MoRTH Complete

Ministry of Road Transport and
Highways
SPECIFICATIONS
FOR ROAD
AND BRIDGE
WORKS
(Up-gradation of Third Revision)
UPGRADED SECTION 500

AND ITS RELATED
ASPECTS IN SECTIONS
900 AND 3000
(Addendum to Third Revision)
Published by the Indian Roads

Congress on behalf of the Govt.
of India, Ministry of Road
Transport and Highways
Copies can be had from

the Secretary, Indian Roads Congress,
Jamnagar House, Shahjahan Road,
New Delhi-110 011.
NEW DELHI 2000 Price Rs. 200/-

Plus packing & postage charges
published : November, 2000
(Rights of Publication and of Translation are reserved)
Printed at Dee Kay Printers, New Delhi-110015

2000 Copies
PREFACE TO 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
modernisation of Highway 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 who were intimately connected with this work, 1 wish to record
my appreciation of the efforts put in by all concerned.
As with all specifications, the Third Revision of the Specifications

will also no doubt need further updating in course of time. Feed back and
suggestions for 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 INTRODUCTION 3
102 DEFINITIONS 3
103 MATERIALS AND T EST STANDARDS 6
104 SIEVE; DESIGNATIONS 6
105 SCOPE OF WORK 7
106 CONSTRUCTION EQUIPMENT 8
107 CONTRACT DRAWINGS 9
108 SIT E INFORMATION 9
109 SETTING OUT 10
110 PUBLIC UTILITIES 11
111 PRECAUTIONS FOR SAFEGUARDING 13
T HE ENVIRONMENT
112 ARRANGEMENT FOR TRAFFIC 14
DURING CONSTRUCTION
113 GENERAL RULES FOR THE 17
MEASUREMENT OF WORKS FOR
PAYMENT
114 SCOPE OF RATES FOR 19
DIFFERENT ITEMS OF WORK
115 METHODOLOGY AND SEQUENCE OF 21
WORK
116 CRUSHED ST ONE AGGREGATES 21
117 APPROVAL OF MATERIALS 21
118 SUPPLY OF QUARRY SAMPLES 21
119 USE OF SURFACES BY 22
CONSTRUCTION TRAFFIC
120 SITE OFFICE FOR ENGINEER AND 22
OTHER SUPERVISORY STAFF
121 FIELD LABORATORY 26
122 SITE RESIDENTIAL 30
ACCOMMODATION FOR
ENGINEER AND OTHER
SUPERVISORY STAFF
123 PROVIDING AND MAINTAINING 32
WIRELESS COMMUNICATION
SYSTEM
124 PROVIDING AND MAINTAINING 33
VEHICLES FOR THE ENGINEER
125 SUPPLY OF COLOUR RECORD 35
PHOTOGRAPHS AND ALBUMS
126 SUPPLY OF VIDEO CASSETTES 36
ii Contents

NO. TITLE NO. NO.
200 SIT E 201 CLEARING AND GRUBBING 41
CLEARANCE 202 DISMANTLING CULVERTS, 44
BRIDGES AND OTHER
STRUCTURES/PAVEMENTS
3 00 EARTH WORK, 301 EXCAVATION FOR ROADWAYAN 49

EROSION DRAINS
CONTROL AND 302 BLASTING OPERATIONS 57
DRAINAGE 303 PRESPL1TTING ROCK EXCAVATION 61
SLOPES
304 EXCAVATION FOR STRUCT URES 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
TREATMENT OF FORMATION
311 WORKS T O BE KEPT FREE OF WATER 95
312 WATER COURSES AT CULVERTS 95
313 CONSTRUCTION OF ROCK FILL 96
EMBANKMENT
400 SUB-BASE S, 401 GRANULAR SUB-BASE 101

BASES (NON- 402 LIME TREATED SOIL FOR IMPROVE 105
BIT UMINOUS) SUB-GRADE/SUB-BASE
AND 403 CEMENT TREATED SOIL SUB- 109
SHOULDERS BASE/BASE
404 WATER BOUND MACADAM 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 FOOT PATHS AND SEPARATORS 132
410 CRUSHER-RUN MACADAM BASE 133
500 BASES AND 501 PREPARATION OF SURFACE 139

SURFACE 502 PRIME COAT OVER GRANULAR BASE 145
COURSES 503 TACK COAT 148
(BI T 504 BITUMINOUS MACADAM 149
UMINOUS)
505 BITUMINOUS PENETRATION 157
MACADAM
506 BUILT -UP SPRAY GROUT 160
iii Contents

NO. TITLE NO. NO.
507 DENSE BITUMINOUS MACADAM 163
508 SURFACE DRESSING 170
509 OPEN GRADED PREMIX CARPET 177
510 MIX SEAL SURFACING 185
511 SEMI-DENSE BITUMINOUS 186
CONCRETE
512 BITUMINOUS CONCRETE 189
513 SEAL COAT 192
514 SUPPLY OF MINERAL AGGREGATES 194
FOR PAVEMENT COURSES
515 BITUMEN MAST IC 197
516 SLURRY SEAL 202
517 RECYCLING OF BITUMINOUS 204
PAVEMENT
600 CONCRETE 601 DRY LEAN CEMENT CONCRETE 211

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

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

MARKINGS & 802 OVERHEAD SIGNS 27S
OTHER ROAD 803 ROAD MARKINGS 282
APPURTENANCES 804 HECTOMETRE/KILOMETRE 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
CONST RUCTION
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 323
1008. SAND/FINE AGGREGATES 326
1009. STEEL 326
1010. WATER 329
1011. TIMBER 330
1012. CONCRETE ADMIXTURES 330
1013. REINFORCED CONCRETE PIPES 331
1014. STORAGE OF MATERIALS 331
1015. TESTS AND STANDARD OF 334
ACCEPTANCE
1100 PILE 1101. DESCRIPTION 339

FOUNDATIONS 1102. SUB-SURFACE INVESTIGATION 339
1103. TYPE OF PILES 340
1104. MATERIALS 340
1105. TEST PILES 341
1106. PRECAST CONCRETE PILES 341
1107. CAST-IN-SITU CONCRETE PILES 344
1108. STEEL PILES 347
1109. TIMBER PILES 348
1110. DRIVING EQUIPMENT 348
1111. DRIVING 349
1112. RAKER (INCLINED) PILES 352
1113. PILE TESTS 353
1114. PILE CAP 353
1115. IMPORTANT CONSIDERATIONS, 354
INSPECTION/PRECAUTIONS
FOR DIFFERENT TYPES OF PILES
1116. TOLERANCES 356
1117. TESTS AND STANDARDS OF 357
ACCEPTANCE
1118. MEASUREMENTS FOR PAYMENT 357
1119. RATE 358
1200. W ELL 1201. DESCRIPTION 361

FOUNDATIONS 1202. GENERAL 361
1203. SETTING OUT AND PREPARATIONS 362
FOR SINKING
1204. CUTTING EDGE 364
1205. WELL CURB 364
1206. WELL STEINING 365
1207. WELL SINKING 366
v Contents

NO. TITLE NO. NO.
1208. BOTTOM PLUG 375
1209. SAND FILLING 376
1210. TOP PLUG 376
1211. WELL CAP 376
1213. TESTS AND STANDARDS 377
OF ACCEPTANCE
1214. MEASUREMENT FOR PAYMENT 377
1215. RAT E 377
1300 BRICK 1301. DESCRIPT ION 381

MASONRY 1302. MATERIALS 381
1303. PERSONNEL 3S1
1304. CEMENT MORTAR 381
1305. SOAKING OF BRICKS 382
1306. JOINT S 382
1307. LAYING 382
1308. JOINTING OLD AND NEW WORK 383
1309. CURING 3S3
1310. SCAFFOLDING 384
1311. EQUIPMENT 384
1312. FINISHING OF SURFACES 384
1313. ARCHITECTURAL COPING FOR 386
WING/RET URN/PARAPET WALL
1314. ACCEPTANCE OF WORK 386
1316. RATE 387
140 0 STONE 1401. DESCRIPTION 391

MASONRY 1402. MATERIALS 391
1403. PERSONNEL 391
1404. TYPE OF MASONRY 391
1405. CONSTRUCTION OPERATIONS 391
1406. ARCHITECTURAL COPING FOR 397
WING/RETURN/PARAPET WALLS
1407. TESTS AND STANDARD 397
OF ACCEPTANCE
MEASUREMENTS FOR PAYMENT 397
RATE 398
15 00 FORMWORK 1501. DESCRIPT ION 401

1502. MATERIALS 401
1503. DESIGN OF FORMWORK 401
1504. WORKMANSHIP 402
1505. FORMED SURFACE AND FINISH 403
1506. PRECAUTIONS 404
1507. PREPARATION OF FORMWORK 404
BEFORE CONCRETING
vi Contents

NO. TITLE NO. NO.
1503. REMOVAL OF FORMWORK 405
1509. RE-USE OF FORMWORK 406
1510. SPECIALISED FORMWORK 406
OF ACCEPTANCE
1513. RATE 407
1600 STEEL REINFOR- 1601. DESCRIPTION 411

CEMENT 1602. GENERAL 411
(UNTENSIONED) 1603. PROTECTION OF REINFORCEMENT 411
1604. 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. PROPORTIONING OF CONCRETE 421
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 AND CURING 431
1714. FINISHING 432
ACCEPTANCE
1718. RATE 435
1800 PRESTRESSING 1801. DESCRIPTION 439

1802. MATERIALS 439
1803. TESTING OF PRESTRESSING 441
STEEL AND ANCHORAGES
1805. SUPERVISION 445
1806. TENSION1NG EQUIPMENT 445
1807. POST-TENSIONING 446
vii Contents

NO. TITLE NO. NO.
1808. GROUTING OF PRESTRESSED 447
TENDONS
1809. PRE-TENSIONING 447
1810. SAFETY PRECAUTIONS 450
DURING TENSIONING
1811. TRANSPORTATION AND 451
STORAGE OF UNITS
1813. TEST SAND STANDARDS 451
OF ACCEPTANCE
1814. MEASUREMENT S FOR PAYMENT 451
1815. RATE 452
1900 STRUCTURAL 1901. DESCRIPTION 455

STEEL 1902 GENERAL 455
1903. MATERIALS 455
1904. FABRICATION 458
1905. ERECTION 471
1906. PAINTING 481
OF ACCEPTANCE
1908. MEASUREMENTS FOR PAYMENT 4S8
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. INSPECT ION AND TESTING 519
ACCEPTANCE
2010. RATE 519
2100 OPEN 2101. DESCRIPTION 523

FOUNDATIONS 2102. MATERIALS 523
2103. GENERAL 523
ACCEPTANCE
2108. RATE 526
2200 SUB-STRUCTURE 2201. DESCRIPT ION 529
2202. MATERIALS 529
viii Contents

NO. TITLE NO. NO.
2203. GENERAL 529
2204. PIERS AND ABUTMENT S 529
2205. PIER CAP AND ABUTMENT CAP 530
2206. DIRT/BALLAST WALL, 531
RETURN WALL & WING WALL
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. PRESTRESSED CONCRETE 536
CONSTRUCTION
2306. TOLERANCES 53S
ACCEPTANCE
2309. RATE 539
2400 SURFACE AND 2401. GENERAL 543

SUB-SURFACE 2402. PRELIMINARY INVESTIGATION 544
GEOTECHNICAL 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, HA NDLING 554
AND LABELLING OF SAMPLES
2410. TESTS FOR EXPLORATION 555
OF SHALLOW FOUNDATIONS
OF BRIDGES
2411. TESTS FOR EXPLORATION 555
FOR DEEP FOUNDATIONS OF
BRIDGES
ix Contents

NO. TITLE NO. NO.
2412. TESTING OF MATERIAL FOR 556
GUIDE BUND AND HIGH
EMBANKMENT AND
ITS FOUNDATIONS.
2414. RATE 559
2500 RIVER TRAINING 2501. DESCRIPTION 563

WORK AND 2502. GUIDE BUND 563
PROTECTION 2303. APRON 564
WORK 2504 PITCHING/REVETMENT 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. DESCRIPT ION 575

JOINTS 2602 GENERAL 575
2603. REQUIREMENTS 576
2604. STEEL PLATE SLIDING 577
EXPANSION JOINTS
2605. FILLER JOINTS 578
2606. ELASTOMERICS LAB 578
SEAL EXPANSION JOINT
2607. STRIP SEAL EXPANSION, JOINT 583
ACCEPTANCE
2610. RATE 587
2700 WEARING 2701. DESCRIPT ION 591

COAT AN D 2702 WEARING COAT 591
APPURTENANCES 2703. RAILINGS 592
2704. APPROACH SLAB 593
2705. DRAINAGE SPOUT S 594
2706. WEEP HOLE 595
ACCEPTANCE
2709. RATE
x Contents

NO. TITLE NO. NO.
2800 REPAIR OF 2801. DESCRIPTION 599
STRUCTURES 2801. 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 T O OLD CONCRETE
2806. CEMENT GROUTING 609
2807. GUNITING/SHOTCRETE 612
2808. REPLACEMENT/RECTIFICATION 614
OF BEARINGS
2809. DISMANTLING OF CONCRETE 615
WEARING COAT
2810. EXTERNAL PRESTRESSING 616
ACCEPTANCE
2813. RATE 618
2900 PIPE 2901. SCOPE 621

CULVERTS 2902. MATERIALS 621
2903. EXCA VATION FOR PIPE 621
2904. BEDDING FOR PIPE 622
2905. LAYING OF PIPE 622
2906. JOINTING 623
2907. BACKFILLING 623
2908. HEADWALLS AND OT HER 624
ANCILLARY WORKS
2909. OPENING TO TRAFFIC 624
2911. RATE 624
3000 MAINTENANCE 3001. GENERAL 627

OF ROAD 3002. RESTORATION OF RAIN-CUTS 627
3003. MAINTENANCE OF EARTHEN 628
SHOULDERS
3004. BITUMINOUS WORK IN 629
CONNECTION WITH
MAINTENANCE AND REPAIRS
3005. MAINTENAINING OF CEMENT 631
CONCRETE ROAD
xI Contents

NO. TITLE NO. NO.
APPENDICES
APPENDIX 1. LIST OF I.R.C, PUBLICATIONS 637

REFERRED TO IN THE SPECIFICATIONS
CODES & STANDARDS
APPENDIX 2. LIST OF INDIAN AND FOREIGN 640

STANDARDS REFERRED TO IN
THE SPECIFICATIONS
APPENDIX 3 METHOD OF SIEVING FOR 647

WET SOILS TO DETERMINE THE
DEGREE OF PULVERISATION
APPENDIX 4. GUIDELINES ON SELECT ION 648

OF THE GRADE OF BITUMEN
APPENDIX 5. ANT I-STRIPPPING AGENTS USED FOR 650

BITUMINOUS MATERIALS AND MIXES
APPENDIX 1000-1 DRAFT DOCUMENT ON ISC 9077-1979 CODE 655

OF PRACTICE FOR CORROSION PROTECTION
OF STEEL REINFORCEMENT IN RB AND
RCC CONSTRUCTION (REVISED)
APPENDIX 1200/I-1 HISTORY OF SINKING OF WELL 660

1200/I-2 PLAN OF WELL NOS. 661
1200/II TILT & SHIFT IN WELL NOS. 662
APPENDIX 1500/I INFORMATION TO BE SUPPLIED TO THE 663

MANUFACTURERS OF PROPRIETARY
SYSTEMS
APPENDIX 1700/I SPECIFICATION FOR CONSTRUCTION JOIN 665

1700/II PERMEABILITY TEST 667
APPENDIX 1800/I TESTS ON SHEATHING DUCTS 668

1800/II PRESTRESSING REPORT 674
1 800/III SPECIFICATIONS FOR GROUTING OF POST - 675
TENSIONED CABLES IN PRESTRESSED
CONCRETE
1800/IV 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 executed under the Contract or otherwise directed
by the Engineer-in-charge (hereinafter referred to as the Engineer). 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. The
quality of materials, processing of materials as may be needed at the
site, salient 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 the
work in only general terms, and not in complete detail, it shall be
understood that only the best general practice is to prevail, materials and
workmanship of the best quality or to be employed and instructions
of the Engineer are to be fully complied with.
A list of Indian roads Congress Specifications and Recommended
Codes of Practice which have been made use of in the preparations
of these Specifications is given at Appendix-1. The latest edition of all
Specifications/Standards till 30 (thirty) days before the final date of
submission of the tender, shall be adopted.
102. DEFINITIONS
The words like Contract, Contractor, Engineer (synonymous with

Engineer-in-charge), Drawings, Employer, Government, Works and Work
Site used in these Specifications shall be considered to have meaning
as understood from the definitions of these terms given in the General
Conditions of Contract.
The following abbreviations shall have the meaning as set forth

below:
AASHTO : American Association of State Highway and Transportation Officials
ASTM : American Society for Testing and Material
BS : British Standard published by the British Standards Institution
CBR : California Bearing Ratio
IRC : Indian Roads Congress
IS : Indian Standard published by the Bureau of Indian Standards
The various elements in the cross-section of a road referred to in

these Specifications are shown in the cross-sections in Figs. 100-1 and
100-2.
3
General Section 100
Fig.100.1: Terms used in the specifications to describe road cross-section elements with a flexible pavement.
4
General Section 100
Fig.100.2: Terms used in the specifications to describe road cross-section elements with a concrete pavement
5
General Section 100
Treated shoulders shown in the cross-section shall be of two types:-
(i) “Head” shoulders which have select gravel/moorum, any other compacted
granular layer of bricks.
(ii) “Paved” Shoulders which have a bituminous surfacing over granular layers
103. MATERIALS AND TEST STANDARDS
The relevant standards for materials, as well as the testing

procedures, have been indicated at appropriate places in the Specifi-
cations. A list of these standards with their full title and the years of
publication applicable is included at Appendix-2.
104. SIEVE DESIGNATIONS
The sieve designations referred to in the Specifications correspond

to those specified by Bureau of Indian Standards in IS: 460. Table
100.1 gives the list of the commonly used IS sieves.
TABLE 100.1 DESIGNATIONS OF TEST SIEVES

(in mm) (in micron)
* 128 850
106
* 710
* 90 600
75
* 500
* 63 425
53 355
300
* 45
37.5 * 250
212
* 31.5
26.5 * 180
150
* 22.4
19.0 * 125
106
* 16.0
13.2 * 90
75
* 11.2
9.50 * 63
53
* 8.00
6.70 * 45
6
General Section 100
* 5.60
4.75
* 4.00
3.35
* 2.80
2.36
* 2.00
1.70
* 1.40
1.18
* 1.00
Note: 1. ‘*’ are the principal sizes stated in ISO-565 and are preferred.
2. Sieve sizes given in BS:410 & ASTM-E 11 are same as in is:460.
3. Only sieves with square openings shall be used.
105. SCOPE OF WORK
105.1. 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 included 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 be
issued by the Engineer from time to time. The scope of work shall include
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 wo rks, 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 work, safety of the public and protection
of the works and adjoining land.
7
General Section 1007
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 suc h 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 be covered in the scope of the work.
105.4. The Contractor shall furnish, at least 15 days in advance, 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, surface, 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 Engineer 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.
106. 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 be required to give a trial run of the equipment for establishing
their capability to achieve the laid down Specifications and tolerance to the
satisfaction of the Engineer before commencement of the work.
(b) All equipment provided shall be of proven efficiency and shall be 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-
ment of work.
(d) 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;
(f) The Contractor shall also make available the equipment for site quality control
work as directed by the Engineer.
8
General Section 100
107.1. The Contract Drawings provi ded fro tendering purposes shall
be as contained in the Tender Documents and shall be used as a reference
only. The Contractor should visualize 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
involves 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 negative 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-
gineer. 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/or approval by the Engineer of any drawings
or other documents submitted by the Contractor shall not relieve the Con-
tractor of this responsibilities or liabilities under the Contract.
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 but
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
be provide 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
indicated the location of quarries and other sources from which naturally
occurring the location are available, for guidance of the Contractor. The
leads indicated in the said charts are only approximate. It is assumed
9
General Section 100
that the Contractor has inspected the quarries, borrow areas etc., before
quoting his rates for the work to assess the availability of construction
materials in required quantity and quality.
109. SETTING OUT
109.1. The Contractor shall establish working Bench Marks tied

with the Reference Bench Mark in the area soon after taking possession
of the site. The Reference Bench Mark for the area shall be as indicated
in the Contract Documents and the values of the same shall be obtained
by 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-bridges and underpasses. The working Bench Marks/levels should
be got approved from the Engineer. Checks must be made on these
Bench Marks once every month and adjustments, if any, got agreed with the
Engineer and recorded. An up-to-date record of all Bench. Marks
including approved adjustments, if any, shall be maintained by the
Contractor and also a copy supplied to the Engineer for his record.
109.2. The lines and levels of formation, side slopes, drainage works,
carriageways and shoulders shall be carefully set out and frequently
checked, care being taken to ensure that correct gradients and cross-
sections are obtained everywhere.
109.3. In order to facilitate the setting out of the works, the centre
lines of the carriageway or highway must accurately established by
the Contractor and approved by the Engineer. It must then be accurately
referenced in a manner satisfactory to the Engineer, every 50 m intervals
in plain and rolling terrains and 20m intervals in hilly terrain and
in all curve points as directed by the engineer, with marker pags and
chainage boards set in or near the fence line, and a schedule of reference
dimensions shall be prepared and supplied by the Contractor to the
Engineer. The markers shall be maintained until the works reach
finished formation level and are accepted by the Engineer.
109.4. On construction reaching the formation level stage, the centre
line shall again in set out by the Contractor and when approved by the
Engineer, shall be accurately referenced in a manner satisfactory to
the Engineer by marker pegs set at the outer limits of the formation.
109.5. No reference peg or market shall be 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.
109.6. The contractor will be the sole responsible party for safe-
10
General Section 100
guarding all survey monuments, bench marks, beacons, etc. The Engineer
will 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 be verified by the Contractor on the 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
out of the centre line, survey the terrain along the road and shall submit
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 be responsible for ensuring
that all the basis traverse points are in place at the
commencements 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 be
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 issue detailed instructions to the Contractor and the Contractor shall
perform the modification in the field, as required, and modify the ground
levels on the cross-sections accordingly as many times as required. There
will be no separate payment for any survey work performed by the
Contractor. The cost of these service shall be 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 be made for the same.
109.9. Precision automatic levels, having a standard deviation of
±2 mm per km, and fitted with micrometer attachment shall be used
for all double run leveling work. Setting out of the road alignment
and measurement of angles shall be done by using theodolite 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, oil pipelines, cables, gas ducts etc owned by various authorities
including Public Undertakings and Local Authorities included in the
11
General Section 100
Contract Documents shall be verified by the Contractor for the accuracy

of the information prior to the commencement of any work.
110.2. Notwithstanding the fact that the information on affected

serviced may not be exhaustive, the final position of these servi ce
within the works shall be supposed to have been indicated based on the
information furnished by different bodies and to the extent the bodies
and familiar with the final proposals. The intermediate states 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 t the period of notice and duration of
diversionary works and each body as given on the Drawings and the
Contractor must also allow for any effect of these services and altera-
tions upon the Works and for arranging regular meetings with the various
bodies 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 opinion
of the Engineer, the Contractor has received reasonable notice thereof
before the relevant alternations are put in hand.
110.3. No clearance or alterations to the utility shall be carried out
unless specially ordered by the Engineer.
110.4. Any services affected by the Works must be temporarily
supported by the Contractor who must also take all measures reasonably
required by the various bodies to protect their services and property
during the progress of the works.
110.5. The Contractor may be required to carry out certain wo rks
for 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 authorized by the Engineer.
110.6. The work of temporarily supporting and protecting the public
utility services during execution 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 be required to carry out the removal or shifting of
certain services/utilities on specific orders form the Engineer
for which payment shall be made to him. Such works shall be taken
up by the Contractor only after obtaining clearance form the Engineer
and ensuring adequate safety measures.
12
General Section 100
111. PRECAUTIONS FOR SAFEGUARDING THE

ENVIRONMENT
111.1. 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
erosion is fully controlled, and sedimentation and pollution of natural
water courses, 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 plants and concrete batching plants shall be
located sufficiently away from habitation, agricultural operations or
industrial establishments. The Contractor shall take every precaution
to reduce the levels of noise, vibration, dust and emissions from his
plant and shall be 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, animaJs 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 shail be used only where permitted by the Engineer.
13
General Section 100
The Contractor shall provide the Engineer with a copy of the regulations
governing the safe use of nuclear gauges he intends to employ and
shall abide by such regulations.
111.8. The Contractor must take all reasonable steps to minimise
dust nuisance during the construction of the works.
111.9. All existing highways and roads used by vehicle of the
Contractor or any of his sub-contractors or suppliers of materials or plant,
and similarly any new road* which are part of 'the works and which
are being used by traffic, shall be kept clean and clear of all dust/mud
or other extraneous materials dropped by the said vehicles or their tyres.
Similarly, all dust/mud or other extraneous materials from the works
spreading on these highways shall be 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
sweeping and clearing equipment, and all dust, mud and other debris
shall be removed entirely from the road surface. Additionally, if so
directed by the Engineer, the road surface shall be hosed or watered
using suitable equipment.
111.11. Any structural damage caused to the existing roads by
the Contractor's construction equipment shall be made good without
any extra cost.
111.12. Compliance with the foregoing will not relieve the Contractor
of any responsibility for complying with the requirements of any Highway
Authority in respect of the roads used by him.
112. ARRANGEMENT 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 t he 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 pant
of the existing carriageway tinder improvement, or along a temporary diversion
constructed close to the highway. The Contractor shall take
prior approval of the Engineer regarding traffic arrangements during
construction.
14
General Section 100
112.2. Passage of Traffic along a part of the Existing 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 mm thick granular base course covered with bituminous
surface dressing in a width of atleast 1.5 m and the surface shall
be maintained throughout the period during which traffic uses the same
to the satisfaction of the Engineer. The continuous length in which
such work shall be carried out, would be limited normally to 500 m
at a place. However, where work is allowed by the Engineer in longer
stretches passing places atleast 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 be constructed first and the traffic diverted to it and
only thereafter the required treatment to the existing carriageway would
be carried out. However, in case where on the request of the Contractor,
work on existing two -lane carriageway is allowed by the Engineer
with traffic using part of the existing carriageway, stipulations as in
para above shall apply.
After obtaining permission of the Engineer, the treated shoulder
shall be dismantled, 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 constructed
with 7 m 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 m width:
(i) 200 mm (compacted) granular subbase;
(it) 225 mm (compacted) granular base course; and
(iii) Premix carpet with Seal Coal/Mix Seal Surfacing.
The alignment and longitudinal section of diversion including

junctions and temporary cross drainage provision shall be as approved
by the Engineer.
15
General Section 100
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
be 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 be mounted on the barricades
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 traffic signals
or flagmen kept positioned on opposite sides during all hours. For
regulation of traffic, the flagmen shall be equipped with red and green
flags and l anterns/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.
112.5. 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 lime 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.
16
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 Contractors 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-
pensation 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 lumpsum
contracts.
All measurements and computations, unless otherwise indicated, shall
be carried nearest to the following limits:
(i) length and breadth 10 mm
(it) height, depth or thickness of
earthwork, sub grade, sub-bases,
bases, surfacing and structural members 5 mm
(iii) areas 0.01 sq. m.
(iv) cubic contents 0.01 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
17
General Section 100
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
be 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.
Normally, 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 1.25 m from either edge of the carriageway. For
multi-lane roads, levels shall be taken at two positions transversely
for each lone at locations specified by the Engineer.
Suitable 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
after each successive course is laid.
For pavement courses laid only over widening portions, atleast one
line of levels shall be taken on each strip of widening, or more depending
on the width of widening as decided by the Engineer,
Notwithstanding the above, the measurements may be taken at closer
intervals 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
for profile corrective course (levelling course). The average thickness
of the pavement course in any area shall be the arithmetic mean of the
difference of levels before and after construction at all the grid points
falling in that area, provided that the thickness of finished work shall
be 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.
18
General Section 100
113.4. Checking of Pavement Thickness for Payme nt on Area

7Basis
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
Plant-mixed 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 mean scales that
are of size, capacity, kind and type suitable for the weighing to be 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 Engineer, 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 be as designated by the .Engineer, Trucks
used for hauling the material to be weighed shall be weighed empty
daily at such times as the Engineer directs, and each truck shall bear
a plainly legible 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 be 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 determined
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 for finished work covering
all labour, materials, wastage, temporary work, plant, equipment, ovcr-
19
General Section 100
head 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 selling out, clearance of site before setting out and clearance
of -works after completion;
(ii) A detailed programme for the construction and completion of the worlc(using CPM/
PERT techniques) giving, in addition to construction activities, detailed network
activities for the submission and approval of materials, procurement of critical
materials and equipment, fabrication of special products/equipment and their in*
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 directed
by the Engineer;
(iii) Samples of various materials proposed to be used on the Work for conducting
tests thereon as required as per the provisions of the Contract;
(iv) Design of mixes as per the relevant Clauses of the Specifications giving proportions
of ingredients, sources of aggregates and binder along with accompanying trial
mixes as per the relevant Clauses of these Specifications to be 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; specialised constructional handling and launching
equipment and the like);
(vi) Detailed drawings for templates, support and end anchorage, details for prestressing
cable profiles, bar bending and cutting schedules for reinforcement, material lists
for fabrication of structural steel, etc;
(vii) Mill test reports for all mild and high tensile steel and cast steel as per the relevant
provisions of the Specifications;
(viii) Testing of various finished items and materials including bitumen, cement,
concrete, bearings as required under these Specifications and furnishing test
reports/certificates;
(ix) Inspection Reports in respect of formwork, staging, reinforcement and other
items of work as per the relevant Specifications;
(x) Any other data which may be required as per these Specifications or
the Conditions of Contract or any other annexures/schedules forming part of the
Contract;
(xi) Any other item of work which is not specifically provided in the Bill of Quantities
but which is necessary for complying with the provisions of the Contract;
(xii) All temporary works, formwork and false work;
(xiii) Establishing and running a laboratory with facilities for testing for various items
of works as specified in Section 900 and other relevant Clauses, where there
is no separate item in the Bill of Quantities for establishing and running a laboratory;
20
General Section 100
(xiv) Cost of in-built provisions for Quality Assurance;

(xv) Cost of safeguarding the environment; and
(xvi) Cost of providing "as-built drawings" in original and two sets of prints.
114.3. Portions of road works beyond (he 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 agencies and adjust
his construction programme for the completion of work accordingly and
no claim or compensation due to any reason whatsoever will be
entertained on this account. The Employer will be 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
to the Engineer for approval, the detailed construction methodology including
mechanical equipment proposed to be used, sequence of vari-
ous activities and schedule from start to end of the project. Programme
relating to pavement and shoulder construction shall be an integrated
activity to be done simultaneously in a coordinated manner. The
methodology and the sequence shall be so planned as to provide
proper safety, drainage and free flow of traffic.
116. CRUSHED STONE AGGREGATES
Where 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
shingle/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 use 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.
21
General Section 100
119. USE OF SURFACES BY 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
surface 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 /or 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 Engineer, 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 accommodation for the supervisory staff of Engineer and main
taining the same.
120.2. Description
The Contractor shall 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, fittings, 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 be
22
General Section 100
provided and maintained for Engineer's site office shall be as in Table

100-2.
Table 100-2. LIST OF FURNITURE TO BE PROVIDED AND MAINTAINED

FOR ENGINEER'S _SITE OFFICE
S.No. Item Specifications Nos. Reqd.*

1. Executive table Make - Godrej Modal
(for the Engineer) No. T-I08 or equivalent
2. Executive chair Make-Godrej Model

(for the Engineer) No, PCH-701 or equivalent
3. Table (for Site Make-Godrej Model No.

Engineer. Accountant T-104 or equivalent.
and Head Clerk)
4. Ordinary chair Type Make-Godrej Model No.

I(For the Engineer, CHR-6 or equivalent.
Accountant. Head
Clerk and visitors)
5. Table (for ail Make-Godrej Model No

other staff) T-IOI or equivalent
6. Ordinary chair-Type Make-Godrej Model

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

ST-2 or equivalent.
8. Steel Almirah Make-Godrej Model

1980mm x 915mm x No, 1 Storewcl plain
485mm or equivalent
9. Steel Atmirah Make-Godrej Model Minor

1270mrn x 765 mm x plain or equivalent
440 mm
10. Racks - 5 Tier Made of slotted

1800 mm x 900 mm x angles and M.S. Sheets
375 mm of Godrej make
11. Typewriter Electronic -Bilingual

(English & Hindi)
Network make or equivalent.
23
General Section 100
S.No. Item Specifications Nos. Reqd.*

Make-Godrej Storewel
SICE! Cash Chest or equivalent
of size 1.5' x 1.5'
(450 mm x 450 mm)
(approx.)
Air Coolers The cooler* shall have 24"

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

2000 W capacity - Bajaj
make or equivalent
Ceiling Fans Ceiling fans shall be of

1400 mm size approved make and colour
Computer with PC 486 with hard disc capacity

printer 230 MB. Maths coprocessor.
Two disc drives of 5.25" (132 mm)
and 3.5" (88 mm), 14" (350 mm)
size colour VGA monitor lelter-
quality dotmatrix printer of 132
columns and 101 Key board
Photocopie r Make RICOH Model FT 4065 or

equivalent
* Numbers to be decided by the Engineer as per requirements of the Project.
120.3. Ownership
The site office with all services, furniture and finings shall be the
property of the Employer. The land for the site office shall be provided
by the Engineer and the location shall be 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
24
General Section 100
glasses, furniture and other hardware and maintaining necessary watch

and ward during day and night.
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,
120.5. 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 -
dation within the period stipulated under Clause 120,2, an amount
of Rs. 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 Engineer's site office ac-
commodation shall be on 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 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
be made for the 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.
120.6. Rate
The Contract unit rate for constructing and providing the site office
accommodation shall include the expenses of all the operations involved
25
General Section 100
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 maintenance of an adequately
equipped field laboratory as required for site control on the quality of
materials and the works.
121.2. Description
The Contractor shall arrange to provide fully furnished and adequately
equipped field laboratory constructed as shown in drawings. The field
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 field laboratory shall be 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 1m in size and a fume chamber. The
furnishing in each of two offices of the Materials Engineers shall be
as provided for the Site Engineer in Table 100-2. Wooden/concrete work-
ing table with a working platform area of about 1m x 10m shall be
provided against the walls, 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 M.S. sheets as at Sl.No. 10
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 be provided
in the field laboratory.
26
General Section 100
121.3.1. General
(i) Oven – Electrically operated, 1 No.
thermostatically controlled, range
upto 200° C sensitivity 1 °C
(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 No.
(v) Water bath-electrically operated and 1 No.

thermostatically controlled with adjustable
shelves, sensitivity 1°C
(vi) Thermometers: 4 No.

Mercury-in-glass thermometer range
0° to250°C
Mercury-in-steel thermometer with 30cm
stem, range upto 30Q°C
(vii) Kerosene or gas stove or electric hot plate 1 No.
Glasswares, spatulas, wire gauzes. As required

steels cales, measuring tape, casseroles,
katahis, enameled trays of assorted sizes,
pestle -mortar, porcelain dishes, gunny bags,
plastic bags, chemicals, digging tools like
pickaxes, shovels etc.
(viii) Set of IS sieves with lid and pan:

450 rnm diameter; 1 Set.
63mm, 53mm, 37.5mm, 26,5mm, 13.2mrn, 9.5 mm
6.7mm and 4.75mm size
200 mm diameter: 2 Sets.
2.36mrn, 2.0mm, 1.18mm, 600micron, 425micro
300micron, 150micron, and 75micron
(ix) Water testing kit 1 Set.
(x) First aid box 1 Set.
121.3.2.For soil sand aggregates
(i) Riffle Box 1 No.
(ii) Atterberg Limits (liquid and plastic

limits) determination apparatus 1 Set.
27
General Section 100
(iii) Compaction Test Equipment both 2.5 kg and 4.5 kg 1 set

rammers (Light and Heavy compactive efforts)
(iv) Dry Bulk Density Test apparatus (sand pouring 1 set

cylinder, tray, can etc.) complete
(v) Speedy Moisture Meter complete with chemicals 1 set
(vi) Post.-hole Auger with extensions 1 set
(vii) Core cutter apparatus 10 cm dia, 10/15 cm 1 set

height, complete with dolly, rammer etc.
(viii) Aggregate Impact Value Test apparatus/Los 1 set

Angeles Abrasion Test apparatus
(ix) Flakiness and Elongation Test Gauges 1 set
(x) Standard measures of 30, 15 and 3 litres 1 set

capacity along with standard tamping rod
(xi) California Bearing Ratio lest apparatus 1 set
(xii) Unconfined compression test apparatus 1 set
121.3.3. For bitumen and bituminous mixes
(i) Penetrometer with standard needles 1 set
(ii) Riffle box—small size 1 No.
(iii) Centrifuge type bitumen extractor, hand 1 set

operated, complete with
petrol/commercial benzene
(iv) Marshall stability test apparatus, complete 1 set

with all accessories
(v) Field density bottle along with cutting tray, 2 Nos.

chisel, hammer and standard sand
(vi) 3 m straight edge 1 No.
(vii) Camber board 1 No.
(viii) Core cutting machine with 10 cm dia diamond 1 set

cutting edge
(ix) Vacuum pump and 3 specific gravity bottles 1 set
28
General Section 100
121.3.4. For cement and concrete

(i) Vicat apparatus for testing setting limes 1 set
(ii) Slump testing apparatus 4 sets
(iii) Compression and Flexural strength testing
machine of 200 tonne capacity with additional
dial for flexural testing 1 No.
(iv) Needle Vibrator 2 Nos,
(v) Air Meter 1 No.
(vi) Vibrating hammer for vibrating dry mix as
for Dry Lean Cement concrete sub-base 1 No.
Note : The item and their numbers listed above in this Cause shall be decided by
the Engineer as per requirements of the Project and modified accordingly.
121.4. Ownership
If provided as a separate payable item in the Bill of Quantities,
the field laboratory building and equipment shall be the property of the
Employers and the land for laboratory will be provided by the Employer.
121.5. Maintenance
If provided for as a separate payable item in the Bill of Quantities,
the Contractor shall arrange to maintain the field laboratory in a
satisfactory manner until the issue of Taking Over Certificate for the
complete work. Maintenance includes all activities described in Clause
120.4.
If provided as a separate payable item in the Bill of Quantities,
the measurement for payment for the construction of the field laboratory
shall be on square metres of plinth area.
The supply of testing equipment, the erection, maintenance and
running the same shall be on a lump sum basis.
121.7. Rate
If provided in die Bill of Quantities as a separate payable item,
the contract unit rate for constructing and providing the field laboratory
shall include expenses of all operations involved in construction of
the building 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.
29
General Section 100
The Contract lumpsum rate for the supply, erection, maintenance

and running of testing equipment shall 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
site 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, fittings, 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 be the property of the Employer. The land for the residential
accommodation shall be provided by the Engineer and the location shall
be as indicated by the Engineer. The Contractor shall provide the
residential accommodation within 4 months from the date of commence -
ment 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 Certificate for
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
30
General Section 100
providing uninterrupted supply. All sources/tappings and connected

equipment and fittings, 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
shall be on square metres of plinth 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 period of delay.
The measurement for maintenance 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 amount of Rs. 25,000 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 resi-
dential accommodation in accordance with Clause 122.3 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. 60,000 per month or pan thereof shall be debited
122.5. Rate
The Contract unit rate for constructing and providing residential
accommodation for (he Engineer and other supervisory staff shall include
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.
31
General Section 100
123. PROVIDING AND MAINTAINING WIRELESS

COMMUNICATION SYSTEM
123.1. Scope
The work covers the provision and maintenance of wireless com-
munication systems with necessary mobile/base trans -receivers and other
accessories.
123.2. Supply
The Contractor shall arrange to supply, install and commission the
complete wireless system of approved quality suitable for a range of upto
65 km. The system shall consist of the following:
(a) Mobile Trans-receiver suit able for mounting on 4 wheelers with Microphone as-
sembly, Mobile Antenna with Cable and External Speaker assembly (3 W audio
output) with all necessary fittings and accessories - 10 lets.
(b) Base Trans-receivers with Microphone assembly, suitable Antenna, external
speaker unit (3 W audio output) with all necessary fittings and accessories - 3
sets,
(c) Hand held radio sets - 10 Nos.
The Contractor shall provide the complete wireless system within

12 months from the date of commencement of work or 8 months from
the date on which frequency is allotted to him by the Govt. Department,
whichever is later. He shall submit a guarantee for replacement of any
defective trans-receiver/trans -receivers during the currency 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 by 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,
32
General Section 100

The measurement for supply and installation of wireless system shall
be on lumpsum basis for the complete system as described in the
preceding paras.
If the Contractor fails to commission and hand over the complete
wireless system in the stipulated time, an amount of Rs. 10,000 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 per month or part thereof shall be debited to the Contractor.
In addition, the month/months during which the Contractor fails to
carry out the required maintenance shall not be measured for payment.
If die 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 123.4 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
123.6. 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 approvals and operating
frequency, erection, commissioning and handing over, guarantee for
replacement of the trans -receiver/trans -receivers (which are found defec-
tive) during the currency of the Contract and 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 incidentals to keep the complete
system in satisfactory working condition.
124. PROVIDING AND MAINTAINING VEHICLES FOR
THE ENGINEER
124.1. Scope
The work covers providing and maintaining of hard top passenger
33
General Section 100
cars and /or hard top jeeps 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 be Am-
bassador or equivalent having cylinder capacity of minimum 1400 cc.
The hard top jeeps shall be 4 W Drive either petrol or diesel driven
and may be Maruti Gypsy Model MG - 410, Mahindra & Mahindra Jeep
Model MM-540/MM-440 or equivalent. The number of vehicles to be
provided by the Contractor shall be decided by the Engineer at various
times, out of the total provision in the Bill of Quantities and indicated
in writing.
The Contractor shall provide within one month from the date of
order by the Engineer, vehicles as indicated above. The vehicles shall
be provided and maintained until issue of the Taking Over Certificate
for the complete Work. Initially, new vehicles shall be provided. In
case of vehicles of Indian make, a vehicle shall be replaced with a
new vehicle after a maximum run of 75,000 km or two years whichever
is earlier. In case of vehicles of foreign make approved by the Engineer,
the vehicle shall be replaced with a new vehicle after a maximum run
of 1,00,000 km or three years whichever is earlier. All necessary taxes
for operating the vehicles shall be fully paid and all necessary papers
shall be provided as required by prevailing Motor Vehicles Act with
comprehensive insurance cover for the vehicles. The vehicles shall be
provided day and night as required by the Engineer. The Contractor
shall also make available drivers having valid licence at such times and
for such duration as instructed by the Engineer.
124.3. Maintenance
The vehicles shall be maintained in a smooth running condition. All
expenses required for keeping the vehicles in smooth running condition
such as fuel, lubrication oil and other consumables, necessary service
and maintenance, drivers, repairs and replacement etc. are to be met
by the Contractor. In the event of any vehicle being off the road
for maintenance or on account of breakdown, the Contractor shall provide
substitute vehicle(s) immediately. If the Contractor at any time fails to
provide vehicle(s) or substitute vehicle(s) as specified above, an amount
of Rs. 500 per day or part thereof for each vehicle (that the Contractor
failed to provide) shall be debited to the Contractor's account. Also the
number of days for which the vehicle(s) were not provided shall
not be included for payment.
34
General Section 100
If the Contract Works are not completed within the stipulated period
or within the granted extended time of completion, provision and main-
tenance of vehicles in accordance with Clause 124,1 through 124.4 shall
be carried out by the Contractor at his own cost and no payment shall
be made for the same. In case of any failure by the Contractor to
do so, an amount of Rs. 700 per day or part thereof per vehicle shall
be debited to the Contractor's account.
124.4. Withdrawal of Vehicles
The Contractor shall withdraw particular vehicle/vehicles for the
non-use by the Engineer if so directed by the Engineer. In such cases-
the instructions for non-use of vehicle shall be given in writing 15 days
in advance and the withdrawal of vehicles shall not be for a period of
less than 15 days continuously at a time.
The payment for providing and maintaining vehicles shall be on
vehicle day basis for actual number of days the vehicles were provided
in satisfactory working order. No payment shall be made for the period
of withdrawal as per Clause 124.4 irrespective of the fact whether
vehicle was available or not.
124.6. Rates
The Contract unit rate for providing and maintaining vehicles for
Engineer shall include all expenses towards providing and keeping the
vehicles in smooth running condition including taxes etc., mentioned
in the preceding paras.
125. SUPPLY OF COLOUR RECORD PHOTOGRAPHS
AND ALBUMS
125.1. Scope
The work covers the supply of photographs, negatives and albums
to serve as a permanent record of various stages/facets of the work
needed for an authentic documentation as approved by the Engineer.
125.2. Description
The Contractor shall arrange to take colour photographs at various
stages/facets of the work including interesting and novel features
of the work as desired by the Engineer. The photographs shall be of
acceptable quality and they shall be taken by a-professionally competent
photographer with camera having the facility to record the date of
35
General Section 100
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 co lour 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 costs
incurred.
The photographs and materials including negatives shall form a par:
of the records of the Department and the prints of the same cannot
be supplied to anybody else or published without the written permission
of the Department.
126. SUPPLY OF VIDEO CASSETTES
126.1. Description
The work consists of taking video films of important activities of
the work as directed by the Engineer during the currency of the project
and editing them to a video film of playing time not less than 60 minutes
and upto 180 minutes as directed by the Engineer, It shall contain
narration of the activities in English by a competent narrator. The
edition of the video film and the script for narration shall be as approved
by the Engineer. The video cassettes shall be of acceptable quality
and the film shall be capable of producing colour pictures.
The measurement shall be by number of sets of edited master
cassettes each with four copies thereof.
36
General Section 100
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 alongwith
four copies thereof.
37
Site Clearance
200
Site Clearance
Site Clearance Section 200
201. CLEARING AND GRABBING
201.1. Scope
This work shall consist of cutting, removing and disposing of all
materials such as trees, bushes, shrubs, stumps , roots, grass, weeds, lop
organic soil not exceeding 150 mm in thickness, rubbish etc., which in
the opinion of the Engineer are unsuitable for incorporation in the
works, from the area of road land containing road embankment, drains,
cross-drainage structures and such other areas as may be specified on
the drawings or by the Engineer., It shall include necessary excava-
tion, backfilling of pits resulting from uprooting of trees and stumps to
required compaction, handling, salvaging, and disposal of cleared
materials. Clearing and grubbing shall be performed in advance of
earthwork operations and in accordance with the requirements of these
Specifications.
201.2. Preservation of Property/Amenities
Roadside trees, shrubs, any other plants, pole lines, fences, signs,
monuments, buildings, pipelines, sewers and all highway facilities within
or adjacent to the highway which are not to be disturbed shall be protected
from injury or damage. The Contractor shall provide and install at
his own expense, suitable safeguards approved by the Engineer for
this purpose.
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 Contractor shall submit to the Engineer for approval,
his work plan including -he 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.
201.3. 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 case
these fall within 500 mm of the subgrade. Also, all vegetation such as
41
roots, under-growth, grass and other deleterious matter unsuitable for

incorporation in the embankment/subgrade shall be removed between
fill lines to the satisfaction of the Engineer. On areas beyond these
limits, trees and stumps required to be removed as directed by the
Engineer shall be cut down to 1 m below ground level so that these
do not present an unsightly appearance.
All branches of trees extending above the roadway shall be
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.
Ant-hills both above and below the ground, as are liable to collapse
and obstruct free subsoil water flow shall be removed and their workings,
which may extend to several metres, shall be suitably treated.
201.4. Disposal of Materials
All materials arising from clearing and grubbing operations shall
be the property of Government and shall be disposed of by the Contractor
as hereinafter provided or directed by the Engineer,
Trunks, branches and stumps of trees shall be cleaned of limbs and
roots and slacked. 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 be 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 be taken
to see that unsuitable waste materials are disposed of in such a manner
that there is no likelihood of these getting mixed up with the materials
meant for embankment, subgrade and road construction.
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 be a part
of works preparatory to embankment construction and shall be deemed
to have been included in the rates quoted for the embankment construction
item and no separate payment shall be made for the same. Cutting of
42
trees upto 300 mm in girth including removal of stumps and roots, and
trimming of branches of trees 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 backfilling to required compaction shall be measured
in terms of number according to the sizes given below: -
i) Above 300 mm to 600 mm

ii) Above 600 mm to 900 mm
iii) Above 900 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 if 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 will
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
agency, 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 mm shall include
excavation and bac kfilling 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 same shall be considered i ncidental to the earthwork
items and the Contract unit prices for the same shall be considered as
including clearing and grubbing operations.
43
202. DISMANTLING CULVERTS, BRIDGES AND

OTHER STRUCTURES/PAVEMENTS
202.1. 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 be carried out with such
equipment and in such a manner as to leave undisturbed, adjacent
pavement, structures and any other work to be left in place.
All operations necessary for the removal of any existing structure
which might endanger new construction shall be completed prior to
the start of new work.
202.2. Dismantling Culverts and Bridges
The structures shall be dismantled carefully and the resulting
materials so removed as not to cause any damage to the serviceable
materials to be salvaged, the part of the structure to be retained and
any other properties or structures nearby.
Unless otherwise specified, the superstructure portion of culverts/
bridges shall be 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 dismantling of the structures, shall
be incidental to this item.
Where existing culverts/bridges are to be extended or otherwise
incorporated in the new work, only such part or parts of the existing
structure shall be 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 be taken to ensure that reinforcing bars which are to be
44
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 be 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
members shall be match-marked by the Contractor with white lead paint
before dismantling; end pins, nuts, loose plates, etc., shall be similarly
marked to indicate their proper location; all pins, pin holes and 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 be 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, kerbs, gutters, and other structures like
guard-rails, fences, manholes, catch basins, inlets, etc., where portions
of the existing construction are to be left in the finished work, the
same shall 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,
All concrete pavements, base courses in carriageway and shoulders
etc., designated for removal shall be broken to pieces whose volume shall
not exceed 0.02 cu. m. and stockpiled at designated locations if
the material is to be used later or otherwise arranged for disposal as
directed (see Clause 202.5).
202.4. Back-filling
Holes and depressions caused by dismantling operations shall be
backfilled with excavated or other approved materials and compacted to
required density as directed by the Engineer,
202.5. Disposal of Materials
All materials obtained by dismantling shall be the property of
Government. Unless otherwise specified, materials having any salvage
45
value shall be placed in neat stacks of like materials within the right –
of-way, as directed by the Engineer with all lifts and upto a lead of
1000 m.
Pipe culverts that are removed shall be cleaned and neatly piled
on the right -of-way at points designated by the Engineer with all lifts
and lead upto 1000 m,
Structural steel removed from old structures shall, unless otherwise
specified or directed, be stored in a neat and presentable manner on
blocks in locations suitable for loading. Structures or portions (hereof
which are specified in the Contract for re -erection shall be stored in
separate piles.
Timber or lumber from old structures which is designated by the
Engineer as materials to be salvaged shall have all nails and bolts removed
therefrom and shall be stored in neat piles in locations suitable for
loading.
All materials obtained from dismantling operations which, in the
opinion of the Engineer, cannot be^ used or auctioned shall be disposed
of as directed by the Engineer widi all lifts and upto a lead of 1000
m.
The work of dismantling structures shall be paid for in units indicated
below by taking measurements before and after, as applicable:
(i) Dismantling brick/stone masonry/

concrete (plain and reinforced) cu. m.
(ii) Dismantling flexible and cement
concrete pavement cu. m.
(iii) Dismantling steel structures tonne
(iv) Dismantling limber structures cu. m.
(v) Dismantling pipes, guard rails,
kerbs, gutters and fencing linear m.
(vi) Utility services Nos.
202.7. Rates
The Contract unit rates for the various items of dismantling shall
be paid in full for carrying out the required operations including full
compensation for all labour, materials, tools, equipment, safeguards and
incidents necessary to complete the work. These will also include ex -
cavation and backfilling where necessary to the required compaction
and for handling, salvaging, piling and disposing of the dismantled
materials within all lifts and upto a lead of 1000 m.
46
Earthwork, Erosion Control and
Drainage
300
Earthwork, Erosion
Control and Drainage
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
be classified by the Engineer in the following manner:
(a) Soil
This shall comprise topsoil, turf, land, sill, loon, day, mud, peat. Mack cotton
toil, loft shale or loose mooium, a mixture of these and similar material which
yields to the ordinary application of pick, spade and/or shovel, rake or other
ordinary digging implement. Removal of gravel or any other nodular material
having dimension in any one direction not exceeding 75 mm occurring in such
strata shall be deemed to be covered under mil category.
(b) Ordinary Rock (not requiring blasting this shall include:
(i) rock types such as lalerites, shales and conglomerates, varieties of limestone
and sandstone etc., which may be quarried or split with crow ban, also
including any rock which in dry state may be hard, requiring- blasting but
which, when wet, becomes soft and manageable by means other than
blasting;
(ii) macadam surfaces such as water bound and bitumen Air bound; soling
of roads, paths etc. and hard core; compact' moorum or stabilized soil
requiring grafting tool or pick or both and shovel, closely applied; gravel
and cobble stone having maximum dimension in any one direction between
75 and 300 mm;
(iii) lime concrete, stone masonry in lime mortar and brick work in lime/cement
mortar below ground level, reinforced cement concrete which may be broken
up with crow bars or picks and stone masonry in cement mortar below
ground level; and
(iv) boulders which do not require blasting having maximum dimension in any
direction of more than 300 mm, found lying loose on (he surface or embedded
in river bed, soil, talus, slope wash and terrace material of dissimilar origin.
49
Earthwork, Erosion Control and Drainage Section 300
(c) Hard Rock (requiring blasting)

This shall comprise:
(i) any rock or cement concrete for the excavation of which the use of
mechanical plant and/or blasting is required;
(ii) reinforced cement concrete (reinforcement cut through but not separated
from the concrete) below ground level; and
(iii) boulders requiring blasting.
(d) Hard Rock (blasting prohibited)
Hard rock requiring blasting as described under (c) but where blasting is prohibited
for any reason and excavation has to be carried out by chiselling, wedging or
any other agreed method.
(e) Marshy Soil
This shall include soils like soft clays and peats excavated below the original
ground level of marshes and swamps and soil) excavated fromother areas
requiring continuous pumping or bailing out of water.
301.2.2. Authority For classification : The classification of exca-

vation shall be decided by the Engineer and his decision shall be final
and binding on the Contractor. Merely the use of explosives in excavation
will not be considered as a reason for higher classification unless blasting
is clearly necessary in the opinion of the Engineer.
3013. Construction Operations
301.3.1. Setting out : After the site has been cleared as per Clause
201, the limits of excavation shall be set out true to tines, curves, slopes,
grades and sections as shown on the drawings or as directed by the
Engineer. The Contractor shall provide all labour, survey instruments
and materials such as strings, pegs, nails, bamboos, stones, lime, mortar,
concrete, etc., required in connection with the setting out of works and
the establishment of bench marks. The Contractor shall be responsible
for the maintenance of bench marks and other marks and stakes as long
as in the opinion of the Engineer, they are required for the work.
301.3.2. Stripping and storing topsoil : When so directed by the
Engineer, the topsoil existing over the sites of excavation shall be stripped
to specified depths constituting Horizon "A" and stockpiled at designated
locations^ for re -use in covering embankment slopes, cut slopes, berms
and other 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 be carried
out in conformity with the directions laid here-in -under and in a manner
50
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 311.
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 permitted tolerances, any excess depth/ width excavated beyond
the specified levels/dimensions on the drawings shall be made good at
the cost of the Contractor with suitable material of characteristics similar
to that removed and compacted to the requirements of Clause 305.
All debris and loose material on the slopes of cuttings shall be
removed. No backfilling shall be allowed to obtain required slopes
excepting that when boulders or soft materials are encountered in cut
slopes, these shall be excavated to approved depth on instructions of the
Engineer and the resulting cavities filled with suitable material and
thoroughly compacted in an approved manner.
After excavation, the sides of excavated area shall be trimmed and
the area contoured to minimise erosion and ponding, allowing for natural
drainage to take place. If trees were removed, new trees shall be planted,
as directed by the Engineer. The cost of planting new trees shall
be deemed to be incidental to the work.
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, the 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 formation level, these shall be
excavated to the extent of 500 mm below the formation level or as
otherwise specified. In all cases, 'the excavation operations shall be so
carried out that at no point on cut formation the rock protrudes above
the specified levels. Rocks and large boulders which are likely to cause
51
differential settlement and also local drainage problems should be

removed to the extent of 500 mm below the formation level in full
formation width including drains and cut through the side drains.
Where excavation is done to levels lower than those specified, the
excess excavation shall be made good as per Clauses 301.3.3 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 loose pieces of rock on excavated
slope surface which move when pierced by a crowbar shall be removed.
Where blasting is to be resorted to, the same shall be carried out
to Clause 302 and all precautions indicated therein observed.
Where presplitting is prescribed to be done for the establishment
of a specified slope in rock excavation, the same shall be carried out
to Clause 303.
301.3.6. Marsh excavation : The excavation of soils from marshes/
swamps shall be carried out as per the programme approved by the
Engineer.
Excavation of marshes shall begin at one end and proceed in one
direction across the entire marsh immediately ahead of backfilling. The
method and sequence of excavating and backfilling shall be such as to
ensure, to the extent practicable, the complete removal or displacement
of all muck from within the lateral limits called for on the drawings
or as slaked by the Engineer, and to the bottom of the marsh, firm support
or levels indicated.
301.3.7. Excavation of road shoulders/verge/median for widening
of pavement or providing treated shoulders : In works involving
widening of existing pavements or providing treated shoulders, unless
otherwise specified, the shoulder/verge/median shall be removed to their
full width and to levels shown on drawings or as indicated by the
Engineer. White doing so, care shall be taken to see that no portion
of the existing pavement designated for retention is loosened or disturbed.
If the existing pavement gets disturbed or loosened, it shall be dismantled
and cut to a regular shape with sides vertical and the disturbed/loosened
portion removed completely and relaid as directed by the Engineer, at
the cost of the Contractor.
301.3.8. Excavation for surface/sub-surface drains : Where the
Contract provides for construction of surface/sub-surface drains to Clause
52
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
be removed and paid for at the Contract rate for the class of excavation
involved, provided the slides are 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 be removed
by suitable diversions, pumping or bailing out and the excavation
kept dry whenever so required or directed b y the Engineer. Care shall
be taken to discharge the drained 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 be the sole responsibility of the Contractor to
repair/restore to the original condition at his own cost or compensate
for the damage.
301.3.11. Disposal of excavated materials : All the excavated
materials shall be the property of the Employer. The material obtained
from the excavation of roadway, shoulders, verges, drains, cross-
drainage works etc., shall be used for filling up of (i) roadway embank
ment, (ii) the existing pits in the right -of-way and (iii) for landscaping
of the road as directed by the Engineer, including levelling and spreading
with all lifts and lead upto 1000 m and no extra payment shall be
made for the same.
All hard materials, such as hard moorum, rubble, etc., not intended
for use as above shall be stacked neatly on specified land as directed
by the Engineer with all lifts and lead upto 1000 m.
Unsuitable and surplus material not intended for use within the lead
specified above shall also, if necessary, be transported with all lifts and
lead beyond initial 1000 m, disposed of or used as directed by the
Engineer.
53
3013.12, Backfilling : Backfilling of masonry /concrete/hume pipe

drain excavation shall be done with approved material after concrete/
masonry/hume pipe is fully set and carried out in such a way as not
to cause undue thrust on any part of the structure and/or not to cause
differential settlement. All space between the drain walls and the side
of the excavation shall be refilled to the original surface making due
allowance for settlement, in layers generally not exceeding 150 mm
compacted thickness to the required density, using suitable compaction
equipment such as mechanical tamper, rammer or plate compactor as
directed by the Engineer.
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 be 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. Howe ver,
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 th e opinion of the Engineer,
the actions initiated by 'the Contractor to replace/restore 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 formation, which serves as a subgrade, shall be prepared
to receive the" sub-base/base course as directed by the Engineer.
Where the material in the subgrade (t hat is within 500 mm from
the lowest level of the pavement) has a density less than specified in
Table 300-2, the same shall be loosened to a depth of 500 mm and
compacted in layers in accordance with the requirements of Clause 305.
54
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
material as directed by the 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. Af ter
satisfying the 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/basc course.
301.7. 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
designated 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 shall any portion of the slope encroach on the roadway.
The finished cut formation shall satisfy the surface tolerances
described in Clause 902,
Where directed, 'the topsoil removed earlier and conserved
(Clauses 301.3.2 and 305.3.3) shall be spread over cut slopes, where
feasible, berms and other disturbed areas. Slopes may be roughened and
moistened slightly, prior 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.
Excavation for roadway shall be measured by taking cross-
sections at suitable intervals in the original position before the work
starts and after its 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 be
computed by other accepted methods.
At the option of the Engineer , the Contractor shall leave depth
indicators during excavations of such shape and size and in such
55
positions as directed so as to indicate the original 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 be 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 volumes.
Works involved in 'the preparation of cut formation shall be measured
in units indicated below :
(j) Loosening and recompacting the ... cu. m.

loosened material at subgrsde
(ii) Loosening and removal of unsuitable ... cu. 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,
beyond initial 1000 m lead
301.9. Rates
301.9.1. The Contract unit rates for the items of roadway and drain
excavation shall be 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
embankments, spoil banks or stacking as directed within all lifts and lead upto
1000 m or as otherwise specified;
(iii) trimming bottoms and slopes of excavation;
(iv) dewatering;
(v) keeping the work free of water as per Clause 311; and
(vi) a ll labour, materials, tools, equipment, safety measures, testing and incidentals nec-
essary to complete the work to Specifications.
Provided, however, where presplitting is prescribed to achieve a
56
specified slope in rock excavation, the same shall be paid for vide Clause
303.5.
301.9.2. The Contract unit rate for loosening and recompacting
the loosened materials at iubgrade shall include full compensation for
loosening to the specified depth, including breaking clods, spreading in
layers, watering where necessary and compacting to the requirements.
301.9.3. 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 subgrade
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.
301.9.5. 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 ail lifts, but 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
consistent 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
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 lightning conductor.
The following shall be hung in the lobby of the magazine:
(a) A copy of the relevant rules regarding safe storage both in English and in the
language with which the workers concerned are familiar.
(b) A statement of up-to-date stock in the magazine.
(c) A certificate showing the last date of testing of the lightning conductor.
(d) A notice that smoking Is strictly prohibited.
All explosives shall be stored in a secure manner in compliance with

all laws and ordinances, and all such storage places shall be clearly
marked. Where no local laws or ordinances apply, storage shall be
provided to the satisfaction of the Engineer and in general not closer
than 300 m from the road or from any building or camping area or
place of human occupancy. In addition to these, the Contractor shall
also observe the following instructions and any further additional
instructions which may be given by the Engineer and shall be responsible
for damage to property and any accident which may occur to workmen
or the public on account of any operations connected with the storage,
handling or use of explosives and 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 be sufficiently water-resistant as to be unaffected when
immersed in water for 30 minutes. The rate of burning of the fuse
shall be uniform and definitely known to permit such a length being
cut as will permit sufficient time to the firer to reach safety before
explosion takes place. Detonators shall be c apable of giving effective
blasting of the explosives. The blasting powder, explosives, detonators,
fuses, etc., shall be fresh and not damaged due to dampness, moisture
or any other cause. They shall be inspected before use and damaged
articles shall be discarded totally and removed from the site immediately.
302.3. Personnel
The blasting operation shall remain in the charge of competent and
experienced supervisor and workmen who are thoroughly acquainted with
the details of handling explosives and blasting operations.
58
302.4. Blasting Operations

