdInary Portland Cement
This should conform to lS:269 and should be sieved topaaa through 75 microns IS sievc.
656
<<
STEPS
DURATION
STORAGE YARD (For iOns length
Rebar)
PICKLING [ TANK 15 — 30 stirs
RINSING 2 — 3 sin
PHOSPHATING (brushing) -f 3 — 4 sin
REACTION TIME F’ 40 sin
RINSING
~-Ii~~IiIII] 2 — 3 main
“A” SOLUTION (Brushing)
INHIBITED CEMENT SLSJRRY

FIRST COAT (Brushing)
~ii’iiixiii’ii~ 2
3
—
—
3
4
sin
rain
AIR DRYING 12 — 24 rain
“B’ SOLSYTION (Brushing) 2 — 3 sin
INHIBITED CEMENT SLURRY 3 - 4 sin

SECOND COAT (Brushing)
AIR DRYING 12 — 24 h
“B” SOLUTION (Brushing) ~iiiiiiiiii~ 2 — 3 sin

AIR DRYING
“B” SOLUTION (Brushing) ~i~ixiiiiiiiii~ 2-4
2 - 3
h
sin
AIR DRYING 2-4 h
“B” SOLUTION (Brushing) 2 — 3 sin
AIR DRYING 2-4 h
STACKING YARD
[I~I~~1
Fig. 10O~W1: Flow Diagram for Anti-Corrosive Treatment of Reinforcement Bars
<<
657
Appendices
5.3. Cement and inhibitor admixture shouldbemixed inspecified proportionso have suitable
consissency. Coating should be appliedpreferably by brushing. However, underspecific circurn~
stances spraying or dipping is also allowable.
5.4. Sufficient time lag should be allowed in between successive coatings to ensure final
setting of theundercoat. A minimum of6 to 12 hours may be necessary.
5.5 A minimum oftwo coats with sufficient time lag in between should be applied.
6. SEALING TREATMENT
The sealing treatment should be performed over the coated surface immediately after final
setting of the sop coat. Sealingtreatment can be applied by brushing. spraying or dipping.
6.1. A typical sealing solution should have the following characteristics:-
(a) Specific gravity when tested using a standard specific gravity bottle should be 1.09
+0.02
(b) pH when measured using a pH meter should be4 2.25 ±0.25
(c) Tolerable limit for chloride in sealing solution using anodic polarisation technique
should be 450 ±25ppm (as per test procedure B).
7. SPECIFICATIONS FOR FINISHED END PRODUCT
7.1. Finished coating when visually examined should be fairly uniform in thickness and
should be devoid of any defects such as cracks, pinholes, peeling, bulging etc. No surface area
shou’d be left uncoated. No rust spot should be visible so the naked eye.
7.2. Thickness of theCoating
The minimum thickness ofshe coating shall be 200 microns. Preferable range is 200 so 400
microns.
7.3. Bond Strength of the Coated Rebar
The bond strength of she coated rebar and concrete shall not be less than that specified in
IS:456 at per clause No, 0,2, 5, ii and 44.1.2 and tested as per IS:2770 (Part 1).
7.4. Hardness ofthe coating when measured using a pencil hardness tester shall be around
5 IIto7H.
7.5. Tolerable limit for chloride in 0.04 Normal NaOH medium using anodic polarisasion
technique (as per test procedure B) shall be around 4500 to 5000 ppm.
7.6. No film failure as evidenced by evolution of hydrogen gas at the cathode or
appearance of corrosion products at the anode shall take place during one hour oftesting (as per
test procedure C).
8. GENERAL REMARKS:
Is is advisable that severely rusted and heavily pitted reinforcements are not accepted for
treatment.
TEST PROCEDUREA
Determination ofphosphate coating weight
7.5 cm a 2.5 cm or 7.5 cm a 5 cm mild steel polished and degreased specimens are to be
used for this test. First the blank loss of unphospbated specimen is to be found out. For this,
the initial weighs (W,) is accurately weighed. The specimen is kept immersed in the Clark’s
solution or patented inhibitedde-russing solution for 1 minute. The specimen is removed, rinsed
658
<<
Appendices
in distilled water and dried using hotairblower. The specimen is immediately weighed (W
2) The
difference between W1 andW2 is termed as blank loss.
Another specimen (polished arid degreased) is brushed with phosphating jelly and kept
for 45 minutes. Then the specimen is washed free ofjelly, rinsed in clean water and dried
using hot air blower. The phosphated specimen (Vi’,) is accurately weighed. After weighing,
the specimen is kept immersed in Ouk’s solution or patented inhibited dc-rusting solution for
one minute. Then the specimen is removed, rinsed in distilled water and dried using hot air
blower. The specimen is immediately weighed (W4). Coating weight = W3- W4 - blank loss.
TEST PROCEDUREB
Anodic Polarisasion Technique
Mild steel reinforcement / HYSD Bar test specimens of size 10mm in dia and 100 mm
in length wish stems of size 5mm india and 50mm in length is polished, degreased and sealed
at bottom edge and as the stem with suitable scalers like wax, lacquer. Then test specimen is
kept immersed in tess solution and potential is momtored using high impedance mulsimeter
against suitable reference electmde such as saturated calomel electrodel copper-copper
sulphate elecsrode. After getting stabilised potential using appropriate current regulator (0-100
mA), the test specimen is anodically polarised at a constant current density of 290 ~.tAcm
using a platinum/stainless steel/TSIA/polished mild steel reinforcement/HYSD Bar as cathode.
Potential with tirefé is followed for 5 minuses after current is applied. The maximwn chloride
concentration upto which the potential remains constant for 5 minutes is taken as a measure of
tolerable limit,
TEST PROCEDURE C
Resistance to Applied .Vol cage Test
Two mild steel reinforcement / HYSD bars of size not less than 10mm india and 800mm
in length shall be given anti-corrosive treatment as per specified procedure. The end of the
rebars shall be soldered with insulated copper elecsrical connecting wire (14 gauge) to serve as
electrical contact poinL Coated rebus at the two ends shall be sealed with an insulating
material to a length of 25 mm as each end, Test area shall be the area between the edge of the
bottom sealed end and immersion line which shall not be less than 250mm in this case.
The coated rebus shall be suspended vertically in a non-conductive plastic container of
size not less than 150 mm x 150 mm square and 850 mm high. The rebars shall be so
suspended as so have a clearance of25 mm at bottom, 45 mm at the sides and 40mm in between
the rods.
Thecontainershall thenbe rifled toa heightof800mm with an aqueous solution of7 percent
NaCI, A potential of2 Yin between the coated rods shall be impressed for a period of60 minutes
using a high resistance volt meter for direct current having an internal resistance ofnot less than
10 mega Ohms and having a range upto S V (minimum). Storage batseries may be used for
impressing the voltage.
During this 60 minuses oftesting, there shall not be any coating failure as evidenced by
evolution of hydrogen gas at the cathode or by appearance of corrosion products of iron at the
anode.
<<
659
H~TORVOF SINKING OF WELL NO - AIPENJ)JX - 120041-I
LOWEST BED LEVEL — L0WESr WATER LEVEL, HIGHEST FLOOD LEVEL _____________ FOUNDING LEVEL
HEIGHT OF CURB __________ HEIGHT OF (~UT~ING