The 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-
tures in proximity to the site of the work of his intention to use
explosives. Such notice shall be given sufficiently in advance to enable
the companies 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, date, 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 directions. People, except those who actually light
the fuse, shall be prohibited from entering this area, and all persons
including workmen shall be excluded from the flagged area at least
10 minutes before the firing, a warning siren being sounded for the
purpose.
The charge holes shall be drilled to required depths and at suitable
places. Blasting should be as light as possible consistent with thorough
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 be inserted into the hole and the powder dropped in. The powder
shall be gently tamped with copper rods with rounded ends. The explosive
powder shall then be covered with tamping material which shall be
tamped lightly but firmly.
When blasting is done with dynamite and other high explosives, dy-
namite cartridges shall be prepared by inserting the square cut end of
a fuse into the detonator and finishing it with nippers at the open end,
the detonator gently pushed into the primer leaving l/3rd of the copper
tube exposed outside. The paper of the cartridge shall then be closed
up and securely bound with wire or twine. The primer shall be housed
into the explosive. Boreholes shall be of such size that the cartridge
can easily go down. The holes shall be cleared of all debris and
59
explosive inserted. The space of about 200 mm 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
fired. The man in charge shall blow a siren in a recognised manner
for cautioning the people. All the people shall then be required to move
to safe distances. The charges shall be lighted by the man-in-charge only.
The man-in-charge shall count the number of explosions. He shall satisfy
himself that all the charges have been exploded before allowing the
workmen to go back to the work site.
After blasting operations, the Contractor shall compact the loose re-
sidual material below subgrade and replace die material removed
below subgrade with suitable material
302.5. Misfire
In case of misfire, the following procedure shall be observed:
(i) Sufficient lime shall be allowed to account for the delayed blast. The man-in-
charge shall inspect all the charges and determine the missed charge.
(ii) If it is the blasting powder charge, it shall be completely flooded with water.
A new hole shall be drilled at about 450 mm from the old hole and fired. This
should blast the old charge. Should it not blast the old charge, the procedure
shall be repeated till the old charge is blasted.
(iii) In case of charges of gelignite, dynamite, etc., the man-in-charge shall gently
remove the tamping and the primer with the detonator. A fresh detonator and
primer shall then be used to blast the charge. Alternatively, the hole may be
cleared of 300 mm of tamping and the direction then ascertained by placing
a stick in [he hole. Another hole may then be drilled 150 mm away and parallel
to ii. This hole shall then be charged and fired when the misfired hole should
explode at the same lime. The man-in-charge shall at once report to the
Contractor's office and the Engineer all cases of misfire, the cause of the same
and what steps were taken in connection therewith.
If a misfire has been found to be due to defective detonator or
dynamite, the whole quantity in the box from which defective article
was taken must be sent to the authority directed by the Engineer for
inspection to ascertain whether all the remaining materials in the box
are also defective.
302.6. Account
A careful and day to day account of the explosive shall be maintained
by the Contractor in an approved register and manner which shall be
open to inspection 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 presplitling technique shall be used for forming rock excavation
slopes at locations shown on the plans or as otherwise decided by the
Engineer.
303.2, Construction Operations
Prior to starting drilling operations for presplitting, the Contractor
shall furnish the Engineer a plan outlining the position of all drill, holes,
depth of drilling, type of explosives to be used, loading pattern and
sequence 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 Engineer, The
test section shall be presplit, production drilled and blasted and sufficient
material excavated whereby the Engineer can determine if the Contrac-
tor’s methods have produced an acceptable slope.
All overburden soil and weathered rock along the top of the
excavation for a distance of about 5 to 15 m beyond the drilling limits,
or to the end of the excavation, as decided by Engineer shall be removed
before drilling the presplitting holes. Particular care and attention shall
be directed to the beginning and end of excavations to ensure complete
removal of all overburden soil and weathered rock and to expose fresh
rock to an elevation equal to the bottom of the adjacent lift pf the
presplitting holes being drilled.
Slope holes for presplitting shall be drilled along the line 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
operations shall be controlled by the use of proper equipment and
technique to ensure that no hole shall deviate from the plane of the
planned 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 exceed
9 m.
61
The spacing of presplit holes shall not exceed 900 mm on centres

and shall be adjusted 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 m
of a presplit plane except as approved by the Engineer. The bottom
of the production holes shall not be lower than the bottom of the presplit
holes.
A maximum offset of 600 mm will be permitted for a construction
working bench at the bottom of each lift for use in drilling t he next
lower presplitting pattern. The drilling operations shall be adjusted to
compensate for drift of previous levels and for the offset at the start
of new levels to maintain the specified slope plane.
The 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
manufacturing firms shall be used in presplit holes. These shall be fired
as recommended by the manufacturer. Ammonium nitrate composition
blasting agents will not be permitted in presplit ting operations.
Stemming may be required to achieve a satisfactory presplit face.
Stemming material shall be dry free-running material all of which passes
11.2 mm sieve and 90 per cent of which is retained on 2.80 mm sieve.
Stemmed presplit holes shall be completely filled to the collar.
All charges in each presplitting pattern shall be detonated simul -
taneously.
3033. 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
conform to the slopes indicated on the plans and no point on the
completed slopes shall vary from the designated slopes by more than
300 mm. These tolerances shall be measured perpendicular to the plane
of the slope. In 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
be done at the same time, provided that the presplitting drill holes
are fired with zero delay and the production holes are delayed starting
at the row of holes farthest from the slope and progressing in steps
to the row of holes nearest the presplit line, which row shall be delayed
at least 50 milliseconds. In either case the presplhting holes shall
extend either to the end of the excavation or for a distance of not
less than 15 m beyond the limits of the production holes to be detonated.
The area of presplitting to be paid for will be measured as square
metres of acceptable presplit slope surface.
303.5. Rates
The Contract unit rate for presplitting work shall be payment in
full for carrying out the required operations for obtaining acceptable
presplit slope surfaces. The quantity of rock excavated through the
production/presplit holes shall be paid for as per Clause 301.9.1.
304. EXCAVATION FOR STRUCTURES
304.1. Scope
Excavation for structures shall consist of the removal of material
for the construction of foundations for bridges, culverts, retaining walls,
headwalls, cutoff wails, pipe culverts and other similar structures, in
accordance with the requirements of these Specifications and the lines
and dimensions shown on the drawings or as indicated by the Engineer.
The work shall include construction of the necessary cofferdams and cribs
and their subsequent removal; all necessary sheeting, shoring, bracing,
draining and pumping; the removal of all logs, stumps, grubs and other
deleterious matter and obstructions, necessary for placing the foundations;
trimming bottoms of excavations; backfilling and clearing up the site
and the disposal of all surplus material.
63
304.2, Classification of Excavation
All materials involved in excavation shall be classified in accordance

with Clause 301.2.
304.3. Construction Operations
304.3.1. Setting out : After 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
the lowest step of the footing and the sides shall be left plumb 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 permit 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 and 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
as to require changes, in which case the depth shall be as ordered
by the Engineer. Propping shall be "undertaken when any foundation
or stressed zone from an adjoining structure is within a line of 1 vertical
to 2 horizontal from the bottom of the excavation.
Where blasting is to be resorted to, the same shall be carried out
in accordance with Clause 302 and all precautions indicated therein
observed. Where blasting 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 be
taken to prevent any damage.
304.3.3. Dewatering and protection : Normally, open foundations
shall be laid dry. Where water is met with in excavation due to stream
flow, seepage, springs, rain or other reasons, the Contractor shall take
adequate measures such as bailing, pumping, constructing diversion
channels, drainage channels, bunds, depression of water level by well-
point system, cofferdams and other necessary works to keep the
foundation trenches dry when so required and to protect the green
concrete/masonry against damage by erosion or sudden rising of water
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
relieve the Contractor of the responsibility for the adequacy of

dewatering and protection arrangements and for the quality and safety
of the works.
Where cofferdams are required, these shall be carried to adequate
depths and heights, be safely designed and constructed and be made as
watertight as is necessary for facilitating construction to be "carried out
inside them. The interior dimensions of the cofferdams shall be such as
to give sufficient clearance for the construction and inspection and to
permit installation of pumping equipments, etc., inside the enclosed
area.
If it is determined beforehand that the foundations cannot be laid
dry or the situation is found that the percolation is too heavy for keeping
the foundation dry, the foundation concrete shall be laid under water
by tremie pipe only. In case of flowing water or artesian springs, the
flow shall be stopped or reduced as far as possible at the time of
placing the concrete.
Pumping from the interior of any foundation enclosure shall be done
in such a manner as to preclude the possibility .of the movement of
water through any fresh concrete. No pumping shall be permitted during
the placing of concrete or for any period of at least 24 hours thereafter,
unless it is done from a suitable sump separated from the concrete work
by a watertight wall or other similar means.
At the discretion of the Contractor, cement grouting or other
approved methods may be used to prevent or reduce seepage and
to protect the excavation area.
The Contractor shall take all precautions in diverting channels and
in discharging die drained water as not to cause damage to die works,
crops or any other property.
304.3.4. Preparation of foundation : The bottom of the foundation
shall be levelled both longitudinally and transversely or stepped as
directed by the Engineer. Before footing is laid, the surface shall be
slightly watered and rammed. In the event of excavation having been
made deeper than that shown on the drawings or as otherwise ordered
by the Engineer, the extra depth shall be made up with concrete
or masonry of the foundation at the cost of the Contractor as per Clause
2104.1. Ordinary filling shall not be used for the purpose to bring the
foundation to level.
When rock or other hard strata is encountered, it shall be freed
65
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 (1:3:6nominal mix) upto the top level
of rock.
if the depth of the fill required is more than 1.5n 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 bulders 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 are slip-outs in
the excavation, these shall be removed by the contractor at his own
cost.
304.3.6. 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. The 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
ets, 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 with, cutting
of slopes, shoring, shuttering and pl anking 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 in square metres.
Foundation sealing, dewatering, including pumping shall be deemed
to be incidental to the work unless separate provision is made for in
the Contract. In the letter 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 of all logs, stumps, grubs and other deleterious matter and obstructions,
for placing the foundations including trimming of bottoms of excavations.]
(iv) foundation sealing, dewatering including pumping when no separate provision for
it is made in the Contractor:
(v) backfilling, clearing up the site and disposal of all surplus material within all lifts
and leads upto 1000 m or as other wise specified; and
(vi) all 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 full 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
miscellaneous backfills with approved material obtained from roadway

and drain excavation, borrow pits or other sources. All embankments,
subgrades, earthen shoulders and miscellaneous backfills shall be 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
305.2.1. Physical requirements:
305.2.1.1. The materials used in embankments, subgrades, earthen
shoulders and miscellaneous backfills shall be soil, moorum, gravel, a
mixture of these or any other material approved by the Engineer. Such
materials shall be free of logs, stumps, roots, rubbish or any other
ingredient likely to deteriorate or affect the stability of the embankment/
subgrade.
The following types of material shall be considered unsuitable for
embankment:
(») Materials from swamps, marshes and bogs;

(b) Peat, log, stump and perishable material: any soil that, classifies as OL, OI,
OH or Pt in accordance with IS : 1498;
(c) Materials susceptible to spontaneous combustion;
(d) Materials in a frozen condition;
(e) Clay having liquid limit exceeding 70 and plasticity index exceeding 45; and
(f) Materials with sails resulting in leaching in the embankment.
305.2.1.2. Expansive clay exhibiting marked swell and s hrinkage

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 fill material, subgrade and top 500 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 consent exceeding
1.9 grams of sulphate (expressed as SO3) per litre when tested in
accordance with BS : 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
9 shall not be deposited within 500 mm, or other distances described

in 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
shall ordinarily not exceed 75 mm when being placed in the embankment
and 50 mm when placed in the subgrade. However, the Engineer may
at his discretion permit the use of material coarser than this also if he
is satisfied that the same will not present any difficulty as regards the
placement of fill material and its compaction to the requirements of
these Specifications. The maximum particle, size shall not. be., more than
two-thirds of the compacted layer thickness.
305.2.1.5. Ordinarily, only the materials satisfying the density
requirements given in Table 300*1 shall be employed for the construction
of the embankment and the subgrade.
TABLE 300-1. DENSITY REQUIREMENTS OF EMBANKMENT AND
SUBGRADE MATERIALS
S. No, Type of Work Maximum laboratory dry unit weight when
tested as per IS: 2720 (Part 8)
1. Embankments up to 3 metres Not less than 15.2 kN/cu.m.

height, not subjected to
e xtensive flooding,
Z Embankments exceeding 3 Not less than 16.0 kN/cu. m.

metres height or embankments
of any height subject to long
periods of inundation
3. Subgrade and earthen Not less than 17.5 kN/cu. m.

shoulders/verges/backfill
Notes: (1) This Table is not applicable for lightweight fill material e.g. cinder, fly ash
etc.
(2) The Engineer may relax these requirements at his discretion taking into account
the availability of materials for construction and other relevant factors.
(3) The material to be used in subgrade should also satisfy design CBR at the
dry unit weight applicable as per Table 30Q-Z
305.2.2. General requirements :

305.2.2.1. The materials for embankment shall be obtained from ap-
proved sources with preference given to materials becoming available
from nearby roadway excavation or any other excavation under the same
Contract.
69
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 remo ved-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 unacceptable materials. The
acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the
70
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
SUBGRADE
Type of work/ material Relative compaction as percentage
of max. laboratory dry density as per
IS: 2720 (Part g)
1. Subgrade and earthen shoulders Not less than 97
2. Embankment Not less than 95
3. Expansive Clays
a) Subgrade and 500 mm Not allowed Not
portion just below
the subgrade
b) Remaining portion 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 dry 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 fit! 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 embankment/subgrade shall be built sufficiently wider than the
71
design dimension so that surplus material may be trimmed, ensuring

that the remaining material is to the desired density and in position
specified and conforms to the specified side slopes.
305.3.2. Dewatering : If the foundation of the embankment is in
an area with stagnant water, and in the opinion of the Engineer it
is feasible to remove it, the same shall be removed by bailing out or
pumping, as directed by the Engineer and the area of the embankment
foundation shall be kept dry. Care shall be taken to discharge the
drained water so 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 be the sole responsibility of the
Contractor to repair/restore it to original condition or compensate
the damage at his own cost.
If the embankment is to be constructed under water, Clause
305.4.6 shall apply.
305.3.3. Stripping and storing topsoil : In localities where most
of the available embankment materials are not conducive to plant growth,
or when so directed by the Engineer, the topsoil from all areas of
cutting and from all areas to be covered by embankment foundation
shall be stripped to specified depths not exceeding 150 mm and stored
in stockpiles of height not exceeding 2 m for covering embankment
slopes, cut slopes and other disturbed areas where re-vegetation is
desired. Topsoil shall not be unnecessarily trafficked either before
stripping or when in a stockpile. Stockpiles shall not be surcharged or
otherwise loaded and multiple handling shall be kept to a minimum.
305.3.4. Compacting ground supporting embankment/subgrade:
Where necessary, the original ground shall be levelled to facilitate
placement of first layer of embankment, scarified, mixed with water
and then compacted by rolling so as to achieve minimum dry density
as given in Table 300-2.
In case where the difference between the subgrade level (top of the
subgrade on which pavement rests) and ground level is less than 0.5
m and the ground does not have 97 per cent relative compaction
with respect to the dry density as given in Table 300-2, the ground
shall be loosened upto a level 0.5 m below the subgrade level, watered
and compacted in layers in accordance with Clauses 305.3,5 and 305.3.6
to not less than 97 per cent of dry density as given in Table 300-2.
Where so directed by the Engineer, any unsuitable material occurring
72
in the embankment foundation shall be removed and replaced by

approved materials laid in layers to the required degree of compaction.
Embankment or subgrade work shall not proceed until the foundat-
ions for embankment/subgrade have been inspected by the Engineer
for satisfactory condition and approved.
Any foundation treatment specified for embankments especially high
embankments, resting on suspect foundations as revealed by borehole
logs shall be carried out in a manner and to the depth as desired by
the Engineer. Where the ground on which an embankment is to be built
has any of the material types (a) to (f) in Clause 305.2.1, at least 500
mm of such material must be removed and replaced by acceptable
fill material before embankment construction commences.
305.3.5. Spreading material in layers and bringing to appro-
priate moisture content
305.3.5.1. The embankment and subgrade material shall be spread
in layers of uniform thickness not exceeding 200 mm compacted
thickness over the entire width of embankment by mechanical means,
finished by a motor grader and compacted as per Clause 305.3.6. The
motor grader blade shall have hydraulic control suitable for initial
adjustment and maintain the same so as to achieve the specific slope
and grade. Successive layers shall not be p laced until the layer
under construction has been thoroughly compacted to the specified
requirements as in Table 300-2 and got approved by the Engineer. Each
compacted layer shall be finished parallel to the final cross-section
of the embankment.
305.3.5.2. Moisture content of the material shall be checked at the
site of placement prior to commencement of compaction; if found to
be out of agreed limits, the same shall be made good. Where water
is required to be added in such constructions, water shall be sprinkled
from a water tanker fitted with sprinkler capable of applying water
uniformly with a controllable rate of flow to variable widths of surface
but without any flooding. The water shall be added uniformly and
thoroughly mixed in soil by blading, discing or harrowing until a uniform
moisture content is obtained throughout the depth of the layer.
If the material delivered to the roadbed is too wet, it shall be dried,
by aeration and exposure to the sun. till the moisture content is acceptable
for compaction. Should circumstances arise, where owing to wet weather,
the moisture content cannot be reduced to the required amount by the
above procedure, compaction work shall be 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 th e 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 1 vertical on 4 horizontal, such faces
shall be benched as per Clause 305.4.1 immediately before placing the
subsequent fill.
All permanent 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 bt 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-
ment/subgrade/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 embankment/subgrade at
all limes 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 305.3.6. 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
carried 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, leve ls, cross-sections and
dimensions shown on the drawings or as directed by the Engineer
subject to .the surface tolerance described in Clause 902. Both the
upper and lower ends of the side slopes shall be rounded off to
improve appearance and to merge the embankment with the adjacent
terrain.
The topsoil, removed and conserved carrier (Clause 301.3.2 and
305,3,3) shall be spread over the fill slopes as per directions of the
Engineer to facilitate the growth of vegetation. Slopes shall be roughened
and moistened slightly prior to the application of the topsoil in order
to provide satisfactory bond. The depth of the topsoil shall be sufficient
to sustain plant growth, the usual thickness being from 75 rnm to 150
mm.
Where directed, the slopes shall be turfed wi th sods in accordance
with Clause 307. If seeding and mulching of slopes is prescribed, this
shall be done to the requirement of Clause 30S,
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
305.4.1. Earthwork for widening existing road embankment:
When an 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 ensuring 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 embankment/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 wi th
the help of small vibratory rollers/plate compactors/power rammers or
any 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 shall be appropriately benched
or ploughed/scarified as required in Clause 305.4.1 before placing the
embankment/subgrade material. Extra earthwork involved in benching or
due 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 fill is placed against sloping ground.
Where the Contract requires construction of transverse subsurface
drain at the cut-fill interface, work on the same shall be carried out to
Clause 309 in proper sequence with the embankment and subgrade 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
be carried out as indicated below :
(i) If the existing road surface is of granular or bituminous type and lies within
1 m of the new subgrade level, the same shall be scarified to a depth of 50 mm
or more if specified, so as to provide ample bond between the old and new material
ensuring that at least 500 mm portion below the top of new subgrade level
is compacted to the desired density.
(ii) If the existing road surface is of cement concrete type and lies within 1 m
of the new subgrade level the same shall be removed completely.
(iii) If the level difference between the existing road surface and the new formation
level is more than 1m, the existing surface shall be permitted to stay in place
without any modification.
77
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 die 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 twice the height of the road from
the back of die 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 die 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 plasticity 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 ail structures shall conform to the general
guidelines given in Appendix 6 of IRC:78 (Standard Specifications and
Code of Practice Road Bridges-Section VII) in respect of the type
of material, the extent of backfill, its laying and Compaction etc. The
fill material 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 of 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 necessary
soil investigations and redesign the high embankment at his own cost.
The Contractor shall then furnish the soil test data and design o f high
embankment for approval of the 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
material, which is unacceptable for use in the fill being surcharged, lying
below formation level, the Contractor shall remove the unacceptable
material and dispose it as per direction of the Engineer. He shall
then bring the resultant level up to formation level with acceptable
material.
305.4.8. Settlement period : Where settlement period is specified
in the Contract, the embankment shall remain in place for the required
settlement 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
Construction and other vehicular traffic shall not use the prepared
surface of the embankment and/or subgrade without the prior permission
of the Engineer, Any damage arising out of such use shall, however,
be made good by the Contractor at his own expense as directed by the
Engineer.
305.6. Surface Finish and Quality Control of Work
The surface finish of construction of subgrade shall conform to the
requirements of Clause 902. Control on the quality of materials and
works shall be exercised in accordance with Clause 903.
305.7. Subgrade Strength
305.7.1. It shall be ensured prior to actual execution that the borrow
area material to be used in the subgrade satisfies the requirements of
design CBR.
305.7.2. Subgrade shall be compacted and finished to the design
strength consistent with other physical requirements. The actual
laboratory CBR values of constructed subgrade shall be determined on
undisturbed samples cut out from the compacted sub grade in CBR mould
fitted with cutting shoe or on remoulded samples, compacted to the
field density at the field moisture content.
Earth embankment/subgrade 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 ave rage 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 compacted fill and all bulking 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 embankment/subgrade 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 and
subgrade construction shall be payment in full for carrying out the
required operations including full compensation for :
(i) 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 recompacting is involved;
(iv) Scarifying or cutting continuous horizontal benches 300 mm wide on side slopes
of existing embankment and subgrade as applicable;
(v) Coil of watering or drying of material in borrow areas and/or embankment and
subgrade during construction as - required;
81
(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 comers;
(viii) Restricted working at sites of structures;
(ix) Working on narrow width of embankment and subgrade;
(x) Excavation in all soils from borrow pits/designated borrow areas including clearing
and grubbing and transporting the material to embankment and subgrade site
with all lifts and leads unless otherwise provided for in the Contract;
(xi) All labour, materials, tools, equipment 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
portation 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 rccompacting the embankment/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 scarifying 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
the required operations including all materials, labour, tools, equipment

and incidentals to complete the work to Specifications.
305.9.9. Clause 305.4.6 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

306.1. Description
This work shall consist of measures as shown on plans or as
directed by the Engineer to control 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
approve d by the Engineer before being used in the work.
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 erosion/sedimentation control works as are
applicable for the items of clearing and grubbing, roadway and drainage
excavation, embankment/subgrade construction, 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
grubbi ng, 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 properties, or cause contami -
nation of nearby streams or other water courses, lakes, reservoirs
etc. Such work may involve the construction of temporary berms, dikes,
83
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 credible 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 justified.
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 pan of the work
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 labour,
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 specified, 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 die locality where it is to be used, and
shall be practically free from weeds or other undesirable mailer. 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 i n size
but not so large that it is inconvenient to handle and transport these
85
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
dropping of the soil in handling.
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, stump s 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 shall 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 shall be spread uniformly at the
rate indicated on the plans. After spreading, the materials arc incorporated
in the soil by discing or other means to the depths shown on the pians.
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
lamped 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 1 (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 tin's 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
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. Watering and 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, equipmems and incidentals Lo complete the work in accordance
with these Specifications.
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. Material s
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 putrefied organic matter such as cow
Mulching material] 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 to 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 agricultural authority to determine the residual in the soil. Topsoil
shall not contain less than 2 per cent and more than 12 per cent organic matter.
C. Bituminous Emulsion: A suitable grade of bituminous cutback or emulsion
used as a tie down for mulch shall be as described in the Contract document
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 be 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 i mplements. AH stones 150 mm in smallest dimension and
larger shall be removed. The s oil 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 remulche d as
specified. Jute netting/Geonetting shall be unrolled and placed parallel
to the flow of water immediately following the bringing, to 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 includes protection of
traffic by approved warning signs or barricades arid 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 specified.
89
308.6. Measurements for payment

Seeding and mulching shall be measured as finished work in square
metres.
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 wo rk 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.
309.3. Sub-surface Drains
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 for the drains may be of metal/asbestos cement/
cement concrete/PVC, and unperforated pipes of vitrified clay/cement concrete/
asbestos cement. The type, size and grade of the pip: 10 be used shall be
ai specified in the Contract In no 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 D85
size of the material surrounding the pipe, subject to being minimum 3 mm and
maximum 6 mm, DM stands for the size of the sieve that allows 85 per cent
of the material to pass through it.
B. 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 grading? 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 there of ) 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 10 Class II grading
of Table 300-3.
(iii) Where soil met with in the trench is gravelly sand, the backfill material
shall correspond to Class 111 grading of Table 300-3.
Thickness of backfill material around the pipe shall be as shown
on the drawings subject to being at least 15 0 mm alround 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
Per cent passing by weight
Sieve Designation Class I Class 11 Class III
53 mm — — 100
45 mm — — 97-100
26.5 mm — 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 —
ISO micron 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 pip e 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 backfilled with approved material which
shall be thoroughly compacted to the specified degree.
309.3.4. Laying of pipe and backfilling : 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 and comp acted to a
minimum thickness of 150 mm or as shown on the drawings. The
pipe shall then be embedded firmly 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 t he open joints wrapped with suitable pervious material (like double
layer of hessian, suitable Geosynthetics or some other material of
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 exceeding 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 die 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 laying of pipe and backfilling :

After excavating the trench for subsurface drain, the filter fabric shall
be placed, ihe pipe installed and the trench backfilled with permeable
material according to dimensions and details shown on the plans.
Surfaces to receive filter fabric prior to placing shalJ be free of loose
or extraneous material and sharp objects that may damage the filter
fabric during installation. 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 snail 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 Be 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 flowing to the pipe and is likely to get slowly blocked. Type A
grading allows a much wider range.
93
TABLE 300-4. GRADING REQUIREMENTS FOR AGGREGATE DRAINS
Sieve Size Per cent pas sing by weight
Type A Type B
63 mm 100
37.5 mm 100 85-100
19 mm — 0-20
9.5 mm 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 remo val 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) AH 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.
94
(b) The surface shall be compacted by + passes of a smooth wheeled roller of 80

to 100 kN weigh! after spraying requisite amount of water, if required, before
the commencement of rolling.
(c) The formation shall, wherever necessary, be regulated and trimmed to the re -
quirements of Clause 305.3.9 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 respect ive
item of work and as such no separate payment shall be made for
the some.
312. WATER COURSES AT CULVERTS
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
95
materials, pumping, timbering etc. necessary for dealing with ihe flow
of water.
312.2. 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 0oncrete. 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 now 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 culverts and no
extra payment shall be made for the same.
312.4. Rates
The Contract unit rates for different items for water courses at
culverts shall be payment in full for carrying out all required operations
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 iht; En-
gineer because of imperative economic or technical reasons, construction
of rockfill embankments shall be in accordance with the 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 should be a minimum of 500 mm thick earthen
cushion over the rockfill.
313.2. Material
The size of rock pieces used in rockfill embankments shall be
such that they can be deposited in layers so as to suit the conditions
96
evaluated in the field compaction trials or as directed by the Engineer.

The rockfill shall consist of hard, durable and inert material, preferably
maximum size not exceeding 300 mm and per cent finer than 125 mm
not exceeding 10 per cent.
Argillaceous rocks (clay, shales etc.), unburni colliery stock and chalk
shall not be used in rockfill.
The rock fragments and blinding materia l 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 lop 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. in. 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.
97
Sub-Base, Bases (Non-Bituminous) and
Shoulders
400
Sub-Bases, Bases (Non-
Bituminous) and Shoulders
Sub-Bases, Bases (Nor-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 sixes 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 111). The water absorption
value of the coarse aggregate shall be determined as per IS : 2386 (Pan
3); if this value is greater than 2 per cent, the soundness test shall
be carried out on the material delivered to site as per IS : 383.
For Grading II and III materials, the CBR shall be determined at
the density and moisture content likely to be developed in equilibrium
conditions which shall be taken as being the density relating to a
uniform air voids content of 5 per cent.
101
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 11 Grading III
75.0 mm 100 — —
53.0 mm 80-100 100 —
26.5 mm 55-90 70-100 100-
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20
TABLE 400-2. GRADING FOR COARSE GRADED GRANULAR SUB -BASK
MATERIALS
IS Sieve Per cent by weight passing the IS Sieve
Designation Grading 1 Grading II Grading III
75.0 mm 100 — —
53.0 mm 100
26.5 mm 55-75 50-80 100
9,50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm <10 <10 <10
CBR Value (Minimum) 30 25 20

Note : The material passing 425 micron (0.425 mm) sieve for all the ihrce grading!
when vested according to IS : 2720 (Pan 5) shall 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
102
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 15:2720 (Part 2) and suitably adjusted by sprinkling additional water
from a truck mounted or trailer mounted water tank and suitable for
applying water uniformly and at controlled quantities to variable widths
of surface or other means approved by the Engineer so that, at the time
of compaction, it is from 1 per cent above to 2 per cent below the
optimum moisture content corresponding to IS:2720 (Part 8). While
adding water, due allowance shall be made for evaporation losses. After
water has been added, the material shall be processed by mechanical
or other approved means like disc harrows, rotavators until the layer
is uniformly wet.
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 t yre pressure of 0,7 MN/m2 or equivalent capacity
roller capable of achieving the required compaction. Rolling shall
commence at the lower edge and proceed towards the upper edge
longitudinally for portions having unidirectional crossfall and super-
103
Sub-Bases, Bases (Non-Bituminous) and Shoulders Section 400
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 become apparent, corrected by removing or adding fresh material.
The speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued all the density achieved is at least 98
per cent of the maximum dry density for the material determined as per
IS:2720 (Part 8). The surface of any layer of material on completion
of compaction shall be well closed, free from movement under compaction
equipment and from compaction planes, ridges, cracks or loose material.
All loose, segregated or otherwise defective areas shall be made good
to the full thickness of layer and re -compacted.
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 lo Clause 112 except for initial treatment to verges,
shoulders and construction of diversions;
104
(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 pan widths of road where directed; and
(v) carrying out the required tests for quality control.
402. LIME TKEATED SOIL FOR IMPROVED

SUB-GRADE/SUB -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 silly
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 no t 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 specified. 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 work. 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 CBR/Unconfmed Compressive Strength (UCS) value specified
in the Contract. The laboratory CBR/UCS value shall be at least 1.5
limes the minimum field value of CBR/UCS stipulated in the Contract.
105
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 stabilisation shall not be
done when the air temperature in the shade is less than 10° 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 extern 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 SO
402.33. 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 rotavaior
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 shaJl 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,
106
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 die 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, ihe 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
lime or other suitable means selected by the Contractor, with the
approval o f 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
107
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 phenolphthalein alcohol indicator, will be considered
evidence of 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. Rolling: Immediately after spreading, grading and leve lling
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 removing/
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 be laid to prevent the surface from drying out and becoming
108
friable. No traffic of any kind shall ply over the completed sub -base
unless permitted by the Engineer.
of Clause 902.
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
actual 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
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.L 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, lateritc, ,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
20per cent determined in accordance with 15:2720 (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 shall comply with
the requirements of IS: 269, 455 or 1489.
Table 400-4. GRADING LIMITS OF MATERIAL FOR STABILISATION'
WITH CEMENT
IS Skve size Percentage by mass passing
Sub -base Base
Finer than; Within the range:
53,0 mm 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 8 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 pretreatmentfor
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) and/or 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 necessary, 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 p lus 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) shal! 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 sha ll 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.
111
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 die design UCS, in situ va lue being on lower
side, prior to proceeding with laying of base/surface course 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.
403-6. Arrangements for Traffic
Stabilised soil sub-base/ base shall be measured as finished work
in positio n 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 -BASE/BASE5
404.1. Scope
404.1.1. This work shall consist of clean, crushed aggregates me
chanically interlocked by roiling 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 facility for water that would get accumulated at the interface
of existing bituminous surface and water bound macadam.
112
404.2, Materials
404.2.1. Coarse aggregates : Coarse aggregates shall be either
crushed or broken stone, crushed slag, overburnt (Jha ma) 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 SVJB-BASE/BASE COURSES
Test Test Method Requirements
1. * Los Angeles IS:2386 40 per cent (Mai)
Abrasion value (Pan-4)
Or
* Aggregate IS: 2386 30 per cent (Max)
Impact value (Part -4) or
IS:5640**
2. Combined
Flak mess and IS 23 86 30 per cent (Max)
Elongation (Part-1)
Indices (Total)
***
* Aggregate may satisfy requirements of cither of the two tests.

** Aggregates like bride metal, kankar, laterite etc. which get softened in presence of water
shall be tested for Impact value under wet conditions in accordance with IS: 5640.
*** The 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 be less than 11.2 kN per m3 and the percentage of glossy
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 : 1W7
(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 overburm 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.l
shall be restricted to sub -base courses only.
TABLE «0-7. GRADING REQUIREMENTS OF COARSE AGGREGATES
Grading Size Range IS Sieve Per cent by
No. Designation weight passing
1. 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 nun 25-60
45 mm 0-15
22.4 mm 0-5
2. 63 mm to 45 mm 90 mm 100
63 mm 0-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3. 53 mm to 22.4 mm 63 mm 100
53 nun 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5
Note : The compacted thickness for a layer with Grading 1 shall be 100 mm while for
layer with other Grading! i.e. 2 & 3, it 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
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 m 2 for sub-base/base
compacted thickness of 100/75 mm.
The use of screenings shall be omitted in the case of soft aggregates
such as brick metal, kankar, lateriles, etc. as they arc 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 100/75 MM COMPACTED THICK-
NESS OF WATER BOUND MACADAM (WBM) SUB -BASE/BASFJ
COURSE FOR 10M 1 AREA
Screenings
Classifi- Size Compacted Loose Stone Screening Crushable Type such
cation Range thickness Qty as Moorum or Gravel
Grading For. WBM Grading Loose
Clasi- Sub-base/ Classi- Qty.
fication base Course fication
& Size (Loose & Size
quantity)
Grading 90 mm to 100 mm 1.21 to Type A 0.27 to Not 0.30 to
45 mm 1.43 m3 13.2 mm 0.30 m3 uniform 0.32 m3
Grading 2 63 mm to 73 nun 0.91 to Type A 0.12 to -do- 0.22 to

45 mm 1.07 m3 13,2 mm 0.15 m3 0.24 m3
-do- -do- -do- -do- Type B 0.20 to -do- -do-

3
11.2 mm 0,22 m
Grading 3 53 mm to 75 mm -do- -do- 0.18 to -do- -do-

22.4 mm 0.21 m3
115
404.2.7. Binding material : Binding material to be used for water

bound macadam as a filler material meant for preventing ravelling,
shall comprise of a suitable material approved by the Engineer having
a Plasticity Index(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
0.06-0.09 m3 /10m2 and 0.08-0. lOm3 /10m2 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) arid 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.
116
7
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 js taken up. In case of a fine sand or silty or clayey subgrade,
it is advisable to lay 100 mm insulating layer of screening or coarse
sand on top of fine grained 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 evenly upon the prepared subgrade/sub-base/
base to proper profile by using templates placed across the road about
6 m apart, in such quantities that the thickness of each compacted
layer is not more than 100 mm for Grading 1 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 gradatio n 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 and 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. Curing 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 rolled 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
118
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 surfa ce 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
thoroughly 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,
404.3.7. 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
119
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 h would
cause excessive damage £o 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 10 the
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
when the atmospheric temperature is less than 0°C in 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 recompacted. In 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 401.8
(i) to (v) including arrangement of water used in the work as approved
by the Engineer,
120
405. CRUSHED CEMENT CONCRETE SUB-BASE/BASE

405.1. Scope
This work shall consist of breaking and crushing the damaged
cement concrete slabs and recompacting the same as sub-base/base
course in one or more layers. Where specified, it shall also include
treating the surface of the lop 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 conformity 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 broken 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
400-7.
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 o r other deleterious matter and adherent
coatings. The aggregate shall be hydrophobic and of low 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 physic al 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 requireme nts 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,
121
the top layer shall be treated with a penetration coat of binder described
in Clause 405.3.2.
4053.2. Application of penetration coat over the top layer:
Before the application of the penetration 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
at 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 rn2 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.
405.4. Surface Finish and Quality Control of Works
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.
122
Penetration coat shall be measured as finished work in square

metres.
405.7. Rates
405.7.1. 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:
(i) making arrangements for traffic to Clause 112 except for initial treatment to
verges/shoulders and construction of diversions;
(ii) breaking the cement concrete slabs, 'crashing, sieving and recompacting the
slab material as sub-base/base course;
(iii) all labour, toots, 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 shall 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 shall consist of laying and compacting clean,
crushed, graded aggregate and granular material, premixed with water,
to a dense mass on a prepared subgrade/sub -base/base or existing
pavement as the case may be in accordance with the requirements
of 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 arc 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
406.2.1. Aggregates
406.2.1.1. Physical requirements: Coarse aggregates .shall be
crushed stone. If crushed gravel/shingle is used, not less than 90 per cent
by weight of the gravel/shingle pieces retained on 4,75 mm sieve shall
have-at least two fractured faces. The aggregates shall conform
to the physical requirements set forth in Table 400 -10 below,
123
Sub-Base, Bases (Not-Bituminous and Shoulders Sections 400
Table 400-10. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR

WET MIX MACADAM FOR SUB-BASE/BASE COURSES
1. *Los Angles 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-4)
Indices (Total)
* Aggregate may satisfy requirements of either of the two tests.
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 aggregate shall conform to
the grading given in Table 400-11.
Tabl e 400-11. GRADING REQUIREMNTS OF AGGREGATES FOR
WET MIX MACADAM
IS Sieve Per cent by weight
Designation passing the IS sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm ---
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8
Materials finer than 425 micron shall have Plasticity Index (PI)
not exceeding 6.
The final gradation approved within these limits shall be well graded
from coarse to fin 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.
406.3.2.1. Provision of lateral confinement of aggregates: While
constructing 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. Preparation 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
be 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_22A mm sieve with material of 4.75 mm to 22.4 mm size. While
adding water, dup 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 should 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 payer 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 al! 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 following
features :
(i) Loading hoppers and suitable distribution mechanism
(ii) The screed shall have lamping and vibrating arrangement for initial compaction
to the layer as it is spread without rutting or otherwise marring the surface
profile.
(iii) The paver shall be equipped with necessary 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
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 crossfall/camber 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
to 100 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.
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 overlapping 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 1 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 m the sub-base/base course or
subgrade. If irregularities develop during rolling which exceed 12 mm
when tested with a 3 metre straight edge, the surface should be loosened
and premixed material added or removed as required before rolling again
so as to achieve a uniform surface conforming to the desired grade and
126
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
compaction 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 recompacted.
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.
406.5.1. 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
full thickness of the layer shall be scarified over the affected area, re -
shaped with added premised material or removed and replaced with
fresh premixed material as applicable and recompacted 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 cas e shall depressions
be filled up with unmixed and ungraded material or fines,
During the period of construc tion, arrangement of traffic shall be
done as per Clause 112,
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 full
compensation for all components listed in Clause 401.8.
407. SHOULDERS, ISLANDS AND MEDIAN
407.1. Scope
The work shall consist of cons tructing 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 conforming to the requirements of Clause
305/401 and the median may be of selected each conforming to the
Median/Traffic islands shall be raised and kerbed at the perimeter
and the enclosed area filled with earth and suitably covered with grass
turf/shrubs as per Clause 307 and/or paved as per Clause 409.3.4 or
409.3.5.
Paved shoulders shall consist of sub-base, base and surfacing courses,
as shown in the drawings and materials for the same shall conform to
relevant Specifications of the corresponding items. Where paved or
hard shoulders are not provided, the pavement shall be provided
with brick/stone 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 of Shoulders/Median/Islands
Shoulder (earthen/hard/paved}/median/traffic island dimensions shall
be as shown on the drawings or as directed by the Engineer.
128

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 ma terial 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 excavated
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 (earthen/
hard/paved), 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 alter 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
407.4.3. Brick/stone block edging: The bricks/stones blocks shall

be laid on edge, with the length parallel to the transverse direction of
rolled into position by a light roller and made flush with the finished
level of the pavement.
407.5. Surface Finish and Quality Control of works
of Clause 902. Control on the quality of materials and works shall be
exercised by the engineer in accordance with Section 900.
Shoulder (earthen /hard/paved), island and madian 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 courses in units as for respective items.
(iv) For kerb in running metres.
(v) For turfing and tile/slab finish in sq. m.
(vi) For Brick/stone block edging in se. m.
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 listen in Clause 408.8 (i) 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
specified in the drawings.
108.2. Materials
Kerbs and kerb with channel shall be provided in cement concrete
of grade M20 in accordance with Section 1700 of these Specification.
130
408.3. Type of Construction

These shall be cast- in-situ construction with suitable kerb casting
machine in all situations except at locations where continues casting
with equipment is not practicable. In those situations, precast concrete
blocks shall be used.
408.4. Equipment
A continuous kerb casting equipment of adequate 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. Construction Operations.
408.5.1. Kerbs shall be laid on firm foundation of minimum 150
mm thickness and extending minimum 100 mm beyond the kerb which
may consist of extended width of pavement or concrete of M 15 grade
cast in situ or bituminous premix material of the same Specification
as the profile corrective course. Before laying ti-c foundation, its base
shall be levelled, watered and compacted with plate compactor/power
rammer. In case of foundation consisting of granular material, the base
of foundation shad be well compacted with plate compactor/power
rammer and bituminous primer applied @ 14.6 kg/l0 sq. m.
408.5.2. In the median portions itt the straight reaches, the kerb
shall be cast in continuous 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.
408.5.3. After laying the kerbs and just prior to hardening of the
concrete, saw-cut grooves shall be provided at 10 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 drainage of the
road surface.
408.5.5. Vertical and horizontal tolerances with respect to true line
and level shall be ±6 mm.
Cement concrete kerb/kerb with channel shall be measured in
linear metre for the complete item of work.
131
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 kerbAerb 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 constructing 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
following types :
(a) Cast-in-situ cemenl 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 diwings, 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 Specifications
in specified thickness.
409.3.3. The base shall be prepared and finished to the required
lines, levels and dimensions as indicated in the drawings with the
132
following ;-
(3) Minimum 150 mm thick, compacted granular sub-base material as 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/natural stone slabs

and/or cast- in-situ slab shall be set/laid as described in Clauses 409.3,4 and
4093.5.
4093.4, Precast cement concrete blocks/tiles/natural stone slab:
The blocks/tiles/slabs shall be set on a layer of average 12 mm thick cement-
sand mortar (1:3) 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 be filled with cement-sand mortar (1:3).
409.3,5. Cast-in-situ cement concrete: The minimum thickness of the
cement concrete shall be 25 mm and it shall be 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 sq. metre between inside
of kerbs.
409.5. Rates
Contract unit rates shall be inclusive of full compensation of all labour,
materials, tools, equipment and incidentals to construction 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 Engineer,
410.2. Materials
The material to be used for the work shall be crushed rock. 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. It
shall be free from any organic mailer and other deleterious substances and
shall be of such nature that it can be compacted readily under watering and
133
Stances and shall be such nature that it can be compacted readily under
watering and rolling to form a firm, stable base. The aggregate shall
conform to the grading and quality requirement shown in Tables
400-12 and 400-13.
At the option of the contractor, the grading 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.
400.12. AGGREGATE GRADING REQUIREMENTS
Sieve size Per cent passing by weight
53 mm max. size 37.5 mm max. size
63 mm 100
45 mm 87-100 100
22.4 mm 50-85 90-100
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
1. *Los Angeles IS : 2386 40 maximum
Abrasion value (Part - 4)
or
* Aggregate IS : 2386 30 maximum
Impact value (Part- 4) or
IS : 5640
2. Combined
Flakiness and IS : 2386 30maximum
Elongation (Part-1)
Indices (Total)
3. ** Water absorption IS : 2386 2 per cent

(Pan-3) Maximum
4.
Liquid Limit of IS : 2720 Not more than
material passing (Part-5) 25
425 micron
5.
Plasticity Index IS : 2720 Not more than
of material (Part-5) 6
passing
425 micron
* Aggregate may satisfy requirements of either of the two tests.
** If the water absorption is more than 2 per cent, soundness test shall be carried out
as per IS:2386(Part -5).
134

410.3.1. Preparation of 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 10 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 to 100 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 not less
than 98 per cent of the maximum density as determined by IS: 2720
(Part-8).
410.4. Surface Finish and Quality Control or Work
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. GENERAL REQUIREMENTS FOR BITUMINOUS

PAVEMENT LAYERS
501.1. General
Bituminous pavement courses shall be made using the materials
described in the following Specifications.
The use of machinery and equipment mentioned in various Clauses
of these Specifications is mandatory. Details of the machinery and
equipment are available in the Manual for Construction and Supervision
of Bituminous Works. Equipment mandatory for any particular project
shall be in accordance with the Contract Specification for that project.
501.2. Materials
501.2.1. Binder: The binder shall be an appropriate type of
bituminous material complying with the relevant Indian Standard (IS),
as defined in the appropriate Clauses of these Specifications, or as
otherwise specified herein. The choice of binder shall be stipulated in
the Contract or by the Engineer. Where penetration grades of bitumen
are specified, they are referred to by a single- figure designation in
accordance with IS:73. Thus bitumen grade 35 refers to a bitumen in the
penetration range 30 to 40. Where Modified Binder is specified, the Clause
521 of these Specifications shall apply.
501.2.2. Coarse Aggregates: The coarse aggregates shall consist of
crushed rock, crushed gravel or other hard material retained on the 2.36
mm sieve. They shall be clean, hard, durable, of cubical shape, free from
dust and soft or friable matter, organic or other deleterious matter. Where
the Contractor's selected source of aggregates have poor affinity for
bitumen, as a condition for the approval of that source, the bitumen shall
be treated with approved anti-stripping agents, as per the manufacturer's
recommendations, without additional payment. Before approval of the
source the aggregates shall be tested for stripping.
The aggregates shall satisfy the physical requirements set forth in
the individual relevant clause for the material in question.
Where crushed gravel is proposed for use as aggregate, not less than
90% by weight of the crushed material retained on the 4.75 mm sieve
shall have at least two fractured faces.
3
501.2.3. Fine Aggregates: Fine aggregates shall consist of crushed

or naturally occurring material, or a combination of the two, passing
2.36mm sieve and retained on the 75 micron sieve. They shall be clean,
hard, durable, dry and free from dust, and soft or friable matter, organic
or other deleterious matter.
501.2.4. Source of material: The source of all materials to be used
on the project must be tested to the satisfaction of and be expressly
approved by the Engineer. The Engineer may from time to time withdraw
approval of a specific source, or attach conditions to the existing approval.
Any change in aggregate source for bituminous mixes, will require a
new mix design, and laying trials, where the mix is based on a job mix
design. Stockpiled from different sources, approved or otherwise, shall
be kept separate, such that there is no contamination between one material
and another. Each source submitted for approval shall contain sufficient
material for at least 5 days work.
501.3. Mixing
Pre-mixed bituminous materials, including bituminous macadam,
dense bituminous macadam, semi-dense bituminous concrete and
bituminous concrete, 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. Appropriate mixing temperatures can
be found in Table 500-5 of these Specifications; the difference in
temperature between the binder and aggregate should at no time exceed
14°C. In order to ensure uniform quality of the mix and better coating of
aggregates, the hot mix plant shall be calibrated from time to time.
If a continuous mixing-plant is to be used for mixing the bituminous
bound macadam; the Contractor must demonstrate by laboratory analysis
that the cold feed combined grading is within the grading limits specified
for that bituminous bound material. In the case of a designed job mix, the
bitumen and filler content shall be derived using this combined grading.
Further details are available in the Manual for Construction and
Supervision of Bituminous Works.
501A Transporting
Bituminous materials shall be transported in clean insulated vehicles,
and unless otherwise agreed by the Engineer, shall be covered while in
transit or awaiting tipping. Subject to the approval of the Engineer, a thin
4
coating of diesel or lubricating oil may be applied to the interior of the

vehicle to prevent sticking and to facilitate discharge of the material.
501.5. Laying
501.5.1. Weather and seasonal limitations: Laying shall be
suspended while free-standing water is present on the surface to be
covered, or during rain, fog and dust storms. After rain, the bituminous
surface, prime or tack coat, shall be blown off with a high pressure air jet
to remove excess moisture, or the surface left to dry before laying shall
start. Laying of bituminous mixtures shall not be carried out when the air
temperature at the surface on which it is to be laid is below 10°C or when
the wind speed at any temperature exceeds 40 km/h at 2m height unless
specifically approved by the Engineer.
501.5.2. Cleaning of surface: The surface on which the bituminous
work is to be laid shall be cleaned of all loose and extraneous matter by
means of a mechanical broom or any other approved equipment / method
as specified in the contract. The use of a high pressure air jet from a
compressor to remove dust or loose matter sha ll be available full time on
the site, unless otherwise specified in the Contract.
501.5.3. Spreading: Except in areas where a mechanical paver cannot
access, bituminous materials shall be spread, levelled and tamped by an
approved self-propelled paving machine. As soon as possible after arrival
at site, the materials shall be supplied continuously to the paver and laid
without delay.
The rate of delivery of material to the paver shall be regulated to
enable the paver to operate continuously. The travel rate of the paver,
and its method of operations, shall be adjusted to ensure an even and
uniform flow of bituminous material across the screed, free from dragging,
tearing and segregation of the material. In areas with restricted space
where a mechanical pave r cannot be used, the material shall be spread,
raked and levelled with suitable hand tools by experienced staff, and
compacted to the satisfaction of the Engineer.
The minimum thickness of material laid in each paver pass shall be
in accordance with the minimum values given in the relevant parts of
these Specifications. When laying binder course or wearing course
approaching an expansion joint of a structure, machine laying shall stop
300mm short of the joint. The remainder of the pavement up to the joint,
5
and the corresponding area beyond it, shall be laid by hand, and the joint
or joint cavity shall be kept clear of surfacing material.
Bituminous material, with a temperature greater than 145°C, shall p
not be laid or, deposited on bridge deck waterproofing systems, unless
precautions against heat damage have been approved by the Engineer.
Hand placing of pre -mixed bituminous materials shall only be
permitted in the following circumstances:
(i) For laying regulating courses of irregular shape and varying thickness.
(ii) In confined spaces where it is impracticable for a paver to operate.
(iii) For footways.
(iv) At the approaches to expansion joints at bridges, viaducts or other structures.
(v) For laying mastic asphalt in accordance with Clause 515.
(vi) For filling of potholes.
(vii) Where directed by the Engineer.
Manual spreading of pre - mixed wearing course material or the

addition of such material by hand-spreading to the paved area, for
adjustment of level, shall only be permitted in the following circumstances:
(i) At the edges of the layers of material and at gullies and manholes.
(ii) At the approaches to expansion joints at bridges, viaducts or other structures.
(iii) As directed by the Engineer.
501.5.4. Cleanliness and overlaying: Bituminous material shall be
kept clean and uncontaminated. The only traffic permitted to run on
bituminous material to be overlaid shall be that engaged in laying and
compacting the next course or, where a binder course is to be sealed or
surface dressed, that engaged on such surface treatment. Should any
bituminous material .become contaminated the Contractor shall make it
good to the satisfaction of the Engineer, in compliance with Clause 501.8.
Binder course material shall not remain uncovered by either the
wearing course or surface treatment, whichever is specified in the
Contract, for more than three consecutive days after being laid. The
Engineer may extend this period, by the minimum amount of time
necessary, because of weather conditions or for any other reason. If the
surface of the base course is subjected to traffic, or not covered within
three days, a tack coat shall be applied, as directed by the Engineer.
6
501.6. Compaction
Bituminous materials shall be laid and compacted in layers which
enable the specified thickness, surface level, regularity requirements and
compaction to be achieved.
Compaction of bituminous materials shall commence as soon as
possible after laying. Compaction shall be substantially completed before
the temperature falls below the minimum rolling temperatures stated in
the relevant part of these Specifications. Rolling of the longitudinal joints
shall be done immediately behind the paving operation. After this, rolling
shall commence at the edges and progress towards the centre
longitudinally except that on super elevated and unidirectional cambered
portions, it shall progress from the lower to the upper edge parallel to the
centre line of the pavement. Rolling shall continue until all roller marks
have been removed from the surface. All deficiencies in the surface after
laying shall be made good by the attendants behind the paver, before
initial rolling is commenced. The initial or breakdown rolling shall be
done with 8-10 tonnes dead weight smooth-wheeled rollers. The
intermediate rolling, shall be done with 8-10 tonnes dead weight or
vibratory roller or with a pneumatic tyred roller of 12 to 15 tonnes weight
having nine wheels, with a tyre pressure of at least 5.6 kg/sqcm. The
finish rolling shall be done with 6 to 8 tonnes smooth wheeled tandem
rollers.
Where compaction is to be determined by density of cores the
requirements to prove the performance of rollers shall apply in order to
demonstrate that the specified density can be achieved. In such cases the
Contractor shall nominate the plant, and the method by which he intends
to achieve the specified level of compaction and finish at temperatures
above the minimum specified rolling temperature. Laying trials shall then
demonstrate the acceptability of the plant and method used.
Bituminous materials shall be rolled in a longitudinal direction, with
the driven rolls nearest the paver. The roller shall first compact material
adjacent to joints and then work from the lower to the upper side of the
layer, overlapping on successive passes by at least one-third of the width
of the rear roll or, in the case of a pneumatic -tyred roller, at least the
nominal width of 300mm
In portions with super-elevated and uni-directional camber, after the
edge has been rolled, the roller shall progress from the lower to the upper
edge.
7
Rollers should move at a speed of not more than 5 km per ho ur. The
roller shall not be permitted to stand on pavement which has not been
fully compacted, and 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 rollers
shall be kept moist with water, and the spray system provided with the
machine shall be in good working order, to prevent the mixture from
adhering to the wheels. Only sufficient moisture to prevent adhesion
between the wheels of rollers and the mixture should be used. Surplus
water shall not be allowed to stand on the partially compacted pavement.
501.7. Joints
Where longitudinal joints are made in pre-mixed bituminous
materials, the materials shall be fully compacted and the joint made flush
in one of the following ways; only method (iii) shall be used for transverse
joints:
(i) by heating the joints with an approved joint beater when the adjacent width is being
laid, but without cutting back or coating with binder. The heater shall raise the
temperature of the full depth of material, to within the specified range of minimum
rolling temperature and maximum temperature at any stage for the material, for a
width not less, Am 75 mm, The Contractor shall have equipment available, for use in
the event of a beater breakdown, to form joints by method (iii);
(ii) by using two or more pavers operating in echelon, where this is practicable, and in
sufficient proximity for adjacent widths to be fully compacted by continuous rolling;
(iii) bycuttmgbaeklbeexposedjou<,foradistanceequaltothespecifiedlayerthickness,
to vertical face, discarding all loosened material and coating the vertical face
completely, with 80/100 penetration grade hot bitumen, or cold-applied bitumen, or
polymer modified adhesive bitumen tape with a minimum thickness of 2 mm, before
the adjacent width is laid.
All joints shall be offset at least 300 mm from parallel joints in the
layer beneath or as directed, and in a layout approved by the Engineer.
Joints in the wearing course shall coincide with either the lane edge or
the lane marking, which ever is appropriate. Longitudinal joints shall not
be situated in wheel track zones.
501.8. Preparation of Surface
501.8.1. Scope : This work shall consist of preparing an existing
granular Or black-topped surface bituminous course. The work shall be
performed on such widths and lengths as shown on the drawings or as
instructed by the Engineer. The existing surface shall be firm and clean,
8
and treated with Prime or Tack coat as shown on the drawings as otherwise
stated in the Contract.
501.8.2. Materials
501.8.2.1. For scarifying and re -laying the granular surface: The
material used shall be coarse aggregate salvaged from the scarification
of the existing granular base course supplemented by fresh coarse
aggregate and screenings so that aggregates and screenings thus
supplemented correspond to Clause 404: Water Bound Macadam or Clause
406: Wet Mix Macadam of the Ministry's Specification for Road and
Bridge Works (third revision) 1995.
501.8.2.2. For patching potholes and sealing cracks: Where the
existing surface to be overlaid is bituminous, any existing potholes and
cracks shall be repaired and sealed in accordance with Clauses 3004.2
and 3004.3, or as directed by the Engineer.
501.8.2.3. For profile corrective course: A profile corrective course
for correcting the existing pavement profile shall be laid to varying
thickness as shown on the Drawings, or as indicated in the Contract
Documents. The profile corrective course shall be laid to tolerances and
densities as specified for wearing course if a single layer, or base course,
if it is to be covered with a wearing course layer.
501.8.2.4. Profile corrective course and its application: The type
of material for use as profile corrective course shall be as shown on the
drawings or as directed by the Engineer. Where 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 separate layer, it shall be of the
specification and details given in the contract drawings.
(i) Any high spots in the existing surface shall be removed by a milling machine or other
approved method, and all loose material shall be removed to the satisfaction of the
Engineer.
(ii) Where the maximum thickness of profile corrective course will be not more than 40
mm, the profile corrective course shall be constructed as an integral pan of the overlay
course. In other cases, the profile corrective course shall be constructed as a separate
layer, adopting such construction procedures and using such equipment as approved
by the Engineer, to lay the specified type of material, to thickness and tolerance as
specified, for the course, to be provided.
9
501.8.3. Construction Operations

501.8.3.1. Preparing existing granular surface: Where the existing
surface is granular, all loose materials shall be removed, and the surface
lightly Watered where the profile corrective course to be provided as a
separate layer is also granular. Where the profile corrective course of
bituminous material is to be laid over the existing granular surface, the
latter shall, after removal of all loose material, be primed in accordance
with Clause 502.
The surface finish of all granular layers on which bituminous works
are to be placed, shall, unless otherwise specifically instructed by the
Engineer, be free from dust. All such layers must be capable of being
swept, after the removal of any non- integral loose material, by means of
a mechanical broom, without shedding significant quantities of material
and dust removed by air jet, washing, or other means approved by the
Engineer.
After cleaning the surface shall be correct to line and level, within
the tolerances specified for base course.
501.8.3.2. Scarifying existing bituminous surface: Where specified
or shown on the drawings, the existing bituminous layer in the specified
width shall be removed with care and without causing undue disturbance
to the underlying layer, by a suitable method approved by the Engineer.
After removal, all loose and disintegrated material, the underlying layers
which might have been disturbed should be suitably reworked and
compacted to line and level. After supplementing the base material as
necessary with suitable fresh stone, the compacted finished surface shall
be primed in accordance with Clause 502. Reusable materials shall be
stacked as directed by the Engineer within 1000 m of their origin.
501.8.3.3. Patching of potholes and sealing of cracks: Where the
existing surface to be overlaid is bituminous, any existing potholes and
cracks shall be repaired and sealed in accordance with clauses 3004.2
and 3004.3, or as directed by the Engineer.
501.83.4. Laying the profile corrective course
501.8.3.4.1. Laying on granular base: After preparing the granular
surface in accordance with Clauses 501.8.3.1 and 501.8.3.2, the profile
corrective course shall be laid using material as described in Clauses
10
501.8.2.3 and 501.8.2.4, or as otherwise described in the Contract, and

compacted to the requirements of the particular Specification.
501.8.3.4.2. Laying on existing bituminous surface: The existing
bituminous surface shall be prepared in accordance with Clause 501.8.3.3,
and after applying a tack coat conforming to Clause 503, the bituminous
profile corrective course shall be laid and compacted to the requirements
of the particular Specification.
501.8.3.4.3. Correction of local depressions: Where local sags or
depressions occur in the existing pavement, a specific filling operation
shall be instructed by the Engineer, which should be laid in accordance
with Figure 500-1. Normally, the maximum layer thickness at any point
should not exceed 100 mm. In placing multiple lifts, they should be
arranged according to the correct method as illustrated.
For correction of camber or super -elevation of the existing
carriageway, the method shown in Figure. 500-2 shall be adopted,
depending on the profile of the existing carriageway.
501.8.3.5. Covering the profile corrective courses: Profile
corrective course particularly shall be so planned that the layer shall be
covered by the designed base/wearing course at the earliest opportunity,
before opening to regular traffic.
501.8.4. Surface finish and quality control of work: The relevant
provisions of Section 900 shall apply.
501.8.5. Arra ngements for traffic: During construction operations,
arrangements for traffic shall be made in accordance with the provisions
of Clause 112 of the Ministry's Specification for Road and Bridge Works
(third revision) 1995.
501.8.6. Environmental protection: The provisions of Clause 111
of the Ministry's Specification for Road and Bridge Works (third revision)
1995 and the provision of Annexure A to Clause 501 shall apply.
501.8.7. Measurement for payment
501.8.7.1. Potholes and cracks: The work of filling potholes shall
be measured separately and be paid for in square metres.
The work of filling cracks by applying fog spray or emulsion slurry
seal shall be measured in square metres, for the area covered by the spray.
11
Note: Profile corrective course material to be in accordance with the lift thickness
Figure. 500-1, Methods for providing corrective course for short sags and depressions
12
Figure. 500-2. Correction of Camber or Superelevation

13
The work in filling-cracks larger than 3mm in width shall be measured

and paid for- on a linear metre basis.
501.8.7.2. Scarifying: Scarifying the existing bituminous surface
shall be measured on a square metre basis.
501.8.7 3. Profile corrective course: Profile corrective course shall
be measured as the volume instructed and compacted in position and
measured in cubic metres, or in tonnage, as stipulated in the Contract.
The volume shall be calculated by plotting the exact profile of profile
corrective course as required, and laid, superimposed on the existing
pavement profile. Cross-sectional areas of the profile corrective course
shall be measured at intervals as used in the design, or as determined by
the Engineer, and the volume shall be calculated using the method of end
areas.
501.8.7.4 Prime coat: Prime coat is to be measured and paid for on
a per square metre basis.
501.8.7.5 Tack coat: This is to be a PROVISIONAL item, which
may be used in-part or not at all, at the Engineers direction, and is to be
measured and paid paid if used, on a square metre basis.
501.8.8. Rates
501.8.8.1. Rate for scarifying: The contract unit rate for scarifying
existing bituminous surfaces, including repairing / reworking disturbed
underlying layers and removing and stacking reusable / unusable materials,
shall include for but not necessarily be limited to, the cost of all labour,
supply of materials needed for repair /reworking, hire charges of tools
and plant, and transportation of scarified materials within 1000 m of their
origin.
501.8.8.2. Rate for premixed bituminous material: The contract
unit rate for premixed bituminous material shall be payment in full for
carrying out the required operations including full compensation for, but
not necessarily limited to:
(i) Making arrangements for traffic to Clause 112 except for initial treatment to verge,
shoulders and construction of diversions;
(ii) Preparation of the surface to receive the material.
(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;
14
(iv) Mixing, transporting, laying and compacting the mix, as specified.