EDGE _______
SThINING SINKING KENTLEDGE
REDUCED RI. OFTCP RI. OFTOP HEIGHTOF TOTAL RL. OF. — INITI,\1, FINAL SINKING RI. OF DEPTH OF STRATA wEIGHT ECCENTRI- ECUEN]RI QUANTITY REPORT REPORT REMARKS SIGNATURE
OF STFINING 511 INING HFICH1 UI RI Fl RI N( I GAUGE (,AU( I DL RIM BOFIOM STJMP MI ~‘ CIIY ~ OF [MU[Xii I) RIG \RDINC ANY SPU( tAt 01
LVI I ~RI ) OF SlEININU
I3UTIDM BEIORI Al [I R C \S1 SF1 INING LI VII RI Al )1N RI ADIM I UI DM UI C I I I IL’.( Bit OW \\ Ii H Al UNG X Al ONG MAIl RIM OBS I I S OR MI tHUD 01 SUPFR\~ISING
t UI UNG CASTING LASTING (CCII 4 CCII 3) (IN(I I DING) (Al WHICH ~LUI 9 LU] ~ I IX,1 CLTIING AXIS Y AXJ~ SA’JI) I~I1 ()\V SINKING Oil ICLR
CURB ANI) CUllING (COI..7 C )E.K~ EDGE DURING SINKING EMPLOYED
EDGE
CUFFING EDGE IS
EDGE- Pt ACE1)) .
(COI~$..C0L3)
MEFRE METRE MUIRI-. MEIRE MITRE METRE METRE TONNF METRE MEfl~E ~ METRE
3 4 c 7 9 10 II 12 Ii 14 I~ 17 IS E) 20 21
~____-_
660
<<
APPENDIX 1200/1-2
(PLACE) (PLACE)
WELL ELO -
PLAN SHOWING WELL NOS.

0%
0-~
U’s
- TftAHC DW5~
PLAN OF WELL NO
C)
CD
<<
APP ENLEX 1200/Il
TILT ANt) SHIFT IN WELL NO~-
REDUCED LEVELS (RL~S) OFGAUGF MAt KS

TILT ALONG TILT ALONG RESULTANT .H~
ALONGX~AXlS ALON(JY-AXIS X~AXIS YAXIS TiLT AJONG ALONG 1.~ThNT ACTION REMARKS SIGNATURE
COLUMN COLUMN •J(COL, l0’+ X-AXIS Y-AXIS ‘~S(COL. I3)~* TAKEN FOR
TOTAL DIFFERFNCE OF
DATE TOTAL (PLACE) (PLACE) (U!S) (1)15> DIFFERENCE 6 9 COL, WITH WITH RCOL, 1~jV~ REC11FICAT1ON
(COL.5 SUPERVISING
SmINING SINKING ENI) ENI) (COL.8 - DIVIDED BY DIVIDEF) 1W DIRECTh)N DIRECTION OFFICER
COL;) WLLLDIA WI] I )I~ \•U RI
MFFRF Mfl1~I ~ MFIRJ MI FRF
— I 2 3 4 5 6 7 8 9 II) Ii 12 13 II 15
-_________.~_________
652
<<
Appendices
Appea4fr - 15%/f
INFORMATION TO BE SUPPLIED BY THE
MANUFACTURERS OF PROPRIETARY SYSTEMS
L GENERAL
LI. The ifonnation ‘atidi the manufacturer is required so supply shall be in such
desail as to obviate 1515515 use of the equipnens due to Ut intention of the manufacturer
not hawing been snide clear or disc to wn~gassumptions on Ut past of the user.
Li. The user shall refer unusual problem or çaoblesns of erection/assembly not
in keqir!g with the Seeded use of Ut equipom too she manufacturer of the equipment.
2. INFORMAl ION REQUIRED
ii, The masssiifaetusen of Ivopsiesary syssons shall sqçiy the following information:
a) E)eacripaion of basic fsascsiests of equ.ipmera
b) List of kans of equ~pmu*svailable, giving singe of sizes, spans and such like,
with the snassufacusser’s idasti1~casionnusnbers or other references.
c) The basis on whkls Ut safe wosking loads have beets determined and
whether the factor of safety given ~pp4ies so collapse or yield.
d) Whether Ut ss!c&r’s data ia based on calcnlEions or teats, ml shall
be dearly ssased as there may be wide variasieass between results o&ained
by either method.
e) [nstnscaions for use and maintenance, including any points whAck require special
attention during ‘eressioss, especsally where safety is concerned.
I) l~aik4Idisnensional information, as follows:

(i) Overall dimensions and depth and wifls of members
(ii) Line drawing, including perspectives and photographa showing normal uses.
(iii) Self ntight~
(iv) Full dimensions of connecsiass and any special positioning arrangements.
(v) Sizes of mats, including tube diamesers and thicknesses of materials,
(vi) Any pennanera camber buils into Ut ecpsipnens
(vii) Sizes of holes and dimensions giving their positions.
g) Data relating to strength of equipnens as foLlows
0) Avenge faibre loads as detennined by tests
(ii) Recorntnasded snasinsumn working loads for various conditions of usc,
(iii) Working resistance moments derived from rests,
(iv) Working tar capacities derived from reset
fr) Recosnmendcsl facross of safety used in assessing recommended loads and
dellecsions based cm teas results,.
663
<<
Appendices
(vi) Deflections under load together with recommended pm-camber and limiting
dellectiona,
(xii) If working loads depend on calculations,, working stresses should be stared,
U’ deflections depend on theoretical moments ofio,rtia or equivalent moments
of inertia rather than tests, this should S noted,
(viii) information on the design of sway bracing against wind and other horizon-
tal loadings.
(ix) Ailowahlc loading relating to maximum ntension of bases and/or heads.
<< 664
Appendices
Appendix - 1700/i
SPECIFICATION FOR CONSTRUCTION JOINTS
Location
The location of consft’uction joints shall be as shown on the drawing
or as approved by the Engineer. If addilionalfnew joints are approved
by the Engineer, the following considerations for their location shall he
taken into account
(i) Joints shall he provided in non-aggressive zones or in noo-splash zones, If not
feasible., the joints shall he sealed.
(ii) Joints should be positioned where they are readily accessible for preparation and
concreting, such as location where the cross section is relatively small, and where
reinforcement is not congested.
(iii) In beams and slabs, joints should not be near the supports. Construction joints
between slabs and ribs in composite beams should be avoided,
(iv) For box girders, it ia preferable so cast the sofia sod the webs without any joint.
(v) location of joints shall minimise the effects of the discontinuity on the dunsbility,
structural integrity and the ar.. arsnce of the stnicture.
Preparation of Surface of the Joint
I...,aitance shall be removed be,fore. fresh concrete is cast. The surface
shall he roughened.~Care shall be taken that they should not dislodge
ihe coarse aggregates, Concrete may he brushed with a stiff brush soon
after casting while the concrete is still fresh,
if the concrete has partially hardened, it shall he treated by wire
brushing or with a stiff water jet followed by drying with air jet
i rnmediateiy.
Fully hardened concrete shafi be treated with mechanical hand tools
or grit blasting, hIking care not to split or crack aggregate particles.
Before further concrete is cast, the surface should be thorot~ghly
cleaned to remove debris and accumulated ntbbish, one effective method
being by air jet.
Where there is likely to he a delay before placing the next concrete
lit’l, protruding reinforcement shall be protected. Before the next lift is
placed, rust, lose mortar or other contamination shall he removed from
the reinforcements, In aggressive environment, the conctele shall he cut
back to expose the reinforcements for a length of about 50 mm to ensure
that contaminated concrete is removed,
665
<<
Appendices
The joint surface shall not be contaminated with release agents, dust
or curing membrane.,
Concreting of Joints
The old surface shall be thoroughly cleaned and soaked with water,
Standing water shall he removed shortly before the new concrete is placed
.iui.d the new concrete shall be thoroughly compacted. Concreting shall
be carried out continuously upto the construction joints.
Surface retarders may be used to improve the quality of construction
joints.
For a vertical construction joint, a stopping board shall be fixed pre-
viously at the predetermined position and shall be properly stayed to
prevent its displacement or bulging when concrete is compacted against
it, Concreting shall be continued right upto the board,
666
<<
Appendices
<<
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667
Appendices
Appendix - 1800/I
TESTS ON SHEATHING DUCTS
All tests specified below shall be carried out on the same sample in the order given
below.
At least 3 samples for one lot of supply (not exceeding 7000 metre length) shall
be tested.
The tests are applicable for sheathing transported to site in straight lengths where
the pressressing cable is threaded inside the sheathing prior to concreting. These tests are
not applicable for sheathing tsar for coiled cable and transported to site as an assembled
unit, nor for sheathing ducts placed in position without threading of prestressing cable
prior to concreting.
(A) WORKABILITY TEST
A tett sample 1100 mm long is soldered to a fixed base plate with a soft solder (Fig.
1800(1-I). The sample is then bent so a radius of 1800 mm alternately on either tide to
complete 3 cycles.
Thereafter, the sealing joints will be visually inspected to verify that no failurel
opening has taken place.
(B) TRANSVERSE LOAD RATING TEST
The lest ensures that stiffness of the sheathing is sufficient to prevent permanent
distortion during site handling.
The sample i~placed on a horizontal support 500 mm long so that the sample is
supported at all points of outward comagations.
A load as specified in Table I is applied gradually at the centre of the supported
portion through a contact surface 12 mm long. It shall be ensured that the load is applied
approximately at the centre of two corrugations, Fig. 1800/1-2. The load as specified is
applied in increments.
TABLE 1
dia (mm) 25.35 35-45 45-55 55-65 65-75 75-85 85-90
load (N) 250 400 500 600 700 800 1000
The sample is considered acceptable if the permanent defonnation is less than 5 per
cent of the diameter of the sheathing.
(C) TENSION LOAD TEST
A test specimen is subjected to a tensile loact The hollow core is filled with a wooden
circular piece having a diasfleter of 95 per cent of the inner dia of the sample to ensure
circular profile during test loading, Fig. 180(W[-3.
A coupler is screwed on and the sample loaded in increments, till reaching the load
specified in Table 2. If no deformation of the joints nor slippage of couplers is noticed,
the rest shall be considered satisfactory.
TABLE 2
dia (mm) 25-35 35-45 45-55 55-65 65-75 75-85 85-90
load (N) 300 500 800 1100 1400 1600 1800
668
<<
Appendices
(D) WATER LOSS TEST
The sample is sealed at one end. The sample is filled with waler and after sealing,
the end is connected to a system capable of applying a pressure of 0.05 MPa, Fig. 180W
1-4, and kept constant for 5 minutes using a hand pump with pressure gauge or stand pipe
system can be used.
The sample is acceptable if the water loss does not exceed 1.5% of the volume.
669
<<
Appendices
<<
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670
Appendices
I~S PLATE 153 ~53
l5O~15C)a()tr.m
— -... - — —--.~ L—25s25a4 Cd~L~.)
ELEVATION
I. --••• ... 500