(v) All labour, tools, equipment, plant including installation of hot mix plant, power
supply un its and all machinery, incidental to complete the work to these Specifications;
(vi) Carrying out the work in part widths of the road where directed; (vii)
Carrying out all tests for control of quality; and
(viii) The rate shall cover the provision of bitumen at the rate specified in the contract, with
the provision that the variation in actual percentage of bitumen used will be assessed
and the payment adjusted accordingly.
(ix) The rates for premixed material are to include for all wastage in cutting of joints etc.
(x) The rates are to include for all necessary testing, mix design, transporting and testing
of samples, and cores. If there is not a project specific laboratory, the Contractor
must arrange to carry out all necessary testing at an outside Laboratory, approved by
the Engineer, and all costs incurred are deemed to be included in the rate quoted for
the material.
(xi) The cost of all plant and laying trials as specified to prove the mixing and laying
methods is deemed to be included in the Contractor's rates for the material.
501.8.8.3. Rate for potholes and crack sealing: The rate for patching
potholes shall include for breaking out, trimming edges, cleaning out,
painting edges and bottom with bitumen, and filling and compacting the
excavation with the specified material. The rate should be inclusive of
all plant, tools, labour and materials, transport, and disposal of surplus
material,
The contract unit rate for sealing cracks by applying fog spray shall
be inclusive of providing all materials, tools, labour and 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.
The contract unit rate for crack sealing 3mm to 6mm cracks with
straight run or other specified bitumen, shall be based on either a square
metre basis, or linear metre of cracks as measured, as stipulated by the
Contract.
The contract unit rate for cracks between 6mm and 15mm is to be
measured on a linear metre basis, and the rate is to include for all materials,
tools, plant, labour, and transport.
15
Annexure 'A' to Clause 501

Annexure ‘A’
PROTECTION OF THE ENVIRONMENT
1. General
1.1. This section of the Specification sets out limitations on the
Contractor's activities specifically intended to protect the
environment.
1.2. The Contractor shall take all necessary measures and precautions
and otherwise ensure that the execution of the works and all
associated operations on site or off-site are carried out in
conformity with statutory and regulatory environmental
requirements including those prescribed elsewhere in this
document.
1.3. The Contractor shall take all measures and precautions to avoid
any nuisance or disturbance arising from the execution of the
Works. This shall wherever possible be achieved by suppression
of the nuisance at source rather than abatement of the nuisance
once generated.
1.4. In the event of any spoil, debris, waste or any deleterious
substance from the Site being deposited on any adjacent land,
the Contractor shall immediately remove all such material and
restore the affected area to its original state to the satisfaction of
the Engineer.
2. Water Quality
2.1. The Contractor shall prevent any interference with the supply to
or abstraction from, and prevent any pollution of, water resources
(including underground percolating water) as a result of the
execution of the Works.
2.2. Areas where water is regularly or repetitively used for dust
suppression purposes shall be laid to fall to specially-constructed
settlement tanks to permit sedimentation of particulate matter.
After settlement, the water may be re-used for dust suppression
and rinsing.
2.3. All water and other liquid waste products arising on the Site
shall be collected and disposed of at a location on or off the Site
and in a manner that shall not cause either nuisance or pollution.
16
2.4. The Contractor shall not discharge or deposit any matter arising
from the execution of the Works into any waters except with the
permission of the Engineer and the regulatory authorities
concerned.
2.5. The Contractor shall at all times ensure that all existing stream
courses and drains within, and adjacent to, the Site are kept safe
and free from any debris and any materials arising from the
Works.
2.6. The Contractor shall protect all watercourses, waterways, ditches,
canals, drains, lakes and the like from pollution as a result of the
execution of the Works.
3. Air Quality
3.1. The Contractor shall devise and arrange methods of working to
minimise dust, gaseous or other air-borne emissions and carry
out the Works in such a manner as to minimise adverse impacts
on air quality.
3.2. The Contractor shall utilise effective water sprays during delivery
manufacture, processing and handling of materials when dust is
likely to be created, and to dampen stored materials during dry
and windy weather. Stockpiles of friable materials shall be
covered with clean tarpaulins, with application of sprayed water
during dry and windy weather. Stockpiles of material or debris
shall be dampened prior to their movement, except where this is
contrary to the Specification.
3.3. Any vehicle with an open load-carrying area used for transporting
potentially dust producing material shall have properly fitting
side and tail boards. Materials having the potential to produce
dust shall not be loaded to a level higher than the side and tail
boards, and shall be covered with a clean tarpaulin in good
condition. The tarpaulin shall be properly secured and extend at
least 300 mm over the edges of the side and tail boards.
3.4. In the event that the Contractor is permitted to use gravel or
earth roads for haulage, he shall provide suitable measures for
dust palliation, if these are, in the opinion of the Engineer,
necessary. Such measures may include spraying the road surface
with water at regular intervals.
17
4. Noise:
4.1. The Contractor shall: consider noise as an environmental
constraint in his planning and execution of the Works.
4.2. The Contractor shall take all necessary measures so that the
operation of all mechanical equipment and construction processes
on and off the Site shall not cause any unnecessary or excessive
noise, taking into account applicable environment requirements.
The Contractor shall use all necessary measures and shall
maintain all plant and silencing equipment in good condition so
as to minimise the tioise emission during construction works.
5. Control of Wastes
5.1. The Contractor shall control the disposal of all forms of waste
generated by the construction operations and in all associated
activities. No uncontrolled deposit ion or dumping shall be
permitted. Wastes to be so controlled shall include, but shall not
be limited to, all forms of fuel and engine oils, all types of
bitumen, cement, surplus aggregates, gravels, bituminous
mixtures etc. The Contractor shall make specific provision for
the proper disposal of these and any other waste products,
conforming to local regulations and acceptable to the Engineer.
6. Emergency Response
6.1. The Contractor shall plan and provide for remedial measures to
be implemented in the event of occurrence of emergencies such
as spillages of oil or bitumen or chemicals.
6.2. The Contractor shall, provide the Engineer with a statement of
the measures he intends to implement in the event of such an
emergency which shall include a statement of how he intends to
provide personnel adequately trained to implement such
measures.
7. Measurement
7.1. No separate measurement shall be made in respect of compliance
by the Contractor with the provisions of this Section of the
Specification., The Contractor shall be deemed to have made
allowance for such compliance with these provisions in the
preparation of his prices for items of work included in the Bills
of Quantities and full compensation for such compliance will be
deemed to be covered by them.
18
502. PRIME COAT OVER GRANULAR BASE

502.1. Scope
This work shall consist of the application of a single coat of low
viscosity liquid bituminous material to a porous granular surface
preparatory to the superimposition of bituminous treatment or mix.
502.2. Materials
502.2.1. Primer: The choice of ,a bituminous primer shall depend
upon the porosity characteristics of the surface to be primed as classified
in IRC: 16. These are:
(i) Surfaces of low porosity; such as wet mix macadam and water bound macadam,
(ii) Surfaces of medium porosity; such as cement stabilised soil base,
(iii) Surfaces of high porosity; such as a gravel base.
502.2.2. Primer viscosity: The type and viscosity of the primer shall
comply with the requirements of IS 8887, as sampled and tested for
bituminous primer in accordance with these standards. Guidance on
viscosity and rate of spray is given in Table 500-1.
TABLE 500-1. VISCOSITY REQUIREMENT AND QUANTITY OF LIQUID
BITUMINOUS PRIMER
Type of surface Kinematic Viscosity Quantity of Liquid
of Primer at 60°C Bituminous Material
per 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. Choice of primer: The primer shall be bitumen emulsion,
complying with IS 8887 of a type and grade as specified in the Contract
or as directed by the Engineer. The use of medium curing cutback as per
IS 217 shall be restricted only for sites at sub-zero temperatures or for
emergency applications as directed by the Engineer.
502.3. Weather and Seasonal Limitations
Bituminous primer shall not be applied to a wet surface (see 502.4.2)
or during a dust storm or when the weather is foggy, rainy or windy or
when the temperature in the shade is less than 10°C. Surfaces which are
19
to receive emulsion primer should be damp, but no free or standing water

shall be present.
502.4. Construction
502.4.1. Equipment: The primer distributor shall be a self-propelled
pi or towed bitumen pressure sprayer equipped for spraying the material
uniformly at specified rates and temperatures. Hand spraying of small &
areas, inaccessible to the distributor, or in narrow strips shall be sprayed with a
pressure hand sprayer, or as directed by the Engineer.
502.4.2. Preparation of road surface: The surface to be primed
shall be prepared in accordance with Clauses 501.8. and 902 as
appropriated Immediately prior to applying the primer the surface shall
be carefully swept clean of dust and loose particles, care being taken not ,
to disturb the interlocked aggregate. This is best achieved when the surface
layer is slightly moist (lightly sprayed with water and the surface allowed
to dry) and the surface should be kept moist until the primer is applied.
502.43. Application of bituminous primer: The viscosity and rate
of application of the primer shall be as specified in the Contract, or as
determined by site trials carried out as directed by the Engineer. Where a
geosynthetic is proposed for use, the requirements of Clauses 704.3.2
and 704.4 of the Ministry's Specification for Road and Bridge Works
(thirtfrevision) 1995 shall apply. The bituminous primer shall be sprayed
uniformly in accordance with Clause 501.The method for application of
the primer will depend on the type of equipment to be used, size of nozzles,
pressure at the spray bar and speed of forward movement. The Contractor
shall demonstrate at a spraying trial, that the equipment and method to
be used is capable of producing a uniform spray, within the tolerances
specified.
502.4.4. Curing of primer and opening to traffic: A primed surface
shall be allowed to cure for at least 24 hours or such other period as is
found to be necessary to allow all the volatiles to evaporate before any
subsequent surface treatment or mix is laid. Any unabsorbed primer shall
first be blotted with an application of sand, using the minimum quantity
possible. A primed surface shall not be opened to traffic other than that
necessary to lay the next course. A very thin layer of clean sand may be
applied to the surface of the primer, to prevent the primer picking up
under the wheels of the paver and the trucks delivering bituminous
material to the paver.
20
502.4.5. Tack coat: Over the primed surface, a tack coat should be
applied in accordance with Clause 503.
502.5. Quality Control of Work
For control of the quality of materials supplied and the works carried
out, the relevant provisions of Section 900 shall apply.
During construction operations, arrangements for traffic shall be made
in accordance with the provisions of Clause 112 of the Ministry's
Specification for Road and Bridge Works (third revision) 1995.
Prime coat shall be measured in terms of surface area of application
in square metres.
502.8. Rate
The contract unit rate for prime coat with adjustments as described
in Clause 502.7 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) of the Ministry's Specification for Road and Bridge Works
(third revision) 1995, and as applicable to the work specified in these
Specifications. Payment shall be made on the basis of the provision of
prime coat at an application rate of 0.6 kg per square metre, with
adjustment, plus or minus, for the variation between this amount and the
actual amount approved by the Engineer after the preliminary trials
referred to in Clause 502.4.3.
503. TACK COAT
503.1. Scope
This work shall consist of the application of a single coat of low
viscosity liquid bituminous material to an existing bituminous road surface
preparatory to the superimposition of a bituminous mix, when specified
in the Contract or instructed by the Engineer.
503.2. Materials
503.2.1. Binder: The binder used for tack coat shall be bitumen
emulsion complying with IS 8887 of a type and grade as specified in the
21
Contract or as directed by the Engineer. The use of cutback bitumen as

per IS 217 shall be restricted only for sites at sub-zero temperatures or
for emergency applications as directed by the Engineer.
Bituminous material shall not be applied to a wet surface or during a
dust storm or whe n the weather is foggy, rainy or windy or when the
temperature in the shade is less than 10°C. Where the tack coat consists
of emulsion, (he surface shall be slightly damp, but not wet. Where the
tack coat is of cutback bitumen, the surface shall be dry.
503.4. Construction
503.4.1. .Equipment: The tack coat distributor shall be a self-
propelled or towed bitumen pressure sprayer, equipped for spraying the
material uniformly at a specified rate. Hand spraying of small areas,
inaccessible to the distributor, or in narrow strips, shall be sprayed with a
pressure hand sprayer, or as directed by the Engineer.
503.4.2. Preparation of base: The surface on which the tack coat is
to be Applied shall be clean and free from dust, dirt, and any extraneous
material, and be otherwise prepared in accordance with the requirements
of Clauses 501.8 and 902 as appropriate. Immediately before the
application of the tack coat, the surface shall be swept clean with a
mechanical broom, and high pressure air jet, or by other means as directed
by the Engineer.
503.43. Application of tack coat: The application of tack coat shall
be at the rate specified in the Contract, and shall be applied uniformly. If
rate of application of Tack Coat is not specified in the contract then it
shall be at the rate specified in Table 500-2. The normal range of spraying
TABLE 500-2. RATE OF APPLICATION OF TACK COAT
Type of Surface Quantity of liquid bituminous material in
Kg per sq. m. area
i) Normal bituminous surfaces 0.20 to 0.25
ii) Dry and hungry bituminous surfaces 0.25 to 0.30
iii) Granular surfaces treated with primer 0.25 to 0.30
iv) Non bituminous surfaces
a) Granular base.(not primed) 0.35 to 0.40
b) Cement concrete pavement 0.30 to 0.35
22
temperature for a bituminous emulsion shall be 20°C to 70°C and for a

cutback, 50°C to 80°C if RC-70/MC-70 is used. Where a geosynthetic is
proposed for use, the provisions of Clauses 704.3.2 and 704.4.4 of the
Ministry's Specification for Road and Bridge Works (third revision) 1995
shall apply. The method of application of the tack coat will depend on
the type of equipment to be used, size of nozzles, pressure at the spray
bar, and speed of forward movement. The Contractor shall demonstrate
at a spraying trial, that the equipment and method to be used is capable
of producing a uniform spray, within the tolerances specified.
Where the material to receive an overlay is a freshly laid bituminous
layer, that has not been subjected to traffic, or contaminated by dust, a
tack coat is not mandatory where the overlay is completed within two
days.
503.4.4. Curing of tack coat: The tack coat shall be left to cure
until all the volatiles have evaporated before any subsequent construction
is started. No plant or vehicles shall be allowed on the tack coat other
than those essential for the construction.
During the period of construction, arrangements for traffic shall be
made in accordance with the provisions of Clause 112 of the Ministry's
Tack coat shall be measured in terms of surface area ot application
in square metres.
503.8. Rate
The contract unit rate for tack coat shall be payment in full for carrying
out the required operations including for all components listed in Clause
401.8 (i) to (v) of the Ministry's Specification for Road and Bridge Works
(third revision) 1995 and as applicable to the work specified in these
Specifications. The rate shall cover the provision of tack coat at 0.2 kg
23
per square metre, with the provision that the variance in actual quantity
of bitumen used will be assessed and t he payment adjusted accordingly.
504. BITUMINOUS MACADAM
504.1. Scope
This work shall consist of construction in a single course having
50mm to 100mm thickness or in multiple courses of compacted crushed
aggregates premixed with a bituminous binder on a previously prepared
base to the requirements of these Specifications. Bituminous macadam
is more open graded than the dense graded bituminous materials described
in Clauses 507, 508 and 509.
504.1. Materials
504.2.1. Bitumen: The bitumen shall be paving bitumen of
Penetration Grade complying with Indian Standard Specifications for
"Paving Bitumen" IS:73, and of the penetration indicated in Table 500-
4.
504.2.2. Coarse aggregates: The coarse aggregates shall consist of
dust and soft or friable matter, organic or other deleterious matter. Where
the Contractor's selected source of aggregates have poor affinity for
bitumen, as a condition for the approval of that source, the bitumen shall
be treated with approved anti-stripping agents, as per the manufacturer's
recommendations, without additional payment. Before approval of the
source, the aggregates shall be tested for stripping.
The aggregates shall satisfy the physical requirements set forth in
Table 500-3.
shall have at least two fractured faces
(text is corrupted in book)
or naturally occurring, material, 01 a combination of the two, passing
2.36 mm sieve and retained on 75 micron sieve. They shall be clean,
hard, durable, dry and free from dust, and soft or friable matter, organic
or other deleterious matter.
24
TABLE 500-3. PHYSICAL REQ1REMENTS FOR COARSE AGGREGATES FOR

BITUMINOUS MACADAM
Property Test Specification
Cleanliness Grain size analysis 1 Max 5 % passing 0.075 mm sieve

Particle shape Flakiness and Elongation Index Max 30 %
(Combined) 2
Strength Los Angeles Abrasion Value 3 Max 40 %
Aggregate Impact Value 3 Max 30 %
Durability Soundness:4
Sodium Sulphate Max 12 %
Magnesium Sulphate Max 18%
Water Absorption Water absorption5 Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures6 95%
Water Sensitivity7 Retained Tensile Strength Min 80 %
Notes: 1. IS: 2386 Part I 4. IS: 2386 Part 5
2. IS: 2386 Part I 5. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 6. IS: 6241
7. The water sensitivity test is only to be carried out if the minimum retained coating in
the stripping test is less than 95%.
* Aggregate may satisfy requirements of either of these two tests.
504.2.4. Aggregate grading and binder content: When tested in
accordance with IS: 2386 Part 1 (wet sieving method), the combined
aggregate grading for the particular mixture shall fall within the limits
shown in Table 500-4 for the grading specified in the Contract. The type
and quantity of bitumen, and appropriate thickness, are also indicated
for each mixture type.
504.2.5. Proportioning of material: The aggregates shall be
proportioned and blended to produce a uniform mixture complying with
the requirements of Table 500-4. The binder content shall be within a
tolerance of ± 0.3 per cent by weight of total mixture when individual
specimens are taken for quality control tests in accordance with the
(text is corrupted in book)
504.3.1. Weather and seasonal limitations : The provisions of Clause
25
TABLE 500-4. COMPOSITION OF BITUMINOUS MACADAM

Mix designation Grading 1 Grading 2
Nominal aggregate size 40mm 19mm
Layer thickness 80- 100 mm 50 - 75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
Bitumen content, % by weight 3.1 -3.4 3.3-3.5
of total mixture 1
Bitumen grade 35 to 90 35 to 90
Notes; 1. Appropriate bitumen contents for conditions in cooler areas of India may be up to
0.5% higher subject to the approval of the Engineer.
504.3.2. Preparation of the base: The base on which bituminous

macadam is to be laid shall be prepared, shaped and compacted to the
required profile in accordance with Clauses 501.8 and 902.3 as
appropriate, and a prune coat, shall be applied in accordance with Clause
502 where specified, or as directed by the Engineer.
504.3.3. Tack coat: A tack coat in accordance with Clause 503
shall be applied as required by the Contract documents, or as directed by
the Engineer.
504.3.4. Preparation and transportation of the mixture: The
provisions of Clauses 501.3 and 501.4 shall apply.
504.3.5. Spreading: The provisions of Clauses 501.5.3 shall apply.
TABLE 500-5. MANUFACTURING AND ROLLING TEMPERATURES
Bitumen Bitumen Aggregate Mixed Rolling Laying
Penetration Mixing (°C) Mixing (°C) Material (°C) (°C) (°C)
35 160-170 160-175 170 Maximum 100 Minimum 130 Minimum
26
504.3.6. Rolling: Compaction shall be carried out in accordance with

the provisions of Clauses 501.6 and 501.7.
Rolling shall be continued until the specified density is achieved, or
where no density is specified, until there is no further movement under
the roller. The required frequency of testing is defined in Clause 903.
The surface finish of the completed construction shall conform to
the requirements of Clause 902. For control of the quality of materials
supplied and the works carried out, the relevant provisions of Section
900 shall apply.
504.5. Protection of the Layer
The bituminous macadam shall be covered with either the next
pavement course or wearing course, as the case may be, within a maximum
of forty-eight hours. If there is to be any delay, the course shall be covered
by a seal coat to the requirement of Clause 513 before opening to any
traffic. The seal coat in such cases shall be considered incidental to the
work and shall not be paid for separately.
Bituminous macadam shall be measured as finished work in cubic
metres, or by weight in metric tonnes, where used as regulating course,
or square metres at the specified thickness as indicated in the Contract or
shown on the drawings, or as otherwise directed by the Engineer.
504.8. Rate
The cont ract unit rate for bituminous macadam shall be payment in
full for carrying out the required operations as specified. The rate shall
include for, all components listed in Clause 501.8.8.2. (i) to (xi).
27
This page is not proper printing and text missing
505.3.4. Spreading coarse aggregates: The coarse aggregate shall

be dry and clean and free from dust, and shall be spread uniformly and
evenly at the rate specified in Table 500-6. It shall be spread by 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 to
ensure correct line and level and cross fall. The spreading shall be carried
out such that the rolling and penetrating operations can be completed on
the same day. Segregated aggregates or aggregates contaminated with
foreign material shall be removed and replaced.
TABLE 500-6. COMPOSITION OF PENETRATION MACADAM
Cumulative per cent by weight of total aggregate passing
For 50 mm compacted For 75 mm compacted

Thickness Thickness
IS Sieve Coarse Key Coarse Key

Designation (mm) Aggregate Aggregate Aggregate Aggregate
63 — — 100 —
45 100 — 58 - 82 —
26.5 37- 72 — — 100
22.4 — 100 5 - 27 50 -75
13.2 2 - 20 50 -75 — —
11.2 — — — 5 - 25
5.6 — 5 -25 — —
2.8 0-5 0-5 0-5 0-5
Approx. Loose
aggregate quantities 0.06 0.015 0.09 0.018
2
cu.m/m
Binder quantity
(penetration 5 6.8
(1) 2
grade) (kg/m )
Note:(l) If cutback bitumen is used, adjust binder quantity such that the residual bitumen is
equal to the values in this table.
505.3.5. Compaction: After the spreading of coarse aggregates, dry

rolling shall be carried out with an 8 — 10 tonne smooth steel wheel roller.
The requirements given in Clause 501.6 and 501.7 shall apply.
After initial dry rolling, the surface shall be checked with a crown
29
template and a 3 metre straight-edge. The surface shall not vary more
than 10 mm from die template or straight-edge. All surface irregularities
exceeding the above limit shall be corrected by removing or adding
aggregates as required.
The rolling shall continue until the compacted coarse aggregate has
a firm surface true to the cross section shown on the plans and has a
texture that will allow free and uniform penetration of the bituminous
material.
505.3.6. Application of bituminous material: After the coarse
aggregate has been rolled and checked, the bituminous binder shall be
applied, at the rate given in Table 500-6, in accordance with Clause SOI,
and at a temperature directed by the Engineer.
At the time of applying the binder, the aggregates shall be surface
dry for the full depth of the layer.
In certain circumstances, depending on the type and size of aggregate
used, the Engineer may direct the placing of a bed of clean sand or quarry
fines, hot exceeding10mm in thickness, on the prepared foundation before
placing the coarse aggregate. The sand or fine material shall be slightly
wetted, just sufficient for it to slurry up during the compaction process.
Where cut back is used, if flooding of the binder occurs it should be
applied in two operations, or as directed by the Engineer.
505.3.7. Application of key aggregates: Immediately after the first
application of bitumen, the key aggregates, which shall be clean, dry,
and free from dust shall be spread uniformly over the surface by means
of an approved mechanical spreader or by approved manual methods at
the rate specified in fable 500-6.
Where directed by the Engineer, the surface shall be swept and the
quantity of key aggregate adjusted to ensure uniform application, with
all the surface voids in the coarse aggregate being filled without excess.
The entire surface shall then be rolled with a 8 - 10 tonnes smooth steel
wheel roller (or vibrating roller operating in non-vibratory mode) in
accordance with the procedure specified in Clause 505.3.5.
505.4. Surface Finish and Quality Control
the requirements of Clause 902. For control of the quality of materials
30
supplied and the works carried out the relevant provisions of Section 900
shall apply.
505.5. Surfacing
The Penetration Macadam shall be provided with a surfacing (binder/
wearing course) within a maximum of forty-eight hours. If there is to be
any delay, the penetration macadam shall be covered by a seal coat to the
requirements of Clause 513 before opening to traffic. The seal coat in
such cases shall be considered incidental to the work and shall not be
paid for separately.
Penetration Macadam base course shall be measured as finished work
in square metres.
505.8. Rate
The contract unit rate for Penetration Macadam course shall be
payment in full for carrying out the required operations including, but not necessarily
limited to, all components listed in Clause 501.8.8.2 (i)
to (xi).
506. BUILT-UP SPRAY GROUT
506.1. Scope
This work shall consist of a two-layer composite construction
compacted crushed coarse aggregates with application of bituminous
binder after each layer, and with key aggregates placed on top of the
second layer, in accordance with the requirements of these Specifications,
to serve as a base course and in conformity with the lines, grades
and cross-sections shown on the drawings or as directed by the Engineer.
The thickness of the course shall be 75 mm.
Built-up spray grout shall be used in a single course in a pavement
structure.
31
506.2, Materials
506.2.1. Bitumen: Clause 504.2.1. shall apply. Where permitted by
the Engineer, an appropriate grade of emulsion complying with IS 8887
may be used.
506.2.2. Aggregates: The coarse aggregate shall conform to Clause
504.2.2.
The aggregate shall satisfy the physical requirements set out in Table
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 FOR COARSE AND KEY
AGGREGATES FOR BUILT-UP SPRAY GROUT
IS Sieve Cumulative per cent by weight of total aggregate passing

Designation (mm) Coarse Aggregate Key Aggregate
53.0 100 —
26:5 40 -75 —
22.4 — 100
13.2 0-20 40 -75
5.6 — 0-20
2.8 0-5 0-5
506.3.1. Weather and seasonal limitations: The provisions of Clause
506.3.2. Equipment: The provisions of Clause 505.3.2 shall apply.
506.3.3. Preparation of base: The base on which the built-up spray
grout course is to be laid shall be prepared, shaped and compacted to the
specified lines, grades and cross-sections in accordance with Clauses
501 and 902 as appropriate. A prime coat shall be applied in accordance
with Clause 502 with approved primer as directed by the Engineer.
506.3.4. Tack coat: A tack coat shall be applied in accordance with
the procedure described in Clause 503, as directed by the Engineer.
506.3.5. Spreading and rolling coarse aggregates for the first
layer: Immediately after the application of prime or tack coat, the clean,
dry and dust free coarse aggregates shall be spread uniformly and evenly,
32
by mechanical means, at the rate of 0.5 cu. m. per 10 sq. m. area.

Immediately after spreading of the aggregates, the entire surface shall
be rolled with an 8 - 10 tonnes smooth wheel steel 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.
The surface of the layer shall be carefully checked, after rolling,
with a template and straight edge and shall be within the tolerances
specified, and any deficiencies corrected by reworking and recompacting
the layer.
Care shall be taken not to over-compact the layer.
506.3.6. Application of binder - first spray: The binder shall be
heated to the temperature appropriate to the grade of bitumen approved
by the Engineer and sprayed on the aggregate at the rate of IS kg/10
sq. m. (measured in terms of residual bitumen content) at a uniform rate
of spray by mechanical sprayers capable of spraying bitumen uniformly
at the specified rates and temperatures. Excessive deposits of binder
caused by stopping or starting of the sprayers or through leakage or for
any other reason shall be removed and made good.
506.3.7. 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 in accordance with
the procedure detailed in Clause 506.3.5.
506.3.8. Application of binder - second spray: The second aggregate
layer shall then be sprayed with binder at the rate of 15 kg/10 sq. m.
(measured in terms of residual bitumen content) in accordance with Clause
506.3.6.
506.3.9. Application of key aggregate: Immediately after the second
application of binder, key aggregates shall be 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. The key aggregate shall be clean, dry
and free from dust and deleterious matter. If necessary, the surface shall
be swept to ensure uniform application of the key aggregates. The entire
33
surface shall then be rolled with an 8-10 tonnes smooth wheel steel roller
in accordance with Clause 506.3.5. 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. All materials shall comply with the requirements of the
relevant provisions in Section 900 of the Specifications.
506.5. Final Surfacing
The built- up-spray-grout shall be provided with final surfacing within
a maximum of forty-sight hours. If there is to be any delay, the course
shall be covered by a seal coat to the requirement of Clause 513 before it
is open to traffic. Where the seal coat is required as a result of the selected
method of performing this operation, then it shall be considered incidental
to the work and shall not be paid for separately.
Built-up spray grout shall be measured as finished work in square
metres.
506.8. Rite
The contract unit rate for built- up spray grout shall be payment in
full for carrying out the required operations as specified. The rate shall
include for, but not necessarily be limited to the components listed in
Clause 50 L8.8.2. (i) to (xi).
507. DENSE GRADED BITUMINOUS MACADAM
507,1. Scope
This clause specifies the construction of Dense Graded Bituminous
Macadam, (DBM), for use mainly, but not exclusively, in base/binder
34
and profile corrective courses. DBM is also intended for use as road base
material. This work shall consist of construction in a single or multiple
layers of DBM on a previously prepared base or sub-base. The thickness
of a single layer shall be 50mm to 100mm.
507.2. Materials
Penetration Grade complying with Indian Standard Specifications for
"Paving Bitumen" IS: 73, and of the penetration indicated in Table 500-
10 for dense bitumen macadam, or this bitumen as modified by one of
the methods specified in Clause 521, or as otherwise specified in the
Contract. Guidance on the selection of an appropriate grade of bitumen
is given in The Manual for Construction and Supervision of Bituminous
Works.
507.2.2. Coarse aggregates: The coarse aggregates shall consist of
dust and soft or friable matter, organic or other deleterious substances.
Where the Contractor's selected source of aggregates have poor affinity
for bitumen, as a condition for the approval of that source, the bitumen
shall be treated with an approved anti-stripping agent, as per the
manufacturer's recommendations, without additional payment. Before
approval of the source, the aggregates shall be tested for stripping. The
aggregates shall satisfy the physical requirements specified in Table 500-
8, for dense bituminous macadam.
shall have at least two fractured faces.
507.2.3. Fine aggregates: Fine aggregates shall consist of crushed
or naturally occurring mineral material, or a combination of the two,
passing the 2.36mm sieve and retained on the 75 micron sieve. They
shall be clean, hard, durable, dry and free from dust, and soft or friable
matter, organic or other deleterious matter.
35
The plasticity index of the fraction passing the 0.425 mm sieve shall
not exceed 4. when tested in accordance with IS: 2720 (Part 5)
TABLE 500-8. PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR
DENSE GRADED BITUMINOUS MACADAM
Property Text Specification
Cleanliness (dust) Grain size analysis 1 Max 5% passing 0.075mm sieve

Particle shape Flakiness and Elongation Index Max 30%
(Combined)2
Strength* Los Angeles Abrasion Value3 Max 35%
Aggregate Impact Value4 Max 27%
Sodium Sulphate Max 12%
Water Absorption Water absoption6 Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained
Aggregate Mixtures 7 coating 95%
Water Sensitivity Retained Tensile Strength Min80%
Notes: 1. IS:2386Part I 5. IS:2386Part5

2. IS: 2386 Part I 6. IS: 2386 Part 3
(the elongation test to be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 7. IS: 6241
4. IS: 2386Part4* 8. AASHTOT283**
** The water sensitivity test is only required if the minimum retained coating in the
stripping lest is less than 95%.
507.2.4. Filler: Filler shall consist of finely divided mineral matter

such as rock dust, hydrated lime or cement approved by the Engineer.
The filler shall be graded within the limits indicated in Table 500-9.
TABLE 500-9. GRADING REQUIREMENTS FOR MINERAL FILLER
IS Sieve (mm) Cumulative per cent passing by weight of total aggregate
0.6 100
0.3 95- 100
0.075 85-100
The filler shall be free from organic impurities and have a Plasticity
Index not greater than 4. The Plasticity Index requirement shall not apply
if filler is cement or lime. When the coarse aggregate is gravel, 2 per cent
36
by weight of total aggregate, shall be Portland cement or hydrated lime

and the percentage of fine aggregate reduced accordingly. Cement or
hydrated lime is not required when the limestone aggregate is used. Where
the aggregates fail to meet the requirements of the water sensitivity test
in Table 500-8, then 2 per cent by total weight of aggregate, of hydrated
lime shall be added without additional cost.
accordance with IS:2386 Part 1 (wet sieving method), the combined
grading of the coarse and fine aggregates and added filler for the particular
mixture shall fall within the limits shown in Table 500-10, for dense
bituminous macadam grading 1 or 2 as specified in the Contract. The
type and quantity of bitumen, and appropriate thickness, are also indicated
for each mixture type.
TABLE 500-10. COMPOSITION OF DENSE GRADED BITUMINOUS
MACADAM PAVEMENT LAYERS
Grading 1 2
Nominal aggregate size 40mm 25 mm
Layer Thickness 80-100 mm 50-75 mm
IS Sieve 1 (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 2«^2 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content % by
mass of total mix 2 Min4.0 Min4.5
Bitumen grade (pen) 65 or 90 65 or 90
Notes: 1. The combined aggregate grading shall not vary from the low limit on one sieve to the
high limit on the adjacent sieve.
2. Determined by the Marshall method.
37
507.3. Mixture Design

507.3.1. Requirement for the mixture: Apart from conformity with
the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 500-11.
TABLE 500-11. REQUIREMENTS FOR DENSE GRADED BITUMINOUS MACADAM
Minimum stability (kN at 60°C) 9.0

Minimum flow (mm) Maximum flow 24
(mm) Compaction level (Number of blows) 75 blows on each of the two
faces of the specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate (VMA) See Table 500-12 below.
Per cent voids filled with bitumen (VFB) 65-75
The requirements for minimum per cent voids in mineral aggregate

(VMA). are set out in Table 500-12.
TABLE 500-12. MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE (VMA)
Nominal Maximum Minimum VMA, Per cent
Practice Size 1 Related to
(mm) Design Air Voids, Per cent 2
3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0' 11.0 12.0 13.0
37:5 10.0 11.0 12.0
Notes: 1. The nominal maximum particle size is one size larger than the first sieve to retain
more than: 10'per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids
values between those listed.
507.3.2. Binder content: The binder content shall be optimised to

achieve the requirements of the mixture set out in Table 500-11 and the
traffic volume specified in the Contract. The Marshall method for
determining the optimum binder content shall be adopted as described in
The Asphalt Institute Manual MS-2, replacing the aggregates retained
on the 26.5 mm sieve by the aggregates passing the 26.5 mm sieve and
retained on the 22.4 mm sieve, where approved by the Engineer.
38
Where 40 mm dense bituminous macadam mixture is specified, the

modified Marshall method described in MS-2 shall be used. This method
requires modified equipment and procedures; particularly the minimum
stability values in Table 500-11 shall be multiplied by 2.25, and the
minimum flow shall be 3 mm.
507.3.3. Job mix formula: The Contractor shall inform the Engineer
in writing, at least 20 days before the start of the work, of the job mix
formula proposed for use in the works, and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder type, and percentage by weight of total mixture;
(b) Coarse aggregate/Fine 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 individual gradings of the individual aggregate fractions, and the proportion of
each in the combined grading.
(v) The results of tests enumerated in Table 500-11 as obtained by the Contractor;
(vi) Where the mixer is a batch mixer, the individual weights of each type of aggregate,
and binder per batch,
(vii) Test results of physical characteristics of aggregates to be used;
(viii) Mixing temperature and compacting temperature.
While establishing 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 mixture 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 Engineer.
The approved job mix formula shall remain effective unless and until
a revised Job Mix Formula is approved. Should a change in the source of
materials be proposed, a new job mix formula shall be forwarded to the
Engineer for approval before the placing of the material.
5073.4. Plant trials - permissible variation in job mix formula:
Once the laboratory job mix formula is approved, the Contractor shall
39
carry out plant trials at the mixer to establish that the plant can be set up
to produce a uniform mix conforming to the approved job mix formula.
The permissible variations of the individual percentages of the various
ingredients in the actual mix from the job mix formula to be used shall be
within the limits as specified in Table 500- 13. These variations are
intended to apply to individual specimens taken for quality control tests
in accordance with Section 900.
TABLE 500-13. PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA
Description Permissible variation

Base/binder coarse Wearing coarse
Aggregate passing 1 9mm sieve or larger ±8% ±7%
Aggregate passing 13.2mm, 9.5mm ±7% ±6%
Aggregate passing 4.75min ±6% ±5%
Aggregate passing 2.36mm, 1 . 1 8mm, 0.6mm ±5% ±4%
Aggregate passing 0.075nim, ±2% ±1.5%
Binder content ±0.3% ±0.3%
Mixing temperature ±10°C ±10°C
Once the plant trials have demonstrated the capability of the plant,
and the trials are approved, the laying operation may commence. Over
the period of the first month of production for laying on the works, the
Engineer shall require additional testing of the product to establish the
reliability and consistency of the plant.
507.3.5. Laving Trials: Once the plant trials have been successfully
completed and approved, the Contractor shall carry out laying trials, to
demonstrate that the proposed mix can be successfully laid, and compacted
all in accordance with Clause SO 1. The laying trial shall be carried out on
a suitable area which is not to form part of the works, unless specifically
approved in writing, by the Engineer. The area of the laying trials shall
be a minimum of 100 sq. m. of construction similar to that of the project
road, and it shall be in all respects, particularly compaction, the same as
the project construction, on which the bituminous material is to be laid.
The Contractor .shall previously inform the Engineer of the proposed
method for laying and compacting the material. The plant trials shall
then establish if the proposed laying plant, compaction plant, and
40
methodology is capable of producing satisfactory results. The density of

the finished paving layer shall be determined by taking cores, no sooner
than 24 hours after laying, or by other approved method.
Once the laying trials have been approved, the same plant and
methodolo gy shall be applied to the laying of the material on the project,
and no variation of either shall be acceptable, unless approved in writing
by the Engineer, who may at his discretion require further laying trials.
507.4.2. Preparation of base: The base on which Dense Graded
Bituminous Material is to be laid shall be prepared in accordance with
Clauses 501 and 902 as appropriate, or as directed by the Engineer. The
surface shall be thoroughly swept clean by a mechanical broom, and the
dust removed by compressed air. In locations where- mechanical broom
cannot access, other approved methods shall be used as directed by the
Engineer.
507.4.3. Geosynthetics: Where Geosynthetics are specified in the
Contract this shall be in accordance with the requirements stated in Clause
704 of the Ministry's Specification for Road and Bridge Works (third
revision) 1995.
507.4.4. Stress absorbing layer: Where a stress absorbing layer is
specified in the Contract, this shall be applied in accordance with the
507.4.5. Prime coat: Where the material on which the dense
bituminous macadam is to be laid is other than a bitumen bound layer, a
prime coat shall be applied, as specified, in accordance with the provisions
of Clause 502, or as directed by the Engineer.
507.4.6. Tack coat: Where the material on which the dense
bituminous macadam is to be placed is a bitumen bound surface, a tack
coat shall be applied as specified, in accordance with the provisions of
Clause 503, or as directed by the Engineer.
507.4.7. Mixing and transportation of the mixture: The provisions
as specified in Clauses 501.3 and 501.4 shall apply.
41
507.4.8. Spreading: The provisions of Clauses 501.5.3 and 501.5.4.

shall apply.
507.4.9. Rolling: The general provisions of Clauses 501.6 and 501.7
shall apply, as modified by the approved laying trials. The compaction
process shall be carried out by the same plant, and using the same method,
as approved in the laying trials, which may be varied only with the express
approval of the Engineer in writing.
The newly laid surface shall not be open to traffic for at least 24 hrs
after laying and completion of compaction, without the express approval
of the Engineer in writing.
The surface finish; of the completed construction shall conform to
the requirements of Clause 902. All materials and workmanship shall
comply with the provisions set out in Section 900 of this Specification.
Dense Graded Bituminous Materials shall be measured as finished
work either in cubic metres, tons or by the square metre at a specified
thickness as detailed on the Contract drawings, or documents, or as
507.9. Rate
The contract unit rate for Dense Graded Bituminous Macadam shall
be payment in full for carrying out the all required operations as specified,
and shall include, but not necessarily limited to all components listed in
Clause 501.8 8.2 (i) to (xi). The rate shall include the provision of bitumen,
at 4.25 per cent by weight of the total mixture.
The variance in actual percentage of bitumen used will be assessed
and the payment adjusted, up or down, accordingly.
42
508. SEMI-DENSE BITUMINOUS CONCRETE

508.1. Scope
This clause specifies the construction of Semi Dense Bituminous
Concrete, for use in wearing/binder and profile corrective courses. This
work shall consist of construction in a single or multiple layers of semi
dense bituminous concrete on a previously prepared bituminous bound
surface. A single layer shall be 25mm to 100mm in thickness.
508.2. Materials
Penetration grade complying with Indian Standard Specification for
Paving Bitumen, IS: 73 and of the penetration indicated in Table 500-15,
for semi dense bituminous concrete, or this bitumen as modified by one
of the methods specified in Clause 521, or as otherwise specified in the
Contract. Guidance on the selection of an appropriate grade of bitumen
is given in The Manual for Construction and Supervision of Bituminous
Works.
508.2.2. Coarse aggregates: The coarse aggregates shall be generally
as specified in Clause 507.2.2, except that the aggregates shall satisfy
the physical requirements of Table 500-14.
508.23. Fine aggregates: The fine aggregates shall be all as specified
in Clause 507.2.3.
508.2.4. Filler: Filler shall, be generally as specified in Clause 507.2.4.
Where the aggregates fail to meet the requirements of the water sensitivity
test in Table 500-14 then 2 per cent by total weight of aggregate, of
hydrated lime shall be added without additional cost.
accordance with IS:2386 Part 1 (Wet sieving method), the combined
grading of the coarse and fine aggregates and added filler shall fall within
the limits shown in Table 500-15 for gradings 1 or 2 as specified in the
Contract.
508.3.1. Requirements for the mixture: Apart from conformity with
the grading and quality requirements for individual ingredients the mixture
shall meet the requirements set out in Table 500-16.
43
TABLE 500-14. PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR

SEMI DENSE BITUMINOUS CONCRETE PAVEMENT LAYERS
Cleanliness (dust) Gra in size analysis' Max 5% passing
0.075mm sieve
Panicle shape Flakiness and Elongation Index Max 30%
(Combined)2
Polishing Polished Stone Value5 Min55
6
Durability Soundness:
Stripping Coating and Stripping of Bitumen Minimum Retained
Aggregate Mixtures 9 Coating 95%
Water Sensitivity** Retained Tensile Strength8 Min 80%
Notes:1. IS: 2386 Part 1 6. IS: 2386 Part 5

2. IS: 2386 Part 1 7. IS: 2386 Part 3
(the elongation test may be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 8. AASHTOT283**
4. IS: 2386 Part 4* 9. IS: 6241
5. BS: 812 Part 114
** The water sensitivity test is only require d if the minimum retained coating in the
stripping test is less than 95%.

(VMA) are set out in Table 500-12.
traffic volume as specified in the Contract. The Marshall method for
the Asphalt Institute Manual MS-2, replacing the aggregates retained on
the 26.5mm sieve and retained on the 22.4mm sieve, where approved by
the Engineer.
44
TABLE 500-15. COMPOSITION OF SEMI DENSE BITUMINOUS CONCRETE

PAVEMENT LAYERS
Grading 1 2
45
37.5
26.5
19 100
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 15-30
0.6 - -
0.3 9-19 9-19
0.15 - -
0.075 3-8 3-8
Bitumen content % by mass
of total mix 2 Min 4.5 Min 5.0
Bitumen grade (pen) 65* 65*
* Only in exceptional circumstances, 80/100 penetration grade may be used, as approved
by the Engineer.
TABLE 500-16. REQUIREMENTS FOR SEMI DENSE
BITUMINOUS PAVEMENT LAYERS

Minimum flow (mm) 2
Maximum flow(mm) 4
Compaction level (Number of blows) 75 blows on each of the two
Per cent voids in mineral aggregate (VMA) See Table 500-12
Per cent voids filled with bitumen (VFB) 65-78
45
508.3.3. Job mix formula: The procedure for formulating the job
mix formula shall be generally as specified in Clause 507.3.3 and the
results of tests enumerated in Table 500- 1 6 as obtained by the Contractors.
508.3.4. Plant trials - permissible variation in job mix formula:
The requirements for plant trials shall be alt as specified in Clause 507.3.4,
and permissible limits for variation as shown in Table 500-13.
508-3.5. Laying trials: The requirements for laying trials shall be
all as specified iii Clause 507.3.5.
508.4.1. Weather and seasonal limitations: The provisions of
Clause 501.5.1 shall apply.
508.4.2. Preparation of base: The surface on which the Semi Dense
Bituminous material is to be laid shall be prepared in accordance with
Clauses 501 and 902 as appropriate, or as directed by the Engineer. The
surface shall be thoroughly swept clean by mechanical broom and dust
removed by compressed air. In locations where a mechanical broom cannot
access, other approved methods shall be used as directed by the Engineer.
revision) 1995.
508 4.4. Stress absorbing layer: Where a stress absorbing layer is
specified in the Contract, this shall be applied in accordance with the
508.4.5. Tack coat: Where specified in the Contract, or otherwise
required by the Engineer, a tack coat shall be applied in accordance with
the requirements 'of Clause 503.
as specified in Clauses 501. 3. and 501.4 shall apply.
508.4.7. Spreading: The general provisions of Clauses 501.5.3 and
508.4.8. Rolling: The general provisions of Clauses 501.6 and 501.7
shall apply, as modified by the approved laying trials. The compaction
46
process shall be carried out by the same plant, and using the same method,
as approved in the laying trials, which may be varied only with the express
The newly laid surface shall not be open to traffic for at least 24
hours after laying and the completion of compaction, without the express
The measurement shall be all as specified in Clause 507.8.
508.9. Rate
The contract unit rate shall be all as specified in Clause 5Q7.9, except
that the rate shall include the provision of bitumen at 4.75. pe* cent, by
weight of total mixture. The variance in actual percentage of bitumen
used will be assessed and the payment adjusted up or down, accordingly.
509. BITUMINOUS CONCRETE
509.1. Scope
This clause specifies the construction of Bituminous Concrete, for
use in wearing and profile corrective courses. This work shall consist of
construction in a single or multiple layers of bituminous concrete on a
previously prepared bituminous bound surface. A single layers shall be
25mm to 100mm in thickness.
509.2. Materials
47
Penetration grade complying with Indian Standard Specification for

Paving Bitumen, IS: 73 and of the penetration indicated in Table 500-18,
for bituminous concrete, or this bitumen as modified by one of the methods
specified in Clause 521, or as otherwise specified in the Contract.
Guidance on the selection of an appropriate grade of bitumen is given in
The Manual for Construction and Supervision of Bituminous Works.
509.2.2. Coarse aggregates: The coarse aggregates shall be generally
as specified in Clause 507.2.2, except that the aggregates shall satisfy
the physical requirements of Table 500-17.
509.2.3. Fine aggregates: The fine aggregates shall be all as specified
in Clause 507.2.3.
509.2.4. Filler: Filler shall be generally as specified in Clause 507.2.4.
Where the aggregates fail to meet the requirements of the water sensitivity
test in Table 500-17 then 2 per cent by total weight of aggregate, of
hydrated lime shall be added without additional cost.
accordance with IS:2386 Part 1 (Wet grading method), the combined
grading-of the coarse and fine aggregates and added filler shall fall within
the limits shown in Table 500-18 for gradings 1 or 2 as specified in the
Contract.
5093.1. Requirements for the mixture: Apart from conformity with
(VMA) are set out in Table 500-12.
traffic volume as specified in the Contract. The Marshall method for
the Asphalt Institute Manual MS-2, replacing the aggregates retained on
the 26.5mm sieve and retained on the 22.4mm sieve, where approved by
the Engineer.
509.3.3. Job mix formula: The procedure for formulating the job
48
TABLE 500-17. PHYSICAL REQ UIREMENTS FOR COARSE AGGREGATE FOR

BITUMINOUS CONCRETE PAVEMENT LAYERS
1
Cleanliness (dust) Grain size analysis Max 5% passing
0.075mm sieve
Particle shape Flakiness and Elongation Index Max 30%
(Combined)2
Polishing Polished Stone Value3 MinS5
Stripping Coating and Stripping of Minimum retained
Bitumen Aggregate Mixtures 9 coating 95%
Water Sensitivity** Retained Tensile Strength8 Min80%
Notes:1. IS: 2386 Part 1 6. IS: 2386 Part 5
2. IS: 2386 Part 1 7. IS: 2386 Part 3
(the elongation test may be done only on non-flaky aggregates in the sample)
3. IS: 2386 Part 4* 8. AASHTOT283**
4. IS: 2386 Part 4* 9. IS: 6241
5. BS: 812 Part 114
** The water sensitivity test is only require d if the minimum retained coating in the
stripping test is less than 95%.
mix formula shall be generally as specified in Clause 507.3.3 and the

results of tests enumerated in Table 500-19 as obtained by the Contractors.
509L3.4. Plant trials - permissible variation in job mix formula:
The requirements for plant trials shall be all as specified in Clause 507.3.4,
and permissible limits for variation as shown in Table 500-13.
509.3.5. Laving trials: The requirements for laying trials shall be
all as specified in Clause 507.3.5.
509.4.1. Weather and seasonal limitations: The provisions of
49
TABLE 500-18. COMPOSITION OF BITUMINOUS

CONCRETE PAVEMENT LAYERS
Grading 1 2
45
37.5
26.5 100
19 79-100 100
13.2 59-79 79-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by mass
of total mix 2 5.0-6.0 5.0-7.0
Bitumen grade (pen) 65 65*
TABLE 500 -19. REQUIREMENTS FOR BITUMINOUS PAVEMENT LAYERS

Minimum stability {kN at 60°C) 9.0
Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 blows on each of the two
Per cent voids in mineral aggregate (VMA) See Table 500-12
Percent voids filled with bitumen (VFB) 65-75
Loss of stability on immersion in water at Min. 75 percent
60°C (ASTM D 1075) retained strength
50
509.4.2. Preparation of base: The surface on which the bituminous

concrete is to be laid shall be prepared in accordance with Clauses 501
and 902 as appropriate, or as directed by the Engineer. The surface shall
be thoroughly swept clean by mechanical broom and dust removed by
compressed air. In locations where a mechanical broom cannot access,
other approved methods shall be used as directed by the Engineer.
revision) 1995.
509.4.4. Stress absorbing layer. Where a stress absorbing layer is
specified in the Contract, this shall be applied in accordance- with the
509.4.5. Tack coat: Where specified in the Contract, or otherwise
required by the Engineer, a tack coat shall be applied in accordance with
the requirements of Clause 503.
as specified in Clauses 501.3 and 501.4 shall apply.
509.4.7. Spreading: The general provisions of clauses 501.5.3 and
509.4.8. Rolling: The general provisions of clauses 501.6 and 501.7
shall apply, as modified by the approved laying trials.
The newly laid surface shall not be open to traffic for at least 24
hours after laying and the completion of compaction, without the express
51

The measurement shall be all as specified in Clause 507.8.
509.9. Rate
The contract unit rate shall be all as specified in Clause 507.9, except
that the rate shall include the provision of bitumen at 5.0 per cent, by
weight of total mixture. The variance in actual percentage of bitumen
used will be assessed and the payment adjusted up or down, accordingly.
510. SURFACE DRESSING
510.1. Scope
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 a previously prepared base, followed by a cover of stone
chips rolled in to form a wearing course to the requirements of these
Specifications. For information on the Design of Surface Dressing refer
to the Manual for Construction and Supervision of Bituminous Works.
510.2. Materials
510.2.1. Binder: The binder shall have a kinematic viscosity lying
in the range IxlO4 to TxlO5 centistokes at the expected range of road
surface temperatures at the construction site during the period of laying.
The type of binder to be used will be stated in the Contract documents
and shall .comply with one of the following:
Paving Bitumen IS:73
Bitumen Emulsion IS:8887
510.2.2. Aggregates: The chips shall conform to the requirements
of Clause 504.2.2., except that their water absorption shall be restricted
to a maximum of 1 per cent and they shall have a Polished Stone value,
as measured by the method given in BS812 (Part 114), of not less than
60. The chips shall be single sized, clean, hard, durable, of cubical shape,
free from dust and soft or friable matter, organic or other deleterious
matter and conforming to one of the gradings given in Table 500-21.
52
510.2.3. Rates of spread of binder and chips: For the purpose of

pricing the Bill of Quantities the rates of spread given in Table 500-20
shall be priced.
TABLE 500-20. NOMINAL RATES OF SPREAD FOR BINDER AND CHIPPINGS (1)
Chipping Size mm Binder (penetration grade Chips
bitumen) Cum/m2
kg/m2
19 1.2 0.015
13 1.0 0.010
10 0.9 0.008
6 0.75 0.004
Note: (1) These rates of spread are for pricing purposes - see Clause 510.2.3 and Clause 510.8
(2) For emulsion, these rates of spread are for the residual bitumen and appropriate
adjustment must be made to determine the total quantity.
(3) Refer to Manual for Construction and Supervision of Bituminous Works for the
procedure of determining the rates of spread of binder and chips.
510.2.4. Anti-stripping agent: Where the proposed aggregate fails

to pass the stripping test then an approved adhesion agent (Appendix 5
for details) may be added to the binder in accordance with the
manufacturer's instructions. The effectiveness of the proposed anti-
stripping agent must be demonstrated by the Contractor, before approval
by the Engineer.
510.2.5. Pre -coated chips: As an alternative to the use of an adhesion
agent the chips may be pre-coated before they are spread except when
the sprayed binder film is a bitumen emulsion. Pre-coating the chips may
be carried out in any one of the two methods:
(a) Mixing them with 0.75 to 1.0 per cent of paving bitumen by we ight of chips in a
suitable mixer, the chips being heated to 160°C and the bitumen to its application
temperature. The pre-coated chips shall be allowed to cure for at least one week or
until they become non sticky and can be spread easily.
(b) Spraying the chips with a light application of creosote, diesel oil or kerosene at ambient
temperature. This spraying can be done in a concrete mixer or on a belt conveying
the chips from stockpile to gritting lorries.
510.3. Construction operations

510.3.1. Weather and seasonal limitations : Clause 501.5.1 shall
apply.
53
TABLE 500-21. GRADING REQUIREMENTS FOR CHIPS FOR

SURFACE DRESSING
IS Sieve Designation Cumulative per cent by weight of total aggregate passing
mm for the following nominal sizes (mm)
19 13 10 6
26.5 100 - - -
19.0 85-100 100 - -
13.2 0-40 85-100 100 -
9.5 0-7 0-40 85-100 100
6.3 - 0-7 0-35 85-100
4.75 - - 0-10 -
3.35 - - 0-35
2.36 0-2 0-2 0-2 0-10
0.60 - 0-2
0.075 0-1.5 0-1.5 0-1.5 0-1.5
Minimum 65% Passing 19 mm, Passing 13.2 mm, Passing 9.5 Passing 6.3
by weight retained 13.2mm retained 9.5 mm mm, retained mm, retained
of aggregate 6.3mm 3.35mm
510.3.2. 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 or as directed
by the Engineer. Prime coat, where needed, shall be provided as per Clause
502 or as directed by the Engineer. Where the existing surface shows
signs of fatting up, the excess bitumen shall be removed by burning off,
or manually, as specified in the Contract or directed by the Engineer. The
bituminous surface to be dressed shall be thoroughly cleaned either by
using a mechanical broom and / or compressed air, or any other approved
equipment / method as specified in the Contract or by the Engineer. The
prepared surface shall be dust free, clean and dry, (except in the case of
cationic emulsion where the surface shall be damp).
510.3.3. Application of binder : The equipment and general
procedures shall all be in accordance with the Manual for Construction
and Supervision of Bituminous Works. The application temperature for
the grade of binder used shall be as given in Table 500-22 and the rate of
spray as given in 510.2.3.
5103.4. Application of stone chips : The equipment and general
54
TABLE 500-22. SPRAYING TEMPERATURES FOR BINDERS

Binder grades Whirling Slot jets
spray jets
Min°C Max°C Min°C Max°C
Penetration Grades
400/500 160 170 140 150
280/320 165 175 150 160
180/200 170 190 155 165
80/100 180 200 165 175
procedure shall all be in accordance with the Manual for Construction

and Supervision of Bituminous Works. For relatively small areas of
surface dressing, careful application of chips by hand may be acceptable
if approved by the Engineer. The rate of application of chips shall be as
determined by the procedure given in the Manual for Constructio n and
Supervision of Bituminous Works. Immediately after application of the
binder, clean, dry chips (in the case of emulsion binder the chippings
may be damp) shall be spread uniformly on the surface so as to cover the
surface completely with a single layer of chips.
5103.5. Rolling : Rolling of the chips should preferably be carried
out by a pneumatic tyred roller in accordance with Clause 501.6 and
Clause 501.7. Traditional steel wheeled rollers tend to crush the aggregates
and if their use cannot be avo ided their weight should be limited to 8
tonnes. 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. While rolling is in progress additional chips
shall be spread by hand in necessary quantities required to make up
irregularities. Rolling shall continue until all aggregate particles are firmly
embedded in the binder and present a uniform closed surface.
510.3.6. Application of second coat of surface dressing : Where
surface dressing in two coats is specified, the second coat should not be
applied until the first coat has been open to traffic for 2 or 3 weeks. The
surface on which the second coat is laid must be clean and free of dust.
The construction operations for the second coat shall be the same as
described in Clauses 510.3.3 to 510.3.5.
55

Traffic shall not be permitted to run on any newly surface dressed
area until the following day. In special circumstances, however, the
Engineer may allow the road to be opened to traffic immediately after
rolling, but in such cases traffic speed shall be limited to 20 km per hour
until the following day.
of Clause 902.
For control on the quality of materials supplied and the works carried
made in accordance with the provisions of Clause 112.
Each coat of surface dressing shall be measured as finished work,
for the area instructed to be covered, in square metres.
510.8. Rate
The Contract unit rate for surface dressing, based on the notional
rates of spread for binder and each size of chippings given in Clause
510.2.3, which shall be adjusted, plus or minus, for the difference between
the notional rates; of spread and the rates of spread determined as described
in the Manual for Construction and Supervision of Bituminous Works,
and approved by the Engineer, multiplied by the rates entered in the Bill
of Quantities for binder and each size of chipping. The adjusted rate
shall be payment in full for carrying out the required operations including
full compensation for all components listed in Clause 501.8.8.2. (i) to
(xi).
511. OPEN-GRADED PREMIX SURFACING
511.1. Open-graded Premix Surfacing using Penetration Bitumen
or Cutback.
511.1.1. Scope : This work shall consist of the preparation, laying
and compaction of an open- graded premix surfacing material of 20 mm
56
thickness composed of small-sized aggregate premixed with a bituminous

binder on a previously prepared base, in accordance with the requirements
of these Specifications, to serve as a wearing course.
511.1.2. Materials
511.1.2.1. Binder : The binder shall be a penetration bitumen of a
suitable grade as specified in the Contract, or as directed by the Engineer,
and satisfying the requirements of IS: 73.
511.1.2.2. Aggregate: The aggregate shall conform to Clause 504.2.2
except that the water absorption shall be limited to a maximum of 1 per
cent. The Polished Stone Value, as measured by the test in BS 812- (Part
114), shall not be less tha n 55.
511.1.2.3. Proportioning of materials: The materials shall be
proportioned in accordance with Table 500-23.
511.13. Construction operations
511.1.3.1. Weather and seasonal limitations: Clause 501.5.1 shall
apply.
511.1.3.2. Preparation of surface: The underlying surface on which
the bituminous surfacing 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
TABLE 500-23. QUANTITIES OF MATERIALS REQUIRED FOR 10 m' OF ROAD
SURFACE FOR 20mm THICK OPEN-GRADED PREMIX SURFACING
USING PENETRATION BITUMEN OR CUTBACK
Aggregates
(a) Nominal Stone size 13.2mm (passing 22.4 mm 0.18m1

sieve and retained on 11.2 mm sieve) -
(b) Nominal Stone size 1 1.2mm (passing 13.2 mm 0.09m3

sieve and retained on 5.6 mm sieve).
Total 0.27m3
Binder (quantities in terms of straight run bitumen)
(a) For 0.18 m 3 of 13.2mm nominal size stone 9.5kg

at 52 kg bitumen per m 3
(b) For 0.09 m' of 11.2 mm nominal size stone 5.1 kg

at 56 kg bitumen per m 3
Total 14.6kg
57
accordance with Clause 502 as directed by the Engineer.

511.1.3.3. Tack coat: A tack coat complying with Clause 503, shall
be applied over the base preparatory to laying of the surfacing.
511.1.3.4. Preparation of premix : Hot mix plant of appropriate
capacity and type shall be used for the preparation of the mix material.
The hot mix plant shall have separate dryer arrangement for heating
aggregate.
The temperature of the binder at the time of mixing shall be in the
range of 150°C to 163°C and that of the aggregate in the range of 155'C
to 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 and 160°C.
The mix shall be immediately transported from the mixer to the point
of use in suitable vehicles or hand barrows. The vehicles employed for
transport shall be clean and the mix being transported covered in transit
if so directed by the Engineer.
511.1.3.5. Spreading and rolling : The pre mixed material shall be
spread by suitable means to the desired thickness, grades and cross- full
(camber) making due allowance for any extra quantity required to fill up
depressions, if any. The crossfall should be checked by means of camber
boards and irregularities levelled out. Excessive use of blades or rakes
should be avoided. As soon as sufficient length of bituminous material
has been laid, rolling shall commence with 8 – 10 tonne rollers, - smooth
wheel tandem type, or other approved equipment. Rolling shall begin at
the edge and progress toward the centre longitudinally, except that on
superelevated and uni-directional cambered portions, it shall progress
from the lower to upper edge parallel to the centre line of the pavement.
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 premixed materials. Rolling shall then be continued until the
entire surface has been rolled and all the roller marks eliminated. In each
pass of the roller the 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. In no case shall fuel / lubricating oil be used
58
for this purpose. Excess use of water for this purpose shall also be avoided.
Rollers shall not stand on newly laid material. Rolling operations
shall be completed in every respect before the temperature of the mix
falls below 100° C. Joints along and transverse to the surfacing laid and
compacted earlier shall be cut vertically to "heir full depth so as to expose
fresh surface which shall be painted with a L in coat of appropriate binder
before the new mix is placed against it.
511.1.3.6. Seal coat : A seal coat conforming to Clause 513 of the
type specified in the Contract shall be applied to the surface immediately
after laying the surfacing.
511.1.4. Opening to traffic : No traffic shall be allowed on the road
until the seal coat has been laid. After the seal coat is laid, the road may
be opened to traffic according to Clause 513.4.
511.1.5. Surface finish and quality control of work : The surface
finish of construction shall conform to the requirements of Clause 902.
511.1.6. Arrangements for traffic : During the period of
construction, arrangement of traffic shall be made in accordance with the
provisions of Clause 112.
511.1.7. Measurement for payment : Open graded premix surfacing
shall be measured as finished work, for the area instructed to be covered,
in square metres. The area will be the net area covered, and all allowance
for wastage and cutting of joints shall be deemed to be included in the
rate.
511.1.8. Rate : The contract unit rate for open-graded premix
surfacing shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 501.8.8.2.
(i) to (xi).
511.2. Open graded premix surfacing using cationic bitumen
emulsion
511.2.1. Scope : This work shall consist of the preparation, laying
and compaction of an open graded premix surfacing of 20 mm thickness
composed of small-sized aggregate premixed with a cationic bitumen
59
emulsion on a previously prepared surface, in accordance with the

requirements of these Specifications, to serve as a wearing course.
511.2.2. Materials
511.2.2.1. Binder : The binder for Premix wearing course shall be
cationic bitumen emulsion of Medium Setting (MS) grade complying
with I.S.8887 and having a bitumen content 65 per cent minimum by
weight. For liquid seal coat RS grade of Cationic bitumen emulsion shall
be used. Where expressly specified in the Contract MS grade emulsion
shall be used or otherwise directed by the Engineer. Slow Setting (SS)
grade Cationic bitumen Emulsion shall be used for premix seal coat.
511.2.2.2. Aggregate : The requirements of Clause 511.1.2.2. shall
apply.
511.2.3. Proportioning of materials: The materials shall be
proportioned as quantities given in Tables 500-24 and 500-25.
TABLE 500-24. QUANTITIES OF AGGREGATE FOR 10 M1 AREA
(A) Premix Carpet
(a) Coarse aggregate nominal 13.2 mm size; passing IS 22.4 mm

sieve and retained on IS 11.2 mm sieve 0.18 m3
(b) Coarse aggregate nominal 11.2 mm size; passing IS 13.2 mm

sieve and retained on IS 5.6 mm sieve 0.09 m3
(B) For Seal Coat:

Refer to Clause 513.
TABLE 500-25. QUANTITIES OF EMULSION BINDER
For 10m2 area
(B) For Seal Coat:

(a) for liquid seal coa: 12 to 14 kg
(b) for premix seal coat 10 to 12 kg
511.2.4. Construction operations

511.2.4.1. Weather and seasonal limitations : Clause 501.5.1 shall
apply except that the minimum air temperature for laying shall be 10°C
Cationic bitumen emulsions shall not normally be stored below 0°C.
511.2.4.2. Preparation of surface : The underlying surface on which
60
the premix surfacing is to be laid shall be prepared, in accordance with

the requirements of Clause 504.3.2 for a newly primed surface, and in
accordance with Clause 507.4.2 where an existing bituminous surface is
to be overlaid.
511.2.4.3. Preparation of binder : Before opening, the cationic
bitumen emulsion drums shall be rolled at slow speed, to and fro, at least
5 times, for a distance of about 10 metres, to distribute any storage
sedimentation.
51 1.2.4.4. Tack coat : A tack coat complying with Clause 503, shall
be applied over the surface preparatory to laying of the surfacing where
specified in the Contract, or directed by the Engineer.
511.2.4.5. Preparation of premix : Premixing of cationic bitumen
emulsion and aggregates can be carried out in a suitable mixer such as
cold mixing plant as per IS: 5435 (Revised) or concrete mixer or by pay
loaders in exceptional cases where approved by the Engineer. Where
specified in the Contract continuous mixing operation shall be done either
in batch or continuous hot mix plant 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 shall be used which quantity will cover 5 sq.m. of
road surface with 20 mm average thickness.
The aggregates required for one batch shall be prepared adjacent to
the mixer.
First the coarse aggregate of 13.2 mm size shall be placed into the
mixer followed by 5 to 6.5 kg of Cationic bitumen emulsion and then the
(this line is corrupted in the text is also)
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.
When mixed manually by shovels, 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 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
61
remaining quantity of emulsion are added and mixed. Too much mixing
shall be avoided.
511.2.4.6. Spreading and rolling: The premixed cationic bitumen
emulsion and aggregates shall be spread within 10 minutes of applying
the tack coat. All levelling, raking, etc. should be completed within 20
minutes of the time of mixing.
The mix should be spread uniformly to the desired thickness, grades
and crossfall (camber) making due allowance for any extra quantity
required to fill up depressions, if any. The crossfall should be checked by
means of camber boards and irregularities leveled out. Too much raking
is to be avoided.
The rolling shall start immediately after laying the premix. A smooth
wheeled tandem roller of 8-10 tonnes shall be used, unless other
compaction methods are approved by the Engineer, based on the results
of laying trials, if necessary. While rolling, wheels of roller should be
clean and kept moist to prevent the premix from adhering to the wheels.
In no case shall fuel / lubricating oil be used for this purpose. Use of
water for this purpose shall be strictly limited to an absolute minimum.
Rolling shall commence at the edges and progress towards the centre
longitudinally except in the case of superelevated and uni-directional
cambered sections where rolling shall be carried out from the 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 maximum compaction
and all the roller marks eliminated. In each pass of the roller the preceding
track shall be overlapped uniformly by at least 1/3 width. Roller(s) shall
not stand on newly laid material. Joints both longitudinal and transverse
to the road sections laid and compacted earlier, shall be cut vertically 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.
511.2.4.7. Seal coat: A seal coat, conforming to Clause 510 or Clause
513, as specified in the Contract, shall be applied 4 to 6 hours after laying
the premix carpet.
511.2.5. Opening to traffic : Traffic should not be allowed over the
62
premix surface with or without seal coat, for 6 to 8 hours after rolling. In
case of single lane roads, traffic shall be allowed onto the surface once it
has reached ambient temperature, but speed must be rigorously restricted
to not more tha n 16 km per hour. If any premix material is picked up by
vehicle tyres, the spot shall be filled up by new mix. If traffic conditions
permit, the road shall not be opened until a full 24 hours after laying.
511.2.6. Surface finish and quality control : The surface finish of
construction shall conform to the requirements of Clause 902.
511.2.7. Arrangements for traffic : During the period of
construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
511.2.8. Measurement for payment : Open graded premix carpet
shall be measured as finished work, for the area specified to be covered,
in square metres at the specified thickness, in cubic metres, or in tonnes
weight as specified in the Contract. The area will be the net area covered,
and all allowances for wastage and cutting of joints shall be deemed to
be included in the rate.
511.2.9. Rate : The contract unit rate for premix carpet and seal coat
shall be payment in full for carrying out the required operations including
full compensation for all components listed in Clause 501.8.8.2. (i) to
(xi).
Bitumen quantities are to be as stated in Table 500-23 for premix,
3.0 Kg per 10 sq.m., for tack coat, 13Kg per 10 sq.m. for liquid seal coat
and 11 Kg per 10 sq.m. for premix seal coat. The rate will be adjusted
according to actual material used.
512. CLOSE-GRADED PREMIX SURFACING/
MIXED SEAL SURFACING
512.1. Scope
512.1.1. This work shall consist of the preparation, laying and
compaction of a close-graded premix surfacing material of 20 mm
thickness composed of graded aggregates premixed with a bituminous
binder on a previously prepared surface, in accordance with the
requirements of these Specifications, to serve as a wearing course.
63
512.1.2. Close graded premix surfacing shall be of Type A or Type B

as specified in the Contract documents.
512.2. Materials
512.2.1. Binder : The provisions of Clause 511.1.2.1 shall apply.
512.2.2. Coarse aggregates : The provisions of Clause 511.1.2.2
shall apply.
512.2.3. Fine aggregates : The fine aggregates shall consist of
crushed rock quarry sands, natural gravel / sand or a mixture of both.
These shall be clean, hard, durable, un-coated, mineral particles, dry and
free from injurious, soft or flaky particles and organic or deleterious
substances.
512.2.4. Aggregate gradation: The coarse and fine aggregates sha ll
be so graded or combined as to conform to one or the other gradings
shown in Table 500-26, as specified in the contract.
TABLE 500-26. AGGREGATE GRADATION
IS Steve Cumulative percent by weight of
Designation total aggregate pawing
(mm) Type A Type B
13.2mm - 100
11.2mm 100 88-100
5.6mm 52-88 31 -52
2.8mm 14-38 5-25
0.090mm 0-5 0-5
512.2.5. Proportioning of materials: The total quantity of aggregates
used for Type A or B close- graded premix surfacing shall be 0.27 cubic
metre per 10 square metre area. The quantity of binder used for premixing
in terms of straight-run bitumen shall be 22.0 kg and 19.0 kg per 10
square metre area for Type A and Type B surfacing respectively.
The provisions of Clause 511.1.3.1 through 511.1.3.5 shall apply.
Traffic may be allowed after completion of the final rolling when the
mix has cooled down to the surrounding temperature. Excessive traffic
speeds should not be permitted.
64

of Clause 902. For control on the quality of materials supplied and the
works carried out, the relevant provisions of Section 900 shall apply.
in accordance with the provisions of Clause 112.
Close- graded premix surfacing, Type A or B shall be measured as
finished work, for the area specified to be covered, in square metres at a
specified thickness. The area will be the net area covered, and all
allowances for wastage and cutting of joints shall be deemed to be included
in the rate.
512.8. Rate
The contract unit rate for close-graded premix surfacing, Type A or
B shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 501.8.8.2.
(i) to (xi).
513. SEAL COAT
513.1. Scope
513.1.1. This work shall consist of the application of a seal coat for
sealing the voids in a bituminous surface laid to the specified levels,
grade and cross fall (camber).
513.1.2. Seal coat shall be of either of the two types specified below:
(A) Liquid sea! coat comprising of an application of a layer of bituminous binder followed
by a cover of stone chips.
(B) Premixed seal coat comprising of a thin application of tine aggregate premixed \MI|I
bituminous binder.
513.2. Materials
513.2.1. Binder : The requirements of Clauses 511.1.2.1 and 51 1.2.2.1
shall apply.
The quantity of bitumen per 10 square metres, shall be 9.8 kg for
65
Type A, and 6.8 kg for Type B seal coal. Where bituminous emulsion is
used as a binder the quantities for Type A and Type B seal coats shall be
15 Kg and 10.5 Kg respectively.
513.2.2. Stone chips for Type A seal coat : The stone chips shall
consist of angular fragments of clean, hard, tough and durable rock of
uniform quality throughout. They should be free of soft or disintegrated
stone, organic or other deleterious matter. Stone chips shall be of 6.7mm
size defined as 100 per cent passing through 11.2 mm sieve and retained
on 2.36 mm sieve. The quantity used for spreading shall be 0.09 cubic
metre per 10 square metre area. The chips shall satisfy the quality
requirements in Table 500-3 except that the upper limit for water
absorption value shall be 1 per cent.
513.2.3. Aggregate for Type B seal coat : The aggregate shall be
sand or grit and shall consist of clean, hard, durable, uncoated dry particles
and shall be free from dust, soft or flaky / elongated material, organic
matter or other deleterious substances. The aggregate shall pass 2.36mm
sieve and be retained on 180 micron sieve. The quantity used for premixing
shall be 0.06 cubic metres per 10 square metres area.
513.3.1. Weather and seasonal limitations: The requirements of
513.3.2. Preparation of surface : The seal coat shall be applied
immediately after laying the 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.
513.3.3. Construction of Type A seal coat: Bitumen shall be heated
to 150°C-163°C and sprayed at the rate specified on the dry surface in a
uniform manner with a self-propelled mechanical sprayer as described in
the Manual for Construction and Supervision of Bituminous Works.
Immediately after the application of binder, stone chips, which shall
be clean and dry, shall be spread uniformly at the rate specified on the
surface preferably by means of a self-propelled or towed mechanical grit
spreader so as to cover the surface completely. If necessary, the surface
shall be brushed 10 ensure uniform spread of chips.
Immediately after the application of the cover material, the entire
66
surface shall be rolled with a 8 - 10 tonne smooth wheeled steel roller, 8

- 10 tonne static weight vibratory roller, or other equipment approved by
the Engineer after laying trials if required. Rolling shall commence at the
edges and progress towards the centre except in superelevated and unidirectional
cambered portions where it shall proceed from the lower edge
to the higher edge. Each pass of the roller shall uniformly overlap not
less than one-third of the track made in the preceding pass. While rolling
is in progress, additional chips shall be spread by hand in necessary
quantities required to make up irregularities. Rolling shall continue until
all aggregate panicles are firmly embedded in the binder and present a
uniform closed surface.
513.3.4. Construction of Type B seal coat: A mixer of appropriate
capacity and type approved by the Engineer shall be used for preparation
of the mixed material. The plant shall have separate dryer arrangements
for heating aggregate.
The binder shall be heated in boilers of suitable design, approved by
the Engineer to the temperature appropriate to the grade of bitumen or as
directed by the Engineer. The aggregates shall be dry and suitably heated
to a temperature between 150°Cand 165°C or as directed by the Engineer
before these components are placed in the mixer. Mixing of binder with
aggregates to the specified proportions shall be continued until! the latter
are thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to
the point of use and spread uniformly on the bituminous sur face to be
sealed.
As soon as a sufficient length has been covered with the premixed
material, the surface shall be rolled with an 8-10 tonne smooth-wheeled
roller. Rolling shall be continued until the premixed material completely
seals the voids in the bituminous course and a smooth uniform surface is
obtained.
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. In the case of Type A seal coat, traffic shall not
be permitted to run on any newly sealed area until the following day. In
special circumstances, however, the Engineer may open the road to traffic
67
immediately after rolling, but in such cases traffic speed shall be rigorously
limited to 16 km per hour until the following day.
of Clause 902.
Seal coat, Type A or B shall be measured as finished work, over the
area specified to be covered, in square metres at the thickness specified
in the Contract.
513.8. Rate
The contract unit rate for seal coat Type A or B shall be payment in
for all components listed in Clause 501.8.8.2. (i) to (xi).
514. SUPPLY OF STONE AGGREGATES
FOR PAVEMENT COURSES
514.1. Scope
This Specification Clause shall apply to the supply of stone aggregates
only. The work shall consist only of collection, transportation and stacking
the stone aggregates and stone filler for subsequent use in pavement
courses. The actual work of laying the pavement courses shall, however,
be governed by the individual Specification Clause for the actual work,
given elsewhere in this Specification. The size and quantities of the
aggregates to be supplied shall be so selected by the Engineer that the
grading requirements set forth in the individual Specification Clauses
for the pavement 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
68
Specification Clauses for the individual items given elsewhere in this

Specification.
514.2. Sizes of Stone Aggregates
The stone aggregates shall be designated by their standard sizes in
the Contract and shall conform to the requirements shown in Table 500-
27.
TABLE 500-27. SIZE REQUIREMENTS FOR COARSE STONE AGGREGATES
S. No. Nominal size of Designation of sieve Designation of sieve on
aggregate through which the which the aggregates
aggregates shall shall be wholly retained
wholly pass
(0 75 mm 106mm 63mm
(ii) 63 mm 90mm 53 mm
(iii) 45mm 53 mm 26.5 mm
(iv) 26.5 mm 45mm 22.4mm
(v) 22.4mm 26.5 mm 13.2mm
(vi) 13.2mm 22.4 mm 11.2mm
(vii) 11 .2 mm 13.2mm 6.7mm
(viii) 6.7mm 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 sha ll be stacked separately and in such a manner that there is no
contamination of one source with another..
2. Fine Aggregate: As stated in the individual relevant
Specification Clauses.
The aggregates shall be stacked entirely clear of the roadway on
even clear hard ground, 01 on a platform prepared in advance for the
purpose by the Contractor at his own cost and in a manner that allows
correct and ready measurement. If the stockpile is placed on ground
where the scraping action of the loader can contaminate the material
with underlying soil, then the stockpile shall be rejected by the
69
Engineer. Materials shall not he stacked in locations liable to inundation

or flooding.
The dimensions of the stockpiles and their location shall be approved
by the Engineer. Where the material is improperly stacked, the Engineer
shall direct complete re -stacking of the materials in an approved manner
at the Contractor's cost.
Stone filler shall be supplied in a dry state in bags or other suitable
containers approved by the Engineer and shall be protected from the
environment, so as to prevent deterioration in quality.
514.4. Quality Control of Materials
The Engineer shall exercise control over the quality of the materials
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 may,
at his discretion, direct these to be modified according to requirements:
Coarse and fine: One test for each specified property per 50 m3 of
stone aggregates.
Stone filler: One test for each specified property for every five
tonnes, subject to a minimum of one test for each
consignment.
Materials shall only be brought to site from a previously tested and
approved source, and any materials not conforming to the requirements
of the Specification shall be rejected by the Engineer and removed from
the work site.
Coarse and fine aggregates supplied to the site 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 in Table 500-28, from
the volume computed by stack measurements, to allow for bulking.
Unless otherwise directed by the Engineer, measurements shall not
be taken until sufficient 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.
Stone filler as delivered to the site shall be measured in tonnes.
70
TAKLE 500-28. PER CENT REDUCTION IN VOLUME OF AGGREGATES

S. No. Standard size Percentage reduction in volume
of aggregates computed by stack measurements to
arrive at the volume to be paid for
1. 75 mm and 63 mm 12.5
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
514.6. Rates
The contract unit rates for different sizes of coarse aggregate, fine
aggregate and stone filler shall be payment in full for collecting, conveying
and stacking or storing at the site including full compensation for :
(i) all royalties, fees, rents where necessary;
(ii) all leads and lifts; and
(iii) all labour, tools, equipment and incidentals to complete the work to the Specifications.
(iv) all necessary testing of material, both initial, to approve the source, and regular control
testing thereafter.
515. MASTIC ASPHALT

515.1. Scope
This work shall consist of constructing a single layer of mastic asphalt
wearing course for road pavements and bridge decks.
Mastic asphalt is an intimate homogeneous mixture of selected well-
graded aggregates, filler and bitumen in such proportions as to yield a
plastic and voidless mass, which when applied hot can be trowelled and
floated to form a very dense impermeable surfacing.
515.2. Materials
515.2.1. Binder: Subject to the approval of the Engineer, the binder
shall be a paving grade bitumen meeting the requirements given in Table
500-29.
515.2.2. Coarse aggregate : The coarse aggregate shall consist of
crushed stone, crushed gravel/shingle or other stones. They shall be clean,
hard, durable, of fairly cubical shape, uncoated and free from soft, organic
or other deleterious substances. They shall satisfy the physical
71
TABLE 500-29. REQUIREMENTS FOR PHYSICAL PROPERTIES OF BINDER

Property Test method Requirement
Penetration at 25°C IS 1203 15 ±5*
Softening point. °C IS 1205 65 ± 10
Loss on heating for 5h at 163°C, % by mass Max. IS 1212 2.0
Solubility in trichloroethylene, % by mass Min. IS 1216 95
Ash (mineral matter), % by mass Max. IS 1217 1.0
* In cold climatic regions (temperature <10°C), a softer penetration grade of 30/40 may be used.
requirements given in Table 500-3.