TIMB ER
PAC KING
L—FRAME
A 25 x 25 x 4
PLAN
A VIEW A-A
PIg. llIOWL-2 : Dimensions are in nun,
<<
671
Appendices
SPLATE ISO x!50x~0mm

SOFT SOLDERED JOINT
-SHEATHING PIPE 1100mm LONG
WOODEN CYLINDRICAL MEMBER

OF 95% INNER DiAMETER OF
SHEATHING
SOLDERED JOINT
1W
U
n I 0~
—
M.SPLATE 100*100*10mm
49
PAN
fig. 1890/1—3 flin1cn~ionsare in mm.
<< 672
Appendices
PVC TUBE ~0rn.m~ SUBJECTED

TO A PRE5SURE OFO.O5 MPa
H S FL. ATE Bt PUMP/ WATER HE. AD FOR
S MONUTES
so oso~0mm
~OL.DERNO
NI 5 pEAT L
lOOxlOOx 3 mm~
k --- 100
I SHEATHING SAMPLE LENGTH I
Fig 1800/1 4 F)imcnsions are in mm.
<< 673
PJ.~STRESSINGREPORT: APPEN[)JX I 800/U
SPAN No. ___________________________ Stressing Sequence Drg. No.

NUMIIER OR NAME OF THE BRIDGE: Left end of Cable = A
Right end of C~bk.= UI
2 ELEMENT/GIRDER No. __________________ Marks ofPlant Used Jacks
Ave. Cube Strength at the time of stressing kglcni Specified (Jau~ePressure
LAST DAlE OF CONCRETING____________ during Jacking
High Tensile Steel (UTS)—~ kg/cm2 Pumps:
Cube Strength : at 28 days kg/cm’ DATh OF PRESTRESSING______________ Gauges
Max-Jack Pressure not to exceed under any circumstances kg/cm2
COLUMNSI 2 3 4 5 4 6 7 9 0 11 12 13 14 15 16 17 18 19 ~20~211 22 23 24 25 26
Cable Calculated Gauge Mark Readings Gauge Mark . SLIP (Draw~in>mm

Stressing Elongation Readings cii extens~on Reading at ~nstanmot
of extension in mm at Inisnediately
Secjuence mm the pressure of 100 kg/ in mm it the pressure I.x,ckiog
~e c after kiter Total
cm of200k~/cm —~ ~
~
~
~
~E
S <r
locking 24Ht~ Drawmn
<
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~ ~ ~ ~.,
..
— > — ~< ~
<~ ~ ~ ~° ~,
.~
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—
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~ ~3 z~ <~ ~1 ~3 ~
~ ~
aiC flaw IC ~ ~i i leers pIVSCflI Ounhig plrst res sIng : . Contrn—tor System supolier
Client
674
<<
Appendices
Appendix - 1800/Ill
SPECIFICATIONS FOR GROUTING OF POST-TENSiONED
CABLES IN PRESTRESSED CONCRETE
1. GENERAL
1,1, The recommendations cover the cement grouting of post-
tensioned tendons of prestressed concrete members of bridges. This’
also covers some of the essential protective measures to be adopted
for minimising corrosion in PSC bridges.
1.2. The purpose of grouting is to provide permanent protection
to the post-tensioned steel against corrosion and to develop bond between
the prestressing steel and the surrounding structural concrete. The grout
ensures encasement of steel in an alkaline environment for corrosion
protection and by filling the duct space, it prevents water collection and
freezing..
2. MATERIALS
2.1. Water
Only cle.an potable water free from impurities conforming to section
10(X) shall be permitted. No sea or creek water is to he. used at all.
2.2. Cement
Ordinary Portland cement should he used for preparation of the
grout. it should he as fresh as possible and free of any lumps. Pozzolana
cement shall not be used.
23. Sand
it is not recommended to use sand for growing of prestress-
lug, tendons. in case the internal diameter of the ducts exceeds: 150 mm,,
use of sand may be considered. Sand, used, shall conform to 15:383
and shall pass through !S Sieve. No. 156. The weight of sand in the
grout shall not he. more than 10 per cent of the weight of cement, unless
prope.r workability can be ensure.d by addition of suitable plasticizers.
2,4. Admixtures
Acceptable admixtures conforming to 15:9102 may be used if tests
have shown that their use improves the properties of grout, i.e. increasing
fluidity, reducing bleeding, entraining air or expanding the grout.
Admixtures must not contain chlorides, nitrates, sulphides, sulphites or
any olhe.r products which are likely to damage the steel or grout. When
an expanding agent is used, the total unrestrained expansion should
<< 675
Appendices
not exceed lO per cent. Aluminum powder as an expanding agent is not

recommended for grouting be..cause its long term effects are not free
from doubt.
2.5. Sheathing
2,5,1. For specifications of sheathing, section 1800 may be referred
2.5.2. Grout openings or vents
a) All ducts should have grout openings at bnt.h ends. For this porpose special
openings should be provided where such openings are not available at end an-
chorages. For draped (curved) cables vents shall be provided at all crown and
valley points. 0 is a good practice so provide additions] air vents at suitable
intervals not exceeding 20 m. All grout openings or vents should include provisions
for preventing grout leakage.
h) Standard details of fixing couplers, inlets, outlets and air vents to the duct!
anchorage shall be followed as recommended by the supplier of the prestressing
systetn.
23,3. Ducts should be securely fastened at close intervals. All un-
intended holes or openings in th’e duct must he repaired prior to concrete
placing. The joints of the couplers and the. .s’heathing should be made
‘water proof by use of adhesive tape or similar suitable sy~itemcapable
of giving leak proof joints. Groin openings and vents must be securely
anchored to the duct and to either the forms or to reinforchig steel
to prevent displacement during concreting operations due to weight,
buoyancy and vibrations.
2.5.4. Ducts require very ‘careful handling as, being of thin metal,
they are susceptible to leakage due to corrosion in transit or storage,
by It lnng/nppLno in handl ng parttc til irl) ~slu_n p1 KL d adjotn tng to
reinforcing steel, by pulling apart at j.oints while insertin,g tendons
prior to concreting, or by accidental p’unctur~ng while drilling for form
ties/inserts. Duels are also liable to damage by rough use of internal
vibrator and sparks from welding being done. close by.
3. EQuIPMENT
3.1, Grout Mixer and Agitator
It is ~ssentialthat the. grout is maintained in a homogeneous state
and of uniform consistency so that there is no separation of cement.
Use of grout niixers to obtain a colloidal grout is essential. The mixer
should ha.ve an additional storage device, with an agitator to keep the
groifi moving continuously before it is pumped in the duct. Positive
reciprocating type grout pumps should be used.
<< 676
Appendices
3.2. Grout Pump