The percentage and grading of the coarse aggregate to be incorporated
in the mastic asphalt depending upon the thickness of the finished course
shall be as specified in Table 500-30.
TABLE 500-30. GRADE AND THICKNESS OF MASTIC ASPHALT PAVING, AND
GRADING OF COARSE AGGREGATE
Application Thickness Nominal size Coarse aggregate
range (mm) of coarse content, % by mass
aggregate (mm) of total mix
Roads and carriageways 25-50 13 40± 10
Heavily stressed areas i.e. 40 - 50 13 45 ± 10
junctions and toll pla zas
Nominal size of coarse aggregate 13mrn
IS Sieve (mm) Cumulative % passing by weight
19 100
13.2 88-96
2.36 0-5
Fine aggregate : The fine aggregate shall be the fraction passing the
2.36 mm and retained on the 0.075 mm sieve consisting of crusher run
screening, natural sand or a mixture of both. These shall be clean, hard,
durable, uncoated, dry and free from soft or flaky pieces and organic or
other deleterious substances.
Filler : The filler shall be limestone powder passing the 0.075 mm
sieve and shall have a calcium carbonate content of not less than 80
percent by weight when determined in accordance with IS: 1514.
The grading of the fine aggregate inclusive of filler shall be as given
in Table 500-31.
72
TABLE 500-31. GRADING OF FINE AGGREGATE (INCLUSIVE OF FILLER)

I.S. Sieve Percentage by weight of aggregate
Passing 2.36 mm but retained on 0.600 mm 0 - 25
Passing 0.600 mm but retained on 0.212 mm 10- 30
Passing 0.212 mm but retained on 0.075 mm 10 - 30
Passing 0.075 30 - 55
515.3. Mix Design

515.3.1. Hardness number: The mastic asphalt shall have a hardness
number at the time of manufacture of 60 to 80 at 25°C prior to the addition
of coarse aggregate and 10 to 20 at 25°C at the time of laying after the
addition of coarse aggregate.
The hardness number shall be determined in accordance with the
method specified in 18:1195-1978.
515.3.2. Binder content: The binder content shall be so fixed as to
achieve the requirements of the mixture specified in Clause 515.3.1. and
shall be in the range of 14 to 17 per cent by weight of total mixture as
indicated in Table 500-32.
TABLE 500-32. COMPOSITION OF MASTIC ASPHALT BLOCKS
WITHOUT COARSE AGGREGATE
IS Sieve Percentage by weight of mastic asphalt
Minimum Maximum
Passing 2.36 mm but retained on Q.600 mm 0 22
Passing 0.600 mm but retained on 0.212 mm 4 30
Passing 0.212 mm but retained on 0.075 mm 8 18
Passing 0.075 mm 25 45
Bitumen Content 14 17
515.3.3. Job mix formula : The Contractor shall inform the Engineer
in writing at least 1 month before the start of the work of 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
aggregate and results of the tests recommended in the various Tables and
Clauses of this Specification.
73

501.5.1 shall apply, except that laying shall not be carried out when the
air temperature at the surfa ce on which the Mastic Asphalt is to be laid is
below 10°C.
515.4.2. Preparation of the base: The base on which mastic asphalt
is to be laid shall be prepared, shaped and conditioned to the profile
required, in accordance with Clause 501 or 902 as appropriate or as
directed by the Engineer. In the case of a cement concrete base, the surface
shall be thoroughly power brushed clean and free of dust and other
deleterious matter. Under no circumstances shall mastic asphalt be spread
on a base containing a binder which might soften under high application
temperatures. If such material exists, the same shall be cut out and repaired
before the mastic asphalt is laid.
515.4.3. Tack coat: A tack coat in accordance with Clause 503 shall
be applied on the base or as directed by the Engineer.
515.4.4. Preparation of mastic asphalt: Penetration of mastic asphalt
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°C to
210°C. Required quantity of bitumen shall be heated to 170°C to 180°C
and added to the heated aggregated. 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 half the quantity of binder is
added. After heating and mixing for some time, the fine 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 210°C.
Where the material is not required for immediate use it shall be cast
into blocks consisting of filler, fine aggregates and binder, but without
the addition of coarse aggregate, weighing about 25 Kgs each. Before
use, these blocks shall be reheated to a temperature of not less than 175°C
and not more than ?. 10°C, thoroughly incorporated with the requisite
quantity of coarse aggregates and mixed continuously. Mixing shall be
74
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 210°C.
The mastic asphalt blocks (without coarse aggregate) shall show on
analysis a composition within the limits as given in Table 500-32.
The mixture shall be transported to the laying site in a towed mixer
transporter having arrangement for stirring and keeping the mixture hot
during transportation.
515.4.5. Spreading : The mastic asphalt shall be laic;, normally in
one coat, at a temperature between 175°C and 210°C and spread uniformly
by hand using wooden floats or by machine on the prepared and regulated
surface. The thickness of the mastic asphalt and the percentage of added
coarse aggregate shall be in accordance with Table 500-30 or as specified
by the Engineer. Where necessary, battens of the requisite dimensions
should be employed. Any blow holes that appear in the surface shall be
punctured while the material is hot, and the surface made good by further
floating.
515.4.6. Joints : All construction joints shall be properly and truly
made. These joints shall be made by warming existing mastic asphalt by
the application of an excess quantity of the hot mastic asphalt mixture
which afterwards shall be trimmed to leave it flush with the surfaces on
either side.
515.4.7. Surface finish : The mastic asphalt surface can have poor
skid resistance after floating; in order to provide resistance to skidding,
the mastic asphalt after spreading, while still hot and in a plastic condition,
shall be covered with a layer of stone aggregate. This aggregate shall be
13.2 mm size (passing the 19.0 mm sieve and retained on the 9.5 mm
sieve) or 9.5mm size (passing the 13.2 mm sieve and retained on the 6.7
mm sieve) subject to the approval of the Engineer. Hard stone chips,
complying with the quality requirements of Table 500-17, shall be
precoated with bitumen at the rate of 2 ± 0.4% of S-65 penetration grade.
The addition of 2% of filler complying with Table 500-9 may be required
to enable this quantity of binder to be held without draining. The chips
shall then be applied at the rate of 0.005 cu. m. per 10 sq. m. and rolled or
otherwise pressed into the surface of the mastic layer when the temperature
of the mastic asphalt is not less than 100°C.
75

Traffic may be allowed after completion of the work when the mastic
asphalt temperature at the mid-depth of the completed layer has cooled
to the daytime maximum ambient temperature.
The surface of the mastic asphalt, tested with a straight edge 3.0m
long, placed parallel to the centre line of the carriageway, shall have no
depression greater than 7mm. The same limit shall also apply to the
transverse profile when tested with a camber template.
Mastic asphalt shall be measured as finished work in square metres
at a specified thickness, or by weight in tonnes as stated in the Contract.
515.9. Rate
The contract unit rate for mastic asphalt shall be payment in full for
carrying out the required operations including full compensation for all
components listed under Clause 501.8.8.2. (i) to (ix).
516. SLURRY SEAL
516.1. Scope
Slurry seals are mixtures of fine aggregate, portland cement filler,
bitumen emulsion and additional water. When freshly mixed, they have
a thick consistency and can be spread to a thickness of 1.5 - 5 mm. They
may be used to seal cracks, arrest fretting and fill voids and minor
depressions, to provide a more even riding surface or a base for further
treatment; they may also be used on top of a single coat surface dressing.
76
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 of IS: 8887. Where special mobile mixing machines are
available, Class A4* rapid setting or Class K3* road emulsions to BS
434: Part 1 should be used to obtain very early resistance to traffic and
rain. Generally, emulsion for slurry seal should be capable of producing
a slurry that will develop early resistance to traffic and rain and is
sufficiently stable to permit mixing with the specified aggregate, without
breaking dur ing the mixing and laying processes. If approved by the
Engineer, a slow setting emulsion may be used. Guidance on selection of
an appropriate grade of emulsion is given in the Manual for Construction
and Supervision of Bituminous Works.
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.
The pH of the water must lie in the range 4 to 7, and if the total
dissolved solids in the water amount to more than 500ppm, the Engineer
may reject it, or order the Contractor to conduct a trial emulsion mix to
demonstrate that it does not cause early separation.
516.2.3. Aggregate : The aggregate shall be crushed rock, or slag

and may be blended, if required, with clean, sharp, naturally occurring
sand free from soft pieces and organic and other deleterious substances
to produce a grading as given in Table 500-33. The aggregates shall meet
the requirements of the film stripping test (IS: 6241), and a suitable amount
and type of anti-stripping agent added, as may be needed (details given
in Appendix 5).
516.2.4. Additives: It is usual to use ordinary Portland cement,
hydrated lime or other additives to control consistency, mix segregation
and setting rate. The proportion of the additive sho uld not normally exceed
2 percent by weight of dry aggregates.
* The corresponding grades m IS:8887 are only broadly classified as RS.

MS and SS and further sub-classification is not available at present.

A range of residual binder contents for each aggregate grading is
given in Table 500-33. The optimum mixture design for the aggregate,
additive, water and bitumen emulsion mixture should be determined in
accordance with ASTM D 3910.
516.4.1. Weather and seasonal limitations: Clause 501.5.1 shall
apply.
TABLE 500-33. AGGREGATE GRADING, BINDER CONTENT AND
APPROXIMATE COVERAGE RATE
Sieve Size (mm) Percentage by mass pissing

finished thickness of sealing
5mm 3mm 1. 5mm
9.5 100 - -
4.75 90 - 100 100 —
3.35 - 80- 100 100
236 65 - 90 75-100 95-100
1.18 45 - 70 55 -90 70-95
u.600 30 - 50 35 -70 55-75
0.300 18- 30 20- 45 30- 50
0.150 10-21 10-25 10-30
0.075 5- 15 5- 15 5-15
Quantity of residual binder, 7.5- 13.5 10- 16 12-20
percentage by mass of
aggregate
Approximate coverage 8 -15 4-6 2-4
rate (kg/m2 )
516.4.2. Surface preparation: Any necessary remedial work to the

road surface and structure shall be completed either prior to or as part of
the Contract and agreed as acceptable by the Engineer, according to the
provisions of Clause 501.
Before slurry seal is applied, street furniture and, where directed by
the Engineer, road markings, shall be masked using self-adhesive masking
material or other material firmly secured against the passage of the
spreader box or the tools used for hand laying. Any packed mud or other
deposits on the surface shall be removed, all organic growth shall be
78
removed by suitable means, and the surface shall be swept free of all
loose material.
516.4.3. Tack coat: If required by the Engineer, a tack coat may be
applied prior to the slurry seal, with or without grit or chips, in order to
seal the existing substrata and enhance the bond to the existing road
surface. Unless otherwise agreed by the Engineer, the rate of spread of
tack coat shall be 0.15 to 0.30 litres/m2 for bituminous surfaces and 0.4
to 0.6 litres/m2 for concrete surfaces
516.4.4. Mixing and transportation of mixture: Mixing (and laying)
techniques vary according to the type of emulsion used. For class A4
rapid setting and K3 emulsions, only special mobile mixing machines
should be used. These carry supplies of aggregate, emulsion, water and
filler (e.g. ordinary Portland cement or hydrated lime) and are fitted with
metering devices to feed the ingredients in their correct proportions to a
mixer fitted to the rear of the machine. From the mixer the slurry is fed
into the screed box towed by the machine.
For all other emulsions, mixing may be by hand, concrete mixer or
other mixer which effectively coats the aggregate uniformly and produces
a slurry seal of suitable consistency for satisfactory laying. For large areas,
a bulk transit concrete mixer may be used into which the ingredients
(including water) are measured and mixed as the mixer travels to the
area to be treated. A screed box fitted with an adjustable rubber screed
should be towed by the mixer which feeds it during laying.
The special mobile mixing machine, when used, shall be capable of
uniform application to provide a continuous surface without ridges or
segregation. Before laying begins, the Contractor shall provide the
Engineer with a test certificate showing test results for rate of application
carried out under the supervision of a competent authority, demonstrating
that the machine has been tested, using the system to be used in the
Contract, not more than six weeks before the commencement of the work.
Where the material is to be hand laid, the slurry may be supplied to
site pre-mixed in suitable containers and steps shall be taken to ensure
that the material in each container is of an even consistency throughout
the container immediately prior to use.
516.4.5. Application: Transverse joints for machine laid areas shall
be formed with spreading, starting and finishing on a protective strip not
79
less than 100 mm wide at each end of the lane length being treated.
Transverse joints shall be formed such that there shall be no ridges or
bare strips.
Unless otherwise approved by the Engineer, longitudinal joints shall
coincide with lane markings. Longitudinal joints shall be formed such
that there shall be no ridges or bare strips.
Hand work around street furniture and other obstructions should meet
the same performance requirements and form a homogeneous surface
with the rest of the treated carriageway.
Footways and other confined areas may be spread by hand using
squeegees and brooms. Transverse joints shall be formed with spreading,
starting and finishing on a protective strip not less than 100 mm wide at
each end of the lane length being treated. Transverse joints shall be formed
such that there shall be no ridges or bare strips. Kerb edges and other
areas not being treated shall be suitably masked with self adhesive masking
material. Footways shall be finished by dragging a dampened broom
transversely over the footway under its own weight.
All voids, cracks and surface irregularities shall be completely filled,
In warm dry weather the surface, immediately ahead of the spreading,
shall be slightly damped by mist water spray applied mechanically, or for
hand laying by a hand operated pressure sprayer, unless otherwise
approved by the Engineer.
516.4.6. Rolling: The need for rolling shall be as instructed by the
Engineer. Where rolling is required, a pneumatic-tyred roller having an
individual wheel load between 0.75 and 1.5 tonnes shall be used, 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.
Masking shall be removed after the slurry seal has been applied,
without damage to the edge of the surfacing, and before opening the road
or footway to traffic.
The Contractor shall remove surplus aggregate from the treated areas
using a method agreed by the Engineer. The Contractor shall monitor the
slurry seal closely for a minimum period of 2 hours and if necessary the
80
lane shall be swept again. The monitoring shall continue until the slurry
seal has reached sufficient stability to carry unrestricted traffic. If there
are signs of distress, the Engineer shall require the Contractor to reinstate
traffic safety and management procedures or other such remedial action
where necessary in order to prevent further damage.
Further operations to remove subsequently loosened aggregate shall
be carried out over the next 48 hours. The areas treated and adjacent side
roads, footways and paved areas shall be kept substantially free of loose
aggregate for a period of 30 days after completion of the work.
Generally, the surface finish of the completed construction shall
conform to the requirements of Clause 902. For control of the quality of
materials supplied and the works carried out, the relevant provisions of
Section 900 shall apply.
In addition, the finished slurry shall have a uniform surface texture
throughout the work, without variations of texture within the lane width,
or from lane to lane, due to segregation of aggregates, or due to variations
in the emulsion/water content of the mixture.
The finished surface shall be free from blow holes and surface
irregularities in excess of 3 mm beneath a 1 metre straight edge due to
scraping, scabbing, dragging, droppings, excess overlapping or badly
aligned longitudinal or transverse joints, damage by rain or frost, or other
defects which remain 24 hours after laying.
Slurry seal shall be measured as finished work as specified, in square
metres.
516.9. Rate
The contract unit rate for slurry seal shall be payment in full for
carrying out the required operations including full compensation for all
components listed in Clause 501.8.8.2. (i) to (xi).
81
517. RECYCLING OF BITUMINOUS PAVEMENT

517.1. Scope
This Clause of the Specifications covers the recycling of existing
bituminous pavement materials to upgrade an existing 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 aggregate in the
requisite proportions, mixing, spreading and compaction of the blended
materials.
Recycling processes can be categorised into in-situ recycling (where
processing takes place on site), and central plant recycling (where
reclaimed material is processed off site). The processes can be further
sub-divided into hot and cold processes. This Specification covers the
hot process only. However, reclaimed aggregate from cold insitu recycling
can be used in the Bituminous Cold Mix process specified in Clause 519,
subject to the resultant mixes achieving the specified standards.
517.2. Reclaimed Bituminous Materials for Central Plant
Recycling
517.2.1. Proportion of reclaimed materials less than 10 per cent:
If not more than 10% of reclaimed bituminous material is to be used in
the production of bituminous macadam or dense graded bituminous base
or binder course material, then Clauses 517.2.2 to 517.2.9 do not apply.
However:
a) all reclaimed bituminous material shall be pre-treated before use such that the material
is homogeneously mixed and the maximum panicle size of reclaimed material does
not exceed 40 mm.
b) the mixed material shall comply with the requirements of Clauses 504 or 507 as
appropriate.
517.2.2. Proportions of reclaimed materials greater than 10 per

cent: Reclaimed bituminous material of an amount greater than 10 per
cent, may be used in the production of bituminous macadam and dense
graded bituminous base and binder course material, subject to the
requirements of Clauses 517.2.3 to 517.2.9 and subject to the satisfactory
completion of full trial investigations in respect of all related materials,
layer thickness, machine operations and finished works on a case-by-
82
case basis entirely at the contractors cost and subject to the approval of
the Engineer. For estimating purposes, a maximum amount not greater
than 30 per cent reclaimed bituminous material should be assumed.
517.2.3. Materials for recycled pavement: The recycled materials
shall be a blend of reclaimed and new materials proportioned to achieve
a paving mixture with the specified engineering properties. The reclaimed
materials shall be tested and evaluated to find the optimum blend meeting
the mixture requirements. Such testing and evaluation shall be carried
out on representative samples, either cores sampled from the carriageway
or samples taken from stockpiles in accordance with current practice.
The sampling frequency should be sufficient to determine how consistent
the reclaimed material is and to provide representative samples for
composition analysis and measurement of properties of recovered binder.
As an absolute minimum, one sample to represent 500m of lane
carriageway shall be taken.
517.2.4. Bitumen extraction : The procedure described in ASTM
D-2172 shall be used to quantitatively separate aggregate and bitumen
from any representative sample of reclaimed bituminous pavement.
517.2.5. Aggregate evaluation: Mechanical sieve analysis (IS: 2386,
Part I, wet sieving method) shall be performed on the aggregate portion
of the reclaimed bituminous pavement sample to determine the grading.
It is essential that the reclaimed materials to be recycled are consistent,
as variable materials will cause problems with the control of quality and
impede the efficiency of the recycling operation. Suitable sources of
consistent material of sufficient quantity for the scheme being considered
need to be identified either in existing pavements, from stockpiled planings
of known origin or from another suitable source, before a decision can
be made on the optimum percentage of reclaimed material.
After selecting the proportion of reclaimed materials to be recycled,
the grading of the mixture may need adjustment, to meet Specification
requirements, by the addition of selected aggregate sizes.
517.2.6. Evaluation of bitumen : When the amount of reclaimed
bituminous materials to be used in the mixture exceeds 10%, the
penetration value of the recovered binder from the reclaimed bituminous
material, before mixing, shall exceed 15 pen, after recovery of binder in
accordance with the requirements of BS 2000 : Part 397, when tested in
83
accordance with IS : 1203. Provided the above requirement is met,

hardening of the old binder, during the original mixing process or through
ageing, can be compensated for by adding a softer bitumen, to obtain the
appropriate final grade of binder.
The determination of the type and amount of binder required to be
added in the final mix is essentially a trial and error procedure.
After mixing with recycled materials, the binder recovered from the
mixture shall have a recovered penetration value not less than the value
specified in Table 500-34.
TABLE 500-34. MINIMUM RECOVERED BINDER PENETRATION
OF RECYCLED MIXTURE
Specified Grade of Binder Minimum Recovered Penetration Value

(Penetration) of Binder after Mixing
45 27
65 39
90 54
517.2.7. Rejuvenators: The use of rejuvenators, and a test to measure

their effective ness, is described in Clause 517.6.3.
517.2.8. Untreated aggregate : If necessary, - fresh untreated
aggregate shall be added to the reclaimed bituminous pavement to produce
a mix with the desired grading. The aggregate shall be checked for quality
requirements in accordance with Table 500-3 or Table 500-8 as
appropriate. Reclaimed aggregate, if any, or any aggregate normally used
for the desired bituminous mixture, or both, may be used for this purpose.
517.2.9. Combined aggregate grading : The blend of reclaimed
and new aggregate shall meet the grading criteria specified in the relevant
parts of Clause 504 or 507, as appropriate and as approved by the Engineer.
The blend of aggregates shall be checked for resistance to stripping as
specified in Tables 500-3 or 500-8 as appropriate.
The combined aggregate grading and binder content shall comply
with the relevant tables in Clauses 504 or 507. For dense graded
bituminous mixtures the mixture design shall also comply with the
requirements of Table 500-11.
84
517.4. Reclaiming Old Pavement Materials

The removal of pavement materials to the required depth shall be
accomplished either at ambient temperature (cold process) or at an
elevated temperature (hot process), as approved by the Engineer.
517.4.1. Cold removal process: 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 required size as
directed by the Engineer. Alternatively, cold milling or planing machines
can be used to reclaim bituminous pavement to controlled depths. After
the bituminous layers are removed, any remaining aggregate materials
that are to be incorporated in the recycled hot mixture shall be scarified
and removed. When the pavement material removal is completed, any
drainage deficiencies shall be corrected. After that, the base/sub-base as
the case may be shall be cut, graded and compacted to the required profile
and density.
517.4.2. Hot removal process: In this process, the road surface shall
be heated, by any suitable means approved by the Engineer, before
scarification. A self propelled 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
requirements as directed by the Engineer. During the heating process,
the surface temperature of the road shall not exceed 200°C for more than
5 minutes.
517.4.3. Stockpiling : In the cold process, the reclaimed bituminous
pavement material shall be stockpiled with the height of stockpiles not
exceeding 3 m. The reclaimed untreated aggregate base/sub-base material
shall be stockpiled in the same manner as new aggregate. The number
and location of stockpiles shall be carefully planned for efficient operation
of the hot- mix plant.
517.5. Mixing and Laying
Generally, the requirements of Clauses 504.3 or 507.4, as appropriate,
shall apply.
517.6. In Situ Recycling - The Remix and Repave Processes
These processes are suitable for the production of bituminous concrete
wearing course in accordance with the provisions of Clause 509.
85
517.6.1. Scope: In the process of repaying, the existing surface is

preheated and scarified but the scarified material is not removed. A layer
of fresh bituminous mix material prepared in the integrated mixing unit
of the plant is then spread evenly on the scarified surface to give a uniform
profile. The spread material should be compacted as soon as possible
after laying. In the process the total thickness of the pavement is increased
by up to 50mm.
In the remix process, the scarified material should be taken from the
mixing unit of the plant where it is recycled with fresh binder, aggregate
and recycling agent. Then the recycled mixture is spread on the preheated
surface and tamped and compacted to the required profile.
517.6.2. Heating and scarifying: Surfaces to be treated shall be
heated by plant with surfaces insulated and fully enclosed. The heated
width of surfacing shall exceed the scarified width by at least 75 mm on
each side, except against the edge of the carriageway or kerb face. When
new surfacing material is spilled onto the road surface it shall be removed
before the existing surface is heated and scarified. Areas of unscarified
material shall not exceed 50 mm x 50 mm.
The depth of scarification shall be such that the bottom of the scarified
layer is parallel to and below the finished road surface level by the
thickness of wearing course material specified. A tolerance of ± 6 mm is
permissible.
Where street furniture and other obstructions occur, these shall be
suitably protected or removed and the void covered. Surface dressing
and large areas of road markings shall be removed by milling, planing,
scarifying or by similar approved processes.
The heated surface shall be evenly scarified to comply with the
requirements of this Clause. When street furniture is left in place or raised,
the adjacent areas shall be scarified by other means, with the material
either left in place or removed, prior to passage of the machine. If furniture
needs to be repositioned on completion of work, the new wearing course
material shall be used to make good the road surface for a maximum
width of 200 mm around the obstruction.
During the reheating process the surface temperature of the road shall
not exceed 200°C fo r more than 5 minutes.
86
517.6.3. Rejuvenator: For Remix, when required, rejuvenator shall

be uniformly sprayed across the full- width of the processed material.
The machine shall incorporate a meter for continuous verification of
quantities which shall be within ±5% of the specified rate. The volume
of rejuvenator shall vary in relation to the operating speed of the machine,
which shall be related to the volume of material mixed or scarified.
The rejuve nator shall be a non-emulsified aromatic extract. Its
properties shall be verified using the Rolling Thin Film Oven Test.
Rejuvenation of the existing pavement may also be performed by
adding new hot-mix bituminous material containing a soft binder of
suitable penetration for restoring the binder in the existing pavement to
the required penetration.
517.6.4. Mixing: When required, new hot- mix material shall be mixed
with the heated and scarified road pavement material in a pugmill within
the Remix machine, observing the mixing temperatures specified in Table
500-5.
After mixing, the recycled bituminous materials shall be automatically
fed to a finishing unit, which spreads and levels the mixture to the specified
thickness and cross-section. The new bituminous concrete wearing course
shall be material complying with Clause 509.
517.6.5. Additional material (general): The proportion of new hot-
mix bituminous material, and the proportion of existing bituminous
pavement material shall be as directed by the Engineer, together with the
amount the road surface level is to be raised (if any).
The type and quantity of the new hot- mix material shall be determined
by using the Marshall Mix Design procedure specified in The Asphalt
Institute Manual MS-2, before work commences. Remix designs shall
incorporate the stated proportion of material sampled from the existing
road surface.
When additional coarse or fine aggregate or filler are required to
be added, they shall comply with the requirements of Clause 509.2.
The amount of additional coarse or fine aggregate or filler to be added
to the existing bituminous pavement material shall be notified to the
Engineer.
517.6.6. Additional aggregate (remix process): The coarse
87
aggregate, fine aggregate and filler added to the Remixed material shall
comply with the requirements of Clause 509.2.
517.6.7. New surfacing (repave and remix/repave processes): New
surfacing material shall be bituminous concrete wearing course complying
with Clause 509, or other wearing course material approved by the
Engineer.
The new surfacing material shall be laid on, and compacted with, the
reprofiled surfacing, which shall be at a temperature within the range of
100°Cto 150°C.
517.6.8. Binder: The binder shall be recovered from samples taken
from each layer of material laid. The method of recovery shall be in
accordance with BS 2000 : Part 397 or an equivalent test. The penetration
of the binder shall be in the range 35-70 pen.
517.6.9. Mixture design: The surfacing material shall be sampled
from the paver hopper or augers. Care shall be taken that only the material
forming the new surface layer is sampled. The sample shall be reduced
on site by rifling or quartering to approximately 5 kg and placed loose in
an air-tight container.
The sample shall only be reheated once whilst within the container.
As soon as the sample reaches the required temperature, the reheated
material shall be remixed and three Marshall test specimens prepared in
accordance with the procedures specified in MS-2.
The bulk density of each specimen shall be measured before Marshall
Stability testing. The mean stability and flow of the three specimens,
measured in accordance with the procedures specified in MS-2, shall
comply with the requirements of Table 500-19.
Finally the 3 Marshall specimens shall be combined and the maximum
theoretical specific gravity (Gmn) of the mixture is determined in
accordance with ASTM D 2041. This maximum theoretical specific
gravity (Gmm) corresponds to 0% air voids in the mixture. The actual
bulk specific gravity of a Marshall specimen determined in the Laboratory
(Gmm) naturally be less than Gmm The percent air voids (Pa) in the
G − G mb
specimen of the compacted mixture given by Pa = mm ×100 should
G mm
meet the requirements of air voids laid down in Table 500-19.
88

For recycled material forming the base or binder course layer, Clause
504.5 or 507.5 shall apply as appropriate. For recycled material forming
the wearing course layer, Clause 509.5 shall apply.
out the relevant provisions of Section 900 shall apply.
The recycled pavement work shall be measured in cubic metres or
tonnes of finished work as stated in the Contract..
517.11. Rate
The contract unit rate for recycled pavement shall be payment in full
for carrying out the required operations including full compensation for
all items as Clause 50.1.8.8.2. (i) to (xi)
518. FOG SPRAY
518.1. Scope
Fog spray is a very light application of low viscosity bitumen emulsion
for purposes of sealing cracks less than 3mm wide or incipient fretting or
disintegration in an existing bituminous surfacing, and to help reduce
loosening of chips by traffic on newly finished surface dressing.
518.2. Material
The bitumen emulsion shall be as specified in the Contract 01 as
instructed by the Engineer. The emulsion shall be
SS-lh* (SS-1 can be used if the former is not available) complying
with the requirements of ASTM D-977, or;
89
CSS-lh* (CSS-1 can be used it the 1'ornieris not available) complying

with the requirements of ASTM U-2397.
Before use these emulsions shall be diluted, 1 part emulsion to 1 part
water. Alternatively, Class A1 -40* or K1 -40* emulsions complying with
the requirements of BS434:Part 1:1984 may be used. These emulsions
have a lower viscosity than the above ASTM grades, they are rapid setting
and they do not require to be diluted. Because of their low viscosity they
should be used as soon as possible after delivery. If this is not possible,
the drums should be very thoroughly rolled before use.
Spraying shall not take place when the temperature is below 10°C,
nor in windy or dusty conditions, nor when it is raining or the surface to
be sprayed is wet (a damp surface is acceptable but refer to Clause
518.4.2.).
518.4.1. Equipment: The fog spray shall be applied by means of a
self-propelled or towed bitumen pressure sprayer complying with the
requirements of the Manual for Construction and Supervision of
Bituminous Works. The spray bar should be protected from gusts of wind
by means of a hood.
518.4.2. Preparation of surface: The surface on which the fog spray
is to be applied shall be thoroughly cleaned with compressed air, scrubbers
etc. The cracks shall be cleaned with a pressure air jet to remove all dirt,
dust etc.
518.4.3. Application: The fog seal shall be applied at a rate of 0.5 -
1.0 litres/m3, using equipment such as pressure tank, flexible hose and
spray bar or lance.
518.5. Blinding
If specified in the Contract or ordered by the Engineer, the fog spray
shall be blinded with graded grit of 3mm size and under, coated with
about 2 per cent of the emulsion by weight. The pre coated grit s hall be
* The grades in IS:8887 are only broadly classified as RS, MS and SS and
further sub-classification is not available at present.
90
allowed to be cured for at least one week or until they become non-sticky
and can be spread easily.
out, the relevant provisions of Section 900 Shall apply.
During the spraying operations, arrangements for traffic shall be made
in accordance with the provisions of Clause 112. The surface should not
be opened to traffic for 24 hours after spraying. If pick-up does occur a
light blinding of crusher dust or sand should be applied.
Fog spray and blinding (if used) shall be measured in terms of surface
area of application, for the area covered, in square metres.
518.9. Rate
The contract unit rate for fog spray and blinding (if used) shall be
payment in full for carrying out the required operations including full
compensation for all components listed in Clause 501.8.8.2. (i) to (xi) as
applicable to the work specified in these Specifications.
519. BITUMINOUS COLD MIX (INCLUDING
GRAVEL EMULSION)1
519.1. The Design Mix
Bituminous Cold Mix consists of a mixture of unheated mineral
aggregate and emulsified or cutback bitumen. This Specification deals
only with plant mix (as opposed to mixed- in-place). Two types of mix
are considered, namely Designed Cold Mix and Recipe Cold Mix. The
Design Mix procedure shall be used unless the Recipe Mix procedure is
specifically approved by the Engineer.
1
This Specification Clause has been introduced for the first time. Difficulties
in using this Clause and suggestions for improvement may be forwarded to
DG(RD), Ministry of Road Transport & Highways, Transport Bhavan.
Parliament Street, New Delhi-110 001. Fax #3710236
91
519.2. Designed Cold Mix

This Specification is based on The Asphalt Institute Manual MS-14,
which contains additional information for guidance. These mixes are
considered suitable for use as base course, appropriate to their stability,
in new work or major repair work.
519.2.1. Materials
519.2.1.1. Binder: The binder shall be a bituminous emulsion as
specified in AASHTO M 140 (ASTM D977)* or AASHTO M 208 (ASTM
D2397)*, namely MS-2, MS-2h, HFMS-2, HFMS-2h, HFMS-2s, SS-1,
SS-lh, CMS-2, CMS-2h, CSS-1 and CSS-In. Alternatively, a cutback
bitumen as specified in AASHTO M 82 (ASTM D2027) or ASTM D
2026, namely MC 70, 250, 800 & 3000 and SC 250, 800 and 3000 may
be used, or, if approved by the Engineer, an equivalent material which
conforms with 1S:8887 and 18:217.
A general guide for the use of these binders is given in Table 500-35
and in the Manual for Construction and Supervision of Bituminous Works.
However the final selection shall be made only after laboratory evaluation
TABLE 500-35. USES OK BITUMEN IN COLD MIX
Type Emulsified Bitumen Cutback Bitumen
of Anionic Cationic Medium Slow
Construction Curing (MC) Curing (SC)
Cold-Laid Plant Mix
MS-2H, HFMS-Sh
Pavement Base and

MS-2, HFMS-2
Surfaces
HFMS-2s
CMS-2h
CSS=1h
CMS-2
CSS-1
SS-1h
3000
3000
SS-1
250
800
250
800
70
Open-Graded Aggregate * * * *
Well-Graded Aggregate * * * * * * * * * * *
Patching, Immediate Use * * * * *
Patching, Stockpile * * * *
* The corresponding grades in 1S:8887 arc only broadly classified as RS,

MS and SS and further sub-classification is not available at present.
92
with the aggregates to be used. The binder with the highest residual
viscosity at ambient temperatures that can reasonably be handled by the
mixing and laying equipment proposed shall be used.
519.2.1.2. Aggregates: The aggregates shall comply with the
requirements of Clause 504.2.2. and 504.2.3. If the aggregates are not
properly coated with anionic emulsion or cutback bitumen, a small amount
of hydrated lime, an approved antistripping agent (see Appendix 5) or a
change to cationic emulsion shall be proposed by the Contractor, for the
approval of the Engineer.
519.2.1.3. Aggregate grading and binder content: The combined
aggregate grading for the particular mixture, when tested in accordance
with IS:2386 Part 1, (wet sieving method), shall fall within the limits
shown in Table 500-36.
519.2.2. Mixture Design
519.2.2.1. Requirements for the mixture: Apart from conformity
with the grading and quality requirements for individual ingredients, the
519.2.2.2. Binder content: The binder content shall be optimised to
achieve the requirements of the mixture set out in Table 500-41. The
method adopted shall be that described in Appendix F and H of Asphalt
Institute's Manual, MS-14.
519.2.2.3. Job Mix Formula: The Contractor shall inform the
Engineer in writing, at least one month before the start of the work, the
job mix formula proposed for us e in the works and shall give the following
details:
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder, as percentage by weight of total mixture;
(b) Coarse aggregate/fine aggregate as percentage by weight of total aggregate;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 500-39 as obtained by the Contractor;
(v) Test results of the physical characteristics of the aggregates to be used;
(vi) Spraying temperature of binder if appropriate.
While working out the job mix formula, the Contractor shall ensure
93
TABLE 500-36. AGGREGATE GRADING AM) BITUMEN CONTENT
Nominal maximum 9.5 13.2 19.0 26.5

size (mm)
Allowable thickness 25-35 36-50 51-75 76-100
(mm)
IS Sieve (mm) Cumulative % by weight of total aggregate passing
37.5 100
26.5 100 90-100
19.0 100 90-100
13.2 100 90-100 - 56-80
9.5 90-100 60-80
4.75 60-80 45-70 35-65 29-59
2.36 35-65 25-55 20-50 19-45
0.30 6-25 5-20 3-20 5-17
0075 2-10 2-9 2-8 1-7
1
Guide to binder content, % by weight of total mixture
Cutback Min 4 to Max 6
Emulsion Min7toMax 10
1
To be determined by the modified Marshall Test.
TABLE 500-37. MIXTURE REQUIREMENTS FOR DESIGNED COLD MIX
Parameter Emulsion1 Cutback 2

Minimum Stability (kN at 22. 2°C) Emulsion
(kN at 25"C) Cutback 2.2 fo r paving 2.2 for maintenance
3.3 for paving
1
50 254
Percent maximum stability loss on soaking 2 2
Minimum flow (mm)
Compaction level (number of blows) 50 75
5
Per cent air voids 3-5 3-5
Per cent voids in mineral aggregate (VMA) Sec Table 500-38
Percent minimum coating' 50 -
1
Notes : Using "Marshall method for emulsified asphalt -aggregate cold mixture design".
Appendix K, MS -14.
2
Using "Marshall method for cut -back asphalt -aggregate cold mixture design". Appendix
H. MS-14.
3
With vacuum saturation Mid immersion.
4
Hour days soak at 25°C.
5
Refers to total voids in the mix occupied by air and water.
6
Coating Test, Appendix 1;, MS-14.
94
TABLE 500-38. MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE (VMA)
Nominal Maximum
Particle Size Minimum VMA (per cent)
IS Sieve (mm)
9.5 16.0
12.5 15.0
19.0 14.0
25.0 13.0
37.5 12.0

Specifications.
by the Engineer for which samples selected jointly with the Engineer of
all ingredients of the mix shall be furnished by the Contractor as required
by the former.
modified by the Engineer. Should a change in the source of materials be
proposed, a new job mix formula shall be established and approved by
the Engineer before actually using the materials.
519.2.2.4. Permissible variation from the 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 500-39. These variations are intended to apply to
individual specimens taken for quality control tests in accordance with
Section 900.
519.2.3.1. Weather and seasonal limitations: Construction with
cold mix must not be undertaken when ambient temperatures below 10°C
are expected, during rain, in standing water, or generally when poor
weather is predicted. Bitumen emulsions and cutbacks depend on the
evaporation of water and/or solvent for the development of their curing
and adhesion characteristics. Cold weather, rain and high humidity slow
down the rate of curing. Extra manipulation may be required to remove
95
TABLE 500-39. PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA

Base/binder course Wearing course6
Aggregate passing 19mm sieve or larger ±8% ±7%
Aggregate passing 4.75mm ±6% ±5%
Aggregate passing 2.36mm, 1.18mm, 0.6mm ±5% ±4%
Aggregate passing 0.075mm ±2% ± 1.5%
Binder content ±0.3% ±0.3%
volatiles in cool and humid conditions. Wind increases the rate of

evaporation.
519.2.3.2. Preparation of the base: The base on which cold mix is
to be laid shall be prepared, shaped and levelled to the required profile in
accordance with Clauses 501 and 902 as appropriate, and a prime coat,
where specified, shall be applied in accordance with Clause 502 or as
519.2.3.3. Tack coat: A tack coat in accordance with Clause 503
shall be applied over the base on which the cold mix is to be laid where
specified in the Contract.
519.2.3.4. Preparation and transportation of the mixture: Mixing
can be carried out using one of the following types of mixer, which is
provided with equipment for spraying the binder at a controlled rate and,
if necessary, for heating the binder to a temperature at which it can be
applied uniformly to the aggregate:
(a) rotary drum type concrete mixer;
(b) single or twin shaft concrete or macadam mixer;
(c) batch or continuous type mixer without dryer or screens other than a scalping screen.
A sufficient number of haul trucks with smooth, clean beds should

be available to ensure continuous operation of the mixing plant. The
type of truck used for transporting the mixture from the mixer to the road
site must be suited to the Contractor's nominated laying procedure
methodology.
519.2.3.5. Spreading: Designed cold mix shall be placed only when
the specified density can be obtained. The mixture shall not be placed on
96
any wet surface or when weather conditions will otherwise prevent it.-,
proper handling or finishing.
If spreading by motor grader, the grader must have a blade that is
straight and sharp and long enough to ensure finishing to close, straight,
transverse tolerances and all joints and linkages must be in good condition.
The grader must be heavy enough to hold the blade firmly and uniformly
on the surface while spreading the mixture.
If climatic conditions and aggregate grading permit evaporation of
moisture or volatiles without aeration by manipulation, a conventional
self-propelled asphalt paver shall be used to place designed cold mix.
Other methods of spreading may be used as approved by the Engineer.
519.2.3.6. Compaction: Initial compaction of the laid material shall
be carried out using a pneumatic-tyred roller of a weight appropriate to
the layer thickness to be compacted with single layer thicknesses being
25-100mm and all compaction being in accordance with Clause 501.6
and Clause 501.7. Smooth tyres shall be used. Final rolling and smoothing
of the surface should be completed using steel wheel rollers. The
Contractor shall demonstrate at laying trials that his proposed laying and
compaction methods can achieve a satisfactory result.
519.2.4. Opening to traffic: Traffic shall not be allowed to run on
new work until all the water or volatiles in the mixture have evaporated,
as determined by the Engineer. The rate of evaporation will be influenced
by the temperature, humidity and wind conditions.
519.2.5. Surface finish and quality control of work: The surface
For control of the quality of supplied materials and the works carried
519.2.6. Arrangements for traffic: During the period of
construction, arrangements for traffic sha ll be made in accordance with
519.2.7. Measurement for payment: Designed Cold Mix shall be
measured as finished work, for the area covered, in cubic metres, by
weight in metric tonnes, or by square metres at a specified thickness as
specified in the Contract.
519.2.8. Rate : The contract unit rate for Designed Cold Mix shall
97
be payment in full for carrying out the required operations including full
compensation for all components listed in Clause 501.8.8.2. (i) to (xi).
The rate shall cover the provision of the specified grade of cutback in the
mix at 5 per cent of the weight of the total mix or emulsion at 8 per cent
of the weight of the total mix, with the provision that the variation of
quantity of binder will be assessed on the basis of the amount agreed by
the Engineer and the payment adjusted as per the rate for cutback or
emulsion quoted in the Bill of Quantities.
Recipe Cold Mix
519.3. Recipe Cold Mix
This Specification is based on BS434:Part 2:1984 which contains
additional information. These are premixes made with emulsion binder
which are laid immediately after mixing and while the emulsion is still
substantially in an unbroken state. These mixes are considered suitable
for use only for emergency and minor repair work and temporary road
surface improvement.
519.3.1. Materials
519.3.1.1. Binder: Emulsions of sufficient stability for mixing with
the particular graded aggregate should be used. Grades of emulsion quoted
are in accordance with BS434: Part 1:1984 but comparable grades to IS
or AASHTO specifications may be used. Guidance on selection of an
appropriate grade of emulsion is given in the Manual for Construction
and Supervision of Bituminous Works. The corresponding grades in
IS:8887 are only broadly classified as RS, MS and SS and further sub-
classification is not available at present.
519.3.1.2. Aggregates: Any normal, clean, but not necessarily dry,
aggregate can be used, provided that it has a sufficiently high crushing
strength with regard to the traffic to be earned. Typical gradings are given
in Table 500-40.
519.3.1.3 Aggregate grading and binder content: When tested in
accordance with IS:2386 Part 1 (wet sieving method)the combined
aggregate grading for the particular mixture shall fall within the limits
shown in Table 500-40. The grade and range of quantity of emulsion are
also indicated in this table. The actual quantity of emulsion to be used
shall be approved by the Engineer after seeing the results of trial mixes
made in the laboratory.
98
TABLE 500-40. COMPOSITION OF RECIPE MIXES
Nominal Size 40 40 14 6
(mm) and Type Single Open textured Open textured Medium Fine coated
of Macadam course base course wearing course textured
wearing course
Allowable
Thickness (mm) 75-100 75-100 31-50 21-30 15-20
IS Sieve
Size mm Cumulative % by weight of total aggregate passing
45 100 100 - - -
37.5 90-100 90-100 - - -
26.5 55-90 55-85 - - -
19 - - 100 - -
13.2 35-55 15-35 90-100 - -
9.5 - - 55-75 100 -
6.3 20-30 - 25-45 90-100 100
3.35 10-20 0-10 15-25 45-65 -
2.36 - - - - 75-100
1.18 - - - 10-30 -
0.60 - - - 30-55
0.30 2-10 - - - -
0.15 - - - - 10-25
0.075 - - 2-6 2-8 5-15
Emulsion grade and quantity
(4)
Generally A2 – 57 or A2 – 50(4)
Under some
circumstances A3 A3
Quantity(1) 55 45 to 70 to 85to 100 to (2)(3)
lit res/stone 70 65 90 100 120
Note: (l) For pricing purposes the lower quantity in these ranges should be assumed
(2) With coarser grading quantity may sometimes be reduced to 80 lilres/stonne and
finer grading it may sometimes be increased up to 135 litres/stonne.
(3) Use 0 - 70 litres/stonne of water as necessary.
(4) A2-50 and A2-57 are Britis h grades of emulsion and their grading system is explained
in the Manual
99

519.3.2.1. Weather and seasonal limitations: Construction with
cold mix must not undertaken when ambient temperatures below 10°C
are expected of generally when poor weather is predicted. Bitumen
emulsion and cutbacks depend on the evaporation of water and/or solvent
for the development of their curing and adhesive characteristics. Cold
weather, rain, and high humidity slow down the rate of curing. Extra
manipulation may be required to remove volitiles in cool or humid
conditions. Wind increases the rate of evaporation.
519.3.2.2. Preparation of base: The base on which the cold mix is
to be laid shall be prepared shaped and graded to the required profile in
accordance with Clauses 501 and 902 as appropriate, and a prime coat if
specified in the contract, or required by the Engineer, shall be applied in
accordance with Clause 502, or as directed by the Engineer.
519.3.2.3. Tack coat: A tack coat in accordance with Clause 503
shall be applied over the base on which the cold mix is to be laid if
specified in the Contract or required by the Engineer.
519.3.2.4. Preparation and transportation of the mixture: Mixing
shall be carried out using one of the following types of mixer, which is
provided with equipment for spraying the binder at a controlled rate,
and, if necessary, for heating the binder to a temperature at which it can
be applied uniformly to the aggregate:
(a) rotary drum type concrete mixer,
(b) single or twin shaft concrete or macadam mixer,
(c) batch or continuous type mixer without dryer or screens other than a scalping screen.
A sufficient number of haul trucks with smooth, clean beds sho uld
be available to ensure continuous operation of the mixing plant. The
type of truck used for transporting the mixture from the mixer to the road
site must be suited to the chosen laying procedure.
519.3.2.5. Spreading: The mixed material should be spread
immediately after preparation. The mixture shall be placed only when
the specified density can be obtained. The mixture shall not be placed on
any wet surface or when weather conditions will otherwise prevent its
proper handling or finishing.
If spreading by motor grader, the grader must have a blade that is
100
straight and sharp and long enough to ensure finishing to close straight
transverse tolerances and all joints and linkages must be in good condition.
The grader must be heavy enough to hold the blade firmly and uniformly
on the surface while spreading the mixture. On surface courses, the tyres
must be smooth.
The methodology for spreading shall be approved by the Engineer
prior to laying, and if required a laying trial conducted to prove the laying
method satisfactory before approval.
519.3.2.6. Compaction: Initial compaction of the laid material shall
be carried out using a pneumatic-tyred roller of a weight appropriate to
the layer thickness to be compacted with single layer thicknesses being
25-100mm and all compaction being in accordance with Clause 501.6
and 501.7. Smooth tyres shall be used. Final rolling and smoothing of
the surface should be completed using steel wheel rollers. The Contractor
shall demonstrate at laying trials that his proposed laying and compaction
methods can achieve a satisfactory result.
519.3.3. Opening to traffic: Traffic shall not be allowed to run on
new work until all the water or volatiles in the mixture have evaporated.
The rate of evaporation will be influenced by the temperature, humidity
and wind conditions.
519.3.4. Surface finish and quality control of work: The surface
519.3.5. Arrangements for traffic: During the period of
construction, arrangements for traffic shall be made in accordance with
519.3.6. Measurement for payment: Recipe Cold Mix shall be
measured as finished work, for the area instructed to be covered, in cubic -
metres, by weight in metric tonnes, or in square metres at a specified
thickness, as specified in the Contract.
519.3.7. Rate
The contract unit rate for Recipe Cold Mix shall be payment in full
for carrying out the required operations including full compensation for
all components listed in Clause 501.8.8.2. (i) to (xi). The rate shall cover
the provision of the specified grade of emulsion at the lower quantity in
101
the range for each type of mix indicated in Table 500-44 with the provision
that the variation of quantity of emulsion will be assessed on the basis of
the amount agreed by the Engineer and the payment adjusted as per the
rate for emulsion quoted in the Bill of Quantities.
520. SAND ASPHALT BASE COURSE1
520.1. Scope
This work shall consist of a base course composed of a mixture of
sand, mineral filler where required and bituminous binder, placed and
compacted upon a prepared and accepted subgrade in accordance with
these Specifications and the lines, levels, grades dimensions and cross
sections shown on the Drawings or as directed by the Engineer,
Note: Sand Asphalt Base course is used in special situations like quality coarse aggregates
not being available within economical leads and/or water needed for conventional
base course not being readily available, as in desert areas.
520.2. Materials
Penetration Grade S65 (60/70) or S90 (80/100), as specified in the
Contract, both as per Indian Standard Specifications for "Paving Bitumen"
IS:73.
520.2.2. Sand: The sand shall be clean, naturally occurring or blended
material free from any deleterious substances, dry and well graded within
the limits given in Table 500-41 and with other physical properties
conforming to the requirements of this table.
520.2.3. Filler: When required, filler shall consist of finely divided
mineral matter such as rock dust, hydrated lime or cement as approved
by the Engineer. The filler shall conform to Clause 507.2.4.
520.3. Mix Design
520.3.1. Requirements for the mixture: Apart from conformity with
1
DG(RD), Ministry of Road Transport & Highways. Transport Bhavan,
Parliament Street, New Delhi 1 10 001. Fax No. * 3710236.
102
TABLE 500-41. SAND GRADING AND PHYSICAL REQUIREMENTS
Sieve Size Cumulative percentage by weight of

(mm) total aggregate passing
9.5 100
4.75 85- 100
2.36 80- 100
1.18 70 - 98
0.60 55 - 95
0.30 30 -75
0.15 10- 40
0.075 4 - 10
Plasticity Index (%) 6 max.
Sand equivalent (IS:2720, Part 37) 30min.
Los Angeles Abrasion Value (IS:2386, part 4) 40 max.
Note : Maximum thickness for sand asphalt is 80 mm.
TABLE 500-42, REQUIREMENTS FOR SAND ASPHALT BASE COURSE
Parameter Requirement
Minimum flow (mm) 2
Compaction level (Number of blows) 2 x 75
Percent voids in mineral aggregate (VMA) > 16
Percent voids filled with bitumen (VFB)' 65 - 75

achieve the requirements of the mixture set out in Table 500-46. The
Marshall method for determining the optimum binder content shall be
adopted as described in The Asphalt Institute Manual MS-2.
520.3.3. Job mix formula : The Contractor shall develop the job
mix formula proposed for use in the works and shall give the following
details:
(n) Proportions of all materials expressed as follows where each is applicable:
(a) Binder, as percentage by weight of total mixture;
(b) Sand/Mineral filler as percentage by weight of total aggregate
including mineral filler;
103
(iii) A single defin ite percentage passing each sieve for the mixed aggregate:
(iv) The results of tests enumerated in Table 500-46 as obtained by the Contractor:
(v) Test results of physical characteristics of aggregates to be used:
vi) Mixing temperature and compacting temperature
While working out the job mix formula, the Contractor shall ensure
Specifications.
by the Engineer for which joint samples of all ingredients of the mix
shall be furnished by the Contractor as required by the former.
modified by the Engineer. Should a change in the source of materials be
proposed, a new job mix formula shall be established and approved by
the Engineer before actually using the materials.
520.3.4. Permissible variation from job mix formula : The
Contractor shall 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 500-43. These
variations are intended to apply to individual specimens taken for quality
control tests as described in Section 900.
520.4.1. Weather and seasonal limitations : Clause 501.5.1 shall
apply.
520.4.2. Preparation of base : The surface on which Sand Aspha lt
Basecourse Material is to be Ltd shall be prepared, shaped and graded to
the profile required for the particular layer in accordance with Clauses
501 and 9(i2 as appropriate or as directed by the Engineer. The surface
shall he thoroughly swept clean free from dust and foreign matter using
a mechanical brush, and the dust blown off by compressed air. In confined
locations where mechanical plant cannot access, other methods shall be
used as approved by the Engineer. A prime coat, where specified, shall
be applied in accordance with Clause 502 or as directed by the Engineer.
104
TABLE 500-43. PERMISSIBLE VARIATIONS FROM I HE JOB MIX FORMULA

Aggregate passing 4.75mm ± 0%
Aggregate passing 2.36mm. 1.18mm. 0.6mm ± 5%
Aggregate passing 0.3mm. 0.15mm ± 4%
Aggregate passing 0.075mm ± 2%
Binder content ± 0.3%
Mixing temperature ± 10°C
520.4.3. Tack coat : A tack coat over the base shall be applied in
accordance with Clause 503, or otherwise as directed by the Engineer.
520.4.4. Preparation and transportation of the mixture : The
provisions of Clauses 501.3 and 501.4 shall apply.
520.4.5. Spreading: The provisions of Clauses 501.5.2 to 501.5.4.
shall apply. Mixing must be accomplished at the lowest temperature and
in the shortest time that will produce a mixture with complete coating of
the aggregate and at a suitable temperature to ensure proper compaction.
The ideal mixing and compaction temperatures for the particular bitumen
in use shall be obtained from the Bitumen Test Data Chart given in the
Manual for Construction and Supervision of Bituminous Works and shall
correspond to a viscosity of 2 Poise (0.2 Pa.s) and 3 Poise (0.3 Pa.s)
respectively, based on the original (unaged) bitumen properties. For
guidance, the ranges of acceptable mixing and rolling temperatures for
some typical penetration grade bitumen are shown in Table 500-5.
520.4.6. Rolling : Clause 501.6 shall apply. Generally the initial or
breakdown rolling sha ll be done with 8-10 tonne deadweight smooth-
wheeled rollers. The intermediate rolling shall be done with 8 -10 tonne
deadweight or vibratory rollers or with a pneumatic tyred roller of 12-15
tonne weight having a tyre pressure of at least 5.6 kg / sq.cm.. The finish
rolling shall be done with 8 - 10 tonne deadweight smooth wheeled tandem
rollers. The exact pattern of rolling shall be established at the laying
trials.
Traffic may be allowed alter completion of the final rolling when the
temperature of the mixture at the mid-depth of the completed layer has
cooled to the daytime maximum ambient temperature. When daytime
105
maximum ambient temperatures are in excess of 35°C, great care is needed

to ensure that this criterion is met. particularly where slow moving heavy
traffic is involved.
out, the relevant provisions of Section WO shall apply.
Sand Asphalt Basecourse materials shall be measured as finished
work, for ihe area covered, in cubic metres, metric tonnes, or in square
metres at a specified thickness, as stated in the Contract.
520.9. Rate
The contract unit rate for Sand Asphalt Basecourse materials shall
be payment in full for carrying out the required operations including full
compensation for all components listed in Clause 501.8.8.2 (i) to (xi).
The rate shall cover the provision of 5 per cent of bitumen by weight of
the total mixture.
The variation from the actual percentage of bitumen approved by
the Engineer and used will be assessed and the rate adjusted, plus or
minus, using the rate for bitumen in the Bill of Quantities.
521. MODIFIED BINDER1
521.1. Scope
Modified binders comprise a base binder, to which is added either
natural rubber, crumb rubber or a polymer such as Styrene- Butadiene-
1
DG(RD). Ministry of Road Transport & Highways, Transport Bhavan,
Parliament Street, New Delhi - 110 001. Fax No. # 3710236.
106
Styrene (SBS), Ethylene-Vinyl- Acetate (EVA) or Low Density

Polyethylene (LDPE). The purpose is to achieve a high performance
binder with improved properties, particularly at extremes of temperature.
521.2. Materials
521.2.1. Base Binder : The base binder into which the modifier is
incorporated shall conform to IS:73. The choice of grade shall be such
that it is compatible with the modifier and, when mixed shall have the
properties described in Clause 521.3.
521.2.2. Modifier : The modifier shall be a natural rubber, crumb
rubber or any other polymer which is compatible with >he base binder
and which allows the properties given in Clause 521.3 to be achieved
For further details, IRC:SP:53-1999 may be referred to. The modifier, in
the required quantity shall be blended at the refinery or at the site plan:
capable of producing modified binder.
521.3. Modifier Proportions
The quantity of modifier to be added shall be determined by tests on
the base binder and the modified binder and the properties desired. A
reference may be made to the Manual for Construction and Supervision
of Bituminous Works for indicative dosage of different types of modifiers.
The properties of the modified binder shall be as given in Table 500-44,
500-45 or 500-46 according to the requirements of the Contract.
521.4. Mixing
The modifier shall be blended with the base binder so that it disperses
thoroughly prior to use. The type of mixing equipment used shall be
suited to the modifier type. Further guidance is given in the Manual for
Construction and Supervision of Bituminous Works.
521.5. Quality Control of Materials
521.5.1. Binder Properties : For control of the quality of the base
binder, the relevant provisions of Section 900 shall apply. Additionally.
the modified binder shall be tested for all the properties listed in Table
500-44, 500-45 or 500-46 as appropriate and certificates produced prior
to use.
During use, the requirements for softening point, penetration and
elastic recovery shall be tested regularly. If the modified binder is producer
107
TABLE 500-44. REQUIREMENTS OF POLYMER MODIFIED BINDERS

(ELASTOMERIC THERMOPLASTICS AND RUBBER LATEX)
Designation Grade and Requirements Method of Test
PMB 120 PMB 70 PMB40
Penetration at 25°C, 0. 1 mm, 90 to 1 50 50 In X9 30 to 49 IS:1203-1978

l00g, 5 sec.
Penetration at 4°C, 0.lmm, 35 22 18 IS:1205-1978

200°, 60 sec.. Minimum*
Softening Point, (R&B), °C, Minim um 38 48 59 IS:1205-1978
Fraass Breaking Point, °C, Maximum * -24 -16 -12 IS:9381-1978
Ductility at 27°C, cm. Minimum 75 50 50 IS:1208-1978
Flash Point, COC, °C, Minimum 220 220 220 IS:1209-1978
Elastic Recovery of Half Thread in 70 60 50 ASTM
Ductilo meter at 15°C, %, Minimum (50)** (40)** (30)** D5976-1996
Separation, Difference in Softening 4 4 4 ASTM
Point, R&B, °C, Maximum D5976-1996
Viscosity at 150°C, Poise 1-3 2-6 4-8 15:1206-1978
Test on Thin Film Oven Test Residue, TFOT(IS:9382-1979)

Penetration at 4°C, 0 1 mm, 200g, 18 15 12 IS:1203-1978

60 sec , Minimum*
Loss in Weight, %., Maximum 1.0 1.0 1.0 IS:9382-1979
Increase in Softening Point, °C, 7 6 5 IS:1205-1978
Maximum
Reduction in Penetration at 25°C, 35 35 35 IS:1203-1978
%, Maximum
Ductilometer at 15°C, %, Minimum (35)** (30)** (25)** D5976-1996
* Relevant to snow bound cold climate areas
** Natural Rubber Modified Bitumen
on site then tests shall be carried out daily. If pre-blended modified binder
is used tests shall be carried out weekly.
521.5.2. Storage Stability : Pre-blended modified binders which
are to be stored without circulation or agitation facility shall be tested for
storage stability prior to use, in accordance with Appendix 1 of IRC:SP:53-
1999. The mean of the differences in softening point, top to bottom, of
108
TABLE 500-45. REQUIREMENTS OF POLYMER MODIFIED BINDERS