The pump should he a positive displacement type. and should be
capable of ejecting the grout in a continuous operation and not. by
way of pulses. The grout pump iii ust he fitted with a pressure gauge.
to enable pressure of injection to be controlled. The minimum pressure.
at which grout should be pumped shall he 0.3 M’Pa and the grout pump
must have a relie.f arrangement. for bypass of the grout. in case of build
up ctt’ pressure beyond 1 MPa, The capacity of the grout pump should
he such as to achieve forward speed of grout of around 5 to 10 metres
per minute.. The slower rates are referable as they reduce the possibility
of occurrence of voids. If th.e capacity of the pump is large, it is
usual to grout two or more cables simultaneously through a comtnon
manifold.
Use of hand pumps for ,grouting, is not recommended. Use of com-
rresse.d air operated equipment for injection is prohibited, as it is likely
that there. will he some air trapped itt grout.
3.3. Water Pump
Before comrnenten’ient of grouting, a stand by direct feed high
pressure water pump should he available at site for an emergency. In
case of any problem in growing the. ducts, such pump shall immediately
be connected to the duct and all grout flushed by use .of high pressure.
water flushing. it is, therefore, necessary to have adequate storage~of
clean potable water for operation of the water pump for such eaergencies.
3.4. Grout Screen
The grouting equipment should contain a screen having a mesh size
of 106 micron size of 150 microns if sand is used.). Prior to introduction
into the grout pump, the grout should he passed through such screen.
‘This screen should he easily accessible for inspection and cleaning.
3,5. Connections and Air Venls
Standard details of fixing inlets, outlets and air vents to the sheathing
and! or anchorage should he followed as recommended by specialist
supplier of the system of prestressing. In general, all connections.
are to he of the “Quick couple” type and at change of diameters suitable
reducers are to be provided.
4. PROPERTIES OF THE GROUT
4.1. Water/cement ratio should be as low as possible, consistent with
workability. This ral.io should not normally exceed 0.45.
<< ‘677
44.nendice.s
4.2. Before grouting, the properties of the grout mix should he
tested in a laboratory depending on the facilities available. Tests should
be. conducted for each job periodically. The recommended test is.
described beLow.
4.3. Compressive Strength: The. compressive strength of 100 mm
cubes of the grout shall not be les.s than 17 MPa at 7 days. Cube.s.shall
be cured in a moist atmosphere for the first 24 hottrs and subsequently
in water, These tests shall be conducted in advance to ascertain the
suitability of the grout mix.
5. MIXING OF GROUT
5.l. Proportions of materials should be based on field trials made
on the grout belore commencement of grouting’, but subject to the limits
specified above. The materials should be measured by ‘weight.
5.2. Water should h, added lo the mixer, first, followed by Port-
land ccitt ent and s~mnd, if used. Admixture if any, may be addt’,.d as
recommended by the manufacturer.
5.3. Mixing time depends upon the type of the tnixer, but will
normally be betwee.n 2. and 3 niinutes. However, mixing should he for
such a duration as to obtain uniform and thoroughly blended grout,
without excessive tempe.rature. increase or loss of expansive properties
of the. admixuires. The g’rout should he continuously agitated until it
is injected.
5.4. Once mixed, no water shall he added to the grout to increase
us fluidity.
5.5. ‘Hand mixing is not permitted.
6. 6 ROUTING OPERATIONS
6.1. General
a) Grouting shall be carried out as early as possible hut not later than 2 weeks
of stressing a tendon. Whenever this stipulation cannot be complied with ‘for
unavoidable reasons, adequate temporary protect~onof the steel against corrosion
by methods or products which will not impair the tsltintate adherence of the
iejected grout should he ensured till grooting. The sealing of the anchorage ends
after concreting is considered to he a good practice to prevent ingress of water.
For structores in aggressivc environment, sealing of the anchorage ends is
mandatory.
Notes
i) Application of some patented water soluble oils ‘for coating of sieel/VPI powder
injection! sending in of hot, dry, oil—free compressed air through the vents at frequent
intervals have shown some good results.
<<
67’:.
Appendices
ii) Some of the method.t recommended for sealing of anchorages are to seal the openings
‘with h:itstmen impregnated gunny bag or water proof pape:r or by building a brick
l:)edestal plastered on all faces enclosing the exposed wirea outside the anchorages.
iii) Aey traces of oil if applied to steel for presenting corrosion should he removed
before grouting operation..
iv) Ducts shall be flushed with ‘water for cleaning as well as for wtttiog the surfaces
of the duct walls. Water used for flushing should be of same citsslity as used for
grousing. Is may, however, contain about I per cent of staked lime or quick lime.
All water should he drained ‘thorough the lowest vent pipe or by blowing compressed
air through the duet
v) The water in the duct shoukl he blown out with oil free compressed air.
Blowing out water from duct for cables longer than 50 m draped up at both
ends by compressed air is not effective, outlet! vent provided at or near the lowest
point shall be used to drain out ‘water from duct
vi) ‘l’he connection between the noxate of the injection pipe and duct should be such that
air cannot he ssteked in.
vii) All outlet points including vent openings should be kept open prior so commencement
of injection grout
‘viii) Before grousing, all air in the pump and hose tlsould be expelled.. i’he suction
circuit of the pump should be air-tight
6.2. Injection of Grout

a) After mixing the grout ~shouldbe ke
1* in continuous ‘movement.
h) Injection of grout must be continuous and should not be interrupted.
c) For vertical cable or cables inclined more than 60 degrees to the hori~.,.ontal,
injection should be effected from the lowest anchorage or vent of she duct
d) The method of injection should ensure complete filling of the ducu, To verify
this, it is advisable to compare the volume of the space to be fitted by the injected
grout with the quantity of grout actually injected.
e) Grout.ing should be commenced initially w~tha low pressure of injection of upto
0.3 .M,Pa increasing it until the grout comes out at the other end. Th.e grout
should be. allowed to flow freely from thd other end until the consistency of the
grotit at this end it the same £ that of the grout at the iniecrion end. When the
grout (Iowa at the otlter end, it should be closed off and building up of pressure
comntenced, Full injection pressure at about 0.5 MPa shall be maintained for at
least one minute before closing the injection pipe. It is recommended practice
to provide a stand pipe at the highest point of the tendon profile to hold all water
displaced by sedimentation or bleeding. If there is a Stilt up of pressure much
in excess of I MPa without flow of grout coming at the other end, the grouting
operation shuuld be discontintted and the entire duct flushed with ltigh pressure
water, Also, the bypass system indicated in para 3.2 above is essential for further
safety.
I) In the case of cablea draped downwards e.g. in cantilever constnsction simul-
taneous injection from both ends may be adopted Fig. lSOO!lII- 1.
g) Grout not used within 30 minutes of miaing should he rejected.
<<
679
Appendices
~Eit’11
PSPE ~ LWL’
- -
~ THPDLSOH tUTH CO:MS’SsE.S.SED A~t
c~ivtLt’’ s~c:~PLUG ~ 10’~SINT
5T55
a rwt. OUCT ~IT.H SSA’T.tFS