(PLASTOMERIC THERMOPLASTICS)
Penetration at 25°C, 0.lmm, l00g, 90 to 1 50 50 to 89 30 to 49 IS:1203-1978

5 sec.
Penetration at 4°C, 0.lmm, 200g, 35 22 18 IS:1205-1978

60 sec.. Minimum*
Softening Point, (R&B), °C, Minimum 38 48 59 IS:1205-1978
Fraass Breaking Point, °C, Maximum* -20 -15 -10 IS:9381-1978
Ductility at 27°C, cm, Minimum 50 40 30 IS:1208-1978
Flash Point, COC, °C, Minimum 220 220 220 IS:1209-1978

Ductilometer at 15°C, %, Minimum D5976-1996
Separation, Difference in Softening 3 3 3 ASTM
Point, R&B, °C, Maximum D5976-1996

Viscosity at 150°C, Poise 1-2 2-4 4-8 IS:1206-1978
Test on Thin Film Oven Test Residue, TFOT (9382-1979)
Penetration at 4°C, 0. 1mm, 200g, 18 15 12 IS:1203-1978

60 sec., Minimum*
Loss in Weight, %, Maximum 1.0 1.0 1.0 IS:9382-1979
Increase in Softening Point, °C, 7 6 5 IS:1205-1978

Maximum

%, Maximum

Ductilometer at 15°C, %, Minimum D5976-1996
* Relevant to snow bound cold climate areas
not less than three pairs of samples shall not exceed 5°C.
Other pre-blended modified binders shall be stored with appropriate
circulation or agitation facility, according to the manufacturer's
instructions.
Modified binder supplied for the Contract shall be paid for in Tonnes.
109
TABLE 500-46. REQUIREMENTS OK POLYMER MODIFIED BINDERS

(TREATED WITH MODIFIED CRUMB RUBBER)
Designation Grade Method of Test
CRMB CRMB CRMB
60 55 50
Penetration at 25°C, 0.1mm, 50-70 50-60 40-60 IS:1203-1978
100 g. 5 sec
Softening Point. (R&B), °C, 50 55 60 IS:1205-1978

Minimum

Ductilometer at 15°C. % Minimum D5976-1996
Test on Thin Film Oven Test Residue (IS:9382-1979)
% Maximum
Increase in Softening Point (R&B), 5 5 5 IS:1205-1978

°C, Maximum
Elastic Recovery of Residue of Half 25 20 15 ASTM

Thread in Ductilometer at 15°C, %, D 5976-1996
Minimum
CRMB - Crumb Rubber Modified Bitumen
521.7 Rate
The contract rate for modified binder shall be as per contract
agreement.
522. CRACK PREVENTION COURSES1
522.1. Scope
This clause covers the provision of Stress Absorbing Membrane
(SAM) and Stress Absorbing Membrane Interlayer (SAMI) as measures
to inhibit the propagation of cracks. A SAM is an elastomeric bitumen
rubber membrane, which is laid over a cracked road surface, together
with a covering of aggregate chips, in order to extend the life of the
pavement before major treatment is carried out. SAM can be laid as a
1
DG(RD), Ministry of Road Transport & Highways, Transport Bhavan,
Parliament Street, New Delhi - 110 001. Fax No. # 3710236.
110
single coat or a double coat. A SAMI is a layer which is applied to a

cracked pavement surface but which is followed (within 12 months) by
the application of an overlay course. A SAMI may be a material similar
to that used for a SAM. It may alternatively consist of a bitumen
impregnated geotextile.
522.2. Materials
522.2.1. Binder : Binder shall be a modified binder complying with
the requirements of Clause 523, according to the requirements of the
Contract, except that paving grade bitumen of 80-100 penetration
complying with the requirements of IS:73 shall be used in the case of a
bitumen impregnated geotextile.
522.2.2. Aggregate : The requirements of Clause 510.2.2 apply
except that the Polished Stone Value requirement does not apply in the
case of a SAMI. Where required by the contract, aggregate shall be pre-
coated using either of the techniques permitted by Clause 510.2.5.
522.2.3. Rates of spread of binder and aggregate : The rates of
spread of binder and aggregate shall be according to one of the size
alternatives in Table 500-47, as required by the Contract.
522.2.4. Geotextile: The use of geotextile as prescribed for SI. No. 7
in Table 500-47 shall conform to the requirements of Clause 704.3 of the
Ministry’s Specification for Road and Bridge Works (third revision) 1995.
522.3.1. Weather and seasonal limitations: Clause 501.5.1 shall
apply.
522.3.2. Preparation of base: The base on which the SAM, SAMI
or bitumen impregnated geotextile is to be laid shall be prepared, in
accordance with Clause 501 and as directed by the Engineer. The surface
shall be thoroughly cleaned either by using a mechanical brush or any
other equipment / method approved by the Engineer. Dust removed in
the process shall be blown off with compressed air.
522.3.3. Application of binder: The equipment and general
and Supervision of Bituminous Works. The application temperature for
modified binder shall be 160-170°C. Binder for bitumen impregnated
111
TABLE 500-47. QUANTITY OK MATERIALS REQUIRED FOR 10 SQ.M. OK

ROAD SURFACE FOR STRESS ABSORBING MEMBRANE
SI. Type and Width of Crack Specification of Quantity Quantity of chipping

No. SAM lobe of binder
applied Kg/10m2
1. Hair cracks and map cracks Single coal SAM 8 - 10 0. 10 m3 of 5.6mm chips
upto 3mm width or 2nd coat of two
coal SAM
2. Map cracks or alligator Single coal SAM 10- 12 0.11m3 of 5.6mm chips
cracks 3mm to 6mm width `
3. Map cracks or alligator Two coat SAM 1 12 – 14 0.12m1 of 5.6mm and

cracks 6mm to 9mm width 1st coat 11.2mm chips in 1:1 ratio
2nd coat 8 – 10 0.103 of 5.6mm chips
4. Cracks above 9mm width and Two coat SAM 14- 16 0.12m3 of 11.2mm chips
cracked area above 50% 1st coat 8 – 10 0.103 of 5. 6mm chips
2nd coat
5. All types of cracks with Single coat SAM 8 – 10 0. 10 m3 of 5.6mm chips.

crack width below 6mm as interlayer
6. All types of cracks with Single coat SAM 10 - 12 0.10m3 of 11.2mm chips.
crack width above 6mm as interlayer
7. Bitumen Impregnated
Geotextile
Note: 1 Binder quantities for bitumen impregnated geotextile shall be in the range 0.9 to 1.2
lures/nr. Binder quantities outside this range are permitted according to the geotextile
manufacturer's instructions and subject to the agreement of the Engineer.
geotextile shall be applied according to Clause 502.4. The surface on

which the binder is to be applied shall be dry.
522.3.4. Application of aggregates : The equipment and general
and Supervision of Bituminous Works. Immediately after application of
the modified binder, clean, dry aggregate shall be spread uniformly on
the surface.
522.3.5. Sweeping : The surface of SAMs and SAMIs shall be swept
to ensure uniform spread of aggregate and that there are no loose chips
on the surface.
522.3.6. Two coat SAM or SAMI: Where a two coat SAM or SAMI
is required by the Contract, the second coat shall be applied within 90
days of the first.
522.3.7. Geotextile placement: For bitumen impregnated geotextile,
113
the requirements of Clause 704.4.5 of the Ministry's Specification for

Road and Bridge Works (third revision) shall apply.
Traffic may be permitted over a SAM or SAMI 2 hours after rolling.
but the speed shall be limited to 20 km/h, until the following day. Speed
control measures are to be approved by the Engineer, prior to laying.
The surface finish shall conform to the requirements of Clause 902.
Each application of SAM, SAMI or bitumen impregnated geotextile
shall be measured as finished work, for the area specified, in square metres.
522.8. Rate
The contract unit rate for SAM, SAMI or bitumen impregnated
geotextile shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 501.8.8.2,
(i) to (xi).
113
Quality Control of
Road Works
900
Quality Control of
Road Works
Quality Control for Road Works Section 900
903. QUALITY CONTROL TESTS DURING CONSTRUCTION

903.4. Tests on Bituminous Construction
903.4.1. Tests and Frequency : The tests and their minimum
frequencies for the different types of bituminous works shall be as given
in Table 900-4. The Engineer may direct additional testing as required.
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:
 1.65 
1.65 − ( No. of Samples) 0.5  times the standard deviation
 
TABLE 900-4. CONTROL TESTS FOR BITUMINOUS WORKS, AND THKIR
MINIMUM FREQ UENCY
SI. Type of Test Frequency (min.)
No. Construction
1. Prime Coat/Tack Coat/ Fog (i) Quality of binder Number of samples per lot
Spray and tests as per 1S:73.
IS:217and IS:8887 as
applicable.
(ii) Binder temperature At regular close intervals

for application
(iii) Rate of spread of One test per 500m2 and not

Binder less than two tests per day
2. Seal Coat/Surface Dressing (i) Quality of Binder Same as mentioned under

Serial No. 1
(ii) Aggregate Impact One test per 50 m3 of

Value/Los Angeles aggregate
Abrasion Value
(iii) Flakiness index and -do-

Elongation Index
(iv) Stripping value of Initially one set of 3

aggregates representative specimens
(Immersion Tray Test) for each source of supply
Subsequently when
warranted by changes in the
quality of aggregates
(v) Water absorption of -do-

aggregates
117
(vi) water sensitivity of mix Initially one set of 3

representative specimens
for each source of supply.
Subsequently when
(if required)
(vii) Grading of aggregates One test per 25 m3 of
aggregate
(viii) Soundness (Magnesium Initially, one determination
and Sodium Sulphate) by each method for each
source of supply, then as
warranted by change in the
quality of the aggregates
(ix) Polished stone value As required
(x) temperature of binder At regular close intervals at
application
(xi) Rate of spread of One test per 500 m2 of work,
materials and, not less than two tests
per day
(xii) Percentage of When gravel is used, one
fractured faces test per 50m3 of aggregate
3 Open-graded Premix (i) Quality of binder Same as mentioned under
Surfacing/Close-graded Serial No. 1
Premix Surfacing
(ii) Aggregate Impact Same as mentioned under
Value/Los Angeles Serial No.2
Abrasion Value
(iii) Flakiness Index and -do-
Elongation Index
(iv) Stripping value Same as mentioned under
Serial No.2
(v) Water absorption of Same as mentioned under
aggregates Serial No.2
(vi) Water sensitivity of mix Same as mentioned under
Serial No. 2
(vii) Grading of aggregates Same as mentioned under
Serial No.2
(viii) Soundness (Magnesium Same as mentioned under
and Sodium Sulphate) Serial No.2
(x) Temperature o I binder At regular close intervals at
application
(xi) Binder content One test per 500m3 and not
less than two tests per day
118
(vi) Water sensitivity of mix Initially one set of 3

for each source of supply.
Subsequently when
(if required)
(vii) Grading of aggregates One test per 25 m3 of
aggregate
(viii) Soundness (Magnesium Initially, one determination
and Sodium Sulphate) by each method for each
source of supply, then as
warranted by change in the
quality of the aggregates.
(x) temperature of binder At regular close intervals at
application
(xi) Rate of spread of One test per 500 m2 of work,
materials and, not less than two tests
per day
(xii) Percentage of When gravel is used, one
fractured faces test per 50m3 of aggregate
3. Open-graded Premix (i) Quality of binder Same as mentioned under
Surfacing/Close-graded Serial No. 1
Premix surfacing
Value/Los Angeles Serial No.2 5ef71>/f.
Abrasion Value
Elongation Index
Serial No.2
aggregates Serial No.2
(vi) Water sensitivity of mix Same as mentioned under
Serial No. 2
(vii) Grading of aggregates Same as mentioned under
Serial No.2
(x) Temperature o I binder At regular close intervals at
application
(xi) Binder content One test per 500m3 and not
less than two tests per day
118
(xii) Rate of spread of Regular control through

mixed material checks of layer thickness
(xiii) percentage of fractured Same as mentioned under
faces Serial No.2
4. Bituminous Macadam (i) Quality of binder Same as mentioned under
Serial No 1
Abrasion Value
(iii) Flakiness Index and Same as mentioned under
Elongation Index Serial No.2
(iv) Stripping Value Same as mentioned under
Serial No.2
(v) Water sensitivity of mix -do-
(vi) Grading of aggregates Two tests per day per plant
both on the individual
constituents and mixed
aggregates from the dryer
(vii) Water absorption of Same as in Serial No. 2
aggregates
(ix) Percentage of fractured Same as mentioned under
faces Serial No.2
(x) Binder content and Periodic, subject to
aggregate grading minimum of two tests per
day per plant
(xi) Control of temperature At regular close interval
of binder and aggregate
for mixing and of the
mix at the time of laying
and rolling
(xii) Rate of spread of mixed Regular control through
material checks of layer thickness
(xiii) Density of compacted One test per 250m2 of area
layer
5. Bituminous Penetration (i) Quality of binder Same as mentioned under
Macadam/Built-up Serial No. 1
Spray-Grout
(ii) Aggregate Impact One test per 200 m3 of
Value/Los Angeles aggregate
Abrasion Value
Elongation Index
119

Serial No. 2
(v) Water absorption of Same as Serial No. 2
aggregates
(vi) Water sensitivity of mix Same as Serial No. 2
(vii) Aggregate grading One test per 100 m3 of
aggregate
(viii) Soundness (Magnesium Same as mentioned under and
Sodium Sulphate) Serial No.2
faces Serial No.2
(x) Temperature of binder At regular close intervals at
application
(xi) Rate of spread of binder Same as mentioned under
Serial No.2
6. Dense Bituminous (i) Quality of binder Same as mentioned under
Macadam/Semi Dense Serial No. 1
Bituminous Concrete/
Bituminous Concrete (ii) Aggregate Impact Same as mentioned under
Abrasion Value
Elongation Index
(iv) Stripping Value Same as mentioned under
Serial No.2
(v) Soundness (Magnesium Same as mentioned under
(vi) Water absorption of As in Serial No. 2
aggregates
(vii) Sand equivalent test As required
(viii) Plasiticity Index As required
(ix) Polished stone value As required, for Semi Dense
Bituminous Concrete/
Bituminous Concrete
(x) Percentage of fractured) Same as mentioned under
faces Serial No. 2
(xi) Mix grading One set of tests on
individual constituents and
mixed aggregate from the
dryer for each 400 tonnes of
mix subject to a minimum of
two tests per plant
per day
120
(xii) Stability of Mix For each 400 tonnes of

mix produced, a set of 3
Marshall specimens to be
prepared and tested for
stability, flow value,
density and void content
subject to a minimum of
two sets being tested per
plant per day
(xiii) Water sensitivity of mix Samc as mentioned under
(Retained Tensile Serial No.2
Strength)
(xiv) Swell test on the mix As required for the
Bituminous Concrete
(xv) Control of temperature At regular close intervals
of binder in boiler,
aggregate in the dryer
and mix at the time of
laying and rolling
(xvi) Control of binder One test for each 400 tonnes
content and grading of of mix subject to a
the mix minimum of two tests per
day per plant
(xvii) Rate of spread of mixed Regular control through
material checks on the weight of
mixed material and layer
thickness
(xviii) Density of compacted One test per 250 m2 area
layer
7. Mastic Asphalt (i) Quality of binder Same as mentioned under
Serial No. 1
Abrasion Value
Elongation Index
(iv) Stripping Value -do-
(v) Water sensitivity of mix do-
(vi) Grading of aggregates Two lefts per day per plant
(vii) Water absorption of Same as in Serial No. 2
aggregates
121

faces Serial No.2
(x) Binder content and Periodic, subject to
aggregate grading minimum of two tests
per day per plant
(xi) Control of temperature At regular close intervals
for mixing and of the mix
at the time of laying
and rolling
(xii) Rate of spread of mixed Regular control through
material checks of layer thickness
(xiii) Hardness number One test for each 400 tonnes
of mix subject to a
minimum of two tests
per day
8. Slurry-seal (i) Quality of binder Same as mentioned under
Serial No. 1.
(ii) Film stripping test Initially one set of 3
for each source of supply,
then as warranted by
changes in the quality of
aggregates
9. Recycled material (i) Binder content and Minimum of one test per
aggregate grading 25 m3 of recycled material
(ii) Recovered hinder Minimum of one test per
penetration 50m1 of recycled material
(iii) Mix stability (Remix/ For each 400 tonnes of mix
Repave) recycled, a set of 3 Marshall
specimens to be prepared
and tested for stability, flow,
density and void content,
subject to a minimum of two
sets of tests per day
10. Cold Mix (i) Quality of binder Same as mentioned under
Serial No. 1
Value/Los Angles Serial No. 2
Abrasion Value
Elongation Index
(iv) Striping Value -do-
(v) Water sensitivity of mix -do-
122
(vi) Grading of aggregates Two tests per day per plant

(vii) Percentage minimum Two tests per day per plant
coaling
(viii) Water absorption of Same as in Serial No. 2
aggregates
(ix) Soundness (Magnesium Same as mentioned under
(x) Percentage of fractured When gravel is used, one
faces test per 50m3 of aggregate
(xi) Binder content and Periodic, subject to
aggregate grading minimum of two tests per
day per plant
(xii) Mix stability For each 400 tonnes of mix
produced, one set of 3
stability, (low, density and
void content, subject to a
minimum of two sets of
tests per plant per day
11. Sand Asphalt Base Course(i) Quality of binder Same as mentioned under
Serial No. 1
(ii) Los Angeles Abrasion Same as mentioned under
Value Serial No.2
(iii) Sand equivalent test As required
(iv) Plasiticity Index As required
(v) Mix grading One set of tests on
individual constituents and
mixed aggregate from the
dryer for each 400 tonnes of
mix subject to a minimum
of two tests per plant per
day
(vi) Stability of Mix For each 400lonnesofmix
produced, a set of 3
stability, flow value, density
and void content subject lo
a minimum of two sets
being tested per plant
per day
123
(vii) Control of temperature At regular close intervals

and mix al the time of
laying and rolling
(viii) Control of binder One test for each 400 tonnes
content and grading of of mix subject to a
the mix minimum of two tests
per day per plant
(ix) Rate of spread of mixed Regular control and through
maternal checks on the weight of
mixed material and layer
thickness
(x) Density of compacted One test per 250 m- area
layer
12. Modified Binder (i) Softening Point Initially on submission
thereafter daily if site
blended, weekly if pre -
blended
(ii) Penetration at 25"C -do-
and 4°C
(iii) Elastic Recovery -do-
(iv) Ductility -do-
(v) Flash Point -do-
(vi)
Fraass Breaking Initially on submission
(vii) Viscosity at 150°C -do-
(viii) Thin film oven test, -do-
penetration, softening
point, elastic recovery
of residue, loss on
heating
13. Geotextiles (i) The requirements of
Clause 704.3.1 of the
Ministry's Specification
for Road and Bridge
Works (third revision)
shall apply
124
Maintenance of Road
3000
Maintenance of Road
125
126
Maintenance of Road Section 3000
3004. BITUMINOUS WORK IN CONNECTION WITH

3004.1. General
The scope and type of maintenance work to be carried out shall be in
accordance with the provisions of the Contract or as instructed by the
Engineer.
In all instances it will have been necessary to identify the causes of
defects in order to permit effective repair. Where investigation work into
the causes of defects is included in the Contract it shall be carried out in
accordance with the appropriate provisions of this Specification.
Maintenance treatments required under the Contract or instructed by
the Engineer may include pothole and patch repair, crack-sealing, fog
spray, dusting, slurry sealing, surface dressing, overlays and specialist
repairs.
When the pavement to be maintained is intended to carry volumes of
traffic in excess of 1.5 million e.s.a. the constructed materials (particularly
patching and overlay materials) used in maintenance operations shall be
of a standard not less than those specified for the original construction.
Traffic control during maintenance operations shall conform to the
requirements of the Contract documents.
3004.2. Filling Pot-holes and Patch Repairs
3004.2.1. Scope : This work shall include repair of potholes and
patching of all types of bituminous pavement.
The work shall include the removal of all failed material, in the
pavement courses and, if necessary, below the pavement, until the root
cause of the failure is removed; the trimming of the completed excavation
to provide firm vertical faces; the replacement of material of at least as
high a standard as that which was originally specified for the pavement
layer; the painting of tack coat on to the sides and bases of excavations
prior to placing of any bituminous materials and the compaction, trimming
and finishing of the surfaces of all patches to form a smooth continuous
surface, level with the surrounding road.
3004.2.2. Materials : All materials used for the pot- hole and patch
repair of bituminous surface and underlying layers shall be in accordance
127
with this Specification and shall be of the same type as specified for the
original construction. A mix superior to the one on the existing surface
may also be used for repair work. An emulsified bitumen / modified
bitumen mix compatible with the existing layer shall also be considered
appropriate.
The bituminous mixture used for such patch repairs shall be in
accordance with the appropriate Clause of these Specifications. Materials
to be used for patching shall always be of the same type and standard of
construction as, or better than, the material being patched at the same
level of construction. Materials used for patching shall never be of lesser
bearing capacity nor of a greater porosity than the adjacent previous
construction. Non-bituminous material must not be used for patching
bituminous materials. Where modified binder is to be used, Clause 521
of these Specifications shall apply.
The grading of aggregates and bitumen content of the mix used for
such patch repair shall be in accordance with Clause 501.
3004.2.3. Preparation of the 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 jac k hammers
or with hand tools suitable for the purpose, such that the defective material
responsible for the failure is all removed and such that the excavation is
of a regular shape.
The edges of the excavation shall be cut vertically. The area shall be
thoroughly cleaned with compressed air or any appropriate method
approved by the Engineer to remove all dust and loose particles. Layers
below the level of the bituminous construction shall be replaced using
material of the equivalent specification to the original construction, which
shall particularly include the specified standards of compaction. The area
for bituminous construction shall be tacked or primed with cutback or
emulsion depending upon whether the lower area is bituminous or granular
in nature. The sides, however, are to be painted with hot tack coat material.
The prime coat and tack coat shall conform to Clauses 502 and 503 of
these Specifications, respectively.
3004.2.4. Backfilling operation : The mixture to be used in
bituminous patching shall be either a hot mix or a cold mix in accordance
with the appropriate Clauses of these Specifications. Mixing shall be
128
done in a plant of suitable capacity. The bituminous mixture shall be

placed in layers of thickness not more than 100 mm (loose) and shall be
compacted in layers with roller/plate compactor/hand roller/rammer to
the compaction standards defined in the appropriate Clauses of these
Specifications. 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 shovels and wooden straight edges.
During the process of compaction, the surface levels sha ll be checked
using a 3m straight edge.
3004.2.5. Measurement for payment: Filling of pot-holes and patch
repair shall be measured in sq.m.
3004.2.6. Rate : The contract unit rate for filling of potholes and
patch repair shall be payment in full for:
(i) furnishing all materials required:
(ii) all works involved including excavation, trimming, back filling with any non-
bituminous layers required, tacking, priming with cutback or emulsion, and back
filling with bituminous materials;
(iii) all labour, tools, equipment and incidentals to complete the work in accordance with
the Specifications.
3004.3. Crack Sealing

3004.3.1. Scope: Crack sealing shall consist of one or more of the
following operations as instructed under the Contract:
(i) fog seal
(ii) filling cracks with a binder, or a combination of crusher dust and a binder
(iii) by treating the crack sealing as a patch repair.
3004.3.2. Fog Seal

3004.3.2.1. Scope : Fog seal for use in maintenance work shall
conform to the requirements of Clause 518 of these Specifications, and
shall consist of an application of emulsified bitumen, without any
aggregate cover for sealing fine hair-cracks or for rejuvenating oxidised
bituminous surfaces. Areas having cracks with less than 3mm width shall
be considered for this treatment, unless otherwise instructed by the
Engineer.
129
3004.3.2.2. Material: Bituminous emulsion for Fog Seal shall be of

a slow setting type. Where modified binder is to be used, Clause 521 of
these Specifications shall apply.
3004.3.2.3. Application : The area to be treated with fog seal shall
be thoroughly cleaned using compressed air, scrubbers, etc. The cracks
shall be cleaned with a compressed air jet to remove all dirt, dust, etc.
The fog seal shall be applied at the rate of 0.5-1.0 litre/sq.m. of emulsion,
or as otherwise instructed by the Engineer, using equipment such as a
pressure tank, flexible hose and spraying bar or lance. Traffic shall be
allowed on to the surface only after the seal has set to a non-tacky and
firm condition so that it is not picked up by the traffic.
3004.3.2.4. Measurement for payment: The fog seal work shall be
measured in sq.metres, calculated from the dimensions of work instructed
in the Contract or by the Engineer.
3004.3.2.5. Rate : The contract unit rate for application of fog seal
shall be payment in full for:
(i) supplying of fog seal material and all the operations for applying it; and
(ii) all the labour, tools, equipment and incidentals to complete the work in accordance
with this Specification.
3004.3.3. Crack filling

3004.3.3.1. Scope: Crack filling shall be carried out using a binder
of a suitable viscosity, normally a slow-curing bitumen emulsion, as
instructed by the Engineer. For wider cracks, in excess of an average of
3 mm in width the application of emulsion may be preceded by an
application of crusher dust, or other fine material acceptable to the
Engineer.
3004.3.3.2. Materials: Bitumen for use in crack sealing shall be of a
slow curing type as instructed by the Engineer. Dust for crack sealing,
when used, shall be crusher dust or some other suitable fine material
approved by the Engineer, passing the 4.75 mm sieve but with a maximum
of 10% passing the 0.075 mm sieve.
3004.3.3.3. Construction: If dust is to be used it shall be placed in
the cracks before the application of binder and the cracks filled to a level
approximately 5 mm below road surface level. The surface of the road
shall be swept clear of dust prior to the application of binder. Binder
130
shall be poured into the cracks, taking care to minimise spillage. If spillage
onto the road surface does occur, dust shall be applied to the excess
bitumen until it is blotted up.
3004.3.3.4. Measurement: Crack sealing shall be paid by the linear
metre of crack as instructed by the Engineer.
3004.3.3.5. Payment: The contract rate for crack sealing shall be
payment in full for:
(i) supplying all necessary materials and for the work of applying them;
(ii) all labour, tools, equipment and all incidentals necessary to complete the work
according to these Specifications.
3004.3.4. Crack prevention courses: Clause 522 specifies crack

prevention courses. These may be included in substantial maintenance
treatments.
3004. 4. Dusting
3004.4.1. Scope: Dusting shall consist of the application of crusher
dust or other fine graded material approved by the Engineer to areas of
road where bleeding of excess bitumen is occurring.
3004.4.2. Material: Dust shall consist of crusher dust or other graded
fine material acceptable to the Engineer, and shall generally be finer than
3.0 mm with not more than 10% passing the 0.075 mm sieve.
3004.4.3. Dust shall be spread by manual application, to the areas of
road defined by the Engineer. Dust shall generally be applied during the
hottest part of the day and, when so instructed by the Engineer, surplus
dust displaced by passing traffic shall be manually swept back onto the
area where further bleeding of excess bitumen is apparent. Dust shall be
applied at a nominal rate of 2.5 kg per square metre.
3004.4.4. Measurement: Dusting shall be paid for by the square
metre of road surface instructed to be dusted by the Engineer.
3004.4.5. Payment: The Contract unit rate for dusting shall be in
payment in full for:
(i) supplying all necessary materials and for the work of applying them;
(ii) all labour, tools, equipment and all incidentals necessary to complete the work
according to the Specifications.
131
3004.5. Slurry Seal

Slurry seal for use in maintenance work shall conform to the
requirements of Clause 516. Manual methods of spreading and levelling
may be used, subject to the prior agreement of the Engineer.
3004.6. Surface Dressing for Maintenance Work
Surface dressing for maintenance applications shall he carried out in
conformity with the requirements of Clause 510, except that the use of
small and portable equipment shall be permitted provided that it can be
demonstrated, to the satisfaction of the Engineer, that it can produce work
consistently in accordance with the requirements of these Specifications.
3004.7. Specialist Repairs
3004.7.1. Specialist repairs include repairs of localized areas of
damage to materials for which repairs using normal hot- mix or cold- mix
patching materials are inappropriate. Such specialist repairs will include
repairs to mastic asphalt and stone mastic asphalt.
3004.7.2. In such cases, pot-hole and patch repairs shall be carried
out in accordance with the provisions of Clause 3004.2 above, except
that the construction to the mastic asphalt, stone mastic asphalt or other
specialist material layer shall, subject to the instructions of the Engineer,
be carried out in accordance with the provisions of the appropriate Clause
of these Specifications.
132
List of Indian and Foreign
Standards Referred to in the
Specifications
(A) INDIAN STANDARDS
Number Designation Title
IS:73-1992 Paving Bitumen-Specification
IS:2 17-1988 Cutback Bitumen-Specification
IS:454-1961 Cutback Bitumen from Waxy Crude-
Specification
Methods of Testing Tar and Bituminous
Materials
IS: 1203-1978 Determination of Penetration
IS:1205-1978 Determination of Softening Point
IS: 1206-1978 Determination of Viscosity
IS:1208-1978 Determination of Ductility
IS: 1209-1978 Determination of Flash Point and Fire Point
IS: 1212-1978 Determination of Loss of Heating
IS:1216-1978 Determination of Solubility in Carbon
Disuiphide or Trichoroethylene
IS: 1217-1978 Determination of Mineral Matter (Ash)
IS:1514-1959 Methods of Sampling and Test for
Quicklime and Hydrated Lime
IS:2386-1963 Methods of Test for Aggregates for Concrete
Particle Size and Shape
Part 1 Specific Gravity, Density, Voids, Absorption and
Part 3 Bulking
Mechanic Properties
Part 4 Soundness
Part 5 Methods of Tests for Soils
IS:2720 Determination of Liquid and Plastic Limits
Part 5-1985
135
Part 37-1976 Determinatio n of Sand Equivalent Values of
Soils and Fine Aggregates
IS:5317-1987 Specification for Bitumen Mastic for
Bridge Decking and Roads
IS:5435-1969 General Requirements for Cold
Bituminous Macadam Mixing Plants
IS:6241-1971 Methods of Test for Determination of
Stripping Value of Road Aggregates
JS:8887-1995 Bitumen Emulsion for Roads (Cationic
type)-Specification
IS:9381-1979 Methods of Testing Tar and Bituminous
Materials: Determination of Fraass
Breaking Point of Bitumen
IS:9382-1979 Methods of Testing Tar and Bituminous
Materials: Determination of Effect of Heat
and Air by Thin Film Oven .Tests
136
(B) FOREIGN STANDARDS
ASTM:D977-9 1 Standard Specification for Emulsified Asphalt
Standard Practice for Sampling Bituminous
ASTM: D979-89 Paving Mixtures
Standard Specification for Cutback Asphalt
ASTM:D2026-72 (Slow-Curing Type)
(Reapproved 1993) Standard Specification for Cutback Asphalt
(Medium-Curing Type)
ASTM:D2027-76 Standard Test Method for Theoretical
(Reapproved 1992) Maximum Specific Gravity and Density of
Bituminous Paving Mixtures
ASTM:D2041-95 Standard Test Methods for Quantitative
Extraction of Bitumen From Bituminous
ASTM:D2172-95 Paving Mixtures
Standard Specification of Cationic Emulsified
ASTM:D2397-94 Asphalt
Standard Test Method for Per cent Air
ASTM:D3203-94 Voids in Compacted Dense and Open
Bituminous Paving Mixtures
Standard Practices for Design, Testing and
ASTM:D3910-90 Construction of Slurry Seal
(Reapproved 1995) Standard Specification for Type I Polymer
ASTM:D5976-96 Modified Asphalt Cement for Use in
Pavement Construction
Equivalent to ASTM:D2027-76 or
AASHTO:M82 ASTM :D2026-72
Equivalent to ASTM:D977-9 I
AASHTO:M 140 Coating and Stripping of Bitumen Aggregate
AASHTO:T182-84 Mixtures
137
AASHTO:M208 Equivalent to ASTM:D2397-94
AASHTO:T283-89 Resistance of Compacted Bituminous
Mixture to Moisture Induced Damage
BS:434 : Bitumen Road Emulsions (Anionic and
- Part 2:1984 Cationic)
- Part 2:1984 Specification for Bitumen Road Emulsion
Code of Practice for Use of Bitumen Road
Emulsions
BS:598 Sampling and Examination of Bituminous
Mixtures for Roads and other Paved Areas
- Part 104:1987 Methods of Test for the Determination of
Density and Compaction
- Part 107:1990 Method of Test for the Determination of
the Composition of Design Wearing Course
Rolled Asphalt
BS:812 Testing Aggregates
- Part 114:1989 Method for Determination of the Polished-
Stone Value
BS:2000 Methods of test for Petroleum and its
products.
- Part 397:1995 Recovery of Bitumen Binders
Dichloromethane Extraction Rotary Film
Evaporator Method
BS:DD232 1996 Method for Determination of the Maximum
Binder Content of Bituminous Mixtures
without excessive binder drainage.
Asphalt Institute Manual Series No. 2 (MS-2)- Mix Design
Methods for Asphalt Concrete and Other
Hot-Mix Types.
Manual Series No. 14 (MS-14)- Asphalt
Cold Mix Manual.
138

During the period of construction, arrangement for the traffic shall
be done to Clause 112.
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 112;
(ii) Providing all materials to be incorporated in the work, including all royalties,
fees, rents where necessary and all leads and lifts;
(iii) All labour, loots, equipment, plant and incidentals to complete the work
to the Specification;
(iv) Carrying out the work in part width of the road where directed; and
(v) Carrying out 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
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
(iij) Portland Poziolana Cemeni IS : 1489
If the subgrade is found to consist of soluble sulphates in a

concentration more than 0.5 per cent, cement used shall be sulphate
resistant and shall conform to IS: 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.
601.2.3. Aggregates:
601.2.3.1. Aggregates for lean concrete shall be natural material complying
with IS: 383. The aggregates shall not be alkali reactive. The limits
211
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
din, 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 he 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 shall be free from soft particles, clay,
shale, loam, cemented particles, mica, organic and other foreign matter.
The fine aggregate shall comply with Clause 602.2.4.3.
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 together
intimately before use.
(ii) Separately as 25 mm nominal single size, 12.5 mm nominal size graded aggregates -
and Tine 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 600-1.
TABLE 600-1. AGGREGATE GRADATION FOR DRY LEAN CONCRETE
Sieve Designation Percentage passing the

sieve by weight
26.50 mm 100
19.00 mm 80-100
9.50 mm 55-75
4.75 mm 35-60
600.00 micron 10-35
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
212
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 use in 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 lest
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
60L3.1. The mix shall be proportioned with a maximum aggregate
cement ratio of 15 : 1. The waiter content 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 concrete to be heaving up before
the wheels and 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 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.
601.3.3. Cement content: The minimum cement content in the
lean concrete shall not be less than 150 kg/cu.m. of concrete. If this
minimum cement content is not sufficient to produce concrete of UK
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
shall be got approved from the Engineer and demonstrated in the trial
length construction.
601.4. Subgrade
The subgradc 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.
601.5. Construction
601.5.1. General: The pace and programme of the lean concrete sub-
base construction shall be matching suitably with the programme of
construction 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 ha ving 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 ±1 per 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 601.5.5.2 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 concrete 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
snail 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 i he 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 compact-
tion and immediately before overlaying, shall be well closed, free from
movement under roller and free from ridges, 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 he
spread and compacted. It is necessary to check the level of the rolled
216
surface for comp liance. 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 wilh 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 shall be done by spraying with liquid curing compound. The
curing compound shall he white pigmented or transparent type with water Mention
index 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 lost its tackiness, the surface shall be covered with wet hessian for
three days.
(b) Curing shall be done by covering the surface by gunny bags/hessian, which
shall be kept continuously moist for 7 days by sprinkling water.
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 percent 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 mo isture 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
717
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 day-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 sha ll 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, plant, 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 lenglh 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 repealed till the Contractor proves his ability to satisfactorily construct
the subbasc.
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.
601.7.3. 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 from 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 surfa ce 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.
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
be payment in full for carrying out the required operations including
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 trie
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 before 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 10

acceptance test just prior to its use.
602.2.3. Admixtures : Admixtures conforming to IS:6925 and IS:
9103 shall be permitted to improve workability of the concrete or
extension of setting time, on satisfactory evidence that they will not have
any adverse effect on the properties of concrete with respect to strength,
volume change, durability and have no deleterious effect on steel bars.
The particulars of the admixture and the quantity to be used, must be
furnished to the Engineer in advance to obtain his approval before use.
Satisfactory performance of the admixtures should be proved boih 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 sha ll 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 (S03) 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 approved
manner. In case the Engineer considers that the aggregates are not free
221
from din, 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 10 per cent
Material pissing IS Sieve No. 75 micron 4.0 per cent
be clean and free from injurious amount of oil, sail, 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 shall conform to Grade S 240 and tie bars to
Grade S 415 of I.S.
602.2.7. Premoulded joint filler: Joint filler board for expansion
joints which are proposed for use only at some abutting structures like
bridges and culverts shall be of 20-25 mm thickness within a tolerance
of ± 1.5 mm and of a firm compressible material and complying
with the requirements of IS: 1838, or BS Specification Clause No. 2630
or Specification for Highway Works, Vol. I Clause 1015. It shall be 25
mm less in depth than the thickness of the slab within a tolerance of ±
3 mm and provided to the full width between the side forms. It shall
be in suitable lengths which shall not be less than one lane width. Holes
to accommodate dowel bars shall be accurately bored or punched out to
give a sliding fit on the dowel bars.
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).
602.2.9. Storage of materials: All materials shall be stored in
accordance with the provisions of Clause 1014 of the Specifications and
other relevant IS Specifications. Ail 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 dram to drain off rain
water. The storage space must also permit easy inspection, removal
and storage of the materials. Aggregates of different sizes 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 15:10262 (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 drawings/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 strengt hs shall be

established for die 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, die 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, die 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 die 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 die 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 proportions
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 and Specifica-
tions 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 repaired with
fine cement concrete or bituminous concrete before laying separation
layer. Prior 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 damage.
602.5. Separation Membrane
A separation membrane shall be used between the concrete slab and
the subbase. Separation membrane shall be impermeable plastic sheeting
125 microns thick laid flat without creases. Before placing the separation
membrane, the sub-base shall be swept clean of all the extraneous
materials using air compressor. Wherever overlap of plastic sheets is
necessary, the same shall be at least 300 mm and any 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 their functional
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 1m 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
construc ted at the spacing described in the Drawings. Transverse joints
shall be straight within the following tolerances 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 she 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 ± 10 mm.
(ii) The best fit straight line through the joint grooves as constructed shall be
not more than 25 mm from the intended line of the joint.
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 mm.
(iv) Transverse joints on each side 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 .he slab ± 5 mm or as stipulated in the drawings and dowel bars
complying with Clause 602,6.5 and as detailed in the drawings.
The contraction joints shall 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. Expansion joints: The expansion joints shall consist of a
joint filler board complying with Clause 602.2.7 and dowel bars comply-
ing with Clause 602.6.5 and as detailed in the drawings. The filler board
shall be positioned vertically with the prefabricated joint assemblies along
226
the line of the joint within the tolerances given in Clause 602,6.2.1. and
at such depth below the surface as will not impede the passage of the
finishing straight edges or oscillating beams of the paving machines. The
adjacent slabs sha ll 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.
602.6.3. 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 he 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 head/
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 m 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 longitudinal 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 prefabricated 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 placemen
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. They shall be aligned parallel to the finished
surface of the slab and to the centre line of the carriageway and to each
other within tolerances given hereunder, the compliance of which shall
be checked as per Clause 602.10.7,
(i) For bars supported on cradles prior to the laying of the slab:
(a) All bars in a joinl shall be within ± 3 mm pet 300 mm lenglh 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 lenglh of bar in either the horizontal or vertical plane
(d) Cradles supporting dowel bar shall nol extend across the line of joint i.e. no
steel bar of the cradle assembly shall be continuous across the joinl.
(ii) For all bars inserted 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 [he lop edge of the filler 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 distributed over a length of 600 mm by means
of a bat or timber packing, at mid depth and midway between 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 1.3kN load applied
for testing the rigidity of the assembly but shall fail before the 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 reaches 2.6 kN when applied over a length of 600 mm by 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 form of fixing, under the test load. The displacement
shall be measured at the nearest part of the assembly lo the centre of the bar or
limber 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
joints 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 n 150 x 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 mm. The average bond stress to achieve
this movement shall not be greater than 0.14 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 GI 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 comp ressible 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 15:1786 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 75mrn 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 tic 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
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 die surface and approximately perpendicular to the line of the
joint, with the centre of each bar on the intended line of the joints within
a tolerance of ± 50mm, and with a minimum cover of 30 mm below the
joint groove,
602.7.1. 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 lime when it rains, all freshly
laid concrete which had not been covered for curing purposes shall be
adequately protected. Any concrete damaged by rain shall be removed
and replaced. If the damage is limited to texture, it shall be retextured in
accordance with the directives of die 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 accommodate
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 subbase.
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,
602.8.3. 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 shali 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 ± 3mrn.
Additionally, one of the wires shall be kept al 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 mm apart by connectors capable of fine horizontal and vertical adjust-
ment. The guidewire shall be lensioned 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 al 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, situated 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
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-resetnble 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 the job 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 1 month.
233
(5) Control cabin - An air-conditioned centralised control cabin

shall be provided for automatic operation of the equipment.
602.9.3.3. 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 10 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
234
shall not exceed 120 minutes when concrete temperature is less than 25°C
and 90 minutes when the concrete temperature is between 25°C to 30°C.
Trucks/tippers delivering 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 pavers 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. In 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 upto 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 overworking.
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-off the concrete shall be capable
of being rapidly adjusted for changes of the average and differential
surcharge necessitated by 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 laying speed 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 required
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
1. Between 24 hours and 7 days after An average of 1.00 ±0.25
the constn., of the slab or until 5 measurements
(he dab is first used by vehicles.
2. Not later than 6 weeks before the An average of 1.00 ±0.25
mad is opened to public 5 measurements ±0.35
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 impervious
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 impervious
to evaporation of water from the surface of the concrete within 60
minutes of application and shall be of approved type. The curing compounds
shall have a water retention efficiency index of 90 per cent in accordance
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/torn 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 oil • month in
advance of the proposed start of concrete paving work. At least one
month prior to the construction of the tria l 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 clay 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 of permitted irregularities of pavement surface shall comply
with the requirements of Clause 902.4. Shorter trial lengths shall be assessed pro-
rata 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 my
two consecutive transverse joint. If the position or alignment of the dowel bars
at one of these joints does not comply with Clause 602.6.5. if that joint remains
the only one that does not comply after the next 3 consecutive joints of the same
typo 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 arc 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 trial
expansion joints shall be made as pan of the trial length which shall not form part
of die permanent works, unless agreed by the Engineer.
240
602.10.5.3. Density
(v) Density shall be assessed as described in Clause 602.3.3. from at leasl 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 been removed, unless that can be remedied to the satisfaction
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 Specificatio n,
with the exception of areas which are deficient only in surface texture and
which can be remedied in accordance with Clause 602.9.8.6 shall be
removed immediately upon notification of deficiencies by 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 shall be measured after
carefully exposing them in the plastic concrete across die 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. After 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,
602.10.7.3. 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 1m 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
described in 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.
Depth/width 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 shall be sawn wider
and perpendicular to the surface to encompass the defects upto a maximum
width, 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 shall 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 sealing the temporary seal provided for blocking
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 shall 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
be inserted to block the leakage through bottom of the joint.
602.11.3. Sealing with sealants
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 be cleaned our at the end of each day in accordance with
the manufacturer's recommendations and reheated material 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
lime limit specified by the manufacturer. If primers are recommended
they shall be applied neatly with an appropriate brush. The Movement
Accommodation Factor (MAP) 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 sealants: 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
602.12.1. The following apparatus shall be used:
(i) A cylindrical container of 25 ml internal capacity
(ii) A flat wooden disc 64 mm diameter with a hard rubber disc. 1,5mm thick, slack
to one face, the reverse face being provided with a handle
(iii) Dry natural sand with a rounded particle shape passing a 300 micron IS sieve and
retained on a 150 micron IS 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
31000/(D×D) 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 arc permanently sealed. The road may be opened to
regular traffic after completion of the curing period of 28 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 pave ment 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
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, debonding strip, sealant
primer, joint sealant, dowel bar and tie rod.
602.15.2. Pavement thickness
All precautions and care shall be 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 rri 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 it 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.
TABLE 600-3. PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNESS
Deficiency in the average Per cent of Contract
thickness of day's work unit price payable
Up to 5 ram 100
6 - 10 mm 87
11 - 15 mm SI
16 - 20 mm 75
21 - 25 mm 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
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 50 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.
603.2.2. 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 soluble sulphates in a

concentration more than 0.5 per cent, cement used shall be sulphate
resistant and shall conform to IS : 12230, Cement to be used may
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 of
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
panicles, 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:-
(i) 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 CONCRKTE
Sieve Designation Percentage Passing the

sieve by weight
37.5 mm 100
19.0 mm 80-100
9,5 mm 55-80
4.15 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.
603.2.5. Storage of materials: Air materials shall be stored in
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 Clause 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 compact-
tion by rolling. The target mean strength for the design mix as well as
acceptance Specification 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 roiling 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 die 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/cu.m. of concrete. If this
minimum cement content is not sufficient 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 flexural 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 sha ll not be laid on a subgrade
softened by rain after its final preparation; any surface trenches, soft spots
etc., must be properly backfilled 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 she base course.
603.5. Construction
Clause 601,5 shall apply.
250
603.6. Trial Mix

Using the specified cement content and 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 Cla use 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 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
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 and
Reinforced Earth
Geosynthetics and Reinforced Earth Section 700
701. GEOSYNTHETICS IN ROAD AND BRIDGE WORKS

701.1 Scope
This specification covers the various applications of Geosymhetic ma-
terials in road and bridge works including supplying and laying as per
special provisions.
"Geosynihetic is a general classification for all synthetic materials
used in geotechnical engineering application. It includes geotextiles,
geogrids, geonets, geomembranes and geocomposites.
(i) Geotextile: Any permeable textile natural or Synthetic, used with foundation, soil,
rock, earth, or any other geotechnical engineering related material. In the present
chapter, it 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, rock, earth, or any other geolech-
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 my olher geotechnical engineering related
material, to control fluid migration.-
(v) Geocompositt : A manufactured material using geoie xliles, geogrids, geoneu and/
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
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 varies 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 : Geometnbrane 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
heatbondeti or seamed for effective permeation cut off, at site using
standard equipment as part of Ihe laying process. While fixing on to a
slope, they shall not be punctured or stappled to impair their use.
701.2.5. Geocomposite : Geocomposites shall be made from combi-
nation of geonets, geogrids or geomembrancs 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 : Geosymhetics shall be tested in
accordance with tests prescribed by BIS. In absence of IS Codes, tests
prescribed either by ASTM or British Standards or Internationa l Standards
Organisation, shall be conducted.
701.3 Application Areas
Some of the application areas for geotextiles and related materials and
256
their functions are given below in table 700-1,

Table 700-1. Applications and Functions of Geosynthctics
S. No. Application Area Geosynthetics Functions for
Involved Performance
1. Embankments on soft soils GT. GG R, S
2. Retaining walls GG. GT R
3. Drainage and Filtration GT F, S
4. Drain age- prefab, composite GC, GN D, F, S, B
5. Erosion Control rip rap GT F, S
6. Sediment control-sill fence GT B, R, S
7. Asphalt overlay GT. GC B, R, S
Note : GT = geotextile S = separation
GG = geogrid R = reinforcement
GC = geocomposite F = filtration
GN = 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
filler 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 yams 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 m-
plane flow shall be identified.
702.2.3. The geotextile shall :
(a) Sustain a load of not less than 10 kN/rn at break and have 3 minimum Failure strain
257
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 he as per TF 25 # 6
(c) allow water lo flow through it at right angles to its principal plane, in either
direction at a rate of not less than 10 litres/ml/sec, under a constant head of water
of 100 mm, determined in accordance with BS:6906 (Part 3) or ASTM D 4491 or
as slated in the design drawing. The flow rate determined in the lest shall be
corrected lo that applicable to a temperature of 15°C using published data on
variation in viscosity of water with te mperature.
(d) have a minimum puncture resistance of 200 N when determined in accordance with
DS:6906 (Part 4) or ASTM D 4833
(e) have a minimum tear resistance of 150 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. Installation
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 ultravio let
radiation) for a period exceeding a cumulative total of 50 hours. Where
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
tilled 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 systems or
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
laid in a narrow trench surrounded by a layer of geotextile 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 alt 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 clement shall be of Geotexiile, aluminium
alloy strip, copper strip, carbon steel strip, mals 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 alloy 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 1/2 H condition and shall have 0.2 per cent proof stress of not
less than 580 N/mm2 .
259
703.2.5. Carbon steel strip which shall be galvanized shall comply

with BS:1449 (Pan 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 mo
than 0.40 per cent. The fabricated element shall be galvanized
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 that the 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 s hall not be les s 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 charact-
istic design tensile strength at a strain not exceeding 10 per cent in 100
years shall be at least 40 kN/m when measured as per GRI:GG3. The
strength for bi-directionally 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 the following:
(i) Reinforced concrete (Cast in situ or precast) slabs:
(ii) Plain cement concrete form fill bellow block (Precast).
(iii) Masonry construction,.Rubble facia
(iv) Other proprietary and patented proven system.
260
The facing shall be sufficiently flexible to withstand any deforma tion

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 sealing such as resin bonded cork strip.
703.4.4. Connection between the facia and the reinforcing
clement 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
703.5.5. 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 1300 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 le vel 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 mm, 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
262
transportation costs and storage of the same as per special provisions. The
rate sha ll 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 geosynthc tic materials over existing
bituminous surface, including preparation of surface and joining,
stitching or overlapping of geosynthetic fabric etc., as pan 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
704.3. Material Requirements
704.3.1. Paving fabric : The paving fabric will be a nonwoven heat
set material consisting of at least 85 per cent by weight polyolefins,
polyesters or polyamides. 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 :
263
Table 704.2. Physical Requirements-Paving Fabrics
Property Units Standard Test Method

Requirements
Tensile Strength Kg 36.3 ASTM 13 4632
50
Elongation Asphalt % Kg/10 sq.m. ASTM D 4632
10
Retention Texas DOT 3<m
Melting Point °C 150 ASTM D 276
Surface Tenure — Heal bonded on Visual Inspection
one side only
Notes:
1 Certification of conformance from paving fabric manufacturer may he 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 he
determined as per ASTM D <l75Ui.--''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 of 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 tha t it is protected from the elements during shipping
and storage. At no lime 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°C and 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 sha ll be placed when weather
conditions, in the opinion of the engineer, arc not suitable.
264
704.4.3. 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 in locations of fabric overlap. Every effort shall
be made to keep hand spraying to a minimum. The tack coal 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 about 20 per cent as directed by the
engineer. The lack coat application rate must be sufficient to saturate the
fabric and to bond the fabric to the existing pavement surface.
The temperature of the lack 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 shall
not exceed I60°C, For bitumen emulsions, the distributor tank tempera-
tures shall be maintained between 55°C and 70°C.
The target width of tack coal 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 coal 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 shall 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 determined by the engineer to satisfy bitumen
retention of the lapped paving fabric. All areas with paving fabrics placed
will be paved the 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 fabric1 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 Geosynthctics in the form of bolsters, on slopes of embankments or in
apron. Gabions or Mattresses are also used for stone spurs. Geotcxtifes 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 geosyntheiic in
cutting off pieces. The mesh opening may very depending on functional
requirement but shall have aperture between 35 mm and 100 mm. The
266
mesh/ne t shall have following characteristics'":

Aperture : Rectangular, square or oval shaped (and not in diamond, round or
polygonal shape).
Colour : Black
Mechanical : Peak strength not less than 10 kN/m at maximum elongation of
Properties 15 per cent. Not more 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 by1 GRI-GG3 standards. Material shall have
ISO 9002 certification,'
Life : Atleast 8 years in case of continuous exposure and 5 years for
burned applications (defined as capable of retaining atleast 75 per
cent of its origin*! strength after the life span slated.
705.3. 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 shall 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 shall be used. The typical size of a single continuous unit
shall be 1 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 me drawing and

the specific gravity of stones not less than 2.65. Methodology of laying
boulders shall be as per 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 sha ll be filled in situ. In streams or water body having
running boulders in the bed, the gabions/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/geocomposiie 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/
geocompostte 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
Gabions/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
geognd/geonet, tensioning and staking arrangements, tying, internal
crossbraids, etc., for forming of the crates in an engineered manner and
filling the crate by laying boulders. The cost shall include transportation
of material from store to site.
Wherever composite system using Geosynthetics with natural mater-
rial like stone revetment etc. shall be used, the provision of measurement
and rate as per Clauses 2509 and 2510 are applicable.
_________
269
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-reflectorised 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: 1786 unless otherwise shown on the drawing.
801.2.3. Bolts, nuts, washers: High strength bolts shall conform to
IS : 1367 whereas precision bolts, nuts, etc., shall 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 other relevant
IS Specifications.
801.2.5. 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.
273
Traffic Signs and Appurtenances Section 800
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 tha t it does not bend or deform
under the prevailing wind and other loads.
801.2.7. In respect of sign sizes not covered by IRC67, 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 surface. The retro-reflective surface
after cleaning with soap and water and in dry condition shall have the
minimum co-efficient of retro-reflection (determined in accordance
with ASTM Standard E : 810) as indicated in Table 800-1.
TABLE 800-1. ACCEPTABLE MINIMUM COEFFICIENT OK 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 -6 95 62 30 15 73
0.5 + 30 65 45 25 10 5.0
274
When totally wet, the sheeting shall not show less than 90 per cent
of the values of retro-reflectance indicated in Table 800-1. At the end
of 7 years, the sheeting shall retain at least 75 per cent of its original
retro-reflectance.
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-830) as indicated in Table 800-2.
TABLE 800-2. ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-
REFLECTION FOR ENGINEERING GRADE SHEETING
(CANDELAS PER LUX PER SQUARE MFJTRE)
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
0.2 +30 30 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 sha ll either be screen-printed or of cut-outs. Screen
printing sha ll 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 sha ll be bonded with the
sheeting in the manner specified by the manufacturer.
801.3.5. 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 800-1 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. Adhe sives : 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 lack 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-reflective 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
device 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 overlapped not 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 specified 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 finished sign with retro-reflective sheeting of high
intensity grade and engineering grade respectively, inclusive-of the screen
printed or cut out letters/legends arid 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 dimensional
change and shall not have less than 50 per cent of the specified
minimum reflective intensity values (Tables 800-1 and 800-2) when
subjected to accelerated weathering for 1000 hours, using type E or EH
Weatherometer (AASHTO 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 toads 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 (G.I). Post-
277
end(s) shall be firmly fixed to the ground by means of property designed

foundation. The work of foundation shall conform to relevant Specifications
as specified.
801.4.2. All components of signs and supports, other than the
reflective portion and G.I. 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 of suitable size in the case
of reinforced concrete or G.I. posts. After the nuts have been tightened,
the tails of the bolts shall be furred over with a hammer to prevent
removal.
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 volume at or near capacity
(2) Complex interchange design
(3) Three or more lines in each direction
(4) Restricted sight distance
(5) Closely spaced interchanges
(6) Multi-lane 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 principles,
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/m1 normal to the face of
the sign and 30 kg/m1 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
uncountable 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
1.80m, 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, consideration
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 on the over head
structure or on its support.
802.5. Materials for Overhead Sign and Support Structure
802.5.1. Aluminium alloy or galvanized steel to be used as truss
design supports shall conform to relevant IS. These shall be of sections
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 unites 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. The thickness of sheet
as 1.5mm.
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: 266 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 placements 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
as 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 he 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 he
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 arid carefully checked after
construction of the sign foundation arid before the concrete has set.
802.7.9. All 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 o galvanized steel trusses, with the exception of
high strength bolt connections, shall be tightened only to a snug condition.
802.7.11. Field welding shall not 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.
802.8.1. 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, complete in place.
802.9. Rate
802.9.1. The structural steel part of the overhead sign shall be
measured in tonnes while the sign board shall be measured in sq. m. 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 reflectorised paint 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 thermoplastic
compound meeting the requirements specified herein.
(ii) The thermoplastic compound shall be screeded/extruded on to the pavement surface
in a molten state by suitable machine capable of controlled preparation and laying
with surface application of glass beads at a specific rate. Upon cooling to ambient
pavement temperature, it shall produce an adherent pavement marking of specified
thickness and width and capable of resisting deformation by traffic,
(iii) The colour of the compound shall be white or yellow (IS colour No. 556) 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.
803.4.2. Thermoplastic Material

803.4.2.1. General : The thermoplastic material shall be homo
geneously composed of aggregate, pigment, resins and glass reflectorizmg
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 OF MARKING MATERIAL
(Percentage by weight)
Component White Yellow
Binder 18.0 min. 18.0 min.