~ ~
~AT[ S cR5.5 SLOW ‘: RAT IFS SN DUCT
c ~ ~ CROUT
5, Cossut’NCe OFSOUTLNG 5SMULT,ANE’OUSLV FROM 60TH ENDS

SE.MOVE tNTLFSMt,DLATE PLODS AT SNTESFVALS ‘TO CHICK FLOW
WATER OLIN FLOW NAT sv s~DucT
~ ~
4. FLUD INTISMEDIATE VENTS A~rER GFSOUT FLOWS
r COLOURED W.ATL~
050551 ~ ~ osoijr
5. WHCN WATCR FLOW OUT Of TOP LTNT ThKIS ON COL’OU~OF

CsstNT STeW PUw.S’IaO eWOUT 555GM ONE END CONTLNU5.
UT
(~5~
6. tF GROUT 6E5~NSTO FLOW FROM 105’ VEPeT,STOS’ PuNFPSN’G AND
PESTAST rFsoM OTpStFS END SF’ C LEAFS WATER FLOWS FROM TOP
VrF~r ~ r~r,I ~i,Jn.
-.~.,,_
7 WHEN PUMS’SNO FROM BOTH CNDS tN TURN ,CAUSES GROUT

TO FLOW FROP~4TOP VENT
PLUG . PLUG PLUG
- ~ GROUT
.5.. PLUG ALt.. VENTS AND tNCREASI FUASF’ PRESSURE AT 6~DTHENDS

TO o.~MP~HOLD TH’~SPRESSURE 5055 AT LEAST ONE MSNUTI
Fig. 111051/1 ft.! Procedure for (houtin,f of Cables Draped Downwards
<< 680
Appendices
Appendix 1800/IV
C ROUTING RECORD
,loh Naistc: — —.__._._—_
Span No. ~_.._. __~_ Cable No:

Datc of Cable lrss:allation: —_____. — Date of Grouting:.—.
type of Ccrsicnt: CPC/I 150FF
\Vcck’otd ‘5 cur of Manufacture ot OP 11501k.
W!C Ratio:
Name and amotirst of admixture used, il any —.—........ ——________________
‘l”cmpcrature: Mixing waler _. Grout ...__._.~. ._ —.
‘j’isrte: Start,. ...,~ Finish ___________.~. ——__________
tLC~SJip.rtteStt (;ro’ut mixer —~ ‘Grout ptsmp
Cable dues: Diarrteter ._...... _._.... 1_englls ..._..____.
Voltime of grout .n litre’s — Regrouting ___________________—.______________

Grouting pressure
(‘~crnentconsu sp~iort: 1)seoresseal ._........_.. : Aetu:sl ________________________________
5re~gtoutitigebeUks:
l
Free of block’aee Inlet: Yes/No : outlet : Yes/No
Vents: Yes/No Cable duct : Yes/No
f..eak age obsers’cd : Yes/No Sealed : Yes/No
11’ cable duct blocked: Remedial Measures

Grotjtirs~observ:is ions:
Passane of ,grous i.:rougls vents : Yes/No
i~s’ss~:
ge of grout througlt i:sutlet Yes/No
i\ny equijarnent Solute — ______________ —.————____________
Post eroutine ebeL’ks