Glass Beads 30-40 30-40
Titanium Dioxide 10.0 min. —
Calcium Carbonate and
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
(i) Properties: The properties of thermoplastic material, when tested in accordance
with ASTM D36/BS-3 262-(Part 1), shall be as below:
(a) Luminance :
White : Daylight luminance at 45 dcgrees-65 per cent min. as per AASHTO
M 249
283
Yellow: Daylight luminance at 45 degrees-45 per cent min. as per AASHTO

M 249
(b) Drying time : When applied at a temperature specified by the manufacturer
and to the required thickness, the material shall set LO 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 i-o cracks
on application to concrete blocks.
(e) Softening point : 102.5 ± 9,5° C as per ASTM D 36.
(f) How resistance : Not more than 25 per cent as per AASHTO 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 thermoplastic material must also melt uniformly
with no evidence of skins or unmelted panicles for the one year storage period.
Any material not meeting the above requirements shall be replaced by the
manufacturer/ supplier/Contractor.
(iv) Reflectorisation : Shall be achieved by incorporation of beads, the grading and
other properties of the beads shall be as specified in 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 other means of identification of manufacturer
2. Batch number
3. Date of manufacture
4. Colour (white or yellow)
5. 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 10 be used for the production of reflectorised pave ment 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.
284
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 requirements
for the two types as given in Table 800-4. TABLE 800-4.
GRADATION REQUIREMENTS FOR GLASS BEADS
Per cent retained

Sieve size
Type 1 Type 2
1.18 mm 0 to 3
850 micron 5 to 20 0 to 5
600 -do- - 5 to 20
425 -do- 65 to 95 -
300 -do- - 30 to 75
ISO -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 250 mm inside diameter desiccator which is filled within
25 mm of the lop of a desiccator plate with sulphuric acid water solution {
specific gravity 1.10). Cover the desiccator and let it stand for 4 hours at 20 lo 29
degree C. Remove sample from desiccator, transfer beads to a pan aid inspect
for lumps or clusters. Then pour beads into a clean, dry glass funnel having a 100
mm stern 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 B3 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
285
results of all tests specified herein mid shall certify that the material meets
all requirement of this Specification. However, 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 at temperatures specified by the manufacturers for respective
method of application to produce a tine 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 healer filled with a mechanical stirrer to give a smooth consistency to the
thermoplastic material lo avoid local overheating. The temperature of the mass
shall be within the range specified by the manufacturer, and shall on no account
be allowed lo 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 lo prolonged heating,
the material shall not be maintained in a molten condition for more than 4 hours.
(ii) After transfer lo 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) The 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) The stripe or marking shall 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.
(f) The colour of yellow marking shall conform 10 IS Colour No. 356 as given in IS:
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.
286
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 be 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 renewable
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 quantity 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).
803.6.5. The finished lines shall be free from ruggedncss 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
803.7.1. The painted markings shall be measured in sq. metres of
actual area marked (excluding the gaps, if any).
287
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
drawmg(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) Heciometre siones
(ii) Kilometre stones
(iii) 5th Kilometre siones
804.2. The dimensions 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 IRC: 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 hectorneu-e/kilornetrc/5ih 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.
288
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 oilier incidental costs
necessary to complete the work to these Specifications.
806. BOUNDARY STONKS
806.1. General
The work comprises of supplying and fixing boundary stones as per
designs and Specifications given in IRC: 25 "Type Designs for Boundary
Stones" and at locations indicated in the drawings or-as directed by the
Engineer.
The measurement shall be made in numbers of boundai y stones 1'ixeu
at site.
806.3. Rate
The Contract unit rate for boundary stones shall be payment in full
compensation for furnishing all labour, materials, tools, equipment for
preparing, supplying and fixing and all other incidental costs necessary
to complete the work to these Specifications.
807. FENCING
807.1. General
The work comprises of fixing Mild Steel (M.S.) posts and providing
barbed wire fencing including necessary stays and entry gates as shown
in the drawing (s) and as directed by the Engineer.
289
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 15:278.
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 compensation
for furnishing all labour, materials, tools, equipment for
fabrication and fixing at site and all other incidental costs necessary to
complete the work to 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 6 mm 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
290
in full compensation for furnishing alllabour, materials, tools, equipment

and plant required for fabrication, connection, oiling, painting, temporary
erection, inspection, test and final erection at site and a!l 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 1000-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 "extrusio n 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.
809.2.3. An expansion joint with premoulded asphalt filler board
shall be provided at the junction of crash barrier 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 premoulded asphalt 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 barriers 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 of lumps, sags
or other irregularities. The top and exposed faces of the barriers shall
conform to the specified tolerances, as defined in Clause 809.4, when
tested with 3 m straight edge, laid on the surface.
291
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 die 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
faces shall not vary more than 12 mm from the edge of a 3 m straight
edge. Barriers shall be at the specified height as shown in die 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 \n 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
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, 0.55 kg per square metre, minimum single
spot) unless otherwise specified. The galvanising on all other steel parts
shall conform tp 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.
810.3.1. 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 ens ure proper matching at abutting joints arid 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 from distortion
and burring or any other damage.
810.4.2. All post holes that are dug or drilled shall be of such size
s will permit proper setting of the posts and allow sufficient room
or backfilling and lapping.
810.4.3. Holes shall be backfilled with selected earth or stable
293
materials in layers not exceeding 100 mm thickness and each la yer shall
be thoroughly tamped and rammed. When backfilling and tamp 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 back filled with concrete.
810.4.5. Posts for metal beam guardrails on bridges shall be ed 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
rand 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
which such extensions might interfere with or endanger traffic in which
case the bolts shall be cut 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.
810.7.1. Metal beam railing barriers will be measured by linear
metre of completed length as per plans and accepted in place. Terminals/
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 backfilling performed in connection with this construction.
810.8. Rate
The Contract unit rate shall include full compensation for furnishing
294
of labour, materials, tools, equipments and incidental costs necessary for

doing all the work involved in constructing the metal beam rating 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 traffic signals shall have a complete electronic mechanism
for controlling the operation of traffic with an auxiliary manual
controller. The time plan of signals shall be as per drawing and shall be
modified as directed by the Engineer.
811.3. Materials
The various materials and fabricatio n thereof shall conform to
the following:
811.3.1. 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 staled in IRC: 93. The post shall be painted and
protected as per Clause 3.7. of IS: 7537.
811.3.3. 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 15:7537.
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.
295
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,
tools, equipment for preparing, supplying, fixing at site, testing and
maintenance throughout warranty period and all other incidental costs
necessary to complete and maintain the work to these Specifications.
________
296
Quality Control for
Road Works
900
Quality Control for
Road Works
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
approved by the Engineer and equip the same with adequate equipment and
personnel in order 10 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 as per Clause 121 and/or as directed 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 go t 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 satisfying himself about the quality of the 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 hereinunder. Additional tests ma y also
be conducted where, in the opinion of the Engineer, need for such 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 required by 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 and pavement, construc-
tion of subsequent layer of same or other material over the finished layer shall
be done after obtaining 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 ne xt 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 removed from the site of works
by the Contractor at his own cost.
299
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
at laboratories 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 the 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 of Quality Control for Construction of Roads and
Runways" (IRC : SP: 11), and these MOST Specifications. 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 of materials
in the required quantity during the construction period.
Similarly, the supply of aggregates for construction of road pavement
shall be from quarries approved by the Engineer, Responsibility for
arranging uninterrupted 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, the Engineer/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's responsibility 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
of the tests carried out. In addition, certified mill test reports clearly identified
to the lot of materials shall be furnished at the Contractor's cost.
902. CONTROL OF ALIGNMENT, LEVEL AND SURFACE
REGULARITY
902.1. 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 shall be reckoned with respect to the centre line
of the carriageway as shown on the drawings. The edges of the carriageway
as constructed shall be correct within a tolerance of ± 10 mm there from. 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 900-1,
TABLE 900-1. TOLERANCES IN SURFACE LEVELS
1. Subgrade + 20mm
-25 mm
2. Sub-base + 10mm
(a) Flexible pavement - 20mm
(b) Concrete pavement + 6 mm
[Dry lean concrete or Rolled concrete] - 10mm
3. Base-course for flexible pavement

(a) Bituminous course + 6 mm
- 6mm
(b) Other than bituminous + 10 mm
(i) Machine laid - 10mm
+ 15 mm
(ii) Manually laid - 15 mm
4. Wearing course for flexible pavement
(a) Machine laid + 6 mm
- 6 mm
(b) Manually laid + 10mm
- 10mm
5. Cement concrete pavement + 5 mm
- 6mm *
* This may not exceed - 8 mm at 0 - 30 cm from the edges.
Provided, however, that the negative tolerance for wearing course

shall not be permitted in conjunction with the positive tolerance for base
course, if the thickness of the former is thereby reduced 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 (he surface levels shall be taken on
a grid of points placed at 6.25m 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 points spaced at 6.25 m along the
length and at 0.5 m from the edges and at the centre 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 Pavement 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 PERMITTED NUMBER OF SURFACE
IRREGULARITIES
Surfaces of Surfaces oflajbjs, service
carriageways areas and ail bituminous base
and paved courses
shoulders
Irregularity 4 mm 7 mm 4 mm 7 mm
Length(m) 300 75 300 75 300 75 300 75
National Highways/
Expressways 20 9 2 1 40 18 4 3
Roads of lower
category* 40 18 4 2 60 27 6 3
*Category of each lection of road as described in the Contract.
The maximum allowable difference between the road surface and

underside of a 3 m straight-edge when placed parallel with, or at right angles
to the centre line of the road at points decided by the Engineer shall be:
for pavement surface (bituminous and cement concrete) 3 mm
for bituminous base courses 6 mm
for granular sub-base/ base courses 8 mm
for sub-bases under concrete pavements 10 mm
303
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 satisfaction of
the Engineer.
(i) Subgrade; Where the surface is high, it shall be trimmed and suitably compacted
Where the same is low, the deficiency shall he corrected by scarifying the lower layer
and adding fresh material and recompacting to the required density. The degree of
compaction and the type of material to t>e 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 of material to be used shall conform to the requirements of Clause 401.
(iii) Lime/Cement Stabilized Soil Sub-base: For lime/cement treated materials where
the surface is high, the same shall be suitably trimmed while taking care (hat the
material below is not disturbed 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 lime 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 2hours, the full depth of the layer shall be removed from the pavement and
replaced with fresh material to Specification. This shall also apply to lime treated
material except that the time criterion shall be 3 hours instead of 2 hours.
(iv) Water Bound Macadam/Wet Mix Macadam Sub-base/Base: Where the surface
is high or low, the lop 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: For bituminous construction other than wearing course,
where the surface is low, the deficiency shall be corrected by adding fresh material
over a suitable tack coat if needed and recompacting to specifications. Where the
surface is high, 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 replacement of a bituminous layer is involved, the area
treated shall not be less than 5 m in length and not less than 3.5 m in width.
(vi) Dry Lean Concrete Sub-base/Rolled Cement Concrete; The defective length of
the course shall be removed Lo full depth and replaced with material conforming to
Clauses 601 or 603, as applicable. The area treated shall be at least 3 m long, not less
than 1 lane wide and ex lend to the full depth. Before relaying the course, the disturbed
sub grade or layer below shall be corrected by levelling, watering and compacting.
(vli) Cement concrete pavement; The defective areas having surface irregularly
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
in an approved manner either by cutting grooves ( 5 mm deep) or roughening the

surface by hacking the surface. IS high areas in excess 6 mm or low areas in excess
of 3 mm occur, exceeding the permitted numbers and if the Contractor cannot rectify,
the slab shall be demolished and reconstructed at the Contractor's expense and
in no case the area removed shall be less than the full width of the lane in which 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 and tolerances shall be demolished and reconstructed at 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. When; 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 of proposed 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 (Part4)]: 2 tests per 3000 cubic metres of soil,
(b) Plasticity Test [IS:2720(Part 5)]:Each type to be tested, 2 tests per 3000 cub.metres
of soil.
(c) Density Test (IS:2720 (Part 5)]: Each soil type to be tested, 2 tests per 3000 cubic
metres of soil.
(d) Deleterious Content Test [15:2720 (Part -27)]: As and when required by the
Engineer.
305
(e) Moisture Content Test [IS :2720 (Part-2)]: One test for every 250 cubic metres of
soil.
(f) CBR Test on materials to be incorporated in the subgrade on suaked/unsoaked
samples [IS : 2720 (Part-16)]: One CBR lest for every 3000 cu. m. atleast or closer
as and when required by the Engineer.
903.2.2. Compaction Control: Control shall be exercised on each layer

by taking at least one measurement of density for each 1000 square metres
of compacted area, or closer as 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 anyone test but on the mean value of a set of
5-10 density determinations. The number of tests 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. If considerable 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 the mean density is not less than
the specified density plus:
1.65
1.65 − times the standard deviation.
( No. of samples) 0.5
However, for earthwork in shoulders (earthen) and in the subgrade,
atleast one density measurement shall be taken for every 500 square metres
for the compacted area provided further that the number of tests in each set
of measurements 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 of bases and sub-
bases shall be as given in Table 900-3.Theevaluation 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 criteria for tests on the
strength of cernent/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
TABLE 900-3. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR S UB -
BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)
SI. Type of Test Frequency (min)
No. Construction
1. Granular (i) Gradation One test per 200 m3
(ii) Atterberg limits One test per 200 m3
(iii) Moisture content One test per 250m3
prior to compaction
(iv) Density of One test per 500 m3
compacted layer
(v) Deleterious As required
constituents
(vi) C.B.R. As required
2. Lime/Cement (i) Quality of lime/ One test for each

Stabilised cement consignment subject to
Soil Sub-base a minimum of one test
per 5 tonnes
(ii) Lime/Cement Regularly, through

content procedural checks
(iii) Degree of Periodically as

pulverization considered necessary
(iv) CBR or Unconfined As required

Compressive Strength
test on a set of 3
specimens
(v) Moisture content prior One lest per 250 sq. m.

to compaction
(vi) Density of compacted One test per 500 m2
layer
(vii) Deleterious As required
constituents
3. Water Bound One test per 200 m3 of
Macadam (i) Aggregate Impact aggregate
Value One test per 100 m3
(ii) Grading One test per 200 m3 of
(iii) Flakiness Index and aggregate
Elongation
Index One test per 25 m3 of
(iv) Atterberg limits binding material
of binding material
307

No. Construction
(v) Alterberg limits of One test per
portion of aggregate 100 cubic metre
passing 425 micron of aggregate
sieve
4. Wet Mix Macadam (i) Aggregate Impact One test per 200 m3
Value of aggregate
(ii) Grading One test per 100m3

of aggregate
(iii) Flakiness and One test per 200 m3
Elongation Index of aggregate
(iv) Atierberg limits of One test per 100m3
portion of aggregate of aggregate
passing 425 micron
sieve
(v) Density of compacted One test per 500 m2
layer.
903.4. Tests on Bituminous Constructions

903.4.1. The tests and their minimum frequencies for the different types
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:
1.65
TABLE 900-4. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR
BITUMINOUS WORKS
No. Construction
1. Prime Coat/Tack Coal (i) Quality of binder Two samples per lot to be
subjected to all or some tests
as directed by the Engineer
(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 loi Dressing
Dressing to be subjected to all or
308

No. Construction
some tests as directed by
the Engineer
(ii) Aggregate Impact One test per 50m5 of
Value aggregate
(iii) Flakiness Index -do-
and Elongation Index
(iv) Stripping value of " Initially one set of 3
aggregates representative specimens
for each "source of supply.
Subsequently when war-
ranted by changes in the
(v) Water absorption of -do-
aggregates
(vi) Grading of aggregates One test per 25 m3 of
aggregate
(vii) Stone polishing value As required
(viii) Temperature o f At regular close intervals
binder at application
(ix) Rate of spread of One test per 500 m1 of
materials work
3. Open-graded Premix (i) Quality of binder Two samples per lot to be

Carpet/Mix-Seal subjected to all or some
Surfacing tests as directed by Engineer
(ii) Aggregate Impact One test per 50 ms of
Value aggregate
(iii) Fla kiness Index and -do-
Elongation Index of
aggregates
Serial No, 2
aggregates Serial No, 2
(vi) Grading of aggregates One test per 25 m1 of aggre-
gates
(vii) Stone polishing value As required
(viii) Temperature of At regular close intervals
binder at application
(ix) Binder content Two tests per day
(x) Rate of spread of Regular control through
mixed material checks on materials and
layer thickness
4. Bituminous Macadam (i) Quality of binder Two samples per lot to be

subjected to all or some tests
as directed by the Engineer
309

No. Construction
(ii) Aggregate Impact One lest per 50 m3 of
Value aggregate
Elongation Index of
aggregates
Semi No. 2
(v) Grading of aggregates Two tests per day per plant
both on the individual con-
stituents and mixed aggre-
gates from the dryer
(vi) Water absorption of Same as in Serial No. 2
aggregates
(vii) Binder content Periodic, subject to minimum
of two tests per day per
plant
(viii) Control of temperature At regular close intervals
for mixing and of the
mix at the time of
laying and rolling
(ix) Rate of spread of Regular control through
mixed material checks of layer thickness
5. Bituminous (i) Quality of binder Two samples per lot to be

Penetration Macadam/ subjected to alt or some tests
Built-up Spray-Grout as directed by the Engineer.
(ii) Aggregate Impact Value One test per 200m! of
aggregate
Elongation Index
Serial No 2
(v) Water absorption of Same as in Serial No. 2
aggregates
(vi) Aggregate grading One test per 100 m! of aggre-
gate
(vii) Temperature o f binder At regular close intervals
at application
(viii) Rate of spread of One test per 500 m2 of area
binder
6. Dense Bituminous (i) Quality of binder Two samples per lot lo be

Macadam/Semi Dense subjected lo all or some
Bituminous Concrete/ tests as directed by the
Bituminous Concrete Engineer
(ii) Aggregate Impact Value One test pet 50 m1 of
aggregate
310

No. Construction
(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 Concrcle/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 ID a minimum of
two tests per plant per day
(ix) Stability of Mix For each 400 tonnes of mix
produced, a set of 3 Marshall
specimens to be prepared
and tested for stability, flow
value, density and void
content subject to a minimum
of two sets being vested
per plant per day
(x) Water sensitivity of As required for Bituminous
mix (Retention of Concrete
Marshall Stability)
(xi) Swell lest on the mix -do-
(xii) Control of temperature Al regular close intervals
and mix at the time of
laying and rolling
(xiii) Control of binder One test for each 400
content and gradation tonnes of mix subject to a
in the mix minimum of two tests per
day per plant
(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 lest per 250 m1 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 taken 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 IS:516
except that the cubes shall be compacted by means of a vibratory hammer
with the moulds placed on a level and rigid base. The vibrating hammer shall
be electric or pneumatic type fitted with a square or rectangular foot having
anareaofbetween7500 to 14000 sq.mm. The compaction shall be uniformly
applied for 60± 5secondswith a downwardforceofbetween300Nand400
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 scarified before 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 m accordance withlS:516.
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 Clause60l.5.5.1.Thisraleof
testing may be increased at the 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 at edges,
903.5.1.3. Thickness: The average thickness of the subbase layer as
computed by the level data of sub-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 corrected as stated in Clause 601.5.5.5. Areas which cannot be
repaired should be replaced over full wid th. 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. Sampling and testing of beam and cube specimens: Atleast
two beam and two cube specimens, one each for 7-day and 28 day strength
testing shall be cast for eve; 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 of mix from the concrete delivered to
the paving plant. Each pair shall be from a different delivery of concrete and
tested at a place to be 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 at 28 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 test results
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 150cu. m.of concrete. The results of crushing strength 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= 0.11 n+0.78
where f = correction factor and
n = height to diameter ratio
The corrected test results shall be analysed for conformity with the speci-
fication requirements for cube samples. Where the 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 cm 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 at 28 days exceeding the specified strength by
2.33 limes the standard deviation calculated first from the flexural strengths
of test beams made from the trial mix and subsequently from the accumulating
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 the specified strength shall not
be evidence for condemnation of the concrete concerned if the 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 shall be made each day in pairs at intervals, each pair being 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 the minimum permissible
flexural strength and the other for testing at an early age for the Engineer
to assess the quality of the mix. When the first thirty number of 28-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 of 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 tested before 28 days shall be
used in conjunction with a correlation between them and the28 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 shall not constitute sole evidence
314
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 flexural strength of the batch, of beams is less than the
specified strength plus 2.33 times the standard deviation of the batch.
Should the concrete fail 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 - STRENGTH RELATION OF CONCRETE
(RELATED TO 100 PER CENT 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
30 101.0 102.0 103.5 104.5 105.5
40 106.5 107.0 108.0 109.5 110.0
50 I10.5 111.0 112.0 112.5 113.0
60 114.0 114.5 115.0 115.5 116.0
70 116.5 117.0 117.5 118.0 118.5
80 119.0 119.5 119.5 120.0 120.5
90 121.0 121.5 122.0 122.0 122.5
100 123.5 123.5 123.5 124.0 124.5
110 125.0 125.0 125.5 125.5 126.0
120 126.0 126.5 127.0 127.0 127.5
130 127.5 128.0 128.5 128.5 129.0
140 129.0 129.5 129.5 130.0 130.0
150 130.5 130.5 131.0 131.0 131.5
160 131.5 131.5 132.0 132.0 132.5
170 132.5 132.5 133.0 133.0 1J3.5
180 133.5 134.0 134.0 134.5 134.5
190 135.0 135.0 135.0 135.5 135.5
200 135.5 135.5 136.0 136.0 136.5
315
Quality Contro l for Road Works Section 900
210 136.5 136.5 137.0 137.0 137.0

220 137.0 137.5 137.5 137.5 138.0
230 138.0 138.5 138.5 138.5 138.5
240 139.0 139.0 139.0 139.5 139.5
250 139.5 140.0 140.0 140.0 140.0
260 140.5 140.5 140.5 140.5 141.0
270 141.0 141.0 141.5 141.5 141.5
280 142.0 142.0 142.0 142.0 142.0
290 142.5 142.5 142.5 142.5 142.5
300 143.0 143.0 143.0 143.0 143.5
310 143.5 143.5 144.0 144.0 144.0
320 144.0 144.5 144.5 144.5 144.5
330 144.5 145.0 145.0 145.0 145.0
340 145.0 145.5 145.5 145.5 145.5
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 of the 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 is being constructed during normal working. The proportions
of the mix and the vibratory effort imparted 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 determining
in-situ strength. Incase of doubt, additional 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 dowel/tie bars without any compensation
being paid for 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 part of 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
903.5.2 3. Thickness : Thickness shall be controlled by taking levels as

indicated in Clause 9023. Thickness of the slab at any point checker) 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 at a reduced rate given in Clause 602.15.2. In
no case, however, thickness deficiency 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) Width of pavement and position of Clause 902.2
paving edges
(iii) Pavement thickness Clauses 902.3 and 903.5,13
(iv) Alignment of joints, widths. To be checked® one Joint
depths of dowel grooves per 400m 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/tie bars as per Clause 602. 10.5.2
and once on every 2 km.
(vii) Texture depth Clause 602,9.8
2. Quality of Materials and Concrete
Control tests for materials and concrete shall be as under
1. Cement Physical and chemical IS ; 269 Once for each source of
tests IS : 455 supply and occasionally
IS : 14S9 when called for in case
IS : 8112 of long/improper storage,
IS : 12269 Besides, the Contractor also
will submit daily data on
cement released by the
Manufacturer.
IS : 2386 One use test for every day's

2. Coarse and (i) Gradation (Pt. 1) work of each fraction of
Fine coarse aggregate and fine
aggregates aggregate, initially; may be
relaxed later at the discretion
of the Engineer.
(ii) Deleterious IS : 2386 -do-

constituents (Pt. 2)
317
(iii) Water absorption 13:2386 Regularly as required

(Pt. 3) subject to a minimum of one
lest a day for coarse aggre-
gate & two tests a day for
fine aggregate. This data
shall be used for correcting
the water demand of the mix
on daily basis.
3. Coarse (i) Los Angeles Abrasion IS:2386 Once for each source of
Aggregate value or Aggregate (Pt. 4) supply and subsequently on
Impact lest monthly basis.
(ii) Soundness IS:23S6 Before approving the
(Pt.5) aggregates and every month
subsequently
(iii) Alkali aggregate IS:2386 -do-
reactivity (Pt. 7)
4. Water Chemical Tests IS:456 Once for approval of source
of supply, subsequently only
in case of doubt,
5. Concrete (i) Strength of IS:516 2 cubes and 2 beams per
concrete 150 in' or part thereof (one
for 7day and other for 28 day
strength) or minimum 6
cubes and 6 beams per day's
work whichever is more.
(ii) Core strength on IS:516 As per the requirement of

hardened concrete the Engineer; only in case of
doubt.
(iii) Workability of fresh IS:1199 One lest per each dumper

concrete-Slump Test load at both Batching plant
site and paving site initially
when work starts. Subse-
quently 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 S/
6.25 m x 3.5 m
'(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 5.0m or
forms in the case of fixed 6.25 m. The level tolerance
form paving allowed shall be ± 2mm.
These shall be got approved
1-2 hours before the com-
memcement of the concret-
ing activity.
318
903.5.3. Rolled Concrete Base

903.5.3.1. Sampling and testing of beams and cubes: Clause 903,5.2.1
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 day and
shall comply with the requirements as per Clause 601.5.5,1. This rate of
testing may be increased at the 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 at edges.
903.5.3.4. Summary of control tests liable 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. m. or part thereof laid each day.
(ii) Density : 3 density holes for each 2000 sq.m. or part thereof bid each day
(iii) Cotes : 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
1001. 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 materia l from other
sources at his own expense.
1003. BRICKS
Burnt clay bricks shall conform to the requirements of IS:1077,
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 comers and emit a clear ringing sound when struck. The size
may be according to local practice with a tolerance of ± 5 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:1124.
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
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, conforming to IS:8041.
c) Ordinary Portland Cement, 43 Grade, conforming to IS:8112.
d) Ordinary Portland Cement, 53 Grade, conforming to IS:12269.
e) Sulphate Resistant Portland Cement, conforming to IS: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 C3 S/C 2 S, where C3 S is Tricalcium Silicate and C2 S 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 conc rete. The recommended threshold values as per
IS:456 are sulphate concentration in excess of 0.2 per cent in soil substrata
or 300 ppm (0.03per 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
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 tri-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 15:2386,
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 PCC, 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 cent by Weight Passing the Sieve
40 mm 20mm 12.5mm
63 mm 100 — —
40 mm 95-100 100 —
20 mm 30-70 95-100 100
12.5 mm — — 90-100
10 mm 10-35 25-55 40-85
4.75 mm 0-5 0-10 0-10
325
1008. SAND/FINE AGGREGATES

For masonry work, sand shall conform to the requirements of
IS:2116.
For plain and reinforced cement concrete (PCC 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, (Parts I to VIII). The Contractor
shall submit to the Engineer the entire information indicated in Appendix
A of IS: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 following
grading requirements :
TABLE 1000-2
IS Sieve Size Per cent by Weight Passing the Sieve
Zone 1 Zone II Zone 111
10 mm 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 micron 15-34 35-59 60-79
300 micron 5-20 S-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
1009.2. Steel for Prestressing

The prestressing steel shall conform to either of the following :
(a) Plain hard drawn steel wire conforming to IS:1785 (Part I) and IS:1785 (Part II).
(b) Cold drawn indented wire conforming to IS.6003
(c) High tensile steel bar conforming to IS:2090
(d) Uncoated stress relieved strands conforming to IS:6006.
1009.3. Reinforcement / Untensioned Steel

For plain and reinforced cement concrete (PCC and RCC) or
prestressed concrete (PSC) works, the reinforcement / umensioned steel
as the case may be shall consist of the following grades of reinforcing
bars.
TABLK 1000-3
Grade Bar Type conforming Characteristic Elastic
Designation to governing IS Strength fy MPa Modulus GPa
Specification
S 240 IS:432 Part I 240 200
Mild Steel Bar
S 415 IS:17B6 High Yield 415 200
Strength Deformed
Bars (I1YSD)
Other grades of bars conforming to IS:432 and IS:1786 shall not
be permitted.
All steel shall be procured from original producers, no re-rolled steel
shall be incorporated in the work.
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 requirements
of IS: 13620, Additional requirements for the use of such reinforcement
bars have been given below :
(a) Patch up materials shall be procured in sealed containers with certificates from
the agency who has supplied the fusion bonded epoxy bars.
(b) PVC coated G.I. binding wires of 18G shall only be used in conjunction with
fusion bonded epoxy bars.
(c) Chain for supporting the reinforcement shall also be of fusion bonded epoxy
coated bars.
(d) The cut ends and damaged portions shall be touched up repair patch up
material.
327
(e) The bars shall be cut by saw-cutting rather than flame culling.
(f) 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.
(h) While concreting, the workmen 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 shall be provided in conformance to specifications given in
Appauiix 1000.1. 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 workmanship are in accordance with prescribed
specifications developed by the Institute.
1009.4. Grey Iro n 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 MPa
(iii) Bnnell Hardness 230 MPa
(iv) Shear Strength 370 MPa
(v) Compressive Strength 1370 MPa
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. Alternatively, 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)
15:961 : Structural Steel (High Tensile)
IS:2062 : Weldable Structural Steel
1S:8500 : Weldable Structural Steel (medium & high strength qualities)
328
IS:1148 : Hoi rolled rivet bars (upto 40mm dia) for structural purposes
IS:1149 : High tensile rivet bars for structural purposes
IS:1161 : Steel tubes for structural purposes
IS:4923 : Hollow Steel sections for structural use
IS:11587 : 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 and general engineering purposes
IS:1732 : Dimension for round and square steel bars for structural and general
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. Stainless Steel
Stainless steel shall be austenitic chromium- nickel steel, possessing
rust, acid and heat resistant properties conforming Lo IS:66Q3 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 AIS1 grades. A1SI 304 which
is equivalent to grade 04Crl8NillO 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 A1SI 316L or 02G17 Ni Mo2 of 13:6911.
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 neutralize 200 ml sample of water. using phenolpthalem as an indicator, it
should not require more than 2 ml of 0.1 normal NaOH.
(b) To neutralize 200 ml sample of water, using methyl orange as an indicator, it
should not require more than 10 ml of 0.1 normal HCl.
329
(c) The permissible limits for solids shall be as follows when tested in accordance
with IS:3025 :
Permissible Limits (max)
Organic 200 mg/lit
Inorganic 3000 mg/lit
Sulphates (SO4 ) 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 to the requirements slated
herein.
(d) The pH value shall not be less than 6.
1011. TIMBER
The timber used for structural purposes shall conform lo IS:883,
1012. CONCRETE ADMIXTURES
1012.1. Central
Admixtures arc materials added lo 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
be obtained only from established manufacturers with proven track record,
quality 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) Normal dosage and detrimental effects, if any, of t inder 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
admixture.
(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
(f) Where two or more admixtures are proposed to he 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".
(b) Except where resistance to freezing and thawing and to disruptive action of de-
icing salts is necessary, the air content of freshly mixed concrete in accordance
with the pressure method given in IS: 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 cement 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 godowns/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
331
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 from the stockpile within 30 cm of the ground until the
final cleaning up of the work, and then only the clean aggregate will
be permitted to be used.
In 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 sha ll
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 pan 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.
332
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 damp 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 lo protect them from splashes from
my 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 lei any welding operation or on site heal treatment or metallic coaling
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, for wires above 5mm dia, coils of
about 2m 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.
(b) 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 solvable- grease.
The prestressing steel should be absolutely clean and without any signs
of rust.
333
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. Water
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.
334
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.
__________
335
Pile Foundations
1100
Pile Foundations
Pile Foundations Section 1100
1101. DESCRIPTION
1101.1. 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, impact/
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:2911 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
around 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 minimum 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.
139
1102.3. Pressure meter tests may be used in the case of rock, gravel
or soil for direct evaluation of strength and compressibility charac-
teristic. 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 100 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.
340
Where piles are exposed to action 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 lobe furnished shall conform to die 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 proposed
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, die comers
shall be chamfered at least 25 mm unless otherwise specified
on die 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 die 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.
341
Piles shall be stored at least 300 mm above firm level ground

which is not liable to unequal 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. Whenever 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 bed (days)
the pile (hours) (days) (days)
Ordinary Portland 24 7 10 28
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 penetration
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 overlapped for this distance. Unless otherwise specified, the
extension of the pile shall be formed to the same cross-sectional profile
and with 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 al 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 prestrcssing 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 15:2911 (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 arc 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 ES: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 presticssed 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, if 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 present,
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 extraneous
matter. Special care shall be taken in silly 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 arc 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 could 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 inflo1-1 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 shaft shall be cleaned of all loose materials. Cover to
reinfircing 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 bottom 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 (he bore, lowering of
reinforcement cage and concreting of pile for full height must be accomplished
in one continuous operation without any stoppage.
(b) The concrete should be coherent, rich in cement with high slump and restricted
water cement ratio.
(c) The tremie pipe will 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.
(d) 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 safely 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 deposition should
not be changed part way up the pile to prevent the laitance from being entrapped
within the pile.
(g) All tremie tubes should be scrupulously cleaned after use.
346
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 painting
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
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 limber 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 treatment.
Timber piles shall be furnished 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 lip 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 10 damage
the pile. The minimum weight of the hammer 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 lender 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 construction. 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 drive n 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 docs 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
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 borne 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
350
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, cons ideration 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 m 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
351
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
finish d 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 p: sssure 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
direct d by the Engineer and shall not proceed below one metre above
the ft unding 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 manner as not to impair
the baring capacity of piles already in place, the stability of the
soil o 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 (he
following :
i) 1 in 8 [or large diameter cast-in-situ piles viz 0.75 m diameter and above
ii) I in 5 for smaller diameter cast-in-situ piles
iii) 1 in 4 for precast driven piles
352
1113. PILE TESTS

1113.1. General
The bearing capacity of a single pile may be determined froth test
loading a pile. The load test on a concrete pile 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 subsurface
strata.
The methodology of carrying out load tests and of arriving at
safe load on piles shall conform to IS-.29H (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 concrete in the installed pile and
utilisation 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 after 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 m in 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.
T e top of concrete in a pile shall be brought above cut-off
level o 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
1 15.1. 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 install-
lation equipment and accessories for pile driving and recording
of dam.
1 15.1.2. 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 top level of pile, which shall be stripped
off at the time of construction of pile cap.
354
1115.2. Bored Cast-in-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) The density of bentonite suspension to 1.05 g/cc
ii) The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 per cent
v) The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing contamination

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 to
concreting after 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 bore-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 shall 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 drilling mud to rise inside it before pouring concrete.
(v) The tremie pipe shall always he kepi 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-destuctive 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
along with reinforcement cage before concreting.
1116. TOLERANCES
1116.l. Permissible Tolerances for Pile
i) Precast Concrete Piles :
a) Variation in cross-sectional dimensions : ± 5 mm
b) Variation in length : ± 25 mm
c) Surface irregularities measured
with 3 m straight edge • : 5 mm
d) Bow 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 mm
iii) Bored 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 : 50 mm
of the head in plan
d) Variation of level1 of top of piles : ± 25 mm
356
1116.2. Permissible Tolerances for Pile Caps

(a) Variation in dimensions : ± 50 mm - 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-
tions 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 specified
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 crosss-
ection, the measurement shall be the length in metres of the accepted
pile that remains in the finished structure complete in place. Reinforcement
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 pene tration through hard strata or rock
and socketing into rock.
For steel liners/casing shown 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 2700. 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 Section 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- m-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 bad
tests.
The contract unit rate for reinforcement in cast- in-situ driven arid
bored piles shall be as per Section 1600.
The contract unit rate for installation of piles shall include full compensation
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 inc lude 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.
_________
358
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 sub-strata, 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 complements in plan. The outer
wall of the well is known as well steining which may be cellular,
The process of taking down the well the founding level is
known as well sinking. After reaching the founding level, 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 he ight of well steining 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 die 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 IRC78. 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
of the rocky strata, at the level at which the well has to be seated,
etc.
1202.3. 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 foundation. 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 adopting pneumatic sinking shall be decided by the
Engineer.
The curb and steining, have to be specifically designed for special
loading when pneumatic sinking is adopted.
1203. SETTING OUT AND PREPARATIONS FOR SINKING
1203.1. 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 permanent
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-X axis) 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
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 shall be ensured against overturning
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.
1203.3. 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 cum.
(b) Submersible pumps
(c) Air compressors, air locks and other accessories where pneumatic sinking of well
is anticipated.
(d) Chisels of appropriate sizes
363
(e) Aqua-header for culling rocky strata

(f) 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" 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.
1204.3. The cutting edge shall be laid about 300 mm above
.prevalent water leve l.
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 the 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 ort inner face shall be removed after
72 hours.
1205.2. All concreting in the well curb shall be done in one
continuous operation.
364
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 formwork 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 any time. For stability, the first lift of steining shall be
cast only after sinking the curb at least partially for stability.
Concreting 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. Laiunce
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.
1206.3. 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 the 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 lea
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 gauges shall 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 steining. 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 d, swings.
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 divert
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 shall however 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 1200/1.
1207.2. Use of Kentledge as Sinking Load
Kemedge 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 me 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.
1207.4. 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 1 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 explosives
shall be strictly followed.
All safety precautions shall be taken as per 1S:4081 "Safety Code
for Blasting and related Drilling Operations", to the extent applicable,
whenever blasting is resorted to.
There should 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 rubber 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 sinking with 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 complications
arising as a result of working under high pressure, shall be
stationed at the construction site when pne umatic 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 specifications
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 pan 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 clean 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 emplo yee 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 &;d 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
alt 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 independent
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 noncombustible,
non-absorbing insulating sockets, approved handles,
basket guards and approved cables. The use of worn or defective
portable and pendant conductors, shall be prohibited.
370
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 tanks 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 be provided at the top of every caisson. Where fire 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 accommodation 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 thai of steining and kentledge, if
any. shall be sufficient to resist the uplift from air inside, skin friction being
neglected in this case. If, at any section the total weight acting downwards is
371
less 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 pressure. "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 reduction in air pressure, kentledge should be added, "Blowing
down" should be in short stages and the drop should not exceed, 0.5 metre at
any stage. To control sinking during blowing down, use of packings are
recommended.
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 of appropriate spares, standbys,
safety of personnel as recommended in IS:4138 for working in compressed air
must be ensured at site. Codes for safety and for working in compressed air
and other labour laws and practices prevalent in the country, as specified 10
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
same 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 alternately so that sinking of wells proceeds
uniformly. Simultaneous and even dredging shall be carried OUL 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 welts, 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 than so as to
take prompt decisions.
d) Before seasonal floods all wells on which sinking is in progress shall be
sunk w sufficient depths below the designed scour level. Further, they shall
be temporarily filled and plugged so that they do not suffer any tilt or shift
during the floods.
e) All necessary precaution; shall be taken against any possible damage to the
372
foundations of existing structures in the vicinity of the wells, prior to commence-

ment 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 river
current flows.
g) Very deep sump shall not be made below the well curb, as it entails risk of
jumping (sudden sinking) of the well. The depth of sump shall be generally limited
to one-sixth of the outer 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) In case a well sinks suddenly with a jerk, the steining 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 working 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.
l) In soft strata prone to settlement/creep, the construction 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 lilt 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/H 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
373
unevenly and depositing dredge material unequally, pulling 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 till 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 1 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 :
(i) Calculations for foundation pressures and stiening stresses, accounting for 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
on the well cap etc}, shall he carried out by the Contractor without chiming
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 lest 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
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. BOTTOM 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 tremie 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 he required
height.
375
Least disturbance shall be caused to the water inside the welt

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 verified
before starling 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
lop 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,iaking account the water level prevalent at the lime of casting.
Bond rods of steining shall be anchored into the well cap.
376
1212. TOLERANCES
The permissible lilt and shift 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.
For the well steining and well cap the permissible tolerances
shall be as follows :
a) Variation in dimension : +50 mm - 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

The materials shall be tested in accordance with these Specifications
and shall meet 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 culling 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 tonnes separately in each of the items, as per Section 1600.
c) The measurement for welt sinking shall be made in running 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 the
low water level or from the level at which the cutting edge was laid, whichever
is higher.
d) The quantity 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 m cubic metres.
f) 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 of culling edge shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, sampling and testing.
377
and. supervision, all as per respective Section of Structural Steel Work

and as described in this section.
b) The Contract unit rates for concrete in curb, steining, boltom p lug, top plug
and well cap, shall cover all costs of labour, material, toots, plant and
equipment, fo rmwork and staging including placing in position, sampling and
testing, and, supervision, all as per respective Section of Structural 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
ID 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 excepting provisions 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.
f) The Contract unit rate of material to be excavated by pneumatic sinking
shall cover all costs of 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 reduction in
the rates as follows :
S. No. Amount of tilt and/or shift Per. cent deduction
on the rate(s) for
sinking of whole
well
1 Tilt exceeding the specified permissible value but 5 per cent
equal to or within 1 in 60
2 Tilt exceeding 1 in 60 10 pet cent
but equal to or within 1 in 50
3 Tilt exceeding 1 in 50 20 per cent
4 Shift exceeding the specified permissible 1 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 Section 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 minimum 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
as frequently as needed to restore the requisite consistency, but this retempering

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 from 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 lo 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 true 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. Comers 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
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 and 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.
In 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, ail 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
ma-le 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 these
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
hall 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
welted before plaster is applied to the adjacent areas.
No portion of the surface shall be left unfinished for patching up
a, 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 thickness over any portion of the
surface shall not be less than the specified thickness by more than
3 mm.
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-done as 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 WING/RETURN/
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 15:2250 for
compressive strength, consistency of mortar and its water retentivity.
The frequency of testing shall be one sample for every 2 cubic metres
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 arch 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 shall 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 archit ectural 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 drawings.
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 IS:1597 and requirement for dressing of stone covered in IS:lj_29^
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 each 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
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. AH 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 and 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 \-s 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 set. 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 sharp 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
broken, it shall be 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 lop 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-situ headers 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 walls, 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
1405.3, 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.
1405.3.2. 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 volume.
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 10 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 wo rk 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
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 Ashlar)
1405.5.1. Dressing : Every stone shall b cut to the required size
and shape, chisel dressed on all beds and joints so as to be free from
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 e 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
1405.6. Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by
volume of cement and sand or as sho wn on the drawing. The mortar
shall be filled and pressed into the raked out joints be ore giving
the required finish. The pointing shall conform to Clause 1312.3 of
the specification. The work shall conform to LS:2212. The thickness
of joints shall no be less than 3 mm for Ashlar masonry. However,
the maximum thickness of points in different works shall be as follows:
Random Rubble : 20 mm
Coursed Rubble : 15 mm
Ashlar Mason : 5 mm
1405.7. Curing
Curing shall conform to Clauses 1309 and 1312.5
1405.8. Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9. Wee 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. ARCH1TEC URAL COPING FOR WING/RETURN/
PARAPET WALLS
Architectural coping for wing/return/parapet walls sha ll conform to
Clause 1313.
1407. TES S AND STANDARD OF ACCEPTANCE
All work shall be done to the tines and lines as indicated on
he drawing or as directed by the Engineer subject to tolerances as
specified 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 subject to a minimum 3 samples for a day's work.
Stone masonry shall be measured in cubic metres.
397
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 testing 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 IRC87. Materials
and components used for formwork shall be examined for damage 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 thickne ss
of 4 mm. Other materials conforming to the requirements of IRC:87
may also be used if approved by the Engineer.
1503. DESIGN OF FORMWORK
1503.1. The Contractor shall furnish the design and drawing of
complete formwork (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. 150011 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
consideration shall be given to redistribution of loads on props due to

prestressing.
1504. WORKMANSHIP
1504.1. 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 of ties shall be restricted, as far as practicable. Wherever
ties are used they shall be used with HOPE 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.
1504.5. Unless otherwise specified, or directed, chamfers or fillets
of sizes 25 mm x 25 mm shall be provided at all angles of the formwork
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 shuttering 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
soffit to allow for deflection of the formwork. Pre-camber to allow
for deflection of formwork shall be in addition to that indicated for the
permanent 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 be strong 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 long 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 coaled 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 imperfections 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 the Engineer.
1506. PRECAUTIONS
(i) Special measures in the design of formwork shall be taken lo ensure that it
does not hinder the shrinkage of concrete. The soffit of the formwork shall
be so designed as to ensure that the formwork does not restrain the shortening
and,'or hogging of beams during prestressing. 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, formwork shall be so arranged that the soffit form, properly
supported on props only can be retained in position for such period as may
be required by maturing conditions.
(iii) Any cut-outs or openings provided in any structural member LO facilitate erection
of formwork shall be closed with the same grade of concrete as the adjoining
structure immediately after removal of formwork ensuring watertight joints.
(iv) Provision shall be made for safe access on. to and about the formwork at the
levels as required.
(v) Close watch shall be maintained lo check for settlement of formwork during
concreting. Any settlement of formwork during concreting shall be 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 sha ll 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 fo llowing actions shall be taken :
(i) The contact surfaces of the forms shall be cleaned carefully and dried before
applying a release agent.
(it) It should be ensured that the release agent is appropriate to the surface to
be coaled. The same type and make of release agent shall be used throughout
on similar formwork materials and different types should not be mixed.
404
(iii) The form surfaces shall be evenly and thinly coaled with release agent. 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 be 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.
1508. REMOVAL OF FORMWORK
The scheme for removal of formwork {i.e. de-shuttering 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 be
columns and vertical faces decided by the Engineer
of structural members
b) Soffits of Slabs : 3 days

(with props left under)
c) Props (left under slabs) : 14 days
d) Soffit of Gilders : 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 or 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. SPECIALISED 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 segmenlal construction,
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

The work shall conform to these Specifications and sha ll meet the
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 shall 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)
1600
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. The y 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 to 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 coaling 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
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 snail 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 lo 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 be placed strictly
in accordance with the drawings and shall be assembled in position only
when the structure is otherwise ready for placing 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 al every
intersection with binding wire (annealed), conforming to 1S:280 to make the
skeleton of the reinforcement 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 less than 1 mm.
c) Bars shall be kept in position usually by the following methods:
(i) In case of beam and slab construction, industrially produced polymer cover
blocks of thickness equal to the specified cover shall be placed between the
bars and formwork subject lo satisfactory evidence that the polymer
composition is not harmful lo concrete and reinforcement. Cover blocks
made of concrete may be permitted by the Engineer, provided they have
the same strength and specification as those of the member.
(ii) In case of dowels for columns and walls, the vertical reinforcement shall
be kept in position by means of limber templates with slots cut in them
accurately, or with cover blocks tied to the reinforcement. Timber templates
shall be removed alter the concreting has progressed upto a level just
below their location.
(iii) Layers of reinforcements 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 reinforcement 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
wires 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 not be permitted.
d) Bars 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 such that planes of weakness are not created in hardened concrete.
The coated reinforcing steel shall be held in place by use of plastic or plastic
coaled 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 lengths 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 W limes 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. We lding
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 that of 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
15:1786 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 IS: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 + + +
6 5 15
is 0.4 or less.
1606.2.3. The method of welding shall conform to IS:2751 and
1S:94J7 and to any supplemental specifications to the satisfaction of the
Engineer.
413
Welding may be carried out by metal arc welding process. Oxyacetelene

welding shall not be permissible. Any other process may be
used 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 current 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 welding 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 carrying 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:814,
1606.2.4. Welded joints shall preferably 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 swagged on to bars in end to end contact or by
screwed couplers. Incase 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 specifications
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, transportation
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. DESCRIPTION
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
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 characteristic
strength as given in Table 1700-1, 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 Co mpressive strength
of 150 mm cubes at 28 days, in MPa
M 15 15
M 20 20
VI 25 25
M 30 30
VI 35 35
M 4(1 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 B RIDGES WITH PRESTRESSED CONCRETE 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 Mia cement content Max. water cement ratio
for all exposure Exposure conditions
conditions (kg/cu.m) Normal Severe
a) PCC members 360 0.45 0.45
b) RCC members 400 0.45 0.40
c) PSC members 400 0.40 0.40
419
(B) MINIMUM STRENGTH OF CONCRETE
Member Conditions of Exposure

Moderate Severe
a) PCC members M 25 M 30
b) RCC members M 35 M 40
c) PSC members M 35 M 40
TABLE 1700-3. FOR BRIDGES OTHER THAN THOSE MENTIONED IN TABLE
1700-2 AND FOR CULVERTS AND OTHER INCIDENTAL CON-
STRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO
Structural Member M in. cement content Max. water cement
(Kg/cu. m) ratio
Exposure Conditions Exposure Conditions
Normal Severe Normal Severe
a) PCC 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) PCC members M 15 M 20
h) RCC members M 20 M 25
Notes Applicable to Tables 1700-2 and 1700-3
(i) The minimum cement content is based on 20 mm aggregate (nominal max. size).
For 40 mm and larger size aggregates, it may be reduced suitably but the reduction
shall not be more man 10 per cent.
(ii) For underwater concreting, the cement content shall be increased by 10 per cent.
(iii) Severe conditions of exposure shall mean alternate wetting and drying due 10 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)
above.
The cement content shall be as low as possible but not less than
the quantities specified above. In no case shall it exceed 540 kg/cu.m.
of concrete.
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
emulated as per drawing or by the Engineer "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 screed
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 10 the start of construction, the Contractor shall design the mix
in case of "Design Mix Concrete" or propose nominal mix in case of
"Nominal Mix Concrete", and submit lo 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 as directed by the Engineer. The slump
of concrete shall be checked as per 15:516.
TABLE 1700-4.
TYPE SLUMP (mm)
1 (a) Structures with exposed inclined surface requiring low 25
slump concrete lo allow proper compaction
(b) plain cement concrete 25
2. RCC structures with widely spaced reinforcements; e.g. solid 40 - 50

columns, piers, abutments, footings, well steining
3. RCC structures 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
1704.2. Requirements for Designed Mixes

1704.2.1. Target mean strength
The target mean strength of specimen shall exceed the specified characteristic
compressive strength by at least the "current margin".
(i) The current margin far a concrete mix shall be determined by the Contractor and
shall be taken as 1.64 times the standard deviation of sample lest results taken
from at least 40 separate hatches 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 date 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
(MPa) (MPa)
M 15 10 25
M 20 10 50
M 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
till sufficient data is available 10 determine the current margin as per
sub-clause (i) above.
1704.2.2. Trial mixes
The Contractor shall give no tice 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 al! 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 al! 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
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.
1704.2.3. Control of strength of design mixes
a) Adjustment to Mix Proportions
Adjustments to mix proportions arrived at 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 shall 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 accordance with Clause 1704.1.1. The recalculated value shall be adopted as
directed by the Engineer, and it shall become the current margin fur 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 (a) 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 by Proportion of fine to

Grade mass per 50 kg of cement to be Coarse aggregate (by
taken as the sum of individual mass)
masses of fine and coarse
aggregates (kg)
M15 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 of concrete as a percentage of mass
of cement in mix shall be limited to values given below :
- Prestressed Concrete : 0. t 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 percentage of mass of cement in the mix shall be limited lo 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
b) Quantities of each material per cubic metre of fully compacted concrete
c) Either of the following :
(i) appropriate existing data as evidence of satisfactory previous performance
for the target mean strength, current margin. consistency and water/cement
ratio and any other additional requirement(s) as specified.
(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,
1705. 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 manufacture,
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)
1} RCC well curb 20
ii) RCC/PCC welt steining 40
iii) Well tap or Pile Cap

Solid type piers and abutments 40
iv) RCC work in girders, slabs,

wearing coal, kerb, approach
slab, hollow piers and
abutments, pier/abutment caps,
piles
v) FSC 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 Production of Concrete :
i) For overall bridge length of less than 200 melees - 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:
425
Measurement of Cement ± 3 per cent of the quantity °f 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 the 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 tonnes capacity
ii) Powered hoists minimum 0.5 tonnes capacity
iii) Chutes
iv) Buckets handled by cranes
v) Transit truck mixer
vi) Concrete pump
vii) Concrete distributor booms
viii) Belt conveyor
ix) Cranes with skips
x) Tremies
c) For Compaction of Concrete :
i) Internal vibrators size 25 mm lo 70 mm
ii) Form vibrators minimum 500 walls
iii) Screed vibrators full width of carriageway
(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 of the mixes and the transportation arrange-
ments available with the Contractor. The mixer or the plant shall be
Mixing shall be continued till materials arc uniformly distributed and
a uniform colour of die 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.
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 Lakes 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 water used for this purpose shall be
discharged outside the 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 sha ll 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 shall 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
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 shall not be applied through reinforcement
and where vibrators of immersion type are used, contact with reinforcement
and all inserts like duels 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,
IS;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 shall be 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
170011.
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 got
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 deposited. 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 laitance, great care shall be
exercised not to disturb the concrete as far as 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. The 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 situation.
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 trermie 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 wil! 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 he emptied
so that water is not allowed to enter above the concrete in the pipe.
At times after placing of concrete is started and until all the required
429
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 scaled 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 taken 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 dry heat or stream
Aggregates shall not be healed 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 fr eezing 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 hoi 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 lime
between mixing and placing to the minimum, cooling Formwork by
sprinkling water, starting curing before concrete dries out and restric ting
concreting as far as possible lo early mornings and late evenings. When
ice is used Lo 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 ail ice in the mixing drum has melted.
The Contractor will be required to suite his methodology for the En-
gineer's approval when temperatures of concrete arc likely lo exceed 40
degrees Celsius during the work.
430
1713. PROTECTION AND CURING

Concreting operations shall not commence until adequate arrangements
for concrete curing have been made by the Contractor.
Curing and protection of concrete shall start immediately after compaction
of the concrete to protect it from :
a) Premature drying out particularly by solar radiation and wind
b) High internal thermal gradients
c) Leaching out by rain and flowing water
d) Rapid cooling during the first few days after placing
e) Low temperature or frost
f) 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 curing 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 kepi 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 10 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 10 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 he directly on the concrete
and the ambient air temperature shall increase at a rate not exceeding
431
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 10 whic h
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 permuted 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, cured 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 water 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 bolls, if
any, shall be cut inside the concrete member to a depth of at 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 tilling in all voids.
Surfaces which have he en pointed sha ll be kept moist for a period of
432
twenty four hours. Special pre-packaged proprietary mortars shall be used

where appropriate or where specified in the drawing.
All construction and expansion joints in the completed work shall
be left carefully tooled and free from any mortar and 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 arc made good.
a) The work that has sagged or contains honeycombing to an extent detrimental io
structural safety or architectural appearance shall 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 sha ll 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
lots 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 forming 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

1. Concrete for making 3 test cubes shall be taken from a batch of concrete at point
of delivery into construction, according to procedure hid down in 15:1199.
2. A random 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. ISO mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with 13:516. The 28-day test strength result
for each cube shall form an item of the sample.
433
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 be required for various purposes such as to determine the strength
of concrete at 7 days or for any other purpose.
The lest 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.
1716.2A Frequency : The minimum frequency of sampling of
concrete of each grade shall be in accordance with Table 1700-8
TABLE 1700-8
Quantity of Concrete in work, m3 No. of samples
1– 5 1
6 - 15 2
16 - 30 3
31 - 50 4
51 and above 4 plus one additional sample for
additional 50 m' or part thereof
At least one sample shall be taken from each shift of work,
1716.2.5. 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 four consecutive 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 (SO3 ) 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.
434
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 lest if it is properly compacted
and is not considered permeable.
(i) Prepare a cylindrical test specimen 150 mm dia and 160 mm high
(ii) After 28 days of curing, the lest specimen is fitted in a machine such that the
specimen can be placed in water under pressure upto 7 bars. A typical machine is
shown in Appendix 1700II
(iii) At first a pressure of one bar is applied [or 48 hours, followed by 3 bars [or
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 he 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 our.
by the Contractor at his cost. In case the concrete is no t found to be
acceptable 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 me beam as me 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, finishing and
curing as per this Section or as directed by the Engineer, including all
435
incidental expenses, sampling and testing, quality assurance and supervision.

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 reduction = ×100
Design Strength
__________
436
Prestressing
1800
Prestressing
Prestressing Section 1800
1801. DESCRIPTION
Structural concrete containing prestressed steel reinforcement to introduce
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
1802.1. All materials shall conform to Section 1000.
1802.2. Sheathing
1802.2.1. 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 IS:513 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, galvanised
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 1800/1.
For major projects, the sheathing ducts should preferably be
manufactured at the project site utilising appropriate machines. With
such 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
439
slurry tight by the use of corrugated threaded sleeve couplers which

may be tightly screwed onto the outer side of the sheathing duels.
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 duel shall be sealed with adhesive
scaling tape lo 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 internal 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,
12T13 and 19T13 sizes of tendons comprising 12/13 mm dia strands,
the inner diameter of the sheathing shall not be less than 50 mm,
15 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.
1802.2.3. 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
during concreting.
1802.3. Apchorages
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 tha n
12 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 all times. Threaded parts 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 other deleterious coaling.
440
1802.3.2. Swages of presiressing stand 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 furnished free of cost
and shall be delivered in time for tests to be made well 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 be like-wise identified.
All samples submitted shall be representative of the lot to be
furnished and in the case of wire or strand, shall be taken from the
same master roll. The Contractor shall furnish samples of at least 5.0
m length selected from each lot for testing. Also, two anchorage
assemblies, complete with distribution plates of each size or types1 to
be used, shall be furnished alongwith short lengths of strands as required.
1804 WORKMANSHIP
1804.1. Cleaning
Tendons shall be 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
solvent solutions, wire brushing or passing through a pressure box
containing carborundum powder. However, the tendons shall not be
brought to a polished condition.
1804.2. Straightening
High tensile steel wire and strand shall be supplied in coils of
sufficiently large diameter such that tendons shall retain their physical
properties and shall be straight as it unwinds from the coil. Tendons
of any type that are damaged, kinked or bent shall not be used.
441
The packing of presuessing wire/strand shall be removed only

just prior to making of cable for placement. Suitable stands shall be
provided to facilitate uncoiling of wires/strands without 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 facilitate
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 their anchorages arc not located in
the top deck surface. Where two or more rows of cables have to
be used, the cables shall 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 provided
at intervals of 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 shall not be placed until immediately
442
prior to stressing. Tendons shall be handled with care to avoid damage

or contamination, 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 cleaned 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 flame cutters. When a flame cutter is used,
care shall be taken to ensure that the flame docs 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 presuessing steel projecting beyond
the anchorages, shall be cut after the grout has set.
1804.5. Protection of Prestressing Steel
Presuessing steel shall be continuously protected against corrosion,
until grouted. The corrosion protector shall have no deleterious
effect on the steel or concrete or on the bond strength of steel
to concrete. Grouting 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
The joints of all sheathings shall be 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
thereafter sealed preferably with heat shrink tape, to make it waterproof.
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 tha t after
heating the bandage material shrinks on the sheathing duct and
ensures formation 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 me prestressing system shall
be effectively 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 length to provide for the extension of the tendons.
1804.7. Grout Vents
Grout 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 provided along the length
of sheathing such that the spacings of consecutive vents do not exceed
20 m. 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 surfaces of the anchorages shall be cleaned prior to concreting
and tensioning.
Anchor cones, blocks and plates shall be securely positioned and
maintained during concreting such that the centre line of the duct
passes axially through the anc horage assembly.
The anchorages shall be recessed from the concrete surface by a
minimum coyer of 100 mm.
After the prestressing operations are completed and prestressing
wires/strands are cut, the surface shall be painted with two coats
of epoxy of suitable formulation having a dry film thickness of 80
444
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 formwork
shall conform to Section 1500.
1805. SUPERVISION
All prestressing and grouting operations shall be undertaken by
trained personnel only. A representative of supplier of the prestiessing
system shall be present during all tensioning and grouting operations
and shall ensure, monitor and certify their correctness.
1806. 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 shall satisfy the
following requirements :
(i) The means of attachments of the prestressing steel to the jack of any other
tensioning apparatus shall be safe and secure.
(ii) Where two or more wires/strands constitute a tendon, a single multipull stressing
jack shall be used which is capable of tensioning simultaneously all the wires/
strands of the tendon. Suitable facilities for handling and attaching the multi-
pull jack lo the tendons shall be provided.
(iii) The tensioning equipment shall be such that it can apply controlled total force
gradually on the concrete without inducing dangerous secondary stresses in steel,
anchorage or concrete; and
(iv) Means shall be provided for direct measurement of the force by use of dynamometers
or pressure gauges fitted in the hydraulic system itself to determine the
pressure in the jacks. Facilities shall also be provided for the linear measurement
of the extension of prestressing steel to the nearest mm and of any slip of the
gripping devices at transfer.
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
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.
1807. 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 measured 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 anchorage.
The tensioning force applied to any tendon shall be determined by
direct reading of the pressure gauges or dynamometers and by
comparison of the measured elongation with the calculated elongation.
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) If the calculated elongation is reached before the specified gauge pressure
is obtained, continue tensioning till attaining the specified gauge pressure, provided
the elongation does not exceed 1.05 times the calculated elongation. If 1.05
times the calculated elongation is reached before the specified gauge pressure
is attained, stop stressing and inform the Engineer.
b) If the calculated elongation has not been reached at the specified gauge pressure,
continue tensioning by intervals of 5 kg/sq, c.m. until the calculated elongation
is reached provided the gauge pressure does not exc eed 1.05 times the
specified gauge pressure.
c) If the elongation 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 jack, pump and leads.
ii) Detension 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 staling, should not be undertaken without the approval 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 1800HI. The number of stages of prestressing and grouting
shall be reduced to a minimum, preferably 2 in the case of simply
supported girders.
1808. GROUTING OF PRESTRESSED TENDONS

Grouting shall conform to Appendix I800HII, A record of grouting
operations shall be maintained in the format given in Appendix 1800!
IV.
1809. PRE-TENSIONING
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 lo slide in the direction of their length
and thus permit the transfer of the prestressing force lo all 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 shall 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 shall be the force remaining in the strands/wires after all
strands/wires have been anchored to the abutments of the stressing
bed and after the anc horage slip has already taken place. The tensioning
force shall be determined by direct reading of the pressure gauges
or dynamometers 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.
The 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 sha ll 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 vario us
positions along the lendon 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 units affected 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 tension.
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 prestrcssing 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, me cubes shall be placed in the same environment as the
449
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
presiressing 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
3mm at any end of the concrete element. In case this slip is exceeded,
the concrete element in question shall 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 all rust, loose mortar,
grease and din.
The exposed ends of the tendons and concrete surface within 50 mm
of tendons shall 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 shall then be immediately applied over the ends
of the tendons unless otherwise directed.
A second coat of paint shall be applied prior to the drying out
of the first coat.
1810. SAFETY PRECAUTIONS DURING TENSIONING
Care shall be taken during tensioning to ensure 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 while 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 approval 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.
1811. 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 in
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 of instability.
Care shall be taken during storage, hoisting and handling of the
precast units to prevent their cracking or being damaged. Units damaged
by improper storing or handling shall be replaced by the Contractor
at his expense.
1812. TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons
shall be limited to the following :
a) Variation from the specified horizontal profile : 5 mm
b) Variation from the specified vertical profile : 5 nun
c) Variation from the specified position in member : 5 mm

Prestressed Concrete sha ll be measured in cubic metres. The
volume occupied by mild steel reinforcement/HYSD bars, high tensile
steel, sheathing and anchorages shall not be deducted.
High tensile (prestressing) steel sha ll be paid for separately and
its length shall be measured as actually incorporated 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,
duels 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.
1815. 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 contract 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
same, 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. DESCRIPTION
This work shall include furnishing, fabricating, transporting, erecting
and painting structural steel, rivet steel, cast steel, steel 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 IS: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 IS: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 IS: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
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 4VSo (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
IS: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:2155 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 bolls 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 (1SMB)
IS: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 Standards
as appropriate :
15:814 Covered Electrodes for Metal Arc Welding of structural
(Part 1) steel for welding other than sheets
IS:814 For welding sheets
(Pan 2)
IS: 1278 Filler rods and wires for gas welding
IS: 1395 Low and medium alloy Steel covered electrodes for
manual Metal Arc Welding
1S:3613 Acceptance Tests for wire flux combinations for submerged
arc welding of structural steel
15:7280 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 requirements
specified on the drawings or other special provisions laid down
by the Engineer.
457
The type of paints which can be used sha ll be as follows :

a) Ordinary i.e. paints based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy
b) Chemical Resistant - one pack type (ready for use) and two pack type (mixed
before use).
c) Vinyl
d) Chlorinated rubber
e) Bituminous
f) 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 consumption.
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 assembly
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
Ail structural steel-parts, where required, shall be sheared, cropped,
sawn or flame cut and ground accurately to the required dimension and
shape.
End/edge planning and cutting shall be done by any one of the
following prescribed methods or left as rolled :
a) Shearing, cropping, sawing, machining, machine flame culling.
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.
d) smooth profile, which are for secondary use such as stiffeners 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 cm edge is not subjected to applied stress.
b) The edge is incorporated in weld.
c) The hardness 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 3SO 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 materials
conforming to IS:226 and IS:2062. The requirement of hardness below 350 HV
30 of flame out edges should 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 (f).
Where machining for edge preparation in bull 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 materia l from
the flame cut edge shall be removed by machining.
Longitudinal edges of all plates and cover plates in plate girders and
built- up members shall be machined except in the following cases :
a) Rolled edges of single universal plates or flats may not he machined
b) Covers to single flange plates may be left unmachined.
c) Machine flame cutting instead of machining is acceptable for edges of single plates
in compression and for edges of single plates, 25 mm or less thick, in tension,
d) Edges of single shaped plates over 25 mm thick not capable of being machined
by ordinary method may be machine flame cut and the end 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- up members sha ll 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, sheared 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 Holes
1904.3.1. Drilling and punching : Holes for rivets, black bolts, high
strength bolts and countersunk bolts/rivets (excluding close tolerance
and turn fitted bolts) shall be either punched or drilled. The diameter
460
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 IS:226.
Holes through more than one thickness of material or when any of
the main material thickness exceeds 20 mm for steel conforming to
15:2062 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 comple te. 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 1900-1 below:
461
TABLE 1900-1 DIAMETER OF HOLES FOR RIVETS

Nominal dia of Rivets (mm) Dia 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 015 mm to
0.0 mm.
The members to be connected with close tolerance or turn 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 IS: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
if 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
462
When countersunk heads are required, the heads shall fill the
countersunk. The included angle of the head s hall be as follows :
a) For plates over 14 mm thickness 90 degree
b) For plates upto and including 14 mm thickness 120 degree
The tolerance on the diameter of rivets shall be in accordance with

IS: 1148 and IS: 1149 for mild steel rivets and high tensile a«! rivets
respectively and unless otherwise specified, the tolerance shall be minus
tolerance.
Rivets s hall be driven when hot s o as to fill the hole as com-
pletely as possible and shall be of sufficient length to form a bead 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 healed uniformly to a "light cherry red" colour
between 650 degrees Celsius to 700 degrees Celsius for hydraulic riveting
and "orange colour" lor 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 pres sure 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 bolted
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
s hall be done by hydraulic or pneumatic machine unless otherwise
Driven rivets, when s truck 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
463
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 prevent damage 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 IRC24. 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
464
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 3V2 times the diameter of
bolts and with a thickness not less than one quarter of diame ter 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 bolls
to ensure that correct tightening procedure is used and shall determine
that all bolls 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 inspection
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 bolls shall be checked and, if necessary, re-tightened.
465
1904.5.9. Drifts : The ban-el shall be drawn or machined to the

required diameter for a length of no t 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 l½ 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 protect the thread when
being drawn to place.
Pins more than 175 mm in length or diameter shall be forged and
THIS PART OF TEXT IS CURRUPTED

DUE TO XEROX PROBLEM
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 pan 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 of 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
1S: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 free 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 preparation
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
467
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 'he 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:73lO (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.
1904.8.4. Pecning of weld shall be carried out wherever specified
by the Engineer :
a) it specified, peening may be employed to be effective on each weld layer except
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 but! 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 us e
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) Intermittent grove welds
d) Intermittent fillet welds
e) Bevel-grooves and j-grooves in butt joints for other than horizontal positions.
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 s hall comply with the following requirements.
(i) One pair of “run-on” and one pair of “run-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 clumps.
(ii) When “run-on” and “run-off” plates shall be removed by blame cutting , it should
be cut at more than 3 mm from parent metal and remaining metal shall be
removed by grinding or by any other method approved by the engineer.
1904.8.7. Welding of studs hear connectors : The studs hear

connectors shall be welded in accordance with the manufacturer's
instruction.1! including preheating.
The stud and the surface to which studs are welded s hall 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 s hall be visually free from cracks and shall be capable
of developing at leas t the nominal ultimate s strength of studs.
469
The procedural trial for welding the stud shall be carried out when
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 tha t can
be inscribed within a square of side 0.5 m.
TABLE 1900-2 FABRICATION TOLERANCES A.
A. INDIVIDUAL COMPONENTS
1. Length
a) Member with both ends finished for ± 1 mm
contact bearing
b) Individual components of members with + 0 mm - 2
end plate connection mm
c) Other members
i) Upto and including 12 M + 2 mm +3.5
ii) Over 12 M mm
2. Width
a) 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 straightness of L/3000 subject to a
columns maximum of 15 mm
where L is length of
member
i) In elevation +5 mm
-0 mm
ii) In plan L/1000 subject to a
maximum of 10 mm
5. Deviation of centre line of web from centre

line of flanges in built-up members at contact
surfaces 3 mm
470
6. Deviation from flatness of plate of webs of 0.005 d to a maximum

built-up membe r to 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) t splices and s tiffeners, at 0.005 b to a
supports. ax the top flanges of minimum of 2 mm where b
late girders and at bearings is width of the member
b) t other places 0.015 b to a

maximum of 4 mm where
b is width of the member
8. Deviation from squareness of L/1000, where

flange to web of colu mns and L is nominal length
box girders of the diagonal
9. deviation from equareness 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
10. Deviation from squareness of D/1000m where D is

machined ends to axes of columns as defined in 9 above
11. Deviation from squareness of D/1000, where D is

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. Gene ral
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 seperate
contracts, the department will provide the substructure. construc ted 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 temporary
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 Codal 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 fasteners
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 V2 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 cent
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
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’ qualifications 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 safely, 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
number 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 adequately
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 wo rk. 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
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. Eearing 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 arid 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 I 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 1904 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 prevent s proper
assembling and fitting up of parts by moderate use of drifts Of 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
including labour 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 be finally checked until all welding and healing
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
be applicable and shall conform to requirements specified in IS:226,
IS:2062, 15:11587, 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 IS: 1852. The thickness
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 be inspected and tested for
compliance of codal 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
struck 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 codal 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 specimens.
1905.7.5. Welding and welding consumables : Welding procedure,
welded connection and testing shall be in compliance with codal
requirements.
All facilities necessary for stage inspection during welding and on
completion shall be provided to the Engineer or their inspecting
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
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 all be carried
out cording 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 in the weld or in the HAZ
(Heat Affected Zone) etc. Suitable magnifying glass may be used for sua1
inspection. A weld shall be acceptable by visual inspection if it that :
a) The weld has no cracks.
b) Through fusion exists between weld arid base metal and between adjacent
layers of weld metal.
c) Weld profiles art in accordance with requisite clauses of IS:9595 or as seed
with the Engineer.
d) The weld shall be of full cross section, except for the ends of intermittent
fillet welds outside their effective length.
e) When weld is transverse to the primary stress, undercut shall not be more
than 0.25 mm deep in the part of that is undercut and shall not be more than
0.8 mm deep when the weld is parallel to the primary stress in the part that
is undercut.
f) The fillet weld in any single continuous weld shall be permitted to under
run the nominal fillet weld size specified by 1.6 mm without correction
provided that undersize portion 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-
run 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 stiffeners 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 3020 mm length of weld.
h) The full penetration groove weld in butt joints transverse to the direction
of computed tensile stress shall have no piping porosity. For all other groove
welds, the piping porosity shall 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 internal flaws in the weld
such as crack, piping porosity inclusion, lack of fusion, incomplete penetration,
etc. This test mat be carried out as per IS:1182 and 15:4853.
Acceptance Criteria: The weld shall be unacceptable if radiographic or magnetic
particle testing shows any of the type of discontinuities 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 IS:4260 or any other relevant IS Specification and as agreed
to by the Engineer.
iv) Liquid Penetration Inspection : The liquid penetrant test shall be carried out for
detection of surface defect in the weld, as per 15:3658, in addition to visual
inspection.
The non-destructive 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
compression flanges.
d) 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
a) The fixing of studs after being welded in position shall be tested by striking
the side of the head of the stud with a 2 kg hammer to the satisfaction of the
Engineer.
b) The selected stud head stroked with 6 kg hammer shall be capable of lateral
displacement of approximately 0.25 the height of the stud from its original position.
The stud weld shall not show any sign of crack or lack of fusion.
The studs whose welds have failed the tests given in (a) and (b)
shall be replaced.
1905.7.6. Inspection requirement : The fabricated member/com-
ponent made out of rolled and built- up section shall be checked for
compliance of the tolerances given in Table 1900-2. Inspection of
member/components for compliance with tolerances, and the check for
deviations shall be made over the full length.
During checking, the inspection requirement shall be placed in
such a manner that local surface irregularities do not influence the results.
For plate, out-of-plane deviation shall be checked at right angle to
the surface over the full area of plate.
The relative cross-girder or cross frame deviation shall be checked
over the middle third of length of the cross girder or frame between
each pair of webs and for cantilever at the end of member.
The web of rolled beam or channel section shall be checked for
out-of-plane deviation in longitudinal direction equal to the depth of the
section.
During inspection, the component/member shall not have any load
or external restraint.
Inspection Stages : The inspection to be carried out for compliance
of tolerances shall include but not be limited to the following stages:
a) For completed pans, component/members on completion of fabrication and before
any subsequent operation such as surface preparation, painting, transportation,
erection.
b) For webs of plate and box girder, longitudinal compression flange stiffeners
in box girder? and orthotropic decks and all web stiffeners at site joints, on
completion of site joint.
c) For cross girders and frames, cantilevers in orthotropic decks and other parts
in which deviations have apparently increased on completion of site assembly.
Where, on checking member/component for the deviations in respect

of out-of-plane or out-of-straightness at right angles to the plate surface,
and any other instances, exceed tolerance, the maximum deviation shall
be measured and recorded. The recorded measurements shaft be submitted
480
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, scaffold ing,
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 imperviousness
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.
Howeve r, 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
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 / 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: 1477 (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) Dry or wet grit / Sand blasting
b) Pickling which should be restricted to single plates, bars and sections
c) Flame cleaning
Primary coat shall be applied as soon as practicable after cleaning

and in case of flame cleaning, primary coat shall be applied while
He metal is still warm.
All slag from welds shall be removed before painting. Surfaces
shall be maintained dry and free from din 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 coal shall preferably be from
the same manufacturer. Successive coats of paints shall 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 convent ional painting 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 (15:1745) and Grit blasting to near while metal surface.
ii) Paint system; 2 coals 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 coal 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 s hop. After
the steel work is erected at site, the second coat s hall be given after
touching up the primer and the cover coats if damaged in trans it.
c) Conventional Painting System for areas where corrosion is
severe
Priming Coat :
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 coal of zinc chromate conforming oxide primer to
IS:2074.
Finishing Coats :
Two coats of aluminum paint conforming to 1S:2339 shall be ap-
plied over the primer coat One coat s hall be applied before the
fabricated steel work leaves the s hop. After the steel work is erected
at site, the second coat s hall 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
s hall be applied to galvanized 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 after 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 coating
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
486
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 us ed 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
1 under coat alkyd type where regular maintenance is intended.
paint; 1 finishing coat alkyd This system may deteriorate to a marked
type. Total dry film thickness extent if it is exposed to moderate
= 150 µm aggressive atmospheric conditions for
lengthy period.
ii) Wire brush to remo ve all loose
rust and scale; 2 coats drying oil Similarly to (i) but where appearance
type primer. 2 under coats micaceous is not very important provides longer life
iron oxide (MXO) pigmented in mild condition. Will provide upto 5
phenolic modified drying oil. Total years life to first maintenance in polluted
dry film thickness = 170 µm inland environment
iii) Blest clean the surface; 2 coats Compared to (i), this would provide a
of quick drying primer, longer life in mild conditions and could
undercoat alkyd type paint; 1 be used in less mild situation e.g.,
finishing coat alkyd type. inland polluted, where maintenance
Total dry film thickness: could easily be carried out at
130 – 150 µm 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 µm
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, 1 undercoat of high Will provide long-term protection than
build chlorinated rubber; I finishing (iv) in non-coastal situations. Also
coal of chlorinated rubber. Total dry suitable for aggressive interior situation!
film thickness : 200 µm such as industrial areas.
vi) Blast clean the surface; Suitable for sea water splash zones
350 - 450 µm thickness. or for conditions of occurrence of
coal tar epoxy. frequent salt sprays.
vii) Pickle; hot dip galvanized Suitable for steel work in reasonably
(Zinc). Total thickness : 85 nm mild conditions Life of 15-20 yean
before first maintenance could be
expected in many situations
viii) Grit blast, hot dip galvanised. Provides a longer life than (vii)
(Zinc}. Total thickness = 140 µm 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 µm in aggressive atmosphere

The materials-shall be tested in accordance with relevant IS specifications
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 10-3 kg/cu. cm.
Cast Iron : 7.21 x 10-3 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
Weight of weld fillets 'and the weight of protective coatings s hall

not be included.
Weight of rivet heads s hall be computed by taking the weight of
100 s nap 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 agreement.
TABLE 1900-4 : WEIGHT OF RIVET HEADS
Dia of 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 s hall be made for the weight of protective coating
or weld fillets.
Where computed weight forms the basis for payment, the weight
shall be calc ulated 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 bas is 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 and other expansion or fixed devices shall
be constructed in accordance with the details shown on the drawings.
ii) The bearings may cither be supplied directly to the Engineer by the manufacturer
to be installed by the Contractor or the Contractor is 10 supply and install the
bearings as part of the contract. In the former case, 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. In the detailed description
of the specification, a general reference shall be made to the Contractor or
manufacturer and the interpretation 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 art shown on the drawings 10 be placed (not
embedded) directly on concrete, the concrete bearing area shall be constructed
slightly above grade (not exceeding 12 mm) 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 mm) may even be made w meet
with this requirement.
vii) It shall be ensured that the bottoms of girders to be received on the bearings
are plane at the locations of these bearings and care shall be taken that the bearings
are not displaced while placing the girders.
viii) M.S. bearings sliding on M.S. Plates shall not be permitted. For sliding plate
bearings stainless, steel surface sliding on stainless steel plate with mild steel matrix
shall 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 requirement
493
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 1S:7666 with
acceptance standard as per IS:9565. The castings may also be checked by any
other accepted method of non-destructive 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 ofIS:503

(Grade 4).
a) All work shall conform strictly lo the drawings and shall be in accordance with
the provisions of this section. Care shall be taken lo 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 surf aces of the rollers and bearing surface of the bearing
plates shall be machined and all boll 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 arc to be grouted
or bedded on a suitable yielding material on any surface which is to be in
permanent contract 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 lo vibration or jolts, adequate
measures may be taken to ensure that the roller assembly is not disturbed. It
is normal practice lo provide rocker bearings on the bunching end and place
the beam on Iris rocker end slightly in advance of placing on the roller.
d) During concreting of girders, the bearings shall he held in position securely by
providing temporary connection between the top and bottom plates in cast of
fined bearings and between top plate, base plate and saddle plate in case of roller
cum-rocker bearing or by any other suitable arrangement which prevents the
relative displacement of the components.
e) In prestressed precast girders, where recesses arc left on the underside of girders
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 organization experienced and qualified in
undertake precision engineering of this type and be approved by the Engineer
b) Workmanship shall be of good quality, neatly finished and of good appearance
c) Castings shall be true to the forms and dimensions shown on the drawings and
stall be free from pouring faults, sponginess, cracks, blow holts and other defeat
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 to 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 surface or cannot be remedied to
the approval of the Engineer.
f) Imperfections which are not located in bearing surface 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 fittings, 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 s hall
conform lo K7 of 15:919.
Tolerances on diameter of all concave surfaces shall conform 10
D8 of IS:919.
Height of Bearings
Tolerances on height of any component casting shall not exceed
+0.5 mm. No minus tolerance s hall be allowed. The edges of all ribs
s hall be parallel throughout their length.
Bas e Plate
Tolerance on length and width of the base plate shall not exceed
+1.0 mm, tolerance on the thickness of the plate s hall 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
of the castings . The edges of all
(This line is cut due to Xerox adjustment)
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 arc
horizontal and normal lo the direction of movement of the members they support.
Upper and tower 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 bearing plates shall be placed in a horizontal plane.
2003.5.2. Placing
a) On supporting structures, pockets shall be provided to receive anchor bolts;
one side of the pocket shall project beyond the bearing plate The pocket shall
be Tilted with mortar of mil 1:1 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
12mm) 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 finish for housing the bearing plate. A thin and stiff mortar pad
of mi* 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 mortar that is more than 30 minutes old after completion of mixing, shall
be used,
0 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.
496
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 bearing) shall conform to the specifications
laid down in clause 2003.1.
ii) If required, a suitable number of complete bearings as specified by an accepting
authority shall be tested lo 1.25 times the design load. Recovery should be 100
per cent. 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 (consis ting of 1:2 jets 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 bearing or certify
the acceptance of the bearings.
b) Test certificates of all raw materials shall be submitted. If manufacturer's
lest certificates ire not available for the raw materials, the bearings manu-
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 including 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 lo witness such inspection al manu-
facturer's works with or without prior permission of the manufacturer. For
this, the bearing 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.
f) 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 bearings
or pan 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 mid hall perform
various tests including destructive testing on h al his discretion, either ,11
the manufacturer's works or al any other approved test laboratory, notwith-
standing the lest 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 bearing is found
to be acceptable after destructive testing, the minor defects in the test
bearings shall not be a bar to the acceptance of the entire lot.
k) The opinion of the Engineer in cases (i) and (j) 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 to sliding friction. The bearing will permit aniaxial translatory
movement along longitudinal axis of the bridge and rotation along all
axes.
The bearing shall consist of the following parts :
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 bolls, 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
be slightly less than that of the concave top surface of the bottom plate
to ensure sufficient contact over a small area. Rotation along all axes
shall be permitted along the contact surface of the saddle plate and
the 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 FIFE/
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 bearing shall 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 ail 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 gel 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 Steel; Mild Steel, Stainless Steel shall conform to Clause 2003,1.
- Copolymer Poly Tetra Fluora Ethylene (FIFE) unfilled quality "shall have required
properties as per BS:5400 and thickness shall be as specified.
- Anchor Bolls shall be as per relevant IS specifications. 499
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 manufacturer.
ii) This backing plate shall be accurately positioned on the reinforcement grid of
the pedestal and levelled.
iii) Studs shall be tacit welded/tied to the reinforcement to keep the backing plate
in proper location during casting.
iv) Depth of embedment of the backing plate in the concrete shall be as per
relevant drawing.
v) The round base of the pot (bottom) of the pin bearing assembly shall be connected
to the backing plates by anchor screws after concreting of pier cap/pedestal.
vi) In order to ensure successful transfer of large horizontal forces to be resisted
by the Pin bearing, great care shall be taken in detailing the reinforcement in
the sub-structure and the super-structure adjacent to the studs in the backing plate,
2004.6. Acceptance Test on Spherical Bearings

1. AH bearings shall be checked for overall dimensions
2. All bearings shall be load tested to 1.25 times design vertical load
3. A pair of bearings selected at random shall undergo testing in order lo determine
coefficient of friction which shall be less than 0.05.
4. Two bearings selected at random shall be tested for permissible rotation.
2004.7. Acceptance Test on Pin Bearings

1. All bearings shall be checked for ovtrall dimensions.
2. All bearings shall 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 110, Skyprene B-5 and Denka S40V) shall be used.
No reclaimed rubber or vulcanized wastes or natural rubber sha ll
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 permitted,
Properties
The elastomer shall comform to the properties specified in Table
2000.1
TABLE 2000-1. PROPERTIES OF ELASTOMER
Property Unit Test Method, IS Value of the

specification characteristic
reference specified
1. Physical Properties
1.1. Hardness IRHD IS:3400 60 + 5

(Part II)
1.2. Minimum Tensile MPa IS:3400 17
Strength (Part I)
1.3. Minimum Elongation Per cent IS:3400 400
at break (Put I)
2. Maximum Compression
Set Per cent IS:3400
(Part X)
duration temperature
(h) (deg C)
CR +0 to 100±1 35
24.2
3. Accelerated Ageing
IS:3400
(Part IV)
duration temperature
(h) (deg C)
CR 70 100±1
-
3.1 Max change in
Hardness RHD + 15
3.2. Max change in Per cent - 15
Tensile Strength
3.3. Max change in
Elongation Per cent - 40
Shear modulus of the elastomer 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 ± 1 degree Celsius, 96 h and 50 pphm by volume respectively.
No cracking detected by visual observation at the end of the test
shall be considered satisfactory. No specific tests for assessment 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 specifications
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 permitted
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
Chloroprene (Appendix X-2)
b) Ash content test : to determine the percentage (sub-section 34)
c) Specific gravity test : (sub-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 test 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 test 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 culling from large si/,e cast be permitted.
Bearings of similar size 10 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 2000-2 TOLERANCES
ITEMS TOLERANCES
1. Overall plan dimensions -0, + 6 mm
2. Total bearing thickness -0, + 5 mm
3. Parallelism
a) Of top surface of bearing with
respect to the bottom surface as datum 1 in 200
b) Of one side surface with
respect to the other as datum 1 in 100
4a. Thickness of individual internal ± 20 per cent (max, of 2 mm)
layer of elastomer
b) Thickness of individual outer layer -0, + I mm
5a. Plan dimensions of laminates -3mm, +0
b) Thickness of laminates ±10 per cent
c) Parallelism of laminate with
respect to bearing base as datum 1 in 100
503
The vulcanising equipment/press shall 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 vulcanizate.
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 standard
slab and buttons shall be prepared in accordance with prescribed
standards and salient properties tested and recorded regularly against
each batch of production to 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 acceptanc e, 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 lot
When the number of bearings of equal or near equal size for

a single bridge project is large and phased production and acceptance
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 1 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 selected at random
for carrying out material tests. This bearing shall be excluded from
the lot accepted.
Acceptance inspection level 1 may be specified at 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 sha ll comprise general inspection,
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 1
General Inspection
1. All bearings of the lot shall be visually inspected for any defects in surface
finish, shape or any other discernible superficial defects,
2. Alt hearings of the lot shall be checked for tolerances specified in Table 2000-
2.
3. All bearings of the lot shall be subjected to axial load to correspond to cm
(i.e. average cornpressive 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 al laminate/steel interface
c) Variation in thickness of elastomer layers
d) Any surface defects
e) Low stiffness
Deflection under loads between σm=5 MPa and σm=15 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 d the
bearings of (he 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, lest method and criterion for acceptance.
Composition (see Note 1 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 1.
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 2000-1 , 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 lest on accelerated
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
1. Two bearings shall be selected at random from the lot as test bearings- These
beatings 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 determination of elastic modulus
Test for determination of shear modulus (short term 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 on
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 following

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 gene ral 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 2005.33.2 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 clearly 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 acceptance:
That an adequate system of continuous quality control was operated
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 and 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 IRC:83 (Part II) supplementing the quality control

certificate.
2005.3.7 Acceptance : The manufacturer shall furnish the following
to Engineer for the acceptance judgement :
1. Quality control certificate as laid down in Clause 2005.3.6.
2. Inspection certificate as laid down in Clause 2005.3.5.
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 acceptance control 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 acceptance of 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
entire cost of such tightened inspection shall be borne by the manu-
facturer.
2005.4. Certification 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
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 Handling
Each elasiomeric 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
comers and edges.
Care shall be taken to avoid mechanical damage, contamination
with oil, grease and din, 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 ± 1 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 specificatio ns 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 Elastomeric Bearings on a Non-Horizontal
Plane
Installation of elastomeric bearings on a Non-Horizontal Plane shall
be as follows :
i) Elastomeric 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 fitted
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 formwork at its
proper location and in a vertical plane.
iii) After casting of the pedestal and removal of the formwork, the template is to
be removed.
A. Installation with face plate and without template in-situ casting

i) The sub-assembly of elastomeric bearing with 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 elastomeric bearing
and that of the vertical face of the face plate with stainless steel top installed
on the projection below the soffit. This shall be achieved by inserting removable
steel sheeting of thickness as per the drawing, during preparation of the formwork
before casting of the superstructure.
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 fitted 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-structure.
B. Installation with face plate and with template in-situ casting

i) Template of 6 mm MS plate and of size same as face plate with stainless steel
top and matching holts 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 elastomer 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 formwork for the super-structure at its proper location and in
a vertical plane.
ii) After removal of the superstructure formwork, the template shall be removed.
512
iii) The face plate with the required thickness of pack plate shall be loosely filled
to the anchors embedded in the projection below the superstructure, with elastomer
washers and anchor screws.
iv) The sub-assernbly of elastomeric bearing with the MS backing plate shall be
filled u> the embedded anchors in the pedestal with anchor screws and elastomeric
washers replacing the steel washer this time.
v) The required clearance between the stainless steel face of the elaslotneric 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 projection 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 (Pan I) shall be applicable for all
metallic elements. Provisions of 1RG83 (Part II) shall be applicable
for all elastomer elements. Whe n any items are not covered by IRC83
(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 me other, the provisions of IRC will be guiding.
2006.1.3. Combination bearings using any judicious combination and
sliding element shall be permitted. As for example :
Name Rotation Sliding Generally for
Element Element
Pot Pot None Vertical Load
Elastomer Elasurni!1 ,; None* Horizontal Buffer

Pot PTFE Pot PTFE-SS** Vertical Load and
Horizontal Load
Spherical Spherical PTFE-SS** Vertical Load and
Knuckle PTFB Knuckle Horizontal Load
Elastomer PTFE Elastomer PTFE-SS*' Transverse Guide
Elastomer SS** Elastomer SS-SS** Transverse Guide

* Elastomer 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 after approval by
the Engineer.
2006.2. Fabrication
i) The surface mating with the PTFE 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 PTFE after full movement on all sides. If
stainless steel sheet is used, it should be bonded by continuous welding along
the edges. Adhesive or any other bonding can be approved by the Engineer. The
surface shall be prepared by thorough cleaning to remove grease, dust or any
other foreign substance.
ii) PTFE 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 flow 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 of the confined 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 mast 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 superstructure.
viii) The external surfaces of the assemblies shall be completely cleaned by sand
blasting. After sand blasting, dust shall be removed from the surface using clean
and dry compressed air or a clean brush after which suitable coaling shall be
applied.
ix) Pot bearings including all pans as shown on the drawings shall be fully shop
assembled at the manufacturer's works to ensure proper fitting of all pans.
514
2006.3. Materials
a) Steel
i) Structural steel shall conform to !S:226 and IS;2062, as applicable.
ii) Cast steel shall conform to Gr 280-520W of 15:1030. 0.3 to 0.5 per cent
copper may be added lo increase the corrosion resistance properties.
ii) Stainless steel shall conform to A1SL3W or XO4Crl8NilO of IS:69ll for
ordinary applications. For applications with adverse/corrosive environment,
the stainless steel shall conform to A1SI:316L or O2Crl7NiI2Mo2 of
IS:6911.
b) PTFE
PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality. It shall
be free sintered. The mechanical properties of unfilled PTFE shall comply with
Grade A of BS:37S4.
c) Elastomer
The confined elastomer inside pot will have the following properties :
a) Hardness IRHD IS:3400 (Part II) 50 + 5
b) Min tensile MPa IS:3400 (Pan I) 15.5
strength
c) Min 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 IS:9595.
2006.4.2. Cast steel assemblies : Cast steel for pot bearing
assemblies shall conform lo requirements of relevant IS. Castings shall
be true lo the forms arid dimensions shown on the drawings, and
shall be free from pouring faults, sponginess, cracks, blow ho les and
other defects affecting their appearance or their strength. Warped or
distorted castings shall not be accepted. Exposed surfaces shall le 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 composition 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 plates shall be flat and rolled bars and shapes straight before
marking our or being worked . Straightening shall be done by methods
which shall not damage the material. Sharp kinks and bends shall 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 shall be machined or ground.
2006.4.4. Tolerances
i) Plan dimensions : -0 10 +5 mm
ii) Overall height : -0 to +3 mm
iii) Height of elastomer : ± 5 pet cent
iv) Height of any steel component
a) Machined : -0 to +1 mm
b) Unmachined : Class 2 of IS:4897
v) Stainless steel sliding surface
a) Flatness : 0.0004L, where L = length in
direction of measurement
b) Surface Finish : Ra < 0.25 pm as per IS:3073
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 < 0.150
Urn or any other painting scheme as approved by the Engineer.
ii) Silicon grease shall be applied at me PTFE/SS interface 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 dimensions.
ii) All bearings shall be load tested to 1.1 times maximum design capacity
including seismic force. Bearing tested at higher loads cannot be used.
iii) A pair of bearings selected at random wilt undergo testing in order to determine
the coefficient of friction "µ". The coefficient of friction shall be < 0.05 at
the design load.
iv) Two bearings selected at random shall be tested for permissible 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 formwork shall only be
removed after lapse of appropriate time. In special cases, this can be ensured by
suitable devices like jades, etc.
iv) Temporary clamps and shims (introduced 10 maintain working clearance) shall
be removed at an 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) Preparation->concrete cleaning, roughening, pre-soaking, etc.

b) Forms ->sturdiness, leak proofing, shape, header funnel vents, etc.
c) Bearing Base->cleaning, etc.
d) Placement->mixing, consistency, lime period, finishing, etc,
e) Protection->curing, ambient temperature, etc.
2006.6.2. In-situ casting of superstructure

i) Formwork around the bearing shall be carefully scaled to prevent leakage
ii) Sliding plates shall be fully supported and care taken to prevent tilling, displacement
or distortion of the bearings under the weight of wet concrete.
iii) Bearings shall be protected during concreting operation. Any mortar
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 be used.
ii) All the anchors shall be fitted to the lower face of the template using the
anchor screws but with steel washer replacing the elastomer washers,
Separate screws may be used in case of in convenience in the length of the
original anchor screws.
iii) The template assembly shall be located with regard lo level and alignment.
!t shall be ensured that the lop of the anchors lie in a horizontal plane al
(he required elevation. The anchors shall be tied/welded lo reinforcements
to avoid displacement during concreting.
iv) Concreting of the pedestal/pier cap shall be done to a level leaving a gap
of'25-50 mm below the template.
v) The template and steel washers shall be removed prior to placement
of the bearing assembly with temporary clamps. The hearing assembly
shall be fitted lo the anchors with the help of anchor screws and elastomer
washers, Level al the bearing shall 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 Template with Gap

i) Pockets commensurate with the sizes of the anchors shall be kept in pedestals
during concreting of the same. The pedestal shall be cast approximately 25
mm short of the required finished level.
ii) Anchors shall be fitted lo the bearing bottom with elastomer washers and
anchor screws. The bearing assembly shall be sealed in the location on
sled chairs/packs. The anchors filled below the bearing shall go into pockets
in the bed block. Level and alignment of the bearing shall be checked. Ii
shall 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 grout. Reference may be made to 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
mm 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 1mm -
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 submitted alongwith the design and got approved
by the Engineer before their use in work.
The materials shall be tested in accordance with these specifications
The work shall conform to these specifications and shall meet the
Bearings shall be measured in numbers, according to their capacities
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 foundation placed in open excavation, in accordance with the
drawings and these specifications or as directed by the Engineer.
2102. MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2103. 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 open foundation :
i) Sources of Materials
ii) Design, erection and removal of formwork
iii) Production, transportation, laying and curing of concrete
iv) Personnel employed for execution and supervision
v) Tests and sampling procedures
vi) Equipment details
vii) Any other point
Necessary 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.
2104. WORKMANSHIP
2104.1. Preparation of Foundations
Excavation for laying the foundation shall be carried out in accordance
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 M15 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
foundations shall be constructed in dry conditions and the Contractor
523
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. Formwo rk for
top of the foundation concrete shall also be provided, if its top has
slopes steeper than 1 (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
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 during 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 steel/concrete caissons or sheet piling for creating in enclosure for the
foundations, which can subsequently be dewatered.
Before backfilling 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 M15 concrete
upto the top of rock.
The protective works, where provided shall be completed before
the floods so that the foundation does net get undermined.
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, shall be higher man the founding level shown en 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
2106. TOLERANCES
a) Variation in dimensions : +50 min - 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
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 1700, based on the quant ity ordered or as shown
on the drawing.
Reinforcement 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 and 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
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 :
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 construction
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
specifications and arrangements shall be subject lo the approval of the

Engineer.
The surface of foundation/well cap/pile cap shall be scrapped with
wire brush and al! 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 welled.
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 accordance
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 lop surface
of the pedestal on which bearings are to be placed shall also k- 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
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
surface of foundation shall be prepared in the same manner as prescribed
for construction of abutment. No horizontal construction joint shall be
provided. If shown on drawing or 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.
2208. TOLERANCES IN CONCRETE ELEMENTS
(a) Variation in cross-sectional dimensions : +10 mm, -5mm
(b) Misplacement from specified position in plan : 10 mm
(c) Variation of levels at the top : ±10 mm
(d) Variations of reduced levels of bearing areas : ± 5 mm
(e) Variations from plumb over full height : ±10 mm
(f) Surface irregularities measured with 3 m straight edge
All surfaces except bearing areas : 5 mm
Bearing areas : 3 mm
531

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 superstructure
in accordance with the drawings as per these specifications or
2302. MATERIALS
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 :
iv) Prestressing system, if applicable
v) Personnel employed for execution and supervision
vi) Tests and samp ling 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 tines 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) Formwork Section 1500
ii) Steel Reinforcement Section 1600
iii) Structural Concrete Section 1700
iv) Presiressing Section 1800
Additionally, some of the common types of superstructure construction

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
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 lop 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 T-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 may be provided at the junction of the web and the
fillet between the web and the deck slab with the permission of the
Engineer.
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 oh 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 and launching of girders shall be included in the method
statement.
536
In case of cast- in-situ construction, the sequence of construction including

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 construc tion
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 die concrete
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 construction and 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 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
on the drawings.
23053. Cantilever Construction
Continuity of untensioned reinforcement from one segment to the
next must be ensured by providing full lap length as necessary.
537
The design of the superstructure shall take into account the following
aspects which form an integral part of the construction operations :
a) Stability against over-turning for each statical condition through which the
assembly passes, shall be checked.
b) Stresses at each preceding segment joint with the addition of every segment or
change of statical conditions shall be checked. The load of equipment as well
as construction live load shall be taken into account.
c) Precambering of the superstructure during construction shall be done in such a
manner that the finally constructed structure under permanent load strains 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 +10 mm
bearings or ±0.1 per 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 in 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
bearings or ±0.1 per cent of the
span length, whichever
is lesser
e) Permissible surface irregularities when : 5 mm
measured with a 3 m straight edge or template

538

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.
__________
539
Surface and Sub-surface
Geotechnical Exploration
2400
Surface and Sub-surface
Surface and Sub-surface Section 2400
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 samples/cores taken 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 examination".
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
Surface and Sub-surface Geotechnical Exploration Section 2400
structure with span arrangement and the location and type of foundations,
shall be tentatively decided. Thereafter, the scope of detailed investigation
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 Indian Standards such as 15:1498, IS:1888,
IS:1892, IS:2131, IS:2132, 15:2720, 15:4434 and 15:4968 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 15:2131.
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 deposit.
544
For guidance reference may be made to IRC: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 entire length 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 viaduct or earthen embankment, the extended length and
location of the borings beyond the proposed location of abutment
should be determined and executed.
2402.1.3. The depth of exploration should be at least 1½ 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 may
be decreased based on difficulty to conduct core drilling and the
minimum depth may be restricted 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 firm strata is sufficiently
thick, the boring should extend 3 metre into the firm strata.
545
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 invest-
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 exploration
ii) Foundation requiring large depth of exploration
iii) Fills behind abutments and protection works
2403.3. Location Boring

Where the data made available by detailed exploration indicates
appreciable variation or where variations in a particular foundation
are likely 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 comprehend-
sive enough to. enable the designer to estimate or determine the fol-
lowing:
i) the engineering properties of the soil/rock,
546
ii) the location and client of soft layers and gas pockets, if any, under the hard
founding strata,
iii) the geological condition like type of rock, faults, fissures or subsidence 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 opacity of the foundation,
x) probable settlement and probable differential settlement of the foundation!,
xi) likely linking or driving effort, and
xii) likely conjunction difficulties.
2404. EXPLORATION FOR BRIDGE FOUNDATIONS RESTING

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 distributio n 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.
2404.3. Basic Information Required from Explorations
i) Depth of rock strata and its variation over the site,
ii) Whether isolated boulder or massive rock formation,
iii) Extent and character of weathered zone,
iv) Structure of rock - including bedding planes, faults, fissures, solution cavities etc.,
v) Properties of rock material-strength, geological formation, etc.,
vi) Erodibility of nock to the extent possible,
vii) Colour of water.
547
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 mentioned 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
general 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, 15:5313 may be referred to. The data shall
be presented in accordance with IS;4464.
2404.7.3. The cores shall be stored properly in accordance with
IS:4078.
548
2404.7.4. The rock cores obtained shall be subjected to following

laboratory tests :
i) Visual identification for texture, structure, 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:7317; and IS:7746. In addition, laboratory tests can also be made
on samples.
2404.7.6. Use 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 credibility 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 1RC: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
2404.10. Presentation of 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 1RO.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) Wash 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 oflRC: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 exploration
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 and
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) Pit/Bore-hole number
d) Reduced level (R.L.) of ground surface or other reference point
e) Dates of starting and completion
f) Name of s upervisor
g) Scales of plans and sections
h) Dimensions, methods of advancing exploration such as by hand tools, blasting,
bonng, etc.
i) General description of strata met with and RLs at which they are met
j) Position and altitude of contacts, faults, strong joint, slicken sides, etc.
k) Inflow of water, methods of controlling the water, required capacity of pumps
for de wale ring
l) The level at which the sub-soil water is met with
m) Dtp and strike of bedding and of cleavage.
n) Visual descriptor] of strata
o) Results of field tests e.g. SPT, in-situ vane shear lest etc.
p) Any other information and remarks.
2406.3. Upon removal of sampling tube, the length of the sample

in the tube and the length between the top of the tube and the top
of the sample m the tube shall be measured and recorded.
2407. METHODS OF SAMPLING
There arc two types of samples viz. (a) Disturbed sample (b)
551
Undisturbed sample. The usual methods for sampling conforming to

IS:1892 and IS:2132 arc given below :
Nature of Ground Type of Sample Method of Sampling
Soil Disturbed Hand Samples
Auger Sample
Shell Samples
Undisturbed Hand Samples
Tube Samples
Rock Disturbed Wash Samples from
percussion or rotary drilling
Undisturbed Cores
2408. PROCEDURE FOR TAKING SAMPLES
2408.1. 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
TABLE 2400-1 SIZE, OF SOIL SAMPLE REQUIRED

S. NO. PURPOSE OF SAMPLE SOIL TYPE WEIGHT OF SAMPLE
REQUIRED Kg
1. Soil identification. Cohesive soils 1
natural moisture Sands and
content tests, Gravels 3
mechanical analysis
and index properties,
chemical tests
2. Compression test) 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
stabilisation
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 Soil Samples
2408.3.1. 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 01 as directed by the
Engineer.
2408.3.2. 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 IS: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 gels
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 taken 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 lube 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) lob designation
c) Sample location
d) Boring number
c) Sample number
f) Depth
g) Penetration
h) Gross recovery 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 open pits. The use of Plate Load Test (as per
IS: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 \}jl 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 DEEP FOUNDATIONS
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.
555
2411.1.1. Cohesion less soil

a) Classification tests, density, etc.
b) Field tests.
- Plate Load lest as per IS:1S88.
- Dynamic Penetration test as per 15:2131 and Use of Dynamic Cone
penetration test as per IS:4968 (Part 1 or Part 2) may be conducted where
considered appropriate
c) Laboratory tests : Shearing strength test - triaxial or box shear test - in case of
the possibility of rise of water table, the tests shall be done on saturated samples.
2411.1.2. Cohesive soils

a) Classification tests, density, etc.
b) Field tests :
- Plate Load Test.
- Unconfined Compression Test as per IS:2720 (Part 10).
- Vane Shear Test as per IS:4434.
- Static Cone Penetration Test (1S:4%8 Part 3).
c) Laboratory tests : Shearing strength test - triaxial tests (IS:2720 Part 9). Consoli-
dation Test (13:2720 Part 15)
Note : Where dewatering is expected, samples may be tested for

permeability (IS: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 1½ 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 10 foundations. Where dewatering
is expected to be required, permeability characteristics shall be deter
mined.
2411.4. For the different zones categorised in para 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
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 investigations for sub-soil strata shall consist of raking minimum
two bore holes for each approach to a bridge along centre line of the
alignment at a distance of 50 m and 120 in behind the abutment positions
on both sides. The depth of bore holes below the ground level may
ordinarily be 2.5 times the maximum height of the embankment subject
to minimum depth of 20 m. Thin walled sampling tubes of 100 mm
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 1RC: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 ID Life Strength Shear Test Type of
No. Embankment Parameters Analysis
I. (a) During construction Un consolidated un drained Total
or immediate triaxial shear test on stress
post-construction undisturbed samples analysis
°uu, φuu and on compacted
embankment material
1 (b) — do — S Unconfined compression — do —

test in laboratory or
vane shear test
1 (c) During construction Cφ’ Consolidated undrained Effective

or immediate post- test with pore-pressure stress
construct! on measurement on as analysis
compacted soil samples of
embankment materials and on
undisturbed samples
2. Long term stability Cφ’ — do — — do —
557
Surface and Sub-surface Geotechnical Ex ploration Section 2400
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 METHOD
i) Gradation Test (Sieve Analysis) IS:2720 (Part 4)
ii) Alterberg Limit Test Standard IS:2720 (Part 5)
iii) Proctor Test Naiural Moisture IS:2720 (Part 7)
Content 15:2720 (Pan 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 shear 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 (IS: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 presented
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

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 an-, 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
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 IRC89 and these specifications
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 specifications or as approved by the Engineer.
The provisions given hereunder are applicable only to guide bunds
for bridges across alluvial rivers. Guide bunds 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 bund shall conform to provisions of Section 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 bunds 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 bund 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.
563
River Training Work & Protection Work Section 2500
2502.4. Construction of apron and pitching of the guide bunds shall

generally conform to clause 2503 and 2504 of these Specifications.
Sufficient length of pit along the guide bund shall be ready within
one to two months of commencement of work so that the placing
of stories 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 cent working season shall be
available for laying apron and pitching. No portion of the guide bund
should be left below HFL before the onset of monsoon. Bottom of
apron pit shall be as low as permitted by sub-soil water/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 taking 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 for laying within the
time frame for construction of guide bund. 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 bund or the approach
embankment crosses a branch 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 bund.
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
Quarry stones arc 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 blocks in M15 grade conforming to Section 1700 or
stones in wire crates in combination may be used in place of isolated
stones of equivalent weight. Cement concrete blocks will be preferred,
wherever practicable.
2503.2. Laying Boulder Apron
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 all along the
length and width of the apron. Within these walls, 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 waler 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
wire of diameter not less than 4 mm in annealed condition having tensile
strength of 300-450 MPa conforming to 1S:280. The galvanizing
coating sha ll 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 1.5
metre compartments by cross netting.
565
For deep or inaccessible situations, wire crates can be made

smaller subject to the approval of the Engineer.
Wire rates built in-situ, shall not be 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 he
bent at the middle around one of the spikes arid the weaving commenced
from one corner.
A double twist shall be given at each intersection. This twisting shall
be 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 be made
at one time. The other two sides shall be made separately and shall
be secured to the bottom and the ends by twisting adjacent vires together.
The top shall be made separately and shall be fixed in the same manner
as 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 tilled by carefully hand-paking
the boulders as tightly as possible and not by merely throwing in
stones or boulders.
For laying of wire crates in apron of bridges, two situations arise:
i) Where the crates are to be laid us deep water and have to be dumped and then
joined together.
ii) Where depth of water s low or dry bed is available. In 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 bunds,
training works and road embankments 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 01 the river,
566
may be protected against ordinary wave splashing by 0.3-0,6 metre thick

cover of clayey or silly 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 be
shown on the drawing.
The stone shall be sound, hard, durable and fairly regular in shape.
Quarry stone should be used. Round boulders shall not be allowed. The
stones subject to marked deterioration by water or weather shall not be
accepted.
The size ar4 weight of stone shall conform to clause 5.3.5.1 of^
IRC:89. No stone, weighing less than 40 kg shall, however, be used.
The sizes of spalls shall be a minimum of 25 mm and shall be suitable
to fill the voids in the pitching.
Where the required size stones are not economically available,
cement concrete blocks in Ml 5 grade conforming to Section 1700 or
stones 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 : The material for the .filter shall consist of
sand, 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-
quirements:
Provision of a suitably designed filter is necessary under the slope
pitching to prevent the escape of underlying embankment material
through the voids of stone pitching/cement concrete blocks when sub-
jected to the attack of flowing water and wave action, etc. In order
to achieve this requirement, the filter may be provided in one or more
layers satisfying the following criteria :
D 15 (Filter)
<5
D 85 (Base)
D 15 (Filter)
4< < 20
D 15 (Base)
567
D 50 (Filter)
< 25
D 50 (Base)
Notes : 1. Filter design may not be required if embankment consists of CH or Ch
soils with liquid limit greater than 30, resistant to surface erosion. In
this case, if a layer of material is used as bedding for pitching, it shall
be well graded and its D 85 size shall be at least twice the maximum
void size in pitching.
2. In the foregoing, D 15 means the size of that sieve which allows 15 per
cent by weight of the filter material to pass through it and similar is
the meaning of D 50 and D 85.
3. If more than one filler layer is required, the same requirement as above
shall be followed for each layer. The finer filter shall be considered as
base material for selection of coarser filter.
4. The filter shall be compacted to a firm condition. The thickness of filter
is generally of the order of 200 mm to 300 mm. Where filter is provided
in two layers, thickness of each layer shall be 150 mm.

Before laying the pitching, the sides of banks shall be 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 filter granular material shall be laid over the prepared base and
suitably compacted to the thickness specified on the drawings.
The lowest course of pitching shall be started from the toe wall
and built up in courses upwards. The toe wall shall be in dry rubble
masonry (uncoursed) conforming 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 be placed by derrick or by hand to the required
length, thickness and depth conforming to the drawings. Stones shall
be set normal to the slope, and placed so that the largest dimension
is perpendicular to the face of the slope, unless such dimension is
greater than the specified thickness of pitching.
The largest stones shall be placed in the bottom courses and for
use as headers for subsequent courses.
In hand placed pitching, the stone of flat stratified nature should
be 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
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,
die stones shall be laid breaking joints and all interstices between
adjacent stones shall be filled in with spalls 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 used and stones
shall be 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
height of the specified thickness at suitable intervals and all along
the length and width of the pitching. Within these walls the stones
shall be hand packed as specified,
2504.4. Toe Protection
In conformity with clause 5.3.7. of IRC:89, a toe wall shall be
provided at the junction of slope pitching and launching apron of a guide
bund so as to protect the slope pitching from falling even when the
apron is not laid at low water level. The toe wall shall be 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 cement
concrete blocks have been used in pitching. For protection of toes of
bank slopes terminating cither in short aprons at bed levels or anchored
in flooring / rocky bed, the provisions of clause 8.2.2 of IRC:89 may
be complied with. The relevant specifications of the protective works
for individual components will be followed,
2505. RUBBLE STONE/CEMENT CONCRETE BLOCK
FLOORING OVER CEMENT CONCRETE BEDDING
2505.1. This work shall consist of constructing rubble 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 flexible apron.
Excavations for laying the bedding and floor protection works shall
be carried out as per specifications under proper supervision. Before
laying the foundation and protection walls, the excavated trenches shall
be thoroughly inspected by the Engineer- in-Charge LO ensure that :
569
a) There are no loose pockets and unfilled depressions left in the trench.
b) The soil at the founding level is properly compacted to true lines and level so
as to have an even bedding.
c) All concrete and other elements are laid 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
except that the surface of the concrete shall not be given a smooth
finish. The paving work shall be embedded in green concrete.
Flooring shall consist of 150 mm thick flat stone/cement concrete
blocks (Nominal mix Grade M 15 conforming to Section 1700). It shall
be bedded on a layer of cement mortar (1:3) prepared to Clause 1304.
Spalls shall be used to fill in the voids. The joints shall then be filled
with cement mortar and finished neat. The stone shall break joints
and the joints shall not exceed 20 mm in thickness. Spacing of joints
may be 20 m or so. The top of flooring shall be kept to 300 mm below
the lowest bed level.
2506. DRY 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 .means
to have an even bedding.
The thickness of 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 m on upstream
side and 2.5 m on downstream side. The curtain wall will be in cement
concrete M 15/stone masonry in cement mortar 1:3. The rigid flooring
shall be continued over the top width of curtain wall.
2507.2. Flexible Apron
Flexible apron 1 m thick comprising loose 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.
570
work of floor protection shall be simultaneously completed alongwith the

work on bridge foundations.
The protection works shall be measured as set forth below. If
directed by the Engineer for measurement, the materials may have to
be stacked at site before laying and nothing extra will be paid to
the Contractor for this stacking.
The earth work in construction of embankment for guide bund shall
be measured in cubic metres unless otherwise specified.
The boulders/cement concrete blocks and wire crates in apron shall
be measured in cubic metres.
The filter and stone pitching shall be measured separately in cubic
metres unless otherwise specified.
Rubble stone/cement concrete blocks, flooring and cement concrete
bedding shall be measured in cubic metres for each class of material.
Preparation of base for laying the flooring shall be deemed incidental
to the work.
For laying apron, excavation upto an average depth of 150 mm shall
be deemed to be included in the main item and shall not be measured
separately unless otherwise specified. Excavation more than 150 mm
shall be 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, tools, 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 for completing
the work according to above specifications. Excavation upto an average
depth of 150 mm shall also be deemed to be included in the rate as
571
dressing of the bed. Excavation beyond this depth shall be paid for
separately unless otherwise specified.
The contract unit rate for one cubic metre of filter or stone/cement
concrete block pitching on slopes shall include the cost of preparing
the bases, putting to the profiles, laying and compacting the filter
and stone pitching of dry rubble/cement concrete block rivetment for
embankment slopes to the specified thickness, lines, curves, slopes and
levels and all labour and materials as well as tools and plant required
for the work.
The contract unit rate for rubble stone/cement concrete block
flooring shall include the cost of all material, labour and tools and plant
for completing the work as per these specifications.
__________
572
Expansion Joints
2600
Expansion Joints
Expansion Joints Section 2600
2601. DESCRIPTION
This work shall consist of fabrication and placing of expansion
joints as indicated on the drawing and conforming to these specifications
2602. GENERAL
a) The expansion joints shall be designed and duly got approved by the Engineer.
It shall cater for expected movement and rotation of the structure at the
joints and provide smooth riding surface. It shall also be easy for inspection.
maintenance and replacement
b) Expansion joints shall be robust, durable, water-light and replaceable. Site
fabricated expansion joints shall be prohibited. Expansion joints shall be obtained
by the Engineer either directly or through the Contractor from approved
manufacturers and be of proven type.
c) For bridges with prestressed concrete superstructure, with individual span length
more than 20 m or built with innovative design/construction elastomeric expansion
joints of slab seal or strip seal type shall be provided.
d) For slab type of bridges of spans less than 10 metres continuous surfacing
may be provided across the expansion gaps, supported on a -20 mm thick plate
placed and fixed at the level of the deck slab.
e) For bridges other than those mentioned in (c) above with spans above 10 metres,
an alternative specification of sliding steel plate joint or filled joints with copper
plates may also be adopted if approved by the Engineer, apart from elastomeric
expansion joint of slab seal or strip seal type.
f) Vehicular traffic shall not be allowed over expansion joints after its construction
for such period as may be determined by the Engineer.
g) Proprietary type deck joints offered by the Contractor in lieu of the type specified
shall comply in all respects with the manufacturer's specifications and meet
the required range of movements and rotations and be fit for the purpose of
ensuring satisfactory long term performance in the bridge.
Where alternative type proprietary deck joints are proposed by the

Contractor, the following information shall be provided.
i) Name and location of the proposed manufacturer.
ii) Dimensions and general details of the joint including material specifications,
holding down bolt or anchorage details and installation procedures.
iii) Evidence of satisfactory performance under similar environmental 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
facturer's recommendations and to the general requirements of this Speci-

fication.
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 be made different from that used for the carriageway expansion joint.
2603. REQUIREMENTS
2603.1. 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 ex-
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 imposed load including the impact load from live load and other
sources.
b) Allow expansion and contraction movement due to temperature, creep, shrinkage,
prestressing and structural deformations.
c) Permit relative rotation in elevation and plan due to the causes as noted above,
d) Be waterproof. Bridge deck expansion joint seals play a critical role in preventing
the degradation of the structural 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 sealing. In case bridge deck joints arc not sealed, apart from loss of
waterproofing, grit and other forms of road debris may enter the joint. Debris,
when impacted with the joint can seriously restrict the movement instead of
facilitating the same. In the case of proprietary joints being accepted for
adoption, the sealing shall be as specified by them,
f) Ensure long life by being resistant to corrosion,
g) Be easy to install,
h) Be easy to maintain. Replaceability of expansion joint shall be one of the basic
criteria for selection of type of expansion joint,
i) Be resistant to the materials likely to collect/spill over the deck in its normal
service.
576
2603.4. Performance Requirement with Respect to User

The expansion joint snail :
a) Provide smooth continuity at the top of the deck for riding comfort,
b) Be of skid resistant surface,
c) Be non-damaging to the rubber tyre,
d) Make minimum noise during vehicular crossing.
e) Ensure that animal paws and hooves should not get entangled where bridges are
used by animal drawn traffic,
f) Permit passing of bullock Cart steel tyre for bridges where bullock cans ply,
g) Look good aesthetically.
2603.5. Performance Requirement for Transition Zone

It is the zone of connection of joint assembly and the adjoining deck.
The expansion joint shall :
a) Permit transfer of generated forces without distress, i.e.. without getting uprooted.
The purpose will not be served if the bonding is with the wearing COM only.
Anchorage must be provided with the deck structural element.
b) Ensure that surface in the transition zone slays 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 alternative shall be to keep a gap in the wearing coal which
is filled up with a seal and filler, to be provided in extremely hoi areas.
b) Materials for steel plates shall conform to Section 1900. The exposed metallic
components shall be galvanised or coaled with approved anti-corrosive paint. The
thickness shall be 20 mm or so for obtaining satisfactory performance.
c) Plates shall be placed to the line, grade and expansion gap shown on the drawings
with any adjustment required for temperature, particular care being taken with
the top of the plates.
d) Plates shall be firmly held in place during concreting by methods approved by
the Engineer,
e) Any temporary bolls or other fixings which prevent relative movement of the
adjacent pans of the joint shall be removed as soon is the concrete has set
sufficiently to 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.
f) Care shall be taken to prevent damage to expansion joint plates or its coating.
g) If any damage occurs. the plates and coatings shall be restored by the Contractor
to the satisfaction of the Engineer.
h) Plates shall be free of oil, rust, loose paint or other similar material before coating.
577
2605. FILLER JOINTS

a) The components of this type of joint shall be at least 2 mm thick corrugated
copper plate placed slightly below the wearing coat, 20 mm thick compressible
fibre board to protect the edges. 20 mm thick pre-moulded joint filler Tilling the
gap upto the lop level of the wearing coat, sealed with a joint scaling compound.
b) The material used for filling expansion joint shall be bitumen impregnated fell,
clastomer or any other suitable material, as specified on the drawings. Impregnated
felt shall conform to the requirements of 1S:1838, and shall be got approved
from 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 joint material) 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 expense of the Contractor.
e) Joint gaps (hall be constructed as shown on the drawings, Surfaces of joint
grooves shall be thoroughly cleaned with a wire brush to remove all loose
materials and dirt and debris, then washed or jelled out.
f) Pre-moulded expansion joint filler shall not be placed in position until immediately
prior to the placing of the abutting 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 fact is about to be placed.
g) Sealants shall be installed in accordance with the manufacturer's recommen-
dations and all appropriate requirement;! for joint face priming,
h) Sealants shall be finished approximately 3 mm below the upper surfaces of the
joint,
i) Joint materials spill or splashed onto finished surfaces of the bridge during joint
Tilling operations shall be removed and the surfaces made good to the Engineer's
approval.
j) No joint shall be sealed until inspected by the Engineer and approval is givers
to proceed with 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 be permitted.
b) Elastomer for elasiomeric slab unit (ESU) shall conform to clause 915.1 of
KC:S3 (Pan 11), compounded to give hardness 1RHD 60 +5, subject to the
following additional stipulations :
i) Chloropiene (CR) only shall be used in the manufacture of elasiomeric expansion
joints. No reclaimed/natural rubber or vulcanised wastes shall be
used.
ii) The chloroprene material used in the manufacture of elastomeric (expansion
joints) shall be Neoprene WRT. Bayprene 110, Skyprene B5 or Denka S-
40V.
578
iii) Chloroprene content of the compound shall not be lower than 60 pet cent
by weight. The ash content shall not exceed 5 pr cent (»s per tests conducted
in accordance with ASTM D-297 for (i) and (ii) above.
iv) EPDM and other similar candidate elastomers for expansion joints shall
not be permitted.
c) Elasiomeric plugs,
d) Spacer bars, marked with centre to centre distance of fixing holes.
e) Fixing bolts and nuts made of stainless steel.
f) Anchor bars comprising hooked anchor stiffeners welded with tower steel inserts
and sinusoidal anchor bars welded with horizontal leg of the edge steel inserts.
The elaborate anchoring arrangements of steel inserts shall be permanently welded/
tied with the steel reinforcement
2606.2- Fabrication
a) Steel inserts shall be grit blasted and provided with epoxy paint.
b) Edges of reinforcing steel sections shall be founded.
c) Expansion joints shall be fully moulded to thc required size in One single
vulcanising operation including the encasing layers as integral and homogeneous
part.
d) Tolerances of fabrication shall be as follows :
i) Plan dimension -> ± 5 mm
ii) Total height -> ± 3 mm
2606.3. Supply and Handling

i) The Contractor shall supply all steel-reinforced elasiomeric expansion 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 joint material shall he handled with care and stored under cover by
the Contractor to prevent damage. Any damage occurring after delivery shall
be made good at the expense of the Contractor to the satisfaction of the Engineer.
2606.4.1. Expansion joints shall be installed as per approved
drawing. Steel inserts, spacer bars, concreting of pockets, fixing of
elastomer 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 inserts shall be lowered at the appropriate location inside the pocket
iii) The top of the insert shall be flush with the finished level of wearing course
maintaining the camber.
iv) Spacer bars, duly set appropriately to the month of installation, shall be
filled under proper supervision.
579
v) Anchor rods shall be lied/welded with the existing deck main reinforcement,
maintaining level and alignment.
vi) Welding Between anchor rods and deck reinforcement is preferable.
If welding is not possible, strong steel tie wires shall be used for fastening,
under proper supervision,
b) Spacer Bar
i) Spacer bars shall be used to ensure proper positioning of bolts and also
levelling of the steel inserts during fixing of the same with the deck
reinforcement and casting second stage concreting in the pocket thereafter.
ii) The 2nd stage concreting operation shall preferably be started within
24 hours of fixing 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 elasiomeric bearings,
(with no dowel pins), insert shall be placed in position with spacer
bars at every alternate joints. Such joints shall be called restrained
joints hereafier. In other words, inserts shall not be fixed simulta-
neously at two ends of one span. If the above condition is satisfied,
inserts with spacer bars shall be kepi in position for a substantially
longer period at such restrained joints. Spacer bars shall be removed
after concreting of such restrained joints and inserts placed in position
with spacer bars at the other unrestrained joints thereafter.
b) For bridges resting on other than elasiomeric bearings (including
bearings with dowel pins at one end), after placing and aligning
the inserts and securing the same, the spacer bars shall be 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 lake care to see
that the concrete is not damaged during withdrawal of spacer bar. If the
spacer bar happens to be snugly fitted, it shall not be pulled by any means;
it shall be gas cut in two pieces and then removed.
c) Concreting of Pocket
i) Concreting of pocket shall be done with great care using proper mi*
conforming 10 grade similar to that of the deck casting besides ensuring
efficient bonding between deck and steel insert. Also proper care shall be
given for ensuring efficient bonding with the already cast concrete.
ii) Needle vibrators shall be used. Care shall be taken so that the position of
steel insert is not disturbed during vibration.
iii) Spacer bar shall be removed within an appropriate lime before the joint
is required to permit movement,
d) Riling of Elstomeric Slab Unit (ESU)
i) Special jig shall be used to preset the ESU during installation
ii) ESU (mounted on the jig. if preset) shall he lowered to position.
581
iii) The line and level on the ESU should be adjusted.

iv) ESU shall be removed and coated with special adhesive
v) ESU shall be placed in position again, ensuring waterproof joining at
required faces.
vi) ESU shall be 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 elastomeric plugs shall be pressed in position after applying adhesive
on the appropriate surface.
viii) ESU shall be fitted 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 the already existing wearing course,
e) Pre-Setting
i) The main purpose of presetting of the steel inserts at the time of its
installation is to ensure as closely as possible the condition that in the
long run at the mean average annual temperature, the ESU remains at
its nominal state.
ii) Major factors responsible for changing the longitudinal length of the
bridge superstructure are indicated below :
a) Temperature variation from annual mean.
b) Changes due to shrinkage of concrete.
c) Changes due to elastic shortening and creep of the prcstressed bridge
superstructure.
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 lo
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 between 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 between the mean temperature of the month of fixing of
steel insert and the annual average temperature.
ii) The elapsed period between the casting and/or prestressing and fixing of
steel insert for calculating the remnant creep and shrinkage.
581
2606.4.2. Special requirements for installation

i) Prior to construction of bridge deck area adjacent lo 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
superstructure shall be amended as required to ensure that there will be no
interference in the installation of The joint.
ii) All bearing surfaces and recesses which are in contact with the joint assembly
shall be checked with a straight edge to ensure flatness of profile.
iii) No holes shall be drilled for fixing bolts within 7 days of concreting. Holes for
the bolts shall be drilled lo the size and depth shown on the drawings,
iv) Sections of the jointing making the completed joint shall follow a straight
line.
v) The fixing bolts shall not be placed in a position until al least 4 weeks after
stressing is completed in post-tensioned box or beam and slab structures.
Prior To placing sections of jointing, contact surfaces shall be cleaned lo remove
all grease, tar, paint, oil, mud or any other foreign material that may affect
adhesion of the sealant.
vi) Sealant shall only be applied lo dry contact surfaces. Sufficient sealant shall be
applied to the contact surfaces lo cause extrusion of sealant when the jointing
is fixed in position.
vii) Final sealing 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 shall be filled with sealant. All voids
between the sides of the jointing and concrete or plates shall be filled with
sealant.
viii) Boll cavities shall be cleaned and plugged with neoprene cavity plugs. Prior
to placing the plugs sufficient sealant shall be placed in the cavities lo cause
extrusion of the sealant by the plugs.
ix) All excess 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 environment, ozone resistance test as per clause 915.2.3
of IRC:83 (Part II), shall be carried out for elastomer.
The properties of the elastomer shall conform to Table I of clause
915.2 ofIRC:83(Part II).The acceptance testing for elastomer, material
shall conform to clause 918.4.1.2 of IRC:83 (Part II) with additional
criteria as stated in Clause 2005.
582
2606.5.2. The fabricated expansion joint / shall be- subjected to

the following acceptance tests :
i) Routine lest. Each expansion joint shall be tested- for at least 100 cycles for
a test movement which shall be 10 per cent mom than the design expansion/
contraction movement
ii) In addition to routine test, one out of every 20 expansion joints shall be subjected
to the test movement for 4000 cycles.
The lot shall be rejected if the elastomer material shows signs of fatigue or
permanent set or distress in the test, the test piece shall not be used in the
iii) The type test for abrasion resistance shall be carried out for one joint out of
every 20 not, as per IS:34QQ (Part1 3) and the standard deviation shall be within
± 20 per cent
N.B, The manufacturer shall preferably have in-house testing

facility. Otherwise, the testing shall be got done by him at his expense
at any testing establishment selected by the Engineer, A manufacturer
who cannot cany out the acceptance test shall not be entitled to supply
elastomeric slab seal joint.
2607. STRIP SEAL EXPANSION JOINT
2607.1. Components
Strip seal expansion joint shall comprise the following items :
a) Edge beams - This special claw leg profiled member shall be of extruded rolled
steel section combining good weldability with notch toughness.
b) Strip seal - This shall be of chloroprene with high tear strength, insensitive
to oil, gasoline, and ozone. U shall have high resistance to aging. This component,
provided to ensure water lightness, shall have bulbous shape of the part of the
seal which is inserted into the groove, provided in the edge beam. The sea) should
be vulcanised b single operation for minimum full length of joint,
c) Rigid Anchorage - This shall be welded to the edge beam at staggered distance.
d) Anchor loops - This shall be made of weldable steel connecting the rigid
anchorage with deck reinforcement
2607.2. Material
a) Edge beam) of this special section are at present being directly imported
in India. The steel shall conform to steel grade Rs t 37-2 of Gentian Standard
or equivalent
b) Chloroprene of strip seal shall conform to clause 915.1 of RC:83 (Pan II). The
properties of chloroprene shall conform to Table 2600-1.
c) Anchorage steel shall conform to IS:2062.
d) Anchor loop shall conform to IS:2062.
583
TABLE 2600-1. STRIP SEAL ELEMENT SPECIFICATION

Sealing element is made of chloroprene and must be a extruded
section. The working movement range of the sealing element shall be
at least 80 mm with a maximum of 100 mm at right angles to the joint
and ±40 mm parallel to the joint.
PROPERTY SPECIFIED VALUE
Hardness 63 ± 5 Shore A
Tensile Strength Min 11 MPa
Elongation at fracture Min 350 per cent
Tear Propagation Strength
Longitudinal Min 10 N/mm
Transverse Min 10 N/mm
Shock Elasticity Min 25 per cent
Abrasion Min 220 mm3
Residual Compressive Strain
(22 h/70 deg C /30 per cent strain) Max 28 per cent
Ageing in hot air
(14 days/70 deg C)
Change in hardness Max +5 Shore A
Change in tensile strength Max -20 per cent
Change in elongation at fracture Max -20 per cent
Ageing in ozone
(24 h/50pphm/25 deg C/20 per cent strain) No cracks
Swelling behaviour in Oil
(116 W25 per cent C) ASTM Oil no.
Volume Change Max 5 per cent
Change in hardness Max 10 Shore A
ASTM Oil no.3
Volume Change Max'25 per cent
Change in hardness Max 20 Shore A
Cold Hardening Point Min -35 deg C
2607.3. Fabrication (Pre -installation)
a) Rolled steel profiles for edge beams shall be long enough to cater for a 2-lane
carriageway. These shall be cut to size of actual 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-section on 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 lacked by arc welding.
b) 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 clamp ed 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.
b) The manufacturer shall supply either directly to the Engineer or 10 The
Bridge Contractor all the materials of strip seal joint? including sealants and 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 Contractor's
expense to the satisfaction of the Engineer.
2607.5.1. 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 be determined and
intimated to the manufacturer. Depending upon the temperature at which
the joint is likely to be installed, the gap dimension shall be preset.
2607.5.2. 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 be 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 shut tered in such a way that
dimensions in the joint drawing are maintained. The formwork shall
be 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 presetting
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 lake 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
strength as that of the superstructure, but in any case not less than M
35 grade. Good compaction and careful curing of concrete is particularly
important. After the concrete has cured, the movable installation brackets
still in place shall be removed,
2607.5.7. Rolled up neoprene strip seal shall be cut into the required
length and inserted between the edge beams by using a crow bar pushing
the bulb of the seal into the steel grooves of the edge beams. A landing
to a bead shall be 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.
2607.5.8. As soon as the concrete in the recess has become initially
set, a sturdy ramp shall be placed over the joint to protect the exposed
steel beams and neoprene seals from site traffic. Expansion joint shall
not be exposed to traffic loading before the carriageway surfacing is
placed.
26073.9. The carriageway surfacing shall be 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
be cleaned beforehand. It is particularly important to ensure thorough
and careful compaction of the surfacing in order to prevent any
premature 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
in Table 2600-1 It shall also be stretch tested. If a manufacturer is to supply
this type of joint, they will have to produce a test certificate accordingly conducted
in a recognised laboratory, in India or abroad.
iii) In view of the importance of the built up edge beams, special investigation
of fatigue strength of this section with anchorages to withstand 2 \ \Cf load
change cycles 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 been tested in a recognised laboratory to determine optimum configuration
of anchorage assembly under dynamic loading.
v) The manufacturer shall satisfy the Engineer that water tightness test for
the type of joint has been carried out in a recognised laboratory to check the
water tightness under a water pressure of 4 bars.
vi) As strip seal type of joint is specialised in nature, generally of the proprietary
586
type, the manufacturer shall be required 10 produce evidence of satisfactory

performance of this type of joint.