Prohbirtg by still’ ~‘ii.e
kern arks _______________ _____________ ________
.Si,ers:stijres s’sf cslt. :‘ers Ires’eItt sluitng gtcsuting:
tli’L:r’st (Tontractor Systerts Supplier
681
<<
A
1:spendiees
Li) Disconnec Lion is facitiutted if a short length of tles.thie tube connects the duct
and injection pipe. This can be squeezed and cut off after she grout has hardened
7. PRECAUTIONS AND RECOMMENDATIONS
FOR EFFECTIVE GROUTING
si ln cold and frosty weather, injection should be postponed, unless speciat
pnTcsutions are taken. If frost is likely so occur a ithin 48 hours after injection,
heat must he applied to the member astd maintained for at least 48 hestirs after
inject ion so that the temperature of the grout does not fall below 5 dc.
grees Ccl stu.s, Prior to cottunencemens of grouting, care must be taken to ensure
that the duct is completely free of frost/ice by flushing with warn water, but
not with steam.
h) ‘l’be temperature of the grout shall not exceed 25 degrees Celsius. For increasing
the workability of grout, tts temperature may be lowered by use of chilled water
or by putting ice outside she grout storage container.
c) When the cahlcs are threaded after concreting, the duct must be tetnporaril~
stiffened during cond.sct ing by insertmg bunch of strandt, wires or reinforcemen
or a rigid PVC pipe or any other suitable method.
d) Duruig concreting, case shall be taken to ensure that the sheathing is not damaged.
Needle vibrators shall be used with extreme care by well experienced staff
only, to ensure against such damage.
e) It is A gsrod prsctic:e to sstose she cables in h:rsh iti rections dursng the c:oncreting
opemations. This can easily he done by light hammering she ends of the wtresf
stndnds during concreting It ts also advisable that 3 to 4 hours after cdncreung
the cable should be moved bosh ways through a distance of about 20 ems. With
such movement, any leakage of tnorumr svhich has taken place in spite of all
precautions, loses bond with the cables, thus reducing the chance of blockages
This operation can also be clone by fit irig prestresssng jacks, at one end pulling
the entire cable and then repeating she ot.Teration by fixing the jack at the other
esid.
5) The cables to he gmouted should be separated h1 as much distance as possible
g) In ease. sif stage pmest nr ssing, cables tsTnsioncd in tbe. first stage should not rr.mnain
usigrosite.d till all cables are stressed Is is good pmacttce, while grouting any
duct in stage prestressing, to keep all the remaining duets filled up with watem
containing I per cent time or by running water through such dtsete till the gn:tut
has set. After grouting the particular cable, the water in the other cables
should be draineit and removed wish compressed air so prevent corrosion
hi Care should he t:tkemt so avoist leaks frnm one duct to atsother at joints of precast
metnbers in pamntettlar
i) End faces whese anchorages are located are vulnerable points of entry of water.
‘thisy hase io he necessarily protected with an effective harrier. Recesses shosild
be packed with mortar concrete and should preferably be painted with water
proof paint.
.ti After grouting is completed, the projecting portion of the vents should he
cut off and the face protected to prevent corrosion.
<< 682

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Ministry of Surface Transport

Indian Roads Congress

LIBRARY & DOCUMENTATION CENTRE

Acc. No. - ...

Published by the Indian Roads

NEW DELHI-lgg7 Prk~eRs. 400/-

(The Rights of Publication and Translation are rese,ved)

Printed at M/s Dec Kay Printers, New Delhi-hO 015

“Specifications for Road and Bridge Works” first published in 1973

Revision of these specifications could be carried out in a short time

As with all specifications, the Third Revision of the Specifications

New Delhi M. V. SASTRY

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

100 GENERAL 101 IN1RODUCTION 3

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

200 SITE 201 CLEARING AND GRUBBING 41

300 EARTHWORK~ 301 EXCAVATION FOR ROADWAY AND 49

500 BASES AND 501 PREPARATION OF SURFACE 139

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

507 DENSE BITUMINOUS MACADAM 163

600 CONCRETE 601 DRYLEANCEMENTCONCRETE 211

700 GEOSYNTHETICS 701 GEOSYNTHETICS IN ROAD AND 255

800 TRAFFIC SIGNS, 801 TRAFFIC SIGNS 273

900 QUALITY 901 GENERAL 299

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1000 MATERIALS 1001. GENERAL 323

1100 PILE 1101. DESCRIP’IlON 339

1200. WELL 1201. DESCRIPTION 361

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1208 BO11’OM PLUG 375

1300 BRICK 1301. DESCRIPTION 381

1400 STONE 1401. DESCRIPTION 391

1500 FORMWORK 1501, DESCRIPTION 401

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1508. REMOVAL OF FORMWORK 405

1600 STEEL REINFOR- 1601. DESCRIPTION 411

1700 STRUCTURAL 1701. DESCRIPTION 419

1800 PRESTRESSINC 1801. DESCRIPTION 439

1808. GROUTING OF PRESTRESSEI) 447

1900 STRUCTURAL 1901. DESCRIPTION 455

2000 BEARINGS 2001. DESCRIPTION 493

2100 OPEN 2101. DESCRIPTION 523

2200. SUB-STRUCTURE 2201. DESCRIPTION 529

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

2203. GENERAL 529

2300 CONCRETE 2301. DESCRIPTION 535

2400 SURFACE AND 2401. GENERAL 543

SECTION SECTION CLAUSE CLAUSE TITLE PACE

2412. TESTING OF MATERIAL FOR 556

2500 RIVER TRAINING 2501. DESCRIPTION 563

2600 EXPANSION 2601. DESCRIPTION 575

2700 WEARING 2701. DESCRIPTION 591

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

2800 REPAIR OF 2801. DES~R1PTION 599

2.900 PIPE 2901. SCOPE 621

3000 MAINTENANCE 3001. GENERAL 627

A PPFEN DEC ‘ES

APPENDIX I. LIST OF I.R,C, PUBI.ICATIONS 637

APPENDIX 1,15 OF INDIAN AND FOREIGN 640

APPENDIX 4. GEIDEI.JNES ON SELECTION 648

APPENDIX 5. ANTI STRIPPING AGENTS USFEI) FOR 6 0

APPENDIX 1 (X)i-1 IE)RAF’F DOCUMENT ON ISC 9077-1979 CODE 655

APPENDIX 1 2oO/I~ HISTOR N’ GE SINKING Oi~\\rI.:I .1. 666