The expansion joint shall be measured in running metres. For
filled joints, the rate per running metre shall include the cost of sealant
for the depth provided in this drawing.
2610. RATE
The contract unit rate shall include the cost of all material, labour,
equipment and other incidental charges for fixing the joints complete
in all respects as per these specifications in the case of Bridge Contractor
supplying the expansion joint. If the manufacturer supplies the expansion
joint directly to the Engineer, the cost of installation, handling and fixing
shall be borne by the Bridge Contractor.
___________
587
Wearing Coat and Appurtenances
2700
Wearing Coat and
Appurtenances
Wearing Coat and Appurtenances Section 2700
2701. DESCRIPTION
This 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 specifications
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 requirements
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 shall be laid as per Clauses 503 and 515 respectively.
ii) SO mm thick asphaltic concrete wearing coat in two layers of 25 mm each as
per Clause 512.
In case of high rainfall intensity areas, the thickness of mastic asphalt

layer may be increased to 12 mm.
2702.1.2. For high traffic density, an alternative specification
for wearing course comprising 40 mm bituminous concrete overlaid
with 25 mm thick bitumen mastic layer can be adopted. The work shall
be done in conformity with Section 500.
2702.2. Cement Concrete Wearing Coat
Cement concrete wearing coat may be provided in case of isolated
bridge construction or bridges located in remote areas. It shall not be
laid monolithic with the deck.
The thickness of wearing coat shall be 75 mm. The minimum grade
of concrete shall be 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 footpath surfaces shall have non-skid characteristics.
591
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,
b) Railings shall not be constructed until the centering falsework for the
span has been released and the span is self-supporting. For concrete with steel
reinforcement, specifications of the items of controlled 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-shrink able 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 railings ID ensure
that they function properly.
f) 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 art kepi clean and free from damage.
Railing materials shall be stored above the ground on platforms, skids, or
other supports and kept free from grease, din 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
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, metal railing shall be
given one shop coat of paint and three coats of paint after erection
if sections are not galvanised.
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 be cast in
place shall be constructed in accordance with the requirements for
Structural Concrete in Section 1700. The reinforcement shall conform
to Section 1600.
Forms shall either be of single width boards 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 comers 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 reinforces cement
concrete and shall conform to the specifications given in Sections
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 u: which the
surface of the cast- m-situ portion of the deck.
2704. APPROACH SLAB
Reinforced concrete approach slab covering the entire width of the
593
roadway shall be provided 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 be
as shown on the drawings or as directed by the Engineer.
2705. DRAINAGE SPOUTS
2705.1. This work shall consist of furnishing and fixing in position
of drainage spouts and drainage pipes for bridge decks.
Drainage along longitudinal direction shall be ensured by
sufficient number of drainage fixtures embedded in the deck slab. The
spouts shall be of not less than 100 mm in diameter and shall be of
corrosive resistant material such as galvanised steel with suitable cleanout
fixtures. The spacing of drainage spouts shall not exceed 10 m.
The discharge from drainage spout shall be kept away from the deck
structure. In case of viaducts in urban areas, the drainage spouts should
be connected with suitably located pipelines to discharge the surface
run-off to drains provided at ground level.
2705.2. Fabrication
The drainage assembly shall be fabricated to the dimensions shown
on the drawings; all materials shall be corrosion resistant; steel
components shall be of mild steel conforming to IS:226. The drainage
assembly shall be seam welded for water tightness and then hot-dip
galvanised.
2705.3. Placement
The galvanised assembly shall be given two coats of bituminous
painting before placement. The whole assembly shall be placed in true
position, lines and levels as shown in the drawing with necessary
cut-out in 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
After setting of the deck slab concrete, the shrinkage cracks
around the assembly shall be totally sealed with polysulphide sealant
or bituminous sealant as per 15:1834 and the excess sealant trimmed
to receive the wearing coat. After the wearing coat is completed, similar
594
sealant shall be finished to cover at least 50 mm on the wearing

coat surface all round the drainage assembly.
2706. WEEP HOLE
Weep holes shall be provided in solid plain concrete/reinforced
concrete, brick/stone masonry, abutment, wing wall and return walls as
shown on the drawing or directed by the Engineer to drive moisture
from the back filling. Weep holes shall be provided with 100 mm dia
AC pipe for structures in plain/reinforced concrete or brick masonr y. In
case of stone masonry, weep holes shall be 80 mm wide, 150 mm
high or circular with 150 mm diameter. Weep holes shall extend through
the full width of concrete/masonry with slope of about 1 vertical:20
horizontal towards the draining face. The spacing of weep holes shall
generally be 1m in either direction or as shown in the drawing with
the lowest at about 150 mm above the low water level or ground
level whichever is higher or as directed by the Engineer.
The measurement for payment for wearing coat, railings and
approach slab shall be made as given below :
i) Cement concrete wearing coat shall be measured in cubic metres. Asphaltic
concrete wearing coal shall be measured in square metres.
ii) Railings shall be measured in running metres.
iii) Approach slab and its base shall be measured separately in cubic metres
iv) Drainage spouts shall be measured in numbers.
v) Weep holes in concrete/brick masonry structure shall he measured in numbers.
For structures in stone masonry, weep holes shall be deemed to he included
in the Item of stone masonry work arid shall not be measured separately.
2709. RATE
The contract unit 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.
The 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 of
all labour, material, tools and plant required for completing the work
as per these Specifications. The rate for base sha ll 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 cost
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 shown 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 of Structures
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 specification
may be framed.
Implementation of repair schemes 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 with the drawings or
2802.3. Traffic Management
Traffic management, signage, signalling arrangement, barricading,
and lighting arrangement shall be in accordance with Section 100 and
with these 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
Dismantling 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
2803.2. The Contractor shall furnish detailed methodology of con-

struction including sources of supply of material, tools, equipment and
appliances to be used on work, details of personnel and supervision.
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 polysulphide resin may be 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 1 to 1 and
2 to 1 by volume subject 10 manufacturer's recommendation.
ii) Neither the mixed epoxy adhesive; nor their individual components shall contain
solvents and thinners.
iii) The component shall be free of lumps or foreign material. The viscosity of the
individual components shall not change more than +15 per cent when kepi in
closed containers at 25 degrees Celsius after two weeks.
iv) Consistency requirement.
Standard Low Viscosity
Version Version
cps cps
Viscosity of Mixed Adhesive
al 25 degrees Celsius (200-300) (100-190)
v) Pot Life of mixed adhesive 1 hour ±15 minutes *
at 25 degrees Celsius
vi) Set lime of mixed adhesive 3 - 6 hours

al 25 degrees Celsius
* In the case of two component injection system where resin and hardener gel mixed
al point of injection pot life al 25 degrees Celsius shall be not greater than 15 min +10
minutes.
2803.5. Equipment for Injection

The equipment shall be portable, positive displacement type pumps
with interlock to provide positive ratio control of exact proportions
of the two components at nozzle. The pumps shall be generally electrically
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
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 injection
gun can be used with prior approval of the Engineer for manual
injection of mix when resin and hardener had been mixed in a separate
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 matter
by brushing/water jetting/sand blasting. Acids and corrosives shall not
be permitted for cleaning.
Entry ports shall be provided along the crack at intervals of not more
than the thickness of concrete at the location.
Surface seal material shall be 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 injection, 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 port 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
adjacent port, injection shall be discontinued on the entry port being
pumped and entry port shall be sealed. Thereafter, epoxy injection shall
be 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 material
601
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) Unless otherwise specified, components A and B, i.e., resin and hardener, shall
be at a temperature between 10 degrees Celsius and 35 degrees Celsius at the
time of mixing.
b) Temperature of structural member during epoxy injection shall be between
10 degrees Celsius and 35 degrees Celsius unless otherwise specified.
c) immediately prior to use, each component shall be thoroughly mixed -with a
clean paddle. The paddle shall be of a type that does not induce air into the
material. Separate clean paddle must be used for each comp onent.
d) Any heating of the adhesive components shall be done by application of indirect
heat in case the work is to be done in cold climate.
e) Just before use, the two components shall be thoroughly mixed in the ratios
specified by the manufacturer. The length of mixing time shall be in strict
accordance with manufacturer's recommendations. When mined, all adhesives
with different coloured components shall have a uniform colour without streaks.
f) The use of solvents and thinners will not be permitted except for cleaning
of equipment,
2803.9. Testing
2803.9.1. Material 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 cost of the Contractor.
i) Viscosity test for resin and hardener and the mix - three specimens each.
ii) Pot life test - three specimens each,
iii) Bond test - three specimens each.
iv) Shear test - six specimens each, 3 after 24 hours and the other three after 72
hours of curing
Subsequent tests shall be carried out as directed by the Engineer.

a) Pot Life Tests
i) 500 gm of resin formulation shall be prepared by thoroughly mixing the
resin and hardener/accelerator/catalyst component in proposed proportion
in a 1 kg capacity hemispheral porcelain bowl by means of a spatula or
any other agitating device and note down the time and (he 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 15-
20 cm length, starting immediately after mixing the formulation and
repeating operation every five minutes. When it becomes just difficult
to spread the resin properly with the brush, the lime is noted. The
602
lime elapsed since completion of mixing of resin formulation is taken as

its pot life.
iii) One pot life test shall be performed on commencement of work and the
same shall be repeated every four hours,
iv) In case the material fails to satisfy the poi life lest it shall not be used
for injection.
Where the resin and hardener get mined at point of injection, the pot life is not
important and no tests may be required.
b) Bond Test
A standard 150 mm diameter and 300 mm long concrete cylinder shall be cast
in 2 pieces by providing a separating media at an axis of 45 degrees Celsius
to the longer axis of the cylinder (refer to Fig. 2800/1).
Three sets of such split cylinders shall be prepared in advance. Two pieces of
each set shall be joined with epoxy mortar at four points to give a clear gap
of about 0.2 mm, which will be injected with epoxy resin at site. After epoxy
has been cured, load test is carried out on the cylinder which shall not be less
than 80 per cent of the cube strength of the concrete mix and the failure shall
not take place at the joint injected with epoxy resin.
c) Shear Tests
Two steel plates, minimum 3mm thick, shall be bonded with epoxy at site using
the same resin mix as used/proposed lo be used for injection. The assembly shall
be kept in mechanical clamp till epoxy is cured, A total of six specimens shall
be prepared for each batch of materials. Three test specimens shall then be
subjected to a shear force along the axis after 24 hours and the minimum shear
strength before failure shall not 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 failure shall not be less than 2.5
MPa.
2803.9.2. Core test : If directed by the Engineer, core tests shall
be conducted 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 obtain 5 cm diameter initial core samples in
the first 50 linear metres. Thereafter, frequency of core sampling
shall be as specified or as agreed by the Engineer.
The depth of the core shall generally be less than 20 cm.
Tests and Acceptance Criteria shall be as follows :
a) Pen el ration/Visual Examination - a minimum of 90 per cent of the crack shall
be full of epoxy adhesive.
603
604
b) Bond Strength : Concrete failure before adhesive failure or 40 MPa with no failure
of cither concrete “or 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 rodcled
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 for 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) Pressure Test
The mixing head of the injection equipment shall be disconnected and the two
adhesive component delivery lines shall be attached Lo the pressure check device,
which .shall consist of two independent valved nozzles capable of sensing the
pressure. The check device shall be closed and equipment operated until the
gauge pressure in each line reads 5 MPa. The pumps shall be stopped and
the gauge pressure shall not drop below 4 MPa within 2 minutes.
The pressure 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 road 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 determine
that the volume/discharge conforms to the manufacturer's recommended
ratio 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 conformity
with the manufacturer's recommendations.
They shall 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
of 1 kg or less, hand mixing will be sufficient. For quantities in excess
of 1 kg, die 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,
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, whe ther epoxy or cement based, shall be done
within pot life of the base epoxy layer.
2804.4. Contaminants, such as oil, grease, tar, aspha lt, 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
it 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 snail be uniformly thick.
Before the primer coat is fully cured, epoxy mortar shall be
applied by means of trowels and floats. The interval between the
application of primer coat and epoxy mortar shall be approximately
15/30 minutes depending upon the ambient temperature.
Seal 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 sha ll be as
under :
a) Primer Coat. One kg of resin-hardener mix covers an area of 3-6 square metres
per coat depending on the finish of the concrete,
b) Epoxy Mortar. One square metre of surface requires approximately 20-
24 kg of epoxy mortar when laid to a thickness of 10mm.
c) Seal Coat. 4 to 6 square metres per kg of mix depending on the temperature
of application.
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 snail 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. Barrier 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 shall be scaled 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 2803.9.
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 ne at 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
609
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. Grouts
with as little as 16 litres of water per bag of cement could be handled
and it should 'seldom be necessary to use more than 35 to 40 litres
of water per bag of cement.
Where necessary and approved by the Engineer, admixtures to
Portland Cement grout mixtures may be added for delaying the setting
time, increasing flow ability, minimising segregation and shrinkage.
2806.2. Preparation
The surface shall be cleaned with wire brush and compressed air,
15 mm dia and 150 to 200 mm deep holes along the length of
the cracks at a spacing of 500 mm may be drilled by wet drilling using
rotary percussion drills and nipples, inserted in these holes.
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 cement.
Where the mixer and pump are combined in one unit, the dry
material shall be screened before mixing. If the mixer and pump are
in separate units, the grout shall pass through a screen before ii enters
the pump.
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 the pressure
may be distributed hydraulically over considerable areas, vigilance must
be exercised to prevent damage or the needless waste of grout. Grouting
is to be done by attaching a packer (consisting of expansible tube
of rubber) to the end of the grout supply pump through the holes and
nipples.
Pressure shall be steady to ensure a continuous flow of grout.
Grouting shall not be continued till the hole consumes mix at the rate
of not less than 30 litres in 20 minutes or until refusal at the grouting
pressure of 400 kPa at any hole until refusal. Should the grout escape
from an adjacent nipple, it should be plugged or capped. Any scam,
crack or joint through which grout escapes shall be caulked with epoxy
mortar as soon as thick grout appears.
2806.5. Cleaning of Equipment
After completion of each grouting operation or temporary shutdown,
it is advisable to force clear water through the pump until the discharge
line shows no colour, after which the pump covers shall be removed
and the valve chambers thoroughly cleaned.
2806.6. Testing
Percolation test done at the end of grouting operation shall give a
value of less than 2 lugions.
NOTE : For specialised treatment like polymer modified cementitious groin injection.
manufacturer's literature and specification shall be followed.
2807. GUNITING/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 quart/,
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 Portland cement conforming to IS:269 shall be used
in guniting.
2807.3. Sand for guniting shall comply with the requirements stipu-
lated in !S:383.In general, sand should neither be too coarse to increase
the rebound nor too fine to increase the slump. Sand should preferably
have a moisture content between 3 to 6 per cent.
612
The grading of sand shall lie within the limits given below :
IS Sieve per cent Passing the sieve
Designation
4.75 mm 95 – 100
2.36 mm 65 - 90
1.18 mm 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. Workmanship
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 150 cm away from the surface, preferably
normal to that surface. While enclosing reinforcement bars during
repairs the nozzle shall be held closer at a slight angle and the
mix shall be wetter than the normal.
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 IS:9012 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 in the full depth
613
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 neat
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 application of the
subsequent layer. It would always be necessary to apply guniting on
a damp concrete surface.
2807.13. Where required, welded wire fabrics 5cm x 5 cm X No.
10 gauge shall be provided in the first layer of guniting. The fabric
shall be tied properly. In case die 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.
2867.10. The stipulations given in 15:9012 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.
2807.10. It would be desirable that green gunite is moistened for
at least 7 days. Guniting work shall not be done during windy or rainy
conditions.
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 Engineer.
614
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 manua l over ride
to control die 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 ascertained. The Contractor
shall familiarise himself with the structural design and ensure that the overall
stability of the bridge is not affected
ii). The existing expansion joint assemblies shall he 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 bolls
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,
615
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 mishap/emergency.
Safety helmets conforming to IS:2925 shall be used by the workmen
engaged in dismantling work. The sheds and tool boxes should be
located away from the work site. Goggles preferably made up of celluloids
and gas masks shall be worn at the time of 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 strand/
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.
616
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 shall be carried 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 structure 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 fined as not to allow any
movement due to prestressing forces, Radius of curvature 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
"T" 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 prestressing is
imparted to the girder. Care shall be taken to avoid excess prestressing
and impairment to the girders.
prescribed standards of acceptance,
a) Measurement for sealing of cracks and injection shall be made by weight
of epoxy consumed in kg for epoxy grouting. For provision of nipples required
for grouting, the payment shall 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 [or application of epoxy mortar for specified thickness shall 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.
617
e) Measurement for guniting/shotcreting, shall be per square metre of surface area

of application.
f) Payment for replacement/rectification of bearings shall be for each number of
bearing assembly replaced/rectified.
g) Dismantling of wearing coat shall be measured in square metre of area of
wearing course dismantled.
h) Provision of external presiressing shall be measured in tonnes of H.T. steel
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, tools 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 satisfactory completion of the work as per
these specifications and as shown on the drawings.
The contract unit rate for guniting/shotcreting 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 ail 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 materials, 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 prestressing 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
shown on 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 of cement concrete pipes shall be inspected, tested,
if necessary, and approved by the Engineer either at the place of manufacture
or at the site before their incorporation in the works.
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 embankments, taken down to levels as shown
on the drawings. In case of high embankments where the height of fill is
more than three times the external diameter of the pipe, the embankment
shall first be built to an elevation above the top of the pipe equal to the
external diameter of the pipe, and to width on each side of the pipe of not less
than five times the diameter of pipe, after which a trench shall be excavated
and the pipe shall be laid.
Where trenching is involved, its width on either side of the pipe shall
be a minimum of 150 mm or one- fourth of the diameter of the pipe whichever
is more and shall not be more than one-third the diameter of the pipe.
The sides of the trench shall be as nearly vertical as possible.
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
backfilled 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
621
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 of the pipe exterior for alleast ten per cent of its
overall height or as otherwise shown on the drawings. The bedding material shall be
well graded sand or another granular material passing 5.6 mm sieve suitably
com patted/rammed. The compacted thickness of the bedding layer shall be as shown
on the drawings and in no case shall it be less than 75 mm.
(it) Concrete cradle bedding: When indicated on the drawings or directed by the
Engineer, the pipe shall be bedded in a cradle constructed of concrete having a mi*
not leaner than M IS conforming no Section 1700, The shape and dimensions of the
cradle shall be as indicated on the drawings. The pipes shall be laid on the concrete
bedding before the concrete has set.
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 a distance 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. It may be with tripod-pulley arrangement
or simply by manual labour in a manner that the pipe is placed in the
proper position without damage.
The laying of pipes on the prepared foundation shall start from the outlet
and proceed towards the inlet and be completed to the specified lines and
grades. In case of use of pipes with bell- mouth, the belled end shall face
622
upstream. The pipes shall be fitted and matched so that when laid in work,
(hey form a culvert with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed
at the cost of the Contractor.
2906. JOINTING
The pipes shall be jointed either by collar joint or by flush joint. In the
former case, the collars shall be of RCC 150 to 200 mm wide and having the
same strength as the pipes to be jointed. Caulking space shall be between 13
and 20 ram according to the diameter of the pipe. Caulking material shall be
slightly wet mix of cement and sand in the ratio of 1:2 rammed with caulking
irons. Before caulking, the collar shall be so placed that its centre coincides
with the joint and an even annular space is left between the collar and the pipe.
Flush joint may be internal flush joint or external flush joint. In either
case, the ends of the pipes shall be specially shaped to form a self centering
joint with a jointing 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 whe n 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 of the 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 and consistent 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 the jointing material has hardened. The backfill soil shall be clean, free
from boulders, large roots, excessive amounts of sods or other vegetable
matter, and lumps and shall be approved by the Engineer. Backfilling upto
300 mm above the top of the pipe shall be carefully done and the soil
thoroughly rammed, tamped or vibrated in layers not exceeding 150 mm,
particular care being taken to thoroughly consolidate the materials under the
haunches of the pipe. Approved pneumatic or light mechanical tamping
equipment can be used.
623
Filling of the trench shall be carried out simultaneously on both sides

of the pipe in such a manner that unequal pressures do not occur.
In case of high embankment, after filling the trench upto the top of the
pipe in the above said manner, a loose fill of a depth equal to external
diameter of the pipe shall be placed over the pipe before further layers are
added and compacted.
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 shall 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 headways, 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 backfilling, concrete
and masonry shall be paid for separately, as provided under the respective
Clauses.
_________
624
Maintenance of Road
3000
Maintenance of Road
3001. GENERAL
The Specifications shall apply to all items of road maintenance works as
required to be carried out under the Contract or as directed by the Engineer.
The works shall be carried out in conformity with the relevant Specifications
to the required level, grade and lines using approved materials. The works'
shall be carried out using light duty machinery or manual means provided
the quality of the end product docs not suffer. In execution of maintenance
works, a reference is made to the IRC publications: "Manual for Maintenance
of Roads" and "Code of Practice for Maintenance for Bituminous Surfaces
of Highways, IRC 82-1982" for guidance and compliance wherever applicable.
Wherever the Specification is not clear, good engineering practice
shall be adopted in the construction to the satisfaction of the Engineer,
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 wid th of the benches shall be at least 300 mm and they shall
extend continuously for a sufficient length. The height of the benches shall be
in the range of 150-300 mm.
Fresh material shall be deposited in layers not exceeding 250 mm loose
thickness and compacted so as to match with the benching a: a moisture
content close to the optimum. Compaction shall be carried out using suitable
equipment such as plate compactors and rammers or by suitable implements
handled manually. The finished work shall conform to alignment, levels and
slopes as indicated in the drawing.
The earthwork for restoration of rain cuts shall be measured in cubic
metres.
627
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 of material including alt leads and lifts and the cost of arrangement of land;
(ii) Selling out;
(iii) Removal of loose material from the rain cuts;
(iv) Benching of old earthwork; and
(v) Compacting after adding required quantity of water.
3003. MAINTENANCE OF EARTHEN SHOULDER

3003.1. Scope
The work of maintenance of earthen shoulder shall include making up the
irregularities/loss of material on shoulder LO 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 lo the shoulder, if required, shall be a select soil
conforming to Clause 305.
3003.3. Construction Procedure
This work shall involve:
(i) Making up of the earthen shoulder by adding extra soil and compacting the same; and/
or
(ii) Stripping a foyer 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
layer compacted by 80 to 100 kN smooth wheel roller, 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 the required 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 manual 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 accordance with
IS : 2720 (Pan 8). 5f the surface is no t 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.
Maintenance of earthen shoulder shall 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 for making 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

3004.1. Filling Pot-holes and Patch Repairs
3004.1.1. Scope : This work shall include repair of potholes and
patching of all types of bituminous surfaces with a bituminous mix either
produced at plant site or at the 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, A mix superior to the
one on existing surface can also be considered appropriate for repair work.
An emulsified bitumen mix compatible with the existing layer sha ll also be
considered appropriate.
The grading of aggregates and bitumen content of the mix used for such
patch repair shall be in accordance with Clause 501.
3004.1.3. Preparation of the 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
rectangle or square. The edges shall be cut vertically upto the level where the
lower layer 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 loose 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 hoi lack coat material using a brush. The prime coat 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
a hot 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). H 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 process of compaction with roller or other means, the surface level shall
be checked using a 3 m straightedge.
3004.1.5. Measurements for payment: Filling of potholes and patch
repair shall be measured in sq.m.
3004.1.6. Rate : The Contract unit rate for filling of poi- holes and patch
repair shall be in full compensation for:
(i) furnishing all materials required;
(ii) works involved in trimming, tacking, palming with cutback or emulsion;
(iii) all labour, tools, equipments and incidentals to complete !he work in accordance with
the Specifications.
3004.2. Sealing of Cracks with Fog Seal

3004.2.1. Scope : Fog seal shall consist of an application of emulsified
bitumen, without 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 cracks shall be
cleaned with pressure air jet 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 it 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 ii: and
(ii) all the labour, tools, equipments and incidentals lo 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 shaft be used.
3004.4. Premix Carpet for Renewal of Surface
The work shall consist of laying a 20 mm thick open-graded premix
carpel 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 shall be 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. metres 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 Grooves 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 m ix for repairing
spalled or damaged edges.
3005.1.3. Repairing Procedure: Spalled or broken edges shall be
shaped neaily 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, straightedges,
brushes etc. The repair edge shall be in line with the joint groove and shall
be flush with the concrete slabs. During the repair work, any damage noticed
to the joint sealant shall be made good by raking out the affected portion
and resealing.
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 (if the
manufacturers.
3005.1.5. Measurements for payment: Repair of joint grooves shall
be measured in linear metres.
3005.1.6. Rate : The Contract unit 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 Involving Removal of Old Joint 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 polysulphid e 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 he 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 reseating 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
10 clean the joint grooves to clean the joint groove. A heat resistant, papers
backed compressible debonding strip or tape should be inserted in accor-
dance with the requirement of Clause 602.11.2. Sealant may be poured
cither using hand held poorer 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 of joint 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 sealing groove and placing of
debonding strip or tape.
(ii) all tools, equipments and incidentals to complete the work in accordance with the
above Specification.
_________
633
Appendices
Appendices
Appendices
Appendix 1
LIST OF IRC PUBLICATIONS REFERRED TO IN THE

SPECIFICATIONS, CODES & STANDARDS

IRC : 2-1968 Route Marker Signs for National Highways (First Revision)
IRC : 5-1985 Standard Specifications & Code of Practice for Road Bridges, Section
I-General Features of Design (Sixth Revision)
IRC : 6-1966 Standard Specifications & Code of Practice forRoad Bridges, Section
II-Loads and Stresses (Third Revision)
IRC : 8-1980 Type Designs for Highway Kilometre Stones (Second Revision)
IRC : 10-1961 Recommended Practice for Borrow pits for Road Embankments
Constructed by Manual Operation
IRC : 14-1977 Recommended Practice for 2 cm Thick Bitumen and Tar Carpets (Third
Revision)
[RC : !6-1989 Tentative Specification for Priming of Base Course with Bituminous
Primers
IRC : 17-1965 Tentative Specification for Single Coat Bituminous Surface Dressing
IRC : 18-1985 Design Criteria for Prestressed Concrete Road Bridges (Post-
Tensioned Concrete) (Second Revision)
IRC : 19-1977 Standard Specifications and Code of Practice for Water Bound Mac-
adarn (Second Revision)
IRC : 20-1966 Recommended Practice for Bituminous Penetration Macadam (Full

Grout)
IRC : 21-1987 Standard Specifications and Code of Practice for Road Bridges, Section
III-Cement Concrete (Plain and Reinforced) (First Revision)
VI- Composite Construction for Road Bridges (First Revision)
IRC :23-1966 Tentative Specification for Two Coat Bituminous Surface Dressing
SRC : 24-1967 Standard Specifications and Code of Practice for Road Bridges, Section
V-Steel Road Bridges
IRC : 25-1967 Type Designs for Boundary Stones
IRC : 26-1967 Type Designs for 200-metre Stones
IRC : 27-1967 Tentative Specification for Bituminous Macadam (Base & Binder
Course)
IRC :29-196S 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

IRC : 35-1970 Code of Practice for Road Markings (with Paints)
IRC : 36-1970 Recommended Practice for the Construction of Earth Embankments

for Road Works
IRC : 37-1984 Guidelines for the Design of Flexible Pavements (First Revision)
IV-(Brick, Stone and Block Masonry)
IRC : 45-1972 Recommendations for Estimating the Resistance of Soil below the
Maximum Scour Level in the Design of Well 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 Pulverization of Black Cotton Soils for
Lime Stabilisation
IRC :50-1970 Recommended Design Criteria for the Use of Cement Modified Soil
in Road Construction
IRC : 51-1973 Recommended Design Criteria for the Use of Soil Lime Mixes in 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 Low Grade Aggregates and Soil
Aggregate Mixtures in Road Pavement Construction
IRC : 67-1977 Code of Practice for Road Signs
IRC : 72-1978 Recommended Practice for Use and Upkeep of Equipment, Tools and
Appliances for Bituminous Pavement Construction
IRC : 75-1979 Guidelines for the Design of High Embankments
VII -Eoundation of Substructure (First Revision)
IRC : 79-1981 Recommended Practice for Road Delineators
IRC : 82-1982 Code of Practice for Maintenance of Bituminous Surface of Highways
IX-Bearings, Pan I: Metallic Bearings
IRC : 83-1987 Standard Specification and Code of Practice for Road Bridges. Section
IX, Bearings, Part II: Elastomeric Bearings
IRC : 87-1981 Guidelines f or the Design& Erection of False Work for Road Bridges
IRC : 89-1985 Guidelines for Design and Construction of River Training and Control
Works for Road Bridges
IRC : 90-1985 Guidelines for Selection, Operation and Maintenance of Bituminous

Hoi Mix Plant
IRC : 93-1985 Guidelines on Design and Installation of Road Traffic Signals

638
Appendices

IRC : 94-1986 Specifications for Dense Bituminous Macadam
IRC : SP :11-1977 Handbook: of Quality Control for Construction of Roads and Runways
(First Revision)
IRC :SP:31-1986 New Traffic Signs

Ministry of Shipping & Transport (Roads Wing) Handbook on Road
Construction Machinery (1985)
IRC : Special IRC Highway Research Board, State of the 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 marking, 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 Cutback bitumen
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 and hard-drawn steel wire for
concrete reinforcement
(Part I) Mild steel and medium tensile steel bars
(Pan II) Hard-drawn steel wire
IS : 443-1975 Methods of sampling and test for rubber hoses
IS : 454-1961 Digboi type cutback bitumen
IS : 455-1989 Portland slog cement (fourth version)

IS : 456-1978 Code of practice fro plain and reinforced concrete (third version)
IS : 458-1971 Concrete pipes (with and without reinforcement)
IS : 460-1985 Test sieves
IS : 508-1973 Specification grease graphited (second version)
IS : 516-1959 Methods of test for strength of concrete
IS : 702-1988 Industrial bitumen (second version)
IS : 736-1986 Wrought aluminium and aluminium alloys, plates for general engineer-
ing purpose
IS : 814-1974 Covered electrodes for metal are welding for mild steel
640
Appendices

IS : 823-1964 Code of procedure for manual metal arc welding of mild steel
IS : 961-1975 Structural steel (High tensile)
IS : 1002-1956 Multipurpose grease No. 1, No.2 and No.3
IS : 1030-1974 Steel castings for general engineering purposes

IS : 1077-1976 Common burnt clay building bricks
IS : 1124-1974 Method of test for water absorption of natural building stones /
IS : 1129-J972 Dressing of natural building stones
IS : 1139-1966 Hot rolled mild steel and medium tensile steel deformed bars
concrete reinforcement
IS : 1148-1973 Rivet bars for structural purposes
IS : 1149-1973 High tensile rivet bars for structural purposes
IS : 1195-1968 Procedure for testing for hardness number of bitumen mastic
IS : 1199-1959 Method of sampling and analysis of concrete
IS : 1201 to Indian standard methods for testing 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 flip* fittings (second revi-
(Pan II) sion)
IS : 1364-1967 Precision and semi-precision hexagon bolts, screws, nuts and lock nuts
(diameter range 6 to 39mm) (first revision)
IS : 1367-!984 Technical supply conditions for threaded steel fastners
IS : 1387-1967 Genera! requirements for the supply of metallurgical materials
IS : 139S-1960 Packing paper, waterproof, bitumen-laminated
IS : 1.442-1964 Covered electrodes for metal arc welding of high tensile structural steel,
IS : 1448 Method of tests for petroleum and its products
IS : 1477 Code of practice for finishing of iron and steel/ferrous metal in

buildings: painting and allied finishes
(Part I)-1971 Operations and workmanship
IS : 1489-1991 Portland-pozzolana cement
IS : M9S-1970 Classification and identification of soils for general engineering

purposes
IS : 1514-1959 Methods of samp ling and lest for quick lime and hydrated lime
IS : 1732-1971 Dimensions for round and square steel bars for structural and general
IS : 1785 Plain hard-drawn steel wire for prestressed concrete

(Pan I)-I966 Cold-twisted steel bars for concrete reinforcement
641
Appendices

IS : 1786-1985 High strength deformed steel bars and wires for concrete reinforcement
IS : 1838 Preformed filler for expansion joint in concrete pavement and structures
(nun extruding and resilient type)
(Part I) – 1983 Bitumen impregnated fibre (first revision)
IS : 1888-1982 Method of load tests on soils
IS : 2004-1978 Carbon steel forging for general engineering purposes
IS : 2062-1980 Structural 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 for masonry mortars
IS : 2386-1963 Methods of test for aggregates for concrete
(Part 1) Particle size and shape
(Part 2) Estimation of deleterious materials and organics impurities
(Part 3) Specific gravity, density, voids absorption and bulking
(Part 4) Mechanical Properties
(Part 5) Soundness
(Part 6) measuring mortar making properties of fine aggregates
(Part 7) Alkali – Aggregate reactivity
(Part 8) Petrographic examination
IS : 2720 Methods of test for soils
(Pan 2)-1973 Determination of water content
(Pan 3)- 1980 Determination of specific gravity
Section I Fine grained soils
Section II Medium and coarse grained soils
(Part 4)-1985 Grain size analysis
(Part 5)-1985 Determination of liquid and plastic limits
(Part 7)-1980 Determination of moisture content/dry density relation using light
compaction
(Pan 8)- 1983 Determination of water content-dry density relation using heavy
compaction
(Pan 10)-1973 Determination of unconfined compressive strength
(Part 13)-1985 Direct shear test
(Part 14)-1983 Determination of density index (relative density) of copesionless soils
(Part 16)-1987 Laboratory determination of CBR
(Part 27)-1977 Determination of total soluble sulphates
642
Appendices

(Part 28) -1974 Determination of dry density of soils in-place by the sand replacement
method
(Part 29)- 1975 Determination of dry density of soils in-place by core cutter method
(Part 37)- 1976 Determination of sand equivalent values of soils and fine aggregate}
(Part 40)-1977 Determination of free swell index of soil
IS : 3117-1965 Specification for bitumen emulsion for roads (cationic type)
IS : 3466-1967 Masonry cement
IS : 3764-1992 Code of safety for excavation work
IS : 4138-1977 Safety code for working in compressed air
IS : 4332 Method of test for stabilized soils
(Part 1)-1967 Method of sampling and preparation of stabilized soils for testing
(Part 3)-1967 Test for determination of moisture content-dry density relation for
stabilized soil mixtures
(Part 4)- 1968 Welting and drying and, freezing and thawing tests for compacted soil-
cement mixtures
(Part 5)- 1970 Determination of unconfined compressive strength of stabilized soil
(Part 7)- 1973 Determination of cement content of cement stabilized soils
(Part 8)- 1969 Determination of lime content of lime stabilized soils Code of practice
IS :4434-1978 for in-situ vane shear test for soils Hot dipped galvanised coating on
IS :4826 sound scaled wires Specification for bitumen mastic for bridge
IS :5317-1969 decking and roads General requirements for old asphalt macadam
IS : 5435 (Revised) mixing plant
IS :5640-1970 Method for determining the aggregate impact value of soft coarse
aggregate
IS :6006-1970 Uncoated stress relieved strands for prestressed concrete
IS :6241-1971 Method of lest for determination of stripping value of road aggregates
IS :6909-1991 Supersulphated cement
IS :6925-1973 Methods of test for determination of water 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
IS :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

IS:12269-1987 Specification for 53 grade ordinary portland cement
IS:12330-1988 Specification for sulphate resisting portland cement
IS :13321 Glossary of terms for geosymhetics part 1: terms used in materials and
(Part 1)-1992 properties
IS : 13325-1992 Determination of tensile properties of extruded polymer geogiids
using the wide strip-test method
IS : 13326 Evaluation of interface friction between geo-synthetics and soil-
(Part 1)-1992 method of test part 1 : Modified direct shear technique
IS:SP23-19S2 Handbook on concrete mixes (based on indian standards)
(B) FOREIGN STANDARDS
ASTM : D-36 Thermoplastic material
ASTM : D-395 Compression set of vulcanized rubber
ASTM : D-4i2 Tension testing of vulcanized rubber
ASTM : D-429 Adhesion of vulcanized rubber to metal
ASTM : D-573 Accelerated aging of vulcanized rubber by the oven method
ASTM : D-624 Tear resistance of vulcanized rubber
ASTM : D-664 Test method for neutralisation number for potentiometric titiation
ASTM : D-797 Young's modulus in flexure of elastomer at normal and subnormal
temperature
ASTM : D-i075 Effect of water on cohesion of compacted bituminous mixtures
ASTM : D-1149 Accelerated ozone cracking of vulcanized rubber
ASTM : D-1559 Test for resistance to plastic flow of bituminous mixtures using
Marshall apparatus
ASTM : 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 of geotextiles.
ASTM: E-11 Specification for wire cloth sieves for testing purposes.
ASTM: E-810 Test method for coefficient of retro-reflection or retro reflection sheet-
AASHTO: DM 283 ing.
AASHTO : DM 294-70 Coarse aggregate for highway and airport construction Fine
AASHTO: DM 288-82 aggregate for bituminous paving mixtures Geotextiles used for
AASHTO : DM 17-77 subsurface drainage purposes Mineral filler for bituminous paving
AASHTO: DR 5-80 mixtures Selection and use of emulsified asphalts
644
Appendices

AASHTO: DM 81-75 Cut-back asphalt (rapid-curing type) Cut-
AASHTO: DM 82-75 back asphalt (medium-curing type)
AASHTO: DM 140-80 Emulsified asphalt Materials for
AASHTO: DM 57-80 embankments and subgrades
AASHTO: DM 147-65 Materials for aggregate and soil-aggregate
(1980) sub-base, base and surface courses
AASHTO. DM 216-68 Lime for soil stabilisation
AASHTO -. DM 249-79 White and yellow reflective thermoplastic striping materials (sol id form)
AASHTO: DM 268-77 Weatherometer
AASHTO: DM 282-80 Joint sealants, hot poured, elaslomeric type, (of ASTM : D 3406) for
Portland cement concrete pavements
BS : 410-1969 Test sieves
BS : 729-1971 Hot dip galvanized coatings on iron and steel articles
BS : 812-1975 Testing aggregates
Part 2- Methods for determination of physical properties
Part 3- Methods for determination of mechanical properties
Part 111 - Method for determination of ten per cent fines value (TFV)
Part 114 - Method for determination of the polished- stone value
BS : 1047-1952 Air-cooled blastfurnace slag coarse aggregate for concrete
BS : 1154-1970 Vulcanized natural rubber compounds
BS : 1377-1975 Methods of test for soils for civil engineering purposes
BS : 1447-1973 Mastic asphalt (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 heal resisting plate, sheet and strip
BS : 1470-1972 Wrought aluminium and aluminium alloys for general engineering
purposes plate, sheet and strip
IS : 2630 Preformed joint filler
BS : 2870 Rolled copper and copper alloys : sheet, strip and foil
BS : 3262 Hot-applied thermoplastic road marking materials
Part-1 Specification for constituent materials and mixtures
Part-2 Specification for road 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
BS : 6088 Specification for solid glass beads for use with road marking compounds
and
BS : 6906 for other industrial uses
Part 1 Methods of test for geotextiles
Part 2 Determination of the tensile properties using a wide width strip
Part 3 Determination of the apparent pore size distribution by dry sieving
Determination of water flow normal to the plane of the geotextile under a
Part 4 constant head
Part 7 Determination of the puncture- resistance (CBR puncture lest)
BS : 7542 Determination of in-plane waterflow
CRRI and IOC, Method of test for curing compound for concrete
New Delhi Bituminous Road Construction Hand Book
Asphalt Institute
The asphalt handbook, manual series
GRI-GG1 No. 4 (MS-4) 1989 edition
GR1-GG2 Geogrid rib tensile strength
GR1-GG3 Geogrid junction strength
Tensile creep testing of Geogrids
(GRI denotes standards for test prepared by Geosythetic Research Institute at Dre xe l
University Philadelphia, USA)
________
646
Appendices
Appendix 3
(Clause 4023.2 and 403.3.2)
METHOD OF SIEVING FOR WET SOILS TO

DETERMINE THE DEGREE OF PULVERISATION
1. A sample of pulverised soil approximately 1 kg 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 (W 2 ).
Lumps of finer 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 3 ).
4. Weight of soil by per cent passing the sieve can than be calculated from the expression:
( W1 − W2 ) ×100
( W1 − W3 )
_________
647
Appendices
Appendix 4
GUIDELINES ON SELECTION OF THE GRADE OF BITUMEN

(Source : Bituminous Road Construction Handbook, Indian Oil Corporation and Central Road
Research Institute)
A. For bituminous premix carpel, choice is governed by climatic conditions and intensity of
traffic.
(i) Grade 30/40 for areas where difference between maximum and minimum
atmospheric temperatures is less than 25° C and traffic intensity is greater than 1500
commercial vehicles per day. For traffic intensity less than 1500 commercial vehicles
per day, Grade 50/60 is preferred.
(ii) Where the difference between maximum and minimum atmospheric temperature
is more than 25" C and traffic intensity is greater than 1500 commercial vehicles per
day. Grade 50/60 may be used. For traffic intensity of less than 1500 commercial
vehicles per day, Grade 80/iOOmay be used. For roads with very heavy traffic greater
than 4500 commercial vehicles per day, such as metropolitan 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 consideration.
B. For bituminous macadam and penetration macadam as also built-up spray grout. Grade
30/40 (for hoi climates) and 60/70 or 80/100 for other climates are suggested,
C. For a dense-graded bituminous concrete, a more viscous grade like 60/70 can withstand
stresses of heavier wheel loads better than a less viscous grade of 80/100. Similarly
paving bitumen grade 60/70 is more advantageous for roads with large number of repetitions
of wheel to ads like expressways, urban roads, factory roads etc. High stability requirement
cannot be met effectively by less viscous bitumen.
D. A more viscous grade of bitumen is advantageous in reducing stripping of bitumen film
from aggregates in the presence of water..
E. With rounded river shingles, a more viscous grade of bitumen compensates of some extent
for poor mechanical interlock. A comparison of penetration grades and viscosity grades
(AC-2.5 to AC-40) of asphalt cement and AR grades (based on Rolling Thin Film Oven Test
residue) is shown below.
__________
648
Appendices
649
Appendices
Appendix 5
ANTI-STRIPPING AGENTS USED FOR BITUMINOUS

MATERIALS AND MIXES
1. Scope
1.1. Ami-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 anti-stripping agents shall conform to
the physical and chemical requirements as detailed in Table A5-1.
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 of rubber are not suitable for use. As 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 for the eyes shall be used while handling them, specially in case of 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 mixed with liquid bituminous material or
with straight run bitumen. When used with straight run bitumen, the correct dose of antistripping
agent shall be mined in a hot bitumen tank boiler.
The two constituents shall be agitated tilt the anti-stripping agent is thoroughly mixed The
dose of anti-stripping agent shall suitably be increased if the binder is to remain in bitumen boiler
for a longer period.
4. Use in Premix Work
4.1. Additive Dosage: The dosage shall be determined depending on the nature
(stripping value) of the aggregate and the per cent voids in the mix. While the recommended
minimum doses for different types of bituminous premix materials in terms of voids content are
given in Table A5-3, the actual dosage shall be determined in the laboratory as directed by the
Engineer.
650
Appendices
TABLE AS-1. SPECIFICATION FOR ANTISTRIPPWG COMPOUND
S. No. Test Method Limit
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 ° (COQ IS : 1448 150

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

Maximum
7. Solubility in diesel oil As given at Complete

(HDO or LDO) in the end of
the ratio of 2:58 at Appendix
50°C
8. Total base value mg ASTM D 664 200

KOH/g minimum
9. Nitrogen content per cent Elemental 7.0

Wt. minimum Analyser
10. Stripping value with bitumen IS :6241 As No stripping

containing 1 per cent WL anti given at the
stripping compound at 40° C end of
24 hours Appendix
11. Under water coating -do- Complete

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

163°C 5hours its efficacy
13. Boiling water lest per cent ASTM D 3625 95

minimum coaling
14. Retained Marshall Stability As given at 75

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

ANTISTRIPP1NG AGENT FOR SPRAYED WORK
Aggregate Dose of antistripping 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 0.8
25-50 0.6 0.7 0.8 1.0
50-100 0.75 1.0 1.0 1.0
4.2. Muting Procedure During Construction : The required dose of the anti-stripping
agent shall be poured into the hoi bitumen lank and allowed 15 lo 30 minutes of circulation
or stirred lo ensure a homogeneous mix. It is necessary to use a stable antistripping agent or
increase the dose according to expected degradation. Alternatively, the correct dose shall be
injected into the bitumen line by means of a pump. The agent is fed 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 into the hard surface while (he mix is sti11 hot to make the 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

aggregate
aggregate Voids content Voids content Voids con tent
3-5 per cent 5-10 percent 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
Appendices Annexure to the Appendix 5
TESTING PROCEDURE FOR SOLUBILITY OF

ANTISTRIPPING AGENT IN DIESEL OIL
Procedure: 98ml of diesel oil (IIDO or LDO) and 2 ml of antis tripping agent shall be taken
in a measuring cylinder with stopper. The cylinder along with its contents shall be kept in water
bath, maintained at 50°+ 1*C for half an hour. It shall then be taken out from water bath and shaken
vigorously for 10 minutes. The stopper shall be removed and the cylinder kept in water bath for
half an hour and examined for separation of settlement.
Reporting of results: An antis tripping agent is reported to be completely soluble in diesel
oil if no separation or settlement is observed for half an hour.
TESTING STRIPPING VALUE OF AGGREGATES USING BITUMEN WITH
VARYING PERCENTAGES OF ANTISTRIPPING AGENT.
Procedure: Coarse aggregate passing 19 mm sieve 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 of coarse aggregates
shall be heated at 149° C and then mixed with 80/100 penetration grade bitumen 5 per cent by
weight of coarse aggregate heated upto 163° C. The mixture shall be mixed thoroughly for
uniform costing of aggregates by bitumen, The mix shall then be transferred toa500ml beaker
and allowed to cool to room temperature. Distilled water shall be added in the beaker, which shall
be placed in a water bath maintained at 40° + 1° C for 24 hours. The percentage degree 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
repealed using bitumen containing upto one per cent of antistripping agent in stages of 0.25 per
cent.
TESTING EFFICACY OF ANTISTRIPPING AGENT TO COAT AGGREGATES
WITH BITUMEN IN PRESENCE OF WATER
Procedure: The antistripping agent shall be added in per cent content! of 0.0, 0.25, 0.50.,
0.75, 1.00 and 1.25 to cutback bitumen MC 3 (4 parts of bitumen 80/200 and 1 part of kerosene
oil). The blends shall be used foresting their ability to coat the road aggregates under water.
(a) 100 gm of clean and dry stone dust conforming to following gradation shall be taken:
Sieve Size per cent passing
2.36 mm 100
1.18 mm 80
600 mic 75
300 mic 45
The bottle shall be filled to 3/4 of its volume with distilled water at 40° C. The
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 for satisfying complete coating. The minimum per cent
content of antistripping agent at which the stone dust sample is thoroughly coated shall be recorded. The
test shall be repealed 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 the cutback-anti stripping agent Wend shall be kept al 5 per cent by weight
of coarse aggregate. In order lo take care of contaminate on in water, the test shall
also be carried out in the 1 per cent Sodium Chloride in water.
The minimum per cent content of antistripping agent at which stone dust/coarse aggregate
is thoroughly coated as per (a) and (b) 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 contents of antistripping agent and kept in oven at
163'Cfor five hours. After the heat exposure, the blend samples are fluxed with kerosene oil
to obtain the consistency of MC 3 and tested for under water coating test.
Reporting of test results: An antistripping agent shall be deemed to be hear resistant if the
dose requirement before and after heat exposure remains unchanged.
QUANTITATIVE EVALUATION OF RETAINED MARSHALL STABILITY
VALUES AFTER IMMERSION IN WATER
Procedure: For quantitative evaluation, the tests shall be carried out as stipulated in
ASTM D1075 (Effect of Water on Cohesion of Compacted Bituminous Mixtures). The gradation
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:
Sieve Size per cent Passing

19.00mm 100
13.20mm 75-100
9.50mm 60-80
4.75 mm 35-55
2.36 mm 20-35
600 mic 10-22
300 mic 6-16
150 mic 4-12
75 mic 2-8
The Marshall test specimen s shall be prepared using 5 per cent bitumen of 80/100 grade by
weight of aggregates blended with varying percentages of antistripping agents from 0 to 1 per
cent 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. Each set of 8 test specimens shall be sorted out in two groups of 4 each so that the
average specific gravity of the specimen in group I shall be essentially the same as in group II.
Group-I shall be tested for Marshall Stability in the usual procedure ASTM D1559. Group-II
specimens shall be immersed in water for 24 hours at 60°C ± 1°C. and then shall be tested
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 of Group-II × 100 percent
Average Marshall Stability of Group-I
Requirement for acceptance: A minimum of 75 per cent of retained 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 those have taken place subsequently and also considering the
need for evolving suitable acceptance tests for quality control. In this regard, the electrochemical
tests developed at the Central Electrochemical Research Institute, Karaikudi, and also the tests
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, it was decided to cover the various test procedures required to ensure the quality
of individual product as well as the finished products. It 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 for corrosion protection of mild steel reinforcement / H YSD bars in conventional
reinforced concrete structures and conventional reinforced brickwork, constructions. This
practice is also applicable for non-prestressing steels (mild steel reinforcement/HYSD bars) used
in prestressed Concrete structure.
1.2. This standard applies only for in-situ corrosion protection of mild steel reinforcement/
HYSD bars after all bending and shaping operations are completed. However, this docs no:
preclude the possibility of using this practice as a factory process.
2. ANTICORROSIVE TREATMENT PROCESS SEQUENCES
The anticorrosive treatment should necessarily include the following sequential steps:
(a) Surface preparation (de- rusting)
Since presence of oil, grease, dirt, heavy scale and rust will adversely affect the performance
of any anticorrosive treatment, it is essential to adopt suitable surface preparation technique.
Surface preparation 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 lime lag between the de-rusting and finish coaling.
This pretreatment should not adversely affect either the adhesion of the finish coat or corrosion
performance.
(c) Inhibited Cement Slurry coating
A minimum of 2 coats should be applied to ensure full coverage.
(d) Sealing treatment
Sealing treatment should make the coaling 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 to prevent base metal attack.
A typical de-rusting solution should have the following characteristics:
(a) inhibitor efficiency should not be less than 97 per cent.
(b) weight loss of a polished standard mild steel reinforcement / HYSD bars
specimen when dipped in the solution for 10 minutes should not be more than 2 g per
sq. metre.
(c) Specific gravity when tested using a standard specific gravity bottle should be around
1.12.
4. PROCEDURE FOR SURFACE PRE-TREATMENT
De-rusted surface should be immediately converted by using phosphating treatment. It
should be ensured by a suitable rinsing process that no residual acid is remaining on the
surface at the time of phosphating. A typical phosphating composition of brushable consistency
should have the following characteristics :
(a) Coating weight when tested as per test procedure A given hereunder should d be around
4.5 gms ./sq.m,
(b) Density of the 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 in colour.
(d) Presence of phosphating chemical in jelly shall be ensured with ammonia molybdate
test.
(e) pH of the composition when tested )n a standard specific gravity bottle should be
around 2.5±0.1
(f) Nail scratch test should clearly have a mark on the specimen. This indicates the
existence of the coating.
5. PROCEDURE FOR INHIBITED CEMENT SLURRV COATING
5.1. A typical inhibitor admixture used should have the fallowing characteristics:-
(i) It should in liquid form ready for mining with the ordinary Portland cement.
(ii) Specific gravity when tested using a standard specific gravity bottle should he 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 S) should be 300+25 ppm
5.2. Ordinary Portland Cement
This should conform lo IS:269 and should be sieved to pass through 75 microns IS sieve,
656
Appendices
657
Appendices
5.3. Cement and inhibitor admixture should be mixed in specified proportion to have suitable
consistency. Coating should be applied preferably by brushing. However, under specific circumstances
spraying or dipping is also allowable.
5.4. Sufficient time lag should be allowed in between successive coatings 10 ensure final
setting of the undercoat. A minimum of 6 to 12 hours may be necessary.
5.5. A minimum of two 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
selling of the top coat Sealing treatment 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 be 12.25 ±0.25.
(c) Tolerable limit for chloride in seating solution using anodic polarisation technique
should be 450+25 ppm (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
should be left uncoated. No rust spot should be visible lo the naked eye.
7.2. Thickness of the Coating
The minimum thickness of the coating shall be 200 microns. Preferable range is 200 to 400
microns.
7.3. Bond Strength of the Coated Rebar
The bond strength of the coated rebar and concrete shall not be less than that specified in
IS:456 as per clause No. 0, 2, 5, 11 and 44.1.2 and tested as per IS:2770 (Part 1).
7.4. Hardness of the coating when measured using a pencil hardness tester shall be around
5 H to 7 H.
7.5. Tolerable limit for chloride in 0.04 Normal NaOH medium using anodic polarisation
technique (as per lest procedure B) shall be around 4500 to 5000 ppm.
7.6. No film failure as evidenced by evolution of hydrogen gas al ihe cathode or
appearance of corrosion products at the anode shall take place during one hour of testing (as per
lest procedure C).
8. GENERAL REMARKS:
It is advisable that severely rusted and heavily pitted reinforcements are not accepted for
treatment
TEST PROCEDURE A
Determination of phosphate coating weight
7.5 cm × 2.5 cm or 7.5 cm × 5 cm mild steel polished and degreased specimens are lo be
used for this lest. First the blank loss of unphosphated specimen is to be found out. For this,
the initial weight (Wt) is accurately weighed. The specimen is kept immersed in the Clark's
solution or patented inhibited de-rusting solution for 1 minute. The specimen is removed, rinsed
658
Appendices
in distilled water and dried using hot air blower. The specimen is immediately weighed (W 3 ) The
difference between W 1 and W2 is termed as blank toss.
Another specimen (polished and degreased) is brushed with phosphating jelly and kept
for 45 minutes. Then the specimen is washed free of jelly, rinsed in clean water and dried
using hot air blower. The phosphated specimen (W 3 ) is accurately weighed. After weighing,
the specimen is kept immersed in Clark's solution or patented inhibited de-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 (W 4 ). Coaling weight = W3 - W4 - blank loss.
TEST PROCEDURE B
Anodic Polarisation Technique
Mild steel reinforcement / HYSD Bar test specimens of size 10 mm in dia and 100 mm
in length with items of size 5 mm in dia and 50 mm in length is polished, degreased and sealed
at bottom edge and at the stem with suitable sealers like wax, lacquer. Then test specimen is
kept immersed in test solution and potential is monitored using high impedance multimeter
against suitable reference electrode such as saturated calomel electrode/ copper-copper
sulphate electrode. After getting stabilised potential using appropriate current regulator (0-100
mA), the test specimen is anodically polarised at a constant current density of 290 µA cm
using a platinum/ stainless steel/TSIA/polished mild steel reinforcement/HYSD Bar as cathode.
Potential with lime is followed for 5 minutes after current is applied. The maximum chloride
concentration upto which the potential remains constant for 5 minutes is taken as a measure of
tolerable limit.
TEST PROCEDUREC
Resistance to Applied .Voltage Test
Two mild steel reinforcement / HYSD bars of size not less than 10 mm in dia and 800 mrn
in length shall be given anti-corrosive treatment as per specified procedure. The end of the
rebars shall be soldered with insulated copper electrical connecting wire (14 gauge) to serve as
electrical contact point. Coated rebars at the two ends shall be sealed with an insulating
material lo a length of 25 mm at 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 250 mm in this case.
The coaled rebars 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 to have a clearance of 25 mm at bottom, 45 mm at the sides and 40 mm in between
the rods.
The container shall then be filled to a height of 800 mm with an aqueous solution of 7 per cent
NaCl. A potential of 2 V in between the coated rods shall be impressed for a period of 60 minutes
Using » high resistance volt meter for direct current having an internal resistance of not less than
10 mega Ohms and having a range upto 5 V (minimum). Storage batteries may be used for
impressing the voltage.
During this 60 minutes of testing, 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
HISTORY OF SINKING OF WEL NO:…………………………
LOWEST BED LEVEL______________ LOWEST WATER LEVEL________________
HEIGHT OF CURB_________________ HEIGHT OF CUTTING EDGE_____________
STEINING SINKING
DATE REDUCED RL OF TOP RL OF TOP HEIGHT OF TOTAL RL OF INITIAL FINAL RL OF RL OF
LEVEL (RL) OF TENING OF STEINING STEINING HEIGHT OF REFERENCE GAUDE GAUGE BOTTOM BOTTOM
OF BOTTOM BEFIRE AFTER CAST (INCLUDING) LEVEL READING READING OF CUTTING OF CUTTING
OF CUTTING CASTING CASTING (COL.4-COL 3) CURB AND (AT WHICH EDGE EDGE
EDGE CUTTING CUTTING (COL.9–COL.8) (COL.7-COL.8)
EDGE EDGE IS
(COL.4-COL.3) PLACED)
METER METRE METRE METRE METRE METRE

1 2 3 4 5 6 7 8 9 10 11
660
HISTORY OF SINKING OF WEL NO:………………………… APPENDIX – 1200/1-1
HIGHEST FLOOD LEVEL __________________ FOUNDING LEVEL_____________________
KENTLEDGE
DEPTH OF STRATA WEIGHT ECCENTRI - ECCENTRI - QUANTITY REPORT REPORT REMARKS SIGNATURE
SUMP MET CITY CITY OF DREDGED REGARDING ANY SPECIAL OF
BELO WITH ALONG X- ALONG MATERIAL OBSTANCL ES OR METHOD OF SUPERVISING
CUTTING AXIS Y-AXIS SAND BELOW SINKING OFFICER
EDGE CUBIC METRE DURING SINKING EMPLOYED
METRE METRE
METRE
12 13 14 15 16 17 18 19 20 21
661
TILT AND SHIFT IN WELL NO:-
TOTAL TOTAL REDUCED LEVELS (R.P.S) OF GAUGE MARKS TILT ALONG TILT ALONG
STEINING SINKING ALONG X-AXIS ALONG Y-AXIS X-AXIX Y-AXIX
METRE METRE (PLACE) (PLACE) DIFFERENCE U/S D/S DIFFERENCE COLUMN COLUMN
END END (COL.5- (COL.5- 6 9
COL.4) COL.4) DIVIDED BY DIVIDED BY
METRE METRE WELL DIA WELL DIA
2 3 4 5 6 7 8 9 10 11
TILT AND SHIFT IN WELL NO:-
RESULTANT SHIFT
TILT ALONG ALONG RESULTANT
X-AXIS y-AXIS
(COL.10 + 2
WITH WITH
S(COL.13) 2 +
COL.11
2
DIRECTION DIRECTION [(COL.14)2 ]½
METRE METRE METRE

12 13 14 15
662
Appendices
Appendix – 1500-I
INFORMATION TO BE SUPPLIED BY THE

MANUFACTURERS OF PROPRIETARY SYSTEMS
1. GENERAL
1.1. The information which the manufacturer is required to supply shall be in such
detail as to obviate unsafe use of the equipment due to the intention of the manufacturer
not having been made clear or due to wrong assumptions on the part of the user.
1.2. The user shall refer unusual problem of problems of erection/assembly not
in keeping with the intended use of the equipment, to the manufacturer of the equipment.
2. INFORMATION REQUIRED
2.1. The manufacture of proprietary systems shall supply the following information:
a) Description of basic functions of equipment.
b) List of items of equipment available, giving range of sizes, spans and such like,
with the manufacturer’s identification numbers or other references.
c). The basis on which the safe working loads have been determined and
whether the factor of safety given applies to collapse or yield
d) Whether the supplier’s data is based on calculations or tests. This shall
be clearly stated as there may be wide variations between results obtained
by either method.
e) Instructions for use and maintenance, including any points which require special
attention during erection, especially where safety is concerned.
f) Detailed dimensional information, as follows:
(i) Overall dimensions and depth and widths of members.
(ii) Line drawings including perspectives and photographs showing normal uses.
(iii) Self weight.
(iv) Full dimensions of connections and any special positioning arrangements.
(v) Sizes of members, including tube diameters and thicknesses of materials.
(vi) Any permanent camber built into the equipment
(vii) Sizes of holes and dimensions giving their positions.
g) Data relating to strength of equipment as follows:
(i) Average failure loads as determined by tests.
(ii) Recommended maximum working loads for various conditions of use
(iii) working resistance moments derived from tests.
(iv) Working shear capacities derived from tests.
(v) Recommended factors of safety used in assessing recommended loads and
deflections based on tests results.
663
Appendices
(vi) Deflections under load together with recommended pre-camber and luniting
deflections.
(vii) If working loads depend on calculations, working stresses should be stated
If deflection depend on theoretical moments of inertia or equivalent moments
of inertia rather than tests, this should be noted.
(viii) Information on the design of sway bracing against wind and other harizan-
tal loadings.
(ix) Allowable loading relating to maximum extension of bases and/or heads.
___________
664
Appendices
Appendix – 1700/I
SPECIFICAIONS FOR CONSTRUCTION JOINTS

Location
The location of construction joints shall be as shown on the drawing
or as approved by the Engineer. If additional/new joints are approved
by the Engineer, the following considerations for their location shall be
taken into account :
(i) joints shall be provided in non-aggressive zones or in non-splash zones. If not
feasible, the joints shall be 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 griders, it is preferable to cast the soffit and the webs without any joints.
(v) Location of joints shall minimize the effects of the discontinuity on the durability,
Structural integrity and the appearance of the structure.
Preparation 'of Surface of the Joint

Laitance shall be removed before fresh concrete is cast. The surface
shall be roughened. Care shall be taken that they should not dislodge
the coarse aggregates. Concrete may be brushed with a stiff brush soon
after casting while the concrete is still fresh.
If the concrete has partially hardened, it s hall be treated by wire
brushing or with a s tiff water jet followed by drying with air jet
immediately.
Fully hardened concrete s hall be treated with mechanical hand tools
or grit blasting, taking care not to split or crack aggregate particles .
Before further concrete is cast, the surface should be thoroughly
cleaned to remove debris and accumulated rubbish, one effective method
being by air jet.
Where there is likely to be a delay before placing the next concrete
lift, protruding reinforcement s hall be protected. Before the next lift is
placed, rust, loose mortar or other contamination shall be removed from
the reinforcements. In aggressive environment, the concrete shall be 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 be removed shortly before the new concrete is placed
and the new concrete shall be thoroughly compacted. Concreting s hall
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 dis placement or bulging when concrete is compacted against
it. Concreting s hall be continued right upto the board.
666
Appendix – 1700/II.: Permeability Test
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 whete
the prestressing cable is threaded inside the sheathing prior ton concreting. These tests are
not applicable for sheathing nor 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 test sample 1100 mm long is soldered to a fixed base plate with a soft solder (Fig
1800/I-1). the sample is then bent to a radius of 1800 mm alternately on either side to
complete 3 cycles.
thereafter, the sealing joints will be visually inspected to verify that no failure/
opening has taken place.
(B) TRANSERSE LOAD RATING TEST
The test ensures that stiffness of the sheathing is sufficient to prevent permanent
distortion during site handling.
The sample is placed on a horizontal support 500 mm long so that the sample is
supported at all points of outward corrugations.
A load as specified in Table 1 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/I-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 deformation is less than 5 per
cent of the diameter of the sheathing.
(C) TENSION LOAD TEST
A test specimen is subjected to a tensile load. The bellow core is filled with a wooden
circular piece having a diameter of 95 per cent of the inner dia of the sample to ensure
circular profile during test loading, Fig. 1800/I -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 test 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 water and after sealing,
the end is connected to a system capable of applying a pressure of 0.05 MPa. Fig. 1800/
I-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
Fig. 1800/I-1 : Dimensions are in mm
670
Appendices
Fig 1800/I-2: Dimensions are in mm.
671
Appendices
Fig. 1800/I-3: Dimensions are in mm
672
Appendices
Fig. 1800/I – 4: Dimensions are in mm
673
Appendices
Appendix – 1800/III
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 clean potable water free from impurities conforming to section
1000 shall be permitted. No sea or creek water is to be. used at all.
2.2. Cement
Ordinary Portland cement should be used for preparation of the
grout. It should be 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 grouting of prestressing
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 IS Sieve No. 150. The weight of sand in the grout
shall not be more than 10 per cent of the weight of cement, unless proper
workability can be ensured by addition of suitable plasticizers.
2.4. Admixtures
Acceptable admixtures conforming to IS: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 other 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 10 per cent. Aluminum powder as an expanding agent is not

recommended for grouting because 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 both ends. For this purpose 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. It is a good practice to provide additional air vents at suitable
intervals not exceeding 20 m. All grout openings or vents should include provisions
for preventing grout leakage.
b) Standard details of fixing couplers, inlets, outlets and air vents to the duct/
anchorage shall be followed as recommended by the supplier of the presiressing
system.
2.5.3. Ducts should be securely fastened at close intervals. All un

intended holes or openings in the duct must be repaired prior to concrete
placing. The joints of the couplers and the sheathing should be made
water proof by use of adhesive tape or similar suitable system capable
of giving leak proof joints. Grout openings and vents must be securely
anchored to the duct and to either the forms or to reinforcing 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 tearing/ripping in handling particularly when placed adjoining 10
reinforcing steel, by pulling apart at joints while inserting tendons
prior to concreting, or by accidental puncturing while drilling for form
ties/inserts. Ducts 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 essential that the grout is maintained in a homogeneous state
and of uniform consistency so that there is no separation of cement.
Use of grout mixers to obtain a colloidal grout is essential. The mixer
should have an additional storage device with an agitator to keep the
grout 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 be 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 must be fitted with a pressure gauge
to enable pressure of injection to be controlled. The minimum pressure
at which grout should be pumped shall be 0.3 MPa and the grout pump
must have a relief arrangement for bypass of the grout in case of build
up of pressure beyond 1 MPa. The capacity of the grout pump should
be 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 the capacity of the pump is large, it is
usual to grout two or more cables simultaneously through a common
manifold.
Use of hand pumps for grouting, is not recommended. Use of compressed
air operated equipment for injection is prohibited, as it is likely
that there will be some air trapped in grout.
3.3. Water Pump
Before commencement of grouting, a stand by direct feed high
pressure water pump should be available at site for an emergency. In
case of any problem in grouting 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 emergencies.
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 be passed through such screen.
This screen should be easily accessible for inspection and cleaning.
3.5. Connections and Air Vents
Standard details of fixing inlets, outlets and air vents to the sheathing
and/ or anchorage should be followed as recommended by specialist
supplier of the system of prestressing. In general, all connections
are to be 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 ratio should not normally exceed 0.45.
677
Appendices
4.2. Before grouting, the properties of the grout mix should be

tested in a laboratory depending on the facilities available. Tests should
be conducted for each job periodically. The recommended lest is
described below.
4.3. Compressive Strength: The comprcssive strength of 100 mm
cubes of the grout shall not be less than 17 MPa at 7 days. Cubes shall
be cured in a moist atmosphere for the first 24 hours and subsequently
in water. These tests shall be conducted in advance to ascertain the
suitability of the grout mix.
5. MIXING OF GROUT
5.1. Proportions of materials should be based on field trials made
on the grout before commencement of grouting, but subject to the limits
specified above. The materials should be measured by weight.
5.2. Water should be added to the mixer, first, followed by Port
land cement and sand, if used. Admixture if any, may be added as
recommended by the manufacturer.
5.3. Mixing time depends upon the type of the mixer, but will
normally be between 2 and 3 minutes. However, mixing should be for
such a duration as to obtain uniform and thoroughly blended grout,
without excessive temperature increase or loss of expansive properties
of the admixtures. The grout should be continuously agitated until it
is injected.
5.4. Once mixed, no water shall be added to the groul to increase
its fluidity.
5.5. Hand mixing is not permitted,
6. GROUTING 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 protection of the steel against corrosion
by methods or products -which will not impair the ultimate adherence of the
injected grout should be ensured till grouting. The sealing of the anchorage ends
after concreting is considered to be a good practice to prevent ingress of water.
For structures in aggressive environment, scaling of the anchorage ends is
mandatory.
Notes :
i) Application of some patented water soluble oils for coating of steel/VPI powder
injection/ sending in of hot, dry, oil-free compressed air through the vents at frequent
intervals have shown some good results.
678
Appendices
ii) Some of the methods recommended for sealing of anchorages are to seal the openings
with bitumen impregnated gunny bag or water proof paper or by building a brick
pedestal plastered on all faces enclosing the exposed wires outside the anchorages,
iii) Any traces of oil if applied to steel for preventing corrosion should be removed
before grouting operation.
iv) Ducts shall be flushed with water for cleaning as well as for willing the surfaces
of the duct walls. Water used for flushing should be of same quality as used for
grouting. It may. however, contain about 1 per cent of slaked lime or quick lime.
All water should be drained thorough the lowest vent pipe or by blowing compressed
air through the duct.
v) The water in the duct should be blown out with oil free compressed air.
Blowing out water from duct for cables longer than SO m draped up al 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) The connection between the nozzle of the injection pipe and duct should be such that
air cannot be sucked in.
vii) All outlet points including vent openings should be kept open prior to commencement
of injection grout.
viii) Before grouting, all air in the pump and hose should be expelled. The suction
circuit of the pump should be air-tight
6.2. Injection of Grout

a) After mixing the grout should be kept in continuous movement.
b) Injection of grout must be continuous and should not be interrupted.
c) For vertical cable or cables inclined more than 60 degrees to the horizontal,
injection should be effected from the lowest anchorage or vent of the duct.
d) The method of injection should ensure complete filling of the ducts. To verify
this, it is advisable to compare the volume of the space to be filled by the injected
grout with the quantity of grout actually injected,
e) Grouting should be commenced initially with a low pressure of injection of upto
0.3 MPa increasing it until the grout comes out at the other end. The grout
should be allowed to flow freely from the other end until the consis tency of the
grout al this end is the same as that of the grout al the injection end. When the
grout flows al the other end, it should be closed off and building up of pressure
commenced. 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 built up of pressure much
in excess of 1 MPa without flow of grout coming at the other end, the grouting
operation should be discontinued and the entire duct flushed with high pressure
water. Also, the bypass system indicated in para 3.2 above is essential for further
safety.
f) In the case of cables draped downwards e.g. in cantilever construction simul-
taneous injection from both ends may be adopted Fig. I8QO/IH-1
g) Grout not used within 30 minutes of mixing should be rejected.
679
Appendices
Fig. 1800/III-1 : Procedure for Grouting of Cables Draped Downwards
680
Appendices
GROUTING RECORD
Job Name: _________________________________________________________________

Span No. _________________________________ Cable No. _______________________
Date of Cable Installation: ___________________ Date of Grouting: _________________
Type of Cement: OPC/IISOPC
Week and Year of Manufacture of OPC/IISOPC
W/C Ratio:
Name and amount of admixture used, if any ______________________________________
Temperature : Mixing water _______________ ; Grout __________________________
Time Start __________________ ; Finish _________________________
Equipment: Grout mixer ____________ ; Grout pump ____________________
Cable duct: Diameter ______________ ; Length ________________________
Volume of grout in litres _________________ ; Regrouting _____________________
Grouting pressure _______________________ ;
Cement consumption : Theoretical __________ ; Actual _________________________
Pre-grouting checks :
Free of blockage Inlet: Yes/No ; Outlet : Yes/No
Vents: Yes/No ; Cable duct : Yes/No
Leakage observed: Yes/No ; Sealed : Yes/No
If cable duct blocked : Remedial Measures ___________________________________

Grouting observations:
Passage of grout through vents ; Yes/No
Passage of grout through outlets ; Yes/No
Any equipment failure ; _______________________________
Post grouting checks ;
Probbing by stiff wire ; _______________________________
Remarks ; _______________________________
Signature of officers present during grouting ;
Client Contractor System Supplier
681
Appendices
h) Disconnection is facilitated if a short length of flexible tube connects the duct

and injection pipe. This can be squeezed and cut off after the grout has nardened.
7. PRECAUTIONS AND RECOMMENDATIONS

FOR EFFECTIVE GROUTING
a) In cold and frosty weather, injection should be postponed, unless special
precautions are taken. If frost is likely to occur within 48 hours after injection,
heat must be applied to the member and maintained for at least 48 hours after
injection so that the temperature of the grout does not fall below 5 de-
grees Celsius. Prior to commencement of grouting, care must be taken water, but
not with steam.
b) The temperature of the grout shall not exceed 25 degrees Celsius. For uncreasing
the workability of grout, its temperature may be lowered by use of chilled water
or by putting ice outside the grout storage container.
c) When the cables are threaded after concreting, the duct must be temporarily
stiffened during concreting by inserting bunch of strands, water of reinforcement
or a rigid PVC pipe or any other suitable method.
d) During concreting, care 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) H is a good practice to move the cables in both directions during the concreting
operations. This can easily be done by light hammering the ends of the wires/
strands during concreting. It is also advisable that 3 to 4 hours after concreting
the cable should be moved both ways through a distance of about 20 cms. With
such movement, any leakage of mortar which has taken place in spite of all
precautions, loses bond with the cables, thus reducing the chance of blockages.
This operation can also be done by fixing prestressiug jacks, at one end pulling
the entire cable and then repeating the operation by fixing the jack at the other
end.
f) The cables to be grouted should be separated by as much distance as possible.
g) In case of stage pres tressing, cables tensioned in the first stage should not remain
ungrouted till all cables are stressed. It is good practice, while grouting any
duct in stage prestressing, to keep all the remaining ducts filled up with -water
containing 1 per cent lime or by running water through such ducts till the grout
has set. After grouting the particular cable, the water in the other cables
should be drained and removed with compressed air 10 prevent corrosion.
h) Care should be taken to avoid leaks from one duct to another at joints of precast
members in particular.
i) End faces where anchorages are located are vulnerable points of entry of water.
They have to be necessarily protected with an effective barrier. Recesses should
be packed with mortar concrete and should preferably be painted with water
proof paint.
j) After grouting is completed, the projecting portion of the vents should be
cut off and the face protected to prevent corrosion.
________
682

MoRTH Complete

Uploaded by

Copyright:

Available Formats

MoRTH Complete

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MoRTH Complete

Uploaded by

Copyright:

Available Formats

What is the document about?

What is the document about?

What are some precautions mentioned for effective grouting?

What are some precautions mentioned for effective grouting?

Ministry of Road Transport and

(Up-gradation of Third Revision)

UPGRADED SECTION 500

Published by the Indian Roads

Copies can be had from

NEW DELHI 2000 Price Rs. 200/-

(Rights of Publication and of Translation are reserved)

Printed at Dee Kay Printers, New Delhi-110015

“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

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

3 00 EARTH WORK, 301 EXCAVATION FOR ROADWAYAN 49

400 SUB-BASE S, 401 GRANULAR SUB-BASE 101

500 BASES AND 501 PREPARATION OF SURFACE 139

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

600 CONCRETE 601 DRY LEAN CEMENT CONCRETE 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

1100 PILE 1101. DESCRIPTION 339

1200. W ELL 1201. DESCRIPTION 361

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1300 BRICK 1301. DESCRIPT ION 381

140 0 STONE 1401. DESCRIPTION 391

15 00 FORMWORK 1501. DESCRIPT ION 401

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1600 STEEL REINFOR- 1601. DESCRIPTION 411

1700 STRUCTURAL 1701. DESCRIPTION 419

1800 PRESTRESSING 1801. DESCRIPTION 439

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

1900 STRUCTURAL 1901. DESCRIPTION 455

2000 BEARINGS 2001. DESCRIPTION 493

2100 OPEN 2101. DESCRIPTION 523

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

2300 CONCRETE 2301. DESCRIPTION 535

2400 SURFACE AND 2401. GENERAL 543

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

2500 RIVER TRAINING 2501. DESCRIPTION 563

2600 EXPANSION 2601. DESCRIPT ION 575

2700 WEARING 2701. DESCRIPT ION 591

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

2900 PIPE 2901. SCOPE 621

3000 MAINTENANCE 3001. GENERAL 627

SECTION SECTION CLAUSE CLAUSE TITLE PAGE

APPENDIX 1. LIST OF I.R.C, PUBLICATIONS 637

APPENDIX 2. LIST OF INDIAN AND FOREIGN 640

APPENDIX 3 METHOD OF SIEVING FOR 647

APPENDIX 4. GUIDELINES ON SELECT ION 648

APPENDIX 5. ANT I-STRIPPPING AGENTS USED FOR 650

APPENDIX 1000-1 DRAFT DOCUMENT ON ISC 9077-1979 CODE 655

APPENDIX 1200/I-1 HISTORY OF SINKING OF WELL 660

APPENDIX 1500/I INFORMATION TO BE SUPPLIED TO THE 663